Beruflich Dokumente
Kultur Dokumente
: KM-1HH-E
Vol. No.
: W1HH-E-01
Workshop Manual
330 330LC
350H 350LCH
370MTH
Excavator
Service Manual (Manual No. KM-1HH-E) consists of the following three separate volumes;
Technical Manual (Operational Principle)
: Vol. No. TO1HH-E
Technical Manual (Troubleshooting)
: Vol. No. TT1HH-E
Workshop Manual
: Vol. No. W1HH-E
Zaxis330/350/370-WSM
1/7/05, 16:28
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
MANUAL COMPOSITION
This manual consists of three portions: the Techni-
PAGE NUMBER
Each page has a number, located on the center
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.
CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev
Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
SAFETY
RECOGNIZE SAFETY INFORMATION
This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.
001-E01A-0688
SA-688
the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert
symbol.
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
SA-2
SA-437
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
SA-438
006-E01A-0434
SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
S007-E01A-0435
SA-3
SA-435
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 operators
work boots the operators foot may slip off the
pedal, possibly resulting in a personal accident.
After using the ashtray, always cover it to extinguish the match and/or tobacco.
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you mounting and dismounting the machine, always face the machine and maintain a
three-point contact with the steps and handrails.
SA-439
SA-5
SA-378
SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may
become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.
SA-237
010-E01A-0237
SA-6
SA-426
SAFETY
OPERATE
SEAT
ONLY
FROM
OPERATOR'S
SA-444
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 operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SA-032
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as
SA-379
018-E01A-0481
SA-481
SA-8
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the
direction you wish to drive.
SA-388
SA-441
019-E01D-0492
SA-9
SA-589
SAFETY
AVOID
INJURY
ACCIDENTS
FROM
ROLLAWAY
To avoid rollaways:
Select level ground when possible to park
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-391
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the machine may hit or run over that person, resulting in
serious injury or death.
SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
SA-11
SA-384
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
SA-012
To avoid tipping:
SA-12
SA-440
SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or
SA-381
029-E01A-0381
OBJECT HANDLING
If a lifted load should fall, any person nearby may
be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.
SA-13
SA-014
SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
SA-432
SA-14
SA-390
SAFETY
HANDLE FLUIDS SAFELYAVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
SA-018
flammable.
034-E01A-0496
SA-15
SA-019
SAFETY
SAFETY TRANSPORTING
The danger of tipping is present when load-
SA-16
SA-395
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-028
S500-E02B-0497
SA-17
SA-527
SAFETY
Use a portable safety light for working inside or
under the machine.
SA-037
S500-E02B-0497
SS2045102
SA-527
519-E01A-0527
SA-18
SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
SA-344
SA-034
504-E01A-0034
S522-E01A-0040
SA-19
SA-040
SAFETY
PREVENT BURNS
Hot spraying fluids:
SA-039
SA-225
cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious
injury or death.
S506-E01A-0019
SA-20
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
SA-031
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Always
SA-22
SA-019
SAFETY
Check Emergency Engine Stop Switch:
3)
replaced
before
operating
the
S508-E02B-0019
SA-393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
PRECAUTIONS
GRINDING
FOR
WELDING
SA-016
AND
SA-818
523-E01A-0818
Clean
510-E01B-0030
SA-24
SA-030
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
Hazardous fumes can be generated when paint is
SA-029
511-E01A-0029
SA-25
SA-032
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
SA-26
SA-309
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the en-
SA-226
S516-E01A-0226
firm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced
S517-E01A-0435
SA-27
SA-435
SAFETY
(Blank)
SA-28
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL
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 Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
All information, illustrations and specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2005
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 5 ENGINE
SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.................................................W1-1-1
Maintenance Standard Terminology............W1-1-7
Group 3 Painting
Painting.................................................... W1-3-1
1HHW-1-1
(Blank)
1HHW-1-2
DISASSEMBLING
W1-1-1
W1-1-2
W1-1-3
M104-07-021
tears,
W105-03-05-019
breaks,
Correct
Incorrect
Correct
W105-03-05-020
Incorrect
a=b
ab
W110-03-05-004
W1-1-4
Correct Eyehole
Lifting Method
W102-04-02-016
Incorrect Eyehole
Lifting Method
W105-04-01-008
Bent Sling
W1-1-5
W162-01-01-009
Damaged Appearance
2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples 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.
W162-01-01-002
Scuffing
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Scoring
Fuzz
Separation of
Belt
Scuffing
W162-01-01-006
W162-01-01-007
Broken Warp
W162-01-01-008
W1-1-6
Allowable Limit
1. Normal machine performance cannot be accomplished after exceeding this limit.
2. Repair or adjustment is impossible after exceeding this limit.
3. Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the Allowable Limit.
W1-1-7
W1-1-8
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Descriptions
Engine cushion rubber mounting bolt
(Fan Side)
Engine bracket mounting bolt
(Pump Side)
Engine oil filter mounting bolt
Radiator mounting bolt
Hydraulic oil tank mounting bolt
Fuel tank mounting bolt
23
24
Counterweight
mounting bolt
Bolt Dia
Wrench
Qty
Size (mm)
mm
18
4
27
10
10
17
12
8
19
10
4
17
16
4
24
18
4
27
16
6
24
3
12UNF
1
36
16
7
12UNF
1
41
16
11
12UNF
1
50
16
10
8
17
16
4
24
16
4
24
22
12
32
12
12
10
10
2
17
16
4
24
27
36
36
27
36
36
ZAXIS330, 330LC
ZAXIS350H, 350LCH, 370MTH
Nxm
400
60
90
50
210
300
210
Torque
(kgfxm)
(41)
(6)
(9)
(5.1)
(21)
(30.5)
(21)
(lbfxft)
(300)
(43)
(65)
(37)
(151)
(220)
(151)
175
(18)
(130)
210
(21.5)
(155)
255
(26)
(188)
50
210
210
640
90
50
210
1226
1226
(5.1)
(21.5)
(21.5)
(65)
(9.2)
(5.1)
(21.5)
(125)
(125)
(37)
(155)
(155)
(470)
(66)
(37)
(155)
(905)
(905)
20
40
30
620
(63)
(460)
22
40
32
740
75
(540)
20
32
30
490
(50)
(360)
22
48
32
740
75
(540)
16
16
24
270
(27.5)
(200)
18
20
20
22
22
22
24
20
20
22
8
6
18
20
22
32
36
16
64
72
64
360
384
392
8
24
28
4
4
27
30
30
32
30
30
32
30
30
32
13
11
27
30
32
50
55
390
670
670
740
1130
1130
1370
620
620
740
40
(68)
(68)
75
(115)
(115)
(140)
(63)
(63)
(75)
(290)
(490)
(490)
(540)
(830)
(830)
(1010)
(460)
(460)
(540)
NOTE 1.Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to
W1-2-1
5.9
400
550
750
2260
2840
(0.6)
(41)
(56)
(76.5)
230
290
(4.3)
(300)
(405)
(550)
(1665)
(2100)
W1-2-2
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
correctly when assembling the machine or components.
Hexagon T Bolt
SA-040
Hexagon H Bolt
Hexagon M Bolt
Socket Bolt
W162-01-01-001
Nm
19.5
49
88
137
205
295
390
540
690
1030
1420
1910
2400
W1-2-3
(kgfm) (lbfft)
(2)
(14.5)
(5)
(36)
(9)
(65)
(14)
(101)
(21)
(152)
(30)
(220)
(40)
(290)
(55)
(400)
(70)
(505)
(105)
(760)
(145) (1050)
(195) (1410)
(245) (1770)
M Bolt
Nm
9.8
19.5
34
54
78
118
167
215
275
390
540
740
930
(kgfm)
(1)
(2)
(3.5)
(5.5)
(8)
(12)
(17)
(22)
(28)
(40)
(55)
(75)
(95)
(lbfft)
(7.2)
(14.5)
(25.5)
(40)
(58)
(87)
(123)
(159)
(205)
(290)
(400)
(540)
(690)
Tighten diagonally
1
1st to 4th
14
13
10
11
4
2
2nd to 3rd
W105-01-01-003
W1-2-4
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
WRONG
RIGHT
RIGHT
WRONG
RIGHT
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while loosening.
RIGHT
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
RIGHT
RIGHT
WRONG
Loosen
W105-01-01-009
WRONG
Tighten
W105-01-01-010
W1-2-5
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
Description
30male
37female
Wrench Size
mm
Union Nut
17
19
22
27
32
36
41
17
19
22
27
32
36
41
Wrench Size mm
Hose Fittings
17
19
22
27
32
36
41
14
17
19
22
27
32
36
Tightening
Torque
Nm (kgfm, lbfft)
24.5 (2.5,18)
29.5 (3.0,21.5)
39 (4.0,28.5)
93 (9.5,69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
24.5 (2.5,18)
29.5 (3.0,21.5)
39 (4.0,28.5)
93 (9.5,69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
W1-2-6
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 in
O-ring groove (e). Tightening nut (9)
with O-ring (6) displaced will damage
O-ring (6), resulting in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10).
Damage to O-ring (6) will cause oil
leakage.
4. If nut (9) is loose and oil is leaking,
do not re-tighten nut (9). Replace
O-ring (6) with a new one and check
that O-ring (6) is correctly seated in
place, tighten nut (9).
W1-2-7
Wrench Size
mm
Union Nut
19
22
27
32
36
41
46
Wrench Size
mm
Hose Fittings
17
19
22
27
30,32
36
41
Hose Fittings
M104-07-033
Tightening Torque
Nm (kgfm, lbfft)
29.5 (3.0,21.5)
69 (7.0,51)
93 (9.5,69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
205 (21.0,151)
PT
30
PF
W105-01-01-018
Wrench Size
mm
Hose Fittings
19
22
27
36
41
50
60
Internal Thread
External Thread
Clearance
Application Procedure
W105-01-01-019
M114-07-041
T-Bolt Type
M114-07-043
W1-2-8
M114-07-042
WRONG
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 high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being
kinked.
W105-01-01-011
RIGHT
WRONG
Rubbing Against
Each Other
WRONG
Clamp
RIGHT
Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG
Rubbing Against
Each Other
RIGHT
Clamp
W105-01-01-014
W1-2-9
Engine
Base Machine
Hydraulic
System
Front
Attachment
W1-2-10
Replacement
Intervals
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
GENERAL / Painting
PAINTING
Surfaces to Be Painted
Main surface of upperstructure
Bed cover
Tool box cover
Inner face
Front attachment
Track (undercarriage)
Floor plate
Rear left portion of cab
Painting Colour
YR-01 [TAXI yellow]
High Grade Beige
YR-01 [TAXI yellow]
Grey
YR01 [TAXI yellow]
N1.0 [Black]
M/F cation colour
YR-01 [TAXI yellow]
Engine Cover
Engine Cover
Right Window
Beam
Right Ladder
Rail
Mirror Stay
900
350
Main Surface of
Upperstructure
Bed Cover
W178-01-03-002
W1-3-1
720
Main Surface of
Upperstructure
W178-01-03-001
GENERAL / Painting
A
YR-01
(TAXI Yellow)
185
Section A
W178-01-03-003
Section B
Mask Garnished Portion
YR-01(TAXI Yellow)
Door
W178-01-03-004
W178-01-03-005
Antislip Cover
KASAI PAINT
Amilack 1400
Deep Black
Front Attachment
YR-01 (TAXI Yellow)
W178-01-03-007
Upper Side of
Frame
W1HH-01-03-001
Track (Undercarriage)
N1.0 (Black)
W178-01-03-008
W1-3-2
MEMO
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.......................................................................................................................................................................
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Group 2 Counterweight
Remove and Install
Counterweight..........................................W2-2-1
1HHW-2-1
1HHW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal
1. Remove nuts (2) to remove seat (1).
: 17 mm
W178-02-07-006
ZAXIS370MTH:
W1HH-02-01-004
3
4
5
W178-02-01-012
W2-1-1
UPPERSTRUCTURE / Cab
4. Remove filter (6) to remove screws (7) with a
screwdriver, then remove duct (8) from the cab.
7
8
W178-02-01-013
10
11
12
13
W178-02-01-014
W178-02-01-015
16
17
15
W178-02-01-016
W2-1-2
UPPERSTRUCTURE / Cab
8. Remove screws (18) and bolts (21) to remove
duct (19) and duct (20).
: 17 mm
18
19
20
21
W178-02-01-017
22
W178-02-01-018
ZAXIS370MTH:
A
A
W1HH-02-01-003
Section A-A
Lifting Strap
W1HH-02-01-002
W2-1-3
UPPERSTRUCTURE / Cab
10. Remove cab mounting bolts (23) and nut (24)
from the cab.
: 17 mm
: 24 mm
: 8 mm
23
24
W157-02-01-010
W157-02-01-001
W2-1-4
UPPERSTRUCTURE / Cab
Installation
CAUTION: Cab weight:
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
1. Attach the cab with lifting straps to hoist it by
crane.
W157-02-01-001
23
24
W157-02-01-010
W178-02-01-013
10
11
12
13
W178-02-01-014
W2-1-5
UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
3
4
5
W178-02-01-012
18
19
20
W2-1-6
21
W178-02-01-017
UPPERSTRUCTURE / Cab
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17).
16
17
15
W178-02-01-016
ZAXIS370MCH:
W178-02-07-006
W1HH-02-01-004
W2-1-7
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
A
NOTE: Unit: mm
(1 mm=0.039 in)
Chamfer Here
67
303.5
11
R2
R35
R98
4-13 0-1
R3018
30
405
Section A
Chamfer both
sides
W178-02-01-019
375
238
612
51
R118
(5 mm)
343.5
148.5
196
100
50
R70
370.5
W178-02-01-006
Along the
Periphery
c1
Along the
Periphery
W178-02-01-002
c1
(60.3)
261.61
(9.4)
R42
R72
Section C
W178-02-01-019
366
R2992
5461
14
733
R92
(4 mm)
R58
R58
170.6
R11508
70
50
R1808
882.5
R42
997
321.91
(4 mm)
R308
W178-02-01-024
Remove sharp
edges along the
periphery
R1898
R258
100
150
Section B
943
W178-02-01-007
W2-1-8
W178-02-01-019
UPPERSTRUCTURE / Cab
Unit: mm
Chamfer
Slightly
unless the
Periphery
Polish
Chamfered
Chamfer Here
Chamfer Here
85.4
343.3
213
R105
R10
R72
R105
(4 mm)
39.5
D
733
733
R2465
2-12.2
Section C
and D
(4 mm)
+0.5
-0
6.754
40
W178-02-01-019
3-R4
2-R4
86.9
50
50
556.3
50
W178-02-01-011
423
W178-02-01-008
366.1
R12
104.5
R95
(5 mm)
982.7
Chamfer along
the Periphery
W178-02-01-004
R2002
872
R123
R5 for 3 Places
38.2
51
364.7
R2475
(5 mm)
R115
888.58
W178-02-01-010
W2-1-9
R14
470.6
W178-02-01-009
UPPERSTRUCTURE / Cab
Suitable for the standard machine after March in
2002
W178-02-01-005
A
753
R63
R63
610.5
490
(4 mm)
R115
R115
R167
50
50
512.5
R167
W178-02-01-025
Remove Sharp
edges along the
periphery
Section A
W2-1-10
W178-02-01-019
UPPERSTRUCTURE / Cab
Remove Cab Glass
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber
CAUTION: When
removing
broken
or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or similar
should be used to tape the broken or
cracked glass ready to reinforce them so as
to prevent injury from occurring. Be sure to
remove all glass fragments.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal.
Cab
Seal Rubber
W178-02-01-022
Glass
W178-02-01-004
Mounting Rubber
W2-1-11
Glass
Cab
Seal Rubber
W178-02-01-022
UPPERSTRUCTURE / Cab
Procedures to Remove Right-Hand Cab Glass
Glass
Mounting Rubber
A
Cab
W216-02-01-005
W178-02-01-002
Glass
Cab Inside
A
Stopper
(Groove Rubber)
A
Cab
W216-02-01-003
W178-02-01-005
W2-1-12
UPPERSTRUCTURE / Cab
Cab Glass Installation Procedure
Procedure of installing left-hand cab glass, lower
glass of the door and upper front glass.
CSE Braid
Seal Rubber
Section A
A
CSE Braid
Seal Rubber
10
10
Mounting
Rubber
W178-02-01-020
Cab Glass
5
W178-02-01-023
Cab
Seal Rubber
W178-02-01-022
W178-02-01-004
W2-1-13
UPPERSTRUCTURE / Cab
Procedures of installing right-hand cab glass
Cab Glass
Mounting
Rubber
Cab
W216-02-01-005
W178-02-01-002
Mounting
Rubber
W2-1-14
Cab Glass
Stopper
Cab
W216-02-01-003
W178-02-01-005
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Removal
W178-02-02-001
Wire Rope
Sling Bolt
W178-02-02-002
4
2
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight weight:
ZAXIS330, 330LC: 6800 kg (15000 lb)
ZAXIS350H, 350LCH, 370MTH:
7550 kg (16650 lb)
1. Hoist and install counterweight (3) onto the main
frame.
Install washers (4) and tighten bolts (2) to counterweight (3) temporarily.
3
2
ZAXIS330, 330LC:
: 50 mm
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
4
W178-02-02-003
2. Remove the wire ropes. Tighten bolts (2) by using a power wrench and torque wrench.
ZAXIS330, 330LC:
: 50 mm
: 2260 Nm (230 kgfm, 1660 lbfft)
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
: 2840 Nm (290 kgfm, 2100 lbfft)
Torque Wrench
Power Wrench
W178-02-02-004
W178-02-02-001
W2-2-2
Removal
CAUTION: Cab weight:
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS 370MTH: 395kg (870 lb)
W157-02-01-001
W178-02-02-002
W2-3-1
W173-03-03-001
Boom Bracket
W105-02-03-004
W105-02-03-005
W157-02-03-001
W2-3-2
W105-02-03-007
W157-02-03-002
W2-3-3
W157-02-03-002
W105-02-03-007
3
4
W173-03-03-001
W2-3-4
W157-02-01-001
ZAXIS330, 330LC:
: 50 mm
: 2260 Nm (230 kgfm, 1660 lbfft)
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
: 2840 Nm (290 kgfm, 2100 lbfft)
W178-02-02-002
W2-3-5
7
W105-02-03-002
8. Start the engine. Set the front attachment in posture for checking hydraulic oil level in its tank.
Check the hydraulic oil level and any oil leakage.
