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1. EX550-5, EX600H-5
Workshop Manual

2. 167W-1-1
SECTION 1
GENERAL INFORMATION
—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 .......................................... W1-2-3
Piping Joint ............................................ W1-2-6

3. 167W-1-2
(Blank)

4. 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 dur-
ing disassembling/assembling, resulting in damage
to machine components, as well as decreased effi-
ciency in service work.
• Inspect the Machine
Be sure to thoroughly understand all disassem-
bling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as well
as purchasing unnecessary parts.
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).
• Contamination or 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 or storing disassembled
parts.
• Precautions for Disassembling
• To prevent dirt contamination, cap or plug all re-
moved pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the re-
duction 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 at-
tempt 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 disas-
sembled 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 slid-
ing 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 re-
move 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 dis-
assembly/assembly. After assembling is complete,
count the number of tools, so as to make sure that
no tools are missing.

5. 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 instal-
lation of the pump, swing motor, travel motor or cylin-
der 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 hous-
ing, 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 en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug (upper side) / 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 op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
M104-07-021

6. GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-3
Precautions for Handling Floating Seal
1. In general, replace the floating seal with a new
one after disassembling.
If the floating is to be reused, follow these proce-
dures:
(1) Keep seal rings together as a matched set
with seal ring faces together. Insert a piece of
card-board to protect surfaces.
(2) Check slide surface (C) on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for tears, breaks, deforma-
tion or hardening.
2. If incorrectly assembled, oil leaks or damage will
occur. Be sure to do the following, to prevent trou-
ble.
(1) Clean the floating seal and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with com-
pressed air.
(2) Clean the floating seal and seal mounting
bores. Check the bore surface for scuffing or
scoring by touching the surface with finger.
(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 surface (C) is parallel with idler face (D)
by measuring the distances (a) and (b) as il-
lustrated. If these distances differ, correct the
O-ring seating.
W105-03-05-019
W105-03-05-020
W110-03-05-004
Incorrectly
Correctly
Incorrect
bb
aa
a≠ba=b
Correct
A
B
D
C
B

7. GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-4
MAINTENANCE STANDARD TERMINOL-
OGY
“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 neces-
sary.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished 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 op-
erating hours accumulate. It is recommended that
parts are repaired or replaced before reaching the
“Allowable Limit”.

8. GENERAL INFORMATION / Tightening
W1-2-1
TIGHTENING TORQUE SPECIFICATIONS
Bolt and Nut on Base Machine Standard Torques
Torque Specifications
Torque
No. Descriptions
Bolt Dia
mm
Q’ty
Wrench Size
mm N⋅m kgf⋅m lbf⋅ft
Engine cushion rubber 16 2 24 205 21 152
Front
Cushion rubber-machine 16 2 24 205 21 152
Engine cushion rubber 22 2 32 540 55 400
1 Engine cushion
rubber mounting
bolt
Rear
Cushion rubber-machine 16 4 24 205 21 152
2 Radiator mounting bolt 16 4 24 205 21 152
3 Hydraulic oil tank mounting bolt 16 8 24 205 21 152
4 Fuel tank mounting bolt 16 8 24 205 21 152
5 ORS fittings for hydraulic hoses and piping 1-3/16-12UNF
1-7/16-12UNF
36
41
175
205
18
21
130
152
6 Pump transmission mounting bolt 7/16-14UNF 14 16 69 7 51
7 Pump device mounting bolt 20 8 30 390 40 290
8 Control valve mounting bolt 20 4 30 390 40 290
9 Swing device mounting bolt
Ring gear housing mounting bolt
(hexagonal wrench)
22
18
26
24
32
14
740
295
75
30
540
215
10 Swing motor mounting bolt (hexagonal wrench) 12 16 10 88 9 65
11 Battery mounting nut 12 2 19 34 3.5 25.5
STD, LC 16 4 24 205 21 15212 Cab mounting bolt
H, LCH 16 6 24 205 21 152
13 Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
30
30
36
36
46
46
1910
1720
195
175
1410
1270
Continued on next page

9. GENERAL INFORMATION / Tightening
W1-2-2
Torque Specifications (continued)
Torque
No. Descriptions
Bolt Dia
mm
Q’ty
Wrench Size
mm N⋅m kgf⋅m lbf⋅ft
14 Travel device mounting bolt
Travel motor mounting bolt
Sprocket mounting bolt
22
18
22
40
8
48
32
27
32
740
295
32
75
30
75
540
215
540
15 Upper roller mounting 20 24 30 540 55 400
STD, H 24 64 36 930 95 69016 Lower roller mounting bolt
LC, LCH 24 72 36 930 95 690
STD, H 24 392 32 1370 140 101017 Track shoe bolt
LC, LCH 24 416 32 1370 140 1010
STD, H 24 16 36 930 95 69018 Track guard mounting bolt
LC, LCH 24 24 36 930 95 690
19 Track frame mounting bolt 33 36 50 2160 225 1590
Coupling 8 13 10.5 to
12.5
10.5 to
1.26
7.6 to
9.1
20 Coupling and clamp of low pres-
sure piping
Clamp 1/4-28UNF 11 5.9 0.6 4.3
21 Counterweight mounting bolt
Counterweight retaining bolt
45
24
2
4
65
36
2750
440
280
45
2030
330
22 Front pin-retaining bolt
Front pin-retaining nut
20
20
30
30
390
390
40
40
290
290
NOTE: 1. When tightening bolts and nuts, apply a
lubricant to threads to reduce friction.
(i.e.: white zinc B dissolved into spindle
oil)
2. Remove rust, soil, and dust before
tightening.
3. Use LOCTITE to the engine cushion
rubber mounting nuts and the lower
roller mounting bolts.

10. GENERAL INFORMATION / Tightening
W1-2-3
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and parts
create safety hazards. If an incorrect tool is
used, the tool may slip or come off or break,
resulting in personal injury.
Bolt Types
When tightening bolts and nuts, use the specified
torque. Bolts are classified according to materials and
applications. Be sure to use the correct bolts and nuts,
and tighten them to specification.
SA-040
W105-01-01-007
Specified Tightening Torque Chart
T Bolt, Socket bolt H Bolt M BoltBolt
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 M BoltHexagon H BoltHexagon T Bolt

11. GENERAL INFORMATION / Tightening
W1-2-4
IMPORTANT: (1) Apply lubricant (i.e. white zinc B
dissolved into spindle oil) to
nuts and bolts to reduce friction.
(2) Torque tolerance should be
±±±±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.
Torque as specified.
(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 al-
ternately, as shown, to ensure even tightening.
W105-01-01-003
Tighten diagonally Tighten from center
and diagonally
Equally tighten upper
and lower alternately
4
6
2
1476149121
2, 3
1, 4
5
3
1110325813

12. GENERAL INFORMATION / Tightening
W1-2-5
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect
sealing surfaces. Scratches /
roughness cruse 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 contact 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 tight-
ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
W105-01-01-015
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
WRONG
WRONG
WRONG
RIGHTRIGHT
RIGHT
Bend along edge sharply
Do not bend it roundBend along edge
sharply
WRONGRIGHTRIGHT
WRONGRIGHT
Loosen
Tighten

13. GENERAL INFORMATION / Tightening
W1-2-6
PIPING JOINT
Pipe Thread Connection / Union Joint Tightening
Torque Specifications
Union Joint
Metal sealing faces (4) of adapter (1) and (5) of hose
(2) fit together to seal pressure oil. Union joints are
used to join small-diameter lines.
IMPORTANT: (1) Do not over-tighten nut (3). If ex-
cessive force is applied to metal
sealing faces (4) and (5), adaptor
(1) will be cracked. Always
tighten nut (3) to specifications.
(2) Scratches or other damage to
sealing faces (4) or (5) will cause
oil to leak at the joint. Take care
not to damage the sealing faces
when connecting or
disconnecting the union joint.
M202-07-051
W105-01-01-017
Wrench Size (mm) Tightening Torque
Union Joint
Union Nut Joint Body N⋅m (kgf⋅m) lbf⋅ft
30° Male
19
22
27
36
41
50
60
70
19
22
27
36
41
50
60
70
59 (6)
98 (10)
118 (12)
235 (24)
295 (30)
490 (50)
670 (68)
980 (100)
43
72
87
134
215
360
490
720
37° Female
19
22
27
36
41
50
17
19
22
30, 32
36
46
44 (4.5)
59 (6)
118 (12)
235 (24)
295 (30)
490 (50)
32.5
43
87
134
125
360
NOTE: 37° male union joint tightening torque val-
ues are equal to those for 37° female union
joint.
1 4 3 5 2
Female Joint
30° or 37°
30° or 37°
Male Joint
Joint Body

14. GENERAL INFORMATION / Tightening
W1-2-7
O-ring Seal Joint
O-ring (6) is located on the end face of adapter (7) to
seal pressure oil at the joint.
IMPORTANT: (1) Be sure to replace O-ring (6) with
new one when reconnecting.
(2) Check that O-ring (6) is Correctly
seated in O-ring groove (8)
before tightening union nut (9). If
union nut (6) is tightened with
O-ring (6) displaced from the
groove, O-ring (6) will be
damaged, causing oil leaks.
(3) Take care not to damage O-ring
groove (8) on adapter (7) and
sealing face (10) of the hose end.
Damaged O-ring (6) will cause oil
leaks.
(4) If oil leaks due to looseness of
union nut (9), always replace O-
ring (6) with new one and check
that the O-ring is correctly
seated in O-ring groove (8)
before re-tightening union nut
(9).
M104-07-033
Wrench Size Tightening Torque
Union Nut Union Body N⋅m (kgf⋅m) lbf⋅ft
19
22
27
36
41
50
17
19
22
30, 32
36
46
59 (6)
98 (10)
118 (12)
235 (24)
295 (30)
490 (50)
43
72
87
134
215
360
7 6 9
8 10
Union Body

15. GENERAL INFORMATION / Tightening
W1-2-8
Screwed-In Connector
IMPORTANT: Many types of screwed-in connec-
tors are used for hose or pipe con-
nections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) correctly match before
connection.
Seal Tape Application
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up the
thread clearances. Wrapping too much tape has no
effect.
• 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 Tightening Torque
Joint Body N⋅m (kgf⋅m) lbf⋅ft
17, 19
19, 22
27, 22
36, 32
41
50
61
70
59 (6)
98 (10)
118 (12)
235 (24)
295 (30)
490 (50)
670 (68)
980 (100)
43
72
87
134
215
360
190
720
W105-01-01-019
M114-07-041
M114-07-042 M114-07-043
30°
PFPT
Male Straight ThreadMale Tapered Thread
Male Thread Clearance
Female Thread
Leave one to two pitch threads uncovered
Worm Gear TypeT-Bolt Type

16. GENERAL INFORMATION / Tightening
W1-2-9
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 leaks, 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 check if hoses
are installed properly.
(3) If hoses contact each other, wear on the
hoses will result, leading to hose
rupture. Take necessary measures to
protect hoses from contacting each
other.
Take care that hoses do not come into
contact with moving parts or sharp
objects.
W105-01-01-011
W105-01-01-012
W105-01-01-013
W105-01-01-014
RIGHTWRONG
Rubbing
Each Other
RIGHTWRONG
RIGHTWRONG
RIGHTWRONG
Rubbing
ClampClamp
Rubbing
Clamp

17. GENERAL INFORMATION / Tightening
W1-2-10
(Blank)

18. 167W-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........ W2-3-4
Assemble Pump Transmission ............ W2-3-6
Remove and Install
Main Pump ........................................ W2-3-8
Disassemble Main Pump................... W2-3-10
Assemble Main Pump........................ W2-3-16
Disassemble and Assemble
Pilot Pump....................................... W2-3-24
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 Device.................. W2-5-4
Assemble Swing Device ...................... W2-5-8
Disassemble Swing Motor ................. W2-5-12
Assemble Swing Motor ...................... W2-5-16
Maintenance Standard....................... W2-5-20

19. 167W-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 Front Attachment
Pilot Valve ......................................... W2-6-8
Assemble Front Attachment
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 Front
Attachment Shockless Valve.............. W2-8-4
Remove and Install
Travel Shockless Valve...................... W2-8-7
Disassemble and Assemble
Travel Shockless Valve...................... W2-8-8
Group 9 Solenoid Valve
Remove and Install
Three-Spool Solenoid Valve............... W2-9-1
Disassemble and Assemble
Three-Spool Solenoid Valve............... W2-9-3

20. UPPERSTRUCTURE / Cab
W2-1-1
REMOVE AND INSTALL CAB
Remove Cab
1. Remove seat mounting nut (2) to remove seat (1).
: 13 mm
2. Loosen bolt (5) in the cab rear section and bolt (6)
in rear boxes (3 and 4) to remove rear boxes (3
and 4).
: 13 mm
3. Loosen bolt (8) to remove lower cover (7) of the
rear box.
: 13 mm
4. Remove filter (24) and loosen screw (9) to remove
duct (10) from the cab.
W157-02-01-005
W157-02-01-017
W158-02-01-001
1
2
3
65
6
5
4
7
8
24
10 9

21. UPPERSTRUCTURE / Cab
W2-1-2
5. Disconnect harness connectors (11) located at the
rear inside the cab.
6. Disconnect connectors for wiper limit switch (12),
cab light (13), speaker (14), antenna (15) and
ground (17) located in the cab.
Remove washer vinyl hose (16) located behind
the cab.
7. Remove cap (20) from duct cover (18). Loosen
screws (19) to remove duct cover (18).
8. While pushing the mating face of duct (21) back-
ward, remove duct (21).
W167-02-01-001
W162-02-01-002
W158-02-01-002
W157-02-01-011
Duct Mating Face
13 14
12
15
1617
18
1920
21
11

22. UPPERSTRUCTURE / Cab
W2-1-3
9. Attach a sling belt to the top of the cab.
CAUTION: Cab weight: 260 kg (573 lb)
10. Remove cab mounting bolt (22) and nuts (23).
: 17 mm
: 24 mm
: 8 mm
11. Slowly lift the cab with a crane to remove the cab
from the machine.
W157-02-01-009
W157-02-01-010
W157-02-01-001
22
23
23

23. UPPERSTRUCTURE / Cab
W2-1-4
Install Cab
1. Attach cab to crane with sling belts and install cab
onto the machine.
CAUTION: Cab weight: 260 kg (573 lb)
2. Tighten cab mounting bolts (22) and nuts (23).
: 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) into the cab and tighten screw (9).
Install filter (24).
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
4. Connect harness connectors (11) at the rear, in-
side the cab.
W157-02-01-001
W157-02-01-010
W158-02-01-001
W167-02-01-001
22
23
23
11
24
10
9

24. UPPERSTRUCTURE / Cab
W2-1-5
5. Connect wiper limit switch (12), cab light (13),
speaker (14), antenna (15) and ground (17) in the
cab.
Connect washer vinyl hose (16) behind the cab.
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
6. Install rear box lower cover (7) and tighten bolts
(8).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
7. Install rear boxes (3 and 4) and tighten bolts (5
and 6).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8. Push duct (21) to the cab front until the duct mat-
ing face comes in contact.
W162-02-01-002
W157-02-01-017
W157-02-01-011
13 14
12
15
1617
3
65
6
5
4
7
8
Duct Mating Face
21

25. UPPERSTRUCTURE / Cab
W2-1-6
9. Install duct cover (18). Tighten screw (19) and put
cap (20) on.
10. Install seat (1) and tighten nut (2).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W158-02-01-002
W157-02-01-005
18
1920
1
2

26. UPPERSTRUCTURE / Cab
W2-1-7
DIMENSIONS OF THE CAB GLASS
W157-02-01-013
NOTE: Material: JIS- R3211,R3212
ANSI - AS2
ECE - ANNEX5 or
equivalent
Unit : mm
NOTE : 1 mm=0.03937 in
Section B
Section A
4-φ13
+0
-1
(5 mm)
51.03
360.78
30
142.25
221.399
580
R9487
4°
(87.81)
(64.74)
3.015
154.81
43.59
66.84
(5 mm)
(4 mm)
R9509
R209
R4009
R84
R509
R1009
R4009
R2309
R115092-R59
87.84
66.41
905
4-R62
756
612
63.97
35.73
947.152
900.7
15
216.73
222.65
230.50
558.78
164.12
188.5
391.8
25.106
R118
R15
R3018
R78
R11516
R70
R2
Chamfer fringe
comers.
Chamfer
both
fringes
All Around
c1
All Around
c1
B
A

27. UPPERSTRUCTURE / Cab
W2-1-8
W157-02-01-014
Section C and D
2-φ12.2
+0.5
-0
541.5
910
833±1.0
370±1.0
503±1.0
728.5±1.0
728.5±1.0
398.5±1.0
337.5±1.0
333.5±1.0
60.1
61.8
3.139.5
39.5
10.6
3-R4
R1985.1
R3985.4
R2285.4
(38.5)
(38.5)
(5 mm)
(5 mm)
(4 mm)
(4 mm)
9.2
22.5
40
40
R105
475.8
113.9
488.5
208
Chamfer
both
fringesChamfer
both
fringes
Chamfer fringe
comers.
Chamfer fringe comers.
Chamfer fringe corners.
Chamfer fringe
comers.
C
R3
45.67
90.672
549.86
516.26
468.17
7735.4
33.60
50.71
39.63
19.70
19.29
740.51
904.13
165
74.95 213.97
276.58
227.39
890.03
59
11.22
18
8
980
753.99
290
R120885.4
R12.5
R120
R8075
R3877
R2590
R5175
R345
R895
R295
R595
R1145
R12095
R1995
R2477
R72.5R30 D
2-φ12.2
+0.5
-0
4-R5
2-R5
2-R4
Unit : mm
NOTE : 1 mm=0.03937 in

28. UPPERSTRUCTURE / Counterweight
W2-2-1
REMOVE AND INSTALL COUNTER-
WEIGHT
Removal
CAUTION: Approximate counterweight
weight: 10500 kg (23200 lb)
1. Install lifting accessories and wire ropes to sling
brackets on the top of the counterweight. Set the
wire rope taut using a crane.
CAUTION: Watch out the power-wrench re-
action bar movement. Take care not to be hit
the reaction bar.
2. Loosen bolts (10) using a power wrench to re-
move bolts (10), nuts (8), shims (7), and washers
(9).
NOTE: Shims (7) are used only when any gap be-
tween nuts (8) and the lock brackets exist.
When no gap exists, shims are not re-
quired.
: 65 mm
3. Loosen bolts (1) to remove lock washers (2),
washers (3), and spacers (4). If shims (5 and 6)
are provided, remove shims (5 and 6).
: 36 mm
4. Remove the counterweight using a crane.
W166-02-02-002
W166-02-02-003
W166-02-02-001
1
10
987
9
2
6
4
5
3
1
2
7
3
4
5
9
8
6
10
9
2,1
6,5,4
3
8
7
9

29. UPPERSTRUCTURE / Counterweight
W2-2-2
Installation
CAUTION: Approximate counterweight
weight: 10500 kg (23200 lb)
1. Install lifting accessories and wire ropes to sling
brackets on the top of the counterweight. Then, lift
the counterweight by crane.
CAUTION: Do not allow anyone under the
lifted counterweight.
2. Insert protrusions on the counterweight into holes
on the frame to install the counterweight.
CAUTION: Watch out the power-wrench re-
action bar movement. Take care not to be hit
the reaction bar.
IMPORTANT: Apply lubricant to bolts (10) before
installing. Install shims (7) between
nuts (4) and the lock brackets with
the flange positioned in the upper
side.
3. Install bolts (10), nuts (4), shims (7), and washers
(9). Using a power wrench, tighten bolts (10).
: 65 mm
: 2750 N⋅m (280 kgf⋅m, 2030 lbf⋅ft)
4. Install shims (5 and 6), spacers (4), washers (3)
lock washers (2), and bolts (1). Remove wire
ropes and lifting accessories.
: 36 mm
: 440 N⋅m (45 kgf⋅m, 330 lbf⋅ft)
W166-02-02-002
W166-02-02-003
W166-02-02-001
1
10
987
9
2
6
4
5
3
1
2
7
3
4
5
9
8
6
10
9
2,1
6,5,4
3
8
7
9

30. UPPERSTRUCTURE / Pump Device
W2-3-1
REMOVE AND INSTALL PUMP DEVICE
CAUTION:
1. Escaping fluid under pressure can
penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
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 any repair
work.
3. 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. Stop the engine. Move all control levers to release
pressure remaining in the system.
Turn the hydraulic oil tank cap approx. 30° coun-
terclockwise to release any pressure remaining in
the hydraulic tank.

31. UPPERSTRUCTURE / Pump Device
W2-3-2
Removal
1. Disconnect all hoses and electrical cables from
the pump.
Tightening Torque
Wrench size (mm)
N⋅m kgf⋅m lbf⋅ft
Remark
: 19 29.5 3 22 Piping
: 22 59 6 44 Piping
: 27 93 9.5 69 Piping
: 36 175 18 130 Piping
: 10 108 11 80 Piping
: 12 175 18 130 Piping
: 14 265 27 195 Piping
: 30 390 40 290 Bolt
: 16 69 7 50 Bolt
: 32 540 55 400 Bolt
2. Lay a wooden block (300 mm long, 200 mm wide,
and 20 mm thick) under the engine oil pan.
CAUTION: Main pump weight:
125 kg (276 lb)
3. Remove the main pump mounting bolts to remove
the main pump.
CAUTION: Pump transmission weight:
150 kg (330 lb)
4. Remove the pump transmission mounting bolts
and the engine rear mounting bolts to remove the
pump transmission.
Installation
NOTE: Refer to the “removal” section above for
wrench sizes and tightening torque.
1. Secure the pump device with the mounting bolts.
2. Re-connect all hoses and electrical cables to the
pump device.
3. Bleed any trapped air from the pump (refer to
page W1-1-2).
IMPORTANT: After installing the pump, be sure to
perform break-in operation to pre-
vent seizure.
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 min-
utes repeatedly. (Do not operate the control
levers quickly. Slowly move the levers to full
stroke.)
W167-02-03-005
W167-02-03-003
Wooden
Block
Engine Rear
Mounting Bolt
Main Pump
Mounting Bolt
Pump Transmission
Mounting Bolt

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

33. UPPERSTRUCTURE / Pump Device
W2-3-4
DISASSEMBLE PUMP TRANSMISSION
W167-02-03-001
1 - Casing 4 - Coupling 7 - Bearing 10 - Bolt (10 Used)
2 - Bearing 5 - Retaining Ring 8 - O-Ring 11 - Oil Seal
3 - Retaining Ring 6 - Gear 9 - Cartridge 12 - Drain Plug
11
2
10
3
4
5
6
7
8
9
1

34. UPPERSTRUCTURE / Pump Device
W2-3-5
Disassemble Pump Transmission
• Be sure to thoroughly read all precautions for disas-
sembly/assembly work on page W1-1-1 before start-
ing any repair work.
1. Loosen drain plug (12) to drain gear oil from the
pump transmission. Remove the pilot pump from
casing (1).
: 27 mm
: 8mm
CAUTION: Pump transmission weight:
150 kg (330 lb)
2. Place casing (1) on a work bench with the main
pump mounting side facing downward.
3. Remove bolts (10).
: 19 mm
CAUTION: Pump transmission weight:
150 kg (330 lb)
4. Turn casing (1) over and place it on a work bench.
NOTE: At this time, set a wooden block (100 mm
high) so that it does not come in contact
with cartridge (9).
5. Attach a protection plate (Dia. 50 mm) to coupling
(4). While tapping the protection plate, remove
cartridge (9), bearing (2 and 7) and gear (6) from
casing (1).
6. Remove bearing (7), O-ring (8) and oil seal (11)
from cartridge (9).
7. Remove retaining ring (3), coupling (4) and retain-
ing ring (5) from gear (6).
8. Using a press or a puller, remove bearings (2 and
7) from gear (6).

35. UPPERSTRUCTURE / Pump Device
W2-3-6
ASSEMBLE PUMP TRANSMISSION
W167-02-03-002
1 - Casing 4 - Coupling 7 - Bearing 10 - Bolt (10 Used)
2 - Bearing 5 - Retaining Ring 8 - O-Ring 11 - Oil Seal
3 - Retaining Ring 6 - Gear 9 - Cartridge 12 - Drain Plug
A A
Pilot Pump
Section A-A
10
12
3261 4 5
9 8 11 7

36. UPPERSTRUCTURE / Pump Device
W2-3-7
Assemble Pump Transmission
1. Press bearings (2 and 7) into gear (6).
2. Install retaining ring (5), coupling (4), and retaining
ring (3) to gear (6).
CAUTION: Casing (1) weight:
95 kg (210 lb)
3. With the main pump mounting face .downward,
place casing (1) on a work bench.
4. Press bearing (2) along with gear (6) into casing
(1).
5. Using a protection plate, press oil seal (11)into
cartridge (9).
6. Coat the inner diameter of oil seal (11) with
grease.
7. Install O-ring (8) to cartridge (9).
IMPORTANT: Position the casting imprint on car-
tridge (9) upward (the oil filler side)
and install the cartridge on casing
(1).
8. Install cartridge (9) on casing (1).
9. Tighten bolts (10) (10 used).
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
10. Install the pilot pump on casing (1).
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
W167-02-03-006
Casting Imprint
Upward

37. UPPERSTRUCTURE / Pump Device
W2-3-8
REMOVE AND INSTALL MAIN PUMP
CAUTION:
1. Escaping fluid under pressure can
penetrate the skin, causing serious
injury. Avoid this hazard by relieving
pressure before disconnecting
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 any repair
work.
3. 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. Stop the engine. Move all control levers to release
pressure remaining in the system.
Turn the hydraulic oil tank cap approx. 30° coun-
terclockwise to release any pressure remaining in
the hydraulic tank.

38. UPPERSTRUCTURE / Pump Device
W2-3-9
Removal
1. Disconnect all hoses and electrical cables from
the pump.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
CAUTION: Main pump weight:
Approx. 125 kg (276 lb)
2. Remove the main pump mounting bolts to remove
the main pump.
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
Installation
NOTE: Refer to the “Removal” section above for
wrench sizes and tightening torque.
1. Secure the pump device with the mounting bolts.
2. Re-connect all hoses and electrical cables to the
pump device.
3. Bleed any trapped air from the pump (refer to
page W1-1-2).
IMPORTANT: After completing installation of the
pump device, be sure to perform
break-in operation to prevent pump
seizure during initial machine opera-
tion.
Procedure:
1. Start the engine. Run at slow idle speed for 20
minutes. Check for oil leaks during this opera-
tion.
2. Increase the engine speed to the first idle
speed and raise or lower the boom for 20 min-
utes. (Do not operate the control lever quickly.
Slowly operate the lever full stroke.)
T167-01-02-003
Main Pump
Mounting Bolt

39. UPPERSTRUCTURE / Pump Device
W2-3-10
DISASSEMBLE MAIN PUMP
W116-02-04-048
Pump displacement Angle Sensor (6)
W116-02-04-049
1 - Retaining Ring 8 - Socket Bolt 15 - Shaft 22 - Washer
2 - Seal Case 9 - Socket Bolt (4 Used) 16 - Spring 23 - Socket Bolt (2 Used)
3 - Oil Seal 10 - Regulator 17 - Oil Seal 24 - Spring
4 - O-Ring 11 - Control Plate 18 - Retainer 25 - Spring Seat
5 - Housing 12 - Rotary Group 19 - Retaining Ring 26 - Arm
6 - Pump Displacement Angle
Sensor (A-Sensor)
13 - Socket Bolt (3 Used) 20 - O-Ring 27 - Set Screw (2 Used)
7 - Socket Bolt (3 Used) 14 - Case 21 - Potentiometer 28 - O-Ring
1
4
3
2
5
A
6
7 8
9
12
10
9
11
13
14
28
23
22
21
15
24
25
26
27
20
16
17
18
19

40. UPPERSTRUCTURE / Pump Device
W2-3-11
Regulator (10)
W116-02-04-050
Regulator Cover (29) Section
W116-02-04-051
29 - Regulator Cover 38 - Plate 47 - Lock Nut 56 - Guide (2 Used)
30 - Socket Bolt (4 Used) 39 - Socket Bolt (4 Used) 48 - Guide 57 - Steel Ball (2 Used)
31 - Spring Seat 40 - Piston Ring (2 Used) 49 - O-Ring 58 - Plug (2 Used)
32 - Spring 41 - Piston 50 - Adjusting Screw 59 - Plug (2 Used)
33 - Spring 42 - Packing 51 - O-Ring 60 - O-Ring (6 Used)
34 - Pump Control Solenoid
Valve
43 - Rod 52 - Spring 61 - Retainer
35 - Body 44 - Knock Pin (2 Used) 53 - Distant Piece 62 - O-Ring
36 - Set Screw 45 - Bushing 54 - Spool 63 - Filter
37 - O-Ring 46 - Pin 55 - Barrel
30
29
31
32
33 A
34
46
45
44
41
40
43
42
39
38
37
36
63
29
62
61
60
56
57
58
59
59
58
57
56
47
30
48
49
50
51
52
53
54
55

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