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Eye Bolt

Parts No. ST 0002


Size M12 X 1.75 mm
Application model ZX200/200-E/225US/225USR/230/270

The use:
Remove and install pump device.

Method of use:
Remove pump device.
Attach eyebolts (M12, Pitch 1.75) (ST 0002) to the pump
device, then hold it by crane.
CAUTION: Do not install the eyebolt to the regulator Example of use:
which is with solenoid valve.

Eyebolt Mounting Position

Eye Bolt (B-36)

Parts No. ST 0021


Size M36 X 4.0 mm
Application model ZX200/200-E

The use:
Remove and install counterweight.

Method of use:
Remove counterweight
1. Remove caps from upper counterweight. Install sling bolts
(B-36: M36, Pitch 4.0 mm) to the counterweight.
2. Attach wire rope to sling bolts using shackles. Take out Example of use:
slack of wire rope by applying tension slowly by crane or
Wire Rope
hoist.

ST 0021
Sling Bolt

SPECIAL TOOLS 1
Bracket

Example of use: Parts No. ST 0050


Application model ZX200/200-E/225US/225USR/230/270

The use:
Remove and install swing bearing.

Method of use:
Remove swing bearing
Attach lifting tools (ST 0050), hoist swing bearing and remove it.

ST 0050

Lifting Tool

Parts No. ST 0916


Application model ZX200/200-E/225US/225USR/230/270

The use:
Disassembly and assembly travel device.
Composition parts:
Item Parts No. Name Q’ty
05
02 00 3092119 Body 1
03

00 01 8084133 Arm 3
02 _ Bolt 3
01 03 A590110 Washer 6
04 J951010 Nut 3
05 4083751 Eye bolt 1
04

Operational precaution:
1. Firmly tighten three nuts "04" according to the size of car-
rier using three tooth section on arm "01", taking care that
the carrier dose not fall.
(M10 X 1.5, tightening torque: 49~69 N·m (5~7 kgf·m, 36~51
lbf·ft).
2. The eyebolt (M16 X 2.0) should be tightened to 29~49
N·m (3~5 kgf·m, 22~36 lbf·ft).
3. This illustration shows a special tool to be used to lift the
last stage carrier assembly during disassembly and as-
sembly the swing device.

Method of use:
Disassemble travel reducer
Hook claws (ST 0916) to the third stage carrier and lift it by
crane to remove the third stage carrier assembly from drum.

2 SPECIAL TOOLS
Disassembly Tool For Center Joint

Parts No. ST 1020, ST 1033


Application model ZX200/200-E/225US/225USR/230/270 ST 1020

The use: ST 1033


Pulling the center joint body out.

Composition parts:
Item Tool No. Name Q’ty
01 ST 1020 Puller(screw) 1
02 ST 1033 Plate 1 Example of use:

Method of use:
Disassemble center joint
1. Attach the special tools (ST 1033, ST 1020) to body with
mounting bolts (2 pcs) on cover.
2. Remove spindle from body .
CAUTION: Do not damage the center shaft seal sliding
surface of center joint.

Guide

Parts No. ST 1237


Size M12 X 1.75 mm
Application model ZX200/200-E/225US/225USR/230/270

The use:
Remove spring pin of pilot valve for travel.

Method of use:
Example of use:
Disassemble travel pilot Valve
1.Place a stand under bracket .
2.Remove both spring pins from bracket at the same time
by using special tool (ST 1237).
3.Remove bracket from pin (2 places)
CAUTION: Do not remove spring pin from the bracket un- Spring Pins (2 pcs)
Pin
less necessary. Bracket
Spring Pin
Crimped Here

Stand

SPECIAL TOOLS 3
Chuck

Parts No. ST 1288


Size Ø95 mm
Application model ZX200/200-E/225US/225USR/270

The use:
Chuck assembly for head bush extracting tool.

Method of use:
Assemble arm cylinder
As install the bushing of arm cylinder to cylinder head with a
press, use the bushing installing special tool ST 1288 (Ø95
mm).