M104-07-021
W2-3-6
Removal
1. Remove the connectors from the pump device.
CAUTION: Pump device weight: 205 kg
(452 lb)
2. Remove all hoses and pipes from the pump
device.
: 17 mm, 27 mm, 36 mm
: 10 mm
W110-02-04-002
W2-4-1
Wrench
Size (mm)
: 36
: 27
: 10
: 17
Tightening Torque
Remarks
Nm (kgfm) (lbfft)
175
(18) (130)
Hose
93
(9.5)
(69)
Hose
88
(9)
(65)
Bolt
49
(5)
(36)
Bolt
14
13
20
12
13
22
15
13
21
18
17
16
22
19
10
9
7
8
22
11
6
5
3
4
2
37
19
36
32
23
33
10
31
1
39
22
34
35
42
40
41
28
45
38
24
43
26 30
25
27
44
29
W1HH-02-04-004
12345678910 11 12 -
13 14 15 16 17 18 19 20 21 22 23 24 -
Fitting (4 Used)
Pipe
Bolt
Nut
Washer
Clamp (2 Used)
Pipe (2 Used)
Pipe
Fitting
Fitting (5 Used)
Flange
Bearing
25 26 27 28 29 30 31 32 33 34 35 -
W2-4-2
Seal Cover
Retaining Ring
Oil Seal
Center Shaft
Coupling Assembly
O-Ring
Seal Washer (4 Used)
Socket Bolt (2 Used)
Spring Washer (2 Used)
Washer (2 Used)
Pilot Pump
36 37 38 39 40 41 42 43 44 45 46 -
Adapter
Plug
Center Gear
Level Gauge
Pipe
Socket Bolt (2 Used)
Packing
Drain Plug
Retaining Ring
Bearing
P Sensor (2 Used)
46
W173-02-04-002
G
F
assembly
on
a
B
W2-4-3
W110-02-04-006
14
20
12
18
16
19
15
17
10
9
11
19
36
32
33
31
34
35
40
41
W1HH-02-04-004
W2-4-4
W2-4-5
23
28
45
38
24
26
30
25
27
44
W1HH-02-04-004
W2-4-6
ST 1236
W173-02-04-003
ST 1235
W173-02-04-004
W2-4-7
1
22
21
20
19
A
18
B
B
17, 16, 15
3, 4
5, 6
14
7, 8
13
W1HH-02-04-001
12
10
11
37
Section B-B
45
38
23
24
25
26
44
27
28
29
46
30
36
35
32, 33, 34
31
W1HH-02-04-002
W2-4-8
View A
W1HH-02-04-003
41, 42
43
12345678910 11 12 -
13 14 15 16 17 18 19 20 21 22 23 24 -
Fitting (4 Used)
Pipe
Bolt
Nut
Washer
Clamp (2 Used)
Pipe (2 Used)
Pipe
Fitting
Fitting (5 Used)
Flange
Bearing
25 26 27 28 29 30 31 32 33 34 35 -
W2-4-9
40
Seal Cover
Retaining Ring
Oil Seal
Center Shaft
Coupling Assembly
O-Ring
Seal Washer (4 Used)
Socket Bolt (2 Used)
Spring Washer (2 Used)
Washer (2 Used)
Pilot Pump
39
36 37 38 39 40 41 42 43 44 45 46 -
Adapter
Plug
Center Gear
Level Gauge
Pipe
Socket Bolt (2 Used)
Packing
Drain Plug
Retaining Ring
Bearing
P Sensor (2 Used)
38
23
24
25
26
44
27
28
46
30
W1HH-02-04-002
W2-4-10
ST 2307
W173-02-04-005
ST 2308
W173-02-04-006
W2-4-11
W1HH-02-04-001
11
10
23
36
35
W2-4-12
32, 33, 34
31
W1HH-02-04-002
40
41, 42
W1HH-02-04-003
W2-4-13
20
19
18
17, 16, 15
3
14
W1HH-02-04-001
12
37
28
46
W1HH-02-04-002
W2-4-14
G
F
W2-4-15
W110-02-04-006
41
43
42
31
1
3
10
11
17
15
16
14
30
44
49
24
25
25
23
39
40
19
7
22
34
25
21
20
13
37
38
46
31 45
29
27
25
25
33 32
18
9
12
8
21
25
20
22
28
26
48
36
35
40
39
W173-02-04-026
12345678910 11 12 13 -
Casing
Drive Disc
Roller Bearing (2 used)
Roller Bearing
Spacer
Bearing Nut
Plunger (7 used)
Cylinder Block
Center Shaft
Drive Gear
Retaining Ring
Spring
Pin
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Oil Seal
Seal Cover
O-Ring
Retaining Ring
Valve Plate
Link
Lever (2 Used)
Pin (2 Used)
Pin (2 Used)
Pin
Feedback Pin
Retaining Ring (6 Used)
Servo Piston
27 28 29 30 31 32 33 34 35 36 37 38 39 -
Servo Pin
Set Screw
Head Cover
Spring Pin (2 Used)
O-Ring (10 Used)
Bolt (8 Used)
Spring Washer (8 Used)
Plug
Stopper L
O-Ring
Stopper S
O-Ring
Bolt (8 Used)
W2-4-16
40 41 42 43 44 45 46 47 48 49 50 -
W2-4-17
1
16
17
15
14
13
9
2
W173-02-04-026
W2-4-18
14
15. Remove oil seal (14) from seal cover (15) by using a screwdriver.
16. Remove O-ring (16) from casing (1).
W173-02-04-007
W173-02-04-008
W2-4-19
4
6
3
5
W173-02-04-026
W2-4-20
ST 5905
W173-02-04-009
ST 3054
W173-02-04-010
Puller
W173-02-04-011
ST 1271
W173-02-04-012
W2-4-21
39
40
37
38
27
29
28
2
26
36
35
40
39
W173-02-04-026
W2-4-22
ST 1272
2
W173-02-04-013
Puller
W2-4-23
3
W173-02-04-014
37
31
43
47, 48
41
42 24
23
19
38
10
11
A
28
27
15
26
29
35
36
Section B-B
49
18
30
44
12
21 25
20
22
13
16
17
14
W1HH-02-04-005
W1HH-02-04-006
W2-4-24
45
46
View A
34
50
32, 33
W173-02-04-002
12345678910 11 12 13 -
Casing
Drive Disc
Roller Bearing (2 used)
Roller Bearing
Spacer
Bearing Nut
Plunger (7 used)
Cylinder Block
Center Shaft
Drive Gear
Retaining Ring
Spring
Pin
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Oil Seal
Seal Cover
O-Ring
Retaining Ring
Valve Plate
Link
Lever (2 Used)
Pin (2 Used)
Pin (2 Used)
Pin
Feedback Pin
Retaining Ring (6 Used)
Servo Piston
27 28 29 30 31 32 33 34 35 36 37 38 39 -
Servo Pin
Set Screw
Head Cover
Spring Pin (2 Used)
O-Ring (10 Used)
Bolt (8 Used)
Spring Washer (8 Used)
Plug
Stopper L
O-Ring
Stopper S
O-Ring
Bolt (8 Used)
W2-4-25
40 41 42 43 44 45 46 47 48 49 50 -
39, 40
37
3
38
28
27
26
29
W1HH-02-04-005
W2-4-26
ST 7923
W173-02-04-015
W2-4-27
W1HH-02-04-005
W2-4-28
W173-02-04-016
Check that roller bearings (3, 4) are securely installed on drive disc (2) after they have cooled
down to atmosphere temperature.
Apply hydraulic oil to the bearing race surfaces.
ST 7102
8. Place drive disc (2) on special tool (ST 5905). Install bearing nut (6) on the thread part in drive
disc (2). Tighten bearing nut (6) until it contacts
bearing (4).
Apply lubricating oil to the thread part in bearing
nut (6).
W173-02-04-017
6
ST 5905
W173-02-04-018
W2-4-29
15
16
W2-4-30
14
W1HH-02-04-005
ST 3054
W173-02-04-023
ST 3055
ST 5905
CAUTION:
Casing (1) becomes too hot. When applying
grease, avoid being burned.
11. Heat casing (1) to 50 to 80 C (122 to 176 F).
Apply grease to the inside of casing (1).
W173-02-04-024
14. Install oil seal (14) into seal cover (15) by using
special tool (ST 2409). Apply grease to the oil
seal (14) lip.
15
W173-02-04-019
W2-4-31
23
19
15
12
13
17
W1HH-02-04-005
18
W1HH-02-04-006
W2-4-32
W2-4-33
14
15
ST 2410
W173-02-04-020
23
19
27
29
49
18
13
W1HH-02-04-005
30
W1HH-02-04-006
W2-4-34
18
26. Align servo pin (27) on head cover (29) with the
valve plate (18) hole.
ST 7094
W173-02-04-021
32, 33
W173-02-04-002
W2-4-35
47, 48
43 41
42
24
39, 40
2
10
11
29
35
W1HH-02-04-005
36
44
W2-4-36
W2-4-37
35, 36
39, 40
44
ST 7923
ST 7094
W173-02-04-022
27
11
12
20
22
24
23
21
18
30
19
31
28
15
14
29
17
16
13
15
8
2
14
26
25
11
12
10
32
W173-02-04-029
9
12345678-
Stopper
O-Ring (3 Used)
Sleeve
Spool
Casing
Spring
Piston
Cylinder
910 11 12 13 14 15 16 -
Nut
Screw
Nut (2 Used)
Nut (2 Used)
Stopper
Stopper (2 Used)
O-Ring (2 Used)
Spring
17 18 19 20 21 22 23 24 -
Spring
Sleeve
Spool
Cylinder
Piston
O-Ring
Backup Ring
O-Ring
W2-4-38
25 26 27 28 29 30 31 32 -
UPPERSTRUCTURE/Pump Device
Disassemble Regulator
1. Clamp casing (5) in a vise.
2. Remove air bleed plug (30) and O-ring (31) from
casing (5). Remove elbows (4 used) from casing
(5).
: 19 mm, 41 mm
3. Remove socket bolts (25) (8 used). Remove front
cover (27) and rear cover (32).
: 6 mm
IMPORTANT: If loosening stoppers (1, 13, 14),
nuts (9, 11, 12), and screw (10), the
regulator setting will change. Do not
loosen stoppers (1, 13, 14), nuts (9,
11, 12), and screw (10).
4. Remove springs (16, 17) from the rear cover (32)
side in casing (5).
5. Push spool (19). Remove cylinder (20) from the
front cover (27) side in casing (5).
6. Remove piston (21), O-ring (22), and backup ring
(23) from cylinder (20).
7. Remove sleeve (18) and spool (19) from the front
cover (27) side in casing (5).
8. Remove spool (19) from sleeve (18).
9. Remove spring (6) from the front cover (27) side
in casing (5).
10. Push spool (4). Remove piston (7) and cylinder
(8) from the rear cover (32) side in casing (5).
11. Remove piston (7) and O-ring (2) from cylinder
(8).
12. Remove sleeve (3) and spool (4) from the front
cover (27) side in casing (5). Remove spool (4)
from sleeve (3) .
W2-4-39
UPPERSTRUCTURE/Pump Device
ASSEMBLE REGULATOR
24 23
25, 26
27
22
21 20
19
18
17
16
28, 29
15 14 13 12
30
31
10
11
T173-03-01-005
32
W173-02-04-001
12345678-
Stopper
O-Ring (3 Used)
Sleeve
Spool
Casing
Spring
Piston
Cylinder
910 11 12 13 14 15 16 -
Nut
Screw
Nut (2 Used)
Nut (2 Used)
Stopper
Stopper (2 Used)
O-Ring (2 Used)
Spring
17 18 19 20 21 22 23 24 -
Spring
Sleeve
Spool
Cylinder
Piston
O-Ring
Backup Ring
O-Ring
W2-4-40
25 26 27 28 29 30 31 32 -
UPPERSTRUCTURE/Pump Device
Assemble Regulator
1. Clamp casing (5) in a vise.
2. Install spool (19) into sleeve (18).
3. Install sleeve (18) and spool (19) from the front
cover (27) side in casing (5).
4. Install spool (4) into sleeve (3). Install sleeve (3)
from the front cover (27) side in casing (5).
5. Install piston (7) into cylinder (8).
6. Install O-ring (2) to cylinder (8). Apply grease to
O-ring (2). Install cylinder (8) from the rear cover
(32) side in casing (5).
7. Install the rear cover (32) assembly and springs
(16, 17) to casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.6 Nm (2 kgfm, 14.5 lbfft)
8. Install O-ring (22), backup ring (23), and piston
(21) to cylinder (20).
9. Apply grease to O-ring (22). Install cylinder (20)
from the front cover (27) side in casing (5).
10. Install the front cover (27) assembly and spring
(6) into casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.5 Nm (2 kgfm, 14.5 lbfft)
11. Apply grease to O-ring (31). Install O-ring (31) to
plug (30).
12. Tighten plug (30).
: 41 mm
: 78.5 Nm (8 kgfm, 58 lbfft)
13. Install elbows (4 used) to casing (5).
W2-4-41
UPPERSTRUCTURE/Pump Device
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
14
10
15
12
13
6
9
8
1
16
5
15
11
14
5
7
9
4
2
W110-02-04-022
1234-
Housing
Flange
Oil Seal
Retaining Ring
5678-
Seal (2 Used)
Cover
Backup Ring (2 Used)
Key (2 Used)
910 11 12 -
O-Ring (2 Used)
Gear
Drive Gear
Washer (4 Used)
W2-4-42
13 14 15 16 -
Bolt (4 Used)
Bushing (2 Used)
Bushing (2 Used)
Knock Pin (2 Used)
UPPERSTRUCTURE/Pump Device
Disassemble Pilot Pump
1. Clamp flange (2) in the pilot pump in a vise with
cover (6) up.
2. Remove bolts (13) (4 used).
: 17 mm
3. Remove cover (6) from housing (1).
4. Remove O-ring (9) from cover (6).
5. Remove flange (2) from housing (1).
6. Remove O-ring (9) from flange (2).
7. Remove retaining ring (4) from flange (2).
8. Remove oil seal (3) from flange (2) by using a
screwdriver.
9. Remove seal (5) and backup ring (7) from bushings (14, 15) in cover (6) side.
10. Lightly push drive gear (11). Remove bushings
(14, 15) in cover (6) side from housing (1).
Do not fall off the key between the bushings.
11. Remove seal (5) and backup ring (7) in flange (2)
side from bushings (14, 15).
12. Remove bushings (14, 15) in frange (2) side from
housing (1). Remove gear (10) and drive gear
(11) from housing (1).
W2-4-43
UPPERSTRUCTURE/Pump Device
14
10
15
12
13
6
9
8
1
16
5
15
11
14
5
7
9
4
2
W110-02-04-022
1234-
Housing
Flange
Oil Seal
Retaining Ring
5678-
Seal (2 Used)
Cover
Backup Ring (2 Used)
Key (2 Used)
910 11 12 -
O-Ring (2 Used)
Gear
Drive Gear
Washer (4 Used)
W2-4-44
13 14 15 16 -
Bolt (4 Used)
Bushing (2 Used)
Bushing (2 Used)
Knock Pin (2 Used)
UPPERSTRUCTURE/Pump Device
Assemble Pilot Pump
1. Install oil seal (3) into flange (2) by using special
tool.
2. Install retaining ring (4) to flange (2).
3. Install bushings (14, 15) in cover (6) side to
housing (1) with the seal groove side down.
4. Install gear (10) and drive gear (11) to housing
(1).
5. Install bushings (14, 15) in flange (2) side to
housing (1) with the seal groove side up.
6. Install seal (5) and backup ring (7) into the seal
groove on bushings.
7. Install O-ring (9) on flange (2).
8. Install flange (2) on housing (1).
9. Turn over the housing and flange assembly.
Clamp the flange in a vise. Do not fall off the
bushings and gears when turning over. Install
seal (5) and backup ring (7) into the seal groove
on bushings.
