ZX330 Series ZX330W Workshop Manual

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.
001-E01A-0688 SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.
• Some safety signs don’t use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.
• CAUTION also calls attention to safety messages in

this manual.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.
• NOTE indicates an additional explanation for an

element of information.
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the ma-

chine and all safety messages in this manual.
• Safety signs should be installed, maintained and re-

placed when necessary.
• If a safety sign or this manual is damaged or miss-

ing, order a replacement from your authorized
dealer in the same way you order other replace-
ment parts (be sure to state machine model and
serial number when ordering).
SA-003
• Learn how to operate the machine and its controls

correctly and safely.
• Allow only trained, qualified, authorized personnel to

operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the fire-
extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu- SA-437
lance service, hospital, and fire department

posted near your telephone.
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full

attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all

points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work
boots the operator’s foot may slip off the pedal,
possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the op-

erator’s seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Don’t

attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives

away from the machine.
• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you mounting and dismounting the ma-

chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or

dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
008-E01B-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again. SA-378
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly

examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component before operating the machine.
• Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-426
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.
• Start the engine only when seated in the

operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals. SA-444
• Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
SA-379
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in

serious injury death.
• Before driving the machine, confirm the position of

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-491
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection you wish to drive.
• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay around
the machine while traveling.
SA-387
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
SA-383
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person. SA-384
• No machine motions shall be made unless signals

are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and

markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in

good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in

the operator’s manual.
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious SA-012
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper SA-440
than 15 degrees if crossing the grade is

unavoidable.
• Reduce swing speed as necessary when swinging
loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site. SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is
SA-014
safely and securely situated on supporting blocks
or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position. SA-390
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELYҥ
ҥAVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are SA-018

flammable.
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
• Be sure to observe local regulations when

transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine: SA-395
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

work.
• Keep work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from power-
driven parts.
• Before servicing the machine:

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
• If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527
replace as necessary. Refer to the section

discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine,

attach a “Do Not Operate” tag on the control lever.
S501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
• Always lower the attachment to the ground before

you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a
SA-527
machine that is supported solely by a jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS
• Entanglement in moving parts can cause serious

injury.
• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.

SA-344
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY
• Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
stop. Allow all pressure to be released before
removing the cap.
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
• Wait for the oil and components to cool before

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the

page of “Periodic replacement of parts” in the
operator’s manual.)
SA-019
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from high- SA-031
pressure fluids. Wear a face shield or goggles for

eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to

fires.
• Check for oil leaks due to missing or loose clamps,

kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-
cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil- SA-019
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
• Always check key switch function before

operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair

them before operating the machine.
S508-E02B-0019
SA-22
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
SA-030
hoses or other materials before engaging in
welding, soldering, etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that

contain flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal ob-
ject across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold

contact burn.
• Refer to the freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air SA-226
can damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
WORKSHOP MANUAL Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
All information, illustrations and speci-
fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2001
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Others (Upperstructure)
Group 3 Electrical System Group 7 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Engine Test Group 3 Troubleshooting A
Group 3 Excavator Test Group 4 Troubleshooting B
Group 4 Component Test Group 5 Troubleshooting C
Group 5 Standard Group 6 Electrical System Inspection
Group 7 ICX
SECTION 1
GENERAL INFORMATION
— CONTENTS —
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology....... W1-1-7
Group 2 Tightening Torque

Tightening Torque Specification......... W1-2-1
Torque Chart ..................................... W1-2-3
Piping Joint ....................................... W1-2-6
Periodic Replacement of Parts ........ W1-2-10
Group 3 Painting
Painting ............................................. W1-3-1
1HHW-1-1
(Blank)
1HHW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop may removed pipes.
cause machine components to be contaminated • Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place on a work bench.
damage to machine components, as well as • Before disassembling, drain gear oil from the
decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help • If a part or component cannot be removed after
avoid incorrect disassembling of components as well removing its securing nuts and bolts, do not
as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if any. disassembled parts for abnormal wear, sticking,
• Capacities and condition of lubricants. or other damage.
• Loose or damaged parts. • Measure and record the degree of wear and
clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area

for disassembling work.
W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for any When hydraulic oil is drained, the suction filter or the
damage. If any damage is found, repair or replace suction lines are replaced, or the removal and instal-
part. lation of the pump, swing motor, travel motor or cylin-
• Dirt or debris on the contact or sliding surfaces der is done, bleed air from the hydraulic system in the
may shorten the service life of the machine. Take following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a new
may result.
part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, damage
• Be sure to use the designated tools to assemble to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • 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.
W1-1-2
• 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 M104-07-021
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.
W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces. Apply oil to the
sliding surface (C) on seal ring (A).
(2) Check the slide surface (C) on seal ring (A) for B W105-03-05-019
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 Correct

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

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

is installed correctly on the seal ring. W105-03-05-020
Correct D Incorrect
(4) After installing the floating seal, check that seal

a a
ring surface (C) is parallel with seal mating
C
face (D) by measuring the distances (C) and
(D) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
a=b aҐb
W110-03-05-004
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 Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
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 W105-04-01-008
slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
2. Before using a nylon sling, visually check the ny- Scuffing
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.
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening Torque
TIGHTENING TORQUE SPECIFICATION
Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
1 Engine cushion rubber mounting bolt 18 4 27 400 (41) (300)
(Fan Side) 10 10 17 60 (6) (43)
2 Engine bracket mounting bolt
(Pump Side) 12 8 19 90 (9) (65)
3 Engine oil filter mounting bolt 10 4 17 50 (5.1) (37)
4 Radiator mounting bolt 16 4 24 210 (21) (151)
5 Hydraulic oil tank mounting bolt 18 4 27 300 (30.5) (220)
6 Fuel tank mounting bolt 16 6 24 210 (21) (151)
3
1− −12UNF 36 175 (18) (130)
16
7
7 ORS fittings for hydraulic hoses and piping 1− −12UNF 41 210 (21.5) (155)
16
11
1− −12UNF 50 255 (26) (188)
16
8 Pump mounting bolt 10 8 17 50 (5.1) (37)
9 Control valve mounting bolt 16 4 24 210 (21.5) (155)
10 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
11 Swing device mounting bolt 22 12 32 640 (65) (470)
12 Swing motor mounting bolt 12 12 10 90 (9.2) (66)
13 Battery mounting nut 10 2 17 50 (5.1) (37)
14 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 27 36 36 1226 (125) (905)
15
Swing bearing mounting bolt to undercarriage 27 36 36 1226 (125) (905)
ZAXIS330, 330LC, 350H,
Travel device 20 40 30 620 (63) (460)
16 350LCH
mounting bolt
ZAXIS370MTH 22 40 32 740 75 (540)
ZAXIS330, 330LC, 350H,
Sprocket mount- 350LCH 20 32 30 490 (50) (360)
17
ing bolt
ZAXIS370MTH 22 48 32 740 75 (540)
ZAXIS330, 330LC, 350H,
Upper Ӹ roller 350LCH 16 16 24 270 (27.5) (200)
18
mounting bolt
ZAXIS370MTH 18 16 27 390 40 (290)
ZAXIS330, 330LC 20 64 30 670 (68) (490)
Lower roller
19 ZAXIS350H, 350LCH 20 72 30 670 (68) (490)
mounting bolt
ZAXIS370MTH 22 64 32 740 75 (540)
ZAXIS330, 330LC 22 360 30 1130 (115) (830)
20 Track shoe bolt ZAXIS350H, 350LCH 22 384 30 1130 (115) (830)
ZAXIS370MTH 24 392 32 1370 (140) (1010)
ZAXIS330, 330LC 20 8 30 620 (63) (460)
Track guard
21 ZAXIS350H, 350LCH 20 24 30 620 (63) (460)
mounting bolt
ZAXIS370MTH 22 28 32 740 (75) (540)
Coupling, Jubilee and T-bolt clamp of low pressure 8 ҥ 13 10.3 to 12.4 (1.05 to 1.26) (7.59 to 9.11)
22
piping 6 ҥ 11 5.9 (0.6) (4.3)
18 ҥ 27 400 (41) (300)
23 Front pin-retaining bolt and nut 20 ҥ 30 550 (56) (405)
22 ҥ 32 750 (76.5) (550)
Counterweight ZAXIS330, 330LC 32 4 50 2260 230 (1665)
24
mounting bolt ZAXIS350H, 350LCH, 370MTH 36 4 55 2840 290 (2100)
W1-2-1
NOTE 1.Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
3.Apply LOCTITE to threads before install-
ing and tightening swing bearing mounting
bolts and lower roller mounting bolts.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use correct
size tools. Otherwise, tightening tools may
slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or compo-

nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Hexagon T Bolt H Bolt, Socket 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)
W1-2-3
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.
Tighten from center and diago-
Equally tighten upper and lower alter- Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
Service Recommendations for Split 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.
W105-01-01-015
2. Be sure to use only specified O-
WRONG
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
W105-01-01-016
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- W105-01-01-008
ening of one bolt fully before RIGHT WRONG

tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round
Nut and Bolt Locking

RIGHT RIGHT WRONG
• 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- Bend along edge sharply
W105-01-01-009
ening, not while loosening.
RIGHT RIGHT WRONG
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
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.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37ѯ
30ѯ
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
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.
Wrench Size Wrench Size mm Tightening Torque

Description mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30ѯmale 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,21.5)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37ѯfemale 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,21.5)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37ѯmale coupling without union is similar
to tightening torque of 37ѯfemale.
W1-2-6
O-ring Seal Joint 7 6 9
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with a

new one when reconnecting.
2. Before tightening nut (9), confirm that
O-ring (6) is seated correctly in O-ring Hose Fittings
8 10
groove (e). Tightening nut (9) with O- M104-07-033
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). Wrench Size Wrench Size Tightening Torque
Damage to O-ring (6) will cause oil mm mm
leakage. Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
4. If nut (9) is loose and oil is leaking, do 19 17 29.5 (3.0,21.5)
not re-tighten nut (9). Replace O-ring 22 19 69 (7.0,51)
(6) with a new one and check that O- 27 22 93 (9.5,69)
ring (6) is correctly seated in place, 32 27 137 (14.0,101)
tighten nut (9). 36 30,32 175 (18.0,129)
41 36 205 (21.0,151)
46 41 205 (21.0,151)
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types of 30ѯ
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- Male Tapered Thread Male Straight Thread
in connection.
W105-01-01-018
Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 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 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male and
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

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 depend-

ing on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
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)
M114-07-043 M114-07-042
W1-2-8
Connecting Hose
WRONG RIGHT
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, pos-
sibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or sepa-
ration of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
Each Other
If hoses rub against each other, wear to the hoses
will result, leading to hose rupture. Take neces-
sary measures to protect hoses from rubbing
against each other.
W105-01-01-012
Take care so that hoses do not come into contact
WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic in-
spection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual inspec-
tion alone. For this reason, replace these parts at the inter-
vals shown in the table below. However, if any of these
parts are found to be defective, replace before starting op-
eration, regardless of the interval.
Also, when replacing hoses, check the clamps for deforma-
tion, cracks, or other deterioration, and replace as neces-
sary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings
and gaskets, when replacing hoses.
W1-2-10
GENERAL / Painting
PAINTING
Surfaces to Be Painted Painting Colour

• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover High Grade Beige
Tool box cover YR-01 [TAXI yellow]
Inner face Grey
• Front attachment YR01 [TAXI yellow]
• Track (undercarriage) N1.0 [Black]
• Floor plate M/F cation colour
• Rear left portion of cab YR-01 [TAXI yellow]
Final painted colour

• Inside and outside surface of cab High Grade Beige
[KASAI PAINT LF-113-230B
• Right window beam
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black) ]
• Lever [N2.0 (Black) ]
(Travel, lock, foot rest)
• Engine cover High Grade Black
• Ladder rail on right side of upperstructure High Grade Black
• Mirror stay High Grade Black
• Antislip cover KASAI PAINT Amilack 1400 deep black.
Cab Inside and Outside
Engine Cover Engine Cover

Right Window
Beam
Right Ladder
Rail
Mirror Stay
900 720
350
Bed Cover W178-01-03-001
Main Surface of Tool Box Cover Main Surface of
Upperstructure Upperstructure
W178-01-03-002
W1-3-1
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
Door Catch Cover YR-01

(TAXI Yellow)
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01(TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
Antislip Cover
W178-01-03-004 KASAI PAINT
Amilack 1400
Deep Black
Front Attachment YR-
01 (TAXI Yellow)
W178-01-03-007
Upper Side of
Frame
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, care not to W1HH-01-03-001
pour washing liquid directly on them.

The ambient temperature shall be Track (Undercarriage)
N1.0 (Black)
controlled under 70°°C when painting
and drying.
W178-01-03-008
W1-3-2
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab Group 5 Control Valve
Remove and Install Cab ........................... W2-1-1 Remove and Install Control Valve ............. W2-5-1
Dimensions of the Cab Glass ................... W2-1-8 Disassemble Control Valve (1).................. W2-5-4
Assemble Control Valve (1) ...................... W2-5-6
Group 2 Counterweight Disassemble Control Valve (2).................. W2-5-8
Remove and Install Assemble Control Valve (2) .................... W2-5-10
Counterweight ........................................ W2-2-1 Disassemble Control Valve (3)................ W2-5-12
Assemble Control Valve (3) .................... W2-5-14
Group 3 Main Frame Disassemble Control Valve (4)................ W2-5-18
Remove and Install Assemble Control Valve (4) .................... W2-5-20
Main Frame ............................................ W2-3-1 Disassemble Control Valve (5)................ W2-5-22
Assemble Control Valve (5) .................... W2-5-24
Group 4 Pump Device Disassemble Control Valve (6)................ W2-5-26
Remove and Install Pump Device ............. W2-4-1 Assemble Control Valve (6) .................... W2-5-28
Disassemble Pump Device ....................... W2-4-4 Structure of Valves ................................. W2-5-30
Assemble Pump Device ......................... W2-4-10
Disassemble Main Pump ....................... W2-4-18 Group 6 Swing Device
Assemble Main Pump ............................ W2-4-26 Remove and Install Swing Device............. W2-6-1
Disassemble Regulator .......................... W2-4-40 Disassemble Swing Device....................... W2-6-4
Assemble Regulator ............................... W2-4-42 Assemble Swing Device ......................... W2-6-10
Disassemble and Assemble Disassemble Swing Motor ...................... W2-6-16
Pilot Pump ............................................ W2-4-44 Assemble Swing Motor ........................... W2-6-18
Maintenance Standard ........................... W2-4-48 Disassemble and Assemble
Parking Brake Release Valve................ W2-6-20
Maintenance Standard............................ W2-6-21
1HHW-2-1
Group 7 Pilot Valve
Remove and Install Right
Pilot Valve .............................................. W2-7-1
Remove and Install Left
Pilot Valve .............................................. W2-7-5
Remove and Install
Travel Pilot Valve .................................... W2-7-8
Disassemble Right and Left
Pilot Valves........................................... W2-7-10
Assemble Right and Left
Pilot Valves........................................... W2-7-14
Disassemble Travel Pilot Valve............... W2-7-18
Assemble Travel Pilot Valve ................... W2-7-22
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
Group 9 Shockless Valve

Remove and Install
Shockless Valve ..................................... W2-9-1
Disassemble and Assemble
Shockless Valve ..................................... W2-9-4
Group 10 Solenoid Valve

Remove and Install
Solenoid Valve Unit............................... W2-10-1
Disassemble Propotional Solenoid
Valves (SC, SI and SG) ........................ W2-10-4
Assemble Propotional Solenoid
Valves (SC, SI and SG) ........................ W2-10-6
Disassemble Proportional Solenoid
Valves (Torque Control Solenoid Valve,
Maximum Pump2 Flow Rate Limit
Solenoid Valve)..................................... W2-10-8
Assemble Proportional Solenoid
Valves (Torque Control Solenoid Valve,
Maximum Pump2 Flow Rate Limit
Solenoid Valve)................................... W2-10-10
Disassemble and Assemble
Pilot Relief Valve ................................ W2-10-12
1HHW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB ZAXIS330, 330LC, 350H, 350LCH:
Removal
1. Remove nuts (2) to remove seat (1).
: 17 mm 2
W178-02-07-006
2. Remove bolts (4) behind the cab to remove rear ZAXIS370MTH:

box (3).
: 17 mm
3. Raise duct (5) to remove it.

1
W1HH-02-01-004
4. Remove filter (6) to remove screws (7) with a

screwdriver, then remove duct (8) from the cab.
4
5
W178-02-01-012
W178-02-01-013
W2-1-1
5. Disconnect harness connectors (10, 11, 12, and
13) on the right side in the cab and ground (9) at
rear inside of the cab.
10
11
12
13
W178-02-01-014
6. Remove washer vinyl hose (14) at rear inside of

the cab.
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a
17
screwdriver. Use a screwdriver to loosen screws
(16) to remove duct cover (17).
15
W178-02-01-016
8. Remove screws (18) and bolts (21) to remove

duct (19) and duct (20). 18
: 17 mm Mating Surface of Duct
19
W178-02-01-017
20 21
W2-1-2
ZAXIS330, 330LC, 350H, 350LCH
CAUTION: Cab weight:
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
22
9. Attach the cab upside with lifting straps (22).
W178-02-01-018
ZAXIS370MTH:
A
A
10. Remove cab mounting bolts (23) and nut (24)
from the cab.
: 17 mm
: 24 mm
: 8 mm
W1HH-02-01-003
Section A-A
Lifting Strap
W1HH-02-01-002
23
24
W157-02-01-010
W2-1-3
11. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-4
Installation
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
1. Attach the cab with lifting straps to hoist it by

crane.
W157-02-01-001
23
2. Install bolts (23) and nuts (24) to the cab.

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 150 Ibf⋅ft) 24
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W157-02-01-010
7
3. Install duct (8) to the rear console of the cab with
screws (7). Install filter (6) into duct (8).
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
8
W178-02-01-013
4. Install harness connectors (10, 11, 12 and 13) at

the right side of the cab and install ground (9) at
rear side in the cab. 9
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
10
11
12
13
W178-02-01-014
W2-1-5
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
6. Aligning the mounting hole for duct (5). While

pressing duct downward, install it.
4
5
7. Install rear box (3) with bolts (4).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W178-02-01-012
8. Install duct (20) with bolts (21). Install duct (19)

into duct (20) and fix them with bolt (18).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
18
Mating Surface of Duct
19
W178-02-01-017
20 21
W2-1-6
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
ZAXIS330, 330LC, 350H, 350LCH:
10. Secure seat (1) with nut (2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2
ZAXIS370MCH: W178-02-07-006
W1HH-02-01-004
W2-1-7
DIMENSIONS OF THE CAB GLASS
A
Unit: mm Chamfer Here
R2
67 303.5
Chamfer along the
11
Periphery unless
Otherwise Specified
R98 R35
4-φ13 0 -1
R3018
Section A W178-02-01-019
405 30 Chamfer Both
Sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
Along the Along the W178-02-01-002

B
Periphery Periphery
c1 c1
14
733
R58
R58
R11508
Section B W178-02-01-019
R1808
882.5 997
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-8
Unit: mm
Chamfer Here Chamfer
Slightly
Chamfer Here
85.4 unless the
Periphery
343.3 213 Polish
Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the Pe-
riphery Polish Chamfered
39.5 D
733
733
C R2465 2-φ12.2 +0.5 -0
(4 mm) Section C 6.754°

40
and D
W178-02-01-019
Polish Chamfer the
Both Fringes
289.5
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
(5 mm) Chamfer along

the Periphery
982.7
W178-02-01-004
R2002
872
R123
R5 for 3 Places 38.2

R14
364.7 51
R2475 470.6
Chamfer along the W178-02-01-009
(5 mm) Periphery
R115
888.58
W178-02-01-010
W2-1-9
Cab Glass Installation Procedure
Left-Hand Cab Glass
Procedure of installing left-hand cab glass, lower
glass of the door and upper front glass.
1. Install the seal rubber on the left-hand cab glass A

and lower glass of the door. CSE Braid
Section A
Seal Rubber
Put Connect End in Center of

Glass Edge and Then Stick It.
W178-02-01-021
Lower Glass of Door

50
5
W178-02-01-023
A
CSE Braid
Seal Rubber
2. When the mounting rubber is already on the glass, 10 10

pull and fasten the mounting rubber onto the
mounting face of cab. Mounting Rubber Section W178-02-01-020
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special Mounting
bonding agent. The cab glass may Rubber Cab Glass
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 an
assembly.
The upper front glass is arched- Cab
fringed. If this glass needs to be re- Seal Rubber
placed, replace it as an assembly.
W178-02-01-022
W178-02-01-004
W2-1-10
Procedures of installing right-hand cab glass Mounting Rubber Section
1. Install the mounting rubber into the surrounding of

Cab Glass Mounting
cab glass. Bond the connectors of mounting rub-
Rubber
ber with the bonding agent (Cemedine 366 Stan-
dard or equivalent).
NOTE: Rubber aging will cause the contraction of Cab

rubber, be sure to leave a little extra, install
by pressing with hands.
W216-02-01-005
2. Put and fasten the mounting rubber on the mount-
ing face of cab after installing rubber.
W178-02-01-002
Procedures of installing rear cab glass

Mounting Rubber Section
1. Insert mounting rubber around the cab glass. In-
stall the connectors or mounting rubber with the Cab Glass
bonding agent (Cemedine 366 Standard or Mounting
Rubber
equivalent).
Stopper
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
Cab
2. After installing the glass assembly on the cab, in-
sert the stopper into rubber. W216-02-01-003
IMPORTANT: The rear side glass is arched-fringed.

If this glass needs to be replaced,
replace it as an assembly.
W178-02-01-005
W2-1-11
(Blank)
W2-1-12
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal
CAUTION: Counterweight weight:
ZAXIS330, 330LC: 6800 kg (15000 lb)
ZAXIS350H, 350LCH 370MTH:
7550 kg (16650 lb)
1. Remove caps (1) from upper counterweight. In-

stall sling bolts (FLENO RING BOLT B-42: M42, W178-02-02-001
Pitch 4.5) to the counterweight.
Wire Rope
Sling Bolt
2. Attach wire ropes to sling bolts with shackles.
Take out slack of wire ropes by applying tension
slowly by crane.
W178-02-02-002
3. Remove bolts (2) from the counterweight. Hoist

and remove the counterweight by crane.
ZAXIS330, 330LC:
: 50 mm
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
2
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
1. Hoist counterweight (3) and install it onto the

frame by crane.
Install washers (4) and tighten bolts (2) to coun-
terweight temporarily. 3
2
ZAXIS330, 330LC: 4
: 50 mm
W178-02-02-003
: 55 mm
2. Remove wire ropes. Tighten the bolts with a

power wrench and torque wrench.
ZAXIS330, 330LC:
: 50 mm
: 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft)
: 55 mm
: 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft) Torque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
3. Remove the sling bolts. Install caps (1) to the

counterweight.
W2-2-2
UPPERSTRUCTURE / Main Frame
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,
and may spurt, possibly causing severe
burns. Be sure to wait for oil to cool before
starting work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Ȁ
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau- M104-07-021
lic oil tank.
NOTE: Be sure to run the vacuum pump continu-
ously while working.
W2-3-1
Removal

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS 370MTH: 395kg (870 lb)
1. Remove the cab (Refer to “Remove Cab” in this

section.).
: 24 mm, 17 mm, 13 mm
: 8 mm
W157-02-01-001

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
2. Remove the counterweight.

(Refer to “Remove Counterweight” in this
W178-02-02-002
section.)
ZAXIS330, 330LC:
: 50 mm
: 55 mm
W2-3-2
CAUTION: Front attachment weight:

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350H, 350LCH: 7050 kg (15540 lb)
ZAXIS 370MTH: 7120 kg (15700 lb)
3. Remove the front attachment assembly.

(Refer to “Removal of Front Attachment” in this
section.)
: 19, 27, 30, 41 mm W105-02-03-002
4. Remove all hoses from upper side of the center

joint. Then remove the stopper from the center
joint.
: 17, 22, 27, 41 mm
CAUTION: Upperstructure weight:

6560 kg (14460 lb)
5. Attach wire ropes to the rear (counterweight

W173-03-03-001
bracket) of frame and boom bracket. Pull wire
ropes taut then.
If chain block (1) is used, it is not only easy to ad-
just the length of wire rope, but also easy to level
the frame.
IMPORTANT: Make sure that rear slings do not

touch engine. Rear
W105-02-03-004
Front
W105-02-03-005
W157-02-03-001
W2-3-3
6. Put matching marks on the outer race of the upper-
structure and the swing bearing.
Loosen and remove bolt (2) of the swing bearing.
: 41 mm
NOTE: The mounting angle of swing bearing is

specified. (Refer to W3-1).
7. Chain block (1) shall be used to adjust and level W105-02-03-007
the frame, then hoist it slightly to remove it from

the undercarriage by crane.
1
W157-02-03-002
W2-3-4
Installation
CAUTION: Upperstructure weight:

6560 kg (14460 lb)
1
1. Fasten wire ropes to main frame. Level the main

frame by adjusting chain block (1).
Hoist it by crane to install it to the undercarriage.
As for lifting method, refer to “Removal” section.
W157-02-03-002
2. Align the matching marks on the outer race of the

upperstructure and the swing bearing.
Install bolts (2) to the swing bearing and tighten it
temporarily. Remove wire ropes and tighten the
bolts to the swing bearing to specification.
: 41 mm
: 1226 N⋅m (125 kgf⋅m, 900 lbf⋅ft)
2
3. Install all hoses to the center joint.

: 17 mm W105-02-03-007
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft)
3
: 41 mm
4
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
4. Install stopper (4) and bolt (3) to the center joint.

: 22 mm
: 54 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)
W173-03-03-001
W2-3-5

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH: 395 kg (870 lb) 5
5. Install cab (5).

(Refer to “Removal and Installation of Cab” in this
section.)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W157-02-01-001
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
6. Install counterweight (6).

(Refer to “Counterweight” in this section.)
6
ZAXIS330, 330LC:
: 50 mm
W178-02-02-002
: 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft)
: 55 mm
: 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft)

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350H, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH: 7120 kg (15700 lb)
7. Install front attachment assembly (7). And fill hy-

draulic oil. 7
(Refer to “Removal and Installation of Front At-
W105-02-03-002
tach-ment” in this section.)
: 19 mm
: 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
: 27 mm
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) M104-07-021
8. Start the engine and set the front attachment in

posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if there is
any oil leakage.
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

can penetrate the skin, causing serious in-
jury.
Avoid this hazard by relieving pressure be-
fore 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 any repair work.
pressure.
Preparation
1. Park the machine on a firm, level surface.

pressure.
M104-07-021
pump to maintain negative pressure in the hydrau-
lic oil tank.

ously while working on the hydraulic sys-
tem.
W2-4-1
Removal
1. Disconnect harness connectors from the pump

device.
CAUTION: Pump device weight: Air Bleed Plug

200 kg (440 lb)
2. Disconnect all hoses and pipes from the pump

device.
ȀȚ17 mm, 27 mm, 36 mm
ȀȚ10 mm
3. Attach eyebolts (M12, Pitch 1.75) to the pump

device, then fasten a hoist.
4. Remove the pump device mounting bolts to

remove the pump device.
ȀȚ17 mm W110-02-04-002
Installation Tightening Torque

Wrench
Remarks
Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1. Install eyebolts on the pump device. Hoist it by
crane. : 36 175 (18) (130) Hose
: 27 93 (9.5) (69) Hose
2. Install the pump device with the pump device
: 10 88 (9) (65) Bolt
mounting bolts.
: 17 49 (5) (36) Bolt
3. Connect all hoses and pipes.
4. Connect harness connectors to the pump device.
5. Remove the air bleed plugs (2 used) on top of the

regulators, then fill hydraulic oil into the pump
casings. (Refer to W1-1-2)
IMPORTANT: Be sure to check hydraulic oil level

and oil leakage, after assembling.
Bleed the air from the pump.
W2-4-2
(Blank)
W2-4-3
DISASSEMBLE PUMP DEVICE
14
13
20
12
13 22
13 15 21
22 18
17
16
10
19 9
7 22
8
11
1
6
2
5
3 37 19
4 36
23 32
33
10
39 31
1 22
2
34
35
45
41 28
40 38
42
24
43 44
27
25
30
26
29
W1HH-02-04-004
1- Drive Gear (2 Used) 13 - Fitting (4 Used) 25 - Seal Cover 36 - Adapter

2- Retaining Ring (2 Used) 14 - Pipe 26 - Retaining Ring 37 - Plug
3- N Sensor 15 - Bolt 27 - Oil Seal 38 - Center Gear
4- O-Ring 16 - Nut 28 - Center Shaft 39 - Level Gauge
5- Washer 17 - Washer 29 - Coupling Assembly 40 - Pipe
6- Socket Bolt 18 - Clamp (2 Used) 30 - O-Ring 41 - Socket Bolt (2 Used)
7- Socket Bolt 19 - Pipe (2 Used) 31 - Seal Washer (4 Used) 42 - Packing
8- Spring Washer 20 - Pipe 32 - Socket Bolt (2 Used) 43 - Drain Plug
9- Spring Washer (4 Used) 21 - Fitting 33 - Spring Washer (2 Used) 44 - Retaining Ring
10 - Bolt (8 Used) 22 - Fitting (5 Used) 34 - Washer (2 Used) 45 - Bearing
11 - Main Pump (2 Used) 23 - Flange 35 - Pilot Pump 46 - P Sensor (2 Used)
12 - Pipe 24 - Bearing
W2-4-4
Disassemble Pump Device
Clean the outside of the pump device.
1. Remove socket bolts (6, 7) to remove N sensor.

: 5 mm
2. Remove P sensor (46) (2 used).

: 27 mm
3. Loosen bolts (E) (4 used) of coupling assembly

(29), then remove inserts (H) from hub (A).
: 6 mm
46
4. Remove screws (B) (2 used) from hub (A).
Remove hub (A) and insert (D) from center shaft
(28).
: 8 mm W173-02-04-002
D A G
NOTE: Inserts (F) are installed by spring pins (C)
F C
and bolts (G).
E
5. Remove drain plug (43) to drain gear oil.
: 22 mm
CAUTION: Pump device assembly weight:

200 kg (440 lb)
6. Secure pump device assembly with workbench.
Workbench : ST 5050
B H W110-02-04-006
W2-4-5
14
20
12
15
18
17
19
16
10
9
11
19
36
32
33
31
34
35
41
40
W1HH-02-04-004
W2-4-6
7. Remove bolt (15), nut (16), washer (17), and
clamp (18) from the pipe.
: 13 mm
8. Remove pipes (12, 14, 19, and 20).

: 19 mm, 22 mm
9. Remove adapter (36) from pilot pump (35).

: 27 mm
10. Remove socket bolts (32) (2 used), spring

washers (33), and washers (34) to remove pilot
pump (35).
: 8 mm
11. Remove bolts (10) (4 used), spring washers (9),

and seal washers (31).
: 24 mm
12. Install eyebolt (M12, Pitch 1.75) to main pump

(11) to hoist and remove main pump (11) by
crane.
CAUTION: Main pump weight: 67 kg (148 lb)
13. Remove other main pump same as steps 11. and

12.
14. Remove socket bolts (41) (2 used) to remove pipe

(40).
: 6 mm
W2-4-7
23
45
28
38
24
44
27
25
30
26
W1HH-02-04-004
W2-4-8
CAUTION: Flange assembly weight:

48 kg (106 lb)
15. Turn over flange (23) and place it on the
workbench, then remove retaining ring (26) from
flange (23).
16. Remove seal cover (25) from flange (23).
17. Remove oil seal (27) from seal cover (25), using
special tool (ST 1234).
18. Remove O-ring (30) from flange (23). Remove

retaining ring (44) from center shaft (28).
CAUTION: Flange weight: 39 kg (86 lb)

workbench, then place it onto the press. Press out
center shaft (28) and bearing (24) from flange (23)
using special tool (ST 1236).
ST 1236
20. Take out center gear (38) from flange (23).
W173-02-04-003
21. Remove bearing (45) from flange (23), using

22. Remove bearing (24) from center shaft (28), using ST 1235
a press or puller.
W173-02-04-004
W2-4-9
ASSEMBLE PUMP DEVICE
1
22 2
21
20
19
A
18 B
B
17, 16, 15
3, 4
5, 6
14
7, 8
13
W1HH-02-04-001
12 11 10 9
Section B-B
37 45 38 23 24 25
26
44
27
28
29
46
30
36 35 32, 33, 34 31
W1HH-02-04-002
W2-4-10
View A
W1HH-02-04-003
43 41я
я 42 40 39
1- Drive Gear (2 Used) 13 - Fitting (4 Used) 25 - Seal Cover 36 - Adapter

2- Retaining Ring (2 Used) 14 - Pipe 26 - Retaining Ring 37 - Plug
3- N Sensor 15 - Bolt 27 - Oil Seal 38 - Center Gear
4- O-Ring 16 - Nut 28 - Center Shaft 39 - Level Gauge
5- Washer 17 - Washer 29 - Coupling Assembly 40 - Pipe
6- Socket Bolt 18 - Clamp (2 Used) 30 - O-Ring 41 - Socket Bolt (2 Used)
7- Socket Bolt 19 - Pipe (2 Used) 31 - Seal Washer (4 Used) 42 - Packing
8- Spring Washer 20 - Pipe 32 - Socket Bolt (2 Used) 43 - Drain Plug
9- Spring Washer (4 Used) 21 - Fitting 33 - Spring Washer (2 Used) 44 - Retaining Ring
10 - Bolt (8 Used) 22 - Fitting (5 Used) 34 - Washer (2 Used) 45 - Bearing
11 - Main Pump (2 Used) 23 - Flange 35 - Pilot Pump 46 - P Sensor (2 Used)
12 - Pipe 24 - Bearing
W2-4-11
45 38 23 24 25
26
44
27
28
46
30
W1HH-02-04-002
W2-4-12
Assemble Pump Device
CAUTION: Flange weight: 39kg (86 lb) ST 2307

1. Face input shaft side upward of flange (23), then
press in bearing (45) using special tool (ST 2307).
2. Insert center gear (38) into flange (23) from the

pump mounting hole to set it onto bearing (45).
3. Press center shaft (28) into bearing (45), aligning

center shaft (28) and the center gear (38) spline.
4. Press bearing (24) into flange (23) and center

shaft (28), using special tool (ST 2308).
W173-02-04-005
ST 2308
CAUTION: Flange assembly weight:

48 kg (106 lb)
5. Place flange (23) on the workbench, then install W173-02-04-006
retaining ring (44) onto center shaft (28), O-ring
(30) into flange (23) respectively.
6. Press oil seal (27) into seal cover (25) with special
tool (ST 2248).
7. Insert special tool (ST 2280) onto center shaft

(28), then install seal cover (25) into flange (23).
8. Install retaining ring (26) into flange (23).
W2-4-13
W1HH-02-04-001
11 10 9
23
36 35 32, 33, 34 31
W1HH-02-04-002
W2-4-14
workbench, then apply THREEBOND #1215 on
the pump mounting surface.
Workbench : ST 5050
CAUTION: Main pump weight :
67 kg (148 lb)
10. Install eyebolt (M12, Pitch 1.75) to main pump
(11) to hoist and install it to flange (23) by crane.
11. Tighten bolts (10) (4 used) with spring washers (9)

and seal washes (31).
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
12. Install other main pump same as steps 10 and 11.
13. Apply THREEBOND #1215 on the pilot pump (35)

mounting surface of flange (23). Install pilot pump
(35) to flange (23), then tighten socket bolts (32)
(2 used) with spring washers (33) and washers
(34).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 136 lbf⋅ft)
14. Install pipe (40) and packing (42) to flange (23),

then tighten socket bolts (41).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
40
W1HH-02-04-003
41, 42
15. Install adapter (36) to pilot pump (35).

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
W2-4-15
20
19
18
17, 16, 15
14
W1HH-02-04-001
12
37
28
46
W1HH-02-04-002
W2-4-16
16. Install pipes (12, 14, 19 and 20).
: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
: 22 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
17. Install clamp (18), bolt (15), nut (16), and washer
(17).
: 13 mm
: 3 N⋅m (0.3 kgf⋅m)
18. Place the pump device horizontal, then install hub

(A) to center shaft (28) with screws (B) (2 used). D A G
: 8 mm F C
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) E
19. Install inserts (H, D) to hub (A), then tighten bolts

(E) (4 used).
: 6 mm
: 310 N⋅m (32 kgf⋅m, 232 lbf⋅ft)
20. Install N sensor (3).

: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
B H W110-02-04-006
21. Install P sensor (46).

: 27 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
CAUTION: Pump device weight:

200 kg (440 lb)
22. Place the pump device horizontal, then remove
plug (37) to add engine oil.
Engine oil : 1.4 L (0.37 US gal.)
23. Set plug (37) hole to the counter weight direction.

: 17 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
W2-4-17
DISASSEMBLE MAIN PUMP
47, 48
4
41 6
31
42 31
43
1
3
10
11 16 5
14
15
17
49
44 30
24
25
25
23
39
19 40 37
7 22 34 38
25 46
31 45
21 29
27
13 20 25
25
33 32
18
21
9 12 25
8 20 28
22
2
26
48
36
35
40
39
W173-02-04-026
1- Casing 14 - Oil Seal 27 - Servo Pin 40 - Spring Washer (8 Used)

2- Drive Disc 15 - Seal Cover 28 - Set Screw 41 - Regulator
3- Roller Bearing (2 used) 16 - O-Ring 29 - Head Cover 42 - O-Ring
4- Roller Bearing 17 - Retaining Ring 30 - Spring Pin (2 Used) 43 - Spring Pin (2 Used)
5- Spacer 18 - Valve Plate 31 - O-Ring (10 Used) 44 - Plug
6- Bearing Nut 19 - Link 32 - Bolt (8 Used) 45 - Name Plate
7- Plunger (7 used) 20 - Lever (2 Used) 33 - Spring Washer (8 Used) 46 - Screw (2 Used)
8- Cylinder Block 21 - Pin (2 Used) 34 - Plug 47 - Bolt (4 Used)
9- Center Shaft 22 - Pin (2 Used) 35 - Stopper L 48 - Spring Washer (4 Used)
10 - Drive Gear 23 - Pin 36 - O-Ring 49 - Packing
11 - Retaining Ring 24 - Feedback Pin 37 - Stopper S 50 - P Sensor
12 - Spring 25 - Retaining Ring (6 Used) 38 - O-Ring
13 - Pin 26 - Servo Piston 39 - Bolt (8 Used)
W2-4-18
Disassemble Main Pump
Clean the outside of the main pump, before disas-

sembling.
1. Remove retaining ring (11) from the main pump.
2. Remove drive gear (10) with a puller.
CAUTION: Main pump weight: 67 kg (148 lb)
3. Secure the main pump on workbench (ST 5050).
4. Remove bolts (47) (4 used) and spring washer

(48) to remove regulator (41).
: 8 mm
5. Remove O-rings (31) (5 used), O-ring (42), and

two spring pins (43) (2 used).
6. Remove bolts (32) (8 used) and spring washers

(33) to remove head cover (29).
: 10 mm
7. Remove O-rings (31) (3 used) from casing (1).
8. Place valve plate (18) on casing (1).
9. Pull up cylinder block (8) to remove valve plate

(18) and link (19).
10. Remove spring (12).
W2-4-19
16
14
15
17
13
W173-02-04-026
W2-4-20
11. Pull up center shaft (9) straight to remove. Be
careful not lose pin (13).
12. Remove plungers (7) (7 used). Place plungers (7)

horizontally against drive disc (2), and remove.
13. Place casing (1) on the bed. Remove retaining

ring (17).
16
14. Place the casing (1) drive disc end upward on the
workbench. Remove seal cover (15) with a
screwdriver.
15. Remove oil seal (14) from seal cover (15) with a
screwdriver.
16. Remove O-ring (16) from casing (1).
W173-02-04-007
ȑȗȎȀȀTurn over casing (1) and place it on a press. Re-

move drive disc (2) and the bearing, using a
press and special tool (ST 1239)Ȏ ST 1239
W173-02-04-008
W2-4-21
4
6
3
5
W173-02-04-026
W2-4-22
18. Place drive disc (2) on special tool (ST 5905) to
loosen bearing nut (6). 2
ST 5905
W173-02-04-009
19. Install special tool (ST 3054) on the spline of drive

ST 3054
disc (2) to loosen bearing nut (6).
W173-02-04-010
20. Remove bearing nut (6) from drive disc (2).
21. Remove roller bearing (4) and spacer (5) from

drive disc (2) with a puller.
Puller
5 4
W173-02-04-011
22. Remove the roller bearing (3) outer race.
23. Remove roller bearing (4) from spacer (5) using

special tool (ST 1271). ST 1271
W173-02-04-012
W2-4-23
39
40 37
38
27
28
2
26
36
35
40
39
W173-02-04-026
W2-4-24
24. Install special tool (ST 1272) between drive disc
(2) and roller bearing (3), and clamp the assembly
in a vise. Tighten the vise as necessary to widen
ST 1272 3
the clearance.
2
W173-02-04-013
25. Remove roller bearings (3) (2 used) from drive

disc (2) with a puller.
Puller
3
26. Remove four bolts (39) and spring washers (40)
to remove stopper S (37) from the head cover. W173-02-04-014
Remove O-ring (38) and stopper S (37).

