INTRODUCTION

TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX:81-29-831-1162
E-mail: dc@hitachi-kenki.com

ADDITIONAL REFERENCES

Please refer to the other materials (operator’s

manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.

MANUAL COMPOSITION
This manual consists the Technical Manual and the
Workshop Manual.
• Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, operational performance tests, and
troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
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.
NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED
SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system
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
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 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 Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or

in this manual, be alert to the potential for per-
sonal injury.
• Follow recommended precautions and safe oper-
ating practices.

001-E01A-0001

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 desig-
nated signal words above after the safety alert
symbol are occasionally used on this machine.

To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indi-
cates a situation which, if not avoided, could result in
damage to the machine. SA-1223

NOTE indicates an additional explanation for an

element of information.

002-E01A-1223

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Safety signs should be installed, maintained and
replaced when necessary.

• If a safety sign or this manual is damaged or

missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine. SA-003

Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• Do not modify any machine parts without au-
thorization. Failure to do so may deteriorate the
part safety, function, and/or service life. In addi-
tion, personal accident, machine trouble, and/or
damage to material caused by unauthorized
modifications will void Hitachi Warranty Policy.
• Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do
so may deteriorate the safety, function, and/or
service life of the machine. In addition, personal
accident, machine trouble, and/or damage to
material caused by using unauthorized attach-
ments and/or optional parts or equipment will void
Hitachi Warranty Policy.
The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.

003-E01B-0003

SA-2
 SAFETY
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-
lance service, hospital, and fire department
posted near your telephone. SA-437

004-E01A-0437

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
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances. SA-428

• 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 atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.

005-E01A-0438

SA-3
 SAFETY
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objec-
tionable 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 per-
sonal injury.

• In the walk-around inspection be sure to cover all

points described in the "RE-START INSPEC-
TION" chapter in the operator's manual.

007-E01A-0435
SA-435

SA-4
 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.
• Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions 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.
• Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.

524-E01A-0000

SA-5
 SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.

• When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.

008-E01A-0439
SA-439

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 mis-operations.

• 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.
• Adjust the rear view mirror position so that the
best rear visibility is obtained from the operator's
seat. If the mirror is broken, immediately replace it SA-462

with a new one.

009-E01A-0462

SA-6
 SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
Before rising from the operator's seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the ma-
chine to unexpectedly move when a body part un-
intentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower

the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK posi-
tion. Turn the key switch OFF to stop the engine.
• Before leaving the machine, close all windows,
doors, and access covers and lock them up.

FASTEN YOUR SEAT BELT

If the machine should overturn, the operator may
become injured and/or thrown from the cab. Addi-
tionally the operator may be crushed by the over-
turning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly ex-

amine 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 se-
curely 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 SA-237

every three years regardless of its apparent con-

dition.

010-E01A-0237

SA-7
 SAFETY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.

• Take extra care not to run over bystanders. Con-

firm 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. Coor-
dinate hand signals before starting the machine.
• Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
SA-426

011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and
cables.
• Remove container from machine if engine does
not need starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the con-
tainer, and store it in a cool, well-protected loca-
tion.
• Do not incinerate or puncture a starting fluid con-
SA-293
tainer.

036-E01A-0293-3

SA-8
 SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.

• Start the engine only when seated in the opera-

tor's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
• Before starting the engine, confirm the safety SA-444

around the machine and sound the horn to alert

bystanders.

012-E01B-0431

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 op-
eration.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032

S013-E01A-0032

SA-9
 SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as be-
ing 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.

014-E01B-0427

SA-379

PRECAUTIONS FOR OPERATIONS

Investigate the work site before starting operations.

• Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard
hat, etc. when operating the machine.
• Clear all persons and obstacles from area of op-
eration and machine movement.
Always beware of the surroundings while operat-
ing. When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles.
• When loading onto trucks, bring the bucket over
the truck beds from the rear side. Take care not to
swing the bucket over the cab or over any person.

M104-05-015

SA-10
 SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
• Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
• Make a work plan. Use machines appropriate to
the work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
• Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
• When the footing is weak, reinforce the ground
before starting work.
• When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
• Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks po-
sitioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
Soft ground may collapse when operating the ma-
chine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with
machine movements.

SA-11
 SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

SA-490

PROVIDE SIGNALS FOR JOBS 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
position. 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.

017-E01A-0491

SA-491

SA-12
 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.

Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or
death. SA-657

• Never attempt to ascend or descend 35 degrees

or steeper slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to
1.0 m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.

SA-658

SA-441

SA-442

SA-13
 SAFETY
DRIVE MACHINE SAFELY
• 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 safe operation.
• Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure down-
hill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed. Travel Motor
• If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control lev-
M104-05-008
ers to neutral. Then, restart the engine.
• Be sure to thoroughly warm up the machine be-
fore ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
• Use a signal person when moving, swinging or
operating the machine in congested areas. Coor-
dinate hand signals before starting the machine.
• Before moving machine, determine which way to
move travel pedals/levers for the direction you
Arrow-Mark
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or M178-03-001

pushing the levers forward moves the machine

forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface
of the side frame to indicate the machine front
direction.
• Select a travel route that is as flat as possible.
Steer the machine as straight as possible, making
small gradual changes in direction.
• Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if nec-
essary.

SA-14
 SAFETY
• Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
• When crossing train tracks, use wood plates in
order not to damage them.
• Do not make contact with electric wires or
bridges.
• When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
• When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
• Avoid operations that may damage the track and SA-011

undercarriage components.
• During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.

SA-15
 SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
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 ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine. SA-391

• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
tion.
• 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-E02A-0493

SA-16
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOV-
ING INTO THE WORK AREA. USE THE HORN SA-383

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.
• No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and mark-
ings used on the job and confirm who has the SA-384
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.

021-E01A-0494

SA-17
 SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Keep all persons clear from the area of operation

and machine movement.
• Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

022-E01A-0386

SA-386

NEVER POSITION BUCKET OVER ANY-

ONE
Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

023-E01A-0487

SA-487

AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if
the footing should collapse, always position the un-
dercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.

024-E01A-0488 SA-488

SA-18
 SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING IN-
JURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when oper-
ating on a grade, possibly resulting in serious injury
or death.

To avoid tipping:
Be extra careful before operating on a grade.
SA-012

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or slip-
ping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is un-
avoidable.
• Reduce swing speed as necessary when swing-
ing loads.
SA-440
Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.

025-E03B-0463

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur
causing serious injury or death.

026-E01A-0519

SA-489

SA-19
 SAFETY
DIG WITH CAUTION
Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.

• Before digging check the location of cables, gas

lines, and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally sev-
ered, do not look into the end. Doing so may re-
sult in serious eye injury.
• Contact your local "diggers hot line" if available in
SA-382
your area, and/or the utility companies directly.
Have them mark all underground utilities.

027-E01A-0382

OPERATE WITH CAUTION

If the front attachment or any other part of the ma-
chine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.

• Take care to avoid hitting overhead obstacles with

the boom or arm.

SA-389

028-E01A-0389

SA-20
 SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.

• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m 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

PRECAUTIONS FOR LIGHTENING

The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately

stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
• After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the ma-
chine only after repairing them.
SA-1088

OBJECT HANDLING
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath 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 safely and securely situated on supporting
blocks or on the ground. SA-014

• Never attach a sling or chain to the bucket teeth.

They may come off, causing the load to fall.
032-E01A-0132

SA-21
 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.

031-E01A-0432

SA-432

PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch 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.
• Close windows, roof vent, and cab door. SA-390

• Lock all access doors and compartments.

HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possi-
bly 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 ma-
chine.
• Fill the fuel tank outdoors.

All fuels, most lubricants, and some coolants are

flammable.

• Store flammable fluids well away from fire haz- SA-018

ards.
• Do not incinerate or puncture pressurized con-
tainers.
• 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-22
 SAFETY
TRANSPORT SAFELY
Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.

• Observe the related regulations and rules for safe

transportation.
• Select an appropriate truck or trailer for the ma-
chine to be transported.
• Be sure to use a signal person.
• Always follow the following precautions for load-
ing or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight. SA-395

3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the
travel mode switch.
5. Never load or unload the machine onto or off a
truck or trailer using the front attachment func-
tions when driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the
ramp, unload the machine from the ramp, repo-
sition the machine on the ground, and then try
loading again.
7. The top end of the ramp where it meets the flat-
bed is a sudden bump. Take care when traveling
over it.
8. Place blocks in front of and behind the tracks.
Securely hold the machine to the truck or trailer
deck with wire ropes.

Be sure to further follow the details described in the

TRANSPORTING section in the operator's manual.

035-E07A-0454

SA-23
 SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting
work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.

Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load
for 5 minutes.
5. Turn the key switch to OFF to stop engine.
SA-028
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.

500-E02C-0520

SA-527

SA-24
 SAFETY
• 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
100° angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Inspect certain parts periodically and repair or re-
place as necessary. Refer to the section discuss-
ing that part in the "MAINTENANCE" chapter of
this manual.
SA-037
• Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or de-
bris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before mak-
ing adjustments to electrical systems or before
performing welding on the machine.
• Sufficiently illuminate the work site. Use a main-
tenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch
fire.

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious
injury.

• Before performing any work on the machine, at-

tach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.

501-E01A-0287

T1J1-01-01-001

SA-25
 SAFETY
SUPPORT MACHINE PROPERLY
Never attempt to work on the machine without se-
curing 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 attach-
ment, securely support the machine or attach-
ment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a ma-
chine that is supported solely by a jack.

SA-527
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-26
 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.
• Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster
may cause the parts such as a spring to fly off,
possibly resulting in severe personal injury or
death.
SA-344

Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and

face away from AIR RELEASE PLUG to avoid
injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, and
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.

504-E01A-0034

SA-034

SA-27
 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
stop. Allow all pressure to be released before
SA-039
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.

• Wait for the oil and components to cool before SA-225

starting any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODI-

CALLY
Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the

page of "Periodic replacement of parts" in the
operator's manual.)

• Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may SA-019

result in severe burns, gangrene, or otherwise

serious injury or death.

S506-E01A-0019

SA-28
 SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing se-
rious injury, blindness or death.

• Avoid this hazard by relieving pressure before

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

few hours or gangrene may result.

507-E03A-0499

SA-292

SA-044

SA-29
 SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
SA-019

Check for Shorts:

Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight(8) to ten(10)
hours operation for loose, kinked, hardened or
frayed electrical cables and wires.
• Check before each shift or after eight(8) to ten(10)
hours operation for missing or damaged terminal
caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris, ac-
cumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the ma-
chine daily and by removing spilled or accumu-
lated 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 con-
firm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
508-E02B-0019

Check Heat Shields:

Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be re-
paired or replaced before operating the machine.
508-E02A-0393

SA-30
 SAFETY
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the fol-
lowing way:

• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
In an emergency, if the cab door or front window
cannot be opened, break the front or rear window
panes with the emergency evacuation hammer to
SA-393
escape from the cab. Refer the explanation pages
on the Emergency Evacuation Method in the op-
erator's manual.

18-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.

• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

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
starting grinding.
After finishing welding and grinding, recheck that
there are no abnormalities such as the area sur- SA-818
rounding the welded area still smoldering.

523-E01A-0818

SA-31
 SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

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

AVOID APPLYING HEAT TO LINES CON-

TAINING 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

REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

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

• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator. SA-029

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

SA-32
 SAFETY
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.

• Depending on the wok site conditions, the risk of

inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Don't
use compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask
rated to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during op-
eration. SA-029

• Asbestos might be present in imitation parts. Use

only genuine Hitachi Parts.

PREVENT BATTERY EXPLOSIONS

Battery gas can explode.

• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery or start engine with
frozen battery.
There is fear of explosion. If battery electrolyte is
frozen, wait until it is liquefied completely in an
atmospheric temperature room.
• 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-E01B-0032

SA-33
 SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.

• Refer to the instructions described on the con-

tainer for proper use when handling the refriger-
ant.
• Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
• Never touch the refrigerant.

513-E01A-0405

SA-405

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
hazardous chemical. That way you will know ex-
actly what the risks are and how to do the job
safely. Then follow procedures and use recom- SA-309

mended equipment.
• See your authorized dealer for MSDS's (available
only in English) on chemical products used with
your machine.

515-E01A-0309

SA-34
 SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the en-
vironment 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
can damage the Earth's atmosphere. Govern-
ment regulations may require a certified air condi- SA-226

tioning 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, or from your authorized dealer.

516-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-35
 SAFETY
(Blank)

SA-36
 SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
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 Solenoid Valve
Group 9 Signal Control Valve
Group 10 2-Spool Solenoid Valve Unit
Group 11 Engine
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
All information, illustrations and speci-
fications in this manual are based on Group 5 Front Idler
the latest product information available
at the time of publication. The right is
Group 6 Upper and Lower Roller
reserved to make changes at any time Group 7 Track
without notice.
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
COPYRIGHT(C)2008
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER-
FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 e-Shovel
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
 SECTION 1
GENERAL

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
Tightening Torque Specifications ............. 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

Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil Tank........ W1-4-1

1R7W-1-1
(Blank)

1R7W-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if
any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
 GENERAL / Precautions for Disassembling and Assembling
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 hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
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.

(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019

uneven wear.

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

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B

b b

a=b a b
W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
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
 GENERAL / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may re- Damaged Appearance
Broken Sewing Thread
sult. Be sure to visually check the nylon sling
for any damage before using.

2. Before using a nylon sling, visually check the ny-

lon sling for any damage corresponding to exam- W162-01-01-002
Scuffing
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
 GENERAL / Precautions for Disassembling and Assembling
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 “Allow-
able Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL / Tightening

TIGHTENING TORQUE SPECIFICATIONS

ZX110-3 Class, 120-3 Class

Wrench
Bolt Dia Torque
No. Descriptions Q’ty Size
mm mm Nm (kgf m, lbf ft)
1 Engine cushion rubber mounting bolt and nut 16 4 24 235 (24, 173)
2 Engine bracket mounting bolt (Pump side) 12 8 19 110 (11, 81)
3 Hydraulic oil tank mounting bolt 16 4 24 270 (27, 200)
4 Fuel tank mounting bolt 16 4 24 270 (27, 200)
Radiator mounting bolt (Upper side) 10 4 17 50 (5, 37)
5
Radiator mounting bolt (Lower side) 12 3 19 90 (9, 66)
6 Pump transmission mounting bolt 10 8 17 65 (6.5, 48)
Control valve mounting bolt 14 4 22 140 (14, 103)
7
Control valve bracket mounting bolt 16 4 24 270 (27, 200)
8 Swing device mounting bolt 20 10 30 500 (51, 370)
9 Swing motor mounting bolt 10 7 8 64 (6.5, 47)
17 25 (2.5,18)
19 30 (3, 22)
22 40 (4, 30)
10 ORS fittings for hydraulic hoses and piping 27 95 (9.5, 70)
32 140 (14, 103)
36 180 (18, 133)
41 210 (21, 155)
11 Hycolin tube mounting nut – – 17 35 (3.5, 26)
12 Battery mounting nut 10 4 17 50 (5, 37)
Cab mounting nut 16 4 24 210 (21, 155)
13 Cab mounting anchor bolt 20 1 30 550 (55, 406)
Cab cushion rubber mounting bolt 12 8 19 110 (11, 81)
6 10 10 (1, 7)
14 Cover mounting bolt 10 – 17 50 (5, 37)
12 19 90 (9, 66)
Flexible master coupling of piping 1/4-28UNF – 11 5.9 (0.6, 4)
15
T-bolt clamp of high pressure piping – 8 10 6 (0.6, 4)
(Upperstructure) 18 30 27 390 (40, 288)
16 Swing bearing mounting bolt to
(Undercarriage) 16 36 24 265 (27, 195)
ZX110-3, 120-3, 130K-3 16 28 24 310 (32, 229)
Travel device mounting bolt
ZX110M-3, 130L-3 16 32 24 310 (32, 229)
Travel reductuin device cover ZX110-3, 120-3, 130K-3 14 8 22 175 (18, 129)
17
mounting bolt ZX110M-3, 130L-3 14 12 22 175 (18, 129)
ZX110-3, 120-3, 130K-3 16 32 24 265 (27, 195)
Sprocket mounting bolt
ZX110M-3, 130L-3 20 32 30 460 (47, 339)
ZX110-3, 120-3, 130K-3 12 8 19 98 (10, 72)
18 Upper roller mounting bolt
ZX110M-3, 130L-3 16 16 24 265 (27, 195)
ZX110-3 16 48 24 300 (31, 221)
19 Lower roller mounting bolt ZX120-3, 130K-3 16 56 24 300 (31, 221)
ZX110M-3, 130L-3 18 48 27 450 (46, 332)
ZX110-3 16 328 24 410 (42, 302)
20 Track shoe mounting bolt ZX120-3, 130K-3 16 352 24 410 (42, 302)
ZX110M-3, 130L-3 20 336 27 804 (82, 593)
21 Track guard mounting bolt ZX110M-3, 130L-3 18 8 27 500 (51, 370)

W1-2-1
 GENERAL / Tightening
ZX135US-3 Class
Wrench
Bolt Dia Torque
No. Descriptions Q’ty Size
mm mm Nm (kgf m, lbf ft)
1 Engine cushion rubber mounting bolt and nut (Pump side) 16 4 24 235 (24.0, 173)
2 Engine bracket mounting bolt (Pump side) 12 8 19 110 (11.0, 81)
3 Hydraulic oil tank mounting bolt 16 4 24 270 (27.0, 200)
4 Fuel tank mounting bolt 16 4 24 270 (27.0, 200)
Radiator mounting bolt (Upper side) 10 4 17 50 (5.1, 37)
5
Radiator mounting bolt (Lower side) 12 3 19 90 (9.2, 66)
6 Pump transmission mounting bolt 10 8 17 65 (6.5, 48)
Control valve mounting bolt 14 4 22 140 (14.3, 103)
7
Control valve bracket mounting bolt 16 4 24 270 (27.0, 200)
8 Swing device mounting bolt 20 10 30 500 (51.0, 370)
9 Swing motor mounting bolt 10 7 8 64 (6.5, 47)
– – 17 25 (2.5, 18)
– – 19 30 (3.0, 22)
– – 22 40 (4.0, 30)
10 ORS fittings for hydraulic hoses and piping – – 27 95 (9.5, 70)
– – 32 140 (14.0, 103)
– – 36 180 (18.0, 133)
– – 41 210 (21.0, 155)
11 Hycolin tube mounting nut – – 17 35 (3.5, 26)
12 Battery mounting nut 10 4 17 50 (5.1, 37)
Cab mounting nut 16 4 24 210 (21.0, 21)
13 Cab mounting anchor bolt 20 1 30 550 (55.0, 55)
Cab cushion rubber mounting bolt 12 8 19 110 (11.0, 11)
6 – 10
8 – 13
14 Cover mounting bolt
10 – 17 50 (5.1, 37)
12 – 19 90 (9.2, 66)
10.3 to (1.05 to 1.26),
8 13
Flexible master coupling of piping 4 pairs 12.4 (8 to 9)
15 1/4-28UNF
11 6 (0.6, 4)
T-bolt clamp of high pressure piping – 8 10 6 (0.6, 4)
(Upperstructure) 18 30 27 390 (40.0, 288)
16 Swing bearing mounting bolt to
(Undercarriage) 16 36 24 265 (27.0, 195)
(31)/(32),
Travel device mounting bolt Except ZX135USL-3/135USL-3 16 28/32 24 305/310
(225)/(229)
Travel reductuin device (14.3)/(18),
17 Except ZX135USL-3/135USL-3 14 8/12 22 140/175
cover mounting bolt (103)/(129)
(27)/(47),
Sprocket mounting bolt Except ZX135USL-3/135USL-3 16/20 32 24/30 265/460
(195)/(339)
(10)/(27),
18 Upper roller mounting bolt Except ZX135USL-3/135USL-3 12/16 8/16 19/24 98/265
(72)/(195)
(31)/(46),
19 Lower roller mounting bolt Except ZX135USL-3/135USL-3 16/18 56/48 24/27 300/460
(221)/(339)
(42)/(82),
20 Track shoe mounting bolt Except ZX135USL-3/135USL-3 16/20 352/336 24/27 410/804
(302)/(593)
21 Track guard mounting bolt Except ZX135USL-3 18 8 27 500 (51), (370)
NOTE 1. Apply lubricant (e.g. white zinc B dis- 2. Make sure bolt and nut threads are
solved into spindle oil) to bolts and nuts clean before installing.
to reduce friction coefficient of them.

W1-2-2
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect 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
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092

Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)

W1-2-3
 GENERAL / Tightening
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 lu-
bricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific 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 al-

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

1 9 4 1 6 7
6 3
1st to 4th

4 5
2 8 5 2 3

2nd to 3rd
W105-01-01-003

W1-2-4
 GENERAL / Tightening
Service Recommendations for Spilt Flange

IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
2. Be sure to use only specified
O-rings. Inspect O-rings for any Incorrect
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
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008
Correct Incorrect
an air wrench often causes tight-
ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply

Nut and Bolt Locking Correct Correct Incorrect

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 Bend along edge sharply
W105-01-01-009
holes in the bolt and nut while tight-
ening, not while loosening.
Correct Correct Incorrect
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Correct Loosen Incorrect

Tighten

W105-01-01-010

W1-2-5
 GENERAL / Tightening
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. 37

30
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

Description mm Torque
Union Nut Hose Fittings N m (kgf m, lbf ft)
30 male 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)
37 female 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 37 male coupling without union is similar
to tightening torque of 37 female.

W1-2-6
 GENERAL / Tightening
O-ring Seal Joint 9
7 6

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 Hose Fittings
8 1
in O-ring groove (e). Tightening M104-07-033

nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (8) or sealing surface mm mm
(10). Union Nut Hose Fittings N m (kgf m, lbf ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,21.5)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14.0,101)
place O-ring (6) with a new one 36 30,32 175 (18.0,129)
and check that O-ring (6) is cor- 41 36 205 (21.0,151)
rectly seated in place, tighten nut 46 41 205 (21.0,151)
(9).

W1-2-7
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-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 be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
clearances. Do not overwrap. Clearance

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

depending 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
 GENERAL / Tightening
Connecting Hose
Incorrect Correct
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.

Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a Incorrect Correct
kinked hose may result in oil leaks, hose rup-
ture or separation of fitting. Utilize Print Rubbing Against
marks on hoses when installing to prevent Each Other
hose from being kinked.

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses W105-01-01-012

from rubbing against each other.

Incorrect Correct
Take care so that hoses do not come into Clamp Clamp
contact with moving parts or sharp objects.

Rubbing Against
Each Other

W105-01-01-013

Incorrect Correct

Rubbing Against
Each Other
Clamp
W105-01-01-014

W1-2-9
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Periodic Replacement Parts Replacement Intervals
Fuel hose (Fuel tank to supply 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
Pump delivery hose Every 2 years
Basic Machine
Swing hose Every 2 years
Hydraulic
Travel high pressure hose Every 2 years
System
Boom cylinder line hose Every 2 years
Front-End
Arm cylinder line hose Every 2 years
Attachment
Bucket cylinder line hose Every 2 years
Seat belt Every 3 years

NOTE: Replace seals, such as O-rings and gas-

kets, when replacing hoses.

W1-2-10
 GENERAL / Painting
PAINTING
ZX110-3 CLASS, 120-3 CLASS

Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure YR-01 [TAXI yellow]
(except cab)
Main frame HG [Beige Deep]
Internal parts [Grey]
• Front attachment YR-01 [TAXI yellow]
• Track N1.0 [Black]
• Floor plate M/F Cation [allowed]

Final painted colour

• Inside and outside surface of cab HG Beige Deep
Shaded area on cab [Left side only] Shining Silver
• Right window guards, U-Bolt [KANSAI PAINT LF-113-230B (Charcoal series black,
half glossy)]
• Suspension lifter [N2.0 (Black)]
• Lever High Grade Black
(Travel, pilot shut-off, foot rest)
• Engine cover High Grade Black
• Tool box, Tool box cover HG Beige Deep
• Cover, Step HG Beige Deep
• Handrail on upperstructure right side High Grade Black
• Mirror stay High Grade Black
• Nonslip cover KANSAI PAINT Amilac 1400 Deep Black
• Camera cover HG Beige Deep

W1-3-1
 GENERAL / Painting

Handrail on Upperstructure
Right Side Cover

Step Engine Cover

Camera
Tool Box Cover
Cover

Mirror Stay

Tool Box
W1R7-01-03-001

Decal TAXI yellow Decal Shining Silver Decal TAXI yellow

Paint All Circumference in

the Hinge Swing Position
[Shining Silver]

Shaded Area
Shining Silver

(Door)
(Door) Rear Panel
A

10
Painted Range on Door W178-01-03-005
Shining Silver

Section A

WCJB-01-03-004

Align with the Panel

Shining Silver IMPORTANT: When cleaning arm, cylinder, etc.
fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
should not exceed 70 C when
painting and drying.
Panel

WCEB-01-03-003

W1-3-2
 GENERAL / Painting
PAINTING
ZX135US-3 CLASS

Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure YR-01 [TAXI yellow]
(except cab)
Main frame HG [Beige Deep]
Internal parts [Grey]
• Front attachment YR-01 [TAXI yellow]
• Track N1.0 [Black]
• Floor plate M/F Cation [allowed]

Final painted colour

• Inside and outside surface of cab HG Beige Deep
Shaded area on cab [Left side only] Shining Silver
• Right window guards, U-Bolt [KANSAI PAINT LF-113-230B (Charcoal series black,
half glossy)]
• Suspension lifter [N2.0 (Black)]
• Lever High Grade Black
(Travel, pilot shut-off, foot rest)
• Engine cover High Grade Black
• Tool box, Control valve cover HG Beige Deep
• Handrail on cab left side HG Beige Deep
• Handrail on upperstructure right side High Grade Black
• Mirror stay High Grade Black
• Nonslip cover KANSAI PAINT Amilac 1400 Deep Black
• Camera cover HG Beige Deep
• Upper cover on the fuel tank HG Beige Deep
• Upper cover on the swing device HG Beige Deep
• Boom cylinder HG Beige Deep

W1-3-3
 GENERAL / Painting

Handrail on Upperstructure Control Valve Cover Handrail on the Cab Left Side
Right Side
Engine Cover

Camera Cover

Mirror Stay

W1R7-01-03-002
Decal Shining Silver

Painted All Circumference

in the Hinge Swing Position
[Shining Silver]
Shaded Area
Shining Silver

Door
A (Door) Rear Panel

10
W178-01-03-005
Painted Range on Door
Shining Silver

Section A
WCJB-01-03-004

Upper Cover on the Swing Device

Align with the Panel
Shining Silver

Panel

W1R7-01-03-003

IMPORTANT: When cleaning arm, cylinder, etc.

WCEB-01-03-003
fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
should not exceed 70 C when
painting and drying.

W1-3-4
 GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK

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
M104-07-021
work.
ZX110-3 class, 120-3 class
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the 1 3
hydraulic oil tank to release any remaining
pressure.

Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.

W1V1-04-01-008
2. Stop the engine. Push the air bleed valve (1) on
the air breather to release any remaining pressure ZX135US-3 class
from hydraulic oil tank (3).
1 2
3. Remove cap (2) of hydraulic oil tank (3).
3

4. Connect a vacuum pump with the hole removed

cap (2) to maintain negative pressure in the W1R7-04-01-009

hydraulic oil tank (3). Vacuum Pump

NOTE: Be sure to run the vacuum pump Hose

continuously while working.

Adapter

W562-02-03-008

W1-4-1
 GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)

W1-4-2
 MEMO

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UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab
Removal and Installation of Cab
(ZX110-3 class, 120-3 class) ..................... W2-1-1
Removal and Installation of Cab
(ZX135US-3 class) .................................... W2-1-9
Dimensions of Cab Glass
(ZX110-3 class, 120-3 class) ................... W2-1-21
Dimensions of Cab Glass
(ZX135US-3 class) .................................. W2-1-25
Group 2 Counterweight
Removal and Installation of Counterweight
(ZX110-3 Class, 120-3 Class) ................... W2-2-1
Removal and Installation of Counterweight
(ZX135US-3 Class) ................................... W2-2-3
Group 3 Main Frame
Removal and Installation of Main Frame..... W2-3-1
Group 4 Pump Device
Removal and Installation of Pump Device
(ZX110-3 class, 120-3 class) ..................... W2-4-1
Removal and Installation of Pump Device
(ZX135US-3 class) .................................... W2-4-5
Disassembly of Main Pump....................... W2-4-10
Assembly of Main Pump............................ W2-4-20
Disassembly of Regulator ......................... W2-4-34
Assembly of Regulator .............................. W2-4-36
Disassembly of Solenoid Valve ................. W2-4-38
Assembly of Solenoid Valve ...................... W2-4-40
Disassembly and Assembly of
Gear Pump .............................................. W2-4-42
Disassembly and Assembly of
Gear Pump (Optional) ............................. W2-4-44
Maintenance Standard .............................. W2-4-46
1R7W-2-1
SECTION 2
Group 5 Control Valve
Removal and Installation of Control Valve
(ZX110-3 class, 120-3 class) .....................W2-5-1
Removal and Installation of Control Valve
(ZX135US-3 class).....................................W2-5-5
Disassembly of Control Valve
4-Spool Side.............................................W2-5-10
Disassembly of Control Valve
5-Spool Side.............................................W2-5-18
Assembly and Disassembly of
4-Spool Side and 5-Spool Side ................W2-5-24
Assembly of Control Valve 4-Spool Side ...W2-5-26
Assembly of Control Valve 5-Spool Side ...W2-5-32
Disassembly of Blade Control Valve
(Optional)..................................................W2-5-38
Assemble of Blade Control Valve
(Optional)..................................................W2-5-40
Group 6 Swing Device
Removal and Installation of Swing Device
(ZX110-3 class, 120-3 class) .....................W2-6-1
Removal and Installation of Swing Device
(ZX135US-3 class).....................................W2-6-3
Disassembly of Swing Device......................W2-6-6
Assembly of Swing Device.........................W2-6-14
Disassembly of Swing Motor......................W2-6-24
Assembly of Swing Motor ..........................W2-6-28
Disassembly of Valve Unit .........................W2-6-34
Assembly of Valve Unit ..............................W2-6-36
Maintenance Standard ...............................W2-6-38
 Group 7 Pilot Valve
Removal and Installation of Pilot Valve ....... W2-7-1
Disassembly of Right and Left
Pilot Valves .............................................. W2-7-18
Assembly of Right and Left
Pilot Valves .............................................. W2-7-22
Disassembly of Travel Pilot Valve ............. W2-7-26
Assembly of Travel Pilot Valve .................. W2-7-30

Group 8 Pilot Shut-Off Solenoid Valve

Removal and Installation of
Pilot Shut-Off Solenoid Valve..................... W2-8-1
Disassembly of Pilot Shut-Off
Solenoid Valve ........................................... W2-8-4
Assembly of Pilot Shut-Off
Solenoid Valve ........................................... W2-8-6

Group 9 Signal Control Valve

Removal and Installation of Signal
Control Valve
(ZX110-3 class, 120-3 class) ..................... W2-9-1
Removal and Installation of Signal
Control Valve (ZX135US-3 class).............. W2-9-3
Structure of Signal Control Valve................. W2-9-8

Group 10 2-Spool Solenoid Valve Unit

Removal and Installation of 2-Spool
Solenoid Valve Unit
(ZX110-3 class, 120-3 class) ................... W2-10-1
Removal and Installation of 2-Spool
Solenoid Valve Unit (ZX135US-3 class) .. W2-10-3
Structure of 2-Spool Solenoid Valve Unit .. W2-10-6

Group 11 Engine
Removal and Installation of Engine
(ZX110-3 class, 120-3 class) ................... W2-11-1
Removal and Installation of Engine
(ZX135US-3 class) ................................ W2-11-23

1R7W-2-2
 UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB
(ZX110-3 CLASS, 120-3 CLASS)
Removal

CAUTION: Seat (1) weight: 40 kg (90 lb)

1
1. Remove bolts (2) (2 used). Remove seat belts (2
used) from bracket (4).
: 16 mm

Seat Belt

3
2
W1JB-02-01-008

2. Remove socket bolts (3) (4 used) from seat (1). 1 3

Remove seat (1) from bracket (4).
: 6 mm

W1JB-02-07-007

3. Remove mat (6) from cab (5). 5

6 W1JB-02-07-015

W2-1-1
 UPPERSTRUCTURE / Cab
7 8, 9 5
4. Remove bolts (8) (3 used) and washers (9) (3
used) from bracket (7). Remove bracket (7) from
bracket (10) and cab (5).
: 19 mm

10 W1JB-02-01-003

5. Remove bolts (12) (2 used) from cover (11).

: 13 mm

11

12

W1JB-02-01-004
6. Remove caps (13) (6 used) from cover (11).
Remove screws (14) (6 used) from cover (11).
5

7. Remove cover (11) from cab (5).

13, 14

11

13, 14 W1JB-02-01-005

W2-1-2
 UPPERSTRUCTURE / Cab
8. Remove bolts (15) (2 used) from bracket (16) and
cover (17).
: 13 mm 15

9. Remove bolts (19) (2 used) from cover (17).

Remove cover (17) from bracket (18). 16
: 17 mm

17

18

15 19 W1JB-02-01-040

20 21
10. Remove screws (21) (2 used) from cover (20).
Remove cap (22) and screw (23) from cover (20).
Remove cover (20) from cab (5).

22, 23 5 W1JB-02-01-001

24 16
11. Remove bolt (24) from duct (25). Remove duct
(25) from bracket (26).
25
: 13 mm

26

W1JB-02-01-041
5
12. Remove bolts (27) and washers (28) (15 used for
each) from under covers (29, 38) under cab (5).
Remove under covers (29, 38) from main frame
(30). 30
: 17 mm
38
29

27, 28 27, 28 W1R7-02-01-001

W2-1-3
 UPPERSTRUCTURE / Cab
13. Remove anchor bolts (31) (2 used) and spacers 31, 32 30
(32) (2 used) from main frame (30).
: 32 mm

W1R7-02-01-002

14. Attach a nylon sling onto the bracket in cab (5). Bracket 35 5 Bracket
Hoist and hold cab (5).

15. Remove nuts (33) (4 used) and washers (34) (4

used) from cab (5).
: 24 mm

16. Remove socket bolts (35) (6 used) from cab (5).

: 8 mm 33, 34
33, 34
17. Remove bolts (36) (5 used) and washers (37) (5
used) from cab (5). 35
: 17 mm
33, 34
18. Disconnect all connectors, plugs and vinyl hoses W1JB-02-01-006

from cab (5). 36, 37 35

CAUTION: Cab (5) weight: 330 kg (730 lb)

19. Remove cab (5) from main frame (30).

W1J7-02-01-001

W2-1-4
 UPPERSTRUCTURE / Cab
Installation

CAUTION: Cab (5) weight: 330 kg (730 lb)

1. Attach a nylon sling onto the bracket in cab (5).

Hoist cab (5). Align cab (5) with the mounting hole
on main frame (30). 5

W1J7-02-01-001

2. Install cab (5) to main frame (30) with nuts (33) (4

used) and washers (34) (4 used). Bracket 35 5 Bracket
: 24 mm
: 210 N m (21 kgf m, 155 lbf ft)

3. Install cab (5) to main frame (30) with socket bolts

(35) (6 used).
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)
33, 34
4. Install cab (5) to main frame (30) with bolts (36) (5 33, 34
used) and washers (37) (5 used).
: 17 mm 35
: 50 N m (5 kgf m, 37 lbf ft)
33, 34
W1JB-02-01-006

36, 37 35

5. Install cab (5) to main frame (30) with anchor bolts

(32) (2 used) and spacers (31) (2 used). 31, 32 30
: 30 mm
: 550 N m (56 kgf m, 410 lbf ft)

W1R7-02-01-002

W2-1-5
 UPPERSTRUCTURE / Cab
6. Install under covers (29, 38) to main frame (30)
with bolts (27) (13 used) and washers (28) (15
used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 30

38
29

27, 28 27, 28 W1R7-02-01-001

24 16
7. Install duct (25) to brackets (16, 26) with bolt (24).
: 13 mm 25
: 20 N m (2 kgf m, 15 lbf ft)

8. Connect the connector, the plug and the vinyl

26
hose to cab (5).

W1JB-02-01-041

9. Install cover (20) to cab (5) with screws (21) (2 20 21

used). Install cover (20) to cab (5) with screw (23).
Install cap (22) to the screw (23) mounting hole.

W1JB-02-01-001
22, 23 5

W2-1-6
 UPPERSTRUCTURE / Cab
10. Install bracket (16) to bracket (18) with bolts (15)
(2 used). Install cover (17) to bracket (18) with
bolts (19) (2 used). 15
: 13 mm
: 20 N m (2 kgf m, 15 lbf ft)
: 17 mm 16
: 50 N m (5 kgf m, 37 lbf ft)

17

18

15 19 W1JB-02-01-040

11. Install cover (11) to cab (5) with screws (14) (6 5

used). Install caps (13) (6 used) to the screw (14)
holes (6 used). 13, 14

11

13, 14 W1JB-02-01-005

12. Install cover (11) to cab (5) with bolts (12) (2 5

used).
: 13 mm
: 20 N m (2 kgf m, 15 lbf ft) 11

12

W1JB-02-01-004

W2-1-7
 UPPERSTRUCTURE / Cab
13. Install bracket (7) to bracket (10) and cab (5) with 7 8, 9 5
bolts (8) (3 used) and washers (9) (3 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft)

10 W1JB-02-01-003

CAUTION: Seat (1) weight: 40 kg (90 lb) 1 3

Seat Belt
14. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm 4
: 20 N m (2 kgf m, 15 lbf ft)

W1JB-02-07-007

15. Install seat belts (2 used) to bracket (4) with bolts

(2) (2 used).
: 16 mm
: 50 N m (5 kgf m, 37 lbf ft)

Seat Belt

2
W1JB-02-01-008

16. Install mat (6) to the inside of cab (5).

5

6 W1JB-02-07-015

W2-1-8
 UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB
(ZX135US-3 CLASS)
Removal

CAUTION: Seat (1) weight: 40 kg (90 lb)

1
1. Remove bolts (2) (2 used). Remove seat belts (2
used) from bracket (4).
: 16 mm

Seat Belt

3
2
W1JB-02-01-008

2. Remove socket bolts (3) (4 used) from seat (1). 1 3

Remove seat (1) from bracket (4).
: 6 mm

W1JB-02-07-007

3. Remove mat (5) from the cab. Cab

5 W1JB-02-07-015

W2-1-9
 UPPERSTRUCTURE / Cab
4. Remove screw (7). Remove cup holder (6) from
cover (8). Remove cap (9) from cover (8). 6 7
Remove bolt (10). Remove cover (8) from the
cab.

W1V1-02-01-011
9, 10 8

5. Remove screw (15). Remove duct (14) from the

cab.

6. Remove screws (13) (2 used) and screw (11). 11

Remove duct (12) from the cab. 12

13

W1V1-02-01-012
15 14 Air Conditioner Unit

7. Remove screws (17) (4 used). Remove cover (18)

from covers (16, 19).

16

17

18

19

W1V1-02-01-013

W2-1-10
 UPPERSTRUCTURE / Cab
8. Disconnect connectors (21) (3 used) and (22) (2
used) of the harnesses tied with the left pilot valve Relay
hose. Fuse

9. Disconnect connectors (23) (2 used) and (26) (3

20
used) of the harnesses tied with the left pilot valve
hose. A B

10. Remove screws (24) (2 used). Disconnect ground

harnesses (25) (2 used) from the main frame.

W1V1-02-01-014

23

24, 25
26
W1V1-02-01-019

Detail for Position A

21

22

Detail for Position B W1V1-02-01-020

W2-1-11
 UPPERSTRUCTURE / Cab
11. Disconnect connectors (27, 28) from the rear of
the cab. Remove screw (29). Disconnect ground 27
harness (30) from the main frame.

Harness Cover W1V1-02-01-015

29, 30 28

12. Remove nuts (31A) (2 used) and washers (32) (2 31A

used) from the front floor inside the cab. 32 Cab Floor
: 24 mm 31A

13. Remove nut (31C) and washer (32) from the 32 31C
bottom of the rear right outside the cab. 32
: 24 mm

Main Frame

W1V1-02-01-016

W2-1-12
 UPPERSTRUCTURE / Cab
14. Open and lock the door in the washer tank space.
Remove wing nuts (34) (4 used) from cover (33).
Remove cover (33) from bracket (35). Disconnect
the hose of the washer tank.

33, 34

35

W1V1-02-01-017
Cab Mounting Bolt (31B) Mounting Hole
Stand

15. Remove nut (31B) and washer (32) from the

cover (33) mounting side. 31B Cab Floor
32

Main Frame

W1V1-02-01-016

16. Remove nuts (36) (4 used), socket bolts (37) (5

36 Floor 37
used) and socket bolt (39) from the floor part in
the cab. Remove socket bolts (38) (2 used) from
the bottom of the rear in the cab.
: 17 mm
: 8 mm

38
39 W1V1-02-01-018

W2-1-13
 UPPERSTRUCTURE / Cab
17. Remove bolts (41) (4 used). Remove under cover
40 41
(40) from the bottom of the main frame.
: 17 mm

W1R7-02-07-003

42, 43 Main Frame

18. Remove anchor bolt (42) and washer (43) from
the bottom of the main frame.
: 32 mm

W1R7-02-01-002

CAUTION: Cab weight: 310 kg (690 lb)

IMPORTANT: Before hoisting the cab, check if the

harness and, the connector are
disconnected, and the duct is
removed. Cab
19. Attach a nylon sling onto the lifting holes (4 used)
on the cab top. Hoist and remove the cab from the
main frame.

W1J7-02-01-001

W2-1-14
 UPPERSTRUCTURE / Cab
Installation

CAUTION: Cab weight: 310 kg (690 lb)

1. Attach a nylon sling onto the lifting holes (4 used)

on the cab top. Hoist and install the cab to the
main frame.
Cab

2. Install the front floor part inside the cab with nuts W1J7-02-01-001

(31A) (2 used) and washers (32) (2 used).

: 32 mm
: 550 N m (56 kgf m, 410 lbf ft)

3. Install the bottom of the rear right outside the cab 31A
with nut (31C) and washer (32).
32 Cab Floor
32 mm 31A
: 550 N m (56 kgf m, 410 lbf ft)
32 31C
32

Main Frame

W1V1-02-01-016

W2-1-15
 UPPERSTRUCTURE / Cab
4. Install the bottom of the rear left outside the cab
through the cover (33) mounting side with nut
(31B) and washer (32).
: 32 mm
: 550 N m (56 kgf m, 410 lbf ft)

5. Install cover (33) to bracket (35) with wing nuts 33, 34

(34) (4 used).
35

W1V1-02-01-017
Cab Mounting Bolt (31B) Mounting
Stand Hole

31B Cab Floor

32

Main Frame

W1V1-02-01-016

6. Install the cab to the floor with nuts (36) (4 used), Floor
36 37
socket bolts (37) (5 used) and socket bolt (39).
Install the rear of the cab with socket bolts (38) (2
used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)

38
39 W1V1-02-01-018

W2-1-16
 UPPERSTRUCTURE / Cab
7. Remove anchor bolt (42) and washer (43) to the
bottom of the main frame. 42, 43 Main Frame
: 32 mm
: 550 N m (56 kgf m, 410 lbf ft)

W1R7-02-01-002

40 41
8. Install under cover (40) to the bottom of the main
frame with bolts (41) (6 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

W1R7-02-07-003

27
9. Connect connectors (27, 28) of the rear in the cab.
Install ground harness (30) to the main frame with
screw (29).

Cover W1V1-02-01-015
29, 30 28

W2-1-17
 UPPERSTRUCTURE / Cab
10. Install ground harnesses (25) (2 used) to the main
frame with screws (24) (2 used). Relay

fuse
11. Connect connectors (21) (3 used) and (22) (2
used) of the harnesses tied with the left pilot valve
20
hose.
A B
12. Connect connectors (23) (2 used) and (26) (3
used) of the harnesses tied with the right pilot
valve hose.

W1V1-02-01-014

23

24, 25
26
W1V1-02-01-019

Detail for Position A

21

22

W1V1-02-01-020
Detail for Position B

W2-1-18
 UPPERSTRUCTURE / Cab
13. Install cover (18) to covers (16, 19) with screws
(17) (4 used).

16

17

18

19

W1V1-02-01-013

14. Install duct (12) to the cab with screws (13) (2

used) and screw (11).

11
12

13

W1V1-02-01-012
15 14 Air Conditioner Unit

15. Install cup holder (6) to cover (8) in the right side 6 7
of the cab with screw (7). Install cap (9) to cover
(8).

W1V1-02-01-011
9, 10 8

W2-1-19
 UPPERSTRUCTURE / Cab
16. Install mat (5) to the floor inside the cab.

Cab
CAUTION: Seat (1) weight: 40 kg (90 lb)

6 W1JB-02-07-015

1 3

17. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm
: 20 N m (2 kgf m, 15 lbf ft) 4

W1JB-02-07-007

18. Install seat belts (2 used) to bracket (4) with bolts

(2) (2 used).
: 16 mm
: 50 N m (5 kgf m, 37 lbf ft) 1

Seat Belt

3
2
W1JB-02-01-008

W2-1-20
 UPPERSTRUCTURE / Cab
DIMENSIONS OF CAB GLASS
(ZX110-3 CLASS, 120-3 CLASS)
Black Ceramic
NOTE: Unit: mm (1 mm=0.039 in) 115 Coating Range
70

21

107
60 2-R50 2-R50
2-R250
2-R127 2-R20
C0.5 2-R10

70

106.6 A
C0.5 1081
R50
Black Ceramic Coating Surface W1JB-02-01-013 R2975 (4 mm) R800
28
Section A
R75 B
R120
Black R40 268
20 70
Ceramic
Coating
Surface 50 16.5 W1JB-02-01-011
2R-5
271 21
214 21
847

Black Ceramic
Coating Range

R1075

C
372.9
(4 mm)
22
50

54.1 25 W1JB-02-01-012
W1JB-02-01-009
25 84

865

R2

C0.5
W1JB-02-01-019

Black Ceramic Coating Surface

W1JB-02-01-014
C0.5 Section C

Section B

W2-1-21
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

375 214

R155

(4 mm) (4 mm)
+0.5
796.5 796.5 2- 12.2 -0

40
R2852

34.2

267.5

3-R4
50 50
50 234.5 W1JB-02-01-015 W1JB-02-01-016
390 50
13.9
434.5

C0.5

C0.5
Black Ceramic Coating Surface

Section A W1JB-02-01-013

W1JB-02-01-010

860.8
833
Black Ceramic Coating Range 506
63.5 581
50 438.5 26.5
2- 21 353.5
2-R4
R150 64.5
R2854
R50 109.5 336
R25 102.5
A

498.5 448
R58 R75 (4 mm) 1
152.5
R60
R250 185
R964 R103
R5031 34
R42 R329
R10
118
R5004 82

327.5
R10 R60 W1JB-02-01-018
173
17

W2-1-22
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic Coating Range

R30 30
39
29

652
87.5 (4 mm) R200
87.5
R200
R500 R500 A
R50 185 185
45
70
R50
4-R10 205
848 W1JB-02-01-021

W1JB-02-01-010

Black Ceramic
567.5
Coating Range
496

123.5 80 59.5
C0.5
3-R4 85
75.5 100 R25

C0.5 R25
R20 R25 R25 B
Black Ceramic Coating Surface W1JB-02-01-013 R75
87.7

Section A R4139.5
887 1008
1099
1145.5
R4044.5
1127.3 19.5

(4 mm)

R40
R35
C0.5 R100
R35
R550
R135 83
13
A
W1JB-02-01-014 228
112 109
C0.5
105
65 R250
R20 102
Section B R70 R60
W1JB-02-01-017
76
140
78.5 57 195
447
483

W2-1-23
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

C1

C1
Black Ceramic Coating Surface W1JB-02-01-013

Section A

W1JB-02-01-009

1646.47

1599.44

187 Black Ceramic 313.6

Coating Range
R20
80 50

106 R300
2-R25
R2145 50
R30
696.73 R75
50 R2940
(5 mm) A
R25
R30 90
40 R3025
R30 R50
R20 158 R10

R2875 R575 R50

R125

R1040 R30 R50

R1525 28
W1JB-02-01-020
R55 R30
393
400

807.65

963.7

W2-1-24
 UPPERSTRUCTURE / Cab
DIMENSIONS OF CAB GLASS
(ZX135US-3 CLASS)
Black Ceramic
115 Coating Range
NOTE: Unit: mm (1 mm 0.039 in)
70

21

107
60 2-R50 2-R50
2-R250
C0.5 2-R20
2-R127
2-R10

70

C0.5
106.6 A
Black Ceramic 1081
W1JB-02-01-013
R50
Coating Surface
R2975 (4 mm) R800
28
Section A
R75 B
Black R120
Ceramic R40 20 70
268
Coating
Surface
50 16.5 W1JB-02-01-011
2R-5
271 21
214 21
847

Black Ceramic
Coating Range

R1075

C
372.9
(4 mm)
22
50
W1JB-02-01-009
54.1 25 W1JB-02-01-012
25 84

865

C0.5

R2
W1JB-02-01-014
C0.5 W1JB-02-01-019
Black Ceramic
Coating Surface
Section B
Section C

W2-1-25
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm 0.039 in)

242 213

370 (4 mm)
3-R4 2- 12.2 +0.5
-0

R2800
R150 91°

35

50
430.6

4-R4 W1V1-02-01-010

50 50

242 181.4 0
383

W1V1-02-01-005

W1JB-02-01-016

W1V1-02-01-006

660.8
633
506.5
50 195.5
2- 21 0.5 272 27.5
2-R4

R25
R2600 R150
R600
R215 R100

R125
R800 R1200
R40 R320 R10
R80
R10 80
R310
R1200
17 327.5
R60
W1V1-02-01-007

W2-1-26
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm 0.039 in)

Black Ceramic
Coating Range

30 2-R5
25
30

30
R75 R75
35

2-R10 200

848

W1V1-02-01-008

W1V1-02-01-006

567.5
Black Ceramic
496
59.5
Coating Range

150 138
3-R4
R25
R20 R25
87.7° R25
C0.5 R4139.5
19.5

6.5

Black Ceramic C0.5

W1JB-02-01-013
Coating Surface

Section A R150
R1500

83
R100
R135
109°
R50
C0.5
R250 R60
65° R20 102°
316
W1JB-02-01-014
R70
C0.5 483
76
140
195
Section B 447
W1V1-02-01-009

W2-1-27
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm 0.039 in)

C1

C1
Black Ceramic W1JB-02-01-013
Coating Surface

Section A

W1JB-02-01-009

1646.47

1599.44

Black Ceramic
187 313.6
Coating Range
R20
80 50

106 R300
2-R25
R2145 50
R30
696.73 R75
50 R2940
(5 mm) A
R25
R30 90
40 R3025
R30 R50
R20
158 R10

R2875 R575 R50

R125

R1040 R30 R50

R1525 28
W1JB-02-01-020
R55 R30
393
400

807.65

963.7

W2-1-28
 UPPERSTRUCTURE / Cab
Removal of Cab Glass
Right-Hand Glass

Procedures to Remove Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass

CAUTION: When removing the broken or

cracked glass, the glass shards may cause
serious injury.
Before removing, use the gummed tape or
something like in order to paste the broken or
cracked glass and reinforce them. Remove
the glass pieces away. W1JB-02-01-009

1. Remove the resin panel, the garnish and the

spacer around the glass. Rear Glass

Rear
Left-Hand
Garnish Glass

Garnish

Lower Door Glass Resin Panel W1JB-02-01-010

2. Prick a hole in the adhesive by using an awl (or a Cab

cutter knife). Cab Glass
Awl

Adhesive W1SE-02-01-033

3. Pass a piano wire (or a metal wire) through the Piano Wire
(or Metal Wire)
hole.

W1SE-02-01-034

W2-1-29
 UPPERSTRUCTURE / Cab
4. Wind the both ends of the piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab. Cab Glass (Cab Outside)

NOTE: Cut off the middle of adhesive between Cab Glass

glass and cab.
The piano wire is easily broken if a part of
the piano wire turns hot. Change the
position and cut the adhesive.

