Hitachi ex450 lc 5 excavator service repair manual

EX400-5, EX400LC-5, EX450LC-5
Workshop Manual

166W-1-1
SECTION 1
GENERAL INFORMATION
—CONTENTS—
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology........ W1-1-6
Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-3
Piping joint ............................................. W1-2-6
Periodic Replacement of Parts ............. W1-2-10

GENERAL INFORMATION / Precautions for Disassembling and Assembling
W1-1-1
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop may
cause machine components to be contaminated
during disassembling/assembling, resulting in
damage to machine components, as well as
decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all dis-
assembling/assembling procedures beforehand, to
help avoid incorrect disassembling of components
as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area
for disassembling work.
• Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place it on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.
• Precautions for Assembling
• 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 to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no tools are missing.

W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or cylin-
der is done, bleed air from the hydraulic system in the
following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic mo-
tor housing, damage to the motor
may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage
to the cylinder may result.
Be sure to bleed air before starting
the engine.
• Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine 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 op-
eration (never fully stroke the cylinders during ini-
tial 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. Re-
plenish oil as necessary.
M104-07-021

W1-1-3
Floating Seal Precautions
1. In general, 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 the slide surface on seal ring surface
(A) for scuffing, scoring, corrosion, deformation
or uneven wear.
(3) Check O-ring (B) for tears, breaks, deformation
or hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
(2) Clean the floating seal and seal mounting
bores. Check the bore surface for scuffing or
scoring by touching the surface with finger.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating face
(C) by measuring the distances seal ring
surface (A) and seal mating face (C) at point
(a) and (b), as illustrated. If these distances
differ, correct the O-ring seating.
W105-03-05-019
W105-03-05-020
W110-03-05-004
a b
b b
aa
a=b
C
A
B
IncorrectCorrect
Incorrect
Correct
A
B

W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings
safely.
• Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from damage and the lifted load from slip-
ping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the
lifted load balanced.
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal piece.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
W102-04-02-016
W105-04-01-008
W162-01-01-009
Correct Eyehole
Lifting Method
Incorrect Eyehole
Lifting Method
Bent Sling

W1-1-5
CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
Damaged Appearance
W162-01-01-002
W162-01-01-003
W162-01-01-004
W162-01-01-005
W162-01-01-006
W162-01-01-007
W162-01-01-008
Broken Sewing Thread
Scuffing
Broken Sewing
Thread
Fuzz
Broken Sewing
Thread
Separation of
Belt
Broken Sewing
Thread
Scuffing
Scoring
Broken Warp
Fuzz

W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies adjusted
to specification.
Both dimensions are shown with tolerances as
necessary.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or replacement is required before reaching
this limit.
Machine performance will decrease, and
maintenance and down time expense will increase as
machine operating hours accumulate. It is
recommended that parts are repaired or replaced
before reaching the “Allowable Limit”.

GENERAL INFORMATION / Tightening
W1-2-1
TIGHTENING TORQUE SPECIFICATIONS
Bolt and Nut on Base Machine Standard Torques
Bolt Dia
Wrench
Size
Torque
No. Location
mm
Q’ty
(mm) N m (kgf m) (lbf ft)
1 Engine-cushion Front 22 2 32 740 (75) (540)
rubber mount- Engine-cushion rubber 22 2 32 740 (75) (540)
ing bolt Rear
Cushion rubber-machine 16 4 24 265 (27) (195)
2 Engine bracket mounting bolt 14 8 22 175 (18) (130)
3 Radiator mounting bolt 16 4 24 205 (21) (152)
4 Hydraulic oil tank mounting bolt 16 8 24 205 (21) (152)
5 Fuel tank mounting bolt 16 8 24 205 (21) (152)
6 ORS fittings for Hydraulic hoses and piping
Fittings
36
41
175
205
(18)
(21)
(130)
(152)
7 Pump transmission mounting bolt 12 12 19 88 (9) (65)
8 Pump mounting bolt 20 4 30 390 (40) (290)
9 Control valve mounting bolt (hexagon wrench) 20 4 17 390 (40) (290)
10 Swing device mounting bolt 22 26 32 740 (75) (540)
11 Swing motor mounting bolt (hexagon wrench) 18 24 14 295 (30) (220)
12 Battery mounting nut 8 3 13 19.5 (2) (14.5)
13 Cab mounting nut 16 6 24 205 (21) (152)
14 Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
27
27
36
36
41
41
1370
1370
(140)
(140)
(1010)
(1010)
15 Travel device mounting bolt
Travel motor mounting bolt
Sprocket mounting bolt
22
18
22
40
8
48
32
27
32
740
390
740
(75)
(40)
(75)
(540)
(290)
(540)
STD, H 18 16 27 390 (40) (290)16 Upper roller mounting
LC, LCH 18 24 27 390 (40) (290)
STD, H 22 64 32 740 (75) (540)17 Lower roller mounting bolt
LC, LCH 22 72 32 740 (75) (540)
STD, H 24 392 32 1370 (140) (1010)18 Track Shoe bolt
LC, LCH 24 424 32 1370 (140) (1010)
Continued on next page
1– — -12UNF
1– — -12UNF7
16
3
16