: 6 mm
27. Remove bolts (39) and spring washers (40) to

remove stopper L (35) from the head cover.
Remove O-ring (36) and stopper L (35).
: 6 mm
28. Remove set screw (28) from servo piston (26) to

remove servo pin (27).
: 8 mm
NOTE: LOCTITE #829 is applied to set screw (28).

Warm set screw (28) before disassembling.
29. Remove servo piston (27) from the head cover.
W2-4-25
ASSEMBLE MAIN PUMP
39, 40 37 31 47, 48 43 41 42 24 23 19 1 3 5 4 6
10
38
11
28
27
B 15
26 B
29
35 13 16 17 14
W1HH-02-04-005
36 49 44 12 7 8 9
18 30 21 25 20 22
Section B-B
W1HH-02-04-006
W2-4-26
45
View A 46
34
50
32, 33
W173-02-04-002
1- Casing 14 - Oil Seal 27 - Servo Pin 40 - Spring Washer (8 Used)
2- Drive Disc 15 - Seal Cover 28 - Set Screw 41 - Regulator
3- Roller Bearing (2 used) 16 - O-Ring 29 - Head Cover 42 - O-Ring
4- Roller Bearing 17 - Retaining Ring 30 - Spring Pin (2 Used) 43 - Spring Pin (2 Used)
5- Spacer 18 - Valve Plate 31 - O-Ring (10 Used) 44 - Plug
6- Bearing Nut 19 - Link 32 - Bolt (8 Used) 45 - Name Plate
7- Plunger (7 used) 20 - Lever (2 Used) 33 - Spring Washer (8 Used) 46 - Screw (2 Used)
8- Cylinder Block 21 - Pin (2 Used) 34 - Plug 47 - Bolt (4 Used)
9- Center Shaft 22 - Pin (2 Used) 35 - Stopper L 48 - Spring Washer (4 Used)
10 - Drive Gear 23 - Pin 36 - O-Ring 49 - Packing
11 - Retaining Ring 24 - Feedback Pin 37 - Stopper S 50 - P Sensor
12 - Spring 25 - Retaining Ring (6 Used) 38 - O-Ring
13 - Pin 26 - Servo Piston 39 - Bolt (8 Used)
W2-4-27
39, 40 37
3 4
38
28
27
26
29
W1HH-02-04-005
W2-4-28
Assemble Main Pump
NOTE: Assemble by following the disassemble

procedures in reverse.
(1) Before assembling, clean all parts with
pure solvent and dry them with com-
pressed air.
(2) Do not mix up the parts.
1. Insert servo piston (26) into head cover (29). In-

stall servo pin (27) into the pin bore on servo pis-
ton (26). Apply LOCTITE #829 to set screw (28).
Tighten set screw (28) to secure servo pin (27) in
piston.
: 8 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
2. Install O-ring (38) on stopper S (37). Install stop-

per S (37) to head cover (29) with bolts (39) (4
used) and spring washers (40) (4 used).
: 6 mm
: 30 N⋅m (3.1 kgf⋅m, 22.4 lbf⋅ft)
3. Install servo pin (27) positioning tool (ST 7923) on

the large chamber side of the head cover (29). Set
servo piston (26) so that servo pin (27) is at the
center of the suction port.
CAUTION: Take care to avoid being burned

when heating the bearings in an oil bath.
4. Heat roller bearings (3) (2 used) and the inner
race of bearing (4) to 50 to 80 °C (122 to 176 °F).
Apply hydraulic oil to roller bearings (3) and (4) in-
side.
ST 7923
W173-02-04-015
W2-4-29
3 5 4 6 2
W1HH-02-04-005
W2-4-30
5. Place drive disc (2) on a workbench with the
splined end up. Install two roller bearings (3) (2
used) on drive disc (2).
NOTE: Apply oil to bearing race surfaces after in-
stalling.
6. Install roller bearing (4) outer race in spacer (5)

ST 2408
using special tool (ST 2408).
W173-02-04-016
7. Install roller bearing (4) (include inner race) and
spacer (5) on drive disc (2).
Press roller bearing (4) inner race on drive disc (2),
using a plastic hammer and special tool (ST
7102).
NOTE: (1) Confirm that roller bearings (3, 4) are ST 7102
securely installed on drive disc (2), after
they have cooled down to room
temperature.
(2) Be sure to apply oil to bearing race
surfaces after installing.
8. Place drive disc (2) on special tool (ST 5905). In- W173-02-04-017
stall bearing nut (6) on drive disc (2) and tighten
bearing nut (6) until it contacts bearing (4).
6
NOTE: Apply lubricating oil to bearing nut (6)

threads when tightening. ST 5905
W173-02-04-018
W2-4-31
1 3 4 6 2
15
16 14
W1HH-02-04-005
W2-4-32
9. Tighten bearing nut (6) by turning drive disc (2)
clockwise using tool (ST 3054).
NOTE: When tightening bearing nut (6), tighten ST 3054
counterclockwise.
10. Install a torquemeter and adapter (ST 3055) on W173-02-04-023
the spline of drive disc (2) to measure bearing pre-

load. Make a record of the starting torque. Be sure
to rotate drive disc (2) two or three times before
recording, for smoother movement of drive disc ST 3055
(2).
Starting Torque Specification:

2.94±0.49 N⋅m (0.30±0.05 kgf⋅m, 2.17±0.36 lbf⋅ft) ST 5905
CAUTION:
Take care to avoid being burned when heat-
ing the bearings in an oil bath.
11. Heat casing (1) to 50 to 80 °C (122 to 176 °F).
Apply grease to the inside of casing (1). W173-02-04-024
12. Install drive disc (2) into casing (1).

NOTE: Confirm that drive disc (2) is securely in-
stalled in casing (1) after the casing has
cooled down to room temperature.
13. Install O-ring (16) into the groove on casing (1)

bore. Apply grease to O-ring (16).
14. Install oil seal (14) into seal cover (15), using spe- ST 2409
cial tool (ST 2409). Apply grease to the oil seal
(14) lip.
15
W173-02-04-019
W2-4-33
23 19 1
15
12 7 9 13 17 W1HH-02-04-005
18
W1HH-02-04-006
W2-4-34
15. Install special tool (ST 2410) on the spline of drive 14
disc (2). Install seal cover (15) in casing (1).
NOTE: Tap seal cover (15) into casing (1) with a
plastic hammer until the retaining ring
groove on casing (1) is visible.
16. Install retaining ring (17) to casing (1). 15

NOTE: Be sure to confirm that the ring seats well in
ST 2410
the groove on casing (1) after installing.
17. Turn over casing (1) and place it on a workbench

with the input shaft side down. Apply lubrication oil
to the spherical surface of drive disc (2). Place
each plunger (7) horizontally against drive disc (2) W173-02-04-020
and install.
18. Install pin (13) on center shaft (9).

NOTE: Secure pin (13) to center shaft (9) with
grease.
19. Install center shaft (9) on drive disc (2).
20. Install spring (12) on center shaft (9).
21. After link (19) is connected to valve plate (18).

place valve plate (18) on casing (1). Insert pin (23)
on the other end of link (19) assembly to the open-
ing on the casing (1) regulator mounting surface.
W2-4-35
23 19 1
27
29
49 7 8 9 13 W1HH-02-04-005
18 30
W1HH-02-04-006
W2-4-36
22. Install plungers (7) (7 used) and center shaft (9)
into cylinder block (8).
NOTE: Install pin (13) into the groove of cylinder
block while rotating the end of center shaft
(9).
23. Face the spherical surface of valve plate (18) to

cylinder block (8) and insert the end of center
shaft (9).
NOTE: Be sure to apply hydraulic oil to the match-
ing surfaces of valve plate (18) and cylinder
block (8).
24. Apply grease to O-rings (31) (3 used). Install O-

rings (31) (3 used) and packing (49) on casing (1).
NOTE: When installing O-rings (31), refer to W2-4- 1
18.
25. Install valve plate positioning tool (ST 7094) on 18

the drain port of casing (1) to position valve plate
(18) at the center position.
26. Install head cover (29) on casing (1), aligning

servo pin (27) on head cover (29) with the orifice
in valve plate (18). The valve plate (18) guide sur-
face mates with head cover (29) bottom surface, ST 7094
forming a sliding fit. W173-02-04-021
27. Install head cover (29) on casing (1) with aligning

the holes of spring pins (30). Tighten bolts (32) (8
used) with spring washers (33) (8 used).
: 12 mm
: 110 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
32, 33
W173-02-04-002
W2-4-37
47, 48 43 41 42 24 1
39, 40 2
10
11
29
35 W1HH-02-04-005
36 44
W2-4-38
28. Remove valve plate positioning tool (ST 7094)
from casing (1) and install plug (44).
Remove servo pin positioning tool (ST 7923) from 35, 36
head cover (29). Install O-ring (36) on stopper L 39, 40
(35). Install stopper L (35) with spring washers
(40) (4 used) and bolts (39) (4 used). 44
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
: 8 mm ST 7923 ST 7094
: 49 N⋅m (5 kgf⋅m, 36.2 lbf⋅ft)
29. Apply grease to O-rings (31) (42). Install O-rings

(31) (5 used) and O-ring (42) onto the regulator
mounting surface of casing (1).
NOTE: Be sure to install spring pins (43) (2 used). W173-02-04-022
When installing O-rings (31), refer to W2-4-

18.
30. Install regulator (41) on casing (1).

CAUTION: Main pump weight:
67 kg (148 lb)
IMPORTANT: Align pump feedback pin (24) with

the notches on regulator (41)
sleeves confirming from the plug
hole of regulator (41).
31. Install bolts (47) (4 used) and spring washers (48)
(4 used). Tighten bolts (47).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
32. Install drive gear (10) into drive disc (2).
33. Install retaining ring (11) into drive disc (2).
W2-4-39
DISASSEMBLE REGULATOR
25
26
27
11
12
24
20
23
22
21
18
30
19
14
31 2
28
6
15
1
29
4
17
16 3
13
15
7 5
8
2
2
14
26
25
12 32
11 10
W173-02-04-029
9
1- Stopper 9- Nut 17 - Spring 25 - Socket Bolt (8 Used)
2- O-Ring (3 Used) 10 - Screw 18 - Sleeve 26 - Spring Washer (8 Used)
3- Sleeve 11 - Nut (2 Used) 19 - Spool 27 - Front Cover
4- Spool 12 - Nut (2 Used) 20 - Cylinder 28 - Bolt (4 Used)
5- Casing 13 - Stopper 21 - Piston 29 - Spring Washer (4 Used)
6- Spring 14 - Stopper (2 Used) 22 - O-Ring 30 - Plug
7- Piston 15 - O-Ring (2 Used) 23 - Backup Ring 31 - O-Ring
8- Cylinder 16 - Spring 24 - O-Ring 32 - Rear Cover
W2-4-40
UPPERSTRUCTURE/Pump Device
Disassemble Regulator
1. Clean the regulator outside.
2. Clamp casing (5) with a vise.
3. Remove air bleed plug (30) and O-ring (31) from

casing (5). Remove elbows (4 used) from casing
(5).
: 19 mm, 41 mm
4. Remove socket bolts (25) (8 used) to remove

front cover (27) and rear cover (32).
: 6 mm
IMPORTANT: Never loosen stopper (1), (13) and

(14), nut (9), (11) and (12), and screw
(10). If loosened, the regulator set-
ting will change.
5. Remove springs (16, 17) from the casing (5) rear

cover side.
6. Remove cylinder (20) from the casing (5) front

cover (27) side, pulling spool (19).
7. Remove piston (21), O-ring (22), and backup ring

(23) from cylinder (20).
8. Remove sleeve (18) and spool (19) from the cas-

ing (5) front cover (27) side.
9. Remove spool (19) from sleeve (18).
10. Remove spring (6) from the casing (5) front cover
(27) side.
11. Remove piston (7) and cylinder (8) from the cas-
ing (5) rear cover (32) side, pulling spool (4).
12. Remove piston (7) and O-ring (2) from cylinder

(8).
13. Remove sleeve (3) and spool (4) from the casing
(5) front cover (27) side. Then remove spool (4)
from sleeve (3) .
W2-4-41
ASSEMBLE REGULATOR
6 1 4 3 5 7 8 2 9 10
24 23 22 21 20 19 18 17 16 15 14 13 12 11 T173-03-01-005
25, 26 27 28, 29 30 31 32
W173-02-04-001
1- Stopper 9- Nut 17 - Spring 25 - Socket Bolt (8 Used)

2- O-Ring (3 Used) 10 - Screw 18 - Sleeve 26 - Spring Washer (8 Used)
3- Sleeve 11 - Nut (2 Used) 19 - Spool 27 - Front Cover
4- Spool 12 - Nut (2 Used) 20 - Cylinder 28 - Bolt (4 Used)
5- Casing 13 - Stopper 21 - Piston 29 - Spring Washer (4 Used)
6- Spring 14 - Stopper (2 Used) 22 - O-Ring 30 - Plug
7- Piston 15 - O-Ring (2 Used) 23 - Backup Ring 31 - O-Ring
8- Cylinder 16 - Spring 24 - O-Ring 32 - Rear Cover
W2-4-42
Assemble Regulator
NOTE: Assemble by following the disassemble

procedures in reverse.
(1) Before assembling, Clean all parts with
pure solvent and dry with compressed
air.
(2) Do not mix up the parts.
1. Clamp casing (5) with a vise.
2. Install spool (19) into sleeve (18).
3. Install sleeve (18) with spool (19) from the casing

(5) front cover (27) side.
4. Install spool (4) into sleeve (3), then install them

from the casing (5) front cover (27) side.
5. Install piston (7) into cylinder (8).
6. Install O-ring (2) to cylinder (8), then apply a film

of grease to O-ring (2). Install cylinder (8) from the
casing (5) rear cover (32) side.
7. Install rear cover (32) assembly and springs (16)

and (17) to casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8. Install O-ring (22), backup ring (23), and piston

(21) to cylinder (20).
9. Apply a film of grease to O-ring (22), then Install

cylinder (20) from the casing (5) front cover (27)
side.
10. Install front cover (27) assembly and spring (6)

into casing (5). Tighten socket bolts (25) (4 used)
with spring washers (26).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
11. Apply a film of grease to O-ring (31). Install O-ring

(31) to plug (30).
12. Tighten plug (30).

: 41 mm
: 78.5 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
13. Install elbows (4 used) to casing (5).
W2-4-43
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
14
10
15
12
13
6
8 9
1
16
7
5
15
11
14
5
7
9
4 3 2
W110-02-04-022
1- Housing 5- Seal (2 Used) 9- O-Ring (2 Used) 13 - Bolt (4 Used)

2- Flange 6- Cover 10 - Gear 14 - Bushing (2 Used)
3- Oil Seal 7- Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4- Retaining Ring 8- Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
W2-4-44
Disassemble Pilot Pump
NOTE: (1) Clean the outside of the pilot pump

before disassembling.
(2) Make matching marks on cover (6),
housing (1) and flange (2) before
disassembling to aid reassembly.
1. Clamp pump flange (2) in a vise with cover (6) up.
2. Remove bolts (13) (4 used).

: 17 mm
3. Remove cover (6) from housing (1).
4. Remove O-ring (9) from cover (6).
5. Remove flange (2) from housing (1).
6. Remove O-ring (9) from flange (2).
7. Remove retaining ring (4) from flange (2).
8. Remove oil seal (3) from flange (2) with a screw

driver.
9. Remove seal (5) and backup ring (7) from cover

(6) side bushings (14, 15).
10. Lightly push drive gear (11) to remove cover (6)

side bushings (14, 15) from housing (1).
NOTE: Be careful not to allow the key between the
bushings to fall off when removing them.
11. Remove seal (5) and backup ring (7) from flange
(2) side bushings (14, 15).
12. Remove flange (2) side bushings (14, 15). Re-

move gear (10) and drive gear (11) from housing
(1).
W2-4-45
14
10
15
12
13
6
8 9
1
16
7
5
15
11
14
5
7
9
4 3 2
W110-02-04-022
1- Housing 5- Seal (2 Used) 9- O-Ring (2 Used) 13 - Bolt (4 Used)

2- Flange 6- Cover 10 - Gear 14 - Bushing (2 Used)
3- Oil Seal 7- Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4- Retaining Ring 8- Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
W2-4-46
Assemble Pilot Pump
1. Tap oil seal (3) in flange (2) with a plastic hammer

and tool.
2. Install retaining ring (4) to flange (2).
3. Install cover (6) side bushings (14, 15) in housing

(1) with the seal groove side down.
NOTE: Position the bushings in the correct
direction when installing.
4. Install gear (10) and drive gear (11) in housing (1).
5. Install flange (2) side bushings (14, 15) in housing

(1) with the seal groove side up.
6. Install seal (5) and backup ring (7) into the seal
groove on bushings (14, 15).
7. Install O-ring (9) on flange (2).
8. Install flange (2) on housing (1).
9. Turn over the housing and flange assembly and

clamp flange (2) in a vise. Install seal (5) and
backup ring (7) into the seal groove on the
bushings.
NOTE: Be careful not to allow the bushings or

gears to fall off when rotating the assembly.
10. Install O-ring (9) on cover (6).
11. Install cover (6) on housing (1).
12. Install washers (12) (4 used) and bolts (13) (4

used). Tighten the bolts.
: 17 mm
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 29 to 32.5 lbf⋅ft)
W2-4-47
MAINTENANCE STANDARD
Pump Device
Unit : mm (in)
Standard Allowable Limit Remedy
Gear backlash 0.48 (0.019) 1.5 (0.059) Replace
Main Pump
1. Drive disc: Spline tooth thickness
Unit : mm (in)
Standard Allowable Limit
4.9 (0.193) 3.5 (0.138)
2. Drive disc: Oil seal outer diameter
Unit : mm (in)
60.0 (2.362) 59.8 (2.354)
3. Spherical joint: The clearance between plunger

and drive disc
Unit : mm (in)

0.060 (0.0024) 0.4 (0.0016)
W157-02-04-016
4. Cylinder block: Clearance between plunger outer

diameter and cylinder block bore
D-a Unit : mm (in) D

0.044 (0.0017) 0.08 (0.0031) a
W157-02-04-017
W2-4-48
5. Clearance between plunger and connecting rod
Unit : mm (in)
0.1 (0.0039) 0.4 (0.0016)
W157-02-04-033
6. Clearance between center shaft and valve plate
D-a Unit : mm (in)

Standard Allowable Limit a
0.081 (0.0032) 0.3 (0.012)
Center Shaft
W110-02-04-013
Valve Plate
7. Clearance between small chamber inner diameter

and servo piston D W110-02-04-014
a
D-a Unit : mm (in)
0.089 (0.0035) 0.2 (0.0079)
8. Clearance between large chamber inner diameter

and servo piston
D-a Unit : mm (in) a

Standard Allowable Limit D W157-02-04-018
0.090 (0.0035) 0.2 (0.0079)
9. Clearance between servo pin and valve plate

D a
D-a Unit : mm (in)

0.051 (0.0020) 0.3 (0.012)
W157-02-04-019
W2-4-49
(Blank)
W2-4-50
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

can penetrate the skin, causing serious in-
jury.
pressure.
Preparation

pressure.
M104-07-021
lic oil tank.

tem.
W2-5-1
Removal
Arm 2
Boom 1
IMPORTANT: Attach a tag to each hose to aid in 4-Spool Side
Bucket 5-Spool Side
assembly. Travel Right
1. Remove all hoses, pipings, and connectors from
the control valve.
Main Swing
Relief Arm 1
: 17 mm valve Boom 2
: 24.5 N⋅m (25 kgf⋅m, 18 lbf⋅ft) Auxiliary
: 19 mm Travel Left
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) Machine Front T1HH-01-02-005
NOTE: Cap all hose and piping ends.
CAUTION: Control valve weight:

210 kg (460 lb)
2. Remove bolts (1) to remove the control valve.
: 24 mm
: 205 N⋅m (21 kgf⋅m 152 lbf⋅ft )
Installation
NOTE: Refer to “Removal” section for wrench size

and tightening torque.
1. Install the control valve on the frame and tighten

bolts (1).
2. Connect all hoses, pipings, and connectors to the

control valve. 1 W1HH-02-05-001
IMPORTANT: After assembling, check hydraulic

oil level, start the engine and check
for oil leaks.
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE CONTROL VALVE (1)
13 4 4 43
12 41
5
7
46 4
12a
13a
15 6
17
32 35 15 4
15 4
30 31 15 42
14
4
29 5
38 47
25
28 17
37 23
33 14 15
34 12
30
31 20
27 21
22
2 10 19
15 18 24
26
35 45 1
44
16
31
8
11
40
17 8
39 15
15
8
16 8
36
9
31 8 9
5
17
3
W173-02-05-021
1- Casing A 13 - Needle Valve 25 - Spool: Bypass Shut-Off 38 - Spring (7 Used)
2- Casing B 13a O-Ring (3 Used) 26 - Spool: Auxiliary 39 - Spring
3- Plug 14 - O-Ring (10 Used) 27 - Spool: Travel Right 40 - Spring
4- Plug (㈐ Used) 15 - O-Ring (11 Used) 28 - Spring (2 Used) 41 - Plug
5- O-Ring (6 Used) 16 - O-Ring (8 Used) 29 - Spring (2 Used) 42 - Plug
6- Spring Cover A 17 - Socket Bolt (32 Used) 30 - Spring Seat (4 Used) 43 - Plug
7- Spring Cover B 18 - Spool: Travel Left 31 - Spring Seat (16 Used) 44 - Plug
8- Spool Cover (5 Used) 19 - Spool: Arm 1 32 - Spacer Bolt (2 Used) 45 - O-Ring
9- Spool Cover (2 Used) 20 - Spool: Boom 1 33 - Stopper (2 Used) 46 - Socket Bolt (4 Used)
10 -Spool Cover: Arm 2 21 - Spool: Bucket 34 - Stopper (7 Used) 47 - Socket Bolt (4 Used)
11 -Spool Cover: Boom 1 22 - Spool: Swing 35 - Spacer Bolt (8 Used)
12 -Anti-Drift Valve (2 Used): 23 - Spool: Arm 2 36 - Stopper
Boom Bottom, Arm Rod
12a O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used)
W2-5-4
Disassemble control valve (1)
• Read carefully “Precautions for Disassembly and • Spool Cover

Assembly” (W1-1-1) before starting repair work. IMPORTANT: Attach matching mark not to make a
• Attach a tag to spool mounting positions of the mistake in assembly of casing and
casing. spool cover.
9. Loosen socket bolts (17) (2 used) and remove
• Anti-drift Valve and Needle Valve spool cover (11) from casing B (2).
1. Loosen socket bolt (46) and remove needle valve : 6 mm
(13) and anti-drift valve (12) from spring cover B
(7). 10. Disassemble spool covers (8) to (10) following the
: 5 mm same procedures.
: 6 mm
2. Loosen socket bolt (47) and remove anti-drift
valve (12) from spring cover A (6).
: 5 mm
• Spring Cover
spring cover A (6) from casing A (1). Remove
spring cover B (7) from casing B (2) similarly.
: 6 mm
• Spool
IMPORTANT: Remove spools while carefully turn-
ing them. If they stick even a little,
try it again instead of pulling roughly.
Since spool and hole of casing are a
matched fit, make marks to aid in
assembly.
Be careful not to damage casing and
spool.
4. Remove spool (18) assembly from casing A (1).
5. Remove spools (19) to (27) following the same

procedures.
6. Clamp spool (18) in a vise.
7. Loosen spacer bolt (32) and disassemble spring

seat (30), springs (28), (29), and stopper (33).
: 10 mm
8. Disassemble spools (19) to (27) following the

same procedures.
: 10 mm
W2-5-5
ASSEMBLE CONTROL VALVE (1)
Machine Front 21 27
B 15, 14
A
16
4
5, 42
8
11
46
12, 12a
35
13, 13a
10
5, 43 31
47
5, 41 40
12 A B 39 36 31 7 2 25 23 20 W1HH-02-05-017
17 T1HH-03-03-002
Section B-B
Control Valve Upper View
Machine Front 18 26 15, 14 30 33 28 29
30
16
32
3
5
44, 45
9
35
15
8 31
17 37 38
W1HH-02-05-005 W1HH-02-05-004
24 19 22 1 6 31 34
Control Valve Lower View
Section A-A
1- Casing A 13 - Needle Valve 25 - Spool: Bypass Shut-Off 38 - Spring (7 Used)

2- Casing B 13a O-Ring (3 Used) 26 - Spool: Auxiliary 39 - Spring
3- Plug 14 - O-Ring (10 Used) 27 - Spool: Travel Right 40 - Spring
4- Plug (4 Used) 15 - O-Ring (11 Used) 28 - Spring (2 Used) 41 - Plug
5- O-Ring (6 Used) 16 - O-Ring (8 Used) 29 - Spring (2 Used) 42 - Plug
6- Spring Cover A 17 - Socket Bolt (32 Used) 30 - Spring Seat (4 Used) 43 - Plug
7- Spring Cover B 18 - Spool: Travel Left 31 - Spring Seat (16 Used) 44 - Plug
8- Spool Cover (5 Used) 19 - Spool: Arm 1 32 - Spacer Bolt (2 Used) 45 - O-Ring
9- Spool Cover (2 Used) 20 - Spool: Boom 1 33 - Stopper (2 Used) 46 - Socket Bolt (4 Used)
10 -Spool Cover: Arm 2 21 - Spool: Bucket 34 - Stopper (7 Used) 47 - Socket Bolt (4 Used)
11 -Spool Cover: Boom 1 22 - Spool: Swing 35 - Spacer Bolt (8 Used)
12 -Anti-Drift Valve (2 Used) 23 - Spool: Arm 2 36 - Stopper
Boom Bottom, Arm Rod
12a O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used)
W2-5-6
Assemble Control Valve (1)
• Read carefully “Precautions for Disassembly and • Spring Cover

Assembly” (W1-1-1) before starting repair work. 10. Install O-rings (14) (5 used) and O-rings (15) (4
used) to spring cover A (6)
• Lower Spool Cover
IMPORTANT: Install spool covers (8) to (11) with 11. Install spring cover A (6) to casing A (1) with
matching marks. socket bolts (17) (7 used).
Be sure to install O-rings (15) and : 6 mm
(16). : 24 to 34 N⋅m
1. Install O-rings (15) and (16) to spool cover (11). (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)
2. Install spool cover (11) to casing B (2) with socket 12. Install spring cover B (7) following the same pro-
bolts (17) (2 used). cedures.
: 6 mm : 6 mm
: 24 to 34 N⋅m : 24 to 34 N⋅m
(2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)
3. Install spool cover(8) to (10) following the same • Anti-drift Valve and Needle Valve
procedures. 13. Install O-rings (12a) (3 used) to anti-drift valve
: 6 mm (12). Install anti-drift valve (12) to spring cover A
: 24 to 34 N⋅m (6) with socket bolts (47) (4 used).
(2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) : 5 mm
: 9.8 to 14 N⋅m
• Spool (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
4. Clamp spool (18) in a vise.
14. Install O-rings (12a) (3 used) to anti-drift valve
5. Clean screw section of spacer bolt (32) and apply (12). Install O-rings (13a) (3 used) to needle valve
LOCTITE #262. (13). Install needle valve (13) and anti-drift valve
(12) to spring cover B (7) with socket bolts (46) (4
6. Install spring sheet (30), springs (28), (29), stop- used).
per (33) and spacer bolt (32) to spool (18). : 5 mm
: 9.8 to 14 N⋅m
7. Tighten spacer bolt (32). (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
: 10 mm
: 15 to 18 N m
(1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft)
8. Assemble spools (19) to (27) following the same

procedures.
: 10 mm
: 15 to 18 N⋅m
(1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft)
IMPORTANT: Install spool (18) to (27) assemblies

with matching marks.
Be careful not to damage casing and
spool when installing.
9. Install spool (18) to (27) assemblies to casing A
(1) and casing B (2).
W2-5-7
1
22 12
23
5 6
13 19
18
20
24
21a
11 4 21
9 14
14 9
8
16
Casing A 25 11 17
10
15
W173-02-05-022
1 - Anti-Drift Valve Assembly: 8 - O-Ring (2 Used) 15 - Plug 21a - O-Ring

Arm Bottom Side
2 - Casing 2 9- O-Ring (2 Used) 16 - Poppet 22 - Piston
3 - Casing 3 10 - O-Ring 17 - Spring 23 - Piston
4 - Casing 4 11 - O-Ring (2 Used) 18 - Spool 24 - Socket Bolt (4 Used)
5 - O-Ring 12 - Plug 19 - Spring 25 - Socket Bolt (8 Used)
6 - O-Ring 13 - Plug 20 - Bushing
7 - O-Ring (3 Used) 14 - Plug (2 Used) 21 - Relief Valve
W2-5-8
Disassemble Control Valve (2)
• Read carefully “Precautions for Disassembly and

Assembly” (W1-1-1) before starting repair work.
• Arm Anti-drift Valve

IMPORTANT: Put matching marks to install cor-
rectly.
casing 2 (2) from casing 4 (4).
: 10 mm

casing 4 (4) from casing A.
: 10 mm
3. Clamp casings 2 (2) and 3 (3) in a vise.

casing 3 (3) from casing 2 (2).
: 5 mm
5. Loosen plug (15) and take out poppet (16) and

spring (17) from casing 2 (2).
: 17 mm
IMPORTANT: Do not disassemble lock nut part.

6. Remove relief valve (21) from casing 3 (3).
: 22 mm
IMPORTANT: Mark extraction sequence of piston

(22) and (23).
7. Loosen plug (13) and take out piston (23) and pis-
ton (22) from casing 3 (3).
: 10 mm
8. Loosen plug (12) and take out bushing (20), spool

(18), and spring (19) from casing 3 (3).
: 22 mm
W2-5-9
9 14 13 5
Machine Front
9 23
14
22
7
F
F
21 21a 3 20
19
T1HH-03-03-002 6
18
Control Valve Upper View Section Y-Y
12
W1HH-02-05-006
Arm 1 Arm 2
24
Y Y
15
10
17
Casing B
16 Casing A
Section F-F
2 25 11 4 25 11 T1HH-03-03-007
1 - Anti-Drift Valve Assembly: 8 - O-Ring (2 Used) 15 - Plug 21a - O-Ring

Arm Bottom Side
2 - Casing 2 9- O-Ring (2 Used) 16 - Poppet 22 - Piston
3 - Casing 3 10 - O-Ring 17 - Spring 23 - Piston
4 - Casing 4 11 - O-Ring (2 Used) 18 - Spool 24 - Socket Bolt (4 Used)
5 - O-Ring 12 - Plug 19 - Spring 25 - Socket Bolt (8 Used)
6 - O-Ring 13 - Plug 20 - Bushing
7 - O-Ring (3 Used) 14 - Plug (2 Used) 21 - Relief Valve
W2-5-10
• Read carefully “Precautions for Disassembly and 10. Install casing 3 (3) to casing 2 (2) with socket
Assembly” (W1-1-1) before starting repair work. bolts (24) (4 used).
: 5 mm
• Arm Anti-drift Valve : 9.8 to 13.5 N⋅m
1. Install O-rings (7) (3 used) to bushing (20). (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
2. Install O-ring (6) to plug (12). 11. Install O-ring (11) to casing 4 (4).
3. Install bushing (20), spool (18), and spring (19) 12. Install casing 4 (4) to casing A with socket bolts
into casing 3 (3), and install plug (12). (25) (4 used).
: 22 mm : 10 mm
: 69 to 79 N⋅m : 98 to 118 N⋅m
(7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft) (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)
4. Install O-ring (5) to plug (13). 13. Install O-ring (11) to casing 2 (2).
IMPORTANT: Be sure to install pistons (22) and 14. Install casing 2 (2) to casing 4 (4) with socket
(23) in their correct positions. bolts (25) (4 used).
5. Install pistons (22) and (23) into casing 3 (3), and : 10 mm
install plug (13). : 98 to 118 N⋅m
: 10 mm (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)
: 127 to 147 N⋅m
(13 to 15 kgf⋅m, 94 to 108 lbf⋅ft)
IMPORTANT: Do not use lock nut part.

6. Install O-ring (21a) to relief valve (21). Tighten and
install relief valve (21) in casing 3 (3).
: 22 mm
: 69 to 79 N⋅m
(7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft)
7. Install O-ring (10) to plug (15).
8. Install poppet (16) and spring (17) into casing 2

(2), and install plug (15).
: 17 mm
: 370 to 410 N⋅m
(38 to 42 kgf⋅m, 275 to 300 lbf⋅ft)
9. Install O-rings (8) (2 used) to casing 3 (3).
W2-5-11
16 13
19 7 13a
25
23 3
18 16
21 17 19
25 20 22
24
29 29a Casing A
1 4
9
6
6 14
9 1
4
33
14a
6
1
26
9
8
12
31
32
15 10
27
27
5 12 11
31 25
28a 2
28
30a
30b
30c
30
W1HH-02-05-019
1 - Plug (4 Used) 11 - P3 Cover 19 - Spring (4 Used) 28a O-Ring

2 - Plug 12 - Flange (2 Used) 20 - Spring (2 Used) 29 - Overload Relief Valve:
Arm Rod Side
3 - Plug 13 - Travel Flow Rate Control 21 - Spring 29a O-Ring
Valve Assembly
4 - Plug (2 Used) 13a - O-Ring 22 - Spacer 30 - Pump Control Valve:
5-Spool Section
5- Plug (3 Used) 14 - Blank Flange Assembly 23 - Plug (3 Used) 30a - O-Ring
6- O-Ring (4 Used) 14a - O-Ring (2 Used) 24 - Plug 30b - O-Ring
7- O-Ring 15 - Socket Bolt (4 Used) 25 - O-Ring (5 Used) 30c - O-Ring
8- O-Ring (2 Used) 16 - Poppet (4 Used) 26 - O-Ring 31 - Socket Bolt (8 Used)
9- O-Ring (3 Used) 17 - Poppet (2 Used) 27 - O-Ring (2 Used) 32 - Socket Bolt (4 Used)
10 - Cover 18 - Poppet 28 - Overload Relief Valve: 33 - Socket Bolt (4 Used)
Boom Rod Side
W2-5-12
• Read carefully “Precautions for Disassembly and • Overload Relief Valve

IMPORTANT: Note that there are two kinds of over-
• P3 Cover load relief valves.
1. Loosen socket bolts (32) (4 used) and remove P3 Attach identification marks to each
cover (11). port and part to aid reassembly.
: 8 mm Be sure to loosen the valve of over-
load relief valve. If lock nut and ad-
2. Take out poppet (16), spring (19), and spacer (22) justing screw are loosened, the set
from casing A. pressure will change. Never loosen
lock nut and adjusting screw.
• Blank Flange Assembly 8. Loosen and remove overload relief valves (28)
3. Loosen socket bolts (33) (4 used) and remove and (29) with tool as below.
blank flange (14). : 32 mm
: 8 mm
4. Take out poppet (17) and spring (20) from casing
(Wrench: 32 mm)
A.
(12.7 mm)
(43 mm)
32 mm
• Travel Flow Rate Control Valve (13) Assembly
5. Loosen the plug and take out the piston, sleeve,
poppet, and spring from casing A. (45 mm)
: 32 mm
(80 mm) W1HH-02-05-002
• Arm Anti-Drift Check Valve

6. Loosen plug (24) and take out spring (21) and
poppet (18) from casing A. • Pump Control Valve (5-Spool Section)
: 12 mm 9. Loosen and remove pump control valve (30) from
base.
• Travel Left, Boom 2, Swing Load Check Valve : 36 mm
(common to three places)
IMPORTANT: Attach matching marks to each port

and part to aid reassembly.
spring (19) from casing A.
: 12 mm
W2-5-13
Machine Front
X
5
B
C C
D D
F F
W1HH-02-05-003
G
30 30a 30c 30b
Casing A Section B
T1HH-03-03-002
X
Auxiliary Bucket
31
Travel Left Travel Right
12
27
16
13a
19
22
13 2
23 25
32
11
25 8
19 27
16 31 T1HH-03-03-005
12
Section C-C T1HH-03-03-004
Section D-D
W2-5-14
Boom 2 Boom 1 Arm 1 Arm 2
1 6
18
29 21
24
29a 25
17
25 20
14
23 14a
33
19
16
7 Section F-F
T1HH-03-03-006 T1HH-03-03-007
28a Section E
28
15 10 9, 26 4 9
Swing
Travel
Left
Auxiliary
16
19
Boom 2
23
Arm 1
25
Swing
W1HH-02-05-004
Section G T1HH-03-03-006 Section X-X
1 - Plug (4 Used) 11 - Cover 19 - Spring (4 Used) 28a O-Ring

2 - Plug 12 - Flange (2 Used) 20 - Spring (2 Used) 29 - Overload Relief Valve:
Arm Rod Side
3 - Plug 13 - Travel Flow Rate Control 21 - Spring 29a O-Ring
Valve Assembly
4 - Plug (2 Used) 13a - O-Ring 22 - Spacer 30 - Pump Control Valve:
5-Spool Section
5- Plug (3 Used) 14 - Blank Flange 23 - Plug (3 Used) 30a - O-Ring
6- O-Ring (4 Used) 14a - O-Ring (2 Used) 24 - Plug 30b - O-Ring
7- O-Ring 15 - Socket Bolt (4 Used) 25 - O-Ring (5 Used) 30c - O-Ring
8- O-Ring (2 Used) 16 - Poppet (4 Used) 26 - O-Ring 31 - Socket Bolt (8 Used)
9- O-Ring (3 Used) 17 - Poppet (2 Used) 27 - O-Ring (2 Used) 32 - Socket Bolt (4 Used)
10 - Cover 18 - Poppet 28 - Overload Relief Valve: 33 - Socket Bolt (4 Used)
Boom Rod Side
W2-5-15
Machine Front
X
5
B
C C
D D
E
W1HH-02-05-003
F F
30 30a 30c 30b
G Section B
Casing A 31 12
T1HH-03-03-002 Auxiliary Bucket
X

27
16
19
22
13a 2
13
15 25
23 32
11
8
27
19
16 31 Section D-D T1HH-03-03-005
12
Arm 1 Arm 2
Section C-C T1HH-03-03-004 1 6 18
Boom 2 Boom 1
21 17
29 24
25
29a
20
14
25
14a
23
33
19
16
3
Section F-F
7
T1HH-03-03-006 T1HH-03-03-007
Section E
28a 28
W2-5-16
• Read carefully “Precautions for Disassembly and • Arm Anti-drift Check Valve
Assembly” (W1-1-1) before starting repair work. 5. Install O-ring (25) to plug (24).
• Pump Control Valve (5-Spool Section) 6. Install poppet (18) and spring (21) into casing A,
1. Install O-rings (30a) (30b) (30c) to pump control and install plug (24).
valve (30). Tighten and install pump control valve : 12 mm
(30) to base. : 226 to 265 N⋅m
: 69 to 78 N⋅m
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft) • Travel Flow Rate Control Valve (13) Assembly
7. Install O-ring (13a) to the plug. Install the piston,
• Overload Relief Valve sleeve, poppet, and spring into casing A, and in-
stall the plug.
IMPORTANT: Note that there are two kinds of over- : 32 mm
load relief valves. : 147 to 177 N⋅m
Install according to the identification (15 to 18 kgf⋅m, 108 to 130 lbf⋅ft)
marks.
2. Install O-ring (28a) to overload relief valve (28). • Blank Flange Assembly
Install O-ring (29a) to overload relief valve (29). 8. Install two O-rings (14a) (2 used) to blank flange
Tighten and install overload relief valve (28) and (14). Install poppet (17) and spring (20) into cas-
(29) to base with tool as below. ing A. Install blank flange (14) with socket bolts
: 32 mm (33) (4 used).
: 69 to 78 N⋅m : 8 mm
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft) : 49 to 65 N⋅m
(5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)
• P3 Cover
(Wrench: 32 mm)
9. Install O-rings (8) to cover (11).