Retainer

Parts No. ST 1297, ST 1298, ST 1299


Application model ZX200/200-E/225US/225USR/270

The use:
Retainer for head bush extracting tool.

Method of use
Assemble cylinders
Install wiper ring to cylinder head by using a plastic hammer.

Special tool when installing wiper ring:


Boom cylinder (ST 1298)
Arm cylinder (ST 1299)
Bucket cylinder (ST 1297)

4 SPECIAL TOOLS
Spring Pin Extracting Tool

Parts No. ST 1391


Application model ZX200/200-E/225US/225USR/230/270

The use:
Spring pin extracting tool for travel reduction gear.

Method of use:
Disassemble travel reducer
Disassemble the first stage carrier assembly.
Tap spring pin out from the first stage carrier using pin
(ST1391) (3 places).
Example of use:

Pin

Gear Extracting Tool

Parts No. ST 1393


Size M12 X 1.75 mm
Application model ZX200/200-E/225US/225USR/230/270

The use: ST 1393-1


Gear extracting tool for pilot pump.
ST 1393-2
Composition parts: ST 1393-3

Item Tool No. Name Q'ty


ST 1393-4
1 ST 1391-1 Bolt 1 Gear Casing
2 ST 1391-2 Nut 1 Ball Bearing

3 ST 1391-3 Cover 1
4 ST 1391-4 Holder 1

Method of use:
Disassemble pump device
Pull out upper ball bearing and gear shaft from gear casing
using special tool (ST 1393).

SPECIAL TOOLS 5
Bush Extracting Tool

Example of use: Parts No. ST 1425


Application model ZX200/200-E/225US/225USR/230/270

ST 1427 The use:


ST 1426 Bush extracting tool for front ilder.
ST 1331 Composition parts:
Item Tool No. Name Q’ty
00 ST 1426 Half-split back plate 1
01 ST 1331 Center plate 1
Bushing 02 ST 1427 Backing plate 1
03 ST 1151 Push rod 1

Method of use:
ST 1151 Disassemble front Idler
When replacing bushing, special tool (ST 1425) can be used
to push it out via a press.

HN Bush Extracting Tool

Example of use: Parts No. ST 1454


Application model ZX200/200-E/225US/225USR

HN Bush The use:


HN Bush extracting tool assembly.

Method of use:
Install front attachment
CAUTION: For handling of HN bushing for the fro-
nt attachment, pay attention to following
requirements.
Precautions for pressing the bushing in:
If a hammer is used to drive the bushing in, the bushing
may be damaged. Use a press.
Precautions when reinforcing the arm:
Welding heat for arm reinforcement may cause oil to leak
from the bushing and decrease lubrication performance.
If oil leak occurs because of heated bushing after welding,
replace the bushing.
CAUTION: Special tools should be used to pull the bush-
ing out or press it in.

6 SPECIAL TOOLS
Bearing Inner Race Extracting Tool

Parts No. ST 1460, ST 1461 ST 1460

Application model ZX200/200-E/225US/225USR/230

The use: ST 1467


Bearing inner race extracting tool.

Method of use:
Disassemble swing device
1. Push the upper end of shaft with a press and remove it
from housing. The inner race of roller bearing and sleeve
are removed with the shaft.
Example of use:
2. Place pulling tool B (ST 1460) of roller bearing onto the
stepped part of pulling tool A (ST 1461) for roller bearing. Press
3. Insert the pinion gear of shaft into the tooth-hole of pull-
ing tool B (ST 1460) for roller bearing. Install it onto press.
4. Push spline side on propeller shaft with press and re-
move inner race of roller bearing and sleeve. Shaft

Roller Bearing
Sleeve
ST 1460

ST 1461

Carrier Spring Pin Extracting Tool

Parts No. ST 1462, ST 1463


Application model ZX200/200-E/225US/225USR/230

The use:
Carrier spring pin extracting tool.