Adhesive
(Cab Inside)

W1SE-02-01-035

W2-1-30
 UPPERSTRUCTURE / Cab
Installation of Cab Glass
Right-Hand Glass

Procedures to Install Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass

1. Cut off residual adhesive at the cab side to make

1 to 2 mm (0.04 to 0.08 in) deep all around by
using a cutter knife.
NOTE: Do not damage the cab paint.

W1JB-02-01-009

Rear Glass

Lower Door Rear Left-Hand W1JB-02-01-010

Glass Glass

Cab

2. Clean the cutting edge of adhesive at cab side by

Cutter Knife
using white spirit.

Cut off adhesive by 1 to 2 mm

(0.04 to 0.08 in) deep.
W1SE-02-01-036

IMPORTANT: Primer should be shaken for about 1

minute and mix thoroughly before Cab
Apply Primer by
opening the cap. using a brush.
After opening Primer, apply Primer
as quickly as possible and replace Cutting Edge of
the cap immediately after using. Adhesive at Cab
After opening Primer, all the Side
contents should be used within 180
W1SE-02-01-038
days (or 2 hours with the cap off).
3. Apply Primer for paint (Sika Aktivator DM-1) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
NOTE: The painting primer should be applied
evenly in order to leave no blemishes.

W2-1-31
 UPPERSTRUCTURE / Cab
4. Clean the mating edge of the new glass by using
clean rag and ethyl alcohol.
IMPORTANT: Primer (Sika Primer 206G+P) should
be shaken for about 1 minute and
mix thoroughly before opening the
cap.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer 206G+P) to
the cutting edge of adhesive at cab side by using
a brush. Wait for about 15 minutes in order to let it
dry by itself.
(As for the position to apply Primer, refer to
W2-1-34.)
11. Raise the glass by using sucker lifter 4355282
(refer to W2-1-34), and adhere it to the cab within
5 minutes.
NOTE: Install the glass while aligning the spacer
position on the glass. Remove all adhesive
except the mounting surface, before
solidifying by using white spirit.
12. Secure the glass by using the gummed tape until
the adhesive becomes solid in order to prevent
them from being mispositioned or coming off.
(Refer to W2-1-33).
NOTE: Time for adhesive (Sika Tack-Drive) to
become solid: 8 hours (just for reference)

6. Install the spacer with facing to the glass surface

by using the instant adhesive.
(As for the positions to install spacers A, B, C and
a dam rubber, refer to W2-1-34.)

7. Cut off the nozzle of adhesive cartridge (Sika

Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-34.)

8. Remove the seal of the cartridge end. Install the

V-shaped nozzle.

9. Install the cartridge to the manual coking gun.

10. Evenly apply adhesive to the old adhesive left at

cab side.
(As for the position to apply adhesive, refer to
W2-1-34.)

W2-1-32
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

Rear Glass Right-Hand Glass

250 300 350 500

100

200
200 200 500

200

200 200

250 300
W1JB-02-01-029

200
200
100
100 W1JB-02-01-030

Rear Left-Hand Glass

150 200

Lower Door Glass

200

500

200
W1JB-02-01-035
W1JB-02-01-038

W2-1-33
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm
(1 mm 0.039 in)
Spacer A Spacer B Spacer C

20 6 20 6
20 6
2
4 4
4 R0.5
R5 84 R8 75
6 R0.5 6 R0.5
3 8 78
R10
3 12
Two-Side Two-Side 10.5
10.5
Adhesive Tape Adhesive Tape
W1JB-02-01-022 W1JB-02-01-023
W1JB-02-01-024

Dam Rubber
30 6.4

W1JB-02-01-025
Lower Door Grass

Rear Left-Hand Glass

Right-Hand Glass
Suction Lifter
Spacer A
Rubber
Dam
Rubber
Spacer B Spacer A
Spacer B
Spacer A Dam W1JB-02-01-039
Rubber
Spacer B
Rear Glass

Spacer C
W1JB-02-01-027
W1JB-02-01-026

W1JB-02-01-042
8 to 9 mm

13 to 15 mm
Adhesive
Cut nozzle
end into
V-shaped.

W1SE-02-01-027

Apply adhesive
9 evenly.

12 Remove
the seal.
W1JB-02-01-031

Adhesive
W1SE-02-01-043
Cartridge
Panel

W1SE-02-01-028

W2-1-34
 UPPERSTRUCTURE / Cab
13. The required amount (just for reference) of adhesive and primer

Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack-Drive Sika Aktivator DM-1 Sika Primer 206G+P
310 ml Cartridge 250 ml Can 30 ml Bottle
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Door Glass 150 ml 0.5 ml 0.45 ml
Rear Left-Hand Glass 250 ml 0.65 ml 0.6 ml
Rear Right-Hand Glass 100 ml 1 ml 0.9 ml
Rear Glass 210 ml 0.5 ml 0.45 ml

W2-1-35
 UPPERSTRUCTURE / Cab
Installation of Upper Door Glass
Sash
1. Before installing the glass, remove the garnish Assembly
around the sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.
Garnish

2. Install glass A and glass B into the sash grooves.

3. Install the sash assembly, which the glass is

Glass A Glass B
installed on, onto the door from the outside of the
cab. Secure the sash assembly at the inside of W1JB-02-01-010

the cab by using the garnish.

W2-1-36
 UPPERSTRUCTURE / Cab
Installation of Upper Front Glass
Adhere the glass in the same method as
right-hand glass.
1. Stick seal (1) to the lower side of the front upper
glass by using Cemedine Super X.
Stick and secure both right and left ends (the
thicker part) of seal (1) to the glass by using
Cemedine Super X.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.

NOTE: Cemedine Super X Black No.8008

Glue-state adhesive, tubed

IMPORTANT: The upper front glass is

arched-fringed. When replacing the
glass, contact with the nearest
HITACHI Office and replace it as an
assembly.

W1JB-02-01-034

Cemedine Super X Upper Cemedine Super X Upper

Seal here. Glass Glass

Seal (1) Seal (1)

Lower Lower
Glass Glass
W1JB-02-01-032 W1JB-02-01-033

W2-1-37
 UPPERSTRUCTURE / Cab
(Blank)

W2-1-38
 UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT
(ZX110-3 CLASS, 120-3 CLASS)
1 2
Removal

1. Remove bolts (5) (2 used) and clips (6) (2 used)

3
from bracket (2). Disconnect harness (4).
: 17 mm

2. Remove caps (3) (2 used) of the upper side in 4

counterweight (1). Install a Freno-Linkbolt (B-36:
M36, Pitch 4.0 mm) to the hole where cap (3) has
been removed.

CAUTION: Counterweight (1) weight: W1R7-02-02-001

ZX110-3 class: 1850 kg (4080 lb) 5, 6
ZX120-3 class: 2500 kg (5520 lb)

3. Attach a wire rope onto the Freno-Linkbolt. Hoist

and hold counterweight (1).

CAUTION: Be careful to avoid getting your

hand caught by reaction bar on the power 1
wrench.

4. Remove bolts (8) (4 used) and washers (9) (4 7

used) from counterweight (1) by using a power
wrench.
: 41 mm

5. Hoist and remove counterweight (1) from main

frame (7). 8, 9 W1R7-02-02-002

W2-2-1
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight (1) weight:

ZX110-3 class: 1850 kg (4080 lb)
ZX120-3 class: 2500 kg (5520 lb)
1
1. Hoist counterweight (1). Align counterweight (1)
with the mounting hole on main frame (7).
7
2. Temporarily tighten counterweight (1) to main
frame (7) with bolts (8) (4 used) and washers (9)
(4 used).
: 41 mm

CAUTION: Be careful to avoid getting your W1R7-02-02-002

hand caught by reaction bar on the power 8, 9
wrench.

3. Remove the wire rope and the Freno-Linkbolt

from counterweight (1). Tighten bolts (8) (4 used)
by using a power wrench.
: 41 mm
: 1150 N m (115 kgf m, 850 lbf ft) 1 2

4. Install caps (3) (2 used) to counterweight (1).

3
5. Connect harness (4). Secure harness (4) to
bracket (2) with bolts (5) (2 used) and slips (6) (2
used).
4
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

W1R7-02-02-001
5, 6

W2-2-2
 UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT
(ZX135US-3 CLASS)
1
Removal

1. Remove clip (4). Disconnect harness (3).

2. Remove caps (2) (2 used) of the upper side in

counterweight (1). Install a Freno-Linkbolt (B-36:
2
M36, Pitch 4.0 mm) to counterweight (1).

CAUTION: Counterweight (1) weight: 3680

kg (8120 lb)

3. Attach a wire rope onto the Freno-Linkbolt. Hoist

and hold counterweight (1). 4 3 W1R7-02-02-003

CAUTION: Be careful to avoid getting your 1 5, 6

hand caught by reaction bar on the power
wrench.

4. Remove bolts (5) (3 used) and washers (6) (3

used) from counterweight (1) by using a power
wrench. 7
: 50 mm

5. Hoist and remove counterweight (1) from main

frame (7).
W1R7-02-02-004

W2-2-3
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight (1) weight: 3680

1 5, 6
kg (8120 lb)

1. Hoist counterweight (1). Align counterweight (1)

with the mounting hole on main frame (7).

2. Temporarily tighten counterweight (1) to main

7
frame (7) with bolts (5) (3 used) and washers (6)
(3 used).
: 50 mm

CAUTION: Be careful to avoid getting your W1R7-02-02-004

hand caught by reaction bar on the power

wrench. 1

3. Remove the wire rope and the Freno-Linkbolt

from counterweight (1). Tighten bolts (5) (3 used)
by using a power wrench and a torque wrench.
: 50 mm
: 2250 N m (230 kgf m, 1660 lbf ft) 2

4. Install caps (2) (2 used) to counterweight (1).

5. Connect harness (3). Install clip (4) to harness

(3).

W1R7-02-02-003
4 3

W2-2-4
 UPPERSTRUCTURE / Main Frame
REMOVAL AND INSTALLATION OF MAIN
FRAME

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
1
CAUTION: Cab (1) weight:
ZX110-3 class, 120-3 class: 330 kg (730 lb)
ZX135US-3 class: 310 kg (690 lb)

1. Remove cab (1). (Refer to REMOVAL AND

INSTALLATION OF CAB on W2-1-1.)
: 17 mm, 24 mm, 30 mm
: 8 mm
W157-02-01-001

2 ZX110-3 class, 120-3 class

CAUTION: Counterweight (2) weight:

ZX110-3 class: 1850 kg (4080 lb)
ZX120-3 class: 2500 kg (5520 lb)
ZX135US-3 class: 3680 kg (8120 lb)

2. Remove counterweight (2).

(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
(ZX110-3 class, 120-3 class)
: 41 mm
(ZX135US-3 class) W1R7-02-02-001

: 50 mm
ZX135US-3 class

W1R7-02-02-003

W2-3-1
 UPPERSTRUCTURE / Main Frame

CAUTION: The front attachment (3) assem-

bly weight:
ZX110-3 class: 1980 kg (4370 lb)
ZX120-3 class: 2220 kg (4900 lb) 3
ZX135US-3 class: 3100 kg (6840 lb)

3. Remove the front attachment (3) assembly.

(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-2.)
: 17 mm, 24 mm, 27 mm, 36 mm

4. Disconnect hoses (4) (6 used) from the upper

side of center joint (5). Remove bolts (6) (2 used) W105-02-03-002
and remove stopper (7). (Refer to Removal and
Installation of Center Joint on W3-3-1.) 4
: 19 mm, 22 mm, 27 mm

5
CAUTION: Upperstructure weight:
ZX110-3 class: 2850 kg (6290 lb)
ZX120-3 class: 2920 kg (6440 lb) 6
ZX135US-3 class: 2970 kg (6550 lb)

5. Attach a wire rope to the rear side (counterweight 7

mounting part) of the main frame and the boom
bracket. At this time, do not damage the engine.
W102-03-03-001

Rear Side of Main Frame

W105-02-03-004

Boom Bracket
W105-02-03-005

W2-3-2
 UPPERSTRUCTURE / Main Frame
6. Hoist and hold the upperstructure. If the chain
block is used, it is not only easy to adjust the
length of wire rope, but also easy to level the Chain Block
center of gravity.

W1V1-02-03-001

7. The mounting angle of swing bearing (8) is

specified. Put the matching marks on the
8
upperstructure and the outer race of swing
bearing (8). 9
Remove bolts (9) (36 used) from swing bearing
(8). (Refer to REMOVAL AND INSTALLATION
OF SWING BEARING on W3-1-1.)
: 24 mm

W105-03-01-002

Chain Block

8. Adjust the chain block in order to level the main

frame. Hoist and remove the mainframe from the
undercarriage.

Main Frame

Undercarriage

W157-02-03-002

W2-3-3
 UPPERSTRUCTURE / Main Frame
Installation

Chain Block
CAUTION: Upperstructure weight:
ZX110-3 class: 2850 kg (6290 lb)
ZX120-3 class: 2920 kg (6440 lb)
ZX135US-3 class: 2970 kg (6550 lb)

1. Attach a wire rope onto the main frame. Adjust Main Frame
the chain block in order to level the main frame.
Hoist and install the main frame to the Undercarriage
undercarriage. Refer to Removal on W2-3-1 as
for the hoisting procedure.

W157-02-03-002

8
2. Align the matching marks on the upperstructure
and the outer race of swing bearing (8). 9
Temporarily tighten bolts (9) (36 used) to swing
bearing (8). Remove the wire rope from swing
bearing (8). Tighten bolts (9) (36 used).
: 27 mm
: 270 N m (27 kgf m, 200 lbf ft)

W105-03-01-002

3. Install stopper (7) to center joint (5) with bolts (6)

(2 used).
: 19 mm 4
: 110 N m (11 kgf m, 81 lbf ft)

4. Connect hoses (4) (6 used) to the upper side of

center joint (5).
: 19 mm 5
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 70 N m (7 kgf m, 52 lbf ft) 6
: 27 mm
: 95 N m (9.5 kgf m, 70 lbf ft)
Machine Front
Side
7
W102-03-03-001

W2-3-4
 UPPERSTRUCTURE / Main Frame

CAUTION: Cab (1) weight:

ZX110-3 class, 120-3 class: 330 kg (730 lb)
ZX135US-3 class: 310 kg (690 lb)
1
5. Install cab (1).
(Refer to REMOVAL AND INSTALLATION OF
CAB on W2-1-1.)
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
: 24 mm
: 210 N m (21 kgf m, 155 lbf ft)
: 30 mm W157-02-01-001
: 550 N m (55 kgf m, 410 lbf ft)
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)

CAUTION: Counterweight (2) weight: 2 ZX200-3 class, 120-3 class

ZX110-3 class: 1850 kg (4080 lb)
ZX120-3 class: 2500 kg (5520 lb)
ZX135US-3 class: 3680 kg (8120 lb)

6. Install counterweight (2).

(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
(ZX110-3 class, 120-3 class)
: 41 mm
: 1150 N m (115 kgf m, 850 lbf ft)
(ZX135US-3 class)
: 50 mm W1R7-02-02-001
: 2250 N m (230 kgf m, 1660 lbf ft)
ZX135US-3 class

W1R7-02-02-003

W2-3-5
 UPPERSTRUCTURE / Main Frame

CAUTION: The front attachment (3) assem-

bly weight:
ZX110-3 class: 1980 kg (4370 lb)
ZX120-3 class: 2220 kg (4900 lb)
ZX135US-3 class: 3100 kg (6840 lb)

7. Install the front attachment (3) assembly. Add 3

hydraulic oil.
(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-2.)
Hose
: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf ft)
: 27 mm
: 78 N m (8 kgf m, 58 lbf ft)
: 36 mm W105-02-03-002
: 175 N m (18 kgf m, 130 lbf ft)
Bolt
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf ft)
: 27 mm
: 400 N m (40 kgf m, 295 lbf ft)

8. Start the engine. Set the front attachment in M104-07-021

position for checking hydraulic oil level in the
hydraulic oil tank. Check the hydraulic oil level
and any oil leakage.

W2-3-6
 UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE (ZX110-3 CLASS, 120-3 CLASS)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
1 2
Removal

1. Remove bolts (1) (11 used). Remove cover (2)

from the upper side of the machine.
: 17 mm

Machine Front W1R7-02-04-001

3 4, 5, 6 7
2. Attach a nylon sling onto muffler (3). Hoist and
hold muffler (3). Remove U-nuts (4) (2 used), nuts
(5) (8 used) and washers (6) (4 used) from muffler
bracket (7).
: 17 mm 8

3. Remove bolts (10) (2 used) and clamp (8) from

muffler (3). Hoist and remove muffler (3) from
9
exhaust pipe (9).
: 19 mm 12

11 10 W1R7-02-04-003

14
4. Attach a nylon sling onto the cover (12) assembly.
Remove bolts (14) (4 used) from the cover (13) 13
side. Remove bolts (11) (3 used) from the cover 12
(12) side. Hoist and remove the cover (12)
assembly.
: 17 mm

W1R7-02-04-004

W2-4-1
 UPPERSTRUCTURE / Pump Device
5. Remove bolts (15) (3 used). Remove muffler 7 15 16
bracket (7) from pump device (16).
: 17 mm

W1R7-02-04-005

6. Disconnect hoses (17) (11 used), pipe (19) and 17 16

harness (18) from pump device (16). Cap
disconnected hoses (17) and pipe (19).
: 17 mm, 19 mm, 27 mm, 36 mm
: 8 mm, 10 mm

CAUTION: Pump device (16) weight: 95 kg

(210 lb)

7. Install the eyebolt (ST 0002) to pump device (16).

Hoist and hold pump device (16).
19 18 W1R7-02-04-006

8. Remove other bolts (15) (5 used). Hoist and

remove pump device (16) from the engine.
: 17 mm

W2-4-2
 UPPERSTRUCTURE / Pump Device
Installation
7 15 16

CAUTION: Pump device (16) weight: 95 kg

(210 lb)

1. Install the eyebolt (ST 0002) to pump device (16).

Hoist pump device (16).

2. Install pump device (16) and muffler bracket (7) to

the engine with bolts (15) (8 used).
W1R7-02-04-005
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 17 16

3. Connect hoses (17) (11 used), pipe (19) and

harness (18) to pump device (16).
: 17 mm
: 9.8 N·m (1 kgf·m, 7 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 27 mm
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 130 lbf·ft)
: 8 mm 19 18 W1R7-02-04-006
: 50 N·m (5 kgf·m, 37 lbf·ft)
: 10 mm
: 90 N·m (9 kgf·m, 66 lbf·ft)

W2-4-3
 UPPERSTRUCTURE / Pump Device
4. Attach a nylon sling onto the cover (12) assembly. 14
Hoist the cover (12) assembly. Install the cover
(12) assembly with bolts (11) (3 used) and bolts 13
(14) (4 used). 12
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-004

3 4, 5, 6 7
5. Attach a nylon sling onto muffler (3). Hoist muffler
(3). Install muffler (3) to exhaust pipe (9) with
clamp (8) and bolts (10) (2 used).
: 19 mm
: 90 N·m (9 kgf·m, 66 lbf·ft)
8
6. Install U-nuts (4) (2 used) to muffler bracket (7)
with nuts (5) (8 used) and washers (6) (4 used).
: 17 mm 9
: 50 N·m (5 kgf·m, 37 lbf·ft)
12

11 10 W1R7-02-04-003

7. Install cover (2) to the upper side of the machine 1 2

with bolts (1) (11 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

Machine Front W1R7-02-04-001

W2-4-4
 UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE (ZX135US-3 CLASS) 1 2

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED 3
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

1. Remove bolts (4) (3 used). Remove cover (3) from

cover (2).
: 17 mm Machine Front 4 W1R7-02-04-002

5 6 7
2. Remove bolts (1) (10 used). Remove cover (2)
from the upper side of the machine.
: 17 mm

3. Remove bolts (7) (5 used). Remove bracket (5)

from bracket (6).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-007

4. Attach a nylon sling onto muffler (8). Hoist and 8 9, 10, 11

hold muffler (8). Remove U-nuts (9) (2 used), nuts
(10) (8 used) and washers (11) (4 used) from
12
muffler bracket (12).
: 17 mm

5. Remove bolts (14) (2 used) and clamp (13) from 13

muffler (8). Remove muffler (8) from exhaust pipe
(15).
14
: 19 mm

15
6. Remove bolt (16) from bracket (17).
17 16 W1R7-02-04-008
: 17 mm

W2-4-5
 UPPERSTRUCTURE / Pump Device
17 18
7. Remove bolts (19) (2 used). Remove bracket (18)
from bracket (17).
: 17 mm

19 W1R7-02-04-009

20 17 21, 22
8. Remove bolts (20) (2 used). Remove bracket (17)
from bracket (21).
: 17 mm 20

9. Remove bolt (22) of bracket (21) from the engine

side. Remove bracket (21) from the engine
bracket.
: 17 mm

W1R7-02-04-010

10. Remove bolts (23) (3 used). Remove muffler 12 23 24

bracket (12) from pump device (24).
: 17 mm

11. Disconnect hoses (25) (11 used), pipe (27) and

harness (26) from pump device (24). Cap
disconnected hoses (25) and pipe (27).
: 17 mm, 19 mm, 27 mm, 36 mm
: 8 mm, 10 mm

W1R7-02-04-005

CAUTION: Pump device (24) weight: 95 kg 25 26

(210 lb)

12. Install the eyebolt (ST 0002) to pump device (24).

Hoist and hold pump device (24).

13. Remove other bolts (23) (5 used). Hoist and

remove pump device (24) from the engine. 24
: 17 mm

27 W1R7-02-04-011

W2-4-6
 UPPERSTRUCTURE / Pump Device
Installation 12 23 24

CAUTION: Pump device (24) weight: 95 kg

(210 lb)

1. Install the eyebolt (ST 0002) to pump device (24).

Hoist pump device (24).

2. Install pump device (24) and muffler bracket (12)

to the engine with bolts (23) (8 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
W1R7-02-04-005

25 26
3. Connect hoses (25) (11 used), pipe (27) and
harness (26) to pump device (24).
: 17 mm
: 9.8 N·m (1 kgf·m, 7 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 27 mm 24
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 130 lbf·ft)
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
27
: 10 mm W1R7-02-04-011

: 90 N·m (9 kgf·m, 66 lbf·ft)

20 17 21, 22

4. Install brackets (17, 21) to the engine bracket with

bolts (20) (2 used) and bolt (22). 20
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-010

W2-4-7
 UPPERSTRUCTURE / Pump Device
17 18
5. Install bracket (18) to bracket (17) with bolts (19)
(2 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

6. Install bolt (16) to bracket (17).

: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

19 W1R7-02-04-009

7. Attach a nylon sling onto muffler (8). Hoist muffler 8 9, 10, 11

(8). Install muffler (8) to exhaust pipe (15) with
clamp (13) and bolts (14) (2 used).
: 19 mm 12
: 90 N·m (9 kgf·m, 66 lbf·ft)

8. Install U-nuts (9) (2 used) to muffler bracket (12)

with nuts (10) (8 used) and washers (11) (4 used). 13
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
14

15

17 16 W1R7-02-04-008

5 6 7
9. Install bracket (5) to bracket (6) with bolts (7) (5
used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-007

W2-4-8
 UPPERSTRUCTURE / Pump Device
10. Install cover (2) to the upper side of the machine
with bolts (1) (10 used). 1 2
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

3
11. Install cover (3) to cover (2) with bolts (4) (3 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

Machine Front 4 W1R7-02-04-002

W2-4-9
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF MAIN PUMP
10
9
8 27
7 28
6
5 26 29
4
3 25
30 32
2 24 31
1
22
11
7 23

12
13
14 22 33
34

21
20
19
18
17 2
16 35 1
15 36
37
38 47
46

39 4
40 44
45
41
44

43
9
11
49 48
42 5
16 14
13
17 12
50

19 51
20
21
38 10

41
40
18

W176-02-04-005

W2-4-10
 UPPERSTRUCTURE / Pump Device

1- Socket Bolt (12 Used) 14 - Restrictor Pin (2 Used) 27 - O-Ring (2 Used) 40 - Plate (2 Used)
2- Spring Washer (12 Used) 15 - Swash Plate R 28 - O-Ring (10 Used) 41 - Knock Pin (2 Used)
3- Rear Casing 16 - Servo Piston (6 Used) 29 - O-Ring (4 Used) 42 - Swash Plate F
4- Knock Pin (2 Used) 17 - Spring (6 Used) 30 - Pin (2 Used) 43 - Inner Race
5- Pin (4 Used) 18 - Plunger (18 Used) 31 - Feedback Link (2 Used) 44 - Retaining Ring (2 Used)
6- O-Ring 19 - Retainer (2 Used) 32 - Spring Pin (4 Used) 45 - Roller Bearing
7- Retaining Ring (2 Used) 20 - Bushing (2 Used) 33 - Valve Plate F 46 - Oil Seal
8- Roller Bearing 21 - Disc Spring (8 Used) 34 - Needle Bearing 47 - Retaining Ring
9- O-Ring (4 Used) 22 - Knock Pin (4 Used) 35 - Pump Casing 48 - Front Casing
10 - Socket Bolt (8 Used) 23 - Spring Pin (2 Used) 36 - Needle Bearing 49 - O-Ring
11 - Cradle Plate (2 Used) 24 - Link Pin (2 Used) 37 - Valve Plate R 50 - Drive Shaft
12 - O-Ring (4 Used) 25 - Pin (2 Used) 38 - Rotor (2 Used) 51 - Retaining Ring
13 - Backup Ring (4 Used) 26 - Spring Pin (2 Used) 39 - Shaft

W2-4-11
 UPPERSTRUCTURE / Pump Device

33

35 1

44
45

43

11
42 48
14

50

19
20
21
38 10

40
18

W176-02-04-005

W2-4-12
 UPPERSTRUCTURE / Pump Device
Disassembly

4. Place the front casing (48) assembly on a

CAUTION: The front casing (48) assembly
weight: 27 kg (60 lb)
1. Install the eyebolt (M12, Pitch 1.75 mm, Length
22 mm) (ST 0002) to the front casing (48)
assembly. Attach a nylon sling onto the eyebolt.
Hoist and hold the front casing (48) assembly.
ST 0002
Mounting Position
wooden block (30 mm square or more) with the
rotor (38) side facing upward.
IMPORTANT: The valve plate F (33) side of rotor
(38) is a sliding surface. Do not
damage the sliding surface.
5. Remove the rotor (38) assembly from drive shaft
(50). Place the rotor (38) assembly with the valve
plate F (33) side facing downward.

6. Remove retainer (19) with plunger (18) together

from rotor (38).

7. Remove bushing (20) and disc springs (21) (4

used) from rotor (38).

8. Remove plate (40) from swash plate F (42).

W176-02-04-015
NOTE: When tapping the yoke part with plate (40)
facing upward, plate (40) is raised.
2. Remove socket bolts (1) (6 used).
: 10 mm 9. Remove socket bolts (10) (4 used). Remove
cradle plate (11) from front casing (48).
IMPORTANT: Inner race (43) with drive shaft (50) : 5 mm
attached cannot be replaced. Do not
damage inner race(43).
3. Remove the front casing (48) assembly from
pump casing (35). At this time, drive shaft (50),
the rotor (38) assembly and restrictor pin (14) are
removed together with front casing (48).
NOTE: When removing the front casing (48)
assembly, raise the pump casing (35) side
a little in order to prevent rotor (38) from
falling off.
NOTE: Do not remove restrictor pin (14) unless
necessary.

W2-4-13
 UPPERSTRUCTURE / Pump Device

31

33
34

35

45
44

48

16
17
50

W176-02-04-005

W2-4-14
 UPPERSTRUCTURE / Pump Device
10. Remove drive shaft (50) with roller bearing (45) 13. Remove servo pistons (16) (3 used) and springs
together from front casing (48). (17) (3 used) from pump casing (35).

NOTE: If it is difficult to remove drive shaft (50), tap
drive shaft (50) from the front casing (48)
side by using a plastic hammer.
IMPORTANT: When removing retaining ring (44),
do not damage the seal lip
contacting surface of drive shaft
(50).
11. Remove retaining rings (44) (2 used) from drive
shaft (50).
IMPORTANT: Check the direction to insert drive
shaft (50) into the special tool (ST
7266).
12. Insert drive shaft (50) from the large diameter
side into the special tool (ST 7266).
Tap the end of the special tool (ST 7266) and
remove roller bearing (45) from drive shaft (50).
NOTE: If replacing inner race (43), replace the
assembly with drive shaft (50).
14. Remove valve plate F (33) from pump casing
(35).
NOTE: Needle bearing (34) is still left in pump
casing (35). When removing needle
bearing (34), remove needle bearing (34)
by tapping from the backside after
disassembling the rear pump side of pump
casing (35).
IMPORTANT: Do not disassemble feedback link
(31) unless necessary.
15. Remove the feedback link (31) assembly from
pump casing (35).

50 ST 7266

45

W176-02-04-009

W2-4-15
 UPPERSTRUCTURE / Pump Device

10

8
7

11

14

19
18

35
15

38

39
40

W176-02-04-005

W2-4-16
 UPPERSTRUCTURE / Pump Device
16. Remove socket bolts (1) (6 used). Remove the
rear casing (3) assembly from pump casing (35).
At this time, shaft (39) and the rotor (38)
assembly are removed with the rear casing (3)
assembly together.
: 10 mm
17. Place the rotor (38) assembly on a wooden block
(80 mm square or more) with the rotor (38) side
facing downward.
IMPORTANT: Retaining ring (7) is placed under
roller bearing (8). Do not hook the
claws of the puller on retaining ring
(7).
23. Insert the guide (ST 7267) into the hole on the
shaft (39) end. Remove the inner race of roller
bearing (8) from shaft (39) by using a small
puller.

18. Remove retaining ring (7) from shaft (39). ST 7267

19. Remove the inner ring plate from roller bearing 39

(8).
8
20. Remove the rear casing (3) assembly from shaft
(39). At this time, the outer race of roller bearing
(8), restrictor pin (14) and cradle plate (11) are
7 W176-02-04-010
removed with the rear casing (3) assembly
together.
NOTE: Do not remove restrictor pin (14) unless 24. Remove retaining ring (7) from shaft (39).
necessary.
25. Remove swash plate R (15) from shaft (39).
21. Remove socket bolts (10) (4 used). Remove
cradle plate (11) from rear casing (3). 26. Remove plate (40) from swash plate R (15).
: 5 mm
NOTE: When tapping the yoke part with plate (40)
facing upward, plate (40) is raised.
22. Remove the outer race of roller bearing (8) from
rear casing (3).
27. Remove retainer (19) with plunger (18) together
NOTE: Insert your finger in the outer race of roller from shaft (39).
bearing (8) and remove the outer race
from rear casing (3) straightly.

W2-4-17
 UPPERSTRUCTURE / Pump Device

29

31

33
34

21
20

17
16 35
36
37
38

39

W176-02-04-005

W2-4-18
 UPPERSTRUCTURE / Pump Device
28. Remove bushing (20) and disc springs (21) (4
used) from shaft (39).

29. Remove rotor (38) from shaft (39).

30. Remove valve plate R (37) from pump casing

(35).

31. Remove servo pistons (16) (3 used) and springs

(17) (3 used) from pump casing (35).

32. Remove the feedback link (31) assembly from

pump casing (35).
NOTE: Do not disassemble feedback link (31)
unless necessary.

33. The outer races of needle bearings (34, 36) are

still left in pump casing (35). Do not remove the
outer races unless necessary.
When removing the outer races, remove the
outer races by tapping from the backside by
using a bar and a hammer.

W2-4-19
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF MAIN PUMP

2 15 16 17 22 35 17 16 42
4
1

4
47

44

10 46
14
10

40 14

21 20 18 37 36 51 43 34 33 18 20 21 40

48

6 24 25 31 26 23 30 23 26 31 25 24

11 49
3 11
7 45

8
9
9

5 41 19 39 38 38 50 19 41 W176-02-04-011
1
2

W2-4-20
 UPPERSTRUCTURE / Pump Device

1- Socket Bolt (12 Used) 14 - Restrictor Pin (2 Used) 27 - *O-Ring (2 Used) 40 - Plate (2 Used)
2- Spring Washer (12 Used) 15 - Swash Plate R 28 - *O-Ring (10 Used) 41 - Knock Pin (2 Used)
3- Rear Casing 16 - Servo Piston (6 Used) 29 - *O-Ring (4 Used) 42 - Swash Plate F
4- Knock Pin (2 Used) 17 - Spring (6 Used) 30 - Pin (2 Used) 43 - Inner Race
5- Pin (4 Used) 18 - Plunger (18 Used) 31 - Feedback Link (2 Used) 44 - Retaining Ring (2 Used)
6- O-Ring 19 - Retainer (2 Used) 32 - *Spring Pin (4 Used) 45 - Roller Bearing
7- Retaining Ring (2 Used) 20 - Bushing (2 Used) 33 - Valve Plate F 46 - Oil Seal
8- Roller Bearing 21 - Disc Spring (8 Used) 34 - Needle Bearing 47 - Retaining Ring
9- O-Ring (4 Used) 22 - Knock Pin (4 Used) 35 - Pump Casing 48 - Front Casing
10 - Socket Bolt (8 Used) 23 - Spring Pin (2 Used) 36 - Needle Bearing 49 - O-Ring
11 - Cradle Plate (2 Used) 24 - Link Pin (2 Used) 37 - Valve Plate R 50 - Drive Shaft
12 - *O-Ring (4 Used) 25 - Pin (2 Used) 38 - Rotor (2 Used) 51 - Retaining Ring
13 - *Backup Ring (4 Used) 26 - Spring Pin (2 Used) 39 - Shaft

NOTE: As for the item with mark *, refer to

W2-4-10.

W2-4-21
 UPPERSTRUCTURE / Pump Device

15 16 17 22 35

40

21 20 18 37 36 34

24 31 30

3
7

19 39 38 W176-02-04-011

W2-4-22
 UPPERSTRUCTURE / Pump Device
Assembly
1. Install the outer races of needle bearings (34, 36)
to pump casing (35) with the stamped mark
facing outside by using the special tool (ST 7262)
and a hammer.
IMPORTANT: Install valve plate R (37) with the
oval hole facing downward.
2. Apply grease onto the flat surface of valve plate
R (37). Install valve plate R (37) while aligning
the position of knock pin (22) in pump casing
(35).
3. Insert spring (17) into servo piston (16). Install
servo piston (16) to pump casing (35). (3 places)
IMPORTANT: Check the direction to install the
feedback link (31) assembly.
4. Install the feedback link (31) assembly while
aligning with the groove for pin (30) of pump
casing (35). At this time, face link pin (24) to the
rear casing (3) side.
NOTE: Both surfaces of pin (30) are parallel to
each other. Install pin (30) while aligning
the parallel surface with the groove.
30
31
35
Parallel Surface Parallel Surface W176-02-04-016
W2-4-23
IMPORTANT: Check the direction of disc spring
(21) and retainer (19).
5. Assemble rotor (38) into an assembly in the
following procedures.
• Place rotor (38) with the center projection part
facing upward.
• Assemble disc springs (21) (4 used) so that the
outer surface is matching with the outer surface
and the inner surface is matching with the inner
surface. Place the assembled disc springs on the
center projection part of rotor (38).
21
20
38
W176-02-06-015
• Cover disc spring (21) with bushing (20).
• Insert plungers (18) (9 used) through the retainer
(19) flat surface. Install them to rotor (38).
IMPORTANT: The larger diameter side of shaft
(39) is the inner race of needle
bearing (36). Do not damage the
inner race surface.
6. Insert shaft (39) into the rotor (38) assembly.
7. Apply grease onto the knock pin hole side of
plate (40). Install plate (40) while aligning knock
pin (41) in swash plate R (15).
8. Install swash plate R (15) to shaft (39).
9. Install retaining rings (7) (2 used) to the ring
groove (2 places) of shaft (39).
 UPPERSTRUCTURE / Pump Device

10
14

11
3
7

8
9

5 39 W176-02-04-011

W2-4-24
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the direction of the roller 11. Assemble rear casing (3) into an assembly in the
bearing (8) inner race. following procedures.
10. Install the inner race of roller bearing (8) to shaft • Install the outer race of roller bearing (8) to rear
(39) with the flange side facing inside by using casing (3) with the stamped mark facing forward.
the special tool (ST 7265), the guide (ST 7267) NOTE: If inserting the outer race straightly while
and a hammer. aligning the center, the outer race can be
ST 7265
installed by hand.
8 • Install O-rings (9) (2 used) to rear casing (3).
ST 7267 • Align the knock pin (5) positions and install cradle
plate (11) to rear casing (3) with socket bolts (10)
39 (4 used).
: 5 mm
7 : 9.8 N m (1 kgf m)
• If restrictor pin (14) has been removed, install
backup rings (13) (2 used) and O-rings (12) (2
W176-02-04-012 used) to restrictor pin (14). Install restrictor pin
(14) to rear casing (3). At this time, install
restrictor pin (14) with the orifice hole side facing
inside.
12

3 14

W176-02-04-013

Orifice 13

• Install O-ring (6) to rear casing (3).

W2-4-25
 UPPERSTRUCTURE / Pump Device

2 15 35

24 31

11
3

W176-02-04-011

W2-4-26
 UPPERSTRUCTURE / Pump Device
12. Align the cylindrical surface of cradle plate (11)
with that of swash plate R (15). Install the rear
casing (3) assembly to shaft (39).
At this time, the mounting concave part with
feedback link (31) in swash plate R (15) and the
lifting screw hole on rear casing (3) are
positioned in the same direction.
NOTE: As the roller of roller bearing (8) is tilted, it
is difficult to install shaft (39). For easy
installation, roll a clean cloth, push the
cloth into the inner bore of roller bearing
(8), extend the inner diameter and install
the cloth to shaft (39).
Mounting
15 Concave Part

W176-02-04-018

13. Install the inner ring plate of roller bearing (8) to

shaft (39) with the stamped mark facing outside.

14. Install retaining ring (7) to shaft (39).

IMPORTANT: Install retaining ring (7) so that link

pin (24) of feedback link (31) can be
inserted into the mounting concave
part of swash plate R (15).
15. Align the mounting concave part of swash plate R
(15) with the link pin (24) position of swash plate
R (15). Install the rear casing (3) assembly to
pump casing (35).

16. Install rear casing (3) to pump casing (35) with

socket bolts (1) (6 used) and spring washers (2)
(6 used).
: 10 mm
: 108 N m (11 kgf m, 80 lbf ft)

W2-4-27
UPPERSTRUCTURE / Pump Device

22 35 17 16

51 43 33

48

30 31 24

45

38 50 W176-02-04-011

W2-4-28
 UPPERSTRUCTURE / Pump Device
Assembly of Front Pump 6. Install retaining ring (51) to drive shaft (50).
IMPORTANT: Do not damage the retaining ring
IMPORTANT: Install valve plate F (33) with the (44) sliding surface of drive shaft
oval hole facing downward. (50).
1. Apply grease onto the flat surface of valve plate F 7. Install retaining ring (44) to the ring groove on
(33). Install valve plate F (33) while aligning the drive shaft (50) closer to the end surface.
position of knock pin (22) in pump casing (35).
8. Install roller bearing (45) to drive shaft (50) with
2. Insert spring (17) into servo piston (16). Install the stamped mark facing forward by using the
servo piston (16) to pump casing (35). (3 places) special tool (ST 7266) and a hammer.

IMPORTANT: Check the direction to install 9. Install the inner ring plate of roller bearing (45) to
feedback link (31). drive shaft (50) with the stamped mark facing
3. Install the feedback link (31) assembly while forward.
aligning with the groove for pin (30) of pump
casing (35). At this time, face link pin (24) to the 10. Install retaining ring (44) to drive shaft (50).
front casing (48) side.
NOTE: Both surfaces of pin (30) are parallel to
each other. Install pin (30) while aligning
with the groove on the parallel surface.
30
31
35

Parallel Surface Parallel Surface W176-02-04-016

4. Assemble rotor (38) in the same way as steps 5

on the assembling procedure of the rear pump
side. (Refer to W2-4-23.)

5. Install inner race (43) to drive shaft (50) by

tapping evenly by using the special tool (ST
7264) and a hammer.

W2-4-29
 UPPERSTRUCTURE / Pump Device

35 42

47

46

10

14

40

48

24

49

11

9
9

50 41 W176-02-04-011

W2-4-30
 UPPERSTRUCTURE / Pump Device
11. Assemble front casing (48) into an assembly in
the following procedures.
• Place front casing (48) with the pump casing (35)
side facing downward.
• Apply grease onto the inner surface of oil seal
(46).
• Install oil seal (46) to front casing (48) by tapping
evenly by using the special tool (ST 7263) and a
plastic hammer.
• Install retaining ring (47) to front casing (48).
• Turn over and place front casing (48) on a
wooden block (30 mm square or more).
• Install drive shaft (50) to front casing (48). At this
time, roller bearing (45) can be installed by
tapping lightly by using a plastic hammer.
• Install O-rings (9) (2 used) to front casing (48).
• Align cradle plate (11) with knock pin (5) of front
casing (48). Install cradle plate (11) with socket
bolts (10) (4 used).
: 5 mm
: 9.8 N m (1 kgf m, 7 lbf ft)
• Install O-ring (49) to front casing (48).
• If restrictor pin (14) has been removed, install
backup rings (13) (2 used) and O-rings (12) (2
used) to restrictor pin (14). Install restrictor pin
(14) to front casing (48). At this time, install
restrictor pin (14) with the orifice hole side facing
inside.
12
3 14
W176-02-04-013
Orifice 13
W2-4-31
12. Apply grease onto the knock pin hole surface on
plate (40). Install plate (40) while aligning with
knock pin (41) in swash plate F (42).
IMPORTANT: Install swash plate F (42) with the
mounting part of link pin (24) in
swash plate F (42) facing upward (to
the regulator mounting side).
13. Apply grease onto the cylindrical surface of
swash plate F (42). Install swash plate F (42) to
the front casing (48) assembly while aligning with
the cylindrical surface of cradle plate (11).
42 Mounting Part
of Link Pin
W176-02-04-018
CAUTION: The front casing (48) assembly
weight: 24 kg (53 lb)
14. Install the eyebolt (M12, Pitch 1.75 mm, Length
22 mm) (ST 0002) to front casing (48). Raise the
front casing (48) assembly almost to the vertical
position. Hoist and hold the front casing (48)
assembly.
NOTE: As swash plate F (42) may come off, do
not raise the front casing (48) assembly
excessively.
ST 0002
48
W176-02-04-017
UPPERSTRUCTURE / Pump Device

35 42

18

48

23 31 24

39 38 50 W176-02-04-011
1
2

W2-4-32
 UPPERSTRUCTURE / Pump Device
15. Install the rotor (38) assembly to the front casing 18. Install front casing (48) to pump casing (35) with
(48) assembly. Do not drop plunger (18) from the socket bolts (1) (6 used) and spring washers (2)
rotor (38) assembly. (6 used).
: 10 mm
: 108 N m (11 kgf m, 80 lbf ft)
CAUTION: The front casing (48) assembly
weight: 27 kg (60 lb) 19. Install O-rings (27) (2 used), (28) (10 used), (29)
(4 used) and spring pins (32) (4 used) to pump
16. Hoist the front casing (48) assembly. casing (35).
NOTE: Do not tilt the casing (48) assembly as
center of gravity is at the rotor (38) side.
Do not drop rotor (38). 27 32 28 29
35
IMPORTANT: Install the front casing (48)
assembly so that link pin (23) can be
inserted into the mounting concave
part with feedback link (31) in swash
plate F (42). W176-02-04-014
17. Align the front casing (48) assembly with the
position of link pin (24). Install the front casing
(48) assembly to pump casing (35).
NOTE: In case the spline of drive shaft (50) and
that of shaft (39) are not aligned, rotate
drive shaft (50) or shaft (39) by using the
special tool (ST 3315).

W2-4-33
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR

1 2 3

Regulator for Front Pump Regulator for Rear Pump

6 7 8 9 10 11 12 13 14 15

5 16

4 17

18
19
33
W176-02-04-001

32
31 30 29 28 27 26 25 24 23 22 21 20

1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing

W2-4-34
 UPPERSTRUCTURE / Pump Device
Disassembly of Regulator

• The regulators are used for front pump and rear
pump. The inner structure in the regulator is fully
identical, and the difference is only in its
accessories.
The rear regulator is explained here.
IMPORTANT: As the setting changes, do not
disassemble regulator adjusting
screw parts (4, 5, 16, 17, 18, 19).
When the regulator adjusting screw
parts should be disassembled,
adjust according to the procedure of
performance test after assembling.
1. Secure casing (9) in a vise. Disconnect pipe (1)
from casing (9).
: 17 mm
2. Remove socket bolts (2) (2 used). Remove
solenoid valve (3) from casing (9).
5. Remove springs (23, 24) from casing (9).
6. Insert a round bar into the hole on casing (9).
Push the spool (26) end. Remove cylinder (28),
sleeve (25) and spool (26) from casing (9). At this
time, piston (27) is removed with cylinder (28)
together.
7. Remove piston (27) from cylinder (28).
8. Remove spring (8) from casing (9).
9. Insert a round bar into the hole on casing (9).
Push the spool (10) end. Remove cylinder (13),
sleeve (11) and spool (10) from casing (9). At this
time, piston (12) is removed with cylinder (13)
together.
10. Remove piston (12) from cylinder (13).