(12.7 mm)
32 mm
43 mm
10. Install poppet (16), spring (19), and spacer (22)

into casing A. Install P3 cover (11) with socket
bolts (32) (4 used).
(45 mm) : 8 mm
(80 mm) W1HH-02-05-002 : 49 to 65 N⋅m
(5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)
• Left Travel, Boom 2, Swing Load Check Valve

(common to 3 places)
IIMPORTANT: Install according to the matching

marks.
4. Install poppet (16) and spring (19) into casing A,

and install plug (23).
: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
W2-5-17
3
11 21
11a
18
21
15
12
19
21
2
16 7
14 4
8
5
1
18 6
21
15
12
10
9
23
9a
20
22
17
13
Casing B
W173-02-05-024
1- Plug (2 Used) 8 - O-Ring (2 Used) 13 - Poppet 20 - Plug

2- Plug 9 - Switch Valve 14 - Poppet 21 - O-Ring (6 Used)
3- Plug (3 Used) 9a - O-Ring (2 Used) 15 - Spring (2 Used) 22 - O-Ring
4- Plug 10 - Poppet Valve 16 - Spring 23 - Socket Bolt (4 Used)
5- Plug (2 Used) 11 - Load Check Valve 17 - Spring
6- O-Ring (2 Used) 11a - O-Ring 18 - Plug (2 Used)
7- O-Ring 12 - Poppet (2 Used) 19 - Plug
W2-5-18

• Bucket Flow Rate Control Valve

1. Loosen four socket bolts (23) (4 used) and re-
move switch valve (9).
: 8 mm
2. Take out poppet valve (10) from casing B.
• Arm 2 Load Check Valve (with orifice)

3. Loosen the plug and take out load check valve
(11) from casing B.
: 12 mm
• Boom 1, Arm 2 Load Check Valve

IMPORTANT: Attach matching marks to each port

and part to aid reassembly.
spring (15) from casing B.
: 12 mm
• Boom Anti-drift Check Valve

: 12 mm
• Travel-Bucket Compound Check Valve

: 10 mm
W2-5-19
Machine Front
C C 13
D D 22
E 20
F F
17
G
Control Valve Upper View T1HH-03-03-002

Section C-C T1HH-03-03-004
Auxiliary Bucket Boom 2 Boom 1
6
1
10
9a
14
16
9 19
21
18
15
23 21
12
Section D-D Section E T1HH-03-03-006

T1HH-03-03-005
Swing
Arm 1 Arm 2
11a
11 21
12 3
15
18 7
21 2
4
8
Section F-F Section G T1HH-03-03-008
T1HH-03-03-007
1- Plug (2 Used) 8 - O-Ring (2 Used) 13 - Poppet 20 - Plug

2- Plug 9 - Switch Valve 14 - Poppet 21 - O-Ring (6 Used)
3- Plug (3 Used) 9a - O-Ring (2 Used) 15 - Spring (2 Used) 22 - O-Ring
4- Plug 10 - Poppet Valve 16 - Spring 23 - Socket Bolt (4 Used)
5- Plug (2 Used) 11 - Load Check Valve 17 - Spring
6- O-Ring (2 Used) 11a - O-Ring 18 - Plug (2 Used)
7- O-Ring 12 - Poppet (2 Used) 19 - Plug
W2-5-20
• Read carefully “Precautions for Disassembly and • Bucket Flow Rate Control Valve
Assembly” (W1-1-1) before starting repair work. 8. Install O-rings (9a) (2 used) to switch valve (9).
Poppet valve (10) is put into the casing. Install
• Travel-Bucket Compound Check Valve switch valve (9) with socket bolts (23) (4 used).
1. Install O-ring (22) to plug (20). : 8 mm
: 52 to 62 N⋅m
2. Install poppet (13) and spring (17) into the casing, (5.3 to 6.3 kgf⋅m, 38 to 46 lbf⋅ft)
: 10 mm
: 128 to 147 N⋅m
(13 to 15 kgf⋅m, 94 to 108 lbf⋅ft)
• Boom Anti-drift Check Valve

4. Install poppet (14) and spring (16) into the casing,

: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Boom 1, Arm 2 Load Check Valve

IIMPORTANT: Install according to the identification

mark.
6. Install poppet (12) and spring (15) into the casing,

: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Arm 2 Load Check Valve (with orifice)

7. Install O-ring (11a) to the plug. Install load check
valve (11).
: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
W2-5-21
1
Casing B
21
21a
19 5
20 6
18
17
19
20
7
18
11
17
14 7
6
16
6
4
22
23
15 17
2
18
15
8 20
3 19
9
10
12
13
W173-02-05-025
1 - Flow Combiner Valve As- 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used)

sembly
2 - Block 8- O-Ring 14 - Stopper 20 - O-Ring (3 Used)
3 - Plug 9- Plug 15 - Orifice (2 Used) 21 - Main Relief Valve
4 - Plug 10 - O-Ring 16 - Spool 21a - O-Ring
5 - O-Ring (3 Used) 11 - O-Ring 17 - Poppet (3 Used) 22 - Socket Bolt (5 Used)
6 - O-Ring (4 Used) 12 - Spring 18 - Spring (3 Used) 23 - Name Plate
W2-5-22

• Flow Combiner Valve

flow combiner valve assembly (1).
: 14 mm
2. Clamp block (2) in a vise.
3. Loosen main relief valve (21) from base, and re-

move from block (2).
: 32 mm
4. Loosen plug (9) and take out spool (16), stopper

(14), springs (12) and (13) from block (2).
: 32 mm
IMPORTANT: Attach matching mark to each port

and part.
5. Loosen plug (19), and take out poppet (17) and
spring (18) from block (2).(common to 3 places)
: 12 mm
6. Loosen and remove plug (3).

: 5 mm
7. Take out orifices (15) (2 used) from block (2).

: 4 mm
W2-5-23
Machine Lower
Machine Front
3, 8, 15 22
T1HH-03-03-002
W1HH-02-05-007
Control Valve Upper View Control Valve Front View
15 16 10 9 12 13
14
20
7
19
6
18
17 20
4 19
11
2
18
17
21a
21
W1HH-02-05-010
Section A
1 - Flow Combiner Valve As- 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used)
sembly
2 - Block 8- O-Ring 14 - Stopper 20 - O-Ring (3 Used)
3 - Plug 9- Plug 15 - Orifice (2 Used) 21 - Main Relief Valve
4 - Plug 10 - O-Ring 16 - Spool 21a - O-Ring
5 - O-Ring (3 Used) 11 - O-Ring 17 - Poppet (3 Used) 22 - Socket Bolt (5 Used)
6 - O-Ring (4 Used) 12 - Spring 18 - Spring (3 Used) 23 - Name Plate
W2-5-24
• Read carefully “Precautions for Disassembly and 10. Install O-rings (5) (3 used), O-rings (6) (4 used),
Assembly” (W1-1-1) before starting repair work. O-rings (7) (2 used) and O-ring (11) to block (2).
• Flow Combiner Valve 11. Install flow combiner valve assembly (1) with
1. Clamp block (2) in a vise. socket bolt (22) (5 used).
: 14 mm
2. Install orifices (15) (2 used) in block (2). : 215 to 255 N⋅m
: 7.8 to 9.8 N⋅m
(0.8 to 1.0 kgf⋅m, 5.8 to 7.2 lbf⋅ft)
4. Install plug (3).

: 5 mm
: 12.7 to 16.7 N⋅m
(1.3 to 1.7 kgf⋅m, 9.4 to 12.3 lbf⋅ft)
IMPORTANT: Install according to the matching

mark.
6. Put poppet (17) and spring (18) into block (2), and
install plug (19).(common to 3 places)
: 12 mm
: 225 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
8. Put spool (16), stopper (14), springs (12) and (13)

into block (2), and install plug (9).
: 32 mm
: 68.6 to 78.4 N⋅m
(7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)
9. Install O-ring (21a) to main relief valve (21). Install

main relief valve (21) in block (2) base.
: 32 mm
: 68.6 to 78.4 N⋅m
W2-5-25
9a
10 9
9c
9b
7
8 7a
11
2 Casing B
8a 1
1
3
3
4 6
5
6 Casing A
5
6
6
7a
4
6
7
7a
W173-02-05-026
1 - Plug (2 Used) 5 - O-Ring (6 Used) 8 - Overload Relief Valve: 9b - O-Ring

Bucket Bottom Side
2 - Plug 6 - O-Ring (5 Used) 8a - O-Ring 9c - O-Ring
3 - O-Ring (2 Used) 7 - Overload Relief Valve 9 - Pump Control Valve: 10 - Socket Bolt
(3 Used): Bucket Rod, Arm (4-Spool Section)
Bottom, Boom Bottom Side
4 - O-Ring (6 Used) 7a - O-Ring (3 Used) 9a - O-Ring 11 - Socket Bolt (8 Used)
W2-5-26

• Pump Control Valve (4-Spool Section)

1. Loosen and remove pump control valve (9) from
casing B base.
: 36 mm
• Overload Relief Valve
IMPORTANT: Note that there are 2 kinds of over-

load relief valve.
Attach identification mark to each
port and part.
IMPORTANT: Be sure to loosen the valve of over-

load relief valve. If loosening the
lock nut and adjusting screw, the set
pressure will change. Never loosen
the lock nut and adjusting screw.
2. Loosen and remove overload relief valve (7) and
(8) from casing B base with tool as below.
: 32 mm
(12.7 mm)
(Wrench: 32
32 mm
43 mm
(45 mm)
(80 mm) W1HH-02-05-002
• Casing
IMPORTANT: As long as there is no necessity, do

not disassemble socket bolts (10)
and (11).
3. Loosen socket bolt (10) and socket bolts (11) (8
used) and disassemble casing A and casing B.
: 12 mm
W2-5-27
Boom 2 Boom 1
Machine Front 10
5
C C
D D 6
E
4
F F
Control Valve Upper View T1HH-03-03-002

Section E
T1HH-03-03-006
Travel Left Travel Right Arm 1 Arm 2
4
6
7
7a
5
5
6
4
7a
7
4
Section C-C T1HH-03-03-004 Section F-F

T1HH-03-03-007
Auxiliary Bucket 6
Swing
8 9
8a 9a
5 9c
9b
6
b
7a
Section D-D 4 Section G T1HH-03-03-008

T1HH-03-03-005
1 - Plug (2 Used) 5 - O-Ring (6 Used) 8 - Overload Relief Valve: 9b - O-Ring

Bucket Bottom Side
2 - Plug 6 - O-Ring (5 Used) 8a - O-Ring 9c - O-Ring
3 - O-Ring (2 Used) 7 - Overload Relief Valve 9 - Pump Control Valve: 10 - Socket Bolt
(3 Used): Bucket Rod, Arm (4-Spool Section)
Bottom, Boom Bottom Side
4 - O-Ring (6 Used) 7a - O-Ring (3 Used) 9a - O-Ring 11 - Socket Bolt (8 Used)
W2-5-28

• Casing
1. Install O-rings (4) (6 used), O-rings (5) (6 used)
and O-rings (6) (5 used) to casing B.
2. Connect casing A and casing B and tighten socket

bolts (10) and socket bolts (11) (8 used).
: 12 mm
: 137 to 177 N⋅m
(14 to 18 kgf⋅m, 101 to 130 lbf⋅ft)
IMPORTANT: Note that there are 2 kinds of over-

load relief valve.
Install according to the matching
mark.
3. Install O-ring (7a) to overload relief valve (7). In-
stall O-ring (8a) to overload relief valve (8).Tighten
and install overload relief valves (7) and (8) to the
base with tool as below.
: 32 mm
: 69 to 78 N⋅m
(Wrench: 32 mm)
(12.7 mm)
32 mm
43 mm
(45 mm)
(80 mm) W1HH-02-05-002
• Pump Control Valve (4-Spool Section)

4. Install O-rings (9a), (9b) and (9c) to pump control
valve (9). Install pump control valve (9).
: 36 mm
: 69 to 78 N⋅m
W2-5-29
STRUCTURE OF VALVES
Main Relief Valve ITEM PART NAME QTY
2 1 Lock Nut 1
2 Lock Nut 1
9 3 O-Ring 1
6 4 O-Ring 1
5 5 O-Ring 1
1 6 Adjusting Screw 1
8 7 Spring 1
16 8 Piston 1
3 9 Stopper 1
7
22 10 Poppet 1
4 PL 11 Backup Ring 1
12 O-Ring 1
10 23
13 Seat 1
11 20 14 Spring 1
12 21 15 Plunger 1
16 O-Ring 1
17 13 17 Filter 1
18 14 18 Filter Stopper 1
19 19 C-Ring 1
R 20 Spacer 1
15 21 C-Ring 1
22 Adjusting Plug 1
P 23 Plug 1
W173-02-05-030
Overload Relief Valve ITEM PART NAME QTY

1 Lock Nut 1
5 1 2 O-Ring 1
3 Adjusting Screw 1
2 4 Spring 1
3
5 Spring Seat 1
4 6 Poppet 1
21
6 7 Backup Ring 1
8 O-Ring 1
19
9 9 Backup Ring 1
10 O-Ring 1
10 22 11 Seat 1
16 12 Spring 1
11 13 Spring 1
17
14 Plunger 1
18 20 15 Piston 1
13 16 Filter 1
R 12
17 Filter Stopper 1
8
18 C-Ring 1
14
7 19 O-Ring 1
P
15 20 O-Ring 1
W173-02-05-031
21 Plug 1
22 Body 1
W2-5-30
Flow Combiner Valve B
10
15 11
14 5 6 7 7 6 5 4 2 3
8 12
4
9
22
16
W1HH-02-05-011
B
21 4 5 6 7
9
W1HH-02-05-012
Section B-B Section A-A
A A
ITEM PART NAME QTY

1 Name Plate 1
20 2 Socket Bolt 5
3 Main Relief 1
W1HH-02-05-013
4 O-Ring 3
5 ROMH Plug 3
18 17 13 18 19 19 19 6 Spring 3
7 Poppet 3
18 8 Spool 1
9 Orifice 2
10 Stopper 1
18 11 Spring 1
12 Spring 1
17 13 O-Ring 1
14 O-Ring 1
15 Plug 1
16 O-Ring 1
17 O-Ring 2
18 O-Ring 4
19 O-Ring 3
20 Plug 1
21 ROM Plug 1
W1HH-02-05-014
22 Block 1
W2-5-31
Switch Valve (Bucket Flow Rate Control Valve)
2 1 4 3
9 5 ITEM PART NAME QTY

1 Spring 1
2 Spring 1
6 3 Spool 1
8 4 Spring Seat 1
5 Plug 1
6 Plug 1
11 7 Socket Bolt 4
8 O-Ring 1
9 O-Ring 1
10 O-Ring 2
11 Casing 1
10 7 W173-02-05-007
Anti-drift Valve
ITEM PART NAME QTY

1 Bushing 1
2 Spring 1
3
3 Spool 1
4 Plug 1
5
5 O-Ring 3
1 6 O-Ring 3
7 O-Ring 1
8 Casing 1
6
W173-02-05-008
W2-5-32
Travel Flow Rate Control Valve Assembly
Pi
3
ITEM PART NAME QTY

1
1 O-Ring 1
6 2 Spring 1
3 Plug 1
DR 4 Poppet 1
2 5 Sleeve 1
6 Piston 1
B 5
A
W173-02-05-009
Poppet Valve (Bucket Flow Rate Control Valve)
B
4
2 ITEM PART NAME QTY

1 Spring 1
3 2 Spring 1
3 Plug 1
1 4 Spring Seat 1
5 Poppet 1
A 6 Logic Poppet 1
5
P
W173-02-05-010
Arm 2 Load Check Valve
3
6 ITEM PART NAME QTY

1 O-Ring 1
2 Spring 1
2 3 Plug 1
4 Poppet 1
5
B 5 Sleeve 1
6 Piston 1
4
A
W173-02-05-011
W2-5-33
Needle Valve
A 5
2
6
7
1
3
Section A-A W173-02-05-013

A
ITEM PART NAME QTY

1 O-Ring 3
2 O-Ring 1
3 Plug 2
4 Nut 1
5 Adjusting Screw 1
6 Poppet 1
W173-02-05-012
7 Casing 1
Blank Flange
W1HH-02-05-016
5 4 4 5 2 4 5
ITEM PART NAME QTY
1 Socket Bolt 4
2 Blank Flange 1
3 O-Ring 2
3 3 4 O-Ring 3
5 ROH Plug 3
LCAT1 LCAP1
W1HH-02-05-015
W2-5-34
Arm Anti-drift Valve
12 13
A
17 21
B1 PL
B 3
17
4
12
5
B 19
24 6
20
8
7
14
18 Dr
Section A-A W1HH-02-05-006
Dr
A
W1HH-02-05-008
ITEM+ PART NAME QTY

1 Socket Bolt 8
9 16 11 10 2 Socket Bolt 4
3 Piston 1
4 Piston 1
5 Relief Valve 1
6 Bushing 1
7 Spring 1
8 Spool 1
9 Spring 1
10 Poppet 1
11 Plug 1
12 Plug 2
13 Plug 1
23 14 Plug 1
15 O-Ring 2
16 O-Ring 1
17 O-Ring 2
22
15 18 O-Ring 2
19 O-Ring 3
20 O-Ring 1
1 21 O-Ring 1
A1 W1HH-02-05-009
22 Casing 1
15 23 Casing 1
Section B-B 24 Casing 1
W2-5-35
Boom 1 Spool Assembly
2 3 6 9 7 4 8 5 1
W173-02-05-015
ITEM PART NAME QTY

1 Plug 2 1
2 Plug 1 1
3 Spring B3 1
4 Spring B2 1
5 Spring B1 1
6 Plunger 3 1
7 Plunger 2 1
8 Plunger 1 1
9 Spool 1
Arm 2 Spool Assembly
8 4
3 10 9 6 11 1 12 7 5 2 W173-02-05-016
ITEM PART NAME QTY

1 Spring Seat (1) 1
2 Plug 1
3 Plug 1
4 Stopper (2) 1
5 Stopper (1) 1
6 C-Ring 1
7 Spring A2 1
8 Spring A1 1
9 Sleeve (1) 1
10 Sleeve (2) 1
11 Sub Spool 1
12 Spool 1
W2-5-36
Bucket Spool Assembly
W1HH-02-05-018
2 5 8 4 7 9 6 3 1
ITEM PART NAME QTY

1 Plug 2 1
2 Plug 1 1
3 Spring B3 1
4 Spring B2 1
5 Spring B1 1
6 Plunger 3 1
7 Plunger 2 1
8 Plunger 1 1
9 Spool 1
W2-5-37
Pump Control Valve
9 Dr
2
Pc
6
PE
5
R
7
P
W173-02-05-017
ITEM PART NAME QTY

1 Lock Nut 1
2 O-Ring 1
3 Adjusting Plug 1
4 Spring 1
5 Spool 1
6 O-Ring 1
7 O-Ring 1
8 O-Ring 1
9 Body 1
W2-5-38
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

may penetrate the skin, causing serious in-
jury. Avoid this hazard by relieving pressure
before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation
starting any repair work.
moved without releasing accumulated pres-
sure first. Push the air release valve on top of
the hydraulic oil tank to release any remain-
ing pressure.
Preparation

pressure.

lic oil tank.

tem. M104-07-021
W2-6-1
Removal
1. Disconnect hoses (1 to 3 and 5 to 7). 7
: 41 mm 6
: 205 N⋅m (21 kgf⋅m)
: 19 mm 1
: 29.5 N⋅m (3 kgf⋅m) 2
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m)
5
NOTE: Attach caps to the hoses and pipes.
2. Attach a nylon sling to the swing motor so as to
hoist it by crane. 3
Nylon sling (eye-type at both ends): 2 places 4
W1HH-02-06-001
CAUTION: Swing device assembly weight:

Nylon Sling
390 kg (800 Ib)
3. Remove bolts (4) and hoist the swing device
assembly by crane.
: 32 mm
: 640 N⋅m (65 kgf⋅m, 470 Ibf⋅ft)
Installation
NOTE: Refer to “Removal” section above for

wrench sizes and tightening torques.
IMPORTANT: Before installing the swing device

assembly, apply liquid packing
(THREEBOND #1102) to both mou-
nting surfaces on the swing device
and frame.
1. Install the swing device with bolts (4).
2. Connect hoses (1 to 3 and 5 to 7).
IMPORTANT: Be sure to fill the swing motor with W176-02-06-002
hydraulic oil after installing it. After

completing installation, check
hydraulic oil level. Add oil as
necessary. Run the engine and
check the component for any oil
leaks.
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING DEVICE
32
22
2
23
4
5
31
6
21
7
30 8
24 18
29 9
25 20
7
28 10
19
11
27 12
18 13
17 14
26 16
13
15 12
W1HH-02-06-002
1 - Socket Bolt (12 used) 9 - First Stage planetary Gear 17 - Bolt (2 Used) 25 - Drain Plug
(3 used)
2- Motor 10 - Pin (3 Used) 18 - Thrust Plate (2 used) 26 - Shaft
3- Retaining Ring 11 - Spring Pin (3 Used) 19 - Second Stage Carrier 27 - O-Ring
4- First Stage Sun Gear 12 - Thrust Plate (6 used) 20 - Second Stage Sun Gear 28 - Oil Seal
5- Pin (3 Used) 13 - Needle Bearing (6 Used) 21 - First Stage Carrier 29 - Sleeve
6- Spring Pin (3 Used) 14 - Second Stage planetary 22 - Ring Gear 30 - Roller Bearing
Gear (3 used)
7 - Thrust Plate (6 used) 15 - Bearing Nut 23 - Roller Bearing 31 - Housing
8 - Needle Bearing (3 Used) 16 - Lock Plate 24 - Pipe 32 - Socket Bolt (12 used)
W2-6-4
Disassemble Swing Device
CAUTION: Swing device weight: CAUTION: Ring gear weight: 34 kg (75 lb)
390 kg (860 lb) 7. Loosen and remove socket bolt (32). Install eye-
1. Attach a nylon sling to the swing motor so as to bolt (M12, pitch 1.75) into the motor mounting
hoist it by crane. thread position of ring gear (22). Hoist it by crane
to remove the ring gear from housing (31).
: 17 mm
2. Put the swing device on bracket (ST 5100).
Secure it with bolts (M22) (2 used). Secure the NOTE: THREEBOND has been applied on the joint
bracket on a working platform. surface between housing (31) and ring gear
: 32 mm (22). Insert a screw driver into the gap be-
Swing Device tween the swing motor and ring gear.
Then pry it up for easy removing.
8. Remove second stage sun gear (20) and the
ST 5100 second stage carrier (19) assembly.
CAUTION: Housing (31) assembly weight:

200 kg (440 lb)
9. Remove bolt (17). Remove lock plate (16).
: 17 mm
W1HH-02-06-011
10. Remove nut (15) from shaft (26) using special nut
3. Remove drain plug (25), then drain off oil. removing tool (ST 3167).
: 8 mm ST 3167 15
4. Remove pipe (24) from housing (31).

: 18 mm
CAUTION: Motor weight: 71 kg (160 lb)

5. Put matching marks at the jointed portion between
motor (2) and ring gear (22), between ring gear
(22) and housing (31).
Loosen and remove socket bolt (1). Hoist and W178-02-06-008
remove motor (2) by crane. 11. Install eyebolt (M20, pitch 2.5) into the bolt (32)
: 10 mm hole of housing (31). Remove bolts (M22) (2
NOTE: Insert the screw driver between motor (2) used) with the housing and bracket. Hoist the
and ring gear (22) to float motor (1), and housing (31) assembly by crane to remove the
remove motor (2) easily. bracket.
6. Remove first stage sun gear (4) from first stage 12. Put the blocks on the press bench. Put the
carrier (21). housing (31) assembly on the blocks.
Remove the first stage carrier (21) assembly from
ring gear (22).
: 8 mm 31
W1HH-02-06-012
Block
W2-6-5
23
31
30
29
27
26
W1HH-02-06-002
W2-6-6
CAUTION: Before pressing shaft (26), pro- Shaft (26)

vide a protection cover (outer diameter: 369 Roller Bearing (23)
mm (14.5 in), inner diameter: 90 mm (3.5 in), Housing (31)
thickness: 25 to 30 mm (1.0 to 1.2 in)). Then,
use the press to remove shaft (26) while cov-
ering housing (31) and roller bearing (23) with
Protection Cover
the protection cover. Failure to use the pro-
tection cover may result in personal injury
due to metal fragments flying off if housing
(31) and/or roller bearing (23) break. Use a
press with the capacity less than 30 tons
(66000 lb). Be sure to degrease the housing
W157-02-06-010
inside before heating roller bearing (23). Fail- Press
ure to degrease may cause a fire.
13. Put the protection cover onto housing (31) and

remove shaft (26) with a press. At this time re- Bearing Removal
Special Tool Set
move the roller bearing (30) inner race and sleeve
(29) with shaft (26).
14. Remove the roller bearing (23) inner race from

housing (31).
15. Attach shaft (26) assembly to the special tool

bearing removal set.
W157-02-06-011
NOTE: Use the following parts as the special tool

set for removing roller bearing (30). Shaft
Hose Clamp
Part Size Remarks

Shaft Length: 220 mm 8 used. All should be
or Bolt (8.7 in) identical in length with no
Diameter: 19 mmwear and deformation on
(3/4 in) both ends.
Material: S35C
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2”
(Applicable Di-
ameter: 185 to W157-02-06-012
215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter: Shaft (26)
292 mm (11.5 in) Roller Bearing (30)
Inner Diameter:
272 mm (10.7 in) Sleeve (29) Hose
Clamp
Shaft
Guide
W157-02-06-01
W2-6-7
23
5
31
6
21
7
30 8
18
29 9
28 10
19
11
27 12
18 13
14
26
13
12
W1HH-02-06-002
W2-6-8
CAUTION: Be sure to use the guide when 20. Insert a bar at the back side of the outer race of
pushing shaft (26) with a press. roller bearing (23). Remove the outer race from
housing (31) by tapping with a bar and hammer.
16. Attach shaft (26) with the special tool to a press.
Then, remove roller bearing (30). 21. Drive spring pin (6) out of first stage carrier (21)
with a round bar and hammer.
Press
22. Remove pins (5) (3 used), first stage planetary
gears (9) (3 used), thrust plates (7) (6 used), and
Shaft (26) needle bearings (8) (3 used) from first stage
Roller carrier (21).
Bearing (30)
Sleeve (29) 23. Remove thrust plates (18) from first stage carrier
(21).
24. Drive spring pin (11) from second stage carrier

Guide
(19) with a round bar and hammer.
25. Remove pins (10) (3 used), second stage

planetary gears (14) (3 used), thrust plates (12) (6
W157-02-06-014
used), and needle bearings (13) (6 used) from
second stage carrier (19).
17. Remove sleeve (29) from shaft (26). Remove O-
ring (27) from sleeve (29).
26. Remove thrust plate (18) from second stage
carrier (19).
18. Insert a round bar into the oil passage in housing
(31), tap the outer race of roller bearing (30) out.
Oil Passage
Outer Race
W1HH-02-06-007
CAUTION: Housing (31) weight:

104 kg (230 lb)
19. Secure housing (31) body with a nylon sling, hoist
it by crane to turn housing (31) over.
Insert a screw driver into the gap on housing (31)
where oil seal (28) is mounted. Remove oil seal
(28).
NOTE: THREEBOND has been applied on the
periphery of oil seal (28). Thus, it can’t be
reused.
W2-6-9
ASSEMBLE SWING DEVICE
3
5
6
2 1
4
7
8
21
9
7
18 11
12
20 13
32
19
22 14
10
18
17
16
15 23
30
24
31
25
26
27
28
29
T1HH-03-02-001
1 - Socket Bolt (12 used) 9 - First Stage planetary Gear 17 - Bolt (2 Used) 25 - Drain Plug
(3 used)
2- Motor 10 - Pin (3 Used) 18 - Thrust Plate (2 used) 26 - Shaft
3- Retaining Ring 11 - Spring Pin (3 Used) 19 - Second Stage Carrier 27 - O-Ring
4- First Stage Sun Gear 12 - Thrust Plate (6 used) 20 - Second Stage Sun Gear 28 - Oil Seal
5- Pin (3 Used) 13 - Needle Bearing (6 Used) 21 - First Stage Carrier 29 - Sleeve
6- Spring Pin (3 Used) 14 - Second Stage planetary 22 - Ring Gear 30 - Roller Bearing
Gear (3 used)
7 - Thrust Plate (6 used) 15 - Bearing Nut 23 - Roller Bearing 31 - Housing
8 - Needle Bearing (3 Used) 16 - Lock Plate 24 - Pipe 32 - Socket Bolt (12 used)
W2-6-10
Assemble Swing Device
1. Install needle bearing (8) in each first stage 8. Install sleeve (29) and the inner race of roller
planetary gears (9) (3 used). bearing (30) into shaft (26). Press sleeve (29) and
inner race using bearing mounting tools (ST 7289)
2. Install thrust plates (18) in first stage carrier (21). and (ST 7292).
NOTE: Press-in distance of the bearing inner race
3. Install first stage planetary gears (9) (3 used) and can be assured by using the bearing mount-
thrust plates (7) (6 used) into first stage carrier ing tool.
(21).
4. Aligning the hole on pin (5) with spring pin hole on

first stage carrier (21), drive pins (5) (3 used) into Press
first stage carrier (21) with a hammer.
IMPORTANT: Be sure to drive the spring pin ST 7292

correctly.
5. Tap spring pin (6) into first stage carrier (21) and 30
ST 7289
pin (5). At this time, the slit of the spring pin
should face to the end of pin (9). 29
26
6
5
Slit
WIHH-02-06-008
W178-02-06-002 CAUTION: Housing weight: 104 kg (230 lb)

9. Secure housing (31) body with a nylon sling, then
6. Assemble second stage carrier (19), referring to hoist it by crane. Place sleeve (29) with the mount-
steps 1 to 5 above. Assemble seond stage ing side up.
planetary gears (14) (3 used), needle bearings
(13) (6 used), thrust plates (12) (6 used), (18),
pins (10) (3 used), and spring pins (11) (3 used). 10. Tap the outer race of roller bearing (30) evenly
with a bar and hammer while installing the outer
7. Install O-ring (27) onto sleeve (29). race into housing (31). Tap the bearing and listen
to ring to confirm if installation is completed.
W2-6-11
32
15 23
31
26
28
29
T1HH-03-02-001
W2-6-12
11. Apply THREEBOND #1102 on the outer surface 19. Place mounting tool (ST 7290) onto the inner race
of oil seal (28). Put oil seal (28) flat on housing of roller bearing (23). Push the inner race down
(31) and push it in gently. Then place seal with a press.
mounting tool (ST 7291) on the oil seal and tap it NOTE: Press in distance of the inner race can be
in with a hammer directly. assured by using the mounting tool.
23
ST 7291
28 ST 7291
31
WIHH-02-06-009
WIHH-02-06-010
20. Hoist the housing (31) assembly and place it on
12. Apply grease to the inner surface of oil seal (28) bracket (ST 5100) by crane. Secure it with bolts
all around. Apply grease to the outer surface of (M22) (2 used) while the stopper at the bottom of
sleeve (29) on shaft (26). bracket is located at the middle of two teeth of the
pinion gear. Secure the bracket on a working
13. Install eye bolt (M20, pitch 2.5) into the bolt (32) platform.
: 32 mm 31
hole in housing (31). Then hoist and place it on
shaft (26) by crane, slowly. Check and align
carefully to protect the oil seal (28) lip from curling
ST 5100
while mounting it.
14. Tap the outer race of roller bearing (23) into hous-
ing (31) with a bar and hammer evenly. Listen to
ring to confirm if installation is completed.
15. Tap the inner race of roller bearing (23) into shaft W1HH-02-06-011
(26) with a bar and hammer. Tap the inner race

IMPORTANT: Pay attention to the direction of the
until two threads of shaft nut (15) appear.
bearing nut.
21. Apply a little amount of grease on the threaded
16. Screw in nut (15) to shaft (26). Tighten as much
surface of nut (15), then install it on shaft (26) with
as possible by hand.
the stepped side of nut facing roller bearing (23).
NOTE: Prevent shaft (26) from falling down when Tighten the nut using mounting tool (ST 3167).
hoisting housing (31). : 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
CAUTION: Housing + shaft + bearing weight: NOTE: Grease must be applied for keeping correct
193 kg (425 lb) tightening torque.
17. Install eyebolt (M20, pitch 2.5) into the bolt (32) ST 3167
hole in housing (31). Hoist housing (31) by crane 15
and place it on a press.
18. Remove nut (15) from shaft (26).
W178-02-06-008
W2-6-13
21
20 32
19
22
17
16
15
24
25 31
26
27
T1HH-03-02-001
W2-6-14
22. Install lock plate (16) onto nut (15) with bolt (17). IMPORTANT: Pay attention to the mounting
In case the spline of lock plate (16) and that of direction of the sun gear.
shaft (26) are not aligned, tighten nut (15) in 28. Install first stage sun gear (4) into the first stage
tightening direction until both splines are aligned. carrier (21) assembly with the stepped side of the
: 17 mm sun gear facing down.
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
29. Install pipe (24) into housing (31) with the seal
tape wound on the threaded part of pipe (24).
CAUTION: Second stage carrier weight:
: 18 mm
42 kg (93 lb)
IMPORTANT: Pay attention to the mounting
30. Wind the seal tape on drain plug (25), then install
direction of the second stage carrier.
it into pipe (24).
23. Install the second stage carrier (19) assembly
: 8 mm
onto the spline of shaft (26), while the concave
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
part of the boss in bottom side of the carrier
comes in contact with lock plate (16).
31. Supply gear oil: 16.3 L (4.31 US gal)
Concave 19 32. Apply new THREEBOND #1215 onto the motor

mounting surface of ring gear (22).
16
26
CAUTION: Motor weight: 71 kg (160 Ib)
33. Hoist motor (2) by crane. Align the matching
marks, and install it into ring gear (22) with socket
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W178-02-06-014
24. Install second stage sun gear (20) into the second
stage carrier (19) assembly.
25. Clean off old THREEBOND and apply new

THREE-BOND #1215 onto the ring gear (22)
mounting surface of in housing (31).
CAUTION: Ring gear weight: 34 kg (75 lb)

26. Install eyebolt (M12, pitch 1.75) to the motor
mounting threaded hole on ring gear (22). Hoist
the ring gear by crane, to install it on housing (31)
with socket bolts (32) (12 used) while aligning the
matching marks made when disassembling.
: 17 mm
: 390 N⋅m (40 kgf⋅m)
27. Install the first stage carrier (21) assembly onto

the spline of second stage sun gear (20).
W2-6-15
DISASSEMBLE SWING MOTOR

12
11
10
9
8
7
6 13
3
5
2 4
1 21
22 26
23 27
24 28
25
20
24
23
22
19 21
18 29
17
16 W1HH-02-06-005
15
14
1 - Casing 9 - Plate 17 - Spring (24 Used) 24 - Poppet (2 Used)

2 - Perking Brake 10 - Retainer 18 - Valve Plate 25 - Valve Casing
Release Valve
3 - Socket Bolt (3 Used) 11 - Rotor 19 - Bearing 26 - Socket Bolt (4 Used)
4 - Oil Seal 12 - Friction Plate (3 Used) 20 - O-Ring 27 - O-Ring
5 - Bearing 13 - Plate (4 Used) 21 - Plug (2 Used) 28 - Plug (2 Used)
6 - Shaft 14 - O-Ring 22 - O-Ring 29 - Relief Valve (2 Used)
7 - Shoe Plate 15 - O-Ring 23 - Spring (2 Used)
8 - Plunger (9 Used) 16 - Brake Piston
W2-6-16
Disassemble Swing Motor
• Be sure to thoroughly read “Precaution for 8. Remove O-rings (14, 15) from casing (1).
Disassembly and Assembly” (W1-1-1) carefully
before starting the disassembly work. IMPORTANT: Take care not to damage the slide
surface of rotor (11) and plunger (8).
CAUTION: Swing motor assembly weight: 9. Place casing (1) horizontally. Remove rotor (11),
70 kg (155 Ib) retainer (10), plate (9) and plungers (8) (9 used)
IMPORTANT: Don’t disassemble relief valve (29). from shaft (6).
1. Remove relief valves (29) (2 used) from valve
casing (25). 10. Remove plates (13) (4 used), friction plates (12)
: 41 mm (3 used) from casing (1).
2. Remove plugs (21) (2 used) from valve casing IMPORTANT: Take care not to damage the slide
(25). surface of shoe plate (7).
: 17 mm 11. Remove shoe plate (7) from casing (1).
3. Remove springs (23) (2 used) and poppets (24) IMPORTANT: When removing shaft (6), the spline
(2 used) from valve casing (25). damages the oil seal. Be sure to
wind the tape around the spline of
4. Loosen socket bolts (3) (3 used) and remove shaft (6) before removing.
parking brake release valve (2) from casing (1). 12. Tap shaft (6) with a plastic hammer lightly to
remove it from casing (1).
5. Make matching marks at the mounting surface
between valve casing (25) and casing (1). Then 13. Push out oil seal (4) from casing (1).
loosen socket bolts (26) (4 used). Remove valve
casing (25) from casing (1). 14. Remove the outer race of bearing (5) from casing
: 17 mm (1) with a bar and plastic hammer.
NOTE: Pay attention that valve casing (25) is 15. Remove the inner race of bearing (5) from shaft
floated by spring (17). Pay attention to (6) with a press.
valve plate (18) when removing valve
casing (25). It has a tendency to fall. 16. Remove bearing (19) from valve casing (25) with
IMPORTANT: Be sure not to damage the mating a bearing puller.
surface when separating valve plate
(18) from valve casing (25) or rotor
(11) with a screw driver.
6. If valve plate (18) is still attached with rotor (11) in

step 5, remove the valve plate from the rotor.
Remove springs (17) (24 used).
7. Attach the special tool (ST 7288) onto the brake

piston (16) groove and hoist brake piston (16).
26
ST 7288
16
W1HH-02-06-006
W2-6-17
ASSEMBLE SWING MOTOR
24
23
22
21
26
28
27
T1HH-03-02-003
25
29
17
16
15
19
14
20
18
12
3 13
2 8
10
11
7
9 5
4
6
T1HH-03-02-002
1 - Casing 9 - Plate 17 - Spring (24 Used) 24 - Poppet (2 Used)
2 - Perking Brake 10 - Retainer 18 - Valve Plate 25 - Valve Casing
Release Valve
3 - Socket Bolt (3 Used) 11 - Rotor 19 - Bearing 26 - Socket Bolt (4 Used)
4 - Oil Seal 12 - Friction Plate (3 Used) 20 - O-Ring 27 - O-Ring
5 - Bearing 13 - Plate (4 Used) 21 - Plug (2 Used) 28 - Plug (2 Used)
6 - Shaft 14 - O-Ring 22 - O-Ring 29 - Relief Valve (2 Used)
7 - Shoe Plate 15 - O-Ring 23 - Spring (2 Used)
8 - Plunger (9 Used) 16 - Brake Piston
W2-6-18
Assemble Swing Motor
11. Install brake piston (16) into casing (1).
IMPORTANT: Be sure to place the inner race NOTE: If it is not easy to install O-rings (14), (15)
flange of bearing (5) facing the into brake piston (16) due to the resistant
stepped side of shaft (6). force from the O-rings, tap them evenly with
1. Push the inner races of bearings (5), (19) into a plastic hammer to force them in.
shaft (6) with a press.
12. Install springs (17) (24 used) onto brake piston
IMPORTANT: Push oil seal (4) in, with its lip facing (16).
the bearing (5) mounting side.
2. Push oil seal (4) into casing (1) with a guide plate. IMPORTANT: Tap the bearing type indicated
surface with a plastic hammer while
3. Install the outer race of bearing (5) into casing (1) installing bearing (19).
with a guide bar. 13. Tap the outer race of bearing (19) with a plastic
hammer while installing it into valve casing (25).
IMPORTANT: Wind the tape on the spline at the
end of shaft (6) to prevent damaging 14. Install O-ring (20) onto valve casing (25). Then
oil seal (4). install valve plate (18).
4. Place casing (1) horizontally. Install shaft (6) into NOTE: Apply grease onto valve plate (18) to avoid
casing (1). it coming off from valve casing (25).
5. Place casing (1) with the valve casing (25) 15. Align the mating marks on valve casing (25) and
mounting side up. Then install shoe plate (7). casing (1). Secure them with socket bolts (26) (4
used).
6. Assemble plate (9) and retainer (10) with the : 17 mm
notch matched. Then install plungers (8) (9 used). : 431 N⋅m (44 kgf⋅m, 320 lbf⋅ft)
IMPORTANT: Apply hydraulic oil into the plunger 16. Install poppets (24) (2 used) and springs (23) ( 2
hole in rotor (11), then install plunger used) into valve casing (25). Tighten plug (21)
(8). with O-ring (22) attached.
7. Insert the plunger (8) assembly into rotor (11). : 17 mm
: 539 N⋅m (55 kgf⋅m, 400 lbf⋅ft)
8. Place casing (1) horizontally. Install the rotor (11)
assembly onto shaft (6). 17. Install relief valves (29) (2 used) into valve casing
(25).
IMPORTANT: 4 notches are on the outer side of : 41 mm
plate (13). And 4 notches are at the : 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
spline teeth side of friction plate (12).
Be sure to align each notch at the 18. Install parking brake release valve (2) into casing
same place when installing. (1) with socket bolts (3) (3 used).
9. Place casing (1) vertically. Alternately install plates : 5 mm
(13) (4 used), friction plates (12) (3 used) into : 12 N⋅m (1.2 kgf⋅m, 8.68 lbf⋅ft)
casing (1).
10. Install O-rings (14) and (15) onto casing (1).

