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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.

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
E-mail: dc@hitachi-kenki.com

ADDITIONAL REFERENCES
Please refer to the other materials (operators
manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.

MANUAL COMPOSITION
This manual consists the Technical Manual and the
Workshop Manual.
Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, 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.

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

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.

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.

UNITS USED
SI Units (International System of Units) are used in

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

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

Quantity
Length
Volume

Weight
Force
Torque

To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm

Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft

A table for conversion from SI units to other system


units is shown below for reference purposees.

Quantity

Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375

Pressure
Power
Temperature
Velocity
Flow rate

IN-02

To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev

Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev

Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0

SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.

When you see these symbols on your machine or


in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.

001-E01A-0001

SA-688

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

To avoid confusing machine protection with personal


safety messages, a signal word IMPORTANT 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-1

SA-1223

SAFETY
FOLLOW SAFETY INSTRUCTIONS

Carefully read and follow all safety signs on the


machine and all safety messages in this manual.

Safety signs should be installed, maintained and


replaced when necessary.

If a safety sign or this 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 authorization. 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

SA-2

SA-003

SAFETY
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 attached 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, ambulance service, hospital, and fire department
posted near your telephone.

SA-437

004-E01A-0437

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 attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438

SA-3

SA-428

SAFETY
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as


earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

006-E01A-0434

SA-434

INSPECT 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 "RE-START INSPECTION" chapter in the operator's manual.

007-E01A-0435
SA-435

SA-4

SAFETY
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 locations.
Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decorations 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 extinguish 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

SA-5

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
SA-439

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 mis-operations.

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

SA-6

SA-462

SAFETY
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 position. Turn the key switch OFF to stop the engine.
Before leaving the machine, close all windows,
doors, and access covers and lock them up.

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 examine 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 securely 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 condition.
010-E01A-0237

SA-7

SA-237

SAFETY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.

Take extra care not to run over bystanders. Confirm the location of bystanders before moving,
swinging, 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. Coordinate 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.
SA-426
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 container, and store it in a cool, well-protected location.
Do not incinerate or puncture a starting fluid container.

036-E01A-0293-3

SA-8

SA-293

SAFETY
OPERATE
SEAT

ONLY

FROM

OPERATOR'S

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 operator'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

SA-444

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.
SA-032
S013-E01A-0032

SA-9

SAFETY
KEEP RIDERS OFF MACHINE

Riders on machine are subject to injury such as being 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

SA-379

PRECAUTIONS FOR OPERATIONS

Investigate the work site before starting operations.


Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard
hat, etc. when operating the machine.
Clear all persons and obstacles from area of operation and machine movement.
Always beware of the surroundings while operating. When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles.
When loading onto trucks, bring the bucket over
the truck beds from the rear side. Take care not to
swing the bucket over the cab or over any person.

M104-05-015

SA-10

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 conditions 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 becomes loose and slippery.
Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cautious with
machine movements.

SA-11

SA-380

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

SA-490

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-481

CONFIRM DIRECTION OF MACHINE TO


BE DRIVEN
Incorrect travel pedal/lever operation may result in
serious injury death.

Before driving the machine, confirm the position


of the undercarriage in relation to the operator's
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.

017-E01A-0491
SA-491

SA-12

SAFETY
DRIVE MACHINE SAFELY

Before driving the machine, always confirm that the


travel levers/pedals direction corresponds to the direction you wish to drive.

Be sure to detour around any obstructions.


Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don't allow personnel to stay around
the machine while traveling.

Driving on a slope may cause the machine to slip or


overturn, possibly resulting in serious injury or
death.

SA-657

Never attempt to ascend or descend 35 degrees


or steeper slopes.

Be sure to fasten the seat belt.


When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to
1.0 m (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.

SA-658

SA-441

SA-442

SA-13

SAFETY
DRIVE MACHINE SAFELY

Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.


If the direction must be changed, move the machine to level ground, then, change the direction
to ensure safe operation.
Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed.
If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control levers to neutral. Then, restart the engine.
Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
Use a signal person when moving, swinging or
operating the machine in congested areas. Coordinate hand signals before starting the machine.
Before moving machine, determine which way to
move travel pedals/levers for the direction you
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or
pushing the levers forward moves the machine
forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface
of the side frame to indicate the machine front
direction.
Select a travel route that is as flat as possible.
Steer the machine as straight as possible, making
small gradual changes in direction.
Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if necessary.

Travel Motor

M104-05-008

Arrow-Mark

SA-14

M178-03-001

SAFETY
Use wood plates in order not to damage the road

surface. Be careful of steering when operating on


asphalt roads in summer.
When crossing train tracks, use wood plates in
order not to damage them.
Do not make contact with electric wires or
bridges.
When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
Avoid operations that may damage the track and
undercarriage components.
During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.

SA-15

SA-011

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 machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch and the H/P mode
switch off.
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 pilot control shut-off lever to LOCK position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.

SA-391

SA-392
020-E02A-0493

SA-16

SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when

backing or swinging the upperstructure, the machine


may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:
Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN
OR OTHER SIGNAL TO WARN BYSTANDERS
BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
Learn the meanings of all flags, signs, and markings used on the job and confirm who has the
responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
Read and understand all operating instructions in
the operator's manual.
021-E01A-0494

SA-17

SA-383

SA-384

SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

A person may be hit severely by the swinging front


attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

Keep all persons clear from the area of operation


and machine movement.

Before operating the machine, set up barriers to


the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

022-E01A-0386
SA-386

NEVER POSITION BUCKET OVER ANYONE

Never lift, move, or swing bucket above anyone or a


truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

023-E01A-0487

SA-487

AVOID UNDERCUTTING

In order to retreat from the edge of an excavation if


the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

If the footing starts to collapse and if retreat is not


possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.

024-E01A-0488

SA-18

SA-488

SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:

Be extra careful before operating on a grade.


SA-012

Prepare machine operating area flat.


Keep the bucket low to the ground and close to
the machine.

Reduce operating speeds to avoid tipping or slipping.

Avoid changing direction when traveling on


grades.

NEVER attempt to travel across a grade steeper


than 15 degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging loads.
SA-440

Be careful when working on frozen ground.


Temperature increases will cause the ground to
become soft and make ground travel unstable.

025-E03B-0463

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur


causing serious injury or death.

026-E01A-0519

SA-489

SA-19

SAFETY
DIG WITH CAUTION

Accidental severing of underground cables or gas


lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.

Before digging check the location of cables, gas


lines, and water lines.

Keep the minimum distance required, by law, from


cables, gas lines, and water lines.

If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.
Contact your local "diggers hot line" if available in
your area, and/or the utility companies directly.
Have them mark all underground utilities.

SA-382

027-E01A-0382

OPERATE WITH CAUTION

If the front attachment or any other part of the machine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.

Take care to avoid hitting overhead obstacles with


the boom or arm.

SA-389
028-E01A-0389

SA-20

SAFETY
AVOID POWER LINES

Serious injury or death can result if the machine or


front attachments are not kept a safe distance from
electric lines.

When operating near an electric line, NEVER


move any part of the machine or load closer than
3 m plus twice the line insulator length.
Check and comply with any local regulations that
may apply.
Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
029-E01A-0381

SA-381

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 machine only after repairing them.
SA-1088

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 travel motors at the rear.
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-21

SA-014

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

SA-432

PARK MACHINE SAFELY


To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle switch and H/P mode switch OFF.
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.
Pull the pilot control shut-off lever to the LOCK
position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.

SA-390

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 machine.

Fill the fuel tank outdoors.


All fuels, most lubricants, and some coolants are
flammable.

Store flammable fluids well away from fire haz-

SA-018

ards.

Do not incinerate or puncture pressurized containers.

Do not store oily rags; they can ignite and burn


spontaneously.

Securely tighten the fuel and oil filler cap.


034-E01A-0496

SA-22

SA-019

SAFETY
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 machine to be transported.

Be sure to use a signal person.


Always follow the following precautions for loading or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight.
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the
travel mode switch.
5. Never load or unload the machine onto or off a
truck or trailer using the front attachment functions when driving up or down the ramp.
6. 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, and then try
loading again.
7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling
over it.
8. Place blocks in front of and behind the tracks.
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 in the operator's manual.

035-E07A-0454

SA-23

SA-395

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. Pull the pilot control shut-off lever to the LOCK
position.
10. Allow the engine to cool.

SA-028

500-E02C-0520

SA-527

SA-24

SAFETY
If a maintenance procedure must be performed

with the engine running, do not leave machine


unattended.
If the machine must be raised, maintain a 90 to
100 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the "MAINTENANCE" chapter of
this manual.
Keep all parts in good condition and properly installed.
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 making adjustments to electrical systems or before
performing welding on the machine.
Sufficiently illuminate the work site. Use a maintenance 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.

SA-037

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious


injury.

Before performing any work on the machine, attach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.

501-E01A-0287

T1J1-01-01-001

SA-25

SAFETY
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing 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 attachment, 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

SA-527

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

SA-026

SA-26

SAFETY
PREVENT PARTS FROM FLYING

Grease in the track adjuster is under high pressure.


Failure to follow the precautions below may result in
serious injury, blindness, or death.

Do not attempt to remove GREASE FITTING or


VALVE ASSEMBLY.

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


face away from valve.

Never attempt to disassemble the track adjuster.


Inadvertent disassembling of the track adjuster
may cause the parts such as a spring to fly off,
possibly resulting in severe personal injury or
death.
SA-344

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, and
then gradually loosen AIR RELEASE PLUG to
release pressure.

503-E01B-0344

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

SA-034

SA-27

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.

SA-039

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.

SA-225

505-E01B-0498

REPLACE
CALLY

RUBBER

HOSES

PERIODI-

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-28

SA-019

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.

SA-031

507-E03A-0499

SA-292

SA-044

SA-29

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.
SA-019

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, accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the machine 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.
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 repaired or replaced before operating the machine.
508-E02A-0393

SA-30

SAFETY
EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the following 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.

In an emergency, if the cab door or front window


cannot be opened, break the front or rear window
panes with the emergency evacuation hammer to
escape from the cab. Refer the explanation pages
on the Emergency Evacuation Method in the operator's manual.

SA-393

18-E02B-0393

SS-1510

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
SA-016

PRECAUTIONS
GRINDING

FOR

WELDING

AND

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-31

SA-818

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 fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

Do not weld or flame cut pipes or tubes that contain


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.
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-32

SA-029

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. Don't
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 operation.
Asbestos might be present in imitation parts. Use
only genuine Hitachi Parts.

SA-029

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 or start engine with
frozen battery.
There is fear of explosion. If battery electrolyte is
frozen, wait until it is liquefied completely in an
atmospheric temperature room.
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

SA-33

SA-032

SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.

Refer to the instructions described on the container 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-405

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

SA-34

SA-309

SAFETY
DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment 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.

SA-226

516-E01A-0226

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-35

SAFETY
(Blank)

SA-36

SECTION AND GROUP


CONTENTS

SECTION 1 GENERAL
Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank

WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE


Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Solenoid Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve Unit
Group 11 Engine

SECTION 3 UNDERCARRIAGE

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.

Group 1 Swing Bearing


Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track

SECTION 4 FRONT ATTACHMENT


Group 1 Front Attachment
Group 2 Cylinder
COPYRIGHT(C)2008
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved

SECTION 5 ENGINE
Group 1 General Information
Group 2 Engine

SECTION 1

GENERAL
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 of Parts................ W1-2-9

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

Group 4 Bleeding Air from Hydraulic Oil


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

1P1W-1-1

(Blank)

1P1W-1-2

GENERAL / Precautions for Disassembling and Assembling


PRECAUTIONS FOR
AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling

Clean the Machine

Precautions for Disassembling

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.

W1-1-1

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.

GENERAL / Precautions for Disassembling and Assembling


Precautions for Assembling

Bleeding Air from Hydraulic System

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.

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 hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to
the motor 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.

Bleeding Air from Travel Motor / Swing Motor


With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.

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, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
Reposition the front attachment to check hydraulic oil level.
Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W1-1-3

M1CC-07-002

GENERAL / Precautions for Disassembling and Assembling


Floating Seal Precautions
A

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. Apply oil to the
sliding surface (C) on seal ring (A).

W105-03-05-019

(2) Check the slide surface (C) on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for
deformation or hardening.

tears,

breaks,

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.

Correct

Incorrect

(2) Clean the floating seal and seal mounting


bores. Check the bore surface for scuffing or
scoring by touching the surface.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.

Correct

(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 the O-ring
seating.

W105-03-05-020

Incorrect

b
W110-03-05-004

a=b

W1-1-4

ab

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 wont 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

W1-1-5

W162-01-01-009

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.

Damaged Appearance

Broken Sewing Thread

W162-01-01-002

Scuffing

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.

W162-01-01-003

Fuzz
Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005

Broken Sewing
Thread

Scoring

Fuzz

Separation of
Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

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

GENERAL / Precautions for Disassembling and Assembling


(Blank)

W1-1-8

GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATIONS
No.

Descriptions

Engine cushion rubber mounting bolt

Engine bracket mounting bolt

3
4

Hydraulic oil tank mounting bolt


Fuel tank mounting bolt

ORS fittings for hydraulic hoses and piping

6
7

Pump mounting bolt


Control valve mounting bolt
Control valve bracket ZX70-3, 70LC-3, 70LCN-3
mounting bolt
ZX75US-3, 85US-3
Swing device mounting bolt
Swing motor mounting bolt
Battery mounting nut
Cab mounting nut
Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
Travel device mounting bolt
Travel reduction device cover mounting bolt
Sprocket mounting bolt
Upper roller mounting bolt
Lower roller mounting bolt
ZX70-3, 70LCN-3
Track shoe bolt
ZX70LC-3, 75US-3, 85US-3

8
9
10
11
12
13
14
15
16
17
18

19

Cover mounting bolt

20

Flexible master coupling of low pressure piping


Coupling of low pressure piping
Suction hose
T-bolt clamp of low
In-take air duct
pressure piping
Radiator hose
Side-cutter mounting bolt

21

22

Bolt Dia
mm
14
16
10
12
16
16

18
14
12
14
16
14
10
16
16
16
16
14
16
14
14
14
14
6
18
10
12
8

20

NOTE: 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts
to reduce friction coefficient of them.
2. Make sure bolt and nut threads are
clean before installing.

W1-2-1

Qty
2
2
8
8
4
4

2
3
4
4
10
8
4
4
24
24
20
8
24
2
40
304
320

4
4
2
1
1
6

Wrench
Torque
Size
mm
Nm
(kgfm)
(lbfft)
22
180
(18.4)
(133)
24
270
(27.5)
(200)
17
50
(5.1)
(37)
19
90
(9.2)
(66)
24
270
(27.5)
(200)
24
210
(21.5)
(155)
17
2.5
(2)
(15)
19
29.5
(3)
(22)
22
39
(4)
(29)
27
93
(9.5)
(69)
32
137
(14)
(101)
36
175
(18)
(129)
41
205
(21)
(151)
27
300
(30.5)
(220)
22
180
(18.4)
(133)
19
90
(9.2)
(66)
22
140
(14.3)
(103)
24
210
(21.5)
(155)
12
175
(18)
(129)
17
20
(2.0)
(15.0)
24
210
(21.5)
(155)
24
210
(21.5)
(155)
24
270
(27.5)
(200)
24
300
(31)
(220)
22
140
(14.3)
(103)
24
270
(27.5)
(200)
22
140
(14.3)
(103)
22
245
(25)
(180)
22
245
(25)
(180)
22
245
(25)
(180)
(7.4)
(1)
10
10
(15)
(2)
20
13
(37)
(5.1)
50
17
(66)
(9.2)
90
19
13
10.3 to 12.4 (1.05 to 1.26) (7.6 to 9.1)
9.5
4.4
(0.45)
(3.3)
11
10
(1.0)
(7.4)
9.5
7.3
(0.74)
(5.4)
9.5
7.3
(0.74)
(5.4)
30
540
(55)
(400)

GENERAL / Tightening
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or components.

Bolt Dia.

Wrench
Size

Hexagon
Wrench
Size

SA-040

M552-07-091

M552-07-092

M552-07-090

Socket Bolt
Nm
M6

10

(kgfm)

(lbfft)

Nm

(kgfm)

(lbfft)

Nm
3.3 to 4.2

(kgfm)

(lbfft)

(0.3 to 0.4) (2.4 to 3.0)

M8

13

30

(3.0)

(21.5)

20

(2.0)

(14.5)

10

(1.0)

(7.2)

M10

17

65

(6.5)

(47)

50

(5.0)

(36)

20

(2.0)

(14.5)

M12

19

10

110

(11)

(80)

90

(9.0)

(65)

35

(3.5)

(25.5)

M14

22

12

180

(18)

(130)

140

(14)

(101)

55

(5.5)

(40)

M16

24

14

270

(27)

(195)

210

(21)

(152)

80

(8.0)

(58)

M18

27

14

400

(40)

(290)

300

(30)

(215)

120

(12)

(87)

M20

30

17

550

(55)

(400)

400

(40)

(290)

170

(17)

(123)

M22

32

750

(75)

(540)

550

(55)

(400)

220

(22)

(159)

M24

36

950

(95)

(690)

700

(70)

(510)

280

(28)

(205)

M27

41

1400

(140)

(1010)

1050

(105)

(760)

400

(40)

(290)

M30

46

1950

(195)

(1410)

1450

(145)

(1050)

550

(55)

(400)

M33

50

2600

(260)

(1880)

1950

(195)

(1410)

750

(75)

(540)

M36

55

3200

(320)

(2310)

2450

(245)

(1770)

950

(95)

(690)

W1-2-2

GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lubricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific application.
5. Make sure that nut and bolt
threads are clean before installing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately

Tighten diagonally
1

1st to 4th

Tighten from center and diagonally


12

14

13

10

11

4
2
2nd to 3rd

W105-01-01-003

W1-2-3

GENERAL / Tightening
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect
sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tightening of one bolt fully before
tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

Incorrect

W105-01-01-016

Correct

Do not bend it round

Bend along edge sharply

Correct

Nut and Bolt Locking

W105-01-01-008

Incorrect

Incorrect

Correct

Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while loosening.
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.

Bend along edge sharply


W105-01-01-009

Correct

Correct

Correct

Incorrect

Loosen

Incorrect

Tighten

W105-01-01-010

W1-2-4

GENERAL / Tightening
PIPING JOINT
1

IMPORTANT: The torques given in the chart are


for general use only.
Do not use these torques if a different torque is given for a specific application.
M202-07-051

Union Joint

Joint Body

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.
37

IMPORTANT: 1. Do not over-tighten nut (3). Excessive 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
30 male

37 female

30

Male Union Joint

Female Union Joint


W105-01-01-017

Wrench Size
mm
Union Nut
17
19
22
27
32
36
41
17
19
22
27
32
36
41

Wrench Size
mm
Hose Fittings
17
19
22
27
32
36
41
14
17
19
22
27
32
36

Tightening Torque
Nm (kgfm, lbfft)
24.5 (2.5, 18)
29.5 (3.0, 21.5)
39 (4.0, 28.5)
93 (9.5, 69)
137 (14.0, 101)
175 (18.0, 129)
205 (21.0, 151)
24.5 (2.5, 18)
29.5 (3.0, 21.5)
39 (4.0, 28.5)
93 (9.5, 69)
137 (14.0, 101)
175 (18.0, 129)
205 (21.0, 151)

NOTE: Tightening torque of 37 male coupling without union is similar


to tightening torque of 37 female.

W1-2-5

GENERAL / Tightening
O-ring Seal Joint

O-ring (6) seats against the end face of adapter (7) to


seal pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with
a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly
in O-ring groove (e). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring
groove (8) or sealing surface
(10).
Damage to O-ring (6) will cause
oil leakage.
4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one
and check that O-ring (6) is correctly seated in place, tighten nut
(9).

Wrench Size
mm
Union Nut
19
22
27
32
36
41
46

W1-2-6

Wrench Size
mm
Hose Fittings
17
19
22
27
30, 32
36
41

Hose Fittings
M104-07-033

Tightening Torque
Nm (kgfm, lbfft)
29.5 (3.0, 21.5)
69 (7.0, 51)
93 (9.5, 69)
137 (14.0, 101)
175 (18.0, 129)
205 (21.0, 151)
205 (21.0, 151)

GENERAL / Tightening
Screw-In Connection
PT

Depending on types of screw and sealing, different


types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.

30

Male Tapered Thread

PF

Male Straight Thread

W105-01-01-018

Wrench Size
mm
Hose Fittings
19
22
27
36
41
50
60

Male Tapered Thread


Tightening Torque
Nm (kgfm, lbfft)
FC material
SS material
14.5 (1.5, 10.5)
34 (3.5, 25)
29.5 (3.0, 21.5)
49 (5.0, 36)
49 (5.0, 36)
93 (9.5, 69)
69 (7.0, 51)
157 (16, 116)
108 (11, 80)
205 (21, 151)
157 (16, 116)
320 (33, 235)
195 (20, 144)

Seal Tape Application


Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks between threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.

Internal Thread

External Thread

Clearance

Application Procedure

W105-01-01-019

Confirm that the thread surface is clean and, free of


dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque


Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
T-Bolt Type Band Clamp:
4.4 Nm (0.45 kgfm, 3.25 lbfft )
Worm Gear Type Band Clamp:
5.9 to 6.9 Nm (0.6 to 0.7 kgm, 4.3 to 5.1 lbfft)

W1-2-7

M114-07-041

T-Bolt Type

Worm Gear Type

M114-07-043

M114-07-042

GENERAL / Tightening
Connecting Hose
Incorrect

Correct

CAUTION: When replacing hoses, be sure to


use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.
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 Print
marks on hoses when installing to prevent
hose from being kinked.

W105-01-01-011

Incorrect

Correct

Rubbing Against
Each Other

If hoses rub against each other, wear to the


hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other.
Take care so that hoses do not come into
contact with moving parts or sharp objects.

W105-01-01-012

Incorrect

Correct

Clamp

Clamp

Rubbing Against
Each Other
W105-01-01-013

Incorrect

Rubbing Against
Each Other

Correct

Clamp
W105-01-01-014

W1-2-8

GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless of the interval.
Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replacement.
Periodic Replacement Parts
Fuel hose (Fuel tank to Supply pump)
Engine
Oil filter hose (Engine to oil filter)
Heater hose (Heater to engine)
Pump suction hose
Pump delivery hose
Base Machine
Swing hose
Hydraulic
Travel high pressure hose
System
Boom cylinder line hose
Front
Arm cylinder line hose
Attachment
Bucket cylinder line hose
Seat belt
Clear hatch (If equipped)
NOTE: Replace seals, such as O-rings and gaskets, when replacing hoses.

W1-2-9

Replacement Intervals
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 3 years
Every 5 years

GENERAL / Tightening
(Blank)

W1-2-10

GENERAL / Painting
PAINTING
Painting Specification
Surfaces to Be Painted
Painting Colour
Main surface of upperstructure (except YR-01[TAXI yellow]
cab)
Main frame
HG Beige Deep
Front attachment
YR-01 [TAXI yellow]
Track (including swing bearing)
PB5-01 [SP-424 Dark Gray]
Floor plate
H4-224 [Beige]

Final Painted Colour


Inside and outside surface of cab
Shaded area on cab[Left side only]
Right window guards, U-Bolt

Suspension lifter
Lever

(Travel, Pilot shut-off, foot rest)


Engine cover
Cover
Oil tank under cover
Handrail on upperstracture right side
Mirror stay
Camera cover
Air conditioner bracket
Controller cover
Under cover
Boom foot pin
Standard pipe clamp
Grease maintenance plate

HG Beige Deep
Shining Silver
[KANSAI PAINT LF-113-23DB (Charcoal series black, half
glossy)]
[TN2D(Black)]
High Grade Black
YR-01 [TAXI yellow]
HG Beige Deep
HG Beige Deep
HG Beige Deep
High Grade Black
HG Beige Deep
Cation electric coating only
[TN2D (Black)]
HG Beige Deep
HG Beige Deep
HG Beige Deep
HG Beige Deep

W1-3-1

GENERAL / Painting
ZX70-3

Handrail on Upper
structure Right Side

Fuel tank front cover

Engine Cover
Camera Cover

W1P1-01-03-001
W1P1-01-03-002

ZX75US-3
Control valve Cover

Engine Cover

Mirror Stay

Camera Cover

W1P1-01-03-003

W1-3-2

W1P1-01-03-004

GENERAL / Painting
ZX70-3

ZX75US-3
Paint All Circumference in
the Hinge Swing Position
[Shining Silver]

Shaded Area
[Shining Silver]

Shaded Area
[Shining Silver]

Paint All Circumference in


the Hinge Swing Position
[Shining Silver]

Align with the Panel


[Shining Silver]

(Door)

Panel

(Door) Rear Panel

10
Painted Range on Door
[Shining Silver]
Section B

W1V1-01-03-004

W1-3-3

GENERAL / Painting
(Blank)

W1-3-4

GENERAL / Bleeding Air from Hydraulic Oil Tank


BLEED AIR FROM HYDRAULIC OIL TANK
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.

Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.

M1CC-07-002

ZX70-3

2
ZX75US-3

W1P1-01-04-001

2. Stop the engine. Press the cap (1) to release any


remaining pressure in the hydraulic oil tank (2).
3. Remove hydraulic oil tank (2) cap (1).
: 5 mm
: 32.5 Nm (3.3 kg fm, 24 lbfft)

4. Connect a vacuum pump (3) with the hole


removed cap (1) to maintain negative pressure in
the hydraulic oil tank (2).
NOTE: Be sure to run the vacuum pump (3)
continuously while working.

WBAT-06-01-044

Vacuum Pump
Hose

Adapter

2
W562-02-03-008

W1-4-1

GENERAL / Bleeding Air from Hydraulic Oil Tank


(Blank)

W1-4-2

MEMO
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SECTION 2

UPPERSTRUCTURE
CONTENTS
Group 1 Cab

Group 6 Swing Device

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


Dimensions of Cab Glass.......................W2-1-11

Group 2 Counterweight
Removal and Installation of
Counterweight (ZX70-3) ........................ W2-2-1
Removal and Installation of
Counterweight (ZX75US-3) ................... W2-2-3

Group 3 Main Frame


Removal and Installation of
Main Frame (ZX70-3) ............................ W2-3-1
Removal and Installation of
Main Frame (ZX75US-3) ....................... W2-3-5

Group 4 Pump Device


Removal and Installation of
Pump Device (ZX70-3) .......................... W2-4-1
Removal and Installation of
Pump Device (ZX75US-3) ................... W2-4-13
Disassembly of Main Pump 3 ................ W2-4-26
Assembly of Main Pump 3..................... W2-4-32
Disassembly of Main Pumps 1 and 2 .... W2-4-38
Assembly of Main Pumps 1 and 2 ......... W2-4-46
Structure of Gear Pump Assembly ........ W2-4-54
Maintenance Standard .......................... W2-4-55

Group 5 Control Valve


Removal and Installation of
Control Valve (ZX70-3).......................... W2-5-1
Removal and Installation of
Control Valve (ZX75US-3) ..................... W2-5-9
Disassembly of Control Valve................ W2-5-16
Assembly of Control Valve .................... W2-5-26

Removal and Installation of


Swing Device (ZX70-3).......................... W2-6-1
Removal and Installation of
Swing Device (ZX75US-3) ..................... W2-6-3
Disassembly of Swing Device.................. W2-6-6
Assembly of Swing Device .................... W2-6-12
Disassembly of Swing Motor ............... W2-6-16
Assembly of Swing Motor ...................... W2-6-20
Disassembly and Assembly of
Valve Block .......................................... W2-6-24
Maintenance Standard........................... W2-6-26

Group 7 Pilot Valve


Removal and Installation of
Pilot Valve.............................................. W2-7-1
Disassembly of Left and
Right Pilot Valves................................. W2-7-20
Assembly of Left and
Right Pilot Valves................................. W2-7-24
Disassembly of Travel Pilot Valve.......... W2-7-28
Assembly of Travel Pilot Valve............... W2-7-32
Disassembly of Blade Pilot Valve .......... W2-7-38
Assembly of Blade Pilot Valve ............... W2-7-40

Group 8 Pilot Shut-Off Solenoid Valve


Removal and Installation of
Pilot Shut-Off Solenoid Valve
(ZX70-3) ................................................ W2-8-1
Removal and Installation of
Pilot Shut-Off Solenoid Valve
(ZX75US-3) ........................................... W2-8-3
Structure of
Pilot Shut-Off Solenoid Valve................. W2-8-5

1P1W-2-1

Group 9 Shockless Valve


Removal and Installation of
Shockless Valve (ZX70-3) ..................... W2-9-1
Removal and Installation of
Shockless Valve (ZX75US-3) ................ W2-9-3
Structure of Shockless Valve................... W2-9-6

Group 10 Solenoid Valve Unit


Removal and Installation of
Solenoid Valve Unit (ZX70-3) .............. W2-10-1
Removal and Installation of
Solenoid Valve Unit (ZX75US-3) ......... W2-10-3
Structure of 2-Spool
Solenoid Valve Unit ............................. W2-10-5

Group 11 Engine
Removal and Installation of Engine
(ZX70-3)...............................................W2-11-1
Removal and Installation of Engine
(ZX75US-3) ........................................W2-11-17

1P1W-2-2

UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB
Removal
CAUTION: Seat (1) weight: 40 kg (90 lb)
1. Remove bolts (3) (2 used) from seat belt (2).
Remove seat belt (2) from bracket (5).
: 16 mm

3
W1JB-02-01-008

2. Remove socket bolts (4) (4 used) from seat (1).


Remove seat (1) from bracket (5).
: 6 mm

W1JB-02-07-007

3. Remove mat (7) from the inside of cab (6).

W1P1-02-08-001

W2-1-1

UPPERSTRUCTURE / Cab
4. Remove screw (9) from cup holder (8). Remove
cup holder (8) from cover (10). Remove cap (11)
from cover (10). Remove bolt (12) from cover (10).
Remove cover (10) from cab (6).

11, 12

5. Remove screw (17) from duct (16). Remove duct


(16) from cab (6).

10

W1V1-02-01-011

6
13

6. Remove screws (15) (2 used) and screw (13)


from duct (14). Remove duct (14) from cab (6).

14
15

17

7. Remove screws (19) (4 used) from cover (20).


Remove cover (20) from covers (18, 21).

16

Air Conditioner Unit

W1V1-02-01-012

18
19

20

21
W1V1-02-01-013

W2-1-2

UPPERSTRUCTURE / Cab
Only ZX75US-3
8. Remove clip band (26) from cover
Disconnect harness (25) from cover (24).

22

23

24

25

(24).
26

9. Remove sems bolts (23) (4 used). Remove cover


(24) from support (22) and main frame (27).
: 17 mm

27

W1P1-02-06-003

Only ZX75US-3
10. Remove sems bolts (28) (5 used). Remove cover
(29) from support (22) and cab (6).
: 17 mm

22

28

29

W1P1-02-01-004

11. Disconnect connectors (30) (4 used) from cab (6).


NOTE: The quantity of the connectors differs
depending on the front attachment
specifications.

30

W1P1-02-01-003

12. Remove nuts (32) (4 used) and washers (31) (4


used) from dampers (33) (4 used) of inside and
outside in cab (6).
: 24 mm

32
31
32
31

32
31

Cab Floor

32
31

33

Main Frame

W1P1-02-01-005

W2-1-3

UPPERSTRUCTURE / Cab
13. Open cover (34).

ZX70-3

34

35

14. Disconnect hose (36) from washer tank (35). Cap


the open ends.
36

M1P1-07-037

ZX75US-3

34

35

36

M1P1-07-001

15. Remove sems bolts (37) (4 used), socket bolts


(38) (5 used), and socket bolt (40) from the floor
part in the cab. Remove socket bolts (39) (2 used)
from the bottom of the rear in the cab.
: 17 mm
: 8 mm

Floor

37

38

39
40

16. Remove sems bolts (41) (ZX70-3: 4 used,


ZX75US-3: 6 used). Remove cover (42) from
main frame (27).
: 17 mm

41

W1V1-02-01-018

42

27

W1P1-02-01-001

W2-1-4

UPPERSTRUCTURE / Cab
17. Remove anchor bolt (44) and washer (43) from
main frame (27).
: 32 mm

43

27

44

W1P1-02-01-002

CAUTION: Cab (6) weight: 310 kg (690 lb)


IMPORTANT: Before hoisting cab (6), check if the
harness and the connector are
disconnected, and the duct is
removed.
18. Attach a nylon sling onto the lifting holes (4 used)
on the cab (6) top. Hoist and remove cab (6) from
main frame (27).

W1J7-02-01-001

W2-1-5

UPPERSTRUCTURE / Cab
Installation
CAUTION: Cab (6) weight: 310 kg (690 lb)
1. Attach a nylon sling onto the lifting holes (4 used)
on the cab (6) top. Hoist and align cab (6) with the
mounting holes on main frame (27).

W1J7-02-01-001

2. Install cab (6) to dampers (33) (4 used) with


washers (31) (4 used) and nuts (32) (4 used).
: 24 mm
: 210 Nm (21 kgfm, 155 lbfft)

32

32

31
32

Cab Floor

31

32

31

31

33

27

W1P1-02-01-005

3. Install cab (6) to the floor with sems bolts (37) (4


used), socket bolts (38) (5 used), and socket bolt
(40). Install the rear of cab (6) with socket bolts
(39) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

Floor

37

38

39
40

W2-1-6

W1V1-02-01-018

UPPERSTRUCTURE / Cab
4. Secure the cab to main frame (27) with washer
(43) and anchor bolt (44).
: 32 mm
: 550 Nm (55 kgfm, 410 lbfft)

43

27

44

W1P1-02-01-002

41

5. Install cover (42) to main frame (27) with sems


bolts (41) (ZX70-3: 4 used, ZX75US-3: 6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

42

27

6. Connect hose (36) to washer tank (35).

W1P1-02-01-001

ZX70-3

34

35

36

M1P1-07-037

ZX75US-3

34

35

36

M1P1-07-001

W2-1-7

UPPERSTRUCTURE / Cab
6

7. Connect connectors (30) (4 used) to cab (6).

30

W1P1-02-01-003

Only ZX75US-3
8. Install cover (29) to support (22) and cab (6) with
sems bolts (28) (5 used).
: 17 mm
: 50 Nm (5 kgfm,37 lbfft)

22

28

29

Only ZX75US-3
9. Install cover (24) to support (22) and main frame
(27) with sems bolts (23) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
10. Secure harness (25) to cover (24) with clip band
(26).

22

23

24

W1P1-02-01-004

25
26

27

W1P1-02-06-003

W2-1-8

UPPERSTRUCTURE / Cab
11. Install cover (20) to covers (18, 21) with screws
(19) (4 used).
18
19

20

21
W1V1-02-01-013

12. Install duct (14) to cab (6) with screws (15) (2


used) and screw (13).

13
14
15

17

16

13. Install cup holder (8) to cover (10) in the right side
of cab (6) with screw (9).

Air Conditioner Unit

W1V1-02-01-012

14. Install cover (10) to cab (6) with bolt (12). Install
cap (11) to cover (10).

11, 12

W2-1-9

10

W1V1-02-01-011

UPPERSTRUCTURE / Cab
6

15. Install mat (7) to the floor in cab (6).

W1P1-02-08-001

CAUTION: Seat (1) weight: 40 kg (90 lb)


16. Install seat (1) to bracket (5) with socket bolts (4)
(4 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

W1JB-02-07-007

17. Install seat belt (2) to bracket (5) with bolts (3) (2
used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)

3
W1JB-02-01-008

W2-1-10

UPPERSTRUCTURE / Cab
DIMENSIONS OF CAB GLASS
Black Ceramic
Coating Range

115

NOTE: Unit: mm (1 mm=0.039 in)


70

21
60

C0.5

107

2-R50
2-R250

2-R50

2-R20
2-R10

2-R127

70

Black Ceramic
Coating Surface

106.6

C0.5

1081

W1JB-02-01-013

R50

(4 mm)

R2975

R800

Section A

28

R75

Black
Ceramic
Coating
Surface

R120
R40

2R-5

271

50

268

20 70

16.5

W1JB-02-01-011

21
214

847

21

Black Ceramic
Coating Range

R1075

372.9

(4 mm)
22

50

W1JB-02-01-009

54.1

25

W1JB-02-01-012

84

25
865

C0.5
R2
W1JB-02-01-014

C0.5

W1JB-02-01-019

Black Ceramic
Coating Surface

Section B

Section C

W2-1-11

UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)

242

644.5

370

644.5

213

3-R4

(4 mm)

2-12.2 +0.5
-0
40

R2800
139.7

91

35
248.2

50

R150

50
430.6

50

50

W1V1-02-01-010

4-R4
50

50
181.4

383

W1V1-02-01-005
W1JB-02-01-016

W1V1-02-01-006

660.8
633
506.5
50

195.5
272

27.5
2-R4

R215
R125

R800

R40 R320
R10

R100

327.5

335

R1200
R80

R310
17

R25

322.5

R150

30

R600

327.5

447

406.5

R2600

64.5

109

2-210.5

500

242

R10
80
R1200

R60
W1V1-02-01-007

W2-1-12

UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
Black Ceramic
Coating Range

30

25

2-R5

560

30

30
R75

R75
60

35

200

2-R10
848

W1V1-02-01-008

W1V1-02-01-006

567.5

Black Ceramic
Coating Range

496
59.5

R20

R25

87.7

R25
666.5

C0.5

138

100
85

75.5

150
3-R4
R25

R4139.5

19.5

W1JB-02-01-013

Section A

1099
1145.5

C0.5

1008

Black Ceramic
Coating Surface

(1127.3)

6.5

R150

83
R100
R135
R50
65

C0.5

W1JB-02-01-014

R250

109
105

C0.5

228

R1500

R60
R20
316

R70

102

483
76
140
195

Section B

447
W1V1-02-01-009

W2-1-13

UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
C1

C1
Black Ceramic
Coating Surface

W1JB-02-01-013

Section A

W1JB-02-01-009

1646.47
1599.44

Black Ceramic
Coating Range

187
80

50
106

2-R25

50

R75

R20

R30

90

R30

R50
158

R2875

R575
R125
R1040

R10

R50

R30 R50
28

R1525
R30

R55

393
400
807.65
963.7

W2-1-14

1636.3

R3025

1496.7

40

A
1205

R2940

(5 mm)

R25

873.14

50

1230

R30

150 145

696.73

R300

R2145

900

R20

313.6

W1JB-02-01-020

UPPERSTRUCTURE / Cab
Removal of Cab Glass

Right-Hand Glass

Procedures to Remove Right-Hand Glass, Rear


Left-Hand Glass, Lower Door Glass and Rear Glass
CAUTION: When removing the broken or
cracked glass, the glass shards may cause
serious injury.
Before removing, use the gummed tape or
something like in order to paste the broken or
cracked glass and reinforce them. Remove
the glass pieces away.

W1JB-02-01-009

1. Remove the resin panel, the garnish and the


spacer around the glass.

Rear Glass
Rear
Left-Hand
Glass

Garnish

Garnish

Lower Door Glass

2. Prick a hole in the adhesive by using an awl (or a


cutter knife).

Resin Panel

W1JB-02-01-010

Cab
Cab Glass
Awl

Adhesive

3. Pass a piano wire (or a metal wire) through the


hole.

W1SE-02-01-033

Piano Wire
(or Metal Wire)

W1SE-02-01-034

W2-1-15

UPPERSTRUCTURE / Cab
4. Wind the both ends of the piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab.
NOTE: Cut off the middle of adhesive between
glass and cab.
The piano wire is easily broken if a part of
the piano wire turns hot. Change the
position and cut the adhesive.

Glass (Cab Outside)

Cab

Cab Glass

Adhesive
(Cab Inside)
W1SE-02-01-035

W2-1-16

UPPERSTRUCTURE / Cab
Installation of Cab Glass

Right-Hand Glass

Procedures to Install Right-Hand Glass, Rear


Left-Hand Glass, Lower Door Glass and Rear Glass
1. Cut off residual adhesive at the cab side to make
1 to 2 mm (0.04 to 0.08 in) deep all around by
using a cutter knife.
NOTE: Do not damage the cab paint.

W1JB-02-01-009

Rear Glass

Lower Door
Glass

Rear Left-Hand
Glass

W1JB-02-01-010

Cab

2. Clean the cutting edge of adhesive at cab side by


using white spirit.

Cutter Knife

Cut off adhesive by 1 to 2 mm


(0.04 to 0.08 in) deep.
W1SE-02-01-036

IMPORTANT: Primer should be shaken for about 1


minute and mix thoroughly before
opening the cap.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180
days (or 2 hours with the cap off).
3. Apply Primer for paint (Sika Aktivator DM-1) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
NOTE: The painting primer should be applied
evenly in order to leave no blemishes.

W2-1-17

Cab

Apply Primer by
using a brush.
Cutting Edge of
Adhesive at Cab
Side
W1SE-02-01-038

UPPERSTRUCTURE / Cab
4. Clean the mating edge of the new glass by using
clean rag and ethyl alcohol.
IMPORTANT: Primer (Sika Primer 206G+P) should
be shaken for about 1 minute and
mix thoroughly before opening the
cap.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer 206G+P) to
the cutting edge of adhesive at cab side by using
a brush. Wait for about 15 minutes in order to let it
dry by itself.
(As for the position to apply Primer, refer to
W2-1-17.)

11. Raise the glass by using sucker lifter 4355282


(refer to W2-1-20), and adhere it to the cab within
5 minutes.
NOTE: Install the glass while aligning the spacer
position on the glass. Remove all adhesive
except the mounting surface, before
solidifying by using white spirit.
12. Secure the glass by using the gummed tape until
the adhesive becomes solid in order to prevent
them from being mispositioned or coming off.
NOTE: Time for adhesive (Sika Tack-Drive) to
become solid: 8 hours (just for reference)

6. Install the spacer with facing to the glass surface


by using the instant adhesive.
(As for the positions to install spacers A, B, C and
a dam rubber, refer to W2-1-20.)
7. Cut off the nozzle of adhesive cartridge (Sika
Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-20.)
8. Remove the seal of the cartridge end. Install the
V-shaped nozzle.
9. Install the cartridge to the manual coking gun.
10. Evenly apply adhesive to the old adhesive left at
cab side.
(As for the position to apply adhesive, refer to
W2-1-20.)

W2-1-18

UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
Right-Hand Glass

Rear Glass
250

350

300

500
100

200
200

500

200
200

200

200

250

300

W1JB-02-01-029

200
200
100

100

W1JB-02-01-030

Rear Left-Hand Glass


150 200

Lower Door Glass


200

500

200

W1JB-02-01-035

W2-1-19

W1JB-02-01-038

UPPERSTRUCTURE / Cab
NOTE: Unit: mm
(1 mm=0.039 in)
Spacer A

Spacer C

Spacer B

20

20

6
4

4
6

Two-Side
Adhesive Tape

20

R0.5

R5

84

R8

R0.5

8
12

Two-Side
Adhesive Tape

10.5

R0.5

75

R10

78

10.5
W1JB-02-01-023

W1JB-02-01-022

W1JB-02-01-024

Dam Rubber
30

6.4
6
W1JB-02-01-025

Lower Door Grass


Rear Left-Hand Glass

Right-Hand Glass

Suction Lifter

Spacer A
Rubber

Dam
Rubber
Spacer A

Spacer A
Spacer B

Spacer B
Dam
Rubber

W1JB-02-01-039

Spacer B

Rear Glass

Spacer C

W1JB-02-01-027
W1JB-02-01-026

W1JB-02-01-042

8 to 9 mm

13 to 15 mm

Adhesive
Cut nozzle
end into
V-shaped.

W1SE-02-01-027

Apply adhesive
evenly.

Remove
the seal.

12
W1JB-02-01-031

Adhesive
Cartridge

W1SE-02-01-028

W2-1-20

W1SE-02-01-043

Panel

UPPERSTRUCTURE / Cab
13. The required amount (just for reference) of adhesive and primer

Upper Front Glass


Lower Door Glass
Rear Left-Hand Glass
Rear Right-Hand Glass
Rear Glass

Adhesive
Sika Tack-Drive
310 ml Cartridge
310 ml
150 ml
250 ml
100 ml
210 ml

Painted Surface or
Adhesive Surface
Primer
Sika Aktivator DM-1
250 ml Can
0.75 ml
0.5 ml
0.65 ml
1 ml
0.5 ml

W2-1-21

Glass Surface
Primer
Sika Primer 206G+P
30 ml Bottle
0.67 ml
0.45 ml
0.6 ml
0.9 ml
0.45 ml

UPPERSTRUCTURE / Cab
Installation of Upper Door Glass
1. Before installing the glass, remove the garnish
around the sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.

Sash
Assembly

Garnish

2. Install glass A and glass B into the sash grooves.


3. Install the sash assembly, which the glass is
installed on, onto the door from the outside of the
cab. Secure the sash assembly at the inside of
the cab by using the garnish.

W2-1-22

Glass A

Glass B
W1JB-02-01-010

UPPERSTRUCTURE / Cab
Installation of Upper Front Glass

Adhere the glass in the same method as


right-hand glass.

1. Stick seal (1) to the lower side of the front upper


glass by using Cemedine Super X.
Stick and secure both right and left ends (the
thicker part) of seal (1) to the glass by using
Cemedine Super X.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.
NOTE: Cemedine Super X Black No.8008
Glue-state adhesive, tubed
IMPORTANT: The
upper
front
glass
is
arched-fringed. When replacing the
glass, contact with the nearest
HITACHI Office and replace it as an
assembly.

W1JB-02-01-034

Cemedine Super X
Seal here.

Upper
Glass

Cemedine Super X

Seal (1)
Lower
Glass
W1JB-02-01-032

W2-1-23

Upper
Glass

Seal (1)
Lower
Glass
W1JB-02-01-033

UPPERSTRUCTURE / Cab
(Blank)

W2-1-24

UPPERSTRUCTURE / Counterweight
REMOVAL
AND
INSTALLATION
COUNTERWEIGHT (ZX70-3)

OF

Removal
1. Open engine cover (1).

W1P1-02-02-001

2. Secure engine cover (1) with stopper (2).

W1P1-02-04-003

3. Remove caps (3) (2 used) from counterweight (4).

CAUTION: Counterweight (4) weight: 750 kg


(1660 lb)
4. Install Freno-Linkbolts (A-20: M20, Pitch 2.5
mm) (2 used) to counterweight (4). Attach a wire
rope onto the Freno-Linkbolts (2 used). Hoist and
hold counterweight (4).

W1P1-02-02-002

5. Remove bolts (6) (4 used) and washers (7) (4


used)
from
counterweight
(4).
Raise
counterweight (4) from main frame (5) a little.
Slide and remove counterweight (4) backward.
: 30 mm

6, 7

W1P1-02-02-003

W2-2-1

UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight (4) weight: 750 kg
(1660 lb)

6, 7

1. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)


(2 used) to counterweight (4). Attach a wire rope
onto the Freno-Linkbolt. Hoist and align
counterweight (4) with the mounting hole of main
frame (5).

2. Install counterweight (4) to main frame (5) with


bolts (6) (4 used) and washers (7) (4 used).
: 30 mm
: 550 Nm (55 kgfm, 410 lbfft)

W1P1-02-02-003

3. Remove the wire rope and the Freno-Linkbolts (2


used) from counterweight (4). Install caps (3) (2
used) to counterweight (4).

W1P1-02-02-002

4. Remove stopper (2) from engine cover (1). Shut


engine cover (1).

W1P1-02-04-003

W1P1-02-02-001

W2-2-2

UPPERSTRUCTURE / Counterweight
REMOVAL
AND
INSTALLATION
COUNTERWEIGHT (ZX75US-3)

OF

Removal
1. Open engine cover (2) and side covers (1) (2
used).

WBAT-06-01-019

2
3

CAUTION: Engine cover (2) weight: 22 kg (50


lb)
2. Attach a nylon sling onto engine cover (2). Hoist
and hold engine cover (2).

WBAT-06-01-020

3. Remove split pin (5) and washer (6) from the pin
part of support (3). Remove cylinder (4) from
support (3).

WBAT-06-01-021

4. Remove split pin (8) and washer (7) from stopper


(9). Remove stopper (9) from engine cover (2).
8

W2-2-3

WBAT-06-01-022

UPPERSTRUCTURE / Counterweight
CAUTION: Engine cover (2) weight: 25 kg (60
lb)

10

2
3

5. Remove sems bolts (10) (4 used). Remove


engine cover (2) from support (3).
: 17 mm

WBAT-06-01-020

6. Disconnect hoses (11) (2 used) from reserve tank


(14). Cap the open ends.

11

12

13

7. Remove sems bolts (12) (2 used). Remove the


cover (15) assembly from bracket (13).
: 13 mm

11
14
12

15

8. Remove caps (16) (2 used) from counterweight


(17).

W1P1-02-02-004

16

CAUTION: Counterweight (17) weight: 1380


kg (3050 lb)
9. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)
(2 used) to counterweight (17). Attach a wire rope
onto the Freno-Linkbolts (2 used). Hoist and hold
counterweight (17).

17

WBAT-06-01-026

10. Remove bolts (18) (3 used) and washers (19) (3


used)
from
counterweight
(17).
Raise
counterweight (17) from main frame (20) a little.
Slide and remove counterweight (17) backward.
: 30 mm

17

18, 19

WBAT-06-01-027

20

W2-2-4

UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight (17) weight: 1380
kg (3050 lb)

17

18, 19

1. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)


(2 used) to counterweight (17). Attach a wire rope
onto the Freno-Linkbolt. Hoist and align
counterweight (17) with the mounting hole of main
frame (20).

WBAT-06-01-027

20

2. Install counterweight (17) to main frame (20) with


bolts(18) (3 used) and washers (19) (3 used).
: 30 mm
: 550 Nm (55 kgfm, 410 lbfft)

16

3. Remove the wire rope and the Freno-Linkbolts (2


used) from counterweight (17). Install caps (16) (2
used) to counterweight (17).

17

WBAT-06-01-026

4. Install the cover (15) assembly to bracket (13) with


sems bolts (12) (2 used).
: 13 mm
: 20 Nm (2 kgfm, 44 lbfft)

11

12

13

11

5. Connect hoses (11) (2 used) to reserve tank (14).

14
12

15

W2-2-5

W1P1-02-02-004

UPPERSTRUCTURE / Counterweight
CAUTION: Engine cover (2) weight: 22 kg (50
lb)

10

2
3

6. Attach a nylon sling onto engine cover (2). Hoist


and align engine cover (2) with the mounting hole
of support (3). Install engine cover (2) to support
(3) with sems bolts (10) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
WBAT-06-01-020

7. Install stopper (9) to engine cover (2). Secure


stopper (9) to engine cover (2) with washer (7)
and split pin (8).

WBAT-06-01-022

8. Install cylinder (4) to support (3). Secure cylinder


(4) to stopper (3) with washer (6) and split pin (5).

WBAT-06-01-021

9. Shut covers (1) (2 used) and engine cover (2).

WBAT-06-01-019

W2-2-6

UPPERSTRUCTURE / Main Frame


REMOVAL AND INSTALLATION OF MAIN
FRAME (ZX70-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Frame

Counterweight

Bolt, Washer

Removal
CAUTION: Counterweight weight: 750 kg
(1660 lb)
1. Remove the counterweight from the frame.
(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 30 mm

W1P1-02-02-003

CAUTION: The front attachment assembly


weight: 1050kg (2320 lb)
2. Remove the front attachment assembly from the
frame.
(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 24 mm, 27 mm
W102-04-01-007

CAUTION: Center joint weight: 32 kg (71 lb)

Hose

Stopper

3. Disconnect the hoses (8 used) from the center


joint. Remove the bolts (2 used). Remove the
stopper from the center joint.
(Refer to REMOVAL AND INSTALLATION OF
CENTER JOINT on W3-3-1.)
: 17 mm, 19 mm, 22 mm, 27 mm

Center Joint

W2-3-1

Bolt

W1P1-03-03-001

UPPERSTRUCTURE / Main Frame


CAUTION: Upperstructure weight: 4700 kg
(10400 lb)
IMPORTANT: Do not damage the engine due to the
wire ropes attached onto the rear
side of the frame.
4. Attach the wire ropes onto the rear side of the
frame and the boom mounting hole. Take up slack
of the wire rope.
NOTE: If the chain block is used, it is not only easy
to adjust the length of wire rope, but also
easy to level the center of gravity.

Rear Side
W105-02-03-004

5. Put the matching mark onto the upperstructure


and the outer race of the swing bearing.
Remove the swing bearing mounting bolt.
: 24 mm
6. Adjust a chain block in order to level the center of
gravity in the frame. Hoist and remove the
upperstructure from the swing bearing.
Bolt

W2-3-2

WBAT-06-01-091

UPPERSTRUCTURE / Main Frame


Installation
CAUTION: Upperstructure weight: 4700 kg
(10400 lb)
1. Attach the wire ropes onto the frame. Adjust the
chain block in order to level the center of gravity in
the frame. Hoist and place the upperstructure onto
the swing bearing.
(Refer to the Removal procedures.)
2. Align the matching marks on the upperstructure
and the outer race of the swing bearing.
Install and temporarily tighten the mounting bolts
for the swing bearing. Remove the wire ropes.
Tighten the mounting bolts for the swing bearing.
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
Bolt

WBAT-06-01-091

Hose

Stopper

3. Connect the hoses (8 used) to the center joint.


: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
4. Apply LOCTITE #262 onto the bolts (2 used).
Install the stopper to the center joint with the bolts
(2 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

W2-3-3

Center Joint

Bolt

W1P1-03-03-001

UPPERSTRUCTURE / Main Frame


CAUTION: Counterweight weight: 750 kg
(3270 lb)

Frame

Counterweight

Bolt, Washer

5. Install the counterweight.


(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 30 mm
: 550 Nm (55 kgfm, 410 lbfft)

CAUTION: The front attachment assembly


weight: 1050 kg (2320 lb)

W1P1-02-02-003

6. Install the front attachment assembly to the frame.


(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
7. Start the engine. Set the front attachment in
position for checking hydraulic oil level in the
hydraulic oil tank. Check the hydraulic oil level and
any oil leakage.
W102-04-01-007

W2-3-4

UPPERSTRUCTURE / Main Frame


REMOVAL AND INSTALLATION OF MAIN
FRAME (ZX75US-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal

Counterweight

Bolt, Washer

CAUTION: Counterweight weight: 1380 kg


(3050 lb)
1. Remove the counterweight from the frame.
(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 41 mm

Frame

WBAT-06-01-027

CAUTION: The front attachment assembly


weight: 1050 kg (2320 lb)
2. Remove the front attachment assembly from the
frame.
(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 24 mm, 27 mm

W102-04-01-007

CAUTION: Center joint weight: 32 kg (71 lb)


Center Joint

3. Disconnect the hoses (8 used) from the center


joint. Remove the bolts (2 used). Remove the
stopper from the center joint.
(Refer to REMOVAL AND INSTALLATION OF
CENTER JOINT on W3-3-1.)
: 17 mm, 19 mm, 22 mm, 27 mm

Stopper

Bolt

W2-3-5

Hose

W1P1-03-03-003

UPPERSTRUCTURE / Main Frame


CAUTION: Upperstructure weight: 4770 kg
(10600 lb)
IMPORTANT: Do not damage the engine due to the
wire ropes attached onto the rear
side of the frame.
4. Attach the wire ropes onto the rear side of the
frame and the boom mounting hole. Take up slack
of the wire rope.
NOTE: If the chain block is used, it is not only easy
to adjust the length of wire rope, but also
easy to level the center of gravity.

Rear Side
W105-02-03-004

5. Put the matching mark onto the upperstructure


and the outer race of the swing bearing.
Remove the swing bearing mounting bolt.
: 24 mm
6. Adjust a chain block in order to level the center of
gravity in the frame. Hoist and remove the
upperstructure from the swing bearing.
Bolt

W2-3-6

WBAT-06-01-091

UPPERSTRUCTURE / Main Frame


Installation
CAUTION: Upperstructure weight: 4770 kg
(10600 lb)
1. Attach the wire ropes onto the frame. Adjust the
chain block in order to level the center of gravity in
the frame. Hoist and place the upperstructure onto
the swing bearing.
(Refer to the Removal procedures.)
2. Align the matching marks on the upperstructure
and the outer race of the swing bearing.
Install and temporarily tighten the mounting bolts
for the swing bearing. Remove the wire ropes.
Tighten the mounting bolts for the swing bearing.
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
Bolt

WBAT-06-01-091

Center Joint

3. Connect the hoses (8 used) to the center joint.


: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
4. Apply LOCTITE #262 onto the bolts (2 used).
Install the stopper to the center joint with the bolts
(2 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

W2-3-7

Stopper

Bolt

Hose

W1P1-03-03-003

UPPERSTRUCTURE / Main Frame


CAUTION: Counterweight weight: 1380 kg
(3050 lb)

Counterweight

5. Install the counterweight.


(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 41 mm
: 1400 Nm (143 kgfm, 1030 lbfft)

Bolt, Washer

WBAT-06-01-027

Frame

CAUTION: The front attachment assembly


weight: 1050 kg (2320 lb)
6. Install the front attachment assembly to the frame.
(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
W102-04-01-007

7. Start the engine. Set the front attachment in


position for checking hydraulic oil level in the
hydraulic oil tank. Check the hydraulic oil level and
any oil leakage.

W2-3-8

UPPERSTRUCTURE/Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE (ZX70-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Open engine cover (1).

W1P1-02-02-001

2. Secure engine cover (1) with stopper (3).

3. Remove split pins (5) (2 used) and washers (2) (2


used) from the pinpart of engine cover (1).
Remove cylinders (4) (2 used) from engine cover
(1).

CAUTION: Engine cover (1) weight: 25 kg


(60 lb)

W1P1-02-04-003

4. Attach a nylon sling onto engine cover (1). Hoist


and hold engine cover (1). Remove stopper (3)
from engine cover (1).

5. Open cover (6).

W1P1-02-04-001

W2-4-1

UPPERSTRUCTURE/Pump Device
1

CAUTION: Engine cover (1) weight: 25 kg


(60 lb)
6. Remove sems bolts (8) (4 used). Remove engine
cover (1) from support (7).
17 mm

7
8

W1P1-02-04-002

7. Remove sems bolts (9) (2 used) from brackets (11,


12). Remove support (10) from brackets (11, 12).
17 mm

10

11

12

W1P1-02-04-004

13

8. Remove sems bolts (13) (2 used) from bracket


(12). Remove bracket (12) from bracket (14) and
frame (15).
17 mm

14

12

W1P1-02-04-007

12

13

W2-4-2

15

W1P1-02-04-011

UPPERSTRUCTURE/Pump Device
9. Remove bolts (17) (5 used). Remove cover (16)
from engine (18).
10 mm, 13 mm

16

17

18

W1P1-02-04-006

10. Loosen bolts (20) (2 used). Make a play of band


(21). Remove muffler (22) from turbocharger (19).
14 mm

19

20

21
22

W1P1-02-04-013

11. Remove sems bolts (23) (6 used). Remove cover


(24) from frame (15).
17 mm

23

15

25

12. Disconnect connector (25).


13. Remove socket bolt (31) and bolt (32) from clips
(30) (2 used). Remove clips (30) (2 used) and
disconnect harness (28) from pump device (26).
10 mm
5 mm
14. Remove socket bolts (27) (8 used) from suction
pipes (29) (2 used). Disconnect suction pipes (29)
(2 used) from pump device (26). Cap the open
ends.
8 mm

W2-4-3

26

27

24

W1P1-02-04-012

28
29

30, 31, 32

W1P1-02-04-010

UPPERSTRUCTURE/Pump Device
15. Disconnect hoses (35) (2 used) from oil filter (33).
Cap the open ends.
36 mm

33

34

14

16. Remove bolts (34) (4 used) from oil filter (33).


Remove oil filter (33) from bracket (14).
13 mm

W1P1-02-04-007

35
14

17. Remove sems bolt (36) from clip (37). Remove


clip (37) and disconnect hose (35) from bracket
(14).
17 mm

36

37

35

18. Disconnect hoses (38) (6 used) from pump device


(26). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
17 mm, 27 mm

W1P1-02-04-008

38

26

W1P1-02-04-009

W2-4-4

UPPERSTRUCTURE/Pump Device
19. Remove sems bolt (40) from support (7). Remove
bracket (14) from support (7).
17 mm

39

14

40
41

W1P1-02-04-004

14

20. Remove sems bolts (39) (4 used) from bracket


(14). Remove bracket (14) from support (7),
covers (41, 42), and frame (15).
17 mm

42

41

43

21. Remove sems bolts (43) (2 used). Remove cover


(42) from cover (41).
17 mm

39

W1P1-02-04-008

15

22. Remove sems bolt (45). Remove cover (41) from


cover (44).
17 mm

41

44

45

W1P1-02-04-005

W2-4-5

UPPERSTRUCTURE/Pump Device
46

23. Remove sems bolts (46) (3 used) from bracket


(47). Remove the bracket (47) assembly from
flange (48).
17 mm

47

26

CAUTION: The pump device (26) assembly


weight: 77 kg (170 lb)
24. Attach a nylon sling onto pump device (26). Hoist
and hold pump device (26). Remove sems bolts
(46) (7 used) from flange (48). Remove the pump
device (26) assembly from engine (18).
17 mm

18

48

25. Remove bolts (49) (2 used) and washers (50) (2


used) from pump device (26). Remove pump
device (26) from flange (48).
27 mm

49, 50
26

48

W2-4-6

WBAT-06-01-065

WBAT-06-01-065

UPPERSTRUCTURE/Pump Device
Installation

46

CAUTION: Pump device (26) weight: 74 kg


(163 lb)

49, 50
26

1. Install flange (48) to pump device (26) with bolts


(49) (2 used) and washers (50) (2 used).
27 mm
300 Nm (30 kgfm, 221lbfft)
CAUTION: The pump device (26) assembly
weight: 77 kg (170 lb)
2. Attach a nylon sling onto the pump device (26)
assembly. Hoist and hold the pump device (26)
assembly. Align pump device (26) with the
mounting hole on engine (18).
3. Install pump device (26) to engine (18) with sems
bolts (46) (7 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)

18

18

WBAT-06-01-065

48

46

47

4. Install the bracket (47) assembly to engine (18)


and flange (48) with sems bolts (46) (3 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)
48

WBAT-06-01-065

5. Connect suction pipes (29) (2 used) to pump


device (26) with socket bolts (51) (8 used).
8 mm
50 Nm (5 kgfm, 37 lbfft)

26

27

29

W1P1-02-04-010

W2-4-7

UPPERSTRUCTURE/Pump Device
25

6. Connect connector (25).

26

7. Install clips (30) (2 used) to harness (28). Install


clips (30) (2 used) to pump device (26) with socket
bolt (31) and bolt (32).
10 mm
5 mm
3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to3 lbfft)

28

30, 31, 32

W1P1-02-04-010

41

44

8. Install cover (41) to cover (44) with sems bolt (45).


17 mm
50 Nm (5 kgfm, 37 lbfft)

45

W1P1-02-04-005

14

9. Install cover (42) to cover (41) with sems bolts


(43) (2 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)

42

41

43

10. Install bracket (14) to support (7) with sems bolt


(40).
17 mm
50 Nm (5 kgfm, 37 lbfft)

39

11. Install bracket (14) to covers (41, 42) and frame


(15) with sems bolts (39) (4 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)
W1P1-02-04-008

15
39

14

40
41

W1P1-02-04-004

W2-4-8

UPPERSTRUCTURE/Pump Device
12. Install oil filter (33) to bracket (14) with bolts (34)
(4 used).
13 mm
20 Nm (2 kgfm, 11 lbfft)

33

34

14

13. Connect hoses (35) (2 used) to oil filter (33).


36 mm
175 Nm (18 kgfm, 129 lbfft)
14. Install clip (37) to hose (35). Install the clip (37)
assembly to bracket (14) with sems bolt (36).
17 mm
50 Nm (5 kgfm, 37 lbfft)

W1P1-02-04-007

35
14

36

37

35

15. Connect hoses (38) (6 used) to pump device (26).


17 mm
24.5 Nm (2.5 kgfm, 18 lbfft)
27 mm
78 Nm (8 kgfm, 58 lbfft)

W1P1-02-04-008

38

26

W1P1-02-04-009

16. Install cover (24) to frame (15) with sems bolts


(23) (6 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)

23

15

24

W1P1-02-04-012

W2-4-9

UPPERSTRUCTURE/Pump Device
13

17. Install bracket (12) to bracket (14) and frame (15)


with sems bolts (13) (2 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)

14

12

W1P1-02-04-007

12

13

W1P1-02-04-011

15

10

18. Install support (10) to brackets (11, 12) with sems


bolts (9) (2 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)

11

12
19

19. Install turbocharger (19) to muffler (22) with band


(21) and bolts (20) (2 used).
14 mm
20 Nm (2 kgfm, 15 lbfft)

W1P1-02-04-004

20

21

22

W1P1-02-04-013

20. Install cover (16) to engine (18) with bolts (17) (5


used).
10 mm
3.3 to 4.2 Nm (0.3 to 0.4 kgfm, 2 to 3
lbfft)
13 mm
20 Nm (2 kgfm, 15 lbfft)

16

17

18

W1P1-02-04-006

W2-4-10

UPPERSTRUCTURE/Pump Device
1

CAUTION: Engine cover (1) weight: 25 kg


(60 lb)
21. Attach a nylon sling onto engine cover (1). Hoist
engine cover (1). Align engine cover (1) with the
mounting hole of support (7). Install engine cover
(1) to support (7) with sems bolts (8) (4 used).
17 mm
50 Nm (5 kgfm, 37 lbfft)

7
8

W1P1-02-04-002

22. Secure engine cover (1) with stopper (3).

23. Install cylinders (4) (2 used) to the pin part of


engine cover (1) with washers (2) (2 used) and
split pins (5) (2 used).
IMPORTANT: Bleed air from the pump device.
(Refer to W1-1-2.)
After completing the work, check the
hydraulic oil level. Start the engine
and check for any oil leaks.

4
W1P1-02-04-003

24. Shut engine cover (1) and cover (6).


1

W1P1-02-02-001

W1P1-02-04-001

W2-4-11

UPPERSTRUCTURE/Pump Device
(Blank)

W2-4-12

UPPERSTRUCTURE / Pump Device


REMOVAL AND INSTALLATION OF PUMP
DEVICE (ZX75US-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Open engine cover (1) and side cover (2).

WBAT-06-01-019

CAUTION: Engine cover (1) weight: 22 kg (46


lb)

1
3

2. Attach a nylon sling onto engine cover (1). Hoist


and hold engine cover (1).

WBAT-06-01-020

3. Remove split pin (5) and washer (6) from the pin
part of support (3). Remove cylinder (4) from
support (3).

4. Remove split pin (8) and washer (7) from


stopper (9). Remove stopper (9) from engine
cover (1).

WBAT-06-01-021

W2-4-13

WBAT-06-01-022

UPPERSTRUCTURE / Pump Device


CAUTION: Engine cover (1) weight: 22 kg (46
lb)

10

1
3

5. Remove sems bolts (10) (4 used). Remove


engine cover (1) from support (3).
: 17 mm

WBAT-06-01-020

6. Remove clip band (14) from cover


Disconnect harness (13) from cover (12).

(12).

11

12

13

7. Remove sems bolts (11) (4 used). Remove cover


(12) from frame (15) and support (3).
: 17 mm

14

15

W1P1-02-06-003

8. Remove sems bolts (17) (6 used). Remove cover


(18) from bracket (16) and hydraulic oil tank (19).
: 17 mm

16

17

18, 19

WBAT-06-01-044

20

9. Remove sems bolts (20) (5 used). Remove cover


(22) from support (3) and cover (21).

21

W2-4-14

22

W1P1-02-01-004

UPPERSTRUCTURE / Pump Device


10. Remove sems bolts (24) (3 used) from support (3).
Remove support (3) from brackets (23, 25).
: 17 mm

23

24

25

24

WBAT-06-01-020

25

11. Remove sems bolts (27) (4 used). Remove cover


(26) from bracket (25).
: 17 mm

26

27

WBAT-06-01-057

12. Remove sems bolts (33) (2 used) from muffler


(32). Remove cover (28) from muffler (32).
: 17 mm

28

29

13. Remove nuts (30) (3 used) and washers (31) (3


used) from muffler (32). Remove muffler (32) from
turbocharger (29).
: 13 mm

30, 31
32

WBAT-06-01-058

33

14. Remove sems bolts (35) (3 used). Remove cover


(36) from fuel tank (34) and bracket (25).
: 17 mm

34

35

36

25

WBAT-06-01-056

W2-4-15

UPPERSTRUCTURE / Pump Device


15. Remove sems bolts (38) (3 used). Remove covers
(37) (2 used) from bracket (25).
: 17 mm

37

38

37

25

WBAT-06-01-057

16. Remove sems bolt (41) from clip (40). Remove


clip (40) from bracket (25) and hoses (39) (2
used).
: 17 mm

39

40
41

25

WBAT-06-01-062

17. Remove bolts (42) (4 used) from oil filter (43).


Remove oil filter (43) from bracket (25).
: 13 mm

42

43

25

WBAT-06-01-059

18. Remove sems bolts (44) (2 used) from bracket


(25).
: 17 mm

25

44

WBAT-06-01-060

W2-4-16

UPPERSTRUCTURE / Pump Device


19. Remove sems bolts (47) (6 used). Remove cover
(45) from frame (46).
: 17 mm

45

46

47

WBAT-06-01-063

20. Remove sems bolts (49) (3 used) from bracket


(25). Remove bracket (25) from bracket (48) and
frame (46).
: 17 mm

48

25

49

WBAT-06-01-056

25

49

WBAT-06-01-062

46

21. Disconnect connectors (54) (2 used).


22. Remove socket bolts (51) (2 used) from clips (52)
(2 used). Remove clips (52) (2 used) from pump
device (50) and harness (53).
: 5 mm

50

51

52

53

54

WBAT-06-01-064

W2-4-17

UPPERSTRUCTURE / Pump Device


23. Remove socket bolts (57) (8 used) from suction
pipes (56) (2 used). Disconnect suction pipes (56)
(2 used) from pump device (50). Cap the open
ends.
: 8 mm

55

50

24. Disconnect hoses (55) (9 used) from pump device


(50). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 27 mm
CAUTION: The pump device (50) assembly
weight: 77 kg (170 lb)

56

57

25. Remove sems bolts (58) (3 used) from bracket


(59). Remove the bracket (59) assembly from
flange (60).
: 17 mm

58

59

50

26. Attach a nylon sling onto pump device (50). Hoist


and hold pump device (50). Remove sems bolts
(58) (7 used) from flange (60). Remove the pump
device (50) assembly from engine (61).
: 17 mm

61

60

27. Remove bolts (62) (2 used) and washers (63) (2


used) from pump device (50). Remove pump
device (50) from flange (60).
: 27 mm

WBAT-06-01-065

62, 63
50

60

W2-4-18

WBAT-06-01-061

WBAT-06-01-065

UPPERSTRUCTURE / Pump Device


Installation

58
62, 63

CAUTION: Pump device (50) weight: 74 kg


(163 lb)

50

1. Install flange (60) to pump device (50) with bolts


(62) (2 used) and washers (63) (2 used).
: 27 mm
: 300 Nm (30.5 kgfm, 221 lbfft)
CAUTION: The pump device (50) assembly
weight: 77 kg (170 lb)
2. Attach a nylon sling onto the pump device (50)
assembly. Hoist and align the pump device (50)
assembly with the mounting hole of engine (61).

61

61

WBAT-06-01-065

60

58

59

3. Install pump device (50) to engine (61) with sems


bolts (58) (7 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
4. Install the bracket (59) assembly to engine (61)
and flange (60) with sems bolts (58)(3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

60

WBAT-06-01-065

50

5. Connect suction pipes (56) (2 used) to pump


device (50) with socket bolts (57) (8 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)
56

57

W2-4-19

WBAT-06-01-064

UPPERSTRUCTURE / Pump Device


6. Connect harness (53) to clips (52) (2 used). Install
clips (52) (2 used) to pump device (50) with socket
bolts (51) (2 used).
: 5 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

50

51

52

53

54

7. Connect connectors (54) (2 used).

WBAT-06-01-064

8. Connect hoses (55) (9 used) to pump device (50).


: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

55

9. Install bracket (25) to bracket (48) and frame (46)


with sems bolts (49) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

50

WBAT-06-01-061

48

25

49

WBAT-06-01-056

25

49

WBAT-06-01-062

46

W2-4-20

UPPERSTRUCTURE / Pump Device


37

10. Install bracket (25) to fuel tank (34) and cover (37)
with sems bolts (44) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

34
44

WBAT-06-01-060

25

11. Install oil fileter (43) to bracket (25) with bolts (42)
(4 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

42

43

25

WBAT-06-01-059

39

12. Install clip (40) to hoses (39) (2 used). Install clip


(40) to bracket (25) with sems bolt (41).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

40
41

25

WBAT-06-01-062

13. Install covers (37) (2 used) to bracket (25) with


sems bolts (38) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
14. Install cover (26) to bracket (25) with sems bolts
(27) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

37

38

37

25

27

26

WBAT-06-01-057

W2-4-21

UPPERSTRUCTURE / Pump Device


28

15. Install muffler (32) to turbocharger (29) with


washers (31) (3 used) and nuts (30) (3 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

29

30, 31
32

16. Install cover (28) to muffler (32) with sems bolts


(33) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WBAT-06-01-058

33

17. Install cover (36) to fuel tank (34) and bracket (25)
with sems bolts (35) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

34

35

36

25

WBAT-06-01-056

18. Install support (3) to brackets (23, 25) with sems


bolts (24) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

23

24

24

25

WBAT-06-01-020

19. Install cover (18) to bracket (16) and hydraulic oil


tank (19) with sems bolts (17) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

16

17

18, 19

WBAT-06-01-044

W2-4-22

UPPERSTRUCTURE / Pump Device


20. Install cover (22) to support (3) and cover (21) with
sems bolts (20) (5 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

20

21

21. Install cover (12) to support (3) and frame (15)


with sems bolts (11) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

22

11

W1P1-02-01-004

12

13

14

22. Secure harness (13) to cover (12) with clip band


(14).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

15

W1P1-02-06-003

CAUTION: Engine cover (1) weight: 22 kg (46


lb)
23. Attach a nylon sling onto engine cover (1). Hoist
and align engine cover (1) with the mounting hole
of support (3). Install engine cover (1) to support
(3) with sems bolts (10) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

10

1
3

WBAT-06-01-020

24. Install stopper (9) to engine cover (1). Secure


stopper (9) to engine cover (1) with washer (7)
and split pin (8).

