HITACHI EX2500 EXCAVATOR Service Repair Manual PDF

EX2500
Workshop Manual
SECTION 1
GENERAL IMFORMATION
—CONTENTS—
Group 1 Precautions for Disassembly
and Assembly
Precautions for Disassembly and
Assembly.............................................. W1-1-1
Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
117W-1-1
(Blank)
117W-1-2
GENERAL INFORMATION / Precautions for Disassembly and Assembly
PRECAUTIONS FOR DISASSEMBLY AND
ASSEMBLY
Preparations for Disassembly Precautions for Disassembly and Assembly
• Clean the Machine • Precautions for Disassembly
Thoroughly wash the machine before bringing it into • To prevent dirt from entering the hydraulic system,
the shop. Bringing a dirty machine into the shop may cap or plug the removed pipes.
cause machine components to be contaminated • Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place them on a clean work
damage to machine components, as well as bench.
decreased efficiency in service work. • Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
• Inspect the Machine fluids.
• Use matching marks for easier reassembling.
Be sure to thoroughly understand all disassem- • Be sure to use the specified tools, when
bling/assembling procedures beforehand, to help instructed.
avoid incorrect disassembling of components as well • If a part or component cannot be removed after
as personal injury. removing its securing nuts and bolts, do not
Check and record the items listed below to prevent attempt to remove forcibly. Find the cause(s), then
problems from occurring in the future. take the appropriate measures.
• Orderly arrange disassembled parts. Mark and
• The machine model, machine serial number, and tag them as necessary.
hour meter reading. • Store common parts, such as bolts and nuts with
• Reason for disassembly (symptoms, failed parts, reference to where they are to be used and in a
and causes). manner that will prevent loss.
• Clogging of filters and oil, water or air leaks, if any. • Inspect the contact or sliding surfaces of
• Capacities and condition of lubricants. disassembled parts for abnormal wear, sticking,
• Loose or damaged parts. or other damage.
• Measure and record the degree of wear and
• Prepare and Clean Tools and Disassembly Area clearances.
Prepare the necessary tools to be used and the area • Precautions for Assembly
for disassembling work.
• Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
it.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the tools, so as to make sure that
no tools are missing.
W1-1-1
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and install
ation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
• Bleeding Air from Hydraulic Pump
IMPORTANT: If the engine is started with air

trapped in the hydraulic pump
housing, damage to the pump may
result. Be sure to bleed air before
starting the engine.
• Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary.
M104-07-021
W1-1-2
Floating Seal Precautions
A
1. In general, always replace the floating seal with a
new one.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check seal ring face (A) for scuffing, scoring, B

corrosion, deformation or uneven wear.
W105-03-05-019
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Correct
(2) Clean the floating seal and seal mounting

bores, as dust on them tends to enter the
floating seal when installing it.
Incorrect
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
W105-03-05-020
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with mating face (C) Correct Incorrect
by measuring the distances (A) and (C) at point C
(a) and (b), as illustrated. If these distances
a a
differ, correct the O-ring seating.
A
b b
a=b aҐb
W110-03-05-004
W1-1-3
(Blank)
W1-1-4
GENERAL INFORMATION / Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
Wrench Torque
Bolt Dia
No. Descriptions Q'ty Size
mm
mm N⋅m (kgf⋅m) (lbf⋅ft)
1 Engine cushion rubber mounting bolt: 36 6 55 3140 (320) (2310)

2 Engine bracket mounting bolt: 30 12 46 1420 (145) (1050)
22 4 32 740 (75) (540)
3 Hydraulic oil tank mounting bolt: 30 10 46 1420 (145) (1050)
4 Fuel tank mounting bolt: 30 12 46 1420 (145) (1050)
5 Pump transmission mounting bolt: 12 16 19 108 (11) (80)
6 Pump device mounting bolt: 24 12 36 690 (70) (510)
7 Fan drive mounting bolt: 20 4 30 390 (40) (290)
8 Gear pump moounting bolt: 12 4 19 88 (9) (65)
9 Control valve mounting nut: 20 12 30 390 (40) (290)
10 Swing device mounting bolt: 33 50 50 2550 (260) (1880)
11 Swing motor mounting bolt: 20 16 30 390 (40) (290)
12 Battery mounting bolt: 10 16 17 49 (5) (36)
13 Cab mounting bolt: 18 8 27 295 (30) (215)
14 Cab bed mounting bolt: 16 36 24 205 (21) (152)
15 Swing vearing mounting bolt: 48 60 75 4900 (500) (3620)
16 Counterweight mounting nut: 48 6 75 5150 (525) (3800)
17 Engine bed mounting bolt: 30 26 46 1420 (145) (1050)
18 Oil cooler mounting nut: 24 8 36 690 (70) (510)
19 Radiator mounting nut: 27 16 41 1370 (140) (1010)
20 Fan motor mounting bolt: 12 10 10 108 (11) (80)
21 Fan motor bracket mounting bolt: 12 12 19 88 (9) (65)
22 Travel device mounting bolt: 27 24 41 1370 (140) (1010)
36 56 55 3140 (320) (2310)
20 30 30 390 (40) (290)
16 32 24 205 (21) (152)
23 Travel motor mounting bolt: 22 8 32 740 (75) (540)
24 Upper roller mounting bolt: 22 24 32 540 (55) (400)
25 Lower roller mounting bolt: 36 64 55 3140 (320) (2310)
26 Track pin-retaining bolt: 30 156 46 1910 (195) (1410)
27 Side frame mounting bolt: 48 68 85 4900 (500) (3620)
28 Front pin-retaining bolt: 24 28 36 690 (70) (510)
20 16 30 390 (40) (290)
16 6 24 265 (27) (195)
NOTE: (1) Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction
coefficient of them.
(2) Make sure bolt and nut threads are clean before installing.
(3) Apply LOCTITE to threads before installing and tightening swing bearing mounting bolts.
W1-2-1
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
the correct tools. Avoid bodily injury caused
by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four kinds of bolts, hexagon bolts T, H, M and socket SA-040
bolts, each made of different material, are used.
Make sure to employ the correct bolts and tighten
them to specification when assembling the machine
or components.
Hexagon H Bolt Hexagon M Bolt Socket Bolt

Hexagon T Bolt
W162-01-01-001
Specified Tightening Torque Chart

Hexagon T Bolt, Socket Bolt H Bolt M Bolt
Bolt Wrench
Wrench
Dia. Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
Size
M 8 13 6 29.5 (3) (22) 19.5 (2) (14.5) 9.8 (1) (7.2)
M 10 17 8 64 (6.5) (47) 49 (5) (36) 19.5 (2)) (14.5)
M 12 19 10 108 (11) (80) 88 (9) (65) 34 (3.5) (25.5)
M 14 22 12 175 (18) (130) 137 (14) (101) 54 (5.5) (40)
M 16 24 14 265 (27) (195) 205 (21) (152) 78 (8) (58)
M 18 27 14 390 (40) (290) 295 (30) (220) 118 (12) (87)
M 20 30 17 540 (55) (400) 390 (40) (290) 167 (17) (123)
M 22 32 17 740 (75) (540) 540 (55) (400) 215 (22) (159)
M 24 36 19 930 (95) (690) 690 (70) (505) 275 (28) (205)
M 27 41 19 1370 (140) (1010) 1030 (105) (760) 390 (40) (290)
M 30 46 22 1910 (195) (1410) 1420 (145) (1050) 540 (55) (400)
M 33 50 24 2550 (260) (1880) 1910 (195) (1410) 740 (75) (540)
M 36 55 27 3140 (320) (2310) 2400 (245) (1770) 930 (95) (690)
W1-2-2
IMPORTANT: (1) Apply lubricant (i. e. white zinc B
dissolved into spindle oil) to nuts
and bolts to stabilize their friction
coefficients.
(2) Torque tolerance is ±10 %.
(3) Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop
sufficient tightening force.
(4) The torques given in the chart
are for general use only.
Do not use these torques if a
different torque is given for a
specific application.
(5) Make sure that the nut and bolt
threads are clean before
installing. Remove dirt or
corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Equally tighten upper Tighten diagonally Tighten from center