10. Install O-ring (9) on cover (6).
11. Install cover (6) on housing (1).
12. Tighten washers (12) and bolts (13).
: 17 mm
: 39 to 44 Nm
(4 to 4.5 kgfm, 29 to 32.5 lbfft)
W2-4-45
UPPERSTRUCTURE/Pump Device
MAINTENANCE STANDARD
Pump Device
Unit : mm (in)
Gear backlash
Standard
Allowable Limit
Remedy
0.48 (0.019)
1.5 (0.059)
Replace
Main Pump
1. Drive disc: Spline tooth thickness
Unit : mm (in)
Standard
Allowable Limit
4.9 (0.193)
3.5 (0.138)
Standard
Allowable Limit
60.0 (2.362)
59.8 (2.354)
Standard
Allowable Limit
0.060 (0.0024)
0.4 (0.0016)
W157-02-04-016
Unit: mm (in)
D-a
Standard
Allowable Limit
0.044 (0.0017)
0.08 (0.0031)
W157-02-04-017
W2-4-46
UPPERSTRUCTURE/Pump Device
5. Plunger: Clearance between plunger and
connecting rod
Unit : mm (in)
Standard
Allowable Limit
0.1 (0.0039)
0.4 (0.0016)
W157-02-04-033
D-a
Standard
Allowable Limit
0.081 (0.0032)
0.3 (0.012)
a
Center Shaft
W110-02-04-013
Valve Plate
chamber
inner
D
a
W110-02-04-014
Unit : mm (in)
D-a
Standard
Allowable Limit
0.089 (0.0035)
0.2 (0.0079)
chamber
inner
Unit : mm (in)
D-a
Standard
Allowable Limit
0.090 (0.0035)
0.2 (0.0079)
a
D
W157-02-04-018
Unit : mm (in)
D-a
Standard
Allowable Limit
0.051 (0.0020)
0.3 (0.012)
W157-02-04-019
W2-4-47
UPPERSTRUCTURE/Pump Device
(Blank)
W2-4-48
Arm 2
Boom 1
Bucket
Right Travel
4-Spool Section
5-Spool Section
Main
Relief
valve
Removal
Swing
Arm 1
Boom 2
Auxiliary
Left Travel
T1HH-01-02-005
W2-5-1
W1HH-02-05-001
Arm 2
Boom 1
Bucket
Right Travel
Main
Relief
valve
4-Spool Section
5-Spool Section
Swing
Arm 1
Boom 2
Auxiliary
Left Travel
Machine Front
T1HH-01-02-005
W2-5-2
W1HH-02-05-001
W2-5-3
12
43
41
5
7
46
12a
4
13a
32
35
30
31
29
15
17
15
14
6
4
15
38
25
28
37
47
17
23
33
14
34
30
42
15
15
12
20
31
21
27
22
10
15
35
31
40
44
19
24
26
18
45
16
8
17
11
15
15
39
16
36
8
9
31
17
3
W173-02-05-021
12345678910 11 12 -
Casing A
Casing B
Plug
Plug (4 Used)
O-Ring (6 Used)
Spring Cover A
Spring Cover B
Spool Cover (5 Used)
Spool Cover (2 Used)
Spool Cover: Arm 2
Spool Cover: Boom 1
Anti-Drift Valve (2 Used):
Boom Bottom, Arm Rod
12a - O-Ring (6 Used)
13 - Needle Valve
13a - O-Ring (3 Used)
14 - O-Ring (10 Used)
15 - O-Ring (11 Used)
16 - O-Ring (8 Used)
17 - Socket Bolt (32 Used)
18 - Spool: Left Travel
19 - Spool: Arm 1
20 - Spool: Boom 1
21 - Spool: Bucket
22 - Spool: Swing
23 - Spool: Arm 2
25 26 27 28 29 30 31 32 33 34 35 36 -
24 - Spool: Boom 2
37 - Spring (7 Used)
W2-5-4
38 39 40 41 42 43 44 45 46 47 -
Spring (7 Used)
Spring
Spring
Plug
Plug
Plug
Plug
O-Ring
Socket Bolt (4 Used)
Socket Bolt (4 Used)
Spring Cover
Spool Cover
Spool
IMPORTANT: Turn and remove the spools. If the
spools stick even a little, try again
instead of pulling roughly.
4. As spool and hole of casing are a matched fit, put
the matching marks for reassembling.
5. Remove the spool (18) assembly from casing A
(1).
6. Remove the spool (19) to (27) assemblies in the
same procedures.
7. Clamp spool (18) in a vise.
8. Remove spacer bolt (32) and disassemble spring
seat (30), springs (28, 29), and stopper (33).
: 10 mm
9. Disassemble the spool (19) to (27) assemblies in
the same procedures.
: 10 mm
W2-5-5
Machine Front
27
15, 14
B
A
16
4
5, 42
8
11
46
12, 12a
13, 13a
47
12
17
35
5, 43
31
5, 41
40
39
T1HH-03-03-002
10
36 31
2
25
Section B-B
23
20
W1HH-02-05-017
Machine Front
26
15, 14
30 33
28
29
30
16
32
8
3
5
44, 45
9
35
15
8
17
Control Valve Lower View
12345678910 11 12 -
Casing A
Casing B
Plug
Plug (4 Used)
O-Ring (6 Used)
Spring Cover A
Spring Cover B
Spool Cover (5 Used)
Spool Cover (2 Used)
Spool Cover: Arm 2
Spool Cover: Boom 1
Anti-Drift Valve (2 Used)
Boom Bottom, Arm Rod
12a - O-Ring (6 Used)
W1HH-02-05-005
24
19 22
13 - Needle Valve
13a - O-Ring (3 Used)
14 - O-Ring (10 Used)
15 - O-Ring (11 Used)
16 - O-Ring (8 Used)
17 - Socket Bolt (32 Used)
18 - Spool: Left Travel
19 - Spool: Arm 1
20 - Spool: Boom 1
21 - Spool: Bucket
22 - Spool: Swing
23 - Spool: Arm 2
25 26 27 28 29 30 31 32 33 34 35 36 -
24 - Spool: Boom 2
37 - Spring (7 Used)
W2-5-6
1
6
Section A-A
38 39 40 41 42 43 44 45 46 47 -
31
38
37 W1HH-02-05-004
31 34
Spring (7 Used)
Spring
Spring
Plug
Plug
Plug
Plug
O-Ring
Socket Bolt (4 Used)
Socket Bolt (4 Used)
Spool Cover
IMPORTANT: Install spool covers (8) to (11) while
aligning the matching marks.
1. Install O-rings (15, 16) to spool cover (11).
2. Install spool cover (11) to casing B (2) with socket
bolts (17) (2 used) while aligning the matching
marks.
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
3. Install spool covers (8) to (10) in the same procedures.
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
Spool
Spring Cover
W2-5-7
23
22
12
6
19
13
18
20
7
24
3
11
21a
14
9
8
21
14
25
16
Casing A
11
25
17
10
15
W173-02-05-022
8 - O-Ring (2 Used)
15 - Plug
21a - O-Ring
910 11 12 13 14 -
16 17 18 19 20 21 -
22 23 24 25 -
O-Ring (2 Used)
O-Ring
O-Ring (2 Used)
Plug
Plug
Plug (2 Used)
W2-5-8
Poppet
Spring
Spool
Spring
Bushing
Relief Valve
Piston
Piston
Socket Bolt (4 Used)
Socket Bolt (8 Used)
W2-5-9
Machine Front
14
13
9
14
23
22
F
F
21
21a
20
19
T1HH-03-03-002
18
Control Valve Upper View
Section Y-Y
12
W1HH-02-05-006
Arm 1
Arm 2
24
15
17
10
Casing B
16
Casing A
2
1 - Anti-Drift Valve Assembly:
Arm Bottom Side
2 - Casing 2
3 - Casing 3
4 - Casing 4
5 - O-Ring
6 - O-Ring
7 - O-Ring (3 Used)
25 11
25
Section F-F
11
T1HH-03-03-007
8 - O-Ring (2 Used)
15 - Plug
21a - O-Ring
910 11 12 13 14 -
16 17 18 19 20 21 -
22 23 24 25 -
O-Ring (2 Used)
O-Ring
O-Ring (2 Used)
Plug
Plug
Plug (2 Used)
Poppet
Spring
Spool
Spring
Bushing
Relief Valve
W2-5-10
Piston
Piston
Socket Bolt (4 Used)
Socket Bolt (8 Used)
W2-5-11
18
19
21
13
13a
7
25
23
16
17
25
19
20
29 29a
Casing A
1
6
14
22
24
33
14a
6
9
26
8
12
31
32
15
10
27
12
27
11
31
25
28a
28
30a
30b
30c
30
W1HH-02-05-019
1 - Plug (4 Used)
2 - Plug
11 - P3 Cover
12 - Flange (2 Used)
19 - Spring (4 Used)
20 - Spring (2 Used)
3 - Plug
21 - Spring
4 - Plug (2 Used)
5678910 -
23 24 25 26 27 28 -
Plug (3 Used)
O-Ring (4 Used)
O-Ring
O-Ring (2 Used)
O-Ring (3 Used)
Cover
22 - Spacer
Plug (3 Used)
Plug
O-Ring (5 Used)
O-Ring
O-Ring (2 Used)
Overload Relief Valve:
Boom Side
W2-5-12
28a - O-Ring
29 - Overload Relief Valve:
Arm Side
29a - O-Ring
30 - Pump Control Valve:
5-Spool Section
30a - O-Ring
30b - O-Ring
30c - O-Ring
31 - Socket Bolt (8 Used)
32 - Socket Bolt (4 Used)
33 - Socket Bolt (4 Used)
32 mm
(45 mm)
6. Remove plug (24). Remove spring (21) and poppet (18) from casing A.
: 12 mm
(80 mm)
(43 mm)
(12.7 mm)
P3 Cover
W2-5-13
W1HH-02-05-002
D
E
F
W1HH-02-05-003
30
30a
30c
Casing A
Section B
T1HH-03-03-002
30b
Left Travel
Bucket
31
Right Travel
12
27
16
19
22
2
13a
13
23
25
32
11
8
25
27
19
31
16
Section C-C
T1HH-03-03-004
12
W2-5-14
T1HH-03-03-005
Section D-D
Boom 1
Arm 1
Arm 2
18
21
24
25
17
20
14
29
29a
25
23
28
28a
14a
33
28a
19
16
28
3
7
Section F-F
T1HH-03-03-006
29a
29
T1HH-03-03-007
Section E
15
10
9, 26
Swing
Left
Travel
Auxiliary
16
19
Boom 2
23
Arm 1
25
Swing
W1HH-02-05-004
Section G
Section X-X
T1HH-03-03-006
1 - Plug (4 Used)
2 - Plug
11 - Cover
12 - Flange (2 Used)
19 - Spring (4 Used)
20 - Spring (2 Used)
3 - Plug
21 - Spring
4 - Plug (2 Used)
5678910 -
14 - Blank Flange
14a - O-Ring (2 Used)
15 - Socket Bolt (4 Used)
16 - Poppet (4 Used)
17 - Poppet (2 Used)
18 - Poppet
23 24 25 26 27 28 -
Plug (3 Used)
O-Ring (4 Used)
O-Ring
O-Ring (2 Used)
O-Ring (3 Used)
Cover
22 - Spacer
Plug (3 Used)
Plug
O-Ring (5 Used)
O-Ring
O-Ring (2 Used)
Overload Relief Valve:
Boom Side
W2-5-15
28a - O-Ring
29 - Overload Relief Valve:
Arm Side
29a - O-Ring
30 - Pump Control Valve:
5-Spool Section
30a - O-Ring
30b - O-Ring
30c - O-Ring
31 - Socket Bolt (8 Used)
32 - Socket Bolt (4 Used)
33 - Socket Bolt (4 Used)
5
B
D
E
W1HH-02-05-003
30
30a
30c
31
Casing A
12
Auxiliary
T1HH-03-03-002
30b
Section B
Bucket
Right Travel
27
16
19
22
13a
13
15
23
2
25
32
11
8
27
19
16
Section C-C
Boom 2
T1HH-03-03-004
Boom 1
31
12
21
Section D-D
1
Arm 1
T1HH-03-03-005
Arm 2
18
28
17
29
24
20
25
29a
28a
14
25
23
14a
33
28a
19
28
16
3
Section F-F
7
Section E
29a
T1HH-03-03-006
29
W2-5-16
T1HH-03-03-007
(12.7 mm)
43 mm
32 mm
(45 mm)
(80 mm)
P3 Cover
W1HH-02-05-002
W2-5-17
11
11a
18
21
15
12
19
21
16
14
8
5
1
18
6
21
15
12
10
9
23
9a
20
22
17
13
Casing B
W173-02-05-024
1234567-
Plug (2 Used)
Plug
Plug (3 Used)
Plug
Plug (2 Used)
O-Ring (2 Used)
O-Ring
8 - O-Ring (2 Used)
9 - Switch Valve
9a - O-Ring (2 Used)
10 - Poppet Valve
11 - Load Check Valve
11a - O-Ring
12 - Poppet (2 Used)
13 14 15 16 17 18 19 -
Poppet
Poppet
Spring (2 Used)
Spring
Spring
Plug (2 Used)
Plug
W2-5-18
20 21 22 23 -
Plug
O-Ring (6 Used)
O-Ring
Socket Bolt (4 Used)
W2-5-19
Left Travel
Right Travel
13
22
20
17
T1HH-03-03-002
Section C-C
Bucket
Auxiliary
Boom 2
T1HH-03-03-004
Boom 1
6
1
10
9a
23
15
21
12
Section E
Section D-D
Arm 1
14
16
19
21
18
T1HH-03-03-005
T1HH-03-03-006
Swing
Arm 2
11a
11
21
12
15
18
21
4
8
Section G
Section F-F
T1HH-03-03-008
T1HH-03-03-007
1234567-
Plug (2 Used)
Plug
Plug (3 Used)
Plug
Plug (2 Used)
O-Ring (2 Used)
O-Ring
8 - O-Ring (2 Used)
9 - Switch Valve
9a - O-Ring (2 Used)
10 - Poppet Valve
11 - Load Check Valve
11a - O-Ring
12 - Poppet (2 Used)
13 14 15 16 17 18 19 -
Poppet
Poppet
Spring (2 Used)
Spring
Spring
Plug (2 Used)
Plug
W2-5-20
20 21 22 23 -
Plug
O-Ring (6 Used)
O-Ring
Socket Bolt (4 Used)
W2-5-21
Casing B
21
21a
19
6
20
18
17
5
19
20
18
11
17
7
14
16
6
4
22
23
15
15
17
18
20
19
9
10
12
13
W173-02-05-025
7 - O-Ring (2 Used)
13 - Spring
19 - Plug (3 Used)
8910 11 12 -
14 15 16 17 18 -
20 - O-Ring (3 Used)
21 - Main Relief Valve
21a - O-Ring
22 - Socket Bolt (5 Used)
23 - Name Plate
O-Ring
Plug
O-Ring
O-Ring
Spring
Stopper
Orifice (2 Used)
Spool
Poppet (3 Used)
Spring (3 Used)
W2-5-22
W2-5-23
Machine Lower
Machine Front
3, 8, 15
22
T1HH-03-03-002
W1HH-02-05-007
16
10
12
13
14
20
7
19
18
17
20
19
11
2
18
17
5
21a
21
Section A
1 - Flow Combiner Valve Assembly
2 - Block
3 - Plug
4 - Plug
5 - O-Ring (3 Used)
6 - O-Ring (4 Used)
W1HH-02-05-010
7 - O-Ring (2 Used)
13 - Spring
19 - Plug (3 Used)
8910 11 12 -
14 15 16 17 18 -
20 - O-Ring (3 Used)
21 - Main Relief Valve
21a - O-Ring
22 - Socket Bolt (5 Used)
23 - Name Plate
O-Ring
Plug
O-Ring
O-Ring
Spring
Stopper
Orifice (2 Used)
Spool
Poppet (3 Used)
Spring (3 Used)
W2-5-24
W2-5-25
9
9c
9b
7
11
7a
2
8a
Casing B
1
3
3
Casing A
5
6
4
6
6
7a
7a
7
W173-02-05-026
1 - Plug (2 Used)
5 - O-Ring (6 Used)
2 - Plug
3 - O-Ring (2 Used)
6 - O-Ring (5 Used)
7 - Overload Relief Valve
(3 Used): Bucket Rod, Arm
Bottom, Boom Bottom Side
7a - O-Ring (3 Used)
4 - O-Ring (6 Used)
9b - O-Ring
9a - O-Ring
W2-5-26
9c - O-Ring
10 - Socket Bolt
(80 mm)
(12.7 mm)
(45 mm)
43 mm
32 mm
W1HH-02-05-002
Casing
IMPORTANT: Do not disassemble socket bolts (10,
11) unless necessary.
4. Remove socket bolt (10) and socket bolts (11) (8
used). Disassemble casing A and casing B.
: 12 mm
W2-5-27
Boom 1
10
Machine Front
5
C
E
F
F
G
Section E
T1HH-03-03-002
Right Travel
Arm 1
T1HH-03-03-006
Arm 2
4
7
7a
5
5
6
4
7a
7
4
Section C-C
Section F-F
T1HH-03-03-004
T1HH-03-03-007
Auxiliary
Bucket
Swing
8
8a
9a
9c
9b
7a
7
Section D-D
1 - Plug (2 Used)
5 - O-Ring (6 Used)
2 - Plug
3 - O-Ring (2 Used)
6 - O-Ring (5 Used)
7 - Overload Relief Valve
(3 Used): Bucket Rod, Arm
Bottom, Boom Bottom Side
7a - O-Ring (3 Used)
4 - O-Ring (6 Used)
Section G
T1HH-03-03-005
T1HH-03-03-008
9b - O-Ring
9a - O-Ring
W2-5-28
9c - O-Ring
10 - Socket Bolt
Casing
(80 mm)
(12.7 mm)
(45 mm)
43 mm
32 mm
4. Install O-ring (7a) to overload relief valve (7). Install O-ring (8a) to overload relief valve (8). Install
overload relief valves (7, 8) by using special tool
below.