IMPORTANT: Do not rotate set bolt (16) and lock

nuts (17, 18, 19) as the setting
changes.
3. Remove socket bolts (20) (4 used). Remove the
cover (15) assembly from casing (9). At this time,
set bolt (16) and stopper assembly (21) are
removed with the cover (15) assembly together.
: 6 mm

IMPORTANT: Do not rotate lock nuts (4, 5) as the

setting changes.
4. Remove socket bolts (32) (4 used). Remove the
cover (33) assembly from casing (9). At this time,
stopper assembly (6) is removed with the cover
(33) assembly together.
: 6 mm

W2-4-35
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR

1 2 3

Regulator for Front Pump Regulator for Rear Pump

6 7 8 9 10 11 12 13 14 15

5 16

4 17

18
19
33
W176-02-04-001

32
31 30 29 28 27 26 25 24 23 22 21 20

1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing

W2-4-36
 UPPERSTRUCTURE / Pump Device
Assembly of Regulator

IMPORTANT: The sleeve holes (2 places) in
casing (9) are the same bores. The
shapes of various parts are very
similar. Assemble the regulator
while checking the illustration in
order not to confuse.
9. Install O-ring (22) and springs (23, 24) to stopper
assembly (21) with cover (15) attached. Install
cover (15) to casing (9) with socket bolts (20) (4
used)
: 6 mm
: 19.5 N m (2 kgf m, 14 lbf ft)

1. Clean all parts and apply hydraulic oil.
IMPORTANT: Check the direction to install sleeve
(11) and spool (10).
2. Insert spool (10) into sleeve (11). Install sleeve
(11) to the center of casing (9) by using a round
bar.
3. Install O-ring (14) to cylinder (13).
10. Install solenoid valve (3) to casing (9) with socket
bolts (2) (2 used).
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
11. Apply grease onto the thread part of pipe (1).
Connect pipe (1) to casing (9).
: 17 mm
: 34 N m (3.5 kgf m, 25 lbf ft)

4. Insert piston (12) into cylinder (13). Install

cylinder (13) to casing (9).

IMPORTANT: Check the direction to install sleeve

(25) and spool (26).
5. Insert spool (26) into sleeve (25). Install sleeve
(25) to the center of casing (9) by using a round
bar.

6. Install O-rings (29, 31) and backup ring (30) to

cylinder (28).

7. Insert piston (27) into cylinder (28). Install

cylinder (28) to casing (9).

8. Install O-ring (7) and spring (8) to stopper

assembly (6) with cover (33) attached. Install
cover (33) to casing (9) with socket bolts (32) (4
used)
: 6 mm
: 19.6 N m (2 kgf m, 14 lbf ft)

W2-4-37
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF SOLENOID VALVE

1
2
3
4
5
6
7
8
9
10
11
12

13
14
15

16

17
18
19
20
21

W178-02-04-050

1- Socket Bolt 7- Spring 13 - Orifice 19 - O-Ring

2- Solenoid 8- O-Ring 14 - Plate 20 - Filter
3- Spring 9- O-Ring 15 - Wave Washer 21 - O-Ring
4- O-Ring 10 - O-Ring 16 - Filter
5- Diaphragm 11 - Sleeve 17 - Body
6- Retaining Ring 12 - Spool 18 - O-Ring

W2-4-38
 UPPERSTRUCTURE / Pump Device
Disassembly of Solenoid Valve
• Do damage the mounting surface for the
regulator.
• When replacing the inner parts, replace them as
an assembly.
• Do not hit the solenoid part.
• When disconnecting the connector, do not pry,
but disconnect straightly.
1. Remove socket bolt (1). Remove solenoid (2)
and O-ring (4) from body (17).
: 4 mm
NOTE: When removing solenoid (2), do not drop
O-ring (4) and spring (3).
IMPORTANT: Do not remove orifice (13) from
spool (12).
4. Remove retaining ring (6), spring (7) and
diaphragm (5) from spool (12).
NOTE: Spring (7) and spool (12) are removed to
the opposite direction.
5. Remove filters (16, 20) from body (17).
: 6 mm
NOTE: When cleaning filter (16), blow filter (16) by
using air from the both surfaces. Finally
blow filter (16) by using the air from the
outer side (thread side).

2. Remove the sleeve (11) assembly from body (17)

by using the special tool (ST 2953).
NOTE: When removing sleeve (11), do not drop
plate (14) and wave washer (15) inside.

ST 2953

W178-02-04-052

3. Remove plate (14) and wave washer (15) from

body (17).

W2-4-39
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF SOLENOID VALVE

2 1 5 6 7 11 12 13 14 15 17 16

8 9 10
21 20

19

18

W178-02-04-051

1- Socket Bolt 7- Spring 13 - Orifice 19 - O-Ring

2- Solenoid 8- O-Ring 14 - Plate 20 - Filter
3- Spring 9- O-Ring 15 - Wave Washer 21 - O-Ring
4- *O-Ring 10 - O-Ring 16 - Filter
5- Diaphragm 11 - Sleeve 17 - Body
6- Retaining Ring 12 - Spool 18 - O-Ring

NOTE: As for the item with mark *, refer to

W2-4-38.

W2-4-40
 UPPERSTRUCTURE / Pump Device
Assembly of Solenoid Valve
1. Install filters (16, 20) to body (17).
: 6 mm
: 10+3 N m (1+0.3 kgf m, 7+2 lbf ft)
2. Install wave washer (15) and plate (14) to body
(17).
NOTE: When installing with body (17) placed
horizontally, apply grease onto wave
washer (15) and plate (7) in order not to
fall off. Check that plate (14) is installed
straightly.
3. Install O-rings (8, 9 and 10) to sleeve (11).
4. Insert spool (12) into sleeve (11). Install spring (7),
retaining ring (6) and diaphragm (5) to spool (12).
NOTE: Install diaphragm (5) with the curling side
facing outside. Check that spool (12)
moves smoothly.
W2-4-41
IMPORTANT: Install sleeve (11) so that the ends of
sleeve (11) and body (17) are
positioned at the same position.
Do not pry and damage O-ring when
installing sleeve (11).
5. Install the sleeve (11) assembly to body (17) by
using the special tool (ST 2953).
NOTE: When the special tool (ST 2953) is not
available, install solenoid (2) alternately
with socket bolts (1) (2 used).
ST 2953
W178-02-04-052
6. Install solenoid (2) and O-ring (4) to body (17)
with socket bolt (1).
: 4 mm
: 5+2 N m (0.5+0.2 kgf m, 4+1 lbf ft)
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY AND ASSEMBLY OF GEAR
PUMP
1

5
6

4
7
8
3
9

8
7
10
11
12

15
14
13
W137-02-04-034
4

W2-4-42
 UPPERSTRUCTURE / Pump Device
IMPORTANT: The housing is made of aluminum.
Do not damage the housing. In
addition, take care in order to
control the tightening torque.

Wrench Size Tightening Torque

No. Part Name Q’ty Remarks
(mm) Nm (kgf m) (lbf ft)
Apply hydraulic oil when
1 Bushing 2
assembling.
2 Gear 1
Apply hydraulic oil when
3 Bushing 2
assembling.
Apply grease when
4 O-ring 2
assembling.
5 Key 2
6 Housing 1
Apply grease when
7 Backup ring 2
assembling.
Apply grease when
8 Seal 2
assembling.
9 Gear 1
10 Flange 1
Apply grease onto the lip
11 Oil seal 1
part when assembling.
12 Retaining ring 1
13 Cover 1
14 Washer 4
15 Bolt 4 : 17 39 to 44 (4 to 4.5) (29 to 32)

W2-4-43
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY AND ASSEMBLY OF GEAR
PUMP (OPTIONAL)
1
2

7
8
6
1
9 5
10
4

11

2
10
14 9

12
13
2

1 3

21 7
20
19
6 7

18

1
9
10
4

17
2
10
9
6
16 W212-02-04-006

6
15

W2-4-44
 UPPERSTRUCTURE / Pump Device
IMPORTANT: The housing is made of aluminum.
Do not damage the housing. In
addition, take care in order to
control the tightening torque.

Wrench Size Tightening Torque

No. Part Name Q’ty Remarks
(mm) Nm (kgf m) (lbf ft)
1 Pin 6
Apply hydraulic oil when
2 Bushing 4
assembling.
3 Gear 2
Apply hydraulic oil when
4 Bushing 4
assembling.
5 Flange 1
Apply grease when
6 O-ring 4
assembling.
7 Key 4
8 Housing 1
Apply grease when
9 Backup ring 4
assembling.
Apply grease when
10 Seal 4
assembling.
11 Gear 1
Apply grease onto the lip
12 Oil seal 1
part when assembling.
13 Retaining ring 1
14 Nut 4 : 17 39 to 44 (4 to 4.5) (29 to 32)
15 Coupling 1
16 Flange 1
17 Gear 1
18 Housing 1
19 Cover 1
20 Bolt 4
21 Washer 4

W2-4-45
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
Pump Device
1. Drive shaft: Shaft outer diameter A

Standard Allowable Limit

A 35 mm (1.4 in) 34.8 mm (1.4 in)

W176-02-04-019

B
2. Plunger assembly: Shoe thickness
Standard Allowable Limit
B 5.5 mm (0.2 in) 5.2 mm (0.2 in)

W176-02-04-020

C
3. Plunger: Clearance between shoe and plunger
Standard Allowable Limit
0.15 mm 0.4 mm
C
(0.006 in) (0.02 in)

W176-02-04-020

4. Cylinder block: Clearance between plunger outer

diameter and cylinder block bore
D
Standard Allowable Limit
0.033 mm 0.07 mm
(D-a) a
(0.001 in) (0.003 in)

W176-02-04-021

5. Clearance between housing inner diameter and

servo piston outer diameter
Standard Allowable Limit E

0.06 mm 0.12 mm
(E-b)
(0.002 in) (0.005 in)

W176-02-04-022

W2-4-46
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
CONTROL VALVE
1 2
(ZX110-3 CLASS, 120-3 CLASS)

CAUTION: Bleed air from the hydraulic oil

Machine Front
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Remove bolts (1) (8 used). Remove cover (2) from
the upper side of the machine.
: 17 mm

2. Remove bolts (3) (7 used). Remove cover (4) from W1R7-02-05-001

the upper side of the machine.
Cab 3 4
: 17 mm

Machine
Front

W1R7-02-05-002

2-Spool Solenoid
Signal Control Valve Hydraulic
3. Remove clamp (5) from pipe (6). (2 places) Valve Unit
Oil Tank
Disconnect pipe (6) from the hydraulic oil tank.

4. Remove the signal control valve and the 2-spool

solenoid valve unit. (Refer to REMOVAL AND
INSTALLATION OF SIGNAL CONTROL VALVE
on W2-9-1 and REMOVAL AND INSTALLATION
OF 2-SPOOL SOLENOID VALVE UNIT on
W2-10-1.)

5. Disconnect all hoses (7), pipes (11) and W1R7-02-05-003

connectors (9) from control valve (8). Attach an 8 7 6 5

identification tag onto disconnected hoses (7) and 9 10 7
pipes (11) for assembling. Cap the open ends.
: 17 mm, 19 mm, 27 mm, 36 mm
: 6 mm, 8 mm

11

W1R7-02-05-004

W2-5-1
 UPPERSTRUCTURE / Control Valve

CAUTION: Control valve (8) weight: 135 kg

8
(300 lb)

6. Attach a nylon sling onto control valve (8). Hoist

and hold control valve (6). Remove bolts (12) (4
used) from the lower side of the main frame.
: 22 mm

W1R7-02-05-005

8
7. Hoist and remove control valve (8) from brackets
(13) (2 used).
12

13

W1R7-02-05-006

W2-5-2
 UPPERSTRUCTURE / Control Valve
Installation
8
CAUTION: Control valve (8) weight: 135 kg
(300 lb)

1. Attach a nylon sling onto control valve (8). Hoist

control valve (8).

W1R7-02-05-005

2. Install control valve (8) from the lower side of the 8

main frame with bolts (12) (4 used).
: 22 mm
: 140 N m (14 kgf m, 103 lbf ft) 12

3. Connect all hoses (7), pipes (11) and connectors

13
(9) to control valve (8).
: 17 mm
: 9.8 N m (1 kgf m, 7 lbf ft)
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
W1R7-02-05-006
: 27 mm
: 78 N m (8 kgf m, 58 lbf ft) 9 10 7
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
: 6 mm
: 20 N m (2 kgf m, 15 lbf ft)
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)
11

W1R7-02-05-004

Signal Control 2-Spool Solenoid Hydraulic

4. Install the signal control valve and the 2-spool Valve Valve Unit Oil Tank
solenoid valve unit. (Refer to REMOVAL AND
INSTALLATION OF SIGNAL CONTROL VALVE
on W2-9-1 and REMOVAL AND INSTALLATION
OF 2-SPOOL SOLENOID VALVE UNIT on
W2-10-1.)

5. Connect pipe (6) to the hydraulic oil tank with

clamp (5). (2 places)

W1R7-02-05-003

8 7 6 5

W2-5-3
 UPPERSTRUCTURE / Control Valve
6. Install cover (4) to the upper side of the machine Cab 3 4
with bolts (3) (7 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
Machine
Front

7. Install cover (2) to the upper side of the machine

W1R7-02-05-002
with bolts (1) (8 used).
: 17 mm 1 2
: 50 N m (5 kgf m, 37 lbf ft)

IMPORTANT: After completing the work, check the

hydraulic oil level. Start the engine Machine
Front
and check for any oil leaks.

W1R7-02-05-001

W2-5-4
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
1 2
CONTROL VALVE
(ZX135US-3 CLASS)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

1. Remove bolts (1) (5 used). Remove cover (2) from

the upper side of the machine.
W1R7-04-01-004
: 17 mm
3 4
2. Open cover (3). Remove bolts (6) (12 used) from
covers (4, 5). Remove covers (4, 5) from the main 5
frame.
: 17 mm

W1R7-04-01-005

Main Frame

7 8 9 10

3. Remove bolt (11) from support (10). Remove

support (10) from the main frame.
: 17 mm

4. Disconnect all hoses (9), pipes (12) and

connectors (7) from control valve (8). Attach an 12
identification tag onto disconnected hoses (9) and
pipes (12) for assembling. Cap the open ends.
: 17 mm, 19 mm, 27 mm, 36 mm
: 6 mm, 8 mm

10 W1R7-02-05-007

11

W1R7-02-05-009
Main Frame

W2-5-5
 UPPERSTRUCTURE / Control Valve
5. Remove bolts (14) (6 used). Remove cover (13) Main Frame 13
from the main frame in the lower side of control
valve (8). Machine Front
: 17 mm

14

W1R7-02-05-008
CAUTION: Control valve (8) weight: 135 kg
(300 lb)
8

6. Attach a nylon sling onto control valve (8). Hoist

and hold control valve (8). Remove bolts (15) (4
used) from the lower side of the main frame.
: 22 mm

W1R7-02-05-005

7. Hoist and remove control valve (8) from brackets 8

(16) (2 used).

15

16

W1R7-02-05-006

W2-5-6
 UPPERSTRUCTURE / Control Valve
Installation
8
CAUTION: Control valve (8) weight: 135 kg
(300 lb)

1. Attach a nylon sling onto control valve (8). Hoist

control valve (8).

2. Install control valve (8) to brackets (16) (2 used)

from the lower isde of the main frame with bolts
(15) (4 used).
: 22 mm W1R7-02-05-005

: 140 N m (14 kgf m, 103 lbf ft) Main Frame

13

3. Install cover (13) to the main frame with bolts (14) Machine Front
(6 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 14

4. Connect all hoses (9), pipes (12) and connectors

(7) to control valve (8).
: 17 mm
: 9.8 N m (1 kgf m, 7 lbf ft)
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft) W1R7-02-05-008

: 27 mm
: 78 N m (8 kgf m, 58 lbf ft) 8
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
: 6 mm 15
: 20 N m (2 kgf m, 15 lbf ft)
: 8 mm
16
: 50 N m (5 kgf m, 37 lbf ft)

W1R7-02-05-006

7 8 9 10

12

W1R7-02-05-007

W2-5-7
 UPPERSTRUCTURE / Control Valve
5. Install support (10) to the main frame with bolt 10
(11).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

11

W1R7-02-05-009
6. Install covers (4, 5) to the main frame with bolts Main Frame
(6) (12 used). Shut cover (3).
: 17 mm 3 4
: 50 N m (5 kgf m, 37 lbf ft)
5

7. Install cover (2) to the upper side of the machine

with bolts (1) (5 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) W1R7-04-01-005

Main Frame
IMPORTANT: After completing the work, check the 1 2
hydraulic oil level. Start the engine
and check for any oil leaks.

W1R7-04-01-004

W2-5-8
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-9
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE 4-SPOOL SIDE
X
41
1
2
42
3 29
23 43 51
4
5 30
44 52
6
24 31
7
8 45
25 53
9
Boom 32
Arm
Anti-Drift
10 Regenerative 26
Valve 54
Valve 46
(Switch Valve) 36 33
11 55
19 27
12 34
20
13 57
21 28 56
14
15 37 35 47 58 Check Valve
16 22 38 59 (Main Relief
48 Circuit)
60
17 49
39 50 61
18
40

66 73
64 67
65 68
69 74
75 W
72

62
70
63
71

X 76 W176-02-05-010
1- O-Ring 20 - Washer 39 - O-Ring 58 - Backup Ring
2- Screw 21 - O-Ring 40 - Plug 59 - O-Ring
3- Backup Ring 22 - Spool 41 - O-Ring 60 - Spring
4- O-Ring 23 - O-Ring 42 - Bolt 61 - Poppet
5- O-Ring 24 - Bolt 43 - Spring Seat 62 - Cap
6- O-Ring 25 - Spring Seat 44 - Spring 63 - Nut
7- Backup Ring 26 - Spring 45 - Spring Seat 64 - Plug
8- Backup Ring 27 - Spring Seat 46 - Main Spool 65 - O-Ring
9- O-Ring 28 - Main Spool 47 - Poppet 66 - Cap
10 - Sleeve 29 - O-Ring 48 - Spring 67 - Retaining Ring
11 - Spool 30 - Screw 49 - O-Ring 68 - Shim
12 - Washer 31 - O-Ring 50 - Plug 69 - Nut
13 - Spring 32 - Bolt 51 - O-Ring 70 - Pilot Housing
14 - Backup Ring 33 - Spring Seat 52 - Bolt 71 - Socket Bolt (11 Used)
15 - O-Ring 34 - Spring 53 - Spring Seat 72 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Spring 73 - Overload Relief Valve
17 - Spring 36 - Main Spool 55 - Spring Seat 74 - Backup Ring
18 - Poppet 37 - Poppet (2 Used) 56 - Main Spool 75 - O-Ring
19 - Spring 38 - Spring 57 - Plug 76 - Housing

W2-5-10
 UPPERSTRUCTURE / Control Valve
Disassembly of control valve 4-spool side (Up-
per)
• Attach an identification tag which specifies the
location of spool in the housing for each spool in
order to assemble correctly.
1. Remove socket bolts (71) (11 used). Remove pi-
lot housing (70) from housing (76).
: 8 mm
2. Remove boom anti-drift valve assembly (5 to 16)
from pilot housing (70). Remove O-ring (4) and
backup ring (3) from housing (76).
NOTE: Remove boom anti-drift valve assembly (5
to 16) from pilot housing (70) by moving by
hand.
3. Remove plug (16), O-ring (15), backup ring (14),
spring (13), washer (12) and spool (11) from
sleeve (10).
4. Remove O-rings (4, 5, 6, 9) and backup rings (3,
7, 8) from sleeve (10).
5. Remove spring (17) and poppet (18) from hous-
ing (76).
W2-5-11
6. Remove cap (66), retaining ring (67), shim (68)
and nut (69) from pilot housing (70).
Remove screw (30) and O-ring (29) from pilot
housing (70).
: 17 mm
: 4 mm
7. Remove cap (62) and nut (63) from pilot housing
(70).
Remove screw (2) and O-ring (1) from pilot hous-
ing (68).
: 17 mm
: 4 mm
IMPORTANT: Remove the main spool (28, 36, 46,
56) assemblies by turning. If they
stick even a little, try again instead
of pulling them roughly.
8. Remove the main spool (28, 36, 46, 56) assem-
blies and O-rings (23, 31, 41, 51) from housing
(76).
IMPORTANT: Put the matching marks on main
spools (28, 36, 46, 56) and housing
(76).
9. Secure main spools (28, 36, 46, 56) in a vise by
using wooden pieces. Remove bolts (24, 32, 42,
52), spring seats (25, 27, 33, 35, 43, 45, 53, 55)
and springs (26, 34, 44, 54) from main spools (28,
36, 46, 56).
: 17 mm
 UPPERSTRUCTURE / Control Valve

Boom
Arm
Anti-Drift
Regenerative
Valve
Valve 46
(Switch Valve) 36
19
20
21 57
37 47 58 Check Valve
22 38 59 (Main Relief
48 Circuit)
60
49
50 61
39
40

73

W
72

X 76 W176-02-05-010

W2-5-12
 UPPERSTRUCTURE / Control Valve
10. Remove plugs (40, 50), O-rings (39, 49), springs
(38, 48) and poppets (37, 47) from main spools
(36, 46).

11. Remove spring (19), washer (20), O-ring (21) and

spool (22) from housing (76).

12. Remove plug (57), backup ring (58), O-ring (59),

spring (60) and poppet (61) from housing (76).
: 14 mm

13. Remove overload relief valves (72, 73) from

housing (76).
: 27 mm

W2-5-13
 UPPERSTRUCTURE / Control Valve

76

Bypass Shut-Out Valve

83

82
81 87
80 86
Check Valve
85
79 Orifice 84 91
90
78 (Arm 1 Parallel 89
Load Check
77 Circuit)
(Arm 2
88
Tandem Circuit)
102
101
100
99
98
97 Bucket Flow Rate
96 Control Valve
95 (Poppet Valve)
94
93
103 92 112
113
111

Bucket Flow Rate

Control Valve
(Switch Valve)
106
104 107
108
105
109
W176-02-05-012
110

76 - Housing 86 - Poppet 96 - O-Ring 105 - Socket Bolt (7 Used)

77 - Plug 87 - Bushing 97 - Spring 106 - Spool
78 - O-Ring 88 - O-Ring 98 - Plug 107 - Washer
79 - Plug 89 - Backup Ring 99 - O-Ring 108 - Spring
80 - O-Ring 90 - Spring 100 - Spring 109 - O-Ring
81 - Spring 91 - Check Valve 101 - Poppet 110 - Plug
82 - Seat 92 - O-Ring 102 - Valve Seat 111 - O-Ring
83 - Spool 93 - Backup Ring 103 - Pilot Plate 112 - O-Ring
84 - Plug 94 - Bushing 104 - Socket Bolt (3 Used) 113 - Backup Ring
85 - Spring 95 - Backup Ring

W2-5-14
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 4-Spool Side (Side) 19. Remove plug (84), spring (85), poppet (86) and
bushing (87) from housing (76).
14. Remove plug (110) from pilot plate (103), spring
(108), washer (107) and spool (106) and O-ring 20. Remove plug (79), O-ring (80), spring (81), seat
(109) from pilot plate (103). (82) and spool (83) from housing (76).
: 36 mm

15. Remove socket bolts (104) (3 used) and socket

bolts (105) (7 used). Remove pilot plate (103),
O-rings (111, 112) and backup ring (113) from
housing (76).
: 6 mm, 8 mm

16. Remove bushing (94) from pilot plate (103). Re-

move O-rings (92, 96), backup rings (93, 95) and
spring (97) from bushing (94).

17. Remove plug (98) from housing (76).

Secure the step part of plug (98) in a vise by us-
ing wooden pieces. Remove valve seat (102),
poppet (101), spring (100) and O-ring (99) from
plug (98).

18. Remove O-ring (88), backup ring (89), spring (90)

and poppet (91) from housing (76). (2 places)

W2-5-15
 UPPERSTRUCTURE / Control Valve

76

135
130 144
136
131 137
132 138
133 Check Valve
(Flow Combiner 146
Circuit)
134
Auxiliary Flow Rate
Control Valve

154

150

W176-02-05-014

76 - Housing 133 -Backup Ring 137 -O-Ring 150 -Socket Bolt (5 Used)
130 -Poppet 134 -Plug 138 -Plug 154 -Pilot Housing
131 -Spring 135 -Poppet 144 -Overload Relief Valve
132 -O-Ring 136 -Spring 146 -O-Ring (9 Used)

W2-5-16
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 4-Spool Side
(Lower)

21. Remove overload relief valve from housing (76).

: 27 mm

22. Remove socket bolts (150) (5 used). Remove pi-

lot housing (154) and O-rings (146) (4 used) from
pilot housing (154).
: 6 mm

23. Remove plug (138), O-ring (137), spring (136)

and poppet (135) from housing (76).
: 14 mm

24. Remove plug (134), backup ring (133), spring

(131) and poppet (130) from housing (76).

W2-5-17
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE 5-SPOOL SIDE 216
215
155 217

156
187
157
158 188
181
159 218
160 189
161 182
162 190
163 197
Arm Anti-Drift 183
Valve 176 191
164 203
184
166 177 198
167 165 178 209
168 185 192 199 204
169 179
175
170 173 200 205 210
180 186
171
201 206 211
172
193
174 207 212
194
195 202
213
196 208

214

219

W176-02-05-011
155 - Backup Ring 172 - Poppet 188 - Bolt 204 - Bolt
156 - O-Ring 173 - Backup Ring 189 - Spring Seat 205 - Spring Seat
157 - Plug 174 - O-Ring 190 - Spring 206 - Spring
158 - O-Ring 175 - Overload Relief Valve 191 - Spring Seat 207 - Spring Seat
159 - O-Ring 176 - Plug 192 - Main Spool 208 - Main Spool
160 - O-Ring 177 - O-Ring 193 - Poppet 209 - O-Ring
161 - Backup Ring 178 - Backup Ring 194 - Spring 210 - Bolt
162 - Backup Ring 179 - O-Ring 195 - O-Ring 211 - Spring Seat
163 - O-Ring 180 - Main Relief Valve 196 - Plug 212 - Spring
164 - Sleeve 181 - O-Ring 197 - O-Ring 213 - Spring Seat
165 - Spool 182 - Bolt 198 - Bolt 214 - Main Spool
166 - Washer 183 - Spring Seat 199 - Spring Seat 215 - Socket Bolt (10 Used)
167 - Spring 184 - Spring 200 - Spring 216 - Plug
168 - Backup Ring 185 - Spring Seat 201 - Spring Seat 217 - O-Ring
169 - O-Ring 186 - Main Spool 202 - Main Spool 218 - Pilot Housing
170 - Plug 187 - O-Ring 203 - O-Ring 219 - Housing
171 - Spring

W2-5-18
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 5-Spool Side (Up-
per)
1. Remove socket bolts (215) (10 used). Remove
pilot housing (218) from housing (219).
: 8 mm
2. Remove arm anti-drift valve assembly (157 to
170), O-ring (156) and backup ring (155) from
pilot housing (218).
NOTE: Remove arm anti-drift valve assembly (157
to 170) from pilot housing (218) by moving
by hand.
3. Remove plug (170), O-ring (169), backup ring
(168), spring (167), washer (166) and spool (165)
from sleeve (164).
4. Remove plug (157), O-rings (158, 159, 160, 163)
and backup rings (161, 162) from sleeve (164).
5. Remove spring (171) and poppet (172) from
housing (219).
6. Remove main spool (186, 192, 202, 208, 214)
assemblies and O-rings (181, 187, 197, 203,
209) from housing (219).
W2-5-19
IMPORTANT: Put the matching marks on main
spools (186, 192, 202, 208, 214) and
housing (219).
7. Secure main spools (186, 192, 202, 208, 214) in
a vise by using wooden pieces. Remove bolts
(182, 188, 198, 204, 210), spring seats (183, 185,
189, 191, 199, 201, 205, 207, 211, 213) and
springs (184, 190, 200, 206, 212) from main
spools (186, 192, 202, 208, 214).
: 17 mm
8. Remove plug (196), O-ring (195), spring (194)
and poppet (193) from main spool (192).
: 17 mm
9. Remove overload relief valves (175, 180) from
housing (219).
: 27 mm
 UPPERSTRUCTURE / Control Valve

Load Check 245 Load Check

Auxiliary Flow Rate 229 Valve (Arm 1 246 Valve (Arm 2
Control Valve 230 Parallel Circuit) Parallel Circuit)
240 247
(Poppet Valve) 231
241 248
232
233 242
Load Check 234 243
223 Valve 235 244
(Travel Parallel 225 236
224 Circuit) 226 237
227 238
228 239

220
221
222

219

255

256
254
257
258
Auxiliary Flow Rate
Control Valve
(Switch Valve) 253
252
251
250 W176-02-05-013
249

219 - Housing 229 - O-Ring 239 - Valve Seat 249 - Plug

220 - Socket Bolt (4 used) 230 - Backup Ring 240 - O-Ring 250 - O-Ring
221 - Cover 231 - Bushing 241 - Backup Ring 251 - Spring
222 - O-Ring 232 - Backup Ring 242 - Plug 252 - Washer
223 - Socket Bolt (6 Used) 233 - O-Ring 243 - Spring 253 - Spool
224 - Pilot Plate 234 - Spring 244 - Poppet 254 - Socket Bolt (6 Used)
225 - O-Ring 235 - Plug 245 - O-Ring 255 - Socket Bolt (4 used)
226 - Backup Ring 236 - O-Ring 246 - Backup Ring 256 - Pilot Plate
227 - Spring 237 - Spring 247 - Spring 257 - O-Ring
228 - Poppet 238 - Poppet 248 - Poppet 258 - O-Ring

W2-5-20
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 5-Spool Side (Side)

10. Remove plug (249), O-ring (250), spring (251),
washer (252) and spool (253) from pilot plate
(256).
: 36 mm
11. Remove socket bolts (254) (6 used) and socket
bolts (255) (4 used). Remove pilot plate (256)
and O-rings (257, 258) from housing (219).
: 6 mm, 8 mm
12. Remove bushing (231) from pilot plate (256).
Remove O-rings (229, 233), backup rings (230,
232) and spring (234) from bushing (231).
16. Remove socket bolts (223) (6 used). Remove pi-
lot plate (224) from housing (219).
: 6 mm
17. Remove O-ring (240), backup ring (241), plug
(242), spring (243) and poppet (244) from the pi-
lot plate (224) mounting surface of housing (219).
(2 places)
18. Remove O-ring (245), backup ring (246), spring
(247) and poppet (248) from the pilot plate (224)
mounting surface of housing (219).

13. Remove plug (235) from the pilot plate (256)

mounting surface of housing (219).
Secure the step part of plug (235) in a vise by
using wooden pieces. Remove valve seat (239),
poppet (238), spring (237) and O-ring (236) from
plug (235).

14. Remove O-ring (225), backup ring (226), spring

(227) and poppet (228) from the pilot plate (256)
mounting surface of housing (219).

15. Remove O-ring (245), backup ring (246), spring

(247) and poppet (248) from the pilot plate (256)
mounting surface of housing (219). (3 places)

W2-5-21
 UPPERSTRUCTURE / Control Valve

219

140
122
139 141
114 123 142
115 124
116 143
125 146
117
145
126
118 127
119 128 153

120
129
Flow
121 Combiner
Valve
Auxiliary Flow
Combiner
147 151
Valve
148 152
149

W176-02-05-014

114 - Plug 122 - Plug 139 - Overload Relief Valve 147 - Socket Bolt (9 Used)
115 - Spring 123 - Spring 140 - O-Ring 148 - O-Ring
116 - Poppet 124 - Poppet 141 - Backup Ring 149 - Plug
117 - Spool 125 - Spool 142 - O-Ring 151 - O-Ring
118 - O-Ring 126 - O-Ring 143 - Plug 152 - Plug
119 - Washer 127 - Washer 145 - O-Ring (5 Used) 153 - Pilot Housing
120 - Spring 128 - Spring 146 - O-Ring (4 Used) 219 - Housing
121 - Bolt 129 - Bolt

W2-5-22
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 5-Spool Side
(Lower)

19. Remove overload relief valve (139) from housing

(219).
: 27 mm

20. Remove socket bolts (147) (9 used). Remove pi-

lot housing (153) and O-rings (145) (5 used) from
housing (219).
: 8 mm

21. Remove O-rings (118, 126), flow combiner valve

assembly (112 to 129) and auxiliary flow com-
biner valve assembly (114 to 121) from housing
(219).

IMPORTANT: Do not remove plug (114), spring

(115) and poppet (116) from spool
(117). When replacing these parts,
replace them as an assembly.
22. Secure spool (117) in a vise by using wooden
pieces. Remove bolt (121), spring (120) and
washer (119) from spool (117).
: 17 mm

IMPORTANT: Do not remove plug (122), spring

(123) and poppet (124) from spool
(125). When replacing these parts,
replace them as an assembly.

23. Secure spool (125) in a vise by using wooden

pieces. Remove bolt (129), spring (128) and
washer (127) from spool (125).
: 17 mm

W2-5-23
 UPPERSTRUCTURE / Control Valve
ASSEMBLY AND DISASSEMBLY OF
4-SPOOL SIDE AND 5-SPOOL SIDE

219

266
265

260
261
263
262

76 264
267
268
269
259 270 271
272
273
274

275
276
277 281
279 280
278
W176-02-05-015

76 - Housing 264 - O-Ring 270 - O-Ring 276 - O-Ring

219 - Housing 265 - O-Ring 271 - Backup Ring 277 - Backup Ring
259 - Socket Bolt (9 Used) 266 - Backup Ring 272 - O-Ring 278 - O-Ring
260 - O-Ring 267 - O-Ring 273 - O-Ring 279 - Backup Ring
261 - O-Ring 268 - Backup Ring 274 - O-Ring 280 - O-Ring
262 - O-Ring 269 - O-Ring 275 - O-Ring 281 - Backup Ring
263 - Backup Ring

W2-5-24
 UPPERSTRUCTURE / Control Valve
Disassembly Assembly

1. Install O-rings (260 to 262, 264, 265, 267, 269,

CAUTION: Housing (76) weight: 45 kg (100 270, 272 to 276, 278, 280) and backup rings (263,
Ib) 266, 268, 271, 277, 279, 281) to housing (219).
Housing (219) weight: 49 kg (110 lb)

1. Remove socket bolts (259) (9 used). Divide
housing (76) and housing (219).
2. Remove O-rings (260 to 262, 264, 265, 267, 269,
270, 272 to 276, 278, 280) and backup rings (263,
266, 268, 271, 277, 279, 281) from housing
(219).
CAUTION: Housing (76) weight: 45 kg (100
Ib)
Housing (219) weight: 49 kg (110 Ib)
2. Connect housing (76) and housing (219) with
socket bolts (259) (9 used).
: 12 mm
: 108+9.8 N·m (11+1 kgf·m 80+7 lbf·ft)

W2-5-25
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
4-SPOOL SIDE Main Spools Main Spools
A (28, 56) (36, 46)
23 31 41 51 25, 53 33, 43
26, 54
19 34, 44
24, 52 32, 42
20
21 27, 55 35, 45
57
22
58, 59
60
61
76
28, 56 36, 46

37, 47
38, 48

W176-02-05-020
39, 49
Section A Boom 1 40, 50
67, 68
W176-02-05-024
66
Boom Anti-Drift Valve
69
70 5
29 10
30 6
62 11
63 7
1 8
2 14 9
Boom 12
Anti-Drift 13
Valve 15
16
17
18
3 4 W176-02-05-022 W176-02-05-025

1- O-Ring 20 - Washer 39 - O-Ring 58 - Backup Ring

2- Screw 21 - O-Ring 40 - Plug 59 - O-Ring
3- Backup Ring 22 - Spool 41 - O-Ring 60 - Spring
4- O-Ring 23 - O-Ring 42 - Bolt 61 - Poppet
5- O-Ring 24 - Bolt 43 - Spring Seat 62 - Cap
6- O-Ring 25 - Spring Seat 44 - Spring 63 - Nut
7- Backup Ring 26 - Spring 45 - Spring Seat 64 - Plug
8- Backup Ring 27 - Spring Seat 46 - Main Spool 65 - O-Ring
9- O-Ring 28 - Main Spool 47 - Poppet 66 - Cap
10 - Sleeve 29 - O-Ring 48 - Spring 67 - Retaining Ring
11 - Spool 30 - Screw 49 - O-Ring 68 - Shim
12 - Washer 31 - O-Ring 50 - Plug 69 - Nut
13 - Spring 32 - Bolt 51 - O-Ring 70 - Pilot Housing
14 - Backup Ring 33 - Spring Seat 52 - Bolt 71 - Socket Bolt
15 - O-Ring 34 - Spring 53 - Spring Seat 72 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Spring 73 - Overload Relief Valve
17 - Spring 36 - Main Spool 55 - Spring Seat 74 - Backup Ring
18 - Poppet 37 - Poppet 56 - Main Spool 75 - O-Ring
19 - Spring 38 - Spring 57 - Plug 76 - Housing

W2-5-26
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 4-Spool Side (Upper)

1. Secure main spools (36, 46) in a vise by using
wooden pieces. Install poppets (37, 47), springs
(38, 48), O-rings (39, 49) and plugs (40, 50).
: 17 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
2. Install spring seats (25, 27, 33, 35, 43, 45, 53,
55), springs (26, 34, 44, 54), and bolts (24, 32, 42,
52) to spools (28, 36, 46, 56).
: 17 mm
: 12 N·m (1.2 kgf·m, 9 lbf·ft)
IMPORTANT: When sleeve (10) or spool (11) is re-
placed, replace both of them as an
assembly.
6. Install O-ring (15), backup ring (14), spring (13),
washer (12) and spool (11) to plug (16). Install
the plug (16) assembly to sleeve (10).
NOTE: Install washer (12) with the chamfered side
facing to the spring (13) side.
7. Install boom anti-drift valve assembly (5 to 16) to
pilot housing (70).

3. Install screw (30) and O-ring (29) to pilot housing IMPORTANT: When housing (76) or poppet (18) is
(70). Install nut (69), shim (68), retaining ring (67) replaced, tap poppet (18) by using a
and cap (66) to screw (30). steel bar in order to make it fit.
: 4 mm 8. Install poppet (18) and spring (17) to housing
: 17 mm (76).
: 20 N·m (2 kgf·m, 15 lbf·ft)
9. Install spool (22), O-ring (21), washer (20) and
4. Install screw (2) and O-ring (1) to pilot housing spring (19) to housing (76).
(70). Install nut (63) and cap (62) to screw (2).
NOTE: Install washer (20) with the chamfered side
: 4 mm
facing to the spring (19) side.
: 17 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
10. Install poppet (61), spring (60), O-ring (59),
backup ring (58) and plug (57) to housing (76).
5. Install backup rings (7, 8) and O-rings (5, 6, 9) to
: 14 mm
sleeve (10).
: 120+20 N·m (12+2 kgf·m, 87+15 lbf·ft)
NOTE: Check the mounting positions of backup
rings (7, 8) and O-rings (6, 9). 11. Install main spool (28, 36, 46, 56) assemblies,
10 9 8 7 6 O-rings (4, 23, 31, 41, 51) and backup ring (3) to
housing (76).

W176-02-05-023

W2-5-27
 UPPERSTRUCTURE / Control Valve
A
B
C
Section B Arm 2 Arm 1

73

Load Check Valve

(Arm 2 Tandem
Circuit) 90 91

T176-03-03-038
Section D 110 109 108 107 106
Bucket Flow Rate
Control Valve 84 85 86 87
(Switch Valve) Check Valve Orifice
(Arm 1 Pallarel Cir-
cuit)
T176-03-03-006
98
92
97
93
94 99 Section C Boom 1
95 100 Boom 2
96
101
102
Bucket Flow Rate
Control Valve (Pop-
pet Valve)
W176-02-05-026
Section A Swing

88, 89

79 90
78
91
77 Load Check Valve
(Boom 1 Pallarel
Circuit)

80 81 82 83
T176-03-03-007 T176-03-03-005
Bypass Shut-Out Valve
70 - Pilot Housing 83 - Spool 94 - Bushing 105 - Socket Bolt (7 Used)
71 - Socket Bolt (11 Used) 84 - Plug 95 - Backup Ring 106 - Spool
72 - Overload Relief Valve 85 - Spring 96 - O-Ring 107 - Washer
73 - Overload Relief Valve 86 - Poppet 97 - Spring 108 - Spring
76 - Housing 87 - Bushing 98 - Plug 109 - O-Ring
77 - Plug 88 - O-Ring 99 - O-Ring 110 - Plug
78 - O-Ring 89 - Backup Ring 100 - Spring 111 - *O-Ring
79 - Plug 90 - Spring 101 - Poppet 112 - *O-Ring
80 - O-Ring 91 - Poppet 102 - Valve Seat 113 - * Backup Ring
81 - Spring 92 - O-Ring 103 - Pilot Plate
82 - Seat 93 - Backup Ring 104 - Socket Bolt (3 Used)
NOTE: As for the parts with mark *, refer to
W2-5-14.

W2-5-28
 UPPERSTRUCTURE / Control Valve
12. Install pilot housing (70) to housing (76) with
socket bolts (71) (11 used).
Install overload relief valves (72, 73) to housing
(76).
: 8 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
: 27 mm
: 78+3 N·m (8+0.3 kgf·m, 58+3 lbf·ft)
NOTE: Apply grease onto O-rings of overload re-
lief valves (72, 73).
Assembly of Control Valve 4-Spool Side (Side)
13. Install spool (106), washer (107), spring (108)
and O-ring (109) to pilot plate (103). Temporarily
install plug (110).
: 36 mm
NOTE: Tighten plug (110) after installing pilot plate
(103) to housing (76). Do not confuse plug
(110) and (249) as their thread part length
are different. Refer to W2-5-20 as for plug
(249).
14. Install poppet (101), spring (100), O-ring (99) and
plug (98) to valve seat (102).
17. Install poppet (91), spring (90), O-ring (88) and
backup ring (89) to housing (76). (2 places)
18. Install bushing (87), poppet (86), spring (85) and
plug (84) to housing (76).
19. Install O-rings (111, 112) and backup ring (113) to
housing (76). Install pilot plate (103) to housing
(76) with socket bolts (104) (3 used) and socket
bolts (105) (7 used).
: 6 mm
: 25 N m (2.5 kgf m, 18 lbf ft)
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)
20. Completely tighten plug (110) which was tempo-
rarily tightened in step 13.
: 36 mm
: 200 N m (20 kgf m, 150 lbf ft)
21. Install spool (83), washer (82), spring (81), O-ring
(80) and plug (79) to housing (76).
: 27 mm
: 180+3 N m (18+3 kgf m, 131+21 lbf ft)
NOTE: Install washer (82) with the chamfered side
facing to the spring (81) side.

15. Install O-rings (92, 96) and backup rings (93, 95)
to bushing (94).

16. Install the valve seat (102) assembly, spring (97)

and bushing (94) to housing (76).

W2-5-29
 UPPERSTRUCTURE / Control Valve

Section A

76

154
150

B 144 T176-03-03-036 W176-02-05-020

146 146 146 146

Section B

130
131

132, 133

135
Check
Valve 136
(Flow Com-137
biner Cir-
cuit)
138 134
Auxiliary Flow Rate Control Valve T176-03-03-002

76 - Housing 133 -Backup Ring 137 -O-Ring 146 -O-Ring (4 Used)

130 -Poppet 134 -Plug 138 -Plug 150 -Socket Bolt (5 Used)
131 -Spring 135 -Poppet 144 -Overload Relief Valve 154 -Pilot Housing
132 -O-Ring 136 -Spring

W2-5-30
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 4-Spool Side (Lower)

22. Install O-rings (146) (4 used) to housing (76). In-

stall pilot housing (154) to housing (76) with
socket bolts (150) (5 used).
: 8 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)

23. Install poppet (135), spring (136), O-ring (137)

and plug (138) to housing (76).
: 14 mm
: 120+20 N·m (12+2 kgf·m, 87+15 lbf·ft)

24. Install poppet (130), spring (131), O-ring (132),

backup ring (133) and plug (134) to housing (76).
: 14 mm
: 120+20 N·m (12+2 kgf·m, 87+15 lbf·ft)

25. Install overload relief valves (144) (2 used) to

housing (76).
: 8 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
: 27 mm
: 78+3 N·m (8+0.3 kgf·m, 58+2 lbf·ft)

NOTE: Apply grease onto O-rings of overload re-

lief valve (144).

W2-5-31
 UPPERSTRUCTURE / Control Valve
Main Spool Main Spool
ASSEMBLY OF CONTROL VALVE (186 202 208 214) (192)
5-SPOOL SIDE 183, 199, 189
197 205, 211
Section A 190
184, 200,
203 187 206, 212
188
182, 198,
181 204, 210
209
191
185, 201,
207, 213
192
186, 202,
208, 214

193
194
195
Arm Anti-Drift Valve W176-02-05-021 196
B
W176-02-05-024
A
175 Section B Arm Anti-Drift Valve
164 157
159
158
160
218
215 161
180 165 162
219 163
168
166
169 167

170
171
172

W176-02-05-027
T176-03-03-038
155 - *Backup Ring 172 - Poppet 189 - Spring Seat 206 - Spring
156 - *O-Ring 173 - Backup Ring 190 - Spring 207 - Spring Seat
157 - Plug 174 - O-Ring 191 - Spring Seat 208 - Main Spool
158 - O-Ring 175 - Overload Relief Valve 192 - Main Spool 209 - O-Ring
159 - O-Ring 176 - Plug 193 - Poppet 210 - Bolt
160 - O-Ring 177 - O-Ring 194 - Spring 211 - Spring Seat
161 - Backup Ring 178 - Backup Ring 195 - O-Ring 212 - Spring
162 - Backup Ring 179 - O-Ring 196 - Plug 213 - Spring Seat
163 - O-Ring 180 - Main Relief Valve 197 - O-Ring 214 - Main Spool
164 - Sleeve 181 - O-Ring 198 - Bolt 215 - Socket Bolt (10 Used)
165 - Spool 182 - Bolt 199 - Spring Seat 216 - Plug
166 - Washer 183 - Spring Seat 200 - Spring 217 - O-Ring
167 - Spring 184 - Spring 201 - Spring Seat 218 - Pilot Housing
168 - Backup Ring 185 - Spring Seat 202 - Main Spool 219 - Housing
169 - O-Ring 186 - Main Spool 203 - O-Ring
170 - Plug 187 - O-Ring 204 - Bolt
171 - Spring 188 - Bolt 205 - Spring Seat
NOTE: As for the parts with mark *, refer to W2-5-18.

W2-5-32
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 5-Spool Side (Upper)

1. Secure main spool (192) by using wooden pieces
in a vise. Install poppet (193), spring (194), O-ring
(195) and plug (196) to main spool (192).
: 17 mm
: 25 N m (2.5 kgf m 18 lbf ft)
2. Install spring seats (183, 185, 189, 191, 199, 201,
205, 207, 211, 213), springs (184, 190, 200, 206,
212) and bolts (182, 188, 198, 204, 210) to main
spools (186, 192, 202, 208, 214).
: 17 mm
: 12 N m (1.2 kgf m, 9 lbf ft)
5. Install arm anti-drift valve assembly (157 to 170)
to pilot housing (218).
IMPORTANT: When housing (219) or poppet (172)
is replaced, tap poppet (172) by us-
ing a steel bar in order to make it fit.
6. Install poppet (172) and spring (171) to housing
(219).
7. Install the main spool (186, 192, 202, 208, 214)
assemblies, O-rings (156, 181, 187, 197, 203,
209) and backup ring (155) to housing (219).

3. Install backup rings (161, 162) and O-rings (159, 8. Install pilot housing (218) to housing (219) with
162, 163) to sleeve (164). Install O-ring (158) to socket bolts (215) (10 used).
plug (157). Install overload relief valve (175) and main relief
NOTE: Check the mounting positions of backup valve (180) to housing (219).
rings (137, 138) and O-rings (136, 139). : 8 mm
: 25 N m (2.5 kgf m, 18 lbf ft)
: 27 mm
: 78+3 N m (8+0.3 kgf m, 58+2 lbf ft)
163 162 161 160

W176-02-05-023

IMPORTANT: When sleeve (164) or spool (165) is

replaced, replace both of them as an
assembly.
4. Install O-ring (169), backup ring (168), spring
(167), washer (166) and spool (165) to plug (170).
Install the plug (170) assembly to sleeve (164).
NOTE: Install washer (166) with the chamfered
side facing to the spring (167) side.

W2-5-33
 UPPERSTRUCTURE / Control Valve
223 Section B Travel (Left) Boom 2 Section C
224 219
255
254
256
Load Check Valve
(Travel Tandem
Circuit)

E 248
D
C
247 248
247
B
Auxiliary 245, 246
Flow Rate A
Load
Control 225, Check
Valve 226 Valve
T176-03-03-036 (Boom 2
249 250 251 252 253 Pallarel
Circuit)
Auxiliary Flow Rate 227
Control Valve 228
(Switch Valve) Load
Check
Valve
235 (Travel
229 Pallarel W176-02-05-029
234 Section D Arm 1 Circuit) Swing Section E
230
231 236
232 237
233
238
239 Load
Auxiliary Flow Rate Load Check Check
Control Valve Valve (Arm 1 Valve
(Poppet Valve) W176-02-05-026 Parallel Cir- (Swing
Section A cuit) Circuit)
248 248
248 247 247
240,
247 245,
241
246
245, 246 242
Check Valve
(Main Circuit) 242
240,
241
243
244
Load Check
Valve (Arm 1
Tandem Cir-
cuit)
W176-02-05-030
W176-02-05-028

219 - Housing 229 - O-Ring 239 - Valve Seat 249 - Plug

220 - Socket Bolt 230 - Backup Ring 240 - O-Ring 250 - O-Ring
221 - Cover 231 - Bushing 241 - Backup Ring 251 - Spring
222 - O-Ring 232 - Backup Ring 242 - Plug 252 - Washer
223 - Socket Bolt 233 - O-Ring 243 - Spring 253 - Spool
224 - Pilot Plate 234 - Spring 244 - Poppet 254 - Socket Bolt (6 Used)
225 - O-Ring 235 - Plug 245 - O-Ring (3 used) 255 - Socket Bolt (4 used)
226 - Backup Ring 236 - O-Ring 246 - Backup Ring (3 used) 256 - Pilot Plate
227 - Spring 237 - Spring 247 - Spring (5 used) 257 - *O-Ring
228 - Poppet 238 - Poppet 248 - Poppet (5 used) 258 - *O-Ring
NOTE: As for the parts with mark *, refer to W2-5-20.

W2-5-34
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 5-Spool Side (Side)
9. Install spool (253), washer (252), spring (251)
and O-ring (250) to pilot plate (256). Temporarily
install plug (249).
: 36 mm
NOTE: Tighten plug (249) after installing pilot plate
(256) to housing (219). Do not confuse
plug (249) and plug (110) as their thread
part length are different.
10. Install poppet (238), spring (237), O-ring (236)
and plug (235) to valve seat (239).
11. Install O-rings (229, 233) and backup rings (230,
232) to bushing (231).
12. Install the valve seat (239) assembly, spring (234)
and bushing (231) to housing (219).
13. Install poppet (248), spring (247), O-ring (245)
and backup ring (249) to housing (219). (3
places)
14. Install poppet (228), spring (227), backup ring
(226) and O-ring (225) to housing (219).
W2-5-35
15. Install O-rings (257, 258) to housing (219). Install
pilot plate (256) to housing (219) with socket bolts
(254) (6 used) and socket bolts (255) (4 used).
: 6 mm
: 25 N m (2.5 kgf m, 18 lbf ft)
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)
16. Completely tighten plug (249) which was tempo-
rarily tightened in step 9.
: 36 mm
: 200 N m (20 kgf m, 150 lbf ft)
17. Install poppet (244), spring (243), plug (242),
backup ring (241) and O-ring (240) to housing
(219). (2 places)
18. Install poppet (248), spring (247), backup ring
(246) and O-ring (245) to housing (219).
19. Install pilot plate (224) to housing (219) with
socket bolt (223).
: 6 mm
: 25 N m (2.5 kgf m, 18 lbf ft)
 UPPERSTRUCTURE / Control Valve

Section B

219

147

153
A
139
T176-03-03-036 W176-02-05-021
145 145 145 145 145
Section A

114
122
123 115
Flow 124
Auxiliary Flow
Combiner 116 Combiner
Valve
125 Valve
117
126, 127
118, 119
128
120
129
121
W176-02-05-028

114 - Plug 122 - Plug 129 - Bolt 147 - Socket Bolt (9 Used)
115 - Spring 123 - Spring 139 - Overload Relief Valve 148 - *O-Ring
116 - Poppet 124 - Poppet 140 - *O-Ring 149 - *Plug
117 - Spool 125 - Spool 141 - *Backup Ring 151 - *O-Ring
118 - O-Ring 126 - O-Ring 142 - *O-Ring 152 - *Plug
119 - Washer 127 - Washer 143 - *Plug 153 - Pilot Housing
120 - Spring 128 - Spring 145 - O-Ring (5 Used) 219 - Housing
121 - Bolt
NOTE: As for the parts with mark *, refer to
W2-5-22.

W2-5-36
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 5-Spool Side (Lower)

IMPORTANT: If spool (117) is disassembled, or
poppet (116), spring (115) and plug
(114) are replaced, replace as an
assembly as the external dimen-
sions of spool (117) are specified.
20. Secure spool (117) in a vise by using wooden
pieces. Install washer (119), spring (120) and bolt
(121) to spool (117).
: 17 mm
: 12 N m (1.2 kgf m, 9 lbf ft)
NOTE: Install washer (119) with its chamfered side
facing to the spring (120) side.
IMPORTANT: If spool (125) is disassembled, or
poppet (124), spring (123) and plug
(122) are replaced, replace as an
assembly as the external dimen-
sions of spool (125) are specified.
23. Install O-rings (145) (5 used) to housing (219).
Install pilot housing (153) to housing (219) with
socket bolts (147) (9 used).
: 8 mm
: 25 N m (2.5 kgf m, 18 lbf ft)
24. Install overload relief valve (139) to housing
(219).
: 27 mm
: 78+3 N m (8+0.3 kgf m, 58+2 lbf ft)
NOTE: Apply grease onto O-rings of overload re-
lief valve (139).

21. Secure spool (125) in a vise by using wooden

pieces. Install washer (127), spring (125) and bolt
(129) to spool (125).
: 17 mm
: 12 N m (1.2 kgf m, 9 lbf ft)
NOTE: Install washer (127) with its chamfered
side facing to the spring (128) side.

22. Install O-rings (118, 126), flow combiner valve

assembly (122 to 129) and auxiliary flow com-
biner valve assembly (114 to 121) to housing
(219).

W2-5-37
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF BLADE CONTROL
VALVE (OPTIONAL)
10
9 22
8
7
6
5
4
3
2
1

37

38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11
44

56 45
55
54
53 46
52 47
51
48
62
61
60

50
49
59
58
57
W198-02-05-001

1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Valve 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt 60 - Rivet
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring

W2-5-38
 UPPERSTRUCTURE / Control Valve
Disassembly of Blade Control Valve (Optional)

1. Remove socket bolts (45) (2 used) and socket 5. Remove sleeve assembly (37 to 42) from hous-
bolts (48, 49). Remove covers (46, 50) and ing (62).
O-rings (47, 56) from housing (62). : 36 mm
: 6 mm
6. Remove spring (43) and valve (44) from housing
NOTE: When removing spool assembly (51 to 59) (62).
with it tilted, the inside of housing (62) and
spool (57) may be damaged and cannot be 7. Secure seat (37) in a vise. Remove sleeve (41),
used. Prevent spool assembly (51 to 59) spring (40), valve (39) and O-rings (38, 42) from
from being tilted. seat (37).
: 36 mm
2. Remove spool assembly (51 to 59) from housing NOTE: Plate (61) is not disassembled as it is in-
(62). stalled with rivet (60).

3. Secure spool (57) in a vise by using wooden

pieces. Remove end spool (51), seats (52, 55),
springs (53, 54), plug (59) and O-ring (58) from
spool (57).
: 5 mm, 8 mm

IMPORTANT: Do not disassemble overload relief

valve assemblies (1 to 18), (19 to 36)
as the set pressures is changed.
4. Remove overload relief valve assemblies (1 to
18), (19 to 36) from housing (62).
: 32 mm
NOTE: As each of overload relief valve assem-
blies (1 to 18), (19 to 36) has a different
set pressure, they should be identified for
assembling.

W2-5-39
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF BLADE CONTROL VALVE
(OPTIONAL)
Section X-X 37 39 40 38
41

43
62
42
44 19 to 36
1 to 18 A1 B1

A1 B1
X X

W198-02-05-002 W198-02-05-003

57
Section W-W

54 53 55 56 62
50 51 52 47

48 45

W W

W198-02-05-004
49
57 59 58 46
W198-02-05-005

1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Valve 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring

W2-5-40
 UPPERSTRUCTURE / Control Valve
Assembly of Blade Control Valve (Optional)
1. Secure seat (37) in a vise. Install O-rings (38, 42), 6. Insert spool assembly (51 to 59) into housing
valve (39), spring (40) and sleeve (41) to seat (62) from the port A1 side.
(37). NOTE: When inserting spool assembly (51 to 59)
: 36 mm with it tilted, the inside of housing (62) and
: 59 N m (6 kgf m, 44 lbf ft) spool (57) may be damaged and cannot be
used. Prevent spool assembly (51 to 59)
2. Insert valve (44) and spring (43) into housing from being tilted.
(62).
7. Install O-rings (47, 56) to covers (46, 50). Install
3. Install seat assembly (37 to 42) to housing (62). covers (46, 50) to housing (62) with socket bolts
: 36 mm (45) (2 used) and socket bolts (48, 49).
: 59 N m (6 kgf m, 44 lbf ft) : 6 mm
: 25.5 N m (2.6 kgf m, 19 lbf ft)
IMPORTANT: As each of overload relief valve as-
semblies (1 to 18), (19 to 36) has a
different set pressure, do not install
them at an incorrect position.
4. Install overload relief valve assemblies (1 to 18),
(19 to 36) to housing (62).
: 32 mm
: 59 N m (6 kgf m, 44 lbf ft)

5. Secure spool (57) in a vise by using wooden

pieces. Install O-ring (58) to plug (59). Install plug
(59), seats (52, 55), springs (53, 54) and end
spool (51) to spool (57).
: 5 mm
: 9.8 N m (1 kgf m, 7 lbf ft)
: 8 mm
: 18.6 N m (1.9 kgf m, 14 lbf ft)

W2-5-41
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-42
 UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF SWING
DEVICE
(ZX110-3 CLASS, 120-3 CLASS)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1 2 3

1. Disconnect hoses (2) (5 used) and harness (1) 4

from swing device (3). Cap disconnected hoses
(2).
: 19 mm, 22 mm, 32 mm
: 6 mm Machine Front

2. Attach a nylon sling onto the body of swing device

(3). Hoist and hold swing device (3).

CAUTION: Swing device (3) weight: 135 kg

(300 lb)

3. Remove bolts (4) (10 used). Hoist and remove

swing device (3) from the main frame. Main Frame M175-00-002

: 30 mm

Nylon Sling

W176-02-06-002

W2-6-1
 UPPERSTRUCTURE / Swing Device
Installation

CAUTION: Swing device (3) weight: 135 kg

(300 lb) Nylon Sling

1. Apply liquid packing onto both the mounting parts

of the reduction gear side on swing device (3) and
the main frame for swing device (3).

2. Attach a nylon sling onto the body of swing device

(3). Hoist swing device (3).

3. Install swing device (3) to the main frame with

bolts (4) (10 used).
3
: 30 mm
: 500 N m (50 kgf m, 370 lbf ft)

4. Connect hoses (2) (5 used) and harness (1) to

swing device (3).
: 19 mm
: 30 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 40 N m (4 kgf m, 30 lbf ft) W176-02-06-002

: 32 mm
: 140 N m (14 kgf m, 103 lbf ft) 1 2 3
: 6 mm
4
: 20 N m (2 kgf m, 15 lbf ft)

IMPORTANT: After completing the work, fill the

swing motor with hydraulic oil. Start Machine Front
the engine and check for any oil
leaks.

Main Frame M175-00-002

W2-6-2
 UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF SWING
DEVICE
1 2 3
(ZX135US-3 CLASS)
Removal

1. Remove bolts (1) (3 used). Remove cover (2) from

cover (3).
: 17 mm

Machine Front

W1R7-02-06-002

2. Disconnect hoses (6) (5 used) and harness (5) 4 5 6 Main Frame

from swing device (4). Cap disconnected hoses
(6).
: 19 mm, 22 mm, 32 mm
: 6 mm

3. Attach a nylon sling onto the body of swing device

(4). Hoist and hold swing device (4).
Machine
Front
CAUTION: Swing device (4) weight: 135 kg
(300 lb)
W1R7-02-06-001

4. Remove bolts (7) (10 used). Hoist and remove 7

swing device (4) from the main frame. Nylon Sling
: 30 mm

W176-02-06-002

W2-6-3
 UPPERSTRUCTURE / Swing Device
Installation
Nylon Sling
CAUTION: Swing device (4) weight: 135 kg
(300 lb)

1. Apply liquid packing onto both the mounting parts

of the reduction gear side on swing device (4) and
the main frame for swing device (4).

2. Attach a nylon sling onto the body of swing device

(4). Hoist swing device (4).
4
3. Install swing device (4) to the main frame with
bolts (7) (10 used).
: 30 mm
: 500 N m (50 kgf m, 370 lbf ft)

4. Connect hoses (6) (5 used) and harness (5) to

swing device (4).
: 19 mm
: 30 N m (3 kgf m, 22 lbf ft) W176-02-06-002
: 22 mm
: 40 N m (4 kgf m, 30 lbf ft)
4 5 6 Main Frame
: 32 mm
: 140 N m (14 kgf m, 103 lbf ft)
: 6 mm
: 20 N m (2 kgf m, 15 lbf ft)

Machine
5. Install cover (2) to cover (3) with bolts (1) (3 used). Front
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
W1R7-02-06-001
7
IMPORTANT: After completing the work, fill the
swing motor with hydraulic oil. Start 1 2
the engine and check for any oil
leaks. 3

Machine Front

W1R7-02-06-002

W2-6-4
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-6-5
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING DEVICE

22
23 1

24

2
3

32 21
25 4

31 5

20 6
26 7
19
8

27
18 9

28 10
17
11
29
16
12

30 15 13

14 11

W176-02-06-003

1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-6
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Device

4. Disconnect pipe (32) from housing (25).

CAUTION: Swing device weight: 135 kg (300 : 18 mm
lb)
5. Put the matching marks at the jointed part
1. Attach a nylon sling onto the body of swing motor between swing motor (1) and ring gear (24),
(1). Hoist the swing motor. between ring gear (24) and housing (25).
Nylon Sling

CAUTION: Swing motor (1) weight: 34 kg (75

lb)

6. Remove swing motor (1) from ring gear (24).

: 8 mm
NOTE: THREEBOND has been applied onto the
jointed surface. Insert a screwdriver into
the notch between jointed parts and
separate the surfaces in order to remove
easily.

7. Remove first stage sun gear (2) from first stage

carrier (21).

8. Remove the first stage carrier (21) assembly from

ring gear (24).

9. Remove ring gear (24) from housing (25).

W176-02-06-002
2. Place and secure the swing device on the
bracket (ST 5098) with the bolts (M20) (2 used).
At this time, insert the stopper at the bottom of
bracket into the clearance between teeth of the
pinion gear. Secure the bracket on a workbench
in order to reduce the reaction force.
: 30 mm
Swing Device
NOTE: THREEBOND has been applied onto the
jointed surface. Insert a screwdriver into
the notch between jointed parts and
separate the surfaces in order to remove
easily.
: 12 mm
10. Remove second stage sun gear (20) from second
stage carrier (18).

11. Remove the second stage carrier (18) assembly

ST 5098 from shaft (30).
Stopper

W178-02-06-012

3. Remove drain plug (31) and drain off oil.

: 8 mm

W2-6-7
UPPERSTRUCTURE / Swing Device

23

25 21
4

7
8

18

17
11
16

30 15

11

W176-02-06-003

W2-6-8
 UPPERSTRUCTURE / Swing Device
IMPORTANT: The hole for spring pin (5) located
on first stage carrier (21) is not a
through one. Check the tapping-in
distance of spring pin (5).
12. Install spring pin (5) with the first stage carrier
(21) assembly attached to pin (4) by using the
special tool (ST 1462). At this time, stop tapping
when spring pin (5) reaches the middle of pin (4)
hole and do not tap spring pin (5) to the end.
13. Remove pin (4), planetary gear (7), needle
bearing (6) and thrust plate (8) from first stage
carrier (21).
14. Remove other two sets of pin (4), planetary gear
(7), needle bearing (6) and thrust plate (8) from
first stage carrier (21) in the same orders as
steps 12 and 13.
15. Remove thrust plate (3) from first stage carrier
(21).
IMPORTANT: Do not damage the rotating surface
for needle bearing (6) of pin (4)
except for the both ends. Do not
damage the rotating surface.
16. Secure the end of pin (4) opposite the spring pin
(5) hole in a vise. Remove spring pins (5) (3
used) by using the special tool (ST 1462).
W2-6-9
17. Disassemble the second stage carrier (18)
assembly in the same way as the first stage
carrier (21) assembly. Remove planetary carriers
(13) (3 used), needle bearings (12) (3 used) and
thrust plates (11) (6 used). Remove spring pin
(10) by using the special tool (ST 1463).
18. Remove the bolts (17 used). Remove lock plate
(16) from bearing nut (15).
: 17 mm
19. Remove bearing nut (15) from shaft (30) by using
the special tool (ST 2927).
ST 2927
15
W178-02-06-008
CAUTION: The housing (25) assembly
weight: 63 kg (140 lb)
20. Install an eyebolt (M14) to the bolt (23) hole on
housing (25). Hoist housing (25). Remove the
bracket (ST 5098) with the pinion side attached.
: 30 mm
UPPERSTRUCTURE / Swing Device

25

26

28

30 15

14

W176-02-06-003

W2-6-10
 UPPERSTRUCTURE / Swing Device

CAUTION: If pushing shaft (30) by using a
press, provide a protection cover (outer
diameter: 290 mm (11.4 in), inner diameter:
90 mm (3.5 in), thickness: 25 to 30 mm (1 to
1.2 in)). When housing (25) and/or roller
bearing (14) are broken and flown off without
the cover, the metal fragments may result in
personal injury.
Press at 30 ton or less.
Degrease the housing (25) inside before
warming up roller bearing (14). Failure to
degrease may cause a fire.
21. Remove shaft (30) from housing (25) by using a
press. The inner race of roller bearing (26) and
sleeve (28) are removed with shaft (30) together
at this time.
Press
30
14
25
Cover
Cover
CAUTION: Push the shaft of special tool in
the con cave part of pinion and secure by
using a hose clamp in order not to loosen
the shaft.
22. Set a special tool to the shaft (30) assembly.
NOTE: Use the following parts as a special tool
when removing roller bearing (26).
Part size remarks:
Shaft or bolt: length: 200 mm (7.9 in),
diameter: 19 mm (0.7 in) (8 used) (All
should be identical in length with no wear
and deformation on both ends.
Material: S35C
Hose clamp: standard diameter: 8-1/2 inch
(applicable diameter: 185 to 215 mm (7.3
to 8.5 in)) (2 used)
Guide: height: 160 mm (6.3 in), outer
diameter: 230 mm (9.1 in), inner diameter:
210 mm (8.3 in)
Special tool when removing roller bearing (26)
Hose Clamp Shaft

W157-02-06-010 W157-02-06-011

W157-02-06-012

30
26

28

Shaft

W157-02-06-013
Guide

W2-6-11
UPPERSTRUCTURE / Swing Device

25

26

27

28

29

30

14

W176-02-06-003

W2-6-12
 UPPERSTRUCTURE / Swing Device

CAUTION: Push shaft (30) inside the guide CAUTION: Housing (25) weight: 36 kg (80 lb)
by using a press.
26. Attach a nylon sling onto the body of housing (25).
Press
Hoist housing (25). Turn over housing (25).
26 30
27. Insert a screwdriver into the notch on housing
(25) where oil seal (27) is mounted. Remove oil
seal (27).
28
NOTE: THREEBOND has been applied onto the
Guide outer surface of oil seal (27). Oil seal (27)
cannot be reused.

28. Remove the outer race of roller bearing (14) from

housing (25) by using a bar and a hammer.
W157-02-06-014

23. Push the spline side on shaft (30) by using a

press. Remove the inner race of roller bearing
(26) and sleeve (28) from shaft (30).

24. Remove O-ring (29) from sleeve (28).

25. Insert a round bar into the oil passage in housing

(26).Tap and remove the outer race of roller
bearing (26).

Oil Passage
Outer Race

W178-02-06-001

W2-6-13
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING DEVICE
1

5
3
22

21
7
24
6
20
18
4
19
8
10
23
11
13
12
11
17 9
15

16 14
32

25

26

27 31

28 30
29

W176-02-04-016

1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-14
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Device
1. Install O-ring (29) to sleeve (28).
IMPORTANT: Check the direction to install sleeve
(28) and the inner race of roller
bearing (26).
2. Install sleeve (28) and the inner race of roller
bearing (26) to shaft (30) by using a press and
the special tool (ST 2929).
NOTE: The press-in distance of the inner race of
roller bearing (26) can be assured by using
the special tool (ST 2929).
Press
ST 2929
26
28
30
W178-02-06-013
CAUTION: Housing (25) weight: 36 kg (80 lb)
3. Attach a nylon sling onto the body of housing (25).
Hoist housing (25). Place housing (25) with the
sleeve (28) mounting side facing upward.
4. Install the outer race of roller bearing (26) to
housing (25) by using a bar and a hammer. Tap
and listen to ring in order to check if the
installation is completed.
W2-6-15
5. Apply THREEBOND #1215 onto the outer
surface of oil seal (27). Place oil seal (27) flat on
housing (25) and push it by hands in gently.
Place the special tool (ST 2928) on oil seal (27).
Tap it in by using a hammer straight.
ST 2928
27
25
W176-02-06-006
NOTE: Replace oil seal (27) in the following way if
shaft (30) is not removed.
Drain oil from the reduction gear.
Place the swing device horizontally.
Remove oil seal (27) by using a screwdriver.
Clean off THREEBOND on housing (25).
Apply THREEBOND #1215 onto the outer
surface of oil seal (27).
Push oil seal (27) to housing (25) a little by
hands.
Install the special tool guide (ST 7247) to a
pinion gear.
Cover the upper side of the special tool guide
(ST 7247) with the special tool (ST 2928).
Push it onto oil seal (27).
Tap and install oil seal (27) to housing (25) by
using the special tool (ST 2928) and a
hammer.
Pinion Gear
27
ST 7247
ST 2928
25
W176-02-06-005
 UPPERSTRUCTURE / Swing Device

24

23

15

14

25

27
28 30

W176-02-06-004

W2-6-16
 UPPERSTRUCTURE / Swing Device
6. Apply grease onto the inner surface of oil seal
(27). Apply grease onto the outer surface of
sleeve (28) with shaft (30) attached.
NOTE: Apply grease carefully when installing
shaft (30) in order not to curl the lip.
7. Attach a nylon sling onto the body of housing (25).
Hoist housing (25). Place housing (25) with the
ring gear mounting side facing upward.
8. Install the outer race of roller bearing (14) to
housing (25) by using a bar and a hammer. Tap
and listen to ring in order to check if the
installation is completed.
CAUTION: Housing (25) + roller bearing (14)
outer race weight: 38 kg (28 lb)
IMPORTANT: Prevent the oil seal (27) lip from
curling.
9. Install an eyebolt (M14) to the bolt (23) hole on
housing (25). Install housing (25) to shaft (30). At
this time, check and align carefully in order to
prevent the oil seal (27) lip from curling.
W2-6-17
10. Install the inner race of roller bearing (14) to shaft
(30) by using a bar and a hammer. Tap the inner
race until the upper end on the inner race of roller
bearing (14) reaches two threads for bearing nut
(15) in shaft (30).
NOTE: The fitting between the inner race of roller
bearing (14) and shaft (30) is tight.
11. Tighten bearing nut (15) to shaft (30) by hand.
CAUTION: The housing (25) assembly
weight: 59 kg (44 lb)
CAUTION: Prevent shaft (30) from falling off
when hoisting housing (25).
12. Hoist the housing (25) assembly by using the
eyebolt (M14) installed in step 9. Set the housing
(25) assembly to the press.
13. Remove bearing nut (15) from shaft (30).
 UPPERSTRUCTURE / Swing Device

18
19

10
11
13
12
11
17 9
15

16 14

25

30

W176-02-06-004

W2-6-18
 UPPERSTRUCTURE / Swing Device
14. Place the special tool (ST 2930) on the inner race
of roller bearing (14). Install the inner race of
roller bearing (14) by using a press.
NOTE: The specified press-in distance of the inner
race can be assured by using the special
tool (ST 2930).
ST 2930
14
W178-02-06-011
15. Hoist the housing (25) assembly. Install the
housing (25) assembly to the bracket (ST5098)
with bolts (M20) (2 used). At this time, insert the
stopper at the bottom of the bracket between
teeth of the pinion gear. Secure the bracket on a
workbench in order to reduce the reaction force.
: 30 mm
25
ST 5098
Stopper
W178-02-06-012
W2-6-19
IMPORTANT: Check the direction to install
bearing nut (15).
16. Apply a film of grease onto the thread part of
bearing nut (15). Install bearing nut (15) to shaft
(30). At this time, face the step side of bearing nut
(15) to the roller bearing (14) side. Tighten it by
using the special tool (ST 2927) to the specified
torque.
: 390 N m (40 kgf m, 290 lbf ft)
NOTE: Apply grease for keeping correct tightening
torque.
ST 2927
14
W178-02-06-008
17. Install lock plate (16) to bearing nut (15) with bolt
(17). In case the spline of lock plate (16) and that
of shaft (30) are not aligned, tighten bearing nut
(15) in tightening direction until both splines are
aligned.
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
 UPPERSTRUCTURE / Swing Device

5
3

21
7

6
20
18
4
19
8
10
11
13
12
11
9

16

30

W176-02-06-004

W2-6-20
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Check the direction to install spring
pin (10) and thrust plate (19).
18. Assemble second stage carrier (18) into an
assembly in the following way.
Install needle bearing (12) to planetary gear
(13). Install planetary gear (13) and thrust
plates (2 used) to second stage carrier (18).
Install pin (9) to the position where needle
bearing (12) has been installed with the spring
pin (10) hole facing front. The spring pin (10)
holes both on second stage carrier (18) and pin
(9) should be in line at this time.
Install spring pin (10) to second stage carrier
(18) by using the special tool (ST 1462). Face
the slit of spring pin (10) to the end of pin (9) at
this time.
10
9 Concave Part
Slit
W178-02-06-002
Install thrust plate (19) to second stage carrier
(18) with the oil groove facing outside.
Install needle bearings (12) (2 used), thrust
plates (11) (4 used), pins (9) (2 used) and
spring pins (10) (2 used) to other hole (2
places) on the second stage carrier (18) in the
same way.
W2-6-21
IMPORTANT: Check the position to install thrust
plate (8).
19. Assemble first stage carrier (21) in the same way
as second stage carrier (18). Install planetary
gears (7) (3 used), needle bearings (6) (3 used),
thrust plates (8) (3 used), pins (4) (3 used),
spring pins (5) (3 used) and thrust plate (3).
Check that mounting position of thrust plate (8) is
located under needle bearing (6) at this time.
IMPORTANT: Check the direction to install
second stage carrier (18).
20. Install the second stage carrier (18) assembly to
the spline of shaft (30). Check that the concave
part of the boss in bottom side of second stage
carrier (18) comes in contact with lock plate (16)
at this time.
18
16
30
W178-02-06-014
21. Install second stage sun gear (20) to the second
stage carrier (18) assembly with the small
diameter part facing upward.
 UPPERSTRUCTURE / Swing Device

22

21
24

20

23

32

25

31

W176-02-06-004

W2-6-22
 UPPERSTRUCTURE / Swing Device
22. Apply THREEBOND #1215 onto the ring gear
(24) mounting surface of housing (25). Clean off
old adhesive in advance.
23. Align the matching marks when disassembling
and install ring gear (24) to housing (25) with
bolts (23) (12 used).
: 12 mm
: 140 N m (15 kgf m, 103 lbf ft)
28. Add gear oil to ring gear (24) until gear oil
reaches the middle part of first stage sun gear
(2).
NOTE: Gear oil amount: 3.2 L (0.8 US gal.)
29. Apply THREEBOND #1102 onto the swing motor
(1) mounting surface of ring gear (24). Clean off
old adhesive in advance.

24. Align with the spline of second stage sun gear
(20) and install the first stage carrier (21)
assembly.
30. Attach a nylon sling onto the body of swing motor
IMPORTANT: Check the direction to install first
stage sun gear (2).
25. Install first stage sun gear (2) to the first stage
carrier (21) assembly. At this time, face the step
part facing downward.
CAUTION: Swing motor (1) weight: 34 kg (75
lb)
(1). Hoist swing motor (1). Align the matching
marks when disassembling and install swing
motor (1) to ring gear (24) with bolts (22) (7
used).
: 8 mm
: 64 N m (6.5 kgf m, 47 lbf ft)

26. Wind the seal tape onto the thread part of pipe
(32). Install pipe (32) to housing (25). Face pipe
(32) downward.
: 18 mm

27. Wind the seal tape onto drain plug (31). Install
drain plug (31) to pipe (32).
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)

W2-6-23
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING MOTOR

34 1

33 2

32 3

4
31
5
30
6
29

28 7

27

26

8
25
9
24
10
23
11
22

23 12
13
22
14
23
15
22
23

22 16
17
21 18
19
20
W176-02-06-008

1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring

W2-6-24
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Motor

6. Apply air through the parking brake port of casing

CAUTION: Swing motor weight: 34 kg (75 lb)
1. Attach a nylon sling onto the body of the swing
motor. Hoist the swing motor. Place the swing
motor with valve unit (32) facing upward. As shaft
(7) is out of casing (20), place the swing motor on
the wooden block (50 mm (2.0 in) or more
square).
(20). Raise and remove piston (25).
NOTE: If piston (25) is not raised, push in piston
(25) by using special tools (ST 2921 and
ST 2922) and retry to raise piston (25). As
for the special tools (ST 2921 and ST
2922), refer to ASSEMBLY OF SWING
MOTOR on W2-6-28.

IMPORTANT: Do not drop valve plate (27).

2. Remove socket bolt (34). Remove valve unit (32)
20
from casing (20). Port
: 14 mm

3. Wind the vinyl tape onto the end of shaft (7).

NOTE: The end of shaft (7) is the rotating surface
of needle bearing (30).

4. Remove needle bearing (30) from valve unit (32). W176-02-06-009

NOTE: Insert your finger in the back of needle

7. Remove rotor (1) from casing (20). At this time,
bearing (30). Remove needle bearing (30)
plate (23) and friction plate (22) are removed with
straight while rotating. If needle bearing
rotor (1) together.
(30) cannot be removed, push in by using
the special tool (ST 2899) and pull it up
8. Remove plungers (5) (2 used) at the opposite
again. As for the assembly, refer to
corner from casing (20). Disc spring (2), bushing
ASSEMBLY OF SWING MOTOR on
(3) and retainer (4) are removed with plunger (5)
W2-6-28.
together at this time.
5. Remove disc spring (29) from casing (20).
9. Remove other plungers (5) (7 used) from casing
(20).

W2-6-25
 UPPERSTRUCTURE / Swing Device

30
6

10

11

12

14
15

16
17

19
20
W176-02-06-008

W2-6-26
 UPPERSTRUCTURE / Swing Device
10. Hang the claws of the special tools (ST 1458) (2
used) to the inner diameter of swash plate (6).
Remove swash plate (6) from casing (20).
ST 1458
6 16. Secure the special tool (ST 1459) in a vise. Insert
20
W176-02-06-011
11. Remove retaining ring (8) from casing (20).
12. Place casing (20) horizontally.
13. Remove spline of shaft (7) from casing (20) by
tapping by using a plastic hammer. At this time,
roller bearing (9) is removed with shaft (7)
together.
14. Tap and remove oil seal (11) by using a
screwdriver. As THREEBOND is applied to the
outer surface of oil seal (11), oil seal (11) cannot
be reused.
IMPORTANT: Do not damage the oil seal (11) lip
surface of shaft (7).
15. Remove retaining ring (10) from shaft (7).
W2-6-27
IMPORTANT: When shaft (7) falls down from roller
bearing (9), the rotating surface of
needle bearing (30) may be
damaged. Hold shaft (7) in order not
to drop.
shaft (7) into the special tool (ST 1459) with the
spline side facing upward. Remove roller bearing
(9) from shaft (7) by tapping by using a plastic
hammer.
ST 1459
W176-02-06-021
17. Remove plug (12) from casing (20). Remove
spring (14) and poppet (15) from casing (20).
: 6 mm
18. Remove plug (19) from casing (20). Remove
spring (17) and plunger (16) from casing (20).
: 6 mm
NOTE: Do not remove a reinforcing mesh and a
filter which are set inside plunger (16)
unless necessary. If the reinforcing mesh
and the filter are removed, secure plunger
(16) in a vise. Remove plug (19) by using a
3 mm hexagonal wrench. Before
assembling, degrease plunger (16) and
plug (19). Apply LOCTITE #242 onto the
thread part. Tighten them to torque of 5.9
N·m (0.6 kgf·m).
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING MOTOR

34
32
33
30
28

29
27
16 17 18 19
15 31
14
25
13
26
12
24
23

22

5
Parking Brake Release Block
4
21

8
6

9
2

20
3

10 11 W176-02-06-012
7

1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring

W2-6-28
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Motor

1. Place casing (20) with the mounting surface for IMPORTANT: Check the direction to install roller
valve unit (32) facing upward on a wooden block bearing (9).
(50 mm (2 in) or more square). 7. Install roller bearing (9) with all the stamped
marks on the outer race, inner race and inner
2. Install spring (17) to plunger (16). Insert plunger ring plate facing outward.
(16) into the hole on the parking brake release
block. Marked Surface on Marked Surface on
Outer Race Inner Race
3. Install O-ring (18) to plug (19). Install plug (19) to
the hole on the parking brake release block.
: 6 mm
: 34.3 N m (3.5 kgf m, 25 lbf ft) W176-02-06-014

4. Install spring (14) to poppet (15). Insert poppet
(15) into the hole on the parking brake release
block.
5. Install O-ring (13) to plug (12). Install plug (12) to
the hole on the parking brake release block.
: 6 mm
: 34.3 N m (3.5 kgf m, 25 lbf ft)
6. Clean off old adhesive on the mounting part for
oil seal (11) of casing (20).
Apply THREEBOND #1104 or #1215 onto the
outer surface of oil seal (11). Install oil seal (11)
to casing (20) by using the special tools (ST 2897
and ST 2898).
Marked Surface on
Inner Ring Plate
IMPORTANT: Check the direction to install roller
bearing (9).
8. Insert the inner ring plate side of roller bearing (9)
into the spline side of shaft (7) first. Push in roller
bearing (9) to the front end of the mating position
with shaft (7). At this time, do not damage the
seal lip surface of shaft (7).
9. Insert the spline side of shaft (7) into the special
tool (ST 2896). Tap the opposite side of shaft (7)
by using a plastic hammer and install roller
bearing (9) to shaft (7).

ST 2898
9

ST 2897
ST 2896
20

W176-02-06-018

11 W176-02-06-010

W2-6-29
 UPPERSTRUCTURE / Swing Device

27

5
Parking Brake Release Block
4
21
8
6

20
3

10 11 W176-02-06-012
7

W2-6-30
 UPPERSTRUCTURE / Swing Device
10. Install retaining ring (10) to shaft (7). At this time,
do not damage the seal lip surface of shaft (7).
11. Apply grease onto the inner surface of oil seal
(11) and the seal lip surface of shaft (7).
12. Insert shaft (7) into casing (20). Install the end of
shaft (7) to casing (20) by using a plastic hammer
while adjusting. Tap and listen to ring in order to
check if the installation is completed.
13. Install retaining ring (8) to casing (20).
14. Apply grease onto the chamfered surface and the
outer surface of swash plate (6).
15. Install swash plate (6) to casing (20) with the
chamfered surface facing downward.
NOTE: After installing swash plate (6), rotate it. If
swash plate (6) does not rotate, it may be
seizing. In that case, install swash plate (6)
again.
W2-6-31
IMPORTANT: The flat surface of rotor (1) is a
sliding surface with the valve plate.
Do not damage the sliding surface.
16. Assemble rotor (1) into an assembly.
• Place rotor (1) with the flat surface facing
downward.
• Assemble disc springs (2) (4 used) as the
outer surface is matching with the outer
surface and the inner surface is matching with
the inner surface. Place them on the projection.
Cover them with bushing (3). Check the
direction of disc spring (2). Refer to the
illustration below.
3
2
1
W176-02-06-015
• Place retainer (4) on bushing (3) with the
chamfered surface facing downward.
4
Chamfered
Surface
3 W176-02-06-016
• Align the plunger (5) hole of retainer (4) with
that of rotor (1). Insert plungers (5) (9 used).
17. Place casing (20) horizontally with the drain plug
(21) side facing downward.
18. Install rotor (1) assembled in step 16 to casing
(20) while aligning with the spline of shaft (7).
 UPPERSTRUCTURE / Swing Device

34
32
33
30
28

29
27

31

25

26
24

23

22

Parking Brake Release Block

20

W176-02-06-012
7

W2-6-32
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Shaft (7) is out of casing (20). Place 24. Install needle bearing (30) to valve unit (32) by
casing (20) on a wooden block (50 using the special tool (ST 2899).
mm or more square).
19. Place casing (20) vertically with the mounting
surface for valve unit (32) facing upward. ST 2899

IMPORTANT: Check the installation order of plate

30
(23) and friction plate (22).
20. Install plates (23) (4 used) and friction plates (22)
(4 used) to casing (20) alternately. Install friction 32
plate (22) first.

21. Install O-rings (24, 26) to piston (25).

22. Place piston (25) evenly on casing (20). Install

piston (25) to casing (20) by using the special
tools (ST 2921, ST 2922) and a hammer.
W176-02-06-019

ST 2922
25. Install O-ring (31) to valve unit (32).

ST 2921
26. Apply grease onto the flat surface of valve plate
(27).
25
NOTE: Apply grease more in order not to drop
20 valve plate (27) when installing valve unit
(32) to casing (20).

IMPORTANT: Do not drop valve plate (27).

27. Install valve plate (27) while aligning with knock
pin (28) of valve unit (32). Turn over valve unit
(32). Place valve unit (32) on casing (20).

28. Install valve unit (32) to casing (20) with spring

W176-02-06-020 washers (33) (4 used) and socket bolts (34) (4
used).
IMPORTANT: Check the direction of disc spring : 14 mm
(29). : 265 N m (27 kgf m, 195 lbf ft)
23. Install disc spring (29) to casing (20). At this time,
install disc spring (29) with the outer surface side
facing to the back.

W2-6-33
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF VALVE UNIT

7
6

1 2 3 4 5 9

10

11

12
4
3
2
1

13
14
15
16

W176-02-06-007
16
15
14
13

1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Spring Seat (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)

W2-6-34
 UPPERSTRUCTURE / Swing Device
Disassembly of Valve Unit
• As for removal/ installation of the valve unit from/
to the swing motor, refer to DISASSEMBLY OF
SWING MOTOR on W2-6-4 and ASSEMBLY OF
SWING MOTOR on W2-6-28.
IMPORTANT: The lower surface of valve housing
(5) is the contact surface of the
valve plate. Do not damage the
contact surface.
1. Set the cloth on the workbench. Place valve
housing (5) on the cloth.
IMPORTANT: Do not damage the inside of valve
housing (5).
5. Insert a round bar into valve housing (5).
Remove spool (12) to the opposite side. At this
time, spring seat (4) is removed with spool (12)
together. If spool (12) cannot be removed, push
back spool (12) by using a round bar and remove
spool (12) again.
6. Remove other spring seat (4) in valve housing (5)
by using a magnet.

IMPORTANT: As the set pressure changes, do not

rotate the lock nut of relief valve (8).
2. Rotate the cartridge of relief valve (8). Remove
relief valve (8) from valve housing (5). (2 places)
: 32 mm

8 Lock Nut

W176-02-06-017

3. Remove plug (13). Remove spring (15) and

poppet (16) from valve housing (5) by using a
magnet. (2 places)
: 12 mm

4. Remove plug (1). Remove spring (3) from valve

housing (5) (2 places).
: 8 mm

W2-6-35
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF VALVE UNIT
8

10

11

13

14

15

16

2 3 4 12 4 3 2
Section E

1 1

W176-02-06-013

1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Spring Seat (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)

W2-6-36
 UPPERSTRUCTURE / Swing Device
Assembly of Valve Unit
1. Install O-ring (9) to relief valves (8) (2 used).
IMPORTANT: Check the installation order of
O-ring (7) and backup ring (10).
2. Install O-ring (7) and backup ring (10) to relief
valves (8) (2 used).
IMPORTANT: Check the installation order of
O-ring (11) and backup ring (6).
3. Install backup ring (6) and O-ring (11) to relief
valves (8) (2 used).
IMPORTANT: As the set pressure changes, do not
rotate the lock nut of relief valve (8).
4. Install the cartridge of relief valve (8) to valve
housing (5) by rotating. (2 places)
: 32 mm
: 235 N m (24 kgf m, 173 lbf ft)
Cartridge Lock Nut
10. Install O-ring (2) to plug (1). Install plug (1) to
W176-02-06-017
5. Install spring (15) to poppet (16). Install poppet
(16) to valve housing (5). (2 places)
W2-6-37
6. Install O-ring (14) to plug (13). Install plug (13) to
valve housing (5). (2 places)
: 12 mm
: 235 N m (24 kgf m, 173 lbf ft)
7. Install spring seat (4) to spool (12) only at one
side. Install spool (12) to the center of valve
housing (5) from the side without spring seat (4)
Push in spool (12) just before the spool (12) end
comes out from the hole at the opposite side of
valve housing (5). At this time, do not drop spring
seat (4) inside of valve housing (5).
8. Insert spring seat (4) into the spool (12) end
coming out from the opposite side of valve
housing (5). Install and push spring (3) to the
step part of spool (12).
9. Push back spool (12) approximately half way of
valve housing (5). Insert spring (3) from the hole
at the opposite side.
valve housing (5). (2 places)
: 8 mm
: 69 N m (7 kgf m, 51 lbf ft)
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
Swing Motor Shoe

1. Clearance between plunger and shoe bottom

Unit: mm (in)
Standard Allowable Limit
0 0.2 (0.008)

0.2 mm (0.008 in) Plunger

2. Clearance between plunger outer diameter and Rotor

rotor cylinder inner bore
Unit: mm (in)
Standard Allowable Limit
0 0.05 (0.002)

D-d 0.05 mm (0.002 in)

Plunger Assembly

Rotor

W2-6-38
 UPPERSTRUCTURE / Swing Device

Parking Brake
A

W176-02-06-022
C
Unit: mm
Part Name Standard Allowable Limit Remedy
A Friction plate Thickness 2.4 2.35
B Disc spring (Overall height) 6.8 6.7
C Piston Thickness 41 -
D Plate Thickness 1.4 1.35
Remarks No wear on the piston as it does not slide.

IMPORTANT: The piston thickness is shown as

the distance from the contact point
of the disc spring to the contact
point of the plate.

NOTE: 1 mm = 0.03937 in

Plunger

Unit: mm
Standard Allowable Limit Remedy
A 5.5 5.3 Replace

NOTE: 1 mm = 0.03937 in

W2-6-39
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-6-40
 UPPERSTRUCTURE / Pilot Valve
REMOVAL AND INSTALLATION OF PILOT
VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal of Left Pilot Valve

1
CAUTION: Seat (1) weight: 40 kg (90 lb)

1. Remove bolts (2) (2 used).

: 16 mm

3
2
W1JB-02-01-008

2. Remove socket bolts (3) (4 used). Remove seat 1 3

(1) from bracket (4).
: 6 mm

W1JB-02-07-007

W2-7-1
 UPPERSTRUCTURE / Pilot Valve
3. Remove cap (7) from lever (5). Remove screw (8).
Remove cover (6) from lever (5). 5 6

W1JB-02-07-013

7, 8
4. Remove bolts (10) (2 used). Remove lever (5)
5
from bracket (9).
: 13 mm
9

10 W1JB-02-07-012

11
5. Remove screws (12) (4 used). Move boot (11)
upward from bracket (9).
9

12

W1JB-02-07-002

6. Remove screw (13). 13 11

W1JB-02-07-014

W2-7-2
 UPPERSTRUCTURE / Pilot Valve
7. Remove bolts (14) (2 used) and screw (17).
Remove covers (15, 16) from bracket (9).
: 10 mm

14 15 16

17

9
W1JB-02-07-011

8. Remove clip bands (20) (2 used). Disconnect the

connector of harness (21). 18 19 20

9. Loosen lock nut (19). Remove the lever (18)

assembly from pilot valve (22).
: 19 mm, 22 mm

21

W1JB-02-07-005

22

10. Disconnect hoses (23) (6 used) from pilot valve

(22). Attach an identification tag onto the 22
disconnected hoses (23) for assembling. Cap the
open ends.
: 19 mm

W1JB-02-07-006

23

W2-7-3
 UPPERSTRUCTURE / Pilot Valve
11. Remove bolt (24). Remove pilot valve (22) from
bracket (9).
: 13 mm 24 9

22

W1JB-02-07-005

24

W2-7-4
 UPPERSTRUCTURE / Pilot Valve
Installation of Left Pilot Valve
24 9
1. Install pilot valve (22) to bracket (9) with bolts (24)
(4 used).
: 13 mm
: 20 N m (2 kgf m, 15 lbf ft) 22

W1JB-02-07-005

24

2. Connect hoses (23) (6 used) to pilot valve (22). 22

: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)

W1JB-02-07-006

23

3. Install the lever (18) assembly to pilot valve (22).

Secure the lever (18) assembly to pilot valve (22) 18 19 20
with lock nut (19).
: 22 mm
: 55 N m (5.5 kgf m, 41 lbf ft)
21
4. Connect the connector of harness (21).

W1JB-02-07-005
22

W2-7-5
 UPPERSTRUCTURE / Pilot Valve
5. Connect harness (21) to pilot valve (22) and
bracket (9) with clip bands (20) (2 used).

6. Install covers (15, 16) to bracket (9) with bolts (14)

(2 used) and screw (17).
: 10 mm
: 3.3 to 4.2 N m 14 15 16
(0.3 to 0.4kgf m, 2 to 3 lbf ft)
17

9
W1JB-02-07-011

7. Install covers (15, 16) to bracket (9) with screw

(13). 13 9 16

15
W1JB-02-07-014

11 9
8. Install boot (11) to bracket (9) with screws (12) (4
used).

12

W1JB-02-07-002

9. Install lever (5) to bracket (9) with bolts (10) (2 5

used).
: 13 mm
9
: 20 N m (2 kgf m, 15 lbf ft)

10 W1JB-02-07-012

W2-7-6
 UPPERSTRUCTURE / Pilot Valve
10. Install cover (6) to lever (5) with screw (8). Install
cap (7) to cover (6). 5 6

W1JB-02-07-013

7, 8

CAUTION: Seat (1) weight: 40 kg (90 lb)

11. Install seat (1) to bracket (4) with socket bolts (3)
(4 used). 1
: 6 mm
: 20 N m (2 kgf m, 15 lbf ft)

3
2
W1JB-02-01-008

1 3
12. Install a seat belt to bracket (4) with bolts (2) (2
used).
: 16 mm
: 50 N m (5 kgf m, 37 lbf ft)
4

W1JB-02-07-007

W2-7-7
 UPPERSTRUCTURE / Pilot Valve
Removal Right Pilot Valve

1. Remove the seat. (Refer to W2-7-1.)

2. Remove caps (1) (2 used). Remove screws (2, 4)

(2 used for each). Remove cover (3) from bracket 1, 2
(5).

W1JB-02-07-009
5 4

3. Remove screw (6).

1, 2

4
7 6 5
W1JB-02-07-008

4. Remove screws (9) (4 used). Move boot (8)

upward from bracket (5). Remove screw (10). 5

5. Remove cover (7) from bracket (5). 9

W1JB-02-07-002

10
8

W1JB-02-07-016

W2-7-8
 UPPERSTRUCTURE / Pilot Valve
6. Remove clip bands (13) (2 used). Disconnect the 11 12 13
connector of harness (14).

7. Loosen lock nut (12). Remove the lever (11)

assembly from pilot valve (15). 14
: 19 mm, 22 mm

W1JB-02-07-005
15
8. Remove bolts (17) (3 used). Remove the bracket
(5) assembly from stand (16). Lay down the
bracket (5) assembly.
: 17 mm

17
16
W1JB-02-07-008

18 19
9. Remove bolt (19). Remove cover (18) from
bracket (5).
: 10 mm
5

W1JB-02-07-010

10. Disconnect hoses (20) (6 used) from pilot valve 15

(15). Attach an identification tag onto the
disconnected hoses for reassembling. Cap the
open ends.
: 19 mm

W1JB-02-07-006

20

W2-7-9
 UPPERSTRUCTURE / Pilot Valve
11. Remove bolts (21) (4 used). Remove pilot valve
21 5
(15) from bracket (5).
: 13 mm

15

W1JB-02-07-005

21

W2-7-10
 UPPERSTRUCTURE / Pilot Valve
Installation of Right Pilot Valve
21 5
1. Install pilot valve (15) to bracket (5) with bolts (21)
(4 used).
: 13 mm
: 20 N m (2 kgf m, 15 lbf ft) 15

W1JB-02-07-005

21

2. Connect hoses (20) (6 used) to pilot valve (15). 15

: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)

W1JB-02-07-006

20

11 12 13
3. Install the lever (11) assembly to pilot valve (15).
Install the lever (11) assembly to pilot valve (15)
with lock nut (12).
: 22 mm 14
: 56 N m (5.7 kgf m, 41 lbf ft) 5

4. Connect the connector of harness (14).

15
5. Connect harness (14) to pilot valve (15) and
bracket (5) with clip bands (13) (2 used).

