Upperstructure: Section 2

SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab Group 5 Control Valve
Remove and Install Cab ........................... W2-1-1 Remove and Install Control Valve ............. W2-5-1
Dimensions of the Cab Glass ................... W2-1-8 Disassemble Control Valve (1).................. W2-5-4
Assemble Control Valve (1) ...................... W2-5-6
Group 2 Counterweight Disassemble Control Valve (2).................. W2-5-8
Remove and Install Assemble Control Valve (2) .................... W2-5-10
Counterweight ........................................ W2-2-1 Disassemble Control Valve (3)................ W2-5-12
Assemble Control Valve (3) .................... W2-5-14
Group 3 Main Frame Disassemble Control Valve (4)................ W2-5-18
Remove and Install Assemble Control Valve (4) .................... W2-5-20
Main Frame ............................................ W2-3-1 Disassemble Control Valve (5)................ W2-5-22
Assemble Control Valve (5) .................... W2-5-24
Group 4 Pump Device Disassemble Control Valve (6)................ W2-5-26
Remove and Install Pump Device ............. W2-4-1 Assemble Control Valve (6) .................... W2-5-28
Disassemble Pump Device ....................... W2-4-4 Structure of Valves ................................. W2-5-30
Assemble Pump Device ......................... W2-4-10
Disassemble Main Pump ....................... W2-4-18 Group 6 Swing Device
Assemble Main Pump ............................ W2-4-26 Remove and Install Swing Device............. W2-6-1
Disassemble Regulator .......................... W2-4-40 Disassemble Swing Device....................... W2-6-4
Assemble Regulator ............................... W2-4-42 Assemble Swing Device ......................... W2-6-10
Disassemble and Assemble Disassemble Swing Motor ...................... W2-6-16
Pilot Pump ............................................ W2-4-44 Assemble Swing Motor ........................... W2-6-18
Maintenance Standard ........................... W2-4-48 Disassemble and Assemble
Parking Brake Release Valve................ W2-6-20
Maintenance Standard............................ W2-6-21
1HHW-2-1
Group 7 Pilot Valve
Remove and Install Right
Pilot Valve .............................................. W2-7-1
Remove and Install Left
Pilot Valve .............................................. W2-7-5
Remove and Install
Travel Pilot Valve .................................... W2-7-8
Disassemble Right and Left
Pilot Valves........................................... W2-7-10
Assemble Right and Left
Pilot Valves........................................... W2-7-14
Disassemble Travel Pilot Valve............... W2-7-18
Assemble Travel Pilot Valve ................... W2-7-22
Group 8 Pilot Shut-Off Valve

Remove and Install
Pilot Shut-off Valve ................................. W2-8-1
Disassemble Pilot Shut-off Valve .............. W2-8-4
Assemble Pilot Shut-off Valve................... W2-8-6
Group 9 Shockless Valve

Remove and Install
Shockless Valve ..................................... W2-9-1
Disassemble and Assemble
Shockless Valve ..................................... W2-9-4
Group 10 Solenoid Valve

Remove and Install
Solenoid Valve Unit............................... W2-10-1
Disassemble Propotional Solenoid
Valves (SC, SI and SG) ........................ W2-10-4
Assemble Propotional Solenoid
Valves (SC, SI and SG) ........................ W2-10-6
Disassemble Proportional Solenoid
Valves (Torque Control Solenoid Valve,
Maximum Pump2 Flow Rate Limit
Solenoid Valve)..................................... W2-10-8
Assemble Proportional Solenoid
Valves (Torque Control Solenoid Valve,
Maximum Pump2 Flow Rate Limit
Solenoid Valve)................................... W2-10-10
Disassemble and Assemble
Pilot Relief Valve ................................ W2-10-12
1HHW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB ZAXIS330, 330LC, 350H, 350LCH:
Removal
1. Remove nuts (2) to remove seat (1).
: 17 mm 2
W178-02-07-006
2. Remove bolts (4) behind the cab to remove rear ZAXIS370MTH:

box (3).
: 17 mm
3. Raise duct (5) to remove it.

1
W1HH-02-01-004
4. Remove filter (6) to remove screws (7) with a

screwdriver, then remove duct (8) from the cab.
4
5
W178-02-01-012
W178-02-01-013
W2-1-1
5. Disconnect harness connectors (10, 11, 12, and
13) on the right side in the cab and ground (9) at
rear inside of the cab.
10
11
12
13
W178-02-01-014
6. Remove washer vinyl hose (14) at rear inside of

the cab.
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a
17
screwdriver. Use a screwdriver to loosen screws
(16) to remove duct cover (17).
15
W178-02-01-016
8. Remove screws (18) and bolts (21) to remove

duct (19) and duct (20). 18
: 17 mm Mating Surface of Duct
19
W178-02-01-017
20 21
W2-1-2
ZAXIS330, 330LC, 350H, 350LCH
CAUTION: Cab weight:
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
22
9. Attach the cab upside with lifting straps (22).
W178-02-01-018
ZAXIS370MTH:
A
A
10. Remove cab mounting bolts (23) and nut (24)
from the cab.
: 17 mm
: 24 mm
: 8 mm
W1HH-02-01-003
Section A-A
Lifting Strap
W1HH-02-01-002
23
24
W157-02-01-010
W2-1-3
11. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-4
Installation
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
1. Attach the cab with lifting straps to hoist it by

crane.
W157-02-01-001
23
2. Install bolts (23) and nuts (24) to the cab.

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 150 Ibf⋅ft) 24
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W157-02-01-010
7
3. Install duct (8) to the rear console of the cab with
screws (7). Install filter (6) into duct (8).
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
8
W178-02-01-013
4. Install harness connectors (10, 11, 12 and 13) at

the right side of the cab and install ground (9) at
rear side in the cab. 9
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
10
11
12
13
W178-02-01-014
W2-1-5
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
6. Aligning the mounting hole for duct (5). While

pressing duct downward, install it.
4
5
7. Install rear box (3) with bolts (4).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W178-02-01-012
8. Install duct (20) with bolts (21). Install duct (19)

into duct (20) and fix them with bolt (18).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
18
Mating Surface of Duct
19
W178-02-01-017
20 21
W2-1-6
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
ZAXIS330, 330LC, 350H, 350LCH:
10. Secure seat (1) with nut (2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2
ZAXIS370MCH: W178-02-07-006
W1HH-02-01-004
W2-1-7
DIMENSIONS OF THE CAB GLASS
A
Unit: mm Chamfer Here
R2
67 303.5
Chamfer along the
11
Periphery unless
Otherwise Specified
R98 R35
4-φ13 0 -1
R3018
Section A W178-02-01-019
405 30 Chamfer Both
Sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
Along the Along the W178-02-01-002

B
Periphery Periphery
c1 c1
14
733
R58
R58
R11508
Section B W178-02-01-019
R1808
882.5 997
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-8
Unit: mm
Chamfer Here Chamfer
Slightly
Chamfer Here
85.4 unless the
Periphery
343.3 213 Polish
Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the Pe-
riphery Polish Chamfered
39.5 D
733
733
C R2465 2-φ12.2 +0.5 -0
(4 mm) Section C 6.754°

40
and D
W178-02-01-019
Polish Chamfer the
Both Fringes
289.5
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
(5 mm) Chamfer along

the Periphery
982.7
W178-02-01-004
R2002
872
R123
R5 for 3 Places 38.2

R14
364.7 51
R2475 470.6
Chamfer along the W178-02-01-009
(5 mm) Periphery
R115
888.58
W178-02-01-010
W2-1-9
Cab Glass Installation Procedure
Left-Hand Cab Glass
Procedure of installing left-hand cab glass, lower
glass of the door and upper front glass.
1. Install the seal rubber on the left-hand cab glass A

and lower glass of the door. CSE Braid
Section A
Seal Rubber
Put Connect End in Center of

Glass Edge and Then Stick It.
W178-02-01-021
Lower Glass of Door

50
5
W178-02-01-023
A
CSE Braid
Seal Rubber
2. When the mounting rubber is already on the glass, 10 10

pull and fasten the mounting rubber onto the
mounting face of cab. Mounting Rubber Section W178-02-01-020
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special Mounting
bonding agent. The cab glass may Rubber Cab Glass
fall if the special bonding agent is
not used. The cab glass assembly
can’t be replaced individually. Be
sure to change the cab glass as an
assembly.
The upper front glass is arched- Cab
fringed. If this glass needs to be re- Seal Rubber
placed, replace it as an assembly.
W178-02-01-022
W178-02-01-004
W2-1-10
Procedures of installing right-hand cab glass Mounting Rubber Section
1. Install the mounting rubber into the surrounding of

Cab Glass Mounting
cab glass. Bond the connectors of mounting rub-
Rubber
ber with the bonding agent (Cemedine 366 Stan-
dard or equivalent).
NOTE: Rubber aging will cause the contraction of Cab

rubber, be sure to leave a little extra, install
by pressing with hands.
W216-02-01-005
2. Put and fasten the mounting rubber on the mount-
ing face of cab after installing rubber.
W178-02-01-002
Procedures of installing rear cab glass

Mounting Rubber Section
1. Insert mounting rubber around the cab glass. In-
stall the connectors or mounting rubber with the Cab Glass
bonding agent (Cemedine 366 Standard or Mounting
Rubber
equivalent).
Stopper
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
Cab
2. After installing the glass assembly on the cab, in-
sert the stopper into rubber. W216-02-01-003
IMPORTANT: The rear side glass is arched-fringed.

If this glass needs to be replaced,
replace it as an assembly.
W178-02-01-005
W2-1-11
(Blank)
W2-1-12
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal
CAUTION: Counterweight weight:
ZAXIS330, 330LC: 6800 kg (15000 lb)
ZAXIS350H, 350LCH 370MTH:
7550 kg (16650 lb)
1. Remove caps (1) from upper counterweight. In-

stall sling bolts (FLENO RING BOLT B-42: M42, W178-02-02-001
Pitch 4.5) to the counterweight.
Wire Rope
Sling Bolt
2. Attach wire ropes to sling bolts with shackles.
Take out slack of wire ropes by applying tension
slowly by crane.
W178-02-02-002
3. Remove bolts (2) from the counterweight. Hoist

and remove the counterweight by crane.
ZAXIS330, 330LC:
: 50 mm
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
2
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
1. Hoist counterweight (3) and install it onto the

frame by crane.
Install washers (4) and tighten bolts (2) to coun-
terweight temporarily. 3
2
ZAXIS330, 330LC: 4
: 50 mm
W178-02-02-003
: 55 mm
2. Remove wire ropes. Tighten the bolts with a

power wrench and torque wrench.
ZAXIS330, 330LC:
: 50 mm
: 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft)
: 55 mm
: 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft) Torque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
3. Remove the sling bolts. Install caps (1) to the

counterweight.
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
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 re-
moved 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.
2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Ȁ
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau- M104-07-021
lic oil tank.
NOTE: Be sure to run the vacuum pump continu-
ously while working.
W2-3-1
Removal

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS 370MTH: 395kg (870 lb)
1. Remove the cab (Refer to “Remove Cab” in this

section.).
: 24 mm, 17 mm, 13 mm
: 8 mm
W157-02-01-001

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
2. Remove the counterweight.

(Refer to “Remove Counterweight” in this
W178-02-02-002
section.)
ZAXIS330, 330LC:
: 50 mm
: 55 mm
W2-3-2
CAUTION: Front attachment weight:

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350H, 350LCH: 7050 kg (15540 lb)
ZAXIS 370MTH: 7120 kg (15700 lb)
3. Remove the front attachment assembly.

(Refer to “Removal of Front Attachment” in this
section.)
: 19, 27, 30, 41 mm W105-02-03-002
4. Remove all hoses from upper side of the center

joint. Then remove the stopper from the center
joint.
: 17, 22, 27, 41 mm
CAUTION: Upperstructure weight:

6560 kg (14460 lb)
5. Attach wire ropes to the rear (counterweight

W173-03-03-001
bracket) of frame and boom bracket. Pull wire
ropes taut then.
If chain block (1) is used, it is not only easy to ad-
just the length of wire rope, but also easy to level
the frame.
IMPORTANT: Make sure that rear slings do not

touch engine. Rear
W105-02-03-004
Front
W105-02-03-005
W157-02-03-001
W2-3-3
6. Put matching marks on the outer race of the upper-
structure and the swing bearing.
Loosen and remove bolt (2) of the swing bearing.
: 41 mm
NOTE: The mounting angle of swing bearing is

specified. (Refer to W3-1).
7. Chain block (1) shall be used to adjust and level W105-02-03-007
the frame, then hoist it slightly to remove it from

the undercarriage by crane.
1
W157-02-03-002
W2-3-4
Installation
CAUTION: Upperstructure weight:

6560 kg (14460 lb)
1
1. Fasten wire ropes to main frame. Level the main

frame by adjusting chain block (1).
Hoist it by crane to install it to the undercarriage.
As for lifting method, refer to “Removal” section.
W157-02-03-002
2. Align the matching marks on the outer race of the

upperstructure and the swing bearing.
Install bolts (2) to the swing bearing and tighten it
temporarily. Remove wire ropes and tighten the
bolts to the swing bearing to specification.
: 41 mm
: 1226 N⋅m (125 kgf⋅m, 900 lbf⋅ft)
2
3. Install all hoses to the center joint.

: 17 mm W105-02-03-007
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft)
3
: 41 mm
4
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
4. Install stopper (4) and bolt (3) to the center joint.

: 22 mm
: 54 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)
W173-03-03-001
W2-3-5

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH: 395 kg (870 lb) 5
5. Install cab (5).

(Refer to “Removal and Installation of Cab” in this
section.)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W157-02-01-001
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
6. Install counterweight (6).

(Refer to “Counterweight” in this section.)
6
ZAXIS330, 330LC:
: 50 mm
W178-02-02-002
: 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft)
: 55 mm
: 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft)
CAUTION: Front attachment weight:

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350H, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH: 7120 kg (15700 lb)
7. Install front attachment assembly (7). And fill hy-

draulic oil. 7
(Refer to “Removal and Installation of Front At-
W105-02-03-002
tach-ment” in this section.)
: 19 mm
: 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
: 27 mm
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) M104-07-021
8. Start the engine and set the front attachment in

posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if there is
any oil leakage.
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

can penetrate the skin, causing serious in-
jury.
Avoid this hazard by relieving pressure be-
fore disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation.
Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting any repair work.
pressure.
Preparation
1. Park the machine on a firm, level surface.

pressure.
M104-07-021
pump to maintain negative pressure in the hydrau-
lic oil tank.

ously while working on the hydraulic sys-
tem.
W2-4-1
Removal
1. Disconnect harness connectors from the pump

device.
CAUTION: Pump device weight: Air Bleed Plug

200 kg (440 lb)
2. Disconnect all hoses and pipes from the pump

device.
ȀȚ17 mm, 27 mm, 36 mm
ȀȚ10 mm
3. Attach eyebolts (M12, Pitch 1.75) to the pump

device, then fasten a hoist.
4. Remove the pump device mounting bolts to

remove the pump device.
ȀȚ17 mm W110-02-04-002
Installation Tightening Torque

Wrench
Remarks
Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1. Install eyebolts on the pump device. Hoist it by
crane. : 36 175 (18) (130) Hose
: 27 93 (9.5) (69) Hose
2. Install the pump device with the pump device
: 10 88 (9) (65) Bolt
mounting bolts.
: 17 49 (5) (36) Bolt
3. Connect all hoses and pipes.
4. Connect harness connectors to the pump device.
5. Remove the air bleed plugs (2 used) on top of the

regulators, then fill hydraulic oil into the pump
casings. (Refer to W1-1-2)
IMPORTANT: Be sure to check hydraulic oil level

and oil leakage, after assembling.
Bleed the air from the pump.
W2-4-2
(Blank)
W2-4-3
DISASSEMBLE PUMP DEVICE
14
13
20
12
13 22
13 15 21
22 18
17
16
10
19 9
7 22
8
11
1
6
2
5
3 37 19
4 36
23 32
33
10
39 31
1 22
2
34
35
45
41 28
40 38
42
24
43 44
27
25
30
26
29
W1HH-02-04-004
1- Drive Gear (2 Used) 13 - Fitting (4 Used) 25 - Seal Cover 36 - Adapter

2- Retaining Ring (2 Used) 14 - Pipe 26 - Retaining Ring 37 - Plug
3- N Sensor 15 - Bolt 27 - Oil Seal 38 - Center Gear
4- O-Ring 16 - Nut 28 - Center Shaft 39 - Level Gauge
5- Washer 17 - Washer 29 - Coupling Assembly 40 - Pipe
6- Socket Bolt 18 - Clamp (2 Used) 30 - O-Ring 41 - Socket Bolt (2 Used)
7- Socket Bolt 19 - Pipe (2 Used) 31 - Seal Washer (4 Used) 42 - Packing
8- Spring Washer 20 - Pipe 32 - Socket Bolt (2 Used) 43 - Drain Plug
9- Spring Washer (4 Used) 21 - Fitting 33 - Spring Washer (2 Used) 44 - Retaining Ring
10 - Bolt (8 Used) 22 - Fitting (5 Used) 34 - Washer (2 Used) 45 - Bearing
11 - Main Pump (2 Used) 23 - Flange 35 - Pilot Pump 46 - P Sensor (2 Used)
12 - Pipe 24 - Bearing
W2-4-4
Disassemble Pump Device
Clean the outside of the pump device.
1. Remove socket bolts (6, 7) to remove N sensor.

: 5 mm
2. Remove P sensor (46) (2 used).

: 27 mm
3. Loosen bolts (E) (4 used) of coupling assembly

(29), then remove inserts (H) from hub (A).
: 6 mm
46
4. Remove screws (B) (2 used) from hub (A).
Remove hub (A) and insert (D) from center shaft
(28).
: 8 mm W173-02-04-002
D A G
NOTE: Inserts (F) are installed by spring pins (C)
F C
and bolts (G).
E
5. Remove drain plug (43) to drain gear oil.
: 22 mm
CAUTION: Pump device assembly weight:

200 kg (440 lb)
6. Secure pump device assembly with workbench.
Workbench : ST 5050
B H W110-02-04-006
W2-4-5
14
20
12
15
18
17
19
16
10
9
11
19
36
32
33
31
34
35
41
40
W1HH-02-04-004
W2-4-6
7. Remove bolt (15), nut (16), washer (17), and
clamp (18) from the pipe.
: 13 mm
8. Remove pipes (12, 14, 19, and 20).

: 19 mm, 22 mm
9. Remove adapter (36) from pilot pump (35).