: 32 mm
: 69 to 78 Nm
(7 to 8 kgfm, 50 to 58 lbfft)
W1HH-02-05-002
W2-5-29
ITEM
2
9
8
16
7
4
PL
PART NAME
QTY
Lock Nut
Lock Nut
O-Ring
O-Ring
O-Ring
Adjusting Screw
Spring
1
1
Piston
Stopper
22
10
Poppet
1
1
10
23
11
20
12
21
17
13
18
14
19
R
15
P
11
Backup Ring
12
O-Ring
13
Seat
14
Spring
15
Plunger
16
O-Ring
17
Filter
18
Filter Stopper
19
C-Ring
20
Spacer
21
C-Ring
22
Adjusting Plug
23
Plug
W173-02-05-030
ITEM
5
2
10
18
13
15
1
1
Adjusting Screw
1
1
1
21
Poppet
Backup Ring
19
O-Ring
Backup Ring
10
O-Ring
11
Seat
12
Spring
13
Spring
14
Plunger
20
15
Piston
12
16
Filter
17
Filter Stopper
14
18
C-Ring
19
O-Ring
20
O-Ring
21
Plug
22
Body
8
7
O-Ring
Spring
11
17
Lock Nut
Spring Seat
22
16
6
9
QTY
PART NAME
P
W173-02-05-031
W2-5-30
10
15
14
11
5
12
1
9
22
16
W1HH-02-05-011
21
9
Section B-B
W1HH-02-05-012
Section A-A
ITEM
A
20
W1HH-02-05-013
18 17
13 18 19
19
19
18
18
17
W1HH-02-05-014
W2-5-31
PART NAME
QTY
Name Plate
Socket Bolt
Main Relief
O-Ring
ROMH Plug
Spring
Poppet
Spool
Orifice
10
Stopper
11
Spring
12
Spring
13
O-Ring
14
O-Ring
15
Plug
16
O-Ring
17
O-Ring
18
O-Ring
19
O-Ring
20
Plug
21
ROH Plug
22
Block
11
10
ITEM
PART NAME
QTY
Spring
Spring
1
1
Spool
Spring Seat
Plug
Plug
Socket Bolt
O-Ring
O-Ring
10
O-Ring
11
Casing
W173-02-05-007
Anti-Drift Valve
4
2
7
ITEM
3
5
1
W173-02-05-008
W2-5-32
PART NAME
QTY
Bushing
Spring
1
1
Spool
Plug
O-Ring
O-Ring
O-Ring
Casing
3
ITEM
1
6
DR
PART NAME
QTY
O-Ring
Spring
Plug
Poppet
Sleeve
Piston
4
A
W173-02-05-009
ITEM
3
1
A
PART NAME
QTY
Spring
Spring
1
1
Plug
Spring Seat
Poppet
Logic Poppet
6
P
W173-02-05-010
ITEM
2
5
A
W173-02-05-011
W2-5-33
PART NAME
QTY
O-Ring
Spring
Plug
Poppet
Sleeve
Piston
5
4
2
6
7
Section A-A
A
ITEM
W173-02-05-012
PART NAME
W173-02-05-013
QTY
O-Ring
O-Ring
3
1
Plug
Nut
Adjusting Screw
Poppet
Casing
Blank Flange
W1HH-02-05-016
ITEM
LCAT1
LCAP1
W1HH-02-05-015
W2-5-34
PART NAME
QTY
Socket Bolt
Blank Flange
O-Ring
O-Ring
ROH Plug
12
13
17
21
PL
B1
17
4
12
2
19
24
20
14
18
Section A-A
Dr
Dr
W1HH-02-05-006
W1HH-02-05-008
ITEM+
1
16
11
10
23
22
15
1
A1
W1HH-02-05-009
15
Section B-B
W2-5-35
PART NAME
QTY
Socket Bolt
Socket Bolt
Piston
Piston
Relief Valve
Bushing
Spring
Spool
Spring
10
Poppet
11
Plug
12
Plug
13
Plug
14
Plug
15
O-Ring
16
O-Ring
17
O-Ring
18
O-Ring
19
O-Ring
20
O-Ring
21
O-Ring
22
Casing
23
Casing
24
Casing
1
W173-02-05-015
ITEM
PART NAME
QTY
Plug 2
Plug 1
Spring B3
Spring B2
Spring B1
Plunger 3
Plunger 2
Plunger 1
Spool
10
ITEM
11
PART NAME
12
QTY
Plug
Plug
Stopper (2)
Stopper (1)
C-Ring
Spring A2
Spring A1
Sleeve (1)
10
Sleeve (2)
11
Sub Spool
12
Spool
W2-5-36
W173-02-05-016
W1HH-02-05-018
ITEM
1
PART NAME
QTY
Plug 2
Plug 1
Spring B3
Spring B2
Spring B1
Plunger 3
Plunger 2
Plunger 1
Spool
W2-5-37
4
8
9
Dr
Pc
PE
7
P
W173-02-05-017
ITEM
PART NAME
QTY
Lock Nut
O-Ring
Adjusting Plug
Spring
Spool
O-Ring
O-Ring
O-Ring
Body
W2-5-38
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
6
1
2
Removal
1. Remove hoses (1 to 3 and 5 to 7).
: 41 mm, 19 mm, 17 mm
: 8 mm
5
3
4
W1HH-02-06-001
Nylon Sling
W176-02-06-002
W2-6-1
7
6
1
5
3
4
W1HH-02-06-001
W2-6-2
W2-6-3
32
1
22
2
23
3
4
5
31
21
7
30
29
24
18
25
20
9
7
28
10
19
11
27
12
26
18
13
17
14
16
13
12
15
W1HH-02-06-002
Motor
Retaining Ring
First Stage Sun Gear
Pin (3 Used)
Spring Pin (3 Used)
17 - Bolt (2 Used)
25 - Drain Plug
18 19 20 21 22 -
26 27 28 29 30 -
23 - Roller Bearing
24 - Pipe
W2-6-4
Shaft
O-Ring
Oil Seal
Sleeve
Roller Bearing
31 - Housing
32 - Socket Bolt (12 used)
ST 5100
sun
gear
(20)
W1HH-02-06-011
W2-6-5
31
17
26
16
15
W1HH-02-06-002
W2-6-6
15
W178-02-06-008
W2-6-7
32
23
31
30
29
26
W1HH-02-06-002
W2-6-8
12. Set the blocks on the press. Set the housing (31)
assembly on the blocks.
Housing (31)
W1HH-02-06-012
Block
Protection Cover
Press
W157-02-06-010
Protection Cover
Special Tool
W157-02-06-011
W2-6-9
31
30
29
27
26
W1HH-02-06-002
W2-6-10
Part
Size
Shaft Length: 220 mm
or Bolt (8.7 in)
Diameter: 19 mm
(3/4 in)
Remarks
8 used. All should be
identical in length with no
wear and deformation on
both ends.
Material: S35C
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2 (Applicable Diameter:
185 to 215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter:
292 mm (11.5 in)
Inner Diameter:
272 mm (10.7 in)
Press
Shaft (26)
Roller
Bearing (30)
Sleeve (29)
Guide
W157-02-06-014
Hose Clamp
Shaft
Oil Passage
W157-02-06-012
Outer Race
Shaft (26)
Roller Bearing (30)
W1HH-02-06-007
Sleeve (29)
Guide
Hose
Clamp
Shaft
W157-02-06-01
W2-6-11
23
31
21
6
7
8
9
10
28
19
11
18
14
13
12
W1HH-02-06-002
W2-6-12
W2-6-13
7
8
21
9
7
18
11
12
20
13
32
19
14
22
10
18
17
16
15
23
30
24
31
25
26
27
28
29
T1HH-03-02-001
Motor
Retaining Ring
First Stage Sun Gear
Pin (3 Used)
Spring Pin (3 Used)
17 - Bolt (2 Used)
25 - Drain Plug
18 19 20 21 22 -
26 27 28 29 30 -
23 - Roller Bearing
24 - Pipe
W2-6-14
Shaft
O-Ring
Oil Seal
Sleeve
Roller Bearing
31 - Housing
32 - Socket Bolt (12 used)
Press
ST 7292
ST 7289
29
5. Face the slit of spring pin (6) to the end of pin (5).
Install spring pin (6) into first stage carrier (21)
and pin (5) by using a hammer.
5
30
26
WIHH-02-06-008
Slit
W178-02-06-002
W2-6-15
32
22
15
23
31
26
28
29
T1HH-03-02-001
W2-6-16
19. Place special tool (ST 7290) onto the inner race
of roller bearing (23). Install the inner race by using a press.
28
23
ST 7290
31
WIHH-02-06-009
WIHH-02-06-010
W2-6-17
20
19
22
17
16
23
15
31
26
T1HH-03-02-001
W2-6-18
ST 5100
Concave
Stopper
19
16
26
W178-02-06-012
15
W178-02-06-014
W178-02-06-008
22. Install lock plate (16) onto nut (15) with bolt (17).
In case the spline of lock plate (16) and that of
shaft (26) are not aligned, tighten nut (15) in
tightening direction until both splines are aligned.
: 17 mm
: 50 Nm (5 kgfm, 36 lbfft)
W2-6-19
1
4
21
20
32
22
24
31
25
T1HH-03-02-001
W2-6-20
W2-6-21
13
5
4
21
22
23
26
24
27
28
25
20
24
16
17
18
23
22
19
21
29
W1HH-02-06-005
15
14
1 - Casing
2 - Parking Brake
Release Valve
3 - Socket Bolt (3 Used)
4 - Oil Seal
5 - Bearing
6 - Shaft
7 - Shoe Plate
8 - Plunger (9 Used)
9 - Plate
10 - Retainer
24 - Poppet (2 Used)
25 - Valve Casing
11 12 13 14 15 16 -
19 20 21 22 23 -
26 27 28 29 -
Rotor
Friction Plate (3 Used)
Plate (4 Used)
O-Ring
O-Ring
Brake Piston
Bearing
O-Ring
Plug (2 Used)
O-Ring
Spring (2 Used)
W2-6-22
ST 7288
16
W1HH-02-06-006
W2-6-23
12
11
10
9
8
7
6
13
5
4
1
25
19
W1HH-02-06-005
W2-6-24
W2-6-25
26
28
27
T1HH-03-02-003
25
29
17
16
15
19
14
20
18
12
3
13
8
10
11
6
T1HH-03-02-002
1 - Casing
2 - Parking Brake
Release Valve
3 - Socket Bolt (3 Used)
4 - Oil Seal
5 - Bearing
6 - Shaft
7 - Shoe Plate
8 - Plunger (9 Used)
9 - Plate
10 - Retainer
24 - Poppet (2 Used)
25 - Valve Casing
11 12 13 14 15 16 -
19 20 21 22 23 -
26 27 28 29 -
Rotor
Friction Plate (3 Used)
Plate (4 Used)
O-Ring
O-Ring
Brake Piston
Bearing
O-Ring
Plug (2 Used)
O-Ring
Spring (2 Used)
W2-6-26
W2-6-27
26
T1HH-03-02-003
25
29
19
20
18
3
2
T1HH-03-02-002
W2-6-28
W2-6-29
10
11
8
3
7
12
6
2
13
W110-02-06-005
1234-
Casing
Spool
Spring
Plunger
5 - Bushing
6 - Filter
7 - Spacer
8 - Orifice
9 - Spring
10 - O-Ring
W2-6-30
11 - O-Ring (2 used)
12 - Steel Ball
13 - Bolt (3 used)
D-d
Standard
0.028 (0.001)
Unit:m (in)
Allowable Limit
0.058 (0.002)
W107-02-06-138
W107-02-06-139
0 (0)
0.3 mm (0.0118)
W107-02-06-140
W107-02-06-141
W2-6-31
Standard
5.5 (0.22)
Unit: mm (in)
Allowable Limit
5.3 (0.21)
Standard
2.0 (0.08)
Unit: mm (in)
Allowable Limit
1.8 (0.07)
W107-02-06-142
W107-02-06-143
W2-6-32
2
1
W178-02-07-006
30
3
29
28
5
27
26
25
6
7
10
24
23
21
20
19
18
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
W2-7-1
30
3
29
7. Remove nut (4) and remove crips (5, 27). Remove connector (6) and remove grip (3) (with the
harness).
Remove nut (28). Remove lever (30), washers
(25, 26), and boot (29).
: 22 mm
: 19 mm
28
5
27
26
25
6
7
10
24
23
21
20
19
18
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
35
36
31
32
33
34
W178-02-07-002
31 32 33 34 35 36 -
W2-7-2
31
36
32
33
34
W178-02-07-002
30
3. Temporarily tighten nut (28) to lever (30) and install washers (25, 26). Install lever (30) onto pilot
valve (10) with nut (28). Install boot (29).
Temporarily tighten nut (4) to lever (30) and install grip (3) with nut (4).
Pass the harness of grip (3) through the upper
hole of boot (29) and install lever (30) with clips
(5, 27). Arrange the harness to the outside of
spring pin (7) over bolt (8) head.
Install connector (6).
: 22 mm
: 26 Nm (2.0 kgfm, 14.5 Ibfft)
: 19 mm
: 26 Nm (2.0 kgfm, 14.5 Ibfft)
29
4
28
5
27
26
25
6
7
10
24
23
21
20
19
18
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
W2-7-3
30
3
29
4
28
27
26
25
6
7
10
24
23
21
20
19
18
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
W178-02-07-006
W2-7-4
AND
INSTALL LEFT
PILOT
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. The console is at the most front position. Remove screws (2) (4 used) and cover (3). Move
boot (1) up.
: 17 mm
10
9
Radio
3
4
5
W178-02-07-003
15
16
11
12
13
14
W178-02-07-004
11 12 13 14 15 16 -
W2-7-5
17
29
18
19
28
1
20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6
17
29
28
IMPORTANT: If the harness is arranged to the inside of spring pin (22), the harness
makes contact with the moving part
of pilot valve and the harness is
damaged. Arrange the harness to
the outside of spring pin (22).
3. Temporarily tighten nut (20) to lever (19) and install washers (25, 26). Install lever (19) onto pilot valve (27) with nut (20). Install boot (1).
Temporarily tighten nut (18) to lever (19) and install grip (17) with nut (18).
Pass the harness of grip (17) through the upper
hole of boot (1) and install lever (19) with grips
(29, 21). Arrange the harness to the outside of
spring pin (22) over bolt (23) head. Install connector (28).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 lbfft)
: 22 mm
: 55 Nm (5.6 kgfm, 40.5 lbfft)
: 19 mm
: 35 Nm (3.6 kgfm, 26 lbfft)
W2-7-7
18
19
10
20
21
22
23
24
25
26
27
2
3
4
5
W178-02-07-003
17
29
18
19
28
10
20
21
22
23
24
25
26
27
2
3
4
5
W2-7-8
W178-02-07-003
Removal
1. Remove floor mat (1).
WIHH-02-07-001
2
3
WIHH-02-07-002
17
16
4
5
15
14
14
13
13
12
12
11
10
W178-02-07-005
678910 11 -
W2-7-9
Pipe T4:
Pipe P1:
Hose 11:
Hose 12:
Hose 10:
Hose 9:
3. Install pedal (5) and levers (16, 17) with bolts (4).
: 17 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
4. Install under cover (2) with bolts (3) (6 used).
: 17 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
2
3
17
16
4
5
15
14
14
13
13
12
12
11
10
W178-02-07-005
12 13 14 15 16 17 -
W2-7-10
Pipe T4:
Pipe P1:
Hose 11:
Hose 12:
Hose 10:
Hose 9:
W2-7-11
13
12
14
11
15
11
10
9
8
9
21
20
21
16
20
19
3
2
18
17
W176-02-07-001
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 -
12 13 14 15 16 -
Cam
Screw Joint
Universal Joint
Oil Seal (4 Used)
Spring Guide (4 Used)
W2-7-12
17 18 19 20 21 -
Spool (4 Used)
Housing
O-Ring
Knock Pin (2 Used)
O-Ring (2 Used)
16
ST 7257
W176-02-07-005
W2-7-13
21
20
21
20
19
18
17
W176-02-07-001
W2-7-14
W2-7-15
16
15
14
13
12
11
10
22
9
8
7
6
21
5
4
20
18
19
2
1
W178-02-07-064
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 12 -
13 14 15 16 17 -
W2-7-16
O-Ring (4 Used)
Plate
Universal Joint
Cam
Screw Joint
18 19 20 21 22 -
Retaining Ring
Plug
O-Ring
Spool (4 Used)
Casing
W2-7-17
17
16
22
7
6
21
5
4
19
18
2
1
W178-02-07-064
W2-7-18
ST 4146
22
ST 4145
W178-02-07-048
W2-7-19
14
13
10
12
15
11
8, 9
7
16
3, 4
5, 6
2
19
1
17
W176-02-07-006
21
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 -
20
18
12 13 14 15 16 -
Cam
Screw Joint
Universal Joint
Oil Seal (4 Used)
Spring Guide (4 Used)
W2-7-20
17 18 19 20 21 -
Spool (4 Used)
Housing
O-Ring
Knock Pin (2 Used)
O-Ring (2 Used)
Port
No.
1
2
Spool
(17)
Shim
(2)
Push Rods
(8, 9)
Same to Same to
the former the former
one
one
3
4
ST 7255
With outer
groove
Without outer
groove
With outer
groove
Without outer
groove
Port
No.
Return Springs
(5, 6)
Balance Springs
(3, 4)
1
2
3
4
43 mm
48 mm
43 mm
48 mm
29.9 mm
30.1 mm
29.9 mm
30.1 mm
W176-02-07-008
ST 7257
17
Packing Material
W176-02-07-009
W2-7-21
13
14
10
12
15
11
8, 9
W176-02-07-006
20
W2-7-22
18
IMPORTANT:
Oil Seal
Mounting Hole
10
8, 9
14. Clamp screw joint (13) in a vise. Tighten universal joint (14). Tighten cam (12) by using a spanner.
: 32 mm
: 88.2 Nm (9 kgfm, 65 Ibfft)
W176-02-07-007
W2-7-23
17
15
16
14
9, 10
11
12
13
8
7
3, 4
5, 6
2
19
19
22
21
18
W178-02-06-055
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 12 -
13 14 15 16 17 -
W2-7-24
O-Ring (4 Used)
Plate
Universal Joint
Cam
Screw Joint
18 19 20 21 22 -
Retaining Ring
Plug
O-Ring
Spool (4 Used)
Casing
Spool
(21)
Shim
(2)
Same to
the former
one
Same to
the former
one
3
4
Pushers A, B
(9, 10)
Outer grooves
(3 Used)
Without outer
groove
Outer grooves
(3 Used)
Without outer
groove
Port
No.
