Page 1 PART NO. WDCD-EN-00 Workshop Manual 200LC 210H 210LCH 210K URL:http://www.hitachi-c-m.com 210LCK Hydraulic Excavator Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TODCD-EN Technical Manual (Troubleshooting) : Vol. No.TTDCD-EN Workshop Manual : Vol. No.WDCD-EN...
Page 3 Form” at the end of this manual. (Note: Do not tear off  Be sure to thoroughly read this manual for correct the form. Copy it for usage.): product information and service procedures.  Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162 ...
Page 4 INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the potential Indicated potentially hazardous situation which could, if for personal injury of machine damage. not avoided, result in personal injury or death.
Page 5 SYMBOL AND ABBREVIATION Symbol / Name Explanation Abbreviation Technical manual (Operational principle) Technical manual (Operational Principle). Technical manual (Troubleshooting) Technical manual (Troubleshooting). Technical manual Technical manual. W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller.
Page 6 SYMBOL AND ABBREVIATION (Blank) SY-2...
Page 7 SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words ...
Page 8  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
Page 9 SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...
Page 10 SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
Page 11 SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/ or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
Page 12 SAFETY Use Handholds and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as hand-holds. ...
Page 13 SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position.
Page 14 SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).
Page 15 SAFETY Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts.
Page 16 SAFETY Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.  Clear all persons and obstacles from area of operation and machine movement.
Page 17 SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.
Page 18 Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, equip Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. The guard can be compliant with ROPS standards depending on the machine specifications.
Page 19 SAFETY Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions. SA-481 Confirm Direction of Machine to Be Driven ...
Page 20 SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine.
Page 21 SAFETY  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground.
Page 22 SAFETY Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways:  Select level ground when possible to park the machine.  Do not park the machine on a grade. ...
Page 23 SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: ...
Page 24 SAFETY Keep Person Clear from Working Area  A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.  Keep all persons clear from the area of operation and machine movement.
Page 25 SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic.
Page 26 SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-489 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.
Page 27 SAFETY Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.
Page 28 SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.
Page 29 SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket to the ground.  Turn auto-idle switch OFF and power mode switch E or P.  Run engine at slow idle speed without load for 5 minutes. ...
Page 30 SAFETY Transport Safely  Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to be transported.
Page 31 SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving. ...
Page 32 SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
Page 33 SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 SA-2294 Prevent Parts from Flying...
Page 34 SAFETY Store Attachments Safely  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas. SA-034 Prevent Burns Hot spraying fluids: ...
Page 35 SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. ...
Page 36 SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
Page 37 SAFETY Clean up Flammables:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.
Page 38 SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time. ...
Page 39 SAFETY Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.
Page 40  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. SA-34...
Page 41  Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts. SA-35...
Page 42 SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...
Page 43  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 44 SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice. Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.
Page 45 SAFETY Precaution for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the driver's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.
Page 46 SAFETY Before Returning the Machine to the Customer  After maintenance or repair work is complete, confirm that:  The machine is functioning properly, especially the safety systems.  Worn or damaged parts have been repaired or replaced. SA-435 SA-40...
Page 47 Group 3 Center Joint Group 4 Track Adjuster Group 5 Upper and Lower Rollers Group 6 Track SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment COPYRIGHT(C)2012 Hitachi Construction Machinery Co., Ltd. Group 2 Cylinder Tokyo, Japan All rights reserved...
Page 48 TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting) SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Specification Group 1 Introduction Group 2 Component Layout Group 2 Standard Group 3 Component Specifications Group 3 Engine Test SECTION 2 SYSTEM Group 4 Excavator Test Group 1 Controller Group 5 Component Test Group 2 Control System...
Page 49: Table Of Contents
SECTION 1 GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ..............W1-1-1-1 Group 2 Tightening Tightening Bolts and Nuts ..........W1-2-1-1 Piping Joint ..............W1-2-1-4 Group 3 Painting Painting ................W1-3-1-1 Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank ......W1-4-1-1 Bleeding Air from Hydraulic System .......W1-4-1-2 Bleeding Air from Fuel System ........W1-4-1-3 Group 5 Pressure Release Procedure...
Page 50 (Blank) DCDW-1-2...
Page 51: Group 1 Precautions For Disassembling And Assembling
SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and  If a part or component cannot be removed after Assembling removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), then take the appropriate measures to remove it.
Page 52 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures: ...
Page 53 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely.  Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners.
Page 54 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right.
Page 55 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary. “Allowable Limit” 1.
Page 56 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank) W1-1-1-6...
Page 57: Group 2 Tightening
SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure.
Page 58 SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads.  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Torque tolerance is ±10 %.
Page 59 SECTION 1 GENERAL Group 2 Tightening Precautions for Spilt Flange IMPORTANT:  Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the WDAA-01-02-005 O-ring.  Use only specified O-rings.
Page 60: Piping Joint
SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT: The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque. Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil.
Page 61 SECTION 1 GENERAL Group 2 Tightening Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil.  Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.
Page 62 SECTION 1 GENERAL Group 2 Tightening Quick Coupling 1. Coupling procedure  Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.  Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2).
Page 63 SECTION 1 GENERAL Group 2 Tightening Screw-In Connection 30° Depending on types of screw and sealing, different types of screw-in connection are used. IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, Male Tapered Thread b - Male Straight Thread the screw-in connection of male tapered thread is...
Page 64 Incorrect Correct genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure,...
Page 65: Group 3 Painting
SECTION 1 GENERAL Group 3 Painting Painting Painting specification Surfaces to Be Painted Painting Colour Main surface of upperstructure (except cab) YR-01 [TAXI yellow] Main frame High Grade Black Inner Gray Front YR-01 [TAXI yellow] Track (including swing bearing) N1.0 [Black] Floor plate M/F Cation (allowed) Final painted color...
Page 66 SECTION 1 GENERAL Group 3 Painting WDCD-01-03-001 WDCD-01-03-002 WDAA-01-03-003 Paint all circumference in the lower hinge swing position shining silver Handrail on Upperstructure Step Tool Box Camera Cover Right Side Tool Box Cover Decal (TAXI Yellow) Decal (TAXI Yellow) Cover Mirror Stay Engine Cover Shaded Area (Shining Silver)
Page 67: Group 4 Bleeding Air
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns.
Page 68: Bleeding Air From Hydraulic System
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic System Bleed air from the hydraulic system as follows when hydraulic oil has been drawn, the suction filter and suction pipe have been replaced, or the pump device, swing motor, travel motor, cylinders have been removed/ installed.
Page 69: Bleeding Air From Fuel System
SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Fuel System Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the fuel filter, replacing the fuel filter, cleaning the fuel solenoid pump strainer or running the fuel tank dry, be sure to bleed the air from the fuel system.
Page 70 SECTION 1 GENERAL Group 4 Bleeding Air Air Bleeding by Priming Pump In case air is not bled due to malfunction of the fuel solenoid pump, operating the priming pump only can bleed air. 1. Check that fuel cock (1) on bottom of the fuel tank is opened.
Page 71 SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Radiator CAUTION: Do not loosen the radiator cap until the system has cooled. Hot steam may spout out and cause severe burns. Wait until coolant cools and loosen the cap slowly. Release all pressure and remove the cap.
Page 72 SECTION 1 GENERAL Group 4 Bleeding Air (Blank) W1-4-1-6...
Page 73: Group 5 Pressure Release Procedure
SECTION 1 GENERAL Group 5 Pressure Release Procedure Hydraulic Circuit Pressure Release Procedure Release any remaining pressure as follows before removing/installing the front attachment. 1. Set pilot shut-off lever (1) to the UNLOCK position. 2. Turn engine stop switch (2) ON. NOTE: Perform step 1 and step 2, and set the key switch to the START position.
Page 74 SECTION 1 GENERAL Group 5 Pressure Release Procedure (Blank) W1-5-1-2...
Page 75: Group 6 Preparation
SECTION 1 GENERAL Group 6 Preparation Preparation before Inspection and Maintenance Before performing the maintenance procedures given in the following chapters, park the machine as described below, unless otherwise specified. 1. Park the machine on a level surface. M104-07-021 2. Lower the bucket to the ground. 3.
Page 76 SECTION 1 GENERAL Group 6 Preparation (Blank) W1-6-1-2...
Page 77 MEMO...
Page 78 MEMO...
Page 79 SECTION 2 MAINTENANCE STANDARD CONTENTS Group 1 Upperstructure Pump Device ..............W2-1-1-1 Swing Motor ..............W2-1-2-1 Group 2 Undercarriage Travel Motor ..............W2-2-1-1 Sprocket ................W2-2-1-3 Front Idler .................W2-2-2-1 Upper Roller ..............W2-2-3-1 Lower Roller ..............W2-2-3-2 Track ..................W2-2-4-1 Group 3 Front Attachment Pin and Bushing ..............W2-3-1-1 Side Cutter (2014503, 2014504) .......W2-3-1-3 Point (4427919) ..............W2-3-1-4 Standard Dimensions for Arm and Bucket...
Page 80 (Blank) DCDW-2-2...
Page 81: Group 1 Upperstructure
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Pump Device WDCD-02-01-002 Gear Shaft Valve Plate (Right, Left) Servo Piston (2 Used) Shaft Plunger (14 Used) Pin (2 Used) Gear Rotor (2 Used) Gear W2-1-1-1...
Page 82 SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Pump Device Unit: mm (in) Standard Allowable Limit Remedy Backlash of gears (1, 3, and 9) 0.68 (0.027) 1.5 (0.059) Replace Main Pump 1. Spline tooth thickness of shafts (2, 4) (T Unit: mm (in) Standard Allowable Limit 5.4 (0.213)
Page 83 SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure 5. Clearance between plunger (5) and connecting rod Unit: mm (in) Standard Allowable Limit 0.15 (0.006) 0.4 (0.016) 6. Clearance between inner diameter (D) of servo Connecting Rod small chamber and outer diameter (a) of servo W178-02-11-107 piston (10) Unit: mm (in)
Page 84 SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure (Blank) W2-1-1-4...
Page 85: Swing Motor
SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Swing Motor W178-02-11-153 Rotor Plunger (9 Used) Friction Plate (3 Used) W2-1-2-1...
Page 86 SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure 1. Clearance between outer diameter (d) of plunger (2) and inner diameter (D) of rotor (1) Unit: mm (in) Standard Allowable Limit 0.027 (0.001) 0.052 (0.002) W178-02-11-155 W178-02-11-156 2. Clearance (δ) between plunger (2) and shoe (a) bottom Unit: mm (in) Standard...
Page 87 SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure 3. Shoe (a) thickness (t) Unit: mm (in) Standard Allowable Limit 5.5 (0.22) 5.3 (0.21) Shoe W178-02-11-157 4. Friction plate (3) thickness (t) Unit: mm (in) Standard Allowable Limit 2.0 (0.08) 1.8 (0.07) W178-02-11-158 W2-1-2-3...
Page 88 SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure (Blank) W2-1-2-4...
Page 89: Group 2 Undercarriage
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Travel Motor WDCD-04-02-004 Rotor Plunger (9 Used) W2-2-1-1...
Page 90 SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage 1. Clearance (ε) between shoe (a) and plunger (2) bottom Unit: mm (in) Standard Allowable Limit 0 (0) 0.5 (0.02) ε Shoe W1V1-03-02-005 2. Clearance between outer diameter (d) of plunger (2) and inner diameter (D) of rotor (1) Unit: mm (in) Standard Allowable Limit...
Page 91: Sprocket
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Sprocket W178-02-11-236 W178-02-11-235 Unit: mm (in) Standard Allowable Limit 70 (2.8) [62 (2.4)] Build up welding and 80.3 (3.2) 75.3 (3.0) hand finishing 119.7 (4.7) 114.7 (4.5) 644.6 (25.4) 190.0 (7.5) NOTE: Values in [ ] are just for reference. W2-2-1-3...
Page 92 SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank) W2-2-1-4...
Page 93: Front Idler
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Front Idler W166-03-05-001 Unit: mm (in) Standard Allowable Remedy Limit 84 (3.31) [68 (2.67)] Build up welding and 159 (6.26) hand finishing 500 (19.7) [488 (19.2)] 538 (21.2) 19 (0.75) 25 (0.98) Axle and Bushing Unit: mm (in) Standard Allowable...
Page 94 SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank) W2-2-2-2...
Page 95: Upper Roller
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Upper Roller WDDE-02-02-001 Unit: mm (in) Standard Allowable Remedy Limit 84 (3.3) Replace 165 (6.5) 120 (4.7) [110 (4.3)] NOTE: Values in [ ] are just for reference. W2-2-3-1...
Page 96: Lower Roller
SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Lower Roller W157-03-06-003 Roller Unit: mm (in) Standard Allowable Remedy Limit 169.0 (6.7) [187 (7.4)] Build up welding and 218.0 (8.6) hand finishing 24.5 (1.0) [15.5 (0.6)] or replace 150.0 (5.9) 132 (5.2) NOTE: Values in [ ] are just for reference.
Page 97: Track
NOTE: Values in [ ] are just for reference. Grouser Shoe W105-03-07-024 ZX210H-5G, 210K-5G ZX210LCH-5G, 210LCK-5G Unit: mm (in) ZX200-5G, 200LC-5G Unit: mm (in) Shoe Size 600 mm Grouser Shoe Size 600 mm Grouser Standard Allowable...
Page 98 SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage Master Bushing W105-03-07-023 Unit: mm (in) Standard Allowable Remedy Limit 129.2 (5.08) Replace 38.7 (1.52) [41.7 (1.64)] 59 (2.32) [54 (2.13)] NOTE: Values in [ ] are just for reference. Master Pin W105-03-07-021 Unit: mm (in) Standard Allowable...
Page 99 SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage W142-03-07-004 Unit: mm (in) Standard Allowable Remedy Limit 212 (8.35) Replace 38 (1.50) [35 (1.4)] NOTE: Values in [ ] are just for reference. Bushing W105-03-07-023 Unit: mm (in) Standard Allowable Remedy Limit 137.5 (5.41) Replace 38.7 (1.52)
Page 100 SECTION 2 MAINTENANCE STANDARD Group 2 Undercarriage (Blank) W2-2-4-4...
Page 101: Group 3 Front Attachment
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Pin and Bushing W1V1-04-01-012 Unit: mm (in) Part Name Standard Allowable Limit Remedy 90 (3.54) 89.0 (3.50) Replace Bushing (Main Frame) 90 (3.54) 91.5 (3.60) Bushing (Boom) 90 (3.54) 91.5 (3.60) 80 (3.15) 79.0 (3.11) Boss (Main Frame) 80 (3.15)
Page 102 SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Unit: mm (in) Part Name Standard Allowable Limit Remedy 71 (2.80) 70.0 (2.76) Replace Boss (Arm) 71 (2.80) 72.5 (2.85) Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85) 80 (3.15) 79.0 (3.11) Boss (Link B) 80 (3.15) 81.5 (3.21) Bushing (Link A)
Page 103: Side Cutter (2014503, 2014504)
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Side Cutter (2014503, 2014504) W155-04-01-002 Unit: mm (in) Standard Allowable Remedy Limit 278 (10.9) 181 (7.1) Replace 295 (11.6) 433 (17.0) 135 (5.3) W2-3-1-3...
Page 104: Point (4427919)
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Point (4427919) W105-04-01-020 Unit: mm (in) Standard Allowable Remedy Limit 215 (8.5) 107.5 (4.2) Replace 95 (3.7) 108 (4.3) 95 (3.7) W2-3-1-4...
Page 105: Standard Dimensions For Arm And Bucket Connection
IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine. WDCD-02-03-005 Section A Section B WDCD-02-03-003 Unit: mm (in) ZX200-5G Class ZX200-3 Class 450 (17.7)  10 (0.39)  604 (23.8) ...