and lower alternately and diagonally
1,4 1 12 9 4 1 6 7 14
6 3
4 5
2 13 8 5 2 3 10 11
2,3
W105-01-01-003
W1-2-3
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear. Unevenness causes seal
extrusion. If defects cannot be
removed, replace the component.
(2) Be sure to use only specified O-
rings. Inspect O-rings for any W105-01-01-015
damage. Take care not to file O- WRONG

ring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
(3) Loosely assemble split flange
halves. Make sure that the split is
centrally located and
perpendicular to the port. Hand-
tighten the bolts to hold the parts W105-01-01-016
in place. Take care not to pinch

the O-ring.
(4) Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening.
(5) Do not use air wrenches. Using
an air wrench often causes
tightening of one bolt fully before
tighten the others, resulting in W105-01-01-008
damage to O-rings or uneven RIGHT WRONG

tightening of bolts.
Nut and Bolt Lockings

Bend along edge sharply Do not bend it round
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try RIGHT RIGHT WRONG
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening. Bend along edge sharply
W105-01-01-009
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt- RIGHT RIGHT WRONG
tightening direction, not in the bolt-
loosening direction.
RIGHT Loosen WRONG
Tighten
W105-01-01-010
W1-2-4
PIPING JOINT
Pipe Thread Connection/Union Joint Tightening
Torque Specifications 1 4 3 5 2
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Joint Body
IMPORTANT: (1) Do not over-tighten union nut (3). M202-07-051
Excessive force will be applied to

metal sealing surfaces (4) and (5), 30° or 37°
possibly cracking adaptor (1). Be
sure to tighten union nut (3) to 30° or 37°
specifications.
(2) Scratches or other damage to

sealing surfaces (4) or (5) will Male Union Joint Female Union Joint
cause oil leakage at the joint. W105-01-01-017
Take care not to damage them
when connecting /disconnecting. Wrench Size Tightening Torque
mm N⋅m (kgf⋅m) (Ibf⋅ft)
19 29 (3.0) (22)
22 39 (4.0) (29)
27 93 (9.5) (69)
O-Ring Seal Joint 32 137 (14) (101)
36 175 (18) (130)
O-ring (6) seats against the end face of adaptor (7) to 41 205 (21) (152)
seal pressure oil. 50 255 (26) (188)
IMPORTANT: (1) Be sure to replace O-ring (6) with

7 6 9
a new one when reconnecting.
(2) Before tightening union nut (9),

confirm that O-ring (6) is seated
correctly in O-ring groove (8).
Tightening union nut (9) with O-
ring (6) displaced will damage O-
ring (6), resulting in oil leakage.
8 10
(3) Take care not to damage O-ring M104-07-033
groove (8) or sealing face (10).
Damage to O-ring (6) will cause
Wrench Size Tightening Torque
oil leakage.
mm N⋅m (kgf⋅m) (Ibf⋅ft)
(4) If union nut (9) is found to be 27 93 (9.5) (69)
loose, causing oil leakage, do not 32 137 (14) (101)
tighten it to stop the leak. Instead,
36 175 (18) (130)
replace O-ring (6) with a new one,
then tighten union nut (9) after 41, 46 205 (21) (152)
confirming that O-ring (6) is
securely seated in place.
W1-2-5
Screwed-In Connection
PT PF
IMPORTANT: Many types of screwed-in connec-

30°
tions are used for hose connections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Straight Thread
W105-01-01-018
Wrench Tightening Torque

NOTE: Cas Iron:For tightening screwed-in connec- Size Cast Iron Steel
tion to cast-iron components. mm N⋅m (kgf⋅m) (Ibf⋅ft) N⋅m (kgf⋅m) (Ibf⋅ft)
Steel :For tightening screwed-in connec- 19 14.5 (1.5) (10) 34 (3.5) (25)
tion to steel components. 22 29.5 (3.0) (22) 49 (5.0) (36)
27 49 (5.0) (36) 93 (9.5) (69)
36 69 (7.0) (51) 157 (16) (116)
41 108 (11) (80) 205 (21) (152)
50 157 (16) (116) 20 (33) (240)
60 195 (20) (145) 410 (42) (300)
70 255 (26) (190)
Seal Tape Application
Seal tape is used to seal clearances between male Internal Thread

and female threads, so as to prevent any leakage
between threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap. External Thread Clearance
W105-01-01-019
• Application Procedure Leave one to two pitch threads uncovered
Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque M114-07-041
Low-pressure-hose clamp tightening torque differs T-Bolt Type Worm Gear Type
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp.
T-Bolt Type Band Clamp:

4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft )
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft )
M114-07-042 M114-07-043
W1-2-6
Connecting Hose
WRONG RIGHT
CAUTION:
(1) When replacing hoses, be sure to use
only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses
may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in
a fire on the machine.
(2) Do not install hoses kinked. Application
of high oil pressure, vibration, or an
impact to a kinked hose may result in oil W105-01-01-011
leakage, hose rupture or separation of
fitting. Utilize print marks on hoses when
installing hoses to prevent hose from
being installed kinked. WRONG RIGHT
(3) If hoses rub against each other, wear to Rubbing Against
the hoses will result, leading to hose Each Other
rupture. Take necessary measures to
protect hoses from rubbing against each
other.
Take care that hoses do not come into
contact with moving parts or sharp
objects.
W105-01-01-012
WRONG RIGHT
Clamp Clamp
Rubbing
W105-01-01-013
WRONG RIGHT
Rubbing
Clamp
W105-01-01-014
W1-2-7
(Blank)
W1-2-8
SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab Group 4 Swing Device
Windowpane Dimensions ......................... W2-1-1 Remove and Install Swing Device............. W2-4-1
Disassemble Swing Device....................... W2-4-2
Group 2 Pump Device Assemble Swing Device ........................... W2-4-6
Remove and Install Disassemble Swing Motor ...................... W2-4-12
Pump Device .......................................... W2-2-1 Assemble Swing Motor ........................... W2-4-14
Pump Device Line Connection.................. W2-2-3 Maintenance Standard............................ W2-4-16
Disassemble Main Pump .......................... W2-2-4 Disassemble and Assemble
Assemble Main Pump............................. W2-2-10 Relief Block .......................................... W2-4-17
Maintenance Standards.......................... W2-2-13
Disassemble Regulator .......................... W2-2-14 Group 5 Pilot Valve
Assemble Regulator ............................... W2-2-20 Remove and Install Front/Swing
Disassemble and Assemble Pilot Valve............................................... W2-5-1
4-Unit Pump ......................................... W2-2-27 Remove and Install Travel and Bucket
Disassemble Fan Drive Pump ................ W2-2-28 Open/Close Pilot Valves ......................... W2-5-3
Assemble Fan Drive Pump ..................... W2-2-32 Pilot Valve Ports ....................................... W2-5-5
Maintenance Standards.......................... W2-2-34 Disassemble and Assemble
Disassemble Regulator .......................... W2-2-36 Pilot Valve............................................... W2-5-6
Assemble Regulator ............................... W2-2-40
Disassemble and Assemble Compressor Group 6 Pilot Shut-Off Valve
Drive Pump ⋅ Pilot Pump....................... W2-2-42 Remove and Install
Disassemble and Assemble Transmission Shut-Off Valve .......................................... W2-6-1
Oil Cooling Pump.................................. W2-2-44 Disassemble Pilot Shut-Off Valve ............. W2-6-2
Assemble Pilot Shut-Off Valve .................. W2-6-4
Group 3 Control Valve
Remove and Install
Control Valve .......................................... W2-3-1
Pilot Line Port Location ............................ W2-3-3
Main Hydraulic Line Port Location ............ W2-3-4
Disassemble and Assemble
Control Valve .......................................... W2-3-5
117W-2-1
Group 7 Solenoid Valve
Remove and Install
Solenoid Valve........................................ W2-7-1
Fan Motor Solenoid Valve ....................... W2-7-2
Disassemble and Assemble Horsepower
Reducing Solenoid Valve ........................ W2-7-3
EHC Valve .............................................. W2-7-4
Swing Stop Solenoid Valve ..................... W2-7-5
Disassemble and Assemble Travel Mode Shift
Solenoid Valve........................................ W2-7-6
Group 8 Fan Drive Motor

