Hitachi ZW310 Workshop Manual

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician

to provide technical information needed to maintain and repair this machine.

• Be sure to thoroughly read this manual for correct product information and service procedures.

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this manual.

• The Operator’s Manual

• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of three portions: the Techni-

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.

• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains the following information:

Example : T

1-3-5

Consecutive Page Number for Each Group

Group Number

Section Number

T: Technical Manual W: Workshop Manual

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):

Publications Marketing & Product Support

Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162

• The Engine Manual

• Parts Catalog of the Engine

• Hitachi Training Material

• Information included in the Technical Manual

(Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

IN-01

INTRODUCTION

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

UNITS USED

• SI Units (International System of Units) are used in

this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity

Volume

Weight kg lb 2.205

To Convert

From

mm in 0.03937 Length mm ft 0.003281

L US gal 0.2642 L US qt 1.057

3

m

yd3 1.308

N kgf 0.10197 Force

N lbf 0.2248 N⋅m kgf⋅m 1.0197 Torque N⋅m lbf⋅ft 0.7375

Into Multiply By

Temperature °C °F °C×1.8+32

Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0

• CAUTION:

Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT:

Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

• NOTE:

Indicates supplementary technical information or know-how.

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

To Convert

From

MPa kgf/cm2 10.197 Pressure MPa psi 145.0

kW PS 1.360 Power kW HP 1.341

km/h mph 0.6214 Velocity

-1

rpm 1.0

min

Into Multiply By

IN-02

SAFETY

RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or

in operator`s manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe oper-

ating practices.

001-E01A-0001

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death or serious injury.

• WARNIN G indicates a potentially hazardous

situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous

situation

• which, if not avoided, may result in minor or

moderate injury.

• DANGER or WARNING safety signs are located

near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the desig-

nated signal words above after the safety alert symbol are occasionally used on this machine.

• To avoid confusing machine protection with per-

sonal safety messages, a signal word IMPOR- TANT indicates a situation which, if not avoided, could result in damage to the machine.

•

NOTE indicates an additional explanation for

an element of information.

002-E01A-1223

SA-688

SA-1223

SA-1

SAFETY

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the

machine and all safety messages in operator`s manual.

• Safety signs should be installed, maintained and

replaced when necessary.

• If a safety sign or operator`s manual is damaged

or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Learn how to operate the machine and its controls

correctly and safely.

• Allow only trained, qualified, authorized personnel to

operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

impair its function and/or safety and affect machine life.

• Do not modify any machine parts without au-

thorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.

• Do not use attachments and/or optional parts or

equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.

• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

003-E01B-0003

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-

tached on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always

used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to

cope with fires and accidents.

• Keep emergency numbers for doctors, ambu-

lance service, hospital, and fire department posted near your telephone.

SA-003

004-E01A-0437

SA-437

SA-2

SAFETY

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear

Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other

parts of the machine.

• Operating equipment safely requires the full atten-

tion of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause im-

pairment or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objec-

tionable or uncomfortably loud noises.

006-E01A-0434

NSPECT MACHINE

• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal injury.

• In the walk-around inspection be sure to cover all

points described in the “PRE-START INSPEC-

TION” chapter in the operator’s manual.

007-E01A-0435

SA-438

SA-434

SA-435

SA-3

GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any

controls such as a pedal is operated while with

dirt and/or oil on the soles of the operator’s work

boots the operator’s foot may slip off the pedal,

possibly resulting in a personal accident.

• Do not leave parts and/or tools lying around the

operator’s seat. Store them in their specified lo-

cations.

• Avoid storing transparent bottles in the cab. Do

not attach any transparent type window decora-

tions on the windowpanes as they may focus

sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab

while operating the machine.

• Keep all flammable objects and/or explosives

away from the machine.

• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.

• Do not leave cigarette lighters in the cab. When

the temperature in the cab increases, the lighter

may explode.

524-E01A-0000

SAFETY

SA-4

SAFETY

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always

face the machine and maintain a three-point

contact with the steps and handrails.

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

dismount a moving machine.

• Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator leading to misoperations.

• The seat should be adjusted whenever changing

the operator for the machine.

• The operator should be able to fully depress the

pedals and to correctly operate the control levers

with his back against the seat back.

• If not, move the seat forward or backward, and

check again.

• Adjust the rear view mirror position so that the

best rear visibility is obtained from the operator’s

seat. If the mirror is broken, immediately replace it

with a new one.

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT

• Before rising from the operator’s seat to open/close

either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower

the front attachment to the ground and then move

the pilot control shut-off lever to the LOCK posi-

tion. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows,

doors, and access covers and lock them up.

SA-439

SA-462

SA-5

SAFETY

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may

become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly ex-

amine webbing, buckle and attaching hardware. If

any item is damaged or worn, replace the seat

belt or component before operating the machine.

• Be sure to remain seated with the seat belt se-

curely fastened at all times when the machine is

in operation to minimize the chance of injury from

an accident.

• We recommend that the seat belt be replaced

every three years regardless of its apparent con-

dition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Con-

firm the location of bystanders before moving, or

operating the machine.

• Always keep the travel alarm and horn in working

condition (if equipped). It warns people when the

machine starts to move.

• Use a signal person when moving, swinging, or

operating the machine in congested areas. Coor-

dinate hand signals before starting the machine.

• Use appropriate illumination. Check that all lights

are operable before operating the machine. If any

faulty illumination is present, immediately repair it.

011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and

cables.

• Remove container from machine if engine does

not need starting fluid.

• To prevent accidental discharge when storing a

pressurized container, keep the cap on the con-

tainer, and store it in a cool, well-protected loca-

tion.

• Do not incinerate or puncture a starting fluid con-

tainer.

036-E01A-0293-3

SA-237

SA-398

SA-293

SA-6

SAFETY

OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the opera-

tor's seat.

• NEVER start the engine while standing on the

track or on ground.

• Do not start engine by shorting across starter

terminals.

• Before starting the engine, confirm that all control

levers are in neutral.

• Before starting the engine, confirm the safety

around the machine and sound the horn to alert

bystanders.

012-E01B-0431

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING

THE ENGINE” chapter in the operator’s manual.

• The operator must be in the operator’s seat so

that the machine will be under control when the

engine starts.

• Jump starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway

machine.

S013-E01A-0032 SA-032

SA-431

SA-032

SA-7

SAFETY

INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a

road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground condi-

tions of the job site beforehand to prevent the

machine from falling and to prevent the ground,

stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to

the work and job site.

• Reinforce ground, edges, and road shoulders as

necessary. Keep the machine well back from the

edges of excavations and road shoulders.

• When working on an incline or on a road shoulder,

employ a signal person as required.

• Confirm that your machine is equipped a FOPS

cab before working in areas where the possibility

of falling stones or debris exist.

• When the footing is weak, reinforce the ground

before starting work.

• When working on frozen ground, be extremely

alert. As ambient temperatures rise, footing be-

comes loose and slippery.

• Beware the possibility of fire when operating the

machine near flammable objects such as dry

grass.

015-E01B-0447

SA-447

SA-8

SAFETY

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.)

ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481

SA-521

SA-481

SA-9

SAFETY

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as be-

ing struck by foreign objects and being thrown off the machine.

• Only the operator should be on the machine.

Keep riders off.

• Riders also obstruct the operator’s view, resulting

in the machine being operated in an unsafe

manner.

014-E01B-0427

DRIVE SAFELY

• Beware of the possibility of slipping and/or turning

over the machine when driving on a slope.

• When driving on level ground, hold the bucket at

mark (A) 400 to 500 mm above the ground as il-

lustrated.

• Avoid driving over any obstacles.

• Drive the machine slowly when driving on rough

terrain.

• Avoid quick direction changes. Failure to do so

may cause the machine to turn over.

• If the engine stops while driving, the steering

function becomes inoperative. Immediately stop

the machine by applying the bake to prevent

personal accident.

019-E07A-0448

DRIVE MACHINE SAFELY (WORK SITE)

• Before driving the machine, always confirm that the

steering wheel/F-N-R lever direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to

300 mm (approximately 8 to 12 in) (A) above the

ground.

• If the machine starts to skid or becomes unstable,

immediately lower the bucket to the ground and

stop.

• Driving across the face of a slope or steering on a

slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

019-E05B-0515

SA-427

SA-448

SA-449

SA-450

SA-451

SA-10

SAFETY

DRIVE SAFELY WITH BUCKET LOADED

• If the machine is incorrectly operated while driving

with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below.

• When driving the machine on a job site with the

bucket loaded, hold the bucket as low as possible

to keep the machine balanced and to have good

visibility.

• Do not exceed the rated load capacity. Always

operate the machine within the rated load capac-

ity.

• Avoid fast starts, stops, and quick turns. Failure to

do so may result in personal injury and/or death.

• Avoid rapid drive direction changes which could

possibly cause personal injury and/or death.

051-E02A-0400

DRIVE ON SNOW SAFELY

• Beware of the possibility of slipping or turning over

the machine when driving on frozen snow surfaces.

• The machine may slip more easily than expected

on frozen snow surfaces even if the inclination is

small. Reduce speed when driving. Avoid fast

starts, stops and quick turns.

