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1. EX750-5, EX800H-5
Workshop Manual

2. 162W-1-1
SECTION 1
GENERAL IMFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard
Terminology.......................................... W1-1-4
Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5

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

4. GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and install
ation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
• Bleeding Air from Hydraulic Pump
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump
housing, damage to the pump may
result. Be sure to bleed air before
starting the engine.
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor/Swing Motor
• With the drain plug/hose on travel motor/swing
motor removed, fill the motor case with hydraulic
oil.
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary. M104-07-021

5. GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-3
Floating Seal Precautions
1. In general, replace the floating seal with a new
one.
If the floating is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with
seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check seal ring face (C) for scuffing, scoring,
corrosion, deformation or uneven wear.
(3) Check O-ring (B) for tears, breaks, deformation
or hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following, to prevent
trouble.
(1) Clean floating seal (A) and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
(2) Clean the floating seal and seal mounting
bores, as dust on them tends to enter the
floating seal when installing it.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
(4) After installing the floating seal, check that seal
face (C) is parallel with seal mounting bores
ring face (D) by measuring the distances (C)
and (D) at point (a) and (b), as illustrated. If
these distances differ, correct the O-ring
seating.
W105-03-05-019
W105-03-05-020
W110-03-05-004
Correctly
Incorrectly
A
B
a
b
a=b a≠b
a
b
Correctly IncorrectlyD
C
B

6. GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-4
MAINTENANCE STANDARD
TERMINOLOGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies adjusted
to specification.
Both dimensions are shown with tolerances as
necessary.
“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or replacement is required before reaching
this limit.
Machine performance will decrease, and maintenance
and down time expense will increase as machine
operating hours accumulate. It is recommended that
parts are repaired or replaced before reaching the
“Allowable Limit”.

7. GENERAL INFORMATION / Tightening
W1-2-1
TIGHTENING TORQUE SPECIFICATIONS
Bolt Dia Wrench Size Torque
No. Descriptions
mm
Q’ty
(mm) N⋅m kgf⋅m lbf⋅ft
Engine cushion rubber 16 2 24 265 27 195
Front
Cushion rubber-machine 16 2 24 265 27 195
Engine cushion rubber 24 2 36 690 70 510
1
Engine cushion
rubber mount-
ing bolt Rear
Cushion rubber-machine 18 4 27 390 40 290
2 Muffler bracket mounting bolt
UNC 1/2
UNC 3/8
4
6
19
14
88
49
9
5
65
36
3 Radiator mounting bolt 24 4 36 690 70 510
4 Hydraulic oil tank mounting bolt 18 8 27 295 30 215
5 Fuel tank mounting bolt 18 4 27 295 30 215
6 ORS fittings for hydraulic hoses and piping 1- -12UNF 41 205 21 152
7 Pump transmission mounting bolt UNC 14 16 69 7 51
8 Pump device mounting bolt 24 4 36 690 70 510
9 Control valve mounting bolt 20 4 30 390 40 290
10 Swing device mounting bolt 24 28 36 930 95 690
11 Swing motor mounting bolt (hexagonal wrench) 20 24 30 390 40 290
12 Battery mounting bolt 12 2 19 34 3.5 25.5
STD 16 4 24 205 21 152
13 Cab mounting bolt
H 16 6 24 205 21 152
14
Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
33
33
30
36
4
40
50
50
46
2160
2160
1720
220
220
175
1590
1590
1270
15
Travel device mounting bolt
Travel motor mounting bolt
Sprocket mounting bolt
27
18
27
40
8
48
41
27
41
1370
295
1370
140
30
140
1010
215
1010
16 Upper roller mounting 20 24 30 540 55 400
17 Lower roller mounting bolt STD, H 24 72 36 930 95 690
18 Track shoe bolt STD, H 27 408 41 1960 200 1450
19 Track guard mounting bolt STD, H 27 16 41 1370 140 1010
20 Track frame mounting bolt 36 44 55 2750 280 2030
Coupling 8 13
10.5 to
12.5
1.05 to
1.26
7.6 to
9.121
Coupling and clamp of low
pressure piping
Clamp -28UNF 11 5.9 0.6 4.3
22
Counterweight mounting bolt
Counterweight retaining bolt
45
24
2
4
65
36
2750
690
280
70
2030
510
23 Front pin-retaining bolt 20 30 30 390 40 290
NOTE: (1) Apply lubricant (e.g. white Zinc B
dissolved into spindle oil) to bolts and
nuts to stabilize friction coefficient of
them.
(2) Make sure bolt and nut threads are
clean before installing.
(3) Apply LOCTITE to threads before
installing and tightening swing bearing
mounting bolts.
7
16
7
16
1
4

8. GENERAL INFORMATION / Tightening
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
the correct tools. Avoid bodily injury caused
by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Four kinds of bolts, hexagon bolts T, H, M and socket
bolt, each made of different material, are used. Make
sure to employ the correct bolts and tighten them to
specification when assembling the machine or
components.
SA-040
W105-01-01-007
Specified Tightening Torque Chart
T Bolt, Socket bolt H Bolt M Bolt
Bolt
Dia.
Wrench
Size
Hexagon
Wrench
Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2
M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M 12 19 10 108 11 80 88 9 65 34 3.5 25.5
M 14 22 12 175 18 130 137 14 101 54 5.5 40
M 16 24 14 265 27 195 205 21 152 78 8 58
M 18 27 14 390 40 290 295 30 220 118 12 87
M 20 30 17 540 55 400 390 40 290 167 17 123
M 22 32 17 740 75 540 540 55 400 215 22 159
M 24 36 19 930 95 690 690 70 505 275 28 205
M 27 41 19 1370 140 1010 1030 105 760 390 40 290
M 30 46 22 1910 195 1410 1420 145 1050 540 55 400
M 33 50 24 2550 260 1880 1910 195 1410 740 75 540
M 36 55 27 3140 320 2310 2400 245 1770 930 95 690
Socket BoltHexagon T Bolt Hexagon H Bolt Hexagon M Bolt