Remove and Install
Fan Drive Motor...................................... W2-8-1
Disassemble Fan Drive Motor .................. W2-8-4
Assemble Fan Drive Motor ....................... W2-8-6
Maintenance Standards............................ W2-8-8
Group 9 Compressor Drive Motor

Remove and Install
Compressor Drive Motor......................... W2-9-1
Compressor Drive Motor......................... W2-9-4
Group 10 Air Conditioner

Work After Component
Replacement ........................................ W2-10-1
Add Compressor Oil ............................... W2-10-1
Charge Air Conditioner with
Refrigerant ........................................... W2-10-2
117W-2-2
UPPERSTRUCTURE / Cab
WINDOWPANE DIMENSIONS
Material : JIS R 3211 or equivalent
NOTE: 1 mm=0.03937 in Unit:mm
1378±1.5
6
1 4-R91
7 1
Laminated glass
Color : Transparent
1679+2.0 −0 Thickness : 10 mm
2 Chamfer all fringe Corners.
3 5
4
W117-02-01-001
W117-02-01-002
1369±1.5
4-R61
4-R61
2 3
Tempered glass Tempered glass
Color : Bronze Color : Bronze
769±1.0
917±1.0 Thickness : 6 mm Thickness : 5 mm
Chamfer all fringe Corners. Chamfer all fringe
Corners.
433±1.0
1256±1.5
W117-02-01-004
W117-02-01-003
W2-1-1
UPPERSTRUCTURE / Cab
NOTE: 1 mm=0.03937 in
422±1.0
4-R61
4-R61
4 5
Tempered glass Tempered glass
Color : Bronze Color : Bronze
Thickness : 5 mm 777±1.0 Thickness : 5 mm
Chamfer all fringe Corners. Chamfer all fringe Corners.
934±1.0
514±1.0
W117-02-01-005
W117-02-01-006
1400±1.0
667±1.0
4-R61
4-R61
7
6
Tempered glass
Tempered glass Color : Bronze
848±1.0 Color : Bronze Thickness : 5 mm 645±1.0
Thickness : 6 mm Chamfer all fringe
Chamfer all fringe Corners. Corners.
185 403±1.0
1296±1.0
W117-02-01-008
W117-02-01-007
W2-1-2
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
CAUTION: Escaping fluid under pressure

can penetrate the skin and eyes, causing
serious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic or
other lines.
Hydraulic oil may be hot just after operation.
Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting work.
Do not quickly loosen the cap on the hydrau-
lic oil tank. The cap may fly off due to internal
pressure. Always turn the cap slowly to re-
lease any remaining pressure before remov-
ing it.
Preparation:
1. Stop the engine. Move all control levers to release

the pressure remaining in the system. Slowly turn
the cap on the hydraulic oil tank approximately 30
degrees counter-clockwise to release any
remaining pressure.
2. Close all hydraulic line stop valves.
W2-2-1
Removal
Mounting Bolt
1. Disconnect all wire harness ends and hydraulic
line ends from the pump.
CAUTION: Pump Device Weight:

298 kg (657 Ib)
Approximate Quadruple Pump Weight: 100 kg
(220 Ib)
2. Remove the pump mounting bolts to remove the

pumps.
: 36 mm
: 690 N⋅m (70 kgf⋅m, 507 lbf⋅ft)
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
Installation T117-02-01-001
Air Bleed Position Air Bleed Position

NOTE: Refar to the Removal section for wrench
size and tightening torque.
1. Install the pumps using the mounting bolts.
2. Connect all wire harness ends and hydraulic line

ends to the pump.
3. Bleed the air from the pump. (Refer to W1-1-2)
IMPORTANT: Prevent pump seizure from

occurring. Be sure to perform
running-in operation after installing
the pumps. M117-07-118
Pump Running-In Operation Procedure:

1. Run the engine at slow idle for 20 minutes.
Check for oil leaks during the engine idling
operation.
2. Increase the engine speed to the maximum
speed. Slowly operate the boom from stroke
end to stroke end repeatedly for 20 minutes.
W2-2-2
PUMP DEVICE LINE CONNECTION
6
6
3
5
4
5
T117-02-01-001
1 - Main Pump 3 (Transmission Side) 3 - Main Pump 1 (Transmission Side) 5 - Suction Line 6 - Delivery Line
Main Pump 4 (Tip Side) Main Pump 2 (Tip Side)
2 - Main Pump 5 (Transmission Side) 4 - Quadruple Pump
Main Pump 6 (Tip Side)
Psv Pz
Pi Pf
Pz Psv Pi
T117-02-01-004
Psv - Pump Servo Assist Pressure (From the pilot pump) Pf - Horsepower Reducing Control Pressure
(Horsepower Reducing Solenoid Valve)
Pi - Flow Rate Control Pressure Pz -Horsepower Increasing Control Pressure
(Switch Valves 1 and 2, Pressure Reducing Valve) (EHC Valve)
W2-2-3
DISASSEMBLE MAIN PUMP 20
21
19
18
22
17 23
16
15 24
14 25
13
12 A
11 26
27
10
29
9 28
8
7
6
5
30
4 31 36 34
35
3
2 32
1 37
38 C
33
39
40
41
42 51
43
44
45
46
81 47 52
48 53
54
55
49 60 56
50 61 57
58
62
63
64
65
66
A 68 67
69
70
71
59
72 80
73
74
75
C 76
77
78
79 W117-02-02-002
W2-2-4
1 - Socket Bolt (2 Used) 22 - Stopper (2 Used) 42 - Cylinder Block 62 - Housing

