WDBR50 en 00

PART NO.
WDBR50-EN-00
ZX160LC-6
HYDRAULIC EXCAVATOR
Workshop Manual
WORKSHOP MANUAL
ZX
160LC-6
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
WDBR50-EN-00
Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TODBR50-EN
Technical Manual (Troubleshooting) : Vol. No.TTDBR50-EN
Workshop Manual : Vol. No.WDBR50-EN
PRINTED IN JAPAN (K) 2016, 12 Engine Manual : Vol. No.EDBR50-EN
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SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting..............................................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic System........................W1-4-1-1
Bleeding Air from Fuel System...................................W1-4-1-2
Air Bleeding from the Diesel Exhaust Fluid
Defrosting Piping......................................................W1-4-1-4
Group 5 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-5-1-1
Hydraulic Circuit Pressure Release Procedure......W1-5-1-3
Pressure Release from Hydraulic Oil Tank..............W1-5-1-4
Pressure Release from Expansion Tank ..................W1-5-1-5
WDBR50-EN-00(20171222)
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WDBR50-EN-00(20171222)
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Group 1 Upperstructure
Pump Device....................................................................W2-1-1-1
Swing Motor.....................................................................W2-1-2-1
Group 2 Undercarriage
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-3
Front Idler..........................................................................W2-2-2-1
Upper Roller......................................................................W2-2-3-1
Lower Roller......................................................................W2-2-3-2
Track.....................................................................................W2-2-4-1
Group 3 Front Attachment
Pin and Bushing...............................................................W2-3-1-1
Side Cutter (2015428, 2015429)................................W2-3-1-3
Point (963228)..................................................................W2-3-1-4
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-5
Standard Dimensions for Arm and Boom
Connection..................................................................W2-3-1-6
Cylinder..............................................................................W2-3-2-1
WDBR50-EN-00(20171222)
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WDBR50-EN-00(20171222)
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Removal and Installation of Cab...............................W3-1-1-1 Disassembly of Travel Pilot Valve............................ W3-11-5-1
Dimensions of Cab Glass..............................................W3-1-2-1 Assembly of Travel Pilot Valve................................. W3-11-5-5
Group 2 Counterweight Group 12 Solenoid Valve

Removal and Installation of Counterweight.........W3-2-1-1 Removal and Installation of Pilot Shut-Off
Solenoid Valve......................................................... W3-12-1-1
Group 3 Main Frame Removal and Installation of 3-Spool
Removal and Installation of Main Frame................W3-3-1-1 Solenoid Valve Unit................................................ W3-12-2-1
Group 4 Engine Removal and Installation of 2-Spool
Removal and Installation of Engine.........................W3-4-1-1 Solenoid Valve Unit................................................ W3-12-3-1
Disassembly of Pilot Shut-Off Solenoid
Group 8 Pump Device Valve............................................................................ W3-12-4-1
Removal and Installation of Pump Device.............W3-8-1-1 Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-4-3
Removal and Installation of Coupling.....................W3-8-2-1 Structure of 3-Spool Solenoid Valve Unit............ W3-12-5-1
Disassembly of Pump Device.....................................W3-8-3-1 Structure of 2-Spool Solenoid Valve Unit............ W3-12-6-1
Assembly of Pump Device...........................................W3-8-3-8
Disassembly of Regulator............................................W3-8-4-1 Group 13 Signal Control Valve
Assembly of Regulator..................................................W3-8-4-3 Removal and Installation of Signal
Disassembly of Solenoid Valve Unit.........................W3-8-5-1 Control Valve............................................................ W3-13-1-1
Assembly of Solenoid Valve Unit...............................W3-8-5-3 Structure of Signal Control Valve........................... W3-13-2-1
Structure of Pilot Pump................................................W3-8-6-1 Group 14 Aftertreatment Device
Group 9 Control Valve Removal and Installation of
Removal and Installation of Control Valve.............W3-9-1-1 Aftertreatment Device.......................................... W3-14-1-1
Disassembly of Housing...............................................W3-9-2-1 Group 15 DEF Tank
Assembly of Housing.....................................................W3-9-2-3 Removal and Installation of DEF Tank.................. W3-15-1-1
Disassembly of Control Valve (A Side).....................W3-9-3-1
Assembly of Control Valve (A Side)...........................W3-9-3-8 Group 16 Coolant Control Valve
Disassembly of Control Valve (B Side).....................W3-9-4-1 Removal and Installation of Coolant
Assembly of Control Valve (B Side)...........................W3-9-4-8 Control Valve............................................................ W3-16-1-1
Group 10 Swing Device Group 17 DEF Supply Module

Removal and Installation of Swing Device......... W3-10-1-1 Removal and Installation of DEF Supply
Disassembly of Swing Reduction Gear................ W3-10-2-1 Module....................................................................... W3-17-1-1
Assembly of Swing Reduction Gear...................... W3-10-2-6
Disassembly of Swing Motor................................... W3-10-3-1
Assembly of Swing Motor......................................... W3-10-3-4
Group 11 Pilot Valve
Removal and Installation of Pilot
Valve (Left)................................................................ W3-11-1-1
Valve (Right)............................................................. W3-11-2-1
Removal and Installation of Travel Pilot
Valve............................................................................ W3-11-3-1
Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
WDBR50-EN-00(20171222)
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WDBR50-EN-00(20171222)
SECTION 4
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-5
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-4
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-3
Precautions for Using Floating Seal.........................W4-2-5-1
Group 3 Center Joint
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Front Idler...........................................W4-4-2-1
Assembly of Front Idler.................................................W4-4-2-4
Disassembly of Track Adjuster....................................W4-4-3-1
Assembly of Track Adjuster.........................................W4-4-3-5
Group 6 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-6-1-1
Removal and Installation of Lower Roller..............W4-6-2-1
Disassembly of Lower Roller.......................................W4-6-3-1
Assembly of Lower Roller.............................................W4-6-3-3
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1
WDBR50-EN-00(20171222)
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WDBR50-EN-00(20171222)
SECTION 5
FRONT ATTACHMENT
CONTENTS
Removal and Installation of Front
Attachment..................................................................W5-1-1-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Removal and Installation of Positioning
Cylinder.........................................................................W5-2-4-1
Disassembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-1
Assembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-8
Disassembly of Positioning Cylinder.......................W5-2-6-1
Assembly of Positioning Cylinder.............................W5-2-6-6
Group 3 Hose Rupture Valve
Removal and Installation of Hose Rupture
Valve for Boom Cylinder..........................................W5-3-1-1
Valve for Arm Cylinder.............................................W5-3-2-1
Valve for Positioning Cylinder...............................W5-3-3-1
Structure of Hose Rupture Valve for Boom
Cylinder (Right)..........................................................W5-3-4-1
Cylinder (Left).............................................................W5-3-4-3
Structure of Hose Rupture Valve for Arm
Cylinder.........................................................................W5-3-4-5
Structure of Hose Rupture Valve for
Positioning Cylinder.................................................W5-3-4-7
WDBR50-EN-00(20171222)
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WDBR50-EN-00(20171222)
INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: HCM-TIC-GES@hitachi-kenki.com
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
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:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
Trademark
AdBlue® is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).
WDBR50-EN-00(20171222) IN-1
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 d CAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate fNOTE:
lifting techniques and equipment when lifting heavy Indicates supplementary technical information or know-
parts. how.
Units Used
SI Units (International System of Units) are used in this A table for conversion from SI units to other system units
manual. is shown below for reference purposes.
Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm 2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min -1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
WDBR50-EN-00(20171222) IN-2
SYMBOL AND ABBREVIATION
Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
WDBR50-EN-00(20171222) SY-1
SYMBOL AND ABBREVIATION
Symbol / Name Explanation

Abbreviation
DPF Diesel Particulate Filter DPF is a filter which removes particulate matter (PM)
including the toxic substance of exhaust gas of the diesel
engine. Exhaust particulate removal equipment.
DPD Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF,
which cleans up particulate matter (PM) of diesel engine
exhaust gas. DPD is a ceramic filter which traps and filters
PM of exhaust gas. DPD burns up accumulated PM when PM
increases and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter Filter. The filter traps, burns, and remove particulate matter
(PM) by using high-temperature-exhaust gas with diesel
oxidation catalyst. Catalyst is applied onto the filter. This
advances PM burning.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.
HRV Hose Rupture Valve Hose rupture valve.
LLC Long Life Coolant Long life coolant.
SCR Selective Catalytic Reduction The urea SCR system injects diesel exhaust fluid to nitrogen
oxide (NOx) exhausted from the engine and purifies NOx.
DCU Dosing Control Unit Urea SCR system controller. DCU controls the diesel exhaust
fluid injection amount according to the machine operating
condition.
S/M Supply Module Diesel exhaust fluid supply module. The diesel exhaust fluid
supply module pumps diesel exhaust fluid to the dosing
module (D/M). Then, it returns diesel exhaust fluid in the
diesel exhaust fluid circuit when the key switch is turned
OFF.
D/M Dosing Module Dosing module. The dosing module (D/M) injects diesel
exhaust fluid into the exhaust piping according to the signal
from DCU.
NOx Nitrogen Oxide Nitrogen oxide.
DEF Diesel Exhaust Fluid Diesel exhaust fluid. The diesel exhaust fluid concentration is
32.5 %, which is specified in ISO22241.
WDBR50-EN-00(20171222) SY-2
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.
SA-2644
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 are occasionally used on this machine
that do not use any of the designated signal words
mentioned above after the safety alert symbol.
 CAUTION also calls attention to safety message in this

manual.
SA-1223
 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.
 fNOTE: Indicates an additional explanation for a piece of

information.
WDBR50-EN-00(20171222) SA-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in the operator's manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or operator's manual is damaged or
missing, order a replacement from your authorized dealer
in the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine. SA-003
 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 safety, function, and/
or service life of the part. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the aftertreatment device. Avoid shocks to the
element of the aftertreatment device, such as striking
or dropping objects onto the element. Failure to do so
may affect the exhaust gas purifying device, possibly
damaging it or lowering its performance.
 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.
WDBR50-EN-00(20171222) SA-2
SAFETY
Prepare for Emergencies

 Be prepared for a fire or an accident.
 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
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 SA-438
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.
WDBR50-EN-00(20171222) SA-3
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.
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 "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
WDBR50-EN-00(20171222) SA-4
SAFETY
General Precautions for the Cab
 Before entering the cab, thoroughly remove all dirt
and/or oil such as mud, grease, soil or stones 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 mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 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
 Keep all flammable materials 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.
 Correctly lay the floor mat specific to the machine. If
another floor mat is used, it may be displaced and
contact with the travel pedals during operation, resulting
in serious injury or death.
WDBR50-EN-00(20171222) 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.
 Before getting on or off the machine, check the condition
of the steps and handrails for sticking of slippery material
like grease or mud. Thoroughly remove such material if
stack. In addition, repair the damage to the steps and/or
SA-439
handrails. Retighten loose bolts.
 Never get on and off the machine with tools in your
hands.
Adjust the Operator's Seat

 A seat which is poorly adjusted for the individual operator,
or the work to be undertaken, may quickly fatigue the
operator leading to misoperation.
 The seat should be adjusted whenever the operator of the
machine changes.
 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
SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
WDBR50-EN-00(20171222) SA-6
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 and/or pedal, 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.
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 SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt is replaced every three
years regardless of its apparent condition.
WDBR50-EN-00(20171222) SA-7
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
 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 SA-426
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the cab for
problems.
If there is, replace the problem part (s) or clean the mirror,
camera lens and the monitor display.
Refer to Rear View Monitor section in the operator's
manual for information on cleaning the camera lens and
the monitor display.
Operate Only from Operator's Seat

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 Never start the engine while standing on the track or
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the SA-444
machine and sound the horn to alert bystanders.
WDBR50-EN-00(20171222) SA-8
SAFETY
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
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.
SA-379
WDBR50-EN-00(20171222) SA-9
SAFETY
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.
 Keep bystanders and obstacles clear of the area of
machine operation.
Keep persons other than the operator away from areas
where there is danger, such as from flying objects.
Always be aware 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.
M178-05-007
WDBR50-EN-00(20171222) 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, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the ground 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 materials such as dry grass.
WDBR50-EN-00(20171222) SA-11
SAFETY
 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 the machine is operated on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using 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 M104-05-016
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.
Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, equip Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
In order not to impair operator protective structure:
Replace damaged OPG guard. Never attempt to repair or
modify the guard.
OPG: Operator Protective Guard
SA-490
Restriction of Attachment Installation

Do not install an attachment which exceeds the specified
weight for the machine structure.
WDBR50-EN-00(20171222) SA-12
SAFETY
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple 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.
SA-481
Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or 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 facing forwards.
SA-491
WDBR50-EN-00(20171222) SA-13
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. Do A
not allow personnel to stay around the machine while
traveling.
 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 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 0.2 to 0.3 m (see A
on the right) above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
SA-441
WRONG
SA-590
WDBR50-EN-00(20171222) SA-14
SAFETY
 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 Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
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
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 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.
SA-011
 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 the machine, to
prevent the machine from slipping.
WDBR50-EN-00(20171222) SA-15
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 the machine.
 Do not park the machine on a gradient.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle 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.
SA-391
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a gradient.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-2273
WDBR50-EN-00(20171222) 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. SA-383
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 signal person 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 SA-384
operator’s manual.
WDBR50-EN-00(20171222) SA-17
SAFETY
Keep People Clear from Working Area

 People around the operating machine may be hit severely
by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects,
 Set up barriers and/or put a “NO ADMISSION” sign at
the machine operating site and areas exposed by flying
objects to prevent anyone from entering the work area.
 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.
SA-386
Never Position the Bucket Over Anyone

 Never lift, move, or swing the bucket above anyone or
above the truck cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
SA-487
WDBR50-EN-00(20171222) SA-18
SAFETY
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.
SA-488
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 gradient.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the SA-012
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.
 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-440
WDBR50-EN-00(20171222) SA-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-489
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.
SA-382
Have them mark all underground utilities.
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
WDBR50-EN-00(20171222) 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 to within 3 m plus twice the line
insulator length of overhead wires.
 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.
SA-381
Precautions for Lightning

 Lightning may strike the machine.
If lightning comes close, immediately stop the operation,

and take the following action.
 When you are around the machine or operating cab-

less machine, evacuate to a safe place far away from the
machine.
 When you are in the cab, stay in the cab until lightning
has passed and safety is assured. Close the cab doors and
windows. Lower the bucket to the ground, and stop the
engine. Put your hands on your lap to avoid contact with
any metal surfaces. Never go out of the cab.
SA-1088
If lightning strikes the machine or near the machine,
check all of the machine safety devices for any failure after
lightning has passed and safety is assured. If any trouble is
found, operate the machine only after repairing it.
WDBR50-EN-00(20171222) SA-21
SAFETY
Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
 When using the machine for craning operations, be sure
to comply with all local regulations.
 Do not use damaged chains or frayed cables, 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.
SA-014
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.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.
SA-432
WDBR50-EN-00(20171222) SA-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle 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
 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 hazards.
 Do not incinerate or puncture pressurized containers.
 Do not store oily rags; they can ignite and burn SA-018
spontaneously.
 Securely tighten the fuel and oil filler caps.
SA-019
WDBR50-EN-00(20171222) SA-23
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. SA-395
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 on the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
7. At the top end of the ramp where it meets the flatbed,
there is a sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
fasten 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.
WDBR50-EN-00(20171222) SA-24
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. SA-028
7. Remove the key from the key 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.
 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
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 in the operator's manual. SA-527
 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.
 Turn the battery disconnect switch to OFF before
adjusting the electrical systems or performing welding on
the machine.
WDBR50-EN-00(20171222) SA-25
SAFETY
 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. If 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.
SS2045102
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.
SA-527
WDBR50-EN-00(20171222) SA-26
SAFETY
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.
SA-026
SA-2294
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.
 Do not attempt to remove the valve stop plate.
 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 SA-344
resulting in severe personal injury or death.
 Travel reduction gears are under pressure.

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
WDBR50-EN-00(20171222) SA-27
SAFETY
Avoid Injury from Attachment Falling Accident

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 To avoid possible personal injury from attachment falling
accident, use a platform when replacing an attachment.
 Securely store attachments such as a bucket, blade,
breaker and other parts to prevent falling.
 Keep children and bystanders away from attachment
storage areas.
SA-034
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, expansion
tank and heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 Avoid possible injury from hot spraying water. DO NOT
remove the expansion tank 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 SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
WDBR50-EN-00(20171222) SA-28
SAFETY
Replace Rubber Hoses Periodically

 Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
 Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
 Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
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 SA-031
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
WDBR50-EN-00(20171222) 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.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
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.
 Never attempt to modify electric wirings.
WDBR50-EN-00(20171222) SA-30
SAFETY
Clean up Flammable Materials:
 Spilled fuel and oil, trash, grease, debris, accumulated coal
dust, and other flammable materials may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean high
temperature parts such as the exhaust outlet and muffler
earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammable materials away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.
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.
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.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as muffler may cause fire. Always close the engine cover
while operating the machine.
WDBR50-EN-00(20171222) SA-31
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 can not
be opened, break the front or rear window pane with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator's manual.
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.
 White smoke may be generated during the
aftertreatment device regeneration. Do not attempt to
do aftertreatment device manual regeneration in a badly
ventilated indoors.
SA-016
WDBR50-EN-00(20171222) SA-32
SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable materials in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Turn the battery disconnect switch to the OFF position
before performing welding on the machine.
 Grinding on the machine may create fire hazards. Store
flammable materials in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are SA-818
no abnormalities such as the area surrounding the welded
area still smoldering.
WDBR50-EN-00(20171222) SA-33
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 pipes and tubes thoroughly with non-flammable
solvent before welding or flame cutting.
Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.
Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing of the unit, sealed gas must be released.
Consult your authorized dealer.
WDBR50-EN-00(20171222) SA-34
SAFETY
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 SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable materials from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Beware of Asbestos and Silica Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silica dust or other contaminations
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silica dust or other
contaminations may exist. Spray water to prevent
asbestos fibers, silica dust or other contaminations from
becoming airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silica dust or other contaminations might SA-029
be present, be sure to operate the machine upwind, and
wear a mask rated to prevent the inhalation of asbestos,
silica dust or other contaminations.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
WDBR50-EN-00(20171222) SA-35
SAFETY
Prevent Battery Explosions

 Battery gas can explode.
 Keep sparks, lighted matches, and flame away from the
top of battery.
 Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 ˚C first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.
 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.
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.
SA-405
WDBR50-EN-00(20171222) SA-36
SAFETY
Handle Chemical Products Safely

 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
 Safety Data Sheet (SDS) provides specific details on
chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
 Check the SDS 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 SDS’s (available only in
English) on chemical products used with your machine. SA-2579
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, DEF, 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 SA-226
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.
WDBR50-EN-00(20171222) SA-37
SAFETY
Never Ride Attachment

Never allow anyone to ride on attachments or the load. This is
an extremely dangerous practice.
Notes on Aftertreatment Device

About Aftertreatment Device
The aftertreatment device removes particulate matter (PM)
and NOx (Nitrogen Oxide) from the exhaust gas. Follow the
instructions below to prevent the aftertreatment device
from being damaged.
dWARNING: Exhaust gas from the aftertreatment

device, muffler, exhaust piping and tail piping
becomes hot during and right after engine running
and regeneration of aftertreatment device. Keep away
from the exhaust system or hot gas from the exhaust
piping during regeneration. Be careful to avoid skin
contact with exhaust gas. It may cause severe burns.
 White smoke may be generated during aftertreatment

device regeneration. Do not attempt to perform
aftertreatment device manual regeneration in a badly
ventilated area.
 Do not touch water coming directly out of the

aftertreatment device. The water is mildly-acidic by
oxidation catalyst mounted in the aftertreatment device.
If filter water spills on your skin, immediately flush it out
with clean water.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire to the device manufacturer for information on
electrical wave disturbance when using an electronic device
near the communication terminal.
WDBR50-EN-00(20171222) SA-38
SAFETY
Precautions for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside the rear tray situated
at the back of the operator's seat. There is a possibility that
a medical device, including an implantable device such as a
cardiac pacemaker, could be affected and malfunction due the
electrical waves emitted from the communication terminal
equipment.
Any person fitted with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters apart at all times. If
this condition cannot be met, please contact your authorized
dealer and have the person in charge stop the communication
terminal equipment from functioning completely, and confirm
that it is not emitting electrical waves.
This machine is equipped with a communication terminal type
A or type B.
Consult your nearest authorized dealer for the type of
communication terminal.
Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
Type A Type B
E-GSM900 0.573 W/kg (914.8 MHz) 0.12 W/kg (897.6 MHz)
DCS-1800 0.130 W/kg (1710.2 MHz) 0.06 W/kg (1748.0 MHz)
WCDMA Band I 0.271 W/kg (1950.0 MHz) 0.05 W/kg (1950.0 MHz)
WCDMA Band VIII - 0.10 W/kg (892.6 MHz)
*This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 centimeters.
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.
In Japan: *Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).
In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).
WDBR50-EN-00(20171222) SA-39
SAFETY
 Do not attempt to disassemble, repair, modification and
displacement of the communication terminal, antenna
and cables. Failure to do so may cause damage or fire on
the machine and the communication terminal. (Before
removing or installing the communication terminal, consult
your authorized dealer.)
 Do not pinch or forcibly pull cables, cords and connectors.

Failure to do so may cause damage or fire on the machine
and the communication terminal due to short/broken
circuit.
WDBR50-EN-00(20171222) SA-40
SAFETY
Notes on Protection of Operator’s Station when

the Machine Rolls Over
The cab corresponds to the structure to protect the operator
by absorbing impact energy when the machine rolls over (Roll-
Over Protective Structure (ROPS)).
However, when modifying the machine or installing a
special attachment causing the machine mass to exceed the
maximum operating mass described in the ROPS certification,
the cab cannot fulfill its protective function, possibly causing
In order to safeguard the protective structure, follow the

instructions below.
 Consult your authorized dealer before welding parts or
drilling a hole on the cab, which possibly reduces the cab SS-3636
strength.
 Be sure to always fasten the seat belt when operating
the machine. If the machine rolls over without operator
fastening the seat belt, the operator may become injured,
may be thrown out from the cab and/or may become
crushed under the machine even though the cab has the
protective structure.
The ROPS certification is valid under the following conditions.

 The machine mass is lower than the maximum operating
mass described in the ROPS certification.
 The ROPS is properly installed.
 No modification is made to the ROPS.
 The ROPS is free from damage.
Maximum operating
Applicable Machine Model Number mass assuring the ROPS
SS-3671
Certificate number ROPS Model
of the ROPS Number
WDBR50-EN-00(20171222) SA-41
SAFETY
Before Returning the Machine to the Customer
 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.
SA-435
WDBR50-EN-00(20171222) SA-42
SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 5 Preparation
WORKSHOP MANUAL SECTION 2 MAINTENANCE STANDARD
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Engine
Group 5 Missing Number
Group 8 Pump Device
Group 9 Control Valve
Group 10 Swing Device
Group 12 Solenoid Valve
Group 13 Signal Control Valve
Group 14 Aftertreatment Device
All information, illustrations and Group 15 DEF Tank
specifications in this manual are based on Group 16 Coolant Control Valve
the latest product information available
at the time of publication. The right is Group 17 DEF Supply Module
reserved to make changes at any time
without notice.
COPYRIGHT(C)2016
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WDBR50-EN-00(20171222)
WDBR50-EN-00(20171222)
SECTION AND GROUP SECTION 4 UNDERCARRIAGE
CONTENTS Group 1 Swing Bearing
Group 6 Upper and Lower Roller
WORKSHOP MANUAL
Group 7 Track
SECTION 5 ATTACHMENT
Group 2 Cylinder
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.
COPYRIGHT(C)2016
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WDBR50-EN-00(20171222)
WDBR50-EN-00(20171222)
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting..............................................................................W1-3-1-1
Bleeding Air from Hydraulic System........................W1-4-1-1
Bleeding Air from Fuel System...................................W1-4-1-2
Defrosting Piping......................................................W1-4-1-4
Group 5 Preparation
Maintenance...............................................................W1-5-1-1
Hydraulic Circuit Pressure Release Procedure......W1-5-1-3
Pressure Release from Hydraulic Oil Tank..............W1-5-1-4
Pressure Release from Expansion Tank ..................W1-5-1-5
WDBR50-EN-00(20171222) DBR50W-1-1
(Blank)
WDBR50-EN-00(20171222) DBR50W-1-2
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), and then
Precautions for Disassembling take the appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil to parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water, or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing.
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes have  Be sure to use the designated tools to assemble
been disconnected. In addition, attach identification bearings, bushings, and oil seals.
tags onto the connectors, hoses, and pipes for  Keep a record of the number of tools used for
assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.
WDBR50-EN-00(20171222) W1-1-1-1
SECTION 1 GENERAL
Precautions for Using Floating Seal 1
1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil to sliding surface
(e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a- Correct c- Twist of O-Ring
 After installing the floating seal, check that O-ring b- Incorrect d- Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
between (e) and (f ) at point (A) and (B), as illustrated.
If these distances differ, correct O-ring (2) seating. a A b A
B B
A=B A≠B
W178-02-11-003
a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface
WDBR50-EN-00(20171222) W1-1-1-2
SECTION 1 GENERAL
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
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 the temperature of the lifted
load is over 100 °C (212 °F), do not lift the load.
 Do not lift acid or alkali chemicals.
 Take care not to allow the sling to become wet. The W102-04-02-016
load may slip.
a- Correct Eyehole Lifting
 When required to use more than one sling, use slings
Method
with the same width and length to keep the lifted
load balanced. b
 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. W105-04-01-008
 Avoid dragging slings on the ground, throwing
slings, or pushing slings with a metal object. b- Incorrect Eyehole Lifting
Method
 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 that they won’t
deteriorate with heat, sun light, or chemicals.
c W162-01-01-009
c- Bent of Sling
WDBR50-EN-00(20171222) W1-1-1-3
SECTION 1 GENERAL
dCAUTION: If a load is lifted with a damaged

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

sling for any damage corresponding to following
examples. If any damage is found, cut and discard
the sling.
Even if no damage is found, do not use slings older
than 7 years.
Damaged Appearance a
a
W162-01-01-002 W162-01-01-006
e
a- Broken Sewing Thread a- Broken Sewing Thread e- Separation of Belt
b f
W162-01-01-003 W162-01-01-007
b
b- Scuffing b- Scuffing f- Scoring
c
c g
W162-01-01-004
W162-01-01-008
c- Fuzz d- Broken Sewing Thread
c- Fuzz g- Broken Warp
W162-01-01-005
a- Broken Sewing Thread
WDBR50-EN-00(20171222) W1-1-1-4
SECTION 1 GENERAL
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.
“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.
WDBR50-EN-00(20171222) W1-1-1-5
SECTION 1 GENERAL
(Blank)
WDBR50-EN-00(20171222) W1-1-1-6
SECTION 1 GENERAL
Group 2 Tightening
Tightening Bolts and Nuts
dCAUTION: 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 injure.
Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used, WDAA-01-02-001
use and tighten the correct bolts correctly when
assembling the machine or components.
Specified Tightening Torque Chart
2013/09
Bolt Hexagon Head Bolt Socket Bolt
Dia. Wrench Socket Bolt Wrench
mm Size mm Size mm
WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004

N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft)
6 3 to 4 (2.2 to 3) 10 5
8 30 (22) 20 (15) 10 (7.4) 13 20 (15) 6
10 65 (48) 50 (37) 20 (15) 17 50 (37) 8
12 110 (81) 90 (66) 35 (26) 19 90 (66) 10
14 180 (133) 140 (103) 55 (41) 22 140 (103) 12
16 270 (200) 210 (155) 80 (59) 24 210 (155) 14
18 400 (300) 300 (220) 120 (89) 27 300 (220) 14
20 550 (410) 400 (300) 170 (125) 30 400 (300) 17
22 750 (550) 550 (410) 220 (162) 32
24 950 (700) 700 (520) 280 (205) 36
27 1400 (1030) 1050 (770) 400 (300) 41
30 1950 (1440) 1450 (1070) 550 (410) 46
33 2600 (1920) 1950 (1440) 750 (550) 50
36 3200 (2360) 2450 (1810) 950 (700) 55
WDBR50-EN-00(20171222) W1-2-1-1
SECTION 1 GENERAL
Group 2 Tightening
IMPORTANT: The following items are applied to both

fine and coarse pitch threads.
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)
 Torque tolerance is ±10 %.
 Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.
 The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.
 Clean the nut and bolt threads and remove dirt
or corrosion before installing.
Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
a b c
1 12 9 4 1 6 7 14
1, 4 6 3
4 5
2 13 8 5 2 3 10 11
2, 3
W105-01-01-003
a- Equally tighten upper and b- Tighten diagonally c- Tighten from center

lower alternately diagonally
WDBR50-EN-00(20171222) W1-2-1-2
SECTION 1 GENERAL
Group 2 Tightening
Precautions for Spilt Flange

IMPORTANT:
 Clean the sealing surfaces. Check if there are
any scratches and roughness on the surface of
the seal that cause oil leaks and damage to the
WDAA-01-02-005
O-ring.
 Use only specified O-rings. Inspect O-rings for
any damage. Do not file the O-ring surfaces. Incorrect
When installing O-ring into a groove, use grease
in order to hold O-ring in place.
 While tightening the bolt by hand, check that
flange is installed to the port correctly. Do not
pinch the O-ring.
 Tighten the bolts up and down, right and left
alternately, in order to ensure even tightening
WDAA-01-02-006
to the specified torque.
 Do not use an impact wrench. It is difficult to
evenly tighten the bolts by using an impact
wrench. Using an impact wrench often causes
uneven tightening of bolts or damage to
O-rings.
Nut and Bolt Locking

W105-01-01-008
 Lock Plate
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice. Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
a b
in order to align the grooves and holes on the nut.
Always turn in the tightening direction. Do not
reuse the split pins. Correct Correct Incorrect
 Wire
IMPORTANT: Attach wires to bolts in the bolt-
tightening direction. Do not reuse the wires.
a
WDAA-01-02-007
a- Bend along edge sharply b- Do not bend it round
Correct Correct
Incorrect
Correct d Incorrect
c
WDAA-01-02-008
c- Tighten d- Loosen
WDBR50-EN-00(20171222) W1-2-1-3
SECTION 1 GENERAL
Group 2 Tightening
Piping Joint
IMPORTANT:
 The torque given in table below are for general
use only, however, a different torque is given for
a specific application. Use the specified torque.
 Apply lubricant, such as the Grease Spray to
the bolts and nuts in order to reduce friction
coefficient of them.
 Torque tolerance is ±10 %.
 Slightly apply lubricant onto the threads first by
using the Grease Spray.
WDBR50-EN-00(20171222) W1-2-1-4
SECTION 1 GENERAL
Group 2 Tightening
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1 4 3 5 2
 Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten
union nut (3) to the specifications.
 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 / a- Joint Body WDAA-01-02-009
a
disconnecting.
37 °
2013/09
Description Wrench Size mm Tightening Torque 30 °
Union Nut N·m (lbf·ft)
30 ° male 17 25 (18.5) b c
19 30 (22)
22 40 (29.5) b- Male Union Joint c- Female Union Joint
27 80 (59) WDAA-01-02-010
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37 ° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
fNOTE: Tightening torque of 37 ° male coupling without

union is similar to tightening torque of 37° female.
WDBR50-EN-00(20171222) W1-2-1-5
SECTION 1 GENERAL
Group 2 Tightening
Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)
Metal (3) of adapter (1) and pipe (2) seals pressure oil.
 Precautions for use

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling. 1 4 5 3 2
Tightening Torque
Use the specified tightening torque in the table below.
2013/09
Wrench Size (mm) 17 19 22 27
Tightening N·m 25 30 40 80 M1M7-07-005
Torque (lbf·ft) (18.5) (22) (29.5) (59)
O-Ring Face Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
IMPORTANT:
 Replace O-ring (6) with the new one when 7 6 9
reinstalling.
 Before tightening union nut (9), confirm that
O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.
 Do not damage O-ring groove (8) of adapter (7)
or sealing surface (10) on the hose side. Damage 8 10 a
WDAA-01-02-011
to O-ring (6) may cause oil leakage. a- Joint Body
 If union nut (9) is found to be loose, causing
oil leakage, do not tighten it to stop the leak.
Instead, replace O-ring (6) with the new one, and 2013/09
then tighten union nut (9) after confirming that Wrench Size mm Tightening Torque
O-ring (6) is securely seated in O-ring groove (8). Union Nut N·m (lbf·ft)
19 30 (22)
22 70 (52)
27 95 (70)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
WDBR50-EN-00(20171222) W1-2-1-6
SECTION 1 GENERAL
Group 2 Tightening
Quick Coupling
3 1
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2
2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.
d CAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
WDBR50-EN-00(20171222) W1-2-1-7
SECTION 1 GENERAL
Group 2 Tightening
Screw-In Connection R G
Depending on types of screw and sealing, different

types of screw-in connection are used.
IMPORTANT: Check that the thread pitch and thread

type (tapered or straight) are the correct type
before using any screw-in connection. a b
a- Male Tapered Thread b- Male Straight Thread
W105-01-01-018
2013/09
Wrench Size mm Tightening Torque
Joint Body Cast iron Structural rolled
steel
Seal Tape Application 19 15 (11) 35 (26)
Seal tape is used in order to seal clearances between 22 30 (22) 50 (37)
male (d) and female (c) threads so that any leaks 27 50 (37) 95 (70)
between threads may be prevented. Therefore, apply 36 70 (52) 160 (118)
just enough seal tape to fill up thread clearances (e). Do 41 110 (81) 200 (148)
not overwrap. 50 160 (118) 330 (245)
60 200 (148)
 Application Procedure
Check that the thread surface is clean and, free of dirt
or damage. Apply the seal tape around threads in order
fNOTE: Unit: N·m (lbf·ft)
to leave one to two pitch threads uncovered. Wrap the c

seal tape in the same direction as the threads.
d e
W105-01-01-019
Low-Pressure-Hose Clamp Tightening c- Internal Thread e- Clearance
d- External Thread
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp. Tighten them f
according to each step.
 T-Bolt Type Band Clamp (g)
 Worm Gear Type Band Clamp (h)
f- Leave one to two pitch

M114-07-041
threads uncovered
g h
WDAA-01-02-012 M114-07-043
g- T-Bolt Type Band Clamp h- Worm Gear Type Band Clamp
WDBR50-EN-00(20171222) W1-2-1-8
SECTION 1 GENERAL
Group 2 Tightening
Connecting Hose
dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct
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
kinked hoses. Application of high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012
a- Rubbing Against Each Other
Incorrect Correct
b b
W105-01-01-013
a- Rubbing Against Each Other b- Clamp
Incorrect Correct
a
b
W105-01-01-014
a- Rubbing Against Each Other b- Clamp
WDBR50-EN-00(20171222) W1-2-1-9
SECTION 1 GENERAL
Group 2 Tightening
(Blank)
WDBR50-EN-00(20171222) W1-2-1-10
SECTION 1 GENERAL
Group 3 Painting
Painting
Painting specification
Surfaces to Be Painted Painting Color
Main surface of upperstructure (except cab) YR1-01 [TAXI yellow]
Main frame P1-01 [High Grade Black]
Inner N-40 [N4 Gray]
Engine cover P1-01 [High Grade Black]
Handrail P1-01 [High Grade Black]
Front YR1-01 [TAXI yellow]
Track (including swing bearing) N-10 [Black]
Floor plate N-40 [N4 Gray]
Final painted color

Inside and outside surface of cab P1-01 [High Grade Black]
Y1-03 [Shining Silver]
Right window beam Charcoal Black
Seat stand Black (N2.0)
Lever (Travel, pilot shut-off ) Warm Gray (N2.5)
Rear Camera P1-01 [High Grade Black]
Exhaust pipe Black Heat-Resistant Coating
Tool box, Tool box cover P1-01 [High Grade Black]
Decoration cover, Step P1-01 [High Grade Black]
Handrail on upperstructure right side P1-01 [High Grade Black]
Mirror stay P1-01 [High Grade Black]
Nonslip plate Kansai Paint Co., Ltd. 1400 (Deep Black)
DEF tank bracket Black Cation Electric Deposited Coating
Muffler bracket Black Cation Electric Deposited Coating
Center cover mounting support P1-01 [High Grade Black]
Handrail (CAB) P1-01 [High Grade Black]
WDBR50-EN-00(20171222) W1-3-1-1
SECTION 1 GENERAL
Group 3 Painting
(Blank)
WDBR50-EN-00(20171222) W1-3-1-2
SECTION 1 GENERAL
Bleeding Air from Hydraulic System

Bleed air from the hydraulic system as follows when
hydraulic oil has been drawn, the suction filter and
suction pipe have been replaced, or the pump device,
swing motor, travel motor, and cylinders have been
removed and installed.
IMPORTANT: If air is accumulated inside of the pump IMPORTANT: If air is accumulated inside of the motor
and if the engine starts in lacking of hydraulic oil, and if the motor starts in lacking of hydraulic oil,
the pump may be damaged. the motor may be damaged.
 Bleeding Air from Pump  Bleeding Air from Travel Motor and Swing Motor
1. Remove air bleed plug (1) on top of each pump. 1. Remove the air bleed plug (1) (top) from the travel
Add hydraulic oil to each pump. motor or swing motor. Fill the motor case with
hydraulic oil.
2. After the pump is filled with hydraulic oil,
temporarily tighten air bleed plug (1) on each IMPORTANT: If air is accumulated inside of the
pump. Then, start the engine and run it at slow idle cylinder and if the cylinder is operated suddenly
speed. in lacking of hydraulic oil, the seal may be
damaged or the cylinder may seize.
3. Slightly loosen air bleed plug (1) on one of the
pumps and bleed air from the pump until hydraulic  Bleeding Air from Hydraulic Circuit
oil comes out from the gap. After bleeding all air, 1. After refilling hydraulic oil, start the engine. While
securely tighten air bleed plugs (1). operating each cylinder, swing motor, or travel
motors evenly, operate the machine under light
m : 95 N·m loads for 10 to 15 minutes. Slowly start each
operation at first.
4. Bleed air from other pump in the same way as step
3. 2. As the pilot circuit has an air bleed device, air in the
pilot circuit will be bled while performing the above
operation for approx. 5 minutes.
3. Return the position to check hydraulic oil level.
4. Stop the engine. Check hydraulic oil level. Add
hydraulic oil if necessary.
TDBR-03-01-002
WDBR50-EN-00(20171222) W1-4-1-1
SECTION 1 GENERAL
Bleeding Air from Fuel System

Air in the fuel system may make the engine hard to
start or make it run irregularly.
When the engine has run out of fuel, draining water 1
from the fuel filter, or replacing the fuel filter element,
be sure to bleed air from the fuel system.
This machine is equipped with an electric fuel pump.

d CAUTION: Fuel leaks may lead to fires.
MDAA-07-007
1. Check that fuel cock (1) at bottom of fuel tank is
opened.
2. Set the key switch to the ON position and hold it in
that position for approx. three minutes. The electric
fuel pump operates and starts to bleed air.
3. Loosen air bleed plug (3) on fuel main filter (2) while
turning the key switch to the ON position. When
2
air is bled from fuel main filter (2), tighten air bleed
plug (3).
4. After fuel main filter (2) is filled with fuel, hold the
key switch to the ON position for 30 seconds. 3
5. Start the engine. Check the fuel system for any fuel WDCX-01-04-003
leaks.
IMPORTANT: Even if air is not thoroughly bled, do
not hold the key switch in the ON position for
more than five minutes continuously. If air is not 3
thoroughly bled, first, return the key switch to
the OFF position. Then, after waiting for more
than 30 seconds, set the key switch to the ON
position again. Failure to do so may cause damage
to the electric fuel pump and/or discharging the
batteries.
WDCX-01-04-004
WDBR50-EN-00(20171222) W1-4-1-2
SECTION 1 GENERAL
If Air Mixed Downstream from Common Rail

If air becomes mixed into the fuel system of
downstream from common rail, bleed air by following
the procedure below.
1. Following the bleeding air procedures, bleed
enough air up to the engine supply pump entrance.
2. Operate the starter motor for cranking within 20
seconds. If the engine fails to start at a time, return
the key switch to the OFF position. Wait more than
about 60 seconds, then try again.
WDBR50-EN-00(20171222) W1-4-1-3
SECTION 1 GENERAL

Defrosting Piping
The DEF defrosting piping is equipped along with the
DEF piping in order to prevent DEF from freezing. After
performing the following procedures, bleed air from the
DEF defrosting piping and fill the DEF defrosting piping
with coolant.
 When the DEF supply module, DEF sensor unit,

coolant control valve, or coolant hose has been
replaced
 When coolant has been drained
Procedure
TDBR-04-06-001
1. Remove bolts, washers (1) (6 used). Remove cover
2 1
(2). A
j : 17 mm
IMPORTANT: Do not damage coolant piping (3)
of the dosing module when using the line hose
clamp. View A
IMPORTANT: Completely block coolant piping (3) of
the dosing module by using the line hose clamp.
2. Secure the (B) part in coolant piping (3) of the
dosing module by using the line hose clamp.
3
TDBR-04-06-002
WDBR50-EN-00(20171222) W1-4-1-4
SECTION 1 GENERAL
3. Turn ON the key switch with stopping the engine.

4. Start MPDr.. Select the [E] Air Bleeding from the
DEF/Defrosting Piping (4).
5. Click START (5).
4
6. Ensure that the Executing icon (6) is displayed. Start
the engine within 10 seconds.
7. After starting the engine, set the engine control dial
to the fast idle position.
8. When the Executing icon (6) disappears after 150
seconds have passed, the operation is completed. TDC1-04-06-005EN
9. Turn OFF the key switch.

10. Remove the line hose clamp from the (B) part in
coolant piping (3) of the dosing module.
11. Install cover (2) with bolts, washers (1) (6 used).
j : 17 mm 5
m : 50 N·m
TDC1-04-06-006EN
TDC1-04-06-007EN
WDBR50-EN-00(20171222) W1-4-1-5
SECTION 1 GENERAL
(Blank)
WDBR50-EN-00(20171222) W1-4-1-6
SECTION 1 GENERAL
Group 5 Preparation

Maintenance
dCAUTION: Components, hydraulic oil, lubricant,

and coolant just after operation are too hot. Allow
oil to cool before starting any work.
Secure Work Place and Co-Workers

Before starting the work, select wide and solid footing M104-07-021
and keep bystanders away from machine moving area.
Slowly operate the front attachment. Secure co-workers
according to the work. When working with co-workers,
thoroughly check hand signals and sufficiently pay 1
attention.
Machine Position for Inspection and Maintenance

Before performing the maintenance procedures given in
the following items, park the machine as described below,
unless otherwise specified.
1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn OFF the auto-idle switch. 2
4. Set the engine control dial to the slow idle position.

Run the engine at slow idle speed without load for
five minutes. WDAA-01-06-001
5. Set the key switch to the OFF position. Stop the
engine. Remove the key from the key switch.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach
tag (2) in a highly visible place such as the door or
control lever.
WDBR50-EN-00(20171222) W1-5-1-1
SECTION 1 GENERAL
Group 5 Preparation
dCAUTION: Never attempt to maintain the

machine when the engine is running in order to
prevent the accident. If maintenance work while
engine running is unavoidable, strictly comply
with the following items.
 One person should take the operator's seat
to be ready to stop the engine any time while
communicating with other workers.
 When working around the moving parts is
unavoidable, do not approach hands, feet, and
clothes which are easy to be entangled. SA-2294
 If parts or tools are dropped or inserted into
the fan or the belt, they may fly off or be cut off.
Do not drop or insert parts and tools into the
moving parts.
 Set pilot shut-off lever (1) to the LOCK position,
and let the front attachment will not move.
 Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, give the hand signals to co-
workers and evacuate them to the safer place.
SA-026
WDBR50-EN-00(20171222) W1-5-1-2
SECTION 1 GENERAL
Group 5 Preparation
Hydraulic Circuit Pressure Release Procedure

Release any remaining pressure as follows before
removing/installing the front attachment.
1. Set pilot shut-off lever (1) to the UNLOCK position.

2. Turn engine stop switch (2) ON.
fNOTE: Perform step 1 and step 2, and set the key switch
to the START position. Although the starter rotates, the
engine does not start.
IMPORTANT: Battery will deplete. Operate the key
switch for short period.
3. With the key switch set in the START position, 1 2
operate the control lever in order to release any M1U1-01-029
pressure in the hydraulic circuit 4 to 5 times.
4. Return pilot shut-off lever (1) to the LOCK position.
5. Turn engine stop switch (2) OFF.
WDBR50-EN-00(20171222) W1-5-1-3
SECTION 1 GENERAL
Group 5 Preparation
Pressure Release from Hydraulic Oil Tank
dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
injury. Release pressure before disconnecting the
hydraulic pipings or removing other equipment.
Hot hydraulic oil just after operation may spout
out and cause severe burns. Allow oil to cool
before starting any work.
1. Park the machine on a solid and level surface. Set

the position to check hydraulic oil level.
2. Stop the engine. Push pressure release button (1) of 1 2 3
hydraulic oil tank (3) and release any pressure from
hydraulic oil tank (3).
fNOTE: Hydraulic oil tank (3) becomes negative pressure W1R7-01-04-001

by installing vacuum pump (a) to the position where
cap (2) is removed and operating vacuum pump (a).
This operation prevents hydraulic oil from draining
when disconnecting hoses. Operate vacuum pump (a)
a
continuously while working.
W1R7-01-04-002
a- Vacuum Pump
b- Hose
c- Adapter
WDBR50-EN-00(20171222) W1-5-1-4
SECTION 1 GENERAL
Group 5 Preparation
Pressure Release from Expansion Tank 1
dCAUTION: Do not loosen cap (1) when the

coolant temperature of radiator is too high. Hot
steam may spout out and cause severe burns.
Wait until coolant cools and loosen cap (1) slowly. 2
Release all pressure and remove the cap.
1. Park the machine on a solid and level surface.

Set the front attachment in position for checking
hydraulic oil level.
2. After stopping the engine, remove cap (1) of
expansion tank (2).
WDBR-01-05-001
WDBR50-EN-00(20171222) W1-5-1-5
SECTION 1 GENERAL
Group 5 Preparation
(Blank)
WDBR50-EN-00(20171222) W1-5-1-6
MEMO
WDBR50-EN-00(20171222)
MEMO
WDBR50-EN-00(20171222)
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Pump Device....................................................................W2-1-1-1
Swing Motor.....................................................................W2-1-2-1
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-3
Front Idler..........................................................................W2-2-2-1
Upper Roller......................................................................W2-2-3-1
Lower Roller......................................................................W2-2-3-2
Track.....................................................................................W2-2-4-1
Pin and Bushing...............................................................W2-3-1-1
Side Cutter (2015428, 2015429)................................W2-3-1-3
Point (963228)..................................................................W2-3-1-4
Connection..................................................................W2-3-1-5
Connection..................................................................W2-3-1-6
Cylinder..............................................................................W2-3-2-1
WDBR50-EN-00(20171222) DBR50W-2-1
(Blank)
WDBR50-EN-00(20171222) DBR50W-2-2
SECTION 2 MAINTENANCE STANDARD
Pump Device
8 7 6 5
WDCD-02-01-002
9
1- Gear 4- Shaft 7- Valve Plate (Right, Left)

2- Shaft 5- Plunger (14 Used) 8- Pin (2 Used)
3- Gear 6- Rotor (2 Used) 9- Servo Piston (2 Used)
WDBR50-EN-00(20171222) W2-1-1-1
Pump Device
Unit: mm
Standard Allowable Limit Remedy
Backlash of gears (1 and 3) 0.68 1.5 Replace
Main Pump
1. Spline tooth thickness of shafts (2, 4) (T1)
Unit: mm
Standard Allowable Limit T1
T1 5.4 3.8 d1
d2 d2
2. Oil seal outer diameter (d1, d2) of shafts (2, 4)
Unit: mm
Standard Allowable Limit
d1 45 44.8
d2 55 54.8
4 2 W157-02-04-015
3. Clearance between plunger (5) and shafts (2, 4)
Unit: mm
Standard Allowable Limit 5
0.058 0.4
4. Clearance between outer diameter (a) of plunger (5) 2, 4

and inner diameter (D) of rotor (6)
Unit: mm
D-a 0.043 0.08
W178-02-11-105
5 a
W178-02-11-106
WDBR50-EN-00(20171222) W2-1-1-2
5. Clearance between plunger (5) and connecting rod

(b)
5
Unit: mm
0.15 0.4
b
6. Clearance between inner diameter (D) of servo b- Connecting Rod

small chamber and outer diameter (a) of servo W178-02-11-107
piston (9)
D
Unit: mm
a c
D-a 0.083 0.2
7. Clearance between inner diameter (D) of servo large

chamber and outer diameter (a) of servo piston (9)
Unit: mm
9
D-a 0.079 0.2
d
a
W178-02-11-108
D
c- Small Diameter Side
d- Large Diameter Side
8. Clearance between inner diameter (D) of valve plate
(7) and outer diameter (a) of pin (8)
7
Unit: mm
D-a 0.051 0.3
D
WDCD-02-01-003
WDBR50-EN-00(20171222) W2-1-1-3
(Blank)
WDBR50-EN-00(20171222) W2-1-1-4
Swing Motor
2 3
W178-02-11-153
1- Rotor 2- Plunger (9 Used) 3- Friction Plate (3 Used)
WDBR50-EN-00(20171222) W2-1-2-1
1. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1)
Unit: mm
D-d 0.027 0.052

d
W178-02-11-155
D D
W178-02-11-156
2. Clearance (δ) between plunger (2) and shoe (a)

bottom 2
Unit: mm
a
0 0.3 δ
a- Shoe
W107-02-06-140
WDBR50-EN-00(20171222) W2-1-2-2
3. Shoe (a) thickness (t)

Unit: mm
5.5 5.3 a
a- Shoe
W178-02-11-157
4. Friction plate (3) thickness (t) 3
Unit: mm
Standard Allowable Limit t
2.0 1.8
W178-02-11-158
WDBR50-EN-00(20171222) W2-1-2-3
(Blank)
WDBR50-EN-00(20171222) W2-1-2-4
Travel Motor
1 2
WDCD-04-02-004
1- Rotor 2- Plunger (9 Used)
WDBR50-EN-00(20171222) W2-2-1-1
1. Clearance (ε) between shoe (a) and plunger (2)

bottom a
Unit: mm
0.10 to 0.25 0.5
ε
2
a- Shoe
W1V1-03-02-005
2. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1) D
Unit: mm
0.03 0.08
W105-02-06-134
W105-02-06-135
3. Shoe (a) thickness (t)
a
Unit: mm
6.0 5.6
t
2
a- Shoe
W1V1-03-02-005
WDBR50-EN-00(20171222) W2-2-1-2
Sprocket
C´
B
C
A D
WDBF-02-02-002
Unit: mm
A 70 [64] Build up
B [88.3] [85.3] welding and
C [127.7 ] [123.7] hand finishing
C' 644.6 -
D 190 -
fNOTE: Values in [ ] are just for reference.
WDBR50-EN-00(20171222) W2-2-1-3
(Blank)
WDBR50-EN-00(20171222) W2-2-1-4
Front Idler
C D
W166-03-05-001
A
Unit: mm
A 84 [79] Build up welding and
B 159 - hand finishing or
C 500 [495] replace
D 538 -
E 19 21.5
Axle and Bushing

Unit: mm (in)
Axle Outer Diameter 75.0 [74.2] Replace
Bushing Inner Diameter 75.0 [75.8]
Flange Thickness 2.0 [1.6]
WDBR50-EN-00(20171222) W2-2-2-1
(Blank)
WDBR50-EN-00(20171222) W2-2-2-2
Upper Roller
A
B
WDDE-02-02-001
Unit: mm
Standard Allowable Remedy
Limit
A 84 78 Replace
B 165 -
C 120 [114]
Axle and Bushing

Unit: mm
Limit
Axle Outer 45 [44.2] Replace
Diameter
Bushing Inner 45 [45.8]
Diameter
Flange 2.0 [1.6]
Thickness
WDBR50-EN-00(20171222) W2-2-3-1
Lower Roller
C A C
WDCA-02-01-003
B
Roller
Unit: mm
Limit
A 169 [183] Build up
B 224 - welding and
C 27.5 [20.5] hand finishing
D 150 136 or replace
E 185 -
Axle and Bushing

Unit: mm
Limit
Axle Outer 65 [64.2] Replace
Diameter
Bushing Inner 65 [65.8]
Diameter
Flange 4.5 [4.1]
Thickness
WDBR50-EN-00(20171222) W2-2-3-2
Track
Link
Measure the length of four links.
 Do not measure the part included the master pin.
 Measure the length with tension on the track.
A
W155-03-07-001
Unit: mm
Limit
A 762 786 Build up
B 105 [98] welding and
hand finishing
or replace
Grouser Shoe
W105-03-07-024
Unit: mm
Shoe Size 600 mm Grouser
Limit
A 220 - Build up
B 10 - welding or
C 26 [21] replace
WDBR50-EN-00(20171222) W2-2-4-1
Master Bushing
W105-03-07-023
Unit: mm
Limit
A 129.2 - Replace
B 38.7 [41.7]
C 59 [54]
Master Pin
W105-03-07-021
Unit: mm
Limit
A 203 - Replace
B 38.4 [35.4]
WDBR50-EN-00(20171222) W2-2-4-2
Pin
W142-03-07-004
A
Unit: mm
Limit
A 212 - Replace
B 38 [35]
Bushing
WDDQ50-02-02-001
Unit: mm
Limit
A 137.5 - Replace
B 38.7 [39.7]
C 59 [54]
WDBR50-EN-00(20171222) W2-2-4-3
(Blank)
WDBR50-EN-00(20171222) W2-2-4-4
Pin and Bushing
C F
E
A G
H
J
B I K
W1V1-04-01-012
Unit: mm
Part Name Standard Allowable Limit Remedy
A Pin 80 79.0 Replace
Bushing (Main Frame) 80 81.5
Bushing (Boom) 80 81.5
B Pin 80 79.0
Boss (Main Frame) 80 81.5
Bushing (Boom Cylinder) 80 81.5
C Pin 80 79.0
Bushing (Boom Cylinder) 80 81.5
Boss (Boom) 80 81.5
D Pin 80 79.0
Boss (Boom) 80 81.5
Bushing (Arm) 80 81.5
E Pin 71 70
Boss (Arm) 71 72.5
Bushing (Arm Cylinder) 71 72.5
F Pin 71 70
Boss (Boom) 71 72.5
Bushing (Arm Cylinder) 71 72.5
WDBR50-EN-00(20171222) W2-3-1-1
Unit: mm
Part Name Standard Allowable Limit Remedy
G Pin 65 64.0 Replace
Boss (Arm) 65 66.5
Bushing (Bucket Cylinder) 65 66.5
H Pin 71 70.0
Boss (Link B) 71 72.5
Bushing (Link A) 71 72.5
Bushing (Bucket Cylinder) 71 72.5
I Pin 71 70.0
Boss (Link B) 71 72.5
J Pin 80 79.0
Boss (Bucket) 80 81.5
Bushing (Link A) 80 81.5
K Pin 80 79.0
Boss (Bucket) 80 81.5
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.
WDBR50-EN-00(20171222) W2-3-1-2
Side Cutter (2015428, 2015429)
A
D
W1T1-04-01-004
Unit: mm
Limit
A 229 149 Replace
B 245 -
C 330 -
D 135 -
WDBR50-EN-00(20171222) W2-3-1-3
Point (963228)
B C
W105-04-01-020
Unit: mm
Limit
A 178.5 90 Replace
B 79.2 -
C 95 -
D 81 -
WDBR50-EN-00(20171222) W2-3-1-4

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.
WDCD-02-03-005
Section A Section B
WDBR-02-03-002
Unit: mm
ZX160LC-6 Class ZX160LC-5B Class View C
a 370 
b 2 
c 540 
d 520 
e 401 
f 1430  h
g 433 
h 305 
i 80 
j 400 
k 31  WDBR-02-03-001
l 433 
m 307 
n 80 
o 0° 
p 30 ° 
q 449 
WDBR50-EN-00(20171222) W2-3-1-5

Connection
WDCD-02-03-001
Unit: mm
Section C
ZX160LC-6 Class ZX160LC-5B Class
s 80 
t 307 
u 421 
IMPORTANT: If the front attachment of a previous

model machine is used, use the grease intervals
for previous model machine.
WDCD-02-03-004
s- Pin Hole Inner Diameter
WDBR50-EN-00(20171222) W2-3-1-6
Cylinder
Rod Rod Bend and Run Out
b
a
A
W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1m
Unit: mm Unit: mm
Cylinder Name Recommended Size After Re- Bend Run Out Remedy
manufacturing (A) 0.5 1.0 Repair
Boom 80-0.012-0.027 1.0 2.0 Replace
Arm 90-0.012-0.027
Bucket 75-0.010-0.023
Positioning 95-0.012-0.027
WDBR50-EN-00(20171222) W2-3-2-1
(Blank)
WDBR50-EN-00(20171222) W2-3-2-2
MEMO
WDBR50-EN-00(20171222)
MEMO
WDBR50-EN-00(20171222)
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Removal and Installation of Cab...............................W3-1-1-1 Disassembly of Travel Pilot Valve............................ W3-11-5-1
Dimensions of Cab Glass..............................................W3-1-2-1 Assembly of Travel Pilot Valve................................. W3-11-5-5
Group 2 Counterweight Group 12 Solenoid Valve

Removal and Installation of Counterweight.........W3-2-1-1 Removal and Installation of Pilot Shut-Off
Solenoid Valve......................................................... W3-12-1-1
Group 3 Main Frame Removal and Installation of 3-Spool
Removal and Installation of Main Frame................W3-3-1-1 Solenoid Valve Unit................................................ W3-12-2-1
Group 4 Engine Removal and Installation of 2-Spool
Removal and Installation of Engine.........................W3-4-1-1 Solenoid Valve Unit................................................ W3-12-3-1
Disassembly of Pilot Shut-Off Solenoid
Group 8 Pump Device Valve............................................................................ W3-12-4-1
Removal and Installation of Pump Device.............W3-8-1-1 Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-4-3
Removal and Installation of Coupling.....................W3-8-2-1 Structure of 3-Spool Solenoid Valve Unit............ W3-12-5-1
Disassembly of Pump Device.....................................W3-8-3-1 Structure of 2-Spool Solenoid Valve Unit............ W3-12-6-1
Assembly of Pump Device...........................................W3-8-3-8
Disassembly of Regulator............................................W3-8-4-1 Group 13 Signal Control Valve
Assembly of Regulator..................................................W3-8-4-3 Removal and Installation of Signal
Disassembly of Solenoid Valve Unit.........................W3-8-5-1 Control Valve............................................................ W3-13-1-1
Assembly of Solenoid Valve Unit...............................W3-8-5-3 Structure of Signal Control Valve........................... W3-13-2-1
Structure of Pilot Pump................................................W3-8-6-1 Group 14 Aftertreatment Device
Group 9 Control Valve Removal and Installation of
Removal and Installation of Control Valve.............W3-9-1-1 Aftertreatment Device.......................................... W3-14-1-1
Disassembly of Housing...............................................W3-9-2-1 Group 15 DEF Tank
Assembly of Housing.....................................................W3-9-2-3 Removal and Installation of DEF Tank.................. W3-15-1-1
Disassembly of Control Valve (A Side).....................W3-9-3-1
Assembly of Control Valve (A Side)...........................W3-9-3-8 Group 16 Coolant Control Valve
Disassembly of Control Valve (B Side).....................W3-9-4-1 Removal and Installation of Coolant
Assembly of Control Valve (B Side)...........................W3-9-4-8 Control Valve............................................................ W3-16-1-1
Group 10 Swing Device Group 17 DEF Supply Module

Removal and Installation of Swing Device......... W3-10-1-1 Removal and Installation of DEF Supply
Disassembly of Swing Reduction Gear................ W3-10-2-1 Module....................................................................... W3-17-1-1
Assembly of Swing Reduction Gear...................... W3-10-2-6
Disassembly of Swing Motor................................... W3-10-3-1
Assembly of Swing Motor......................................... W3-10-3-4
Valve (Left)................................................................ W3-11-1-1
Valve (Right)............................................................. W3-11-2-1
Removal and Installation of Travel Pilot
Valve............................................................................ W3-11-3-1
Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
WDBR50-EN-00(20171222) DBR50W-3-1
(Blank)
WDBR50-EN-00(20171222) DBR50W-3-2
Group 1 Cab
Removal and Installation of Cab
1 5
6, 7
11
6, 7
12
8, 9, 10
4 3 2 WDAA-03-01-023
WDAE-03-01-029
IMPORTANT: Cap the open ends in case the hoses 4. Remove bolt (8), spring washer (9), washers (10) (2
and pipes have been disconnected. In addition, used), and belt (12).
attach identification tags onto the connectors,
hoses, and pipes for assembling. If the clips which j : 5/8 in
secure the hoses have been removed, install the
clips after connecting the hoses. dCAUTION: Seat (5) weight: 45 kg
5. Remove socket bolts (6) (4 used) and washers (7) (4
used). Remove seat (5).
Removal
1. Set the machine position for inspection and l : 6 mm
maintenance. (Refer to W1-5-1.) 6. Remove floor mat (3).
2. Open door (2). 7. Remove bolts, washers (4) (4 used). Remove travel
3. Disconnect connectors (11) (2 used). control levers (1) (2 used).
j : 17 mm
WDBR50-EN-00(20171222) W3-1-1-1
Group 1 Cab
3 A
Detail A
6 7 6
8 WDAA-03-01-051
5 4 WDAA-03-01-050
8. Remove cover (3).