9. GENERAL INFORMATION / Tightening
W1-2-3
IMPORTANT: (1) Apply lubricant (i. e. white zinc B
dissolved into spindle oil) to
nuts and bolts to stabilize their
friction coefficients.
(2) Torque tolerance is ±±±±10 %.
(3) Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot
develop sufficient tightening
force.
(4) The torques given in the chart
are for general use only.
Do not use these torques if a
different torque is given for a
specific application.
(5) Make sure that the nut and bolt
threads are clean before
installing. Remove dirt or
corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
W105-01-01-003
Equally tighten upper
and lower alternately
1,4
2,3
Tighten diagonally
1
132
3
4 5
6
1
2 3
4
5
6 7
8
9
10 11
12 14
Tighten from center
and diagonally

10. GENERAL INFORMATION / Tightening
W1-2-4
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect
sealing surfaces. Scratches/
roughness cause leaks and seal
wear. Unevenness causes seal
extrusion. If defects cannot be
polished out, replace the
component.
(2) Be sure to use only specified O-
rings. Inspect O-rings for any
damage. Take care not to file O-
ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
(3) Loosely assemble split flange
halves. Make sure that the split
is centrally located and
perpendicular to the port. Hand-
tighten the bolts to hold the
parts in place. Take care not to
pinch the O-ring.
(4) Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening.
(5) Do not use air wrenches. Using
an air wrench often causes
tightening of one bolt fully
before tighten the others,
resulting in damage to O-rings
or uneven tightening of bolts.
Nut and Bolt Lockings
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
Bend along edge sharply
Do not bend it round
Bend along edge sharply
RIGHT WRONG
RIGHT RIGHT WRONG
Tighten
Loosen
RIGHT RIGHT WRONG
RIGHT WRONG

11. GENERAL INFORMATION / Tightening
W1-2-5
PIPING JOINT
Pipe Thread Connection/Union Joint Tightening
Torque Specifications
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: (1) Do not over-tighten union nut (3).
Excessive force will be applied
to metal sealing surfaces (4) and
(5), possibly cracking adaptor (1).
Be sure to tighten union nut (3)
to specifications.
(2) Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
M202-07-051
W105-01-01-017
Type Wrench Size Tightening Torque
Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft
30° Male Union 19 19 59 6 43
Joint 22 22 98 10 72
27 27 118 12 87
36 36 235 24 134
41 41 295 30 215
50 50 490 50 360
60 60 670 68 490
70 70 980 100 720
37° Female Union 19 17 44 4.5 32.5
Joint 22 19 59 6 43
27 22 118 12 87
36 30 32 235 24 134
41 36 295 30 215
50 46 490 50 360
NOTE: Tightening torque for the non-union type
37° male joint is the same as the 37°
female union joint.
1 4 3 5 2
Male Union Joint Female Union Joint
30° or 37°
30° or 37°
Joint Body

12. GENERAL INFORMATION / Tightening
W1-2-6
O-ring Seal Joint
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.
IMPORTANT: (1) Be sure to replace O-ring (6) with
a new one when reconnecting.
(2) Before tightening union nut (9),
confirm that O-ring (6) is seated
correctly in O-ring groove (8).
Tightening union nut (9) with O-
ring (6) displaced will damage O-
ring (6), resulting in oil leakage.
(3) Take care not to damage O-ring
groove (8) or sealing face (10).
Damage to O-ring (6) will cause
oil leakage.
(4) If union nut (9) is found to be
loose, causing oil leakage, do
not tighten it to stop the leak.
Instead, replace O-ring (6) with a
new one, then tighten union nut
(9) after confirming that O-ring
(6) is securely seated in place.
M104-07-033
Wrench Size Tightening Torque
Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft
19 17 59 6 43
22 19 98 10 72
27 22 118 12 87
36 30, 32 235 24 134
41 36 295 30 215
50 46 490 50 360
Joint Body
7 6 9
8 10

13. GENERAL INFORMATION / Tightening
W1-2-7
Screwed-In Connection
IMPORTANT: Many types of screwed-in con-
nections are used for hose
connections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Seal Tape Application
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leakage
between threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
• Application Procedure
Confirm that the thread surface is clean, free of dirt
or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp.
T-Bolt Type Band Clamp:
4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft)
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft)
W105-01-01-018
Male Tapered Thread
Wrench Size Tightening Torque
Joint Body N⋅m kgf⋅m lbf⋅ft
17, 19 59 6 43
19, 22 98 10 72
27, 22 118 12 87
36, 32 235 24 134
41 295 30 215
50 490 50 360
60 670 68 490
70 980 100 720
W105-01-01-019
M114-07-041
M114-07-042 M114-07-043
PT
Male Straight Thread
PF
°
Male Tapered Thread
Leave one to two pitch threads uncovered
Internal Thread
External Thread Clearance
Worm Gear TypeT-Bolt Type

14. GENERAL INFORMATION / Tightening
W1-2-8
Connecting Hose
CAUTION:
(1) When replacing hoses, be sure to use
only genuine Hitachi service parts.
Using hoses other than genuine Hitachi
hoses may cause oil leakage, hose
rupture or separation of fitting,
possibly resulting in a fire on the
machine.
(2) Do not install hoses kinked. Application
of high oil pressure, vibration, or an
impact to a kinked hose may result in
oil leakage, hose rupture or separation
of fitting. Utilize print marks on hoses
when installing hoses to prevent hose
from being installed kinked.
(3) If hoses rub against each other, wear to
the hoses will result, leading to hose
rupture. Take necessary measures to
protect hoses from rubbing against
each other.
Take care that hoses do not come into
contact with moving parts or sharp
objects.
WRONG RIGHT
W105-01-01-011
WRONG RIGHT
W105-01-01-012
WRONG RIGHT
W105-01-01-013
WRONG RIGHT
W105-01-01-014
Rubbing Against
Each Other
Clamp Clamp
Rubbing
Rubbing
Clamp

15. 162W-2-1
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Remove and Install Cab ...................... W2-1-1
Dimensions of the Cab Glass .............. W2-1-7
Group 2 Counterweight
Remove and Install
Counterweight ................................... W2-2-1
Group 3 Pump Device
Remove and Install
Pump Device ..................................... W2-3-1
Disassemble Pump Transmission........ W2-3-2
Assemble Pump Transmission ............ W2-3-6
Remove and Install
Main Pump ........................................ W2-3-9
Disassemble Main Pump................... W2-3-10
Assemble Main Pump........................ W2-3-16
Maintenance Standard ...................... W2-3-20
Disassemble Regulator ..................... W2-3-22
Assemble Regulator .......................... W2-3-24
Disassemble and Assemble
Pilot Pump....................................... W2-3-26
Group 4 Control Valve
Remove and Install
Control Valve ..................................... W2-4-1
Disassemble
Control Valve 1 .................................. W2-4-4
Assemble
Control Valve 1 .................................. W2-4-8
Disassemble
Control Valve 2 ................................ W2-4-14
Assemble
Control Valve 2 ................................ W2-4-16
Disassemble
Control Valve 3 ................................ W2-4-18
Assemble
Control Valve 3 ................................ W2-4-24
Disassemble
Control Valve 4 ................................ W2-4-30
Assemble
Control Valve 4 ................................ W2-4-32
Disassemble
Control Valve 5 ................................ W2-4-34
Assemble
Control Valve 5 ................................ W2-4-36
Group 5 Swing Device
Remove and Install
Swing Device..................................... W2-5-1
Disassemble Swing Reduction
Gears ................................................ W2-5-4
Assemble Swing Reduction
Gears ................................................ W2-5-8
Disassemble Swing Motor ................. W2-5-12
Assemble Swing Motor ...................... W2-5-16
Disassemble and Assemble
Swing Parking Brake
Release Valve.................................. W2-5-20
Maintenance Standard....................... W2-5-22

16. 162W-2-2
Group 6 Pilot Valve
Remove and Install Right
Pilot Valve ......................................... W2-6-1
Remove and Install Left
Pilot Valve ......................................... W2-6-4
Remove and Install
Travel Pilot Valve............................... W2-6-7
Disassemble Right and Left
Pilot Valve ......................................... W2-6-8
Assemble Right and Left
Pilot Valve ....................................... W2-6-10
Disassemble Travel
Pilot Valve ....................................... W2-6-14
Assemble Travel
Pilot Valve ....................................... W2-6-16
Group 7 Pilot Shut-Off Valve
Remove and Install
Pilot Shut-off Valve ............................ W2-7-1
Disassemble Pilot Shut-off Valve ......... W2-7-4
Assemble Pilot Shut-off Valve.............. W2-7-6
Group 8 Shockless Valve
Remove and Install Front
Attachment Shockless Valve.............. W2-8-1
Disassemble and Assemble
Shockless Valve
(Front Attachment) ............................ W2-8-4
Remove and Install
Travel Shockless Valve...................... W2-8-7
Disassemble and Assemble
Travel Shockless Valve.................... W2-8-10
Group 9 Solenoid Valve
Remove and Install
Two-Spool Solenoid Valve ................. W2-9-1
Disassemble and Assemble
Two-Spool Solenoid Valve ................. W2-9-3

17. UPPERSTRUCTURE / Cab
W2-1-1
REMOVE AND INSTALL CAB
Removal
1. Remove nuts (2) and seat (1).
: 13 mm
2. Loosen bolts (5) behind the cab and bolts (6) in
rear boxes (3 and 4).
Remove rear boxes (3 and 4).
: 13 mm
3. Loosen bolts (8) to remove rear box lower cover
(7).
: 13 mm
4. Remove filter (25). Loosen screws (9) to remove
duct (10) from the cab.
W157-02-01-005
W157-02-01-017
W158-02-01-001
1
2
5
4
6
65
7
8
3
25
10
9

18. UPPERSTRUCTURE / Cab
W2-1-2
5. Remove cable connectors (11) located inside cab
at the rear.
6. Disconnect wiper limit switch (12), cab light (13),
speaker (14), antenna (15) and ground (17) lo-
cated inside the cab.
Remove washer vinyl hose(16) outside the cab.
7. Disconnect work light plug connector (18) outside
the cab.
8. Remove cap (21) from duct cover (19). Loosen
screws (20) to remove duct cover (19).
W162-02-01-001
W162-02-01-002
W162-02-01-003
W158-02-01-002
11
12
13 14
15
16
16
18
21 20 19

19. UPPERSTRUCTURE / Cab
W2-1-3
9. While pushing the mating face of duct (22) toward
the rear side of the cab, remove duct (22).
10. Attach lifting straps to the top of the cab.
CAUTION: cab weight : 260 kg (573 lb)
11. Remove cab mounting bolts (23) and nuts (24).
: 17 mm
: 24 mm
: 8 mm
12. Carefully remove the cab.
W157-02-01-011
W157-02-01-009
W157-02-01-010
W157-02-01-001
Duct Mating Face
22
24
23

20. UPPERSTRUCTURE / Cab
W2-1-4
Installation
CAUTION: cab weight : 260 kg (573 lb)
1. Attach the lifting straps to the cab. Install the cab
onto the frame.
2. Tighten bolts (23) and nut (24).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
3. Install duct (10) to the cab with screws (9).
Install filter (25) into the duct.
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
4. Connect cable connectors (11) at the rear inside
the cab.
W157-02-01-001
W157-02-01-010
W158-02-01-001
W162-02-01-001
11
24
23
25
10
9

21. UPPERSTRUCTURE / Cab
W2-1-5
5. Reconnect wiper limit switch (12), cab light (13),
speaker (14) antenna (15) and ground (17) lo-
cated in the cab.
Reinstall washer vinyl hose (16) outside the cab.
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
6. Reconnect work light plug connector (18) outside
the cab.
7. Install rear box lower cover (7) with bolts (8).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8. Install rear boxes (3 and 4) with bolts (5 and 6).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W162-02-01-002
W162-02-01-003
W157-02-01-017
5
4
6
12
6
13
5
14
7
15
8
16
16
3
18

22. UPPERSTRUCTURE / Cab
W2-1-6
9. While pushing duct (22) to the front of the cab, in-
sert duct (22) into the front duct until the mating
faces come in contact with each other.
10. Install duct cover (19) with screws (20). Install
caps (21).
11. Secure seat (1) with nuts (2).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W157-02-01-011
W158-02-01-002
W157-02-01-005
1
2
Duct Mating Face
22
21 20 19