Method of use:
Disassemble swing device
1. Hit the spring pin on 1 stage planetary carrier assembly Example of use:
into the pin hole using special tool (ST 1462). As the pring
pin is hit into mid position of pin hole, stop hitting. Do not
hit the spring pin into the bottom.
2. Clamp the pin with a vice, pull spring pin out using spe- Pin
cial tool (ST 1462).
3. When disassembling 2 stage planetary carrier assembly,
Spring Pin
the tool for pulling spring pin out is (ST 1463), the using
method is (ST 1462).
Slit

SPECIAL TOOLS 7
Propeller Shaft Extracting Tool

Parts No. ST 1464


Application model ZX200/200-E/225US/225USR/230
Press
The use:
Propeller shaft extracting tool.

Method of use:
Disassemble swing device
1. Install eyebolt (M16) into bolt hole in housing. Lift it by
Housing
crane.
2. After removing bracket, install bracket (ST 1464). Install
the housing assembly on a press.
3. Push the upper end of shaft with a press and remove it
ST 1464
from housing. The inner race of roller bearing and sleeve
are removed with the shaft.

Brake Pin Extracting Tool


Parts No. ST 1468
Example of use: Application model ZX200/200-E/225US/225USR/230

The use:
Brake pin extracting tool for swing motor.

Method of use:
Disassemble swing motor
Install tool (ST 1468) into notch A of brake piston, then pull it
out from casing.

Notch A

8 SPECIAL TOOLS
Pump Shaft Extracting Tool

Parts No. ST 1470, ST 1471


Application model ZX200/200-E/225US/225USR/230

The use:
Pump shaft extracting tool.

Method of use:
Disassemble pump device
1. Attach a nylon sling to pump device, lift it up and place the
pump casing on the wooden blocks with mission side
facing down. Wooden block size: 100 mm or more in width Example of use:
and height.
2. Remove shafts from pump casing with special tool (ST
ST 1471
1470, ST 1471). At this time, bearings are removed with
ST 1470
the shafts.
Shaft

Pump Casing

Puller Ass'y

Parts No. ST 1955 Example of use:


Application model ZX200/200-E/225US/225USR/230

The use:
ST 1262
Remove the bushing of track rollers.
ST 1258
Composition parts:
ST 1146
Item Tool No. Name Q'ty
00 ST 1258 Puller 1
01 ST 1146 Center plate 1
02 ST 1262 Plate 1
03 ST 1150 Pusher 1 ST 1150

Method of use:
Disassemble lower roller.
In case of replacing bushing, push out bushing via a press
and special tools.
Pulling Tool: ST 1955

SPECIAL TOOLS 9
Puller Ass'y Tool

Parts No. ST 1970


Application model ZX200/200-E/225US/225USR/230/270

The use:
Remove the master pin.
Composition parts:
Example of use: Item Tool No. Name Q'ty
ST 1970 00 ST 1060 Guide 1
01 ST 1061 Bushing 1
02 ST 1063 Bar 1
03 ST 1066 Cap 2
04 ST 1068 Pin 2
05 ST 1065 Bar 1
06 ST 1067 Cap 2
Bushing Seal 07 ST 1069 Pin 2
Corner
08 ST 1062 Bar 1
Master Pin
09 ST 1064 Bar 1

Method of use:
Retaining Link Install tracks
Track Link Master Link
Install master pin using special tool (ST 1970).

Guide

Parts No. ST 2345, ST 2362, ST 2363


Application model ZX200/200-E/225US/225USR/270

The use:
Cylinder head insertion guide.

Method of use:
Assemble cylinders
Install the cylinder head assembly to piston rod.
Special tool when installing cylinder head:
Boom (ST 2362)
Arm (ST 2363)
Bucket (ST 2345)

10 SPECIAL TOOLS
Pressing Tool

Parts No. ST 2558 Example of use:


Application model ZX200/200-E/225US/225USR/230/270
Press ST 2558

The use:
Bushing pressing tool for center joint.
Body
Method of use: Bushing
Replacing body (Assemble center joint)
Press bushing into body, using the pressing tool.
Pressing force: 0.5 ~ 1.5 t

Driving Tool

Parts No. ST 2559 D


C
Application model ZX200/200-E/225US/225USR/230/270

r
The use:
A
B

Ball driving tool.