Return Springs
(5, 6)
Balance Springs A, B
(3, 4)
1
2
3
4
Short
Long
Short
Long
Short
Long
Short
Long
ST 4145
W178-02-07-049
W2-7-25
17
15
16
14
11
13
9, 10
12
8
3, 4
22
W178-02-06-055
W2-7-26
W2-7-27
1
2
35
34
33
32
31
30
3
4
5
28
29
27
8
9
10
26
11
12
25
13
23
24
22
21
20
19
18
14
17
15
16
W176-02-07-002
123456789-
Bolt (2 Used)
Cover
Pin (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Damper (2 Used)
Rubber Seat (2 Used)
Socket Bolt (2 Used)
Spring Washer (2 Used)
10 11 12 13 14 15 16 17 18 -
Holder
Oil Seal (4 Used)
O-Ring (4 Used)
Bushing (4 Used)
Casing
O-Ring
Plug
Spool (4 Used)
Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
Spacer (4 Used)
Shim (Several)
Balance Spring (4 Used)
Spring Guide (4 Used)
Pusher (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Bracket (2 Used)
Spring Pin (2 Used)
W2-7-28
28 29 30 31 32 33 34 35 -
26
3
27
Caulked Here
Stand
W176-02-07-019
W2-7-29
35
34
33
32
31
30
3
5
10
14
W176-02-07-002
W2-7-30
W2-7-31
2
3
4
5
6
35
34
33
32
31
30
9
10
29
11
28
27
14
12
26
15
13
25
16
24
17
18
23
19
20
21
22
W178-02-07-063
123456789-
Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
Spring Washer (4 Used)
Socket Bolt (4 Used)
10 11 12 13 14 15 16 17 18 -
Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring (4 Used)
Bushing (4 Used)
Pusher (4 Used)
Spring Guide (16 Used)
Balance Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
W2-7-32
O-Ring (2 Used)
Plug (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Casing
Spool
Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)
28 29 30 31 32 33 34 35 -
W2-7-33
3
4
6
3
4
10
11
12
13
35
34
33
32
31
9
10
31
11
32
33
34
35
12
13
23
19
20
21
22
W178-02-07-063
W2-7-34
12, 13
11
35
10
Crimped
Here
Stand
W176-02-07-019
W2-7-35
26
31
25 27
24
10
32
30
34, 35
33
13
22
4
28
29
11
21
12
18
23
20
19
17
14
W176-02-07-010
15, 16
123456789-
Bolt (2 Used)
Cover
Pin (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Damper (2 Used)
Rubber Seat (2 Used)
Socket Bolt (2 Used)
Spring Washer (2 Used)
10 11 12 13 14 15 16 17 18 -
Holder
Oil Seal (4 Used)
O-Ring (4 Used)
Bushing (4 Used)
Casing
O-Ring
Plug
Spool (4 Used)
Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
Spacer (4 Used)
Shim (Several)
Balance Spring (4 Used)
Spring Guide (4 Used)
Pusher (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Bracket (2 Used)
Spring Pin (2 Used)
W2-7-36
28 29 30 31 32 33 34 35 -
10
W176-02-07-015
31
ST 7256
10
Outside of
Holder
W176-02-07-014
as illustrated.
31
ST 7256
10
10
31
W176-02-07-016
W2-7-37
W176-02-07-013
10
32
30
33
34, 35
23
14
W176-02-07-010
W2-7-38
35
Slit
Slit
W176-02-07-017
30
33
32
10
W2-7-39
26
25 27
24
10
4
28
29
W176-02-07-010
W2-7-40
Caulked Here
26
Stand
Caulked Here
24, 25
W176-02-07-011
W2-7-41
11
32
31 1
35
12
10
13
3, 4
29
34
9
15
33 28
30
17
18
14
25
27
16
26
24
23
W178-02-06-056
123456789-
Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
Spring Washer (4 Used)
Socket Bolt (4 Used)
10 11 12 13 14 15 16 17 18 -
Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring
Bushing (4 Used)
Pusher (4 Used)
Spring Guide (16 Used)
Balance Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
W2-7-42
*O-Ring (2 Used)
*Plug (2 Used)
*Plug (2 Used)
*O-Ring (2 Used)
Casing
Spool (4 Used)
Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)
28 29 30 31 32 33 34 35 -
W176-02-07-016
ST 7256
W176-02-07-015
Outside of
Holder
W176-02-07-014
6
7
W176-02-07-01313
W2-7-43
32
31
35
31 32
3, 4
30
29
9
34
33
23
W178-02-06-056
W2-7-44
Slit
Slit
W178-02-07-050
W2-7-45
11
32
35
12
10
13
W178-02-06-056
W2-7-46
Crimped
Here
11
Stand
Crimped
Here
35
12, 13
W176-02-07-011
W2-7-47
W2-7-48
Removal
1. Remove spring (3).
2
3
5
W178-02-08-001
2
View A
6
10
7
8
WIHH-02-08-001
14
View A
15
W2-8-1
12
13
11
WIHH-02-08-002
Wrench
Size (mm)
: 17
: 19
: 19
678910 11 12 13 14 15 -
Tightening Torque
Nm
(kgfm) (lbfft)
49
(5)
(36)
35
(3.6)
(26)
29.5
(3)
(21.5)
3
5
Remark
Bolt
Pipe
Hose
W178-02-08-001
2
View A
6
10
7
8
WIHH-02-08-001
14
View A
15
W2-8-2
12
13
11
WIHH-02-08-002
W2-8-3
8
9
13
10
11
12
W178-02-08-005
1234-
Washer
Backup Ring
O-Ring
Body
5678-
Socket Bolt
Retaining Ring
Washer
Backup Ring
910 11 12 -
W2-8-4
O-Ring
Spool
Bracket
Pin
13 - Socket Bolt
W2-8-5
Section ZZ
10
W178-02-08-006
11
13
T178-03-07-002
1234-
Washer
Backup Ring
O-Ring
Body
5678-
Socket Bolt
Retaining Ring
Washer
Backup Ring
910 11 12 -
W2-8-6
O-Ring
Spool
Bracket
Pin
13 - Socket Bolt
W2-8-7
W2-8-8
14
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
15 16
17 18 19
13
20
Removal
21
12
11
10
Install
the
Tightening Torque
Nm (kgfm) (lbfft)
20
(2)
(14.5)
29.5
(3)
(21.5)
39
(4)
(29)
79
(8)
(58)
Remark
Bolt
Hose
Hose
Pressure
Sensor
8B
8A
2
W173-02-09-001
W2-9-1
17
16
14
15
C
A
E
Section T
Section S
14
15
1
S2
S4
S7
7
S3
Section U
14
S1
Section V
15
Z
3
A4
6
3
Section W
2
12,13 11 10 9
19
Section Z-Z
1
14
15
7
6
5
7 6
Section X
Section Y
W2-9-2
WIHH-02-09-001
Part Name
10. Plug
O-Ring
Steel Ball
Steel Ball
Spring
O-Ring
Plug
Orifice
Spring
Ring
Orifice
Plunger
Plunger Assembly
O-Ring
Plug
Body
Seat
Steel Ball
Plug
Qty
3
4
4
4
4
4
4
1
2
1
1
1
1
4
4
1
1
1
1
Wrench Size
(mm)
:8
Tightening Torque
Nm
(kgfm) (lbfft)
49
(5)
(36.2)
:5
:5
14.7
14.7
(1.5)
(1.5)
(10.8)
(10.8)
:6
24.5
(2.5)
(18.1)
:5
9.8
(1.0)
(7.2)
:8
49
(5)
(36.2)
W2-9-3
Remark
W2-9-4
INSTALL
SOLENOID
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
3
4
5
10
1
Removal
1. Remove each harness of solenoid valves from
connectors.
7
9
View A
16
15
14
6
13
12
11
17
WIHH-02-10-001
20
21
22
23
18
19
24
25
26
27
WIHH-02-10-002
19 - Socket bolt
20 - Hose SB: To main pump 2
21 - Hose PD: To pilot shut-off
valve
W2-10-1
Installation
1. Install the solenoid valve unit with bolts (7, 19).
2. Install pilot lines (1 to 6, 11 to 18, 20 to 23, 25
and 27).
3
4
Tightening Torque
Remark
Nm (kgfm) (Ibfft)
24.5 (2.5)
(18) Pipe, Hose
29
(3)
(22)
Hose
93
(9.5)
(43)
Hose
20
(2)
(16)
Bolt
20
(2)
(16)
Bolt
10
1
7
9
8
View A
16
15
14
6
13
12
11
17
WIHH-02-10-001
20
21
23
18
19
22
24
25
26
27
WIHH-02-10-002
1 - Pipe PF:
From
pilot shut- off valve
8-
22 - Hose PI:
trol valve
9-
10 11 12 13 14 -
19 - Socket bolt
20 - Hose SB: To main pump 2
21 - Hose PD: To pilot shut-off
valve
W2-10-2
To con-
W2-10-3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
W178-04-05-001
12345-
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Washer
11 12 13 14 15 -
Spring
Spool
Orifice
O-Ring
O-Ring
W2-10-4
16 17 18 19 -
O-Ring
Sleeve
Plate
Wavespring
W2-10-5
3, 5
17
14
15
12
16
13
10 11
19
18
W157-02-11-001
12345-
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Washer
11 12 13 14 15 -
Spring
Spool
Orifice
O-Ring
O-Ring
W2-10-6
16 17 18 19 -
O-Ring
Sleeve
Plate
Wavespring
14
15
16
11
17
9
10
17
W178-02-10-002
Housing
W157-02-11-005
10
W157-02-11-010
1
W157-02-11-011
W2-10-7
1
12
2
13
14
4
5
6
7
8
9
10
11
15
16
17
18
WIHH-02-10-003
19
12345-
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Retaining Ring
11 12 13 14 15 -
Spring
O-Ring
O-Ring
O-Ring
Sleeve
W2-10-8
16 17 18 19 -
Spool
Orifice
Plate
Wavespring
W2-10-9
15
12
13
16
14
17
19
18
WIHH-02-10-007
3, 5
12345-
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Retaining Ring
11 12 13 14 15 -
Spring
O-Ring
O-Ring
O-Ring
Sleeve
W2-10-10
10
11
16 17 18 19 -
Spool
Orifice
Plate
Wavespring
14
15
16
17
10
15
W178-02-10-002
Housing
W157-02-11-005
10
W157-02-11-010
1
W157-02-11-011
W2-10-11
3
4
5
6
7
WIHH-02-10-004
1 - Plug
2 - Shim
3 - Spring
4 - O-Ring
5 - Poppet
6 - Sleeve
W2-10-12
7 - Gasket
8 - Housing
W2-10-13
W2-10-14
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
ZAXIS370MTH
Up to Serial No.31357
ZAXIS370MTH
1HHW-3-1
Group 7 Track
Remove and Install Track ........................ W3-7-1
Maintenance Standard ............................. W3-7-7
1HHW-3-2
Matching Mark
2
W105-03-01-001
3
W158-03-01-001
W3-1-1
W110-03-01-004
W110-03-01-004
Machine Front
S (Soft Zone)
Marking Position
Position for Plug
15
20
Position for
Grease Fitting
5
W110-03-01-001
3
W158-03-01-001
W3-1-2
Pinion
5 mm
Grease Bath
W3-1-3
W175-03-01-002
W157-03-01-003
8
2
9
7
6
W157-03-01-002
1 - Outer Race
2 - Seal
3 - Pin
4 - Plug
5 - Seal
W3-1-4
4
W1HH-03-01-006
3. Install the hand tap (M10, pitch 1.5 mm) into part
A in the hole on plug (4). Install the bolt (M10,
pitch 1.5 mm) into the hole on plug (4). Tap the
bolt from its back or pull out plug (4).
W1HH-03-01-001
5. Rotate outer race (1). Remove balls (6) and supports (9) from the plug (4) hole.
When removing balls (6), use rod magnet (C).
Use wire (D) and remove support (9).
W3-1-5
W1HH-03-01-002
W1HH-03-01-007
W157-03-01-003
8
2
9
7
6
W157-03-01-002
1 - Outer Race
2 - Seal
3 - Pin
4 - Plug
5 - Seal
W3-1-6
2
1
5
W1HH-03-01-003
3. Install plug (4) into outer race (1) and install pin
(3).
Caulk the head of pin (3) by using a punch.
Add grease 0.9 L (Alvania EP2 grease or equivalent) into the swing bearing through the grease
fitting.
W1HH-03-01-004
3
1
4
W1HH-03-01-005
W3-1-7
W3-1-8
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
The procedure starts on the premise that the track
link has already been removed.
Refer to page W3-7-1 for track removal.
3
2
W3-2-1
W157-03-02-006
3
2
W3-2-2
W157-03-02-006
W3-2-3
15
17
13
12
37
4
3
14
38
11
10
40
5
9
23
18
19
27
26
27
26
25
20
21
19
22
35
31
24
28
30
41
43
39
42
29
34
33
36
31
32
W1HH-03-02-001
1234-
78910 -
18 19 20 21 -
11 - Propeller Shaft
12 13 14 15 -
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
W3-2-4
34 35 36 37 -
38 - Bearing
39 - O-Ring
40 41 42 43 -
Spacer
Housing
Lock Plate
Bolt (2 Used)
W107-03-02-008
W3-2-5
16
13
12
35
31
30
41
43
42
36
31
32
W1HH-03-02-001
W3-2-6
ST 3052
ST 3050
35
ST 3051
W157-03-02-005
W3-2-7
40
10
23
8
1
19
20
21
19
22
18
31
24
25
27
26
27
26
28
34
36
32
W1HH-03-02-001
W3-2-8
W3-2-9
33, 34
32 12 13
29
23
10
39
17
40
11
15
14
38
37
19
18
20
22
21
16
41
30
36
1234-
78910 -
18 19 20 21 -
11 - Propeller Shaft
12 13 14 15 -
31
35
42
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
43
28 27 25 26
23 24 25 26 -
24
W3-2-10
34 35 36 37 -
W164-03-02-002
38 - Bearing
39 - O-Ring
40 41 42 43 -
Spacer
Housing
Lock Plate
Bolt (2 Used)
NOTE: Check if the inner race is driven in completely by listening to the sound.
2. Apply grease to the O-ring outer surface of floating seal (30). Install one half of floating seal (30)
on housing (41).
W3-2-11
41
32
36
35 42 43 26 28 27
W3-2-12
26
24
W164-03-02-002
NOTE: Apply grease to the threaded part of bearing nut (35) to tighten the torque to correct
specification.
8. Hold the travel device securely. Attach the special
tools to bearing nut (35). Then, tighten with a
torque wrench.
Special Tools: ST 3050, ST 3051, ST 3052
Bolt: M16 (60 to 90 mm in length)
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
ST 3052
ST 3050
35
W140-03-02-001
ST 3051
36
W157-03-02-005
W3-2-13
12 13
23
15
16
41
32
28
W3-2-14
25
24 6
W164-03-02-002
25
Slit
W178-02-06-002
carrier
assembly
W166-03-02-001
W3-2-15
W166-03-02-002
29
12
10
17
40
11
21
15
22
18
19
16
20
W164-03-02-002
W3-2-16
W3-2-17
12
10
13
14
11
9
8
7
Brake Releasing
Oil Passage
6
3
1
15
16
25
26
27
20
18
19
21
17
22
23
28
24
32
29
30
31
40
39 38
37
36
33
34
35
12345678910 -
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
11 12 13 14 15 16 17 18 19 20 -
W164-03-02-003
Bearing
Housing
Oil Seal
Retaining Ring
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
Friction Plate (4 Used)
21 22 23 24 25 26 27 28 29 30 -
Link
Reamer Bolt
Plug (2 Used)
O-Ring (2 Used)
Pin
Center Shaft
Center Spring
Bushing
Valve Plate
Plate
W3-2-18
31 32 33 34 35 36 37 38 39 40 -
33
22
23
W178-03-02-014
IMPORTANT: Plug (19) has been bound with LOCTITE. If removing it by force, its
hexagon hole may be damaged. Do
not remove plug (19) unless necessary.
19
W178-03-02-009
W107-03-02-098
W3-2-19
12
10
13
14
11
9
8
7
6
16
25
26
27
20
18
17
33
W164-03-02-003
W3-2-20
ST 3058
ST 5904
W107-03-02-119
8
11
10
9
Thrust Block
W107-03-02-121
W3-2-21
35, 34
28
15
5 6
30
29
31
33
8
9
10
11
12
13
14
16
18
25
17
20
36
37
38
39
40
23, 24
27
19
26
32
21
W178-03-02-016
22
12345678910 -
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
11 12 13 14 15 16 17 18 19 20 -
Bearing
Housing
Oil Seal
Retaining Ring
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
Friction Plate (4 Used)
21 22 23 24 25 26 27 28 29 30 -
Link
Reamer Bolt
Plug (2 Used)
O-Ring (2 Used)
Pin
Center Shaft
Center Spring
Bushing
Valve Plate
Plate
W3-2-22
31 32 33 34 35 36 37 38 39 40 -
16
ST 5904
W107-03-02-119
W3-2-23
27
18
12 4
18
13
25
17
Slit (4 Places)
20 26
W178-03-02-019
W3-2-24
11. Turn housing (12) over and place it with its oil seal
(13) side facing down. Tap drive disc (8) assembly
lightly with a plastic hammer and brass bar to install it into housing (12).