9. Disconnect connector (7) and connectors (6) (2
used).
10. Remove bolt, washer (4) and screw (8). Remove
cover (5).
j : 13 mm
WDBR50-EN-00(20171222) W3-1-1-2
Group 1 Cab
1 2 3, 4 11 12 13 14
A
B
6, 7
6, 7 8, 9, 10
WDAA-03-01-052
WDAA-03-01-053
16 15
19 22
17 18
Detail A Detail B
WDAA-03-01-065
WDAA-03-01-062
20, 21, 22
11. Open cover (1). 15. Remove caps (3) (2 used). Remove screws (4) (2
used). Remove cover (2) and duct (13).
12. Turn caps (20) (2 used) counterclockwise. Remove
caps (20) (2 used). Remove seals (21) (2 used) and 16. Remove bolts, washers (15) (2 used).
screws (22) (3 used). Remove cover (19).
j : 17 mm
13. Remove bolts (6) (2 used) and washers (7) (2 used).
17. Remove bolt, washer (14). Remove cover (16).
j : 13 mm
j : 13 mm
14. Remove caps (8) (3 used). Remove rubbers (9) (3
used) and screws (10) (3 used). Remove cover (5). 18. Remove screws (11) (2 used). Remove duct (12).
19. Remove bolt, washer (18). Remove duct (17).
j : 13 mm
WDBR50-EN-00(20171222) W3-1-1-3
Group 1 Cab
A 1
Detail A
WDAD-03-01-005
WDAD-03-01-004
20. Disconnect connectors (1) (6 used).
WDBR50-EN-00(20171222) W3-1-1-4
Group 1 Cab
A B
WDAA-03-01-063 WDAA-03-01-064
a a
Detail A Detail B
a- Machine Front WDBR-03-01-004 a- Machine Front WDBR-03-01-005
21. Remove clip band (2).

23. Remove clip bands (4) (3 used).
WDBR50-EN-00(20171222) W3-1-1-5
Group 1 Cab
3, 4 6, 7
WDCX-03-01-005
8
2 WDCX-03-01-006
25. Loosen socket bolts (2) (2 used).
l : 8 mm
used). Move the right console (1) assembly inward.
l : 8 mm
l : 8 mm
used). Move the left console (5) assembly inward.
l : 8 mm
WDBR50-EN-00(20171222) W3-1-1-6
Group 1 Cab
WDBR-03-01-001
1
5 4 3 WJBA-03-01-001
29. Close door (1).

30. Open cover (5).
31. Remove filter (3).
32. Remove screws (4) (6 used). Remove filter case (2).
12
33. Open cover (6).
34. Remove clip bands (12) (2 used). Disconnect hose
(10).
10 MDAA-07-067
WDBR50-EN-00(20171222) W3-1-1-7
Group 1 Cab
4
1
WDBR-03-16-001 WDBR-03-09-016
3 2
35. Open engine cover (1).

(2).
j : 17 mm
37. Remove bolts, washers (4) (3 used). Open cover (5).
j : 17 mm
WDBR50-EN-00(20171222) W3-1-1-8
Group 1 Cab
1 5 3
4
2
1 5
WDBR-03-09-017
WDBR-03-09-015
View A

(2).
j : 17 mm
(8).
7
j : 17 mm
40. Remove bolts, washers (4) (3 used) and bolts,
washers (5) (6 used). Remove clip (6). Remove the
cover (3) assembly.
j : 17 mm
WDBR-03-09-018
8
WDBR50-EN-00(20171222) W3-1-1-9
Group 1 Cab
Detail A
WDBR-03-01-003
a- Machine Front Side WDBR-03-01-002
3
(1). 4
j : 17 mm
9
42. Remove bolts, washers (5) (2 used), clip (8), and
bracket (7).
10
j : 17 mm
43. Remove bolt (4). Disconnect connector (3).
j : 12 mm
44. Push and unlock the lock. Shift lever (10).
Disconnect connector (9).
5, 8 5, 7 WDBL-03-01-105
WDBR50-EN-00(20171222) W3-1-1-10
Group 1 Cab
a a 1
a- Lifting Bracket WDAA-03-01-058 WDBE-03-12-005
dCAUTION: The cab (1) assembly weight: 380 kg

45. Attach nylon slings onto lifting brackets (a) (4
places) of cab (1). Hoist and hold the cab (1)
assembly.
dCAUTION: Remove cover (2) while holding it. Do

not drop cover (2).
(2).
j : 17 mm
WDBR50-EN-00(20171222) W3-1-1-11
Group 1 Cab
1 5, 6 7 5, 6 8, 9
7 8, 9 7 5, 6 10, 11 5, 6
2, 3, 4 WDAD-03-01-003 WDAA-03-01-059
47. Remove bolt (2), washer (3), and spacer (4).
j : 32 mm
48. Remove socket bolts (10) (2 used) and washers (11)
(2 used).
l : 8 mm
used).
l : 8 mm
50. Remove bolts, washers (7) (5 used).
j : 17 mm
51. Remove nuts (5) (4 used) and washers (6) (4 used).
Remove the cab (1) assembly.
j : 24 mm
WDBR50-EN-00(20171222) W3-1-1-12
Group 1 Cab
Detail A
1
A B
2, 3
WJBE-03-01-009
Detail B
4 5 11 14 12 8 15 13
WDBL-03-01-106

53. Remove bolt, washer (2). Disconnect ground cable
(3).
j : 13 mm
55. Remove bolt, washer (6) and clip (7).
j : 17 mm
56. Remove screws (4) (4 used). Remove connector (5).
57. Remove screws (11) (5 used). Remove covers (14, 15) WDBL-03-01-108
6, 7 9, 10
and wire harness (12).
58. Remove bolt, washer (9). Remove horn (10).
j : 13 mm
59. Disconnect connector (13).
WDBR50-EN-00(20171222) W3-1-1-13
Group 1 Cab
Detail B
1 2 3
A B
WDBL-03-01-106 WDAD-03-01-008
4, 5
60. Remove bolts, washers (1) (4 used). Remove MC (2). Detail A 7
j : 13 mm
62. Remove bolt, washer (4) and clip (5). 6
j : 17 mm 6
63. Remove screws, washers (6) (4 used). Remove

controller (7).
WJBE-03-01-009
WDBR50-EN-00(20171222) W3-1-1-14
Group 1 Cab
WDAA-03-01-061
1
WDAA-03-01-067
64. Remove bolts, washers (2) (6 used). Remove the

bracket (1) assembly.
j : 17 mm
WDBR50-EN-00(20171222) W3-1-1-15
Group 1 Cab
WDAA-03-01-061
1
WDAA-03-01-067
Installation
1. Install the bracket (1) assembly with bolts, washers
(2) (6 used).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-1-1-16
Group 1 Cab
Detail B
1 2 3
A B
WDBL-03-01-106 WDAD-03-01-008
4, 5
2. Install controller (7) with screws, washers (6) (4 Detail A 7

used).
3. Install clip (5) with bolt, washer (4).
j : 17 mm 6
m : 50 N·m 6
4. Connect connector (3).
5. Install MC (2) with bolts, washers (1) (4 used).
j : 13 mm
WJBE-03-01-009
m : 10 N·m
WDBR50-EN-00(20171222) W3-1-1-17
Group 1 Cab
Detail A
1
A B
2, 3
WJBE-03-01-009
Detail B
4 5 11 14 12 8 15 13
WDBL-03-01-106

7. Install horn (10) with bolt, washer (9).
j : 13 mm
m : 10 N·m
8. Install wire harness (12) and covers (14, 15) with
screws (11) (5 used).
9. Install connector (5) with screws (4) (4 used).
WDBL-03-01-108
j : 17 mm 6, 7 9, 10
m : 50 N·m
11. Connect connectors (8) (2 used).
12. Connect ground cable (3) with bolt, washer (2).
j : 13 mm
m : 10 N·m
WDBR50-EN-00(20171222) W3-1-1-18
Group 1 Cab
a a 1 5, 6 7 5, 6 8, 9
7 8, 9 7 5, 6 10, 11 5, 6
a- Lifting Bracket WDAA-03-01-058 WDAA-03-01-059
18. Install washers (11) (2 used) and socket bolts (10) (2

d CAUTION: The cab (1) assembly weight: 380 kg used).
14. Attach nylon slings onto lifting brackets (a) (4
places) of cab (1). Hoist the cab (1) assembly. l : 8 mm
15. Install the cab (1) assembly to the main frame with m : 50 N·m
washers (6) (4 used) and nuts (5) (4 used).
j : 24 mm
m : 210 N·m
16. Install bolts, washers (7) (5 used).
j : 17 mm
m : 50 N·m
17. Install washers (9) (5 used) and socket bolts (8) (5
used).
l : 8 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-1-1-19
Group 1 Cab
WDBE-03-12-005
1, 2, 3 WDAD-03-01-003
19. Install spacer (3), washer (2), and bolt (1).
j : 32 mm
m : 550 N·m
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-1-1-20
Group 1 Cab
Detail A
WDBR-03-01-003

3
4
IMPORTANT: Do not use the impact wrench when
tightening bolt (4). The cover may be damaged. 9
21. Connect connector (3) with bolt (4).
10
j : 12 mm
B
m : 9.8 N·m
IMPORTANT: Check that the parts on the cab side are
surely seen from the (C) part of connector (3).
22. Connect connector (9). Shift lever (10). Lock the
lock.
23. Install clip (8) and bracket (7) with bolts, washers (5)
(2 used). WDCX-03-01-007
5, 8 5, 7
j : 17 mm
View B
m : 50 N·m
24. Install cover (1) with bolts (2) (2 used).
j : 17 mm
m : 50 N·m C
WDDK-03-01-005
WDBR50-EN-00(20171222) W3-1-1-21
Group 1 Cab
A
View A
5 3
WDBR-03-09-017 WDBR-03-09-018
8
25. Install the cover (3) assembly with clip (6), bolts, 1
washers (4) (3 used) and bolts, washers (5) (6 used).
j : 17 mm
m : 50 N·m
2
j : 17 mm
m : 50 N·m
j : 17 mm 1
m : 50 N·m
WDBR-03-09-015
WDBR50-EN-00(20171222) W3-1-1-22
Group 1 Cab
4
5
WDBR-03-09-016 WDBR-03-16-001
3 6
28. Close cover (2). Install bolts, washers (4) (3 used).
j : 17 mm
m : 50 N·m
j : 17 mm
m : 50 N·m
30. Close engine cover (5).
WDBR50-EN-00(20171222) W3-1-1-23
Group 1 Cab
7 6
WDBR-03-01-001
8 MDAA-07-067 1
31. Connect hose (8). Install clip bands (7) (2 used).

32. Close cover (6).
33. Install filter case (2) with screws (4) (6 used).
m : 3 N·m
34. Install filter (3).
36. Open door (1).
5 4 3 WJBA-03-01-001
WDBR50-EN-00(20171222) W3-1-1-24
Group 1 Cab
5
6, 7 3, 4
WDCX-03-01-005
8
WDCX-03-01-006 2
37. Fully move the left console (5) assembly outward. 40. Tighten socket bolts (2) (2 used).
Install washers (7) (2 used) and socket bolts (6) (2
used). l : 8 mm
l : 8 mm m : 50 N·m
m : 50 N·m
38. Tighten socket bolts (8) (2 used).
l : 8 mm
m : 50 N·m
39. Fully move the right console (1) assembly outward.
used).
l : 8 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-1-1-25
Group 1 Cab
A B
WDAA-03-01-063 WDAA-03-01-064
a a
Detail A Detail B
a- Machine Front WDBR-03-01-004 a- Machine Front WDBR-03-01-005

42. Install clip bands (4) (3 used).
44. Install clip band (2).
WDBR50-EN-00(20171222) W3-1-1-26
Group 1 Cab
A 1
Detail A
WDAD-03-01-005
WDAD-03-01-004
WDBR50-EN-00(20171222) W3-1-1-27
Group 1 Cab
1 2 3, 4 11 12 13 14
A
B
6, 7
6, 7 8, 9, 10
WDAA-03-01-052
WDAA-03-01-053
16 15
19 22
17 18
Detail A Detail B
WDAA-03-01-065
WDAA-03-01-062
20, 21, 22
46. Install duct (17) with bolt, washer (18). 50. Install duct (13) and cover (2) with screws (4) (2
used). Install caps (3) (2 used).
j : 13 mm
51. Install cover (5) with screws (10) (3 used). Install
m : 8 N·m rubbers (9) (3 used) and caps (8) (3 used).
47. Install duct (12) with screws (11) (2 used). 52. Install washers (7) (2 used) and bolts (6) (2 used).
m : 3 N·m j : 13 mm
48. Install cover (16) with bolt, washer (14). m : 10 N·m
j : 13 mm 53. Install cover (19) with screws (22) (3 used). Install
seals (21) (2 used) and caps (20) (2 used).
m : 10 N·m
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-1-1-28
Group 1 Cab
9 A
Detail A
11 10 11
13 WDAA-03-01-051
14 12 WDAA-03-01-050
55. Install cover (14) with screw (13) and bolt, washer
(12).
j : 13 mm
m : 20 N·m
56. Connect connectors (11) (2 used) and connector
(10).
57. Install cover (9).
WDBR50-EN-00(20171222) W3-1-1-29
Group 1 Cab
5
6, 7
11
6, 7
12
8, 9, 10
4 3 2 WDAA-03-01-023
58. Install travel control levers (1) (2 used) with bolts, WDAE-03-01-029
washers (4) (4 used).
j : 17 mm
m : 50 N·m
59. Install floor mat (3).
dCAUTION: Seat (5) weight: 45 kg

60. Install seat (5) with washers (7) (4 used) and socket
bolts (6) (4 used).
l : 6 mm
m : 20 N·m
61. Install belt (12) with washers (10) (2 used), spring
washer (9), and bolt (8).
j : 5/8 in
m : 50 N·m
63. Close door (2).
WDBR50-EN-00(20171222) W3-1-1-30
Group 1 Cab
Dimensions of Cab Glass
dCAUTION: Use the genuine parts for the glasses

Unit: mm Section A
WDAA-03-01-036
WDAA-03-01-030
a- Black Ceramic Painted b- Black Ceramic Painted Range WDAA-03-01-001

Surface
Section B Detail C
a- Black Ceramic Painted

WDAA-03-01-035 WDAA-03-01-002
Surface
WDBR50-EN-00(20171222) W3-1-2-1
Group 1 Cab
Unit: mm
WDAA-03-01-030
a- Black Ceramic Painted

WDAA-03-01-034
Surface
Section A
a- Black Ceramic Painted WDAA-03-01-037

Surface
WDBR50-EN-00(20171222) W3-1-2-2
Group 1 Cab
Unit: mm
Section A
WDAA-03-01-004
WDAA-03-01-031
a- Chamfer along the Periphery WDAA-03-01-003
WDBR50-EN-00(20171222) W3-1-2-3
Group 1 Cab
Unit: mm
Section A
WDAA-03-01-006
WDAA-03-01-031
a- Chamfer along the Periphery WDAA-03-01-005
WDBR50-EN-00(20171222) W3-1-2-4
Group 1 Cab
Unit: mm Section A

WDAA-03-01-031 Surface
d- Shaded Paint along the
Periphery Here
a- Black Ceramic Painted c- Chamfer here. WDAA-03-01-007

Surface
b- Black Ceramic Painted Range
Section B Section C
WDAA-03-01-008 WDAA-03-01-009
WDBR50-EN-00(20171222) W3-1-2-5
Group 1 Cab
Unit: mm
WDAA-03-01-031
a- Black Ceramic Painted b- Black Ceramic Painted Range WDAA-03-01-010

Surface
Section A Detail B
a- Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-011

Surface
d- Dotted edge along the
Periphery Here
WDBR50-EN-00(20171222) W3-1-2-6
Group 1 Cab
Unit: mm
WDAA-03-01-031

Surface
c- Chamfer here.
Section A Section B
a- Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-008

Surface
d- Dotted edge along the
Periphery Here
WDBR50-EN-00(20171222) W3-1-2-7
Group 1 Cab
Unit: mm Section A

WDAA-03-01-030 Surface
d- Shaded Paint along the
Periphery Here

Surface
WDBR50-EN-00(20171222) W3-1-2-8
Group 1 Cab
Procedure to Remove Cab Glass
Procedures to Remove Right-Hand Glass (1), Rear Left- 1

Hand Glass (2), Lower Door Glass (3), and Rear Glass (4)
dglass,
CAUTION: When removing the broken or cracked
the glass shards may cause serious injury.
Before removing, use the duct tape or equivalent
in order to paste the broken or cracked glass and
reinforce them. Remove the glass pieces away. WDAA-03-01-030
1. Remove resin panel (5), garnish (6), and the spacer
around the glass.
6
2
3
5 WDAA-03-01-031
2. Prick a hole in adhesive (b) by using awl (a) (or a 7

knife). 8
a
b
W1SE-02-01-033
7- Cab a- Awl
8- Glass b- Adhesive
3. Pass piano wire (c) (or a metal wire) through the

hole.
c- Piano Wire W1SE-02-01-034
WDBR50-EN-00(20171222) W3-1-2-9
Group 1 Cab
IMPORTANT: The piano wire is easily broken if a part

of the piano wire turns hot. Change the position 7 a
and cut the adhesive.
4. Wind the both ends of the piano wire onto the 8
screwdriver. Draw the wire back and forth in order
to cut adhesive (b) between cab (7) and glass (8).
Remove glass (8) from cab (7).
fNOTE: Cut off the middle of adhesive between glass

and cab. b
c
a- Cab Outside W1SE-02-01-035

b- Adhesive
c- Cab Inside
WDBR50-EN-00(20171222) W3-1-2-10
Group 1 Cab
Procedure to Install Cab Glass
Procedures to Install Right-Hand Glass (1), Rear Left-Hand 1

Glass (2), Lower Door Glass (3), and Rear Glass (4)
1. Cut off the residual adhesive from the cab (7) side
by 1 to 2 mm deep all around by using a knife or
similar.
fNOTE: Do not damage the cab (7) paint.

WDAA-03-01-030
3
2 WDAA-03-01-031
2. Clean the cutting edge of adhesive at cab (7) side by
using white spirit. 7
W1SE-02-01-036
IMPORTANT: Primer should be shaken for about 1
minute and mix thoroughly before opening the a- Knife b- Cut off adhesive by 1 to 2 mm
cap. After opening Primer, apply Primer as quickly deep.
as possible and close the cap immediately after
using. After opening Primer, all the contents
should be used within 180 days (or 2 hours with
the cap off). 7
3. Apply Primer for paint (Sika Aktivator DM-1) to the c
cutting edge of adhesive at cab (7) side by using a
brush. Wait for about 15 minutes in order to let it d
dry by itself.
W1SE-02-01-038
c- Apply Primer by using a d- Cutting edge of adhesive at

brush. cab (7) side
WDBR50-EN-00(20171222) W3-1-2-11
Group 1 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 close
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.
6. Install the spacer with facing to the glass surface by
using the instant adhesive. (As for the positions to
install spacers A, B, and C dam rubber, refer to W3-1-
2-14 to W3-1-2-16.)
7. Cut off the nozzle of adhesive cartridge (Sika Tack
Go!) into V-shaped by using a knife. (As for the
cutting procedure of nozzle, refer to W3-1-2-17.)
8. Remove the seal of the cartridge end. Install the
V-shaped nozzle.
9. Install the cartridge to the manual coking gun.
10. Apply adhesive to the adhesive position at cab side
so that the bead triangle may be even. (As for the
position to apply adhesive, refer to W3-1-2-17.)
11. Raise the glass by using the suction lifter (rubber
sucker 4355282), and adhere it to the cab within 5
minutes.
fNOTE: Install the glass while fitting 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 duct tape until the
adhesive becomes solid in order to prevent them
from being mispositioned or coming off. (Refer to
W3-1-2-13.)
fNOTE: Time for adhesive (Sika Tack Go!) to become

solid: 8 hours (just for reference)
WDBR50-EN-00(20171222) W3-1-2-12
Group 1 Cab
Unit: mm
Rear Glass Right-Hand Glass
WDAA-03-01-039
Rear Left-Hand Glass

WDAA-03-01-040
Lower Door Glass
WDAA-03-01-041 WDAA-03-01-042
Spacer A Spacer B Spacer C
WDAA-03-01-043 WDAA-03-01-044 WDAA-03-01-045

a- Two-Side Adhesive Tape a- Two-Side Adhesive Tape
Dam Rubber
WDAA-03-01-046
WDBR50-EN-00(20171222) W3-1-2-13
Group 1 Cab
Unit: mm
Left-Hand Glass
1- Spacer A a- From Radius Curve End

WDAA-03-01-014
2- Dam Rubber b- Glass External Form Line
3- Stopper c- Adhesive Range
Section A Section B Section C
WDAA-03-01-017 WDAA-03-01-018 WDAA-03-01-019

d- Clearance between glass and panel: 6 mm e- Glass e- Glass
e- Glass
Section D Detail E
WDAA-03-01-020 WDAA-03-01-024
e- Glass f- Apply Super X.
WDBR50-EN-00(20171222) W3-1-2-14
Group 1 Cab
Unit: mm
Right-Hand Glass
1- Spacer A a- From Radius Curve End WDAA-03-01-016

2- Spacer C b- Glass External Form Line
3- Dam Rubber c- Adhesive Range
Section A Section B Section C
WDAA-03-01-022 WDAA-03-01-027 WDAA-03-01-028

e- Glass d- Glass and panel: Clearance OR-02: 8 mm a- From Radius Curve End
e- Glass e- Glass
WDBR50-EN-00(20171222) W3-1-2-15
Group 1 Cab
Unit: mm
Rear Glass
Section A
WDAA-03-01-021
a- From Radius Curve End

e- Glass
WDAA-03-01-015
1- Spacer B b- Glass External Form Line

a- From Radius Curve End c- Adhesive Range
Section B Section C
WDAA-03-01-025 WDAA-03-01-026
d- Glass and panel: Clearance e- Glass

OR-02: 8 mm
e- Glass
WDBR50-EN-00(20171222) W3-1-2-16
Group 1 Cab
8~9 mm
a
13~15 mm
b
W1SE-02-01-027
12
W1SE-02-01-043
b- Cut nozzle end into V-shaped. f
W1JB-02-01-031
a- Apply adhesive (bead) here. e- Apply bead so that bead triangle may be
even.
f- Panel
W1SE-02-01-028
c- Remove the seal.

d- Adhesive Cartridge
13. The required amount (just for reference) of adhesive and primer
Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack Go! Sika Aktivator DM-1 Sika Primer 206G+P
(Sika Tack Go!) (Sika Aktivator DM-1) (Sika Primer-206G+P)
310 ml Cartridge 250 ml Can 30 ml Bottle

Lower Door Glass 170 ml 0.6 ml 0.5 ml
Rear Left-Hand Glass 220 ml 0.55 ml 0.5 ml
Rear Right-Hand Glass 105 ml 1 ml 0.9 ml
Rear Glass 205 ml 0.5 ml 0.45 ml
WDBR50-EN-00(20171222) W3-1-2-17
Group 1 Cab
Procedures to Install Upper Door Glass

1. Before installing the glass, remove garnish (2) 1
around sash assembly (1) from the cab inside for
easy removal. Push sash assembly (1) by hands and
remove the sash outside.
2
2. Install glass A (3) and glass B (4) into the sash

grooves.
3 4
WDAA-03-01-031
3. Install sash assembly (1) onto the door from the
outside of cab. Secure sash assembly (1) at the
inside of cab by using garnish (2).
WDBR50-EN-00(20171222) W3-1-2-18
Group 1 Cab
Procedures to Install Upper Front Glass
1. Stick the seal 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 the seal to the glass by using adhesive.
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.
fNOTE: Cemedine Super X No. 8008

Glue-state adhesive, tubed
Cemedine 366 Deluxe
IMPORTANT: The front glass is arched-fringed. When

replacing the glass, contact with the nearest
HITACHI Office and replace it as an assembly.
WDAA-03-01-029
Detail A (Inside) Detail A (Outside)
WDAA-03-01-032 WDAA-03-01-033
a- Cemedine Super X No. 8008 a- Cemedine Super X No. 8008

b- Cemedine 366 Deluxe b- Cemedine 366 Deluxe
c- Fill seal for the inside of installation point here. e- No gap between drainage and wedge
d- Do not apply seal to this groove.
WDBR50-EN-00(20171222) W3-1-2-19
Group 1 Cab
(Blank)
WDBR50-EN-00(20171222) W3-1-2-20
Removal and Installation of Counterweight
Detail A
a WDBR-03-02-001 WDBR-03-02-002
a- Machine Front Side
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-5-1.)
3. Remove clip band (6). Disconnect connector (5).
j : 17 mm
WDBR50-EN-00(20171222) W3-2-1-1
a- Machine Front Side WDBR-03-02-003 WDBR-03-02-005

rearview camera (2) assembly.
j : 17 mm
dCAUTION: Counterweight (3) weight: 3250 kg

6. Remove caps (4) (2 used) and packings (5) (2 used).
Install Freno-Linkbolts (B-42, M42, Pitch 4.5 mm) to
the cap (5) mounting holes (2 places). Attach wire
ropes onto the Freno-Linkbolts. Hoist and hold
counterweight (3).
Remove counterweight (3) from main frame (8).
j : 55 mm
WDBR-03-02-006
WDBR50-EN-00(20171222) W3-2-1-2
Installation
dCAUTION: Counterweight (3) weight: 3250 kg

1. Install Freno-Linkbolts (B-42, M42, Pitch 4.5
mm) to the cap (4) mounting holes (2 places).
Attach wire ropes onto the Freno-Linkbolts. Hoist
counterweight (3).
2. Install counterweight (3) to main frame (8) with
washers (7) (4 used) and bolts (6) (4 used).
j : 55 mm
m : 2840 N·m
3. Remove the Freno-Linkbolts from the cap (4)
mounting holes (2 places). Install packings (5) (2 WDBR-03-02-006
used) and caps (4) (2 used).
4. Install the rearview camera (2) assembly with bolts,
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-2-1-3
Detail A
WDBR-03-02-002
a WDBR-03-02-001

6. Connect connector (5). Install clip band (6).
j : 17 mm
m : 2.5 N·m
WDBR50-EN-00(20171222) W3-2-1-4
Group 3 Main Frame
Removal and Installation of Main Frame
1 2 3
WDBR-03-03-001
IMPORTANT: The hoses and pipes contain hydraulic

oil. When removing the hoses and pipes, receive
oil with a container in order to avoid spilling oil.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
hoses, and pipes for assembling. If the clips which
clips after connecting the hoses.
Removal
dCAUTION: Release any pressure in the hydraulic

oil tank. (Refer to W1-5-1.)
2. Remove boom cylinders (2) (2 used). (Refer to W5-2-
1.)
3. Remove front attachment (1). (Refer to W5-1-1.)
4. Remove cab (3). (Refer to W3-1-1.)
WDBR50-EN-00(20171222) W3-3-1-1
Group 3 Main Frame
Detail A
WDBR-03-03-002
WDBR-03-04-056
dCAUTION: Engine cover (1) weight: 41 kg

6. Attach nylon slings onto engine cover (1). Hoist and
hold engine cover (1).
7. Remove pin (6). Remove washer (7) and stay (5) at
the engine cover (1) side.
8. Remove bolts, washers (2) (4 used) from the inside
of engine cover (1). Remove engine cover (1).
j : 17 mm
9. Remove the aftertreatment device. (Refer to W3-14-
1.)
10. Remove the counterweight. (Refer to W3-2-1.)
WDBR50-EN-00(20171222) W3-3-1-2
Group 3 Main Frame
Detail B
WDBR-03-03-004 WDBR-03-03-005
11. Remove wire harness (6) from clips (5) (2 used).

12. Remove clips (7) (2 used) and clip (9). Disconnect
hoses (8) (2 used) and hose (10).
support (1) assembly.
j : 17 mm
WDBR50-EN-00(20171222) W3-3-1-3
Group 3 Main Frame
WDBR-03-03-014
14. Disconnect hoses (1) (4 used). 18. Remove adapter (2).
j : 36 mm j : 22 mm
15. Disconnect hose (3). 19. Remove elbow (7).
j : 27 mm j : 19 mm
16. Disconnect hose (9). 20. Remove rubber (8).
j : 17 mm
17. Remove bolts (5) (2 used) and spring washers (6) (2
used). Remove stopper (4).
j : 22 mm
WDBR50-EN-00(20171222) W3-3-1-4
Group 3 Main Frame
C Detail A
WDBR-03-03-006 WDBR-03-03-007
View B
21. Remove bolts, washers (1) (2 used). Remove clips (2)

(2 used).
j : 17 mm
22. Remove clips (3) (2 used).
23. Remove bolts, washers (4) (2 used). Remove clips (5)
(2 used).
j : 17 mm
24. Disconnect connector (8). Remove bolt, washer (6).
Remove bracket (7).
j : 17 mm
WDBR-03-03-008
View C
WDBR-03-03-009
WDBR50-EN-00(20171222) W3-3-1-5
Group 3 Main Frame
Detail A
WDBR-03-03-010 WDBR-03-03-011
25. Remove bolts, washers (2, 3) (2 used for each).

Remove the support (1) assembly.
j : 17 mm
WDBR50-EN-00(20171222) W3-3-1-6
Group 3 Main Frame
WDBR-03-03-012
a- Counterweight Mounting b- Boom Mounting Bracket Hole
WDAD-03-03-001
Part 1 2
dCAUTION: Main frame (1) weight: 3950 kg c

26. Attach wire ropes onto the rear side (counterweight View A
mounting parts (a) (2 places)) of main frame (1) and
boom mounting bracket holes (b) (2 places).
27. Reduce slack of the wire ropes by using chain
blocks. Put the matching marks on main frame (1)
and outer race (2) of the swing bearing.
28. Remove bolts (3) (2 used) and bolts (4) (33 used).
j : 30 mm
fNOTE: THREEBOND #1102 or equivalent has been

applied to bolt (3).
29. Adjust the center of gravity of main frame (1) by
using chain blocks. Hoist and remove main frame (1)
from outer race (2) of the swing bearing.
fNOTE: THREEBOND #1102 or equivalent has been

applied on the mating surface.
WDBR-03-03-013
c- Machine Front Side
WDBR50-EN-00(20171222) W3-3-1-7
Group 3 Main Frame
Detail A
1
3
A
b
WDCF-03-03-004
b- THREEBOND Applying Surface
c 4
B 2 WDBR-04-01-001 c
Installation
IMPORTANT: When installing the main frame, apply
THREEBOND #1102 or equivalent so that it does
not overflow the main frame mounting surface.
1. Apply THREEBOND #1102 or equivalent to WDAK90-03-03-010
THREEBOND applying surface (b) of the main frame
c- Grease Applying Position
mounting surface of swing bearing (1). At this time,
apply THREEBOND #1102 or equivalent until the
hole center of bolt (3) in the outer race.
View B
fNOTE: If knock pin (2) has been removed, apply 1 2
THREEBOND #1102 or equivalent to knock pin (2). Install
knock pin (2) to swing bearing (1).
2. Apply grease (Alvania EP2 or equivalent) to the d
whole surface of grease applying position (c) of seal
(4) at the track frame side.
WDDK-03-03-008
d- 35 mm
WDBR50-EN-00(20171222) W3-3-1-8
Group 3 Main Frame
WDBR-03-03-012
a- Counterweight Mounting b- Boom Mounting Bracket Hole WDAD-03-03-001

1 2
Part
A
c
View A
dCAUTION: Main frame (1) weight: 3950 kg

3. Attach wire ropes onto the rear side (counterweight
mounting parts (a) (2 places)) of main frame (1) and
boom mounting bracket holes (b) (2 places).
4. Adjust the center of gravity of main frame (1) by
using chain blocks.
5. Fit the matching marks on outer race (2) of the
swing bearing and main frame (1), and the knock
pins.
6. Apply THREEBOND #1102 or equivalent to the end
of bolts (3) (2 used). Temporarily install main frame
(1) to outer race (2) of the swing bearing with bolts
(3) (2 used), and bolts (4) (33 used). WDBR-03-03-013
j : 30 mm c- Machine Front Side
7. Tighten bolts (3) (2 used) and bolts (4) (33 used).
j : 30 mm
m : 510 N·m
WDBR50-EN-00(20171222) W3-3-1-9
Group 3 Main Frame
Detail A
WDBR-03-03-010 WDBR-03-03-011
8. Install the support (1) assembly with bolts, washers

(2, 3) (2 used for each).
WDBR50-EN-00(20171222) W3-3-1-10
Group 3 Main Frame
C Detail A
WDBR-03-03-006 WDBR-03-03-007
View B
9. Install bracket (7) with bolt, washer (6). Connect

connector (8).
j : 17 mm
m : 50 N·m
10. Install clips (5) (2 used) with bolts, washers (4) (2
used).
j : 17 mm
m : 50 N·m
11. Install clips (3) (2 used).
12. Install clips (2) (2 used) with bolts, washers (1) (2 WDBR-03-03-008
used).
View C
j : 17 mm
m : 50 N·m
WDBR-03-03-009
WDBR50-EN-00(20171222) W3-3-1-11
Group 3 Main Frame
WDBR-03-03-014
13. Install rubber (8). 16. Install stopper (4) with spring washers (6) (2 used)
and bolts (5) (2 used).
14. Install adapter (2).
j : 22 mm
j : 19 mm
m : 140 N·m
m : 30 N·m
17. Connect hose (9).
15. Install elbow (7).
j : 17 mm
j : 22 mm
m : 25 N·m
m : 40 N·m
j : 27 mm
m : 80 N·m
19. Connect hoses (1) (4 used).
j : 36 mm
m : 180 N·m
WDBR50-EN-00(20171222) W3-3-1-12
Group 3 Main Frame
Detail B
WDBR-03-03-004 WDBR-03-03-005

(2) (6 used).
j : 17 mm
m : 50 N·m
21. Connect hoses (8) (2 used) and hose (10) with clips
(7) (2 used) and clip (9).
22. Install harness (6) with clips (5) (2 used).
WDBR50-EN-00(20171222) W3-3-1-13
Group 3 Main Frame
Detail A
WDBR-03-03-002
WDBR-03-04-056
23. Install the aftertreatment device. (Refer to W3-14-1.)

24. Install the counterweight. (Refer to W3-2-1.)

25. Attach nylon slings onto engine cover (1). Hoist
engine cover (1).
26. Install engine cover (1) with bolts, washers (2) (4
used).
j : 17 mm
m : 50 N·m
27. Install the engine cover (1) side of stay (5) with
washer (7) and pin (6).
WDBR50-EN-00(20171222) W3-3-1-14
Group 3 Main Frame
1 2 3
WDBR-03-03-001
29. Install cab (3). (Refer to W3-1-1.)

30. Install front attachment (1). (Refer to W5-1-1.)
31. Install boom cylinders (2) (2 used). (Refer to W5-2-1.)
32. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
WDBR50-EN-00(20171222) W3-3-1-15
Group 3 Main Frame
(Blank)
WDBR50-EN-00(20171222) W3-3-1-16
Group 4 Engine
Removal and Installation of Engine
1, 2, 3 4
5
b
WDBR-03-04-001 a- OFF Position WDBR-03-04-002

b- ON Position

penetrate the skin and eyes, and cause serious
dCAUTION: Release any pressure in hydraulic oil
tank (4). (Refer to W1-5-1.)
injury. Release the pressure before disconnecting 2. Remove bolts, washers (1) (6 used). Remove the
the hydraulic pipings or removing other cover (2) assembly and O-ring (3) from the upper
equipment. Hot hydraulic oil just after operation part of hydraulic oil tank (4).
may spout out and cause severe burns. Allow oil to
cool before starting any work. j : 17 mm
IMPORTANT: The hoses and pipes contain hydraulic 3. Place a container. Drain off hydraulic oil by using an
oil. When removing the hoses and pipes, receive oil feed pump.
IMPORTANT: Cap the open ends in case the hoses fNOTE: Total oil amount of hydraulic oil tank (4): 190 L
and pipes have been disconnected. In addition, 4. Open cover (5).
attach identification tags onto the connectors, IMPORTANT: Set the key switch to the OFF position.
hoses, and pipes for assembling. If the clips which Wait 5 minute or longer, and then set battery
secure the hoses have been removed, install the disconnect switch (6) to the OFF position.
5. Set battery disconnect switch (6) to OFF position (a).
Removal
WDBR50-EN-00(20171222) W3-4-1-1
Group 4 Engine
Detail A
WDBR-03-04-056
WDBR-03-04-003

7. Attach nylon slings onto engine cover (1). Hoist and
hold engine cover (8).
8. Remove pin (6). Remove washer (7) and stay (5) at
the engine cover (1) side.
9. Remove bolts, washers (4) (4 used). Remove engine
cover (1).
j : 17 mm
10. Remove bolts, washers (2) (3 used). Open cover (3).
j : 17 mm
11. Remove bolts, washers (8) (4 used). Remove cover WDBR-03-04-004
(3).
j : 17 mm
12. Release any pressure in the expansion tank. (Refer
to W1-5-1.)
WDBR50-EN-00(20171222) W3-4-1-2
Group 4 Engine
WDBR-03-04-006 WDBR-03-04-007
a- Machine Front Side a- Machine Front Side
a
13. Remove the counterweight. (Refer to W3-2-1.)

14. Remove the aftertreatment device. (Refer to W3-14-
1.)
15. Remove the pump device. (Refer to W3-8-1.)
a
not drop cover (2).
(2).
j : 17 mm
17. Place a container under hose (4). Loosen cock (3).
Drain off coolant. Close cock (3).
fNOTE: Amount of coolant: 24 L

6 WDC150-03-04-003
18. Close fuel cock (6) of fuel tank (5). a- Machine Front Side
WDBR50-EN-00(20171222) W3-4-1-3
Group 4 Engine
Detail B
WDBR-03-04-008 WDBR-03-04-009
a- Machine Front Side a

20. Remove clips (7) (2 used) and clip (9). Disconnect
hoses (8) (2 used) and hose (10).
Remove the separator (11) assembly.
j : 17 mm
22. Remove bolts, washers (2) (4 used). Remove step (4).
j : 17 mm
23. Remove bolts, washers (3) (4 used). Remove support
assembly (1).
j : 17 mm
WDBR50-EN-00(20171222) W3-4-1-4
Group 4 Engine
View B
WDBR-03-04-057
WDBR-03-04-053
Detail C
24. Remove clips (15, 16) and clips (21) (3 used).

Disconnect hoses (19) (2 used).
25. Remove clip (25). Disconnect hose (26).
27. Remove clip (20). Disconnect connector (9).
washers (18) (4 used). Remove the expansion tank
(14) assembly.
j : 17 mm
WDBR-03-04-054
WDBR50-EN-00(20171222) W3-4-1-5
Group 4 Engine
WDBR-03-04-012
29. Remove clamps (8, 9). Disconnect the both ends of

hose (6).
j : 7 mm, 8mm
30. Remove clamps (7, 11). Disconnect the both ends of
the pipe (1) assembly.
j : 7 mm
Remove the hose (1) assembly.
j : 17 mm
WDBR50-EN-00(20171222) W3-4-1-6
Group 4 Engine
B
4
WDBR-03-09-017
5
WDBR-03-04-013
a View B

(2). 6
j : 17 mm
a
(7).
j : 17 mm
washers (4) (4 used). Remove the cover (5) assembly.
j : 17 mm WDBR-03-09-018
a- Machine Front Side 7
WDBR50-EN-00(20171222) W3-4-1-7
Group 4 Engine
a
Detail B
WDBR-03-04-014 WDBR-03-04-015
35. Remove bolts, washers (2, 3). Remove cover (1).
j : 17 mm
37. Remove clamps (4, 8).
j : 7 mm, 11 mm
duct (7) assembly of the air cleaner.
j : 17 mm
WDBR-03-04-016
WDBR50-EN-00(20171222) W3-4-1-8
Group 4 Engine


not drop cover (2).
(2).
40. Remove bolt, washer (5). Remove clip (6).
j : 17 mm
41. Remove clip band (4). Disconnect connectors (3) (6
used).
WDBR50-EN-00(20171222) W3-4-1-9
Group 4 Engine
42. Remove clamps (1, 3) (2 used for each). Disconnect View B

the both ends of hoses (2, 4).
j : 7 mm, 8 mm
43. Remove clips (5) (2 used). Remove clip band (7).
44. Remove bolts, washers (8) (3 used) and clips (9) (3
used). Disconnect hoses (6) (2 used).
j : 17 mm
WDBR-03-04-021
WDBR50-EN-00(20171222) W3-4-1-10
Group 4 Engine
View A
WDBR-03-04-022
Detail B
WDBR-03-04-023
45. Disconnect connector (2). Remove clip bands (3) (2

used).
used). Place harness (7) outside the work area.
j : 17 mm
47. Disconnect connector (4). Remove connect (4) from
bracket (5).
48. Remove bolts, washers (6, 10) (2 used for each). WDBR-03-04-024
Remove the support (1) assembly.
j : 17 mm Detail C
WDBR-03-04-025
WDBR50-EN-00(20171222) W3-4-1-11
Group 4 Engine
Detail A
WDBR-03-04-026 WDBR-03-04-027
WDBR-03-04-028
49. Loosen bolt (7) of tension pulley (6). 51. Remove socket bolts (2) (4 used), washer assemblies
(3) (4 used), and bracket (4). Place belt (5) and the
j : 22 mm compressor (1) assembly outside of the work area.
50. Loosen adjusting bolt (8). Move tension pulley (6).
l : 6 mm
Release the belt (5) tension.
52. Remove socket bolts (11) (3 used), socket bolt (12),
j : 12 mm spring washers (9) (4 used), and washers (10) (4
used). Remove the bracket (13) assembly.
l : 6 mm
WDBR50-EN-00(20171222) W3-4-1-12
Group 4 Engine
Detail A
WDBR-03-04-029 WDBR-03-04-052
53. Remove nut (1) and washer (2). Disconnect ground

cable (3).
j : 17 mm
54. Remove clamps (4, 5). Disconnect hoses (6, 13).
j: 7 mm
55. Remove sleeve (14).
56. Remove screw (7). Disconnect terminal (8).
57. Remove nut (9) and washer (10). Disconnect
terminals (11, 12).
j : 13 mm
WDBR-03-04-031
WDBR50-EN-00(20171222) W3-4-1-13
Group 4 Engine
Detail A
WDBR-03-04-035 WDBR-03-04-036
WDBR50-EN-00(20171222) W3-4-1-14
Group 4 Engine
A View A
WDBR-03-04-043
B
WDBR-03-04-033
59. Disconnect connector (3). View B
60. Remove bolt, washer (6). Disconnect terminal (7).
j : 10 mm
61. Remove nut (4). Disconnect terminal (5).
j : 10 mm
65. Disconnect hoses (10) (2 used).
j : 36 mm
IMPORTANT: Band (16) cannot be reused.
66. Remove lock (15). Cut and remove band (16).
Remove rubber (13) from cover (14).
WDBR-03-04-034
WDBR50-EN-00(20171222) W3-4-1-15
Group 4 Engine
WDBR-03-04-037 a- Machine Front Side WDBR-03-04-038

b- Lifting Bracket
a
Detail C
dCAUTION: Engine (1) weight: 355 kg
67. Install shackles (2 used) to lifting brackets (b) (2
places) of engine (1). Attach nylon slings onto the
shackles. Hoist and hold engine (1).
68. Disconnect hose (3) from rubber (2).
WDBR-03-04-039
WDBR50-EN-00(20171222) W3-4-1-16
Group 4 Engine
1 13
2
3
5
1
11
3
a
13
5
6
2
1
7 2
1
12
6
7
6
6 8
9
WDBR-03-04-040
a- Machine Front Side 8 9
69. Remove bolts (3) (2 used), nuts (1) (4 used), nuts (9) 70. Hoist engine (11) by 15 mm.
(2 used), washers (2) (4 used), washers (5, 8) (2 used
71. Move engine (11) to the pump device mounting
for each), stopper (6) (2 used), rubber cushions (7) (2
side by 50 mm. Remove engine (11) from main
used) under main frame (12).
frame (12).
j : 24 mm, 27 mm 72. Remove remaining stoppers (6) (2 used) and rubber
cushions (13, 7) (2 used for each).
fNOTE: LOCTITE #263 or equivalent has been applied to
bolt (3). fNOTE: 10 identification mark is marked on rubber
f NOTE: 4D identification mark is marked on rubber cushion (13).
cushion (7). fNOTE: 4D identification mark is marked on rubber
cushion (7).
WDBR50-EN-00(20171222) W3-4-1-17
Group 4 Engine
3 2 1
3
2
2
3
4
3
2
WDBR-03-04-041
73. Remove bolts (3) (12 used) and washers (2) (12
used). Remove brackets (1) (2 used).
j : 22 mm
74. Remove the adapters and couplings from engine (4)
if necessary.
WDBR50-EN-00(20171222) W3-4-1-18
Group 4 Engine
3 2 1
3
2
2
3
4
3
2
WDBR-03-04-041
Installation
1. Install all removed adapters and couplings to 2. Install brackets (1) (2 used) with washers (2) (12
engine (4). used) and bolts (3) (12 used).
j : 22 mm
m : 180 N·m
WDBR50-EN-00(20171222) W3-4-1-19
Group 4 Engine
1 13
2
3
5
1
11
3
a
13
5
6
2
WDBR-03-04-051 1
b- Lifting Bracket 7 2
1
12
6
7
6
6 8
9
8 9 WDBR-03-04-040
3. Install rubber cushions (13, 7) (2 used for each) 5. Apply LOCTITE #263 or equivalent to bolts (3) (2
and stoppers (6) (2 used) to the upper side of main used). Install engine (11) to main frame (12) with
frame (12). rubber cushions (7) (2 used), stoppers (6) (2 used),
washers (5, 8) (2 used for each), washers (2) (4 used),
fNOTE: 10 identification mark is marked on rubber nuts (9) (2 used), nuts (1) (4 used) and bolts (3) (2
cushion (13). used).
fNOTE: 4D identification mark is marked on rubber
j : 24 mm
cushion (7).
dCAUTION: Engine (11) weight: 355 kg m : 235 N·m

4. Install shackles (2 used) to lifting brackets (b) (2 j : 27 mm
places) of engine (11). Attach nylon slings onto the
shackles. Hoist engine (11). m : 400 N·m
fNOTE: 4D identification mark is marked on rubber

cushion (7).
WDBR50-EN-00(20171222) W3-4-1-20
Group 4 Engine
Detail C
WDBR-03-04-038 WDBR-03-04-039
b- Machine Front Side
b
6. Connect hose (3) to rubber (2).

7. Connect connectors (4) (6 used). Install clip band (5).
j : 17 mm
m : 50 N·m
WDBR-03-04-046
WDBR50-EN-00(20171222) W3-4-1-21
Group 4 Engine
View A
WDBR-03-04-043
A
WDBR-03-04-042
Section B-B 13
IMPORTANT: Replace band (16) with the new one.

9. Install rubber (13) to cover (14) with band (16) and
lock (15). At this time, check that part (c) of rubber
(13) is in part (d) of fan ring (1).
e- Engine Side WDBR-03-04-050

d 1
WDBR50-EN-00(20171222) W3-4-1-22
Group 4 Engine
A Detail A
WDBR-03-04-043
WDBR-03-04-033
j : 36 mm
m : 180 N·m
11. Connect hoses (2, 9, 11). Install clips (1, 8, 12).
12. Install terminal (5) with nut (4).
j : 10 mm
m : 3 to 4 N·m
13. Install terminal (7) with bolt, washer (6).
j : 10 mm
m : 3 to 4 N·m
WDBR50-EN-00(20171222) W3-4-1-23
Group 4 Engine
Detail A
WDBR-03-04-035 WDBR-03-04-036
15. Connect hose (2) with clip (1).
WDBR50-EN-00(20171222) W3-4-1-24
Group 4 Engine
Detail A
WDBR-03-04-029 WDBR-03-04-052
IMPORTANT: Check the angle to install the wire

harness.
16. Connect terminals (11, 12) with washer (10) and nut
(9).
j : 13 mm
m : 8.8 N·m
17. Connect terminal (8) with screw (7).
18. Install sleeve (14).
19. Connect ground cable (3) with washer (2) and nut
(1).
j : 17 mm
m : 50 N·m
20. Connect hoses (6, 13) with clamps (4, 5). WDBR-03-04-031
j : 7 mm
m : 6 to 7 N·m
a- 75° WDBR-03-04-044
WDBR50-EN-00(20171222) W3-4-1-25
Group 4 Engine
WDBR-03-04-026 WDBR-03-04-028
Detail A
21. Install bracket (13) assembly with washers (10) (4

used), spring washers (9) (4 used), socket bolt (12),
and socket bolts (11) (3 used).
l : 6 mm
m : 30 N·m
IMPORTANT: Washer assembly (3) is consist of
two washers. Fit mating surfaces (b) of washer
assemblies (3) (2 used) when installing.
22. Install belt (5) and the compressor (1) assembly
with bracket (4), washer assemblies (3) (4 used) and
socket bolts (2) (4 used).
l : 6 mm
m : 35 N·m
WDBR-03-04-045
b- Mating Surface
WDDQ50-03-04-023
WDBR50-EN-00(20171222) W3-4-1-26
Group 4 Engine
1 2 3 4
c M1U1-07-086
WDAD-03-04-014
a- Compressor Pulley
b- 14.0 to 17.8 mm, 98 N
c- Crank Pulley
23. Adjust the belt (4) tension correctly by moving

tension pulley (1) by using adjusting bolt (3).
j : 12 mm
m : 6±1 N·m
24. Tighten bolt (2) of tension pulley (1).
j : 24 mm
m : 40±5 N·m
IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
again after running the engine at slow idle for 3 to
5 minutes.
WDBR50-EN-00(20171222) W3-4-1-27
Group 4 Engine
View A
WDBR-03-04-022
Detail B
WDBR-03-04-023

j : 17 mm
m : 50 N·m
26. Connect connector (4). Install connector (4) to
bracket (5).
27. Install harness (7) with clips (9) (2 used) and bolts,
washers (8) (2 used). WDBR-03-04-024
j : 17 mm
Detail C
m : 50 N·m
28. Connect connector (2). Install clip bands (3) (2 used).
WDBR-03-04-025
WDBR50-EN-00(20171222) W3-4-1-28
Group 4 Engine
View B
WDBR-03-04-020 WDBR-03-04-021
29. Connect hoses (6) (2 used). Install clips (5) (2 used).