• Road shoulder and/or set-up utilities covered with

snow are difficult to locate. Be sure where they

are before removing snow.

• Be sure to use tire chains when driving on snow.

• Avoid applying the brake for quick stops on snow.

If a quick stop is required, lower the bucket to the

ground.

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY

• This machine is not allowed to drive on public loads

with the bucket loaded.

• Be sure to empty the bucket.

• Hold the bucket at mark (A) 400 to 500 mm above

the road surface as illustrated.

053-E02A-0453

SA-400

SA-452

SA-11

SA-453

SAFETY

AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to

mount or stop a moving machine.

To avoid rollaways:

• Select level ground when possible to park ma-

chine.

• Do not park the machine on a grade.

• Lower the bucket to the ground.

• Place the F-N-R lever in neutral, and put the park

brake switch in the ON (parking brake) position.

• Run the engine at slow idle speed without load for

5 minutes to cool down the engine.

• Stop the engine and remove the key from the key

switch.

• Pull the lock lever to LOCK position.

• Block both tires and lower the bucket to the

ground.

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

020-E02A-0516

SA-457

SA-458

SA-12

SAFETY

AVOID ACCIDENTS FROM BACKING UP AND TURNING

• Make sure no one is working under or close to the

machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.

• Keep all personnel away from the machine by

sounding the horn and/or using hand signals. Use

extra care to be sure no one is in from the articu-

lation area before turning the machine.

• Keep windows, mirrors, and lights in good condi-

tion.

• Reduce travel speed when dust, heavy rain, fog,

etc., reduce the visibility.

• In case good visibility is not obtained, use a signal

person to guide you.

021-E02A-0517

SA-383

SA-312

SA-13

SAFETY

AVOID POSITIONING BUCKET OVER ANYONE

• Never allow the bucket to pass over co-workers

and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine.

• Avoid carrying the bucket over the co-workers to

ensure safe operation.

023-E02A-0518

AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE.

SA-518

MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when oper-

ating on a grade, possibly resulting in serious injury or death. To avoid tipping:

• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to

the machine.

• Reduce operating speeds to avoid tipping or slip-

ping.

• Avoid changing direction when traveling on

grades.

• NEVER attempt to travel across a grade steeper

than 5 degrees if crossing the grade is unavoid-

able.

• Reduce swing speed as necessary when swing-

ing loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.

SA-463

SA-14

SAFETY

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

026-E01A-0519

DIG WITH CAUTION

Before digging, check the location of cables, gas lines, and water lines.

027-E01A-0396

SA-519

PERFORM TRUCK LOADING SAFELY

• Do not operate the machine involuntarily. Unex-

pected machine movement may cause personal injury and/or death.

• Do not lower the bucket with the loader control

lever in the FLOAT position. The bucket may free

fall, possibly causing personal injury and/or death.

• Always select a level surface for truck loading.

028-E01A-397

SA-396

SA-397

SA-15

SAFETY

AVOID POWER LINES

Serious injury or death can result from contact with electric lines.

Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length.

29-E01A-0455

PRECAUTIONS FOR OPERATION

• If the front attachment or any part of the machine

comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result.

• Take care to avoid coming in contact with over-

head obstacles with the bucket or arm during op-

eration.

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately

stop operation, and lower the bucket to the

ground. Evacuate to a safe place far away from

the machine.

• After the electrical storm has passed, check all of

the machine safety devices for any failure. If any

failed safety devices are found, operate the ma-

chine only after repairing them.

OBJECT HANDLING

• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

• When using the machine for craning operations,

be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables,

sables, slings, or ropes.

• Before craning, position the upperstructure with

the position of the bucket support located on the

chassis at the front.

• Move the load slowly and carefully. Never move it

suddenly.

• Keep all persons well away from the load.

• Never move a load over a person's head.

• Do not allow anyone to approach the load until it

is safely and securely situated on supporting

blocks or on the ground.

• Never attach a sling or chain to the bucket teeth.

They may come off, causing the load to fall.

032-E01A-0132

SA-455

SA-132

SA-16

SAFETY

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.

• Keep bystanders away from the working area

before striking any object.

031-E01A-0432

PARK MACHINE SAFELY

To avoid accidents:

• Park machine on a firm, level surface.

• Lower bucket to the ground.

• Place the F-N-R lever in neutral, and put the park

brake switch in the ON (parking brake) position.

• Run engine at slow idle speed without load for 5

minutes.

• Turn key switch to OFF to stop engine.

• Remove the key from the key switch.

• Lower the lock lever to the LOCK position.

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

033-E07B-0456

SA-432

SA-456

SA-17

SAFETY

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to

prevent falling. Keep children and bystanders

away from storage areas.

504-E01A-0034

TRANSPORT SAFELY

• Take care the machine may turn over when loading

or unloading the machine onto or off of a truck or trailer.

• Observe the related regulations and rules for safe

transportation.

• Select an appropriate truck or trailer for the ma-

chine to be transported.

• Be sure to use a signal person.

• Always follow the following precautions for load-

ing or unloading:

1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Use the low speed gear.

4. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

5. After loading, install the lock bar to securely hold the articulation mechanism.

6. Wedge the front and rear of tires. Securely hold the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

SA-034

Less than 15°

SA-454

SA-18

SAFETY

HANDLE FLUIDS SAFELY-AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when

near open flame or sparks.

• Always stop the engine before refueling the ma-

chine.

• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

flammable.

• Store flammable fluids well away from fire haz-

ards.

• Do not incinerate or puncture pressurized con-

tainers.

• Do not store oily rags; they can ignite and burn

spontaneously.

• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-018

SA-019

SA-19

SAFETY

PRACTICE SAFE MAINTENANCE

To avoid accidents:

• Understand service procedures before starting

work.

• Keep the work area clean and dry.

• Do not spray water or steam inside cab.

• Never lubricate or service the machine while it is

moving.

• Keep hands, feet and clothing away from

power-driven parts.

Before servicing the machine:

1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 5 minutes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

7. Remove the key from the switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Lower the lock lever to the LOCK position.

10. Lock bar connects the front and rear frames.

11. Allow the engine to cool.

• If a maintenance procedure must be performed

with the engine running, do not leave machine unattended.

• Never work under a machine raised by the lift

arm.

• Inspect certain parts periodically and repair or re-

place as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator`s manual.

• Keep all parts in good condition and properly in-

stalled.

• Fix damage immediately. Replace worn or broken

parts. Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable

detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable (-) before mak-

ing adjustments to electrical systems or before performing welding on the machine.

500-E02C-0520

SA-028

SA-312

SA-134

SA-20

SA-527

SAFETY

• Sufficiently illuminate the work site. Use a main-

tenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In

case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine, at-

tach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287

SA-037

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without se-

curing the machine first.

• Always lower the attachment to the ground before

you work on the machine.

• If you must work on a lifted machine or attach-

ment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

519-E01A-0527

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026

SS2045102

SA-527

SA-026

SA-21

SAFETY

SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can

cause serious injury or death.

• Do not attempt to mount a tire unless you have

the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service.

• Always maintain the correct tire pressure. DO

NOT inflate tire above the recommended pressure.

• When inflating tires, use a chip-on chuck and ex-

tension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available.

• Inspect tires and wheels daily. Do not operate with

low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts.

• Never cut or weld on an inflated tire or rim as-

sembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

521-E02A-0249

PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and

face away from AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for GEAR OIL to cool, then

gradually loosen AIR RELEASE PLUG to release pressure.

503-E03A-0344

SA-249

SA-344

SA-22

SAFETY

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become

hot during operation. The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before

starting any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the

page of “Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

SA-039

SA-225

SA-019

SA-23

SAFETY

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take

care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

507-E03A-0499

SA-031

SA-292

SA-044

SA-24

SAFETY

PREVENT FIRES

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to

fires.

• Check for oil leaks due to missing or loose clamps,

kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or

damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes, or

hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight(8) to ten(10)

hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight(8) to ten(10)

hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires

are loose, kinked, etc..

Clean up Flammables:

• Spilled fuel and oil, and trash, grease, debris, ac-

cumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the ma-

chine daily and by removing spilled or accumulated flammables immediately.

Check Key Switch:

• If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day:

1. Start the engine and run it at slow idle.

SA-019

2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair

them before operating the machine.

508-E02B-0019

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be re-

paired or replaced before operating the machine.

508-E02A-0393

SA-25

SAFETY

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the fol-

lowing way:

• Stop the engine by turning the key switch to the

OFF position if there is time.

• Use a fire extinguisher if there is time.

• Exit the machine.

518-E01A-0393

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

509-E01A-0016

PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated

and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards.

Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that

there are no abnormalities such as the area surrounding the welded area still smoldering.

523-E01A-0818

SA-393

SA-016

SA-818

SA-26

SAFETY

AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when

heat goes beyond the immediate flame area. Install temporary fireresistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that con-

tain flammable fluids.

• Clean them thoroughly with nonflammable solvent

before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated

area. Dispose of paint and solvent properly.

• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

SA-030

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

SA-029

SA-27

SAFETY

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work

site. Inhalation of asbestos fibers may be the cause of lung cancer.

• Depending on the wok site conditions, the risk of

inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

• When operating the machine in a work site where

asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during op-

eration.

• Asbestos might be present in imitation parts. Use

only genuine Hitachi Parts.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away

from the top of battery.

• Never check battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode.

Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when

electrolyte level is lower than specified. Explosion of the battery may result.

• Loose terminals may produce sparks. Securely

tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY

• If spilled onto skin, refrigerant may cause a cold

contact burn.

• Refer to the instructions described on the con-

tainer for proper use when handling the refrigerant.

• Use a recovery and recycling system to avoid

leaking refrigerant into the atmosphere.

• Never touch the refrigerant.

513-E01A-0405

SA-029

SA-032

SA-405

SA-28

SAFETY

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a

hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

• See your authorized dealer for MSDS’s (available

only in English) on chemical products used with your machine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the en-

vironment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain,

or into any water source.

• Air conditioning refrigerants escaping into the air

can

• damage the Earth’s atmosphere. Government

regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of

waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

SA-309

SA-226

SA-29

SAFETY

BEFORE RETURNING THE MACHINE TO THE CUSTOMER

• After maintenance or repair work is complete,

confirm that:

• The machine is functioning properly, especially the safety systems.

• Worn or damaged parts have been repaired or replaced.

S517-E01A-0435

SA-435

SA-30

SECTION AND GROUP

CONTENTS

WORKSHOP MANUAL

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

SECTION 1 GENERAL

Group 1 Precautions for disassembling

and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleed Air from Hydraulic Oil Tank

SECTION 2 BODY (UPPERSTRUCTURE)

Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Hood Group 5 Hydraulic Oil Tank Group 6 Pump Device Group 7 Control Valve Group 8 Pilot Valve Group 9 Pilot Shut-Off Valve Group 10 Hydraulic Fan Pump and Motor

SECTION 3 BODY (TRAVEL SYSTEM)

Group 1 Tire Group 2 Drive Unit Group 3 Axle Group 4 Propeller Shaft Group 5 Brake Valve Group 6 Charging Block Group 7 Steering Pilot Valve Group 8 Steering Valve Group 9 Steering Cylinder

Hitachi Construction Machinery Co., Ltd.

Tokyo, Japan

SECTION 4 FRONT ATTACHMENT

Group 1 Front Attachment Group 2 Cylinder

Group 1 Specification Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Control System Group 2 ECM System Group 3 Hydraulic System Group 4 Electrical System

FORMANCE TEST

Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Wheel Loader Test Group 5 Component Test Group 6 Adjustment

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device Group 2 Control Valve Group 3 Hydraulic Fan Motor Group 4 Steering Pilot Valve Group 5 Steering Valve Group 6 Pilot Valve Group 7 Charging Block Group 8 Ride Control Valve Group 9 Drive Unit Group 10 Axle Group 11 Brake Valve Group 12 Others

SECTION 5 TROUBLESHOOTING

Group 1 Diagnosing Procedure Group 2 Dr. ZX Group 3 e-Wheel Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Troubleshooting C Group 8 Electrical System Inspection

⎯ CONTENTS ⎯

Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and

Assembling ............................................ W1-1-1

Maintenance Standard Terminology......... W1-1-7

Group 2 Tightening

Tightening Torque Specifications ............. W1-2-1

Torque Chart............................................ W1-2-2

Piping Joint.............................................. W1-2-5

Periodic Replacement Parts .................... W1-2-9

Group 3 Painting

Painting ................................................... W1-3-1

Group 4 Bleed Air from Hydraulic Oil Tank

Bleed Air from Hydraulic Oil Tank ............ W1-4-1

SECTION 1

GENERAL

4HAW-1-1

(Blank)

4HAW-1-2

GENERAL / Precautions for Disassembling and Assembling

PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine

Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future.

• The machine model, machine serial number, and hour meter reading.

• Reason for disassembly (symptoms, failed parts, and causes).

• Clogging of filters and oil, water or air leaks, if any.

• Capacities and condition of lubricants.

• Loose or damaged parts.

• Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the area for disassembling work.

• Precautions for Disassembling

• To prevent dirt from entering, cap or plug the removed pipes.

• Before disassembling, clean the exterior of the components and place on a work bench.

• Before disassembling, drain gear oil from the reduction gear.

• Be sure to provide appropriate containers for draining fluids.

• Use matching marks for easier reassembling.

• Be sure to use the specified special tools, when

instructed.

• If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it.

• Orderly arrange disassembled parts. Mark and tag them as necessary.

• Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.

• Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.

• Measure and record the degree of wear and clearances.

W1-1-1

GENERAL / Precautions for Disassembling and Assembling

• Precautions for Assembling

• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part.

• Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.

• Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing.

• Be sure that liquid-gasket-applied surfaces are clean and dry.

• If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.

• Utilize matching marks when assembling.

• Be sure to use the designated tools to assemble

bearings, bushings and oil seals.

• Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:

IMPORTANT: If the engine is started with air

trapped in the hydraulic pump housing, damage to the pump may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.

• Bleeding Air from Hydraulic Pump

• Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil.

• After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed.

• Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out.

• After bleeding all the air, securely tighten the plug.

W1-1-2

GENERAL / Precautions for Disassembling and Assembling

• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While operating each cylinder, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes.

• Reposition the front attachment to check hydraulic oil level.

• Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W4GB-01-01-001

W1-1-3

GENERAL / Precautions for Disassembling and Assembling

A

Floating Seal Precautions

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of cardboard to protect surfaces.

(2) Check sliding surface (C) on seal ring (A) for

scuffing, scoring, corrosion, deformation or uneven wear.

(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.

(1) Clean 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 compressed air.

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or scoring by touching the surface with touch.

(3) Check that O-ring (B) is not twisted, and that it

is installed correctly on seal ring (A).

(4) After installing the floating seal, check that

seal ring surface (C) is parallel with seal mating face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct O-ring (B) seating.

Incorrect

Correct

D

C

B

W105-03-05-019

Incorrect Correct

W105-03-05-020

aa

bb

a=b

a≠b

W110-03-05-004

W1-1-4

GENERAL / Precautions for Disassembling and Assembling

Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings safely.

• Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping.

• Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight.

• Do not lift acid or alkali chemicals.

• Take care not to allow the sling to become wet.

The load may slip.

• When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced.

• When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.

• Avoid using twisted, bound, connected, or hitched slings.

• Do not place any object on twisted or bent slings. (Refer to the right illustration.)

• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.

• Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object.

• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.

• Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W162-01-01-009

W1-1-5

GENERAL / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.

Damaged Appearance

Fuzz

Broken Sewing Thread

Scuffing

Broken Sewing Thread

W162-01-01-002

W162-01-01-003

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Scoring

Separation of Belt

W162-01-01-006

Fuzz

Scuffing

Broken Warp

W162-01-01-007

W162-01-01-008

W1-1-6

GENERAL / Precautions for Disassembling and Assembling

MAINTENANCE STANDARD TERMINOLOGY

“Standard”

1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies adjusted to specification.

“Allowable Limit”

1. Normal machine performance cannot be accomplished after exceeding this limit.

2. Repair or adjustment is impossible after exceeding this limit.

3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.

W1-1-7

(Blank)

GENERAL / Precautions for Disassembling and Assembling

W1-1-8

GENERAL / Tightening

TIGHTENING TORQUE SPECIFICATIONS

Bolts and Nuts of Machine: Standard Tightening Torque Chart

Descriptions Bolt Dia. Q’ty

Wrench

Size (mm)

1 Front axle mounting bolt 30 8 46 1579 (161)

2 Rear axle support mounting bolt 30 8 46 1579 (161)

3 Wheel rim mounting bolt 24 80 36 890 (91)

4 Propeller shaft mounting bolt 12 20 17 **143 (15)

5 Propeller shaft support bearing mounting bolt 20 2 30 206 (21)

6 Transmission mounting bolt; bracket 16 8 24 224 (23)

7 Transmission mounting bolt; cushion rubber 18 4 27 **315 (32)

8 Engine mounting bolt; bracket 14 8 22 180 (18)

9 Engine mounting bolt; cushion rubber 18 2 27 315 (32)

10 Muffler mounting bolt

12 4 17 34.2(3)

12 4 19 100 (10)

16 2 24 200 (20)

16 1 24 205 (21)

11 Counterweight mounting bolt 30 4 46 1510 (154)

12 Flange above upper center pin fixing 16 10 24 224 (23)

13 Lower center pin stopper 16 1 24 86.9 (9)

14 Loader front pin stopper 16 13 24 86.9 (9)

15 Steering cylinder pin stopper 16 4 24 86.9 (9)

16 Radiator frame mounting bolt 16 6 24 **154 (16)

17 Radiator mounting bolt 10 4 14 39 to 49 (4 to 5)

18 Intercooler mounting bolt 12 6 17 67 to 83 (7 to 8)

19 Oil cooler mounting bolt 10 8 14 39 to 49 (4 to 5)

20 Air conditioner condenser mounting bolt 8 4 12 12.5 (1)

21 Air conditioner compressor mounting bolt 8 4 12 23 to 30 (2 to 3)

22 Cab cushion rubber 16 4 24 **205 (21)

23 Bucket teeth mounting bolt (optional)

24 Cutting edge mounting bolt

25 Wear plate mounting bolt

＊

11/4’ 16 46 1940 (198)

＊

1’

＊

1’ 8 37.47 1068(109)

12 37.47 1068 (109)

As for the bolt Dia. with mark *, the dimension is indicated in inch. As for torque with mark **, LOCTITE #262 is used.