Page 106: Standard Dimensions For Arm And Boom Connection
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Standard Dimensions for Arm and Boom Connection WDCD-02-03-001 Section C Unit: mm (in) ZX200-5G Class ZX200-3 Class 90 (3.54)  354 (13.93) 352 (13.85) 490 (19.3)  IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.
Page 107: Cylinder
SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Cylinder Rod Bend and Run Out W166-04-02-022 W105-04-02-094 Cylinder Rod V Block Dial Gauge 1 m (39.4 in) Unit: mm (in) Unit: mm (in) Cylinder Name Recommended Size After Re- Bend Run Out Remedy manufacturing (A) 0.5 (0.020)
Page 108 SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank) W2-3-2-2...
Page 109 MEMO...
Page 110 MEMO...
Page 111 SECTION 3 UPPERSTRUCTURE CONTENTS Group 1 Cab Group 11 Pilot Valve Removal and Installation of Cab ......W3-1-1-1 Removal and Installation of Pilot Valve (Left) ... W3-11-1-1 Dimensions of Cab Glass ..........W3-1-2-1 Removal and Installation of Pilot Valve (Right) ................ W3-11-2-1 Group 2 Counterweight Removal and Installation of Travel Pilot Valve ..
Page 112 (Blank) DCDW-3-2...
Page 113: Group 1 Cab
SECTION 3 UPPERSTRUCTURE Group 1 Cab Removal and Installation of Cab WDAA-03-01-023 WDAA-03-01-047 IMPORTANT: Cap the open ends in case the hoses 4. Remove floor mat (4). and pipes have been disconnected. In addition, 5. Remove bolts, washers (5) (4 used). Remove travel attach an identification tag onto the connectors, control levers (6) (2 used).
Page 114 SECTION 3 UPPERSTRUCTURE Group 1 Cab Detail A WDAA-03-01-051 WDAA-03-01-050 6. Remove cover (9). 7. Disconnect plug (10) and connectors (11) (2 used). 8. Remove bolt, washer (12) and screw (13). Remove cover (14). j : 13 mm W3-1-1-2...
Page 115 SECTION 3 UPPERSTRUCTURE Group 1 Cab 26, 27, 28 20, 21 20, 21 22, 23, 24 WDAA-03-01-052 WDAA-03-01-053 17, 18 Detail A Detail B WDAA-03-01-062 WDAA-03-01-065 16, 17, 18 9. Open cover (15). 14. Remove bolts, washers (30) (2 used). 10.
Page 116 SECTION 3 UPPERSTRUCTURE Group 1 Cab WDAA-03-01-063 WDAA-03-01-064 Detail A Detail B WDAA-03-01-054 WDAA-03-01-055 18. Remove clip (35). 19. Disconnect connectors (34) (7 used). 20. Remove clip (36). 21. Disconnect connectors (37) (4 used). W3-1-1-4...
Page 117 SECTION 3 UPPERSTRUCTURE Group 1 Cab WDCD-03-01-002 WDCD-03-01-003 Detail A WDCD-03-01-001 TDAA-05-08-006 22. Shut door (1). 28. Remove bolts, washers (43) (2 used). Remove cover (44). 23. Open cover (38). j : 17 mm 24. Remove filter (39). 29. Remove bolt (45). Disconnect connector (46). 25.
Page 118 SECTION 3 UPPERSTRUCTURE Group 1 Cab WDAA-03-01-058 WDAA-03-13-005 Lifting Bracket CAUTION: The cab (49) assembly weight: 420 kg (930 lb) 32. Attach nylon slings onto lifting brackets (a) (4 places) of cab (49). Hoist and hold the cab (49) assembly. CAUTION: Remove cover (72) while holding it.
Page 119 SECTION 3 UPPERSTRUCTURE Group 1 Cab 55, 56 55, 56 52, 53 74, 75, 76 52, 53 55, 56 50, 51 55, 56 WDAA-03-01-066 WDAA-03-01-059 34. Remove bolt (74), washer (75), and spacer (76) at the rear side. j : 32 mm 35.
Page 120 SECTION 3 UPPERSTRUCTURE Group 1 Cab Detail A WDAA-03-01-061 WDAA-03-01-060 WDAA-03-01-067 39. Disconnect connectors (57) (5 used). 40. Remove screws (58) (4 used). Remove monitor controller (59). 41. Remove bolt, washer (77). j : 17 mm 42. Remove screws (60) (4 used). Disconnect connector (61).
Page 121 SECTION 3 UPPERSTRUCTURE Group 1 Cab Detail A WDAA-03-01-061 77, 78 WDAA-03-01-060 WDAA-03-01-067 Installation CAUTION: Bracket assembly (67) weight: 29 kg (64 lb) 1. Install bracket assembly (67) with bolts, washers (66) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 2.
Page 122 SECTION 3 UPPERSTRUCTURE Group 1 Cab 55, 56 55, 56 52, 53 52, 53 55, 56 50, 51 55, 56 WDAA-03-01-058 WDAA-03-01-059 Lifting Bracket CAUTION: The cab (49) assembly weight: 420 kg (930 lb) 8. Attach nylon slings onto lifting brackets (a) (4 places) of cab (49).
Page 123 SECTION 3 UPPERSTRUCTURE Group 1 Cab 74, 75, 76 WDAA-03-01-066 WDAA-03-13-005 13. Install spacer (76), washer (75), and bolt (74) at the rear side. j : 32 mm m : 550 N·m (55 kgf·m, 410 lbf·ft) 14. Install cover (72) with bolts, washers (73) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) W3-1-1-11...
Page 124 SECTION 3 UPPERSTRUCTURE Group 1 Cab WDCD-03-01-002 WDCD-03-01-003 Detail A WDCD-03-01-001 TDAA-05-08-006 15. Connect connector (48). Shift lever (47) and lock it. 18. Install cover (80) with bolts (79) (5 used). IMPORTANT: Do not use an impact wrench when j : 17 mm tightening bolt (45).
Page 125 SECTION 3 UPPERSTRUCTURE Group 1 Cab WDAA-03-01-063 WDAA-03-01-064 Detail A Detail B WDAA-03-01-054 WDAA-03-01-055 25. Connect connectors (37) (4 used). 26. Install clip (36). 27. Connect connectors (34) (7 used). 28. Install clip (35). W3-1-1-13...
Page 126 SECTION 3 UPPERSTRUCTURE Group 1 Cab 26, 27, 28 20, 21 20, 21 22, 23, 24 WDAA-03-01-052 WDAA-03-01-053 17, 18 Detail A Detail B WDAA-03-01-062 WDAA-03-01-065 16, 17, 18 29. Install duct (71) with bolt, washer (70). 34. Install cover (25) with screws (24) (3 used). Install seals (23) (3 used) and caps (22) (3 used).
Page 127 SECTION 3 UPPERSTRUCTURE Group 1 Cab Detail A WDAA-03-01-051 WDAA-03-01-050 38. Install cover (14) with screw (13) and bolt, washer (12). j : 13 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 39. Connect connectors (11) (2 used) and plug (10). 40.
Page 128 SECTION 3 UPPERSTRUCTURE Group 1 Cab WDAA-03-01-023 WDAA-03-01-047 41. Install travel control levers (6) (2 used) with bolts, washers (5) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 42. Install floor mat (4). CAUTION: Seat (2) weight: 42 kg (93 lb) 43.
Page 129: Dimensions Of Cab Glass
SECTION 3 UPPERSTRUCTURE Group 1 Cab Dimensions of Cab Glass Unit: mm Section A WDAA-03-01-036 WDAA-03-01-030 Black Ceramic Painted b - Black Ceramic Painted Range WDAA-03-01-001 Surface Section B Detail C Black Ceramic Painted WDAA-03-01-035 WDAA-03-01-002 Surface W3-1-2-1...
Page 130 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm WDAA-03-01-030 Black Ceramic Painted WDAA-03-01-034 Surface Section A Black Ceramic Painted WDAA-03-01-037 Surface W3-1-2-2...
Page 131 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Section A WDAA-03-01-004 WDAA-03-01-031 Chamfer along the Periphery WDAA-03-01-003 W3-1-2-3...
Page 132 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Section A WDAA-03-01-006 WDAA-03-01-031 Chamfer along the Periphery WDAA-03-01-005 W3-1-2-4...
Page 133 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Section A Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-031 Surface d - Shaded Paint along the Periphery Here Black Ceramic Painted Chamfer here. WDAA-03-01-007 Surface b - Black Ceramic Painted Range Section B Section C WDAA-03-01-008 WDAA-03-01-009 W3-1-2-5...
Page 134 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm WDAA-03-01-031 Black Ceramic Painted b - Black Ceramic Painted Range WDAA-03-01-010 Surface Section A Detail B Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-011 Surface d - Dotted edge along the Periphery Here W3-1-2-6...
Page 135 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm WDAA-03-01-031 WDAA-03-01-012 Black Ceramic Painted Surface b - Black Ceramic Painted Range Chamfer here. Section A Section B WDAA-03-01-038 WDAA-03-01-008 Black Ceramic Painted Surface d - Dotted edge along the Periphery Here W3-1-2-7...
Page 136 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Section A WDAA-03-01-038 Black Ceramic Painted Surface WDAA-03-01-030 d - Shaded Paint along the Periphery Here Black Ceramic Painted WDAA-03-01-013 Surface b - Black Ceramic Painted Range W3-1-2-8...
Page 137 SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Remove Cab Glass Procedures to Remove Right-Hand Glass (1), Rear Left- Hand Glass (2), Lower Door Glass (3), and Rear Glass (4) CAUTION: When removing the broken or cracked glass, the glass shards may cause serious injury. Before removing, use the duct tape or equivalent in order to paste the broken or cracked glass and reinforce them.
Page 138 SECTION 3 UPPERSTRUCTURE Group 1 Cab IMPORTANT: The piano wire is easily broken if a part of the piano wire turns hot. Change the position and cut the adhesive. 4. Wind the both ends of the piano wire onto the screwdriver.
Page 139 SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedure to Install Cab Glass Procedures to Install Right-Hand Glass (1), Rear Left-Hand Glass (2), Lower Door Glass (3), and Rear Glass (4) 1. Cut off the residual adhesive from the cab (7) side by 1 to 2 mm deep all around by using a knife or similar.
Page 140 SECTION 3 UPPERSTRUCTURE Group 1 Cab 4. Clean the mating edge of the new glass by using clean rag and ethyl alcohol. IMPORTANT: Primer (Sika Primer 206G+P) should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and close the cap immediately after using.
Page 141 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Rear Glass Right-Hand Glass WDAA-03-01-039 Rear Left-Hand Glass WDAA-03-01-040 Lower Door Glass WDAA-03-01-041 WDAA-03-01-042 Spacer A Spacer B Spacer C WDAA-03-01-043 WDAA-03-01-044 WDAA-03-01-045 Two-Side Adhesive Tape Two-Side Adhesive Tape Dam Rubber WDAA-03-01-046 W3-1-2-13...
Page 142 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Left-Hand Glass Spacer A From Radius Curve End WDAA-03-01-014 Dam Rubber b - Glass External Form Line Stopper Adhesive Range Section A Section B Section C WDAA-03-01-017 WDAA-03-01-018 WDAA-03-01-019 d - Clearance between glass and panel: 6 mm Glass Glass Glass...
Page 143 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Right-Hand Glass WDAA-03-01-016 Spacer A From Radius Curve End Spacer C b - Glass External Form Line Dam Rubber Adhesive Range Section A Section B Section C WDAA-03-01-022 WDAA-03-01-027 WDAA-03-01-028 Glass d - Glass and panel: Clearance OR-02: 8 mm From Radius Curve End Glass Glass...
Page 144 SECTION 3 UPPERSTRUCTURE Group 1 Cab Unit: mm Rear Glass Section A WDAA-03-01-021 From Radius Curve End Glass WDAA-03-01-015 Spacer B b - Glass External Form Line From Radius Curve End Adhesive Range Section B Section C WDAA-03-01-026 WDAA-03-01-025 d - Glass and panel: Clearance Glass OR-02: 8 mm Glass...
Page 145 SECTION 3 UPPERSTRUCTURE Group 1 Cab 8~9 mm 13~15 mm W1SE-02-01-027 W1SE-02-01-043 b - Cut nozzle end into V-shaped. W1JB-02-01-031 Apply bead so that bead triangle may be Apply adhesive (bead) here. even. Panel W1SE-02-01-028 Remove the seal. d - Adhesive Cartridge 13.
Page 146 SECTION 3 UPPERSTRUCTURE Group 1 Cab Procedures to Install Upper Door Glass 1. Before installing the glass, remove garnish (2) around sash assembly (1) from the cab inside for easy removal. Push sash assembly (1) by hands and remove the sash outside. 2.
Page 147 NOTE: Cemedine Super X No. 8008 Glue-state adhesive, tubed Cemedine 366 Deluxe IMPORTANT: The front glass is arched-fringed. When replacing the glass, contact with the nearest HITACHI Office and replace it as an assembly. WDAA-03-01-029 Detail A (Inside) Detail A (Outside) WDAA-03-01-032 WDAA-03-01-033 Cemedine Super X No.
Page 148 SECTION 3 UPPERSTRUCTURE Group 1 Cab (Blank) W3-1-2-20...
Page 149: Group 2 Counterweight
WDCD-03-02-002 Removal CAUTION: Counterweight (4) weight: 1. Set the machine position for inspection and ZX200-5G, 200LC-5G: 4260 kg (9400 lb) maintenance. (Refer to W1-6-1.) ZX210H-5G, 210LCH-5G: 4670 kg (10300 lb) 2. Open the engine cover. ZX210K-5G, 210LCK-5G: 5480 kg (12100 lb) 3.
Page 150 4. Install the rearview camera (3) assembly with bolts, washers (2) (4 used). CAUTION: Counterweight (4) weight: j : 17 mm ZX200-5G, 200LC-5G: 4260 kg (9400 lb) m : 50 N·m (5 kgf·m, 37 lbf·ft) ZX210H-5G, 210LCH-5G: 4670 kg (10300 lb) 5. Connect connector (1).
Page 151: Group 3 Main Frame
SECTION 3 UPPERSTRUCTURE Group 3 Main Frame Removal and Installation of Main Frame WDCD-03-03-001 IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
Page 152 Part 6. Place a container under center joint (5). Disconnect CAUTION: Main frame (12) weight: hoses (6) (4 used). ZX200-5G, 200LC-5G: 4620 kg (10200 lb) j : 36 mm ZX210H-5G, 210LCH-5G: 4780 kg (10600 lb) 7. Disconnect hose (7). ZX210K-5G, 210LCK-5G: 4880 kg (10800 lb) j : 27 mm 10.
Page 153 SECTION 3 UPPERSTRUCTURE Group 3 Main Frame 15, 16 WDAB-03-03-003 11. Reduce slack of wire ropes by using a chain block. Put the matching marks onto main frame (12) and outer race (13) of the swing bearing. 12. Remove bolts (14) (32 used), bolts (15) (5 used), and spacers (16) (5 used).
Page 154 CAUTION: Main frame (12) weight: swing bearing. Install spacers (16) (5 used), bolts (15) (5 used), and bolts (14) (32 used). ZX200-5G, 200LC-5G: 4620 kg (10200 lb) ZX210H-5G, 210LCH-5G: 4780 kg (10600 lb) j : 30 mm ZX210K-5G, 210LCK-5G: 4880 kg (10800 lb) m : 510 N·m (51 kgf·m, 380 lbf·ft)
Page 155 SECTION 3 UPPERSTRUCTURE Group 3 Main Frame WDAA-03-03-005 4. Install stopper (11) with spring washers (10) (2 used) and bolts (9) (2 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft) 5. Connect hose (8). j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 6.