NOTE: Apply grease to O-rings (14) and (15), and
they are not broken easily when installing
brake piston (16).
W2-6-19
DISASSEMBLE AND ASSEMBLE
PARKING BRAKE RELEASE VALVE
ʮʭ ʱ ʶ ʮʮ
ʰ
7
ʮʯ
ʳ
5 ʯ
ʮ ʮʰ
W110-02-06-005
1- Casing 5 - Bushing 8 - Orifice 11 - O-Ring (2 used)

2- Spool 6 - Filter 9 - Spring 12 - Steel Ball
3- Spring 7 - Spacer 10 - O-Ring 13 - Bolt (3 used)
4- Plunger
W2-6-20
Swing Motor
d
1. Clearance between the out diameter of plunger
and the inner bore of cylinder.
D-d Unit:m (in)

0.028 (0.001) 0.058 (0.002) W107-02-06-138
D D
W107-02-06-139
2. Clearance between plunger and shoe at the

caulked position.
δ Unit: mm (in)
0 (0) 0.3 mm (0.0118)
δ
W107-02-06-140
W107-02-06-141
W2-6-21
3. Thickness of shoe
t Unit: mm (in)
5.5 (0.22) 5.3 (0.21)
4. Thickness of friction plate. W107-02-06-142

t Unit: mm (in)
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-22
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE

jury. Avoid the hazard by relieving pressure
pressure.
Preparation

M104-07-021
pressure.
Removal
1. Remove seat mounting bolts (2) (4 used) to re-
move seat (1) (with seat stand).
: 17 mm
W178-02-07-006
W2-7-1
2. Remove screws (24) (4 used), cover (23) to move
boot (29) up.
: 17 mm 30
3
3. Remove caps (17) (2 used) from cover (18). 29
4
28
4. Remove screws (21)(4 used) and (16) (2 used) to 27 5
move cover (18) up. Disconnect each harness 26 6
connectors for key switch (20), air controller (19) 25 7
and grip (3), then remove cover (18). Remove 8
screws (22), (15) and (13) to remove cover (14). 9
24 10
11
23 12
5. Remove the connector and bolt (11) for switch box
(12) to remove switch box (12). 21
20
: 13 mm
19
22
18
IMPORTANT: Attach identification tags on all
disconnected hoses to aid in reas-
sembly. 17
6. Disconnect hoses (31 to 36). 16

: 19 mm
15
NOTE: Attach a cap on all disconnected hose
ends. 14
7. Loosen nut (4) to remove grips (5) and (26). Dis- 13

connect connector (6) to remove grip (3) (with W178-02-07-001
harness).
Loosen nut (28) to remove lever (30), washers
(25), (26) and boot (29).
: 22 mm 31
36
: 19 mm 35 32
33
8. Remove bolts (9) (3 used) and (8) (with pin (7))
from pilot valve (10) to remove pilot valve (10). 34
: 13 mm
W178-02-07-002
31 - Hose T6: (To the pilot shut-off valve)

32 - Hose B: (To the shockless valve port B for boom lower)
33 - Hose G: (To shockless valve port G for bucket roll-in)
34 - Hose P3: (From the pilot shut-off valve)
35 - Hose A: (To the shockless valve port A for boom raise)
36 - Hose H: (To the shockless valve port H for bucket roll-out)
NOTE: Piping location shows that of JIS pattern.
W2-7-2
Installation
1. Secure pilot valve (10) with bolts (9) and (8) (with
pin (7)).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 31
36
35 32
2. Connect hoses (31 to 36).
: 19 mm 33
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 34
IMPORTANT: If the harness is arranged to the inside

of spring pin (7), it may make contact
with the moving part of the pilot
valve which may damage the harness .
Be sure to arrange the harness to
W178-02-07-002
the outside of spring pin (7).
30
3. Temporarily tighten nut (28) to lever (30), then in-
stall washers (25), (26). Install lever (30) onto 3
29
valve (10) with nut (28). Install boot (29).
4
Temporarily tighten nut (4) to lever (30), then in- 28
stall grip (3) with nut (4). 27 5
Pass the harness of grip (3) through the upper
26 6
hole of boot (29), then connect it to lever (30) via
25 7
clips (5) and (27). Arrange the harness to the out- 8
side of spring pin (7) over bolt (8) head. 9
Install connector (6). 24 10
11
: 22 mm 23 12
: 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 21
: 19 mm 20
: 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 19
22
18
4. Install switch box (12) with bolt (11), then connect
the connector.
: 13 mm 17
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
16
5. Connect each harness of key switch (20) and air
controller (19).
15
6. Install cover (14) with screws (22), (15) and (13). 14
Install cover (18) with screws (21) (4 used) and
(16) (2 used). 13
Install caps (17) (2 used) onto cover (18).
W178-02-07-001
7. Install cover (23) with screw (24).
W2-7-3
8. Install seat (1) (with the seat stand) with bolts
(2) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
IMPORTANT: After installation, check the oil level,

start the engine and check for oil
leaks.
2
W178-02-07-006
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE

before disconnecting hydraulic or other
lines.
ing pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
2. Stop the engine. Push the air release valve on the

M104-07-021
hydraulic oil tank to release any pressure remain-
ing in the hydraulic tank.
Removal
1. The console is at the most front position. Remove
screws (2) (4 used) and cover (3) to move boot (1)
up. 1
: 17 mm
2. Remove screws (7), (8) to remove cover (9).
3. Remove cap (10) from cover (6). 10

2
9 Radio
4. Remove screws (4) (3 used), (5) to move cover 3
(6) up to disconnect the radio connector, then re- 8
4
move cover (6).
7
6
5
W178-02-07-003
W2-7-5
sembly.
5. Disconnect hoses (11 to 16).

: 19 mm 11
16
15 12
NOTE: Attach a cap on each disconnected hose 13
end.
14
6. Loosen nut (18) to remove clips (29), (21).
Disconnect connector (28) to remove grip (17)
(with harness).
Loosen nut (20) to remove lever (19), washers
(25), (26) and boot (1).
: 22 mm
: 19 mm
W178-02-07-004
11 - Hose T5 : (To the pilot shut-off valve)
7. Remove bolts (24) and (23) (with pin (22)) to 12 - Hose F : (To the shockless valve port F for swing right)
13 - Hose C : (To the shockless valve port C for arm roll-out)
remove pilot valve (27). 14 - Hose P2 : (From the pilot shut-off valve)
: 13 mm 15 - Hose E : (To the shockless valve port for E swing left)
16 - Hose D : (To the shockless valve port D for arm roll-in)
NOTE: Piping location shows that of JIS pattern.

Installation
17
1. Install pilot valve (27) with bolts (24) and (23) (with
pin (22)).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 29
18
2. Connect hoses (11 to 16). 19
: 19 mm 28
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 1
20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6
IMPORTANT: If the harness is arranged to the in-
side of spring pin (21), it may make
contact with the moving part of the
pilot valve which may damage the 17
harness. Be sure to arrange harness
to the outside of spring pin (21).
29
3. Temporarily tighten nut (20) to lever (19), then
18
install washers (25) and (26). Install lever (19)
onto pilot valve (27) with nut (20). Install boot (1). 19
28
Temporarily tighten nut (18) to lever (19), then se-
1
cure grip (17) with nut (18). 20
Pass the harness of grip (17) through the upper 21
hole of boot (1), then connect it to lever (19) via 22
grips (29). Arrange the harness to the outside of 23
spring pin (22) over bolt (23) head. Connect con- 24
nector (28). 8 9 10 25
: 13 mm 26
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft) 27
: 22 mm
: 26 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft) 2
: 19 mm 3
: 26 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
4
5
4. Connect the connector of the radio and install
cover (6) with screws (4) (4 used) and (5), install
cap (10).
Install cover (9) with screws (7), (8).
7 6 W178-02-07-003
5. Install boot (1) and cover (3) with screw (2) (4 used).
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
W2-7-7
REMOVE AND INSTALL TRAVEL PILOT
VALVE

lines.
ing pressure.
Preparation

M104-07-021
W2-7-8
Removal
1. Remove floor mat (1).
2. Remove bolts (3) (6 used) from swing frame to

remove under cover (2). 1
: 17 mm
3. Loosen bolts (4) (2 used) to remove pedals (5) (2

used), levers (16) and (17).
: 17 mm
WIHH-02-07-001

sembly.
4. Disconnect pipes (6, 7) and hoses (8 to 11).

2
: 19 mm
3
NOTE: Attach a cap on each disconnected hose

WIHH-02-07-002
end.
5. Remove socket bolt (14), spring washer (13) and

plain washer (12) to remove pilot valve (15).
: 8 mm 17
4
16
Installation 5
1. Install pilot valve (15) with socket bolt (14), spring
washer (13) and plain washer (12).
: 8 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 4
2. Connect pipes (6, 7), hoses (8 to 11). 5

: 19 mm 15
14
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) 14
13
13
3. Install pedal (5), levers (16) and (17) with bolts (4). 12
: 17 mm 12 6
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 7
4. Install under cover (2) with bolts (3) (6 used).

: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 11
10
9
5. Install floor mat (1). 8

Start the engine and check for oil
W178-02-07-005
leaks. 6 - Pipe T4: (To the pilot shut-off valve)
7 - Pipe P1: (From the pilot shut-off valve)
8 - Hose 11: (To the control valve port RF for travel right
and forward)
9 - Hose 12: (To the control valve port RR for travel right
and reverse)
10 - Hose 10: (To the control valve port LR for travel left
and reverse)
11 - Hose 9: (To the control valve port LF for travel left
and forward)
W2-7-9
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-10
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage, them. port number after removing.
Therefore, be careful while handling
them.
4. Pull push rods (8), (9) out from block (10).
IMPORTANT: As spool (17) has been selected to
5. With a bamboo spatula, remove oil seals (15) (4
match the hole of housing (18), they
used) from block (10).
must be replaced as a set. In addi-
tion, the dimensions of balance
springs A (3), B (4) and return NOTE: If a metal bar is used, the mating part of the
springs A (5), B (6) as well as those oil seal may be damaged.
of push rods A (8), B (9) are different.
For this reason, be sure to indicate IMPORTANT: The retaining ring may come off
the port number from which it is re- while disassembling. Take care not
moved. Port numbers are stamped to drop it.
on housing (18).
6. Press springs with special tool (ST 7257) from the
IMPORTANT: Don’t clamp housing (18) in a vise to top of spring guide (16). Retaining ring (7) will ap-
remove the screw joint because the pear. Remove it with a screw driver or similar tool.
strong torque may act on the screw (4 places)
joint. 7
1. Secure screw joint (13) in a vise. Then turn cam

(12) with a spanner to remove the screw joint.
: 32 mm
2. Clamp the flat surface of housing (18) in a vise

slightly. Remove cam (12) from universal joint 16
(14). ST 7257
: 32 mm
NOTE: The universal joint has been secured on

block (10) with LOCTITE. Don’t remove it
unless necessary. W176-02-07-005
3. Remove socket bolt (11) to remove block (10). At

this time, push rods (8) and (9) are still on the IMPORTANT: The number of shims has been de-
block side. termined for each port during the
: 6 mm performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when reassem-
bly.
7. Remove spring guide (16), balance springs (3),

(4), return springs (5), (6), shim (2), spacer (1)
from spool (17).
W2-7-11
21
20
21
20
19
18
17
W176-02-07-001
W2-7-12
IMPORTANT: As the spool has been selected to
match the hole in the housing, keep
them carefully so as to install them
to the former port when reassem-
bling.
8. Remove spool (17) from housing (18). Pulling it

out while turning it.
NOTE: The spool and housing must be replaced as

assembly.
9. Remove O-rings (19), (21) from housing (18).

Don’t remove dowel pin (20) unless necessary.
W2-7-13
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
13 14
10
12
15
11
8, 9
7
16
3, 4
5, 6
19
17
W176-02-07-006
21 20 18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-14
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to IIMPORTANT: Install spring guide with the protru-
contamination. sion facing up.
Keep parts clean when assembling.
3. Install spring guide (16) onto the return spring (3)
NOTE: Table below shows the relations between or (4).
each port and the components. Take care
not to confuse them when assembling. 4. Install retaining ring (7) onto ring holder (ST
7255).
Port Spool Shim Push Rods ST 7255
No. 7
(17) (2) (8), (9)
With outer
1
Same to Same to groove
the former the former Without outer
2 W176-02-07-008
one one groove
With outer 5. Insert the spool (17) head into the hole for spring
3
groove special tool (ST 7257) to press the spring from the
Without outer top of spring guide (16). Install retaining ring (7)
4
groove with the ring holder (ST 7255) onto the head of the
spool.
Port Return Springs Balance Springs
ST 7257 ST 7255
No. (5), (6) (3), (4)
1 Short Short
2 Long Long 17
3 Short Short
4 Long Long
Packing Material
IMPORTANT: Make sure of the port hole number,

and insert the spool to the former W176-02-07-009
port. NOTE: Put approx. dia.8 mm, length 10 mm of
packing material into the port hole so as to
1. Insert the thinner end of spool (17) to housing (18), not only make the work easy to do, but also
while rotating it. prevent the spool from lowering to the bot-
tom when compressing the spring.
NOTE: The spool has been selected to match the
hole of the housing. The spool and housing 6. Assemble the remained spools (17) (3 used) into
must be replaced as an assembly. housing (18) in the same procedures as step 2 to
5.
IMPORTANT: Refer to the table above to assemble
them correctly. 7. Install O-rings (19) and (21) (2 used) on to hous-
ing (18).
2. Install spacer (1), shim (2), balance spring (3) or

(4), return spring (5) or (6) onto spool (17) in-
stalled in housing (18).
W2-7-15
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-16
8. Apply grease to the inner face of oil seals (15) IMPORTANT: Make sure of the tightness of cam.
(4 used), then install the oil seals (4 used) into
block (10) with a bamboo spatula. 13. Clamp housing (18) carefully in a vise and then
install cam (12) to universal joint (14).
NOTE: The oil seal may come into the endmost of Tighten the universal joint so that the clearance
the hole during operating. Insert push rods between the cam and push rod (8) (9) become 0
(8 and 9) in first as illustrated to prevent the to 0.2 mm.
oil seal from coming into the endmost of the : 32 mm
hole during operating.
Oil Seal IMPORTANT: Don’t clamp housing (18) in a vise
Mounting Hole
because the strong torque may act
8,9 on the screw joint.
10
14. Clamp screw joint (13) in a vise to tighten univer-
sal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 88.2 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods (8), (9) to block (10). When in-

stalling, install the push rods with periphery
groove to ports # 1 and # 3, install the ones with-
out periphery groove to ports # 2 and # 4, respec-
tively.
10. Apply grease to the ball at the ends of push rods

(8), (9).
11. Apply grease to the joint part of universal joint

(14).
12. Align the position of dowel pin (20), install the

block (10) assembly to housing (18) with socket
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
W2-7-17
DISASSEMBLE TRAVEL PILOT VALVE
35 2
34
33
32
31
30
3
4
5
6
29
28 7
27
8
9
10
26
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-18
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolt (1) to 7. Remove spring (18) from casing (14). (4 places)
remove cover (2) from holder (10).
: 10 mm IMPORTANT: Put a stand under bracket (26) to
form an action force. If holder (10)
2. Remove socket bolts (8) (2 places) to remove bears the reaction force, a strong
holder (10) from casing (14). force acts on pin (3) and the pin′′s
: 8 mm shape become deformed.
3. Pull out pusher (23) from casing (14). (4 places) IMPORTANT: The inside of spring pins (24), (25)
Bushing (13) and oil seal (11) are removed with hole in the bracket is in stepped-
the pusher. shape. Therefore the spring pin can
only be pulled out in one direction.
4. Pull out pusher (23) from bushing (13), with a
bamboo spatula to remove oil seal (11). (4 places)
8. Put a stand under bracket (26).
IMPORTANT: Put marks on spools (4 used) so as Push out both spring pins (24), (25) from bracket
to easily install them to their former (26) at the same time with special tool (ST 1237).
position. Remove the bracket from pin (3). (2 places)
Don’t remove spring pin (27) on bracket unless
necessary.
5. Pull out the spool (17) assembly from casing (14)
turning the spool. (4 places)
NOTE: The outside end of the spring pin has been
Spring guide (22), balance spring (21), shim (20)
caulked.
and spacer (19) are removed with the spool.
NOTE: The spool has been selected to match the 24,25

hole of the casing. The spool and casing
must be replaced as an assembly. 26
3 27
IMPORTANT: The number of shims has been
Caulked
determined during the performance
testing at the factory. They must be
kept together with their spool. Stand
6. Compress balance spring (21). Remove spring

guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17). (4 places) W176-02-07-019
9. Remove socket bolts (28) (2 used) to remove

damper (6) and rubber seat (7) from pin (3). O-
ring (4) is removed with them. (2 places)
: 5 mm
W2-7-19
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-20
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mating sur-
face facing up.
IMPORTANT: The holes for spring pins (34), (35) in

cam (32) are stepped-shape. There-
fore the pins shall be removed from
the bottom of the cam.
12. Pull out spring both pins (34), (35) from cam (32)
at the same time with special puller (ST 1237).
(2 places)
NOTE: The spring pin is a double-pin.
NOTE: The spring pin is caulked in its hole, so it

may feel tight when removing.
13. Remove pin (3) with a round bar and a hammer.

At this time cam (32) is also removed. (2 places)
NOTE: Don’t remove bushings (31) (4 used) left on

holder (10) unless necessary. When re-
moval is necessary, the bushing special
tool (ST 7256) should be used to tap it out.
14. Remove lock nuts (33) (2 used) from cam (32) to

remove adjusting bolts (30) (2 used). (2 places)
: 13 mm
: 4 mm
W2-7-21
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12 18
23
20
19
17
14
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-22
Assemble Travel Pilot Valve
IMPORTANT: Pay attention to the mounting direc- 6. If bushing (31) has been removed from holder
tion of spring guide (22). (10), it shall be installed on the holder using spe-
cial tool (ST 7256) in the following procedures.
IMPORTANT: Install the former number of shims.
NOTE: The bushings (4 used) are identical.
1. Assemble the spool (17) into assembly. (4 used)
y Insert spacer (19), shim (20), balance spring y Insert the bushing into special tool (ST 7256),
(21) into the spool in order. then tap on the special tool (ST 7256) to install
y Press balance spring by hand. Install spring the bushing into the hole of holder with
guide (22) to the spool with the stepped-end hammer.
facing down. Stop tapping when the bushing end is flush
with the inside wall .
10 ST 7256
2. Insert spring (18) to casing (14). (4 places)
IMPORTANT: Insert the spool (17) assembly into

the former port. 31
W176-02-07-016
3. Turn and install the spool (17) assembly into cas- y Install the bushing on the opposite side in the
ing (14). (4 places) same procedure.
31
10
4. Assemble plungers (23) (4 used). ST 7256
y Install oil seal (11) onto bushing (13).
y Apply grease to the inner face of oil seal.
y Install O-ring (12) to the bushing.
y Insert pusher (23) to the bushing.
y Apply grease to the pusher head section.
W176-02-07-015
5. Insert the pusher (23) assembly to holder (10). (4 y Install the bushing in near side as shown
places). bellow. Stop tapping when the bushing end is
flush with the outside of holder.
31
10 ST 7256
Outside of
Holder
W176-02-07-014
y Install the bushing on the opposite side as

shown below. 31
10
ST 7256
W176-02-07-013
W2-7-23
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-24
7. Place adjusting bolt (30) to cam (32). Tighten the IMPORTANT: Don’t adjust the adjusting bolt (30)
bolt by hand, and then lightly secure it temporarily while pressing the pusher (23) head
with lock nut (33). (2 places) with the adjusting bolt. The standard
clearance between the adjusting bolt
NOTE: Adjust the dimensions later. and pusher must be 0 to 0.2 mm (0 to
0.008 in).
8. Apply grease on the head (mating surface for
pusher (23)) of adjusting bolts (30). (2 places) 13. Adjust adjusting bolt (30) by the following proce-
Ȁ dures. (2 places)
9. Install O-ring (5) to pin (3), then assemble the pin : 13 mm
to holder (10) with cam (32). (2 places) : 4 mm
y Loosen lock nut (33).
IMPORTANT: Take care of the inserting direction y Move cam (32) to check whether there is play. If
of the spring pin. none, turn adjusting bolt to adjust.
y Turn both adjusting bolts on the left and right
IMPORTANT: Tap the spring pin in until it makes alternatively to keep the cam horizontal.
contact with the step in hole. y Measure sizes A and B from both left and right
caves on the cam to holder (10). Fine adjust the
adjusting bolt to get same distance for both left
10. Install spring pins (34), (35) to cam (32) using
and right.
special tool (ST 1237), then secure the cam and
y Secure the adjusting bolt with a hexagon-
pin (3). The spring pins should be displaced with
headed wrench. Tighten the lock nut to
their slits at 90°. (2 places)
specified torque first, securing the adjusting
34 35 Slit Slit bolt.
y When adjustment is finished, move cam to
check that there is a little play. If there is no play,
the pusher may be in compressed condition,
and adjustment should be carried out again.
: 9.8 N]m(1 kgf]m, 7.2 Ibf⋅ft)
30 33 32 10
W176-02-07-017
11. Caulk the hole edge of cam (32), where spring A B

pins (34), (35) are inserted, with a punch. (2
places)
12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used), spring
washers (9) (2 used).
: 8 mm
: 49 N]m (5 kgf]m, 36 Ibf⋅ft)
W176-02-07-003
W2-7-25
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-26
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under the bracket. If
holder (10) bears the reaction force,
a strong force acts on the pin (3) and
15. Apply grease to O-ring (5). (2 places) the pin may be deformed.
IMPORTANT: The inside of the spring pin hole in

IMPORTANT: Pay attention to the direction of the bracket is stepped-shape. Make
damper (6). sure of the direction to insert the
spring pin.
IMPORTANT: The inner bore of damper (6) is
edged-shape. If the damper is pried IMPORTANT: Make sure the facing direction of the
upward, O-ring (5) will be damaged. spring pin.
16. With the lever upward, install damper (6) to pin (3) 20. Put a stand under bracket (26).
straight without spring. (2 places) Tap spring pins (24) (25) into the bracket until the
spring pin comes to the stepped end using special
tool (ST 1237). The spring pins shall be displaced
17. Secure damper (6) to holder (10) with socket bolts with their slits in 90°.
(28) (2 used) and spring washers (29) (2 used). (2
places)
: 8 mm
: 7 N⋅m (0.7kgf⋅m, 5.1 Ibf⋅ft)
Caulked Here Caulked Here

18. Apply grease to O-ring (4), then press it to the
endmost of pin (3). (2 places) 26 3
IMPORTANT: As for the direction to install the

bracket, refer to the figure in the dis- Stand 24, 25
assemble section. Take care not to
misassemble it.
W176-02-07-011
19. Install pin (3) into bracket (26), then align the in-
serting holes of spring pin (24), (25) to fix the pin
on bracket.
21. Caulk the hole edge of bracket (26), where spring
pins (24), (25) are inserted, with a punch. (2
places)
(Refer to the figure above.)
22. Install pin (3) on other bracket (26) as steps 19 to

21.
23. Install cover (2) to holder (10) with bolts (1) (2 used).
: 10 mm
: 5 N]m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
24. Apply grease to the spring pin (27) contact part of

damper (6). (2 places)
W2-7-27
(Blank)
W2-7-28
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

ing pressure.
Preparation

pressure.
Ȁ
lic oil tank.
NOTE: Be sure to run the vacuum pump continu- M104-07-021

tem.
W2-8-1
Removal
1. Remove spring (3).
IMPORTANT: Attach tags to hoses to aid in as-

sembly.
1
2. Disconnect hoses (6 to 13) and pipes (14, 15).
: 19 mm
3. Remove spring pin (5) to remove lever (1). 2

3
4. Remove bolt (2) to remove pilot shut-off valve (4). 5
: 17 mm
4
Installation
1. Install pilot shut-off valve (4) with bolt (2).
2. Install lever (1) with spring pin (5). W178-02-08-001
3. Connect hoses (6 to 13) and pipes (14, 15). 2
4. Install spring (3).

View A
Wrench Size Tightening Torque

Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft) 6
: 17 49 (5) (36) Bolt 10
: 19 35 (3.6) (26) Pipe
: 19 29.5 (3) (21.5) Hose
6- Hose DP: (To the solenoid valve unit (hydraulic oil tank)
7- Hose PF: (To the solenoid valve unit)
8- Hose: (To the shockless valve) 7
9- Hose PD: (To the pilot filter)
10 - Hose T6: (To the right pilot valve) 8
9
11 - Hose P2: (To the left pilot valve)
12 - Hose T5: (To the left pilot valve)
13 - Hose P3: (To the right pilot valve) WIHH-02-08-001
14 - Hose P1: (To the travel pilot valve)
15 - Hose T4: (To the travel pilot valve)
14 13
View A
WIHH-02-08-002
15 12 11
W2-8-2
(Blank)
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
3
6
2 7
1
8
9
13 10
11
12
W178-02-08-005
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-4
Disassemble Pilot Shut-Off Valve
• Be sure to thoroughly read all Precautions for
Disassembly / Assembly work on page W1-1-1
1. Make matching marks on body (4) and bracket

(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove spool (10) assembly.
2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).
3. Clamp the spool (10) with wooden pieces in a vise.

Remove socket bolt (13) and bracket (11).
: 4 mm
NOTE: Don’t remove pin (12) unless necessary.
4. Remove socket bolt (5) from body (4).

: 8 mm
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE

12 13 11 4 5 Z
Section ZҥZ W178-02-08-006
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-6
Assemble Pilot Shut-Off Valve
1. Apply LOCTITE # 262 on socket bolt (5) and in-

stall it to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
2. Clamp spool (10) with wooden pieces in a vise.

Apply LOCTITE #262 on socket bolt (13), then in-
stall bracket (11) onto spool (10).
: 4 mm
: 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft)
3. Install O-ring (3), backup ring (2) and washer (1)

onto body (4).
4. Apply hydraulic oil to spool (10) and install it to

body (4).
5. Install O-ring (9), backup ring (8) and washer (7)

to body (4), and install retaining ring (6) to spool
(10).
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL SHOCKLESS
VALVE

can penetrate the skin, causing serious
injury.
Avoid this hazard by relieving pressure

The hydraulic oil tank cap may fly off if

removed without releasing internal pressure
pressure.
Preparation

of the hydraulic oil tank to release any remaining M104-07-021
pressure.

pump to maintain negative pressure in the
hydraulic oil tank.
NOTE: Be sure to run the vacuum pump

continuously while working on the hydraulic
system.
W2-9-1
Removal
14 15 16 17 18 19
IMPORTANT: Attach identication tags to all disco-
nnected hoses to aid in assembly.
13 20
1. Disconnect hoses (1 to 9, 13 to 20).

: 19, 22 mm 9
2. Remove pressure sensors (11), (12) and (21). 12 21

: 24 mm
11
3. Remove bolts (10) to remove the shockless valve.
: 17 mm
Installation 1
10
1. Apply LOCTITE to bolts (10), then install
shockless valve with bolts (10).
8B 7 8A 6 5 4 3 2
2. Install pressure switch (11) and pressure sensor
(12) (21). W173-02-09-001
3. Connect hoses (1 to 9, 13 to 20). 1 - Hose (To right swing control valve)

2 - Hose (To left swing control valve)
3 - Hose (To bucket roll-in control valve)
Wrench Size Tightening Torque Remark 4 - Hose (To bucket roll-out control valve)
(mm) N⋅m (kgf⋅m) (lbf⋅ft) 5 - Hose (To boom lower control valve)
: 17 20 (2) (14.5) Bolt 6 - Hose (To boom raise control valve)
7 - Hose (To arm roll-in control valve)
: 19 29.5 (3) (21.5) Hose 8 A - Hose (To arm roll-out control valve)
: 22 39 (4) (29) Hose 8 B - Hose (To arm roll-out control valve)
Pressure 9 - Hose (From pilot shut-off valve)
: 24 79 (8) (58) 10 - Bolt
Sensor
11 - Pressure Sensor (For boom raise)
12 - Pressure Sensor (For arm roll-in)
13 - Hose (From arm roll-in pilot valve)
14 - Hose (From arm roll-out pilot valve)
15 - Hose (From boom lower pilot valve)
16 - Hose (From boom raise pilot valve)
17 - Hose (From bucket roll-in pilot valve)
18 - Hose (From bucket roll-out pilot valve)
19 - Hose (From right swing pilot valve)
20 - Hose (From left swing pilot valve)
21 - Pressure Sensor (For swing)
W2-9-2
(Blank)
W2-9-3
DISASSEMBLE AND ASSEMBLE
SHOCKLESS VALVE
18 17
16 D B G F
14
15
C A
H E
Section S Section T
14
1 2 2
15
1
S4 S2 S7
7
S3 S1
6 5 4 3 Y W U
Section U 14 Section V X V T S
15
Z
3 1 8 5
7
A4
6 Z
4 2 7 6
5
3 4
Section W
2 9 12,13 11 10 9 2
8 Section Z-Z
19
1
14
15 7
WIHH-02-09-001
5
7 6 5 4 3 3 4
Section X Section Y
W2-9-4
WRENCH SIZE TORQUE SPECIFICATION

ITEM PART NAME QTY REMARK
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 3 ϖ8 49 (5) (36.2)
2 O-Ring 4
3 Steel Ball 4
4 Steel Ball 4
5 Spring 4
6 O-Ring 4
7 Plug 4 ϖ5 14.7 (1.5) (10.8)
8 Orifice 1 ϖ5 14.7 (1.5) (10.8)
9 Orifice 2
10 Ring 1
11 Orifice 1
12 Plunger 1
13 Plunger Assembly 1
14 O-Ring 4
15 Plug 4 ϖ6 24.5 (2.5) (18.1)
16 Body 1
17 Seat 1 ϖ5 9.8 (1.0) (7.2) Use LOCTITE #262
18 Steel Ball 1
19 Plug 1 ϖ8 49 (5) (36.2)
W2-9-5
(Blank)
W2-9-6
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE

UNIT
CAUTION: Escaping fluid under pressure may

penetrate the skin, causing serious injury.
ing pressure.
Preparation

pressure.
Ȁ
lic oil tank.
M104-07-021

tem.
W2-10-1
2
Removal
1. Disconnect each harnesses of solenoid valves
from connectors.
3
2. Disconnect pilot lines (1 to 6, 11 to 18, 20 to 23,
25 and 27). 4
: 17, 19, 27 mm
5
10
3. Remove bolts (7) (19) to remove solenoid valve 1
unit.
7
: 6, 8 mm
8 9 6
A
15 14
View A 16 13
12
17 11
Installation
1. Install solenoid valve unit with bolts (7) (19).
WIHH-02-10-001
2. Connect pilot lines (1 to 6, 11 to 18, 20 to 23, 25 20

and 27). 23
18
21
3. Connect all wire harnesses for solenoid valves to
connectors.
19
22
Wrench Size Tight Torque 24
Remark 25
(mm) N⋅m (kgf⋅m) (Ibf⋅ft)
: 17 24.5 (2.5) (18) Pipe, Hose
: 19 29 (3) (22) Hose
: 27 93 (9.5) (43) Hose 26
:6 20 (2) (16) Bolt
:8 20 (2) (16) Bolt
27
WIHH-02-10-002
1 - Pipe PF: From Pilot shut- 8 - Proportional solenoid valve 15 - Pipe PH: To pump control 22 - Hose PI: To control valve
off valve (SG) valve
(5-spool section)
2 - Pipe SC: To arm 9 - Proportional solenoid valve 16 - Hose PG: To swing 23 - Hose TA: To hydraulic oil
regenerative (SI) parking brake tank
valve control valve
3 - Pipe SG: To main 10 - Proportional solenoid valve 17 - Hose DG: From arm 24 - Torque control solenoid
relief valve (SC) anti-drift valve valve
4 - Hose SI: To 11 - Pipe DD: From arm 18 - Hose ST: To main pump 1 25 - Hose DI: To hydraulic oil
travel motor regenerative tank
valve
5 - Hose DS: To hydraulic oil 12 - Pipe PE: To pump 19 - Socket bolt 26 - Maximum pump 2 flow rate
tank control valve limit solenoid valve
(4-spool section)
6 - Hose DP: From pilot shut- 13 - Pipe DE: From bucket 20 - Hose SB: To main pump 2 27 - Hose SP: To pump control
off valve flow rate control valve
valve switch (5-spool sec-
valve B tion)
7 - Socket bolt 14 - Pipe DH: From bucket 21 - Hose PD: To pilot shut-off
flow rate control valve
valve switch
valve A
W2-10-2
(Blank)
W2-10-3
DISASSEMBLE PROPORTIONAL
SOLENOID VALVES (SC, SI and SG)
1
3
2
4
5
6
7
8
9
10
11 14
12 15
13
16
17
18
19
WIHH-02-10-005
1- Socket Bolt (2 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 19 - Washer
5- Spring 10 - Spool 15 - O-Ring
W2-10-4
Disassemble Proportional Solenoid Valves
• Be sure to thoroughly read “Precaution for Disas-
sembly and Assembly” (W1-1-1) carefully before
starting the disassembly work.
IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Don’t turn lock nut (2) and adjusting
screw (4).
1. Loosen socket bolts (1) (2 used) to remove sole-
noid (6).
: 3 mm
IMPORTANT: Be sure not to remove orifice (11)

from spool (10).
2. Pull out spool (10) and remove diaphragm (9),
washer (12) and spring (13).
3. Pull sleeve (17) out and remove O-rings (14), (15)

(16), plate (18) and washer (19).
W2-10-5
ASSEMBLE PROPORTIONAL SOLENOID

VALVES (SC, SI and SG)
4 2 6 1 8 17 14 15 10 16 11 19
3, 5 9 7 12 13 18
W157-02-11-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
5- Spring 10 - Spool 15 - O-Ring
W2-10-6
Assemble Proportional Solenoid Valves
IMPORTANT: Apply grease to O-rings (14), (15),

(16) and apply a film of hydraulic oil 17
to sleeve (17). 16
15
Install sleeve (17) so that the end 14
faces of sleeve and body come to
the same point.
1. Install washer (19), plate (18) into the housing. In-

stall O-rings (14), (15) and (16) on sleeve (17), Housing
then insert it into the housing.
IMPORTANT: Apply a film of hydraulic oil to spool W157-02-11-005

(10). Take care not to damage the
edge portion in the bore of sleeve
(17) when inserting the spool (10) 10
assembly.
After inserting spool, check that 9
spool (10) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic
oil to the spool. 17
13
2. Install diaphragm (9), washer (12), spring (13) to
spool (10) and install it in to sleeve (17). 12 Housing
11
WIHH-02-10-006
NOTE: Orifice (11) is installed into spool (10).
10
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3), are not sepa-
rated, so no need to assemble them. W157-02-11-010
When assembling solenoid (6), take 6

care not to drop spring (7).
NOTE: As for O-ring (3) and spring (5), refer to
W2-10-4
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
7
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W157-02-11-011
W2-10-7
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVES
(TORQUE CONTROL SOLENOID VALVE,
MAXIMUM PUMP 2 FLOW RATE LIMIT SO-
LENOID VALVE)
1
12
13
14
2
4
5
7
8
9
10
11
15
16
17
18 WIHH-02-10-003
19
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - Spool

2- Lock Nut 7- Spring 12 - O-Ring 17 - Orifice
3- O-Ring 8- O-Ring 13 - O-Ring 18 - Plate
5- Spring 10 - Retaining Ring 15 - Sleeve
W2-10-8
Disassemble Proportional Solenoid Valves
• Be sure to thoroughly read “Precaution for Disas-
starting the disassembly work.
IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Don’t turn lock nut (2) and adjusting
screw (4).
1. Loosen socket bolts (1) (2 used) to remove sole-
noid (6).
: 3 mm
IMPORTANT: Be sure not to remove orifice (17)

from spool (16).
2. Pull out spool (16) and remove diaphragm (9), re-
taining ring (10) and spring (11).
3. Pull sleeve (15) out and remove O-rings (12), (13)

and (14), plate (18) and washer (19).
W2-10-9
ASSEMBLE PROPORTIONAL SOLENOID
VALVES
(TORQUE CONTROL SOLENOID VALVE)
(MAXIMUM PUMP 2 FLOW RATE LIMIT
SOLENOID VALVE)
4 2 6 8 15 12 13 16 14 17 19
18
WIHH-02-10-007
3, 5 7 1 9 10 11
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - Spool

2- Lock Nut 7- Spring 12 - O-Ring 17 - Orifice
3- O-Ring 8- O-Ring 13 - O-Ring 18 - Plate
5- Spring 10 - Retaining Ring 15 - Sleeve
W2-10-10
Assemble Proportional Solenoid Valves
IMPORTANT: Apply grease to O-rings (12), (13),

(14) and apply a film of hydraulic oil 15
to sleeve (15). 14
13
Install sleeve (15) so that the end 12
faces of sleeve and body come to
the same point.
1. Install washer (19), plate (18) into the housing. In-

stall O-rings (12), (13) and (14) on sleeve (15), Housing
then insert it into the housing.
IMPORTANT: Apply a film of hydraulic oil to spool W157-02-11-005

(10). Take care not to damage the
edge portion in the bore of sleeve
(15) when inserting the spool (16) 16
assembly.
After inserting spool, check that 9
spool (16) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic
oil to the spool. 15
11
2. Install diaphragm (9), retaining ring (10), spring
(11) to spool (16) and install it into sleeve (15). 10 Housing
17
WIHH-02-10-006
NOTE: Orifice (17) is installed into spool (16).
16
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3), are not sepa-
rated, so no need to assemble them. W157-02-11-010
When assembling solenoid (6), take 6

care not to drop spring (7).
NOTE: As for O-ring (3) and spring (5), refer to
W2-10-8
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
7
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W157-02-11-011
W2-10-11
DISASSEMBLE AND ASSEMBLE PILOT
RELIEF VALVE
1
2
3
4
5
6
7
WIHH-02-10-004
1 - Plug 3 - Spring 5 - Poppet 7 - Gasket

2 - Shim 4 - O-Ring 6 - Sleeve 8 - Housing
W2-10-12
Disassemble Pilot Relief Valve Assemble Pilot Relief Valve
• Be sure to thoroughly read “Precaution for Disas- 1. Insert gasket (7) into housing (8).
starting the disassembly work. 2. Insert poppet (5) into sleeve (6). Install spring (3)
and O-ring (4) into the relief valve. Insert the relief
IMPORTANT: Take care not to lose shim (2) pro- valve assembly into housing (8).
vided in the plug (1) when removing NOTE: Sleeve (6) with poppet (5) is provided in the
plug (1). relief valve.
1. Remove plug (1) from housing (8).
: 22 mm IMPORTANT: Be sure not to drop shim (2).
3. Install shim (2) into plug (1) to install the plug into
2. Remove spring (3) and O-ring (4) from the relief housing (8).
valve. : 22 mm
NOTE: Sleeve (6) with poppet (5) is provided in the : 25 N⋅m(2.5 kgf⋅m, 18 lbf⋅ft)
relief valve.
3. Remove the assembly of poppet (5) and sleeve

(6) from housing (8).
4. Remove gasket (7) from housing (8).
W2-10-13
(Blank)
W2-10-14
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 3
UNDERCARRIAGE
—CONTENTS—
Group 1 Swing Bearing Group 4 Track Adjuster
Remove and Install Swing Bearing ......... W3-1-1 (ZAXIS330, 330LC, 350H, 350LCH)
Disassemble Swing Bearing ................... W3-1-4 Remove and Install Track Adjuster ......... W3-4-1
Assemble Swing Bearing ........................ W3-1-6 Disassemble Track Adjuster ................... W3-4-2
Assemble Track Adjuster........................ W3-4-8
Group 2 Travel Device (ZAXIS370MTH)
(ZAXIS330, 330LC, 350H, 350LCH) Remove and Install Track Adjuster ....... W3-4-15
Remove and Install Travel Device .......... W3-2-1 Disassemble Track Adjuster ................. W3-4-16
Disassemble Travel Device .................... W3-2-4 Assemble Track Adjuster...................... W3-4-22
Assemble Travel Device ......................... W3-2-8
Disassemble Travel Motor .................... W3-2-16 Group 5 Front Idler
Assemble Travel Motor......................... W3-2-20 Remove and Install Front Idler................ W3-5-1
Disassemble Brake Valve ..................... W3-2-28 Disassemble Front Idler.......................... W3-5-2
Assemble Brake Valve.......................... W3-2-30 Assemble Front Idler .............................. W3-5-6
Maintenance Standard ........................ W3-2-32 Maintenance Standard.......................... W3-5-10
(ZAXIS370MTH)
Remove and Install Travel Device ........ W3-2-35 Group 6 Upper and Lower Roller
Disassemble Travel Device .................. W3-2-38 Remove and Install Upper Roller ............ W3-6-1
Assemble Travel Device ....................... W3-2-44 Remove and Install Lower Roller ............ W3-6-4
Disassemble Travel Motor .................... W3-2-52 Disassemble Lower Roller ...................... W3-6-8
Assemble Travel Motor......................... W3-2-56 Assemble Lower Roller......................... W3-6-10
Disassemble Brake Valve ..................... W3-2-62 Maintenance Standard.......................... W3-6-12
Assemble Brake Valve.......................... W3-2-64
Maintenance Standard ........................ W3-2-66 Group 7 Track
Remove and Install Track ....................... W3-7-1
Group 3 Center Joint Maintenance Standard............................ W3-7-7
Remove and Install Center Joint............. W3-3-1
Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6
Maintenance Standard ........................... W3-3-9
1HHW-3-1
(Blank)
1HHW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section.
In this section, the procedure starts on the premise that
the upperstructure has already been removed.
Removal
1. Put matching marks on inner race (1) of swing
bearing and track frame (2).
Matching Mark
1 2
W105-03-01-001
2. Remove all bolts (3) (36 used) from inner race of

swing bearing.
: 41 mm
W158-03-01-001
CAUTION: Swing bearing weight: 500 kg

(1100 Ib)
ST 0050
3. Attach lifting tools (ST 0050), hoist swing bearing
(4) and remove it.
4 W110-03-01-004
W3-1-1
Installation
Clean the matching surfaces of the track frame and
swing bearing.
1. Apply THREEBOND # 1102 to the matching sur-

faces of the track frame and swing bearing.