W1JB-02-07-005

W2-7-11
 UPPERSTRUCTURE / Pilot Valve
6. Install cover (18) to bracket (5) with bolt (19). 18 19
: 10 mm
: 3.3 to 4.2 N m
(0.3 to 0.4 kgf m, 2 to 3 lbf ft)
5

W1JB-02-07-010

7. Install cover (7) to bracket (5) with screw (6).

8. Install the bracket (5) assembly to stand (16) with

7
bolts (17) (3 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

6
5
17
16
W1JB-02-07-008

9. Install covers (18, 7) to bracket (5) with screw

10
(10).
5

7 18

W1JB-02-07-016

10. Install boot (8) to bracket (5) with screws (9) (4 8

used).
5

W1JB-02-07-002

W2-7-12
 UPPERSTRUCTURE / Pilot Valve
11. Install cover (3) to bracket (5) with screws (2, 4) (2
used for each). Install caps (1) (2 used) to cover
(3).

1, 2

5 4
W1JB-02-07-009

CAUTION: Seat (1) weight: 40 kg (88 lb)

1 3

12. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm 4
: 20 N m (2 kgf m, 15 lbf ft)

W1JB-02-07-007

13. Install a seat belt to bracket (4) with bolts (2) (2

used).
: 16 mm 1
: 50 N m (5 kgf m, 37 lbf ft)

3
2
W1JB-02-01-008

W2-7-13
 UPPERSTRUCTURE / Pilot Valve
Removal of Travel Pilot Valve
1
1. Remove bolts (3) (6 used) and washers (4) (6
used). Remove cover (2) from the lower side of
main frame (1). 2
: 17 mm

3, 4 W1V1-02-08-002

ZX110-3 class, 120-3 class

2 3, 4
1

ZX135US-3 class W1R7-02-07-002

2. Disconnect hoses (5) (6 used) from pilot valve (6).

Attach an identification tag onto disconnected 5 5
hoses (5) for reassembling. Cap the open end.
: 17 mm, 19 mm

3. Remove floor mat (7). W1JB-02-07-001

W1JB-02-07-015
7

W2-7-14
 UPPERSTRUCTURE / Pilot Valve
4. Remove bolts (10) (4 used). Remove levers (9) (2
used) and pedals (8) (2 used) from pilot valve (6).
: 17 mm 9
8

10 6 W1JB-02-07-003

5. Remove socket bolts (11) (2 used). Remove pilot 1

valve (6) from main frame (1).
: 8 mm

6 11
W1JB-02-07-004

W2-7-15
 UPPERSTRUCTURE / Pilot Valve
Installation of Travel Pilot Valve
1
1. Install pilot valve (6) to main frame (1) with socket
bolts (11) (2 used).
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)

6 11
W1JB-02-07-004

2. Install levers (9) (2 used) and pedals (8) (2 used)

to pilot valve (6) with bolts (10) (4 used). 9
: 17 mm 8
: 50 N m (5 kgf m, 37 lbf ft)

10 6 W1JB-02-07-003

5 5

3. Connect hoses (5) (6 used) to pilot valve (6).

: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf ft)
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)

W1JB-02-07-001

W2-7-16
 UPPERSTRUCTURE / Pilot Valve
4. Install cover (2) to the lower side of main frame (1)
1
with bolts (3) (6 used) and washers (4) (6 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
2

3, 4 W1V1-02-08-002

ZX110-3 class, 120-3 class

2 3, 4
1

ZX135US-3 class W1R7-02-07-002

5. Install floor mat (7).

W1JB-02-07-015
7

W2-7-17
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF RIGHT AND LEFT
PILOT VALVES

17

16

15

14

13

12

11
10

9 18

7
6 19
5 20
4 21
3 22

W178-02-07-064

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Casing

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Spool (4 Used)
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Plug
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Retaining Ring
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)

W2-7-18
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Right and Left Pilot Valves
IMPORTANT: Casing (18) is made of aluminum. As
strong force deforms or damages
them, handle them with care.
IMPORTANT: Spool (19) has been selected to
match the hole on casing (18). The
dimensions of balance springs A (3),
B (4) and return springs A (5), B (6)
as well as those of pushers A (9), B
(10) are different. Arrange the
disassembled parts together with
each port in order not to confuse.
The port number is stamped on the
outer surface of casing (18).
1. Secure screw joint (17) in a vise. Loosen cam (16)
by using a spanner. Remove screw joint (17) from
cam (16).
: 19 mm, 32 mm
2. Secure the flat surface of casing (18) in a vise
lightly. Remove cam (16) from universal joint (15).
: 32 mm
W2-7-19
3. Attach a spanner onto the upper part of universal
joint (15). Remove universal joint (15) from casing
(18).
: 17 mm
NOTE: Universal joint (15) has been secured on
casing (18) by using LOCTITE #262.
4. Remove plate (14).
IMPORTANT: Do not damage the surface of sleeve
(12). Insert a soft rubber between
sleeve (12) and a tool. Oil seal (11)
cannot be removed from sleeve (12).
Sleeve (12) and oil seal (11) should
be replaced as an assembly.
5. Remove sleeve (12) upward by using a pair of
pliers.
IMPORTANT: The dimensions of pushers A (9), B
(10) for ports (1, 3) and for ports (2,
4) are different. Keep the
disassembled parts together by the
port number.
6. Remove pushers A (9), B (10) from casing (18).
 UPPERSTRUCTURE / Pilot Valve

18

7
6 19
5
4 21
3 22

W178-02-07-064

W2-7-20
 UPPERSTRUCTURE / Pilot Valve

7. When compressing the spring, do not lower the

IMPORTANT: The quantity of shims (2) has been
spool. Install the special tool (ST 4145) to the determined for each port during the
port hole on casing (18) as illustrated. performance testing at the factory.
: 6 mm Do not lose shims (2). Keep shim (2)
carefully in order to install shim (2)
to the original position when
assembling.
9. Remove the special tool (ST4146). Remove
spring guides (7) (4 used), return springs A (5) (2
used), B (6) (2 used), balance springs A (3) (2
used) and B (4) (2 used) from spools (19) (4
18
used).

10. Remove shim (2) and spacers (1) (4 used) from

spools (19) (4 used).

W178-02-07-048
IMPORTANT: Spool (19) has been selected to
ST 4145
match the hole of casing (18). Spool
8. Install the special tool (ST 4146) to the pusher (19) and casing (18) should be
hole on casing (18). Push the special tool (ST replaced as an assembly
4146) and compress the spring. Tighten the 11. Remove the special tool (ST4145) from casing
special tool (ST 4146) by using the socket bolt (18). Remove spool (19) from casing (18) by
(M14, Pitch 2.0 mm). Remove retaining rings rotating slowly.
(8)(4 used) from spools (19) (4 used) by using a
screwdriver. IMPORTANT: Retaining ring (22) may come off
: 12 mm while disassembling. Do not drop
retaining ring (22) inside casing (18).
If retaining ring (22) falls inside
ST 4146
casing (18), remove retaining ring
(22) completely. Retaining ring (22)
cannot be reused.
12. Remove retaining ring (22) from casing (18) by
18 using a screwdriver. Install a bolt (M8, Pitch 1.25
mm) to plug (21). Remove plug (21) from casing
(18).
: 13 mm

W178-02-07-048

W2-7-21
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF RIGHT AND LEFT PILOT VALVES

17

15
16

11 9, 10
14
12
13
8
7
3, 4

5, 6
2

21
1
20
18 19
22

W1V1-02-07-001

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Casing

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Spool (4 Used)
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Plug
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Retaining Ring
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)

W2-7-22
 UPPERSTRUCTURE / Pilot Valve
Assembly of Right and Left Pilot Valves

IMPORTANT: The pilot valve is susceptible to IMPORTANT: Refer to the table in left in order to
contamination. Keep the parts clean assemble the parts correctly.
when assembling. 3. Install spacers (1) (4 used), shim (2) and balance
springs A (3), B (4) (2 used for each) to spools
NOTE: Table below shows the relations between (19) (4 used). Install return springs A (5), B (6) (2
each port and the parts. Do not confuse used for each) to casing (18).
them when assembling.
4. Install spring guides (7) (4 used) to return springs
Port Spool Shim Pushers A, B A (5), B (6) (2 used for each) with the protrusion
No. (19) (2) (9, 10) facing upward.
Outer grooves
1 5. Install the special tool (ST 4146) to the pusher A
Same to the Same to the (3 used)
(9), B (10) holes on casing (18). Push the special
former one former one Without outer
2 tool (ST 4146) and compress the spring. Tighten
groove
the special tool (ST 4146) by using a bolt (M14,
Outer grooves Pitch 2.0 mm).
3
(3 used) : 12 mm
Without outer
4
groove
ST 4146

Port Return Springs Balance Springs A, B ST 4144

No. (5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long

1. Check the port number. Insert same spools (19)

(4 used) before disassembling. Install the thinner
end of spool (19) into the port hole on casing (18)
W178-02-07-049
by turning slowly. ST 4145
NOTE: Spool (19) has been selected to match the
6. Install retaining ring (8) to the ring holder (ST
port hole. Spool (19) and casing (18)
4144).
should be replaced as an assembly.

2. Install the special tool (ST 4145) to the port hole

on casing (18) in order not to lower spool (19)
when the spring is compressed.
: 6 mm

W2-7-23
 UPPERSTRUCTURE / Pilot Valve

17

15
16

11 9, 10
14
12
13
8

3, 4

18

W1V1-02-07-001

W2-7-24
 UPPERSTRUCTURE / Pilot Valve
7. Install retaining rings (8) (4 used) to ring holder
(ST 4144). Install retaining rings (8) (4 used) to
the groove on the head of spool (21) extending
from special tool (ST 4146).
IMPORTANT: Check the position to install pushers
A (9) (2 used) and pushers B (10) (2
used).
8. Install pushers A (9) (2 used) and pushers B (10)
(2 used) to casing (18).
After pushing pushers A (9) (2 used) and pushers
B (10) (2 used) by hand, remove them. Check if
retaining rings (8) (4 used) fall off or balance
springs A (3), B (4) (2 used for each) are located
correctly.
After checking, install pushers A (9) (2 used) and
pushers B (10) (2 used) to casing (18).
9. Apply grease onto the ball at the end of pushers A
(9) (2 used) and pushers B (10) (2 used).
IMPORTANT: Align the bolt hole on plate (14) with
the screw hole on casing (18).
14. Apply LOCTITE #262 onto the thread part of
universal joint (15). Place plate (14) on casing
(18) and install universal joint (15).
: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf ft)
IMPORTANT: Check the tightness of cam (16).
15. Install cam (16) to universal joint (15). The
clearance between cam (16), and pushers A (9) (2
used) and pushers B (10) (2 used) should be 0 to
0.2 mm (0 to 0.008 in).
16. Secure cam (16) by using a spanner. Tighten
screw joint (17) by using a spanner.
: 19 mm, 32 mm
: 68 N m (7 kgf m, 50 lbf ft)

10. Apply grease onto the joint part of universal joint

(15).

11. Apply grease onto the inner surface of oil seals

(11) (4 used).
NOTE: Sleeve (12) and oil seal (11) should be
replaced as an assembly.

12. Install oil seals (11) (4 used) to sleeves (12) (4

used). Push the sleeve (12) assemblies (4 used)
by hand until O-ring (13) is inserted into the hole
on sleeves (12) (4 used).

13. Secure casing (18) in a vise lightly.

W2-7-25
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF TRAVEL PILOT VALVE

3
4

35
7 34
33
32
8
9 31
30
10
29
11
28

14 27

26
12
13 15
25
16

24
17

18

23
19

20
21 22
W178-02-07-063

1- Bolt (2 Used) 10 - Spring Pin 19 - O-Ring (2 Used) 28 - Oil Seal (4 Used)

2- Cover 11 - Bracket (2 Used) 20 - Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring (4 Used) 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)

W2-7-26
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminium.
As strong force deforms or damages
casing (23), handle casing (23) with
care.
IMPORTANT: Spool (24) has been selected to
match the hole of casing (23).
Arrange the disassembled parts
together with each port in order not
to confuse.
The port number is stamped on the
outer surface of casing (23).
1. Secure casing (23) in a vise. Remove bolts (1) (2
used). Remove cover (2) from holder (7).
: 10 mm
2. Remove socket bolts (30) (2 used) and spring
washers (29) (2 used). Remove the holder (7)
assembly from casing (23).
: 8 mm
3. Remove the pusher (16) assemblies (4 used)
from casing (23).
4. Remove pushers (16) (4 used) from bushings (15)
(4 used). Remove oil seals (28) (4 used) and
O-rings (14) (4 used) from bushings (15) (4 used)
by using a bamboo spatula.
W2-7-27
IMPORTANT: Put the mark on spools (24) (4 used)
when keeping in order to easily
install spools (24) (4 used) to the
original hole.
IMPORTANT: Spool (24) has been selected to
match the hole of casing (23).
Replace spool (24) and casing (23)
as an assembly.
5. Remove the spool (24) assemblies (4 used) from
casing (23) by rotating.
Spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used) and spacers (26)
(4 used) are removed with spools (24) (4 used)
together.
IMPORTANT: The quantity of shim (27) has been
determined during the performance
testing at the factory. Keep shim (27)
together with each spool.
6. Push balance spring (18). Remove spring guides
(17) (4 used), balance springs (18) (4 used),
shims (27) (12 used) and spacers (26) (4 used)
from spools (24) (4 used).
7. Remove springs (25) (4 used) from casing (23).
 UPPERSTRUCTURE / Pilot Valve

3
4
6
3
4

5 10
11
5 12
6 13
6
35
7 34
33
32
9 31

10
31
11 32
33
34
35

12
13

23
19

20
21 22
W178-02-07-063

W2-7-28
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Place a stand under bracket (11) and
reduce a reaction force. If holder (7)
bears the reaction force, strong
force acts on pin (35) and pin (35)
may be deformed.
8. Place a stand under bracket (11).
The inner surfaces of the spring pins (12, 13)
holes (2 used for each) on bracket (11) are
stepped-shape. Spring pins (12, 13) can only be
removed in one direction.
Tap and remove spring pins (12, 13) (2 used for
each) from bracket (11) at the same time by using
the special tool (ST 1237). Remove bracket (11)
from pin (35).
Do not remove spring pin (10) with bracket (11)
attached unless necessary.
The hole end of spring pin (10) has been crimped.
12, 13
11
35 10
Crimped
Position
Stand
W176-02-07-019
9. Remove socket bolts (9) (4 used) and spring
washers (8) (4 used). Remove dampers (32) (2
used) and rubber seats (31) (2 used) from pin (35).
O-rings (34) (2 used) are removed together.
: 5 mm
W2-7-29
10. Remove O-rings (33) (2 used) from pin (35).
11. Place holder (7) with the casing (23) mounting
surface facing upward.
12. The inner surfaces of the spring pin (3, 4) holes (2
used for each) in cam (5) are stepped-shape. Tap
the bottom of cam (5) and remove spring pins (3,
4) (2 used for each) from cams (5) (2 used) at the
same time by using the special tool (ST 1237). As
the spring pin (3, 4) holes (2 used for each) are
crimped, spring pins (3, 4) may feel tight when
removing.
13. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are also
removed.
Do not remove bushings (6) (4 used) in holder (7)
unless necessary. If removing, remove bushings
(6) (4 used) by tapping by using special tool (ST
7256).
14. Remove plugs (20) (2 used) from casing (23).
O-rings (19) (2 used) are removed with plugs (20)
(2 used) together.
: 5 mm
15. Remove plugs (21) (2 used) from casing (23).
O-rings (22) (2 used) are removed with plugs (21)
(2 used) together.
: 6 mm
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF TRAVEL PILOT VALVE

11 32 31 1 2 35 6 12 10 13 5 3, 4 30

29
34 15
9 33 28
17
8 18
14
25

27
16
26

24
23

W178-02-11-316

1- Bolt (2 Used) 10 - Spring Pin 19 - *O-Ring (2 Used) 28 - Oil Seal (4 Used)

2- Cover 11 - Bracket (2 Used) 20 - *Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - *Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - *O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)

NOTE: As for the parts with mark *, refer to

W2-7-26.

W2-7-30
 UPPERSTRUCTURE / Pilot Valve
Assembly of Travel Pilot Valve
IMPORTANT: Check the direction to install spring
guide (17).
1. Assemble spools (24) (4 used) into an assembly.
• Insert spacers (26) (2 used), shims (27) (12 used)
and balance springs (18) (4 used) into spools (24)
(4 used) in this order. Install shim (27) as the
same condition before disassembling.
• Compress balance springs (18) (4 used) by hand.
Install spring guides (17) (4 used) to spools (24)
(4 used) with the stepped-part facing downward.
IMPORTANT: Before inserting the parts into holder
(7) and casing (23), apply hydraulic
oil.
2. Insert springs (25) (4 used) into casing (23).
3. Insert the spool (24) assembly into the former port
before disassembling. Install the spool (24)
assemblies (4 used) into casing (23) by rotating.
4. Assemble pushers (16) (4 used) into an
assembly.
• Install oil seals (28) (4 used) to bushings (15) (4
used).
• Apply grease onto the inner surface of oil seals
(28) (4 used).
• Install O-rings (14) (4 used) and pushers (16) (4
used) to bushings (15) (4 used).
• Apply grease onto the head of pushers (16) (4
used).
5. Insert the pushers (16) assemblies (4 used) into
casing (23).
W2-7-31
6. If bushing (6) has been removed from holder (7),
install bushings (6) (4 used) to holder (7) by using
the special tool (ST 7256) in the following
procedures.
NOTE: Bushings (6)(4 used) are identical.
• Insert bushings (6) (4 used) into the special tool
(ST 7256). Tap the special tool (ST 7256) by
using a hammer and install bushing (6) to the end
of the hole of holder (7).
Stop tapping when the bushing (6) end is flush
with the hole end.
• Install bushing (6) on the opposite side in the
same way.
7 ST 7256
6
W176-02-11-310
• Install bushing (6) in the near side as illustrated.
Stop tapping when the bushing (6) end is flush
with the outside of holder (7).
• Install bushing (6) in the near and opposite side
as illustrated.
6
7 ST 7256
Outside of
Holder
W176-02-11-312
 UPPERSTRUCTURE / Pilot Valve

32 31 35 31 32 5 3, 4 30

29
34

9 33

23

W178-02-11-316

W2-7-32
 UPPERSTRUCTURE / Pilot Valve
7. Install O-rings (33) (2 used) to pin (35).
Apply grease onto O-rings (33) (2 used). Install
pin (35) and cams (5) (2 used) to holder (7).
IMPORTANT: Check the direction to install spring
pins (3, 4) (2 used for each).
8. Install spring pins (3, 4) (2 used for each) to cams
(5) (2 used) by using the special tool (ST 1237).
Secure cams (5) (2 used) and pin (35). At this
time, the slits of spring pins (3, 4) (2 used for
each) should be positioned 90° away each other.
Tap and install spring pins (3, 4) (2 used for each)
until spring pins (3, 4) come in contact with the
step part in the hole.
3 Slit Slit
11. Install rubber seats (31) (2 used) to pin (35).
IMPORTANT: Check the direction of damper (32).
The inner surface of damper (32) is
edged-shape. If damper (32) is pried
when installing, O-ring (33) may be
damaged.
12. Install dampers (32) (2 used) to pin (35) with the
lever facing upward.
13. Secure damper (32) and rubber seat (31) to
holder (7) with socket bolts (9) (4 used) and spring
washers (8) (4 used).
: 5 mm
: 6.9 N m (0.7 kgf m, 5 lbf ft)

14. Apply grease onto O-ring (34). Push O-rings (34)

(2 used) to the end of pin (35).

W178-02-07-050
4

9. Crimp the hole end of cams (5) (2 used) where

spring pins (3, 4) are inserted by using a punch.

10. Place holder (7) on the casing (23) assembly.

Install holder (7) to casing (23) with socket bolts
(30) (2 used) and spring washers (29) (2 used).
Check the mark direction and install holder (7).
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)

W2-7-33
 UPPERSTRUCTURE / Pilot Valve

11 32 1 2 35 12 10 13 1 1

19, 20

21, 22

W178-02-11-316

W2-7-34
 UPPERSTRUCTURE / Pilot Valve
15. As for the direction to install bracket (11), refer to 20. Apply grease onto the spring pin (10) contact part
the figure in Disassembly of Travel Pilot Valve on of dampers (32) (2 used).
W2-7-26. Install bracket (11) to pin (35). Align the
inserting holes of spring pins (12, 13) (2 used for 21. Install O-rings (19) (2 used) to plugs (20) (2 used).
each). Install plugs (20) (2 used) to casing (23).
: 5 mm
IMPORTANT: Place a stand under bracket (11) and : 10 N m (1 kgf m, 7 lbf ft)
reduce a reaction force. If holder (7)
bears the reaction force, strong 22. Install O-rings (22) (2 used) to plugs (21) (2 used).
force acts on pin (35) and pin (35) Install plugs (21) (2 used) to casing (23).
may be deformed. : 6 mm
16. Place a stand under bracket (11). : 19.6 N m (2 kgf m, 14.5 lbf ft)
Install spring pins (12, 13) to bracket (11) until
they come in contact with the step part by using
the special tool (ST 1237). The slits of spring pins
(2 used) should be positioned 90° away each
other.

Crimped Crimped
Position Position

11 35

Stand 12, 13

W176-02-07-011

17. Crimp the hole end of bracket (11) where spring

pins (12, 13) are inserted by using a punch.

18. Install bracket (11) on the opposite side to pin (35)

in the same way as step 16 to 17.

19. Install cover (2) to holder (7) with bolts (1) (2 used).
: 10 mm
: 4.9 N m (0.5 kgf m, 3.6 lbf ft)

W2-7-35
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-36
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
REMOVAL AND INSTALLATION OF PILOT
SHUT-OFF SOLENOID VALVE 1 Main Frame

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
1. Remove bolts (1) (6 used) from cover (2) on
bottom of the cab. Remove cover (2) from the
main frame.
: 17 mm 2 W1V1-02-08-002

ZX110-3 class, 120-3 class

Main Frame 1 2

W1R7-02-07-002
ZX135US-3 class

3
4

2. Disconnect hoses (3) (9 used) pipes (4) (2 used) 5

and harness (6) from pilot shut-off solenoid valve
(5).
Attach an identification tag onto the disconnected
hoses (3) and pipes (4) for assembling. Cap the
open ends. 6
: 22 mm

W1V1-02-08-004

3. Remove the floor mat. Remove bolts (7) (2 used).

Remove pilot shut-off solenoid valve (5) from the
main frame.
: 17 mm

W1V1-02-08-003

W2-8-1
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
Installation
7
1. Install pilot shut-off solenoid valve (5) to the main
frame with bolts (7) (2 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

W1V1-02-08-003

3
2. Connect hoses (3) (9 used), pipes (4) (2 used) 4
and harness (6) to pilot shut-off solenoid valve 5
(5).
: 22 mm
: 48.5 N m (4.9 kgf m, 36 lbf ft)

W1V1-02-08-004

3. Install cover (2) to the main frame with bolts (1) 1 Main Frame
(6 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

2 W1V1-02-08-002

ZX110-3 class, 120-3 class

Main Frame 1 2

W1R7-02-07-002
ZX135US-3 class

W2-8-2
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
(Blank)

W2-8-3
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
DISASSEMBLY OF PILOT SHUT-OFF
SOLENOID VALVE

W1V1-02-08-001

1- Socket Bolt (2 Used) 3- O-Ring 5- Spool 7- O-Ring

2- Solenoid 4- Body 6- Spring 8- Plug

W2-8-4
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
Disassembly of Pilot Shut-Off Solenoid Valve

1. Put the matching marks on body (4) and solenoid

(2). Secure body (4) in a vise. Remove socket
bolts (1) (2 used). Remove solenoid (2) and
O-ring (3) from body (4).
: 4 mm

2. Remove plug (8) from body (4). Remove O-ring

(7) from plug (8).
: 6 mm

3. Remove spring (6) and spool (5) from body (4).

W2-8-5
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
ASSEMBLY OF PILOT SHUT-OFF
SOLENOID VALVE

2
1
3

7
8

T1V1-03-07-012

1- Socket Bolt (2 Used) 3- O-Ring 5- Spool 7- O-Ring

2- Solenoid 4- Body 6- Spring 8- Plug

W2-8-6
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
Assembly of Pilot Shut-Off Solenoid Valve

1. Secure body (4) in a vise. Insert spool (5) and

spring (6) into body (4).

2. Install O-ring (7) to plug (8). Install plug (8) to

body (4).
: 6 mm
: 26.5±2.7 N m
(2.7±0.3 kgf m, 20±2 lbf ft)

3. Install O-ring (3) to solenoid (2). Align the

matching marks on body (4) and solenoid (2).
Install solenoid (2) to body (4).
NOTE: When solenoid (2) is installed after
installing O-ring (3) to body (4), O-ring (3)
may be damaged.

4. Install solenoid (2) to body (4) with socket bolts

(1) (2 used).
: 4 mm
: 3.9 N m
(0.4 kgf m, 3 lbf ft)

W2-8-7
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
(Blank)

W2-8-8
 UPPERSTRUCTURE / Signal Control Valve
REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE
(ZX110-3 CLASS, 120-3 CLASS)
1 2
CAUTION: Bleed air from the hydraulic oil Machine
tank before doing any work. (Refer to BLEED Front
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

1. Remove bolts (1) (8 used). Remove cover (2) from

the upper side of the machine.
: 17 mm

2. Remove bolts (3) (3 used). Remove support (4)

W1R7-02-05-001
from the support.
3 4
: 17 mm Machine Front

Support
3. Disconnect all hoses (7) and connectors (6) (2 5
used) from signal control valve (5). Attach an
identification tag onto the disconnected hoses (7)
for assembling. Cap the open ends.
: 17 mm, 19 mm
6

4. Remove bolts (8) (3 used). Remove the signal

control valve (5) assembly from the control valve.
W1R7-02-09-001
: 22 mm
5 7 Control Valve
Machine
5. Remove socket bolts (9) (4 used). Remove signal Front
control valve (5) from plate (10).
: 8 mm

W1R7-02-05-003

5 7
Control Valve

10 9 8 W1V1-02-09-005

W2-9-1
 UPPERSTRUCTURE / Signal Control Valve
Installation 5 7
Control Valve
1. Install signal control valve (5) to plate (10) with
socket bolts (9) (4 used).
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

2. Install the signal control valve (5) assembly to the

control valve with bolts (8) (3 used).
: 22 mm
: 140 N·m (14 kgf·m, 103 lbf·ft)
10 9 8 W1V1-02-09-005

3. Connect all hoses (7) and connectors (6) (2 used) 5 7 Control Valve
to signal control valve (5). Machine
: 17 mm Front
: 9.8 N·m (1 kgf·m, 7 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)

4. Install support (4) to the support with bolts (3) (3

used).
: 17 mm W1R7-02-05-003
: 50 N·m (5 kgf·m, 37 lbf·ft) 3 4
Machine Front

Support
5. Install cover (2) to the upper side of the machine
5
with bolts (1) (8 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-09-001
1 2
Machine
Front

W1R7-02-05-001

W2-9-2
 UPPERSTRUCTURE / Signal Control Valve
REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE (ZX135US-3
CLASS)
1

CAUTION: Bleed air from the hydraulic oil 2

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
3
1. Open cover (1). Remove bolts (3) (5 used).
Remove cover (2) from the main frame. Main Frame
: 17 mm

W1R7-04-01-005

4 5 6
2. Disconnect all hoses (6) and connectors (4) (2
used) from signal control valve (5). Attach an
identification tag onto the disconnected hoses (6)
for assembling. Cap the open ends.
: 17 mm, 19 mm

3. Remove socket bolts (7) (4 used). Remove signal

control valve (5) from the main frame.
: 8 mm

Main Frame
7 W1R7-02-09-002

W2-9-3
 UPPERSTRUCTURE / Signal Control Valve
Installation

1. Install signal control valve (5) to the main frame 4 5 6

with socket bolts (7) (4 used).
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

2. Connect all hoses (6) and connectors (4) (2 used)

to signal control valve (5).
: 17 mm
: 9.8 N·m (1 kgf·m, 7 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
Main Frame
7 W1R7-02-09-002

3. Install cover (2) to the main frame with bolts (3) (5 1

used). Shut cover (1).
: 17 mm 2
: 50 N·m (5 kgf·m, 37 lbf·ft)

Main Frame

W1R7-04-01-005

W2-9-4
 UPPERSTRUCTURE / Signal Control Valve

Pilot Valve Side PH

A
M
C
B
E
SB
D
H G
F N

PI
Pilot Valve Side I
K J
SH DF

20 W1R7-02-09-004
SA L

Pilot valve side

Port Name Connected to Remark
Port A Right pilot valve Boom raise pilot pressure
Port B Right pilot valve Boom lower pilot pressure
Port C Left pilot valve Arm roll-out pilot pressure
Port D Left pilot valve Arm roll-in pilot pressure
Port E Left pilot valve Left swing pilot pressure
Port F Left pilot valve Right swing pilot pressure
Port G Right pilot valve Bucket roll-in pilot pressure
Port H Right pilot valve Bucket roll-out pilot pressure
Port I Travel pilot valve Left travel forward pilot pressure
Port J Travel pilot valve Left travel reverse pilot pressure
Port K Travel pilot valve Right travel forward pilot pressure
Port L Travel pilot valve Right travel reverse pilot pressure
Port M Auxiliary pilot valve (optional) Auxiliary pilot pressure
Port N Auxiliary pilot valve (optional) Auxiliary pilot pressure
Port SA Pump 1 regulator Pump 1 control pressure
Port SB Pump 2 regulator Pump 2 control pressure
Port PI Pilot shut-off valve Primary pilot pressure
Port PH - Plug
Port SH Swing parking brake Brake release pressure
Port DF Hydraulic oil tank Returning to hydraulic oil tank

W2-9-5
 UPPERSTRUCTURE / Signal Control Valve

Control Valve Side

SM
3
1 5
13
4
2
SK SE
7 8
14 6
Pressure Sensor (Swing)
9
Control Valve Side SN
11
10
SL

Pressure Sensor (Travel) 20 12 SP W1R7-02-09-003

Control valve side

Port Name Connected to Remark
Port 1 Control valve Boom raise pilot pressure
Port 2 Control valve Boom lower pilot pressure
Port 3 Control valve Arm roll-out pilot pressure
Port 4 Control valve Arm roll-in pilot pressure
Port 5 Control valve Left swing pilot pressure
Port 6 Control valve Right swing pilot pressure
Port 7 Control valve Bucket roll-in pilot pressure
Port 8 Control valve Bucket roll-out pilot pressure
Port 9 Control valve Left travel forward pilot pressure
Port 10 Control valve Left travel reverse pilot pressure
Port 11 Control valve Right travel forward pilot pressure
Port 12 Control valve Right travel reverse pilot pressure
Port 13 Control valve Auxiliary pilot pressure
Port 14 Control valve Auxiliary pilot pressure
Port SE - Plug
Port SM Hydraulic oil tank Returning to hydraulic oil tank
Port SN - Plug
Port SP Solenoid valve unit Returning to hydraulic oil tank
Port SL Control valve Flow combiner valve control pressure
Port SK Control valve Bucket flow rate control valve control pressure

W2-9-6
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-9-7
 UPPERSTRUCTURE / Signal Control Valve
STRUCTURE OF SIGNAL CONTROL
VALVE
4 13

12

7
11
7

4
10

9
7 8
7 7

4
4

W1JB-02-10-002

W2-9-8
 UPPERSTRUCTURE / Signal Control Valve

15

14 16
17
18
19
16 20
17
21
19
16 20
17
18
19
20

14
22
23
24
25

26
27
19
28
17
16
20 29
19
18 14
5 17
20 16
19
21
17
20 16
19
18
17
16 W1JB-02-10-003

Detail of Body 2 (5)

1- Bolt (3 Used) 9- Body 3 16 - Plug (7 Used) 23 - O-Ring

2- Body 1 10 - Gasket 17 - O-Ring (7 Used) 24 - Shuttle Valve
3- Gasket 11 - Body 4 18 - Spring (4 Used) 25 - O-Ring
4- Filter (17 Used) 12 - Gasket 19 - Spring Guide (7 Used) 26 - Spring
5- Body 2 13 - Body 5 20 - Spool (6 Used) 27 - Spool
6- Gasket 14 - Socket Bolt (11 Used) 21 - Spring (2 Used) 28 - Spring
7- Shuttle Valve (2 Used) 15 - Plate 22 - Plate 29 - Plate
8- Spring (4 Used)

W2-9-9
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-9-10
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
REMOVAL AND INSTALLATION OF
2-SPOOL SOLENOID VALVE UNIT
(ZX110-3 CLASS, 120-3 CLASS)
IMPORTANT: Bleed air from the hydraulic oil tank
before doing any work. (Refer to
BLEED AIR FROM HYDRAULIC OIL
1 2
TANK on W1-4-1.)

Removal
1. Remove bolts (1) (8 used). Remove cover (2)
Machine Front
from the upper side of the machine.
: 17 mm

2. Disconnect all hoses (7), pipes (5) and

connectors (4) (2 used) from 2-spool solenoid
valve unit (3). Attach an identification tag onto
disconnected hoses (7) and pipes (5) for
assembling. Cap the open ends.
: 17 mm, 19 mm W1R7-02-05-001

3
3. Remove socket bolts (6) (2 used). Remove
2-spool solenoid valve unit (3) from the control
valve.
: 8 mm

5
7

W1R7-02-10-001
6 Control Valve

W2-10-1
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
Installation 3
1. Install 2-spool solenoid valve unit (3) to the
control valve with socket bolts (6) (2 used).
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)

2. Connect all hoses (7), pipes (5) and connectors

(4) (2 used) to 2-spool solenoid valve unit (3). 4
: 17 mm
: 25 N m (2.5 kgf m, 18 lbf ft) 5
: 19 mm 7
: 30 N m (3 kgf m, 22 lbf ft)
W1R7-02-10-001
6 Control Valve
3. Install cover (2) with bolts (1) (8 used). Unlock
and shut the engine cover. 1 2
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

Machine Front

W1R7-02-05-001

W2-10-2
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
REMOVAL AND INSTALLATION OF
2-SPOOL SOLENOID VALVE UNIT
1
(ZX135US-3 CLASS)
IMPORTANT: Bleed air from the hydraulic oil tank 2
before doing any work. (Refer to
BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal 3
1. Open cover (1). Remove bolts (3) (5 used).
Remove cover (2) from the main frame.
: 17 mm

2. Disconnect all hoses (8), pipes (6) and W1R7-04-01-005

connectors (5) (2 used) from 2-spool solenoid Main Frame

valve unit (3). Cap the open ends. Attach an
identification tag onto disconnected hoses (8) and
pipes (5) for assembling. 4
: 17 mm, 19 mm

3. Remove socket bolts (7) (2 used). Remove

2-spool solenoid valve unit (3) from the control
valve.
: 8 mm
5

6
8

W1R7-02-10-001
7 Control Valve

W2-10-3
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
Installation
1. Install 2-spool solenoid valve unit (3) to the 4
control valve with socket bolts (7) (2 used).
: 8 mm
: 50 N m (5 kgf m, 37 lbf ft)

2. Connect all hoses (8), pipes (6) and connectors

(5) (2 used) to 2-spool solenoid valve unit (3).
: 17 mm 5
: 25 N m (2.5 kgf m, 18 lbf ft)
: 19 mm 6
: 30 N m (3 kgf m, 22 lbf ft) 8

3. Install cover (2) to the main frame with bolts (3) (5 W1R7-02-10-001
7 Control Valve
used). Shut cover (1).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 1

W1R7-04-01-005

Main Frame

W2-10-4
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
(Blank)

W2-10-5
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
STRUCTURE OF 2-SPOOL SOLENOID
VALVE UNIT
1

3 B
2 4 2

A 3 3

7
5, 6
8 1

Section A-A

W1R7-02-10-002

9 10 11 12 13 14 15 16 17 18 19 20 21 22

27 26 25 24 23

33 32 31 30 29 3 28
34
W1R7-02-10-003
Section B

W2-10-6
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) Nm (kgf m) (lbf ft)
1 Plug 5 :6
2 Plug 3 :8
3 Socket bolt 4 : 2.5 5+20 (0.5+0.20) (4+10)
4 Body (2-spool solenoid valve) 1
5 Filter 1
6 Plug 1 : 10 20+50 (2+0.50) (15+40)
7 Solenoid 2
8 Orifice 2 :6 10+30 (1+0.30) (7+20)
9 Adjusting screw 1
10 Nut 1
11 Spacer 1
12 O-ring 1
13 Solenoid 1
14 Coil 1
15 Flange 1
16 O-ring 1
17 Diaphragm 1
18 O-ring 1
19 Spring 1
20 Spool 1
21 Orifice 1
22 Wave spring 1
23 Plate 1
24 O-ring 1
25 O-ring 1
26 Sleeve 1
27 O-ring 1
28 Washer 1
29 O-ring 1
30 Spacer 1
31 Plunger 1
32 Spring 1
33 O-ring 1
34 Socket 1

W2-10-7
 UPPERSTRUCTURE / 2-Spool Solenoid Valve Unit
(Blank)

W2-10-8
 UPPERSTRUCTURE / Engine
REMOVAL AND INSTALLATION OF
ENGINE
(ZX110-3 CLASS, 120-3 CLASS)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
CAUTION: Counterweight (1) weight: 1
ZX110-3 class: 1850 kg (4080 lb)
ZX120-3 class: 2500 kg (5520 lb)
2
1. Remove counterweight (1) from main frame (2).
(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)

2. Open and lock the cover in the air cleaner

compartment. Loosen cock (3). Drain off coolant
from the radiator. Close cock (3).
W1R7-02-02-002
Radiator

3 W1R7-02-11-001

IMPORTANT: Remove and install the engine after

disconnecting ground (5) of batteries
(4) (2 used) from main frame (2).
When harness of the starter is
disconnected or connected while
batteries (4) (2 used) are connected
to ground (5), the circuit may short. 2
3. Remove nut (6) from ground (5). Disconnect
ground (5) from main frame (2).

W1R7-02-11-002
5, 6 4

W2-11-1
 UPPERSTRUCTURE / Engine
4. Remove bolts (8) (4 used) from cover (7) under
the radiator. Remove cover (7) from main frame 2 7 8
(2).
: 17 mm

W1R7-02-11-003

5. Remove bolts (9) (6 used) from cover (10) under 2 9 10

the engine. Remove cover (10) from main frame
(2).
: 17 mm

W1R7-02-11-004

6. Remove bolts (11) (6 used) from cover (12) under

the pump device. Remove cover (12) from main 2 11 12
frame (2).
: 17 mm

W1R7-02-11-005

W2-11-2
 UPPERSTRUCTURE / Engine

CAUTION: Engine cover (13) weight: 24 kg 13

(53 lb)
14
7. Attach a nylon sling onto engine cover (13). Hoist
and hold engine cover (13).

8. Open and lock engine cover (13). Remove pin

(14) and washer (15) from stay (16). Remove stay
15
(16) from engine cover (13).

16

W1R7-02-11-006

9. Remove bolts (18) (4 used) and washers (19) (4 13 17 18, 19

used) from hinges (17) (2 used). Hoist and
remove engine cover (13) from the upper side of
the machine.
: 17 mm

W1R7-02-11-007

10. Remove bolts (20) (11 used). Remove cover (21) 20 21

from the upper side of the machine.
: 17 mm

W1R7-02-04-001

W2-11-3
 UPPERSTRUCTURE / Engine
11. Attach a nylon sling onto muffler (22). Hoist and
hold muffler (23). Remove U-nuts (23) (2 used), 22 23, 24, 25 26
nuts (24) (8 used) and washers (25) (4 used) from
muffler bracket (26).
: 17 mm

12. Remove bolts (29) (2 used) and clamp (27) from

muffler (22). Hoist and remove muffler (22) from 27
exhaust pipe (28).
: 19 mm
28
31

30 29 W1R7-02-04-003

13. Attach a nylon sling onto the cover (31) assembly.

Remove bolts (32) (4 used) from the cover (33) 32
side. Remove bolts (30) (3 used) from the cover
33
(31) side. Hoist and remove the cover (31)
assembly. 31
: 17 mm

W1R7-02-04-004

W2-11-4
 UPPERSTRUCTURE / Engine
14. Remove bolts (34) (3 used). Remove muffler
bracket (26) from pump device (35).
: 17 mm 26 34 35

W1R7-02-04-005

15. Disconnect hoses (36) (11 used), pipe (38), and 36 35

harness (37) from pump device (35). Cap the
disconnected hose (36) and pipe (38).
: 17 mm, 19 mm, 27 mm, 36 mm
: 8 mm, 10 mm

CAUTION: Pump device (35) weight: 95 kg

(210 lb)

16. Install the eyebolt (ST 0002) to pump device (35).

Hoist and hold pump device (35).

17. Remove other bolts (34) (5 used). Hoist and 38 37 W1R7-02-04-006

remove pump device (35) from the engine.

: 17 mm

W2-11-5
 UPPERSTRUCTURE / Engine
18. Remove bolts (40) (2 used) from support (39).
Remove support (39) from the upper side of the
engine.

Engine

W1R7-02-11-008
40 39

19. Remove bolts (50) (2 used) from pipe (41).

Loosen bands (44, 47). Disconnect hoses (45, 46)
from the intercooler and the turbocharger. 41
: 17 mm 45

20. Loosen band (42) of hose (43). Disconnect hose

(43) from the turbocharger.

44

43 42 W1T1-02-10-014

21. Loosen bands (48) (2 used) of hose (49). Engine 41 46 47

Disconnect hose (49) from the engine and the
radiator.
: 17 mm

W1R7-02-11-009
50 49 48

W2-11-6
 UPPERSTRUCTURE / Engine
22. Loosen band (53) of hose (52) under the radiator.
Disconnect hose (52) from the radiator. Loosen 51 52
band (54) of hose (51). Disconnect hose (51) from
the radiator.

54 53 W1R7-02-11-010

23. Remove cover (57) from starter (59). Remove 55 56

nuts (58) (2 used) from starter (59). Disconnect
harnesses (55, 56) from starter (59).
: 17 mm 57, 58

59

W1T1-02-10-017

24. Remove nuts (62) (2 used) from alternator (60).

Disconnect harnesses (63) (2 used) from
alternator (60). Disconnect connector (61).
: 13 mm 60

62, 63
61

W1T1-02-10-018

W2-11-7
 UPPERSTRUCTURE / Engine
25. Loosen belt tension adjusting bolt (65) of
compressor (64). Attach a nylon sling onto
compressor (64). Hoist and hold compressor (64).
Disconnect connector (68) from compressor (64).
Remove socket bolts (66) (4 used) from
compressor (64). Remove belt (67) and
compressor (64) from the engine.
: 6 mm
NOTE: Remove and install compressor (64) with
compressor (64) hoisted outside the engine
compartment.

65 64 W1R7-02-11-011

66

68 64

67

Engine W1T1-02-10-020

26. Remove bolt (69) from main frame (2) under the 69
engine. Disconnect connectors (70) (5 used) from
the lower side of the engine.
70

2
W1R7-02-11-012

W2-11-8
 UPPERSTRUCTURE / Engine
27. Loosen band (72) and bands (76) (2 used) of hose
(71) and hoses (75) (2 used) from the
counterweight mounting side of the engine.
Remove bolt (74) from clamp (73). Disconnect
hose (71) and hoses (72) (2 used) from the engine.
Cap the open ends. 75, 76
: 17 mm
71, 72

73, 74

W1T1-02-10-028

Engine
28. Disconnect connector (77) from main frame (2)
under the engine.

29. Loosen band (78) of hose (79). Disconnect hose 79

(79) from the engine.
78

W1T1-02-10-023
2 77

Engine
30. Disconnect hoses (80) (2 used) from the engine.
Cap the open ends.
: 19 mm
84

31. Remove bolt (82) from clamp (81). Loosen band

(84) of hose (83). Disconnect hose (83) from the 83
engine.
: 17 mm, 19 mm

W1T1-02-10-029
81, 82 80

W2-11-9
 UPPERSTRUCTURE / Engine
32. Loosen band (85) of rubber (87). Remove rubber
(87) from shroud (86). 85 86

87

W1T1-02-10-024

33. Remove nuts (89) (2 used) and washers (88) (2

used) from main frame (2) at the pump device
side. Remove engine brackets (90) (2 used) from
the engine.
: 19 mm, 24 mm

34. Remove nuts (89) (2 used) and washers (88) (2 Engine

used) from main frame (2) at the radiator side.
: 24 mm

90

88
88 89
W1R7-02-11-025
89

W2-11-10
 UPPERSTRUCTURE / Engine

CAUTION: Engine weight: 320 kg (710 lb) 91

IMPORTANT: Before hoisting the engine, check

that there is no hose, pipe, and
harness with the engine attached. If Lifting Hole
hoisting the engine with them
connected, the engine may be
damaged.
Pump
35. Install shackles (2 used) to the lifting hole (2 Device Side
places) on the engine. Attach a wire rope onto Lifting Hole
shackles (2 used). Hoist and hold the engine.
Adjust the rope length and make the engine
horizontal.

36. Hoist the engine about 15 mm in vertical direction Upper Side of Engine W1R7-02-11-013

while holding in a horizontal position. Move the

engine to the pump device side horizontally until
fan guard (91) of the engine can be removed from
shroud (87). Hoist and remove the engine from
the machine. 87

W1T1-02-10-024

W2-11-11
 UPPERSTRUCTURE / Engine
Installation
91

CAUTION: Engine weight: 320 kg (710 lb)

Lifting Hole
1. Install shackles (2 used) and attach a wire rope to
the lifting hole (2 places) on the engine. Hoist the
engine. Adjust the wire rope length and make the Pump
Device Side
engine horizontal. Lifting Hole

2. Insert fan guard (91) of the engine into shroud

(87). Lower the engine on the machine.

Upper Side of Engine W1R7-02-11-013

87

3. Install engine brackets (90) (2 used) at the pump

device side to main frame (2) with washers (88) (2
used) and nuts (89) (2 used). W1T1-02-10-024
: 19 mm
: 110 N m (11 kgf m, 81 lbf ft)
: 24 mm
: 240 N m (24 kgf m, 177 lbf ft)

4. Install washers (88) (2 used) and nuts (89) (2

used) to main frame (2) at the radiator side.
: 24 mm
: 240 N m (24 kgf m, 177 lbf ft)

90

88
88 89
W1R7-02-11-025
89

W2-11-12
 UPPERSTRUCTURE / Engine
5. Secure rubber (87) to shroud (86) with band (85). 85 86

87

W1T1-02-10-024

6. Connect connector (77) to the lower side of the

engine. Connect hose (79) to the engine. Secure
hose (79) with band (78).
79

78

W1T1-02-10-023
2 77

7. Connect hoses (72) (2 uses) and hose (71) to the

counterweight mounting side of the engine.
Secure hoses (72) (2 used) and hose (71) with
bands (76) (2 used) and band (72). Install clamp 75, 76
(73) to the engine with bolt (74).
71, 72

73, 74

W1T1-02-10-028

W2-11-13
 UPPERSTRUCTURE / Engine
8. Connect hoses (80) (2 used) to the engine. Engine
: 19 mm
: 29.5 N m (3 kgf·m, 22 lbf·ft)
84
9. Connect hose (83) to the engine. Secure hose
(83) with band (84). Install clamp (81) to the
engine with bolt (82). 83
: 17 mm
: 50 N m (5 kgf·m, 37 lbf·ft)

W1T1-02-10-029
81, 82 80

69
10. Connect connectors (70) (5 used) to the lower
side of the engine.
70
11. Connect connectors (70) (5 used) to main frame
(2) under the engine with bolt (69).
: 17 mm
: 50 N m (5 kgf·m, 37 lbf·ft)

2
W1R7-02-11-012

W2-11-14
 UPPERSTRUCTURE / Engine
12. Attach belt (67) onto the compressor (64) pulley.
Install compressor (64) to the engine with socket
bolts (66) (4 used). Connect connector (68) to
compressor (64).
66
: 6 mm
: 20 N m (2 kgf m, 15 lbf·ft)
68 64

67

W1T1-02-10-020

13. Adjust belt tension (A) between the crank pulley

and the compressor pulley with bolt (65).
NOTE: Tension (A): 8 to 12 mm (0.3 to 0.5 in) (98
N m (10 kgf m, 72 lbf ft))

65 64 W1R7-02-11-011

Tension Pulley Compressor

Pulley
Fan Pulley

150

A
Crank Pulley
W1T1-02-10-030

W2-11-15
 UPPERSTRUCTURE / Engine
14. Connect harnesses (63) (2 used) to alternator (60)
with nuts (62) (2 used). Connect connector (61).
: 13 mm
: 20 N m (2 kgf m, 15 lbf ft) 60

62, 63
61

W1T1-02-10-018

55 56
15. Connect harnesses (55, 56) to starter (59) with
nuts (58) (2 used). Install cover (57) to the terminal
of starter (59). 57, 58
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)
59

W1T1-02-10-017

16. Connect hoses (51, 52) to the radiator. Secure 51 52

hoses (51, 52) with bands (53, 54).