Page 156 SECTION 3 UPPERSTRUCTURE Group 3 Main Frame WDCD-03-03-001 8. Install boom cylinder (4). (Refer to W5-2-1.) 9. Install front attachment (3). (Refer to W5-1-1.) 10. Install counterweight (2). (Refer to W3-2-1.) 11. Install cab (1). (Refer to W3-1-1.) 12. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level.
Page 157: Group 4 Engine
SECTION 3 UPPERSTRUCTURE Group 4 Engine Removal and Installation of Engine 112, 113, 114 WDCD-03-04-009 WDCD-03-04-019 IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (112) (6 used). Remove the and pipes have been disconnected. In addition, cover (113) assembly and O-ring (114) from the top attach an identification tag onto the connectors, of hydraulic oil tank.
Page 158 SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A 115, 116 WDDE-03-04-002 WDCD-03-04-019 10. Remove bolts, washers (11) (8 used) and bolts, CAUTION: Engine cover (9) weight: 31 kg (69 lb) washers (12) (2 used). Remove cover (13). 7. Attach nylon slings onto engine cover (9). Hoist and j : 17 mm hold engine cover (9).
Page 159 SECTION 3 UPPERSTRUCTURE Group 4 Engine WDCD-03-04-005 Detail A WDCD-03-04-004 WDCD-03-04-006 11. Remove bolt (14) and washer (15). Disconnect 16. Remove pins (27) (2 used). Remove cover (28). terminal (16). 17. Remove bolts, washers (29, 30) (2 used for each). Remove cover (31).
Page 160 SECTION 3 UPPERSTRUCTURE Group 4 Engine 43 50 49 51 53, 54 WDCD-03-04-015 WDCD-03-04-003 20. Remove bolts, washers (45) (2 used). Remove cover 26. Remove nuts (49) (4 used). Disconnect exhaust pipe (46). (50). 21. Remove counterweight (38). (Refer to W3-2-1.) j : 13 mm 22.
Page 161 SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A WDCD-03-04-008 WDCD-03-04-007 31. Disconnect connector (56) and terminals (57) (3 36. Remove clamps (68) (2 used). Disconnect the used). radiator side of hose (69) and the engine side of hose (70). 32. Remove bolts, washers (58) (4 used). Remove bracket (59).
Page 162 SECTION 3 UPPERSTRUCTURE Group 4 Engine WDCD-03-04-010 WDCD-03-04-011 39. Remove bolts, washers (75) (2 used). Remove cover 42. Remove clamps (81, 82). Remove bolts, washers (83) (76). (2 used). Remove the duct (84) assembly. j : 13 mm j : 17 mm 40.
Page 163 SECTION 3 UPPERSTRUCTURE Group 4 Engine 91, 92 WDCD-03-04-012 89, 90 44. Disconnect cables (87, 88). 45. Remove clips (89) (2 used). Disconnect hoses (90) (2 used). 46. Remove clips (91) (2 used). Disconnect hoses (92) (2 used). 47. Disconnect hoses (93) (2 used). j : 36 mm 48.
Page 164 SECTION 3 UPPERSTRUCTURE Group 4 Engine WDCD-03-04-020 8 to 12 mm (0.31 to 0.47 in), Crank Pulley 100 N (10 kgf, 23 lbf ) Compressor Pulley 119, 120, 121 M1G6-07-013 WDCD-03-04-013 99, 100, 101 49. Disconnect connector (95). 55. Remove bolts (99, 119) (2 used for each), spring washers (100, 120) (2 used for each), and washers 50.
Page 165 SECTION 3 UPPERSTRUCTURE Group 4 Engine 104, 105 106, 107 Lifting Bracket WDCD-03-04-014 59. Hoist engine (103) by 15 mm. CAUTION: Engine (103) weight: 490 kg (1090 lb) 60. Move engine (103) to the pump device mounting 56. Install shackles to lifting brackets (a) (2 places) of side by 50 mm.
Page 166 SECTION 3 UPPERSTRUCTURE Group 4 Engine 104, 105 106, 107 Lifting Bracket WDCD-03-04-014 Installation 4. Install engine (103) with washers (105) (2 used) and nuts (104) (2 used). 1. Install all removed adapters to engine (103). j : 22 mm CAUTION: Engine (103) weight: 490 kg (1090 lb) 2.
Page 167 SECTION 3 UPPERSTRUCTURE Group 4 Engine WDCD-03-04-020 8 to 12 mm (0.31 to 0.47 in), Crank Pulley 100 N (10 kgf, 23 lbf ) Compressor Pulley 119, 120, 121 M1G6-07-013 WDCD-03-04-013 99, 100, 101 5. Install the compressor (102) assembly with washers 9.
Page 168 SECTION 3 UPPERSTRUCTURE Group 4 Engine 91, 92 WDCD-03-04-012 89, 90 13. Connect terminal (94). 14. Connect hoses (93) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 15. Connect hoses (92) (2 used) with clips (91) (2 used). 16.
Page 169 SECTION 3 UPPERSTRUCTURE Group 4 Engine WDCD-03-04-010 WDCD-03-04-011 18. Install rubber (86) with band (85). 22. Install cover (76) with bolts, washers (75) (2 used). 19. Install the duct (84) assembly with bolts, washers j : 13 mm (83) (2 used) and clamps (82, 81). m : 20 N·m (2 kgf·m, 15 lbf·ft) j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
Page 170 SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A WDCD-03-04-008 WDCD-03-04-007 23. Connect hose (74) with clamps (73) (2 used). 29. Install bracket (59) with bolts, washers (58) (4 used). 24. Install the pipe (72) assembly with bolts, washers j : 17 mm (71) (2 used).
Page 171 SECTION 3 UPPERSTRUCTURE Group 4 Engine 43 50 49 51 40, 108 53, 54 WDCD-03-04-002 WDCD-03-04-003 31. Install the coupling of the engine. (Refer to W3-8-2.) 36. Install cover (44) with bolts, washers (43) (3 used). 32. Install pump device (55). (Refer to W3-8-1.) j : 17 mm CAUTION: The muffler (52) assembly weight: 25 m : 50 N·m (5 kgf·m, 37 lbf·ft)
Page 172 SECTION 3 UPPERSTRUCTURE Group 4 Engine WDCD-03-04-016 WDCD-03-04-004 40. Install cover (33) with bolts, washers (32) (2 used). 45. Connect terminal (22) with washer (21) and bolt (20). j : 17 mm j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 20 N·m (2 kgf·m, 15 lbf·ft) 41.
Page 173 SECTION 3 UPPERSTRUCTURE Group 4 Engine 112, 113, 114 WDCD-03-04-009 WDCD-03-04-019 48. Connect ground (8) with washer (7) and bolt (6). 52. Install O-ring (114). 53. Install the cover (113) assembly to the top of j : 17 mm hydraulic oil tank with bolts, washers (112) (6 used). m : 20 N·m (2 kgf·m, 15 lbf·ft) j : 17 mm 49.
Page 174 SECTION 3 UPPERSTRUCTURE Group 4 Engine Detail A 46 45 WDCD-03-04-017 Detail B 115, 116 WDCD-03-04-001 WDDE-03-04-002 56. Install counterweight (38). (Refer to W3-2-1.) CAUTION: Engine cover (9) weight: 31 kg (69 lb) 57. Install cover (46) with bolts, washers (45) (2 used). 59.
Page 175: Group 5 Radiator Assembly
SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Replacement of Radiator, Oil Cooler, and Intercooler WDCD-03-04-009 WDCD-03-04-019 IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
Page 176 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A 11, 12 WDDE-03-04-002 WDCD-03-04-019 7. Remove bolts, washers (10) (4 used) from the inside CAUTION: Engine cover (9) weight: 31 kg (69 lb) of engine cover (9). Remove engine cover (9). 5.
Page 177 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly WDCD-03-04-005 Detail A WDCD-03-04-004 WDCD-03-04-006 9. Remove bolt (14) and washer (15). Disconnect 14. Remove pins (27) (2 used). Remove cover (28). terminal (16). 15. Remove bolts, washers (29, 30) (2 used for each). Remove cover (31).
Page 178 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 42 44 43 45 WDCD-03-05-001 39 41 Detail A WDCD-03-05-002 38 40 WDCD-03-05-017 21. Remove clamps (42, 43). Disconnect the radiator CAUTION: Remove cover (36) while holding it. side of hoses (44, 45). Do not drop cover (36).
Page 179 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 46, 47 WDCD-03-05-014 WDCD-03-05-015 23. Remove clamp (46). Disconnect hose (47). 27. Remove bolts, washers (53) (7 used). Remove cover (54). 24. Remove clips (48) (2 used). j : 17 mm 25. Remove bolts, washers (50) (2 used) and bolts, washers (51) (4 used).
Page 180 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A WDCD-03-05-018 Lifting Hole Lifting Hole Eyebolt Mounting Hole WDCD-03-05-012 29. Install shackles (2 used) to lifting holes (a) (2 places) 33. Remove bolts (65) (2 used), rubbers (66, 67), and of radiator (62). Attach nylon slings onto shackles. collars (68) (2 used).
Page 181 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A WDCD-03-05-018 Lifting Hole Lifting Hole Eyebolt Mounting Hole WDCD-03-05-012 Installation 4. Install intercooler (69) with collars (68) (2 used), rubbers (66, 67), and bolts (65) (2 used). CAUTION: Oil cooler (71) weight: 26 kg (58 lb) j : 13 mm 1.
Page 182 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 46, 47 WDCD-03-05-014 WDCD-03-05-015 8. Connect pipes (56, 55) with couplings (58, 57). 11. Install the cover (52) assembly with bolts, washers (51) (4 used) and bolts, washers (50) (2 used). j : 13 mm j : 17 mm m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)
Page 183 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly 42 44 43 45 39 41 WDCD-03-05-002 WDCD-03-05-016 38 40 14. Connect the radiator side of hoses (45, 44) with 17. Install cover (33) with bolts, washers (32) (2 used). clamps (43, 42). j : 17 mm 15.
Page 184 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly WDCD-03-04-004 WDCD-03-04-009 20. Install batteries (24) (2 used) with bolts, washers (23) 24. Connect ground (8) with washer (7) and bolt (6). (2 used). j : 17 mm 21. Connect terminal (22) with washer (21) and bolt m : 20 N·m (2 kgf·m, 15 lbf·ft) (20).
Page 185 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A WDCD-03-05-017 WDCD-03-05-001 27. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 28. Install cover (73) with bolts, washers (74) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 29.
Page 186 SECTION 3 UPPERSTRUCTURE Group 5 Radiator Assembly Detail A 11, 12 WDDE-03-04-002 WDCD-03-04-019 30. Install cover (77) with bolts, washers (5 used). 33. Install the support (13) side of stopper (72) with washers (12) (2 used) and pins (11) (2 used). j : 17 mm 34.
Page 187: Group 6 Hydraulic Oil Tank
SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank WDCD-03-06-001 3, 4 CAUTION: Escaping fluid under pressure may CAUTION: Bleed air from hydraulic oil tank (1). penetrate the skin and eyes, and cause serious (Refer to W1-4-1.) injury.
Page 188 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank WDCD-03-06-002 WDCD-03-06-003 4. Open cover (5). 7. Remove bolts, washers (10) (2 used). CAUTION: Remove cover (7) while holding it. Do j : 17 mm not drop cover (7). 8. Open engine cover (11). 5.
Page 189 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank WDCD-03-06-004 11. Place a container under hydraulic oil tank (1) and suction pipe (16). Slowly turn drain plug (17). Drain off hydraulic oil completely. j : 27 mm 12. Remove hose clamps (18) (4 used). Disconnect hose (19).
Page 190 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank WDCD-03-06-006 Lifting Hole 14. Disconnect connector (23) of hydraulic oil CAUTION: Hydraulic oil tank (1) weight: 97 kg temperature sensor (22). (215 lb) 15. Remove bolts, washers (24) (2 used). 18. Install eyebolts (2 used) and nuts (2 used) to lifting holes (a) (2 places) of hydraulic oil tank (1).
Page 191 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank WDCD-03-06-007 Lifting Hole Installation 4. Connect pipes (27, 26) with couplings (25) (2 used). CAUTION: Hydraulic oil tank (1) weight: 97 kg j : 13 mm (215 lb) m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft) 1.
Page 192 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank 3, 4 WDCD-03-06-005 WDCD-03-06-001 7. Install cover assembly (21) with bolts, washers (20) 11. Install O-ring (4). (4 used). 12. Install the cover (3) assembly to the upper part of hydraulic oil tank (1) with bolts, washers (2) (6 used). j : 17 mm j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
Page 193 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank WDCD-03-06-002 WDCD-03-06-001 13. Bleed air from the hydraulic system. (Refer to W1-4- 18. Install bolts, washers (10) (2 used). j : 17 mm IMPORTANT: Check the hydraulic oil level. Start the m : 50 N·m (5 kgf·m, 37 lbf·ft) engine and check for any oil leaks.
Page 194 SECTION 3 UPPERSTRUCTURE Group 6 Hydraulic Oil Tank (Blank) W3-6-1-8...
Page 195: Group 7 Fuel Tank
SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank Removal and Installation of Fuel Tank 5, 6 3, 4 WDCD-03-07-001 IMPORTANT: Cap the open ends in case the hoses 6. Remove bolts (5) (2 used) and washers (6) (2 used). and pipes have been disconnected. In addition, Remove handrail (7).
Page 196 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank WDCD-03-07-002 WDCD-03-07-003 15, 16 Mounting Hole Mounting Hole 9. Remove bolts, washers (12) (2 used). Remove cover CAUTION: Fuel tank (19) weight: 160 kg (355 lb) (13). 13. Install an eyebolt (M10, Pitch 1.5 mm) to mounting j : 17 mm hole (a) of fuel tank (19).
Page 197 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank WDCD-03-07-004 WDCD-03-07-005 16. Place a container under fuel tank (19). Remove hose CAUTION: Remove cover (21) while holding it. clips (24, 25). Disconnect hoses (26, 27). Drain fuel Do not drop cover (21). completely.
Page 198 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank WDCD-03-07-002 WDCD-03-07-003 Mounting Hole Mounting Hole Installation CAUTION: Fuel tank (19) weight: 160 kg (355 lb) 1. Install an eyebolt (M10, Pitch 1.5 mm) to mounting hole (a) of fuel tank (19). Install an eyebolt (M10, Pitch 1.5 mm) and a nut to mounting hole (b) of fuel tank (19).
Page 199 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank WDCD-03-07-004 WDCD-03-07-005 2. Install fuel tank (19) with washers (29) (6 used) and bolts (28) (6 used). j : 24 mm m : 270 N·m (27 kgf·m, 200 lbf·ft) 3. Connect hoses (27, 26) with hose clips (25, 24). 4.
Page 200 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank WDCD-03-07-002 WDCD-03-07-003 15, 16 6. Connect hose (18) with hose clip (17). 7. Install clip (16) with bolt, washer (15). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 8. Connect connector (14). 9.
Page 201 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank 5, 6 3, 4 WDCD-03-07-001 10. Install cover (11) with bolts, washers (10) (4 used). 13. Install washers (4) (2 used) and bolts (3) (2 used). j : 17 mm j : 22 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft) 11.
Page 202 SECTION 3 UPPERSTRUCTURE Group 7 Fuel Tank (Blank) W3-7-1-8...
Page 203: Group 8 Pump Device
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Removal and Installation of Pump Device WDCD-03-08-009 WDCD-03-06-001 3, 4 IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (7) (8 used) and bolts, and pipes have been disconnected. In addition, washers (8) (2 used).
Page 204 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device WDCD-03-08-010 WDCD-03-08-011 9. Remove bolts, washers (15) (3 used). 14. Disconnect hose (28). j : 10 mm j : 27 mm 10. Disconnect connectors (16) (7 used). 15. Remove clamps (21) (4 used). Disconnect rubber hose (22).