NOTE: When tightening, apply lubricant in order to reduce friction coefficient of bolts and nuts.

(Ex. white zinc B dissolved into spindle oil) Remove rust, dirt and dust before installing fasteners.

Torque

N⋅m (kgf⋅m)

W1-2-1

GENERAL / Tightening

TORQUE CHART

CAUTION: Use tools appropriate for the work

to be done. The make-do tools or parts are dangerous. As the incorrect size tools are slipped or removed, personal injury may be caused.

Bolt Types

Tighten the nuts or bolts correctly to the torque specifications. As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components.

Specified Tightening Torque

Hexagon Wrench

Bolt Dia.

(mm)

Target Va l u e Allowable Value Ta r g e t Va l u e Allowable Value Tar ge t Va l u e Allowable Value

N⋅m kgf⋅cm N⋅ m kgf⋅cm N⋅m kgf⋅cm N⋅m kgf⋅cm N⋅mkgf⋅cm N⋅m kgf⋅ cm

4 1.15 11.7 0.92 to 1.38 9.4 to 14.1 3.06 31.2 2.45 to 3.67 25.0 to 37.4 4.49 45.8 3.60 to 5.39 36.7 to 55.0 7

5 2.36 24.1 1.89 to 2.82 19.3 to 28.8 6.30 64.2 5.03 to 7.55 51.3 to 77.0 9.24 94.2 7.40 to 11.1 75.5 to 113 8

6 4.98 40.6 3.20 to 4.79 32.6 to 48.8 10.6 108 8.50 to 12.7 86.7 to 130 15.6 159 12.6 to 18.7 128 to 191 10

8 9.81 100 7.84 to 11.7 79.9 to 119 26.1 266 20.9 to 31.0 213 to 319 38.3 391 30.7 to 46.0 313 to 469 13

10 19.5 199 15.6 to 23.4 159 to 239 52.1 531 41.6 to 62.5 424 to 638 76.5 780 61.2 to 91.8 624 to 936 17

12 34.2 349 27.5 to 41.1 280 to 419 91.2 930 73.1 to 109 745 to 1110 133 1360 108 to 161 1100 to 1640 19

14 55.0 561 43.9 to65.9 448 to 672 146 1490 117 to 177 1190 to 1800 216 2200 173 to 258 1760 to 2630 22

16 86.9 886 69.5 to 104 709 to 1060 232 2370 185 to 279 1890 to 2840 341 3480 272 to 409 2770 to 4170 24

18 118 1200 94.6 to 142 965 to 1450 315 3210 252 to 379 2570 to 3860 463 4720 370 to 555 3770 to 5660 27

20 171 1740 136 to204 1390 to 2080 452 4610 362 to 543 3690 to 5540 665 6780 534 to 797 5440 to 8130 30

22 234 2390 187 to252 1910 to 2570 624 6360 499 to 749 5090 to 7640 918 9360 734 to 1100 7480 to

24 293 2990 234 to 352 2390 to 3590 782 7970 626 to 938 6380 to 9560 1150 11700 919 to 1380 9370 to

27 436 4450 349 to 524 3560 to 5340 1160 11800 931 to 1400 9490 to

30 588 6000 471 to 706 4800 to 7200 1570 16000 1260 to 1880

33 810 8260 648 to 972 6610 to 9910 2160 22000 1730 to 2590

36 1030 10500 828 to 1250

39 1350 13800 1080 to 1140

M4GB-07-121

8440 to 12700

11000 to 11650

2770 28200 2210 to 3310

3600 36700 2880 to 4320

M4GB-07-122

14300

12800 to

19200

17600 to

26400

22500 to

33800

29400 to

44100

1720 17500 1370 to

2300 23500 1840 to 2770

3170 32300 2540 to

4060 41400 3240 to

5290 53900 4240 to

2050

3810

4860

6350

14000 to 20900

18800 to 28200

25900 to 38800

33000 to 49600

43200 to 64800

M4GB-07-123

11200

14100

Wrench

SA-040

Size

mm

32

36

41

46

50

55

60

W1-2-2

GENERAL / Tightening

Specified Tightening Torque

Bolt

Dia.

(mm)

Target Va l u e Allowable Value

N⋅m kgf⋅cm N⋅m kgf⋅cm

4 4.49 45.8 3.60 to 5.39 36.7 to 55.0 3

5 9.24 94.2 7.40 to 11.1 75.5 to 113 4

6 15.6 159 12.6 to 18.7 128 to 191 5

8 38.3 391 30.7 to 46.0 313 to 469 6

10 76.5 780 61.2 to 91.8 624 to 936 8

12 133 1360 108 to 161 1100 to 1640 10

14 216 2200 173 to 258 1760 to 2630 12

16 341 3480 272 to 409 2770 to 4170 14

18 463 4720 370 to 555 3770 to 5660 14

20 665 6780 534 to 797 5440 to 8130 17

22 918 9360 734 to 1100 7480 to 11200 17

24 1150 11700 919 to 1380 9370 to 14100 19

27 1720 17500 1370 to 2050 14000 to 20900 19

30 2300 23500 1840 to 2770 18800 to 28200 22

33 3170 32300 2540 to 3810 25900 to 38800 24

36 4060 41400 3240 to 4860 33000 to 49600 27

39 5290 53900 4240 to 6350 43200 to 64800 27

Socket Bolt

Wrench

Size

(mm)

Tightening Order

When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Equally tighten upper and lower alternately

IMPORTANT: The following items are applied to

both fine and coarse pitch threads.

1. When tightening, apply lubricant in order to reduce friction coefficient of bolts and nuts. (Ex. white zinc B dissolved into spindle oil)

2. Torque tolerance is ±20 %.

3. Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole. The bolts that are too short cannot develop sufficient tightening force.

4. The torques given in table on the previous page are for general use only. Do not use these torques if a different torque is given for a specific application.

5. Clean the nut and bolt threads and remove dirt or corrosion before installing.

Tighten from center and diagonally Tighten diagonally

1.4

2.3

1

6

45

3

2

1

4

9

12 14

5

8

13

6 7

2 3

10 11

W105-01-01-003

W1-2-3

GENERAL / Tightening

Precautions for Spilt Flange

IMPORTANT: 1. Clean the sealing surfaces. Check

if the scratches / roughness that cause leaks and damage of O-ring are found.

2. Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-ring into a groove, use grease in order to hold O-ring in place.

3. While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.

4. Tighten the bolts alternately and diagonally, in order to ensure even tightening to the specified torque.

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 Locking

WRONG

RIGHT

W105-01-01-015

W105-01-01-016

W105-01-01-008

WRONG

• Lock Plate

IMPORTANT: Do not reuse the lock plates. Do not

try to bend the same point twice.

• Split Pin

IMPORTANT: Do not align the holes in the bolt and

nut while loosening. Tighten and align anytime. Do not reuse the cotter pins.

• Wire

IMPORTANT: Attach a wire to bolts in the

bolt-tightening direction. Do not reuse the wire.

Bend along edge sharply

RIGHT RIGHT

RIGHT

Tighten

Do not bend it round

RIGHT RIGHT

WRONG

W105-01-01-009

WRONG

Loosen

WRONG

W1-2-4

W105-01-01-010

GENERAL / Tightening

PIPING JOINT

IMPORTANT: The torques given in the chart below

are for general use only. Do not use these torques if a different torque is given for a specific application.

Union Joint

Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

IMPORTANT: 1. Do not over-tighten nut (3). Ex-

cessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifications.

2. Scratches or other damage to

sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.

Description

37°female 17 14 24.5 (2.5, 18)

19 17 29.5 (3.0, 21.5) 22 19 39 (4.0, 28.5) 27 22 93 (9.5, 69) 32 27 137 (14.0, 101) 36 32 175 (18.0, 129)

NOTE: Tightening torque of 37

to tightening torque of 37

1

4

3

Joint Body

5

2

M202-07-051

37°

Female Union Joint

W4GB-01-02-001

Wrench Size

mm

Wrench Size

mm

Tightening Torque

Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)

°

male coupling without union is similar

°

female.

W1-2-5

GENERAL / Tightening

O-ring Seal Joint

O-ring (6) is installed against the end face of adapter (7) and seals pressure oil.

IMPORTANT: 1. Replace O-ring (6) with a new one

when reinstalling.

2. Before tightening union nut (9),

confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.

3. Do not damage O-ring groove (8)

or sealing surface (10) in adapter (7). Damage to O-ring (6) may cause oil leakage.

4. If union nut (9) is found to be

loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.

7 6 9

8 10

Joint Body

Wrench Size

mm

Wrench Size

mm

Tightening Torque

Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)

27 22 93 (9.5, 69) 32 27 137 (14.0, 101) 36 30,32 175 (18.0, 129) 41 36 205 (21.0, 151) 50 46 330 (33.7, 243)

M104-07-033

W1-2-6

GENERAL / Tightening

Screw-In Connection

Depending on types of screw and sealing, different types of screw-in connection are used.

IMPORTANT: Check that the thread pitch and

thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread is used except when measuring.))

Seal Tape Application

Seal tape is used in order to seal clearances between male and female threads so that any leaks between threads may be prevented. Apply just enough seal tape to fill up thread clearances. Do not overwrap.

• Application Procedure

Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening

Low-pressure-hose clamp tightening torque differs depending on the type of 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 kg⋅m, 4.3 to 5.1 lbf⋅ft)

PT

30°

PF

Male Straight Thread Male Tapered Thread

Wrench Size

mm

Tightening Torque

N⋅m (kgf⋅m, lbf⋅ft)

Joint Body FC material SS material

19 14.5 (1.5,10.5) 34 (3.5,25) 22 29.5 (3.0,21.5) 49 (5.0,36) 27 49 (5.0,36) 93 (9.5,69) 36 69 (7.0,51) 157 (16,116) 41 108 (11,80) 205 (21,151) 50 157 (16,116) 320 (33,235) 60 195 (20,144)

Internal Thread

External Thread

Clearance

Leave one to two pitch threads uncovered

W105-01-01-018

W105-01-01-019

M114-07-041

W1-2-7

T-Bolt Type Band Clamp Worm Gear Type Band Clamp

M114-07-043 M114-07-042

GENERAL / Tightening

Connecting Hose

CAUTION: When replacing the hoses, 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.

Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked.

Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture.

Take care so that the hoses do not come into contact with the moving parts or sharp objects.

WRONG

Clamp

WRONG

Rubbing Against Each Other

Clamp

Rubbing Against

Each Other

RIGHT

RIGHT WRONG

RIGHT

W105-01-01-011

W105-01-01-012

W105-01-01-013

Rubbing Against Each Other

W1-2-8

Clamp

W105-01-01-014

GENERAL / Tightening

PERIODIC REPLACEMENT PARTS

1. Periodic Replacement Parts (1) (Safety Inspection Object)

In order to ensure safe operation, the users must conduct daily checking before starting operation and periodic inspection of the machine by law. In order to ensure safe operation, conduct periodic replacement of the security parts below.

Engine Fuel tank Hose Every 2 years

Brake valve Seals (rubber) Every 1 year

Wet-type brake D-ring in piston Every 4 years

Brake system

Steering system

1. Theses parts deteriorate, fatigue and weaken with time. As it is very difficult to gauge extent of the damaged parts according to periodic inspection, replace them with the new ones regardless of defect in the interval.

2. If any of these parts are found to be defective regardless of the interval, repair or replace these parts.

Brake pipe Hose Every 2 years

Stop Lamp Switch Every 2 years

Accumulator Accumulator (3 used) Every 2 years

Steering pipe Hose Every 2 years

Steering cylinder Seals (rubber) Every 4 years

Steering valve Seals (rubber) Every 2 years

Replacement Parts

Name

Replacement

Intervals

Replacement Cause

Fire breaking may occur because of fuel leakage.

If oil leakage occurs when traveling, the machine cannot be controlled.

If oil leakage occurs, the steering cannot be controlled.

W1-2-9

GENERAL / Tightening

2. Periodic Replacement Parts (2)

In order to ensure safe operation, conduct periodic inspection of the machine.In order to ensure safe operation further, conduct periodic replacement of the parts below specially related to safety. Theses parts deteriorate, fatigue and weaken with time. This may cause serious personal/impersonal hazard. As it is very difficult to gauge remnant life of these parts according to driving sensation or appearance inspection, replace them with the new ones regardless of defect in the interval. If any of these parts are found to be defective according to periodic inspection regardless of the interval, replace these parts

Replacement Parts Name

Pump

Hydraulic system

Working system

Driver’s seat Seat belt Seat belt Every 3 years

NOTE: Replace O-rings and the gaskets when

replacing the hoses.

Suction hose Delivery hose

Bucket cylinder hose Pilot hose Lift arm cylinder line hose

Replacement

Intervals

Every 2 years

W1-2-10

GENERAL / Painting

PAINTING

Surfaces to Be Painted Painting Colour Surfaces to Be Painted Painting Colour 1 Body TAXI Yellow 15 Rear Grill Not painted 2 Deck Plate HG Beige Deep 16 Counterweight TAXI Yellow 3 Handrail Warm Gray 17 Battery Box TAXI Yellow 4 Front Fender TAXI Yellow 18 Cockpit Skirt HG Beige Deep

Fender Cover Not painted

5

6 Lamp Bracket Warm Gray 20 Outside of Cab HG Beige Deep

Step Warm Gray

7

8 Rear Step TAXI Yellow 22 Articulate lock Bar Red 9 Rear Fender HG Beige Deep 23 Rim TAXI Yellow

10 Full Fender HG Beige Deep 24 Tail Pipe Not painted 11 Fuel Tank TAXI Yellow 25 Pre-Cleaner Not painted 12 Oil Tank HG Beige Deep 13 Side Cover TAXI Yellow 14 Lower Cover HG Beige Deep

IMPORTANT: When cleaning around front

attachment or cylinder, etc. fitted with HN bushing, do not pour washing liquid directly on the bushing. The ambient temperature should not exceed 70 °C (158 °F) when painting and drying.

4 6 1 19 21 20 12 25 24 13

8 10 59357222185 23

Cockpit and mounting parts

19

(Valve control box and so on)

Inside and Outside Surface of

21

Cab

HG Beige Deep

14

15

16

17

11

W4GB-01-03-001

W1-3-1

(Blank)

GENERAL / Painting

W1-3-2

GENERAL / Bleed Air From Hydraulic Oil Tank

BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Do not turn the cap on hydraulic oil tank quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap.

Preparation

1. Park the machine on a solid, level surface. Lower the front attachment onto the ground.

2. Stop the engine. Push valve (1) on hydraulic oil tank (3) and release any remaining pressure.

3. Remove cap (2) on hydraulic oil tank (3).

4. Install a vacuum pump to the hole without cap (2). Operate the vacuum pump and maintain negative pressure in hydraulic oil tank (3).

NOTE: Run the vacuum pump continuously while

working.

W4GB-01-01-001

1

2

3

Coupler

Hydraulic oil tank

Front

Clamp

Cover

Vacuum Hose

Coupler

Inlet

W4GB-01-01-002

Vacuum Pump

W4GB-01-04-001

W1-4-1

(Blank)

GENERAL / Bleed Air From Hydraulic Oil Tank

W1-4-2

MEMO

........................................................................................................................................................................

MEMO

........................................................................................................................................................................

SECTION 2

BODY (UPPERSTRUCTURE)

— CONTENTS —

Group 1 Cab

Removal and Installation of Cab................. W2-1-1

Group 2 Counterweight

Removal and Installation of

Counterweight ........................................... W2-2-1

Group 3 Center Hinge

Disassembly of Center Hinge ..................... W2-3-1

Assembly of Center Hinge .......................... W2-3-6

Group 4 Hood

Removal and Installation of Hood............... W2-4-1

Group 5 Hydraulic Oil Tank

Removal and Installation of

Hydraulic Oil Tank ..................................... W2-5-1

Group 6 Pump Device

Removal and Installation of

Pump Device............................................. W2-6-1

Removal and Installation of

Pilot Pump and Regulator ......................... W2-6-8

Disassembly of Main Pump ...................... W2-6-12

Assembly of Main Pump ........................... W2-6-14

Disassembly of Regulator ......................... W2-6-20

Assembly of Regulator.............................. W2-6-22

Disassembly of Priority Valve.................... W2-6-24

Assembly of Priority Valve ........................ W2-6-26

Structure of Pilot Pump ............................. W2-6-28

Maintenance Standard.............................. W2-6-30

Group 7 Control Valve

Removal and Installation of Control Valve...W2-7-1

Disassembly of Control Valve......................W2-7-8

Assembly of Control Valve.........................W2-7-12

Group 8 Pilot Valve

Removal and Installation of Pilot Valve .......W2-8-1

Disassembly of Standard Pilot Valve for

Front Attachment .......................................W2-8-4

Assembly of Standard Pilot Valve for

Front Attachment .....................................W2-8-12

Maintenance Standard ..............................W2-8-20

Disassembly of Joy-Stick Type Pilot Valve

for Additional Circuit (Optional)................W2-8-22

Assembly of Joy-Stick Type Pilot Valve

for Additional Circuit (Optional)................W2-8-26

Disassembly of 2-Way Lever Type Pilot

Valve for Additional Circuit (Optional)......W2-8-30

Assembly of 2-Way Lever Type

Pilot Valve for Additional Circuit...............W2-8-32

Group 9 Pilot Shut-Off Valve

Removal and Installation of

Pilot Shut-Off Valve....................................W2-9-1

Disassembly of Pilot Shut-Off Valve............W2-9-4

Assembly of Pilot Shut-Off Valve .................W2-9-6

4HAW-2-1

Group 10 Hydraulic Fan Pump and Motor

Removal and Installation of

Hydraulic Fan Pump................................ W2-10-1

Removal and Installation of

Hydraulic Fan Motor................................ W2-10-3

Disassembly of Hydraulic Fan Pump........ W2-10-8

Assembly of Hydraulic Fan Pump........... W2-10-10

Hydraulic Fan Motor Standard................ W2-10-14

4HAW-2-2

BODY (UPPERSTRUCTURE) / Cab

REMOVAL AND INSTALLATION OF CAB

Removal of Cab with Cockpit Attached

1. Remove sems bolts (2) (12 used) from covers (1) (5 used). Remove covers (1) (5 used) from cockpit (3).

: 17 mm

CAUTION: Hydraulic pressure is

accumulated in the hydraulic system by an accumulator. Reduce pressure according to the work point for each before disconnecting the main, steering and brake system hoses.