W1-2-2
Bolt Dia Wrench Size Torque
No. Location
mm
Q’ty
(mm) N m (kgf m) lbf ft
STD 22 28 32 740 (75) (540)
LC 22 36 32 740 (75) (540)
H 22 40 32 740 (75) (540)
19 Track guard mounting bolt
LCH 22 40 32 740 (75) (540)
20 Track mounting bolt 33 36 50 1720 (175) (1260)
Coupling 8 13 10.5 to
12.5
(1.05 to
1.26)
(7.6 to
9.1)
21 Coupling and clamp
of low preddure
piping Clamp — -28
UNF
11 9.8 (1.0) (7.2)
22 Counterweight mounting bolt
Counterweight lock bolt
45
24
2
4
65
36
2350
440
(240)
(45)
(1740)
(330)
23 Front pin lock bolt
Front pin lock nut
20
20
15
7
30
30
390
390
(40)
(40)
(290)
(290)
24 Front pin retain bolt (Loading shovel) 12
16
20
4
6
36
12
19
24
24
30
88
205
265
540
(9)
(21)
(57)
(55)
(65)
(152)
(195)
(398)
NOTE: 1. When tightening bolts and nuts, apply a
lubricant to threads to reduce friction.
(i.e.: White zinc B
dissolved into spindle oil)
2. Remove rust, soil, and dust before
tightening.
3. Use LOCTITE to the engine cushion
rubber mounting nuts and the lower
roller mounting bolts.
1
4

W1-2-3
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and parts
create safety hazards. If an incorrect tool is
used, the tool may slip or come off or break,
resulting in personal injury.
Bolt Types
When tightening bolts and nuts, use the specified
torque. Bolts are classified according to materals and
applications. Be sure to use the correct bolts and nuts,
and tighten them to specification. SA-040
W162-01-01-001
Specified Tightening Torque Chart
10.9 Bolt 8.8 Bolt, Socket bolt 4.8 Bolt
Bolt
Dia.
Wrench
Size
Hexagon
Wrench
Size N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft
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
Socket BoltHexagon 4.8 BoltHexagon 8.8 BoltHexagon 10.9 Bolt

W1-2-4
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no lubri-
cant.
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 suf-
ficient 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 ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alter-
nately, as shown, to ensure even tightening.
W105-01-01-003
1
6
4
2
3
Equally tighten upper and lower alter- Tighten diagonally
Tighten from center and diago-
1st to 4th
2nd to 3rd
13 1110
1412 7614
3258
9
5

W1-2-5
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect seal-
ing surfaces. Scratches / rough-
ness cause leaks and seal wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
2. Be sure to use only specified O-
rings. Inspect O-rings for any
damage. Take care not to file O-
ring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tight-
ening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Nut and Bolt Locking
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight-
ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
W105-01-01-015
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
Bend along edge sharply Do not bend it round
Bend along edge sharply
Loosen
Tighten
WRONG
RIGHTRIGHT
RIGHT
WRONG
WRONG
RIGHT
WRONG
WRONGRIGHTRIGHT

W1-2-6
PIPING JOINT
IMPORTANT: The torques given in the chart are for
general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
Union Joint
Metal sealing surfaces (4) and (5) of adaptor (l) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten nut (3) to specifi-
cations.
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
M202-07-051
W105-01-01-017
Wrench Size
mm
Wrench Size
mm
Tightening
TorqueDescription
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30 male 19 19 59 (6,44)
22 22 98 (10,72)
27 27 118 (12,87)
36 36 235 (24,173)
41 41 295 (30,218)
50 50 490 (50,361)
60 60 670 (68,494)
70 70 980 (100,723)
37 female 19 17 44 (4.5,32)
22 19 59 (6,44)
27 22 118 (12,87)
36 30,32 235 (24,173)
41 36 295 (30,218)
50 46 490 (50,361)
NOTE: Tightening torque of 37 male coupling without union is similar
to tightening torque of 37 female.
37
30
Female Union JointMale Union Joint
1 3 5 2
Joint Body
4

W1-2-7
O-ring Seal Joint
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with
a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly
in O-ring groove (e). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10).
Damage to O-ring (6) will cause
oil leakage.
4. If nut (9) is loose and oil is leak-
ing, do not re-tighten nut (9). Re-
place O-ring (6) with a new one
and check that O-ring (6) is cor-
rectly seated in place, tighten nut
(9).
M104-07-033
Wrench Size
mm
Wrench Size
mm
Tightening
Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
19 17 59 (6,44)
22 19 98 (10,72)
27 22 118 (12,87)
36 30,32 235 (24,173)
41 36 295 (30,218)
50 46 490 (50,361)
7 6 9
8 10
Hose Fittings

W1-2-8
Screw-In Connection
Depending on types of screw and sealing, different
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
(This machine is equipped with male-type taper thread
screwed joints except at the inspection joints.)
Seal Tape Application
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
• Application Procedure
Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs de-
pending on the type of clamp.
T-Bolt Type Band Clamp: 4.4 N⋅m
(0.45 kgf⋅m, 3.25 lbf⋅ft )
Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m
(0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
W105-01-01-018
Male Tapered Thread
Wrench Size
mm
Tightening
Torque
Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
17,19 59 (6,44)
19,22 98 (10,72)
27,22 118 (12,87)
36,32 235 (24,173)
41 295 (30,218)
50 490 (50,301)
60 670 (68,494)
70 980 (100,723)
W105-01-01-019
M114-07-041
M114-07-043 M114-07-042
PF
30
PT
Male Straight ThreadMale Tapered Thread
Clearance
External Thread
Internal Thread
Leave one to two pitch threads uncovered
T-Bolt Type Worm Gear Type