: 27 mm
10. Remove socket bolts (32) (2 used), spring

washers (33), and washers (34) to remove pilot
pump (35).
: 8 mm
11. Remove bolts (10) (4 used), spring washers (9),

and seal washers (31).
: 24 mm
12. Install eyebolt (M12, Pitch 1.75) to main pump

(11) to hoist and remove main pump (11) by
crane.
CAUTION: Main pump weight: 67 kg (148 lb)
13. Remove other main pump same as steps 11. and

12.
14. Remove socket bolts (41) (2 used) to remove pipe

(40).
: 6 mm
W2-4-7
23
45
28
38
24
44
27
25
30
26
W1HH-02-04-004
W2-4-8
CAUTION: Flange assembly weight:

48 kg (106 lb)
15. Turn over flange (23) and place it on the
workbench, then remove retaining ring (26) from
flange (23).
16. Remove seal cover (25) from flange (23).
17. Remove oil seal (27) from seal cover (25), using
special tool (ST 1234).
18. Remove O-ring (30) from flange (23). Remove

retaining ring (44) from center shaft (28).
CAUTION: Flange weight: 39 kg (86 lb)

workbench, then place it onto the press. Press out
center shaft (28) and bearing (24) from flange (23)
using special tool (ST 1236).
ST 1236
20. Take out center gear (38) from flange (23).
W173-02-04-003
21. Remove bearing (45) from flange (23), using

special tool (ST 1235).
22. Remove bearing (24) from center shaft (28), using ST 1235
a press or puller.
W173-02-04-004
W2-4-9
ASSEMBLE PUMP DEVICE
1
22 2
21
20
19
A
18 B
B
17, 16, 15
3, 4
5, 6
14
7, 8
13
W1HH-02-04-001
12 11 10 9
Section B-B
37 45 38 23 24 25
26
44
27
28
29
46
30
36 35 32, 33, 34 31
W1HH-02-04-002
W2-4-10
View A
W1HH-02-04-003
43 41я
я 42 40 39
1- Drive Gear (2 Used) 13 - Fitting (4 Used) 25 - Seal Cover 36 - Adapter

2- Retaining Ring (2 Used) 14 - Pipe 26 - Retaining Ring 37 - Plug
3- N Sensor 15 - Bolt 27 - Oil Seal 38 - Center Gear
4- O-Ring 16 - Nut 28 - Center Shaft 39 - Level Gauge
5- Washer 17 - Washer 29 - Coupling Assembly 40 - Pipe
6- Socket Bolt 18 - Clamp (2 Used) 30 - O-Ring 41 - Socket Bolt (2 Used)
7- Socket Bolt 19 - Pipe (2 Used) 31 - Seal Washer (4 Used) 42 - Packing
8- Spring Washer 20 - Pipe 32 - Socket Bolt (2 Used) 43 - Drain Plug
9- Spring Washer (4 Used) 21 - Fitting 33 - Spring Washer (2 Used) 44 - Retaining Ring
10 - Bolt (8 Used) 22 - Fitting (5 Used) 34 - Washer (2 Used) 45 - Bearing
11 - Main Pump (2 Used) 23 - Flange 35 - Pilot Pump 46 - P Sensor (2 Used)
12 - Pipe 24 - Bearing
W2-4-11
45 38 23 24 25
26
44
27
28
46
30
W1HH-02-04-002
W2-4-12
Assemble Pump Device
CAUTION: Flange weight: 39kg (86 lb) ST 2307

1. Face input shaft side upward of flange (23), then
press in bearing (45) using special tool (ST 2307).
2. Insert center gear (38) into flange (23) from the

pump mounting hole to set it onto bearing (45).
3. Press center shaft (28) into bearing (45), aligning

center shaft (28) and the center gear (38) spline.
4. Press bearing (24) into flange (23) and center

shaft (28), using special tool (ST 2308).
W173-02-04-005
ST 2308
CAUTION: Flange assembly weight:

48 kg (106 lb)
5. Place flange (23) on the workbench, then install W173-02-04-006
retaining ring (44) onto center shaft (28), O-ring
(30) into flange (23) respectively.
6. Press oil seal (27) into seal cover (25) with special
tool (ST 2248).
7. Insert special tool (ST 2280) onto center shaft

(28), then install seal cover (25) into flange (23).
8. Install retaining ring (26) into flange (23).
W2-4-13
W1HH-02-04-001
11 10 9
23
36 35 32, 33, 34 31
W1HH-02-04-002
W2-4-14
workbench, then apply THREEBOND #1215 on
the pump mounting surface.
Workbench : ST 5050
CAUTION: Main pump weight :
67 kg (148 lb)
10. Install eyebolt (M12, Pitch 1.75) to main pump
(11) to hoist and install it to flange (23) by crane.
11. Tighten bolts (10) (4 used) with spring washers (9)

and seal washes (31).
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
12. Install other main pump same as steps 10 and 11.
13. Apply THREEBOND #1215 on the pilot pump (35)

mounting surface of flange (23). Install pilot pump
(35) to flange (23), then tighten socket bolts (32)
(2 used) with spring washers (33) and washers
(34).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 136 lbf⋅ft)
14. Install pipe (40) and packing (42) to flange (23),

then tighten socket bolts (41).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
40
W1HH-02-04-003
41, 42
15. Install adapter (36) to pilot pump (35).

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
W2-4-15
20
19
18
17, 16, 15
14
W1HH-02-04-001
12
37
28
46
W1HH-02-04-002
W2-4-16
16. Install pipes (12, 14, 19 and 20).
: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
: 22 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
17. Install clamp (18), bolt (15), nut (16), and washer
(17).
: 13 mm
: 3 N⋅m (0.3 kgf⋅m)
18. Place the pump device horizontal, then install hub

(A) to center shaft (28) with screws (B) (2 used). D A G
: 8 mm F C
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) E
19. Install inserts (H, D) to hub (A), then tighten bolts

(E) (4 used).
: 6 mm
: 310 N⋅m (32 kgf⋅m, 232 lbf⋅ft)
20. Install N sensor (3).

: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
B H W110-02-04-006
21. Install P sensor (46).

: 27 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
CAUTION: Pump device weight:

200 kg (440 lb)
22. Place the pump device horizontal, then remove
plug (37) to add engine oil.
Engine oil : 1.4 L (0.37 US gal.)
23. Set plug (37) hole to the counter weight direction.

: 17 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
W2-4-17
DISASSEMBLE MAIN PUMP
47, 48
4
41 6
31
42 31
43
1
3
10
11 16 5
14
15
17
49
44 30
24
25
25
23
39
19 40 37
7 22 34 38
25 46
31 45
21 29
27
13 20 25
25
33 32
18
21
9 12 25
8 20 28
22
2
26
48
36
35
40
39
W173-02-04-026
1- Casing 14 - Oil Seal 27 - Servo Pin 40 - Spring Washer (8 Used)

2- Drive Disc 15 - Seal Cover 28 - Set Screw 41 - Regulator
3- Roller Bearing (2 used) 16 - O-Ring 29 - Head Cover 42 - O-Ring
4- Roller Bearing 17 - Retaining Ring 30 - Spring Pin (2 Used) 43 - Spring Pin (2 Used)
5- Spacer 18 - Valve Plate 31 - O-Ring (10 Used) 44 - Plug
6- Bearing Nut 19 - Link 32 - Bolt (8 Used) 45 - Name Plate
7- Plunger (7 used) 20 - Lever (2 Used) 33 - Spring Washer (8 Used) 46 - Screw (2 Used)
8- Cylinder Block 21 - Pin (2 Used) 34 - Plug 47 - Bolt (4 Used)
9- Center Shaft 22 - Pin (2 Used) 35 - Stopper L 48 - Spring Washer (4 Used)
10 - Drive Gear 23 - Pin 36 - O-Ring 49 - Packing
11 - Retaining Ring 24 - Feedback Pin 37 - Stopper S 50 - P Sensor
12 - Spring 25 - Retaining Ring (6 Used) 38 - O-Ring
13 - Pin 26 - Servo Piston 39 - Bolt (8 Used)
W2-4-18
Disassemble Main Pump
Clean the outside of the main pump, before disas-

sembling.
1. Remove retaining ring (11) from the main pump.
2. Remove drive gear (10) with a puller.
CAUTION: Main pump weight: 67 kg (148 lb)
3. Secure the main pump on workbench (ST 5050).
4. Remove bolts (47) (4 used) and spring washer

(48) to remove regulator (41).
: 8 mm
5. Remove O-rings (31) (5 used), O-ring (42), and

two spring pins (43) (2 used).
6. Remove bolts (32) (8 used) and spring washers

(33) to remove head cover (29).
: 10 mm
7. Remove O-rings (31) (3 used) from casing (1).
8. Place valve plate (18) on casing (1).
9. Pull up cylinder block (8) to remove valve plate

(18) and link (19).
10. Remove spring (12).
W2-4-19
16
14
15
17
13
W173-02-04-026
W2-4-20
11. Pull up center shaft (9) straight to remove. Be
careful not lose pin (13).
12. Remove plungers (7) (7 used). Place plungers (7)

horizontally against drive disc (2), and remove.
13. Place casing (1) on the bed. Remove retaining

ring (17).
16
14. Place the casing (1) drive disc end upward on the
workbench. Remove seal cover (15) with a
screwdriver.
15. Remove oil seal (14) from seal cover (15) with a
screwdriver.
16. Remove O-ring (16) from casing (1).
W173-02-04-007
ȑȗȎȀȀTurn over casing (1) and place it on a press. Re-

move drive disc (2) and the bearing, using a
press and special tool (ST 1239)Ȏ ST 1239
W173-02-04-008
W2-4-21
4
6
3
5
W173-02-04-026
W2-4-22
18. Place drive disc (2) on special tool (ST 5905) to
loosen bearing nut (6). 2
ST 5905
W173-02-04-009
19. Install special tool (ST 3054) on the spline of drive

ST 3054
disc (2) to loosen bearing nut (6).
W173-02-04-010
20. Remove bearing nut (6) from drive disc (2).
21. Remove roller bearing (4) and spacer (5) from

drive disc (2) with a puller.
Puller
5 4
W173-02-04-011
22. Remove the roller bearing (3) outer race.
23. Remove roller bearing (4) from spacer (5) using

special tool (ST 1271). ST 1271
W173-02-04-012
W2-4-23
39
40 37
38
27
28
2
26
36
35
40
39
W173-02-04-026
W2-4-24
24. Install special tool (ST 1272) between drive disc
(2) and roller bearing (3), and clamp the assembly
in a vise. Tighten the vise as necessary to widen
ST 1272 3
the clearance.
2
W173-02-04-013
25. Remove roller bearings (3) (2 used) from drive

disc (2) with a puller.
Puller
3
26. Remove four bolts (39) and spring washers (40)
to remove stopper S (37) from the head cover. W173-02-04-014
Remove O-ring (38) and stopper S (37).

: 6 mm
27. Remove bolts (39) and spring washers (40) to

remove stopper L (35) from the head cover.
Remove O-ring (36) and stopper L (35).
: 6 mm
28. Remove set screw (28) from servo piston (26) to

remove servo pin (27).
: 8 mm
NOTE: LOCTITE #829 is applied to set screw (28).

Warm set screw (28) before disassembling.
29. Remove servo piston (27) from the head cover.
W2-4-25
ASSEMBLE MAIN PUMP
39, 40 37 31 47, 48 43 41 42 24 23 19 1 3 5 4 6
10
38
11
28
27
B 15
26 B
29
35 13 16 17 14
W1HH-02-04-005
36 49 44 12 7 8 9
18 30 21 25 20 22
Section B-B
W1HH-02-04-006
W2-4-26
45
View A 46
34
50
32, 33
W173-02-04-002
1- Casing 14 - Oil Seal 27 - Servo Pin 40 - Spring Washer (8 Used)
2- Drive Disc 15 - Seal Cover 28 - Set Screw 41 - Regulator
3- Roller Bearing (2 used) 16 - O-Ring 29 - Head Cover 42 - O-Ring
4- Roller Bearing 17 - Retaining Ring 30 - Spring Pin (2 Used) 43 - Spring Pin (2 Used)
5- Spacer 18 - Valve Plate 31 - O-Ring (10 Used) 44 - Plug
6- Bearing Nut 19 - Link 32 - Bolt (8 Used) 45 - Name Plate
7- Plunger (7 used) 20 - Lever (2 Used) 33 - Spring Washer (8 Used) 46 - Screw (2 Used)
8- Cylinder Block 21 - Pin (2 Used) 34 - Plug 47 - Bolt (4 Used)
9- Center Shaft 22 - Pin (2 Used) 35 - Stopper L 48 - Spring Washer (4 Used)
10 - Drive Gear 23 - Pin 36 - O-Ring 49 - Packing
11 - Retaining Ring 24 - Feedback Pin 37 - Stopper S 50 - P Sensor
12 - Spring 25 - Retaining Ring (6 Used) 38 - O-Ring
13 - Pin 26 - Servo Piston 39 - Bolt (8 Used)
W2-4-27
39, 40 37
3 4
38
28
27
26
29
W1HH-02-04-005
W2-4-28
Assemble Main Pump
NOTE: Assemble by following the disassemble

procedures in reverse.
(1) Before assembling, clean all parts with
pure solvent and dry them with com-
pressed air.
(2) Do not mix up the parts.
1. Insert servo piston (26) into head cover (29). In-

stall servo pin (27) into the pin bore on servo pis-
ton (26). Apply LOCTITE #829 to set screw (28).
Tighten set screw (28) to secure servo pin (27) in
piston.
: 8 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
2. Install O-ring (38) on stopper S (37). Install stop-

per S (37) to head cover (29) with bolts (39) (4
used) and spring washers (40) (4 used).
: 6 mm
: 30 N⋅m (3.1 kgf⋅m, 22.4 lbf⋅ft)
3. Install servo pin (27) positioning tool (ST 7923) on

the large chamber side of the head cover (29). Set
servo piston (26) so that servo pin (27) is at the
center of the suction port.
CAUTION: Take care to avoid being burned

when heating the bearings in an oil bath.
4. Heat roller bearings (3) (2 used) and the inner
race of bearing (4) to 50 to 80 °C (122 to 176 °F).
Apply hydraulic oil to roller bearings (3) and (4) in-
side.
ST 7923
W173-02-04-015
W2-4-29
3 5 4 6 2
W1HH-02-04-005
W2-4-30
5. Place drive disc (2) on a workbench with the
splined end up. Install two roller bearings (3) (2
used) on drive disc (2).
NOTE: Apply oil to bearing race surfaces after in-
stalling.
6. Install roller bearing (4) outer race in spacer (5)

ST 2408
using special tool (ST 2408).
W173-02-04-016
7. Install roller bearing (4) (include inner race) and
spacer (5) on drive disc (2).
Press roller bearing (4) inner race on drive disc (2),
using a plastic hammer and special tool (ST
7102).
NOTE: (1) Confirm that roller bearings (3, 4) are ST 7102
securely installed on drive disc (2), after
they have cooled down to room
temperature.
(2) Be sure to apply oil to bearing race
surfaces after installing.
8. Place drive disc (2) on special tool (ST 5905). In- W173-02-04-017
stall bearing nut (6) on drive disc (2) and tighten
bearing nut (6) until it contacts bearing (4).
6
NOTE: Apply lubricating oil to bearing nut (6)

threads when tightening. ST 5905
W173-02-04-018
W2-4-31
1 3 4 6 2
15
16 14
W1HH-02-04-005
W2-4-32
9. Tighten bearing nut (6) by turning drive disc (2)
clockwise using tool (ST 3054).
NOTE: When tightening bearing nut (6), tighten ST 3054
counterclockwise.
10. Install a torquemeter and adapter (ST 3055) on W173-02-04-023
the spline of drive disc (2) to measure bearing pre-

load. Make a record of the starting torque. Be sure
to rotate drive disc (2) two or three times before
recording, for smoother movement of drive disc ST 3055
(2).
Starting Torque Specification:

2.94±0.49 N⋅m (0.30±0.05 kgf⋅m, 2.17±0.36 lbf⋅ft) ST 5905
CAUTION:
Take care to avoid being burned when heat-
ing the bearings in an oil bath.
11. Heat casing (1) to 50 to 80 °C (122 to 176 °F).
Apply grease to the inside of casing (1). W173-02-04-024
12. Install drive disc (2) into casing (1).

NOTE: Confirm that drive disc (2) is securely in-
stalled in casing (1) after the casing has
cooled down to room temperature.
13. Install O-ring (16) into the groove on casing (1)

bore. Apply grease to O-ring (16).
14. Install oil seal (14) into seal cover (15), using spe- ST 2409
cial tool (ST 2409). Apply grease to the oil seal
(14) lip.
15
W173-02-04-019
W2-4-33
23 19 1
15
12 7 9 13 17 W1HH-02-04-005
18
W1HH-02-04-006
W2-4-34
15. Install special tool (ST 2410) on the spline of drive 14
disc (2). Install seal cover (15) in casing (1).
NOTE: Tap seal cover (15) into casing (1) with a
plastic hammer until the retaining ring
groove on casing (1) is visible.
16. Install retaining ring (17) to casing (1). 15

NOTE: Be sure to confirm that the ring seats well in
ST 2410
the groove on casing (1) after installing.
17. Turn over casing (1) and place it on a workbench

with the input shaft side down. Apply lubrication oil
to the spherical surface of drive disc (2). Place
each plunger (7) horizontally against drive disc (2) W173-02-04-020
and install.
18. Install pin (13) on center shaft (9).

NOTE: Secure pin (13) to center shaft (9) with
grease.
19. Install center shaft (9) on drive disc (2).
20. Install spring (12) on center shaft (9).
21. After link (19) is connected to valve plate (18).

place valve plate (18) on casing (1). Insert pin (23)
on the other end of link (19) assembly to the open-
ing on the casing (1) regulator mounting surface.
W2-4-35
23 19 1
27
29
49 7 8 9 13 W1HH-02-04-005
18 30
W1HH-02-04-006
W2-4-36
22. Install plungers (7) (7 used) and center shaft (9)
into cylinder block (8).
NOTE: Install pin (13) into the groove of cylinder
block while rotating the end of center shaft
(9).
23. Face the spherical surface of valve plate (18) to

cylinder block (8) and insert the end of center
shaft (9).
NOTE: Be sure to apply hydraulic oil to the match-
ing surfaces of valve plate (18) and cylinder
block (8).
24. Apply grease to O-rings (31) (3 used). Install O-

rings (31) (3 used) and packing (49) on casing (1).
NOTE: When installing O-rings (31), refer to W2-4- 1
18.
25. Install valve plate positioning tool (ST 7094) on 18

the drain port of casing (1) to position valve plate
(18) at the center position.
26. Install head cover (29) on casing (1), aligning

servo pin (27) on head cover (29) with the orifice
in valve plate (18). The valve plate (18) guide sur-
face mates with head cover (29) bottom surface, ST 7094
forming a sliding fit. W173-02-04-021
27. Install head cover (29) on casing (1) with aligning

the holes of spring pins (30). Tighten bolts (32) (8
used) with spring washers (33) (8 used).
: 12 mm
: 110 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
32, 33
W173-02-04-002
W2-4-37
47, 48 43 41 42 24 1
39, 40 2
10
11
29
35 W1HH-02-04-005
36 44
W2-4-38
28. Remove valve plate positioning tool (ST 7094)
from casing (1) and install plug (44).
Remove servo pin positioning tool (ST 7923) from 35, 36
head cover (29). Install O-ring (36) on stopper L 39, 40
(35). Install stopper L (35) with spring washers
(40) (4 used) and bolts (39) (4 used). 44
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
: 8 mm ST 7923 ST 7094
: 49 N⋅m (5 kgf⋅m, 36.2 lbf⋅ft)
29. Apply grease to O-rings (31) (42). Install O-rings

(31) (5 used) and O-ring (42) onto the regulator
mounting surface of casing (1).
NOTE: Be sure to install spring pins (43) (2 used). W173-02-04-022
When installing O-rings (31), refer to W2-4-

18.
30. Install regulator (41) on casing (1).

