service repair workshop manual

1. SERVICE MANUAL
KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC.
245 E NORTH AVENUE
CAROL STREAM, IL 60188 U.S.A.
English
Part Number S5YY0024E02
Printed in U.S.A. • Rac
S5YY0024E02
Issued September 2012
1st Edition
APPLICABLE:
140SRLC-3 . . . . . . . . . . . . . YH07-09001~
Hydraulic Excavator
140SRLC-3
Tier 4

2. SHOP
MANUAL model
INDEX
HYDRAULIC EXCAVATOR
SPECIFICATIONSMAINTENANCESYSTEMDISASSEMBLINGTROUBLESHOOTINGE/GOPT.
1
2
3
4
5
6
7
SPECIFICATIONS SECTION
MAINTENANCE SECTION
SYSTEM SECTION
DISASSEMBLY SECTION
TROUBLESHOOTING
ENGINE SECTION
PROCEDURE OF INSTALLING
OPTIONS SECTION
Book Code No.S5YY0024E02
0-1
140SRLC-3

3. 0-2
GENERAL SAFETY INFORMATION
Do not operate or perform any maintenance on this
machine until all instructions found in the OPERA-
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine
may cause accidents and could result in serious in-
jury or death.
Always keep the manual in storage.
If it is missing or damaged, place an order with an
authorized our Distributor for a replacement.
If you have any questions, please consult an autho-
rized our Distributor.
(1) Most accidents, which occur during operation, are
due to neglect of precautionary measures and safe-
ty rules. Sufficient care should be taken to avoid
these accidents. Erroneous operation, lubrication
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
2) WARNING- Indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
and its components and is represented as fol-
lows:
(4) It is very difficult to forecast every danger that may
occur during operation. However, safety can be en-
sured by fully understanding proper operating pro-
cedures for this machine according to methods
recommended by Manufacturer.
(5) While operating the machine, be sure to perform
work with great care, so as not to damage the ma-
chine, or allow accidents to occur.
(6) Continue studying the manual until all Safety, Oper-
ation and Maintenance procedures are completely
understood by all persons working with the ma-
chine.

4. 0-3
SAFETY PRECAUTIONS
The proper and safe lubrication and maintenance
for this machine, recommended by Manufacturer,
are outlined in the OPERATOR’S MANUAL for the
machine.
Improper performance of lubrication or mainte-
nance procedures are dangerous and could result
in injury or death. Read and understand the MAN-
UAL before performing any lubrication or mainte-
nance.
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service work.
A knowledge of the system and or components is im-
portant before the removal or disassembly of any com-
ponent.
Because of the size of some of the machine compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of com-
ponents table is shown in the section ;
SPECIFICATIONS.
The following is a list of basic precautions that must al-
ways be observed.
(1) Read and understand all Warning plates and decal
on the machine before Operating, Maintaining or
Repairing this machine.
(2) Always wear protective glasses and protective
shoes when working around machines. In particu-
lar, wear protective glasses when using hammers,
punches or drifts on any part of the machine or at-
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the
welding job being performed. Do not wear loose fit-
ting or torn clothing. Remove all rings from fingers,
loose jewelry, confine long hair and loose clothing
before working on this machinery.
(3) Disconnect the battery and hang a "Do Not Oper-
ate" tag in the Operators Compartment. Remove ig-
nition keys.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the ma-
chine. Hang a "Do Not Operate" tag in the Opera-
tors Compartment.
(5) Do not work on any machine that is supported only
by lift, jacks or a hoist. Always use blocks or jack
stands, capable of supporting the machine, before
performing any disassembly.
Do not operate this machine unless you have
read and understand the instructions in the OP-
ERATOR’S MANUAL. Improper machine opera-
tion is dangerous and could result in injury or
death.
(6) Relieve all pressure in air, oil or water systems be-
fore any lines, fittings or related items are discon-
nected or removed. Always make sure all raised
components are blocked correctly and be alert for
possible pressure when disconnecting any device
from a system that utilizes pressure.
(7) Lower the bucket, dozer, or other attachments to
the ground before performing any work on the ma-
chine. If this cannot be done, make sure the bucket,
dozer, ripper or other attachment is blocked correct-
ly to prevent it from dropping unexpectedly.
(8) Use steps and grab handles when mounting or dis-
mounting a machine. Clean any mud or debris from
steps, walkways or work platforms before using.
Always face to the machine when using steps, lad-
ders and walkways. When it is not possible to use
the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
ations.
(9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
sure all chains, hooks, slings, etc., are in good con-
dition and are the correct capacity. Be sure hooks
are positioned correctly. Lifting eyes are not to be
side loaded during a lifting operation.
(10)To avoid burns, be alert for hot parts on machines
which have just been stopped and hot fluids in
lines, tubes and compartments.
(11)Be careful when removing cover plates. Gradually
back off the last two capscrews or nuts located at
opposite ends of the cover or device and carefully
pry cover loose to relieve any spring or other pres-
sure, before removing the last two capscrews or
nuts completely.
(12)Be careful when removing filler caps, breathers and
plugs on the machine. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liq-
uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
can be hot.