W1-2-9
Connecting Hose
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose rup-
ture or separation of fitting. Utilize Print
marks on hoses when installing to prevent
hose from being kinked.
If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other.
Take care so that hoses do not come into
contact with moving parts or sharp objects.
W105-01-01-011
W105-01-01-012
W105-01-01-013
W105-01-01-014
Rubbing Against
Each Other
RIGHT
RIGHT
RIGHT
RIGHT
WRONG
WRONG
WRONG
WRONG
Rubbing Against
Each Other
Rubbing Against
Each Other
Clamp
ClampClamp

W1-2-10
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Periodic Replacement Parts
Replacement
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 yearsEngine
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Base Machine
Swing hose Every 2 years
Boom cylinder line hose Every 2 years
Arm cylinder line hose Every 2 years
Bucket cylinder line hose Every 2 years
Hydraulic
System
Front
Attachment
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings
and
gaskets, when replacing hoses.

166W-2-1
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Remove and Install Cab ...................... W2-1-1
Dimensions of the Cab Glass .............. W2-1-7
Group 2 Counterweight
Remove and Install Counterweight ...... W2-2-1
Remove and Install Counterweight (With
Counterweight Removal Device)........ W2-2-3
Group 3 Main Frame
Remove and Install Main Frame .......... W2-3-1
Group 4 Pump Device
Remove and Install Pump Device........ W2-4-1
Disassemble Pump Transmission........ W2-4-4
Assemble Pump Transmission ............ W2-4-8
Remove and Install Main Pump ......... W2-4-11
Disassemble Main Pump................... W2-4-14
Assemble Main Pump........................ W2-4-20
Maintenance Standard ...................... W2-4-24
Disassemble Regulator ..................... W2-4-26
Assemble Regulatoer ........................ W2-4-28
Disassemble and Assemble
Pilot Pump....................................... W2-4-30
Group 5 Control Valve
Remove and Install Control Valve........ W2-5-1
Disassemble Control Valve 1............... W2-5-4
Assemble Control Valve 1.................... W2-5-8
Disassemble Control Valve 2 ............ W2-5-14
Assemble Control Valve 2.................. W2-5-16
Disassemble Control Valve 3............. W2-5-18
Disassemble Control Valve 4............. W2-5-30
Disassemble Control Valve 5 ............. W2-5-34
Group 6 Swing Device
Remove and Install Swing Device........ W2-6-1
Disassemble Swing Device.................. W2-6-4
Assemble Swing Device .................... W2-6-10
Disassemble Swing Motor ................. W2-6-14
Assemble Swing Motor ...................... W2-6-18
Maintenance Standard....................... W2-6-22
Group 7 Pilot Valve
Remove and Install Right
Pilot Valve (Front Attachment) ........... W2-7-1
Remove and Install Left
Pilot Valve (Front Attachment) ........... W2-7-5
Remove and Install
Travel Pilot Valve ............................... W2-7-9
Disassemble Front Attachment
Pilot Valve........................................ W2-7-12
Assemble Front Attachment
Pilot Valve........................................ W2-7-14
Disassemble Travel Pilot Valve.......... W2-7-18
Assemble Travel Pilot Valve .............. W2-7-20
Bucket Open / Close and
Breaker Pilot Valve .......................... W2-7-24
Assemble Bucket Open / Close and
Breaker Pilot Valve .......................... W2-7-26
Group 8 Pilot Shut-Off Valve
Remove and Install
Pilot Shut-off Valve ............................ W2-8-1
Disassemble Pilot Shut-off Valve ......... W2-8-4
Assemble Pilot Shut-off Valve.............. W2-8-6

166W-2-2
Group 9 Shockless Valve
Remove and Install Front Attachment
Shockeless Valve .............................. W2-9-1
Disassemble and Assemble Front
Attachment Shockless Valve.............. W2-9-3
Remove and Install Travel
Shockless Valve ................................ W2-9-7
Travel Shockless Valve...................... W2-9-9
Group 10 Solenoid Valve
Remove and Install Three-Spool
Solenoid Valve................................. W2-10-1
Three Spool Solenoid Valve............. W2-10-3

UPPERSTRUCTURE / Cab
W2-1-1
REMOVE AND INSTALL CAB
Remove Cab
1. Remove seat mounting nuts (2) and (1).
: 13 mm
2. Remove bolt (5) in the cab rear section, bolt (6) in
rear boxes (3 and 4) and rear boxes (3 and 4).
: 13 mm
3. Remove bolts (8) and lower cover (7) of the rear
box.
: 13 mm
4. Remove filter (24), screw (9) and duct (10) from
the cab.
W157-02-01-005
W157-02-01-017
W158-02-01-001
1
2
3
4
5
5
6
6
7
8
24
10
9

W2-1-2
5. Disconnect harness connectors (11) located at the
rear inside the cab.
NOTE: Number of connectors differs depending on
the machine serial No.
6. Disconnect connectors for wiper limit switch (12),
cab light (13), speaker (14), antenna (15) and
ground (17) located in the cab.
Remove washer vinyl hose(16) located behind the
cab.
7. Remove caps (20) from duct cover (18). Remove
screws (19) and duct cover (18).
8. While pushing the mating face of duct (21) back-
ward, remove duct (21).
W166-02-01-001
W162-02-01-002
W158-02-01-002
W157-02-01-011
11
12
13 14
15
16
17
18
1920
21
Duct Mating Face