(2 Used)
2 - Cover 23 - Back-Up Ring (2 Used) 43 - Spring (18 Used) 63 - Socket Bolt (4 Used)
3 - O-Ring 24 - O-Ring (2 Used) 44 - Spacer (2 Used) 64 - O-Ring (12 Used)
4 - Cover 25 - Servo Piston (2 Used) 45 - Spherical Bushing 65 - O-Ring
(2 Used)
5 - O-Ring 26 - O-Ring (2 Used) 46 - Retainer (2 Used) 66 - Valve Plate
6 - Retaining Ring 27 - Plug (2 Used) 47 - Plunger (18 Used) 67 - Needle Bearing
(2 Used)
7 - Spacer (2 Used) 28 - Taper Screw 48 - Shoe Plate (2 Used) 68 - Plug
8 - Bearing (2 Used) 29 - Plug 49 - Bushing (2 Used) 69 - O-Ring
9 - Spacer (2 Used) 30 - O-Ring (4 Used) 50 - Swash Plate (2 Used) 70 - Adjusting Screw
(2 Used)
10 - Shaft 31 - O-Ring 51 - Coupling 71 - Nut (2 Used)
11 - Cover 32 - Plug 52 - Plug 72 - O-Ring (3 Used)
12 - Nut (2 Used) 33 - Socket Bolt (4 Used) 53 - Spring Pin 73 - O-Ring
13 - Adjusting Screw 34 - Booster 54 - Pin 74 - Pin
(2 Used)
14 - Spring Pin 35 - Eye Bolt 55 - Socket Bolt (8 Used) 75 - Spring Cover
15 - Stopper (2 Used) 36 - Plug 56 - Cover 76 - Cover
16 - Back-Up Ring (2 Used) 37 - O-Ring 57 - Oil Seal 77 - O-Ring
17 - O-Ring (2 Used) 38 - Valve Cover 58 - O-Ring 78 - Plug
18 - Housing 39 - O-Ring 59 - Shaft 79 - O-Ring
19 - Displacement Angle Shift 40 - Needle Bearing 60 - Regulator 80 - Cover
Pin (2 Used)
20 - Regulator 41 - Valve Plate 61 - Socket Bolt (4 Used) 81 - Socket Bolt (4 Used)
21 - Socket Bolt (4 Used)
NOTE: The components of housing (62): parts (6) to (9), (15) to (17), (19), (22) to (25), and (42) to (50), are
exactly the same as those of housing (18).
W2-2-5
20
21
18
14
13
12 A
11 26
27
5
30
4 31 34
38 C
33
39
40
41
42 51
43
44
45
46
81 47
48 53
54
60
50 61
62
63
64
65
66
A
70
71
72
73
74
75
C 76
79 W117-02-02-002
W2-2-6
Disassemble Main Pump
IMPORTANT: Do not attempt to remove nut (12),

adjusting screw (13), nut (71), and
adjusting screw (70). Leave them as
installed. The set flow rate may be
altered.
1. Remove plugs (27) (2 used) and O-rings (26) (2

used) to drain hydraulic oil from the pump.
: 36 mm
2. Remove socket bolts (21) (4 used) and (61) (4

used) to remove regulators (20) and (60),
respectively.
: 6 mm
3. Turn the pump over (on the regulator mounting

side). Remove socket bolts (33) (4 used) and (63)
(4 used).
: 17 mm
4. Separate housing (18), valve cover (38), cover

(76), and housing (62) assemblies. Be sure to
remove O-rings (39), (65), (64), (72), (73), and
(79) and spring pins (53) and (75) when
separating these assemblies.
NOTE: Take care not to drop valve plates (41) and

(66) while separating these assemblies.
5. Remove booster (34), coupling (51), valve plate

(41) and pin (54) from valve cover (38).
NOTE: Do not remove needle bearing (40) unless

required.
6. Remove cylinder block (42), springs (43) (9 used),

spacer (44), spherical bushing (45), retainer (46),
and plungers (47) (9 used) from housing (18).
7. Remove socket bolts (81) (4 used) to remove

cover (4) and O-ring (5).
: 6 mm
8. Tap on cover (11) using a plastic hammer to

remove it. Remove O-rings (30) (2 used) and (31),
and spring pin (14) as well.
9. Remove swash plate (50) and shoe plate (48)

from housing (18).
W2-2-7
19
18
22
17 23
16
15 24
14 25
A
11
10
9
8
7
6
30
31
42
43
44
45
46
81 47
48
55
56
50 57
58
62
66
A 67
59
80
74
C 76
W117-02-02-002
W2-2-8
10. Remove stopper (15), stopper (22), servo piston
(25) and displacement angle shift pin (19) from
housing (18).
NOTE: As LOCTITE has been applied on the

contacting part between servo piston (25)
and displacement angle shift pin (19), do
not separate them unless required.
11. Tap on the end of shaft (10) using a plastic

hammer to remove it from cover (11).
12. Remove retaining ring (6), spacer (7), bearing (8)

and spacer (9) from shaft (10).
13. Remove needle bearing (67), valve plate (66) and

pin (74) from cover (76).

required.
14. Remove cylinder block (42), springs (43) (9 used),

and plungers (47) (9 used) from housing (62).
15. Remove socket bolts (55) (8 used) to remove

cover (56), oil seal (57) and O-ring (58).
: 8 mm
16. Tap on cover (80) using a plastic hammer to

remove it. Remove O-rings (30) (2 used) and (31),
and spring pin (14) as well.

from housing (62).
18. Tap on the end of shaft (59) using a plastic

hammer to remove it from cover (80).
19. Remove retaining ring (6), spacer (7), bearing (8)


housing (62).
NOTE: As LOCTITE has been applied on the

contacting part between servo piston (25)
and displacement angle shift pin (19), do
not separate them unless required.
W2-2-9
ASSEMBLE MAIN PUMP
80 45 50 48 49 62 65 64 76 73 38 39 64 23, 24 22 19 25 15 16, 17
12
71 13
70 14
8
55 5
3
56
2
59 10
6
7
57
1
58 81
63 4
33
46 47 44 43 42 66 74 67 75 34 51 40 54 53 41 18 31 9 11
W117-02-02-003
1 - Socket Bolt (2 Used) 22 - Stopper (2 Used) 42 - Cylinder Block 62 - Housing

(2 Used)
2 - Cover 23 - Back-Up Ring (2 Used) 43 - Spring (18 Used) 63 - Socket Bolt (4 Used)
3 - O-Ring 24 - O-Ring (2 Used) 44 - Spacer (2 Used) 64 - O-Ring (12 Used)
4 - Cover 25 - Servo Piston (2 Used) 45 - Spherical Bushing 65 - O-Ring
(2 Used)
5 - O-Ring 26 - O-Ring (2 Used) 46 - Retainer (2 Used) 66 - Valve Plate
6 - Retaining Ring 27 - Plug (2 Used) 47 - Plunger (18 Used) 67 - Needle Bearing
(2 Used)
7 - Spacer (2 Used) 28 - Taper Screw 48 - Shoe Plate (2 Used) 68 - Plug
8 - Bearing (2 Used) 29 - Plug 49 - Bushing (2 Used) 69 - O-Ring
9 - Spacer (2 Used) 30 - O-Ring (4 Used) 50 - Swash Plate (2 Used) 70 - Adjusting Screw
(2 Used)
10 - Shaft 31 - O-Ring 51 - Coupling 71 - Nut (2 Used)
11 - Cover 32 - Plug 52 - Plug 72 - O-Ring (3 Used)
12 - Nut (2 Used) 33 - Socket Bolt (4 Used) 53 - Spring Pin 73 - O-Ring
13 - Adjusting Screw 34 - Booster 54 - Pin 74 - Pin
(2 Used)
14 - Spring Pin 35 - Eye Bolt 55 - Socket Bolt (8 Used) 75 - Spring Cover
15 - Stopper (2 Used) 36 - Plug 56 - Cover 76 - Cover
16 - Back-Up Ring (2 Used) 37 - O-Ring 57 - Oil Seal 77 - O-Ring
17 - O-Ring (2 Used) 38 - Valve Cover 58 - O-Ring 78 - Plug
18 - Housing 39 - O-Ring 59 - Shaft 79 - O-Ring
19 - Displacement Angle Shift 40 - Needle Bearing 60 - Regulator 80 - Cover
Pin (2 Used)
20 - Regulator 41 - Valve Plate 61 - Socket Bolt (4 Used) 81 - Socket Bolt (4 Used)
21 - Socket Bolt (4 Used)
NOTE: The components of housing (62): parts (6) to (9), (15) to (17), (19), (22) to (25), and (42) to (50), are
exactly the same as those of housing (18).
W2-2-10
1. Install displacement angle shift pin (19), servo
piston (25), stopper (22) and stopper (15) into
both housing (18) and housing (62).
NOTE: If displacement angle shift pin (19) has