(1100 Ib)
IMPORTANT: Failure to align the marks may result

in misalignment of the inner race W110-03-01-004
soft zone.
2. Hoist the swing bearing by crane. Align the match-

“S” (Soft Zone)
ing marks both on the track frame and swing bear- Front Side
Marking Position
ing.
Position of Plug
20°
15°
Position for
Grease Fitting
5°
3. Install mounting bolts (3) (36 used) to the inner W110-03-01-001
race of the swing bearing and tighten to specifica-

tion.
: 41 mm
: 1230 N⋅m (125 kgf⋅m, 900 lbf⋅ft)
W158-03-01-001
W3-1-2
4. After installing the swing bearing, fill the grease
bath with grease (Shell Alvania EP2 or equivalent) Swing Bearing Grease Level Pinion
until the pinion of the swing bearing is covered 5
mm in grease.
5 mm
W175-03-01-002
Grease Bath
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (95 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (95 Used)
3 - Pin
W3-1-4
Disassemble Swing Bearing
• Be sure to thoroughly read “Precautions for Dis-
assembly and Assembly” on page W1-1-1 before
starting the disassembly work. 3
1. Grind off caulked part of pin (3).

Tap pin (3) out from the bottom side.
4
W105-03-01-007
2. Screw the bolt into screw hole (M10, pitch 1.5) for
removing plug (4), and then tap the bolt head from
its back to pull the plug out.
W105-03-01-008
3. Hoist outer race (1) slightly by crane.

Ȁ Remove seals (2), (5). 1
6 5 W105-03-01-009
4. Rotate inner race (7) to remove balls (6) and sup-

ports (9) from the plug (4) hole.
When removing balls, rod magnet (C) can be
used. Use wire (D) to remove support (9).
D
W105-03-01-010
9
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (95 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (95 Used)
3 - Pin
W3-1-6
Assemble Swing Bearing
1. Clean (degrease) the seal groove for the outer

2
and inner seals (2) and (5).
Apply THREEBOND # 1745 to seal (2) and #
1735 to seal (5). Install both seals respectively
into position.
5
W142-03-01-005
IMPORTANT: Be sure to apply grease to balls (6)

and to supports (9).
(1100 lb)
2. Hoist the outer race by crane horizontally and

match it with the inner race coaxially.
Ȁ Rotating the outer race, insert balls (6), support
(9) into the plug (4) hole one by one with a round 9
bar.
W142-03-01-006
3. Tap plug (4) into outer race (1) and then, drive pin 1
(3) into the pin hole.
Caulk the head of pin (3) with a punch.
Ȁ Fill grease 0.9 L (Alvania EP2 grease or equiva-
lent) through the grease fitting.
W142-03-01-007
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Escaping fluid under pressure may

penetrate the skin, causing serious injury.
fore disconnecting hydraulic lines.
and may spurt possibly causing severe burns.
Be sure to wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off by re-
maining pressure if removed quickly. Slowly
loosen the cap to completely release any re-
maining pressure.
Preparation

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to
M104-07-021
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while

working on the hydraulic system.
W3-2-1
Removal (ZAXIS330, 330LC, 350H, 350LCH)
The procedure starts on the premise that the track 4 5
link has already been removed.
Refer to page W3-7-1 for track removal.
1. Loosen bolts (7) to remove cover (6).

: 22 mm
: 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
1
IMPORTANT: Attach identification tags to aid in
assembling.
2. Disconnect hoses (2) to (5).
: 19 mm 3
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) 2
: 27 mm
: 95 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
NOTE: Install caps on all disconnected hose and 6
line ends.
3. Attach the travel device to a crane with a wire 7 W157-03-02-006

rope.
CAUTION: Travel device weight: 480 kg

(1060 Ib)
4. Remove bolts (1). Remove the travel device by
crane.
: 30 mm
: 620 N⋅m (63 kgf⋅m, 460 lbf⋅ft)
Installation
wrench sizes and tightening torque.
1. Install the travel device with bolts (1).
2. Connect hoses (2) to (5).
3. Install cover (6) with bolts (7).
IMPORTANT: After completing travel motor instal-

lation, be sure to fill the travel motor
with hydraulic oil (1.3 L (0.34 US
gal.)). After completing installation
of the travel motor or the travel de-
vice, be sure to perform test driving
to prevent motor seizure. Test drive
as follows:
Perform break-in operation as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine for two minutes or more.
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL DEVICE
(ZAXIS330, 330LC, 350H, 350LCH) 16
15
17
13
12 38
14
37
6 11
7 40
3
4 10
5
3
9
23
8
2
1 18
22
19
21
8 20
19
35
31
24
25
26
27
28
27
26
30
41
43
39 42
29
34
33
36
32
31
W1HH-03-02-001
1- Third Stage Carrier 12 - Ring Gear 23 - Second Stage Carrier 34 - Bolt (20 Used)
2- Third Stage Sun Gear 13 - Bolt (28 Used) 24 - Spring Pin (3 Used) 35 - Bearing Nut
3- Thrust Plate (6 Used) 14 - Stopper Pin 25 - Pin (3 Used) 36 - Sprocket
4- Second Stage 15 - Cover 26 - Thrust Plate (6 Used) 37 - Retaining Ring
Planetary Gear (3 Used)
5 - Needle Bearing (3 Used) 16 - Bolt (16 Used) 27 - Needle Bearing (6 Used) 38 - Bearing
6 - Pin (3 Used) 17 - Plug (3 Used) 28 - Third Stage Planetary Gear 39 - O-Ring
(3 Used)
7- Spring Pin (3 Used) 18 - Spring Pin (3 Used) 29 - Motor 40 - Spacer
8- Spacer (2 Used) 19 - Thrust Plate (6 Used) 30 - Floating Seal 41 - Housing
9- Second Stage Sun Gear 20 - Needle Bearing (3 Used) 31 - Roller Bearing (2 Used) 42 - Lock Plate
10 - First Stage Carrier 21 - First Stage Planetary Gear 32 - Drum 43 - Bolt (2 Used)
(3 Used)
11 - Propeller Shaft 22 - Pin (3 Used) 33 - Washer (20 Used)
W3-2-4
Disassemble Travel Device
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Pressure may remain in the travel

device. Slowly loosen the air bleed plug to
completely release the residual pressure.
Then, remove the drain plug to drain gear oil
into a container. If the air bleed plug is loos-
ened quickly, the plug may fly off and/or gear
oil may gush out. Position your face and
body away from the plug.

(1060 lb)
1. Turn over the travel device.
Place the travel device securely on a work bench
so that the brake valve does not come into contact
with the work bench, with the motor side down-
ward.
15
2. Remove bolts (16) to remove cover (15) from ring
gear (12).
: 19 mm 16
NOTE: THRREEBOND is applied between cover

(15) and ring gear (12). For easy separa-
tion of cover (15), apply a chisel between
cover (15) and ring gear (12) and lightly tap
on the end of the chisel.
Do not remove stopper pin (14) unless it is
damaged or excessively worn.
3. Remove propeller shaft (11) and first stage carrier W107-03-02-008

(10) assembly from ring gear (12).
4. Remove second stage sun gear (9), second stage

carrier (23) assembly and third stage sun gear (2)
from ring gear (12).
W3-2-5
16
13
12
6
7 40
3
4 10
5
3
23
8
1 18
22
19
8 21
20
19 35
24 31
25
26
27
28
27
26
30
41
43
42
34
36
32
31
W1HH-03-02-001
W3-2-6
10. Remove the inner race of roller bearing (31) from
CAUTION: Ring gear (12) weight:
drum (31).
55 kg (121 Ib)
NOTE: Do not attempt to remove the inner race of
5. Remove bolts (13) (28 used). Attach eyebolt (M12, roller bearing (31) which remained in hous-
Pitch 1.75) to bolt (16) hole of ring gear (12). Re- ing (41) side unless it is to be replaced.
move ring gear (12) from drum (32) by crane.
: 24 mm 11. Remove floating seal (30) from drum (32) and
housing (41).
NOTE: THREEBOND is applied between ring gear
(12) and drum (32).Use the screw driver for 12. Apply a metal bar to the outer race of roller bear-
easy removal. ing (31) on drum (32) side, and tap the bar end
with a hammer to drive the outer race out.
CAUTION: Third stage carrier (1) assembly
13. Apply a round bar to spring pin (18), and tap the
weight: 52 kg (115 lb)
end of the bar to drive spring pin (18) out of first
6. Remove third stage carrier (1) assembly.
stage carrier (10) assembly. (3 places)
7. Remove bolt (43) and lock plate (42) from bearing
nut (35). 14. Remove pins (22) (3 used). Remove first stage
: 19 mm planetary gears (21) (3 used), needle bearings
(20) (3 used), and thrust plates (19) (6 used).
8. Hold the travel device securely. Remove bearing
nut (35) using special tools. 15. Remove spacer (40) from first stage carrier (10).
Special Tools: ST 3050, ST 3051, ST 3052
Bolt: M16 (60 to 90 mm in length):2 pieces 16. Disassemble second stage carrier (23) assembly
following steps 13 to 15 above.
Remove spring pins (7) (3 used), pins (6) (3 used),
second stage planetary gears (4) (3 used), thrust
plates (3) (6 used), needle bearings (5) (3 used),
ST 3052 and spacers (8) (2 used).
ST 3050 17. Disassemble third stage carrier (1) assembly fol-

35 lowing steps 13 to 15 above.
ST 3051
Remove spring pins (24) (3 used), pins (25) (3
used), thrust plates (26) (6 used), third stage
planetary gears (28) (3 used), and needle bear-
ings (27) (6 used).
CAUTION: Sprocket (36) weight: 68 kg

W157-03-02-005 (150 lb)
18. Loosen and remove bolts (34) (20 used). Remove
sprocket (36) by crane after attaching a nylon
CAUTION: Drum (32) + sprocket (36) weight: sling to sprocket (36).
135 kg (300 lb) : 30 mm
IMPORTANT: The housing (41) matching surface NOTE: LOCTITE is applied to bolt (34).
of drum (32) is the sliding surface.
Place the drum assembly onto a
wooden block not to damage it.
9. Attach eyebolt (M16, Pitch 2.0) to drum (32). Re-

move drum (32) from housing (41) by crane.
W3-2-7
ASSEMBLE TRAVEL DEVICE
(ZAXIS330, 330LC, 350H, 350LCH)
33, 34
32 12 13 8 1 2 8 23 9 10
29 39
17
40
11
15
14
38
37
19
18
20
22
21
16
41 30 31 6 4 5 3 7
36 35 42 43 28 27 25 26 24 3 W164-03-02-002
1- Third Stage Carrier 12 - Ring Gear 23 - Second Stage Carrier 34 - Bolt (20 Used)
2- Third Stage Sun Gear 13 - Bolt (28 Used) 24 - Spring Pin (3 Used) 35 - Bearing Nut
3- Thrust Plate (6 Used) 14 - Stopper Pin 25 - Pin (3 Used) 36 - Sprocket
4- Second Stage 15 - Cover 26 - Thrust Plate (6 Used) 37 - Retaining Ring
Planetary Gear (3 Used)
5 - Needle Bearing (3 Used) 16 - Bolt (16 Used) 27 - Needle Bearing (6 Used) 38 - Bearing
6 - Pin (3 Used) 17 - Plug (3 Used) 28 - Third Stage Planetary Gear 39 - O-Ring
(3 Used)
7- Spring Pin (3 Used) 18 - Spring Pin (3 Used) 29 - Motor 40 - Spacer
8- Spacer (2 Used) 19 - Thrust Plate (6 Used) 30 - Floating Seal 41 - Housing
9- Second Stage Sun Gear 20 - Needle Bearing (3 Used) 31 - Roller Bearing (2 Used) 42 - Lock Plate
10 - First Stage Carrier 21 - First Stage Planetary Gear 32 - Drum 43 - Bolt (2 Used)
(3 Used)
11 - Propeller Shaft 22 - Pin (3 Used) 33 - Washer (20 Used)
W3-2-8
Assemble Travel Device
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Drum (32) + sprocket (36) weight:
1. If replacing roller bearing (31), warm the inner
135 kg (300 lb)
race (2 used) 50 to 70 °C (122 to 158 °F) with a
5. Attach eyebolt (M16, Pitch 2.0) to the bolt (13)
heater, then install one of them into housing (41).
hole of drum (32), then hoist and install drum (32)
Wait for the bearing to cool. Then, drive it in posi-
onto housing (41) with motor (29) by crane. At this
tion completely with a metal bar and hammer.
time check if the clearance between the motor
NOTE: Check if the inner race is driven in com- and drum is equal.
pletely by listening to the sound.
6. Warm the inner race of roller bearing (31) 50 to 70
2. Apply grease to the O-ring outer surface of float- °C (122 to 158 °F) with a heater. Install it between
ing seal (30). Install one half of floating seal (30) drum (32) and housing (41).
on housing (41).
NOTE: For easier insertion of floating seal (30) O-
ring, use a bamboo (wooden) spatula to
guide it along the periphery.
IMPORTANT: Be sure to tap only the outer race.

3. Install the outer races (2 used) of roller bearing
(31) on drum (32) in position completely with a
metal bar and hammer.
Install the half of floating seal (30) into drum (32).
NOTE: Check if the roller bearing is installed com-
pletely by listening to the sound.
CAUTION: Sprocket (36) weight:

68 kg (150 lb)
IMPORTANT: Align the chamfered side of sprocket

(36) with drum (32).
4. Attach sprocket (36) with a nylon sling. Hoist it
and place it on drum (32). Apply LOCTITE #262 to
bolts (34) (20 used). Tighten bolts (34) and wash-
ers (33) (20 used).
: 30 mm
: 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
W3-2-9
8 1
41
32 36 35 42 43 26 28 27 26 24 W164-03-02-002
W3-2-10
IMPORTANT: Face bearing nut (35) stepped to the 12. Apply LOCTITE #262 to the thread of bolts (43) (2
bearing. Apply grease to the used). Install lock plate (42) to bearing nut (35)
threaded part of bearing nut (35). with bolts (43) (2 used)
7. Install bearing nut (35) to housing (41) and tighten : 19 mm
manually. : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
NOTE: Apply grease to the threaded part of bear-
ing nut (35) to tighten the torque to correct 43
specification. 42
35
8. Hold the travel device securely. Attach the special
tools to bearing nut (35). Then, tighten with a
torque wrench.
Special Tools: ST 3050, ST 3051, ST 3052
Bolt: M16 (60 to 90 mm in length)
×2 pieces W140-03-02-001
: 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

13. Install two needle bearings (27) (2 used) into each
third stage planetary gears (28) (3 used).
IMPORTANT: One side of third stage planetary

ST 3052 gear (28) is the marked groove. In-
stall third stage planetary gear (28)
ST 3050
with the side with marked groove
35 facing to the spring pin (24) hole.
ST 3051
14. Install spacer (8) into third stage carrier (1). Put-
ting thrust plates (26) (6 used) on both ends of
36 each third stage planetary gears (28) (3 used), in-
stall them into third stage carrier (1).
W157-03-02-005
9. After tighten bearing nut (35) to specification, tap

on drum (32) with a plastic hammer to secure ap-
propriate play. Then, rotate sprocket (36) 4 to 5
turns clockwise and then counterclockwise.
10. Repeat step 8 and 9.
11. Repeat step 9 above. Then, tighten bearing nut

(35) to specification.
Special Tools: ST 3050, ST 3051, ST3052,
Bolt: M16 (60 to 90 mm in length):
×2 pieces
: 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)
W3-2-11
12 13 1 2 8 23 9
43
15
16
41
32 28 25 24 6 4 5 3 7 W164-03-02-002
W3-2-12
15. Insert pins (25) (3 used) into third stage carrier (1)
CAUTION: Ring gear (12) weight: 55 kg
to secure third stage planetary gears (28) (3
(121 lb)
used).
20. Install eyebolt (M12, Pitch 1.75) into the bolt (16)
At this time align third stage carrier (1) with the
hole on ring gear (12). Hoist ring gear (12) by
spring pin (24) hole on pin (25).
crane.
Install ring gear (12) onto drum (32). Apply LOC-
16. Drive spring pins (24) (3 used) into the spring pin
TITE #262 to bolts (13) (28 used). Tighten bolts
hole on third stage carrier (1) and pin (25). Be
(13).
sure that the slit part of spring pin (24) faces to the
: 24 mm
end of pin (25).
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
25 24
21. Install spacer (8), second stage planetary gears
Slit (4) (3 used), needle bearings (5) (3 used), thrust
plates (3) (6 used), pins (6) (3 used), and spring
pins (7) (3 used) into second stage carrier (23) fol-
lowing step 13 to 16 above.
W178-02-06-002
CAUTION: Third stage carrier assembly 22. Install second stage carrier (23) assembly into
weight: 52 kg (115 lb) ring gear (12).
17. Install third stage carrier (1) assembly, aligning 23. Install second stage sun gear (9) into second
splines with housing (41). stage carrier (23). Be sure that the lower tooth
end faces to cover (15).
18. Install third stage sun gear (2) into third stage car-
rier (1). Be sure that the lower tooth end faces to
cover (15). Cover (15) 9
Cover (15)
2
W166-03-02-002
W166-03-02-001
19. Clean (degrease) ring gear (12) mounting surface

of drum (32). Apply THREEBOND #1389B to the
mounting surface.
W3-2-13
29 12 9 10
17
40
11
21
15
22
18
19
16
20
W164-03-02-002
W3-2-14
IMPORTANT: Face the lower tooth height side of
first stage planetary gear (21) to
spacer (40) side.
24. Install spacer (40), first stage planetary gears (21)
(3 used), needle bearings (20) (3 used), thrust
plates (19) (6 used), pins (22) (3 used), spring
pins (18) (3 used) into first stage carrier (10) fol-
lowing step 13 to 16.
25. Install first stage carrier (10) assembly into ring

gear (12), aligning splines between first stage car-
rier (10) and second stage sun gear (9).
26. Add gear oil to ring gear (12).

Gear oil: 9.2 L (2.43 US gal)
27. Insert propeller shaft (11) into the center of carrier.

Be sure that the propeller shaft correctly meshes
with first stage planetary gears (21) and the shaft
of motor (29).
28. Clean (degrease) the cover (15) mounting surface

of ring gear (12). Apply THREEBOND #1389B to
the mounting surface. Install cover (15) to ring
gear (12). Apply LOCTITE #262 to bolts (16) (16
used). Tighten bolts (16) (16 used).
: 19 mm
: 110 N⋅m (11.5 kgf⋅m, 83 lbf⋅ft)
29. Wrap seal tape around plugs (17) (3 used). Install

plugs (17) into cover (15).
: 10 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-2-15
DISASSEMBLE TRAVEL MOTOR
(ZAXIS330, 330LC, 350H, 350LCH) 14
12 13
11
10
9
8
7
Brake Releasing
6 Oil Passage
5
3
4
2 16 15
1
25
26
27
20 18
19
21
17
22
23
28
24
32 29
30
31
40 39 38
37
36
33
34
35 W164-03-02-003
1- O-Ring 11 - Bearing 21 - Link 31 - Knock Pin (2 Used)

2- Disc Spring 12 - Housing 22 - Reamer Bolt 32 - Socket Bolt (4 Used)
3- D-Ring 13 - Oil Seal 23 - Plug (2 Used) 33 - Brake Valve
4- Piston 14 - Retaining Ring 24 - O-Ring (2 Used) 34 - O-Ring
5- D-Ring 15 - O-Ring 25 - Pin 35 - Plug
6- Plate (5 Used) 16 - Bearing Nut 26 - Center Shaft 36 - Servo Piston
7- Spacer 17 - Plunger (7 Used) 27 - Center Spring 37 - Piston Ring (2 Used)
8- Drive Disc 18 - Rotor 28 - Bushing 38 - O-Ring
9- Bearing 19 - Plug (2 Used) 29 - Valve Plate 39 - Cover
10 - Spacer 20 - Friction Plate (4 Used) 30 - Plate 40 - Socket Bolt (4 Used)
W3-2-16
Disassemble Travel Motor
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Travel motor weight: 4. Remove valve plate (29) from brake valve (33). At
87 kg (190 Ib) this time, the valve plate is still with link (21) at-
Brake valve weight: 43 kg (90 Ib) tached.
IMPORTANT: Valve plate (29) is easily cracked and NOTE: The valve plate (29) is with bushing (28)
scratched, so handle it with care. attached, but do not remove the bushing
1. Place the travel motor longitudinally. Remove unless necessary.
socket bolts (32) (4 used) to remove brake valve
(33) from housing (12). At this time, the brake 5. Remove plate (30) from brake valve (33).
valve side is still with valve plate (29) attached.
: 14 mm 6. Remove servo piston (36) from brake valve (33).
At this time, the servo piston is still with piston
2. Remove socket bolts (40) (4 used) from brake rings (37) (2 used) attached.
valve (33) to remove cover (39) and O-ring (38).
7. Remove O-Rings (1), (15) from housing (12).
3. Turn brake valve (33) over to remove plug (23)
and O-ring (24), then insert a hexagon wrench 8. Remove disc spring (2) from housing (12).
into the plug (23) hole to remove reamer bolt (22).
: 8 mm, 10 mm
CAUTION: When removing piston (4) from
the housing filled with air, cover the housing
33
with cloth to prevent the brake piston from
22
flying out.
2
9. Apply 100 to 300 kPa (1 to 3 kgf/cm , 14 to 43 psi)
pressure air to brake releasing oil passage in
23
housing (12), so that brake piston (4) will float up
to be removed.
W178-03-02-014
NOTE: There is an air seat on brake piston (4). Be
sure to place it with the air seat facing up.
IMPORTANT: Plug (19) has been bound with LOC-
TITE. If removing it by force, its Air Seat
hexagon hole may be damaged. Do
not remove plug (19) unless neces-
sary.
4
W178-03-02-009
NOTE: Piston (4) is with D-rings (3), (5) attached, do

19 not remove the D-ring unless necessary.
W107-03-02-098
W3-2-17
14
12 13
11
10
9
8
7
16
25
26
27
20 18
17
33
W164-03-02-003
W3-2-18
10. Remove plates (6) (5 used), friction plates (20) (4
CAUTION: Drive disc (8) assembly weight:
used) from housing (12).
7.0 kg (15 Ib)
15. Install drive disc (8) assembly into special tools
IMPORTANT: When removing center shaft (26), the (ST 3058, 5904) to remove bearing nut (16).
center shaft will be with pin (25)
Ȁ
attached. Be sure not to lose it.
11. Remove rotor (18), spring (27), center shaft (26),
and plungers (17) (7 used) from housing (12).
ST 3058
NOTE: Tilt plunger (17) in the direction of motor
center, the more tilting, the easier remov-
ST 5904
ing.
8
12. Remove spacer (7) from housing (12).
CAUTION: Housing + drive disc (8) + others

W107-03-02-119
weight: 49 kg (110 Ib)
IMPORTANT: The inner race of bearing (9) is left
on drive disc (8).
CAUTION: Drive disc (8) assembly weight: Don’t remove it unless replacing.
7.0 kg (15 Ib) In case the inner race of bearing (9)
has been removed, don’t reuse it.
IMPORTANT: As drive disc (8) has tendency to 16. Place the outer race of bearing (9) on wooden
drop off, keep it with wooden block. block. Press drive disc (8) with a press to remove
13. Place housing (12) with the brake valve (33) the outer race of bearing (9) bearing (11), and
mounting surface facing downward. Tap and re- spacer (10) from drive disc (8).
move drive disc (8) from housing (12) with a plas-
Press
tic hammer lightly. At this time, the drive disc is
still with bearings (9), (11), bearing nut (16), and 8
spacer (10) attached. 11
10
14. Remove retaining ring (14) from housing (12) to
remove oil seal (13) with a screw-driver and 9
hammer. Thrust Block
W107-03-02-121
W3-2-19
ASSEMBLE TRAVEL MOTOR
(ZAXIS330, 330LC, 350H, 350LCH)
35, 34 28 1 15 2 3 4 5 6 7 8
9
30
10
29
31 11
33
12
13
14
16
18
25
17
36 20
37
38
39
19
40 23, 24 27 32 26
21
W178-03-02-016
22
1- O-Ring 11 - Bearing 21 - Link 31 - Knock Pin (2 Used)
2- Disc Spring 12 - Housing 22 - Reamer Bolt 32 - Socket Bolt (4 Used)
3- D-Ring 13 - Oil Seal 23 - Plug (2 Used) 33 - Brake Valve
4- Piston 14 - Retaining Ring 24 - O-Ring (2 Used) 34 - O-Ring
5- D-Ring 15 - O-Ring 25 - Pin 35 - Plug
6- Plate (5 Used) 16 - Bearing Nut 26 - Center Shaft 36 - Servo Piston
7- Spacer 17 - Plunger (7 Used) 27 - Center Spring 37 - Piston Ring (2 Used)
8- Drive Disc 18 - Rotor 28 - Bushing 38 - O-Ring
9- Bearing 19 - Plug (2 Used) 29 - Valve Plate 39 - Cover
10 - Spacer 20 - Friction Plate (4 Used) 30 - Plate 40 - Socket Bolt (4 Used)
W3-2-20
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Drive disc (8) weight: 4.1 kg (9 lb)
1. Heat the inner race of bearing (9) to 70° to 90°C
(158 °F to 194 °F) in a oil bath or drier. Press the 7. Secure drive disc (8) onto special tools (ST 3058,
inner race of bearing (9) into drive disc (8) with ST 5904), tighten bearing nut (16) to the specified
special tool (ST 2155) and a press. torque.
: 3.5±0.5 N⋅m
2. Put the outer race onto the inner race of bearing (0.35±0.05 kgf⋅m, 2.53 ± 0.36 lbf⋅ft)
(9).
3. Tap and insert the outer race of bearing (11) into ST 3058
spacer (10) lightly with a plastic hammer.
16
4. Put spacer (10) on the outer race of bearing (9). ST 5904

8
5. Heat the inner race of bearing (11) to 70° to 90°C
(158 °F to 194 °F) in a oil bath or drier, and press
the inner race of bearing into drive disc (8) with
special tool (ST 2308) and a press. Tap the inner
race lightly and listen to ring to confirm they are fit-
ting tightly. W107-03-02-119
IMPORTANT: Apply grease onto bearing nut (16).

6. Apply grease to the screw part and the side
46 kg (100 Ib)
surface of bearing nut (16). Install bearing nut
8. Place housing (12) with its brake valve mounting
(16) onto drive disc (8), then tighten it by hand.
side facing down.
Ȁ
NOTE: Apply grease to tighten it to the specified IMPORTANT: Apply OCEAN grease #7 to the inner
torque. surface of oil seal (13), and apply
THREEBOND #104 or 1215 to the
outer surface of the oil seal.
9. Tap oil seal (13) evenly and lightly with a plastic
hammer to insert oil seal (13) into housing (12).
The replaced oil seal can be used as a mat then.
10. Install retaining ring (14).

46 kg (100 Ib)
11. Turn housing (12) over. Tap drive disc (8) assembly
lightly with a plastic hammer and brass bar to in-
stall it into housing (12).
W3-2-21
27 18 2 12 4 18 6 7 8
13
25
Oil Slit (4 Places)
17 3 5 Slit (4 Places) 20 26
W178-03-02-019
W3-2-22
12. Turn housing (12) over and place it with its oil seal 16. Install plungers (17) (7 used) into the spherical
(13) side facing down. handle hole in drive disc (8) one by one. Be sure
to confirm plungers (17) (7 used) move smoothly.
IMPORTANT: Be sure to align the oil slot (slit part) 17 8
in spacer (7) with that in housing
(12).
13. Install spacer (7) into housing (12) with its oil slot
(slit part) facing the travel reduction gear side.
Spherical
IMPORTANT: Align 5 teeth of plate (6) with the in- Handle Hole
ner grooves in housing (12).
In addition, the 4 teeth on friction
plate (20) should be placed at same
W107-03-02-146
position when installation is carried
out. Ȁ
14. Install plates (6) (5 used) and friction plates (20) 17. Apply grease to the center shaft (26) spherical
(4 used) into housing (12) alternately. Be sure to part. Install center shaft (26) into drive disc (8).
align the teethless part (no teeth part ) of plate (6) Then install center spring (27) onto enter shaft
(4 places) with the inner slots inside of housing (26).
(12) and install them together.
18. Apply grease to pin (25) to prevent it from coming
Moreover, the teethless part of friction plate (20)
off. Then install it into center shaft (26).
should be put at same position to form a straight
line when installation is carried out. 19. Put center shaft (26) to rotor (18) shallowly. Rotate
center shaft (26) so as to align pin (25) just be-
NOTE: In case the teethless part or slot position neath the slot in rotor (18).
fail to align with each other, heating may be
resulted to motor failure. 18
Groove (4 Places) Groove

12
25
26
W178-03-02-015
W178-03-02-018
15. Install D-rings (3, 5) into piston (4), then tap to in- 20. Insert plungers (17) (7 used) into rotor (18).
stall them into housing (12) with a plastic hammer. IMPORTANT: Be sure to place pin (25) securely
into the rotor (18) groove.
21. Press rotor (18) slowly and install pin (25) into the
rotor (18) groove.
NOTE: If pin (25) can’t be installed into the groove,
insert the end of round rotor into the top
hole of center shaft (26), rotate the center
shaft. When doing this work, be sure to re-
move the dirt and metallic debris from the
former rotor first.
Ȁ
Ȁ
W3-2-23
28 29 15 12 2
30
31
33
36
37
19
23 1
21
W178-03-02-016
W3-2-24
22. Install O-rings (1), (15) into housing (12). IMPORTANT: Pay attention to the direction of link
(21) assembly.
IMPORTANT: Install disc spring (2) into housing 30. Install link (21) assembly into brake valve (33)
(12) with the outer surface side of while aligning the groove in valve plate (29) with
the disc spring facing the brake the groove in plate (30). At this time, the sticking
valve (33) mounting surface. part of link (21) should face the brake valve side.
23. Install disc spring (2) into housing (12). 29
21
Ȁ Rotor (18) Side
24. Fill hydraulic oil into housing (12).
Hydraulic oil: 1.3 L (0.34 US gal)
Plate (30) Side
25. Install plate (30) onto brake valve (33).
W178-03-02-017
26. Install piston rings (37) (2 used) onto servo piston
(36). 31. Insert special tool (ST 7131) into the mounting
hole of plug (23), then align the hole of link (21)
27. Insert servo piston (36) into brake valve (33). with that of servo piston (36).
IMPORTANT: Assemble bushing (28) with the ST 7131

chamfered side facing inside. 36 21
28. Install bushing (28) onto valve plate (29) with a
plastic hammer.
29. Apply LOCTITE #262 on plugs (19) (2 used), then

install link (21) onto valve plate (29) with plugs
(19) (2 used).
: 6 mm
: 49 N⋅m(5 kgf⋅m, 36 Ibf⋅ft)
W107-03-02-174
22
W3-2-25
33 12
36
38
39
40 23, 24 32
21
W178-03-02-016
22
W3-2-26
32. Apply additive grease, Johnson wax JP103, to the
CAUTION: Brake valve (33) weight:
end of reamer bolt (22) in order to prevent it from
43 kg (90 Ib)
seizing.
37. Hoist and install brake valve (33) onto housing
Install reamer bolt (22) to link (21) and servo pis-
(12) by crane, while aligning the hole in removed
ton (36) through the opposite mounting hole of
plug (A) with special tool (ST 7085).
plug (23).
: 8 mm
: 49 N⋅m(5 kgf⋅m, 36 lbf⋅ft) 38. Remove special tool (ST 7085) from brake valve
(33).
33. Install O-ring (24) onto plug (23), then install it to
brake valve (33). 39. Install spool (B), spring (C) and plug (A) into brake
: 10 mm valve (33).
: 118 N⋅m(12 kgf⋅m, 87 lbf⋅ft) : 8 mm
: 34 N⋅m(3.5 kgf⋅m, 25.5 Ibf⋅ft)
34. Install O-ring (38) onto cover (39) and install it to
brake valve (33) with socket bolts (40) (4 used). 40. Install brake valve (33) onto housing (12) with
: 10 mm socket bolts (32) (4 used).
: 88 N⋅m(9 kgf⋅m, 65 lbf⋅ft) : 14 mm
: 390 N⋅m(40 kgf⋅m, 290 Ibf⋅ft)
35. Install special tool (ST 7085) into the end of center
shaft (26).
ST 7085
26
12
W107-03-02-183
36. Remove plug (A) from brake valve (33) to remove

spool (B) and spring (C).
: 8 mm
W3-2-27
DISASSEMBLE BRAKE VALVE
(ZAXIS330, 330LC, 350H, 350LCH)
Counter Balance Valve
9 Shuttle Valve for Parking Brake

Check Valve
10
4
11 16 5
15 6 Overload Relief Valve
12 14
7 1, 2
13
11
10
7
20 13
14 9 6
19 1, 2
15 5
8
16
18 4
17
Shuttle Valve for Servo Piston

Reducing Valve W140-03-02-003
1- O-Ring (2 Used) 6- Spring (2 Used) 11 - Stopper (2 Used) 16 - Plug (2 Used)

2- Overload Relief Valve (2 Used) 7- Poppet (2 Used) 12 - Spool 17 - Plug
3- Casing 8- Plug (2 Used) 13 - Ball (2 Used) 18 - O-Ring
4- Plug (2 Used) 9- O-Ring (2 Used) 14 - Seat (2 Used) 19 - Spool
5- O-Ring (2 Used) 10 - Spring (2 Used) 15 - O-Ring (2 Used) 20 - Spring
W3-2-28
Disassemble Brake Valve
(ZAXIS330, 330LC, 350H, 350LCH)
Be sure to thoroughly read “Precautions for Disassem- • Shuttle valve for servo piston and for parking brake
bly and Assembly Work” on page W1-1-1 before start-
ing the disassembly work. IMPORTANT: LOCTITE was applied on seat (14).
Do not remove the seat unless nec-
essary.
CAUTION: Brake valve weight: 43 kg (90 lb)
6. Remove plugs (16) (2 used) from casing (3) to
• Counter Balance Valve remove balls (13) (2 used) and seats (14) (2
1. Remove plugs (8) (2 used) from casing (3).
used).
: 41 mm
: 5 mm, 6 mm
2. Remove springs (10) (2 used), stoppers (11) (2

• Reducing Valve
used) from casing (3).
7. Remove plug (17) from casing (3) to remove

3. Remove spool (12) from casing (3).
spool (19) and spring (20).
: 8 mm
IMPORTANT: Be sure to loosen and remove over-

load relief (2). Do not turn the lock
nut for adjusting screw on overload
relief valve, or its setting pressure
may change.
4. Remove overload relief valves (2) (2 used) from
casing (3).
: 27 mm
Lock Nut
Adjusting Screw
W140-03-02-005
• Check Valve
5. Remove plug (4) from casing (3) to remove

springs (6) (2 used) and poppets (7) (2 used).
: 12 mm
W3-2-29
ASSEMBLE BRAKE VALVE
(ZAXIS330, 330LC, 350H, 350LCH)
13
14
15
13
14
16
15
Section B 16 Section C
A
2 1 7 6
19 20
18
17
3
4
5
9 B
Section A-A W164-03-02-005

A
12 11 10
1 - O-Ring (2 Used) 6 - Spring (2 Used) 11 - Stopper (2 Used) 16 - Plug (2 Used)

2 - Overload Relief Valve (2 7 - Poppet (2 Used) 12 - Spool 17 - Plug
Used)
3 - Casing 8 - Plug (2 Used) 13 - Ball (2 Used) 18 - O-Ring
4 - Plug (2 Used) 9 - O-Ring (2 Used) 14 - Seat (2 Used) 19 - Spool
5 - O-Ring (2 Used) 10 - Spring (2 Used) 15 - O-Ring (2 Used) 20 - Spring
W3-2-30
(ZAXIS330, 330LC, 350H, 350LCH)
• Reducing Valve • Overload Relief Valve

1. Insert spring (20) and spool (19) into casing (3). 4. Install overload relief valves (2) (2 used) into cas-
Install O-ring (18) onto plug (17) to casing (3). ing (3).
: 8 mm : 27 mm
: 69 N⋅m(7 kgf⋅m, 51 lbf⋅ft) : 540 N⋅m(55 kgf⋅m, 400 lbf⋅ft)
• Shuttle Valve for Servo Piston and for Parking • Counter Balance Valve
Brake
(Section B-B, Section C-C) IMPORTANT: Apply hydraulic oil to spool (12) be-
fore assembling. If any resistant
force is felt, move it back and reas-
IMPORTANT: Before inserting ball (13), put ball semble it. Never assemble it by
(13) on seat (14) and tap on the ball force.
with a hammer to obtain a tight 5. Insert spool (12) into casing (3). Be sure that
fitting between ball (13) and seat (14). spool (12) can move smoothly in casing (3).
Also, after inserting ball (13) and
before tightening seat (14), insert a
metal bar into the plug hole to ball 6. Install spring (10) onto stoppers (11) (2 used),
(13), then tap the other end of the then insert the stoppers into casing (3).
bar to obtain tight fitting between
ball (13) and casing (3). 7. Install O-rings (9) (2 used) onto plugs (8) (2 used),
2. Install balls (13) (2 used) with casing (3) titled. then install the plugs into casing (3).
Apply LOCTITE #262 onto seats (14) (2 used) : 41 mm
and install the seats into casing (3). Install O-rings : 340 N⋅m(35 kgf⋅m, 250 lbf⋅ft)
(15) (2 used) onto plugs (16) (2 used) and install
the plugs into casing (3).
: 5 mm
: 14.5 N⋅m(1.5 kgf⋅m, 11.0 lbf⋅ft)
: 6 mm
: 34 N⋅m(3.5 kgf⋅m, 25 lbf⋅ft)
• Check Valve
IMPORTANT: After inserting poppet (7), insert a

metal bar into the plug hole to
poppet (7), then tap the other end of
the bar to obtain tight fitting
between poppet (7) and casing (3).
3. Install springs (6) (2 used) into poppets (7) (2
used) and insert the poppets into casing (3). In-
stall O-rings (5) (2 used) onto plugs (4) (2 used)
and install the plugs into casing (3).
: 12 mm
: 235 N⋅m(24 kgf⋅m, 174 Ibf⋅ft)
W3-2-31
Sprocket
B
C
D
A E
W1HH-03-02-002
Unit: mm (in)
A 87 (3.4) [77 (3.0)]
B 89.15 (3.5) 84.15 (3.3) Cladding by
C 125.75 (5) - welding and
D 133.55 (5.3) 128.55 (5.1) finishing
E 216.0 (8.5) -
NOTE: Values in [Ӹ] is just for reference.
W3-2-32
Parking Brake
A
E
C
D
W107-03-02-220
Unit: mm (in)
Part Name Remedy
(Thickness) (Thickness)
A Friction Plate 3.3 (0.130) 3.25 (0.128)
B Spacer 9.0 (0.35) −
C Disc Spring (Height) 7.6 (0.3) 6.10 (0.24)
D Piston ∗49.6 (1.95) −
E Plate 1.8 (0.071) 1.75 (0.069)
Remark The spacer and piston do not wear down.
NOTE: *Piston thickness (D) is the distance (width)

between the disc spring contacting left end NOTE: 1 mm=0.03937 in
of the piston and the brake plate contacting
right end of the piston.
W3-2-33
(Blank)
W3-2-34
REMOVE AND INSTALL TRAVEL DEVICE
(ZAXIS370MTH)

can penetrate the skin and eyes, causing se-
rious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic
lines.
Hydraulic oil may be hot after operation and
may spurt, possibly causing severe burns. Be
sure to wait for oil to cool before starting any
repair work.
The hydraulic oil tank cap may fly off due to
remaining pressure if removed quickly.
Slowly loosen the cap to release any remain-
ing pressure completely.
Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
2. Stop the engine. Push the air release valve on top M104-07-021

pressure.
3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while
working on the hydraulic system.
W3-2-35
Removal
Before removing the travel device, the tracks must be
removed first. For removal and installation of the tracks,
refer to “Remove and Install Tracks” section on page
1
W3-7-1.
the track have already been removed.
1. Remove bolts (1) (6 used) to remove cover (2)

from the track frame.
: 22 mm
IMPORTANT: Attach identification tags to hoses 2

for reassembly.
2. Disconnect hoses (3 and 4) from travel device (6) W16J-03-02-006
and cap all disconnected hose ends.

: 27 mm, 17 mm
3. Remove socket bolts (8) (8 used) from split

flanges (7) (4 used) to disconnect hoses (9 and
10) from travel device (6). Cap all disconnected 3 Track Frame 4
hoses.
: 10 mm
10
CAUTION: Travel Device weight: 5

670 kg (1480 Ib)
4. Attach wire ropes on travel device (6), and hoist
the travel device by crane.
5. Put matching marks on travel device (6) and the 6

track frame.
Remove bolts (5) (20 used). Hoist and remove the 9 8 7 W16J-03-02-005
travel device by crane.
: 32 mm
W111-03-02-002
W3-2-36
Installation
CAUTION: Travel device weight:

670 kg (1480 Ib)
IMPORTANT: Be sure to align the matching marks 3 Track Frame 4
made during disassembling. By fail-
ing to do so, it is difficult to install
hoses (3 and 4).
1. Install travel device (6) onto the track frame with 10
: 32 mm 5
: 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft)
2. Connect hoses (9 and 10) to travel device (6) with

split flanges (7) (4 used) and tighten the split
6
flange with socket bolts (8) (8 used).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 9 8 7 W16J-03-02-005
3. Connect hoses (3 and 4) onto travel device (6).

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) 1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
4. Install cover (2) onto the track frame with bolts

(1) (6 used).
: 22 mm
: 180 N⋅m (18.5 kgf⋅m, 134 Ibf⋅ft)
2
Start the engine and check for oil W16J-03-02-006
leaks.
After completing installation of the
travel device, be sure to perform
running-in to prevent motor seizure.
Perform break-in operation as follows:

1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position
3. Drive the machine for 2 minutes or more
W3-2-37
DISASSEMBLE TRAVEL DEVICE
(ZAXIS370MTH) 8
7
6
4
3
1 24
23
22
21
20 25
19
17 18
16
15
14 26
13
12 27
28
29
30
31
10 11 32
9 34 33
35
36
37
38 49
39
40
48
47
46
45
44
43
41
42 W16J-03-02-004
1- Motor 14 - Bolt (24 Used) 26 - Spacer 38 - Needle Bearing (4 Used)

2- O-Ring 15 - 3rd Stage Carrier 27 - 1st Stage Carrier 39 - Needle Bearing (4 Used)
3- Housing 16 - 3rd Stage Sun Gear 28 - Thrust Plate (3 Used) 40 - Thrust Plate (4 Used)
4- Floating Seal 17 - 2nd Stage Carrier 29 - Spring Pin (3 Used) 41 - Shaft
5- Roller Bearing 18 - Spacer 30 - 2nd Stage Planetary Gear (3 Used) 42 - Ring Gear
6- Drum 19 - 2nd Stage Sun Gear 31 - Pin (3 Used) 43 - Bolt (30 Used)
7- Roller Bearing 20 - Thrust Plate (3 Used) 32 - Needle Bearing (3 Used) 44 - Retaining Ring
8- O-Ring 21 - Needle Bearing (3 Used) 33 - Thrust Plate (3 Used) 45 - Stopper Pin
9- Nut 22 - Pin (3 Used) 34 - Thrust Plate (4 Used) 46 - Ball Bearing
10 - Lock Plate 23 - 1st Stage Planetary Gear (3 35 - 3rd Stage Planetary Gear (4 Used) 47 - Cover
Used)
11 - Bolt (2 Used) 24 - Thrust Plate (3 Used) 36 - Spring Pin (4 Used) 48 - Bolt (16 Used)
12 - Sprocket 25 - Spring Pin (3 Used) 37 - Pin (4 Used) 49 - Plug (3 Used)
13 - Washer (24 Used)
W3-2-38
Disassemble Travel Device
(ZAXIS370MTH)
CAUTION: Motor (1) weight: 130 kg (290 Ib)
• Be sure to read “Precautions for Disassembly and 2. Put matching marks on the mounting surface of
Assembly Work” thoroughly on page W1-1-1 be- motor (1) and housing (3).
fore starting any disassembly work. Install eyebolts (M12, Pitch 1.75) (2 used) into the
motor. Remove bolts (4 used), then hoist and re-
move the motor by crane. Remove O-ring (2) from
CAUTION: Pressure may remain in the travel
the motor.
device. Slowly loosen the air bleed plug to
: 27 mm
completely release the residual pressure.
Then, remove the drain plug and drain the 3
gear oil into a container. Motor Mounting Bolt
If the air bleed plug is loosened quickly, the
plug may fly off and/or gear oil may spurt.
Keep your face and body away from the plug.
1
(1480 lb)
1. After loosening plug (49-B) 2 to 3 turns, remove
plug (49-A) to drain gear oil from the travel device.
Lay the travel device on a work bench with motor Eyebolt
(1) facing up. Mounting
Position
: 14 mm
W16J-03-02-002
49 -B
(1190 Ib)
3. Attach a wire rope to the middle of drum (6) and
ring gear (42). Hoist the travel device by crane
and place it on the work bench with cover (47) fac-
ing up.
49 -A
CAUTION: Cover (47) weight: 20 kg (44 Ib)
W111-03-02-006 4. Put matching marks on the mounting surface of
cover (47) and ring gear (42).
Install eyebolts (PT 3/4) into the plug (49) holes.
(2 places)
Remove bolts (48) (16 used), then hoist and re-
move cover (47) from ring gear (42) by crane.
: 22 mm
NOTE: Since THREEBOND has been applied to
the mating surfaces of ring gear (42) and
cover (47), it is better to insert a screw
driver between the ring gear and the cover
to pry the cover up for easier removal.
W3-2-39
7
6
4
3
24
23
22
21
20 25
19
17 18
16
15
26
12 27
28
29
30
31
10 11 32
9 34 33
35
36
37
38
39
40
48
43
41
42 W16J-03-02-004
W3-2-40
10. Install special tool (ST 3136) onto bearing nut (9)
CAUTION: Ring gear (42) weight: 70 kg (150
to loosen and remove the bearing nut.
Ib)
5. Put matching marks on the mating parts of ring ST 3136
gear (42) and drum (6) .
Install eyebolts (M14, Pitch 2.0) into the bolt (48)
holes (2 places) in ring gear (42).
Remove bolts (43) (30 used) to hoist and remove
the ring gear by crane.
Remove O-ring (8) from drum (6).
: 27 mm
6. Remove shaft (41) from first stage carrier (27).

Remove first stage carrier assemblies (20 to 27)
and second stage sun gear (19) from second
stage carrier (17).
W111-03-02-018
CAUTION: The second stage carrier (17) as-

sembly weight: 25 kg (50 Ib) CAUTION: Drum (6), sprocket (12) and other
7. Wind nylon slings (2 used) onto second stage car- parts weight: 180 kg (400 Ib)
rier (17). Hoist and remove second stage carrier IMPORTANT: The mating parts of drum (6) and
assemblies (17, 18, 28 to 33) by crane. housing (3) are sliding surface. Take
Remove third stage sun gear (16). care not to damage the sliding sur-
face and put the removed drum as-
sembly onto wooden blocks.
CAUTION: The third stage carrier (15) as- 11. Put matching marks on the mating parts of drum
sembly weight: 70 kg (150 Ib) (6) and housing (3).
8. Wind nylon slings (2 used) onto third stage carrier Install eyebolts (M18, Pitch 2.5) into the bolt (43)
(15). Hoist and remove third stage carrier assem- holes (2 places) in the drum.
blies (15 and 34 to 40) by crane. Hoist and remove the drum assembly from the
housing by crane.
9. Remove bolts (11) (2 used) to remove lock plate At this time, the inner race of roller bearing (7) is
(10). also removed along with it.
: 19 mm
12. Remove floating seals (4) from housing (3) and
drum (6).
W3-2-41
7
6
25
17 18
15
14 26
12 27
29
34
35
36
37
38
39
40
W16J-03-02-004
W3-2-42
IMPORTANT: Do not remove the inner race of 17. Pull spring pin (36) out from third stage carrier
roller bearing (5) from housing (3) (15) with a round bar (Dia: 8mm (0.3 in)). Remove
unless necessary. In case the inner pin (37) to remove third stage planetary gear (35)
race of roller bearing (5) has been and thrust plates (34 and 40) from the third stage
removed, it must be replaced with a carrier.
new one. Remove needle bearings (38 and 39) from the
13. Remove the inner race of roller bearing (5) from third stage planetary gear.
housing (3) with a bar and hammer.
NOTE: If the inner race of roller bearing (5) can not 18. Remove spring pins (36) (3 used), pins (37) (3
be removed, it can be cut by gas torch. used), third stage planetary gears (35) (3 used),
However care should be taken to protect thrust plates (34) (3 used) and (40) (3 used), nee-
housing (3) from being damaged while do- dle bearings (38) (3 used) and (39) (3 used) from
ing this work. third stage carrier (15) according to the steps in
procedure 17.
CAUTION: Sprocket (12) weight: 85 kg 19. Disassemble the first stage carrier (27) assembly
(190 Ib) and second stage carrier (17) assembly according
14. Put matching marks on the mating surface of to the steps in procedures 17 and 18.
sprocket (12) and drum (6). The diameter of round bar for spring pin (25):
Attach nylon slings (2 used) on the sprocket. Re- 4 mm (0.16 in)
move bolts (14) (24 used). Hoist and remove the The diameter of round bar for spring pin (29):
sprocket by crane. 5 mm (0.20 in)
: 32 mm
20. Remove spacer (26) from first stage carrier (27).
IMPORTANT: Do not remove the outer race of Remove spacer (18) from second stage carrier
roller bearings (5) and (7) from drum (17).
(6) unless necessary.
If the bearing is pressed in insuffi-
ciently, the service life of the bearing
may be affected. In case the outer
race has been removed, it must be
replaced with a new one.
15. Remove the outer race of roller bearing (5) from
drum (6) with a bar and hammer.
CAUTION: Drum (6) including other parts

16. Install eyebolts (M22, Pitch 2.5) into the bolt (14)
holes (2 places) in drum (6) from the motor (1)
side.
Hoist and turn the drum over by crane. Remove
the outer race of roller bearing (7) from the drum
with a bar and hammer.
W3-2-43
ASSEMBLE TRAVEL DEVICE
12 13 14
(ZAXIS370MTH)
3 4 6 5 7 9 8
43 42 15 16 18
2 17
1 19
26
27
49
47
44
46
45
41
23
24
25
22
21
20
48
33 30 32 31 28 29
34 36
T16J-03-05-001
10 11 40 35 39 38 37
1- Motor 14 - Bolt (24 Used) 26 - Spacer 38 - Needle Bearing (4 Used)

2- O-Ring 15 - 3rd Stage Carrier 27 - 1st Stage Carrier 39 - Needle Bearing (4 Used)
3- Housing 16 - 3rd Stage Sun Gear 28 - Thrust Plate (3 Used) 40 - Thrust Plate (4 Used)
4- Floating Seal 17 - 2nd Stage Carrier 29 - Spring Pin (3 Used) 41 - Shaft
5- Roller Bearing 18 - Spacer 30 - 2nd Stage Planetary Gear (3 Used) 42 - Ring Gear
6- Drum 19 - 2nd Stage Sun Gear 31 - Pin (3 Used) 43 - Bolt (30 Used)
7- Roller Bearing 20 - Thrust Plate (3 Used) 32 - Needle Bearing (3 Used) 44 - Retaining Ring
8- O-Ring 21 - Needle Bearing (3 Used) 33 - Thrust Plate (3 Used) 45 - Stopper Pin
9- Nut 22 - Pin (3 Used) 34 - Thrust Plate (4 Used) 46 - Ball Bearing
10 - Lock Plate 23 - 1st Stage Planetary Gear (3 Used) 35 - 3rd Stage Planetary Gear (4 Used) 47 - Cover
11 - Bolt (2 Used) 24 - Thrust Plate (3 Used) 36 - Spring Pin (4 Used) 48 - Bolt (16 Used)
12 - Sprocket 25 - Spring Pin (3 Used) 37 - Pin (4 Used) 49 - Plug (3 Used)
13 - Washer (24 Used)
W3-2-44
Assemble Travel Device
(ZAXIS370MTH)
• Be sure to read “Precautions for Disassembly and 5. Install eyebolts (M18, Pitch 2.5) into the bolt (43)
Assembly Work” thoroughly on page W1-1-1 be- holes (2 places) in drum (6).
fore starting the assembly work. Hoist and place the drum with the ring gear (42)
side facing up by crane.
Install the outer race of roller bearing (7) onto the
CAUTION: Housing (3) weight: 90 kg (200 Ib)
drum by tapping it with a bar and hammer evenly.
1. Wind a nylon sling on housing (3) body. Hoist and
place the housing with motor (1) side facing down NOTE: Tap the bearing and listen to ring to see if
by crane. the installation of the outer race is com-
pleted into drum (6).
IMPORTANT: For handling of the floating seal, re-
fer to the section “Precautions for CAUTION: Sprocket (12) weight: 85 kg (190 Ib)
Floating Seal Handling” on page 6. Attach nylon slings (2 used) on sprocket (12).
W1-1-4. Hoist the sprocket and place it carefully onto drum
2. Install one half of floating seal (4) on housing (3) (6).
with a wooden spatula or similar tool to guide the
seal along the periphery. IMPORTANT: Apply LOCTITE #262 on bolt (14).
Install the inner race of roller bearing (5) into the 7. Install spring washer (13) to each bolts (14) (24
housing by tapping it with a bar and hammer used). Tighten the bolts and install sprocket (12)
evenly. onto drum (6).
NOTE: Tap the bearing and listen to ring to see if : 32 mm
the installation of the inner race is com- : 750 N⋅m (76.5 kgf⋅m, 550 lbf⋅ft)
pleted into housing (3).
CAUTION: Drum (6), sprocket (12), plus
CAUTION: Drum (6) weight: 96 kg (210 Ib) other parts weight: 180 kg (400 Ib)
3. Install eyebolts (M22, Pitch 2.5) into the bolt (14) IMPORTANT: Align the matching marks made be-
holes (2 places) in drum (6) from the motor (1) fore disassembling. Be sure the
side. clearance all around drum (6) in
Hoist and place the drum with the ring gear (42) housing (3) is equal.
side facing down by crane. 8. Hoist the drum (6) assembly by crane and put it
Tap the outer race of roller bearing (5) with a bar onto housing (3).
and hammer evenly to install it onto the drum.
NOTE: Tap the bearing and listen to ring to see if 9. Install the inner race of roller bearing (7) onto the
the installation of the outer race is com- housing by tapping it with a bar and hammer
pleted into drum (6). evenly.
IMPORTANT: Apply grease to the O-ring of float-

ing seal (4) on the drum (6) side.
4. Install one half of floating seal (4) on drum (6).
W3-2-45
12
3 6 7 9 8
15
47
34 36
T16J-03-05-001
10 11 40 35 39 38 37
W3-2-46
IMPORTANT: Install bearing nut (9) with the IMPORTANT: If lock plate (10) fails to engage the
stepped part facing roller bearing spline of housing (3), tighten bearing
(7). nut (9) further in the tightening di-
Apply a film of grease at the rection to align with the spline.
threaded part of the bearing nut. Apply LOCTITE #262 to bolts (11).
10. Install bearing nut (9) onto housing (3) and tighten 14. Install lock plate (10) onto bearing nut (9) with
it by hand. bolts (11) (2 used).
NOTE: Apply a film of grease to the threaded part : 19 mm
of bearing nut (9) so as to tighten the nut to : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
the specified torque.
IMPORTANT: Apply grease on O-ring (8).
11. Install special tool (ST 3136) onto bearing nut (9) 15. Install O-ring (8) onto drum (6).
and tighten it with a wrench.
: 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft) IMPORTANT: There is an identification groove on
one half of third stage planetary gear
ST 3136 (35). Install the third stage planetary
gear with the identification groove
facing cover (47).
16. Install needle bearings (38) (4 used) and (39) (4
used) onto third stage planetary gears (35) (4
used). Install the third stage planetary gear onto
third stage carrier (15) by clamping it with thrust
plates (34) (4 used) and (40) (4 used).
17. Align the spring pin (36) holes in third stage carrier
(15) and pins (37) (4 used), then install the spring
pins.
W111-03-02-018
IMPORTANT: When installing spring pin (36), be
sure to let its slit face the end of pin
12. Rotate sprocket (12) both clockwise and counter- (37).
clockwise 4 to 5 turns. Tap on drum (6) with a 18. Install spring pins (36) (4 used) into third stage car-
plastic hammer to secure appropriate play. rier (15) and pin (37) with a round bar (Dia: 8 mm
(0.3 in)).
13. Perform procedures 11 and 12 twice and tighten 36
bearing nut (9) to the specified torque.
: 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft) 37
Slit
W178-02-06-002
W3-2-47
3 6
43 42 15 16 17 19
26
27
47
41
23
24
25
22
21
20
48
33 30 32 31 28 29
34 36
T16J-03-05-001
40 35 39 38 37
W3-2-48
19. Install spacer (26) to first stage carrier (27).
CAUTION: The second stage carrier (17) as-
sembly weight: 25 kg (60 Ib)
20. Install needle bearings (21) (3 used) onto first
25. Wind nylon slings (2 used) onto second stage car-
stage planetary gears (23) (3 used). Clamp the
rier assemblies (17, 18 and 28 to 33). Hoist the
first stage planetary gear with thrust plates (24) (3
second stage carrier assemblies by crane and
used) and (20) (3 used) and install the first stage
lower it onto third stage sun gear (16).
planetary gear onto first stage carrier (27).
26. Install second stage sun gear (19) onto second
IMPORTANT: When installing spring pin (25), be
stage carrier (17) with the smaller end facing
sure to let its slit face the end of pin
cover (47).
(22).
21. Install spring pins (25) (3 used) into first stage car- Cover (47) Side
rier (27) and pin (22) by a round bar (Dia: 4 mm
(0.16 in)).
25
22
19 W166-03-02-002
Slit
27. Install first stage carrier assemblies (20 to 27)
W178-02-06-002
onto second stage carrier (17).
22. Assemble second stage carrier (17) according to

the procedures 19 to 21. 28. Insert shaft (41) into the center of carrier and be
Round Bar Dia: 5 mm (0.20 in) sure to let it engage with the first stage planetary
gears (23) (3 used).
CAUTION: The third stage carrier (15) as-

sembly weight: 70 kg (150 Ib) CAUTION: Ring gear (42) weight: 70 kg
23. Wind nylon slings (2 used) onto third stage carrier (150 Ib)
assemblies (15 and 34 to 40). Hoist the third IMPORTANT: Align the matching marks made
stage carrier assemblies by crane and lower it when disassembling.
onto housing (3) carefully. 29. Install eyebolts (M14, Pitch 2.0) into the bolt (48)
hole in ring gear (42). Hoist ring gear by crane and
24. Install third stage sun gear (16) onto third stage lower it to drum (6).
carrier (15) with the smaller end facing cover (47).
IMPORTANT: Apply LOCTITE #262 on bolt (43).
30. Install ring gear (42) onto drum (6) with bolts (43)
Cover (47) Side
(30 used).
: 27 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
W166-03-02-001
16
W3-2-49
3
42
2
1
49
47
44
46
45
48
T16J-03-05-001
W3-2-50
31. Attach a tube bar on ball bearing (46). Tap a tube
CAUTION: Travel reduction gear weight:
bar with a hammer and install the ball bearing
540 kg (1190 Ib)
onto cover (47).
37. Install eyebolts (M18, Pitch 2.5) into the bolt holes
Ball Bearing Inner Diameter: 45 mm (1.77 in)
(2 places) in the housing (3) flange. Hoist the
Outer Diameter: 68 mm (2.68 in)
travel reduction gear and turn it over by crane.
32. Attach a tube bar on stopper pin (45). Tap a tube
38. Fill gear oil 11.5 L (3.0 US gal.) into the travel re-
bar with a hammer to install the stopper pin into
duction gear.
ball bearing (46).
Stopper Pin Inner Diameter: 26 mm (1.02 in)
39. Install O-ring (2) to motor (1).
Outer Diameter: 50 mm (1.97 in)
IMPORTANT: Install retaining ring (44). Be sure to CAUTION: Motor (1) weight: 130 kg (290 Ib)
let the chamfered part face cover 40. Install eyebolts (M12, Pitch 1.75) (2 used) into the
(47). bolt holes in motor (1). Hoist the motor and install
33. Install retaining ring (44) onto cover (47). it onto housing (3) by crane while aligning the
splines on shaft (41) with the splines on the motor.
CAUTION: Cover (47) weight: 20 kg (44 Ib) 3
IMPORTANT: Apply THREEBOND #1389B to the Motor Mounting Bolt
cover (47) mounting surface of ring
gear (42).
34. Install eyebolts (PT 3/4) into the plug (49) holes (2
places) in cover (47). 1
Hoist the cover by crane and lower it to ring gear
(42).
IMPORTANT: Apply LOCTITE #262 on bolt (48).

35. Install cover (47) onto ring gear (42) with bolts
(48) (16 used). Eyebolt
Mounting Position
: 22 mm
: 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft) W16J-03-02-002
36. Wrap the seal tape to plugs (49) (3 used) and in-
41. Install spring washers to each bolt (4 used), then
stall the plugs into cover (47).
install motor (1) into housing (3) with the bolts
: 14 mm
(4 used).
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
: 27 mm
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
W3-2-51
DISASSEMBLE TRAVEL MOTOR
(ZAXIS370MTH)
4
3
2
1
7
6
2 5
17
15 16
14
13
11 12
10
28
22
27
20
26
25
24
23
19
18
33
32
21
31
30
29
W16J-03-02-001
1- Casing 10 - Piston (9 Used) 18 - Friction Plate 26 - Backup Ring
2- O-Ring (4 Used) 11 - Retainer 19 - Friction Plate 27 - Brake Piston
3- Spring (2 Used) 12 - Holder 20 - Disc Plate (4 Used) 28 - O-Ring
4- Piston (2 Used) 13 - Spring (9 Used) 21 - Friction Plate (3 Used) 29 - Spring (10 Used)
5- Oil Seal 14 - Cylinder Block 22 - Friction Plate 30 - Pin
6- Roller Bearing 15 - Valve Plate 23 - Backup Ring 31 - Pin (4 Used)
7- Shaft 16 - Collar 24 - O-Ring 32 - Valve Housing
8- Steel Ball (2 Used) 17 - Roller Bearing 25 - O-Ring 33 - Socket Bolt (9 Used)
9- Swash Plate
W3-2-52
Disassemble Travel Motor (ZAXIS370MTH)
• Be sure to read “Precautions for Disassembly and IMPORTANT: Fix casing (1) securely.
Assembly Work” thoroughly on page W1-1-1 be- 4. Install eyebolts (M12, Pitch 1.75) into the pin (31)
fore starting the disassembly work. holes (2 places) in brake piston (27). Hoist the
brake piston and remove it from casing (1) by
CAUTION: Valve housing (32) weight: 39 kg crane.
(90 Ib)
IMPORTANT: Loosen socket bolts (33) (9 used) 5. Remove O-rings (24 and 25), backup rings (23
evenly. When loosening the socket and 26) from brake piston (27).
bolts, valve housing (32) may come
up from casing (1) since there is a IMPORTANT: Since friction plates (18, 19, 21 and
spring force coming from springs 22) are different in thickness and the
(13) and (29). Take down the clear- order to install them has been de-
ance between the casing and the termined, they should be kept in or-
valve housing. der while removing.
When removing the valve housing 6. Remove friction plate (22) from casing (1). Re-
from the casing, valve plate (15) will move disc plates (20) (4 used) and friction plates
come out with the valve housing, do (21) (3 used) one by one alternately. Remove fric-
not let the plate come off. tion plates (19 and 18).
1. Put matching marks on the mating part of valve
housing (32) and casing (1). Install eyebolts (M12, CAUTION: The cylinder block (14) assembly
Pitch 1.75) onto the valve housing. weight: 20 kg (40 Ib)
Remove socket bolts (33) (9 used). Hoist the IMPORTANT: If cylinder block (14) needs to be re-
valve housing and remove it from the casing by placed, cylinder block assemblies (10
crane. to 15) with valve plate (15) should be
: 14 mm replaced.
1 32
7. Remove cylinder block (14) assemblies (10 to 15)
33 from casing (1).
NOTE: Hold cylinder block (14) and turn it left and
right lightly by two hands to take it out
slowly.
8. Remove retainer (11), pistons (10) (9 used),

holder (12) and springs (13) (9 used) from cylinder
block (14).
Eyebolt Mounting
Position IMPORTANT: Do not damage the friction surface
of swash plate (9).
W16J-03-02-002
Piston (4) and steel ball (8) may
2. Remove springs (29) (10 used), O-rings (2) (4 come out with the swash plate. Be
used), pins (31) (4 used) and O-ring (28) from cas- sure to keep the piston and the steel
ing (1). ball from dropping.
9. Remove swash plate (9) from casing (1).
IMPORTANT: Take care not to damage valve plate
(15).
3. Remove collar (16) and valve plate (15) from cyl-
inder block (14).
W3-2-53
4
3
1
7
6
5
W16J-03-02-001
W3-2-54
10. Remove pistons (4) (2 used), springs (3) (2 used)
and steel balls (8) (2 used) from casing (1).
NOTE: If it is difficult to remove steel ball (8), that
means the ball has been set in casing (1),
so use some kerosene or thinner, etc. to
clean grease first, and then with a magnet
to take it out from casing (1).
IMPORTANT: Do not damage the spline part of

shaft (7) and contact part of oil seal
(5). Oil leakage will occur if they are
damaged.
11. Remove shaft (7) from casing (1). At this moment,
the inner race of roller bearing (6) is connecting
with the shaft.
IMPORTANT: Do not remove the inner race of

roller bearing (6) from shaft (7) and
the outer race of roller bearing (6)
from casing (1) unless necessary.
12. Remove the inner race of roller bearing (6) from
shaft (7) with a press.
IMPORTANT: Keep the outer race of roller bearing

(6) properly so that it can be installed
in the same direction before disas-
sembling.
13. Remove the outer race of roller bearing (6) from
casing (1) with a bar and a hammer.
14. Remove oil seal (5) from casing (1).
W3-2-55
(ZAXIS370MTH)
27
25,26 23,24 22 19 18 7 4 3
33 29
30
16
32
17
1
15
31
5
28
T16J-03-05-003
2 6
Brake Release Circuit 14 10 20 21 13 11 12 9
1- Casing 10 - Piston (9 Used) 18 - Friction Plate 26 - Backup Ring

2- O-Ring (4 Used) 11 - Retainer 19 - Friction Plate 27 - Brake Piston
3- Spring (2 Used) 12 - Holder 20 - Disc Plate (4 Used) 28 - O-Ring
4- Piston (2 Used) 13 - Spring (9 Used) 21 - Friction Plate (3 Used) 29 - Spring (10 Used)
5- Oil Seal 14 - Cylinder Block 22 - Friction Plate 30 - Pin
6- Roller Bearing 15 - Valve Plate 23 - Backup Ring 31 - Pin (4 Used)
7- Shaft 16 - Collar 24 - O-Ring 32 - Valve Housing
8- Steel Ball (2 Used) 17 - Roller Bearing 25 - O-Ring 33 - Socket Bolt (9 Used)
9- Swash Plate
W3-2-56
Assemble Travel Motor (ZAXIS370MTH)
• Be sure to read “Precautions for Disassembly and IMPORTANT: Align the spherical hole in swash
Assembly Work” thoroughly on page W1-1-1 be- plate (9) with steel ball (8), then in-
fore starting the assembly work. stall the swash plate.
Apply grease to matching part of
IMPORTANT: Apply grease on inside periphery of casing (1) for the swash plate.
oil seal (5) for casing (1) at the 6. Install swash plate (9) onto casing (1) with its
pressed-in part and outside periph- thicker side facing down.
ery of the oil seal.
In addition, the oil seal should be IMPORTANT: Apply hydraulic oil on the piston (10)
pressed in straight to prevent it from mounting hole of cylinder block (14).
deforming. Pay attention to the mounting direc-
1. Press oil seal (5) into casing (1). tion of retainer (11).
IMPORTANT: Install the outer race of roller bearing 7. Install springs (13) (9 used) and holder (12) into
(6) with the stamp mark on the outer cylinder block (14).
race facing the swash plate (9) side. Install pistons (10) (9 used) onto retainer (11) and
2. Tap the outer race of roller bearing (6) evenly with install them into the cylinder block.
a bar and hammer while installing the outer race
into casing (1).
NOTE: Tap the bearing and listen to ring to confirm CAUTION: The cylinder block (14) assembly
if installation is completed. weight: 20 kg (40 Ib)
IMPORTANT: Apply hydraulic oil to the piston (10)
sliding surface of swash plate (9)
IMPORTANT: Install the inner race of roller bearing and the spherical surface of holder
(6) with its collar facing swash plate (12).
(9). There is the inner race for roller bear-
3. Tap the inner race of roller bearing (6) evenly with ing (17) on the tip of shaft (7). Take
a bar and hammer while installing it into shaft (7). care to keep it away from being
Tap and install the shaft assembly into casing (1) damaged.
with a hammer. Align the shaft splines to those of
cylinder block (14).
IMPORTANT: Apply hydraulic oil on outside pe- 8. Install the cylinder block (14) assembly onto shaft
riphery of steel ball (8) and piston (4). (7).
Apply hydraulic oil the piston and
the steel ball mounting surfaces of
casing (1). CAUTION: The casing (1) assembly weight:
4. Install springs (3) (2 used), pistons (4) (2 used) 54 kg (120 Ib)
and steel balls (8) (2 used) into casing (1). 9. Install eyebolts (M18, Pitch 2.5) into the socket
bolts (33) holes (2 places) in casing (1). Hoist the
casing and place it vertically by crane.
CAUTION: The casing (1) assembly weight:
54 kg (120 Ib)
5. Install eyebolts (M18, Pitch 2.5) into the bolts (33)
holes in casing (1) (2 places). Hoist the casing as-
sembly up by crane and place it with the brake re-
lease circuit facing down.
W3-2-57
27
25,26 23,24 22 19 18
29
30
16
32
17
1
15
31
T16J-03-05-003
14 20 21
W3-2-58
10. Install friction plates (18 and 19) into casing (1). IMPORTANT: As for springs (29) (10 used), there
Then install disc plates (20) (4 used) and friction are twelve spring mounting holes in
plates (21) (3 used) alternately and finally install brake piston (27), so pay attention to
friction plate (22) into the casing. where the spring should be inserted
NOTE: Friction plates (18, 19, 21 and 22) are dif- and not make mistakes.
ferent in thickness. 27
(18), (22): 4.8 mm (0.2 in) Free Hole
(19): 6.5 mm (0.3 in)
(21): 3 mm (1.0 in)
29
So they should be installed while aligning
with their own notch respectively in casing
(1).
When installing disc plate (20), its inner
splines shall be aligned with those of cylin-
29
der block (14).
IMPORTANT: Apply grease to O-rings (24 and 25)

and backup rings (23 and 26). Free Hole W16J-03-02-003
11. Install backup rings (26 and 23) and O-rings (25
and 24) onto brake piston (27). 13. Install springs (29) (10 used) onto brake piston
(27).
IMPORTANT: Pay attention to the mounting direc-
tion for brake piston (27), so that the IMPORTANT: Install the outer race of roller bearing
notch shall be square to the pin (31) (17) with the stamp mark on the
holes in casing (1). outer race facing the valve plate (15)
side.
1
14. Tap the outer race of roller bearing (17) evenly
with a bar and hammer to install the outer race
into valve housing (32).
27
NOTE: Tap the bearing and listen to ring to confirm
if the outer race is installed to the most end
Notch
of valve housing (32).
IMPORTANT: Apply grease to the mating surfaces

of valve plate (15) and valve housing
(32).
15. Install collar (16) into valve housing (32). Align the
pin holes in pin (30) and valve plate (15) to install
W16J-03-02-003 the valve plate into the valve housing.
31
12. Tap brake piston (27) with a plastic hammer to in-

stall it into casing (1).
W3-2-59
33 27
32
31
28
T16J-03-05-003
W3-2-60
IMPORTANT: Apply grease to O-rings (2 and 28).
16. Install O-rings (28) and (2) (4 used) into casing (1)
and install pins (31) (4 used) to valve housing
(32).
CAUTION: Valve housing (32) weight: 39 kg

(90 Ib)
IMPORTANT: When installing valve housing (32)
into casing (1), be sure to confirm
the clearance value between the cas-
ing and the valve housing is equal to
that noted on disassembling. If the
value is different, disassemble them
and reassemble again.
IMPORTANT: Align the matching marks made
when disassembling. If the matching
marks cannot be aligned with each
other, brake piston (27) may be in-
stalled in wrong direction.
17. Install eyebolt (M12, Pitch 1.75) into the bolt hole
in valve housing (32).
Hoist valve housing (32) to put it onto casing (1)
while aligning the pin (31) hole in brake piston (27)
by crane.
Install the valve housing onto the casing with
socket bolts (33) (9 used).
: 14 mm
: 440±21.5 N⋅m
(45±2.2 kgf⋅m, 330±16 lbf⋅ft )
NOTE: Tighten socket bolts (33) (9 used) evenly.
1 32
33
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-61
DISASSEMBLE BRAKE VALVE
(ZAXIS370MTH)
6
1 7
2 8
3 5
4 9
10 Plug
11
10 9
35
Orifice
12
36 13
37 14
38 16 15
39 18
40 20
21
48
17 22
19
24
26 5
47
49
46 28 23
10 30 25
9
41 32
27 33
42 34
43 29
44 31
4
45 3
Orifice
2
1
44
43
36 42
41
50
40
39
35
38
37
W183-03-02-010
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 Used) 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)
W3-2-62
Disassemble Brake Valve
(ZAXIS370MTH)
IMPORTANT: Do not disassemble overload relief
CAUTION: The valve housing (46) assembly
valves (5) (2 used). The overload re-
lief valve should be replaced as as-
1. Secure the valve housing (46) assembly on a firm
sembly. Attach tags on each over-
work bench.
load relief valves so that they can be
installed to their original positions.
2. Remove plugs (6 and 15) and O-rings (7 and 14).
In addition, do not rotate set screw
Then remove spring (8).
(34), or the setting pressure can
: 10 mm
change.
5. Loosen plug (32) to remove overload relief valve
IMPORTANT: Remove valve assembly (13) while
(5) from valve housing (46). (2 places at right and
rotating it. If a little resistance is felt
left)
while removing, do not try to remove
: 36 mm
it by force, return to original position
and retry.
6. Press cap (36) while loosening socket bolts (35)
In addition, do not disassemble the
(4 used) to remove the cap from valve housing
valve assembly. In case replacement
(46). (2 places at right and left)
should be carried out to any parts of
: 10 mm
it, be sure to replace it with the valve
housing (46) assembly including NOTE: In case cap (36) cannot be removed, a
spool assembly (50), valve assembly plastic hammer can be used to tap the cap,
(13), orifices (11 and 49) and the however, the loosened socket bolts (35)
plug. should be still on the cap while tapping.
3. Press valve assembly (13) out carefully and rotate
the valve assembly by hand to remove it from 7. Remove spring seat (38), spring (39) and spring
valve housing (46). seat (40) from valve housing (46). (2 places at
right and left)
4. Remove plug (1). Then remove O-ring (2), spring
(3) and check valve (4). (2 places at right and left) IMPORTANT: Remove spool assembly (50) while
: 14 mm rotating it. In case a little resistance
is felt while removing, do not try to
remove it by force, return to original
position and retry.
8. Press spool assembly (50) out carefully. Rotate
the spool assembly by hand to remove it from
valve housing (46).
9. Clamp spool assembly (50) in a vice with a chip of

wood inserted at both side.
10. Remove plugs (41) (2 used), then remove springs

(43) (2 used) and check valves (44) (2 used) from
spool (45).
W3-2-63
(ZAXIS370MTH) Overload Relief Valve (5)
16 18 21 26 24 27 31 29 32 33
34
17, 19 20 22 23, 25 28 30
36 38
41
6
37
35 39
42
A A A 7
40
43
8
44
45
13
50
14
48 47
12
15
46
5 2 1 3 4
Section A-A-A W183-03-02-016
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 Used) 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- *Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - *O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - *Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - *Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)
NOTE: As for parts with *, refer to W3-2-62.
W3-2-64
Assemble Brake Valve (ZAXIS370MTH)
1. Install O-rings (7 and 14) to plugs (6 and 15) re-
spectively. Install valve assembly (13) and plugs
(6 and 15) into valve housing (46).
: 10 mm
: 64±4.9 N⋅m
(6.5±0.5 kgf⋅m, 47±3.6 lbf⋅ft)
2. Install O-ring (2) to plug (1) and install check valve

(4), spring (3) and the plug into valve housing (46).
(2 places at right and left)
: 14 mm
: 410±19.5 N⋅m
(42±2 kgf⋅m, 300±14.5 lbf⋅ft)
IMPORTANT: Install overload relief valve (5) to the

former position before disassem-
bled.
3. Install overload relief valves (5) (2 used) onto
valve housing (46).
: 36 mm
: 410±19.5 N⋅m
(42±2 kgf⋅m, 300±14.5 lbf⋅ft)
4. Rotate spool assembly (50) slowly to insert it into

valve housing (46).
5. Install O-ring (37) into cap (36). (2 places at right

and left)
6. Install spring seat (40), spring (39) and spring seat

(38) into valve housing (46). Then install cap (36)
with socket bolts (35) (4 used). (2 places at right
and left)
: 10 mm
: 108±4.9 N⋅m
(11±0.5 kgf⋅m, 80±3.6 lbf⋅ft)
W3-2-65
(ZAXIS370MTH)
Cylinder
1. The clearance between the inner diameter of cyl- Block
inder block and the outer diameter of the piston:
Ȁ (D-d): 0.06 mm or less D d
W507-02-04-009
Piston
2. The clearance between the piston and shoe when