Page 205 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 29, 30, 31, 32 36, 37 38, 39 36, 37 WDCD-03-08-012 WDCD-03-08-013 34, 35 18. Remove bolts (29) (2 used) and nuts (30) (2 used). CAUTION: Pump device (17) weight: 170 kg (375 Remove clamp (31) and gasket (32).
Page 206 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 29, 30, 31, 32 36, 37 38, 39 36, 37 WDCD-03-08-012 WDCD-03-08-013 34, 35 Installation 6. Install the muffler (33) assembly with spring washers (35) (3 used) and bolts (34) (3 used). 1. Install all removed adapters to pump device (17). j : 17 mm CAUTION: Pump device (17) weight: 170 kg (375 m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
Page 207 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device WDCD-03-08-020 WDCD-03-08-015 8. Connect hoses (27) (2 used) with flanges (26) (4 13. Connect hoses (19) (2 used). used) and socket bolts (25) (8 used). j : 19 mm l : 10 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) m : 110 N·m (11 kgf·m, 81 lbf·ft) 14.
Page 208 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 10, 42 WDCD-03-08-009 WDCD-03-06-001 3, 4 17. Fill hydraulic oil to hydraulic oil tank (1). 22. Install cover (12) with bolts, washers (11) (5 used). NOTE: Total oil amount of hydraulic oil tank (1): 201 L j : 17 mm (53.1 US gal) m : 50 N·m (5 kgf·m, 37 lbf·ft)
Page 209: Removal And Installation Of Coupling
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Removal and Installation of Coupling WDCD-03-08-021 WDCD-03-09-001 Removal 4. Remove spring pins (7) (4 used) from the engine flywheel. 1. Remove element (2) from insert (1) at the pump side. 5. Remove clamping screws (8) (2 used) from cylinder hub (4).
Page 210 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device WDCD-03-08-021 WDCD-03-09-001 Installation 5. Install inserts (1) (4 used) to cylinder hub (4) with socket bolts (3) (4 used). 1. Install cylinder hub (4) to the pump device. l : 14 mm 2. Secure cylinder hub (4) with clamping screws (8) (2 used).
Page 211: Disassembly Of Pump Device
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Pump Device 11 12 WDCD-03-08-019 W3-8-3-1...
Page 212 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device WDCD-03-08-018 Socket Bolt (4 Used) Retaining Ring (2 Used) Pump Casing Stopper L (2 Used) Regulator Gear Spring Washer (6 Used) Valve Plate Socket Bolt (2 Used) Gasket Bolt (6 Used) Link (2 Used) Socket Bolt (2 Used) Gear Spring Pin (4 Used)
Page 213 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Pump Device 7. Remove socket bolts (3, 5) (2 used for each). Raise 1. Disconnect the both ends of pipe (79) from regulator (6) to the direction of selector head (66). regulators (2, 6).
Page 214 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 11. Remove socket bolts (36) (2 used) from gear casing 14. Remove socket bolts (68) (16 used) from selector (47). While tapping the flange part of pilot pump head (66). Remove stoppers S (69) (2 used) and (39) by using a plastic hammer, remove pilot pump stoppers L (76) (2 used) from selector head (66).
Page 215 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 15. Remove socket bolts (71) (12 used) from selector 20. Both valve plates (62, 77) are very similar and their head (66). Measure and record the clearance installing directions are determined. Record the between pump casing (51) and selector head (66).
Page 216 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device CAUTION: The pump casing (51) assembly CAUTION: The pump casing (51) assembly weight: 71 kg (160 lb) weight: 65 kg (145 lb) 24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the 28.
Page 217 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 32. Remove thrust ring (20) from pump casing (51). 38. Remove retaining ring (40) from gear casing (47). Remove retaining ring (41) from gear shaft (44). 33. Remove bearing nut (9) from shaft (13) by using the special tool (ST 3058).
Page 218: Assembly Of Pump Device
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Pump Device 64 63 18 16 15 17 20 11 58, 61 16 15 11 10 W178-02-11-086 22 21 W3-8-3-8...
Page 219 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 32, 33, 34 36, 37, 38 4 35 40 43 92, 93 30, 31 84, 85 86, 87 88, 89, 90 WDCD-03-08-002 Socket Bolt (4 Used) Retaining Ring (2 Used) Pump Casing Stopper L (2 Used) Regulator Gear Spring Washer (6 Used)
Page 220 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Pump Device 6. Warm up bearings (10, 12) to 50 to 80 °C (122 to 176 IMPORTANT: Before assembling, apply hydraulic oil °F). onto parts in order to prevent them from seizing. 1.
Page 221 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 11. Set the preload of bearings (10, 12) (2 used for 12. Set the preload of bearings (10, 12) with shaft (19) each) with shafts (13, 19) attached according to the attached in the same way as step 11. following procedures.
Page 222 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 14. Warm up pump casing (51) to 50 to 80 °C (122 to 19. Install the special tools (ST 2649, ST 2650) over the 176 °F). spline parts of shafts (13, 19). CAUTION: Take care as pump casing (51) is too NOTE: If the special tools are not available, install a hot.
Page 223 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 23. Fit the matching marks on shafts (13, 19) and 24. Install spring pins (48) (2 used) to gear casing (47). gears (27, 29). Install retaining rings (26) (2 used) Install gasket (28). to shafts (13, 19).
Page 224 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 26. Apply THREEBOND #1215 onto the mounting 30. Insert plungers (17) (7 used for each) into shafts (13, surface of pilot pump (39). Install pilot pump (39) 19). to gear casing (47) with socket bolts (36) (2 used), 31.
Page 225 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 33. Install springs (16) (2 used) to center shafts (15) (2 39. Install regulator (2) to pump casing (51) according used). to the following procedures. 34. Insert center shafts (15) (2 used) and plungers (17) ...
Page 226 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device 43. Apply LOCTITE LI829 onto set screw (72). Install pins 47. Install O-rings (67) (4 used) to selector head (66). (74) (2 used) to servo pistons (73) (2 used) with set 48. Install O-rings (70) (2 used) to stoppers S (69) (2 screws (72) (2 used).
Page 227 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device IMPORTANT: The breather hole of plug (25) is 52. Insert the special tool (ST 2650) into shaft (19). Apply grease onto oil seal (46). Install oil seal (46) to located at the left side, viewed from the front of shaft (19).
Page 228 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device (Blank) W3-8-3-18...
Page 229: Disassembly Of Regulator
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Regulator Pump 1 Regulator Pump 2 Regulator WDCD-03-08-003 WDCD-03-08-004 10 11 12 13 23 22 21 20 19 18 31 30 26 25 TDCD-03-01-007 Cover Spool Lock Nut Cylinder Socket Bolt (2 Used) Sleeve Socket Bolt (8 Used) O-Ring...
Page 230 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Regulator 5. Remove O-ring (7) from stopper assembly (6).  The regulators are used for pump 1 and pump 2. The inner structure in the regulator is fully identical, and 6. Remove springs (23, 24) from casing (9). the difference is only in its accessories.
Page 231: Assembly Of Regulator
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Regulator Pump 1 Regulator Pump 2 Regulator WDCD-03-08-003 WDCD-03-08-004 10 11 12 13 23 22 21 20 19 18 31 30 26 25 TDCD-03-01-007 Cover Spool Lock Nut Cylinder Socket Bolt (2 Used) Sleeve Socket Bolt (8 Used) O-Ring...
Page 232 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Regulator 7. Install O-ring (7) and spring (8) to stopper assembly IMPORTANT: The sleeve (11, 25) holes of casing (9) (6) with cover (1) attached. Install the cover (1) are the same bores. The shapes of various parts assembly to casing (9) with socket bolts (20) (4 are very similar.
Page 233: Disassembly Of Solenoid Valve
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Solenoid Valve WDCD-03-08-007 WDCD-03-08-006 WDCD-03-08-005 Solenoid (2 Used) O-Ring O-Ring O-Ring Socket Bolt Wave Washer Filter (3 Used) Body Sleeve Plate O-Ring (2 Used) O-Ring O-Ring O-Ring W3-8-5-1...
Page 234 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Disassembly of Solenoid Valve 4. Remove filters (10) (3 used), O-rings (11) (2 used),  Take care not to damage the mounting surface for and O-rings (12, 13) from body (14). the regulator. ...
Page 235: Assembly Of Solenoid Valve
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Solenoid Valve WDCD-03-08-007 WDCD-03-08-006 WDCD-03-08-005 Solenoid (2 Used) O-Ring O-Ring O-Ring Socket Bolt Wave Washer Filter (3 Used) Body Sleeve Plate O-Ring (2 Used) O-Ring O-Ring O-Ring W3-8-5-3...
Page 236 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Assembly of Solenoid Valve 1. Install O-rings (12, 13), O-rings (11) (2 used), and filters (10) (3 used) to body (14). l : 6 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) +0.3 +2.2 2.
Page 237: Structure Of Pilot Pump
SECTION 3 UPPERSTRUCTURE Group 8 Pump Device Structure of Pilot Pump W137-02-04-034 W3-8-6-1...
Page 238 SECTION 3 UPPERSTRUCTURE Group 8 Pump Device IMPORTANT: The housing is made of aluminum. Take care not to damage the housing. Take extreme care in order to control the tightening torque. Part Name Q’ty Wrench Size Tightening Torque Remark (mm) N·m (kgf·m) (lbf·ft)
Page 239: Group 9 Control Valve
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Removal and Installation Control Valve WDCD-03-06-001 WDCD-03-04-010 IMPORTANT: The hose and pipe contain hydraulic 3. Remove bolts, washers (2) (2 used). Remove cover oil. When removing the hose and pipe, receive oils (3). with a container in order to avoid spilling oils.
Page 240 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 8, 77 WDCD-03-09-012 WDCD-03-09-002 6. Remove bolts, washers (8) (3 used) and clamps (77) (3 used). j : 17 mm 7. Remove 3-spool solenoid valve unit (9). (Refer to W3-12-2.) 8. Disconnect the connectors and hoses connected to signal control valve (10).
Page 241 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-003 WDCD-03-09-004 10. Disconnect hoses (12) (2 used). 14. Place a container under the disconnecting part of pipe (19). Remove coupling (20). Disconnect the oil j : 27 mm cooler side of pipe (19). 11.
Page 242 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-005 WDCD-03-09-006 16. Place a container under control valve (22). 21. Remove socket bolts (35) (16 used), flanges (36) (2 Disconnect the both ends of pipes (24) (3 used). used), and flanges (37) (6 used). Disconnect hoses (38) (4 used).
Page 243 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-007 Eyebolt Mounting Hole 24. Remove socket bolts (45) (4 used) and flanges (46) CAUTION: The control valve (22) assembly (2 used). Disconnect hose (47). Remove O-ring (48). weight: 280 kg (620 lb) l : 10 mm 29.
Page 244 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-008 WDCD-03-09-009 31. Remove bolts (60) (2 used) and washers (61) 34. Disconnect hoses (68) (2 used). (2 used). Remove the signal control valve (10) j : 17 mm assembly. j : 22 mm 32.
Page 245 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-010 WDCD-03-09-011 Eyebolt Mounting Hole 35. Disconnect hoses (69) (3 used). CAUTION: Control valve (22) weight: 240 kg (530 j : 17 mm 41. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to 36.
Page 246 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-010 WDCD-03-09-011 Eyebolt Mounting Hole Installation 5. Connect the control valve (22) side of hoses (73) (2 used). 1. Install all removed adapters to control valve (22). j : 17 mm CAUTION: Control valve (22) weight: 240 kg (530 m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 2.
Page 247 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-008 WDCD-03-09-009 10. Connect the control valve (22) side of hoses (68) (2 13. Install the signal control valve (10) assembly with used). washers (61) (3 used) and bolts (60) (3 used). j : 17 mm j : 22 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) m : 140 N·m (14 kgf·m, 103 lbf·ft)
Page 248 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-007 Eyebolt Mounting Hole 18. Connect hose (53). CAUTION: The control valve (22) assembly weight: 280 kg (620 lb) j : 36 mm 14. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to m : 180 N·m (18 kgf·m, 133 lbf·ft) eyebolt mounting holes (a) (2 places) of control 19.
Page 249 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-005 WDCD-03-09-006 21. Install O-ring (44). Connect the control valve (22) 25. Install O-rings (30) (2 used). Connect hoses (29) (2 side of pipe (41) with socket bolts (43) (2 used). used) with flanges (28) (4 used) and socket bolts (27) (8 used).
Page 250 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-09-003 WDCD-03-09-004 29. Install O-ring (23). Connect the control valve (22) 32. Install clamp (15) with bolts, washers (14) (2 used). side of pipe (19) with socket bolts (21) (2 used). j : 19 mm l : 8 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)
Page 251 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 8, 77 WDCD-03-09-012 WDCD-03-09-002 35. Connect connectors (11) (2 used). 36. Connect all removed connectors and hoses to signal control valve (10). (Refer to W3-13-1.) 37. Install 3-spool solenoid valve unit (9). (Refer to W3- 12-2.) 38.
Page 252 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve WDCD-03-06-001 WDCD-03-04-010 39. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 40. Install cover (7) with bolts, washers (6) (7 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 41.
Page 253: Disassembly Of Housing
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Housing W1V1-02-05-023 Housing (5-Spool Side) Socket Bolt (9 Used) O-Ring (12 Used) Housing (4-Spool Side) O-Ring (16 Used) O-Ring (3 Used) W3-9-2-1...
Page 254 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Housing CAUTION: The housing (1) assembly weight: 130 kg (290 lb) The housing (2) assembly weight: 120 kg (265 lb) 1. Remove socket bolts (3) (9 used). l : 14 mm 2.
Page 255: Assembly Of Housing
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Housing W1V1-02-05-011 W1V1-02-05-001 Housing (5-Spool Side) Socket Bolt (9 Used) O-Ring (12 Used) Housing (4-Spool Side) O-Ring (16 Used) O-Ring (3 Used) W3-9-2-3...
Page 256 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Housing IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (4) (16 used), O-rings (5) (12 used), and O-rings (6) (3 used) to the mounting surface of housing (2).
Page 257: Disassembly Of Control Valve (4-Spool Side)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (4-Spool Side) W1V1-02-05-024 W3-9-3-1...
Page 258 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve W1V1-02-05-025 W3-9-3-2...
Page 259 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Housing 35- O-Ring 70- Bolt 101- Plug Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring Spring (2 Used) 37- Spool 72- Spring 103- Cap O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used) Flange...
Page 260 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (4-Spool Side)  Disassembly of Spool  Disassembly of Overload Relief Valve (20) IMPORTANT: Do not disassemble the overload 1. Remove socket bolts (63) (6 used). Remove cap (62), relief valve.
Page 261 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Disassembly of Travel (Right) Spool (37)  Disassembly of Boom 1 Spool (50) 13. Secure spool (37) in a vise by using wooden pieces. 17. Secure spool (50) in a vise by using wooden pieces. Remove bolt (41), spring seats (38) (2 used), and Remove bolt (41), spring seats (38) (2 used), and spring (39) from spool (37).
Page 262 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 22. Remove socket bolts (63) (8 used). Remove caps (67)  Disassembly of Arm 2 Flow Rate Control Valve (3 used), cap (64), and O-rings (59) (4 used) from 28. Remove socket bolts (97) (8 used). Remove the body housing (1).
Page 263 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Disassembly of Boom Anti-Drift Valve (Check Valve) 33. Remove socket bolts (6) (4 used). Remove body (40), O-rings (13) (3 used), and O-rings (77, 78) from housing (1). l : 8 mm 34.
Page 264: Assembly Of Control Valve (4-Spool Side)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (4-Spool Side) Control Valve (Upper) Control Valve (Lower) 59, 62 19, 20 19, 20 59, 67 59, 67 59, 67 59, 64 W1V1-02-05-065 W1V1-02-05-066 Control Valve (Side) Control Valve (Front) 19, 20 19, 20 7, 8, 11, 12...
Page 265 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Control Valve (Upper) Section C-C (4-Spool Side) W1V1-02-05-038 W1V1-02-05-065 Section D-D (4-Spool Side) Section E-E (4-Spool Side) Section F-F (4-Spool Side) 43, 44 43, 44 W1V1-02-05-035 W1V1-02-05-036 W1V1-02-05-028 W3-9-3-9...
Page 266 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Section G-G (4-Spool Side) Section H-H (4-Spool Side) W1V1-02-05-029 W626-02-05-001 Section I-I (4-Spool Side) Section J-J (4-Spool Side) 56, 55 W1V1-02-05-071 W1V1-02-05-037 W3-9-3-10...
Page 267 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Detail A Detail B W1V1-02-05-040 W1V1-02-05-033 Detail C Detail D W1V1-02-05-032 W1V1-02-05-031 Detail E Detail F 112 113 W1V1-02-05-042 W1V1-02-05-034 W3-9-3-11...
Page 268 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Housing 35- O-Ring 70- Bolt 101- Plug Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring Spring (2 Used) 37- Spool 72- Spring 103- Cap O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used) Flange...
Page 269 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (4-Spool Side)  Assembly of Boom 1 Spool (50) 6. Secure spool (50) in a vise by using wooden pieces. Install poppet (49) and spring (45) to the bottom of IMPORTANT: Before assembling, apply hydraulic oil spool (50).
Page 270 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Assembly of Arm Regenerative Valve 12. Secure spool (54) in a vise by using wooden pieces. Install O-ring (56) and backup ring (55) to spool (57). Install spool (57) to spool (54). Install the spool (54) assembly and spring (58) to housing (1).
Page 271 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Assembly of Bucket Flow Rate Control Valve  Assembly of Bypass Shut-Out Valve 14. Install O-rings (95, 90) to plugs (96, 89). 21. Install spool (105), spring (106), and O-ring (4) to housing (1).
Page 272 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Assembly of Check Valve 24. Install O-rings (9) (2 used) to plugs (10) (2 used). Install plugs (10) (2 used) to housing (1). l : 6 mm 25. Install O-rings (7) (2 used) to plugs (8) (2 used). Install plugs (8) (2 used) to housing (1).
Page 273 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Assembly of Boom Anti-Drift Valve (Selector Valve)  Assembly of Arm 2 Flow Rate Control Valve 30. Install backup rings (24, 28) and O-rings (25, 26) to 39. Install O-rings (115, 120) (3 used for each) to plugs sleeve (29).
Page 274 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 47. Install body (123) to housing (1) with socket bolts (97) (8 used). l : 8 mm m : 62 N·m (6.2 kgf·m, 46 lbf·ft) 48. Tighten plugs (114, 119) (3 used for each) to body (123).
Page 275: Disassembly Of Control Valve (5-Spool Side)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (5-Spool Side) W1V1-02-05-026 W3-9-4-1...
Page 276 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve W1V1-02-05-027 W3-9-4-2...
Page 277 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Housing 28- Backup Ring (2 Used) 57- O-Ring (2 Used) 84- Cover (2 Used) O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (8 Used) 85- O-Ring (2 Used) Plug (2 Used) 30- Spool 59- Spool 86- Poppet Poppet...
Page 278 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Disassembly of Control Valve (5-Spool Side)  Disassembly of Overload Relief Valve (19) IMPORTANT: Do not disassemble the overload relief valve. If the overload relief valve has been  Disassembly of Spool disassembled, pressure should be adjusted. (Refer 1.
Page 279 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 12. Remove plugs (10) (2 used) and O-rings (9) (2 used)  Disassembly of Arm 1 Spool (47) from housing (1). 18. Secure spool (47) in a vise by using wooden pieces. Remove bolt (44), spring seats (42, 48) (2 used for l : 8 mm each), and springs (49, 43) from spool (47).
Page 280 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 20. Remove socket bolts (52) (10 used). Remove caps  Disassembly of Arm Anti-Drift Valve (98) (4 used), cap (103), and O-rings (51) (5 used) 24. Remove socket bolts (8) (4 used). Remove flange from housing (1).
Page 281 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Disassembly of Load Check Valve (Boom 2 Parallel 33. Remove plug (16), backup ring (15), and O-ring (14) Circuit, Swing Circuit) from housing (1). 29. Remove socket bolts (8) (8 used) from housing (1). j : 24 mm Remove flanges (75) (2 used), O-rings (13) (2 used), springs (12) (2 used), and poppets (76) (2 used).
Page 282: Assembly Of Control Valve (5-Spool Side)
SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (5-Spool Side) Control Valve (Upper) Control Valve (Lower) 51, 55 51, 98 51, 98 51, 103 51, 98 51, 98 W1V1-02-05-065 W1V1-02-05-066 Control Valve (Side) Control Valve (Front) 9, 10 7, 11, 12, 13 2, 3 4, 5, 6, 7...
Page 283 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Control Valve (Upper) Section C-C (5-Spool Side) 9, 10 W1V1-02-05-043 W1V1-02-05-065 Section D-D (5-Spool Side) Section E-E (5-Spool Side) Section F-F (5-Spool Side) 14, 15, 16 W1V1-02-05-044 W1V1-02-05-045 W1V1-02-05-046 W3-9-4-9...
Page 284 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Section G-G (5-Spool Side) Section H-H (5-Spool Side) Section I-I (5-Spool Side) W1V1-02-05-050 W1V1-02-05-051 W1V1-02-05-052 Detail A Detail B 88 89 W1V1-02-05-033 W1V1-02-05-053 W3-9-4-10...
Page 285 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Detail C Detail D W1V1-02-05-033 W1V1-02-05-054 Housing 28- Backup Ring (2 Used) 57- O-Ring (2 Used) 84- Cover (2 Used) O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (8 Used) 85- *O-Ring (2 Used) Plug (2 Used) 30- Spool 59- Spool...
Page 286 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve Assembly of Control Valve (5-Spool Side) 6. Install O-rings (51) (5 used) to housing (1). Install cap (103) and caps (98) (4 used) to housing (1) with socket bolts (52) (10 used). IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.
Page 287 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Assembly of Auxiliary Flow Rate Control Valve  Assembly of Check Valve (Digging Regenerative Circuit) 9. Install O-rings (57, 62) to plugs (56, 63). 16. Install O-ring (88) to plug (87). Install poppet (90), spring (89), and plug (87) to housing (1).
Page 288 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve 21. Install O-ring (9) to plug (10). Install poppet (86),  Assembly of Arm 1 Flow Rate Control Valve spring (38), and plug (10) to housing (1). 30. Install O-rings (57, 62) to plugs (56, 63). 31.
Page 289 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve  Assembly of Arm Anti-Drift Valve  Assembly of Load Check Valve (Arm Regenerative 35. Install O-ring (71) to plug (70). Install plug (70) to Circuit) flange (72). 39. Install poppet (4), spring (5), and O-ring (6) to housing (1).
Page 290 SECTION 3 UPPERSTRUCTURE Group 9 Control Valve (Blank) W3-9-4-16...
Page 291: Group 10 Swing Device
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Removal and Installation of Swing Device WDCD-03-06-001 IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
Page 292 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device WDCD-03-10-001 4. Disconnect connector (4). CAUTION: Swing device (5) weight: 220 kg (490 5. Place a container under swing device (5). Disconnect hose (6). 8. Attach a nylon sling onto the body of swing motor. Hoist and hold swing device (5).
Page 293 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device WDCD-03-10-001 Installation 1. Install all removed adapters to swing device (5). 5. Connect hoses (7) (2 used). CAUTION: Swing device (5) weight: 220 kg (490 j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 2.
Page 294 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device WDCD-03-06-001 8. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 9. Install cover (3) with bolts, washers (2) (5 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10.
Page 295: Disassembly Of Swing Device
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Device WDAA-03-11-006 Motor Spring Pin (3 Used) Thrust Plate Oil Seal First Stage Sun Gear Needle Bearing (6 Used) Second Stage Sun Gear Sleeve Thrust Plate Planetary Gear (3 Used) First Stage Carrier O-Ring Pin (3 Used)
Page 296 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Device 2. Place swing device (b) onto the special tool (ST CAUTION: Swing device (b) weight: 220 kg (490 5097). Secure swing device (b) with bolts (M20, Pitch 2.5 mm) (2 used) so that stopper (c) at the bottom of special tool (ST 5097) should be inserted CAUTION: When hoisting swing device (b), do into the clearance between teeth of the pinion gear...
Page 297 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device IMPORTANT: The hole for spring pin (5) located on CAUTION: Motor (1) weight: 48 kg (110 lb) first stage carrier (21) is not a through one. Check 6. Remove socket bolts (23) (8 used). Insert a the tapping-in distance of spring pin (5).
Page 298 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 21. Remove bearing nut (15) from shaft (31) by using 24. Push the spline side of shaft (31) by using press the special tool (ST 2926). (a). Remove the shaft (31) assembly and the inner race of roller bearing (14) from housing (26).
Page 299 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device CAUTION: The shaft (31) assembly weight: 40 kg CAUTION: Metal fragments may fly off when (89 lb) a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent 26.
Page 300: Assembly Of Swing Device
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Device W1V1-02-06-004 Motor Spring Pin (3 Used) Thrust Plate Oil Seal First Stage Sun Gear Needle Bearing (6 Used) Second Stage Sun Gear Sleeve Thrust Plate Planetary Gear (3 Used) First Stage Carrier O-Ring Pin (3 Used)
Page 301 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Device CAUTION: Metal fragments may fly off when IMPORTANT: Before assembling, apply gear oil onto a hammer is used. Wear necessary protection, parts in order to prevent them from seizing. such as goggles, helmets, etc in order to prevent 1.
Page 302 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 11. Tighten bearing nut (15) to shaft (31) by hand in CAUTION: The housing (26) assembly weight: 62 order not to drop shaft (31). kg (140 lb) CAUTION: The housing (26) assembly weight: 7.
Page 303 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 18. Remove the bolts (M20, Pitch 2.5 mm) (2 used) CAUTION: The housing (26) assembly weight: which secure housing (26) and the special tool (ST 110 kg (245 lb) 5097). IMPORTANT: Check that the flange surface of j : 30 mm housing (26) does not touch the special tool (ST 5097).
Page 304 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device 26. Fit the spline part of lock plate (16) to that of shaft 33. Install planetary gears (12) (2 used), needle bearings (31). Tighten bearing nut (15) further until the bolt (11) (4 used), thrust plates (13) (2 used), pins (9) (2 (17) hole of bearing nut (15) fit to that of lock plate used), and spring pins (10) (2 used) to second stage (16).
Page 305 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device IMPORTANT: Check the mounting position of thrust IMPORTANT: Check the direction to install first stage plate (8). sun gear (2). 38. Install planetary gears (7) (2 used), needle bearings 44. Install first stage sun gear (2) to the first stage carrier (6) (2 used), thrust plates (8) (2 used), pins (4) (2 (21) assembly with the stepped part down.
Page 306 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device CAUTION: Motor (1) weight: 48 kg (110 lb) 50. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to motor (1). Hoist motor (1). Fit the matching marks. Install motor (1) to ring gear (25) with socket bolts (23) (8 used).
Page 307: Disassembly Of Swing Motor
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Motor W178-02-06-015 Casing Plate (4 Used) Brake Piston Valve Casing Oil Seal Friction Plate (3 Used) Spring (24 Used) Socket Bolt (4 Used) Bearing O-Ring Valve Plate O-Ring (2 Used) Shaft Piston Bearing...
Page 308 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Disassembly of Swing Motor IMPORTANT: Do not damage the mating surfaces CAUTION: The swing motor assembly weight: 48 when separating valve plate (21) from valve kg (110 lb) casing (28) or rotor (9) by using a screwdriver. IMPORTANT: Do not disassemble relief valve (32).
Page 309 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device IMPORTANT: Do not damage the sliding surfaces of IMPORTANT: The filter and orifice are installed inside rotor (9) and plunger (6). piston (13). Do not disassemble piston (13) unless they are clogged or deformed. If the inner parts of 10.
Page 310: Assembly Of Swing Motor
SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Motor 27 26 25 24 W178-02-11-152 W178-02-11-151 W178-02-11-153 Casing Plate (4 Used) Brake Piston Valve Casing Oil Seal Friction Plate (3 Used) Spring (24 Used) Socket Bolt (4 Used) Bearing O-Ring Valve Plate O-Ring (2 Used)
Page 311 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device Assembly of Swing Motor 8. Place casing (1) horizontally. Install the rotor (9) IMPORTANT: Before assembling, apply hydraulic oil assembly to shaft (4). onto parts in order to prevent them from seizing. IMPORTANT: There are four notches on the outer 1.
Page 312 SECTION 3 UPPERSTRUCTURE Group 10 Swing Device IMPORTANT: If the inner parts of piston (13) are 18. Install valve casing (28) to casing (1) with socket replaced, replace piston (13) as an assembly. bolts (29) (4 used). 13. Install ball (15), spring (14), and piston (13) to casing l : 17 mm (1) in order to fit the end of piston (13) to that of casing (1).
Page 313: Group 11 Pilot Valve
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Removal and Installation of Pilot Valve (Left) WDAA-03-01-023 WDAA-03-01-047 IMPORTANT: Cap the open ends in case the hoses CAUTION: Seat (5) weight: 20 kg (45 lb) and pipes have been disconnected. In addition, 4.
Page 314 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Detail B WDAA-03-12-002 7, 8 WDAA-03-12-001 5. Remove socket bolts (7) (2 used) and washers (8) (2 used). Remove lever (9). l : 6 mm 6. Remove socket bolts (10) (2 used) and washers (11) (2 used).
Page 315 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 30, 31 WDAA-03-12-023 WDAA-03-12-019 11. Remove clip bands (24, 25). 12. Loosen lock nut (26). Remove the lever (27) assembly. j : 19 mm, 22 mm 13. Disconnect hoses (28) (6 used). j : 19 mm 14.
Page 316 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 30, 31 WDAA-03-12-023 WDAA-03-12-019 Installation 1. Install all removed adapters to pilot valve (29). 2. Install pilot valve (29) and boot (32) with washers (31) (4 used) and socket bolts (30) (4 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 3.
Page 317 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Detail B WDAA-03-12-002 7, 8 WDAA-03-12-001 6. Install cover (23) with screws (22, 21) (2 used for 13. Install lever (9) with washers (8) (2 used) and socket each). bolts (7) (2 used). 7.
Page 318 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-01-023 WDAA-03-01-047 CAUTION: Seat (5) weight: 20 kg (45 lb) 14. Install seat (5) with socket bolts (6) (4 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 15. Install spacers (4) (2 used) and seat belts (3) (2 used) with bolts, washers (2) (2 used).
Page 319: Removal And Installation Of Pilot Valve (Left)
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Removal and Installation of Pilot Valve (Right) WDAA-03-01-023 WDAA-03-01-047 IMPORTANT: Cap the open ends in case the hoses CAUTION: Seat (5) weight: 20 kg (45 lb) and pipes have been disconnected. In addition, attach an identification tag onto the connectors, 4.
Page 320 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Detail A WDAA-03-12-006 WDAA-03-12-005 5. Remove socket bolts (7) (2 used) and washers (8) (2 used). Remove armrest (9). l : 6 mm 6. Remove tray (10). Remove screws (11) (3 used). 7. Raise cover (12). Disconnect connectors (13) (2 used).
Page 321 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-12-007 WDAA-03-12-005 9. Remove clip bands (17, 18). 10. Loosen lock nut (19). Remove the lever (20) assembly. j : 19 mm, 22 mm 11. Remove bolts, washers (21) (3 used). Tilt the bracket (22) assembly with the cover (23) side up.
Page 322 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Detail A 28, 29 WDAA-03-12-008 WDAA-03-12-020 13. Disconnect hoses (26) (6 used). j : 19 mm 14. Remove socket bolts (28) (4 used) and washers (29) (4 used). Remove pilot valve (27) and boot (30). l : 6 mm 15.
Page 323 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Detail A 28, 29 WDAA-03-12-008 WDAA-03-12-020 Installation 1. Install all removed adapters to pilot valve (27). 2. Install pilot valve (27) and boot (30) with washers (29) (4 used) and socket bolts (28) (4 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 3.
Page 324 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-12-007 WDAA-03-12-005 4. Install cover (23) with washer (25) and screws (24) (3 used). 5. Install bracket (22) with bolts, washers (21) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 6.
Page 325 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Detail A WDAA-03-12-006 WDAA-03-12-005 8. Install cover (16) with screws (15) (2 used). 9. Install cover (12). 10. Raise cover (12). Connect connectors (13) (2 used). 11. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level.
Page 326 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-01-023 WDAA-03-01-047 CAUTION: Seat (5) weight: 20 kg (45 lb) 15. Install seat (5) with socket bolts (6) (4 used). l : 6 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 16. Install spacers (4) (2 used) and seat belts (3) (2 used) with bolts, washers (2) (2 used).
Page 327: Removal And Installation Of Travel Pilot Valve
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Removal and Installation of Travel Pilot Valve WDAA-03-13-005 WDAA-03-12-016 IMPORTANT: Cap the open ends in case the hoses 5. Place a container under pilot valve (4). Disconnect and pipes have been disconnected. In addition, hoses (5) (4 used).
Page 328 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-12-017 WDAA-03-12-018 7. Remove bolts, washers (7) (4 used). Remove levers (8) (2 used) and pedals (9) (2 used). j : 17 mm 8. Remove socket bolts (10) (2 used) and washers (11) (2 used).
Page 329 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-12-017 WDAA-03-12-018 Installation 1. Install all removed adapters to pilot valve (4). 2. Install pilot valve (4) with washers (11) (2 used) and socket bolts (10) (2 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3.
Page 330 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve WDAA-03-13-005 WDAA-03-12-016 4. Connect pipes (6) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 19 lbf·ft) 5. Connect hoses (5) (4 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 6.
Page 331: Disassembly Of Pilot Valves (Right And Left)
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Pilot Valves (Right and Left) WDAA-03-12-021 Spacer (4 Used) Spring Guide (4 Used) O-Ring (4 Used) Spool (4 Used) Shim (Several) Retaining Ring (4 Used) Plate O-Ring Balance Spring (2 Used) Pusher (2 Used) Universal Joint Plug...
Page 332 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Pilot Valves (Right and Left) 3. Attach a spanner onto the upper part of universal IMPORTANT: Casing (18) is made of aluminium. joint (15). Remove universal joint (15). Strong force deforms it. Handle it with care. IMPORTANT: Spool (19) has been selected to match j : 17 mm the hole on casing (18).
Page 333 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 7. When compressing the spring, do not lower spool IMPORTANT: The quantity of shims (2) has been determined for each port during the performance (19). Install the special tool (ST 4145) to the port testing.
Page 334: Assembly Of Pilot Valves (Right And Left)
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Pilot Valves (Right and Left) 9, 10 3, 4 5, 6 WDAA-03-12-022 Spacer (4 Used) Spring Guide (4 Used) O-Ring (4 Used) Spool (4 Used) Shim (Several) Retaining Ring (4 Used) Plate O-Ring Balance Spring (2 Used)
Page 335 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Pilot Valves (Right and Left) IMPORTANT: Refer to the table in the left in order to IMPORTANT: Before assembling, apply hydraulic oil assemble the parts correctly. onto parts in order to prevent them from seizing. 3.
Page 336 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 8. Install retaining ring (8) to the groove on the head IMPORTANT: Fit the bolt hole on plate (14) to the screw hole on casing (18). of spool (21) extending from the special tool (ST 4146).
Page 337: Disassembly Of Travel Pilot Valve
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Travel Pilot Valve WDAA-03-12-024 Bolt, Washer (2 Used) Spring Pin O-Ring (2 Used) Oil Seal (4 Used) Cover Bracket (2 Used) Plug (2 Used) Spring Washer (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) Plug (2 Used) Socket Bolt (2 Used)
Page 338 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Disassembly of Travel Pilot Valve IMPORTANT: Spool (24) has been selected to match IMPORTANT: Casing (23) is made of aluminium. the hole of casing (23). Spool (24) and casing (23) Strong force deforms it. Handle it with care. should be replaced as an assembly.
Page 339 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 11. Remove O-ring (33) from pin (35). CAUTION: Metal fragments may fly off when 12. Remove other bracket (11) in the same way as step a hammer is used. Wear necessary protection, 9 to step 11. such as goggles, helmets, etc in order to prevent personal injury.
Page 340 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 15. Remove pin (35) by using a bar and a hammer. At the same time, cams (5) (2 used) are removed.
Page 341: Assembly Of Travel Pilot Valve
SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Travel Pilot Valve 35 6 12 10 3, 4 WDAA-03-12-025 Bolt, Washer (2 Used) Spring Pin *O-Ring (2 Used) Oil Seal (4 Used) Cover Bracket (2 Used) *Plug (2 Used) Spring Washer (2 Used) Spring Pin (2 Used) Spring Pin (2 Used) *Plug (2 Used)
Page 342 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve Assembly of Travel Pilot Valve CAUTION: Metal fragments may fly off when IMPORTANT: Before assembling, apply hydraulic oil a hammer is used. Wear necessary protection, onto parts in order to prevent them from seizing. such as goggles, helmets, etc in order to prevent IMPORTANT: The pilot valve is the susceptible personal injury.
Page 343 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve  Install bushing (6) on the opposite side in the same 12. Install O-rings (33) (2 used) to pin (35). Apply grease way. onto O-rings (33) (2 used). Install pin (35) and cams (5) (2 used) to holder (7).
Page 344 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 16. Place holder (7) on the casing (23) assembly. Install 21. As for the direction to install bracket (11), refer to holder (7) to casing (23) with socket bolts (30) (2 the figure in Disassembly of Travel Pilot Valve on used) and spring washers (29) (2 used).
Page 345 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve 23. Crimp the hole edge of bracket (11) where spring pins (12, 13) are inserted by using a punch. 24. Install other bracket (11) in the same way as step 22 to step 23. 25.
Page 346 SECTION 3 UPPERSTRUCTURE Group 11 Pilot Valve (Blank) W3-11-5-10...
Page 347: Group 12 Solenoid Valve
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Removal and Installation of Pilot Shut-Off Solenoid Valve WDAA-03-13-005 WDAA-03-13-006 IMPORTANT: Cap the open ends in case the hoses 6. Place a container under pilot shut-off solenoid valve and pipes have been disconnected. In addition, (5).
Page 348 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve WDAA-03-13-007 WDAA-03-13-008 7. Disconnect hoses (8) (7 used). j : 19 mm 8. Remove bolts, washers (9) (2 used). Remove pilot shut-off solenoid valve (5). j : 17 mm 9. Remove the adapter with pilot shut-off solenoid valve (5) attached if necessary.
Page 349 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve WDAA-03-13-007 WDAA-03-13-008 Installation 1. Install all removed adapters to pilot shut-off solenoid valve (5). 2. Install pilot shut-off solenoid valve (5) with bolts, washers (9) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3.
Page 350 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve WDAA-03-13-005 WDAA-03-13-006 4. Connect pipes (7, 6). j : 17 mm m : 25 N·m (2.5 kgf·m, 19 lbf·ft) 5. Connect connector (4). 6. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level.
Page 351: Removal And Installation Of 3-Spool Solenoid Valve Unit
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Removal and Installation of 3-Spool Solenoid Valve Unit WDCD-03-06-001 IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed.
Page 352 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve WDCD-03-12-001 WDCD-03-12-002 4. Disconnect connectors (4) (3 used). 5. Place a container under 3-spool solenoid valve unit (5). Disconnect hoses (6) (5 used). j : 17 mm 6. Disconnect both ends of pipes (7) (6 used). j : 17 mm 7.
Page 353 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve WDCD-03-12-001 WDCD-03-12-002 Installation 1. Install all removed adapters to 3-spool solenoid 5. Connect pipes (7) (6 used). valve unit (5). j : 17 mm 2. Install 3-spool solenoid valve unit (5) with socket m : 25 N·m (2.5 kgf·m, 18 lbf·ft) bolts (10) (2 used).
Page 354 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve WDCD-03-06-001 8. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 9. Install cover (3) with bolts, washers (2) (5 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10.
Page 355: Disassembly Of Pilot Shut-Off Solenoid Valve
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Disassembly of Pilot Shut-Off Solenoid Valve WDAA-03-13-014 Socket Bolt (2 Used) Body O-Ring Solenoid Spool Plug O-Ring Spring Filter W3-12-3-1...
Page 356 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Disassembly of Pilot Shut-Off Solenoid Valve IMPORTANT: Filter (9) cannot be removed. 1. Put the matching marks on body (4) and solenoid (2). Secure body (4) in a vise. Remove socket bolts (1) (2 used) from body (4). Remove solenoid (2) and O-ring (3) from body (4).
Page 357: Assembly Of Pilot Shut-Off Solenoid Valve
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Assembly of Pilot Shut-Off Solenoid Valve T1V1-03-07-012 Socket Bolt (2 Used) Body O-Ring Solenoid Spool Plug O-Ring Spring Filter W3-12-3-3...
Page 358 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Assembly of Pilot Shut-Off Solenoid Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Secure body (4) in a vise. Insert spool (5) and spring (6) into body (4).
Page 359: Structure Of 3-Spool Solenoid Valve Unit
SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Structure of 3-Spool Solenoid Valve Unit WDCD-03-12-003 WDAA-03-13-013 W3-12-4-1...
Page 360 SECTION 3 UPPERSTRUCTURE Group 12 Solenoid Valve Wrench Size Tightening Torque Part Name Q’ty Remark (mm) N·m (kgf·m) (lbf·ft) Body Orifice l : 6 (7.4 +0.3 +2.2 Orifice l : 10 +0.5 +3.7 Socket Bolt l : 4 (0.5 (3.7 +0.2 +1.5 Solenoid...
Page 361: Group 13 Signal Control Valve
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Removal and Installation of Signal Control Valve WDCD-03-06-001 WDCD-03-13-001 IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling.
Page 362 SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve WDCD-03-13-002 WDCD-03-13-003 5. Place a container under signal control valve (5). Disconnect hoses (6) (5 used). j : 19 mm 6. Disconnect hoses (7) (3 used). j : 17 mm 7. Disconnect hoses (8) (3 used). j : 19 mm 8.
Page 363 SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve WDCD-03-13-004 WDCD-03-13-005 11. Disconnect hoses (12) (17 used). j : 19 mm 12. Remove socket bolts (13) (4 used) and washers (14) (4 used). Remove signal control valve (5). l : 8 mm 13.
Page 364 SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve WDCD-03-13-004 WDCD-03-13-005 Installation 1. Install all removed adapters to signal control valve (5). 2. Install signal control valve (5) with washers (14) (4 used) and socket bolts (13) (4 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3.
Page 365 SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve WDCD-03-13-002 WDCD-03-13-003 4. Connect hose (11). 8. Connect hoses (7) (3 used). j : 17 mm j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 5.
Page 366 SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve WDCD-03-06-001 WDCD-03-13-001 10. Connect connectors (4) (2 used). 11. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 12.
Page 367: Structure Of Signal Control Valve
SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve Structure of Signal Control Valve W1JB-02-10-002 W3-13-2-1...
Page 368 SECTION 3 UPPERSTRUCTURE Group 13 Signal Control Valve W1JB-02-10-003 Bolt (12 Used) Body 3 O-Ring (7 Used) O-Ring Body 1 Gasket Spring (4 Used) Spring Gasket Body 4 Spring Guide (7 Used) Spool Filter (17 Used) Gasket Spool (5 Used) Spring Body 2 Body 5...
Page 369 MEMO...
Page 370 MEMO...
Page 371 SECTION 4 UNDERCARRIAGE CONTENTS Group 1 Swing Bearing Removal and Installation of Swing Bearing ..W4-1-1-1 Disassembly of Swing Bearing ........W4-1-2-1 Assembly of Swing Bearing ........W4-1-2-4 Group 2 Travel Device Removal and Installation of Travel Device ....W4-2-1-1 Disassembly of Travel Device ........W4-2-2-1 Assembly of Travel Device ..........W4-2-2-5 Disassembly of Travel Motor ........W4-2-3-1 Assembly of Travel Motor..........W4-2-3-4...
Page 372 (Blank) DCDW-4-2...
Page 373: Group 1 Swing Bearing
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Removal and Installation of Swing Bearing 4, 5 ST 0050 Matching Mark WDAA-04-01-001 W110-03-01-004 Before removing and installing the swing bearing, the CAUTION: Swing bearing (1) weight: 230 kg (510 upperstructure must be removed first. (Refer to W3-3-1.) Therefore, the procedure starts on the premise that the 3.
Page 374 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing ST 0050 W110-03-01-004 Matching Mark WDAA-04-01-001 WDCD-04-01-001 Position for Grease Fitting Soft Zone Marking Position Position for Plug Front Side Installation IMPORTANT: If the matching marks (a) do not fit, the soft zone position of inner race will be dislocated. 1.
Page 375 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing 4, 5 WDAA-04-01-001 W175-03-01-002 Swing Bearing Grease Level 5. Install swing bearing (1) with spring washers (5) (36 used) and bolts (4) (36 used). j : 30 mm m : 500 N·m (50 kgf·m, 370 lbf·ft) 6.
Page 376 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing (Blank) W4-1-1-4...
Page 377: Disassembly Of Swing Bearing
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Disassembly of Swing Bearing W178-02-11-193 W178-02-11-194 Outer Race Seal Grease Fitting (2 Used) Seal Ball (111 Used) Inner Race Plug Support (111 Used) W4-1-2-1...
Page 378 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Disassembly of Swing Bearing 3. Install bolt (10) to the screw hole (M10, Pitch 1.5 mm) of plug (4). Tap or pull bolt (10) and remove CAUTION: Metal fragments may fly off when plug (4) from outer race (1).
Page 379 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing 5. Remove balls (6) (111 used) and supports (8) (111 used) from the plug (4) hole while rotating outer race (1). W178-02-11-197 W178-02-11-198 NOTE: Remove ball (6) by using magnet (11). Use wire (12) and remove support (8).
Page 380: Assembly Of Swing Bearing
SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Assembly of Swing Bearing W178-02-11-193 W178-02-11-194 Outer Race Seal Grease Fitting (2 Used) Seal Ball (111 Used) Inner Race Plug Support (111 Used) W4-1-2-4...
Page 381 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Assembly of Swing Bearing CAUTION: Swing bearing weight: 230 kg (510 lb) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, 1. Install special tools (ST 0050) (3 used) to outer race such as goggles, helmets, etc in order to prevent (1).
Page 382 SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing (Blank) W4-1-2-6...
Page 383: Group 2 Travel Device
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Removal and Installation of Travel Device WDAA-04-02-001 WDAA-04-02-002 Removal IMPORTANT: Cap the open ends in case the hoses 5. Disconnect hose (7). and pipes have been disconnected. In addition, j : 27 mm attach an identification tag onto the connectors, hoses, and pipes for assembling.
Page 384 SECTION 4 UNDERCARRIAGE Group 2 Travel Device WDAA-04-02-002 Installation 1. Install all removed adapters to travel device (5). CAUTION: Travel Device (5) weight: 310 kg (685 2. Attach a nylon sling onto travel device (5). Hoist travel device (5). Install travel device (5) with washers (10) (14 used) and bolts (9) (14 used).
Page 385 SECTION 4 UNDERCARRIAGE Group 2 Travel Device WDAA-04-02-001 6. Connect track (1). (Refer to W4-6-1.) 7. Install another travel device in the same way as step 1 to step 6. 8. Bleed air from the hydraulic system. (Refer to W1-4- IMPORTANT: Check the hydraulic oil level.
Page 386 SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank) W4-2-1-4...
Page 387: Disassembly Of Travel Device
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Device WDAA-04-02-003 00- Travel Motor 12- Third Stage Carrier 25- Planetary Gear (3 Used) 35- Needle Bearing (3 Used) 02- Floating Seal 13- Planetary Gear (3 Used) 26- Needle Bearing (3 Used) 36- Thrust Plate (6 Used) 03- Roller Bearing (2 Used) 15- Thrust Plate (6 Used)
Page 388 SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Device IMPORTANT: Do not remove stopper (42) unless CAUTION: There may be pressure accumulated damage and wear are found. inside of the travel device. Loosen the air bleed plug slowly. Release any remaining pressure 4.
Page 389 SECTION 4 UNDERCARRIAGE Group 2 Travel Device 8. Remove sun gear (18) from third stage carrier (12). IMPORTANT: Do not remove knock pin (10) unless necessary. CAUTION: Ring gear (20) weight: 39 kg (86 lb) 11. Remove bearing nut (09) from travel motor (00) by 9.
Page 390 SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Handle floating seal (02) with care. CAUTION: Metal fragments may fly off when (Refer to W4-2-5.) a hammer is used. Wear necessary protection, 13. Remove one side of floating seal (02) from travel such as goggles, helmets, etc in order to prevent motor (00).
Page 391: Assembly Of Travel Device
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Device 09 10 12 18 20 24 23 30 33 32 WDCD-04-02-001 00- Travel Motor 12- Third Stage Carrier 25- Planetary Gear (3 Used) 35- Needle Bearing (3 Used) 02- Floating Seal 13- Planetary Gear (3 Used) 26- Needle Bearing (3 Used) 36- Thrust Plate (6 Used)
Page 392 SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Device IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Handle floating seal (02) with care. onto parts in order to prevent them from seizing. (Refer to W4-2-5.) 2. Apply grease onto O-ring of one side of floating seal (02).
Page 393 SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Handle floating seal (02) with care. CAUTION: Drum (04) weight: 51 kg (115 lb) (Refer to W2-4-5.) 4. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the 6. Apply grease onto O-ring of other side of floating bolt (06) holes on drum (04).
Page 394 SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Check the direction to install bearing CAUTION: Sprocket (05) + drum (04) assembly nut (09). weight: 96 kg (215 lb) 13. Apply grease onto the thread part of bearing nut 10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the (09).
Page 395 SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: When knock pin (10) has been 23. Install other planetary gears (13) (2 used) to third removed, follow the procedure as step 18. stage carrier (12) in the same way as steps 19 to 22. 18.
Page 396 SECTION 4 UNDERCARRIAGE Group 2 Travel Device 34. Install the second stage carrier (23) assembly to ring CAUTION: Ring gear (20) weight: 39 kg (86 lb) gear (20). 26. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the 35. Install sun gear (30) to second stage carrier (23) with bolt, washer (43) holes (2 places) of ring gear (20).
Page 397 SECTION 4 UNDERCARRIAGE Group 2 Travel Device 42. Insert the spline side of shaft (39) into the center of sun gear (30). Rotate sprocket (05) slowly by hand. Engage travel motor (00) and planetary gear (34) with shaft (39), and install them. 43.
Page 398 SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank) W4-2-2-12...
Page 399: Disassembly Of Travel Motor
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Motor WDAA-04-02-007 00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 31- O-Ring (2 Used) 01- Oil Seal 16- Retainer 25- Brake Piston 32- Brake Valve 03- Piston 17- Bushing 26- O-Ring 33- Needle Bearing 07- Shaft...
Page 400 SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Travel Motor 4. Remove valve plate (39) and knock pins (37) (2 used) CAUTION: Travel motor weight: 91 kg (205 lb) from brake valve (32). 1. Attach a nylon sling onto the travel motor. Hoist the 5.
Page 401 SECTION 4 UNDERCARRIAGE Group 2 Travel Device 15. Attach a bar onto the bottom of the spline hole CAUTION: The housing (00) assembly weight: 59 of shaft (07). Tap and remove shaft (07) and roller kg (135 lb) bearing (10) from housing (00) by using a bar and a 12.
Page 402: Assembly Of Travel Motor
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Motor 21 14 16 WDCD-04-02-004 00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 31- O-Ring (2 Used) 01- Oil Seal 16- Retainer 25- Brake Piston 32- Brake Valve 03- Piston 17- Bushing 26- O-Ring...
Page 403 SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Travel Motor CAUTION: Metal fragments may fly off when IMPORTANT: Before assembling, apply hydraulic oil a hammer is used. Wear necessary protection, onto parts in order to prevent them from seizing. such as goggles, helmets, etc in order to prevent personal injury.
Page 404 SECTION 4 UNDERCARRIAGE Group 2 Travel Device IMPORTANT: Install retainer (16) with the chamfered 10. Install balls (09) (2 used) to housing (00). side facing to the bushing (17) side. 11. Apply grease onto the ball (09) hole of swash plate 13.
Page 405 SECTION 4 UNDERCARRIAGE Group 2 Travel Device 20. Install O-rings (31) (2 used) and O-ring (30) to CAUTION: Metal fragments may fly off when housing (00). a hammer is used. Wear necessary protection, 21. Add hydraulic oil to housing (00) until plate (23) is such as goggles, helmets, etc in order to prevent submerged.
Page 406 SECTION 4 UNDERCARRIAGE Group 2 Travel Device 24. Apply grease onto the flat surface of valve plate (39). Install valve plate (39) to brake valve (32) while fitting the knock pin (37) positions. NOTE: Valve plate (39) is secured to brake valve (32) in order not to drop brake valve (32) when turning over.
Page 407: Disassembly Of Brake Valve
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Brake Valve WDAA-04-02-009 01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug 01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring 01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug 02- Stopper (2 Used) 10- Spring (2 Used)
Page 408 SECTION 4 UNDERCARRIAGE Group 2 Travel Device Disassembly of Brake Valve IMPORTANT: As the setting changes, do not disassemble relief valve (15). 1. Remove plugs (05) (2 used) from casing (01A). IMPORTANT: Do not move piston (a) with the outer Remove O-rings (07) (2 used) from plugs (05) (2 surface of relief valve (15) attached.
Page 409: Assembly Of Brake Valve
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Brake Valve WDAA-04-02-010 01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug 01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring 01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug 02- Stopper (2 Used) 10- Spring (2 Used)
Page 410 SECTION 4 UNDERCARRIAGE Group 2 Travel Device Assembly of Brake Valve 8. Install springs (10) (2 used) to poppets (08) (2 used). Install poppets (08) (2 used) to the hole of casing IMPORTANT: Before assembling, apply hydraulic oil (01A) completely. onto parts in order to prevent them from seizing.
Page 411: Precautions For Using Floating Seal
SECTION 4 UNDERCARRIAGE Group 2 Travel Device Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures:  Keep seal rings together as a matched set with seal ring (1) surfaces together.
Page 412 SECTION 4 UNDERCARRIAGE Group 2 Travel Device (Blank) W4-2-5-2...
Page 413: Group 3 Center Joint
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Removal and Installation of Center Joint WDAA-04-03-001 IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hose (4). and pipes have been disconnected. In addition, j : 17 mm attach an identification tag onto the connectors, hoses, and pipes for assembling.
Page 414 SECTION 4 UNDERCARRIAGE Group 3 Center Joint WDCD-04-03-001 5. Disconnect hoses (5) (2 used). j : 27 mm 6. Disconnect hoses (6) (4 used). j : 36 mm 7. Disconnect hoses (7) (2 used). j : 17 mm 8. Remove bolts (8) (2 used) and spring washers (9) (2 used).
Page 415 SECTION 4 UNDERCARRIAGE Group 3 Center Joint WDCD-04-03-001 Installation 7. Connect hoses (6) (4 used). 1. Install all removed adapters to center joint (1). j : 36 mm CAUTION: Center joint (1) weight: 27 kg (60 lb) m : 180 N·m (18 kgf·m, 133 lbf·ft) 2.
Page 416 SECTION 4 UNDERCARRIAGE Group 3 Center Joint WDAA-04-03-001 9. Connect hose (4). j : 17 mm m : 25 N·m (2.5 kgf·m, 18 lbf·ft) 10. Connect hose (3). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 11.
Page 417: Disassembly Of Center Joint
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Disassembly of Center Joint WDAA-04-03-003 00A- Spindle 03- O-Ring 06- Ring 09- Cover 00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used) 01- Body 05- Bushing 08- O-Ring 02- Dust Seal...
Page 418 SECTION 4 UNDERCARRIAGE Group 3 Center Joint Disassembly of Center Joint IMPORTANT: For easy removal of oil seal (04), use the CAUTION: Center joint weight: 27 kg (60 lb) pins (2 used). Do not damage the seal groove. 1. Remove bolts, washers (10) (2 used) diagonally. 6.
Page 419: Assembly Of Center Joint
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Assembly of Center Joint W178-03-03-001 00A- Spindle 03- O-Ring 06- Ring 09- Cover 00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used) 01- Body 05- Bushing 08- O-Ring 02- Dust Seal...
Page 420 SECTION 4 UNDERCARRIAGE Group 3 Center Joint Assembly of Center Joint IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (05). onto parts in order to prevent them from seizing. IMPORTANT: The clearance between body (01) and IMPORTANT: When assembling the seals, apply spindle (00A) is approximately 0.1 mm.
Page 421 SECTION 4 UNDERCARRIAGE Group 3 Center Joint IMPORTANT: Install ring (06) with the chamfered side facing to the spindle (00A) side. 4. Install ring (06) and O-ring (08) to body (01). WDAA-04-03-004 5. Install retaining ring (07) to spindle (00A). 6.
Page 422: Replacement Of Body And Spindle
SECTION 4 UNDERCARRIAGE Group 3 Center Joint Replacement of Body and Spindle ST 2558 IMPORTANT: When replacing body (01) or spindle (00A) with the new one, the following procedures are required. In case of Body (01) 1. Clean body (01) and bushing (05). 2.
Page 423: Group 4 Track Adjuster
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Removal and Installation of Track Adjuster ST 1650 WDCD-04-04-002 Hoisting Position Hoisting Position Before removing and installing the track adjuster, the 3. Attach a weight onto part (b) of the special tool tracks must be removed first. (Refer to W4-6-1.) (ST 1650).
Page 424 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 3, 4 5, 6 WDCD-04-04-004 WDCD-04-04-003 Block 6. Place track adjuster (7) onto blocks (a) (4 used). 7. Remove bolts (3) (2 used) and washers (4) (2 used). j : 24 mm CAUTION: The track adjuster (7) assembly weight: 250 kg (555 lb) 8.
Page 425 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 5, 6 3, 4 WDCD-04-04-004 WDCD-04-04-003 Block Installation 4. Install washers (4) (2 used) and bolts (3) (2 used). CAUTION: Take care not to turn over track j : 24 mm adjuster (7). m : 270 N·m (27 kgf·m, 200 lbf·ft) CAUTION: Front idler (1) weight: 110 kg (245 lb) Track adjuster (7) weight: 140 kg (310 lb)
Page 426 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster ST 1650 WDCD-04-04-002 Hoisting Position Hoisting Position CAUTION: The track adjuster (7) assembly CAUTION: The track adjuster (7) assembly + weight: 250 kg (555 lb) Special tool (ST 1650) weight: 310 kg (685 lb) 5.
Page 427: Disassembly Of Front Idler
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Front Idler WDCD-04-04-006 00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used) 01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used) W4-4-2-1...
Page 428 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Front Idler IMPORTANT: Handle floating seals with care. (Refer CAUTION: The idler (03A) assembly weight: 110 to W4-4-4.) kg (245 lb) 4. Remove bearing (00) from the upper side of idler 1.
Page 429 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster CAUTION: The axle (01) assembly weight: 25 kg CAUTION: Idler (03A) weight: 70 kg (155 lb) (56 lb) IMPORTANT: Do not remove bushing (03B) unless IMPORTANT: Place wooden blocks under bearing necessary. (00) in order not to damage bearing (00). 9.
Page 430: Assembly Of Front Idler
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Front Idler WDCD-04-04-005 00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used) 01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used) W4-4-2-4...
Page 431 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Front Idler IMPORTANT: Handle floating seal (05) with care. CAUTION: Idler (03A) weight: 70 kg (155 lb) (Refer to W4-4-4.) 1. Install bushings (03B) (2 used) to idler (03A). 5. Apply engine oil onto the O-ring of floating seal 2.
Page 432 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster CAUTION: The idler (03A) assembly weight: 95 CAUTION: Metal fragments may fly off when kg (210 lb) a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent 8.
Page 433: Disassembly Of Track Adjuster
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Track Adjuster WDCD-04-04-007 00A- Cylinder 03- Yoke 08- Bracket 15- Valve 00B- Rod 04- Seal 09- Bolt 16- Bracket 01- Spacer 05- Dust Seal 10- Washer 02- Spring 07- Nut 14- Piston Rod W4-4-3-1...
Page 434 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Disassembly of Track Adjuster CAUTION: Special tool (ST 4052) weight: 32 kg (71 lb) CAUTION: The spring force is extremely large. 5. Remove nuts (d) (4 used) from the special tool (ST Carry out the disassembly and assembly work 4950).
Page 435 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 8. Install the special tool (ST 4052) in order to cover 11. Remove nut (07) from rod (00B). the spring (02) assembly. Install washers (J222016) j : 75 mm (4 used) and bolts (J921650) (4 used) to the bolt holes (4 places) of yoke (03).
Page 436 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster CAUTION: Yoke (03) weight: 21 kg (47 lb) 15. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and nuts (2 used) to the bolt holes (2 places) of yoke (03) diagonally. Attach nylon slings onto the eyebolts. Hoist yoke (03).
Page 437: Assembly Of Track Adjuster
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Track Adjuster 08 07 04 05 14 WDCD-04-04-008 Detail A WDCD-04-04-011 00A- Cylinder 03- Yoke 08- Bracket 15- Valve 00B- Rod 04- Seal 09- Bolt 16- Bracket 01- Spacer 05- Dust Seal 10- Washer 02- Spring 07- Nut...
Page 438 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Assembly of Track Adjuster 6. Remove the eyebolts from rod (00B). CAUTION: Cylinder (00A) weight: 20 kg (45 lb) CAUTION: Yoke (03) weight: 21 kg (47 lb) 7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and CAUTION: The cylinder (00A) assembly weight: nuts (2 used) to the bolt holes (2 places) of yoke (03) 29 kg (64 lb)
Page 439 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 9. Tighten nuts (a) (4 used) of the special tool (ST 4950) 12. Install bracket (08) to nut (07) with washer (10) and and secure the spring (02) assembly. bolt (09). j : 46 mm j : 17 mm m : 60 N·m (6 kgf·m, 44 lbf·ft) 13.
Page 440 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster 18. Fill part A of cylinder (00A) with grease. WDCD-04-04-014 19. Install piston rod (14) to cylinder (00A). 20. Bleed air from part A of cylinder (00A) and cylinder (00A). 21. Install bracket (16) and valve (15) to piston rod (14). j : 24 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 22.
Page 441: Precautions For Using Floating Seal
SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures:  Keep seal rings together as a matched set with seal ring (1) surfaces together.
Page 442 SECTION 4 UNDERCARRIAGE Group 4 Track Adjuster (Blank) W4-4-4-2...
Page 443: Group 5 Upper And Lower Rollers
SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers Removal and Installation of Upper Roller W105-03-06-001 TDAA-03-08-002 CAUTION: The pressure inside the track adjuster cylinder is high. Do not loosen valve (1) quickly or too much as valve (1) may fly out or high-pressure grease in the adjuster cylinder may gush out.
Page 444 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers W1V7-03-06-001 W105-03-06-003 Oil Jack Nonskid Cloth Wooden Block W105-03-06-005 CAUTION: Use nonskid cloth (b) between track frame (3) and oil jack (a) in order not to slip. 3. Raise the track in order to get clearance between upper roller (4) and track (5).
Page 445 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers W1V7-03-06-001 W105-03-06-003 Oil Jack Nonskid Cloth Wooden Block WXXX-03-07-001 Track sag specification TDAA-03-08-002 Installation 1. Install upper roller (4) with bolts (6) (4 used). 5. Apply grease through grease fitting (2) and adjust the track tension.
Page 446 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers W158-03-06-001 6. Lower the track. IMPORTANT: Upper roller (4) cannot be disassembled. Replace it as an assembly. 7. Add engine oil (API CD class, SAE #30) through the plug (8) hole of cover (7). NOTE: Amount of oil: 65 mL (0.069 US qt) 8.
Page 447: Removal And Installation Of Lower Roller
SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers Removal and Installation of Lower Roller 3, 4, 5 3, 4, 5 90 ˚ to 110 ˚ WDAA-04-05-001 M104-07-067 Wooden Block b - Stand Removal 1. Set the machine position for inspection and maintenance.
Page 448 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers TDAA-03-08-002 W105-03-06-001 WDCN-04-05-001 CAUTION: The pressure inside cylinder of the track adjuster is high. As valve (1) may fly out and the high-pressure grease may spout out, do not loosen valve (1) quickly and/or excessively. Keep body parts and face away from valve (1) and loosen it carefully.
Page 449 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers WDCN-04-05-002 Wooden Block 8. Put the matching marks on lower roller (1) and track CAUTION: Lower roller (1) weight: 35 kg (78 lb) frame (2). 11. Remove lower roller (1) by using a forklift. CAUTION: When removing bolt (3) without holding lower roller (1), lower roller (1) will come off.
Page 450 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers WDCN-04-05-002 WDCN-04-05-003 Wooden Block Installation CAUTION: Lower roller (1) weight: 35 kg (78 lb) 1. Set lower roller (1) on track link (4) by using a forklift. 2. Raise lower roller (1) in order to adjust its mounting position by using a forklift and place wooden blocks (a) under it.
Page 451 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers 3, 4, 5 3, 4, 5 WDCN-04-05-001 WDAA-04-05-003 CAUTION: Track guard (1) weight: 22 kg (49 lb) 4. Set track guard (1) on track link (2) by using a forklift. CAUTION: Securely support the raised machine by using the blocks.
Page 452 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers TDAA-03-08-002 Wxxx-03-07-001 Track Sag Specification 7. Tighten valve (1) in the track adjuster. j : 24 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) CAUTION: Securely support the raised machine by using the blocks.
Page 453: Disassembly Of Lower Roller
SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers Disassembly of Lower Roller W157-03-06-010 Plug O-Ring (2 Used) Roller Collar Floating Seal (2 Used) Axle Pin (2 Used) Bushing (2 Used) Collar W4-5-3-1...
Page 454 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers Disassembly of Lower Roller 4. Remove pin (3) from the axle (8) assembly. Remove axle (8) from collar (2) by using a press. CAUTION: Lower roller weight: 35 kg (78 lb) 1.
Page 455: Assembly Of Lower Roller
SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers Assembly of Lower Roller W105-03-06-023 Plug O-Ring (2 Used) Roller Collar Floating Seal (2 Used) Axle Pin (2 Used) Bushing (2 Used) Collar W4-5-3-3...
Page 456 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Rollers Assembly of Lower Roller IMPORTANT: Do not dent the flange surface of 5. Install the axle (8) assembly to roller (7). bushing (6). 6. Apply grease onto O-ring (4) at the other side. Install 1.
Page 457: Precautions For Using Floating Seal
SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Roller Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures:  Keep seal rings together as a matched set with seal ring (1) surfaces together.
Page 458 SECTION 4 UNDERCARRIAGE Group 5 Upper and Lower Roller (Blank) W4-5-4-2...
Page 459: Group 6 Track
SECTION 4 UNDERCARRIAGE Group 6 Track Removal and Installation of Track W105-03-07-006 WDCD-04-06-001 Wooden Block Removal 1. Set the machine for inspection and maintenance. (Refer to W1-6-1.) 2. Rotate the track so that master pin (1) is positioned over front idler (2). Place wooden block (a) under shoe (3) and support shoe (3).
Page 460 SECTION 4 UNDERCARRIAGE Group 6 Track Direction to Remove W105-03-07-010 ST 1970 W105-03-07-009 W1V1-03-07-001 4. Remove snap ring (6) from master pin (1). CAUTION: The track adjuster may fly out due to the spring force when removing the track. Do NOTE: If snap ring (6) interferes with master link (7), push master pin (1) to the installing direction in order to not stand in the same direction to remove the...
Page 461 Place stand (a) under the track frame and support the machine at this time. CAUTION: The track assembly weight: ZX200-5G: 1260 kg (2780 lb) ZX210H-5G, 210K-5G: 1330 kg (2940 lb) ZX200LC-5G: 1350 kg (2980 lb) ZX210LCH-5G, 210LCK-5G: 1420 kg (3140 lb) 7.
Page 462 Wind the track while rotating travel device (9). CAUTION: The track assembly weight: ZX200-5G: 1260 kg (2780 lb) ZX210H-5G, 210K-5G: 1330 kg (2940 lb) ZX200LC-5G: 1350 kg (2980 lb) ZX210LCH-5G, 210LCK-5G: 1420 kg (3140 lb) 2.
Page 463 SECTION 4 UNDERCARRIAGE Group 6 Track b - Direction to Install W105-03-07-010 W105-03-07-016 Wooden Block W105-03-07-009 4. Wind the track link until the connection part of the track link reaches the front idler (2) side. Lower the machine. Place wooden block (a) under shoe (3) and support shoe (3).
Page 464 SECTION 4 UNDERCARRIAGE Group 6 Track WDCD-04-06-001 W197-03-07-001 b - Apply grease. Do not apply grease. WXXX-03-07-001 Track Sag Specification IMPORTANT: If link (10) has been disassembled, fill 10. Install pin (12) to link (10) and bushing (11) while grease (Daphne Epones SR) into the clearance holding them in order not to move due to grease.
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Page 467 SECTION 5 FRONT ATTACHMENT CONTENTS Group 1 Front Attachment Removal and Installation of Front Attachment ...W5-1-1-1 Group 2 Cylinder Removal and Installation of Boom Cylinder ..W5-2-1-1 Removal and Installation of Arm Cylinder ....W5-2-2-1 Removal and Installation of Bucket Cylinder ..W5-2-3-1 Disassembly of Boom, Arm, Bucket Cylinder ..W5-2-4-1 Assembly of Boom, Arm, Bucket Cylinder .....W5-2-4-5 DCDW-5-1...
Page 468 (Blank) DCDW-5-2...
Page 469: Group 1 Front Attachment
SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Front Attachment Removal 1. Park the machine on a solid, level surface. Fully retract the bucket and arm cylinders and lower the arm top onto the ground. CAUTION: Bleed air from the hydraulic oil tank before doing any work.
Page 470 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 4. By using a bar and hammer, tap pin (3) into the position where thrust plate (2) can be removed.
Page 471 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 8. Disconnect hoses (7, 8) of the bucket cylinder and arm cylinder. Cap the open ends of the removed pipes and hoses. j : 36 mm, 41 mm 9. Remove the mounting bolts (9 used) for tool box (b) and cover (a).
Page 472 (12) from plate (a) of boom foot pin (11). j : 27 mm CAUTION: The front attachment assembly weight: ZX200-5G, 200LC-5G: 3,450 kg (7,610 lb) ZX210H-5G, 210LCH-5G: 3,650 kg (8,050 lb) ZX210K-5G, 210LCK-5G: 3,800 kg (8,380 lb) 11. Attach wire ropes onto the boom. Reduce slack of the wire ropes.
Page 473 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation CAUTION: Front attachment assembly (a) weight: ZX200-5G, 200LC-5G: 3,450 kg (7,610 lb) ZX210H-5G, 210LCH-5G: 3,650 kg (8,050 lb) ZX210K-5G, 210LCK-5G: 3,800 kg (8,380 lb) 1. Hoist front attachment assembly (a). Move the...
Page 474 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 4. Remove the caps from hoses and pipes. Connect hoses (7, 8) of the bucket cylinder and arm cylinder. j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) W1V1-04-01-001 CAUTION: Boom cylinder (a) weight: 170 kg (375...
Page 475 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 6. Hoist and hold boom cylinder (a). Insert thrust plates (2).
Page 476 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment IMPORTANT: When removing the arm from the boom, perform the following steps when installing the arm. 10. Install thrust plates (14) into left and right sides of the arm. Adjust total clearance of left and right within 1.5 mm (0.059 in).
Page 477: Group 2 Cylinder
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Boom Cylinder Removal 1. Disconnect hose (1) from boom cylinder (2). j : 17 mm CAUTION: Boom cylinder (2) weight: 170 kg (375 2. Attach nylon slings onto boom cylinder (2). Hoist and hold boom cylinder (2).
Page 478 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 6. Stop the engine. CAUTION: Bleed air from the hydraulic oil tank. (Refer to W1-4-1.) CAUTION: Release any pressure in the hydraulic circuit. (Refer to W1-5-1.) 7. Disconnect hoses (12) (4 used) from the bottom of boom cylinder (2).
Page 479 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation IMPORTANT: If a hammer is used to install the bushing, the bushing may be damaged. Install the bushing by using a press. CAUTION: Boom cylinder (2) weight: 170 kg (375 1. Hoist boom cylinder (2). Fit the hole at boom cylinder tube side to the mounting hole on the main frame.
Page 480 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 5. Remove the wire from the boom cylinder (2) rod side. Starts the engine. Operate the boom control lever and fit the hole at cylinder rod side to the mounting hole on boom.
Page 481: Removal And Installation Of Arm Cylinder
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Arm Cylinder Removal 1. Place wooden block (3) between arm cylinder (1) and boom (2). 2. Remove nuts (8) (2 used) and bolt (10) from stopper (9) and pin (5) at the rod side. j : 30 mm W187-04-02-005 CAUTION: Metal fragments may fly off when...
Page 482 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 6. Disconnect hoses (11) (2 used) and hose (12) from the bottom of arm cylinder (1). Cap the open ends. j : 17 mm, 36 mm W178-02-11-290 CAUTION: Arm cylinder (1) weight: 260 kg (575 7.
Page 483 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 8. Remove nuts (15) (2 used) and bolt (17) from stopper (16) and pin (14) at the bottom side.
Page 484 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation IMPORTANT: If a hammer is used to install the bushing, the bushing may be damaged. Install the bushing by using a press. CAUTION: Arm cylinder weight: 260 kg (575 lb) 1. Hoist arm cylinder (1). Fit the hole at the cylinder bottom side with the cylinder mounting hole on the boom.
Page 485 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 4. Connect hose (12) and hoses (11) (2 used) to arm cylinder (1). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft) j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the hydraulic oil level.
Page 486 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank) W5-2-2-6...
Page 487: Removal And Installation Of Bucket Cylinder
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Bucket Cylinder Removal 1. Insert wooden blocks (3) (2 used) under the arm (2) top and between arm (2) and bucket cylinder (1). CAUTION: Before removing pin (7), secure the link by using a wire in order not to fall off.
Page 488 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 6. Disconnect bucket cylinder hoses (12) (2 used) from the bottom of bucket cylinder (1). Cap the open ends. j : 36 mm CAUTION: Bucket cylinder (1) weight: 160 kg (355 lb) CAUTION: Metal fragments may fly off when a hammer is used.
Page 489 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation IMPORTANT: If a hammer is used to install the bushing, the bushing may be damaged. Install the bushing by using a press. CAUTION: Bucket cylinder (1) weight: 160 kg (355 lb) CAUTION: Metal fragments may fly off when a hammer is used.
Page 490 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 4. Remove wire (9) from rod (8) of bucket cylinder (1). CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.
Page 491: Disassembly Of Boom, Arm, Bucket Cylinder
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Boom, Arm, Bucket Cylinder Boom Cylinder 9 10 11 W1V1-04-02-007 Arm Cylinder 9 10 11 16 15 14 13 W1V1-04-02-008 W5-2-4-1...
Page 492 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Bucket Cylinder 9 10 11 W1V1-04-02-009 Cylinder Rod Snap Ring Cushion Seal (Only Arm Steel Ball Wiper Ring Backup Ring Cylinder) Piston Nut Backup Ring O-Ring Snap Ring (Only Arm Cylinder) Cushion Bearing (Only Boom, U-Ring Cylinder Tube Slide Ring (2 Used)
Page 493 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Boom, Arm, Bucket Cylinder  The procedure starts on the premise that the pipes and the bands securing the pipes have been removed. IMPORTANT: Pull out cylinder rod (1) straightly in NOTE: The arm cylinder is explained here.
Page 494 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Cut away the crimped part by using a hand drill. 7. Remove slide rings (17) (2 used), slide rings (18) (2 Remove set screw (22). Remove steel ball (23). used), backup rings (19) (2 used), O-ring (20), and seal ring (21) from piston nut (24).
Page 495: Assembly Of Boom, Arm, Bucket Cylinder
SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Boom, Arm, Bucket Cylinder Boom Cylinder 10, 11 20, 21 W1V1-04-02-005 Arm Cylinder 10, 11 20, 21 23 16 15 W1V1-04-02-003 W5-2-4-5...
Page 496 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Bucket Cylinder 10, 11 20, 21 W1V1-04-02-001 Cylinder Rod Snap Ring Cushion Seal (Only Arm Steel Ball Wiper Ring Backup Ring Cylinder) Piston Nut Backup Ring O-Ring Snap Ring (Only Arm Cylinder) Cushion Bearing (Only Boom, U-Ring Cylinder Tube Slide Ring (2 Used)
Page 497 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Boom, Arm, Bucket Cylinder 5. Install O-ring (20) and seal ring (21) to piston nut NOTE: The arm cylinder is explained here. (24) by using the special tool A. After installing seal IMPORTANT: Before assembling, apply hydraulic oil ring (21), adjust seal ring (21) by using the special onto parts in order to prevent them from seizing.
Page 498 SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: Face the slit in cushion seal (26) to the 11. Install steel ball (23) to cylinder rod (1) and tighten piston side. Check the direction of oil groove in with set screw (22). Crimp set screw (22) by using a cushion bearing (25).
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Page 501 Hitachi Construction Machinery Co. Ltd Hitachi Ref. No. Attn: Publications, Marketing & Product Support Tel: 81-29-982-7084 Fax: 81-29-831-1162 E-mail: dc@hitachi-kenki.com SERVICE MANUAL REVISION REQUEST FORM COMPANY NAME: MODEL: PUBLICATION PART NO.: YOUR NAME: (Located at the left top corner in the cover page) DATE: PAGE NO.:...

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Zx200lc-5g Zx210h-5g Zx210lch-5g Zx210k-5g Zx210lck-5g

Hitachi ZX200-5G Workshop Manual

Section 1 General

Section 2 Maintenance Standard

Section 3 Upperstructure

Section 4 Undercarriage

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