W2-1-3
9. Attach the sling belts to the top of the cab.
CAUTION: Cab weight:
Standard cab : 260 kg (573 lb)
Headguard-Integrated cab : 470 kg (1036 lb)
10. Remove cab mounting bolts (22) and nuts (23).
: 17 mm
: 24 mm
: 8 mm
11. Slowly lift the cab with a crane to remove the cab
from the machine.
W157-02-01-009
W157-02-01-010
W157-02-01-001
22
23
23

W2-1-4
Install Cab
1. Attach cab to crane with sling belts and install cab
onto the machine.
CAUTION: Cab weight:
Standard cab: 260 kg (573 lb)
Headguard-Integrated cab: 470 kg (1036 lb)
2. Tighten cab mounting bolts (22) and nuts (23).
: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
: 24 mm
: 205 N m (21 kgf m, 152 lbf ft)
: 8 mm
64 N m (6.5 kgf m, 47 lbf ft)
3. Install duct (10) into the cab and tighten screw (9).
Install filter (24).
: 4.9 N m (0.5 kgf m, 3.6 lbf ft)
4. Connect harness connectors (11) at the rear,
inside the cab.
NOTE: Number of connectors differs depending on
the machine serial No.
W157-02-01-001
W157-02-01-010
W158-02-01-001
W166-02-01-001
23
23
24
9
10
11
22

W2-1-5
5. Connect wiper limit switch (12), cab light (13),
speaker (14), antenna (15) and ground (17) in the
cab.
Connect washer vinyl hose (16) behind the cab.
: 19.5 N m (2 kgf m, 14.5 lbf ft)
6. Install rear box lower cover (7) and tighten bolts
(8).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
7. Install rear boxes (3 and 4) and tighten bolts (5
and 6).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
8. Push duct (21) to the cab front until the duct
mating face comes in contact.
W162-02-01-002
W157-02-01-017
W157-02-01-011
12
13 14
15
16
17
3
4
5
5
6
6
7
8
21
Duct Mating Face

W2-1-6
9. Install duct cover (18). Tighten screws (19) and
put caps (20) on.
10. Install seat (1) and tighten nuts (2).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
W158-02-01-002
W157-02-01-005
18
1920
1
2

W2-1-7
DIMENSIONS OF THE CAB GLASS
W157-02-01-013
R2
Section B
Section A
25.106
580
391.8
164.12
188.5
66.84
558.78
43.59
154.81
4°
(87.81)
R9487
(64.74)
3.015
+10
−14-∅13
R11516
R78
221.399R70
142.25
30
360.78
(5 mm)
R3018
R118
51.03
R15
Unit: mm
NOTE: 1 mm=0.03937 in
Chamfer
both
fringes
Chamfer fringe
corners.
A
B
230.50
222.65
216.73
15
900.7
905
66.41
87.84
947.152
35.73
63.97
2-R59 R11509
R2309
R4009
R1009
R509
R84
R4009
R209
R9509
(4 mm)
All Around
c1
All Around
c1
612
756
4-R62
(5 mm)
NOTE:Material: JIS-R3211, R3212
ANSI-AS2
ECE-ANNEX5 or
equivalent
Standard Cab

W2-1-8
W157-02-01-014
Unit: mm
NOTE: 1 mm=0.03937 in
Section C and D
208
113.9
333.5±1.0
10.6
R105
R2285.4
39.5 61.8
475.8
728.5±1.0
60.1
R3985.4
40
2–Ø12.2 +0.5
–0
R1985.1
3–R4
503±1.0
541.5
(38.5)
(38.5)
R3
337.5±1.0
22.5
9.2
R30 R72.5
7735.4
39.5 3.1
40
728.5±1.0
488.5
290
R120885.4
2–R4
398.5±1.0
19.70
8 890.03 74.95 213.97
276.58
227.39
370±1.0
833±1.0
11.22 39.63
50.7118
468.17
90.672
45.67
R2477
R3877
753.99
980
904.13
740.51
165
R2590
2–R5
R5175
R8075
R120
R12.5
19.29
516.26
33.60
549.86
910
4–R5
R1995
R895
R345
R12095
R1145
R595
R295
C
2–Ø 12.2+0.5
–0
59
D
Chamfer fringe
corners.
Chamfer fringe corners.
Chamfer
both fringes
Chamfer
both
fringes
Chamfer fringe corners.
Chamfer fringe
corners.
(4 mm)
(4 mm)
(5 mm)
(5 mm)

W2-1-9
Headguard-Integrated Cab
W166-02-01-005
442.5+0.5
-1.5
811+0.5
-1.5
416+0.5
-1.5
4-R73
2-R153
R82
431
120
58.3
(4 mm)
(6 mm)
(6 mm)
(5 mm)
R191
4-R61
3-R61
220.9
327
484
915.8+0.5
-1
857.5+0.5
-1
753+0.5
-1
1154+0.5
-1.5
826+0.5
-1.5
973.9+0.5
-1
304+0.5
-1.5
826+0.5
-1.5
4-R73
Unit: mm
NOTE: 1 mm=0.03937 in
ANSI-AS2
ECE-ANNEX5 or
equivalent