30. Secure hoses (6) (2 used) with bolts, washers (8) (3
used), clips (9) (3 used) and clip band (7).
j : 17 mm
m : 50 N·m
31. Connect the both ends of hoses (2, 4). Install clamps
j : 7 mm
m : 6 N·m
j : 8 mm
m : 6 N·m
WDBR50-EN-00(20171222) W3-4-1-29
Group 4 Engine
a
Detail B
WDBR-03-04-014 WDBR-03-04-015
32. Temporarily install duct (7) of the air cleaner with

bolts, washers (9) (2 used).
j : 17 mm
33. Install clamp (4).
j : 11 mm
m : 10 N·m
34. Install clamp (8).
j : 7 mm
m : 6 N·m
35. Connect hose (6). Install clip (5).
36. Tighten bolts, washers (9) (2 used).
j : 17 mm
WDBR-03-04-016
m : 50 N·m a- Machine Front Side
37. Install cover (1) with bolts, washers (2, 3).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-4-1-30
Group 4 Engine
WDBR-03-04-012
38. Temporarily install the pipe (1) assembly with bolts, 40. Tighten bolts, washers (5, 10) (2 used for each).
washers (5, 10) (2 used for each).
j : 17 mm
j : 17 mm
m : 50 N·m
39. Connect the both ends of the pipe (1) assembly.
Install clamps (7, 11). 41. Connect the both ends of hose (6). Install clamps (8,
9).
j : 7 mm
j : 7 mm
m : 6 N·m
m : 6 N·m
j : 8 mm
m : 6 N·m
WDBR50-EN-00(20171222) W3-4-1-31
Group 4 Engine
View B
WDBR-03-04-055
Detail C
42. Install the expansion tank (14) assembly with bolts,

washers (17) (2 used) and bolts, washers (18) (4
used).
j : 17 mm
m : 50 N·m
46. Connect hoses (19) (2 used) with clip (15, 16). Install
clips (21) (3 used).
WDBR-03-04-054
WDBR50-EN-00(20171222) W3-4-1-32
Group 4 Engine
Detail B
WDBR-03-04-008 WDBR-03-04-009

(3) (4 used).
j : 17 mm
m : 50 N·m
48. Install step (4) with bolts, washers (2) (4 used).
j : 17 mm
m : 50 N·m
49. Install the separator (11) assembly with bolts,
washers (12, 13) (2 used for each).
j : 17 mm
m : 50 N·m
50. Connect hoses (8) (2 used) and hose (10) with clips
(7) (2 used) and clip (9).
51. Install harness (6) with clips (5) (2 used).
WDBR50-EN-00(20171222) W3-4-1-33
Group 4 Engine
a- OFF Position WDBR-03-04-002

2 WDC150-03-04-003
b- ON Position
52. Open fuel cock (2) of fuel tank (1).

53. Set battery disconnect switch (6) to ON position (b).
54. Add coolant to the radiator.
fNOTE: Amount of coolant: 24 L

55. Install the pump device. (Refer to W3-8-1.)
57. Install the counterweight. (Refer to W3-2-1.)
WDBR50-EN-00(20171222) W3-4-1-34
Group 4 Engine
1, 2, 3 4
5
a
WDBR-03-04-001
WDBR-03-04-047
58. Fill hydraulic oil tank (4) with hydraulic oil. a- Machine Front Side
fNOTE: Total oil amount of hydraulic oil tank (4): 190 L

59. Install O-ring (3).
60. Install the cover (2) assembly on the top of hydraulic
oil tank (4) with bolts, washers (1) (6 used).
j : 17 mm
m : 50 N·m
61. Bleed air from the fuel system. (Refer to W1-4-1.)
62. Bleed air from the DEF defrosting piping. (Refer to
W1-4-1.)
63. Bleed air from the cooling system. (Refer to
Operator's Manual.)
1.)
Pump Air Bleed Plug
j : 27 mm
m : 95 N·m
IMPORTANT: Check the engine oil level, hydraulic
oil level, and coolant level. Start the engine and 66. Install cover (7) with bolts, washers (6) (6 used).
check for any oil and coolant leaks. j : 17 mm
IMPORTANT: Warm up the engine and increase the
SCR exhaust temperature over 190 °C. Check the m : 50 N·m
DEF hose for DEF leaks. In addition, check that 67. Install cover (9) with bolts, washers (8) (6 used).
DEF pressure increases up to approx. 9000 hPa by
using the monitor. (Refer to T5-2 in the separated j : 17 mm
volume, Technical Manual.)
m : 50 N·m
WDBR50-EN-00(20171222) W3-4-1-35
Group 4 Engine
B
4
4 a
WDBR-03-09-017
5
WDBR-03-04-013
View B
68. Install the cover (5) assembly with bolts, washers (3)
(3 used) and bolts, washers (4) (6 used).
j : 17 mm
6
m : 50 N·m
69. Install clip (8).
a
j : 17 mm
m : 50 N·m
WDBR-03-09-018
j : 17 mm a- Machine Front Side 7
m : 50 N·m
WDBR50-EN-00(20171222) W3-4-1-36
Group 4 Engine
Detail A
WDBR-03-04-003 WDBR-03-04-056
j : 17 mm
m : 50 N·m

73. Attach nylon slings onto engine cover (1). Hoist
engine cover (1).
74. Install engine cover (1) with bolts, washers (4) (4
used).
j : 17 mm
m : 50 N·m
75. Install the engine cover (1) side of stay (5) with
washer (7) and pin (6). WDBR-03-04-004

WDBR50-EN-00(20171222) W3-4-1-37
Group 4 Engine
(Blank)
WDBR50-EN-00(20171222) W3-4-1-38
Group 8 Pump Device
Removal and Installation of Pump Device
1, 2
WDBR-03-08-004
4 3
Removal
penetrate the skin and eyes, and cause serious 1. Remove the aftertreatment device. (Refer to W3-14-
injury. Release the pressure before disconnecting 1.)
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation dCAUTION: Release any pressure in hydraulic oil
tank (4). (Refer to W1-5-1.)
may spout out and cause severe burns. Allow oil to
cool before starting any work. 2. Remove bolts, washers (3) (6 used). Remove the
cover (1) assembly and O-ring (2) from the upper
part of hydraulic oil tank (4).
oil with a container in order to avoid spilling oil. j : 17 mm
IMPORTANT: Cap the open ends in case the hoses 3. Place a container. Drain off hydraulic oil by using an
and pipes have been disconnected. In addition, oil feed pump.
fNOTE: Total oil amount of hydraulic oil tank (4): 188 L
WDBR50-EN-00(20171222) W3-8-1-1
Group 8 Pump Device
WDBR-03-08-005

(5).
j : 17 mm
WDBR50-EN-00(20171222) W3-8-1-2
Group 8 Pump Device
1 7, 8
1
9, 10
4, 5
2, 3
WDBR-03-08-006 WDBR-03-08-007
2, 3 4, 5 11 9, 10 7
Detail A
5. Remove clip band (11). Disconnect hoses (1) (4

used).
j : 17 mm, 19 mm, 36 mm
6. Remove socket bolts (2) (8 used) and flanges (3)
(4 used). Disconnect hoses (4) (2 used). Remove
O-rings (5) (2 used).
1
l : 10 mm
7. Remove clip bands (8) (3 used). Disconnect
connectors (7) (5 used). Remove bolts, washers (9) (2
used) and clips (10) (2 used).
j : 10 mm WDBR-03-08-008
WDBR50-EN-00(20171222) W3-8-1-3
Group 8 Pump Device
12
WDBR-03-08-011
10
A
View A
WDBR-03-08-010

l : 8 mm
13, 14
9. Remove socket bolts (6) (4 used). Place the pipe (7)
assembly outside the work area. Remove O-ring (8).
l : 10 mm
10. Remove clip bands (9) (3 used). Disconnect hoses
(12) (2 used). WDBR-03-08-012
j : 22 mm
11. Remove bolts (11) (2 used) and spring washers (16)
(2 used). Remove the bracket (10) assembly.
j : 17 mm
fNOTE: LOCTITE #263 or equivalent has been applied on

bolt (11).
12. Disconnect connectors (5) (2 used). Remove bolt,
washer (13) and clip (14).
j : 17 mm
WDBR-03-08-013
11, 16 10
WDBR50-EN-00(20171222) W3-8-1-4
Group 8 Pump Device
1, 2 4, 5
5, 13
12
5, 6
WDBR-03-08-014 WDBR-03-08-015
3
9, 10, 11 9, 10, 11
dCAUTION: Pump device (3) weight: 175 kg

Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
bolt (1) holes. Attach nylon slings onto the eyebolts
(2 used). Hoist and hold pump device (3).
j : 19 mm
dCAUTION: The bracket (8) weight: 49 kg

14. Attach nylon slings onto the bracket (8). Hoist and
hold the bracket (8).
15. Remove bolts (4, 6, 13) (2 used for each), bolts (9)
(5 used), spring washers (10) (5 used), washers (5)
(6 used) and washers (11) (5 used). Remove the WDBR-03-08-016
bracket (8) and bracket (12).
j : 19 mm

bolts (4, 6, 9, 13).
WDBR50-EN-00(20171222) W3-8-1-5
Group 8 Pump Device
1, 2
1, 2
WDBR-03-08-017
1, 2
16. Remove bolts (1) (3 used) and spring washers (2) (3

used). Remove pump device (3) from the engine.
j : 19 mm

bolt (1).
17. Remove the insert of the coupling in the engine.
(Refer to W3-8-2.)
18. Remove the adapters from pump device (3) if
necessary.
WDBR50-EN-00(20171222) W3-8-1-6
Group 8 Pump Device
1, 2 4
1, 2
WDBR-03-08-017 WDBR-03-08-014
1, 2
Installation
1. Install all removed adapters to pump device (3).
2. Install the insert of the coupling to the engine.
(Refer to W3-8-2.)
dCAUTION: Pump device (3) weight: 175 kg

3. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
bolt (4) holes. Attach nylon slings onto the eyebolts
(2 used). Hoist pump device (3).
4. Apply LOCTITE #263 or equivalent to bolts (1) (3
used). Temporally install pump device (3) to the
engine with spring washers (2) (3 used) and bolts (1)
(3 used).
j : 19 mm
WDBR50-EN-00(20171222) W3-8-1-7
Group 8 Pump Device
4, 5 7, 9, 10 7, 9, 10
12, 15
WDBR-03-08-015 WDBR-03-08-016
Detail A 13
dCAUTION: The bracket (8) weight: 49 kg

5. Attach nylon slings onto the bracket (8). Hoist and
hold the bracket (8). 14
used) and bolts (7) (5 used). Temporarily install the
bracket (8) with bolts (4) (2 used), bolts (7) (5 used),
spring washers (9) (5 used), washers (5) (4 used), and 6, 15
j : 19 mm WDBR-03-08-018
7. Apply LOCTITE #263 or equivalent to bolts (6, 12)

(2 used for each). Temporally install washers (15) (4
used) and bolts (6, 12) (2 used for each). Adjust the
clearance between bracket (14) and engine (13) for
0 mm.
WDBR50-EN-00(20171222) W3-8-1-8
Group 8 Pump Device
1 2 3 4 5 6 7
9
8
11
10
WDBR-03-08-016 WDBR-03-08-015
8. Tighten bolts (1 to 11) (11 used) in the order shown

in the number.
j : 19 mm
m : 110 N·m
WDBR50-EN-00(20171222) W3-8-1-9
Group 8 Pump Device
1 4, 5
WDBR-03-08-017 WDBR-03-08-014
1
9. Tighten bolts (1) (3 used).
j : 19 mm
m : 110 N·m
10. Remove the eyebolts (2 used).
11. Install bolts (4) (2 used) and washers (5) (2 used).
j : 19 mm
m : 90 N·m
WDBR50-EN-00(20171222) W3-8-1-10
Group 8 Pump Device
12
WDBR-03-08-011
10
A
View A
WDBR-03-08-010
12. Connect connectors (5) (2 used). Secure wire

harness (17) with clip (14) and bolt, washer (13).
j : 17 mm
used). Install the bracket (10) assembly with spring
13, 14
j : 17 mm
17
14. Connect hoses (12) (2 used). Install clip bands (9) (2
used).
j : 22 mm
WDBR-03-08-012
15. Install the pipe (7) assembly with O-ring (8) and
l : 10 mm
16. Install O-rings (4) (2 used). Install hoses (3) (2 used)
with flanges (2) (4 used) and socket bolts (1) (8
used).
l : 8 mm
WDBR-03-08-013
11, 16 10
WDBR50-EN-00(20171222) W3-8-1-11
Group 8 Pump Device
1 7, 8
1
9, 10
4, 5
2, 3
WDBR-03-08-006 11 WDBR-03-08-007
2, 3 4, 5 9, 10 7
Detail A
17. Connect connectors (7) (5 used). Install wire harness

(11) with clips (10) (2 used), bolts, washers (9) (2
used), and clip bands (8) (3 used).
j : 10 mm
18. Install O-rings (5) (2 used). Install hoses (4) (2 used)
with flanges (3) (4 used) and socket bolts (2) (8
used). 1
l : 10 mm
j : 17 mm, 19 mm, 36 mm
WDBR-03-08-008
WDBR50-EN-00(20171222) W3-8-1-12
Group 8 Pump Device
7, 8
WDBR-03-08-005 WDBR-03-08-004
10 9
20. Install cover (5) with bolts, washers (6) (4 used). 26. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
j : 17 mm
 Pump Air Bleed Plug
j : 27 mm
22. Fill hydraulic oil tank (10) with hydraulic oil.
m : 95 N·m
f NOTE: Total oil amount of hydraulic oil tank (10): 188 L
23. Install O-ring (8). engine and check for any oil leaks.
24. Install the cover (7) assembly on the top of hydraulic IMPORTANT: Warm up the engine and increase the
oil tank (10) with bolts, washers (9) (6 used). SCR exhaust temperature over 190 °C. Check the
DEF hose for DEF leaks. In addition, check that
j : 17 mm DEF pressure increases up to approx. 9000 hpa by
m : 50 N·m using the monitor. (Refer to T5-2 in the separated
25. Bleed air from DEF defrosting piping. (Refer to W1-
4-1.)
WDBR50-EN-00(20171222) W3-8-1-13
Group 8 Pump Device
WDBR-03-14-001

WDBR50-EN-00(20171222) W3-8-1-14
Group 8 Pump Device
Removal and Installation of Coupling
7 5 6 8 1 9
a
8
10 4
7
a 2
9
a- Engine Side a- Engine Side
WDBE-03-08-015 WDBE-03-08-016
Removal 4. Remove socket bolts (6) (4 used) from insert

(5). Remove inserts (5) (4 used) from the engine
1. Remove socket bolts (10) (8 used) from stopper (9).
flywheel.
Remove stopper (9) from cylindrical hub (4).
l : 14 mm
l : 5 mm
fNOTE: LOCTITE #263 or equivalent has been applied to fNOTE: LOCTITE #263 or equivalent has been applied to
socket bolt (6).
socket bolt (10).
5. Remove spring pins (7) (4 used) from the engine
2. Remove element (2) from insert (1) at the pump
flywheel.
side.
6. Remove screws (8) (2 used) from cylindrical hub (4).
3. Remove socket bolts (3) (4 used) from insert (1).
Remove cylindrical hub (4) from the pump device.
Remove inserts (1) (4 used) from cylindrical hub (4).
l : 10 mm
l : 14 mm
screw (8).
socket bolt (3).
WDBR50-EN-00(20171222) W3-8-2-1
Group 8 Pump Device
7 5 6 8 1 9
4
a
8
10 4
7
a 2
9
a- Engine Side a- Engine Side
b- Identification Groove
WDBE-03-08-015 WDBE-03-08-016
Installation 5. Apply LOCTITE #263 or equivalent to socket bolts (3)

(4 used). Install inserts (1) (4 used) to cylindrical hub
1. Install spring pins (7) (4 used) to the engine
(4) with socket bolts (3) (4 used).
flywheel.
2. Apply LOCTITE #263 or equivalent to socket bolts l : 14 mm
(6) (4 used). Install inserts (5) (4 used) to the engine
m : 210 to 230 N·m
flywheel with socket bolts (6) (4 used).
6. Install element (2) to inserts (1) (4 used) at the pump
l : 14 mm side.
m : 210 to 230 N·m 7. Apply LOCTITE #263 or equivalent to socket bolts
(10) (8 used). Install stopper (9) to cylindrical hub (4)
IMPORTANT: There is an identification groove on
with socket bolts (10) (8 used).
one side of cylindrical hub (4). Install cylindrical
hub (4) with the identification groove side facing l : 5 mm
to the engine side.
IMPORTANT: Install cylindrical hub (4) until it comes m : 10 N·m
in contact with the spline shaft of shaft (9).
3. Install cylindrical hub (4) to the pump device.
4. Apply LOCTITE #263 or equivalent to screws (8) (2
used). Secure cylindrical hub (4) with screws (8) (2
used).
l : 10 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-8-2-2
Group 8 Pump Device
Disassembly of Pump Device
79
2
53
52
6
28
25
47 35
33
48
34
82 36
83
32 37
38
30
31
39
46 40
45 41
42
43
44 WDBR-03-08-001
42
2- Regulator 27- Gear 52- Spring Washer (6 Used) 77- Valve Plate
3- Socket Bolt (4 Used) 28- Gasket 53- Bolt (6 Used) 78- Link (2 Used)
4- Socket Bolt (4 Used) 29- Gear 54- Spring Pin (4 Used) 79- Hose
5- Socket Bolt (4 Used) 30- Plug 55- O-Ring (8 Used) 80- Pump 1 Delivery Pressure
6- Regulator 31- O-Ring 56- O-Ring (2 Used) Sensor
7- O-Ring (4 Used) 32- Gasket 57- Pin (2 Used) 80A- O-Ring
8- O-Ring (6 Used) 33- Socket Bolt (2 Used) 58- Retaining Ring (12 Used) 81- Pump 2 Delivery Pressure
9- Bearing Nut (2 Used) 34- Pipe 59- Pin (2 Used) Sensor
10- Bearing (2 Used) 35- Level Gauge 60- Lever (4 Used) 81A- O-Ring
11- Ring (2 Used) 36- Socket Bolt (2 Used) 61- Pin (4 Used) 82- Plug
12- Bearing (2 Used) 37- Spring Washer (2 Used) 62- Valve Plate 83- Elbow
13- Shaft 38- Washer (2 Used) 63- Backup Ring 84- Spacer (2 Used)
14- Pin (2 Used) 39- Pilot Pump 64- O-Ring 85- Bearing (2 Used)
15- Center Shaft (2 Used) 40- Retaining Ring 65- Spring Pin (2 Used) 86- Pin (4 Used)
16- Spring (2 Used) 41- Retaining Ring 66- Selector Head 87- Spacer (2 Used)
17- Plunger (14 Used) 42- Ball Bearing (2 Used) 67- O-Ring (4 Used)
18- Rotor (2 Used) 43- Gear 68- Socket Bolt (16 Used)
19- Shaft 44- Gear Shaft 69- Stopper (2 Used)
20- Thrust Ring 45- Retaining Ring 70- O-Ring (2 Used)
21- O-Ring (2 Used) 46- Oil Seal 71- Socket Bolt (12 Used)
22- Plug (2 Used) 47- Gear Casing 72- Set Screw (2 Used)
23- O-Ring 48- Spring Pin (2 Used) 73- Servo Piston (2 Used)
24- Plug 49- Oil Seal (2 Used) 74- Pin (2 Used)
25- Plug 50- Retaining Ring (2 Used) 75- O-Ring (2 Used)
26- Retaining Ring (2 Used) 51- Pump Casing 76- Stopper (2 Used)
WDBR50-EN-00(20171222) W3-8-3-1
Group 8 Pump Device
4
3
5
4
3
5
2
17
16 18
15
14
6 84, 87
13
11 12
10 85
56 7 9
55
54 17
8
15 14 16
19
85
51
49 84, 87
50 12
27 20
11 68
10
9 67 69
26 80A
66 70
67
80
64 71
21 63
49 65
50 21 22
60 22 23
26 29 58 61 24 81A
62 81
61
58 60
86 74 72
59 58
60
57 86 61
77 73
58 61
58 86 60 75
59 76
78 86 68
57 58
58
78 WDBE-03-08-002
WDBR50-EN-00(20171222) W3-8-3-2
Group 8 Pump Device
Disassembly of Pump Device

6. Remove regulator (6) from pump casing (51) in the
1. Disconnect the both ends of hose (79) from
same way as step 5.
regulators (2, 6).
7. Remove O-rings (56) (2 used), O-rings (55) (8 used),
j : 22 mm O-rings (7) (4 used), and spring pins (54) (4 used)
2. Remove pump 1 delivery pressure sensor (80), from the regulator mounting surface of pump
pump 2 delivery pressure sensor (81), and O-rings casing (51).
(80A, 81A) (2 used) from selector head (66).
dCAUTION: Pump device weight: 160 kg
j : 27 mm
dCAUTION: When hoisting the pump device, do
not take pump casing (51) off the ground but turn
3. Remove plug (25) from gear casing (47).
to the gear casing (47) side.
j : 17 mm
4. Remove plug (30) and O-ring (31) from gear casing 8. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
(47). Drain off engine oil. eyebolt mounting holes (a) (2 places) of pump
casing (51). Attach nylon slings onto the eyebolts.
j : 22 mm Hoist the pump device. Place the pump device with
gear casing (47) down. Place wooden blocks (over
fNOTE: Amount of oil: 1.0 L
80 mm square) under gear casing (47).
5. Remove socket bolts (3, 5) (2 used for each). Raise
regulator (2) to the direction of selector head (66). a
Remove regulator (2) from pump casing (51). Do not
remove socket bolt (4).
l : 8 mm
WDBR-03-08-002
a
a- Eyebolt Mounting Hole
9. Remove socket bolts (33) (2 used) from gear casing

(47). Remove level gauge (35), pipe (34), and gasket
(32).
l : 6 mm
WDBR50-EN-00(20171222) W3-8-3-3
Group 8 Pump Device
10. Remove socket bolts (36) (2 used), spring washers 12. Remove socket bolts (68) (16 used) from selector
(37) (2 used), and washers (38) (2 used) from pilot head (66). Remove stoppers (69, 76) (2 used for
pump (39). While tapping the flange part of pilot each), O-rings (70, 75) (2 used for each), and O-rings
pump (39) by using a plastic hammer, remove pilot (67) (4 used) from selector head (66).
pump (39) from gear casing (47).
l : 6 mm
l : 8 mm
fNOTE: O-rings (70, 75) are installed to stoppers (69, 76).
fNOTE: THREEBOND #1215 or equivalent has been If it is difficult to remove stoppers (69, 76), tap the outer
applied onto the mounting surface of pilot pump (39). periphery of stoppers (69, 76) by using a plastic hammer.
11. Remove plug (82) and elbow (83) from gear casing Turn stoppers (69, 76) until the half of socket bolt (68)
(47). hole can be seen. Insert a screwdriver into the socket bolt
(68) hole. Remove stoppers (69, 76).
j : 30 mm
76
W178-02-11-082
WDBR50-EN-00(20171222) W3-8-3-4
Group 8 Pump Device
13. Loosen socket bolts (71) (12 used). Measure and 17. Remove spring pins (65) (2 used), backup ring
record the clearance between pump casing (51) (63), O-ring (64) and O-rings (8) (6 used) from the
and selector head (66). Remove socket bolts (71) (12 selector head (66) mounting surface of pump casing
used) from selector head (66). (51).
l : 10 mm 18. Both valve plates (62, 77) are very similar and their
installing directions are determined. Record the
fNOTE: When loosening socket bolt (71), selector head position and the direction to install valve plates (62,
(66) will be pushed out due to the force of spring (16). 77) before removing. Remove retaining rings (58) (8
used) from pins (61, 86) (4 used for each). Remove
dCAUTION: The selector head (66) assembly
weight: 29 kg
pins (86) (4 used), valve plates (62, 77) and levers
(60) (4 used) from links (78) (2 used). Do not remove
14. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to pins (61) (4 used) unless necessary.
screw holes (a) (2 places) of selector head (66).
Attach nylon slings onto the eyebolts. Hoist and 19. Remove rotor (18), springs (16) (2 used), center
remove the selector head (66) assembly from pump shafts (15) (2 used), and plungers (17) (14 used)
casing (51). from pump casing (51) in sequence. Remove pins
(14) (2 used) from center shafts (15) (2 used).
66 a
fNOTE: Remove plunger (17) with it tilted inside.
IMPORTANT: As the pump performance is changed,
do not deform link (78).
20. Remove the link (78) assemblies (2 used) from
pump casing (51). Do not disassemble the link (78)
assembly unless necessary.
fNOTE: If it is difficult to remove the link (78) assembly,

use a screwdriver.
WDBE-03-08-006 21. Remove bolts (53) (6 used) and spring washers (52)
(6 used) from pump casing (51).
a- Screw Hole
j : 24 mm
15. Warm up set screw (72) by using a drier. Remove set

screws (72) (2 used) from servo piston (73). Remove
pins (74) (2 used).
l : 6 mm
fNOTE: LOCTITE Li829 has been applied to set screw (72).

16. Remove servo pistons (73) (2 used) from selector
head (66).
WDBR50-EN-00(20171222) W3-8-3-5
Group 8 Pump Device
dCAUTION: The pump casing (51) assembly

weight: 71 kg
weight: 65 kg
22. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to 26. Attach nylon slings onto pump casing (51). Hoist
the socket bolt (71) holes (2 places) of pump casing and place the pump casing (51) assembly with the
(51). Attach nylon slings onto the eyebolts. Hoist selector head (66) mounting side down.
and remove the pump casing (51) assembly from
27. Remove plug (24) from pump casing (51). Remove
gear casing (47). Shafts (13, 19) and gears (27, 29)
O-ring (23) from plug (24).
are removed with pump casing (51) together. Place
pump casing (51) with the regulator mounting j : 19 mm
surface up.
23. Remove spring pins (48) (2 used) and gasket (28) dCAUTION: The pump casing (51) assembly
weight: 65 kg
from gear casing (47).
28. Attach nylon slings onto pump casing (51). Hoist
24. Put the matching marks on the meshed position and place the pump casing (51) assembly on
of the splines on shafts (13, 19) and gears (27, 29). wooden blocks with the pump transmission side
Put the matching marks on the meshed position of down. Use wooden blocks (over 100 mm square).
gears (27, 29).
29. Remove the shaft (13, 19) assembly from pump
casing (51) by using the special tools (ST 1470, ST
1471).
27 29
ST 1470
ST 1471
13 19 13
W137-02-04-007
19
25. Remove retaining rings (26) (2 used) from shafts (13,
19). Remove gears (27, 29) from shafts (13, 19).
51
W178-02-04-054
WDBR50-EN-00(20171222) W3-8-3-6
Group 8 Pump Device
30. Remove thrust ring (20) from pump casing (51). 36. Remove retaining ring (40) from gear casing (47).
Remove retaining ring (41) from gear shaft (44).
31. Remove bearing nut (9) from shaft (13) by using the
special tool (ST 3058). 37. Remove upper side ball bearing (42) and gear shaft
(44) from gear casing (47) by using special tool (ST
1802).
ST 3058
44
42
W137-02-04-023
IMPORTANT: Replace bearings (12, 85) and spacers

(84, 87) as an assembly.
WDCA-03-08-031
32. Remove bearings (10, 12, 85), spacers (84, 87), and
ring (11) from shaft (13) by using a press.
38. Remove gear (43) and lower side ball bearing (42)
33. Remove bearing nut (9), bearings (10, 12, 85), from gear casing (47).
spacers (84, 87), and ring (11) from shaft (19) in the
same way as step 31 and step 32. 39. Install shackles to the outer bolt holes of gear
casing (47). Attach nylon slings onto the shackles.
dCAUTION: Pump casing (51) weight: 42 kg Hoist and turn over gear casing (47).
34. Attach nylon slings onto pump casing (51). Hoist 40. Remove retaining ring (45) and oil seal (46) from
and place pump casing (51) with the selector head gear casing (47).
(66) mounting side down.
35. Remove retaining rings (50) (2 used) and oil seals
(49) (2 used) from pump casing (51).
WDBR50-EN-00(20171222) W3-8-3-7
Group 8 Pump Device
Assembly of Pump Device

77 64 63 86 18 16 15 17 85 84 12 20 11 10 9 49 29
26
19
50
13
26
27
62 58, 61 60 18 86 16 15 17 85 84 12 11 10 9 49
68 69 67 70 8 7 54 55 59 58 57 56 51
66
73
72
74
75
76
W178-02-11-086
68 65 22 21 78 14 24 23 87
WDBR50-EN-00(20171222) W3-8-3-8
Group 8 Pump Device
39 36, 37, 38 32, 33, 34

6 5 4 35 3 41 40 43 42
30, 31
44
25
82 45
83
81, 81A
46
48
79
71
47
80, 80A
2 5 4 3 52, 53 28 WDBR-03-08-003
2- Regulator 27- Gear 52- Spring Washer (6 Used) 77- Valve Plate
3- Socket Bolt (4 Used) 28- Gasket 53- Bolt (6 Used) 78- Link (2 Used)
4- Socket Bolt (4 Used) 29- Gear 54- Spring Pin (4 Used) 79- Hose
5- Socket Bolt (4 Used) 30- Plug 55- O-Ring (8 Used) 80- Pump 1 Delivery Pressure
6- Regulator 31- O-Ring 56- O-Ring (2 Used) Sensor
7- O-Ring (4 Used) 32- Gasket 57- Pin (2 Used) 80A- O-Ring
8- O-Ring (6 Used) 33- Socket Bolt (2 Used) 58- Retaining Ring (12 Used) 81- Pump 2 Delivery Pressure
9- Bearing Nut (2 Used) 34- Pipe 59- Pin (2 Used) Sensor
10- Bearing (2 Used) 35- Level Gauge 60- Lever (4 Used) 81A O-Ring
11- Ring (2 Used) 36- Socket Bolt (2 Used) 61- Pin (4 Used) 82- Plug
12- Bearing (2 Used) 37- Spring Washer (2 Used) 62- Valve Plate 83- Elbow
13- Shaft 38- Washer (2 Used) 63- Backup Ring 84- Spacer (2 Used)
14- Pin (2 Used) 39- Pilot Pump 64- O-Ring 85- Bearing (2 Used)
15- Center Shaft (2 Used) 40- Retaining Ring 65- Spring Pin (2 Used) 86- Pin (4 Used)
16- Spring (2 Used) 41- Retaining Ring 66- Selector Head 87- Spacer (2 Used)
17- Plunger (14 Used) 42- Ball Bearing (2 Used) 67- O-Ring (4 Used)
18- Rotor (2 Used) 43- Gear 68- Socket Bolt (16 Used)
19- Shaft 44- Gear Shaft 69- Stopper S (2 Used)
20- Thrust Ring 45- Retaining Ring 70- O-Ring (2 Used)
21- O-Ring (2 Used) 46- Oil Seal 71- Socket Bolt (12 Used)
22- Plug (2 Used) 47- Gear Casing 72- Set Screw (2 Used)
23- O-Ring 48- Spring Pin (2 Used) 73- Servo Piston (2 Used)
24- Plug 49- Oil Seal (2 Used) 74- Pin (2 Used)
25- Plug 50- Retaining Ring (2 Used) 75- O-Ring (2 Used)
26- Retaining Ring (2 Used) 51- Pump Casing 76- Stopper L (2 Used)
WDBR50-EN-00(20171222) W3-8-3-9
Group 8 Pump Device
Assembly of Pump Device 5. Install O-ring (31) to plug (30). Install plug (30) to
gear casing (47).
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. j : 22 mm
d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
m : 50 N·m
such as goggles, hard hats, etc in order to prevent IMPORTANT: Replace bearings (12, 85) and spacers
personal injury. (84, 87) as an assembly.
1. Install ball bearing (42) to gear casing (47) by using 6. Warm up bearings (10, 12, 85) to 50 to 80 °C.
a bar and a hammer. Tap and listen to ring in order
to check that ball bearing (42) is installed to the end. dCAUTION:
hot.
Take care as bearings (12, 85) are too
fNOTE: Install ball bearing (42) with the stamped mark 7. Install bearings (12, 85) and spacers (84, 87) to
facing to the engine side. shafts (19) by using a press.
2. Place gear (43) onto ball bearing (42). Fit the splines
8. Install ring (11) to shaft (19).
and install gear shaft (44).
47
dCAUTION: Take care as bearing (10) is too hot.
9. Install bearing (10) to shaft (19) by using a press.
43
10. Install bearings (10, 12, 85), spacers (84, 87), and
ring (11) to shaft (13) in the same way as step 6 to
41 44 step 9.
40
42
b
WDDQ50-03-08-013
a- Identification Groove
b- Engine Side
dCAUTION: Metal fragments may fly off when

such as goggles, hard hats, etc in order to prevent
personal injury.
3. Install ball bearing (42) to gear shaft (44) by using a
bar and a hammer. Tap and listen to ring in order to
check that ball bearing (42) is installed to the end.
fNOTE: Install ball bearing (42) with the stamped mark

facing to the engine side.
4. Install retaining ring (40) to gear casing (47). Install
retaining ring (41) to gear shaft (44).
WDBR50-EN-00(20171222) W3-8-3-10
Group 8 Pump Device
11. Set the preload of bearings (10, 12, 85) with 12. Set the preload of bearings (10, 12, 85) with shaft
shaft (13) attached according to the following (19) attached in the same way as step 11.
procedures.
13. Install thrust ring (20) to the side to insert shaft (19)
 Apply hydraulic oil onto the thread part of bearing in pump casing (51).
nut (9). Tighten bearing nut (9) until it comes in
contact with bearing (10) by using special tool (ST
3058).
ST 3058
9
10
W178-02-11-090
 Install special tool (ST 3070) to bearing (10). After

rotating 2 to 3 turns, measure the starting torque.
ST 3070
10
W178-02-11-091
 Adjust bearing nut (9) until the starting torque

reaches the specification.
m : 2±0.5 N·m
fNOTE: If the starting torque is higher than the limit of

specified torque, loosen bearing nut (9). Tap the shaft
end and release the load of bearing (10).
WDBR50-EN-00(20171222) W3-8-3-11
Group 8 Pump Device
14. Warm up pump casing (51) to 50 to 80 ºC. 18. Install special tools (ST 2649, ST 2650) over the
spline parts of shafts (13, 19).
15. Apply hydraulic oil onto bearings (10, 12, 85) (2 used
for each) with shafts (13, 19) attached. Install shafts
(13, 19) to pump casing (51) by using special tool
fNOTE: If the special tools are not available, install a
vinyl tape onto the spline part of the shaft in order not to
(a). damage oil seal (49).
If it is difficult to insert shafts (13, 19), tap them by
using a bar.
a
ST 2650
b 49
51
19
ST 2649 W178-02-11-094
c
c
19. Apply grease to the inside of oil seals (49) (2 used).
W178-02-11-093
Evenly tap and install oil seals (49) (2 used) to shafts
(13, 19).
a- Special Tool c- Wooden Block 20. Remove special tools (ST 2649, ST 2650) from shafts
b- M8, Pitch 1.25 mm
(13, 19).
21. Install retaining rings (50) (2 used) to pump casing
dCAUTION: Be careful as pump casing is too hot. (51).
16. Install O-ring (23) to plug (24). Install plug (24) to
pump casing (51).
j : 19 mm
m : 35 N·m

weight: 65 kg
17. Attach nylon slings onto pump casing (51). Hoist
pump casing (51). Hoist and place the pump casing
(51) assembly with the regulator mounting side up.
WDBR50-EN-00(20171222) W3-8-3-12
Group 8 Pump Device
22. Fit the matching marks on shafts (13, 19) and gears 23. Install spring pins (48) (2 used) to gear casing (47).
(27, 29). Install retaining rings (26) (2 used) to shafts Install gasket (28).
(13, 19). When replacing the shaft and gear, install
the gear according to the following procedures. dCAUTION: The pump casing (51) assembly
weight: 71 kg
 Secure special tool (ST 7934) to the plunger (17)
24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
mounting side of shafts (13, 19) with the socket bolt
the socket bolt (71) holes (2 places) of pump casing
(M8, Pitch 1.25 mm).
(51). Attach nylon slings onto the eyebolts. Hoist
the pump casing (51) assembly. While engaging
19 gear (43) with gear (29), install the pump casing (51)
assembly to gear casing (47) with bolts (53) (6 used)
ST 7934 13 and spring washers (52) (6 used).
j : 24 mm
m : 150 N·m
a W178-02-11-097
a- M8, Pitch 1.25 mm
 Turn shafts (13, 19) clockwise, viewed from the gear

(27, 29) mounting side, until shafts (13, 19) come in
contact with special tool (ST 7934). (Remove a play in
periphery direction.)
 Install gear (27) and retaining ring (26) to the spline
of shaft (13).
 Install gear (29) to the spline of shaft (19) and engage
it with gear (27). If gear (29) does not engage, adjust
shaft (19) within a play of the special tool by turning.
 Install retaining ring (26) to the spline of shaft (19).
 Remove special tool (ST 7934).
WDBR50-EN-00(20171222) W3-8-3-13
Group 8 Pump Device
25. Apply THREEBOND #1215 onto the mounting 29. Install plungers (17) (7 used) to shafts (13, 19).
surface of pilot pump (39). Install pilot pump (39)
30. Apply grease to pins (14) (2 used). Install pins (14) (2
to gear casing (47) with socket bolts (36) (2 used),
used) to center shafts (15) (2 used).
spring washers (37) (2 used), and washers (38) (2
used). 31. Apply grease to the spherical surface of center
shafts (15) (2 used). Install center shafts (15) (2 used)
l : 8 mm to shafts (13, 19).
m : 50 N·m
26. Install gasket (32) and pipe (34) to gear casing (47)
l : 6 mm
m : 20 N·m
IMPORTANT: As the pump performance is changed,
do not deform link (78).
27. Install the link (78) assemblies (2 used) to the
grooves of pins (57) (2 used) in pump casing (51).
fNOTE: Install the link (78) assemblies (2 used) with

lever (60) facing to the selector head (66) side. Fit parallel
surface (a) of pin (57) to the groove.
59 57
78 51
a a W178-02-11-098
a- Parallel Surface
28. Apply hydraulic oil onto the plunger (17) mounting

surface of shafts (13, 19).
WDBR50-EN-00(20171222) W3-8-3-14
Group 8 Pump Device
32. Install springs (16) (2 used) to center shafts (15) (2 38. Install regulator (2) to pump casing (51) according
used). to the following procedures.
33. Install center shafts (15) (2 used) and plungers (17)  Adjust sleeves (b) (2 used) in regulator (2) so that the
(14 used) to rotors (18) (2 used). grooves for pin (59) are in a line.
 Place regulator (2) onto pump casing (51). Insert pin
34. Insert a grip of a file into the center hole of center
(59) of link (79) into the grooves of sleeve (b).
shafts (15) (2 used). While turning center shafts (15)
 Move regulator (2) while fitting to spring pin (54) in
(2 used), insert pins (14) (2 used) into the grooves of
pump casing (51).
rotors (18) (2 used).
 Install regulator (2) to pump casing (51) with socket
fNOTE: If pins (14) (2 used) does not enter the grooves bolts (3, 5) (2 used for each).
of rotors (18) (2 used), selector head (66) cannot be l : 8 mm
installed to pump casing (51).
m : 50 N·m
IMPORTANT: Check the direction to install valve
plate (62).
59
35. Install valve plate (62) to the regulator (2) side of link
(78) with pins (61, 86) (2 used for each), levers (60) (2 b
2
used) and retaining ring (58) (4 used).
77 62
a
51
W178-02-11-101
78 54
b- Sleeve
W178-02-11-100 39. Install regulator (6) to pump casing (51) with socket
bolts (3, 5) (2 used for each) in the same way as step
a- Regulator (2, 6) Side 38.
l : 8 mm
IMPORTANT: Check the direction to install valve
plate (77). m : 50 N·m
36. Install valve plate (77) to the regulator (6) side of link 40. Install backup ring (63), O-ring (64), and O-rings (8)
(78) with pins (61, 86) (2 used for each), levers (60) (2 (6 used) to selector head (66) mounting surface of
used) and retaining ring (58) (4 used). pump casing (51).
37. Install O-rings (56) (2 used), O-rings (55) (8 used), 41. Install servo pistons (73) (2 used) to selector head
O-rings (7) (4 used), and spring pins (54) (2 used) (66).
to the regulator mounting surface of pump casing
(51).
WDBR50-EN-00(20171222) W3-8-3-15
Group 8 Pump Device
42. Apply LOCTITE Li829 to set screw (72). Install pins 47. Install O-rings (70, 75) (2 used for each) to stoppers
(74) (2 used) to servo pistons (73) (2 used) with set (69, 76). Install stoppers (69, 76) (2 used for each) to
screws (72) (2 used). selector head (66) with socket bolts (68) (16 used).
l : 6 mm l : 6 mm
m : 35 N·m m : 20 N·m
43. Install spring pins (65) (2 used) to selector head (66).
dCAUTION: Pump device weight: 175 kg
dCAUTION: The selector head (66) assembly

weight: 29 kg
48. Hoist and place the selector head (66) assembly
with the regulator mounting side up.
44. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to 49. Insert special tool (ST 2650) into shaft (19). Apply
screw holes (a) (2 places) of selector head (66). grease to oil seal (46). Install oil seal (46) to shaft
Attach nylon slings onto the eyebolts. Hoist the (19). Remove special tool (ST 2650). Install oil seal
selector head (66) assembly. Place selector head (46).
(66) onto pump casing (51) while fitting to spring
pin (65). fNOTE: If special tool (ST 2650) is not available, install
a vinyl tape onto the spline part of shaft (19) in order to
fNOTE: Check the clearance between selector head protect. Install oil seal (46).
(66) and pump casing (51) in order to compare with the
clearance before disassembling. When the clearance is
larger, pins (14) (2 used) may not be inserted into the ST 2650
grooves of rotors (18) (2 used), or pins (74) (2 used) may
not be inserted into the holes of valve plates (62, 77).
46
66 a
W178-02-11-103
WDBE-03-08-006
a- Screw Hole
45. Install selector head (66) to pump casing (51) with

l : 10 mm
m : 110 N·m
46. Install O-rings (67) (4 used) to selector head (66).
WDBR50-EN-00(20171222) W3-8-3-16
Group 8 Pump Device
50. Install retaining ring (45) to gear casing (47). 56. Connect the both ends of hose (79) to regulators (2,
6).
gear casing (47). j : 22 mm
j : 22mm m : 35 N·m
52. Install a seal tape onto elbow (83). Install elbow 57. Install level gauge (35) to pipe (34).
(83) to gear casing (47). Add engine oil (Nippon
Oil Corporation DH1 15W-40, DH2 15W-40, or
equivalent) through the elbow (83) hole.

53. Install a seal tape onto plug (82). Install plug (82) to
elbow (83).
j : 30 mm
m : 40 N·m
IMPORTANT: The breather hole of plug (25) is
located at the left side, viewed from the front of
gear casing (47).
54. Install a seal tape onto plug (25). Install plug (25) to
gear casing (47).
j : 17 mm
m : 40 N·m
55. Install O-rings (80A, 81A) to pump 1 delivery
pressure sensor (80) and pump 2 delivery pressure
sensor (81). Install pump 2 delivery pressure sensor
(81) and pump 1 delivery pressure sensor (80) to
selector head (66).
j : 27 mm
m : 98 N·m
WDBR50-EN-00(20171222) W3-8-3-17
Group 8 Pump Device
(Blank)
WDBR50-EN-00(20171222) W3-8-3-18
Group 8 Pump Device
Disassembly of Regulator
4 5 6 7 8 9 10 11 12 13 14 15 16 17
32
1 31 30 29 27 28 26 25 24 23 22 21 20 19 18
WDCA-03-08-019
33 34
35
2, 3
WDDD-03-08-017
1- Cover 10- Spool 19- Lock Nut 28- Cylinder

2- Plug 11- Sleeve 20- Socket Bolt (8 Used) 29- O-Ring
3- O-Ring 12- Piston 21- Stopper Assembly 30- Backup Ring
4- Lock Nut 13- Cylinder 22- O-Ring 31- O-Ring
5- Lock Nut 14- O-Ring 23- Spring 32- Piston
6- Stopper Assembly 15- Cover 24- Spring 33- Socket Bolt (2 Used)
7- O-Ring 16- Set Bolt 25- Sleeve 34- Solenoid Valve
8- Spring 17- Lock Nut 26- Spool 35- O-Ring
9- Casing 18- Lock Nut 27- Piston
WDBR50-EN-00(20171222) W3-8-4-1
Group 8 Pump Device
Disassembly of Regulator
6. Remove O-ring (7) from stopper assembly (6).
 The regulators are used for pump 1 and pump 2. The
inner structure in the regulator is fully identical, and 7. Remove springs (23, 24) from casing (9).
the difference is only in its accessories. The regulator
8. Insert a round bar to the cover (15) side of casing
for pump 2 is explained here.
(9). Push the spool (26) end. Remove cylinder (28),
sleeve (25), and spool (26) from casing (9). At this
IMPORTANT: Do not disassemble adjusting screw time, piston (27) is removed with cylinder (28)
parts (4, 5, 6, 16, 17, 18, 19, 21) of the regulator. together.
When they have been disassembled, adjust
according to the procedures of performance test 9. Remove piston (27), O-rings (29, 31), and backup
after assembling. (Refer to T4-5 in the separated ring (30) from cylinder (28).
volume, T/M.) 10. Remove spring (8) from casing (9).
11. Install a round bar to the cover (1) side of casing
1. Remove socket bolts (33) (2 used). Remove solenoid
(9). Push the spool (10) end. Remove cylinder (13),
valve (34) from casing (9).
sleeve (11), and spool (10) from casing (9). At this
l : 8 mm time, piston (12) is removed with cylinder (13)
together.
IMPORTANT: Do not turn set bolt (16), lock nuts (17, 12. Remove piston (12) and O-ring (14) from cylinder
18, 19), and stopper assembly (21). If turning, the (13).
setting changes.
2. Remove socket bolts (20) (4 used) from cover (15).
Remove the cover (15) assembly from casing (9). At
this time, set bolt (16) and stopper assembly (21) are
removed with the cover (15) assembly together.
l : 6 mm
3. Remove O-ring (22) from stopper assembly (21).
4. Remove plug (2) from cover (1). Remove O-ring (3)
from plug (2).
l : 6 mm
IMPORTANT: Do not turn lock nuts (4, 5) and stopper

assembly (6). If turning, the setting changes.
5. Remove socket bolts (20) (4 used) from cover (1).
Remove the cover (1) assembly from casing (9).
At this time, O-ring (35), piston (32), and stopper
assembly (6) are removed with the cover (1)
assembly together.
l : 6 mm
fNOTE: The regulator for pump 1 is not equipped with

O-ring (35).
WDBR50-EN-00(20171222) W3-8-4-2
Group 8 Pump Device
Assembly of Regulator
4 5 6 7 8 9 10 11 12 13 14 15 16 17
32
1 31 30 29 27 28 26 25 24 23 22 21 20 19 18
WDCA-03-08-019
33 34
35
2, 3
WDDD-03-08-017
1- Cover 10- Spool 19- Lock Nut 28- Cylinder

2- Plug 11- Sleeve 20- Socket Bolt (8 Used) 29- O-Ring
3- O-Ring 12- Piston 21- Stopper Assembly 30- Backup Ring
4- Lock Nut 13- Cylinder 22- O-Ring 31- O-Ring
5- Lock Nut 14- O-Ring 23- Spring 32- Piston
6- Stopper Assembly 15- Cover 24- Spring 33- Socket Bolt (2 Used)
7- O-Ring 16- Set Bolt 25- Sleeve 34- Solenoid Valve
8- Spring 17- Lock Nut 26- Spool 35- O-Ring
9- Casing 18- Lock Nut 27- Piston
WDBR50-EN-00(20171222) W3-8-4-3
Group 8 Pump Device
Assembly of Regulator 7. Install O-ring (7) and spring (8) to stopper assembly
(6) with cover (1) attached. Install O-ring (35), piston
(32), and the cover (1) assembly to casing (9) with
to parts in order to prevent them from seizing.
IMPORTANT: The sleeve (11, 25) mounting holes of
casing (9) are the same bores. The shapes of parts l : 6 mm
are very similar. Assemble them while checking
the illustration in order not to confuse. m : 20 N·m
IMPORTANT: Check the direction to install sleeve fNOTE: The regulator for pump 1 is not equipped with
O-ring (35).
Sleeve (11) 8. Install O-ring (22) and springs (23, 24) to stopper
assembly (21) with cover (15) attached. Install the
cover (15) assembly to casing (9) with socket bolts
(20) (4 used).
l : 6 mm
m : 20 N·m
WDDK-03-08-024
9. Install O-ring (3) to plug (2). Install plug (2) to cover
(1).
Sleeve (25)
l : 6 mm
m : 34.3 N·m
10. Install solenoid valve (34) to casing (9) with socket
bolts (33) (2 used).
l : 8 mm
WDDK-03-08-023
m : 50 N·m
(11), spool (10), and piston (12).

1. Install spool (10) to sleeve (11). Install sleeve (11) to
the center of casing (9) by using a round bar.
2. Install O-ring (14) to cylinder (13).
3. Install piston (12) to cylinder (13). Install cylinder
(13) to casing (9).
IMPORTANT: Check the direction to install sleeve

(25) and spool (26).
4. Install spool (26) to sleeve (25). Install sleeve (25) to
the center of casing (9) by using a round bar.
5. Install O-rings (29, 31) and backup ring (30) to
cylinder (28).
6. Install piston (27) to cylinder (28). Install cylinder
(28) to casing (9).
WDBR50-EN-00(20171222) W3-8-4-4
Group 8 Pump Device
Disassembly of Solenoid Valve Unit
Solenoid Valve for Pump 1 Solenoid Valve for Pumps 2
10 12 13 14
WDCA-03-08-016 WDCD-03-08-006
11
1 2
3 4 5 6
10
8 7
9
WDCD-03-08-005 WDCA-03-08-017
1- Solenoid (Pump 1: 1 Used, 4- O-Ring 8- O-Ring 12- O-Ring

Pump 2: 2 Used) 5- O-Ring 9- O-Ring 13- O-Ring
2- Socket Bolt (2 Used) 6- Wave Washer 10- Filter (3 Used) 14- Body
3- Sleeve 7- Plate 11- O-Ring (2 Used)
WDBR50-EN-00(20171222) W3-8-5-1
Group 8 Pump Device
Disassembly of Solenoid Valve Unit

4. Remove filters (10) (3 used), O-rings (11) (2 used),
 The solenoid valves unit are used for pump 1 and
and O-rings (12, 13) from body (14).
pumps 2. The structure in the solenoid valve units
are fully identical, and the difference is only numbers l : 6 mm
of the solenoid. The solenoid valve for pump 2 is
explained here.
 Take care not to damage the mounting surface for
fNOTE: When cleaning filter (10), blow it from the both
surfaces by using air. Finally blow it from the outside
the regulator.
(screw side) by using air.
 When replacing the parts, replace them as an
assembly. 5. Disassemble another solenoid (1) in the same way
 Take care not to hit the solenoid part. as step 1 to step 4.
 When disconnecting the connector, do not pry it, but
disconnect it straight.
1. Remove socket bolts (2) (2 used). Remove the

solenoid (1) assembly and O-ring (9).
l : 4 mm
IMPORTANT: Do not drop plate (7) and wave washer

(6).
2. Remove plate (7) and wave washer (6) from body
(14).
3. Remove O-rings (4, 5, 8) from sleeve (3).
WDBR50-EN-00(20171222) W3-8-5-2
Group 8 Pump Device
Assembly of Solenoid Valve Unit
Solenoid Valve for Pump 1 Solenoid Valve for Pumps 2
10 12 13 14
WDCA-03-08-016 WDCD-03-08-006
11
1 2
3 4 5 6
10
8 7
9
WDCD-03-08-005 WDCA-03-08-017
1- Solenoid (Pump 1: 1 Used, 4- O-Ring 8- O-Ring 12- O-Ring

Pump 2: 2 Used) 5- O-Ring 9- O-Ring 13- O-Ring
2- Socket Bolt (2 Used) 6- Wave Washer 10- Filter (3 Used) 14- Body
3- Sleeve 7- Plate 11- O-Ring (2 Used)
WDBR50-EN-00(20171222) W3-8-5-3
Group 8 Pump Device
Assembly of Solenoid Valve Unit

1. Install O-rings (12, 13), O-rings (11) (2 used), and
filters (10) (3 used) to body (14).
l : 6 mm
m : 10 to 13 N·m
2. Install wave washer (6) and plate (7) to body (14).
fNOTE: When assembling body (14) in a horizontal

position, apply grease to wave washer (6) and plate (7) in
order not to fall off. After assembling, check that plate (7)
is installed straight.
3. Install O-rings (4, 5, 8) to sleeve (3).