Driving tool size (mm): Y


Z
Expander Dia. Size (mm)
r A B C D ∅ hg Y Z
ST 2559 8 3.5 7.8 6.6 0.4 1.5 10 20 100
Example of use:
Method of use:
Replacing spindle (Assemble center joint) ST 2559
Tap plugs into spindle using special tools (ST 2559).
CAUTION: Tap the balls of plug so that the top of each ball Sleeve
0.4mm
is 0.4 mm or more lower than the respective or more
sleeve edge as illustrated in detail. Ball

SPECIAL TOOLS 11
11
Seal Guide

Example of use: Parts No. ST 2649, ST 2650


Application model ZX200/200-E/225US/225USR/230/270

The use:
Pump seal guide / pump transmission seal guide.
ST 2650
Method of use:
Oil Seal Assemble pump device
1. Install special tools (ST 2649, ST 2650) over the spline parts
of shafts (2 pcs).
2. Evenly tap oil seals (2 pcs) onto shafts.
CAUTION: Apply a film of grease to the inner diameter of oil
seals (2 pcs).
3. Remove special tool (ST 2649, ST 2650) from shafts.
ST 2649

Press-Fitting Tool

Example of use: Parts No. ST 2923


Application model ZX200/200-E/225US/225USR/230

The use:
Press Inner race press-fitting tool.

Method of use:
Assemble swing device
1. Install O-ring onto sleeve.
ST 2923
2. Install sleeve and the inner race of roller bearing into shaft.
Press sleeve and inner race using bearing mounting tool
Roller Bearing (ST 2923).
Sleeve
CAUTION: Press-in distance of the bearing inner race can
be assured by using the bearing mounting tool.
Shaft
3. Secure housing body with a nylon sling, then lift it up by crane.
Place sleeve with the mounting side up.

12 SPECIAL TOOLS
Press-Fitting Tool

Parts No. ST 2924 Example of use:


Application model ZX200/200-E/225US/225USR/230

The use: ST 2924


Inner race press-fitting tool.
Roller
Method of use: Bearing

Assemble swing device


Place mounting tool (ST 2924) onto the inner race of roller
bearing. Push the inner race down using a press.
CAUTION: Press-in distance of the inner race can be as-
sured by using the mounting tool.

Assembling Tool

Parts No. ST 2925 Example of use:


Application model ZX200/200-E/225US/225USR/230
ST 2925
The use:
Oil seal assembling tool.

Method of use: Oil Seal


Assemble swing device
Apply THREEBOND #1215 on the outer surface of oil seal. Put Housing
the oil seal flat on housing and push it in gently.
Then place seal mounting tool (ST 2925) on tne oil seal and tap
it in by hammering directly.
NOTE: If special tool (ST 2925) is used to replace the seal, no
need to remove the sleeve.

SPECIAL TOOLS 13
13
Removal / Installation Tool

Example of use: Parts No. ST 2926


Application model ZX200/200-E/225US/225USR/230

Bearing Nut The use:


Bearing nut removal / installation tool.
ST 2926
Method of use:
Disassemble swing device
Remove bearing nut from shaft using special nut removing tool
(ST 2926).

Removal Tool

Example of use: Parts No. ST 2953


Application model ZX200/200-E/225US/225USR/230

The use:
ST 2953 Sleeve removal tool.

Method of use:
Disassemble solenoid valve
Using special tool (ST 2953), pull out the sleeve assembly
from body.
NOTE: When pulling out sleeve, built-in plate and wave washer
may come off occasionally.

14 SPECIAL TOOLS
Turning Tool

Parts No. ST 3058 Example of use:


Application model ZX200/200-E/225US/225USR/230/270

The use: ST 3058

Bearing nut turning tool for HMT45C motor (travel).


Bearing Nut
Method of use:
Disassemble pump device
Remove bearing nut (9) from shafts (2 pcs) using special tool
(ST 3058).

Inspection Tool

Parts No. ST 3070


Application model ZX200/200-E/225US/225USR/230/270

The use:
Preload inspection tool for pump.

Method of use:
Assemble pump device
1. Attach special tool (ST 3070) on bearing, rotate bearing 2 to 3
turns and measure the starting torque.
2. Adjust the starting torque repeatedly, until it reaches
specification.
Torque: 2.16 ± 0.49 N·m (0.22 ± 0.05 kgf·m, 1.60 ± 0.36 lbf·ft) Example of use:
NOTE: If the starting torque is higher than the limit of specified
torque, loosen the bearing nut, tap the shaft end to re-
lease the bearing's load, and repeat the procedure.

ST 3070

Bearing

SPECIAL TOOLS 15
15
Wrench (90)

Parts No. ST 3263, ST 3264


Application model ZX200/200-E/225US/225USR/270

The use:
Removing and installing cylinder nut.

Method of use:
Disassemble cylinders
Remove nut by using special tool (ST 5908) and special tool
(ST 3263). Remove piston, shim and cushion bearing.
Example of use: Special tool when turning nut: 90 mm (ST 3263)
Special tool when turning nut: 100 mm (ST 3264)

ST 5908

Cushion
Bearing Shim

Piston Nut

16 SPECIAL TOOLS
Track Spring Holder Ass'y

Parts No. ST 4036, ST 4920


Application model ZX200/200-E/225US/225USR/230/270

The use:
Disassembling and assembling for track spring.

Method of use:
Disassemble track adjuster
1. Place an oil jack (30 t) between the base and holder.
2. Loosen the nuts from the special tool to remove plate (ST
4036).
3. Install plate (ST 4036) on the track adjuster and secure them
together.
4. Operate the hydraulic jack, make the nut pass through the top
surface of plate ( until it can be turned using a wrench).
5. Tighten the nut of special tool to fix the track adjuster.
6. Operate the hydraulic jack to press the track adjuster for 10
mm approx, until the space between the washer and nut can
be seen.
7. Remove the plug from nut. Remove the nut and grease from
rod.
CAUTION: Be sure to use special tool (ST 4920) for as-
sembly / disassembly of the track adjuster.
The spring force is extremely large, so disas-
sembly and assembly work must be carried out
carefully. In addition, it is necessary to inspect
the special tool for any damage thoroughly to
ensure safety.

Example of use:

ST 4920 ST 4036

SPECIAL TOOLS 17
17
Workbench

Example of use: Parts No. ST 5090


Application model ZX200/200-E/225US/225USR/230

The use:
Spacer Workbench for assembly / disassembly of travel reduction
device.

Method of use:
Disassemble travel reducer
1. With motor facing upward, secure spacer to the track frame
mounting flange of the motor with bolts (M20, Pitch 2.5 mm)
(2 pcs).
2. Secure motor body with a nylon sling, then hoist it and turn it
Motor
over by crane.
CAUTION: Secure spacer tightly to receive the reaction force.

Bracket

Example of use: Parts No. ST 5097


Application model ZX200/200-E/225US/225USR/230

Swing Device The use:


Swing device disassembly tool.

Method of use:
Disassemble swing device
ST 5097 Put the swing device on bracket (ST 5097). Secure it with 2 bolts
(M20). Insert the stopper located at the bottom of bracket into
the middle of two teeth of pinion gear. Secure the bracket on a
workbench.

Stopper

18 SPECIAL TOOLS
Disassembly / Assembly Device

Parts No. ST 5908


Application model ZX200/200-E/225US/225USR/270

The use:
Hydraulic cylinder disassembly / assembly device.

Method of use:
Disassemble cylinders
1. Secure piston rod on special tool (ST 5908). Put the match-
ing marks on piston rod and nut.
2. Cut away the crimped part by using a hand drill and remove
set screw. Remove steel ball.
3. Remove nut by using special tool (ST 5908) and special tool.
Remove piston, shim and cushion bearing.
Nut turning tool (ST 3263).

Disassembly / Assembly Tool

Parts No. ST 5909


Application model ZX200/200-E/225US/225USR/230/270

The use:
Control valve spool I disassembly / assembly tool.

Method of use:
Disassemble bucket spool
1. Clamp spool with wooden pieces in a vise. Remove bolt,
spring seat, spring and spring seat.
2. Heat the plug part of spool with a drier to melt LOCTITE.
Example of use:
Remove plug using tool (ST 5909).
3. Remove sleeve, spring and poppet from spool.
ST 5909
4. Turn over spool and clamp it in a vice. Heat the plug part of
spool with a drier to melt LOCTITE. Remove plug using tool
(ST 5909).
5. Remove spring and poppet from spool.

SPECIAL TOOLS 19
19
Assembly Tool

Parts No. ST 7229


Application model ZX200/200-E/225US/225USR/230/270

The use:
Track adjuster holder installation tool.

Method of use:
Assemble track adjuster
1. Install flange to piston rod.
2. Apply grease into holder and press it into piston rod using a
press and special tool (ST 7229).
Example of use: 3. Install wear ring, U-ring, retaining ring onto piston rod.
4. Apply grease to O-ring and install it on cylinder. Install rod into
cylinder.
Wear
Retaining Rod Flange Holder
Ring

U-Ring Piston
Rod

Removal / Installation tool

Example of use: Parts No. ST 7248, ST 7249


Application model ZX200/200-E/225US/225USR/230

The use:
Bearing nut removal / Installation tool.

Method of use:
ST 7248 Disassemble travel reducer
Using special tools (ST 7248) and (ST 7249), turn and remove
ST 7249
bearing nut from the motor housing.
CAUTION: Do not remove knock pin unless necessary.

20 SPECIAL TOOLS
Removal / Installation Tool

Parts No. ST 7255


Application model ZX200/200-E/225US/225USR/230/270

The use:
Retaining ring removal / installation tool.

Method of use:
Assemble right and left pilot valves
1. Install spring guide onto return spring with the protrusion
facing upward.
2. Install retaining ring onto ring holder (ST 7255).
3. Insert the spool head into the hole of special tool (ST 7257). Example of use:
Push the spring from the top of spring guide.
Install retaining ring installed to ring holder (ST 7255) onto
the head of spool.
ST 7255
Ring
NOTE: Put approx. dia.8 mm, length 10 mm of packing material
into the port hole in order to not only make the work easy
to do, but also prevent the spool from lowering to the
bottom when pushing the spring.

ST 7255
ST 7257

Spool

Packing Material

SPECIAL TOOLS 21
21
Removal / Installation Tool

Example of use: Parts No. ST 7256


Application model ZX200/200-E/225US/225USR/230/270
ST 7256
The use:
Front pilot valve spool removal / installation tool .

Method of use:
Remove and install the travel pilot valve
1. Hit the bushings on the pilot valve bracket (4 places) out
using a special tool (ST 7256).
2. Insert the bushing to special tool (ST 7256), then hit the
special tool (ST 7256) lightly to install the bushing into the
hole of bracket.
ST 7256 When bushing end is level with inner wall, stop hitting.
Install the bushing on a nearer side. When bushing end is
level with outside of bracket, stop hitting.

Removal / Installation Tool

Example of use: Parts No. ST 7257


Application model ZX200/200-E/225US/225USR/230/270
Ring

The use:
Traveling pilot valve bush removal / installation tool.

Method of use:
Spring Guide Disassemble right and left pilot valves
ST 7257
Push the spring by using special tool (ST 7257) from the top of
spring guide. Remove retaining ring by using a screwdriver or
similar tool.
CAUTION: The retaining ring may come off while dis-
assembling. Take care not to drop it.