W2-1-10
W166-02-01-006
Unit: mm
NOTE: 1 mm=0.03937 in
ANSI-AS2
ECE-ANNEX5 or
equivalent
39+0
-1
262176
2-φ11.2+0.5
-0
2-φ11.2+0
-1
2-R75.4
R5
R5
4 mm
40
292.5
(344)
138
591
453
383
324.5
549
8.46+0.5
-1.5
873.5±1.0
453.5±1.0
(5 mm)
(5 mm)
6-R73
4-R61
423±1.0
398±1
415±1
2-R75.4
39+0
-140
(4 mm)
R5
R5
(376)
351
292.5
727±1727±1
243 513
374
209
305
140
769
5.14+0.5
-1.5

W2-1-11
W166-02-01-007
Serial Number 7495 and up (EX450H-5)
Serial Number 7670 and up (EX450LCH-5)
Unit: mm
NOTE: 1 mm=0.03937 in
Serial Number 7495 and up (EX450H-5)
Serial Number 7670 and up (EX450LCH-5)
ANSI-AS2
ECE-ANNEX5 or
equivalent
720+0.5
-2
435+0.5
-2
4-R41
2-φ12
30
150
(4 mm)
150
2-φ12
535+0.5
-2(4 mm)
4-R41
30
720+0.5
-2

W2-1-12
Cab Glass Installation Method
Standard Cab
Procedure of installing left-hand cab glass
1. Install the mounting rubber on cab glass. Put and
fasten mounting rubber onto the mounting face of
cab.
IMPORTANT: Be sure to install the cab glass and
mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
can’t be replaced individually. Be
sure to change the cab glass as a
unit.
Procedure of installing right-hand cab glass
1. Insert mounting rubber into the surrounding of cab
glass. Stick the connectors of mounting rubber
with the bonding agent (Cemedine 366 Standard
or equivalent).
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little bit long, and
stick by pressing.
2. Put and fasten the mounting rubber on the mount-
ing face of cab, after installing rubber.
W216-02-01-004
W216-02-01-002
W216-02-01-005
W216-02-01-006
Mounting Rubber Section
Cab Glass
Cab
Mounting Rubber
Seal Rubber
Cab Glass
Cab
Mounting
Rubber

W2-1-13
Procedure of installing rear cab glass
1. Insert mounting rubber around the cab glass. In-
stall the connectors of mounting rubber with the
bonding agent (Cemedine 366 Standard or
equivalent).
NOTE: Rubber aging will cause the rubber to con-
tract rubber, be sure to leave a little extra,
install by pressing with hands.
2. After installing glass assembly on the cab, insert
the stopper into rubber.
W216-02-01-003
W216-02-01-007
Cab Glass
Cab
Mounting
Rubber
Stopper

W2-1-14
Headguard-Integrated Cab
Procedure of installing front and both side cab glass
1. Insert mounting rubber into the surrounding of cab
glass. Stick the connectors of mounting rubber
with the bonding agent (Cemedine 366 Standard
or equivalent).
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little bit long, and
stick by pressing.
2. Put and fasten the mounting rubber on the mount-
ing face of cab, after installing rubber. W166-02-01-008
W166-02-01-009
W166-02-01-010
W166-02-01-011
Mounting Rubber
Cab Glass
Cab

UPPERSTRUCTURE / Counterweight
W2-2-1
REMOVE AND INSTALL COUN-
TERWEIGHT
Removal
CAUTION: Counterweight weight: 9300 kg
(20500 lb)
1. Install lifting accessories and wire ropes to sling
brackets on the top of the counterweight. Set the
wire rope taut using a crane.
CAUTION: Watch out the power-wrench re-
action bar movement. Take care not to be hit
the reaction bar.
2. Using a power wrench, remove bolts (10), nuts (8),
shims (7), and washers (9).
NOTE: Shims (7) are used only when any gap
between nuts (8) and the lock brackets
exist. When no gap exists, shims are not
required.
: 65 mm
3. Remove bolts (1), lock washers (2), washers (3),
and spacers (4). If shims (5 and 6) are provided,
remove shims (5 and 6).
: 36 mm
4. Remove the counterweight using a crane.
W166-02-02-002
W166-02-02-003
W166-02-02-001
1 2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
9
10
1, 2
3
6, 5, 4
7
8
9
10
9

W2-2-2
Installation
CAUTION: Counterweight weight: 9300 kg
(20500 lb)
1. Install lifting accessories and wire ropes to sling
brackets on the top of the counterweight. Then, lift
the counterweight by crane.
CAUTION: Do not allow anyone under the
lifted counterweight.
2. Insert protrusions on the counterweight into holes
on the frame to install the counterweight.
CAUTION: Watch out the power-wrench
reaction bar movement. Take care not to be
hit the reaction bar.
IMPORTANT: Apply lubricant to bolts (10) before
installing. Install shims (7) between
nuts (8) and the lock brackets with
the flange positioned in the upper
side.
3. Install bolts (10), nuts (8), shims (7), and washers
(9). Using a power wrench, tighten bolts (10).
: 65 mm
: 2350 N m (240 kgf m, 1740 lbf ft)
4. Install shims (5 and 6), spacers (4), washers (3)
lock washers (2), and bolts (1). Remove wire
ropes and lifting accessories.
: 36 mm
: 440 N m (45 kgf m, 330 lbf ft)
W166-02-02-002
W166-02-02-003
W166-02-02-001
1 2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
9
10
1, 2
3
6, 5, 4
7
8
9
10
9