54 53 W1R7-02-11-010

W2-11-16
 UPPERSTRUCTURE / Engine
17. Connect hose (49) to the engine and the radiator.
Secure hose (49) with bands (48) (2 used). Engine 41 46 47

W1R7-02-11-009
50 49 48

18. Connect hose (43) to the turbocharger. Secure

41
hose (43) with band (42).
45
19. Connect hose (45) to the turbocharger. Secure
hose (45) with band (44). Connect hose (46) to
the intercooler. Secure hose (46) with band (47).
Secure pipe (41) with bolts (50) (2 used).
44
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

43 42 W1T1-02-10-014

20. Install support (39) to the upper side of the engine

with bolts (40) (2 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)
Engine

W1R7-02-11-008
40 39

W2-11-17
 UPPERSTRUCTURE / Engine

CAUTION: Pump device (35) weight: 95 kg 26 34 35

(210 lb)

21. Install the eyebolt (ST 0002) to pump device (35).

Hoist pump device (35).

22. Install pump device (35) and muffler bracket (26)

to the engine with bolts (34) (8 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-005

36 35
23. Connect hoses (36) (11 used), pipe (38) and
harness (37) to pump device (35).
: 17 mm
: 9.8 N·m (1 kgf·m, 7 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 27 mm
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 129 lbf·ft)
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 38 37 W1R7-02-04-006

: 10 mm
: 90 N·m (9 kgf·m, 66 lbf·ft)

W2-11-18
 UPPERSTRUCTURE / Engine
24. Attach a nylon sling onto the cover (31) assembly. 32
Hoist the cover (31) assembly. Install the cover
(31) assembly with bolts (30) (3 used) and (32) (4
used).
: 17 mm 31
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-004

25. Attach a nylon sling onto muffler (22). Hoist 22 23, 24, 25 26
muffler (22). Install muffler (22) to exhaust pipe
(28) with clamp (27) and bolts (29) (2 used).
: 19 mm
: 90 N·m (9 kgf·m, 66 lbf·ft)

26. Install U-nuts (23) (2 used) to muffler bracket (26) 27

with nuts (24) (8 used) and washers (25) (4 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 28
31

30 29 W1R7-02-04-003

27. Install cover (21) to the upper side of the machine 20 21

with bolts (20) (11 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-001

W2-11-19
 UPPERSTRUCTURE / Engine

CAUTION: Engine cover (13) weight: 24 kg 13 17 18, 19

(53 lb)

28. Install engine cover (13) to the upper side of the

machine with hinges (17) (2 used), bolts (18) (4
used), and washers (19) (4 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

W1R7-02-11-007

29. Install stay (16), washer (15) and pin (14) to cover
13
(13).

14

15

16

W1R7-02-11-006

W2-11-20
 UPPERSTRUCTURE / Engine
30. Install cover (12) to main frame (2) with bolts (11)
(6 used). 2 11 12
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

W1R7-02-11-005

31. Install cover (10) to main frame (2) with bolts (9) (6 2 9 10
used). At this time, check that a hose is extended
through the hole of cover (10).
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

Hose W1R7-02-11-004

32. Install cover (7) to main frame (2) with bolts (8) (4 2 7 8
used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

W1R7-02-11-003

W2-11-21
 UPPERSTRUCTURE / Engine
33. Connect ground (5) to main frame (2) with nut (6).
: 17 mm
: 50 N m (5 kgf m, 37 lbf·ft)

CAUTION: Counterweight (1) weight: 2

ZX110-3 class: 1850 kg (4080 lb)
ZX120-3 class: 2500 kg (5520 lb)

34. Install counterweight (1) to main frame (2). (Refer 5, 6

W1R7-02-11-002

to REMOVAL AND INSTALLATION OF

COUNTERWEIGHT on W2-2-1.)
1
35. Add coolant to the radiator.

W1R7-02-02-002

W2-11-22
 UPPERSTRUCTURE / Engine
REMOVAL AND INSTALLATION OF
ENGINE (ZX135US-3 CLASS)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

CAUTION: Counterweight (1) weight: 3680 kg 1

(8120 lb)

1. Remove counterweight (1) from main frame (2).

(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)

W1R7-02-02-004

Radiator
2. Open and lock the cover in the air cleaner
compartment. Loosen cock (3). Drain off coolant
from the radiator. Close cock (3).

3
W1R7-02-11-001

4
IMPORTANT: Remove and install the engine after
disconnecting ground (5) of batteries
(4) (2 used) from main frame (2).
When harness of the starter is
disconnected or connected while
batteries (4) (2 used) are connected
to ground (5), the circuit may short.
3. Remove nut (6) from ground (5). Disconnect
ground (5) from main frame (2).
: 17 mm

6 5 2 W1R7-02-11-014

W2-11-23
 UPPERSTRUCTURE / Engine
4. Remove bolts (7) (6 used) from cover (8) under
the radiator. Remove cover (8) from main frame
(2). 7 8
: 17 mm

W1R7-02-11-015

5. Remove bolts (9) (4 used) from cover (10) under 9 10

the engine. Remove cover (10) from main frame
(2).
: 17 mm

W1R7-02-11-016

2
11 12 2
6. Remove bolts (11) (6 used) from cover (12) under
the pump device. Remove cover (12) from main
frame (2).
: 17 mm

W1R7-02-11-017

W2-11-24
 UPPERSTRUCTURE / Engine
7. Attach a nylon sling onto engine cover (13). Hoist
13
and hold engine cover (13).
: 17 mm
14
8. Open and lock engine cover (13). Remove pin
(14) and washer (15) from stay (16). Remove stay
(16) from engine cover (13).

15

16

W1R7-02-11-006

13
9. Remove bolts (18) (4 used) and washers (19) (4
used) from hinges (17) (2 used). Hoist and
remove engine cover (13) from the upper side of
the machine.
: 17 mm
17

18, 19 W1R7-02-11-018

20 21
10. Remove bolts (23) (3 used). Remove cover (22)
from cover (21).
: 17 mm

11. Remove bolts (20) (10 used). Remove cover (21)

from the upper side of the machine.
22
: 17 mm

W1R7-02-04-002
23

W2-11-25
 UPPERSTRUCTURE / Engine
12. Remove bolts (26) (5 used). Remove bracket (24)
from bracket (25).
24 25 26
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-007

13. Attach a nylon sling onto muffler (27). Hoist and

hold muffler (27). Remove U-nuts (28) (2 used), 27 28, 29, 30
nuts (29) (8 used), and washers (30) (4 used) from
muffler bracket (31).
: 17 mm 31

14. Remove bolts (33) (2 used) and clamp (32) from

muffler (27). Remove muffler (27) from exhaust
pipe (34). 32
: 19 mm

15. Remove bolt (35) from bracket (36). 33

: 17 mm
34
16. Remove bolts (38) (2 used). Remove bracket (37)
from bracket (36). 36 35 W1R7-02-04-008

: 17 mm
36 37

38 W1R7-02-04-009

W2-11-26
 UPPERSTRUCTURE / Engine
17. Remove bolts (39) (2 used). Remove bracket (36) 39 36 40, 41
from bracket (40).
: 17 mm
39

18. Remove bolt (41) of bracket (40) from the engine

side. Remove bracket (40) from the engine
bracket.
: 17 mm

W1R7-02-04-010
31 42 43

19. Remove bolts (42) (3 used). Remove muffler

bracket (31) from pump device (43).
: 17 mm

20. Disconnect hoses (44) (11 used), pipe (46), and

harness (45) from pump device (43). Cap the
disconnected hose (44) and pipe (46).
: 17 mm, 19 mm, 27 mm, 36 mm
: 8 mm, 10 mm
W1R7-02-04-005

CAUTION: Pump device (43) weight: 95 kg 44 45

(210 lb)

21. Install the eyebolt (ST 0002) to pump device (43).

Hoist and hold pump device (43).

43
22. Remove other bolts (42) (5 used). Hoist and
remove pump device (43) from the engine.
: 17 mm

46 W1R7-02-04-011

Radiator

23. Remove bolts (47) (4 used). Remove step (48)

from the radiator.
: 17 mm

48 47 W1R7-02-11-019

W2-11-27
 UPPERSTRUCTURE / Engine
24. Remove bolts (49) (7 used) from supports (50, 51
and 52). Remove supports (50, 51 and 52) from 49 50
the upper side of the engine.
: 17 mm
52
51

W1R7-02-11-020

54
25. Remove bolts (62) (2 used) from pipe (54).
53
Loosen bands (57, 59). Disconnect hoses (53, 58)
from the intercooler and the turbocharger.
: 17 mm

26. Loosen band (55) of hose (56). Disconnect hose

(56) from the turbocharger.

57

56 55 W1T1-02-10-014

27. Loosen bands (60) (2 used) of hose (61). Engine 54 58 59

Disconnect hose (61) from the engine and the
radiator.
: 17 mm

W1R7-02-11-009
62 61 60

W2-11-28
 UPPERSTRUCTURE / Engine
28. Loosen band (65) of hose (64) under the radiator.
Disconnect hose (64) from the radiator. Loosen 63 64
band (66) of hose (63). Disconnect hose (63) from
the radiator.

66 65 W1R7-02-11-010

29. Remove cover (69) from starter (71). Remove 67 68

nuts (70) (2 used) from starter (71). Disconnect
harnesses (67, 68) from starter (71). 69, 70
: 17 mm

71

W1T1-02-10-017

30. Remove nuts (74) (2 used) from alternator (72).

Disconnect harnesses (75) (2 used) from
alternator (72). Disconnect connector (73). 72
: 13 mm
74, 75
73

W1T1-02-10-018

W2-11-29
 UPPERSTRUCTURE / Engine
31. Loosen belt tension adjusting bolt (77) of
compressor (76). Attach a nylon sling onto
compressor (76). Hoist and hold compressor (76).
Disconnect connector (80) from compressor (76).
Remove socket bolts (78) (4 used) from
compressor (76). Remove belt (79) and
compressor (76) from the engine.
: 6 mm
NOTE: Remove and install compressor (76) with
compressor (76) hoisted outside the engine
compartment.

77 76 W1R7-02-11-011

78

80 76

79

Engine W1T1-02-10-020

32. Remove bolt (82) from main frame (2) under the 81
engine. Disconnect connectors (81) (5 used) from
the lower side of the engine.

82 W1R7-02-11-021

W2-11-30
 UPPERSTRUCTURE / Engine
33. Loosen band (84) and bands (88) (2 used) of hose Engine
(83) and hoses (87) (2 used) from the
counterweight mounting side of the engine.
Remove bolt (86) from clamp (85). Disconnect 83, 84
hose (83) and hoses (87) (2 used) from the engine. 87, 88
Cap the open ends.
: 17 mm

85, 86
W1R7-02-11-022

34. Loosen band (89) of hose (90). Disconnect hose Engine

(90) from the engine.

90

89

W1R7-02-11-023

35. Remove bolt (91) and clamp (92) from harness 91, 92
(93) of main frame (2).
: 17 mm
2

93 W1R7-02-11-024

W2-11-31
 UPPERSTRUCTURE / Engine
36. Disconnect hoses (94) (2 used) from the engine. Engine
Cap the open ends.
: 19 mm
98

37. Remove bolt (96) from clamp (95). Loosen band 97

(98) of hose (97). Disconnect hose (97) from the
engine.
: 17 mm, 19 mm

38. Loosen band (99) of rubber (101). Remove rubber

(101) from shroud (100). W1T1-02-10-029
95, 96 94

99 100

101

W1T1-02-10-024

W2-11-32
 UPPERSTRUCTURE / Engine
39. Remove nuts (103) (2 used) and washers (102) (2
used) from main frame (2) at the pump device
side. Remove engine brackets (104) (2 used) from
the engine.
: 19 mm, 24 mm

40. Remove nuts (103) (2 used) and washers (102) (2

used) from main frame (2) at the radiator side.
: 24 mm

104

102
102 103
W1R7-02-11-025
103

CAUTION: Engine weight: 320 kg (710 lb)

IMPORTANT: Before hoisting the engine, check

that there is no hose, pipe, and Lifting Hole
harness with the engine attached. If
hoisting the engine with them
connected, the engine may be Pump
damaged. Device Side
Lifting Hole
41. Install shackles (2 used) to the lifting hole (2
places) on the engine. Attach a wire rope onto
shackles (2 used). Hoist and hold the engine.
Adjust the rope length and make the engine
horizontal.
W1R7-02-11-013
Upper Side of Engine

W2-11-33
 UPPERSTRUCTURE / Engine
42. Hoist the engine about 15 mm in vertical direction
while holding in a horizontal position. Move the
engine to the pump device side horizontally until
fan guard (105) of the engine can be removed 101
from shroud (101). Hoist and remove the engine
from the machine.
105

W1T1-02-10-024

W2-11-34
 UPPERSTRUCTURE / Engine
Installation

1. Install shackles (2 used) and attach a wire rope to

the lifting hole (2 places) on the engine. Hoist and
hold the engine. Adjust the wire rope length and
make the engine horizontal. Lifting Hole

Pump
Device Side
Lifting Hole

W1R7-02-11-013
Upper Side of Engine

2. Insert fan guard (105) of the engine into shroud

(101) lower the engine.
101

105

W1T1-02-10-024

W2-11-35
 UPPERSTRUCTURE / Engine
3. Install engine brackets (104) (2 used) at the pump
device side to the main frame (2) with washers
(102) (2 used) and nuts (103) (2 used).
: 19 mm
: 110 N·m (11 kgf·m, 81lbf·ft)
: 24 mm
: 240 N·m (24 kgf·m, 177 lbf·ft)

4. Install washers (102) (2 used) and nuts (103) (2

used) to main frame (2) at the radiator side.
: 27 mm
: 400 N·m (40 kgf·m, 295 lbf·ft)

104

102
102 103
W1R7-02-11-025
103

99 100
5. Secure rubber (100) to shroud (101) with band
(99).
101

W1T1-02-10-024

W2-11-36
 UPPERSTRUCTURE / Engine
6. Connect hose (90) to the engine. Secure hose Engine
(90) with band (89).

90

89

W1R7-02-11-023
Engine

7. Connect hoses (87) (2 uses) and hose (83) to the

counterweight mounting side of the engine.
Secure hoses (87) (2 used) and hose (83) with 83, 84
bands (88) (2 used) and band (84). Install clamp 87, 88
(85) to the engine with bolt (86).

85, 86
W1R7-02-11-022

8. Connect hoses (94) (2 used) to the engine. Engine

: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)

9. Connect hose (97) to the engine. Secure hose 98

(97) with band (98). Install clamp (95) to the
engine with bolt (96). 97
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1T1-02-10-029
95, 96 94

W2-11-37
 UPPERSTRUCTURE / Engine
10. Connect harness (93) to main frame (2) with bolt
(91) and clamp (92). 91, 92
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
2

93 W1R7-02-11-024

11. Connect connectors (81) (5 used) to the lower 81

side of the engine.

12. Connect connectors (81) (5 used) to main frame

(2) under the engine with bolt (82).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 2

82 W1R7-02-11-021

W2-11-38
 UPPERSTRUCTURE / Engine
13. Attach belt (79) onto the compressor (76) pulley.
Install compressor (76) to the engine with socket
bolts (78) (4 used). Connect connector (80) to
compressor (76).
78
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
80 76

79

Engine W1T1-02-10-020

14. Adjust belt tension (A) between the crank pulley

and the compressor pulley with bolt (77).
NOTE: Tension (A): 8 to 12 mm (0.3 to 0.5 in) (98
N·m (10 kgf·m, 72 lbf·ft))

77 76 W1R7-02-11-011

Tension Pulley Compressor

Pulley
Fan Pulley

150

A
Crank Pulley
W1T1-02-10-030

W2-11-39
 UPPERSTRUCTURE / Engine
15. Connect harnesses (75) (2 used) to alternator (72)
with nut (74). Connect connector (73).
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 72

74, 75
73

W1T1-02-10-018

16. Connect harnesses (67, 68) to starter (71) with 67 68

nuts (70) (2 used). Install cover (69) to the terminal
of starter (71).
69, 70
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
71

W1T1-02-10-017

17. Connect hoses (63, 64) to the radiator. Secure 63 64

hoses (63, 64) with bands (65, 66).

66 65 W1R7-02-11-010

W2-11-40
 UPPERSTRUCTURE / Engine
18. Connect hose (61) to the engine and the radiator.
Secure hose (61) with bands (60) (2 used). Engine 54 58 59

W1R7-02-11-009
62 61 60

19. Connect hose (56) to the turbocharger. Secure

hose (56) with band (55).
54
53
20. Connect hose (53) to the turbocharger. Secure
hose (53) with band (57). Connect hose (58) to
the intercooler. Secure hose (58) with band (59).
Secure pipe (54) with bolts (62) (2 used).
57
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

56 55 W1T1-02-10-014

W2-11-41
 UPPERSTRUCTURE / Engine
21. Install supports (50, 51 and 52) to the upper side
of the engine with bolts (49) (7 used). 49 50
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
52
51

W1R7-02-11-020

22. Install step (48) to the radiator with bolts (47) (4 Radiator
used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

48 47 W1R7-02-11-019

W2-11-42
 UPPERSTRUCTURE / Engine

CAUTION: Pump device (43) weight: 95 kg

31 42 43

23. Install the eyebolt (ST 0002) to pump device (43).

Hoist pump device (43).

24. Install pump device (43) and muffler bracket (31)

to the engine with bolts (42) (8 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

25. Connect hoses (44) (11 used), pipe (46), and

harness (45) to pump device (43).
: 17 mm
: 9.8 N·m (1 kgf·m, 7 lbf·ft) W1R7-02-04-005

: 19 mm 44 45
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 27 mm
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 129 lbf·ft)
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 43
: 10 mm
: 90 N·m (9 kgf·m, 66 lbf·ft)

46 W1R7-02-04-011

26. Install brackets (36, 40) to the engine bracket with 39 36 40, 41
bolts (39) (2 used) and bolt (41).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 39

W1R7-02-04-010

W2-11-43
 UPPERSTRUCTURE / Engine
27. Install bracket (37) to bracket (36) with bolts (38) 36 37
(2 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

28. Install bolt (35) to bracket (36).

: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

29. Attach a nylon sling onto muffler (27). Hoist 38 W1R7-02-04-009

muffler (27). Install muffler (27) to exhaust pipe
(34) with clamp (32) and bolts (33) (2 used). 27 28, 29, 30
: 19 mm
: 90 N·m (9 kgf·m, 66 lbf·ft)
31

30. Install U-nuts (28) (2 used) to muffler bracket (31)

with nuts (29) (8 used) and washers (30) (4 used).
: 17 mm 32
: 50 N·m (5 kgf·m, 37 lbf·ft)

33

34

36 35 W1R7-02-04-008

31. Install bracket (24) to bracket (25) with bolts (26)

(5 used). 24 25 26
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-04-007

W2-11-44
 UPPERSTRUCTURE / Engine
32. Install cover (21) to the upper side of the machine
with bolts (20) (10 used).
20 21
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

22
33. Install cover (22) to cover (21) with bolts (23) (3
used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

23 W1R7-02-04-002

W2-11-45
 UPPERSTRUCTURE / Engine
13
34. Install engine cover (13) on the upper side of the
machine with hinges (17) (2 used), bolts (18) (4
used), and washers (19) (4 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
17

18, 19 W1R7-02-11-018

35. Install stay (16), washer (15), and pin (14) to

engine cover (13). 13

14

15

16

W1R7-02-11-006

36. Install cover (12) to main frame (2) with bolts (11)
11 12 2
(6 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-11-017

W2-11-46
 UPPERSTRUCTURE / Engine
37. Install cover (10) to main frame (2) with bolts (9) (4 9 10
used). At this time, check that a hose is extended
through the hole of cover (10).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

Hose
W1R7-02-11-016

38. Install cover (8) to main frame (2) with bolts (7) (6 7 8
used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

W1R7-02-11-015

39. Connect ground (5) of battery (4) to main frame

(2) with nut (6).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

6 5 2 W1R7-02-11-014

W2-11-47
 UPPERSTRUCTURE / Engine

CAUTION: Counterweight (1) weight: 3680 kg 1

(8120 lb)

40. Install counterweight (1) to main frame (2). (Refer

to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)

41. Add coolant to the radiator.

2

W1R7-02-02-004

W2-11-48
 MEMO

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 MEMO

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UNDERCARRIAGE
— CONTENTNS —
Group 1 Swing Bearing
Removal and Installation of
Swing Bearing............................................ W3-1-1
Disassembly of Swing Bearing.................... W3-1-4
Assembly of Swing Bearing......................... W3-1-8
Group 2 Travel Device
Removal and Installation of
Travel Device ............................................. W3-2-1
Disassembly of Travel Device ..................... W3-2-4
Assembly of Travel Device ........................ W3-2-10
Disassembly of Travel Motor ..................... W3-2-18
Assembly of Travel Motor.......................... W3-2-22
Disassembly of Brake Valve...................... W3-2-28
Assembly of Brake Valve........................... W3-2-30
Maintenance Standard .............................. W3-2-32
Group 3 Center Joint
Removal and Installation of
Center Joint ............................................... W3-3-1
Disassembly of Center Joint........................ W3-3-4
Assembly of Center Joint ............................ W3-3-6
Maintenance Standard ................................ W3-3-9
1R7W-3-1
SECTION 3
Group 4 Track Adjuster
Removal and Installation of
Track Adjuster ............................................W3-4-1
Disassembly of Track Adjuster.....................W3-4-4
Assembly of Track Adjuster .......................W3-4-10
Group 5 Front Idler
Removal and Installation of Front Idler ........W3-5-1
Disassembly of Front Idler ...........................W3-5-4
Assembly of Front Idler ................................W3-5-8
Maintenance Standard ...............................W3-5-12
Group 6 Upper and Lower Roller
Removal and Installation of Upper Roller ....W3-6-1
Removal and Installation of Lower Roller ....W3-6-4
Disassembly of Lower Roller .......................W3-6-8
Assembly of Lower Roller ..........................W3-6-10
Maintenance Standard ...............................W3-6-12
Group 7 Track
Removal and Installation of Track................W3-7-1
Maintenance Standard .................................W3-7-7
(Blank)

1R7W-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVAL AND INSTALLATION OF
SWING BEARING Matching Mark

Before removing and installing the swing bearing, the

upperstructure must be removed first. For removal
and installation of the upperstructure, refer to RE-
MOVAL AND INSTALLATION OF MAIN FRAME on
W2-3-1.
The procedure starts on the premise that the upper-
structure has already been removed. 1 2

W105-03-01-001
Removal
1. Put the matching marks on inner race (1) of the
swing bearing and track frame (2). 3 4 1

W1R7-03-01-001

2. Remove knock pin (3) from outer race (4) of the

swing bearing.
5
3. Remove bolts (5) (36 used) from the swing bear-
ing.
: 24 mm

W105-03-01-002

CAUTION: Swing bearing weight: 160 kg

(355 lb)

4. Install the special tool (ST 0050) to the swing

bearing. Hoist and remove the swing bearing.

ST 0050

W105-03-01-003

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation
1. Clean the mounting surfaces of track frame (2)
and the swing bearing.

2. Apply THREEBOND #1102 onto the swing bear-

ing mounting surface of track frame (2).
ST 0050

W105-03-01-003

Machine
Front

CAUTION: Swing bearing weight: 160 kg Position for

(355 lb) Grease Fitting
”S” (Soft Zone)
Marking Position
IMPORTANT: If the matching mark do not align,
the soft zone position of inner race 6
(1) will be dislocated. Position for
Plug
3. Hoist the swing bearing by using the special tool
(ST 0050). Align the matching marks on track 0.2
frame (2) and inner race (1) of the swing bearing.

10
21

Position for
Position for
Knock Pin
Grease Fitting
WCEB-03-01-003

4. Install bolts (5) (36 used) to the swing bearing. 5

: 24 mm
: 270 N m (27 kgf m, 200 lbf ft)

5. Install knock pin (3) to outer race (4) of the swing

bearing.

W105-03-01-002

3 4 1

W1R7-03-01-001

W3-1-2
 UNDERCARRIAGE / Swing Bearing
6. After installing the swing bearing, add grease
(Shell Alvania EP2 or equivalent) to the grease Swing Bearing Grease Level Pinion Gear
bath until the pinion of the swing device is 5 mm
(0.2 in) under grease.

5 mm
(0.2 in)

W175-03-01-002

Grease Bath

W3-1-3
 UNDERCARRIAGE / Swing Bearing
DISASSEMBLY OF SWING BEARING
1 2 3

8 7 6 5
W1R7-03-01-002

6
9

W105-03-01-011

1- Outer Race 4- Plug 6- Ball (99 Used) 8- Support (99 Used)

2- Seal 5- Seal 7- Inner Race 9- Grease Fitting (2 Used)
3- Pin

W3-1-4
 UNDERCARRIAGE / Swing Bearing
Disassembly of Swing Bearing

1. Tap and remove pin (3) of plug (4) upward from CAUTION: Swing bearing weight: 160 kg
outer race (1). (355 lb)
NOTE: After installing pin (3), pin (3) was crimped. 3. Place inner race (7) of the swing bearing onto a
Grind off the crimped part. wooden block by using the special tool (ST 0050).
Hoist and hold outer race (1) slightly. Remove
seals (2, 5) from outer race (1) and inner race (7)
3 respectively by using a scrapper.

4. Remove balls (6) (99 used) and supports (8) (99

used) from the plug (4) hole while rotating outer
race (1).
4 Remove ball (6) by using magnet (A). Use wire
(B) and remove support (8).

1
2
W105-03-01-007

A
7
2. Remove plug (4) from outer race (1).
NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5 mm) of plug (4). Tap or pull the
bolt from the inner side.
6 5
W105-03-01-009
1

4
B

W105-03-01-008

W105-03-01-010
8

W3-1-5
 UNDERCARRIAGE / Swing Bearing

7
W1R7-03-01-002

W105-03-01-011

W3-1-6
 UNDERCARRIAGE / Swing Bearing

CAUTION: Outer race (1) weight: 67 kg (150

lb)
Inner race (7) weight: 78 kg (170 lb)

5. Remove outer race (1) from inner race (7).

W3-1-7
 UNDERCARRIAGE / Swing Bearing
ASSEMBLY OF SWING BEARING
1 2 3

8 7 6 5
W1R7-03-01-002

6
9

W105-03-01-011

1- Outer Race 4- Plug 6- Ball (99 Used) 8- Support (99 Used)

2- Seal 5- Seal 7- Inner Race 9- Grease Fitting (2 Used)
3- Pin

W3-1-8
 UNDERCARRIAGE / Swing Bearing
Assembly of Swing Bearing

4. Tap and install plug (4) into outer race (1). Secure
CAUTION: Inner race (7) weight: 78 kg (170 plug (4) to outer race (1) with pin (3). Crimp the
lb) head of pin (3) by using a punch.
1. Place inner race (7) onto a wooden block.
3
2. Apply grease onto balls (6) (99 used) and sup-
ports (8) (99 used)
1

CAUTION: Outer race (1) weight: 67 kg (150

lb)

3. Hoist outer race (1) horizontally by using the spe-

cial tool (ST 0050) and align outer race (1) with
4
inner race (7) coaxially.
While rotating outer race (1), install ball (6) and
support (8) to the plug (4) hole by using a round W142-03-01-007

bar.
CAUTION: Swing bearing weight: 160 kg
1 (355 lb)

5. Install the special tool (ST 0050) to outer race (1).

Thoroughly degrease the slots for seals (2, 5).
2
Apply THREEBOND #1530D onto seals (2, 5).
Install seals (2, 5) to outer race (1) and inner race
(7).

6. Add grease (Alvania EP2 or equivalent) to the

swing bearing through grease fitting (9).
6
Grease amount: 0.4 L (0.1 US gal.)
5 W142-03-01-005

W142-03-01-006

W3-1-9
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-10
 UNDERCARRIAGE / Travel Device
REMOVAL AND INSTALLATION OF
TRAVEL DEVICE

Wire Rope
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED 6 7
AIR FROM HYDRAULIC OIL TANK on Travel Device
W1-4-1.)

The procedures start on the premise that the track

has been removed. (Refer to REMOVAL AND 1
INSTALLATION OF TRACK on W3-7-1.) 5

4
Removal

1. Remove bolts (3) (4 used). Remove cover (2)

from the track frame.
: 22 mm

2. Disconnect hoses (4 to 7) from the travel device.

Cap disconnected hoses (4 to 7).
Track Frame
: 17 mm, 19 mm, 27 mm
2
3. Attach a wire rope onto the travel device. Hoist
W155-03-02-009
and hold the travel device. 3

CAUTION: Travel device weight:

ZX110-3 class, 120-3 class: 220 kg (490 lb)
ZX135US-3 class: 230 kg (510 lb)

4. Remove bolts (1) (14 used). Hoist and remove

the travel device from the track frame.
: 24 mm

5. Remove the other travel device in the same way.

W3-2-1
 UNDERCARRIAGE / Travel Device
Installation

CAUTION: Travel device weight:

Wire Rope
ZX110-3 class, 120-3 class: 220 kg (490 lb)
ZX135US-3 class: 230 kg (510 lb) 6 7
Travel Device
1. Hoist the travel device. Install the travel device to
the track frame with bolts (1) (16 used).
: 24 mm
: 310 N m (32 kgf m, 230 lbf ft) 1
5
2. Connect hoses (4 to 7) to the travel device.
4
: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf ft)
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 27 mm
: 95 N m (9.5 kgf m, 70 lbf ft)

3. Install cover (2) to the track frame with bolts (3)

Track Frame
(4 used).
: 22 mm 2
: 175 N m (18 kgf m, 130 lbf ft)
W155-03-02-009
3
4. Install the other travel device in the same way.

IMPORTANT: After connecting the hoses to the

travel motor, fill hydraulic oil 0.5 L
(0.1 US gal.) into the travel motor.
After installing the travel motor or
the travel device, perform the
break-in operation in order to
prevent the travel motor from
seizing.
Conditions: 1. Engine control dial: Slow idle
2. Travel mode switch: Slow speed
3. Operation duration: More than 2
min.

W3-2-2
 UNDERCARRIAGE / Travel Device
(Blank)

W3-2-3
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL DEVICE

13
12 14
11

10
9
8
1
7
6
1
5
4
1
2
3
2
1

15

16

17 20
18

19

21
22

23

24

25
26
23
27

28 W176-03-02-001

1 - Thrust Plate (12 Used) 8 - Pin (3 Used) 15 - Propeller Shaft 22 - Bearing Nut
2 - Needle Bearing (6 Used) 9 - Spring Pin (3 Used) 16 - Spacer 23 - Roller Bearing (2 Used)
3 - Second Stage Planetary 10 - Ring Gear 17 - First Stage Carrier 24 - Sprocket
Gear (3 Used)
4 - Pin (3 Used) 11 - Cover 18 - Sun Gear 25 - Drum
5 - Spring Pin (3 Used) 12 - Stopper Pin 19 - Second Stage Carrier 26 - Bolt (16 Used)
6 - First Stage Planetary Gear 13 - Bolt (12 Used) 20 - Bolt (16 Used) 27 - Floating Seal
(3 Used)
7 - Needle Bearing (3 Used) 14 - Plug (3 Used) 21 - Knock Pin 28 - Motor

W3-2-4
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Device
CAUTION: There may be pressure
accumulated inside of the travel device.
Slowly loosen the air bleed plug and bleed
air.
CAUTION: Travel device weight:
ZX110-3 class, 120-3 class: 220 kg (490 lb)
ZX135US-3 class: 230 kg (510 lb)
1. Hoist and place the travel device with the motor
(28) side facing upward. Install the spacer (ST
5089) to the mounting flange for the track frame
with bolts (M16, Pitch 2.0 mm) (2 used).
: 24 mm
ST 5089
W105-03-02-007
2. Attach a nylon sling onto the body of motor (28).
Hoist motor (28). Turn over and place motor (28).
NOTE: Secure the spacer (ST 5089) tightly in
order to reduce a reaction force when
disassembling.
W3-2-5
3. Remove cover (11) from ring gear (10).
: 19 mm
NOTE: THREEBOND has been applied between
cover (11) and ring gear (10). For easy
removal, insert and slightly tap a chisel
between cover (11) and ring gear (10).
Do not remove stopper pin (12) with cover
(11) attached unless damage and wear are
found.
4. Remove propeller shaft (15), spacer (16) and the
first stage carrier (17) assembly from ring gear
(10).
5. Remove sun gear (18) from ring gear (10).
CAUTION: The second stage carrier (19)
assembly weight:
ZX110-3 class, 120-3 class: 23 kg (51 lb)
ZX135US-3 class: 28 kg (62 lb)
6. Attach the claws of the lifting tool (ST 0916) to
the outer surface of second stage carrier (19).
Hoist second stage carrier (19). Remove the
second stage carrier (19) assembly from ring
gear (10).
ST 0916
Claw
W178-03-02-001
UNDERCARRIAGE / Travel Device

10

20

21

23

24

25

23

27 W176-03-02-001

28

W3-2-6
 UNDERCARRIAGE / Travel Device
7. Remove bearing nut (22) from the motor (28)
housing by using the special tools (ST 7248, ST
7249).
Do not remove knock pin (21) unless necessary.
9. Remove floating seal (27) from motor (28).
10. Remove the inner race of roller bearing (23) from
drum (25).

Bolt M12
CAUTION: Sprocket (24) weight:
ZX110-3 class, 120-3 class: 41 kg (90 lb)
ST 7248
ZX135US-3 class: 38 kg (84 lb)

ST 7249 11. Attach a nylon sling onto sprocket (24). Hoist and
hold sprocket (24). Remove bolt (20). Remove
sprocket (24) from drum (25).
22 : 24 mm
NOTE: LOCTITE has been applied onto bolt (20).

CAUTION: Ring gear (10) + drum (25)

weight:
W176-03-02-013
ZX110-3 class, 120-3 class: 55 kg (125 lb)
ZX135US-3 class: 58 kg (130 lb)
CAUTION: Ring gear (10) + sprocket (24) +
drum (25) weight: 95 kg (210 lb) 12. Install an eyebolt (M16) to the sprocket (24)
mounting thread part on drum (25). Hoist and turn
IMPORTANT: The motor (28) side of drum (25) is over ring gear (10).
the sliding surface for motor (28).
8. Install eyebolts (M12) (2 used) to ring gear (10). 13. Remove floating seal (27) from drum (25).
Hoist ring gear (10). Remove ring gear (10) from
the housing of motor (28). Place ring gear (10) on
a wooden block.
NOTE: If it is difficult to remove ring gear (10),
rotate sprocket (24).
ST 0002

10

24

28

W155-03-02-003

W3-2-7
 UNDERCARRIAGE / Travel Device

10
9
8
1
7
6
1
5
4
1
2
3
2
1

17

19

23

25
26

W176-03-02-001
28

W3-2-8
 UNDERCARRIAGE / Travel Device
14. Remove bolt (26). Install an eyebolt (M16) to the
bolt (26) hole. Hoist drum (25). Place drum (25)
on a wooden block. At this time, align the wooden
block with the ring gear (10) mounting position.
: 24 mm
NOTE: LOCTITE has been applied onto bolt (26).
CAUTION: Drum (25) weight: 24 kg (55 lb)
18. Disassemble the second stage carrier (19)
assembly.
• Remove spring pin (5) from second stage
carrier (19) by using the pulling-out pin (ST
1462). (3 places)
• Remove pins (4) (3 used), thrust plates (1) (6
used), planetary gears (3) (3 used) and needle
bearings (2) (6 used) from second stage
carrier (19).

15. Hoist and remove drum (25) from ring gear (10)

16. Remove the outer races (2 used) of roller bearing

(23) with drum (25) attached by using a bar and a
hammer from the backside of the outer races
respectively. Do not remove the outer race of
roller bearing (23) unless necessary.
NOTE: Do not remove the inner race of roller
bearing (23) remained on the motor (28)
side unless necessary.

17. Disassemble the first stage carrier (17) assembly.

• Remove spring pin (9) from first stage carrier
(17) by using the pulling-out pin (ST 1391). (3
places)
• Remove pins (8) (3 used), thrust plates (1) (6
used), planetary gears (6) (3 used) and needle
bearings (7) (3 used) from first stage carrier
(17).

W3-2-9
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL DEVICE

28 27 23 22 21 10 19 18 17 11

14

16

15

12

13

25
4 1 2 3 1
26

20

24

W176-03-02-002

1 - Thrust Plate (12 Used) 8 - Pin (3 Used) 15 - Propeller Shaft 22 - Bearing Nut
2 - Needle Bearing (6 Used) 9 - Spring Pin (3 Used) 16 - Spacer 23 - Roller Bearing (2 Used)
3 - Second Stage Planetary 10 - Ring Gear 17 - First Stage Carrier 24 - Sprocket
Gear (3 Used)
4 - Pin (3 Used) 11 - Cover 18 - Sun Gear 25 - Drum
5 - Spring Pin (3 Used) 12 - Stopper Pin 19 - Second Stage Carrier 26 - Bolt (16 Used)
6 - First Stage Planetary Gear 13 - Bolt (12 Used) 20 - Bolt (16 Used) 27 - Floating Seal
(3 Used)
7 - Needle Bearing (3 Used) 14 - Plug (3 Used) 21 - Knock Pin 28 - Motor

W3-2-10
 UNDERCARRIAGE / Travel Device
Assembly of Travel Device
1. When replacing roller bearing (23) with motor
(28) attached, install roller bearing (23) to motor
(28) after warning up the inner race of roller
bearing (23) from 50 to 70°C by using a heater.
After roller bearing (23) cools, install the inner
race of roller bearing (23) to motor (28) by using
a bar.
NOTE: Tap and listen to ring in order to check that
roller bearing (23) is installed completely.
2. Apply grease onto O-ring of floating seal (27).
Install one side of floating seal (27) to motor (28).
NOTE: If it is difficult to install O-ring of floating
seal (27), push O-ring into periphery
direction by using a bamboo spatula.
IMPORTANT: Do not tap except for the outer race
of roller bearing (23).
3. Evenly tap and insert the outer race of roller
bearing (23) into drum (25) by using a bar and a
hammer. (2 places)
NOTE: Tap and listen to ring in order to check that
roller bearing (23) is installed to the end.
W3-2-11
CAUTION: Sprocket (24) weight:
ZX110-3 class, 120-3 class: 41 kg (90 lb)
ZX135US-3 class: 38 kg (84 lb)
IMPORTANT: Align the chamfered side of
sprocket (24) with the drum (25)
side.
4. Apply LOCTITE #262 onto bolt (20). Place and
install sprocket (24) to drum (25) with bolts (20)
(16 used).
: 24 mm
: 265 N m (27 kgf m, 195 lbf ft)
CAUTION: Ring gear (10) weight:
ZX110-3 class, 120-3 class: 31 kg (70 lb)
ZX135US-3 class: 34 kg (75 lb)
5. Remove old adhesive on ring gear (10) and drum
(25).
Hoist and place ring gear (10) with the cover (11)
side facing downward. Apply THREEBOND
#1389B onto the drum (25) mounting surface of
ring gear (10) sufficiently.
CAUTION: The sprocket (24) assembly
weight:
ZX110-3 class, 120-3 class: 65 kg (145 lb)
ZX135US-3 class: 62 kg (140 lb)
6. Install eyebolts (ST 0002) (2 used) to the bolt
(26) mounting thread part on the sprocket (24)
assembly. Place the sprocket (24) assembly onto
ring gear (10).
7. Apply LOCTITE #262 onto bolts (26) (16 used).
Install the sprocket (24) assembly to ring gear
(10) with bolts (26) (16 used).
: 24 mm
: 265 N m (27 kgf m, 195 lbf ft)
 UNDERCARRIAGE / Travel Device

28 27 23 22 10 19

13

25

24

W176-03-02-002

W3-2-12
 UNDERCARRIAGE / Travel Device
8. Apply grease onto O-ring of floating seal (27)
sufficiently.
Install one side of floating seal (27) to drum (25).
NOTE: If it is difficult to install O-ring of floating
seal (27), push O-ring into the periphery
direction by using a bamboo spatula.
CAUTION: Ring gear (10) + sprocket (24) +
drum (25) weight: 95 kg (210 lb)
9. Attach a nylon sling onto ring gear (10). Hoist and
turn over ring gear (10). At this time, do not
damage the sliding surfaces of drum (25) and
motor (28) by using wooden blocks.
10. Install eyebolts (ST 0002) (2 used) to the bolt (13)
mounting thread part on the ring gear (10)
assembly. Hoist and place the ring gear (10)
assembly onto motor (28). At this time, check that
the clearance between motor (28) and drum (25)
is even all around.
11. Push the ring gear (10) assembly into motor (28)
straightly while shaking.
12. Install the inner race of roller bearing (23) to
motor (28) by using a bar and a hammer.
NOTE: Repeat steps 11 and 12 until the inner race
side of roller bearing (23) is screwed into 3
threads from the thread end where bearing
nut (22) can be inserted.
W3-2-13
13. Apply grease onto the thread part of bearing nut
(22).
NOTE: If applying grease, the correct tightening
torque can be obtained.
IMPORTANT: Install bearing nut (22) with the step
part facing inside.
14. Install bearing nut (22) to motor (28) and tighten
by hand.
15. Install the special tools (ST 7248, ST 7249) to
bearing nut (22). Tighten bearing nut (22) by
using a torque wrench.
: 790 N m (80 kgf m, 585 lbf ft)
Bolt M12
ST 7248
ST 7249
W176-03-02-013
16. After tightening bearing nut (22) to the specified
torque, reduce play of sprocket (24) by using a
hammer. Rotate sprocket (24) both clockwise
and counterclockwise 4 to 5 turns.
17. Repeat steps 15, 16.
18. Perform the same procedures as step 15 again.
Tighten bearing nut (22) to the specified torque.
: 790 N m (80 kgf m, 585 lbf ft)
 UNDERCARRIAGE / Travel Device

28 22 21 10 19 11

4 1 3 1

W176-03-02-002

W3-2-14
 UNDERCARRIAGE / Travel Device
19. Align the center phase of the spline in motor (28) IMPORTANT: Face the slit of spring pin (5) to the
and knock pin (21) respectively. If the center pin (4) end.
positions are not aligned, turn bearing nut (22) in 23. Install spring pin (5) to the hole of second stage
tightening direction until both center phase are carrier (19).
5
aligned.
NOTE: This is the procedure to align the spline
4
position in second stage carrier (19) and
knock pin (21). If the procedure is Slit
continued without aligning, cover (11) will
be floated when installing cover (11) to ring W178-02-06-002

gear (10).
24. Install other second stage planetary gears (3) (2
Knock Pin Center used) to second stage carrier (19) in the same
28 way as steps 20 to 23.

21
CAUTION: Second stage carrier (19) falls at
the moment when knock pin (21) is inserted
into second stage carrier (19). Do not catch
Spline
22
fingers.
Tooth
C t
25. Hoist the second stage carrier (19) assembly by
using the special tool (ST 0916). Install the
W176-03-02-004 second stage carrier (19) assembly to sprocket
(24) of motor (28). At this time, if the phase
20. Install needle bearings (2) (2 used) to second aligning performed in step 19 is insufficient,
stage planetary gear (3). knock pin (21) cannot be inserted into second
stage carrier (19).
IMPORTANT: There is an identification groove on NOTE: Distance between the upper side of
one side of second stage planetary second stage planetary gear (3) and the
gear (3). Install second stage upper side of ring gear (10) is about 35
planetary gear (3) with the mm after second stage carrier (19) is
identification groove side facing to installed.
the spring pin (5) hole.
21. Secure second stage planetary gear (3) between
thrust plates (1) (2 used). Install them to second
stage carrier (19).

22. Insert pin (4) into second stage carrier (19). At

this time, align the spring pin (5) hole of second
stage carrier (19) and the pin (4) hole.

W178-03-02-001
Attach them to
carrier.

W3-2-15
UNDERCARRIAGE / Travel Device

10 19 18 17 11

14

16

15

13

3 1

W176-03-02-002

W3-2-16
 UNDERCARRIAGE / Travel Device
26. Install sun gear (18) to second stage carrier (19)
with the small diameter part facing upward.
27. Install spacer (16) to the center of first stage
carrier (17).
28. Install needle bearing (7) to first stage planetary
gear (6).
29. Secure first stage planetary gear (6) between
thrust plates (1) (2 used). Install them to first
stage carrier (17).
34. Install cover (11) to ring gear (10) with bolt (13).
: 19 mm
: 110 N m (11 kgf m, 81 lbf ft)
35. Remove plug (14). Add gear oil to ring gear (10).
: 19 mm
NOTE: Gear oil amount: 3.5 L (0.9 US gal.)
36. Wind a seal tape onto plug (14). Install plug (14)
to cover (11).
: 19 mm
: 50 N m (5 kgf m, 37 lbf ft)

30. Install pin (8) and spring pin (9) to first stage
carrier (17) in the same way as steps 22 to 24.

31. Install the first stage carrier (17) assembly to the

spline on sun gear (18).

32. Insert propeller shaft (15) into the center spline of

sun gear (18). At this time, engage propeller shaft
(15) with the spline of motor (28) and first stage
planetary gear.

33. Remove old adhesive.

Degrease the cover (11) mounting surface of ring
gear (10). Apply THREEBOND #1215.