4. Install O-ring (9) to body (14).
5. Install solenoid (1) to body (14) with socket bolts (2)
(2 used).
l : 4 mm
m : 5 to 7 N·m
6. Assemble another solenoid (1) in the same way as
step 1 to step 5.
WDBR50-EN-00(20171222) W3-8-5-4
Group 8 Pump Device
Structure of Pilot Pump
WDCA-03-08-015
WDBR50-EN-00(20171222) W3-8-6-1
Group 8 Pump Device
IMPORTANT: The housing is made of aluminum. Take

care not to damage the housing. Take extreme
care in order to control the tightening torque.
No. Part Name Q’ty Wrench Size Tightening Torque Remark
(mm) N·m
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply grease to the lip part
when installing
5 Retaining Ring 1
6 Seal 2 Apply grease when
installing
7 Cover 1
9 Backup Ring 2 Apply grease when
installing
10 Key 2
12 O-Ring 2 Apply grease when
installing
13 Gear 1
14 Gear 1
15 Washer 4
16 Bolt 4 j : 17 35 to 40
26 Bushing 2 Apply hydraulic oil when
installing
27 Bushing 2 Apply hydraulic oil when
installing
28 Pin 2
WDBR50-EN-00(20171222) W3-8-6-2
Removal and Installation of Control Valve
4
1
WDBR-03-16-001 WDBR-03-09-016
3 2
IMPORTANT: The hoses and pipes contain hydraulic 2. Open engine cover (1).
3. Release any pressure in the the expansion tank.
(Refer to W1-5-1.)
and pipes have been disconnected. In addition, 4. Remove bolts, washers (3) (5 used). Remove cover
attach identification tags onto the connectors, (2).
j : 17 mm
clips after connecting the hoses. 5. Remove bolts, washers (4) (3 used). Open cover (5).
j : 17 mm
Removal


circuit. (Refer to W1-5-1.)
WDBR50-EN-00(20171222) W3-9-1-1
1 5 3
4
2
1 5
WDBR-03-09-017
WDBR-03-09-015
View A

(2).
j : 17 mm
(8).
7
j : 17 mm
washers (5) (6 used). Remove clip (6). Remove the
cover (3) assembly.
j : 17 mm
WDBR-03-09-018
8
WDBR50-EN-00(20171222) W3-9-1-2
Detail A
3
4, 9
4, 5
WDBR-03-09-004
8 6, 7
WDBR-03-09-003
View B
9. Remove 3-spool solenoid valve unit (2). (Refer to

W3-12-2.)
10. Remove signal control valve (1). (Refer to W3-13-1.)
11. Remove bolts, washers (4) (2 used). Remove clips (5,
9). Remove clip band (8).
6, 7
j : 17 mm
Remove bracket (3).
j : 22 mm
WDBR-03-09-005
WDBR50-EN-00(20171222) W3-9-1-3
Detail A 1 1 2, 3
5 WDBR-03-09-006
4
WDBR-03-09-008
Detail B 1
13. Remove socket bolts (4) (2 used). Disconnect pipe 8

(2). Remove O-ring (3).
l : 8 mm
14. Remove clip band (5). Disconnect hoses (1) (3 used).
j : 19 mm, 27 mm
15. Remove clamps (8) (4 used). Disconnect the both
ends of hose (7).
WDBR-03-09-007
7
WDBR50-EN-00(20171222) W3-9-1-4
Detail A
WDBR-03-09-019 WDBR-03-09-020
16. Remove bolts, washers (4) (2 used). Remove plate

(5).
j : 17 mm
17. Remove socket bolts (1) (2 used). Disconnect pipe
(2). Remove O-ring (3).
l : 8 mm
WDBR50-EN-00(20171222) W3-9-1-5
2, 3
WDBR-03-09-010
1
WDBR-03-09-009

a

j : 17 mm, 19 mm, 36 mm
21. Disconnect the both ends of pipe (4).
j : 17 mm
WDBR50-EN-00(20171222) W3-9-1-6
25
24
WDAD-03-09-058
23 22 21
22. Remove bolt, washer (24) and clamp (25).
j : 19 mm
23. Remove bolt, washer (23) and clamps (21, 22).
j : 19 mm
WDBR50-EN-00(20171222) W3-9-1-7
24. Disconnect hoses (9) (2 used). 27. Remove clamps (13) (4 used). Disconnect the both
ends of hose (12).
j : 17 mm
l : 6 mm
(12 used). Disconnect hoses (4) (4 used) and pipes 28. Remove socket bolts (7) (2 used). Remove the pipe
(14) (2 used). Remove O-rings (5) (6 used). (8) assembly. Remove O-ring (15) and valve (16).
l : 8 mm l : 8 mm
26. Remove socket bolts (6) (4 used) and flanges (10) (2
used). Disconnect hose (17). Remove O-ring (18).
fNOTE: Do not drop valve (16) from pipe (8).
l : 10 mm
8
15
16
WDBE-03-09-011
WDBR50-EN-00(20171222) W3-9-1-8
WDBR-03-09-041
WDBR-03-09-013
29. Remove socket bolts (1) (24 used) and flanges (2) View B
l : 6 mm
30. Disconnect the both ends of hose (5).
j : 17 mm
31. Remove socket bolts (8) (4 used) and flanges (9) (2
used). Disconnect hose (7). Remove O-ring (10).
l : 10 mm
j : 17 mm
WDBR-03-09-014
WDBR50-EN-00(20171222) W3-9-1-9
View A 2 1 2
WDBR-03-12-001
WDBR-03-17-001
A
B
View B

j : 17 mm
c- Machine Front Side WDBR-03-09-021
WDBR50-EN-00(20171222) W3-9-1-10
11, 12 a 13 11, 12
17
14, 15 a 14, 15
a- Eyebolt Mounting Hole WDBE-03-09-008
dCAUTION: The control valve (13) assembly

weight: 240 kg
eyebolt mounting holes (a) (2 places) of control
valve (13). Attach nylon slings onto the eyebolts
(2 used). Hoist and hold the control valve (13)
assembly.
36. Remove bolts (11, 14) (2 used for each) and washers
(12, 15) (2 used for each). Remove the control valve
(13) assembly from main frame (17). Place the
control valve (13) assembly on a workbench and
block (b).
j : 24 mm
b- Block c- 221 mm
WDAK90-03-09-013
WDBR50-EN-00(20171222) W3-9-1-11

a WDBR-03-09-023
j : 17 mm
38. Disconnect both ends of hose (1) and hoses (4) (7
used).
j : 17 mm, 19 mm
WDBR50-EN-00(20171222) W3-9-1-12
1, 2 3 a 5
4 a
WDBR-03-09-025 a- Eyebolt Mounting Hole WDBE-03-09-008

1, 2
dCAUTION: Control valve (5) weight: 210 kg

valve (5). Attach nylon slings onto the eyebolts (2
used). Hoist and hold control valve (5).
Remove control valve (5) from brackets (3, 4).
j : 24 mm
41. Remove the adapters from control valve (5) if
necessary.
WDBR50-EN-00(20171222) W3-9-1-13
a 5 1, 2 3
a 4
a- Eyebolt Mounting Hole WDBE-03-09-008 WDBR-03-09-025
1, 2
Installation
1. Install all removed adapters to control valve (5).
dCAUTION: Control valve (5) weight: 210 kg

used). Hoist control valve (5).
3. Install control valve (5) to brackets (3, 4) with
j : 24 mm
m : 210 N·m
WDBR50-EN-00(20171222) W3-9-1-14

a WDBR-03-09-023
4. Connect both ends of hose (1) and hoses (4) (7

used).
j : 17 mm
m : 25 N·m
j : 19 mm
m : 30 N·m
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-9-1-15
11, 12 a 13 11, 12
17
14, 15 a 14, 15
a- Eyebolt Mounting Hole WDBE-03-09-008
dCAUTION: The control valve (13) assembly

weight: 240 kg
used). Hoist the control valve (13) assembly.
7. Install the control valve (13) assembly to main frame
(17) with washers (12, 15) (2 used for each) and bolts
j : 24 mm
m : 270 N·m
WDBR50-EN-00(20171222) W3-9-1-16
View A 2 1 2
WDBR-03-12-001
WDBR-03-17-001
A
B
View B
j : 17 mm
m : 25 N·m c
c- Machine Front Side WDBR-03-09-021
WDBR50-EN-00(20171222) W3-9-1-17
WDBR-03-09-041
WDBR-03-09-013
View B
j : 17 mm
m : 25 N·m
11. Install O-ring (10). Connect hose (7) with flanges (9)
(2 used) and socket bolts (8) (4 used).
l : 10 mm
m : 90 N·m
12. Connect the both ends of hose (5).
j : 17 mm
m : 25 N·m
IMPORTANT: Check the angle to connect the hose.
13. Install O-rings (4) (6 used). Connect hoses (3) (6 WDBR-03-09-014
used) with flanges (2) (12 used) and socket bolts (1)
(24 used).
l : 8 mm
m : 65 N·m
c- 35 °
d- 30 ° WDBR-03-09-026
WDBR50-EN-00(20171222) W3-9-1-18
b- 10 ° WDBR-03-09-027
WDBR-03-09-011
14. Install valve (16) and O-ring (15). Temporarily install IMPORTANT: Check the angle to connect the hose.
the pipe (8) assembly, clamps (13) (4 used) at the 18. Install O-rings (5) (6 used). Connect hoses (4) (4
both ends of hose (12), and socket bolts (7) (2 used). used) and pipes (14) (2 used) with flanges (3) (12
used) and socket bolts (2) (24 used).
fNOTE: Do not drop valve (16) from pipe (8).
l : 8 mm
8
15 m : 65 N·m
16
WDBE-03-09-011 19. Connect hoses (9) (2 used).
j : 17 mm
l : 8 mm
m : 25 N·m
m : 65 N·m
16. Tighten clamps (13) (4 used).
17. Install O-ring (18). Connect hose (17) with flanges
(10) (2 used) and socket bolts (6) (4 used).
l : 10 mm
m : 90 N·m
WDBR50-EN-00(20171222) W3-9-1-19
25
24
WDAD-03-09-058
23 22 21
20. Install clamps (21, 22) with bolt, washer (23).
j : 19 mm
m : 90 N·m
21. Install clamp (25) with bolt, washer (24).
j : 19 mm
m : 90 N·m
WDBR50-EN-00(20171222) W3-9-1-20
2, 3
WDBR-03-09-010
1
WDBR-03-09-009

a
22. Connect the both ends of pipe (4).
j : 17 mm
m : 25 N·m
j : 17 mm
m : 25 N·m
j : 19 mm
m : 30 N·m
j : 36 mm
m : 180 N·m
WDBR50-EN-00(20171222) W3-9-1-21
Detail A
WDBR-03-09-019 WDBR-03-09-020
26. Install O-ring (3). Connect pipe (2) with socket bolts
(1) (2 used).
l : 8 mm
m : 65 N·m
27. Install plate (5) with bolts, washers (4) (2 used).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-9-1-22
Detail A 1 1 2, 3
5 WDBR-03-09-006
4
Detail B C 1
WDBR-03-09-008
28. Install O-ring (3). Temporarily install pipe (2) with

l : 8 mm
IMPORTANT: Check the direction to install clamp (8).
29. Connect hose (7) with clamps (8) (4 used).
30. Connect hoses (1) (3 used). Install clip band (5).
j : 19 mm
m : 30 N·m
j : 27 mm WDBR-03-09-007
7
m : 80 N·m
31. Tighten socket bolts (4) (2 used). Detail C
l : 8 mm
m : 50 N·m
WDBR-03-09-035
WDBR50-EN-00(20171222) W3-9-1-23
Detail A
3
4, 9
4, 5
WDBR-03-09-004
8 6, 7
WDBR-03-09-003
View B
32. Install bracket (3) with washers (7) (3 used) and bolts
(6) (3 used).
j : 22 mm
m : 140 N·m
6, 7
33. Install clips (5, 9) with bolts, washers (4) (2 used).
Install clip band (8).
j : 17 mm
m : 50 N·m
34. Install signal control valve (1). (Refer to W3-13-1.)
35. Install 3-spool solenoid valve unit (2). (Refer to W3-
12-2.) WDBR-03-09-005
WDBR50-EN-00(20171222) W3-9-1-24
5 3 View A
WDBR-03-09-017 WDBR-03-09-018
8

1.)
(3 used) and bolts, washers (5) (6 used). Install clip
(6).
j : 17 mm
m : 50 N·m
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-9-1-25
1 4
2
2
WDBR-03-09-016
WDBR-03-09-015
j : 17 mm
m : 50 N·m
j : 17 mm
m : 50 N·m
j : 17 mm
WDBR-03-16-001
m : 50 N·m 3 6
WDBR50-EN-00(20171222) W3-9-1-26
Disassembly of Housing
3
3
4
5
4
4
6 5
5 4
4
6
4
6
4
5 4 5
WDBR-03-09-028
1- Housing (B Side) 3- Socket Bolt (9 Used) 5- O-Ring (12 Used)

2- Housing (A Side) 4- O-Ring (16 Used) 6- O-Ring (3 Used)
WDBR50-EN-00(20171222) W3-9-2-1
Disassembly of Housing
dCAUTION:
kg
The housing (1) assembly weight: 105
The housing (2) assembly weight: 100 kg
1. Remove socket bolts (3) (9 used).
l : 14 mm
2. Remove housing (1) from housing (2).
3. Remove O-rings (4) (16 used), O-rings (5) (12 used),
and O-rings (6) (3 used) from housing (1) or housing
(2).
WDBR50-EN-00(20171222) W3-9-2-2
Assembly of Housing
4 5 2
4
4
5 6
4 5
6 6
5 5
4
4
4 5 WDBR-03-09-029
3
3
3
3
3
W1V1-02-05-001
1- Housing (B Side) 3- Socket Bolt (9 Used) 5- O-Ring (12 Used)

2- Housing (A Side) 4- O-Ring (16 Used) 6- O-Ring (3 Used)
WDBR50-EN-00(20171222) W3-9-2-3
Assembly of Housing

onto parts in order to prevent them from seizing.
1. Install O-rings (4) (16 used), O-rings (5) (12 used),
and O-rings (6) (3 used) to the mounting surface of
housing (2).
dCAUTION:
kg
The housing (2) assembly weight: 100 kg

2. Install housing (1) to housing (2) with socket bolts
(3) (9 used).
l : 14 mm
m : 206 to 216 N·m
WDBR50-EN-00(20171222) W3-9-2-4
Disassembly of Control Valve (A Side) r

6
5
10 8 a
4 9 7
3
2 q 16 6
12
1 11
4
3
8
7 15
13 19
14 20
b
21
22
13 23
30
24 d
25
26
7 28
29
8 19 c 9 10
20 32
33
34
42 35
43 36
44 37 31
45
48
43 46
44 47 38 6
45
49 39
51
50 38 38
39 41
38
52 38 38
53 39 41
e
39 38
41 f
54 52
38 59
55 41
56 g
63
57
58 h 59
4
62
W1V1-02-05-024
WDBR50-EN-00(20171222) W3-9-3-1
68
69
4
j
70
63 71
67 72
63 71
67 59 73
63
67
59 k
74
63 59
74
1
64
l
59
19
102
103
104
105
106 m 7
4
7
107 7 8
6 w 8
8
p
98
108 99
x 100 o n
109
110 111 101
83
87 75
112 84
87 77
77 76
113 13 85
u 13 78 86 82 81
77 77
114 128 87
118 13
88
89 13
115 77
78
127 91
116 117 40
s
126 92
114 119 120 79
120 93
119 90 94 80
95
115 96
124 6
115
121 116 114
122 97 v
t
123 120 119
116
97 125
WDBR-03-09-036
WDBR50-EN-00(20171222) W3-9-3-2
1- Housing 35- O-Ring 70- Bolt 101- Plug

2- Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring
3- Spring (2 Used) 37- Spool 72- Spring 103- Cap
4- O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used)
5- Flange 39- Spring (4 Used) 74- Overload Relief Valve (2 Used) 105- Spool
6- Socket Bolt (13 Used) 40- Body 75- Poppet 106- Spring
7- O-Ring (6 Used) 41- Bolt (4 Used) 76- Spring 107- Flange
8- Plug (6 Used) 42- Plug 77- O-Ring (5 Used) 108- Poppet
9- O-Ring (2 Used) 43- Backup Ring (2 Used) 78- O-Ring (2 Used) 109- Poppet
10- Plug (2 Used) 44- O-Ring (2 Used) 79- O-Ring 110- Spring
11- Poppet 45- Spring (2 Used) 80- Plug 111- Plug
12- Spring 46- Poppet 81- O-Ring 112- Poppet
13- O-Ring (12 Used) 47- Spool 82- Plug 113- Spring
14- O-Ring 48- Plug 83- Poppet 114- Plug (3 Used)
15- Poppet 49- Poppet 84- Poppet 115- O-Ring (3 Used)
16- Flange 50- Spool 85- Spring 116- Spring Seat (3 Used)
20- Overload Relief Valve (2 Used) 52- Spring Seat (2 Used) 87- Spring (3 Used) 118- Spool
21- Spring 53- Spring 88- Sleeve 119- Plug (3 Used)
22- Seat 54- Spool 89- Plug 120- O-Ring (3 Used)
23- Poppet 55- O-Ring 90- O-Ring 121- Spring
24- Backup Ring 56- Backup Ring 91- Body 122- Spool
25- O-Ring 57- Spool 92- Spool 123- Body
26- O-Ring 58- Spring 93- Spring 124- Spool
28- Backup Ring 59- O-Ring (8 Used) 94- Spring Seat 125- Spring
29- Sleeve 62- Cap 95- O-Ring 126- O-Ring
30- Spool 63- Socket Bolt (14 Used) 96- Plug 127- Plug
31- O-Ring 64- Cap 97- Socket Bolt (12 Used) 128- Orifice
32- Body 67- Cap (3 Used) 98- Poppet
33- Spring 68- Socket Bolt (2 Used) 99- Poppet
34- Piston 69- Cap 100- Spring
a- Check Valve (Main Relief h- Arm 2 o- Bucket Flow Rate Control Valve t- Boom Lower Meter-In Cut
Circuit) i- Arm Regenerative Valve (Poppet Valve) Valve
b- Overload Relief Valve (Bucket: j- Flow Combiner Valve p- Arm 2 Flow Rate Control Valve u- Boom Flow Rate Control Valve
Rod Side) k- Overload Relief Valve (Bucket: (Poppet Valve) (Selector Valve)
c- Overload Relief Valve (Boom: Bottom Side) q- Load Check Valve (Orifice) v- Bucket Flow Rate Control Valve
Bottom Side) l- Overload Relief Valve (Boom: (Bucket) (Selector Valve)
d- Boom Anti-Drift Valve (Selector Rod Side) r- Check Valve (Flow Combiner w- Boom Flow Rate Control Valve
Valve) m- Bypass Shut-Out Valve Circuit) (Poppet Valve)
e- Travel (Right) n- Boom Anti-Drift Valve (Check s- Arm 2 Flow Rate Control Valve x- Load Check Valve (Arm 2
f- Bucket Valve) (Selector Valve) Tandem Circuit)
g- Boom 1
WDBR50-EN-00(20171222) W3-9-3-3
Disassembly of Control Valve (A Side)
IMPORTANT: The shapes of the control valve parts  Disassembly of Overload Relief Valves (b, c, k, l)
are similar and the directions to install the control IMPORTANT: Do not disassemble the overload
valve parts have been determined. Put the marks relief valve. If it has been disassembled, pressure
for the mounting directions and positions of the should be adjusted. (Refer to TROUBLESHOOTING
parts. / Operational Performance Test in the separated
 Disassembly of Spool volume, T/M.)
1. Remove socket bolts (63) (6 used). Remove cap (62), 7. Remove overload relief valves (20, 74) (2 used for
O-rings (59) (4 used), and O-rings (4, 13, 14) from each) and O-rings (19) (4 used) from housing (2).
housing (1).
j : 32 mm
l : 8 mm
IMPORTANT: Slowly remove the spool (37, 47, 50, 51,  Disassembly of Check Valve (Main Relief Circuit) (a)
54) assemblies by turning. 8. Remove socket bolts (6) (2 used). Remove flange
IMPORTANT: Do not disassemble the spool (54) (16), O-ring (4), spring (3), and poppet (15) from
assembly unless necessary. housing (1).
2. Remove the spool (37, 47, 50, 51, 54) assemblies and l : 8 mm
spring (58) from housing (1).
9. Remove plugs (8) (2 used) and O-rings (7) (2 used)
from housing (1).
 Disassembly of Boom Anti-Drift Valve (Selector Valve)
(d) l : 10 mm
3. Remove plug (36) and O-ring (35) from body (32).
j : 38 mm from housing (1).
4. Remove socket bolts (6) (3 used). Remove the body l : 6 mm

(32) assembly, O-rings (13) (5 used), and O-ring (31)
from housing (1).
 Disassembly of Check Valve (Flow Combiner Circuit) (r)
l : 8 mm 11. Remove socket bolts (6) (2 used). Remove flange (5),
5. Remove piston (34) and spring (33) from body (32). O-ring (4), spring (3), and poppet (2) from housing
(1).
6. Remove the sleeve (29) assembly, seat (22), and
spring (21) from housing (1). Remove backup rings l : 8 mm
(24, 28), O-rings (25, 26), poppet (23), and spool (30)
from sleeve (29).
 Disassembly of Load Check Valve (Orifice) (Bucket) (q)
12. Remove plug (8), O-ring (7), spring (12), and poppet
(11) from housing (1).
l : 10 mm
WDBR50-EN-00(20171222) W3-9-3-4
 Disassembly of Travel (Right) Spool (e)  Disassembly of Boom 1 Spool (g)

13. Secure spool (37) in a vise by using wooden pieces. 17. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (41), spring seats (38) (2 used), and Remove bolt (41), spring seats (38) (2 used), and
spring (39) from spool (37). spring (39) from spool (50).
l : 8 mm l : 8 mm
bolt (41). bolt (41).
18. Warm the plug (48) part of spool (50) by using a
 Disassembly of Bucket Spool (f ) drier. Remove plug (48) by using special tool (ST
14. Secure spool (47) in a vise by using wooden pieces. 5909). Remove O-ring (44) and backup ring (43)
Remove bolt (41), spring seats (38) (2 used), and from plug (48).
spring (39) from spool (47).
l : 8 mm plug (48).
19. Remove spring (45) and poppet (49) from spool (50).
bolt (41).
15. Warm the plug (42) part of spool (47) by using a  Disassembly of Arm 2 Spool (h)
drier. Remove plug (42) by using special tool (ST 20. Secure spool (51) in a vise by using wooden pieces.
5909). Remove O-ring (44) and backup ring (43) Remove bolt (41), spring seats (38, 52) (2 used for
from plug (42). each), and springs (53, 39) from spool (51).
ST 5909
l : 8 mm

bolt (41).
W157-02-05-049
 Disassembly of Arm Regenerative Valve (i)
21. Secure spool (54) in a vise by using wooden pieces.
Remove spool (57) from spool (54). Remove backup
ring (55) and O-ring (56) from spool (57).
plug (42).
16. Remove spring (45) and poppet (46) from spool (47).
WDBR50-EN-00(20171222) W3-9-3-5
 Disassembly of Caps (64, 67)  Boom Flow Rate Control Valve (Selector Valve) (u)
22. Remove socket bolts (63) (8 used). Remove caps (67) 28. Remove socket bolts (97) (8 used). Remove the body
(3 used), cap (64), and O-rings (59) (4 used) from (123) assembly, O-rings (77) (3 used), O-rings (13) (2
housing (1). used), O-ring (78) and orifice (128) from housing (1).
l : 8 mm l : 8 mm
29. Remove plug (114), O-ring (115), spring seat (116),
 Disassembly of Flow Combiner Valve (j) spring (117), and spool (118) from body (123).
23. Remove socket bolts (68) (2 used). Remove cap
(69), O-ring (4), and the spool (73) assembly from j : 24 mm
housing (1). Secure spool (73) in a vise by using
wooden pieces. Remove bolt (70), spring seats (71)  Disassembly of Arm 2 Flow Rate Control Valve (Selector
(2 used), and spring (72) from spool (73). Valve) (s)
l : 5 mm
spring (121), and spool (122) from body (123).
 Disassembly of Bucket Flow Rate Control Valve (Poppet j : 24 mm

Valve) (o)
24. Remove socket bolts (97) (4 used). Remove the body  Disassembly of Boom Lower Meter-In Cut Valve (t)
(91) assembly and O-rings (13, 77) from housing (1). 31. Remove plug (114), O-ring (115), spring seat (116),
l : 8 mm
25. Remove sleeve (88), springs (85, 87), plug (86), and j : 24 mm
the poppets (83, 84) from housing (1).
j : 8 mm
 Disassembly of Bucket Flow Rate Control Valve
(Selector Valve) (v)
j : 27 mm
27. Remove plug (89) and O-ring (90) from body (91).
l : 6 mm
WDBR50-EN-00(20171222) W3-9-3-6
32. Remove plugs (119) (3 used), plug (127), O-rings  Disassembly of Boom Anti-Drift Valve (Check Valve) (n)
(120) (3 used), and O-ring (126) from body (123). 36. Remove socket bolts (6) (4 used). Remove body
(40), O-rings (13) (3 used), and O-rings (77, 78) from
(Plug (119))
housing (1).
l : 6 mm
l : 8 mm
(Plug (127))
37. Remove plugs (80, 82) and O-rings (79, 81) from
l : 5 mm body (40).
(Plug (80))
 Disassembly of Load Check Valve (Arm 2 Tandem
j : 19 mm
Circuit) (x)
33. Remove O-rings (13, 77), spring (113) and poppet (Plug (82))
l : 5 mm
 Disassembly of Boom Flow Rate Control Valve (Poppet 38. Remove spring (76) and poppet (75) from housing
Valve) (w) (1).
34. Remove O-rings (13, 77), spring (87) and the poppet
(98) assembly from housing (1). Remove plug (101),  Disassembly of Bypass Shut-Out Valve (m)
spring (100), and poppet (99) from poppet (98) 39. Remove socket bolts (6) (2 used). Remove flange
assembly. (107) and O-ring (4) from housing (1).
j : 8 mm l : 8 mm
40. Remove spring (106) and spool (105) from housing
 Disassembly of Arm 2 Flow Rate Control Valve (Poppet (1).
Valve) (p)
35. Remove O-rings (77, 87), spring (87) and the poppet 41. Remove socket bolts (104) (4 used). Remove cap
(108) assembly from housing (1). Remove plug (103) and O-ring (102) from housing (1).
(111), spring (110), and poppet (109) from poppet l : 8 mm
(108) assembly.
j : 8 mm from housing (1).
l : 10 mm
WDBR50-EN-00(20171222) W3-9-3-7
Assembly of Control Valve (A Side)
c E
7, 8 1
63
19, 20
59, 62
97
19, 20
91
6
19, 74
36
123 D
6
123
40
19, 20 97
19, 20
104
a- A Side 6
b- B Side 103
c- Machine 107
Front b a WDBR-03-09-030 WDBR-03-09-031
Side
View D View E
63
59, 67
63
6
59, 67
L L
63
K K
59, 67
WDBR-03-09-038
59, 64
Section L-L Section K-K

r q
63
11
WDBR-03-09-032
12
7
2 8
4 3
5
WDBR-03-09-037
WDBR50-EN-00(20171222) W3-9-3-8
Section B-B
d a
6 4
16 3
B
9
C C
D D
E E
F F
G G
H H
I
I
J J
b- A Side
c- B Side B
d- Machine c b WDBR-03-09-030
Front
Side
T1V1-03-03-002
Section D-D (A Side) Section C-C (A Side)
Detail A
j
e
41
1
38
73
70
39
38 8 4
37 71
1
72
71
1
A 7 69
W1V1-02-05-038
W1V1-02-05-040
W1V1-02-05-035
WDBR50-EN-00(20171222) W3-9-3-9
Section E-E (A Side) Detail B
v
b
1 96
20
1 95
94
19 93
47 Q
91
92
B
90
89
88
83 84 77 13 85 86 87
46
45
W1V1-02-05-033
43, 44 19
74
42
c
W1V1-02-05-036
Section I-I (A Side) Section J-J (A Side)

i
m
105 106 4
58
57
107
56, 55
54
W1V1-02-05-071 W1V1-02-05-037
WDBR50-EN-00(20171222) W3-9-3-10
Section F-F (A Side) Detail C

d
g 36
35
32
C 34
33
30
29 31
23 1
50 13
13 78
28 80
26
25 79 n
24
22
21 40
49 81
D
82
45 1 75 76 77
19 W1V1-02-05-031
43, 44
74
48
l
Detail D
W1V1-02-05-028
77 13 u
1 119
120
118
123
117
116
115
114
98 99 100 101 87
W1V1-02-05-032
WDBR50-EN-00(20171222) W3-9-3-11
Section G-G (A Side) Detail E
t
128 114
78 115
116
125
1 124
p
E
120
119
108 109 77
110 111 87 123 W1V1-02-05-042
W1V1-02-05-029
Section H-H (A Side) Detail F s

1 119
h
120
41
38 c
52 122
x
53 20 121
39 116
52 115
19 114
38
51 112 113 77 13 123
F
W1V1-02-05-034
65
66
W626-02-05-001
WDBR50-EN-00(20171222) W3-9-3-12
1- Housing 35- O-Ring 70- Bolt 101- Plug

2- Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring
3- Spring (2 Used) 37- Spool 72- Spring 103- Cap
4- O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used)
5- Flange 39- Spring (4 Used) 74- Overload Relief Valve (2 Used) 105- Spool
6- Socket Bolt (13 Used) 40- Body 75- Poppet 106- Spring
7- O-Ring (6 Used) 41- Bolt (4 Used) 76- Spring 107- Flange
8- Plug (6 Used) 42- Plug 77- O-Ring (5 Used) 108- Poppet
9- O-Ring (2 Used) 43- Backup Ring (2 Used) 78- O-Ring (2 Used) 109- Poppet
10- Plug (2 Used) 44- O-Ring (2 Used) 79- O-Ring 110- Spring
11- Poppet 45- Spring (2 Used) 80- Plug 111- Plug
12- Spring 46- Poppet 81- O-Ring 112- Poppet
14- O-Ring 48- Plug 83- Poppet 114- Plug (3 Used)
15- Poppet 49- Poppet 84- Poppet 115- O-Ring (3 Used)
16- Flange 50- Spool 85- Spring 116- Spring Seat (3 Used)
20- Overload Relief Valve (2 Used) 52- Spring Seat (2 Used) 87- Spring (3 Used) 118- Spool
21- Spring 53- Spring 88- Sleeve 119- Plug (3 Used)
22- Seat 54- Spool 89- Plug 120- O-Ring (3 Used)
23- Poppet 55- O-Ring 90- O-Ring 121- Spring
24- Backup Ring 56- Backup Ring 91- Body 122- Spool
25- O-Ring 57- Spool 92- Spool 123- Body
26- O-Ring 58- Spring 93- Spring 124- Spool
28- Backup Ring 59- O-Ring (8 Used) 94- Spring Seat 125- Spring
29- Sleeve 62- Cap 95- O-Ring 126- *O-Ring
30- Spool 63- Socket Bolt (14 Used) 96- Plug 127- *Plug
31- O-Ring 64- Cap 97- Socket Bolt (12 Used) 128- Orifice
32- Body 67- Cap (3 Used) 98- Poppet
33- Spring 68- Socket Bolt (2 Used) 99- Poppet
34- Piston 69- Cap 100- Spring
a- Check Valve (Main Relief h- Arm 2 o- Bucket Flow Rate Control Valve t- Boom Lower Meter-In Cut
Circuit) i- Arm Regenerative Valve (Poppet Valve) Valve
b- Overload Relief Valve (Bucket: j- Flow Combiner Valve p- Arm 2 Flow Rate Control Valve u- Boom Flow Rate Control Valve
Rod Side) k- Overload Relief Valve (Bucket: (Poppet Valve) (Selector Valve)
c- Overload Relief Valve (Boom: Bottom Side) q- Load Check Valve (Orifice) v- Bucket Flow Rate Control Valve
Bottom Side) l- Overload Relief Valve (Boom: (Bucket) (Selector Valve)
d- Boom Anti-Drift Valve (Selector Rod Side) r- Check Valve (Flow Combiner w- Boom Flow Rate Control Valve
Valve) m- Bypass Shut-Out Valve Circuit) (Poppet Valve)
e- Travel (Right) n- Boom Anti-Drift Valve (Check s- Arm 2 Flow Rate Control Valve x- Load Check Valve (Arm 2
f- Bucket Valve) (Selector Valve) Tandem Circuit)
g- Boom 1
fNOTE: As for the item with mark *, refer to W3-9-3-2.
WDBR50-EN-00(20171222) W3-9-3-13
Assembly of Control Valve (A Side)  Assembly of Arm 2 Flow Rate Control Valve (Poppet
Valve) (p)
8. Install poppet (109), spring (110), and plug (111)
to poppet (108). Install the poppet (108) assembly,
spring (87), and O-rings (77, 78) to housing (1).
 Assembly of Bypass Shut-Out Valve (m)
1. Install spool (105), spring (106), and O-ring (4) to j : 8 mm
housing (1). Install flange (107) to housing (1) with
socket bolts (6) (4 used). m : 34 to 39 N·m
l : 8 mm
 Assembly of Boom Flow Rate Control Valve (Poppet
m : 62 N·m Valve) (w)
9. Install poppet (99), spring (100), and plug (101) to
2. Install plugs (8) (3 used) and O-rings (7) (3 used) to poppet (98). Install the poppet (98) assembly, spring
housing (1). (87), orifice (128) and O-rings (13, 77) to housing (1).
l : 10 mm j : 8 mm
m : 76±3 N·m m : 34 to 39 N·m
3. Install O-rings (102) to housing (1). Install cap (103)
to housing (1) with socket bolts (104) (4 used).
 Assembly of Load Check Valve (Arm 2 Tandem Circuit)
l : 8 mm (x)
10. Install poppet (112), spring (113), and O-rings (77,
m : 61±3 N·m 13) to housing (1).
11. Install plug (127) and O-ring (126) to body (123).
 Assembly of Boom Anti-Drift Valve (Check Valve) (n)
4. Install O-rings (79, 81) to plugs (80, 82). l : 5 mm
5. Install poppet (75), spring (76), O-rings (77, 78) and m : 14.7±2 N·m
O-rings (13) (3 used) to housing (1).
6. Install body (40) to housing (1) with socket bolts (6)  Assembly of Boom Lower Meter-In Cut Valve (t)
(4 used). 12. Install O-rings (115, 120) to plugs (114, 119).
l : 8 mm 13. Install spool (124), spring (125), and spring seat
(116) to body (123). Temporarily install plugs (114,
m : 61±3 N·m 119) to body (123).
7. Install plugs (80, 82). (Plug (114))
(Plug (80))
j : 24 mm
j : 19 mm (Plug (119))
m : 29±1 N·m l : 6 mm
(Plug (82))
l : 5 mm
m : 14 to 18 N·m
WDBR50-EN-00(20171222) W3-9-3-14
 Assembly of Arm 2 Flow Rate Control Valve (Selector  Assembly of Bucket Flow Rate Control Valve (Selector
Valve) (s) Valve) (v)
14. Install O-rings (115, 120) to plugs (114, 119). 20. Install O-rings (95, 90) to plugs (96, 89).
15. Install spool (122), spring seat (116), and spring 21. Install spring (93), spool (92), spring seat (94), and
(121) to body (123). Temporarily install plugs (114, plug (96) to body (91).
119) to body (123).
j : 27 mm
(Plug (114))
m : 29±1 N·m
j : 24 mm
22. Install plug (89) to body (91).
(Plug (119))
l : 6 mm
l : 6 mm
m : 29±1 N·m
 Assembly of Boom Flow Rate Control Valve (Selector  Assembly of Bucket Flow Rate Control Valve (Poppet
Valve) (u) Valve) (o)
16. Install O-rings (115, 120) to plugs (114, 119). 23. Install poppet (84), spring (85), and plug (86) to
poppet (83). Install the poppet (83) assembly, spring
17. Install spool (118), spring (117), and spring seat
(87), and sleeve (88) to housing (1).
(116) to body (123). Temporarily install plugs (114,
119) to body (123). j : 8 mm
(Plug (114))
m : 34 to 39 N·m
j : 24 mm 24. Install O-rings (13, 77) to housing (1). Install body
(Plug (119)) (91) to housing (1) with socket bolts (97) (4 used).
l : 6 mm l : 8 mm
18. Install body (123) to housing (1) with socket bolts m : 76±3 N·m
(97) (8 used).
l : 8 mm  Assembly of Flow Combiner Valve (j)

25. Install spring seats (71) (2 used) and spring (72) to
m : 61±3 N·m bolt (70). Install bolt (70) to spool (73).
19. Tighten plugs (114, 119) (3 used for each). 26. Install spool (73) and O-ring (4) to housing (1).
Install cap (69) to housing (1) with socket bolts (68)
(Plug (114))
(2 used).
j : 24 mm
l : 5 mm
m : 83±5 N·m
m : 20±1 N·m
(Plug (119))
l : 6 mm
m : 29±1 N·m
WDBR50-EN-00(20171222) W3-9-3-15
 Assembly of Caps (64, 67)  Assembly of Bucket Spool (f )

27. Install O-rings (59) (4 used) to housing (1). Install 34. Secure spool (47) in a vise by using wooden pieces.
caps (67) (3 used) and cap (64) to housing (1) with Install poppet (46) and spring (45) to the lower part
socket bolts (63) (8 used). of spool (47).
l : 8 mm 35. Install O-ring (44) and backup ring (43) to plug (42).
Apply LOCTITE #263 or equivalent to the thread part
m : 42±2 N·m of plug (42).
 Assembly of Arm Regenerative Valve (i) 36. Install plug (42) to spool (47) by using special tool
28. Secure spool (54) in a vise by using wooden pieces. (ST 5909).
Install O-ring (56) and backup ring (55) to spool (57).
Install spool (57) to spool (54). Install the spool (54) m : 15 N·m
assembly and spring (58) to housing (1). ST 5909
 Assembly of Arm 2 Spool (h)

29. Apply LOCTITE #263 or equivalent to the thread
part of bolt (41). Secure spool (51) in a vise by using
W157-02-05-049
wooden pieces. Install spring seats (38, 52) (2 used
for each) springs (39, 53) and bolt (41) to spool (51).
37. Apply LOCTITE #263 or equivalent to the thread part
l : 8 mm of bolt (41). Install spring seats (38) (2 used), spring
(39), and bolt (41) to the upper part of spool (47).
m : 15 N·m
l : 8 mm
 Assembly of Boom 1 Spool (g) m : 15 N·m
Install poppet (49) and spring (45) to the lower part
of spool (50).  Assembly of Travel (Right) Spool (e)
31. Install O-ring (44) and backup ring (43) to plug (48). part of bolt (41). Secure spool (37) in a vise by using
Apply LOCTITE #263 or equivalent to the thread part wooden pieces. Install spring seats (38) (2 used),
of plug (48). spring (39), and bolt (41) to spool (37).
32. Install plug (48) to spool (50) by using special tool
l : 8 mm
(ST 5909).
m : 15 N·m
m : 15 N·m
33. Apply LOCTITE #263 or equivalent to the thread part
of bolt (41). Install spring seats (38) (2 used), spring
(39), and bolt (41) to the upper part of spool (50).
l : 8 mm
m : 15 N·m
WDBR50-EN-00(20171222) W3-9-3-16
 Assembly of Load Check Valve (Orifice) (Bucket) (q)  Assembly of Overload Relief Valves (b, c, k, l)
39. Install O-ring (7) to plug (8). Install poppet (11), IMPORTANT: If the overload relief valve has been
spring (12), and plug (8) to housing (1). disassembled, pressure should be adjusted.
(Refer to TROUBLESHOOTING / Operational
l : 10 mm
Performance Test in the separated volume, T/M.)
m : 76±3 N·m 46. Install O-rings (19) (4 used) to overload relief valves
(20, 74) (2 used for each). Install overload relief
valves (20, 74) (2 used for each) to housing (1).
 Assembly of Check Valve (Flow Combiner Circuit) (r)
40. Install poppet (2), spring (3), and O-ring (4) to j : 32 mm
housing (1).
m : 83±5 N·m
41. Install flange (5) to housing (1) with socket bolts (6)
(2 used).
l : 8 mm
m : 61±3 N·m
 Assembly of Check Valve (Main Relief Circuit) (a)

42. Install O-rings (9) (2 used) to plugs (10) (2 used).
Install plugs (10) (2 used) to housing (2).
l : 6 mm
m : 34+8.9-2.9 N·m
l : 10 mm
m : 76±3 N·m
44. Install poppet (15), spring (3), and O-ring (4) to
housing (1).
45. Install flange (16) to housing (1) with socket bolts (6)
(2 used).
l : 8 mm
m : 61±3 N·m
WDBR50-EN-00(20171222) W3-9-3-17
 Assembly of Boom Anti-Drift Valve (Selector Valve) (d)

47. Install backup rings (24, 28) and O-rings (25, 26) to
sleeve (29).
48. Apply grease to seat (22) and spring (21) in order
to prevent them from falling off. Face the hole of
spool (30) to the poppet (23) side. Install spool (30),
poppet (23), seat (22), and spring (21) to sleeve (29).
Install the sleeve (29) assembly to housing (1).
49. Install O-ring (35) to plug (36). Install spring
(33), piston (34), and O-ring (31) to body (32).
Temporarily install plug (36).
j : 38 mm
50. Install O-rings (13) (5 used) to housing (5). Install the
body (32) assembly with socket bolts (6) (3 used).
l : 8 mm
m : 61±3 N·m
51. Tighten plug (36).
j : 38 mm
m : 93 to108 N·m
 Assembly of Spool
IMPORTANT: Slowly install the spool (37, 47, 50, 51,
54) assemblies to housing (1) by turning.
52. Install the spool (37, 47, 50, 51, 54) assemblies,
O-rings (59) (4 used) and O-ring (4) to housing (1).
Install cap (62) to housing (1) with socket bolts (63)
(6 used).
l : 8 mm
m : 42±2 N·m
WDBR50-EN-00(20171222) W3-9-3-18
Disassembly of Control Valve (B Side) t

7
3 6
2 5 u
4
8
13
12
1 11 8
7
17
10 14
9 15
b
16
10
9 18
19
20 22 c
23
24
30
25
20 27
20 28
21 d
29
37 31
38 32
39 26 33
28 34
40 35
a 36
41
8
45 42
43
47 46 42 42
43 44
42 42
48 42 e
49 43 44
50 42
f
43
44
48
42 42 g
43 44
42 51
h
44 52
51
i
W1V1-02-05-026
55
WDBR50-EN-00(20171222) W3-9-4-1
56 57
104
58
77 w
56 78
57 61
62
63
104
20
58
59 v 13
60 64
61 o, x
62 65
20 63
79 8
13 8 80
81 7
64 75
65 82
70
66 71 6
k l
j 67
68 8 5
13
69 83
12
72
76
73 13
74
8
p n
91 20
87 84
88 85
6 r
91 89
93
92 q 90
96
6 m
92
97 93 10
94
16 10 9
95
15 9 38
14 52
86
s 98
3
2 52 51 10
98 9
52
99 51
100 52
98 103
52 51
98
51
51
10
9
W1V1-02-05-027
WDBR50-EN-00(20171222) W3-9-4-2
1- Housing 28- Backup Ring (2 Used) 57- O-Ring (2 Used) 84- Cover (2 Used)
2- O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (8 Used) 85- O-Ring (2 Used)
3- Plug (2 Used) 30- Spool 59- Spool 86- Poppet
4- Poppet 31- O-Ring 60- Spring 87- Plug
5- Spring (2 Used) 32- Body 61- Spring Seat (2 Used) 88- O-Ring
6- O-Ring (4 Used) 33- Spring 62- O-Ring (2 Used) 89- Spring
7- Flange (3 Used) 34- Piston 63- Plug (2 Used) 90- Poppet
8- Socket Bolt (29 Used) 35- O-Ring 64- Sleeve (2 Used) 91- Socket Bolt (4 Used)
9- O-Ring (6 Used) 36- Plug 65- Spring (2 Used) 92- Cap (2 Used)
10- Plug (6 Used) 37- Poppet 66- Plug 93- Spring Seat (2 Used)
11- Poppet 38- Spring (2 Used) 67- Spring 94- Spring
12- Spring (3 Used) 39- O-Ring 68- Poppet 95- Spool
13- O-Ring (6 Used) 40- Spacer 69- Poppet 96- Spring
14- O-Ring (2 Used) 41- Spool 70- Plug 97- Spool
15- Backup Ring (2 Used) 42- Spring Seat (10 Used) 71- O-Ring 98- Cap (4 Used)
16- Plug (2 Used) 43- Spring (5 Used) 72- Flange 99- Overload Relief Valve
17- Main Relief Valve 44- Bolt (5 Used) 73- Spring 100- O-Ring
18- O-Ring 45- Spool 74- Poppet 103- Cap
19- Overload Relief Valve 46- Spool 75- Flange (2 Used) 104- Body (2 Used)
20- O-Ring (11 Used) 47- Spool 76- Poppet (2 Used)
21- O-Ring 48- Spring Seat (2 Used) 77- Spool
22- Spring 49- Spring 78- Spring
23- Seat 50- Spool 79- Plug
24- Poppet 51- O-Ring (10 Used) 80- Spring
25- Backup Ring 52- Socket Bolt (16 Used) 81- Poppet
26- O-Ring 55- Cap 82- Poppet
27- O-Ring 56- Plug (2 Used) 83- Poppet
a- Load Check Valve (Arm h- Arm 1 n- Load Check Valve (Digging t- Load Check Valve (Travel (Left)
Regenerative Circuit) i- Swing Regenerative Circuit) Tandem Circuit)
b- Main Relief Valve j- Arm 1 Flow Rate Control Valve o- Load Check Valve (Boom 2 u- Check Valve (Main Relief
c- Overload Relief Valve (Arm: (Poppet Valve) Parallel Circuit) Circuit)
Rod Side) k- Auxiliary Flow Rate Control p- Arm Anti-Drift Valve (Check v- Arm 1 Flow Rate Control Valve
d- Arm Anti-Drift Valve (Selector Valve (Poppet Valve) Valve) (Selector Valve)
Valve) l- Check Valve (Auxiliary Flow q- Auxiliary Flow Combiner Valve w- Auxiliary Flow Rate Control
e- Travel (Left) Combiner Valve Circuit) r- Digging Regenerative Valve Valve (Selector Valve)
f- Auxiliary m- Load Check Valve (Travel (Left) s- Overload Relief Valve (Arm: x- Load Check Valve (Swing
g- Boom 2 Parallel Circuit) Bottom Side) Circuit)
WDBR50-EN-00(20171222) W3-9-4-3
Disassembly of Control Valve (B Side)  Disassembly of Overload Relief Valves (Arm: Rod Side)
(c)
IMPORTANT: Do not disassemble the overload
IMPORTANT: The shapes of the control valve parts
relief valve. If it has been disassembled, pressure
are similar and the directions to install the control
should be adjusted. (Refer to TROUBLESHOOTING/
valve parts have been determined. Put the marks
Operational Performance Test in the separated
for the mounting directions and positions of the
volume, T/M.)
parts.
7. Remove overload relief valve (19) and O-ring (18)
 Disassembly of Spool
from housing (1).
1. Remove socket bolts (52) (6 used). Remove cap
(55), O-rings (51) (5 used), and O-rings (20, 21) from j : 32 mm
housing (1).
l : 8 mm  Disassembly of Main Relief Valve (b)

IMPORTANT: Do not disassemble the main relief
IMPORTANT: Slowly remove the spool (41, 45, 46, 47,
valve. If it has been disassembled, pressure
50) assemblies by turning.
2. Remove the spool (41, 45, 46, 47, 50) assemblies Operational Performance Test in the separated
from housing (1). volume, T/M.)
8. Remove main relief valve (17) from housing (1).
 Disassembly of Arm Anti-Drift Valve (Selector Valve) (d)
IMPORTANT: Replace O-rings (31, 35), body (32), j : 32 mm
spring (33), piston (34), and plug (36) as an
assembly.  Disassembly of Load Check Valve (Arm Regenerative
3. Remove plug (36) and O-ring (35) from body (32). Circuit) (a)
9. Remove spacer (40), spring (38), and poppet (37)
j : 38 mm from housing (1). Remove backup ring (28) and
4. Remove socket bolts (8) (3 used). Remove the body O-ring (39) from spacer (40).
(32) assembly, O-ring (31), and O-rings (20) (5 used)
from housing (1).  Disassembly of Load Check Valve (Travel (Left) Tandem
Circuit) (t)
l : 8 mm
10. Remove socket bolts (8) (2 used). Remove flange (7),
5. Remove piston (34) and spring (33) from body (32). O-ring (6), spring (5), and poppet (4) from housing
(1).
6. Remove spool (30), sleeve (29), poppet (24), seat l : 8 mm
(23), and spring (22) from housing (1). Remove
backup rings (25, 28) and O-rings (26, 27) from
sleeve (29).  Disassembly of Check Valve (Main Relief Circuit) (u)
11. Remove socket bolts (8) (2 used). Remove flange
(7), O-ring (13), spring (12), and poppet (11) from
housing (1).
l : 8 mm
WDBR50-EN-00(20171222) W3-9-4-4
 Disassembly of Plugs (10, 3, 16)  Disassembly of Arm 1 Spool (h)

12. Remove plugs (10) (5 used) and O-rings (9) (5 used) 18. Secure spool (47) in a vise by using wooden pieces.
from housing (1). Remove bolt (44), spring seats (42, 48) (2 used for
each), and springs (49, 43) from spool (47).
l : 8 mm
l : 8 mm
from housing (1). fNOTE: LOCTITE #263 or equivalent has been applied to
bolt (44).
l : 10 mm
14. Remove plugs (16) (2 used), backup rings (15) (2  Disassembly of Swing Spool (i)
used), and O-rings (14) (2 used) from housing (1). 19. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42) (2 used), and
j : 24 mm
 Disassembly of Travel (Left) Spool (e) l : 8 mm

Remove bolt (44), spring seats (42) (2 used), and fNOTE: LOCTITE #263 or equivalent has been applied to
bolt (44).
l : 8 mm

bolt (44).
 Disassembly of Auxiliary Spool (f )

l : 8 mm

bolt (44).
 Disassembly of Boom 2 Spool (g)

l : 8 mm

bolt (44).
WDBR50-EN-00(20171222) W3-9-4-5
 Disassembly of Caps (98, 103)  Disassembly of Arm Anti-Drift Valve (Check Valve) (p)
20. Remove socket bolts (52) (10 used). Remove caps 25. Remove socket bolts (8) (4 used). Remove flange
(98) (4 used), cap (103), and O-rings (51) (5 used) (72), O-rings (20) (3 used), O-ring (13), spring (73),
from housing (1). and poppet (74) from housing (1). Remove plug (70)
and O-ring (71) from flange (72).
l : 8 mm
(Socket bolt (8))
 Disassembly of Digging Regenerative Valve (r) l : 8 mm

21. Remove socket bolts (91) (2 used). Remove cap (92),
(Plug (70))
O-ring (6), spring seat (93), spring (96), and spool
(97) from housing (1). l : 5 mm
l : 5 mm
 Disassembly of Arm 1 Flow Rate Control Valve (Poppet
Valve) (j)
 Disassembly of Auxiliary Flow Combiner Valve (q)
26. Loosen plugs (56, 63).
22. Remove socket bolts (91) (2 used). Remove cap (92),
O-ring (6), spring seat (93), spring (94), and spool (Plug (56))
l : 6 mm
l : 5 mm
(Plug (63))
 Disassembly of Overload Relief Valves (Arm: Bottom j : 27 mm

Side) (s) 27. Remove socket bolts (58) (4 used). Remove the body
IMPORTANT: Do not disassemble the overload (104) assembly and O-rings (20, 13) from housing
relief valve. If it has been disassembled, pressure (1).
Operational Performance Test in the separated l : 8 mm
volume, T/M.) 28. Remove sleeve (64), spring (65), and the poppet (69)
23. Remove overload relief valve (99) and O-ring (100) assembly from housing (1).
from housing (1).
29. Remove plug (66), spring (67), and poppet (68) from
j : 32 mm poppet (69).
j : 8 mm
 Disassembly of Check Valve (Auxiliary Flow Combiner
Circuit) (l)
 Disassembly of Arm 1 Flow Rate Control Valves
24. Remove socket bolts (8) (2 used). Remove flange (7),
(Selector Valve) (v)
O-ring (6), spring (5), and poppet (83) from housing
(1).
spring (60), and spool (59) from body (104). Remove
l : 8 mm plug (56) and O-ring (57) from body (104).
(Plug (56))
l : 6 mm
(Plug (63))
j : 27 mm
WDBR50-EN-00(20171222) W3-9-4-6
 Disassembly of Auxiliary Flow Rate Control Valve  Disassembly of Load Check Valve (Travel (Left) Parallel
(Poppet Valve) (k) Circuit) (m)
31. Loosen plugs (56, 63). 37. Remove plug (10), O-ring (9), spring (38), and
poppet (86) from housing (1).
(Plug (56))
l : 8 mm
l : 6 mm
(Plug (63)) 38 86
j : 27 mm
10
32. Remove socket bolts (58) (4 used). Remove the body
(104) assembly and O-rings (20, 13) from housing 1
9
(1).
l : 8 mm
33. Remove sleeve (64), spring (65), and the poppet (82)
assembly from housing (1).
W1V1-02-05-016
34. Remove plug (79), spring (80), and poppet (81) from
poppet (82).
 Disassembly of Load Check Valve (Digging
j : 8 mm Regenerative Circuit) (n)
38. Remove plug (87), O-ring (88), spring (89), and
poppet (90) from housing (1).
 Disassembly of Auxiliary Flow Rate Control Valves
(Selector Valve) (w) j : 24 mm
spring (78), and spool (77) from body (104). Remove
plug (56) and O-ring (57) from body (104).  Disassembly of Cover (84)
39. Remove socket bolts (8) (8 used). Remove covers
(Plug (56)) (84) (2 used) and O-rings (85) (2 used) from housing
(1).
l : 6 mm
(Plug (63)) l : 8 mm
j : 27 mm
 Disassembly of Load Check Valve (Boom 2 Parallel

Circuit, Swing Circuit) (o, x)
36. Remove socket bolts (8) (8 used) from housing (1).
Remove flanges (75) (2 used), O-rings (13) (2 used),
springs (12) (2 used), and poppets (76) (2 used).
l : 8 mm
WDBR50-EN-00(20171222) W3-9-4-7
Assembly of Control Valve (B Side)

E h
9, 10 9, 10
17
52
N N
51, 55
9, 10
75
D
104 19
36
32
99, 100
1 b a WDBR-03-09-030
58 8 75 72 8 a- A Side
WDBR-03-09-033 b- B Side
h- Machine
Front
Side
View E
View D (B Side)
52
51, 98
52
51, 98
M M
52
51, 103 T1V1-03-03-027
52 Section M-M Section N-N

51, 98 u m
10
52 7
13 42 9
51, 98
12 38
WDBR-03-09-032 11
86
WDBR-03-09-039
WDBR50-EN-00(20171222) W3-9-4-8
h Section C-C (B Side)

b
A
17
C C 1
9, 10
D D
E E
F F 6
l
G G
7 95
5
H H 6
83 94
I I 93
J J 92
q
W1V1-02-05-043
f- A Side A
g f WDBR-03-09-030
g- B Side
h- Machine
Front
Side
Section A-A Section D-D (B Side)
h
e
j 55
t 44
42
43
42
51
41
WDBR-03-09-040
1
j- Machine Upper Side h- Machine Front Side 51
98
W1V1-02-05-044
WDBR50-EN-00(20171222) W3-9-4-9
Section E-E (B Side) Section F-F (B Side) Section G-G (B Side)
f
g
42 c
44
44 42
21
43 43 19
14, 15, 16
85 42 42 18
76
84
8 12 46
45 13
75
A 8
1
97
B 6
1
8
96
103
84 93
85 1 92
14, 15, 16 r
W1V1-02-05-045 W1V1-02-05-046 W1V1-02-05-050
Detail A Detail B
88 89 90
w
87
63 1
62
61 n
78
104 k
77 1
57
56
64
10
65 79 80 20 13 81 82
9 2 3
WDBR-03-09-034 W1V1-02-05-053
WDBR50-EN-00(20171222) W3-9-4-10
Section H-H (B Side) Section I-I (B Side)
h
44 i
42
C
48
49
43
48 76
42
47 12 50
13
D
8
75
1
100
99
1
s
W1V1-02-05-051 W1V1-02-05-052
Detail C Detail D
36
35
d 34
32 63 1
v
33 62
24
30 61
60
13 104 j
29 59
28
20 27 57
26
20 25 56
23 64
p
22 65 66 20 13 67 68 69
72
WDBR-03-09-034
71 70 13 73 74 W1V1-02-05-054
WDBR50-EN-00(20171222) W3-9-4-11
1- Housing 28- Backup Ring (2 Used) 57- O-Ring (2 Used) 84- Cover (2 Used)
2- O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (8 Used) 85- *O-Ring (2 Used)
3- Plug (2 Used) 30- Spool 59- Spool 86- *Poppet
4- Poppet 31- *O-Ring 60- Spring 87- *Plug
5- Spring (2 Used) 32- Body 61- Spring Seat (2 Used) 88- O-Ring
6- O-Ring (4 Used) 33- Spring 62- O-Ring (2 Used) 89- Spring
7- Flange (3 Used) 34- Piston 63- Plug (2 Used) 90- Poppet
8- Socket Bolt (29 Used) 35- O-Ring 64- Sleeve (2 Used) 91- * Socket Bolt (4 Used)
9- O-Ring (6 Used) 36- Plug 65- Spring (2 Used) 92- Cap (2 Used)
10- Plug (6 Used) 37- *Poppet 66- Plug 93- Spring Seat (2 Used)
11- Poppet 38- *Spring (2 Used) 67- Spring 94- *Spring
12- Spring (3 Used) 39- *O-Ring 68- Poppet 95- *Spool
13- O-Ring (6 Used) 40- *Spacer 69- Poppet 96- Spring
14- O-Ring (2 Used) 41- Spool 70- Plug 97- Spool
15- Backup Ring (2 Used) 42- Spring Seat (10 Used) 71- O-Ring 98- Cap (4 Used)
16- Plug (2 Used) 43- Spring (5 Used) 72- Flange 99- Overload Relief Valve
17- Main Relief Valve 44- Bolt (5 Used) 73- Spring 100- O-Ring
18- O-Ring 45- Spool 74- Poppet 103- Cap
19- Overload Relief Valve 46- Spool 75- Flange (2 Used) 104- Body (2 Used)
20- O-Ring (11 Used) 47- Spool 76- Poppet (2 Used)
21- O-Ring 48- Spring Seat (2 Used) 77- Spool
22- Spring 49- Spring 78- Spring
23- Seat 50- Spool 79- Plug
24- Poppet 51- O-Ring (10 Used) 80- Spring
25- Backup Ring 52- Socket Bolt (16 Used) 81- Poppet
26- O-Ring 55- Cap 82- Poppet
27- O-Ring 56- Plug (2 Used) 83- Poppet
a- Load Check Valve (Arm h- Arm 1 n- Load Check Valve (Digging t- Load Check Valve (Travel (Left)
Regenerative Circuit) i- Swing Regenerative Circuit) Tandem Circuit)
b- Main Relief Valve j- Arm 1 Flow Rate Control Valve o- Load Check Valve (Boom 2 u- Check Valve (Main Relief
c- Overload Relief Valve (Arm: (Poppet Valve) Parallel Circuit) Circuit)
Rod Side) k- Auxiliary Flow Rate Control p- Arm Anti-Drift Valve (Check v- Arm 1 Flow Rate Control Valve
d- Arm Anti-Drift Valve (Selector Valve (Poppet Valve) Valve) (Selector Valve)
Valve) l- Check Valve (Auxiliary Flow q- Auxiliary Flow Combiner Valve w- Auxiliary Flow Rate Control
e- Travel (Left) Combiner Valve Circuit) r- Digging Regenerative Valve Valve (Selector Valve)
f- Auxiliary m- Load Check Valve (Travel (Left) s- Overload Relief Valve (Arm: x- Load Check Valve (Swing
g- Boom 2 Parallel Circuit) Bottom Side) Circuit)
fNOTE: As for the item with mark *, refer to W3-9-4-1

and W3-9-4-2.
WDBR50-EN-00(20171222) W3-9-4-12
Assembly of Control Valve (B Side)  Assembly of Load Check Valves (Boom 2 Parallel Circuit
, Swing Circuit) (o, x)
4. Install poppets (76) (2 used), springs (12) (2 used),
and O-rings (13) (2 used) to housing (1).
 Assembly of Cover (84) 5. Install flanges (75) (2 used) to housing (1) with
1. Install O-rings (85) (2 used) to housing (1). Install socket bolts (8) (8 used).
covers (84) (2 used) to housing (1) with socket bolts
l : 8 mm
(8) (8 used).
m : 61±3 N·m
l : 8 mm
m : 61±3 N·m
 Assembly of Load Check Valve (Digging Regenerative

Circuit) (n)
2. Install O-ring (88) to plug (87). Install poppet (90),
spring (89), and plug (87) to housing (1).
j : 24 mm
m : 93±5 N·m
 Assembly of Load Check Valve (Travel (Left) Parallel

Circuit) (m)
3. Install O-ring (9) to plug (10). Install poppet (86),
spring (38), and plug (10) to housing (1).
l : 8 mm
m : 76±3 N·m
38 86
10
1
9
W1V1-02-05-016
WDBR50-EN-00(20171222) W3-9-4-13
 Assembly of Auxiliary Flow Rate Control Valve (Selector  Assembly of Arm 1 Flow Rate Control Valve (Poppet
Valve) (w) Valve) (j)
6. Install O-rings (57, 62) to plugs (56, 63). 14. Install poppet (68), spring (67), and plug (66) to
poppet (69).
7. Install spring (78), spool (77) and spring seat (61) to
body (104). Temporarily install plugs (56, 63). j : 8 mm
(Plug (56))
m : 34~39 N·m
l : 6 mm
(Plug (63)) 15. Install the poppet (69) assembly, spring (65), and
sleeve (64) to housing (1).
j : 27 mm
16. Install O-rings (13, 20) to housing (1). Install the
 Assembly of Auxiliary Flow Rate Control Valve (Poppet
body (104) assembly to housing (1) with socket
Valve) (k)
8. Install poppet (81), spring (80), and plug (79) to
poppet (82). l : 8 mm
j : 8 mm m : 61±3 N·m
m : 34~39 N·m 17. Tighten plugs (56, 63)
9. Install the poppet (82) assembly, spring (65), and (Plug (56))
sleeve (64) to housing (1).
l : 6 mm
10. Install O-rings (13, 20) to housing (1). Install the
body (104) assembly to housing (1) with socket m : 29±1 N·m
(Plug (63))
l : 8 mm
j : 27 mm
m : 61±3 N·m
m : 29±1 N·m
11. Tighten plugs (56, 63)
(Plug (56))  Assembly of Arm Anti-Drift Valve (Check Valve) (p)
l : 6 mm flange (72).
m : 29±1 N·m l : 5 mm
(Plug (63))
m : 14 to 18 N·m
j : 27 mm 19. Install flange (72), O-rings (20) (3 used), O-ring (13),
spring (73) and poppet (74) to housing (1) with
m : 29±1 N·m
l : 8 mm
 Assembly of Arm 1 Flow Rate Control Valve (Selector
Valve) (v) m : 61±3 N·m
12. Install O-rings (57, 62) to plugs (56, 63).
13. Install spring (60), spool (59) and spring seat (61) to  Assembly of Check Valve (Auxiliary Flow Combiner
body (104). Temporarily install plugs (56, 63). Circuit) (l)
20. Install poppet (83), spring (5), and O-ring (6) to
(Plug (56)) housing (1). Install flange (7) to housing (1) with
l : 6 mm
(Plug (63)) l : 8 mm
j : 27 mm m : 61±3 N·m
WDBR50-EN-00(20171222) W3-9-4-14
 Assembly of Overload Relief Valves (Arm: Bottom Side)  Assembly of Swing Spool (i)
(s) 25. Apply LOCTITE #263 or equivalent to the thread
IMPORTANT: If the overload relief valve has been part of bolt (44). Secure spool (50) in a vise by using
disassembled, pressure should be adjusted. (Refer wooden pieces. Install spring seats (42) (2 used),
to TROUBLESHOOTING/Operational Performance spring (43), and bolt (44) to spool (50).
Test in the separated volume, T/M.)
l : 8 mm
21. Install O-ring (100) to overload relief valve (99).
Install overload relief valve (99) to housing (1). m : 15 N·m
j : 32 mm
 Assembly of Arm 1 Spool (h)
m : 83±5 N·m 26. Apply LOCTITE #263 or equivalent to the thread
part of bolt (44). Secure spool (47) in a vise by using
 Assembly of Auxiliary Flow Combiner Valve (q) wooden pieces. Install spring seats (42, 48) (2 used
22. Install spool (95), spring (94), O-ring (6), and spring for each), springs (43, 49), and bolt (44) to spool (47).
seat (93) to housing (1). Install cap (92) to housing
l : 8 mm
m : 15 N·m
l : 5 mm
m : 10 N·m  Assembly of Boom 2 Spool (g)

 Assembly of Digging Regenerative Valve (r) part of bolt (44). Secure spool (46) in a vise by using
23. Install spool (97), spring (96), O-ring (6), and spring wooden pieces. Install spring seats (42) (2 used),
seat (93) to housing (1). Install cap (92) to housing spring (43), and bolt (44) to spool (46).
l : 8 mm
l : 5 mm
m : 15 N·m
m : 10 N·m
 Assembly of Auxiliary Spool (f )
 Assembly of Caps (98, 103) 28. Apply LOCTITE #263 or equivalent to the thread
24. Install O-rings (51) (5 used) to housing (1). Install cap part of bolt (44). Secure spool (45) in a vise by using
(103), caps (98) (4 used) to housing (1) with socket wooden pieces. Install spring seats (42) (2 used),
bolts (52) (10 used). spring (43), and bolt (44) to spool (45).
l : 8 mm l : 8 mm
m : 42±2 N·m m : 15 N·m
WDBR50-EN-00(20171222) W3-9-4-15
 Assembly of Travel (Left) Spool (e)  Assembly of Check Valve (Main Relief Valve) (u)
29. Apply LOCTITE #263 or equivalent to the thread 33. Install poppet (11), spring (12), and O-ring (13) to
part of bolt (44). Secure spool (41) in a vise by using housing (1). Install flange (7) to housing (1) with
wooden pieces. Install spring seats (42) (2 used), socket bolts (8) (2 used).
spring (43), and bolt (44) to spool (41).
l : 8 mm
l : 8 mm
m : 61±3 N·m
m : 15 N·m
 Assembly of Load Check Valve (Travel (Left) Tandem
 Assembly of Plugs (10, 3, 16) Circuit)
30. Install backup rings (15) (2 used) and O-rings (14) 34. Install poppet (4), spring (5), and O-ring (6) to
(2 used) to plugs (16) (2 used). Install plugs (16) (2 housing (1). Install flange (7) to housing (1) with
used) to housing (1). socket bolts (8) (2 used).
j : 24 mm l : 8 mm
m : 83±5 N·m m : 61±3 N·m

Install plugs (3) (2 used) to housing (1).  Assembly of Load Check Valve (Arm Regenerative
Circuit) (a)
l : 10 mm 35. Install backup ring (28) and O-ring (39) to spacer
(40). Install spacer (40), spring (38), and poppet (37)
m : 106~141 N·m
to housing (1).
 Assembly of Main Relief Valve (b)
l : 8 mm IMPORTANT: If the main relief valve has been
disassembled, pressure should be adjusted. (Refer
m : 76±3 N·m to TROUBLESHOOTING/Operational Performance
Test in the separated volume, T/M.)
36. Install main relief valve (17) to housing (1).
j : 32 mm
m : 83±5 N·m
WDBR50-EN-00(20171222) W3-9-4-16
 Assembly of Overload Relief Valves (Arm: Rod Side) (c)  Assembly of Spool
IMPORTANT: If the overload relief valve has been IMPORTANT: Slowly install the spool (41, 45, 46, 47,
disassembled, pressure should be adjusted. (Refer 50) assemblies to housing (1) by turning.
to TROUBLESHOOTING/Operational Performance 44. Install the spool (41, 45, 46, 47, 50) assemblies to
Test in the separated volume, T/M.) housing (1).
37. Install O-ring (18) to overload relief valve (19). Install
45. Install O-rings (51) (5 used) and O-rings (20, 21)
overload relief valve (19) to housing (1).
to housing (1). Install cap (55) to housing (1) with
j : 32 mm socket bolts (52) (6 used).
m : 83±5 N·m l : 8 mm
m : 42±2 N·m
 Assembly of Arm Anti-Drift Valve (Selector Valve) (d)
38. Install backup rings (25, 28) and O-rings (26, 27) to
sleeve (29).
39. Apply grease to seat (23) and spring (22) in order to
prevent them from falling off.
40. Face the hole of spool (29) to the poppet (24) side.
Install spool (30), poppet (24), seat (23), and spring
(22) to sleeve (29). Install the sleeve (29) assembly to
housing (1).
41. Install O-ring (35) to plug (36). Install spring (33),
piston (34) and O-ring (31) to body (32). Temporarily
install plug (36).
j : 38 mm
42. Install O-rings (20) (5 used) and O-ring (31) to
housing (1). Install the body (32) assembly to
housing (1) with socket bolts (8) (3 used).
l : 8 mm
m : 61±3 N·m
j : 38 mm
m : 93 to 108 N·m
WDBR50-EN-00(20171222) W3-9-4-17
(Blank)
WDBR50-EN-00(20171222) W3-9-4-18
Removal and Installation of Swing Device
a
1
WDBR-03-10-002
WDBR-03-16-001
3 2 a- Machine Front Side
IMPORTANT: The hose and pipe contain hydraulic oil.