CAUTION: Main pump weight:
67 kg (148 lb)
IMPORTANT: Align pump feedback pin (24) with

the notches on regulator (41)
sleeves confirming from the plug
hole of regulator (41).
31. Install bolts (47) (4 used) and spring washers (48)
(4 used). Tighten bolts (47).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
32. Install drive gear (10) into drive disc (2).
33. Install retaining ring (11) into drive disc (2).
W2-4-39
DISASSEMBLE REGULATOR
25
26
27
11
12
24
20
23
22
21
18
30
19
14
31 2
28
6
15
1
29
4
17
16 3
13
15
7 5
8
2
2
14
26
25
12 32
11 10
W173-02-04-029
9
1- Stopper 9- Nut 17 - Spring 25 - Socket Bolt (8 Used)
2- O-Ring (3 Used) 10 - Screw 18 - Sleeve 26 - Spring Washer (8 Used)
3- Sleeve 11 - Nut (2 Used) 19 - Spool 27 - Front Cover
4- Spool 12 - Nut (2 Used) 20 - Cylinder 28 - Bolt (4 Used)
5- Casing 13 - Stopper 21 - Piston 29 - Spring Washer (4 Used)
6- Spring 14 - Stopper (2 Used) 22 - O-Ring 30 - Plug
7- Piston 15 - O-Ring (2 Used) 23 - Backup Ring 31 - O-Ring
8- Cylinder 16 - Spring 24 - O-Ring 32 - Rear Cover
W2-4-40
UPPERSTRUCTURE/Pump Device
Disassemble Regulator
1. Clean the regulator outside.
2. Clamp casing (5) with a vise.
3. Remove air bleed plug (30) and O-ring (31) from

casing (5). Remove elbows (4 used) from casing
(5).
: 19 mm, 41 mm
4. Remove socket bolts (25) (8 used) to remove

front cover (27) and rear cover (32).
: 6 mm
IMPORTANT: Never loosen stopper (1), (13) and

(14), nut (9), (11) and (12), and screw
(10). If loosened, the regulator set-
ting will change.
5. Remove springs (16, 17) from the casing (5) rear

cover side.
6. Remove cylinder (20) from the casing (5) front

cover (27) side, pulling spool (19).
7. Remove piston (21), O-ring (22), and backup ring

(23) from cylinder (20).
8. Remove sleeve (18) and spool (19) from the cas-

ing (5) front cover (27) side.
9. Remove spool (19) from sleeve (18).
10. Remove spring (6) from the casing (5) front cover
(27) side.
11. Remove piston (7) and cylinder (8) from the cas-
ing (5) rear cover (32) side, pulling spool (4).
12. Remove piston (7) and O-ring (2) from cylinder

(8).
13. Remove sleeve (3) and spool (4) from the casing
(5) front cover (27) side. Then remove spool (4)
from sleeve (3) .
W2-4-41
ASSEMBLE REGULATOR
6 1 4 3 5 7 8 2 9 10
24 23 22 21 20 19 18 17 16 15 14 13 12 11 T173-03-01-005
25, 26 27 28, 29 30 31 32
W173-02-04-001
1- Stopper 9- Nut 17 - Spring 25 - Socket Bolt (8 Used)

2- O-Ring (3 Used) 10 - Screw 18 - Sleeve 26 - Spring Washer (8 Used)
3- Sleeve 11 - Nut (2 Used) 19 - Spool 27 - Front Cover
4- Spool 12 - Nut (2 Used) 20 - Cylinder 28 - Bolt (4 Used)
5- Casing 13 - Stopper 21 - Piston 29 - Spring Washer (4 Used)
6- Spring 14 - Stopper (2 Used) 22 - O-Ring 30 - Plug
7- Piston 15 - O-Ring (2 Used) 23 - Backup Ring 31 - O-Ring
8- Cylinder 16 - Spring 24 - O-Ring 32 - Rear Cover
W2-4-42
Assemble Regulator
NOTE: Assemble by following the disassemble

procedures in reverse.
(1) Before assembling, Clean all parts with
pure solvent and dry with compressed
air.
(2) Do not mix up the parts.
1. Clamp casing (5) with a vise.
2. Install spool (19) into sleeve (18).
3. Install sleeve (18) with spool (19) from the casing

(5) front cover (27) side.
4. Install spool (4) into sleeve (3), then install them

from the casing (5) front cover (27) side.
5. Install piston (7) into cylinder (8).
6. Install O-ring (2) to cylinder (8), then apply a film

of grease to O-ring (2). Install cylinder (8) from the
casing (5) rear cover (32) side.
7. Install rear cover (32) assembly and springs (16)

and (17) to casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8. Install O-ring (22), backup ring (23), and piston

(21) to cylinder (20).
9. Apply a film of grease to O-ring (22), then Install

cylinder (20) from the casing (5) front cover (27)
side.
10. Install front cover (27) assembly and spring (6)

into casing (5). Tighten socket bolts (25) (4 used)
with spring washers (26).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
11. Apply a film of grease to O-ring (31). Install O-ring

(31) to plug (30).
12. Tighten plug (30).

: 41 mm
: 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
13. Install elbows (4 used) to casing (5).
W2-4-43
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
14
10
15
12
13
6
8 9
1
16
7
5
15
11
14
5
7
9
4 3 2
W110-02-04-022
1- Housing 5- Seal (2 Used) 9- O-Ring (2 Used) 13 - Bolt (4 Used)

2- Flange 6- Cover 10 - Gear 14 - Bushing (2 Used)
3- Oil Seal 7- Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4- Retaining Ring 8- Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
W2-4-44
Disassemble Pilot Pump
NOTE: (1) Clean the outside of the pilot pump

before disassembling.
(2) Make matching marks on cover (6),
housing (1) and flange (2) before
disassembling to aid reassembly.
1. Clamp pump flange (2) in a vise with cover (6) up.
2. Remove bolts (13) (4 used).

: 17 mm
3. Remove cover (6) from housing (1).
4. Remove O-ring (9) from cover (6).
5. Remove flange (2) from housing (1).
6. Remove O-ring (9) from flange (2).
7. Remove retaining ring (4) from flange (2).
8. Remove oil seal (3) from flange (2) with a screw

driver.
9. Remove seal (5) and backup ring (7) from cover

(6) side bushings (14, 15).
10. Lightly push drive gear (11) to remove cover (6)

side bushings (14, 15) from housing (1).
NOTE: Be careful not to allow the key between the
bushings to fall off when removing them.
11. Remove seal (5) and backup ring (7) from flange
(2) side bushings (14, 15).
12. Remove flange (2) side bushings (14, 15). Re-

move gear (10) and drive gear (11) from housing
(1).
W2-4-45
14
10
15
12
13
6
8 9
1
16
7
5
15
11
14
5
7
9
4 3 2
W110-02-04-022
1- Housing 5- Seal (2 Used) 9- O-Ring (2 Used) 13 - Bolt (4 Used)

2- Flange 6- Cover 10 - Gear 14 - Bushing (2 Used)
3- Oil Seal 7- Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4- Retaining Ring 8- Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
W2-4-46
Assemble Pilot Pump
1. Tap oil seal (3) in flange (2) with a plastic hammer

and tool.
2. Install retaining ring (4) to flange (2).
3. Install cover (6) side bushings (14, 15) in housing

(1) with the seal groove side down.
NOTE: Position the bushings in the correct
direction when installing.
4. Install gear (10) and drive gear (11) in housing (1).
5. Install flange (2) side bushings (14, 15) in housing

(1) with the seal groove side up.
6. Install seal (5) and backup ring (7) into the seal
groove on bushings (14, 15).
7. Install O-ring (9) on flange (2).
8. Install flange (2) on housing (1).
9. Turn over the housing and flange assembly and

clamp flange (2) in a vise. Install seal (5) and
backup ring (7) into the seal groove on the
bushings.
NOTE: Be careful not to allow the bushings or

gears to fall off when rotating the assembly.
10. Install O-ring (9) on cover (6).
11. Install cover (6) on housing (1).
12. Install washers (12) (4 used) and bolts (13) (4

used). Tighten the bolts.
: 17 mm
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 29 to 32.5 lbf⋅ft)
W2-4-47
MAINTENANCE STANDARD
Pump Device
Unit : mm (in)
Standard Allowable Limit Remedy
Gear backlash 0.48 (0.019) 1.5 (0.059) Replace
Main Pump
1. Drive disc: Spline tooth thickness
Unit : mm (in)
Standard Allowable Limit
4.9 (0.193) 3.5 (0.138)
2. Drive disc: Oil seal outer diameter
Unit : mm (in)
60.0 (2.362) 59.8 (2.354)
3. Spherical joint: The clearance between plunger

and drive disc
Unit : mm (in)

0.060 (0.0024) 0.4 (0.0016)
W157-02-04-016
4. Cylinder block: Clearance between plunger outer

diameter and cylinder block bore
D-a Unit : mm (in) D

0.044 (0.0017) 0.08 (0.0031) a
W157-02-04-017
W2-4-48
5. Clearance between plunger and connecting rod
Unit : mm (in)
0.1 (0.0039) 0.4 (0.0016)
W157-02-04-033
6. Clearance between center shaft and valve plate
D-a Unit : mm (in)

Standard Allowable Limit a
0.081 (0.0032) 0.3 (0.012)
Center Shaft
W110-02-04-013
Valve Plate
7. Clearance between small chamber inner diameter

and servo piston D W110-02-04-014
a
D-a Unit : mm (in)
0.089 (0.0035) 0.2 (0.0079)
8. Clearance between large chamber inner diameter

and servo piston
D-a Unit : mm (in) a

Standard Allowable Limit D W157-02-04-018
0.090 (0.0035) 0.2 (0.0079)
9. Clearance between servo pin and valve plate

D a
D-a Unit : mm (in)

0.051 (0.0020) 0.3 (0.012)
W157-02-04-019
W2-4-49
(Blank)
W2-4-50
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

can penetrate the skin, causing serious in-
jury.
pressure.
Preparation

pressure.
M104-07-021
lic oil tank.

tem.
W2-5-1
Removal
Arm 2
Boom 1
IMPORTANT: Attach a tag to each hose to aid in 4-Spool Side
Bucket 5-Spool Side
assembly. Travel Right
1. Remove all hoses, pipings, and connectors from
the control valve.
Main Swing
Relief Arm 1
: 17 mm valve Boom 2
: 24.5 N⋅m (25 kgf⋅m, 18 lbf⋅ft) Auxiliary
: 19 mm Travel Left
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) Machine Front T1HH-01-02-005
NOTE: Cap all hose and piping ends.
CAUTION: Control valve weight:

210 kg (460 lb)
2. Remove bolts (1) to remove the control valve.
: 24 mm
: 205 N⋅m (21 kgf⋅m 152 lbf⋅ft )
Installation
NOTE: Refer to “Removal” section for wrench size

and tightening torque.
1. Install the control valve on the frame and tighten

bolts (1).
2. Connect all hoses, pipings, and connectors to the

control valve. 1 W1HH-02-05-001
IMPORTANT: After assembling, check hydraulic

oil level, start the engine and check
for oil leaks.
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE CONTROL VALVE (1)
13 4 4 43
12 41
5
7
46 4
12a
13a
15 6
17
32 35 15 4
15 4
30 31 15 42
14
4
29 5
38 47
25
28 17
37 23
33 14 15
34 12
30
31 20
27 21
22
2 10 19
15 18 24
26
35 45 1
44
16
31
8
11
40
17 8
39 15
15
8
16 8
36
9
31 8 9
5
17
3
W173-02-05-021
1- Casing A 13 - Needle Valve 25 - Spool: Bypass Shut-Off 38 - Spring (7 Used)
2- Casing B 13a O-Ring (3 Used) 26 - Spool: Auxiliary 39 - Spring
3- Plug 14 - O-Ring (10 Used) 27 - Spool: Travel Right 40 - Spring
4- Plug (㈐ Used) 15 - O-Ring (11 Used) 28 - Spring (2 Used) 41 - Plug
5- O-Ring (6 Used) 16 - O-Ring (8 Used) 29 - Spring (2 Used) 42 - Plug
6- Spring Cover A 17 - Socket Bolt (32 Used) 30 - Spring Seat (4 Used) 43 - Plug
7- Spring Cover B 18 - Spool: Travel Left 31 - Spring Seat (16 Used) 44 - Plug
8- Spool Cover (5 Used) 19 - Spool: Arm 1 32 - Spacer Bolt (2 Used) 45 - O-Ring
9- Spool Cover (2 Used) 20 - Spool: Boom 1 33 - Stopper (2 Used) 46 - Socket Bolt (4 Used)
10 -Spool Cover: Arm 2 21 - Spool: Bucket 34 - Stopper (7 Used) 47 - Socket Bolt (4 Used)
11 -Spool Cover: Boom 1 22 - Spool: Swing 35 - Spacer Bolt (8 Used)
12 -Anti-Drift Valve (2 Used): 23 - Spool: Arm 2 36 - Stopper
Boom Bottom, Arm Rod
12a O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used)
W2-5-4
Disassemble control valve (1)
• Read carefully “Precautions for Disassembly and • Spool Cover

Assembly” (W1-1-1) before starting repair work. IMPORTANT: Attach matching mark not to make a
• Attach a tag to spool mounting positions of the mistake in assembly of casing and
casing. spool cover.
9. Loosen socket bolts (17) (2 used) and remove
• Anti-drift Valve and Needle Valve spool cover (11) from casing B (2).
1. Loosen socket bolt (46) and remove needle valve : 6 mm
(13) and anti-drift valve (12) from spring cover B
(7). 10. Disassemble spool covers (8) to (10) following the
: 5 mm same procedures.
: 6 mm
2. Loosen socket bolt (47) and remove anti-drift
valve (12) from spring cover A (6).
: 5 mm
• Spring Cover
spring cover A (6) from casing A (1). Remove
spring cover B (7) from casing B (2) similarly.
: 6 mm
• Spool
IMPORTANT: Remove spools while carefully turn-
ing them. If they stick even a little,
try it again instead of pulling roughly.
Since spool and hole of casing are a
matched fit, make marks to aid in
assembly.
Be careful not to damage casing and
spool.
4. Remove spool (18) assembly from casing A (1).
5. Remove spools (19) to (27) following the same

procedures.
6. Clamp spool (18) in a vise.
7. Loosen spacer bolt (32) and disassemble spring

seat (30), springs (28), (29), and stopper (33).
: 10 mm
8. Disassemble spools (19) to (27) following the

same procedures.
: 10 mm
W2-5-5
ASSEMBLE CONTROL VALVE (1)
Machine Front 21 27
B 15, 14
A
16
4
5, 42
8
11
46
12, 12a
35
13, 13a
10
5, 43 31
47
5, 41 40
12 A B 39 36 31 7 2 25 23 20 W1HH-02-05-017
17 T1HH-03-03-002
Section B-B
Control Valve Upper View
Machine Front 18 26 15, 14 30 33 28 29
30
16
32
3
5
44, 45
9
35
15
8 31
17 37 38
W1HH-02-05-005 W1HH-02-05-004
24 19 22 1 6 31 34
Control Valve Lower View
Section A-A
1- Casing A 13 - Needle Valve 25 - Spool: Bypass Shut-Off 38 - Spring (7 Used)

2- Casing B 13a O-Ring (3 Used) 26 - Spool: Auxiliary 39 - Spring
3- Plug 14 - O-Ring (10 Used) 27 - Spool: Travel Right 40 - Spring
4- Plug (4 Used) 15 - O-Ring (11 Used) 28 - Spring (2 Used) 41 - Plug
5- O-Ring (6 Used) 16 - O-Ring (8 Used) 29 - Spring (2 Used) 42 - Plug
6- Spring Cover A 17 - Socket Bolt (32 Used) 30 - Spring Seat (4 Used) 43 - Plug
7- Spring Cover B 18 - Spool: Travel Left 31 - Spring Seat (16 Used) 44 - Plug
8- Spool Cover (5 Used) 19 - Spool: Arm 1 32 - Spacer Bolt (2 Used) 45 - O-Ring
9- Spool Cover (2 Used) 20 - Spool: Boom 1 33 - Stopper (2 Used) 46 - Socket Bolt (4 Used)
10 -Spool Cover: Arm 2 21 - Spool: Bucket 34 - Stopper (7 Used) 47 - Socket Bolt (4 Used)
11 -Spool Cover: Boom 1 22 - Spool: Swing 35 - Spacer Bolt (8 Used)
12 -Anti-Drift Valve (2 Used) 23 - Spool: Arm 2 36 - Stopper
Boom Bottom, Arm Rod
12a O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used)
W2-5-6
Assemble Control Valve (1)
• Read carefully “Precautions for Disassembly and • Spring Cover

Assembly” (W1-1-1) before starting repair work. 10. Install O-rings (14) (5 used) and O-rings (15) (4
used) to spring cover A (6)
• Lower Spool Cover
IMPORTANT: Install spool covers (8) to (11) with 11. Install spring cover A (6) to casing A (1) with
matching marks. socket bolts (17) (7 used).
Be sure to install O-rings (15) and : 6 mm
(16). : 24 to 34 N⋅m
1. Install O-rings (15) and (16) to spool cover (11). (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)
2. Install spool cover (11) to casing B (2) with socket 12. Install spring cover B (7) following the same pro-
bolts (17) (2 used). cedures.
: 6 mm : 6 mm
: 24 to 34 N⋅m : 24 to 34 N⋅m
(2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)
3. Install spool cover(8) to (10) following the same • Anti-drift Valve and Needle Valve
procedures. 13. Install O-rings (12a) (3 used) to anti-drift valve
: 6 mm (12). Install anti-drift valve (12) to spring cover A
: 24 to 34 N⋅m (6) with socket bolts (47) (4 used).
(2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) : 5 mm
: 9.8 to 14 N⋅m
• Spool (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
4. Clamp spool (18) in a vise.
14. Install O-rings (12a) (3 used) to anti-drift valve
5. Clean screw section of spacer bolt (32) and apply (12). Install O-rings (13a) (3 used) to needle valve
LOCTITE #262. (13). Install needle valve (13) and anti-drift valve
(12) to spring cover B (7) with socket bolts (46) (4
6. Install spring sheet (30), springs (28), (29), stop- used).
per (33) and spacer bolt (32) to spool (18). : 5 mm
: 9.8 to 14 N⋅m
7. Tighten spacer bolt (32). (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
: 10 mm
: 15 to 18 N m
(1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft)
8. Assemble spools (19) to (27) following the same

procedures.
: 10 mm
: 15 to 18 N⋅m
(1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft)
IMPORTANT: Install spool (18) to (27) assemblies

with matching marks.
Be careful not to damage casing and
spool when installing.
9. Install spool (18) to (27) assemblies to casing A
(1) and casing B (2).
W2-5-7
1
22 12
23
5 6
13 19
18
20
24
21a
11 4 21
9 14
14 9
8
16
Casing A 25 11 17
10
15
W173-02-05-022
1 - Anti-Drift Valve Assembly: 8 - O-Ring (2 Used) 15 - Plug 21a - O-Ring

Arm Bottom Side
2 - Casing 2 9- O-Ring (2 Used) 16 - Poppet 22 - Piston
3 - Casing 3 10 - O-Ring 17 - Spring 23 - Piston
4 - Casing 4 11 - O-Ring (2 Used) 18 - Spool 24 - Socket Bolt (4 Used)
5 - O-Ring 12 - Plug 19 - Spring 25 - Socket Bolt (8 Used)
6 - O-Ring 13 - Plug 20 - Bushing
7 - O-Ring (3 Used) 14 - Plug (2 Used) 21 - Relief Valve
W2-5-8
Disassemble Control Valve (2)
• Read carefully “Precautions for Disassembly and

Assembly” (W1-1-1) before starting repair work.
• Arm Anti-drift Valve

IMPORTANT: Put matching marks to install cor-
rectly.
casing 2 (2) from casing 4 (4).
: 10 mm

casing 4 (4) from casing A.
: 10 mm
3. Clamp casings 2 (2) and 3 (3) in a vise.

casing 3 (3) from casing 2 (2).
: 5 mm
5. Loosen plug (15) and take out poppet (16) and

spring (17) from casing 2 (2).
: 17 mm
IMPORTANT: Do not disassemble lock nut part.