been separated from servo piston (25),
apply LOCTITE to the threaded part of
servo piston (25).
2. Install cover (11) onto housing (18). Install cover

(80) onto housing (62).
3. Place housings (18) and (62) on a workbench with

their regulator mounting side on the bottom. Install
swash plate (50) with shoe plate (48) onto
displacement angle shift pin (19).
NOTE: After installing swash plate (50), check if it

moves smoothly.
4. Install spacer (9), bearing (8), spacer (7), and

retaining ring (6) onto each shaft (11) and shaft
(80).
5. Install O-ring (5) onto cover (4). Install cover (4)

onto cover (11) using socket bolts (81).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
6. Install O-ring (58) and oil seal (57) onto cover (56).
Install cover (56) onto cover (80) using socket
bolts (55).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
7. Install spring (43), spacer (44), spherical bushing

(45), retainer (46), and plungers (47) into each
cylinder block (42) (2 used). Aligning the splines,
install the cylinder block assembly onto both shaft
(10) and shaft (59).
8. Install pin (54), valve plate (41), O-ring (64), O-

ring (39), and pin (53) onto cover (38). Install
cover (38) onto housing (18) using socket bolts
(33).
: 17 mm
: 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft)
W2-2-11
9. Install pin (74), valve plate (66), O-ring (64), O-
ring (65) and pin (75) onto cover (76). Install cover
(76) onto housing (80) using socket bolts (33).
10. Install booster (34) and coupling (51) onto shaft

(10).
NOTE: Be sure that booster (34) is facing the

correct direction when installing.
11. Install O-rings (72), (73), and (79) onto cover (76).
Connect housing (18) and (62) using socket bolts
(63).
: 17 mm
: 630 N⋅m (64 kgf⋅m, 463 lbf⋅ft)
12. Install regulators (20) and (60) using socket bolts

(21) and (61), respectively.
: 6 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W2-2-12
MAINTENANCE STANDARDS NOTE: 1 mm= 0.03937 in
1. Clearance between plunger (47) diameter (d) and

cylinder block (42) bore (D).
D-d Unit : mm d D
Standard Allowable Limit

0.047 0.094
W117-02-02-009
2. Spring (43) free length (L)
Unit : mm
49.5 48.0
W117-02-02-010
3. Clearance between plunger and shoe: (e), and

shoe thickness (t)
e Unit : mm
0∼0.1 0.35 e
t
t Unit : mm
Standard Allowable Limit W117-02-02-011
6.5 6.3
4. Distance between retainer (46) bottom and

spherical bushing (45) top. Stand
H-h Unit : mm
Standard Allowable Limit h H
16.5 15.5
W117-02-02-012
W2-2-13
DISASSEMBLE REGULATOR
13
12
11
10
9
8
7
6
5 22 23
4 24 32
3 25 31
2 21 26 30
1 20 29 63
27
19 62
18 61
17
16 60
15 28 59
14 58
57 74
75
56 76
33 55
54 78
34 35 53 73
52 72
36 71
51 70
50
49 69
68 77
79
43
45 67
42 44
41 40
39
80
38 81
37 47
46 48 82
64 98 83
97 84
65
66
89
96 95 91 85
86
92 90 87
93 88
94 W117-02-02-005
W2-2-14
1- Pin 26 - Lever 51 - Washer 75 - Cover

2- Sleeve 27 - Pin 52 - Sleeve 76 - Lock Nut
3- O-Ring 28 - Pilot Piston 53 - Piston 77 - Adjusting Screw
4- O-Ring 29 - Spring Seat 54 - Spool 78 - Lock Nut
5- Sleeve 30 - Spring 55 - Spring Seat 79 - Socket Bolt
6- Compensating Piston 31 - Spring Seat 56 - Spring 80 - Casing
7- Compensating Rod 32 - O-Ring 57 - Spring 81 - Pin
8- Spring Seat 33 - Socket Bolt 58 - Spring Seat 82 - Support Plug
9- Spring 34 - Cover 59 - O-Ring 83 - O-Ring
10 - Spring 35 - Cover 60 - Cover 84 - Lock Ring
11 - Piston 36 - O-Ring 61 - Socket Bolt 85 - Pin
12 - Spring Seat 37 - Stopper 62 - Lock Nut 86 - Support Plug
13 - O-Ring 38 - Ball 63 - Adjusting Screw 87 - O-Ring
14 - Retaining Ring 39 - Seat 64 - Cover 88 - Lock Ring
15 - Spring Seat 40 - O-Ring 65 - Socket Bolt 89 - Pin
16 - Spring 41 - O-Ring 66 - Socket Bolt 90 - O-Ring
17 - Spring 42 - Plug 67 - Socket Bolt 91 - Stopper
18 - Retaining Ring 43 - Plug 68 - O-Ring 92 - Ball
19 - Sleeve 44 - Plug 69 - O-Ring 93 - Seat
20 - Spool 45 - O-Ring 70 - Adjusting Screw 94 - O-Ring
21 - Pin 46 - Plug 71 - Adjusting Screw 95 - O-Ring
22 - Lever 47 - O-Ring 72 - Lock Nut 96 - O-Ring
23 - Feedback Lever 48 - Pin 73 - O-Ring 97 - O-Ring
24 - Pin 49 - Cover 74 - Plug 98 - Plug
25 - Pin 50 - Socket Bolt
W2-2-15
13
12
11
10
9
8
6
5
32
31
2 30
1 29 63
62
61
17
60
59
58
57
75
56 76
33 55
54 78
34 35 53
52 72
36 71
51 70
50
49 77
79
45 67
44
40
39
80
38
37 47
48
64
97
65
66
96 95
W117-02-02-005
W2-2-16
1. Remove socket bolts (50) and (67) to remove the
regulators.
: 6 mm
2. Remove socket bolts (33). Remove cover (34),

O-ring (40), cover (35), O-ring (36), cover (49), O-
ring (47), and pin (48).
: 5 mm
3. Remove stopper (37), ball (38), and seat (39)

from cover (35).
4. Remove socket bolts (61) from cover (49).

Remove cover (60), O-ring (59), spring seat (58),
spring (57), spring (56), spring seat (55), spool
(54), piston (53), sleeve (52), and washer (51).
IMPORTANT: Never attempt to remove lock nut

(62) and adjusting screw (63) from
cover (60). Setting for the relief oil
flow minimizing control may be
altered.
: 5 mm
5. Remove socket bolts (79) from casing (80).