17
Spherical
Handle Hole
W107-03-02-146
26
25
12
W178-03-02-015
W178-03-02-018
W3-2-25
29
28
15
12
18
30
31
33
25
36
37
23
17
19
26
21
W178-03-02-016
W3-2-26
29
W178-03-02-017
36
ST 7131
21
W3-2-27
22
W107-03-02-174
12
33
36
38
39
40
23, 24
32
21
W178-03-02-016
22
W3-2-28
34. Install special tool (ST 7085) into the end of center shaft (26).
ST 7085
26
12
W107-03-02-183
W3-2-29
8
9
10
11
16
12
15
14
13
4
5
6
1, 2
11
10
20
19
13
14
15
16
18
1, 2
17
Shuttle Valve for Servo Piston
Reducing Valve
12345-
O-Ring (2 Used)
Overload Relief Valve (2 Used)
Casing
Plug (2 Used)
O-Ring (2 Used)
W140-03-02-003
678910 -
Spring (2 Used)
Poppet (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
11 12 13 14 15 -
W3-2-30
Stopper (2 Used)
Spool
Ball (2 Used)
Seat (2 Used)
O-Ring (2 Used)
16 17 18 19 20 -
Plug (2 Used)
Plug
O-Ring
Spool
Spring
Reducing Valve
Lock Nut
Adjusting Screw
Check Valve
W140-03-02-005
W3-2-31
15
13
14
16
15
16
Section B
Section C
19
17
20
18
3
4
5
C
8
9
Section A-A
A
12
1 - O-Ring (2 Used)
2 - Overload Relief Valve (2
Used)
3 - Casing
4 - Plug (2 Used)
5 - O-Ring (2 Used)
11
10
6 - Spring (2 Used)
7 - Poppet (2 Used)
11 - Stopper (2 Used)
12 - Spool
16 - Plug (2 Used)
17 - Plug
8 - Plug (2 Used)
9 - O-Ring (2 Used)
10 - Spring (2 Used)
13 - Ball (2 Used)
14 - Seat (2 Used)
15 - O-Ring (2 Used)
18 - O-Ring
19 - Spool
20 - Spring
W3-2-32
W164-03-02-005
Reducing Valve
Check Valve
IMPORTANT: After inserting poppet (7), insert a
metal bar into the plug hole to
poppet (7), then tap the other end of
the bar to obtain tight fitting between
poppet (7) and casing (3).
3. Install springs (6) (2 used) into poppets (7) (2
used) and insert the poppets into casing (3). Install O-rings (5) (2 used) onto plugs (4) (2 used)
and install the plugs into casing (3).
: 12 mm
: 235 Nm (24 kgfm, 174 Ibfft)
W3-2-33
W1HH-03-02-002
A
B
C
D
E
Standard
Allowable Limit
87 (3.4)
[77 (3.0)]
89.15 (3.5)
84.15 (3.3)
125.75 (5)
133.55 (5.3)
128.55 (5.1)
216.0 (8.5)
-
W3-2-34
Unit: mm (in)
Remedy
Cladding by
welding and
finishing
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
The procedure starts on the premise that the track
link has already been removed.
Refer to page W3-7-1 for track removal.
3
2
W3-2-35
W157-03-02-006
3
2
W3-2-36
W157-03-02-006
W3-2-37
13
12
37
4
3
14
38
11
10
40
5
9
23
8
18
19
27
26
27
26
25
20
21
19
22
35
31
24
28
30
43
29
42
34
33
36
31
32
W1HH-03-02-004
1234-
78910 -
18 19 20 21 -
11 - Propeller Shaft
12 13 14 15 -
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
W3-2-38
34 35 36 37 -
38 - Bearing
39 - Spacer
42 - Lock Plate
43 - Bolt (2 Used)
15
16
12
W3-2-39
13
12
35
31
30
43
29
42
36
31
32
W1HH-03-02-004
W3-2-40
ST 3052
ST 3050
35
ST 3051
W157-03-02-005
W3-2-41
4
3
40
10
5
23
8
18
19
27
26
27
26
25
20
21
19
22
31
24
28
34
36
32
W1HH-03-02-004
W3-2-42
W3-2-43
33, 34
32 12 13 8
29
23
10
17
40
11
15
14
38
37
19
18
20
22
21
16
30 31 36 35 42 43 28 27 25 26 24 3
4 5
7
W1HH-03-02-003
1234-
78910 -
18 19 20 21 -
11 - Propeller Shaft
12 13 14 15 -
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
W3-2-44
34 35 36 37 -
38 - Bearing
40 - Spacer
42 - Lock Plate
43 - Bolt (2 Used)
W3-2-45
29
32 36 35 42 43 26 28 27 25 26 24
W1HH-03-02-003
W3-2-46
NOTE: Apply grease to the threaded part of bearing nut (35) to tighten the torque to correct
specification.
8. Hold the travel device securely. Attach the special
tools to bearing nut (35). Then, tighten with a
torque wrench.
Special Tools: ST 3050, ST 3051, ST 3052
Bolt: M16 (60 to 90 mm in length)
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
ST 3052
ST 3050
35
W140-03-02-001
ST 3051
36
W157-03-02-005
W3-2-47
29
12 13
23
15
16
32
28
25
24
4 5
7
W1HH-03-02-003
W3-2-48
25
Slit
W178-02-06-002
carrier
assembly
Cover (15)
W166-03-02-001
W166-03-02-002
W3-2-49
29
12
10
17
40
11
15
19
18
20
22
21
16
W1HH-03-02-003
W3-2-50
W3-2-51
5
4
3
Piston Pushing
Oil Passage
2
1
16
28
7
15
14
17
13
19
12
18
20
11
10
9
21
22
23
24
25
26
27
1234567-
Shaft
Retaining Ring
Retaining Ring
Oil Seal
O-Ring (2 Used)
Housing
Piston
8910 11 12 13 14 -
Roller Bearing
Disc Spring
Brake Piston
O-Ring
O-Ring
Plate (4 Used)
Rotor
15 16 17 18 19 20 21 -
Bushing
Swash Plate
Ball (2 Used)
Plunger (9 Used)
Retainer
Spring (6 Used)
Friction Plate (4 Used)
W3-2-52
W1HH-03-02-005
22 23 24 25 26 27 28 -
W3-2-53
4
3
W1HH-03-02-005
W3-2-54
8
1
W172-03-02-003
W3-2-55
27
25
23
11
12
10
14 18
16
17
3
4
1
26
22
24
13
21
20
15
19
Shaft
Retaining Ring
Retaining Ring
Oil Seal
O-Ring (2 Used)
Housing
Piston
8910 11 12 13 14 -
Roller Bearing
Disc Spring
Brake Piston
O-Ring
O-Ring
Plate (4 Used)
Rotor
15 16 17 18 19 20 21 -
Bushing
Swash Plate
Ball (2 Used)
Plunger (9 Used)
Retainer
Spring (6 Used)
Friction Plate (4 Used)
W3-2-56
28
6
W1HH-03-02-006
22 23 24 25 26 27 28 -
ST 7270
Inner Bore Spline
Inner Ring Plate
4
6
ST 7268
ST 7271
12
W176-03-02-007
W176-03-02-008
W176-02-06-014
W3-2-57
27
25
23
11
12
10
14 18
16
17
13
21
20
15
19
6
W1HH-03-02-006
W3-2-58
19
Chamfered
15
W172-03-02-001
W3-2-59
27
25
26
22
24
6
W1HH-03-02-006
W3-2-60
27
26
W176-03-02-012
W3-2-61
1
2
3
4
5
4
16
14
15
13
10
11
W1HH-03-02-007
12
1234-
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Stopper (2 Used)
5678-
Spool
Valve Housing
Plug
O-Ring
910 11 12 -
Poppet (2 Used)
Spring (2 Used)
O-Ring (2 Used)
Overload Relief Valve
(2 Used)
W3-2-62
13 14 15 16 -
Plug
O-Ring
Spring
Spool
W176-03-02-011
Piston
W3-2-63
13
14
15
16
10
11
12
7
W1HH-03-02-008
1234-
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Stopper (2 Used)
5678-
Spool
Valve Housing
Plug
O-Ring
910 11 12 -
Poppet (2 Used)
Spring (2 Used)
O-Ring (2 Used)
Overload Relief Valve
(2 Used)
W3-2-64
13 14 15 16 -
Plug
O-Ring
Spring
Spool
W3-2-65
Sprocket
W1HH-03-02-002
A
B
C
D
E
Standard
Allowable Limit
87 (3.4)
[77 (3.0)]
89.15 (3.5)
84.15 (3.3)
125.75 (5)
133.55 (5.3)
128.55 (5.1)
216.0 (8.5)
-
W3-2-66
Unit: mm (in)
Remedy
Cladding by
welding and
finishing
Travel Motor
1. End play between plunger and shoe.
Standard
0
0.2 mm (0.008 in)
Allowable Limit
0.2 mm (0.008 in)
Plunger
W105-02-06-130
Allowable Limit
0
0.04 mm (0.0016 in)
D-d 0.04 mm (0.0016 in)
W105-02-06-134
Plunger Assembly
d
Rotor
W105-02-06-135
Shoe
3. Shoe thickness
Standard
Allowable Limit
W105-02-06-130
W3-2-67
Removal
Before removing the travel device, the tracks must be
removed first. For removal and installation of the
tracks, refer to Remove and Install Tracks section on
page W3-7-1.
In this section, the procedure starts on the premise
that the track have already been removed.
2
W16J-03-02-006
Track Frame
10
6
9
W16J-03-02-005
W111-03-02-002
W3-2-68
Track Frame
10
5
6
9
W16J-03-02-005
W111-03-02-002
W3-2-69
Track Frame
10
5
6
9
W16J-03-02-005
2
W16J-03-02-006
W3-2-70
W3-2-71
ZAXIS370MTH
7
5
4
3
2
1
21
22
24
23
20
17
16
15
13
18
25
19
14
26
27
12
28
29
10
11
37
40
39
36
34 33
35
32
31
30
38
49
48
47
44
45
46
43
41
42
12345678910 11 12 13 -
Motor
O-Ring
Housing
Floating Seal
Roller Bearing
Drum
Roller Bearing
O-Ring
Nut
Lock Plate
Bolt (2 Used)
Sprocket
Washer (24 Used)
14 15 16 17 18 19 20 21 22 23 24 25 -
26 27 28 29 30 31 32 33 34 35 36 37 -
Spacer
1st Stage Carrier
Thrust Plate (3 Used)
Spring Pin (3 Used)
2nd Stage Planetary Gear (3 Used)
Pin (3 Used)
Needle Bearing (3 Used)
Thrust Plate (3 Used)
Thrust Plate (4 Used)
3rd Stage Planetary Gear (4 Used)
Spring Pin (4 Used)
Pin (4 Used)
W3-2-72
W16J-03-02-004
38 39 40 41 42 43 44 45 46 47 48 49 -
49-B
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-73
4
3
21
22
24
23
20
17
16
18
25
19
15
26
12
27
28
29
10
11
37
40
39
36
34 33
35
32
31
30
38
48
43
41
42
W3-2-74
W16J-03-02-004
ST 3136
W111-03-02-018
CAUTION: The third stage carrier (15) assembly weight: 70 kg (150 Ib)
8. Wind nylon slings (2 used) onto third stage carrier
(15). Hoist and remove third stage carrier assemblies (15 and 34 to 40) by crane.
9. Remove bolts (11) (2 used) to remove lock plate
(10).
: 19 mm
W3-2-75
1
25
17
18
15
12
14
26
27
29
37
40
39
36
34
35
38
W16J-03-02-004
W3-2-76
17. Pull spring pin (36) out from third stage carrier
(15) with a round bar (Dia: 8mm (0.3 in)). Remove
pin (37) to remove third stage planetary gear (35)
and thrust plates (34 and 40) from the third stage
carrier.
Remove needle bearings (38 and 39) from the
third stage planetary gear.
18. Remove spring pins (36) (3 used), pins (37) (3
used), third stage planetary gears (35) (3 used),
thrust plates (34) (3 used) and (40) (3 used), needle bearings (38) (3 used) and (39) (3 used) from
third stage carrier (15) according to the steps in
procedure 17.
19. Disassemble the first stage carrier (27) assembly
and second stage carrier (17) assembly according to the steps in procedures 17 and 18.
The diameter of round bar for spring pin (25):
4 mm (0.16 in)
The diameter of round bar for spring pin (29):
5 mm (0.20 in)
20. Remove spacer (26) from first stage carrier (27).
Remove spacer (18) from second stage carrier
(17).
W3-2-77
13 14
12
ZAXIS370MTH
5
43 42
15 16
18
17
19
26
27
49
47
44
46
45
41
23
24
25
22
21
20
48
33 30 32 31
34
40 35 39 38
10 11
12345678910 11 12 13 -
Motor
O-Ring
Housing
Floating Seal
Roller Bearing
Drum
Roller Bearing
O-Ring
Nut
Lock Plate
Bolt (2 Used)
Sprocket
Washer (24 Used)
14 15 16 17 18 19 20 21 22 23 24 25 -
26 27 28 29 30 31 32 33 34 35 36 37 -
36
T16J-03-05-001
37
Spacer
1st Stage Carrier
Thrust Plate (3 Used)
Spring Pin (3 Used)
2nd Stage Planetary Gear (3 Used)
Pin (3 Used)
Needle Bearing (3 Used)
Thrust Plate (3 Used)
Thrust Plate (4 Used)
3rd Stage Planetary Gear (4 Used)
Spring Pin (4 Used)
Pin (4 Used)
W3-2-78
28 29
38 39 40 41 42 43 44 45 46 47 48 49 -
W3-2-79
12
3
15
47
34
10 11
40 35 39 38
W3-2-80
37
36
T16J-03-05-001
W111-03-02-018
12. Rotate sprocket (12) both clockwise and counterclockwise 4 to 5 turns. Tap on drum (6) with a
plastic hammer to secure appropriate play.
36
37
Slit
W178-02-06-002
W3-2-81
43 42
15 16
17 19
26
27
47
41
23
24
25
22
21
20
48
33 30 32 31
34
40 35 39 38
W3-2-82
37
28 29
36
T16J-03-05-001
25
22
19
Slit
W178-02-06-002
CAUTION: The third stage carrier (15) assembly weight: 70 kg (150 Ib)
23. Wind nylon slings (2 used) onto third stage carrier
assemblies (15 and 34 to 40). Hoist the third
stage carrier assemblies and lower it onto housing (3) carefully.
24. Install third stage sun gear (16) onto third stage
carrier (15) with the smaller end facing cover (47).
W166-03-02-002
W166-03-02-001
16
W3-2-83
3
1
42
49
47
44
46
45
41
48
T16J-03-05-001
W3-2-84
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-85
7
5
15
16
17
14
13
11
12
10
9
8
28
22
27
20
26
25
24
23
18
19
33
32
21
30
29
123456789-
Casing
O-Ring (4 Used)
Spring (2 Used)
Piston (2 Used)
Oil Seal
Roller Bearing
Shaft
Steel Ball (2 Used)
Swash Plate
10 11 12 13 14 15 16 17 -
Piston (9 Used)
Retainer
Holder
Spring (9 Used)
Cylinder Block
Valve Plate
Collar
Roller Bearing
18 19 20 21 22 23 24 25 -
Friction Plate
Friction Plate
Disc Plate (4 Used)
Friction Plate (3 Used)
Friction Plate
Backup Ring
O-Ring
O-Ring
W3-2-86
26 27 28 29 30 31 32 33 -
31
W16J-03-02-001
Backup Ring
Brake Piston
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing
Socket Bolt (9 Used)
32
33
Eyebolt Mounting
Position
W16J-03-02-002
W3-2-87
4
3
7
5
W16J-03-02-001
W3-2-88
W3-2-89
27
33
29
25,26
23,24
22
19 18
30
16
32
17
1
15
31
5
28
T16J-03-05-003
123456789-
Casing
O-Ring (4 Used)
Spring (2 Used)
Piston (2 Used)
Oil Seal
Roller Bearing
Shaft
Steel Ball (2 Used)
Swash Plate
10 11 12 13 14 15 16 17 -
14 10 20 21
Piston (9 Used)
Retainer
Holder
Spring (9 Used)
Cylinder Block
Valve Plate
Collar
Roller Bearing
13
18 19 20 21 22 23 24 25 -
11
12
Friction Plate
Friction Plate
Disc Plate (4 Used)
Friction Plate (3 Used)
Friction Plate
Backup Ring
O-Ring
O-Ring
W3-2-90
26 27 28 29 30 31 32 33 -
Backup Ring
Brake Piston
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing
Socket Bolt (9 Used)
W3-2-91
27
29 25, 26
23, 24 22
19 18
30
16
32
17
1
15
31
T16J-03-05-003
14
20 21
W3-2-92
NOTE: Friction plates (18, 19, 21 and 22) are different in thickness.
(18), (22): 4.8 mm (0.2 in)
(19): 6.5 mm (0.3 in)
(21): 3 mm (1.0 in)
So they should be installed while aligning
with their own notch respectively in casing
(1).
When installing disc plate (20), its inner
splines shall be aligned with those of cylinder block (14).
IMPORTANT: Apply grease to O-rings (24 and 25)
and backup rings (23 and 26).
11. Install backup rings (26 and 23) and O-rings (25
and 24) onto brake piston (27).
IMPORTANT: Pay attention to the mounting direction for brake piston (27), so that the
notch shall be square to the pin (31)
holes in casing (1).
1
27
27
Free Hole
29
29
W16J-03-02-003
Free Hole
Notch
W16J-03-02-003
31
12. Tap brake piston (27) with a plastic hammer to install it into casing (1).
W3-2-93
33
27
32
31
28
T16J-03-05-003
W3-2-94
32
33
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-95
6
2
10
11
Plug
10
35
Orifice
12
13
36
37
14
38
16
39
15
18
20
40
21
48
17
24
26
47
49
10
9
41
42
23
30
25
28
46
32
27
43
29
44
45
43
34
3
2
36
33
31
Orifice
44
40
22
19
42
41
50
39
38
35
37
W183-03-02-010
12345678910 11 12 13 -
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Overload Relief Valve (2 Used)
Plug
O-Ring
Spring
Plug (6 Used)
O-Ring (6 Used)
Orifice
Socket Bolt (9 Used)
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Spring Seat (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 -
W3-2-96
Spring (2 Used)
Spring Guide (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Socket Bolt (8 Used)
Cap (2 Used)
O-Ring (2 Used)
Spring Seat (2 Used)
39 40 41 42 43 44 45 46 47 48 49 50 -
Spring (2 Used)
Spring Seat (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Spool
Valve Housing
Pin (4 Used)
Pin
Orifice
Spool Assembly
W3-2-97
18
21
26
24
27 31
29
32
33
34
17, 19
20
22
23, 25
30
28
36
38
41
37
39
35
42
A
40
43
44
45
13
50
14
48
47
12
15
46
5
12345678910 11 12 13 -
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Overload Relief Valve (2 Used)
Plug
O-Ring
Spring
*Plug (6 Used)
*O-Ring (6 Used)
*Orifice
Socket Bolt (9 Used)
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Spring Seat (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 -
W3-2-98
A-A-A
Spring (2 Used)
Spring Guide (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Socket Bolt (8 Used)
Cap (2 Used)
O-Ring (2 Used)
Spring Seat (2 Used)
4
W183-03-02-016
39 40 41 42 43 44 45 46 47 48 49 50 -
Spring (2 Used)
Spring Seat (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Spool
Valve Housing
Pin (4 Used)
Pin
*Orifice
Spool Assembly
W3-2-99
Cylinder
Block
W507-02-04-009
Piston
Piston
: 0.4 mm or less
Shoe
W107-02-06-140
Piston
W3-2-100
W162-03-02-005
W1HH-03-02-002
Unit: mm (in)
Remedy
92 (3.62)
[82 (3.23)]
86.1 (3.39)
81.1 (3.19)
Cladding by
122.1 (4.8)
welding and
132 (5.2)
127 (5.0)
finishing
215.9 (8.46)
W3-2-101
W3-2-102
Removal
1. Attach an identification tag to all the hoses of
center joint for reassembling.