W2-2-3
REMOVE AND INSTALL COUNTER-
WEIGHT (WITH COUNTERWEIGHT RE-
MOVAL DEVICE)
Removal
NOTE: Counterweight removal procedure must be
performed with machine located on a level
surface.
1. Park the machine on a level surface with the up-
perstructure rotated 90°.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if
the engine is not properly shut
down.
4. Run the engine at slow idle speed without load for
three minutes.
5. Stop the engine.
6. Pull the pilot control shut-off lever to the LOCK
position.
CAUTION: Avoid personal injury from unex-
pected counterweight movement. DO NOT go
directly under machine counterweight. To
remove or install counterweight hardware, go
under machine entering from the area on ei-
ther SIDE of the counterweight. The counter-
weight weighs approximately 8200 kg (18100
lb). Clear everyone from the area before re-
moving or installing the counterweight.
7. Remove bolts (1) to remove counterweight top
cover plate (2).
8. Open the engine hood.
9. Remove bottom covers (3) and (5).
10. Remove cylinder guard (4).
M116-06-019
M111-06-023
M116-06-020
1
2
53 4

W2-2-4
11. Set variable orifice (1) by turning in the direction of
the arrow until closed. Then open orifice 2 turns.
IMPORTANT: Linkage pivot areas may bind if not
properly lubricated resulting in fail-
ure of cylinder (3) to raise counter-
weight to full height.
12. Grease all pivot areas of counterweight lift linkage
(three fittings at the bottom and one fitting at the
top of the counterweight cylinder), the FIRST
TIME and every time the counterweight device is
operated.
13. Open shut off valve (2) by turning the handle
counterclockwise to supply hydraulic pressure to
cylinder (3).
14. Make sure length (A) is correct and lock nuts (4)
are not loose.
Length A: 110±2 mm (4.33±0.08 in)
M116-06-021
M116-06-022
M116-06-023
1
2
3
4
A

W2-2-5
15. Remove both lock pins (3) from nut (2) on bolts
(1).
16. Open the left rear access door and pull off lever
cover (4) of counterweight pilot control valve (5).
17. Start the engine. Run machine in “precision” work
mode (6) with the engine control dial set to the
fully counterclockwise position (slow idle).
M116-06-024
M111-06-024
M166-01-016
6
4
5
1
32

W2-2-6
CAUTION: To insure good footing and visi-
bility, always stand on the machine catwalk
when operating counterweight pilot control
valve.
IMPORTANT: To prevent possible damage to hy-
draulic cylinder lines and adjustable
orifice canister, cylinder guard (See
step 10) must be removed before
lowering the counterweight.
18. Slowly move the counterweight pilot control valve
lever UP and DOWN several times to check the
response of cylinder control.
CAUTION: Keep hands (fingers) out of slots
(1) and out of movable parts of linkage during
cylinder movement.
19. Slide the lifting yokes forward to the upward posi-
tion of slot (1) away from the rear of counterweight
and slowly raise cylinder (counterweight pilot con-
trol valve lever “UP”) to hold both lifting yokes in
the forward position.
20. Alternately loosen each bolt (2) 2 or 3 turns.
21. Using a screwdriver, pry the corner of lock plate
(4) away from the head of each of bolts (3).
22. Loosen each bolts (3) 5 mm (0.20 in).
M116-06-025
M116-06-026
M116-06-036
1
3
4
2

W2-2-7
NOTE: Lifting yokes must be in the forward posi-
tion or highest point of the slot.
23. Slowly move the counterweight pilot valve lever
UP until counterweight bottom bosses (2) move
away from machine mainframe (1) approximately
5 mm (0.20 in.) (A). This will ensure that the
weight of the counterweight is on the lift cylinder.
CAUTION: When the threads of tie bolt (7)
disengage from nut (6), nut (6) and nut spacer
may drop to the ground. Stay clear from un-
der the machine when removing bolts (7).
24. To avoid binding, loosen bolts (7) by alternately
turning each bolt one turn at-a-time.
NOTE: It is not necessary to remove bolts (7) from
the counterweight/frame holes. It is enough
nuts (6) are dropped down. The bolts (7)
will be removed from frame holes when the
counterweight is lowered by the lift cylinder.
25. Remove bolts (4), lock plates (5), spacers and
shims (3) from each counterweight boss. To avoid
binding, alternately loosen left hand and right
hand bolts (4) 2 or 3 turns at-a-time.
M116-06-028
M116-06-036
6
3
1
2
7 4
5
A

W2-2-8
26. Slowly lower counterweight to the ground until all
weight is removed from the linkage and the yokes
move freely in their slots.
IMPORTANT: Do not operate the pilot control
valve with full stroke of lever. Move
the cylinder as slowly as possible.
27. Remove yoke-to-link pins (1).
28. Tighten adjusting cap screw jam nut.
29. Raise lift cylinder to end of its stroke.
30. Store yoke-to-link pins (1) by attaching pins to the
counterweight lift brackets.
31. Close hydraulic shut off valve by turning valve
handle clockwise.
32. Install top cover to the counterweight and two bot-
tom covers to the machine mainframe.
33. Install lift cylinder lower guard.
34. Install the lever cover over the counterweight pilot
valve.
35. Close left rear access door and engine hood.
M116-06-023
1