Remove cover (75), spring seat (12), piston (11),
spring (10), spring (9), spring seat (8), spring seat
(31), spring (30), and spring seat (29).
IMPORTANT: Never attempt to remove adjusting

screw (70), lock nut (76), adjusting
screw (71) and lock nut (72) from
cover (75). Setting for the
horsepower reducing control and
horsepower increasing controls may
be altered.
Also, never attempt to remove
adjusting screw (77) and lock nut
(78) from cover (75). Setting for the
flow control may be altered.
: 5 mm
6. Remove socket bolts (65) and (66) from casing

(80). Remove cover (64), O-rings (95), (96), and
(97), spring (17), pin (1), sleeve (2), sleeve (5)
and compensating piston (6).
: 5 mm
W2-2-17
7
22 23
24
21 26
20
27
19
17
16
15 28
14
80
81
82
84
85
86
88
W117-02-02-005
W2-2-18
7. Remove retaining ring (14) to remove spring seat
(15), spring (16), spring (17), and sleeve (19).
IMPORTANT: Put identification mark on support

plug (82) (86) for assembling.
8. Remove lock rings (84) and (88) from casing (80).

Remove support plugs (82) and (86) and pin (85)
utilizing a M6 bolt.
9. Remove lever (26) from casing (80) with a pair of

tweezers.
NOTE: Do not remove pin (27).
10. Remove pin (24) using a thin copper bar (less

than φ 4). Remove feedback lever (23).
NOTE: Take care not to hit pin (24) against lever

(22) when pulling it out.
11. Remove lever (22) from casing (80).
NOTE: Do not remove pins(81) and (21) when

removing lever (22).
12. Remove pilot piston (28), spool (20), and

compensating rod (7) from casing (80).
W2-2-19
ASSEMBLE REGULATOR 79 47 36 37 38 39
A C
33
40
A' B C'
A-B 35 34
16 18 19 20 24 81 22 8 9 73 68 74 69 75 76 W117-02-02-004
97
17 10 11
15
14
70
3 72
1
2
71
4 6 5 7 23 21 90 89 12 13
W117-02-02-007
A-A’
64 80 28 85 25 26 27 30 31 32
65
78
96
77
66
29
W117-02-02-006
C-C 49 60
82 83 84
46
61
45
62
44
63
86 87 88
51 53 52 54 49 55 56 57 58 59 W117-02-02-008 W117-02-02-023
W2-2-20
1- Pin 26 - Lever 51 - Washer 75 - Cover
2- Sleeve 27 - Pin 52 - Sleeve 76 - Lock Nut
3- O-Ring 28 - Pilot Piston 53 - Piston 77 - Adjusting Screw
4- O-Ring 29 - Spring Seat 54 - Spool 78 - Lock Nut
5- Sleeve 30 - Spring 55 - Spring Seat 79 - Socket Bolt
6- Compensating Piston 31 - Spring Seat 56 - Spring 80 - Casing
7- Compensating Rod 32 - O-Ring 57 - Spring 81 - Pin
8- Spring Seat 33 - Socket Bolt 58 - Spring Seat 82 - Support Plug
9- Spring 34 - Cover 59 - O-Ring 83 - O-Ring
10 - Spring 35 - Cover 60 - Cover 84 - Lock Ring
11 - Piston 36 - O-Ring 61 - Socket Bolt 85 - Pin
12 - Spring Seat 37 - Stopper 62 - Lock Nut 86 - Support Plug
13 - O-Ring 38 - Ball 63 - Adjusting Screw 87 - O-Ring
14 - Retaining Ring 39 - Seat 64 - Cover 88 - Lock Ring
15 - Spring Seat 40 - O-Ring 65 - Socket Bolt 89 - Pin
16 - Spring 41 - O-Ring 66 - Socket Bolt 90 - O-Ring
17 - Spring 42 - Plug 67 - Socket Bolt 91 - Stopper
18 - Retaining Ring 43 - Plug 68 - O-Ring 92 - Ball
19 - Sleeve 44 - Plug 69 - O-Ring 93 - Seat
20 - Spool 45 - O-Ring 70 - Adjusting Screw 94 - O-Ring
21 - Pin 46 - Plug 71 - Adjusting Screw 95 - O-Ring
22 - Lever 47 - O-Ring 72 - Lock Nut 96 - O-Ring
23 - Feedback Lever 48 - Pin 73 - O-Ring 97 - O-Ring
24 - Pin 49 - Cover 74 - Plug 98 - Plug
25 - Pin 50 - Socket Bolt
W2-2-21
A C
A' B C'
A-B
16 19 20 24 22 W117-02-02-004
97
17
15
14
3
1
2
4 6 5 7 23 21
W117-02-02-007
A-A’
64 80 28 85 26 27
65
96
66
W117-02-02-006
C-C
82 83 84
86 87 88
W117-02-02-008 W117-02-02-023
W2-2-22
Assemble Regulator
1. Install compensating rod (7) into casing (80).
2. Attach pin (21) into the designated hole on lever

(22). Install lever (22) by inserting pin (21) into the
groove on compensating rod (7) and, at the same
time, by inserting pin (81), which is already at-
tached on lever (22), into the designated hole on
casing (80).
3. Insert sleeve (19) and spool (20) into casing (80).
NOTE: Before inserting, be sure that the correct

end of spool (20) is facing the casing.
Also, confirm that spool (20) moves
smoothly in the casing.
4. Install feedback lever (23), aligning its pin hole

with that on spool (20). Insert pin (24) into the pin
hole.
NOTE: Be sure that the correct end of feedback

lever (23) is inserted into casing (80).
5. Insert pilot piston (28) into casing (80).
NOTE: Confirm that pilot piston (28) moves

smoothly in casing (80).
6. Install lever (26) so that the lever attached pin (27)

fits in the groove on pilot piston (28). Install sup-
port plug (86) so that pin (85) on the support plug
fits into the hole on lever (26). Install O-ring (87)
and lock ring (88) onto support plug (86).
7. Install adjusting plug (82), O-ring (83), and lock

ring (84) onto casing (80).
8. Install spring (17), spring (16), spring seat (15),

and retaining ring (14) onto spool (20).
9. Install compensating piston (6), sleeve (5), O-ring

(4), O-ring (3), sleeve (2), and pin (1) into casing
(80).
10. Install O-rings (95), (96), and (97) onto casing

(80). Install cover (64) using socket bolts (65) and
(66).
: 5 mm
: 11.8 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
W2-2-23
79 47 36 37 38 39
A C
33
40
A' B C'
A-B 35 34
8 9 75 W117-02-02-004
10 11
12
W117-02-02-007
A-A’
80 30 31
29
W117-02-02-006
C-C 49 60
61
51 53 52 54 55 56 57 58 59 W117-02-02-008 W117-02-02-023
W2-2-24
11. Install spring seat (29), spring (30), and spring
seat (31) into casing (80).
12. Install spring seat (8), spring (9), and spring (10)
into casing (80).
13. Install spring seat (12) and seat (11) into cover
(75). Install cover (75) onto casing (80).
: 5 mm
: 11.8 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
14. Install washer (51), sleeve (52), piston (53), spool