W2-4-23

WBAT-06-01-022

UPPERSTRUCTURE / Pump Device


25. Install cylinder (4) to support (3). Secure cylinder
(4) to support (3) with washer (6) and split pin (5).

IMPORTANT: Bleed air from the pump device.


(Refer to W1-1-2.)
After completing the work, check the
hydraulic oil level. Start the engine
and check for any oil leaks.

26. Install cover (40) to frame (41) with sems bolts


(42) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

40

WBAT-06-01-021

41

42

WBAT-06-01-063

27. Shut side cover (2) and engine cover (1).

WBAT-06-01-019

W2-4-24

UPPERSTRUCTURE / Pump Device


(Blank)

W2-4-25

UPPERSTRUCTURE / Pump Device


DISASSEMBLY OF MAIN PUMP 3
Main Pumps 1, 2

15
14
12

13

11
10

7
6
9
5

24
22
23

21
19

17

25

20
27

18

44

29

26

16

45

28

46

45

30

44

42
43

41

40

39

38

36

37

36

35

34

33

32

31
W1P1-02-04-051

W2-4-26

UPPERSTRUCTURE / Pump Device

1 - Gasket
2 - Retaining Ring
3 - Spacer
4 - Bearing
5 - Shaft
6 - Support Plate
7 - Swash Plate
8 - Pin (2 Used)
9 - Retaining Ring (2 Used)
10 - Piston (9 Used)
11 - Retainer
12 - Spherical Bushing

13 - Spring (6 Used)
14 - Cylinder Block
15 - Valve Plate
16 - Pin
17 - Piston Case
18 - O-Ring
19 - Plug
20 - O-Ring
21 - Socket Bolt (6 Used)
22 - Socket Bolt
23 - O-Ring
24 - Gear Pump Assembly

25 - Socket Bolt (4 Used)


26 - Casing
27 - O-Ring
28 - N Sensor
29 - Washer
30 - Socket Bolt
31 - Lock Nut
32 - Cover
33 - O-Ring
34 - O-Ring
35 - Adjusting Screw
36 - Spring Seat (2 Used)

W2-4-27

37 - Spring
38 - Retaining Ring
39 - Bushing
40 - Spool
41 - Tilt Piston
42 - Spring Pin
43 - Needle Bearing
44 - O-Ring (2 Used)
45 - Backup Ring (2 Used)
46 - Seal Pipe

UPPERSTRUCTURE / Pump Device


Main Pumps 1, 2

15

13

24
22
23

21
19

17

25

20
27

18

28
29

26

16

41

40

39

38

36

37

36

35

34

33

32

30

31
W1P1-02-04-051

W2-4-28

UPPERSTRUCTURE / Pump Device


Disassembly of Main Pump 3
CAUTION: The pump assembly weight: 72 kg
(160 lb)
1. Remove plug (19) and O-ring (20) from casing
(26). Drain oil.
: 10 mm
IMPORTANT: As the setting changes, do not
disassemble lock nut (31) and
adjusting screw (35).
IMPORTANT: When replacing inner parts (31 to 38)
of the cover (32) assembly, replace
as an assembly.
2. Remove the cover (32) assembly from casing
(26).
IMPORTANT: When replacing spool (40) and tilt
piston (41), replace as an assembly.
3. Remove bushing (39) and the tilt piston (41)
assembly from casing (26).

4. Remove socket bolt (30) and washer (29).


Remove N sensor (28) and O-ring (27) from
casing (26).
: 5 mm
5. Remove socket bolts (25) (4 used). Remove gear
pump assembly (24) and O-ring (23) from casing
(26).
: 6 mm
IMPORTANT: Do not drop and damage valve plate
(15) when removing casing (26).
6. Remove socket bolt (22). Loosen socket bolts
(21) (6 used). Record the clearance between
main pumps (1, 2) and casing (26). Remove
socket bolts (21) (6 used). Remove casing (26)
and gasket (1) from main pumps (1, 2).
: 10 mm
NOTE: When loosening socket bolts (21) (6 used),
casing (26) will be pushed out due to the
force of spring (13).
7. Remove pin (16) from piston case (17).
8. Remove piston case (17) from casing (26).
Remove O-ring (18) from piston case (17).

W2-4-29

UPPERSTRUCTURE / Pump Device


Main Pumps 1, 2

15
14
12

13

11
8

10

7
6
9
5

26

44

45

46

45

44

43
W1P1-02-04-051

W2-4-30

UPPERSTRUCTURE / Pump Device


IMPORTANT: Do not damage the sliding surface
and the mounting surface of valve
plate (15).
IMPORTANT: When replacing valve plate (15),
replace with cylinder block (14)
together as an assembly.
9. Remove valve plate (15) from casing (26).
10. Remove the seal pipe (46) assembly from casing
(26). Remove O-rings (44) (2 used) and backup
rings (45) (2 used) from seal pipe (46).
IMPORTANT: Do not remove needle bearing (43)
unless necessary.
11. Remove needle bearing (43) from casing (26).

IMPORTANT: When replacing inner parts (7 to 9) of


the swash plate (7) assembly,
replace as an assembly.
14. Remove the swash plate (7) assembly from
support plate (6).
15. Remove the shaft (5) assembly from main pumps
(1, 2).
16. Remove support plate (6) from shaft (5).
17. Remove retaining ring (2), spacer (3), and bearing
(4) from shaft (5).

IMPORTANT: Do not damage the sliding surfaces


of cylinder block (14), piston (10),
spherical bushing (12), and swash
plate (7).
IMPORTANT: When replacing cylinder block (14),
replace with valve plate (15) to
together as an assembly.
12. Remove the cylinder block (14) assembly from
shaft (5).
13. Remove pistons (10) (9 used), retainer (11),
spherical bushing (12), and springs (13) (6 used)
from cylinder block (14).

W2-4-31

UPPERSTRUCTURE / Pump Device


ASSEMBLY OF MAIN PUMP 3
19, 20

21

22

W1P1-02-04-052

46

44, 45

8, 9

29, 30

28

26

11 10 16

17

27

18

14

15

43

12
23

24

5
42

25

33

32

4
6

35

13

Main Pump 1, 2

41

40

39

38 36

W2-4-32

37

34

31
W1P1-02-04-053

UPPERSTRUCTURE / Pump Device

12345678910 11 12 -

Gasket
Retaining Ring
Spacer
Bearing
Shaft
Support Plate
Swash Plate
Pin (2 Used)
Retaining Ring (2 Used)
Piston (9 Used)
Retainer
Spherical Bushing

13 14 15 16 17 18 19 20 21 22 23 24 -

Spring (6 Used)
Cylinder Block
Valve Plate
Pin
Piston Case
O-Ring
Plug
O-Ring
Socket Bolt (6 Used)
Socket Bolt
O-Ring
Gear Pump Assembly

25 26 27 28 29 30 31 32 33 34 35 36 -

Socket Bolt (4 Used)


Casing
O-Ring
N Sensor
Washer
Socket Bolt
Lock Nut
Cover
O-Ring
O-Ring
Adjusting Screw
Spring Seat (2 Used)

W2-4-33

37 38 39 40 41 42 43 44 45 46 -

Spring
Retaining Ring
Bushing
Spool
Tilt Piston
Spring Pin
Needle Bearing
O-Ring (2 Used)
Backup Ring (2 Used)
Seal Pipe

UPPERSTRUCTURE / Pump Device

W1P1-02-04-052

46

44, 45

8, 9

26

11 10 16

17

18

14

15

43

12

2
5

3
4
6

Main Pumps 1, 2

13

42
W1P1-02-04-053

W2-4-34

UPPERSTRUCTURE / Pump Device


Assembly of Main Pump 3
1. Install bearing (4), spacer (3), and retaining ring
(2) to shaft (5).
2. Install support plate (6) to shaft (5).
3. Install the shaft (5) assembly to main pumps (1,
2).
IMPORTANT: When replacing inner parts (7 to 9) of
the swash plate (7) assembly,
replace as an assembly.
4. Apply grease onto the sliding surfaces of support
plate (6) and the swash plate (7) assembly. Install
the swash plate (7) assembly to support plate (6).
IMPORTANT: When replacing cylinder block (14),
replace with valve plate (15) together
as an assembly.
5. Install springs (13) (6 used), spherical bushing
(12), retainer (11), and pistons (10) (9 used) to
cylinder block (14).

IMPORTANT: Install valve plate (15) as illustrated


below.
IMPORTANT: When replacing valve plate (15),
replace with cylinder block (14)
together as an assembly.
9. Apply grease onto the casing (26) mounting
surface of valve plate (15). Align groove (a) on
valve plate (15) with spring pin (42) of casing (26)
when installing.
26

15

6. Install the cylinder block (14) assembly to shaft


(5).
7. Install needle bearing (43) to casing (26).
8. Install backup rings (45) (2 used) and O-rings (44)
(2 used) to seal pipe (46). Install the seal pipe
(46) assembly to casing (26).

42
W1P1-02-04-054

10. Install O-ring (18) to piston case (17). Apply


THREEBOND #1305N onto the thread part of
piston case (17). Install piston case (17) to casing
(26).
: 78 Nm (8 kgfm, 58 lbfft)
11. Install pin (16) to piston case (17).

W2-4-35

UPPERSTRUCTURE / Pump Device


19, 20

21

22

W1P1-02-04-052

29, 30

28

15

26

27

23

24

42

25

33
32
35

Main Pumps 1, 2

41

40

39

38 36

W2-4-36

37

34

31
W1P1-02-04-053

UPPERSTRUCTURE / Pump Device


12. Install gasket (1) and casing (26) to main pumps
(1, 2) with socket bolts (21) (6 used). Install socket
bolt (22).
: 10 mm
: 98 Nm (10 kgfm, 72 lbfft)
NOTE: Check the clearance between main pumps
(1, 2) and casing (26). If the clearance is
larger, spring pin (42) may not be inserted
into the groove on valve plate (15). The
inner parts may not be installed correctly.

IMPORTANT: When replacing spool (40) and tilt


piston (41), replace as an assembly.
15. Install the tilt piston (41) assembly and bushing
(39) to casing (26).

13. Install O-ring (23) and the gear pump assembly


(24) to casing (26) with socket bolts (25) (4 used).
: 6 mm
: 17 Nm (1.7 kgfm, 13 lbfft)

17. Install O-ring (20) and plug (19) onto casing (26).
: 10 mm
: 108 Nm (11 kgfm, 80 lbfft)

IMPORTANT: When replacing inner parts (31 to 38)


of the cover (32) assembly, replace
as an assembly.
16. Install the cover (32) assembly to casing (26).
: 157 Nm (16 kgfm, 116 lbfft)

14. Install O-ring (27) and N sensor (28) to casing


(26) with socket bolt (30) and washer (29).
: 5 mm
: 6 Nm (0.6 kgfm, 4 lbfft)

W2-4-37

UPPERSTRUCTURE / Pump Device


DISASSEMBLY OF MAIN PUMPS 1 AND 2
8

16

19

20

21

18
17
13

10

23

15
70

14

69

22
11

12

65
66
67

58

68

40

41

39
59
60

36

37

46

38

34
61

42

35

43

33

49

31

63
26

25

48

45

32

62
64

44

47

27

28

29

30

29

28

50

24

53
54

52

51

55
56

W1P1-02-04-055

57

W2-4-38

UPPERSTRUCTURE / Pump Device

1 - Plug
2 - O-Ring
3 - Pf Piston Case
4 - O-Ring
5 - Pf Piston
6 - Piston Case
7 - Compensating Piston
8 - Socket Bolt (8 Used)
9 - Cover
10 - Gasket
11 - Plug
12 - O-Ring
13 - Pin
14 - O-Ring (2 Used)
15 - O-Ring (5 Used)
16 - Feedback Lever
17 - Tilt Pin
18 - Servo Piston

19 - O-Ring
20 - Backup Ring
21 - Stopper
22 - Casing
23 - Swash Plate
24 - Piston (10 Used)
25 - Retainer
26 - Gasket
27 - Check Valve (2 Used)
28 - O-Ring (4 Used)
29 - Backup Ring (4 Used)
30 - Seal Pipe (2 Used)
31 - Sleeve
32 - Spool
33 - Spring Seat
34 - Eyebolt (2 Used)
35 - Valve Block
36 - Adjusting Screw

37 - O-Ring
38 - O-Ring
39 - Cover
40 - Lock Nut
41 - Lock Nut
42 - O-Ring
43 - Adjusting Screw
44 - Outer Spring
45 - Inner Spring
46 - Socket Bolt (2 Used)
47 - Pin
48 - Pressure Reducing Valve
49 - Stopper Pin (2 Used)
50 - Socket Bolt (3 Used)
51 - Spring Pin
52 - O-Ring
53 - Needle Bearing
54 - Valve Plate

W2-4-39

55 - Cylinder Block
56 - Spring (10 Used)
57 - Spherical Bushing
58 - O-Ring (3 Used)
59 - Retaining Ring
60 - Spacer
61 - Shaft
62 - Bearing
63 - Spacer
64 - Retaining Ring
65 - Oil Seal
66 - O-Ring
67 - Cover
68 - Socket Bolt (4 Used)
69 - Plug
70 - O-Ring

UPPERSTRUCTURE / Pump Device


8

16

13

10

15
14
22
11

12

58

40

41

39

36

37

46

38

42

35

43

33

44

48

45

32

49

31

50
26

54

56

W1P1-02-04-055

W2-4-40

UPPERSTRUCTURE / Pump Device


Disassembly of Main Pumps 1 and 2
1. Remove plug (11) and O-ring (12) from casing
(22). Drain oil.
: 10 mm
2. Remove socket bolts (8) (8 used). Remove cover
(9), gasket (10), pin (13), O-rings (14) (2 used),
and O-rings (15) (5 used) from casing (22).
: 6 mm

6. Remove plug (1), O-rings (2), Pf piston case (3),


O-rings (4), Pf piston (5), piston case (6), and
compensating piston (7) from casing (22).
: 10 mm
IMPORTANT: Do not disassemble pressure
reducing valve (48).
7. Remove pressure reducing valve (48) from valve
block (35).

3. Remove feedback lever (16) from casing (22).


IMPORTANT: As the setting changes, do not
disassemble lock nuts (40, 41) and
adjusting screws (36, 43).
IMPORTANT: When replacing inner parts (36 to 43)
of the cover (39) assembly, replace
as an assembly.
IMPORTANT: Slowly remove socket bolts (46) (2
used) alternately as the spring force
is applied to the cover (39)
assembly.
4. Remove socket bolts (46) (2 used). Remove the
cover (39) assembly, outer spring (44), inner
spring (45), and spring seat (33) from valve block
(35).
: 5 mm

8. Remove stopper pins (49) (2 used) from valve


block (35).
IMPORTANT: Do not drop and damage valve plate
(54) when removing valve block (35).
9. Loosen socket bolts (50) (3 used). Record the
clearance between casing (22) and valve block
(35). Remove socket bolts (50) (3 used). Remove
valve block (35), gasket (26), and O-rings (58) (3
used) from casing (22).
: 10 mm
NOTE: When loosening socket bolts (50) (3 used),
valve block (35) will be pushed out due to
the force of spring (56).

IMPORTANT: When replacing sleeve (31) and


spool (32), replace as an assembly.
5. Remove the sleeve (31) assembly from casing
(22).

W2-4-41

UPPERSTRUCTURE / Pump Device

23

22

65
66
67
68

59
60

61

35

62
64

63

28

25

29

30

29

28

24

53
54

52

55
56

W1P1-02-04-055

57

W2-4-42

UPPERSTRUCTURE / Pump Device


10. Remove O-ring (52) and the seal pipe (30)
assemblies (2 used) from valve block (35).
Remove O-rings (28) (4 used) and backup rings
(29) (4 used) from seal pipes (30) (2 used).

15. Remove socket bolts (68) (4 used). Install bolts


(M6) (2 used) to thread part (b) (2 places) of cover
(67). Tighten the bolts evenly. Remove the cover
(67) assembly from casing (22).
: 5 mm

IMPORTANT: Do not damage the sliding surface


and the mounting surface of valve
plate (54).
IMPORTANT: When replacing valve plate (54),
replace with cylinder block (55)
together as an assembly.
11. Remove valve plate (54) from valve block (35).

IMPORTANT: Do not remove needle bearing (53)


unless necessary.
12. Remove needle bearing (53) from valve block
(35).

67
W1P1-02-04-056

IMPORTANT: Do not damage the sliding surfaces


of cylinder block (55), piston (24),
spherical bushing (57), and swash
plate (23).
13. Remove the cylinder block (55) assembly from
shaft (61).
IMPORTANT: When replacing cylinder block (55),
replace with valve plate (54) together
as an assembly.
14. Remove pistons (24) (10 used), retainer (25),
spherical bushing (57), and springs (56) (10 used)
from cylinder block (55).

16. Remove oil seal (65) and O-ring (66) from cover
(67).
17. Lightly tap the rear end of shaft (61) by using a
plastic hammer. Remove the shaft (61) assembly
from casing (22).
18. Remove retaining ring (64), spacer (63), bearing
(62), spacer (60), and retaining ring (59) from
shaft (61).

W2-4-43

UPPERSTRUCTURE / Pump Device

19

20

21

18
17

23

22

27

W1P1-02-04-055

W2-4-44

UPPERSTRUCTURE / Pump Device


IMPORTANT: Do not damage the sliding surfaces
of tilt pin (17) and swash plate (23).
19. Remove swash plate (23) from tilt pin (17).
20. Install a bolt to the screw hole of stopper (21).
Remove the stopper (21) assembly from casing
(22). Remove backup ring (20) and O-ring (19)
from stopper (21).
21. Warm up tilt pin (17) and servo piston (18) by
using a drier. Remove servo piston (18) from tilt
pin (17). Remove tilt pin (17) from casing (22).
22. Remove check valves (27) (2 used) from casing
(22).

W2-4-45

UPPERSTRUCTURE / Pump Device


ASSEMBLY OF MAIN PUMPS 1 AND 2
1, 2

31

11, 12

32

45

44

34

39

46

40
36
41
43

48

33

50

38

42

37

W1P1-02-04-057

15

17

16

13

18

21

19, 20

55

54

51

53

47

10
69, 70
68
62
67
65
61

59
64
63
60
66
22

23

25

57

24

56

27

28, 29

26

30

35

49
W1P1-02-04-058

W2-4-46

UPPERSTRUCTURE / Pump Device

12345678910 11 12 13 14 15 16 17 18 -

Plug
O-Ring
Pf Piston Case
O-Ring
Pf Piston
Piston Case
Compensating Piston
Socket Bolt (8 Used)
Cover
Gasket
Plug
O-Ring
Pin
*O-Ring (2 Used)
O-Ring (5 Used)
Feedback Lever
Tilt Pin
Servo Piston

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

O-Ring
Backup Ring
Stopper
Casing
Swash Plate
Piston (10 Used)
Retainer
Gasket
Check Valve (2 Used)
O-Ring (4 Used)
Backup Ring (4 Used)
Seal Pipe (2 Used)
Sleeve
Spool
Spring Seat
Eyebolt (2 Used)
Valve Block
Adjusting Screw

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

O-Ring
O-Ring
Cover
Lock Nut
Lock Nut
O-Ring
Adjusting Screw
Outer Spring
Inner Spring
Socket Bolt (2 Used)
Pin
Pressure Reducing Valve
Stopper Pin (2 Used)
Socket Bolt (3 Used)
Spring Pin
*O-Ring
Needle Bearing
Valve Plate

NOTE: As for the item with mark *, refer to W2-4-14.

W2-4-47

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 -

Cylinder Block
Spring (10 Used)
Spherical Bushing
*O-Ring (3 Used)
Retaining Ring
Spacer
Shaft
Bearing
Spacer
Retaining Ring
Oil Seal
O-Ring
Cover
Socket Bolt (4 Used)
Plug
O-Ring

UPPERSTRUCTURE / Pump Device

21

18

17

19, 20

55

54

53

68
62
67
65
61

59
64
63
60
66
22

23

25

57

24

56

35

27

W1P1-02-04-058

W2-4-48

UPPERSTRUCTURE / Pump Device


Assembly of Main Pumps 1 and 2
1. Install check valves (27) (2 used) to casing (22).
IMPORTANT: After installing tilt pin (17) and servo
piston (18), check if servo piston
(18) moves smoothly.
2. Install tilt pin (17) to casing (22). Apply
THREEBOND #1305N onto the thread part of
servo piston (18). Install servo piston (18) to tilt
pin (17).
: 240 Nm (24.5 kgfm, 177 lbfft)
3. Install O-ring (19) and backup ring (20) to stopper
(21). Install the stopper (21) assembly to casing
(22).
4. Apply grease onto the sliding surfaces of casing
(22) and swash plate (23). Install swash plate (23)
to tilt pin (17).
5. Install retaining ring (59), spacer (60), bearing
(62), spacer (63), and retaining ring (64) to shaft
(61).

6. Install the shaft (61) assembly to casing (22).


7. Install O-ring (66) and oil seal (65) to cover (67).
IMPORTANT: When installing the cover (67)
assembly to casing (22), do not
damage oil seal (65).
8. Install the cover (67) assembly to casing (22) with
socket bolts (68) (4 used).
: 5 mm
: 12 Nm (1.2 kgfm, 9 lbfft)
IMPORTANT: When replacing cylinder block (55),
replace with valve plate (54) together
as an assembly.
9. Install springs (56) (10 used), spherical bushing
(57), retainer (25), and pistons (24) (10 used) to
cylinder block (55).
10. Install the cylinder block (55) assembly to shaft
(61).
11. Install needle bearing (53) to valve block (35).

W2-4-49

UPPERSTRUCTURE / Pump Device

1, 2

50

48

W1P1-02-04-057

55

22

28, 29

26

30

54

51

35

49
W1P1-02-04-058

W2-4-50

UPPERSTRUCTURE / Pump Device


IMPORTANT: Install valve plate (54) as illustrated
below.
IMPORTANT: When replacing valve plate (54),
replace with cylinder block (55)
together as an assembly.
12. Apply grease onto the valve block (35) mounting
surface of valve plate (54). Align groove (c) on
valve plate (54) with spring pin (51) of valve block
(35).
51

14. Install O-rings (58) (3 used), gasket (26), and


valve block (35) to casing (22) with socket bolts
(50) (3 used).
: 10 mm
: 98 Nm (10 kgfm, 72 lbfft)
NOTE: Check the clearance between valve block
(35) and casing (22). If the clearance is
larger, spring pin (51) may not be inserted
into the groove on valve plate (54). The
inner parts may not be installed correctly.
15. Install stopper pins (49) (2 used) to valve block
(35).
16. Install pressure reducing valve (48) to valve block
(35).
: 38 Nm (3.9 kgfm, 28 lbfft)

54

17. Install compensating piston (7), piston case (6), Pf


piston (5), O-rings (4), Pf piston case (3), O-ring
(2), and plug (1) to casing (22).
: 10 mm
: 108 Nm (11 kgfm, 80 lbfft)
35
W1P1-02-04-059

13. Install backup rings (29) (4 used) and O-rings (28)


(4 used) to seal pipes (30) (2 used). Install O-ring
(52) and the seal pipe (30) assemblies (2 used) to
valve block (35).

W2-4-51

UPPERSTRUCTURE / Pump Device

31

11, 12

32

44

45

39

46

40
36
41
43

33

38

42

37

W1P1-02-04-057

15

17

13

16

22

10

35
W1P1-02-04-058

W2-4-52

UPPERSTRUCTURE / Pump Device


IMPORTANT: When replacing sleeve (31) and
spool (32), replace as an assembly.
18. Install the sleeve (31) assembly to casing (22)
with hole (d) facing upward.
d

IMPORTANT: Pin (e) in feedback lever (16) should


be inserted into hole (f) on the
sleeve (31) assembly and pin (g) in
tilt pin (17) should be inserted into
groove (h) on feedback lever (16)
when installing.
20. Install feedback lever (16) to casing (22).

22

16

31

f
22

31
17
g

W1P1-02-04-060

IMPORTANT: When replacing inner parts (36 to 43)


of the cover (39) assembly, replace
as an assembly.
19. Install spring seat (33), inner spring (45), outer
spring (44), and the cover (39) assembly to valve
block (35) with socket bolts (46) (2 used).
: 5 mm
: 12 Nm (1.2 kgfm, 9 lbfft)

W1P1-02-04-061

20. Install O-rings (15) (5 used), O-rings (14) (2 used),


pin (13), gasket (10), and cover (9) to casing (22)
with socket bolts (8) (8 used).
: 6 mm
: 29 Nm (3 kgfm, 21 lbfft)
21. Install O-ring (12) and plug (11) to casing (22).
: 10 mm
: 108 Nm (11 kgfm, 80 lbfft)

W2-4-53

UPPERSTRUCTURE / Pump Device


STRUCTURE OF GEAR PUMP ASSEMBLY
9
8
6

10

5
4
3
2
1
6
12
11
W1P1-02-04-062

No.

Part Name

Qty

Flange

Drive gear

Driven gear

Seal

Knock pin

Plug

O-ring

Gear case

Socket bolt

10

Socket bolt

11

Plug

12

O-ring

Wrench Size
(mm)

Tightening Torque
Nm

(kgfm)

Remark

Apply grease when


assembling.

Apply grease when


assembling.

W2-4-54

UPPERSTRUCTURE / Pump Device


MAINTENANCE STANDARD
Main Pump 3
1. Clearance (D-d) between piston (10) and cylinder
(14)
Unit: mm (in)
Standard
Allowable Limit
0.024 (0.001)
0.044 (0.002)

10

14

2. Piston (10): Clearance () of the crimped part of


the shoe bottom
Unit: mm (in)
Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.22 (0.009)

W1P1-02-04-063

10

3. Piston (10): Shoe thickness (t)


Standard
2.9 (0.1)

Unit: mm (in)
Allowable Limit
2.75 (0.1)

W1P1-02-04-064

13

4. Spring (13) free length (L)


Standard
31.3 (1.2)

Unit: mm (in)
Allowable Limit
30.6 (1.2)

L
W1P1-02-04-065

5. Combined height (H-h) between retainer (11) and


spherical bushing (12)
Unit: mm (in)
Standard
Allowable Limit
12.6 (0.5)
11.3 (0.4)

11

12

W1P1-02-04-066

W2-4-55

UPPERSTRUCTURE / Pump Device


Main Pumps 1, 2
1. Clearance (D-d) between piston (24) and cylinder
(55)
Unit: mm (in)
Standard
Allowable Limit
0.032 (0.001)
0.056 (0.002)

24

55

W1P1-02-04-063

2. Piston (24): Clearance () of the shoe bottom


Unit: mm (in)
Standard
Allowable Limit
0 to 0.1 (0 to 0.004)
0.3 (0.01)

24

3. Piston (24): Shoe thickness (t)


Standard
3.9 (0.2)

Unit: mm (in)
Allowable Limit
3.7 (0.1)

W1P1-02-04-064

56

4. Spring (56) free length (L)


Standard
41.1 (1.6)

Unit: mm (in)
Allowable Limit
40.3 (1.6)

L
W1P1-02-04-065

5. Combined height (H-h) between retainer (25) and


spherical bushing (57)
Unit: mm (in)
Standard
Allowable Limit
17.2 (0.7)
15.6 (0.6)

25

57

W1P1-02-04-066

W2-4-56

UPPERSTRUCTURE / Control Valve


REMOVAL
AND
INSTALLATION
CONTROL VALVE (ZX70-3)

OF

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Remove sems bolts (3) (4 used). Remove cover
(2) from frame (1).
: 17 mm

W1P1-02-05-006

2. Disconnect hoses (6) (3 used) from pipe (9). Cap


the open ends.
: 19 mm, 22 mm, 36 mm

9, 10
11
12

3. Remove sems bolts (13) (2 used) from clamps


(12) (2 used). Remove clamps (12) (2 used) from
pipe (9).
: 19 mm
4. Remove couplings (5) (2 used) from hydraulic oil
tank (4), oil cooler (10), and pipe (9). Disconnect
pipe (9) from hydraulic oil tank (4) and oil cooler
(10). Cap the open ends.
: 13 mm
5. Remove sems bolt (8) from brackets (11) (2 used).
Remove brackets (11) (2 used) from control valve
(7).
: 17 mm

W2-5-1

13

W1P1-02-05-002

UPPERSTRUCTURE / Control Valve


6. Open cover (14).
14

W1P1-02-02-001

15

7. Remove sems bolts (15) (6 used). Remove cover


(16) from bracket (17).
: 17 mm

16

17

W1P1-02-11-020

10

8. Remove coupling (18) from oil cooler (10) and


pipe (19).
: 13 mm

18

19

W1P1-02-05-007

9. Remove socket bolts (20) (4 used) from pipe (19).


Disconnect pipe (19) from control valve (7). Cap
the open ends.
: 8 mm

20

19

W1P1-02-05-002

W2-5-2

UPPERSTRUCTURE / Control Valve


7

10. Disconnect hoses (21) (10 used) from the front


side of control valve (7). Cap the open ends.
Attach an identification tag onto the disconnected
hoses for assembling.
: 17 mm

21

W1P1-02-05-001

21
22

11. Disconnect connectors (22) (2 used) from the left


side of control valve (7) .

W1P1-02-05-003

12. Disconnect hoses (26) (11 used) from the left side
of control valve (7). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm, 27 mm

23

24

25

26

13. Remove coupling (23) from hydraulic oil tank (4)


and pipe (24).
: 13 mm
14. Remove socket bolts (25) (2 used) from pipe (24).
Disconnect pipe (24) from control valve (7).
: 8 mm

W1P1-02-05-002

27

15. Disconnect hoses (27) (9 used) from the right side


of control valve (7). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm, 27 mm, 32 mm

W1P1-02-05-002

W2-5-3

UPPERSTRUCTURE / Control Valve


16. Disconnect hoses (28) (9 used) from the rear of
control valve (7). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 27 mm

28

W1P1-02-05-002

CAUTION: The control valve (7) assembly


weight: 87 kg (192 lb)

29, 30, 31

17. Attach a nylon sling onto control valve (7). Hoist


and hold control valve (7).
18. Remove bolts (32) (4 used) and washers (33) (4
used) from bracket (29). Remove the control valve
(7) assembly from frame (1).
: 22 mm
W1P1-02-05-005

CAUTION: Control valve (7) weight: 76 kg


(170 lb)
19. Remove bolts (30) (3 used) and washers (31) (3
used) from bracket (29). Remove control valve (7)
from bracket (29).
: 22 mm

W2-5-4

32, 33

UPPERSTRUCTURE / Control Valve


Installation
CAUTION: Control valve (7) weight: 76 kg
(170 lb)
29, 30, 31

1. Attach a nylon sling onto control valve (7). Hoist


control valve (7). Align control valve (7) with the
mounting hole on bracket (29). Install bracket (29)
to control valve (7) with bolts (30) (3 used) and
washers (31) (3 used).
: 22 mm
: 140 Nm (14 kgfm)
W1P1-02-05-005

CAUTION: The control valve (7) assembly


weight: 87 kg (192 lb)

32, 33

2. Attach a nylon sling onto the control valve (7)


assembly. Hoist the control valve (7) assembly.
Align the control valve (7) assembly with the
mounting hole on frame (1). Install bracket (29) to
frame (1) with bolts (32) (4 used) and washers
(33) (4 used).
: 22 mm
: 140 Nm (14 kgfm, 103 lbfft)

3. Connect hoses (27, 28) (9 used for each) to


control valve (7).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 32 mm
: 137 Nm (14 kgfm, 101 lbfft)

27

28

W1P1-02-05-002

24

25

4. Connect pipe (24) to control valve (7) with socket


bolts (25) (2 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-05-002

W2-5-5

UPPERSTRUCTURE / Control Valve


5. Connect hydraulic oil tank (4) to pipe (24) with
coupling (23).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

23

24

6. Connect hoses (26) (11 used) to control valve (7).


: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

26

W1P1-02-05-002

22

7. Connect connectors (22) (2 used).

W1P1-02-05-003

8. Connect hoses (21) (10 used) to control valve (7).


: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

21

21

W2-5-6

W1P1-02-05-001

UPPERSTRUCTURE / Control Valve


20

9. Connect pipe (19) to control valve (7) with socket


bolts (20) (4 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

19

W1P1-02-05-002

10

10. Connect pipe (19) to oil cooler (10) with coupling


(18).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

18

19

W1P1-02-05-007

11. Install cover (16) to bracket (17) with sems bolts


(15) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

15
16

17

W1P1-02-11-020

12. Shut cover (14).


14

W1P1-02-02-001

W2-5-7

UPPERSTRUCTURE / Control Valve


13. Install bracket (11) to control valve (7) with bolt (8).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

9, 10
11

14. Connect pipe (9) to hydraulic oil tank (4) and oil
cooler (10) with couplings (5) (2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

12
13

15. Secure pipe (9) to brackets (11) (2 used) with


clamps (12) (2 used) and bolts (13) (2 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
6

16. Connect hoses (6) (3 used) to pipe (9).


: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
17. Install cover (2) to frame (1) with sems bolts (3) (4
used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-05-002

W1P1-02-05-006

W2-5-8

UPPERSTRUCTURE / Control Valve


REMOVAL
AND
INSTALLATION
CONTROL VALVE (ZX75US-3)

OF

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Open cover (1).
: 17 mm

W1P1-02-05-008

2. Remove sems bolts (4) (5 used).


: 17 mm

3. Disconnect plugs (6) (2 used).

W1P1-02-05-009

4. Remove sems bolts (7) (2 used). Remove cover


(2) from frame (5) and bracket (3).
: 17 mm
7

W2-5-9

WBAT-06-01-067

UPPERSTRUCTURE / Control Valve


5. Remove sems bolts (9) (4 used). Remove cover
(13) from brackets (3, 8).
: 17 mm

10

11

12

6. Remove sems bolts (12) (6 used). Remove cover


(11) from bracket (8) and hydraulic oil tank (10).
: 17 mm

13
W1P1-02-05-010

7. Remove sems bolts (15) (4 used) from cover (16).


Remove the brackets (14) (2 used) assembly from
cover (16).
: 17 mm

14
15

8. Remove cover (16) from brackets (3, 8).


16
3
W1P1-02-05-010

9. Remove nuts (21), washers (22) (2 used), and bolt


(23) from bracket (24). Remove bracket (20) from
bracket (24).
: 17 mm

17

18

10. Remove socket bolts (18) (2 used) from pipe (17).


Disconnect pipe (17) from control valve (19). Cap
the open ends.
: 8 mm

19
20
21, 22, 23
24

11. Remove coupling (25) from hydraulic oil tank (10)


and pipe (17). Disconnect pipe (17) from hydraulic
oil tank (10).
: 13 mm

WBAT-06-01-066

10

25

17

WBAT-06-01-068

W2-5-10

UPPERSTRUCTURE / Control Valve


12. Remove socket bolts (27) (4 used) from pipe (26).
Disconnect pipe (26) from control valve (19). Cap
the open ends.
: 8 mm

26

27

19

WBAT-06-01-068

13. Remove sems bolt (30) from clip (29). Remove


clip (29) from bracket (31).
: 17 mm
14. Disconnect hoses (28) (11 used) from the front
side of control valve (19). Cap the open ends.
Attach an identification tag onto the disconnected
hoses for assembling.
: 17 mm
15. Disconnect hoses (28) (9 used) from the right side
of control valve (19). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 19 mm, 27 mm

19

28

29, 30
31
WBAT-06-01-066

16. Disconnect hoses (28) (11 used) from the rear of


control valve (19). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm, 27 mm
17. Disconnect hoses (28) (13 used) from the left side
of control valve (19). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 17 mm, 22 mm, 27 mm

W2-5-11

UPPERSTRUCTURE / Control Valve


19

18. Disconnect connectors (33) (2 used) from


pressure sensors (32) (2 used) of the left side of
control valve (19) .

32

CAUTION: The control valve (19) assembly


weight: 87 kg (192 lb)

33

19. Attach a nylon sling onto control valve (19). Hoist


and hold control valve (19).
WBAT-06-01-069

20. Remove bolts (32) (4 used) and washers (33) (4


used) from bracket (31). Remove the control valve
(19) assembly from frame (5).
: 22 mm

31

WBAT-06-01-070

32, 33

CAUTION: Control valve (19) weight: 76 kg


(170 lb)

34, 35

19

21. Remove bolts (34) (3 used) and washers (35) (3


used) from bracket (31). Remove control valve
(19) from bracket (31).
: 22 mm

31

W2-5-12

W1P1-02-05-005

UPPERSTRUCTURE / Control Valve


Installation
CAUTION: Control valve (19) weight: 76 kg
(170 lb)
1. Attach a nylon sling onto control valve (19). Hoist
control valve (19). Align control valve (19) with the
mounting hole on bracket (31). Install bracket (31)
to control valve (19) with bolts (34) (3 used) and
washers (35) (3 used).
: 22 mm
: 140 Nm (14 kgfm)

32, 33

34, 35

19

31

W1P1-02-05-005

CAUTION: The bracket (31) assembly weight:


87 kg (192 lb)
2. Attach a nylon sling onto the bracket (31)
assembly. Hoist the bracket (31) assembly. Align
the bracket (31) assembly with the mounting hole
on frame (5). Install bracket (31) to frame (5) with
bolts (32) (4 used) and washers (33) (4 used).
: 22 mm
: 140 Nm (14 kgfm, 103 lbfft)
3. Connect connectors (33) (2 used) to pressure
sensors (32) (2 used).

32
33

WBAT-06-01-069

W2-5-13

UPPERSTRUCTURE / Control Valve


17

4. Connect hoses (31) (44 used) to control valve


(19).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

18

19

28

5. Secure hoses (28) (2 used) to bracket (31) with


clip (29) and sems bolt (30).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

29, 30
31
WBAT-06-01-066

6. Connect pipe (17) to control valve (19) with socket


bolt (18).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)
7. Install the pipe (17) assembly to hydraulic oil tank
(10) with coupling (25).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

10

25

17
26

8. Connect pipe (26) to control valve (19) with socket


bolts (27) (4 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

27

19

9. Install bracket (20) to bracket (24) with bolts (23),


washers (22) (2 used), and nut (21).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WBAT-06-01-068

20
21, 22, 23
24

WBAT-06-01-066

W2-5-14

UPPERSTRUCTURE / Control Valve


8

10. Install cover (16) to brackets (3, 8).

14

10

11
12

11. Install covers (16, 11) to bracket (8) and hydraulic


oil tank (10) with sems bolts (12) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

16
3

12. Install the brackets (14) (2 used) assembly to


cover (16) with sems bolts (15) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

13

15

W1P1-02-05-010

13. Install cover (13) to cover (16) with sems bolts (9)
(4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

14. Align cover (2) with the mounting holes on bracket


(3) and frame (5). Install cover (2) to frame (5) with
sems bolts (7) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

15. Connect plugs (6) (2 used).


2

WBAT-06-01-067

16. Install cover (2) to bracket (3) and frame (5) with
sems bolts (4) (5 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
4

5
W1P1-02-05-009

17. Shut cover (1).


1

W1P1-02-05-008

W2-5-15

UPPERSTRUCTURE / Control Valve


DISASSEMBLY OF CONTROL VALVE
1

Upper Section

5
3

2
3

25
5

7
1

11

Lower Section

12

26

10

24

4
5

7
18

13

14
3

26

2
5

3
6

2
3

4
5

15
5

6
7

16
7

7
19

20
6

17

4
5

21

22

4
5

9
7
23

W1CD-02-05-025

W2-5-16

UPPERSTRUCTURE / Control Valve

27

28

1
3
5

28

2
28
28

5
28

5
5

3 5
5

1
5

29
25

28
3

29

3
28

28

28

24
W1CD-02-05-026

12345-

Plug (9 Used)
O-Ring (9 Used)
Socket Bolt (54 Used)
Cover (10 Used)
O-Ring (27 Used)

6 - Spool End (14 Used)


7 - Spring Seat (28 Used)
8 - Spring (13 Used)

910 11 12 13 -

Spring
Spool (Blade)
Spool (Swing)
Spool (Arm 3)
Spool (Auxiliary Flow
Combiner)
14 - Spool (Arm 2)
15 - Spool (Boom 1)

16 17 18 19 20 -

Spool (Bucket)
Spool (Left Travel)
Spool (Boom Swing)
Spool (Auxiliary)
Spool (Arm 1)

21 - Spool (Boom 2)
22 - Spool (Right Travel)

W2-5-17

23 24 25 26 27 -

Spool (Flow Combiner Valve)


Plug (2 Used)
O-Ring (2 Used)
Cover (2 Used)
Housing

28 - Cover (9 Used)
29 - Cover (2 Used)

UPPERSTRUCTURE / Control Valve


31
32

52
53

31

33

50 51

34

32

39
31

35

39

36

40

40
48

32

49

46
47

27

45

34
43

33
44
38
37
40
39
32
31

32
31

40
39
32

42

31

41
31 32 33 34 35 36 -

Overload Relief Valve (6 Used)


O-Ring (6 Used)
Overload Relief Valve (2 Used)
O-Ring (2 Used)
Plug
O-Ring

37 38 39 40 41 42 -

Plug
O-Ring
Shut-Off Valve (4 Used)
O-Ring (4 Used)
Plug
O-Ring

W2-5-18

W1CD-02-05-023

43 44 45 46 47 48 -

Main Relief Valve


O-Ring
Plug
Signal Plug
O-Ring
Plug

49 50 51 52 53 -

O-Ring
Plug
O-Ring
Main Relief Valve
O-Ring

UPPERSTRUCTURE / Control Valve


60
61
62
63

55
54

65
66
67

64

68

56
57
58
59
65
66

86

87

88

67

68

27

89

68
67
66
65
73
80
79

85
84

78
83

72
71
70

69

77
76
75

82
81

74
W1CD-02-05-019

54 55 56 57 58 59 60 61 62 -

Anti-Drift Valve
Socket Bolt(4 Used)
O-Ring
O-Ring
Spring
Poppet
Plug
O-Ring
Spring

63 64 65 66 67 68 69 70 71 -

Poppet
Sleeve
Plug (13 Used)
O-Ring (13 Used)
Spring (13 Used)
Poppet (13 Used)
Socket Bolt
Cover
O-Ring

72 73 74 75 76 77 78 79 80 -

Spring
Poppet
Plug
O-Ring
Spring
Poppet
Sleeve
Spring
Poppet

W2-5-19

81 82 83 84 85 86 87 88 89 -

Socket Bolt (2 Used)


Cover
O-Ring
Spring
Spool
Plug
O-Ring
Spring
Poppet

UPPERSTRUCTURE / Control Valve


1

26
5

10

11

24

5
6

5
6

Upper Section

18

14
1
3

5
5

4
6

13

26

Lower Section

12

4
5

15
6

16
6

17

5
3

4
5

27

28 28 28

19

20

21

22

23

28
1
3
5

1
3

5
1
28

5
5

1
3

28

28
3

29

28

W2-5-20

5 28

29

24

W1CD-02-05-024

UPPERSTRUCTURE / Control Valve


Disassembly of Control Valve
IMPORTANT: Do not remove plugs (1, 24) from the
head part of covers (4, 26, 28, and
29). In case they have been removed,
do not damage the thread part when
installing them as the cover is made
of aluminium.
1. Remove socket bolts (3) (28 used) from covers
(4) (10 used) and (26) (2 used). Remove covers
(4) (10 used) and (26) (2 used) from housing (27).
Remove O-rings (5) (14 used) from housing (27).
: 5 mm
IMPORTANT: When it is difficult to remove the
spool out for sticking, remove the
spool clockwise and counterclockwise by rotating after inserting a
hexagon wrench (5 mm) into the
spool end.
2. Remove the spools (10 to 23) assemblies (14
used) from housing (27).

IMPORTANT: LOCTITE has been applied onto the


thread part of spool end (6). Warm
its thread part to temperature of 200
to 250 C (392 to 482F) (for 1 to 5
minutes by using a dryer of 1kW)
first, and by using wooden pieces
remove it.
4. Secure spools (10 to 23) in a vise by using
wooden pieces. Remove spool ends (6) (14 used)
from each spool. Remove spring seats (7) (28
used), springs (8) (13 used) and spring (9) from
spools (10 to 23).
: 5 mm
NOTE: As springs (8) (13 used) and spring (9) are
in their free length, there is no danger of
the spring flying out.

NOTE: Attach an identification tag onto the spool


for reassembling.
3. Remove socket bolts (3) (26 used) from covers
(28) (9 used) and (29) (2 used). Remove covers
(28) (9 used), (29) (2 used) and O-rings (5) (13
used) from housing (27).
: 5 mm

W2-5-21

UPPERSTRUCTURE / Control Valve

31
32

52
53

31

33

50 51

34

32

39
31

35

39

36

40

40
48

32

49

46
47

27

45

34
43

33
44
38
37
40
39
32
31

32
31

40
39
32

42
41

31
W1CD-02-05-023

W2-5-22

UPPERSTRUCTURE / Control Valve


5. Remove main relief valves (43, 52) and overload
relief valves (31) (6 used), (33) (2 used) from
housing (27).
Remove O-rings (44, 53) from main relief valves
(43, 52). Remove O-rings (32) (6 used) and (34)
(2 used) from overload relief valves (31) (6 used)
and (33) (2 used).
: 24 mm, 32 mm
: 5 mm
6. Remove shut-off valves (39) (4 used) from housing (27). Secure shut-off valves (39) (4 used) in a
vise.
Remove the lock nut and the adjusting screw and
the poppet from the plug.
: 14 mm, 17 mm
: 5 mm

Adjusting Screw
Lock Nut
Plug

27
Poppet

40
W1CD-02-05-001

7. Remove signal plug (46) and O-ring (47) from


housing (27).
: 22 mm

W2-5-23

UPPERSTRUCTURE / Control Valve

60
61
62
63

55
54

65
66
67

64

68

56
57
58
59
65
66

86

87

88

67

68

27

89

68
67
66
65
73
80
79

85
84

78
83

72
71
70

69

77
76
75

82
81

74
W1CD-02-05-019

W2-5-24

UPPERSTRUCTURE / Control Valve


8. Remove socket bolts (55) (4 used)from anti-drift
valve (54). Remove anti-drift valve (54), O-rings
(56, 57), spring (58), and poppet (59) from
housing (27).
: 5 mm
9. Remove plug (60), O-ring (61), spring (62), poppet (63), and sleeve (64) from housing (27).
: 27 mm

13. Remove plug (74), O-ring (75), spring (76), poppet (77), sleeve (78), spring (79), and poppet (80)
from housing (27).
: 27 mm
14. Remove plug (86), O-ring (87), spring (88), and
poppet (89) (no identification groove) from housing (27).
: 8 mm

10. Remove plugs (65) (13 used), O-rings (66) (13


used), springs (67) (13 used) and poppets (68)
(13 used) from housing (27).
: 24 mm
11. Remove socket bolts (69) (4 used) from cover
(70). Remove cover (70), O-ring (71), spring (72)
and poppet (73) (with an identification groove)
from housing (27).
: 5 mm
12. Remove socket bolts (81) (2 used) from cover
(82). Remove cover (82), O-ring (83), spring (84)
and spool (85) from housing (27).
: 5 mm

W2-5-25

UPPERSTRUCTURE / Control Valve


ASSEMBLY OF CONTROL VALVE
A

W1CD-02-05-005

Back
7

27 5

28

18

10
1, 2

1, 2

7
1, 2

1, 2

11
12
26
26

13
14
29

19

15
29

21
24, 25
22

20

16
17

9
Section A-A
12345-

Plug (9 Used)
O-Ring (9 Used)
Socket Bolt (54 Used)
Cover (10 Used)
O-Ring (27 Used)

6 - Spool End (14 Used)


7 - Spring Seat (28 Used)
8 - Spring (13 Used)

910 11 12 13 -

W1CD-02-05-009

Spring
Spool (Blade)
Spool (Swing)
Spool (Arm 3)
Spool (Auxiliary
Flow Combiner)
14 - Spool (Arm 2)
15 - Spool (Boom 1)
16 - Spool (Bucket)

17 18 19 20 21 -

Section B-B
Spool (Left Travel)
Spool (Boom Swing)
Spool (Auxiliary)
Spool (Arm 1)
Spool (Boom 2)

22 - Spool (Right Travel)


23 - Spool (Flow Combiner Valve)

W2-5-26

24 25 26 27 28 -

23
Plug (2 Used)
O-Ring (2 Used)
Cover (2 Used)
Housing
Cover (9 Used)

29 - Cover (2 Used)

W1CD-02-05-008

UPPERSTRUCTURE / Control Valve


27
33

34

66 65

67 68 27 34

33

Section D
Section E
Section F
Section G
Section H
Section I
Section J

39

40

Section K

66 65

67 68

40 39

Section L

Right Side

52

31 32 33 34 35 36 -

Section D

W1CD-02-05-002

66

65

53

Section E

27

67 68 27

W1CD-02-05-011

Overload Relief Valve (6 Used)


O-Ring (6 Used)
Overload Relief Valve (2 Used)
O-Ring (2 Used)
Plug
O-Ring

37 38 39 40 41 42 -

Plug
O-Ring
Shut-Off Valve (4 Used)
O-Ring (4 Used)
Plug
O-Ring

66

Section F

43 44 45 46 47 48 -

W2-5-27

Main Relief Valve


O-Ring
Plug
Signal Plug
O-Ring
Plug

49 50 51 52 53 -

W1CD-02-05-010

65 67 68

W1CD-02-05-012

O-Ring
Plug
O-Ring
Main Relief Valve
O-Ring

UPPERSTRUCTURE / Control Valve


65 67 68 27

66

39 40

66 65

67

68

31

40 39

32 61 60

31

32 66

W1CD-02-05-013

Section G

62 63 64 27

65

67 68 32 31
W1CD-02-05-014

Section H

54
57 66 65 67 68 27 32
31

31

32

66 65

67 68

27 32 31

56
58
59
73
72
70

Identification Groove
on Poppet (73) of
Boom Flow Combiner
Check Valve

71

66 65

67

Section I

54 55 56 57 58 59 60 61 62 -

Anti-Drift Valve
Socket Bolt (4 Used)
O-Ring
O-Ring
Spring
Poppet
Plug
O-Ring
Spring

63 64 65 66 67 68 69 70 71 -

75

68
W1CD-02-05-015

Poppet
Sleeve
Plug (13 Used)
O-Ring (13 Used)
Spring (13 Used)
Poppet (13 Used)
Socket Bolt
Cover
O-Ring

72 73 74 75 76 77 78 79 80 -

Spring
Poppet
Plug
O-Ring
Spring
Poppet
Sleeve
Spring
Poppet

W2-5-28

74
Section J

81 82 83 84 85 86 87 88 89 -

76

78
80
79
77
W1CD-02-05-016

Socket Bolt (2 Used)


Cover
O-Ring
Spring
Spool
Plug
O-Ring
Spring
Poppet

UPPERSTRUCTURE / Control Valve


46

47

67 68

27

27 85

83 82

84

65

66
68
68
67
67

66 65

66

65

W1CD-02-05-017

43

W1CD-02-05-018

44
Section L

Section K
3

27

86

27

Bottom

86
87
88
89
W1CD-02-05-006

Section C-C

Front

W1CD-02-05-004

W2-5-29

UPPERSTRUCTURE / Control Valve


27

33

34

66 65

67 68 27 34

33

Section D
Section E
Section F
Section G
Section H

39

40
66 65

W1CD-02-05-002

Section D

Right Side

52

65

27

67 68 27

W1CD-02-05-011

53

40 39

Install spring (67) with its bigger


diameter side facing to the poppet
W1CD-02-05-010
(68) side.

Poppet (68)

66

67 68

66

Section F

65 67 68

W1CD-02-05-012

Section E
65 67 68 27

66

39 40

66

65

Section G

67

68

31

40 39
W1CD-02-05-013

W2-5-30

31

32 61 60

32 66

62 63 64 27

65

Section H

67 68 32

31

W1CD-02-05-014

UPPERSTRUCTURE / Control Valve


Assembly of Control Valve
1. Apply grease onto O-rings (34) (2 used). Install
O-rings (34) (2 used) to overload relief valves (33)
(2 used). Install overload relief valves (33) (2
used) to housing (27).
: 24 mm
: 59 to 69 Nm
(6 to 7 kgfm, 44 to 51 Ibfft)
2. Apply grease onto O-rings (40) (4 used). Install
poppets (4 used), adjusting screws (4 used), and
lock nuts (4 used) to plugs (4 used). Install
shut-off valves (39) (4 used) to housing (27).
Tighten the adjusting screws (4 used) and the
lock nuts (4 used).
: 14 mm
: 19 to 22 Nm
(1.9 to 2.2 kgfm, 14 to 16 Ibfft)
: 17 mm
: 59 to 69 Nm
(6 to 7 kgfm, 44 to 51 Ibfft)
: 5 mm (Adjusting screw)
: 19 to 22 Nm
(1.9 to 2.2 kgfm, 14 to 16 Ibfft)
Shut-Off Valve (39)

IMPORTANT: As for the spring (67) diameter, one


is smaller and the other is big. Install
spring (67) with its bigger side facing to the poppet (68) side.
3. Apply grease onto O-rings (66) (7 used). Install
O-rings (66) (7 used) to plugs (65) (7 used). Install
poppets (68) (7 used), springs (67) (7 used), and
plugs (65) (7 used) to housing (27).
: 24 mm
: 88 to 98 Nm
(9 to 10 kgfm, 65 to 72 Ibfft)
4. Apply grease onto O-ring (53). Install O-ring (53)
to main relief valve (52). Install main relief valve
(52) to housing (27).
: 24 mm
: 49 to 54 Nm
(5 to 5.5 kgfm, 36 to 40 Ibfft)
5. Apply grease onto O-rings (32) (3 used). Install
O-rings (32) (3 used) to overload relief valves (31)
(3 used). Install overload relief valves (31) (3
used) to housing (27).
: 24 mm
: 59 to 69 Nm
(6 to 7 kgfm, 44 to 51 Ibfft)

Adjusting Screw

Lock Nut
Plug

Poppet

40

27

6. Apply grease onto O-ring (61). Install O-ring (61)


to plug (60).
Install sleeve (64), poppet (63), spring (62), and
plug (60) to housing (27).
: 27 mm
: 167 to 196 Nm
(17 to 20 kgfm, 123 to 145 Ibfft)

W1CD-02-05-001

W2-5-31

UPPERSTRUCTURE / Control Valve


27

27

55

Section I
Section J
Section K

81
82

Section L

Right Side

Back

W1CD-02-05-002

W1CD-02-05-005

54
57 66 65 67 68 27 32

31

31

32

66

65

67 68

27

32

31

56
58
59

66 65

67

75

68

47

76

W1CD-02-05-016

Section J

W1CD-02-05-015

Section I
46

74

67 68

27

27 85

80
78
79
77

83 82

84

65

66
68
68
67
67
43
66

65 66

65

W1CD-02-05-017

Section K

W2-5-32

W1CD-02-05-018

44
Section L

UPPERSTRUCTURE / Control Valve


7. Install poppet (59), spring (58), O-rings (56, 57),
and anti-drift valve (54) to housing (27) with
socket bolts (55) (4 used).
: 5 mm
: 8.8 to 11 Nm
(0.9 to 1.1 kgfm, 6.5 to 8.1 Ibfft)
IMPORTANT: As for the spring (67) diameter, one
is smaller and the other is big. Install
spring (67) with its bigger side facing to the poppet (68) side.
8. Apply grease onto O-rings (66) (6 used). Install
O-rings (66) (6 used) to plugs (65) (6 used).
Install poppets (68) (6 used), springs (67) (6 used),
and plugs (65) (6 used) to housing (27).
: 24 mm
: 88 to 98 Nm
(9 to 10 kgfm, 65 to 72 Ibfft)
9. Apply grease onto O-rings (32) (3 used). Install
O-rings (32) (3 used) to overload relief valves (31)
(3 used). Install overload relief valves (31) (3
used) to housing (27).
: 24 mm
: 59 to 69 Nm
(6 to 7 kgfm, 44 to 51 Ibfft)
10. Apply grease onto O-rings (75). Install O-ring (75)
to plug (74).
Install poppet (80), spring (79), sleeve (78), poppet (77), spring (76), and plug (74) to housing
(27).
: 27 mm
: 167 to 196 Nm
(17 to 20 kgfm, 123 to 145 Ibfft)

IMPORTANT: As the filter is crimped in signal plug


(46), the filter cannot be disassembled.
In case the filter is clogged, or the
foreign matter cannot be removed
even by washing and cleaning as
well as being damaged, signal plug
(46) should be replaced as an assembly.
11. Apply grease onto O-ring (47). Install O-ring (47)
to signal plug (46). Install signal plug (46) to
housing (27).
: 22 mm
: 49 to 59 Nm
(5 to 6 kgfm, 36 to 44 Ibfft)
12. Apply grease onto O-rings (44). Install O-ring (44)
to main relief valve (43). Install main relief valve
(43) to housing (27).
: 32 mm
: 49 to 59 Nm
(5 to 6 kgfm, 36 to 44 Ibfft)
13. Install spool (85), spring (84), O-ring (83), and
cover (82) to housing (27) with socket bolts (81) (2
used).
: 4 mm
: 7.3 to 10 Nm
(0.7 to 1 kgfm, 5.4 to 7.4 Ibfft)

W2-5-33

UPPERSTRUCTURE / Control Valve


27

69

Section I

Right Side

Back

W1CD-02-05-002

W1CD-02-05-005

86

27

27

73
72
70
Identification Groove
on Poppet (73) of
Boom Flow Combiner
Check Valve

Bottom

86

71

Section I

87
88
89

W1CD-02-05-015

Section C-C

W2-5-34

Poppet of
Bucket Flow
Combiner
Check Valve
W1CD-02-05-006

UPPERSTRUCTURE / Control Valve


IMPORTANT: The shape of poppet (73) is similar
to that of poppet (89).
An identification groove is located
on the end of poppet (73),
14. Apply grease onto O-ring (71). Install poppet (73),
spring (72), O-ring (71), and cover (70) to housing
(27) with socket bolts (69) (4 used).
: 5 mm
: 8.8 to 11 Nm
(0.9 to 1.1 kgfm, 6.5 to 8.1 Ibfft)
15. Apply grease onto O-ring (87). Install O-ring (87)
to plug (86).
Install poppet (89) (without identification groove),
spring (88), and plug (86) to housing (27).
: 8 mm
: 61.8 to 82.4 Nm
(6.3 to 8.4 kgfm, 46 to 61Ibfft)

W2-5-35

UPPERSTRUCTURE / Control Valve

W1CD-02-05-005

W1CD-02-05-004

Front

Back
7

27 5

28
10

27

18

11
12
26
26

13
14
29

19

15

21

29
16
17

22

20

9
23

W1CD-02-05-009

Section A-A

Section B-B

W2-5-36

W1CD-02-05-008

UPPERSTRUCTURE / Control Valve


16. Remove LOCTITE from the thread parts of spools
(10 to 23) (14 used) and spool ends (6) (14 used)
with a dies (8 mm, Pitch 1.25 mm) and a tap (8
mm, Pitch 1.25 mm).
17. Secure spools (10 to 23) (14 used) vertically by
using wooden pieces. Apply LOCTITE (#271)
onto one pitch in the thread hole of spools (10 to
23) (14 used). Install spring seats (7) (14 used),
springs (8) (13 used), spring (9), spring seats (7)
(14 used), and spool ends (6) (14 used) respectively.
: 5 mm
: 19 to 22 Nm
(1.9 to 2.2 kgfm, 14.0 to 16.0 Ibfft)
18. Apply grease on to O-rings (5) (13 used). Install
O-rings (5) (13 used), covers (28) (9 used), and
(29) (2 used) to housing (27) with socket bolts (3)
(26 used).
: 5 mm
: 8.8 to 11 Nm
(0.9 to 1.1 kgfm, 6.5 to 8.1 Ibfft)
19. Insert the spool (10 to 23) (14 used) assemblies
to housing (27).
Install O-rings (5) (14 used), covers (4) (10 used),
and (26) (2 used) to housing (27) with socket bolt
(3) (28 used).
: 5 mm
: 8.8 to 11 Nm
(0.9 to 1.1 kgfm, 6.5 to 8.1 Ibfft)

W2-5-37

UPPERSTRUCTURE / Control Valve


(Blank)

W2-5-38

UPPERSTRUCTURE / Swing Device


REMOVAL AND INSTALLATION OF SWING
DEVICE (ZX70-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

3,4

CAUTION: Swing device (1) weight: 71 kg


(160 lb)
Removal
1. Disconnect hoses (6) (4 used) from pipes (7) (4
used). Cap the open ends.
: 27 mm
2. Disconnect hoses (2) (6 used) from swing device
(1). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 27 mm, 36 mm
3. Remove bolts (3) (10 used) and washers (4) (10
used) from swing device (1). Attach a nylon sling
onto swing device (1). Hoist and remove swing
device (1) from frame (5).
: 24 mm

W2-6-1

W1P1-02-06-001

UPPERSTRUCTURE / Swing Device


Installation
CAUTION: Swing device (1) weight: 71 kg
(160 lb)
1. Attach a nylon sling onto swing device (1). Hoist
swing device (1). Align swing device (1) with the
mounting hole on frame (5).

3,4

2. Install swing device (1) to frame (5) with bolts (3)


(10 used) and washers (4) (10 used).
: 24 mm
: 210 Nm (21.5 kgfm, 16 lbfft)
3. Connect hoses (2) (6 used) to swing device (1).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 m
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)

W1P1-02-06-001

4. Connect hoses (6) (4 used) to pipes (7) (4 used).


: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

W2-6-2

UPPERSTRUCTURE / Swing Device


REMOVAL AND INSTALLATION OF SWING
DEVICE (ZX75US-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Remove clip band (5) from cover (3). Disconnect
harness (4) from cover (3).
2. Remove sems bolts (2) (4 used). Remove cover
(3) from support (1) and frame (6).
: 17 mm

CAUTION: Swing device (8) weight: 71 kg


(160 lb)
W1P1-02-06-003

3. Disconnect hose (12) from swing device (8) and


pipe (11). Cap the open ends.
: 36 mm
7

4. Disconnect hose (10) from pipe (11). Cap the


open ends.
: 19 mm
5. Disconnect hoses (7) (5 used) from swing device
(8). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 22 mm, 27 mm

10

6. Remove bolts (13) (10 used) and washers (14)


(10 used) from swing device (8). Attach a nylon
sling onto swing device (8). Hoist and remove
swing device (8) from frame (9).
: 24 mm

11

W1P1-02-06-002

13,14

W2-6-3

12

UPPERSTRUCTURE / Swing Device


Installation
CAUTION: Swing device (8) weight: 71 kg
(160 lb)
7

1. Attach a nylon sling onto swing device (8). Hoist


swing device (8). Align swing device (8) with the
mounting hole on frame (9).

2. Install swing device (8) to frame (9) with bolts (13)


(10 used) and washers (14) (10 used).
: 24 mm
: 210 Nm (21.5 kgfm, 16 lbfft)

10

3. Connect hoses (7) (5 used) to swing device (8).


: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 m
: 78 Nm (8 kgfm, 58 lbfft)

11

W1P1-02-06-002

12

13,14

4. Connect hose (12) to swing device (8).


: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
5. Connect hose (10) to pipe (11).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

6. Install cover (3) to support (1) and frame (6) with


sems bolts (2) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
6

7. Secure harness (4) to cover (3) with clip band (5).

W1P1-02-06-003

W2-6-4

UPPERSTRUCTURE / Swing Device


(Blank)

W2-6-5

UPPERSTRUCTURE / Swing Device


DISASSEMBLY OF SWING DEVICE

2
3
4

28

27

6
7

26

25

24

10
8

23

11, 12

22

13

21

14

20

15

19

16

18
17
WBAT-06-01-001

1 - Swing Motor
2 - First Stage Carrier
3 - Socket Bolt (8 Used)
4 - Retaining Ring (3 Used)
5 - Needle Bearing (3 Used)
6 - First Stage Planetary Gear
(3 Used)
7 - Pin (3 Used)

8 - Plate (6 Used)
9 - Needle Bearing (3 Used)
10 - Second Stage Planetary
Gear (3 Used)
11 - Spring Pin (3 Used)
12 - Spring Pin (3 Used)
13 - Socket Bolt (13 Used)

15 - Seal
16 - Plate
17 - Shaft

22 - Adjusting Washer
23 - Ring Gear
24 - Thrust Plate

18 - Spacer
19 - Roller Bearing
20 - Housing

25 - Second Stage Carrier


26 - Second Stage Sun Gear
27 - First Stage Sun Gear

14 - Oil Seal

21 - Roller Bearing

28 - Plate

NOTE: The adjusting (22) thickness is as follows;


7.9 mm, 8.05 mm, 8.2 mm, 8.35 mm, 8.5
mm, 8.65 mm,

W2-6-6

UPPERSTRUCTURE / Swing Device


Disassembly of Swing Device
1. Tilt the swing device and drain hydraulic oil for the
motor and the swing reduction gear through the
drain port.

6. Remove pins (7) (3 used), second stage planetary


gears (10) (3 used), needle bearings (9) (3 used),
plates (8) (6 used), and thrust plate (24) from
second stage carrier (25).
7. Remove spring pins (11, 12) (3 used for each)
from pins (7) (3 used).

Drain Port

8. Remove socket bolts (13) (13 used). Remove ring


gear (23) from housing (20).
: 12 mm
NOTE: THREEBOND has been applied onto the
mounting surface of ring gear (23).

WBAT-06-01-003

CAUTION: Swing motor (1) weight: 20 kg (44


lb)

9. Set the shaft (17) assembly on a press stand.


Remove adjusting washer (22) from shaft (17) by
using a special tool.

2. Remove socket bolts (1) (8 used). Insert a


screwdriver into the clearance between swing
motor (1) and ring gear (23). Float swing motor (1).
Hoist and remove swing motor (1) from ring gear
(23).
: 12 mm
3. Remove the first stage carrier (2) assembly,
second stage sun gear (26), and the second
stage carrier (25) assembly from ring gear (23).
4. Remove retaining rings (4) (3 used) from first
stage carrier (2). Remove plate (28), first stage
sun gear (27), first stage planetary gears (6) (3
used), and needle bearings (5) (6 used) from first
stage carrier (2).
5. Tap and install spring pins (11, 12) of the second
stage carrier (25) assembly to the end of pin (7)
by using a round bar (length 100 mm (3.9 in) or
more, dia. 5 mm (0.2 in)).
NOTE: If spring pins (11, 12) are installed to the
innermost part, pin (7) cannot be removed
as they comes in contact with second stage
carrier (25).

W2-6-7

Press
Special Tool

17
22
21

WBAT-06-01-083

UPPERSTRUCTURE / Swing Device

21

20
19

16

18
17
WBAT-06-01-001

W2-6-8

UPPERSTRUCTURE / Swing Device


CAUTION: If pushing shaft (17) from housing
(20) by using a press, provide a protection
cover (outer diameter: 190 mm (7.5 in), inner
diameter: 65 mm (2.6 in), thickness: 25 to 30
mm (1 to 1.2 in)). When housing (20) and/or
roller bearing (21) are broken and flown off
without the cover, the metal fragments may
result in personal injury.
Degrease the housing (20) inside before
warming up roller bearing (21). Failure to
degrease may cause a fire.

11. Set a special tool to the shaft (17) assembly.


Special tool when removing roller bearing (21)
Hose Clamp

Shaft

10. Set the housing (20) assembly on a press stand.


Remove shaft (17) from housing (20).
W157-02-06-012

30
26
28

Shaft
Guide

W157-02-06-013

NOTE: Use the following parts as a special tool


when removing roller bearing (19).
Part size remarks:
Shaft or bolt: length: 160 mm (6.3 in),
diameter: 19 mm (0.7 in) (6 to 8 used) (All
should be identical in length with no wear
and deformation on both ends.
Material: S35C
Hose clamp: standard diameter: 6-1/2 inch
(applicable diameter: 125 to 155 mm (4.9
to 6.1 in)) (2 used)
Guide: height: 120 mm (4.7 in), outer
diameter: 170 mm (6.7 in), inner diameter:
150 mm (5.9 in)

W2-6-9

UPPERSTRUCTURE / Swing Device

21

14

20

15

19

16

18
17
WBAT-06-01-001

W2-6-10

UPPERSTRUCTURE / Swing Device


CAUTION: When pushing shaft (17) by using
a press inside the guide.
12. Set shaft (17) with the special tool attached on the
press stand.
Press

17
19
16
18
Guide

W157-02-06-014

13. Remove the inner race of roller bearing (19) and


spacer (18) from shaft (17).
IMPORTANT: Do not remove the outer races of
roller bearings (21, 19) from housing
(20). As pushing force for the outer
races of roller bearings (21, 19)
decreases, the service life of the
bearing is influenced by this. If they
have been removed, replace them
and housing (20) with the new ones.
14. Remove the inner race of roller bearing (21), oil
seal (14), and seal (15) from housing (20).
15. Thoroughly degrease housing (20), roller bearing
(19), and spacer (18).

W2-6-11

UPPERSTRUCTURE / Swing Device


ASSEMBLY OF SWING DEVICE

2
3
4

28

27

6
7

26

25

24

10
8

23

11, 12

22

13

21

14

20

15

19

16

18
17
WBAT-06-01-001

1 - Swing Motor
2 - First Stage Carrier
3 - Socket Bolt (8 Used)
4 - Retaining Ring (3 Used)
5 - Needle Bearing (3 Used)
6 - First Stage Planetary Gear
(3 Used)
7 - Pin (3 Used)

8 - Plate (6 Used)
9 - Needle Bearing (3 Used)
10 - Second Stage Planetary
Gear (3 Used)
11 - Spring Pin (3 Used)
12 - Spring Pin (3 Used)
13 - Socket Bolt (13 Used)

15 - Seal
16 - Plate
17 - Shaft

22 - Adjusting Washer
23 - Ring Gear
24 - Thrust Plate

18 - Spacer
19 - Roller Bearing
20 - Housing

25 - Second Stage Carrier


26 - Second Stage Sun Gear
27 - First Stage Sun Gear

14 - Oil Seal

21 - Roller Bearing

28 - Plate

NOTE: The adjusting (22) thickness is as follows;


7.9 mm, 8.05 mm, 8.2 mm, 8.35 mm, 8.5
mm, 8.65 mm,

W2-6-12

UPPERSTRUCTURE / Swing Device


6. Install the inner race of roller bearing (21) to shaft
(17).

Assembly of Swing Device


IMPORTANT: Apply grease onto the inside of oil
seal (14) and seal (15). Install oil seal
(14) with the lip part facing upward
(to the motor side).
1. Install oil seal (14) and seal (15) to housing (20).
2. If roller bearings (19, 21) and housing (20) are
replaced, install the outer races of roller bearings
(19, 21) to housing (20) by using a press.

7. Adjust preload of roller bearings (19, 21).


Install roller bearing (21) by using a special tool
(ST 2725). Rotate housing (20) and adjust roller
bearings (19, 21) with pushing force 3430 N (350
kgf, 772 lbf).

Insert adjusting washers (22) in this order


into clearance a. Check the thickness of
adjusting washer (22) which cannot be
inserted.

3. Install spacer (18) and plate (16) to shaft (17).


Install the inner race of roller bearing (19) to shaft
(17) by using a press.
4. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to
the ring gear (23) mounting screw hole of housing
(20). Hoist housing (20).
IMPORTANT: Do not damage oil seal (14) with
shaft (17).
5. Slowly place and install housing (20) to the upper
of shaft (17). At this time, check the positions of
the end of the screw part, and the step part of
shaft (17) in order not to curl oil seal (14).

Adjusting
Washer (22)

Thickness
(mm)

A
B
C
D
E
F

7.9
80.5
8.2
8.35
8.5
8.65

Insert the thinnest adjusting washer (22) which


cannot be inserted into shaft (17) with pushing
force 16200 N (1650 kgf, 3650 lbf).
Press
Special Tool
(ST 2725)

21

WBAT-06-01-004

8. Apply THREEBOND #1215 onto the ring gear


(23) mounting surface of housing (20).

W2-6-13

UPPERSTRUCTURE / Swing Device

2
3
4

28

27

6
7

26

25

24

10
8

23

11, 12
13

20

17
WBAT-06-01-001

W2-6-14

UPPERSTRUCTURE / Swing Device


9. Install ring gear (23) to housing (20) with socket
bolts (13) (13 used).
: 12 mm
: 180 Nm (18 kgfm, 133 lbfft)
IMPORTANT: Install retaining rings (4) (3 used)
with the chamfered surface facing to
the plate (28) side.
28

14. Install second stage sun gear (26) to second


stage carrier (25).
15. Install the first stage carrier (26) assembly to
second stage sun gear (2).
IMPORTANT: Make the drain hole open when
installing the motor in order to
protect the oil seal.
16. Apply THREEBOND #1215 onto the step part of
the swing motor (1) side. Install swing motor (1) to
ring gear (23) with socket bolts (3) (8 used).
: 12 mm
: 180 Nm (18 kgfm, 133 lbfft)

Chamfered Surface

13. Install the second stage carrier (25) assembly to


shaft (17).

WBAT-06-01-006

Drain Hole

10. Install needle bearings (5) (3 used), first stage


planetary gears (6) (3 used), first stage sun gear
(27), and plate (28) to first stage carrier (2). Install
plate (28) with retaining rings (4) (3 used).

11. Install needle bearings (9) (3 used) to second


stage planetary gears (10) (3 used). Install thrust
plate (24), plates (8) (6 used), second stage
planetary gears (10) (3 used), and pins (7) (3
used) to second stage carrier (25).
IMPORTANT: Replace spring pins (11, 12) (3 used
for each) with the new ones. Install
spring pins (11, 12) (3 used for each)
with them facing upward (to the
swing motor (1) side).
12. Align second stage carrier (25) with the holes for
pins (7) (3 used) and install spring pins (11, 12) (3
used for each).
Slit

11, 12

THREEBOND
#1215

W1CD-02-06-015

17. Add hydraulic oil (approx. 2.5 L (0.7 US gal.)) to


the swing reduction gear through the drain hole.
Install a cap.

25

WBAT-06-01-002

WBAT-06-01-005

W2-6-15

UPPERSTRUCTURE / Swing Device


DISASSEMBLY OF SWING MOTOR

1
2

3
27
28

26

29

30

25
24

31

23
32

33
34

35
36
37

10

38

11

39

40

12
13

41

21

14

22

15

16

17

18

20
19

1 - O-Ring
2 - Needle Bearing
(Outer Race)
3 - Rotor
4 - Spherical Bushing
5 - Retainer
6 - Plunger (7 Used)
7 - Swash Plate
8 - Bearing (Inner Race)
9 - Bearing (Outer Race)
10 - Block
11 - Socket Bolt (2 Used)

W1CD-02-06-006

12 - O-Ring (2 Used)
13 - Housing

22 - Relief Valve (2 Used)


23 - Friction Plate (2 Used)

32 - Teflon Ring (2 Used)


33 - Piston (2 Used)

14 15 16 17 18 19 20 -

24 25 26 27 28 29 30 -

34 35 36 37 38 39 40 -

Poppet (2 Used)
Spring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Plug (2 Used)
Plug (2 Used)
O-Ring (2 Used)

21 - O-Ring (2 Used)

Plate (2 Used)
Piston
Spring (14 Used)
O-Ring
O-Ring
Retaining Ring
Needle Bearing
(Inner Race)
31 - Valve Plate

W2-6-16

Bushing (4 Used)
Teflon Ring (4 Used)
Scrowave (4 Used)
Pin (2 Used)
O-Ring (2 Used)
Cover
Orifice

41 - Socket Bolt (5 Used)

UPPERSTRUCTURE / Swing Device


Disassembly of Swing Motor
IMPORTANT: Do not disassemble relief valves (22)
(2 used).
1. Remove relief valves (22) (2 used) from housing
(13).
: 32 mm
2. Remove plugs (18) (2 used), springs (15) (2 used),
and poppets (14) (2 used) from housing (13).
Remove backup rings (17) (2 used) and O-rings
(16) (2 used) from plugs (18) (2 used).
: 36 mm
3. Remove socket bolts (11) (2 used) from block (10).
Remove block (10) and O-rings (12) (2 used) from
housing (13).
: 5 mm

IMPORTANT: Measure and record dimension A


between the upper surfaces of piston (25) and housing (13). This dimension is necessary for assembly
work.
8. Remove springs (26) (14 used) from housing (13).
Insert a bolt (M6, Pitch 1.0 mm) into the tap hole
on piston (25) through housing (13). Remove piston (25) by using a plate and a spanner.
Spanner

Bolt (M6, Pitch 1.0 mm)

Tap Hole
Plate

IMPORTANT: Do not remove pins (37) (2 used)


from cover (39).
4. Remove socket bolts (41) (5 used). Remove
cover (39) from housing (13).
: 10 mm

25
13

IMPORTANT: Put the mating marks on valve plate


(31) and cover (39).
5. Remove retaining ring (29), needle bearing (30),
and valve plate (31) from cover (39).

W152-02-06-006

6. Remove pistons (33) (2 used) and teflon rings


(32) (2 used) from valve plate (31).

9. Remove O-ring (27) from piston (25). Remove


O-ring (1) from housing (13).

7. Remove O-ring (28) and O-rings (38) (2 used),


bushings (34) (4 used), teflon rings (35) (4 used),
and scrowaves (36) (4 used) from cover (39).

10. Remove plates (24) (2 used) and friction plates


(23) (2 used) from housing (13).
IMPORTANT: Do not damage the upper surface
(valve plate side) of rotor (3).
11. Remove the rotor (3) assembly from housing (13).
12. Remove outer race (9) of the bearing from housing (13).

W2-6-17

UPPERSTRUCTURE / Swing Device

6
7
8

W1CD-02-06-006

W2-6-18

UPPERSTRUCTURE / Swing Device


13. Remove inner race (8) of the bearing from rotor
(3) by using a puller.

Puller

W152-02-06-007

14. Remove swash plate (7), plungers (6) (7 used),


retainer (5), and spherical bushing (4) from rotor
(3).

W2-6-19

UPPERSTRUCTURE / Swing Device


ASSEMBLY OF SWING MOTOR
40
37
41

11
10

24

38 25

31 32

33 2 30 39 36 35

34

23

A
B

22

29
26
28
27
12
1

14

15 16

17 18

21

6
4
5
7

B-B

13
9
19, 20

W1CD-02-06-002

1 - O-Ring
2 - Needle Bearing
(Outer Race)
3 - Rotor
4 - Spherical Bushing
5 - Retainer
6 - Plunger (7 Used)
7 - Swash Plate
8 - Bearing (Inner Race)
9 - Bearing (Outer Race)

12 - O-Ring (2 Used)
13 - Housing

22 - Relief Valve (2 Used)


23 - Friction Plate (2 Used)

32 - Teflon Ring (2 Used)


33 - Piston (2 Used)

14 15 16 17 18 19 20 -

24 25 26 27 28 29 30 -

34 35 36 37 38 39 40 -

10 - Block

21 - O-Ring (2 Used)

Poppet (2 Used)
Spring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Plug (2 Used)
Plug (2 Used)
O-Ring (2 Used)

Plate (2 Used)
Piston
Spring (14 Used)
O-Ring
O-Ring
Retaining Ring
Needle Bearing
(Inner Race)
31 - Valve Plate

11 - Socket Bolt (2 Used)

W2-6-20

Bushing (4 Used)
Teflon Ring (4 Used)
Scrowave (4 Used)
Pin (2 Used)
O-Ring (2 Used)
Cover
Orifice

41 - Socket Bolt (5 Used)

UPPERSTRUCTURE / Swing Device


Assembly of Swing Motor
1. Install spherical bushing (4) to rotor (3).
2. Install plungers (6) (7 used) to retainer (5). Apply
hydraulic oil onto the plunger hole of rotor (3). Install the plunger (6) assembly to rotor (3).
3. Apply hydraulic oil onto the contacting surfaces of
plungers (6) (7 used) and swash plate (7). Install
swash plate (7) to rotor (3).

IMPORTANT: Push piston (25) into housing (13)


until dimension A between the upper
surfaces of piston (25) and housing
(13) is equal to the one measured
when disassembling.
10. Apply hydraulic oil onto the outer surface of piston
(25). Install piston (25) to housing (13) by using a
plate.
11. Install springs (26) (14 used) to piston (25).

4. Install inner race (8) of the bearing to rotor (3) by


using a press.

12. Install teflon rings (35) (4 used) to bushings (34)


(4 used).

5. Install outer race (9) of the bearing to housing (13)


by using a press.

13. Install teflon rings (32) (2 used) to piston (33) (2


used).
Install piston (33) (2 used) to valve plate (31).

IMPORTANT: After installing the rotor (3) assembly into housing (13), check that the
upper surface of rotor (3) is 7.5 mm
(0.3 in) below the end of housing
(13).
6. Install the rotor (3) assembly to housing (13).
7. Apply hydraulic oil onto friction plates (23) (2
used) and plates (24) (2 used). Install friction
plate (23) and plate (24) to housing (13) alternately.
8. Apply grease onto O-ring (1). Install O-ring (1) to
housing (13).

IMPORTANT: Align the mating marks when installing valve plate (31).
14. Install bushings (34) (with teflon ring) (32) (4
used) and scrowaves (36) (4 used) to cover (39).
Install valve plate (31) (with piston (33) and teflon
ring (32)) to cover (39).
15. Install inner race (30) of the needle bearing to
cover (39). Install retaining ring (29) to cover (39).
16. Apply grease onto O-ring (28) and O-rings (38) (2
used). Install O-ring (28) and O-rings (38) (2 used)
to cover (39).

9. Apply grease onto O-ring (27). Install O-ring (27)


to piston (25).

W2-6-21

UPPERSTRUCTURE / Swing Device

41

11
10

39

14

15 16

17 18

12

A
B

22

B
B-B

13
W1CD-02-06-002

W2-6-22

UPPERSTRUCTURE / Swing Device


17. Apply THREEBOND #1211 onto the cover (39)
mounting surface of housing (13). Install cover
(39) to housing (13) with socket bolts (41) (5
used).
: 8 mm
: 65 Nm (6.6 kgfm, 48 lbfft)
18. Install O-rings (12) (2 used) to block (10). Install
block (10) to housing (13) with socket bolts (11) (2
used).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)
19. Install backup rings (17) (2 used) and O-rings (16)
(2 used) to plugs (18) (2 used). Install poppets
(14) (2 used), springs (15) (2 used), and the plug
to housing (13).
: 36 mm
: 137 Nm (14 kgfm, 101 lbfft)
20. Install relief valves (22) (2 used) to housing (13).
: 32 mm
: 78 Nm (8 kgfm, 58 lbfft)

W2-6-23

UPPERSTRUCTURE / Swing Device


DISASSEMBLY
VALVE BLOCK

AND

ASSEMBLY

OF
Valve Block
9

10

6
12

12

W1CD-02-06-008

10

2
C

3
11

Section C-C

123-

Plug
O-Ring
Plug

456-

O-Ring
Spring
Spool

789-

Spring
Spool
Block

W2-6-24

W1CD-02-06-009

10- Socket Bolt (2 Used)


11- Housing
12- O-Ring (2 Used)

UPPERSTRUCTURE / Swing Device


Disassembly of Valve Block

Assembly of Valve Block

1. Remove socket bolts (10) (2 used) from block (9).


Remove block (9) and O-rings (12) (2 used) from
housing (11).
: 5 mm

1. Install O-ring (4) to plug (3). Install spool (6),


spring (5), and plug (3) to block (9).
: 5 mm
: 20 Nm (2 kgfm, 15 lbfft)

2. Remove plug (1) from block (9). Remove spool


(8) and spring (7) from block (9).
: 5 mm

2. Install O-ring (2) to plug (1). Install spring (7),


spool (8), and plug (1) to block (9).
: 5 mm
: 20 Nm (2 kgfm, 15 lbfft)

3. Remove plug (3) from block (9). Remove spring


(5) and spool (6) from block (9).
: 5 mm
4. Remove O-rings (2, 4) from plugs (1, 3).

3. Install O-rings (12) (2 used) to block (9). Install


block (9) to housing (11) with socket bolts (10) (2
used).
: 5 mm
: 12 Nm (1.2 kgfm, 8.9 lbfft)

W2-6-25

UPPERSTRUCTURE / Swing Device


MAINTENANCE STANDARD
Swing Motor

Plunger

1. Clearance between plunger and rotor bore


d

Standard clearance (D-d): 0.04 mm (0.0016 in) or


less

W107-02-06-138

D
Rotor

W107-02-06-139

2. Clearance between plunger and shoe bottom

Plunger

Standard clearance (): 0.4 mm (0.016 in) or less

W2-6-26

Shoe

UPPERSTRUCTURE / Pilot Valve


REMOVAL AND INSTALLATION OF PILOT
VALVE
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal of Left Pilot Valve
1

CAUTION: Seat (1) weight: 40 kg (90 lb)


1. Remove bolts (3) (2 used) from seat belt (2).
: 16 mm

3
W1JB-02-01-008

2. Remove socket bolts (4) (4 used) from seat (1).


Remove seat (1) from bracket (5).
: 6 mm

W1JB-02-07-007

3. Remove cap (8) from cover (7). Remove screw (9)


from cover (7). Remove cover (7) from lever (6).

W1JB-02-07-013

8, 9

W2-7-1

UPPERSTRUCTURE / Pilot Valve


4. Remove bolts (11) (2 used) from lever (6).
Remove lever (6) from bracket (10).
: 13 mm

10

11

W1JB-02-07-012

12

5. Remove screws (13) (4 used) from boot (12). Roll


up boot (12) from bracket (10).

10

13

W1JB-02-07-002

15

6. Remove screw (15) from covers (14, 16).

12

14

16

W1JB-02-07-014

7. Remove bolts (17) (2 used) and screw (18) from


covers (14, 16). Remove covers (14, 16) from
bracket (10).
: 10 mm
17

14

16
18

10

W2-7-2

W1JB-02-07-011

UPPERSTRUCTURE / Pilot Valve


8. Remove clip bands (21) (2 used) from harness
(22). Disconnect a connector from harness (22).

19

20

21

9. Loosen lock nut (20). Remove the lever (19)


assembly from pilot valve (23).
: 19 mm, 22 mm

22

W1JB-02-07-005

23

10. Disconnect hoses (24) (6 used) from pilot valve


(23). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm

23

W1JB-02-07-006

24

11. Remove bolts (25) (4 used) from bracket (10).


Remove pilot valve (23) from bracket (10).
: 13 mm

25

10

23

W1JB-02-07-005

25

W2-7-3

UPPERSTRUCTURE / Pilot Valve


Installation of Left Pilot Valve
1. Install pilot valve (23) to bracket (10) with bolts
(25) (4 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

25

10

23

W1JB-02-07-005

25

2. Connect hoses (24) (6 used) to pilot valve (23).


: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

23

W1JB-02-07-006

24

W2-7-4

UPPERSTRUCTURE / Pilot Valve


19

3. Install the lever (19) assembly to pilot valve (23).


Secure the lever (19) assembly to pilot valve (23)
with lock nut (20).
: 22 mm
: 55 Nm (5.5 kgfm, 41 lbfft)

20

21

22

4. Connect a connector to harness (22).


10

5. Connect harness (22) to pilot valve (23) and


bracket (10) with clip bands (21) (2 used).
6. Install covers (14, 16) to bracket (10) with bolts
(17) (2 used) and screw (18).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

W1JB-02-07-005

23

17

14

16
18

10

7. Install covers (14, 16) to bracket (10) with screw


(15).

W1JB-02-07-011

15

10

16

14
W1JB-02-07-014

12

10

8. Install boot (12) to bracket (10) with screws (13) (4


used).

13

W1JB-02-07-002

W2-7-5

UPPERSTRUCTURE / Pilot Valve


9. Install lever (6) to bracket (10) with bolts (11) (2
used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

10

11

W1JB-02-07-012

10. Install cover (7) to lever (6) with screw (9). Install
cap (8) to cover (7).

W1JB-02-07-013

8, 9

CAUTION: Seat (1) weight: 40 kg (90 lb)


1

11. Install seat (1) to bracket (5) with socket bolts (4)
(4 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

3
W1JB-02-01-008

12. Install seat belt (2) to bracket (4) with bolts (3) (2
used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1JB-02-07-007

W2-7-6

UPPERSTRUCTURE / Pilot Valve


Removal of Right Pilot Valve
1. Remove the seat. (Refer to W2-7-1.)
1, 2

2. Remove caps (1) (2 used) from cover (3). Remove


screws (2, 4) (2 used for each) from cover (3).
Remove cover (3) from bracket (5).

W1JB-02-07-009

3. Remove screw (6) from cover (7).

1, 2
3

4
7

5
W1JB-02-07-008

4. Remove screws (9) (4 used) from boot (8). Roll up


boot (8) from bracket (5). Remove screw (10) from
cover (7).

5
9

5. Remove cover (7) from bracket (5).


7

W1JB-02-07-002

10
8
7

W1JB-02-07-016

W2-7-7

UPPERSTRUCTURE / Pilot Valve


11

6. Remove clip bands (13) (2 used) from harness


(14). Disconnect a connector from harness (14).

12

13

7. Loosen lock nut (12). Remove the lever (11)


assembly from pilot valve (15).
: 19 mm, 22 mm

14

15

W1JB-02-07-005

8. Remove sems bolts (17) (3 used) from bracket (5).


Remove the bracket (5) assembly from stand (16).
Lay down the bracket (5) assembly.
: 17 mm

17
16
W1JB-02-07-008

9. Remove bolt (19). Remove cover (18) from


bracket (5).
: 10 mm

18

19

W1JB-02-07-010

15

10. Disconnect hoses (20) (6 used) from pilot valve


(15). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm

W1JB-02-07-006

20

W2-7-8

UPPERSTRUCTURE / Pilot Valve


11. Remove bolts (21) (4 used) from bracket (5).
Remove pilot valve (15) from bracket (5).
: 13 mm

21

15

W1JB-02-07-005

21

W2-7-9

UPPERSTRUCTURE / Pilot Valve


Installation of Right Pilot Valve
1. Install pilot valve (15) to bracket (5) with bolts (21)
(4 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

21

15

W1JB-02-07-005

21

2. Connect hoses (20) (6 used) to pilot valve (15).


: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

15

W1JB-02-07-006

20

W2-7-10

UPPERSTRUCTURE / Pilot Valve


3. Install the lever (11) assembly to pilot valve (15).
Secure the lever (11) assembly to pilot valve (15)
with lock nut (12).
: 22 mm
: 56 Nm (5.5 kgfm, 41 lbfft)

11

12

13

14
5

4. Connect a connector to harness (14).


15

5. Connect harness (14) to pilot valve (15) and


bracket (5) with clip bands (13) (2 used).

W1JB-02-07-005

6. Install cover (18) to bracket (5) with bolt (19).


: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

18

19

W1JB-02-07-010

7. Install cover (7) to bracket (5) with screw (6).


8. Install the bracket (5) assembly to stand (16) with
sems bolts (17) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

6
5
17
16
W1JB-02-07-008

9. Install covers (18, 7) to bracket (5) with screw


(10).

10
5
7

18

W1JB-02-07-016

W2-7-11

UPPERSTRUCTURE / Pilot Valve


8

10. Install boot (8) to bracket (5) with screws (9) (4


used).

W1JB-02-07-002

11. Install cover (3) to bracket (5) with screws (2, 4) (2


used for each). Install caps (1) (2 used) to cover
(3).
1, 2

W1JB-02-07-009

CAUTION: Seat (1) weight: 40 kg (90 lb)


12. Install seat (1) to bracket (5) with socket bolts (4)
(4 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

W1JB-02-07-007

13. Install seat belt (2) to bracket (5) with bolts (2) (2
used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)

3
W1JB-02-01-008

W2-7-12

UPPERSTRUCTURE / Pilot Valve


Removal of Travel Pilot Valve
1. Remove sems bolts (3) (4 used). Remove cover
(2) from frame (3).
: 17 mm

W1P1-02-08-002

2. Disconnect hoses (5) (6 used) from pilot valve (4).


Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 17 mm

WBAT-06-01-039

3. Remove mat (6) from cab (7).

W1P1-02-08-001

W2-7-13

UPPERSTRUCTURE / Pilot Valve


4. Remove sems bolts (10) (2 used) from levers (9)
(2 used). Remove levers (9) (2 used) and pedals
(8) (2 used) from pilot valve (4).
: 17 mm

10

5. Remove socket bolts (11) (2 used) from pilot valve


(4). Remove pilot valve (4) from frame (3).
: 8 mm

W1JB-02-07-003

11
W1JB-02-07-004

W2-7-14

UPPERSTRUCTURE / Pilot Valve


Installation of Travel Pilot Valve
1. Install pilot valve (4) to frame (3) with socket bolts
(11) (2 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

11
W1JB-02-07-004

2. Install levers (9) (2 used) and pedals (8) (2 used)


to pilot valve (4) with sems bolts (10) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

10

W2-7-15

W1JB-02-07-003

UPPERSTRUCTURE / Pilot Valve


3. Connect hoses (5) (6 used) to pilot valve (4).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

WBAT-06-01-039

4. Install cover (2) to frame (3) with sems bolts (3) (6


used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-08-002

5. Install mat (6) to cab (7).

W1P1-02-08-001

W2-7-16

UPPERSTRUCTURE / Pilot Valve


Removal of Blade Pilot Valve
1. Remove sems bolts (1) (6 used). Remove cover
(2) from frame (3).
: 17 mm

W1P1-02-08-002

2. Disconnect hoses (7) (4 used) from pilot valve (6).


Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 17 mm

3. Remove sems bolts (5) (2 used) from pilot valve


(6). Remove the pilot valve (6) assembly from
bracket (4).
: 17 mm
4. Remove bolts (9) (2 used) from bracket (8).
Remove pilot valve (6) from bracket (8).
: 13 mm

W2-7-17

8, 9

W1P1-02-07-001

UPPERSTRUCTURE / Pilot Valve


Installation of Blade Pilot Valve
1. Install pilot valve (6) to bracket (8) with bolts (9) (2
used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

2. Install the pilot valve (6) assembly to bracket (4)


with sems bolts (5) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
8, 9

3. Connect hoses (7) (4 used) to pilot valve (6).


: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
4. Install cover (2) to frame (3) with sems bolts (1) (6
used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-07-001

W1P1-02-08-002

W2-7-18

UPPERSTRUCTURE / Pilot Valve


(Blank)

W2-7-19

UPPERSTRUCTURE / Pilot Valve


DISASSEMBLY OF LEFT AND RIGHT
PILOT VALVES

13

12
14
11

15

11
10

8
8
7

9
21

16

20

20

21

19

18

4
1

17

W176-02-07-001

123456-

Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)

7 - Retaining Ring (4 Used)


8 - Push Rod A (2 Used)
9 - Push Rod B (2 Used)
10 - Block
11 - Socket Bolt (2 Used)

12 - Cam
13 - Screw Joint
14 - Universal Joint
15 - Oil Seal (4 Used)
16 - Spring Guide (4 Used)

W2-7-20

17 - Spool (4 Used)
18 - Housing
19 - O-Ring
20 - Knock Pin (2 Used)
21 - O-Ring (2 Used)

UPPERSTRUCTURE / Pilot Valve


Disassembly of Left and Right Pilot Valves
IMPORTANT: Block (10) and housing (18) are
made of aluminum. As strong force
deforms or damages them, handle
them with care.
IMPORTANT: Spool (17) has been selected to
match the hole on housing (18). The
dimensions of balance springs A (3),
B (4) and return springs A (5), B (6)
as well as those of push rods A (8),
B (9) are different. Arrange the
disassembled parts together with
each port in order not to confuse.
The port number is stamped on the
outer surface of housing (18).
IMPORTANT: When removing screw joint (13), do
not secure housing (18) in a vise.
The strong torque may act on screw
joint (13).
1. Secure screw joint (13) in a vise. Rotate cam (12)
by using a spanner and remove screw joint (13)
from cam (12).
: 32 mm

IMPORTANT: There are two kinds of push rods A


(8), B (9). Handle and keep push rods
A (8), B (9) in order of the port
number after removing.
4. Remove push rods A (8), B (9) from block (10).
5. Remove oil seals (15) (4 used) from block (10) by
using a bamboo spatula.
NOTE: If using a metal bar, the mating part of oil
seal (15) may be damaged.
IMPORTANT: Retaining ring (7) may come off
while disassembling. Do not lose
retaining ring (7).
6. Compress the spring by using the special tool (ST
7257) from the upper side of spring guide (16).
Remove retaining rings (7) (4 used) from spools
(17) (4 used) by using a screwdriver.
7

2. Lightly secure the flat surface of housing (18) in a


vise. Remove cam (12) from universal joint (14).
: 32 mm
NOTE: Universal joint (14) has been secured on
block (10) by using LOCTITE. Do not
remove it unless necessary.
3. Remove socket bolts (11) (2 used) from block
(10). Remove block (10) from housing (18). At this
time, push rods A (8), B (9) are removed with
block (10) together.
: 6 mm

16
ST 7257

W176-02-07-005

IMPORTANT: The quantity of shims (2) has been


determined for each port during the
performance testing at the factory.
Do not lose shims (2). Keep shim (2)
carefully in order to install shim (2)
to the original position when
assembling.
7. Remove spring guides (16) (4 used), balance
springs A (3), B (4) (2 used for each), return
springs A (5), B (6) (2 used for each), shim (2),
and spacers (1) (4 used) from spools (17) (4
used).

W2-7-21

UPPERSTRUCTURE / Pilot Valve

21
20

21
20
19

18

17

W176-02-07-001

W2-7-22

UPPERSTRUCTURE / Pilot Valve


IMPORTANT: Spool (17) has been selected to
match the hole on housing (18).
Keep spool (17) in order to install it
to the original position when
assembling.
8. Remove spools (17) (4 used) from housing (18).
At this time, slowly turn and remove spools (17) (4
used).
NOTE: Spool (17) and housing (18) should be
replaced as an assembly.
9. Remove O-ring (19) and O-rings (21) (2 used)
from housing (18). Do not remove knock pins (20)
(2 used) unless necessary.

W2-7-23

UPPERSTRUCTURE / Pilot Valve


ASSEMBLY OF LEFT AND RIGHT PILOT
VALVES

14

13

10

12
15
11
8, 9
7
16
3, 4
5, 6
2
19
1

17
W176-02-07-006

21

123456-

Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)

20

7 - Retaining Ring (4 Used)


8 - Push Rod A (2 Used)
9 - Push Rod B (2 Used)
10 - Block
11 - Socket Bolt (2 Used)

18

12 - Cam
13 - Screw Joint
14 - Universal Joint
15 - Oil Seal (4 Used)
16 - Spring Guide (4 Used)

W2-7-24

17 - Spool (4 Used)
18 - Housing
19 - O-Ring
20 - Knock Pin (2 Used)
21 - O-Ring (2 Used)

UPPERSTRUCTURE / Pilot Valve


Assembly of Left and Right Pilot Valves
IMPORTANT: The pilot valve is susceptible to
contamination. Keep the parts clean
when assembling.
NOTE: The table below shows the relations
between each port and the parts. Do not
confuse them when assembling.
Port
No.

Spool
(17)

Shim
(2)

Same to the
former one

Same to the
former one

1
2
3
4
Port
No.
1
2
3
4

Return Springs
A (5), B (6)
Short
Long
Short
Long

Push Rods
A (8), B (9)
With outer
groove
Without outer
groove
With outer
groove
Without outer
groove

IMPORTANT: Install spring guide (16) with the


protrusion facing upward.
3. Install spring guides (16) (4 used) to return
springs A (5), B (6) (2 used for each).
4. Install retaining ring (7) to the ring holder (ST
7255).
7

ST 7255

W176-02-07-008

5. Install the spool (17) head into the hole on the


special tool (ST 7257). Compress the spring from
the upper side of spring guide (16). Install
retaining ring (7) with to the ring holder (ST 7255)
attached to the spool head.
7

Balance Springs
A (3), B (4)
Short
Long
Short
Long

ST 7255

ST 7257

17
16
Put the material.

IMPORTANT: Check the port hole number and


insert same spool (17) before
disassembling.
1. Install the thinner end of spools (17) (4 used) into
the port hole on housing (18) while slowly
rotating.
NOTE: Spool (17) has been selected to match the
port hole. Spool (17) and housing (18)
should be replaced as an assembly.
IMPORTANT: Refer to the table above in order to
assemble the parts correctly.
2. Install spacers (1) (4 used), shim (2), balance
springs A (3), B (4) (2 used for each), and return
springs A (5), B (6) (2 used for each) to spools
(17) (4 used).

W176-02-07-009

NOTE: If putting the packing material of approx.


diameter 8 mm, length 10 mm into the port
hole, the work can be done easily in order
to prevent spool (17) from lowering when
pushing the spring.
6. Install other spools (17) (3 used) to housing (18)
in the same way as steps 2 to 5.
7. Install O-ring (19) and O-rings (21) (2 used) to
housing (18).

W2-7-25

UPPERSTRUCTURE / Pilot Valve

13

14
10

12
15
11
8, 9

W176-02-07-006

20

W2-7-26

18

UPPERSTRUCTURE / Pilot Valve


8. Apply grease onto the inner surface of oil seals
(15) (4 used). Install oil seals (15) (4 used) to
block (10) by using a bamboo spatula.
NOTE: Oil seal (15) may get into the endmost of
hole during work. Insert push rods A (8),
B(9) first as illustrated in order to prevent oil
seal (15) from getting into the endmost of
hole before work.
Oil Seal
Mounting Hole

10

8, 9

IMPORTANT: Check the tightness of cam (12).


13. Secure housing (18) in a vise lightly. Install cam
(12) to universal joint (14). At this time, tighten
universal joint (14) so that the clearance between
cam (12) and push rods A (8), B (9) should be 0 to
0.2 mm.
: 32 mm
IMPORTANT: During work, do not secure housing
(18) in a vise. The strong force may
act on screw joint (13).
14. Secure screw joint (13) in a vise. Install universal
joint (14). Tighten cam (12) by using a spanner.
: 32 mm
: 90 Nm (9 kgfm, 66 lbfft)

W176-02-07-007

IMPORTANT: Check the position to install push


rods A (8), B (9).
9. Install push rods A (8), B (9) (2 used for each) to
block (10). At this time, install push rods A (8), B
(9) with the outer groove to ports #1 and #3 and
install push rods A (8), B (9) without the outer
groove to ports #2 and #4.
10. Apply grease onto the ball part at the ends of
push rods A (8), B (9) (2 used for each).
11. Apply grease onto the joint part of universal joint
(14).
12. Align the positions of knock pins (20) (2 used) in
housing (18). Install the block (10) assembly with
socket bolts (11) (2 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

W2-7-27

UPPERSTRUCTURE / Pilot Valve


DISASSEMBLY OF TRAVEL PILOT VALVE
1

2
3
4
5
6
35
34

33
32

31
30

9
10

29

11
28
27

14
12

26
15

13

25
16
24

17
18

23
19
20
21

22
W178-02-07-063

123456789-

Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
Spring Washer (4 Used)
Socket Bolt (4 Used)

10 11 12 13 14 15 16 17 18 -

Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring (4 Used)
Bushing (4 Used)
Pusher (4 Used)
Spring Guide (16 Used)
Balance Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

W2-7-28

O-Ring (2 Used)
Plug (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Casing
Spool
Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)

28 29 30 31 32 33 34 35 -

Oil Seal (4 Used)


Spring Washer (2 Used)
Socket Bolt (2 Used)
Rubber Seat (2 Used)
Damper (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Pin

UPPERSTRUCTURE / Pilot Valve


Disassembly of Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminum. As
strong force deforms or damages
them, handle them with care.
IMPORTANT: Spool (24) has been selected to
match the hole of casing (23).
Arrange the disassembled parts
together with each port in order not
to confuse.
The port number is stamped on the
outer surface of casing (23).
1. Secure casing (23) in a vise. Remove bolts (1) (2
used). Remove cover (2) from holder (7).
: 10 mm
2. Remove socket bolts (30) (2 used) and spring
washers (29) (2 used) from holder (7). Remove
the holder (7) assembly from casing (23).
: 8 mm
3. Remove the pusher (16) assemblies (4 used)
from casing (23).
4. Remove pushers (16) (4 used) from bushings (15)
(4 used). Remove oil seals (28) (4 used) and
O-rings (14) (4 used) from bushings (15) (4 used)
by using a bamboo spatula.

IMPORTANT: Put the mark on spools (24) (4 used)


when keeping in order to install
them to the original hole.
5. Remove the spool (24) assemblies (4 used) from
casing (23) by rotating.
Spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used), and spacers (26)
(4 used) are removed with spools (24) (4 used)
together.
NOTE: Spool (24) has been selected to match the
hole on casing (23). Replace spool (24)
and casing (23) as an assembly.
IMPORTANT: The quantity of shims (27) has been
determined for each port during the
performance testing at the factory.
Do not lose shims (27). Keep shim
(27) carefully in order to install shim
(27) to the original position when
assembling.
6. Compress balance spring (18). Remove spring
guides (17) (4 used), balance springs (18) (4
used), shims (27) (several), and spacers (26) (4
used) from spools (24) (4 used).
7. Remove springs (25) (4 used) from casing (23).

W2-7-29

UPPERSTRUCTURE / Pilot Valve

3
4
6

3
4

10

11

12

13

35
34

33
32

31

9
10

31

11

32
33
34
35
12

13

23
19
20
21

22
W178-02-07-063

W2-7-30

UPPERSTRUCTURE / Pilot Valve


IMPORTANT: Place a stand under bracket (11) and
reduce a reaction force. If holder (7)
bears the reaction force, strong
force acts on pin (35) and pin (35)
may be deformed.
8. Place a stand under bracket (11).
The inner surfaces of the spring pin (12, 13) holes
(2 used for each) on bracket (11) are
stepped-shape. Spring pins (12, 13) can only be
removed in one direction.
Tap and remove spring pins (12, 13) (2 used for
each) from bracket (11) at the same time by using
the special tool (ST 1237). Remove bracket (11)
from pin (35).
Do not remove spring pin (10) with bracket (11)
attached unless necessary.
The hole end of spring pin (10) has been crimped.

12, 13
11
35

10
Crimped Position
Stand

10. Remove O-rings (33) (2 used) from pin (35).


11. Place holder (7) with the casing (23) mounting
surface facing upward.
12. The inner surfaces of the spring pin (3, 4) holes (2
used for each) on cam (5) are stepped-shape. Tap
the bottom of cam (5) and remove spring pins (3,
4) (2 used for each) from cams (5) (2 used) at the
same time by using the special tool (ST 1237).
As the spring pin (3, 4) holes (2 used for each) are
crimped, spring pins (3, 4) may feel tight when
removing.
13. Remove pin (35) from holder (7) by using a bar
and a hammer. At the same time, cams (5) (2
used) are also removed.
Do not remove bushings (6) (4 used) in holder (7)
unless necessary. When removing, remove
bushings (6) (4 used) from holder (7) by tapping
by using the special tool (ST 7256).
14. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).
: 5 mm
15. Remove plugs (21) (2 used) from casing (23).
Remove O-rings (22) (2 used) from plugs (21) (2
used).
: 6 mm

W176-02-07-019

9. Remove socket bolts (9) (4 used) and spring


washers (8) (4 used) from damper (32). Remove
dampers (32) (2 used) and rubber seats (31) (2
used) from pin (35). O-rings (34) (2 used) are
removed together.
: 5 mm

W2-7-31

UPPERSTRUCTURE / Pilot Valve


ASSEMBLY OF TRAVEL PILOT VALVE

11

32

31 1

35

12

10

13 7

3, 4

29

34
9

15

33 28

30

17
18

14

25
27

16

26
24
23
W178-02-11-316

123456789-

Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
Spring Washer (4 Used)
Socket Bolt (4 Used)

10 11 12 13 14 15 16 17 18 -

Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring
Bushing (4 Used)
Pusher (4 Used)
Spring Guide (16 Used)
Balance Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

NOTE: As for the item with mark *, refer to


W2-7-26.

W2-7-32

* O-Ring (2 Used)
* Plug (2 Used)
* Plug (2 Used)
* O-Ring (2 Used)
Casing
Spool (4 Used)
Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)

28 29 30 31 32 33 34 35 -

Oil Seal (4 Used)


Spring Washer (2 Used)
Socket Bolt (2 Used)
Rubber Seat (2 Used)
Damper (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Pin

UPPERSTRUCTURE / Pilot Valve


Assembly of Travel Pilot Valve
IMPORTANT: Check the direction to install spring
guide (17).
1. Assemble spools (24) (4 used) into an assembly.
Insert spacers (26) (2 used), shims (27) (2 used),
and balance springs (18) (4 used) into spools (24)
(4 used) in this order. Install shim (27) as the
same condition before disassembling.
Compress balance springs (18) (4 used) by hand.
Install spring guides (17) (4 used) to spools (24)
(4 used) with the step part facing downward.

NOTE: Bushings (6) (4 used) are identical.


Insert bushings (6) (4 used) into the special tool

(ST 7256). Tap the special tool (ST 7256) by


using a hammer and install bushing (6) to the end
of the hole of holder (7).
Stop tapping when the bushing (6) end is flush
with the hole end.
ST 7256

IMPORTANT: Before inserting the parts into holder


(7) and casing (23), apply hydraulic
oil.
2. Insert springs (25) (4 used) into casing (23).
3. Insert the spool (24) assembly into the same port
before disassembling. Insert the spools (24)
assemblies (4 used) into casing (23) by rotating.
4. Assemble pushers (16) (4 used) into an
assembly.
Install oil seals (28) (4 used) to bushings (15) (4
used).
Apply grease onto the inner surface of oil seals
(28) (4 used).
Install O-rings (14) (4 used) and pushers (16) (4
used) to bushing (15) (4 used).
Apply grease onto the head of pushers (16) (4
used).

6
W178-02-11-310

Install bushing (6) on the opposite side in the

same way.

ST 7256

W178-02-11-311

Install bushing (6) in the near side as illustrated

below. Stop installing when the bushing (6) end is


flush with the outside of holder (7).
6
7

ST 7256

5. Insert the pusher (16) assemblies (4 used) into


casing (23).
6. When bushing (6) has been removed from holder
(7), install bushings (6) (4 used) to holder (7) by
using the special tool (ST 7256) in the following
procedures.

Outside of Holder (7)


W178-02-11-312

Install bushing (6) in the near and opposite side


as illustrated below. 6
7
ST 7256

W178-02-11-313

W2-7-33

UPPERSTRUCTURE / Pilot Valve

32

31

35

31

32

3, 4

30

29

34
9

33

23
W178-02-11-316

W2-7-34

UPPERSTRUCTURE / Pilot Valve


7. Apply grease onto O-rings (33) (2 used). Install
O-rings (33) (2 used) to pin (35).
Install pin (35) and cams (5) (2 used) to holder
(7).
IMPORTANT: Check the direction to install spring
pins (3, 4) (2 used for each).
8. Install spring pins (3, 4) (2 used for each) to cams
(5) (2 used) by using the special tool (ST 1237).
Secure cams (5) (2 used) and pin (35). At this
time, the slits of spring pins (3, 4) (2 used for
each) should be positioned 90 away each other.
Tap and install spring pins (3, 4) (2 used for each)
until spring pins (3, 4) come in contact with the
step part in the hole.
3

Slit

11. Install rubber seats (31) (2 used) to pin (35).


IMPORTANT: Check the direction of damper (32).
The inner surface of damper (32) is
edged-shape. If damper (32) is pried
when installing, O-ring (33) may be
damaged.
12. Install dampers (32) (2 used) to pin (35) with the
lever facing upward.
13. Secure damper (32) and rubber seat (31) to
holder (7) with socket bolts (9) (4 used) and spring
washers (8) (4 used).
: 5 mm
: 6.9 Nm (0.7 kgfm, 5 lbfft)
14. Apply grease onto O-rings (34) (2 used). Push
O-rings (34) (2 used) to the end of pin (35).

Slit

W178-02-07-050

9. Crimp the hole end of cams (5) (2 used) where


spring pins (3, 4) are inserted by using a punch.
10. Place holder (7) on the casing (23) assembly.
Install holder (7) to casing (23) with socket bolts
(30) (2 used) and spring washers (29) (2 used).
Check the mark direction and install holder (7).
: 8 mm
: 49 Nm (5 kgfm, 37 lbfft)

W2-7-35

UPPERSTRUCTURE / Pilot Valve

11

32

35

12

10

13

19, 20

21, 22

W178-02-11-316

W2-7-36

UPPERSTRUCTURE / Pilot Valve


15. As for the direction to install bracket (11), refer to
the figure in Disassembly of Travel Pilot Valve on
W2-7-29. Install bracket (11) to pin (35). Align the
inserting holes of spring pins (12, 13) (2 used for
each).
IMPORTANT: Place a stand under bracket (11) and
reduce a reaction force. If holder (7)
bears the reaction force, strong
force acts on pin (35) and pin (35)
may be deformed.
16. Place a stand under bracket (11).
Install spring pins (12, 13) to bracket (11) until
they come in contact with the step part by using
the special tool (ST 1237). The slits of spring pins
(12, 13) (2 used for each) should be positioned
90 away each other.

Crimped Position

11

Stand

20. Apply grease onto the spring pin (10) contact part
of dampers (32) (2 used).
21. Apply grease onto O-rings (19) (2 used). Install
O-rings (19) (2 used) to plugs (20) (2 used). Install
plugs (20) (2 used) to casing (23).
: 5 mm
: 10 Nm (1 kgfm, 7 lbfft)
22. Apply grease onto O-rings (22) (2 used). Install
O-rings (22) (2 used) to plugs (21) (2 used). Install
plugs (21) (2 used) to casing (23).
: 6 mm
: 19.6 Nm (2 kgfm, 14 lbfft)

Crimped Position

35

12, 13

W176-02-07-011

17. Crimp the hole edge of bracket (11) where spring


pins (12, 13) are inserted by using a punch.
18. Install bracket (11) on the opposite side to pin (35)
in the same way as steps 16 to 17.
19. Install cover (2) to holder (7) with bolts (1) (2
used).
: 10 mm
: 4.9 Nm (0.5 kgfm, 4 lbfft)

W2-7-37

UPPERSTRUCTURE / Pilot Valve


DISASSEMBLY OF BLADE PILOT VALVE

1
22

21

4
5

6
20

7
8
19

19

18

18

8
9

17

17

10
14

16

11

10

12

11
12

14
15

13

W192-02-07-001

123456-

Dust Seal (2 Used)


Bushing (2 Used)
Oil Seal (2 Used)
O-Ring (2 Used)
Pusher (2 Used)
Washer (4 Used)

78910 11 12 -

Spring Seat (2 Used)


Return Spring (2 Used)
Balance Spring (2 Used)
Spacer (2 Used)
Shim (2 Used)
Spool (2 Used)

13 14 15 16 17 -

Casing
Bushing (2 Used)
Pin
Cover
Socket Bolt (2 Used)

W2-7-38

18 19 20 21 22 -

Lock Nut (2 Used)


Adjusting Screw (2 Used)
Cam
Set Screw
Boot

UPPERSTRUCTURE / Pilot Valve


Disassembly of Blade Pilot Valve
1. Remove boot (22) from cover (16).
2. Secure the pilot valve in a vise. Loosen set screw
(21) from cam (20). Remove pin (15) from cover
(16) by using a round bar. Remove the cam (20)
assembly from cover (16).
: 3 mm
IMPORTANT: Record the position for casing (13).
The pusher (5) assembly may fly out
due to return spring (8). When
assembling adjusting screw (19), do
not disassemble lock nut (18) and
adjusting screw (19) as the neutral
adjustment is required for adjusting
screw (19).
3. Loosen and remove socket bolts (17) (2 used)
from cover (16) alternately. Remove cover (16)
and the pusher (5) assemblies (2 used) from
casing (13).
: 6 mm
4. Remove pushers (5) (2 used), O-rings (4) (2
used), oil seals (3) (2 used), and dust seals (1) (2
used) from bushings (2) (2 used).
IMPORTANT: Indicate the port number in order not
to confuse the parts.
5. Remove the spool (12) assemblies (2 used) and
return springs (8) (2 used) from casing (13).
6. Compress balance springs (9) (2 used). Remove
washers (6) (2 used) and spring guides (7) (2
used) from spools (12) (2 used). Remove spacers
(10) (2 used) and shims (11) (2 used) from spools
(12) (2 used).

W2-7-39

UPPERSTRUCTURE / Pilot Valve


ASSEMBLY OF BLADE PILOT VALVE

18

19

21

14

15

20

22

17
2
16

1
3

4
12
8
10

11
13

T554-02-07-010

123456-

Dust Seal (2 Used)


Bushing (2 Used)
Oil Seal (2 Used)
O-Ring (2 Used)
Pusher (2 Used)
Washer (4 Used)

78910 11 12 -

Spring Seat (2 Used)


Return Spring (2 Used)
Balance Spring (2 Used)
Spacer (2 Used)
Shim (2 Used)
Spool (2 Used)

13 14 15 16 17 -

Casing
Bushing (2 Used)
Pin
Cover
Socket Bolt (2 Used)

W2-7-40

18 19 20 21 22 -

Lock Nut (2 Used)


Adjusting Screw (2 Used)
Cam
Set Screw
Boot

UPPERSTRUCTURE / Pilot Valve


Assembly of Blade Pilot Valve
IMPORTANT: Install washers (6) (4 used) with the
sharp edge side facing upward.
Check the direction of spring seat
(7). When installing spring seat (7),
do not push in it 4 mm or more.
1. Install shims (11) (2 used), spacers (10) (2 used),
and balance springs (9) (2 used) to spools (12) (2
used). Compress balance springs (9) (2 used).
Install spring seats (7) (2 used) and washers (6)
(4 used) to spools (12) (2 used).
IMPORTANT: Insert the spools (12) (2 used)
assembly in the same number when
disassembling.
2. Insert return springs (8) (2 used) and the spool
(12) assemblies (2 used) into casing (13).
IMPORTANT: Check the direction of oil seals (3) (2
used) and dust seals (1) (2 used).
Apply grease onto the lip part in oil
seal (3) and dust seal (1), and the
inner surface of the bushing (2).
3. Install oil seals (3) (2 used), dust seals (1) (2
used), and O-rings (4) (2 used) to bushings (2) (2
used). Insert pushers (5) (2 used) into the
bushings (2) assemblies (2 used).
Use the following greases.
Apolloil Autorex C (Idemitsu)
Ocean 7 (Nihon Ore Louve)
Screw Bar L60 (NOK)

4. Place the pusher (5) assemblies (2 used) on the


spool (12) assemblies (2 used). Place cover (16)
on the pusher (5) assemblies (2 used). Install
cover (16) to casing (13) by tightening socket
bolts (17) (2 used) alternately.
: 6 mm
: 29.52.9 Nm (30.3 kgfm, 222 lbfft)
5. Temporarily tighten adjusting screws (19) (2 used)
and lock nuts (18) (2 used) to cam (20). Install the
cam (20) assembly to cover (16) with pin (15).
: 5 mm
6. Apply LOCTITE #241 onto set screw (21).Secure
cam (20) to pin (15) with set screw (21).
: 3 mm
: 6.91 Nm (0.70.1 kgfm, 51 lbfft)
7. Adjust adjusting screws (19) (2 used).
Keep cam (20) horizontally. The clearance
between pushers (5) (2 used) and adjusting screw
(19) should be 0 mm. Tighten lock nuts (18) (2
used).
: 5 mm
: 17 mm
: 33.33.4 Nm (3.40.4 kgfm, 253 lbfft)
8. Tilt cam (20). Apply grease onto the end of
pushers (5) (2 used).
9. Install boot (22) to cover (16).

W2-7-41

UPPERSTRUCTURE / Pilot Valve


(Blank)

W2-7-42

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve


REMOVAL AND INSTALLATION OF PILOT
SHUT-OFF SOLENOID VALVE (ZX70-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Remove sems bolts (1) (6 used). Remove cover
(2) from frame (3).
: 17 mm

2. Remove mat (4) from the inside of the cab.

3. Disconnect hoses (5) (14 used) from pilot shut-off


solenoid valve (7). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm

W1P1-02-08-002

4. Disconnect connector (8).

W1P1-02-08-001

5. Remove sems bolts (9) (2 used) from bracket (6).


Remove pilot shut-off solenoid valve (7) from
bracket (6).
: 17 mm

W1P1-02-08-004

W1P1-02-08-003

W2-8-1

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve


Installation
1. Install pilot shut-off solenoid valve (7) to bracket
(6) with sems bolts (9) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-08-003

2. Connect hoses (5) (14 used) to pilot shut-off


solenoid valve (7).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

3. Connect connector (8).

4. Install cover (2) to frame (3) with sems bolts (1) (6


used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-08-004

5. Install mat (4) to the inside of the cab.

W1P1-02-08-002

W1P1-02-08-001

W2-8-2

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve


REMOVAL AND INSTALLATION OF PILOT
SHUT-OFF SOLENOID VALVE (ZX75US-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Remove sems bolts (1) (6 used). Remove cover
(2) from frame (3).
: 17 mm

2. Disconnect hoses (9) (9 used) from pilot shut-off


solenoid valve (7). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm
3. Disconnect connector (8).

W1P1-02-01-001

4, 5

4. Remove sems bolts (6) (4 used) from bracket (4).


Remove the bracket (4) assembly from frame (3).
: 17 mm

5. Remove sems bolts (5) (2 used) from bracket (4).


Remove pilot shut-off solenoid valve (7) from
bracket (4).
: 17 mm

W2-8-3

WBAT-06-01-081

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve


Installation
1. Install pilot shut-off solenoid valve (7) to bracket
(4) with sems bolts (5) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

4, 5

2. Install the bracket (4) assembly to frame (3) with


sems bolts (6) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
WBAT-06-01-081

3. Connect hoses (9) (9 used) to pilot shut-off


solenoid valve (7).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

4. Connect connector (8).

WBAT-06-01-081

5. Install cover (2) to frame (3) with sems bolts (1) (6


used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-01-001

W2-8-4

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve


STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE

W1JB-02-08-001

2
1

9
W1JB-02-08-002

No.
1
2
3
4
5
6
7
8
9

Part Name
Plug
O-ring
Spring
Spool
Filter
Body
O-ring
Solenoid
Socket bolt

Qty
1
1
1
1
1
1
1
1
2

Wrench Size
(mm)
: 6

Tightening Torque
Nm
(kgfm)
(lbfft)
26.5
(2.7)
(20)

Remark
(1B P11)

(1A P16)
: 4

3.92

W2-8-5

(0.4)

(3)

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve


(Blank)

W2-8-6

UPPERSTRUCTURE / Shockless Valve


REMOVAL
AND
INSTALLATION
SHOCKLESS VALVE (ZX70-3)

OF

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Open cover (1).

2. Remove wing nuts (4) (2 used) and washers (5) (2


used) from cover (3). Remove cover (3) from
bracket (2).

W1P1-02-09-001

3. Disconnect hoses (9) (12 used) from shockless


valve (8). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm
4. Remove sems bolt (10) in the front from bracket
(6). Loosen sems bolt (10) in the rear from bracket
(6). Move the bracket (6) assembly to the right
from bracket (11).
: 17 mm

4, 5

W1P1-02-09-002

6, 7

5. Remove sems bolts (7) (2 used) from bracket (6).


Remove shockless valve (8) from bracket (6).
: 17 mm

11

W2-9-1

10

W1P1-02-09-003

UPPERSTRUCTURE / Shockless Valve


Installation
1. Install shockless valve (8) to bracket (6) with sems
bolts (7) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

6, 7

2. Install the bracket (6) assembly to bracket (11)


with sems bolts (10) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
3. Connect hoses (9) (12 used) to shockless valve
(8).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

11

W1P1-02-09-003

10

4. Install cover (3) to bracket (2) with washers (5) (2


used) and wing nuts (4) (2 used).

4, 5

W1P1-02-09-002

5. Shut cover (1).

W1P1-02-09-001

W2-9-2

UPPERSTRUCTURE / Shockless Valve


REMOVAL
AND
INSTALLATION
SHOCKLESS VALVE (ZX75US-3)

OF

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4- 1 .)

Removal
1. Remove sems bolts (1) (6 used). Remove cover
(2) from frame (3).
: 17 mm

W1P1-02-01-001

2. Disconnect hoses (6) (10 used) from shockless


valve (7). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm

3. Remove sems bolts (4) (4 used) from bracket (5).


Remove the bracket (5) assembly from frame (3).
: 17 mm

7, 8

4. Remove sems bolts (8) (2 used) from bracket (5).


Remove shockless valve (7) from bracket (5).
: 17 mm

W2-9-3

WBAT-06-01-081

UPPERSTRUCTURE / Shockless Valve


Installation
1. Install shockless valve (7) to bracket (5) with sems
bolts (8) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

2. Install the bracket (5) assembly to frame (3) with


sems bolts (4) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

7, 8
WBAT-06-01-081

3. Connect hoses (6) (10 used) to shockless valve


(7).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 25 lbfft)
4. Install cover (2) to frame (3) with sems bolts (1) (6
used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-01-001

W2-9-4

UPPERSTRUCTURE / Shockless Valve


(Blank)

W2-9-5

UPPERSTRUCTURE / Shockless Valve


STRUCTURE OF SHOCKLESS VALVE
4

A
C

10

11

12

Section B-B

14

View A-A

15

13

16

Section D-D (5 Places)

Detail C

W2-9-6

WBAT-06-01-084

UPPERSTRUCTURE / Shockless Valve

No.

Part Name

Qty

Socket bolt

Socket bolt

Body

Packing

Body

Cover

Stopper

O-ring

Spring

10

Spring seat

11

Spool

12

Spring

13

Filter

14

Shuttle

15

Spring

16

Steel ball

Wrench Size
(mm)
:8

Nm
49 0.2

Tightening Torque
(kgfm)
(5 0.02)

(lbfft)
(37 to 0.1)

6.9 0.3

(0.7 0.03)

(5 to 0.2)

W2-9-7

Remark

UPPERSTRUCTURE / Shockless Valve


(Blank)

W2-9-8

UPPERSTRUCTURE/Solenoid Valve Unit


REMOVAL
AND
INSTALLATION
SOLENOID VALVE UNIT (ZX70-3)

OF

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4- 1 .)
Removal
1. Open cover (1).

W1P1-02-04-001

2. Disconnect connectors (5) (2 used) from 2-spool


solenoid valve unit (6).
3. Disconnect hoses (2) (4 used) from 2-spool
solenoid valve unit (6). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 17 mm
4. Remove sems bolts (4) (2 used) from 2-spool
solenoid valve unit (6). Remove 2-spool solenoid
valve unit (6) from bracket (3).
: 17 mm

6
W1P1-02-10-001

W2-10-1

UPPERSTRUCTURE/Solenoid Valve Unit


Installation
1. Install 2-spool solenoid valve unit (6) to bracket (3)
with sems bolts (4) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

2. Connect hoses (2) (4 used) to 2-spool solenoid


valve unit (6).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

3. Connect connectors (5) (2 used) to 2-spool


solenoid valve unit (6).

W1P1-02-10-001

4. Shut cover (1).

W1P1-02-04-001

W2-10-2

UPPERSTRUCTURE/Solenoid Valve Unit


REMOVAL
AND
INSTALLATION
SOLENOID VALVE UNIT (ZX75US-3)

OF

CAUTION: Bleed air from the hydraulic oil


tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4- 1 .)

Removal
1. Open cover (1).

W1P1-02-05-008

2. Disconnect connectors (5) (2 used) from 2-spool


solenoid valve unit (2).

3. Disconnect hoses (4) (4 used) from 2-spool


solenoid valve unit (2). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 17 mm
4. Remove sems bolts (6) (2 used) from 2-spool
solenoid valve unit (2). Remove 2-spool solenoid
valve unit (2) from bracket (3).
: 17 mm

W2-10-3

WBAT-06-01-053

UPPERSTRUCTURE/Solenoid Valve Unit


Installation
1. Install 2-spool solenoid valve unit (2) to bracket (3)
with sems bolts (6) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

2. Connect hoses (4) (4 used) to 2-spool solenoid


valve unit (2).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

3. Connect connectors (5) (2 used) to 2-spool


solenoid valve unit (2).
6

WBAT-06-01-053

4. Shut cover (1).

W1P1-02-05-008

W2-10-4

UPPERSTRUCTURE/Solenoid Valve Unit


STRUCTURE OF 2-SPOOL SOLENOID VALVE UNIT
A

W8HT-02-03-008

1
2
3
4
5
8

9
10

7
Cross Section A-A

No.

Part Name

Qty

Solenoid

O-ring

Plug

Filter

Sleeve

Spool

Body

Orifice

Plate

10

Wave spring

Wrench Size
(mm)

W2-10-5

Nm

Tightening Torque
(kgfm)
(lbfft)

W8HT-02-03-009

Remark

UPPERSTRUCTURE/Solenoid Valve Unit


(Blank)

W2-10-6

UPPERSTRUCTURE / Engine
REMOVAL
AND
ENGINE (ZX70-3)

INSTALLATION

OF

Removal
1. Open cover (1). Disconnect minus terminal (3)
from battery (2).

2
3
M1P1-07-037

2. Open engine cover (4).


4

W1P1-02-02-001

3. Secure engine cover (4) with stopper (6).


4. Remove split pins (8) (2 used) and washers (5) (2
used) from the pin part of engine cover (4).
Remove cylinders (7) (2 used) from engine cover
(4).
CAUTION: Engine cover (4) weight: 25 kg (60
lb)
5. Attach a nylon sling onto engine cover (4). Hoist
and hold engine cover (4). Remove stopper (6)
from engine cover (4).

7
W1P1-02-04-003

6. Open cover (9).

W1P1-02-04-001

W2-11-1

UPPERSTRUCTURE / Engine
CAUTION: Engine cover (4) weight: 25 kg (60
lb)

10

7. Remove sems bolts (11) (4 used). Remove engine


cover (4) from support (10).
: 17 mm
11

W1P1-02-04-002

8. Remove caps (12) (2 used) from counterweight


(13).
12

CAUTION: Counterweight (13) weight: 750 kg


(1660 lb)
9. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)
(2 used) to counterweight (13). Attach a wire rope
onto the Freno-Linkbolts (2 used). Hoist and hold
the Freno-Linkbolt.

13

W1P1-02-02-002

14

15, 16

10. Remove bolts (15) (4 used) and washers (16) (4


used)
from
counterweight
(13).
Float
counterweight (13) from main frame (14). Slide
counterweight (13) backward and remove it.
: 30 mm
13

W1P1-02-02-003

17

11. Remove sems bolts (18) (6 used). Remove cover


(17) from main frame (14).
: 17 mm

14

18

W1P1-02-11-001

W2-11-2

UPPERSTRUCTURE / Engine
19

12. Loosen bands (20, 22) of intake hose (21).


: 10 mm

20

21

21

W1P1-02-11-021

13. Remove sems bolts (24) (2 used) from intake


hose (21). Disconnect intake hose (21) from air
cleaner (19), turbocharger (23), and bracket (25).
: 17 mm

21

22

23

W1P1-02-11-016

24

25

W1P1-02-11-017

26

14. Loosen band (27). Disconnect hose (28) from


engine (26).

27

28

W1P1-02-11-013

29

30

31

15. Remove sems bolts (34) (2 used) from cover (33).


Remove cover (33) from bracket (25).
: 17 mm
16. Loosen band (30). Remove sems bolts (32) (2
used) from pipe (31). Remove the pipe (31)
assembly from hose (29) and bracket (25).
: 17 mm

32
33
34
25

W2-11-3

W1P1-02-11-017

UPPERSTRUCTURE / Engine
17. Loosen bands (36) (2 used). Disconnect hose (37)
from pipe (35) and engine (26).

35

36

37

38

39
26

18. Remove sems bolt (38) from clip (40). Remove


clip (40) from harness (39) and engine (26).
: 17 mm

40

W1P1-02-11-004

41

19. Loosen bands (41) (2 used). Disconnect hose (42)


from radiator (43) and engine (26).

42
43

41
26
W1P1-02-11-019

20. Remove bolts (45) (5 used) from cover (44).


Remove cover (44) from engine (26).
: 10 mm, 13 mm

44

45

26

W1P1-02-04-006

21. Loosen bolts (46) (2 used). Adjust play of band


(47). Remove muffler (48) from turbocharger (23).
: 14 mm

23

46

47
48

W1P1-02-04-013

W2-11-4

UPPERSTRUCTURE / Engine
49

CAUTION: The pump device (49) assembly


weight: 77 kg (170 lb)
22. Remove the pump device (49) assembly. (Refer to
REMOVAL AND INSTALLATION OF PUMP
DEVICE on W2-4-1.)

W1P1-02-04-009

50 51

52

53

50

23. Remove sems bolts (50) (6 used). Remove cover


(52) from bracket (25).
: 17 mm
24. Remove sems bolts (51) (2 used) from bracket
(53). Remove bracket (53) from bracket (25).
: 17 mm
25

W1P1-02-11-020

54

25. Remove sems bolts (56) (3 used). Remove cover


(55) from bracket (25) and cover (57).
: 17 mm

25

55

56

57

58

26. Remove coupling (59) from oil cooler (54) and


pipe (58).
: 13 mm
27. Remove sems bolts (60) (9 used). Remove fan
cover (61) from bracket (25).
: 17 mm

59
25

W1P1-02-05-007

61

60

W1P1-02-11-005

W2-11-5

UPPERSTRUCTURE / Engine
62

28. Remove clip band (62) from engine (26).


Disconnect connector (63) from engine (26).

64

29. Disconnect connector (66).

63

65

26

66

W1P1-02-11-013

30. Remove bolts (64) (2 used) from pipes (65) (2


used). Disconnect pipes (65) (2 used) from cooler
pump (67).
: 13 mm
67

W1P1-02-11-014

68

31. Disconnect connector (70).

69

70
69

32. Disconnect harnesses (69) (2 used) from dynamo


(68).
: 10 mm

71

33. Disconnect harness (73) and connector (71) from


cell motor (72).
: 12 mm

72

W1P1-02-11-015

73

34. Remove nut (75) from ground (74). Disconnect


ground (74) from main frame (14).
: 17 mm

W1P1-02-11-018

74

14

75

W2-11-6

W1P1-02-11-006

UPPERSTRUCTURE / Engine
76

35. Loosen bands (77) (3 used). Disconnect hoses


(78) (3 used) and hose (81) from engine (26).

26

77

79, 80

77

36. Disconnect connectors (76) (4 used).


37. Disconnect harness (80) from heater plug (79).

81

38. Loosen lock nuts (84) (2 used). Disconnect cables


(82) (2 used) from bracket (83).
: 17 mm

82

83

78

W1P1-02-11-012

84

85
86
87

39. Remove nuts (86) (2 used) from ball joints (85) (2


used). Remove ball joints (85) (2 used) from
levers (87) (2 used).
W1P1-02-11-011

W1P1-02-11-010

88

40. Disconnect harness (88) from pressure switch


(89).

89

W1P1-02-11-007

90

26

41. Disconnect connector (92).


42. Disconnect hose (91) from engine (26). Cap the
open ends.

91

43. Remove bolt (90) from clip (93). Remove harness


(94) from engine (26).
: 10 mm

94

W2-11-7

93

92

W1P1-02-11-009

UPPERSTRUCTURE / Engine
CAUTION: Engine (26) assembly weight: 210
kg (470 lb)

Wire Rope Mounting Bracket

44. Attach a wire rope onto engine (26). Hoist and


hold engine (26).

26

W1P1-02-11-003

Wire Rope Mounting Bracket

26

W1P1-02-11-002

26

45. Remove nuts (96) (4 used), washers (97) (4 used),


and dampers (98) (2 used) from bolts (95) (4
used). Remove bolts (95) (4 used) and washers
(97) (4 used) from brackets (99) (4 used).
: 22 mm, 24 mm

95, 96
97

46. Hoist the engine (26) assembly about 10 mm.


Move the engine (26) assembly toward the pump
device side. Remove the engine (26) assembly
and dampers (98) (4 used) from main frame (14).

98

14

99

26

W1P1-02-11-004

95, 96
97
98

99

W2-11-8

14

W1P1-02-11-006

UPPERSTRUCTURE / Engine
Installation
CAUTION: Engine (26) assembly weight: 210
kg (470 lb)

26

1. Install dampers (98) (4 used) to the main frame


(14) mounting position.
95, 96

2. Attach a wire rope onto the engine (26) assembly.


Hoist and align the engine (26) assembly with the
mounting hole on main frame (14).
3. Install brackets (99) (4 used) to main frame (14)
with dampers (98) (4 used), bolts (95) (4 used),
washers (97) (8 used), and nuts (96) (4 used).
: 22 mm
: 180 Nm (18 kgfm, 133 lbfft)
: 24 mm
: 270 Nm (27 kgfm, 200 lbfft)

97
98

14
74

W1P1-02-11-004

99

26

95, 96
97
98

4. Connect ground (74) onto main frame (14) with


nut (75).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
75

5. Connect hose (91) to engine (26).

99

90

W1P1-02-11-006

14
26

6. Connect connector (92). Connect harness (94) to


engine (26) with clip (93) and bolt (90).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

91

7. Connect harness (88) to pressure switch (89).


94

93
88

92

W1P1-02-11-009

89

W1P1-02-11-007

W2-11-9

UPPERSTRUCTURE / Engine
8. Install ball joints (85) (2 used) to levers (87) (2
used) with nuts (86) (2 used).

82

83

84

85
86

9. Connect cables (82) (2 used) to bracket (83) with


lock nuts (84) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

87

W1P1-02-11-011

76

10. Connect hoses (78) (3 used) and hose (81) to


engine (26). Secure hoses (78) (3 used) to engine
(26) with bands (77) (3 used).

W1P1-02-11-010

26

77

79, 80

77

11. Connect harness (80) to heater plug (79).


12. Connect connectors (76) (4 used).

81

71

13. Connect harness (73) and connector (71) to cell


motor (72).
: 12 mm
: 10 Nm (1 kgfm, 7 lbfft)

78

W1P1-02-11-012

72

73

W1P1-02-11-018

68

14. Connect connector (70).


15. Connect harnesses (69) (2 used) to dynamo (68).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

69

70
69

W1P1-02-11-015

W2-11-10

UPPERSTRUCTURE / Engine
16. Connect pipes (65) (2 used) to cooler pump (67)
with bolts (64) (2 used).
: 13 mm
: 10 Nm (1 kgfm, 7 lbfft)

64

65

66

17. Connect connector (66).


67

W1P1-02-11-014

62

18. Connect connector (63) to engine (26). Secure the


connector (63) assembly to engine (26) with clip
band (62).

63

26

W1P1-02-11-013

19. Install fan cover (61) to bracket (25) with sems


bolts (60) (9 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

25

61

60

W1P1-02-11-005

20. Install cover (55) to bracket (25) and cover (57)


with sems bolts (56) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

54

25

55

21. Connect oil cooler (54) and pipe (58) with coupling
(59).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

57

58

59

W2-11-11

56

W1P1-02-05-007

UPPERSTRUCTURE / Engine
41

22. Connect hose (42) to radiator (43) and engine (26).


Secure hose (42) to radiator (43) and engine (26)
with bands (41) (2 used).

42

43

41
26
W1P1-02-11-019

50 51

23. Install cover (52) to bracket (25) with sems bolts


(50) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
24. Install bracket (53) to bracket (25) with sems bolts
(51) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

52

53

25

50

W1P1-02-11-020

CAUTION: The pump device (49) assembly


weight: 77 kg (170 lb)

49

25. Install the pump device (49) assembly. (Refer to


REMOVAL AND INSTALLATION OF PUMP
DEVICE on W2-4-1.)

W1P1-02-04-009

26. Connect turbocharger (23) and muffler (48) with


band (47) and bolts (46) (2 used).
: 14 mm
: 20 Nm (2 kgfm, 15 lbfft)

23

46

47
48

W1P1-02-04-013

W2-11-12

UPPERSTRUCTURE / Engine
27. Install cover (44) to engine (26) with bolts (45) (5
used).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

44

45

26

W1P1-02-04-006

35

36

37

38

39

28. Install clip (40) to harness (39). Install clip (40) to


engine (26) with sems bolt (38).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

26
40

29. Connect hose (37) to pipe (35) and engine (26).


Secure hose (37) to pipe (35) and engine (26) with
bands (36) (2 used).
W1P1-02-11-004

26

30. Connect rubber hoses (28) to engine (26). Secure


rubber hose (28) to engine (26) with band (27).
27

28

W1P1-02-11-013

29

30

31

31. Connect pipe (31) to hose (29). Secure hose (29)


to pipe (31) with band (30).
32. Install the pipe (31) assembly to bracket (25) with
sems bolts (32) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

32

25

W2-11-13

W1P1-02-11-017

UPPERSTRUCTURE / Engine
33. Connect intake hose (21) to air cleaner (19) and
turbocharger (23). Secure intake hose (21) to air
cleaner (19) and turbocharger (23) with bands (20,
22).

19

20

21

21

W1P1-02-11-021

34. Connect intake hose (21) to bracket (25) with


sems bolts (24) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

21

35. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)


(2 used) to counterweight (13). Attach a wire rope
onto the Freno-Linkbolt. Hoist and align the
counterweight (13) with the mounting hole of main
frame (14).
36. Install counterweight (13) to main frame (14) with
bolts (15) (4 used) and washers (16) (4 used).
: 30 mm
: 550 Nm (55 kgfm, 410 lbfft)
37. Remove the wire rope and the Freno-Linkbolts (2
used) from counterweight (13). Install caps (12) (2
used) to counterweight (13).

14

23

W1P1-02-11-016

24

25

CAUTION: Counterweight (13) weight: 750 kg


(1660 lb)

22

W1P1-02-11-017

15, 16

13

W1P1-02-02-003

12

13

W1P1-02-02-002

W2-11-14

UPPERSTRUCTURE / Engine
38. Install cover (17) to main frame (14) with sems
bolts (18) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

17

14

18

W1P1-02-11-001

10

CAUTION: Engine cover (4) weight: 25 kg (60


lb)

39. Attach a nylon sling onto engine cover (4). Hoist


and align engine cover (4) with the mounting hole
on support (10). Install engine cover (4) to support
(10) with sems bolts (11) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

11

W1P1-02-04-002

40. Secure engine cover (4) with stopper (6).


6

41. Install cylinders (7) (2 used) to the pin part of


engine cover (4) with washers (5) (2 used) and
split pins (8) (2 used).

7
8

W2-11-15

W1P1-02-04-003

UPPERSTRUCTURE / Engine
42. Shut engine cover (4) and cover (9).

W1P1-02-02-001

W1P1-02-04-001

43. Connect minus terminal (3) to battery (2).

44. Shut cover (1).

2
3
M1P1-07-037

W2-11-16

UPPERSTRUCTURE / Engine
REMOVAL
AND
INSTALLATION
ENGINE (ZX75US-3)

OF

Removal
1. Open engine cover (2) and side covers (1) (2
used).

WBAT-06-01-019

2. Disconnect minus terminal (4) from battery (3).

3
4

M1P1-07-002

CAUTION: Engine cover (2) weight: 22 kg (50


lb)
2

3. Attach a nylon sling onto engine cover (2). Hoist


and hold engine cover (2).

WBAT-06-01-020

4. Remove split pin (7) and washer (8) from the


support (5) pin part. Remove cylinder (6) from
support (5).

W2-11-17

WBAT-06-01-021

UPPERSTRUCTURE / Engine
9

5. Remove split pin (10) and washer (9) from stopper


(11). Remove stopper (11) from engine cover (2).

10

WBAT-06-01-022

11

CAUTION: Engine cover (2) weight: 22 kg (50


lb)

12

2
5

6. Remove sems bolts (12) (4 used). Remove


engine cover (2) from support (5).
: 17 mm

WBAT-06-01-020

7. Disconnect hoses (13) (2 used) from reserve tank


(14). Cap the open ends.

13

14

15

8. Remove sems bolts (14) (2 used). Remove the


cover (17) assembly from bracket (15).
: 13 mm

13
16
14

17

9. Remove caps (18) (2 used) from counterweight


(19).

W1P1-02-02-004

18

CAUTION: Counterweight (19) weight: 1380


kg (3050 lb)
10. Install the Freno-Linkbolts (A-20: M20, Pitch 2.5
mm) (2 used) to counterweight (19). Attach a wire
rope onto the Freno-Linkbolts (2 used). Hoist and
hold counterweight (19).

19

WBAT-06-01-026

W2-11-18

UPPERSTRUCTURE / Engine
11. Remove bolts (20) (3 used) and washers (21) (3
used)
from
counterweight
(19).
Float
counterweight (19) from main frame (22) slightly.
Remove counterweight (19) while sliding
backward.
: 41 mm

19

20, 21

WBAT-06-01-027

22

23

22

12. Remove sems bolts (24) (6 used). Remove cover


(23) from main frame (22).
: 17 mm

24

W1P1-02-11-001

25

22

13. Remove sems bolts (26) (4 used). Remove cover


(25) from main frame (22).
: 17 mm

26

W1P1-02-05-006

14. Remove clip band (30) from cover


Disconnect harness (29) from cover (28).

(28).

27

28

29
30

15. Remove sems bolts (27) (4 used). Remove cover


(28) from support (5) and main frame (22).
: 17 mm

22

W1P1-02-06-003

W2-11-19

UPPERSTRUCTURE / Engine
16. Remove sems bolts (31) (5 used). Remove cover
(33) from support (5) and cab (32).
: 17 mm

31

32

33

17. Remove sems bolts (35) (3 used) from support (5).


Remove support (5) from brackets (34, 15, and
36).
: 17 mm

34

35

W1P1-02-01-004

15

W1P1-02-11-023

36

35

WBAT-06-01-020

18. Remove bolts (38) (5 used). Remove cover (37)


from engine (39).
: 10 mm, 13 mm

37

38

39

W1P1-02-04-006

W2-11-20

UPPERSTRUCTURE / Engine
19. Loosen bolts (41) (2 used). Make a play in band
(42). Remove muffler (43) from turbocharger (40).
: 14 mm

40

41

42
43

W1P1-02-04-013

20. Remove sems bolts (47) (2 used) from intake duct


(44). Remove intake duct (44) from bracket (34).
: 17 mm

44, 45, 46

34

47

21. Loosen bands (45) (2 used) from intake duct (44).


Remove intake duct (44) from air cleaner (46) and
turbocharger (40).

39

22. Loosen band (48) from hose (49). Disconnect


hose (49) from engine (39).

48
40
50

49

51

23. Loosen band (54) from hose (56). Remove sems


bolt (53) from pipe (50). Remove the pipe (50)
assembly from bracket (55).
: 17 mm

W1P1-02-11-022

52

50

24. Remove sems bolts (51) (3 used). Remove cover


(52) from bracket (55).
: 17 mm

56

W2-11-21

55

54

53

W1P1-02-11-023

UPPERSTRUCTURE / Engine
25. Remove sems bolts (57) (4 used) from bracket
(15). Remove bracket (15) from brackets (34, 55)
and support (58).
: 17 mm

34

57

15

58
55

W1P1-02-11-023

57

15

W1P1-02-11-022

59, 60

61

62

63

26. Loosen bands (59) (2 used). Disconnect hose (61)


from radiator (60) and engine (39).

64

27. Remove sems bolts (63) (2 used) from fan guard


(64). Remove fan guard (64) from fan cover (62).
: 17 mm

59
39
W1P1-02-11-019

28. Loosen bands (66) (2 used). Disconnect hose (67)


from pipe (65) and engine (39).

65

66

67

68

69
39

29. Remove sems bolt (68) from clip (70). Remove


clip (70) from harness (69) and engine (39).
: 17 mm

70

W1P1-02-11-004

W2-11-22

UPPERSTRUCTURE / Engine
71

CAUTION: The pump device (71) assembly


weight: 77 kg (170 lb)
30. Remove the pump device (71) assembly.
(Refer to REMOVAL AND INSTALLATION OF
PUMP DEVICE on W2-4-1.)

W1P1-02-04-009

31. Remove sems bolts (80, 76) from clips (81, 77).
Remove clips (80, 76) from harness (73) and
cable (74).
: 17 mm
32. Remove sems bolts (83) (2 used) and (79) (4
used). Remove covers (82, 78) from brackets (72,
55) and cover (75).
: 17 mm

72

73

74

75

55

76, 77

82, 83

80, 81

78, 79

55

W1P1-02-11-024

84

85

33. Remove sems bolt (86). Remove cover (75) from


bracket (55).
: 17 mm
34. Remove coupling (87) from oil cooler (84) and
pipe (85).
: 13 mm
W1P1-02-05-004

87

W2-11-23

75, 86

UPPERSTRUCTURE / Engine
35. Remove sems bolts (88) (8 used). Remove fan
cover (62) from bracket (55).
: 17 mm

55

62

88

W1P1-02-11-005

36. Remove clip band (89) from engine (39).


Disconnect connector (90) from engine (39).

89

90

39

W1P1-02-11-013

91

37. Disconnect connector (92).

92

93

38. Remove bolts (94) (2 used) from pipes (91) (2


used). Disconnect pipes (91) (2 used) from cooler
pump (93).
: 13 mm

94
95

39. Disconnect connector (97).


40. Disconnect harnesses (96) (2 used) from dynamo
(95).
: 10 mm

96

W1P1-02-11-022

97
96

W1P1-02-11-015

W2-11-24

UPPERSTRUCTURE / Engine
98

41. Disconnect harness (100) and connector (98)


from starter motor (99).
: 12 mm

99

100

W1P1-02-11-018

101

42. Remove nut (102) from ground (101). Disconnect


ground (101) from main frame (22).
: 17 mm

22

W1P1-02-11-006

102

103

43. Loosen bands (104) (3 used). Disconnect hoses


(105) (3 used) and hose (108) from engine (39).

39

104

44. Disconnect connectors (103) (4 used).


45. Disconnect harness (107) from heater plug (106).

W1P1-02-11-012

108

46. Loosen lock nuts (111) (2 used). Disconnect


cables (109) (2 used) from bracket (110).
: 17 mm

109

110

106, 107

105

111
112
113
114

47. Remove nuts (113) (2 used) from ball joints (112)


(2 used). Remove ball joints (112) (2 used) from
levers (114) (2 used).

W1P1-02-11-011

W2-11-25

104

W1P1-02-11-010

UPPERSTRUCTURE / Engine
48. Disconnect harness (115) from pressure switch
(116).

115

116

W1P1-02-11-007

117

49. Disconnect connector (119).

39

50. Disconnect hose (118) from engine (39). Cap the


open ends.

118

51. Remove bolt (117) from clip (120). Disconnect


harness (121) from engine (39).
: 10 mm

121

120

119

W1P1-02-11-009

Wire Rope Mounting Bracket

CAUTION: Engine (39) weight: 210 kg (470 lb)


52. Attach a wire rope onto engine (39). Hoist and
hold engine (39).

39

W1P1-02-11-003

Wire Rope Mounting Bracket

39

W1P1-02-11-002

W2-11-26

UPPERSTRUCTURE / Engine
39

53. Remove nuts (123) (4 used), washers (124) (4


used), and dampers (125) (2 used) from bolts
(122) (4 used). Remove bolts (122) (4 used) and
washers (124) (4 used) from brackets (126) (4
used).
: 22 mm, 24 mm

122, 123
124
125

CAUTION: The engine (39) assembly weight:


210 kg (470 lb)
54. Hoist the engine (39) assembly about 10 mm.
Move the engine (39) assembly toward the pump
device. Remove the engine (39) assembly and
dampers (125) (4 used) from main frame (22).

22

126

39

W1P1-02-11-004

122, 123
124
125

W1P1-02-11-006

126

W2-11-27

22

UPPERSTRUCTURE / Engine
Installation
1. Install dampers (125) (4 used) to the mounting
part of main frame (22).
39

CAUTION: The engine (39) assembly weight:


210 kg (470 lb)
122, 123

2. Attach a sire rope onto the engine (39) assembly.


Hoist the engine (39) assembly. Align the engine
(39) assembly with the mounting hole on main
frame (22).

124
125

22
101

W1P1-02-11-004

126

39

122, 123

3. Install brackets (126) (4 used) to main frame (22)


with dampers (125) (4 used), bolts (122) (4 used),
washers (124) (8 used), and nuts (123) (4 used).
: 22 mm
: 180 Nm (18 kgfm, 133 lbfft)
: 24 mm
: 270 Nm (27 kgfm, 200 lbfft)

4. Connect ground (101) to main frame (22) with nut


(102).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

124
125

W1P1-02-11-006

102

126

117

22
39

5. Connect hose (118) to engine (39).

118

6. Connect connector (119). Connect harness (121)


to engine (39) with clip (120) and bolt (117).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)
121
115

120

W1P1-02-11-009

119
116

7. Connect harness (115) to pressure switch (116).

W1P1-02-11-007

W2-11-28

UPPERSTRUCTURE / Engine
8. Install ball joints (112) (2 used) to levers (114) (2
used) with nuts (113) (2 used).

109

110

111
112
113

9. Connect cables (109) (2 used) to bracket (110)


with lock nuts (111) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

114

W1P1-02-11-011

10. Connect hoses (105) (3 used) and hose (108) to


engine (39). Secure hoses (105) (3 used) to
engine (39) with bands (104) (3 used).

103

39

W1P1-02-11-010

104

11. Connect harness (107) to heater plug (106).


12. Connect connectors (103) (4 used).

W1P1-02-11-012

108

106, 107

98

13. Connect harness (100) and connector (98) to


starter motor (99).
: 12 mm
: 10 Nm (1 kgfm, 7 lbfft)

104

105

99

100

W1P1-02-11-018

95

14. Connect connector (97).


15. Connect harnesses (96) (2 used) to dynamo (95).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

96

97
96

W1P1-02-11-015

W2-11-29

UPPERSTRUCTURE / Engine
91

16. Connect pipes (91) (2 used) to cooler pump (93)


with bolts (94) (2 used).
: 13 mm
: 10 Nm (1 kgfm, 7 lbfft)

92

93

17. Connect connector (92).

94
89

18. Connect connector (90) to engine (39). Secure the


connector (90) assembly to engine (39) with clip
band (89).

90

W1P1-02-11-022

39

W1P1-02-11-013

19. Install fan cover (62) to bracket (55) with sems


bolts (88) (8 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

55

62

88

W1P1-02-11-005

20. Connect oil cooler (84) to pipe (85) with coupling


(87).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

55

84

85

21. Install cover (75) to bracket (55) with sems bolt


(86).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-02-05-004

87

W2-11-30

75, 86

UPPERSTRUCTURE / Engine
22. Install cover (78) to bracket (55) and cover (75)
with sems bolts (79) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

23. Install cover (82) to brackets (72) (2 used) and


cover (78) with sems bolts (83, 79) (2 used for
each).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

72

73

74

75

55

76, 77

82, 83

80, 81

78, 79

W1P1-02-11-024

24. Connect harness (73) and cable (74) to covers (82,


78) with clips (80, 76) and sems bolts (81, 76).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

CAUTION: The pump device (71) assembly


weight: 77 kg (170 lb)
71

25. Install the pump device (71) assembly.


(Refer to REMOVAL AND INSTALLATION OF
PUMP DEVICE on W2-4-1.)

W1P1-02-04-009

26. Connect hose (61) to radiator (60) and engine (39).


Secure hose (61) to radiator (60) and engine (39)
with bands (59) (2 used).
27. Install fan guard (64) to fan cover (62) with sems
bolts (63) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

59, 60

61

62

63

64

59
39
W1P1-02-11-019

W2-11-31

UPPERSTRUCTURE / Engine
34

28. Install cover (52) to bracket (55) with sems bolts


(51) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

51

57

52

15

58

29. Install bracket (15) to brackets (34, 55) and


support (58) with sems bolts (57) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

30. Install the pipe (50) assembly to hose (56),


bracket (55) and engine (39).

55
50

56

54

31. Connect pipe (50) to bracket (55) with sems bolt


(53).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

53

57

W1P1-02-11-023

15

32. Secure hose (56) to pipe (50) with band (54).

39

33. Secure hose (49) to engine (39) with band (48).


48

34. Install clip (70) to harness (69). Install clip (70) to


engine (39) with sems bolt (68).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

35. Connect hose (67) to pipe (65) and engine (39).


Secure hose (67) to pipe (65) and engine (39) with
bands (66) (2 used).

50

49

65

66

67

68

W1P1-02-11-022

69
39
70

W1P1-02-11-004

W2-11-32

UPPERSTRUCTURE / Engine
36. Install intake duct (44) to air cleaner (46), bracket
(34), and turbocharger (40). Secure intake duct
(44) to bracket (34) with sems bolt (47).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

44, 45, 46

34

47

37. Secure intake duct (44) to air cleaner (46) and


turbocharger (40) with bands (45) (2 used).

40
W1P1-02-11-022

38. Install turbocharger (40) and muffler (43) with


band (42) and bolts (41) (2 used).
: 14 mm
: 20 Nm (2 kgfm, 15 lbfft)

40

41

42
43

W1P1-02-04-013

39. Install cover (37) to engine (39) with bolts (38) (5


used).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

37

38

39

W1P1-02-04-006

W2-11-33

UPPERSTRUCTURE / Engine
34

40. Install support (5) to brackets (34, 15, and 36) with
sems bolts (35) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

35

15

W1P1-02-11-023

36

35

WBAT-06-01-020

41. Install cover (33) to support (5) and cab (32) with
sems bolts (31) (5 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

31

32

33

42. Install cover (28) to support (5) and main frame


(22) with sems bolts (27) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

43. Secure harness (29) to cover (28) with clip band


(30)

27

28

W1P1-02-01-004

29
30

22

W1P1-02-06-003

W2-11-34

UPPERSTRUCTURE / Engine
23

44. Install covers (23, 25) to main frame (22) with


sems bolts (24) (6 used) and (26) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

22

24

W1P1-02-11-001

25

22

26

W1P1-02-05-006

CAUTION: Counterweight (19) weight: 1380


kg (3050 lb)

19

45. Install the Freno-Linkbolts (A-20: M20, Pitch 2.5


mm) (2 used) to counterweight (19). Attach a wire
rope
onto
the
Freno-Linkbolts.
Hoist
counterweight (19). Align counterweight (19) with
the mounting hole on main frame (22).

20, 21

WBAT-06-01-027

22

46. Install counterweight (19) to main frame (22) with


bolts (20) (3 used) and washers (21) (3 used).
: 41 mm
: 1400 Nm (140 kgfm, 1040 lbfft)

47. Remove the wire rope and the Freno-Linkbolts (2


used) from counterweight (19). Install caps (18) (2
used) to counterweight (19).

18

19

WBAT-06-01-026

W2-11-35

UPPERSTRUCTURE / Engine
48. Install the cover (17) assembly to bracket (15) with
sems bolts (14) (2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

13

14

15

13

49. Connect hoses (13) (2 used) to reserve tank (16).


16
14

17

W1P1-02-02-004

12

CAUTION: Engine cover (2) weight: 22 kg (50


lb)

50. Attach a nylon sling onto engine cover (2). Hoist


engine cover (2). Align engine cover (2) with the
mounting hole on support (5). Install engine cover
(2) to support (5) with sems bolts (12) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

51. Install stopper (11) to engine cover (2). Secure


stopper (11) to engine cover (2) with washer (9)
and split pin (10).

WBAT-06-01-020

10

WBAT-06-01-022

11

52. Install cylinder (6) to support (5). Secure cylinder


(6) to support (5) with washer (8) and split pin (7).

W2-11-36

WBAT-06-01-021

UPPERSTRUCTURE / Engine
53. Connect minus terminal (4) to battery (3).

3
4

54. Shut side covers (1) (2 used) and engine cover


(2).

M1P1-07-001

WBAT-06-01-019

W2-11-37

UPPERSTRUCTURE / Engine
(Blank)

W2-11-38

MEMO
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SECTION 3

UNDERCARRIAGE
CONTENTNS
Group 1 Swing Bearing

Group 5 Front Idler

Removal and Installation of


Swing Bearing ....................................... W3-1-1
Disassembly of Swing Bearing ................ W3-1-4
Assembly of Swing Bearing..................... W3-1-8

Group 2 Travel Device

Removal and Installation of Front Idler .... W3-5-1


Disassembly of Front Idler....................... W3-5-4
Assembly of Front Idler ........................... W3-5-6
Maintenance Standard............................. W3-5-8

Group 6 Upper and Lower Roller

Removal and Installation of


Travel Device ........................................ W3-2-1
Disassembly of Travel Device ................. W3-2-4
Assembly of Travel Device ...................... W3-2-8
Disassembly of Travel Motor ................. W3-2-12
Assembly of Travel Motor...................... W3-2-16
Disassembly of Brake Valve.................. W3-2-24
Assembly of Brake Valve....................... W3-2-28
Maintenance Standard .......................... W3-2-32

Removal and Installation of


Upper Roller .......................................... W3-6-1
Removal and Installation of
Lower Roller .......................................... W3-6-4
Disassembly and Assembly of
Lower Roller .......................................... W3-6-6
Maintenance Standard............................. W3-6-8

Group 7 Track
Removal and Installation of Track............ W3-7-1
Maintenance Standard............................. W3-7-7

Group 3 Center Joint


Removal and Installation of
Center Joint (ZX70-3)............................ W3-3-1
Removal and Installation of
Center Joint (ZX75US-3)....................... W3-3-3
Disassembly of Center Joint ................... W3-3-8
Assembly of Center Joint ...................... W3-3-10
Maintenance Standard .......................... W3-3-13

Group 4 Track Adjuster


Removal and Installation of
Track Adjuster ....................................... W3-4-1
Disassembly of Track Adjuster ................ W3-4-2
Assembly of Track Adjuster ..................... W3-4-8

1P1W-3-1

(Blank)

1P1W-3-2

UNDERCARRIAGE / Swing Bearing


REMOVAL AND
SWING BEARING

INSTALLATION

OF

Before removing and installing the swing bearing, the


upperstructure should be removed first. For removal
and installation of the upperstructure, refer to REMOVAL AND INSTALLATION OF MAIN FRAME on
W2-3-1.
The procedure starts on the premise that the upperstructure has already been removed.
Removal
1. Put the matching marks on inner race (1) of the
swing bearing (4) and track frame (2).

Matching Mark

2. Remove bolts (3) (24 used) from inner race (1) of


swing bearing (4).
: 24 mm

W105-03-01-001

3
1

4
W105-03-01-002

CAUTION: Swing bearing (4) weight: 91 kg


(200 lb)
3. Install the special tool (ST 0050) to swing bearing
(4). Attach a wire rope onto the special tool (ST
0050). Remove swing bearing (4) from track
frame (2).

ST 0050

4
W105-03-01-003

W3-1-1

UNDERCARRIAGE / Swing Bearing


Installation
1. Clean the mounting surfaces of track frame (2)
and swing bearing (4).

2. Apply THREEBOND #1102 onto the swing bearing (4) mounting surface of track frame (2).
ST 0050

2
W105-03-01-003

Position for
Grease Fitting

CAUTION: Swing bearing (4) weight: 91 kg


(200 lb)

Position
for Plug
10
S

IMPORTANT: If the matching mark do not align,


the soft zone position of inner race
(1) will be dislocated.
3. Hoist swing bearing (4) by using the special tool
(ST 0050). Align the matching marks on track
frame (2) and inner race (1) of swing bearing (4).

Machine Front

9
(S) (Soft Zone)
Marking Position
Position for Grease
Fitting
W1CD-03-01-001

4. Install inner race (1) of swing bearing (4) to track


frame (2) with bolts (3) (24 used).
: 24 mm
: 270 Nm (27 kgfm, 200 lbfft)

2
3

4
W105-03-01-002

W3-1-2

UNDERCARRIAGE / Swing Bearing


5. After installing the swing bearing, add grease
(Shell Alvania EP2 or equivalent) to the grease
bath until the pinion of the swing device is 5 mm
(0.2 in) under grease.

Swing Bearing Grease Level

Pinion Gear

5 mm
(0.2 in)

W175-03-01-002

Grease Bath

W3-1-3

UNDERCARRIAGE / Swing Bearing


DISASSEMBLY OF SWING BEARING
1

W155-03-01-001

7
6
8

W105-03-01-011

123-

Outer Race
Seal
Pin

45-

Plug
Seal

67-

W3-1-4

Ball (79 Used)


Inner Race

89-

Support (79 Used)


Grease Fitting (2 Used)

UNDERCARRIAGE / Swing Bearing


Disassembly of Swing Bearing
1. Tap and remove pin (3) of plug (4) upward from
outer race (1).
NOTE: After installing pin (3), pin (3) was crimped.
Grind off the crimped part.
3

CAUTION: Swing bearing weight: 91 kg (200


lb)
3. Place inner race (7) of the swing bearing onto a
wooden block by using the special tool (ST 0050).
Hoist and hold outer race (1) slightly. Remove
seals (2, 5) from outer race (1) and inner race (7)
respectively by using a scrapper.
4. Remove balls (6) (79 used) and supports (8) (79
used) from the plug (4) hole while rotating outer
race (1).
Remove ball (6) by using magnet (A). Use wire
(B) and remove support (8).

1
2
W105-03-01-007

2. Remove plug (4) from outer race (1).


NOTE: Install the bolt into the screw hole (M8,
Pitch 1.25 mm) of plug (4). Tap or pull the
bolt from the inner side.
6

W105-03-01-009

4
B

Bolt

W105-03-01-008

W3-1-5

W105-03-01-010

UNDERCARRIAGE / Swing Bearing

W155-03-01-001

W105-03-01-011

W3-1-6

UNDERCARRIAGE / Swing Bearing


CAUTION: Outer race (1) weight: 38 kg (84
lb)
Inner race (7) weight: 46 kg (100 lb)
1. Remove outer race (1) from inner race (7).

W3-1-7

UNDERCARRIAGE / Swing Bearing


ASSEMBLY OF SWING BEARING
1

W155-03-01-001

9
7
6
8

W105-03-01-011

123-

Outer Race
Seal
Pin

45-

Plug
Seal

67-

W3-1-8

Ball (79 Used)


Inner Race

89-

Support (79 Used)


Grease Fitting (2 Used)

UNDERCARRIAGE / Swing Bearing


Assembly of Swing Bearing
CAUTION: Inner race (7) weight: 46 kg (100
lb)

4. Tap and install plug (4) into outer race (1). Secure
plug (4) to outer race (1) with pin (3). Crimp the
head of pin (3) by using a punch.

1. Place inner race (7) onto a wooden block.

2. Apply grease onto balls (6) (79 used) and supports (8) (79 used)

CAUTION: Outer race (1) weight: 38 kg (84


lb)
3. Hoist outer race (1) horizontally by using the special tool (ST 0050) and align outer race (1) with
inner race (7) coaxially.
While rotating outer race (1), install ball (6) and
support (8) to the plug (4) hole by using a round
bar.

4
W142-03-01-007

CAUTION: Swing bearing weight: 91 kg (200


lb)

5. Install the special tool (ST 0050) to outer race (1).


Thoroughly degrease the slots for seals (2, 5).
Apply THREEBOND #1530 onto seals (2, 5). Install seals (2, 5) to outer race (1) and inner race
(7).

6. Add grease (Alvania EP2 or equivalent) to the


swing bearing through grease fitting (9).
Grease amount: 0.2 L (0.1 US gal.)

6
5

W142-03-01-005

W142-03-01-006

W3-1-9

UNDERCARRIAGE / Swing Bearing


(Blank)

W3-1-10

UNDERCARRIAGE / Travel Device


REMOVAL
AND
TRAVEL DEVICE

INSTALLATION

OF

Before removing and installing the travel device, the


track should be removed first. (Refer to REMOVAL
AND INSTALLATION OF TRACK on W3-7-1.)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Remove bolts (1) (5 used) and washers (2) (5
used) from cover (3). Remove cover (3) from track
frame (4).
: 22 mm

1, 2

2. Disconnect hoses (5) (4 used) from travel device


(8). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 22 mm, 27 mm
CAUTION: Travel device (8) weight: 110 kg
(250 lb)
3. Attach a nylon sling onto travel device (8). Hoist
and hold travel device (8). Remove bolts (6) (12
used) and washers (7) (12 used) from track frame
(4). Remove travel device (8) from track frame (4).
: 24 mm

W1P1-03-02-001

6, 7

W1P1-03-02-002

W3-2-1

UNDERCARRIAGE / Travel Device


Installation
CAUTION: Travel device (8) weight: 110 kg
(250 lb)

6, 7

1. Attach a nylon sling onto travel device (8). Hoist


and align travel device (8) with the mounting hole
of track frame (4).
2. Install travel device (8) to track frame (4) with bolts
(6) (12 used) and washers (7) (12 used).
: 24 mm
: 300 Nm (31 kgfm, 221 lbfft)
3. Connect hoses (5) (4 used) to travel device (8).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

W1P1-03-02-002

1, 2

4. Install cover (3) to track frame (4) with bolts (1) (5


used) and washers (2) (5 used).
: 22 mm
: 90 Nm (9 kgfm, 66 lbfft)

W1P1-03-02-001

W3-2-2

UNDERCARRIAGE / Travel Device


(Blank)

W3-2-3

UNDERCARRIAGE / Travel Device


DISASSEMBLY OF TRAVEL DEVICE
1

10

11

12

13

14

15
16
17
18
19
20
21
22
23
24
25
26

31

30

29

28

27

32

33
WBAT-06-01-079

123456789-

Travel Motor
Floating Seal
Floating Seal
Ball Bearing
Ring
Ball Bearing
Bearing Nut
Thrust Plate (2 Used)
Planetary Gear (4 Used)

10 11 12 13 14 15 16 17 -

Ring (4 Used)
Needle Bearing (4 Used)
Ring Gear
O-ring
Ring
Plug (3 Used)
Thrust Plate
Flash Bolt

18 19 20 21 22 23 24 25 -

W3-2-4

Retaining Ring
Sun Gear
Shaft
Stopper Pin
Thrust Plate
Retaining Ring (3 Used)
Ring (3 Used)
Cover

26 27 28 29 30 31 32 33 -

Thrust Plate
Planetary Gear (3 Used)
Needle Bearing (3 Used)
Thrust Plate (3 Used)
Carrier
Lock Plate
Bolt (16 Used)
Sprocket

UNDERCARRIAGE / Travel Device


Disassembly of Travel Device
CAUTION: The pressure may be applied to
the inside of the travel device. Loosen the air
bleed plug slowly. Release any remaining
pressure. Remove the drain plug and drain
gear oil.
If the air bleed plug is loosened suddenly, the
plug may be fly out and gear oil may gush out.
Keep body and face away from the plug.

7. Remove flash bolts (17) (4 used) from thrust


plate (16). Remove thrust plate (16) from travel
motor (1).
8. Remove planetary gears (9) (4 used), needle
bearings (11) (4 used), rings (10) (4 used), and
thrust plates (8) (2 used) from travel motor (1).
9. Extend the claw of lock plate (31). Remove lock
plate (31) from bearing nut (7). Remove bearing
nut (7) from travel motor (1).

1. Place travel motor (1) with the brake valve side


facing downward.
2. Remove plugs (15) (3 used) from cover (25).
Drain gear oil from the travel reduction gear.
: 10 mm
3. Remove ring (14) from ring gear (12) by using a
screwdriver. Remove cover (25) from ring gear
(12). Remove O-ring (13) from cover (25).
4. Remove shaft (20) and the carrier (30) assembly
from ring gear (12).
5. Remove sun gear (19) from travel motor (1).
Remove retaining ring (18) from sun gear (19).
CAUTION: Sprocket (33) weight: 29 kg (64 lb)

CAUTION: Ring gear (12) weight: 20 kg (44


lb)
10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the sprocket (33) mounting hole of ring gear (12).
Attach a nylon sling onto the eyebolt. Hoist and
hold ring gear (12).
11. Remove ring gear (12) from travel motor (1) by
using a plastic hammer.
12. Remove roller bearing (6) from ring gear (12) by
using a bar and a plastic hammer. Remove ring
(5) from ring gear (12).
13. Remove ball bearing (4) and floating seals (2, 3)
from travel motor (1).

6. Remove bolts (32) (12 used) from sprocket (2).


Attach a nylon sling onto sprocket (33). Hoist and
remove sprocket (33) from ring gear (12).
: 24 mm

W3-2-5

UNDERCARRIAGE / Travel Device

22
23
24

26

30

29

28

27

WBAT-06-01-079

W3-2-6

UNDERCARRIAGE / Travel Device


IMPORTANT: Do not remove rings (24) (3 used)
from carrier (30) unless necessary.
14. Remove retaining rings (23) (3 used) and thrust
plate (26) from carrier (30).
15. Remove planetary gears (27) (3 used), needle
bearings (28) (3 used), thrust plates (29) (3 used),
and thrust plate (22) from carrier (30).

W3-2-7

UNDERCARRIAGE / Travel Device


ASSEMBLY OF TRAVEL DEVICE

10

11

12

13

14

15
16
17
18
19
20
21
22
23
24
25
26

31

30

29

28

27

32

33
WBAT-06-01-079

123456789-

Travel Motor
Floating Seal
Floating Seal
Ball Bearing
Ring
Ball Bearing
Bearing Nut
Thrust Plate (2 Used)
Planetary Gear (4 Used)

10 11 12 13 14 15 16 17 -

Ring (4 Used)
Needle Bearing (4 Used)
Ring Gear
O-ring
Ring
Plug (3 Used)
Thrust Plate
Flash Bolt

18 19 20 21 22 23 24 25 -

W3-2-8

Retaining Ring
Sun Gear
Shaft
Stopper Pin
Thrust Plate
Retaining Ring (3 Used)
Ring (3 Used)
Cover

26 27 28 29 30 31 32 33 -

Thrust Plate
Planetary Gear (3 Used)
Needle Bearing (3 Used)
Thrust Plate (3 Used)
Carrier
Lock Plate
Bolt (16 Used)
Sprocket

UNDERCARRIAGE / Travel Device


Assembly of Travel Device

CAUTION: Sprocket (23) weight: 29 kg (64 lb)

CAUTION: Ring gear (12) weight: 20 kg (44


lb)
1. Install ring (5) to ring gear (12). Install ball
bearings (4, 6) to ring gear (12) by using a bar
and a plastic hammer.
2. Install floating seal (3) to ring gear (12).
CAUTION: Travel motor (1) weight: 41 kg (90
lb)
3. Place travel motor (1) with the brake valve side
facing downward.
4. Install floating seal (2) to travel motor (1).
5. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the sprocket (33) mounting hole of ring gear (12).
Attach a nylon sling onto the eyebolt. Hoist and
align ring gear (12) with travel motor (1).
6. Install the ring gear (12) assembly to travel motor
(1) by using a bar and a plastic hammer.

7. Apply LOCTITE #262 onto bolts (32) (16 used).


8. Install sprocket (33) to ring gear (12) with bolts
(32) (16 used).
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
9. Install bearing nut (7) to travel motor (1). Install
lock plate (31) to bearing nut (7). Bend lock plate
(31).
Tighten bearing nut (7) with the force (170 Nm
(17 kgfm, 125 lbfft)) and rotate sprocket (33)
clockwise and counterclockwise 4 to 5 turns
respectively.
Tap bearing nut (7) by using a hammer and
tighten it with the force (170 Nm (17 kgfm, 125
lbfft)) again.
If the bending position of lock plate (31) is not
located correctly, tighten bearing nut (7) again.
10. Install thrust plates (8) (2 used), rings (10) (4
used), needle bearings (11) (4 used), and
planetary gears (9) (4 used) to travel motor (1).
11. Install thrust washer (16) to travel motor (1) with
flash bolts (17) (4 used).
: 21 Nm (2.1 kgfm, 15 lbfft)

W3-2-9

UNDERCARRIAGE / Travel Device

12

13

14

15

18
19
20

22
23
24
25
26

30

29

28

27

WBAT-06-01-079

W3-2-10

UNDERCARRIAGE / Travel Device


12. Install retaining ring (18) to sun gear (19). Install
sun gear (19) to travel motor (1).
13. Install thrust plate (22) to carrier (30).
14. Install thrust washers (29) (3 used), needle
bearings (28) (3 used), planetary gears (27) (3
used), and thrust plate (26) to carrier (30).
15. Secure thrust plate (26) to carrier (30) with
retaining rings (23) (3 used).
16. Install the carrier (30) assembly to sun gear (19).
17. Align the spline of planetary gears (27) (3 used)
with travel motor (1). Install shaft (20).
18. Apply grease onto O-ring (13). Install O-ring (13)
to cover (25).
19. Install cover (25) to ring gear (12) with ring (14).
20. Add gear oil to the travel reduction gear through
the hole of plugs (15) (3 used).
Gear oil amount: 1.2 L (0.3 US gal)
21. Install plugs (15) (3 used) to cover (25).
: 10 mm
: 50 Nm (5 kgfm, 37 lbfft)

W3-2-11

UNDERCARRIAGE / Travel Device


DISASSEMBLY OF TRAVEL MOTOR
Parking Brake Releasing Oil
Passage

10

11

12

13

14

15

16

17

26

1234567-

25

Spring Pin
Bolt (6 Used)
Valve Plate
O-ring
Disc S pring
Brake Piston
Plunger Assemnly (9 Used)

24

8910 11 12 13 14 -

Rotor
Retainer
Swash Plate
Bushing
Housing
Ball (2 Used)
Shaft

23

22

21

15 16 17 18 19 20 -

20

19

Oil Seal
Ball Bearing
Piston
Spring (6 Used)
Friction Plate (3 Used)
Plate (4 Used)

W3-2-12

18

21 22 23 24 25 26 -

WBAT-06-01-080

O-ring
O-ring
O-ring
O-ring
Roller Bearing
Brake Valve Assembly

UNDERCARRIAGE / Travel Device


Disassembly of Travel Motor
IMPORTANT: When
removing
brake
valve
assembly (26) from the motor, valve
plate (3) and the outer race roller
bearing (25) may be removed with
the brake valve together. Do not
drop valve plate (3) and the outer
race roller bearing (25),
IMPORTANT: The open part of brake valve
assembly (26) is the seat surface to
prevent pressure oil leakage when
releasing the parking brake. When
placing brake valve assembly (26)
with the open part facing downward,
do not damage the seat surface.

CAUTION: When removing brake piston (6)


by applying air, hold brake piston (6) by using
a cloth in order to prevent brake piston (6)
from flying out.
4. Apply air, 98 to 294 kPa(1 to 3 kgf/cm2, 14.2 to
42.6 psi) or less to the parking brake releasing oil
passage. Remove brake piston (6) from housing
(12).
5. Remove plates (20) (4 used) and friction plates
(19) (3 used) from housing (12).
6. Remove swash plate (10) from housing (12).
7. Remove balls (13) (2 used) and piston (17) from
housing (12) by using a magnet.

26

CAUTION: Housing (12) weight: 21 kg (50 lb)

W172-03-02-006

Seat Surface

CAUTION: Travel motor weight: 41 kg (90 lb)


1. Place the travel motor with the brake valve
assembly (26) side facing upward. Remove bolts
(2) (6 used) from brake valve assembly (26).
Remove brake valve assembly (26) from housing
(12).
: 12 mm

8. Place housing (12) horizontally. Lightly tap the


inner surface spline side of shaft (14) by using a
bar and a plastic hammer. Remove bearing (14)
and bearing (16) from housing (12).
9. Remove oil seal (15) from the shaft (14) mounting
hole side of housing (12) by using a screwdriver.
NOTE: Oil seal (15) is installed by applying
adhesive onto the outer surface. When
removing, oil seal (15) cannot be reused.

2. Remove valve plate (3) and O-ring (23) from


brake valve assembly (26).
3. Remove disc spring (5), rotor (8), springs (18) (6
used), bushing (11), retainer (9), and plunger
assemblies (7) (9 used) from housing (12) in this
order.

W3-2-13

UNDERCARRIAGE / Travel Device

12

14

16

WBAT-06-01-080

25

W3-2-14

UNDERCARRIAGE / Travel Device


CAUTION: When removing shaft (14) from
the inner race of roller bearing (25), do not
drop shaft (14).
IMPORTANT: If dropping shaft (14), the seal
contacting surface of shaft (14) may
be damaged.
IMPORTANT: Do not damage the inner race of
roller bearing (25).
10. Remove the inner race of roller bearing (25) from
shaft (14). Align the inner race flange with the vise
open part. Lightly tap shaft (14) by using a bar and
a hammer. Remove the inner race of roller
bearing (25) from shaft (14).

CAUTION: When removing ball bearing (16)


from shaft (14), do not drop shaft (14).
IMPORTANT: If dropping shaft (14), the seal
contacting surface of shaft (14) may
be damaged.
11. Remove ball bearing (16) from shaft (14). Secure
the inner race of ball bearing (16) to the vise open
part. Lightly tap shaft (14) by using a bar and a
hammer. Remove ball bearing (16) from shaft
(14).

Bar

Bar

16
14

14

Inner Race

W172-03-02-003

W172-03-02-002

W3-2-15

UNDERCARRIAGE / Travel Device


ASSEMBLY OF TRAVEL MOTOR
Parking Brake Releasing
Oil Passage

10

11

12

13

14

15

16

17

26

1234567-

25

Spring Pin
Bolt (6 Used)
Valve Plate
O-ring
Disc S pring
Brake Piston
Plunger Assemnly (9 Used)

24

8910 11 12 13 14 -

Rotor
Retainer
Swash Plate
Bushing
Housing
Ball (2 Used)
Shaft

23

22

21

15 16 17 18 19 20 -

W3-2-16

20

19

Oil Seal
Ball Bearing
Piston
Spring (6 Used)
Friction Plate (3 Used)
Plate (4 Used)

18

21 22 23 24 25 26 -

WBAT-06-01-080

O-ring
O-ring
O-ring
O-ring
Roller Bearing
Brake Valve Assembly

UNDERCARRIAGE / Travel Device


Assembly of Travel Motor
CAUTION: Housing (12) weight: 22 kg (50 lb)
1. Place housing (12) with the brake valve assembly
(26) mounting surface facing upward.
IMPORTANT: Do not deform oil seal (15).
2. Apply THREEBOND #1104 or #1215 onto the
outer surface of oil seal (15). Install oil seal (15) to
housing (12) by using a special tool. After
installation, apply grease onto the inner surface of
oil seal (18).
Special tool: ST 2891, ST 2892
NOTE: Use OCEAN #7 as the grease.

IMPORTANT: The lip contacting surface of oil seal


(15) is located on the ball bearing
(16) mounting side in shaft (14). Do
not damage the contacting surface.
3. Install ball ring (16) to the inner surface spline
side of shaft (14).
NOTE: Prepare a pipe for the outer diameter of
shaft (14). Attach the pipe onto the inner
race of ball bearing (16) and tap it by using
a plastic hammer.
IMPORTANT: Install the inner race of roller bearing
(25)
with
the
flange
facing
downward.
4. Install the inner race of roller bearing (25) to shaft
(14) by using the special tool (ST 2890).

ST 2892

ST 2891

12

ST 2890
W172-03-02-004

Inner Race

15
14
W172-03-02-005

W3-2-17

UNDERCARRIAGE / Travel Device

Parking Brake Releasing


Oil Passage

10

11

12

13

14

17

26

25

18

W3-2-18

WBAT-06-01-080

UNDERCARRIAGE / Travel Device


CAUTION: Housing (12) weight: 22 kg (50 lb)
5. Place housing (12) with the brake valve assembly
(26) mounting side facing upward.

IMPORTANT: Align the taper surface of the


retainer outer surface with bushing
(11).
10. Install springs (18) (6 used), bushing (11), retainer
(9), and plunger assemblies (7) (9 used) to rotor
(8) in this order.

6. Install shaft (14) to housing (12) by tapping lightly


by using a plastic hammer. At this time, do not tap
the inner race of roller bearing (25).

IMPORTANT: Insert piston (17) into the hole with


the step part facing downward.
7. Apply grease onto balls (13) (2 used). Install
piston (17) and balls (13) (2 used) to housing (12).
8. Install swash plate (10) to housing (12). At this
time, align the hollow (2 places) on the back side
of swash plate (10) with the ball (13) position.
CAUTION: The housing
weight: 24 kg (53 lb)

(12)

11

W172-03-02-001

IMPORTANT: When installing rotor (8), prevent


spring (18) from falling off.
11. Install the rotor (8) assembly to shaft (14).

assembly

9. Place the housing (12) assembly horizontally with


the parking brake releasing oil passage facing
downward. At this time, check that swash plate
(10) is located in the center.
NOTE: If placing the housing (12) assembly with
the parking brake releasing oil passage
facing upward and as the thicker part of
swash plate (10) faces upward, swash
plate (10) may be located out of the center.

W3-2-19

UNDERCARRIAGE / Travel Device

12

17

26

25

24

23

22

21

W3-2-20

20

19

WBAT-06-01-080

UNDERCARRIAGE / Travel Device


CAUTION: The housing
weight: 27 kg (60 lb)

(12)

assembly

12. Place the housing (12) assembly with the brake


valve assembly (26) mounting surface facing
upward.
IMPORTANT: Install plate (20) first.
13. Install plates (20) (4 used) and friction plates (19)
(3 used) to the groove on housing (12) alternately
while aligning with the groove on rotor (8).
IMPORTANT: The notch (1 place) on brake piston
(5) should be located at the piston
(17) operating oil passage side.
IMPORTANT: Brake piston (6) is kept floating due
to O-ring (21) in the outer surface
without inserting. Evenly push brake
piston (6) into housing (12) by hand.
14. Install O-rings (21, 22) to brake piston (6). Install
brake piston (6) to housing (12).

IMPORTANT: Install disc spring (5) so that the


outer surface comes in contact with
brake piston (6).
15. Install disc spring (5) to housing (12).
16. Install O-rings (4, 24) to housing (12).
17. Add hydraulic oil to housing (12).
NOTE: Hydraulic oil amount: 0.5 L (0.1 US gal)
18. Install O-ring (23) to brake valve assembly (26).
IMPORTANT: Face the stamped mark side on the
outer race of roller bearing (25)
upward.
19. Install the outer race of roller bearing (25) to brake
valve assembly (26).

Piston Operating Oil Passage

6
Notch

17

W172-03-02-013

W3-2-21

UNDERCARRIAGE / Travel Device

12

WBAT-06-01-080

26

W3-2-22

UNDERCARRIAGE / Travel Device


IMPORTANT: Install valve plate (3) with the brass
thrust surface facing upward.
20. Apply grease onto the back of valve plate (3).
Install valve plate (3) while aligning the positions
of spring pin (1) in brake valve assembly (26) and
valve plate (3).
IMPORTANT: Do not drop valve plate (3) when
installing as the positioning may
become more difficult or missing
may occur.
21. Install brake valve assembly (26) to housing (12)
by aligning with the bolt (2) hole. At this time, as
brake piston (6) is not pushed in housing (12)
completely, the clearance, about 10 mm is
generated between brake valve assembly (26)
and housing (12). Tighten bolts (2) (6 used)
evenly. Install brake valve assembly (26) while
pushing brake piston (6) into housing (12).
: 12 mm
: 140 Nm (14 kgfm, 103 lbfft)

W3-2-23

UNDERCARRIAGE / Travel Device


DISASSEMBLY OF BRAKE VALVE

25

24

23

22

21

20

19

18

17

16 15

14

13

10

12

11

W172-03-02-014

1 - Valve Casing
2 - Spool

8 - O-ring
9 - Adapter

14 - O-ring
15 - Plug

34567-

10 11 12 13 -

16 17 18 19 -

Stopper (2 Used)
Spring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Spindle

Spool
Poppet
Spring
Plug

W3-2-24

O-ring
Spring
Plug
O-ring

20 - Poppet (2 Used)
21 - Relief Valve Cartridge
(2 Used)
22 - O-Ring (2 Used)
23 - Piston (2 Used)
24 - Spring (2 Used)
25 - Seat Plug

UNDERCARRIAGE / Travel Device


Disassembly of Brake Valve
IMPORTANT: Protect the seat surface in order not
to damage when placing the brake
valve with the travel motor mounting
surface facing downward.

4. Remove spool (2) from the hole where plug (6)


was removed at step 3.
5. Remove plug (13), spring (12), and poppet (11)
from valve casing (1). Remove O-ring (14) from
plug (13).
: 6 mm

W172-03-02-006

Seat Surface

IMPORTANT: Do not disassemble relief valve


cartridge (21).
IMPORTANT: Remove piston (23) with relief valve
cartridge (21) attached. O-ring in
piston (23) is damaged by the oil
hole on relief valve cartridge (21).
1. Remove relief valve cartridge (21) from valve
casing (1). Remove springs (24) (2 used) and
poppets (20) (2 used) from valve housing (1) by
using a magnet.
: 10 mm
IMPORTANT: Unless necessary, do not remove
seat plug (25) which is installed to
the hole without plug (18). LOCTITE
has been applied onto seat plug (25).
2. Remove plug (18) from valve casing (1). Remove
O-ring (19) from plug (18).
: 6 mm
3. Remove plugs (6) (2 used) from valve casing (1).
Remove springs (4) (2 used) and stoppers (3) (3
used) from valve casing (1). Remove O-rings (5)
(2 used) from plugs (6) (2 used).
: 30 mm

W3-2-25

UNDERCARRIAGE / Travel Device

17

10

15
W172-03-02-014

W3-2-26

UNDERCARRIAGE / Travel Device


6. Remove plug (15) from valve casing (1). Remove
spring (17) and spindle (7) from valve casing (1)
by using a magnet.
NOTE: Spool (10) in spindle (7) cannot be
removed through the plug (15) side.
: 6 mm
7. Remove adapter (9) and spool (10) from valve
casing (1). Remove O-ring (8) from adapter (9).
: 19 mm

W3-2-27

UNDERCARRIAGE / Travel Device


ASSEMBLY OF BRAKE VALVE

25

24

23

22

21

20

19

18

17

16 15

14

13

10

12

11

W172-03-02-014

1 - Valve Casing
2 - Spool

89-

O-ring
Adapter

14 - O-ring
15 - Plug

34567-

10 11 12 13 -

Spool
Poppet
Spring
Plug

16 17 18 19 -

Stopper (2 Used)
Spring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Spindle

W3-2-28

O-ring
Spring
Plug
O-ring

20 - Poppet (2 Used)
21 - Relief Valve Cartridge
(2 Used)
22 - O-Ring (2 Used)
23 - Piston (2 Used)
24 - Spring (2 Used)
25 - Seat Plug

UNDERCARRIAGE / Travel Device


Assembly of Brake Valve
IMPORTANT: Protect the seat surface in order not
to damage when placing the brake
valve with the travel motor mounting
surface facing downward.

5. Insert spool (2) into the center of valve casing (1).


6. Install springs (4) (2 used) and stoppers (3) (2
used) to plugs (6) (2 used). Install the plugs (6) (2
used) assmebly to valve casings (1) (2 used).
: 30 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
7. Install plug (18) to valve casing (1).
: 6 mm
: 35 Nm (3.6 kgfm, 26 lbfft)

W172-03-02-006

IMPORTANT: Do not insert spool (10) through the


plug (15) side.
IMPORTANT: Insert the thinner side of spool (10)
into valve casing (1).
1. Apply grease onto O-rings (5) (2 used), O-rings (8,
14, 16, 19), and O-rings (22) (2 used).
2. Install O-rings (5) (2 used), O-rings (8, 14, 16, 19),
and O-rings (22) (2 used) to plugs (6) (2 used),
adapter (9), plugs (13, 15, 18), and relief valve
cartridges (21) (2 used).
3. Install spindle (7) to spool (10). Install the spool
(10) assembly and adapter (9) to valve casing (1).
: 19 mm
: 30 Nm (3 kgfm, 22 lbfft)
4. Install spring (17) and plug (15) to valve casing
(1).
: 6 mm
: 35 Nm (3.6 kgfm, 26 lbfft)

W3-2-29

UNDERCARRIAGE / Travel Device

24

22

21

20
W172-03-02-014

W3-2-30

UNDERCARRIAGE / Travel Device


8. Install spring (24) to poppet (20). Insert poppets
(20) (2 used) into the mounting hole for relief
valve cartridges (21) (2 used) until poppets (20) (2
used) are hidden.
NOTE: If poppet (30) is installed to the end at this
time, spring (24) may come off on the way.
Insert poppet (30) and relief valve cartridge
(21) together.
9. Install the relief valve cartridges (21) (2 used)
assembly to valve casing (1).
: 10 mm
: 120 Nm (12 kgfm, 90 lbfft)

W3-2-31

UNDERCARRIAGE / Travel Device


MAINTENANCE STANDARD
Sprocket

D
A
W1CF-03-02-001

Unit: mm (in)
A
B
C
C
D

Standard
38.00 (1.5)
92.70 (3.6)
120.80 (4.8)
PCD 115.25
(4.5)
154.0 (6.1)

Allowable Limit
[28.00 (1.5)]
87.70 (3.5)
115.80 (4.6)
-

Cladding
by
welding
and hand
finishing

NOTE: The value in ( ) is just for reference.

W3-2-32

UNDERCARRIAGE / Travel Device


Travel Motor

Shoe

1. Clearance between plunger and shoe bottom


Standard
Allowable Limit
0
0.2 mm (0.008 in)
0.2 mm

Plunger

W105-02-06-130

2. Clearance between plunger outer diameter and


rotor inner bore
Standard
Allowable Limit
0
0.04 mm (0.002 in)

D
Rotor

D-d0.04 mm

W105-02-06-134

Plunger Assembly

Rotor

W105-02-06-135

Shoe

3. Shoe thickness
Standard
4.5 mm (0.2 in)

Allowable Limit
4.3 mm (0.2 in)
Plunger

W105-02-06-130

W3-2-33

UNDERCARRIAGE / Travel Device


Parking Brake

A
B

W1CD-03-02-001

Unit: mm (in)
Part Name

Standard

Allowable Limit

Plate

Thickness

1.4 (0.1)

1.35 (0.1)

Disc spring

(Overall height) 5.2 (0.2)

5.1 (0.2)

Brake piston

Thickness

36 (1.4)

Friction plate

Thickness

2.4 (0.1)

2.35 (0.1)

Remark

Remedy

No wear on the piston as it does not slide.

NOTE: The brake piston thickness is shown as the


distance from the contact point of the disc
spring to the contact point of the plate.

W3-2-34

UNDERCARRIAGE / Center Joint


REMOVAL AND INSTALLATION OF CENTER JOINT (ZX70-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
2

Removal
1. Disconnect hoses (1) (7 used) and (7) (10 used)
from center joint (5). Cap the open ends. Attach
an identification tag onto disconnected hoses (1,
7) for assembling.
: 17 mm, 22 mm, 27 mm

3
4

2. Remove bolts (4) (2 used) from stopper (2). Remove stopper (2) from center joint (5).
: 19 mm
CAUTION: Center joint (5) weight: 32 kg (71
lb)

W1P1-03-03-001

3. Remove fittings (3) (2 used) from center joint (5).


Install an eyebolt to center joint (5). Attach a nylon sling onto the eyebolt. Hoist and hold center
joint (5).
4. Remove bolts (8) (3 used) from center joint (5).
Remove center joint (5) from track frame (6).
: 17 mm
7
5

W3-3-1

W1P1-03-03-002

UNDERCARRIAGE / Center Joint


Installation
CAUTION: Center joint (5) weight: 32 kg (71
lb)
1. Install an eyebolt to center joint (5). Attach a nylon sling onto the eyebolt. Hoist and align center
joint (5) with the mounting hole on track frame
(6).

2. Install fittings (3) (2 used) to center joint (5).


: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
3. Install center joint (5) to track frame (6) with bolts
(8) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

7
5

4. Connect hoses (7) (10 used) and (1) (7 used) to


center joint (5).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

3
4

5. Install stopper (2) to center joint (5) with bolts (4)


(2 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
IMPORTANT: After completing the work, start the
engine and check for any oil leaks.

W3-3-2

W1P1-03-03-002

W1P1-03-03-001

UNDERCARRIAGE / Center Joint


REMOVAL AND INSTALLATION OF CENTER JOINT (ZX75US-3)
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
Removal
1. Remove clip (5) from cover (3). Disconnect harness (4) from cover (3).

2. Remove sems bolts (2) (4 used) from cover (3).


Remove cover (3) from support (1) and frame (6).
: 17 mm
6

W1P1-02-06-003

3. Disconnect connectors (8) (3 used).


4. Disconnect hoses (7) (2 used) from swing device
(12). Cap the open ends.
: 27 mm
9

5. Disconnect hoses (9) (7 used) from center joint


(11). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 22 mm, 27 mm
6. Remove bolts (13) (2 used) from stopper (10).
Remove stopper (10) from center joint (11).
: 19 mm

W3-3-3

13

12

11

10

W1P1-03-03-003

UNDERCARRIAGE / Center Joint


CAUTION: Center joint (11) weight: 32 kg (71
lb)
7. Remove fittings (14) (2 used) from center joint
(11). Install and eyebolt to center joint (11). Attach
a nylon sling onto the eyebolt. Hoist and hold
center joint (11).

14

11

W1P1-03-03-003

15

8. Disconnect hoses (15) (10 used) from center joint


(11). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 22 mm, 27 mm
9. Remove bolts (17) (3 used) from center joint (11).
Remove center joint (11) from track frame (16).
: 17 mm

15
W1P1-03-03-002

17

W3-3-4

11

16

UNDERCARRIAGE / Center Joint


Installation
CAUTION: Center joint (11) weight: 32 kg (71
lb)

15

1. Install and eyebolt to center joint (11). Attach a


nylon sling onto the eyebolt. Hoist center joint
(11). Align center joint (11) with the mounting hole
on track frame (16).
2. Install fittings (14) (2 used) to center joint (11).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
3. Install center joint (11) to track frame (16) with
bolts (17) (3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

15
W1P1-03-03-002

17

11

16

4. Connect hoses (15) (10 used) and (9) (7 used) to


center joint (11).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (5 kgfm, 58 lbfft)
5. Install stopper (10) to center joint (11) with bolts
(13) (2 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
9
14

W3-3-5

13

11

10

W1P1-03-03-003

UNDERCARRIAGE / Center Joint


6. Connect hoses (7) (2 used) to swing device (12).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

7. Connect connectors (8) (3 used).


IMPORTANT: Start the engine and check for any
oil leaks.

W1P1-03-03-003

12

8. Install cover (3) to support (1) and frame (6) with


sems bolts (2) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

9. Secure harness (4) to cover (3) with clip band


(5).
6

W1P1-02-06-003

W3-3-6

UNDERCARRIAGE / Center Joint


(Blank)

W3-3-7

UNDERCARRIAGE / Center Joint


DISASSEMBLY OF CENTER JOINT

1
2

7
3

5
6
8

10
11
12

W196-03-03-001

1 - Plug
2 - Spindle
3 - Dust Seal

4 - O-Ring
5 - Bushing
6 - Oil Seal (8 Used)

7 - Body
8 - Ring
9 - O-Ring

W3-3-8

10 - Retaining Ring
11 - Cover
12 - Bolt (4 Used)

UNDERCARRIAGE / Center Joint


Disassembly of Center Joint
CAUTION: Center joint weight: 19 kg (42 lb)
1. Remove bolts (12) (2 used) diagonally. Install an
eyebolt (M10, Pitch 1.5 mm, Length 18 mm) to
the bolt (12) hole (2 places). Place the center
joint on a workbench.
: 17 mm
IMPORTANT: Put the matching marks on body (7)
and spindle (2).
2. Remove bolts (12) (2 used). Remove cover (11)
from body (7).
: 17 mm

IMPORTANT: Do not damage the seal sliding surface of spindle (2).


5. Remove spindle (2) from body (7).
IMPORTANT: For easy removal of oil seal (6), use
the pins (2 used). Do not damage
the seal groove by the pin.
6. Remove oil seals (6) (6 used), O-ring (4), and
dust seal (3) from body (7).

3. Remove O-ring (9), retaining ring (10), and ring


(8) from body (7).
4. Install the special tools (ST 1033, ST 1020) to
body (7) with bolts (12) (2 used).
: 17 mm
ST 1020
W105-03-03-015

ST 1033

IMPORTANT: While welding, cover the seal surface in order to prevent from welding spatter.
7. When replacing bushing (5), weld four places on
the bushing (5) bore by using a welding bar.
Shrink and remove bushing (5).

12

W506-03-03-002

W3-3-9

UNDERCARRIAGE / Center Joint


ASSEMBLY OF CENTER JOINT
1

3
4
5

8
10

9
11
12

W196-03-03-002

1 - Plug
2 - Spindle
3 - Dust Seal

4 - O-Ring
5 - Bushing
6 - Oil Seal (8 Used)

7 - Body
8 - Ring
9 - O-Ring

W3-3-10

10 - Retaining Ring
11 - Cover
12 - Bolt (4 Used)

UNDERCARRIAGE / Center Joint


Assembly of Center Joint
IMPORTANT: If bushing (5) has been removed, install bushing (5) first. (Refer to
W3-3-12.)

IMPORTANT: Install ring (8) with the chamfered


side facing to the spindle (2) side.
5. Install ring (8) and O-ring (9) to body (7).

1. Install O-ring (4) and dust seal (3) to body (7).

6. Install retaining ring (10) to spindle (2).

2. Install oil seals (6) (6 used) to body (7).

7. Install cover (11) with bolts (12) (4 used).


: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

IMPORTANT: Apply molybdenum disulfide onto


the bushing (5) part and grease onto
the seal part when inserting spindle
(2). Do not damage bushing (5).
3. Place spindle (2) on a workbench. Align the
matching marks made when disassembling and
install body (7) to spindle (2).
IMPORTANT: As the clearance between body (7)
and spindle (2) is approximately 0.1
mm (0.004 in), insert body (7) along
the axis straight and slowly.
4. Lightly tap body (7) by using a plastic hammer.
Insert body (7) until body (7) comes in contact
with the flange part of spindle (2).
2

0.1 mm
(0.004 in)

W105-03-03-024

W3-3-11

UNDERCARRIAGE / Center Joint


NOTE: When replacing body (7) with the new one,
the following procedures are required.

ST 2770

1. Clean body (7) and bushing (5).


2. Install bushing (5) to body (7) by using the special tool (ST 2770) and a press.
Pushing Force: 0.5 to 1.5 t (1100 to 3300 lb)

W105-03-03-029

W3-3-12

UNDERCARRIAGE / Center Joint


MAINTENANCE STANDARD
Item

Remedy

Allowable Limit (basis of judgment)


1. Wear more than 0.2 mm (0.008 in)

Replace

2. Seizure, abnormal wear

Replace

3. Uneven wear within 180

Replace

Wear Area within


Half Range

Bushing

T157-01-01-040

Heavily damaged one by seizure or foreign


Sliding surface with seals
matter
1) Excessively worn one by seizure or foreign
matter, or one having the score or 0.1 mm
Sliding surface between
(0.004 in) or more
body and spindle other
than sliding surfaces with 2) One having the score of less than 0.1 mm
seals
(0.004 in)
Body / Spindle

1) One that has worn 0.5 mm (0.02 in) or


more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or less
Sliding surface with ring

Cover

Sliding surface with ring

3) One that has scores due to seizure or foreign matter but the damage is less than the
allowable wear limit 0.5 mm (0.02 in) and is
repairable
1) One that has worn 0.5 mm (0.02 in) or more
2) One that has worn less than 0.5 mm (0.02
in)
3) One that has scores due to seizure or foreign matter but the damage is less than the
allowable wear limit 0.5 mm (0.02 in) and is
repairable

W3-3-13

Replace
Replace

Replace the surface smooth by


using an oil stone
Replace
Repair the surface
smooth
Repair the surface
smooth

Replace
Repair the surface
smooth
Repair the surface
smooth

UNDERCARRIAGE / Center Joint


(Blank)

W3-3-14

UNDERCARRIAGE / Track Adjuster


REMOVAL AND INSTALLATION
TRACK ADJUSTER

OF

Before removing and installing the track adjuster, the


track and the front idler should be removed first.
(Refer to REMOVAL AND INSTALLATION OF TRACK
on W3-7-1, REMOVAL AND INSTALLATION OF
FRONT IDLER on W3-5-1.)
Therefore, the procedure starts on the premise that
the track and the front idler have already been
removed here.
Removal
CAUTION: Track adjuster weight: 34 kg (75
lb)
2

CAUTION: Track adjuster (1) may fly out due


to the spring force when removing track
adjuster (1). Do not stand in the same
direction to remove track adjuster (1) or
where track adjuster (1) may fly out.
Particularly, the spring force is always
applied to the thread part of the rod. If the
rod and/or the threads are damaged, metal
fragments due to the spring force may fly
out.

W157-03-04-003

1. Pry and remove track adjuster (1) from track


frame (2) by using a pry bar.
Installation
IMPORTANT: Check that track adjuster (1) is
inserted into plate (4).
1. Install track adjuster (1) to spring guide (3) in
track frame (2) as illustrated.

2
3

View A

W157-03-04-001

W3-4-1

W157-03-04-002

UNDERCARRIAGE / Track Adjuster


DISASSEMBLY OF TRACK ADJUSTER
7
6
5

3
9

10
14

11
W1CC-03-04-001

12
13
1234-

Cylinder
Retaining Ring
U-Ring
Wear Ring

5678-

Piston Rod
Flange
Dust Seal
Holder

9 - Socket Bolt (4 Used)


10 - Spring
11 - Washer

W3-4-2

12 - Nut
13 - Valve
14 - Plug

UNDERCARRIAGE / Track Adjuster


Disassembly of Track Adjuster
IMPORTANT: Use the special tool (ST 4920) when
assembling and disassembling the
track adjuster.
CAUTION: As the spring force is too strong,
carry out the disassembly and assembly
work carefully. Inspect the special tool (ST
4920) for any damage thoroughly in order to
perform the work safely.
CAUTION: The special
weight: 225 kg (500 lb)

tool

(ST

CAUTION: Track adjuster weight: 34 kg (75


lb)
3. Remove holder (8) from the track adjuster.
Attach a wire rope onto the track adjuster. Hoist
the track adjuster. Place the track adjuster on the
holder of the special tool (ST 4920).

Track Adjuster

4920)

1. Place an oil jack (30 ton) between the holder and


the base of the special tool (ST 4920).
Holder
Nut

Holder

W105-03-04-009

Oil Jack

Base
W105-03-04-006

CAUTION: Plate (ST 4036) weight: 34 kg (75


lb)
2. Remove nuts (4 used) from the special tool (ST
4920). Attach a nylon sling onto the eyebolts (2
used) in the plate (ST 4036). Hoist and remove
the plate (ST 4036) from the special tool (ST
4920).
: 46 mm

ST 4036

W105-03-04-007

W3-4-3

UNDERCARRIAGE / Track Adjuster

14

11
W1CC-03-04-001

12
13

W3-4-4

UNDERCARRIAGE / Track Adjuster


CAUTION: Plate (ST 4036) weight: 34 kg (75
lb)
4. Install the plate (ST 4036) to the special tool (ST
4920) in order to cover the track adjuster.

6. Tighten the nut of the special tool (ST 4920) and


secure the track adjuster.
Operate the oil jack. Compress the track adjuster
until a clearance is observed between washer
(11) and nut (12). (Approximately 10 mm (0.4 in))
: 46 mm

ST 4036
Nut

Track Adjuster

W105-03-04-012

W105-03-04-011

5. Operate the oil jack. Raise the holder.


Holder

7. Remove plug (14) from nut (12). Remove nut


(12) and valve (13) from cylinder (1).
: 5 mm
: 60 mm
12

Oil Jack

1
14

W105-03-04-013

W105-03-04-014

W3-4-5

UNDERCARRIAGE / Track Adjuster

7
6
5

4
3
9

10

11
W1CC-03-04-001

W3-4-6

UNDERCARRIAGE / Track Adjuster


CAUTION: Plate (ST 4036) weight: 34 kg (75
lb)
Remove the nut and the plate (ST 4036) after
lowering the oil jack. Prevent washer (11)
and spring (10) from flying out by the
reaction force of spring (10).
8. Remove the nut and the plate (ST 4036) after
lowering the oil jack. Remove washer (11) from
cylinder (1).

10. Remove spring (10) from cylinder (1).


11. Remove socket bolts (9) (4 used) from flange (6).
Remove flange (6) and dust seal (7) from cylinder
(1).
: 6 mm
12. Remove piston rod (5) from cylinder (1).
13. Remove retaining ring (2), U-ring (3), and wear
ring (4) from piston rod (5).

ST 4036

11
10

W105-03-04-016

CAUTION: The spring (10) assembly weight:


28 kg (62 lb)
9. Remove the spring (10) assembly from the
special tool (ST 4920).

10

W105-03-04-017

W3-4-7

UNDERCARRIAGE / Track Adjuster


ASSEMBLY OF TRACK ADJUSTER
Steel Crawler
13

14

12

11

10

W152-03-04-002

267 mm (10.5 in) (Free Length 316.9 mm (12.5 in))


412 mm (16.2 in)

Rubber Crawler
13

14

12

11

10

446 mm (16.2 in)

Cylinder
Retaining Ring
U-Ring
Wear Ring

5678-

Piston Rod
Flange
Dust Seal
Holder

9 - Socket Bolt (4 Used)


10 - Spring
11 - Washer

W3-4-8

WBAT-06-01-043

242 mm (9.5 in) (Free Length 316.9 mm (12.5 in))

1234-

12 - Nut
13 - Valve
14 - Plug

UNDERCARRIAGE / Track Adjuster


Assembly of Track Adjuster
IMPORTANT: Install U-ring (3) with its lip part
facing to the retaining ring (2) side.
Apply hydraulic oil onto wear ring
(4) and U-ring (3).
1. Install wear ring (4), U-ring (3), and retaining ring
(2) to piston rod (5).

CAUTION: The spring (10) assembly weight:


28 kg (62 lb)
4. Install spring (10) to cylinder (1). Install an
eyebolt (M16, Pitch 1.5 mm) to cylinder (1). Hoist
and place the spring (10) assembly on the
special tool (ST 4920).

IMPORTANT: Fill grease in chamber B of cylinder


(1). Push piston rod (5) into cylinder
(1) and completely bleed air from
cylinder (1). Apply hydraulic oil onto
cylinder (1) and piston rod (5).
2. Install the piston rod (5) assembly to cylinder (1).
IMPORTANT: Fill grease in chamber A of flange
(6).
3. Install dust seal (7) to flange (6). Install the flange
(6) assembly to cylinder (1) with socket bolts (9)
(4 used)
: 6 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

W3-4-9

10
ST 4920

W105-03-04-017

UNDERCARRIAGE / Track Adjuster

13

14

12

11

10

W152-03-04-002

W3-4-10

UNDERCARRIAGE / Track Adjuster


CAUTION: Plate (ST 4036) weight: 34 kg (75
lb)
5. Install washer (11) to cylinder (1). Install the plate
(ST 4036) to spring (10).
: 46 mm

7. Install nut (12) and valve (13) to cylinder (1).


Install plug (14) to nut (12).
: 60 mm
: 5 mm
: 14.5 Nm (1.5 kgfm, 11 lbfft)
12

14

ST 4036

W105-03-04-014

W105-03-04-012

6. Operate the oil jack. Compress spring (10) to the


specified length.
Specified length:
Steel crawler: 267 mm (10.5 in)
Rubber crawler:
ZX70-3: 252 (9.9 in)
ZX75US-3: 242 mm (9.5 in)

CAUTION: Plate (ST 4036) weight: 34 kg (75


lb)
8. Loosen the oil jack. Remove the nut. Remove the
plate (ST 4036).
: 46 mm
ST 4036

Oil Jack

W105-03-04-011
W105-03-04-026

W3-4-11

UNDERCARRIAGE / Track Adjuster


CAUTION: Track adjuster weight: 31 kg (70
lb)
9. Attach a wire rope onto the track adjuster.
Remove the track adjuster from the special tool
(ST 4920).

Track Adjuster

Holder

W105-03-04-009

CAUTION: The special


weight: 64 kg (141 lb)

tool

(ST

4930)

IMPORTANT: If only the track adjusted is


transported, use the special tool (ST
4930) in order to transport the track
adjuster safely.
: 24 mm
Track Adjuster

W105-03-04-028

ST 4930

W3-4-12

UNDERCARRIAGE / Front Idler


REMOVAL AND INSTALLATION OF FRONT
IDLER
Removal
Before removing the front idler, the tracks should be
removed first. (Refer to REMOVAL AND INSTALLATION OF TRACK on W3-7-1.)
Therefore, the procedure starts on the premise that
the tracks have already been removed here.

CAUTION: Front idler (1) may fly out due to


the spring force when removing front idler (1).
Do not stand in the same direction to remove
front idler (1) or where front idler (1) may fly
out.

W110-03-05-001

1. Remove front idler (1) with yoke (2) together from


track frame (3) by using a pry bar.

CAUTION: Front idler (1) weight: 52 kg (115


lb)

1
2
W178-03-05-001

2. Attach a sling belt onto the bearing part and the


yoke (2) part of front idler (1) as illustrated. Hoist
and remove front idler (1) from track frame (3).
3. When keeping front idler (1) temporarily, place
front idler (1) on the wooden blocks as illustrated.

Wooden
Block

W178-03-05-002

W3-5-1

UNDERCARRIAGE / Front Idler


Installation
CAUTION: Front idler (1) weight: 52 kg (115
lb)

(b)

1. Install the front idler (1) in the reverse way of removal. Check the followings.
Clean sliding surface (a) of yoke (2) and sliding
surface (b) of track frame (3). Apply grease.

(a)

3
W178-03-05-004

W3-5-2

UNDERCARRIAGE / Front Idler


(Blank)

W3-5-3

UNDERCARRIAGE / Front Idler


DISASSEMBLY OF FRONT IDLER
3
2
4
7

1
7
6
5
3

1
10
9
W1CC-03-05-001

1 - Plug (2 Used)
2 - Bearing (2 Used)
3 - Pin (2 Used)

4 - Floating Seal (2 Used)


5 - O-Ring (2 Used)
6 - Axle

7 - Bushing (2 Used)
8 - Idler

W3-5-4

9 - Socket Bolt (4 Used)


10 - Yoke

UNDERCARRIAGE / Front Idler


Disassembly of Front Idler
CAUTION: The front idle assembly weight:
42 kg (93 lb)

5. Remove pin (3) from bearing (2) at another side.


Remove axle (6) from bearing (2) by using a
press.

1. Remove socket bolts (9) (4 used) from yoke (10).


Remove yoke (10) from bearings (2) (2 used).
Remove plugs (1) (2 used) from bearings (2) (2
used). Drain engine oil from bearings (2) (2 used).
: 6 mm, 12 mm

2. Remove pin (3) from bearing (2) at one side.


3. Remove axle (6) from bearing (2) by using a
press.
6
2

W105-03-05-010

6. Remove O-rings (5) (2 used) from axle (6).


W105-03-05-008

CAUTION: Idler (8) weight: 29 kg (64 lb)


4. Remove floating seals (4) (2 used) from idler (8)
and bearings (2) (2 used).

IMPORTANT: Do not remove bushings (7) (2 used)


unless necessary.
7. Weld four places, 90 apart from each other on
the bushing (7) (2 used) bore. Shrink and remove
bushings (7) (2 used) from idler (8).
90

90

2
4

W105-03-05-012

4
5
6

W105-03-05-009

W3-5-5

UNDERCARRIAGE / Front Idler


ASSEMBLY OF FRONT IDLER

10

W152-03-05-001

1 - Plug (2 Used)
2 - Bearing (2 Used)
3 - Pin (2 Used)

4 - Floating Seal (2 Used)


5 - O-Ring (2 Used)
6 - Axle

7 - Bushing (2 Used)
8 - Idler

W3-5-6

9 - Socket Bolt (4 Used)


10 - Yoke

UNDERCARRIAGE / Front Idler


Assembly of Front Idler
CAUTION: Idler (8) weight: 29 kg (64 lb)
1. Install bushings (7) (2 used) to idler (8) by using a
press.

4. Install other floating seal (4) to idler (8) and bearing (2).
Install O-ring (5) to axle (6). Align the pin holes
and install bearing (2) to axle (6). Secure bearing
(2) to axle (6) with pin (3).

IMPORTANT: When installing bearing (2) to axle


(6), do not damage O-ring (5).
2. Install O-ring (5) to axle (6). Align the pin holes
and install bearing (2) to axle (6). Secure bearing
(2) to axle (6) with pin (3).

W157-03-05-005

W105-03-05-014

3. Install floating seal (4) to idler (8) and bearing (2).


Install axle (6) to idler (8) through the side where
floating seal (4) has been installed by using a
press.
8

5. Add engine oil (140 cm3, SAE #30, API CD class)


through the plug (1) hole on bearings (2) (2 used).
Install plugs (1) (2 used) to bearings (2) (2 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)
6. Install yoke (10) to bearing (2) with socket bolts
(9) (4 used).
: 12 mm
: 175 Nm (18 kgfm, 129 lbfft)

6
W157-03-05-006

W3-5-7

UNDERCARRIAGE / Front Idler


MAINTENANCE STANDARD

C D

E
A
B

W157-03-05-001

Unit: mm (in)
Standard

Allowable Limit

43 (1.7)

[33.4 (1.3)]

100 (3.9)

390 (15.4)

378 (14.9)

434 (17.1)

22 (0.9)

28.0 (1.1)

Remedy

Cladding by
welding and hand
finishing

Axle and Bushing

Axle

Unit: mm (in)
Standard

Allowable Limit

Outer Dia.

55 (2.2)

[54.2 (2.1)]

Inner Dia.

55 (2.2)

[56.0 (2.2)]

Flange Thickness

2 (0.08)

[1.2 (0.05)]

Bushing
NOTE: The value in [ ] is just for reference.

W3-5-8

Remedy

Replace

UNDERCARRIAGE / Upper And Lower Roller


REMOVAL AND INSTALLATION OF UPPER ROLLER
Removal
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the high-pressure grease may spout out, do
not loosen valve (1) quickly and/or excessively.
Keep body parts and face away from valve
(1) and loosen valve (1) carefully. Do not
loosen grease fitting (2).
IMPORTANT: Loosening valve (1) 1 to 1.5 turns is
enough. Do not loosen valve (1)
over those turns.
IMPORTANT: When gravel or mud is packed between sprockets and track links,
remove them before loosening.
1. Loosen valve (1) in the track adjuster and drain
grease.
: 24 mm

W105-03-06-001

Grease Outlet
W8HY-04-03-001

Hydraulic Jack

CAUTION: Use a nonskid cloth between


track frame (5) and the hydraulic jack in order not to slip.

Wooden Block

3
4

Nonskid
Cloth

2. Raise track (3) until enough clearance is observed between upper roller (4) and track (3) by
using a hydraulic jack.
Insert the wooden blocks between track (3) and
track frame (5).

5
W105-03-06-003

3. Remove bolt (6) from track frame (5). Remove


upper roller (4) from track frame (5).
: 22 mm
6

W3-6-1

M152-07-046

UNDERCARRIAGE / Upper And Lower Roller


Installation
IMPORTANT: I-shaped
mark
(punching)
is
stamped on the axle end of upper
roller (4). Install upper roller (4)
track frame (5) with I-shaped mark
facing upward.

Up ward

1. Install upper roller (4) onto track (5) with bolt (6).
: 22 mm
: 140 Nm (14 kgfm, 103 Ibfft)

M152-07-046

Hydraulic Jack

Wooden Block

3
4

2. Remove the wooden block and the hydraulic


jack.

5
W105-03-06-003

3. Tighten valve (1) of the track adjuster.


: 24 mm
: 88 Nm (9 kgfm, 65 Ibfft)
4. Raise track (3) to be adjusted. Rotate track (3) in
the reverse direction a little. Apply grease
through grease fitting (2) and adjust the track (3)
tension.

Grease Outlet
W8HY-04-03-001

Track sag specifications (A): 210 to 235 mm


(8.3 to 9.3 in)

W1R7-03-07-005

W3-6-2

UNDERCARRIAGE / Upper And Lower Roller


4. Apply LOCTITE # 503 onto plug (8). Add engine
oil (API CD class, SAE 30) through the plug (8)
hole on cover (7).
Engine oil amount: 35 mL

5. Install plug (8) to cover (7).


: 5 mm
: 15 Nm (1.5 kgfm, 11 lbfft)
NOTE: The upper roller (4) cannot be disassembled. Replace it as an assembly.

W158-03-06-001

W3-6-3

UNDERCARRIAGE / Upper And Lower Roller


REMOVAL AND
LOWER ROLLER

INSTALLATION

OF

Removal

90 to 110

CAUTION: Securely support the raised machine by using wooden blocks.


1. Loosen bolts (1) (4 used) of lower roller (2).
Raise the track by using the front attachment.
: 22 mm

M1CC-07-014

2
3

M102-07-063

CAUTION: The pressure inside the adjuster


cylinder is high. As valve (4) may fly out and
the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or excessively.
Keep body parts and face away from valve
(4) and loosen valve (4) carefully. Do not
loosen grease fitting (5).
IMPORTANT: Loosening valve (4) 1 to 1.5 turns is
enough. Do not loosen valve (4)
over those turns.
IMPORTANT: When gravel or mud is packed between sprockets and track links,
remove them before loosening.
2. Loosen valve (4) of the track adjuster. Drain
grease until the clearance is enough to remove
lower roller (2).
: 24 mm

W105-03-06-001

3. Remove bolts (3) (4 used) from lower roller (2)


Remove lower roller (2) from track frame (1).
: 22 mm
W8HY-04-03-001

W3-6-4

UNDERCARRIAGE / Upper And Lower Roller


Installation
1. Align lower roller (2) with the mounting position to
the track frame and set lower roller (2) to the
track.
Lower the machine so that track frame (1) may
keep a little away from lower roller (2).

W105-03-06-012

2. Install lower roller (2) to track frame (1) with bolts


(3) (4 used).
: 22 mm
: 245 Nm (25 kgfm, 180 Ibfft)

2
3

M102-07-063

3. Tighten valve (4) of the track adjuster.


: 24 mm
: 147 Nm (15 kgfm, 108 lbf fft)

4. Raise and rotate the track to be adjusted in the


reverse direction a little. Apply grease through
grease fitting (5) and decreases track tension.
Track sag specifications (A): 210 to 235 mm
(8.3 to 9.3 in)

W8HY-04-03-001

W1R7-03-07-005

W3-6-5

UNDERCARRIAGE / Upper And Lower Roller


DISASSEMBLY AND
LOWER ROLLER

ASSEMBLY

OF

W1CD-03-06-001

1 - Collar
2 - Floating Seal (2 Used)
3 - Roller

4 - Axle
5 - Bushing (2 Used)

6 - O-Ring
7 - Pin

W3-6-6

8 - Collar
9 - Plug

UNDERCARRIAGE / Upper And Lower Roller


Disassembly of Lower Roller

Assembly of Lower Roller

1. Remove plug (9) from collar (8). Drain engine oil


from roller (3).
: 5 mm

1. Apply grease onto O-ring (6). Install O-ring (6) to


axle (4).

2. Remove pin (7) from collar (8). Remove axle (4)


from the collar (8) side in roller (3) by using a
press. At this time, collar (1) at the opposite side
is removed with axle (4) together.
NOTE: Axle (4) and collar (1) cannot be disassembled.
3. Remove floating seals (2) (2 used) from both
sides of roller (3) and collars (1, 8).
4. Remove O-ring (6) from axle (4).
IMPORTANT: Do not remove bushing (5) from
roller (3). In case the bushing
should be replaced, replace the
roller (3) assembly.

2. Install floating seals (2) (2 used) to collars (1, 8)


and both sides of roller (3). Install axle (4) with
collar (1) attached to roller (3) by using a press.
3. Align the pin holes and install collar (8) to axle (4).
Install pin (7) to collar (8).
4. Apply LOCTITE #503 onto plug (9). Add engine
oil (SAE #30, API CD class) through the plug (9)
hole on collar (8).
Engine oil amount: 120 mL
5. Install plug (9) to collar (8).
: 5 mm
: 14.51.5 Nm
(1.50.15 kgfm, 10.51.1 lbfft)

W3-6-7

UNDERCARRIAGE / Upper And Lower Roller


MAINTENANCE STANDARD
Upper Roller

W110-03-06-009

Standard

Allowable Limit

43 (1.7)

90 (3.5)

86 (3.4)

76 (3.0)

W3-6-8

Unit: mm (in)
Remedy
Replace

UNDERCARRIAGE / Upper And Lower Roller


Lower Roller

A
B
W102-03-06-006

Standard

Allowable Limit

45 (1.8)

143 (5.6)

110 (4.3)

92 (3.6)

Unit: mm (in)
Remedy
Cladding by welding and
hand finishing or replace

Axle and Bushing

Axle
Bushing

NOTE: The value in [

Standard

Allowable Limit

Outer Dia.

40 (1.6)

[39.2 (1.5)]

Inner Dia.

40 (1.6)

[41.0 (1.6)]

Flange
Thickness

2 (0.08)

[1.2 (0.05)]

] is just for reference.

W3-6-9

Unit: mm (in)
Remedy

Replace

UNDERCARRIAGE / Upper And Lower Roller


(Blank)

W3-6-10

UNDERCARRIAGE / Track
REMOVAL
TRACK

AND

INSTALLATION

OF
1
2

Removal
1. Rotate the tracks so that master pin (3) is
positioned over front idler (2). Place a wooden
block under shoe (1) and support shoe (1).
3

CAUTION: The pressure inside the adjuster


cylinder is high. As valve (4) may fly out and
the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or
excessively.
Keep body parts and face away from valve
(4) and loosen valve (4) carefully. Do not
loosen grease fitting (5).

Wooden
Block

W105-03-07-006

IMPORTANT: Loosening valve (4) 1 to 1.5 turns is


enough. Do not loosen valve (4)
over those turns.
IMPORTANT: When gravel or mud is packed
between sprockets and track links,
remove them before loosening.
2. Loosen the track tension.
: 24 mm

W105-03-07-002

5
Grease Outlet
W1V7-03-04-006

W3-7-1

UNDERCARRIAGE / Track
3. Remove snap ring (6) from master pin (3).
NOTE: If snap ring (6) cannot be removed, push
master pin (3) to the removing direction in
order to make clearance between snap
ring (6) and master pin (3).

7
3

CAUTION: The front idler may fly out due to


the spring force when removing the track.
Particularly, strong force is always applied to
the thread part of the rod. If the rod and/or
the threads are damaged, metal fragments
due to the spring force may fly out.

W105-03-07-009

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary
protection, such as goggles and hard hats.
IMPORTANT: Master pin (3) can be removed to
only one direction. Check the
removing direction.
4. Remove master pin (3) by using the special tool
(ST 1970) and a hammer.

Corner Part
Direction to
Install

Direction to
Remove

Snap Ring
Track Link

3
Master Link
W105-03-07-010

ST 1970

W1V1-03-07-001

W3-7-2

UNDERCARRIAGE / Track
5. Operate the boom and the arm so that the angle
between them is 90 to 110. Lower the boom with
the round bottom contacting with the ground.
Raise the track frame and pull out the track. At
this time, place a stand under the track frame and
support the machine.
CAUTION: The track assembly weight:
ZX70-3, 75US-3: 820 kg (1810 lb)
ZX70LC-3: 860 kg (1900 lb)

90 to 110

Stand

M104-07-067

6. Slowly operate the travel lever on the side with


the track to be removed to the reverse position
and extend the track.

W105-03-07-011

W3-7-3

UNDERCARRIAGE / Track
Installation
1. Raise the machine. Set the track under the
machine so that sprocket (8) meshes with the
track end. Check the direction of the track at this
time.

Sprocket (8)
Side

Front Idler
(2) Side

CAUTION: The track assembly weight:


ZX70-3, 75US-3: 820 kg (1810 lb)
ZX70LC-3: 860 kg (1900 lb)
W105-03-07-013

2. Hoist and mesh sprocket (8) with the claws of the


track.

W105-03-07-014

3. With the machine raised, slowly operate the lever


for the track to be installed in the forward
direction. Turn travel device (9) and wind the
track.

W105-03-07-015

4. Wind the track link until the connection part of the


track link reaches the front idler (2) side. Lower
the machine. Place a wooden block under shoe
(1) and support shoe (1).

1
W105-03-07-016

Wooden
Block

W3-7-4

UNDERCARRIAGE / Track
IMPORTANT: Master pin (3) can be installed to
only one direction. Check the
installing direction.
5. Install the special tool (ST 1970). Install master
pin (3) to the track.

Corner Part
Direction
to Install

Direction to
Remove

Snap Ring
Track Link

Master Link

ST 1970

W105-03-07-010

W1V1-03-07-001

IMPORTANT: As snap ring (6) is easy to deform,


replace snap ring (6) with a new one
rather than reuse.
6. Install snap ring (6).
Snap ring (6) has the direction to install. Install
snap ring (6) to the groove of master link (7) with
the flat surface of a pair of pliers hole facing
forward.

IMPORTANT: If disassembling the link, fill grease


(Daphne Epones SR) into the
clearance between the pin and the
bushing. Apply grease onto the
bushing end.
Stand the bushing on a flat plate. Fill
the bushing bore with grease. Insert
the pin into the bushing while
holding the bushing in order not to
move due to grease. Wipe off
excess grease.
Check the direction to install the
seal.

Bushing

W105-03-07-009

Seal
Pin

Do not apply
grease.

Apply
grease.

Do not apply
grease.

W197-03-07-001

Seal

W3-7-5

UNDERCARRIAGE / Track
7. Tighten adjuster valve (4). Apply grease through
grease fitting (5). Adjust the track tension.
: 24 mm
: 88 Nm (9 kgfm, 65 lbfft)
NOTE: Track sag specification (A): 250 to 280 mm
(9.8 to 11 in)

5
W1V7-03-04-006

W1R7-03-07-005

W3-7-6

UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link
Measure the length of four links.
Do not include the master pin.
Measure the length with tension on the track.

A
W155-03-07-001

Unit: mm (in)
Standard
A
B

617 (24.3)
74 (2.9)

Allowable
Limit
634.1 (25)
69 (2.7)

W3-7-7

Remedy
Cladding by welding and hand
finishing, or replace

UNDERCARRIAGE / Track
Master Bushing

W105-03-07-023

Unit: mm (in)

A
B
C

Standard

Allowable Limit

Remedy

74.7 (2.9)
24.5 (1)
41.26 (1.6)

[27.5 (1.1)]
[37.76 (1.5)]

Replace

Master Pin

W105-03-07-021

Unit: mm (in)

A
B
NOTE: The value in [

Standard

Allowable Limit

Remedy

123.5 (4.9)
24.2 (1)

[21.2 (0.8)]

Replace

] is just for reference.

W3-7-8

UNDERCARRIAGE / Track
Pin

A
W142-03-07-004

A
B

Standard
131 (5.2)
24 (0.9)

Allowable Limit
[21 (0.8)]

Unit: mm (in)
Remedy
Replace

Bushing

W105-03-07-023

A
B
C
NOTE: The value in [

Standard
81 (3.2)
24.5 (1)
41.26 (1.6)

Allowable Limit
[25.5 (1)]
[37.76 (1.5)]

] is just for reference.

W3-7-9

Unit: mm (in)
Remedy
Replace

UNDERCARRIAGE / Track
Grouser Shoe

W105-03-07-024

Unit: mm (in)
Shoe Size
A
B
C

Standard
165 (6.5)
6 (0.2)
20 (0.8)

500 mm Grouser
Allowable Limit
14 (0.6)

W3-7-10

Remedy
Cladding by
welding

MEMO
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SECTION 4

FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Hydraulic Circuit Pressure
Release Procedure ............................... W4-1-1
Removal and Installation of
Front Attachment (ZX70-3) .................... W4-1-2
Removal and Installation of
Front Attachment (ZX75US-3) ............... W4-1-9
Maintenance Standard .......................... W4-1-16
Standard Dimensions for
Arm and Bucket Connection................ W4-1-19

Group 2 Cylinder
Hydraulic Circuit Pressure
Release Procedure ............................... W4-2-1
Removal and Installation of Cylinder ....... W4-2-2
Disassembly of Cylinder........................ W4-2-16
Assembly of Cylinder ............................ W4-2-30
Maintenance Standard .......................... W4-2-42

1P1W-4-1

(Blank)

1P1W-4-2

FRONT ATTACHMENT / Front Attachment


HYDRAULIC
CIRCUIT
RELEASE PROCEDURE

PRESSURE

NOTE: This operates the pilot pump by using the


power of the battery without starting the
engine and delivers the pilot pressure to
the control valve spool.
1. Push the pilot control shut-off lever forward
(OFF).
2. Pull and secure the engine stop knob.
IMPORTANT: The battery will deplete. Operate the
key switch for short period.
3. Turn the key switch to the START position.
Operate the control lever 4 to 5 times in order to
release pressure from the circuit.
IMPORTANT: Push the engine stop knob
completely.
4. Return the engine stop knob to the original
position.

W4-1-1

FRONT ATTACHMENT / Front Attachment


REMOVAL AND INSTALLATION
FRONT ATTACHMENT (ZX70-3)

OF

Removal
1

1. Remove nuts (5) (2 used) from bolt (6). Remove


bolt (6) from boom (2).
: 24mm

W1CD-04-01-001

CAUTION: Boom cylinder (4) weight: 90 kg


(200 Ib)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
2. Hoist and hold the boom cylinder (4) tube end. By
using a bar and a hammer, tap pin (1) into the
position where thrust plate (3) behind can be
removed. Remove thrust plate (3) from boom (2).
NOTE: When pin (1) cannot be removed, start the
engine and operate the boom lever. Adjust
the rod end pin hole on boom cylinder (4).

4
W102-04-01-011

5, 6

W152-04-01-001

IMPORTANT: A grease fitting is located at the


boom cylinder (4) rod part. Place
boom cylinder on a stand so that the
grease fitting does not come in
contact with the stand.
3. In order not to extend the rod, pass a wire
through the rod hole and secure the rod to the
cylinder tube. Hoist and place boom cylinder (4)
on a stand.

Wire

W554-02-03-007

W4-1-2

FRONT ATTACHMENT / Front Attachment


CAUTION: Front attachment weight: 1050 kg
(2320 lb)

4. Attach a wire onto boom (2). Hoist and hold


boom (2).

W102-04-01-007

5. Disconnect hoses (8) (6 used) from pipes (7) (6


used). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 27 mm, 36 mm
NOTE: The number of hoses is different according
to specification of the front attachment.

7
8

W1P1-04-01-002

W1P1-04-01-004

6. Disconnect plug (9).


9

W1P1-04-01-003

W4-1-3

FRONT ATTACHMENT / Front Attachment


7. Remove sems bolts (11) (4 used). Remove cover
(10) from fuel tank (12).
: 17 mm

10

11

12

CAUTION: Front attachment weight: 1050 kg


(2320 lb)
8. Remove bolts (15) (2 used) and washers (16) (2
used) from plate (18). Remove plate (18) from
frame (17). Remove boom foot pin (13) from
frame (17).

W1P1-04-01-001

13

14

9. Hoist and remove the front attachment from


frame (17). Remove thrust plates (14) (2 used)
from both right and left sides of the boom (2)
boom foot part.

15, 16

18

W4-1-4

17

W1P1-04-01-002

FRONT ATTACHMENT / Front Attachment


Installation
2

CAUTION: Front attachment weight: 1050 kg


(2320 lb)
1. Hoist the front attachment. Align the boom (2)
boom foot part with the mounting hole of frame
(17). Install thrust plates (14) (2 used) to the right
and left sides of the boom (2) boom foot part.
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.

W102-04-01-007

13

2. Install boom foot pin (13) to frame (17) by using a


bar and a hammer. Secure boom foot pin (13) to
frame (17) with plate (18), bolts (15) (2 used) and
washers (16) (2 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

14

15, 16

3. Install cover (10) to fuel tank (12) with sems bolts


(11) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

W1P1-04-01-002

17

18

10

11

12

W1P1-04-01-001

4. Connect plug (9).

W1P1-04-01-003

W4-1-5

FRONT ATTACHMENT / Front Attachment


7

5. Connect hoses (8) (6 used) to pipes (7) (6 used).


: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 130 lbfft)

W1P1-04-01-004

8
7
8

W1P1-04-01-002

W4-1-6

FRONT ATTACHMENT / Front Attachment


CAUTION: Boom cylinder (4) weight: 90 kg
(200 lb)
2

6. Hoist boom cylinder (4). Start the engine. Extend


the boom cylinder (4) rod part. Align the pin holes
of boom (2) and boom cylinder (4).

4
W102-04-01-011

7. Install thrust plate (3) to both right and left sides


of the boom cylinder rod part. Adjust the
clearances on both sides within 1.5 mm (0.06 in).

2
5, 6

W152-04-01-001

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
8. Secure the boom cylinder (4) rod part to boom (2)
with pin (1).

1
6

9. Secure pin (1) to boom (2) with bolt (6) and nuts
(5) (2 used).
: 24mm
: 210 Nm (21 kgfm, 155 lbfft)
IMPORTANT: After completing the work, add
hydraulic oil to the specified level.
Operate each cylinder to the stroke
end several times and bleed air from
the circuit. Check for any oil leaks of
the hose connections.

W4-1-7

2
5

W1CD-04-01-001

FRONT ATTACHMENT / Front Attachment


(Blank)

W4-1-8

FRONT ATTACHMENT / Front Attachment


REMOVAL AND INSTALLATION
FRONT ATTACHMENT (ZX75US-3)

OF

Removal
1

1. Remove nuts (5) (2 used) from bolt (6). Remove


bolt (6) from boom (2).
: 24mm

W1CD-04-01-001

CAUTION: Boom cylinder (4) weight: 92 kg


(210 Ib)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
2. Hoist and hold the boom cylinder (4) tube end. By
using a bar and a hammer, tap pin (1) into the
position where thrust plate (3) behind can be
removed. Remove thrust plate (3) from boom (2).

4
W102-04-01-011

NOTE: When pin (1) cannot be removed, start the


engine and operate the boom lever. Adjust
the rod end pin hole on boom cylinder (4).

5, 6

W152-04-01-001

IMPORTANT: A grease fitting is located at the


boom cylinder (4) rod part. Place
boom cylinder on a stand so that the
grease fitting does not come in
contact with the stand.
3. In order not to extend the rod, pass a wire
through the rod hole and secure the rod to the
cylinder tube. Hoist and place boom cylinder (4)
on a stand.

Wire

W554-02-03-007

W4-1-9

FRONT ATTACHMENT / Front Attachment


4. Remove clip band (9) from cover (10). Raise
harness (7). Disconnect plug (8).

7, 8

10

W1P1-02-06-003

CAUTION: Front attachment weight: 1050 kg


(2320 lb)
2

5. Attach a wire onto boom (2). Hoist and hold


boom (2).

W102-04-01-007

6. Open cover (11).

11

W1P1-02-05-008

7. Disconnect hoses (13) (4 used) from pipes (12)


(4 used). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 27 mm
NOTE: The number of hoses is different according
to specification of the front attachment.

12

13

W1P1-04-01-005

W4-1-10

FRONT ATTACHMENT / Front Attachment


8. Remove sems bolts (18) (6 used). Remove cover
(17) from hydraulic oil tank (16) and bracket (14).
: 17 mm

14

15

16

17
18

9. Remove sems bolts (15) (4 used). Remove cover


(14) from brackets (14, 19).
: 17 mm
20

10. Remove sems bolts (22) (4 used). Remove the


bracket (21) (2 used) assembly from cover (23).
: 17 mm

14

W1P1-02-05-010

21

22

11. Remove sems bolts (24) (5 used) from cover


(25).
: 17 mm

23
19

12. Remove cover (23) from brackets (14, 19).

25

24

W1P1-02-05-010

26

13. Remove socket bolts (27) (2 used) from pipe (26).


Disconnect pipe (26) from control valve (28). Cap
the open ends.
: 8 mm

14. Remove coupling (29) from hydraulic oil tank (16)


and pipe (26). Remove pipe (26) from hydraulic
oil tank (16).
: 13 mm

27
28

16

29

WBAT-06-01-066

26

WBAT-06-01-068

W4-1-11

FRONT ATTACHMENT / Front Attachment


15. Remove bolts (30) (2 used) and washers (31) (2
used) from plate (33). Remove plate (33) from
frame (34).
: 24 mm

30, 31

32

33

34, 35

16. Remove boom foot pin (32) from frame (34) by


using a pry bar.

CAUTION: Front attachment weight: 1050 kg


(2320 lb)
17. Hoist and remove the front attachment from
frame (34). Remove thrust plates (35) (2 used)
from both sides of the boom (2) boom foot part.

W191-04-01-004

W102-04-01-007

W4-1-12

FRONT ATTACHMENT / Front Attachment


Installation
2

CAUTION: Front attachment weight: 1050 kg


(2320 lb)
1. Hoist the front attachment. Align the boom (2)
boom foot part with the mounting hole of swing
post (14). Install thrust plates (35) (2 used) to the
right and left sides of the boom (2) boom foot
part.

W102-04-01-007

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.

30, 31

32

2. Install boom foot pin (32) to frame (34) by using a


bar and a hammer. Secure boom foot pin (32) to
frame (34) with washers (31) (2 used) and bolts
(30) (2 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

33

34, 35

W191-04-01-004

26

3. Connect pipe (26) to control valve (28) with


socket bolts (27) (2 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

4. Connect pipe (26) to hydraulic oil tank (16) with


cupling (29).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

27
28

16

29

WBAT-06-01-066

26

WBAT-06-01-068

W4-1-13

FRONT ATTACHMENT / Front Attachment


5. Align cover (23) with the mounting holes of
brackets (14, 19). Install covers (23, 25) to
bracket (19) with sems bolts (24) (5 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

14

21

22
23

6. Install the bracket (21) (2 used) assembly to


cover (23) with bolts (22) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

19
25

7. Install cover (17) to hydraulic oil tank (16) and


bracket (14) with sems bolts (18) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

14

24

15

W1P1-02-05-010

16

17
18

8. Install cover (20) to brackets (14, 19) with sems


bolts (15) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

19

20

W1P1-02-05-010

9. Connect hoses (13) (4 used) to pipes (12) (4


used).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

12

13

W1P1-04-01-005

10. Connect plug (8) to harness (7). Secure harness


(7) to cover (10) with clip band (9).

7, 8

10

W1P1-02-06-003

W4-1-14

FRONT ATTACHMENT / Front Attachment


CAUTION: Boom cylinder (4) weight: 92 kg
(210 lb)

11. Hoist boom cylinder (4). Start the engine. Extend


the boom cylinder (4) rod part. Align the pin holes
of boom (2) and boom cylinder (4).

4
W102-04-01-011

12. Install thrust plate (3) to both right and left sides
of the boom cylinder rod part. Adjust the
clearances on both sides within 1.5 mm (0.06 in).

4
2
5, 6

W152-04-01-001

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
13. Secure the boom cylinder (4) rod part to boom (2)
with pin (1).

1
6

14. Secure pin (1) to boom (2) with bolt (6) and nuts
(5) (2 used).
: 24mm
: 210 Nm (21 kgfm, 155 lbfft)
IMPORTANT: After completing the work, add
hydraulic oil to the specified level.
Operate each cylinder to the stroke
end several times and bleed air from
the circuit. Check for any oil leaks of
the hose connections.

2
5

W1CD-04-01-001

11

15. Shut cover (11).

W1P1-02-05-008

W4-1-15

FRONT ATTACHMENT / Front Attachment


MAINTENANCE STANDARD
Front Attachment
Pin and Bushing

E
F

B
I
M

N
M1CD-01-010

Unit: mm (in)
Part Name
A
B

C
D
E
F

Pin (boom foot)


Bushing
Pin (boom cylinder foot)
Boss (main frame)
Bushing (boom cylinder)
Pin (boom cylinder piston)
Boss (boom)
Bushing (boom cylinder)
Pin (boom end)
Bushing (arm)
Pin (arm cylinder piston)
Boss (arm)
Bushing (arm cylinder)
Pin (arm cylinder foot)
Bushing (arm cylinder)

Standard

Allowable Limit

Remedy

60 (2.4)
60 (2.4)
55 (2.2)
55 (2.2)
55 (2.2)
55 (2.2)
55 (2.2)
55 (2.2)
60 (2.4)
60 (2.4)
55 (2.2)
55 (2.2)
55 (2.2)
55 (2.2)
55 (2.2)

59.0 (2.3)
61.5 (2.4)
54.0 (2.1)
56.5 (2.2)
56.5 (2.2)
54.0 (2.1)
56.5 (2.2)
56.5 (2.2)
59.0 (2.3)
61.5 (2.4)
54.0 (2.1)
56.5 (2.2)
56.5 (2.2)
54.0 (2.1)
56.5 (2.2)

Replace

W4-1-16

FRONT ATTACHMENT / Front Attachment

Unit: mm (in)
Part Name
G
H
I
J
K
L
M
N

Pin (bucket cylinder)


Bushing
Pin (bucket ccylinder piston)
Bushing (bucket cylinder)
Bushing
Pin
Bushing
Pin
Bushing
Pin
Bushing
Pin
Bushing (blade)
Pin
Bushing (blade cylinder)
Pin
Bushing (blade cylinder)

Standar
d
45 (1.8)
45 (1.8)
55 (2.2)
55 (2.2)
55 (2.2)
50 (2.0)
50 (2.0)
50 (2.0)
50 (2.0)
50 (2.0)
50 (2.0)
50 (2.0)
50 (2.0)
71 (2.8)
71 (2.8)
71 (2.8)
71 (2.8)

W4-1-17

Allowable Limit

Remedy

44.0 (1.7)
46.5 (1.8)
54.0 (2.1)
56.5 (2.2)
56.5 (2.2)
49.0 (1.9)
51.5 (2.0)
49.0 (1.9)
51.5 (2.0)
49.0 (1.9)
51.5 (2.0)
49.0 (1.9)
51.5 (2.0)
70.0 (2.8)
72.5 (2.9)
70.0 (2.8)
72.5 (2.9)

Replace

FRONT ATTACHMENT / Front Attachment


Side Cutter

C
D
A

B
W505-04-01-001

A
B
C
D

Standard
225 (8.9)
250 (9.8)
295 (11.6)
150 (5.9)

Unit: mm (in)
Remedy

Allowable Limit
145 (5.7)
-

Replace

Point

W554-04-01-003

A
B
C
D

Standard
165 (6.5)
57 (2.2)
60 (2.4)
62 (2.4)

Allowable Limit
85 (3.3)
-

W4-1-18

Unit: mm (in)
Remedy

Replace

FRONT ATTACHMENT / Front Attachment


STANDARD DIMENSIONS FOR ARM
AND BUCKET CONNECTION

Section A

a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r

Unit: mm (in)
255 (10.0)
15 (0.59)
417 (16.5)
359 (14.1)
310 (12.2)
1060 (42)
298 (11.7)
200 (7.9)
50 (2.0)
299 (11.8)
82 (3.2)
298 (11.7)
202 (8.0)
50 (2.0)
90
90
312 (12.3)
224 (8.8)

Section B

W1CD-04-01-002

NOTE: Dimension h: 200 mm (7.9 in) includes the


clearance for the bucket adjuster.

W4-1-19

FRONT ATTACHMENT / Front Attachment


(Blank)

W4-1-20

FRONT ATTACHMENT / Cylinder


HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
NOTE: This operates the pilot pump by using the
power of the battery without starting the
engine and delivers the pilot pressure to
the control valve spool.
1. Push the pilot shut-off lever forward (OFF).
2. Pull and secure the engine stop knob.
IMPORTANT: The battery will deplete. Operate the
key switch for short period.
3. Turn the key switch to the START position. Operate the control lever 4 to 5 times in order to release pressure from the circuit.
IMPORTANT: Push the engine stop knob completely.
4. Return the engine stop knob to the original position.

W4-2-1

FRONT ATTACHMENT / Cylinder


REMOVAL AND INSTALLATION OF CYLINDER

Removal of Bucket Cylinder


1. Insert wooden block (3) between the ground and
the end of arm (2), and between arm (2) and
bucket cylinder (1).

3
2

2. Stop the engine. Push the air bleed button and


bleed air from the hydraulic oil tank. Remove the
cap. (Refer to BLEED AIR FROM HYDRAULIC
OIL TANK on W1-4-1.)
Release the pressure in the bucket circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.
CAUTION: Before removing pin (7), fasten
the link by using a wire in order not to fall
off.

3
W554-04-02-006

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.
3. Remove nuts (7) (2 used) and bolt (5) from link
(8). Remove pin (9) from links (8, 4) and bucket
cylinder (1) by using a bar and a hammer.
Remove thrust plate (6).
: 24 mm
4. In order not to extend piston rod (10) of bucket
cylinder (1), pass wire (11) through the piston rod
(10) pin hole and secure to the bucket cylinder
(1) tube.

8
W158-04-02-006

1
10

11

W4-2-2

W102-04-02-005

FRONT ATTACHMENT / Cylinder


5. Disconnect hoses (16) (2 used) from bucket cylinder (1). Cap the open ends.
: 27 mm
12

CAUTION: Bucket cylinder (1) weight: 56 kg


(123 lb)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

14

15

6. Attach a nylon sling onto bucket cylinder (1).


Hoist and hold bucket cylinder (1). Remove nuts
(13) (2 used) and bolt (14) from arm (2).
: 24 mm
7. Remove pin (15), shim (12), and bucket cylinder
(1) from arm (2) by using a bar and a hammer.

13

1
2

16

W4-2-3

W187-04-02-004

FRONT ATTACHMENT / Cylinder


Installation of Bucket Cylinder
IMPORTANT: If a hammer is used when installing
a bushing, the bushing may be
damaged. Use a press.
CAUTION: Bucket cylinder (1) weight: 56 kg
(123 lb)
CAUTION: Metal fragments may fly off when
a hammer is used when installing pin (15).
Wear necessary protection, such as goggles
and hard hats, in order to prevent personal
injury.

12

14

1. Attach a nylon sling onto bucket cylinder (1).


Hoist bucket cylinder (1). Align the hole on the
cylinder tube side with the bucket cylinder (1)
mounting hole on arm (2).

15
13

2. Install shim (12) between bucket cylinder (1) and


arm (2). Secure bucket cylinder (1) to arm (2)
with pin (15).
3. Install pin (15) to the stopper part of arm (2) with
bolt (14) and nuts (13) (2 used).
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)

1
2

16

W187-04-02-004

4. Connect hoses (12) (2 used) to bucket cylinder


(1).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
5. Remove wire (11) from piston rod (10) of bucket
cylinder (1).

1
10

11

W4-2-4

W102-04-02-005

FRONT ATTACHMENT / Cylinder


CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

6. Start the engine. Operate the bucket lever. Align


the pin hole on the piston rod (10) side with those
on links (4, 8). Install thrust plate (6) and pin (9).
7. Secure pin (9) to link (8) with bolt (5) and nuts (7)
(2 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

10
W158-04-02-006

W4-2-5

FRONT ATTACHMENT / Cylinder


Removal of Arm Cylinder
1

1. Insert wooden block (3) between arm cylinder (1)


and boom (2).
2. Stop the engine. Push the air bleed button and
bleed air from the hydraulic oil tank. Remove the
cap. (Refer to BLEED AIR FROM HYDRAULIC
OIL TANK on W4-1-1.)
Release the pressure in the arm circuit.
(Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.)

3
W187-04-02-005

3. Remove nuts (8) (2 used) and bolt (5) from arm


(4).
: 24 mm

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

4. Start the engine. While operating the boom and


the arm, adjust the rod pin hole. Remove pin (7)
and thrust plate (6) from arm (4). Lower boom (2)
gently.
8

5. In order not to extend piston rod (9) of arm cylinder (1), pass wire (10) through the piston rod (9)
pin hole and secure to the arm cylinder (1) tube.

2
W187-04-02-006

6. Disconnect hoses (11) (2 used) from arm cylinder


(1). Cap the open ends.
: 27 mm
7. Disconnect lubrication pipe (12) from arm cylinder (1).
: 17 mm

10
W187-04-02-010

11
1

12

W102-04-02-014

W4-2-6

FRONT ATTACHMENT / Cylinder


CAUTION: Arm cylinder (1) weight: 70 kg
(154 lb)
1

8. Attach a nylon sling at the center of gravity of arm


cylinder (1). Hoist and hold arm cylinder (1).
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.
9. Remove nuts (16) (2 used) and bolt (13) from
boom (2). Remove pin (15), shim (14), and arm
cylinder (1) from boom (2).
: 24 mm

W102-04-02-016

13

14
15

2
16

W187-04-02-007

W4-2-7

FRONT ATTACHMENT / Cylinder


Installation of Arm Cylinder
CAUTION: Arm cylinder (1) weight: 70 kg
(154 lb)
1. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist arm cylinder (1). Align the pin
hole on the arm cylinder (1) tube side with the
arm cylinder (1) mounting hole on boom (2).
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

13

14
15

2. Insert thrust plate (14) between boom (2) and


arm cylinder (1). Install arm cylinder (1) to boom
(2) with pin (15).

2
16

3. Secure pin (15) to boom (2) with bolt (13) and


nuts (16) (2 used).
4. Connect lubrication pipe (12) and hoses (11) (2
used) to arm cylinder (1).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

W187-04-02-007

11
1

12

W102-04-02-014

W4-2-8

FRONT ATTACHMENT / Cylinder


5. Remove wire (10) from piston rod (9) of arm cylinder (1). Hoist arm cylinder (1). Start the engine.
Operate the arm lever and align the pin hole at
the piston rod (9) side with the mounting hole on
arm (4).
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

4
10
W187-04-02-010

6. Install thrust plate (6) between piston rod (9) and


arm (4). Install piston rod (9) to arm (4) with pin
(7).

7. Secure pin (7) to arm (4) with bolt (5) and nuts (8)
(2 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

9
W187-04-02-006

W4-2-9

FRONT ATTACHMENT / Cylinder


1

Removal of Boom Cylinder


1. Remove nuts (3) (2 used) and bolt (2) from boom
(1).
: 17 mm
CAUTION: Boom cylinder (4) weight: 90 kg
(200 lb)

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

2. Attach a nylon sling onto the end of the boom


cylinder (4) tube. Hoist and hold boom cylinder
(4). Push out pin (5) to the position where thrust
plate (6) in the end can be removed from boom
cylinder (4) by tapping by using a bar and a
hammer. Remove thrust plate (6) from boom cylinder (4).

W1CD-04-01-001

NOTE: If it pin (5) cannot be removed, start the


engine and operate the boom lever. Adjust
the piston rod pin hole on boom cylinder
(4).
4

IMPORTANT: Place boom cylinder (4) on a stand


so that boom cylinder (4) does not
put on the grease fitting at the piston rod part.

W102-04-01-011

4
1

3. In order not to extend the rod, pass a wire


through the rod hole and secure to the cylinder
tube. Lower boom cylinder (4) on a stand.
4. Stop the engine. Push the air bleed button and
bleed air from the hydraulic oil tank. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
Release the pressure in the boom circuit.
(Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.)

W152-04-01-001

Wire

4
Boom Swing
Post

W4-2-10

W187-04-02-008

FRONT ATTACHMENT / Cylinder


5. Disconnect hoses (10) (2 used) from boom cylinder (4). Cap the open ends.
: 27 mm

11

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

7
8

6. Remove nuts (9) (2 used) and bolt (7) from the


cylinder tube side of the swing post.
Remove pin (8) and thrust plate (11) from the
swing post.
: 24 mm

10

W1CD-04-02-001

CAUTION: Boom cylinder (4) weight: 90 kg


(200 lb)
7. Attach a wire rope at the center of gravity of
boom cylinder (4). Hoist and remove boom cylinder (4) from the swing post.

W187-04-01-001

W4-2-11

FRONT ATTACHMENT / Cylinder


Installation of Boom Cylinder
CAUTION: Boom cylinder (4) weight: 90 kg
(200 lb)
CAUTION: Attach a nylon sling onto boom
cylinder (4) so that the nylon sling does not
touch the pipe of boom cylinder (4).
1. Attach a wire rope at the center of gravity of
boom cylinder (4). Hoist boom cylinder (4). Align
the pin hole at the boom cylinder (4) bottom side
with the mounting pin hole on the swing post.
4

CAUTION: Metal fragments may fly off when


a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

W187-04-01-001

2. Insert thrust plate (11) between the swing post


and boom cylinder (4). Install boom cylinder (4) to
the swing post with pin (8).
3. Secure pin (8) to the swing post with bolt (7) and
nuts (9) (2 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

11

4. Connect hoses (10) (2 used) to boom cylinder


(4).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

7
8

10

W4-2-12

W1CD-04-02-001

FRONT ATTACHMENT / Cylinder


5. Hoist boom cylinder (4). Operate the boom lever
and align the pin hole at the piston rod side with
the mounting pin hole on boom (1).
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles and hard hats, in order
to prevent personal injury.

6. Insert thrust plate (6) between boom (1) and


boom cylinder (4). Install boom cylinder (4) to
boom (1) with pin (5).
7. Secure pin (5) to boom (1) with bolt (2) and nut
(3).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

4
W102-04-01-011

5
2
3

6
W1CD-04-01-001

W4-2-13

FRONT ATTACHMENT / Cylinder


Removal of Blade Cylinder
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order
to prevent personal injury.
1. Remove bolts (1) (2 used) from cover (2). Remove cover (2) from blade cylinder (3).
: 19 mm

3
4

CAUTION: Blade cylinder (3) weight: 51 kg


(112 lb)

4
7

2. Attach a nylon sling onto blade cylinder (3). Hoist


and hold blade cylinder (3).
3. Disconnect hoses (2 used) from blade cylinder
(3). Cap the open ends.
: 22 mm, 27 mm
4. Remove bolts (7) (2 used) and bushings (6) (2
used) from pins (5) (2 used). Remove pins (5) (2
used) from track frame (8) and blade (9).
Remove thrust plate (4) between the bottom part
and blade (9) and between the rod part and track
frame (8) in blade cylinder (3).
: 24 mm
5. Hoist and remove blade cylinder (3).

W4-2-14

Hose

8
5
9

6
W197-04-02-001

FRONT ATTACHMENT / Cylinder


Installation of Blade Cylinder
1

CAUTION: Blade cylinder (3) weight: 51 kg


(122 lb)
1. Hoist blade cylinder (3). Align the pin holes on the
bottom part and the rod part with those on blade
(9) and track frame (8). Install thrust plate (4)
among blade (9), track frame (8), and blade cylinder (3).

3
4

4
7

2. Install blade cylinder (3) to blade (9) and track


frame (8) with pins (5) (2 used). Secure pins (5)
(2 used) to blade (9) and track frame (8) with
bushings (6) (2 used) and bolts (7) (2 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
3. Connect hoses (2 used) to blade cylinder (3).
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

Hose

8
5
9

4. Install cover (2) to blade cylinder (3) with bolts (1)


(2 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
IMPORTANT: When completing the work, operate
the blade cylinder to the stroke end
several times and bleed air from the
circuit.

W4-2-15

6
W197-04-02-001

FRONT ATTACHMENT / Cylinder


DISASSEMBLY OF CYLINDER
Boom Cylinder
2
3
4
5

6
7
8
1

9
10
11

Detent

12
13
14
15
16
17

27

18
19
20
21
22
23
24
25
26

W1CD-04-02-002

1234567-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head
Bushing
Retaining Ring

8910 11 12 13 14 -

O-Ring
Backup Ring
O-Ring
Collar
Cushion Seal
Cushion Seal
Holder

15 16 17 18 19 20 21 -

Backup Ring
O-Ring
Backup Ring
Cushion Bearing
Slide Ring
Piston
Seal Ring

W4-2-16

22 23 24 25 26 27 -

O-Ring
Slide Ring
Nut
Steel Ball
Set Screw
Cylinder Tube

FRONT ATTACHMENT / Cylinder


Disassembly of Boom Cylinder
The disassembling procedure starts on the
premise that the hydraulic pipe and the bands
securing the pipe have been removed.

4. Secure piston rod (1) on the special tool (ST


5908). Put the matching marks on piston rod (1)
and nut (24).
ST 5908

CAUTION: Boom cylinder weight: 90 kg (200


lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.
W158-04-02-022

W102-04-02-027

2. Raise a detent (a part of cylinder tube (27), Refer


to W4-2-20.) in the groove on cylinder head (5).
Loosen cylinder head (5) one to two turns by
using the R-wrench (ST 3219).
IMPORTANT: Remove piston rod (1) straight in
order not to damage the rod surface.
3. Pull out piston rod (1) from cylinder tube (27) fully.
Attach a nylon sling onto piston rod (1). Hold
piston rod (1). Remove cylinder head (5) from
cylinder tube (27). Remove the piston rod (1)
assembly from cylinder tube (27).

5. Remove set screw (26) and steel ball (25) from


nut (24).
: 8 mm
NOTE: Set screw (26) has been crimped by using
a punch at 2 places after installing. Cut
away the crimped position by using a hand
drill and remove set screw (26).
6. Remove nut (24) from piston rod (1) by using the
special tool (ST 5908) and special tool.
Remove piston (20) and cushion bearing (18)
from piston rod (1).
Special tool: 80 mm (ST 3262)
7. Remove holder (14) and cylinder head (5) from
piston rod (1).

W4-2-17

FRONT ATTACHMENT / Cylinder

2
3
4
5

6
7
8
9
10
11

Detent

12
13
14
15
16
17

W1CD-04-02-002

W4-2-18

FRONT ATTACHMENT / Cylinder


IMPORTANT: When removing the seals, do not
damage the parts.
IMPORTANT: Slide rings (19, 23) cannot be reused.
When disassembling the cylinder,
replace them with new ones.
8. Remove slide rings (19, 23), seal ring (21), and
O-ring (22) from piston (20).
9. Remove wiper ring (2), U-ring (3), buffer ring (4),
retaining ring (7), and bushing (6) from the inside
of cylinder head (5) by using the special tool.
Special tool: 65 mm (ST 8015)
10. Remove O-rings (8, 10) and backup ring (9) from
the outside of cylinder head (5).
11. Remove cushion seals (13, 12) and collar (11)
from the inside of holder (14).
12. Remove backup rings (17, 15) and O-ring (16)
from the outside of holder (14).

W4-2-19

FRONT ATTACHMENT / Cylinder


Arm Cylinder

2
3
4
1

5
6
7

Detent

8
9
10

11
12
22

13
14
15
16
17
18
19
20
21
Halved Stopper

W1CD-04-02-003

123456-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head
Bushing

78910 11 12 -

Retaining Ring
O-Ring
Backup Ring
O-Ring
Slide Ring
Piston

13 14 15 16 17 18 -

Steel Ball
Set Screw
Seal Ring
O-Ring
Slide Ring
Retaining Ring

W4-2-20

19 20 21 22 -

Cushion Seal
Cushion Bearing
Halved Stopper (2 Used)
Cylinder Tube

FRONT ATTACHMENT / Cylinder


Disassembly of Arm Cylinder
The disassembling procedure starts on the
premise that the hydraulic pipe and the bands
securing the pipe have been removed.

4. Secure piston rod (1) on the special tool (ST


5908). Put the matching marks on piston rod (1)
and the end of piston (12).
ST 5908

CAUTION: Arm cylinder weight: 70 kg (154


lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.

W158-04-02-022

5. Cut away the crimped part by using a hand drill


and remove set screw (14). Remove set screw
(14) and steel ball (13) from piston (12).
: 5 mm
NOTE: Set screw (14) has been crimped by using
a punch at 2 places after installing.
W102-04-02-027

2. Raise a detent (a part of cylinder tube (18), Refer


to W4-2-44.) in the groove on cylinder head (5).
Loosen cylinder head (5) one to two turns by
using the R-wrench (ST 3220).

6. Remove piston (12) from piston rod (1) by using


the special tool (ST 5908) and the special tool.
Special tool: 70 mm (ST 3261)

IMPORTANT: Remove piston rod (1) straight in


order not to damage the rod surface.
3. Pull out piston rod (1) from cylinder tube (22) fully.
Attach a nylon sling onto piston rod (1). Hold
piston rod (1). Remove cylinder head (5) from
cylinder tube (22). Remove piston rod (1) from
cylinder tube (22).

7. Remove halved stoppers (21) (2 used), cushion


bearing (20), cushion seal (19), and retaining ring
(18) from piston rod (1).
NOTE: Halved stopper (21) can be removed after
removing retaining ring (18) and sliding
cushion bearing (20).
Insert a screwdriver into the notch and
remove cushion seal (19).

W4-2-21

FRONT ATTACHMENT / Cylinder

2
3
4
1

Detent

6
7
8
9
10

11
12

15
16
17

Halved Stopper

W1CD-04-02-003

W4-2-22

FRONT ATTACHMENT / Cylinder


8. Remove cylinder head (5) from piston rod (1).
IMPORTANT: When removing the seals, do not
damage the parts.
IMPORTANT: Slide rings (11, 17) cannot be reused.
When disassembling the cylinder,
replace them with new ones.
9. Remove slide rings (11, 17), seal ring (15), and
O-ring (16) from piston (12).
10. Remove wiper ring (2), U-ring (5), buffer ring (4),
retaining ring (7), and bushing (6) from the inside
of cylinder head (5) by using the special tool.
Special tool: 60 mm (ST 8012)
11. Remove backup ring (9) and O-rings (8, 10) from
the outside of cylinder head (5).

W4-2-23

FRONT ATTACHMENT / Cylinder


Bucket Cylinder

11
12

13
14

15
16

17

Detent

18
2
3
4
5
6
7
8
9
10

W1CD-04-02-004

12345-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head

678910 -

Bushing
Retaining Ring
O-Ring
Backup Ring
O-Ring

11 12 13 14 15 -

Slide Ring
Piston
Steel Ball
Set Screw
Seal Ring

W4-2-24

16 - O-Ring
17 - Slide Ring
18 - Cylinder Tube

FRONT ATTACHMENT / Cylinder


Disassembly of Bucket Cylinder
The disassembling procedure starts on the
premise that the hydraulic pipe and the bands
securing the pipe have been removed.

4. Secure piston rod (1) on the special tool (ST


5908). Put the matching marks on piston rod (1)
and the end of piston (12).
ST 5908

CAUTION: Bucket cylinder weight: 56 kg


(123 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.
W158-04-02-022

W102-04-02-027

2. Raise a detent (a part of cylinder tube (18), Refer


to W4-2-46.) in the groove on cylinder head (5).
Loosen cylinder head (5) one to two turns by
using the R-wrench (ST 3213).
IMPORTANT: Remove piston rod (1) straight in
order not to damage the rod surface.
3. Pull out piston rod (1) from cylinder tube (18) fully.
Attach a nylon sling onto piston rod (1). Hold
piston rod (1). Remove cylinder head (5) from
cylinder tube (18). Remove the piston rod (1)
assembly from cylinder tube (18).

5. Cut away the crimped part by using a hand drill


and remove set screw (14). Remove set screw
(14) and steel ball (13) from piston (12).
: 5 mm
NOTE: Set screw (14) has been crimped by using
a punch at 2 places after installing.
6. Remove piston (12) from piston rod (1) by using
the special tool (ST 5908) and the special tool.
Special tool: 65 mm (ST 3270)
7. Remove cylinder head (5) from piston rod (1).

W4-2-25

FRONT ATTACHMENT / Cylinder

11
12
15
16
17

Detent

2
3
4
5
6
7
8
9
10

W1CD-04-02-004

W4-2-26

FRONT ATTACHMENT / Cylinder


IMPORTANT: When removing the seals, do not
damage the parts.
IMPORTANT: Slide rings (11, 17) cannot be reused.
When disassembling the cylinder,
replace them with new ones.
8. Remove slide rings (11, 17), seal ring (15), and
O-ring (16) from piston (12).
9. Remove wiper ring (2), U-ring (3), buffer ring (4),
retaining ring (7), and bushing (6) from the inside
of cylinder head (5) by using the special tool.
Special tool: 55 mm (ST 8011)
10. Remove backup ring (9) and O-rings (8, 10) from
the outside of cylinder head (5).

W4-2-27

FRONT ATTACHMENT / Cylinder


Blade Cylinder

11
1

12
13
14
15

2
16

17

18
5

19

7
8
9
10

W18C-04-02-010

1 - Piston Rod

6 - Bushing

11 - Slide Ring

16 - Nut

2 - Wiper Ring

7 - Retaining Ring

12 - Piston

17 - Steel Ball

3 - U-Ring

8 - O-Ring

13 - Seal Ring

18 - Set Screw

4 - Buffer Ring

9 - Backup Ring

14 - O-Ring

19 - Cylinder Tube

5 - Cylinder Head

10 - O-Ring

15 - Slide Ring

W4-2-28

FRONT ATTACHMENT / Cylinder


Disassembly of Blade Cylinder
The disassembling procedure starts on the
premise that the hydraulic pipe and the bands
securing the pipe have been removed.
CAUTION: Blade cylinder weight: 51 kg (112
lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.

5. Cut away the crimped part by using a hand drill


and remove set screw (18). Remove set screw
(18) and steel ball (17) from nut (16).
: 6 mm
NOTE: Set screw (18) has been crimped by using
a punch at 2 places after installing.
6. Remove nut (16) from piston rod (1) by using the
special tool (ST 5908) and the special tool.
Remove piston (12) from piston rod (1).
Special tool: 85 mm (ST 3304)
7. Remove cylinder head (5) from piston rod (1).

W102-04-02-027

2. Raise a detent (a part of cylinder tube (19), Refer


to W4-2-52.) in the groove on cylinder head (5).
Loosen cylinder head (5) one to two turns by
using the R-wrench (ST 3223).
IMPORTANT: Remove piston rod (1) straight in
order not to damage the rod surface.
3. Pull out piston rod (1) from cylinder tube (19) fully.
Attach a nylon sling onto piston rod (1). Hold
piston rod (1). Remove cylinder head (5) from
cylinder tube (19). Remove the piston rod (1)
assembly from cylinder tube (19).

IMPORTANT: When removing the seals, do not


damage the parts.
IMPORTANT: Slide rings (11, 15) cannot be reused.
When disassembling the cylinder,
replace them with new ones.
8. Remove slide rings (11, 15), seal ring (13), and
O-ring (14) from piston (12).
9. Remove wiper ring (2), U-ring (3), buffer ring (4),
retaining ring (7), and bushing (6) from the inside
of cylinder head (5) by using the special tool.
Special tool: 70 mm (ST 8017)
10. Remove backup ring (9) and O-rings (8, 10) from
the outside of cylinder head (5).

4. Secure piston rod (1) on the special tool (ST


5908). Put the matching marks on piston rod (1)
and the end of nut (18).
ST 5908

W158-04-02-022

W4-2-29

FRONT ATTACHMENT / Cylinder


ASSEMBLY OF CYLINDER
Boom Cylinder

14 11 15 16 17
3

8 6

9 10

27

18

20

19 21

22

12 13

23 24 26 25

Detail of
Position S

Hole

W1CD-04-02-005

1234567-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head
Bushing
Retaining Ring

8910 11 12 13 14 -

O-Ring
Backup Ring
O-Ring
Collar
Cushion Seal
Cushion Seal
Holder

15 16 17 18 19 20 21 -

Backup Ring
O-Ring
Backup Ring
Cushion Bearing
Slide Ring
Piston
Seal Ring

W4-2-30

22 23 24 25 26 27 -

O-Ring
Slide Ring
Nut
Steel Ball
Set Screw
Cylinder Tube

FRONT ATTACHMENT / Cylinder


Assembly of Boom Cylinder
1. Install bushing (6) to cylinder head (5) by using
the special tool and a press. Install retaining ring
(7) to cylinder head (5).
Special tool: 65 mm (ST 8015)

IMPORTANT: Install slide rings (19, 23) in order


not to align their split positions at
the same place.
8. Install slide rings (19, 23) to piston (20).

IMPORTANT: Install U-ring (3) with its lip part


facing to the bushing (6) side.
Install buffer ring (4) with its
projection part and slit part facing to
the bushing (6) side.
2. Install U-ring (3) and buffer ring (4) to cylinder
head (5).

IMPORTANT: Install cushion bearing (18) with the


larger split part facing to the cylinder
head (5) side.
9. Install cushion bearing (18) to piston rod (1).

3. Install wiper ring (2) to cylinder head (5) by using


the special tool and a plastic hammer.
Special tool: ST 8015

10. Install piston (20) to piston rod (1). Align the


matching marks and tighten nut (24) by using the
special tool (ST 5908) and the special tool.
Special tool: 80 mm (ST 3262)
: 2900 Nm (300 kgfm, 2140 lbfft)
ST 5908

IMPORTANT: Install backup ring (9) to the pin hole


side on piston rod (1) of O-ring (10).
4. Install O-rings (8, 10) and backup ring (9) to
cylinder head (5).
5. Install cushion seals (13, 12), collar (11), backup
ring (17), O-ring (16), and backup ring (15) to
holder (14).
6. Install the cylinder head (5) assembly and the
holder (14) assembly to piston rod (1) by using
the special tool.
Special tool: ST 8015
IMPORTANT: After installing O-ring (22), check
that O-ring (22) is not twisted.
7. Install O-ring (22) and seal ring (21) to piston (20).
At this time, do not push them in the groove on
slide ring (19) by using a spatula.

W158-04-02-022

11. Align the holes on piston rod (1) and nut (24).
Install steel ball (25). Tighten steel ball (25) to nut
(24) with set screw (26). Crimp set screw (26) by
using a punch (2 places) after tightening set screw
(26).
: 6 mm
: 56.910.7 Nm
(5.81.1 kgfm, 428 lbfft)

W4-2-31

FRONT ATTACHMENT / Cylinder

Detent

27

Hole

W1CD-04-02-005

W4-2-32

FRONT ATTACHMENT / Cylinder


IMPORTANT: When inserting piston rod (1), do not
damage the rings. Align the piston
rod (1) assembly with the center of
cylinder tube (27) and insert it
straight.
12. Secure cylinder tube (27) on a workbench
horizontally. Insert the piston rod (1) assembly
into cylinder tube (27).
13. Tighten cylinder head (5) to cylinder tube (27) by
using the R-wrench (ST 3219). Bend the detent
and secure cylinder head (5).
: 950216 Nm
(9722 kgfm, 701160 lbfft)

W4-2-33

FRONT ATTACHMENT / Cylinder


Arm Cylinder

8 6

10

12

22

11

16

15

17

14

13 18

19
20
Hole

21

W1CD-04-02-006

Face the slit to the piston side.


W1CD-04-02-009

123456-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head
Bushing

78910 11 12 -

Retaining Ring
O-Ring
Backup Ring
O-Ring
Slide Ring
Piston

13 14 15 16 17 18 -

Steel Ball
Set Screw
Seal Ring
O-Ring
Slide Ring
Retaining Ring

W4-2-34

19 20 21 22 -

Cushion Seal
Cushion Bearing
Halved Stopper (2 Used)
Cylinder Tube

FRONT ATTACHMENT / Cylinder


Assembly of Arm Cylinder
1. Install bushing (6) to cylinder head (5) by using
the special tool. Install retaining ring (7) to cylinder
head (5).
Special tool: 65 mm (ST 8012)

IMPORTANT: Install slide rings (11, 17) in order


not to align their split positions at
the same place.
7. Install slide rings (11, 17) to piston (12).

IMPORTANT: Install U-ring (3) with its lip part


facing to the bushing (6) side.
Install buffer ring (4) with its
projection part and slit part facing to
the bushing (6) side.
2. Install U-ring (3) and buffer ring (4) to cylinder
head (5).

IMPORTANT: Install cushion seal (19) with its slit


part facing to the piston (12) side.
Install cushion bearing (20) with the
larger split part facing to the cylinder
bottom side.
8. Install cushion seal (19) and cushion bearing (20)
to piston rod (1).

3. Install wiper ring (2) to cylinder head (5) by using


the special tool and a plastic hammer.
Special tool: ST 8012

9. Slide cushion bearing (20) to the piston (12) side


and install halved stoppers (21) (2 used).
Slide cushion bearing (20) to the halved stopper
(21) side and install retaining ring (18).

IMPORTANT: Install backup ring (9) to the pin hole


side on piston rod (1) of O-ring (10).
4. Install O-rings (8, 10) and backup ring (9) to
cylinder head (5).
5. Install the cylinder head (5) assembly to piston
rod (1) by using the special tool.
Special tool: ST 8012

10. Install piston (12) to piston rod (1). Align the


matching marks and tighten piston (12) by using
the special tool (ST 5908) and the special tool.
Special tool: 70 mm (ST 3261)
: 2470 Nm (250 kgfm, 1830 lbfft)
ST 5908

IMPORTANT: After installing O-ring (16), check


that O-ring (16) is not twisted.
6. Install O-ring (16) and seal ring (15) to piston (12).
At this time, do not push them in the groove on
slide ring (11) by using a spatula.
W158-04-02-022

W4-2-35

FRONT ATTACHMENT / Cylinder

Detent

22

Hole

W1CD-04-02-006

W4-2-36

FRONT ATTACHMENT / Cylinder


11. Align the holes on piston rod (1) and piston (12).
Install steel ball (13) to piston (12). Tighten steel
ball (13) to piston (12) with set screw (14). Crimp
set screw (14) by using a punch (2 places) after
tightening set screw (14).
: 5 mm
: 31.55.88 Nm
(3.20.6 kgfm, 234 lbfft)
IMPORTANT: When inserting piston rod (1), do not
damage the rings. Align the piston
rod (1) assembly with the center of
cylinder tube (27) and insert it
straight.
12. Secure cylinder tube (27) on a workbench
horizontally. Insert the piston rod (1) assembly
into cylinder tube (27).
13. Tighten cylinder head (5) to cylinder tube (27) by
using the R-wrench (ST 3220). Bend the detent
and secure cylinder head (5).
: 570 Nm (58 kgfm, 420 lbfft)

W4-2-37

FRONT ATTACHMENT / Cylinder


Bucket Cylinder

3 4

Detent

8 6

10

18

12

11

15

16

17

14

13

Hole

W1CD-04-02-007

12345-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head

678910 -

Bushing
Retaining Ring
O-Ring
Backup Ring
O-Ring

11 12 13 14 15 -

Slide Ring
Piston
Steel Ball
Set Screw
Seal Ring

W4-2-38

16 - O-Ring
17 - Slide Ring
18 - Cylinder Tube

FRONT ATTACHMENT / Cylinder


Assembly of Bucket Cylinder
1. Install bushing (6) to cylinder head (5) by using
the special tool. Install retaining ring (7) to cylinder
head (5).
Special tool: 55 mm (ST 8011)

IMPORTANT: Install slide rings (11, 17) in order


not to align their split positions at
the same place.
7. Install slide rings (11, 17) to piston (20).

IMPORTANT: Install U-ring (3) with its lip part


facing to the bushing (6) side.
Install buffer ring (4) with its
projection part and slit part facing to
the bushing (6) side.
2. Install U-ring (3) and buffer ring (4) to cylinder
head (5).

8. Install piston (12) to piston rod (1). Align the


matching marks and tighten piston (12) by using
the special tool (ST 5908) and the special tool.
Special tool: 65 mm (ST 3270)
: 1480 Nm (151 kgfm, 1100 lbfft)
ST 5908

3. Install wiper ring (2) to cylinder head (5) by using


the special tool and a plastic hammer.
Special tool: ST 8011
IMPORTANT: Install backup ring (9) to the pin hole
side on piston rod (1) of O-ring (10).
4. Install O-rings (8, 10) and backup ring (9) to
cylinder head (5).
5. Install the cylinder head (5) assembly to piston
rod (1) by using the special tool.
Special tool: ST 8011
IMPORTANT: After installing O-ring (16), check
that O-ring (16) is not twisted.
6. Install O-ring (16) and seal ring (15) to piston (12).
At this time, do not push them in the groove on
slide ring (11) by using a spatula.

W158-04-02-022

9. Align the holes on piston rod (1) and piston (12).


Install steel ball (13). Tighten steel ball (13) to
piston (12) with set screw (14). Crimp set screw
(14) by using a punch (2 places) after tightening
set screw (14).
: 6 mm
: 31.55.88 Nm
(3.20.6 kgfm, 234 lbfft)
IMPORTANT: When inserting piston rod (1), do not
damage the rings. Align the piston
rod (1) assembly with the center of
cylinder tube (18) and insert it
straight.
10. Secure cylinder tube (18) on a workbench
horizontally. Insert the piston rod (1) assembly
into cylinder tube (18).
11. Tighten cylinder head (5) to cylinder tube (18) by
using the R-wrench (ST 3213). Bend the detent
and secure cylinder head (5).
: 450 Nm (46 kgfm, 340 lbfft)

W4-2-39

FRONT ATTACHMENT / Cylinder


Blade Cylinder

Detent

9 10

19

12 11

13

14 15 16 18 17

Hole

W1CD-04-02-008

123456-

Piston Rod
Wiper Ring
U-Ring
Buffer Ring
Cylinder Head
Bushing

78910 11 -

Retaining Ring
O-Ring
Backup Ring
O-Ring
Slide Ring

12 13 14 15 16 -

Piston
Seal Ring
O-Ring
Slide Ring
Nut

W4-2-40

17 - Steel Ball
18 - Set Screw
19 - Cylinder Tube

FRONT ATTACHMENT / Cylinder


Assembly of Blade Cylinder
1. Install bushing (6) to cylinder head (5) by using
the special tool. Install retaining ring (7) to cylinder
head (5).
Special tool: 70 mm (ST 8017)

IMPORTANT: Install slide rings (11, 15) in order


not to align their split positions at
the same place.
7. Install slide rings (11, 15) to piston (12).

IMPORTANT: Install U-ring (3) with its lip part


facing to the bushing (6) side.
Install buffer ring (4) with its
projection part and slit part facing to
the bushing (6) side.
2. Install U-ring (3) and buffer ring (4) to cylinder
head (5).

8. Install piston (12) to piston rod (1). Align the


matching marks and tighten nut (16) by using the
special tool (ST 5908) and the special tool.
Special tool: 85 mm (ST 3304)
: 3310 Nm (340 kgfm, 2250 lbfft)
ST 5908

3. Install wiper ring (2) to cylinder head (5) by using


the special tool and a plastic hammer.
Special tool: ST 8017
IMPORTANT: Install backup ring (9) to the pin hole
side on piston rod (1) of O-ring (10).
4. Install O-rings (8, 10) and backup ring (9) to
cylinder head (5).
5. Install the cylinder head (5) assembly to piston
rod (1) by using the special tool.
Special tool: ST 8017
IMPORTANT: After installing O-ring (14), check
that O-ring (14) is not twisted.
6. Install O-ring (14) and seal ring (13) to piston (12).
At this time, do not push them in the groove on
slide ring (11) by using a spatula.

W158-04-02-022

9. Align the holes on piston rod (1) and nut (16).


Install steel ball (17). Tighten steel ball (17) to nut
(16) with set screw (18). Crimp set screw (18) by
using a punch (2 places) after tightening set
screw (18).
: 6 mm
: 56.910.7 Nm
(5.81.1 kgfm, 428 lbfft)
IMPORTANT: When inserting piston rod (1), do not
damage the rings. Align the piston
rod (1) assembly with the center of
cylinder tube (19) and insert it
straight.
10. Secure cylinder tube (19) on a workbench
horizontally. Insert the piston rod (1) assembly
into cylinder tube (19).
11. Tighten cylinder head (5) to cylinder tube (19) by
using the R-wrench (ST 3223). Bend the detent
and secure cylinder head (5).
: 1060 Nm (108 kgfm, 790 lbfft)

W4-2-41

FRONT ATTACHMENT / Cylinder


MAINTENANCE STANDARD
Piston Rod
A

W105-04-02-094

Cylinder Name

Unit: mm (in)
Recommended Size after
Re-Manufacturing (A)

Boom

65

Arm

60

Bucket

55

Boom Swing

60

Blade

70

+0.023
-0.053
+0.023
-0.053
+0.023
-0.043
+0.023
-0.053
+0.023
-0.053

W4-2-42

+0.001

(2.6 -0.002 )
+0.001

(2.4 -0.002 )
+0.001

(2.2 -0.002 )
+0.001

(2.4 -0.002 )
+0.001

(2.8 -0.002 )

MEMO
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SECTION 5

ENGINE
CONTENTS
Group 1 General Information
General Information ........................................ 0A-1
General Information W0A0001 .................... 0A-2

Group 2 Engine
4LE2 Engine Mechanical ................................ 1A-1
ISUZU Diesel Engine W1A0002.................. 1A-2
Engine Accessories W1A0003 .................. 1A-12
Engine Exterior Equipment W1A0004 ....... 1A-17
Rocker Arm Shaft W1A0075 ..................... 1A-35
Cylinder Head W1A0014........................... 1A-41
Piston, Connecting Rod W1A0015 ............ 1A-52
Flywheel W1A0016 ................................... 1A-63
Crankshaft Front Oil Seal W1A0022 ......... 1A-66
Crankshaft Rear Oil Seal W1A0023 .......... 1A-70
Timing Gear Train W1A0010 ..................... 1A-73
Camshaft W1A0012 .................................. 1A-78
Crankshaft W1A0024 ................................ 1A-83
Cylinder Block W1A0025 .......................... 1A-90
Special Tool W1A0072 .............................. 1A-93

4LE2 Exhaust System.....................................1G-1


EGR Control W1G0082 ...............................1G-2
4LE2 Lubrication System ................................ 1H-1
Lubrication System W1H0026 ..................... 1H-2
Oil Filter W1H0036 ...................................... 1H-4
Oil Pump W1H0034 ..................................... 1H-5
4LE2 Intake System .........................................1J-1
Turbocharger W1J0069 ................................1J-2
4LE2 Preheating System ................................ 1K-1
Preheating System W1K0061...................... 1K-2

4LE2 Cooling System ..................................... 1B-1


Cooling System W1B0037 .......................... 1B-2
Water Pump W1B0040................................ 1B-7
Thermostat W1B0041 ................................. 1B-8
Fan Clutch, Cooling Fan W1B0044 ............. 1B-9
4LE2 Fuel System .......................................... 1C-1
Fuel System W1C0045 ............................... 1C-2
Governor W1C0079 .................................... 1C-6
4LE2 Electrical System................................... 1D-1
Charging System W1D0053 ........................ 1D-2
Generator (24V-50A) W1D0081 .................. 1D-4
Starting System W1D0057 ........................ 1D-13
Starter W1D0060 ...................................... 1D-17

1P1W-5-1

(Blank)

1P1W-5-2

General Information 0A-1

General Information
General Information
Table of Contents
General Information W0A0001.............................. 0A-2
Service Precautions W0A00010001 .................. 0A-2
Reading the Model W0A00010002 .................... 0A-6
General Information W0A00010003................... 0A-6
Recommended Lubricant W0A00010038 ........ 0A-13
List of Trouble Symptom W0A00010013 ......... 0A-14
Repair Standard W0A00010039 ...................... 0A-23

0A-2 General Information

General Information

W0A0001

Service Precautions W0A00010001


In order to carry out work safely W0A0001000101
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical system, always remove the minus side cable from the
battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
WSHK0190

6. All regular tools, gauges and special tools should


be regularly inspected, and prepared before starting work. Do not use bent spanners, hammers with
damaged edges, chipped chisels, or any other
faulty or damaged tools.

4. Do not perform painting work or leave the engine


running for long periods of time in an enclosed or
badly ventilated indoor workshop.
5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
cause damage to the parts or injury to the person
using the tool.
7. Always pay close attention to safety and handling
requirements when using grinders, cranes, welders, and other such equipment.
Moreover, always wear the correct protective garments and use the necessary safety tools for the
job in hand.

General Information 0A-3

WSHK0192

WSHK0191

8. Always check that there are no fuel leaks when


performing maintenance work on the fuel system.
(It may cause a fire.)

Replacement parts and part numbers

1. Always replace packing, oil seals, O-rings, caulking lock nuts, folding lock plates, split pins and
other such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to revisions. Therefore, parts should always be checked
against a parts catalogue before use.

Liquid gasket

9. Pay close attention to the risk of ignition if you are


handling parts that carry a high voltage.
Furthermore, any oil or grease spilt onto rubber
parts must be wiped off immediately, as it will
cause deterioration of the rubber.

W0A0001000102

W0A0001000103

1. Each time you disassemble parts that use liquid


gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to completely remove oil, water, and dirt etc. from the various surfaces by a cloth. Using the specified type
of liquid gasket, apply new liquid gasket to each of
the surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket surfaces, apply gasket remover liquid (Pando- 391D
made by ThreeBond Co., Ltd.) and leave the part
to stand for approximately 10 minutes, after which
the old liquid gasket residue will be easier to
remove.
However, this should not be used on resin components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when reinstalling
the liquid gasket parts to each other. If there are
gaps between the two parts, re-apply the liquid
gasket. Some parts, especially the oil pan, use the
same size studs as a guide to eliminate the need
for knock pin positioning etc.

0A-4 General Information


5. Re-install these parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes passes, remove the previous liquid gasket and re-apply it.

6. Please wait for at least 30 minutes since the last


part is installed before starting the engine.

Liquid gasket
Applied area
Parts

Use conditions
Matching parts

Seal object

Application
groove

Liquid gasket
name

Engine oil (10W


30)

Equipped

TB 1207B

Air

Equipped

TB 1207C

Cylinder block

Engine oil (10W


30)

Equipped

TB 1207B

Housing cover; injection pump

Cylinder block

Engine oil (10W


30)

None

TB 1207C

Solenoid; fuel cut

Cylinder block

Engine oil (10W


30)

Equipped

TB 1207C

Retainer; oil seal

Cylinder block

Engine oil (10W


30)

Equipped

TB 1207B

Housing ASM; PCV

Cylinder head cover

Blow-by gas

None

TB 1207C

Indicator; air cleaner

Air cleaner

Air

None

(Seal tape)

Rocker bracket

Cylinder head

Air inlet pipe

Cylinder head cover

Timing case

Always use the liquid gasket products listed above,


or a liquid gasket identical to the ones listed above.
Use the correct quantity of liquid gasket. Always
follow the handling instructions for each product.
Application procedure
1. Wipe the contact surfaces clean of all water, oil or
grease. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.
Note:
If there are special regulations concerning the application procedure in the repair document, please follow
those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
threads clean of water, grease, and oil. The contact surfaces should be dry.
2. Apply Loctite to the top 1/3 of the screw.
3. Tighten the bolt to the specified torque.

Important:
After tightening the bolt, do not apply excessive
torque or try to rotate the bolt until at least one
hour has passed, and the Loctite has hardened.

Procedure for using the plastigauge

W0A0001000104

Type

Measurable range mm {in}

PG-1 (Green)

0.025 0.076 {0.001 0.003}

PR-1 (Red)

0.051 0.152 {0.002 0.006}

PB-1 (Blue)

0.102 0.229 {0.004 0.009}

General Information 0A-5


Example: Procedure for measuring the clearance
between the connecting rod bearing and crank pin.
Clean the connecting rod and bearing, and install
the bearing to the rod.
Cut the plastigauge to the same width as the crank
pin, and while avoiding the oil hole of the crank pin
lay the gauge parallel to the pin.
Line up the marks on the connecting rod and cap,
and install the crank pin. Apply molybdenum disulfide to the thread section and seating surface of
the tightening bolt, and rotate both cap and bolt to
the correct torque.
Important:
Do not move the connecting rod while using the
plastigauge.
Gently remove the cap and connecting rod, and
measure the crushed width of the plastigauge
(clearance between rod and pin) using the scale
printed on the bag.

Example: Measuring the clearance between the crank


bearing and crank journal
Clean the clamp face of the cylinder block and
crankcase bearing, and also the bearing, and
install the cylinder block to the crankcase.
Gently rest the crankshaft on the cylinder block,
and rotate it approximately 30 degree to stabilize it.
Cut the plastigauge to the same size as the journal
width, and while avoiding the oil hole of the journal
lay the gauge parallel to the journal.
Gently rest the crankcase on the cylinder block,
apply molybdenum disulfide to the thread section
and seating surface of the tightening bolt, and
tighten in sequence to the correct torque.
Important:
Do not rotate the crankshaft while using the plastigauge.
Gently remove the crankcase, and measure the
crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.

0A-6 General Information

Reading the Model W0A00010002


Engine number stamping position

W0A0001000201

WSLE0352

General Information W0A00010003


Terminology, description of abbreviations
W0A0001000301

Terminology definitions
Maintenance standard

The generic name for reference values required for


maintenance, such as nominal dimension, assembly
specification, and limit.
Nominal dimension
Shows the standard value at the point of manufacture
that does not include the common difference.

General Information 0A-7


Assembly specification
Shows the standard value after assembling, repairing,
or adjusting.
Service limit
When this value (dimensions) is reached, it shows that
the part has reached its full limit and must be replaced
or repaired.
Wear
Shows the difference between the dimension of nonworn part (nominal dimension unless there is such part)
and that of the most worn part (the dimension of worn
part).
Uneven wear
Shows the difference between the maximum and the
minimum wear amount.

Abbreviation
BTDC
CO
CONN

Description
Before Top Dead Center
Carbon Oxide
Connector

CPU

Central Processing Unit

C/U

Control Unit

DC

Direct Current

DI

Direct Injection

ECU

Engine Control Unit/Electronic Control Unit

ECM

Engine Control Module

EGR

Exhaust Gas Recirculation

Front/Rear, Right/Left, Top/Bottom


These show each orientations of parts installed to the
vehicle when looking from the vehicle's forward direction.

Exh, EXH

FWD

Forward

Unit
Units written to SI conventions (mainly torque, pressure, force)
[Example] Length: mm, Torque: Nm {kgfm}

F/C

Fuel Cut

GND

Ground

Warning
Items that carry the warning mark pose a danger to life
or threat of serious injury if not strictly observed.
Caution
Items that carry the caution mark may cause injury or
lead to accidents if not strictly observed.
Important
Items that carry the important mark may cause the
vehicle to break down, or may prevent the guaranteed
normal operation of the system or related parts if not
strictly observed.
Note
Items that should receive special mention within a work
procedure.
Description of abbreviations
Abbreviation
AC

Description
Alternating Current

ACC

Accessory

ACG

Alternating Current Generator

API

American Petrol Institute

ASM
(Assy)

Assembly

ATDC

After Top Dead Center

BAT, BATT

Battery

BRG, Brg

Bearing

BKT, BRKT

Bracket

Ft, FRT

Exhaust
Front

IC

Integrated Circuit

ID Plate

Identification Plate

IN
ISO
I/PUMP
JIS
L/H, LH

Intake, Inlet
International Organization for Standardization
Injection Pump
Japanese Industrial Standard
Left Hand

M/V

Magnetic Valve

NOx

Nitrogen Oxide

N-TDC

Number - Top Dead Center

OPT

Option

Pole(S)

PCV

Pump Control
Ventilation

PM

Particulate Matter

PS

Pre-Stroke

PTO

Power Take Off

QOS

Quick On System

Rr, RR
R/H, RH

Right Hand
Relay

STD

Standard

SW

Switch

VGS Turbo

Crankcase

Rear

R/L

TICS

Valve/Positive

Timing & Injection rate Control System


Variable Geometry turbocharger System

0A-8 General Information


Abbreviation
W/L

Description
Warning Lamp

SI (International System of Units) W0A0001000302


With regards the conversion to SI (International
System of Units)
The introduction of the SI systems aims to internationally unify the metric system and the various units used
by different countries (traditional weights and measures, the foot pound method etc.), and to curb the
confusion that occurs between the different units (conversion calculations etc.).

The new calculating method which adopted SI units


was completely adopted in Japan in 1992, and is standardized by JIS-Z-8203.
All of the units in this manual are written in line
with the International System of Units SI units, and
conventional units are written in { } brackets.
SI
Abbreviation of French word Le Systeme International
dUnites

Connection between main SI units and conventional units


SI

Conventional unit

Length

Same as the conventional unit

Weight (Mass)

kg

kg

Same as the conventional unit

Force

* kg, kgf

Torque

Nm

* kgm, kgfm

Pressure

Pa

* kg/cm2, mmHg

Power
output,
horsepower

PS

Capacity, air volume displacement

m3

Liter, L, cc

g/(kWh)

g/(PSh)

Fuel consumption

*1 Published service data may conveniently use kg for


force and mass (weight) instead of kgf.
*2 Some conversion results may be rounded off to 1 or
2 decimal places.
Converting expressions of quantity
When converting, prefixes such as k (kilo) or m (milli)
are used.
Mega

106

1,000,000

Kilo

103

1,000

Hecto

102

100

Deci

10-1

0.1

Centi

10-2

0.01

Milli

10-3

0.001

Micro

10-6

0.000001

d
c

200 kgf/cm2 = 19,620 kPa = 19.6 MPa


40 mmHg = 5,332 Pa = 5.3 kPa
Conversion formula
Length
km 0.6214 = mile
m 3.281 = ft

Item, unit conversion

1 kgf = 9.80665 N
1 kgfm = 9.80665 Nm
1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
1 PS = 0.74 kW
1 Liter = 1 dm3, 1 cc = 1 m Liter = 1 cm3
1 g/(PSh) = 1.360 g/(kWh)

mm 0.03937 = in
Pressure
kPa 0.0101972 = kg/cm2
kPa 0.145038 = psi
MPa 10.197162 = kg/cm2
MPa 145.03774 = psi
Tightening torque
Nm 0.101972 = kgm
Nm 0.737562 = lbft
Speed
km/h 0.6214 = MPH
Temperature
C 1.8 + 32 = F

General Information 0A-9


Table of Isuzu standard tightening torque W0A0001000303
The tightening torque values in the table below apply to all situations unless a special tightening torque is specified.
Isuzu standard bolts, nuts
Nm {kgfm}
Strength classification

4.8
4T

7T

Shape of bolt head

Hexagon head bolt

Flange bolt

Hexagon head bolt

Flange bolt

*M10 1.5

19.6 33.3 {2.0 3.4}

22.3 37.2 {2.3 3.8}

27.5 45.1 {2.8 4.6}

30.3 50.4 {3.1 5.1}

M12 1.25

49.0 73.5 {5.0 7.5}

54.9 82.3 {5.6 8.4}

60.8 91.2 {6.2 9.3}

68.1 102.1 {6.9


10.4}

*M12 1.75

45.1 68.6 {4.6 7.0}

51.0 76.5 {5.2 7.8}

56.9 84.3 {5.8 8.6}

62.7 94.0 {6.4 9.6}

M14 1.5

76.5 114.7 {7.8


11.7}

83.0 124.5 {8.5


12.7}

93.2 139.3 {9.5


14.2}

100.8 151.1 {10.3


15.4}

*M14 2

71.6 106.9 {7.3


10.9}

77.2 115.8 {7.9


11.8}

88.3 131.4 {9.0


13.4}

94.9 142.3 {9.7


14.5}

M16 1.5

104.0 157.0 {10.6


16.0}

115.6 173.3 {11.8


17.7}

135.3 204.0 {13.8


20.8}

150.1 225.2 {15.3


23.0}

*M16 2

100.0 149.1 {10.2


15.2}

109.4 164.2 {11.2


16.7}

129.4 194.2 {13.2


19.8}

142.5 213.8 {14.5


21.8}

M18 1.5

151.0 225.6 {15.4


23.0}

195.2 293.2 {19.9


29.9}

*M18 2.5

151.0 225.6 {15.4


23.0}

196.1 294.2 {20.0


30.0}

M20 1.5

206.0 310.0 {21.0


31.6}

269.7 405.0 {27.5


41.3}

*M20 2.5

190.2 286.4 {19.4


29.2}

249.1 374.6 {25.4


38.2}

M22 1.5

251.1 413.8 {25.6


42.2}

362.8 544.3 {37.0


55.5}

*M22 2.5

217.7 327.5 {22.2


33.4}

338.3 507.0 {34.5


51.7}

M24 2

358.9 539.4 {36.6


55.0}

430.5 711.0 {43.9


72.5}

*M24 3

338.3 507.0 {34.5


51.7}

406.0 608.0 {41.4


62.0}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
Nm {kgfm}
Strength classification

9.8
9T

8.8

Shape of bolt head

Hexagon head bolt

Flange bolt

Hexagon head bolt

Flange bolt

M6 1

5.6 11.2 {0.6 1.1}

6.6 12.2 {0.6 1.2}

M8 1.25

13.4 25.7 {1.4 2.6}

15.3 28.4 {1.6 2.9}

16.7 30.4 {1.7 3.1}

18.1 33.6 {1.9 3.4}

M10 1.25

31.3 52.5 {3.2 5.4}

35.4 58.9 {3.6 6.1}

37.3 62.8 {3.8 6.4}

42.3 70.5 {4.3 7.2}

*M10 1.5

31.3 51.4 {3.2 5.2}

34.5 57.5 {3.5 5.8}

36.3 59.8 {3.7 6.1}

40.1 66.9 {4.1 6.8}

M12 1.25

69.3 104.0 {7.1


10.6}

77.7 116.5 {7.9


11.9}

75.5 113.8 {7.7


11.6}

85.0 127.5 {8.7


13.0}

0A-10 General Information


Nm {kgfm}
Strength classification

9.8
9T

8.8

Shape of bolt head

Hexagon head bolt

Flange bolt

Hexagon head bolt

Flange bolt

*M12 1.75

64.8 96.1 {6.6 9.8}

71.4 107.2 {7.3


10.9}

71.6 106.9 {7.3


10.9}

79.5 119.2 {8.1


12.2}

M14 1.5

106.2 158.8 {10.8


16.2}

114.9 172.3 {11.7


17.6}

113.8 170.6 {11.6


17.4}

123.4 185.1 {12.6


18.9}

*M14 2

100.6 149.8 {10.3


15.3}

108.2 162.2 {11.1


16.6}

106.9 160.0 {10.9


16.3}

115.5 173.3 {11.8


17.7}

M16 1.5

154.3 232.5 {15.7


23.7}

171.1 256.7 {17.4


26.2}

160.0 240.3 {16.3


24.5}

176.9 265.3 {18.0


27.1}

*M16 2

147.6 221.4 {15.0


22.6}

162.5 243.8 {16.6


24.9}

153.0 229.5 {15.6


23.4}

168.5 252.7 {17.2


25.8}

M18 1.5

222.5 334.3 {22.7


34.1}

229.5 345.2 {23.4


35.2}

*M18 2.5

223.6 335.4 {22.8


34.2}

230.5 346.2 {23.6


35.3}

M20 1.5

307.4 461.7 {31.4


47.1}

316.8 475.6 {32.3


48.5}

*M20 2.5

284.0 472.1 {29.0


43.5}

293.2 440.3 {29.2


44.9}

M22 1.5

413.6 620.5 {42.2


63.3}

424.6 636.5 {43.3


64.9}

*M22 2.5

385.7 578.0 {39.3


58.9}

394.2 592.3 {40.0


60.4}

M24 2

490.8 810.5 {50.0


82.7}

554.1 830.6 {56.5


84.7}

*M24 3

462.8 693.1 {47.2


70.7}

520.7 781.6 {53.1


79.7}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.

General Information 0A-11


Designations for Isuzu standard bolt heads

Name
1. Hexagon Head Bolt (4.8, 4T)
2. Hexagon Head Bolt (4.8, 4T)
3. Flange Bolt (4.8, 4T)
4. Flange Bolt (4.8, 4T)
5. Hexagon Head Bolt (7T)
6. Flange Bolt (7T)
7. Hexagon Head Bolt (Thermal Refined 8.8)
8. Hexagon Head Bolt (Thermal Refined 8.8)

9.
10.
11.
12.
13.
14.
15.
16.

Hexagon Head Bolt (Nonthermal Refined 8.8)


Hexagon Head Bolt (Nonthermal Refined 8.8)
Flange Bolt (8.8)
Flange Bolt (8.8)
Hexagon Head Bolt (9.8, 9T)
Hexagon Head Bolt (9.8, 9T)
Flange Bolt (9.8, 9T)
Flange Bolt (9.8, 9T)

Flare nut
Pipe diameter

Flare nut tightening torque


(service standard value) Nm {kgfm}

Tightening torque
(for medium and large size
vehicles)

Width across flats of flare nut


(mm)
Old

New

4.76 mm

12.8 18.6 {1.3 1.9}

14

14

6.35 mm

23.5 49 {2.4 5.0}

17

17

8.0 mm

23.5 49 {2.4 5.0}

19

17

10.0 mm

44.1 93.2 {4.5 9.5}

22

19

12.0 mm

58.8 137.3 {6.0 14.0}

27

24

15.0 mm

78.5 156.9 {8.0 16.0}

30

30

0A-12 General Information


Taper screw from connectors (brass)
Nm {kgfm}
Screw size

PT (R) 1/8

PT (R) 1/4

PT (R) 3/8

PT (R) 1/12

2.0 14.7
{0.2 1.5}

4.9 15.7
{0.5 1.6}

9.8 16.7
{1.0 1.7}

9.8 17.7
{1.0 1.8}

About angle method tightening W0A0001000304


Though the general and current way to tighten bolts
and nuts is torque indication, using this way results in
large unevenness of shaft power to indicated torque.
Therefore, bolts may be damaged at upper limit when
you try to ensure minimal shaft power.
To ensure shaft power with small unevenness, it is necessary to tighten bolts measuring stretch amount of
bolts, but this is actually impossible. So the angle
method focuses on screw pitch as equivalent to bolt
stretch, and controls using the screw rotation amount.
The method can reduce the unevenness of shaft power
by tightening to plastic range.

A
C
B

How to tighten
1. Apply molybdenum disulfide or engine oil to the
threads and the seating surface of the bolt following the instruction.
2. Tighten all bolts to the pre-indicated tightening
torque.
3. Draw lines on the surface of the parts you tighten:
the lines which pass through the bolts center (A
B: bolt side) (C D: parts side) and the line at the
specified tightening angle from the bolts center (E
F).

WSLE0009

Be sure to check the mark to see whether you


tighten the bolt to the specified angle or not.
If you fail this, you may tighten the bolt by the
angle method again by accident and damage the
bolt. Take extreme care.
Important:
Follow the instructed order to tighten bolts.
Do not retighten if you tighten by the angle
method.
Bolt angle gauge (5-8840-0266-0), the tool for tightening bolts by the angle method, is set.

Special tool classification

W0A0001000305

A; Essential tool
Servicing operation cannot be done with any other
tools than the essential tool.

B; Recommend tool

WSLE0008

Name
1. Specified Tightening Torque
4. Tighten the bolt with wrench until the line on the
bolt (A B) aligns with the specified angle line (E
F on the surface of the parts).

Servicing work can be done with a general-purpose


tool commercially available. However, it is advisable to
use the recommended tool as much as possible for a
reduced work time and an improved safety in work
operations.
C; Available tool
Although it takes a more working time, servicing operations can be made with a tool commercially available as
substitute for the available tool.

General Information 0A-13


Recommended Lubricant W0A00010038
Engine oil

W0A0001003801

Use the engine oil below.


Engine oil grade
Engine classification

Engine oil grade (API service category)

With turbocharger

CD or CF-4
* (CE, CF, CH-4, CI-4 or CI-4 Plus)

* mark may vary depending on each machine. Refer to the machine manufacturer specification.
ISUZU genuine engine oil
Besco Super: CC
Besco S 3: CD
Besco Multi Z: CD

Engine oil viscosity chart

W0A0001003802

ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE

SAE 5W-20
[Single grade]

SAE 40

SAE 20, 20W


SAE 10W

Ambient
temperature

-25 C -20 C -15 C


(-13 F) (-4 F) (5 F)

SAE 30
-0 C
(32 F)

15 C
(59 F)

25 C 30 C
(77 F) (86 F)

SAE 10W-30
[Multi grade]

SAE 15W-40, 20W-40

WSLE0034

The engine oil affects the startability, driving performance, oil consumption, wear of the sliding part, and seizure,
depending on the viscosity. You should select the engine oil depending to a temperature and the chart above.

Engine oil level

W0A0001003803

4LE2X model: Approx. 9.3 12.1 L {9.8 12.8 qts}


Note:
Engine oil level may vary depending on the machine
specification.

0A-14 General Information


List of Trouble Symptom W0A00010013
Engine does not start W0A0001001301
Engine does not start

Starter does not run

Engine starts but


does not run
continuously.

Starter runs but does


not start

Check battery
Engine
Battery in
discharging
(Charge)

Fuel system

Fuel injected

No fuel
injected

Fuel injected

Air mixed in
fuel pump

OK
Check
compression
pressure

(*)

Check wiring

Loosened
connector or
broken wire
(Retighten or
replace with
new wiring)

OK

Low
compression

OK

Check for air


mixing

Defective
valve, spring,
gasket, etc.
(Overhaul)

Air mixed
(Retighten it,
replace
packing, bleed
air)

OK

OK

Check magnetic
switch
(*)

OK

Clogged
(Clean)

Poor
operation
of glow
plug
control
resistance
(Replace)

Normal
operation
of glow
plug
control
resistance
OK

Abnormal
(Adjust)

Disordered
idling

Adjust
idling

Check
injection
timing

Check fuel
filter

Defective
(Replace)

OK

OK

pressure

Check starter switch

Defective
(Replace)

Check
preheating
circuit

Check if fuel
comes
to fuel pump

Retighten,
replace
packing,
bleed air

(*2)

OK

(*2)
OK

Check for the


stuck EGR valve
(opened position)

(*3)

OK

Check nozzle
Check engine stop
solenoid return

Defective
(Repair or
replace)

Check starter bush

OK

Replace the EGR


cut solenoid and
valve case by
the set

OK

Check solenoid

Poor contact
(Repair or
replace)

OK

Defective starter
(Bring it to a specialty
shop for repair)

Stuck solenoid or
poor operation
(Repair or replace)

OK

Defective injection
pump (Bring
it to a specialty
shop for repair)

(*3) Refer to "EGR Control"


in the Exhaust System
section.

Note: "Bring it to a specialty shop" means that defective parts of the injection pump
and electricals must be brought to a specialty shop for repair. (This note is
applicable to all the following procedures.)

WSLE0192

General Information 0A-15


Engine speed lacks smoothness

W0A0001001302

Unstable engine rotation

Unstable engine
idling

Idling speed
too high

Unstable rotation at
medium speed
(Hunting)

Unstable rotation at
high speed

Engine does not


change from high to
low rotation

Defective idling
adjustment

Defective control
lever adjustment

Governor spring
deteriorated

Check fuel for air


mixing

Check accelerator
pedal

Defective
valve return
(Adjust)

OK

Check high pressure


pipe for cracking,
clogging or bending

Cracked,
clogged or
bent
(Replace)

OK

OK

Check cylinder for


uneven compression
pressure

Uneven
compression
pressure
(Adjust)

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

Air mixed
(Bleed air)

Check fuel pipe for


crash

Crash
(Replace)

OK

OK

Pedal
sticking or
hitching
(Clean or
replace)

OK

Check fuel filter for


clogging

Clogged
(Clean or
replace)

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

Check uneven fuel


injection

Check nozzle

Defective
(Repair or
replace)

Defective
(Repair or
replace)

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

Uneven
(Adjust)

OK

Check valve clearance


adjustment

Poor
adjustment
(Adjust)

OK

Defective injection
pump (Bring it to a
specialty shop for
repair)

WSLE0193

0A-16 General Information


Output shortage W0A0001001303
Insufficient output

Fuel system

Check fuel for air


mixing

Air mixed
(Bleed air)

Mechanical
system

Check engine
control

OK
Poor
adjustment

Clogged
(Clean or
Replace)

Check inlet air


temperature

Replace the
EGR cut
solenoid
and valve
case by
the set

OK

OK
Temperatu
re too high
(Improve
ventilation)

Check high
pressure pipe for
clogging or
bending

Clogged
or bent
(Replace)

Check for the


stuck EGR valve
(opened position)
(*)

OK

(Adjust)
Check fuel filter
or fuel hose for
clogging

There is insufficient
torque and a lot of
black smoke at
low-speed

OK

OK

Insufficient inlet
air

Air cleaner
stained
(Clean or
replace)

Check the fuel


system and
mechanical system

(*) Refer to "EGR Control"


in the Exhaust System
section.

OK

Check nozzle

Defective
(Repair or
replace)

OK

Check injection
timing

Abnormal
(Adjust)

OK

Check valve
clearance and
cam lift

Abnormal
(Adjust or
replace)

OK

Check compression
pressure

Low
Defective
injection pump
(Bring it to a
specialized shop
for repair)

Low
Excessive
blow-by
gas
(Overhaul)

Gas leak from


valve and gasket
(Repair or replace)
WSLE0194

General Information 0A-17


Overheat W0A0001001304

Overheat

Cooling system

Check cooling
water level

Insufficient

Replenish

OK

Check
for
leakage

Handling

Check fan belt


for slip

Slipping
(Adjust)

Leak to
external

Leak to
internal

Repair

Repair or
replace

OK

Check thermostat

Malfunction
(Replace)

Check if oil used


is inferior quality,
or engine oil is
too much

OK

Care must
be taken
when
replenishing
(Replace)

OK
Engine
rotation
too high

Overloaded

Check cooling
system for stain,
and radiator for
clogging
Temperature
abnormally high
Stained or
clogged
(Clean)

OK

Improve
ventilation

WSLE0195

0A-18 General Information


Exhaust fault

W0A0001001305

Abnormal exhaust gas

Check if fuel used is of


inferior quality

Change fuel

OK

Check if engine oil is too


much

White smoke too much

Black smoke too much

Check fuel for water


mixing

Check nozzle

Water mixed
(Change fuel)

OK

Defective (Repair
or replace)

Check for the stuck EGR


valve (opened position) (*)

Air cleaner clogged

OK

Check injection timing

Replace air
cleaner
element

OK

Check air hose for crash

Check injection timing


Advanced too much

Delayed
(Adjust)

OK

OK

Replace the EGR


cut solenoid and
valve case by
the set

OK

(*) Refer to "EGR Control"


in the Exhaust System
section.

(Adjust)

Check injection pump


Check compression ratio

Low

Excessive
blow-by gas
(Overhaul)

Gas leak from


valve and
gasket (Repair
or replace)

OK

Check up and
down
movement of oil

Stuck (Overhaul)

Defective injection pump


(Bring it to a specialty
shop for repair)

OK

1. Disordered valve timing


2. Broken piston ring or
misassembly
3. Worn camshaft
4. Worn valve or insert
(Overhaul)

WSLE0196

General Information 0A-19


Battery over discharge

W0A0001001306

Over-discharge of battery
Battery

Wiring

Regulator and generator

Check electrolyte level

Check terminals for warp,


deformation or corrosion

Check belt for slip or damage

Low

OK
Poor contact
(Repair or replace)

Battery
Natural
case
consumpt
cracked
ion
(Replace) (Replenish)

Over
charge

Note: Improper maintenance

Check for broken wire


(Repair or replace)

OK

Slipping or
damaged (Repair
or replace)

OK

Test charging condition

Abnormal

OK

Bring it to a battery shop


Check specific gravity
Low

Recharge

Recharging
impossible

Bring it to a battery specialty shop


WSLE0197

0A-20 General Information


Oil pressure is too low W0A0001001307

Fuel consumption deteriorates

W0A0001001308

Oil pressure too low

Fuel consumption too much

Check oil level

Check for fuel leakage

Low (Replenish)

OK

Leaking (Retighten,
replace packing seal)

OK

Check cooling water temperature


Check nozzle
High
(See "Overheat")

OK
Defective
(Repair or replace)

OK

Check oil in crankcase


Check injection timing
Improper
viscosity

OK
Abnormal (Adjust)

Water or fuel mixed. Check fuel


system and cooling system

Check compression ratio

Check relief valve

Defective
(Repair or replace)

1.
2.
3.
4.

OK

Low
OK

OK

Defective injection pump


(Bring it to a specialty
shop for repair)

Oil pump malfunction


Loosened or cracked pipe
Wear of sliding part
Oil pump clogged
(Overhaul)

Excessive
blow-by gas

WSLE0198

Gas leak from


valve and gasket
(Repair or
replace)

WSLE0199

General Information 0A-21


Oil consumption deteriorates W0A0001001309

Oil consumption too much


Check for oil leakage

Leaking (Retighten,
replace packing seal)

OK

Check oil quality

Poor quality
(Change to specified oil)

OK

Check bleeder for clogging

Clogged (Clean)

OK

Check up and down movement of oil

1.
2.
3.
4.
5.

Oil pump malfunction


Loosened or cracked pipe
Wear of sliding part (*)
Oil pump clogged
Defective valve stem seal
(Overhaul)

(*) Worn bore,and worn or broken


ring (Measure compression
pressure, and check entrance of
dust)

WSLE0200

0A-22 General Information


Engine knocking

W0A0001001310

Engine knocking
Mechanical system

Fuel system

Check up movement of oil

Check injection timing

Oil stained (Overhaul)

OK

Check compression pressure

Low

Abnormal (Adjust)

OK

Check nozzle

OK

Defective
(Repair or replace)

OK

To fuel system
Note: Fuel used is of poor quality.
Excessive
blow-by gas
(Overhaul)

Gas leak from


valve and gasket
(Repair or
replace)

WSLE0201

General Information 0A-23


Repair Standard W0A00010039
1. This table specifies the repair standard for 4LE2X model ISUZU diesel engine.
2. This repair standard consists of items to be checked, nominal dimension, assembly specifications, service limit,
and repairing procedure.
Nominal dimension is the standard value at the time of manufacture.
Assembly specification is the target value after repairing (at assembling). It may differ in some degree from
assembly dimension of the new engine.
Service limit is the limit value of wear, etc. which must not be exceeded. When it is reached, the part should
be repaired or replaced.
Repairing procedure indicates general methods to repair.
The unit for the numbers in the table are all millimeter {inch} if not otherwise specified.
3. If the whole engine is requested for repair, check the locations which need to be repaired first by the bench
test or something. Then perform the minimum overhaul. If a part of engine is requested for repair, perform
repairing based on this repair standard.
4. This repair standard may be changed in the value, specification, and others without notice due to design
change of the engine.

0A-24 General Information


Time to overhaul the engine W0A0001003901
Item to be checked

Compression pressure of the cylinder


(MPa {psi})

Standard
value

3.04 {441}

Service limit

Repairing procedure

2.5 {363}
Overhaul the engine.

Fuel consumption rate (L/h)

100 %

140 %

Lubricant consumption rate (L/h)

100 %

200 %

Standard
value

Service limit

Repairing procedure

85.2
{3.354}

Perform boring along the


oversize piston, then perform honing.

Cylinder block

Coolant temperature: 70
85C {158 185F}
Engine speed: approx.
250 rpm
Vary depending on altitude.

W0A0001003902

Item to be checked
Wear of the cylinder bore
Measurement position: 13 {0.512}
lower from the top surface of the cylinder block

85 {3.3465}

Distortion of upper surface of the cylinder block

0.075
{0.00295} or
less

Water pressure test (three minutes)


(kPa {psi})

490 {71}

Cylinder head

Remarks

0.15 {0.006}

Repair with
grinder.

Remarks

Maximum
amount
of
repaired value; 0.3 {0.012}
surface The total amount of
repaired values of the cylinder head and of the cylinder block.

Repair or replace the one


with water leakage.

W0A0001003903

Item to be checked

Valve seat depression

Standard
value

Service limit

IN

0.7 {0.028}

1.2 {0.047}

EX

0.9 {0.035}

1.5 {0.059}

2.0 {0.079}

2.5 {0.098}

Repair with the valve seat Wrap the contact surface


cutter.
sufficiently after repair.

0.15 {0.006}

Repair with
grinder.

Maximum
amount
of
repaired value; 0.3 {0.012}
surface The total amount of
repaired values of the cylinder block and of the cylinder head.

0.2 {0.008}

Repair

Contact width of the valve seat

Distortion (flatness) of the under surface (installation surface) of the cylinder head

0.075
{0.00295} or
less

Distortion of exhaust manifold instal- 0.05 {0.002} or


lation surface
less
Water pressure test (three minutes)
(kPa {psi})

490 {71}

Repairing procedure

Remarks

Replace the valve and


Valve seat angle is 45
insert.

Repair or replace the one


with water leakage.

General Information 0A-25


Item to be checked

Tightening torque of M12 1.5


the cylinder head bolt:
(Nm {kgfm/lbft})
(Angle method)
M8 1.25

Standard
value

Service limit

83.4 93.2
{8.5 9.5/
61.5 68.7}

60 90

Repairing procedure

Remarks

- Clean the seating surface and thread of the


bolt.
- Apply engine oil to the
seating
surface
and
thread of the bolt.
- Never retighten after
angle method tightening.

24.5 34.3
{2.5 3.5/
18.1 25.3}

Piston W0A0001003904
Item to be checked

Standard
value

Service limit

Repairing procedure

Remarks

Clearance with the cylinder


0.040 0.085
Grade position from the top surface:
{0.0016
54.85 {2.159}
0.0033}
Clearance between piston pins and
piston pin holes

0.004 0.017
{0.00016
0.0007}
27 {1.063}

Wear of the pin

Piston ring end gap

Top ring

0.20 0.35
{0.008
0.014}

Second
ring

0.35 0.50
{0.014
0.020}

Oil ring

0.20 0.40
{0.008
0.016}

If significant knocking
sound occurs, replace the
piston pin or the piston.
26.970
{1.0618}

1.5 {0.059}

Replace piston ring. When


overhauling the engine,
replace the piston ring.

1.0 {0.039}

Piston W0A0001003905
Item to be checked

Standard
value

Top ring

0.085 0.105
{0.0033
0.0041}

Clearance
between
Second
the piston ring groove
ring
and the ring

0.050 0.085
{0.0020
0.0033}

Oil ring

0.030 0.070
{0.00120
0.00276}

Service limit

Remarks

0.2 {0.008}

When assembling the ring to


the piston, be sure to
assemble with the mark of
Replace the ring or the the ring facing upward.
0.15 {0.006}
piston.
Inverse assembly makes oil
consumption deteriorate.
The oil ring is independent
of top or bottom.
0.15 {0.006}

The ring end direction

Connecting rod

Repairing procedure

180 alternate

W0A0001003906

Item to be checked
Play of the small end and the piston
boss between front and back direction (one side)

Standard
value
1.0 {0.039}

Service limit

Repairing procedure

Remarks

Reference value

0A-26 General Information


Item to be checked

Standard
value

Service limit

Extrusion
Tension of the connecting rod bear- 0.055 0.085
ing
{0.00217

0.00330}
Clearance between the connecting
rod bearing and crank pin

0.026 0.067
{0.0010
0.0026}

Repairing procedure
Use the one with extrusion
and tension, and be careful about sticking of rear
side.

0.1 {0.0039} Replace the bearing.

Clearance between the small end


bushing and the piston pin

0.008 0.020
{0.00031
0.00080}

0.05 {0.002}

Axial play of the connecting rod and


the crank pin

0.20 0.33
{0.008
0.013}

0.35 {0.014}

Center distance between the big end


and small end

133.5 {5.256}

Clearance should be wide


Replace the bushing or
enough to turn smoothly
the pin.
with its big end held.

Reference value

Torsion of holes on the big end and


0.05 {0.002} or
small end (L = per 100 mm {3.937
less
in})

0.2 {0.008}

Parallelism of holes on the big end


0.05 {0.002} or
and small end (L = per 100 mm
less
{3.937 in})

0.15 {0.006} Repair or replace.

Crankshaft

Be careful with the precision of the crank pin.

Replace the one with


defective contact or abrasion.

Contact surface of the connecting


rod bearing and crank pin

Tightening torque of the bearing cap


bolt (Nm {kgfm/lbft})

Remarks

Repair or replace.

Apply engine oil to the


thread of the bolt and the
seating surface of the nut,
and tighten.

23 26 {2.3
2.7/17.0
19.2} 100
115

W0A0001003907

Item to be checked

Standard
value

Uneven wear of the journal and the


pin

Service limit

Repairing procedure

Remarks

0.05 {0.002} Replace the crankshaft.

Wear of the journal

60 {2.362}

Wear of the pin

46 {1.811}

0.14
{0.0055}

Replace the crankshaft.

0.13 {0.005} Replace the crankshaft.

0.007
{0.00028} for
Finishing precision of the journal and
both
ellipse
the pin (taper and ellipse)
and taper

Tension of the journal bearing

Extrusion
0.02 0.06
{0.0008

0.00236}

Use the one with extrusion


and tension, and be careful about sticking of rear
side.

Clearance between the journal and


the bearing

0.029 0.072
{0.0011
0.0028}

0.11
{0.0043}

Axial play of the crankshaft

0.058 0.208
{0.0023
0.0082}

0.3 {0.012}

Replace the bearing.


Measure at the front of the
Replace the thrust bearthrust in No.2 journal poring.
tion of the crankshaft.

General Information 0A-27


Item to be checked

Standard
value
0.025
{0.00098} or
less

Crankshaft runout

Service limit

Repairing procedure

Remarks

0.05 {0.002} Replace.

Ring gear

Chamfer the warped ones


and replace the remarkably damaged ones.

0.20
Balance of the crankshaft (Ncm
{20/ 0.2778} or
{gfcm/onin})
less

Check the dynamic bal- (Reference value) At both


ance.
ends of the journal

Tightening torque of the crank bearing cap bolt (Nm {kgfm/lbft})

Apply engine oil to the


thread and the seating
surface of the bolt, and
tighten.

83.4 93.2
{8.5 9.5/
61.5 68.7}

Be careful with the oil seal


Replace the oil seal when
collapsed. (Apply oil suffithere is oil leakage.
ciently before assembly.)

Wear of the oil seal in the crankshaft


rear part

Camshaft

Be sure that there is no


scratch or foreign object
pinched on the bearing
cap match surface.

W0A0001003908

Item to be checked

Standard
value

Uneven wear of the center journal


Wear of the center journal

Repairing procedure

0.05 {0.002}

Repair or replace the camshaft.

51.92
{2.044}

Remarks

Replace the camshaft.

0.02 {0.0008}
or less

0.1 {0.0039} Replace the camshaft.

Inlet

6.13 {0.241}

5.83 {0.230}

Exhaust

6.43 {0.253}

6.13 {0.241}

Standard
value

Service limit

0.04 {0.0016}

0.2 {0.008}

Camshaft runout
Height of the cam

52 {2.047}

Service limit

Replace the camshaft.

Repair light stepped wear


of the cam.

Timing gear W0A0001003909


Item to be checked
Crank gear/Idle
Backlash of the gear
timing gear
Idle gear/Camshaft gear

Replace the gear.


0.03 {0.0012}

Clearance between the crank gear


and the crankshaft

0.004
+0.050
{0.00016
+0.0020}

Clearance between the camshaft


gear and camshaft

0 0.042
{0 0.0017}

Clearance between the idle gear


bushing and shaft

0.025 0.085
{0.00098
0.00330}

Uneven wear of the idle gear shaft


Play between front and back direction of the idle gear

Repairing procedure

0.2 {0.008}

0.2 {0.008}

Replace the idle gear or


the shaft.

0.1 {0.0039} Replace the gear shaft.


0.058 0.115
{0.0023
0.0045}

0.2 {0.008}

Replace the thrust collar.

Remarks

0A-28 General Information


Valve

W0A0001003910

Item to be checked

Standard
value

Service limit

Wear of the inlet valve stem

7 {0.276}

6.85
{0.270}

7 {0.276}

6.80
{0.268}

0.023 0.056
{0.0009
0.0022}

0.2 {0.008}

Wear of the exhaust valve stem


Clearance between the inlet valve
stem and valve guide

0.030 0.063
Clearance between the exhaust
{0.0012
valve stem and valve guide
0.0025}

0.25
{0.0098}

Repairing procedure

Replace the valve.

1 {0.039}

0.7 {0.028}

EX

0.8 {0.031}

0.5 {0.020}

9.5 {0.374}

Lip of the valve stem oil seal

6.5 {0.256}

Valve spring

Apply oil to the valve


guide and press-fit.

IN

Height of the valve guide from the


cylinder head

Tension (N {lb})
(When compressed
to installing length
29.9 mm {1.177 in})

6.8 {0.268} Replace oil seal

147 {33}

Free height

42.1 {1.657}

40.0 {1.575}

Squareness

1.8 {0.071} or
less

2.5 {0.098}

0.40 {0.016}

0.35 0.45
{0.014
0.018}

Wear of the rocker arm shaft

Be careful not to damage


the lip.

Replace the valve spring.

Adjust.
Repair light stepped wear
Replace if there is excesand damage with the oil
sive wear or damage.
stone.

Contact surface of the valve stem


end and the rocker arm
Clearance between the rocker arm
and the rocker arm shaft

Replace the valve.


Reference value

167 {38}

Valve clearance; inlet and exhaust


(at cold condition):

If the valve should be


replaced due to wear of
the valve seat, also
replace the valve guide.

Replace the valve or valve


guide.

Interference of the valve guide and


0.023 {0.0009}
cylinder head
Thickness of
valve

Remarks

0.005 0.045
{0.0002
0.0018}

0.2 {0.008}

12 {0.472}

11.85
{0.467}

Replace.

0.3 {0.012}
or less

Replace.

Bend of the push rod

Replace the rocker arm or


the shaft.

Tappet W0A0001003911
Item to be checked

Standard
value

Clearance between the tappet and


the cylinder block

0.020 0.054
{0.0008
0.0021}

Wear of the tappet

20.97
20.98 {0.8256
0.8260}

Service limit

Repairing procedure

0.1 {0.0039} Replace the tappet.

20.92
{0.824}

Replace the tappet.

Remarks

General Information 0A-29


Item to be checked

Standard
value

Service limit

Contact surface of the tappet and the


cam

Air cleaner

Repairing procedure

Remarks

Replace if there is exces- Repair light damage with


sive wear or deformation. the oil stone.

W0A0001003912

Item to be checked

Standard
value

Service limit

Repairing procedure

Machine
manufacturer
arrangement parts

Condition of the air cleaner element

Water pump

Remarks

W0A0001003913

Item to be checked

Standard
value

Play of the water pump ball bearing


(radius direction)

0.008 0.010
{0.00031
0.00040}

Discharge amount (L/min)


(pump speed 2,800 rpm
Coolant temperature is normal.
Maximum lift 0.035 MPa {3.5 mAq})

76

Deflection of the fan belt

0.2 {0.008}

With two belts:


approx. 7.5
8.5 {0.295
0.335}
With one belt:
approx. 5.5
6.0 {0.217
0.236}

Thermostat working start temperature (at barometric pressure)

82C {180F}

Thermostat full-open temperature (at


barometric pressure)

95C {203F}

Fuel feed pump

Service limit

Remarks

Replace.

Adjust.

(Reference) 98 N {22 lb}

Replace the thermostat if


its working is incomplete.
The temperature when
thermostat lift amount is
9.5 mm {0.374 in} or more

W0A0001003914

Standard
value

Service limit

Discharge amount (L/min)


At 11.8 kPa {1.7 psi}

0.8 or more

0.3

Airtight (98.1 kPa {14.2 psi})

Be sure that
there is no
leakage.

Item to be checked

Injection pump

Repairing procedure

Repairing procedure

Remarks

Repair or replace.
Repair or replace when
there is leakage.

W0A0001003916

Adjustment conditions
Pump part number
Revolution direction
Nozzle

89-7229-3680
Clockwise (viewed from drive-end)
105780-0060
NP-DNOSD1510

Remarks

0A-30 General Information


Pump part number

89-7229-3680

Nozzle holder ASM

Remarks

105780-2150 (BOSCH minimus)

Nozzle opening pressure (MPa {psi})

13.0 {1885}

Oil feed pressure (MPa {psi})

0.05 {7.3}

Pipe
Outside diameter inside diameter
length (mm {in})

6 {0.236} 2 {0.079} 450 {17.717}

Inspecting oil

JIS No.2 diesel fuel

Oil temperature C {F}

35 40 {95 104}

Injection amount adjustment


Adjustment point

Rack position
(mm)

Pump
speed (rpm)

Average injection amount


(mm3/stroke)

a = 8.2 {0.323}

1,300

12.0 0.3

Standard

a + 1.0 {0.039}

400

*(10)

Standard

Service limit

Repairing procedure

Remarks

* ( ) for reference value

Generator (24V30A Mitsubishi Electric)


W0A0001003917

Item to be checked

Standard
value

Shaft bend

Replace the rotor.

Play of bearing

Replace the bearing.

Outside diameter of the slip ring

Replace the rotor.

Slip ring surface dirty

Repair with a sand paper


or the like if there is dirt or
damage.
Brush
length
(amount of
extrusion)

Brush
spring

and

Remarks

Turn it by hand and check


that it rotates smoothly
and has no noise or play.

Repair when the following


occurs: the spring contact
surface of the brush is
incomplete, the brush
spring pressure is not
even or not appropriate,
the brush is excessively
worn or chipping, supporting degree of the brush
holder is not appropriate.

brush
Tension
N {lb}

Output current (V rpm)


Regulated voltage by regulator (V)

Replace the regulator.

Generator (24V50A Nikko Electric)


Item to be checked

Wear of the shaft (front)

W0A0001003918

Standard
value
24.996
25.005
{0.9841
0.9844}

Service limit

24.95
{0.982}

Repairing procedure

Replace the rotor.

Remarks

General Information 0A-31


Item to be checked

Standard
value
16.996
17.012
{0.6691
0.6698}

Wear of the shaft (rear)

Service limit

16.95
{0.667}

Play of bearing

Repairing procedure

Replace the rotor.

Replace the bearing.

Output current (27V 5000rpm)

50 A or more

Regulated voltage by regulator (V)

27.5 29.5

Remarks

Turn it by hand and check


that it rotates smoothly
and has no noise or play.

50 A or less
Replace the regulator.

Starter (24V3.2kW Mitsubishi Electric)


W0A0001003919

Item to be checked

Standard
value

Service limit

Wear of the outside diameter of commutator

32 {1.26}

31.4 {1.236} Replace.

Uneven wear of the outside diameter


of commutator

0.1 {0.0039}
or more

Replace.

Depth of mica between commutator


segments

0.5 0.8
{0.020
0.031}

0.2 {0.008}
or less

Repair or replace.

17.5 {0.689}

11 {0.433}

Replace.

Brush length

0.5
{0.020
0.079}

Pinion (gap)

Clutch action

Restraint test
Load
8 V/760 A or less

Preheating device

3,750 r/min or
more

3,750 r/min
or less

Repair or replace.

Torque

12.94 Nm {1.3
kgfm}

12.94 Nm
{1.3 kgfm
or less

Repair or replace.

Revolution
speed

1,550 r/min or
more

1,550 r/min
or less

Repair or replace.

Torque

47.07 Nm {4.8
kgfm} or more

47.07 Nm
{4.8 kgfm}
or less

Repair or replace.

Rotates smoothly when


the pinion is turned to the
drive direction, and locks
when turned to the inverse
direction.

W0A0001003921

Item to be checked

Glow plug

Remarks

2.0 2.0 {0.079} Repair or replace if there


or more
is excessive wear or chipping.

No load test
Revolution speed (23 V/80 A or less)

Load test
18.6 V/250 A or less

Repairing procedure

Standard
value

Service limit

Repairing procedure
Replace when there is an
open circuit or a short circuit.

Remarks

0A-32 General Information


Oil pressure

W0A0001003922

Item to be checked
Lubrication oil pressure kPa {psi}
(at 2,000 rpm)

Oil pump and relief valve

Standard
value

Service limit

441 490
{64 71}

200 {29}

Repairing procedure

Remarks

Repairing procedure

Remarks

W0A0001003923

Item to be checked

Standard
value

Clearance between the pump body


and outer circle of the outer rotor

0.100 0.185
{0.0039
0.0073}

Discharge amount (L/min)


(engine speed 2,700 rpm SAE#30
discharge pressure 392 kPa {57 psi}
oil temperature 50C {122F})

26.8

Axial clearance between the pump


cover and the rotor

Service limit

0.4 {0.016}

Replace the
rotor, or body.

0.040 0.085
{0.0016
0.0033}

0.15 {0.006}

Replace the rotor or the


cover.

Tip clearance between the inner rotor


and the outer rotor

0.17 {0.0067}
or less

0.2 {0.008}

Replace the rotor.

Clearance between the drive shaft


and the pump cover

0.032 0.077
{0.0013
0.0030}

0.15 {0.006}

22 {0.866}

21.9
{0.862}

Diameter of the drive shaft


Relief valve starting
Oil pump
pressure kPa {psi}

Complete inspection

bushing,

Replace the shaft.

392 490 {57


71}

W0A0001003924

Item to be checked

Standard
value

Service limit

3.04 {441}

Difference between the compression 5 % or less to


pressure of the cylinders
the average
(approx. 250 rpm)
value
Lubrication oil pressure (kPa {psi})
(2,200 rpm)

Remarks

Perform for 30 minutes or


more

Grinding drive of the engine


Compression pressure of the cylinder
(MPa {psi})
(approx. 250 rpm)

Repairing procedure

2.5 {363}

Repair.

Coolant temperature: 70
85C {158 185F}

Repair.

Coolant temperature: 70
85C {158 185F}

441 490 {64


71}

Output inspection

90 % or more

Fuel consumption inspection

110 % or less

Assume that the actual


performance of the new
engine is 100 %.

4LE2 Engine Mechanical 1A-1

Engine
4LE2 Engine Mechanical
Table of Contents
ISUZU Diesel Engine W1A0002 ........................... 1A-2
Service Precautions W1A00020001 .................. 1A-2
How to Read the Model W1A00020029............. 1A-3
Explanations
on
Functions
and
Operation
W1A00020027 ................................................... 1A-3
Function Check W1A00020012 ......................... 1A-4
Specifications W1A00020004 .......................... 1A-11
Engine Accessories W1A0003............................ 1A-12
Components W1A00030005 ............................ 1A-12
Removal W1A00030006 .................................. 1A-13
Installation W1A00030007 ............................... 1A-14
Torque Specifications W1A00030008.............. 1A-16
Engine Exterior Equipment W1A0004................. 1A-17
Components W1A00040005 ............................ 1A-17
Removal W1A00040006 .................................. 1A-19
Installation W1A00040007 ............................... 1A-25
Torque Specifications W1A00040008.............. 1A-34
Rocker Arm Shaft W1A0075 ............................... 1A-35
Components W1A00750005 ............................ 1A-35
Removal W1A00750006 .................................. 1A-35
Disassembly W1A00750010 ............................ 1A-36
Inspection W1A00750009 ................................ 1A-36
Reassembly W1A00750011............................. 1A-38
Installation W1A00750007 ............................... 1A-38
Torque Specifications W1A00750008.............. 1A-40
Cylinder Head W1A0014..................................... 1A-41
Components W1A00140005 ............................ 1A-41
Removal W1A00140006 .................................. 1A-41
Disassembly W1A00140010 ............................ 1A-42
Inspection W1A00140009 ................................ 1A-43
Reassembly W1A00140011............................. 1A-47
Installation W1A00140007 ............................... 1A-50
Torque Specifications W1A00140008.............. 1A-51
Piston, Connecting Rod W1A0015...................... 1A-52
Components W1A00150005 ............................ 1A-52
Removal W1A00150006 .................................. 1A-52
Disassembly W1A00150010 ............................ 1A-54
Inspection W1A00150009 ................................ 1A-54
Reassembly W1A00150011............................. 1A-58
Installation W1A00150007 ............................... 1A-60
Torque Specifications W1A00150008.............. 1A-62
Flywheel W1A0016 ............................................. 1A-63
Components W1A00160005 ............................ 1A-63
Removal W1A00160006 .................................. 1A-63
Installation W1A00160007 ............................... 1A-64
Torque Specifications W1A00160008.............. 1A-65
Crankshaft Front Oil Seal W1A0022 ................... 1A-66
Components W1A00220005 ............................ 1A-66
Removal W1A00220006 .................................. 1A-66
Inspection W1A00220009 ................................ 1A-67
Installation W1A00220007 ............................... 1A-68
Torque Specifications W1A00220008.............. 1A-69

Crankshaft Rear Oil Seal W1A0023....................1A-70


Components W1A00230005 ............................1A-70
Removal W1A00230006 ..................................1A-70
Installation W1A00230007 ...............................1A-71
Torque Specifications W1A00230008..............1A-72
Timing Gear Train W1A0010 ..............................1A-73
Components W1A00100005 ............................1A-73
Removal W1A00100006 ..................................1A-73
Inspection W1A00100009 ................................1A-74
Installation W1A00100007 ...............................1A-75
Torque Specifications W1A00100008..............1A-77
Camshaft W1A0012 ............................................1A-78
Components W1A00120005 ............................1A-78
Removal W1A00120006 ..................................1A-78
Inspection W1A00120009 ................................1A-79
Installation W1A00120007 ...............................1A-81
Torque Specifications W1A00120008..............1A-82
Crankshaft W1A0024 .......................................... 1A-83
Components W1A00240005 ............................1A-83
Removal W1A00240006 ..................................1A-83
Disassembly W1A00240010 ............................1A-84
Inspection W1A00240009 ................................1A-84
Reassembly W1A00240011............................. 1A-86
Installation W1A00240007 ...............................1A-87
Torque Specifications W1A00240008..............1A-89
Cylinder Block W1A0025 ....................................1A-90
Components W1A00250005 ............................1A-90
Removal W1A00250006 ..................................1A-90
Inspection W1A00250009 ................................1A-90
Installation W1A00250007 ...............................1A-92
Special Tool W1A0072........................................1A-93
List of Special Tool W1A00720028 ..................1A-93

1A-2 4LE2 Engine Mechanical

ISUZU Diesel Engine

W1A0002

Service Precautions W1A00020001

Service precautions specific to this engine

Service precautions about maintenance

W1A0002000102

W1A0002000101

To prevent damage to the engine and ensure reliability


of its performance, pay attention to the following in
maintaining the engine:
When taking down the engine on the ground, do
not make the bearing surface of the oil pan touch
directly the ground. Use a wood frame, for example, to support the engine with the engine foot and
the flywheel housing.
Because there is only a small clearance between
the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer.
When the air duct or air cleaner is removed, cover
the air intake port to prevent foreign matter from
getting into the cylinder. If foreign matter gets in, it
can considerably damage the cylinder and others
while the engine is operating.
When maintaining the engine, never fail to remove
the battery ground cable. Otherwise, this may
damage the wire harness or electrical parts. If you
need electricity on for the purpose of inspection,
for instance, watch out for short circuits and others.
Apply engine oil to the sliding contact surfaces of
the engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in
order and keep them.
When installing them, put them back to the same
location as they were removed.
Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust may be
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes have elapsed, remove the
existing liquid gasket and apply new liquid gasket.
When assembling or installing parts, fasten them
with the specified tightening torque so that they
may be installed properly.

Holes or clearances in the fuel system, which serve as


a passage of fuel, including the inside of the nozzle
holder, are made with extreme precision. They are
therefore highly sensitive to foreign matter and the
entry of foreign matter could cause serious damage.
Take extreme care not to allow foreign matter to enter.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
Before beginning the service procedure, wash the
fuel line and the surrounding area.
Perform the service procedures with clean hands.
Do not wear work gloves.
Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
If parts are to be replaced (fuel hose, fuel pipe,
etc.), do not open the new part packaging until
installation.

Work procedure

W1A0002000103

The fuel opening must be quickly sealed when


removing the fuel pipe, injection pipe, nozzle
holder, and injection pump.
The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage after
starting the engine.

4LE2 Engine Mechanical 1A-3


How to Read the Model W1A00020029

WSLE0353

Name
1. Stamped Engine Number

Explanations on Functions and Operation

Cylinder head

W1A00020027

The cylinder head is cast-iron and there are two valves


per cylinder. The angular tightening method of the cylinder head bolt further increases reliability and durability.

Cylinder block W1A0002002702


The cylinder block is cast-iron with the center distance
of each bore being equal and is of the highly rigid, symmetrical structure with the crankshaft center being the
center.

Piston W1A0002002704
The piston is aluminum-alloy and an autothermatic piston with a strut cast, while the combustion chamber is a
round reentrant type.

Crankshaft

W1A0002002705

W1A0002002706

The crankshaft which is stamped N on the front end


surface is made of tufftride.

EGR system W1A0002002707


Based on coolant temperature and engine speed, it is
controlled by EGR cut controller to purify exhaust by
recycling part of it.

1A-4 4LE2 Engine Mechanical


Its main components include an EGR cut solenoid, an
EGR cooler and various sensors.

Connecting rod cap bolt

W1A0002002708

Do not pull out the connecting rod cap bolt from the
connecting rod except when you need to replace it.

Nozzle holder W1A0002002710


Multi-hole type nozzle is used for the nozzle holder.

Sedimenter

2. Remove the cylinder head cover and check


whether the No.1 cylinder is in the compression
top dead center position or in the exhaust top dead
center position.
The cylinder is in the compression top dead center
position if both intake and exhaust valves are
closed. The cylinder is in the exhaust top dead
center position if both intake and exhaust valves
are open.

W1A0002002711

Sedimenter gets rid of water by making use of the difference in specific gravity between diesel oil and water.

Preheating system W1A0002002712


The preheating system consists of the glow plug timer,
the glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Lubrication system

2
W1A0002002713

It is an oil filter with full-flow bypass, which uses a


water-cooled oil cooler and oil jet to cool the piston.

Function Check W1A00020012

WSLE0022

Inspection/adjustment of valve clearance


W1A0002001201

To do this work, use the thickness gauge when the


engine is cold.
1. Rotate the crankshaft over 360 degrees into a
proper direction (clockwise), and set the mark
groove of the crank pulley to the TDC mark (cast)
of the timing gear case cover.

Name
1. Intake of No.1 Cylinder
2. Exhaust of No.1 Cylinder
3. Measure the clearance of the valve with mark or
mark in the table, depending on the status of the
No.1 cylinder. If the clearance is not the standard
value, adjust it to the standard value using the
adjusting screw.
CAUTION:
To measure the clearance, use the thickness gauge
when the engine is cold.

Valve clearance standard


value
Inlet valve
Exhaust valve

WSLE0021

Name
1. TDC Mark
2. Mark Groove

mm {in}
0.40 0.05 {0.016 0.002}
(at cold condition)

4LE2 Engine Mechanical 1A-5

2
2

WSLE0020

Name
1. Adjusting Screw
2. Lock Nut
4. Rotate the crankshaft again into a proper direction,
and set the mark in the same way as 1. after 3. is
completed. Then measure and adjust the clearances of the remaining valves.
CAUTION:
Rocker arm is die-cast aluminum. So do not
over-tighten the rocker arm when tightening the
adjusting screw.
The load of the used valve spring is low. So do
not push down the spring when measuring or
adjusting the clearance.
Adjustment table
Cylinder No.
Valve arrangement
No.1 cylinder
compression
top dead center
position
No.1 cylinder
exhaust
top
dead
center
position

IN

EX

IN

3
EX

IN

4
EX

IN

EX

WSLE0026

Name
1. Delivery Valve Holder
2. Delivery Spring
3. Delivery Valve
4. Injection Pump
3. Install the delivery valve holder and tighten it, leaving the delivery valve and spring removed.
Tightening torque:
39.2 44.1 Nm {4.0 4.5 kgfm/28.9 32.5
lbft}
4. Turn the starter switch to the drive position with the
lever of the sedimenter in the open position. Then
rotate the crankshaft slowly feeding fuel by the
electromagnetic pump, the gap with the fuel tank,
the feed pump lever, etc. And when the fuel stops
flowing from the delivery holder and bulging at the
dent on top, stop the crankshaft rotating.
Note:
Take extreme care to rotate the crankshaft as slowly as
possible and not to miss the position where the fuel
stops bulging.
5. Check the degree in the timing mark on the timing
gear case where the mark groove of the crank pulley is positioned in above 4. status.
Adjust if the value is out of the standard value of
the injection timing.
* Injection timing

BTDC 2

Inspection and adjustment of injection timing


W1A0002001202

1. Remove the No.1 cylinder injection pipe.


2. Then remove the delivery valve holder of the No.1
cylinder injection pump, and pull out the delivery
valve and the delivery spring.

Note:
Injection timing varies depending on the machine specification.

1A-6 4LE2 Engine Mechanical

1
2
3
5

WSLE0027

WSLE0021

Name
1. TDC Mark
2. Mark Groove
6. Adjust injection timing by the shim between the
injection pump and the cylinder block.
The following nine types of identifying symbols are
stamped (or sealed) on the shim.
The identifying symbols and thickness
of the shim

mm {in}

Symbol

Thickness

Symbol

Thickness

Symbol

Thickness

0.2
{0.008}

0.5
{0.020}

0.8
{0.031}

0.3
{0.012}

0.6
{0.024}

10

1.0
{0.039}

0.4
{0.016}

0.7
{0.028}

12

1.2
{0.047}

CAUTION:
Adjust the shims for each injection pump of four
cylinders at the same time.
Note:
If the shim is thickened by 0.1 mm {0.0039 in}, the
injection timing is delayed for approx. 0.6 degree, and if
thinned by 0.1 mm {0.0039 in}, put forward for approx.
0.6 degree.

Name
1. Injection Pump
2. Cylinder Block
3. Shim
4. Knock Hole
5. Identifying Symbol
7. Assemble removed delivery valve to the injection
pump after cleaning, and tighten the delivery
holder to the specified torque.
Tightening torque:
39.2 44.1 Nm {4.0 4.5 kgfm/28.9 32.5
lbft}
CAUTION:
Be careful with dirt getting inside when removing
and installing the delivery valve or spring.
8. Install the injection pipe to the injection pump and
the nozzle holder, and tighten it with the sleeve
nut.
a. Screw the thread portion of the sleeve nut two
or three turns by your hand.
b. Hold the delivery valve holder of the injection
pump with a wrench and tighten the sleeve nut
securely.
Tightening torque:
14.7 24.5 Nm {1.5 2.5 kgfm/10.8 18.1
lbft}
Important:
If over-tightening the delivery valve holder, the rack
cannot move smoothly as the plunger and the
housing are compressed. Therefore, when tightening the sleeve nuts of the injection pipe, hold the
delivery valve holder with a wrench to prevent
corotation.

4LE2 Engine Mechanical 1A-7

1
1
2

WSLE0159

Name
1. Compression Gauge
2. Adapter

Name
1. Injection Pipe
2. Nozzle Holder
3. Injection Pump

Inspection of compression pressure

WSLE0029

W1A0002001203

1. Warm-up the engine.


2. Disconnect the battery cable from the negative terminal and remove all the glow plugs.
3. Disconnect the wire connector of the solenoid for
engine stopping.
4. Install the battery cable to the negative terminal.
5. Install an adapter and a gauge of a compression
gauge (special tool).
Special tool
Compression gauge (with adapter)
5-8840-2675-0
Adapter
5-8840-9029-0

6. Turn the starter until the indicator of compression


gauge becomes stable and measure the compression pressure.
Compression pressure (250 rpm)

MPa {psi}

Standard value

Service limit

Difference between cylinders

3.04 {441}

2.5 {363}

5 % or less to the
average value

Perform the measurement described above for all


cylinders. If the compression pressure is the service limit or less, overhaul the engine.
CAUTION:
Be sure to measure for all cylinders.

1A-8 4LE2 Engine Mechanical


Be sure to use the full-charged battery to maintain the engine speed of 250 rpm or more.

Injection nozzle

W1A0002001204

Use the nozzle tester to check the injecting condition.


WARNING:
Do not put hands close to the nozzle hole area
when checking.
Diesel oil may permeate to your body and cause
blood poisoning due to high pressure injection.

Note:
Do not overhaul the engine as a two-step valve
pressure nozzle is adapted to this engine.
If a overhaul of the nozzle and inspection and
adjustment of the injection pressure are required,
contact a BOSCH service center.

Bleeding air from fuel system

W1A0002001205

In case of automatic air bleed system


Turn the starter switch to the drive position. The electromagnetic pump operates, the fuel is pressure-fed to
the fuel pipe and the leak-off pipe, and the air in the fuel
system is automatically bled out.
In case of other than automatic air bleed system
Bleed air from the fuel pipe eyebolt of the No.1 cylinder
injection pump, the leak-off pipe eyebolt of the injection
nozzle, and the air bleed plug of the fuel filter in the
order from the part installed to lower portion, feeding
the fuel by the electromagnetic pump, the gap with the
fuel tank, the feed pump lever, etc.

WSLE0033

Injecting condition
Judge the nozzle condition by injecting condition.

WSLE0028

Name
1. Injection Pump

Electromagnetic pump inspection procedure


W1A0002001207

WSLE0032

Name
1. Good
2. Defective (fine or clogged)
3. Defective (dropping)

1. Turn the key switch to ON, and check for pulsation


in the fuel hose.
It is normal if pulsation exists.
2. Disconnect the electromagnetic pump connector,
and connect 24V power supply to the electromagnetic pump side to check if the pump operates.
If it operates properly, there may be open circuit, short circuit or poor contact in the
machine-side harness. Repair the faulty part,
and check again from Step 1.
If the electromagnetic pump does not operate,
replace the pump.

4LE2 Engine Mechanical 1A-9


Deflection
Standard
value

mm {in}
With two belts: approx. 7.5 8.5 {0.295
0.335}
With one belt: approx. 5.5 6.0 {0.217
0.236}

1
2

1
3

2
5
TSHK0106

Name
1. Electromagnetic Pump
2. + Terminal
3. - Terminal

3
4

3. Blow air into the inlet of the electromagnetic pump


with your mouth.
The internal seal may be stuck. Blow air to eliminate sticking.

WSLE0025

Name
1. Fan Pulley
2. Deflection
3. Generator Pulley
4. Crank Pulley
5. Fan Belt
Adjustment procedure
1. Loosen the adjusting plate which fixes the generator, and the mounting bolt of the generator.
2. Adjust the adjusting bolt to the standard value and
fix the generator at this position.
Be sure to tighten the mounting bolts which you
have loosened.

Note:
Recheck the tension of the belt after fixing the generator since the tension varies in some degree when the
generator gets fixed.
TSHK0107

Name
1. Fuel Inlet Port
2. Fuel Outlet Port
4. Install the removed parts, and check again from
Step 1.

Fan belt

W1A0002001206

Tension inspection
Push between the fan pulley and the generator pulley
with your finger (about 98 N {22 lb}). If the deflection is
out of the standard value, adjust the belt tension.

Tightening torque:
Upper part of the generator: 18.6 28.4 Nm {1.9
2.9 kgfm/13.7 20.9 lbft}
Lower part of the generator (24 V-30 A) : 18.6
28.4 Nm {1.9 2.9 kgfm/13.7 20.9 lbft}
Lower part of the generator (24 V-50 A) : 41.2
55.0 Nm {4.2 5.6 kgfm/30.4 40.6 lbft}
Adjusting plate: 18.6 28.4 Nm {1.9 2.9 kgfm/
13.7 20.9 lbft}

1A-10 4LE2 Engine Mechanical


1

Name
1. Nut
2. Adjusting Bolt
3. Mounting Bolt

WSLE0204

4LE2 Engine Mechanical 1A-11


Specifications W1A00020004
Engine name
Item
Engine structure type

4LE2X
4-cycle, water cooled-type, inline four-cylinder, OHV type

Cylinder number bore stroke (mm {in})


Total displacement (L {cuin})
Compression ratio

4 85{3.35} 96{3.78}
2.179 {133}
18.3:1

Combustion chamber type

Direct injection

Overall length front width overall height (mm


{in})
Dry weight (kg)

* 756.3{29.78} 557{21.93} 747.3{29.42}


* 210

Firing order

1342

Fuel injection timing (BTDC) (at stop)


Compression pressure (MPa {psi})
Intake
Valve clearance (at cold condition) air
(mm {in})
Exhaust
Intake
valve
Opening/closing period of
valve
Exhaust
valve

* 2
3.04 {441} / 250 rpm
0.40 {0.016}
0.40 {0.016}

Open (before top


dead center)

15

Closed (after bottom dead center)

29

Open (before bottom dead center)

40

Closed (after top


dead center)

16

Injection pump type


Governor type
Nozzle type
Injection pressure (MPa {psi})
Fuel type
Cooling method
Cooling fan
Coolant amount (L {qts})

Bosch type, PFR1KZ model, four


Centrifugal type, all speeds controlled
Multi-hole type (KBDL model)
* First step: 16.7 {2422}
Second step: 25.0 {3626}
Diesel (JIS K2204)
Forced circulation, water cooling pressurization type
* 500 8 pieces
Approx. 4.3 {4.5} (Engine only)

Lubrication oil amount: total (L {qts})

* Approx. 12.1 {12.8} at MAX, 9.3 {9.8} at MIN

Lubricant type (API service category)

CD or CF-4
* (CE, CF, CH-4, CI-4 or CI-4 Plus)

Generator output (V A)
Starter output (V kW)
Recommended battery (rating)

* 24 30 (Mitsubishi)
* 24 50 (Nikko)
* 24 3.2
95D31R 64 (five hour rating), the machine manufacturer arrangement

Caution: This specification may be changed partially without notice.


* mark may vary depending on each machine. Refer to the machine manufacturer specification.

1A-12 4LE2 Engine Mechanical

Engine Accessories

W1A0003

Components W1A00030005

7
1
4

3
2
6

9
8

10

WSLE0312

Name
1. Cooling Fan
2. Fan Clutch
3. Fan Clutch Set Plate
4. Spacer
5. Fan Pulley

6.
7.
8.
9.
10.

Fan Belt
Starter
Adjusting Plate
Generator
Generator Bracket

4LE2 Engine Mechanical 1A-13


Removal W1A00030006
1. Remove the cooling fan.
Remove the nuts and remove the cooling fan
from the fan clutch set plate. (With the fan
clutch)
Remove the nuts and remove the fan clutch
from the cooling fan. (With the fan clutch)
Remove the bolts and remove the fan clutch set
plate and the spacer. (With the fan clutch)

2
3

4
1

3
2

WSLE0345

Name
1. Cooling Fan
2. Spacer
3. Fan Belt

WSLE0208

Name
1. Cooling Fan
2. Fan Clutch
3. Fan Clutch Set Plate
4. Spacer
5. Fan Belt

2. Loosen the mounting bolts of the generator and of


the adjusting plate, loosen the belt tension, and
remove the fan belt.
3. Remove the mounting bolts of the fan pulley, and
remove the fan pulley from the water pump.
4. Remove the generator together with the adjusting
plate.

Remove the bolts, and remove the cooling fan


and the spacer. (Without the fan clutch)

WSLE0209

Name
1. Fan Pulley
2. Adjusting Plate
3. Generator
5. Remove the generator bracket.
6. Remove the starter.

1A-14 4LE2 Engine Mechanical


Installation W1A00030007
1. Install the starter to the flywheel housing and
tighten to the specified torque.
Tightening torque:
93.2 113 Nm {9.5 11.5 kgfm/68.7 83.3
lbft}

1
2

WSLE0166

Name
1. Water Pump
2. Adjusting Plate
3. Generator

WSLE0165

Name
1. Starter
2. Install the generator bracket.
Tightening torque:
M8 bolt: 18.6 28.4 Nm {1.9 2.9 kgfm/13.7
20.9 lbft}
M10 bolt: 41.2 55.0 Nm {4.2 5.6 kgfm/30.4
40.6 lbft}

4. Install the fan pulley to the water pump and tighten


two positions.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7 lbft}
5. Install the fan belt to each pulley.

3. Install the generator.


a. Temporarily install and tighten the adjusting
plate with the water pump.
b. Install the lower side of the generator to the
generator bracket and temporarily tighten the
bolts and nuts.
c. Install the mounting bolt to the upper part of the
generator through the adjusting plate. (Temporarily tighten)

WSLE0167

Name
1. Fan Pulley
2. Water Pump
3. Fan Belt
6. Adjust the tension of the fan belt.
Move the generator installation position outside,
adjust the belt deflection to the specified value,
and tighten the generator and the adjusting plate.

4LE2 Engine Mechanical 1A-15


mm {in}
Deflection (Push between
the pulleys by 98 N {22 lb})

With two belts: approx. 7.5


8.5 {0.295 0.335}
With one belt: approx. 5.5
6.5 {0.217 0.236}

Tightening torque:
Upper part of the generator: 18.6 28.4 Nm {1.9
2.9 kgfm/13.7 20.9 lbft}
Lower part of the generator (24 V-30 A) : 18.6
28.4 Nm {1.9 2.9 kgfm/13.7 20.9 lbft}
Lower part of the generator (24 V-50 A) : 41.2
55.0 Nm {4.2 5.6 kgfm/30.4 40.6 lbft}
Adjusting plate: 18.6 28.4 Nm {1.9 2.9 kgfm/
13.7 20.9 lbft}

4
3
2
1

WSLE0169

Name
1. Cooling Fan
2. Fan Clutch
3. Fan Clutch Set Plate
4. Spacer
Assemble the spacer and install the cooling fan.
(Without the fan clutch)
Tighten this part to the torque according to the
tightening torque specification table in this
workshop manual. (Find the torque value
{medium value upper limit} depending on a
screw size against the symbols on the bolt
head.)
WSLE0168

7. Install the cooling fan.


Install the fan clutch set plate and the spacer.
(With the fan clutch)

Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}
Install the fan clutch to the cooling fan.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}
Install the cooling fan to the fan clutch set plate.
(With the fan clutch)
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

WSLE0346

Name
1. Cooling Fan
2. Spacer

1A-16 4LE2 Engine Mechanical


Torque Specifications W1A00030008
N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

93.2 - 113 (9.5 - 11.5 / 68.7 - 83.3)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)


7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)


24V - 30A : 18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
24V - 50A : 41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

WSLE0301

4LE2 Engine Mechanical 1A-17

Engine Exterior Equipment

W1A0004

Components W1A00040005

1
8

11

10

WSLE0035

Name
1. Water Pump
2. Water Pump Outlet Pipe (Thermostat)
3. Exhaust Manifold
4. Cylinder Head Cover
5. Air Inlet Pipe
6. Intake Chamber

7.
8.
9.
10.
11.

EGR Cooler Inlet Pipe


Turbocharger
Oil Level Gauge
Turbocharger Oil Return Pipe
Turbocharger Oil Feed Pipe

1A-18 4LE2 Engine Mechanical

WSLE0036

Name
1. Injection Pipe
2. Leak-off Pipe
3. Fuel Pipe
4. Fuel Hose
5. Injection Pump

6.
7.
8.
9.

Injection Pump Housing Cover


Oil Cooler
Solenoid ASM
EGR Cooler Bracket

4LE2 Engine Mechanical 1A-19

6
5

WSLE0359

Name
1. PCV Valve
2. Orifice Plate
3. Valve Case

4. EGR Cooler Outlet Pipe


5. EGR Cut Solenoid
6. EGR Cooler

Removal W1A00040006
1. Disconnect the drain plug of the oil pan and drain
the engine oil.
2. Loosen the water drain cock on the cylinder block
to drain the coolant remaining in the engine.

2
1

Name
1. Drain Plug (Oil)
2. Drain Cock (Coolant)
3. Remove the EGR cooler outlet pipe.

WSLE0207

1A-20 4LE2 Engine Mechanical


Note:
After removing the pipe, seal so that foreign matter
does not enter.

3
2

4. Remove the connector of the EGR cut solenoid,


and remove the orifice plate, the valve case and
the EGR cut solenoid.

4
WSLE0334

Name
1. EGR Cooler Water Inlet Hose
2. EGR Cooler
3. EGR Cooler Water Outlet Hose
4. Rear Hanger
5. EGR Cooler Bracket

WSLE0333

Name
1. EGR Cut Solenoid
2. Valve Case
3. Orifice Plate
4. EGR Cooler Outlet Pipe

9. Remove the EGR cooler inlet pipe.


Note:
After removing the pipe, seal so that foreign matter
does not enter.

5. Remove the EGR cooler water inlet hose and the


outlet hose.
6. Remove the EGR cooler.
Note:
After removing the EGR cooler, seal so that foreign
matter does not enter.
7. Remove the EGR cooler bracket from the cylinder
head.
8. Remove the rear hanger from the EGR cooler
bracket.

WSLE0335

Name
1. EGR Cooler Inlet Pipe
10. Remove the turbocharger oil feed pipe and the
return pipe.
11. Remove the exhaust adapter from the turbocharger.
12. Remove the turbocharger ASM from the exhaust
manifold.

4LE2 Engine Mechanical 1A-21


2

4
5

6
7
WSLE0210

WSLE0336

Name
1. Turbocharger Oil Return Pipe
2. Turbocharger Oil Feed Pipe
3. Turbocharger
4. Exhaust Adapter
13. Remove the PCV valve from the intake chamber.
14. Remove the air inlet pipe from the intake chamber.
15. Remove the intake chamber from the cylinder
head.
16. Remove the mounting bolts (M61.0, 15 bolts) of
the head cover, and remove the head cover
together with the gasket from the cylinder head.
Remove the baffle plate from the cylinder head
cover.
17. Remove the mounting bolts and nuts of the
exhaust manifold, and remove the manifold and
the gaskets.

Name
1. PCV Valve
2. Intake Chamber
3. Cylinder Head Cover
4. Air Inlet Pipe
5. Gasket
6. Exhaust Manifold
7. Gasket
18. Disconnect the water outlet pipe and pull out the
thermostat.
19. Remove the water pump from the cylinder head
and the cylinder block. (M8: 5 bolts, 2 nuts)
Note:
The water pump is installed to both the cylinder head
and the cylinder block.

1A-22 4LE2 Engine Mechanical

2
1
3

4
6

WSLE0211

Name
1. Thermostat
2. Water Outlet Pipe
3. Packing
4. Water Pump
20. Loosen the sleeve nuts on the nozzle holder side
and on the injection pump side and remove the
injection pipe.
Important:
If over-tightening the delivery valve holder, the rack
cannot move smoothly as the plunger and the
housing are compressed. Therefore, when loosening the sleeve nuts of the injection pipe, hold the
delivery valve holder with a wrench to prevent
corotation.
CAUTION:
Always put a cap to prevent dust from getting in
the delivery valve holder and the nozzle holder.
21. Disconnect the leak-off pipe and remove the packing.
CAUTION:
Always put a cap to prevent dust from getting in
the delivery valve holder and the nozzle holder.
22. Remove the eyebolt and disconnect the fuel pipe.
CAUTION:
Always put a cap to prevent dust from getting in
the delivery valve holder and the nozzle holder.

WSLE0037

Name
1. Leak-off Pipe
2. Fuel Pipe
3. Eyebolt
4. Nozzle Holder
5. Injection Pump
6. Injection Pipe
23. Remove the solenoid ASM inserted in the back of
the injection pump installation part of the cylinder
block.
Note:
Take care when removing it since liquid gasket is used.
24. Remove the housing cover of the injection pump
installation part.
Since the liquid gasket is applied to the mating surface of the cylinder body, insert a bolt to the hole
for M8 1.25 thread on the cover to remove the
housing cover.
Do not extract the two stud bolts since the sealant
is attached to them.
Note:
Take care when removing it since liquid gasket is used.

4LE2 Engine Mechanical 1A-23

1
2
3

2
3

WSLE0039

WSLE0041

Name
1. Fuel Cut Lever
2. Pin (6 mm {0.236 in})
3. Governor Cover

Name
1. Solenoid ASM
2. Housing Cover
3. Stud Bolt

b. Make sure that the pin groove of the control link


is aligned with the center of the injection pump.
CAUTION:
If the pin groove of the control link is not aligned
with the center of the injection pump, you may not
remove the injection pump because the rack pin of
the injection pump is stuck to the cylinder block.

2
1

WSLE0040

Name
1. Housing Cover
2. M8 1.25 for Replacer
25. Remove the injection pump.
a. Align the hole of the fuel cut lever with the hole
of the governor cover, and then insert a pin (6
mm {0.236 in}) to the hole to hold the fuel cut
lever.

WSLE0042

Name
1. Control Link
2. Center Position of Injection Pump
3. Rack Pin of Injection Pump
c. Remove the injection pump, and remove the
shim inserted in the pump installation part.

1A-24 4LE2 Engine Mechanical


CAUTION:
Put the removed shim and the injection pump
together, attach a tag with cylinder number, and
check the thickness.
The removed shim cannot be reused.
Do not extract the eight studs since the sealant
is attached to them.

3
1

2
WSLE0212

Name
1. Control Link
2. Link Plate (Governor)
3. Snap Pin

4
3

WSLE0043

Name
1. Injection Pump ASM
2. Shim
3. Cylinder Block
4. Stud

27. Disconnect the oil cooler water outlet hose and the
inlet hose.
28. Disconnect the water hose (between water pipe
and water pump).

26. Remove the control link.


Pull out the snap pin on the connecting part to the
link plate of the governor assembled in the timing
gear case.

Note:
Take care not to lose the snap pin.
2

WSLE0337

Name
1. Water Hose
2. Oil Cooler Water Outlet Hose
3. Oil Cooler Water Inlet Hose
29. Remove the water pipe from the rocker arm
bracket.

4LE2 Engine Mechanical 1A-25


Install the packing to the oil cooler ASM and the
center bolt.
Tightening torque:
Center bolt: 24.5 34.3 Nm {2.5 3.5 kgfm/
18.1 25.3 lbft}
3. Install the oil cooler cover to the oil cooler.
Install the O-ring to the oil cooler cover.
Tightening torque:
24.5 34.3 Nm {2.5 3.5 kgfm/18.1 25.3
lbft}

1
WSLE0338

Name
1. Water Pipe
5

30. Remove the plug, and remove the oil cooler cover
from the oil cooler.
31. Remove the center bolt, and remove the oil cooler
ASM from the cylinder block.

2
3

WSLE0213

Name
1. Oil Cooler ASM
2. Center Bolt
3. Oil Cooler Cover
4. Plug
5. Packing

4. Install the water pipe to the rocker arm bracket.


1

Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

2
3

WSLE0213

Name
1. Oil Cooler ASM
2. Center Bolt
3. Oil Cooler Cover
4. Plug
5. Packing
32. Pull out the oil level gauge.

Installation W1A00040007
1. Insert the oil level gauge.
2. Install the oil cooler ASM to the cylinder block.

1A-26 4LE2 Engine Mechanical

1
WSLE0338

Name
1. Water Pipe
5. Install the water hose (between water pipe and
water pump).
6. Install the oil cooler water outlet hose and the inlet
hose with a white paint applied area in the oil
cooler side.

WSLE0212

Name
1. Control Link
2. Link Plate (Governor)
3. Snap Pin
8. Install the injection pump.
a. Align the hole of the fuel cut lever with the hole
of the governor cover, insert a pin (6 mm
{0.236 in}) to the hole and get the lever upright.
(Control link is positioned on the center.)
CAUTION:
If the control link is not positioned on the center,
you may fold the link when installing the injection
pump.

3
1

WSLE0339

Name
1. Water Hose
2. Oil Cooler Water Outlet Hose
3. White Paint Applied Area
4. Oil Cooler Water Inlet Hose
7. Install the control link.
a. Insert the control link from the back to the connecting hole of the injection pump of the cylinder block, align it with the guide pin in the
connecting hole and assemble.
b. Assemble the pin part of the control link to the
link plate hole of the governor assembled in the
timing gear case, and fix it with the snap pin.

WSLE0151

Name
1. Control Link
2. Center Position of Injection Pump
3. Pin (6 mm {0.236 in})
4. Fuel Cut Lever

4LE2 Engine Mechanical 1A-27


b. Align the shim with each stud and the knock
pin, check the thickness of the shim and install
it. (Shim thickness; Refer to 1A-5, ISUZU Diesel Engine W1A0002, Function Check
W1A00020012, Inspection and adjustment of
injection timing W1A0002001202)
2

CAUTION:
Install a new shim whose thickness is the same as
one being removed when disassembling.

1
3

WSLE0153

Name
1. Control Link
2. Center Position of Injection Pump
3. Rack Pin
3

WSLE0152

Name
1. Injection Pump ASM
2. Shim
3. Cylinder Block
c. Align the rack pin of the injection pump with the
center position of the pump.
d. Insert the injection pump along with the two
studs, align the knock hole with the knock pin of
the cylinder block, and assemble them.
e. Make sure that the rack pin and the groove of
the control link are aligned from the housing
cover installation part of the cylinder block side,
and tighten the injection pump.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

f. Remove the pin (6 mm {0.236 in}) inserted into


the fuel cut lever, and make sure that the fuel
cut lever moves smoothly.
9. Install the injection pump housing cover.
Apply the liquid gasket (TB1207C) to the housing
cover and install it to the cylinder block on the
injection pump side.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7 lbft}
Note:
Remove the sealant attached to the housing cover
installation part of the cylinder block with a packing
scraper completely and degrease sufficiently.
Apply approx. 4 mm {0.157 in} width of liquid gasket
to the cover edge and approx. 2 mm {0.079 in} width
of liquid gasket to the circumference of the bolt in
the housing cover.

1A-28 4LE2 Engine Mechanical


b. Insert the solenoid ASM from the back of the
cylinder block (back of the No.4 injection pump
rack) and tighten to the specified torque.
Tightening torque:
14.7 24.5 Nm {1.5 2.5 kgfm/10.8 18.1
lbft}

WSLE0154

Name
1. Housing Cover

WSLE0156

Name
1. Solenoid ASM

WSLE0155

Name
1. Housing Cover
2. Liquid Gasket Applied Area
3. Approx. 4 mm {0.157 in} width of the cover edge
4. Approx. 2 mm {0.079 in} of the circumference of
the bolt

WSLE0157

10. Install the solenoid ASM.


a. Apply liquid gasket (TB1207C) to the installation surface (bit groove) of the solenoid for the
engine stopping.

Name
1. Solenoid ASM
2. Installation Surface (Liquid Gasket Applied Area)
3. Thread Portion (Do not apply the liquid gasket.)

Note:
Remove the sealant attached to the installation part
of the solenoid and of the cylinder block with a packing scraper completely and degrease.
Do not apply the liquid packing to the thread portion.

11. Install the fuel pipe to the injection pump and


tighten to the specified torque.
Tightening torque:
19.6 24.5 Nm {2.0 2.5 kgfm/14.5 18.1
lbft}
12. Install the leak-off pipe to the nozzle holder and
tighten to the specified torque.

4LE2 Engine Mechanical 1A-29


CAUTION:
Hold the pipe by your hand to prevent it from rotating when tightening.
Tightening torque:
9.8 13.7 Nm {1.0 1.4 kgfm/7.2 10.1 lbft}

13. Connect the fuel pipe and the leak-off pipe with the
fuel hose and fix it with a clip.

3
2
1
5

WSLE0159

Name
1. Injection Pipe
2. Nozzle Holder
3. Injection Pump

WSLE0158

Name
1. Leak-off Pipe
2. Fuel Pipe
3. Nozzle Holder
4. Injection Pump
5. Fuel Hose
14. Install the injection pipe to the injection pump and
the nozzle holder, and tighten it with the sleeve
nut.
a. Screw the thread portion of the sleeve nut two
or three turns by your hand.
b. Hold the delivery valve holder of the injection
pump with a wrench and tighten the sleeve nut
securely.

15. Install the water pump ASM.


Install the water pump ASM and the gasket to
the cylinder block and the cylinder head, and
tighten it to the specified torque.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

Tightening torque:
14.7 24.5 Nm {1.5 2.5 kgfm/10.8 18.1
lbft}
Important:
If over-tightening the delivery valve holder, the rack
cannot move smoothly as the plunger and the
housing are compressed. Therefore, when tightening the sleeve nuts of the injection pipe, hold the
delivery valve holder with a wrench to prevent
corotation.

1
2

WSLE0160

Name
1. Tighten adjusting plate together.
2. Bolt: L = 40
3. Bolt: L = 60
16. Connect the water outlet pipe.

1A-30 4LE2 Engine Mechanical


a. Assemble the thermostat, install the packing
and the water outlet pipe, and tighten it to the
specified torque.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

1
4
2

3
WSLE0331

Name
1. Liquid Gasket Applied Area
b. Install the gasket to the cylinder head cover.

WSLE0161

Name
1. Water Outlet Pipe
2. Packing
3. Water Pump
4. Thermostat
17. Install the exhaust manifold to the cylinder head.
Insert the gasket and tighten to the specified
torque.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}
18. Install the cylinder head cover.
a. Apply the liquid gasket (TB1207B) to the position in the cylinder head cover shown in the figure, and install the baffle plate to the cylinder
head cover.

Note:
Take care not to slide or distort the gasket when installing.
c. Install the cylinder head cover to the rocker arm
bracket and tighten it to the specified torque.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7
lbft}
19. Install the intake chamber to the cylinder head
cover.
Insert the gasket and tighten to the specified
torque.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7
lbft}
20. Apply the liquid gasket (TB1207C) to the air inlet
pipe and install it.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7 lbft}
21. Install the PCV valve.

4LE2 Engine Mechanical 1A-31


2

4
4
5

6
7
WSLE0210

Name
1. PCV Valve
2. Inlet Chamber
3. Cylinder Head Cover
4. Air Inlet Pipe
5. Gasket
6. Exhaust Manifold
7. Gasket
22. Install the turbocharger ASM to the exhaust manifold.
Insert the gasket and tighten to the specified
torque.

WSLE0336

Name
1. Turbocharger Oil Return Pipe
2. Turbocharger Oil Feed Pipe
3. Turbocharger
4. Exhaust Adapter
26. Install the EGR cooler inlet pipe to the exhaust
manifold.
Insert the gasket and temporarily tighten the
bolts and nuts.

Tightening torque:
21.6 31.4 Nm {2.2 3.2 kgfm/15.9 23.2
lbft}
23. Install the exhaust adapter to the turbocharger.
Insert the gasket and tighten to the specified
torque.
Tightening torque:
21.6 31.4 Nm {2.2 3.2 kgfm/15.9 23.2
lbft}
24. Install the turbocharger oil feed pipe.
Tightening torque:
Turbocharger side: 9.8 14.7 Nm {1.0 1.5
kgfm/7.2 10.8 lbft}
Cylinder block side: 22.0 27.0 Nm {2.2 2.8
kgfm/16.2 19.9 lbft}
25. Install the turbocharger oil return pipe.
Insert the gasket and tighten to the specified
torque.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7
lbft}

WSLE0335

Name
1. EGR Cooler Inlet Pipe
27. Install the EGR cooler bracket to the cylinder head
and temporarily tighten the bolts.
28. Install the EGR cooler.
Insert the gasket and temporarily tighten the
bolts.

1A-32 4LE2 Engine Mechanical

2
WSLE0340

Name
1. EGR Cooler
2. EGR Cooler Bracket

WSLE0342

Name
1. EGR Cooler Outlet Pipe

29. Install the orifice plate, the valve case and the
EGR cut solenoid to the intake chamber.
Install the orifice plate and the gasket with protruding section in the position shown in the figure.
Install the connector of the EGR cut solenoid.

31. Temporarily tighten the bolts and nuts to the specified torque according to the order given on the figure.

1
3

4
WSLE0341

Name
1. EGR Cut Solenoid
2. Valve Case
3. Protruding Section
4. Orifice Plate
30. Install the EGR cooler outlet pipe.
Insert the gasket and temporarily tighten the
bolts and nuts.

6
WSLE0344

Name
1-6. Show the order to tighten bolts and nuts.
Tightening torque:
1, 2, 3, 5: 21.6 31.4 Nm {2.2 3.2 kgfm/15.9
23.2 lbft}

4LE2 Engine Mechanical 1A-33


4, 6: 18.6 28.4 Nm {1.9 2.9 kgfm/13.7
20.9 lbft}
32. Install the rear hanger.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

WSLE0354

Name
1. Rear Hanger
33. Install the EGR cooler water inlet hose with a white
paint applied area in the cylinder block side.
34. Install the EGR cooler water outlet hose with a
white paint applied area in the water return pipe
side.
2

3
WSLE0343

Name
1. EGR Cooler Water Inlet Hose
2. EGR Cooler Water Outlet Hose
3. White Paint Applied Area
35. Add coolant.
36. Add engine oil.

1A-34 4LE2 Engine Mechanical


Torque Specifications W1A00040008
N m (kg m / lb ft)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)


18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
9.8 - 13.7 (1.0 - 1.4 / 7.2 - 13.8)
21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

14.7 - 24.5 (1.5 - 2.5 / 10.8 - 18.1)

21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

14.7 - 24.5 (1.5 - 2.5 / 10.8 - 18.1)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)


24.5 - 34.3 (2.5 - 3.5 / 18.1 - 25.3)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)


18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)


21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

9.8 - 14.7 (1.0 - 1.5 / 7.2 - 10.8)

22.0 - 27.0 (2.2 - 2.8 / 16.2 - 19.9)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

21.6 - 31.4 (2.2 - 3.2 / 15.9 - 23.2)

WSLE0311

4LE2 Engine Mechanical 1A-35

Rocker Arm Shaft

W1A0075

Components W1A00750005

8
4

WSLE0214

Name
1. Rocker Arm Shaft
2. Lock Nut
3. Rocker Arm
4. Adjusting Screw

Removal W1A00750006
1. Remove the EGR cooler.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
2. Remove the cylinder head cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
3. Remove the water pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.

5.
6.
7.
8.

Rocker Arm Shaft Plug


Rocker Arm Bracket
Rocker Arm Shaft Pin
Rocker Arm Spring

4. Remove the rocker arm bracket ASM.


(M6 1.0: 5 bolts, 6 nuts)
Note:
Since liquid gasket is used on the mating surface to the
cylinder head, be careful not to damage the rocker arm
bracket when removing it.
* With screws for replacer (M8 1.25)

1A-36 4LE2 Engine Mechanical

2
3

*
1
*

WSLE0047

Name
1. Rocker Arm Bracket
2. Nut
3. Bolt
5. Pull out the eight push rods.

Disassembly W1A00750010
1. Remove plug of the rocker arm shaft.
2. Pull out the rocker arm shaft backward.

WSLE0232

Inspection for a bend of the rocker arm shaft


W1A0075000902

Hold the shaft on both ends with V block, and measure


the runout of the center by the dial gauge. (The bend
value should be a half of the runout.)
mm {in}
Standard value

Service limit

Repairing procedure

0.2 {0.008} or
less

0.3 {0.012}

Replace.

CAUTION:
When reinstalling the rocker arm, prepare tags written down the cylinder numbers and symbols to distinguish intake and exhaust, to avoid installing
the improper position.

Inspection W1A00750009
Inspection of rocker arm and rocker arm shaft
W1A0075000901

Check for wear, damage, clogging of oil port and other


abnormality.

Inspection for wear of the rocker arm shaft


W1A0075000903

Measure the outside diameter of the shaft at sliding


portions (eight points) in the rocker arm.

4LE2 Engine Mechanical 1A-37


mm {in}
Nominal dimension

Service limit

Repairing procedure

12 {0.472}

11.85 {0.467}

Replace.

WSLE0088

Inspection of rocker arm

Inspection of clearance between the rocker


arm and the rocker arm shaft W1A0075000904

W1A0075000905

Check the contact surface of the valve stem of the


rocker arm for stepped wear or damage.
If the stepped wear (1) and damage (2) of the contact
surface are slight, repair with the oil stone.
If the stepped wear and damage are extreme, replace
the rocker arm.

Measure the bushing bore and calculate the clearance


between the arm and the outside diameter of the shaft.
Clearance between the arm and the
shaft
Standard value
0.005 0.045
{0.0002 0.0018}

mm {in}

Service limit

Repairing procedure

0.2 {0.008}

Replace the rocker


arm or the shaft.

3
1
4

WSLE0236

Name
1. Stepped Wear of the Contact Surface
2. Damage of the Contact Surface
3. Rocker Arm
4. Oil Stone

Visual check of push rod


WSLE0235

W1A0075000906

Replace with new one if there is excessive wear or


damage.

Inspection for a bend of the push rod

W1A0075000907

Rotating the push rod on a surface plate, measure the


bend with the thickness gauge.

1A-38 4LE2 Engine Mechanical


If the measured value exceeds the limit, replace with
new one.
Push rod bend
Service limit

mm {in}
0.3 {0.012} or less

WSLE0251

Name
1. Pin
2. Rocker Arm Shaft

4. Install the plug of the rocker arm.


WSLE0080

Name
1. Push Rod
2. Thickness Gauge

Reassembly W1A00750011
1. Clean the rocker arm shaft and the oil port of the
rocker arm by air.
2. Apply the engine oil to the rocker arm shaft and the
rocker arm sliding portion.
3. Install the rocker arm shaft and the rocker arm.
When positioning the rocker arm shaft, align the
rocker shaft pin inserted to the rocker arm bracket
with the cutout of the rocker arm shaft.
Note:
When reinstalling the rocker arm, be sure to check the
tag and install to the original position.

Installation W1A00750007
1. Put the push rod through the cylinder block and
insert it to the tappet.
2. Align it with a groove on the bottom of the rocker
arm bracket and apply liquid gasket (TB1207B).
Note:
Do not apply the liquid gasket to a groove around the
oil gallery.

WSLE0254

Name
1. Liquid Gasket Applied Area
2. Do not apply the liquid gasket to the groove.
(important)
3. Oil Gallery

4LE2 Engine Mechanical 1A-39


Applied width of sealant

2
1

WSLE0145
WSLE0255

Name
1. Approx. 4 mm {0.157 in}
2. Approx. 2 mm {0.079 in}
3. Contact the rocker arm to the rocker spring, rotate
the crank, and set the No.1 cylinder to the exhaust
top dead center.
4. Install the rocker arm bracket ASM along with the
stud bolt of the cylinder head, and tighten it to the
specified torque.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7 lbft}
Note:
Remove paint and sealant attached to the top of the
cylinder head and the bottom of the rocker arm
bracket with a PKG scraper etc., and degrease sufficiently.
Assemble it to the cylinder head within 5 minutes
after applying the sealant.
When assembling, align the saucer part of the push
rod and the rocker arm adjusting screw.

Name
1. Rocker Arm Bracket
2. Nut
3. Bolt
5. Adjustment of valve clearance
Refer to 1A-4, ISUZU Diesel Engine
Function Check W1A00020012.
6. Install the water pipe.
Refer to 1A-17, Engine Exterior
W1A0004.
7. Install the cylinder head cover.
Refer to 1A-17, Engine Exterior
W1A0004.
8. Install the EGR cooler.
Refer to 1A-17, Engine Exterior
W1A0004.

W1A0002,

Equipment

Equipment

Equipment

1A-40 4LE2 Engine Mechanical


Torque Specifications W1A00750008
N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

WSLE0302

4LE2 Engine Mechanical 1A-41

Cylinder Head

W1A0014

Components W1A00140005
2
3

4
6
5
7
8

12

10

11

Name
1. Connector
2. Glow Plug
3. Do not extract the five stud bolts since the sealant is attached to them.
4. Valve Seal
5. Valve Guide
6. Split Collar

WSLE0050

7.
8.
9.
10.
11.
12.

Removal W1A00140006
1. Remove the cooling fan.
Refer to 1A-12, Engine Accessories W1A0003.
2. Remove the fan belt.
Refer to 1A-12, Engine Accessories W1A0003.
3. Remove the fan pulley.
Refer to 1A-12, Engine Accessories W1A0003.
4. Remove the generator.
Refer to 1A-12, Engine Accessories W1A0003.
5. Remove the EGR cooler and the bracket.
Refer to 1A-12, Engine Accessories W1A0003.
6. Remove the cylinder head cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
7. Remove the turbocharger.

8.

9.

10.

11.
12.

Spring Seat
Valve Spring
Valve
Hot Plug
Valve Seat Insert
Nozzle Holder

Refer to 1A-17, Engine Exterior Equipment


W1A0004.
Remove the water pump.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the injection pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the leak-off pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
Remove the front hanger.

1A-42 4LE2 Engine Mechanical

2. Remove the connector, glow plug and nozzle


holder ASM before disassembling the valve system.
3. Compress the valve spring to remove the split collar, spring seat, valve spring and valve.
Special tool
Valve spring remover
5-8840-9030-0

CAUTION:
Disassemble the cylinder head ASM on the flat
wood to prevent part damage.
When removing the nozzle holder ASM, take
great care not to damage the nozzle tip.

1
5

4. Remove the valve seal.


Use pliers to remove the valve seal.
WSLE0048

Name
1. Cylinder Head ASM
2. Head Bolt (M12)
3. Head Gasket
4. Front Hanger
5. Head Bolt (M8)
13. Gradually loosen the cylinder head bolts at an
equal balanced rate from outside toward the center
as the order indicated in the diagram. (M12: 10
bolts, M8: 5 bolts)

5
8

12
13

15
14

11
10

WSLE0356

5. Remove the valve guide.


Use a valve guide installer to pull out the valve
guides from the bottom of the cylinder head.
Special tool
Valve guide installer
5-8840-9035-0

7
6

WSLE0049

14. Remove the cylinder head ASM and the head gasket.
15. Pull out the tappet from the cylinder block.

Disassembly W1A00140010
1. Remove the exhaust manifold.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.

4LE2 Engine Mechanical 1A-43


mm {in}
Standard
value

0.075
{0.00295}
or less

Abnormal
value (need
repair)

Repairing procedure

Repair it with a surface


grinder. The total amount of
repaired values of the cylinder
block and of the cylinder head
0.15 {0.006} should not exceed 0.3
{0.012}. If the measured value
exceeds
the
maximum
repaired value, replace the
cylinder head.

WSLE0330

Inspection W1A00140009
Inspection of cylinder head

W1A0014000901

Remove any carbon attached to the bottom of the


head, taking care not to damage the valve seat surface.
Check each part for damage and perform the color
check as required.
Water leakage: Water pressure test 490 kPa {71 psi}
(for three minutes)

WSLE0064

WSLE0063

Inspection of bottom distortion

W1A0014000902

Place a straightedge on the four side-directions and the


two diagonal directions, and measure the distortion
with the thickness gauge. (Refer to the diagram.)

WSLE0230

(Reference) Cylinder head height

mm {in}

Engine model

Standard value

4LE2X

63.90 64.10 {2.516 2.524}

1A-44 4LE2 Engine Mechanical


Depression level: B
Install the valve to the cylinder head. Measure the
depression level of the seat with a depth gauge or with
a straightedge and a scale.
If the measured value exceeds the limit, replace the
valve seat insert.
mm {in}

Standard
value

Service
limit

Repairing
procedure

Contact width (A)

2.0 {0.079}

2.5 {0.098}

IN

0.7 {0.028}

1.2 {0.047}

Repair or
replace.

EX

0.9 {0.035}

1.5 {0.059}

Depression
level (B)

WSLE0066

Distortion of exhaust manifold installation


surface W1A0014000910

Place a straightedge on the four side-directions and the


two diagonal directions, and measure the distortion
with the thickness gauge.

mm {in}
Standard value

Service limit

Repairing procedure

0.05 {0.002} or less

0.2 {0.008}

Repair.

B
4

45

WSLE0067

Name
1. Cylinder Head
2. Valve Seat Insert
3. Valve
4. Cylinder Head Lower Surface

Repair of valve seat

W1A0014000904

1. Remove any carbon attached to the valve seat surface. Use a seat cutter (15, 45, 75) to cut off
scratches and hollows at minimum until they disappear, and adjust the contact width to the standard
value.
2. Grind them after repair.
WSLE0332

Inspection of valve seat

W1A0014000903

Contact width: A
Check the contact surface of the valve seat. If any
scratches and hollows exist or measured contact width
exceeds the limit, repair it.

4LE2 Engine Mechanical 1A-45


6. Apply compound to the valve seat surface, grind
them while rotating the valve, and make sure that it
contacts evenly over the circumference.
CAUTION:
After grinding, remove compound completely.

Replacement of valve seat insert W1A0014000905


If the depression level of the seat exceeds the limit,
replace the valve seat insert.
1. Arc-weld the entire inside diameter of the valve
seat insert.
2. Cool the valve seat insert for two to three minutes.
It contracts as it cools down, making it easier to
remove the valve seat insert.
3. Remove the valve seat insert, using a screwdriver.
Be sure not to hurt the cylinder head.

Name
1. Pad
2. Valve Seat Insert
3. Press

Inspection for wear of the valve stem

W1A0014000906

Measure the outside diameter at position as shown in


the figure.
Repair light stepped wear with the oil stone.
If the measured value is below the service limit, replace
the valve guide and the valve as a set.
mm {in}

Name
1. Arc-weld
2. Valve Seat Insert
3. Screwdriver
4. Clean off carbon and metallic oxides on the insert
bore of the cylinder head.
5. Use a smooth pad and press-fit with a press. (9.8
14.7 kN {2,203 3,305 lb})

Nominal
dimension

Service limit

Inlet

7 {0.276}

6.85 {0.270}

Exhaust

7 {0.276}

6.80 {0.268}

Repairing
procedure
Replace.

1A-46 4LE2 Engine Mechanical

Inspection of valve guide

Inspection of thickness of the valve

W1A0014000911

Note:
If there is a scratch or abnormal abrasion on the valve
stem and the inside diameter part of the valve guide,
replace the valve and valve guide together.
1. Measure the valve guide clearance.
Measure the clearance between the valve
guide and valve stem within 10 mm {0.39 in}
from the valve guide, using a dial gauge.
If the measured value exceeds the limit, replace
the valve guide and valve altogether.
Clearance between the valve guide and
valve stem

W1A0014000907

If the measured value is below the service limit, replace


the valve guide and the valve as a set.
mm {in}
Nominal
dimension

Service limit

Repairing procedure

IN

1 {0.039}

0.7 {0.028}

Replace.

EX

0.8 {0.031}

0.5 {0.020}

mm {in}

Standard

Limit

Inlet valve

0.023 0.056
{0.0009 0.0022}

0.2 {0.008}

Exhaust valve

0.030 0.063
{0.0012 0.0025}

0.25 {0.0098}

Inspection of force (tension) of the valve


spring W1A0014000908
Use a spring tester and read the scale when the spring
is compressed to the specified dimension.

4LE2 Engine Mechanical 1A-47


N {lb}

When compressed to
29.9 mm {1.177 in}

Standard
value

Service
limit

Repairing
procedure

167 {38}

147 {33}

Replace.

WSLE0075

Reassembly W1A00140011

Inspection of free height and squareness of


the valve spring W1A0014000909

1. Install the valve guide.


a. Hammer in the valve guide from the upper surface of the cylinder head, using the valve guide
installer.
Special tool
Valve guide installer
5-8840-9035-0

Free height (free length) ; A


Measure free length of the valve spring and if it is
shorter than the limit, replace the valve spring.
mm {in}
Standard value

Service limit

Repairing procedure

42.1 {1.657}

40 {1.575}

Replace.

Squareness; B
Use a surface plate and a square to measure the valve
spring squareness.
If the measurement exceeds the limit, replace the valve
spring.
mm {in}
Standard value

Service limit

Repairing procedure

1.8 {0.071} or
less

2.5 {0.098}

Replace.

WSLE0357

Height from the upper surface of the cylinder


head to the edge surface of the valve guide: 9.5
mm {0.374 in}
Note:
When replacing the valve guide, it must be replaced
together with the valve.

1A-48 4LE2 Engine Mechanical

3
WSLE0247

2. Install the valve seal.


a. When press-fitting, apply engine oil sufficiently
over the outer circle of the valve guide.
b. Beat until the oil seal protruding section is
securely held to the valve guide groove.
Also, check that the spring does not come off.
Special tool
Valve seal setting tool
5-8840-9033-0
CAUTION:
Take care to avoid damaging the lip of the seal.

Name
1. Valve Guide
2. Groove
3. Protruding Section
3. Install the valve.
Apply the mixture of the oil and Bellmoly Paste
(molybdenum disulfide) to the valve stem part.
Engine oil : molybdenum = 1:1
CAUTION:
Be sure to prevent the valve from coming off and
causing dents after installing the valve.

WSLE0108

WSLE0248

Name
1. Valve Stem
4. Install the valve spring and the spring seat.
Install the valve spring with its narrow pitched side
(white paint side) facing downward.

4LE2 Engine Mechanical 1A-49


c. Install the nozzle holder ASM and tighten the
nozzle bracket to the specified torque.
Tightening torque:
31.4 41.2 Nm {3.2 4.2 kgfm/23.2 30.4
lbft}
CAUTION:
Be sure to prevent the nozzle holder tip from
adhering of dirt and from damaging.
Use new gasket.

1
1
WSLE0110

Name
1. White Paint
3

5. Install the split collar.


Use the tool (remover) to compress the spring and
insert the split collar securely.
Special tool
Valve spring remover
5-8840-9030-0

4
5

WSLE0112

Name
1. Bolt
2. Eyebolt
3. Bracket
4. Nozzle ASM
5. Gasket

7. Install the exhaust manifold.


Assemble the stamp mark (or seal) side of the gasket facing the manifold.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

WSLE0111

Name
1. Split Collar
2. Remover
6. Install the nozzle holder ASM.
a. Check the injection condition and injection
pressure of the injection nozzle, and perform
service before assembly. (Refer to 1A-4,
ISUZU Diesel Engine W1A0002, Function
Check W1A00020012.)
b. Install the gasket to the cylinder head.

1A-50 4LE2 Engine Mechanical


Installation W1A00140007
1. Assemble the tappet to the cylinder block. (Check
the assemble position marked at the disassembling.)
2. Install the head gasket.
Install the head gasket with the stamped mark facing upward.

WSLE0249

Name
1. Exhaust Manifold
2. Gasket

8. Assemble the glow plug to the cylinder head and


tighten to the specified torque.
Tightening torque:
20.0 25.0 Nm {2.0 2.5 kgfm/14.8 18.4
lbft}
9. Install the connector to the glow plug and tighten to
the specified torque.
Tightening torque:
0.9 1.1 Nm {0.09 0.11 kgfm/0.7 0.8 lbft}

WSLE0143

Name
1. Stamped Mark
3. Install the cylinder head ASM gently on the gasket.
4. Apply engine oil to the threads and the seating surfaces of the head bolts, and tighten them from the
center part to the outside bolts symmetrically in the
numerical order shown in the illustration.
Tightening torque:
M12: 83.4 93.2 Nm {8.5 9.5 kgfm/61.5
68.7 lbft} 60 90
M8: 24.5 34.3 Nm {2.5 3.5 kgfm/18.1
25.3 lbft}

WSLE0113

Name
1. Glow Plug
2. Connector

WSLE0144

5. Install the rocker arm bracket.

4LE2 Engine Mechanical 1A-51


Refer to 1A-35, Rocker Arm Shaft W1A0075.
6. Install the front hanger and tighten to the specified
torque.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

WSLE0147

Name
1. Front Hanger

7. Install the leak-off pipe.


Refer to 1A-17, Engine Exterior Equipment
W1A0004.
8. Install the injection pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
9. Install the water pump.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
10. Install the turbocharger.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
11. Install the cylinder head cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
12. Install the EGR cooler and the bracket.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
13. Install the generator.
Refer to 1A-12, Engine Accessories W1A0003.
14. Install the fan pulley.
Refer to 1A-12, Engine Accessories W1A0003.
15. Install the fan belt.
Refer to 1A-12, Engine Accessories W1A0003.
16. Install the cooling fan.
Refer to 1A-12, Engine Accessories W1A0003.

Torque Specifications W1A00140008


N m (kg m / lb ft)
20.0 - 25.0 (2.0 - 2.5 / 14.8 - 18.4)
31.4 - 41.2 (3.2 - 4.2 / 23.2 - 30.4)

83.4 - 93.2 (8.5 - 9.5 / 61.5 - 68.7)


60 - 90

24.5 - 34.3 (2.5 - 3.5 / 18.1 - 25.3)

WSLE0303

1A-52 4LE2 Engine Mechanical

Piston, Connecting Rod

W1A0015

Components W1A00150005

3
4
2

6
10

9
8

WSLE0053

Name
1. Piston Pin
2. Piston
3. Piston Ring
4. Snap Ring
5. Bushing

Removal W1A00150006
1. Remove the cylinder head cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
2. Remove the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
3. Remove the cylinder head ASM.
Refer to 1A-41, Cylinder Head W1A0014.
4. Remove the mounting bolts and nuts of the oil pan,
and then remove the oil pan from the cylinder
block. (M6: 18 bolts, 4 nuts)

6.
7.
8.
9.
10.

Bearing
Cap Nut
Cap
Connecting Rod
Connecting Rod Bolt

4LE2 Engine Mechanical 1A-53


d. Put a handle of a hammer or something on the
bottom of the connecting rod, and push the piston ASM upward from the inside of the cylinder
block.

CAUTION:
Remove any carbon attached to the inner wall of
the cylinder using a scraper before removing
the piston.
Be careful not to damage the inner wall of the
cylinder when pushing out the piston ASM.
Attach tags with each cylinder number to the
removed cap and the bearing and arrange them.
2

WSLE0215

Name
1. Oil Pan
2. Drain Plug

5. Remove the oil strainer mounting bolts from the


bearing cap, and remove the oil strainer from the
oil pump.
6. Loosen the sleeve nut and remove the oil pipe
(between the oil pump and the cylinder block).

1
2

WSLE0054

Name
1. Piston
2. Connecting Rod Cap

WSLE0216

Name
1. Oil Pump
2. Cylinder Block
3. Oil Pipe
4. Oil Strainer
7. Remove the piston and the connecting rod.
a. Rotate the crank and bring the removed piston
to the bottom dead center.
b. Loosen the cap nut of the connecting rod and
remove the cap.
c. Further rotate the crank and bring the piston to
the top dead center.

1A-54 4LE2 Engine Mechanical


Disassembly W1A00150010
1. Use the ring remover (tool commercially available
is also acceptable) to remove the piston ring.
Special tool
Piston ring remover
1-8522-1029-0

CAUTION:
Piston ring deforms if it is expanded beyond the
limit.

WSLE0056

Name
1. Piston Pin
2. Brass Stick

Inspection W1A00150009
Axial play of the connecting rod and the crank
pin W1A0015000916
WSLE0055

2. Remove the piston pin.


a. Use a commercial tool to remove the snap ring.
b. Put a brass stick on the piston pin and gently
tap by a hammer to knock it out.
CAUTION:
Put the piston, piston ring, piston pin, connecting
rod, and so on in order according to the cylinder
number.

Measure an axial play before removing the connecting


rod.
1. Pull the connecting rod all the way to the front.
2. Insert a thickness gauge to the clearance between
the connecting rod cap and the crankshaft, and
then measure a play.
mm {in}
Standard value

Service limit

0.20 0.33 {0.008 0.013}

0.35 {0.014}

Inspection of clearance with the cylinder bore


W1A0015000901

1. Measure the outside diameter of the piston at the


specified distance from top surface in the rightangle direction to the piston pin.
Measurement position of outside diameter: 54.85
mm {2.159 in} from the top surface.

4LE2 Engine Mechanical 1A-55


Inspection for wear of the piston pin (outside
diameter) W1A0015000904
Use a micrometer to measure the outside diameter of
the piston pin.
If the measured value exceeds the limit, replace the
piston pin.
mm {in}
Nominal dimension

Service limit

Repairing procedure

27 {1.063}

26.970
{1.0618}

Replace.

WSLE0089

2. Calculate the clearance by the dimension of the


cylinder bore and the outside diameter dimension
of the piston.
mm {in}
Clearance with
major axis

0.040 0.085
{0.0016 0.0033}

Outside diameter of the piston for service


W1A0015000903

mm {in}
Engine model

Piston outside diameter

Grade

4LE2X

84.945 84.960
{3.3443 3.3449}

NON

85.195 85.210
{3.3541 3.3547}

025

WSLE0239

Inspection of clearance between the piston


pins and piston pin holes W1A0015000905
Measure the inner diameter of the piston pin hole and
calculate the clearance with the outside diameter of the
piston pin.
mm {in}
Standard value
4LE2X

0.004 0.017 {0.00016 0.00070}

Inspection of piston ring end gap

W1A0015000906

Insert the ring to the cylinder bore and push it with the
piston head so that the ring makes a right angle with
the cylinder, then measure.
mm {in}
Standard value

WSLE0090

Top ring

0.20 0.35
{0.008 0.014}

Second
ring

0.35 0.50
{0.014 0.0.20}

Oil ring

0.20 0.40
{0.008 0.016}

Service limit

Repairing
procedure

1.5 {0.059}
Replace.
1.0 {0.039}

1A-56 4LE2 Engine Mechanical

WSLE0093

Inspection of clearance between the piston


ring groove and the ring W1A0015000907
1. Remove any carbon sludge from the piston ring
groove.
Using the old piston ring helps you to remove the
carbon easily.
2. Measure the clearance between the piston ring
and the ring groove using a thickness gauge at
several points.
If the measured value exceeds the limit, replace
the piston ring or the piston.
CAUTION:
When replacing the piston, replace the piston ring
also at the same time.

Inspection of distortion and parallelism of the


connecting rod W1A0015000908
Use a connecting rod aligner to measure it.
mm {in}
Standard
value

Service limit

Distortion
0.05 {0.002}
(L = per 100 mm
or less
{3.937 in})

0.2 {0.008}

Distortion
0.05 {0.002}
(L = per 100 mm
or less
{3.937 in})

0.15 {0.006}

Repairing
procedure
Repair or
replace.

mm {in}
Standard value

Service
limit

Repairing
procedure

Top ring

0.085 0.105
{0.0033 0.0041}

0.2
{0.008}

Second
ring

0.050 0.085
{0.0020 0.0033}

Replace
the ring or
the piston.

Oil ring

0.030 0.070
{0.00120 0.00276}

0.15
{0.006}

Inspection of clearance between the


connecting rod small end pin holes and the
piston pins W1A0015000909
Measure the bushing bore and the piston pin outside
diameter and calculate the clearance.

4LE2 Engine Mechanical 1A-57


mm {in}
Standard
value
4LE2X

0.008 0.020
{0.00031
0.00080}

Service limit

0.05 {0.002}

Repairing procedure
Replace the
bushing or the
piston pin.

WSLE0240

Name
1. Press

Inspection of tension of the connecting rod


bearing W1A0015000912
Check whether the tension of the bearing is sufficient.
mm {in}

Replacement of bushing

Standard value

W1A0015000910

Use the bench press to press-fit the bushing to the connecting rod.
Finished size of the bore after the bushing is
press-fitted

mm {in}

Standard value
4LE2X

27.00 {1.063}
(+0.008 0.015 {+0.00031 0.00060})

Repairing procedure

W = 49.5 {1.949} or Use the one with extrusion and


more
tension, and be careful about
D = 49 {1.929}
sticking of rear side.
L = 0.055 0.085
{0.00217 0.00330}

Standard for the bearing tension (reference)


1

3kN {674lbf}
2
L

WSLE0241

Name
1. Tension (Free Condition)
2. Extrusion

1A-58 4LE2 Engine Mechanical


Clearance between the bearing and the crank
pin W1A0015000913
1. Tighten the bearing cap to the specified torque.
Then measure the inside diameter.

mm {in}

Pin

Service limit

Repairing procedure

0.13 {0.005}

Replace the crankshaft.

Tightening torque:
23 26 Nm {2.3 2.7 kgfm/17.0 19.2 lbft}
100 115
2. Measure the outside diameter of the after-mentioned crankshaft pin, and calculate the clearance.
mm {in}
Standard value

Service limit

Repairing procedure

0.026 0.067
{0.0010 0.0026}

0.1 {0.0039}

Replace the bearing.

Y
X

X
Y

WSLE0098

Cylinder and piston combination

W1A0015000915

The pistons are selected by the grade when assembled


at the factory. However, the grades are not set to the
standard pistons for service.
Piston grade
Cylinder bore
grade
At the ISUZU factory
When servicing

WSLE0097

Inspection of outside diameter of the


crankshaft pin W1A0015000914
Measure the outside diameter of the crankshaft pin,
and calculate the wear and the uneven wear.
If it exceeds the limit, replace the crankshaft.
1. Nominal dimension
mm {in}
Pin
4LE2X

46 {1.811}

2. Uneven wear (the difference between the measurements in X X, Y Y directions)


mm {in}

Pin

Service limit

Repairing procedure

0.05 {0.002}

Replace the crankshaft.

3. Amount of wear

NON-Grade

Reassembly W1A00150011
1. Assemble pistons and connecting rods.
a. It is advisable to warm the piston at a temperature of approx. 100C {212F} with a piston
heater. However, the piston is able to be
assembled when it is cold.

4LE2 Engine Mechanical 1A-59

WSLE0115

b. Apply engine oil sufficiently to the piston pin.


c. Assemble the connecting rod with the cylinder
number stamped side facing the piston combustion chamber direction, and push in the piston pin.
At this time, check that the front mark on the
piston head and the casting mark (ISUZU) on
the connecting rod are in the same direction.

WSLE0117

3. Install the piston ring.


Use the piston ring remover to install the piston
ring.
Special tool
Piston ring remover
1-8522-1029-0
a. Install the oil ring so that the end of the ring is in
the opposite direction of 180 to that of the coil
expander.
Note:
For the coil expander, make sure that there is no gap in
the joint.

1
2

b. Install the compression rings with T, 1T or 2T


mark facing upward in the order of the second
and top compression rings.

CAUTION:
The shapes of the top and second compression
rings are different.

4
5

WSLE0116

Name
1. Combustion Receiver Side
2. Front Mark
3. Engine Forward Direction
4. ISUZU Mark
5. Cylinder Number Stamped Side
2. Install the snap ring.
Insert the snap ring and fix it with the piston pin.
Check to see the piston and connecting rod move
smoothly.

1A-60 4LE2 Engine Mechanical

1
1
2
2

WSLE0118

WSLE0125

Name
1. Top Ring
2. Second Ring
3. Oil Ring

Name
1. Top Ring
2. Second Ring
3. Oil Ring

2. Bring the crankshaft to the top dead center position.


3. Install the bearing to the connecting rod and the
bearing cap.
4. Apply engine oil to the inside of the bearing, the
piston ring, the ring groove and the side surface of
the piston, and the inside of the cylinder. Then
push the piston in the cylinder bore with the front
mark on it facing forward.
Also, check that the connecting rod alignment
number (cylinder number) is facing to the injection
pump side.
Special tool
Piston setting tool
5-8840-9018-0

WSLE0252

Name
1. T, 1T or 2T
2. Joint

Installation W1A00150007
1. Before inserting the piston ASM to the cylinder, set
the piston ring end as shown in the illustration,
avoiding the side-pressure direction (the rightangle direction to the piston pin).

WSLE0253

5. Install the connecting rod cap.

4LE2 Engine Mechanical 1A-61


a. Rotate the crank slowly to the bottom dead center position.
At this time, push in the piston ASM as it follows
the crank.
b. Apply engine oil to the bearing and crank pin,
and install aligning the marking numbers of the
connecting rod and the bearing cap.
c. Apply engine oil to the threads and the seating
surface of the connecting rod.

Tightening torque:
23 26 Nm {2.3 2.7 kgfm/17.0 19.2
lbft} 100 115
Note:
Check that the crankshaft turns smoothly after assembly of the connecting rod.

WSLE0141

Name
1. Oil Pipe
2. Oil Strainer
3. To No.2 Bearing Cap
8. Install the oil pan.
a. Install the oil pan and the packing to the cylinder block and tighten the bolts evenly.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7
lbft}

b. Install the drain plug.


Tightening torque:
68.6 88.2 Nm {7.0 9.0 kgfm/50.6 65.1
lbft}
WSLE0127

Name
1. Cylinder Number
6. Install the oil pipe (between the oil pump and the
cylinder block) and tighten the sleeve nut.

Tightening torque:
24.5 34.3 Nm {2.5 3.5 kgfm/18.1 25.3
lbft}
7. Install the oil strainer to the oil pump and tighten
the strainer bracket to No.2 bearing cap.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

WSLE0215

Name
1. Oil Pan
2. Drain Plug
9. Install the cylinder head ASM.
Refer to 1A-41, Cylinder Head W1A0014.

1A-62 4LE2 Engine Mechanical


10. Install the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.

11. Install the cylinder head cover.


Refer to 1A-17, Engine Exterior Equipment
W1A0004.

Torque Specifications W1A00150008


N m (kg m / lb ft)

23 - 26 (2.3 - 2.7 / 17.0 - 19.2)

100 - 115

WSLE0304

4LE2 Engine Mechanical 1A-63

Flywheel

W1A0016

Components W1A00160005

WSLE0313

Name
1. Flywheel

Removal W1A00160006
1. Remove the flywheel.
a. Block the crankshaft from rotating, and loosen
the mounting bolts in the order indicated in the
diagram to remove the flywheel.
b. Put alignment marks before removing the flywheel from the crankshaft. (Doing so makes
installing easy because the positions of the
mounting bolts are fixed even if pitch of them is
not equal.)
c. Gently tap the flywheel by a plastic hammer or
similar tool to remove it.

CAUTION:
Be careful not to damage the ring gear.

WSLE0218

2. Take out the ring gear.


Put a brass stick on the ring gear and strike with a
hammer to remove it.

1A-64 4LE2 Engine Mechanical


Note:
Install the flywheel checking the installation position
since the bolt hole pitch is not equal.

1
WSLE0103

Installation W1A00160007
1. Install the ring gear.
Heat the ring gear evenly using a gas burner and
strike with a hammer to install it.
After shrinkage fit, make sure that the ring gear is
stuck to the flywheel.
CAUTION:
Do not heat the ring gear at a temperatures above
200C {392F}.

2. Install the flywheel.


Apply engine oil to the threads and the seating surface of the mounting bolts, and then install the flywheel to the crankshaft.
Tighten the mounting bolts in a balanced way in
the numerical order shown in the illustration.
Tightening torque:
88.3 108 Nm {9.0 11.0 kgfm/65.1 79.7
lbft}

WSLE0139

Name
1. Engine Oil Application

4LE2 Engine Mechanical 1A-65


Torque Specifications W1A00160008
N m (kg m / lb ft)

88.3 - 108 (9.0 - 11.0 / 65.1 - 79.7)

WSLE0314

1A-66 4LE2 Engine Mechanical

Crankshaft Front Oil Seal

W1A0022

Components W1A00220005

1
WSLE0315

Name
1. Crankshaft Pulley
2. Front Oil Seal

3. Timing Gear Case


4. Governor Cover

Removal W1A00220006
1. Remove the cooling fan and the fan belt.
Refer to 1A-12, Engine Accessories W1A0003.
2. Remove the fan pulley.
Refer to 1A-12, Engine Accessories W1A0003.
3. Remove the generator.
Refer to 1A-12, Engine Accessories W1A0003.
4. Remove the generator bracket.
Refer to 1A-12, Engine Accessories W1A0003.
5. Remove the injection pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
6. Remove the fuel pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
7. Remove the solenoid ASM.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
8. Remove the injection pump housing cover.

9.

10.

11.

12.

Refer to 1A-17, Engine Exterior Equipment


W1A0004.
Remove the injection pump.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the control link.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the oil pan.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
Remove the crank pulley.
a. Block the crankshaft from rotating, and loosen
the mounting bolts of the pulley to remove it.
b. Remove the washer and the pulley.

CAUTION:
Do not reuse the bolt and washer.

4LE2 Engine Mechanical 1A-67


Note:
Since liquid gasket is applied to the mating surface to
the cylinder block, take great care not to remove them
forcedly to damage or deform them.
4

2
1

WSLE0217

Name
1. Mounting Bolt
2. Washer
3. Crank Pulley
4. Crankshaft

WSLE0221

13. Remove the timing gear case.


a. Before removing the timing gear case, make
sure that control link supported by the cylinder
block and the link plate of the governor are separated.
If they are connected, remove the snap pin and
separate them.

14. Remove the front oil seal from the timing gear
case.
Remove the oil seal with a screwdriver avoiding
damage to the oil seal contact surface on the
timing gear case.

Inspection W1A00220009
Inspection of oil seal

W1A0022000901

If fault is found in the lip section of the oil seal, replace it


with the new one.

3
2

WSLE0212

Name
1. Control Link
2. Link Plate (Governor)
3. Snap Pin
b. The timing gear case should be removed with
the governor and the front oil seal.

WSLE0102

Name
1. Timing Gear Case
2. Front Oil Seal

1A-68 4LE2 Engine Mechanical


Installation W1A00220007
1. Install the front oil seal.
a. Apply enough engine oil to the felt section of
the oil seal.
b. Install the front oil seal to the timing gear case
with a front oil seal installer.
Install it at the position due to the L dimension
shown in the illustration.
Special tool
Front oil seal installer
5-8840-9031-0

Note:
Apply enough engine oil to the main and dust lip section of the front oil seal before installing.

mm {in}
L dimension

60.50.1 {2.3820.0039}

WSLE0137

Name
1. Governor Cover
2. Timing Gear Case
3. Front Oil Seal

3. Install the crank pulley.


a. Install the crank pulley to the crankshaft.
b. Block the crankshaft from rotating, assemble
the washer, and tighten it with the mounting
bolts.
WSLE0136

Name
1. Front Oil Seal
2. Timing Gear Case
2. Install the timing gear case (with governor) to the
cylinder block.
a. Let the link plate of the governor which is
assembled in the gear case through the connection hole of the injection pump.
b. Apply engine oil to the both ends of the bushing
section of the governor main spring lever.
c. Apply the liquid gasket (TB1207B) to the gear
case and install to the cylinder block.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}
d. Assemble the packing and the governor cover
to the top of the gear case and tighten them to
the specified torque.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7
lbft}

CAUTION:
Replace the bolt and washer with new ones.
Tightening torque:
167 186 Nm {17.0 19.0 kgfm/123.2
137.2 lbft}

4LE2 Engine Mechanical 1A-69

3
1
WSLE0140

Name
1. Washer
2. Crank Pulley
3. Front Oil Seal
4. Crankshaft
4. Install the oil pan.
Refer to 1A-52,
W1A0015.

Piston,

Connecting

Rod

5. Install the control link.


Refer to 1A-17, Engine Exterior Equipment
W1A0004.
6. Install the injection pump.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
7. Install the injection pump housing cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
8. Install the solenoid ASM.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
9. Install the fuel pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
10. Install the injection pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
11. Install the generator bracket.
Refer to 1A-12, Engine Accessories W1A0003.
12. Install the generator.
Refer to 1A-12, Engine Accessories W1A0003.
13. Install the fan pulley.
Refer to 1A-12, Engine Accessories W1A0003.
14. Install the cooling fan and the fan belt.
Refer to 1A-12, Engine Accessories W1A0003.

Torque Specifications W1A00220008


7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)

18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

167 - 186 (17.0 - 19.0 / 123.2 - 137.2)

WSLE0305

1A-70 4LE2 Engine Mechanical

Crankshaft Rear Oil Seal

W1A0023

Components W1A00230005

3
1

WSLE0316

Name
1. Flywheel Housing
2. Rear Oil Seal

3. Retainer

Removal W1A00230006
1. Remove the starter.
Refer to 1A-12, Engine Accessories W1A0003.
2. Remove the flywheel.
Refer to 1A-63, Flywheel W1A0016.
3. Remove the flywheel housing.
a. Remove the mounting bolt to the cylinder block.
b. Gently tap the housing by a plastic hammer or
similar tool to remove it from the cylinder block.

WSLE0138

4. Remove the retainer.


Remove the retainer with the rear oil seal from the
back of the cylinder block.

4LE2 Engine Mechanical 1A-71


CAUTION:
Since liquid gasket is applied, be careful not to
remove it forcedly to damage or deform it.
1

1
2
2

WSLE0329

WSLE0226

Name
1. Retainer
2. Rear Oil Seal
5. Remove the rear oil seal from the retainer.
Remove the oil seal with a screwdriver avoiding
damage to the oil seal contact surface on the
retainer.

Installation W1A00230007
1. Install the rear oil seal to the retainer with a rear oil
seal installer.
Special tool
Rear oil seal installer
5-8840-9032-0

Name
1. Retainer
2. Rear Oil Seal
3. 1.75 mm {0.069 in}
4. 1.25 mm {0.049 in}
2. Install the retainer.
Apply a thin coat of engine oil to the lip section of
the oil seal and install the retainer. (Apply the liquid
gasket TB1207B)
CAUTION:
Be sure to prevent the big end of the crankshaft
from adhering of dust or foreign materials.
The tightening order of the retainer is as shown in
the illustration and you should tighten it to the following torque.
Tightening torque:
7.8 11.8 Nm {0.8 1.2 kgfm/5.8 8.7 lbft}

6
8

4
7

WSLE0128

1A-72 4LE2 Engine Mechanical


3. Install the flywheel housing to the cylinder block.
Tightening torque:
41.2 54.9 Nm {4.2 5.6 kgfm/30.4 40.5
lbft}

WSLE0138

4. Install the flywheel.


Refer to 1A-63, Flywheel W1A0016.
5. Install the starter.
Refer to 1A-12, Engine Accessories W1A0003.

Torque Specifications W1A00230008


N m (kg m / lb ft)

7.8 - 11.8 (0.8 - 1.2 / 5.8 - 8.7)


41.2 - 54.9 (4.2 - 5.6 / 30.4 - 40.5)

WSLE0306

4LE2 Engine Mechanical 1A-73

Timing Gear Train

W1A0010

Components W1A00100005

WSLE0317

Name
1. Thrust Collar
2. Idle Gear

3. Idle Gear Shaft


4. Crankshaft Gear

Removal W1A00100006
1. Remove the cooling fan and the fan belt.
Refer to 1A-12, Engine Accessories W1A0003.
2. Remove the fan pulley.
Refer to 1A-12, Engine Accessories W1A0003.
3. Remove the generator.
Refer to 1A-12, Engine Accessories W1A0003.
4. Remove the generator bracket.
Refer to 1A-12, Engine Accessories W1A0003.
5. Remove the injection pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
6. Remove the fuel pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
7. Remove the solenoid ASM.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
8. Remove the injection pump housing cover.

9.

10.

11.

12.

13.

14.

Refer to 1A-17, Engine Exterior Equipment


W1A0004.
Remove the injection pump.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the control link.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
Remove the oil pan.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
Remove the crank pulley.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
Remove the timing gear case.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
Remove the idle gear and the idle gear shaft.

1A-74 4LE2 Engine Mechanical


Inspection W1A00100009
Inspection of backlash of the timing gear
W1A0010000901

Before removing the timing gear, measure backlash of


it.
1. Put a dial gauge on the tooth of the measured
gear.
2. Move the gear right and left lightly, and read the
deflection of the dial gauge.
If it exceeds the limit, replace the timing gear.
Backlash of the timing gear

mm {in}

Location

Standard
value

Service limit

Crank gear/Idle gear

0.04 {0.0016}

0.2 {0.008}

Idle gear/Camshaft gear

0.03 {0.0012}

0.2 {0.008}

WSLE0225

Name
1. Thickness Gauge

Inspection of idle gear and gear shaft W1A0010000903


1. If there is excessive wear or damage on the sliding
surface of the idle gear and the gear shaft, and on
the inside of the idle gear bushing, replace either
the shaft or the gear.
2. If there is stepped wear or something on the idle
gear and the thrust collar, replace either the idle
gear or the thrust collar.

WSLE0224

Inspection of axial play of the idle gear


W1A0010000902

Measure an axial play of the gear before removing the


idle gear.
1. Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance.
2. If the measurement exceeds the limit, replace
either the thrust collar or the idle gear.
Axial play of idle gear

mm {in}

Standard value

Service limit

0.058 0.115 {0.0023


0.0045}

0.2 {0.008}

WSLE0246

Name
1. Idle Gear Shaft

Inspection of uneven wear of the idle gear


shaft W1A0010000904
Measure the outside diameter of the idle gear shaft
using a micrometer, and calculate the amount of
uneven wear.

4LE2 Engine Mechanical 1A-75


mm {in}
Nominal dimension

Service limit

Repairing procedure

45 {1.772}

0.1 {0.0039}

Replace.

a. Install the idle gear shaft to the cylinder block.


(The position where the oil hole is located
obliquely upward)
b. Apply engine oil to the bushing surface and the
tooth surface of the idle gear, and the idle gear
shaft. Then assemble the idle gear with its timing points (black dots) facing the forward direction and aligning the timing points (black dots)
of the camshaft gear and the crank gear at the
same time.

1
2

WSLE0105

Inspection of clearance between the idle gear


bushing and the shaft W1A0010000905
Measure the idle gear bushing bore and calculate the
clearance between the bushing and the outside diameter of the idle gear shaft.
mm {in}
Standard value

Service limit

Repairing procedure

0.025 0.085
{0.00098 0.00330}

0.2 {0.008}

Replace the idle gear


or the shaft.

WSLE0132

Name
1. Camshaft Gear
2. Timing Point
3. Crank Gear
4. Idle Gear
c. Apply engine oil to the thrust collar sliding surface and the threads and the seating surfaces
of the bolts. Then install to the idle gear with the
chamfered side of the collar facing the outside,
and tighten it with the bolts.
Tightening torque:
20.6 30.4 Nm {2.1 3.1 kgfm/15.2 22.4
lbft}
CAUTION:
Assemble the idle gear shaft aligning the positioning pin with the knock hole.

Installation W1A00100007
1. Install the idle gear.

1A-76 4LE2 Engine Mechanical


Refer to 1A-12, Engine Accessories W1A0003.
14. Install the cooling fan and the fan belt.
Refer to 1A-12, Engine Accessories W1A0003.

3
2

1
4
5

WSLE0131

Name
1. Thrust Collar
2. Timing Point
3. Idle Gear
4. Idle Gear Shaft
5. Timing Point
2. Install the timing gear case.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
3. Install the crank pulley.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
4. Install the oil pan.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
5. Install the control link.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
6. Install the injection pump.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
7. Install the injection pump housing cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
8. Install the solenoid ASM.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
9. Install the fuel pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
10. Install the injection pipe.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
11. Install the generator bracket.
Refer to 1A-12, Engine Accessories W1A0003.
12. Install the generator.
Refer to 1A-12, Engine Accessories W1A0003.
13. Install the fan pulley.

4LE2 Engine Mechanical 1A-77


Torque Specifications W1A00100008
N m (kg m / lb ft)

20.6 - 30.4 (2.1 - 3.1 / 15.2 - 22.4)

WSLE0307

1A-78 4LE2 Engine Mechanical

Camshaft

W1A0012

Components W1A00120005

10
9

8
7
6
5
4
3
2
1

WSLE0318

Name
1. Sleeve
2. Lock Nut
3. Flyweight ASM
4. Camshaft Gear
5. Snap Ring

Removal W1A00120006
1. Remove the EGR cooler and the bracket.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
2. Remove the cylinder head cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
3. Remove the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
4. Remove the cylinder head.
Refer to 1A-41, Cylinder Head W1A0014.
5. Remove the tappet.
Refer to 1A-41, Cylinder Head W1A0014.
6. Remove the timing gear case.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
7. Remove the camshaft gear.

6.
7.
8.
9.
10.

Bearing
Pin
Camshaft
Wear Ring
Bearing

a. Pull out the sleeve from the end of the camshaft.


b. Remove the lock nut from the camshaft gear,
and remove the flyweight ASM and the camshaft gear.
8. Remove the camshaft.
a. Remove the snap ring which holds the front
bearing of the camshaft from the ring groove of
the cylinder block.
b. Pull out the camshaft with the bearing from the
cylinder block.

4LE2 Engine Mechanical 1A-79


Inspection of journal and cam W1A0012000902
1. Height of the cam (A B)
mm {in}
Standard
value
1

Service limit

Inlet

6.13 {0.241} 5.83 {0.230}

Exhaust

6.43 {0.253} 6.13 {0.241}

Repairing
procedure
Replace.

2. Center journal diameter (the dimensions in X X


and Y Y directions)
mm {in}

WSLE0052

Name
1. Camshaft
2. Snap Ring

Nominal dimension

Service limit

Repairing procedure

52 {2.047}

51.92 {2.044}

Replace.

3. Uneven wear of the journal (the difference


between the measurements in X X and Y Y
directions)
mm {in}

Inspection W1A00120009
Inspection of camshaft

Nominal dimension

Service limit

Repairing procedure

52 {2.047}

0.05 {0.002}

Replace.

W1A0012000901

Check the journal portion and the cam portion for wear,
damage, and other abnormality.
CAUTION:
The ball bearings are fitted to the front and rear
parts of the camshaft. Also, the roller bearing is
press-fitted to the cylinder block at the center part.
Check that each bearing has no rattle and rotates
smoothly with this condition.

WSLE0082

WSLE0081

Name
1. Camshaft

1A-80 4LE2 Engine Mechanical

I II
I II
Y
A

X
Y

WSLE0083

Inspection of camshaft runout

W1A0012000903

1. Put the camshaft on the V block.


2. Place the dial gauge to the center journal part.
3. Rotate the camshaft once and read the deflection
of the indicator.
If the measured value exceeds the limit, replace
the camshaft.
mm {in}
Standard value

Service limit

Repairing procedure

0.02 {0.0008} or
less

0.1 {0.0039}

Replace.

WSLE0237

Name
1. Normal
2. Cracks
3. Pitching
4. Abnormal Contact

Inspection for wear of the tappet outside


diameter W1A0012000905
Use a micrometer to measure the outside diameter of
the tappet.
If the measured value exceeds the limit, replace the
tappet.
Outside diameter of the tappet

mm {in}

Standard value

Service limit

20.97 20.98 {0.8256


0.8260}

20.92 {0.8240}

WSLE0084

Inspection of tappet

W1A0012000904

Check the contact surface with the camshaft.


If there is pitching, defective contact, vermiculation, or
crack, replace the tappet.

WSLE0091

4LE2 Engine Mechanical 1A-81


Inspection of clearance between the tappet
and the cylinder block W1A0012000906
Use the bore gauge to measure the bore diameter of
the tappet insertion hole on the cylinder block and calculate the clearance.
Clearance between the tappet and the cylinder
block hole

mm {in}

Standard value

Service limit

0.020 0.054 {0.0008


0.0021}

0.1 {0.0039}

WSLE0129

2. Install the camshaft gear and the sleeve.


a. Install the camshaft gear to the camshaft with
its timing point (black dot) facing the forward
direction.
b. Assemble the flyweight, apply engine oil to the
thread and the seating surface of the lock nut,
and tighten.
Tightening torque:
165 185 Nm {16.8 18.8 kgfm/121.7
136.4 lbft}
WSLE0238

Installation W1A00120007
1. Install the camshaft ASM.
a. Apply engine oil to the camshaft journal, bearing, cam surface, and the inside of the cylinder
block bearing. Then assemble the camshaft
ASM.
CAUTION:
Be careful not to damage the bearing when assembling.
b. Install the snap ring to the outside of the front
bearing, and check that the camshaft rotates
smoothly.

c. Apply engine oil to the sleeve shaft and the sliding surface of the flyweight.
d. Insert the sleeve collar section to the concave
portion of the flyweight. Then insert the sleeve
shaft to the end of the camshaft.
Note:
Check that the sleeve moves smoothly.

1A-82 4LE2 Engine Mechanical

3. Install the timing gear case.


Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
4. Install the tappet.
Refer to 1A-41, Cylinder Head W1A0014.
5. Install the cylinder head.
Refer to 1A-41, Cylinder Head W1A0014.
6. Install the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
7. Install the cylinder head cover.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.

3
2
1

WSLE0130

Name
1. Sleeve
2. Lock Nut
3. Flyweight
4. Timing Point
5. Camshaft Gear

Torque Specifications W1A00120008


N m (kg m / lb ft)

165 - 185 (16.8 - 18.8 / 121.7 - 136.4)

WSLE0308

4LE2 Engine Mechanical 1A-83

Crankshaft

W1A0024

Components W1A00240005

WSLE0319

Name
1. Crankshaft Gear
2. Bearing Cap

Removal W1A00240006
1. Remove the engine accessories.
Refer to 1A-12, Engine Accessories W1A0003.
2. Remove the engine exterior equipment.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
3. Remove the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
4. Remove the cylinder head.
Refer to 1A-41, Cylinder Head W1A0014.
5. Remove the piston and the connecting rod.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
6. Remove the flywheel.
Refer to 1A-63, Flywheel W1A0016.
7. Remove the crankshaft front oil seal.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
8. Remove the crankshaft rear oil seal.

3. Crankshaft

Refer to 1A-70, Crankshaft Rear Oil Seal


W1A0023.
9. Remove the idle gear.
Refer to 1A-73, Timing Gear Train W1A0010.
10. Remove the camshaft.
Refer to 1A-78, Camshaft W1A0012.
11. Remove the oil pump ASM from the cylinder block.

1A-84 4LE2 Engine Mechanical


Disassembly W1A00240010
1. Remove the gear from the crankshaft.

Inspection W1A00240009

Inspection of axial play of the crankshaft


W1A0024000901

Measure an axial play before removing the crankshaft.


1. Pull the crankshaft all the way to the front.
2. Insert the thickness gauge to the front side of No.2
journal portion of the crankshaft (thrust bearing
installation part) and measure the play.
If the measured value exceeds the limit, replace
the thrust bearing.
Axial play of crankshaft
WSLE0223

Name
1. Cylinder Block

mm {in}

Standard value

Service limit

0.058 0.208 {0.0023


0.0082}

0.3 {0.012}

12. Remove the crankshaft.


a. Gradually loosen the bolts of each bearing cap
evenly in the order shown in the illustration.
Tap the cap lightly with a copper hammer to
remove it with the bearing.
b. Remove the crankshaft ASM.
c. Remove the thrust bearing from No.2 journal of
the cylinder block.

CAUTION:
Attach tags with each cylinder number to the
removed cylinder parts to identify installation positions, and put them in order.

WSLE0228

Name
1. Measurement of Play
2. Front

9 8

Inspection of crankshaft

2
2

10

W1A0024000908

Check for wear, damage, clogging of oil port and other


abnormality.

Inspection of outside diameter of the


crankshaft journal W1A0024000902
WSLE0229

Name
1. Arrow Mark
2. Front

Measure the outside diameter of the crankshaft journal,


and calculate the amount of wear and uneven wear.
If it exceeds the limit, replace the crankshaft.
1. Nominal dimension

4LE2 Engine Mechanical 1A-85


mm {in}

3. Amount of wear
mm {in}

Journal
60 {2.362}

4LE2X

Pin

Service limit

Repairing procedure

0.13 {0.005}

Replace the crankshaft.

2. Uneven wear (the difference between the measurements in X X, Y Y directions)


mm {in}

Journal

Service limit

Repairing procedure

0.05 {0.002}

Replace the crankshaft.

3. Amount of wear

mm {in}

Journal

Service limit

Repairing procedure

0.14 {0.0055}

Replace the crankshaft.

X
Y

WSLE0098

Inspection of clearance between the journal


and the bearing W1A0024000903

Y
X

Tighten the bearing cap to the specified torque and


measure the inside diameter of the bearing to calculate
the clearance.

X
Y

Tightening torque:
83.4 93.2 Nm {8.5 9.5 kgfm/61.5 68.7 lbft}
Clearance between the journal and
the bearing
WSLE0098

Inspection of outside diameter of the


crankshaft pin W1A0024000906
Measure the outside diameter of the crankshaft pin,
and calculate the wear and the uneven wear.
If it exceeds the limit, replace the crankshaft.
1. Nominal dimension
mm {in}
Pin
4LE2X

46 {1.811}

2. Uneven wear (the difference between the measurements in X X, Y Y directions)


mm {in}

Pin

Service limit

Repairing procedure

0.05 {0.002}

Replace the crankshaft.

mm {in}

Standard value

Service limit

Repairing procedure

0.029 0.072
{0.0011 0.0028}

0.11 {0.0043}

Replace the bearing.

1A-86 4LE2 Engine Mechanical


Inspection of crankshaft runout W1A0024000905
Hold the journal portions on both ends of the crankshaft
with V block, and measure the runout of the center journal using the dial gauge.
mm {in}
Standard value

Service limit

Repairing procedure

0.025 {0.00098}
or less

0.05 {0.002}

Replace.

WSLE0099

Inspection of tension of the journal main


bearing W1A0024000904
Check whether the tension of the bearing is sufficient.
mm {in}

4LE2X

Standard value

Service limit

W = 64.5 65.5
{2.539 2.579}
D = 64 {2.520}
L = 0.02 0.06
{0.0008 0.00236}

W = 64.1 {2.524}

WSLE0100

Inspection of crankshaft gear

Repairing procedure: use the one with extrusion and


tension, and be careful about sticking of the rear side.

W1A0024000907

Check visually for damage and other abnormality.


Replace if there is damage or serious pitching.

Standard for the bearing tension (reference)


1

4.9kN {1101.6lbf}
2
L

WSLE0101
WSLE0242

Name
1. Tension (Free Condition)
2. Extrusion

Reassembly W1A00240011
1. Install the crankshaft gear.
Put a brass stick on the gear and strike with a
hammer to install.

4LE2 Engine Mechanical 1A-87


c. Assemble the pawl of the bearing to the cutout
portion of the cylinder block securely, and apply
engine oil sufficiently to the inside of the bearing (sliding surface).
2. Install the crankshaft.
Put the crankshaft on the cylinder block carefully.
3. Install the crankshaft lower bearing.
Assemble the thrust bearing with the oil groove
facing outward. (No.2 journal portion)
CAUTION:
Be sure to prevent the installation position and
sliding surface of the bearing from adhering of
dirt.
Be sure to prevent the backside of the bearing
(installation position) from adhering of oil.
WSLE0245

Installation W1A00240007

1. Install the crankshaft upper bearing.


a. While there are the oil holes and oil grooves on
the upper bearing (block side), there is none on
the lower bearing (bearing cap side). Take care
when assembling.
CAUTION:
If assembling the lower bearing and upper bearing
inversely, seizure occurs in the crankshaft bearing.
Be careful with it.

WSLE0123

Name
1. Thrust Bearing
2. Crankshaft
3. Upper Bearing Pawl
4. Lower Bearing Pawl
2

WSLE0122

Name
1. Upper Bearing
2. Lower Bearing
b. Wipe the rear side of the crankshaft bearing
and the inside of the crank bearing housing of
the cylinder block, and check that there is no
foreign matter.

4. Install the crankshaft bearing cap.


a. Install the bearings to each bearing cap and
apply engine oil sufficiently. Then assemble
them from the front so that the arrow marks on
the caps facing toward the front of the engine in
the order of the marking numbers.
b. Apply engine oil to the threads and the seating
surface of the bearing cap bolt. Then tighten
evenly in several batches in the order shown in
the illustration, and at the end, tighten to the
specified torque.
Tightening torque:
83.4 93.2 Nm {8.5 9.5 kgfm/61.5 68.7
lbft}
c. After assembling, check that the crankshaft
rotates.

1A-88 4LE2 Engine Mechanical

1
10

2 3
1

7
2

WSLE0124

Name
1. Arrow Mark
2. Engine Oil Application
5. Install the oil pump ASM.
a. Pour engine oil to the oil pipe and installation
port of the oil strainer.
b. Install the oil pump ASM to the cylinder block.
Tightening torque:
18.6 28.4 Nm {1.9 2.9 kgfm/13.7 20.9
lbft}

WSLE0133

Name
1. Cylinder Block
6. Install the camshaft.
Refer to 1A-78, Camshaft W1A0012.
7. Install the idle gear.
Refer to 1A-73, Timing Gear Train W1A0010.
8. Install the crankshaft rear oil seal.
Refer to 1A-70, Crankshaft Rear Oil Seal
W1A0023.

9. Install the crankshaft front oil seal.


Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
10. Install the flywheel.
Refer to 1A-63, Flywheel W1A0016.
11. Install the pistons and connecting rods.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
12. Install the cylinder head.
Refer to 1A-41, Cylinder Head W1A0014.
13. Install the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
14. Install the engine exterior equipment.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
15. Install the engine accessories.
Refer to 1A-12, Engine Accessories W1A0003.

4LE2 Engine Mechanical 1A-89


Torque Specifications W1A00240008
N m (kg m / lb ft)

83.4 - 93.2 (8.5 - 9.5 / 61.5 - 68.7)


WSLE0309

1A-90 4LE2 Engine Mechanical

Cylinder Block

W1A0025

Components W1A00250005

WSLE0310

Name
1. Cylinder Block

Removal W1A00250006
1. Remove the engine accessories.
Refer to 1A-12, Engine Accessories W1A0003.
2. Remove the engine exterior equipment.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
3. Remove the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
4. Remove the cylinder head.
Refer to 1A-41, Cylinder Head W1A0014.
5. Remove the piston and the connecting rod.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
6. Remove the flywheel.
Refer to 1A-63, Flywheel W1A0016.
7. Remove the crankshaft front oil seal.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
8. Remove the crankshaft rear oil seal.
Refer to 1A-70, Crankshaft Rear Oil Seal
W1A0023.

9. Remove the idle gear.


Refer to 1A-73, Timing Gear Train W1A0010.
10. Remove the camshaft.
Refer to 1A-78, Camshaft W1A0012.
11. Remove the crankshaft.
Refer to 1A-83, Crankshaft W1A0024.

Inspection W1A00250009
Inspection of cylinder block

W1A0025000901

Check the cylinder block for wear, damage, water leakage and other abnormality.
1. Use a wooden plug or something to block the
water passage and check for leakage.
Water leakage: Water pressure test 490 kPa {71
psi} (for three minutes)
2. Check for damage by the color check.
3. Check the jet hole of the piston cooling and water
hole between bores for clogging or something
abnormal.

4LE2 Engine Mechanical 1A-91

Y
X

X
Y

WSLE0057

Inspection of cylinder bore

WSLE0058

Cylinder bore diameter and grade mark

W1A0025000902

Measure the cylinder bore at specified positions with a


cylinder gauge.
Measurement position: 13 mm {0.512 in} lower from the
top surface.
(Measure in the X X and Y Y directions.)
(Near top ring)

W1A0025000903

Grade mark is stamped to each installation surface of


the injection pump of the cylinder block.
mm {in}
Engine model

mm {in}
Nominal
dimension

Service limit

85
{3.3465}

85.2
{3.354}

Repairing procedure
4LE2X
Perform boring along the piston and perform honing.

CAUTION:
Oversized piston and piston ring are set to 0.25
mm {0.0098 in}.
Be sure to perform honing after boring.
Honing should be at 0 to 0.03 mm {0 to 0.0012
in} against oversize diameter. Difference of
each cylinder bore should be 0.02 mm {0.0008
in} or less.

Bore diameter

Grade

85.000 85.010
{3.3465 3.3468}

85.011 85.020
{3.3469 3.3472}

85.021 85.030
{3.3473 3.3476}

WSLE0059

Name
1. Bore Grade Mark (Marking Position)

1A-92 4LE2 Engine Mechanical


Inspection of top distortion W1A0025000904
Place a straightedge on the four side-directions and the
two diagonal directions, and measure the distortion
with the thickness gauge.
mm {in}
Standard
value

Abnormal value
(need repair)

0.075
{0.00295} or
less

0.15 {0.006}

Repairing procedure
Repair it with a surface
grinder. The total amount
of repaired values of the
cylinder head and of the
cylinder block should not
exceed 0.3 {0.012}.
If the measured value
exceeds the maximum
repaired value, replace
the cylinder block.

WSLE0062

Installation W1A00250007

WSLE0060

(Reference) Cylinder block height

mm {in}

Engine model

Standard value

4LE2X

307.94 308.06 {12.124 12.128}

1. Install the crankshaft.


Refer to 1A-83, Crankshaft W1A0024.
2. Install the camshaft.
Refer to 1A-78, Camshaft W1A0012.
3. Install the idle gear.
Refer to 1A-73, Timing Gear Train W1A0010.
4. Install the crankshaft rear oil seal.
Refer to 1A-70, Crankshaft Rear Oil Seal
W1A0023.
5. Install the crankshaft front oil seal.
Refer to 1A-66, Crankshaft Front Oil Seal
W1A0022.
6. Install the flywheel.
Refer to 1A-63, Flywheel W1A0016.
7. Install the pistons and connecting rods.
Refer to 1A-52, Piston, Connecting Rod
W1A0015.
8. Install the cylinder head.
Refer to 1A-41, Cylinder Head W1A0014.
9. Install the rocker arm bracket.
Refer to 1A-35, Rocker Arm Shaft W1A0075.
10. Install the engine exterior equipment.
Refer to 1A-17, Engine Exterior Equipment
W1A0004.
11. Install the engine accessories.
Refer to 1A-12, Engine Accessories W1A0003.

4LE2 Engine Mechanical 1A-93

Special Tool
List of Special Tool W1A00720028
Illustration

W1A0072

Illustration

Tool No./Tool Name/Rank

Tool No./Tool Name/Rank


1-8522-1029-0
Piston ring setting tool
Rank B

5-8840-2675-0
J-26999-12
Compression gauge
Rank B

5-8840-9018-0
J-8037
Piston ring compressor
Rank B

5-8840-9029-0
Compression gauge adapter
Rank A

5884090290

5-8840-9016-0
J-28829
Nozzle tester
Rank B

5-8840-9031-0
Front oil seal installer
Rank A

5884090310

5884090160

5-8840-9030-0
J-29760
Valve spring remover
Rank B
5884090300

5-8840-9035-0
Valve guide installer
Rank B

5884090350

5-8840-9033-0
JKM-1009
Valve seal setting tool
Rank B
5884090330

5-8840-9032-0
Rear oil seal installer
Rank A

5884090320

1A-94 4LE2 Engine Mechanical

4LE2 Cooling System 1B-1

Engine
4LE2 Cooling System
Table of Contents
Cooling System W1B0037 .................................... 1B-2
Service Precautions W1B00370001 .................. 1B-2
Explanations
on
Functions
and
Operation
W1B00370027 ................................................... 1B-2
Function Check W1B00370012 ......................... 1B-4
Water Pump W1B0040 ......................................... 1B-7
Components W1B00400005 .............................. 1B-7
Inspection W1B00400009 .................................. 1B-7
Thermostat W1B0041 ........................................... 1B-8
Inspection W1B00410009 .................................. 1B-8
Fan Clutch, Cooling Fan W1B0044....................... 1B-9
Inspection W1B00440009 .................................. 1B-9

1B-2 4LE2 Cooling System

Cooling System

W1B0037

Service Precautions W1B00370001

Explanations on Functions and Operation

WARNING:
Do not remove the radiator cap when the cooling
water is at high temperature. Steam or boiling
water will gush out and you may be burnt. To open
the radiator cap, cover the cap with a thick cloth
when the cooling water is cool, release the pressure by slowly turning the cap, and then remove
the cap.

W1B00370027

Cooling water system

W1B0037002701

The cooling water system, which is the forced circulation system, consists of a water pump, thermostat, and
radiator as its main components.

3
2

7
5

WSLE0172

Name
1. Thermostat (Bottom Bypass type)
2. Oil Cooler
3. EGR Cooler
4. Cylinder Head

Water pump

W1B0037002702

The water pump, which uses the centrifugal impeller


system, is driven by the engine fan belt.

5.
6.
7.
8.

Cylinder Block
Water Pump
Radiator
Bypass Circuit

4LE2 Cooling System 1B-3

WSLE0350

Name
1. Fan Center
2. Impeller

Thermostat

W1B0037002703

The thermostat, which is a wax pellet type, has an


valve initial opening temperature of 821.5C
{18034.7F}.

3. Seal Unit
4. Bearing Unit

1B-4 4LE2 Cooling System

WSLE0349

Name
1. Valve
2. Piston

3. Jiggle Valve

Function Check W1B00370012


Cooling water level check

W1B0037001201

Check the cooling water level within the reserve


tank and the level is appropriate when the cooling
water level is within the MAX (upper limit) and MIN
(lower limit) range. In case the volume of the cooling water is deficient, remove the reserve tank cap
and replenish with a mixture of tap water and
engine coolant in the ratio of 1:1 until the level
comes close to the MAX line.

Use engine coolant with a mix ratio in the range


of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and corrosion prevention is inadequate if the ratio is less
than 30%.

Standard value
Cooling water level

4.3 L {4.5 qts}


(Engine only)

Cooling water leak check W1B0037001202


Use the radiator cap tester and apply a pressure of
200 kPa {29.0 psi} and check for leaks in the locations given below. Check that the radiator hose
and heater hose are not damaged or degraded
and the hose clamp is not loose.
Inspection location
Radiator ASM, water pump ASM, radiator hose,
heater hose

Coolant

Freezing
temperature
guideline

Concentration
of engine coolant

Engine
coolant

Tap water

18C {0.4F}

4.2 {4.4}

7.8 {8.2}

35%

25C {13F}

5.0 {5.3}

7.0 {7.4}

42%

35C {31F}

6.0 {6.3}

6.0 {6.3}

50%

40C {40F}

6.4 {6.8}

5.6 {5.9}

53%

W1B0037001203

1. About the engine coolant concentration


Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the concentration of the engine coolant.
Use only Isuzu genuine engine coolant.

Maximum mix ratio


L {qts}

4LE2 Cooling System 1B-5


2. Engine coolant concentration measurement
Methods for measuring specific gravity
Measure the specific gravity and the temperature
of the cooling water using an antifreeze hydrometer and thermometer.
Take precautionary measures as the boiled cooling water may gush out at high temperatures if the
cap is removed.
Use a deep container to suit the height of the specific gravity meter.

Coolant scope method


Name
1. Antifreeze Hydrometer
2. Radiator
Fix the temperature of the cooling water being
measured in the range of 0 to 50C {32 to 122F}.
Measure the temperature and specific gravity and
determine the concentration from the table given
below.

Measure the concentration using the coolant


scoop.
EGR cooler air bleeding procedure
When replacing the coolant, bleed air from the EGR
cooler with the following procedure.
Note:
Be sure to replace the coolant when it is cooled.
1. Loosen the air bleed plug (1) on the EGR cooler.

WSLE0355

1B-6 4LE2 Cooling System


2. Pour coolant into the radiator via its opening.
3. Tighten the plug when the coolant spills over from
the air bleed plug.
Replace the copper packing if it is faulty.
Note:
Take care to prevent the spilt coolant from getting
the exhaust system parts wet.
Be sure to wipe off the spilt coolant.
Tightening torque:
24.5 30.5 Nm {2.5 3.1 kgfm/18.1 22.5
lbft}
4. Pour coolant into the radiator via its opening again
until it is filled.
5. Bleed air from the engine body coolant with idling
the engine.

4LE2 Cooling System 1B-7

Water Pump

W1B0040

Components W1B00400005

WSLE0173

Name
1. Water Pump

Inspection W1B00400009
Appearance check

W1B0040000901

Check for cracks or damage in the pump body.


Check for cracks and corrosion in the impeller.
Check for water leakage from the seal unit.
If you find abnormalities, replace the water pump
ASM.

Inspection of bearing W1B0040000902


Rotate the fan center while pushing it along the
radial direction. Confirm that there is no abnormal
noise and no excessive play.
If you find abnormalities, replace the water pump
ASM.

Inspection of the bearing rattle


Rattle of the water pump ball bearing

W1B0040000903

mm {in}

Standard value

Service limit

Repairing procedure

0.008 0.010
{0.00031 0.00040}

0.2 {0.008}

Replace.

1B-8 4LE2 Cooling System

Thermostat
Inspection W1B00410009
Replace it if there is wear, damage, or other abnormality.
Open start temperature
Valve lifting height

C {F}

821.5 {18034.7}

mm {in}

9.5 {0.374} or more


(95C {203F})

WSJJ0148

Name
1. Thermometer
2. Stirrer
3. A Piece of Wood

W1B0041

4LE2 Cooling System 1B-9

Fan Clutch, Cooling Fan

W1B0044

Inspection W1B00440009
If wear, damage or any fault is found during the inspection, replace or repair as required.
Visually check for damage, silicon grease leakage or
other faults.
1. Inspection (on-vehicle)
a. Before starting the engine, rotate the fan clutch
when it is cold by hand to check if it rotates easily.
b. Start the engine and warm it up until the temperature of the fan clutch reaches approx. 85C
{185F}. Then stop the engine, and rotate the
fan clutch by hand to check if considerable
force (clutch torque) is required to rotate. However, if the fan clutch rotates easily, this indicates that the silicon grease is leaked inside.
Replace the fan clutch with new one.

WSJJ0278

2. Inspection (single unit)


a. Warm up the bimetal area of the fan clutch
using a heat gun until the temperature reading
on the thermistor reaches approx. 85C
{185F}. Then check if considerable force
(clutch torque) is required to rotate the fan
clutch.
At this time, if the fan clutch rotates easily, this
indicates that the silicon grease is leaked
inside. Replace the fan clutch with new one.

Heat gun

Thermistor

WSJJ0279

1B-10 4LE2 Cooling System

4LE2 Fuel System 1C-1

Engine
4LE2 Fuel System
Table of Contents
Fuel System W1C0045 .........................................1C-2
Service Precautions W1C00450001 ..................1C-2
Explanations
on
Functions
and
Operation
W1C00450027 ...................................................1C-3
Governor W1C0079 ..............................................1C-6
Service Precautions W1C00790001 ..................1C-6
Components W1C00790005..............................1C-7
Disassembly W1C00790010..............................1C-9
Reassembly W1C00790011 ..............................1C-9

1C-2 4LE2 Fuel System

Fuel System
Service Precautions W1C00450001
Parts of the fuel system such as the internal part of the
nozzle holder, holes and clearances that form passages for fuel are finished to a very high degree of
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Take extreme care not to
allow foreign matter to enter.
If water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use water removal agent in the fuel
tank.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
Before beginning the service procedure, wash the
fuel line and the surrounding area.
Perform the service procedures with clean hands.
Do not wear work gloves.
Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
If parts are to be replaced (fuel hose, fuel pipe,
etc.), do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with
new ones.

Work procedure W1C0045000101


The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, nozzle
holder, and injection pump.
The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage after
starting the engine.

W1C0045

4LE2 Fuel System 1C-3


Explanations on Functions and Operation W1C00450027
Fuel system diagram W1C0045002701

C
O

2
3

WSLE0180

Name
1. Fuel Tank
2. Sedimenter
3. Fuel Filter
Note:
Be careful foreign material does not enter into the
fuel system, because the precise fuel system is
used.

4. Injection Pump
5. Nozzle Holder
6. Nozzle

1C-4 4LE2 Fuel System


Injection pump W1C0045002702

WSLE0328

Name
1. Nozzle

Fuel filter

W1C0045002704

WSLE0348

Name
1. Rack Pin

Nozzle holder W1C0045002703


Note:
Do not disassemble the injection nozzle installed
on this engine since it has the 2-stage open valve
pressure nozzle.
If a overhaul of the nozzle and inspection and
adjustment of the injection pressure are required,
contact a BOSCH service center.

WSLE0327

Name
1. Cartridge

4LE2 Fuel System 1C-5


Sedimenter

W1C0045002705

C
O

3
WSLE0326

Name
1. Lever (Opening Position)
2. Lever (Closing Position)
3. Drain Plug

1C-6 4LE2 Fuel System

Governor
Service Precautions W1C00790001
1. Engine performance test is required for adjustment
of the governor-related parts.
2. Measure the dimensions of A and B in the structure diagram (1) before disassembling, and set
them to the same dimensions when reassembling.
3. When you cannot carry out a performance test
after reassembling, do not disassemble it.
4. Apply engine oil to each sliding portion (the lever
end surface, the shaft hole and the outer circumference of the shaft) when reassembling it.
5. Install the set spring securely to a groove of the pin
connecting the floating lever, taking care of the
assembly direction.
6. Before installing the start spring, make sure that
each lever moves by its weight.
7. After installing the start spring, make sure that
each lever moves smoothly.
Also, make sure that each spring operates normally.

W1C0079

4LE2 Fuel System 1C-7


Components W1C00790005
Structure diagram (1) W1C0079000501

4
5

A
2

22

21

10
20
11
19

12

18

13
17
14
16
15
WSLE0181

Name
1. Control Link
2. Link Plate
3. Start Spring
4. Idle Speed Screw
5. Idle Spring (Sub)
6. Fuel Cut Lever
7. Governor Shaft
8. Set Spring
9. Governor Cover
10. Guide Lever
11. Timing Gear Case

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Tension Lever
Angleich
Full Load Stopper
Shifter
Flyweight
Sleeve
Camshaft
Floating Lever
Main Spring
Lever (Main Spring)
Injection Pump

1C-8 4LE2 Fuel System


Structure diagram (2)

W1C0079000502

18

20

17

19

16
15
21

14

22

23

13

24
26

12

8
25

A
27

11
29

10
5

28
30

A
35

34
33

2
B
31
32
36
1

WSLE0182

Name
1. Timing Gear Case
2. Lever Bushing
3. Control Lever
4. O-ring
5. Speed Control Screw
6. Speed Control Screw
7. Start Spring Bracket
8. Fuel Cut Shaft
9. Return Spring
10. Idle Spring
11. O-ring
12. Fuel Cut Lever
13. Set Screw
14. Cap Nut
15. Floating Lever
16. Guide Lever
17. Set Spring
18. Start Spring

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Snap Pin
Control Link
Link Plate
Guide Piece
Shifter
Shaft (Floating Lever)
Shifter Shaft
Main Spring
Tension Lever
Angleich
Lever (Main Spring)
Return Spring
Cam Gear
Flyweight
Sleeve
Lever Bushing
Shaft
Full Load Set Screw

4LE2 Fuel System 1C-9


Disassembly W1C00790010

Disassembly of the shifter

Disassembly of the governor lever-related


components W1C0079001001
1. Remove the levers and spring from the timing gear
case.

Disassembly of the full load stopper

W1C0079001002

1. Remove the full load stopper from the timing gear


case.

Disassembly of the governor cover W1C0079001003


1. Remove the fuel cut lever and the idle springrelated components from the governor lever.

W1C0079001004

1. Remove the snap ring and the shaft to remove the


shifter from the guide lever.

Disassembly of the control lever-related


components W1C0079001005
1. Remove the nut to remove the control lever.
2. Take off the hook on the return spring from the projection of the lever (main spring) and pin.
3. Remove the bushing.
4. Remove the return spring.
5. Remove the lever (main spring).

Reassembly W1C00790011
Reassembly of the control lever-related components

W1C0079001101

1. Put the lever (main spring) through lever holes of the timing gear case.
CAUTION:
Put both axes of the lever through lever holes alternately before assembling the bushings.
2. Put the return spring of the control lever through a axis of the lever (main spring).
3. Assemble the bushing.
Assemble the bushing of the lever (main spring), and then assemble the bushing of the control lever.
CAUTION:
Apply Loctite (No.601) to the outer circle of the bushing when assembling the bushing.

3
4

5
WSLE0183

Name
1. Lever (Main Spring)
2. Bushing
3. Return Spring
4. Pin

5. Timing Gear Case


6. Bushing
7. Protrusion

4. Assemble the hooks on both ends of the return spring (control lever) to the protrusion of the lever (main spring)
and pin securely.
5. Assemble the control lever.

1C-10 4LE2 Fuel System


After installing the O-ring to a groove of the bushing (control lever), assemble the washer and the control lever,
and tighten the nut.
Tightening torque:
11.8 17.7 Nm {1.2 1.8 kgfm/8.7 13.1 lbft}

5
3
1

7
2

WSLE0184

Name
1. Bushing
2. Groove
3. O-ring
4. Washer

5. Control Lever
6. Spring Washer
7. Nut

CAUTION:
When tightening the control lever, fix the control lever.
(Fix the lever of the main spring. Do not over-tighten it.)
After assembling, make sure that the control lever moves smoothly.

Reassembly of the shifter

W1C0079001102

1. Assemble the shifter to the guide lever, put the


shaft through it, and assemble the snap ring.
2. Make sure that the shaft rotates smoothly.
3. Make sure that the shifter moves smoothly.

4LE2 Fuel System 1C-11

2
3

WSLE0185

Name
1. Guide Lever
2. Shifter
3. Snap Ring
4. Shaft

Reassembly of the governor cover

W1C0079001103

Assemble the fuel cut lever and the idle spring-related components to the governor cover.
5

22

22

7
3

9
12
14

13

10

11

Z
WSLE0186

Name
1. Folding Part
2. Governor Cover
3. Return Spring
4. Thrust Washer
5. Stop
6. Driving
7. Governor Cover
1. Apply engine oil to the sliding surface of the governor cover when assembling the shaft.

8.
9.
10.
11.
12.
13.
14.

Idle Spring
Nut
Spring Washer
Fuel Cut Lever
O-ring
Cutout Groove
Shaft

2. Assemble the both ends of the return spring to the


cutout groove on the bottom of the cover and the
folding part of the lever securely.

1C-12 4LE2 Fuel System


3. After assembling, make sure that it moves
smoothly.
4. When assembling the governor cover to the timing
gear case, temporarily tighten it with dimension A
in the diagram 2 3 mm {0.079 0.118 in}.
Assemble B part after the performance set.

Reassembly of the full load stopper W1C0079001104


Install the full load stopper to the timing gear case, and
temporarily tighten the nut.

mm {in}
Dimension A

(When temporarily assembling) 2 3


{0.079 0.118}
1

Arrow view of WSLE0186

1
2
3

5
6

WSLE0188

Name
1. Timing Gear Case
2. Full Load Stopper
3. Set Screw Nut

8
12
9
11

10

WSLE0187

Name
1. Cap
2. Cap Nut
3. Packing
4. Lock Nut
5. Packing
6. Idle Screw
7. Governor Cover
8. Tension Lever
9. Idle Spring
10. Snap Ring
11. Washer
12. Washer

Reassembly of the governor lever-related components


Assemble each lever and the spring to the timing gear case.

W1C0079001105

4LE2 Fuel System 1C-13


8
6

10
5

4
11

12
3
1
2

13

14

WSLE0189

Name
1. Plug
2. Shaft (Floating Lever)
3. Snap Piece
4. Guide Piece
5. Start Spring Eye
6. Lever Shaft
7. Link Plate

8.
9.
10.
11.
12.
13.
14.

Main Spring Lever


Tension Lever
Main Spring
Set Screw
Start Spring
Guide Lever
Floating Lever

4LE2 Electrical System 1D-1

Engine
4LE2 Electrical System
Table of Contents
General Description W1D00530015 .....................1D-2
General Description W1D00530015 ..................1D-2
Maintenance W1D00530034..............................1D-3
Generator (24V-50A) W1D0081............................1D-4
Structure W1D00810017....................................1D-4
Removal W1D00810006 ....................................1D-4
Installation W1D00810007 .................................1D-5
Torque Specifications W1D00810008................1D-5
Specifications W1D00810004 ............................1D-6
Connector Terminal W1D00810036...................1D-6
Internal Connections W1D00810037 .................1D-6
Disassembly W1D00810010..............................1D-7
Inspection W1D00810009..................................1D-7
Bench Test W1D00810018 ..............................1D-10
Handling W1D00810040 ..................................1D-11
Trouble and Action W1D00810041 ..................1D-11
Starting System W1D0057..................................1D-13
General Description W1D00570015 ................1D-13
Service Precautions W1D00570001 ................1D-13
List of Trouble Symptom W1D00570013 .........1D-14
Specifications W1D00570004 ..........................1D-14
Sectional View W1D00570022.........................1D-15
Starter W1D0060 ................................................1D-17
Components W1D00600005............................1D-17
Removal W1D00600006 ..................................1D-17
Installation W1D00600007 ...............................1D-17
Torque Specifications W1D00600008..............1D-18
Disassembly W1D00600010............................1D-18
Inspection W1D00600009................................1D-19
Reassembly W1D00600011 ............................1D-22
No Load Test W1D00600024...........................1D-25
Maintenance Standard W1D00600025 ............1D-25

1D-2 4LE2 Electrical System

Charging System

W1D0053

General Description W1D00530015


The main charging system components are the batteries, the generator and the battery charge indicator light
circuit. The generator is a self-rectifying type with a
built-in regulator.

7
WSLE0373

Name
1. Nut
2. Sliding Piece
3. Generator Adjusting Plate
4. Adjusting Nut

5. Tension Adjusting Bolt


6. Generator
7. Lower Mounting Bolt

4LE2 Electrical System 1D-3


Maintenance W1D00530034
The most common indication of charging system troubles is an undercharged or overcharged battery.
Since the battery itself may be defective, check the battery first. Check if the battery is discharged because of
short circuit, or electrical components left turned on for
extended periods.
Keep the generator and all other electrical system terminals clean and tight. A loose or badly corroded terminal connection will create excessive resistance in the
circuit and result in hard starting, dim lights, etc.
Inspect the generator system at regular intervals and
correct any potential causes of trouble before machine
performance is affected.

Diagnosis of charging system

W1D0053003401

Trouble in the charging system will be evidenced as


one or more of the following three conditions:
1. The battery charge warning lamp will stay on.
2. An undercharged battery as evidenced by slow
cranking.
3. An overcharge, or overvoltage, condition.
Undercharged battery
Inspection
1. Accessories were not left turned on for extended
periods.
2. Drive belt for proper tension.
3. The ECM main relay has been stuck ON with the
key switch in OFF position. (Battery voltage is consumed.)
4. Wiring and connections for corrosion or looseness.
Overcharge (or Overvoltage) condition
A charging rate in excess of 29.5 volts for a prolonged
period may cause early electrical system failure.
Blown fuses, light bulbs burned out, and even battery
failure may result. If this condition exists, test the generator as described under Generator Output Test later
in this section.
Noisy generator
Inspection
1. Drive pulley for looseness.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
Generator noise may also be caused by the loose
belt, core touch, or worn or damaged diodes and/
or starter.

Electrical tests

W1D0053003402

Before performing the following generator electrical


tests on the vehicle, be certain that the system wiring is
not defective and generator belts are not slipping. Also,
the battery must be fully charged for a valid test of the
charging system.

Note:
To avoid damage to the vehicle electrical system,
always observe the following precautions:
Do not polarize the generator.
Do not short across or ground any of the terminals
in the charging circuit.
Never operate the generator with the output terminal open-circuited.
Be sure the generator and battery have the same
ground polarity.
When connecting a charger or other battery to the
machine's battery, connect negative to negative
and positive to positive.
1. With the engine control switch ON and engine not
running, connect a voltmeter from terminal E to
ground. The voltmeter should show 0 volts.
2. With the engine control switch ON and engine not
running, connect a voltmeter from terminal B to
ground. The voltmeter should show 24 volts or
more.
3. With the engine control switch ON and the engine
not running, connect a voltmeter from white wire
side of the connector to ground. The voltmeter
should show 24 volts or more.
4. With the engine control switch ON and the engine
not running, the charge light should be on. This
shows that the current is running into the initiating
excitation circuit to the generator.
5. With the engine running and the headlight high
beams (if equipped) turned on, read the voltage at
the B post on the generator. The voltmeter
should show 24 volts or more.
6. If steps 1 through 4 are not OK, check connectors
in the harness for looseness or corrosion and
retest.
7. If step 5 voltage is low, substitute a known good
regulator and test again. If the voltage is still low,
bench test the generator.

1D-4 4LE2 Electrical System

Generator (24V-50A)

W1D0081

Structure W1D00810017

WSLE0367

Removal W1D00810006

1.
2.
3.
4.

Battery ground cable


Electrical wiring at the generator.
Loosen the adjusting nut.
Loosen the ACG adjusting bolt.
Loosen the lower mounting bolt.

4LE2 Electrical System 1D-5


Loosen the lower mounting bolt while holding
the nut located on the back using a tool.
5. Drive belt.
6. Generator.

Installation W1D00810007
1. Generator
Tighten the lower mounting bolt while holding
the nut located on the back using a tool.
Tightening torque:
Lower mounting bolt: 41.2 55.0 Nm {4.2
5.6 kgfm/30.4 40.6 lbft}

2. ACG adjusting bolt.


3. Adjusting nut.
Tightening torque:
Adjusting nut: 18.6 28.4 Nm {1.9 2.9 kgfm/
13.7 20.9 lbft}
4. Electrical wiring at the generator.
Battery ground cable
Install wiring (AV5.0 mm2, black) from the negative terminal of the generator to the engine
ground and connect it to ground securely.

Torque Specifications W1D00810008


N m (kg m / lb ft)
18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)
18.6 - 28.4 (1.9 - 2.9 / 13.7 - 20.9)

41.2 - 55.0 (4.2 - 5.6 / 30.4 - 40.6)


WSLE0374

1D-6 4LE2 Electrical System


Specifications W1D00810004
Isuzu Part No.

8980890630

Nominal output

(V-A)

24-50

Rated speed

(rpm)

5000

Regulator-type
Regulated voltage
Mass

IC type
(V)

28.51

(kg)

9.2

Connector Terminal W1D00810036


Terminal symbol

Lead wire color

Wire specifications

AEX 0.75f

AEX 0.75f

WSHK0101

Name
1. R Terminal
2. L Terminal

Internal Connections W1D00810037

SG

IC
REGULATOR

WSHK0102

4LE2 Electrical System 1D-7


Disassembly W1D00810010
Disassembly procedure
5
6
7

8 3

12
11

10

9 13
18
15
14

19
23

21
20
2

17
16
22
WSLE0369

Name
1. Screw
2. Cover
3. Through Bolt
4. Rotor, Front Bracket Assembly
5. Nut, Washer
6. Pulley
7. Fan
8. Collar
9. Screw
10. Retainer
11. Ball Bearing
12. Front Bracket
Assembly is the reverse order of disassembly.

Inspection W1D00810009
Diode

W1D0081000901

Check for continuity of forward and inverse directions


with a tester. Normal diodes show low resistance in forward direction and high resistance in inverse one.
Judge that they are faulty other than those above.

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

Collar
Ball Bearing
Rotor Assembly
Screw
Field Coil Assembly
Stator Assembly
Holder
Regulator Assembly
Bolt (B Terminal)
Condenser
Rectifier Assembly

1D-8 4LE2 Electrical System

WSHK0104
Condenser

WSHK0106
Field coil

W1D0081000902

Charge the condenser with a tester (at 1000


range), and connect a tester lead inversely. Judge it as
normal if the needle on a meter deflects a little and
returns to the original position.
Judge that they are faulty other than those above.

WSHK0105
Diode for initiating excitation, resistor
W1D0081000903

Check for continuity between connector terminals R


and L with a tester (at 100 range). Normal diodes
and resistors show low resistance in forward direction
and high resistance in inverse one.
Judge that they are faulty other than those above.

W1D0081000904

To judge the insulating condition of field coil, measure between the protrusion portions and core of
the coil with a tester (at 1000 range). Judge as
faulty if it has continuity.

WSHK0107
Measure between the protrusion portions of field
coil with a tester, and judge as normal if the resistance is about 6.7 (20C {68F}).

4LE2 Electrical System 1D-9

WSHK0110

WSHK0108
Stator coil

Bearing

W1D0081000905

To judge the insulating condition of stator coil,


measure between the stator coil and core with a
tester (at 1000 range). Judge as faulty if it has
continuity.

W1D0081000906

Check if the bearing rotates smoothly or has no


noise.
If the result of the inspection is unsatisfactory,
replace the bearing.

WSHK0109
Judge as normal if there is continuity between N
lead of stator coil and three leads.

WSHK0111
Rotor

W1D0081000907

Measure the outside diameter of the shaft at the


bearing mounting part.
Replace the rotor if the measurement exceeds limit
value.
mm {in}
Standard value

Service limit

Front

24.996 25.005
{0.9841 0.9844}

24.95{0.982}

Rear

16.996 17.012
{0.6691 0.6698}

16.95 {0.667}

Repairing
procedure

Replace.

1D-10 4LE2 Electrical System


Bench Test W1D00810018
In the performance test of generator, connect as follows and measure the regulated voltage and output
current.

Actual wiring diagram for performance test of IC regulator built-in generator

W1D0081001801

Disassembly procedure

SW 1

SW 2

WSLE0368

Name
1. Voltmeter
2. R Terminal
3. L Terminal
4. Charging Lamp 24 V-3 W

Regulated voltage measurement of regulator


W1D0081001802

Close SW1 switch, and warm-up five to ten minutes at


approx. 1500 rpm in generator until an ammeter shows
6 A or less.
After confirming that an ammeter shows between 2 and
6 A, set the generator between approx. 3000 to 4000
rpm. If an voltmeter shows between 27.5 and 29.5 V,
the regulated voltage of regulator is normal.
If the ammeter shows 6 A or more, charge the battery
for a while or replace it with full-charged battery.
Replace the regulator if the voltmeter shows out of
range between 27.5 and 29.5 V.

5. Clamp Tester Ammeter


6. Battery 24 V
7. Variable Resistor

Specified value of regulated voltage


27.5 29.5 V (+25C {77F})

Measurement of the output current

W1D0081001803

Close SW1 and SW2 switches, and raise the generator


speed to 5000 rpm. While keeping the voltmeter showing 27 V, measure the maximum value of output current
with a variable resistor.
In this time, judge as normal if the output current is 50
A or more.
Note:
Do not cut off battery circuit during generator rotating.

4LE2 Electrical System 1D-11


Do not connect to L terminal if the charging lamp
(24 V-3 W) is not used.
Never connect L terminal and B circuit directly.
Diode for excitation may be broken.
The electrical load from the L terminal should be
1.0 A or less continuously.

Handling W1D00810040
Be careful with the following when handling a generator.
Connecting the polarities of battery inversely
causes generator diode to be broken.
While the engine runs, Never disconnect the wiring
of battery terminal and charging circuit.
Wiring connection to terminal must be performed
properly according to terminal symbol.

Do not perform megger test on semiconductor


device.
Be sure to disconnect the battery terminal ()
before inspection on equipment.
Do not open/close the battery relay switch while
the engine runs.
Disconnect the battery terminal when charging
from external source such as quick charge.
Do not pour steam cleaner or water directly on it.
After connecting to B terminal and E terminal,
tighten them to the following torque.
B terminal: 4.9 6.9 Nm {50.0 70.4 kgfcm/
43.4 61.1 lbin}
E terminal: 4.9 6.9 Nm {50.0 70.4 kgfcm/
43.4 61.1 lbin}
Refer to 1A-4, ISUZU Diesel Engine W1A0002,
Function Check W1A00020012 for tension adjustment of the v-belt.

Trouble and Action W1D00810041


Trouble symptom

Trouble location

Charging is impossi- Wiring and ammeter


ble.
Generator

Regulator

Insufficient charging

Trouble cause
Open or short circuit, disconnection

Replace.

Broken diode

Replace.

Defective regulator

Replace.

Poor contact in terminal of regulator

Repair.

Wiring

Open or short circuit, looseness in connection

Repair.

Generator

Looseness of generator drive belt

Repair.

Regulator

Layer or short circuit in field coil

Replace.

Layer or short circuit in stator coil

Replace.

Defective diode

Replace.

Defective regulator
Poor contact in terminal of regulator

Unstable
current

Repair.

Open circuit, short to ground, short circuit in each coil

Poor contact in each terminal

Overcharging

Action to be
taken

Regulator

charging Wiring
Generator

Regulator

Defective regulator

Repair.
Replace.
Repair.
Replace.

Intermittent contact or nearly disconnected connection in wiring

Repair.

Looseness of generator drive belt

Repair.

Short circuit or nearly disconnected connection in field coil

Repair.

Short circuit or nearly disconnected connection in stator coil

Repair.

Poor contact in each terminal

Repair.

Defective regulator
Poor contact in terminal of regulator

Replace.
Repair.

1D-12 4LE2 Electrical System


Trouble symptom
Noisy generator

Trouble location
Generator

Trouble cause
Improper installation of generator
Defective bearing
Contact of rotor core and stator core

Action to be
taken
Repair.
Replace.
Repair.

Defective diode

Replace.

Short circuit in stator coil

Replace.

4LE2 Electrical System 1D-13

Starting System

W1D0057

General Description W1D00570015


The starter output is 3.2 kw.

1
WSLE0385

Name
1. Starter

Service Precautions W1D00570001


Handling of starter W1D0057000101
1. Precautions on handling
Improper gap between pinion and ring gear
causes faulty mesh. (Gap 2 3.5 mm {0.079
0.138 in})
Also, the front bracket is installed on the engine
side securely.
Be sure to turn off the battery switch before
removal/installation of starter.

Tightening/inserting wiring must be performed


properly. Looseness causes starting trouble
due to high contact resistance.
2. Precautions on starting
Be careful with charging status of battery. Insufficiently-charged battery causes starting trouble.
After checking engine starting, turn off the
starter switch immediately.
One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.

1D-14 4LE2 Electrical System


If the starter does not stop rotating when the
starter switch is turned off, turn off the battery
switch immediately. In this case, check the wiring, switch, etc.

List of Trouble Symptom W1D00570013


Condition
Starter does not operate when starter switch
is turned on.

Pinion moves forward but it does not engage


with ring gear.

Pinion engages and rotates motor but it does


not run engine.

Pinion engages but it does not run engine.

Possible cause
Full discharge of battery

Replace the battery.

Open circuit, poor contact

Repair.

Poor contact in starter switch


or defective tightening of terminal

Repair or replace it.

Poor contact in starter relay or


plug terminal

Repair or replace it.

Short or open circuit in magnetic switch coil

Replace.

Insufficient capacity of battery

Charge the battery.

Wear of pinion or ring gear


tooth edge

Replace the pinion or the ring


gear.

Dust on pinion shaft

Repair.

Slippage of clutch

Replace the clutch or the


starter.

Breakage of reduction gear

Replace
starter.

Insufficient capacity of battery

Charge the battery.

Defective tightening of wiring


circuit terminal

Repair.

Short circuit of armature or


field coil

Replace the starter.

Contamination of commutator

Repair, or replace the starter.

Fatigue or wear of brush


spring

Replace the brush spring or


the brush.

Locking of bearing

Replace the bearing or the


starter.

Poor contact
switch
When turning starter switch off after engine
starts, starter does not stop.

Correction

in

magnetic

the

or

the

Replace the magnetic switch.

Returning failure of starter


switch contact

Replace the starter switch.

Returning failure of starter


relay contact

Replace the starter relay.

Short circuit
switch coil

Replace the magnetic switch.

in

magnetic

Specifications W1D00570004

Power output

gear

Manufacturer

Mitsubishi Electric Co.

Isuzu Part No.

898072-3151

Manufacturer code No.

M008T81571
V-kW

24-3.2

4LE2 Electrical System 1D-15


Rating

Sec

Outside diameter of yoke

30

mm/in

81.6/3.213

Revolution direction

Clockwise

Reduction mechanism

Planetary gear

Weight

kg

Pinion

5.8

Module

3.0

Pressure angle

14.5

The number of teeth

11

Gear ratio {ring gear/pinion gear}


No load

Voltage

23

Current

80 or less

Revolution speed
Restraint

9 {99/11}

r/min

3,750 or more

Voltage

Current

760 or less

Torque

Nm {kgfm}

Pinion engagement voltage

47.07 {4.8} or more


16.0 or less

Sectional View W1D00570022


Reference
5

4
8
3
2

9
1
13

12

11

10
WSLE0376

Name
1. Through Bolt
2. Bearing
3. Rear Bracket

4. Brush Holder
5. Magnetic Switch
6. Shift Lever

1D-16 4LE2 Electrical System


7.
8.
9.
10.

Gear Shaft
Pinion
Bearing
Front Bracket

11. Gear
12. Yoke
13. Armature

4LE2 Electrical System 1D-17

Starter

W1D0060

Components W1D00600005

21

18

17

20
9
27
28
29

6
13
15
16
14
19

5
8

26
22

4
1

10

25

12

24
23
30
11

WSLE0377

Name
1. Snap Ring
2. Stop Ring
3. Pinion
4. Pinion Spring
5. Lead Wire with Terminal
6. Screw
7. Magnetic Switch
8. Screw
9. Through Bolt
10. Rear Bracket
11. Yoke Assembly
12. Brush Holder
13. Armature
14. Ball
15. Plate

Removal W1D00600006
1.
2.
3.
4.

Battery ground cable from the battery.


Cables and electrical leads from the starter.
Two mounting bolts.
Starter.

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Packing
Packing
Plate
Planetary Gear
Lever
Lever Spring
E-shaped Retaining Ring
Overrunning Clutch
Internal Gear
Washer
Gear Shaft
Front Bracket
Bearing
Washer
Brush

Installation W1D00600007
1. Starter.
2. Two mounting bolts.
Tightening torque:
Mounting bolt: 93.2 113 Nm {9.5 11.5 kgfm/
68.7 83.3 lbft}
3. Cables and electrical leads to the starter.

1D-18 4LE2 Electrical System


4. Battery ground cable to the battery.

Torque Specifications W1D00600008


N m (kg m / lb ft)

93.2 - 113 (9.5 - 11.5 / 68.7 - 83.3)

WSLE0386

Disassembly W1D00600010
CAUTION:
Before disassembling the starter, put alignment
marks on each magnetic switch, yoke, front bracket
and rear bracket to facilitate re-assembly.
Note:
In normal condition, if tap the pinion or stop ring toward
the front bracket side, the front bracket will be broken.
Therefore, tap the stop ring when the pinion comes out
to cranking position.
1. Remove the nut on M terminal of magnetic switch
and the lead wire with terminal as shown in the
illustration, and connect the starter to the battery.
When closing the switches SW1 and SW2, the pinion move forward to the cranking position and the
armature rotates.
Then, open the switch SW2 to stop the armature
rotating.
Note:
Remove the pinion within 10 seconds since heat is
generated during electric discharge.

SW 1

B
S
M

Battery
24V

SW 2
Disconnect the lead wire
(attached with terminal)
from the M terminal.

Wiring diagram to move pinion forward

WSLE0378

2. Apply the pipe, which just fits the stop ring, on the
ring and tap the pipe with a hammer to remove the
stop ring toward the pinion side once.
Then, remove the snap ring and remove the stop
ring, pinion and pinion spring.

4LE2 Electrical System 1D-19


11. Remove the two E-shaped retaining rings.
To remove the overrunning clutch, rotate the spline
by one tooth to remove it from gearshift assembly.

CAUTION:
Do not reuse the snap ring.

CAUTION:
Do not reuse removed E-shaped retaining ring.
12. Remove the internal gear.
In this time, take out one washer which adjusts
axial play of gearshift.

5
4
3
2

Inspection W1D00600009

1. Armature
Check the armature coil for internal short circuit
with a growler tester.
Replace the armature if internal circuit is
present.

WSLE0379

Name
1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
5. Pipe
6. Pinion Spring
3. Remove the screw of the magnetic switch, then
remove the magnetic switch.
CAUTION:
Tightening screw is tight. Use a shock driver to
loosen.
4. Remove the brush holder-tightening screw and
through bolt.
5. Apply a socket (outside diameter 32 mm {1.260
in}) on a commutator of armature.
Then, slide the brush on the socket, and remove
the yoke assembly with the brush rested on the
socket.
This facilitates to re-assemble.
6. Remove the brush from brush holder by pulling up
the brush spring, and then remove the brush
holder.
7. Remove the armature.
Remove a bearing using a general puller.
8. Remove the plate in planetary gear and remove
the packing.
Then, remove the packing and plate on the lever
support.
9. Remove the internal gear, gearshift, overrunning
clutch and lever as a unit from front bracket.
10. Remove the lever.
CAUTION:
Remember the direction of lever.

WSHK0074
Check the armature coil for grounding (faulty
insulating) with a circuit tester.
Replace the armature if grounding is present.

WSHK0075
Check the outside of commutator for wear.

1D-20 4LE2 Electrical System


Replace the armature if wear exceeds limit.

WSHK0076
Check the depth (undercut) of insulating mold
of commutator.
Remove abrasion powder on brush, and repair
if faulty.

WSHK0078
Check the coil for grounding (faulty insulating)
with a circuit tester.
Repair or replace the yoke assembly if grounding is present.

2
3

Name
1. Good
2. Insulating
3. Commutator Segment
4. Defective

WSHK0077

Check the gears for wear or damage.


Replace the armature if fault is present.
Check the bearings for noise, rattle or grease
leakage.
2. Field coil
Check the coil for open circuit with a circuit
tester.
Replace the yoke assembly if open circuit is
present.

WSHK0079
3. Brush
Measure the length of the brush.
If it is worn to the limit, replace the brush holder
assembly on the brush holder as a unit and only
brush on the yoke assembly side.
Make sure the brush moves smoothly in the
brush holder. Also, check the brush spring
pressure.
Check the brush holder for grounding (faulty
insulating) with a circuit tester.
Clean the brush holder before checking.
Replace the brush holder assembly if the continuity is present when putting one probe of circuit tester to brush holder plate (metal part) and
another one to insulated holder.

4LE2 Electrical System 1D-21


Check the internal gear and planetary gear, and
replace them if excessive wear or damage is
present.
7. Lever
If the portion which contacts the overrunning
switch is worn, the protruded position of pinion will
be faulty.
(Refer to 4. Assembly section to adjust the protruded position of pinion.)

Name
1. Brush Length
2. Insulated Holder

WSHK0080

4. Overrunning clutch and pinion


Hold the housing of overrunning clutch by hand.
Make sure that the pinion can be rotated by hand
with a light resistance in one direction and cannot
be in the opposite direction. Replace the overrunning clutch if faulty.
Check the pinion, and replace it if wear or scratch
is present.
CAUTION:
Grease is present in overrunning clutch. Do not
use wash oil or cleaning agent for cleaning.
Wipe off stain on overrunning clutch with a cloth.

WSHK0081
5. Front bracket
Check the bearing and oil seal, and replace the
front bracket assembly (including bearing, oil seal)
if faulty.
6. Internal gear and planetary gear

WSLE0380

Name
1. Worn Part
8. Magnetic switch
Check for continuity between the M terminal and
the body, and replace the magnetic switch if no
continuity is present.
Then, make sure that no continuity is present
between B terminal and M terminal. Replace the
magnetic switch if continuity is present.

1D-22 4LE2 Electrical System

1
WSLE0381

Name
1. M Terminal
2. S Terminal
3. B Terminal

Reassembly W1D00600011

24

10

13

14

11
22
4
3
2

25
18
16
15
17
12

26
23

5
9

27
30

29

21

28

19

7
8
1
20

WSLE0382

Name
1. Brush
2. Washer
3. Bearing

4. Front Bracket
5. Gear Shaft
6. Washer

4LE2 Electrical System 1D-23


7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Internal Gear
Overrunning Clutch
E-shaped Retaining Ring
Lever Spring
Lever
Planetary Gear
Plate
Packing
Packing
Plate
Ball
Armature

Brush Holder
Yoke Assembly
Rear Bracket
Through Bolt
Screw
Magnetic Switch
Screw
Lead Wire with Terminal
Pinion Spring
Pinion
Stop Ring
Snap Ring

1. Lubricant locations and tightening torque


N m (kg m / lb ft)
I
9.8 - 11.8
(1.0 - 1.2 / 7.2 - 8.7)

4.9 - 8.82
(0.50 - 0.90 / 3.61 - 6.51)

2.35 - 4.41
(0.24 - 0.45 / 1.73 - 3.25)

G
F
E

7.84 - 12.74
(0.79 - 1.30 / 5.78 - 9.40)
WSLE0383

Lubricant locations
Shown in the
illustration

Lubricant locations

Lubricant agent

Sleeve bearing and ball

MolycoteAG650

Clutch shaft sliding surface

MULTEMP 6129

Gear shaft spline section

Sliding portion of lever and overrunning clutch

MULTEMP 6129

Armature shift gear, planetary gear, internal gear

MolycoteAG650

Sliding portion of gear shaft

MULTEMP 6129

Outer surface of armature bearing (tiny amount)

MULTEMP 6129

Oil seal

MULTEMP 6129

Surface of plunger (tiny amount)

MULTEMP 6129

MULTEMP 0A-171

1D-24 4LE2 Electrical System


2. Axial play of armature shift
Adjustment is unnecessary (assemble the ball into
a tip of shaft.)
3. Axial play of gear shaft
Adjustment is unnecessary
Appropriate gap will be obtained automatically
when one washer (removed in step 12 of disassembly procedure) is inserted between internal
gear and gearshift.
4. Assembly of gear shaft
Pass the gear shaft through washer, internal gear
and overrunning clutch. Then move the overrunning clutch by one tooth of spline to make sure that
the clutch cannot be pulled out. Assemble the Eshaped retaining ring.
CAUTION:
Do not reuse removed E-shaped retaining ring.
If assembling the E-shaped retaining ring prior
to the overrunning clutch, the clutch cannot be
assembled. Be careful with it.

3
2

4
5

Name
1. Overrunning Clutch
2. Washer
3. Gear Shaft
4. E-shaped Retaining Ring
5. Internal Gear

WSHK0086

5. Assembly of pinion
Assemble the pinion spring, pinion and stop ring to
clutch shaft in this order, then assemble the snap
ring to the groove of clutch shaft at the end.
Then, pull strongly the stop ring toward the snap
ring side with a gear puller and fix both of them.
CAUTION:
Assemble the pinion before assembling the
magnetic switch to front bracket.
Do not reuse the removed snap ring.

4
3
2
1

WSLE0384

Name
1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
5. Pinion Spring
6. Check of the pinion protruded position
After assembling the starter, check the protruded
position of pinion.
How to measure and adjust
Connect the starter to battery.
When closing the switches SW1 and SW2, the
pinion move forward to the cranking position
and the armature rotates.
Then, open the switch SW2 to stop the armature rotating.
Push into or pull back a tip of the clutch shaft
lightly by hand and measure the moving distance of it.
Adjust by using one or two packings (0.5 mm
{0.020 in}) between magnetic switch and front
bracket so that this measurement value is
between 0.5 2.0 mm {0.020 0.079 in}.
If this adjustment cannot be done, replace the
lever.

4LE2 Electrical System 1D-25


No Load Test W1D00600024

SW 1

1. After adjusting the protruded position of pinion,


connect the starter as shown in the illustration
above.

B
S

CAUTION:
Use a thick electric wire and tighten the connected
portion securely.

M
Battery
24V

SW 2

2. Close the switch and read the speed, current and


voltage.
If the measured values are out of specified value,
disassemble and inspect again.

Disconnect the lead wire


(attached with terminal)
from the M terminal.

Wiring diagram to move pinion forward

WSLE0378

SW

B
S
M

Amount of shaft moved

Push back the clutch


shaft lightly by hand.

WSHK0090

Name
1. Battery 24 V
2. Ammeter
3. Voltmeter

Check of pinion moving out position

WSHK0089

Maintenance Standard W1D00600025


Item
No load characteristic

Voltage

23

Current

80 or less

Speed
Commutator

Commutator

Brush

Brush spring

Standard value or limit

r/min

3,750 or more

Outside diameter

mm/in

32/1.260

Limit

mm/in

31.4/1.236

Undercut

mm/in

0.5/0.020

Limit

mm/in

0.2/0.008

Length

mm/in

17.5/0.689

Limit

mm/in

11/0.433

Pressure

26.7 36.1

Limit

14.7

Protruded position of pinion

mm/in

0.5 2.0/0.020 0.079

1D-26 4LE2 Electrical System

4LE2 Exhaust System 1G-1

Engine
4LE2 Exhaust System
Table of Contents
EGR Control W1G0082.........................................1G-2
Appearance of EGR Controller W1G00820046 .1G-2
EGR Controller Wiring Diagram W1G008200471G-2
Connector Pin Layout W1G00820048 ...............1G-2
Engine Coolant Temperature Sensor Circuit Diagram
W1G00820049 ...................................................1G-3
Tachosensor Circuit Diagram W1G00820050 ...1G-3
Boost
Pressure
Sensor
Circuit
Diagram
W1G00820051 ...................................................1G-4
Engine Coolant Temperature Control W1G00820052
1G-4
Engine Speed and Boost Pressure Control
W1G00820053 ...................................................1G-4
Control When the Sensor Has an Open Circuit
W1G00820054 ...................................................1G-4
Inspection W1G00820009..................................1G-5

1G-2 4LE2 Exhaust System

EGR Control

W1G0082

Appearance of EGR Controller W1G00820046


4

10

(9)
(8)
1

(1)

11
(7)

13
3
1

(10)

(2)
(3)

(6)
2

PC

(5)
12

(4)

8
WSLE0361

WSLE0360

Name
1. Connector

EGR Controller Wiring Diagram W1G00820047


The harnesses between the EGR controller and EGR
cut solenoid are machine parts. Contact the machine
manufacturer if it is found to be faulty.

Name
1. Boost Pressure Sensor
2. Glow Plug Timer
3. Engine Coolant Temperature Sensor
4. Tachometer
5. Tachosensor
6. Starter Switch
7. EGR Relay
8. Stop Relay
9. Ignition Switch
10. EGR Cut Controller

Connector Pin Layout W1G00820048


Pins are numbered by the arrangement when viewing
the EGR cut controller from the wiring side.

4LE2 Exhaust System 1G-3


Engine Coolant Temperature Sensor
Circuit Diagram W1G00820049
(1)
5V

9 10 11 12 13

6
(2)

(3)

WSLE0370

Name
1. Starter Switch
2. EGR Cut Controller GND
3. Engine Coolant Temperature Sensor
4. Ignition Switch (+)
5. (TXD)
6. Stop Relay
7. Tachosensor(+)
8. Tachosensor()
9. Boost Pressure Sensor Power Supply
10. Boost Pressure Sensor Signal
11. Boost Pressure Sensor GND
12. (EXD)
13. EGR Relay

WSLE0364

Name
1. EGR Cut Controller
2. Engine Coolant Temperature Sensor
3. Glow Plug Timer

Tachosensor Circuit Diagram W1G00820050


(1)
5V

8
(2)

(3)

WSLE0362

Name
1. EGR Cut Controller
2. Tachosensor
3. Tachometer

1G-4 4LE2 Exhaust System


Boost Pressure Sensor Circuit Diagram
W1G00820051

When the engine speed and boost pressure


increase W1G0082005301

(1)
kPa
{psi}

Vcc

10

Boost pressure

15
{2.2}

(2)

1400
Engine speed

1850

rpm

WSLE0365

WSLE0363

Name
1. EGR Cut Controller
2. Boost Pressure Sensor

Name
1. EGR Valve Closed
2. EGR Valve Open
3. Engine Speed and Boost Pressure Increase

Engine Coolant Temperature Control

When the engine speed and boost pressure


decrease W1G0082005302

W1G00820052

The EGR valve is opened when the engine coolant


temperature becomes 60C {140F} or more, and is
closed when 55C {131F} or less.

kPa
{psi}

Engine Speed and Boost Pressure Control


Boost pressure

W1G00820053

Boost pressure

kPa
{psi}

15
{2.2}
OFF

OFF
ON

ON

4
{0.6}
0

OFF

1820

rpm

ON
WSLE0366

Name
1. EGR Valve Closed
2. EGR Valve Open
3. Engine Speed and Boost Pressure Decrease

4
{0.6}

1250
Engine speed

1250

1400
Engine speed

1820 1850

rpm

WSLE0371

Name
1. EGR Valve Closed
2. EGR Valve Open

Control When the Sensor Has an Open


Circuit W1G00820054
Close the EGR valve if the engine coolant temperature
sensor, tachosensor, or boost pressure sensor has an
open circuit.

4LE2 Exhaust System 1G-5


Inspection W1G00820009
EGR valve check W1G0082000901
1. Shine a light from the direction shown in the illustration.
2. Replace the EGR cut solenoid and valve case
together if the light can be seen from the opposite
side. The EGR valve has been stuck at opened
position.

WSLE0372

1G-6 4LE2 Exhaust System

4LE2 Lubrication System 1H-1

Engine
4LE2 Lubrication System
Table of Contents
Lubrication System W1H0026...............................1H-2
Service Precautions W1H00260001 ..................1H-2
Explanations
on
Functions
and
Operation
W1H00260027 ...................................................1H-2
Function Check W1H00260012 .........................1H-3
Oil Filter W1H0036................................................1H-4
Removal W1H00360006 ....................................1H-4
Installation W1H00360007 .................................1H-4
Oil Pump W1H0034 ..............................................1H-5
Components W1H00340005..............................1H-5
Inspection W1H00340009..................................1H-5

1H-2 4LE2 Lubrication System

Lubrication System
Service Precautions W1H00260001

W1H0026

Always, the start and end of the application should


be overlapped.

During each disassembly, remove the old gasket


adhering to each part and mating part completely
using a scraper at the location, where the fluid gasket is to be used, clean the traces of oil, moisture
and dirt completely using a cloth, and apply the
specified new fluid gasket at each location.
Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.

Explanations on Functions and Operation


W1H00260027

The lubrication system uses the filter element combined with a full flow bypass, water-cooled oil cooler,
and oil jet for piston cooling.

Lubricating system diagram W1H0026002701


Valve opening pressure 98 kPa (14.2psi)

Oil filter

Oil cooler
Valve
opening
pressure
539kPa (78.2psi)

Oil gallery

Turbocharger

Main bearing

Idle gear bush

Cylinder head

Crankshaft

Timing gear

Rocker arm
bracket

Connecting rod

Governor

Rocker shaft

Rocker arm

Oil pump

Injection pump

Strainer

Piston

Tappet

Valve stem
end

Piston
pin boss

Oil pan
Pressure feeding

Non pressure feeding


WSLE0170

4LE2 Lubrication System 1H-3


Function Check W1H00260012
Engine oil

W1H0026001202

Ensure the engine is at a level ground. Before


starting the engine or when 5 minutes or more
have elapsed after stopping the engine, check the
engine oil volume using the level gauge. The volume is appropriate if the engine oil is between the
upper and lower limits of the level gauge. Replenish the engine oil, if level is below the lower limit.
Also, check for contamination of the engine oil.

WSLE0325

Name
1. Max.
2. Min.

Engine oil leakage W1H0026001203


In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.

1H-4 4LE2 Lubrication System

Oil Filter
Removal W1H00360006
Remove the oil filter using the oil filter wrench.

WSLE0375

Installation W1H00360007
Install the oil filter using the oil filter wrench.
Tightening torque:
14.7 20.6 Nm {1.5 2.1 kgfm/10.8 15.2 lbft}

W1H0036

4LE2 Lubrication System 1H-5

Oil Pump

W1H0034

Components W1H00340005

6
5
4
3
1

8
9
10

WSLE0171

Name
1. Pump Gear
2. Pump Cover
3. O-ring
4. Inner Rotor
5. Outer Rotor

6.
7.
8.
9.
10.

Pin
Oil Pump Body
Relief Valve
Spring
Plug

Inspection W1H00340009
Replace or repair if there is wear, damage, or any other
defect on the rotor, etc.

Inspection of clearance between the outer or


inner rotor and the pump cover W1H0034000901
Use a thickness gauge and square to measure the
clearance between the outer or inner rotor and the
pump cover, and replace the outer or inner rotor if they
exceed the limit.
mm {in}
Standard value

Service limit

Repairing procedure

0.040 0.085
{0.0016 0.0033}

0.15 {0.006}

Replace.

Inspection of clearance between the outer


circle of the outer rotor and the pump body
W1H0034000902

Use a thickness gauge to measure the clearance


between the outer rotor and the oil pump body, and
replace the outer rotor if they exceed the limit.

mm {in}
Standard value

Service limit

Repairing procedure

0.100 0.185
{0.0039 0.0073}

0.4 {0.016}

Replace.

Inspection of tip clearance between the inner


rotor and the outer rotor W1H0034000903
Use a thickness gauge to measure the tip clearance
between the inner rotor and the outer rotor, and replace
the inner or outer rotor if it exceeds the limit.
mm {in}
Standard value

Service limit

Repairing procedure

0.17 {0.0067} or
less

0.2 {0.008}

Replace.

1H-6 4LE2 Lubrication System

4LE2 Intake System 1J-1

Engine
4LE2 Intake System
Table of Contents
Turbocharger W1J0069 .........................................1J-2
Table of Specifications W1J00690025................1J-2
Structure W1J00690017 .....................................1J-3
Disassembly W1J00690010................................1J-4
Inspection W1J00690009....................................1J-7
Reassembly W1J00690011 ..............................1J-10
List of Measurement Tool W1J00690032 .........1J-15
List of Other Material W1J00690033.................1J-15

1J-2 4LE2 Intake System

Turbocharger

W1J0069

Table of Specifications W1J00690025


Item
Turbine shaft

Assembly specification

Service limit

Axial play

mm {in}

0.06 0.09
{0.00236 0.00354}

0.011 {0.000433}

Radial play

mm {in}

0.10 0.17
{0.00394 0.00669}

0.205 {0.00807}

Journal outside diameter

(A)

mm {in}

11.380 {0.44803}

Seal ring groove width

(E)

mm {in}

1.33 {0.05236}

mm {in}

0.011 {0.00043}

Runout
Seal ring insertion
part

Turbine side (bearing housing)

(F)

mm {in}

17.03 {0.67047}

Compressor side (seal plate)

(H)

mm {in}

14.05 {0.55315}

Oil thrower

Seal ring groove width

(G)

mm {in}

1.52 {0.05984}

Bearing
housing

Bearing housing inside diameter

(B)

mm {in}

16.11 {0.63425}

Thrust bearing inside diameter for


press-fit portion

(L)

mm {in}

23.020 {0.90630}

Thrust bearing

Bearing pad height at compressor side

(J)

mm {in}

0.0 0.060 {0.0


0.00236}

Thrust collar thickness

(K)

mm {in}

2.950 {0.11614}

F
B

A
K

WSHK0126

4LE2 Intake System 1J-3


Structure W1J00690017

4
2

10
1

9
8

WSHK0127
Name
1. Turbine Housing
2. Heat Protector
3. Floating Metal
4. Oil Thrower
5. Compressor Housing

6.
7.
8.
9.
10.

Seal Plate
Compressor Impeller
Seal Ring
Seal Ring
Turbine Shaft

1J-4 4LE2 Intake System


Disassembly W1J00690010
Disassembly diagram: disassemble in the order of the numbers.
1

6
14
17
16

13

16

15

8
18
7
11
12
10
9

WSHK0128
Name
1. Compressor Housing
2. Nut
3. Compressor Impeller
4. Seal Plate
5. Oil Thrower
6. Seal Ring
7. G Coupling
8. Turbine Housing
9. Turbine Shaft

10.
11.
12.
13.
14.
15.
16.
17.
18.

CAUTION:
If you perform inspection with the turbocharger
removed from the engine, plug the oil port opening
before work.

Inspection prior to disassembly

W1J0069001001

Measurement of axial play of turbine shaft


Axial play

mm {in}

Assembly specification

0.06 0.09 {0.0024 0.0035}

Service limit

0.11 {0.0043}

If it exceeds the service limit, check the thrust


metal, the thrust bushing, and the oil thrower.

Seal Ring
Gasket
Heat Protector
Thrust Bearing
Thrust Collar
Snap Ring
Floating Metal
Thrust Bearing
Bearing Housing

4LE2 Intake System 1J-5


Liquid gasket is applied to the mating surface of
the compressor housing and the seal plate.
CAUTION:
Take care not to damage the impeller during
removal of the compressor housing.

WSHK0129

Measurement of radial play of turbine shaft


Radial play

mm {in}

Assembly specification

0.10 0.17 {0.00394 0.00669}

Service limit

0.205 {0.00807}

If it exceeds the service limit, check the floating


metal.

Name
1. Alignment Mark

2. Compressor impeller
Attach the box spanner to the turbine-side shaft
end of the turbine shaft, and remove the nut.
(The nut is left-hand screw.)
Remove the impeller from the turbine shaft.
Washing of impeller
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic
scraper or hard brush.
CAUTION:
Do not use a wire brush.

WSHK0130
Measurement on the machine of radial play of turbine shaft
Insert a thickness gauge into the gap between the
compressor impeller and housing, and measure
the clearance.
The thickness gauge to be inserted must be 0.2
mm {0.0078 in} or less.
1. Compressor housing
Put alignment marks between the compressor
housing and the seal plate, and tap the compressor housing to drive it out.

WSHK0131

1J-6 4LE2 Intake System

Name
1. Left-hand Thread

WSHK0132

3. Seal plate
Loosen the pot small screw.
Lightly tap the bearing housing in the seal plate
with a wooden hammer.
Liquid gasket is applied to the mating surfaces
of the seal plate and the bearing housing.

WSHK0134
7. Turbine shaft
Hold the heat protector lightly by hand, and
take out the turbine shaft.
If it is hard to remove, lightly tap the compressor-side shaft end with a wooden hammer.
Washing of turbine shaft
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic
scraper or hard brush.
CAUTION:
Do not use a wire brush.
Foreign matters remaining on the surface
causes the unbalance of weight. Therefore,
wash it thoroughly.
Take care not to damage the floating metal contact surface of the shaft and the seal ring
groove.

WSHK0133
4. Oil thrower
Remove the oil thrower from the seal plate.
5. G coupling
Loosen the nut and remove the G coupling from
the turbine housing and the center housing.
6. Turbine housing
Remove the turbine housing from the center
housing.
Washing of turbine housing
Soak in the cleaning solvent to remove the foreign matters.

WSHK0135
8. Heat protector

4LE2 Intake System 1J-7


Remove the heat protector from the bearing
housing.
9. Thrust bearing (compressor side)
Loosen the plate small screw with a screwdriver, and remove the thrust bearing and the
thrust collar.
10. Floating metal
Remove the turbine-side snap ring with snap
ring pliers.
Draw out the floating metal from the bearing
housing.
11. Thrust bearing (turbine side)
Using a brass bar, push out the compressorside floating metal from the turbine-side bearing
housing, together with the thrust bearing.

Impeller

W1J0069000903

Check the impeller for scratch, dent or crack.

CAUTION:
While pushing out with a bar, take care that they do
not run on to damage the snap ring.
12. Snap ring
Remove the two snap rings from the bearing
housing with snap ring pliers.
13. Seal ring
Remove the seal ring from the turbine shaft and
the oil thrower.

WSHK0137
Heat protector

W1J0069000904

Check the heat protector for damage, thermal


deformation or corrosion.

Inspection W1J00690009
Compressor housing W1J0069000901
Check the compressor housing for crack or damage, and replace if defective.

WSHK0138
Turbine shaft

W1J0069000905

Measure the journal outside diameter of the turbine shaft, and the groove width of the seal ring
insertion part.
Journal outside diameter

WSHK0136
Turbine housing

W1J0069000902

Check the turbine housing for crack or damage,


and replace if defective.

Service limit

Groove width of the seal ring


insertion part
Service limit

mm {in}
11.38 {0.4480}

mm {in}
1.33 {0.0524}

1J-8 4LE2 Intake System

H
1

WSHK0139

Name
1. Journal Outside Diameter
2. Ring Groove Width

Oil thrower

W1J0069000907

Inspection of damage on the oil thrower sliding surface, measurement of the seal ring groove width

Measurement of turbine shaft runout


Turbine shaft runout
Service limit

WSHK0141

mm {in}
0.011 {0.00043}

Seal ring groove width G

mm {in}
Service limit

1.52 {0.0598}

Thrust collar W1J0069000908


Measure the thrust collar thickness (K), and
replace with new one if it exceeds the service limit.
Thrust collar thickness

mm {in}
Service limit

2.950 {0.11614}

WSHK0140
Seal plate

W1J0069000906

Inspection of damage on the seal plate, measurement of inside diameter of the seal ring insertion
part
Inside diameter of the seal
ring insertion part

mm {in}
Service limit

14.05 {0.5531}

WSHK0142

4LE2 Intake System 1J-9


Thrust bearing W1J0069000909
Replace the compressor-side and the turbine-side
thrust bearings with new ones.

Floating metal

W1J0069000910

Replace the floating metal with new one.

Bearing housing

W1J0069000911

Check the casting surface for peeling from oxidation-deterioration, dent or crack. Replace with new
one if faulty.
mm {in}
Location

Service limit

Bearing housing inside diameter

(B)

16.11
{0.6343}

Turbine-side seal ring insertion part

(F)

17.03
{0.6705}

Turbine-side thrust bearing press-fit


portion inside diameter

(L)

23.02
{0.9063}

WSHK0143
G coupling

W1J0069000912

Replace with new one.

Seal ring W1J0069000913


Replace with new one.

Others

W1J0069000914

Check the bolts for deformation, and replace with


new ones if faulty. Also, replace the plate small
screw with new one.

1J-10 4LE2 Intake System


Reassembly W1J00690011
Assembly diagram: Assemble in the order of the numbers.
18

17

15

16

13

14

11
1
12
10
6
5
7

WSHK0144
Name
1. Bearing Housing
2. Snap Ring
3. Floating Metal
4. Thrust Bearing
5. Seal Ring
6. Heat Protector
7. Turbine Shaft
8. Thrust Collar
9. Thrust Bearing
1. Bearing housing
Check that the bearing housing is free of damage and foreign matters.
2. Snap ring
Install the two snap rings to the bearing housing
with snap ring pliers.
After assembling the floating metal (turbine
side), install the snap ring at the position shown
in the figure.

10.
11.
12.
13.
14.
15.
16.
17.
18.

Gasket
Turbine Housing
G Coupling
Seal Ring
Oil Thrower
Seal Plate
Compressor Impeller
Nut
Compressor Housing

4LE2 Intake System 1J-11

Name
1. Turbine-side Floating Metal

WSHK0145

3. Floating metal
Apply oil to the floating metal, and assemble it
to the bearing housing.
After securing it with a snap ring, assemble the
compressor-side floating metal.
CAUTION:
Place the snap ring with its rounded-side facing
to the floating metal.
Assemble the inner snap ring with its end gap
facing to the oil outlet-direction of the housing,
to prevent it from blocking the oil passage.
Assemble the turbine-side snap ring to the
housing with its end gap facing to the direction
as shown in the illustration.
Apply oil to the floating metal before assembly.
Besco super engine oil

Name
1. Apply Oil.

WSHK0146

4. Thrust bearing
a. Press-fitting of turbine-side thrust bearing
Press-fit the turbine-side thrust bearing into
the bearing housing.
Position the pawl of the turbine-side thrust
bearing for more than 2 mm {0.0787 in}
apart from the existing press-fitting part.
Do not press the thrust bearing pad surface
during press-fitting.
The press-fit pressure must be between
215.6 N {22.0 kgf} and 1,862 N {190 kgf}.
After press-fitting, remove the dust powder
by vacuum.
b. After press-fitting, check the depth and flatness
of the turbine-side thrust bearing.
(Depth 3.080.02 mm {0.12130.0008 in}, Flatness is below 0.01 mm {0.0004 in}: See illustration)

1J-12 4LE2 Intake System


Apply engine oil to the thrust collar, and install it
to the turbine shaft.
9. Thrust bearing
Apply engine oil to the metal portion of the
thrust bearing, and insert it to the bearing housing.
Apply Loctite to the plate small screw threads,
and install it using torque screwdriver.
Tightening torque:
3.7 Nm {0.38 kgm/33 lbin}

1
12

3.08 0.02
(0.1213 0.0008)

mm(in)

120

WSHK0147

Name
1. Common Tolerance

5. Seal ring
Insert the seal ring to the turbine shaft.
Use new seal ring.
6. Heat protector
Install the heat protector to the bearing housing.
7. Turbine shaft
Apply engine oil to the journal portion of the turbine shaft, and insert it from the turbine side of
the bearing housing.
Take care not to damage the floating metal with
the turbine shaft. Also, insert with the end gap
of the seal ring facing to the oil inlet side so that
its core matches with the turbine shaft.

Name
1. Apply Oil.
8. Thrust collar

WSHK0149

WSHK0150
Name
1. Apply Oil.
10. Gasket
Set the gasket to the turbine housing, and
install it to the bearing housing.
11. Turbine housing
Assemble by aligning the phase of the turbine
housing and the bearing housing with the turbine housing positioning pin and the bearing
housing hole.

4LE2 Intake System 1J-13


Hammering procedure
1. Using a metal hammer (Approx. 250 g in
weight), lightly tap 2 to 3 times (same place),
from the outer portion toward the center.
2. Do not hammer the G coupling directly. Place
brass bar between as shown in the illustration.

150 ~ 200 mm
(6 ~ 8 in)

4
5

WSHK0151
12. G coupling
a. Check that it does not run on the turbine housing or the bearing housing.
b. Tighten temporarily to the specified torque
using a torque wrench.

c. Hammering: Perform the hammering of (1) to


(6) in the numerical order, using the following
procedure.
d. Tighten to the specified torque using a torque
wrench.
Tightening torque:
83 Nm {8.5 kgm/61 lbft}
e. Perform (c) and (d) of the above step again.

(2)

(3)
3

2
(6)

(4)

Name
1. Approx. 13 mm {0.5 in}
2. Hammer
3. G Coupling
4. Bearing Housing
5. Gasket
6. Heat Shield Plate
7. Turbine Housing
13. Seal ring
Install the seal ring to the oil thrower.
Use new one.
14. Oil thrower
Insert the oil thrower into the seal plate.
Insert with the end gap of the seal ring facing to
the oil inlet side.
15. Seal plate
Apply liquid gasket to the turbine-side flange
surface.
Application thickness 0.1 0.2 mm {0.004
0.008 in} (B)
ThreeBond No.1207

Install the seal plate to the bearing housing.


Apply Loctite (B) to the pot small screw threads,
and install it using torque screwdriver.

(5)

WSHK0152

Name
1. Approx. 60
2. Approx. 60
3. Torque Wrench

WSHK0153

Tightening torque:
83 Nm {8.5 kgm/61 lbft}

(1)

Tightening torque:
23 Nm {2.3 kgm/17 lbft}

1J-14 4LE2 Intake System

WSHK0156

WSHK0154

16. Compressor impeller


Insert the compressor impeller to the turbine
shaft.
17. Nut
Attach the box spanner to the turbine-side shaft
end of the turbine shaft, and tighten the nut.
The nut is left-hand thread. Make sure the turning direction.
Tightening torque:
7.8 Nm {0.80 kgm/69 lbin}
18. Compressor housing
Apply liquid gasket to the compressor-side
flange surface of the seal plate. Illustration
shown in Step 15 (A)
Application thickness 0.1 0.2 mm {0.004
0.008 in}
ThreeBond No.1207

Align the alignment marks that marked during


the disassembly, and assemble the compressor
housing to the seal plate.
Tightening torque:
7.9 Nm {0.81 kgm/70 lbin}

Check after assembly

W1J0069001101

Make sure that the axial play and radial play of


rotor are within the specified value.
Refer to the section on inspection.

4LE2 Intake System 1J-15


List of Measurement Tool W1J00690032
Shape

Name

Part number

Usage

Caliper

Measurement of the seal ring groove width


Measurement of inside diameter of the seal ring insertion part
Measurement of turbine shaft journal outside diameter
Measurement of thrust bushing groove clearance
Measurement of thrust bearing thickness
Measurement of floating metal inside/outside diameter
Measurement of inside diameters of the center housing metal portion and ring portion

Dial gauge

Measurement of turbine shaft axial gap, radial gap


and runout

WSHK0157

WSHK0158

List of Other Material W1J00690033


Name

Usage

Besco super engine oil

Floating metal sliding portion


Thrust bushing sliding portion
Thrust bearing sliding portion
Turbine shaft journal portion

ThreeBond No.1207

Housing installation surface of the seal plate


Flange of the compressor housing

Loctite No.242

Seal plate tightening screw thread

4LE2 Preheating System 1K-1

Engine
4LE2 Preheating System
Table of Contents
Preheating System W1K0061 ............................... 1K-2
Explanations
on
Functions
and
Operation
W1K00610027 ................................................... 1K-2
Glow Plug Check W1K00610035....................... 1K-2
List of Trouble Symptom W1K00610013 ........... 1K-2

1K-2 4LE2 Preheating System

Preheating System

W1K0061

Explanations on Functions and Operation


W1K00610027

The preheating system consists of the glow plug timer,


the glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Glow Plug Check W1K00610035


Use the circuit tester and measure the resistance
of the glow plug.
If the measured value deviates from the specified
value, then replace the glow plug.
Resistance value of glow plug is 3.
Note:
Use a set of glow plug from the same manufacturer.

List of Trouble Symptom W1K00610013


Condition
The glow indicator lamp does not light up.

Preheating does not work.

Preheating time is too long or too short.

Possible cause

Correction

Slow-blow fuse has blown.

Replace the slow-blow fuse.

Fuse is unavailable.

Replace the fuse.

Indicator bulb is burnt out.

Replace the indicator bulb.

Slow-blow fuse has blown.

Replace the slow-blow fuse.

Defective or faulty glow plug


relay connector contact.

Re-mount or replace the glow


plug relay.

Thermo-sensor
fault
and
break in circuit or short circuit.

Replace the thermo-sensor.


Repair the circuit.

Fault in glow plug.

Replace or tighten the glow


plug.

MEMO
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Hitachi Construction Machinery Co. Ltd


Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

Hitachi Ref. No.

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