6. Remove relief valve (21) from casing 3 (3).
: 22 mm
IMPORTANT: Mark extraction sequence of piston

(22) and (23).
7. Loosen plug (13) and take out piston (23) and pis-
ton (22) from casing 3 (3).
: 10 mm
8. Loosen plug (12) and take out bushing (20), spool

(18), and spring (19) from casing 3 (3).
: 22 mm
W2-5-9
9 14 13 5
Machine Front
9 23
14
22
7
F
F
21 21a 3 20
19
T1HH-03-03-002 6
18
Control Valve Upper View Section Y-Y
12
W1HH-02-05-006
Arm 1 Arm 2
24
Y Y
15
10
17
Casing B
16 Casing A
Section F-F
2 25 11 4 25 11 T1HH-03-03-007
1 - Anti-Drift Valve Assembly: 8 - O-Ring (2 Used) 15 - Plug 21a - O-Ring

Arm Bottom Side
2 - Casing 2 9- O-Ring (2 Used) 16 - Poppet 22 - Piston
3 - Casing 3 10 - O-Ring 17 - Spring 23 - Piston
4 - Casing 4 11 - O-Ring (2 Used) 18 - Spool 24 - Socket Bolt (4 Used)
5 - O-Ring 12 - Plug 19 - Spring 25 - Socket Bolt (8 Used)
6 - O-Ring 13 - Plug 20 - Bushing
7 - O-Ring (3 Used) 14 - Plug (2 Used) 21 - Relief Valve
W2-5-10
• Read carefully “Precautions for Disassembly and 10. Install casing 3 (3) to casing 2 (2) with socket
Assembly” (W1-1-1) before starting repair work. bolts (24) (4 used).
: 5 mm
• Arm Anti-drift Valve : 9.8 to 13.5 N⋅m
1. Install O-rings (7) (3 used) to bushing (20). (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
2. Install O-ring (6) to plug (12). 11. Install O-ring (11) to casing 4 (4).
3. Install bushing (20), spool (18), and spring (19) 12. Install casing 4 (4) to casing A with socket bolts
into casing 3 (3), and install plug (12). (25) (4 used).
: 22 mm : 10 mm
: 69 to 79 N⋅m : 98 to 118 N⋅m
(7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft) (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)
4. Install O-ring (5) to plug (13). 13. Install O-ring (11) to casing 2 (2).
IMPORTANT: Be sure to install pistons (22) and 14. Install casing 2 (2) to casing 4 (4) with socket
(23) in their correct positions. bolts (25) (4 used).
5. Install pistons (22) and (23) into casing 3 (3), and : 10 mm
install plug (13). : 98 to 118 N⋅m
: 10 mm (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)
: 127 to 147 N⋅m
(13 to 15 kgf⋅m, 94 to 108 lbf⋅ft)
IMPORTANT: Do not use lock nut part.

6. Install O-ring (21a) to relief valve (21). Tighten and
install relief valve (21) in casing 3 (3).
: 22 mm
: 69 to 79 N⋅m
(7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft)
7. Install O-ring (10) to plug (15).
8. Install poppet (16) and spring (17) into casing 2

(2), and install plug (15).
: 17 mm
: 370 to 410 N⋅m
(38 to 42 kgf⋅m, 275 to 300 lbf⋅ft)
9. Install O-rings (8) (2 used) to casing 3 (3).
W2-5-11
16 13
19 7 13a
25
23 3
18 16
21 17 19
25 20 22
24
29 29a Casing A
1 4
9
6
6 14
9 1
4
33
14a
6
1
26
9
8
12
31
32
15 10
27
27
5 12 11
31 25
28a 2
28
30a
30b
30c
30
W1HH-02-05-019
1 - Plug (4 Used) 11 - P3 Cover 19 - Spring (4 Used) 28a O-Ring

2 - Plug 12 - Flange (2 Used) 20 - Spring (2 Used) 29 - Overload Relief Valve:
Arm Rod Side
3 - Plug 13 - Travel Flow Rate Control 21 - Spring 29a O-Ring
Valve Assembly
4 - Plug (2 Used) 13a - O-Ring 22 - Spacer 30 - Pump Control Valve:
5-Spool Section
5- Plug (3 Used) 14 - Blank Flange Assembly 23 - Plug (3 Used) 30a - O-Ring
6- O-Ring (4 Used) 14a - O-Ring (2 Used) 24 - Plug 30b - O-Ring
7- O-Ring 15 - Socket Bolt (4 Used) 25 - O-Ring (5 Used) 30c - O-Ring
8- O-Ring (2 Used) 16 - Poppet (4 Used) 26 - O-Ring 31 - Socket Bolt (8 Used)
9- O-Ring (3 Used) 17 - Poppet (2 Used) 27 - O-Ring (2 Used) 32 - Socket Bolt (4 Used)
10 - Cover 18 - Poppet 28 - Overload Relief Valve: 33 - Socket Bolt (4 Used)
Boom Rod Side
W2-5-12
• Read carefully “Precautions for Disassembly and • Overload Relief Valve

IMPORTANT: Note that there are two kinds of over-
• P3 Cover load relief valves.
1. Loosen socket bolts (32) (4 used) and remove P3 Attach identification marks to each
cover (11). port and part to aid reassembly.
: 8 mm Be sure to loosen the valve of over-
load relief valve. If lock nut and ad-
2. Take out poppet (16), spring (19), and spacer (22) justing screw are loosened, the set
from casing A. pressure will change. Never loosen
lock nut and adjusting screw.
• Blank Flange Assembly 8. Loosen and remove overload relief valves (28)
3. Loosen socket bolts (33) (4 used) and remove and (29) with tool as below.
blank flange (14). : 32 mm
: 8 mm
4. Take out poppet (17) and spring (20) from casing
(Wrench: 32 mm)
A.
(12.7 mm)
(43 mm)
32 mm
• Travel Flow Rate Control Valve (13) Assembly
5. Loosen the plug and take out the piston, sleeve,
poppet, and spring from casing A. (45 mm)
: 32 mm
(80 mm) W1HH-02-05-002
• Arm Anti-Drift Check Valve

6. Loosen plug (24) and take out spring (21) and
poppet (18) from casing A. • Pump Control Valve (5-Spool Section)
: 12 mm 9. Loosen and remove pump control valve (30) from
base.
• Travel Left, Boom 2, Swing Load Check Valve : 36 mm
(common to three places)
IMPORTANT: Attach matching marks to each port

and part to aid reassembly.
spring (19) from casing A.
: 12 mm
W2-5-13
Machine Front
X
5
B
C C
D D
F F
W1HH-02-05-003
G
30 30a 30c 30b
Casing A Section B
T1HH-03-03-002
X
Auxiliary Bucket
31
Travel Left Travel Right
12
27
16
13a
19
22
13 2
23 25
32
11
25 8
19 27
16 31 T1HH-03-03-005
12
Section C-C T1HH-03-03-004
Section D-D
W2-5-14
Boom 2 Boom 1 Arm 1 Arm 2
1 6
18
29 21
24
29a 25
17
25 20
14
23 14a
33
19
16
7 Section F-F
T1HH-03-03-006 T1HH-03-03-007
28a Section E
28
15 10 9, 26 4 9
Swing
Travel
Left
Auxiliary
16
19
Boom 2
23
Arm 1
25
Swing
W1HH-02-05-004
Section G T1HH-03-03-006 Section X-X
1 - Plug (4 Used) 11 - Cover 19 - Spring (4 Used) 28a O-Ring

2 - Plug 12 - Flange (2 Used) 20 - Spring (2 Used) 29 - Overload Relief Valve:
Arm Rod Side
3 - Plug 13 - Travel Flow Rate Control 21 - Spring 29a O-Ring
Valve Assembly
4 - Plug (2 Used) 13a - O-Ring 22 - Spacer 30 - Pump Control Valve:
5-Spool Section
5- Plug (3 Used) 14 - Blank Flange 23 - Plug (3 Used) 30a - O-Ring
6- O-Ring (4 Used) 14a - O-Ring (2 Used) 24 - Plug 30b - O-Ring
7- O-Ring 15 - Socket Bolt (4 Used) 25 - O-Ring (5 Used) 30c - O-Ring
8- O-Ring (2 Used) 16 - Poppet (4 Used) 26 - O-Ring 31 - Socket Bolt (8 Used)
9- O-Ring (3 Used) 17 - Poppet (2 Used) 27 - O-Ring (2 Used) 32 - Socket Bolt (4 Used)
10 - Cover 18 - Poppet 28 - Overload Relief Valve: 33 - Socket Bolt (4 Used)
Boom Rod Side
W2-5-15
Machine Front
X
5
B
C C
D D
E
W1HH-02-05-003
F F
30 30a 30c 30b
G Section B
Casing A 31 12
T1HH-03-03-002 Auxiliary Bucket
X

27
16
19
22
13a 2
13
15 25
23 32
11
8
27
19
16 31 Section D-D T1HH-03-03-005
12
Arm 1 Arm 2
Section C-C T1HH-03-03-004 1 6 18
Boom 2 Boom 1
21 17
29 24
25
29a
20
14
25
14a
23
33
19
16
3
Section F-F
7
T1HH-03-03-006 T1HH-03-03-007
Section E
28a 28
W2-5-16
• Read carefully “Precautions for Disassembly and • Arm Anti-drift Check Valve
Assembly” (W1-1-1) before starting repair work. 5. Install O-ring (25) to plug (24).
• Pump Control Valve (5-Spool Section) 6. Install poppet (18) and spring (21) into casing A,
1. Install O-rings (30a) (30b) (30c) to pump control and install plug (24).
valve (30). Tighten and install pump control valve : 12 mm
(30) to base. : 226 to 265 N⋅m
: 69 to 78 N⋅m
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft) • Travel Flow Rate Control Valve (13) Assembly
7. Install O-ring (13a) to the plug. Install the piston,
• Overload Relief Valve sleeve, poppet, and spring into casing A, and in-
stall the plug.
IMPORTANT: Note that there are two kinds of over- : 32 mm
load relief valves. : 147 to 177 N⋅m
Install according to the identification (15 to 18 kgf⋅m, 108 to 130 lbf⋅ft)
marks.
2. Install O-ring (28a) to overload relief valve (28). • Blank Flange Assembly
Install O-ring (29a) to overload relief valve (29). 8. Install two O-rings (14a) (2 used) to blank flange
Tighten and install overload relief valve (28) and (14). Install poppet (17) and spring (20) into cas-
(29) to base with tool as below. ing A. Install blank flange (14) with socket bolts
: 32 mm (33) (4 used).
: 69 to 78 N⋅m : 8 mm
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft) : 49 to 65 N⋅m
(5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)
• P3 Cover
(Wrench: 32 mm)
9. Install O-rings (8) to cover (11).

(12.7 mm)
32 mm
43 mm
10. Install poppet (16), spring (19), and spacer (22)

into casing A. Install P3 cover (11) with socket
bolts (32) (4 used).
(45 mm) : 8 mm
(80 mm) W1HH-02-05-002 : 49 to 65 N⋅m
(5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)
• Left Travel, Boom 2, Swing Load Check Valve

(common to 3 places)
IIMPORTANT: Install according to the matching

marks.
4. Install poppet (16) and spring (19) into casing A,

and install plug (23).
: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
W2-5-17
3
11 21
11a
18
21
15
12
19
21
2
16 7
14 4
8
5
1
18 6
21
15
12
10
9
23
9a
20
22
17
13
Casing B
W173-02-05-024
1- Plug (2 Used) 8 - O-Ring (2 Used) 13 - Poppet 20 - Plug

2- Plug 9 - Switch Valve 14 - Poppet 21 - O-Ring (6 Used)
3- Plug (3 Used) 9a - O-Ring (2 Used) 15 - Spring (2 Used) 22 - O-Ring
4- Plug 10 - Poppet Valve 16 - Spring 23 - Socket Bolt (4 Used)
5- Plug (2 Used) 11 - Load Check Valve 17 - Spring
6- O-Ring (2 Used) 11a - O-Ring 18 - Plug (2 Used)
7- O-Ring 12 - Poppet (2 Used) 19 - Plug
W2-5-18

• Bucket Flow Rate Control Valve

1. Loosen four socket bolts (23) (4 used) and re-
move switch valve (9).
: 8 mm
2. Take out poppet valve (10) from casing B.
• Arm 2 Load Check Valve (with orifice)

3. Loosen the plug and take out load check valve
(11) from casing B.
: 12 mm
• Boom 1, Arm 2 Load Check Valve

IMPORTANT: Attach matching marks to each port

and part to aid reassembly.
spring (15) from casing B.
: 12 mm
• Boom Anti-drift Check Valve

: 12 mm
• Travel-Bucket Compound Check Valve

: 10 mm
W2-5-19
Machine Front
C C 13
D D 22
E 20
F F
17
G
Control Valve Upper View T1HH-03-03-002

Section C-C T1HH-03-03-004
Auxiliary Bucket Boom 2 Boom 1
6
1
10
9a
14
16
9 19
21
18
15
23 21
12
Section D-D Section E T1HH-03-03-006

T1HH-03-03-005
Swing
Arm 1 Arm 2
11a
11 21
12 3
15
18 7
21 2
4
8
Section F-F Section G T1HH-03-03-008
T1HH-03-03-007
1- Plug (2 Used) 8 - O-Ring (2 Used) 13 - Poppet 20 - Plug

2- Plug 9 - Switch Valve 14 - Poppet 21 - O-Ring (6 Used)
3- Plug (3 Used) 9a - O-Ring (2 Used) 15 - Spring (2 Used) 22 - O-Ring
4- Plug 10 - Poppet Valve 16 - Spring 23 - Socket Bolt (4 Used)
5- Plug (2 Used) 11 - Load Check Valve 17 - Spring
6- O-Ring (2 Used) 11a - O-Ring 18 - Plug (2 Used)
7- O-Ring 12 - Poppet (2 Used) 19 - Plug
W2-5-20
• Read carefully “Precautions for Disassembly and • Bucket Flow Rate Control Valve
Assembly” (W1-1-1) before starting repair work. 8. Install O-rings (9a) (2 used) to switch valve (9).
Poppet valve (10) is put into the casing. Install
• Travel-Bucket Compound Check Valve switch valve (9) with socket bolts (23) (4 used).
1. Install O-ring (22) to plug (20). : 8 mm
: 52 to 62 N⋅m
2. Install poppet (13) and spring (17) into the casing, (5.3 to 6.3 kgf⋅m, 38 to 46 lbf⋅ft)
: 10 mm
: 128 to 147 N⋅m
(13 to 15 kgf⋅m, 94 to 108 lbf⋅ft)
• Boom Anti-drift Check Valve

4. Install poppet (14) and spring (16) into the casing,

: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Boom 1, Arm 2 Load Check Valve

IIMPORTANT: Install according to the identification

mark.
6. Install poppet (12) and spring (15) into the casing,

: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Arm 2 Load Check Valve (with orifice)

7. Install O-ring (11a) to the plug. Install load check
valve (11).
: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
W2-5-21
1
Casing B
21
21a
19 5
20 6
18
17
19
20
7
18
11
17
14 7
6
16
6
4
22
23
15 17
2
18
15
8 20
3 19
9
10
12
13
W173-02-05-025
1 - Flow Combiner Valve As- 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used)

sembly
2 - Block 8- O-Ring 14 - Stopper 20 - O-Ring (3 Used)
3 - Plug 9- Plug 15 - Orifice (2 Used) 21 - Main Relief Valve
4 - Plug 10 - O-Ring 16 - Spool 21a - O-Ring
5 - O-Ring (3 Used) 11 - O-Ring 17 - Poppet (3 Used) 22 - Socket Bolt (5 Used)
6 - O-Ring (4 Used) 12 - Spring 18 - Spring (3 Used) 23 - Name Plate
W2-5-22

• Flow Combiner Valve

flow combiner valve assembly (1).
: 14 mm
2. Clamp block (2) in a vise.
3. Loosen main relief valve (21) from base, and re-

move from block (2).
: 32 mm
4. Loosen plug (9) and take out spool (16), stopper

(14), springs (12) and (13) from block (2).
: 32 mm
IMPORTANT: Attach matching mark to each port

and part.
5. Loosen plug (19), and take out poppet (17) and
spring (18) from block (2).(common to 3 places)
: 12 mm
6. Loosen and remove plug (3).

: 5 mm
7. Take out orifices (15) (2 used) from block (2).

: 4 mm
W2-5-23
Machine Lower
Machine Front
3, 8, 15 22
T1HH-03-03-002
W1HH-02-05-007
Control Valve Upper View Control Valve Front View
15 16 10 9 12 13
14
20
7
19
6
18
17 20
4 19
11
2
18
17
21a
21
W1HH-02-05-010
Section A
1 - Flow Combiner Valve As- 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used)
sembly
2 - Block 8- O-Ring 14 - Stopper 20 - O-Ring (3 Used)
3 - Plug 9- Plug 15 - Orifice (2 Used) 21 - Main Relief Valve
4 - Plug 10 - O-Ring 16 - Spool 21a - O-Ring
5 - O-Ring (3 Used) 11 - O-Ring 17 - Poppet (3 Used) 22 - Socket Bolt (5 Used)
6 - O-Ring (4 Used) 12 - Spring 18 - Spring (3 Used) 23 - Name Plate
W2-5-24
• Read carefully “Precautions for Disassembly and 10. Install O-rings (5) (3 used), O-rings (6) (4 used),
Assembly” (W1-1-1) before starting repair work. O-rings (7) (2 used) and O-ring (11) to block (2).
• Flow Combiner Valve 11. Install flow combiner valve assembly (1) with
1. Clamp block (2) in a vise. socket bolt (22) (5 used).
: 14 mm
2. Install orifices (15) (2 used) in block (2). : 215 to 255 N⋅m
: 7.8 to 9.8 N⋅m
(0.8 to 1.0 kgf⋅m, 5.8 to 7.2 lbf⋅ft)
4. Install plug (3).