(54), spring seat (55), spring (56), spring (57),
spring seat (58), and O-ring (59) into cover (49).
Install cover (60) onto cover (49) using socket
bolts (61).
15. Install O-ring (36), O-ring (47) and pin (48) onto
cover (49). Install seat (39), ball (38), and stopper
(37) into cover (35). Install O-ring (40) onto cover
(35).
16. Assemble covers (49), (35), and (34). Install them

onto casing (80) using socket bolts (33).
: 5 mm
: 11.8 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
W2-2-25
(Blank)
W2-2-26
DISASSEMBLE AND ASSEMBLE 4-UNIT PUMP
A B C D
T117-02-01-017
A - Fan Drive Pump (Plunger Pump) C - Compressor Drive Pump

(Tumdem Gear Pump: Tip End)
B - Pilot Pump D - Transmission Lubricating Pump (Gear Pump)
(Tumdem Gear Pump: Transmission Side)
NOTE: The 4-unit pump consists of plunger pump

(A), tumdem gear pumps (B) and (C), and
gear pump (D).
W2-2-27
DISASSEMBLE FAN DRIVE PUMP 21
20 22
23
24
19 25
18
17
16
15
14
13
12
11
10
26
27
9
8
7
6 50
49
5
28 48
4
47
3 46
2 45, 44, 43
1
29
42 51
41 52
40 53
39 54, 55, 56
38
37 57
36
35 58
60
34
32
59
61
31 62
30
33
W117-02-02-013
1- Socket Bolt 17 - O-Ring 32 - Shoe Plate 48 - Nut
2- Cover 18 - Housing 33 - Shoe 49 - Plate
3- O-Ring 19 - Displacement Angle 34 - Plunger 50 - Socket Bolt
4- Oil Seal Shift Pin 35 - Retainer 51 - O-Ring
5- Shaft 20 - Regulator 36 - Spherical Bushing 52 - Coupling
6- Spacer 21 - Socket Bolt 37 - Spacer 53 - Retaining Ring
7- Bearing 22 - Stopper 38 - Spring 54 - Stopper
8- Spacer 23 - Back-Up Ring 39 - Cylinder Block 55 - Steel Ball
9- Retaining Ring 24 - O-Ring 40 - Valve Plate 56 - Seat
10 - Cover 25 - Servo Piston 41 - Needle Bearing 57 - Casing
11 - Nut 26 - O-Ring 42 - O-Ring 58 - Socket Bolt
12 - Adjusting Screw 27 - Plug 43 - Stopper 59 - Plug
13 - Spring 28 - Plug 44 - Steel Ball 60 - O-Ring
14 - Spring Pin 29 - Socket Bolt 45 - Seat 61 - Spring Pin
15 - Stopper 30 - Swash Plate 46 - Valve Cover 62 - Pin
16 - Back-Up Ring 31 - Bushing 47 - Adjusting Screw
W2-2-28
IMPORTANT: Never attempt to remove adjusting
screw (12), nut (11), adjusting screw
(47) and nut (48). The set flow rate
may be altered.
1. Remove plug (59) and O-ring (60) to drain hydrau-

lic oil from the pump.
: 36 mm
2. Remove socket bolts (21) to remove regulator

(20).
: 6 mm
3. Turn the pump over so that the regulator mounting

side is on the bottom. Remove socket bolts (50)
(4 used) to remove plate (49), O-ring (51) and
coupling (52).
NOTE: Do not remove retaining ring (53) unless it

is required.
: 10 mm
4. Remove socket bolts (29) to remove valve cover

(46) from casing (18).
NOTE: Valve plate (40) may drop when removing

valve cover (46). Take care not to drop
valve plate (40).
5. Remove O-ring (42), stopper (43), steel ball (44),

seat (45a), valve plate (40), pin (62), spring pin
(61), socket bolts (58), cover (57), stopper (54),
steel ball (55), and seat (56) from valve cover
(46).

required.
6. Remove cylinder block (39), spring (38) (9 used),

plungers (34) (9 used), and shoes (33) from hous-
ing (18).
7. Remove socket bolts (1) to remove cover (2) and

O-ring (3).
: 6 mm
8. Tap on cover (10) using a plastic hammer to re-

move it. Remove O-ring (14) and spring (13) at
the same time.
W2-2-29
21
20 22
23
24
19 25
18
17
16
15
14
13
12
11
10
26
27
9
8
7
6 50
49
5
28 48
4
47
3 46
2 45, 44, 43
1
29
42 51
41 52
40 53
39 54, 55, 56
38
37 57
36
35 58
60
34
32
59
61
31 62
30
33
W117-02-02-013
W2-2-30
from housing (18).

housing (18).
NOTE: As LOCTITE has been applied on the con-

tacting part between servo piston (25) and
displacement angle shift pin (19), do not
separate them unless required.
11. Tap on the end of shaft (5) using a plastic hammer

to remove it from cover (10).
Remove oil seal (4) at the same time.
12. Remove retaining ring (9), spacer (8), bearing (7),

W2-2-31
ASSEMBLE FAN DRIVE PUMP
17 24
12 11 10 15 32 25 30 18 31 22 42 40 48 47 53 49
16 23
13
14
50
1
51
6
52
4
2
3
29
7 8 9 35 33 34 36 37 38 39 61 62 41 46
W117-02-02-014

W2-2-32
Assemble Fan Drive Pump
1. Install displacement angle shift pin (19), servo pis-

ton (25), stopper (22) and stopper (15) into hous-
ing (18).
2. If displacement angle shift pin (19) has been

separated from servo piston (25), apply LOCTITE
to the threaded part of servo piston (25).
3. Place housing (18) on a workbench with the regu-

lator mounting side on the bottom. Attach the
shoe plate (30) attached swash plate (30) to dis-
placement angle shift pin (19).
NOTE: Check if swash plate (30) moves smoothly

after installing.
4. Install spacer (6), bearing (7), spacer (8), and re-

taining ring (9) onto shaft (5). Install shaft (5) into
cover (11).
5. Install O-ring (3) onto cover (2). Install oil seal (4)
and cover (2) onto cover (10) using socket bolts
(1).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
6. Install spring (38), spacer (37), spherical bushing

(36), retainer (35), plungers (34) and shoes (33)
into cylinder block (39). Install cylinder block (39)
onto shaft (5), aligning splines.
7. Install pin (62), valve plate (40), O-ring (42), pin

(61), stopper (43), steel ball (44), seat (45), stop-
per (54), steel ball (55), and seat (56) onto valve
cover (46). Install cover (57) onto valve cover (46)
using socket bolts (58).
8. Install valve cover (46) onto housing (18) using

socket bolts (29).
: 17 mm
: 430 N⋅m (44 kgf⋅m, 318 lbf⋅ft)
9. Install coupling (52) onto shaft (5). Install O-ring

(51) and plate (49) onto valve cover (46).
: 19 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
10. Install regulator (20) using socket bolts (21).
W2-2-33
MAINTENANCE STANDARDS NOTE: 1 mm= 0.03937 in
1. Clearance between plunger (34) diameter (d) and

cylinder block (39) bore (D).
D−d Unit : mm d D

0.047 0.094
W117-02-02-009
2. Spring (38) free length (L)
Unit : mm
49.5 48.0
3. Clearance between plunger (34) and shoe (33):(e), W117-02-02-010

and shoe thickness (t)
e Unit : mm
0∼0.1 0.35
t Unit : mm
e
Standard Allowable Limit t
6.5 6.3
W117-02-02-011
4. Distance between retainer (35) bottom and

spherical bushing (36) top.
H−h Unit : mm
16.5 15.5
Stand
h H
W117-02-02-012
W2-2-34
(Blank)
W2-2-35
DISASSEMBLE REGULATOR
13
12
10
9
8
7
6
5 22
4 23
3 24 32
2 25 31
1 26
21
20 30
29
19
18 27
17
16 28
15
14
46
45 48
47
44
43
42
37 38 41
34 40
33
49
50
68 35
51
36
67 52
65 53
54
59
64
63
66 62 55
56
61 60 57
58
W117-02-02-015
W2-2-36
1- Pin 19 - Sleeve 36 - O-Ring 53 - O-Ring