W2-2-9
Installation
NOTE: Counterweight installation procedure must
be performed with machine located on a
level surface.
1. Park the machine on a level surface.
2. Rotate upperstructure 90° with front attachment
on the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if
the engine is not properly shut
down.
4. Run the engine at slow idle speed without load for
three minutes.
5. Stop the engine.
6. Pull the pilot control shut-off lever to the LOCK
position.
7. Open the engine hood.
8. Remove two pump drive covers (1) and (2) and
bolts (3).
9. Remove both machine mainframe bottom access
covers and counterweight top cover.
10. Remove the lift cylinder guard.
11. Turn the handle of shut off valve (4) (located
through opening under the engine) counterclock-
wise to open hydraulic pressure to cylinder (5).
12. Start the engine. Run machine in “precision” work
mode with the engine dial set to the fully counter-
clockwise position (slow idle).
M116-06-029
M111-06-025
M111-06-026
M116-06-022
5
4
3
2
3
3
3
1
3
3
3

W2-2-10
CAUTION: To insure good footing and visi-
bility, always stand on the machine catwalk
when operating counterweight pilot control
valve.
13. Lower the lift cylinder.
14. Install counterweight lifting yoke-link-pins (4) to
the counterweight pin brackets (5). Slide yoke (3)
forward to the top position of the slot in the coun-
terweight pin bracket.
15. When installing the counterweight for the first time,
check removal device adjustment as follows.
(When installing counterweight next times [not the
first time] see item 16.)
(1) Adjust bolts (1) on each yoke (3) to length (A)
A: 110±2 mm (4.3±0.08 in)
(2) Slowly raise the counterweight until the coun-
terweight bosses are set into the mainframe
holes. If alignment of the counterweight
bosses to the mainframe holes is incorrect
(Bosses can’t be set into holes), lower the
counterweight to the ground and adjust length
(A) as required. After adjusting correct length
(A), tighten lock nut (2).
Tightening torque 390 N m (40 kgf m, 290
lbf ft)
CAUTION:
•••• Length (A) can not be made for more than
120 mm (4.7 in). Damage to bolts may oc-
cur.
•••• Stop cylinder when bosses are set to the
main frame holes. Do not raise the cylinder
when bosses are engaged with the main
frame holes.
16. Make sure length (A) is correct and lock nut (2)
are not loose.
17. Put bolts (6) into the counterweight holes.
M116-06-023
M116-06-030
1
2
3
4
5
6
A

W2-2-11
18. Slowly raise the counterweight until the counter-
weight bosses are set into the main frame holes.
NOTE: When raising counterweight, bolts (1) are
set into frame holes.
19. Install spacers (2) and nut (3) at the pump side.
Turn nut (3) into bolts (1) until the end of the bolt
face with end of nut.
20. Install spacer (2) and nut (3) at the radiator side.
Turn nut (3) into bolts (1) until the end of the bolt
face with end of nut.
21. Lower the lift cylinder slightly until yoke (4) slide
backward in slots (5) to the “REST” position.
22. Install shims (6), spacer (7), new lock plate (9)
and bolts (8) to each of the lower counterweight
bosses.
23. Tighten bolts (1).
Tightening torque: 2400 N m (245 kgf m, 1770
lbf ft)
NOTE: Tighten or loosen bolts (1) (from torque) to
align lock pins.
24. Tighten bolts (8).
Tightening torque: 690 N m (70 kgf m, 510 lbf ft)
M116-06-031
M116-06-032
M116-06-036
321
4
5
6
1
9
7
8

W2-2-12
25. Make sure the counterweight lift arms are below
the top surface of the counterweight and are not
touching the counterweight plate from inside.
Make sure yoke connected to the counterweight
pin brackets are not tight.
(If necessary, lower or raise cylinder slightly to
meet above requirements and check again
torques.)
26. Install lock pins (1) into the nuts from the top side
of the machine.
27. Bend one top and bottom corner of lock plate (2)
against the head of each bolt.
28. Close shut off valve (3).
29. Install two pump drive covers.
30. Install the both machine mainframe bottom ac-
cess covers and counterweight top cover.
31. Install the cylinder guard.
M116-06-024
M116-06-036
M116-06-022
1
2
3

UPPERSTRUCTURE / Main Frame
W2-3-1
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious
injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation.
Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting work.
The hydraulic oil tank cap may pop off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the
hydraulic oil tank.
NOTE: Be sure to run the vacuum pump
continuously while working.
M104-07-021
W166-02-03-011

W2-3-2
Removal
CAUTION: Approximate weight of cab:
Headguard-Integrated: 470 kg (1040 lb)
1. Remove cab assembly.
(See Remove Cab in this section.)
: 24 mm, 17 mm
: 8 mm
CAUTION: Approximate weight of counter-
weight: 9300 kg (20500 lb)
2. Remove the counterweight.
(See Remove Counterweight in this section.)
Wrench size : 36 mm
: 65 mm
W157-02-01-001
W155-02-02-001

W2-3-3
CAUTION: Approximate weight of front
attachment assembly;
Backhoe
7530 kg (16600 lb)
Loading shovel
9550 kg (21100 Ib) (EX400-5)
9880 kg (21800 Ib) (EX450H-5)
3. Remove front attachment assembly from the
upperstructure.
(See Remove Front Attachment in this section.)
: 19 mm, 30 mm, 36 mm, 41 mm
W105-02-03-002
M162-07-071
4. Drain hydraulic oil from the hydraulic oil tank, and
disconnect hydraulic lines from the control valve
to the center joint on top of the center joint.
Disconnect drain hose, and remove the fitting and
stopper from the center joint.
: 22 mm, 27 mm, 41 mm
W166-02-03-010
W166-02-03-009
CAUTION: Approximate weight of main
frame;
9380 kg (20700 lb) (EX400-5)
9500 kg (21000 Ib) (EX450H-5)
5. Install special tool (ST 0915), bolts (12) (M45
Pitch3, 2 used) and nuts (13) to main frame.
Install shackles (4.8 ton) to special tool (ST 0915).
6. Attach wire ropes to the front and shackle of main
frame. See wire ropes taut using a crane. Use
chain blocks (1) for easy adjustment of wire rope
lengths and to level the frame.
: 70 mm
IMPORTANT: Make sure rear slings and special
tool (ST0915) do not touch engine.
W105-02-03-005
W157-02-03-002
12
Rear
ST 0915
Shackle
ST 0915
12
Front
1
13

W2-3-4
7. Put matching marks on swing bearing and main
frame. Remove bolts (2) and the knock pins from
the swing bearing.
: 41 mm
8. Lift main frame slightly from undercarriage.
Level main frame by adjusting chain blocks (1).
Remove main frame.
W105-02-03-007
W157-02-03-002
1
2

W2-3-5
Installation
CAUTION: Approximate weight of main
frame: 9380 kg (20700 lb) (EX400-5)
9500 kg (21000 Ib) (EX450H-5)
1. Fasten hoist to front and shackle of main frame.
Level main frame by adjusting chain blocks (1)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.
2. Install bolts (2) and the knock pins on the swing
bearing and tighten temporary.
Remove wire ropes and the special tool (ST
0915).
Install main frame and tighten bolts to
specification.
: 41 mm
Upperstructure side
: 1370 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)
3. Connect drain hose (7) to the center joint.
Connect lines (3 to 6).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
W157-02-03-002
W105-02-03-007
M162-07-071
2
1
4
5
6
3
7

W2-3-6
CAUTION: Approximate weight of cab;
Headguard-Integrated cab: 470 kg (1040 lb)
4. Install cab (9).
(See Cab in this section.)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 159 lbf⋅ft)
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
CAUTION: Approximate weight of counter-
weight: 9300 kg (20500 lb)
5. Install counterweight (10).
(See Counterweight in this section.)
Wrench size: 65 mm
: 2350 N⋅m (240 kgf⋅m, 1740 lbf⋅ft)
CAUTION: Approximate weight of front
attachment assembly:
Backhoe
7530 kg (16600 lb)
Loading Shovel
9550 kg (21100 Ib) (EX400-5)
9880 kg (21800 Ib) (EX450H-5)
6. Install front attachment assembly (3).
(See Front Attachment in this section.)
: 19 mm
: 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 30 mm
: 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft)
: 36 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
7. Fill the hydraulic oil tank with hydraulic oil to the
specified level.
Run the engine at slow idle. Check hose
connections for any oil leakage.
W157-02-01-001
W155-02-02-001
W105-02-03-002
M104-07-021
9
11
10

UPPERSTRUCTURE / Pump Device
W2-4-1
REMOVE AND INSTALL PUMP DEVICE
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure
before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot
hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting any repair work.
The hydraulic oil tank cap may pop off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely release
any remaining pressure.
Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
2. After stopping the engine, move the control levers
several times to release any pressure remaining
in the system.
2. Rotate the hydraulic oil tank cap approx. 30°
counterclockwise to release trapped air in the
hydraulic oil tank.

UPPERSTRUCTURE / Pump Device
W2-4-2
Remove Pump Device
1. Disconnect all hydraulic lines and electrical cables
from the pump.
: 19 mm, 27 mm, 32 mm, 36 mm, 41 mm
: 10 mm, 14 mm
CAUTION: Pump device weight:
275 kg (610 lb)
2. Sling the pump device with a crane or hoist.
3. Remove the pump device mounting bolts (12
used) and the pump device.
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
Install Pump Device
1. Hoist the pump device.
2. Install the pump with the mounting bolts.
3. Connect all hydraulic lines and electrical cables to
the pump.
4. Bleed air trapped inside the pump. (Refer to page
W1-1-2.)
IMPORTANT: After installing the pump, be sure to
perform break-in operation to
prevent seizure.
Break-In Operation Process:
1. Start the engine and run at slow idle speed for
20 minutes. Check for oil leaks while running
at slow idle.
2. Increase the engine speed to the fast idle
speed. Raise and lower the boom for 20
minutes repeatedly. (Do not operate the
control levers quickly. Slowly move the levers
to full stroke.)
W166-02-03-001
Tightening Torque
Wrench Sizes
N⋅m (kgf⋅m) (lbf⋅ft)
Remarks
: 19 mm 29.5 (3) (21.5)
Hydraulic
lines
: 27 mm 93 (9.5) (69)
Hydraulic
lines
: 32 mm 68.6 (7) (51)
Hydraulic
lines
: 36 mm 175 (18) (130)
Hydraulic
lines
: 41 mm 205 (21) (152)
Hydraulic
lines
: 10 mm 108 (11) (80)
Socket
Bolts
: 14 mm 265 (27) (195)
Socket
Bolts
Pump Device Mounting Bolt

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