22 SPECIAL TOOLS
Removal / Installation Tool

Parts No. ST 7268 Example of use:


Application model ZX200/200-E/225US/225USR/230
ST 7268
The use: Mating Surface
Travel motor roller bearing removal / installation tool. Oil Seal

Method of use:
Disassemble travel motor disassemble travel motor Roller
Bearing
Remove roller bearing from shaft using special tool (ST 7268).
NOTE: In order to protect the oil seal mating surface of the shaft,
insert the special tool from the oil seal mating surface
side.

Assembling Tool

Parts No. ST 7269 Example of use:


Application model ZX200/200-E/225US/225USR/230

The use:
ST 7269
Travel motor needle bearing assembling tool.

Method of use: Brake Valve Needle Bearing


Assemble travel motor
Using special tool (ST 7269), tap needle bearing lightly with a
hammer into brake valve. Be sure to let the mark on the needle
bearing face outside.
CAUTION: Pay attention to the needle bearing direction.

SPECIAL TOOLS 23
23
Assembling Tool

Example of use: Parts No. ST 7270, ST 7271


Application model ZX200/200-E/225US/225USR/230

The use:
ST 7270 Travel motor oil seal assembling tool.
*Use in combination with ST 7271.

Method of use:
ST 7271
Assemble travel motor
1. Place housing with the brake valve mounting surface facing
Housing Oil Seal upward.
2. Clean the oil seal mating part of housing.
Tap and install oil seal into housing by using special tools
(ST 7270,ST 7271) and a plastic hammer.
CAUTION: Apply OCEAN grease #7 to the inner surface of
oil seal and apply THREEBOND #1104 or #1215
to the outer surface of oil seal.

Assembling Tool
ST 7272
Parts No. ST 7272, ST 7273
Application model ZX200/200-E/225US/225USR/230

ST 7273
The use:
Brake piston assembling tool.
*Use in combination with ST 7273.

Method of use:
Assemble travel motor
Tap brake piston into housing using special tool (ST 7272, ST
7273) and a hammer to push it into the housing.
NOTE: Since the O-ring is positioned around the brake piston,
the brake piston can't be fully fitted. When installing brake
Example of use: valve, push the brake piston with tightening bolts.
Brake Releasing
Housing Notch Brake Piston Oil Passage

24 SPECIAL TOOLS
Timing Adjuster

Parts No. ST 7934


Application model ZX200/200-E/225US/225USR/230/270

The use:
Timing adjuster for pump.

Method of use:
Assemble pump device
When replacing the shafts and gears, install the gear accord-
ing to the following procedure.
1. Secure the special tool (ST 7934) to the mounting surface of
shafts (2 pcs) for plunger. Example of use:
2. Turn shafts (2 pcs) clockwise, viewed from the mounting
side of gears (2 pcs), until it comes into contact with the
special tool. (To remove the play in periphery direction)
3. Install gear and retaining ring to the spline of shaft. Shaft
4. Install gear onto the spline of shaft, with engaging to gear.
If it does not engage, turn shaft in the play range of special
Shaft
tool to find the engaging position. ST 7934
5. Install retaining ring to the spline of shaft.
6. Remove the special tool.

M8. Pitch 1.25

SPECIAL TOOLS 25
25
Disassembly / Assembly Tool

Parts No. ST 8019, ST 8020


Application model ZX200/200-E/225US/225USR

ST 1286
The use:
(ST 1287) Cylider head disassembly / assembly tool.
Composition parts:
ST 8019
Item Tool No. Name
01 ST 1286 Bush extracting tool
02 ST 1297 Wiper ring pressing tool
03 ST 2345 Head insertion guide tool

ST 8020
Item Tool No. Name
ST 1297 01 ST 1287 Bush extracting tool
(ST 1298)
02 ST 1298 Wiper ring pressing tool
03 ST 2362 Head insertion guide tool

NOTE: A tool box should be included.

Method of use:
Disassemble cylinders
ST 2345 Remove O-rings and backup rings from cylinder head. Remove
(ST 2362)
wiper ring, U-ring, buffer ring, snap ring and bushing.

Special tool when removing bushing:


Boom 85 mm (ST 8020)
Bucket 80 mm (ST 8019)

26 SPECIAL TOOLS