5. 0-4
(13)Always use the proper tools that are in good condi-
tion and that are suited for the job at hand. Be sure
you understand how to use them before performing
any service work.
(14)Reinstall all fasteners with the same part number.
Do not use a lesser quality fastener if replacements
are necessary.
(15)Repairs which require welding should be per-
formed only with the benefit of the appropriate ref-
erence information and by personnel adequately
trained and knowledgeable in welding procedures.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or
wire to provide a weld metal strength equivalent at
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
(21)Do not operate a machine if any rotating part is
damaged or contacts any other part during opera-
tion. Any high speed rotating component that has
been damaged or altered should be checked for
balance before reusing.
(22)Be careful when servicing or separating the tracks
(crawlers). Chips can fly when removing or install-
ing a track (crawlers) pin. Wear safety glasses and
long sleeve protective clothing. Tracks (crawlers)
can unroll very quickly when separated. Keep away
from front and rear of machine. The machine can
move unexpectedly when both tracks (crawlers)
are disengaged from the sprockets. Block the ma-
chine to prevent it from moving.

6. 0-5
33
51
47
34
11
21
46
31
32
25 1
2
3
12
13
22
23
24
Index
No.
Title
Book Code No.
Distribution Year Month
S5YY0224E01
2011-12
S5YN0129E01
2011-12
S5YY0324E01
2011-12
S5YY1123E01
2011-12
S5YY1224E01
2011-12
S5YY1323E01
2011-12
S5YY2123E01
2011-12
S5YY2224E01
2011-12
S5YY232401
2011-12
S5YY2424E01
2011-12
S5YY2523E01
2011-12
S5YN3129E01
2011-12
_
_
S5YY3224E01
2011-12
S5YY3324E01
2011-12
S5YY4723E01
2011-12
_
_
_
S5YY5123E01
2012-02
_
YH07-09001~
S5YY3424E01
2011-12
S5LC4625E01
2011-12
STANDARD MAINTENANCE
TIME SCHEDULE
MAINTENANCE STANDARD
AND TEST PROCEDURE
MECHATRO CONTROL
SYSTEM
DISASSEMBLING
& ASSEMBLING
2
1
3
11
12
13
21
22
23
24
25
31
32
33
34
46
47
51
OUTLINE
SPECIFICATIONS
ATTACHMENT DIMENSIONS
TOOLS
HYDRAULIC SYSTEM
ELECTRIC SYSTEM
COMPONENTS SYSTEM
AIR-CONDITIONER SYSTEM
ATTACHMENT
UPPER STRUCTURE
TRAVEL SYSTEM
BY ERROR CODES
BY TROUBLE
ENGINE
APPLICABLE MACHINES
SPECIFICATIONSMAINTENANCESYSTEMDISASSEMBLINGTROUBLESHOOTINGE/G
INDEX 140SRLC-3NA

7. 0-6
NOTE:
This Manual is prepared as a technical material in
which the information necessary for the maintenance
and repairing services of our hydraulic excavators are
collected, and is categorized into 7 Chapters, Specifica-
tion, Maintenance, System, Disassembly, Trouble-
shooting, Engine, and Installation Procedures for
Optional Attachment.
• The Chapter "Specification" describes the specifi-
cations for entire machine and material, which are
instructive for replacement and repairing of attach-
ments.
• The Chapter "Maintenance" describes the material,
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
This Manual may be properly revised due to the im-
provement of products, modification of specifications,
etc. And there are cases where the system on actual
machine and a part of the contents of this manual may
differ due to the variations of specification by countries.
For the section in which the description is hardly under-
stood, contact our distributor.
The number is assigned to every part handled in this
Manual on account of the description, but the parts,
which cannot be supplied as service parts are con-
tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
Parts Manual for applicable machine.