When removing the hose and pipe, receive oil with
a container in order to avoid spilling oil.
Removal

(3).
j : 17 mm
j : 36 mm
WDBR50-EN-00(20171222) W3-10-1-1
10 10
1, 2, 3, 4
11
5, 13
10
12
7
WDBR-03-10-003
8, 9
WDAD-03-10-004
5. Remove clip band (9). Disconnect connector (8). 10. Remove plugs (7) (2 used).
6. Disconnect hoses (10) (3 used). j : 30 mm
j : 22 mm, 36 mm 11. Install bolts (M20, Pitch 2.5 mm) to the holes where
plugs (7) have been removed.
(4 used). Disconnect hoses (3) (2 used). Remove 12. Turn the bolts and raise swing device (12) from main
O-rings (4) (2 used). frame (11). Hoist and remove swing device (12) from
main frame (11).
l : 8 mm
j : 30 mm
d CAUTION: Swing device (12) weight: 220 kg
8. Attach nylon slings onto the body of swing motor. fNOTE: THREEBOND #1102 has been applied to the
Hoist and hold swing device (12). main frame (11) mounting surface of swing device (12).
13. Remove knock pins (6) (2 used).
used). fNOTE: THREEBOND #1102 has been applied to knock
pin (6).
j : 30 mm
14. Remove the adapters from swing device (12) if
necessary.
WDBR50-EN-00(20171222) W3-10-1-2
10 10
1, 2, 3, 4
11
5, 13
10
12
7
WDBR-03-10-003
8, 9
WDAD-03-10-004
Installation
1. Install all removed adapters to swing device (12). 6. Install plugs (7) (2 used).
dCAUTION: Swing device (12) weight: 220 kg j : 30 mm

2. Apply THREEBOND #1102 to the main frame (11) 7. Install O-rings (4) (2 used). Connect hoses (3) (2
mounting surface of swing device (12). Attach nylon used) with flanges (2) (4 used) and socket bolts (1)
slings onto the body of swing motor. Hoist swing (8 used).
device (12).
l : 8 mm
3. Fit the positions of knock pin (6) holes (2 places).
Install swing device (12) to main frame (11). m : 50 N·m
4. Apply THREEBOND #1102 to knock pins (6) (2 used). 8. Connect hoses (10) (3 used).
Install knock pins (6) (2 used) to main frame (11).
j : 22 mm
5. Install swing device (12) with washers (13) (14 used)
and bolts (5) (14 used). m : 40 N·m
j : 30 mm j : 36 mm
m : 500 N·m m : 180 N·m
9. Connect connector (8). Install clip band (9).
WDBR50-EN-00(20171222) W3-10-1-3
a
1
WDBR-03-10-002
WDBR-03-16-001
a- Machine Front Side 3 2
10. Connect hoses (4) (4 used). Install clip band (5).
j : 36 mm
m : 180 N·m
1.)
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-10-1-4
Disassembly of Swing Reduction Gear
34
35
23
24
1
25
22
2
3
33
26
21 4
32
20
6
27 7
19
8
28
9
18
29 10
17
30 11
16
12
15
31 13
14
WDBR-03-10-004
1- Motor 10- Spring Pin (3 Used) 19- Thrust Plate 28- Oil Seal
2- First Stage Sun Gear 11- Needle Bearing (6 Used) 20- Second Stage Sun Gear 29- Sleeve
3- Thrust Plate 12- Planetary Gear (3 Used) 21- First Stage Carrier 30- O-Ring
4- Pin (3 Used) 13- Thrust Plate (3 Used) 22- Retaining Ring 31- Shaft
5- Spring Pin (3 Used) 14- Roller Bearing 23- Socket Bolt (8 Used) 32- Drain Plug
6- Needle Bearing (3 Used) 15- Bearing Nut 24- Socket Bolt (12 Used) 33- Pipe
7- Planetary Gear (3 Used) 16- Lock Plate 25- Ring Gear 34- Level Gauge
8- Thrust Plate (3 Used) 17- Bolt (2 Used) 26- Housing 35- Pipe
9- Pin (3 Used) 18- Second Stage Carrier 27- Roller Bearing
WDBR50-EN-00(20171222) W3-10-2-1
Disassembly of Swing Reduction Gear

2. Place swing device (a) onto special tool (ST 5097).
d CAUTION: Swing device (a) weight: 220 kg Secure swing device (a) to special tool (ST 5097)
1. Attach nylon slings onto swing device (a). Hoist with bolts (M20, Pitch 2.5 mm) (2 used). Secure
swing device (a). special tool (ST 5097) to a workbench in order to
receive the reaction force.
j : 30 mm
a
c
ST 5097
W178-02-11-134
a a- Swing Device
c- Stopper
3. Remove drain plug (32). Drain off oil from swing

device (a).
l : 8 mm

WDC150-03-10-005 4. Remove pipe (33) from housing (26).
a- Swing Device
j : 18 mm
5. Remove level gauge (34) from pipe (35). Remove
pipe (35) from motor (1).
j : 13 mm
6. Put the matching marks on the mating surfaces of
motor (1) and ring gear (25), and ring gear (25) and
housing (26).
WDBR50-EN-00(20171222) W3-10-2-2
dCAUTION: Motor (1) weight: 53 kg dCAUTION: Metal fragments may fly off when a
hammer is used. Wear necessary protection, such
7. Remove socket bolts (23) (8 used). Insert a
screwdriver into the gap around the jointed part. as goggles, hard hats, etc. in order to prevent
Hoist and remove motor (1) from ring gear (25). personal injury.
15. Install spring pin (5) mounted on the first stage
l : 10 mm carrier (21) assembly into pin (4) by using special
tool (ST 1462) and a hammer.
fNOTE: THREEBOND #1215 or LOCTITE #5020 has been
applied to the mating surface. 16. Remove pins (4) (3 used), planetary gears (7) (3
8. Remove retaining ring (22) from motor (1). used), needle bearings (6) (3 used), and thrust plates
(8) (3 used) from first stage carrier (21).
9. Remove first stage sun gear (2) from first stage
carrier (21). 17. Remove thrust plate (3) from first stage carrier (21).
10. Remove the first stage carrier (21) assembly from IMPORTANT: Do not damage the rotating surface for
ring gear (25). the needle bearing of pin (4).
11. Remove socket bolts (24) (12 used). dCAUTION: Metal fragments may fly off when a
l : 14 mm as goggles, hard hats, etc. in order to prevent
personal injury.
dCAUTION: Ring gear (25) weight: 22 kg
18. Secure pin (4) at opposite side of the spring pin (5)
12. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the hole in a vise. Remove spring pins (5) (3 used) by
motor (1) mounting thread part of ring gear (25). using special tool (ST 1462) and a hammer.
Insert a screwdriver into the gap around the jointed
part. Hoist and remove ring gear (25) from housing
(26).
dCAUTION: Metal fragments may fly off when a
as goggles, hard hats, etc. in order to prevent
fNOTE: THREEBOND #1215 or LOCTITE #5020 has been personal injury.
applied to the mating surface.
19. Disassemble the second stage carrier (18) assembly
13. Remove second stage sun gear (20) from second in the same way as the first stage carrier (21)
stage carrier (18). assembly. Remove planetary gears (12) (3 used),
14. Remove the second stage carrier (18) assembly from needle bearings (11) (6 used), and thrust plates (13)
shaft (31). (3 used). Remove spring pin (10) (3 used) by using
special tool (ST 1463) and a hammer.
20. Remove thrust plate (19) from second stage carrier
(18).
21. Remove bolts (17) (2 used). Remove lock plate (16)
from bearing nut (15).
j : 17 mm
WDBR50-EN-00(20171222) W3-10-2-3
22. Remove bearing nut (15) from shaft (31) by using

special tool (ST 2926). dCAUTION: If pushing shaft (31) by using press (c),
provide protection cover (b) (outer diameter: 358
mm, inner diameter: 90 mm, thickness: 25 to 30
15 mm). Push shaft (31) with protection cover (b) on
by using press (c). When housing (26) and/or roller
bearing (14) are broken and flown off without
protection cover (b), the metal fragments may
result in personal injury. Use press (c) with the
capacity less than 30 tons. Degrease the housing
(26) inside before heating roller bearing (14).
ST 2926 Failure to degrease may cause a fire. Heat it less
than 120°C.
W178-02-11-135
dCAUTION:
hot.
Take care as roller bearing (14) is too
25. Put protection cover (b) onto housing (26) and

remove shaft (31) by using press (c). The inner race
dCAUTION:
110 kg
The housing (26) assembly weight:
of roller bearing (27) and sleeve (29) are removed
with shaft (31) together.
bolt (24) hole on housing (26). Remove the bolts 31 14
(M20, Pitch 2.5 mm) which secure housing (26)
and special tool (ST 5097). Hoist the housing (26) 26
assembly and remove special tool (ST 5097).
j : 30 mm
24. Set blocks (a) on a press. Set the housing (26) b
assembly on blocks (a).
26
W157-02-06-010
b- Protection Cover
a W1HH-02-06-012
a- Block
W1V7-02-06-002
b- Protection Cover
c- Press
WDBR50-EN-00(20171222) W3-10-2-4
26. Place special tool (ST 1460) onto the stepped part of
special tool (ST 1461). dCAUTION: Metal fragments may fly off when a
ST 1460 personal injury.
30. Insert a round bar to the oil passage in housing (26).
Remove outer race (a) of roller bearing (27) by using
ST 1461 a round bar and a hammer.
b
a
W178-02-11-137
dCAUTION: The shaft (31) assembly weight: 40 kg

W178-02-11-139
27. Insert the pinion gear of the shaft (31) assembly
into the tooth-hole of special tool (ST 1460). Set the a- Outer Race b- Round Bar Inserting Hole
pinion gear of shaft (31) to press (a).
a dCAUTION:
kg
31. Attach nylon slings onto the body of the housing

(26) assembly. Hoist and turn over the housing (26)
assembly.
31 32. Insert a screwdriver into the notch of housing (26)
where oil seal (28) is installed. Remove oil seal (28)
from housing (26).
27
29
fNOTE: THREEBOND #1215 or LOCTITE #5020 has been
ST 1460 applied to the outer surface of oil seal (28). Oil seal (28)
cannot be reused.
ST 1461
personal injury.
W178-02-11-138 33. Remove the outer race of roller bearing (14) from
a- Press housing (26) by using a bar and a hammer.
28. Push the spline side of shaft (31) by using press (a).
Remove the inner race of roller bearing (27) and
sleeve (29).
29. Remove O-ring (30) from sleeve (29).
WDBR50-EN-00(20171222) W3-10-2-5
Assembly of Swing Reduction Gear
34
1 22
35 4
2
5
3
23
21
6
20 7
18
8
25
19 10
24 12
17 11
16 13
9
15
33
14
27
26
28 32
30
29
31
WDBR-03-10-005
1- Motor 10- Spring Pin (3 Used) 19- Thrust Plate 28- Oil Seal
2- First Stage Sun Gear 11- Needle Bearing (6 Used) 20- Second Stage Sun Gear 29- Sleeve
3- Thrust Plate 12- Planetary Gear (3 Used) 21- First Stage Carrier 30- O-Ring
4- Pin (3 Used) 13- Thrust Plate (3 Used) 22- Retaining Ring 31- Shaft
5- Spring Pin (3 Used) 14- Roller Bearing 23- Socket Bolt (8 Used) 32- Drain Plug
6- Needle Bearing (3 Used) 15- Bearing Nut 24- Socket Bolt (12 Used) 33- Pipe
7- Planetary Gear (3 Used) 16- Lock Plate 25- Ring Gear 34- Level Gauge
8- Thrust Plate (3 Used) 17- Bolt (2 Used) 26- Housing 35- Pipe
9- Pin (3 Used) 18- Second Stage Carrier 27- Roller Bearing
WDBR50-EN-00(20171222) W3-10-2-6
Assembly of Swing Reduction Gear

IMPORTANT: Before assembling, apply gear oil to dCAUTION: Metal fragments may fly off when
parts in order to prevent them from seizing.
such as goggles, hard hat, etc. in order to prevent
1. Install O-ring (30) to sleeve (29).
personal injury.
dCAUTION: The shaft (31) assembly weight: 40 kg 4. Evenly tap and install the outer race of roller bearing
(27) to housing (26) by using a bar and a hammer.
2. Install sleeve (29) and the inner race of roller
bearing (27) to shaft (31) by using special tool (ST Tap and listen to ring in order to check if the
4149) and press (a). installation is completed.
fNOTE: The press-in distance of the inner race can be dCAUTION: Metal fragments may fly off when
assured by using special tool (ST4149).
personal injury.
5. Apply THREEBOND #1215 or LOCTITE #5020 to the
outer surface of oil seal (28). Place oil seal (28) flat
a
onto housing (26) and push it by hand. Place special
tool (ST 2925) onto oil seal (28). Hit-in the special
tool (ST 2925) straight by using a hammer.
ST 4149
27 ST 2925
29
28
31 26
W178-02-06-013
W178-02-11-144
a- Press
6. Apply grease to the inner circumference of oil seal

(28). Apply grease to the outer circumference of
dCAUTION: Housing (26) weight: 58 kg
sleeve (29) which is installed in shaft (31). Apply
3. Attach nylon slings onto the body of housing (26). grease carefully in order to prevent the lip from
Hoist and place housing (26) with the sleeve (29) curling when installing shaft (31).
mounting side up.
WDBR50-EN-00(20171222) W3-10-2-7
11. Tighten bearing nut (15) to shaft (31) by hand in

d CAUTION: The housing (26) assembly weight:
62 kg
order to prevent shaft (31) from falling off.
7. Attach nylon slings onto the body of the housing dCAUTION:

110 kg
(26) assembly. Hoist and place the housing (26)
assembly with the ring gear (25) side up. 12. Install eyebolts (M16, Pitch 2.0 mm) to the ring gear
(25) mounting holes of housing (26). Hoist and set
housing (26) onto the press.
as goggles, hard hats, etc. in order to prevent 13. Remove bearing nut (15) from shaft (31).
personal injury. 14. Place special tool (ST 2924) onto the inner race of
8. Install the outer race of roller bearing (14) to roller bearing (14). Install the inner race by using the
housing (26) by using a bar and a hammer. Tap and press.
listen to ring in order to check if the installation is
completed. fNOTE: The press-in distance of the inner race can be
assured by using special tool (ST 2924).
dCAUTION:
64 kg

bolt (24) hole on housing (26). Hoist housing (26). ST 2924
Slowly lower and install housing (26) onto shaft (31). 14
Adjust the position in order to prevent the lip of oil
seal (28) from curling.

personal injury.
10. Install the inner race of roller bearing (14) to shaft
W178-02-11-145
(31) by using a bar and a hammer. Tap the inner race
until the upper surface of the inner race reaches two
threads of bearing nut (15) on shaft (31).
fNOTE: The fitting between the inner race and shaft (31)
is tight.
WDBR50-EN-00(20171222) W3-10-2-8
18. Remove the bolts (M20, Pitch 2.5 mm) (2 used)

d CAUTION: The housing (26) assembly weight:
110 kg
which secure housing (26) and special tool (ST
5097).
IMPORTANT: Check that the flange surface of
housing (26) does not come in contact with special j : 30 mm
tool (ST 5097). 19. Turn housing (26) both clockwise and
15. Hoist and place the housing (26) assembly onto counterclockwise by 5 turns. Tap housing (26) by
special tool (ST 5097). Install the housing (26) using a plastic hammer several times.
assembly to special tool (ST 5097) with the bolts
20. Install housing (26) to special tool (ST 5097) with the
(M20, Pitch 2.5 mm) (2 used). Secure special tool
bolts (M20, Pitch 2.5 mm) (2 used).
(ST 5097) to a workbench in order to receive the
reaction force. j : 30 mm
j : 30 mm 21. Tighten bearing nut (15) by using special tool (ST
26 2926).
m : 500 N·m
a 22. Repeat step 18 to step 21 two to three times and
ST 5097
bearing nut (15) and bearings of roller bearings (14,
27) can fit.
23. Remove the bolts (M20, Pitch 2.5 mm) (2 used)
which secure housing (26) and special tool (ST
W178-02-11-134 5097).
a- Stopper
j : 30 mm
IMPORTANT: Check the direction to install bearing dCAUTION:

110 kg
nut (15).
24. Hoist and place the housing (26) assembly onto
16. Apply grease to the thread part of bearing nut
a flat stand. When the housing (26) assembly is
(15). Place it onto shaft (31). At this time, face the
placed, check that the contacting position of oil seal
stepped end side of bearing nut (15) to the roller
(28) on the sleeve (29) outer circumference does not
bearing (14) side.
move up and down. In case the contacting position
17. Tighten bearing nut (15) by using special tool (ST of oil seal (28) moves up and down, bearing nut (15)
2926). is tightened insufficiently. Repeat step 17 to step 23
again.
m : 500 N·m
25. Install housing (26) to special tool (ST 5097) with the
15 bolts (M20, Pitch 2.5 mm) (2 used).
j : 30 mm
ST 2926
W178-02-11-146
WDBR50-EN-00(20171222) W3-10-2-9
26. Fit the spline part of lock plate (16) to that of shaft IMPORTANT: Check the position to install thrust
(31). Tighten bearing nut (15) further until the bolt plate (13).
(17) hole of bearing nut (15) fits to that of lock plate 33. Install planetary gears (12) (2 used), needle bearings
(16). (11) (4 used), thrust plates (13) (2 used), pins (9) (2
27. Remove the bolts (M20, Pitch 2.5 mm) (2 used) used), and spring pins (10) (2 used) to second stage
which secure housing (26) and the special tool (ST carrier (18) in the same way as step 30 to step 32.
5097). IMPORTANT: Check the direction to install thrust
plate (3).
j : 30 mm
34. Install thrust plate (3) to the first stage carrier (21)
28. Apply LOCTITE #263 or equivalent to bolts (17) (2 assembly with the oil groove side facing to the
used). Install lock plate (16) to bearing nut (15) with upper side.
35. Install needle bearing (6) to planetary gear (7).
j : 17 mm Install thrust plate (8) and the planetary gear (7)
assembly to first stage carrier (21). Install thrust
m : 50 N·m plates (8) to the housing (26) side of needle bearing
IMPORTANT: Check the direction to install thrust (6).
plate (19). 36. Install pin (4) to the position where planetary gear
29. Install thrust plate (19) to second stage carrier (18) (7) of first stage carrier (21) has been installed with
with the oil groove side facing to the upper side. the spring pin hole facing to the near side. The
30. Install needle bearings (11) (2 used) to planetary spring pin holes of both first stage carrier (21) and
gear (12). Install thrust plate (13) and the planetary pin (4) should be in line.
gear (12) assembly to second stage carrier (18). IMPORTANT: Check the direction of spring pin (5).
Install thrust plates (13) to the housing (26) side of
needle bearing (11). dCAUTION: Metal fragments may fly off when
31. Install pin (9) to the position where planetary gear such as goggles, hard hat, etc. in order to prevent
(12) of second stage carrier (18) has been installed personal injury.
with the spring pin hole facing to the near side. The 37. Install spring pin (5) to first stage carrier (21) by
spring pin holes of both second stage carrier (18) using a hammer with slit (a) of spring pin (5) facing
and pin (9) should be in line. to end surface (c) of pin (4).
IMPORTANT: Check the direction of spring pin (10).
5
a hammer is used. Wear necessary protection, 4
such as goggles, hard hat, etc. in order to prevent c
personal injury. a
32. Install spring pin (10) to second stage carrier (18) by
using a hammer with slit (a) of spring pin (10) facing W178-02-11-147
to end (c) of pin (9). a- Slit c- End Surface
10
9
c
a
W178-02-11-147
a- Slit c- End Surface
WDBR50-EN-00(20171222) W3-10-2-10
IMPORTANT: Check the position to install thrust IMPORTANT: Check the direction to install first stage
plate (8). sun gear (2).
38. Install planetary gears (7) (2 used), needle bearings 44. Install first stage sun gear (2) to the first stage carrier
(6) (2 used), thrust plates (8) (2 used), pins (4) (2 (21) assembly with the stepped side down.
used), and spring pins (5) (2 used) to first stage
45. Install a seal tape onto the thread part of pipe (33).
carrier (21) in the same way as step 35 to step 37.
Install pipe (33) to housing (26). Face pipe (33)
39. Fit the spline parts and install the second stage down.
carrier (18) assembly to shaft (31).
j : 18 mm
40. Install second stage sun gear (20) to the second
stage carrier (18) assembly with the small diameter m : 50 N·m
side up.
46. Install a seal tape onto drain plug (32). Install drain
41. Apply THREEBOND #1215 or LOCTITE #5020 to the plug (32) to pipe (33).
ring gear (25) mounting surface of housing (26).
l : 8 mm
d CAUTION: Ring gear (25) weight: 22 kg
m : 35 N·m
motor (1) mounting thread part of ring gear (25). 47. Fill ring gear (25) with gear oil to the center of first
Hoist ring gear (25). Fit the matching marks. Install sun gear (2).
ring gear (25) to housing (26) with socket bolts (24) Amount of oil: 6.9 L
(12 used).
48. Install retaining ring (22) to motor (1).
l : 14 mm
49. Apply THREEBOND #1215 or LOCTITE #5020 to the
m : 210 N·m motor (1) mounting surface of ring gear (25).
43. Fit the spline parts and install the first stage carrier
(21) assembly to second stage sun gear (20).
WDBR50-EN-00(20171222) W3-10-2-11
dCAUTION: Motor (1) weight: 53 kg

motor (1). Hoist motor (1). Fit the matching marks.
Install motor (1) to ring gear (25) with socket bolts
(23) (8 used).
l : 10 mm
m : 90 N·m
WDC150-03-10-007
a- Eyebolt Mounting Position
51. Install a seal tape onto the thread part of pipe (35).
Install pipe (35) to motor (1). Install level gauge (34)
to pipe (35).
j : 13 mm
WDBR50-EN-00(20171222) W3-10-2-12
Disassembly of Swing Motor
33
24 29
25
26
27
31
30
23
27
22 26
25
24
21
28
32 19
18
17
11
20
9
8
6 7
10
5
3
2
12
13
14
15
16 WDAA-03-11-011
1- Casing 10- Plate (4 Used) 19- Brake Piston 28- Valve Casing
2- Oil Seal 11- Friction Plate (3 Used) 20- Spring (24 Used) 29- Socket Bolt (4 Used)
3- Bearing 12- O-Ring 21- Valve Plate 30- O-Ring (2 Used)
4- Shaft 13- Piston 22- Bearing 31- Plug (2 Used)
5- Shoe Plate 14- Spring 23- O-Ring 32- Relief Valve (2 Used)
6- Plunger (9 Used) 15- Ball 24- Plug (2 Used) 33- Combination Valve (2 Used)
7- Plate 16- Plug (2 Used) 25- O-Ring (2 Used)
8- Retainer 17- O-Ring 26- Spring (2 Used)
9- Rotor 18- O-Ring 27- Poppet (2 Used)
WDBR50-EN-00(20171222) W3-10-3-1
Disassembly of Swing Motor

IMPORTANT: Do not damage the mating surfaces
d CAUTION: The swing motor assembly weight: 53
kg
when separating valve plate (21) from valve
casing (28) or rotor (9) by using a screwdriver.
IMPORTANT: As the setting changes, do not 8. If valve plate (21) is still attached on rotor (9) in step
disassemble combination valves (33) (2 used). 7, remove valve plate (21) from the rotor (9) side.
1. Remove combination valves (33) (2 used) from valve Remove springs (20) (24 used).
casing (28).
9. Put the matching marks on casing (1) and brake
j : 24 mm piston (19). Attach a claw of the special tool (ST
1468) onto the brake piston (19) groove by using
IMPORTANT: Do not disassemble relief valve (32). the special tool (ST 1468). Raise and remove brake
2. Remove relief valves (32) (2 used) from valve casing piston (19) straight.
(28).
j : 41 mm
ST 1468
3. Remove plug (24) from valve casing (28). Remove
O-ring (25) from plug (24). 19
l : 14 mm
4. Remove spring (26) and poppet (27) from valve
casing (28).
5. Remove another poppet (27) in the same way as
step 3 to step 4.
W1HH-02-06-006
6. Put the matching marks at the jointed surface
between valve casing (28) and casing (1). Remove
socket bolts (29) (4 used). Record the clearance 10. Remove O-rings (17, 18) from casing (1).
between valve casing (28) and casing (1).
l : 17 mm
IMPORTANT: Do not remove bearing (22) unless
necessary.
7. Remove valve casing (28) from casing (1). As valve
plate (21) may be removed with valve casing (28)
together, do not drop valve plate (21). Remove
O-ring (23).
WDBR50-EN-00(20171222) W3-10-3-2
IMPORTANT: Do not damage the sliding surfaces of IMPORTANT: The filter and orifice are installed inside
rotor (9) and plunger (6). piston (13). Do not disassemble piston (13) unless
11. Place casing (1) horizontally. Remove rotor (9), they are clogged or deformed. If the inner parts of
retainer (8), plate (7), and plungers (6) (9 used) from piston (13) are replaced, replace piston (13) as an
shaft (4). assembly.
18. Remove piston (13) from casing (1) by using a pair
12. Remove plates (10) (4 used) and friction plates (11)
of pliers.
(3 used) from casing (1).
19. Remove spring (14) and ball (15) from casing (1).
IMPORTANT: Do not damage the sliding surface of
shoe plate (5). 20. Remove plugs (16) (2 used) from casing (1).
13. Remove shoe plate (5) from casing (1).
l : 6 mm
14. Tap and remove shaft (4) from casing (1) by using a
plastic hammer.
15. Remove oil seal (2) from casing (1).

such as goggles, helmets, etc in order to prevent
personal injury.
16. Remove the outer race of bearing (3) from casing (1)
by using a bar and a hammer.
17. Remove the inner race of bearing (3) from shaft (4)
by using a press.
WDBR50-EN-00(20171222) W3-10-3-3
Assembly of Swing Motor

27 26 25 24
12
13
14
15
16
32
29
WDAA-03-11-009 WDAA-03-11-010
31 30
33 28
22
23
20
21 19
18 9
11
17
6
10
8
1
4 2 3 5 7
TDAA-03-02-003
1- Casing 10- Plate (4 Used) 19- Brake Piston 28- Valve Casing
2- Oil Seal 11- Friction Plate (3 Used) 20- Spring (24 Used) 29- Socket Bolt (4 Used)
3- Bearing 12- O-Ring 21- Valve Plate 30- O-Ring (2 Used)
4- Shaft 13- Piston 22- Bearing 31- Plug (2 Used)
5- Shoe Plate 14- Spring 23- O-Ring 32- Relief Valve (2 Used)
6- Plunger (9 Used) 15- Ball 24- Plug (2 Used) 33- Combination Valve (2 Used)
7- Plate 16- Plug (2 Used) 25- O-Ring (2 Used)
8- Retainer 17- O-Ring 26- Spring (2 Used)
9- Rotor 18- O-Ring 27- Poppet (2 Used)
WDBR50-EN-00(20171222) W3-10-3-4
Assembly of Swing Motor

8. Place casing (1) horizontally. Install the rotor (9)
assembly to shaft (4).
1. Install the inner race of bearings (3, 22) to shaft (4) IMPORTANT: There are four notches on the outer
by using a press. Install the inner race of bearing (3) side of plate (10). There are four notches on the
with the flange part facing to the stepped part of spline teeth side of friction plate (11).
shaft (4). 9. Place casing (1) vertically. Alternately install plates
(10) (4 used) and friction plates (11) (3 used) in order
2. Install oil seal (2) to casing (1) by using a plate with
to align each notch at the same place.
the lip part up.
10. Install O-rings (17, 18) to casing (1).
a hammer is used. Wear necessary protection, 11. Fit the matching marks and install brake piston (19)
such as goggles, helmets, etc in order to prevent to casing (1).
personal injury.
3. Install the outer race of bearing (3) to casing (1) by
fNOTE: If it is not easy to install brake piston (19) due to
the resistant force from O-rings (17, 18), evenly tap brake
using a bar and a hammer. piston (19) by using a plastic hammer.
4. Install a tape onto the spline at the end of shaft (4) 12. Install springs (20) (24 used) to brake piston (19).
in order not to damage oil seal (2). Place casing (1)
horizontally. Install shaft (4) to casing (1).
5. Place casing (1) vertically with the valve casing (28)
mounting side up. Install shoe plate (5) to casing (1)
with the chamfered surface facing inside.
6. Fit the notches on plate (7) and retainer (8). Install
plungers (6) (9 used). Install retainer (8) to plunger
(6) with the notch facing to the shoe plate (5) side.
7. Apply hydraulic oil onto the plunger hole on rotor
(9). Install the plunger (6) assembly into rotor (9).
WDBR50-EN-00(20171222) W3-10-3-5
IMPORTANT: If the inner parts of piston (13) are 18. Install valve casing (28) to casing (1) with socket
replaced, replace piston (13) as an assembly. bolts (29) (4 used).
13. Install ball (15), spring (14), and piston (13) to casing
l : 17 mm
(1) in order to fit the end of piston (13) to that of
casing (1). ml : 440 N·m
14. Tap and install the outer race, the bearing type 19. Install poppet (27) and spring (26) to valve casing
indicated surface of bearing (22) to valve casing (28) (28). Install O-ring (25) to plug (24). Install plug (24)
by using a plastic hammer. to valve casing (28).
IMPORTANT: Check the surfaces of valve plate (21).
l : 14 mm
15. Install O-ring (23) to valve casing (28). Install valve
plate (21) to valve casing (28) with the notch in the m : 340 N·m
port facing to rotor (9). 20. Install another poppet (27) in the same way as step
Apply grease onto valve plate (21) in order to 19.
prevent from falling off from valve casing (28). 21. Install relief valves (32) (2 used) to valve casing (28).
16. Apply grease onto the needle part of bearing (22) in
order to install shaft (4) to bearing (22) easily. j : 41 mm
17. FIt the matching marks on valve casing (28) and m : 180 N·m
casing (1). Place valve casing (28) onto casing (1). 22. Install combination valves (33) (2 used) to valve
Check that a clearance between valve casing (28) casing (28).
and casing (1) is equal to that before disassembling.
If the clearance is larger than that before j : 24 mm
disassembling, repeat the procedures from step 5.
m : 70 N·m
WDBR50-EN-00(20171222) W3-10-3-6
Removal and Installation of Pilot Valve (Left)

2
3
4
6, 7, 8
1 WDAA-03-01-023
WDDQ50-03-11-001
IMPORTANT: The hoses and pipes contain hydraulic 4. Remove bolt (6), spring washer (7), and washers (8)
oil. When removing the hoses and pipes, receive (2 used).
j : 5/8 in
clips after connecting the hoses. l : 6 mm
Removal

2. Open door (1).
WDBR50-EN-00(20171222) W3-11-1-1
5
6, 7
8
WDCX-03-01-006
l : 8 mm
used). Move the left console (5) assembly inward.
l : 8 mm
WDBR50-EN-00(20171222) W3-11-1-2
Detail B
14
13
24 14
21 23 22
15
B
17
10
16
9 WDAA-03-12-002
11
36
12
WDDQ50-03-11-003
C 20 17, 37 18 19
8. Remove screws (34) (3 used). Remove cover (35). Detail C

9 34
used). Remove lever (9).
l : 6 mm
10. Put matching marks on console (36) and armrest
(12) for assembling. Remove socket bolts (10) (2
used) and washers (11) (2 used). Remove armrest
(12).
l : 6 mm
35
11. Raise boot (13) and remove screws (14) (3 used).
12. Raise cover (15). Disconnect connector (16). Remove WDDQ50-03-11-004
cover (15). 7 8
13. Remove screws (17) (2 used), bolt, washer (18), and

washers (19, 37). Remove cover (20).
j : 10 mm
14. Remove screws (21, 22) (2 used for each). Remove
cover (23).
WDBR50-EN-00(20171222) W3-11-1-3
40
27
26
25
39
WDDQ50-03-11-017
24 WDDQ50-03-11-005
30, 31
16. Remove clip bands (24, 25, 39) and clip bands (40) (3
used).
17. Loosen lock nut (26). Remove the lever (27)
assembly.
j : 19 mm
j : 19 mm
(4 used). Remove pilot valve (29) and boot (32).
l : 6 mm
20. Remove the adapters with pilot valve (29) attached
if necessary.
WDAA-03-12-019
29 28 32
WDBR50-EN-00(20171222) W3-11-1-4
30, 31
WDAA-03-12-019
29 28 32
Installation
1. Install all removed adapters to pilot valve (29).
2. Install pilot valve (29) and boot (32) with washers
l : 6 mm
m : 20 N·m
j : 19 mm
m : 30 N·m
WDBR50-EN-00(20171222) W3-11-1-5
27
c
a
26
25
39 e d WDDQ50-03-11-006
b- Machine Front Side d- Wire harness length from

c- Wire harness length from position (c): 150 mm
position (a): 35 mm
24 WDDQ50-03-11-005
40
IMPORTANT: If the lever (27) assembly has been

disassembled, perform step 24 to step 26.
4. Adjust the grip mounting position at the right and
left sides so that the installation error is less than 33
10 mm. Install the lever (27) assembly with lock nut
(26).
j : 19 mm
m : 40 N·m
WDDQ50-03-11-017
IMPORTANT: Check the direction to install the wire
harness. View e
f
6. Install clip bands (39, 25, 24) and clip bands (40) (3
used) as illustrated. g
f- Less than 10 mm
g- Less than 10 mm WDDQ50-03-11-008
WDBR50-EN-00(20171222) W3-11-1-6
Detail A
WDDQ50-03-11-004
A WDDQ50-03-11-003
7. Temporarily install lever (1) with washers (2) (2 used)

l : 6 mm
1.)
used). Remove lever (1).
l : 6 mm
WDBR50-EN-00(20171222) W3-11-1-7
Detail B
14
13
24 14
21 23 22
15
B
17
10
16
9 WDAA-03-12-002
11
36
12
WDDQ50-03-11-003
C 20 17, 37 18 19
10. Install cover (23) with screws (22, 21) (2 used for Detail C 9 34
each).
11. Install cover (20) with washers (19, 37), bolt, washer
(18), and screws (17) (2 used).
j : 10 mm
m : 3.3 to 4.2 N·m

12. Fit the mounting position and place cover (15).
13. Raise cover (15). Connect connector (16).
35
14. Install cover (15) with screws (14) (3 used). Lower
boot (13).
15. Fit the matching marks on console (36) and armrest WDDQ50-03-11-004
7 8
(12). Install armrest (12) with washers (11) (2 used)
16. Install lever (9) with washers (8) (2 used) and socket
l : 6 mm
bolts (7) (2 used).
m : 20 N·m
l : 6 mm
m : 20 N·m
17. Install cover (35) with screws (34) (3 used).
WDBR50-EN-00(20171222) W3-11-1-8
5
6, 7
8
WDCX-03-01-006
18. Fully move the left console (5) assembly outward.

used).
l : 8 mm
m : 50 N·m
l : 8 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-11-1-9
3
4
6, 7, 8
1 WDAA-03-01-023
9 WDDQ50-03-11-001

20. Install seat (2) with socket bolts (3) (4 used) and
l : 6 mm
m : 20 N·m
j : 5/8 in
m : 50 N·m
23. Close door (1).
WDBR50-EN-00(20171222) W3-11-1-10
Installation of Lever Assembly
2
a
5
1
4
WDDQ50-03-11-009
c
3
a- 33 mm c- Pilot Valve Side
b- 25 mm
24. Install shaft (1) to lever (2) with lock nut (5). (except
the machine with AFL attached)
j : 19 mm
m : 30 N·m
25. Install shaft (1) to lever (2) with spring pin (6). (only
the machine with AFL attached) WDDQ50-03-11-010
26. Install the lever (2) assembly to pilot valve (3) with
lock nut (4).
Machine with AFL Attached
j : 19 mm 2
m : 40 N·m
WDDQ50-03-11-007
d- Machine Front Side
WDBR50-EN-00(20171222) W3-11-1-11
(Blank)
WDBR50-EN-00(20171222) W3-11-1-12
Removal and Installation of Pilot Valve

(Right)
2
3
4
6, 7, 8
1 WDAA-03-01-023
WDDQ50-03-11-001
IMPORTANT: The hoses and pipes contain hydraulic 4. Remove bolt (6), spring washer (7), and washers (8)
oil. When removing the hoses and pipes, receive (2 used).
j : 5/8 in
clips after connecting the hoses. l : 6 mm
Removal

2. Open door (1).
WDBR50-EN-00(20171222) W3-11-2-1
3, 4
WDCX-03-01-005
l : 8 mm
used). Move the right console (1) assembly inward.
l : 8 mm
WDBR50-EN-00(20171222) W3-11-2-2
Detail A
14
13
15 11
10 12
16
31
WDAA-03-12-006
9 11
7 8
WDAA-03-12-005
8. Put matching marks on console (31) and armrest

(9) for assembling. Remove socket bolts (7) (2 used)
and washers (8) (2 used). Remove armrest (9).
l : 6 mm
9. Remove tray (10). Remove screws (11) (3 used).
10. Raise cover (12). Disconnect connectors (13) (2
used). Remove cover (12).
11. Raise boot (14). Remove screws (15) (2 used).
Remove cover (16).
WDBR50-EN-00(20171222) W3-11-2-3
1
Detail A
1 2 1 WDAA-03-01-054
WDAA-03-01-063
12. Remove clip (2).

14. Remove clips (3) (3 used).
3 WDDQ50-03-11-014
WDBR50-EN-00(20171222) W3-11-2-4
WDDQ50-03-11-015
15. Remove screws (2) (2 used) and screw (3). Remove

the switch box (1) assembly.
WDBR50-EN-00(20171222) W3-11-2-5
24 18 17
20
19
23 24
24
WDDQ50-03-11-016
25 24
WDDQ50-03-11-002
32 24 31 24
16. Remove screws (24) (6 used), screw (31), and washer

(25). Remove covers (23, 32).
17. Remove clip bands (17, 18).
18. Loosen lock nut (19). Remove the lever (20)
assembly.
j : 19 mm
WDBR50-EN-00(20171222) W3-11-2-6
A Detail A
28, 29
30
WDAA-03-12-008
26
27 26 WDAA-03-12-020
j : 19 mm
(4 used). Remove pilot valve (27) and boot (30).
l : 6 mm
21. Remove the adapters with pilot valve (27) attached
if necessary.
WDBR50-EN-00(20171222) W3-11-2-7
Detail A
A 28, 29
30
WDAA-03-12-008
26
27 26 WDAA-03-12-020
Installation
2. Install pilot valve (27) and boot (30) with washers
l : 6 mm
m : 20 N·m
j : 19 mm
m : 30 N·m
WDBR50-EN-00(20171222) W3-11-2-8
20
a
17
19 b
e- Less than 10 mm WDDQ50-03-11-008

d
f- Less than 10 mm
18 c WDDQ50-03-11-011
b- Wire harness length from d- Machine Front Side

position (a): 35 mm
c- Wire harness length from
position (b): 150 mm
IMPORTANT: If the lever (20) assembly has been

disassembled, perform step 24 to step 26.
4. Adjust the grip mounting position at the right and
left sides so that the installation error is less than
10 mm. Install the lever (20) assembly with lock nut
(19).
j : 19 mm
m : 45 N·m
IMPORTANT: Check the direction to install the wire
harness.
5. Install clip bands (18, 17) as illustrated.
WDBR50-EN-00(20171222) W3-11-2-9
24
1
23 24
24
2
WDDQ50-03-11-015
25 24
WDDQ50-03-11-002
32 24 31 24
6. Install covers (23, 32) with washer (25), screws (24)

(6 used), and screw (31).
7. Install the switch box (1) assembly with screws (2) (2
used) and screw (3).
WDBR50-EN-00(20171222) W3-11-2-10
1
Detail A
1 2 1 WDAA-03-01-054
WDAA-03-01-063

9. Install clip (2).
10. Install clips (3) (3 used).
3 WDDQ50-03-11-014
WDBR50-EN-00(20171222) W3-11-2-11
Detail A
14
13
15 11
10 12
16
31
WDAA-03-12-006
9 11
7 8
WDAA-03-12-005

1.)
12. Install cover (16) with screws (15) (2 used).
13. Fit the mounting position and place cover (12).
14. Raise cover (12). Connect connectors (13) (2 used).
15. Install boot (14).
16. Install cover (12) with screws (11) (3 used). Install
tray (10).
17. Fit the matching marks on console (31) and armrest
(9). Install armrest (9) with washers (8) (2 used) and
l : 6 mm
m : 20 N·m
WDBR50-EN-00(20171222) W3-11-2-12
3, 4
WDCX-03-01-005
18. Fully move the right console (1) assembly outward.

used).
l : 8 mm
m : 50 N·m
l : 8 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-11-2-13
3
4
6, 7, 8
1 WDAA-03-01-023
9 WDDQ50-03-11-001

20. Install seat (2) with socket bolts (3) (4 used) and
l : 6 mm
m : 20 N·m
j : 5/8 in
m : 50 N·m
23. Close door (1).
WDBR50-EN-00(20171222) W3-11-2-14
Installation of Lever Assembly
2
a
5
1
4
WDDQ50-03-11-009
c
a- 33 mm c- Pilot Valve Side
b- 25 mm 3
24. Install shaft (1) to lever (2) with lock nut (5). (except
the machine with AFL attached)
j : 19 mm
m : 30 N·m
25. Install shaft (1) to lever (2) with spring pin (6). (only
the machine with AFL attached) WDDQ50-03-11-010
26. Install the lever (2) assembly to pilot valve (3) with
lock nut (4).
Machine with AFL Attached
j : 19 mm 2
m : 40 N·m
6
d
WDDQ50-03-11-012
d- Machine Front Side
WDBR50-EN-00(20171222) W3-11-2-15
(Blank)
WDBR50-EN-00(20171222) W3-11-2-16
Removal and Installation of Travel Pilot Valve

5
1
3 2 WDBE-03-12-005 WDC150-03-11-002
IMPORTANT: The hoses and pipes contain hydraulic 5. Disconnect hoses (5) (4 used).
IMPORTANT: Cap the open ends in case the hoses 6. Disconnect pipes (6) (2 used).
attach identification tags onto the connectors, j : 17 mm
Removal
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-5-1.)

2. Open door (1).
3. Remove the floor mat.

not drop cover (3).
(3).
j : 17 mm
WDBR50-EN-00(20171222) W3-11-3-1
9
8
4
10, 11
7
WDC150-03-11-003 WDC150-03-11-004
7. Remove bolts, washers (7) (4 used). Remove levers

(8) (2 used) and pedals (9) (2 used).
j : 17 mm
(2 used). Remove pilot valve (4).
l : 8 mm
9. Remove the adapters with pilot valve (4) attached if
necessary.
WDBR50-EN-00(20171222) W3-11-3-2
9
8
4
10, 11
7
WDC150-03-11-004 WDC150-03-11-003
Installation
2. Install pilot valve (4) with washers (11) (2 used) and
l : 8 mm
m : 50 N·m
3. Install pedals (9) (2 used) and levers (8) (2 used) with
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-11-3-3
5
1
WDC150-03-11-002 3 2 WDBE-03-12-005
4. Connect pipes (6) (2 used).
j : 17 mm
m : 25 N·m
j : 19 mm
m : 30 N·m
1.)
j : 17 mm
m : 50 N·m
8. Install the floor mat.
9. Close door (1).
WDBR50-EN-00(20171222) W3-11-3-4
Disassembly of Pilot Valves (Right and Left)
17
16
15
14
13
12
11
10
18
9
7
6 19
23
5 20
4 21
22
3
WDAA-03-12-021
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
WDBR50-EN-00(20171222) W3-11-4-1
Disassembly of Pilot Valves (Right and Left)

3. Attach a spanner onto the upper part of universal
IMPORTANT: Casing (18) is made of aluminium.
joint (15). Remove universal joint (15).
Strong force deforms it. Handle it with care.
IMPORTANT: Spool (19) has been selected to match j : 17 mm
the hole on casing (18). The dimensions of balance
springs (3, 4) and return springs (5, 6) as well as fNOTE: LOCTITE #263 or equivalent has been applied to
those of pushers (9, 10) are different. Arrange universal joint (15).
the disassembled parts together with the port in 4. Remove plate (14).
order not to confuse. The port number is stamped
IMPORTANT: Do not damage sleeve (12). Insert a soft
on the outer surface of casing (18).
rubber between sleeve (12) and a tool. Oil seal (11)
IMPORTANT: Do not remove screw joint (17) while cannot be removed from sleeve (12).
securing casing (18) in a vise. The strong torque
Sleeve (12) and oil seal (11) should be replaced as
may act on screw joint (17).
an assembly.
1. Secure screw joint (17) in a vise. Turn cam (16) by
5. Remove sleeves (12) (4 used) upward by using a pair
using a spanner. Remove screw joint (17).
of pliers. Remove O-rings (19) (4 used) from sleeves
j : 19 mm, 32 mm (12) (4 used).
IMPORTANT: The dimensions of pushers (9, 10) for
2. Secure the flat surface of casing (18) in a vise. ports (1, 3) and for ports (2, 4) are different. Keep
Remove cam (16) from universal joint (15). the disassembled parts together by the port
number in order not to confuse.
j : 32 mm 6. Remove pushers (9, 10) (2 used for each) from
casing (18).
WDBR50-EN-00(20171222) W3-11-4-2
7. When compressing the spring, do not lower spool IMPORTANT: The quantity of shims (2) have been
(19). Install special tool (ST 4145) to the port hole on determined for each port during the performance
casing (18) as illustrated. testing. Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2) to the original
l : 6 mm port when assembling.
9. Remove special tool (ST4146). Remove spring
guides (7) (4 used), return springs (5, 6) (2 used for
each), and balance springs (3, 4) (2 used for each)
from spools (19) (4 used).
18 10. Remove shim (2) and spacers (1) (4 used) from
spools (19) (4 used).
IMPORTANT: Spool (19) has been selected to match
the hole on casing (18). Spool (19) and casing (18)
should be replaced as an assembly.
11. Remove special tool (ST 4145) from casing (18).
Slowly turn and remove spools (19) (4 used) from
W178-02-07-048
ST 4145
casing (18).
IMPORTANT: Retaining ring (22) may come off while
8. Install special tool (ST 4146) to the pusher hole disassembling. Do not drop retaining ring (22)
on casing (18). Push special tool (ST 4146) and inside casing (18). If retaining ring (22) falls inside
compress the spring. Tighten special tool (ST 4146) casing (18), remove retaining ring (22) completely.
by using the socket bolt (M14, Pitch 2.0 mm). Retaining ring (22) cannot be reused.
Remove retaining rings (8) (4 used) from spools (19) 12. Remove retaining ring (22) from casing (18) by
(4 used) by using a screwdriver. using a screwdriver. Install a bolt (M8, Pitch 1.25
mm) to plug (21). Remove plug (21) from casing
l : 12 mm (18). Remove O-ring (20) from plug (21).
j : 13 mm
ST 4146
13. Remove filter (23) from casing (18).
j : 10 mm
18
W178-02-07-048
WDBR50-EN-00(20171222) W3-11-4-3
Assembly of Pilot Valves (Right and Left)
17
15
16
11
14 9, 10
13
12
8
7
3, 4
5, 6
2
1
21
20
23 18 19
22
WDAA-03-12-022
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
WDBR50-EN-00(20171222) W3-11-4-4
Assembly of Pilot Valves (Right and Left)

IMPORTANT: Refer to the table in the left in order to
assemble the parts correctly.
3. Install spacer (1), shim (2), and balance spring (3) to
IMPORTANT: The pilot valve is the susceptible
spool (19). Install return spring (5) to casing (18).
hydraulic component to contamination. Keep the
parts clean when assembling. 4. Install spring guide (7) to return spring (5) with the
protrusion up.
fNOTE: The table below shows the relations between 5. Install other spools (19) (3 used) in the same way as
step 1 to step 4.
each port and the parts. Do not confuse them when
assembling. 6. Install special tool (ST 4146) to the pusher (9, 10)
Spool Shim holes on casing (18). Push special tool (ST 4146) and
Port No. Pushers (9, 10) compress the spring. Tighten special tool (ST 4146)
(19) (2)
1 One outer groove by using a bolt (M14, Pitch 2.0 mm).
Two outer l : 12 mm
2
Same to the Same to the grooves
3 former one former one One outer groove ST 4146
Two outer
4
grooves
ST 4144
Return Springs Balance Springs
Port No.
(5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long
1. Check the port hole number and insert same spool

(19) before disassembling. Install the thinner end W178-02-07-049
of spool (19) into the port hole on casing (18) by ST 4145
turning slowly.
7. Install retaining ring (8) to ring holder (ST 4144).
fNOTE: Spool (19) has been selected to match the port
hole. Spool (19) and casing (18) should be replaced as an
assembly.
2. Install special tool (ST 4145) to the port hole on
casing (18) in order not to lower spool (19) when
the spring is compressed.
j : 6 mm
WDBR50-EN-00(20171222) W3-11-4-5
8. Install retaining ring (8) to the groove on the head IMPORTANT: Fit the bolt hole on plate (14) to the
of spool (19) extending from special tool (ST 4146). screw hole on casing (18).
IMPORTANT: Check the position to install pusher (9). 16. Apply LOCTITE #263 or equivalent onto the screw
part of universal joint (15). Place plate (14) on casing
9. Install pusher (9).
(18). Install universal joint (15).
After pushing pusher (9) several times by hand,
remove it. Check if retaining ring (8) comes off or j : 17 mm
balance spring (3) is located correctly.
Install pusher (9) to casing (18) after checking. m : 25 N·m
10. Install other pushers (9, 10) in the same way as step IMPORTANT: Check the tightness of cam (16).
8 to step 9. 17. Install cam (16) to universal joint (15). The clearance
11. Apply grease onto the ball part at the ends of between cam (16) and pushers (9, 10) (2 used for
pushers (9, 10) (2 used for each). each) should be 0 to 0.2 mm.
12. Apply grease onto the joint part of universal joint 18. Secure cam (16) by using a spanner. Tighten screw
(15). joint (17) by using a spanner.
13. Apply grease onto the inner surface of oil seals (11) j : 19 mm, 32 mm
(4 used).
m : 70 N·m
f NOTE: Sleeve (12) and oil seal (11) should be replaced
19. Install plug (23) to casing (18).
as an assembly.
14. Install oil seals (11) (4 used) to sleeves (12) (4 used). l : 10 mm
Push the sleeve (12) assemblies (4 used) by hand
until O-ring (13) is inserted into the hole on sleeves m : 20 N·m
(12) (4 used).
15. Secure casing (18) in a vise lightly.
WDBR50-EN-00(20171222) W3-11-4-6
Disassembly of Travel Pilot Valve
3
4
7 35
34
33
32
8 31
9
30
10 29
11
28
14
27
12
15 26
13
25
16
17 24
18
19 23
36
20
21 22
WDAA-03-12-024
1- Bolt, Washer (2 Used) 10- Spring Pin (2 Used) 19- O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (16 Used) 26- Spacer (4 Used) 35- Pin (2 Used)
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used) 36- Filter
WDBR50-EN-00(20171222) W3-11-5-1
Disassembly of Travel Pilot Valve

IMPORTANT: Casing (23) is made of aluminium.
the hole of casing (23). Spool (24) and casing (23)
Strong force deforms it. Handle it with care.
should be replaced as an assembly.
IMPORTANT: Put the mark on spools (24) (4 used)
the hole on casing (23).
when keeping in order to easily install spools (24)
Arrange the disassembled parts together with (4 used) to the original hole.
each port in order not to confuse.
5. Remove the spool (24) assembly from casing (23) by
The port number is stamped on the outer surface rotating.
of casing (23). Spring guide (17), balance spring (18), shims (27) (3
1. Secure casing (23) in a vise. Remove bolts, washers used), and spacer (26) are removed with spool (24)
(1) (2 used). Remove cover (2) from holder (7). together.
j : 10 mm IMPORTANT: The quantity of shims (27) have been
determined during the performance testing at the
2. Remove socket bolts (30) (2 used) and spring factory. When keeping, pair shim (27) with each
washers (29) (2 used). Remove the holder (7) spool.
assembly from casing (23).
6. Compress balance spring (18). Remove spring guide
l : 8 mm (17), balance spring (18), shims (27) (3 used), and
spacer (26) from spool (24).
3. Remove the pusher (16) assemblies (4 used) from
casing (23). 7. Remove spring (25) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) 8. Remove other spools (24) in the same way as step 5
(4 used). Remove oil seals (28) (4 used) and O-rings to step 7.
(14) (4 used) from bushings (15) (4 used) by using a
bamboo spatula.
WDBR50-EN-00(20171222) W3-11-5-2
11. Remove O-ring (33) from pin (35).

a hammer is used. Wear necessary protection, 12. Remove other bracket (11) in the same way as step
such as goggles, hard hats, etc in order to prevent 9 to step 11.
personal injury. 13. Place holder (7) with the casing (23) mounting
IMPORTANT: Place a stand under bracket (11) and surface up.
receive a reaction force. If holder (7) bears the
reaction force, strong force acts on pin (35). dCAUTION: Metal fragments may fly off when
Therefore, pin (35) may be deformed.
9. Place a stand under bracket (11). The inner surfaces
personal injury.
of the spring pins (12, 13) holes on bracket (11) are
stepped-shape. The spring pin can only be removed 14. The holes of spring pins (3, 4) (2 used for each) in
in one direction. Tap and remove spring pins (12, 13) cam (5) are stepped-shape. Tap the bottom of cam
from bracket (11) at the same time by using special (5) and remove spring pins (3, 4) (2 used for each)
tool (ST 1237). Remove bracket (11) from pin (35). from cams (5) (2 used) at the same time by using
Do not remove spring pin (10) with bracket (11) special tool (ST 1237).
attached unless necessary. The hole end of spring As the holes of spring pins (3, 4) (2 used for each)
pin (10) has been crimped. are crimped, spring pins (3, 4) may feel tight when
removing.
12, 13
11
35
10
W176-02-07-019
a- Crimped Position
b- Stand
10. Remove socket bolts (9) (2 used) and spring washers

(8) (2 used). Remove damper (32) and rubber seat
(31) from pin (35). O-ring (34) is removed together.
l : 5 mm
WDBR50-EN-00(20171222) W3-11-5-3

personal injury.
15. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary. If removing, remove
bushings (6) (4 used) by tapping by using special
tool (ST 7256).
16. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).
l : 5 mm
17. Remove plugs (21) (2 used) from casing (23).
Remove O-rings (22) (2 used) from plugs (21) (2
used).
l : 6 mm
WDBR50-EN-00(20171222) W3-11-5-4
Assembly of Travel Pilot Valve
11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30
29
34 15
9
33
8 17
28
18
14
25
27
16
26
24
23
36
WDAA-03-12-025
1- Bolt, Washer (2 Used) 10- Spring Pin (2 Used) 19- *O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- *Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- *Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- *O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (16 Used) 26- Spacer (4 Used) 35- Pin (2 Used)
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used) 36- Filter
fNOTE: As for the parts with mark *, refer to W3-11-5-1.
WDBR50-EN-00(20171222) W3-11-5-5
Assembly of Travel Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
IMPORTANT: The pilot valve is the susceptible
personal injury.
hydraulic component to contamination. Keep the
parts clean when assembling. fNOTE: Bushings (6) (4 used) are identical.
1. Install spacer (26), shims (27) (3 used), and balance  Install bushings (6) (4 used) into special tool (ST
spring (18) into spool (24) in sequence. Install shim 7256). Tap special tool (ST 7256) by using a hammer
(27) as the same condition before disassembling. and install bushing (6) to the end of hole on holder
(7). Stop tapping when the bushing (6) end is flush
IMPORTANT: Check the direction to install spring
with the hole end.
guide (17).
2. Compress balance spring (18) by hand. Install spring
guide (17) to spool (24) with the stepped part down. 7 ST 7256
IMPORTANT: Before inserting the parts into holder

(7) and casing (23), apply hydraulic oil.
3. Install spring (25) into casing (23).
6
4. Install the spool (24) assembly into the original W178-02-11-310
port before disassembling. Install the spool (24)
assembly into casing (23) by rotating.
5. Install oil seal (28) to bushing (15).
6. Apply grease onto the inner surface of oil seal (28).
7. Install O-ring (14) and pusher (16) to bushing (15).
8. Apply grease onto the head of pusher (16).
9. Install the pusher (16) assembly into casing (23).
10. Install other spools (24) in the same way as step 1 to
step 9.
11. When bushing (6) has been removed from holder
(7), install bushings (6) (4 used) to holder (7)
by using special tool (ST 7256) in the following
procedures.
WDBR50-EN-00(20171222) W3-11-5-6
 Install bushing (6) on the opposite side in the same 12. Install O-rings (33) (2 used) to pins (35) (2 used).
way. Apply grease onto O-rings (33) (2 used). Install pins
6 (35) (2 used) and cams (5) (2 used) to holder (7).
ST 7256 7
personal injury.
IMPORTANT: Check the direction to install spring
pins (3, 4).
W178-02-11-311
13. Install spring pins (3, 4) to cam (5) by using special
tool (ST 1237). Secure cam (5) and pin (35).At this
 Install bushing (6) in the near side as illustrated. Stop time, the slits (a) of spring pins (3, 4) should be
tapping when the bushing (6) end is flush with the positioned 90° away each other. Tap and install
outside of holder (7). spring pins (3, 4) until spring pins (3, 4) come in
contact with the stepped part in the hole.
6
7 ST 7256 3 a a
a
4 W178-02-07-050
W178-02-11-312
a- Slit
a- Outside of Holder
14. Crimp the hole end of cam (5) where spring pins (3,
 Install bushing (6) in the near and opposite side as 4) are inserted by using a punch.
illustrated.
15. Install other cam (5) in the same way as step 13 to
6 step 14.
ST 7256 7
W178-02-11-313
WDBR50-EN-00(20171222) W3-11-5-7
16. Place holder (7) on the casing (23) assembly. Install 21. As for the direction to install bracket (11), refer to
holder (7) to casing (23) with socket bolts (30) (2 the figure in Disassembly of Travel Pilot Valve on
used) and spring washers (29) (2 used). W3-11-5-1. Install bracket (11) to pin (35). Fit the
Check the mark direction and install holder (7). holes to insert spring pins (12, 13).
l : 8 mm IMPORTANT: Place a stand under bracket (11) and

receive a reaction force. If holder (7) bears the
m : 50 N·m reaction force, strong force acts on pin (35).
Therefore, pin (35) may be deformed.
17. Install rubber seats (31) (2 used) to pin (35).
22. Place a stand (b) under bracket (11). Install spring
IMPORTANT: Check the direction of damper (32). pins (12, 13) to bracket (11) until they come in
The inner surface of damper (32) is edged-shape. contact with the stepped part by using special tool
If damper (32) is pried when installing, O-ring (33) (ST 1237). The slits of spring pins (2 used) should be
may be damaged. positioned 90° away each other.
18. Install dampers (32) (2 used) to pin (35) with the
lever up. a a
19. Secure damper (32) and rubber seat (31) to holder
(7) with socket bolts (9) (4 used) and spring washers 11 35
(8) (4 used).
l : 5 mm
m : 7 N·m b
12, 13
20. Apply grease onto O-rings (34) (2 used). Install

O-rings (34) (2 used) to the end of pins (35) (2 used).
W176-02-07-011
a- Crimped Position
b- Stand
WDBR50-EN-00(20171222) W3-11-5-8
23. Crimp the hole edge of bracket (11) where spring

pins (12, 13) are inserted by using a punch.
24. Install other bracket (11) in the same way as step 22
to step 23.
25. Install cover (2) to holder (7) with bolts, washers (1)
(2 used).
j : 10 mm
m : 5 N·m
26. Apply grease onto the spring pin (10) contact part
of dampers (32) (2 used).
Install plugs (20) (2 used) to casing (23).
j : 5 mm
m : 10 N·m
Install plugs (21) (2 used) to casing (23).
j : 6 mm
m : 20 N·m
29. Install filter (36) to casing (23).
WDBR50-EN-00(20171222) W3-11-5-9
(Blank)
WDBR50-EN-00(20171222) W3-11-5-10
Removal and Installation of Pilot Shut-Off

Solenoid Valve
View A
1
7 8 4
6 WDC150-03-12-006
WDBE-03-12-005
3 2

oil. When removing the hoses and pipes, receive dCAUTION: Remove cover (3) while holding it. Do
not drop cover (3).
IMPORTANT: Cap the open ends in case the hoses 4. Remove bolts, washers (2) (7 used). Remove cover
and pipes have been disconnected. In addition, (3).
j : 17 mm
secure the hoses have been removed, install the 5. Remove connect (4) from bracket (8).
clips after connecting the hoses. Disconnect connector (4).
6. Disconnect the both ends of pipes (6, 7).
Removal
1. Swing the upperstructure by 90 degrees and set the j : 17 mm
(Refer to W1-5-1.)