2. Disconnect hose (5) between charging block (4) and oil filter (6). Attach an identification tag onto the disconnected hoses for assembling. Cap the disconnected hoses.

: 22 mm, 27 mm

3. Remove sems bolts (7) (2 used) from clamps (8) (2 used). Disconnect hose (9) between charging block (4) and return pipe (10). Disconnect hose (12) between main pump (11) and charging block (4).

: 14 mm, 17 mm, 22 mm, 27 mm

2

1

2

Front

1

4

2

Front

1

2

Main Pump

6

Front

3

2

1

2

1

W4GB-02-01-001

4

5

W4GB-02-01-002

7

8

W2-1-1

12

11

10

9

W4GB-02-01-003

BODY (UPPERSTRUCTURE) / Cab

4. Remove sems bolts (17) (3 used) from clamps (18) (3 used). Disconnect hose (19) between charging block (4) and main pump (11). Disconnect hoses (14, 16) between charging block (4) and the rear side of hydraulic oil tank (15).

: 14 mm, 17 mm

5. Disconnect hoses (21, 22) between pilot valve (20) and main valve (23).

: 19 mm, 22 mm

6. Disconnect hoses (25, 26) between steering pilot valve (24) and stop valve (27).

: 19 mm, 22 mm

4

19

Pilot Shut-Off Valve

14

11

15 (Rear Side of Hydraulic Oil Tank)

16

17

18

W4GB-02-01-004

20

22

21

23

W4GB-02-01-005

Front

Steering Valve

24

25

26

W2-1-2

27

W4GB-02-01-006

BODY (UPPERSTRUCTURE) / Cab

A

7. Remove sems bolts (29) (4 used) from clamps (31) (4 used). Disconnect hose (30) between steering pilot valve (28) and hydraulic oil tank (15).

: 17 mm, 22 mm, 27 mm

8. Remove sems bolts (38) (4 used) from clamps (37) (4 used). Disconnect hose (33) between brake valve (39) and front axle (32). Disconnect hose (35) between brake valve (39) and suction tube (34). Disconnect hose (36) between brake valve (39) and the rear axle.

: 19 mm, 22 mm, 27 mm

9. Disconnect hose (40) between charging block (4) and parking brake (41) in the transmission.

: 17 mm

15

Front

29

28

29

30

31

Charging Block

29

W4GB-02-01-007

32

35

39

37, 38

33

34

36

To R e a r

xle

W4GB-02-01-008

40

4

41

Transmission

W4GB-02-01-009

W2-1-3

BODY (UPPERSTRUCTURE) / Cab

10. Remove bolt (43) for terminal minus from battery (42) either left or right side. Disconnect battery cable (44).

: 12 mm

11. Disconnect connectors (45, 46) of the wire harness under the cab.

CAUTION: This machine uses new freon

R134a as refrigerant. Recover all the refrigerants. Do not release them into the atmosphere.

12. Disconnect refrigerant hoses (49, 50) attached to the lower of cockpit (3).

: 17 mm, 19 mm, 24 mm, 27 mm

13. Drain off coolant from the radiator. Disconnect the hose from heater pipings (47, 48).

42

44

43

W4GB-02-01-010

45

46

W4GB-02-01-011

Front

47

3

W2-1-4

48

49

50

W4GB-02-01-012

BODY (UPPERSTRUCTURE) / Cab

14. Remove caps (51) (4 used) and plates (52) (4 used) with the packing attached from the top of cab (53). Install eyebolts (M16, Pitch 2.0 mm) (4 used) to cab (53).

15. Remove bolts (54, 63) (2 used for each), nuts (60) (2 used) nuts, (57) (4 used), plates (59, 62) (2 used for each), spacers (58, 61) (2 used for each) and washers (56) (8 used) which secure cockpit (3) and frame (55).

: 17 mm, 30 mm

CAUTION: Cab (53) Weight:

1145 kg (2550 lb)

16. Attach a nylon sling onto the eyebolt on the top of cab (53). Hoist and remove cab (53) from the cockpit.

Front

51

52

53

58

59

60

W4GB-02-01-013

54

55

56

57

W4GB-02-01-014

56 57

3

61

62

63

53

W2-1-5

W4GB-02-01-015

BODY (UPPERSTRUCTURE) / Cab

Installation of Cab

CAUTION: Cab (53) Weight:

1145 kg (2550 lb)

1. Attach a nylon sling onto an eyebolt on the top of cab (53). Hoist and align cab (53) with the holes on the cockpit.

2. Install cockpit (3) to frame (55) with bolts (54, 63) (2 used for each), nuts (60) (2 used) nuts, (57) (4 used), plates (59, 62) (2 used for each), spacers (58, 61) (2 used for each) and washers (56) (8 used). At this time, install washer (56) between the cockpit mount and frame (55).

: 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf·ft) : 30 mm : 137 N⋅m (14 kgf⋅m, 101 lbf·ft)

3. Remove eyebolts (4 used) from the top of cab (53). Install caps (51) (4 used) and plates (52) (4 used) with the packing attached to cab (53).

Cockpit Mount

Front

56 57

61

62

63

51

52

53

W4GB-02-01-015

3

54

55

58

59

60

56

57

W4GB-02-01-014

W2-1-6

53

W4GB-02-01-013

BODY (UPPERSTRUCTURE) / Cab

4. Connect hoses (49, 50) under cockpit (3). Connect heater pipings (47, 48).

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) : 19 mm : 29.4 N⋅m (3 kgf⋅m, 21.5 lbf·ft) : 24 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 57.5 lbf·ft)

5. This machine uses new freon R134a as refrigerant. Check for any gas leakage after injecting gas for the required amount.

Type Refrigerant

Number

Q’ty

kg (lb)

HFC R134a 1.05±0.05

(2.32±0.11)

6. Connect connectors (45, 46) of the wire harness under the cab.

7. Connect battery cable (44) to terminal minus of battery (42) with bolt (43).

: 12 mm : 10 N⋅m (1 kgf⋅m, 7.2 lbf·ft)

Front

47

3

48

49

50

W4GB-02-01-012

45

46

W4GB-02-01-011

W2-1-7

44

42

43

W4GB-02-01-010

BODY (UPPERSTRUCTURE) / Cab

A

8. Connect hose (40) between charging block (4) and parking brake (41) in the transmission.

: 17 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

9. Connect hose (33) between brake valve (39) and front axle (32). Connect hose (35) between brake valve (39) and suction tube (34). Connect hose (36) between brake valve (39) and the rear axle. Secure clamps (37) (4 used) to the frame with sems bolts (38) (4 used).

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf·ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 57.5 lbf·ft)

10. Connect hose (30) between steering pilot valve (28) and hydraulic oil tank (15). Secure clamps (31) (4 used) to the frame with sems bolts (29) (4 used).

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 57.5 lbf·ft)

40

41

4

Transmission

W4GB-02-01-009

32

35

39

37, 38

33

34

36

To R e a r

xle

W4GB-02-01-008

15

Front

30

29

25

31

29

Charging Block

29

W4GB-02-01-007

W2-1-8

BODY (UPPERSTRUCTURE) / Cab

11. Connect hoses (25, 26) between steering pilot valve (24) and stop valve (27).

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf·ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

12. Connect hoses (21, 22) between pilot valve (20) and main valve (23).

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf·ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

13. Connect hose (19) between charging block (4) and main pump (11). Connect hoses (14, 16) between charging block (4) and the rear side of hydraulic oil tank (15). Secure clamps (18) (3 used) to the frame with sems bolts (17) (3 used).

: 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)

Front

Steering Valve

24

25

26

27

W4GB-02-01-006

21

20

22

14

18

W4GB-02-01-005

15

Rear Side of Hydraulic Oil Tank

16

17

23

Pilot Shut-Off Valve

4

19

11

W4GB-02-01-004

W2-1-9

BODY (UPPERSTRUCTURE) / Cab

14. Connect hose (9) between charging block (4) and return pipe (10). Secure clamps (8) (2 used) to the frame with sems bolts (7) (2 used). Connect hose (12) between main pump (11) and charging block (4).

: 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 57.5 lbf·ft)

15. Connect hose (5) between charging block (4) and oil filter (6).

: 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 57.5 lbf·ft)

16. Add coolant to the radiator. Start the engine and the test run. Check for any oil leakage at the hose connections.

4

12

11

Front

10

7

8

9

W4GB-02-01-003

Front

Main Pump

6

4

5

W4GB-02-01-002

CAUTION: Wear safety goggles and gloves

when checking oil leaks. Apply cardboard or laminated wood at the check point. High-pressure oil may cause serious injury to the skin and eyes.

W2-1-10

BODY (UPPERSTRUCTURE) / Cab

17. Install covers (1) (5 used) to cockpit (3) with sems bolts (2) (12 used).

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)

2

1

2

Front

2

1

2

3

2

1

2

1

2

1

2

W4GB-02-01-001

W2-1-11

(Blank)

BODY (UPPERSTRUCTURE) / Cab

W2-1-12

BODY (UPPERSTRUCTURE) / Counterweight

REMOVAL AND INSTALLATION OF COUNTERWEIGHT

Removal

CAUTION: Counterweight weight:

1810 kg (4000 lb)

CAUTION: 1. Park the machine on a flat

place and stop the engine.

2. Put a chock and apply the parking brake in order not to move the machine.

3. Lower the bucket onto the ground. Release hydraulic pressure in the hydraulic device.

1. Open the rear grill.

CAUTION: When removing counterweight (3)

with the rear grill closed, the rear grill may be damaged.

2. Install a lifting tool to counterweight (3). Hoist counterweight (3) a little.

CAUTION: When hoisting counterweight (3)

too much, it difficult to remove bolt (5) and the screw part may be damaged.

3. Remove nuts (1) (2 used) and washers (2) (2 used).

: 46 mm

4. Loosen bolts (5) (4 used). Remove bolts (5) (4 used) and washers (4) (4 used) from counterweight (3) while finely adjusting the hoist of counterweight (3).

: 46 mm

5. Move counterweight (3) to the rear side of frame (6) and remove counterweight (3).

Lifting Tool

1

2

3

4

5

6

W4GB-02-02-001

W2-2-1

BODY (UPPERSTRUCTURE) / Counterweight

Installation

CAUTION: Counterweight weight:

1810 kg (4000 lb)

1. Hoist counterweight (3) by using a lifting tool. Move counterweight (3) to about 200 mm (8 in) in front of the counterweight (3) mounting part of frame (6).

2. Align the screw holes on counterweight (3) and frame (6). Place counterweight (3) onto frame (6).

3. Install counterweight (3) to frame (6) with blots (5) (4 used) and washers (4) (4 used).

: 46 mm : 1510 N⋅m (154 kgf⋅m, 1110 lbf·ft)

4. Install nuts (1) (2 used) and washers (2) (2 used) to bolts (5) (2 used) on the upper side.

: 46 mm : 1510 N⋅m (154 kgf⋅m, 1110 lbf·ft)

Lifting Tool

1

2

3

4

5

6

W4GB-02-02-001

W2-2-2

BODY (UPPERSTRUCTURE) / Center Hinge

DISASSEMBLY OF CENTER HINGE

2

3

25

1

24

16

1

4

5

6

7

8

9

10

11

12

13

14

15

17

18

8

24

23

18

10

15

19

9

20

21

22

1 - Washer (10 Used) 8 - Shim (2 Used) 14 - Pin 20 - Bushing 2 - Bolt (4 Used) 9 - Dust Seal (2 Used) 15 - Bushing (2 Used) 21 - Bolt (6 Used) 3 - Bolt (6 Used) 10 - Bearing (2 Used) 16 - Bolt (6 Used) 22 - Pin 4 - Flange 11 - Bolt 17 - Cap 23 - Cap 5 - Shim (2 Used) 12 - Washer 18 - Dust Seal (2 Used) 24 - Grease Fitting (2 Used) 6 - Bushing 13 - Washer 19 - Cap 25 - Front Frame 7 - Cap

W4GB-02-03-021

W2-3-1

BODY (UPPERSTRUCTURE) / Center Hinge

2

3

4

5

6

7

8

9

25

19

9

20

22

10

11

12

13

14

21

W4GB-02-03-021

W2-3-2

BODY (UPPERSTRUCTURE) / Center Hinge

Disassembly of Center Hinge

CAUTION: The center hinge is required to

disassemble for the major maintenance work such as removal of the front frame from the rear frame. At this time, move the machine into the factory.

Preparation

Carry out the following procedures before disassembling the center hinge.

1. Remove the cab and the cockpit.

2. Remove the mounting component between the front frame and the rear frame.

• Propeller Shaft

• Steering Cylinder

• Hydraulic Hose

• Brake Piping

• Wire Harness

Removal of Hinge Pin

1. Support the front frame and the rear frame by using firm support stands.

W4GB-02-03-002

2. Remove bolts (2) (4 used) and bolts (3) (6 used) from flange (4) of the upper hinge part. Remove flange (4), shims (5) (2 used) and pin (22) from front frame (25).

: 24 mm

3. Remove bolt (11) and washers (12, 13) from pin (14). Remove pin (14) from front frame (25).

: 24 mm

4. Remove bushing (6) from front frame (25). (Remove bushing (6) after cutting by gas or pulling out by welding a cardboard.)

CAUTION: Front frame (25) weight:

2080 kg (4600 lb)

5. Attach a nylon sling onto front frame (25). Hoist and move front frame (25) so that bearing (10) can be removed.

6. Remove bushing (20) from front frame (25).

7. Remove bolts (21) (6 used) from cap (19). Remove caps (7, 19) and shim (8) from front frame (25).

: 24 mm

8. Remove dust seals (9) (2 used) from caps (7, 19).

9. Remove bearing (10) from front frame (25).

W2-3-3

BODY (UPPERSTRUCTURE) / Center Hinge

16

25

23

18

10

15

17

18

8

W4GB-02-03-021

W2-3-4

BODY (UPPERSTRUCTURE) / Center Hinge

10. Remove bolts (16) (6 used) from cap (17). Remove caps (17, 23) and shim (8) from front frame (25).

: 17 mm

11. Remove dust seals (18) (2 used) from caps (17,

23).

12. Remove bearing (10) from front frame (25).

13. Remove bushings (15) (2 used) from the lower hinge part of the rear frame.

W2-3-5

BODY (UPPERSTRUCTURE) / Center Hinge

ASSEMBLY OF CENTER HINGE

Upper Hinge

4

1, 3 1, 2

6

Lower Hinge Pin

25

18

16

5

7

19

20

922

11, 12, 13

9

8

24

10

21

W4GB-02-03-003

15

17

25

10

18

14

8

24

23

15

1 - Washer (10 Used) 8 - Shim (2 Used) 14 - Pin 20 - Bushing 2 - Bolt (4 Used) 9 - Dust Seal (2 Used) 15 - Bushing (2 Used) 21 - Bolt (6 Used) 3 - Bolt (6 Used) 10 - Bearing (2 Used) 16 - Bolt (6 Used) 22 - Pin 4 - Flange 11 - Bolt 17 - Cap 23 - Cap 5 - Shim (2 Used) 12 - Washer 18 - Dust Seal (2 Used) 24 - Grease Fitting (2 Used) 6 - Bushing 13 - Washer 19 - Cap 25 - Front Frame 7 - Cap

W4GB-02-03-004

W2-3-6

BODY (UPPERSTRUCTURE) / Center Hinge

Assembly of Center Hinge

1. Continuously apply LOCTITE #262 onto the outer circumference of dust seal (18). Lightly tap and insert dust seal (18) into cap (17) by using a hammer. Wipe out the stick-out LOCTITE #262 by using a waste. Install dust seal (18) to cap (23) in the same way.

IMPORTANT: Check the direction of dust seal (18).

Install dust seal (18) with the wider rubber side facing to the unpainted side of caps (17, 23).

17, 23

18

Face the lip to the outer side (painted side of the cap)

W4GB-02-03-005

2. Insert dust seals (9) (2 used) into caps (7, 19) in the same way.

3. Insert bearing (10) into the upper hinge part of front frame (25).

4. Add grease through grease fitting (24) into the inside of bearing (10) while rotating bearing (10).

5. Insert bearing (10) into the lower hinge part of front frame (25). Add grease through grease fitting (24).

6. Install caps (7, 19) and shim (8) to the upper hinge part of front frame (25). Apply LOCTITE #262 onto bolts (21) (6 used). Install caps (7, 19) to front frame (25) with bolts (21) (6 used).

: 24 mm : 224 N⋅m (23 kgf⋅m, 165 lbf·ft)

7. Tap the space among caps (7, 19) and dust seals (9) (2 used) by using an iron nail.

8. Install caps (17, 23) and shim (8) to the lower hinge part of front frame (25). Apply LOCTITE #262 onto bolts (16) (6 used). Install caps (17, 23) to front frame (25) with bolts (16) (6 used).

: 17 mm : 88 N⋅m (9 kgf⋅m, 65 lbf·ft)

9. Tap the space among caps (17, 23) and dust seals (18) (2 used) by using an iron nail.

W2-3-7

BODY (UPPERSTRUCTURE) / Center Hinge

Upper Hinge

25

Lower Hinge Pin

4

5

20

1, 3 1, 2

6

22

W4GB-02-03-003

11, 12, 13

25

15

14

W4GB-02-03-004

W2-3-8

BODY (UPPERSTRUCTURE) / Center Hinge

10. Insert bushings (15) (2 used) into the lower hinge part of the rear frame.

CAUTION: Front frame (25) weight:

2080 kg (4600 lb)

11. Attach a nylon sling onto front frame (25). Hoist and align front frame (25) with the center hinge pin holes on the rear frame.

12. Install pin (22), bushings (6, 20), shims (5) (2 used) and flange (4) to the upper hinge part. Tighten bolts (2) (4 used), bolts (3) (6 used) and washers (1) (10 used).

: 24 mm : 224 N⋅m (23 kgf⋅m, 165 lbf·ft)

13. Insert pin (14) into the lower hinge part. Tighten bolt (11) and washers (12, 13).

: 24 mm (0.94 in) : 86.9 N⋅m (8.9 kgf⋅m, 64 lbf·ft)

W2-3-9

(Blank)

BODY (UPPERSTRUCTURE) / Center Hinge

W2-3-10

BODY (UPPERSTRUCTURE) / Hood

A

REMOVAL AND INSTALLATION OF HOOD

Removal

1. Open the left and right side covers.

2. Loosen hose bands (3) (2 used) which secure intake hose (4). Disconnect intake hose (4) from pipe (2) and the engine.

3. Disconnect the harness for sensor (1) at the connector part.

CAUTION: The hood (5) assembly weight:

159 kg (350 lb)

4. Attach a nylon sling onto hood (5). Hoist and hold hood (5). Remove bolts (7) (4 used) and washers (6) (4 used) from hood (5). Hoist and remove hood (5) from the frame.

: 17 mm

Installation

1

2

ir Cleaner

3

CAUTION: The hood (5) assembly weight:

159 kg (350 lb)

1. Attach a nylon sling onto hood (5). Hoist hood (5). Align the exhaust pipe and the vent of the muffler. Install hood (5) to the frame with bolts (7) (4 used) and washers (6) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf·ft)

2. Connect the harness for sensor (1) at the connector part.

3. Connect intake hose (4) to the engine and pipe (2). Secure intake hose (4) with hose bands (3) (2 used).

4. Shut the left and right side covers.

5

4

W4GB-02-03-007

6

7

W4GB-02-03-006

W2-4-1

(Blank)

BODY (UPPERSTRUCTURE) / Hood

W2-4-2

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

REMOVAL AND INSTALLATION OF HYDRAULIC OIL TANK

CAUTION: Hydraulic oil tank (5) weight:

215 kg (475 lb)

Removal

1. Remove the hood. (Refer to W2-4-1.)

2. Remove the left and right side fenders.

: 17 mm

3. Remove bolts (1) (6 used) and washers (2) (6 used) from cover (3). Remove cover (3) and suction filter (4) from hydraulic oil tank (5).

: 14 mm

4. Drain hydraulic oil from the suction filter mounting part of hydraulic oil tank (5) by using a pump.

CAUTION: Drain hydraulic oil from the

suction pipe at the bottom of hydraulic oil tank (5).

CAUTION: Attach an identification tag onto

each hose connected to hydraulic oil tank (5) for assembling.

5. Disconnect hose (6) from hydraulic oil tank (5).

: 22 mm

6. Disconnect hose (8) and remove O-ring (7) from hydraulic oil tank (5).

: 36 mm

1

2

3

4

5

W4GB-02-03-010

6

5

CAUTION: O-ring (7) cannot be reused.

7. Loosen hose clamps (9) (2 used). Disconnect hose (10) from hydraulic oil tank (5) and pipe (11).

W2-5-1

10

9

7

8

9

11

W4GB-02-03-011

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

8. Loosen hose clamps (12) (2 used). Disconnect hose (13) from hydraulic oil tank (5) and pipe (15).

9. Disconnect hose (14) from hydraulic oil tank (5).

: 27 mm

10. Disconnect hoses (16, 17) from hydraulic oil tank (5).

: 17 mm

5

12

13

12

14

15

W4GB-02-03-012

5

W2-5-2

16

17

W4GB-02-03-013

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

11. Disconnect hoses (18, 19) from block (20) when the emergency steering pump is installed.

: 17 mm, 22 mm

12. Disconnect the connector from hydraulic oil temperature sensor (23) and level sensor (24).

13. Remove bolts (22) (8 used) from clamps (21) (8 used). Disconnect wire harness (25) from hydraulic oil tank (5).

： 12 mm

18

20

19

W4GB-02-03-014

5

21, 22

24

23

21, 22

W2-5-3

25

21, 22

W4GB-02-03-017

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

CAUTION: Hydraulic oil tank (5) weight:

215 kg (475 lb)

14. Attach a nylon sling onto hydraulic oil tank (5). Hoist and hold hydraulic oil tank (5). Remove bolts (26) (6 used) and washers (27) (6 used) from hydraulic oil tank (5).

: 24 mm

15. Hoist and remove hydraulic oil tank (5) from the frame.

5

26

27

26

27

W4GB-02-03-016

W2-5-4

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

Installation

CAUTION: Hydraulic oil tank (5) weight:

215 kg (475 lb)

1. Attach a nylon sling onto hydraulic oil tank (5). Hoist and align hydraulic oil tank (5) with the mounting position of the frame.

2. Install hydraulic oil tank (5) to the frame with bolts (26) (6 used) and washers (27) (6 used).

: 24 mm : 210 N⋅m (21.5 kgf⋅m, 152 lbf·ft)

3. Connect hoses (18, 19) to block (20) as shown in the identification tag when the emergency steering pump is installed.

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

5

26

27

26

27

W4GB-02-03-016

18

19

20

W4GB-02-03-014

W2-5-5

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

4. Connect hoses (16, 17) to hydraulic oil tank (5).

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)

5. Connect hose (14) to hydraulic oil tank (5).

: 27 mm : 93 N⋅m (9.5 kgf⋅m, 68.5 lbf·ft)

6. Connect hose (13) to hydraulic oil tank (5) and pipe (15). Secure hose (13) with hose clamps (12) (2 used).

5

16

17

W4GB-02-03-013

5

W2-5-6

12

13

12

14

15

W4GB-02-03-012

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

7. Connect hose (10) to hydraulic oil tank (5) and pipe (11). Secure hose (10) with hose clamps (9) (2 used).

8. Install hydraulic oil tank (5) and new O-ring (7), and connect hose (8).

: 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf·ft)

9. Connect hose (6) to hydraulic oil tank (5).

: 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

10. Add hydraulic oil to hydraulic oil tank (5). Hydraulic oil amount: 120 L (31.7 US gal.)

11. Install suction filter (4) to hydraulic oil tank (5).

12. Install cover (3) to hydraulic oil tank (5) with bolts (1) (6 used) and washers (2) (6 used).

: 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft)

6

9

10

9

11

5

7

8

W4GB-02-03-011

1

2

3

4

W2-5-7

5

W4GB-02-03-010

BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank

13. Connect wire harness (25) to hydraulic oil tank (5) with bolts (22) (8 used) and clamps (21) (8 used).

: 12 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft)

14. Connect the connectors of level sensor (24) and hydraulic oil temperature sensor (23).

15. Install the left and right side fenders.

: 17 mm : 50 N⋅m (5.1 kgf⋅m, 36 lbf·ft)

16. Install the hood. (Refer to W2-4-1.)

5

21, 22

24

23

25

21, 22

W4GB-02-03-017

W2-5-8

BODY (UPPERSTRUCTURE) / Pump Device

REMOVAL AND INSTALLATION OF PUMP DEVICE

Removal

1. Remove the cab with the cockpit attached. (Refer to REMOVAL AND INSTALLATION OF CAB in W2-1.)

CAUTION: Pump device weight:

108 kg (240 lb)

2. Remove sems bolts (1) (6 used) from hydraulic oil tank (4). Remove cover (2) and suction filter (3) from hydraulic oil tank (4). Drain hydraulic oil.

: 14 mm

3. Disconnect hoses (5) (2 used) from main pump (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 22 mm

Main Pump

Priority Valve

Regulator

Pilot Pump

Pump Delivery Pressure Switch

T4GB-01-02-009

1

2

3

4

W4GB-02-03-010

Control Valve

5

6

W2-6-1

W4GB-02-04-012

BODY (UPPERSTRUCTURE) / Pump Device

4. Disconnect hose (7) from main pump (6). Cap the open ends. Remove socket bolts (8) (4 used) from pipe (9). Disconnect pipe (9) from main pump (6).

: 32 mm, 36 mm : 10 mm

5. Disconnect hose (11) from main pump (6). Disconnect hose (12) from priority valve (10). Cap the open ends.

: 36 mm, 41 mm

6. Disconnect hose (13) from priority valve (10). Cap the open ends.

: 14 mm, 17 mm

Steering Valve

7

8

6

9

W4GB-02-04-019

6

10

11

12

W4GB-02-04-014

Steering Valve

10

W2-6-2

13

W4GB-02-04-015