W3-2-17
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL MOTOR

Brake Releasing
Oil Passage

5
4
3
Piston Oil
2 Passage

5
8 7 16

15
14

13 17

18
12 19
20
11
10
9

21

22

23
24

25
26
W176-03-02-005
27

1- Shaft 8- Roller Bearing 15 - Bushing 22 - Socket Bolt (8 Used)

2- Retaining Ring 9- Disc Spring 16 - Swash Plate 23 - O-Ring
3- Retaining Ring 10 - Brake Piston 17 - Ball (2 Used) 24 - Valve Plate
4- Oil Seal 11 - O-Ring 18 - Plunger (9 Used) 25 - Knock Pin (2 Used)
5- O-Ring (2 Used) 12 - O-Ring 19 - Retainer 26 - Needle Bearing
6- Housing 13 - Plate (4 Used) 20 - Spring (9 Used) 27 - Brake Valve
7- Piston 14 - Rotor 21 - Friction Plate (3 Used)

W3-2-18
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Motor
CAUTION: Travel motor weight: 60 kg (135
lb)
IMPORTANT: When removing the brake valve (27)
assembly from the travel motor,
valve plate (24) is removed with
brake valve (27) together. Do not
drop valve plate (24).
1. Remove socket bolt (22). Remove brake valve
(27) from housing (6).
: 12 mm
IMPORTANT: As valve plate (24) is easily cracked
and scratched, handle with care.
2. Remove valve plate (24) and knock pins (25) (2
used) from brake valve (27). Do not remove
needle bearing (26) unless necessary.
NOTE: Remove needle bearing (26) by using a
small puller. Do not reuse needle bearing
(26) as the outer race. At this time, as the
outer race of needle bearing (26) is
deformed, do not reuse it.
3. Wind a vinyl tape onto the rotating surface of
needle bearing (26) on shaft (1) in order to
protect.
4. Remove disc spring (9) from housing (6).
W3-2-19
CAUTION: When removing brake piston (10)
by applying air to housing (6), hold brake
piston (10) by using a cloth in order to
prevent brake piston (10) from flying out.
5. Apply air 100 to 300 kPa (1.0 to 3.0 kgf/cm2, 14
to 43 psi) to the brake releasing oil passage in
housing (6). Float and remove brake piston (10).
NOTE: A bicycle pump can be used. Do not use
screwdriver in order not to damage the
parts.
6. Remove rotor (14), springs (20) (9 used),
bushing (15), retainer (19) and plungers (18) (9
used) from housing (6) in this order.
7. Remove plates (13) (4 used) and friction plates
(21) (3 used) from housing (6).
CAUTION: Housing (6) weight: 34 kg (75 lb)
8. Place housing (6) horizontally with the brake
releasing oil passage facing downward.
NOTE: If placing housing (6) with the brake
releasing oil passage upward, the thick
part of swash plate (16) faces upward.
Swash plate (16) may suddenly come off
while placing housing (6) horizontally.
 UNDERCARRIAGE / Travel Device

4
3

8 7 16

17

W176-03-02-005

W3-2-20
 UNDERCARRIAGE / Travel Device
9. Remove swash plate (16) from housing (6).
NOTE: When swash plate (16) cannot be removed,
apply air 100 to 300 kPa (1 to 3 kgf/cm2)
through the piston oil passage hole. Swash
plate (16) and piston (7) can be removed.
At this time, cover and lightly hold piston
(7) by using a cloth in order not to fly out. A
bicycle pump can be used.
10. Remove balls (17) (2 used) and piston (7) from
housing (6) by using a magnet.
11. Remove retaining ring (2) from housing (6).
12. Remove shaft (1) with roller bearing (8) together
from housing (6) by using a bar and a plastic
hammer.
W3-2-21
13. Insert a screwdriver into the shaft (1) hole on
housing (6). Remove oil seal (4).
NOTE: Adhesive has been applied on oil seal (4).
Oil seal (4) cannot be reused.
14. Remove retaining ring (3) from shaft (1)
CAUTION: When shaft (1) is removed from
roller bearing (8), do not drop shaft (1).
15. Secure the inner race of roller bearing (8)
remained in shaft (1) in a vise opening. Remove
roller bearing (8) from shaft (1) by using a bar
and a plastic hammer.
Bar
W172-03-02-003
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL MOTOR

Brake Releasing
Oil Passage

27 25 23 5 11 12 10 14 18 16 17 2 8

26 22 24 5 9 13 21 20 15 19 7
Piston Oil
Passage
W176-03-02-006

1- Shaft 8- Roller Bearing 15 - Bushing 22 - Socket Bolt (8 Used)

2- Retaining Ring 9- Disc Spring 16 - Swash Plate 23 - O-Ring
3- Retaining Ring 10 - Brake Piston 17 - Ball (2 Used) 24 - Valve Plate
4- Oil Seal 11 - O-Ring 18 - Plunger (9 Used) 25 - Knock Pin (2 Used)
5- O-Ring (2 Used) 12 - O-Ring 19 - Retainer 26 - Needle Bearing
6- Housing 13 - Plate (4 Used) 20 - Spring (9 Used) 27 - Brake Valve
7- Piston 14 - Rotor 21 - Friction Plate (3 Used)

W3-2-22
 UNDERCARRIAGE / Travel Device
Assembly of Travel Motor

CAUTION: Housing (6) weight: 34 kg (75 lb) IMPORTANT: Check the direction to install roller
bearing (8).
1. Place housing (6) with the brake valve (27) 4. Insert roller bearing (8) into the inner bore spline
mounting surface facing upward. side of shaft (1) until bearing (8) reaches the
contacting part with shaft (1). At this time, do not
IMPORTANT: Apply OCEAN grease #7 onto the damage the seal lip surface of shaft (1).
inner surface of oil seal (4). Apply
THREEBOND #1104 or #1215 onto 5. Install roller bearing (8) to shaft (1) by using the
the outer surface of oil seal (4). special tool (ST 2895) and a plastic hammer.
2. Clean the oil seal (4) mating part of housing (6).
Install oil seal (4) to housing (6) by using the 1
special tool (ST 2893).
ST 2893 Inner Bore
Spline Part
Inner Ring Plate
4
ST 2895 12
6

W176-03-02-007 W176-03-02-008

IMPORTANT: Check the direction to install roller 6. Install retaining ring (3) to shaft (1). At this time,
bearing (8). do not damage the sliding surface of oil seal (4).
3. Install the outer race, the inner race and the inner
ring plate of roller bearing (8) with all stamped 7. Apply grease onto the ball (17) surface
mark facing outside. sufficiently. Install balls (17) (2 used) to housing
(6).
Marked Surface on Marked Surface on NOTE: If not applying grease on ball (17), ball (17)
Outer Race Inner Race
and swash plate (16), which will be
installed, cannot be secured.

8. Install piston (7) to housing (6). As for piston (7),

W176-02-06-014 face the step side inside.
Marked Surface on
Inner Ring Plate

W3-2-23
 UNDERCARRIAGE / Travel Device

27 25 23 5 11 12 10 14 18 16 17 2

5 9 13 21 20 15 19

W176-03-02-006

W3-2-24
 UNDERCARRIAGE / Travel Device
IMPORTANT: As the small diameter side of shaft
(1) is the inner race of needle
bearing (26), do not damage the
inner race.
9. Install shaft (1) to housing (6) by using a plastic
hammer.
10. Install retaining ring (2) to housing (6).
NOTE: If the open part of retaining ring (2) is
located at the lowest bottom of housing (6),
retaining ring (2) can be removed and
installed easily.
11. Apply grease onto the ball hole on swash plate
(16). Align the position of balls (17) (2 used) and
install swash plate (16) to housing (6).
CAUTION: Housing (6) weight: 35 kg (80 lb)
12. Place housing (6) horizontally with the brake
releasing oil passage facing downward.
NOTE: If placing housing (6) with the brake
releasing oil passage facing upward,
swash plate (16) may come off.
IMPORTANT: Check the direction of retainer (19).
13. Install springs (20) (9 used), bushing (15),
retainer (19) and plungers (18) (9 used) to rotor
(14) in this order. At this time, face the chamfered
side of retainer (19) to the bushing (15) side.
19
15
Chamfered Side
W172-03-02-001
14. Install the rotor (14) assembly to housing (6).
W3-2-25
CAUTION: Housing (6) weight: 40 kg (90 lb)
15. Place housing (6) with the for brake valve (27)
mounting surface facing upward.
16. Install plates (13) (4 used) and friction plates (21)
(3 used) to housing (6) alternately.
17. Apply grease onto O-rings (11, 12). Install O-rings
(11, 12) to brake piston (10).
18. Install brake piston (10) to housing (6). Tap and
insert brake piston (10) into housing (6) by using
a plastic hammer.
NOTE: As O-rings (11, 12) are positioned at the
outside of brake piston (10), brake piston
(10) cannot be fully inserted.
IMPORTANT: Check the direction to install disc
spring (9).
19. Install disc spring (9) to the upper side of brake
piston (10).
20. Install O-rings (5) (2 used) and O-ring (23) to the
brake valve (27) mating surface of housing (6).
21. Add hydraulic oil to housing (6) until plate (13) is
submerged.
IMPORTANT: Check the direction to install knock
pin (25).
21. Install knock pins (25) (2 used) to brake valve
(27). Insert the large diameter side of knock pin
(25) into the pin hole on brake valve (27).
 UNDERCARRIAGE / Travel Device

27 25

26 22 24

W176-03-02-006

W3-2-26
 UNDERCARRIAGE / Travel Device
IMPORTANT: Check the direction to install needle
bearing (26).
23. Install needle bearing (26) to brake valve (27) by
using the special tool (ST 2894) and a hammer.
Install needle bearing (26) with the stamped mark
facing outside.

ST 2894

26
27

W176-03-02-012

24. Apply grease onto the flat surface of valve plate

(24). Install valve plate (24) while aligning the
position of knock pin (25) in brake valve (27).
NOTE: Apply grease and valve plate (24) is
secured to brake valve (27) tightly. This
prevents valve plate (24) from falling off
when turning over brake valve (27).

IMPORTANT: Do not drop valve plate (24). If valve

plate (24) is damaged, oil leakage
may occur.
25. Install brake valve (27) to housing (6) with socket
bolts (22) (8 used).
: 12 mm
: 177 N m (18 kgf m, 131 lbf ft)

W3-2-27
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF BRAKE VALVE

2
3
4

4
16
3
15
14 2
13 1

8
9 7
10
11
W176-03-02-009
12

1- Plug (2 Used) 5- Spool 9- Poppet (2 Used) 13 - Plug

2- O-Ring (2 Used) 6- Valve Housing 10 - Spring (2 Used) 14 - O-Ring
3- Spring (2 Used) 7- Plug 11 - O-Ring (2 Used) 15 - Spring
4- Stopper (2 Used) 8- O-Ring 12 - Relief Valve (2 Used) 16 - Spool

W3-2-28
 UNDERCARRIAGE / Travel Device
Disassembly of Brake Valve

1. Remove plug (1) from valve housing (6). (2 6. Remove spring (10) and poppet (9) from valve
places) housing (6) by using a magnet. (2 places)
: 36 mm

7. Remove plug (13) from valve housing (6). (2

2. Remove spring (3) and stopper (4) from valve places)
housing (6) by using a magnet. (2 places) : 6 mm

3. Remove spool (5) from valve housing (6) by 8. Remove spring (15) and spool (16) from valve
using a magnet. housing (6) by using a magnet.

4. Remove plug (7) from valve housing (6).

The plug is screwed into the plug (7) hole. Do not
remove it unless necessary.
: 6 mm

IMPORTANT: Do not disassemble relief valve (12).

When relief valve (12) is
disassembled, the set pressure is
changed.
IMPORTANT: Do not move the piston with the
outer surface of relief valve (12)
attached. O-ring may be damaged
by the hole on the cartridge.
5. Remove relief valve (12) from valve housing (6).
(2 places)
: 30 mm

12

Piston W176-03-02-011

W3-2-29
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF BRAKE VALVE

6
5 4
4
3
3
2
2

1 1

16

9
10 W176-03-02-010
14 13 15
11
8
12

1- Plug (2 Used) 5- Spool 9- Poppet (2 Used) 13 - Plug

2- O-Ring (2 Used) 6- Valve Housing 10 - Spring (2 Used) 14 - O-Ring
3- Spring (2 Used) 7- Plug 11 - O-Ring (2 Used) 15 - Spring
4- Stopper (2 Used) 8- O-Ring 12 - Relief Valve (2 Used) 16 - Spool

W3-2-30
 UNDERCARRIAGE / Travel Device
Assembly of Brake Valve

1. Install spool (5) approximately half way into valve 7. Install O-rings (11) (2 used) to relief valves (12)
housing (6). (2 used).

2. Install O-ring (2), spring (3) and stopper (4) to
plug (1) at one side. Install plug (1) to valve
housing (6). At this time, install plug (1) to valve
housing (6) with a thread left out.
NOTE: If plug (1) is fully tightened, it is difficult to
install plug (1) to other side as spool (5) is
pushed.
3. Install O-ring (2), spring (3) and stopper (4) to
plug (1) at the other side. Install plug (1) to valve
housing (6). Tighten plug (1) by hand.
4. Tighten plug (1) on both sides by using a
spanner.
: 36 mm
: 440 N m (45 kgf m, 325 lbf ft)
5. Install O-ring (8) to plug (7). Install plug (7) to
valve housing (6).
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
8. While slowly pushing poppet (9) which was
inserted in step 6, install relief valve (12) to valve
housing (6). (2 places)
: 30 mm
: 310 N m (32 kgf m, 230 lbf ft)
IMPORTANT: Check the direction to install spool
(16).
9. Install spool (16) to valve housing (6) with the
hole end facing forward.
10. Insert spring (15) into valve housing (6).
11. Install O-ring (14) to plug (13). Install plug (13) to
valve housing (6).
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft)

6. Install spring (10) to poppet (9). Install poppet (9)

to the hole of valve housing (6) completely. (2
places)
NOTE: If poppet (9) is installed to the end, spring
(10) may come off on the way.

W3-2-31
 UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Sprocket

B
C

D
A W105-03-07-040
W1SE-03-02-001

ZX110-3 Class, 120-3 Class Unit: mm (in)

Standard Allowable Limit

A 61.0 (2.4) [51.0 (2)]

Cladding
B 87.35 (3.4) 82.35 (3.2)
by
C 122.0 (4.8) 117.0 (4.6) welding
and hand
C’ PCD115.85 (4.6) -
finishing
D 171.45 (6.8) -
NOTE: The value in ( ) is for reference only.

ZX135US-3 Class Unit: mm (in)

Standard Allowable Limit

A 61.0 (2.4) 51.0 (2)

Cladding
B 73.85 (2.9) 68.85 (2.7)
by
C 108.5 (4.3) 103.5 (4.1) welding
and hand
C’ PCD102.35 (4) -
finishing
D 171.45 (6.8) 171.45 (6.8)
NOTE: The value in ( ) is just for reference.

W3-2-32
 UNDERCARRIAGE / Travel Device
Travel Motor
Shoe
1. Clearance between plunger and shoe bottom
Standard Allowable Limit
0 0.2 mm (0.008 in)

0.2 mm
Plunger

W105-02-06-130

2. Clearance between plunger outer diameter and

D
rotor inner bore
Standard Allowable Limit
0 0.04 mm (0.002 in)
Rotor

D-d 0.04 mm

W105-02-06-134

Plunger Assembly

d
Rotor

W105-02-06-135

3. Shoe thickness Shoe

Standard Allowable Limit
5.5 mm (0.2 in) 5.3 mm (0.2 in)

Plunger

W105-02-06-130

W3-2-33
 UNDERCARRIAGE / Travel Device
Parking Brake

B D

C W176-03-02-014

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Friction plate Thickness 2.4 (0.1) 2.35 (0.1)
B Disc spring (Overall height) 6.5 (0.3) 6.4 (0.3)
C Piston Thickness 40.2 (1.6) -
D Plate Thickness 1.4 (0.1) 1.35 (0.1)
Remarks No wear on the piston as it does not slide.

NOTE: The piston thickness is shown as the

distance from the contact point of the
spring to the contact point of the plate.

W3-2-34
 UNDERCARRIAGE / Center Joint
REMOVAL AND INSTALLATION OF
CENTER JOINT

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal

1. Disconnect hoses (2) (14 used) from the center 2

joint. Cap the open ends. Attach an identification
tag onto disconnect hoses (2) for assembling.
: 19 mm, 22 mm, 27 mm
Center Joint
1
2. Remove bolts (1) (2 used) from the center joint
and remove stopper (3).
: 19 mm
3
Machine Front
CAUTION: Center joint weight: 20 kg (44 lb)

3. Install an eyebolt to the center joint. Attach a wire

rope onto the eyebolt. Hoist and hold the center W102-03-03-001

joint. 4
Remove bolts (4) (3 used). Remove the center
joint. 2
: 17 mm

Track Frame

Machine Front
W190-03-03-001

W3-3-1
 UNDERCARRIAGE / Center Joint
Installation
4
CAUTION: Center joint weight: 20 kg (44 lb)
2
1. Install an eyebolt to the center joint. Attach a wire
rope onto the eyebolt. Install the center joint to
the track frame with bolts (4) (3 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)

2. Install stopper (3) to the center joint with bolts (1)

(2 used).
: 19 mm Track Frame
: 110 N m (11 kgf m, 81 lbf ft)
Machine Front
3. Connect hoses (2) (4 used) to the center joint. W190-03-03-001
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 70 N m (7 kgf m, 52 lbf ft)
: 27 mm 2
: 95 N m (9.5 kgf m, 70 lbf ft)

IMPORTANT: After completing the work, start the

engine and check for any oil leaks. 1
Center Joint

Machine Front

W102-03-03-001

W3-3-2
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-3
 UNDERCARRIAGE / Center Joint
DISASSEMBLY OF CENTER JOINT

3
7

10

11

12

W175-03-03-001

1 - Plug (with Ball Attached) 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
 UNDERCARRIAGE / Center Joint
Disassembly of Center Joint

IMPORTANT: Do not damage the seal sliding

CAUTION: Center joint weight: 20 kg (44 lb) surface of spindle (2).
5. Remove spindle (2) from body (7).
1. Remove bolts (12) (2 used) diagonally. Install an
eyebolt (M10, Pitch 1.5 mm, Length 18 mm: ST IMPORTANT: For easy removal of oil seal (6), use
0001) to the bolt (12) hole (2 places). Place the the pins (2 used). Do not damage
center joint on the workbench (ST 5061).
the seal groove by the pin.
: 17 mm 6. Remove oil seals (6) (6 used), O-ring (4) and
dust seal (3) from body (7).
IMPORTANT: Put the matching marks on body (7)
and spindle (2).
2. Remove bolts (12) (2 used). Remove cover (11)
from body (7).
: 17 mm

3. Remove O-ring (9), retaining ring (10) and ring

(8) from body (7).

4. Install the special tools (ST 1033, ST 1020) to

body (7) with bolts (12) (2 used).
: 17 mm

ST 1020

W105-03-03-015
ST 1033

12 IMPORTANT: While welding, cover the seal

surface in order to prevent from
welding spatter.
7. When replacing bushing (5), weld four places on
7 the bushing (5) bore by using a welding bar.
Shrink and remove bushing (5).

W506-03-03-002

W3-3-5
 UNDERCARRIAGE / Center Joint
ASSEMBLY OF CENTER JOINT

7 6

8
10
9

11
12

W175-03-03-002

1 - Plug (with Ball Attached) 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
 UNDERCARRIAGE / Center Joint
Assembly of Center Joint

IMPORTANT: If bushing (5) has been removed, IMPORTANT: Install ring (8) with the chamfered
install bushing (5) first. (Refer to side facing to the spindle (2) side.
W3-3-8.) 5. Install ring (8) and O-ring (9) to body (7).

1. Install O-ring (4) and dust seal (3) to body (7). 6. Install retaining ring (10) to spindle (2).

2. Install oil seals (6) (6 used) to body (7). 7. Install cover (11) with bolts (12) (4 used).
: 17 mm
IMPORTANT: Apply molybdenum disulfide onto : 50 N m (5.0 kgf m, 37 lbf ft)
the bushing (5) part and grease onto
the seal part when inserting spindle
(2). Do not damage bushing (5).
3. Place spindle (2) onto a workbench. Align the
matching marks made when disassembling and
install body (7) to spindle (2).

IMPORTANT: As the clearance between body (7)

and spindle (2) is approximately 0.1
mm (0.004 in), insert body (7) along
axis straight and slowly.
4. Lightly tap body (7) by using a plastic hammer.
Insert body (7) until body (7) comes in contact
with the flange part of spindle (2).

2 0.1 mm
(0.004 in)
7

W105-03-03-024

W3-3-7
 UNDERCARRIAGE / Center Joint

NOTE: When replacing body (7) or spindle (2) with

the new one, the following procedures are
required. ST 2770

In case of body (7) 7

1. Clean body (7) and bushing (5).

2. Install bushing (5) to body (7) by using the

special tool (ST 2770) and a press. 5
Pushing Force: 0.5 to 1.5 t (1100 to 3300 lb)

W105-03-03-029

In case of spindle (2) 1

1. Clean spindle (2). D
2
2. Install plug (1) to spindle (2) by using the special
tool (ST 2559).

3. Tap the ball of plug (1) so that the top of each ball
is 0.4 mm (0.02 in) or more lower than the
respective sleeve edge as illustrated in detail D.

W136-03-03-031

ST 2559

0.4 mm
Sleeve
(0.02 in)
or more

Ball

W157-03-03-004 Detail D
W135-03-03-001

W3-3-8
 UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD

Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure, abnormal wear Replace
3. Uneven wear within 180 Replace
Wear Area within
Half Range
Bushing

T157-01-01-040

Heavily damaged one by seizure or foreign Replace

Sliding surface with seals
matter
1) Excessively worn one by seizure or foreign Replace
Sliding surface between matter, or one having the score or 0.1 mm
body and spindle other (0.004 in) or more
than sliding surfaces with 2) One having the score of less than 0.1 mm Replace the
seals (0.004 in) surface smooth by
Body / using an oil stone
Spindle 1) One that has worn 0.5 mm (0.02 in) or Replace
more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or less Repair the surface
smooth
Sliding surface with ring
3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less than smooth
the allowable wear limit 0.5 mm (0.02 in)
and is repairable
1) One that has worn 0.5 mm (0.02 in) or more Replace
2) One that has worn less than 0.5 mm (0.02 Repair the surface
in) smooth
Cover Sliding surface with ring 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less than smooth
the allowable wear limit 0.5 mm (0.02 in)
and is repairable

W3-3-9
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-10
 UNDERCARRIAGE / Track Adjuster
REMOVAL AND INSTALLATION OF
TRACK ADJUSTER
Before removing and installing the track adjuster, the
track and the front idler should be removed first. (Refer
to REMOVAL AND INSTALLATION OF TRACK on
W3-7-1, REMOVAL AND INSTALLATION OF FRONT
IDLER on W3-5-1.)
Therefore, the procedure starts on the premise that the
track and the front idler have already been removed
here.

Removal
2

CAUTION: Track adjuster (1) weight: 1

ZX110-3 class: 50 kg (110 lb)
ZX120-3 class: 55 kg (125 lb)
ZX135US-3 class: 60 kg (135 lb)

CAUTION: Track adjuster (1) may fly out due W157-03-04-003

to the spring force when removing track
adjuster (1). Do not stand in the same Spring
direction to remove track adjuster (1) or Nut
where track adjuster (1) may fly out.
Particularly, the spring force is always
applied to the thread part of the rod. If the rod
and/or the threads are damaged, metal
fragments due to the spring force may fly out.

1. Pry and remove track adjuster (1) from track

frame (2) by using a pry bar.
W1R7-03-04-001
Rod
Thread Part

W3-4-1
 UNDERCARRIAGE / Track Adjuster
Installation
2

CAUTION: Track adjuster (1) weight: 1

ZX110-3 class: 50 kg (110 lb)
ZX120-3 class: 55 kg (125 lb)
ZX135US-3 class: 60 kg (135 lb)

1. Hoist track adjuster (1). Insert track adjuster (1)

into spring guide (3) in track frame (2). W157-03-04-003

At this time, check that track adjuster (1) comes

into contact with the end of plate (4).

2. Install the front idler. (Refer to REMOVAL AND 4

INSTALLATION OF FRONT IDLER on W3-5-1.)
3
3. Install the track. (Refer to REMOVAL AND
2
INSTALLATION OF TRACK on W3-7-1.)

W1V7-03-04-008

W3-4-2
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-3
 UNDERCARRIAGE / Track Adjuster
DISASSEMBLY OF TRACK ADJUSTER

2
3
4
5

9
10 11

12 W1R7-03-04-002

1 - Holder 4 - U-Ring 7 - Spring 10 - Plug

2 - Piston Rod 5 - Cylinder 8 - Spacer 11 - Nut
3 - Dust Seal 6 - Rod 9 - Washer 12 - Valve

W3-4-4
 UNDERCARRIAGE / Track Adjuster
Disassembly of Track Adjuster

IMPORTANT: Use the special tool (ST 4920) when

CAUTION: Track adjuster weight:
assembling and disassembling the
track adjuster. ZX110-3 class: 50 kg (110 lb)
ZX120-3 class: 55 kg (125 lb)
ZX135US-3 class: 60 kg (135 lb)
CAUTION: As the spring force is too strong,
carry out the disassembly and assembly 3. Attach a wire rope onto the track adjuster. Hoist
work carefully. Inspect the special tool (ST the track adjuster. Place the track adjuster on the
4920) for any damage thoroughly in order to holder of the special tool (ST 4920).
perform the work safely.
Wire Rope
CAUTION: The special tool (ST 4920) weight:
225 kg (500 lb)
Track Adjuster
1. Place an oil jack (30 tons) between the holder and
the base.

Nut

Holder

Holder

W105-03-04-009

Oil Jack

CAUTION: The special tool (ST 4036) weight:

Base
36 kg (80 lb)
W105-03-04-006
Install the plate (ST 4036) on the track adjuster in
order to cover.

CAUTION: The special tool (ST 4036) weight:

36 kg (80 lb) ST 4036

2. Remove nuts (4 used) from the special tool (ST

4920). Attach a nylon sling onto the eyebolts (2
used) in the plate (ST 4036). Hoist and remove
the plate (ST 4036) from the special tool (ST
4920).
: 46 mm

ST 4036
W105-03-04-011

ST 4920

W105-03-04-007

W3-4-5
UNDERCARRIAGE / Track Adjuster

9
10 11

12 W1R7-03-04-002

W3-4-6
 UNDERCARRIAGE / Track Adjuster
6. Tighten the nut of the special tool (ST 4920) and
CAUTION: As spring (7) is compressed, a
secure the track adjuster.
strong force is applied. Check if the track Operate the oil jack. Compress the track adjuster
adjuster assembly is installed correctly when until a clearance is observed between washer (9)
raised. and nut (11). (Approximately 10 mm)
: 46 mm
5. Operate the oil jack. Raise the track adjuster
assembly until nut (11) comes out from the center
hole on the plate (ST 4036).

Spring (7) compression length:

ZX110-3 class:
Spring free length (428.3 mm (16.9 in)) - spring set
length (354 mm (13.9 in)) = spring compressed
length (74.3 mm (2.9 in))
Nut
ZX120-3 class:
Spring free length (464 mm (18.3 in)) - spring set
length (383.5 mm (15.1 in)) = spring compressed
length (80.5 mm (3.2 in))
W105-03-04-012
ZX135US-3 class:
Spring free length (479 mm (18.9 in)) - spring set
length (407 mm (16 in)) = spring compressed
7. Remove plug (10) from nut (11). Remove nut (11)
length (72 mm (2.8 in))
and valve (12) from rod (6).
: 5 mm
: 24 mm, 65 mm
Oil Jack

11 6 10

W105-03-04-013

W105-03-04-014

W3-4-7
 UNDERCARRIAGE / Track Adjuster

2
3
4
5

9
10 11

12 W1R7-03-04-002

W3-4-8
 UNDERCARRIAGE / Track Adjuster
8. Loosen the oil jack.
CAUTION: Spring (7) weight:
ZX110-3 class: 22 kg (50 lb)
ZX120-3 class: 25 kg (60 lb)
ZX135US-3 class: 31 kg (70 lb)

11. Remove the eyebolt. Remove spring (7) from the

rod (6) assembly.
Oil Jack

Eyebolt

W105-03-04-015

CAUTION: The special tool (ST 4036) weight:

36 kg (80 lb)

9. Remove the nuts (4 used) and the plate (ST

4036) of the special tool (ST 4920). Remove W105-03-04-017
washer (9) from spring (7).
12. Remove spacer (8) from rod (6).
ST 4036
IMPORTANT: Holder (1) is installed in piston rod
(2).
13. Remove piston rod (2) from cylinder (5).

14. Remove holder (1) from piston rod (2) by using a

9 press.

IMPORTANT: Rod (6) is installed in cylinder (5).

15. Remove rod (6) from cylinder (5).
W105-03-04-016

IMPORTANT: Do not damage dust seal (3) and

U-ring (4).
CAUTION: The spring (7) assembly weight:
16. Remove dust seal (3) and U-ring (4) from cylinder
ZX110-3 class: 47 kg (105 lb)
(5).
ZX120-3 class: 51 kg (115 lb)
ZX135US-3 class: 58 kg (130 lb)

10. Install an eyebolt (M16, Pitch 1.5 mm) to rod (6).

Hoist and remove the spring (7) assembly from
the special tool (ST 4920).

W3-4-9
 UNDERCARRIAGE / Track Adjuster
ASSEMBLY OF TRACK ADJUSTER

1 2 5 APart A 7 6 11 12

10

9
3 4 8
B

C
W1R7-03-04-003

1 - Holder 4 - U-Ring 7 - Spring 10 - Plug

2 - Piston Rod 5 - Cylinder 8 - Spacer 11 - Nut
3 - Dust Seal 6 - Rod 9 - Washer 12 - Valve

ZX110-3 Class ZX120-3 Class ZX135US-3 Class

354 mm 383.5 mm 407 mm
B
(Free length 428.3 mm) (Free length 464 mm) (Free length 479 mm)
C 506.5 mm 542 mm 562.5 mm
NOTE: 1 mm = 0.03937 in

W3-4-10
 UNDERCARRIAGE / Track Adjuster
Assembly of Track Adjuster

1. Install rod (6) to cylinder (5).

CAUTION: The spring (7) assembly weight:
2. Apply grease onto the inner surface of U-ring (4) ZX110-3 class: 47 kg (105 lb)
and dust seal (3). Install U-ring (4) and dust seal ZX120-3 class: 51 kg (115 lb)
(3) to cylinder (5). Fill part A in cylinder (5) with ZX135US-3 class: 58 kg (130 lb)
grease.
7. Install an eyebolt (M16, Pitch 1.5 mm) to rod (6).
Hoist and place the spring (7) assembly on the
3. Install holder (1) to piston rod (2).
special tool (ST 4920).
4. Install the piston rod (2) assembly to cylinder (5).
Bleed air from part A and rod (6).

5. Install spacer (8) to rod (6). 6

CAUTION: Spring (7) weight:

ZX110-3 class: 22 kg (50 lb)
ZX120-3 class: 25 kg (60 lb)
ZX135US-3 class: 31 kg (70 lb)

6. Install spring (7) to the rod (6) assembly.

W105-03-04-017

CAUTION: The special tool (ST 4036) weight:

36 kg (80 lb)

8. Remove the eyebolt. Place washer (9) on spring

(7) and install the plate (ST 4036).

ST 4036

W105-03-04-016

W3-4-11
UNDERCARRIAGE / Track Adjuster

7 6 11

10

W1R7-03-04-003

W3-4-12
 UNDERCARRIAGE / Track Adjuster
9. Tighten the nut of the special tool (ST 4920) and 11. Install nut (11) and plug (10) to rod (6).
secure the spring (7) assembly. : 65 mm
: 46 mm : 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
Nut

6
11 10

W105-03-04-012

10. Operate the oil jack. Compress spring (7) to the

specified length.
Specified length: W105-03-04-014
ZX110-3 class: 354 mm (13.9 in)
ZX120-3 class: 383.5 mm (15.1 in)
ZX135US-3 class: 407 mm (16 in)

Oil Jack

W105-03-04-026

W3-4-13
UNDERCARRIAGE / Track Adjuster

6 12

W1R7-03-04-003

W3-4-14
 UNDERCARRIAGE / Track Adjuster
12. Install valve (12) to rod (6).
: 24 mm CAUTION: Track adjuster weight:
: 90 N m (9 kgf m, 66 lbf ft) ZX110-3 class: 50 kg (110 lb)
ZX120-3 class: 55 kg (125 lb)
ZX135US-3 class: 60 kg (135 lb)
13. Loosen the oil jack.
15. Attach a wire rope onto the track adjuster. Hoist
and remove the track adjuster from the special
Oil Jack tool (ST 4920).

Wire Rope

ST 4920

W105-03-04-013

W105-03-04-009

CAUTION: The special tool (ST 4036) weight:

36 kg (80 lb)
CAUTION: If only the track adjusted is
transported, use a special tool as illustrated
14. Remove the nuts (4 used) of the special tool (ST
in order to transport the track adjuster safely.
4920). Attach a nylon sling onto eyebolts (2 used)
in the plate (ST 4036). Hoist and remove the plate
(ST 4036) from the special tool (ST 4920).
: 46 mm

ST 4036

W105-03-04-028

ST 4920

W105-03-04-011

W3-4-15
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-16
 UNDERCARRIAGE / Front Idler
REMOVAL AND INSTALLATION OF FRONT
IDLER
Removal

Before removing the front idler, the tracks should be

removed first. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-7-1.)
Therefore, the procedure starts on the premise that
the tracks have already been removed here.

CAUTION: Front idler (1) may fly out due to W110-03-05-001

the spring force when removing front idler (1).
Do not stand in the same direction to remove
front idler (1) or where front idler (1) may fly
out.

1. Remove front idler (1) with yoke (2) together from 3

track frame (3) by using a pry bar.

CAUTION: Front idler (1) weight: 82 kg (181 1

lb)
2

W178-03-05-001
2. Attach a sling belt onto the bearing part and the
yoke (2) part of front idler (1) as illustrated. Hoist
and remove front idler (1) from track frame (3).

3. When keeping front idler (1) temporarily, place

front idler (1) on the wooden blocks as illustrated. Wooden
Block

W178-03-05-002

W3-5-1
 UNDERCARRIAGE / Front Idler
Installation
CAUTION: Front idler (1) weight: 82 kg (181
lb)
(b)

1. Install the front idler (1) in the reverse way of

removal. Check the followings. 3
• Clean sliding surface (a) of yoke (2) and sliding
surface (b) of track frame (3). Apply grease.

(a)
3
W178-03-05-004

W3-5-2
 UNDERCARRIAGE / Front Idler
(Blank)

W3-5-3
 UNDERCARRIAGE / Front Idler
DISASSEMBLY OF FRONT IDLER

2
1
3 8
4
7 6

5
4
3
2
1
8

9 W1V7-03-05-001

10

1 - Bearing (2 Used) 4 - O-Ring (2 Used) 7 - Idler 9 - Yoke

2 - Pin (2 Used) 5 - Axle 8 - Plug (2 Used) 10 - Bolt (4 Used)
3 - Floating Seal (2 Used) 6 - Bushing (2 Used)

W3-5-4
 UNDERCARRIAGE / Front Idler
Disassembly of Front Idler

1. Attach a nylon sling onto yoke (9). Hoist and hold 4. Put the matching marks on bearing (1) and axle
yoke (9). Remove bolts (10) (4 used). Remove (5) by using a press. Remove the axle (5)
yoke (9) from the idler (7) assembly. assembly from the idler (7) assembly. Remove
: 24 mm O-ring (4) from axle (5).

CAUTION: The idler (7) assembly weight: 67 1 5

kg (150 lb)
4
2. Place the idler (7) assembly horizontally. Remove
plug (8) at the lower side. Drain oil from the idler 7
(7) assembly.
: 6 mm

3. Remove pin (2) from upper bearing (1) by using a

round bar (Dia.: 16 mm) and a hammer.
W105-03-05-008

IMPORTANT: As for handling floating seal (3),

refer to Floating Seal Precautions on
W1-1-4.
5. Remove upper bearing (1) from idler (7). Remove
floating seals (3) (2 used) from both sides of idler
(7) and bearing (1).

W105-03-05-009

W3-5-5
 UNDERCARRIAGE / Front Idler

2
1

4
6

5
4

2
1

W1V7-03-05-001

W3-5-6
 UNDERCARRIAGE / Front Idler
IMPORTANT: Place a wooden block under bearing
(1) in order not to damage bearing CAUTION: Idler (7) weight: 48 kg (110 lb)
(1).
6. Attach a nylon sling onto the axle (5) assembly. IMPORTANT: Do not remove bushing (6) unless
Hoist and place bearing (1) onto wooden blocks. necessary.
8. When replacing bushing (6), remove bushing (6)
7. Remove pin (2) by using a bar and a hammer. Put by using the special tools (ST 1955) and a press.
the matching marks on bearing (1) and axle (5).
Remove axle (5) from bearing (1) by using a
press. Remove O-rings (4) (2 used) from axle (5).

7
ST 1955
2 4

Wooden
Block
6

5
W105-03-05-011

4
W105-03-05-010

W3-5-7
 UNDERCARRIAGE / Front Idler
ASSEMBLY OF FRONT IDLER

1 2 3 5 6 7 8

4 10 9
W1V7-03-05-002

1 - Bearing (2 Used) 4- O-Ring (2 Used) 7- Idler 9 - Yoke

2 - Pin (2 Used) 5- Axle 8- Plug (2 Used) 10 - Bolt (4 Used)
3 - Floating Seal (2 Used) 6- Bushing (2 Used)

W3-5-8
 UNDERCARRIAGE / Front Idler
Assembly of Front Idler

IMPORTANT: As for handling floating seal (3),

CAUTION: Idler (7) weight: 48 kg (110 lb)
refer to Floating Seal Precautions on
W1-1-4.
1. Install bushings (6) (2 used) to idler (7). 4. Apply oil onto the O-ring outer surface of floating
seal (3). Install a pair of floating seals (3) to idler
2. Place axle (5) vertically. Install O-ring (4) to the (7) and bearing (1).
upper side of axle (5).
5. Attach a nylon sling onto bearing (1) of the axle
3. Align the matching marks made when (5) assembly. Hoist and insert the axle (5)
disassembling. Evenly tap and install bearing (1) assembly into idler (7) where floating seal (3) was
to axle (5) by using a plastic hammer. Insert pin installed. Apply LOCTITE #503 onto plug (8).
(2) by using a bar and a hammer. (Sealant has been applied on new plug (8).)
Install plug (8) to bearing (1).
2 : 6 mm
5 : 30 N m (3 kgf m, 22 lbf ft)

1
3 1

4 W105-03-05-014

W157-03-05-006
7

W3-5-9
 UNDERCARRIAGE / Front Idler

1 2 3 5 7 8

4 10 9
W1V7-03-05-002

W3-5-10
 UNDERCARRIAGE / Front Idler
CAUTION: The idler (7) assembly weight: 61
kg (135 lb)
6. Attach a nylon sling onto the idler (7) assembly.
Hoist and turn over the idler (7) assembly. Install
O-ring (4) to axle (5).
IMPORTANT: As for handling floating seal (3),
refer to Floating Seal Precautions on
W1-1-4.
7. Apply oil onto the O-ring outer surface of floating
seal (3). Install other floating seal (3) to idler (7)
and bearing (1).
10. Apply LOCTITE #503 onto plug (8). (Sealant has
been applied on new plug (8).) Install plug (8) to
bearing (1).
: 6 mm
: 30 N m (3 kgf m, 22 lbf ft)
11. Attach a nylon sling onto yoke (9). Hoist yoke (9).
Align the bolt (10) holes of bearing (1) and yoke
(9) of on both sides.
12. Install yoke (9) to bearing (1) with bolts (10) (4
used).
: 24 mm
: 206 N m (21 kgf m, 152 lbf ft)

1 3 4 7

W157-03-05-005

IMPORTANT: Align the matching marks made

when disassembling.

8. Evenly tap and install other bearing (1) to axle (5)

by using a plastic hammer. Insert pin (2) by using
a bar and a hammer. At this time, do not damage
O-ring (4).

9. Add engine oil (API CD class SAE30) through the

plug (8) hole on bearing (1).
NOTE: Oil amount: 235 mL (0.06 US gal.)

W3-5-11
 UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD

C D

A
B

W157-03-05-001

Unit: mm (in)
Standard Allowable Limit Remedy

A 68 (2.7) [52 (2)]

B 135 (5.3) -
Cladding by
C 454 (17.9) 442 (17.4) welding and hand
finishing
D 489 (19.3) -

E 17.5 (0.7) 23.5 (0.9)

Axle and Bushing Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outer Dia. 65.0 (2.6) [64.2 (2.5)]

Inner Dia. 65.0 (2.6) [66 (2.6)] Replace

Bushing
Flange Thickness 2 (0.1) [1.2 (0.05)]

NOTE: The value in [ ] is just for reference.

W3-5-12
 UNDERCARRIAGE / Upper And Lower Roller
REMOVAL AND INSTALLATION OF
UPPER ROLLER
Removal
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the high-pressure grease may spout out, do
not loosen valve (1) quickly and/or
excessively.
Keep body parts and face away from valve
(1), and loosen valve (1) carefully.
Do not loosen grease fitting (2).
W105-03-06-001

IMPORTANT: Remove gravel or mud between the

sprockets and tracks (3) before
1
loosening valve (1). Loosen valve (1)
1 to 1.5 turns is enough. Do not
loosen valve (1) over those turns.
1. Loosen valve (1) in the track adjuster and drain
grease.
: 24 mm 2
Grease Outlet

W1V7-03-04-006

Hydraulic Jack
3
CAUTION: Use a nonskid cloth between
track frame (5) and the hydraulic jack in
order not to slip.

2. Raise track (3) until enough clearance is

observed between upper roller (4) and track (3)
by using a hydraulic jack.

Nonskid Cloth 4
5
W105-03-06-002
3. Insert the wooden blocks between track (3) and
Wooden Block 3
track frame (5).

W105-03-06-003

W3-6-1
 UNDERCARRIAGE / Upper And Lower Roller
4. Remove bolts (6) (4 used).
: 19 mm

W157-03-06-001

5. Remove upper roller (4) from track frame (5).

Installation
1. Install upper roller (4) to track frame (5) with bolts
(6) (4 used). 5
: 19 mm W105-03-06-005

: 98 N m (10 kgf m, 72 lbf ft)

6
5
2. Remove the wooden block and the hydraulic
W157-03-06-001
jack.
Hydraulic Jack
3

5 Wooden Block
W105-03-06-003

W3-6-2
 UNDERCARRIAGE / Upper And Lower Roller

CAUTION: Support the raised machine by

using blocks.
1
3. Tighten valve (1) in the track adjuster.
: 24 mm
: 90 N m (9 kgf m, 66 lbf ft)

4. Raise track (3) to be adjusted. Rotate track (3) in 2

the reverse direction a little. Apply grease
through grease fitting (2) and adjust the track (3)
Grease Outlet
tension.
W1V7-03-04-006
NOTE: Track sag specifications (A) steel crawler:
250 to 280 mm (9.8 to 11 in)

5. Lower track (3).

3
W1R7-03-07-005

IMPORTANT: Replace upper roller (4) as an 4

assembly.
6. Add engine oil (API CD class SAE30) through the
plug (8) part on cover (7).
NOTE: Oil amount: 40 mL (0.01 US gal.)
7

7. Apply LOCTITE #503 or equivalent onto plug (8).

(Sealant has been applied on new plug (8).)
8
Install plug (8) to cover (7).
: 6 mm
: 29.5 N m (3 kgf m, 22 lbf ft)

W158-03-06-001

W3-6-3
 UNDERCARRIAGE / Upper And Lower Roller
REMOVAL AND INSTALLATION OF
LOWER ROLLER
Removal 5
1. After removing the track guard, remove bolts (1)
(4 used).
: 24 mm 1

W105-03-06-008

2. Raise track frame (2) high enough (90 to 110

between boom and arm is obtained when the
bucket is lowered with the round bottom
contacting with ground). At this time, place a 90 to 110
stand under track frame (2) and support the
machine.

2 M104-07-067

CAUTION: The pressure inside the adjuster

cylinder is high. As valve (3) may fly out and
the high-pressure grease may spout out, do
not loosen valve (3) quickly and/or
excessively.
Keep body parts and face away from valve
(3) and loosen valve (3) carefully.
Do not loosen grease fitting (4).
Loosening valve (3) 1 to 1.5 turns is enough.
Do not loosen valve (3) over those turns.

W105-03-06-001

3. Loosen valve (3) of the track adjuster. Adjust the

track sag enough.
3
: 24 mm

Grease Outlet
W1V7-03-04-006

W3-6-4
 UNDERCARRIAGE / Upper And Lower Roller

CAUTION: Lower roller (5) weight: 21 kg (46

lb)

4. Remove lower roller (5) by using a fork lift.

W105-03-06-010

Installation
1. Set lower roller (5) below track frame (2) by using
a fork lift.

5
W105-03-06-011

2
2. Lower the machine so that track frame (2) may
keep a little away from collar (6).

6 W105-03-06-012

3. Align the bolt holes on lower roller (5). Install

lower roller (5) to track frame (2) with bolts (1) (4
used).
: 24 mm
: 310 N m (31 kgf m, 230 lbf ft)
1

W105-03-06-008

W3-6-5
 UNDERCARRIAGE / Upper And Lower Roller

CAUTION: Support the raised machine by

using blocks.
3
4. Tighten valve (3) on the track adjuster.
: 24 mm
: 90 N m (9 kgf m, 66 lbf ft)

4
5. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
Grease Outlet
W1V7-03-04-006

6. Apply grease through grease fitting (4) and adjust

the track tension.
NOTE: Track sag specifications (A) steel crawler:
250 to 280 mm (9.8 to 11 in)

W1R7-03-07-005

W3-6-6
 UNDERCARRIAGE / Upper And Lower Roller
(Blank)

W3-6-7
 UNDERCARRIAGE / Upper And Lower Roller
DISASSEMBLY OF LOWER ROLLER

3
2
4 1
5

7
6
5
4
3
2
1

W157-03-06-004

1 - Plug (2 Used) 3 - Pin (2 Used) 5 - Floating Seal (2 Used) 7 - Roller

2 - Collar (2 Used) 4 - O-Ring (2 Used) 6 - Bushing (2 Used) 8 - Axle

W3-6-8
 UNDERCARRIAGE / Upper And Lower Roller
Disassembly of Lower Roller 4. Remove pin (3) from the axle (8) assembly.
Remove axle (8) from collar (2) by using a press.
CAUTION: Lower roller weight: 21 kg (46 lb) 4 2

1. Remove plug (1) from the end of collar (2). Drain

oil from roller (7).
: 6 mm
8
2. Put the matching marks on collar (2) and axle (8).
Remove pin (3) from collar (2) on one side by
using a round bar (Dia.: 8 mm) and a hammer.
Remove axle (8) from roller (7), from the side
where pin (3) was removed by using a press. At
this time, pin (3) and collar (2) at the opposite W178-02-11-268

side are removed together. At this time, do not

damage O-ring (4). 5. Remove O-rings (4) (2 used) from axle (8).

IMPORTANT: Do not remove bushing (6) unless

necessary.
2 5 7 5 6. When replacing bushing (6), remove bushing (6)
by using the special tool (ST 1928) and a press.

5
2 ST 1928

6
4 8
7
W1R7-03-06-002

3. Remove floating seals (5) (2 used) from both

sides of roller (7) and collars (2) (2 used) W178-02-11-269

respectively.

W3-6-9
 UNDERCARRIAGE / Upper And Lower Roller
ASSEMBLY OF LOWER ROLLER

2 7 6 5 4 3 1

W105-03-06-023

1 - Plug (2 Used) 3 - Pin (2 Used) 5 - Floating Seal (2 Used) 7 - Roller

2 - Collar (2 Used) 4 - O-Ring (2 Used) 6 - Bushing (2 Used) 8 - Axle

W3-6-10
 UNDERCARRIAGE / Upper And Lower Roller
Assembly of Lower Roller

1. Install bushings (6) (2 used) to roller (7). 4. Insert axle (8) into roller (7). Apply grease onto
At this time, do not dent the flange surface of O-ring (4). Install O-ring (4) to the roller (7)
bushing (6). assembly. Install other collar (2) in the same way
Apply grease onto O-ring (4). Install O-ring (4) to and secure with pin (3).
axle (8).
2 5 8 7
2. Install collar (1) to one side of axle (8) and secure
with pin (2) while aligning the pin holes.
At this time, do not damage O-ring (4).

3
4
8 W157-03-06-009

IMPORTANT: Apply LOCTITE #503 or equivalent

onto plug (1). (Sealant has been
applied on new plug (1).)
5. Add engine oil (API CD class SAE30) through the
plug (1) part on collar (2) and install plug (1).
2 4
W105-03-06-031 NOTE: Oil amount: 200 mL (0.05 US gal.)
: 6 mm
IMPORTANT: As for handling floating seal (3), : 30 N m (3 kgf m, 22 lbf ft)
refer to Floating Seal Precautions
on W1-1-4.
3. Apply oil onto the O-ring outer surface of floating 3 7
seal (5). Install floating seal (5) to roller (7) and
1
collar (2).

7 5

2 W1R7-03-06-001

5 2

W157-03-06-008

W3-6-11
 UNDERCARRIAGE / Upper And Lower Roller
MAINTENANCE STANDARD
Upper Roller

A
B
W1V7-03-06-002

Unit: mm (in)
Standard Allowable Limit Remedy

A 72 (2.8) -

B 120 (4.7) - Replace

C 100 (3.9) 90 (3.5)

W3-6-12
 UNDERCARRIAGE / Upper And Lower Roller
Lower Roller

W157-03-06-003

Unit: mm (in)
Standard Allowable Limit Remedy

A 146 (5.7) [165.4 (6.5)]

B 186 (7.3) - Cladding by

welding and
C 20 (0.8) [10.3 (0.3)] hand finish

D 130 (5.1) 112 (4.4)

Axle and Bushing Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outer dia. 50 (2) [49.2 (1.9)]

Inner dia. 50 (2) [51 (2)] Replace

Bushing
Flange thickness 2 (0.1) [1.2 (0.05)]

NOTE: The value in [ ] is just for reference.

W3-6-13
 UNDERCARRIAGE / Upper And Lower Roller
(Blank)

W3-6-14
 UNDERCARRIAGE / Track
REMOVAL AND INSTALLATION OF
TRACK 1
2
Removal

1. Rotate the tracks so that master pin (3) is

positioned over front idler (2). Place a wooden
block under shoe (1) and support shoe (1).

Wooden
Block W105-03-07-006

CAUTION: The pressure inside the adjuster

cylinder is high. As valve (4) may fly out and
the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or 4
excessively.
Keep body parts and face away from valve
(4) and loosen valve (4) carefully. Do not
loosen grease fitting (5).

IMPORTANT: Loosening valve (4) 1 to 1.5 turns is

enough. Do not loosen valve (4)
over those turns.
W105-03-07-002
IMPORTANT: When gravel or mud is packed
between sprockets and track links, 4
remove them before loosening.
2. Loosen the track tension.
: 24 mm

Grease Outlet
W1V7-03-04-006

W3-7-1
 UNDERCARRIAGE / Track
3. Remove snap ring (6) from master pin (3).
7
NOTE: If snap ring (6) cannot be removed, push
master pin (3) to the removing direction in
order to make clearance between snap 3
ring (6) and master pin (3).

CAUTION: The front idler may fly out due to

the spring force when removing the track. 6
Particularly, strong force is always applied to
the thread part of the rod. If the rod and/or
the threads are damaged, metal fragments
due to the spring force may fly out. W105-03-07-009

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary
protection, such as goggles and hard hats.

IMPORTANT: Master pin (3) can be removed to

only one direction. Check the
removing direction.
4. Remove master pin (3) by using the special tool
(ST 1970) and a hammer.

Corner Part
Direction to
Direction to Install
Remove

Snap Ring
Track Link 3
Master Link

W105-03-07-010
ST 1970

W1V1-03-07-001

W3-7-2
 UNDERCARRIAGE / Track
5. Operate the boom and the arm so that the angle
between them is 90 to 110°. Lower the boom with
the round bottom contacting with the ground.
Raise the track frame and pull out the track. At
this time, place a stand under the track frame and
support the machine. 90 to 110

CAUTION: The track assembly (standard

spec.) weight:
ZX110-3 class: 1360 kg (3000 lb) Stand M104-07-067

ZX120-3 class, 135US-3 class: 1470 kg (3250

lb)

6. Slowly operate the travel lever on the side with

the track to be removed to the reverse position
and extend the track.

W105-03-07-011

W3-7-3
 UNDERCARRIAGE / Track
Installation

1. Raise the machine. Set the track under the

machine so that sprocket (8) meshes with the
track end. Check the direction of the track at this
time. Front Idler Sprocket (8)
(2) Side Side

CAUTION: The track assembly (standard

spec.) weight:
ZX110-3 class: 1360 kg (3000 lb)
ZX120-3 class, 135US-3 class: 1470 kg (3250 W105-03-07-013

lb)

2. Hoist and mesh sprocket (8) with the claws of the

track.

W105-03-07-014

3. With the machine raised, slowly operate the lever

for the track to be installed in the forward
direction. Turn travel device (9) and wind the
track.

W105-03-07-015

4. Wind the track link until the connection part of the

track link reaches the front idler (2) side. Lower
the machine. Place a wooden block under shoe
(1) and support shoe (1).

W105-03-07-016

Wooden
Block

W3-7-4
 UNDERCARRIAGE / Track
IMPORTANT: Master pin (3) can be installed to
only one direction. Check the Corner Part
installing direction.
5. Install the special tool (ST 1970). Install master Direction to Direction
Remove to Install
pin (3) to the track.

Snap Ring
3
Track Link Master Link

ST 1970 W105-03-07-010

W1V1-03-07-001
IMPORTANT: As snap ring (6) is easy to deform,
replace snap ring (6) with a new one 7
rather than reuse.
6. Install snap ring (6).
Snap ring (6) has the direction to install. Install
snap ring (6) to the groove of master link (7) with
the flat surface of a pair of pliers hole facing
forward. 6

W105-03-07-009
Bushing
IMPORTANT: If disassembling the link, fill grease Seal
(Daphne Epones SR) into the
clearance between the pin and the Pin
bushing. Apply grease onto the
bushing end.
Stand the bushing on a flat plate. Fill
the bushing bore with grease. Insert
the pin into the bushing while
holding the bushing in order not to
move due to grease. Wipe off
excess grease.
Check the direction to install the Apply
Do not apply grease. Do not apply
seal. grease. grease.

W197-03-07-001
Seal

W3-7-5
 UNDERCARRIAGE / Track
7. Tighten adjuster valve (4). Apply grease through
grease fitting (5). Adjust the track tension. 4
: 24 mm
: 88 N m (9 kgf m, 65 lbf ft)
NOTE: Track sag specification (A): 250 to 280 mm
(9.8 to 11 in)

W1V7-03-04-006

W1R7-03-07-005

W3-7-6
 UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link
Measure the length of four links.
• Do not include the master pin.
• Measure the length with tension on the track.

W155-03-07-001

Unit: mm (in)
Allowable
Standard Remedy
Limit
A 687.4 (27) [707.9 (28)] Cladding by welding and hand
B 89 (3.5) [82 (3.2)] finishing, or replace

W3-7-7
 UNDERCARRIAGE/ Track
Master Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy

A 107.5 (4.2) -

B 34.1 (1.3) [37.1 (1.5)] Replace

C 50.67 (2) [45.67 (1.8)]

Master Pin

W105-03-07-021

Unit: mm (in)
Standard Allowable Limit Remedy

A 163.9 (6.5) -
Replace
B 33.75 (1.3) [30.75 (1.2)]

NOTE: The value in [ ] is just for reference.

W3-7-8
 UNDERCARRIAGE/ Track
Pin

W142-03-07-004

Unit: mm (in)
Standard Allowable Limit Remedy

A 175 (6.9) -
Replace
B 33.5 (1.3) [30.5 (1.2)]

Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy

A 117.4 (4.6) -

B 34.1 (1.3) [35.1 (1.4)] Replace

C 50.67 (2) [45.67 (1.8)]

NOTE: The value in [ ] is just for reference.

W3-7-9
 UNDERCARRIAGE/ Track
Grouser Shoe

W105-03-07-024

Unit: mm (in)
Shoe Size 500 mm Grouser

Standard Allowable Limit Remedy

A 191.5 (7.5) -
Cladding by
B 8 (0.3) -
welding
C 20 (0.8) 14 (0.6)

A
W187-03-07-001

Unit: mm (in)
Shoe Size 500 mm Pat Crawler

Standard Allowable Limit Remedy

A 181 (7.1) -

B 8 (0.3) - Replace

C 65 (2.6) 14 (0.6)

NOTE: If any crack, damage or falling off is shown

in the pat shoe, check the broken condition
of the shoe and replace the shoe before
reaching the above allowable limit.

W3-7-10
 MEMO

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 MEMO

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........................................................................................................................................................................
 SECTION 4
FRONT ATTACHMENT

CONTENTS
Group 1 Front Attachment
Hydraulic Circuit Pressure
Release Procedure ................................ W4-1-1
Removal and Installation of
Front Attachment (Monoblock Boom)..... W4-1-2
Maintenance Standard........................... W4-1-12
Standard Dimensions for
Arm and Bucket Connection ................ W4-1-15
Standard Dimensions for
Arm and Boom Connection .................. W4-1-16

Group 2 Cylinder
Hydraulic Circuit Pressure
Release Procedure ................................ W4-2-1
Removal and Installation of Cylinder ....... W4-2-2
Disassembly of Boom and
Bucket Cylinders.................................. W4-2-14
Disassembly of Arm Cylinder................. W4-2-18
Assembly of Boom and
Bucket Cylinders.................................. W4-2-22
Assembly of Arm Cylinder...................... W4-2-26
Maintenance Standard........................... W4-2-30

1R7W-4-1
(Blank)

1R7W-4-2
 FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE

NOTE: This operates the pilot pump by using the

power of the starter without starting the
engine and delivers the pilot pressure to the
control valve spool. Control Lever

1. Turn pilot shut-off lever (1) to the UNLOCK

position.

2. Turn engine stop switch (2) ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position,
operate the control lever 4 to 5 times.

4. Return pilot shut-off lever (1) to the LOCK

2 1
position.
M1U1-01-029

5. Turn engine stop switch (2) OFF.

W4-1-1
 FRONT ATTACHMENT / Front Attachment
REMOVAL AND INSTALLATION OF FRONT
ATTACHMENT (MONOBLOCK BOOM)
Adapter
Removal
1
1. As for the lubrication hoses to the front attachment,
disconnect hose (1) to the boss at the boom
cylinder rod side from the adapter. (2 places at
right and left)
: 17 mm Boom Cylinder

W105-04-01-002

2 3
2. Remove nut (4) and bolt (6). Remove stopper (5)
from pin (4).
: 24 mm
6 Boom Cylinder
CAUTION: Boom cylinder weight:
ZX110 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to 5
prevent personal injury. 4
W178-04-01-004
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylinder
tube end. By using a bar and a hammer, tap pin
(2) into the position where thrust plate (3) can be
removed. Remove thrust plate (3).
NOTE: When pin (2) cannot be removed, start the
engine and operate the boom lever. Adjust
the rod end pin (4) hole on the boom
cylinder.

W4-1-2
 FRONT ATTACHMENT / Front Attachment
4. Place the end of the boom cylinder on a stand of 1
m (39 in) height.
Start the engine. Operate the boom lever and
retract the boom cylinder. In order not to extend
the rod, pass a wire through the rod hole and Boom Cylinder
secure the rod to the cylinder tube.
Stop the engine.
Wire
5. After stopping the engine, push the air bleed
button. Bleed air from the hydraulic oil tank and
remove the cap.
W1R7-04-01-010
Release the pressure in the hydraulic circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RRLEASE PROCEDURE on W4-1-1.
ZX110-3 class, 120-3 class
Air Bleed Button

W1V1-04-01-008
6. Disconnect hoses (10) (4 used) of the boom
cylinder at the cylinder side. Install a plug to
disconnected hoses (12). ZX135US-3 class
: 27 mm Air Bleeding Circuit

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to
prevent personal injury.

7. Remove nuts (9) (2 used) and bolt (7) from the

cylinder bottom side of the main frame.
Remove pin (8) and thrust plate (11) from the
W1R7-04-01-009
boom cylinder.
: 24 mm Boom Cylinder
11 7

9
10 W187-04-02-009

W4-1-3
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom cylinder weight:

ZX110 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)
CAUTION: Attach a wire rope onto the boom
cylinder so that the wire rope does not touch
the pipe of the boom cylinder.

8. Attach a wire rope at the center of gravity of the

boom cylinder. Hoist and remove the boom
Boom Cylinder
cylinder.
Remove other boom cylinder in the same way as
steps 3 to 8.
W187-04-01-001

9. Disconnect hoses (12) (4 used) from the bucket

cylinder and the arm cylinder. Cap disconnected ZX110-3 class, 120-3 class
hoses (12) (4 used).
: 27 mm, 36 mm

12 12

W1R7-04-01-001

ZX135US-3 class
12
12

10. Remove bolts (15) (9 used). Remove tool box (13)

and cover (14) from the main frame.
: 17 mm

W1R7-04-01-002

15

14

13

W1R7-04-01-003

Main Frame

W4-1-4
 FRONT ATTACHMENT / Front Attachment

NOTE: Steps 11 and 12 are required for removal of

ZX135US-3 class.
11. Remove bolts (17) (5 used). Remove cover (16)
from the upper side of the upperstructure side. 16
: 17 mm

W1R7-04-01-004
17

18 19, 20
12. Open cover (18). Remove bolts (20) (5 used) and
(22) (7 used) from covers (19, 21). Remove
covers (19, 21) from the main frame.
: 17 mm
21, 22

W1R7-04-01-005

Main Frame

W4-1-5
 FRONT ATTACHMENT / Front Attachment
13. Remove bolt (25) and spring washer (24) from
plate (26) of boom foot pin (23). Remove plate 23
(26) and block (27) from the main frame.
: 27 mm

CAUTION: Front attachment weight:

ZX110-3 class: 1980 kg (4370 lb) 27
ZX120-3 class: 2220 kg (4890 lb) 26 Main Frame
ZX135US-3 class: 3100 kg (6840 lb)
25
14. Attach a wire rope onto the boom. Take up slack of
24
the wire rope.
W1R7-04-01-006

Boom
15. Insert a pry bar between the plate of boom foot pin
(23) and the main frame. Pull out the plate a little.

16. While rotating the plate upward by hand, remove

boom foot pin (23) by rotating to right and left.
(Adjust the position by using a lifting rope for the
front attachment.)

CAUTION: Boom foot pin (23) weight: 23 kg W105-04-01-008

(51 lb)
23
17. Hoist the front attachment and move the machine
backward.

18. Place a wooden block under the front attachment.

Lower the front attachment.
Plate
Insert a pry bar.

W1R7-04-01-006

W178-04-01-005

W4-1-6
 FRONT ATTACHMENT / Front Attachment
Installation

CAUTION: Front attachment weight:

ZX110-3 class: 1980 kg (4370 lb)
ZX120-3 class: 2220 kg (4890 lb)
ZX135US-3 class: 3100 kg (6840 lb)

1. Hoist the front attachment. Move the machine

forward and align the boom foot with the mounting
hole on the main frame.
Insert a thrust plate into the left and right sides of
the boom. Adjust the clearance between the main
frame and the boom within 1 mm (0.039 in).
(Adjust the position by using a lifting rope for the W178-04-01-005
front attachment.)

CAUTION: Boom foot pin (23) weight: 23 kg

(51 lb)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles and hard hats in order to
prevent personal injury. 23

2. Install boom foot pin (23). Secure boom foot pin

(23) with bolt (25), washer (24), plate (26) and
block (27). 27
: 27 mm
26
: 400 N m (41 kgf m, 295 lbf ft)
25

24
W1R7-04-01-006

15
3. Install tool box (13) and cover (14) to the main
14
frame with bolts (15) (9 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft)
13

W1R7-04-01-003

Main Frame

W4-1-7
 FRONT ATTACHMENT / Front Attachment

NOTE: Steps 4 and 5 are required for installation of 18 19, 20

ZX135US-3 class.

4. Install covers (19, 21) to the main frame with bolts

(20) (5 used) and (22) (7 used). Shut cover (18).
: 17 mm
21, 22
: 50 N m (5 kgf m, 37 lbf ft)

W1R7-04-01-005

Main Frame

5. Install cover (16) to the upper side of the

upperstructure side with bolts (17) (5 used).
: 17 mm
: 50 N m (5 kgf m, 37 lbf ft) 16

W1R7-04-01-004
17

6. Connect hoses (12) (4 used) to the bucket ZX110-3 class, 120-3 class
cylinder and the arm cylinder.
: 27 mm
: 78 N m (8 kgf m, 58 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft) 12 12

W1R7-04-01-001

ZX135US-3 class
12
12

W1R7-04-01-002

W4-1-8
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom cylinder weight:

ZX110 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg(243 lb)
CAUTION: Attach a wire rope onto the boom
cylinder so that the wire rope does not touch
the pipe of the boom cylinder.

7. Attach a wire rope at the center of gravity of the

boom cylinder. Hoist the boom cylinder. Align the
hole on the cylinder bottom side with the mounting Boom Cylinder
hole on the main frame.

CAUTION: Metal fragments may fly off when W187-04-01-001

a hammer is used. Wear necessary protection,

such as goggles, hard hats, etc in order to
prevent personal injury. Boom Cylinder
11 7
8. Insert thrust plate (11) and pin (8). Install them
with bolt (7) and nut (9).
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf ft) 8

9. Install other boom cylinder in the same way. 9

10. Connect hoses (10) (4 used) to the boom

cylinders (2 used). 8
: 27 mm 9
: 78 N m (8 kgf m, 58 lbf ft)
10 W187-04-02-009

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose
connections.

W4-1-9
 FRONT ATTACHMENT / Front Attachment
11. Hoist and hold the boom cylinder rod side.
Operate the boom lever and align the rod side pin
hole with the mounting hole on the boom.

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to 2 3
prevent personal injury.

12. Install thrust plate (3). Install pin (2).

6
Boom Cylinder
13. Install stopper (5) to the boom cylinder with bolt (8)
and nut (6).
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf ft)

14. Install other boom cylinder in the same way.

5
4
W178-04-01-004

15. Connect lubrication hose (1) to the rod side of the Adapter
boom cylinder. (2 places on both right and left) 1
: 17 mm
: 24.5 N m (2.5 kgf m, 18 lbf ft)

IMPORTANT: When completing the work, operate Boom Cylinder

the boom cylinder to the stroke end
several times and bleed air from the
circuit.

W105-04-01-002

W4-1-10
 FRONT ATTACHMENT / Front Attachment
16. Apply grease onto the boom cylinder rod side, the ZX110-3 class, 120-3 class
bottom side and the boom foot side.

IMPORTANT: When the arm has been removed Boom Cylinder

from the boom, perform the Rod Side
following steps when installing the Boom Foot
arm. Side
17. Install thrust plate (25) to the left and right sides of
the arm. Adjust total clearance of left and right
within 1.5 mm (0.1 in).

18. After installing the arm, apply grease onto grease W1R7-04-01-001

fitting (26) in the boom connecting boss of the ZX135US-3 class

arm. Boom Cylinder Rod
Side
IMPORTANT: For handling of the HN bushing for
the front attachment, check the
followings. Boom Foot
Side
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged.
Use a press.

Precautions when reinforcing the arm

W1R7-04-01-002
The heat when welding in order to reinforce the arm
may cause oil leakage from HN bushing and decrease
lubrication performance.
When the welding heat causes the oil leakage of the
bushing, replace it.

Use the special tool (ST 1454) when removing or

installing the bushing.

Boom Cylinder W1R7-04-01-007

Bottom Side

25 25

26 26

W1R7-04-01-011

W4-1-11
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD F E
G

Pin and Bushing C H

J
A D

II
B K

W1R7-04-01-008

Unit: mm (in)
Standard Allowable Limit
Part Name ZX120-3 class, ZX120-3 class, Remedy
ZX110-3 class ZX110-3 class
Pin 71 (2.8) 70 (2.8)
A
Bushing 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70 (2.8)
B Boss (main frame) 71 (2.8) 72.5 (2.9)
Bushing (boom cylinder) 71 (2.8) 72.5 (2.9)
Pin 65 (2.6) 71 (2.8) 64 (2.5) 70 (2.8)
C Bushing (boom cylinder) 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Boss (boom) 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Pin 65 (2.6) 71 (2.8) 64 (2.5) 70 (2.8)
D
Bushing 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Pin 65 (2.6) 71 (2.8) 64 (2.5) 70 (2.8)
E Boss (arm) 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Bushing (arm cylinder) 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Pin 65 (2.6) 71 (2.8) 64 (2.5) 70 (2.8)
Replace
F Boss (boom) 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Bushing (arm cylinder) 65 (2.6) 71 (2.8) 66.5 (2.6) 72.5 (2.9)
Pin 60 (2.4) 59 (2.3)
G Boss (boom) 60 (2.4) 61.5 (2.4)
Bushing (bucket cylinder) 60 (2.4) 61.5 (2.4)
Pin 65 (2.6) 64 (2.5)
H Bushing 65 (2.6) 66.5 (2.6)
Bushing (bucket cylinder) 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64 (2.5)
I
Bushing 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64 (2.5)
J
Bushing 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64 (2.5)
K
Bushing 65 (2.6) 66.5 (2.6)

W4-1-12
 FRONT ATTACHMENT / Front Attachment
IMPORTANT: When replacing the HN bushing for
the front attachment, install it by
using a press and the special tool
(ST 1454).

W4-1-13
 FRONT ATTACHMENT / Front Attachment
Side Cutter

C
D

W155-04-01-002

Unit: mm (in)
Standard Allowable Limit Remedy
A 229 (9) 149 (5.9)
B 245 (9.6) -
Replace
C 330 (13) -
D 135 (5.3) -

Point

B C

W105-04-01-020

Unit: mm (in)
Standard Allowable Limit Remedy
A 178.5 (7) 90 (3.5)
B 79 (3.1) -
Replace
C 95 (3.7) -
D 81 (3.2) -

W4-1-14
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

Section A Section B
W187-04-01-003

Unit: mm (in)
ZX110-3 ZX110 ZX120-3 ZX120 ZX135US-3 ZX135US
a 325 (12.8)
b 5 (0.2)
c 505 (19.9)
d 460 (18.1)
e
f 1230 (48.4)
g 377 (14.8)
h 254 (10)
i 65 (2.6)
j 355.2 (14)
k 70 (2.8)
l 377 (14.8)
m 255 (10)
n 65 (2.6)
o 90
p 30 90 30 90 30 90
q 391 (15.4)

IMPORTANT: If the front attachment of a previous NOTE: Dimension h: 254 mm (10 in) includes the
model machine is used, use the clearance for shims to adjust bucket
grease intervals for the previous clearance.
model machine.

W4-1-15
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION

Section C

W187-04-01-002

Unit: mm (in)
ZX110-3 ZX110 ZX120-3 ZX120 ZX135US-3 ZX135US
s 65 (2.6) 71 (2.8)
t 260 (10.2) 273 (10.7)
u 390 (15.4) 403 (15.9)

IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals for the previous
model machine.

W4-1-16
 FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

NOTE: This operates the pilot pump by using the

power of the starter without starting the
engine and delivers the pilot pressure to
the control valve spool. Control Lever

1. Turn pilot shut-off lever (1) to the UNLOCK posi-

tion.

2. Turn engine stop switch (2) ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, oper-
ate the control lever 4 to 5 times in order to re-
lease any pressure in the circuit.
2 1
4. Return pilot shut-off lever (1) to the LOCK posi-
tion. M1U1-01-029

5. Turn engine stop switch (2) OFF.

W4-2-1
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF CYL-
INDER
1
Removal of Bucket Cylinder

1. Insert wooden block (3) between the ground and

the end of arm (2), and between arm (2) and
bucket cylinder (1). 3

2. Stop the engine. Push the air bleed button and 2

bleed air from the hydraulic oil tank. Remove the 3
cap. (Refer to BLEED AIR FROM HYDRAULIC
OIL TANK on W1-4-1.) W554-04-02-006

Release the pressure in the bucket circuit.

Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.

CAUTION: Before removing pin (7), fasten

the link by using a wire in order not to fall
off.
4 5
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles and hard hats, in order
to prevent personal injury.

3. Remove nut (6) and bolt (4). Remove pin (7).

Remove thrust plates (5) (4 used).
: 24 mm

4. In order not to extend rod (8) of bucket cylinder

7 6
(1), pass wire (9) through the cylinder rod hole
and secure to the bucket cylinder (1) tube. W158-04-02-006
8 1

9 W102-04-02-005

W4-2-2
 FRONT ATTACHMENT / Cylinder
5. Disconnect hoses (12) (2 used) from bucket cyl-
10
inder (1). Cap the open ends.
: 27 mm

CAUTION: Bucket cylinder (1) weight:

ZX110-3 class: 95 kg (210 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb) 15
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec- 14 11
tion, such as goggles and hard hats, in order 13
to prevent personal injury.

6. Hoist and hold bucket cylinder (1). Remove nut

(13) and bolt (15). Remove pin (11). Remove
thrust plates (10) (2 used) and stopper (14). 1
: 24 mm

7. Remove bucket cylinder (1).

12 W187-04-02-004

W4-2-3
 FRONT ATTACHMENT / Cylinder
Installation of Bucket Cylinder
10

CAUTION: Bucket cylinder (1) weight:

ZX110-3 class: 95 kg (210 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)
CAUTION: Metal fragments may fly off when
a hammer is used when installing pin (11). 15
Wear necessary protection, such as goggles 14
and hard hats, in order to prevent personal 11
injury. 13

1. Hoist bucket cylinder (1). Align the hole on the

cylinder tube side with the bucket cylinder (1)
mounting hole on the arm. Install thrust plates
(10) (2 used) and pin (11). 1

2. Install stopper (14) and pin (11) to the arm. Se-

cure with bolt (15) and nut (13).
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf·ft) 12 W187-04-02-004

3. Connect hoses (12) (2 used) to bucket cylinder

(1). 8 1
: 27 mm
: 78 N m (8 kgf m, 58 lbf·ft)

4. Remove wire (9) from rod (8) of bucket cylinder

(1).

9 W102-04-02-005

W4-2-4
 FRONT ATTACHMENT / Cylinder

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 16 4 17 5 1
tion, such as goggles and hard hats, in order
to prevent personal injury.

5. Start the engine. Operate the lever and align the

hole on the bucket cylinder (1) rod side with
those on links (16, 18). Install thrust plates (5) (4
used) and pin (7).

6. Secure stopper (17) and pin (7) with bolt (4) and
7 18 6
nuts (6) (2 used).
: 24 mm W158-04-02-006

: 270 N m (27.5 kgf m, 200 lbf·ft)

IMPORTANT: In case link (18) has been removed

19 19
from the arm, insert thrust plate (19)
when installing link (18).
IMPORTANT: After completing the work, add hy-
draulic oil to the specified level.
Operate bucket cylinder (1) to the
stroke end several times and bleed
air from the circuit.
At the same time, check each con- 18 18
W157-04-01-015

nection of the hoses for any oil

leaks.

W4-2-5
 FRONT ATTACHMENT / Cylinder
Removal of Arm Cylinder
1
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).

2. Remove nuts (8) (2 used) and bolt (10) from pin

(5) at the rod side in arm cylinder (1). 2
(ZX110-3 class)
: 24 mm
(ZX120-3 class, 135US-3 class)
: 30 mm
3 W187-04-02-005

CAUTION: Metal fragments may fly off when 10 4 5

a hammer is used. Wear necessary protec- 9
tion, such as goggles and hard hats, in order 1
to prevent personal injury.

3. Start the engine. While operating the boom and

the arm, adjust the rod pin hole. Remove pin (5).
Remove stopper (9) and thrust plates (4) (4
used). Lower the boom gently.

W187-04-02-006

4. In order not to extend rod (6) of arm cylinder (1),

pass wire (7) through the cylinder rod hole and 6 1
secure to the arm cylinder (1) tube.

5. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank. Remove the
cap. (Refer to BLEED AIR FROM HYDRAULIC
OIL TANK on W4-1-1.)
Release the pressure in the arm circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.
7 W187-04-02-010

W4-2-6
 FRONT ATTACHMENT / Cylinder
6. Disconnect hoses (11) (2 used) at the bottom of 11
arm cylinder (1). Cap the disconnected hoses
(11). 1
: 36 mm

7. Disconnect lubrication hose (12) from arm cylin-

der (1).
: 17 mm

CAUTION: Arm cylinder (1) weight:

ZX110-3 class: 130 kg (290 lb)
ZX120-3 class, 135US-3 class: 160 kg (360 lb) 12 W102-04-02-014

8. Attach a nylon sling at the center of gravity of arm

1
cylinder (1). Hoist and hold arm cylinder (1).

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles and hard hats, in order
to prevent personal injury.

9. Remove nuts (15) (2 used) and bolt (17) from the

tube side in arm cylinder (1). Remove pin (14).
Remove thrust plate (13) and stopper (16). Hoist
W102-04-02-016
and remove arm cylinder (1).
(ZX110-3 class)
17 13 14
: 24 mm
(ZX120-3 class, 135US-3 class)
1
: 30 mm

15

W187-04-02-007

W4-2-7
 FRONT ATTACHMENT / Cylinder
Installation of Arm Cylinder
17 13 14

CAUTION: Arm cylinder (1) weight: 1

ZX110-3 class: 130 kg (290 lb)
ZX120-3 class, 135US-3 class: 160 kg (360 lb)

1. Attach a nylon sling at the center of gravity of arm

16
cylinder (1). Hoist arm cylinder (1). Align the hole 15
on the cylinder tube side with the arm cylinder (1)
mounting hole on the boom.

W187-04-02-007
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec- 11
tion, such as goggles and hard hats, in order 1
to prevent personal injury.

2. Install thrust plate (13) and pin (14). Install bolt

(17) to pin (14) and stopper (16). Install nuts (15)
(2 used).
(ZX110-3 class)
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf·ft)
(ZX120-3 class, 135US-3 class)
: 30 mm 12 W102-04-02-014
: 550 N m (56 kgf m, 410 lbf·ft)

3. Connect lubrication hose (12) and hoses (11) (2

used) of arm cylinder (1).
: 17 mm
: 29.5 N m (3 kgf m, 22 lbf·ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf·ft)

W4-2-8
 FRONT ATTACHMENT / Cylinder
4. Remove wire (7) from rod (6) of arm cylinder (1).
6 1
Hoist and hold arm cylinder (1). Start the engine.
Operate the lever and align the hole at the cylin-
der rod (6) side with the mounting hole on arm
(18).
18

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles and hard hats, in order
to prevent personal injury. 7
W187-04-02-010

5. Install thrust plate (4) and pin (5). Secure pin (5) 9 10 4 5
and stopper (9) with bolt (10) and nuts (8) (2
used).
(ZX110-3 class)
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf·ft)
(ZX120-3 class, 135US-3 class) 1
: 30 mm
: 550 N m (56 kgf m, 410 lbf·ft)

IMPORTANT: After completing the work, add hy-

draulic oil to the specified level.
8
Operate arm cylinder (1) to the
stroke end several times and bleed W187-04-02-006

air from the circuit.

At the same time, check each con-
nection of the hoses for any oil
leaks.

W4-2-9
 FRONT ATTACHMENT / Cylinder
Removal of Boom Cylinder
1
1. Disconnect lubrication hose (1) from boom cylin-
der (4).
: 17 mm

CAUTION: Boom cylinder (4) weight:

ZX110-3 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)

IMPORTANT: Attach a wire rope onto boom cyl-

inder (4) so that the wire rope does
not touch the pipe of boom cylinder W105-04-02-032
(4).
2. Attach a wire rope onto boom cylinder (4). Hoist
2 3
and hold boom cylinder (4).

CAUTION: Metal fragments may fly off when

4
a hammer is used. Wear necessary protec- 7
tion, such as goggles and hard hats, in order
to prevent personal injury.

3. Remove nuts (5) (2 used), bolt (7) and stopper

(6) from the boom cylinder (4) rod side. Remove
pin (2) and thrust plate (3).
6
4. Place the tube end of boom cylinder (4) on a 5
stand. Remove other boom cylinder (4) in the W178-04-01-004

same way.

5. Operate the lever and retract boom cylinder (4).

Wire
In order not to extend the rod, pass a wire
through the rod hole and secure to the cylinder
tube.
Stand
6. Stop the engine. Push the air bleed button and
bleed air from the hydraulic oil tank. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
Release the pressure in the circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
4
RELEASE PROCEDURE on W4-2-1. W187-04-02-008

W4-2-10
 FRONT ATTACHMENT / Cylinder
7. Disconnect hoses (13) (4 used) at the bottom of
boom cylinder (4). Install a plug (13/16-16UN) to
disconnected hoses (13). Cap the open end of
boom cylinder (2).
: 27 mm

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles and hard hats, in order
to prevent personal injury.

8. Remove nuts (12) (2 used) and bolts (10) (2

used) from the cylinder bottom side of the main
frame. W187-04-02-009
Remove pin (11) and thrust plates (9) (4 used).
: 24 mm

CAUTION: Boom cylinder (4) weight:

ZX110-3 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)

IMPORTANT: Attach a wire rope onto boom cyl-

inder (4) so that the wire rope does
not touch the pipe of boom cylinder
4
(4).
9. Attach a wire rope at the center of gravity of
boom cylinder (4). Hoist and remove boom cyl-
inder (4).
Remove other boom cylinder (4) in the same
way. W187-04-01-001

W4-2-11
 FRONT ATTACHMENT / Cylinder
Installation of Boom Cylinder

CAUTION: Boom cylinder (4) weight:

ZX110-3 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)

IMPORTANT: Attach a wire rope onto boom cyl-

inder (4) so that the wire rope does
not touch the pipe of boom cylinder
(4).
1. Attach a wire rope at the center of gravity of
boom cylinder (4). Hoist boom cylinder (4). Align
the hole at the cylinder bottom side with the
mounting hole on the main frame.
4

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles and hard hats, in order W187-04-01-001

to prevent personal injury.

2. Install thrust plates (9) (4 used) and pin (11). Se-

cure them with bolt (10) and nuts (12) (2 used).
4
(Monoblock boom) 9 10
: 24 mm
: 270 N m (27.5 kgf m, 200 lbf·ft)

3. Install other boom cylinder (4) in the same way. 11

4. Connect hoses (13) (4 used) to boom cylinders 12

(4) (2 used).
: 27 mm
: 78 N m (8 kgf m, 58 lbf·ft) 11

12
13 W187-04-02-009

W4-2-12
 FRONT ATTACHMENT / Cylinder
5. Hoist boom cylinder (4). Start the engine. Oper-
ate the lever and align the hole at the cylinder rod
side with the mounting hole on the boom. 2 3
4

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 7
tion, such as goggles and hard hats, in order
to prevent personal injury.

6. Insert thrust plate (3) and install pin (2).

7. Secure stopper (6) with bolt (7) and nuts (5) (2

used). 6
: 24 mm 5
: 270 N m (27.5 kgf m, 200 lbf·ft) W178-04-01-004

8. Connect lubrication hose (1).

: 17 mm 1
: 29.5 N m (3 kgf m, 22 lbf·ft)

9. Install other boom cylinder (4) in the same way.

IMPORTANT: After completing the work, add hy-

draulic oil to the specified level.
Operate boom cylinder (4) to the
stroke end several times and bleed
air from the circuit. 4
At the same time, check each con-
nection of the hoses for any oil
leaks. W105-04-02-032

W4-2-13
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF BOOM AND BUCKET CYLINDERS
Boom Cylinder
11 1 2 3 4 8 7 5 6 9 10

19 20 21 24 23 22

W191-04-02-001

14 13 20 19 16 15 17 18 16 12

Bucket Cylinder
11 1 2 3 4 8 7 5 6 9 10

20 21 24 23 22

W191-04-02-002

20 19 16 15 17 18 16 19 12

1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt 14 - Cushion Seal 20 - Slide Ring (2 Used)
Bucket Cylinder
(ZX110-3 class: 10 Used)
ZX120-3 class, 135US-3 class: 12 Used)
Boom Cylinder
(ZX110-3 class: 10 Used)
ZX120-3 class, 135US-3 class: 12 Used)
3- U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut

W4-2-14
 FRONT ATTACHMENT / Cylinder
Disassembly of Boom and Bucket Cylinders
• The disassembling procedure starts on the
premise that the hydraulic pipings and the bands
securing the pipings have been removed.
4. Secure piston rod (11) to the special tool (ST
5908). Put the matching marks on piston rod (11)
and the end of nut (24).

ST 5908
CAUTION: Cylinder weight:
Boom cylinder
ZX110-3 class: 100 kg (220 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)
Bucket cylinder
ZX110-3 class: 95 kg (210 lb)
ZX120-3 class, 135US-3 class: 110 kg (243 lb)
W158-04-02-022
1. Hoist the cylinder. Secure the cylinder horizon-
tally on a workbench. Drain hydraulic oil from the
cylinder.

W102-04-02-027

IMPORTANT: Remove piston rod (11) straight in

order not to damage the sliding
surface.
Fully extend piston rod (11). Hold piston rod (1).
Remove socket bolts (8) (ZX110-3 class: 10
used) (ZX120-3 class, 135US-3 class: 12 used).
: 12 mm

3. Tap and remove cylinder head (7) from cylinder

tube (12) by using a plastic hammer.

W4-2-15
 FRONT ATTACHMENT / Cylinder
Boom Cylinder

11 1 2 3 4 7 5 6 9 10

19 20 21 24 23 22

W191-04-02-001

14 13 20 19 16 15 17 18 16

Bucket Cylinder
11 1 2 3 4 7 5 6 9 10

20 21 24 23 22

W191-04-02-002

20 19 16 15 17 18 16 19

W4-2-16
 FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill 7. Remove seal ring (17), slide rings (19, 20) (2
and remove set screw (22). Remove steel ball used for each), O-ring (18) and backup rings (16)
(23). (2 used) from piston (15).
Boom cylinder
(ZX110-3 class) 8. Remove cylinder head (7) from piston rod (11).
: 8 mm
(ZX120-3 class, 135US-3 class) 9. Remove O-ring (10) and backup rings (2, 9) from
: 10 mm cylinder head (7). Remove wiper ring (1), U-ring
Bucket cylinder (3), buffer ring (4), snap ring (6) and bushing (5)
: 8 mm by using the special tool.
Special tool (outer diameter at rod part):
NOTE: Set screw (22) has been crimped by using Boom cylinder
a punch at 2 places after installing. (ZX110-3 class)
ST 8017, ST 1284 (70 mm)
6. Remove piston nut (24), piston (15) and shim (ZX120-3 class, 135US-3 class)
(21) by using the special tool (ST 5908) and the
ST 8017, ST 1284 (70 mm)
special tool. (As for the boom cylinder only, re-
Bucket cylinder
move cushion bearing (13) and cushion seal
(ZX110-3 class)
(14).)
ST 8015, ST 1283 (65 mm)
Special tool (outer diameter at nut part): (ZX120-3 class, 135US-3 class)
Boom cylinder ST 8017, ST 1284 (70 mm)
(ZX110-3 class)
ST 3271 (75 mm)
(ZX120-3 class, 135US-3 class)
ST 3262 (80 mm)
Bucket cylinder
ST 3271 (75 mm)

ST 5908

W158-04-02-022

W4-2-17
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF ARM CYLINDER

NOTE: The illustration shows ZX110-3 class.

11 1 2 3 4 7 5 6 9 10

15 16 25 26 28 22 12
14 13

20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017

1 - Wiper Ring 8 - Socket Bolt 15 - Piston 22 - Set Screw

Bucket Cylinder (ZX110-3 class: 12 Used)
ZX120-3 class, 135US-3 class: 10 Used)
2- Backup Ring 9 - Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper

W4-2-18
 FRONT ATTACHMENT / Cylinder
Disassembly of Arm Cylinder
• The disassembling procedure starts on the
premise that the hydraulic pipings and the bands
securing the pipings have been removed.
4. Secure piston rod (11) to the special tool (ST
5908). Put the matching marks on piston rod (11)
and the end of piston nut (24).

ST 5908
CAUTION: Arm cylinder weight:
ZX110-3 class: 130 kg (290 lb)
ZX120-3 class, 135US-3 class: 160 kg (353 lb)

1. Hoist the cylinder. Secure the cylinder horizon-

tally on a workbench. Drain hydraulic oil from the
cylinder.
W158-04-02-022

W102-04-02-027

IMPORTANT: Pull out piston rod (11) straight in

order not to damage the sliding
surface.
2. Fully extend piston rod (11). Hold piston rod (11).
Remove socket bolts (8) (ZX110-3 class: 10
used) (ZX120-3 class, 135US-3 class: 12 used).
Socket bolt (8)
(ZX110-3 class)
: 12 mm
ZX120-3 class, 135US-3 class)
: 14 mm

3. Tap and remove cylinder head (7) from cylinder

tube (12) by using a plastic hammer.

W4-2-19
 FRONT ATTACHMENT / Cylinder

11 1 2 3 4 7 5 6 9 10

15 16 25 26 28 22 12
14 13

20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017

W4-2-20
 FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill
and remove set screw (22). Remove steel ball
(23).
NOTE: Set screw (22) has been crimped by using
a punch at 2 places after installing.
: 10 mm
6. Remove piston nut (24), piston (15), shim (21),
cushion bearing (13) and cushion seal (14) by
using the special tool (ST 5908) and the special
tool.
Special tool (outer diameter at nut part):
(ZX110-3 class)
ST 3262 (80 mm)
(ZX120-3 class, 135US-3 class)
ST 3304 (85 mm)
ST 5908
W158-04-02-022
7. Remove seal ring (17), slide rings (19, 20) (2
used for each), O-ring (18) and backup rings (16)
(2 used) from piston (15).
W4-2-21
8. Remove cylinder head (7) from piston rod (11).
9. Remove O-ring (10) and backup rings (2, 9) from
cylinder head (7). Remove wiper ring (1), U-ring
(3), buffer ring (4), snap ring (6) and bushing (5)
by using the special tool.
Special tool (outer diameter at rod part):
(ZX110-3 class)
ST 8018, ST 1285 (75 mm)
(ZX120-3 class, 135US-3 class)
ST 8019, ST 1286 (80 mm)
10. Remove stopper ring (25) from piston rod (11) by
using a screwdriver. Move cushion bearing (27)
to the snap ring side. Remove stopper (28). Re-
move cushion bearing (27) and cushion seal (26).
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF BOOM AND BUCKET
CYLINDERS
Boom Cylinder

Hole (1 place)
Face the slit to the piston side.
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20
21
22, 23
24

Check the direction of oil

groove when installing. W178-04-02-003

Bucket Cylinder

Hole (1 place)

1 2 3 4 5 6 7 8 9, 10
11 12 15 16 17, 18 19 20
21
22, 23
24

W187-04-02-001

1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt 14 - Cushion Seal 20 - Slide Ring (2 Used)
Bucket Cylinder
(ZX110-3 class: 10 Used)
ZX120-3 class, 135US-3 class: 12 Used)
Boom Cylinder
(ZX110-3 class: 10 Used)
ZX120-3 class, 135US-3 class: 12 Used)
3- U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut

W4-2-22
 FRONT ATTACHMENT / Cylinder
Assembly of Boom and Bucket Cylinders

1. Install bushing (5) to cylinder head (7) by using 6. Install the cylinder head (7) assembly to piston
the special tool. rod (11) by using the special tool.
Special tool (outer diameter at rod): Special tool (outer diameter at rod):
Boom cylinder Boom cylinder
ST 8017, ST 1284 (70 mm) ST 8017, ST 2361 (70 mm)
Bucket cylinder Bucket cylinder
(ZX110-3 class) (ZX110-3 class)
ST 8015, ST 1283 (65 mm) ST 8015, ST 2346 (65 mm)
(ZX120-3 class, 135US-3 class) (ZX120-3 class, 135US-3 class)
ST 8017, ST 1284 (70 mm) ST 8017, ST 2361 (70 mm)

IMPORTANT: Check the direction to install. IMPORTANT: Face the slit in cushion seal (14) to
2. Install U-ring (3), backup ring (2), buffer ring (4) the piston nut (24) side. Check the
and snap ring (6) to cylinder head (7). direction of the oil groove in cushion
bearing (13).
3. Install wiper ring (1) to cylinder head (7) by using 7. (Boom cylinder only)
the special tool and a plastic hammer. Install cushion bearing (13) and cushion seal (14)
Special tool (outer diameter at rod): to piston rod (11). Install the piston (15) assembly
Boom cylinder to piston rod (11).
ST 8017, ST 1295 (70 mm)
Bucket cylinder
(ZX110-3 class)
ST 8015, ST 1294 (65 mm)
(ZX120-3 class, 135US-3 class)
ST 8017, ST 1295 (70 mm)

4. Install O-ring (10) and backup ring (9) to cylinder

head (7).

5. Install O-ring (18), backup rings (16) (2 used),

seal ring (17) and slide rings (19, 20) (2 used for
each) to piston (15).

W4-2-23
 FRONT ATTACHMENT / Cylinder
Boom Cylinder

Detail 8
7
Detail
11 12 21 22, 23

24

W178-04-02-003

Bucket Cylinder

Detail
7 8
11 12 21 22, 23

24

W187-04-02-001

W4-2-24
 FRONT ATTACHMENT / Cylinder
8. Install shim (21) to piston rod (11). 9. Align the holes on piston rod (11) and piston nut
Align the matching marks and tighten piston nut (24). Install steel ball (23) to piston rod (11).
(24) by using the special tool (ST 5908) and the Tighten with set screw (22). Crimp set screw (22)
special tool. by using a punch at 2 places. If the holes cannot
Special tool (outer diameter at nut part): be aligned, tighten piston nut (24).
Boom cylinder Boom cylinder
(ZX110-3 calss) (ZX110-3 class)
ST 3271 (75 mm) : 8 mm
: 2390 N m (245 kgf m, 1770 lbf ft) : 31.5 5.9 N m (3.2 0.6 kgf m, 23 4 lbf ft)
(ZX120-3 class, 135US-3 class) (ZX120-3 class, 135US-3 class)
ST 3262 (80 mm) : 10 mm
: 3140 N m (320 kgf m, 2320 lbf ft) : 57 10.7 N m (5.8 1.1 kgf m, 42 8 lbf ft)
Bucket cylinder Bucket cylinder
(ZX110-3 class) : 8 mm
ST 3271 (75 mm) : 31.5 5.9 N m (3.2 0.6 kgf m, 23 4 lbf ft)
: 3580 N m (365 kgf m, 2640 lbf ft)
(ZX120-3 class, 135US-3 class) IMPORTANT: Align the piston rod (11) assembly
ST 3271 (75 mm) with the center of cylinder tube (12)
: 3970 N m (405 kgf m, 2930 lbf ft) and insert straight in order not to
damage the rings.
10. Secure cylinder tube (12) horizontally on a work-
ST 5908
bench. Insert the piston rod (11) assembly into
cylinder tube (12).

11. Install cylinder head (7) to cylinder tube (12) with

socket bolts (8) (ZX110-3 class: 10 used)
(ZX120-3 class, 135US-3 class: 12 used).
Boom and bucket cylinders:
W158-04-02-022 : 12 mm
: 171 N m (17.4 kgf m, 126 lbf·ft)

W4-2-25
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF ARM CYLINDER

NOTE: The illustration shows ZX110-3 class.

Face the slit to the piston side.

Hole (1 place)

1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26

27

28

Check the direction of oil

groove when installing.
W178-04-02-005

1 - Wiper Ring 8 - Socket Bolt 15 - Piston 22 - Set Screw

Bucket Cylinder (ZX110-3 class: 12 Used)
ZX120-3 class, 135US-3 class: 10 Used)
2- Backup Ring 9 - Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper

W4-2-26
 FRONT ATTACHMENT / Cylinder
Assembly of Arm Cylinder

1. Install bushing (5) to cylinder head (7) by using
the special tool.
Special tool (outer diameter at rod):
(ZX110-3 class)
ST 8018, ST 1285 (75 mm (2.9 in))
(ZX120-3 class, 135US-3 class)
ST 8019, ST 1286 (80 mm (3.1 in))
IMPORTANT: Check the direction to install.
2. Install U-ring (3), backup ring (2), buffer ring (4),
and snap ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) by using
the special tool and a plastic hammer.
Special tool (outer diameter at rod):
(ZX110-3 class)
ST 8018, ST 1296 (75 mm (2.9 in))
(ZX120-3 class, 135US-3 class)
ST 8019, ST 1297 (80 mm (3.1 in))
IMPORTANT: Face the slit in cushion seal (14) to
the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (13).
7. Install cushion seal (14) and cushion bearing (13)
to piston rod (11).
Install the piston (15) assembly to piston rod (11).
IMPORTANT: Face the slit in cushion seal (26) to
the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (27).
8. Install cushion seal (26), cushion bearing (27) and
stopper (28) to piston rod (11).
Move cushion bearing (27) to the stopper (28)
side. Install snap ring (25).

4. Install O-ring (10) and backup ring (9) to cylinder

head (7).

5. Install and seal ring (17), O-ring (18) slide rings

(19, 20) (2 used for each) and backup rings (16)
(2 used) to piston (15).

6. Install the cylinder head (7) assembly to piston

rod (11).
Special tool (outer diameter at rod):
(ZX110-3 class)
ST 8018, ST 2344 (75 mm (2.9 in))
(ZX120-3 class, 135US-3 class)
ST 8019, ST 2345 (80 mm (3.1 in))

W4-2-27
FRONT ATTACHMENT / Cylinder

7 8 11 12 21 22, 23

24

W1SE-04-02-001

W4-2-28
 FRONT ATTACHMENT / Cylinder
9. Install shim (21) to piston rod (11). Align the
matching marks and tighten piston nut (24) by
using the special tool (ST 5908) and the special
tool.
Special tool (outer diameter at nut part):
(ZX110-3 class)
ST 3262 (80 mm)
: 4710 N m (480 kgf m, 3480 lbf ft)
(ZX120-3 class, 135US-3 class)
ST 3304 (85 mm)
: 6180 N m (630 kgf m, 4560 lbf ft)
ST 5908
W158-04-02-022
CAUTION: Align the piston rod (11) assem-
bly with the center of cylinder tube (12) and
insert straight in order not to damage the
rings.
11. Secure cylinder tube (12) horizontally on a work-
bench. Insert the piston rod (11) assembly into
cylinder tube (12).
12. Install cylinder head (7) to cylinder tube (12) with
socket bolts (8) (ZX110-3 class: 12 used)
(ZX120-3 class, 135US-3 class: 10 used).
(ZX110-3 class)
: 12 mm
: 171 N m (17.4 kgf m, 126 lbf ft)
(ZX120-3 class, 135US-3 class)
: 14 mm
: 267 N m (27.2 kgf m, 197 lbf ft)

10. Align the holes on piston rod (11) and piston nut
(24). Install steel ball (23) to piston rod (11).
Tighten with set screw (22). Crimp set screw (22)
by using a punch at 2 places.If the holes cannot
be aligned, tighten piston nut (24)
: 10 mm
: 57 10.7 N m
(5.8 1.1 kgf m, 42 8 lbf ft)

W4-2-29
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
Piston Rod
A

W105-04-02-094

Unit: mm (in)
Recommended Size after
Model Cylinder Name
Re-Manufacturing (A)
0.023 0.001
Boom 70 -0.053
(2.8 -0.002 )
0.023 0.001
ZX110-3 class Arm 75 -0.053
(3.0 -0.002 )
0.023 0.001
Bucket 65 -0.053
(2.6 -0.002 )
0.023 0.001
Boom 70 -0.053
(2.8 -0.002 )
ZX120-3 class, 0.023 0.001
Arm 80 (3.1 -0.002 )
135US-3 class -0.053
0.023 0.001
Bucket 70 -0.053
(2.8 -0.002 )

Rod Bend and Run Out of Piston Rod

Dial Gauge
Piston Rod

W166-04-02-022

1m
V Block

Unit: mm (in)
Bend Run Out Remedy
0.5 (0.02) 1.0 (0.04) Repair
1.0 (0.04) 2.0 (0.08) Replace

W4-2-30
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

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