: 5 mm
: 12.7 to 16.7 N⋅m
(1.3 to 1.7 kgf⋅m, 9.4 to 12.3 lbf⋅ft)
IMPORTANT: Install according to the matching

mark.
6. Put poppet (17) and spring (18) into block (2), and
install plug (19).(common to 3 places)
: 12 mm
: 225 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
8. Put spool (16), stopper (14), springs (12) and (13)

into block (2), and install plug (9).
: 32 mm
: 68.6 to 78.4 N⋅m
(7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)
9. Install O-ring (21a) to main relief valve (21). Install

main relief valve (21) in block (2) base.
: 32 mm
: 68.6 to 78.4 N⋅m
W2-5-25
9a
10 9
9c
9b
7
8 7a
11
2 Casing B
8a 1
1
3
3
4 6
5
6 Casing A
5
6
6
7a
4
6
7
7a
W173-02-05-026
1 - Plug (2 Used) 5 - O-Ring (6 Used) 8 - Overload Relief Valve: 9b - O-Ring

Bucket Bottom Side
2 - Plug 6 - O-Ring (5 Used) 8a - O-Ring 9c - O-Ring
3 - O-Ring (2 Used) 7 - Overload Relief Valve 9 - Pump Control Valve: 10 - Socket Bolt
(3 Used): Bucket Rod, Arm (4-Spool Section)
Bottom, Boom Bottom Side
4 - O-Ring (6 Used) 7a - O-Ring (3 Used) 9a - O-Ring 11 - Socket Bolt (8 Used)
W2-5-26

• Pump Control Valve (4-Spool Section)

1. Loosen and remove pump control valve (9) from
casing B base.
: 36 mm
• Overload Relief Valve
IMPORTANT: Note that there are 2 kinds of over-

load relief valve.
Attach identification mark to each
port and part.
IMPORTANT: Be sure to loosen the valve of over-

load relief valve. If loosening the
lock nut and adjusting screw, the set
pressure will change. Never loosen
the lock nut and adjusting screw.
2. Loosen and remove overload relief valve (7) and
(8) from casing B base with tool as below.
: 32 mm
(12.7 mm)
(Wrench: 32
32 mm
43 mm
(45 mm)
(80 mm) W1HH-02-05-002
• Casing
IMPORTANT: As long as there is no necessity, do

not disassemble socket bolts (10)
and (11).
3. Loosen socket bolt (10) and socket bolts (11) (8
used) and disassemble casing A and casing B.
: 12 mm
W2-5-27
Boom 2 Boom 1
Machine Front 10
5
C C
D D 6
E
4
F F
Control Valve Upper View T1HH-03-03-002

Section E
T1HH-03-03-006
Travel Left Travel Right Arm 1 Arm 2
4
6
7
7a
5
5
6
4
7a
7
4
Section C-C T1HH-03-03-004 Section F-F

T1HH-03-03-007
Auxiliary Bucket 6
Swing
8 9
8a 9a
5 9c
9b
6
b
7a
Section D-D 4 Section G T1HH-03-03-008

T1HH-03-03-005
1 - Plug (2 Used) 5 - O-Ring (6 Used) 8 - Overload Relief Valve: 9b - O-Ring

Bucket Bottom Side
2 - Plug 6 - O-Ring (5 Used) 8a - O-Ring 9c - O-Ring
3 - O-Ring (2 Used) 7 - Overload Relief Valve 9 - Pump Control Valve: 10 - Socket Bolt
(3 Used): Bucket Rod, Arm (4-Spool Section)
Bottom, Boom Bottom Side
4 - O-Ring (6 Used) 7a - O-Ring (3 Used) 9a - O-Ring 11 - Socket Bolt (8 Used)
W2-5-28

• Casing
1. Install O-rings (4) (6 used), O-rings (5) (6 used)
and O-rings (6) (5 used) to casing B.
2. Connect casing A and casing B and tighten socket

bolts (10) and socket bolts (11) (8 used).
: 12 mm
: 137 to 177 N⋅m
(14 to 18 kgf⋅m, 101 to 130 lbf⋅ft)
• Overload Relief Valve
IMPORTANT: Note that there are 2 kinds of over-

load relief valve.
Install according to the matching
mark.
3. Install O-ring (7a) to overload relief valve (7). In-
stall O-ring (8a) to overload relief valve (8).Tighten
and install overload relief valves (7) and (8) to the
base with tool as below.
: 32 mm
: 69 to 78 N⋅m
(Wrench: 32 mm)
(12.7 mm)
32 mm
43 mm
(45 mm)
(80 mm) W1HH-02-05-002
• Pump Control Valve (4-Spool Section)

4. Install O-rings (9a), (9b) and (9c) to pump control
valve (9). Install pump control valve (9).
: 36 mm
: 69 to 78 N⋅m
W2-5-29
STRUCTURE OF VALVES
Main Relief Valve ITEM PART NAME QTY
2 1 Lock Nut 1
2 Lock Nut 1
9 3 O-Ring 1
6 4 O-Ring 1
5 5 O-Ring 1
1 6 Adjusting Screw 1
8 7 Spring 1
16 8 Piston 1
3 9 Stopper 1
7
22 10 Poppet 1
4 PL 11 Backup Ring 1
12 O-Ring 1
10 23
13 Seat 1
11 20 14 Spring 1
12 21 15 Plunger 1
16 O-Ring 1
17 13 17 Filter 1
18 14 18 Filter Stopper 1
19 19 C-Ring 1
R 20 Spacer 1
15 21 C-Ring 1
22 Adjusting Plug 1
P 23 Plug 1
W173-02-05-030
Overload Relief Valve ITEM PART NAME QTY

1 Lock Nut 1
5 1 2 O-Ring 1
3 Adjusting Screw 1
2 4 Spring 1
3
5 Spring Seat 1
4 6 Poppet 1
21
6 7 Backup Ring 1
8 O-Ring 1
19
9 9 Backup Ring 1
10 O-Ring 1
10 22 11 Seat 1
16 12 Spring 1
11 13 Spring 1
17
14 Plunger 1
18 20 15 Piston 1
13 16 Filter 1
R 12
17 Filter Stopper 1
8
18 C-Ring 1
14
7 19 O-Ring 1
P
15 20 O-Ring 1
W173-02-05-031
21 Plug 1
22 Body 1
W2-5-30
Flow Combiner Valve B
10
15 11
14 5 6 7 7 6 5 4 2 3
8 12
4
9
22
16
W1HH-02-05-011
B
21 4 5 6 7
9
W1HH-02-05-012
Section B-B Section A-A
A A
ITEM PART NAME QTY

1 Name Plate 1
20 2 Socket Bolt 5
3 Main Relief 1
W1HH-02-05-013
4 O-Ring 3
5 ROMH Plug 3
18 17 13 18 19 19 19 6 Spring 3
7 Poppet 3
18 8 Spool 1
9 Orifice 2
10 Stopper 1
18 11 Spring 1
12 Spring 1
17 13 O-Ring 1
14 O-Ring 1
15 Plug 1
16 O-Ring 1
17 O-Ring 2
18 O-Ring 4
19 O-Ring 3
20 Plug 1
21 ROM Plug 1
W1HH-02-05-014
22 Block 1
W2-5-31
Switch Valve (Bucket Flow Rate Control Valve)
2 1 4 3
9 5 ITEM PART NAME QTY

1 Spring 1
2 Spring 1
6 3 Spool 1
8 4 Spring Seat 1
5 Plug 1
6 Plug 1
11 7 Socket Bolt 4
8 O-Ring 1
9 O-Ring 1
10 O-Ring 2
11 Casing 1
10 7 W173-02-05-007
Anti-drift Valve
ITEM PART NAME QTY

1 Bushing 1
2 Spring 1
3
3 Spool 1
4 Plug 1
5
5 O-Ring 3
1 6 O-Ring 3
7 O-Ring 1
8 Casing 1
6
W173-02-05-008
W2-5-32
Travel Flow Rate Control Valve Assembly
Pi
3
ITEM PART NAME QTY

1
1 O-Ring 1
6 2 Spring 1
3 Plug 1
DR 4 Poppet 1
2 5 Sleeve 1
6 Piston 1
B 5
A
W173-02-05-009
Poppet Valve (Bucket Flow Rate Control Valve)
B
4
2 ITEM PART NAME QTY

1 Spring 1
3 2 Spring 1
3 Plug 1
1 4 Spring Seat 1
5 Poppet 1
A 6 Logic Poppet 1
5
P
W173-02-05-010
Arm 2 Load Check Valve
3
6 ITEM PART NAME QTY

1 O-Ring 1
2 Spring 1
2 3 Plug 1
4 Poppet 1
5
B 5 Sleeve 1
6 Piston 1
4
A
W173-02-05-011
W2-5-33
Needle Valve
A 5
2
6
7
1
3
Section A-A W173-02-05-013

A
ITEM PART NAME QTY

1 O-Ring 3
2 O-Ring 1
3 Plug 2
4 Nut 1
5 Adjusting Screw 1
6 Poppet 1
W173-02-05-012
7 Casing 1
Blank Flange
W1HH-02-05-016
5 4 4 5 2 4 5
ITEM PART NAME QTY
1 Socket Bolt 4
2 Blank Flange 1
3 O-Ring 2
3 3 4 O-Ring 3
5 ROH Plug 3
LCAT1 LCAP1
W1HH-02-05-015
W2-5-34
Arm Anti-drift Valve
12 13
A
17 21
B1 PL
B 3
17
4
12
5
B 19
24 6
20
8
7
14
18 Dr
Section A-A W1HH-02-05-006
Dr
A
W1HH-02-05-008
ITEM+ PART NAME QTY

1 Socket Bolt 8
9 16 11 10 2 Socket Bolt 4
3 Piston 1
4 Piston 1
5 Relief Valve 1
6 Bushing 1
7 Spring 1
8 Spool 1
9 Spring 1
10 Poppet 1
11 Plug 1
12 Plug 2
13 Plug 1
23 14 Plug 1
15 O-Ring 2
16 O-Ring 1
17 O-Ring 2
22
15 18 O-Ring 2
19 O-Ring 3
20 O-Ring 1
1 21 O-Ring 1
A1 W1HH-02-05-009
22 Casing 1
15 23 Casing 1
Section B-B 24 Casing 1
W2-5-35
Boom 1 Spool Assembly
2 3 6 9 7 4 8 5 1
W173-02-05-015
ITEM PART NAME QTY

1 Plug 2 1
2 Plug 1 1
3 Spring B3 1
4 Spring B2 1
5 Spring B1 1
6 Plunger 3 1
7 Plunger 2 1
8 Plunger 1 1
9 Spool 1
Arm 2 Spool Assembly
8 4
3 10 9 6 11 1 12 7 5 2 W173-02-05-016
ITEM PART NAME QTY

1 Spring Seat (1) 1
2 Plug 1
3 Plug 1
4 Stopper (2) 1
5 Stopper (1) 1
6 C-Ring 1
7 Spring A2 1
8 Spring A1 1
9 Sleeve (1) 1
10 Sleeve (2) 1
11 Sub Spool 1
12 Spool 1
W2-5-36
Bucket Spool Assembly
W1HH-02-05-018
2 5 8 4 7 9 6 3 1
ITEM PART NAME QTY

1 Plug 2 1
2 Plug 1 1
3 Spring B3 1
4 Spring B2 1
5 Spring B1 1
6 Plunger 3 1
7 Plunger 2 1
8 Plunger 1 1
9 Spool 1
W2-5-37
Pump Control Valve
9 Dr
2
Pc
6
PE
5
R
7
P
W173-02-05-017
ITEM PART NAME QTY

1 Lock Nut 1
2 O-Ring 1
3 Adjusting Plug 1
4 Spring 1
5 Spool 1
6 O-Ring 1
7 O-Ring 1
8 O-Ring 1
9 Body 1
W2-5-38
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

may penetrate the skin, causing serious in-
jury. Avoid this hazard by relieving pressure
before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation
starting any repair work.
moved without releasing accumulated pres-
sure first. Push the air release valve on top of
the hydraulic oil tank to release any remain-
ing pressure.
Preparation

pressure.

lic oil tank.

tem. M104-07-021
W2-6-1
Removal
1. Disconnect hoses (1 to 3 and 5 to 7). 7
: 41 mm 6
: 205 N⋅m (21 kgf⋅m)
: 19 mm 1
: 29.5 N⋅m (3 kgf⋅m) 2
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m)
5
NOTE: Attach caps to the hoses and pipes.
2. Attach a nylon sling to the swing motor so as to
hoist it by crane. 3
Nylon sling (eye-type at both ends): 2 places 4
W1HH-02-06-001
CAUTION: Swing device assembly weight:

Nylon Sling
390 kg (800 Ib)
3. Remove bolts (4) and hoist the swing device
assembly by crane.
: 32 mm
: 640 N⋅m (65 kgf⋅m, 470 Ibf⋅ft)
Installation
NOTE: Refer to “Removal” section above for

wrench sizes and tightening torques.
IMPORTANT: Before installing the swing device

assembly, apply liquid packing
(THREEBOND #1102) to both mou-
nting surfaces on the swing device
and frame.
1. Install the swing device with bolts (4).
2. Connect hoses (1 to 3 and 5 to 7).
IMPORTANT: Be sure to fill the swing motor with W176-02-06-002
hydraulic oil after installing it. After

completing installation, check
hydraulic oil level. Add oil as
necessary. Run the engine and
check the component for any oil
leaks.
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING DEVICE
32
22
2
23
4
5
31
6
21
7
30 8
24 18
29 9
25 20
7
28 10
19
11
27 12
18 13
17 14
26 16
13
15 12
W1HH-02-06-002
1 - Socket Bolt (12 used) 9 - First Stage planetary Gear 17 - Bolt (2 Used) 25 - Drain Plug
(3 used)
2- Motor 10 - Pin (3 Used) 18 - Thrust Plate (2 used) 26 - Shaft
3- Retaining Ring 11 - Spring Pin (3 Used) 19 - Second Stage Carrier 27 - O-Ring
4- First Stage Sun Gear 12 - Thrust Plate (6 used) 20 - Second Stage Sun Gear 28 - Oil Seal
5- Pin (3 Used) 13 - Needle Bearing (6 Used) 21 - First Stage Carrier 29 - Sleeve
6- Spring Pin (3 Used) 14 - Second Stage planetary 22 - Ring Gear 30 - Roller Bearing
Gear (3 used)
7 - Thrust Plate (6 used) 15 - Bearing Nut 23 - Roller Bearing 31 - Housing
8 - Needle Bearing (3 Used) 16 - Lock Plate 24 - Pipe 32 - Socket Bolt (12 used)
W2-6-4
Disassemble Swing Device
CAUTION: Swing device weight: CAUTION: Ring gear weight: 34 kg (75 lb)
390 kg (860 lb) 7. Loosen and remove socket bolt (32). Install eye-
1. Attach a nylon sling to the swing motor so as to bolt (M12, pitch 1.75) into the motor mounting
hoist it by crane. thread position of ring gear (22). Hoist it by crane
to remove the ring gear from housing (31).
: 17 mm
2. Put the swing device on bracket (ST 5100).
Secure it with bolts (M22) (2 used). Secure the NOTE: THREEBOND has been applied on the joint
bracket on a working platform. surface between housing (31) and ring gear
: 32 mm (22). Insert a screw driver into the gap be-
Swing Device tween the swing motor and ring gear.
Then pry it up for easy removing.
8. Remove second stage sun gear (20) and the
ST 5100 second stage carrier (19) assembly.
CAUTION: Housing (31) assembly weight:

200 kg (440 lb)
9. Remove bolt (17). Remove lock plate (16).
: 17 mm
W1HH-02-06-011
10. Remove nut (15) from shaft (26) using special nut
3. Remove drain plug (25), then drain off oil. removing tool (ST 3167).
: 8 mm ST 3167 15
4. Remove pipe (24) from housing (31).

: 18 mm
CAUTION: Motor weight: 71 kg (160 lb)

5. Put matching marks at the jointed portion between
motor (2) and ring gear (22), between ring gear
(22) and housing (31).
Loosen and remove socket bolt (1). Hoist and W178-02-06-008
remove motor (2) by crane. 11. Install eyebolt (M20, pitch 2.5) into the bolt (32)
: 10 mm hole of housing (31). Remove bolts (M22) (2
NOTE: Insert the screw driver between motor (2) used) with the housing and bracket. Hoist the
and ring gear (22) to float motor (1), and housing (31) assembly by crane to remove the
remove motor (2) easily. bracket.
6. Remove first stage sun gear (4) from first stage 12. Put the blocks on the press bench. Put the
carrier (21). housing (31) assembly on the blocks.
Remove the first stage carrier (21) assembly from
ring gear (22).
: 8 mm 31
W1HH-02-06-012
Block
W2-6-5
23
31
30
29
27
26
W1HH-02-06-002
W2-6-6
CAUTION: Before pressing shaft (26), pro- Shaft (26)

vide a protection cover (outer diameter: 369 Roller Bearing (23)
mm (14.5 in), inner diameter: 90 mm (3.5 in), Housing (31)
thickness: 25 to 30 mm (1.0 to 1.2 in)). Then,
use the press to remove shaft (26) while cov-
ering housing (31) and roller bearing (23) with
Protection Cover
the protection cover. Failure to use the pro-
tection cover may result in personal injury
due to metal fragments flying off if housing
(31) and/or roller bearing (23) break. Use a
press with the capacity less than 30 tons
(66000 lb). Be sure to degrease the housing
W157-02-06-010
inside before heating roller bearing (23). Fail- Press
ure to degrease may cause a fire.
13. Put the protection cover onto housing (31) and

remove shaft (26) with a press. At this time re- Bearing Removal
Special Tool Set
move the roller bearing (30) inner race and sleeve
(29) with shaft (26).
14. Remove the roller bearing (23) inner race from

housing (31).
15. Attach shaft (26) assembly to the special tool

bearing removal set.
W157-02-06-011
NOTE: Use the following parts as the special tool

set for removing roller bearing (30). Shaft
Hose Clamp
Part Size Remarks

Shaft Length: 220 mm 8 used. All should be
or Bolt (8.7 in) identical in length with no
Diameter: 19 mmwear and deformation on
(3/4 in) both ends.
Material: S35C
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2”
(Applicable Di-
ameter: 185 to W157-02-06-012
215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter: Shaft (26)
292 mm (11.5 in) Roller Bearing (30)
Inner Diameter:
272 mm (10.7 in) Sleeve (29) Hose
Clamp
Shaft
Guide
W157-02-06-01
W2-6-7
23
5
31
6
21
7
30 8
18
29 9
28 10
19
11
27 12
18 13
14
26
13
12
W1HH-02-06-002
W2-6-8
CAUTION: Be sure to use the guide when 20. Insert a bar at the back side of the outer race of
pushing shaft (26) with a press. roller bearing (23). Remove the outer race from
housing (31) by tapping with a bar and hammer.
16. Attach shaft (26) with the special tool to a press.
Then, remove roller bearing (30). 21. Drive spring pin (6) out of first stage carrier (21)
with a round bar and hammer.
Press
22. Remove pins (5) (3 used), first stage planetary
gears (9) (3 used), thrust plates (7) (6 used), and
Shaft (26) needle bearings (8) (3 used) from first stage
Roller carrier (21).
Bearing (30)
Sleeve (29) 23. Remove thrust plates (18) from first stage carrier
(21).
24. Drive spring pin (11) from second stage carrier