8. 1. OUTLINE
1-3
1
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS
1.1.1 PREPARATION BEFORE DISASSEMBLING
(1) Knowledge of operating procedure
Read Operator's Manual carefully to understand the operating procedure.
(2) Cleaning machines
Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the
service shop, causes making less efficient work and damage of parts.
(3) Inspecting machines
Confirm the disassembling section before starting work, determine the disassembly procedure taking the
conditions in work shop into account, and request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and prevent malfunction from recurring.
1. Inspecting date, place
2. Model name, Serial number and Record on hour meter
3. Trouble condition, place, cause
4. Visible oil leak, water leak and damage
5. Clogging of filters, oil level, oil quality, oil contamination and looseness.
6. Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour
meter.
(5) Arrangement and cleaning in service shop
1. Tools required for repair work.
2. Prepare the places to put the disassembled parts.
3. Prepare oil pans for leaking oil, etc.
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING
(1) Safety
1. Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
2. Attach "Don't operate" tag to control lever, and begin a meeting before starting the work.
3. Before starting inspection and maintenance stop the engine.
4. Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency
measure and ambulance to prepare for accidents and fire.
5. Choose a hard, lever and safe place, and put attachment on the ground without fail.
6. Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
7. Use proper tools, and change or repair defective tools.
8. Machine and attachment required to work in the lifting condition should be supported with supports or blocks
securely.
Read Operator's Manual
before disassembling
WARNING

9. 1. OUTLINE
1-4
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT
(1) Removing hydraulic equipment assy
1. Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank,
and take out the filter.
2. Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
3. Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
4. Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before
putting them on working bench.
(2) Disassembling hydraulic equipment
1. Since performance and function of hydraulic equipment after disassembly and assembly results in immunity
from responsibility on the manufacture's side, disassembly, assembly and modification without permission are
strictly prohibited.
2. If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel
qualified through service training.
3. Make match mark on parts for reassembling.
4. Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and
assembly are permitted or not.
5. For parts which are required to use jig and tools, don't fail to use the specified jig and tools.
6. For parts which can not be removed in the specified procedure, never force removal. First check for the cause.
7. The removed parts should be put in order and tagged so as to install on proper places without confusion.
8. For common parts, pay attention to the quantity and places.
(3) Inspecting parts
1. Check that the disassembled parts are free from adherence, interference and uneven working face.
2. Measure the wear of parts and clearance, and record the measured values.
3. If an abnormality is detected, repair or replace the parts.
(4) Reassembling hydraulic equipment
1. During the parts cleaning, ventilate the room.
2. Before assembly, clean parts roughly first, and then completely.
3. Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them.
4. Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before
assembling.
5. Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid
sealant on them.
6. Before assembling, remove rust preventives on new parts.
7. Use special tools to fit bearings, bushing and oil seal.
8. Assemble parts matching to the marks.
9. After completion, check that there is no omission of parts.

10. 32. ATTACHMENTS
32-3
32
32.1 REMOVING AND INSTALLING
32.1.1 ATTACHMENT ASSY
Front attachment and position
32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET
(1) Put the machine in position to remove bucket.
Position to remove bucket
(2) Removing pin (2)
Expand slit of ring (1) with screwdriver, and remove
it. Push out the pin (2) with flat-blade screwdriver .
Removing pin (2)
(D) ARM CYLINDER HEAD PIN(E) ARM CYLINDER
ROD PIN
(F) BOOM TOP PIN
ARM CYLINDER
(G) BUCKET CYLINDER
HEAD PIN
BUCKET CYLINDER 3. ARM
(I) IDLER LINK PIN
IDLER LINK
(H) BUCKET CYLINDER ROD PIN
(J) BUCKET DRIVE PIN
(C) BOOM CYLINDER ROD PIN
4. BOOM (A) BOOM FOOT PIN
BUCKET LINK
(K) BUCKET ATTACHING PIN
(H) BOOM CYLINDER
HEAD PIN
BOSS SECTION
1 2
DRIVER
SECTION OF BOSS

11. 32. ATTACHMENTS
32-4
32.1.2.2 ATTACHING BUCKET
-When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
-Check the seals for damaged and replace as necessary.
-When inserting the pin, coat the shaft with grease.
(3) Removing bucket attaching pin (K)
Lift up bucket, position it so that bucket attaching
pin (K) is not loaded, adjust bucket link, and pull out
bucket attaching pin (K).
Removing bucket attaching pin
(4) Removing bucket drive pin (J)
Put bucket on the ground, position it so that the
bucket drive pin (J) is not loaded, adjust bucket link,
and pull out pin (J).
Store the removed pin (J) in original position again.
Removing bucket drive pin
(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of removing.
Attaching bucket
K
J
J