23. UPPERSTRUCTURE / Cab
W2-1-7
DIMENSIONS OF THE CAB GLASS
391.8
R2
Unit : mm
NOTE: 1 mm=0.03937 in
Section A
25.106
164.12
66.84
43.59
558.78
580
188.5
A
Along
the periphery
C1
154.81
4°
(87.81)
R9487
(64.74)
3.015
51.03
360.7
R15
R118
R3018
30
142.25
221.399
R70
R78
2-R59 R11509
R2309
R4009
R1009
R509
R84
R4009
R209
R9509
4-R62
4-φ13
+0
B
230.50
222.65
216.73
905
900.7
66.41
87.84
947.152
35.73
63.97
756
612
No polish
chamfering is
required in this
range.
15
R11516
Along
the periphery
C1
Section B
(4 mm)
(5 mm)
(5 mm)
NOTE: Material: JIS-R3211,R3212
ANSI-AS2
ECE-ANNEX5 or
equivalent
Chamfer
Both
Sides
W157-02-01-013

24. UPPERSTRUCTURE / Cab
W2-1-8
Unit : mm
NOTE: 1 mm=0.03937 in
Section C,D
208
113.9
333.5±1.0
10.6
R105
R2285.4
39.5 61.8
475.8
728.5±1.0
60.1
R3985.4
40
2-φ12.2
+0.5
0
R1985.1
3-R4
503±1.
541.5
(38.5)
(38.5)
R3
337.5±1.0
22.5
9.2
R30 R72.5
7735.4
39.5 3.1
40
728.5±1.0
488.5
290
R120885.4
2-R4
398.5±1.0
19.70
8 890.03 74.95 213.97
276.58
227.39
370±1.0
833±1.0
11.22 39.63
50.71
18
468.17
90.672
45.67
R2477
R3877
753.99
980
904.13
740.51
165
R2590
2-R5
R5175
R8075
R120
R12.5
19.29
516.26
33.60
549.86
910
4-R5
R1995
R895
R345
R1209
R1145
R595
R295
C
2-φ12.2
+0.5
0
59
D
No polish
chamfering are
required in this
range.
No polish chamfering are required in this range.
Chamfer
Both Sides
Chamfer
Both Sides
No polish chamfering
are required in this
range.
No polish
chamfering are
required in this
range.
(4 mm)
(4 mm)
(5 mm)
(5 mm)
W157-02-01-014

25. UPPERSTRUCTURE / Counterweight
W2-2-1
REMOVE AND INSTALL
COUNTERWEIGHT
Removal
CAUTION: Counterweight weight:
12500 kg (27560 lb)
1. Attach wire ropes with shackles to the lifting lugs
on the top of the counterweight. Take out any
slack on the wire ropes by applying tension slowly
with a crane.
CAUTION: Use care to prevent hand injury
from the power wrench reaction bar.
2. Use a power wrench to remove bolts (7), nuts (10),
stoppers (8) and washers (6 and 9).
: 65 mm
3. Loosen bolts (1) to remove spring washers (2),
stoppers (3) and spacers (4).
Remove shims (5) if equipped.
: 36 mm
4. Remove the counterweight.
W162-02-02-001
W162-02-02-002
W162-02-02-003
1
2
3
4
5
10
9
8
6
7
6
7
1
2
3
10
5
4
9
8

26. UPPERSTRUCTURE / Counterweight
W2-2-2
Installation
CAUTION: Counterweight weight:
12500 kg (27560 lb)
1. Attach wire ropes with shackles to the lifting lugs
on the top of the counterweight.
CAUTION: Never allow anyone under the
lifted counterweight.
2. Lift the counterweight. With the bosses on the
back face of the counterweight aligned with holes
on the frame, install the counterweight.
CAUTION: Use care to prevent hand injury
from the power wrench reaction bar.
IMPORTANT: Apply a lubricant to bolts (7) before
installing. Install stoppers (8) with
flanges positioned downward.
3. Install bolts (7), nuts (10), stoppers (8) and
washers (6 and 9). Tighten bolts (7) using a power
wrench.
: 65 mm
: 2750 N⋅m (280 kgf⋅m, 2025 lbf⋅ft)
4. Install shims (5), spacers (4), stoppers (3), and
spring washers (2) and bolts (1). Detach the wire
ropes and shackles.
: 36 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
W162-02-02-001
W162-02-02-002
W162-02-02-003
1
2
3
4
5
10
9
8
6
7
6
7
1
2
3
10
5
4
9
8

27. UPPERSTRUCTURE / Pump Device
W2-3-1
REMOVE AND INSTALL PUMP DEVICE
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure
before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot
hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting any repair work.
The hydraulic oil tank cap may fly off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely release
any remaining pressure.
Preparation
1. After stopping the engine, move the control levers
several times to release any pressure remaining
in the system.
2. Rotate the hydraulic oil tank cap approx. 30°
counterclockwise to release trapped air in the
hydraulic oil tank.
Removal
1. Disconnect all hydraulic lines and electrical cables
from the pump.
: 22 mm, 27 mm
: 8 mm, 14 mm
2. Place a block (100 mm square, approx. 30 mm
thick) underneath the engine flywheel housing.
CAUTION: Pump device weight:
445 kg (980 lb)
3. Remove the pump device mounting bolts and rear
side engine mounting bolts to remove the pump
device.
: 36 mm, 16 mm
Installation
1. Install the pump with the mounting bolts.
2. Connect all hydraulic lines and electrical cables to
the pump.
3. Bleed air trapped inside the pump. (Refer to page
W1-1-2.)
IMPORTANT: After installing the pump, be sure to
perform break-in operation to
prevent seizure.
W162-02-03-003
W162-02-03-004
Tightening Torque
Wrench Size (mm)
N⋅m kgf⋅m lbf⋅ft
Remark
: 22 49 5 36 Hose
: 27 93 9.5 69 Hose
: 8 108 11 80 Hose
: 14 265 27 195 Hose
: 36 690 70 506 Bolt
: 16 69 7 51 Bolt
Break-In Operation Process:
1. Start the engine and run at slow idle speed for
20 minutes. Check for oil leaks while running
at slow idle.
2. Increase the engine speed to the fast idle
speed. Raise and lower the boom for 20
minutes repeatedly. (Do not operate the
control levers quickly. Slowly move the levers
to full stroke.)
Block
Engine Rear Side
Mounting Bolt
Pump Device
Mounting Bolt

28. UPPERSTRUCTURE / Pump Device
W2-3-2
DISASSEMBLE PUMP TRANSMISSION
W162-02-03-002
1 - Casing 6 - Retaining Ring 10 - Bolt (5 Used) 14 - O-Ring
2 - Bearing 7 - Bearing 11 - Bolt (8 Used) 15 - Bearing
3 - Sleeve 8 - O-Ring 12 - Oil Seal 16 - Gear
4 - Retaining Ring 9 - Cartridge 13 - Cartridge 17 - Bearing
5 - Gear
1
2
3
4
5
6
7
8
9
10
17
16
15
14
13
12

29. UPPERSTRUCTURE / Pump Device
W2-3-3
Disassemble Pump Transmission
• Before starting any repair work, thoroughly read
all “Precautions for Disassembling and
Assembling” (W1-1-1).
CAUTION: Pump device weight:
145 kg (320 lb)
1. Place casing (1) on a work bench with the main
pump mounting side facing downward.
2. Remove bolts (10).
: 8 mm
CAUTION: Pump device weight:
145 kg (320 lb)
3. Re-position casing (1) on the work bench so that
the engine mounting side faces downward.
NOTE: At this time, lay two wooden blocks (100
mm high) under the casing so that the
blocks are not under cartridges (9 and 13).
4. Attach metal protector (dia 30 mm) to top of
sleeve (3) and tap the protector over top of sleeve
(3) with a plastic hammer until gear (5) comes in
contact with casing (1). Then, cartridge (9) and
bearing (7) are pushed out of casing (1).
CAUTION: Pump device weight:
145 kg (320 lb)
5. Lay two wooden blocks (150 mm high) on the
work bench. Place casing (1) on the wooden
blocks with the main pump mounting side facing
downward.
6. Remove cartridge (9) from casing (1). Remove O-
ring (8) from cartridge (9).
7. Attach metal protector (dia 25 mm) to top of
sleeve (3) and tap the protector over top of sleeve
(3) with a plastic hammer until gear (5) comes in
contact with casing (1). Remove sleeve (3) from
the outer race of bearing (7).
8. Using a puller, remove the outer race of bearing
(7).
9. Remove retaining ring (6) from sleeve (3).
10. Attach metal protector (dia. 30 mm) to top of
sleeve (3) and tap the protector over top of sleeve
(3) with a plastic hammer to remove sleeve (3)
and bearing (2) from casing (1).
11. Using a press, remove bearing (2) from sleeve
(3).
12. Remove retaining ring (4) from sleeve (3).
13. Remove bolts (11) and cartridge (13).
: 17 mm
14. Remove oil seal (12) and o-ring (14) from
cartridge (13).
CAUTION: Pump transmission weight:
140 kg (310 lb)
15. Lay two wooden blocks (150 mm high) on the
work bench. Place casing (1) on the wooden
blocks with the engine mounting side facing
downward.
16. Attach metal protector (dia 90 mm) to top of gear
(16). Using a press, push gear (16) out of casing
(1).
17. Take gear (5) out of casing (1).
18. Using a press or puller, remove bearings (15 and
17) from gear (16).

30. UPPERSTRUCTURE / Pump Device
W2-3-4
ASSEMBLE PUMP TRANSMISSION
W162-02-03-001
1 - Casing 6 - Retaining Ring 10 - Bolt (5 Used) 14 - O-Ring
2 - Bearing 7 - Bearing 11 - Bolt (8 Used) 15 - Bearing
3 - Sleeve 8 - O-Ring 12 - Oil Seal 16 - Gear
4 - Retaining Ring 9 - Cartridge 13 - Cartridge 17 - Bearing
5 - Gear
1 5 10 8 9 7 14 12 13 11
1516172346

31. UPPERSTRUCTURE / Pump Device
W2-3-5
Assemble Pump Transmission
1. Press bearings (15 and 17) onto gear (16).
2. Install retaining ring (4) to sleeve (3).
3. Press bearing (2) onto sleeve (3).
4. Install gear (5) into casing (1).
IMPORTANT: Press bearing (2) into casing (1) until
the end face of bearing (2) is flush
with the stepped face in the casing
bore.
5. With splines on sleeve (3) and gear (5) aligned,
press sleeve (3) with bearing (2) into casing (1).
CAUTION: Assembly weight of casing (1),
gear (5), etc.: 125 kg (276 lb)
6. Turn casing (1) over.
7. Install retaining ring (6) to sleeve (3).
8. After centering the outer and inner races of
bearing (7), press the outer race of bearing (7)
into casing (1).
9. Install O-ring (8) around cartridge (9).
10. Install cartridge (9) in casing (1) with bolts (10).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
11. Press gear (16) into casing (1) so that gear (16)
meshes with gear (5).
12. Attaching a protector on oil seal (12), press oil
seal (12) into cartridge (13).
13. Apply grease on the inner lip of oil seal (12).
14. Install O-ring (14) in cartridge (13).
15. Install cartridge (13) in casing (1) with bolts (11).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
CAUTION: Pump transmission weight:
145 kg (320 lb)
16. Check that bearing (2) and sleeve (3) are correctly
installed in casing (1) by softly tapping bearing (2)
with a plastic hammer.

32. UPPERSTRUCTURE / Pump Device
W2-3-6
(Blank)

33. UPPERSTRUCTURE / Pump Device
W2-3-7
REMOVE AND INSTALL MAIN PUMP
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure
before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot
hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting any repair work.
The hydraulic oil tank cap may fly off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely release
any remaining pressure.
Preparation
1. After stopping the engine, move the control levers
several times to release any pressure remaining
in the system.
2. Rotate the hydraulic oil tank cap approx. 30°
counterclockwise to release trapped air in the
hydraulic oil tank.
Removal
1. Disconnect all hydraulic lines and electrical cables
from the pump.
: 22 mm, 27 mm
: 8 mm, 14 mm
CAUTION: Main pump weight: 300 kg (661 lb)
2. Remove the pump mounting bolts to remove the
pump.
: 36 mm
Installation
1. Install the pump with the mounting bolts.
2. Connect all hydraulic lines and electrical cables to
the pump.
3. Bleed air trapped inside the pump. (Refer to page
W1-1-2.)
IMPORTANT: After installing the pump, be sure to
perform break-in operation to
prevent seizure.
T162-03-01-001
Tightening Torque
Wrench Size (mm)
N⋅m kgf⋅m lbf⋅ft
Remark
: 22 49 5 36 Hose
: 27 93 9.5 69 Hose
: 8 108 11 80 Hose
: 14 265 27 195 Hose
: 36 690 70 506 Bolt
Break-In Operation Process:
1. Start the engine and run at slow idle speed for
20 minutes. Check for oil leaks while running
at slow idle.
2. Increase the engine speed to the fast idle
speed. Raise and lower the boom for 20
minutes repeatedly. (Do not operate the
control levers quickly. Slowly move the levers
to full stroke.)
Mounting Bolt

34. UPPERSTRUCTURE / Pump Device
W2-3-8
Disassemble Main Pump
W162-02-04-001
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
47
46
45
48
49
50
51
52
53 54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
737475 72
76
49
48
22

35. UPPERSTRUCTURE / Pump Device
W2-3-9
1 - Socket Bolt 20 - Tilt Pin 39 - Spacer 58 - Valve Plate
2 - Cover 21 - Regulator 40 - Spring 59 - O-Ring
3 - O-Ring 22 - Socket Bolt 41 - Cylinder Block 60 - O-Ring
4 - Oil Seal 23 - Servo Piston 42 - Valve Plate 61 - Housing
5 - Shaft 24 - O-Ring 43 - Bearing 62 - O-Ring
6 - Spacer 25 - Backup Ring 44 - O-Ring 63 - Cover
7 - Bearing 26 - Stopper 45 - Cover 64 - Socket Bolt
8 - Spacer 27 - O-Ring 46 - Plug 65 - Cover
9 - Retaining Ring 28 - Taper Pin 47 - O-Ring 66 - Socket Bolt
10 - Socket Bolt 29 - Plug 48 - Screw 67 - Shaft
11 - Cover 30 - A Sensor 49 - Nut 68 - Pin
12 - Nut 31 - O-Ring 50 - Booster 69 - Filter
13 - Screw 32 - Plug 51 - Coupling 70 - Spring Pin
14 - Pin 33 - Swash Plate 52 - Spring Pin 71 - Cover
15 - O-Ring 34 - Bushing 53 - Filter 72 - O-Ring
16 - Stopper 35 - Shoe 54 - Pin 73 - Plug
17 - Backup Ring 36 - Plunger 55 - Shoe Plate 74 - O-Ring
18 - O-Ring 37 - Retainer 56 - Feed Back Link 75 - O-Ring
19 - Housing 38 - Spherical Bushing 57 - Bearing 76 - O-Ring
NOTE: Parts (6 to 9, 12 to 18, 20 to 41, 55, and 56)
in housing (61) are the same as those used
in housing (19).

36. UPPERSTRUCTURE / Pump Device
W2-3-10
W162-02-04-001
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
47
46
45
48
49
50
51
52
53 54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
737475 72
76
49
48
22

37. UPPERSTRUCTURE / Pump Device
W2-3-11
Disassemble Main Pump
• Before starting any repair work, thoroughly read
all “Precautions for Disassembling and
Assembling” (W1-1-1).
IMPORTANT: Do not remove screws (13 and 48)
and nuts (12 and 49). If removed, the
pump set flow rate may be
changed.
1. Remove two plugs (32) and O-rings (31) to drain
hydraulic oil from the pump.
: 36 mm
2. Remove socket bolt (22) and regulator (21).
Remove A sensors (30) (two places).
: 6 mm
IMPORTANT: Take care not to allow valve plates
(42 and 58) to drop when separating
housing (19) assembly, cover (45)
assembly, cover (71) assembly, and
housing (61) assembly.
3. Insert a steel bar or pipe into the pump mounting
bolt holes in covers (11 and 65). While holding the
bar or pipe to prevent the pump assembly from
rotating, loosen socket bolts (10 and 66) to
separate housing (19) assembly, cover (45)
assembly, cover (71) assembly and housing (61)
assembly.
At this time, remove O-rings (44, 59, 60, and 74 to
76), spring pins (52 and 70), and filters (53 and
69).
: 17 mm
4. Remove booster (50), coupling (51), valve plate
(42) and pin (54) from cover (45). Remove valve
plate (58) and pin (68) from cover (71).
NOTE: Do not remove bearing (43, 57) unless
required.
5. Remove cylinder blocks (41), springs(40),
spacers (39), spherical bushings (38), retainers
(37) plungers (36), and shoes (35) from housings
(19 and 61).
6. Loosen socket bolts (1 and 64) to remove covers
(2 and 63) and O-rings (3 and 62). Remove oil
seal (4) from cover (2).
: 6 mm
7. Tap covers (11 and 65) with a plastic hammer to
remove from housings (19 and 61). Remove O-
rings (27) and spring pins (14).
8. Remove swash plates (33) and shoe plates (55)
from housings (19 and 61).
NOTE: Do not remove feedback links (56) unless
required.
9. Tap with a plastic hammer to remove shafts (5
and 67) from covers (11 and 65).
10. Remove retaining rings (9), spacers (8), bearings
(7) and spacers (6) from shafts (5 and 67)
IMPORTANT: LOCTITE is applied to the joint
between servo piston (23) and tilt
pin (20). Take care not to damage
servo piston (23) when
disassembling.
11. Remove stoppers (16), stoppers (26), servo
pistons (23) and tilt pins (20) from housings (19
and 61).