Guide
(19) with a round bar and hammer.
25. Remove pins (10) (3 used), second stage

planetary gears (14) (3 used), thrust plates (12) (6
W157-02-06-014
used), and needle bearings (13) (6 used) from
second stage carrier (19).
17. Remove sleeve (29) from shaft (26). Remove O-
ring (27) from sleeve (29).
26. Remove thrust plate (18) from second stage
carrier (19).
18. Insert a round bar into the oil passage in housing
(31), tap the outer race of roller bearing (30) out.
Oil Passage
Outer Race
W1HH-02-06-007
CAUTION: Housing (31) weight:

104 kg (230 lb)
19. Secure housing (31) body with a nylon sling, hoist
it by crane to turn housing (31) over.
Insert a screw driver into the gap on housing (31)
where oil seal (28) is mounted. Remove oil seal
(28).
NOTE: THREEBOND has been applied on the
periphery of oil seal (28). Thus, it can’t be
reused.
W2-6-9
ASSEMBLE SWING DEVICE
3
5
6
2 1
4
7
8
21
9
7
18 11
12
20 13
32
19
22 14
10
18
17
16
15 23
30
24
31
25
26
27
28
29
T1HH-03-02-001
1 - Socket Bolt (12 used) 9 - First Stage planetary Gear 17 - Bolt (2 Used) 25 - Drain Plug
(3 used)
2- Motor 10 - Pin (3 Used) 18 - Thrust Plate (2 used) 26 - Shaft
3- Retaining Ring 11 - Spring Pin (3 Used) 19 - Second Stage Carrier 27 - O-Ring
4- First Stage Sun Gear 12 - Thrust Plate (6 used) 20 - Second Stage Sun Gear 28 - Oil Seal
5- Pin (3 Used) 13 - Needle Bearing (6 Used) 21 - First Stage Carrier 29 - Sleeve
6- Spring Pin (3 Used) 14 - Second Stage planetary 22 - Ring Gear 30 - Roller Bearing
Gear (3 used)
7 - Thrust Plate (6 used) 15 - Bearing Nut 23 - Roller Bearing 31 - Housing
8 - Needle Bearing (3 Used) 16 - Lock Plate 24 - Pipe 32 - Socket Bolt (12 used)
W2-6-10
Assemble Swing Device
1. Install needle bearing (8) in each first stage 8. Install sleeve (29) and the inner race of roller
planetary gears (9) (3 used). bearing (30) into shaft (26). Press sleeve (29) and
inner race using bearing mounting tools (ST 7289)
2. Install thrust plates (18) in first stage carrier (21). and (ST 7292).
NOTE: Press-in distance of the bearing inner race
3. Install first stage planetary gears (9) (3 used) and can be assured by using the bearing mount-
thrust plates (7) (6 used) into first stage carrier ing tool.
(21).
4. Aligning the hole on pin (5) with spring pin hole on

first stage carrier (21), drive pins (5) (3 used) into Press
first stage carrier (21) with a hammer.
IMPORTANT: Be sure to drive the spring pin ST 7292

correctly.
5. Tap spring pin (6) into first stage carrier (21) and 30
ST 7289
pin (5). At this time, the slit of the spring pin
should face to the end of pin (9). 29
26
6
5
Slit
WIHH-02-06-008
W178-02-06-002 CAUTION: Housing weight: 104 kg (230 lb)

9. Secure housing (31) body with a nylon sling, then
6. Assemble second stage carrier (19), referring to hoist it by crane. Place sleeve (29) with the mount-
steps 1 to 5 above. Assemble seond stage ing side up.
planetary gears (14) (3 used), needle bearings
(13) (6 used), thrust plates (12) (6 used), (18),
pins (10) (3 used), and spring pins (11) (3 used). 10. Tap the outer race of roller bearing (30) evenly
with a bar and hammer while installing the outer
7. Install O-ring (27) onto sleeve (29). race into housing (31). Tap the bearing and listen
to ring to confirm if installation is completed.
W2-6-11
32
15 23
31
26
28
29
T1HH-03-02-001
W2-6-12
11. Apply THREEBOND #1102 on the outer surface 19. Place mounting tool (ST 7290) onto the inner race
of oil seal (28). Put oil seal (28) flat on housing of roller bearing (23). Push the inner race down
(31) and push it in gently. Then place seal with a press.
mounting tool (ST 7291) on the oil seal and tap it NOTE: Press in distance of the inner race can be
in with a hammer directly. assured by using the mounting tool.
23
ST 7291
28 ST 7291
31
WIHH-02-06-009
WIHH-02-06-010
20. Hoist the housing (31) assembly and place it on
12. Apply grease to the inner surface of oil seal (28) bracket (ST 5100) by crane. Secure it with bolts
all around. Apply grease to the outer surface of (M22) (2 used) while the stopper at the bottom of
sleeve (29) on shaft (26). bracket is located at the middle of two teeth of the
pinion gear. Secure the bracket on a working
13. Install eye bolt (M20, pitch 2.5) into the bolt (32) platform.
: 32 mm 31
hole in housing (31). Then hoist and place it on
shaft (26) by crane, slowly. Check and align
carefully to protect the oil seal (28) lip from curling
ST 5100
while mounting it.
14. Tap the outer race of roller bearing (23) into hous-
ing (31) with a bar and hammer evenly. Listen to
ring to confirm if installation is completed.
15. Tap the inner race of roller bearing (23) into shaft W1HH-02-06-011
(26) with a bar and hammer. Tap the inner race

IMPORTANT: Pay attention to the direction of the
until two threads of shaft nut (15) appear.
bearing nut.
21. Apply a little amount of grease on the threaded
16. Screw in nut (15) to shaft (26). Tighten as much
surface of nut (15), then install it on shaft (26) with
as possible by hand.
the stepped side of nut facing roller bearing (23).
NOTE: Prevent shaft (26) from falling down when Tighten the nut using mounting tool (ST 3167).
hoisting housing (31). : 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
CAUTION: Housing + shaft + bearing weight: NOTE: Grease must be applied for keeping correct
193 kg (425 lb) tightening torque.
17. Install eyebolt (M20, pitch 2.5) into the bolt (32) ST 3167
hole in housing (31). Hoist housing (31) by crane 15
and place it on a press.
18. Remove nut (15) from shaft (26).
W178-02-06-008
W2-6-13
21
20 32
19
22
17
16
15
24
25 31
26
27
T1HH-03-02-001
W2-6-14
22. Install lock plate (16) onto nut (15) with bolt (17). IMPORTANT: Pay attention to the mounting
In case the spline of lock plate (16) and that of direction of the sun gear.
shaft (26) are not aligned, tighten nut (15) in 28. Install first stage sun gear (4) into the first stage
tightening direction until both splines are aligned. carrier (21) assembly with the stepped side of the
: 17 mm sun gear facing down.
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
29. Install pipe (24) into housing (31) with the seal
tape wound on the threaded part of pipe (24).
CAUTION: Second stage carrier weight:
: 18 mm
42 kg (93 lb)
IMPORTANT: Pay attention to the mounting
30. Wind the seal tape on drain plug (25), then install
direction of the second stage carrier.
it into pipe (24).
23. Install the second stage carrier (19) assembly
: 8 mm
onto the spline of shaft (26), while the concave
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
part of the boss in bottom side of the carrier
comes in contact with lock plate (16).
31. Supply gear oil: 16.3 L (4.31 US gal)
Concave 19 32. Apply new THREEBOND #1215 onto the motor

mounting surface of ring gear (22).
16
26
CAUTION: Motor weight: 71 kg (160 Ib)
33. Hoist motor (2) by crane. Align the matching
marks, and install it into ring gear (22) with socket
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W178-02-06-014
24. Install second stage sun gear (20) into the second
stage carrier (19) assembly.
25. Clean off old THREEBOND and apply new

THREE-BOND #1215 onto the ring gear (22)
mounting surface of in housing (31).
CAUTION: Ring gear weight: 34 kg (75 lb)

26. Install eyebolt (M12, pitch 1.75) to the motor
mounting threaded hole on ring gear (22). Hoist
the ring gear by crane, to install it on housing (31)
with socket bolts (32) (12 used) while aligning the
matching marks made when disassembling.
: 17 mm
: 390 N⋅m (40 kgf⋅m)
27. Install the first stage carrier (21) assembly onto

the spline of second stage sun gear (20).
W2-6-15
DISASSEMBLE SWING MOTOR

12
11
10
9
8
7
6 13
3
5
2 4
1 21
22 26
23 27
24 28
25
20
24
23
22
19 21
18 29
17
16 W1HH-02-06-005
15
14
1 - Casing 9 - Plate 17 - Spring (24 Used) 24 - Poppet (2 Used)

2 - Perking Brake 10 - Retainer 18 - Valve Plate 25 - Valve Casing
Release Valve
3 - Socket Bolt (3 Used) 11 - Rotor 19 - Bearing 26 - Socket Bolt (4 Used)
4 - Oil Seal 12 - Friction Plate (3 Used) 20 - O-Ring 27 - O-Ring
5 - Bearing 13 - Plate (4 Used) 21 - Plug (2 Used) 28 - Plug (2 Used)
6 - Shaft 14 - O-Ring 22 - O-Ring 29 - Relief Valve (2 Used)
7 - Shoe Plate 15 - O-Ring 23 - Spring (2 Used)
8 - Plunger (9 Used) 16 - Brake Piston
W2-6-16
Disassemble Swing Motor
• Be sure to thoroughly read “Precaution for 8. Remove O-rings (14, 15) from casing (1).
Disassembly and Assembly” (W1-1-1) carefully
before starting the disassembly work. IMPORTANT: Take care not to damage the slide
surface of rotor (11) and plunger (8).
CAUTION: Swing motor assembly weight: 9. Place casing (1) horizontally. Remove rotor (11),
70 kg (155 Ib) retainer (10), plate (9) and plungers (8) (9 used)
IMPORTANT: Don’t disassemble relief valve (29). from shaft (6).
1. Remove relief valves (29) (2 used) from valve
casing (25). 10. Remove plates (13) (4 used), friction plates (12)
: 41 mm (3 used) from casing (1).
2. Remove plugs (21) (2 used) from valve casing IMPORTANT: Take care not to damage the slide
(25). surface of shoe plate (7).
: 17 mm 11. Remove shoe plate (7) from casing (1).
3. Remove springs (23) (2 used) and poppets (24) IMPORTANT: When removing shaft (6), the spline
(2 used) from valve casing (25). damages the oil seal. Be sure to
wind the tape around the spline of
4. Loosen socket bolts (3) (3 used) and remove shaft (6) before removing.
parking brake release valve (2) from casing (1). 12. Tap shaft (6) with a plastic hammer lightly to
remove it from casing (1).
5. Make matching marks at the mounting surface
between valve casing (25) and casing (1). Then 13. Push out oil seal (4) from casing (1).
loosen socket bolts (26) (4 used). Remove valve
casing (25) from casing (1). 14. Remove the outer race of bearing (5) from casing
: 17 mm (1) with a bar and plastic hammer.
NOTE: Pay attention that valve casing (25) is 15. Remove the inner race of bearing (5) from shaft
floated by spring (17). Pay attention to (6) with a press.
valve plate (18) when removing valve
casing (25). It has a tendency to fall. 16. Remove bearing (19) from valve casing (25) with
IMPORTANT: Be sure not to damage the mating a bearing puller.
surface when separating valve plate
(18) from valve casing (25) or rotor
(11) with a screw driver.
6. If valve plate (18) is still attached with rotor (11) in

step 5, remove the valve plate from the rotor.
Remove springs (17) (24 used).
7. Attach the special tool (ST 7288) onto the brake

piston (16) groove and hoist brake piston (16).
26
ST 7288
16
W1HH-02-06-006
W2-6-17
ASSEMBLE SWING MOTOR
24
23
22
21
26
28
27
T1HH-03-02-003
25
29
17
16
15
19
14
20
18
12
3 13
2 8
10
11
7
9 5
4
6
T1HH-03-02-002
1 - Casing 9 - Plate 17 - Spring (24 Used) 24 - Poppet (2 Used)
2 - Perking Brake 10 - Retainer 18 - Valve Plate 25 - Valve Casing
Release Valve
3 - Socket Bolt (3 Used) 11 - Rotor 19 - Bearing 26 - Socket Bolt (4 Used)
4 - Oil Seal 12 - Friction Plate (3 Used) 20 - O-Ring 27 - O-Ring
5 - Bearing 13 - Plate (4 Used) 21 - Plug (2 Used) 28 - Plug (2 Used)
6 - Shaft 14 - O-Ring 22 - O-Ring 29 - Relief Valve (2 Used)
7 - Shoe Plate 15 - O-Ring 23 - Spring (2 Used)
8 - Plunger (9 Used) 16 - Brake Piston
W2-6-18
Assemble Swing Motor
11. Install brake piston (16) into casing (1).
IMPORTANT: Be sure to place the inner race NOTE: If it is not easy to install O-rings (14), (15)
flange of bearing (5) facing the into brake piston (16) due to the resistant
stepped side of shaft (6). force from the O-rings, tap them evenly with
1. Push the inner races of bearings (5), (19) into a plastic hammer to force them in.
shaft (6) with a press.
12. Install springs (17) (24 used) onto brake piston
IMPORTANT: Push oil seal (4) in, with its lip facing (16).
the bearing (5) mounting side.
2. Push oil seal (4) into casing (1) with a guide plate. IMPORTANT: Tap the bearing type indicated
surface with a plastic hammer while
3. Install the outer race of bearing (5) into casing (1) installing bearing (19).
with a guide bar. 13. Tap the outer race of bearing (19) with a plastic
hammer while installing it into valve casing (25).
IMPORTANT: Wind the tape on the spline at the
end of shaft (6) to prevent damaging 14. Install O-ring (20) onto valve casing (25). Then
oil seal (4). install valve plate (18).
4. Place casing (1) horizontally. Install shaft (6) into NOTE: Apply grease onto valve plate (18) to avoid
casing (1). it coming off from valve casing (25).
5. Place casing (1) with the valve casing (25) 15. Align the mating marks on valve casing (25) and
mounting side up. Then install shoe plate (7). casing (1). Secure them with socket bolts (26) (4
used).
6. Assemble plate (9) and retainer (10) with the : 17 mm
notch matched. Then install plungers (8) (9 used). : 431 N⋅m (44 kgf⋅m, 320 lbf⋅ft)
IMPORTANT: Apply hydraulic oil into the plunger 16. Install poppets (24) (2 used) and springs (23) ( 2
hole in rotor (11), then install plunger used) into valve casing (25). Tighten plug (21)
(8). with O-ring (22) attached.
7. Insert the plunger (8) assembly into rotor (11). : 17 mm
: 539 N⋅m (55 kgf⋅m, 400 lbf⋅ft)
8. Place casing (1) horizontally. Install the rotor (11)
assembly onto shaft (6). 17. Install relief valves (29) (2 used) into valve casing
(25).
IMPORTANT: 4 notches are on the outer side of : 41 mm
plate (13). And 4 notches are at the : 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
spline teeth side of friction plate (12).
Be sure to align each notch at the 18. Install parking brake release valve (2) into casing
same place when installing. (1) with socket bolts (3) (3 used).
9. Place casing (1) vertically. Alternately install plates : 5 mm
(13) (4 used), friction plates (12) (3 used) into : 12 N⋅m (1.2 kgf⋅m, 8.68 lbf⋅ft)
casing (1).
10. Install O-rings (14) and (15) onto casing (1).

NOTE: Apply grease to O-rings (14) and (15), and
they are not broken easily when installing
brake piston (16).
W2-6-19
DISASSEMBLE AND ASSEMBLE
PARKING BRAKE RELEASE VALVE
ʮʭ ʱ ʶ ʮʮ
ʰ
7
ʮʯ
ʳ
5 ʯ
ʮ ʮʰ
W110-02-06-005
1- Casing 5 - Bushing 8 - Orifice 11 - O-Ring (2 used)

2- Spool 6 - Filter 9 - Spring 12 - Steel Ball
3- Spring 7 - Spacer 10 - O-Ring 13 - Bolt (3 used)
4- Plunger
W2-6-20
MAINTENANCE STANDARD
Swing Motor
d
1. Clearance between the out diameter of plunger
and the inner bore of cylinder.
D-d Unit:m (in)

0.028 (0.001) 0.058 (0.002) W107-02-06-138
D D
W107-02-06-139
2. Clearance between plunger and shoe at the

caulked position.
δ Unit: mm (in)
0 (0) 0.3 mm (0.0118)
δ
W107-02-06-140
W107-02-06-141
W2-6-21
3. Thickness of shoe
t Unit: mm (in)
5.5 (0.22) 5.3 (0.21)
4. Thickness of friction plate. W107-02-06-142

t Unit: mm (in)
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-22
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE

jury. Avoid the hazard by relieving pressure
pressure.
Preparation

M104-07-021
pressure.
Removal
1. Remove seat mounting bolts (2) (4 used) to re-
move seat (1) (with seat stand).
: 17 mm
W178-02-07-006
W2-7-1
2. Remove screws (24) (4 used), cover (23) to move
boot (29) up.
: 17 mm 30
3
3. Remove caps (17) (2 used) from cover (18). 29
4
28
4. Remove screws (21)(4 used) and (16) (2 used) to 27 5
move cover (18) up. Disconnect each harness 26 6
connectors for key switch (20), air controller (19) 25 7
and grip (3), then remove cover (18). Remove 8
screws (22), (15) and (13) to remove cover (14). 9
24 10
11
23 12
5. Remove the connector and bolt (11) for switch box
(12) to remove switch box (12). 21
20
: 13 mm
19
22
18
IMPORTANT: Attach identification tags on all
disconnected hoses to aid in reas-
sembly. 17
6. Disconnect hoses (31 to 36). 16

: 19 mm
15
NOTE: Attach a cap on all disconnected hose
ends. 14
7. Loosen nut (4) to remove grips (5) and (26). Dis- 13

connect connector (6) to remove grip (3) (with W178-02-07-001
harness).
Loosen nut (28) to remove lever (30), washers
(25), (26) and boot (29).
: 22 mm 31
36
: 19 mm 35 32
33
8. Remove bolts (9) (3 used) and (8) (with pin (7))
from pilot valve (10) to remove pilot valve (10). 34
: 13 mm
W178-02-07-002
31 - Hose T6: (To the pilot shut-off valve)

32 - Hose B: (To the shockless valve port B for boom lower)
33 - Hose G: (To shockless valve port G for bucket roll-in)
34 - Hose P3: (From the pilot shut-off valve)
35 - Hose A: (To the shockless valve port A for boom raise)
36 - Hose H: (To the shockless valve port H for bucket roll-out)
NOTE: Piping location shows that of JIS pattern.
W2-7-2
Installation
1. Secure pilot valve (10) with bolts (9) and (8) (with
pin (7)).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 31
36
35 32
2. Connect hoses (31 to 36).
: 19 mm 33
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 34
IMPORTANT: If the harness is arranged to the inside

of spring pin (7), it may make contact
with the moving part of the pilot
valve which may damage the harness .
Be sure to arrange the harness to
W178-02-07-002
the outside of spring pin (7).
30
3. Temporarily tighten nut (28) to lever (30), then in-
stall washers (25), (26). Install lever (30) onto 3
29
valve (10) with nut (28). Install boot (29).
4
Temporarily tighten nut (4) to lever (30), then in- 28
stall grip (3) with nut (4). 27 5
Pass the harness of grip (3) through the upper
26 6
hole of boot (29), then connect it to lever (30) via
25 7
clips (5) and (27). Arrange the harness to the out- 8
side of spring pin (7) over bolt (8) head. 9
Install connector (6). 24 10
11
: 22 mm 23 12
: 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 21
: 19 mm 20
: 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 19
22
18
4. Install switch box (12) with bolt (11), then connect
the connector.
: 13 mm 17
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
16
5. Connect each harness of key switch (20) and air
controller (19).
15
6. Install cover (14) with screws (22), (15) and (13). 14
Install cover (18) with screws (21) (4 used) and
(16) (2 used). 13
Install caps (17) (2 used) onto cover (18).
W178-02-07-001
7. Install cover (23) with screw (24).
W2-7-3
8. Install seat (1) (with the seat stand) with bolts
(2) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
IMPORTANT: After installation, check the oil level,

start the engine and check for oil
leaks.
2
W178-02-07-006
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE

before disconnecting hydraulic or other
lines.
Hydraulic oil may be hot just after operation
ing pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
2. Stop the engine. Push the air release valve on the

M104-07-021
hydraulic oil tank to release any pressure remain-
ing in the hydraulic tank.
Removal
1. The console is at the most front position. Remove
screws (2) (4 used) and cover (3) to move boot (1)
up. 1
: 17 mm
2. Remove screws (7), (8) to remove cover (9).
3. Remove cap (10) from cover (6). 10

2
9 Radio
4. Remove screws (4) (3 used), (5) to move cover 3
(6) up to disconnect the radio connector, then re- 8
4
move cover (6).
7
6
5
W178-02-07-003
W2-7-5
sembly.
5. Disconnect hoses (11 to 16).

: 19 mm 11
16
15 12
NOTE: Attach a cap on each disconnected hose 13
end.
14
6. Loosen nut (18) to remove clips (29), (21).
Disconnect connector (28) to remove grip (17)
(with harness).
Loosen nut (20) to remove lever (19), washers
(25), (26) and boot (1).
: 22 mm
: 19 mm
W178-02-07-004
11 - Hose T5 : (To the pilot shut-off valve)
7. Remove bolts (24) and (23) (with pin (22)) to 12 - Hose F : (To the shockless valve port F for swing right)
13 - Hose C : (To the shockless valve port C for arm roll-out)
remove pilot valve (27). 14 - Hose P2 : (From the pilot shut-off valve)
: 13 mm 15 - Hose E : (To the shockless valve port for E swing left)
16 - Hose D : (To the shockless valve port D for arm roll-in)
NOTE: Piping location shows that of JIS pattern.

Installation
17
1. Install pilot valve (27) with bolts (24) and (23) (with
pin (22)).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 29
18
2. Connect hoses (11 to 16). 19
: 19 mm 28
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 1
20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6
IMPORTANT: If the harness is arranged to the in-
side of spring pin (21), it may make
contact with the moving part of the
pilot valve which may damage the 17
harness. Be sure to arrange harness
to the outside of spring pin (21).
29
3. Temporarily tighten nut (20) to lever (19), then
18
install washers (25) and (26). Install lever (19)
onto pilot valve (27) with nut (20). Install boot (1). 19
28
Temporarily tighten nut (18) to lever (19), then se-
1
cure grip (17) with nut (18). 20
Pass the harness of grip (17) through the upper 21
hole of boot (1), then connect it to lever (19) via 22
grips (29). Arrange the harness to the outside of 23
spring pin (22) over bolt (23) head. Connect con- 24
nector (28). 8 9 10 25
: 13 mm 26
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft) 27
: 22 mm
: 26 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft) 2
: 19 mm 3
: 26 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
4
5
4. Connect the connector of the radio and install
cover (6) with screws (4) (4 used) and (5), install
cap (10).
Install cover (9) with screws (7), (8).
7 6 W178-02-07-003
5. Install boot (1) and cover (3) with screw (2) (4 used).
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
W2-7-7
REMOVE AND INSTALL TRAVEL PILOT
VALVE

before disconnecting hydraulic or other
lines.
ing pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
2. Stop the engine. Push the air release valve on the

hydraulic oil tank to release any pressure remain-
ing in the hydraulic tank.
M104-07-021
W2-7-8
Removal
1. Remove floor mat (1).
2. Remove bolts (3) (6 used) from swing frame to

remove under cover (2). 1
: 17 mm
3. Loosen bolts (4) (2 used) to remove pedals (5) (2

used), levers (16) and (17).
: 17 mm
WIHH-02-07-001

sembly.
4. Disconnect pipes (6, 7) and hoses (8 to 11).

2
: 19 mm
3
NOTE: Attach a cap on each disconnected hose

WIHH-02-07-002
end.
5. Remove socket bolt (14), spring washer (13) and

plain washer (12) to remove pilot valve (15).
: 8 mm 17
4
16
Installation 5
1. Install pilot valve (15) with socket bolt (14), spring
washer (13) and plain washer (12).
: 8 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 4
2. Connect pipes (6, 7), hoses (8 to 11). 5

: 19 mm 15
14
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) 14
13
13
3. Install pedal (5), levers (16) and (17) with bolts (4). 12
: 17 mm 12 6
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 7
4. Install under cover (2) with bolts (3) (6 used).

: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 11
10
9
5. Install floor mat (1). 8
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
W178-02-07-005
leaks. 6 - Pipe T4: (To the pilot shut-off valve)
7 - Pipe P1: (From the pilot shut-off valve)
8 - Hose 11: (To the control valve port RF for travel right
and forward)
9 - Hose 12: (To the control valve port RR for travel right
and reverse)
10 - Hose 10: (To the control valve port LR for travel left
and reverse)
11 - Hose 9: (To the control valve port LF for travel left
and forward)
W2-7-9
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-10
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage, them. port number after removing.
Therefore, be careful while handling
them.
4. Pull push rods (8), (9) out from block (10).
IMPORTANT: As spool (17) has been selected to
5. With a bamboo spatula, remove oil seals (15) (4
match the hole of housing (18), they
used) from block (10).
must be replaced as a set. In addi-
tion, the dimensions of balance
springs A (3), B (4) and return NOTE: If a metal bar is used, the mating part of the
springs A (5), B (6) as well as those oil seal may be damaged.
of push rods A (8), B (9) are different.
For this reason, be sure to indicate IMPORTANT: The retaining ring may come off
the port number from which it is re- while disassembling. Take care not
moved. Port numbers are stamped to drop it.
on housing (18).
6. Press springs with special tool (ST 7257) from the
IMPORTANT: Don’t clamp housing (18) in a vise to top of spring guide (16). Retaining ring (7) will ap-
remove the screw joint because the pear. Remove it with a screw driver or similar tool.
strong torque may act on the screw (4 places)
joint. 7
1. Secure screw joint (13) in a vise. Then turn cam

(12) with a spanner to remove the screw joint.
: 32 mm
2. Clamp the flat surface of housing (18) in a vise

slightly. Remove cam (12) from universal joint 16
(14). ST 7257
: 32 mm
NOTE: The universal joint has been secured on

block (10) with LOCTITE. Don’t remove it
unless necessary. W176-02-07-005
3. Remove socket bolt (11) to remove block (10). At

this time, push rods (8) and (9) are still on the IMPORTANT: The number of shims has been de-
block side. termined for each port during the
: 6 mm performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when reassem-
bly.
7. Remove spring guide (16), balance springs (3),

(4), return springs (5), (6), shim (2), spacer (1)
from spool (17).
W2-7-11
21
20
21
20
19
18
17
W176-02-07-001
W2-7-12
IMPORTANT: As the spool has been selected to
match the hole in the housing, keep
them carefully so as to install them
to the former port when reassem-
bling.
8. Remove spool (17) from housing (18). Pulling it

out while turning it.
NOTE: The spool and housing must be replaced as

assembly.
9. Remove O-rings (19), (21) from housing (18).

Don’t remove dowel pin (20) unless necessary.
W2-7-13
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
13 14
10
12
15
11
8, 9
7
16
3, 4
5, 6
19
17
W176-02-07-006
21 20 18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-14
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to IIMPORTANT: Install spring guide with the protru-
contamination. sion facing up.
Keep parts clean when assembling.
3. Install spring guide (16) onto the return spring (3)
NOTE: Table below shows the relations between or (4).
each port and the components. Take care
not to confuse them when assembling. 4. Install retaining ring (7) onto ring holder (ST
7255).
Port Spool Shim Push Rods ST 7255
No. 7
(17) (2) (8), (9)
With outer
1
Same to Same to groove
the former the former Without outer
2 W176-02-07-008
one one groove
With outer 5. Insert the spool (17) head into the hole for spring
3
groove special tool (ST 7257) to press the spring from the
Without outer top of spring guide (16). Install retaining ring (7)
4
groove with the ring holder (ST 7255) onto the head of the
spool.
Port Return Springs Balance Springs
ST 7257 ST 7255
No. (5), (6) (3), (4)
1 Short Short
2 Long Long 17
3 Short Short
4 Long Long
Packing Material
IMPORTANT: Make sure of the port hole number,

and insert the spool to the former W176-02-07-009
port. NOTE: Put approx. dia.8 mm, length 10 mm of
packing material into the port hole so as to
1. Insert the thinner end of spool (17) to housing (18), not only make the work easy to do, but also
while rotating it. prevent the spool from lowering to the bot-
tom when compressing the spring.
NOTE: The spool has been selected to match the
hole of the housing. The spool and housing 6. Assemble the remained spools (17) (3 used) into
must be replaced as an assembly. housing (18) in the same procedures as step 2 to
5.
IMPORTANT: Refer to the table above to assemble
them correctly. 7. Install O-rings (19) and (21) (2 used) on to hous-
ing (18).
2. Install spacer (1), shim (2), balance spring (3) or

(4), return spring (5) or (6) onto spool (17) in-
stalled in housing (18).
W2-7-15
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-16
8. Apply grease to the inner face of oil seals (15) IMPORTANT: Make sure of the tightness of cam.
(4 used), then install the oil seals (4 used) into
block (10) with a bamboo spatula. 13. Clamp housing (18) carefully in a vise and then
install cam (12) to universal joint (14).
NOTE: The oil seal may come into the endmost of Tighten the universal joint so that the clearance
the hole during operating. Insert push rods between the cam and push rod (8) (9) become 0
(8 and 9) in first as illustrated to prevent the to 0.2 mm.
oil seal from coming into the endmost of the : 32 mm
hole during operating.
Oil Seal IMPORTANT: Don’t clamp housing (18) in a vise
Mounting Hole
because the strong torque may act
8,9 on the screw joint.
10
14. Clamp screw joint (13) in a vise to tighten univer-
sal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 88.2 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods (8), (9) to block (10). When in-

stalling, install the push rods with periphery
groove to ports # 1 and # 3, install the ones with-
out periphery groove to ports # 2 and # 4, respec-
tively.
10. Apply grease to the ball at the ends of push rods

(8), (9).
11. Apply grease to the joint part of universal joint

(14).
12. Align the position of dowel pin (20), install the

block (10) assembly to housing (18) with socket
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
W2-7-17
DISASSEMBLE TRAVEL PILOT VALVE
35 2
34
33
32
31
30
3
4
5
6
29
28 7
27
8
9
10
26
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-18
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolt (1) to 7. Remove spring (18) from casing (14). (4 places)
remove cover (2) from holder (10).
: 10 mm IMPORTANT: Put a stand under bracket (26) to
form an action force. If holder (10)
2. Remove socket bolts (8) (2 places) to remove bears the reaction force, a strong
holder (10) from casing (14). force acts on pin (3) and the pin′′s
: 8 mm shape become deformed.
3. Pull out pusher (23) from casing (14). (4 places) IMPORTANT: The inside of spring pins (24), (25)
Bushing (13) and oil seal (11) are removed with hole in the bracket is in stepped-
the pusher. shape. Therefore the spring pin can
only be pulled out in one direction.
4. Pull out pusher (23) from bushing (13), with a
bamboo spatula to remove oil seal (11). (4 places)
8. Put a stand under bracket (26).
IMPORTANT: Put marks on spools (4 used) so as Push out both spring pins (24), (25) from bracket
to easily install them to their former (26) at the same time with special tool (ST 1237).
position. Remove the bracket from pin (3). (2 places)
Don’t remove spring pin (27) on bracket unless
necessary.
5. Pull out the spool (17) assembly from casing (14)
turning the spool. (4 places)
NOTE: The outside end of the spring pin has been
Spring guide (22), balance spring (21), shim (20)
caulked.
and spacer (19) are removed with the spool.
NOTE: The spool has been selected to match the 24,25

hole of the casing. The spool and casing
must be replaced as an assembly. 26
3 27
IMPORTANT: The number of shims has been
Caulked
determined during the performance
testing at the factory. They must be
kept together with their spool. Stand
6. Compress balance spring (21). Remove spring

guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17). (4 places) W176-02-07-019
9. Remove socket bolts (28) (2 used) to remove

damper (6) and rubber seat (7) from pin (3). O-
ring (4) is removed with them. (2 places)
: 5 mm
W2-7-19
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-20
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mating sur-
face facing up.
IMPORTANT: The holes for spring pins (34), (35) in

cam (32) are stepped-shape. There-
fore the pins shall be removed from
the bottom of the cam.
12. Pull out spring both pins (34), (35) from cam (32)
at the same time with special puller (ST 1237).
(2 places)
NOTE: The spring pin is a double-pin.
NOTE: The spring pin is caulked in its hole, so it

may feel tight when removing.
13. Remove pin (3) with a round bar and a hammer.

At this time cam (32) is also removed. (2 places)
NOTE: Don’t remove bushings (31) (4 used) left on

holder (10) unless necessary. When re-
moval is necessary, the bushing special
tool (ST 7256) should be used to tap it out.
14. Remove lock nuts (33) (2 used) from cam (32) to

remove adjusting bolts (30) (2 used). (2 places)
: 13 mm
: 4 mm
W2-7-21
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12 18
23
20
19
17
14
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-22
Assemble Travel Pilot Valve
IMPORTANT: Pay attention to the mounting direc- 6. If bushing (31) has been removed from holder
tion of spring guide (22). (10), it shall be installed on the holder using spe-
cial tool (ST 7256) in the following procedures.
IMPORTANT: Install the former number of shims.
NOTE: The bushings (4 used) are identical.
1. Assemble the spool (17) into assembly. (4 used)
y Insert spacer (19), shim (20), balance spring y Insert the bushing into special tool (ST 7256),
(21) into the spool in order. then tap on the special tool (ST 7256) to install
y Press balance spring by hand. Install spring the bushing into the hole of holder with
guide (22) to the spool with the stepped-end hammer.
facing down. Stop tapping when the bushing end is flush
with the inside wall .
10 ST 7256
2. Insert spring (18) to casing (14). (4 places)
IMPORTANT: Insert the spool (17) assembly into

the former port. 31
W176-02-07-016
3. Turn and install the spool (17) assembly into cas- y Install the bushing on the opposite side in the
ing (14). (4 places) same procedure.
31
10
4. Assemble plungers (23) (4 used). ST 7256
y Install oil seal (11) onto bushing (13).
y Apply grease to the inner face of oil seal.
y Install O-ring (12) to the bushing.
y Insert pusher (23) to the bushing.
y Apply grease to the pusher head section.
W176-02-07-015
5. Insert the pusher (23) assembly to holder (10). (4 y Install the bushing in near side as shown
places). bellow. Stop tapping when the bushing end is
flush with the outside of holder.
31
10 ST 7256
Outside of
Holder
W176-02-07-014
y Install the bushing on the opposite side as

shown below. 31
10
ST 7256
W176-02-07-013
W2-7-23
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-24
7. Place adjusting bolt (30) to cam (32). Tighten the IMPORTANT: Don’t adjust the adjusting bolt (30)
bolt by hand, and then lightly secure it temporarily while pressing the pusher (23) head
with lock nut (33). (2 places) with the adjusting bolt. The standard
clearance between the adjusting bolt
NOTE: Adjust the dimensions later. and pusher must be 0 to 0.2 mm (0 to
0.008 in).
8. Apply grease on the head (mating surface for
pusher (23)) of adjusting bolts (30). (2 places) 13. Adjust adjusting bolt (30) by the following proce-
Ȁ dures. (2 places)
9. Install O-ring (5) to pin (3), then assemble the pin : 13 mm
to holder (10) with cam (32). (2 places) : 4 mm
y Loosen lock nut (33).
IMPORTANT: Take care of the inserting direction y Move cam (32) to check whether there is play. If
of the spring pin. none, turn adjusting bolt to adjust.
y Turn both adjusting bolts on the left and right
IMPORTANT: Tap the spring pin in until it makes alternatively to keep the cam horizontal.
contact with the step in hole. y Measure sizes A and B from both left and right
caves on the cam to holder (10). Fine adjust the
adjusting bolt to get same distance for both left
10. Install spring pins (34), (35) to cam (32) using
and right.
special tool (ST 1237), then secure the cam and
y Secure the adjusting bolt with a hexagon-
pin (3). The spring pins should be displaced with
headed wrench. Tighten the lock nut to
their slits at 90°. (2 places)
specified torque first, securing the adjusting
34 35 Slit Slit bolt.
y When adjustment is finished, move cam to
check that there is a little play. If there is no play,
the pusher may be in compressed condition,
and adjustment should be carried out again.
: 9.8 N]m(1 kgf]m, 7.2 Ibf⋅ft)
30 33 32 10
W176-02-07-017
11. Caulk the hole edge of cam (32), where spring A B

pins (34), (35) are inserted, with a punch. (2
places)
12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used), spring
washers (9) (2 used).
: 8 mm
: 49 N]m (5 kgf]m, 36 Ibf⋅ft)
W176-02-07-003
W2-7-25
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-26
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under the bracket. If
holder (10) bears the reaction force,
a strong force acts on the pin (3) and
15. Apply grease to O-ring (5). (2 places) the pin may be deformed.
IMPORTANT: The inside of the spring pin hole in

IMPORTANT: Pay attention to the direction of the bracket is stepped-shape. Make
damper (6). sure of the direction to insert the
spring pin.
IMPORTANT: The inner bore of damper (6) is
edged-shape. If the damper is pried IMPORTANT: Make sure the facing direction of the
upward, O-ring (5) will be damaged. spring pin.
16. With the lever upward, install damper (6) to pin (3) 20. Put a stand under bracket (26).
straight without spring. (2 places) Tap spring pins (24) (25) into the bracket until the
spring pin comes to the stepped end using special
tool (ST 1237). The spring pins shall be displaced
17. Secure damper (6) to holder (10) with socket bolts with their slits in 90°.
(28) (2 used) and spring washers (29) (2 used). (2
places)
: 8 mm
: 7 N⋅m (0.7kgf⋅m, 5.1 Ibf⋅ft)
Caulked Here Caulked Here

18. Apply grease to O-ring (4), then press it to the
endmost of pin (3). (2 places) 26 3
IMPORTANT: As for the direction to install the

bracket, refer to the figure in the dis- Stand 24, 25
assemble section. Take care not to
misassemble it.
W176-02-07-011
19. Install pin (3) into bracket (26), then align the in-
serting holes of spring pin (24), (25) to fix the pin
on bracket.
21. Caulk the hole edge of bracket (26), where spring
pins (24), (25) are inserted, with a punch. (2
places)
(Refer to the figure above.)
22. Install pin (3) on other bracket (26) as steps 19 to

21.
23. Install cover (2) to holder (10) with bolts (1) (2 used).
: 10 mm
: 5 N]m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
24. Apply grease to the spring pin (27) contact part of

damper (6). (2 places)
W2-7-27
(Blank)
W2-7-28
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

ing pressure.
Preparation

pressure.
Ȁ
lic oil tank.
NOTE: Be sure to run the vacuum pump continu- M104-07-021

tem.
W2-8-1
Removal
1. Remove spring (3).
IMPORTANT: Attach tags to hoses to aid in as-

sembly.
1
2. Disconnect hoses (6 to 13) and pipes (14, 15).
: 19 mm
3. Remove spring pin (5) to remove lever (1). 2

3
4. Remove bolt (2) to remove pilot shut-off valve (4). 5
: 17 mm
4
Installation
1. Install pilot shut-off valve (4) with bolt (2).
2. Install lever (1) with spring pin (5). W178-02-08-001
3. Connect hoses (6 to 13) and pipes (14, 15). 2
4. Install spring (3).

View A
Wrench Size Tightening Torque

Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft) 6
: 17 49 (5) (36) Bolt 10
: 19 35 (3.6) (26) Pipe
: 19 29.5 (3) (21.5) Hose
6- Hose DP: (To the solenoid valve unit (hydraulic oil tank)
7- Hose PF: (To the solenoid valve unit)
8- Hose: (To the shockless valve) 7
9- Hose PD: (To the pilot filter)
10 - Hose T6: (To the right pilot valve) 8
9
11 - Hose P2: (To the left pilot valve)
12 - Hose T5: (To the left pilot valve)
13 - Hose P3: (To the right pilot valve) WIHH-02-08-001
14 - Hose P1: (To the travel pilot valve)
15 - Hose T4: (To the travel pilot valve)
14 13
View A
WIHH-02-08-002
15 12 11
W2-8-2
(Blank)
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
3
6
2 7
1
8
9
13 10
11
12
W178-02-08-005
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-4
Disassemble Pilot Shut-Off Valve
• Be sure to thoroughly read all Precautions for
Disassembly / Assembly work on page W1-1-1
1. Make matching marks on body (4) and bracket

(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove spool (10) assembly.
2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).
3. Clamp the spool (10) with wooden pieces in a vise.

Remove socket bolt (13) and bracket (11).
: 4 mm
NOTE: Don’t remove pin (12) unless necessary.
4. Remove socket bolt (5) from body (4).

: 8 mm
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE

12 13 11 4 5 Z
Section ZҥZ W178-02-08-006
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-6
Assemble Pilot Shut-Off Valve
1. Apply LOCTITE # 262 on socket bolt (5) and in-

stall it to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
2. Clamp spool (10) with wooden pieces in a vise.

Apply LOCTITE #262 on socket bolt (13), then in-
stall bracket (11) onto spool (10).
: 4 mm
: 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft)
3. Install O-ring (3), backup ring (2) and washer (1)

onto body (4).
4. Apply hydraulic oil to spool (10) and install it to

body (4).
5. Install O-ring (9), backup ring (8) and washer (7)

to body (4), and install retaining ring (6) to spool
(10).
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL SHOCKLESS
VALVE

can penetrate the skin, causing serious
injury.
Avoid this hazard by relieving pressure

The hydraulic oil tank cap may fly off if

removed without releasing internal pressure
pressure.
Preparation

of the hydraulic oil tank to release any remaining M104-07-021
pressure.

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

continuously while working on the hydraulic
system.
W2-9-1
Removal
14 15 16 17 18 19
IMPORTANT: Attach identication tags to all disco-
nnected hoses to aid in assembly.
13 20
1. Disconnect hoses (1 to 9, 13 to 20).

: 19, 22 mm 9
2. Remove pressure sensors (11), (12) and (21). 12 21

: 24 mm
11
3. Remove bolts (10) to remove the shockless valve.
: 17 mm
Installation 1
10
1. Apply LOCTITE to bolts (10), then install
shockless valve with bolts (10).
8B 7 8A 6 5 4 3 2
2. Install pressure switch (11) and pressure sensor
(12) (21). W173-02-09-001
3. Connect hoses (1 to 9, 13 to 20). 1 - Hose (To right swing control valve)

2 - Hose (To left swing control valve)
3 - Hose (To bucket roll-in control valve)
Wrench Size Tightening Torque Remark 4 - Hose (To bucket roll-out control valve)
(mm) N⋅m (kgf⋅m) (lbf⋅ft) 5 - Hose (To boom lower control valve)
: 17 20 (2) (14.5) Bolt 6 - Hose (To boom raise control valve)
7 - Hose (To arm roll-in control valve)
: 19 29.5 (3) (21.5) Hose 8 A - Hose (To arm roll-out control valve)
: 22 39 (4) (29) Hose 8 B - Hose (To arm roll-out control valve)
Pressure 9 - Hose (From pilot shut-off valve)
: 24 79 (8) (58) 10 - Bolt
Sensor
11 - Pressure Sensor (For boom raise)
12 - Pressure Sensor (For arm roll-in)
13 - Hose (From arm roll-in pilot valve)
14 - Hose (From arm roll-out pilot valve)
15 - Hose (From boom lower pilot valve)
16 - Hose (From boom raise pilot valve)
17 - Hose (From bucket roll-in pilot valve)
18 - Hose (From bucket roll-out pilot valve)
19 - Hose (From right swing pilot valve)
20 - Hose (From left swing pilot valve)
21 - Pressure Sensor (For swing)
W2-9-2
(Blank)
W2-9-3
DISASSEMBLE AND ASSEMBLE
SHOCKLESS VALVE
18 17
16 D B G F
14
15
C A
H E
Section S Section T
14
1 2 2
15
1
S4 S2 S7
7
S3 S1
6 5 4 3 Y W U
Section U 14 Section V X V T S
15
Z
3 1 8 5
7
A4
6 Z
4 2 7 6
5
3 4
Section W
2 9 12,13 11 10 9 2
8 Section Z-Z
19
1
14
15 7
WIHH-02-09-001
5
7 6 5 4 3 3 4
Section X Section Y
W2-9-4
WRENCH SIZE TORQUE SPECIFICATION

ITEM PART NAME QTY REMARK
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 3 ϖ8 49 (5) (36.2)
2 O-Ring 4
3 Steel Ball 4
4 Steel Ball 4
5 Spring 4
6 O-Ring 4
7 Plug 4 ϖ5 14.7 (1.5) (10.8)
8 Orifice 1 ϖ5 14.7 (1.5) (10.8)
9 Orifice 2
10 Ring 1
11 Orifice 1
12 Plunger 1
13 Plunger Assembly 1
14 O-Ring 4
15 Plug 4 ϖ6 24.5 (2.5) (18.1)
16 Body 1
17 Seat 1 ϖ5 9.8 (1.0) (7.2) Use LOCTITE #262
18 Steel Ball 1
19 Plug 1 ϖ8 49 (5) (36.2)
W2-9-5
(Blank)
W2-9-6
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE

UNIT
CAUTION: Escaping fluid under pressure may

penetrate the skin, causing serious injury.
ing pressure.
Preparation

pressure.
Ȁ
lic oil tank.
M104-07-021

tem.
W2-10-1
2
Removal
1. Disconnect each harnesses of solenoid valves
from connectors.
3
2. Disconnect pilot lines (1 to 6, 11 to 18, 20 to 23,
25 and 27). 4
: 17, 19, 27 mm
5
10
3. Remove bolts (7) (19) to remove solenoid valve 1
unit.
7
: 6, 8 mm
8 9 6
A
15 14
View A 16 13
12
17 11
Installation
1. Install solenoid valve unit with bolts (7) (19).
WIHH-02-10-001
2. Connect pilot lines (1 to 6, 11 to 18, 20 to 23, 25 20

and 27). 23
18
21
3. Connect all wire harnesses for solenoid valves to
connectors.
19
22
Wrench Size Tight Torque 24
Remark 25
(mm) N⋅m (kgf⋅m) (Ibf⋅ft)
: 17 24.5 (2.5) (18) Pipe, Hose
: 19 29 (3) (22) Hose
: 27 93 (9.5) (43) Hose 26
:6 20 (2) (16) Bolt
:8 20 (2) (16) Bolt
27
WIHH-02-10-002
1 - Pipe PF: From Pilot shut- 8 - Proportional solenoid valve 15 - Pipe PH: To pump control 22 - Hose PI: To control valve
off valve (SG) valve
(5-spool section)
2 - Pipe SC: To arm 9 - Proportional solenoid valve 16 - Hose PG: To swing 23 - Hose TA: To hydraulic oil
regenerative (SI) parking brake tank
valve control valve
3 - Pipe SG: To main 10 - Proportional solenoid valve 17 - Hose DG: From arm 24 - Torque control solenoid
relief valve (SC) anti-drift valve valve
4 - Hose SI: To 11 - Pipe DD: From arm 18 - Hose ST: To main pump 1 25 - Hose DI: To hydraulic oil
travel motor regenerative tank
valve
5 - Hose DS: To hydraulic oil 12 - Pipe PE: To pump 19 - Socket bolt 26 - Maximum pump 2 flow rate
tank control valve limit solenoid valve
(4-spool section)
6 - Hose DP: From pilot shut- 13 - Pipe DE: From bucket 20 - Hose SB: To main pump 2 27 - Hose SP: To pump control
off valve flow rate control valve
valve switch (5-spool sec-
valve B tion)
7 - Socket bolt 14 - Pipe DH: From bucket 21 - Hose PD: To pilot shut-off
flow rate control valve
valve switch
valve A
W2-10-2
(Blank)
W2-10-3
DISASSEMBLE PROPORTIONAL
SOLENOID VALVES (SC, SI and SG)
1
3
2
4
5
6
7
8
9
10
11 14
12 15
13
16
17
18
19
WIHH-02-10-005
1- Socket Bolt (2 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 Screw 9- Diaphragm 14 - O-Ring 19 - Washer
5- Spring 10 - Spool 15 - O-Ring
W2-10-4
Disassemble Proportional Solenoid Valves
• Be sure to thoroughly read “Precaution for Disas-
sembly and Assembly” (W1-1-1) carefully before
starting the disassembly work.
IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Don’t turn lock nut (2) and adjusting
screw (4).
1. Loosen socket bolts (1) (2 used) to remove sole-
noid (6).
: 3 mm
IMPORTANT: Be sure not to remove orifice (11)

from spool (10).
2. Pull out spool (10) and remove diaphragm (9),
washer (12) and spring (13).
3. Pull sleeve (17) out and remove O-rings (14), (15)

(16), plate (18) and washer (19).
W2-10-5
ASSEMBLE PROPORTIONAL SOLENOID

VALVES (SC, SI and SG)
4 2 6 1 8 17 14 15 10 16 11 19
3, 5 9 7 12 13 18
W157-02-11-001
1- Socket Bolt (2 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
5- Spring 10 - Spool 15 - O-Ring
W2-10-6
Assemble Proportional Solenoid Valves
IMPORTANT: Apply grease to O-rings (14), (15),

(16) and apply a film of hydraulic oil 17
to sleeve (17). 16
15
Install sleeve (17) so that the end 14
faces of sleeve and body come to
the same point.
1. Install washer (19), plate (18) into the housing. In-

stall O-rings (14), (15) and (16) on sleeve (17), Housing
then insert it into the housing.
IMPORTANT: Apply a film of hydraulic oil to spool W157-02-11-005

(10). Take care not to damage the
edge portion in the bore of sleeve
(17) when inserting the spool (10) 10
assembly.
After inserting spool, check that 9
spool (10) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic
oil to the spool. 17
13
2. Install diaphragm (9), washer (12), spring (13) to
spool (10) and install it in to sleeve (17). 12 Housing
11
WIHH-02-10-006
NOTE: Orifice (11) is installed into spool (10).
10
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3), are not sepa-
rated, so no need to assemble them. W157-02-11-010
When assembling solenoid (6), take 6

care not to drop spring (7).
NOTE: As for O-ring (3) and spring (5), refer to
W2-10-4
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
7
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W157-02-11-011
W2-10-7
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVES
(TORQUE CONTROL SOLENOID VALVE,
MAXIMUM PUMP 2 FLOW RATE LIMIT SO-
LENOID VALVE)
1
12
13
14
2
4
5
7
8
9
10
11
15
16
17
18 WIHH-02-10-003
19
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - Spool

2- Lock Nut 7- Spring 12 - O-Ring 17 - Orifice
3- O-Ring 8- O-Ring 13 - O-Ring 18 - Plate
5- Spring 10 - Retaining Ring 15 - Sleeve
W2-10-8
Disassemble Proportional Solenoid Valves
• Be sure to thoroughly read “Precaution for Disas-
starting the disassembly work.
IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Don’t turn lock nut (2) and adjusting
screw (4).
1. Loosen socket bolts (1) (2 used) to remove sole-
noid (6).
: 3 mm
IMPORTANT: Be sure not to remove orifice (17)

from spool (16).
2. Pull out spool (16) and remove diaphragm (9), re-
taining ring (10) and spring (11).
3. Pull sleeve (15) out and remove O-rings (12), (13)

and (14), plate (18) and washer (19).
W2-10-9
ASSEMBLE PROPORTIONAL SOLENOID
VALVES
(TORQUE CONTROL SOLENOID VALVE)
(MAXIMUM PUMP 2 FLOW RATE LIMIT
SOLENOID VALVE)
4 2 6 8 15 12 13 16 14 17 19
18
WIHH-02-10-007
3, 5 7 1 9 10 11
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - Spool

2- Lock Nut 7- Spring 12 - O-Ring 17 - Orifice
3- O-Ring 8- O-Ring 13 - O-Ring 18 - Plate
5- Spring 10 - Retaining Ring 15 - Sleeve
W2-10-10
Assemble Proportional Solenoid Valves
IMPORTANT: Apply grease to O-rings (12), (13),

(14) and apply a film of hydraulic oil 15
to sleeve (15). 14
13
Install sleeve (15) so that the end 12
faces of sleeve and body come to
the same point.
1. Install washer (19), plate (18) into the housing. In-

stall O-rings (12), (13) and (14) on sleeve (15), Housing
then insert it into the housing.
IMPORTANT: Apply a film of hydraulic oil to spool W157-02-11-005

(10). Take care not to damage the
edge portion in the bore of sleeve
(15) when inserting the spool (16) 16
assembly.
After inserting spool, check that 9
spool (16) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic
oil to the spool. 15
11
2. Install diaphragm (9), retaining ring (10), spring
(11) to spool (16) and install it into sleeve (15). 10 Housing
17
WIHH-02-10-006
NOTE: Orifice (17) is installed into spool (16).
16
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3), are not sepa-
rated, so no need to assemble them. W157-02-11-010
When assembling solenoid (6), take 6

care not to drop spring (7).
NOTE: As for O-ring (3) and spring (5), refer to
W2-10-8
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
7
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W157-02-11-011
W2-10-11
DISASSEMBLE AND ASSEMBLE PILOT
RELIEF VALVE
1
2
3
4
5
6
7
WIHH-02-10-004
1 - Plug 3 - Spring 5 - Poppet 7 - Gasket

2 - Shim 4 - O-Ring 6 - Sleeve 8 - Housing
W2-10-12
Disassemble Pilot Relief Valve Assemble Pilot Relief Valve
• Be sure to thoroughly read “Precaution for Disas- 1. Insert gasket (7) into housing (8).
starting the disassembly work. 2. Insert poppet (5) into sleeve (6). Install spring (3)
and O-ring (4) into the relief valve. Insert the relief
IMPORTANT: Take care not to lose shim (2) pro- valve assembly into housing (8).
vided in the plug (1) when removing NOTE: Sleeve (6) with poppet (5) is provided in the
plug (1). relief valve.
1. Remove plug (1) from housing (8).
: 22 mm IMPORTANT: Be sure not to drop shim (2).
3. Install shim (2) into plug (1) to install the plug into
2. Remove spring (3) and O-ring (4) from the relief housing (8).
valve. : 22 mm
NOTE: Sleeve (6) with poppet (5) is provided in the : 25 N⋅m(2.5 kgf⋅m, 18 lbf⋅ft)
relief valve.
3. Remove the assembly of poppet (5) and sleeve

(6) from housing (8).
4. Remove gasket (7) from housing (8).
W2-10-13
(Blank)
W2-10-14

Upperstructure: Section 2

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Upperstructure: Section 2

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SECTION 2

Group 8 Pilot Shut-Off Valve

Group 9 Shockless Valve

Group 10 Solenoid Valve

2. Remove bolts (4) behind the cab to remove rear ZAXIS370MTH:

3. Raise duct (5) to remove it.

4. Remove filter (6) to remove screws (7) with a

6. Remove washer vinyl hose (14) at rear inside of

8. Remove screws (18) and bolts (21) to remove

1. Attach the cab with lifting straps to hoist it by

2. Install bolts (23) and nuts (24) to the cab.

4. Install harness connectors (10, 11, 12 and 13) at

6. Aligning the mounting hole for duct (5). While

7. Install rear box (3) with bolts (4).

8. Install duct (20) with bolts (21). Install duct (19)

ZAXIS330, 330LC, 350H, 350LCH:

10. Secure seat (1) with nut (2).

Along the Along the W178-02-01-002

(4 mm) Section C 6.754°

(5 mm) Chamfer along

R5 for 3 Places 38.2

1. Install the seal rubber on the left-hand cab glass A

Put Connect End in Center of

Lower Glass of Door

2. When the mounting rubber is already on the glass, 10 10

IMPORTANT: Be sure to install the cab glass and

1. Install the mounting rubber into the surrounding of

NOTE: Rubber aging will cause the contraction of Cab

Procedures of installing rear cab glass

IMPORTANT: The rear side glass is arched-fringed.

1. Remove caps (1) from upper counterweight. In-

3. Remove bolts (2) from the counterweight. Hoist

CAUTION: Counterweight weight:

1. Hoist counterweight (3) and install it onto the

2. Remove wire ropes. Tighten the bolts with a

3. Remove the sling bolts. Install caps (1) to the

CAUTION: Escaping fluid under pressure

2. Stop the engine. Push the air release valve on top

CAUTION: Cab weight:

1. Remove the cab (Refer to “Remove Cab” in this

CAUTION: Counterweight weight:

2. Remove the counterweight.

CAUTION: Front attachment weight:

3. Remove the front attachment assembly.

4. Remove all hoses from upper side of the center

CAUTION: Upperstructure weight:

5. Attach wire ropes to the rear (counterweight

IMPORTANT: Make sure that rear slings do not

NOTE: The mounting angle of swing bearing is

7. Chain block (1) shall be used to adjust and level W105-02-03-007

the frame, then hoist it slightly to remove it from

CAUTION: Upperstructure weight:

1. Fasten wire ropes to main frame. Level the main

2. Align the matching marks on the outer race of the

3. Install all hoses to the center joint.

4. Install stopper (4) and bolt (3) to the center joint.

CAUTION: Cab weight:

5. Install cab (5).