Remove all the hoses and adapters from the
center joint. Cap all the removed ends of hoses.
: 17 mm, 27 mm, 41 mm
2. Remove bolt (1) from the center joint and remove
stopper plate (2).
3. Install eyebolt to the center joint. Attach a wire
rope and hoist the center joint.
W157-03-03-003
W105-03-03-003
W3-3-1
W157-03-03-003
W105-03-03-003
W3-3-2
W3-3-3
1
2
3
4
5
12
11
10
7
W157-03-03-002
4 - O-Ring
5 - Bushing
6 - Oil Seal (6 Used)
7 - O-Ring
8 - Cover
9 - Bolt (4 Used)
W3-3-4
10 - Retaining Ring
11 - Ring
12 - Body
W105-03-03-015
W506-03-03-002
W3-3-5
1
2
3
4
6
12
11
10
9
W178-03-03-001
4 - O-Ring
5 - Bushing
6 - Oil Seal (6 Used)
7 - O-Ring
8 - Cover
9 - Bolt (4 Used)
W3-3-6
10 - Retaining Ring
11 - Ring
12 - Body
0.1 mm
12
Lip
Body (12)
W105-03-03-024
W178-03-03-002
W3-3-7
ST 2558
Sleeve
12
0.4 mm
or More
Detail D
W135-03-03-001
W136-03-03-031
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-8
Item
Remedy
Replace
Replace
Replace
Bushing
T157-01-01-040
Body Spindle
Cover
Sliding surface
Scored or serious damage
and sealed part
Sliding surface of 1) Scored or abnormal wear of more than
body and spindle,
0.1 mm (0.004 in)
except
sealed 2) Scored less than 0.1 mm (0.004 in) deep
part
1) Wear more than 0.5 mm (0.02 in) deep
and abnormal wear
Sliding surface
2) Wear less than 0.5 mm (0.02 in) deep
and ring
3) Scored or abnormal wear less than 0.5 mm
(0.02 in) and repairable.
1) Wear more than 0.5 mm (0.02 in)
Sliding surface
2) Wear less than 0.5 mm (0.02 in)
and ring
3) Scored or abnormal wear less than 0.5 mm
(0.02 in) and repairable.
W3-3-9
Replace
Replace
Repair and finish
with oil stone
Replace
Repair and finish
Repair and finish
Replace
Repair and finish
Repair and finish
W3-3-10
2
1
W157-03-04-003
W157-03-04-002
Section A
W3-4-1
W157-03-04-001
6
7
10
16
11
12
15
14
13
W173-03-04-001
12345-
6789-
U-Ring
Retaining Ring
Rod
O-Ring
10 11 12 13 -
W3-4-2
Cylinder
Plug
Valve
Nut
14 15 16 17 -
Washer
Spacer
Spring
Holder
Holder
Oil Jack
Base
W105-03-04-006
W105-03-04-007
W105-03-04-009
W3-4-3
11
12
14
13
W173-03-04-001
W3-4-4
W105-03-04-011
Oil Jack
NOTE: 1 mm = 0.03937 in
6. Tighten the nuts of special tool and secure the
track adjuster.
Operate the oil jack and compress the track adjuster until a clearance is observed between
washer (14) and nut (13). (Approximately 10 mm
(0.4 in))
: 46 mm
W105-03-04-013
13
11
W105-03-04-014
W3-4-5
17
1
2
3
4
5
6
10
16
15
14
W173-03-04-001
W3-4-6
Oil Jack
W105-03-04-015
W105-03-04-016
Eyebolt
W3-4-7
W105-03-04-017
17
2
3
4
5
6
10
W173-03-04-001
W3-4-8
W3-4-9
6
7
W105-03-04-023
12
11
14
15
16
13
Chamber B
10
Chamber A
17
12345-
6789-
U-Ring
Retaining Ring
Rod
O-Ring
10 11 12 13 -
Cylinder
Plug
Valve
Nut
W3-4-10
14 15 16 17 -
Washer
Spacer
Spring
Holder
4
5
6
7
W3-4-11
W105-03-04-025
10
6
5
W105-03-04-021
14
15
16
557 mm (Free Length 679 mm)
1ft 9.9 in (Free Lenght 2ft 2.7 in)
W1HH-03-04-001
W3-4-12
W105-03-04-017
14
16
W105-03-04-016
W105-03-04-012
W3-4-13
12
13
11
16
W3-4-14
16
Oil Jack
W105-03-04-026
13
11
W105-03-04-014
Oil Jack
W105-03-04-013
W105-03-04-011
W3-4-15
Wire Rope
18. Attach a wire rope to the track adjuster as illustrated. Hoist and remove the track adjuster from
special tool.
CAUTION: If only the track adjusted is
transported, use special tool as illustrated in
order to carry the track adjuster safely.
W105-03-04-009
W105-03-04-028
W3-4-16
2
1
W142-03-04-002
Removal
CAUTION: Track adjuster weight: 250 kg
(550 lb)
W16J-03-04-002
View
W3-4-17
W16J-03-04-001
3
4
5
7
8
9
10
16
11
15
12
14
W166-03-04-003
13
1234-
5678-
Wear Ring
U-Ring
Retaining Ring
Rod
910 11 12 -
Cylinder
O-Ring
Bolt
Valve
W3-4-18
13 14 15 16 -
Nut
Bracket
Spring
Spacer
Track Adjuster
ST 4932
Holder
W142-03-04-019
15
14
8
13
11
12
W142-03-04-020
W3-4-19
16
15
14
W3-4-20
W166-03-04-003
ST 4932
14
W142-03-04-005
15
Holder
W142-03-04-006
15
Holder
W142-03-04-007
W3-4-21
3
4
5
7
8
9
10
W166-03-04-003
W3-4-22
3
1
14. Install eyebolt (M16, Pitch 2.0 mm) into rod (8).
Hoist and remove rod (8) from cylinder (9).
Remove O-ring (10) from the inside of cylinder
(9).
8
W142-03-04-010
5
6
W166-03-04-001
W3-4-23
10
16
Chamber
A
1234-
5678-
Wear Ring
U-Ring
Retaining Ring
Rod
14
Chamber B
11 12
Grease Outlet
W16J-03-04-003
910 11 12 -
15
Cylinder
O-Ring
Bolt
Valve
W3-4-24
13
13 14 15 16 -
Nut
Bracket
Spring
Spacer
5
6
W166-03-04-001
10
W142-03-04-012
2
1
W142-03-04-018
W3-4-25
16
14
Grease Outlet
15
W3-4-26
W16J-03-04-003
15
14
Holder
W142-03-04-007
15
W142-03-04-006
ST 4932
W142-03-04-005
W3-4-27
15
14
11 12
W3-4-28
Grease Outlet
13
W16J-03-04-003
15
ST 4932
14
Wire
W142-03-04-015
W3-4-29
11
12
W142-03-04-020
W3-4-30
Removal
CAUTION: Front idler weight:
ZAXIS330, 330LC: 160 kg (350 lb)
ZAXIS350H, 350LCH: 160 kg (350 lb)
ZAXIS370MTH: 210 kg (460 lb)
W142-03-05-002
1
2
4
5
W17P-03-05-001
Wooden Block
Installation
1. Install the front idler in the reverse procedures
when removing. Clean and apply grease to the
bearing (1) sliding surface on track frame (3).
W17P-03-05-001
W3-5-1
6
7
4
5
4
3
2
10
11
W16J-03-05-001
14
1234-
Bearing (2 Used)
Pin (2 Used)
Floating Seal (2 Used)
O-Ring (2 Used)
5678-
12
13
Axle
Bushing (2 Used)
Idler
Plug (2 Used)
9 - Guard
10 - Bolt (3 Used)
11 - Spring Washer (3 Used)
W3-5-2
12 - Yoke
13 - Bolt (4 Used)
14 - Spring Washer (4 Used)
IMPORTANT: For handling of floating seal (3), refer to the section Precautions for
Floating Seal Handling on page
W1-1-4.
6. Remove bearing (1) from the upper side of idler
(7). Remove floating seals (3) (2 used) from both
sides of idler (7) and bearing (1).
1
3
7
3
4
5
1
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH:
Idler assembly weight: 115 kg (250 lb)
Axle (5) weight: 17 kg (37 lb)
Bearing (1) weight: 15 kg (33 lb)
W105-03-05-009
ZAXIS370MTH:
Idler assembly weight : 150 kg (330 lb)
Axle (5) weight: 28 kg (62 lb)
Bearing (1) weight: 14 kg (31 lb)
5. Put the matching marks on bearing (1) and axle
(5). Remove the axle (5) assembly from idler (7)
by using a press.
1
W105-03-05-008
W3-5-3
6
4
5
4
2
W16J-03-05-001
W3-5-4
4
1
6
Wooden Block
W105-03-05-011
4
W105-03-05-010
W3-5-5
10
11
12
13
14
1234-
Bearing (2 Used)
Pin (2 Used)
Floating Seal (2 Used)
O-Ring (2 Used)
5678-
Axle
Bushing (2 Used)
Idler
Plug (2 Used)
9 - Guard
10 - Bolt (3 Used)
11 - Spring Washer (3 Used)
W3-5-6
W16J-03-05-002
12 - Yoke
13 - Bolt (4 Used)
14 - Spring Washer (4 Used)
7
3
W105-03-05-014
IMPORTANT: For handling of floating seal (3), refer to the section Precautions for
Floating Seal Handling on page
W1-1-4.
4. Apply grease to O-ring on floating seal (3). Install
a pair of floating seals (3) into idler (7) and bearing (1).
W3-5-7
W157-03-05-006
3 5
10
11
12
13
14
W3-5-8
W16J-03-05-002
7
1
5
W157-03-05-005
8. Align the matching marks made when disassembling. Tap the other bearing (1) evenly by using a
plastic hammer. Install bearing (11) into axle (5).
Insert pin (2) by using a bar and hammer.
9. Add engine oil (API CD grade SAE30) through
the plug (8) hole in bearing (1).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
0.3 L (0.32 US gt.)
ZAXIS370MTH:
0.45 L (0.48 US gt.)
10. Apply LOCTITE #503 to plug (8). Install plug (8)
into bearing (1).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
CAUTION: Yoke (12) weight:
ZAXIS330, 330LC, 350H, 350LCH: 25 kg
(55 lb)
ZAXIS370MTH: 56 kg (120 lb)
11. Wind a nylon sling onto yoke (12). Hoist yoke
(12) and align the bolt (13) holes on yoke (12)
and bearing (1).
W3-5-9
E
A
W166-03-05-001
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
102 (402)
[80.4 (3.17)]
200 (7.87)
22.5 (0.89)
A
B
C
D
E
ZAXIS370MTH
Standard
102 (4.02)
200 (7.87)
630 (24.80)
675 (26.57)
22.5 (0.89)
Allowable
Limit
[92 (3.62)]
610 (24)
Remedy
Axle
Bushing
Outside Dia.
Inside Dia
Flange
Thickness
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
85.0 (3.35)
84.2(3.31)
85.0 (3.35)
86.0 (3.39)
110 (4.33)
110 (4.33)
Allowable
Limit
109.2 (4.30)
111 (4.37)
2.0 (0.08)
6.0 (0.24)
5.2 (0.20)
1.2 (0.05)
W3-5-10
ZAXIS370MTH
Standard
Remedy
Replace
Grease Outlet
M116-07-094
Oil Jack
Nonskid Cloth
4
W105-03-06-002
5
Wooden Block
W105-03-06-003
W3-6-1
W157-03-06-001
5
W105-03-06-005
Installation
1. Install upper roller (4) onto track frame (5) with
bolts (6) (4 used).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
ZAXIS370MTH:
: 27 mm
: 400 Nm (41 kgfm, 300 Ibfft)
6
5
3
W157-03-06-001
5
W105-03-06-002
W3-6-2
Grease Outlet
M116-07-094
W157-03-06-002
W158-03-06-001
W3-6-3
5
1
W105-03-06-008
90 to 110
M104-07-067
W105-03-06-001
Grease Outlet
M116-07-094
W3-6-4
5
W105-03-06-010
Installation
1. Set lower rollers (5) below track frame (2) by using a fork lift.
5
W105-03-06-011
W105-03-06-012
W105-03-06-008
W3-6-5
Grease Outlet
M116-07-094
W3-6-6
W3-6-7
7
1
3
4
W166-03-06-006
3 - O-Ring (2 Used)
4 - Collar (2 Used)
5 - Pin (2 Used)
6 - Plug (2 Used)
W3-6-8
7 - Bushing (2 Used)
8 - Roller
Round Bar:
ZAXIS330, 330LC, 350H, 350LCH:
Dia. 14 mm (0.6 in)
ZAXIS370MTH: Dia. 25 mm (1 in)
4
1
W105-03-06-027
2
W105-03-06-026
IMPORTANT: For handling of floating seal (1), refer to the section Precautions for
Floating Seal Handling on page
W1-1-4.
3. Remove floating seal (1) from both sides of roller
(8) and collars (4) (2 used) respectively.
Special
Tool
W105-03-06-028
W3-6-9
W1HH-03-06-001
ZAXIS370MTH:
4
W162-03-06-002
3 - O-Ring (2 Used)
4 - Collar (2 Used)
5 - Pin (2 Used)
6 - Plug (2 Used)
W3-6-10
7 - Bushing (2 Used)
8 - Roller
5. Insert axle (2) into roller (8). Install O-ring (3). Install the other collar (4) with pin (5) in the same
procedures.
6. Add engine oil (API CD class SAE30) through the
plug (6) hole in collar (4).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
0.42 L (0.44 US gt.)
ZAXIS370MTH: 0.5 L (0.53 US gt.)
5
2
5
4
W16J-03-06-001
W157-03-06-008
W3-6-11
W105-03-06-024
C
C
A
B
A
B
ZAXIS370MTH
W173-03-06-001
W166-03-06-007
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
ZAXIS370MTH
Standard
Allowable
Limit
98 (3.86)
103 (4.06)
165 (6.50)
190 (7.48)
120 (4.72)
110 (4.33)
160 (6.30)
150 (5.90)
Remedy
Cladding by
welding and finish or replace
ZAXIS370MTH
Standard
Allowable
Limit
Outside Dia.
45 (1.77)
[44.2 (1.74)]
60 (2.36)
[59.2 (2.37)]
Inside Dia.
45 (1.77)
[46.0 (1.81)]
60 (2.36)
[61 (2.37)]
Flange Thickness
2 (0.079)
[1.2 (0.047)]
4.5 (0.177)
[3.7 (0.146)]
Bushing
NOTE: Values in [
W3-6-12
Remedy
Replace
ZAXIS370MTH
W1HH-03-06-002
W157-03-06-003
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
ZAXIS 370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
203(7.99)
[229.5 (9.06)]
214 (8.43)
[249 (9.80)]
256 (10.08)
284 (11.18)
26.5 (1.04)
[13.25 (0.52)]
35 (1.38)
[17.5 (0.69)]
175 (6.89)
[157 (6.18)]
200 (7.87)
182 (7.17)
Remedy
Cladding by
welding and finish or replace
ZAXIS 370MTH
Standard
Allowable
Limit
Outside Dia.
75 (2.95)
[74.2 (2.92)]
85 (3.35)
[84.2 (3.31)]
Inside Dia.
75 (2.95)
[76 (2.99)]
85 (3.35)
[86.0 (3.39)]
Flange Thickness
2 (0.079)
[1.2 (0.047)]
6 (0.24)
[5.2 (0.20)]
Bushing
NOTE: Values in [
W3-6-13
Remedy
Replace
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or too much as the valve may fly off
or high-pressure grease in the adjusting
cylinder may gush out.
Keep body parts and face away from the
valve and loosen the valve carefully. Do not
loosen grease fitting (2).
W105-03-07-006
W105-03-07-002
1
2
Grease Outlet
M116-07-094
W3-7-1
UNDERCARRIAGE / Track
CAUTION: The front idler may fly off due to
the spring force when removing the track.
Particularly, a strong force is always applied
to the thread part of rod. If the rod and/or the
threads are damaged, metal fragments under
spring force may fly off.
3. ZAXIS330, 330LC, 350LCH:
Remove retaining ring (6) to prevent master pin
(3) from coming off.
NOTE: If retaining ring (6) interferes with master
link (7), push in master pin (3) in order to
make clearance between retaining ring (6)
and master pin (3). Remove retaining ring
(6).
ZAXIS370MTH:
Remove split pin (8) to prevent master pin (3)
from coming off.
NOTE: If split pin (8) interferes with master link (7),
push in master pin (3) in order to make
clearance between split pin (8) and master
pin (3). Remove split pin (8).
7
3
W105-03-07-009
7
3
8
ZAXIS370MTH
W3-7-2
W166-03-07-001
UNDERCARRIAGE / Track
IMPORTANT: Master pin (3) is directional. Be sure
to install it in the correct direction.
4. Remove master pin (3) by using special tool (ST
1970).
ST 1970
W105-03-07-008
Direction for
removing
the master
pin.
Split Pin
Corner
Direction for
removing the
master pin.
Retaining Ring
Track Link
Master Link
ZAXIS370MTH
W166-03-07-002
Boom
Arm
90 to 110
W105-03-07-012
W105-03-07-011
W3-7-3
UNDERCARRIAGE / Track
Installation
1. Jack up the machine. Set the track under the
lower roller so that the sprocket meshes with the
track end.
Check the direction of track.
Sprocket
Side
Idler Side
W105-03-07-013
W105-03-07-014
W105-03-07-015
W3-7-4
W105-03-07-016
UNDERCARRIAGE / Track
5. Install special tool (ST 1970). Install master pin
(3) by using a hammer.
ST 1970
W105-03-07-017
Split Pin
Corner
Direction for
installing the
master pin.
Direction for
installing the
master pin.
3
Retaining Ring
Track Link
Master Link
ZAXIS370MTH
W166-03-07-002
W105-03-07-010
ZAXIS370MTH:
Install split pin (8).
ZAXIS330, 330LC, 350H, 350LCH
W105-03-07-009
ZAXIS370MTH
W3-7-5
W166-03-07-001
UNDERCARRIAGE / Track
IMPORTANT: If disassembling the links, fill grease
(Daphne Epones SR) into the clearance between the pin and 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
pushing the bushing onto the plate
in order not to move because of
grease. After inserting the pin, wipe
off excess grease. Check the direction to install the seal.
Bushing
Seal
Pin
Do not Apply
Grease
Grease
Do not Apply
Grease
W197-03-07-001
Seal
M116-07-094
W105-03-07-018
W157-03-06-002
W3-7-6
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link
Measure the length of four links as illustrated.
Do not measure the master-pin-included part of
the track.
Measure the length with tension on the track.
A
W155-03-07-001
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
865.92 (34.09)
882 (34.72)
863.6 (34.00)
845.6 (33.29)
116 (4.57)
109 (4.29)
129 (5.08)
122 (4.80)
Remedy
Cladding by
welding and finish
or replace
Master Pin
W105-03-07-021
ZAXIS370MTH
W142-03-07-003
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
237 (9.33)
308 (12.1)
45 (1.77)
[42 (1.65)]
47.3 (1.86)
[44.3 (1.40)]
NOTE: Values in [
W3-7-7
Remedy
Replace
UNDERCARRIAGE / Track
Master Bushing
W105-03-07-023
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
148.3 (5.84)
160.80 (6.33)
45.45 (1.79)
48.5 (1.91)
47.90 (1.89)
50.90 (2.00)
66.91 (2.63)
61.91 (2.44)
71.35 (2.81)
66.35 (2.61)
Remedy
Replace
Grouser Shoe
W105-03-07-024
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
Shoe Size
ZAXIS370MTH
Allowable
Limit
Standard
Allowable
Limit
250 (9.84)
247 (9.72)
11 (0.43)
13 (0.51)
30 (1.18)
20 (0.79)
36 (1.42)
21 (0.83)
W3-7-8
Remedy
Replace
UNDERCARRIAGE / Track
Bushing
W105-03-07-023
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
Standard
A
B
C
158.9(6.26)
45.45(1.79)
66.91(2.63)
Allowable
Limit
46.5(1.83)
61.9(2.44)
ZAXIS370MTH
Standard
177(6.97)
48.4(1.91)
71.35(2.81)
Allowable
Limit
49.43(1.95)
66.35(2.61)
Remedy
Replace
Pin
W105-03-07-020
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
Standard
A
B
242(9.53)
44.69(1.76)
Allowable
Limit
41.7(1.64)
ZAXIS370MTH
Standard
254(10.00)
47.57(1.87)
W3-7-9
Allowable
Limit
44.57(1.76)
Remedy
Replace
UNDERCARRIAGE / Track
(Blank)
W3-7-10
MEMO
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SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment .........W4-1-1
Maintenance Standard ................................W4-1-7
Standard Dimensions for
Arm and Bucket Connection....................W4-1-10
Standard Dimensions for
Arm and Boom Connection...................... W4-1-11
Group 2 Cylinder
Remove and Install Cylinder........................W4-2-1
Hydraulic Circuit Pressure
Release Procedure ..................................W4-2-13
Up to serial No.33099 and up
Disassemble Cylinder ................................W4-2-14
Assemble Cylinder .....................................W4-2-20
Maintenance Standard...............................W4-2-24
Serial No.33100 and up
Disassemble Cylinder ................................W4-2-26
Assemble Cylinder .....................................W4-2-32
Maintenance Standard...............................W4-2-36
1HHW-4-1
(Blank)
1HHW-4-2
INSTALL
FRONT
AT1
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Adapter
Boom Cylinder
Removal
1. Remove pipe (1) of lubrication pipes to the front
attachment on the boss at the boom cylinder rod
side from the adapter.
(2 places on both left and right)
: 19 mm
W105-04-01-002
W4-1-1
Boom Cylinder
5
4
W178-04-01-004
Plate
W157-04-01-005
M157-07-173
W157-04-01-001
W4-1-2
10
11
12
13
W178-04-01-001
Plate
Insert Bar
Bracket
W178-04-01-001
W178-04-01-005
W4-1-3
10
11
12
W178-04-01-005
13
W178-04-01-001
W157-04-01-001
W4-1-4
Boom Cylinder
5
4
W178-04-01-004
W105-04-01-002
8. Apply grease to the boom cylinder rod side, bottom side, and boom foot side.
Boom Cylinder
Rod Side
Boom Foot
Side
M157-07-155
9. Fill hydraulic oil to specified level. Start the engine and check the connections for any oil leakage.
10. After completing the work, run each cylinder several times to stroke end in order to release any
pressure in the circuit.
Boom Cylinder
Bottom Side
W4-1-5
M157-07-156
14
14
15
15
W4-1-6
M157-07-157
E
G
C
D
A
I
J
K
W105-04-01-018
Unit: mm (in)
Parts Name
A
Standard
Allowable Limit
Pin
110 (4.33)
109.0 (4.31)
Bushing
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
110 (4.33)
111.5 (4.39)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
110 (4.33)
111.5 (4.39)
Boss (Boom)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Bushing
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Boss (Arm)
110 (4.33)
111.5 (4.39)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Boss (Boom)
110 (4.33)
111.5 (4.39)
110 (4.33)
111.5 (4.39)
W4-1-7
Remedy
Replace
I
J
K
Standard
Allowable Limit
Pin
90 (3.54)
89.0 (3.50)
Boss (Arm)
90 (3.54)
91.5 (3.60)
90 (3.54)
91.5 (3.60)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
100 (3.94)
101.5 (4.00)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
W4-1-8
Remedy
Replace
C
D
A
W105-04-01-019
Unit: mm (in)
Standard
Allowable Limit
258 (10.2)
168 (6.61)
300 (11.8)
400 (15.7)
300 (11.8)
Remedy
Replace
Point
W105-04-01-020
Unit: mm (in)
Standard
Allowable Limit
240 (9.45)
120 (4.72)
96 (3.78)
130 (5.12)
105 (4.13)
W4-1-9
Remedy
Replace
Section B
Section A
T137-01-03-001
Unit : mm (in)
ZAXIS330
ZAXIS350H
ZAXIS370MTH
EX300-5
575 (22.6)
10 (0.39)
700 (27.6)
695 (27.4)
1661 (65.4)
1666 (65.6)
1661 (65.4)
581 (22.9)
573 (22.6)
442 (17.4)
100 (3.94)
578 (22.7)
90 (3.54)
581 (22.9)
573 (22.6)
420 (16.5)
100 (3.94)
8.85
8.85
592 (23.3)
600 (23.6)
592 (23.3)
W4-1-10
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS330
ZAXIS350H
ZAXIS370MTH
EX300-5
90 (3.5)
418.5 (16.5)
571 (22.5)
W4-1-11
W4-1-12
3
2
3
W554-04-02-006
Link A
Link B
7
1
W158-04-02-006
W4-2-1
W102-04-02-005
11
15
13
W4-2-2
W1HH-04-02-009
12
10
11
15
14
1. Hoist bucket cylinder (1). Align the hole on cylinder tube side with the cylinder mounting hole on
arm. Insert thrust plate (10) and install pin (11).
2. Insert stopper pin (15) into arm stopper (14) and
pin (11). Install nuts (13) (2 used).
: 30 mm
: 400 Nm (41 kgfm, 300 lbfft)
13
W1HH-04-02-009
12
W4-2-3
W102-04-02-005
16
17
18
6
W158-04-02-006
19
19
6. Insert stopper pin (4) into stopper (17) and pin (7).
Install nuts (6) (2 used).
: 32 mm
: 550 Nm (56.0 kgfm, 405 lbfft)
7. After completing the work, operate the bucket
cylinder several times to the stroke end and release the pressure in the circuit.
IMPORTANT: In case link (18) has been removed
from the arm, insert thrust plate (19)
when installing.
W4-2-4
18
18
W157-04-01-015
5 9
W1HH-04-02-001
10
11
W4-2-5
10
W1HH-04-02-002
W4-2-6
13
14
15
16
W1HH-04-02-004
13
14
15
W1HH-04-02-004
16
1
10
W4-2-7
11
10
W1HH-04-02-002
4
17
W4-2-8
5 9
W1HH-04-02-001
6
5
2
W158-04-02-013
W4-2-9
W178-04-02-011
W178-04-02-011
2
13
11 10 9
12
W4-2-10
W1HH-04-02-003
W178-04-02-013
W178-04-02-013
2
2
13
W4-2-11
11 10 9
12
W1HH-04-02-003
6
5
2
W158-04-02-013
W105-04-02-032
W4-2-12
W178-04-02-010
W4-2-13
10
11
12
13
14
15
13
12
17
18
16
W1HH-04-02-007
Bucket Cylinder
Up to serial No.33099
1
9 10
11
12 13
14
15
13
12
16
17
18
W1HH-04-02-006
12345-
Piston Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Socket Bolt (8 Used)
Cylinder Head
O-Ring
11 12 13 14 -
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
W4-2-14
15 16 17 18 -
Seal Ring
Set Screw
Nut
Cylinder Tube
1
2
8
9
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
12345-
Piston Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Socket Bolt (8 Used)
Cylinder Head
O-Ring
11 12 13 14 15 -
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
Seal Ring
W4-2-15
16 17 18 19 20 -
Set Screw
Nut
Cylinder Tube
Cushion Ring
Plug
1
2
8
9
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-16
W158-04-02-022
W102-04-02-027
W4-2-17
1
2
9
10
11
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-18
W158-04-02-022
W4-2-19
12
10
18
13
11
15
13
16
12
14
17
19
20
W1HH-04-02-008
12345-
Piston Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Socket Bolt (8 Used)
Cylinder Head
O-Ring
11 12 13 14 15 -
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
Seal Ring
W4-2-20
16 17 18 19 20 -
Set Screw
Nut
Cylinder Tube
Cushion Ring
Plug
W4-2-21
18
16
17
19
20
W1HH-04-02-008
W4-2-22
ST 5908
W158-04-02-022
W4-2-23
Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
Unit: mm (in)
Cylinder
Name
V Block
Boom
105
Arm
115
Bucket
95
-0.036
-0.090
-0.036
-0.090
-0.036
-0.090
(4.13
-0.001
-0.004
(4.53
-0.001
-0.004
(3.74
-0.001
-0.004
Unit: mm (in)
Bend
Allowable
limit
Allowable
limit
Run Out
Remedy
Repair
Replace
Arm
120
Bucket
100
+0.180
+0.115
+0.180
+0.115
+0.165
+0.100
(4.33
(4.72
(4.72
+0.007
+0.005
+0.007
+0.005
+0.006
+0.004
Allowable
Limit
Remedy
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
W4-2-24
W4-2-25
12
10
13
12
11
1
15
14
Boom Cylinder
24
20
19
22
16
17
18
17
19
20
21
23
Bucket Cylinder
*24
W1HH-04-02-014
123456-
Piston Rod
Snap Ring
Dust Seal
Slide Ring
Cylinder Head
Buffer Ring
78910 11 12 -
Bushing
Snap Ring
Backup Ring
O-Ring
Collar
Backup Ring (2 Used)
13 14 15 16 17 18 -
W4-2-26
O-Ring
Bolt (12 Used)
Washer (12 Used)
Cushion Ring
Backup Ring (2 Used)
O-Ring
19 20 21 22 23 24 -
Ring (2 Used)
Wear Ring (2 Used)
Piston Ring
Piston
Set Screw
Cylinder Tube
14
10
11
12
15
16
15
13
9
8
7
6
3
2
1
17
18
27
22
23
25
19
20
21
20
22
23
24
26
W1HH-04-02-012
1234567-
Piston Rod
Cap
Ball (12 Used)
Plunger
Snap Ring
Dust Seal
Slide Ring
8910 11 12 13 14 -
Cylinder Head
Buffer Ring
Bushing
Snap Ring
Backup Ring
O-Ring
Collar
15 16 17 18 19 20 21 -
Backup Ring
O-Ring
Bolt (12 Used)
Washer (12 Used)
Cushion Ring
Backup Ring (2 Used)
O-Ring
W4-2-27
22 23 24 25 26 27 -
Ring (2 Used)
Wear Ring (2 Used)
Piston Ring
Piston
Set Screw
Cylinder Tube
16
14
10
11
12
15
15
13
9
8
7
6
3
2
1
17
18
27
22
23
25
19
20
21
20
22
23
24
26
W1HH-04-02-012
NOTE: Cap (2), balls (3) (12 used) and plunger (4)
are equipped for the arm cylinder only.
W4-2-28
W102-04-02-027
W4-2-29
10
11
12
13
9
8
7
2
1
25
19
20
21
20
22
23
24
W1HH-04-02-012
W4-2-30
10. Wind the tape onto the thread part of piston rod
(1) in order to protect the seal of cylinder head (8).
Remove cylinder head (8) from piston rod (1).
11. Remove the collar (14) assembly from piston rod
(1).
12. Remove O-ring (13) and backup rings (12) (2
used) from the collar (14) assembly.
13. Remove the cylinder head (8) assembly from
piston rod (1).
14. Remove O-ring (13), backup ring (12), snap ring
(5), dust seal (6), slide ring (7) and buffer ring (9)
from cylinder head (8). Remove snap ring (11)
and bushing (10) from cylinder head (8).
Special tools when removing bushing:
Boom 110 mm (ST 1399)
Arm
110 mm (ST 1399)
Bucket 100 mm (ST 1288)
W4-2-31
17, 18
12, 13
10
11 15, 16
22
14
19
23
20, 21
24
23
22
W1HH-04-02-027
1234567-
Piston Rod
Cap
Ball (12 Used)
Plunger
Snap Ring
Dust Seal
Slide Ring
27
8910 11 12 13 14 -
Cylinder Head
Buffer Ring
Bushing
Snap Ring
Backup Ring
O-Ring
Collar
15 16 17 18 19 20 21 -
25 26
Backup Ring
O-Ring
Bolt (12 Used)
Washer (12 Used)
Cushion Ring
Backup Ring (2 Used)
O-Ring
NOTE: Cap (2), balls (3) (12 used) and plunger (4)
are equipped for the arm cylinder only.
W4-2-32
22 23 24 25 26 27 -
Ring (2 Used)
Wear Ring (2 Used)
Piston Ring
Piston
Set Screw
Cylinder Tube
W4-2-33
22
17, 18
19
23
20, 21
24
23
22
W1HH-04-02-027
27
W4-2-34
25
W4-2-35
Cylinder Rod
W166-04-02-022
W105-04-02-094
Unit: mm (in)
Cylinder
Name
1m
V Block
Boom
105
Arm
115
Bucket
95
-0.036
-0.090
-0.036
-0.090
-0.036
-0.090
(4.134
-0.001
-0.004
(4.528
-0.001
-0.004
(3.74
-0.001
-0.004
Unit: mm (in)
Bend
Allowable
limit
Allowable
limit
Run Out
Remedy
Repair
Replace
Boom
110
Arm
110
Bucket
100
+0.250
+0.050
+0.250
+0.050
+0.250
+0.050
(4.331
+0.01
+0.002
) (4.331
+0.01
+0.01
(3.937
+0.002
+0.02
Allowable
Limit
Remedy
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
W4-2-36
MEMO
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SECTION 5
Alternator ...................................................6A-13
Camshaft....................................................6A-32
Timing Gears..............................................6A-66
Piston .........................................................6A-82
Crankshaft..................................................6A-94
Engine Cooling
Service Information
Identification ................................................ 0B-1
Lubrication System ...................................... 0B-2
Fuel System................................................. 0B-2
Cooling System............................................ 0B-6
Valve Clearance Adjustment ........................ 0B-6
Compression Pressure Measure.................. 0B-8
Recommended Lubricants ........................... 0B-9
Engine Oil Viscosity Chart ........................... 0B-9
Engine Fuel
Service Precaution .......................................6C-1
General Description .....................................6C-2
Fuel Filter .....................................................6C-5
Injection Nozzle............................................6C-7
Engine Mechanical
Service Precautions ..................................... 6A-2
General Description ..................................... 6A-2
Turbocharger ............................................... 6A-4
Exhaust Manifold ......................................... 6A-5
Intake Cover ................................................ 6A-7
Water Pump ................................................. 6A-9
1HHW-5-1
Engine Lubrication
Service Precaution.......................................6G-1
General Description .....................................6G-2
Oil Pump ......................................................6G-4
Oil Coolor.....................................................6G-8
Oil Port Cover ............................................ 6G-11
Engine Induction
Service Precaution........................................6J-1
Turbocharger ................................................6J-2
Troubleshooting ............................................6J-4
Inspection and Repair ...................................6J-6
1HHW-5-2
MEMO
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MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
PAGE NO.:
(Located at the bottom center in the page. If two or more revisions are requested, use the comment column)
REPLY: