service repair manual

1. 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

2. 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

3. 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
6
5
6
5
4
7
8
24
10 9

4. 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
16
17
18
19
20
21
11

5. 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

6. 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

7. 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
16
17
3
6
5
6
5
4
7
8
Duct Mating Face
21

8. 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
19
20
1
2

9. 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
R11509
2-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

10. 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
3.1
39.5
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
fringes
Chamfer
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
R72.5
R30 D
2-φ12.2
+0.5
-0
4-R5
2-R5
2-R4
Unit : mm
NOTE : 1 mm=0.03937 in

11. 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
9
8
7
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

12. 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
9
8
7
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

13. 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.

14. 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

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

16. 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

17. 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).

18. 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
3
2
6
1 4 5
9 8 11 7

19. 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

20. 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.

21. 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

22. 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

23. 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

24. UPPERSTRUCTURE / Pump Device
W2-3-12
W116-02-04-048
Pump Displacement Angle Sensor (6)
W116-02-04-049
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

25. UPPERSTRUCTURE / Pump Device
W2-3-13
Disassemble Main Pump
• Be sure to thoroughly read all precautions for disas-
sembly/assembly work on page W1-1-1 before start-
ing any repair work.
CAUTION: Main pump weight:
125 kg (276 lb)
1. Loosen plug (A) to drain-hydraulic oil from the
pump. Place the pump on a work bemch with
regulator (10) positioned upward.
: 10 mm
Regulator (10)
CAUTION: Regulator (10) weight:
45 kg (100 lb)
2. Remove socket bolts (7, 8, and 9). Install eye bolt
(M16, pitch 2.0) to regulator (10).
: 14 mm
IMPORTANT: When removing regulator (10) from
housing (5), take care not to allow
control plate (11) to drop Off.
3. Using a crane, remove regulator (10) from hous-
ing (5).
4. Secure cylinder block to the center pin with a rub-
ber washer and bolt (M6, 55mm long) so that the
cylinder block does not come off when housing (5)
is turned over.
: 10 mm
Rotary Group (12)
CAUTION: Housing (5) and rotary group (12)
assembly weight: 80 kg (176 lb)
5. Turn housing (5) over to remove retaining ring (1)
from housing (5).
6. Remove seal case (2) from housing (5). Remove
O-ring (4) and oil seal (3) from seal case (2).
IMPORTANT: Do not disassemble rotary group
(12).
7. Install special tool (ST 1428) to the drive shaft
threaded hole (M16, pitch 2.0) of rotary group (12)
to remove rotary group (12) from housing (5).
Special Tool: ST 1428
Pump Displacement Angle Sensor (A-Sensor)
8. Remove socket bolts (13) to remove A-sensor (6)
from regulator (10).
: 5 mm
9. Remove socket bolts (23) to remove potentiome-
ter (21) from case (14).
: 5 mm
10. Remove spring (16) from shaft (15).
11. Remove O-ring (20), retaining ring (19) and re-
tainer (18) from case (14).
12. Remove set screws (27). Remove arm (26), shaft
(15), spring seat (25) and spring (24) from case
(14).
: 3 mm
13. Remove oil seal (17) from case (14).

26. UPPERSTRUCTURE / Pump Device
W2-3-14
Regulator (10)
W116-02-04-050
Regulator Cover (29) Section
W116-02-04-051
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

27. UPPERSTRUCTURE / Pump Device
W2-3-15
Regulator (10)
14. Remove pin (46) and bushing (45) from body (35).
15. Loosen socket bolts (A) to dismount pump control
solenoid valve (34).
: 3 mm
16. Remove socket bolts (30) (4 used) to remove
regulator cover (29) from body (35).
: 8 mm
17. Remove spring seat (31) and springs (32 and 33)
from body (35).
18. Remove retainer (61) from body (35).
Regulator Cover (29)
IMPORTANT: When holding regulator cover (29)
with a vise, hold faces other than the
mating face with body (35).
19. Hold regulator cover (29) with a vise. Loosen and
remove guide (48)from regulator cover (29).
: 24 mm
20. Remove O-ring (49) from guide (48).
IMPORTANT: Do not remove lock nut (47) and ad-
justing screw (50). Failure to do so
will change the pump flow rate.
21. Remove spring (52), distant piece (53) and spool
(54) from regulator cover (29).
22. Remove barrel (55) from regulator cover (29).
23. Remove plug (59) from regulator cover (29).
: 8 mm
24. Remove plug (58) to remove steel ball (57) and
guide (56) from regulator cover (29).
: 6 mm
25. Remove filter (63) from regulator cover (29).

28. UPPERSTRUCTURE / Pump Device
W2-3-16
ASSEMBLE MAIN PUMP
W116-02-04-015
A-Sensor (6)
W116-02-04-016
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
A
Packing (42)
5 12
4 11 10
9
6
8
7
9
Section A-A
Section B-B
Pin (46)
Bushing (45)
28
27 26 14 13 15
24
25
A
A
B
B
16
21 20
22
23
17
18
19
1
2
3

29. UPPERSTRUCTURE / Pump Device
W2-3-17
Regulator (10)
W167-02-03-007
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
Regulator Cover (29) Section
Section X-X
Section Y-Y
Section A-A
29
31
41
43
35
38
32
33
36
40
37
39
44
42
30 34
A
45 46
59
A
56
57 58
X
X
Y
Y
62 60
61
60
47
50
49 48 51 52
29
53
55
54
63

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31. UPPERSTRUCTURE / Pump Device
W2-3-18
W116-02-04-015
A-Sensor
W116-02-04-016
A
Packing (42)
5 12
4 11 10
9
6
8
7
9
Section A-A
Section B-B
Pin (46)
Bushing (45)
28
27 26 14 13 15
24
25
A
A
B
B
16
21 20
22
23
17
19
1
2
3
18

32. UPPERSTRUCTURE / Pump Device
W2-3-19
Assemble Main Pump
Rotary Group (12)
CAUTION: Housing (5) weight:
35 kg (77 lb)
1. Set housing (5) on a work bench with regulator
(10) side downward.
CAUTION: Rotary group (12) weight:
45 kg (100 lb)
2. Install eye bolt (M16, pitch 2.0) to the drive shaft
of rotary group (12).
3. Attach rotary group (12) to a crane and install it
into housing (5).
4. Install O-ring (4) to housing (5).
5. Using a protection plate, press oil seal (3) into
seal case (2). Install seal case (2) to housing (5).
IMPORTANT: Check that retaining ring (1) is in-
stalled securely.
6. Install retaining ring (1) to housing (5).
CAUTION: Housing (5) and rotary group (12)
assembly weight: 80 kg (176 lb)
7. Turn housing (5) over and set it on a Work bench.
Remove a bolt and rubber washer from rotary
group (12) center pin.
: 10 mm
8. Apply a film of THREEBOND #1215 to regulator
(10) mounting face on housing (5). Then, install
packing (42) on housing (5). Apply a film of
THREEBOND #1215 to packing (42).
Regulator (10)
9. Install control plate (11) on the slide surface on
regulator (10).
NOTE: Coat control plate (11) with grease.
CAUTION: Regulator (10) weight:
Approx. 40 kg (88 lb)
10. Attach regulator (10) to a crane and install it on
housing (5).
11. Tighten socket bolts (7) (3 used), (8) and (9) (4
used).
: 14mm
: 310 to 390 N⋅m
(32 to 40 kgf⋅m, 230 to 290 lbf⋅ft)
IMPORTANT: Make sure that pin (46) moves
smoothly.
12. Install bushing (45) and pin (46) into regulator
(10).

33. UPPERSTRUCTURE / Pump Device
W2-3-20
W116-02-04-015
A-Sensor
W116-02-04-016
A
Packing (42)
5 12
4 11 10
9
6
8
7
9
Section A-A
Section B-B
Pin (46)
Bushing (45)
28
27 26 14 13 15
24
25
A
A
B
B
16
21 20
22
23
17
19
1
2
3
18