2- Sleeve 20 - Spool 37 - Socket Bolt 54 - Lock Ring
3- O-Ring 21 - Pin 38 - Socket Bolt 55 - Pin
4- O-Ring 22 - Lever 40 - O-Ring 56 - Support Plug
5- Sleeve 23 - Feedback Lever 41 - Adjusting Screw 57 - O-Ring
6- Compensating Piston 24 - Pin 42 - Adjusting Screw 58 - Lock Ring
7- Compensating Rod 25 - Pin 43 - Lock Nut 59 - Pin
8- Spring Seat 26 - Lever 44 - O-Ring 60 - O-Ring
9- Spring 27 - Pin 45 - Cover 61 - O-Ring
10 - Spring 28 - Pilot Piston 46 - Lock Nut 62 - O-Ring
12 - Spring Seat 29 - Spring Seat 47 - Adjusting Screw 63 - O-Ring
13 - O-Ring 30 - Spring 48 - Lock Nut 64 - O-Ring
14 - Retaining Ring 31 - Spring Seat 49 - Socket Bolt 65 - Plug
15 - Spring Seat 32 - O-Ring 50 - Casing 66 - Socket Bolt
16 - Spring 33 - Socket Bolt 51 - Pin 67 - Socket Bolt
17 - Spring 34 - Cover 52 - Support Plug 68 - Cover
18 - Retaining Ring 35 - O-Ring
W2-2-37
13
12
10
9
8
7
6
5 22
4 23
3 24 32
2 25 31
1 26
21
20 30
29
19
18 27
17
16 28
15
14
46
45 48
47
44
43
42
37 38 41
34 40
33
49
50
68 35
51
36
67 52
65 53
54
59
64
63
66 62 55
56
61 60 57
58
W117-02-02-015
W2-2-38
Disassemble Regulator
1. Remove socket bolts (37) and (38) to remove the 7. Remove lever (26) from casing (50) with a pair of
regulator. tweezers.
: 6 mm NOTE: Do not remove pin (27).

2. Remove socket bolts (33) to remove cover (34)
and O-rings (36) and (35). 8. Remove pin (24) using a thin copper bar (less
than φ 4). Remove feedback lever (23).
: 5 mm
NOTE: Take care not to hit pin (24) against lever
3. Remove socket bolts (49), cover (45), spring seat (22) when pulling it out.
(12), spring (10), spring (9), spring seat (8), spring
seat (31), spring (30), and spring seat (29) from 9. Remove lever (22) from casing (50).
casing (50).
IMPORTANT: Never attempt to remove adjusting NOTE: Do not remove pins (51) and (21) when
screw (41), lock nut (46), adjusting removing lever (22).
screw (42) and lock nut (43) from
cover (45). 10. Remove pilot piston (28), spool (20), and com-
Also, never attempt to remove ad- pensating rod (7) from casing (50).
justing screw (47) and lock nut (48)
from cover (45). Setting for the flow
control may be altered.
: 5 mm
4. Remove socket bolts (66) and (67), cover (68),

O-rings (62), (63), and (64), spring (17), pin (1),
sleeve (2), sleeve (5), and compensating piston
(6) from casing (50).
: 5 mm
5. Remove retaining ring (14), spring seat (15),

spring (16), spring (17) and sleeve (19).
IMPORTANT: Put identification mark on plug (52)

(56) for assembling.
6. Remove lock rings (54) and (58) from casing (50).

Utilizing a M6 bolt, remove support plug (52),
support plug (56), and pin (55).
W2-2-39
ASSEMBLE REGULATOR 34 33
A
49
A' B
A-B
64 16 18 19 20 24 51 22 8 9 44 40 45 46 W117-02-02-016
17
10
15
14
41
3 43
1
2
42
4 6 5 7 23 21 60 59 12 13
W117-02-02-017
A-A’
68 50 28 55 25 26 27 30 31 32
67
48
63
47
66
29
W117-02-02-006
52 33 54
56 57 58
W117-02-02-023
W2-2-40
Thank you very much
for your reading.
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EX2500

• Clean the Machine • Precautions for Disassembly

When hydraulic oil is drained, the suction filter or the

• Bleeding Air from Hydraulic Pump

IMPORTANT: If the engine is started with air

• Remove the air bleeding plug from the top of the

• Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing

• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

(1) Keep seal rings together as a matched set with

(2) Check seal ring face (A) for scuffing, scoring, B

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

2. If incorrectly assembled, oil leakage or damage

(1) Clean the floating seal and seal mounting

(2) Clean the floating seal and seal mounting

1 Engine cushion rubber mounting bolt: 36 6 55 3140 (320) (2310)

CAUTION: Use tools appropriate for the

Tighten nuts or bolts correctly to torque specifications.

Hexagon H Bolt Hexagon M Bolt Socket Bolt

Specified Tightening Torque Chart

Bolt Tightening Order

When tightening two or more bolts, tighten them

Equally tighten upper Tighten diagonally Tighten from center

IMPORTANT: (1) Be sure to clean and inspect

damage. Take care not to file O- WRONG

in place. Take care not to pinch

damage to O-rings or uneven RIGHT WRONG

Nut and Bolt Lockings

RIGHT Loosen WRONG

Metal sealing faces (4) and (5) of adaptor (1) and

IMPORTANT: (1) Do not over-tighten union nut (3). M202-07-051

Excessive force will be applied to

(2) Scratches or other damage to

IMPORTANT: (1) Be sure to replace O-ring (6) with

(2) Before tightening union nut (9),

IMPORTANT: Many types of screwed-in connec-

Male Tapered Thread Male Straight Thread

Wrench Tightening Torque

Seal tape is used to seal clearances between male Internal Thread

Confirm that the thread surface is clean, free of dirt

Low-Pressure-Hose Clamp Tightening Torque M114-07-041

T-Bolt Type Band Clamp:

Group 8 Fan Drive Motor

Group 9 Compressor Drive Motor

Group 10 Air Conditioner

Material : JIS R 3211 or equivalent

NOTE: 1 mm=0.03937 in Unit:mm

CAUTION: Escaping fluid under pressure

1. Stop the engine. Move all control levers to release

2. Close all hydraulic line stop valves.

CAUTION: Pump Device Weight:

2. Remove the pump mounting bolts to remove the

Air Bleed Position Air Bleed Position

1. Install the pumps using the mounting bolts.

2. Connect all wire harness ends and hydraulic line

3. Bleed the air from the pump. (Refer to W1-1-2)

IMPORTANT: Prevent pump seizure from

Pump Running-In Operation Procedure:

1 - Socket Bolt (2 Used) 22 - Stopper (2 Used) 42 - Cylinder Block 62 - Housing

IMPORTANT: Do not attempt to remove nut (12),

1. Remove plugs (27) (2 used) and O-rings (26) (2

2. Remove socket bolts (21) (4 used) and (61) (4