2. Open door (1).
3. Remove the floor mat.
WDBR50-EN-00(20171222) W3-12-1-1
WDAA-03-13-007 WDAA-03-13-008
j : 19 mm
dCAUTION: Remove pilot shut-off solenoid valve

(5) while holding it. Do not drop pilot shut-off
solenoid valve (5).
8. Remove bolts, washers (9) (2 used). Remove pilot
shut-off solenoid valve (5).
j : 17 mm
9. Remove the adapters with pilot shut-off solenoid
valve (5) attached if necessary.
WDBR50-EN-00(20171222) W3-12-1-2
WDAA-03-13-007 WDAA-03-13-008
Installation
1. Install all removed adapters to pilot shut-off
solenoid valve (5).
2. Install pilot shut-off solenoid valve (5) with bolts,
j : 17 mm
m : 50 N·m
j : 19 mm
m : 30 N·m
WDBR50-EN-00(20171222) W3-12-1-3
View A
1
7 8 4
6 WDC150-03-12-006
WDBE-03-12-005
3 2
4. Connect the both ends of pipes (7, 6).
j : 17 mm
m : 25 N·m
5. Connect connector (4). Secure connect (4) to
bracket (8).
6. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
j : 17 mm
m : 50 N·m
8. Install the floor mat.
9. Close door (1).
WDBR50-EN-00(20171222) W3-12-1-4
Removal and Installation of 3-Spool Solenoid

Valve Unit
WDBR-03-16-001
3

Removal
dCAUTION: Release any pressure from the

hydraulic oil tank. (Refer to W1-5-1.)
(3).
j : 17 mm
WDBR50-EN-00(20171222) W3-12-2-1
1
a
6, 7
a
1 2 1
WDBR-03-12-004 WDBR-03-12-003
a- Machine Front Side a- Machine Front Side
4. Remove bolt, washer (6) and clamps (7) (2 used). 8. Remove socket bolts (4) (2 used). Remove 3-spool
solenoid valve unit (8) from control valve (5).
j : 13 mm
l : 8 mm
9. Remove the adapters from 3-spool solenoid valve
6. Disconnect the both ends of pipes (1) (6 used).
unit (8) if necessary.
j : 17 mm
7. Disconnect all hoses (2) (12 used) from 3-spool
solenoid valve unit (8).
j : 17 mm, 19 mm
WDBR50-EN-00(20171222) W3-12-2-2
6, 7
1 2 1
WDBR-03-12-004 WDBR-03-12-003
Installation
1. Install all removed adapters to 3-spool solenoid 4. Connect the both ends of pipes (1) (6 used).
valve unit (8).
j : 17 mm
2. Install 3-spool solenoid valve unit (8) to control
valve (5) with socket bolts (4) (2 used). m : 25 N·m
l : 8 mm 5. Connect connectors (3) (3 used).

6. Install clamps (7) (2 used) with bolt, washer (6).
m : 50 N·m
3. Connect hoses (2) (12 used) to 3-spool solenoid j : 13 mm
valve unit (8).
m : 10 N·m
j : 17 mm
m : 25 N·m
j : 19 mm
m : 30 N·m
WDBR50-EN-00(20171222) W3-12-2-3
WDBR-03-16-001
3

1.)
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-12-2-4
Removal and Installation of 2-Spool Solenoid

Valve Unit View A 1
WDBR-03-12-001
A WDBR-03-17-001

Removal
dCAUTION: Release any pressure from the

j : 17 mm, 19 mm
WDBR50-EN-00(20171222) W3-12-3-1
WDBR-03-12-006 WDBR-03-12-005
2
4. Remove bolts, washers (1) (2 used). Remove 2-spool

solenoid valve unit (2) from bracket (3).
j : 13 mm
5. Remove the adapters from 2-spool solenoid valve
unit (3) if necessary.
WDBR50-EN-00(20171222) W3-12-3-2
WDBR-03-12-006 WDBR-03-12-005
2
Installation
1. Install all removed adapters to 2-spool solenoid
valve unit (2).
2. Install 2-spool solenoid valve unit (2) to bracket (3)
with bolts, washers (1) (2 used).
j : 13 mm
m : 20 N·m
WDBR50-EN-00(20171222) W3-12-3-3
View A 1
WDBR-03-12-001
A WDBR-03-17-001
j : 17 mm
m : 25 N·m
j : 19 mm
m : 30 N·m
1.)
WDBR50-EN-00(20171222) W3-12-3-4
Disassembly of Pilot Shut-Off Solenoid Valve
WDAA-03-13-014
1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter
WDBR50-EN-00(20171222) W3-12-4-1
Disassembly of Pilot Shut-Off Solenoid Valve

IMPORTANT: Filter (9) cannot be removed.
1. Put the matching marks on body (4) and solenoid
(2). Secure body (4) in a vise. Remove socket bolts
(1) (2 used) from body (4). Remove solenoid (2) and
O-ring (3) from body (4).
l : 4 mm
2. Remove plug (8) from body (4). Remove O-ring (7)
from plug (8).
l : 6 mm
3. Remove spring (6) and spool (5) from body (4).
WDBR50-EN-00(20171222) W3-12-4-2
Assembly of Pilot Shut-Off Solenoid Valve
2
1
3
T1V1-03-07-012
1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter
WDBR50-EN-00(20171222) W3-12-4-3
Assembly of Pilot Shut-Off Solenoid Valve

to parts in order to prevent them from seizing.
1. Secure body (4) in a vise. Install spool (5) and spring
(6) to body (4).
2. Install O-ring (7) to plug (8). Install plug (8) to body
(4).
l : 6 mm
m : 27 N·m
IMPORTANT: When solenoid (2) is installed after
installing O-ring (3) to body (4), O-ring (3) may be
damaged.
3. Install O-ring (3) to solenoid (2). Fit the matching
marks and install solenoid (2) to body (4).
4. Install solenoid (2) to body (4) with socket bolts (1)
(2 used).
l : 4 mm
m : 4 N·m
WDBR50-EN-00(20171222) W3-12-4-4
Structure of 3-Spool Solenoid Valve Unit
4
3
WDCD-03-12-003
2
5 6 7 8 9 10
11
15 14 13 12
WDAA-03-13-013
WDBR50-EN-00(20171222) W3-12-5-1
Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m
1 Body 1
2 Orifice 3 l:6 10+30
3 Orifice 1 l : 10 20+50
4 Socket Bolt 8 l:4 5+20
5 Solenoid 3
6 Washer 1
7 Spring 1
8 Spool 1
9 Sleeve 1
10 Plate 1
11 Wave Spring 1
12 O-Ring 1
13 O-Ring 1
14 O-Ring 1
15 O-Ring 1
WDBR50-EN-00(20171222) W3-12-5-2
Structure of 2-Spool Solenoid Valve Unit
1 2
5 6
WDC150-03-12-005
9 8 7
3 10 11 12 13 14
15
19 18 17 16
WDAA-03-13-013
WDBR50-EN-00(20171222) W3-12-6-1

No. Part Name Q’ty (mm) Remark
N·m
1 Body 1
2 Socket Bolt 4 l:4 5 to 7
3 Solenoid 2
4 Filter 2 l:6 10
5 O-Ring 1
6 O-Ring 1
7 Filter 1
8 Ball 1
9 Body 1 l : 10 20
10 Washer 1
11 Spring 1
12 Spool 1
13 Sleeve 1
14 Plate 1
15 Wave Spring 1
16 O-Ring 1
17 O-Ring 1
18 O-Ring 1
19 O-Ring 1
WDBR50-EN-00(20171222) W3-12-6-2
Removal and Installation of Signal Control

Valve
1
WDBR-03-16-001
3


Removal

(3).
j : 17 mm
WDBR50-EN-00(20171222) W3-13-1-1
WDBR-03-13-001 WDBR-03-13-002
2, 3

5. Disconnect all hoses (5) (34 used) with signal control
valve (1) attached.
j : 17 mm, 19 mm
used). Remove signal control valve (1) from bracket
(6).
l : 8 mm
7. Remove the adapters from signal control valve (1) if
necessary.
WDBR50-EN-00(20171222) W3-13-1-2
WDBR-03-13-002 WDBR-03-13-001
2, 3
Installation
1. Install all removed adapters to signal control valve
(1).
2. Install signal control valve (1) to bracket (6) with
washers (3) (4 used) and socket bolts (2) (4 used).
l : 8 mm
m : 50 N·m
3. Connect hoses (5) (34 used) to signal control valve
(1).
j : 17 mm
m : 25 N·m
j : 19 mm
m : 30 N·m
WDBR50-EN-00(20171222) W3-13-1-3
WDBR-03-16-001
3

1.)
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-13-1-4
Structure of Signal Control Valve

5
9 23
21
21
23 8
21 22
21
21
23 23
23
10
W1JB-02-10-002
WDBR50-EN-00(20171222) W3-13-2-1
34
18
18A
14
17
36 18
11
18A
13
17
18 11
18A
14
17
19
36
35
20A
20
20B
15
12
17
16
18A
18
33
11
17 36
2 14
18A
18
11 17
13
18A
18
11
17
14
18A
18
W1JB-02-10-003
WDBR50-EN-00(20171222) W3-13-2-2

No. Part Name Q’ty Remark
(mm) N·m
1 Body 1 1
2 Body 2 1
3 Body 3 1
4 Body 4 1
5 Body 5 1
6 Gasket 1
7 Gasket 1
8 Gasket 1
9 Gasket 1
10 Bolt 12 j : 14 44.1±2.0
11 Spool 5
12 Spool 1
13 Spring 2
14 Spring 4
15 Spring 1
16 Spring 1
17 Spring Guide 7
18 Plug 7
18A O-Ring 7
19 Spool 1
20 Shuttle Valve 1
20A O-Ring 1
20B O-Ring 1
21 Poppet 21
22 Spring 4
23 Filter 10
33 Plate 1
34 Plate 1
35 Plate 1
36 Socket Bolt 11 l:5 6.9±0.3
WDBR50-EN-00(20171222) W3-13-2-3
(Blank)
WDBR50-EN-00(20171222) W3-13-2-4
Removal and Installation of Aftertreatment

Device
1 3
WDBR-03-14-001 WDBR-03-14-002
3
6
Removal
(Refer to W1-5-1.)
WDBR-03-14-003
IMPORTANT: After stopping the engine, the DEF 5
pump continues to be operated for a specified
time in order to return DEF from the hose to the
DEF tank. When 5 minutes pass after the engine
has been stopped, start the work.
2. Open engine cover (1). 7
dCAUTION: The cover (4) assembly weight: 30 kg

cover (4) assembly.
j : 17 mm
5. Open cover (2). Remove bolt, washer (7). Remove
cover (5).
WDBR-03-14-004
WDBR50-EN-00(20171222) W3-14-1-1
b
A Detail A 1 1, 2
WDBR-03-14-005 WDBR-03-14-006
8 7 3
6. Remove bolts, washers (1) (3 used). Remove clips (2) 4

(2 used) and connector (3).
j : 17 mm
8. Remove bolts, washers (5, 6) (2 used for each). 5
Remove support (4).
j : 17 mm
9. Remove bolts, washers (7) (2 used). Remove step (8).
j : 17 mm
WDBR-03-14-007
6
WDBR50-EN-00(20171222) W3-14-1-2
2, 3
6, 7, 8
12
WDBR-03-14-008 WDBR-03-14-009
4, 5 9
10. Remove bolt, washer (2). Remove clip (3). 14. Remove bolts (6) (3 used), washers (7) (6 used), and
nuts (8) (3 used). Disconnect exhaust pipe (9).
j : 17 mm
j : 13 mm
j : 17 mm
(Refer to W1-5-1.)
13. Disconnect hoses (1) (4 used). Remove clip band
(12).
WDBR50-EN-00(20171222) W3-14-1-3
1, 2 3
9
10
4 A
8
WDBR-03-14-010 WDBR-03-14-011
7 5, 6
Detail A 11
15. Remove bolts, washers (1) (2 used). Remove clips

(2) (2 used). Place the hose (3) assembly outside the
work area.
j : 17 mm
9
used).
j : 17 mm
Remove cover (7).
j : 17 mm
Remove the cover (11) assembly. WDBR-03-14-012
j : 17 mm
WDBR50-EN-00(20171222) W3-14-1-4
1 1
WDBR-03-14-013 WDBR-03-14-014

(2).
j : 17 mm
WDBR50-EN-00(20171222) W3-14-1-5
8 a
4, 5
3
6
4, 5
WDBR-03-14-015 WDBR-03-14-016
1, 2 6 9
a- Hoisting Position
20. Remove bolts, washers (4) (2 used) and clamps (5) (2

used). Remove pipe (3) from aftertreatment device
(8).
j : 17 mm
dCAUTION: The aftertreatment device (8)

assembly weight: 86 kg
21. Attach nylon slings onto hoisting positions (a) (2
places). Hoist and hold the aftertreatment device (8)
assembly.
j : 19 mm
IMPORTANT: Take care not to break pipe (3).
dCAUTION: The aftertreatment device (8)

Remove the aftertreatment device (9) assembly and
gasket (7) from bracket (8).
j : 19 mm
WDBR50-EN-00(20171222) W3-14-1-6
12 9 13 9 13 4 1, 2
8 3
11
10
WDAQ-03-14-025
4 6 4 5
The machine equipped with AR-4JJ1XASA-01

engine
j : 17 mm
26. Remove wire harnesses (6, 10, 12) from clips (4) (6
used).
27. Remove socket bolts (13) (2 used). Remove sensor
(5).
l : 6 mm, 22 mm
28. Remove bolt, washer (11). Remove sensor (8).
j : 13 mm, 17 mm
WDBR50-EN-00(20171222) W3-14-1-7
12 9 13 9 4 10 5 1, 2
3
4
11
4
4
10
WDAQ-03-14-018
6 13 5

engine
j : 17 mm
26. Remove wire harness (6), wire harnesses (10) (2
used) and wire harness (12) from clips (4) (8 used).
27. Remove socket bolts (13) (4 used). Remove sensors
(5) (2 used).
l : 6 mm, 22 mm
28. Remove bolt, washer (11). Remove sensor (8).
j : 13 mm, 17 mm
WDBR50-EN-00(20171222) W3-14-1-8
7 8 10 1
8
2
9 A
WDAQ-03-14-021 WDAQ-03-14-019
6 4 5 4
View A 6
29. Remove wire harnesses (6) (2 used) and wire

harness (10) from clips (1, 2) (2 used for each and
clips (3) (9 used)).
31. Remove sensors (4) (2 used).
3
j : 14 mm
32. Remove bolts, washers (8) (4 used). Remove clips (1,
2) (2 used for each).
j : 10 mm WDAQ-03-14-020
bracket (9) assembly.
j : 17 mm
WDBR50-EN-00(20171222) W3-14-1-9
The machine equipped with AR-4JJ1XASA-01 The machine equipped with AR-4JJ1XASA-11
engine engine
1 1
5 5
4 4
2 2
3 3
WDAQ-03-14-027 WDAQ-03-14-022

Remove the bracket (1) assembly.
j : 19 mm
35. Remove nuts (3) (3 used). Remove dosing module
(2).
j : 10 mm
WDBR50-EN-00(20171222) W3-14-1-10
The machine equipped with AR-4JJ1XASA-01 The machine equipped with AR-4JJ1XASA-11
engine engine
6 1 6 1
5 5
4 4
2 2
3 3
WDAQ-03-14-027 WDAQ-03-14-022
Installation
1. Install dosing module (2) to aftertreatment device
(6) with nuts (3) (3 used).
j : 10 mm
m : 8.5 N·m
j : 19 mm
m : 90 N·m
WDBR50-EN-00(20171222) W3-14-1-11
7 8 10 1
8
2
3
9 A
WDAQ-03-14-021 WDAQ-03-14-019
6 4 5 4
View A 6
3. Install sensors (4) (2 used).
j : 14 mm
m : 30 N·m
(7) (2 used).
3
j : 17 mm
m : 50 N·m
5. Install clips (1, 2) (2 used for each) with bolts,
WDAQ-03-14-020
j : 10 mm
m : 3~4 N·m
7. Secure wire harnesses (6) (2 used) and wire harness
(10) with clips (1, 2) (2 used for each and clips (9
used)) and clips (3) (9 used).
WDBR50-EN-00(20171222) W3-14-1-12
8
9
5, 6
5, 10 7 WDAQ-03-14-026
Clips (7, 9) Positions for Wire Harness (10)

Distance (L) from Sensor (5) 100 150 200 250 310
(mm)
Color of Mark White Yellow White Red White
Clip No. - - (7) - (9)
150 250
100 200 310
(L)
WDCK-03-14-003

Distance (L) from Sensor (5) 150 170 200 250 300 400 450
(mm)
Color of Mark Yellow Red White Yellow Red White Red
Clip No. - - - - (8) - (7)
170 250 400

150 200 300 450
(L)
WDCK-03-14-002
WDBR50-EN-00(20171222) W3-14-1-13
8 5, 6 WDAQ-03-14-020

Distance (L) from Sensor (5) 150 170 200 250 300 400 450
(mm)
Color of Mark Yellow Red White Yellow Red White Red
Clip No. (7) - (8) - - - -
170 250 400

150 200 300 450
(L)
WDCK-03-14-002
WDBR50-EN-00(20171222) W3-14-1-14
12 15 13 9 13 4 1, 2
8 3
11
14
10
WDAQ-03-14-025
4 6 4 5

engine
13. Install harnesses (6, 10, 12) with clips (4) (6 used).
8. Apply anti-seize to the thread part of sensor (8).
14. Connect connectors (9) (2 used) and connector (15).
fNOTE: Anti-seize has been applied to new sensor (8). Install connector (15) with bolt, washer (11).
9. Install sensor (8) to aftertreatment device (14). j : 17 mm
j : 13 mm m : 50 N·m
m : 30 N·m 15. Connect hoses (3) (2 used). Install hoses (3) (2 used)
with clips (2) (2 used) and bolts, washers (1) (2 used).
10. Apply anti-seize to the thread part of sensor (5).
j : 17 mm
fNOTE: Anti-seize has been applied to new sensor (5).
11. Install sensor (5) to aftertreatment device (14). m : 50 N·m
j : 22 mm
m : 50 N·m
12. Install the connector (9) side of sensor (5) with
l : 6 mm
m : 8.5 N·m
WDBR50-EN-00(20171222) W3-14-1-15
12 15 9 13 9 4 10 5 1, 2
3
4
11
4
4
14 4
10
WDAQ-03-14-018
6 13 5

engine
13. Install harnesses (6, 12) and harnesses (10) (2 used)
8. Apply anti-seize to the thread part of sensor (8). with clips (4) (8 used).
fNOTE: Anti-seize has been applied to new sensor (8). 14. Connect connectors (9) (3 used) and connector (15).
Install connector (15) with bolt, washer (11).
9. Install sensor (8) to aftertreatment device (14).
j : 17 mm
j : 13 mm
m : 50 N·m
m : 30 N·m
15. Connect hoses (3) (2 used). Install hoses (3) (2 used)
10. Apply anti-seize to the thread part of sensors (5) (2
with clips (2) (2 used) and bolts, washers (1) (2 used).
used).
j : 17 mm
fNOTE: Anti-seize has been applied to new sensor (5).
11. Install sensors (5) (2 used) to aftertreatment device m : 50 N·m
(14).
j : 22 mm
m : 50 N·m
12. Install the connector (9) side of sensors (5) (2 used)
l : 6 mm
m : 8.5 N·m
WDBR50-EN-00(20171222) W3-14-1-16
8 a
4, 5
3
6
WDBR-03-14-016 4, 5 WDBR-03-14-015
6 9 1, 2
19. Install pipe (3) with clamps (5) (2 used) and bolts,
d CAUTION: The aftertreatment device (8)
16. Attach nylon slings onto hoisting positions (a) (2 j : 17 mm

places). Hoist and hold the aftertreatment device (8)
m : 50 N·m
assembly.
IMPORTANT: Take care not to break pipe (3).
17. Temporally install the aftertreatment device (8)
assembly to bracket (9) with washers (2) (4 used),
bolts (1) (4 used) and bolts, washers (6) (4 used).
j : 19 mm
18. Tighten bolts (2) (4 used) and bolts, washers (5) (4
used).
j : 19 mm
Bolt (2)
m : 110 N·m
Bolt, Washer (5)
m : 90 N·m
WDBR50-EN-00(20171222) W3-14-1-17
1 1
WDBR-03-14-014 WDBR-03-14-013
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-14-1-18
Detail A 11
9
10
9
WDBR-03-14-011 WDBR-03-14-012
1, 2 3
21. Install cover (11) with bolts, washers (9, 10) (2 used
for each).
j : 17 mm
m : 50 N·m
22. Install cover (7) with bolts, washers (4, 8) (2 used for 4
each). 8
j : 17 mm 12
m : 50 N·m
23. Secure hoses (12) (2 used) with clips (6) (2 used) and
j : 17 mm WDBR-03-14-010
7 5, 6
m : 50 N·m
24. Install the hose (3) assembly with clips (2) (2 used)
and bolts, washers (1) (2 used).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-14-1-19
16 1
2, 3
14
6, 7, 8
12
WDBR-03-14-009 WDBR-03-14-008
13 9 4, 5 15
25. Connect exhaust pipe (9) with gasket (13), nuts (8)
(3 used), washers (7) (6 used) and bolts (6) (3 used).
j : 13 mm
m : 20 N·m
26. Install harness (14) to bracket (15) with clip band
(12).
28. Install hoses (1) (4 used) to bracket (16) with clips (3,
5) and bolts, washers (2, 4).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-14-1-20
4 A
WDBR-03-14-007 WDBR-03-14-005
6 8 7
b
29. Install step (8) with bolts, washers (7) (2 used). Detail A 1 1, 2
j : 17 mm
m : 50 N·m
30. Install support (4) with bolts, washers (5, 6) (2 used
for each).
j : 17 mm
m : 50 N·m
32. Install clips (2) (2 used) and connector (3) to support
(4) with bolts, washers (1) (3 used).
j : 17 mm
m : 50 N·m WDBR-03-14-006
3
WDBR50-EN-00(20171222) W3-14-1-21
7
6
WDBR-03-14-004 WDBR-03-14-003
5
4
W1-4-1.)
IMPORTANT: Check the coolant level. Start the
engine and check for any water leaks.
IMPORTANT: Warn up the engine and increase the
SCR exhaust temperature over 190°C. Check the
DEF tank for any DEF leaks. In addition, check that
using the monitor. (Refer to T5-2 in the separated
34. Install cover (5) with bolts, washers (6) (5 used) and
bolt, washer (7).
WDBR-03-14-002
3
d CAUTION: The cover (4) assembly weight: 30 kg
1
(6 used).
j : 17 mm
m : 50 N·m
36. Close cover (2) and engine cover (1).
WDBR-03-14-001
WDBR50-EN-00(20171222) W3-14-1-22
Group 15 DEF Tank
Removal and Installation of DEF Tank
4 4
2, 3
WDAQ-05-01-001 WDAQ-05-01-002
2, 3
IMPORTANT: Cap the open ends in case the hoses 2. Remove bolts (2) (4 used) and washers (3) (4 used).
and pipes have been disconnected. In addition, Remove the handrail (1) assembly.
hoses, and pipes for assembling. If the clips which j : 19 mm
secure the hoses have been removed, install the 3. Remove bolts, washers (4) (4 used). Remove cover
clips after connecting the hoses. (5).
Removal j : 17 mm
1. Set the machine position for inspection and 4. Open cover (6).
IMPORTANT: After stopping the engine, the DEF
DEF tank. When five minutes pass after the engine
WDBR50-EN-00(20171222) W3-15-1-1
Group 15 DEF Tank
1 View A 5
4
3
WDAQ-05-01-004 WDAQ-03-15-002
5

hose (2) assembly.
j : 17 mm
(1).
j : 17 mm
B
j : 17 mm
6
8. Open cover (6).
9. Disconnect connectors (7) (2 used). Remove wire
harness (8) from clips (9) (2 used).
WDAQ-05-01-002
Detail B
8
7
WDAQ-03-15-003
WDBR50-EN-00(20171222) W3-15-1-2
Group 15 DEF Tank
A
a 3 View A
4
5
2 WDAQ-03-15-004
WDAQ-03-15-005
3
j : 17 mm
11. Close the covers (5, 6). Lock the key.
j : 17 mm
dCAUTION:
kg
The tool box (4) assembly weight: 53
13. Install the eyebolts (M10, Pitch 1.5 mm) (4 used) to

eyebolt mounting hole (a) (1 place) and bolt, washer
(3) mounting holes (3 places). Attach nylon slings
onto the eyebolts. Hoist and remove the tool box (4)
assembly.
WDBR50-EN-00(20171222) W3-15-1-3
Group 15 DEF Tank
3 4, 8
9 5
1
2
12
WDAQ-03-15-006 WDAQ-03-15-007
7 10, 11 6
13 a
a- Machine Front Side a a- Machine Front Side
14. Remove bolts, washers (1) (2 used) and bolts, 19. Remove bolts, washers (12) (2 used), bolts (4) (2
washers (2) (4 used). Remove support (3). used), and washers (8) (2 used). Remove cover (9).
j : 17 mm j : 13 mm
15. Remove cap (13).
used).
j : 17 mm
WDBR50-EN-00(20171222) W3-15-1-4
Group 15 DEF Tank
3
2 a
1
a- Machine Front Side WDAQ-03-15-009 WDAQ-03-15-010
21. Place a container. Slowly turn drain plug (3). Drain

not drop cover (1).
off DEF completely.
20. Remove bolts, washers (2) (2 used). Remove cover j : 13 mm

(1).
fNOTE: Amount of DEF: 36 L
j : 17 mm 22. Tighten drain plug (3).
WDBR50-EN-00(20171222) W3-15-1-5
Group 15 DEF Tank
1, 2 3
WDC150-03-15-012

(Refer to W1-5-1.)
24. Remove bolt, washer (1) and clip (2).
j : 17 mm
26. Remove bolts, washers (3) (2 used). Place the DEF
sensor unit controller (4) assembly on DEF tank (5).
j : 17 mm
WDBR50-EN-00(20171222) W3-15-1-6
Group 15 DEF Tank
4 6
WDAQ-03-15-013 5 WDAQ-03-15-014
27. Remove nuts (4) (4 used). Remove bands (2) (2

used).
j : 17 mm
28. Remove DEF tank (1), DEF sensor unit (5) and the
DEF sensor unit controller (7) assembly from the
frame (3) assembly.
29. Remove clamp (6). Remove DEF sensor unit (5) and
the DEF sensor unit controller (7) assembly.
WDBR50-EN-00(20171222) W3-15-1-7
Group 15 DEF Tank
A 3
10
2 WDAQ-03-15-014 WDAQ-03-15-013
5
Detail A
Installation
9 8
1. Install the DEF sensor unit (2) assembly to DEF
tank (3) with clamp (1). Place the DEF sensor unit
controller (10) assembly on DEF tank (3).
m : 3 N·m
2. Install the DEF tank (3) assembly to the frame (5)
assembly.
fNOTE: Fit and install DEF tank (3) to the frame (5)
7
assembly.
3. Install bands (7) (2 used) with nuts (8) (2 used).
j : 17 mm
m : 3 N·m
4. Install nuts (9) (2 used).
j : 17 mm
WDC150-03-15-015
9 8
m : 15 N·m
WDBR50-EN-00(20171222) W3-15-1-8
Group 15 DEF Tank
1, 2 3
WDC150-03-15-012
5. Install the DEF sensor unit controller (4) assembly

j : 17 mm
m : 50 N·m
7. Install clip (2) and bolt, washer (1).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-15-1-9
Group 15 DEF Tank
4
3
WDAQ-03-15-012 a- Machine Front Side WDAQ-03-15-009
8. Check that drain plug (5) is tightened.

9. Fill DEF tank (2) with DEF.
fNOTE: Amount of DEF: 36 L

W1-4-1.)
IMPORTANT: Check the coolant level. Start the WDAQ-03-15-010
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-15-1-10
Group 15 DEF Tank
3, 4 3
2
1
2
12
WDAQ-03-15-007 WDAQ-03-15-006
7 10, 11 6
13
a
a- Machine Front Side a- Machine Front Side a
13. Install cover (2) with washers (4) (2 used), bolts (3) (2 15. Install harness (7) with clips (6) (2 used).
used), and bolts, washers (12) (2 used).
16. Install support (3) with bolts, washers (1) (2 used)
j : 13 mm and bolts, washers (2) (4 used).
m : 10 N·m j : 17 mm
14. Install clips (10) (2 used) and bolts, washers (11) (2 m : 50 N·m
used).
17. Close cap (13).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-15-1-11
Group 15 DEF Tank
a 3 View A
4
7
2 WDAQ-03-15-004
WDAQ-03-15-005
3
dCAUTION:
kg
The tool box (4) assembly weight: 53
18. Install the eyebolts (M10, Pitch 1.5 mm) (4 used) to

eyebolt mounting hole (a) (1 place) and bolt, washer
(3) mounting holes (3 places). Attach nylon slings
onto the eyebolts. Ensure that covers (6, 7) does not
open. Hoist the tool box (4).
19. Place the tool box (4) assembly onto the mounting
position. Open covers (6, 7). Install the tool box (4)
assembly with bolts, washers (2) (2 used) and bolts,
j : 17 mm
m : 50 N·m
WDAQ-03-15-002
5
WDBR50-EN-00(20171222) W3-15-1-12
Group 15 DEF Tank
1
Detail B
4
8 3
7 2
9
WDAQ-03-15-003
WDAQ-05-01-004
20. Connect connectors (9) (2 used). Install harness (7) View A 10

with clips (8) (2 used).
j : 17 mm
m : 50 N·m 5
22. Install the hose (2) assembly with bolts, washers (3)
(2 used).
j : 17 mm 6
m : 50 N·m
23. Remove the eyebolts (4 used).
j : 17 mm WDAQ-05-01-002
10 B
m : 50 N·m
25. Close covers (5, 6).
WDBR50-EN-00(20171222) W3-15-1-13
Group 15 DEF Tank
4 4
2, 3
WDAQ-05-01-002 WDAQ-05-01-001
2, 3
26. Install cover (5) with bolts, washers (4) (4 used). 27. Install the handrail (1) assembly with washers (3) (4
used) and bolts (2) (4 used).
j : 17 mm
j : 19 mm
m : 50 N·m
m : 110 N·m
WDBR50-EN-00(20171222) W3-15-1-14
Group 16 Coolant Control Valve
Removal and Installation of Coolant Control

Valve
1 4
WDBR-03-16-001 WDBR-03-16-002
3 5

Removal
(Refer to W1-5-1.)
(2).
j : 17 mm
5. Remove bolts, washers (5) (4 used). Remove
handrail (4).
j : 19 mm
WDBR50-EN-00(20171222) W3-16-1-1
4 5
3 1
2 WDBR-03-16-003 WDBR-03-16-004

7. Remove clips (1) (2 used). Disconnect hoses (2) (2
used). 9

coolant control valve (3) assembly from cover (6).
j : 17 mm
used). Remove bracket (9).
l : 6 mm
7, 8 WDBR-03-16-005
WDBR50-EN-00(20171222) W3-16-1-2
7, 8 WDBR-03-16-005 WDBR-03-16-004
Installation
1. Install bracket (9) with washers (8) (2 used) and
l : 6 mm
3 1
m : 22 N·m
2. Install the coolant control valve (3) assembly to
cover (6) with bolts, washers (5) (2 used).
j : 17 mm
m : 50 N·m
3. Connect hoses (2) (2 used). Install clips (1) (2 used).
4. Connect connector (4). WDBR-03-16-003
2
W1-4-1.)
WDBR50-EN-00(20171222) W3-16-1-3
4 1
WDBR-03-16-002 WDBR-03-16-001
5 3
6. Install handrail (4) with bolts, washers (5) (4 used).
j : 19 mm
m : 130 N·m
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W3-16-1-4
Group 17 DEF Supply Module
Removal and Installation of DEF Supply

Module
Detail A 6 3
4, 5
1 2 WDBR-03-17-001 WDBR-03-17-002

Removal 5

WDAQ-03-17-005
IMPORTANT: After stopping the engine, the DEF
DEF tank. When five minutes pass after the engine
2. Release any pressure in the the expansion tank. 5. Remove bolts, washers (3) (2 used). Remove cover
(Refer to W1-5-1.) (6).
3. Open covers (1, 2).
4. Lower lock (5). Disconnect connector (4).
WDBR50-EN-00(20171222) W3-17-1-1
1 5
2, 3 2, 3
1
4
WDBR-03-17-003 WDBR-03-17-004

used). Remove DEF supply module (4) from bracket
(5).
l : 6 mm
WDBR50-EN-00(20171222) W3-17-1-2
1 5
2, 3 2, 3
1
4
WDBR-03-17-003 WDBR-03-17-004
Installation
1. Install DEF supply module (4) to bracket (5) with
washers (3) (3 used) and socket bolts (2) (3 used).
l : 6 mm
m : 22 N·m
WDBR50-EN-00(20171222) W3-17-1-3
Detail A 6 3
4, 5
1 2 WDBR-03-17-001 WDBR-03-17-002
3. Connect connector (4). Raise and lock lock (5).

W1-4-1.)
IMPORTANT: Warm up the engine and increase the
SCR exhaust temperature over 190°C. Check the 5
DEF hose for DEF leaks. In addition, check that
using the monitor. (Refer to T5-2 in the separated WDAQ-03-17-005
j : 17 mm
m : 50 N·m
6. Close covers (1, 2).
WDBR50-EN-00(20171222) W3-17-1-4
MEMO
WDBR50-EN-00(20171222)
MEMO
WDBR50-EN-00(20171222)
SECTION 4
UNDERCARRIAGE
CONTENTS
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-5
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-4
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-3
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Front Idler...........................................W4-4-2-1
Assembly of Front Idler.................................................W4-4-2-4
Disassembly of Track Adjuster....................................W4-4-3-1
Assembly of Track Adjuster.........................................W4-4-3-5
Removal and Installation of Upper Roller..............W4-6-1-1
Removal and Installation of Lower Roller..............W4-6-2-1
Disassembly of Lower Roller.......................................W4-6-3-1
Assembly of Lower Roller.............................................W4-6-3-3
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1
WDBR50-EN-00(20171222) DBR50W-4-1
(Blank)
WDBR50-EN-00(20171222) DBR50W-4-2
SECTION 4 UNDERCARRIAGE
Removal and Installation of Swing Bearing
5, 6 3 1 2
a 4
a- Matching Mark
WDBF-04-01-001
Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.)
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here.
Removal
1. Put matching marks (a) on inner race (3) of swing
bearing (1) and track frame (4).
2. Remove knock pin (2).
used).
j : 30 mm
WDBR50-EN-00(20171222) W4-1-1-1
ST 0050
1
a- Swing Bearing (1) Outer Race Mounting Bolt W110-03-01-004
dCAUTION: Swing bearing (1) weight: 210 kg

4. Install special tools (ST 0050) (3 used) to swing
bearing (1) with the swing bearing (1) outer race
mounting bolts (a) (3 used) and the nuts (3 used).
Attach wire ropes onto special tools (ST 0050)
(3 used). Hoist swing bearing (1). Remove swing
bearing (1) from track frame (2).
j : 30 mm
fNOTE: THREEBOND #1102 has been applied to the

mating surface.
WDBR50-EN-00(20171222) W4-1-1-2
WDEA-04-01-002
Detail A
2
WDBF-04-01-001
b
Installation a
1. Clean the mounting surfaces of track frame (2) and
swing bearing (1).
2. Apply THREEBOND #1102 to the swing bearing (1)
mounting surface (b) of track frame (2).
WDEA-04-01-003
a- THREEBOND Applying b- Swing Bearing (1) Mounting

Surface Surface
WDBR50-EN-00(20171222) W4-1-1-3
1 2 b
ST 0050
1 W110-03-01-004
b- Swing Bearing (1) Outer Race Mounting Bolt
a 3
a- Matching Mark
WDBF-04-01-001 d
e
dCAUTION: Swing bearing (1) weight: 210 kg
3. Install special tools (ST 0050) (3 used) to swing
bearing (1) with the swing bearing (1) outer race
mounting bolts (b) (3 used) and the nuts (3 used).
Attach wire ropes onto special tools (ST 0050) (3
used). Hoist swing bearing (1).
j : 30 mm
4. Fit matching marks (a) on track frame (3) and inner WDBR-04-01-001
race (2) of swing bearing (1) so that soft zone
marking position (d) is as illustrated. c- Machine Front Side
d Soft Zone Marking Position
e- 11.3 ˚
WDBR50-EN-00(20171222) W4-1-1-4
2, 4 1 3
f
WDBR-04-01-001

WDBF-04-01-001
b Soft Zone Marking Position
c- 11.3 ˚
f- Position for Knock Pin
5. Temporally install swing bearing (1) with washers (4)

(36 used) and bolts (2) (36 used).
j : 30 mm
6. Tighten bolts (2) (36 used).
j : 30 mm
m : 510 N·m
IMPORTANT: Check the position to install knock pin
(3).
IMPORTANT: Check the direction to install knock pin
(3).
7. Apply THREEBOND #1102 to knock pin (3). Install
knock pin (3) with taper part (d) up by using a
plastic hammer.
d
WDEA-03-10-018
d- Taper Part
e- Upward
WDBR50-EN-00(20171222) W4-1-1-5
a b 1
5mm
W175-03-01-002
a- Swing Bearing b- Grease Level
8. After installing swing bearing (a), add grease

(Alvania EP2 or equivalent) to the gear part of swing
bearing (a). Add grease (Alvania EP2 or equivalent)
to grease bath (2) until pinion (1) of the swing
device is 5 mm (0.2 in) under grease.
fNOTE: Amount of grease: 17 L
WDBR50-EN-00(20171222) W4-1-1-6
Disassembly of Swing Bearing

1 2 3
8 7 6 5
W178-02-11-193
7 8
W178-02-11-194
1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (121 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (121 Used)
WDBR50-EN-00(20171222) W4-1-2-1
Disassembly of Swing Bearing 3. Install bolt (10) to the screw hole (M10, Pitch 1.5
mm) of plug (4). Tap or pull bolt (10) and remove
plug (4) from outer race (1).

personal injury.
1. Grind off the crimped part of pin (3) by using a
1
grinder. Tap the bottom side of pin (3) of plug (4) by
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4
7
W178-02-11-196
10
dCAUTION: Swing bearing weight: 210 kg

W178-02-11-195 4. Place inner race (7) of the swing bearing on
wooden blocks by using the special tool (ST 0050).
Hoist outer race (1) horizontally. Hold outer race (1).
2. Thread hole (a) of plug (4) by using a tap (M10, Pitch
1.5 mm).
WJAA-04-01-002
a- Hole
WDBR50-EN-00(20171222) W4-1-2-2
5. Remove balls (6) (121 used) and supports (8) (121

used) from the plug (4) hole while turning outer
race (1).
1
2
11 7
6 5
W178-02-11-197
12
8
W178-02-11-198
fNOTE: Use magnet (11) when removing ball (6). Attach

bent wire (12) and remove support (8).
6. Remove seals (2, 5) from outer race (1) and inner
race (7) by using a scrapper.
WDBR50-EN-00(20171222) W4-1-2-3
Assembly of Swing Bearing

1 2 3
8 7 6 5
W178-02-11-193
7 8
W178-02-11-194
1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (121 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (121 Used)
WDBR50-EN-00(20171222) W4-1-2-4
Assembly of Swing Bearing
dCAUTION: Swing bearing weight: 210 kg dCAUTION: Metal fragments may fly off when
1. Install the special tools (ST 0050) (3 used) to outer
race (1). Attach wire ropes onto the special tools (ST such as goggles, hard hat, etc. in order to prevent
0050) (3 used). Hoist the swing bearing horizontally. personal injury.
Align outer race (1) and inner race (7) coaxially. 2. Install plug (4) to outer race (1) by using a hammer.
Secure plug (4) to outer race (1) with pin (3).
Apply grease to balls (6) (121 used) and supports (8)
(121 used). Crimp the head of pin (3) by using a punch.
Install balls (6) (121 used) and supports (8) (121
used) alternately from the plug (4) hole by using a
round bar while turning outer race (1).
3
1
2
7 4
1
6 W178-02-11-201
3. Degrease the groove part for seals (2, 5) completely.

5
W178-02-11-199
Apply THREEBOND #1530D to seals (2,5). Apply
THREEBOND #1745 to seals (2, 5) end. Install seals (2,
5) to outer race (1) and inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fittings (9) (2 used). At this
time, add grease while turning outer race (1).
fNOTE: Grease amount: 0.5 L
W178-02-11-200
WDBR50-EN-00(20171222) W4-1-2-5
(Blank)
WDBR50-EN-00(20171222) W4-1-2-6
Removal and Installation of Travel Device
WDAA-04-02-001 WDBR-04-02-001
IMPORTANT: The hoses and pipes contain hydraulic 5. Disconnect hose (7).
IMPORTANT: Cap the open ends in case the hoses 6. Disconnect hose (8).
attach identification tags onto the connectors, j : 17 mm
secure the hoses have been removed, install the dCAUTION: Travel device (5) weight: 320 kg
clips after connecting the hoses. 7. Attach nylon slings onto travel device (5). Hoist and
hold travel device (5). Remove bolts (9) (14 used)
and washers (10) (14 used). Hoist and remove travel
Removal device (5) from track frame (11).
maintenance. (Refer to W1-5-1.) j : 30 mm
8. Remove the adapters with travel device (5) attached
dCAUTION: Please any pressure from the
if necessary.
2. Disconnect track (1). (Refer to W4-6-1.) 9. Remove other travel device in the same way as step
2 to step 8.
Remove cover (4).
j : 22 mm
j : 36 mm
WDBR50-EN-00(20171222) W4-2-1-1
WDBR-04-02-001
Installation
1. Install all removed adapters to travel device (5).
dCAUTION: Travel device (5) weight: 320 kg

2. Attach nylon slings onto travel device (5). Hoist
travel device (5). Install travel device (5) to track
frame (11) with washers (10) (14 used) and bolts (9)
(14 used).
j : 30 mm
m : 630 N·m
j : 17 mm
m : 25 N·m
j : 27 mm
m : 80 N·m
j : 36 mm
m : 180 N·m
WDBR50-EN-00(20171222) W4-2-1-2
WDAA-04-02-001
6. Connect track (1). (Refer to W4-7-1.)

7. Install other travel device in the same way as step 1
to step 6.
1.)
engine and check for any oil leaks. In order to
prevent the travel motor from seizing, perform
the break-in operation after installing.
Condition: 1. Engine speed: Slow idle speed

2. Travel mode switch: Slow speed
3. Perform forward and reverse travel operation
(0.5 to 1 m) five or more times
9. Install cover (4) with washers (3) (6 used) and bolts
(2) (6 used).
j : 22 mm
m : 180 N·m
10. Install other cover in the same way as step 9.
WDBR50-EN-00(20171222) W4-2-1-3
(Blank)
WDBR50-EN-00(20171222) W4-2-1-4
Disassembly of Travel Device
WDBE-04-02-004
00- Travel Motor 12- Third Stage Carrier 25- Planetary Gear (3 Used) 36- Thrust Plate (6 Used)
02- Floating Seal 13- Planetary Gear (3 Used) 26- Needle Bearing (3 Used) 37- Pin (3 Used)
03- Roller Bearing (2 Used) 15- Thrust Plate (6 Used) 27- Thrust Plate (6 Used) 38- Spring Pin (3 Used)
04- Drum 16- Pin (3 Used) 28- Pin (3 Used) 39- Shaft
05- Sprocket 17- Spring Pin (3 Used) 29- Spring Pin (3 Used) 41- Cover
06- Bolt (18 Used) 18- Sun Gear 30- Sun Gear 42- Stopper
07- Spring Washer (18 Used) 20- Ring Gear 32- First Stage Carrier 43- Bolt, Washer (16 Used)
09- Bearing Nut 21- Bolt (20 Used) 33- Spacer 44- Plug (3 Used)
10- Knock Pin 23- Second Stage Carrier 34- Planetary Gear (3 Used) 48- O-Ring
11- Needle Bearing (6 Used) 24- Spacer 35- Needle Bearing (3 Used)
WDBR50-EN-00(20171222) W4-2-2-1
Disassembly of Travel Device

IMPORTANT: Do not remove stopper (42) unless
dCAUTION: There may be pressure accumulated
inside of the travel device. Loosen the air bleed necessary.
plug slowly. Release any remaining pressure 4. Remove bolts, washers (43) (16 used). Remove cover
completely. Then, remove the drain plug and drain (41).
gear oil. If the air bleed plug is loosened suddenly,
the plug may be fly out and gear oil may gush out. j : 19 mm
Keep body and face away from plug.
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied between cover (41) and ring gear (20). For easy
1. Remove plugs (44) (3 used) from cover (41). Drain removal, insert and tap a chisel between cover (41) and
gear oil from the travel reduction gear. ring gear (20).
l : 10 mm 5. Remove shaft (39) from first stage carrier (32).
6. Remove the first stage carrier (32) assembly.
7. Remove sun gear (30) from second stage carrier
dCAUTION: Travel device weight: 320 kg
(23).
2. Attach nylon slings onto the body of the travel
device. Hoist the travel device. Place the travel 8. Remove the second stage carrier (23) assembly from
device on a workbench with the travel motor (00) ring gear (20).
side up. Install special tool (ST 5090) to the travel
device with bolts (M20, Pitch 2.5 mm) (2 used).
j : 30 mm
ST 5090
00
W105-03-02-007
dCAUTION: Travel device + special tool (ST 5090)

weight: 340 kg
3. Attach nylon slings onto the body of the travel
device. Hoist the travel device. Turn over the travel
device. Place the travel device onto a workbench
with the travel motor (00) side down.
fNOTE: Secure special tool (ST 5090) to the workbench

tightly in order to receive a reaction force when
disassembling.
WDBR50-EN-00(20171222) W4-2-2-2
9. Remove sun gear (18) from third stage carrier (12).

dCAUTION: Ring gear (20) + sprocket (05) + drum
d CAUTION: The third stage carrier (12) assembly
weight: 35 kg
(04) weight: 140 kg
IMPORTANT: The travel motor (00) side of drum
10. Attach claws (a) of the special tool (ST 0916) onto (04) is the seal sliding surface for travel motor
the outer surface of third stage carrier (12). Hoist (00). Place it onto wooden blocks in order not to
and remove the third stage carrier (12) assembly damage it.
from drum (04). 12. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the bolt, washer (43) holes (2 places) of ring gear
ST 0916 (20). Attach nylon slings onto the eyebolts. Hoist
and remove the ring gear (20) assembly from travel
a motor (00).
fNOTE: If it is difficult to remove, rotate sprocket (05).