Piston
engaging:
δ: 0.4 mm or less
Shoe
δ
W107-02-06-140
Piston
3. The clearance between the inner diameter and
outer diameter at the matching position of casing
and piston: D
Ȁ (D-d): 0.03 mm or less
Casing
W162-03-02-005
4. The wear allowance on the sliding surfaces of cyl-
inder block and valve plate:
Check there is no abnormal scratch, wear or
score.
The wear allowance shall be within 0.02 mm or
less.
W3-2-66
Sprocket
B
C
D
A E
W1HH-03-02-002
Unit: mm (in)
Standard Dimension Allowable Limit Remedy
A 92 (3.62) [82 (3.23)]
B 86.1 (3.39) 81.1 (3.19) Cladding by
C 122.1 (4.8) - welding and
D 132 (5.2) 127 (5.0) finishing
E 215.9 (8.46) -
NOTE: Value in [ ] is for reference only.
W3-2-67
(Blank)
W3-2-68
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
CAUTION: Hydraulic flue under pressure can

penetrate the skin or eyes, causing serious
injury. Avoid this hazard by releasing pres-
sure before disconnecting hydraulic or other
lines.
and may spurt, causing severe burns. Be
sure to wait for oil to cool before starting
work.
moved without first releasing internal pres-
sure. Push the air release valve on top of
ing pressure.
Preparation
1. Park the machine on a firm, level surface. Lower
the front attachment onto the ground.

pressure.
M104-07-021
3. Remove hydraulic oil tank cap, connect a vacuum
pump and put it into operation to keep negative
pressure in the hydraulic oil tank.
Be sure to run the vacuum pump continuously
while working.
W3-3-1
Removal
1. Attach tags to hoses and adapters of the center

joint to aid in assembly.
Ȁ Disconnect all hoses and adapters from the cen-
ter joint. Plug all disconnected ends.
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
2. Remove bolt (1) from the center joint to remove

stopper plate (2). 1 2
: 22 mm
: 140 N⋅m (14.5 kgf⋅m, 105 lbf⋅ft)
CAUTION: Center joint weight: 27 kg (60 lb)
3. Remove bolt (3) from the center joint. Hoist the

center joint and remove it by crane.
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
W157-03-03-003
Installation
wrench sizes and tightening torque. 3
1. Install the center joint with bolts (3).
2. Install stopper plate (2) to the center joint with

bolts (1).
3. Connect all hoses to the center joint.
IMPORTANT: After installation, start engine and

check the component for any oil
leaks.
W105-03-03-003
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
3
4
10
9
11
12
W157-03-03-002
1 - Plug (with Ball) 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-4
Disassemble Center Joint IMPORTANT: For easy removal, two pins can be
• Be sure to thoroughly read “Precautions for Dis- used to pry out oil seals (6). Take
assembly and Assembly Work” on page W1-1-1 care not to damage the seal groove
before starting the disassembly work. with the pins.
6. Remove oil seals (6) (6 used) and O-ring (4) from

CAUTION: Center joint weight: 26.5 kg (60 lb)
body (7).
1. Remove mounting bolt (12) from cover (11)
diagonally. Using eyebolts M10 (pitch 1.5, length
18 mm), hoist the center joint then secure it on a
work bench.
IMPORTANT: Put matching marks on body (7) and

spindle (2).
2. Remove bolts (12) to remove cover (11) from

body (7).
: 17 mm
3. Remove O-ring (9), retaining ring (10) and ring (8)

from body (7).
W105-03-03-015
4. Attach the special tool (ST 1033, ST 1020) to 7. Remove dust seal (3) from spindle (2).
body (7) with mounting bolts (12) (2 used) on
cover (11). IMPORTANT: While welding, be sure to cover the
: 17 mm seal surface to prevent it from being
ST 1020
spattered.
ST 1033
8. When replacing bushing (5), build-up weld at 4
places in its inner diameter with welding rod,
shrink bushing (5) to pull it out.
W506-03-03-002
IMPORTANT: Take care not to damage the sliding

surface of the spindle (2) seal.
5. Remove spindle (2) from body (7).
W3-3-5
ASSEMBLE CENTER JOINT
3
4
6
7
8
10
9
11
12
W178-03-03-001
1 - Plug (with Ball) 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-6
Assemble Center Joint
IMPORTANT: If bushing is removed, be sure to IMPORTANT: Clearance between body (7) and
reinstall bushing (5) first. (Refer to spindle (2) is approximately 0.1 mm
page W3-3-8.) (0.004 in), so the spindle must be in-
serted along axis straight and
IMPORTANT: Install dust seal (3) with its lip side slowly.
facing body (6).
4. Tap body (7) with a plastic hammer until its sur-
1. Install dust seal (3) into spindle (2). face A is flush with that of spindle (2).
Surface A 2
0.1 mm
Dust Seal (3) 7
Lip
Body (7)
W105-03-03-024
W178-03-03-002
2. Install oil seals (6) (6 used) and o-ring (4) into IMPORTANT: Be sure to install ring (8) with the
body (7). chamfered side facing spindle.
Ȁ
3. Secure spindle (2) to a work bench. Install body 5. Install ring (8) and O-ring (9) to body (7).
(7) on spindle (2) with their matching marks
aligned. 6. Install retaining ring (10) to spindle (2).
Ȁ
7. Install cover (11) with bolts (12) (4 used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
Ȁ
Ȁ
W3-3-7
When replacing the body or spindle with new one, the
following procedures are required.
IMPORTANT: When press bushing (5) into body (7),

grease or molybdenum disulphide
should be applied to the fitting sur-
face.
Replacing Spindle (2)
Replacing Body (7)
1. Clean spindle (2).
Press bushing (5) into body (7).
2. Tap plugs (1) into spindle (2) using special tools
1. Clean body (7) and bushing (5). (ST 2559).
2. Press bushing (5) into body (7) with the pressing 3. Tap the balls of plug (1) so that the top of each
tool. ball is 0.4 mm (0.016 in) or more lower than the
Pressing force: 0.5 to 1.5 t (1100 to 3300 lb) respective sleeve edge as illustrated in detail D.
Pressing tool: ST 2558
1
ST 2558
Sleeve
2
7
0.4 mm
or More
Detail D
W135-03-03-001
W136-03-03-031
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-8
Item Allowable limit (basis for judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Scored, abnormal wear Replace
3. Uneven wear (wear range is within 180°) Replace
Wear range is within
one half
Bushing
T157-01-01-040
Sliding surface Scored or serious damage Replace

and sealed part
Sliding surface of 1) Scored or abnormal wear of more than Replace
body and spindle, 0.1 mm (0.004 in)
except sealed 2) Scored less than 0.1 mm (0.004 in) deep Repair and finish
Body ⋅ Spindle part with oil stone
1) Wear more than 0.5 mm (0.02 in) deep Replace
And abnormal wear
Sliding surface 2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
and ring
3) Scored or abnormal worn less than 0.5 mm Repair and finish
(0.02 in) deep and able to be repaired.
1) Wear more than 0.5 mm (0.02 in) Replace
Sliding surface 2) Wear less than 0.5 mm (0.02 in) Repair and finish
Cover and ring 3) Scored or abnormal wear less than 0.5 mm Repair and finish
(0.02 in) and able to be repaired.
W3-3-9
(Blank)
W3-3-10
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
Before removing and adjusting the track adjuster, the

tracks and the front idler must be removed first. For
removal of the tracks and front idler, refer to their Re-
moval / Installation sections.
the tracks and front idler have already been removed.
Removal
CAUTION: Track adjuster weight:
180 kg (400 lb)
CAUTION: The front idler may jump out due
to strong spring force when disconnecting
the tracks adjuster (1). Do not stand in the
same direction as to track adjuster’s (1) re-
moval, nor any vicinity where there may be a
clanged of being injured by the idler flying
off.
Particularly, a strong spring force is always
applied to the threaded part of the rod. If the
rod and/or the threads are damaged, metal
2
fragments under spring force may fly off.
Take due care.
1
1. After removing the front idler with yoke, remove

track adjuster (1) from track frame (2) by prying it
out with a pry bar.
W157-03-04-003
3 4
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Ȁ Check that the end face of track adjuster (1)
comes into contact with the face of plate (4).
W157-03-04-002
2 3
Section A
W157-03-04-001
W3-4-1
DISASSEMBLE TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
17
1
2
3
5
6
7
10
16 11
12
15
14
13
W173-03-04-001
1- Socket Bolt (4 Used) 6- U-Ring 10 - Cylinder 14 - Washer

2- Flange 7- Retaining Ring 11 - Plug 15 - Spacer
3- Dust Seal 8- Rod 12 - Valve 16 - Spring
4- Piston Rod 9- O-Ring 13 - Nut 17 - Holder
5- Wear Ring
W3-4-2
Disassemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH)

IMPORTANT: Be sure to use special tool (ST 4920)

for assembly / disassembly of the
track adjuster.
CAUTION: Prevent personal injury. The

spring force of the track adjuster is extremely
large. Thoroughly inspect the special tool for Special Tool
(ST 4290)
any damage. Carefully perform assembly
work referring to the procedure below.
CAUTION: Approximate weight of the track

spring holder assembly: 225 kg (496 lb)
Support
1. Place an oil jack (30 t) on the bottom of the track

Oil Jack
spring holder assembly (ST 4920).
Base
W105-03-04-006
2. Loosen nuts (4 used) to remove the plate (ST Plate (ST 4036)
4036).
: 46 mm
W105-03-04-007

180 kg (400 lb)
3. Attach a wire rope to the track adjuster as illus-

trated.
Hoist the track adjuster to place it onto the holder
of special tool by crane.
W105-03-04-009
W3-4-3
11
12
14
13
W173-03-04-001
W3-4-4
4. Install plate (ST 4036) on the track adjuster and
secure them together.
Plate (ST 4036)
W105-03-04-011
5. Set an oil jack as illustrated.
Jack up the specified amount below to compress

the spring.
Oil Jack
Specified Amount
122 mm = (Free length : 679 mm) − (Set length :
557 mm)
NOTE: 1 mm = 0.03937 in
6. Tighten nuts to secure the track adjuster.

Operate the oil jack to compress the track ad-
juster approximately 10 mm (0.4 in) until a clear- W105-03-04-013
ance is observed between washer (14) and nut

(13).
: 46 mm
7. Remove plug (11) from nut (13). Remove nut (13)

and valve (12) from rod (8).
: 5 mm
: 85 mm
: 24 mm W105-03-04-012
13 8 11
W105-03-04-014
W3-4-5
17
1
2
3
5
6
7
10
16
15
14
W173-03-04-001
W3-4-6
8. Lower jack to release the spring force.
Oil Jack
W105-03-04-015
9. Remove the nuts to remove the plate (ST 4036).

Remove washer (14). Plate (ST 4036)
14
CAUTION: Spring assembly weight:
168 kg (370 lb)
10. Install eyebolt (M16, pitch 1.5) to rod (8).

Hoist the track adjuster by crane, to remove the W105-03-04-016
spring (16) assembly.
Eyebolt
CAUTION: Spring weight: 95 kg (209 lb)
11. Remove spring (16) from rod (8) after removing

the eyebolt.
12. Remove spacer (15) from rod (8).
CAUTION: Note that holder (17) is pressed to

piston rod (4).
W105-03-04-017
13. Remove socket bolts (1) (4 used). Move flange (2)
to holder (17). Pull out flange (2) from cylinder
4
(10).
: 8 mm
5
14. Pull out piston rod (4) assembly from cylinder
(10).
15. Press out holder (17) from piston rod (4) assem-
bly with a press. 6
7
16. Remove flange (2) from piston rod (4). Remove
dust seal (3) from flange (2). W105-03-04-023
17. Remove rod (8) and O-ring (9) from cylinder (10).
18. Remove wear ring (5), retaining ring (7) and U-

ring (6) from piston rod (4).
W3-4-7
ASSEMBLE TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
12 11 14 8 15 9 7 5 10 4 1 2
13 16 Chamber B 6 3 17
Chamber A
557 mm (Free Length 679 mm)

1ft 9.9 in (Free Lenght 2ft 2.7 in)
W1HH-03-04-001
778 mm (2 ft 6.6 in)
1- Socket Bolt (4 Used) 6- U-Ring 10 - Cylinder 14 - Washer

2- Flange 7- Retaining Ring 11 - Plug 15 - Spacer
3- Dust Seal 8- Rod 12 - Valve 16 - Spring
4- Piston Rod 9- O-Ring 13 - Nut 17 - Holder
5- Wear Ring
W3-4-8
Assemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH) 4
1. Install dust seal (3) on flange (2).
IMPORTANT: Fill grease into chamber (A) of flange

(2). 6
2. Install flange (2) on piston rod (4).
7
3. Apply grease to inner face of holder (17). Press
holder (17) to piston rod (4).
5
4. Clean all parts.
Install U-ring (6), retaining ring (7), and wear ring W105-03-04-025
(5) to piston rod (4). 10
5. Apply a firm of grease to O-ring (9) and install it 6

into cylinder (10). 5
Install rod (8) into cylinder (10).
IMPORTANT: Fill chamber (B) in cylinder (10) with 4

grease and insert piston rod (4) to
completely bleed air from chamber
(B) and from the inside of rod (8).
6. Apply grease to U-ring (6), wear ring (5), cylinder

(10), and piston rod (4). Install piston rod (4) as-
W105-03-04-021
sembly into cylinder (10).
7. Tighten flange (2) with socket bolts (1) (4 used).

: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft) 8
8. Install spacer (15) on rod (8).
CAUTION: Spring weight: 95 kg (209 lb)
9. Install spring (16) on rod (8).
CAUTION: Spring assembly weight:

168 kg (370 lb)
W105-03-04-017
10. Install eyebolt (M16, pitch1.5) to rod (8).

Hoist and set the spring (16) assembly onto the
special tool by crane.
W3-4-9
11 14 8
13 16

W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-10
11. Install washer (14) on spring (16) after removing
the eye bolt.
Install the plate (ST 4036). Plate (ST 4036)
14
16
W105-03-04-016
12. Tighten the nuts to secure the spring assembly. Nut

: 46 mm
W105-03-04-012
13. Operate the oil jack to compress spring (16) to 16

specification.
Compressed Length: 557 mm (1 ft 9.9 in)
Oil Jack
W105-03-04-026
13 8 11
14. Install nut (13) and plug (11) to rod (8).
: 85 mm
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
W105-03-04-014 l
W3-4-11
12 8

W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-12
15. Install valve (12) to rod (8).
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
16. Lower the oil jack.

Oil Jack
W105-03-04-013
17. Remove the nuts and plate (ST 4036). Plate (ST 4036)
: 46 mm
W105-03-04-011
Wire Rope
180 kg (397 lb)
18. Attach a wire rope to the track adjuster as illus-

trated. Hoist and remove the track adjuster from
the special tool by crane.
IMPORTANT: If only the spring assembly is to be

transported, be sure to use a special
tool, such as the one illustrated, to
carry the spring assembly safely.
W105-03-04-009
W105-03-04-028
W3-4-13
(Blank)
W3-4-14
REMOVE AND INSTALL TRACK AD-
JUSTER
(ZAXIS370MTH)
Before removing the track adjuster, the tracks and the

front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal and installation sections. In this
section, the procedure starts on the premise that the
tracks and the front idler have already been removed.
CAUTION: When removing track adjuster (1),

the track adjuster may fly off by spring force.
Do not stand in the removal direction of the 2
track adjuster or in places where the track ad- 1
juster may fly out. The rod screw is loaded by
spring force.
Be alert that if the rod or screw section is
broken, the broken pieces may fly out by
spring force, causing personal injury and/or
death.
W142-03-04-002
Removal
3 4
250 kg (550 lb)
1. Remove track adjuster (1) from track frame (2) by
prying it with a crowbar.
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2). A
Check that the end face of track adjuster (1)
comes into contact with the face of plate (4).
W16J-03-04-002
2 3
Viewed from A W16J-03-04-001
W3-4-15
DISASSEMBLE TRACK ADJUSTER
(ZAXIS370MTH)
1 2 3
5
6
7
10
16
11
15
12
14 W166-03-04-003
13
1- Socket Bolt (4 Used) 5- Wear Ring 9- Cylinder 13 - Nut

2- O-Ring 6- U-Ring 10 - O-Ring 14 - Bracket
3- Guide 7- Retaining Ring 11 - Bolt 15 - Spring
4- Piston Rod 8- Rod 12 - Valve 16 - Spacer
W3-4-16
Disassemble Track Adjuster
(ZAXIS370MTH)
• Be sure to read all “Precautions for Disassembly
and Assembly Work” thoroughly on page W1-1-1
before starting the disassembly work.
Use a pump unit which has the maximum pres-
2
sure of 69 Mpa (700 kgf/cm , 9950 psi) and the
flow rate of 8 to 10 liters (2.1 to 2.6 US gal). Be
sure to set the main relief pressure to 49 Mpa
2
(500 kgf/cm , 7110 psi) (80 tons) or lower.
Track Adjuster
IMPORTANT: Be sure to use special tool (ST4932)
ST 4932
to assemble / disassemble the track
adjuster.
CAUTION: Prevent personal injury. The

spring force of the track adjuster is extremely
large. Thoroughly inspect the special tool for
any damage. Carefully perform assembly
work referring to the procedure below.
250 kg (550 lb) Rest
1. Hoist the track adjuster by crane. Position the
track adjuster on the rest of special tool (ST
4932). W142-03-04-019
IMPORTANT: Compress the spring until the clear-

ance between bracket (14) and nut 15 Clearance 10 mm (0.39 in)
(13) is approximately 10 mm (0.4 in).
2. Loosen valve (12). Compress track adjuster
spring (15) using special tool (ST 4932).
: 24 mm
14 8
IMPORTANT: Put matching marks on rod (8) and 13
nut (13). 11
3. Remove valve (12) and bolt (11) to remove nut 12
(13).
: 24 mm, 17 mm, 100 mm
W142-03-04-020
W3-4-17
16
15
14 W166-03-04-003
W3-4-18
4. Slowly return the piston of special tool (ST 4932)
until spring (15) extends to its free length.
NOTE: Spring (15) free length: 774 mm
15 ST 4932

250 kg (550 Ib)
5. Bind bracket (14) and spring (15) together with a 14
wire. Attach a nylon sling to spring (15). Hoist and
remove bracket (14) and spring (15) together out
of special tool (ST 4932) by crane.
6. Install eyebolt (M10, Pitch 1.5) onto piston rod (4).

Attach a nylon sling around spring (15) and
through the eyebolt. Hoist and position the as-
sembly on the rest by crane, as illustrated. W142-03-04-005
15
Rest
CAUTION: Cylinder (9) assembly weight:
80 kg (180 lb)
7. Hoist and remove cylinder (9) assemblies (1 to
10) from spring (15).
W142-03-04-006
CAUTION: Spring weight: 140 kg (310 Ib)

8. Remove the wire fastening spring (15) and
bracket (14). Hoist and remove spring (15) by
9
crane.
CAUTION: Bracket weight: 22 kg (50 Ib)

9. Remove spacer (16) and bracket (14) out of the
rest.
15
Rest
W142-03-04-007
W3-4-19
1 2 3
5
6
7
10
W166-03-04-003
W3-4-20
10. Remove socket bolts (1) (4 used) to remove guide
(3) from piston rod (4).
2
: 12 mm 3
1
11. Pull out piston rod (4) from cylinder (9).
4
12. Remove O-ring (2) from guide (3). 10
CAUTION: Cylinder (9) weight: 40 kg (88 Ib) 9

Rod (8) weight: 21 kg (50 Ib)
13. Install eyebolt (M16, Pitch 2.0) into rod (8).
Hoist and remove the rod from cylinder (9) by 8
crane.
Remove O-ring (10) from inside of the cylinder. W142-03-04-010
14. Remove wear ring (5), retaining ring (7) and U- 4

ring (6) from piston rod (4).
5
6
7
W166-03-04-001
W3-4-21
ASSEMBLE TRACK ADJUSTER
(ZAXIS370MTH)
2 3 9 6 10 16 8 14 11 12
Chamber Chamber B Grease Outlet

A W16J-03-04-003
4 1 5 7 15 13
1- Socket Bolt (4 Used) 5- Wear Ring 9- Cylinder 13 - Nut

2- O-Ring 6- U-Ring 10 - O-Ring 14 - Bracket
3- Guide 7- Retaining Ring 11 - Bolt 15 - Spring
4- Piston Rod 8- Rod 12 - Valve 16 - Spacer
W3-4-22
Assemble Track Adjuster
(ZAXIS370MTH)
4
IMPORTANT: Apply grease onto wear ring (5) and 5

U-ring (6). 6
Install the U-ring with the lip side 7
facing rod (8).
1. After cleaning all parts, install wear ring (5), U-ring
(6) and retaining ring (7) onto piston rod (4).
CAUTION: Rod (8) weight: 21 kg (50 Ib)

W166-03-04-001
2. Apply grease to O-ring (10) and install the O-ring 10
onto cylinder (9). Install eyebolt (M16, Pitch 2.0)
into rod (8). Hoist and install the rod into the cylin-
der by crane.
8
9
CAUTION: Piston rod (4) weight: 16 kg (40 Ib)
IMPORTANT: Fill chamber (B) in cylinder (9) with
grease and insert piston rod (4) to
bleed air completely out from cham-
ber (B) and from the inside of rod (8).
Apply hydraulic oil to the inner sur-
face of the cylinder and on the sur-
W142-03-04-012
face piston rod.
3. Install eyebolt (M10, Pitch 1.5) into piston rod (4).
Hoist and install the piston rod into cylinder (9) by
2
crane. 3
1
IMPORTANT: Fill chamber (A) in guide (3) with 4

grease.
Apply grease to O-ring (2) and apply
LOCTITE #262 to socket bolts (1) (4
used).
4. Install O-ring (2) onto guide (3). Install the guide
onto cylinder (9) with socket bolts (1) (4 used).
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
W142-03-04-018
W3-4-23
9 16 8 14
Grease Outlet
W16J-03-04-003
4 15
W3-4-24
CAUTION: Bracket (14) weight: 22 kg (50 lb)

Spring (15) weight: 140 kg (310 lb)
5. Attach a nylon sling to bracket (14). Hoist and 9
place the bracket and spacer (16) on the rest by
crane. Attach the nylon sling to spring (15). Hoist
and place the spring to the bracket by crane. Bind
the bracket and the spring together with pieces of
wire.
16
CAUTION: Cylinder (9) assembly weight:

60 kg (130 lb) 15
6. Install eyebolt (M10, Pitch 1.5) to piston rod (4).
Hoist and install the cylinder (9) assembly while Rest
14
aligning spacer (16) and bracket (14) by crane.
CAUTION: Track adjuster weight: W142-03-04-007
250 kg (550 lb)

7. Attach a nylon sling to spring (15) and pass it
through the eyebolt on piston rod (4). Hoist and 4
place it horizontally and slowly.
15
IMPORTANT: Set rod (8) with its grease outlet fac- W142-03-04-006
ing down.
8. Hoist and position the track adjuster on special
tool (ST 4932) by crane. Remove the eyebolt.
ST 4932
W142-03-04-005
W3-4-25
8 15 14 11 12

Grease Outlet
24.5 in (Free Length 30.5 in)) 13 W16J-03-04-003
884 mm (35 in)
W3-4-26
IMPORTANT: Be sure to slowly compress spring
(15) while aligning the center of rod
(8) with the center of bracket (14)
using a crowbar.
Take care not to damage the threads
on rod (8). 15
9. Remove a wire from spring (15). Compress spring
(15) by operating the cylinder of special tool (ST ST 4932
4932) until the specified spring length is obtained.
Specified Spring Length: 620 mm (24.5 in)
14
IMPORTANT: Align matching marks put during
disassembling. Moreover, be sure to
align the grease outlets both in rod
Wire
(8) and nut (13).
10. Install nut (13) and bolt (11) to rod (8).
: 100 mm
: 17 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
W142-03-04-015
11. Tighten valve (12).
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
12. Retract the cylinder of special tool (ST 4932).

13
8
250 kg (550 lb)
13. Securely fasten a sling belt to the track adjuster.
Hoist and remove the track adjuster from the spe- 11
cial tool by crane. 12
IMPORTANT: If the spring assembly must be

transported, take care not to damage W142-03-04-020
it. Use a firm steel box for transpor-

tation of the spring assembly and
take any other precautions in order
to insure safe transportation.
W3-4-27
(Blank)
W3-4-28
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing the front idler, the tracks must be

removed first. For removal and installation of the
tracks, refer to “Remove and Install Tracks” section.
the tracks have already been removed.
Removal
CAUTION: Front idler weight:
ZAXIS330, 330LC: 160 kg (350 lb)
W142-03-05-002
ZAXIS350H, 350LCH: 160 kg (350 lb)
ZAXIS370MTH: 210 kg (460 lb)
CAUTION: The front idler may fly off due to
strong spring force from the track adjuster 3
spring when removing it. Give yourself ample
clearance, staying clear of the front idler’s
line.
1. Pry the front idler with a crowbar to remove it from 1

track frame (3). At this time yoke (2) can be
2
removed along with it.
4
2. Attach sling belts to bearing (1) and yoke (2) 5 W17P-03-05-001
sections. Hoist and remove the front idler from

track frame (3) by crane.
3. Remove bolts (5) and remove guard (4) from yoke

(2). (ZAXIS370MTH only) Wooden Block
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
4. When storing the front idler, place it on blocks as

shown.
W105-03-05-003
Installation
IMPORTANT: Apply grease to the bearing (1) slid- 3
ing surface on track frame (3) after
cleaning.
1. Attach the front idler to a hoist, then install it to
track frame following the reverse order of removal
procedures.
1
W17P-03-05-001
W3-5-1
DISASSEMBLE FRONT IDLER
2
3
6 1
6 8
4
5
4
3
1 9
10
11
W16J-03-05-001
14 13 12
1- Bearing (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Pin (2 Used) 6- Bushing (2 Used) 10 - Bolt (3 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (3 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)
NOTE: Guard (9), Bolt (10) (3 used), Spring

Washer (11) (3 used), and (14) (4 used):
These are equipped to ZAXIS370MTH only.
W3-5-2
Disassemble Front Idler
and Assembly Work” thoroughly on page W1-1- IMPORTANT: For handling of floating seal (3), re-
1 before starting the disassembly work. fer to the section “Precautions for
Floating Seal Handling” on page
W1-1-4.
1. Loosen bolts (10) (3 used) to remove guard (9) 6. Remove bearing (1) from upper side of idler (7).
from yoke (12). (ZAXIS370MTH only) Remove floating seals (3) (2 used) from both
: 19 mm sides of the idler and bearing.
CAUTION: Yoke (12) weight: 1

ZAXIS330, 330LC, 350H, 350LCH: 25 kg (55 lb)
ZAXIS370MTH: 56 kg (120 lb) 3
2. Attach a nylon sling to yoke (12) and hold it by
crane. Remove bolts (13) (4 used). Hoist and re- 7
move yoke (12) by crane.
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
ZAXIS370MTH: 3
: 30 mm
4
3. Place idler (7) horizontally. Remove plug (8) from

the lower side to drain oil. 5
: 6 mm
1
4. Pull pin (2) out from bearing (1) with a bar and
hammer.
W105-03-05-009
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH:
Idler assembly weight : 115 kg (250 lb)
Axle (5) weight: 17 kg (37 lb)
Bearing (1) weight: 15 kg (33 lb)
ZAXIS370MTH:
Idler assembly weight : 150 kg (330 lb)
5. Put matching marks on bearing (1) and axle (5).
Pull out the axle (5) assembly from idler (7) with a
press.
1 5
W105-03-05-008
W3-5-3
6 1
6
4
5
4
W16J-03-05-001
W3-5-4
CAUTION: Axle (5) assembly weight: IMPORTANT: Do not remove bushing (6) unless
ZAXIS330, 330LC, 350H, 350LCH: 32 kg (71 lb) necessary.
ZAXIS370MTH: 42 kg (93 lb) 9. When replace bushing (6), pull the bushing out
IMPORTANT: Place wooden blocks or etc. under with a bushing pulling tool and press.
the lower part of the bearing to pre- Bushing pulling tool:
vent bearing (1) from being dam- ZAXIS330, 330LC, 350H, 350LCH: ST 1425
aged. ZAXIS370MTH: ST 1973
7. Wind a nylon sling to the axle (5) assembly. Hoist
and place bearing (1) onto wooden blocks by
crane.
8. Pull pin (2) out with a bar and hammer.

Put matching marks on bearing (1) and axle (5).
Pull out the axle from the bearing with a press. Bushing
Remove O-rings (4) (2 used) from the axle. Pulling
Tool
4
2
1 6
Wooden Block
W105-03-05-011
4
W105-03-05-010
W3-5-5
ASSEMBLE FRONT IDLER
1 2 3 4 5 6 7 8 9 10
11
12
13
W16J-03-05-002
14
1- Bearing (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Pin (2 Used) 6- Bushing (2 Used) 10 - Bolt (3 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (3 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)

W3-5-6
Assemble Front Idler
CAUTION: Axle (5) assembly weight:
and Assembly Work” thoroughly on page W1-1-
1 before starting the assembly work.
IMPORTANT: Apply LOCTITE #503 to plug (8).
CAUTION: Idler weight: 5. Attach a nylon sling to bearing (1) for the axle (5)
ZAXIS330, 330LC: 115 kg (250 lb) assembly. Hoist the axle assembly by crane and
ZAXIS350H, 350LCH: 115 kg (250 lb) insert it into idler (7) from the side where floating
ZAXIS370MTH: 150 kg (330 lb) seal (3) is installed already.
1. Install bushing (6) into idler (7) with a press. Install plug (8) into the bearing.
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH: 7
Axle (5) weight: 17 kg (37 lb) 3 1
ZAXIS370MTH:
2. Attach a nylon sling on axle (5). Hoist and place
the axle vertically by crane. Install O-ring (4) (1 5
used) onto the upper side of the axle.
W157-03-05-006
IMPORTANT: Align the matching marks put during
disassembling. CAUTION: Idler (7) assembly weight:
3. Tap bearing (1) outer race evenly with a plastic ZAXIS330, 330LC: 115 kg (250 lb)
hammer to install the bearing into axle (5). Insert ZAXIS350H, 350LCH: 115 kg (250 lb)
pin (2) with a bar and hammer. ZAXIS370MTH: 150 kg (330 lb)
6. Attach a nylon sling to the idler (7) assembly. Hoist
and turn over the idler assembly by crane.
Install O-ring (4) onto axle (5).
2
5
IMPORTANT: Apply grease to the O-ring of float-
ing seal (3).
1 7. Install the other floating seal (3) into idler (7) and
bearing (1).
1 3 4 7
4 W105-03-05-014
1
IMPORTANT: For handling of floating seal (3), re-

fer to the section “Precautions for
W1-1-4. 5
Apply grease to O-ring on the floating
seal.
W157-03-05-005
4. Install a pair of floating seals (3) into idler (7) and
bearing (1).
W3-5-7
1 2 5 8 9 10
11
12
13
W16J-03-05-002
14

W3-5-8
IMPORTANT: Align the matching marks put during
disassembling.
8. Tap the bearing (1) evenly with a plastic hammer
to install the bearing into axle (5). Insert pin (2)
with a bar and hammer.
9. Fill engine oil (API CD grade SAE30) via the plug

(8) hole in bearing (1).
Engine oil amount:

ZAXIS330, 330LC, 350H, 350LCH:
0.3 L (0.08 US gal.)
ZAXIS370MTH:
0.45 L (0.12 US gal.)

10. Install plug (8) into bearing (1).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
CAUTION: Yoke (12) weight:

11. Attach a nylon sling to yoke (12). Hoist and align
the bolt (13) hole in the yoke and bearing (1).
12. Install spring washer (14) onto each bolt (13) (4

used) (ZAXIS370MTH only). Install yoke (12) into
bearing (1) with the bolts (4 used) on both sides.
ZAXIS330, 330LC, 350H, 350LCH:

: 24 mm
: 210 N⋅m (21 kgf⋅m, 150 lbf⋅ft)
ZAXIS370MTH:
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
13. Install spring washer (11) onto each bolt (10) (3

used). Install guard (9) onto yoke (12) with the
bolts (3 used). (ZAXIS370MTH only)
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W3-5-9
C D
E
A W166-03-05-001
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 102 (402) [82 (3.23)] 102 (4.02) [92 (3.62)]
B 200 (7.87) ҥ 200 (7.87) ҥ Cladding by weld-
C 572 (22.51) [552.2 (21.74)] 630 (24.80) 610 (24) ing and finish or
D 617 (24.29) ҥ 675 (26.57) ҥ replace
E 22.5 (0.89) ҥ 22.5 (0.89) ҥ
Axle and Bushing

Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
Axle Outside Dia. 85.0 (3.35) 84.2(3.31) 110 (4.33) 109.2 (4.30)
Inside Dia 85.0 (3.35) 86.0 (3.39) 110 (4.33) 111 (4.37)
Replace
Bushing Flange
2.0 (0.08) 1.2 (0.05) 6.0 (0.24) 5.2 (0.20)
Thickness
NOTE: Values in [ ] are just for reference.
W3-5-10
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or loosen it too much as the valve
may fly off or high-pressure grease in the ad-
justing cylinder may gush out.
Loosen carefully, keeping body parts and
face away from the valve.
Never loosen grease fitting (2).
W105-03-06-001
IMPORTANT: When gravel or mud is packed be-
tween sprockets and tracks, remove ㈍
2
it before loosening valve (1).
It is enough to loosen the valve by
1 to 1.5 turns.
Do not loosen the valve over that
degree.
1. Loosen valve (1) on the track adjuster to drain
grease.
: 24 mm
Grease Outlet
M116-07-094
Oil Jack 3
CAUTION: Use a nonskid cloth between
track frame (5) and oil jack to prevent slip-
ping.
2. Jack tracks (3) up high enough to permit upper
roller (4) to be removed.
Nonskid Cloth 5 4
W105-03-06-002
3
3. Insert wooden block between tracks (3) and track
frame (5).
Wooden Block
W105-03-06-003
W3-6-1
4. Remove bolts (6) (4 used) on upper roller (4).

ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
ZAXIS370MTH: 4
: 27 mm
W157-03-06-001
CAUTION: Upper roller weight:

5. Remove upper roller (4) from track frame (5).
4
5
Installation W105-03-06-005
1. Install upper roller (4) onto track frame (5) with

bolts (6) (4 used).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
ZAXIS370MTH: 4
: 27 mm
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)
5
W157-03-06-001
3
2. Remove the wooden block and oil jack between

track (3) and track frame (5).
5
W105-03-06-002
W3-6-2
3. Tighten valve (1) on the track adjuster. 2 ㈍

: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
CAUTION: Support the jacked up machine Grease Outlet

firmly with wooden blocks.
4. Jack up the track to be adjusted and rotate it in
reverse direction slightly.
M116-07-094
5. Apply grease to grease fitting (2) to adjust tracks

tension.
ZAXIS330, 330LC, 350H, 350LCH:
Track sag specifications (A):
340 to 380 mm (13.4 to 15.0 in)
ZAXIS370MTH:
380 to 430 mm (15.0 to 16.9 in)
IMPORTANT: The upper roller shall be replaced as W157-03-06-002

an assembly.
6. Apply engine oil (API CD class SAE30) to the plug
(8) hole in cover (7). 7
Engine oil amount:

ZAXIS330, 330LC, 350H, 350LCH:
75 mL (0.02 US gal.)
ZAXIS370MTH:
8
120 mL (0.032 US gal.)
IMPORTANT: Apply LOCTITE #503 onto plug (8).

7. Tighten plug (8).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W158-03-06-001
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove the track guard and then remove mount- 5
ing bolts (1) (4 used) of lower roller (5).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm 1
ZAXIS370MTH:
: 32 mm
W105-03-06-008
2. Raise one side of the track frame high enough 90° to 110°
(90° to 110° between boom and arm is obtained
when the bucket is lowered with the round bottom
contacting with ground) to remove the lower roller.
Insert wooden blocks under track frame (2).
2 M104-07-067
CAUTION: Do not loosen valve (3) quickly or

loosen it too much as high-pressure grease
in the adjusting cylinder may gush out.
face away from the valve.
Never loosen grease fitting (4).
IMPORTANT: It is enough to loosen valve (3) by 1 W105-03-06-001

to 1.5 turns. Do not loosen it over
that degree. 4 3
3. Loosen valve (3) on the track adjuster to drain
enough grease to permit the roller (5) to be re-
moved.
: 24 mm
Grease Outlet
M116-07-094
W3-6-4
CAUTION: Lower roller weight:

ZAXIS330, 330LC, 350H, 350LCH:
54 kg (120 lb)
4. Remove lower roller (5) with a fork lift.
W105-03-06-010
Installation
1. Put lower rollers (5) below track frame (2) with a
fork lift as illustrated.
5
W105-03-06-011
2
2. Lower track frame (2) so that track frame may
keep a little away from collar (6).
6 W105-03-06-012
3. Align the bolt (1) holes and tighten bolts (1) (4

used).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm
: 670 N⋅m (68.5 kgf⋅m, 500 lbf⋅ft)
1
ZAXIS370MTH:
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft)
W105-03-06-008
W3-6-5
4 3
4. Tighten valve (3) on the track adjuster.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
Grease Outlet
M116-07-094
CAUTION: Support the jacked up machine
firmly with wooden blocks.
5. Jack up the track to be adjusted and rotate it in
reverse direction slightly.
6. Apply grease through valve fitting (4) to adjust

tracks tension.
ZAXIS330, 330LC, 350H, 350LCH:

340 to 380 mm (13.4 to 15.0 in)
ZAXIS 370MTH:
380 to 430 mm (15.0 to 16.9 in)
W157-03-06-002
W3-6-6
(Blank)
W3-6-7
DISASSEMBLE LOWER ROLLER
4 5
6
3
3
4
W166-03-06-006
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-8
Disassemble Lower Roller
• Be sure to read all “Precautions for Disassembly 4. Remove pin (5) from the axle (2) assembly to
and Assembly Work” thoroughly on page W1-1- pull the axle out of collar (4) with a press.
1 before starting the disassembly work.
3 4
1. Remove plug (6) from the end of collar (4) to drain
oil.
: 6 mm
IMPORTANT: Put matching marks on collar (4) and

axle (2).
2. Just pull pin (5) out of collar (4) at one side with a 2
bar and hammer. Then pull axle (2) out of roller
(8) with a press just from the side that pin (5) is
removed. At this time, the pin and collar at oppo-
site also can be removed.
Bar:
ZAXIS330, 330LC, 350H, 350LCH: W105-03-06-027
Dia. 14 mm (0.6 in)

ZAXIS370MTH: Dia. 25 mm (1 in) 5. Remove O-rings (3) (2 used) from axle (2).
4 1 8 1
6. In case it is necessary to replace bushing (7), pull
it out with a bushing pulling tool and press.
Bushing puling tool:
ZAXIS330, 330LC, 350H, 350LCH: ST 1475
1 ZAXIS370MTH: ST 1955
4
Bushing
Pulling
Tool
2
W105-03-06-026
IMPORTANT: For handling of floating seal (1), re-

fer to the section “Precautions for 7
W1-1-4.
3. Remove floating seal (1) from both sides of roller
(8) and collars (4) (2 used).
W105-03-06-028
W3-6-9
ASSEMBLE LOWER ROLLER
ZAXIS330, 330LC, 350H, 350LCH:

4 5 6
W1HH-03-06-001
8 2 7 1 3
ZAXIS370MTH:
4 5 6
W162-03-06-002
8 2 7 1 3
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-10
Assemble Lower Roller
1. Install bushings (7) (2 used) onto roller (8) with a
press. Take care not to dent the flange surface of 5. Insert axle (2) into roller (8). Install O-ring (3) and
bushing (7). Apply a coat of grease to O-ring (3) the other collar (4). Then secure them with pin (5).
and install O-ring (3) onto axle (2).
6. Fill engine oil (API CD class SAE30) via the plug
IMPORTANT: Align the matching marks put during (6) hole in collar (4).
disassembling.
2. Install collar (4) onto axle (2). Secure them with Engine oil amount:
pin (5). Take care not to damage O-ring (3). ZAXIS330, 330LC, 350H, 350LCH:
0.42 L (0.11 US gal.)
5 ZAXIS370MTH: 0.5 L (0.13 US gal.)
2
3
7. Install plug (6) into collar (4).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
8
5
4 4
W16J-03-06-001
IMPORTANT: Apply LOCTITE #503 onto plug (6).