12. 32. ATTACHMENTS
32-5
32
32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE
Adjustment of clearance between bucket and arm
-When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
-Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust clearance (B) so
it settles within the standard value evenly all round.
(1) Shift O-ring (3) toward the bucket boss, using a
spatula. (a-->b)
(2) When adjusting clearance (B), bring the non-
adjusting side of the bucket in contact with the arm.
(3) Measure clearance (B) and check that it is within
1.0 mm (0.04 in).
(4) Adjust clearance (B) where it is more than 1.0 mm
(0.04 in).
(5) An average of 5 shims (9) of 1mm (0.04in)
thickness are set in the plate (8) fixed by the three
capscrews (11). The clearance can be decreased
by 1mm (0.04in) if one shim is removed.
Tools: Socket: 22 mm,
Tightening torque : 181 N-m (133 lbf-ft)
(6) After adjustment, tighten the capscrews evenly.
-The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0 mm (0.04 in).
(8) Replace O-ring (3) on its original position.
Adjusting clearance between bucket and arm
+1.0
-0.5
B
3 : O-RING12 : WASHER
11 : CAPSCREW b a
7 : BUSHING
8 : PLATE
9 : SHIM 10 : PIN
Install pin (10) until the top
of pin is even surface
with bushing.
Apply rust preventive oil 251
+0.039"
-0.020"(9.88 )
New bucket

13. 32. ATTACHMENTS
32-6
32.1.3 ARM
32.1.3.1 REMOVING ARM
Plug both end of disconnected pipes.
Plug:
Tools section 11.5.2-(4)
Tools section 11.5.2-(5)
(3) Removing bucket cylinder rod pin (H)
Loosen nut (9), remove capscrew M14X115 (8), and push out pin (H).
Tools: Spanner: 22mm
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
Position to remove arm
(2) Disconnecting piping of bucket cylinder
Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and disconnect pipes.
When the removal of bucket cylinder is not
required, skip to procedure (6).
Disconnecting piping of bucket cylinder
Detail of bucket cylinder rod pin (H)
OIL PAN
H
G A
D
D
A
SHIM
8
9
H
PLASTIC SHIM
Install plastic shims
to bucket link side.
STEEL SHIM
SECTION D-D
After adjustment of shim, the total gap
should be within 0.6~1.0mm (0.02~0.04in).

14. 32. ATTACHMENTS
32-7
32
(6) Removing arm cylinder rod pin (E)
Put a wooden block between the arm cylinder and the boom.
Loosen nut (3), remove capscrew M16X160 (4), and push out arm cylinder rod pin (E).
Tools: Spanner: 24 mm
Retract arm cylinder rod, and return pin (E) to the original position (hole).
(4) Removing cylinder head pin (G)
Loosen nut (3), remove capscrew M16X130 (2),
and push out pin (G).
Tools: Spanner: 24mm
Detail of bucket cylinder head pin (G)
(5) Removing bucket cylinder
Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight: 80 kg (176 lbs)
Slinging bucket cylinder
Detail of arm cylinder rod pin (E)
SHIM
After adjustment of
shim, the total gap
should be within
0.6~1.0mm (0.02~0.04in).
Apply grease
to inner wall
of bushing
Install plastic shims
to bucket link side.
SHIM 2
G
3
SECTION A-A
E
F
BLOCK
SHIM
SHIM
After adjustment of shim, the total gap
should be within 0.6~2.0mm (0.02~0.08in).
Install plastic shims
to bucket link side.
Apply grease to inner wall
of bushing
2
3
E
SECTION B-B

15. 32. ATTACHMENTS
32-8
32.1.3.2 ATTACHING ARM
Instal the arm in the reverse order of removing, paying attention to the following:
1. When aligning the pin holes, do not put your finger in the pin
holes, but align them visually.
2. Check the seals for damage and replace as necessary.
3. When inserting the pin, coat the shaft with grease.
4. Pin lock nut handling procedure
Tools: Spanner: 22-24 mm
5. When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the
thickness of shims by referring to the Maintenance Standard.
6. Tightening torque
(7) Removing boom top pin (F)
Loosen capscrew M12X45 (2), and pull out boom
top pin (F).
Tools: Spanner: 19 mm
Insert pin (F) into the original hole.
Detail of boom top pin (F)
(8) Slinging arm assy
Sling arm with nylon sling and remove it.
Long Arm weight: 472 kg (1,041 lbs)
Slinging arm assy
Install plastic
shims to arm
side.
SHIM
SHIM Apply grease
to inner wall
of bushing
Tightening torque 144N.m (106 lbf.ft)
Apply loctite #242 to bolt.
2 1
After adjustment of
shim, the total gap
should be within
0.5mm (0.02in).
F
SECTION A-A
CLEARANCE
(0.02")
PF,PT threads
M12
M14
M16
1/8"
115
144
147
16.7
84.8
106
108
12.3
SizeClassfication
Tightening torque
N.m lbf.ft
Metric threads

16. 32. ATTACHMENTS
32-9
32
32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM
When removing and attaching boom in the position shown in below Fig. to remove and attach boom foot pin (A),
removing and attaching of cab and guard are required.
32.1.4.2 REMOVING BOOM
(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc. giving
attention for arm cylinder rod not to be extended.
Position to remove boom
(2) Lifting up boom cylinder temporarily
Remove the right and left boom cylinders one side
by one side according to the following procedure:
Lift up boom cylinder temporarily to prevent it from
dropping.
Lifting up boom cylinder temporarily
(3) Press the boom cylinder rod pin (C)
At the one side of pin (C), loosen nut (5), remove
capscrew (3) (M14X135), and remove boss (4).
And push pin (C) to the end of boom boss.
Tools: Spanner: 22 mm
(4) Preparing for disconnecting cylinder pipes
Retract the above mentioned cylinder rod, and
place one side of cylinder on stand. (See right Fig.)
Detail of boom cylinder rod pin (C)
BLOCK
C
STAND
A
A
SECTION A-A
SHIM
4
5
C
3
SHIM
4
After adjustment of shim,
the total gap should be within
0.6~2.0mm (0.02~0.08in).
Install plastic shim to cylinder side.

17. 32. ATTACHMENTS
32-10
(5) Disconnecting the arm cylinder and bucket cylinder pipings
Release pressure from arm and bucket circuit and bleed air in hydraulic tank, and then disconnect pipe at (A1),
(A2), (A3), (A4) and 4 hoses.
Tools: Spanner: 27mm , 36 mm
After disconnection of pipe, plug every pipe.
ORS Plug: See Tools 11.5.2-(4).
Boom piping disconnection
(6) Lifting up boom assy temporarily
Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.
Weight of single boom : 1,300 kg (2,867 lbs)
ARM (R)
ARM (H)
BUCKET (H)
BUCKET (R)
VIEW I
SECTION CC
128
(5") BUCKET(H), ARM
(H)
128
(5") BUCKET(H), ARM
(R)
1275.5 (50.2") BUCKET(H), ARM(R)
98
(3.9") BUCKET(R), ARM
(R)
98
(3.9") BUCKET(R), ARM
(H)
1305.5 (51.4") BUCKET(R), ARM(H)
A1
A4
A2
A3
HOSE (4 pieces)
A
BLOCK
Boom assy temporary lift up procedure

18. 32. ATTACHMENTS
32-11
32
(8) Hoisting boom assy
Hoist and remove boom assy.
Weight of single boom : 1,300 kg (2,867 lbs)
(9) Completion of removal of front attachments
When the removing and attaching of cylinder are not required, the work is finished.
(7) Removing boom foot pin (A)
1. Loosen nut (3) or washer (4) and remove pin(2)
18dia.X135.
2. Draw out pin (A).
Details of boom foot pin (A) section
2
A 3
SHIM
After adjustment of shim,
the total gap should be
within 0.5mm (0.02in).
Install plastic shim to boom side.
Apply molybdenum addition
grease to inner wall of bushing.
SECTION A-A
Boom assy hoisting procedure
D
BLOCK
D

19. 32. ATTACHMENTS
32-12
(10)Removing and installing arm cylinder
(11)Removing and installing boom cylinder
1. Lift up arm cylinder (2) with nylon sling so that the
head of cylinder is not loaded.
2. Disconnect hose (F1) and (F2) at position A. After
disconnection of hose, plug both ends of hose.
Plug: TOOLS
11.5.2-(4) Plugs for ORS fitting
Tools: Spanner: 27 mm, 30 mm, 32 mm, 36 mm
3. Removing arm cylinder head pin (D)
Loosen nut (3), remove capscrew M16X130 (2) and
pull out pin (D).
Tools: Spanner: 24 mm
4. Removing arm cylinder (2)
Weight of arm cylinder: 147 kg (324 lbs)
Removing arm cylinder
1. Release pressure from boom circuit and bleed air in
hydraulic tank.
2. Sling boom cylinder (2) using nylon sling temporally
not to act the weight of cylinder upon the cylinder
head.
3. Disconnect each two hoses (C2) and (C3). And
plug their both ends.
Plug: TOOLS 11.5.2-(4) Plugs for ORS fitting
Tools: Spanner: 27,32 mm
4. Removing boom cylinder foot pin (B)
(See right Fig., below Fig.)
Loosen nut (5), remove capscrews M10X20 (3) and
pull out pin (B).
Tools: Spanner: 17 mm
5. Remove boom cylinder (2).
Weight of boom cylinder: 100 kg (221 lbs)
6. Remove another boom cylinder the same way.
Removing and installing boom cylinder
Removing and installing boom cylinder head pin
(B)
2
D
3
SHIM
SHIM
After adjustment of
shim, the total gap
should be within
0.6~1.0mm (0.02~0.04in).
Install plastic shim to
cylinder side.
Apply grease
to inner wall
of bushing
SECTION D-D
F2
2
F1
A
C2
C3
C3
B
2
2
BB
3
SHIM
SHIM
After adjustment of shim,
the total gap should be within
0.6~2.0mm (0.02~0.08in).
Install plastic shim
to cylinder side.
Apply grease
to inner wall
of bushing
Apply grease
to inner wall
of bushing
SECTION B-B

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21. 32. ATTACHMENTS
32-13
32
32.1.4.3 ATTACHING BOOM
(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the boom assy.
Attach it in the reverse procedure of removing, paying attention to the following points.
1. When aligning the pin holes, do not put your finger
in the pin holes, but align them visually.
2. Check that the dust seals is not damaged and
replace as necessary.
3. When inserting the pin, coat the shaft with grease.
4. M16 capscrew tightening torque : 279 (3.11) N-m
(205 lbf-ft)
5. When installing boom and cylinder, check the
clearance of mounting section in thrust direction,
and decide the thickness of shim according to the
maintenance standard.
Install plastic shim first, and insert iron shim into
remaining gap. Regarding the position of shim,
refer to details of boom foot pin (A) section.
Boom foot pin (A)
A
B

22. 32. ATTACHMENTS
32-14
32.2 DISASSEMBLING AND ASSEMBLING
32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and necessary equipment and facilities.
32.2.1.1.1 WORK AREA
The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this
reason, the first condition is that the working area is long enough for the work. In terms of width, it is also
necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work
can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic
materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in
particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is
assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube
inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding
operation should not be performed in the neighborhood of the working area to keep it clean.
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.

23. 32. ATTACHMENTS
32-15
32
32.2.1.1.3 NECESSARY TOOLS
List of Tools and Jigs
• For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4 EXTERNAL CLEANING
32.2.1.1.5 DISCHARGING OIL
Tool/Jig Remarks Tool/Jig Remarks
Hammer 1. Steel hammer
2. Wooden or plastic hammer
Spatula Metallic one with smooth corners.
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place
of a gimlet.
Chisel Flat chisel Special jig 1. For piston nut.
2. For inserting and reforming seal.
3. For inserting rod cover.
4. For press fitting bushing.
See para 32.2.1.9 for detail)
Vise One having an operation wide enough to
hold cylinder head O.D. and tube
mounting pins (clevis)
Rust
remover
Wrench 1. Eye wrench
2. Allen wrench
3. Extension pipe for wrenches
Measuring
instruments
1. Slide caliper
2. Micrometer
3. Cylinder gauge (Fig. "Cylinder gauge")
4. V-block
The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil and
contamination from the cylinder with water and steam
before bringing it into the workshop.
-The following describes the construction of boom
cylinder. When disassembling and servicing the
cylinder, confirm the construction of cylinder referring
to Parts Manual.
Cylinder gauge
Place a wooden-block on the work bench and place the
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
hydraulic oil in the cylinder is drained out. At this time,
connect a suitable hose to each port so that the hydraulic oil
may not gush out.
Preparation
WOODEN BLOCK
OIL PAN
PORT A
AIR
PORT B
V BLOCK