IMPORTANT: Handle floating seal (02) with care.
(Refer to W4-2-5.)
13. Remove one side of floating seal (02) from travel
motor (00).
14. Remove the inner race of roller bearing (03) from
W178-02-11-203
drum (04).
a- Claw
IMPORTANT: Do not remove knock pin (10) unless

necessary.
11. Remove bearing nut (09) from travel motor (00) by
using the special tools (ST 7248 and ST 7249).
ST 7248
ST 7249
09
W178-03-02-013
WDBR50-EN-00(20171222) W4-2-2-3
19. Remove O-ring (48) from ring gear (20).

d CAUTION: Sprocket (05) weight: 46 kg
dCAUTION: When removing sprocket (05), gather dCAUTION: Metal fragments may fly off when a
up the nylon slings and hoist sprocket (05)
horizontally. Do not drop sprocket (05).
personal injury.
15. Remove bolts (06) (18 used) and spring washers
IMPORTANT: Do not remove the outer race of roller
(07) (18 used). Attach nylon slings onto sprocket
bearing (03) unless necessary.
(05). Hoist sprocket (05). Remove sprocket (05) from
drum (04). 20. Evenly tap and remove the outer races of roller
bearings (03) (2 used) from drum (04) by using a bar
j : 30 mm and a hammer.
fNOTE: LOCTITE #263 or equivalent has been applied to 21. Remove spring pins (38) (3 used) from first stage
carrier (32) by using special tool (ST 1391).
bolt (06).
dCAUTION:
kg
Ring gear (20) + drum (04) weight: 89 22. Remove pins (37) (3 used), thrust plates (36) (6
used), planetary gears (34) (3 used), needle bearings
(35) (3 used), and spacer (33) from first stage carrier
(32).
bolt (06) holes of drum (04). Attach nylon slings
onto the eyebolts. Hoist drum (04). Place drum (04) 23. Remove spring pins (29) (3 used) from second stage
with the ring gear (20) side down. carrier (23) by using special tool (ST 1391).
IMPORTANT: Handle floating seal (02) with care. 24. Remove pins (28) (3 used), thrust plates (27) (6
(Refer to W4-2-5.) used), planetary gears (25) (3 used), needle bearings
17. Remove one side of floating seal (02) from drum (26) (3 used), and spacer (24) from second stage
(04). carrier (23).
25. Remove spring pins (17) (3 used) from third stage
dCAUTION: Drum (04) weight: 40 kg
carrier (12) by using special tool (ST 1463).
bolt (06) holes (2 places) of drum (04). Attach nylon 26. Remove pins (16) (3 used), thrust plates (15) (6
slings onto the eyebolts. Hoist and hold drum (04). used), planetary gears (13) (3 used), and needle
Remove bolts (21) (20 used). Remove drum (04) bearings (11) (6 used) from third stage carrier (12).
from ring gear (20).
j : 24 mm
WDBR50-EN-00(20171222) W4-2-2-4
Assembly of Travel Device
21 04 48
09 10 12 18 20 24 23 30 33 32
44
41
39
42
34
36
35
37
38
02 03 03 43
00
13 11 16 15 17 25 26 28 27 29
05 07 06
WDBE-04-02-001
00- Travel Motor 12- Third Stage Carrier 25- Planetary Gear (3 Used) 36- Thrust Plate (6 Used)
02- Floating Seal 13- Planetary Gear (3 Used) 26- Needle Bearing (3 Used) 37- Pin (3 Used)
03- Roller Bearing (2 Used) 15- Thrust Plate (6 Used) 27- Thrust Plate (6 Used) 38- Spring Pin (3 Used)
04- Drum 16- Pin (3 Used) 28- Pin (3 Used) 39- Shaft
05- Sprocket 17- Spring Pin (3 Used) 29- Spring Pin (3 Used) 41- Cover
06- Bolt (18 Used) 18- Sun Gear 30- Sun Gear 42- Stopper
07- Spring Washer (18 Used) 20- Ring Gear 32- First Stage Carrier 43- Bolt, Washer (16 Used)
09- Bearing Nut 21- Bolt (20 Used) 33- Spacer 44- Plug (3 Used)
10- Knock Pin 23- Second Stage Carrier 34- Planetary Gear (3 Used) 48- O-Ring
11- Needle Bearing (6 Used) 24- Spacer 35- Needle Bearing (3 Used)
WDBR50-EN-00(20171222) W4-2-2-5
Assembly of Travel Device

IMPORTANT: Before assembling, apply gear oil to IMPORTANT: Handle floating seal (02) with care.
parts in order to prevent them from seizing. (Refer to W4-2-5.)
2. Apply grease to the entire circumference of the
O-ring of floating seal (02) of one side. Install one
side of floating seal (02) to travel motor (00). Apply
gear oil to the whole sliding surface of floating seal
(02).
personal injury.
dCAUTION: Be careful as roller bearing (03) is too fNOTE: If it is difficult to install O-ring of floating seal
hot. (02), push O-ring to the circumferential direction by
using a bamboo spatula.
IMPORTANT: When roller bearing (03) has been
removed, perform the procedures as steps 1, 3, 5,
and 12.
1. Warm up the inner race of roller bearing (03) of as goggles, hard hats, etc. in order to prevent
the travel motor (00) side to 50 to 70 °C by using personal injury.
a heater. Push the inner race of roller bearing (03) IMPORTANT: Do not tap except for the outer race of
in travel motor (00). After the inner race of roller roller bearing (03).
bearing (03) cools completely, install the inner race 3. Evenly tap and install the outer race of roller bearing
of roller bearing (03) to travel motor (00) by using a (03) of the cover (41) side to drum (04) by using a
bar and a hammer. bar and a hammer.
fNOTE: Check that inner race of roller bearing (03) of the fNOTE: Check that the outer race of roller bearing (03) of
travel motor (00) side is installed completely. the cover (41) side is installed completely.
03
03
04
WDBR-04-02-002 WDBR-04-02-002
00
WDBR50-EN-00(20171222) W4-2-2-6

d CAUTION: Drum (04) weight: 40 kg (Refer to W2-4-5.)
4. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the 6. Apply grease to the entire circumference of the
bolt (06) holes of drum (04). Attach nylon slings O-ring of floating seal (02) of other side. Install one
onto the eyebolts. Hoist drum (04). Place drum (04) side of floating seal (02) to drum (04).
with the ring gear (20) side down.
fNOTE: If it is difficult to install O-ring of floating seal
(02), push O-ring to the circumferential direction by
using a bamboo spatula.
personal injury. dCAUTION: The drum (04) assembly weight: 41 kg
IMPORTANT: Do not tap except for the outer race of 7. Install eyebolts (M22, Pitch 2.5 mm) (2 used) to the
roller bearing (03). bolt (06) holes of drum (04). Attach nylon slings
onto the eyebolts. Hoist drum (04). Place drum (04)
5. Evenly tap and install the outer race of roller bearing
with the travel motor (00) side down.
(03) of the travel motor (00) side to drum (04) by
using a bar and a hammer.
dCAUTION: Sprocket (05) weight: 46 kg
fNOTE: Check that outer race of roller bearing (03) of the dCAUTION: When installing sprocket (05), gather
travel motor (00) side is installed completely. up the nylon slings and hoist sprocket (05)
horizontally. Do not drop sprocket (05).
04 03 00 IMPORTANT: Fit the chamfered side of sprocket (05)
to the drum (04) side.
8. Attach nylon slings onto sprocket (05). Hoist
sprocket (05). Place sprocket (05) onto drum (04).
9. Degrease the bolt (06) holes of drum (04) and bolts
(06) (18 used). Apply LOCTITE #263 or THREEBOND
#1386B to bolts (06) (18 used). Install sprocket (05)
to drum (04) with spring washers (07) (18 used) and
WDBR-04-02-003 j : 30 mm
m : 485 N·m
WDBR50-EN-00(20171222) W4-2-2-7
IMPORTANT: Check the direction to install bearing

d CAUTION: Sprocket (05) + drum (04) weight: 86
kg
nut (09).
13. Apply grease to the thread part of bearing nut (09).
10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the Tighten bearing nut (09) to travel motor (00) by
bolt (21) holes (2 places) of drum (04). Attach nylon hand with the machining surface side facing to the
slings onto the eyebolts. Hoist drum (04). Place roller bearing (03) side.
drum (04) straight on travel motor (00). At this time,
check that the clearance between travel motor (00) 14. Install bearing nut (09) by using special tools (ST
and drum (04) is even all around. 7248, ST 7249) and a torque wrench.
11. While applying a load and shaking drum (04), push m : 500 N·m
drum (04) into travel motor (00) straight.
dCAUTION:
hot.
Be careful as roller bearing (03) is too
ST 7248
12. Warm up the inner race of roller bearing (03) of
the cover (41) side to 50 to 70 °C by using a heater. ST 7249
Push the inner race of roller bearing (03) in travel
motor (00). After the inner race of roller bearing
(03) cools completely, install the inner race of roller
09
bearing (03) to travel motor (00) by using a bar and
a hammer.
fNOTE: Install roller bearing (03) until the inner race side
of roller bearing (03) reaches three threads for bearing
W178-03-02-013
nut (09).
fNOTE: Check that the inner race of roller bearing (03) of 15. After installing bearing nut (09), tap the sprocket
the cover (41) side is installed completely. (05) end by using a hammer and reduce play. Rotate
sprocket (05) both clockwise and counterclockwise
4 to 5 turns.
03 16. Repeat steps 14, 15 two or three times.
17. Tighten bearing nut (09) in the same way as step 14
again.
m : 500 N·m
00
WDBR-04-02-002
WDBR50-EN-00(20171222) W4-2-2-8
IMPORTANT: When knock pin (10) has been 24. Install spring pin (17) to third stage carrier (12) with
removed, follow the procedure as step 18. the slit (b) side facing to the second stage carrier
18. Fit the phases of the spline center in travel motor (23) side (c).
(00) and the knock pin (10) center. If the phases 17
are not fitted, rotate bearing nut (09) in tightening 16
b
direction until both center phases are fitted.
c
09 10
W178-02-11-210
b- Slit c- Second Stage Carrier (23)
00 Side
25. Install other planetary gears (13) (2 used) to third

stage carrier (12) in the same way as steps 19 to 22.
W178-02-11-208
19. Clean the mating surfaces of drum (04) and ring

dCAUTION: The third stage carrier (12) assembly
weight: 31 kg
gear (20). Apply THREEBOND #1389B. After cleaning
the mating surfaces of drum (04) and ring gear (20), dCAUTION: Third stage carrier (12) falls at the
moment when knock pin (10) is inserted into third
degrease the bolt (21) holes of drum (04). Apply
LOCTITE #263 or equivalent. stage carrier (12). Do not catch fingers.
26. Attach claws (a) of the special tool (ST 0916) onto
dCAUTION: Ring gear (20) weight: 49 kg the outer surface of third stage carrier (12). Hoist
20. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the the third stage carrier (12) assembly. Install the third
bolt, washer (43) holes (2 places) of ring gear (20). stage carrier (12) assembly to the spline part of
Attach nylon slings onto the eyebolts. Hoist ring travel motor (00).
gear (20). Install ring gear (20) to drum (04) with
bolts (21) (20 used). ST 0916
j : 24 mm a
m : 270 N·m
IMPORTANT: There is an identification groove on
one side of planetary gear (13). Install planetary
gear (13) with the identification groove side facing
to the spring pin (17) hole.
21. Install needle bearings (11) (2 used) to planetary
gear (13). W178-02-11-203
a- Claw
22. Sandwich planetary gear (13) between thrust plates
(15) (2 used). Install them to third stage carrier (12).
23. Install pin (16) to third stage carrier (12). At this time,
fit the spring pin (17) hole of third stage carrier (12)
and the pin (16) hole.
WDBR50-EN-00(20171222) W4-2-2-9
27. Install sun gear (18) to third stage carrier (12) with 33. Install other planetary gears (25) (2 used) to second
the thinner diameter part up. stage carrier (23) in the same way as steps 29 to 32.
28. Install spacer (24) to second stage carrier (23). 34. Install the second stage carrier (23) assembly to ring
gear (20).
29. Install needle bearing (26) to planetary gear (25).
35. Install sun gear (30) to second stage carrier (23) with
30. Sandwich planetary gear (25) between thrust plates
the thinner diameter part up.
(27) (2 used). Install them to second stage carrier
(23). 36. Install spacer (33) to first stage carrier (32).
31. Install pin (28) to second stage carrier (23). At this 37. Install needle bearing (35) to planetary gear (34).
time, fit the spring pin (29) hole of second stage
38. Secure planetary gear (34) between thrust plates
carrier (23) and the pin (28) hole.
(36) (2 used). Install them to first stage carrier (32).
32. Install spring pin (29) to second stage carrier (23)
39. Install pin (37) to first stage carrier (32). At this time,
with the slit (a) side facing to the cover (41) (b) side.
fit the spring pin (38) hole of first stage carrier (32)
and the pin (37) hole.
29
28
a
W178-02-11-210
a- Slit b- Cover (41) Side
WDBR50-EN-00(20171222) W4-2-2-10
40. Install spring pin (38) to first stage carrier (32) with
the slit (b) side facing to the cover (41) side.
38
37
b
W178-02-11-210
a- Slit c- Cover (41) Side
41. Install other planetary gears (34) (2 used) to first

stage carrier (32) in the same way as steps 37 to 40.
42. Install the first stage carrier (32) assembly to ring
gear (20).
43. Insert the spline side of shaft (39) into the center
of sun gear (30). Slowly turn sprocket (05) by
hand. Engage shaft (39) with travel motor (00) and
planetary gear (34). Install them.
44. Add gear oil (API GL4 SAE#90) through the ring gear
(20) side.

45. Clean the mating surfaces of ring gear (20) and
cover (41). Apply THREEBOND #1215 or LOCTITE
#5020. Install cover (41) to ring gear (20) with bolts,
j : 19 mm
m : 110 N·m
46. Install a seal tape onto plugs (44) (3 used). Install
plugs (44) (3 used) to cover (41).
l : 10 mm
m : 50 N·m
WDBR50-EN-00(20171222) W4-2-2-11
(Blank)
WDBR50-EN-00(20171222) W4-2-2-12
Disassembly of Travel Motor
WDAA-04-02-007
00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 31- O-Ring (2 Used)
01- Oil Seal 16- Retainer 25- Brake Piston 32- Brake Valve
03- Piston 17- Bushing 26- O-Ring 33- Needle Bearing
07- Shaft 18- Swash Plate 28- O-Ring 37- Knock Pin (2 Used)
08- Retaining Ring 19- Spring (6 Used) 29- Disc Spring 39- Valve Plate
09- Ball (2 Used) 21- Rotor 30- O-Ring 40- Socket Bolt (9 Used)
10- Roller Bearing 22- Friction Plate (4 Used)
WDBR50-EN-00(20171222) W4-2-3-1
Disassembly of Travel Motor IMPORTANT: Do not remove needle bearing (33)

unless necessary. Remove needle bearing (33)
dCAUTION: Travel motor weight: 91 kg by using a small puller if necessary. Needle
1. Attach nylon slings onto the travel motor. Hoist the bearing (33) cannot be reused as the outer race is
travel motor. Place the travel motor with the brake deformed.
valve (32) side up. IMPORTANT: Do not damage valve plate (39).
dCAUTION: Brake valve (32) weight: 21 kg 4. Remove valve plate (39), knock pins (37) (2 used),
and O-ring (30) from brake valve (32).
IMPORTANT: When removing the brake valve (32)
assembly, do not drop valve plate (39). 5. Install a tape onto the thrust surface of shaft (07)
2. Remove socket bolts (40) (9 used). and needle bearing (33) in order to protect.
6. Remove disc spring (29) from housing (00).
l : 14 mm
7. Remove O-rings (31) (2 used) from housing (00).
3. Remove plugs (a) (2 used). Install the adapters
(A852122) (2 used) to the holes of plugs (a) (2 used).
Install special tools (ST 0261) (2 used) to adapters dCAUTION: When removing brake piston (25),
hold brake piston (25) with a cloth in order not to
(A852122) (2 used). Attach nylon slings onto special fly out.
tools (ST 0261) (2 used). Hoist brake valve (32).
IMPORTANT: The upper surface of brake piston (25)
Remove brake valve (32) from housing (00).
is seat surface (b) for high-pressure oil. Place brake
l : 6 mm piston (25) with seat surface (b) for high-pressure
oil up.
j : 19 mm 8. Apply air 100 to 300 kPa to the brake releasing oil
passage in housing (00). Float and remove brake
a piston (25).
b
25
W178-02-11-215
b- Seat Surface of High-Pressure
Oil
a
a- Plug WDCD-04-02-007
WDBR50-EN-00(20171222) W4-2-3-2
9. Remove O-rings (26, 28) from brake piston (25). 14. Remove balls (09) (2 used) and piston (03) from
housing (00) by using a magnet.
10. Remove plates (23) (4 used) and friction plates (22)
(4 used) from housing (00). 15. Tap the bottom of the spline hole of shaft (07) by
using a bar and a plastic hammer. Remove shaft (07)
11. Remove rotor (21), springs (19) (6 used), bushing
together with roller bearing (10) from housing (00).
(17), retainer (16), and plungers (14) (9 used) from
housing (00). IMPORTANT: Oil seal (01) cannot be reused.
16. Remove oil seal (01) from housing (00) by using a
dCAUTION:
kg
screwdriver.
12. Attach nylon slings onto housing (00). Hoist the fNOTE: THREEBOND #1104 or #1215 has been applied
housing (00) assembly. Place the housing (00) to the outer surface of oil seal (01).
assembly horizontally with the brake releasing oil 17. Remove retaining ring (08) from shaft (07).
passage (a) side down.
IMPORTANT: When removing shaft (07) from roller
f NOTE: If housing (00) is placed with the brake releasing bearing (10), do not drop shaft (07).
oil passage (a) side up, the thick part of swash plate (18) 18. Secure the inner race part of roller bearing (10) on
becomes topside. If placing the housing (00) assembly shaft (07) in a vise. Remove shaft (07) from roller
horizontally, swash plate (18) may suddenly come out. bearing (10) by using a bar and a plastic hammer.
00
10
07
W178-02-11-212
WDC4-04-02-001
a- Brake Releasing Oil Passage
dCAUTION: When removing swash plate (18) by

applying air, hold piston (03) with a cloth in order
not to fly out.
IMPORTANT: When swash plate (18) cannot be
removed, apply air 100 to 300 kPa through the
piston oil passage hole. Swash plate (18) and
piston (03) are removed.
13. Remove swash plate (18) from housing (00).
WDBR50-EN-00(20171222) W4-2-3-3
Assembly of Travel Motor
30
31
37 25
40
21 14 16
18
32
09
10
01
07
00
33
19 17 03 08
39 22
23
29
28
26
WDCD-04-02-004
00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 31- O-Ring (2 Used)
01- Oil Seal 16- Retainer 25- Brake Piston 32- Brake Valve
03- Piston 17- Bushing 26- O-Ring 33- Needle Bearing
07- Shaft 18- Swash Plate 28- O-Ring 37- Knock Pin (2 Used)
08- Retaining Ring 19- Spring (6 Used) 29- Disc Spring 39- Valve Plate
09- Ball (2 Used) 21- Rotor 30- O-Ring 40- Socket Bolt (9 Used)
10- Roller Bearing 22- Friction Plate (4 Used)
WDBR50-EN-00(20171222) W4-2-3-4
Assembly of Travel Motor IMPORTANT: Check the direction to install roller

bearing (10).
onto parts in order to prevent them from seizing. IMPORTANT: Do not damage the seal lip contacting
surface of shaft (07).
dCAUTION: Housing (00) weight: 50 kg
6. Insert roller bearing (10) into shaft (07) with the
1. Attach nylon slings onto housing (00). Hoist housing inner ring plate (a) side facing to the spline part (b)
(00). Place housing (00) with the brake valve (32) side until roller bearing (10) reaches the end of shaft
side up. (07) mating part.
IMPORTANT: Replace oil seal (01) with the new one. 7. Install roller bearing (10) to shaft (07) by using
2. Apply OCEAN grease #7 to the inner surface of oil special tool (ST 2654) and a plastic hammer.
seal (01).
3. Apply THREEBOND #1104 or #1215 to the outer
circumference of oil seal (01). b
07
4. Clean the oil seal (01) mating part of housing (00).
Install oil seal (01) to housing (00) by using special a
tools (ST 2652, ST 7270) and a plastic hammer.
ST 7270 ST 2654
10
ST 2652
00 W178-02-11-230
01 a- Inner Ring Plate b- Spline Part
8. Install retaining ring (08) to shaft (07).

WDCD-04-02-006
9. Install piston (03) to housing (00) with the stepped
side facing inside.
5. Install inner ring plate (a) to roller bearing (10) with
the stamped mark facing outside. IMPORTANT: The small diameter side of shaft (07)
is the inner race of needle bearing (33). Do not
a
10 damage the inner race of needle bearing (33).
10. Install shaft (07) to housing (00) by using a plastic
hammer.
fNOTE: When center position of shaft (07) is sufficiently

W178-02-11-221 adjusted, shaft (07) will be inserted without hitting it.
a- Inner Ring Plate
WDBR50-EN-00(20171222) W4-2-3-5
11. Install balls (09) (2 used) to housing (00). IMPORTANT: Install retainer (16) with chamfered
side (b) facing to the bushing (17) side.
12. Apply grease to the ball (09) holes (2 places) of
swash plate (18) for adhesive. Fit the position of 14. Install springs (19) (6 used), bushing (17), retainer
balls (09) (2 used) and install swash plate (18) to (16), and plungers (14) (9 used) to rotor (21).
housing (00).
16
d CAUTION: The housing (00) assembly weight: 56
kg
13. Attach nylon slings onto housing (00). Hoist the 17
housing (00) assembly. Place the housing (00) b
assembly horizontally with the brake releasing oil
passage (a) side down. W178-02-11-225
b- Chamfered Side
fNOTE: If housing (00) is placed with the brake releasing

oil passage (a) side up, the thick part of swash plate (18)
15. Install the rotor (21) assembly to housing (00).
becomes topside. If placing the housing (00) assembly
horizontally, swash plate (18) may suddenly come out.
dCAUTION:
kg
00
16. Attach nylon slings onto housing (00). Hoist the
housing (00) assembly. Place the housing (00)
assembly with the brake valve (32) mounting
surface up.
IMPORTANT: Check the installation order of friction
plate (22) and plate (23).
a
17. Install friction plates (22) (4 used) and plates (23) (4
used) to housing (00).
18. Apply grease to O-rings (28, 26). Install O-rings (28,
26) to brake piston (25).
WDC4-04-02-001
a- Brake Releasing Oil Passage
WDBR50-EN-00(20171222) W4-2-3-6
IMPORTANT: Check the direction to install disc

spring (29).
20. Install disc spring (29) to brake piston (25) with the
inner diameter contacting to brake piston (25).
personal injury.
IMPORTANT: The upper surface of brake piston (25) 21. Install O-rings (31) (2 used) to housing (00).
is seat surface (b) for high-pressure oil. Do not 22. Add hydraulic oil to housing (00) until plate (23) is
damage brake piston (25). submerged.
b IMPORTANT: Check the direction to install knock pin
a (37).
23. Install knock pins (37) (2 used) to brake valve (32)
with the large diameter side facing to the brake
valve (32) side.
25
W178-02-11-215 dCAUTION: Metal fragments may fly off when
a- Notch b- Seat Surface of High-Pressure
Oil
personal injury.
IMPORTANT: Check the direction to install the outer
IMPORTANT: Install brake piston (25) so that notch
race of needle bearing (33).
(a) on the disc spring (29) side of brake piston (25)
is located opposite the brake releasing oil passage 24. Install the outer race of needle bearing (33) to brake
(c) side. valve (32) with the stamped mark facing outside by
using special tool (ST 7269) and a hammer.
19. Install brake piston (25) to housing (00) by using the
special tools (ST 7272 and ST 7273) and a hammer.
ST 7269
f NOTE: As O-ring (28) is positioned around brake piston
(25), brake piston (25) cannot be fully inserted. When 32 33
installing brake valve (32), tighten brake piston (25) with
socket bolt (40).
00 a 25 c
W178-02-11-227
WDCD-04-02-005
a- Notch
c- Brake Releasing Oil Passage
WDBR50-EN-00(20171222) W4-2-3-7
25. Apply grease to the flat surface of valve plate (39). 28. Install brake valve (32) to housing (00) with socket
Install valve plate (39) to brake valve (32) while bolts (40) (9 used).
fitting the knock pin (37) positions.
l : 14 mm
fNOTE: Valve plate (39) is secured to brake valve (32) in
m : 300 N·m
order not to drop brake valve (32) when turning over.
26. Apply grease onto rolling (30). Install rolling (30) to 29. Remove special tools (ST 0261) and adapters
brake valve (32). (A852122) (2 used for each).
IMPORTANT: Do not drop valve plate (39). If valve j : 19 mm
plate (39) is damaged, oil leakage may occur.
30. Install plugs (a) (2 used).
dCAUTION: Brake valve (32) weight: 21 kg
l : 6 mm
27. Remove plugs (a) (2 used). Install the adapters
(A852122) (2 used) to the holes of plugs (a) (2 used). m : 35 N·m
Install special tools (ST 0261) (2 used) to adapters
(A852122) (2 used). Attach nylon slings onto special
tools (ST 0261) (2 used). Hoist brake valve (32).
l : 6 mm
j : 19 mm
a
a- Plug WDCD-04-02-007
WDBR50-EN-00(20171222) W4-2-3-8
Disassembly of Brake Valve
WDAA-04-02-009
01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)
WDBR50-EN-00(20171222) W4-2-4-1
Disassembly of Brake Valve IMPORTANT: As the setting changes, do not

disassemble relief valve (15).
1. Remove plugs (05) (2 used) from casing (01A).
Remove O-rings (07) (2 used) from plugs (05) (2 IMPORTANT: Do not move piston (a) with the outer
used). surface of relief valve (15) attached. O-ring may be
damaged.
j : 36 mm 7. Remove relief valves (15) (2 used) from casing (01A).
2. Remove springs (03) (2 used) and stoppers (02) (2
j : 36 mm
used) from casing (01A) by using a magnet.
15
3. Remove spool (01B) from casing (01A) by using a
magnet.
IMPORTANT: Do not remove plug (22) unless
necessary.
4. Remove plug (22) from casing (01A). Remove O-ring
(22A) from plug (22).
l : 6 mm
a
5. Remove seat (13) from casing (01A).
W1V1-03-02-008
a- Piston
l : 5 mm
6. Remove ball (11) by using a magnet.
8. Remove springs (10) (2 used) and poppet (08) (2
used) from casing (01A) by using a magnet.
9. Remove plug (17) from casing (01A). Remove O-ring
(17A) from plug (17).
l : 6 mm
10. Remove spring (16) and spool (01C) from casing
(01A) by using a magnet.
WDBR50-EN-00(20171222) W4-2-4-2
Assembly of Brake Valve
01B 01A
02
03
07
05
05
22
01C
16
22A 17A 17
08
10
15 11 13 15
WDAA-04-02-010
01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)
WDBR50-EN-00(20171222) W4-2-4-3
Assembly of Brake Valve 8. Install springs (10) (2 used) to poppets (08) (2 used).
Install poppets (08) (2 used) to the hole of casing
(01A) completely.
9. Install relief valves (15) (2 used) to casing (01A)
1. Install spool (01B) into the center of casing (01A). while pushing poppets (2) (2 used).
2. Install O-ring (07), spring (03) and stopper (02) to j : 36 mm

plug (05). Install the plug (05) assembly to casing
(01A) with one thread tighten. m : 450 N·m
IMPORTANT: Check the direction to install spool
fNOTE: If plug (05) is fully tightened, it is difficult to
(01C).
install other plug (05) as spool (01B) is pushed.
10. Install spool (01C) to casing (01A) with the hole side
3. Install O-ring (07), spring (03) and stopper (02) to
facing the near side.
other plug (05). Install the plug (05) assembly to
casing (01A) and tighten by hand. 11. Install spring (16) to casing (01A).
4. Tighten plugs (05) (2 used). 12. Install O-ring (17A) to plug (17). Install plug (17) to
casing (01A).
j : 36 mm
l : 6 mm
m : 450 N·m
m : 35 N·m
5. Install ball (11) to casing (01A).
6. Install seat (13) to casing (01A).
l : 5 mm
m : 15 N·m
7. Install O-ring (22A) to plug (22). Install plug (22) to
casing (01A).
l : 6 mm
m : 35 N·m
WDBR50-EN-00(20171222) W4-2-4-4

these procedures:
ring (1) surfaces together. Apply oil onto sliding W178-02-11-001
surface (e) of seal ring (1). 2
hardening.

trouble.
 Clean the floating seal and seal mounting bores with a
cleaning solvent.
Check the bore surface for scuffing or scoring by d
 After installing the floating seal, check that O-ring (2) W178-02-11-002
a- Correct c- Twist of O-Ring
ring (1).
b- Incorrect d- Bend of O-Ring
 After installing the floating seal, check that O-ring
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.
B B
A=B A≠B
W178-02-11-003

WDBR50-EN-00(20171222) W4-2-5-1
(Blank)
WDBR50-EN-00(20171222) W4-2-5-2
Removal and Installation of Center Joint
4 13 11 8, 9 14 10
WDCX-04-03-002
IMPORTANT: The hoses and pipes contain hydraulic 4. Disconnect hose (4).
IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts (8) (2 used) and spring washers (9) (2
and pipes have been disconnected. In addition, used). Remove stopper (10).
hoses, and pipes for assembling. If the clips which j : 22 mm
secure the hoses have been removed, install the 6. Remove adapter (14).
j : 22 mm
Removal 7. Remove adapter (13).
1. Set the machine position for inspection and j : 19 mm
8. Remove rubber (11).
d CAUTION: Release any pressure in the hydraulic
j : 36 mm
3. Disconnect hose (3).
j : 27 mm
WDBR50-EN-00(20171222) W4-3-1-1
7 12 1 7
2
16
6
6
1 16
WDCX-04-03-002 5 WDCX-04-03-003
dCAUTION: Center joint (1) weight: 27 kg

9. Install special tools (ST 0244) (2 used) to adapters
(16) (2 places) of center joint (1). Attach nylon slings
onto special tools (ST 0244) (2 used). Hoist and hold
center joint (1).
j : 36 mm
j : 27 mm
j : 36 mm
j : 17 mm
13. Remove bolts, washers (12) (4 used). Lower and
remove center joint (1) from track frame (2).
j : 19 mm
14. Remove the adapters with center joint (1) attached
if necessary.
WDBR50-EN-00(20171222) W4-3-1-2
7 12 1 7
15
16
6
6
13 11 8, 9 16 14 10
5 WDCX-04-03-003 WDCX-04-03-002
Installation 6. Connect hoses (5) (2 used).

1. Install all adapters which have been removed in j : 27 mm
step 14 for removal to center joint (1).
m : 80 N·m
dCAUTION: Center joint (1) weight: 27 kg
7. Install rubber (11).
2. Install special tools (ST 0244) (2 used) to adapters
(16) (2 places) of center joint (1). Attach nylon slings 8. Install adapter (13).
onto special tools (ST 0244) (2 used). Hoist and hold
center joint (1). j : 19 mm
j : 36 mm m : 30 N·m
3. Install center joint (1) to track frame (15) with bolts, 9. Install adapter (14).
washers (12) (4 used). j : 22 mm
j : 19 mm m : 70 N·m
m : 90 N·m 10. Install stopper (10) with spring washers (9) (2 used)
4. Connect hoses (7) (2 used). and bolts (8) (2 used).
j : 17 mm j : 22 mm
m : 25 N·m m : 140 N·m
j : 36 mm
m : 180 N·m
WDBR50-EN-00(20171222) W4-3-1-3
WDCX-04-03-002
j : 17 mm
m : 25 N·m
j : 27 mm
m : 80 N·m
j : 36 mm
m : 180 N·m
1.)
WDBR50-EN-00(20171222) W4-3-1-4
Disassembly of Center Joint
WDAA-04-03-003
00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug with Ball 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal
WDBR50-EN-00(20171222) W4-3-2-1
Disassembly of Center Joint

IMPORTANT: For easy removal of oil seal (04), use the
d CAUTION: Center joint weight: 27 kg pins (2 used). Do not damage the seal groove.
1. Remove bolts, washers (10) (2 used) diagonally. 6. Remove oil seals (04) (6 used), O-ring (03), and dust
Install eyebolts (M10, Pitch 1.5 mm) to the bolt (10) seal (02) from body (01).
holes (2 places) of body (01). Attach nylon slings
onto the eyebolts. Hoist the center joint. Secure the
center joint on a workbench.
j : 17 mm
2. Remove other bolts, washers (10) (2 used). Remove
cover (09) from body (01).
j : 17 mm
3. Remove O-ring (08), retaining ring (07), and ring (06)
from body (01).
4. Install special tools (ST 1033, ST 1020) to body (01)
j : 17 mm W178-02-11-240
IMPORTANT: Do not damage the seal surface.

10 7. When replacing bushing (05), weld four places on
the bushing (05) bore by using a welding bar. Shrink
and remove bushing (05).
01
W506-03-03-002
IMPORTANT: Do not damage the seal sliding surface

of the spindle (00A).
5. Remove spindle (00A) from body (01).
j : 32 mm
WDBR50-EN-00(20171222) W4-3-2-2
Assembly of Center Joint
00B
00A
02
03
05
04
01
06
07
08
09
10
W178-03-03-001
00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug with Ball 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal
WDBR50-EN-00(20171222) W4-3-2-3
Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (05).
to parts in order to prevent them from seizing. IMPORTANT: The clearance between body (01) and
IMPORTANT: When assembling the seals, apply spindle (00A) is approximately 0.1 mm (0.004 in).
grease (Apolloil Autorex C) to the seals. Install the Install body (01) along axis straight and slowly. Do
seals to the grooves. not damage the seal.
IMPORTANT: When bushing (05) has been removed, IMPORTANT: Do not make a step on ring (06)
install bushing (05) first. (Refer to W4-3-2-6.) mounting part (b).
1. Install dust seal (02) to spindle (00A) with lip part (a) 3. Place spindle (00A) onto a workbench. Install body
facing to the body (01) side. (01) to spindle (00A).
b 00A
02
01
01
W800-03-03-002
W178-03-03-002 b- Ring (06) Mounting Part
a- Lip Part
2. Install O-ring (03) and oil seals (04) (6 used) to body
(01).
WDBR50-EN-00(20171222) W4-3-2-4
IMPORTANT: Install ring (06) with the chamfered

surface facing to the spindle (00A) side.
4. Install ring (06) and O-ring (08) to body (01).
00A
01
06
08
07
10
09 WDAA-04-03-004
5. Install retaining ring (07) to spindle (00A).

6. Install cover (09) to body (01) with bolts, washers
(10) (4 used).
j : 17 mm
m : 50 N·m
WDBR50-EN-00(20171222) W4-3-2-5
Replacement of Body and Spindle

ST 2558
IMPORTANT: When replacing body (01) or spindle
(00A) with the new one, the following procedures
are required. 01
In case of Body (01)

1. Clean body (01) and bushing (05).
05
2. Apply grease (Apolloil Autolex C) or molybdenum
disulfide to the outer circumference of bushing (05).
3. Install bushing (05) to body (01) by using special
tool (ST 2558) and a press.
fNOTE: Pushing force: 4.9 to 14.7 kN
W178-02-11-242
00B C
In case of Spindle (00A) 00A
1. Clean spindle (00A).

2. Install plug (00B) to spindle (00A) by using special
tool (ST 2559).
3. Install ball (a) of plug (00B) so that the top of each
ball is over 0.4 mm lower than the respective sleeve
(c) edge as illustrated in detail C.
WDAA-04-03-005
ST 2559 Detail C
b
c
WDAA-04-03-006 WDAA-04-03-007
a- Ball b- Over 0.4 mm (0.02 in)

c- Sleeve
WDBR50-EN-00(20171222) W4-3-2-6
Removal and Installation of Track Adjuster
c a 1
ST 1650
7 2
WDCD-04-04-002
c- Hoisting Position
Before removing and installing the track adjuster, the 3. Attach a weight onto part (b) of special tool
tracks must be removed first. (Refer to W4-7-1.) (ST 1650). Set the track adjuster (7) assembly
Therefore, the procedure starts on the premise that the horizontally.
tracks have already been removed here.
4. Pull out the track adjuster (7) assembly until nylon
slings can be attached onto hoisting position (c) of
Removal
track adjuster (7).
dCAUTION: Special tool (ST 1650) weight: 53 kg 5. Reattach nylon slings onto hoisting position (c) from
1. Install special tool (ST 1650) to the yoke (2) part of hoisting position (a) of track adjuster (7). Hoist and
front idler (1). hold the track adjuster (7) assembly.
dCAUTION: The track adjuster (7) assembly

weight: 235 kg
6. Remove special tool (ST 1650) from the track
adjuster (7) assembly. Remove the track adjuster (7)
assembly.
dCAUTION: The track adjuster (7) assembly may
fly out due to the spring force when removing the
track adjuster (7) assembly. Particularly, strong
force is always applied to the thread part of the
rod. If the rod and/or the threads are damaged,
metal fragments may fly out due to the spring
force. Take care to the flying objects.
2. Attach a c-clump onto hoisting position (a) of
front idler (1). Hoist and hold the track adjuster (7)
assembly.
WDBR50-EN-00(20171222) W4-4-1-1
7 3, 4
a 5, 6 a
WDCD-04-04-004 WDDK-04-04-002
a- Block
7. Place the track adjuster (7) assembly onto blocks (a)

(4 used).
j : 24 mm

weight: 235 kg
9. Turn over the track adjuster (7) assembly.
dCAUTION:
adjuster (7).
Take care not to turn over track
dCAUTION: Front idler (1) weight: 110 kg

Remove front idler (1).
j : 24 mm
WDBR50-EN-00(20171222) W4-4-1-2
7 5, 6
a 3, 4 a
WDCD-04-04-004 WDDK-04-04-002
a- Block
Installation 4. Install washers (4) (2 used) and bolts (3) (2 used).
dCAUTION:
adjuster (7).
Take care not to turn over track j : 24 mm
m : 270 N·m
dCAUTION: Front idler (1) weight: 110 kg
Track adjuster (7) weight: 126 kg
1. Place track adjuster (7) and front idler (1) onto
blocks (a) (4 used) with the bolt (5) hole side up.
2. Install front idler (1) with washers (6) (2 used) and
bolts (5) (2 used).
j : 24 mm
m : 270 N·m

weight: 235 kg
3. Turn over the track adjuster (7) assembly.
WDBR50-EN-00(20171222) W4-4-1-3
c a 1
ST 1650
7 2
WDCD-04-04-002
c- Hoisting Position

weight: 235 kg
dCAUTION: The track adjuster (7) assembly +
special tool (ST 1650) weight: 310 kg
5. Attach nylon slings onto hoisting position (c) 10. Attach a weight onto part (b) of special tool
of track adjuster (7). Hoist the track adjuster (7) (ST 1650). Set the track adjuster (7) assembly
assembly. horizontally.
6. Install the track adjuster (7) assembly to the track 11. Install the track adjuster (7) assembly to the track
frame until it reaches where nylon slings can be frame.
removed.
dCAUTION:
adjuster (7).
Take care not to turn over track
7. Remove the nylon slings.
dCAUTION: Special tool (ST 1650) weight: 53 kg

8. Install special tool (ST 1650) to the yoke (2) part of
front idler (1).
9. Attach a c-clump onto hoisting position (a) of
front idler (1). Hoist and hold the track adjuster (7)
assembly.
WDBR50-EN-00(20171222) W4-4-1-4
Disassembly of Front Idler
WDCD-04-04-006
00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)
WDBR50-EN-00(20171222) W4-4-2-1
Disassembly of Front Idler

dCAUTION:
kg
The idler (03A) assembly weight: 110
(Refer to W4-4-4.)
1. Place the idler (03A) assembly horizontally. Remove 4. Remove bearing (00) from the upper side of idler
plugs (06) (2 used) from bearings (00) (2 used). Drain (03A). Remove floating seals (05) (2 used) from idler
off engine oil from the idler (03A) assembly. (03A) and bearing (00).
l : 6 mm
fNOTE: Amount of oil: 0.27 L 00

05

03A
personal injury.
2. Remove pin (04) from bearing (00) at the upper side
by using a round bar and a hammer.
05
fNOTE: Diameter of round bar: 16 mm
02
dCAUTION: The axle (01) assembly weight: 25 kg
3. Put the matching marks on bearing (00) and axle
(01). Remove the axle (01) assembly from the idler 01
(03A) assembly by using a press. 00
00 01
W105-03-05-009
03A
W105-03-05-008
WDBR50-EN-00(20171222) W4-4-2-2
dCAUTION: The axle (01) assembly weight: 25 kg dCAUTION: Idler (03A) weight: 70 kg
IMPORTANT: Place wooden blocks under bearing IMPORTANT: Do not remove bushing (03B) unless
(00) in order not to damage bearing (00). necessary.
5. Attach nylon slings onto the axle (01) assembly. 9. When replacing bushing (03B), remove bushing
Hoist the axle (01) assembly. Place the bearing (00) (03B) by using special tool (ST 1425) and a press.
part of the axle (01) assembly onto wooden blocks
(a).

personal injury. 03A ST 1425
6. Remove pin (04) by using a round bar and a

hammer.

7. Put the matching marks on bearing (00) and axle
(01). Remove axle (01) from bearing (00) by using a
03B
press.
8. Remove O-rings (02) (2 used) from axle (01).
W105-03-05-011
04 02
00
a
01
02
W105-03-05-010
a- Wooden Block
WDBR50-EN-00(20171222) W4-4-2-3
Assembly of Front Idler
03A
03B 04 00
06
01 05 02
WDC150-04-04-001
00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)
WDBR50-EN-00(20171222) W4-4-2-4
Assembly of Front Idler

dCAUTION: Idler (03A) weight: 70 kg
(Refer to W4-4-4.)
1. Install bushings (03B) (2 used) to idler (03A).
5. Apply engine oil to the O-ring of floating seal (05).
2. Place axle (01) vertically. Install O-ring (02) to the Install floating seal (05) to idler (03A) and bearing
upper side of axle (01). (00).
3. Fit the matching marks made when disassembling
and install bearing (00) to axle (01) by using a plastic dCAUTION: The axle (01) assembly weight: 25 kg
hammer. 6. Attach nylon slings onto bearing (00) of the axle (01)
assembly. Hoist the axle (01) assembly. Install the
axle (01) assembly to idler (03A) at the side where
floating seal (05) has been installed.
personal injury.
4. Install pin (04) by using a bar and a hammer. 00
04 00
01
02
05
03A
01
WDDQ50-04-04-002
WDDQ50-04-04-001
7. Install a seal tape onto the thread part of plug (06).
Install plug (06) to bearing (00).
l : 6 mm
m : 15 N·m
WDBR50-EN-00(20171222) W4-4-2-5
dCAUTION:
kg
The idler (03A) assembly weight: 95 dCAUTION: Metal fragments may fly off when
8. Attach nylon slings onto the idler (03A) assembly. such as goggles, hard hat, etc. in order to prevent
Hoist the idler (03A) assembly. Turn over the idler personal injury.
(03A) assembly. 12. Install pin (04) by using a bar and a hammer.
9. Install O-ring (02) to axle (01). 13. Add engine oil (API CD class SAE#30) through the
plug (06) hole of bearing (00).
(Refer to W4-4-4.) fNOTE: Amount of oil: 0.27 L
10. Apply engine oil to the O-ring of floating seal (05). 14. Install a seal tape onto the thread part of plug (06).
Install floating seal (05) to idler (03A) and bearing Install plug (06) to bearing (00).
(00).
l : 6 mm
00 m : 15 N·m
01 05
02
03A
00
WDDQ50-04-04-003
11. Fit the matching marks made when disassembling

and install bearing (00) to axle (01) by using a plastic
hammer.
WDBR50-EN-00(20171222) W4-4-2-6
Disassembly of Track Adjuster
WDC150-04-04-002
00A- Cylinder 03- Yoke 08- Bracket 15- Valve

00B- Rod 04- Seal 09- Bolt (2 Used) 16- Bracket
01- Spacer 05- Dust Seal 10- Washer (2 Used)
02- Spring 07- Nut 14- Piston
WDBR50-EN-00(20171222) W4-4-3-1
Disassembly of Track Adjuster

5. Remove nuts (d) (4 used) from special tool (ST 4950).
dCAUTION: The spring force is extremely large.
Carry out the disassembly and assembly work
Attach nylon slings onto the eyebolts (2 used) of
special tool (ST 4052). Hoist special tool (ST 4052).
carefully. In addition, inspect the special tool for Remove special tool (ST 4052).
any damage thoroughly in order to perform the
work safely. j : 46 mm
1. Remove bolt, washer (09), washer (10), and bracket
(16) from piston (14).
j : 17 mm
2. Remove valve (15) from piston (14).
j : 24 mm ST 4052
3. Remove piston (14) from cylinder (00A).
dCAUTION: Check the surfaces of special tool

(ST 4053). Install special tool (ST 4053) with the
stamped mark (33 TON) up.
4. Place oil jack (c) (300 kN) between holder (a) and
base (b) of special tool (ST 4950).
WDCD-04-04-010
ST 4052
dCAUTION:
kg
The spring (02) assembly weight: 118
6. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and

nuts (2 used) to the bolt holes (2 places) of yoke (03)
ST 4053
diagonally. Attach nylon sling onto the eyebolts.
ST 4950 a Hoist the spring (02) assembly.
7. Place the spring (02) assembly onto holder (a) of
c special tool (ST 4950).
b
WDCD-04-04-009
a- Holder c- Oil Jack

b- Base d- Nut
WDBR50-EN-00(20171222) W4-4-3-2
8. Install special tool (ST 4052) so as to cover the 11. Remove nut (07) from rod (00B).
spring (02) assembly. Install washers (J222016) (4
used) and bolts (J921650) (4 used) to the bolt holes j : 75 mm
(4 places) of yoke (03). Secure special tool (ST 4052) 12. Slowly lower the oil jack.
and the spring (02) assembly.
13. Remove nuts (a) (4 used) from special tool (ST 4950).
j : 24 mm
j : 46 mm

a
J921650, 14. Attach nylon slings onto the eyebolts (2 used) of
J222016
special tool (ST 4052). Hoist and hold special tool
(ST 4052). Remove bolts (J921650) (4 used) and
washers (J222016) (4 used). Remove special tool (ST
4052).
ST 4052
WDCD-04-04-013
a- Nut
dCAUTION: As spring (02) is compressed, a strong

force is applied. Check if the spring (02) assembly
is installed correctly with the machine raised off
the ground.
9. Tighten nuts (a) (4 used) of special tool (ST 4950).
Secure the spring (02) assembly. Slowly operate WDCD-04-04-012
an oil jack. Compress spring (02) until nut (07) is
loosened.
fNOTE: Spring (02) compressed length: 101.4 mm

Spring free length (596.4 mm) - Spring set length (495
mm) = Spring compressed length (101.4 mm)
10. Remove bolt (09) and washer (10) from bracket (08).
Remove bracket (08) from nut (07).
j : 17 mm
WDBR50-EN-00(20171222) W4-4-3-3
dCAUTION: Yoke (03) weight: 21 kg

nuts (2 used) to the bolt holes (2 places) of yoke (03)
diagonally. Attach nylon slings onto the eyebolts.
Hoist yoke (03).
16. Remove yoke (03) from the spring (02) assembly.
dCAUTION:
kg
17. Install eyebolts (M10, Pitch 1.5 mm) to rod (00B).

Attach nylon sling onto the eyebolts. Hoist the
spring (02) assembly.
18. Remove the spring (02) assembly from special tool
(ST 4950).
dCAUTION: Spring (02) weight: 62 kg

19. Remove spring (02) from the rod (00B) assembly.
20. Remove spacer (01) from rod (00B).
IMPORTANT: Rod (00B) has been pressed in cylinder
(00A).
IMPORTANT: Do not remove rod (00B) unless
necessary.
21. Remove rod (00B) from cylinder (00A) by using a
press.
IMPORTANT: Do not damage seal (04) and dust seal
(05).
22. Remove seal (04) and dust seal (05) from cylinder
(00A).
WDBR50-EN-00(20171222) W4-4-3-4
Assembly of Track Adjuster
08 07 02 00B 00A 04 05 14
WDCD-04-04-008
09 10 03 01
Detail A
15
09 10 16 WDC150-04-04-003
00A- Cylinder 03- Yoke 08- Bracket 15- Valve

00B- Rod 04- Seal 09- Bolt (2 Used) 16- Bracket
01- Spacer 05- Dust Seal 10- Washer (2 Used)
02- Spring 07- Nut 14- Piston
WDBR50-EN-00(20171222) W4-4-3-5
Assembly of Track Adjuster 6. Remove the eyebolts from rod (00B).
dCAUTION:
29 kg
The cylinder (00A) assembly weight: dCAUTION: Yoke (03) weight: 21 kg
1. Apply grease to the inner circumference of cylinder nuts (2 used) to the bolt holes (2 places) of yoke (03)
(00A). Install rod (00B) to cylinder (00A) by using a diagonally. Attach nylon slings onto the eyebolts.
press. Hoist yoke (03).
fNOTE: Pushing force: 93 to 191 kN 8. Place yoke (03) onto spring (02). Remove the
eyebolts (2 used) and nuts (2 used) from yoke (03).
2. Apply grease to seal (04) and dust seal (05). Install
Install special tool (ST 4052). Install bolts (J921650)
seal (04) and dust seal (05) to cylinder (00A).
(4 used) and washers (J222016) (4 used) to the bolt
3. Install spacer (01) to rod (00B). holes (4 places) of yoke (03). Secure special tool (ST
4052) and yoke (03).
dCAUTION: Spring (02) weight: 62 kg
j : 24 mm
4. Install spring (02) to rod (00B).
dCAUTION:
kg
5. Install eyebolts to the bolt (09) holes of rod (00B). J921650,

Attach nylon sling onto the eyebolts. Hoist the a J222016
spring (02) assembly. Place the spring (02) assembly
onto special tool (ST 4950).
ST 4052
WDCD-04-04-013
a- Nut
WDBR50-EN-00(20171222) W4-4-3-6
9. Tighten nuts (a) (4 used) of special tool (ST 4950). 12. Install bracket (08) to nut (07) with washer (10) and
Secure the spring (02) assembly. bolt (09).
j : 46 mm j : 17 mm
m : 60 N·m
a 13. Lower the oil jack.
14. Remove nuts (a) (4 used) from special tool (ST 4950).

15. Attach nylon slings onto the eyebolts (2 used) of
special tool (ST 4052). Hoist and hold special tool
(ST 4052). Remove bolts (J921650) (4 used) and
washers (J222016) (4 used). Remove special tool (ST
4052).
dCAUTION:
kg
WDCD-04-04-013 16. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
a- Nut nuts (2 used) to the bolt holes (2 places) of yoke (03)
diagonally. Attach nylon sling onto the eyebolts.
Hoist the spring (02) assembly.
10. Operate an oil jack. Compress spring (02) to the
17. Remove the spring (02) assembly from special tool
specified length.
(ST 4950).
fNOTE: Specified spring length: 495 mm
11. Install nut (07) to rod (00B).
j : 75 mm
WDBR50-EN-00(20171222) W4-4-3-7
18. Fill part A of cylinder (00A) with grease.
A 00A 14
15, 16
WDCD-04-04-014
19. Install piston (14) to cylinder (00A).

20. Bleed air from part A of cylinder (00A) and cylinder
(00A).
21. Install bracket (16) and valve (15) to piston (14).
j : 24 mm
m : 90 N·m
22. Install washer (10) and bolt (09) to bracket (16).
j : 17 mm
m : 60 N·m
WDBR50-EN-00(20171222) W4-4-3-8

these procedures:
hardening.

trouble.
cleaning solvent.
ring (1).
f
A A
B B
A=B A≠B
W178-02-11-003

WDBR50-EN-00(20171222) W4-4-4-1
(Blank)
WDBR50-EN-00(20171222) W4-4-4-2
Removal and Installation of Upper Roller
1 2
1
WDDK-04-05-001 WDCD-04-06-001
dCAUTION: The pressure inside cylinder of the

track adjuster is high. Do not loosen valve (1)
quickly or too much as valve (1) may fly out or
high-pressure grease may spout out. Keep body
parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).
IMPORTANT: When gravel or mud is packed between
the sprockets and the track links, remove them
before loosening.
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen valve (1) over those turns.
Removal
2. Loosen valve (1) in the track adjuster. Drain grease
from the cylinder.
j : 24 mm
WDBR50-EN-00(20171222) W4-6-1-1
b a 5
3 c 4
WDAQ-04-06-004 WDC150-04-06-006
a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
dCAUTION: Use nonskid cloth (b) between track

frame (3) and oil jack (a) in order not to slip.
3. Raise track (5) in order to get clearance between
upper roller (4) and track (5) by using oil jack (a).
4. Place wooden blocks (c) between track (5) and track
frame (3).
5. Loosen bolts (6) (4 used) of upper roller (4). Remove
upper roller (4).
j : 24 mm
WDBR50-EN-00(20171222) W4-6-1-2
5
b a 6
3 c 4
WDAQ-04-06-004
a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
1 WDC150-04-06-006
WDCD-04-06-001 M104-07-067
a- 90 to 110°
Installation
1. Install upper roller (4) with bolts (6) (4 used). dCAUTION: Securely support the raised machine
by using the blocks.
j : 24 mm 4. Raise the machine off the ground. The raised
machine position is as illustrated.
m : 270 N·m
2. Remove wooden blocks (c), oil jack (a), and nonskid
cloth (b) between track (5) and track frame (3).
3. Tighten valve (1) in the track adjuster.
j : 24 mm
m : 88 N·m
WDBR50-EN-00(20171222) W4-6-1-3
WDCD-04-06-001 WXXX-03-07-001
a- Track Sag Specification
5. Apply grease through grease fitting (1) and adjust

the track tension.
fNOTE: Track sag specification (a): 300 to 335 mm
WDBR50-EN-00(20171222) W4-6-1-4
4 W158-03-06-001
6. Lower the machine.

IMPORTANT: Upper roller (4) cannot be
disassembled. Replace it as an assembly.
7. Remove plug (8).
l : 6 mm
8. Add engine oil (API CD class SAE #30) through the
plug (8) hole of cover (7).
fNOTE: Amount of oil: 65 mL

9. Apply THREEBOND #2353 onto plug (8).
l : 6 mm
m : 20 N·m
WDBR50-EN-00(20171222) W4-6-1-5
(Blank)
WDBR50-EN-00(20171222) W4-6-1-6
Removal and Installation of Lower Roller
3, 4, 5 2 3, 4, 5
b
d
1 a WDC150-04-06-004 c M104-07-067
a- Wooden Block b- 90 to 110°

c- Stand
d- 130 mm
Removal
2. Put the matching marks on track guard (1) and track
frame (2).
dCAUTION: When removing bolt (3) without

holding track guard (1), track guard (1) will fall
down.
3. Place wooden blocks (a) under track guard (1).
4. Remove bolts (3) (4 used), spring washers (4) (4
used), and washers (5) (4 used).
j : 27 mm
angle between boom and arm to 90 degrees to 110
degrees. Lower the boom with the round bottom
of the bucket contacting with the ground. Raise the
track frame off the ground. At this time, place stands
(c) under the track frame and support the machine.
WDBR50-EN-00(20171222) W4-6-2-1
Detail A 1 2
A TDAA-03-08-002
WDDK-04-05-001
WDCN-04-05-001
3

quickly or too much as valve (1) may fly out or
the sprocket and track links, remove it before
loosening.
6. Loosen valve (1) in the track adjuster. Drain grease
and loosen the track tension until the clearance in
the track is enough to remove track guard (3).
j : 24 mm
7. Temporarily tighten valve (1) in the track adjuster.
j : 24 mm
dCAUTION: Track guard (3) weight: 22 kg

8. Remove track guard (3) by using a forklift.
WDBR50-EN-00(20171222) W4-6-2-2
1 2
a
3 4
WDC150-04-06-003 c M104-07-067
a- Roller Rotating Surface b- 90 to 110°

c- Stand
9. Put the matching marks on lower roller (1) and track 12. Set the angle between the boom and arm to 90
frame (2). to 110 degrees. Lower the boom with the round
bottom of the bucket contacting with the ground.
10. Lower the machine. Make roller rotating surface (a)
Raise the track frame off the ground. At this time,
touch track link (4).
place stands (c) under the track frame and support
11. Remove bolts (3) (4 used). the machine.
j : 27 mm dCAUTION: Lower roller (1) weight: 35 kg
13. Remove lower roller (1) by using a forklift.
WDBR50-EN-00(20171222) W4-6-2-3
1 2
1
5
3 4
WDDK-04-05-003 WDC150-04-06-003
Installation
dCAUTION: Lower roller (1) weight: 35 kg

1. Set lower roller (1) on track link (4) by using a
forklift.
2. Lower the machine in order to adjust the lower
roller (1) mounting position.
3. Fit the bolt (3) holes of track frame (2) and lower
roller (1) and fit the matching marks made when
removing. Install lower roller (1) with bolts (3) (4
used).
j : 27 mm
m : 460 N·m
fNOTE: Install plug (5) with it facing to outside.
WDBR50-EN-00(20171222) W4-6-2-4
3, 4, 5 6 3, 4, 5
1 2
WDCN-04-05-001 WDC150-04-06-005
dCAUTION: Track guard (1) weight: 22 kg

4. Set track guard (1) on track link (2) by using a
forklift.
dCAUTION: Securely support the raised machine

5. Lower the machine in order to adjust the track
guard (1) mounting position.
6. Fit the bolt (3) holes of track frame (6) and track
guard (1) and fit the matching marks made when
removing by using a pry bar. Install track guard
(1) with washers (5) (4 used), spring washers (4) (4
used), and bolts (3) (4 used).
j : 27 mm
m : 500 N·m
WDBR50-EN-00(20171222) W4-6-2-5
1 2
TDAA-03-08-002 WXXX-03-07-001
a- Track Sag Specification
7. Tighten valve (1) of the track adjuster.
j : 24 mm
m : 90 N·m
dCAUTION: Securely support the raised machine

8. Raise the track to be adjusted off the ground. Rotate
the track in the reverse direction a little.
9. Apply grease through grease fitting (2) and adjust
the track tension.
fNOTE: Track sag specification (a): 285 to 320 mm
WDBR50-EN-00(20171222) W4-6-2-6
Disassembly of Lower Roller
7
3
4
5
3
2
5
4
WDC150-04-06-001
1- Plug 4- O-Ring (2 Used) 7- Roller

2- Collar 5- Floating Seal (2 Used) 8- Axle
3- Pin (2 Used) 6- Bushing (2 Used) 9- Collar
WDBR50-EN-00(20171222) W4-6-3-1
Disassembly of Lower Roller IMPORTANT: Handle the floating seals (5) with care.
(Refer to W4-5-4.)
dCAUTION: Lower roller weight: 35 kg
4. Remove the floating seals (5) (2 used) from both
1. Remove the plug (1) from the end of the collar (2). sides of the roller (7) and collars (2, 9).
Drain oil from the roller (7).
5. Remove the pin (3) from the axle (8) assembly.
l : 6 mm Remove the axle (8) from the collar (9) by using a
press.

a hammer is used. Wear necessary protection, 4 3 9
personal injury.
2. Remove the pin (3) from the collar (2) by using a
round bar and a hammer.
8
W178-02-11-268
2
6. Remove the O-rings (4) (2 used) from the axle (8).
dCAUTION: Roller (7) weight: 21 kg

IMPORTANT: Do not remove the bushing (6) unless
necessary.
a 7. Remove the bushing (6) by using the special tool (ST
1955) and a press.
a- Direction to Remove Pin (3)
WDDK-04-05-004
3. Remove the axle (8) from the collar (2) and roller (7)
ST 1955
by using a press. At this time, the pin (3) and collar
(9) on the opposite side are removed with the axle
(8) together.
6
2 5 7 5
7
b
W178-02-11-269
5
9
8
b- Direction to Remove
W105-03-06-026
WDBR50-EN-00(20171222) W4-6-3-2
Assembly of Lower Roller
2 7 6 5 4 3 1
8 9
WDDK-04-05-005
1- Plug 4- O-Ring (2 Used) 7- Roller

2- Collar 5- Floating Seal (2 Used) 8- Axle
3- Pin (2 Used) 6- Bushing (2 Used) 9- Collar
WDBR50-EN-00(20171222) W4-6-3-3
Assembly of Lower Roller

IMPORTANT: Do not dent the flange surface of the 5. Install the axle (8) assembly to the roller (7).
bushing (6).
6. Apply grease to the O-ring (4). Install the O-ring (4)
1. Install the bushings (6) (2 used) to the roller (7) by to the groove (b) of the roller (7) assembly.
using a press.
IMPORTANT: Handle the floating seals (5) with care.
IMPORTANT: Do not damage the O-ring (4). (Refer to W4-6-4.)
2. Apply grease to the O-ring (4). Install the O-ring (4) 7. Install the floating seal (5) to the roller (7) and collar
to the groove (a) of the axle (8). (9).
3. Fit the pin (3) hole and install the collar (2) to the IMPORTANT: Do not damage the O-ring (4).
axle (8) with the pin (3).
8. Fit the pin (3) hole and install the collar (9) to the
axle (8) with the pin (3).
8 3
a
9
b
2 a
W105-03-06-031
IMPORTANT: Handle the floating seals (5) with care.