3. Install plug (6) to one side of collar (4).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W105-03-06-024
IMPORTANT: Apply grease to O-ring on floating
seal (1). For handling floating seal
(1), refer to the section “Precautions
for Handling Floating Seal” on page
W1-1-4.
4. Install floating seal (1) to roller (8) and collar (4).
8 1
1 4
W157-03-06-008
W3-6-11
Upper Roller
C
C
A A
B B
ZAXIS330, 330LC, 350H, 350LCH ZAXIS370MTH
W173-03-06-001 W166-03-06-007
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 98 (3.86) − 103 (4.06) −
Cladding by
B 165 (6.50) − 190 (7.48) − welding and fin-
ish or replace
C 120 (4.72) 110 (4.33) 160 (6.30) 150 (5.90)
Axle and Bushing
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
Axle Outside Dia. 45 (1.77) [44.2 (1.74)] 60 (2.36) [59.2 (2.37)]
Inside Dia. 45 (1.77) [46.0 (1.81)] 60 (2.36) [61 (2.37)] Replace

Bushing
Flange Thickness 2 (0.079) [1.2 (0.047)] 4.5 (0.177) [3.7 (0.146)]
NOTE: Values in [Ӹ] are just for reference.
W3-6-12
Lower Roller
D D
C A C
C A C
B
B
W1HH-03-06-002 W157-03-06-003
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS 370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 203(7.99) [229.5 (9.06)] 214 (8.43) [249 (9.80)]
B 256 (10.08) − 284 (11.18) − Cladding by

welding and fin-
C 26.5 (1.04) [13.25 (0.52)] 35 (1.38) [17.5 (0.69)] ish or replace
D 175 (6.89) [157 (6.18)] 200 (7.87) 182 (7.17)
Axle and Bushing
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS 370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
Axle Outside Dia. 75 (2.95) [74.2 (2.92)] 85 (3.35) [84.2 (3.31)]
Inside Dia. 75 (2.95) [76 (2.99)] 85 (3.35) [86.0 (3.39)] Replace

Bushing
Flange Thickness 2 (0.079) [1.2 (0.047)] 6 (0.24) [5.2 (0.20)]
W3-6-13
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal
CAUTION: Do not loosen valve (1) quickly or

loosen too much since high-pressure grease
in the adjusting cylinder may gush out.
face away from valve (1). Never loosen
grease fitting (2).
W105-03-07-001
5
1. Move the tracks so that master pin (3) is
positioned over front idler (4).
Put a wooden block under track shoes (5). 4
W105-03-07-006
2. To loosen the track tension, slowly turn valve (1)

counterclockwise one turn; grease will escape
from grease outlet. 1
: 24 mm
W105-03-07-002
㈍
2
Grease Outlet
M116-07-094
W3-7-1
CAUTION: The front idler may jump out of

position due to strong spring force when the
track is disconnected. Especially, the strong
spring force is always applied to the bolt part
of the rod. If the rod and/or the bolt are
damaged, metal fragments may fly off when
the track is disconnected.
Take necessary precautions to prevent any
personal injury from occurring.
3. ZAXIS330, 330LC, 350LCH:

Remove retaining ring (6), which is used to
prevent master pin (3) from coming off.
NOTE: If retaining ring (6) interferes with master W105-03-07-005
link (7), push in master pin (3) to make 7

clearance between retaining ring (6) and
master pin (3) before attempting to remove
3
retaining ring (6).
ZAXIS370MTH: 6
Remove split pin (8), which is used to secure
master pin (3) from coming off.
NOTE: If split pin (8) interferes with master link (7),
push in master pin (3) to make clearance ZAXIS330, 330LC, 350H, 350LCH W105-03-07-009
between split pin (8) and master pin (3)
before attempting to remove split pin (8).
ZAXIS370MTH W166-03-07-001
W3-7-2
IMPORTANT: The direction for removing is as
ST 1970
illustrated.
Be sure to strike master pin (3) out
correctly.
4. Remove master pin (3) with special tool (ST
1970).
W105-03-07-008
Direction for Split Pin

removing Corner
the master Direction for
pin. removing the
master pin.
3
3
Retaining Ring
Track Link
Master Link
ZAXIS330, 330LC, 350H 350LCH ZAXIS370MTH

W105-03-07-010
W166-03-07-002
IMPORTANT: Support the jacked up machine

firmly with wooden blocks. Boom
5. Rotate the upperstructure 90 degrees toward the Arm
removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
90 to 110°
between them is 90 to 110 degrees. Lower the
boom with the bucket rolled-in to jack up the
machine as illustrated.
W105-03-07-012
6. Slowly drive the machine in reverse until the

whole length of the removing track comes on the
ground.
W105-03-07-011
W3-7-3
Installation
1. Jack up the machine and put the track under the

lower roller.
Be sure to position the track in the correct Sprocket
direction as illustrated. Idler Side Side
W105-03-07-013
2. Hoist the track and place it on sprocket (9) by

crane.
W105-03-07-014
3. With the machine kept raised, slowly operate the

lever for the side being installed with track in the
forward direction. Turn travel device (10) while 10
winding the track around the raised track frame.
W105-03-07-015
4. When wind the connecting part of track link onto

front idler (4), lower the machine and place a
wooden block under shoe (5) to support shoe (5).
W105-03-07-016
Wooden Block
W3-7-4
IMPORTANT: Install the master pin in the correct
ST 1970
direction as illustrated below. 3
5. Install master pin (3) with a hammer and special
tool (ST 1970).
W105-03-07-017
Split Pin
Corner
Direction for
installing the Direction for
master pin. installing the
master pin.
3
3
Retaining Ring
Track Link
Master Link

W166-03-07-002
W105-03-07-010
IMPORTANT: Replace retaining ring (6) with new

one, when installing master link (7). 7
IMPORTANT: Replace split pin (8) with new one, 3

when installing the master pin.
6. ZAXIS330, 330LC, 350H, 350LCH: 6

Install retaining ring (6) with the chamfered side
away from the master pin (3).
ZAXIS370MTH:
Install split pin (8). ZAXIS330, 330LC, 350H, 350LCH W105-03-07-009
ZAXIS370MTH W166-03-07-001
W3-7-5
Bushing
Seal
IMPORTANT: If any links have been removed from
the track, be sure to fill grease Pin
(Daphne Epones SR) into the clear-
ance between the pin and bushing.
When reconnecting the links, stand
the bushing on a flat plate. Fill the
bushing bore with grease.
Insert the pin into the bushing while
pushing the bushing onto the plate
to prevent it from floating because
Grease
of grease. When the pin is inserted Do not Apply Do not Apply
in, wipe off excess grease. Pay at- Grease Grease
tention to the direction to install the
seal.
W197-03-07-001
Seal
1
7. Tighten valve (1) on the track adjuster. Apply

grease into the cylinder of the track adjuster
through the grease fitting (2) to adjust the tracks
tension.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
NOTE: Check track sag after cleaning the track Grease Outlet
frame and track.
Track sag specifications (A): M116-07-094
ZAXIS330, 330LC, 350H, 350LCH:

340 to 380 mm (13.4 to 15.0 in)
ZAXIS370MTH:
380 to 430 mm (15.0 to 16.9 in)
W105-03-07-018
W157-03-06-002
W3-7-6
Link Pin and Track Bushing
• Measure the length of four links, as illustrated,

with tension on the track.
• Do not measure the master-pin-included part of
the track.
W155-03-07-001
Unit: mm (in)

Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 865.9 (34.09) 882 (34.72) 863.6 (34.00) 845.6 (33.29) Cladding by

welding and finish
B 116 (4.57) 109 (4.29) 129 (5.08) 122 (4.80) or replace
Master Pin
W105-03-07-021 A
W142-03-07-003
Unit: mm (in)
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 237 (9.33) − 308 (12.1) −
Replace
B 45 (1.77) [42 (1.65)] 47.3 (1.86) [44.3 (1.40)]
W3-7-7
Master Bushing
W105-03-07-023
Unit: mm (in)
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 148.3 (5.84) − 160.80 (6.33) −
B 45.45 (1.79) 48.5 (1.91) 47.90 (1.89) 50.90 (2.00) Replace
C 66.91 (2.63) 61.91 (2.44) 71.35 (2.81) 66.35 (2.61)
Grouser Shoe
W105-03-07-024
Unit: mm (in)
600 mm Grouser Remedy

Allowable Allowable
Standard Standard
Limit Limit
A 250 (9.84) − 247 (9.72) −
B 11 (0.43) − 13 (0.51) − Replace
C 30 (1.18) 20 (0.79) 36 (1.42) 21 (0.83)
W3-7-8
Bushing
W105-03-07-023
Unit: mm (in)
Allowable Allowable
Standard Standard Remedy
Limit Limit
A 158.9(6.26) - 177(6.97) -
B 45.45(1.79) 46.5(1.83) 48.4(1.91) 49.43(1.95) Replace
C 66.91(2.63) 61.9(2.44) 71.35(2.81) 66.35(2.61)
Pin
W105-03-07-020
Unit: mm (in)
Allowable Allowable
Standard Standard Remedy
Limit Limit
A 242(9.53) - 254(10.00) -
Replace
B 44.69(1.76) 41.7(1.64) 47.57(1.87) 44.57(1.76)
W3-7-9
(Blank)
W3-7-10
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 4
FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment
Remove and Install Front Attachment.... W4-1-1
Maintenance Standard ........................... W4-1-8
Standard Dimensions for
Arm and Bucket Connection............... W4-1-11
Standard Dimensions for
Arm and Boom Connection ................ W4-1-12
Group 2 Cylinder
Remove and Install Cylinder .................. W4-2-1
Hydraulic Circuit Pressure
Release Procedure............................. W4-2-15
Disassemble Cylinder........................... W4-2-16
Assemble Cylinder ............................... W4-2-22
Maintenance Standard ......................... W4-2-26
1HHW-4-1
(Blank)
1HHW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT

lines.
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
any repair work.
ing pressure.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.

pressure.
Ȁ
pump to maintain negative pressure in the hydrau- W105-04-02-001
lic oil tank.
tem.
W4-1-1
Removal
1. Remove lubrication pipe (1) from the adapter on
the boss at the boom cylinder rod side. 1
(2 places on both left and right)
: 19 mm
Adapter
2. Remove nuts (4) and stopper pin (6) from boom Boom Cylinder
cylinder rod front pin (3). Then remove stopper
(5).
(2 places on both left and right)
: 30 mm
W105-04-01-002
CAUTION: Boom cylinder weight: 3 2

315 kg (690 lb)
Prevent personal injury.
Metal fragments may fly off when
a hammer is used to remove pins.
Be sure to wear necessary protec- 6 Boom Cylinder
tion, such as goggles, hard hat,
etc.
3. Hoist the boom cylinder by crane. With a bar and

a hammer drive pin (3) into the position where
5
thrust plate (2) can be removed. Remove thrust
plate (2). 4
W178-04-01-004
NOTE: When pin (3) is impossible to pull out. Start

the engine, slightly operate the boom lever
and align the boom cylinder rod pin hole.
W4-1-2
IMPORTANT: Insert a plate which does not come
in contact with the grease fitting in
the boom cylinder.
4. Insert a plate between the boom cylinder and
main frame. Hold the boom cylinder and lower it
by crane.
5. Remove the boom cylinder.

Refer to “Remove Boom Cylinder” (W4-2-10).
6. Remove other boom cylinder in the same proce-

dures as steps 3, 4, 5.
7. After stopping the engine, push the air bleeding Plate

valve on the top of hydraulic oil tank to release
W157-04-01-005
any remaining pressure. Then remove the cap.
Completely release the residual pressure from the
Air Bleeding Valve
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”.
Refer to page W4-2-15.
8. Disconnect hoses (7), (8) for the bucket cylinder

and arm cylinder, to cap all openings of disas-
sembled hoses and pipes.
: 36, 41, 50 mm
M157-07-173
7 8
W157-04-01-001
W4-1-3
9. Remove bolt (12), spring washer (13), plate (11)
and block (10) from the plate of boom foot pin (9). 9
: 27 mm
10
CAUTION: Front attachment weight: 11

ZAXIS330, 330LC: 6440 kg (14200 lb) 12
ZAXIS350, 350LCH: 7050 kg (15540 lb)
13
ZAXIS370MTH: 7120 kg (15700 lb)
W178-04-01-001
10. Attach a wire rope to the boom.

Slightly hoist it to take up any wire rope slack by
crane.
11. Insert a bar between the plate of boom foot pin (9)
and the bracket, slightly pull the plate out.
12. Turn the plate upward by hand and turn it left and
right to pull boom foot pin (9) out. (Adjust the posi-
tion of the boom foot pin hole, hoisting/lowering
the front attachment.)
W105-04-01-008
13. After hoisting the front attachment, move the ma-

9
chine backward.
14. Place the front attachment on wooden blocks.
Plate
Insert Bar
Bracket
W178-04-01-001
W178-04-01-005
W4-1-4
Install Attachment
ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH: 7120 kg (15700 lb)
1. Hoist the front attachment by crane.

Move the machine forward, aligning the boom foot
pin holes.
Insert the thrust plates into boom left and right
W178-04-01-005
sides and adjust the clearance between the plate 9
and frame within 1 mm.
(Adjust the boom foot pin hole, hoisting / lowering
the front attachment.)
CAUTION: Prevent personal injury. Metal

10
fragments may fly off when a hammer is used
to remove pins. Be sure to wear necessary 11
protection, such as goggles, hard hats, etc. 12
13
2. Drive in boom foot pin (9). Install stopper bolt (12),
washer (13), plate (11) and block (10). W178-04-01-001
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
3. Remove the caps from hoses and pipings. Install 8

7
bucket cylinder hoses and arm cylinder hoses (7),
(8).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 50 mm
: 255 N⋅m (26 kg f⋅m) W157-04-01-001
CAUTION: Boom cylinder weight:

315 kg (690 lb)
4. Install the boom cylinder.

Refer to “Install Boom Cylinder” (W4-2-12).
Boom Cylinder
W105-04-02-040
W4-1-5

fragments may fly off when a hammer is used.
Be sure to wear necessary protection, such
as goggles, hard hats, etc. 3 2
5. Hoist the boom cylinder by crane. Insert thrust

plates (2) (2 used), then drive in pin (3), to install 6 Boom Cylinder
the boom cylinders to both sides.
6. Install stopper (5) and secure it with stopper pin 5

(6) and nuts (4) (2 used). (2 places on both left
4
and right)
: 30 mm W178-04-01-004
: 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)

1
7. Install lubrication pipe (1) onto the boom cylinder

rod side boss. (2 places on both left and right)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W105-04-01-002
8. Apply grease to the boom cylinder rod side, bot-

tom side and boom foot side. Boom Cylinder
Rod Side
Boom Foot
Side
M157-07-155
IMPORTANT: After filling hydraulic oil to specified

level, start the engine, check the
connections for any oil leakage.
IMPORTANT: After all work is completed, run each

cylinder several times to stroke end
to bleed air from the circuit.
Boom Cylinder M157-07-156

Bottom Side
W4-1-6
IMPORTANT: When the arm has been removed
from the boom, perform the follow-
ing steps when installing the arm.
9. Install thrust plates (14) into arm left and right

sides. Adjust total clearance of left and right within 14 14
1.5 mm or less.
10. After the arm is installed, apply grease to grease

fitting (15) on the boom connecting boss of the
arm.
IMPORTANT: For handling of HN bushing for the 15 15

front attachment, pay attention to
the following.
Precautions for pressing the bushing in:

If a hammer is used to drive the bushing in, the
bushing may be damaged. Use a press.
M157-07-157
Precautions when reinforcing the arm:

Welding heat for arm reinforcement may cause oil
leakage from the bushing and decrease lubrication
performance.
If oil leak occur, replace the bushing.
IMPORTANT: Pull the bushing out or press it with

W4-1-7
Pin ⋅ Bushing
F E
G
C
H
D J
A
I
K
B
W105-04-01-018
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 110 (4.33) 109.0 (4.31)
A
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
B Boss (Main Frame) 110 (4.33) 111.5 (4.39)
Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
C Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
Boss (Boom) 110 (4.33) 111.5 (4.39)
Replace
Pin 110 (4.33) 109.0 (4.31)
D
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
E Boss (Arm) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
F Boss (Boom) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
W4-1-8
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 90 (3.54) 89.0 (3.50)
G Boss (Arm) 90 (3.54) 91.5 (3.60)
Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60)
Pin 100 (3.94) 99.0 (3.90)
H Bushing 100 (3.94) 101.5 (4.00)
Bushing (Bucket Cylinder) 100 (3.94) 101.5 (4.00)
Replace
Pin 90 (3.54) 89.0 (3.50)
I
Bushing 90 (3.54) 91.5 (3.60)
Pin 100 (3.94) 99.0 (3.90)
J
Bushing 100 (3.94) 101.5 (4.00)
Pin 100 (3.94) 99.0 (3.90)
K
Bushing 100 (3.94) 101.5 (4.00)
IMPORTANT: When replacing HN bushing for the

front attachment, press it with a
press.
W4-1-9
Side Cutter
C
D
W105-04-01-019
Unit: mm (in)
A 258 (10.2) 168 (6.61)
B 300 (11.8) 
Replace
C 400 (15.7) 
D 300 (11.8) 
Point
B C
W105-04-01-020
Unit: mm (in)
A 240 (9.45) 120 (4.72)
B 96 (3.78) 
Replace
C 130 (5.12) 
D 105 (4.13) 
W4-1-10
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section A Section B
T137-01-03-001
Unit : mm (in)
ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5
a 575 (22.6) ұ ұ ұ
b 10 (0.39) ұ ұ ұ
c 700 (27.6) ұ ұ ұ
d 695 (27.4) ұ ұ ұ
e ҥ ҥ ҥ ҥ
f 1661 (65.4) 1666 (65.6) ұ 1661 (65.4)
g 581 (22.9) ұ ұ 573 (22.6)
h 442 (17.4) ұ ұ ұ
i 100 (3.94) ұ ұ ұ
j 578 (22.7) ұ ұ ұ
k 90 (3.54) ұ ұ ұ
l 581 (22.9) ұ ұ 573 (22.6)
m 420 (16.5) ұ ұ ұ
n 100 (3.94) ұ ұ ұ
o 8.85° ұ ұ ұ
p 8.85° ұ ұ ұ
q 592 (23.3) 600 (23.6) ұ 592 (23.3)
W4-1-11
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5

s 90 (3.5) ← ← ←
t 418.5 (16.5) ← ← ←
u 571 (22.5) ← ← ←
IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals of the previous
model machine.
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER

ing pressure.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.

pressure.
Ȁ
3. Release pressure from hydraulic oil circuit accor-
ding to the introduction on page W4-2-15.
W105-04-02-001
W4-2-1
Remove Bucket Cylinder
1. Insert wooden block (3) between bucket cylinder
(1) and arm (2).
1
2. After stopping the engine, push the air release
valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release the bucket circuit pressure. 3
Refer to “Hydraulic Circuit Pressure Release Pro-
cedure” on page W4-2-15. 2
3
W554-04-02-006
CAUTION: Secure links A and B with a wire

to prevent them from falling down before
pushing pin (7) out.

fragments may fly off when a hammer is
used.
as goggles, hard hats, etc.
Link A 4 5
3. Remove nuts (6) (2 used) and stopper pin (4).

Push out pin (7) with a round bar.
Remove thrust plates (5).
6
: 32 mm
Link B
7
1 W158-04-02-006
8
4. To prevent rod (8) of bucket cylinder (1) from
stretching, pass wire (9) through the cylinder rod
hole and secure it to the bucket cylinder (1) tube.
9
W102-04-02-005
W4-2-2
5. Disconnect bucket cylinder hoses (12) (2 used) at
the bucket cylinder (1) bottom. Cap all openings.
: 41 mm
10
CAUTION: Bucket cylinder weight:
255 kg (560 lb)
11
15
fragments may fly off when a hammer is
used.
as goggles, hard hats, etc. 13
1
6. Hoist bucket cylinder (1) by crane, to remove nuts
(13) (2 used) and stopper pin (15). Push pin (11)
out.
Remove thrust plate (10).
: 30 mm W1HH-04-02-009
12
7. Remove bucket cylinder (1).
W4-2-3
Install Bucket Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may be
damaged. Use a press.
CAUTION: Bucket cylinder weight: 10

255 kg (560 lb)
11
CAUTION: Prevent personal injury. Metal 15

fragments may fly off when a hammer is used 14
to install pin (11). Be sure to wear necessary
protection, such as goggles, hard hats, etc.
1. Hoist bucket cylinder (1) by crane. Align cylinder 13

tube side pin hole with the bucket cylinder mount-
ing hole on arm. Insert thrust plate (10) and install
pin (11).
1
Ȁ
2. Insert stopper pin (15) into arm stopper (14) and
pin (11). Install nuts (13) (2 used).
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) W1HH-04-02-009
12
IMPORTANT: After connecting hoses, fill hydraulic
oil to specified level, start the engine, 1
check the connections for any oil 8
leaks.
3. Connect bucket cylinder hoses (12) (2 used).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
4. Remove wire (9) from rod (8) of bucket cylinder 9 W102-04-02-005

(1).
W4-2-4
CAUTION: Prevent personal injury. Metal 16 4 17 5

5. Start the engine and operate the bucket lever to

align the cylinder rod side pin hole with those of
links (16), (18). Insert thrust plate (5) and pin (7).
7 18 6
W158-04-02-006
19 19
6. Insert stopper pin (4) into stopper (17) and pin (7),
to install nuts (6) (2 used).
: 32 mm
: 550 N⋅m (56.0 kgf⋅m, 405 lbf⋅ft)
IMPORTANT: In case link (18) has been removed

W157-04-01-015
from the arm, never forget to reinsert 18 18
thrust plate (19).
IMPORTANT: After all work is completed, run

bucket cylinder for several times to
stroke end to bleed air from the cir-
cuit.
W4-2-5
Remove Arm Cylinder
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).

valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release arm circuit pressure.
Refer to “Hydraulic Circuit Pressure Release Pro-
cedure” on page W4-2-15.
4
3. Remove bolt (8) from pin (5) at the arm cylinder
(1) rod side. Remove spring washer (7) and plate
(6).
: 27 mm
1

Be sure to wear necessary protection, such 8 7 6 5 9 2 3 W1HH-04-02-001
4. Push pin (5) out, then remove thrust plate (4).

10
11
5. To prevent arm cylinder (1) rod (9) from extending,

pass a wire through the cylinder rod hole and se-
cure it to the arm cylinder (1) tube.
10
W1HH-04-02-002
6. Disconnect hoses (10) (2 used) from the bottom

of arm cylinder (1) and cap all openings.
: 41 mm, 50 mm
7. Disconnect lubrication pipe (11) from arm cylinder

(1).
: 19 mm
W4-2-6
12
CAUTION: Arm cylinder weight:
460 kg (1010 lb)
1
8. Attach a sling belt at the center of gravity of arm
cylinder (1). Hoist it by crane to take-up sag.

as goggle, hard hats, etc.
13
9. Remove bolt (16) from the tube side pin (13) of 14
arm cylinder (1). Remove spring washer (15) and 15 W1HH-04-02-004
plate (14). Push out pin (13), to remove thrust 16
plates (12) and remove arm cylinder (1).
: 27 mm
W4-2-7
Install Arm Cylinder
IMPORTANT: When pressing the bushing in, if a 12
hammer is used, the bushing may
be damaged. Use a press.
1
CAUTION: Arm cylinder weight:

460 kg (1010 Ib)
1. Attach a sling belt at the center of gravity of arm

cylinder (1). Hoist it by crane. Align the cylinder
tube side hole with the arm cylinder mounting hole
on the boom.
13
fragments may fly off when a hammer is used. 15 W1HH-04-02-004
Be sure to wear necessary protection, such 16
2. Insert thrust plate (12), then install pin (13). Install

1
plate (14) and spring washer (15) into pin (13) with
bolt (16).
: 27 mm 10
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) 11
3. Connect lubrication pipe (11) and arm cylinder (1)

hoses (10) (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
10
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) W1HH-04-02-002
: 50 mm
: 255 N⋅m (26 kgf⋅m, 190 lbf⋅ft)
MPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leaks.
W4-2-8
4. Remove a wire from arm cylinder (1) rod (9). Hoist
arm cylinder (1) by crane. Start the engine, oper- 4
ate arm lever and align the arm cylinder rod side 17
pin hole with the arm cylinder mounting hole on
arm (17).

8 7 6 5 9 W1HH-04-02-001
5. Insert thrust plate (4), then install pin (5).

Install plate (6) and spring washer (7) into pin (5)
with bolt (8).
: 27 mm
: 300 N⋅m (30.5 kgf⋅m, 220 lbf⋅ft)
IMPORTANT: When all work is completed, operate

the arm cylinder several times to
cuit.
W4-2-9
Remove Boom Cylinder 1
1. Disconnect lubrication pipes (1) from the boom
cylinder.
: 19 mm

315 kg (690 lb)
2. Attach a wire rope to boom cylinder (2) and hoist it

by crane.
W105-04-02-032
7
3. Remove nuts (5) (2 used), stopper pin (7) and
stopper (6) from the boom cylinder (2) rod to push
pin (4) out.
: 30 mm
6
4. Place boom cylinder (2) on a bracket. Remove the
other boom cylinder by same method. 5 3 4 3 2
W158-04-02-013
5. Operate the boom lever to retract the boom.

To prevent the boom cylinder rod from stretching,
pass the wire through the cylinder rod hole and
secure it to the cylinder tube.

valve to release any remaining pressure from hy-
draulic oil tank. Then remove the cap.
Release the circuit pressure.
Refer to “Release Hydraulic Circuit Pressure Pro- 2
W178-04-02-011
cedure” on page W4-2-15.
W4-2-10
7. Disconnect hoses (12) (4 used) from boom cylin-
der (2) at the boom cylinder bottom. Cap all open-
ings.
: 41 mm

2
Be sure to wear necessary protection, such W178-04-02-011
8. Loosen bolt (8) at the cylinder tube side of main 2

frame, and remove bolt (8), spring washer (9) and 13
plate (10).
Pull pin (11) out.
: 27 mm

315 kg (690 lb)
11 10 9 8
9. Attach a wire rope at the center of gravity of boom
12 W1HH-04-02-003
cylinder (2). Hoist it by crane to remove.
Remove the boom cylinder at other side by the
same method.
W178-04-02-013
2
W4-2-11
Install Boom Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may be
damaged. Use a press.

315 kg (690 lb)
1. Attach a wire rope at the center of gravity of boom

cylinder (2). Hoist it by crane. Align the pin hole at
boom cylinder tube side with the boom cylinder
mounting hole on the main frame.
W178-04-02-013
2
fragments may fly off when a hammer is used. 2
13
2. Insert thrust plate (13) and pin (11). Install spring

washer (9) and plate (10), then tighten with bolt
(8).
: 27 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
3. Install the boom cylinder at other side by the same

method.
11 10 9 8
12 W1HH-04-02-003
4. Connect hoses (12) (4 used) on boom cylinders

(2) (2 used).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
IMPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leaks.
W4-2-12
5. Hoist boom cylinder (2) by crane. Operate the
boom lever to align the pin hole at cylinder rod
side with the mounting hole of the boom cylinder.

as goggle, hard hats, etc. 7
6. Install thrust plate (3), drive in pin (4) to connect

boom cylinder (2) with the boom.
7. Install stopper (6), stopper pin (7) and nuts (5) (2

used).
6
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) 5
3 4 3 2
W158-04-02-013
8. Connect lubrication pipes (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
1
9. Install the boom cylinder at other side by the same
method.
IMPORTANT: When all work is completed, run the

boom cylinder for several times to
cuit.
W105-04-02-032
W4-2-13
(Blank)
W4-2-14
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
NOTE: Following method can be used. Do not start

the engine. Operate pilot pump with the
power from battery to deliver pilot pressure
to the spool of control valve.
1. Push the lock lever forward. (Be in OFF condition)
IMPORTANT: Be sure to pull the handle for stop-

ping engine fully out.
Handle to Stop Engine
2. Pull the handle for stopping engine out and secure

it by left foot.
IMPORTANT: Battery will deplete. Be sure to oper-

ate key switch for short period.
3. Turn the key switch to START position and oper-

ate the lever for releasing any pressure from hy-
draulic circuit 4 to 5 times.
IMPORTANT: Push the handle for stopping engine

in.
4. Reset the handle for stopping engine.
W178-04-02-010
W4-2-15
DISASSEMBLE CYLINDER
Boom Cylinder
1 2
3
4
8 5
9 6
10 7
11
12 13
14
15
13
12
17
18
16
W1HH-04-02-007
Bucket Cylinder
1 2
3
4
5
6
7
8
9 10
11
12 13
14
15
13
12
16
17
18
W1HH-04-02-006
1- Piston Rod 6- Bushing 11 - Cushion Ring 15 - Seal Ring

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 16 - Set Screw
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 17 - Nut
4- Seal 9- Cylinder Head 14 - Piston 18 - Cylinder Tube
5- Ring 10 - O-Ring
NOTE: Socket bolt (8) (9 used):

boom cylinder only.
W4-2-16
Arm Cylinder
2
3
4
5
8 6
9 7
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
1- Piston Rod 6- Bushing 11 - Cushion Ring 16 - Set Screw

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 17 - Nut
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 18 - Cylinder Tube
4- Seal 9- Cylinder Head 14 - Piston 19 - Cushion Ring
5- Ring 10 - O-Ring 15 - Seal Ring 20 - Plug
W4-2-17
Arm Cylinder
As the other hydraulic oil cylinders are very similar in
construction, disassembling procedures of the arm
cylinder are shown as an example.
2
3
4
5
8 6
9 7
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
NOTE: Cushion ring (19) and plug (20) are

equipped to the arm cylinder only.
W4-2-18
Disassemble Cylinders
• Read carefully “Precautions for Disassembly and 3. Pull out cylinder head (9) from cylinder tube (18)
Assembly” (W1-1-1) before starting repair work. by tapping with a plastic hammer.
• To avoid duplication, disassembling procedures of
the arm cylinder are shown below as an example, 4. Secure cylinder rod (1) on special tool (ST5908).
as the other cylinders are very similar in Put matching marks between cylinder rod (1) and
construction. nut (17).
The disassembling procedure below starts on the ST 5908

premise that the hydraulic lines and the line
securing bands have been removed.
CAUTION: Cylinder weight:

Boom cylinder: 315 kg (690 lb)
Bucket cylinder: 255 kg (560 lb)
Arm cylinder: 460 kg (1010 lb)
W158-04-02-022
1. Hoist and securely place the cylinder on a

workbench by crane. Be sure that the cylinder is 5. Remove cushion ring (19) and plug (20) from nut
placed horizontally. Drain hydraulic oil from the (17). (arm cylinder only)
cylinder. : 10 mm
W102-04-02-027
2. Fully extend cylinder rod (1). Secure the rod end

by crane. Remove socket bolts (8) (8 used) from
cylinder head (9).
: 19 mm
(Boom, arm and bucket cylinder)
NOTE: Socket bolts (8) (9 used) are equipped to
the boom cylinder only.
IMPORTANT: Be sure to pull piston rod (1) straight

so as not to damage the sliding
surfaces.
W4-2-19
2
3
4
5
6
9 7
10
11
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-20
IMPORTANT: As set screw (16) was mushroomed
with a punch and hammer at two
places after it had been screwed in,
cut away its mushroomed portion
using a drill first.
6. Remove set screw (16).
: 6 mm (Boom, arm and bucket cylinder)
7. Loosen nut (17) with special tool (ST5908).

Remove piston (14).
Nut Turning Special Tools:
Boom cylinder : 120 mm (ST 3267)
Arm cylinder : 125 mm (ST 3268)
Bucket cylinder : 105 mm (ST 3266)
ST 5908
W158-04-02-022
IMPORTANT: When removing the seals, take care

not to damage piston (14).
8. Remove seal ring (15), wear rings (13) (2 used)
and teflon rings (12) (2 used) from piston (14).
9. Remove cushion ring (11) from piston rod (1).
10. Wind tape around the thread part of piston rod (1)
in order to protect the seal of cylinder head (9).
Remove the cylinder head from the piston rod.
11. Remove O-ring (10), retaining rings (2) and (7)

from cylinder head (9). Then remove dust seal (3),
ring (5), seal (4), and bushing (6).
Special tools for bushing removal:
Bucket cylinder : 100 mm (ST 1288)
W4-2-21
ASSEMBLE CYLINDER
Arm Cylinder
As the other hydraulic oil cylinders are very similar in

construction, disassembling procedures of the arm
cylinder are shown as an example.
2 3 4 5 6 12 13 15 13 12 14
16 17
8 7 10 1 18 11
19
20
W1HH-04-02-008
1- Piston Rod 6- Bushing 11 - Cushion Ring 16 - Set Screw

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 17 - Nut
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 18 - Cylinder Tube
4- Seal 9- Cylinder Head 14 - Piston 19 - Cushion Ring
5- Ring 10 - O-Ring 15 - Seal Ring 20 - Plug
NOTE: Cushion Ring (19) and Plug (20) are

equipped to the arm cylinder only.
Socket Bolts (8) are equipped to the boom
cylinder only.
W4-2-22
Assemble Cylinder
IMPORTANT: Apply hydraulic oil to the inside of

cylinder head (9).
1. Install bushing (6) to cylinder head (9) with a
press.
Special tools for bushing installation:
Bucket cylinder: 100 mm (ST 2360)
IMPORTANT: Install them with ring (5) and seal (4)

grooves facing piston (14).
2. Install ring (5), seal (4), and retaining ring (7) to

cylinder head (9).
3. Install dust seal (3) to cylinder head (9) with a

plastic hammer.
Special tools for dust seal installation:
Boom cylinder : (ST 2392)
Arm cylinder : (ST 2672)
Bucket cylinder: (ST 2357)
4. Install O-ring (10) and retaining ring (2) to cylinder

head (9).
5. Install wear rings (13) (2 used), seal ring (15),

teflon rings (12) (2 used) to piston (14).
6. Wind tape around the thread part of piston rod (1)

in order to protect the seal of cylinder head (9).
Install the cylinder head (9) assembly to piston rod
(1).
IMPORTANT: Be sure to install cushion ring (11)

so that “R” part faces cylinder head
(9).
7. Install cushion ring (11) to piston rod (1). Install

the piston (14) assembly to piston rod (1).
W4-2-23
16 17
8 1 18
19
20
W1HH-04-02-008
W4-2-24
8. Secure piston rod (1) to special tool (ST 5908). IMPORTANT: Be sure to align piston rod (1)
Tighten nut (17) using special tool (ST 5908). assembly with the center of cylinder
Be sure to align the matching marks on the rod tube (18) when inserting, in order to
with that on the nut. Tighten nut (17). avoid damaging the rings.
Nut Turning Special Tools:
: Boom cylinder: 8825 ± 883 N⋅m 11. Secure cylinder tube (18) horizontally on a work
(900 ± 90 kg f⋅m, 6500 ± 650 lbf⋅ft) bench. Insert the piston rod (1) assembly into
120 mm (ST 3267) cylinder tube (18).
Arm cylinder: 21867 ± 2187 N⋅m 12. Install cylinder head (9) to cylinder tube (18).
(2230 ± 223 kg f⋅m, 16100 ± 1610 lbf⋅ft) Tighten socket bolts (8) (8 used).
125 mm (ST 3268)
: 19 mm
Bucket cylinder: 10003 ± 1000 N⋅m : 834 ± 83 N⋅m
(1020 ± 102 kg f⋅m, 7380 ± 740 lbf⋅ft) (85 ± 8.5 kgf⋅m, 615 ± 62 lbf⋅ft)
105 mm (ST 3266) (Boom cylinder, Bucket cylinder)
: 19 mm
ST 5908 : 1226 ± 123 N⋅m
(125 ± 12.5 kgf⋅m, 905 ± 90 lbf⋅ft)
(Arm cylinder)
NOTE: Socket bolts (8) (9 used) are equipped to

the boom cylinder only.
W158-04-02-022
9. Tighten nut (17) with set screw (16).

Mushroom the head of set screw (16) at two
places with a punch and hammer.
: 6 mm
: 63.7 ± 6.4 N⋅m
(6.5 ± 0.65 kgf⋅m, 47 ± 4.7 lbf⋅ft)
IMPORTANT: Install cushion ring (19) with “R”

part facing plug (20)
10. Install cushion ring (19) to piston rod (1) with plug
(20). (arm cylinder only)
: 10 mm
: 109.8 ± 11 N⋅m
(11.2 ± 1.1 kgf⋅m, 181 ± 8 lbf⋅ft)
W4-2-25
Wear to Outer Diameter of Rod Rod Bend and Run Out
Dial Gauge
A
Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
Unit: mm (in) V Block
Cylinder Recommended Size After

Name Re-manufacturing (A) Unit: mm (in)
-0.036 -0.001
Boom 105 -0.090 (4.13 ) Bend Run Out Remedy
-0.004
-0.036 -0.001 Allowable
Arm 115 (4.53 ) 0.5 (0.020) 1.0 (0.039) Repair
-0.090 -0.004 limit
-0.036 -0.001 Allowable
Bucket 95 (3.74 ) 1.0 (0.039) 2.0 (0.079) Replace
-0.090 -0.004 limit
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder Allowable
Standard Inner Diameter (C) Remedy
Name Limit
+0.180 +0.007
Boom 110 (4.33 ) +0.3 (+0.012) Replace
+0.115 +0.005
C
+0.180 +0.007
Arm 120 (4.72 ) +0.3 (+0.012) Replace
+0.115 +0.005
+0.165 +0.006
Bucket 100 (4.72 ) +0.3 (+0.012) Replace
+0.100 +0.004
W4-2-26
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 5
ENGINE AND ACCESSORY
— CONTENTS —
General Information Alternator ..................................................6A-13
General Repair Instruction...........................0A-1 Injection Pump ..........................................6A-14
Illustration Arrows........................................0A-2 Bearing Case ............................................6A-18
Abbreviations ..............................................0A-3 Oil Cooler ..................................................6A-20
Nut and Bolt Angular Tightening Method......0A-4 Rocker Arm and Shaft Assembly ...............6A-23
Standard Bolt Torque Specifications ............0A-6 Camshaft...................................................6A-32
Recommended Thread Locking Agents .......0A-8 Cylinder Head............................................6A-39
Main Data and Specifications ......................0A-9 Crank Pulley and Flywheel.........................6A-62
Performance Curve ................................... 0A-11 Timing Gears.............................................6A-66
External View Drawing...............................0A-12 Flywheel Housing ......................................6A-71
Service Standard.......................................0A-13 Oil Pan ......................................................6A-76
Torque Specifications ................................0A-17 Front Cover ...............................................6A-78
Special Tools .............................................0A-25 Piston ........................................................6A-82
Troubleshooting.........................................0A-26 Crankshaft.................................................6A-94
Lubricant Application .................................0A-36 Cylinder Body ..........................................6A-106
Sealant Application....................................0A-36
Engine Cooling
Service Information Service Precautions.....................................6B-1
Identification................................................0B-1 General Description.....................................6B-2
Lubrication System ......................................0B-2 Thermostat ..................................................6B-3
Fuel System ................................................0B-2 Water Pump ................................................6B-6
Cooling System ...........................................0B-6
Valve Clearance Adjustment........................0B-6 Engine Fuel
Compression Pressure Measurement..........0B-8 Service Precautions.................................... 6C-1
Recommended Lubricants ...........................0B-9 General Description.................................... 6C-2
Engine Oil Viscosity Chart ...........................0B-9 Fuel Filter ................................................... 6C-5
Injection Nozzle Holder............................... 6C-7
Engine Mechanical Injection Pump ......................................... 6C-17
Service Precautions ....................................6A-2
General Description.....................................6A-2 Starting and Charging
Turbocharger...............................................6A-4 Service Precautions.................................. 6D3-1
Exhaust Manifold.........................................6A-5 Alternator ................................................. 6D3-2
Intake Cover................................................6A-7 Starter Motor ...........................................6D3-11
Water Pump ................................................6A-9
1HHW-5-1
Engine Lubrication
Service Precautions ................................... 6G-1
General Description.................................... 6G-2
Oil Pump .................................................... 6G-4
Oil Coolor ................................................... 6G-8
Oil Port Cover ...........................................6G-11
Engine Induction
Service Precaution ...................................... 6J-1
Turbocharger............................................... 6J-2
Troubleshooting........................................... 6J-4
Inspection and Repair ................................. 6J-6
1HHW-5-2
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

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

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

ZX330 Series ZX330W Workshop Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ZX330 Series ZX330W Workshop Manual

Uploaded by

Copyright:

Available Formats

INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are located

• Some safety signs don’t use any of the SA-1223

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the ma-

• Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or miss-

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

• Wear close fitting clothing and safety equipment

You may need:

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

• Inspect your machine carefully each day or shift by

• In the walk-around inspection be sure to cover all

• Before entering the cab, thoroughly remove all dirt

• Don’t leave parts and/or tools lying around the op-

• Avoid storing transparent bottles in the cab. Don’t

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

• After using the ashtray, always cover it to extin-

• Don’t leave cigarette lighters in the cab. When the

• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

• Inappropriate engine starting procedures may cause

• Start the engine only when seated in the

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

• Riders on machine are subject to injury such as

• Only the operator should be on the machine.

PROVIDE SIGNALS FOR FOBS INVOLV-