38. UPPERSTRUCTURE / Pump Device
W2-3-12
Assemble Main Pump
W162-02-04-003
1 - Socket Bolt 20 - Tilt Pin 39 - Spacer 58 - Valve Plate
2 - Cover 21 - Regulator 40 - Spring 59 - O-Ring
3 - O-Ring 22 - Socket Bolt 41 - Cylinder Block 60 - O-Ring
4 - Oil Seal 23 - Servo Piston 42 - Valve Plate 61 - Housing
5 - Shaft 24 - O-Ring 43 - Bearing 62 - O-Ring
6 - Spacer 25 - Backup Ring 44 - O-Ring 63 - Cover
7 - Bearing 26 - Stopper 45 - Cover 64 - Socket Bolt
8 - Spacer 27 - O-Ring 46 - Plug 65 - Cover
9 - Retaining Ring 28 - Taper Pin 47 - O-Ring 66 - Socket Bolt
10 - Socket Bolt 29 - Plug 48 - Screw 67 - Shaft
11 - Cover 30 - A Sensor 49 - Nut 68 - Pin
12 - Nut 31 - O-Ring 50 - Booster 69 - Filter
13 - Screw 32 - Plug 51 - Coupling 70 - Spring Pin
14 - Pin 33 - Swash Plate 52 - Spring Pin 71 - Cover
15 - O-Ring 34 - Bushing 53 - Filter 72 - O-Ring
16 - Stopper 35 - Shoe 54 - Pin 73 - Plug
17 - Backup Ring 36 - Plunger 55 - Shoe Plate 74 - O-Ring
18 - O-Ring 37 - Retainer 56 - Feed Back Link 75 - O-Ring
19 - Housing 38 - Spherical Bushing 57 - Bearing 76 - O-Ring
NOTE: Parts (6 to 9, 12 to 18, 20 to 41, 55, and 56)
in housing (61) are the same as those used
in housing (19).
12
13
11
1
2
5
27
15
10
3
4
14 33 55 35 19 34 44 60 46,47 49 26 60577548
74 76
24,25 23 59 20 61 16 17,18 65
64
67
62
9
63
8
66
56 669,70 728,2931,32 71 72,73505145435452,5342 68 58404136 3937 3830

39. UPPERSTRUCTURE / Pump Device
W2-3-13
Assemble Main Pump
IMPORTANT: Apply LOCTITE (medium adhesive)
to the joint between servo piston
(23) and tilt pin (20).
1. Install A sensors (30), tilt pins (20), servo pistons
(23), O-rings (18 and 24), backup rings (17 and
25) and stoppers (16 and 26) into housings (19
and 61).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
2. Heat bearing (7). Install spacers (6), bearings (7),
spacers (8) and retaining rings (9) onto shafts (5
and 67).
3. Install pins (14), O-rings (15 and 27) to covers (11
and 65). Install covers (11 and 65) to housings (19
and 61).
IMPORTANT: Install feedback link (56) to swash
plate (33) with the link hole
connected to tilt pin (20).
4. Install shoe plate (55) to swash plate (33). Install
swash plates (33) into housings (19 and 61) so
that the swash plate joins with tilt pin (20).
NOTE: After installing swash plate (33), make sure
that the swash plate can be moved
smoothly by hand.
5. Press shafts (5 and 67) in covers (11 and 65).
Install oil seals (4), O-rings (3 and 62) to covers (2
and 63). Install covers (2 and 63) to covers (11
and 65) with socket bolts (1 and 64).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
6. Install springs (40), spacer (39), spherical bushing
(38), plungers (36), retainer (37) and shoes (35)
to cylinder block (41). Install the cylinder blocks
onto shafts (5 and 67) while aligning splines.
IMPORTANT: Apply greae to the valve plate (42).
7. Install spring pins (52), filter (53), pin (54), valve
plate (42) and O-rings (44) to cover (45).
NOTE: When installing valve plate (42), align the
pin hole position with pin (54).
8. Install housing (19) assembly to cover (45) with
socket bolts (10).
: 17 mm
: 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft)
9. Install coupling (51) and booster (50) to cover
(45).
IMPORTANT: Apply a film of grease to valve plate
(58).
10. Install spring pins (70), filter (69), pin (68), valve
plate (58) and O-rings (60, 59, 74, 75, and 76) to
cover (71).
NOTE: When installing valve plate (58), align the
pin hole position with pin (68).
11. Install housing (61) to cover (71). Then, install
them to housing (19) assembly with socket bolts
(66).
: 17 mm
: 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft)
12. Install regulator (21) onto housing (19) with socket
bolts (22) so that the regulator feedback lever
joints with tilt pin (20).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
13. Install O-rings (31) and plugs (32).
: 36 mm
: 165 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

40. UPPERSTRUCTURE / Pump Device
W2-3-14
MAINTENANCE STANDARDS
1. Clearance between Plunger (36) Outer Diameter
(d) and Cylinder Block (41) Bore Diameter (D).
D−d Unit : mm (in)
Standard Allowable Limit
0.047 (0.002) 0.094 (0.004)
2. Free Length (L) of Spring (40)
Unit : mm (in)
Standard Allowable Limit
49.5 (1.95) 48.0 (1.89)
3. Clearance (e) between Plunger (36) and Shoe
(35) and Thickness (t) of Shoe (35).
e Unit : mm (in)
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.35 (0.014)
t Unit : mm (in)
Standard Allowable Limit
6.5 (0.26) 6.3 (0.25)
4. Height difference from the reverse face of retainer
(37) to the top of spherical bushing (38)
H−h Unit : mm (in)
Standard Allowable Limit
16.5 (0.65) 15.5 (0.61)
W117-02-02-009
W117-02-02-010
W117-02-02-011
W117-02-02-012
d D
L
e
t
H
Base
h

41. UPPERSTRUCTURE / Pump Device
W2-3-15
(Blank)

42. UPPERSTRUCTURE / Pump Device
W2-3-16
DISASSEMBLE REGULATOR
W162-02-04-002
1 - Casing 11 - Plug 21 - Sleeve 30 - Valve Seat
2 - Spring Seat 12 - Pin 22 - O-Ring 31 - Steel Ball
3 - Spring 13 - O-Ring 23 - Pump Control Solenoid
Valve
32 - Stopper
4 - Stopper 14 - O-Ring 24 - Valve Cover 33 - Socket Bolt
5 - O-Ring 15 - O-Ring 25 - Socket Bolt 34 - Plug
6 - Cover 16 - Spool 26 - Plug 35 - Stopper
7 - Socket Bolt 17 - Pin 27 - O-Ring 36 - Steel Ball
8 - Screw 18 - Feedback Lever 28 - Plug 37 - Valve Seat
9 - Nut 19 - Sleeve 29 - O-Ring 38 - O-Ring
10 - O-Ring 20 - Pilot Piston
1
2
3
4
5
6
7 8 9
10
11
12
13
18
14
15
16
19
20
21
22
23
17
24
25
35
36
37
38
27
28
29
30
31
32
33
34

43. UPPERSTRUCTURE / Pump Device
W2-3-17
Disassemble Regulator
• Before starting any repair work, thoroughly read all
“Precautions for Disassembling and Assembling”
(W1-1-1).
1. Remove pump control solenoid valve (23).
: 32 mm
2. Loosen socket bolts (25) to remove valve cover
(24).
: 5 mm
3. Remove O-ring (29), valve seat (30), steel ball
(31), and stopper (32) from casing (1).
4. Remove O-ring (22), sleeve (21), and pilot piston
(20) from casing (1).
5. Remove plug (11) to remove feedback lever (18),
pin (17), sleeve (19), and spool (16).
: 6 mm
NOTE: Feedback lever (18) and pin (17) will come
off at the same time .
6. Loosen socket bolts (7) to remove cover (6).
: 5 mm
IMPORTANT: Do not remove screw (8) and nut (9).
If removed, the pump flow rate
setting may be changed.
7. Using forcing bolt (M4), remove stopper (4). Then,
remove spring (3) and spring seat (2).
8. Remove O-ring (38), valve seat (37), steel ball
(36), and stopper (35) from casing (1).

44. UPPERSTRUCTURE / Pump Device
W2-3-18
ASSEMBLE REGULATOR
T111-02-03-005
1 - Casing 11 - Plug 21 - Sleeve 30 - Valve Seat
2 - Spring Seat 12 - Pin 22 - O-Ring 31 - Steel Ball
3 - Spring 13 - O-Ring 23 - Pump Control Solenoid
Valve
32 - Stopper
4 - Stopper 14 - O-Ring 24 - Valve Cover 33 - Socket Bolt
5 - O-Ring 15 - O-Ring 25 - Socket Bolt 34 - Plug
6 - Cover 16 - Spool 26 - Plug 35 - Stopper
7 - Socket Bolt 17 - Pin 27 - O-Ring 36 - Steel Ball
8 - Screw 18 - Feedback Lever 28 - Plug 37 - Valve Seat
9 - Nut 19 - Sleeve 29 - O-Ring 38 - O-Ring
10 - O-Ring 20 - Pilot Piston
1 2 3 4 5 6 7
8
9
25
10
11
12 13171814191516
21
20
22
32
31
30292827
35
36
37
38
3433
23 24

45. UPPERSTRUCTURE / Pump Device
W2-3-19
Assemble Regulator
1. Install stopper (35), steel ball (36), valve seat (37)
and O-ring (38) into casing (1).
2. Install sleeve (19) and spool (16) into casing (1).
Then, install feedback lever (18) to sleeve (19)
with pin (17).
NOTE: Take care not to mistake the installing
direction of sleeve (19) and spool (16).
3. Install O-ring (10) around plug (11). Align the pin
holes of feed back lever (18) and casing (1). Then,
install plug (11) with O-ring (10) into casing (1).
: 6 mm
: 19 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
NOTE: After installing plug (11), check that the
feedback lever (18) moves smoothly.
4. Install spring seat (2), spring (3), stopper (4) and
O-ring (5) into casing (1). Install cover (6) with
socket bolts (7).
: 4 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
5. Install pilot piston (20), sleeve (21), and O-ring
(22) into casing (1).
6. Install stopper (32), steel ball (31), valve seat (30)
and O-ring (29) into casing (1).
7. Install pump control solenoid valve (23) to valve
cover (24). Install valve cover (24) to casing (1)
with socket bolts (25).
: 32 mm
: 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
: 4 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)

46. UPPERSTRUCTURE / Pump Device
W2-3-20
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
W137-02-04-034
1
9
6
26
10
27
6
9
2
3
5
10
12
26
13
27
12
7
15
16
14

47. UPPERSTRUCTURE / Pump Device
W2-3-21
Tightening Torque
Item Part Name Q’ty
Wrench Size
(mm) N⋅m kgf⋅m lbf⋅ft
Remarks
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply grease to oil seal lip
when installing.
5 Retaining Ring 1
6 Seal 2 Apply grease to seal when
installing.
7 Cover 1
9 Backup Ring 2 Apply grease to backup ring
when installing.
10 Key 2
12 O-Ring 2 Apply grease to O-ring
when installing.
13 Gear 1
14 Gear 1
15 Washer 4
16 Bolt 4 : 17 39 to 44 4 to 4.5 29 to 33
26 Bushing 2 Apply a film of hydraulic oil
to bushing when installing.
27 Bushing 2 Apply a film of hydraulic oil
to bushing when installing.

48. UPPERSTRUCTURE / Pump Device
W2-3-22
(Blank)

49. UPPERSTRUCTURE / Control Valve
W2-4-1
REMOVE AND INSTALL CONTROL VALVE
CAUTION:
1. Escaping pressure hydraulic oil can
penetrate the skin or eyes, causing
serious injury. Avoid this hazard by
relieving pressure before discon-
necting hydraulic lines.
2. Hydraulic oil may be hot after operation.
Hot hydraulic oil may spout, possibly
causing severe burns. Be sure to wait
for oil to cool before starting work.
3. The hydraulic oil tank cap may fly off
due to internal pressure if turned
quickly. Slowly turn the cap to release
internal pressure before completely
removing the cap.
Preparation
1. Park the machine on firm and level surface. Lower
the front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system.Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining
pressure from the hydraulic oil tank.
Refer to “Bleed Pressure from Hydraulic Circuit”
on page W1-1-2.
3. Remove the cap and connect a vacuum pump.
Operate the vacuum pump constantly to maintain
the negative pressure in the hydraulic oil tank.
NOTE: Keep the vacuum pump running
continuously while working.

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