(Refer to W4-6-4.)
4. Install the floating seal (5) to the roller (7) and collar a- Direction to Install Pin (3)
(2). WDC150-04-06-002
7 5
9. Install a seal tape onto the thread part of the
plug (1). Add engine oil (API CF class SAE#15W40)
through the plug (1) hole of the collar (2). Tighten
the plug (1).
5 2
l : 6 mm
m : 20 N·m
W157-03-06-008
WDBR50-EN-00(20171222) W4-6-3-4

these procedures:
hardening.

trouble.
cleaning solvent.
ring (1).
f
A A
B B
A=B A≠B
W178-02-11-003

WDBR50-EN-00(20171222) W4-6-4-1
(Blank)
WDBR50-EN-00(20171222) W4-6-4-2
Group 7 Track
Removal and Installation of Track
3
4 5
2
a
W105-03-07-006 WDDK-04-06-001
a- Wooden Block
Removal 6
2. Rotate the track so that master pin (1) is positioned
over the front idler (2) side of the track adjuster.
Place wooden blocks (a) under shoe (3) and support 7
shoe (3).
dCAUTION: Do not remove bracket (6). Do not

loosen bolt (7) for the adjustment.

quickly or too much as valve (4) may fly out or MDAA-07-057
the sprocket and track links, remove it before
loosening.
3. Loosen valve (4). Drain grease and loosen the tracks.
j : 24 mm
WDBR50-EN-00(20171222) W4-7-1-1
Group 7 Track
7
6
1 1 7
a- Direction to Remove
W105-03-07-010
6
ST 1970
W105-03-07-009
W1V1-03-07-001
4. Remove snap ring (6) from master pin (1).
fNOTE: If snap ring (6) interferes with master link (7),

dCAUTION: The track adjuster may fly out due
to the spring force when removing the track. Do
push master pin (1) to the installing direction in order to not stand in the same direction to remove the
make a clearance between snap ring (6) and master pin track adjuster or where it may fly out. Particularly,
(1). Then, remove master pin (1). strong force is always applied to the thread
part of the rod. If the rod and/or the threads are
damaged, metal fragments may fly out due to the
spring force.

personal injury.
IMPORTANT: Master pin (1) can be installed/
removed to only one direction. Check direction (a)
to remove master pin (1).
5. Remove master pin (1) by using special tool (ST
1970) and a hammer.
WDBR50-EN-00(20171222) W4-7-1-2
Group 7 Track
c M104-07-067
W105-03-07-011
b- 90 to 110 ˚ c- Stand
6. Set the angle between the boom and arm to 90

to 110 degrees. Lower the boom with the round
the machine.
dCAUTION: The track assembly weight: 1120 kg

7. Slowly operate the travel control lever for the track
to be removed to the reverse position and extend
the track.
WDBR50-EN-00(20171222) W4-7-1-3
Group 7 Track
10 1
a b
W105-03-07-014
WDDK-04-06-002
a- Front Idler Side

b- Sprocket (8) Side
W105-03-07-015
Installation 3. Set the track straight.

IMPORTANT: If link (10) has been disassembled,
perform step 11 to step 15.
dCAUTION: The track assembly weight: 1120 kg
4. Hoist the connection part of track link (1). Place it
1. Raise the machine off the ground. Set the track onto sprocket (8).
under the machine so that sprocket (8) meshes with
the track end. At this time, check the direction of
the track.
2. Lower the machine. Mesh the claws of sprocket (8),
the lower roller, and the front idler with track link
(1).
WDBR50-EN-00(20171222) W4-7-1-4
Group 7 Track
2
a
a- Connection Part of Track Link WDDK-04-06-003
WDDK-04-06-004
5. Insert a pry bar into connection part (a) of the track

link. Travel the machine forward while pulling it
to the front idler (2) side. Wind the track link until
connection part (a) of the track link reaches the
front idler (2) side.
6. Place wooden blocks (b) under shoe (3) and support
shoe (3).
b
W105-03-07-016
b- Wooden Block
WDBR50-EN-00(20171222) W4-7-1-5
Group 7 Track
b 7
6
1 7
a- Direction to Install
W105-03-07-010
b- Machine Front Side W105-03-07-009
IMPORTANT: Master pin (1) can be installed/

removed to only one direction. Check direction (a) 6
to install master pin (1).
7. Install master pin (1) to the track.
c
IMPORTANT: Replace snap ring (6) with the new one.
8. 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 snap ring (6)
outside.
WDDQ50-04-07-001
c- Outside
WDBR50-EN-00(20171222) W4-7-1-6
Group 7 Track
4 5
c M104-07-067
b- 90 to 110 ˚
c- Stand
WDCD-04-06-001
9. Set the angle between the boom and arm to 90

to 110 degrees. Lower the boom with the round
the machine.
a
10. Tighten valve (4). Apply grease through grease
fitting (5) and adjust the track tension.
j : 24 mm
m : 90 N·m
Wxxx-03-07-001
fNOTE: Track sag specification (a): 285 to 320 mm a- Track Sag Specification
WDBR50-EN-00(20171222) W4-7-1-7
Group 7 Track
11
13
12
10
c b c
13
W197-03-07-001
b- Apply grease.
c- Do not apply grease.
IMPORTANT: If link (10) has been disassembled, fill 14. Install pin (12) to link (10) and bushing (11) while
grease (Daphne Eponex SR) into the clearance holding them in order not to move due to grease.
between bushing (11) and pin (12).
15. Wipe off excess grease after installing pin (12).
IMPORTANT: Check the direction to install seal (13).
11. Install seal (13) to link (10).
12. Apply grease to the bushing (11) end. Fit the pin
(12) holes on link (10) and bushing (11). Stand them
on a flat plate.
dCAUTION: Take care not to come off link (10).

13. Apply grease onto the inner circumference of
bushing (11).
WDBR50-EN-00(20171222) W4-7-1-8
MEMO
WDBR50-EN-00(20171222)
MEMO
WDBR50-EN-00(20171222)
SECTION 5
FRONT ATTACHMENT
CONTENTS
Attachment..................................................................W5-1-1-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Cylinder.........................................................................W5-2-4-1
Cylinders.......................................................................W5-2-5-1
Assembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-8
Disassembly of Positioning Cylinder.......................W5-2-6-1
Assembly of Positioning Cylinder.............................W5-2-6-6
Valve for Boom Cylinder..........................................W5-3-1-1
Valve for Arm Cylinder.............................................W5-3-2-1
Valve for Positioning Cylinder...............................W5-3-3-1
Cylinder (Right)..........................................................W5-3-4-1
Cylinder (Left).............................................................W5-3-4-3
Cylinder.........................................................................W5-3-4-5
Positioning Cylinder.................................................W5-3-4-7
WDBR50-EN-00(20171222) DBR50W-5-1
(Blank)
WDBR50-EN-00(20171222) DBR50W-5-2
SECTION 5 FRONT ATTACHMENT

Attachment
4
W105-04-02-001
WDCY-05-01-001

Removal 3

Retract the arm cylinder and bucket cylinder and
lower the arm top onto the ground.
2. Stop the engine. Remove the rod side of the boom
cylinder at the right and left sides. (Refer to W5-2-1.)
WDCR-05-01-001
3. Disconnect hoses (4) (2 used) of the bucket cylinder.
circuit. (Refer to W1-5-1.) j : 36 mm
4. Disconnect hoses (1, 2) of the arm cylinder.
j : 36 mm
WDBR50-EN-00(20171222) W5-1-1-1
2, 3 6 5
WDBR-05-01-001 WDAQ-05-01-002
2, 3

Remove the handrail (1) assembly.
j : 19 mm
(5). 10
j : 17 mm
8. Open cover (6).
hose (8) assembly.
j : 17 mm
WDAQ-05-01-004
WDBR50-EN-00(20171222) W5-1-1-2
2 3 5
a- Machine Front Side WDAQ-05-01-003
WDC150-03-15-003

(2).
j : 17 mm
j : 17 mm
12. Raise tool box (5) to the machine front side.
WDBR50-EN-00(20171222) W5-1-1-3
1 1
5
4 a
c
3
2
a- Plate c- Bracket
W178-02-11-280 W178-02-11-280
d- Front Attachment Assembly
W178-02-11-281 W178-02-11-282
13. Remove bolt (3), washer (2), plate (4), and block (5). 15. Reduce slack of the wire ropes. Insert a pry bar
between plate (a) of boom foot pin (1) and bracket
j : 27 mm (c). Slightly pull out plate (a).
dCAUTION: Front attachment assembly (d)

weight: 2630 kg dCAUTION: Boom foot pin (1) weight: 33 kg
16. Turn plate (a) upward. Turn it right and left and pull
14. Attach wire ropes onto the boom. out boom foot pin (1). (Adjust the position by using
the lifting ropes for the front attachment.)
17. Hoist front attachment assembly (d) and move the
machine backward.
18. Place wooden blocks. Place front attachment
assembly (d) onto the wooden blocks.
WDBR50-EN-00(20171222) W5-1-1-4
1
a
6
b
5
4
3
W178-02-11-282 2
a- Front Attachment Assembly b- Boom Foot Pin Mounting

W178-02-11-280
Hole
Installation c
dCAUTION:
2630 kg
Front attachment assembly (a) weight:
IMPORTANT: Use one or more thrust plates

respectively at the right and left sides.
1. Apply grease to the boom foot pin mounting hole
(b) of main frame (6).
2. Attach wire ropes onto front attachment assembly
(a). Hoist front attachment assembly (a). Fit the
boom foot to the boom mounting hole on the c- Grease Fitting of Boom Foot
frame. Install the thrust plates to right and left sides
and adjust total clearance of right and left within WDBL-05-01-003
1 mm (0.039 in). (Adjust the position by using the
lifting ropes for the front attachment.)
fNOTE: Thrust plate thickness: 2 mm, 2.5 mm, 3 mm
dCAUTION: Boom foot pin (1) weight: 33 kg 4. Apply grease to grease fittings (c) (2 places) of the
boom foot.
personal injury.
3. Install boom foot pin (1) by using a hammer. Install
block (5), plate (4), washer (2), and bolt (3).
j : 27 mm
m : 400 N·m
WDBR50-EN-00(20171222) W5-1-1-5
5 2 3
a- Machine Front Side WDAQ-05-01-003
WDC150-03-15-003
5. Place tool box (5) onto the mounting position.

6. Open cover (6). Install tool box (5) with bolts, 6
j : 17 mm
m : 50 N·m
j : 17 mm
m : 50 N·m
WDAQ-05-01-002
WDBR50-EN-00(20171222) W5-1-1-6
8 4
6 5
10
WDAQ-05-01-004 WDAQ-05-01-002
8. Install the hose (8) assembly with bolts, washers (10)

(2 used). 2, 3
j : 17 mm
m : 50 N·m 1
9. Close cover (6).
j : 17 mm
m : 50 N·m
WDBR-05-01-001
2, 3
11. Install the handrail (1) assembly with washers (3) (4

used) and bolts (2) (4 used).
j : 19 mm
m : 130 N·m
WDBR50-EN-00(20171222) W5-1-1-7
3 1
WDCR-05-01-001 WDCY-05-01-001
12. Connect connector (3). 15. Install the rod side of the boom cylinders at right
and left sides. (Refer to W5-2-1.)
13. Connect hoses (4) (2 used) of the bucket cylinder.
j : 36 mm 1.)
m : 180 N·m IMPORTANT: Check the hydraulic oil level. Start the
14. Connect hoses (1, 2) of the arm cylinder.
j : 36 mm
m : 180 N·m
WDBR50-EN-00(20171222) W5-1-1-8
2 2
3 3
W178-02-11-285
IMPORTANT: When the arm has been removed from IMPORTANT: For handling HN bushing for the front
the boom, perform the following steps when attachment, check the followings.
installing the arm. Precautions when installing the bushing
IMPORTANT: Use one or more thrust plates If a hammer is used to install the bushing, the bushing
respectively at the right and left sides. may be damaged. Use a press.
17. Install thrust plates (2) to right and left sides of the
arm. Adjust total clearance of right and left within 1 Special Tool for Bushing (Bushing Inner Diameter)
mm. (ST 1454): 71 mm
fNOTE: Thrust plate (2) thickness: 2 mm, 2.5 mm, 3 mm

18. Install the arm cylinder rod side to the arm.
Apply grease to grease fittings (1, 3) on the boom Precautions when reinforcing the arm
connecting boss of arm and the arm cylinder rod The heat when welding in order to reinforce the arm may
side. cause oil leakage and decrease lubrication performance.
When lubrication oil leaks, replace the bushing.
WDBR50-EN-00(20171222) W5-1-1-9
(Blank)
WDBR50-EN-00(20171222) W5-1-1-10
Group 2 Cylinder
Removal and Installation of Boom Cylinder
View A
A
1
1
W105-04-02-001
WDBR-05-02-002

Removal
1. Park the machine on a solid and level surface. Fully
retract the arm cylinder and the bucket cylinder and
lower the boom. Place the arm end on the ground.
WDBR50-EN-00(20171222) W5-2-1-1
Group 2 Cylinder
6
5 8 4 3 2
W158-04-02-013
2
WDBR-05-02-003
3. Stop the engine. Disconnect hoses (1) (2 used) from

boom cylinders (2).
j : 17 mm
dCAUTION: Boom cylinder (2) weight: 170 kg

4. Attach nylon slings onto boom cylinder (2). Hoist
and hold boom cylinder (2).

as goggles, hard hats , etc. in order to prevent
personal injury.
5. Remove nuts (5) (2 used), bolt (7), and stopper (6)
from the boom cylinder (2) rod side. Push pin (4) to
the boom by using a bar and a hammer. Remove
thrust plates (3, 8).
j : 24 mm
WDBR50-EN-00(20171222) W5-2-1-2
Group 2 Cylinder
1
W105-04-02-035
6. Place boom cylinder (1) on a stand.

7. Remove other boom cylinder (1) in the same way as
step 4 to step 6.
8. Start the engine. Operate the boom control lever
and retract boom cylinders (1) (2 used). In order not
to extend the rod, pass wires through the rod hole
and secure the rod to the cylinder tube.
9. Stop the engine.


WDBR50-EN-00(20171222) W5-2-1-3
Group 2 Cylinder
10 11
6 1 2
5
WDBR-05-02-001 W1R7-04-01-019
10. Disconnect both ends of hoses (10) (2 used) and

hoses (11) (2 used) from horse rupture valves (9) (2 dCAUTION: Boom cylinder (1) weight: 170 kg
used). 13. Hoist and remove boom cylinder (1) from the main
frame.
j : 19 mm
14. Remove other boom cylinder (1) in the same way as
11. Disconnect hoses (5) (4 used) at the cylinder side step 11 to step 13.
from boom cylinders (1) (2 used).
j : 36 mm

personal injury.
12. Remove nuts (4) (2 used) and bolt (2) from the
cylinder bottom side. Remove pin (3) by using a bar
and a hammer. Remove thrust plates (6).
j : 24 mm
WDBR50-EN-00(20171222) W5-2-1-4
Group 2 Cylinder
6 1 2
4
7
1
W105-04-02-040
5 W1R7-04-01-019
Installation
dCAUTION: Boom cylinder (1) weight: 170 kg

1. Attach nylon slings onto boom cylinder (1). Hoist
boom cylinder (1). Fit the hole at the cylinder
bottom side to the mounting hole on main frame
(7).
IMPORTANT: Use one or more thrust plates (6)
2. Fit thrust plates (6) to the holes of the right and left
sides at cylinder bottom side. Adjust the clearance a M157-07-156
between the cylinder bottom side and main frame
(7) within 1 mm. At this time, Fit thrust plate (6) a- Grease Fitting at Cylinder Bottom Side
(thickness: 1mm) to the opposite side of the cab
and adjust the clearance at the cab side.
4. Install other boom cylinder (1) to main frame (7) in
fNOTE: Thrust plate (6) thickness: 1 mm, 2 mm the same way as step 1 to step 3.
5. Apply grease to grease fittings (a) at the cylinder
bottom side.
personal injury. 6. Connect hoses (5) (4 used) to boom cylinders (1) (2
used).
3. Install pin (3) by using a hammer. Install bolt (2) to
pin (3) with nuts (4) (2 used). j : 36 mm
j : 24 mm m : 180 N·m
m : 140 N·m
WDBR50-EN-00(20171222) W5-2-1-5
Group 2 Cylinder
10 11
WDBR-05-02-001
7. Install both ends of hoses (10) (2 used) and hoses

(11) (2 used) to horse rupture valves (9) (2 used).
j : 19 mm
m : 30 N·m
WDBR50-EN-00(20171222) W5-2-1-6
Group 2 Cylinder
6
5 8 4 3 2
WLBA-05-02-011
2
WDBR-05-02-003

8. Remove the wires from the boom cylinder (2) rod
side.
9. Start the engine. Operate the boom control lever 9
9
and fit the hole at cylinder rod side to the mounting
holes on the boom.

personal injury.
IMPORTANT: Use one or more thrust plates (3, 8)
respectively at the right and left sides. WDBR-05-02-002
10. Fit thrust plates (3, 8) and pin (4) to the mounting
holes on the boom. Install pin (4) by using a
hammer.
11. Install bolt (7) to pin (4) and stopper (6) with nuts (5) 13. Install clip bands (9) (2 used).
(2 used).
14. Connect hoses (1) (2 used) to boom cylinders (2).
j : 30 mm Apply grease.
m : 280 N·m j : 17 mm
12. Install other boom cylinder (2) in the same way as m : 25 N·m
step 8 to step 11.
IMPORTANT: After completing the work, operate the
boom cylinder to the stroke end several times and
bleed air from the circuit.
WDBR50-EN-00(20171222) W5-2-1-7
Group 2 Cylinder
(Blank)
WDBR50-EN-00(20171222) W5-2-1-8
Group 2 Cylinder
Removal and Installation of Arm Cylinder
W105-04-02-001
3
W187-04-02-005
4
IMPORTANT: The hoses and pipes contain hydraulic 8 5
oil. When removing the hoses and pipes, receive 1
and pipes have been disconnected. In addition, 9
attach identification tags onto the connectors, b
Removal
6
W187-04-02-006
Retract the arm cylinder and bucket cylinder and b- Stopper Part
lower the arm top onto the ground.
2. Place wooden blocks (3) between arm cylinder (1)
and boom (2). Stop the engine.
3. Remove nuts (6) (2 used) and bolt (8) from stopper
part (b) of arm (9) and pin (5).
j : 30 mm

personal injury.
4. Remove pin (5) by using a bar and a hammer.
Remove thrust plates (4).
WDBR50-EN-00(20171222) W5-2-2-1
Group 2 Cylinder
6
1 2
3
5
W187-04-02-010
WDAQ-05-02-004
5. Start the engine. Operate the arm control lever and

retract arm cylinder (2). In order not to extend rod
(1), pass wires (3) through the rod hole and secure
rod (1) to the arm cylinder (2) tube.
6. Stop the engine.


7. Disconnect hoses (5) (3 used) from hose rupture
valve (4).
j : 19 mm, 27 mm
WDBR50-EN-00(20171222) W5-2-2-2
Group 2 Cylinder
1
1
2
3
W102-04-02-016
WDAQ-05-02-007
9. Disconnect hoses (2) (2 used) and hose (3) from arm

cylinder (1).
j : 17 mm, 36 mm
dCAUTION: Arm cylinder (1) weight: 235 kg

10. Attach nylon slings onto arm cylinder (1). Hoist and
hold arm cylinder (1).
WDBR50-EN-00(20171222) W5-2-2-3
Group 2 Cylinder
3, 4 6 WDAQ-05-02-007
11. Remove bolt (3) and nuts (4) (2 used) from pin (6).
j : 30 mm

personal injury.
12. Remove pin (6) by using a bar and a hammer.
Remove thrust plates (1).
13. Remove arm cylinder (7) from boom (2).
WDBR50-EN-00(20171222) W5-2-2-4
Group 2 Cylinder
1 2
W102-04-02-016
3, 4 6 WDAQ-05-02-007
Installation a
dCAUTION: Arm cylinder (1) weight: 235 kg

1. Attach nylon slings onto arm cylinder (1). Hoist arm
cylinder (1). Fit the hole on the cylinder bottom side
to the cylinder mounting holes on boom (7).
2. Fit the holes of thrust plates (2) and the right and
left sides at the cylinder bottom side. Adjust total
clearance of right and left between the cylinder and WDBL-05-01-003
a- Grease Fitting of Boom Foot
boom within 1 mm.
fNOTE: Thrust plate (2) thickness: 1 mm, 2 mm

personal injury.
3. Install pin (6) by using a hammer.
4. Install pin (6) to boom (7) with bolt (3) and nuts (4)
(2 used).
j : 30 mm
m : 280 N·m
5. Connect hose (8). Apply grease to grease fitting (a)
of the boom foot.
j : 17 mm
m : 25 N·m
WDBR50-EN-00(20171222) W5-2-2-5
Group 2 Cylinder
WDAQ-05-02-004
6. Connect hoses (2) (3 used) to hose rupture valve (1).
j : 19 mm
m : 30 N·m
j : 27 mm
m : 80 N·m
WDBR50-EN-00(20171222) W5-2-2-6
Group 2 Cylinder
1
10 1
12
11
W187-04-02-010
7
13 8
a
WDAQ-05-02-007
8. Connect hoses (2) (2 used) to arm cylinder (1).
j : 36 mm
9
W187-04-02-006
m : 180 N·m
a- Stopper Part
9. Remove wires (11) from rod (10) of arm cylinder (1).
Start the engine. Operate the arm control lever and
fit the hole at the cylinder rod side to the mounting
holes of arm (12).
left sides at the cylinder rod side. Adjust total
clearance of right and left between arm cylinder (1)
and arm (12) within 1 mm.

personal injury.
12. Install bolt (13) to pin (8) and stopper part (a) of arm
j : 30 mm
m : 280 N·m
WDBR50-EN-00(20171222) W5-2-2-7
Group 2 Cylinder
13. Apply grease to grease fitting (a) at the cylinder rod a

side.
arm cylinder to the stroke end several times and
bleed air from the circuit.
WDDQ50-05-02-014
a- Grease Fitting at Cylinder Rod Side
b- Arm
WDBR50-EN-00(20171222) W5-2-2-8
Group 2 Cylinder
Removal and Installation of Bucket Cylinder
2
W105-04-02-001
a
a- Wooden Block W178-02-11-287
IMPORTANT: The hoses and pipes contain hydraulic 6 5

4
7
Removal
WDBL-05-02-001
Retract the arm cylinder and bucket cylinder and
lower the arm top and bucket teeth onto the
ground.
2. Place wooden blocks (a) (2 used) under the arm (2)
top and between bucket cylinder (1) and arm (2).
Stop the engine.
dCAUTION: Before removing pin (7), secure the

links by using wires in order not to fall off.

personal injury.
3. Remove nuts (6) (2 used) and bolt (4). Remove pin
(7) by using a bar and a hammer. Remove thrust
plates (5) (4 used).
j : 30 mm
WDBR50-EN-00(20171222) W5-2-3-1
Group 2 Cylinder
1 2
2
7
3 W102-04-02-005
WDBE-05-02-001
8
2
4. Start the engine. Operate the bucket control lever 9
and retract bucket cylinder (2). In order not to
extend rod (1), pass wires (3) through the rod hole
and secure rod (1) to the bucket cylinder (2) tube. 10
11
5. Stop the engine.

12

13
6. Disconnect hoses (7, 8).
j : 36 mm
dCAUTION: Bucket cylinder (2) weight: 125 kg

personal injury.
7. Attach nylon slings onto bucket cylinder (2). Hoist WDCA-05-02-005
and hold bucket cylinder (2). Remove nuts (10) (2
used) and bolt (12). Remove pin (11) by using a bar
8. Hoist and remove bucket cylinder (2) from arm (13).
and a hammer. Remove thrust plates (9).
j : 24 mm
WDBR50-EN-00(20171222) W5-2-3-2
Group 2 Cylinder
1
2
3 4 1
b 10
11
a
a- Stopper Part of Arm (6) b- Grease Fitting

WDCA-05-02-005 WDBE-05-02-001
Installation
dCAUTION: Bucket cylinder (1) weight: 125 kg 4. Install bolt (5) to stopper part (a) of arm (6) and pin
1. Attach nylon slings onto bucket cylinder (1). Hoist
bucket cylinder (1). Fit the hole at the cylinder j : 24 mm
bottom side to the cylinder mounting holes of arm
(6). m : 140 N·m
IMPORTANT: Use one or more thrust plates (2) 5. Apply grease to grease fitting (b) at the cylinder
respectively at the right and left sides. bottom side.
2. Fit the holes of thrust plates (2) and the right 6. Connect hoses (10, 11) to bucket cylinder (1).
and left sides at cylinder bottom side. Adjust the
clearance between cylinder bottom side and j : 36 mm
cylinder mounting hole of arm within 1 mm.
m : 180 N·m

personal injury.
WDBR50-EN-00(20171222) W5-2-3-3
Group 2 Cylinder
1 2 11 11
W178-02-11-289
9 9
3 W102-04-02-005 b b
4 8 a 7
10 9 5
b- Grease Fitting
a- Stopper Part of Link B (9)
WDBL-05-02-001
M178-07-007
IMPORTANT: Check the hydraulic oil level. Start the 10. Set the machine position for inspection and
engine and check for any oil leaks. maintenance. (Refer to W1-5-1.)
7. Remove wires (3) from rod (1) of bucket cylinder (2). 11. Apply grease to grease fittings (b) (3 places) at the
Start the engine. Operate the bucket control lever. cylinder rod side.
Fit the hole at cylinder rod side to the holes of link
A (4) and links B (9) (2 used). Fit thrust plates (7) (4 IMPORTANT: In case link B (9) has been removed
used) and pin (10) to the holes of link A (4) and links from the arm, insert thrust plates (11) (2 used)
B (9) (2 used). when installing.
bucket cylinder to the stroke end several times
and bleed air from the circuit.
personal injury.
9. Install bolt (5) to stopper part (a) of link B (9) and pin
j : 30 mm
m : 280 N·m
WDBR50-EN-00(20171222) W5-2-3-4
Group 2 Cylinder

Cylinder
A
WDDQ50-05-02-011
WDBR-05-02-007
Section A
IMPORTANT: Cap the open ends in case the hoses 2
and pipes have been disconnected. In addition, 4
7
Removal
6 10 9
Set the second boom horizontally and the arm
vertically. Lower the boom and place the bucket on
the ground. WDAQ-05-02-005
5
2. Stop the engine. Disconnect hose (9). Remove
elbow (10).
j : 17 mm
d CAUTION: Positioning Cylinder (2) weight: 235

kg as goggles, hard hats, etc. in order to prevent
3. Attach nylon slings onto positioning cylinder (2). personal injury.
Hoist and hold it. 4. Remove nuts (6) (2 used) and bolt (7) from the
positioning cylinder (2) rod side. Remove pin (4) by
using a bar and a hammer. Remove thrust plates (5).
j : 30 mm
WDBR50-EN-00(20171222) W5-2-4-1
Group 2 Cylinder
3
Detail A
B 4
WDBR-05-02-004 WDBR-05-02-005
Detail B
5. Start the engine. Operate the positioning control
lever. Retract positioning cylinder (2). In order not to
2
extend the rod, pass wires through the rod hole and
secure the rod to the cylinder tube.
6. Stop the engine.
1

j : 19 mm
8. Disconnect hoses (1) (2 used). WDBR-05-02-006
j : 36 mm
WDBR50-EN-00(20171222) W5-2-4-2
Group 2 Cylinder
Section B
2 2 4
B
9
WDBR-05-02-007
5 WDAQ-05-02-006
9. Remove grease fitting (9).
j : 14 mm

personal injury.
10. Remove nuts (6) (2 used) and bolt (7) from the
positioning cylinder (2) rod side. Remove pin (4) by
using a bar and a hammer. Remove thrust plates (5).
j : 30 mm
dCAUTION:
kg
Positioning Cylinder (2) weight: 235
11. Hoist and remove positioning cylinder (2).
WDBR50-EN-00(20171222) W5-2-4-3
Group 2 Cylinder
Section B
2 2 4
B
9
3
WDBR-05-02-007
5 WDAQ-05-02-006
Installation
dCAUTION:
kg
Positioning Cylinder (2) weight: 235 dCAUTION: Metal fragments may fly off when a
1. Attach nylon slings onto positioning cylinder (2). as goggles, hard hats, etc. in order to prevent
Hoist positioning cylinder (2). Fit the hole on the personal injury.
cylinder bottom side to the cylinder mounting holes 3. Install pin (4) by using a hammer.
on first boom (3).
4. Install bolt (7) to pin (4) with nuts (6) (2 used).
respectively at the right and left sides. j : 30 mm
2. Fit the holes of thrust plates (5) and the right and m : 280 N·m
left sides at the cylinder bottom side. Adjust total
clearance of right and left between the cylinder and 5. Install grease fitting (9) to pin (4). Apply grease.
first boom (3) within 1.0 mm. j : 14 mm
WDBR50-EN-00(20171222) W5-2-4-4
Group 2 Cylinder
3
Detail A
B 4
WDBR-05-02-004 WDBR-05-02-005
Detail B
j : 19 mm
m : 30 N·m
1
j : 36 mm
m : 180 N·m
7. Install clip band (4).
WDBR-05-02-006
WDBR50-EN-00(20171222) W5-2-4-5
Group 2 Cylinder
A Section A
2
1 2 7 4
6 9 8
3 WDBR-05-02-007
5 WDAQ-05-02-005
IMPORTANT: Check the hydraulic oil level. Start the 12. Install elbow (9). Connect hose (8). Apply grease.
j : 17 mm
8. Remove the wires from positioning cylinder (2).
Start the engine. Operate the positioning control m : 25 N·m
lever. Fit the hole at the cylinder rod side to the
mounting holes on second boom (1).
IMPORTANT: Use one or more thrust plates (5) IMPORTANT: After completing the work, operate
respectively at the right and left sides. the positioning cylinder to the stroke end several
times and bleed air from the circuit.
left sides at the cylinder rod side. Adjust total
clearance of right and left between the cylinder and
second boom (1) within 1.0 mm.

personal injury.
11. Install bolt (7) to pin (4) with nuts (6) (2 used).
j : 30 mm
m : 280 N·m
WDBR50-EN-00(20171222) W5-2-4-6
Group 2 Cylinder

Cylinders
Boom Cylinder
WDBE-05-02-002
1- Cylinder Tube 9- U-Ring 15- Cushion Ring 21- Backup Ring (2 Used)
3- Cylinder Rod 10- Backup Ring 16- Piston 22- Nut
5- Cylinder Head 11- Dust Seal 17- Seal Ring 23- Set Screw (2 Used)
6- Bushing 12- O-Ring 18- Wear Ring (2 Used) 24- Socket Bolt (12 Used)
7- Retaining Ring 13- Backup Ring 19- Wear Ring (2 Used)
8- Seal 14- O-Ring 20- O-Ring
WDBR50-EN-00(20171222) W5-2-5-1
Group 2 Cylinder
Arm Cylinder
WDBE-05-02-003
7- Retaining Ring 13- Backup Ring 19- Wear Ring (2 Used) 25- Plunger
8- Seal 14- O-Ring 20- O-Ring 26- Ring
WDBR50-EN-00(20171222) W5-2-5-2
Group 2 Cylinder
Bucket Cylinder
WDBE-05-02-004
1- Cylinder Tube 9- U-Ring 16- Piston 22- Nut

3- Cylinder Rod 10- Backup Ring 17- Seal Ring 23- Set Screw (2 Used)
5- Cylinder Head 11- Dust Seal 18- Wear Ring (2 Used) 24- Socket Bolt (12 Used)
6- Bushing 12- O-Ring 19- Wear Ring (2 Used)
7- Retaining Ring 13- Backup Ring 20- O-Ring
8- Seal 14- O-Ring 21- Backup Ring (2 Used)
WDBR50-EN-00(20171222) W5-2-5-3
Group 2 Cylinder
Disassembly of Boom, Arm, and Bucket Cylinders 3. Attach a plastic hammer onto part (a) of cylinder
head (5). Make a clearance between cylinder head
The procedure starts on the premise that the pipes
(5) and cylinder tube (1) by tapping the plastic
and the bands securing the pipes have been
hammer by using a hammer. Remove cylinder
removed.
head (5) from cylinder tube (1) while extending the
d CAUTION: Boom cylinder weight: 155 kg clearance by using a screwdriver.
Arm cylinder weight: 205 kg
Bucket cylinder weight: 125 kg
1. Hoist the cylinder. Secure the cylinder horizontally 5
on a workbench. Drain off hydraulic oil from the
cylinder.
a
WDBE-05-02-005
W102-04-02-027

cylinder rod (3).
2. Remove socket bolts (24) (12 used) from cylinder
head (5).
Boom Cylinder, Bucket Cylinder:
l : 12 mm
Arm Cylinder:
l : 14 mm

socket bolt (24).
WDBR50-EN-00(20171222) W5-2-5-4
Group 2 Cylinder
6. Remove nut (22) by using special tool (ST 5908) and

d CAUTION: The cylinder rod (3) assembly weight: special tool (a).
Boom Cylinder: 90 kg Special Tool (a):
Arm Cylinder: 130 kg Boom Cylinder, Bucket Cylinder: ST 3262 (Wrench
Bucket Cylinder: 76 kg Size: 80 mm)
4. Remove the cylinder rod (3) assembly from cylinder Arm Cylinder: ST 3263 (Wrench Size: 90 mm)
tube (1). Secure it to the special tool (ST 5908).
ST 5908
ST 5908
W158-04-02-022
W158-04-02-022
7. Remove piston (16) by using special tool (ST 5908)

5. Cut away the crimped part by using a hand drill. and special tool (b).
Remove set screws (23) (2 used).
Special Tool (b):
l : 4 mm Boom Cylinder: ST 3371 (Pitch 85 mm)
fNOTE: Set screws (23) (2 used) have been crimped by Arm Cylinder: ST 7968 (Pitch 95 mm)
using a punch at two places after installing them.
Bucket Cylinder: ST 7967 (Pitch 80 mm)
set screw (23).
ST 5908
W158-04-02-022
WDBR50-EN-00(20171222) W5-2-5-5
Group 2 Cylinder
8. Install a protective tape onto the thread part of 11. Remove backup rings (21) (2 used) and O-ring (20)
cylinder rod (3) in order to protect the seal of from piston (16) by using a spatula.
cylinder head (5). Remove cylinder head (5) and
12. Remove backup ring (13) and O-rings (12, 14) from
cushion ring (15) from cylinder rod (3). (Cushion ring
cylinder head (5) by using a spatula.
(15) is not equipped for the bucket cylinder.)
9. Remove wear rings (18, 19) (2 used for each) from dCAUTION: Metal fragments may fly off when a
piston (16).
d CAUTION: Metal fragments may fly off when a
personal injury.
as goggles, hard hats, etc. in order to prevent IMPORTANT: Do not damage cylinder head (5).
personal injury.
13. Secure cylinder head (5) in a vise. Remove dust seal
(11) from cylinder head (5) by using a screwdriver
IMPORTANT: Do not damage the seal groove. and a hammer.
10. Remove backup rings (a) (2 used) from piston (16).
Cut seal ring (17) and ring (b) by using a screwdriver
and a hammer. Remove seal ring (17) and ring (b) 5
from piston (16). 11
16 a 17 a
WDDQ50-05-02-009
20
b
21
WDAQ-05-02-008
a- Backup Ring b- Ring
WDBR50-EN-00(20171222) W5-2-5-6
Group 2 Cylinder
14. Remove backup ring (10), U-ring (9), and seal (8)
from cylinder head (5) by using an awl.
10 9 5 8
WDDQ50-05-02-009
IMPORTANT: Do not remove bushing (6) unless

necessary.
IMPORTANT: Bushing (6) cannot be reused. If
bushing (6) has been removed, replace it with the
new one when assembling.
15. Remove retaining ring (7) and bushing (6).
fNOTE: Bushing (6) cannot be tapped and removed from

cylinder head (5). Cut off bushing (6) by using a lathe.
Insert a screwdriver strongly and remove bushing (6).
IMPORTANT: Ring (26) and plunger (25) can not be
disassembled. (only Arm Cylinder)
WDBR50-EN-00(20171222) W5-2-5-7
Group 2 Cylinder
Assembly of Boom, Arm, and Bucket Cylinders
Boom Cylinder
3 9 8 24 5 14 1 15 19 18 17
23 22
11 10 6 7 12, 13 16 20, 21
W1V1-04-02-006
7- Retaining Ring 13- Backup Ring 19- Wear Ring (2 Used)
8- Seal 14- O-Ring 20- O-Ring
WDBR50-EN-00(20171222) W5-2-5-8
Group 2 Cylinder
Arm Cylinder
3 11 8 24 5 14 1 15 19 18 17
23 22
10 9 6 7 12, 13 16 20, 21 26 25
W1V1-04-02-004
7- Retaining Ring 13- Backup Ring 19- Wear Ring (2 Used) 25- Plunger
8- Seal 14- O-Ring 20- O-Ring 26- Ring
WDBR50-EN-00(20171222) W5-2-5-9
Group 2 Cylinder
Bucket Cylinder
3 9 8 24 5 14 12,13 1 19 18 17
23
22
11 10 6 7 16 20, 21
W1V1-04-02-002

WDBR50-EN-00(20171222) W5-2-5-10
Group 2 Cylinder
Assembly of Boom, Arm, and Bucket Cylinders

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Check the direction to install seal (8).
4. Install backup ring (10), U-ring (9) and seal (8) to
1. Install bushing (6) to cylinder head (5). cylinder head (5).
2. Install retaining ring (7) to cylinder head (5).

personal injury. 10 9 5 8
3. Install dust seal (11) to cylinder head (5) by using
special tool (a) and a hammer.
6
Special Tool (a):
7
Boom Cylinder: ST 8019 (Rod Outer Diameter: 80
mm)
Arm Cylinder: ST 8024 (Rod Outer Diameter: 90 mm)
WDDQ50-05-02-009
Bucket Cylinder: ST 8018 (Rod Outer Diameter: 75
mm)

cylinder head (5).
5
11
WDDQ50-05-02-009
WDBR50-EN-00(20171222) W5-2-5-11
Group 2 Cylinder
dCAUTION: Wear fireproof gloves when installing

seal ring (17).
c
IMPORTANT: Check the direction to install backup 17
ring (a).
6. Install ring (b) to piston (16) by using a screwdriver
which made the angle round. Dip seal ring (17) for c
approximately five minutes in hydraulic oil which is
heated at 150 to 180 °C (302 to 356 °F) by using the
electric heater in order to make seal ring (17) soft.
Install seal ring (17) to piston (16) by using special
tool (c). After installing seal ring (17), adjust seal ring
(17) by using special tool (c). Install backup rings (a) c- Special Tool W566-04-02-010
(2 used) to piston (16).
Special Tool (c):
Boom Cylinder: ST 2962 (Tube Inner Diameter: 110
mm)
Arm Cylinder: ST 2964 (Tube Inner Diameter: 120 c
mm)
Bucket Cylinder: ST 2977 (Tube Inner Diameter: 105
mm)
16 a 17 a c- Special Tool W566-04-02-011
7. Install O-ring (20) and backup ring (21) (2 used) to

21
piston (16).
b 20
21
WDAQ-05-02-008
WDBR50-EN-00(20171222) W5-2-5-12
Group 2 Cylinder
dCAUTION: Cylinder rod (3) weight:

Boom Cylinder: 68 kg
Arm Cylinder: 92 kg
Bucket Cylinder: 47 kg
8. Secure cylinder rod (3) to special tool (ST 5908).
ST 5908
W158-04-02-022
9. Install a protective tape onto the thread part of

cylinder rod (1) in order to protect the seal of
cylinder head (5). Install the cylinder head (5)
assembly to cylinder rod (3).
10. Install cushion ring (15) to cylinder rod (3). (only
boom, arm cylinders)
WDBR50-EN-00(20171222) W5-2-5-13
Group 2 Cylinder
11. Install the piston (16) assembly to cylinder rod (3) by 12. Apply LOCTITE #243 or equivalent onto set screws
using special tool (ST 5908) and special tool (e). (23) (2 used). Install set screws (23) (2 used) to nut
(22). Crimp set screws (23) (2 used) by using a punch
Special Tool (e):
(2 places).
Boom Cylinder: ST 3371 (Rod Outer Diameter: 85
mm) l : 4 mm
Arm Cylinder: ST 7968 (Rod Outer Diameter: 90 mm) m : 15±1.5 N·m

Bucket Cylinder: ST 7967 (Rod Outer Diameter: 80 13. Install wear rings (18, 19) (2 used for each) to piston
mm) (16).
Boom Cylinder, Arm Cylinder
dCAUTION: Cylinder tube (1) weight:
m : 981±98 N·m Boom Cylinder: 64 kg
Bucket Cylinder Arm Cylinder: 74 kg
m : 736±74 N·m Bucket Cylinder: 44 kg
IMPORTANT: Fit the cylinder rod (3) assembly to the

ST 5908 center of cylinder tube (1) and install it straight in
order not to damage the rings.
14. Secure cylinder tube (1) to a workbench

horizontally. Install the cylinder rod (3) assembly to
cylinder tube (1).
W158-04-02-022
11. Install nut (22) to cylinder rod (3) by using special

tool (ST 5908) and special tool (f ).
Special Tool (f ):
Boom Cylinder, Bucket Cylinder: ST 3262 (Wrench
Size: 80 mm)
Arm Cylinder: ST 3263 (Wrench Size: 90 mm)
Boom Cylinder, Arm Cylinder
m : 1860±186 N·m
Bucket Cylinder
m : 1275±127 N·m
ST 5908
W158-04-02-022
WDBR50-EN-00(20171222) W5-2-5-14
Group 2 Cylinder

cylinder rod (3).
15. Apply LOCTITE #243 or equivalent to socket bolt

(24). Install cylinder head (5) to cylinder tube (1)
Boom Cylinder, Bucket Cylinder:
l : 12 mm
m : 226 to 235 N·m

Arm Cylinder:
l : 14 mm
m : 353 to 373 N·m
WDBR50-EN-00(20171222) W5-2-5-15
Group 2 Cylinder
(Blank)
WDBR50-EN-00(20171222) W5-2-5-16
Group 2 Cylinder
Disassembly of Positioning Cylinder
24 5 10 9 8 6 7 14 13 12
18 17 18 19 21 20 21
22
23
11 16 19
1 WDDN50-05-02-003

WDBR50-EN-00(20171222) W5-2-6-1
Group 2 Cylinder
Disassembly of Positioning Cylinder 3. Attach a plastic hammer onto part (a) of cylinder
head (5). Make a clearance between cylinder head
 The procedure starts on the premise that the
(5) and cylinder tube (1) by tapping the plastic
pipes and the bands securing the pipes have been
hammer by using a hammer. Remove cylinder
removed.
head (5) from cylinder tube (1) while extending the
d CAUTION: Positioning cylinder weight: 185 kg clearance by using a screwdriver.
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain off hydraulic oil from the
cylinder. 5
W102-04-02-027
WDBE-05-02-005
cylinder rod (3).
2. Remove socket bolts (24) (14 used) from cylinder
head (5).
l : 14 mm

socket bolt (24).
WDBR50-EN-00(20171222) W5-2-6-2
Group 2 Cylinder
6. Remove nut (22) by using special tool (ST 5908) and

d CAUTION: The cylinder rod (3) assembly weight:
100 kg
special tool (a).
Special Tool (a):
4. Remove the cylinder rod (3) assembly from cylinder
tube (1). Secure it to the special tool (ST 5908). ST 3264 (Wrench Size: 100 mm)
ST 5908 ST 5908
W158-04-02-022 W158-04-02-022
5. Cut away the crimped part by using a hand drill. 7. Remove piston (16) by using special tool (ST 5908)
Remove set screws (23) (2 used). and special tool (b).
l : 4 mm Special Tool (b):

ST 3353 (Pitch 110 mm)
fNOTE: Set screws (23) (2 used) have been crimped by
using a punch at two places after installing them.
fNOTE: LOCTITE #243 or equivalent has been applied to ST 5908
set screw (23).
W158-04-02-022
WDBR50-EN-00(20171222) W5-2-6-3
Group 2 Cylinder
8. Install a protective tape onto the thread part of 11. Remove backup rings (21) (2 used) and O-ring (20)
cylinder rod (3) in order to protect the seal of from piston (16) by using a spatula.
cylinder head (5). Remove cylinder head (5) from
12. Remove backup ring (13) and O-rings (12, 14) from
cylinder rod (3).
cylinder head (5) by using a spatula.
9. Remove wear rings (18, 19) (2 used for each) from
piston (16). dCAUTION: Metal fragments may fly off when
personal injury.
personal injury. IMPORTANT: Do not damage cylinder head (5).
13. Secure cylinder head (5) in a vise. Remove dust seal
IMPORTANT: Do not damage the seal groove. (11) from cylinder head (5) by using a screwdriver
10. Remove backup rings (a) (2 used) from piston (16). and a hammer.
Cut seal ring (17) and ring (b) by using a screwdriver
and a hammer. Remove seal ring (17) and ring (b)
from piston (16).
5
11
16 a 17 a
20 WDDQ50-05-02-009
b
21
WDAQ-05-02-008
WDBR50-EN-00(20171222) W5-2-6-4
Group 2 Cylinder
14. Remove backup ring (10), U-ring (9), and seal (8)
from cylinder head (5) by using an awl.
10 9 5 8
WDDQ50-05-02-009
IMPORTANT: Do not remove bushing (6) unless

necessary.
IMPORTANT: Bushing (6) cannot be reused. If
bushing (6) has been removed, replace it with the
new one when assembling.
15. Remove retaining ring (7) and bushing (6).
fNOTE: Bushing (6) cannot be tapped and removed from

cylinder head (5). Cut off bushing (6) by using a lathe.
Insert a screwdriver strongly and remove bushing (6).
WDBR50-EN-00(20171222) W5-2-6-5
Group 2 Cylinder
Assembly of Positioning Cylinder
3 9 8 24 5 14 12,13 1 19 18 17
23
22
11 10 6 7 16 20, 21
WDBR-05-02-008

WDBR50-EN-00(20171222) W5-2-6-6
Group 2 Cylinder
Assembly of Positioning Cylinder

IMPORTANT: Before assembling, apply hydraulic oil 3. Install dust seal (11) to cylinder head (5) by using a
onto parts in order to prevent them from seizing. bar and a hammer.
1. Install bushing (6) to cylinder head (5) by using IMPORTANT: Check the direction to install seal (8).
special tool (ST 2613).
4. Install backup ring (10), U-ring (9), and seal (8) to
2. Install retaining ring (7) to cylinder head (5). cylinder head (5).

10 9 5 8

personal injury.
6
7
5
11
WDDQ50-05-02-009

cylinder head (5).
WDDQ50-05-02-009
WDBR50-EN-00(20171222) W5-2-6-7
Group 2 Cylinder
dCAUTION: Wear fireproof gloves when installing

seal ring (17).
c
IMPORTANT: Check the direction to install backup 17
ring (a).
6. Install ring (b) to piston (16) by using a screwdriver
which made the angle round. Dip seal ring (17) for e
approximately five minutes in hydraulic oil which is
heated at 150 to 180 °C by using the electric heater
in order to make seal ring (17) soft. Install seal ring
(17) to piston (16) by using special tool (c) and
special tool (e). After installing seal ring (17), adjust
c- Special Tool W566-04-02-010
seal ring (17) by using special tool (d). Install backup
e- Special Tool
rings (a) (2 used) to piston (16).
Special Tool (c): ST 2087
Special Tool (d): ST 2090
Special Tool (e): ST 2093
d
16 a 17 a
21 d- Special Tool W566-04-02-011
b 20
21 7. Install O-ring (20) and backup ring (21) (2 used) to
piston (16).
WDAQ-05-02-008
WDBR50-EN-00(20171222) W5-2-6-8
Group 2 Cylinder
dCAUTION: Cylinder rod (3) weight: 76 kg

8. Secure cylinder rod (3) to special tool (ST 5908).
ST 5908
W158-04-02-022
9. Install a protective tape onto the thread part of

cylinder rod (3) in order to protect the seal of
cylinder head (5). Install the cylinder head (5)
assembly to cylinder rod (3).
WDBR50-EN-00(20171222) W5-2-6-9
Group 2 Cylinder
10. Install the piston (16) assembly to cylinder rod (3) by 12. Apply LOCTITE #243 or equivalent onto set screws
using special tool (ST 5908) and special tool (e). (23) (2 used). Install set screws (23) (2 used) to nut
(22). Crimp set screws (23) (2 used) by using a punch
Special Tool (e):
(2 places).
ST 3353 (Pitch 110 mm)
l : 4 mm
m : 981±98 N·m
m : 15 N·m
ST 5908 13. Install wear rings (18, 19) (2 used for each) to piston
(16).
dCAUTION: Cylinder tube (1) weight: 73 kg
dCAUTION:
100 kg
The cylinder rod (3) assembly weight:
W158-04-02-022
IMPORTANT: Fit the cylinder rod (3) assembly to the
center of cylinder tube (1) and install it straight in
order not to damage the rings.
11. Install nut (22) to cylinder rod (3) by using special
tool (ST 5908) and special tool (f ).
14. Secure cylinder tube (1) to a workbench
Special Tool (f ): horizontally. Install the cylinder rod (3) assembly to
cylinder tube (1).
ST 3264 (Wrench Size: 100 mm)
m : 1860±186 N·m
ST 5908
W158-04-02-022
WDBR50-EN-00(20171222) W5-2-6-10
Group 2 Cylinder

cylinder rod (3).
15. Apply LOCTITE #243 or equivalent to socket bolt

(24). Install cylinder head (5) to cylinder tube (1)
l : 14 mm
m : 353 to 373 N·m
WDBR50-EN-00(20171222) W5-2-6-11
Group 2 Cylinder
(Blank)
WDBR50-EN-00(20171222) W5-2-6-12

Valve for Boom Cylinder
oil. When removing the hoses and pipes, receive A
IMPORTANT: Cap the open ends in case the hoses W105-04-02-001

attach identification tags onto the connectors, View A
Removal
1. Park the machine on a solid and level surface. Fully
retract the arm cylinder and the bucket cylinder and
lower the boom. Place the arm end on the ground. 2


2. Disconnect hoses (2) (5 used) from hose rupture
valve (5). WDBR-05-02-002
j : 19 mm
3. Remove socket bolts (7, 8) (2 used for each). 11 2
Disconnect pipe (9).
l : 8 mm
4. Remove socket bolts (4) (4 used). Remove O-ring (6)
and hose rupture valve (5) from boom cylinder (11). 9, 10
Remove O-ring (10) from pipe (9).
l : 8 mm
8 2
5. Remove the adapters from hose rupture valve (5) if
necessary.
7
5, 6 4 WDBR-05-03-001
WDBR50-EN-00(20171222) W5-3-1-1
Installation
1. Install all removed adapters to hose rupture valve
(5).
2. Install O-ring (10) to pipe (9). Temporarily install
hose rupture valve (5) to boom cylinder (11) with
O-ring (6) and socket bolts (4) (4 used).
l : 8 mm
3. Connect pipe (9) with socket bolts (7, 8) (2 used for 2
each).
l : 8 mm
m : 50 N·m
WDBR-05-02-002
l : 8 mm
m : 50 N·m
5. Connect hoses (2) (5 used) to hose rupture valve (5). 11 2
j : 19 mm
m : 30 N·m
9, 10
8 2
5, 6 4 WDBR-05-03-001
WDBR50-EN-00(20171222) W5-3-1-2
6. Loosen the hose rupture valve (2) side of hose (1) by

one to two turns.
7. Start the engine. Slowly lower the boom, drain
hydraulic oil, and bleed air from hose rupture valve
(2).
8. Stop the engine. Tighten hose (1).
j : 19 mm
m : 30 N·m
WDBR-05-02-001
2 1
WDBR50-EN-00(20171222) W5-3-1-3
(Blank)
WDBR50-EN-00(20171222) W5-3-1-4

Valve for Arm Cylinder
IMPORTANT: Cap the open ends in case the hoses W105-04-02-001

8 9 1 2
Removal 7
1. Park the machine on a solid and level surface. Fully 6

retract the arm cylinder and the bucket cylinder and 5
lower the boom. Place the arm end on the ground.

oil tank. (Refer to W1-5-1.) 4
circuit. (Refer to W1-5-1.) 4
2. Disconnect hoses (4) (3 used). 3
j : 19 mm, 27 mm
3. Remove socket bolts (8, 9) (2 used for each).
Disconnect pipe (1). Remove O-ring (7).
l : 10 mm
and hose rupture valve (5) from arm cylinder (3).
l : 10 mm
5. Remove the adapters from hose rupture valve (5) if
necessary.
WDAD-05-03-003
WDBR50-EN-00(20171222) W5-3-2-1
Installation
(5). 8 9 1 2
2. Temporarily install hose rupture valve (5) to arm

cylinder (3) with O-ring (2) and socket bolts (6) (4
used).
7
l : 10 mm
6
3. Install O-ring (7). Connect pipe (1) with socket bolts 5
l : 10 mm
m : 50 N·m 4

4
l : 10 mm
3
m : 50 N·m
j : 19 mm
m : 30 N·m
j : 27 mm
m : 80 N·m
WDAD-05-03-003
WDBR50-EN-00(20171222) W5-3-2-2

one to two turns.
7. Start the engine. Slowly roll in the arm, drain
hydraulic oil, and bleed air from hose rupture valve
(2).
j : 19 mm
m : 30 N·m 2
1
WDAD-05-03-003
WDBR50-EN-00(20171222) W5-3-2-3
(Blank)
WDBR50-EN-00(20171222) W5-3-2-4

Valve for Positioning Cylinder
IMPORTANT: Cap the open ends in case the hoses WDAQ-03-09-044

hoses, and pipes for assembling. If the clips which 1
Removal
1. Fully retract the arm and bucket cylinders. Fully
retract the positioning cylinder. Lower the bucket
onto the ground.


j : 19 mm
WDBR-05-03-002
3. Remove socket bolts (8, 9) (2 used for each).
Disconnect pipe (6). Remove O-ring (7).
2 3 4, 5 6, 7
l : 10 mm
and hose rupture valve (4) from positioning cylinder
(2).
l : 10 mm
5. Remove the adapters from hose rupture valve (4) if 8
necessary.
WDBR-05-03-003
9
WDBR50-EN-00(20171222) W5-3-3-1
Installation
(4). 1
2. Temporarily install hose rupture valve (4) to

positioning cylinder (2) with O-ring (5) and socket
bolts (3) (4 used).
l : 10 mm
3. Install O-ring (7). Connect pipe (6) with socket bolts 2
l : 10 mm
m : 90 N·m
l : 10 mm
m : 90 N·m
WDBR-05-03-002
j : 19 mm 2 3 4, 5 6, 7
m : 30 N·m
WDBR-05-03-003
9
WDBR50-EN-00(20171222) W5-3-3-2

one to two turns.
7. Start the engine. Slowly operate the positioning 1
lever to the retract direction, drain hydraulic oil, and
bleed air from hose rupture valve (2).
j : 19 mm 2
m : 30 N·m
WDBR-05-02-005
WDBR50-EN-00(20171222) W5-3-3-3
(Blank)
WDBR50-EN-00(20171222) W5-3-3-4

Cylinder (Right)
11
12 12 11
7
1
10
9
4
12 5
10
10 11 3
9
9
2
6
WDCA-05-03-005
WDBR50-EN-00(20171222) W5-3-4-1

N·m
1 Hose Rupture Valve 1
2 Relief Valve 1 j : 24 mm 75±5
3 O-Ring 1
4 O-Ring 1
5 Backup Ring 1
6 O-Ring 1
7 Plug 1 j : 27 mm 75±5
8 O-Ring 1
9 Plug 3 l : 6 mm 35±3.5
10 O-Ring 3
11 Plug 3 l : 5 mm 15±1.5
12 O-Ring 3
WDBR50-EN-00(20171222) W5-3-4-2

Cylinder (Left)
11
11 12
12 7
1
10
9
4
5 12
10
3 11 10
9
9 6
2
WDCA-05-03-006
WDBR50-EN-00(20171222) W5-3-4-3

N·m
3 O-Ring 1
4 O-Ring 1
5 Backup Ring 1
6 O-Ring 1
7 Plug 1 j : 27 mm 75±5
8 O-Ring 1
9 Plug 3 l : 6 mm 35±3.5
10 O-Ring 3
11 Plug 3 l : 5 mm 15±1.5
12 O-Ring 3
WDBR50-EN-00(20171222) W5-3-4-4

Cylinder
1
5
6
WDCA-05-03-004
WDBR50-EN-00(20171222) W5-3-4-5

N·m
3 O-Ring 1
4 O-Ring 1
5 Plug 2 l : 5 mm 15±1.5
6 O-Ring 2
WDBR50-EN-00(20171222) W5-3-4-6

Positioning Cylinder
6 5 1
5
6
4
WDC150-05-03-001
WDBR50-EN-00(20171222) W5-3-4-7

N·m
3 O-Ring 1
4 O-Ring 1
5 O-Ring 1
6 Plug 1 l : 6 mm 35±3.5
WDBR50-EN-00(20171222) W5-3-4-8
MEMO
WDBR50-EN-00(20171222)
MEMO
WDBR50-EN-00(20171222)
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
FAX: (Located at the bottom center in the page. If two or more revisions
are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
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PART NO.

Service Manual consists of the following separate Part No.

MEMBERSHIP ACCOUNT HOLDERS CAN

EXPLORE AVAILABLE PLANS

Group 2 Counterweight Group 12 Solenoid Valve

Group 10 Swing Device Group 17 DEF Supply Module

Quantity To Convert From Into Multiply By

Symbol / Name Explanation

Symbol / Name Explanation

Recognize Safety Information

Understand Signal Words

 CAUTION also calls attention to safety message in this

 fNOTE: Indicates an additional explanation for a piece of

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handholds and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

OPG: Operator Protective Guard

Restriction of Attachment Installation

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

 Driving on a slope may cause the machine to slip or SA-657

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep People Clear from Working Area

Never Position the Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

If lightning comes close, immediately stop the operation,

 When you are around the machine or operating cab-

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

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

3. Turn auto-idle switch OFF.

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Remove the key from the key switch.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying