ZX330-Series (ZX330W) Workshop Manual

INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
Be sure to thoroughly read this manual for correct
product information and service procedures.
If you have any questions or comments, at if you

found any errors regarding the contents of this
manual, please contact using Service Manual
Revision Request Form at the end of this manual.
(Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
Operation Manual of the Engine

Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual

The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni-
Information included in the Technical Manual

(Troubleshooting):
technical information needed for operational performance tests, and troubleshooting procedures.
Information included in the Technical Manual

(Operational Principle):
technical information needed for redeliver and
delivery, operation and activation of all devices
and systems.
Information included in the Workshop Manual:

technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assemble/disassemble procedures.
cal Manual (Operational Principle), the Technical

Manual (Troubleshooting) and the Workshop Manual.
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
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:
Indicates a situation which, if not conformed to the

instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
2
SI Units (International System of Units) are used in
Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
3
m
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
3
yd
lb
kgf
lbf
kgfm
lbfft
A table for conversion from SI units to other system

units is shown below for reference purposees.
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
-1
min
L/min
mL/rev
Into
Multiply By
2
kgf/cm
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
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
UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating
the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listed on CAUTION safety signs.
Some safety signs dont use any of the
designated signal words above after the safety
alert symbol are occasionally used on this
machine.
CAUTION also calls attention to safety messages in

this manual.
To avoid confusing machine protection with personal

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

element of information.
002-E01C-1223
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the machine and all safety messages in this manual.
Safety signs should be installed, maintained and replaced when necessary.

If a safety sign or this manual is damaged or missing, order a replacement from your authorized
dealer in the same way you order other replacement parts (be sure to state machine model and
serial number when ordering).
SA-003
Learn how to operate the machine and its controls

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

operate the machine.
Keep your machine in proper working condition.

Unauthorized modifications of the machine may
impair its function and/or safety and affect machine life.
The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES

Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached on the fire extinguisher to use it properly.
To ensure that a fire-extinguisher can be always
used when necessary, check and service the fireextinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
Establish emergency procedure guidelines to
cope with fires and accidents.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department
posted near your telephone.
004-E01A-0437
SA-2
SA-437
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
SA-438
Avoid wearing loose clothing, jewelry, or other

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

attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
In the walk-around inspection be sure to cover all
points
described
in
the
PRE-START
INSPECTION chapter in the operators manual.
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.
Dont leave parts and/or tools lying around the operators seat. Store them in their specified locations.
Avoid storing transparent bottles in the cab. Dont
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives
away from the machine.
After using the ashtray, always cover it to extinguish the match and/or tobacco.
Dont leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you mounting and dismounting the machine, always face the machine and maintain a
three-point contact with the steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dismounting the machine.
SA-439
008-E01B-0439
ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing
the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
If not, move the seat forward or backward, and
check again.
009-E01A-0378
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.
Prior to operating the machine, thoroughly
examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component before operating the machine.
Be sure to remain seated with the seat belt
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
SA-237
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.
Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine.
011-E01A-0426
SA-6
SA-426
SAFETY
OPERATE
SEAT
ONLY
FROM
OPERATOR'S
Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.
Start the engine only when seated in the
operator's seat.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control
levers are in neutral.
SA-444
012-E01B-0444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
follow the instructions shown in the OPERATING
THE ENGINE chapter in the 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
being struck by foreign objects and being thrown off
the machine.
Only the operator should be on the machine.
Keep riders off.
Riders also obstruct the operators view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0379
SA-379
PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES

For jobs involving multiple numbers of machines,
provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal persons directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
Incorrect travel pedal/lever operation may result in
serious injury death.
Before driving the machine, confirm the position of
the undercarriage in relation to the operators position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0491
SA-8
SA-491
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the direction you wish to drive.
Be sure to detour around any obstructions.
Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Dont allow personnel to stay around
the machine while traveling.
SA-387
Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
Driving across the face of a slope or steering on a

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

mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle / acceleration seleclter and the
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.
To avoid back-over and swing accidents:
Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
Read and understand all operating instructions in
the operators manual.
S021-E01A-0494
SA-11
SA-383
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:
Be extra careful before operating on a grade.

Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
Reduce swing speed as necessary when swinging
loads.
Be careful when working on frozen ground.

Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-12
SA-440
SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
Check and comply with any local regulations that
may apply.
Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381
029-E01A-0381
OBJECT HANDLING
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
When using the machine for craning operations,
be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the travel motors at the rear.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks
or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SA-014
SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle / acceleration selector and H/P
mode switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.
033-E09B-0390
SA-14
SA-390
SAFETY
HANDLE FLUIDS SAFELY
AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when
near open flame or sparks.
Always stop the engine before refueling the
machine.
Fill the fuel tank outdoors.
All fuels, most lubricants, and some coolants are
SA-018
flammable.
Store flammable fluids well away from fire
hazards.
Do not incinerate or puncture pressurized
containers.
Do not store oily rags; they can ignite and burn
spontaneously.
Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-15
SA-019
SAFETY
SAFETY TRANSPORTING
The
danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
Be sure to observe local regulations when
transporting the machine on public roads.
Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine:
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SA-395
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before doing
work.
Keep work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from powerdriven parts.
Before servicing the machine:
1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a Do Not Operate tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Never work under a machine raised by the boom.
Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the MAINTENANCE
chapter in the operators manual.
Keep all parts in good condition and properly
installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SA-028
SA-527
SAFETY
Use a portable safety light for working inside or
under the machine.
Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may catch
fire.
SA-037
S500-E02B-0497
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious
injury.
Before performing any work on the machine,
attach a Do Not Operate tag on the control lever.
S501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without
securing the machine first.
Always lower the attachment to the ground before
you work on the machine.
If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a
machine that is supported solely by a jack.
SA-527
519-E01A-0527
STAY CLEAR OF MOVING PARTS

Entanglement in moving parts can cause serious
injury.
To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
Do not attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
As pieces may fly off, be sure to keep body and
face away from valve.
Travel reduction gears are under pressure.

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

Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY

Use tools appropriate for the work to be done.
Makeshift tools, parts, and procedures can create

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

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap.
The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
SA-039
Hot fluids and surfaces:
Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
Wait for the oil and components to cool before

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

PERIODICALLY
Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
Periodically replace the rubber hoses. (See the
page of Periodic replacement of parts in the
operators manual.)
Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
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.
Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take
care to protect hands and body from highpressure fluids. Wear a face shield or goggles for
eye protection.
If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-031
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to

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

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

accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key Switch:
If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-22
SA-019
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air

inside the hydraulic tank will escalate fire, hampering
fire fighting.
Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2)
Turn the emergency engine stop switch to the

EMERG. STOP position.
3)
Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).
If any abnormalities are found, be sure to repair

them before operating the machine.
Check Heat Shields:
Damaged or missing heat shields may lead to fires.
Damaged or missing heat shields must be

repaired or replaced before operating the
machine.
S508-E02B-0019
EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the
following way:
Stop the engine by turning the key switch to the
OFF position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.
In an emergency, if the cab door and/or the front
SA-393
window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on EMERGENCY
EXIT in Operators Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
PRECAUTIONS
GRINDING
FOR
WELDING
SA-016
AND
Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe
place before starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before starting grinding.
After finishing welding and grinding, recheck that
there are no abnormalities such as the area surrounding the welded area still smoldering.
SA-818
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
Do not weld or flame cut pipes or tubes that
contain flammable fluids.
Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
SA-24
SA-030
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
1) If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
SA-029
511-E01A-0029
PREVENT BATTERY EXPLOSIONS

Battery gas can explode.
Keep sparks, lighted matches, and flame away
from the top of battery.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode.
Warm the battery to 16 C ( 60 F ) first.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion
of the battery may result.
Loose terminals may produce sparks. Securely
tighten all terminals.
Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
Be sure to wear eye protection when checking
electrolyte specific gravity.
512-E01C-0032
SA-25
SA-032
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the freon container for proper use when
servicing the air conditioning system.
Use a recovery and recycling system to avoid
venting freon into the atmosphere.
Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SA-309
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain,
or into any water source.
Air conditioning refrigerants escaping into the air
can
damage
the
Earths
atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
SA-226
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
After maintenance or repair work is complete,
confirm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced
S517-E01A-0435
SA-27
SA-435
SAFETY
(Blank)
SA-28
SECTION AND GROUP

CONTENTS
SECTION 1 GENERAL INFORMATION

Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
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
SECTION 4 FRONT ATTACHMENT

Group 1 Front Attachment
Group 2 Cylinder
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)2001
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 5 ENGINE
TECHNICAL MANUAL (Operational Principle)

SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System
SECTION 3 COMPONENT OPERATION

Group 1 Pump Device
Group 4 Pilot Valve
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Engine Test
Group 3 Excavator Test
Group 4 Component Test
Group 5 Standard
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 2 Tightening Torque

Tightening Torque Specification......... W1-2-1
Torque Chart ..................................... W1-2-3
Piping Joint ....................................... W1-2-6
Periodic Replacement of Parts ........ W1-2-10
Group 3 Painting
Painting ............................................. W1-3-1
1HHW-1-1
(Blank)
1HHW-1-2
GENERAL / Precautions for Disassembling and Assembling

PRECAUTIONS FOR
AND ASSEMBLING
DISASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine
Precautions for Disassembling
Thoroughly wash the machine before bringing it into

the shop. Bringing a dirty machine into the shop may
cause machine components to be contaminated
during disassembling/assembling, resulting in
damage to machine components, as well as
decreased efficiency in service work.
Inspect the Machine

Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as well
as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
The machine model, machine serial number, and
hour meter reading.
Reason for disassembly (symptoms, failed parts,
and causes).
Clogging of filters and oil, water or air leaks, if any.
Capacities and condition of lubricants.
Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the area
for disassembling work.
W1-1-1
To prevent dirt from entering, cap or plug the

removed pipes.
Before disassembling, clean the exterior of the
components and place on a work bench.
Before disassembling, drain gear oil from the
reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Use matching marks for easier reassembling.
Be sure to use the specified special tools, when
instructed.
If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
Orderly arrange disassembled parts. Mark and
tag them as necessary.
Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
Measure and record the degree of wear and
clearances.

Precautions for Assembling
Bleeding Air from Hydraulic System
Be sure to clean all parts and inspect them for any

damage. If any damage is found, repair or replace
part.
Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
Be sure that liquid-gasket-applied surfaces are
clean and dry.
If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to
remove the agent.
Utilize matching marks when assembling.
Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the
following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump housing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic motor housing, damage to the motor
may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage
to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from Hydraulic Pump

Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the engine and run at slow idle speed.
Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
After bleeding all the air, securely tighten the plug.
Bleeding Air from Travel Motor / Swing Motor

With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
W1-1-2

Bleeding Air from Hydraulic Circuit
After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
Reposition the front attachment to check hydraulic
oil level.
Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.
W1-1-3
M104-07-021

Floating Seal Precautions
A
1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with
seal ring faces together. Insert a piece of
cardboard to protect surfaces. Apply oil to the
sliding surface (C) on seal ring (A).
(2) Check the slide surface (C) on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
W105-03-05-019
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
Correct
Incorrect
(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
Correct
(4) After installing the floating seal, check that seal

ring surface (C) is parallel with seal mating
face (D) by measuring the distances (C) and
(D) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
W105-03-05-020
Incorrect
a=b
ab
W110-03-05-004
W1-1-4

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

CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may result. Be sure to visually check the nylon sling
for any damage before using.
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.
Broken Sewing Thread
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

MAINTENANCE STANDARD TERMINOLOGY
Standard
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification.
Allowable Limit
1. Normal machine performance cannot be 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

(Blank)
W1-1-8
GENERAL / Tightening Torque

TIGHTENING TORQUE SPECIFICATION
No.
1
2
3
4
5
6
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
ORS fittings for hydraulic hoses and piping
Pump mounting bolt

Control valve mounting bolt
Control valve bracket mounting bolt
Swing device mounting bolt
Swing motor mounting bolt
Battery mounting nut
Cab mounting nut
Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
ZAXIS330, 330LC, 350H,
Travel device
350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC, 350H,
Sprocket mount- 350LCH
ing bolt
ZAXIS370MTH
ZAXIS330, 330LC, 350H,
Upper roller 350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC
Lower
roller
ZAXIS350H, 350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC
Track shoe bolt ZAXIS350H, 350LCH
ZAXIS370MTH
ZAXIS330, 330LC
Track
guard
ZAXIS350H, 350LCH
mounting bolt
ZAXIS370MTH
Coupling, Jubilee and T-bolt clamp of low pressure
piping
23
Front pin-retaining bolt and nut
24
Counterweight
mounting bolt
ZAXIS330, 330LC
ZAXIS350H, 350LCH, 370MTH
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
1
12UNF
36
16
7
1
12UNF
41
16
11
1
12UNF
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
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)
W1-2-1
10.3 to 12.4 (1.05 to 1.26) (7.59 to 9.11)
5.9
400
550
750
2260
2840
(0.6)
(41)
(56)
(76.5)
230
290
(4.3)
(300)
(405)
(550)
(1665)
(2100)

NOTE 1.Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
3.Apply LOCTITE to threads before installing and tightening swing bearing mounting
bolts and lower roller mounting bolts.
W1-2-2

TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct
size tools. Otherwise, tightening tools may
slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or components.
Hexagon T Bolt
SA-040
Hexagon H Bolt
Hexagon M Bolt
Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Hexagon
T Bolt
Bolt Wrench
Wrench
Dia.
Size
Nm
(kgfm)
Size
M 8
13
6
29.5
(3)
M 10
17
8
64
(6.5)
M 12
19
10
108
(11)
M 14
22
12
175
(18)
M 16
24
14
265
(27)
M 18
27
14
390
(40)
M 20
30
17
540
(55)
M 22
32
17
740
(75)
M 24
36
19
930
(95)
M 27
41
19
1370
(140)
M 30
46
22
1910
(195)
M 33
50
24
2550
(260)
M 36
55
27
3140
(320)
H Bolt, Socket bolt

(lbfft)
(22)
(47)
(80)
(130)
(195)
(290)
(400)
(540)
(690)
(1010)
(1410)
(1880)
(2310)
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)

IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no lubricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific application.
5. Make sure that nut and bolt
threads are clean before installing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alter-
Tighten diagonally
1
1st to 4th
Tighten from center and diago12
14
13
10
11
6
4
5
2
2nd to 3rd
W105-01-01-003
W1-2-4

Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear.
Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.
2. Be sure to use only specified Orings. Inspect O-rings for any
damage. Take care not to file Oring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tightening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
WRONG
RIGHT
Do not bend it round
Bend along edge sharply
Nut and Bolt Locking

RIGHT
Lock Plate
WRONG
RIGHT
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.
Bend along edge sharply
RIGHT
RIGHT
WRONG
W105-01-01-009
Lock Wire
IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction.
RIGHT
Loosen
WRONG
Tighten
W105-01-01-010
W1-2-5

PIPING JOINT
IMPORTANT: The torques given in the chart are for

general use only.
Do not use these torques if a different torque is given for a specific application.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
37
30
IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to

metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten nut (3) to specifications.
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Description
30male
37female
Male Union Joint
Female Union Joint

W105-01-01-017
Wrench Size
mm
Union Nut
17
19
22
27
32
36
41
17
19
22
27
32
36
41
Wrench Size mm
Tightening Torque
Hose Fittings
17
19
22
27
32
36
41
14
17
19
22
27
32
36
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)
NOTE: Tightening torque of 37male coupling without union is similar

to tightening torque of 37female.
W1-2-6

O-ring Seal Joint
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 Oring (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 Oring (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
10
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)

Screw-In Connection
Depending on types of screw and sealing, different types of
screw fittings are used.
IMPORTANT: Be sure to confirm that the thread pitch
and thread type (tapered or straight) are
the correct type before using any screwin connection.
PT
30
Male Tapered Thread
PF
Male Straight Thread

W105-01-01-018
Wrench Size
mm
Hose Fittings
19
22
27
36
41
50
60
Male Tapered Thread

Tightening Torque
Nm (kgfm, lbfft)
FC material
SS material
14.5 (1.5,10.5)
34 (3.5,25)
29.5 (3.0,21.5)
49 (5.0,36)
49 (5.0,36)
93 (9.5,69)
69 (7.0,51)
157 (16,116)
108 (11,80)
205 (21,151)
157 (16,116)
320 (33,235)
195 (20,144)
Seal Tape Application

Seal tape is used to seal clearances between male and
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
Internal Thread
External Thread
Clearance
Application Procedure
W105-01-01-019
Confirm that the thread surface is clean and, free of dirt or

damage.
Apply seal tape around threads as shown. Wrap seal tape
in the same direction as the threads.
Leave one to two pitch threads uncovered
Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs depending on the type of clamp.
T-Bolt Type Band Clamp:
4.4 Nm ( 0.45 kgfm, 3.25 lbfft )
Worm Gear Type Band Clamp:
5.9 to 6.9 Nm (0.6 to 0.7 kgm, 4.3 to 5.1 lbfft)
M114-07-041
T-Bolt Type
M114-07-043
W1-2-8
Worm Gear Type
M114-07-042

Connecting Hose
RIGHT
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
If hoses rub against each other, wear to the hoses

will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing
against each other.
W105-01-01-012
Take care so that hoses do not come into contact

with moving parts or sharp objects.
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

PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these
parts are found to be defective, replace before starting operation, regardless of the interval.
Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.
Periodic Replacement Parts
Engine
Base Machine
Hydraulic
System
Front
Attachment
Fuel hose (Fuel tank to filter)

Fuel hose (Fuel tank to injection pump)
Oil filter hose (Engine to oil filter)
Heater hose (Heater to engine)
Pump suction hose
Pump delivery hose
Swing hose
Boom cylinder line hose
Arm cylinder line hose
Bucket cylinder line hose
Pilot hose
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
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]
Final painted colour

Inside and outside surface of cab
High Grade Beige

[KASAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
[N2.0 (Black) ]
[N2.0 (Black) ]
Right window beam

Suspension lifter (chair bottom)
Lever
(Travel, lock, foot rest)
Engine cover
Ladder rail on right side of upperstructure
Mirror stay
Antislip cover
High Grade Black

High Grade Black
High Grade Black
KASAI PAINT Amilack 1400 deep black.
Cab Inside and Outside
Engine Cover
Engine Cover
Right Window
Beam
Right Ladder
Rail
Mirror Stay
900
350
Main Surface of
Upperstructure
Tool Box Cover
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)
Out Surface of Hinge Swing

Portion YR-01 (TAXI Yellow)
185
Door Catch Cover YR-01

(TAXI Yellow)
720
Section A
W178-01-03-003
Section B
Mask Garnished Portion
YR-01(TAXI Yellow)
Door
Panel Behind the

Door
10
Painting Area of the Door
YR-01 (TAXI Yellow)
W178-01-03-004
W178-01-03-005
Antislip Cover
KASAI PAINT
Amilack 1400
Deep Black
Front Attachment YR01 (TAXI Yellow)
W178-01-03-007
Upper Side of
Frame
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, care not to
pour washing liquid directly on them.
The ambient temperature shall be
controlled under 70C when painting
and drying.
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
Remove and Install Cab ........................... W2-1-1
Remove and Install Control Valve ............. W2-5-1
Dimensions of the Cab Glass ................... W2-1-8
Disassemble Control Valve (1).................. W2-5-4

Assemble Control Valve (1) ...................... W2-5-6
Group 2 Counterweight
Disassemble Control Valve (2).................. W2-5-8

Assemble Control Valve (2) .................... W2-5-10
Remove and Install

Counterweight ........................................ W2-2-1
Disassemble Control Valve (3)................ W2-5-12

Group 3 Main Frame
Remove and Install

Main Frame ............................................ W2-3-1

Group 4 Pump Device

Remove and Install Pump Device ............. W2-4-1
Disassemble Pump Device ....................... W2-4-4
Structure of Valves ................................. W2-5-30
Assemble Pump Device ......................... W2-4-10

Disassemble Main Pump ....................... W2-4-18
Assemble Main Pump ............................ W2-4-26
Remove and Install Swing Device............. W2-6-1
Disassemble Regulator .......................... W2-4-40
Disassemble Swing Device....................... W2-6-4
Assemble Regulator ............................... W2-4-42
Assemble Swing Device ......................... W2-6-10
Disassemble and Assemble
Disassemble Swing Motor ...................... W2-6-16
Pilot Pump ............................................ W2-4-44

Maintenance Standard ........................... W2-4-48
Assemble Swing Motor ........................... W2-6-18

Parking Brake Release Valve................ W2-6-20
Maintenance Standard............................ W2-6-21
1HHW-2-1
Group 7 Pilot Valve

Remove and Install Right
Pilot Valve .............................................. W2-7-1
Remove and Install Left
Pilot Valve .............................................. W2-7-5
Remove and Install
Travel Pilot Valve .................................... W2-7-8
Disassemble Right and Left
Pilot Valves........................................... W2-7-10
Assemble Right and Left
Pilot Valves........................................... W2-7-14
Disassemble Travel Pilot Valve............... W2-7-18
Assemble Travel Pilot Valve ................... W2-7-22
Group 8 Pilot Shut-Off Valve

Remove and Install
Pilot Shut-off Valve ................................. W2-8-1
Disassemble Pilot Shut-off Valve .............. W2-8-4
Assemble Pilot Shut-off Valve................... W2-8-6
Group 9 Shockless Valve

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

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

box (3).
: 17 mm
ZAXIS370MTH:
3. Raise duct (5) to remove it.

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

screwdriver, then remove duct (8) from the cab.
3
4
5
W178-02-01-012
7
8
W178-02-01-013
W2-1-1
5. Disconnect harness connectors (10, 11, 12, and
13) on the right side in the cab and ground (9) at
rear inside of the cab.
10
11
12
13
W178-02-01-014
6. Remove washer vinyl hose (14) at rear inside of

the cab.
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a

screwdriver. Use a screwdriver to loosen screws
(16) to remove duct cover (17).
17
15
W178-02-01-016
8. Remove screws (18) and bolts (21) to remove

duct (19) and duct (20).
: 17 mm
18
Mating Surface of Duct
19
20
W2-1-2
21
W178-02-01-017
ZAXIS330, 330LC, 350H, 350LCH
CAUTION: Cab weight:

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
22
9. Attach the cab upside with lifting straps (22).
W178-02-01-018
ZAXIS370MTH:
A
A
10. Remove cab mounting bolts (23) and nut (24)

from the cab.
: 17 mm
: 24 mm
: 8 mm
W1HH-02-01-003
Section A-A
Lifting Strap
W1HH-02-01-002
23
24
W157-02-01-010
W2-1-3
11. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-4
Installation
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
1. Attach the cab with lifting straps to hoist it by
crane.
W157-02-01-001
23
2. Install bolts (23) and nuts (24) to the cab.

: 17 mm
: 50 Nm (5.1 kgfm, 37 Ibfft)
: 24 mm
: 205 Nm (21 kgfm, 150 Ibfft)
: 8 mm
: 50 Nm (5.1 kgfm, 37 Ibfft)
24
W157-02-01-010
3. Install duct (8) to the rear console of the cab with

screws (7). Install filter (6) into duct (8).
: 4.9 Nm (0.5 kgfm, 3.6 Ibfft)
8
W178-02-01-013
4. Install harness connectors (10, 11, 12 and 13) at

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

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

: 17 mm
: 50 Nm (5.1 kgfm, 37 Ibfft)
W178-02-01-012
8. Install duct (20) with bolts (21). Install duct (19)

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

: 17 mm
: 50 Nm (5.1 kgfm, 37 Ibfft)
ZAXIS370MCH:
W178-02-07-006
W1HH-02-01-004
W2-1-7
DIMENSIONS OF THE CAB GLASS
A
Unit: mm
R2
67
Chamfer Here
303.5
Chamfer along the

Periphery unless
Otherwise Specified
11
R35
R98
4-13 0 -1
Section A
R3018
W178-02-01-019
30
405
Chamfer Both
Sides
375
238
612
51
R118
(5 mm)
148.5
343.5
196
100
50
R70
370.5
W178-02-01-006
Along the
Periphery
c1
Along the
Periphery
W178-02-01-002
c1
14
733
R58
R58
R11508
Section B
W178-02-01-019
R1808
882.5
997
(4 mm)
R308
R1898
R258
100
150
943
W178-02-01-007
W2-1-8
Unit: mm
Chamfer
Slightly
unless the
Periphery
Polish
Chamfered
Chamfer Here
Chamfer Here
85.4
343.3
213
R105
R10
R72
R105
(4 mm)
Chamfer Slightly unless the Periphery Polish Chamfered
39.5
733
733
R2465
2-12.2 +0.5 -0
Section C
and D
(4 mm)
6.754
40
W178-02-01-019
Polish Chamfer the

Both Fringes
289.5
50
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)
Chamfer along the

Periphery
R115
888.58
W178-02-01-010
W2-1-9
R14
470.6
W178-02-01-009
Cab Glass Installation Procedure
Procedure of installing left-hand cab glass, lower
glass of the door and upper front glass.
Left-Hand Cab Glass
1. Install the seal rubber on the left-hand cab glass

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

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

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

pull and fasten the mounting rubber onto the
mounting face of cab.
10
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cant be replaced individually. Be
sure to change the cab glass as an
assembly.
The upper front glass is archedfringed. If this glass needs to be replaced, replace it as an assembly.
10
Mounting Rubber Section
Mounting
Rubber
W178-02-01-020
Cab Glass
Cab
Seal Rubber
W178-02-01-022
W178-02-01-004
W2-1-10
Procedures of installing right-hand cab glass
1. Install the mounting rubber into the surrounding of

cab glass. Bond the connectors of mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent).
Cab Glass
Mounting
Rubber
Cab
NOTE: Rubber aging will cause the contraction of

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

1. Insert mounting rubber around the cab glass. Install the connectors or mounting rubber with the
bonding agent (Cemedine 366 Standard or
equivalent).
Mounting
Rubber
Stopper
NOTE: Rubber aging will cause the contraction of

rubber, be sure to leave a little extra, install
by pressing with hands.
2. After installing the glass assembly on the cab, insert the stopper into rubber.
Cab Glass
Cab
W216-02-01-003
IMPORTANT: The rear side glass is arched-fringed.

If this glass needs to be replaced,
replace it as an assembly.
W178-02-01-005
W2-1-11
(Blank)
W2-1-12
UPPERSTRUCTURE / Counterweight
REMOVE
WEIGHT
AND
INSTALL
COUNTER1
Removal
CAUTION: Counterweight weight:
ZAXIS330, 330LC: 6800 kg (15000 lb)
ZAXIS350H, 350LCH 370MTH:
7550 kg (16650 lb)
1. Remove caps (1) from upper counterweight. Install sling bolts (FLENO RING BOLT B-42: M42,
Pitch 4.5) to the counterweight.
W178-02-02-001
Wire Rope
Sling Bolt
2. Attach wire ropes to sling bolts with shackles.

Take out slack of wire ropes by applying tension
slowly by crane.
W178-02-02-002
3. Remove bolts (2) from the counterweight. Hoist

and remove the counterweight by crane.
ZAXIS330, 330LC:
: 50 mm
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
2
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
1. Hoist counterweight (3) and install it onto the
frame by crane.
Install washers (4) and tighten bolts (2) to counterweight temporarily.
3
2
ZAXIS330, 330LC:
: 50 mm
: 55 mm
4
W178-02-02-003
2. Remove wire ropes. Tighten the bolts with a

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

counterweight.
W2-2-2
UPPERSTRUCTURE / Main Frame

REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe
burns. Be sure to wait for oil to cool before
starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum

pump to maintain negative pressure in the hydraulic oil tank.
NOTE: Be sure to run the vacuum pump continuously while working.
W2-3-1
M104-07-021

Removal
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS 370MTH: 395kg (870 lb)
1. Remove the cab (Refer to Remove Cab in this
section.).
: 24 mm, 17 mm, 13 mm
: 8 mm
W157-02-01-001

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

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

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

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

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

6560 kg (14460 lb)
5. Attach wire ropes to the rear (counterweight
bracket) of frame and boom bracket. Pull wire
ropes taut then.
If chain block (1) is used, it is not only easy to adjust the length of wire rope, but also easy to level
the frame.
W173-03-03-001
IMPORTANT: Make sure that rear slings do not

touch engine.
Rear
W105-02-03-004
Front
W105-02-03-005
W157-02-03-001
W2-3-3

6. Put matching marks on the outer race of the upperstructure and the swing bearing.
Loosen and remove bolt (2) of the swing bearing.
: 41 mm
NOTE: The mounting angle of swing bearing is
specified. (Refer to W3-1).
7. Chain block (1) shall be used to adjust and level

the frame, then hoist it slightly to remove it from
the undercarriage by crane.
W105-02-03-007
W157-02-03-002
W2-3-4

Installation
CAUTION: Upperstructure weight:
6560 kg (14460 lb)
1. Fasten wire ropes to main frame. Level the main

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

upperstructure and the swing bearing.
Install bolts (2) to the swing bearing and tighten it
temporarily. Remove wire ropes and tighten the
bolts to the swing bearing to specification.
: 41 mm
: 1226 Nm (125 kgfm, 900 lbfft)
2
3. Install all hoses to the center joint.

: 17 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
: 27 mm
: 118 Nm (12 kgfm, 87 lbfft)
: 41 mm
: 295 Nm (30 kgfm, 220 lbfft)
W105-02-03-007
3
4
4. Install stopper (4) and bolt (3) to the center joint.

: 22 mm
: 54 Nm (5.6 kgfm, 41 lbfft)
W173-03-03-001
W2-3-5

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

(Refer to Removal and Installation of Cab in this
section.)
: 24 mm
: 205 Nm (21 kgfm, 152 lbfft)
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
: 8 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
W157-02-01-001

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
6. Install counterweight (6).
(Refer to Counterweight in this section.)
6
ZAXIS330, 330LC:
: 50 mm
: 2260 Nm (230 kgfm, 1660 lbfft)
: 55 mm
: 2840 Nm (290 kgfm, 2100 lbfft)
W178-02-02-002

ZAXIS330, 330LC:
6440 kg (14200 lb)
ZAXIS350H, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH:
7120 kg (15700 lb)
7. Install front attachment assembly (7). And fill hydraulic oil.
(Refer to Removal and Installation of Front Attach-ment in this section.)
: 19 mm
: 44 Nm (4.5 kgfm, 33 lbfft)
: 27 mm
: 295 Nm (30 kgfm, 220 lbfft)
: 30 mm
: 390 Nm (40 kgfm, 290 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
8. Start the engine and set the front attachment in
posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if there is
any oil leakage.
W2-3-6
7
W105-02-03-002
M104-07-021
UPPERSTRUCTURE / Pump Device

REMOVE AND INSTALL PUMP DEVICE
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation.
Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting any repair work.
pressure.
Preparation
1. Park the machine on a firm, level surface.
pressure.
NOTE: Be sure to run the vacuum pump continuously while working on the hydraulic system.
W2-4-1
M104-07-021

Removal
1. Disconnect harness connectors from the pump
device.
CAUTION: Pump device weight:
200 kg (440 lb)
Air Bleed Plug
2. Disconnect all hoses and pipes from the pump

device.
17 mm, 27 mm, 36 mm
10 mm
3. Attach eyebolts (M12, Pitch 1.75) to the pump
device, then fasten a hoist.
4. Remove the pump device mounting bolts to
remove the pump device.
17 mm
Installation
1. Install eyebolts on the pump device. Hoist it by
crane.
2. Install the pump device with the pump device
mounting bolts.
3. Connect all hoses and pipes.
4. Connect harness connectors to the pump device.
5. Remove the air bleed plugs (2 used) on top of the
regulators, then fill hydraulic oil into the pump
casings. (Refer to W1-1-2)
IMPORTANT: Be sure to check hydraulic oil level
and oil leakage, after assembling.
Bleed the air from the pump.
W2-4-2
W110-02-04-002
Tightening Torque
Wrench
Size (mm)
Nm
(kgfm)
(lbfft)
: 36
175
(18)
(130)
Hose
: 27
93
(9.5)
(69)
Hose
: 10
88
(9)
(65)
Bolt
: 17
49
(5)
(36)
Bolt
Remarks

(Blank)
W2-4-3

DISASSEMBLE PUMP DEVICE
14
13
20
12
13
22
13
22
19 9
7
8
21
15
18
17
16
10
22
11
6
5
3
4
2
19
37
36
32
23
33
39
31
10
22
34
35
42
40
41
28
45
38
24
43
26
30
25
27
44
29
W1HH-02-04-004
12345678910 11 12 -
Drive Gear (2 Used)

Retaining Ring (2 Used)
N Sensor
O-Ring
Washer
Socket Bolt
Socket Bolt
Spring Washer
Spring Washer (4 Used)
Bolt (8 Used)
Main Pump (2 Used)
Pipe
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 -
W2-4-4
Seal Cover
Retaining Ring
Oil Seal
Center Shaft
Coupling Assembly
O-Ring
Seal Washer (4 Used)
Socket Bolt (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
Packing
Drain Plug
Retaining Ring
Bearing
P Sensor (2 Used)

Disassemble Pump Device
Clean the outside of the pump device.
1. Remove socket bolts (6, 7) to remove N sensor.
: 5 mm
2. Remove P sensor (46) (2 used).
: 27 mm
3. Loosen bolts (E) (4 used) of coupling assembly
(29), then remove inserts (H) from hub (A).
: 6 mm
46
4. Remove screws (B) (2 used) from hub (A).

Remove hub (A) and insert (D) from center shaft
(28).
: 8 mm
W173-02-04-002
NOTE: Inserts (F) are installed by spring pins (C)

and bolts (G).
G
F
5. Remove drain plug (43) to drain gear oil.

: 22 mm
CAUTION: Pump device assembly weight:
200 kg (440 lb)
6. Secure pump device assembly with workbench.
Workbench : ST 5050
W2-4-5
W110-02-04-006
14
20
12
19
9
10
15
18
17
16
11
19
36
32
33
31
34
35
40
41
W1HH-02-04-004
W2-4-6

7. Remove bolt (15), nut (16), washer (17), and
clamp (18) from the pipe.
: 13 mm
8. Remove pipes (12, 14, 19, and 20).
: 19 mm, 22 mm
9. Remove adapter (36) from pilot pump (35).
: 27 mm
10. Remove socket bolts (32) (2 used), spring
washers (33), and washers (34) to remove pilot
pump (35).
: 8 mm
11. Remove bolts (10) (4 used), spring washers (9),
and seal washers (31).
: 24 mm
12. Install eyebolt (M12, Pitch 1.75) to main pump
(11) to hoist and remove main pump (11) by
crane.
CAUTION: Main pump weight: 67 kg (148 lb)
13. Remove other main pump same as steps 11. and
12.
14. Remove socket bolts (41) (2 used) to remove pipe
(40).
: 6 mm
W2-4-7
23
28
45
38
24
26
30
25
27
44
W1HH-02-04-004
W2-4-8

CAUTION: Flange assembly weight:
48 kg (106 lb)
15. Turn over flange (23) and place it on the
workbench, then remove retaining ring (26) from
flange (23).
16. Remove seal cover (25) from flange (23).
17. Remove oil seal (27) from seal cover (25), using
special tool (ST 1234).
18. Remove O-ring (30) from flange (23). Remove
retaining ring (44) from center shaft (28).
CAUTION: Flange weight: 39 kg (86 lb)
workbench, then place it onto the press. Press out
center shaft (28) and bearing (24) from flange (23)
using special tool (ST 1236).
ST 1236
20. Take out center gear (38) from flange (23).
W173-02-04-003
21. Remove bearing (45) from flange (23), using

22. Remove bearing (24) from center shaft (28), using

a press or puller.
ST 1235
W173-02-04-004
W2-4-9

ASSEMBLE PUMP DEVICE
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
W2-4-10
View A
W1HH-02-04-003
41
42
43
12345678910 11 12 -
Drive Gear (2 Used)

N Sensor
O-Ring
Washer
Socket Bolt
Socket Bolt
Spring Washer
Bolt (8 Used)
Main Pump (2 Used)
Pipe
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 -
W2-4-11
40
Seal Cover
Retaining Ring
Oil Seal
Center Shaft
Coupling Assembly
O-Ring
Seal Washer (4 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
Packing
Drain Plug
Retaining Ring
Bearing
P Sensor (2 Used)

45
38
23
24
25
26
44
27
28
46
30
W1HH-02-04-002
W2-4-12

Assemble Pump Device
CAUTION: Flange weight: 39kg (86 lb)
1. Face input shaft side upward of flange (23), then
press in bearing (45) using special tool (ST 2307).
ST 2307
2. Insert center gear (38) into flange (23) from the

pump mounting hole to set it onto bearing (45).
3. Press center shaft (28) into bearing (45), aligning
center shaft (28) and the center gear (38) spline.
4. Press bearing (24) into flange (23) and center
shaft (28), using special tool (ST 2308).
W173-02-04-005
ST 2308
CAUTION: Flange assembly weight:

48 kg (106 lb)
5. Place flange (23) on the workbench, then install
retaining ring (44) onto center shaft (28), O-ring
(30) into flange (23) respectively.
6. Press oil seal (27) into seal cover (25) with special
tool (ST 2248).
7. Insert special tool (ST 2280) onto center shaft
(28), then install seal cover (25) into flange (23).
8. Install retaining ring (26) into flange (23).
W2-4-13
W173-02-04-006
W1HH-02-04-001
11
10
23
36
35
W2-4-14
32, 33, 34
31
W1HH-02-04-002

workbench, then apply THREEBOND #1215 on
the pump mounting surface.
Workbench : ST 5050
CAUTION: Main pump weight :
67 kg (148 lb)
10. Install eyebolt (M12, Pitch 1.75) to main pump
(11) to hoist and install it to flange (23) by crane.
11. Tighten bolts (10) (4 used) with spring washers (9)
and seal washes (31).
: 24 mm
: 147 Nm (15 kgfm, 108 lbfft)
12. Install other main pump same as steps 10 and 11.
13. Apply THREEBOND #1215 on the pilot pump (35)
mounting surface of flange (23). Install pilot pump
(35) to flange (23), then tighten socket bolts (32)
(2 used) with spring washers (33) and washers
(34).
: 8 mm
: 49 Nm (5 kgfm, 136 lbfft)
14. Install pipe (40) and packing (42) to flange (23),
then tighten socket bolts (41).
: 6 mm
: 19.5 Nm (2 kgfm, 14.5 lbfft)
40
41, 42
W1HH-02-04-003
15. Install adapter (36) to pilot pump (35).

: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
W2-4-15
20
19
18
17, 16, 15
3
14
W1HH-02-04-001
12
37
28
46
W1HH-02-04-002
W2-4-16

16. Install pipes (12, 14, 19 and 20).
: 19 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
: 22 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
17. Install clamp (18), bolt (15), nut (16), and washer
(17).
: 13 mm
: 3 Nm (0.3 kgfm)
18. Place the pump device horizontal, then install hub
(A) to center shaft (28) with screws (B) (2 used).
: 8 mm
: 108 Nm (11 kgfm, 80 lbfft)
G
F
19. Install inserts (H, D) to hub (A), then tighten bolts

(E) (4 used).
: 6 mm
: 310 Nm (32 kgfm, 232 lbfft)
20. Install N sensor (3).
: 5 mm
: 9.8 Nm (1 kgfm, 7.2 lbfft)
21. Install P sensor (46).

: 27 mm
CAUTION: Pump device weight:
200 kg (440 lb)
22. Place the pump device horizontal, then remove
plug (37) to add engine oil.
Engine oil : 1.4 L (0.37 US gal.)
23. Set plug (37) hole to the counter weight direction.
: 17 mm
W2-4-17
W110-02-04-006

DISASSEMBLE MAIN PUMP
47, 48
4
6
41
31
31
43
42
1
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
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)
Plug
Stopper L
O-Ring
Stopper S
O-Ring
Bolt (8 Used)
W2-4-18
40 41 42 43 44 45 46 47 48 49 50 -

Regulator
O-Ring
Spring Pin (2 Used)
Plug
Name Plate
Screw (2 Used)
Bolt (4 Used)
Packing
P Sensor

Disassemble Main Pump
Clean the outside of the main pump, before disassembling.
1. Remove retaining ring (11) from the main pump.
2. Remove drive gear (10) with a puller.
CAUTION: Main pump weight: 67 kg (148 lb)
3. Secure the main pump on workbench (ST 5050).
4. Remove bolts (47) (4 used) and spring washer
(48) to remove regulator (41).
: 8 mm
5. Remove O-rings (31) (5 used), O-ring (42), and
two spring pins (43) (2 used).
6. Remove bolts (32) (8 used) and spring washers
(33) to remove head cover (29).
: 10 mm
7. Remove O-rings (31) (3 used) from casing (1).
8. Place valve plate (18) on casing (1).
9. Pull up cylinder block (8) to remove valve plate
(18) and link (19).
10. Remove spring (12).
W2-4-19
1
16
17
15
14
13
9
2
W173-02-04-026
W2-4-20

11. Pull up center shaft (9) straight to remove. Be
careful not lose pin (13).
12. Remove plungers (7) (7 used). Place plungers (7)
horizontally against drive disc (2), and remove.
13. Place casing (1) on the bed. Remove retaining
ring (17).
16
14. Place the casing (1) drive disc end upward on the
workbench. Remove seal cover (15) with a
screwdriver.
15. Remove oil seal (14) from seal cover (15) with a
screwdriver.
16. Remove O-ring (16) from casing (1).
W173-02-04-007
Turn over casing (1) and place it on a press. Remove drive disc (2) and the bearing, using a
press and special tool (ST 1239)
ST 1239
W173-02-04-008
W2-4-21
4
6
3
5
W173-02-04-026
W2-4-22

18. Place drive disc (2) on special tool (ST 5905) to
loosen bearing nut (6).
ST 5905
W173-02-04-009
19. Install special tool (ST 3054) on the spline of drive

disc (2) to loosen bearing nut (6).
ST 3054
W173-02-04-010
20. Remove bearing nut (6) from drive disc (2).

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

23. Remove roller bearing (4) from spacer (5) using
ST 1271
W173-02-04-012
W2-4-23
39
40
37
38
27
28
2
26
36
35
40
39
W173-02-04-026
W2-4-24

24. Install special tool (ST 1272) between drive disc
(2) and roller bearing (3), and clamp the assembly
in a vise. Tighten the vise as necessary to widen
the clearance.
ST 1272
2
W173-02-04-013
25. Remove roller bearings (3) (2 used) from drive

disc (2) with a puller.
Puller
26. Remove four bolts (39) and spring washers (40)

to remove stopper S (37) from the head cover.
Remove O-ring (38) and stopper S (37).
: 6 mm
27. Remove bolts (39) and spring washers (40) to
remove stopper L (35) from the head cover.
Remove O-ring (36) and stopper L (35).
: 6 mm
28. Remove set screw (28) from servo piston (26) to
remove servo pin (27).
: 8 mm
NOTE: LOCTITE #829 is applied to set screw (28).
Warm set screw (28) before disassembling.
29. Remove servo piston (27) from the head cover.
W2-4-25
3
W173-02-04-014

ASSEMBLE MAIN PUMP
39, 40
37
31
43
47, 48
41
42 24
23
19
10
38
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
W2-4-26
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
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)
Plug
Stopper L
O-Ring
Stopper S
O-Ring
Bolt (8 Used)
W2-4-27
40 41 42 43 44 45 46 47 48 49 50 -

Regulator
O-Ring
Spring Pin (2 Used)
Plug
Name Plate
Screw (2 Used)
Bolt (4 Used)
Packing
P Sensor
39, 40
37
3
38
28
27
26
29
W1HH-02-04-005
W2-4-28

Assemble Main Pump
NOTE: Assemble by following the disassemble
procedures in reverse.
(1) Before assembling, clean all parts with
pure solvent and dry them with compressed air.
(2) Do not mix up the parts.
1. Insert servo piston (26) into head cover (29). Install servo pin (27) into the pin bore on servo piston (26). Apply LOCTITE #829 to set screw (28).
Tighten set screw (28) to secure servo pin (27) in
piston.
: 8 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
2. Install O-ring (38) on stopper S (37). Install stopper S (37) to head cover (29) with bolts (39) (4
used) and spring washers (40) (4 used).
: 6 mm
: 30 Nm (3.1 kgfm, 22.4 lbfft)
3. Install servo pin (27) positioning tool (ST 7923) on
the large chamber side of the head cover (29). Set
servo piston (26) so that servo pin (27) is at the
center of the suction port.
CAUTION: Take care to avoid being burned
when heating the bearings in an oil bath.
4. Heat roller bearings (3) (2 used) and the inner
race of bearing (4) to 50 to 80 C (122 to 176 F).
Apply hydraulic oil to roller bearings (3) and (4) inside.
ST 7923
W173-02-04-015
W2-4-29
W1HH-02-04-005
W2-4-30

5. Place drive disc (2) on a workbench with the
splined end up. Install two roller bearings (3) (2
used) on drive disc (2).
NOTE: Apply oil to bearing race surfaces after installing.
6. Install roller bearing (4) outer race in spacer (5)
using special tool (ST 2408).
ST 2408
W173-02-04-016
7. Install roller bearing (4) (include inner race) and

spacer (5) on drive disc (2).
Press roller bearing (4) inner race on drive disc (2),
using a plastic hammer and special tool (ST
7102).
NOTE: (1) Confirm that roller bearings (3, 4) are
securely installed on drive disc (2), after
they have cooled down to room
temperature.
(2) Be sure to apply oil to bearing race
surfaces after installing.
ST 7102
8. Place drive disc (2) on special tool (ST 5905). Install bearing nut (6) on drive disc (2) and tighten
bearing nut (6) until it contacts bearing (4).
NOTE: Apply lubricating oil to bearing nut (6)
threads when tightening.
W173-02-04-017
6
ST 5905
W173-02-04-018
W2-4-31
15
16
W2-4-32
14
W1HH-02-04-005

9. Tighten bearing nut (6) by turning drive disc (2)
clockwise using tool (ST 3054).
ST 3054
NOTE: When tightening bearing nut (6), tighten

counterclockwise.
10. Install a torquemeter and adapter (ST 3055) on

the spline of drive disc (2) to measure bearing preload. Make a record of the starting torque. Be sure
to rotate drive disc (2) two or three times before
recording, for smoother movement of drive disc
(2).
W173-02-04-023
ST 3055
Starting Torque Specification:

2.940.49 Nm (0.300.05 kgfm, 2.170.36 lbfft)
ST 5905
CAUTION:
Take care to avoid being burned when heating the bearings in an oil bath.
11. Heat casing (1) to 50 to 80 C (122 to 176 F).
Apply grease to the inside of casing (1).
W173-02-04-024
12. Install drive disc (2) into casing (1).

NOTE: Confirm that drive disc (2) is securely installed in casing (1) after the casing has
cooled down to room temperature.
13. Install O-ring (16) into the groove on casing (1)
bore. Apply grease to O-ring (16).
14. Install oil seal (14) into seal cover (15), using special tool (ST 2409). Apply grease to the oil seal
(14) lip.
ST 2409
15
W173-02-04-019
W2-4-33
23
19
15
12
13
17
W1HH-02-04-005
18
W1HH-02-04-006
W2-4-34

15. Install special tool (ST 2410) on the spline of drive
disc (2). Install seal cover (15) in casing (1).
14
NOTE: Tap seal cover (15) into casing (1) with a

plastic hammer until the retaining ring
groove on casing (1) is visible.
16. Install retaining ring (17) to casing (1).
15
NOTE: Be sure to confirm that the ring seats well in

the groove on casing (1) after installing.
17. Turn over casing (1) and place it on a workbench
with the input shaft side down. Apply lubrication oil
to the spherical surface of drive disc (2). Place
each plunger (7) horizontally against drive disc (2)
and install.
18. Install pin (13) on center shaft (9).
NOTE: Secure pin (13) to center shaft (9) with
grease.
19. Install center shaft (9) on drive disc (2).
20. Install spring (12) on center shaft (9).
21. After link (19) is connected to valve plate (18).
place valve plate (18) on casing (1). Insert pin (23)
on the other end of link (19) assembly to the opening on the casing (1) regulator mounting surface.
W2-4-35
ST 2410
W173-02-04-020
23
19
27
29
49
18
13
W1HH-02-04-005
30
W1HH-02-04-006
W2-4-36

22. Install plungers (7) (7 used) and center shaft (9)
into cylinder block (8).
NOTE: Install pin (13) into the groove of cylinder
block while rotating the end of center shaft
(9).
23. Face the spherical surface of valve plate (18) to
cylinder block (8) and insert the end of center
shaft (9).
NOTE: Be sure to apply hydraulic oil to the matching surfaces of valve plate (18) and cylinder
block (8).
24. Apply grease to O-rings (31) (3 used). Install Orings (31) (3 used) and packing (49) on casing (1).
NOTE: When installing O-rings (31), refer to W2-418.
25. Install valve plate positioning tool (ST 7094) on
the drain port of casing (1) to position valve plate
(18) at the center position.
26. Install head cover (29) on casing (1), aligning

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

the holes of spring pins (30). Tighten bolts (32) (8
used) with spring washers (33) (8 used).
: 12 mm
: 110 Nm (11 kgfm, 80 lbfft)
32, 33
W173-02-04-002
W2-4-37
47, 48
43 41
42
24
39, 40
2
10
11
29
35
W1HH-02-04-005
36
44
W2-4-38

28. Remove valve plate positioning tool (ST 7094)
from casing (1) and install plug (44).
Remove servo pin positioning tool (ST 7923) from
head cover (29). Install O-ring (36) on stopper L
(35). Install stopper L (35) with spring washers
(40) (4 used) and bolts (39) (4 used).
: 6 mm
: 20 Nm (2 kgfm, 14.5 lbfft)
: 8 mm
: 49 Nm (5 kgfm, 36.2 lbfft)
35, 36
39, 40
44
ST 7923
ST 7094
29. Apply grease to O-rings (31) (42). Install O-rings

(31) (5 used) and O-ring (42) onto the regulator
mounting surface of casing (1).
NOTE: Be sure to install spring pins (43) (2 used).
When installing O-rings (31), refer to W2-418.
30. Install regulator (41) on casing (1).
CAUTION: Main pump weight:
67 kg (148 lb)
IMPORTANT: Align pump feedback pin (24) with
the notches on regulator (41)
sleeves confirming from the plug
hole of regulator (41).
31. Install bolts (47) (4 used) and spring washers (48)
(4 used). Tighten bolts (47).
: 8 mm
32. Install drive gear (10) into drive disc (2).
33. Install retaining ring (11) into drive disc (2).
W2-4-39
W173-02-04-022

DISASSEMBLE REGULATOR
25
26
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
W2-4-40
25 26 27 28 29 30 31 32 -

Front Cover
Bolt (4 Used)
Plug
O-Ring
Rear Cover
UPPERSTRUCTURE/Pump Device
Disassemble Regulator
1. Clean the regulator outside.
2. Clamp casing (5) with a vise.
3. Remove air bleed plug (30) and O-ring (31) from
casing (5). Remove elbows (4 used) from casing
(5).
: 19 mm, 41 mm
4. Remove socket bolts (25) (8 used) to remove
front cover (27) and rear cover (32).
: 6 mm
IMPORTANT: Never loosen stopper (1), (13) and
(14), nut (9), (11) and (12), and screw
(10). If loosened, the regulator setting will change.
5. Remove springs (16, 17) from the casing (5) rear
cover side.
6. Remove cylinder (20) from the casing (5) front
cover (27) side, pulling spool (19).
7. Remove piston (21), O-ring (22), and backup ring
(23) from cylinder (20).
8. Remove sleeve (18) and spool (19) from the casing (5) front cover (27) side.
9. Remove spool (19) from sleeve (18).
10. Remove spring (6) from the casing (5) front cover
(27) side.
11. Remove piston (7) and cylinder (8) from the casing (5) rear cover (32) side, pulling spool (4).
12. Remove piston (7) and O-ring (2) from cylinder
(8).
13. Remove sleeve (3) and spool (4) from the casing
(5) front cover (27) side. Then remove spool (4)
from sleeve (3) .
W2-4-41
ASSEMBLE REGULATOR
6
24 23
25, 26
27
22
21 20
19
18
17
16
28, 29
10
15 14 13 12
30
31
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
W2-4-42
25 26 27 28 29 30 31 32 -

Front Cover
Bolt (4 Used)
Plug
O-Ring
Rear Cover
Assemble Regulator
NOTE: Assemble by following the disassemble
procedures in reverse.
(1) Before assembling, Clean all parts with
pure solvent and dry with compressed
air.
(2) Do not mix up the parts.
1. Clamp casing (5) with a vise.
2. Install spool (19) into sleeve (18).
3. Install sleeve (18) with spool (19) from the casing
(5) front cover (27) side.
4. Install spool (4) into sleeve (3), then install them
from the casing (5) front cover (27) side.
5. Install piston (7) into cylinder (8).
6. Install O-ring (2) to cylinder (8), then apply a film
of grease to O-ring (2). Install cylinder (8) from the
casing (5) rear cover (32) side.
7. Install rear cover (32) assembly and springs (16)
and (17) to casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.6 Nm (2 kgfm, 14.5 lbfft)
8. Install O-ring (22), backup ring (23), and piston
(21) to cylinder (20).
9. Apply a film of grease to O-ring (22), then Install
cylinder (20) from the casing (5) front cover (27)
side.
10. Install front cover (27) assembly and spring (6)
into casing (5). Tighten socket bolts (25) (4 used)
with spring washers (26).
: 6 mm
: 19.5 Nm (2 kgfm, 14.5 lbfft)
11. Apply a film of grease to O-ring (31). Install O-ring
(31) to plug (30).
12. Tighten plug (30).
: 41 mm
: 78.5 Nm (8 kgfm, 58 lbfft)
13. Install elbows (4 used) to casing (5).
W2-4-43
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)
W2-4-44
13 14 15 16 -
Bolt (4 Used)
Bushing (2 Used)
Bushing (2 Used)
Knock Pin (2 Used)
Disassemble Pilot Pump
NOTE: (1) Clean the outside of the pilot pump
before disassembling.
(2) Make matching marks on cover (6),
housing (1) and flange (2) before
disassembling to aid reassembly.
1. Clamp pump flange (2) in a vise with cover (6) up.
2. Remove bolts (13) (4 used).
: 17 mm
3. Remove cover (6) from housing (1).
4. Remove O-ring (9) from cover (6).
5. Remove flange (2) from housing (1).
6. Remove O-ring (9) from flange (2).
7. Remove retaining ring (4) from flange (2).
8. Remove oil seal (3) from flange (2) with a screw
driver.
9. Remove seal (5) and backup ring (7) from cover
(6) side bushings (14, 15).
10. Lightly push drive gear (11) to remove cover (6)
side bushings (14, 15) from housing (1).
NOTE: Be careful not to allow the key between the
bushings to fall off when removing them.
11. Remove seal (5) and backup ring (7) from flange
(2) side bushings (14, 15).
12. Remove flange (2) side bushings (14, 15). Remove gear (10) and drive gear (11) from housing
(1).
W2-4-45
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
Key (2 Used)
910 11 12 -
O-Ring (2 Used)
Gear
Drive Gear
Washer (4 Used)
W2-4-46
13 14 15 16 -
Bolt (4 Used)
Bushing (2 Used)
Bushing (2 Used)
Knock Pin (2 Used)
Assemble Pilot Pump
1. Tap oil seal (3) in flange (2) with a plastic hammer
and tool.
2. Install retaining ring (4) to flange (2).
3. Install cover (6) side bushings (14, 15) in housing
(1) with the seal groove side down.
NOTE: Position the bushings
direction when installing.
in
the
correct
4. Install gear (10) and drive gear (11) in housing (1).

5. Install flange (2) side bushings (14, 15) in housing
(1) with the seal groove side up.
6. Install seal (5) and backup ring (7) into the seal
groove on bushings (14, 15).
7. Install O-ring (9) on flange (2).
8. Install flange (2) on housing (1).
9. Turn over the housing and flange assembly and
clamp flange (2) in a vise. Install seal (5) and
backup ring (7) into the seal groove on the
bushings.
NOTE: Be careful not to allow the bushings or
gears to fall off when rotating the assembly.
10. Install O-ring (9) on cover (6).
11. Install cover (6) on housing (1).
12. Install washers (12) (4 used) and bolts (13) (4
used). Tighten the bolts.
: 17 mm
: 39 to 44 Nm
(4 to 4.5 kgfm, 29 to 32.5 lbfft)
W2-4-47
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)
2. Drive disc: Oil seal outer diameter

Unit : mm (in)
Standard
Allowable Limit
60.0 (2.362)
59.8 (2.354)
3. Spherical joint: The clearance between plunger

and drive disc
Unit : mm (in)
Standard
Allowable Limit
0.060 (0.0024)
0.4 (0.0016)
W157-02-04-016
4. Cylinder block: Clearance between plunger outer

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

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

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

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

D
D-a
Unit : mm (in)
Standard
Allowable Limit
0.051 (0.0020)
0.3 (0.012)
W157-02-04-019
W2-4-49
(Blank)
W2-4-50
UPPERSTRUCTURE / Control Valve

REMOVE AND INSTALL CONTROL VALVE
pressure.
Preparation
pressure.
W2-5-1
M104-07-021

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

CAUTION: Control valve weight:
210 kg (460 lb)
2. Remove bolts (1) to remove the control valve.
: 24 mm
: 205 Nm (21 kgfm 152 lbfft )
Installation
NOTE: Refer to Removal section for wrench size
and tightening torque.
1. Install the control valve on the frame and tighten
bolts (1).
2. Connect all hoses, pipings, and connectors to the
control valve.
IMPORTANT: After assembling, check hydraulic
oil level, start the engine and check
for oil leaks.
W2-5-2
W1HH-02-05-001

(Blank)
W2-5-3

DISASSEMBLE CONTROL VALVE (1)
13
12
43
41
5
7
46
12a
13a
32
35
30
31
29
15
17
15
14
15
38
47
25
28
37
17
23
33
14
34
30
42
15
31
27
21
15
12
20
22
2
10
15
35
16
44
18
26
24
19
45
31
8
40
17
11
8
15
39
16
36
15
8
9
31
17
3
W173-02-05-021
12345678910 11 12 -
Casing A
Casing B
Plug
Plug ( Used)
O-Ring (6 Used)
Spring Cover A
Spring Cover B
Spool Cover (5 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)
17 - Socket Bolt (32 Used)
18 - Spool: Travel Left
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
Spool: Bypass Shut-Off

Spool: Auxiliary
Spool: Travel Right
Spring (2 Used)
Spring (2 Used)
Spring Seat (4 Used)
Spacer Bolt (2 Used)
Stopper (2 Used)
Stopper (7 Used)
Stopper
38 39 40 41 42 43 44 45 46 47 -
Spring (7 Used)
Spring
Spring
Plug
Plug
Plug
Plug
O-Ring

Disassemble control valve (1)
Read carefully Precautions for Disassembly and
Assembly (W1-1-1) before starting repair work.
Attach a tag to spool mounting positions of the
casing.
Anti-drift Valve and Needle Valve

1. Loosen socket bolt (46) and remove needle valve
(13) and anti-drift valve (12) from spring cover B
(7).
: 5 mm
Spool Cover
IMPORTANT: Attach matching mark not to make a
mistake in assembly of casing and
spool cover.
9. Loosen socket bolts (17) (2 used) and remove
spool cover (11) from casing B (2).
: 6 mm
10. Disassemble spool covers (8) to (10) following the
same procedures.
: 6 mm
2. Loosen socket bolt (47) and remove anti-drift

valve (12) from spring cover A (6).
: 5 mm
Spring Cover
spring cover A (6) from casing A (1). Remove
spring cover B (7) from casing B (2) similarly.
: 6 mm
Spool
IMPORTANT: Remove spools while carefully turning them. If they stick even a little,
try it again instead of pulling roughly.
Since spool and hole of casing are a
matched fit, make marks to aid in
assembly.
Be careful not to damage casing and
spool.
4. Remove spool (18) assembly from casing A (1).
5. Remove spools (19) to (27) following the same
procedures.
6. Clamp spool (18) in a vise.
7. Loosen spacer bolt (32) and disassemble spring
seat (30), springs (28), (29), and stopper (33).
: 10 mm
8. Disassemble spools (19) to (27) following the
same procedures.
: 10 mm
W2-5-5

ASSEMBLE CONTROL VALVE (1)
21
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
Control Valve Upper View

18
Machine Front
2
25
23
Section B-B
26
15, 14
20
W1HH-02-05-017
30 33 28
29
30
16
32
8
3
5
44, 45
9
35
15
8
17
W1HH-02-05-005
24
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: Arm 2
Spool Cover: Boom 1
Anti-Drift Valve (2 Used)
Boom Bottom, Arm Rod
12a O-Ring (6 Used)
19 22
13 - Needle Valve
13a O-Ring (3 Used)
18 - Spool: Travel Left
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
W2-5-6
1
6
Section A-A
Spool: Bypass Shut-Off

Spool: Auxiliary
Spool: Travel Right
Spring (2 Used)
Spring (2 Used)
Stopper (2 Used)
Stopper (7 Used)
Stopper
38 39 40 41 42 43 44 45 46 47 -
31
37 38
W1HH-02-05-004
31 34
Spring (7 Used)
Spring
Spring
Plug
Plug
Plug
Plug
O-Ring

Assemble Control Valve (1)
Lower Spool Cover

IMPORTANT: Install spool covers (8) to (11) with
matching marks.
Be sure to install O-rings (15) and
(16).
1. Install O-rings (15) and (16) to spool cover (11).
Spring Cover
10. Install O-rings (14) (5 used) and O-rings (15) (4
used) to spring cover A (6)
11. Install spring cover A (6) to casing A (1) with
socket bolts (17) (7 used).
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
2. Install spool cover (11) to casing B (2) with socket

bolts (17) (2 used).
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
12. Install spring cover B (7) following the same procedures.

: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
3. Install spool cover(8) to (10) following the same

procedures.
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
Anti-drift Valve and Needle Valve
Spool
13. Install O-rings (12a) (3 used) to anti-drift valve

(12). Install anti-drift valve (12) to spring cover A
(6) with socket bolts (47) (4 used).
: 5 mm
: 9.8 to 14 Nm
(1 to 1.4 kgfm, 7.2 to 10 lbfft)
4. Clamp spool (18) in a vise.

5. Clean screw section of spacer bolt (32) and apply
LOCTITE #262.
6. Install spring sheet (30), springs (28), (29), stopper (33) and spacer bolt (32) to spool (18).
7. Tighten spacer bolt (32).
: 10 mm
: 15 to 18 N m
(1.6 to 1.8 kgfm, 11.5 to 13 lbfft)
14. Install O-rings (12a) (3 used) to anti-drift valve

(12). Install O-rings (13a) (3 used) to needle valve
(13). Install needle valve (13) and anti-drift valve
(12) to spring cover B (7) with socket bolts (46) (4
used).
: 5 mm
: 9.8 to 14 Nm
8. Assemble spools (19) to (27) following the same

procedures.
: 10 mm
: 15 to 18 Nm
(1.6 to 1.8 kgfm, 11.5 to 13 lbfft)
IMPORTANT: Install spool (18) to (27) assemblies
with matching marks.
Be careful not to damage casing and
spool when installing.
9. Install spool (18) to (27) assemblies to casing A
(1) and casing B (2).
W2-5-7

1
23
22
12
6
19
13
18
20
7
24
3
11
21a
14
9
8
21
14
16
Casing A
11
25
17
10
15
W173-02-05-022
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)
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

Disassemble Control Valve (2)
Arm Anti-drift Valve

IMPORTANT: Put matching marks to install correctly.
casing 2 (2) from casing 4 (4).
: 10 mm
casing 4 (4) from casing A.
: 10 mm
3. Clamp casings 2 (2) and 3 (3) in a vise.
casing 3 (3) from casing 2 (2).
: 5 mm
5. Loosen plug (15) and take out poppet (16) and
spring (17) from casing 2 (2).
: 17 mm
IMPORTANT: Do not disassemble lock nut part.
6. Remove relief valve (21) from casing 3 (3).
: 22 mm
IMPORTANT: Mark extraction sequence of piston
(22) and (23).
7. Loosen plug (13) and take out piston (23) and piston (22) from casing 3 (3).
: 10 mm
8. Loosen plug (12) and take out bushing (20), spool
(18), and spring (19) from casing 3 (3).
: 22 mm
W2-5-9

Machine Front
14
13
9
14
23
22
F
F
21 21a
20
19
T1HH-03-03-002
18
Section Y-Y
12
W1HH-02-05-006
Arm 1
Arm 2
24
15
10
17
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

1. Install O-rings (7) (3 used) to bushing (20).
10. Install casing 3 (3) to casing 2 (2) with socket

: 5 mm
: 9.8 to 13.5 Nm
2. Install O-ring (6) to plug (12).
11. Install O-ring (11) to casing 4 (4).
3. Install bushing (20), spool (18), and spring (19)

into casing 3 (3), and install plug (12).
: 22 mm
: 69 to 79 Nm
(7 to 8 kgfm, 50.5 to 58 lbfft)
12. Install casing 4 (4) to casing A with socket bolts

(25) (4 used).
: 10 mm
: 98 to 118 Nm
(10 to 12 kgfm, 72 to 87 lbfft)
13. Install O-ring (11) to casing 2 (2).
IMPORTANT: Be sure to install pistons (22) and

(23) in their correct positions.
5. Install pistons (22) and (23) into casing 3 (3), and
install plug (13).
: 10 mm
: 127 to 147 Nm
14. Install casing 2 (2) to casing 4 (4) with socket

: 10 mm
: 98 to 118 Nm
IMPORTANT: Do not use lock nut part.

6. Install O-ring (21a) to relief valve (21). Tighten and
install relief valve (21) in casing 3 (3).
: 22 mm
: 69 to 79 Nm
(7 to 8 kgfm, 50.5 to 58 lbfft)
8. Install poppet (16) and spring (17) into casing 2
(2), and install plug (15).
: 17 mm
: 370 to 410 Nm
(38 to 42 kgfm, 275 to 300 lbfft)
9. Install O-rings (8) (2 used) to casing 3 (3).
W2-5-11

16
18
19
21
25
25
13
13a
23
16
17
20
24
29
19
29a
Casing A
1
6
4
14
22
33
14a
6
9
26
8
12
31
32
15
10
27
12
31
27
11
25
2
28a
28
30a
30b
30c
30
W1HH-02-05-019
1 - Plug (4 Used)
2 - Plug
11 - P3 Cover
12 - Flange (2 Used)
3 - Plug
21 - Spring
4 - Plug (2 Used)
13 - Travel Flow Rate Control

Valve Assembly
13a - O-Ring
22 - Spacer
5678910 -
14 - Blank Flange Assembly

14a - O-Ring (2 Used)
16 - Poppet (4 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
Plug (3 Used)
Plug
O-Ring (5 Used)
O-Ring
O-Ring (2 Used)
Overload Relief Valve:
Boom Rod Side
W2-5-12
28a O-Ring
29 - Overload Relief Valve:
Arm Rod Side
29a O-Ring
30 - Pump Control Valve:
5-Spool Section
30a - O-Ring
30b - O-Ring
30c - O-Ring

2. Take out poppet (16), spring (19), and spacer (22)

from casing A.
Blank Flange Assembly

blank flange (14).
: 8 mm
32 mm
4. Take out poppet (17) and spring (20) from casing

A.
Travel Flow Rate Control Valve (13) Assembly

5. Loosen the plug and take out the piston, sleeve,
poppet, and spring from casing A.
: 32 mm
(45 mm)
(12.7 mm)
1. Loosen socket bolts (32) (4 used) and remove P3

cover (11).
: 8 mm
IMPORTANT: Note that there are two kinds of overload relief valves.
Attach identification marks to each
port and part to aid reassembly.
Be sure to loosen the valve of overload relief valve. If lock nut and adjusting screw are loosened, the set
pressure will change. Never loosen
lock nut and adjusting screw.
8. Loosen and remove overload relief valves (28)
and (29) with tool as below.
: 32 mm
(Wrench: 32 mm)
P3 Cover
Overload Relief Valve
(43 mm)

(80 mm)
W1HH-02-05-002
Arm Anti-Drift Check Valve

6. Loosen plug (24) and take out spring (21) and
poppet (18) from casing A.
: 12 mm
Travel Left, Boom 2, Swing Load Check Valve
Pump Control Valve (5-Spool Section)

9. Loosen and remove pump control valve (30) from
base.
: 36 mm
(common to three places)

IMPORTANT: Attach matching marks to each port
and part to aid reassembly.
spring (19) from casing A.
: 12 mm
W2-5-13

Machine Front
X
D
E
F
W1HH-02-05-003
30
30a
30c
Casing A
Section B
T1HH-03-03-002
30b

Auxiliary
Travel Left
Bucket
31
Travel Right
12
27
16
19
22
2
13a
13
23
25
32
11
25
19
27
16
31
Section C-C
T1HH-03-03-004
12
W2-5-14
T1HH-03-03-005
Section D-D

Boom 2
Boom 1
Arm 1
Arm 2
18
21
24
25
17
20
14
29
29a
25
23
14a
33
19
16
3
7
28a
28
Section E
Section F-F
T1HH-03-03-006
T1HH-03-03-007
15
10
9, 26
Swing
Travel
Left
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)
3 - Plug
21 - Spring
4 - Plug (2 Used)
13 - Travel Flow Rate Control

Valve Assembly
13a - O-Ring
22 - Spacer
5678910 -
14 - Blank Flange
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
Plug (3 Used)
Plug
O-Ring (5 Used)
O-Ring
O-Ring (2 Used)
Overload Relief Valve:
Boom Rod Side
W2-5-15
28a O-Ring
Arm Rod Side
29a O-Ring
5-Spool Section
30a - O-Ring
30b - O-Ring
30c - O-Ring

Machine Front
X
5
B
D
E
W1HH-02-05-003
30
30a
30c
31
Casing A
12
Auxiliary
T1HH-03-03-002
30b
Section B
Bucket

Travel Left
Travel Right
27
16
19
22
13a
13
15
23
2
25
32
11
8
27
19
31
12
16
Section C-C
Boom 2
T1HH-03-03-004
Boom 1
Section D-D
6
Arm 1
21
29
T1HH-03-03-005
Arm 2
18
17
24
25
29a
20
14
14a
25
23
33
19
16
3
Section F-F
7
Section E
T1HH-03-03-006
28a 28
W2-5-16
T1HH-03-03-007


1. Install O-rings (30a) (30b) (30c) to pump control
valve (30). Tighten and install pump control valve
(30) to base.
: 36 mm
: 69 to 78 Nm
6. Install poppet (18) and spring (21) into casing A,

and install plug (24).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
Travel Flow Rate Control Valve (13) Assembly

7. Install O-ring (13a) to the plug. Install the piston,
sleeve, poppet, and spring into casing A, and install the plug.
: 32 mm
: 147 to 177 Nm
(15 to 18 kgfm, 108 to 130 lbfft)
Blank Flange Assembly

8. Install two O-rings (14a) (2 used) to blank flange
(14). Install poppet (17) and spring (20) into casing A. Install blank flange (14) with socket bolts
(33) (4 used).
: 8 mm
: 49 to 65 Nm
(5 to 6.6 kgfm, 36 to 48 lbfft)
9. Install O-rings (8) to cover (11).
(45 mm)
(80 mm)
P3 Cover
(12.7 mm)
(Wrench: 32 mm)
43 mm
32 mm
IMPORTANT: Note that there are two kinds of overload relief valves.
Install according to the identification
marks.
2. Install O-ring (28a) to overload relief valve (28).
Install O-ring (29a) to overload relief valve (29).
Tighten and install overload relief valve (28) and
(29) to base with tool as below.
: 32 mm
: 69 to 78 Nm
Arm Anti-drift Check Valve
W1HH-02-05-002
10. Install poppet (16), spring (19), and spacer (22)

into casing A. Install P3 cover (11) with socket
: 8 mm
: 49 to 65 Nm
(5 to 6.6 kgfm, 36 to 48 lbfft)
Left Travel, Boom 2, Swing Load Check Valve

(common to 3 places)
IIMPORTANT: Install according to the matching
marks.
4. Install poppet (16) and spring (19) into casing A,
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
W2-5-17

3
21
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
10 - Poppet Valve
11 - Load Check Valve
11a - O-Ring
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

Bucket Flow Rate Control Valve

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

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

IMPORTANT: Attach matching marks to each port
and part to aid reassembly.
spring (15) from casing B.
: 12 mm
Boom Anti-drift Check Valve

: 12 mm
Travel-Bucket Compound Check Valve

: 10 mm
W2-5-19

Machine Front
Travel Left
Travel Right
13
22
20
17
G
T1HH-03-03-002
Section C-C
Bucket
Auxiliary
Boom 2
Boom 1
Arm 1
6
1
10
9a
Section D-D
T1HH-03-03-004
14
16
19
21
18
23
15
21
12
Section E
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
10 - Poppet Valve
11 - Load Check Valve
11a - O-Ring
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

Travel-Bucket Compound Check Valve

2. Install poppet (13) and spring (17) into the casing,
: 10 mm
: 128 to 147 Nm
Bucket Flow Rate Control Valve

8. Install O-rings (9a) (2 used) to switch valve (9).
Poppet valve (10) is put into the casing. Install
switch valve (9) with socket bolts (23) (4 used).
: 8 mm
: 52 to 62 Nm
(5.3 to 6.3 kgfm, 38 to 46 lbfft)
Boom Anti-drift Check Valve

: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
Boom 1, Arm 2 Load Check Valve

IIMPORTANT: Install according to the identification
mark.
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
Arm 2 Load Check Valve (with orifice)

7. Install O-ring (11a) to the plug. Install load check
valve (11).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
W2-5-21

1
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
1 - Flow Combiner Valve Assembly

2 - Block
3 - Plug
4 - Plug
5 - O-Ring (3 Used)
6 - O-Ring (4 Used)
7 - O-Ring (2 Used)
13 - Spring
19 - Plug (3 Used)
8910 11 12 -
14 15 16 17 18 -
21 - Main Relief Valve
21a - O-Ring
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

Flow Combiner Valve

flow combiner valve assembly (1).
: 14 mm
2. Clamp block (2) in a vise.
3. Loosen main relief valve (21) from base, and remove from block (2).
: 32 mm
4. Loosen plug (9) and take out spool (16), stopper
(14), springs (12) and (13) from block (2).
: 32 mm
IMPORTANT: Attach matching mark to each port
and part.
5. Loosen plug (19), and take out poppet (17) and
spring (18) from block (2).(common to 3 places)
: 12 mm
6. Loosen and remove plug (3).
: 5 mm
7. Take out orifices (15) (2 used) from block (2).
: 4 mm
W2-5-23

Machine Lower
Machine Front
3, 8, 15
22
T1HH-03-03-002
W1HH-02-05-007
Control Valve Front View

15
16
10
12
13
14
20
7
19
18
17
20
19
11
2
18
17
5
21a
21
W1HH-02-05-010
Section A
1 - Flow Combiner Valve Assembly
2 - Block
3 - Plug
4 - Plug
5 - O-Ring (3 Used)
6 - O-Ring (4 Used)
7 - O-Ring (2 Used)
13 - Spring
19 - Plug (3 Used)
8910 11 12 -
14 15 16 17 18 -
21 - Main Relief Valve
21a - O-Ring
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

Flow Combiner Valve
10. Install O-rings (5) (3 used), O-rings (6) (4 used),

O-rings (7) (2 used) and O-ring (11) to block (2).
11. Install flow combiner valve assembly (1) with
socket bolt (22) (5 used).
: 14 mm
: 215 to 255 Nm
(22 to 26 kgfm, 159 to 188 lbfft)
1. Clamp block (2) in a vise.

2. Install orifices (15) (2 used) in block (2).
: 4 mm
: 7.8 to 9.8 Nm
(0.8 to 1.0 kgfm, 5.8 to 7.2 lbfft)
4. Install plug (3).
: 5 mm
: 12.7 to 16.7 Nm
(1.3 to 1.7 kgfm, 9.4 to 12.3 lbfft)
IMPORTANT: Install according to the matching
mark.
6. Put poppet (17) and spring (18) into block (2), and
install plug (19).(common to 3 places)
: 12 mm
: 225 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
8. Put spool (16), stopper (14), springs (12) and (13)
into block (2), and install plug (9).
: 32 mm
: 68.6 to 78.4 Nm
9. Install O-ring (21a) to main relief valve (21). Install
main relief valve (21) in block (2) base.
: 32 mm
: 68.6 to 78.4 Nm
W2-5-25

9a
10
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
4 - O-Ring (6 Used)

Bucket Bottom Side
8a - O-Ring
(4-Spool Section)
9a - O-Ring
W2-5-26
9b - O-Ring
9c - O-Ring
10 - Socket Bolt


1. Loosen and remove pump control valve (9) from
casing B base.
: 36 mm

IMPORTANT: Note that there are 2 kinds of overload relief valve.
Attach identification mark to each
port and part.
(12.7 mm)
(Wrench: 32
43 mm
32 mm
IMPORTANT: Be sure to loosen the valve of overload relief valve. If loosening the
lock nut and adjusting screw, the set
pressure will change. Never loosen
the lock nut and adjusting screw.
2. Loosen and remove overload relief valve (7) and
(8) from casing B base with tool as below.
: 32 mm
(45 mm)
(80 mm)
W1HH-02-05-002
Casing
IMPORTANT: As long as there is no necessity, do
not disassemble socket bolts (10)
and (11).
3. Loosen socket bolt (10) and socket bolts (11) (8
used) and disassemble casing A and casing B.
: 12 mm
W2-5-27

Boom 2
Boom 1
10
Machine Front
5
C
E
F
F
G

Travel Left
Section E
T1HH-03-03-002
Travel Right
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
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
4 - O-Ring (6 Used)
Section G
T1HH-03-03-005

Bucket Bottom Side
8a - O-Ring
(4-Spool Section)
9a - O-Ring
W2-5-28
T1HH-03-03-008
9b - O-Ring
9c - O-Ring
10 - Socket Bolt

Casing
1. Install O-rings (4) (6 used), O-rings (5) (6 used)
and O-rings (6) (5 used) to casing B.
2. Connect casing A and casing B and tighten socket
bolts (10) and socket bolts (11) (8 used).
: 12 mm
: 137 to 177 Nm
(14 to 18 kgfm, 101 to 130 lbfft)
(12.7 mm)
(Wrench: 32 mm)
(45 mm)
43 mm
32 mm
IMPORTANT: Note that there are 2 kinds of overload relief valve.

Install according to the matching
mark.
3. Install O-ring (7a) to overload relief valve (7). Install O-ring (8a) to overload relief valve (8).Tighten
and install overload relief valves (7) and (8) to the
base with tool as below.
: 32 mm
: 69 to 78 Nm
(80 mm)
W1HH-02-05-002

4. Install O-rings (9a), (9b) and (9c) to pump control
valve (9). Install pump control valve (9).
: 36 mm
: 69 to 78 Nm
W2-5-29

STRUCTURE OF VALVES
Main Relief Valve
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
2
9
8
16
3
7
4
PL
22
10
23
11
20
12
21
17
13
18
14
19
R
15
P
ITEM
5
2
21
6
19
9
10
22
16
11
17
20
18
R
8
7
15
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
W173-02-05-030
13
PART NAME
Lock Nut
Lock Nut
O-Ring
O-Ring
O-Ring
Adjusting Screw
Spring
Piston
Stopper
Poppet
Backup Ring
O-Ring
Seat
Spring
Plunger
O-Ring
Filter
Filter Stopper
C-Ring
Spacer
C-Ring
Adjusting Plug
Plug
12
14
P
W173-02-05-031
W2-5-30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PART NAME
Lock Nut
O-Ring
Adjusting Screw
Spring
Spring Seat
Poppet
Backup Ring
O-Ring
Backup Ring
O-Ring
Seat
Spring
Spring
Plunger
Piston
Filter
Filter Stopper
C-Ring
O-Ring
O-Ring
Plug
Body
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Flow Combiner Valve
10
15
14
11
5
12
1
9
22
16
21
W1HH-02-05-011
9
Section B-B
W1HH-02-05-012
Section A-A
A
ITEM
20
W1HH-02-05-013
18 17
13 18 19
19
19
18
18
17
W1HH-02-05-014
W2-5-31
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PART NAME
Name Plate
Socket Bolt
Main Relief
O-Ring
ROMH Plug
Spring
Poppet
Spool
Orifice
Stopper
Spring
Spring
O-Ring
O-Ring
Plug
O-Ring
O-Ring
O-Ring
O-Ring
Plug
ROM Plug
Block
QTY
1
5
1
3
3
3
3
1
2
1
1
1
1
1
1
1
2
4
3
1
1
1

Switch Valve (Bucket Flow Rate Control Valve)
2
11
10
ITEM
1
2
3
4
5
6
7
8
9
10
11
PART NAME
Spring
Spring
Spool
Spring Seat
Plug
Plug
Socket Bolt
O-Ring
O-Ring
O-Ring
Casing
QTY
1
1
1
1
1
1
4
1
1
2
1
W173-02-05-007
Anti-drift Valve
4
2
7
ITEM
1
2
3
4
5
6
7
8
3
5
1
W173-02-05-008
W2-5-32
PART NAME
Bushing
Spring
Spool
Plug
O-Ring
O-Ring
O-Ring
Casing
QTY
1
1
1
1
3
3
1
1

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

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

3
1
6
ITEM
1
2
3
4
5
6
2
5
A
W173-02-05-011
W2-5-33
PART NAME
O-Ring
Spring
Plug
Poppet
Sleeve
Piston
QTY
1
1
1
1
1
1

Needle Valve
A
5
4
2
6
7
Section A-A
A
ITEM
W173-02-05-012
1
2
3
4
5
6
7
PART NAME
O-Ring
O-Ring
Plug
Nut
Adjusting Screw
Poppet
Casing
W173-02-05-013
QTY
3
1
2
1
1
1
1
Blank Flange
W1HH-02-05-016
ITEM
LCAT1
LCAP1
W1HH-02-05-015
W2-5-34
1
2
3
4
5
PART NAME
Socket Bolt
Blank Flange
O-Ring
O-Ring
ROH Plug
QTY
4
1
2
3
3

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

Boom 1 Spool Assembly
1
W173-02-05-015
ITEM
1
2
3
4
5
6
7
8
9
PART NAME
QTY
Plug 2
Plug 1
Spring B3
Spring B2
Spring B1
Plunger 3
Plunger 2
Plunger 1
Spool
1
1
1
1
1
1
1
1
1
Arm 2 Spool Assembly

8
10
9
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
11
PART NAME
Spring Seat (1)

Plug
Plug
Stopper (2)
Stopper (1)
C-Ring
Spring A2
Spring A1
Sleeve (1)
Sleeve (2)
Sub Spool
Spool
W2-5-36
12
QTY
1
1
1
1
1
1
1
1
1
1
1
1
W173-02-05-016

Bucket Spool Assembly
W1HH-02-05-018
ITEM
1
2
3
4
5
6
7
8
9
PART NAME
Plug 2
Plug 1
Spring B3
Spring B2
Spring B1
Plunger 3
Plunger 2
Plunger 1
Spool
W2-5-37
QTY
1
1
1
1
1
1
1
1
1

Pump Control Valve
3
1
4
8
9
Dr
Pc
PE
7
P
W173-02-05-017
ITEM
PART NAME
QTY
Lock Nut
O-Ring
3
4
5
Adjusting Plug
Spring
Spool
1
1
1
O-Ring
7
8
9
O-Ring
O-Ring
Body
1
1
1
W2-5-38
UPPERSTRUCTURE / Swing Device

REMOVE AND INSTALL SWING DEVICE
may penetrate the skin, causing serious injury. Avoid this hazard by relieving pressure
before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation
starting any repair work.
The hydraulic oil tank cap may fly off if removed without releasing accumulated pressure first. Push the air release valve on top of
the hydraulic oil tank to release any remaining pressure.
Preparation
pressure.
W2-6-1
M104-07-021

Removal
1. Disconnect hoses (1 to 3 and 5 to 7).
: 41 mm
: 205 Nm (21 kgfm)
: 19 mm
: 29.5 Nm (3 kgfm)
: 17 mm
: 24.5 Nm (2.5 kgfm)
: 8 mm
: 50 Nm (5.1 kgfm)
7
6
1
2
NOTE: Attach caps to the hoses and pipes.

2. Attach a nylon sling to the swing motor so as to
hoist it by crane.
Nylon sling (eye-type at both ends): 2 places
3
4
W1HH-02-06-001
CAUTION: Swing device assembly weight:

390 kg (800 Ib)
3. Remove bolts (4) and hoist the swing device
assembly by crane.
: 32 mm
: 640 Nm (65 kgfm, 470 Ibfft)
Nylon Sling
Installation
NOTE: Refer to Removal section above for
wrench sizes and tightening torques.
IMPORTANT: Before installing the swing device
assembly, apply liquid packing
(THREEBOND #1102) to both mounting surfaces on the swing device
and frame.
1. Install the swing device with bolts (4).
2. Connect hoses (1 to 3 and 5 to 7).
IMPORTANT: Be sure to fill the swing motor with
hydraulic oil after installing it. After
completing
installation,
check
hydraulic oil level. Add oil as
necessary. Run the engine and
check the component for any oil
leaks.
W2-6-2
W176-02-06-002

(Blank)
W2-6-3

DISASSEMBLE SWING DEVICE
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
1 - Socket Bolt (12 used)

23456-
Motor
Retaining Ring
First Stage Sun Gear
Pin (3 Used)
Spring Pin (3 Used)
7 - Thrust Plate (6 used)

8 - Needle Bearing (3 Used)
9 - First Stage planetary Gear

(3 used)
10 - Pin (3 Used)
11 - Spring Pin (3 Used)
14 - Second Stage planetary
Gear (3 used)
15 - Bearing Nut
16 - Lock Plate
17 - Bolt (2 Used)
25 - Drain Plug
18 19 20 21 22 -
26 27 28 29 30 -
Thrust Plate (2 used)

Second Stage Carrier
Second Stage Sun Gear
First Stage Carrier
Ring Gear
23 - Roller Bearing
24 - Pipe
W2-6-4
Shaft
O-Ring
Oil Seal
Sleeve
Roller Bearing
31 - Housing

Disassemble Swing Device
CAUTION: Swing device weight:
390 kg (860 lb)
1. Attach a nylon sling to the swing motor so as to
hoist it by crane.
2. Put the swing device on bracket (ST 5100).
Secure it with bolts (M22) (2 used). Secure the
bracket on a working platform.
: 32 mm
CAUTION: Ring gear weight: 34 kg (75 lb)

7. Loosen and remove socket bolt (32). Install eyebolt (M12, pitch 1.75) into the motor mounting
thread position of ring gear (22). Hoist it by crane
to remove the ring gear from housing (31).
: 17 mm
NOTE: THREEBOND has been applied on the joint
surface between housing (31) and ring gear
(22). Insert a screw driver into the gap between the swing motor and ring gear.
Then pry it up for easy removing.
Swing Device
8. Remove second stage sun gear (20) and the

second stage carrier (19) assembly.
ST 5100
W1HH-02-06-011
3. Remove drain plug (25), then drain off oil.

: 8 mm
CAUTION: Housing (31) assembly weight:

200 kg (440 lb)
9. Remove bolt (17). Remove lock plate (16).
: 17 mm
10. Remove nut (15) from shaft (26) using special nut
removing tool (ST 3167).
ST 3167
15
4. Remove pipe (24) from housing (31).

: 18 mm
CAUTION: Motor weight: 71 kg (160 lb)
5. Put matching marks at the jointed portion between
motor (2) and ring gear (22), between ring gear
(22) and housing (31).
Loosen and remove socket bolt (1). Hoist and
remove motor (2) by crane.
: 10 mm
NOTE: Insert the screw driver between motor (2)
and ring gear (22) to float motor (1), and
remove motor (2) easily.
6. Remove first stage sun gear (4) from first stage
carrier (21).
Remove the first stage carrier (21) assembly from
ring gear (22).
: 8 mm
W178-02-06-008
11. Install eyebolt (M20, pitch 2.5) into the bolt (32)
hole of housing (31). Remove bolts (M22) (2
used) with the housing and bracket. Hoist the
housing (31) assembly by crane to remove the
bracket.
12. Put the blocks on the press bench. Put the
housing (31) assembly on the blocks.
31
W1HH-02-06-012
Block
W2-6-5
23
31
30
29
27
26
W1HH-02-06-002
W2-6-6

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

remove shaft (26) with a press. At this time remove the roller bearing (30) inner race and sleeve
(29) with shaft (26).
W157-02-06-010
Bearing Removal
Special Tool Set
14. Remove the roller bearing (23) inner race from

housing (31).
15. Attach shaft (26) assembly to the special tool
bearing removal set.
W157-02-06-011
NOTE: Use the following parts as the special tool

set for removing roller bearing (30).
Hose Clamp
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)
Shaft
Part
Size
Shaft Length: 220 mm
or Bolt (8.7 in)
Diameter: 19 mm
(3/4 in)
W157-02-06-012
Shaft (26)
Roller Bearing (30)
Sleeve (29)
Guide
Hose
Clamp
Shaft
W157-02-06-01
W2-6-7
23
31
21
6
7
8
30
18
29
7
28
19
27
10
11
12
18
13
14
26
13
12
W1HH-02-06-002
W2-6-8

CAUTION: Be sure to use the guide when
pushing shaft (26) with a press.
16. Attach shaft (26) with the special tool to a press.
Then, remove roller bearing (30).
Press
20. Insert a bar at the back side of the outer race of

roller bearing (23). Remove the outer race from
housing (31) by tapping with a bar and hammer.
21. Drive spring pin (6) out of first stage carrier (21)
with a round bar and hammer.
22. Remove pins (5) (3 used), first stage planetary
gears (9) (3 used), thrust plates (7) (6 used), and
needle bearings (8) (3 used) from first stage
carrier (21).
Shaft (26)
Roller
Bearing (30)
23. Remove thrust plates (18) from first stage carrier

(21).
Sleeve (29)
24. Drive spring pin (11) from second stage carrier

(19) with a round bar and hammer.
Guide
W157-02-06-014
17. Remove sleeve (29) from shaft (26). Remove Oring (27) from sleeve (29).
18. Insert a round bar into the oil passage in housing
(31), tap the outer race of roller bearing (30) out.
25. Remove pins (10) (3 used), second stage

planetary gears (14) (3 used), thrust plates (12) (6
used), and needle bearings (13) (6 used) from
second stage carrier (19).
26. Remove thrust plate (18) from second stage
carrier (19).
Oil Passage
Outer Race
W1HH-02-06-007
CAUTION: Housing (31) weight:

104 kg (230 lb)
19. Secure housing (31) body with a nylon sling, hoist
it by crane to turn housing (31) over.
Insert a screw driver into the gap on housing (31)
where oil seal (28) is mounted. Remove oil seal
(28).
NOTE: THREEBOND has been applied on the
periphery of oil seal (28). Thus, it cant be
reused.
W2-6-9

ASSEMBLE SWING DEVICE
3
5
6
1
7
8
9
7
21
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

23456-
Motor
Retaining Ring
First Stage Sun Gear
Pin (3 Used)
Spring Pin (3 Used)

9 - First Stage planetary Gear

(3 used)
10 - Pin (3 Used)
14 - Second Stage planetary
Gear (3 used)
15 - Bearing Nut
16 - Lock Plate
17 - Bolt (2 Used)
25 - Drain Plug
18 19 20 21 22 -
26 27 28 29 30 -
Thrust Plate (2 used)

First Stage Carrier
Ring Gear
23 - Roller Bearing
24 - Pipe
W2-6-10
Shaft
O-Ring
Oil Seal
Sleeve
Roller Bearing
31 - Housing

Assemble Swing Device
1. Install needle bearing (8) in each first stage
planetary gears (9) (3 used).
2. Install thrust plates (18) in first stage carrier (21).
8. Install sleeve (29) and the inner race of roller

bearing (30) into shaft (26). Press sleeve (29) and
inner race using bearing mounting tools (ST 7289)
and (ST 7292).
NOTE: Press-in distance of the bearing inner race
can be assured by using the bearing mounting tool.
3. Install first stage planetary gears (9) (3 used) and

thrust plates (7) (6 used) into first stage carrier
(21).
4. Aligning the hole on pin (5) with spring pin hole on
first stage carrier (21), drive pins (5) (3 used) into
first stage carrier (21) with a hammer.
Press
IMPORTANT: Be sure to drive the spring pin

correctly.
5. Tap spring pin (6) into first stage carrier (21) and
pin (5). At this time, the slit of the spring pin
should face to the end of pin (9).
5
ST 7292
ST 7289
30
29
26
Slit
WIHH-02-06-008
W178-02-06-002
6. Assemble second stage carrier (19), referring to

steps 1 to 5 above. Assemble seond stage
planetary gears (14) (3 used), needle bearings
(13) (6 used), thrust plates (12) (6 used), (18),
pins (10) (3 used), and spring pins (11) (3 used).
7. Install O-ring (27) onto sleeve (29).
CAUTION: Housing weight: 104 kg (230 lb)

9. Secure housing (31) body with a nylon sling, then
hoist it by crane. Place sleeve (29) with the mounting side up.
10. Tap the outer race of roller bearing (30) evenly
with a bar and hammer while installing the outer
race into housing (31). Tap the bearing and listen
to ring to confirm if installation is completed.
W2-6-11
32
15
23
31
26
28
29
T1HH-03-02-001
W2-6-12

11. Apply THREEBOND #1102 on the outer surface
of oil seal (28). Put oil seal (28) flat on housing
(31) and push it in gently. Then place seal
mounting tool (ST 7291) on the oil seal and tap it
in with a hammer directly.
ST 7291
19. Place mounting tool (ST 7290) onto the inner race
of roller bearing (23). Push the inner race down
with a press.
NOTE: Press in distance of the inner race can be
assured by using the mounting tool.
23
28
ST 7291
31
WIHH-02-06-009
WIHH-02-06-010
12. Apply grease to the inner surface of oil seal (28)

all around. Apply grease to the outer surface of
sleeve (29) on shaft (26).
13. Install eye bolt (M20, pitch 2.5) into the bolt (32)
hole in housing (31). Then hoist and place it on
shaft (26) by crane, slowly. Check and align
carefully to protect the oil seal (28) lip from curling
while mounting it.
20. Hoist the housing (31) assembly and place it on

bracket (ST 5100) by crane. Secure it with bolts
(M22) (2 used) while the stopper at the bottom of
bracket is located at the middle of two teeth of the
pinion gear. Secure the bracket on a working
platform.
31
: 32 mm
ST 5100
14. Tap the outer race of roller bearing (23) into housing (31) with a bar and hammer evenly. Listen to
ring to confirm if installation is completed.
15. Tap the inner race of roller bearing (23) into shaft
(26) with a bar and hammer. Tap the inner race
until two threads of shaft nut (15) appear.
16. Screw in nut (15) to shaft (26). Tighten as much
as possible by hand.
NOTE: Prevent shaft (26) from falling down when
hoisting housing (31).
W1HH-02-06-011
IMPORTANT: Pay attention to the direction of the

bearing nut.
21. Apply a little amount of grease on the threaded
surface of nut (15), then install it on shaft (26) with
the stepped side of nut facing roller bearing (23).
Tighten the nut using mounting tool (ST 3167).
: 490 Nm (50 kgfm, 360 lbfft)
CAUTION: Housing + shaft + bearing weight:

193 kg (425 lb)
17. Install eyebolt (M20, pitch 2.5) into the bolt (32)
hole in housing (31). Hoist housing (31) by crane
and place it on a press.
NOTE: Grease must be applied for keeping correct

tightening torque.
ST 3167
15
18. Remove nut (15) from shaft (26).
W178-02-06-008
W2-6-13
4
1
21
32
20
19
22
17
16
15
24
25
31
26
27
T1HH-03-02-001
W2-6-14

22. Install lock plate (16) onto nut (15) with bolt (17).
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
CAUTION: Second stage carrier weight:
42 kg (93 lb)
IMPORTANT: Pay attention to the mounting
direction of the second stage carrier.
23. Install the second stage carrier (19) assembly
onto the spline of shaft (26), while the concave
part of the boss in bottom side of the carrier
comes in contact with lock plate (16).
Concave
IMPORTANT: Pay attention to the mounting

direction of the sun gear.
28. Install first stage sun gear (4) into the first stage
carrier (21) assembly with the stepped side of the
sun gear facing down.
29. Install pipe (24) into housing (31) with the seal
tape wound on the threaded part of pipe (24).
: 18 mm
30. Wind the seal tape on drain plug (25), then install
it into pipe (24).
: 8 mm
: 50 Nm (5 kgfm, 36 Ibfft)
31. Supply gear oil: 16.3 L (4.31 US gal)
32. Apply new THREEBOND #1215 onto the motor
mounting surface of ring gear (22).
19
16
26
CAUTION: Motor weight: 71 kg (160 Ib)

33. Hoist motor (2) by crane. Align the matching
marks, and install it into ring gear (22) with socket
: 10 mm
W178-02-06-014
24. Install second stage sun gear (20) into the second
stage carrier (19) assembly.
25. Clean off old THREEBOND and apply new
THREE-BOND #1215 onto the ring gear (22)
mounting surface of in housing (31).
CAUTION: Ring gear weight: 34 kg (75 lb)
26. Install eyebolt (M12, pitch 1.75) to the motor
mounting threaded hole on ring gear (22). Hoist
the ring gear by crane, to install it on housing (31)
with socket bolts (32) (12 used) while aligning the
matching marks made when disassembling.
: 17 mm
: 390 Nm (40 kgfm)
27. Install the first stage carrier (21) assembly onto
the spline of second stage sun gear (20).
W2-6-15

DISASSEMBLE SWING MOTOR
12
11
10
9
8
7
6
3
2
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 - Perking Brake
Release Valve
4 - Oil Seal
5 - Bearing
6 - Shaft
7 - Shoe Plate
8 - Plunger (9 Used)
9 - Plate
10 - Retainer

18 - Valve Plate
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)
W2-6-16

O-Ring
Plug (2 Used)
Relief Valve (2 Used)

Disassemble Swing Motor
Be sure to thoroughly read Precaution for
Disassembly and Assembly (W1-1-1) carefully
before starting the disassembly work.
8. Remove O-rings (14, 15) from casing (1).

IMPORTANT:
Take care not to damage the slide

surface of rotor (11) and plunger (8).
9. Place casing (1) horizontally. Remove rotor (11),
retainer (10), plate (9) and plungers (8) (9 used)
from shaft (6).
CAUTION: Swing motor assembly weight:

70 kg (155 Ib)
IMPORTANT: Dont disassemble relief valve (29).
1. Remove relief valves (29) (2 used) from valve
casing (25).
: 41 mm
10. Remove plates (13) (4 used), friction plates (12)

(3 used) from casing (1).
2. Remove plugs (21) (2 used) from valve casing

(25).
: 17 mm
IMPORTANT: Take care not to damage the slide

surface of shoe plate (7).
11. Remove shoe plate (7) from casing (1).
3. Remove springs (23) (2 used) and poppets (24)

(2 used) from valve casing (25).
IMPORTANT: When removing shaft (6), the spline

damages the oil seal. Be sure to
wind the tape around the spline of
shaft (6) before removing.
12. Tap shaft (6) with a plastic hammer lightly to
remove it from casing (1).

parking brake release valve (2) from casing (1).
5. Make matching marks at the mounting surface
between valve casing (25) and casing (1). Then
loosen socket bolts (26) (4 used). Remove valve
casing (25) from casing (1).
: 17 mm
NOTE: Pay attention that valve casing (25) is
floated by spring (17). Pay attention to
valve plate (18) when removing valve
casing (25). It has a tendency to fall.
IMPORTANT: Be sure not to damage the mating
surface when separating valve plate
(18) from valve casing (25) or rotor
(11) with a screw driver.
13. Push out oil seal (4) from casing (1).

14. Remove the outer race of bearing (5) from casing
(1) with a bar and plastic hammer.
15. Remove the inner race of bearing (5) from shaft
(6) with a press.
16. Remove bearing (19) from valve casing (25) with
a bearing puller.
6. If valve plate (18) is still attached with rotor (11) in

step 5, remove the valve plate from the rotor.
Remove springs (17) (24 used).
7. Attach the special tool (ST 7288) onto the brake
piston (16) groove and hoist brake piston (16).
26
ST 7288
16
W1HH-02-06-006
W2-6-17

ASSEMBLE SWING MOTOR
24
23
22
21
26
28
27
T1HH-03-02-003
25
29
17
16
15
19
14
20
18
12
3
13
8
10
11
6
T1HH-03-02-002
1 - Casing
2 - Perking Brake
Release Valve
4 - Oil Seal
5 - Bearing
6 - Shaft
7 - Shoe Plate
8 - Plunger (9 Used)
9 - Plate
10 - Retainer

18 - Valve Plate
25 - Valve Casing
11 12 13 14 15 16 -
19 20 21 22 23 -
26 27 28 29 -
Rotor
Plate (4 Used)
O-Ring
O-Ring
Brake Piston
Bearing
O-Ring
Plug (2 Used)
O-Ring
Spring (2 Used)
W2-6-18

O-Ring
Plug (2 Used)
Relief Valve (2 Used)

Assemble Swing Motor
11. Install brake piston (16) into casing (1).
IMPORTANT: Be sure to place the inner race
flange of bearing (5) facing the
stepped side of shaft (6).
1. Push the inner races of bearings (5), (19) into
shaft (6) with a press.
IMPORTANT: Push oil seal (4) in, with its lip facing
the bearing (5) mounting side.
2. Push oil seal (4) into casing (1) with a guide plate.
3. Install the outer race of bearing (5) into casing (1)
with a guide bar.
IMPORTANT: Wind the tape on the spline at the
end of shaft (6) to prevent damaging
oil seal (4).
4. Place casing (1) horizontally. Install shaft (6) into
casing (1).
5. Place casing (1) with the valve casing (25)
mounting side up. Then install shoe plate (7).
6. Assemble plate (9) and retainer (10) with the
notch matched. Then install plungers (8) (9 used).
IMPORTANT: Apply hydraulic oil into the plunger
hole in rotor (11), then install plunger
(8).
7. Insert the plunger (8) assembly into rotor (11).
8. Place casing (1) horizontally. Install the rotor (11)
assembly onto shaft (6).
IMPORTANT: 4 notches are on the outer side of
plate (13). And 4 notches are at the
spline teeth side of friction plate (12).
Be sure to align each notch at the
same place when installing.
9. Place casing (1) vertically. Alternately install plates
(13) (4 used), friction plates (12) (3 used) into
casing (1).
NOTE: If it is not easy to install O-rings (14), (15)

into brake piston (16) due to the resistant
force from the O-rings, tap them evenly with
a plastic hammer to force them in.
12. Install springs (17) (24 used) onto brake piston
(16).
IMPORTANT: Tap the bearing type indicated
surface with a plastic hammer while
installing bearing (19).
13. Tap the outer race of bearing (19) with a plastic
hammer while installing it into valve casing (25).
14. Install O-ring (20) onto valve casing (25). Then
install valve plate (18).
NOTE: Apply grease onto valve plate (18) to avoid
it coming off from valve casing (25).
15. Align the mating marks on valve casing (25) and
casing (1). Secure them with socket bolts (26) (4
used).
: 17 mm
: 431 Nm (44 kgfm, 320 lbfft)
16. Install poppets (24) (2 used) and springs (23) ( 2
used) into valve casing (25). Tighten plug (21)
with O-ring (22) attached.
: 17 mm
: 539 Nm (55 kgfm, 400 lbfft)
17. Install relief valves (29) (2 used) into valve casing
(25).
: 41 mm
: 177 Nm (18 kgfm, 130 lbfft)
18. Install parking brake release valve (2) into casing
(1) with socket bolts (3) (3 used).
: 5 mm
: 12 Nm (1.2 kgfm, 8.68 lbfft)
10. Install O-rings (14) and (15) onto casing (1).

NOTE: Apply grease to O-rings (14) and (15), and
they are not broken easily when installing
brake piston (16).
W2-6-19

DISASSEMBLE AND ASSEMBLE
PARKING BRAKE RELEASE VALVE
W110-02-06-005
1234-
Casing
Spool
Spring
Plunger
5 - Bushing
6 - Filter
7 - Spacer
8 - Orifice
9 - Spring
10 - O-Ring
W2-6-20
11 - O-Ring (2 used)
12 - Steel Ball
13 - Bolt (3 used)

Swing Motor
d
1. Clearance between the out diameter of plunger

and the inner bore of cylinder.
D-d
Standard
0.028 (0.001)
Unit:m (in)
Allowable Limit
0.058 (0.002)
W107-02-06-138
W107-02-06-139
2. Clearance between plunger and shoe at the

caulked position.
Unit: mm (in)
Standard
Allowable Limit
0 (0)
0.3 mm (0.0118)
W107-02-06-140
W107-02-06-141
W2-6-21

3. Thickness of shoe
t
Standard
5.5 (0.22)
Unit: mm (in)
Allowable Limit
5.3 (0.21)
4. Thickness of friction plate.

t
Unit: mm (in)
Standard
Allowable Limit
2.0 (0.08)
1.8 (0.07)
W107-02-06-142
W107-02-06-143
W2-6-22
UPPERSTRUCTURE / Pilot Valve

REMOVE AND INSTALL RIGHT PILOT
VALVE
may penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure
pressure.
Preparation
pressure.
M104-07-021
Removal
1. Remove seat mounting bolts (2) (4 used) to remove seat (1) (with seat stand).
: 17 mm
2
1
W178-02-07-006
W2-7-1

2. Remove screws (24) (4 used), cover (23) to move
boot (29) up.
: 17 mm
30
3
29
3. Remove caps (17) (2 used) from cover (18).
28
4. Remove screws (21)(4 used) and (16) (2 used) to

move cover (18) up. Disconnect each harness
connectors for key switch (20), air controller (19)
and grip (3), then remove cover (18). Remove
screws (22), (15) and (13) to remove cover (14).
26
25
6
7
8
10
24
23
21
20
19
18
5. Remove the connector and bolt (11) for switch box

(12) to remove switch box (12).
: 13 mm
IMPORTANT: Attach identification tags on all
disconnected hoses to aid in reassembly.
27
9
11
12
22
17
16
6. Disconnect hoses (31 to 36).

: 19 mm
NOTE: Attach a cap on all disconnected hose
ends.
15
14
13
7. Loosen nut (4) to remove grips (5) and (26). Disconnect connector (6) to remove grip (3) (with
harness).
Loosen nut (28) to remove lever (30), washers
(25), (26) and boot (29).
: 22 mm
: 19 mm
W178-02-07-001
35
36
31
32
33
8. Remove bolts (9) (3 used) and (8) (with pin (7))

from pilot valve (10) to remove pilot valve (10).
: 13 mm
34
W178-02-07-002
31 32 33 34 35 36 -
Hose T6: (To the pilot shut-off valve)

Hose B: (To the shockless valve port B for boom lower)
Hose G: (To shockless valve port G for bucket roll-in)
Hose P3: (From the pilot shut-off valve)
Hose A: (To the shockless valve port A for boom raise)
Hose H: (To the shockless valve port H for bucket roll-out)
NOTE: Piping location shows that of JIS pattern.
W2-7-2

Installation
1. Secure pilot valve (10) with bolts (9) and (8) (with
pin (7)).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 Ibfft)
35
2. Connect hoses (31 to 36).

: 19 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
31
32
36
33
34
IMPORTANT: If the harness is arranged to the inside

of spring pin (7), it may make contact
with the moving part of the pilot
valve which may damage the harness .
Be sure to arrange the harness to
the outside of spring pin (7).
W178-02-07-002
30
3. Temporarily tighten nut (28) to lever (30), then install washers (25), (26). Install lever (30) onto
valve (10) with nut (28). Install boot (29).
Temporarily tighten nut (4) to lever (30), then install grip (3) with nut (4).
Pass the harness of grip (3) through the upper
hole of boot (29), then connect it to lever (30) via
clips (5) and (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)
4. Install switch box (12) with bolt (11), then connect
the connector.
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 Ibfft)
5. Connect each harness of key switch (20) and air
controller (19).
6. Install cover (14) with screws (22), (15) and (13).
Install cover (18) with screws (21) (4 used) and
(16) (2 used).
Install caps (17) (2 used) onto cover (18).
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
7. Install cover (23) with screw (24).
W2-7-3

8. Install seat (1) (with the seat stand) with bolts
(2) (4 used).
: 17 mm
IMPORTANT: After installation, check the oil level,
start the engine and check for oil
leaks.
2
1
W178-02-07-006
W2-7-4

REMOVE
VALVE
AND
INSTALL
LEFT
PILOT

before disconnecting hydraulic or other
lines.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
2. Stop the engine. Push the air release valve on the
hydraulic oil tank to release any pressure remaining in the hydraulic tank.
M104-07-021
Removal
1. The console is at the most front position. Remove
screws (2) (4 used) and cover (3) to move boot (1)
up.
: 17 mm
2. Remove screws (7), (8) to remove cover (9).

3. Remove cap (10) from cover (6).
10
4. Remove screws (4) (3 used), (5) to move cover

(6) up to disconnect the radio connector, then remove cover (6).
Radio
2
3
4
5
W178-02-07-003
W2-7-5

5. Disconnect hoses (11 to 16).
: 19 mm
15
NOTE: Attach a cap on each disconnected hose

end.
11
12
16
13
14
6. Loosen nut (18) to remove clips (29), (21).

Disconnect connector (28) to remove grip (17)
(with harness).
Loosen nut (20) to remove lever (19), washers
(25), (26) and boot (1).
: 22 mm
: 19 mm
7. Remove bolts (24) and (23) (with pin (22)) to
remove pilot valve (27).
: 13 mm
W178-02-07-004
11 12 13 14 15 16 -
Hose T5 : (To the pilot shut-off valve)

Hose F : (To the shockless valve port F for swing right)
Hose C : (To the shockless valve port C for arm roll-out)
Hose P2 : (From the pilot shut-off valve)
Hose E : (To the shockless valve port for E swing left)
Hose D : (To the shockless valve port D for arm roll-in)
NOTE: Piping location shows that of JIS pattern.

Installation
1. Install pilot valve (27) with bolts (24) and (23) (with
pin (22)).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 Ibfft)
2. Connect hoses (11 to 16).
: 19 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
17
29
18
19
28
1
20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6

IMPORTANT: If the harness is arranged to the inside of spring pin (21), it may make
contact with the moving part of the
pilot valve which may damage the
harness. Be sure to arrange harness
to the outside of spring pin (21).
3. Temporarily tighten nut (20) to lever (19), then
install washers (25) and (26). Install lever (19)
onto pilot valve (27) with nut (20). Install boot (1).
Temporarily tighten nut (18) to lever (19), then secure grip (17) with nut (18).
Pass the harness of grip (17) through the upper
hole of boot (1), then connect it to lever (19) via
grips (29). Arrange the harness to the outside of
spring pin (22) over bolt (23) head. Connect connector (28).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 lbfft)
: 22 mm
: 26 Nm (2.0 kgfm, 14 lbfft)
: 19 mm
: 26 Nm (2.0 kgfm, 14 lbfft)
17
29
28
10
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
W2-7-7
20
21
22
23
24
25
26
27
2
3
4
5
4. Connect the connector of the radio and install

cover (6) with screws (4) (4 used) and (5), install
cap (10).
Install cover (9) with screws (7), (8).
5. Install boot (1) and cover (3) with screw (2) (4 used).
18
19
W178-02-07-003

REMOVE AND INSTALL TRAVEL PILOT
VALVE
lines.
Preparation
M104-07-021
W2-7-8

Removal
1. Remove floor mat (1).
2. Remove bolts (3) (6 used) from swing frame to
remove under cover (2).
: 17 mm
3. Loosen bolts (4) (2 used) to remove pedals (5) (2

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

4. Disconnect pipes (6, 7) and hoses (8 to 11).
: 19 mm
2
3
NOTE: Attach a cap on each disconnected hose

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

plain washer (12) to remove pilot valve (15).
: 8 mm
Installation
1. Install pilot valve (15) with socket bolt (14), spring
washer (13) and plain washer (12).
: 8 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
17
16
2. Connect pipes (6, 7), hoses (8 to 11).

: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 Ibfft)
5
15
14
14
13
13
3. Install pedal (5), levers (16) and (17) with bolts (4).
: 17 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
12
12
4. Install under cover (2) with bolts (3) (6 used).

: 17 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
11
5. Install floor mat (1).

leaks.
10
W178-02-07-005
6 - Pipe T4: (To the pilot shut-off valve)

7 - Pipe P1: (From the pilot shut-off valve)
8 - Hose 11: (To the control valve port RF for travel right
and forward)
9 - Hose 12: (To the control valve port RR for travel right
and reverse)
10 - Hose 10: (To the control valve port LR for travel left
and reverse)
11 - Hose 9: (To the control valve port LF for travel left
and forward)
W2-7-9

DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
16
20
21
20
19
18
4
1
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 -

Push Rod A (2 Used)
Push Rod B (2 Used)
Block
12 13 14 15 16 -
Cam
Screw Joint
Universal Joint
Oil Seal (4 Used)
Spring Guide (4 Used)
W2-7-10
17 18 19 20 21 -
Spool (4 Used)
Housing
O-Ring
Dowel Pin (2 Used)
O-Ring (2 Used)

Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are
made of aluminium. Too strong a
force can deform, or damage, them.
Therefore, be careful while handling
them.
IMPORTANT: As spool (17) has been selected to
match the hole of housing (18), they
must be replaced as a set. In addition, the dimensions of balance
springs A (3), B (4) and return
springs A (5), B (6) as well as those
of push rods A (8), B (9) are different.
For this reason, be sure to indicate
the port number from which it is removed. Port numbers are stamped
on housing (18).
IMPORTANT: Dont clamp housing (18) in a vise to
remove the screw joint because the
strong torque may act on the screw
joint.
IMPORTANT: Two kinds of push rods are used.

They must be handled in order of
port number after removing.
4. Pull push rods (8), (9) out from block (10).
5. With a bamboo spatula, remove oil seals (15) (4
used) from block (10).
NOTE: If a metal bar is used, the mating part of the
oil seal may be damaged.
IMPORTANT: The retaining ring may come off
while disassembling. Take care not
to drop it.
6. Press springs with special tool (ST 7257) from the
top of spring guide (16). Retaining ring (7) will appear. Remove it with a screw driver or similar tool.
(4 places)
7
1. Secure screw joint (13) in a vise. Then turn cam

(12) with a spanner to remove the screw joint.
: 32 mm
2. Clamp the flat surface of housing (18) in a vise
slightly. Remove cam (12) from universal joint
(14).
: 32 mm
16
ST 7257
NOTE: The universal joint has been secured on

block (10) with LOCTITE. Dont remove it
unless necessary.
3. Remove socket bolt (11) to remove block (10). At
this time, push rods (8) and (9) are still on the
block side.
: 6 mm
W176-02-07-005
IMPORTANT: The number of shims has been determined for each port during the
performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when reassembly.
7. Remove spring guide (16), balance springs (3),
(4), return springs (5), (6), shim (2), spacer (1)
from spool (17).
W2-7-11
21
20
21
20
19
18
17
W176-02-07-001
W2-7-12

IMPORTANT: As the spool has been selected to
match the hole in the housing, keep
them carefully so as to install them
to the former port when reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it.
NOTE: The spool and housing must be replaced as
assembly.
9. Remove O-rings (19), (21) from housing (18).
Dont remove dowel pin (20) unless necessary.
W2-7-13

ASSEMBLE RIGHT AND LEFT PILOT
VALVES
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

Push Rod A (2 Used)
Push Rod B (2 Used)
Block
18
12 13 14 15 16 -
Cam
Screw Joint
Universal Joint
Oil Seal (4 Used)
W2-7-14
17 18 19 20 21 -
Spool (4 Used)
Housing
O-Ring
Dowel Pin (2 Used)
O-Ring (2 Used)

Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to
contamination.
Keep parts clean when assembling.
NOTE: Table below shows the relations between
each port and the components. Take care
not to confuse them when assembling.
Port
No.
1
2
Spool
(17)
Shim
(2)
3. Install spring guide (16) onto the return spring (3)

or (4).
4. Install retaining ring (7) onto ring holder (ST
7255).
Push Rods
(8), (9)
Same to Same to
the former the former
one
one
IIMPORTANT: Install spring guide with the protrusion facing up.
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
Short
Long
Short
Long
Short
Long
Short
Long
ST 7255
W176-02-07-008
5. Insert the spool (17) head into the hole for spring
special tool (ST 7257) to press the spring from the
top of spring guide (16). Install retaining ring (7)
with the ring holder (ST 7255) onto the head of the
spool.
ST 7255
ST 7257
17
Packing Material
IMPORTANT: Make sure of the port hole number,

and insert the spool to the former
port.
W176-02-07-009
NOTE: Put approx. dia.8 mm, length 10 mm of

packing material into the port hole so as to
not only make the work easy to do, but also
prevent the spool from lowering to the bottom when compressing the spring.
1. Insert the thinner end of spool (17) to housing (18),

while rotating it.
NOTE: The spool has been selected to match the
hole of the housing. The spool and housing
must be replaced as an assembly.
IMPORTANT: Refer to the table above to assemble
them correctly.
6. Assemble the remained spools (17) (3 used) into

housing (18) in the same procedures as step 2 to
5.
7. Install O-rings (19) and (21) (2 used) on to housing (18).
2. Install spacer (1), shim (2), balance spring (3) or

(4), return spring (5) or (6) onto spool (17) installed in housing (18).
W2-7-15
13
14
10
12
15
11
8, 9
W176-02-07-006
20
W2-7-16
18

8. Apply grease to the inner face of oil seals (15)
(4 used), then install the oil seals (4 used) into
block (10) with a bamboo spatula.
NOTE: The oil seal may come into the endmost of
the hole during operating. Insert push rods
(8 and 9) in first as illustrated to prevent the
oil seal from coming into the endmost of the
hole during operating.
Oil Seal
Mounting Hole
10
8,9
IMPORTANT: Make sure of the tightness of cam.

13. Clamp housing (18) carefully in a vise and then
install cam (12) to universal joint (14).
Tighten the universal joint so that the clearance
between the cam and push rod (8) (9) become 0
to 0.2 mm.
: 32 mm
IMPORTANT: Dont clamp housing (18) in a vise
because the strong torque may act
on the screw joint.
14. Clamp screw joint (13) in a vise to tighten universal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 88.2 Nm (9 kgfm, 65 Ibfft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods (8), (9) to block (10). When installing, install the push rods with periphery
groove to ports # 1 and # 3, install the ones without periphery groove to ports # 2 and # 4, respectively.
10. Apply grease to the ball at the ends of push rods
(8), (9).
11. Apply grease to the joint part of universal joint
(14).
12. Align the position of dowel pin (20), install the
block (10) assembly to housing (18) with socket
: 6 mm
: 19.6 Nm (2 kgfm, 14.5 Ibfft)
W2-7-17

DISASSEMBLE TRAVEL PILOT VALVE
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)
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)
Pusher (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Bracket (2 Used)
Spring Pin (2 Used)
W2-7-18
28 29 30 31 32 33 34 35 -

Adjusting Bolt (4 Used)
Bushing (4 Used)
Cam (2 Used)
Lock Nut (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)

Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolt (1) to
remove cover (2) from holder (10).
: 10 mm
2. Remove socket bolts (8) (2 places) to remove
holder (10) from casing (14).
: 8 mm
3. Pull out pusher (23) from casing (14). (4 places)
Bushing (13) and oil seal (11) are removed with
the pusher.
4. Pull out pusher (23) from bushing (13), with a
bamboo spatula to remove oil seal (11). (4 places)
IMPORTANT: Put marks on spools (4 used) so as
to easily install them to their former
position.
5. Pull out the spool (17) assembly from casing (14)
turning the spool. (4 places)
Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with the spool.
7. Remove spring (18) from casing (14). (4 places)

IMPORTANT: Put a stand under bracket (26) to
form an action force. If holder (10)
bears the reaction force, a strong
force acts on pin (3) and the pins
shape become deformed.
IMPORTANT: The inside of spring pins (24), (25)
hole in the bracket is in steppedshape. Therefore the spring pin can
only be pulled out in one direction.
8. Put a stand under bracket (26).
Push out both spring pins (24), (25) from bracket
(26) at the same time with special tool (ST 1237).
Remove the bracket from pin (3). (2 places)
Dont remove spring pin (27) on bracket unless
necessary.
NOTE: The outside end of the spring pin has been
caulked.
NOTE: The spool has been selected to match the

hole of the casing. The spool and casing
must be replaced as an assembly.
24,25
26
3
IMPORTANT: The number of shims has been

determined during the performance
testing at the factory. They must be
kept together with their spool.
27
Caulked
Stand
6. Compress balance spring (21). Remove spring

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

damper (6) and rubber seat (7) from pin (3). Oring (4) is removed with them. (2 places)
: 5 mm
W2-7-19
35
34
33
32
31
30
3
5
10
14
W176-02-07-002
W2-7-20

10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mating surface facing up.
IMPORTANT: The holes for spring pins (34), (35) in
cam (32) are stepped-shape. Therefore the pins shall be removed from
the bottom of the cam.
12. Pull out spring both pins (34), (35) from cam (32)
at the same time with special puller (ST 1237).
(2 places)
NOTE: The spring pin is a double-pin.
NOTE: The spring pin is caulked in its hole, so it
may feel tight when removing.
13. Remove pin (3) with a round bar and a hammer.
At this time cam (32) is also removed. (2 places)
NOTE: Dont remove bushings (31) (4 used) left on
holder (10) unless necessary. When removal is necessary, the bushing special
tool (ST 7256) should be used to tap it out.
14. Remove lock nuts (33) (2 used) from cam (32) to
remove adjusting bolts (30) (2 used). (2 places)
: 13 mm
: 4 mm
W2-7-21

ASSEMBLE TRAVEL PILOT VALVE
26
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)
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)
Pusher (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Bracket (2 Used)
Spring Pin (2 Used)
W2-7-22
28 29 30 31 32 33 34 35 -

Adjusting Bolt (4 Used)
Bushing (4 Used)
Cam (2 Used)
Lock Nut (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)

Assemble Travel Pilot Valve
IMPORTANT: Pay attention to the mounting direction of spring guide (22).
6. If bushing (31) has been removed from holder

(10), it shall be installed on the holder using special tool (ST 7256) in the following procedures.
IMPORTANT: Install the former number of shims.

NOTE: The bushings (4 used) are identical.
1. Assemble the spool (17) into assembly. (4 used)
y Insert spacer (19), shim (20), balance spring
(21) into the spool in order.
y Press balance spring by hand. Install spring
guide (22) to the spool with the stepped-end
facing down.
y Insert the bushing into special tool (ST 7256),

then tap on the special tool (ST 7256) to install
the bushing into the hole of holder with
hammer.
Stop tapping when the bushing end is flush
with the inside wall .
ST 7256
10
2. Insert spring (18) to casing (14). (4 places)

IMPORTANT: Insert the spool (17) assembly into
the former port.
3. Turn and install the spool (17) assembly into casing (14). (4 places)
31
W176-02-07-016
y Install the bushing on the opposite side in the

same procedure.
31
4. Assemble plungers (23) (4 used).

y Install oil seal (11) onto bushing (13).
y Apply grease to the inner face of oil seal.
y Install O-ring (12) to the bushing.
y Insert pusher (23) to the bushing.
y Apply grease to the pusher head section.
ST 7256
10
W176-02-07-015
5. Insert the pusher (23) assembly to holder (10). (4

places).
y Install the bushing in near side as shown

bellow. Stop tapping when the bushing end is
flush with the outside of holder.
31
10
ST 7256
Outside of
Holder
W176-02-07-014
y Install the bushing on the opposite side as

31
shown below.
ST 7256
10
W176-02-07-013
W2-7-23
10
32
30
33
34, 35
23
14
W176-02-07-010
W2-7-24

7. Place adjusting bolt (30) to cam (32). Tighten the
bolt by hand, and then lightly secure it temporarily
with lock nut (33). (2 places)
NOTE: Adjust the dimensions later.
8. Apply grease on the head (mating surface for
pusher (23)) of adjusting bolts (30). (2 places)
9. Install O-ring (5) to pin (3), then assemble the pin

to holder (10) with cam (32). (2 places)
IMPORTANT: Take care of the inserting direction
of the spring pin.
IMPORTANT: Tap the spring pin in until it makes
contact with the step in hole.
10. Install spring pins (34), (35) to cam (32) using
special tool (ST 1237), then secure the cam and
pin (3). The spring pins should be displaced with
their slits at 90. (2 places)
34
35
Slit
Slit
IMPORTANT: Dont adjust the adjusting bolt (30)

while pressing the pusher (23) head
with the adjusting bolt. The standard
clearance between the adjusting bolt
and pusher must be 0 to 0.2 mm (0 to
0.008 in).
13. Adjust adjusting bolt (30) by the following procedures. (2 places)
: 13 mm
: 4 mm
y Loosen lock nut (33).
y Move cam (32) to check whether there is play. If
none, turn adjusting bolt to adjust.
y Turn both adjusting bolts on the left and right
alternatively to keep the cam horizontal.
y Measure sizes A and B from both left and right
caves on the cam to holder (10). Fine adjust the
adjusting bolt to get same distance for both left
and right.
y Secure the adjusting bolt with a hexagonheaded wrench. Tighten the lock nut to
specified torque first, securing the adjusting
bolt.
y When adjustment is finished, move cam to
check that there is a little play. If there is no play,
the pusher may be in compressed condition,
and adjustment should be carried out again.
: 9.8 N]m(1 kgf]m, 7.2 Ibfft)
30
33
32
10
W176-02-07-017
11. Caulk the hole edge of cam (32), where spring

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

and install it with socket bolts (8) (2 used), spring
washers (9) (2 used).
: 8 mm
: 49 N]m (5 kgf]m, 36 Ibfft)
W176-02-07-003
W2-7-25
26
25 27
24
10
4
28
29
W176-02-07-010
W2-7-26

IMPORTANT: Place a stand under the bracket. If
holder (10) bears the reaction force,
a strong force acts on the pin (3) and
the pin may be deformed.
14. Install rubber seat (7) to pin (3). (2 places)

15. Apply grease to O-ring (5). (2 places)
IMPORTANT: Pay attention to the direction of
damper (6).
IMPORTANT: The inner bore of damper (6) is
edged-shape. If the damper is pried
upward, O-ring (5) will be damaged.
16. With the lever upward, install damper (6) to pin (3)
straight without spring. (2 places)
17. Secure damper (6) to holder (10) with socket bolts
(28) (2 used) and spring washers (29) (2 used). (2
places)
: 8 mm
: 7 Nm (0.7kgfm, 5.1 Ibfft)
IMPORTANT: The inside of the spring pin hole in

the bracket is stepped-shape. Make
sure of the direction to insert the
spring pin.
IMPORTANT: Make sure the facing direction of the
spring pin.
20. Put a stand under bracket (26).
Tap spring pins (24) (25) into the bracket until the
spring pin comes to the stepped end using special
tool (ST 1237). The spring pins shall be displaced
with their slits in 90.
Caulked Here
18. Apply grease to O-ring (4), then press it to the

endmost of pin (3). (2 places)
26
IMPORTANT: As for the direction to install the

bracket, refer to the figure in the disassemble section. Take care not to
misassemble it.
Stand
Caulked Here
24, 25
W176-02-07-011
19. Install pin (3) into bracket (26), then align the inserting holes of spring pin (24), (25) to fix the pin
on bracket.
21. Caulk the hole edge of bracket (26), where spring

pins (24), (25) are inserted, with a punch. (2
places)
(Refer to the figure above.)
22. Install pin (3) on other bracket (26) as steps 19 to
21.
23. Install cover (2) to holder (10) with bolts (1) (2 used).
: 10 mm
: 5 N]m (0.5 kgfm, 3.6 Ibfft)
24. Apply grease to the spring pin (27) contact part of
damper (6). (2 places)
W2-7-27

(Blank)
W2-7-28
UPPERSTRUCTURE / Pilot Shut-Off Valve

REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
Preparation
pressure.

W2-8-1
M104-07-021

Removal
1. Remove spring (3).
IMPORTANT: Attach tags to hoses to aid in assembly.
2. Disconnect hoses (6 to 13) and pipes (14, 15).
: 19 mm
3. Remove spring pin (5) to remove lever (1).
2
3
5
4. Remove bolt (2) to remove pilot shut-off valve (4).

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

View A
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)
Remark
Bolt
Pipe
Hose
10
Hose DP: (To the solenoid valve unit (hydraulic oil tank)
Hose PF: (To the solenoid valve unit)
Hose: (To the shockless valve)
Hose PD: (To the pilot filter)
Hose T6: (To the right pilot valve)
Hose P2: (To the left pilot valve)
Hose T5: (To the left pilot valve)
Hose P3: (To the right pilot valve)
Hose P1: (To the travel pilot valve)
Hose T4: (To the travel pilot valve)
7
8
WIHH-02-08-001
14
View A
15
W2-8-2
12
13
11
WIHH-02-08-002

(Blank)
W2-8-3

DISASSEMBLE PILOT SHUT-OFF VALVE
5
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

Disassemble Pilot Shut-Off Valve
Be sure to thoroughly read all Precautions for
Disassembly / Assembly work on page W1-1-1
1. Make matching marks on body (4) and bracket
(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove spool (10) assembly.
2. Remove washer (1), backup ring (2) and O-ring
(3) from body (4).
3. Clamp the spool (10) with wooden pieces in a vise.
Remove socket bolt (13) and bracket (11).
: 4 mm
NOTE: Dont remove pin (12) unless necessary.
4. Remove socket bolt (5) from body (4).
: 8 mm
W2-8-5

ASSEMBLE PILOT SHUT-OFF VALVE
12 13 11
Section ZZ
10
W178-02-08-006
1 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

Assemble Pilot Shut-Off Valve
1. Apply LOCTITE # 262 on socket bolt (5) and install it to body (4).
: 8 mm
: 29.4 Nm (3.0 kgfm, 21.5 lbfft)
2. Clamp spool (10) with wooden pieces in a vise.
Apply LOCTITE #262 on socket bolt (13), then install bracket (11) onto spool (10).
: 4 mm
: 3.9 Nm (0.4 kgfm, 2.9 lbfft)
3. Install O-ring (3), backup ring (2) and washer (1)
onto body (4).
4. Apply hydraulic oil to spool (10) and install it to
body (4).
5. Install O-ring (9), backup ring (8) and washer (7)
to body (4), and install retaining ring (6) to spool
(10).
W2-8-7

(Blank)
W2-8-8
UPPERSTRUCTURE / Shockless Valve

REMOVE
VALVE
AND
INSTALL
SHOCKLESS

can penetrate the skin, causing serious
injury.
Avoid this hazard by relieving pressure
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
pressure.
Preparation
pressure.
pump to maintain negative pressure in the
hydraulic oil tank.
NOTE: Be sure to run the vacuum pump
continuously while working on the hydraulic
system.
W2-9-1
M104-07-021

Removal
14
IMPORTANT: Attach identication tags to all disconnected hoses to aid in assembly.
15 16
17 18 19
13
1. Disconnect hoses (1 to 9, 13 to 20).

: 19, 22 mm
20
2. Remove pressure sensors (11), (12) and (21).

: 24 mm
21
12
11
3. Remove bolts (10) to remove the shockless valve.

: 17 mm
Installation
1
10
1. Apply LOCTITE to bolts (10), then install

shockless valve with bolts (10).
8B
8A
2. Install pressure switch (11) and pressure sensor

(12) (21).
3. Connect hoses (1 to 9, 13 to 20).
Wrench Size
(mm)
: 17
: 19
: 22
:
24
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
2
W173-02-09-001
1 - Hose (To right swing control valve)

2 - Hose (To left swing control valve)
3 - Hose (To bucket roll-in control valve)
4 - Hose (To bucket roll-out control valve)
5 - Hose (To boom lower control valve)
6 - Hose (To boom raise control valve)
7 - Hose (To arm roll-in control valve)
8 A - Hose (To arm roll-out control valve)
8 B - Hose (To arm roll-out control valve)
9 - Hose (From pilot shut-off valve)
10 - Bolt
11 - Pressure Sensor (For boom raise)
12 - Pressure Sensor (For arm roll-in)
13 - Hose (From arm roll-in pilot valve)
14 - Hose (From arm roll-out pilot valve)
15 - Hose (From boom lower pilot valve)
16 - Hose (From boom raise pilot valve)
17 - Hose (From bucket roll-in pilot valve)
18 - Hose (From bucket roll-out pilot valve)
19 - Hose (From right swing pilot valve)
20 - Hose (From left swing pilot valve)
21 - Pressure Sensor (For swing)
W2-9-2

(Blank)
W2-9-3

DISASSEMBLE AND ASSEMBLE
SHOCKLESS VALVE
18
17
16
14
15
C
A
E
Section S
14
Section T
1
15
1
S2
S4
S7
7
6
Section U
14
S3
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
W2-9-4
WIHH-02-09-001
ITEM
PART NAME
QTY
3
WRENCH SIZE
(mm)
TORQUE SPECIFICATION
Nm
(kgfm)
(lbfft)
49
(5)
(36.2)
Plug
O-Ring
Steel Ball
Steel Ball
Spring
O-Ring
Plug
14.7
(1.5)
(10.8)
Orifice
14.7
(1.5)
(10.8)
Orifice
10
Ring
11
Orifice
12
Plunger
24.5
(2.5)
(18.1)
9.8
(1.0)
(7.2)
49
(5)
(36.2)
13
Plunger Assembly
14
O-Ring
15
Plug
16
Body
17
Seat
18
Steel Ball
19
Plug
W2-9-5
REMARK
Use LOCTITE #262

(Blank)
W2-9-6
UPPERSTRUCTURE / Solenoid Valve

REMOVE AND INSTALL SOLENOID VALVE
UNIT
CAUTION: Escaping fluid under pressure may
penetrate the skin, causing serious injury.
Preparation
pressure.

M104-07-021
W2-10-1

2
Removal
1. Disconnect each harnesses of solenoid valves
from connectors.
2. Disconnect pilot lines (1 to 6, 11 to 18, 20 to 23,

25 and 27).
: 17, 19, 27 mm
4
5
10
1
3. Remove bolts (7) (19) to remove solenoid valve

unit.
: 6, 8 mm
View A
16
15
14
13
12
11
17
Installation
1. Install solenoid valve unit with bolts (7) (19).
WIHH-02-10-001
2. Connect pilot lines (1 to 6, 11 to 18, 20 to 23, 25

and 27).
20
21
3. Connect all wire harnesses for solenoid valves to

connectors.
22
Wrench Size
(mm)
: 17
: 19
: 27
:6
:8
Tight 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
23
18
19
24
25
26
27
WIHH-02-10-002
1 - Pipe PF: From Pilot shutoff valve
8 - Proportional solenoid valve

(SG)
2 - Pipe SC: To arm

regenerative
valve
3 - Pipe SG: To main
relief valve
4 - Hose SI: To
travel motor

(SI)
5 - Hose DS: To hydraulic oil

tank
6 - Hose DP: From pilot shutoff valve
7 - Socket bolt

(SC)
11 - Pipe DD: From arm
regenerative
valve
12 - Pipe PE: To pump
control valve
(4-spool section)
13 - Pipe DE: From bucket
flow rate control
valve switch
valve B
14 - Pipe DH: From bucket
flow rate control
valve switch
valve A
15 - Pipe PH: To pump control

valve
(5-spool section)
16 - Hose PG: To swing
parking brake
control valve
17 - Hose DG: From arm
anti-drift valve
18 - Hose ST: To main pump 1
22 - Hose PI: To control valve
23 - Hose TA: To hydraulic oil

tank
24 - Torque control solenoid
valve
25 - Hose DI: To hydraulic oil
tank
19 - Socket bolt
26 - Maximum pump 2 flow rate

limit solenoid valve
20 - Hose SB: To main pump 2
27 - Hose SP: To pump control

valve
(5-spool section)
21 - Hose PD: To pilot shut-off

valve
W2-10-2

(Blank)
W2-10-3

DISASSEMBLE PROPORTIONAL
SOLENOID VALVES (SC, SI and SG)
1
2
3
4
5
6
7
8
9
10
11
14
12
13
15
16
17
18
19
WIHH-02-10-005
12345-

Lock Nut
O-Ring
Adjusting Screw
Spring
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Spool
11 12 13 14 15 -
Orifice
Washer
Spring
O-Ring
O-Ring
W2-10-4
16 17 18 19 -
O-Ring
Sleeve
Plate
Washer

Disassemble Proportional Solenoid Valves
Be sure to thoroughly read Precaution for Disassembly and Assembly (W1-1-1) carefully before
starting the disassembly work.
IMPORTANT: Take care not to lose spring (7) provided in the groove of solenoid (6)
when removing solenoid (6).
Dont turn lock nut (2) and adjusting
screw (4).
1. Loosen socket bolts (1) (2 used) to remove solenoid (6).
: 3 mm
IMPORTANT: Be sure not to remove orifice (11)
from spool (10).
2. Pull out spool (10) and remove diaphragm (9),
washer (12) and spring (13).
3. Pull sleeve (17) out and remove O-rings (14), (15)
(16), plate (18) and washer (19).
W2-10-5

ASSEMBLE PROPORTIONAL SOLENOID
VALVES (SC, SI and SG)
3, 5
17
14
15
10
16
12 13
11
19
18
W157-02-11-001
12345-

Lock Nut
O-Ring
Adjusting Screw
Spring
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Spool
11 12 13 14 15 -
Orifice
Washer
Spring
O-Ring
O-Ring
W2-10-6
16 17 18 19 -
O-Ring
Sleeve
Plate
Washer

Assemble Proportional Solenoid Valves
IMPORTANT: Apply grease to O-rings (14), (15),
(16) and apply a film of hydraulic oil
to sleeve (17).
Install sleeve (17) so that the end
faces of sleeve and body come to
the same point.
17
16
15
14
1. Install washer (19), plate (18) into the housing. Install O-rings (14), (15) and (16) on sleeve (17),
then insert it into the housing.
IMPORTANT: Apply a film of hydraulic oil to spool
(10). Take care not to damage the
edge portion in the bore of sleeve
(17) when inserting the spool (10)
assembly.
After inserting spool, check that
spool (10) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic
oil to the spool.
Housing
W157-02-11-005
10
9
17
13
2. Install diaphragm (9), washer (12), spring (13) to

spool (10) and install it in to sleeve (17).
11
Housing
12
WIHH-02-10-006
NOTE: Orifice (11) is installed into spool (10).
10
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3), are not separated, so no need to assemble them.
When assembling solenoid (6), take
care not to drop spring (7).
W157-02-11-010
NOTE: As for O-ring (3) and spring (5), refer to

W2-10-4
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
: 5 Nm (0.5 kgfm, 3.6 lbfft)
1
W157-02-11-011
W2-10-7

DISASSEMBLE PROPORTIONAL SOLENOID VALVES
(TORQUE CONTROL SOLENOID VALVE,
MAXIMUM PUMP 2 FLOW RATE LIMIT SOLENOID VALVE)
1
12
2
13
14
4
5
6
7
8
9
10
11
15
16
17
18
WIHH-02-10-003
19
12345-

Lock Nut
O-Ring
Adjusting Screw
Spring
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
Washer

Disassemble Proportional Solenoid Valves
IMPORTANT: Take care not to lose spring (7) provided in the groove of solenoid (6)
when removing solenoid (6).
Dont turn lock nut (2) and adjusting
screw (4).
1. Loosen socket bolts (1) (2 used) to remove solenoid (6).
: 3 mm
IMPORTANT: Be sure not to remove orifice (17)
from spool (16).
2. Pull out spool (16) and remove diaphragm (9), retaining ring (10) and spring (11).
3. Pull sleeve (15) out and remove O-rings (12), (13)
and (14), plate (18) and washer (19).
W2-10-9

ASSEMBLE PROPORTIONAL SOLENOID
VALVES
(TORQUE CONTROL SOLENOID VALVE)
(MAXIMUM PUMP 2 FLOW RATE LIMIT
SOLENOID VALVE)
15
12
13
16
14
17
19
18
WIHH-02-10-007
3, 5
12345-

Lock Nut
O-Ring
Adjusting Screw
Spring
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Retaining Ring
11 12 13 14 15 -
10
Spring
O-Ring
O-Ring
O-Ring
Sleeve
W2-10-10
11
16 17 18 19 -
Spool
Orifice
Plate
Washer

Assemble Proportional Solenoid Valves
IMPORTANT: Apply grease to O-rings (12), (13),
(14) and apply a film of hydraulic oil
to sleeve (15).
Install sleeve (15) so that the end
faces of sleeve and body come to
the same point.
15
14
13
12
1. Install washer (19), plate (18) into the housing. Install O-rings (12), (13) and (14) on sleeve (15),
then insert it into the housing.
IMPORTANT: Apply a film of hydraulic oil to spool
(10). Take care not to damage the
edge portion in the bore of sleeve
(15) when inserting the spool (16)
assembly.
After inserting spool, check that
spool (16) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic
oil to the spool.
Housing
W157-02-11-005
16
9
15
11
2. Install diaphragm (9), retaining ring (10), spring

(11) to spool (16) and install it into sleeve (15).
17
Housing
10
WIHH-02-10-006
NOTE: Orifice (17) is installed into spool (16).
16
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3), are not separated, so no need to assemble them.
When assembling solenoid (6), take
care not to drop spring (7).
W157-02-11-010
NOTE: As for O-ring (3) and spring (5), refer to

W2-10-8
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
: 5 Nm (0.5 kgfm, 3.6 lbfft)
1
W157-02-11-011
W2-10-11

DISASSEMBLE AND ASSEMBLE PILOT
RELIEF VALVE
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

Assemble Pilot Relief Valve
Disassemble Pilot Relief Valve

IMPORTANT: Take care not to lose shim (2) provided in the plug (1) when removing
plug (1).
1. Remove plug (1) from housing (8).
: 22 mm
2. Remove spring (3) and O-ring (4) from the relief
valve.
NOTE: Sleeve (6) with poppet (5) is provided in the
relief valve.
1. Insert gasket (7) into housing (8).

2. Insert poppet (5) into sleeve (6). Install spring (3)
and O-ring (4) into the relief valve. Insert the relief
valve assembly into housing (8).
NOTE: Sleeve (6) with poppet (5) is provided in the
relief valve.
IMPORTANT: Be sure not to drop shim (2).
3. Install shim (2) into plug (1) to install the plug into
housing (8).
: 22 mm
: 25 Nm(2.5 kgfm, 18 lbfft)
3. Remove the assembly of poppet (5) and sleeve

(6) from housing (8).
4. Remove gasket (7) from housing (8).
W2-10-13

(Blank)
W2-10-14
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Group 4 Track Adjuster
Remove and Install Swing Bearing ......... W3-1-1
(ZAXIS330, 330LC, 350H, 350LCH)
Disassemble Swing Bearing ................... W3-1-4
Remove and Install Track Adjuster ......... W3-4-1
Assemble Swing Bearing ........................ W3-1-6
Disassemble Track Adjuster ................... W3-4-2

Assemble Track Adjuster........................ W3-4-8
(ZAXIS370MTH)
(ZAXIS330, 330LC, 350H, 350LCH)
Remove and Install Track Adjuster ....... W3-4-15
Remove and Install Travel Device .......... W3-2-1
Disassemble Track Adjuster ................. W3-4-16
Disassemble Travel Device .................... W3-2-4
Assemble Track Adjuster...................... W3-4-22
Assemble Travel Device ......................... W3-2-8

Disassemble Travel Motor .................... W3-2-16
Group 5 Front Idler
Assemble Travel Motor......................... W3-2-20
Remove and Install Front Idler................ W3-5-1
Disassemble Brake Valve ..................... W3-2-28
Disassemble Front Idler.......................... W3-5-2
Assemble Brake Valve.......................... W3-2-30
Assemble Front Idler .............................. W3-5-6
Maintenance Standard ........................ W3-2-32
Maintenance Standard.......................... W3-5-10
(ZAXIS370MTH)
Remove and Install Travel Device ........ W3-2-35
Group 6 Upper and Lower Roller
Disassemble Travel Device .................. W3-2-38
Remove and Install Upper Roller ............ W3-6-1
Assemble Travel Device ....................... W3-2-44
Remove and Install Lower Roller ............ W3-6-4
Disassemble Travel Motor .................... W3-2-52
Disassemble Lower Roller ...................... W3-6-8
Assemble Travel Motor......................... W3-2-56
Assemble Lower Roller......................... W3-6-10
Disassemble Brake Valve ..................... W3-2-62
Maintenance Standard.......................... W3-6-12
Assemble Brake Valve.......................... W3-2-64

Maintenance Standard ........................ W3-2-66
Group 7 Track
Remove and Install Track ....................... W3-7-1
Group 3 Center Joint
Maintenance Standard............................ W3-7-7
Remove and Install Center Joint............. W3-3-1

Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6
1HHW-3-1
(Blank)
1HHW-3-2
UNDERCARRIAGE / Swing Bearing

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

swing bearing.
: 41 mm
3
W158-03-01-001
CAUTION: Swing bearing weight: 500 kg

(1100 Ib)
ST 0050
3. Attach lifting tools (ST 0050), hoist swing bearing

(4) and remove it.
W3-1-1
W110-03-01-004

Installation
Clean the matching surfaces of the track frame and
swing bearing.
1. Apply THREEBOND # 1102 to the matching surfaces of the track frame and swing bearing.
(1100 Ib)
IMPORTANT: Failure to align the marks may result
in misalignment of the inner race
soft zone.
W110-03-01-004
2. Hoist the swing bearing by crane. Align the matching marks both on the track frame and swing bearing.
Front Side
S (Soft Zone)
Marking Position
Position of Plug
15
20
Position for
Grease Fitting
5
3. Install mounting bolts (3) (36 used) to the inner

race of the swing bearing and tighten to specification.
: 41 mm
: 1230 Nm (125 kgfm, 900 lbfft)
W110-03-01-001
3
W158-03-01-001
W3-1-2

4. After installing the swing bearing, fill the grease
bath with grease (Shell Alvania EP2 or equivalent)
until the pinion of the swing bearing is covered 5
mm in grease.
Swing Bearing Grease Level
Pinion
5 mm
Grease Bath
W3-1-3
W175-03-01-002

DISASSEMBLE SWING BEARING
1
W157-03-01-003
8
2
9
7
6
W157-03-01-002
1 - Outer Race
2 - Seal
3 - Pin
4 - Plug
5 - Seal
6 - Ball (95 Used)

7 - Inner Race
W3-1-4
8 - Grease Fitting (2 Used)

9 - Support (95 Used)

Disassemble Swing Bearing
Be sure to thoroughly read Precautions for Disassembly and Assembly on page W1-1-1 before
1. Grind off caulked part of pin (3).

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

Remove seals (2), (5).
C
7
W105-03-01-009
4. Rotate inner race (7) to remove balls (6) and supports (9) from the plug (4) hole.
When removing balls, rod magnet (C) can be
used. Use wire (D) to remove support (9).
D
W105-03-01-010
W3-1-5

ASSEMBLE SWING BEARING
1
W157-03-01-003
8
2
9
7
6
W157-03-01-002
1 - Outer Race
2 - Seal
3 - Pin
4 - Plug
5 - Seal
6 - Ball (95 Used)

7 - Inner Race
W3-1-6
8 - Grease Fitting (2 Used)

9 - Support (95 Used)

Assemble Swing Bearing
1. Clean (degrease) the seal groove for the outer
and inner seals (2) and (5).
Apply THREEBOND # 1745 to seal (2) and #
1735 to seal (5). Install both seals respectively
into position.
6
5
W142-03-01-005
IMPORTANT: Be sure to apply grease to balls (6)

and to supports (9).
(1100 lb)
2. Hoist the outer race by crane horizontally and
match it with the inner race coaxially.
Rotating the outer race, insert balls (6), support
(9) into the plug (4) hole one by one with a round
bar.
W142-03-01-006
3. Tap plug (4) into outer race (1) and then, drive pin
(3) into the pin hole.
Caulk the head of pin (3) with a punch.
Fill grease 0.9 L (Alvania EP2 grease or equivalent) through the grease fitting.
4
W142-03-01-007
W3-1-7

(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device

REMOVE AND INSTALL TRAVEL DEVICE
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Escaping fluid under pressure may
penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure before disconnecting hydraulic lines.
and may spurt possibly causing severe burns.
Be sure to wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off by remaining pressure if removed quickly. Slowly
loosen the cap to completely release any remaining pressure.
Preparation
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while
working on the hydraulic system.
W3-2-1
M104-07-021

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

: 22 mm
: 180 Nm (18 kgfm, 130 lbfft)
IMPORTANT: Attach identification tags to aid in

assembling.
2. Disconnect hoses (2) to (5).
: 19 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
: 27 mm
: 95 Nm (9.5 kgfm, 69 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
3
2
NOTE: Install caps on all disconnected hose and

line ends.
3. Attach the travel device to a crane with a wire
rope.
CAUTION: Travel device weight: 480 kg
(1060 Ib)
4. Remove bolts (1). Remove the travel device by
crane.
: 30 mm
: 620 Nm (63 kgfm, 460 lbfft)
Installation
wrench sizes and tightening torque.
1. Install the travel device with bolts (1).
2. Connect hoses (2) to (5).
3. Install cover (6) with bolts (7).
IMPORTANT: After completing travel motor installation, be sure to fill the travel motor
with hydraulic oil (1.3 L (0.34 US
gal.)). After completing installation
of the travel motor or the travel device, be sure to perform test driving
to prevent motor seizure. Test drive
as follows:
Perform break-in operation as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine for two minutes or more.
W3-2-2
W157-03-02-006

(Blank)
W3-2-3

DISASSEMBLE TRAVEL DEVICE
(ZAXIS330, 330LC, 350H, 350LCH)
16
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-
Third Stage Carrier

Third Stage Sun Gear
Thrust Plate (6 Used)
Second Stage
Planetary Gear (3 Used)
6 - Pin (3 Used)
12 13 14 15 -
78910 -
18 19 20 21 -
Spring Pin (3 Used)

Spacer (2 Used)
First Stage Carrier
11 - Propeller Shaft
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
16 - Bolt (16 Used)

17 - Plug (3 Used)
Spring Pin (3 Used)
Needle Bearing (3 Used)
First Stage Planetary Gear
(3 Used)
22 - Pin (3 Used)

Spring Pin (3 Used)
Pin (3 Used)

28 - Third Stage Planetary Gear
(3 Used)
29 - Motor
30 - Floating Seal
31 - Roller Bearing (2 Used)
32 - Drum
33 - Washer (20 Used)
W3-2-4
34 35 36 37 -
Bolt (20 Used)

Bearing Nut
Sprocket
Retaining Ring
38 - Bearing
39 - O-Ring
40 41 42 43 -
Spacer
Housing
Lock Plate
Bolt (2 Used)

Disassemble Travel Device
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Pressure may remain in the travel
device. Slowly loosen the air bleed plug to
completely release the residual pressure.
Then, remove the drain plug to drain gear oil
into a container. If the air bleed plug is loosened quickly, the plug may fly off and/or gear
oil may gush out. Position your face and
body away from the plug.
(1060 lb)
1. Turn over the travel device.
Place the travel device securely on a work bench
so that the brake valve does not come into contact
with the work bench, with the motor side downward.
2. Remove bolts (16) to remove cover (15) from ring
gear (12).
: 19 mm
15
16
NOTE: THRREEBOND is applied between cover

(15) and ring gear (12). For easy separation of cover (15), apply a chisel between
cover (15) and ring gear (12) and lightly tap
on the end of the chisel.
Do not remove stopper pin (14) unless it is
damaged or excessively worn.
3. Remove propeller shaft (11) and first stage carrier
(10) assembly from ring gear (12).
4. Remove second stage sun gear (9), second stage
carrier (23) assembly and third stage sun gear (2)
from ring gear (12).
W3-2-5
W107-03-02-008

16
13
12
40
10
23
8
1
8
19
20
21
19
22
18
35
31
24
25
27
26
27
26
28
30
41
43
42
34
36
31
32
W1HH-03-02-001
W3-2-6

10. Remove the inner race of roller bearing (31) from
drum (31).
CAUTION: Ring gear (12) weight:

55 kg (121 Ib)
5. Remove bolts (13) (28 used). Attach eyebolt (M12,
Pitch 1.75) to bolt (16) hole of ring gear (12). Remove ring gear (12) from drum (32) by crane.
: 24 mm
NOTE: THREEBOND is applied between ring gear
(12) and drum (32).Use the screw driver for
easy removal.
CAUTION: Third stage carrier (1) assembly
weight: 52 kg (115 lb)
6. Remove third stage carrier (1) assembly.
7. Remove bolt (43) and lock plate (42) from bearing
nut (35).
: 19 mm
8. Hold the travel device securely. Remove bearing
nut (35) using special tools.
Special Tools: ST 3050, ST 3051, ST 3052
Bolt: M16 (60 to 90 mm in length):2 pieces
ST 3052
ST 3050
35
NOTE: Do not attempt to remove the inner race of

roller bearing (31) which remained in housing (41) side unless it is to be replaced.
11. Remove floating seal (30) from drum (32) and
housing (41).
12. Apply a metal bar to the outer race of roller bearing (31) on drum (32) side, and tap the bar end
with a hammer to drive the outer race out.
13. Apply a round bar to spring pin (18), and tap the
end of the bar to drive spring pin (18) out of first
stage carrier (10) assembly. (3 places)
14. Remove pins (22) (3 used). Remove first stage
planetary gears (21) (3 used), needle bearings
(20) (3 used), and thrust plates (19) (6 used).
15. Remove spacer (40) from first stage carrier (10).
16. Disassemble second stage carrier (23) assembly
following steps 13 to 15 above.
Remove spring pins (7) (3 used), pins (6) (3 used),
second stage planetary gears (4) (3 used), thrust
plates (3) (6 used), needle bearings (5) (3 used),
and spacers (8) (2 used).
17. Disassemble third stage carrier (1) assembly following steps 13 to 15 above.
Remove spring pins (24) (3 used), pins (25) (3
used), thrust plates (26) (6 used), third stage
planetary gears (28) (3 used), and needle bearings (27) (6 used).
ST 3051
W157-03-02-005
CAUTION: Drum (32) + sprocket (36) weight:

135 kg (300 lb)
CAUTION: Sprocket (36) weight: 68 kg

(150 lb)
18. Loosen and remove bolts (34) (20 used). Remove
sprocket (36) by crane after attaching a nylon
sling to sprocket (36).
: 30 mm
IMPORTANT: The housing (41) matching surface

of drum (32) is the sliding surface.
Place the drum assembly onto a
wooden block not to damage it.
9. Attach eyebolt (M16, Pitch 2.0) to drum (32). Remove drum (32) from housing (41) by crane.
W3-2-7
NOTE: LOCTITE is applied to bolt (34).

ASSEMBLE TRAVEL DEVICE
(ZAXIS330, 330LC, 350H, 350LCH)
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 35
1234-
Third Stage Carrier

Third Stage Sun Gear
Second Stage
Planetary Gear (3 Used)
6 - Pin (3 Used)
12 13 14 15 -
78910 -
18 19 20 21 -
Spring Pin (3 Used)

Spacer (2 Used)
First Stage Carrier
11 - Propeller Shaft
31
42
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
43
23 24 25 26 -
16 - Bolt (16 Used)

17 - Plug (3 Used)
Spring Pin (3 Used)
First Stage Planetary Gear
(3 Used)
22 - Pin (3 Used)
28 27 25 26
24

Spring Pin (3 Used)
Pin (3 Used)

28 - Third Stage Planetary Gear
(3 Used)
29 - Motor
30 - Floating Seal
31 - Roller Bearing (2 Used)
32 - Drum
W3-2-8
34 35 36 37 -
W164-03-02-002
Bolt (20 Used)

Bearing Nut
Sprocket
Retaining Ring
38 - Bearing
39 - O-Ring
40 41 42 43 -
Spacer
Housing
Lock Plate
Bolt (2 Used)

Assemble Travel Device
(ZAXIS330, 330LC, 350H, 350LCH)
1. If replacing roller bearing (31), warm the inner
race (2 used) 50 to 70 C (122 to 158 F) with a
heater, then install one of them into housing (41).
Wait for the bearing to cool. Then, drive it in position completely with a metal bar and hammer.
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).
CAUTION: Drum (32) + sprocket (36) weight:

135 kg (300 lb)
5. Attach eyebolt (M16, Pitch 2.0) to the bolt (13)
hole of drum (32), then hoist and install drum (32)
onto housing (41) with motor (29) by crane. At this
time check if the clearance between the motor
and drum is equal.
6. Warm the inner race of roller bearing (31) 50 to 70
C (122 to 158 F) with a heater. Install it between
drum (32) and housing (41).
NOTE: For easier insertion of floating seal (30) Oring, use a bamboo (wooden) spatula to
guide it along the periphery.
IMPORTANT: Be sure to tap only the outer race.
3. Install the outer races (2 used) of roller bearing
(31) on drum (32) in position completely with a
metal bar and hammer.
Install the half of floating seal (30) into drum (32).
NOTE: Check if the roller bearing is installed completely by listening to the sound.
CAUTION: Sprocket (36) weight:
68 kg (150 lb)
IMPORTANT: Align the chamfered side of sprocket
(36) with drum (32).
4. Attach sprocket (36) with a nylon sling. Hoist it
and place it on drum (32). Apply LOCTITE #262 to
bolts (34) (20 used). Tighten bolts (34) and washers (33) (20 used).
: 30 mm
: 490 Nm (50 kgfm, 360 lbfft)
W3-2-9
41
32
36
35 42 43 26 28 27
W3-2-10
26
24
W164-03-02-002

IMPORTANT: Face bearing nut (35) stepped to the
bearing. Apply grease to the
threaded part of bearing nut (35).
7. Install bearing nut (35) to housing (41) and tighten
manually.
12. Apply LOCTITE #262 to the thread of bolts (43) (2

used). Install lock plate (42) to bearing nut (35)
with bolts (43) (2 used)
: 19 mm
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)
W140-03-02-001
13. Install two needle bearings (27) (2 used) into each

third stage planetary gears (28) (3 used).
IMPORTANT: One side of third stage planetary
gear (28) is the marked groove. Install third stage planetary gear (28)
with the side with marked groove
facing to the spring pin (24) hole.
14. Install spacer (8) into third stage carrier (1). Putting thrust plates (26) (6 used) on both ends of
each third stage planetary gears (28) (3 used), install them into third stage carrier (1).
ST 3052
ST 3050
35
43
42
35
ST 3051
36
W157-03-02-005
9. After tighten bearing nut (35) to specification, tap

on drum (32) with a plastic hammer to secure appropriate play. Then, rotate sprocket (36) 4 to 5
turns clockwise and then counterclockwise.
10. Repeat step 8 and 9.
11. Repeat step 9 above. Then, tighten bearing nut
(35) to specification.
Special Tools: ST 3050, ST 3051, ST3052,
Bolt: M16 (60 to 90 mm in length):
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
W3-2-11
12 13
23
43
15
16
41
32
28
W3-2-12
25
24 6
W164-03-02-002

15. Insert pins (25) (3 used) into third stage carrier (1)
to secure third stage planetary gears (28) (3
used).
At this time align third stage carrier (1) with the
spring pin (24) hole on pin (25).
16. Drive spring pins (24) (3 used) into the spring pin
hole on third stage carrier (1) and pin (25). Be
sure that the slit part of spring pin (24) faces to the
end of pin (25).
CAUTION: Ring gear (12) weight: 55 kg

(121 lb)
20. Install eyebolt (M12, Pitch 1.75) into the bolt (16)
hole on ring gear (12). Hoist ring gear (12) by
crane.
Install ring gear (12) onto drum (32). Apply LOCTITE #262 to bolts (13) (28 used). Tighten bolts
(13).
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)
24
25
21. Install spacer (8), second stage planetary gears

(4) (3 used), needle bearings (5) (3 used), thrust
plates (3) (6 used), pins (6) (3 used), and spring
pins (7) (3 used) into second stage carrier (23) following step 13 to 16 above.
Slit
W178-02-06-002
assembly
22. Install second stage carrier (23) assembly into

ring gear (12).
17. Install third stage carrier (1) assembly, aligning

splines with housing (41).
23. Install second stage sun gear (9) into second

stage carrier (23). Be sure that the lower tooth
end faces to cover (15).
CAUTION: Third stage carrier

weight: 52 kg (115 lb)
18. Install third stage sun gear (2) into third stage carrier (1). Be sure that the lower tooth end faces to
cover (15).
Cover (15)
Cover (15)
W166-03-02-002
W166-03-02-001
19. Clean (degrease) ring gear (12) mounting surface

of drum (32). Apply THREEBOND #1389B to the
mounting surface.
W3-2-13
29
12
10
17
40
11
21
15
22
18
19
16
20
W164-03-02-002
W3-2-14

IMPORTANT: Face the lower tooth height side of
first stage planetary gear (21) to
spacer (40) side.
24. Install spacer (40), first stage planetary gears (21)
(3 used), needle bearings (20) (3 used), thrust
plates (19) (6 used), pins (22) (3 used), spring
pins (18) (3 used) into first stage carrier (10) following step 13 to 16.
25. Install first stage carrier (10) assembly into ring
gear (12), aligning splines between first stage carrier (10) and second stage sun gear (9).
26. Add gear oil to ring gear (12).
Gear oil: 9.2 L (2.43 US gal)
27. Insert propeller shaft (11) into the center of carrier.
Be sure that the propeller shaft correctly meshes
with first stage planetary gears (21) and the shaft
of motor (29).
28. Clean (degrease) the cover (15) mounting surface
of ring gear (12). Apply THREEBOND #1389B to
the mounting surface. Install cover (15) to ring
gear (12). Apply LOCTITE #262 to bolts (16) (16
used). Tighten bolts (16) (16 used).
: 19 mm
: 110 Nm (11.5 kgfm, 83 lbfft)
29. Wrap seal tape around plugs (17) (3 used). Install
plugs (17) into cover (15).
: 10 mm
W3-2-15

DISASSEMBLE TRAVEL MOTOR
(ZAXIS330, 330LC, 350H, 350LCH)
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
40
31
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 -
Bearing
Housing
Oil Seal
Retaining Ring
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
W164-03-02-003
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
W3-2-16
31 32 33 34 35 36 37 38 39 40 -
Knock Pin (2 Used)

Brake Valve
O-Ring
Plug
Servo Piston
Piston Ring (2 Used)
O-Ring
Cover

Disassemble Travel Motor
(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Travel motor weight:
87 kg (190 Ib)
Brake valve weight: 43 kg (90 Ib)
4. Remove valve plate (29) from brake valve (33). At

this time, the valve plate is still with link (21) attached.
IMPORTANT: Valve plate (29) is easily cracked and

scratched, so handle it with care.
1. Place the travel motor longitudinally. Remove
socket bolts (32) (4 used) to remove brake valve
(33) from housing (12). At this time, the brake
valve side is still with valve plate (29) attached.
: 14 mm
2. Remove socket bolts (40) (4 used) from brake
valve (33) to remove cover (39) and O-ring (38).
NOTE: The valve plate (29) is with bushing (28)

attached, but do not remove the bushing
unless necessary.
5. Remove plate (30) from brake valve (33).
6. Remove servo piston (36) from brake valve (33).
At this time, the servo piston is still with piston
rings (37) (2 used) attached.
7. Remove O-Rings (1), (15) from housing (12).
3. Turn brake valve (33) over to remove plug (23)

and O-ring (24), then insert a hexagon wrench
into the plug (23) hole to remove reamer bolt (22).
: 8 mm, 10 mm
33
22
23
8. Remove disc spring (2) from housing (12).

CAUTION: When removing piston (4) from
the housing filled with air, cover the housing
with cloth to prevent the brake piston from
flying out.
2
9. Apply 100 to 300 kPa (1 to 3 kgf/cm , 14 to 43 psi)
pressure air to brake releasing oil passage in
housing (12), so that brake piston (4) will float up
to be removed.
W178-03-02-014
NOTE: There is an air seat on brake piston (4). Be

sure to place it with the air seat facing up.
IMPORTANT: Plug (19) has been bound with LOCTITE. If removing it by force, its
hexagon hole may be damaged. Do
not remove plug (19) unless necessary.
Air Seat
W178-03-02-009
NOTE: Piston (4) is with D-rings (3), (5) attached, do

not remove the D-ring unless necessary.
19
W107-03-02-098
W3-2-17
12
10
13
14
11
9
8
7
6
16
25
26
27
20
18
17
33
W164-03-02-003
W3-2-18

10. Remove plates (6) (5 used), friction plates (20) (4
used) from housing (12).
IMPORTANT: When removing center shaft (26), the
center shaft will be with pin (25)
attached. Be sure not to lose it.
11. Remove rotor (18), spring (27), center shaft (26),
and plungers (17) (7 used) from housing (12).
CAUTION: Drive disc (8) assembly weight:

7.0 kg (15 Ib)
15. Install drive disc (8) assembly into special tools
(ST 3058, 5904) to remove bearing nut (16).
ST 3058
NOTE: Tilt plunger (17) in the direction of motor

center, the more tilting, the easier removing.
ST 5904
12. Remove spacer (7) from housing (12).

CAUTION: Housing + drive disc (8) + others
weight: 49 kg (110 Ib)
CAUTION: Drive disc (8) assembly weight:
7.0 kg (15 Ib)
IMPORTANT: As drive disc (8) has tendency to
drop off, keep it with wooden block.
13. Place housing (12) with the brake valve (33)
mounting surface facing downward. Tap and remove drive disc (8) from housing (12) with a plastic hammer lightly. At this time, the drive disc is
still with bearings (9), (11), bearing nut (16), and
spacer (10) attached.
W107-03-02-119
IMPORTANT: The inner race of bearing (9) is left

on drive disc (8).
Dont remove it unless replacing.
In case the inner race of bearing (9)
has been removed, dont reuse it.
16. Place the outer race of bearing (9) on wooden
block. Press drive disc (8) with a press to remove
the outer race of bearing (9) bearing (11), and
spacer (10) from drive disc (8).
Press
8
11
10
14. Remove retaining ring (14) from housing (12) to

remove oil seal (13) with a screw-driver and
hammer.
9
Thrust Block
W107-03-02-121
W3-2-19

ASSEMBLE TRAVEL MOTOR
(ZAXIS330, 330LC, 350H, 350LCH)
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)
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
W3-2-20
31 32 33 34 35 36 37 38 39 40 -
Knock Pin (2 Used)

Brake Valve
O-Ring
Plug
Servo Piston
Piston Ring (2 Used)
O-Ring
Cover

(ZAXIS330, 330LC, 350H, 350LCH)
CAUTION: Drive disc (8) weight: 4.1 kg (9 lb)
1. Heat the inner race of bearing (9) to 70 to 90C
(158 F to 194 F) in a oil bath or drier. Press the
inner race of bearing (9) into drive disc (8) with
special tool (ST 2155) and a press.
2. Put the outer race onto the inner race of bearing
(9).
3. Tap and insert the outer race of bearing (11) into
spacer (10) lightly with a plastic hammer.
7. Secure drive disc (8) onto special tools (ST 3058,

ST 5904), tighten bearing nut (16) to the specified
torque.
: 3.50.5 Nm
(0.350.05 kgfm, 2.53 0.36 lbfft)
ST 3058
16
4. Put spacer (10) on the outer race of bearing (9).
ST 5904
5. Heat the inner race of bearing (11) to 70 to 90C

(158 F to 194 F) in a oil bath or drier, and press
the inner race of bearing into drive disc (8) with
special tool (ST 2308) and a press. Tap the inner
race lightly and listen to ring to confirm they are fitting tightly.
IMPORTANT: Apply grease onto bearing nut (16).
6. Apply grease to the screw part and the side
surface of bearing nut (16). Install bearing nut
(16) onto drive disc (8), then tighten it by hand.
NOTE: Apply grease to tighten it to the specified

torque.
W107-03-02-119

46 kg (100 Ib)
8. Place housing (12) with its brake valve mounting
side facing down.
IMPORTANT: Apply OCEAN grease #7 to the inner
surface of oil seal (13), and apply
THREEBOND #104 or 1215 to the
outer surface of the oil seal.
9. Tap oil seal (13) evenly and lightly with a plastic
hammer to insert oil seal (13) into housing (12).
The replaced oil seal can be used as a mat then.
10. Install retaining ring (14).
46 kg (100 Ib)
11. Turn housing (12) over. Tap drive disc (8) assembly
lightly with a plastic hammer and brass bar to install it into housing (12).
W3-2-21
27
18
12 4
18
13
25
Oil Slit (4 Places)
17
Slit (4 Places)
20 26
W178-03-02-019
W3-2-22

12. Turn housing (12) over and place it with its oil seal
(13) side facing down.
16. Install plungers (17) (7 used) into the spherical

handle hole in drive disc (8) one by one. Be sure
to confirm plungers (17) (7 used) move smoothly.
IMPORTANT: Be sure to align the oil slot (slit part)

in spacer (7) with that in housing
(12).
13. Install spacer (7) into housing (12) with its oil slot
(slit part) facing the travel reduction gear side.
IMPORTANT: Align 5 teeth of plate (6) with the inner grooves in housing (12).
In addition, the 4 teeth on friction
plate (20) should be placed at same
position when installation is carried
out.
14. Install plates (6) (5 used) and friction plates (20)
(4 used) into housing (12) alternately. Be sure to
align the teethless part (no teeth part ) of plate (6)
(4 places) with the inner slots inside of housing
(12) and install them together.
Moreover, the teethless part of friction plate (20)
should be put at same position to form a straight
line when installation is carried out.
NOTE: In case the teethless part or slot position
fail to align with each other, heating may be
resulted to motor failure.
Groove (4 Places)
17
Spherical
Handle Hole
W107-03-02-146
17. Apply grease to the center shaft (26) spherical

part. Install center shaft (26) into drive disc (8).
Then install center spring (27) onto enter shaft
(26).
18. Apply grease to pin (25) to prevent it from coming
off. Then install it into center shaft (26).
19. Put center shaft (26) to rotor (18) shallowly. Rotate
center shaft (26) so as to align pin (25) just beneath the slot in rotor (18).
18
Groove
12
26
W178-03-02-015
W178-03-02-018
15. Install D-rings (3, 5) into piston (4), then tap to install them into housing (12) with a plastic hammer.
25
20. Insert plungers (17) (7 used) into rotor (18).

IMPORTANT: Be sure to place pin (25) securely
into the rotor (18) groove.
21. Press rotor (18) slowly and install pin (25) into the
rotor (18) groove.
NOTE: If pin (25) cant be installed into the groove,
insert the end of round rotor into the top
hole of center shaft (26), rotate the center
shaft. When doing this work, be sure to remove the dirt and metallic debris from the
former rotor first.
W3-2-23
29
28
15
12
30
31
33
36
37
23
19
1
21
W178-03-02-016
W3-2-24

22. Install O-rings (1), (15) into housing (12).
IMPORTANT: Install disc spring (2) into housing
(12) with the outer surface side of
the disc spring facing the brake
valve (33) mounting surface.
23. Install disc spring (2) into housing (12).
IMPORTANT: Pay attention to the direction of link

(21) assembly.
30. Install link (21) assembly into brake valve (33)
while aligning the groove in valve plate (29) with
the groove in plate (30). At this time, the sticking
part of link (21) should face the brake valve side.
21
24. Fill hydraulic oil into housing (12).

Hydraulic oil: 1.3 L (0.34 US gal)
Rotor (18) Side
29
Plate (30) Side
25. Install plate (30) onto brake valve (33).

W178-03-02-017
26. Install piston rings (37) (2 used) onto servo piston

(36).
27. Insert servo piston (36) into brake valve (33).
31. Insert special tool (ST 7131) into the mounting

hole of plug (23), then align the hole of link (21)
with that of servo piston (36).
IMPORTANT: Assemble bushing (28) with the

chamfered side facing inside.
28. Install bushing (28) onto valve plate (29) with a
plastic hammer.
36
ST 7131
21
29. Apply LOCTITE #262 on plugs (19) (2 used), then

install link (21) onto valve plate (29) with plugs
(19) (2 used).
: 6 mm
: 49 Nm(5 kgfm, 36 Ibfft)
22
W3-2-25
W107-03-02-174
12
33
36
38
39
40
23, 24
32
21
W178-03-02-016
22
W3-2-26

32. Apply additive grease, Johnson wax JP103, to the
end of reamer bolt (22) in order to prevent it from
seizing.
Install reamer bolt (22) to link (21) and servo piston (36) through the opposite mounting hole of
plug (23).
: 8 mm
: 49 Nm(5 kgfm, 36 lbfft)
33. Install O-ring (24) onto plug (23), then install it to
brake valve (33).
: 10 mm
34. Install O-ring (38) onto cover (39) and install it to
brake valve (33) with socket bolts (40) (4 used).
: 10 mm
CAUTION: Brake valve (33) weight:

43 kg (90 Ib)
37. Hoist and install brake valve (33) onto housing
(12) by crane, while aligning the hole in removed
plug (A) with special tool (ST 7085).
38. Remove special tool (ST 7085) from brake valve
(33).
39. Install spool (B), spring (C) and plug (A) into brake
valve (33).
: 8 mm
: 34 Nm(3.5 kgfm, 25.5 Ibfft)
40. Install brake valve (33) onto housing (12) with
: 14 mm
: 390 Nm(40 kgfm, 290 Ibfft)
35. Install special tool (ST 7085) into the end of center
shaft (26).
ST 7085
26
12
W107-03-02-183
36. Remove plug (A) from brake valve (33) to remove

spool (B) and spring (C).
: 8 mm
W3-2-27

DISASSEMBLE BRAKE VALVE
(ZAXIS330, 330LC, 350H, 350LCH)
Counter Balance Valve
8
9
Shuttle Valve for Parking Brake

Check Valve
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 -
W3-2-28
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

Disassemble Brake Valve
(ZAXIS330, 330LC, 350H, 350LCH)
Be sure to thoroughly read Precautions for Disassembly and Assembly Work on page W1-1-1 before starting the disassembly work.
CAUTION: Brake valve weight: 43 kg (90 lb)
1. Remove plugs (8) (2 used) from casing (3).

: 41 mm
2. Remove springs (10) (2 used), stoppers (11) (2
used) from casing (3).
Shuttle valve for servo piston and for parking brake

IMPORTANT: LOCTITE was applied on seat (14).
Do not remove the seat unless necessary.
6. Remove plugs (16) (2 used) from casing (3) to
remove balls (13) (2 used) and seats (14) (2
used).
: 5 mm, 6 mm
Reducing Valve
7. Remove plug (17) from casing (3) to remove
spool (19) and spring (20).
: 8 mm
3. Remove spool (12) from casing (3).

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

springs (6) (2 used) and poppets (7) (2 used).
: 12 mm
W3-2-29

ASSEMBLE BRAKE VALVE
(ZAXIS330, 330LC, 350H, 350LCH)
13
14
15
13
14
16
15
16
Section B
Section C
19
20
18
17
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)
13 - Ball (2 Used)
14 - Seat (2 Used)
18 - O-Ring
19 - Spool
20 - Spring
W3-2-30
W164-03-02-005

(ZAXIS330, 330LC, 350H, 350LCH)
Reducing Valve
1. Insert spring (20) and spool (19) into casing (3).
Install O-ring (18) onto plug (17) to casing (3).
: 8 mm
Shuttle Valve for Servo Piston and for Parking
Brake
(Section B-B, Section C-C)
IMPORTANT: Before inserting ball (13), put ball
(13) on seat (14) and tap on the ball
with a hammer to obtain a tight
fitting between ball (13) and seat (14).
Also, after inserting ball (13) and
before tightening seat (14), insert a
metal bar into the plug hole to ball
(13), then tap the other end of the
bar to obtain tight fitting between
ball (13) and casing (3).
2. Install balls (13) (2 used) with casing (3) titled.
Apply LOCTITE #262 onto seats (14) (2 used)
and install the seats into casing (3). Install O-rings
(15) (2 used) onto plugs (16) (2 used) and install
the plugs into casing (3).
: 5 mm
: 14.5 Nm(1.5 kgfm, 11.0 lbfft)
: 6 mm
: 34 Nm(3.5 kgfm, 25 lbfft)
4. Install overload relief valves (2) (2 used) into casing (3).

: 27 mm
: 540 Nm(55 kgfm, 400 lbfft)

IMPORTANT: Apply hydraulic oil to spool (12) before assembling. If any resistant
force is felt, move it back and reassemble it. Never assemble it by
force.
5. Insert spool (12) into casing (3). Be sure that
spool (12) can move smoothly in casing (3).
6. Install spring (10) onto stoppers (11) (2 used),
then insert the stoppers into casing (3).
7. Install O-rings (9) (2 used) onto plugs (8) (2 used),
then install the plugs into casing (3).
: 41 mm
: 340 Nm(35 kgfm, 250 lbfft)
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)
W3-2-31

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)
-
NOTE: Values in [] is just for reference.
W3-2-32
Unit: mm (in)
Remedy
Cladding by
welding and
finishing

Parking Brake
C
D
W107-03-02-220
Unit: mm (in)
Part Name
Standard
(Thickness)
Allowable Limit
(Thickness)
Friction Plate
3.3 (0.130)
Spacer
9.0 (0.35)
Disc Spring
Piston
Plate
Remark
3.25 (0.128)
(Height) 7.6 (0.3)
6.10 (0.24)
49.6 (1.95)
1.8 (0.071)
1.75 (0.069)
The spacer and piston do not wear down.
NOTE: *Piston thickness (D) is the distance (width)

between the disc spring contacting left end
of the piston and the brake plate contacting
right end of the piston.
W3-2-33
NOTE: 1 mm=0.03937 in
Remedy

(Blank)
W3-2-34

REMOVE AND INSTALL TRAVEL DEVICE
(ZAXIS370MTH)
can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic
lines.
Hydraulic oil may be hot after operation and
may spurt, possibly causing severe burns. Be
sure to wait for oil to cool before starting any
repair work.
The hydraulic oil tank cap may fly off due to
remaining pressure if removed quickly.
Slowly loosen the cap to release any remaining pressure completely.
Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
pressure.
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while
working on the hydraulic system.
W3-2-35
M104-07-021

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.
the track have already been removed.
1. Remove bolts (1) (6 used) to remove cover (2)

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

for reassembly.
2. Disconnect hoses (3 and 4) from travel device (6)
and cap all disconnected hose ends.
: 27 mm, 17 mm
W16J-03-02-006
3. Remove socket bolts (8) (8 used) from split

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

670 kg (1480 Ib)
4. Attach wire ropes on travel device (6), and hoist
the travel device by crane.
5. Put matching marks on travel device (6) and the
track frame.
Remove bolts (5) (20 used). Hoist and remove the
travel device by crane.
: 32 mm
6
9
W16J-03-02-005
W111-03-02-002
W3-2-36

Installation
CAUTION: Travel device weight:
670 kg (1480 Ib)
IMPORTANT: Be sure to align the matching marks
made during disassembling. By failing to do so, it is difficult to install
hoses (3 and 4).
1. Install travel device (6) onto the track frame with
: 32 mm
: 750 Nm (76.5 kgfm, 550 Ibfft)
2. Connect hoses (9 and 10) to travel device (6) with
split flanges (7) (4 used) and tighten the split
flange with socket bolts (8) (8 used).
: 10 mm
: 90 Nm (9.2 kgfm, 67 Ibfft)
3. Connect hoses (3 and 4) onto travel device (6).
: 27 mm
: 93 Nm (9.5 kgfm, 69 Ibfft)
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 Ibfft)
Track Frame
10
5
6
9
W16J-03-02-005
4. Install cover (2) onto the track frame with bolts

(1) (6 used).
: 22 mm
: 180 Nm (18.5 kgfm, 134 Ibfft)
leaks.
After completing installation of the
travel device, be sure to perform
running-in to prevent motor seizure.
Perform break-in operation as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position
3. Drive the machine for 2 minutes or more
W3-2-37
2
W16J-03-02-006

DISASSEMBLE TRAVEL DEVICE
(ZAXIS370MTH)
8
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
40
39
37
38
36
34 33
35
32
31
30
49
48
47
44
45
46
43
41
42
12345678910 -
Motor
O-Ring
Housing
Floating Seal
Roller Bearing
Drum
Roller Bearing
O-Ring
Nut
Lock Plate
11 - Bolt (2 Used)
12 - Sprocket
14 15 16 17 18 19 20 21 22 23 -
Bolt (24 Used)

3rd Stage Carrier
3rd Stage Sun Gear
2nd Stage Carrier
Spacer
2nd Stage Sun Gear
Pin (3 Used)
1st Stage Planetary Gear (3
Used)
24 - Thrust Plate (3 Used)
26 27 28 29 30 31 32 33 34 35 -
Spacer
1st Stage Carrier
Spring Pin (3 Used)
2nd Stage Planetary Gear (3 Used)
Pin (3 Used)
3rd Stage Planetary Gear (4 Used)

37 - Pin (4 Used)
W3-2-38
W16J-03-02-004
38 39 40 41 42 43 44 45 46 47 -

Shaft
Ring Gear
Bolt (30 Used)
Retaining Ring
Stopper Pin
Ball Bearing
Cover
48 - Bolt (16 Used)

49 - Plug (3 Used)

Disassemble Travel Device
(ZAXIS370MTH)
Be sure to read Precautions for Disassembly and
Assembly Work thoroughly on page W1-1-1 before starting any disassembly work.
CAUTION: Pressure may remain in the travel
device. Slowly loosen the air bleed plug to
completely release the residual pressure.
Then, remove the drain plug and drain the
gear oil into a container.
If the air bleed plug is loosened quickly, the
plug may fly off and/or gear oil may spurt.
Keep your face and body away from the plug.
CAUTION: Motor (1) weight: 130 kg (290 Ib)

2. Put matching marks on the mounting surface of
motor (1) and housing (3).
Install eyebolts (M12, Pitch 1.75) (2 used) into the
motor. Remove bolts (4 used), then hoist and remove the motor by crane. Remove O-ring (2) from
the motor.
: 27 mm
3
Motor Mounting Bolt

(1480 lb)
1. After loosening plug (49-B) 2 to 3 turns, remove
plug (49-A) to drain gear oil from the travel device.
Lay the travel device on a work bench with motor
(1) facing up.
: 14 mm
49 -B
Eyebolt
Mounting
Position
W16J-03-02-002

(1190 Ib)
3. Attach a wire rope to the middle of drum (6) and
ring gear (42). Hoist the travel device by crane
and place it on the work bench with cover (47) facing up.
49 -A
W111-03-02-006
CAUTION: Cover (47) weight: 20 kg (44 Ib)

4. Put matching marks on the mounting surface of
cover (47) and ring gear (42).
Install eyebolts (PT 3/4) into the plug (49) holes.
(2 places)
Remove bolts (48) (16 used), then hoist and remove cover (47) from ring gear (42) by crane.
: 22 mm
NOTE: Since THREEBOND has been applied to
the mating surfaces of ring gear (42) and
cover (47), it is better to insert a screw
driver between the ring gear and the cover
to pry the cover up for easier removal.
W3-2-39

8
7
4
3
21
22
24
23
20
17
16
18
25
19
15
26
27
12
28
29
10
11
40
39
37
38
36
34 33
35
32
31
30
48
43
41
42
W3-2-40
W16J-03-02-004

CAUTION: Ring gear (42) weight: 70 kg (150
Ib)
5. Put matching marks on the mating parts of ring
gear (42) and drum (6) .
Install eyebolts (M14, Pitch 2.0) into the bolt (48)
holes (2 places) in ring gear (42).
Remove bolts (43) (30 used) to hoist and remove
the ring gear by crane.
Remove O-ring (8) from drum (6).
: 27 mm
10. Install special tool (ST 3136) onto bearing nut (9)
to loosen and remove the bearing nut.
ST 3136
6. Remove shaft (41) from first stage carrier (27).

Remove first stage carrier assemblies (20 to 27)
and second stage sun gear (19) from second
stage carrier (17).
W111-03-02-018
CAUTION: The second stage carrier (17) assembly weight: 25 kg (50 Ib)
7. Wind nylon slings (2 used) onto second stage carrier (17). Hoist and remove second stage carrier
assemblies (17, 18, 28 to 33) by crane.
Remove third stage sun gear (16).
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
CAUTION: Drum (6), sprocket (12) and other

parts weight: 180 kg (400 Ib)
IMPORTANT: The mating parts of drum (6) and
housing (3) are sliding surface. Take
care not to damage the sliding surface and put the removed drum assembly onto wooden blocks.
11. Put matching marks on the mating parts of drum
(6) and housing (3).
Install eyebolts (M18, Pitch 2.5) into the bolt (43)
holes (2 places) in the drum.
Hoist and remove the drum assembly from the
housing by crane.
At this time, the inner race of roller bearing (7) is
also removed along with it.
12. Remove floating seals (4) from housing (3) and
drum (6).
W3-2-41
1
25
17
18
15
14
26
27
12
29
40
39
37
38
36
34
35
W16J-03-02-004
W3-2-42

IMPORTANT: Do not remove the inner race of
roller bearing (5) from housing (3)
unless necessary. In case the inner
race of roller bearing (5) has been
removed, it must be replaced with a
new one.
housing (3) with a bar and hammer.
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.
NOTE: If the inner race of roller bearing (5) can not

be removed, it can be cut by gas torch.
However care should be taken to protect
housing (3) from being damaged while doing this work.
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.
CAUTION: Sprocket (12) weight: 85 kg

(190 Ib)
14. Put matching marks on the mating surface of
sprocket (12) and drum (6).
Attach nylon slings (2 used) on the sprocket. Remove bolts (14) (24 used). Hoist and remove the
sprocket by crane.
: 32 mm
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)
IMPORTANT: Do not remove the outer race of

roller bearings (5) and (7) from drum
(6) unless necessary.
If the bearing is pressed in insufficiently, the service life of the bearing
may be affected. In case the outer
race has been removed, it must be
replaced with a new one.
15. Remove the outer race of roller bearing (5) from
drum (6) with a bar and hammer.
20. Remove spacer (26) from first stage carrier (27).

Remove spacer (18) from second stage carrier
(17).
CAUTION: Drum (6) including other parts

16. Install eyebolts (M22, Pitch 2.5) into the bolt (14)
holes (2 places) in drum (6) from the motor (1)
side.
Hoist and turn the drum over by crane. Remove
the outer race of roller bearing (7) from the drum
with a bar and hammer.
W3-2-43

ASSEMBLE TRAVEL DEVICE
(ZAXIS370MTH)
3
1
13 14
12
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
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 -
40 35 39 38
Bolt (24 Used)

3rd Stage Carrier
3rd Stage Sun Gear
2nd Stage Carrier
Spacer
2nd Stage Sun Gear
Pin (3 Used)
1st Stage Planetary Gear (3 Used)
Spring Pin (3 Used)
26 27 28 29 30 31 32 33 34 35 36 37 -
36
T16J-03-05-001
37
Spacer
1st Stage Carrier
Spring Pin (3 Used)
2nd Stage Planetary Gear (3 Used)
Pin (3 Used)
3rd Stage Planetary Gear (4 Used)
Spring Pin (4 Used)
Pin (4 Used)
W3-2-44
28 29
38 39 40 41 42 43 44 45 46 47 48 49 -

Shaft
Ring Gear
Bolt (30 Used)
Retaining Ring
Stopper Pin
Ball Bearing
Cover
Bolt (16 Used)
Plug (3 Used)

Assemble Travel Device
(ZAXIS370MTH)
Assembly Work thoroughly on page W1-1-1 before starting the assembly work.
CAUTION: Housing (3) weight: 90 kg (200 Ib)
1. Wind a nylon sling on housing (3) body. Hoist and
place the housing with motor (1) side facing down
by crane.
IMPORTANT: For handling of the floating seal, refer to the section Precautions for
Floating Seal Handling on page
W1-1-4.
2. Install one half of floating seal (4) on housing (3)
with a wooden spatula or similar tool to guide the
seal along the periphery.
Install the inner race of roller bearing (5) into the
housing by tapping it with a bar and hammer
evenly.
NOTE: Tap the bearing and listen to ring to see if
the installation of the inner race is completed into housing (3).
CAUTION: Drum (6) weight: 96 kg (210 Ib)
holes (2 places) in drum (6) from the motor (1)
side.
Hoist and place the drum with the ring gear (42)
side facing down by crane.
Tap the outer race of roller bearing (5) with a bar
and hammer evenly to install it onto the drum.
the installation of the outer race is completed into drum (6).

holes (2 places) in drum (6).
Hoist and place the drum with the ring gear (42)
side facing up by crane.
Install the outer race of roller bearing (7) onto the
drum by tapping it with a bar and hammer evenly.
the installation of the outer race is completed into drum (6).
CAUTION: Sprocket (12) weight: 85 kg (190 Ib)
6. Attach nylon slings (2 used) on sprocket (12).
Hoist the sprocket and place it carefully onto drum
(6).
IMPORTANT: Apply LOCTITE #262 on bolt (14).
7. Install spring washer (13) to each bolts (14) (24
used). Tighten the bolts and install sprocket (12)
onto drum (6).
: 32 mm
: 750 Nm (76.5 kgfm, 550 lbfft)
CAUTION: Drum (6), sprocket (12), plus
other parts weight: 180 kg (400 Ib)
IMPORTANT: Align the matching marks made before disassembling. Be sure the
clearance all around drum (6) in
housing (3) is equal.
8. Hoist the drum (6) assembly by crane and put it
onto housing (3).
9. Install the inner race of roller bearing (7) onto the
housing by tapping it with a bar and hammer
evenly.
IMPORTANT: Apply grease to the O-ring of floating seal (4) on the drum (6) side.
4. Install one half of floating seal (4) on drum (6).
W3-2-45
12
3
15
47
34
10 11
40 35 39 38
W3-2-46
37
36
T16J-03-05-001

IMPORTANT: Install bearing nut (9) with the
stepped part facing roller bearing
(7).
Apply a film of grease at the
threaded part of the bearing nut.
10. Install bearing nut (9) onto housing (3) and tighten
it by hand.
NOTE: Apply a film of grease to the threaded part
of bearing nut (9) so as to tighten the nut to
the specified torque.
11. Install special tool (ST 3136) onto bearing nut (9)
and tighten it with a wrench.
: 785 Nm (80 kgfm, 580 lbfft)
ST 3136
IMPORTANT: If lock plate (10) fails to engage the

spline of housing (3), tighten bearing
nut (9) further in the tightening direction to align with the spline.
Apply LOCTITE #262 to bolts (11).
14. Install lock plate (10) onto bearing nut (9) with
: 19 mm
IMPORTANT: Apply grease on O-ring (8).
15. Install O-ring (8) onto drum (6).
IMPORTANT: There is an identification groove on
one half of third stage planetary gear
(35). Install the third stage planetary
gear with the identification groove
facing cover (47).
16. Install needle bearings (38) (4 used) and (39) (4
used) onto third stage planetary gears (35) (4
used). Install the third stage planetary gear onto
third stage carrier (15) by clamping it with thrust
plates (34) (4 used) and (40) (4 used).
17. Align the spring pin (36) holes in third stage carrier
(15) and pins (37) (4 used), then install the spring
pins.
W111-03-02-018
12. Rotate sprocket (12) both clockwise and counterclockwise 4 to 5 turns. Tap on drum (6) with a
plastic hammer to secure appropriate play.
IMPORTANT: When installing spring pin (36), be

sure to let its slit face the end of pin
(37).
18. Install spring pins (36) (4 used) into third stage carrier (15) and pin (37) with a round bar (Dia: 8 mm
(0.3 in)).
13. Perform procedures 11 and 12 twice and tighten

bearing nut (9) to the specified torque.
: 785 Nm (80 kgfm, 580 lbfft)
36
37
Slit
W178-02-06-002
W3-2-47
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
W3-2-48
37
28 29
36
T16J-03-05-001

19. Install spacer (26) to first stage carrier (27).
20. Install needle bearings (21) (3 used) onto first
stage planetary gears (23) (3 used). Clamp the
first stage planetary gear with thrust plates (24) (3
used) and (20) (3 used) and install the first stage
planetary gear onto first stage carrier (27).
IMPORTANT: When installing spring pin (25), be
sure to let its slit face the end of pin
(22).
21. Install spring pins (25) (3 used) into first stage carrier (27) and pin (22) by a round bar (Dia: 4 mm
(0.16 in)).
CAUTION: The second stage carrier (17) assembly weight: 25 kg (60 Ib)
25. Wind nylon slings (2 used) onto second stage carrier assemblies (17, 18 and 28 to 33). Hoist the
second stage carrier assemblies by crane and
lower it onto third stage sun gear (16).
26. Install second stage sun gear (19) onto second
stage carrier (17) with the smaller end facing
cover (47).
Cover (47) Side
25
22
19
W166-03-02-002
Slit
27. Install first stage carrier assemblies (20 to 27)

W178-02-06-002
22. Assemble second stage carrier (17) according to

the procedures 19 to 21.
Round Bar Dia: 5 mm (0.20 in)
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 by crane 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).
onto second stage carrier (17).

28. Insert shaft (41) into the center of carrier and be
sure to let it engage with the first stage planetary
gears (23) (3 used).
CAUTION: Ring gear (42) weight: 70 kg
(150 Ib)
IMPORTANT: Align the matching marks made
when disassembling.
hole in ring gear (42). Hoist ring gear by crane and
lower it to drum (6).
30. Install ring gear (42) onto drum (6) with bolts (43)
(30 used).
: 27 mm
: 390 Nm (40 kgfm, 290 lbfft)
Cover (47) Side
W166-03-02-001
16
W3-2-49
3
1
42
49
47
44
46
45
48
T16J-03-05-001
W3-2-50

31. Attach a tube bar on ball bearing (46). Tap a tube
bar with a hammer and install the ball bearing
onto cover (47).
Ball Bearing Inner Diameter: 45 mm (1.77 in)
Outer Diameter: 68 mm (2.68 in)
32. Attach a tube bar on stopper pin (45). Tap a tube
bar with a hammer to install the stopper pin into
ball bearing (46).
Stopper Pin Inner Diameter: 26 mm (1.02 in)
Outer Diameter: 50 mm (1.97 in)
IMPORTANT: Install retaining ring (44). Be sure to
let the chamfered part face cover
(47).
33. Install retaining ring (44) onto cover (47).
CAUTION: Cover (47) weight: 20 kg (44 Ib)
IMPORTANT: Apply THREEBOND #1389B to the
cover (47) mounting surface of ring
gear (42).
34. Install eyebolts (PT 3/4) into the plug (49) holes (2
places) in cover (47).
Hoist the cover by crane and lower it to ring gear
(42).
CAUTION: Travel reduction gear weight:

540 kg (1190 Ib)
37. Install eyebolts (M18, Pitch 2.5) into the bolt holes
(2 places) in the housing (3) flange. Hoist the
travel reduction gear and turn it over by crane.
38. Fill gear oil 11.5 L (3.0 US gal.) into the travel reduction gear.
39. Install O-ring (2) to motor (1).
CAUTION: Motor (1) weight: 130 kg (290 Ib)
40. Install eyebolts (M12, Pitch 1.75) (2 used) into the
bolt holes in motor (1). Hoist the motor and install
it onto housing (3) by crane while aligning the
splines on shaft (41) with the splines on the motor.
3
Motor Mounting Bolt

35. Install cover (47) onto ring gear (42) with bolts
(48) (16 used).
: 22 mm
: 177 Nm (18 kgfm, 130 lbfft)
36. Wrap the seal tape to plugs (49) (3 used) and install the plugs into cover (47).
: 14 mm
Eyebolt
Mounting Position
W16J-03-02-002
41. Install spring washers to each bolt (4 used), then

install motor (1) into housing (3) with the bolts
(4 used).
: 27 mm
: 295 Nm (30 kgfm, 220 lbfft)
W3-2-51

DISASSEMBLE TRAVEL MOTOR
(ZAXIS370MTH)
4
2
7
6
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
Backup Ring
O-Ring
O-Ring
W3-2-52
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

Disassemble Travel Motor (ZAXIS370MTH)
Assembly Work thoroughly on page W1-1-1 before starting the disassembly work.
CAUTION: Valve housing (32) weight: 39 kg
(90 Ib)
IMPORTANT: Loosen socket bolts (33) (9 used)
evenly. When loosening the socket
bolts, valve housing (32) may come
up from casing (1) since there is a
spring force coming from springs
(13) and (29). Take down the clearance between the casing and the
valve housing.
When removing the valve housing
from the casing, valve plate (15) will
come out with the valve housing, do
not let the plate come off.
1. Put matching marks on the mating part of valve
housing (32) and casing (1). Install eyebolts (M12,
Pitch 1.75) onto the valve housing.
Remove socket bolts (33) (9 used). Hoist the
valve housing and remove it from the casing by
crane.
: 14 mm
1
32
33
IMPORTANT: Fix casing (1) securely.

4. Install eyebolts (M12, Pitch 1.75) into the pin (31)
holes (2 places) in brake piston (27). Hoist the
brake piston and remove it from casing (1) by
crane.
5. Remove O-rings (24 and 25), backup rings (23
and 26) from brake piston (27).
IMPORTANT: Since friction plates (18, 19, 21 and
22) are different in thickness and the
order to install them has been determined, they should be kept in order while removing.
6. Remove friction plate (22) from casing (1). Remove disc plates (20) (4 used) and friction plates
(21) (3 used) one by one alternately. Remove friction plates (19 and 18).
CAUTION: The cylinder block (14) assembly
IMPORTANT: If cylinder block (14) needs to be replaced, cylinder block assemblies (10
to 15) with valve plate (15) should be
replaced.
7. Remove cylinder block (14) assemblies (10 to 15)
from casing (1).
NOTE: Hold cylinder block (14) and turn it left and
right lightly by two hands to take it out
slowly.
8. Remove retainer (11), pistons (10) (9 used),
holder (12) and springs (13) (9 used) from cylinder
block (14).
Eyebolt Mounting
Position
W16J-03-02-002
2. Remove springs (29) (10 used), O-rings (2) (4

used), pins (31) (4 used) and O-ring (28) from casing (1).
IMPORTANT: Take care not to damage valve plate
(15).
3. Remove collar (16) and valve plate (15) from cylinder block (14).
IMPORTANT: Do not damage the friction surface

of swash plate (9).
Piston (4) and steel ball (8) may
come out with the swash plate. Be
sure to keep the piston and the steel
ball from dropping.
9. Remove swash plate (9) from casing (1).
W3-2-53
4
3
7
5
W16J-03-02-001
W3-2-54

10. Remove pistons (4) (2 used), springs (3) (2 used)
and steel balls (8) (2 used) from casing (1).
NOTE: If it is difficult to remove steel ball (8), that
means the ball has been set in casing (1),
so use some kerosene or thinner, etc. to
clean grease first, and then with a magnet
to take it out from casing (1).
IMPORTANT: Do not damage the spline part of
shaft (7) and contact part of oil seal
(5). Oil leakage will occur if they are
damaged.
11. Remove shaft (7) from casing (1). At this moment,
the inner race of roller bearing (6) is connecting
with the shaft.
IMPORTANT: Do not remove the inner race of
roller bearing (6) from shaft (7) and
the outer race of roller bearing (6)
from casing (1) unless necessary.
shaft (7) with a press.
IMPORTANT: Keep the outer race of roller bearing
(6) properly so that it can be installed
in the same direction before disassembling.
13. Remove the outer race of roller bearing (6) from
casing (1) with a bar and a hammer.
14. Remove oil seal (5) from casing (1).
W3-2-55

(ZAXIS370MTH)
27
33
29
25,26
23,24
22
19 18
30
16
32
17
1
15
31
5
28
T16J-03-05-003
Brake Release Circuit
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
Backup Ring
O-Ring
O-Ring
W3-2-56
26 27 28 29 30 31 32 33 -
Backup Ring
Brake Piston
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing

Assemble Travel Motor (ZAXIS370MTH)
Assembly Work thoroughly on page W1-1-1 before starting the assembly work.
IMPORTANT: Apply grease on inside periphery of
oil seal (5) for casing (1) at the
pressed-in part and outside periphery of the oil seal.
In addition, the oil seal should be
pressed in straight to prevent it from
deforming.
1. Press oil seal (5) into casing (1).
IMPORTANT: Install the outer race of roller bearing
(6) with the stamp mark on the outer
race facing the swash plate (9) side.
2. Tap the outer race of roller bearing (6) evenly with
a bar and hammer while installing the outer race
into casing (1).
NOTE: Tap the bearing and listen to ring to confirm
if installation is completed.
IMPORTANT: Install the inner race of roller bearing
(6) with its collar facing swash plate
(9).
3. Tap the inner race of roller bearing (6) evenly with
a bar and hammer while installing it into shaft (7).
Tap and install the shaft assembly into casing (1)
with a hammer.
IMPORTANT: Apply hydraulic oil on outside periphery of steel ball (8) and piston (4).
Apply hydraulic oil the piston and
the steel ball mounting surfaces of
casing (1).
4. Install springs (3) (2 used), pistons (4) (2 used)
and steel balls (8) (2 used) into casing (1).
CAUTION: The casing (1) assembly weight:
54 kg (120 Ib)
5. Install eyebolts (M18, Pitch 2.5) into the bolts (33)
holes in casing (1) (2 places). Hoist the casing assembly up by crane and place it with the brake release circuit facing down.
IMPORTANT: Align the spherical hole in swash

plate (9) with steel ball (8), then install the swash plate.
Apply grease to matching part of
casing (1) for the swash plate.
6. Install swash plate (9) onto casing (1) with its
thicker side facing down.
IMPORTANT: Apply hydraulic oil on the piston (10)
mounting hole of cylinder block (14).
Pay attention to the mounting direction of retainer (11).
7. Install springs (13) (9 used) and holder (12) into
cylinder block (14).
Install pistons (10) (9 used) onto retainer (11) and
install them into the cylinder block.
CAUTION: The cylinder block (14) assembly
IMPORTANT: Apply hydraulic oil to the piston (10)
sliding surface of swash plate (9)
and the spherical surface of holder
(12).
There is the inner race for roller bearing (17) on the tip of shaft (7). Take
care to keep it away from being
damaged.
Align the shaft splines to those of
cylinder block (14).
8. Install the cylinder block (14) assembly onto shaft
(7).
CAUTION: The casing (1) assembly weight:
54 kg (120 Ib)
9. Install eyebolts (M18, Pitch 2.5) into the socket
bolts (33) holes (2 places) in casing (1). Hoist the
casing and place it vertically by crane.
W3-2-57
27
29
25,26
23,24
22
19 18
30
16
32
17
1
15
31
T16J-03-05-003
14
20 21
W3-2-58

10. Install friction plates (18 and 19) into casing (1).
Then install disc plates (20) (4 used) and friction
plates (21) (3 used) alternately and finally install
friction plate (22) into the casing.
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
IMPORTANT: As for springs (29) (10 used), there

are twelve spring mounting holes in
brake piston (27), so pay attention to
where the spring should be inserted
and not make mistakes.
27
Free Hole
29
29
Free Hole
13. Install springs (29) (10 used) onto brake piston

(27).
IMPORTANT: Install the outer race of roller bearing
(17) with the stamp mark on the
outer race facing the valve plate (15)
side.
14. Tap the outer race of roller bearing (17) evenly
with a bar and hammer to install the outer race
into valve housing (32).
NOTE: Tap the bearing and listen to ring to confirm
if the outer race is installed to the most end
of valve housing (32).
Notch
31
W16J-03-02-003
W16J-03-02-003
IMPORTANT: Apply grease to the mating surfaces

of valve plate (15) and valve housing
(32).
15. Install collar (16) into valve housing (32). Align the
pin holes in pin (30) and valve plate (15) to install
the valve plate into the valve housing.
12. Tap brake piston (27) with a plastic hammer to install it into casing (1).
W3-2-59
33
27
32
31
28
T16J-03-05-003
W3-2-60

IMPORTANT: Apply grease to O-rings (2 and 28).
16. Install O-rings (28) and (2) (4 used) into casing (1)
and install pins (31) (4 used) to valve housing
(32).
CAUTION: Valve housing (32) weight: 39 kg
(90 Ib)
IMPORTANT: When installing valve housing (32)
into casing (1), be sure to confirm
the clearance value between the casing and the valve housing is equal to
that noted on disassembling. If the
value is different, disassemble them
and reassemble again.
IMPORTANT: Align the matching marks made
when disassembling. If the matching
marks cannot be aligned with each
other, brake piston (27) may be installed in wrong direction.
17. Install eyebolt (M12, Pitch 1.75) into the bolt hole
in valve housing (32).
Hoist valve housing (32) to put it onto casing (1)
while aligning the pin (31) hole in brake piston (27)
by crane.
Install the valve housing onto the casing with
: 14 mm
: 44021.5 Nm
(452.2 kgfm, 33016 lbfft )
NOTE: Tighten socket bolts (33) (9 used) evenly.
1
32
33
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-61

DISASSEMBLE BRAKE VALVE
(ZAXIS370MTH)
1
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)
Plug
O-Ring
Spring
Plug (6 Used)
O-Ring (6 Used)
Orifice
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
O-Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
O-Ring (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 -
W3-2-62
Spring (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Cap (2 Used)
O-Ring (2 Used)
39 40 41 42 43 44 45 46 47 48 49 50 -
Spring (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Spool
Valve Housing
Pin (4 Used)
Pin
Orifice
Spool Assembly

Disassemble Brake Valve
(ZAXIS370MTH)
CAUTION: The valve housing (46) assembly
1. Secure the valve housing (46) assembly on a firm
work bench.
2. Remove plugs (6 and 15) and O-rings (7 and 14).
Then remove spring (8).
: 10 mm
IMPORTANT: Remove valve assembly (13) while
rotating it. If a little resistance is felt
while removing, do not try to remove
it by force, return to original position
and retry.
In addition, do not disassemble the
valve assembly. In case replacement
should be carried out to any parts of
it, be sure to replace it with the valve
housing (46) assembly including
spool assembly (50), valve assembly
(13), orifices (11 and 49) and the
plug.
3. Press valve assembly (13) out carefully and rotate
the valve assembly by hand to remove it from
valve housing (46).
4. Remove plug (1). Then remove O-ring (2), spring
(3) and check valve (4). (2 places at right and left)
: 14 mm
IMPORTANT: Do not disassemble overload relief

valves (5) (2 used). The overload relief valve should be replaced as assembly. Attach tags on each overload relief valves so that they can be
installed to their original positions.
In addition, do not rotate set screw
(34), or the setting pressure can
change.
5. Loosen plug (32) to remove overload relief valve
(5) from valve housing (46). (2 places at right and
left)
: 36 mm
6. Press cap (36) while loosening socket bolts (35)
(4 used) to remove the cap from valve housing
(46). (2 places at right and left)
: 10 mm
NOTE: In case cap (36) cannot be removed, a
plastic hammer can be used to tap the cap,
however, the loosened socket bolts (35)
should be still on the cap while tapping.
7. Remove spring seat (38), spring (39) and spring
seat (40) from valve housing (46). (2 places at
right and left)
IMPORTANT: Remove spool assembly (50) while
rotating it. In case a little resistance
is felt while removing, do not try to
remove it by force, return to original
position and retry.
8. Press spool assembly (50) out carefully. Rotate
the spool assembly by hand to remove it from
valve housing (46).
9. Clamp spool assembly (50) in a vice with a chip of
wood inserted at both side.
10. Remove plugs (41) (2 used), then remove springs
(43) (2 used) and check valves (44) (2 used) from
spool (45).
W3-2-63

(ZAXIS370MTH)
Overload Relief Valve (5)

16
18
21 26
24
27 31
29
32
33
34
17, 19
20
22
30
28
23, 25
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)
Plug
O-Ring
Spring
*Plug (6 Used)
*O-Ring (6 Used)
*Orifice
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
O-Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
O-Ring (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 -
NOTE: As for parts with *, refer to W3-2-62.
W3-2-64
Section A-A-A
Spring (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Cap (2 Used)
O-Ring (2 Used)
39 40 41 42 43 44 45 46 47 48 49 50 -
4
W183-03-02-016
Spring (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Spool
Valve Housing
Pin (4 Used)
Pin
*Orifice
Spool Assembly

Assemble Brake Valve (ZAXIS370MTH)
1. Install O-rings (7 and 14) to plugs (6 and 15) respectively. Install valve assembly (13) and plugs
(6 and 15) into valve housing (46).
: 10 mm
: 644.9 Nm
(6.50.5 kgfm, 473.6 lbfft)
2. Install O-ring (2) to plug (1) and install check valve
(4), spring (3) and the plug into valve housing (46).
(2 places at right and left)
: 14 mm
: 41019.5 Nm
(422 kgfm, 30014.5 lbfft)
IMPORTANT: Install overload relief valve (5) to the
former position before disassembled.
3. Install overload relief valves (5) (2 used) onto
valve housing (46).
: 36 mm
: 41019.5 Nm
(422 kgfm, 30014.5 lbfft)
4. Rotate spool assembly (50) slowly to insert it into
valve housing (46).
5. Install O-ring (37) into cap (36). (2 places at right
and left)
6. Install spring seat (40), spring (39) and spring seat
(38) into valve housing (46). Then install cap (36)
with socket bolts (35) (4 used). (2 places at right
and left)
: 10 mm
: 1084.9 Nm
(110.5 kgfm, 803.6 lbfft)
W3-2-65

(ZAXIS370MTH)
1. The clearance between the inner diameter of cylinder block and the outer diameter of the piston:
Cylinder
Block
(D-d): 0.06 mm or less
W507-02-04-009
Piston
2. The clearance between the piston and shoe when

engaging:
Piston
: 0.4 mm or less
Shoe
W107-02-06-140
3. The clearance between the inner diameter and

outer diameter at the matching position of casing
and piston:
Piston
(D-d): 0.03 mm or less

Casing
D
4. The wear allowance on the sliding surfaces of cylinder block and valve plate:
Check there is no abnormal scratch, wear or
score.
The wear allowance shall be within 0.02 mm or
less.
W3-2-66
W162-03-02-005

Sprocket
W1HH-03-02-002
Unit: mm (in)
Standard Dimension Allowable Limit
NOTE: Value 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)
] is for reference only.
W3-2-67

(Blank)
W3-2-68
UNDERCARRIAGE / Center Joint

REMOVE AND INSTALL CENTER JOINT
CAUTION: Hydraulic flue under pressure can
penetrate the skin or eyes, causing serious
injury. Avoid this hazard by releasing pressure before disconnecting hydraulic or other
lines.
and may spurt, causing severe burns. Be
sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if removed without first releasing internal pressure. Push the air release valve on top of
Preparation
1. Park the machine on a firm, level surface. Lower
the front attachment onto the ground.
pressure.
3. Remove hydraulic oil tank cap, connect a vacuum
pump and put it into operation to keep negative
pressure in the hydraulic oil tank.
Be sure to run the vacuum pump continuously
while working.
W3-3-1
M104-07-021

Removal
1. Attach tags to hoses and adapters of the center
joint to aid in assembly.
Disconnect all hoses and adapters from the center joint. Plug all disconnected ends.
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)
2. Remove bolt (1) from the center joint to remove

stopper plate (2).
: 22 mm
: 140 Nm (14.5 kgfm, 105 lbfft)
CAUTION: Center joint weight: 27 kg (60 lb)

3. Remove bolt (3) from the center joint. Hoist the
center joint and remove it by crane.
: 19 mm
: 90 Nm (9.2 kgfm, 67 lbfft)
W157-03-03-003
Installation
wrench sizes and tightening torque.
1. Install the center joint with bolts (3).

2. Install stopper plate (2) to the center joint with
bolts (1).
3. Connect all hoses to the center joint.
IMPORTANT: After installation, start engine and
check the component for any oil
leaks.
W105-03-03-003
W3-3-2

(Blank)
W3-3-3

DISASSEMBLE CENTER JOINT
1
2
3
4
5
8
10
9
11
12
W157-03-03-002
1 - Plug (with Ball)

2 - Spindle
3 - Dust Seal
4 - O-Ring
5 - Bushing
6 - Oil Seal (6 Used)
7 - Body
8 - Ring
9 - O-Ring
W3-3-4
10 - Retaining Ring
11 - Cover
12 - Bolt (4 Used)

Disassemble Center Joint
Be sure to thoroughly read Precautions for Disassembly and Assembly Work on page W1-1-1
IMPORTANT: For easy removal, two pins can be

used to pry out oil seals (6). Take
care not to damage the seal groove
with the pins.
CAUTION: Center joint weight: 26.5 kg (60 lb)
6. Remove oil seals (6) (6 used) and O-ring (4) from

body (7).
1. Remove mounting bolt (12) from cover (11)

diagonally. Using eyebolts M10 (pitch 1.5, length
18 mm), hoist the center joint then secure it on a
work bench.
IMPORTANT: Put matching marks on body (7) and
spindle (2).
2. Remove bolts (12) to remove cover (11) from
body (7).
: 17 mm
3. Remove O-ring (9), retaining ring (10) and ring (8)
from body (7).
W105-03-03-015
4. Attach the special tool (ST 1033, ST 1020) to

body (7) with mounting bolts (12) (2 used) on
cover (11).
: 17 mm
ST 1020
7. Remove dust seal (3) from spindle (2).

IMPORTANT: While welding, be sure to cover the
seal surface to prevent it from being
spattered.
8. When replacing bushing (5), build-up weld at 4
places in its inner diameter with welding rod,
shrink bushing (5) to pull it out.
ST 1033
W506-03-03-002
IMPORTANT: Take care not to damage the sliding

surface of the spindle (2) seal.
5. Remove spindle (2) from body (7).
W3-3-5

ASSEMBLE CENTER JOINT
1
2
3
4
6
7
8
10
11
12
W178-03-03-001
1 - Plug (with Ball)

2 - Spindle
3 - Dust Seal
4 - O-Ring
5 - Bushing
6 - Oil Seal (6 Used)
7 - Body
8 - Ring
9 - O-Ring
W3-3-6
10 - Retaining Ring
11 - Cover
12 - Bolt (4 Used)

Assemble Center Joint
IMPORTANT: If bushing is removed, be sure to
reinstall bushing (5) first. (Refer to
page W3-3-8.)
IMPORTANT: Install dust seal (3) with its lip side
facing body (6).
IMPORTANT: Clearance between body (7) and

spindle (2) is approximately 0.1 mm
(0.004 in), so the spindle must be inserted along axis straight and
slowly.
4. Tap body (7) with a plastic hammer until its surface A is flush with that of spindle (2).
1. Install dust seal (3) into spindle (2).
Surface A
0.1 mm
Dust Seal (3)
Lip
Body (7)
W105-03-03-024
W178-03-03-002
2. Install oil seals (6) (6 used) and o-ring (4) into

body (7).
3. Secure spindle (2) to a work bench. Install body

(7) on spindle (2) with their matching marks
aligned.
IMPORTANT: Be sure to install ring (8) with the

chamfered side facing spindle.
5. Install ring (8) and O-ring (9) to body (7).
6. Install retaining ring (10) to spindle (2).
7. Install cover (11) with bolts (12) (4 used).

: 17 mm
W3-3-7

When replacing the body or spindle with new one, the
following procedures are required.
IMPORTANT: When press bushing (5) into body (7),
grease or molybdenum disulphide
should be applied to the fitting surface.
Replacing Spindle (2)
Replacing Body (7)
1. Clean spindle (2).
Press bushing (5) into body (7).
2. Tap plugs (1) into spindle (2) using special tools
(ST 2559).
1. Clean body (7) and bushing (5).
3. Tap the balls of plug (1) so that the top of each

ball is 0.4 mm (0.016 in) or more lower than the
respective sleeve edge as illustrated in detail D.
2. Press bushing (5) into body (7) with the pressing

tool.
Pressing force: 0.5 to 1.5 t (1100 to 3300 lb)
Pressing tool: ST 2558
ST 2558
Sleeve
0.4 mm
or More
Detail D
W135-03-03-001
W136-03-03-031
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-8

Item
Allowable limit (basis for judgment)
Remedy
1. Wear more than 0.2 mm (0.008 in)
Replace
2. Scored, abnormal wear
Replace
3. Uneven wear (wear range is within 180)
Replace
Wear range is within

one half
Bushing
T157-01-01-040
Body Spindle
Cover
Sliding surface
Scored or serious damage
and sealed part
Sliding surface of 1) Scored or abnormal wear of more than
0.1 mm (0.004 in)
body and spindle,
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 worn less than 0.5 mm
(0.02 in) deep and able to be repaired.
1) Wear more than 0.5 mm (0.02 in)
2) Wear less than 0.5 mm (0.02 in)
Sliding surface
and ring
3) Scored or abnormal wear less than 0.5 mm
(0.02 in) and able to be repaired.
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

(Blank)
W3-3-10
UNDERCARRIAGE / Track Adjuster

REMOVE AND INSTALL TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
Before removing and adjusting the track adjuster, the
tracks and the front idler must be removed first. For
removal of the tracks and front idler, refer to their Removal / Installation sections.
the tracks and front idler have already been removed.
Removal
CAUTION: Track adjuster weight:
180 kg (400 lb)
CAUTION: The front idler may jump out due
to strong spring force when disconnecting
the tracks adjuster (1). Do not stand in the
same direction as to track adjusters (1) removal, nor any vicinity where there may be a
clanged of being injured by the idler flying
off.
Particularly, a strong spring force is always
applied to the threaded part of the rod. If the
rod and/or the threads are damaged, metal
fragments under spring force may fly off.
Take due care.
2
1
1. After removing the front idler with yoke, remove

track adjuster (1) from track frame (2) by prying it
out with a pry bar.
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Check that the end face of track adjuster (1)
comes into contact with the face of plate (4).
W157-03-04-003
W157-03-04-002
Section A
W3-4-1
W157-03-04-001

DISASSEMBLE TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
17
1
2
3
4
5
6
7
10
16
11
12
15
14
13
W173-03-04-001
12345-

Flange
Dust Seal
Piston Rod
Wear Ring
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

Disassemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH)
IMPORTANT: Be sure to use special tool (ST 4920)
for assembly / disassembly of the
track adjuster.
CAUTION: Prevent personal injury. The
spring force of the track adjuster is extremely
large. Thoroughly inspect the special tool for
any damage. Carefully perform assembly
work referring to the procedure below.
Special Tool
(ST 4290)
CAUTION: Approximate weight of the track

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

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

4036).
: 46 mm
Plate (ST 4036)
W105-03-04-007

180 kg (400 lb)
3. Attach a wire rope to the track adjuster as illustrated.
Hoist the track adjuster to place it onto the holder
of special tool by crane.
W105-03-04-009
W3-4-3
11
12
14
13
W173-03-04-001
W3-4-4

4. Install plate (ST 4036) on the track adjuster and
secure them together.
Plate (ST 4036)
W105-03-04-011
5. Set an oil jack as illustrated.

Jack up the specified amount below to compress
the spring.
Specified Amount
122 mm = (Free length : 679 mm) (Set length :
557 mm)
Oil Jack
NOTE: 1 mm = 0.03937 in
6. Tighten nuts to secure the track adjuster.
Operate the oil jack to compress the track adjuster approximately 10 mm (0.4 in) until a clearance is observed between washer (14) and nut
(13).
: 46 mm
W105-03-04-013
7. Remove plug (11) from nut (13). Remove nut (13)

and valve (12) from rod (8).
: 5 mm
: 85 mm
: 24 mm
W105-03-04-012
13
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

8. Lower jack to release the spring force.
Oil Jack
W105-03-04-015
9. Remove the nuts to remove the plate (ST 4036).

Remove washer (14).
Plate (ST 4036)
14
CAUTION: Spring assembly weight:

168 kg (370 lb)
10. Install eyebolt (M16, pitch 1.5) to rod (8).
Hoist the track adjuster by crane, to remove the
spring (16) assembly.
W105-03-04-016
Eyebolt
CAUTION: Spring weight: 95 kg (209 lb)

11. Remove spring (16) from rod (8) after removing
the eyebolt.
12. Remove spacer (15) from rod (8).
CAUTION: Note that holder (17) is pressed to
piston rod (4).
W105-03-04-017
13. Remove socket bolts (1) (4 used). Move flange (2)

to holder (17). Pull out flange (2) from cylinder
(10).
: 8 mm
14. Pull out piston rod (4) assembly from cylinder

(10).
15. Press out holder (17) from piston rod (4) assembly with a press.
16. Remove flange (2) from piston rod (4). Remove
dust seal (3) from flange (2).
17. Remove rod (8) and O-ring (9) from cylinder (10).
18. Remove wear ring (5), retaining ring (7) and Uring (6) from piston rod (4).
W3-4-7
6
7
W105-03-04-023

ASSEMBLE TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
12
11
14
15
16
13
Chamber B
10
Chamber A
17
557 mm (Free Length 679 mm)

1ft 9.9 in (Free Lenght 2ft 2.7 in)
W1HH-03-04-001
778 mm (2 ft 6.6 in)
12345-

Flange
Dust Seal
Piston Rod
Wear Ring
6789-
U-Ring
Retaining Ring
Rod
O-Ring
10 11 12 13 -
W3-4-8
Cylinder
Plug
Valve
Nut
14 15 16 17 -
Washer
Spacer
Spring
Holder

Assemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH)
1. Install dust seal (3) on flange (2).
IMPORTANT: Fill grease into chamber (A) of flange

(2).
2. Install flange (2) on piston rod (4).
6
7
3. Apply grease to inner face of holder (17). Press

holder (17) to piston rod (4).
4. Clean all parts.
Install U-ring (6), retaining ring (7), and wear ring
(5) to piston rod (4).
5. Apply a firm of grease to O-ring (9) and install it
into cylinder (10).
Install rod (8) into cylinder (10).
5
W105-03-04-025
10
6
5
IMPORTANT: Fill chamber (B) in cylinder (10) with

grease and insert piston rod (4) to
completely bleed air from chamber
(B) and from the inside of rod (8).
6. Apply grease to U-ring (6), wear ring (5), cylinder
(10), and piston rod (4). Install piston rod (4) assembly into cylinder (10).
7. Tighten flange (2) with socket bolts (1) (4 used).
: 8 mm
: 64 Nm (6.5 kgfm, 47 lbfft)
W105-03-04-021
8. Install spacer (15) on rod (8).

CAUTION: Spring weight: 95 kg (209 lb)
9. Install spring (16) on rod (8).
CAUTION: Spring assembly weight:
168 kg (370 lb)
W105-03-04-017
10. Install eyebolt (M16, pitch1.5) to rod (8).

Hoist and set the spring (16) assembly onto the
special tool by crane.
W3-4-9
11
13
14
16
W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-10

11. Install washer (14) on spring (16) after removing
the eye bolt.
Install the plate (ST 4036).
Plate (ST 4036)
14
16
W105-03-04-016
12. Tighten the nuts to secure the spring assembly.

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

specification.
Compressed Length: 557 mm (1 ft 9.9 in)
16
Oil Jack
W105-03-04-026
13
14. Install nut (13) and plug (11) to rod (8).

: 85 mm
: 5 mm
: 14.5 Nm (1.5 kgfm, 11 lbfft)
11
W105-03-04-014
W3-4-11
12

W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-12

15. Install valve (12) to rod (8).
: 24 mm
16. Lower the oil jack.
Oil Jack
W105-03-04-013
17. Remove the nuts and plate (ST 4036).

: 46 mm
Plate (ST 4036)
W105-03-04-011
Wire Rope

180 kg (397 lb)
18. Attach a wire rope to the track adjuster as illustrated. Hoist and remove the track adjuster from
the special tool by crane.
IMPORTANT: If only the spring assembly is to be
transported, be sure to use a special
tool, such as the one illustrated, to
carry the spring assembly safely.
W105-03-04-009
W105-03-04-028
W3-4-13

(Blank)
W3-4-14

REMOVE AND INSTALL TRACK ADJUSTER
(ZAXIS370MTH)
Before removing the track adjuster, the tracks and the
front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal and installation sections. In this
section, the procedure starts on the premise that the
tracks and the front idler have already been removed.
CAUTION: When removing track adjuster (1),
the track adjuster may fly off by spring force.
Do not stand in the removal direction of the
track adjuster or in places where the track adjuster may fly out. The rod screw is loaded by
spring force.
Be alert that if the rod or screw section is
broken, the broken pieces may fly out by
spring force, causing personal injury and/or
death.
2
1
W142-03-04-002
Removal
250 kg (550 lb)
1. Remove track adjuster (1) from track frame (2) by
prying it with a crowbar.
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Check that the end face of track adjuster (1)
comes into contact with the face of plate (4).
W16J-03-04-002
Viewed from A
W3-4-15
W16J-03-04-001

DISASSEMBLE TRACK ADJUSTER
(ZAXIS370MTH)
3
4
5
7
8
9
10
16
11
15
12
14
W166-03-04-003
13
1234-

O-Ring
Guide
Piston Rod
5678-
Wear Ring
U-Ring
Retaining Ring
Rod
910 11 12 -
Cylinder
O-Ring
Bolt
Valve
W3-4-16
13 14 15 16 -
Nut
Bracket
Spring
Spacer

Disassemble Track Adjuster
(ZAXIS370MTH)
Be sure to read all Precautions for Disassembly
and Assembly Work thoroughly on page W1-1-1
Use a pump unit which has the maximum pres2
sure of 69 Mpa (700 kgf/cm , 9950 psi) and the
flow rate of 8 to 10 liters (2.1 to 2.6 US gal). Be
sure to set the main relief pressure to 49 Mpa
2
(500 kgf/cm , 7110 psi) (80 tons) or lower.
Track Adjuster
IMPORTANT: Be sure to use special tool (ST4932)

to assemble / disassemble the track
adjuster.
ST 4932
CAUTION: Prevent personal injury. The

spring force of the track adjuster is extremely
large. Thoroughly inspect the special tool for
any damage. Carefully perform assembly
work referring to the procedure below.
250 kg (550 lb)
1. Hoist the track adjuster by crane. Position the
track adjuster on the rest of special tool (ST
4932).
Rest
W142-03-04-019
IMPORTANT: Compress the spring until the clearance between bracket (14) and nut
(13) is approximately 10 mm (0.4 in).
2. Loosen valve (12). Compress track adjuster
spring (15) using special tool (ST 4932).
: 24 mm
IMPORTANT: Put matching marks on rod (8) and
nut (13).
3. Remove valve (12) and bolt (11) to remove nut
(13).
: 24 mm, 17 mm, 100 mm
15
Clearance 10 mm (0.39 in)
14
13
11
12
W142-03-04-020
W3-4-17
16
15
14
W3-4-18
W166-03-04-003

4. Slowly return the piston of special tool (ST 4932)
until spring (15) extends to its free length.
NOTE: Spring (15) free length: 774 mm
15

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

Attach a nylon sling around spring (15) and
through the eyebolt. Hoist and position the assembly on the rest by crane, as illustrated.
W142-03-04-005
15
CAUTION: Cylinder (9) assembly weight:

80 kg (180 lb)
7. Hoist and remove cylinder (9) assemblies (1 to
10) from spring (15).
Rest
W142-03-04-006
CAUTION: Spring weight: 140 kg (310 Ib)

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

9. Remove spacer (16) and bracket (14) out of the
rest.
15
Rest
W142-03-04-007
W3-4-19
3
4
5
7
8
9
10
W166-03-04-003
W3-4-20

10. Remove socket bolts (1) (4 used) to remove guide
(3) from piston rod (4).
: 12 mm
3
1
11. Pull out piston rod (4) from cylinder (9).

4
10
12. Remove O-ring (2) from guide (3).

CAUTION: Cylinder (9) weight: 40 kg (88 Ib)
Rod (8) weight: 21 kg (50 Ib)
13. Install eyebolt (M16, Pitch 2.0) into rod (8).
Hoist and remove the rod from cylinder (9) by
crane.
Remove O-ring (10) from inside of the cylinder.
14. Remove wear ring (5), retaining ring (7) and Uring (6) from piston rod (4).
9
8
W142-03-04-010
4
5
6
W166-03-04-001
W3-4-21

ASSEMBLE TRACK ADJUSTER
(ZAXIS370MTH)
10
16
Chamber
A
1234-

O-Ring
Guide
Piston Rod
5678-
Wear Ring
U-Ring
Retaining Ring
Rod
14
Chamber B
910 11 12 -
Grease Outlet
15
Cylinder
O-Ring
Bolt
Valve
W3-4-22
11 12
13
13 14 15 16 -
Nut
Bracket
Spring
Spacer
W16J-03-04-003

Assemble Track Adjuster
(ZAXIS370MTH)
IMPORTANT: Apply grease onto wear ring (5) and

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

2. Apply grease to O-ring (10) and install the O-ring
onto cylinder (9). Install eyebolt (M16, Pitch 2.0)
into rod (8). Hoist and install the rod into the cylinder by crane.
W166-03-04-001
10
CAUTION: Piston rod (4) weight: 16 kg (40 Ib)

IMPORTANT: Fill chamber (B) in cylinder (9) with
grease and insert piston rod (4) to
bleed air completely out from chamber (B) and from the inside of rod (8).
Apply hydraulic oil to the inner surface of the cylinder and on the surface piston rod.
3. Install eyebolt (M10, Pitch 1.5) into piston rod (4).
Hoist and install the piston rod into cylinder (9) by
crane.
IMPORTANT: Fill chamber (A) in guide (3) with
grease.
Apply grease to O-ring (2) and apply
LOCTITE #262 to socket bolts (1) (4
used).
4. Install O-ring (2) onto guide (3). Install the guide
onto cylinder (9) with socket bolts (1) (4 used).
: 12 mm
: 175 Nm (18 kgfm, 130 lbfft)
W142-03-04-012
2
1
W142-03-04-018
W3-4-23
16
14
Grease Outlet
15
W3-4-24
W16J-03-04-003

CAUTION: Bracket (14) weight: 22 kg (50 lb)
Spring (15) weight: 140 kg (310 lb)
5. Attach a nylon sling to bracket (14). Hoist and
place the bracket and spacer (16) on the rest by
crane. Attach the nylon sling to spring (15). Hoist
and place the spring to the bracket by crane. Bind
the bracket and the spring together with pieces of
wire.
16
CAUTION: Cylinder (9) assembly weight:

60 kg (130 lb)
6. Install eyebolt (M10, Pitch 1.5) to piston rod (4).
Hoist and install the cylinder (9) assembly while
aligning spacer (16) and bracket (14) by crane.
250 kg (550 lb)
7. Attach a nylon sling to spring (15) and pass it
through the eyebolt on piston rod (4). Hoist and
place it horizontally and slowly.
15
14
Rest
W142-03-04-007
15
IMPORTANT: Set rod (8) with its grease outlet facing down.
8. Hoist and position the track adjuster on special
tool (ST 4932) by crane. Remove the eyebolt.
W142-03-04-006
ST 4932
W142-03-04-005
W3-4-25
15
14
11 12

24.5 in (Free Length 30.5 in))
884 mm (35 in)
W3-4-26
Grease Outlet
13
W16J-03-04-003

IMPORTANT: Be sure to slowly compress spring
(15) while aligning the center of rod
(8) with the center of bracket (14)
using a crowbar.
Take care not to damage the threads
on rod (8).
9. Remove a wire from spring (15). Compress spring
(15) by operating the cylinder of special tool (ST
4932) until the specified spring length is obtained.
Specified Spring Length: 620 mm (24.5 in)
15
ST 4932
14
IMPORTANT: Align matching marks put during

disassembling. Moreover, be sure to
align the grease outlets both in rod
(8) and nut (13).
10. Install nut (13) and bolt (11) to rod (8).
: 100 mm
: 17 mm
Wire
W142-03-04-015
11. Tighten valve (12).

: 24 mm
: 147 Nm (15 kgfm, 108 lbfft)
12. Retract the cylinder of special tool (ST 4932).
13

250 kg (550 lb)
13. Securely fasten a sling belt to the track adjuster.
Hoist and remove the track adjuster from the special tool by crane.
IMPORTANT: If the spring assembly must be
transported, take care not to damage
it. Use a firm steel box for transportation of the spring assembly and
take any other precautions in order
to insure safe transportation.
W3-4-27
11
12
W142-03-04-020

(Blank)
W3-4-28
UNDERCARRIAGE / Front Idler

REMOVE AND INSTALL FRONT IDLER
Before removing the front idler, the tracks must be
removed first. For removal and installation of the
tracks, refer to Remove and Install Tracks section.
the tracks have already been removed.
Removal
CAUTION: Front idler weight:
ZAXIS330, 330LC: 160 kg (350 lb)
ZAXIS350H, 350LCH: 160 kg (350 lb)
W142-03-05-002
CAUTION: The front idler may fly off due to

strong spring force from the track adjuster
spring when removing it. Give yourself ample
clearance, staying clear of the front idlers
line.
1. Pry the front idler with a crowbar to remove it from
track frame (3). At this time yoke (2) can be
removed along with it.
1
2
4
5
2. Attach sling belts to bearing (1) and yoke (2)

sections. Hoist and remove the front idler from
track frame (3) by crane.
3. Remove bolts (5) and remove guard (4) from yoke
(2). (ZAXIS370MTH only)
: 19 mm
W17P-03-05-001
Wooden Block
4. When storing the front idler, place it on blocks as

shown.
W105-03-05-003
Installation
IMPORTANT: Apply grease to the bearing (1) sliding surface on track frame (3) after
cleaning.
1. Attach the front idler to a hoist, then install it to
track frame following the reverse order of removal
procedures.
W17P-03-05-001
W3-5-1

DISASSEMBLE FRONT IDLER
2
3
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)
NOTE: Guard (9), Bolt (10) (3 used), Spring

Washer (11) (3 used), and (14) (4 used):
These are equipped to ZAXIS370MTH only.
W3-5-2
12 - Yoke
13 - Bolt (4 Used)

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

ZAXIS330, 330LC, 350H, 350LCH: 25 kg (55 lb)
2. Attach a nylon sling to yoke (12) and hold it by
crane. Remove bolts (13) (4 used). Hoist and remove yoke (12) by crane.
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
ZAXIS370MTH:
: 30 mm
3. Place idler (7) horizontally. Remove plug (8) from
the lower side to drain oil.
: 6 mm
4. Pull pin (2) out from bearing (1) with a bar and
hammer.
1
3
7
3
4
5
1
W105-03-05-009
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH:
Idler assembly weight : 115 kg (250 lb)
Axle (5) weight: 17 kg (37 lb)
Bearing (1) weight: 15 kg (33 lb)
ZAXIS370MTH:
Idler assembly weight : 150 kg (330 lb)
5. Put matching marks on bearing (1) and axle (5).
Pull out the axle (5) assembly from idler (7) with a
press.
1
W105-03-05-008
W3-5-3
6
4
5
4
2
W16J-03-05-001
W3-5-4

CAUTION: Axle (5) assembly weight:
IMPORTANT: Place wooden blocks or etc. under
the lower part of the bearing to prevent bearing (1) from being damaged.
7. Wind a nylon sling to the axle (5) assembly. Hoist
and place bearing (1) onto wooden blocks by
crane.
IMPORTANT: Do not remove bushing (6) unless

necessary.
9. When replace bushing (6), pull the bushing out
with a bushing pulling tool and press.
Bushing pulling tool:
ZAXIS330, 330LC, 350H, 350LCH: ST 1425
ZAXIS370MTH: ST 1973
8. Pull pin (2) out with a bar and hammer.

Put matching marks on bearing (1) and axle (5).
Pull out the axle from the bearing with a press.
Remove O-rings (4) (2 used) from the axle.
Bushing
Pulling
Tool
4
6
1
Wooden Block
W105-03-05-011
4
W105-03-05-010
W3-5-5

ASSEMBLE FRONT IDLER
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)

W3-5-6
W16J-03-05-002
12 - Yoke
13 - Bolt (4 Used)

Assemble Front Idler
and Assembly Work thoroughly on page W1-11 before starting the assembly work.
CAUTION: Idler weight:
ZAXIS330, 330LC: 115 kg (250 lb)
ZAXIS350H, 350LCH: 115 kg (250 lb)
1. Install bushing (6) into idler (7) with a press.
CAUTION: Axle (5) assembly weight:

IMPORTANT: Apply LOCTITE #503 to plug (8).
5. Attach a nylon sling to bearing (1) for the axle (5)
assembly. Hoist the axle assembly by crane and
insert it into idler (7) from the side where floating
seal (3) is installed already.
Install plug (8) into the bearing.
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH:
ZAXIS370MTH:
2. Attach a nylon sling on axle (5). Hoist and place
the axle vertically by crane. Install O-ring (4) (1
used) onto the upper side of the axle.
IMPORTANT: Align the matching marks put during
disassembling.
3. Tap bearing (1) outer race evenly with a plastic
hammer to install the bearing into axle (5). Insert
pin (2) with a bar and hammer.
7
3
W157-03-05-006
CAUTION: Idler (7) assembly weight:

ZAXIS330, 330LC:
115 kg (250 lb)
ZAXIS350H, 350LCH: 115 kg (250 lb)
ZAXIS370MTH:
150 kg (330 lb)
6. Attach a nylon sling to the idler (7) assembly. Hoist
and turn over the idler assembly by crane.
Install O-ring (4) onto axle (5).
IMPORTANT: Apply grease to the O-ring of floating seal (3).

7. Install the other floating seal (3) into idler (7) and
bearing (1).
1
4
W3-5-7
7
1
W105-03-05-014
W1-1-4.
Apply grease to O-ring on the floating
seal.
4. Install a pair of floating seals (3) into idler (7) and
bearing (1).
5
W157-03-05-005
10
11
12
13
14

W3-5-8
W16J-03-05-002

disassembling.
8. Tap the bearing (1) evenly with a plastic hammer
to install the bearing into axle (5). Insert pin (2)
with a bar and hammer.
9. Fill engine oil (API CD grade SAE30) via the plug
(8) hole in bearing (1).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
0.3 L (0.08 US gal.)
ZAXIS370MTH:
0.45 L (0.12 US gal.)
10. Install plug (8) into bearing (1).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
CAUTION: Yoke (12) weight:
11. Attach a nylon sling to yoke (12). Hoist and align
the bolt (13) hole in the yoke and bearing (1).
12. Install spring washer (14) onto each bolt (13) (4
used) (ZAXIS370MTH only). Install yoke (12) into
bearing (1) with the bolts (4 used) on both sides.
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
: 210 Nm (21 kgfm, 150 lbfft)
ZAXIS370MTH:
: 30 mm
: 390 Nm (40 kgfm, 290 lbfft)
13. Install spring washer (11) onto each bolt (10) (3
used). Install guard (9) onto yoke (12) with the
bolts (3 used). (ZAXIS370MTH only)
: 19 mm
W3-5-9

E
A
W166-03-05-001
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
102 (402)
[82 (3.23)]
200 (7.87)
572 (22.51) [552.2 (21.74)]

617 (24.29)
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
Cladding by welding and finish or

replace
Axle and Bushing

Unit: mm (in)
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)
NOTE: Values in [ ] are just for reference.
W3-5-10
ZAXIS370MTH
Standard
Remedy
Replace
UNDERCARRIAGE / Upper And Lower Roller

REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or loosen it too much as the valve
may fly off or high-pressure grease in the adjusting cylinder may gush out.
Loosen carefully, keeping body parts and
face away from the valve.
Never loosen grease fitting (2).
W105-03-06-001
IMPORTANT: When gravel or mud is packed between sprockets and tracks, remove
it before loosening valve (1).
It is enough to loosen the valve by
1 to 1.5 turns.
Do not loosen the valve over that
degree.
1. Loosen valve (1) on the track adjuster to drain
grease.
: 24 mm
Grease Outlet
M116-07-094
Oil Jack
CAUTION: Use a nonskid cloth between

track frame (5) and oil jack to prevent slipping.
2. Jack tracks (3) up high enough to permit upper
roller (4) to be removed.
Nonskid Cloth
4
W105-03-06-002
3. Insert wooden block between tracks (3) and track

frame (5).
5
Wooden Block
W105-03-06-003
W3-6-1

4. Remove bolts (6) (4 used) on upper roller (4).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
ZAXIS370MTH:
: 27 mm
W157-03-06-001
CAUTION: Upper roller weight:

5. Remove upper roller (4) from track frame (5).
4
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)
W105-03-06-005
6
5
3
W157-03-06-001
2. Remove the wooden block and oil jack between

track (3) and track frame (5).
5
W105-03-06-002
W3-6-2

3. Tighten valve (1) on the track adjuster.
: 24 mm
: 147 Nm (15 kgfm, 108 Ibfft)
CAUTION: Support the jacked up machine

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

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

an assembly.
6. Apply engine oil (API CD class SAE30) to the plug
(8) hole in cover (7).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
75 mL (0.02 US gal.)
ZAXIS370MTH:
120 mL (0.032 US gal.)
W157-03-06-002
IMPORTANT: Apply LOCTITE #503 onto plug (8).

7. Tighten plug (8).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
W158-03-06-001
W3-6-3

REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove the track guard and then remove mounting bolts (1) (4 used) of lower roller (5).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm
ZAXIS370MTH:
: 32 mm
5
1
W105-03-06-008
2. Raise one side of the track frame high enough

(90 to 110 between boom and arm is obtained
when the bucket is lowered with the round bottom
contacting with ground) to remove the lower roller.
Insert wooden blocks under track frame (2).
90 to 110
M104-07-067
CAUTION: Do not loosen valve (3) quickly or

loosen it too much as high-pressure grease
in the adjusting cylinder may gush out.
face away from the valve.
Never loosen grease fitting (4).
IMPORTANT: It is enough to loosen valve (3) by 1
to 1.5 turns. Do not loosen it over
that degree.
3. Loosen valve (3) on the track adjuster to drain
enough grease to permit the roller (5) to be removed.
: 24 mm
W105-03-06-001
Grease Outlet
M116-07-094
W3-6-4
CAUTION: Lower roller weight:

ZAXIS330, 330LC, 350H, 350LCH:
54 kg (120 lb)
4. Remove lower roller (5) with a fork lift.
5
W105-03-06-010
Installation
1. Put lower rollers (5) below track frame (2) with a
fork lift as illustrated.
2. Lower track frame (2) so that track frame may

keep a little away from collar (6).
W105-03-06-011
3. Align the bolt (1) holes and tighten bolts (1) (4

used).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm
: 670 Nm (68.5 kgfm, 500 lbfft)
ZAXIS370MTH:
: 32 mm
: 750 Nm (76.5 kgfm, 550 Ibfft)
W105-03-06-012
W105-03-06-008
W3-6-5

4
4. Tighten valve (3) on the track adjuster.

: 24 mm
: 147 Nm (15 kgfm, 108 Ibfft)
Grease Outlet
CAUTION: Support the jacked up machine

5. Jack up the track to be adjusted and rotate it in
reverse direction slightly.
M116-07-094
6. Apply grease through valve fitting (4) to adjust

tracks tension.
ZAXIS330, 330LC, 350H, 350LCH:
340 to 380 mm (13.4 to 15.0 in)
ZAXIS 370MTH:
380 to 430 mm (15.0 to 16.9 in)
W157-03-06-002
W3-6-6

(Blank)
W3-6-7

DISASSEMBLE LOWER ROLLER
7
1
3
4
W166-03-06-006
1 - Floating Seal (2 Used)

2 - Axle
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

Disassemble Lower Roller
and Assembly Work thoroughly on page W1-11 before starting the disassembly work.
4. Remove pin (5) from the axle (2) assembly to

pull the axle out of collar (4) with a press.
3
1. Remove plug (6) from the end of collar (4) to drain

oil.
: 6 mm
IMPORTANT: Put matching marks on collar (4) and
axle (2).
2. Just pull pin (5) out of collar (4) at one side with a
bar and hammer. Then pull axle (2) out of roller
(8) with a press just from the side that pin (5) is
removed. At this time, the pin and collar at opposite also can be removed.
Bar:
ZAXIS330, 330LC, 350H, 350LCH:
Dia. 14 mm (0.6 in)
ZAXIS370MTH: Dia. 25 mm (1 in)
4
W105-03-06-027
5. Remove O-rings (3) (2 used) from axle (2).

1
6. In case it is necessary to replace bushing (7), pull

it out with a bushing pulling tool and press.
Bushing puling tool:
ZAXIS330, 330LC, 350H, 350LCH: ST 1475
ZAXIS370MTH: ST 1955
1
4
Bushing
Pulling
Tool
2
W105-03-06-026
W1-1-4.
3. Remove floating seal (1) from both sides of roller
(8) and collars (4) (2 used).
W105-03-06-028
W3-6-9

ASSEMBLE LOWER ROLLER
ZAXIS330, 330LC, 350H, 350LCH:
4
W1HH-03-06-001
ZAXIS370MTH:
4
W162-03-06-002
1 - Floating Seal (2 Used)

2 - Axle
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

Assemble Lower Roller
1. Install bushings (7) (2 used) onto roller (8) with a
press. Take care not to dent the flange surface of
bushing (7). Apply a coat of grease to O-ring (3)
and install O-ring (3) onto axle (2).
disassembling.
2. Install collar (4) onto axle (2). Secure them with
pin (5). Take care not to damage O-ring (3).
5. Insert axle (2) into roller (8). Install O-ring (3) and
the other collar (4). Then secure them with pin (5).
6. Fill engine oil (API CD class SAE30) via the plug
(6) hole in collar (4).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
0.42 L (0.11 US gal.)
ZAXIS370MTH: 0.5 L (0.13 US gal.)
5
2

7. Install plug (6) into collar (4).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
5
4
W16J-03-06-001
IMPORTANT: Apply LOCTITE #503 onto plug (6).

3. Install plug (6) to one side of collar (4).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
IMPORTANT: Apply grease to O-ring on floating
seal (1). For handling floating seal
(1), refer to the section Precautions
for Handling Floating Seal on page
W1-1-4.
4. Install floating seal (1) to roller (8) and collar (4).
8
W157-03-06-008
W3-6-11
W105-03-06-024

Upper Roller
C
C
A
B
A
B
ZAXIS330, 330LC, 350H, 350LCH
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
Axle and Bushing

Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
Axle
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 [] are just for reference.
W3-6-12
Remedy
Replace

Lower Roller
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
W1HH-03-06-002
W157-03-06-003
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
ZAXIS 370MTH
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
Axle and Bushing

Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
Axle
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
W3-6-13
Remedy
Replace

(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal
CAUTION: Do not loosen valve (1) quickly or
loosen too much since high-pressure grease
in the adjusting cylinder may gush out.
face away from valve (1). Never loosen
grease fitting (2).
W105-03-07-001
1. Move the tracks so that master pin (3) is

positioned over front idler (4).
Put a wooden block under track shoes (5).
W105-03-07-006
2. To loosen the track tension, slowly turn valve (1)

counterclockwise one turn; grease will escape
from grease outlet.
: 24 mm
W105-03-07-002
Grease Outlet
M116-07-094
W3-7-1
CAUTION: The front idler may jump out of
position due to strong spring force when the
track is disconnected. Especially, the strong
spring force is always applied to the bolt part
of the rod. If the rod and/or the bolt are
damaged, metal fragments may fly off when
the track is disconnected.
Take necessary precautions to prevent any
personal injury from occurring.
3. ZAXIS330, 330LC, 350LCH:
Remove retaining ring (6), which is used to
prevent master pin (3) from coming off.
NOTE: If retaining ring (6) interferes with master
link (7), push in master pin (3) to make
clearance between retaining ring (6) and
master pin (3) before attempting to remove
retaining ring (6).
W105-03-07-005
7
3
ZAXIS370MTH:
Remove split pin (8), which is used to secure
master pin (3) from coming off.
NOTE: If split pin (8) interferes with master link (7),
push in master pin (3) to make clearance
between split pin (8) and master pin (3)
before attempting to remove split pin (8).
ZAXIS330, 330LC, 350H, 350LCH
W105-03-07-009
7
3
8
ZAXIS370MTH
W3-7-2
W166-03-07-001
IMPORTANT: The direction for removing is as
illustrated.
Be sure to strike master pin (3) out
correctly.
4. Remove master pin (3) with 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.
3
3
Retaining Ring
Track Link
Master Link
ZAXIS370MTH
ZAXIS330, 330LC, 350H 350LCH

W105-03-07-010
W166-03-07-002
IMPORTANT: Support the jacked up machine

5. Rotate the upperstructure 90 degrees toward the
removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the
boom with the bucket rolled-in to jack up the
machine as illustrated.
Boom
Arm
90 to 110
W105-03-07-012
6. Slowly drive the machine in reverse until the

whole length of the removing track comes on the
ground.
W105-03-07-011
W3-7-3
Installation
1. Jack up the machine and put the track under the
lower roller.
Be sure to position the track in the correct
direction as illustrated.
Sprocket
Side
Idler Side
W105-03-07-013
2. Hoist the track and place it on sprocket (9) by

crane.
W105-03-07-014
3. With the machine kept raised, slowly operate the

lever for the side being installed with track in the
forward direction. Turn travel device (10) while
winding the track around the raised track frame.
10
W105-03-07-015
4. When wind the connecting part of track link onto

front idler (4), lower the machine and place a
wooden block under shoe (5) to support shoe (5).
5
Wooden Block
W3-7-4
W105-03-07-016
IMPORTANT: Install the master pin in the correct
direction as illustrated below.
5. Install master pin (3) with a hammer and special
tool (ST 1970).
ST 1970
W105-03-07-017
Split Pin
Corner
Direction for
installing the
master pin.
Direction for
installing the
master pin.
3
Track Link
Retaining Ring
Master Link
ZAXIS370MTH
ZAXIS330, 330LC, 350H, 350LCH
W166-03-07-002
W105-03-07-010
IMPORTANT: Replace retaining ring (6) with new

one, when installing master link (7).
IMPORTANT: Replace split pin (8) with new one,

when installing the master pin.
6. ZAXIS330, 330LC, 350H, 350LCH:

Install retaining ring (6) with the chamfered side
away from the master pin (3).
ZAXIS370MTH:
Install split pin (8).
ZAXIS330, 330LC, 350H, 350LCH
W105-03-07-009
ZAXIS370MTH
W3-7-5
W166-03-07-001
Bushing
IMPORTANT: If any links have been removed from

the track, be sure to fill grease
(Daphne Epones SR) into the clearance between the pin and bushing.
When reconnecting the links, stand
the bushing on a flat plate. Fill the
bushing bore with grease.
Insert the pin into the bushing while
pushing the bushing onto the plate
to prevent it from floating because
of grease. When the pin is inserted
in, wipe off excess grease. Pay attention to the direction to install the
seal.
Seal
Pin
Do not Apply
Grease
Grease
Do not Apply
Grease
W197-03-07-001
Seal
7. Tighten valve (1) on the track adjuster. Apply

grease into the cylinder of the track adjuster
through the grease fitting (2) to adjust the tracks
tension.
: 24 mm
: 147 Nm (15 kgfm, 108 lbfft)
NOTE: Check track sag after cleaning the track
frame and track.
ZAXIS330, 330LC, 350H, 350LCH:
340 to 380 mm (13.4 to 15.0 in)
ZAXIS370MTH:
380 to 430 mm (15.0 to 16.9 in)
Grease Outlet
M116-07-094
W105-03-07-018
W157-03-06-002
W3-7-6
Link Pin and Track Bushing
Measure the length of four links, as illustrated,
with tension on the track.
Do not measure the master-pin-included part of
the track.
A
W155-03-07-001
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
865.9 (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
ZAXIS330, 330LC, 350H, 350LCH
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)]
Remedy
Replace
W3-7-7
Master Bushing
W105-03-07-023
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Remedy
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)
Replace
Grouser Shoe
W105-03-07-024
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Remedy
600 mm Grouser
Standard
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
Replace
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
242(9.53)
Allowable
Limit
-
44.69(1.76)
41.7(1.64)
Standard
ZAXIS370MTH
254(10.00)
Allowable
Limit
-
47.57(1.87)
44.57(1.76)
Standard
W3-7-9
Remedy
Replace
(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
Standard Dimensions for
Arm and Bucket Connection............... W4-1-11
Standard Dimensions for
Arm and Boom Connection ................ W4-1-12
Group 2 Cylinder
Remove and Install Cylinder .................. W4-2-1
Hydraulic Circuit Pressure
Release Procedure............................. W4-2-15
Disassemble Cylinder........................... W4-2-16
Assemble Cylinder ............................... W4-2-22
Maintenance Standard ......................... W4-2-26
1HHW-4-1
(Blank)
1HHW-4-2
FRONT ATTACHMENT / Front Attachment

REMOVE AND INSTALL FRONT ATTACHMENT
lines.
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
any repair work.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
pressure.

W4-1-1
W105-04-02-001

Removal
1. Remove lubrication pipe (1) from the adapter on
the boss at the boom cylinder rod side.
(2 places on both left and right)
: 19 mm
1
Adapter
2. Remove nuts (4) and stopper pin (6) from boom

cylinder rod front pin (3). Then remove stopper
(5).
(2 places on both left and right)
: 30 mm
Boom Cylinder
W105-04-01-002
CAUTION: Boom cylinder weight:

315 kg (690 lb)
Prevent personal injury.
Metal fragments may fly off when
a hammer is used to remove pins.
Be sure to wear necessary protection, such as goggles, hard hat,
etc.
3. Hoist the boom cylinder by crane. With a bar and
a hammer drive pin (3) into the position where
thrust plate (2) can be removed. Remove thrust
plate (2).
Boom Cylinder
5
4
W178-04-01-004
NOTE: When pin (3) is impossible to pull out. Start

the engine, slightly operate the boom lever
and align the boom cylinder rod pin hole.
W4-1-2

IMPORTANT: Insert a plate which does not come
in contact with the grease fitting in
the boom cylinder.
4. Insert a plate between the boom cylinder and
main frame. Hold the boom cylinder and lower it
by crane.
5. Remove the boom cylinder.
Refer to Remove Boom Cylinder (W4-2-10).
6. Remove other boom cylinder in the same procedures as steps 3, 4, 5.
Plate
7. After stopping the engine, push the air bleeding

valve on the top of hydraulic oil tank to release
any remaining pressure. Then remove the cap.
Completely release the residual pressure from the
hydraulic circuit by performing the Hydraulic Circuit Pressure Release Procedure.
Refer to page W4-2-15.
W157-04-01-005
Air Bleeding Valve
8. Disconnect hoses (7), (8) for the bucket cylinder

and arm cylinder, to cap all openings of disassembled hoses and pipes.
: 36, 41, 50 mm
M157-07-173
W157-04-01-001
W4-1-3

9. Remove bolt (12), spring washer (13), plate (11)
and block (10) from the plate of boom foot pin (9).
: 27 mm
10
11

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH:
7120 kg (15700 lb)
12
13
W178-04-01-001
10. Attach a wire rope to the boom.

Slightly hoist it to take up any wire rope slack by
crane.
11. Insert a bar between the plate of boom foot pin (9)
and the bracket, slightly pull the plate out.
12. Turn the plate upward by hand and turn it left and
right to pull boom foot pin (9) out. (Adjust the position of the boom foot pin hole, hoisting/lowering
the front attachment.)
W105-04-01-008
13. After hoisting the front attachment, move the machine backward.
14. Place the front attachment on wooden blocks.
Plate
Insert Bar
Bracket
W178-04-01-001
W178-04-01-005
W4-1-4

Install Attachment
ZAXIS330, 330LC:
6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH:
7120 kg (15700 lb)
1. Hoist the front attachment by crane.
Move the machine forward, aligning the boom foot
pin holes.
Insert the thrust plates into boom left and right
sides and adjust the clearance between the plate
and frame within 1 mm.
(Adjust the boom foot pin hole, hoisting / lowering
the front attachment.)
CAUTION: Prevent personal injury. Metal
fragments may fly off when a hammer is used
to remove pins. Be sure to wear necessary
protection, such as goggles, hard hats, etc.
10
11
12
13
2. Drive in boom foot pin (9). Install stopper bolt (12),

washer (13), plate (11) and block (10).
: 27 mm
: 400 Nm (41 kgfm, 295 lbfft)
3. Remove the caps from hoses and pipings. Install
bucket cylinder hoses and arm cylinder hoses (7),
(8).
: 36 mm
: 175 Nm (18 kgfm, 130 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
: 50 mm
: 255 Nm (26 kg fm)
W178-04-01-005
W178-04-01-001
W157-04-01-001

315 kg (690 lb)
4. Install the boom cylinder.
Refer to Install Boom Cylinder (W4-2-12).
Boom Cylinder
W105-04-02-040
W4-1-5

fragments may fly off when a hammer is used.
Be sure to wear necessary protection, such
as goggles, hard hats, etc.
5. Hoist the boom cylinder by crane. Insert thrust

plates (2) (2 used), then drive in pin (3), to install
the boom cylinders to both sides.
6. Install stopper (5) and secure it with stopper pin

(6) and nuts (4) (2 used). (2 places on both left
and right)
: 30 mm
: 550 Nm (56 kgfm, 405 lbfft)
Boom Cylinder
5
4
W178-04-01-004
7. Install lubrication pipe (1) onto the boom cylinder

rod side boss. (2 places on both left and right)
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
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
IMPORTANT: After filling hydraulic oil to specified

level, start the engine, check the
connections for any oil leakage.
IMPORTANT: After all work is completed, run each
cylinder several times to stroke end
to bleed air from the circuit.
Boom Cylinder
Bottom Side
W4-1-6
M157-07-156

IMPORTANT: When the arm has been removed
from the boom, perform the following steps when installing the arm.
9. Install thrust plates (14) into arm left and right
sides. Adjust total clearance of left and right within
1.5 mm or less.
14
14
15
15
10. After the arm is installed, apply grease to grease

fitting (15) on the boom connecting boss of the
arm.
IMPORTANT: For handling of HN bushing for the
front attachment, pay attention to
the following.
Precautions for pressing the bushing in:
If a hammer is used to drive the bushing in, the
bushing may be damaged. Use a press.
M157-07-157
Precautions when reinforcing the arm:

Welding heat for arm reinforcement may cause oil
leakage from the bushing and decrease lubrication
performance.
If oil leak occur, replace the bushing.
IMPORTANT: Pull the bushing out or press it with
W4-1-7

Pin Bushing
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)
Boss (Main Frame)
110 (4.33)
111.5 (4.39)
Bushing (Boom Cylinder)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Bushing (Boom Cylinder)
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)
Bushing (Arm Cylinder)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Boss (Boom)
110 (4.33)
111.5 (4.39)
Bushing (Arm Cylinder)
110 (4.33)
111.5 (4.39)
W4-1-8
Remedy
Replace

Unit: mm (in)
Parts Name
G
I
J
K
Standard
Allowable Limit
Pin
90 (3.54)
89.0 (3.50)
Boss (Arm)
90 (3.54)
91.5 (3.60)
Bushing (Bucket Cylinder)
90 (3.54)
91.5 (3.60)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
Bushing (Bucket Cylinder)
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)
IMPORTANT: When replacing HN bushing for the

front attachment, press it with a
press.
W4-1-9
Remedy
Replace

Side Cutter
B
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)
W4-1-10
Remedy
Replace

STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
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)
W4-1-11

STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS330
ZAXIS350H
ZAXIS370MTH
EX300-5
90 (3.5)
418.5 (16.5)
571 (22.5)
IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals of the previous
model machine.
W4-1-12
FRONT ATTACHMENT / Cylinder

REMOVE AND INSTALL CYLINDER
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
pressure.
3. Release pressure from hydraulic oil circuit according to the introduction on page W4-2-15.
W105-04-02-001
W4-2-1

Remove Bucket Cylinder
1. Insert wooden block (3) between bucket cylinder
(1) and arm (2).
1
2. After stopping the engine, push the air release

valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release the bucket circuit pressure.
Refer to Hydraulic Circuit Pressure Release Procedure on page W4-2-15.
3
2
3
W554-04-02-006
CAUTION: Secure links A and B with a wire

to prevent them from falling down before
pushing pin (7) out.
fragments may fly off when a hammer is
used.
Link A
3. Remove nuts (6) (2 used) and stopper pin (4).

Push out pin (7) with a round bar.
Remove thrust plates (5).
6
: 32 mm
Link B
7
1
W158-04-02-006
4. To prevent rod (8) of bucket cylinder (1) from

stretching, pass wire (9) through the cylinder rod
hole and secure it to the bucket cylinder (1) tube.
W4-2-2
W102-04-02-005

5. Disconnect bucket cylinder hoses (12) (2 used) at
the bucket cylinder (1) bottom. Cap all openings.
: 41 mm
10
CAUTION: Bucket cylinder weight:

255 kg (560 lb)
11
15

fragments may fly off when a hammer is
used.
6. Hoist bucket cylinder (1) by crane, to remove nuts

(13) (2 used) and stopper pin (15). Push pin (11)
out.
Remove thrust plate (10).
: 30 mm
13
W1HH-04-02-009
12
7. Remove bucket cylinder (1).
W4-2-3

Install Bucket Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may be
damaged. Use a press.
10
CAUTION: Bucket cylinder weight:

255 kg (560 lb)
11
15

fragments may fly off when a hammer is used
to install pin (11). Be sure to wear necessary
protection, such as goggles, hard hats, etc.
1. Hoist bucket cylinder (1) by crane. Align cylinder
tube side pin hole with the bucket 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)
14
13
W1HH-04-02-009
12
IMPORTANT: After connecting hoses, fill hydraulic

oil to specified level, start the engine,
check the connections for any oil
leaks.
3. Connect bucket cylinder hoses (12) (2 used).

: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
4. Remove wire (9) from rod (8) of bucket cylinder
(1).
W4-2-4
W102-04-02-005

16
17
18
5. Start the engine and operate the bucket lever to

align the cylinder rod side pin hole with those of
links (16), (18). Insert thrust plate (5) and pin (7).
6
W158-04-02-006
19
19
6. Insert stopper pin (4) into stopper (17) and pin (7),
to install nuts (6) (2 used).
: 32 mm
: 550 Nm (56.0 kgfm, 405 lbfft)
IMPORTANT: In case link (18) has been removed
from the arm, never forget to reinsert
thrust plate (19).
IMPORTANT: After all work is completed, run
bucket cylinder for several times to
stroke end to bleed air from the circuit.
W4-2-5
18
18
W157-04-01-015

Remove Arm Cylinder
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).
valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release arm circuit pressure.
Refer to Hydraulic Circuit Pressure Release Procedure on page W4-2-15.
3. Remove bolt (8) from pin (5) at the arm cylinder

(1) rod side. Remove spring washer (7) and plate
(6).
: 27 mm

5 9
W1HH-04-02-001
4. Push pin (5) out, then remove thrust plate (4).
10
11
5. To prevent arm cylinder (1) rod (9) from extending,

pass a wire through the cylinder rod hole and secure it to the arm cylinder (1) tube.
10
W1HH-04-02-002
6. Disconnect hoses (10) (2 used) from the bottom

of arm cylinder (1) and cap all openings.
: 41 mm, 50 mm
7. Disconnect lubrication pipe (11) from arm cylinder
(1).
: 19 mm
W4-2-6

12
CAUTION: Arm cylinder weight:

460 kg (1010 lb)
1
8. Attach a sling belt at the center of gravity of arm

cylinder (1). Hoist it by crane to take-up sag.
as goggle, hard hats, etc.
9. Remove bolt (16) from the tube side pin (13) of
arm cylinder (1). Remove spring washer (15) and
plate (14). Push out pin (13), to remove thrust
plates (12) and remove arm cylinder (1).
: 27 mm
W4-2-7
13
14
15
16
W1HH-04-02-004

Install Arm Cylinder
hammer is used, the bushing may
be damaged. Use a press.
12
CAUTION: Arm cylinder weight:

460 kg (1010 Ib)
1. Attach a sling belt at the center of gravity of arm
cylinder (1). Hoist it by crane. Align the cylinder
tube side hole with the arm cylinder mounting hole
on the boom.
2. Insert thrust plate (12), then install pin (13). Install
plate (14) and spring washer (15) into pin (13) with
bolt (16).
: 27 mm
: 400 Nm (41 kgfm, 300 lbfft)
3. Connect lubrication pipe (11) and arm cylinder (1)
hoses (10) (2 used).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
: 50 mm
: 255 Nm (26 kgfm, 190 lbfft)
MPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leaks.
W4-2-8
13
14
15
W1HH-04-02-004
16
1
10
11
10
W1HH-04-02-002

4. Remove a wire from arm cylinder (1) rod (9). Hoist
arm cylinder (1) by crane. Start the engine, operate arm lever and align the arm cylinder rod side
pin hole with the arm cylinder mounting hole on
arm (17).
4
17

5. Insert thrust plate (4), then install pin (5).

Install plate (6) and spring washer (7) into pin (5)
with bolt (8).
: 27 mm
: 300 Nm (30.5 kgfm, 220 lbfft)
IMPORTANT: When all work is completed, operate
the arm cylinder several times to
W4-2-9
5 9
W1HH-04-02-001

Remove Boom Cylinder
1. Disconnect lubrication pipes (1) from the boom
cylinder.
: 19 mm

315 kg (690 lb)
2. Attach a wire rope to boom cylinder (2) and hoist it
by crane.
W105-04-02-032

3. Remove nuts (5) (2 used), stopper pin (7) and
stopper (6) from the boom cylinder (2) rod to push
pin (4) out.
: 30 mm
4. Place boom cylinder (2) on a bracket. Remove the
other boom cylinder by same method.
6
5
2
W158-04-02-013
5. Operate the boom lever to retract the boom.

To prevent the boom cylinder rod from stretching,
pass the wire through the cylinder rod hole and
secure it to the cylinder tube.
valve to release any remaining pressure from hydraulic oil tank. Then remove the cap.
Release the circuit pressure.
Refer to Release Hydraulic Circuit Pressure Procedure on page W4-2-15.
W4-2-10
W178-04-02-011

7. Disconnect hoses (12) (4 used) from boom cylinder (2) at the boom cylinder bottom. Cap all openings.
: 41 mm

8. Loosen bolt (8) at the cylinder tube side of main
frame, and remove bolt (8), spring washer (9) and
plate (10).
Pull pin (11) out.
: 27 mm
W178-04-02-011
2
13

315 kg (690 lb)
11 10 9
9. Attach a wire rope at the center of gravity of boom

cylinder (2). Hoist it by crane to remove.
Remove the boom cylinder at other side by the
same method.
12
W4-2-11
W1HH-04-02-003
W178-04-02-013

Install Boom Cylinder
hammer is used, the bushing may be
damaged. Use a press.

315 kg (690 lb)
1. Attach a wire rope at the center of gravity of boom

cylinder (2). Hoist it by crane. Align the pin hole at
boom cylinder tube side with the boom cylinder
mounting hole on the main frame.
W178-04-02-013

2
13
2. Insert thrust plate (13) and pin (11). Install spring

washer (9) and plate (10), then tighten with bolt
(8).
: 27 mm
: 390 Nm (40 kgfm, 290 lbfft)
3. Install the boom cylinder at other side by the same
method.
4. Connect hoses (12) (4 used) on boom cylinders
(2) (2 used).
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
IMPORTANT: After filling hydraulic oil to specified
level, start the engine and check the
connections for any oil leaks.
W4-2-12
11 10 9
12
W1HH-04-02-003

5. Hoist boom cylinder (2) by crane. Operate the
boom lever to align the pin hole at cylinder rod
side with the mounting hole of the boom cylinder.
as goggle, hard hats, etc.
6. Install thrust plate (3), drive in pin (4) to connect

boom cylinder (2) with the boom.
7. Install stopper (6), stopper pin (7) and nuts (5) (2
used).
: 30 mm
: 400 Nm (41 kgfm, 300 lbfft)
6
5
2
W158-04-02-013
8. Connect lubrication pipes (1).

: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)
9. Install the boom cylinder at other side by the same
method.
IMPORTANT: When all work is completed, run the

boom cylinder for several times to
W105-04-02-032
W4-2-13

(Blank)
W4-2-14

HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
NOTE: Following method can be used. Do not start
the engine. Operate pilot pump with the
power from battery to deliver pilot pressure
to the spool of control valve.
1. Push the lock lever forward. (Be in OFF condition)
IMPORTANT: Be sure to pull the handle for stopping engine fully out.
Handle to Stop Engine
2. Pull the handle for stopping engine out and secure

it by left foot.
IMPORTANT: Battery will deplete. Be sure to operate key switch for short period.
3. Turn the key switch to START position and operate the lever for releasing any pressure from hydraulic circuit 4 to 5 times.
IMPORTANT: Push the handle for stopping engine
in.
4. Reset the handle for stopping engine.
W178-04-02-010
W4-2-15

DISASSEMBLE CYLINDER
Boom Cylinder
1
10
11
12 13
14
15
13
12
17
18
16
W1HH-04-02-007
Bucket Cylinder
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
Cylinder Head
O-Ring
11 12 13 14 -
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
NOTE: Socket bolt (8) (9 used):

boom cylinder only.
W4-2-16
15 16 17 18 -
Seal Ring
Set Screw
Nut
Cylinder Tube

Arm Cylinder
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
Cylinder Head
O-Ring
11 12 13 14 15 -
Cushion Ring
Wear Ring (2 Used)
Piston
Seal Ring
W4-2-17
16 17 18 19 20 -
Set Screw
Nut
Cylinder Tube
Cushion Ring
Plug

Arm Cylinder
As the other hydraulic oil cylinders are very similar in
construction, disassembling procedures of the arm
cylinder are shown as an example.
1
2
8
9
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
NOTE: Cushion ring (19) and plug (20) are

equipped to the arm cylinder only.
W4-2-18

Disassemble Cylinders
To avoid duplication, disassembling procedures of
the arm cylinder are shown below as an example,
as the other cylinders are very similar in
construction.
3. Pull out cylinder head (9) from cylinder tube (18)

by tapping with a plastic hammer.
4. Secure cylinder rod (1) on special tool (ST5908).
Put matching marks between cylinder rod (1) and
nut (17).
The disassembling procedure below starts on the

premise that the hydraulic lines and the line
securing bands have been removed.
ST 5908
CAUTION: Cylinder weight:

Boom cylinder: 315 kg (690 lb)
Bucket cylinder: 255 kg (560 lb)
Arm cylinder:
460 kg (1010 lb)
W158-04-02-022
1. Hoist and securely place the cylinder on a

workbench by crane. Be sure that the cylinder is
placed horizontally. Drain hydraulic oil from the
cylinder.
5. Remove cushion ring (19) and plug (20) from nut

(17). (arm cylinder only)
: 10 mm
W102-04-02-027
2. Fully extend cylinder rod (1). Secure the rod end

by crane. Remove socket bolts (8) (8 used) from
cylinder head (9).
: 19 mm
(Boom, arm and bucket cylinder)
NOTE: Socket bolts (8) (9 used) are equipped to
the boom cylinder only.
IMPORTANT: Be sure to pull piston rod (1) straight
so as not to damage the sliding
surfaces.
W4-2-19
1
2
9
10
11
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-20

IMPORTANT: As set screw (16) was mushroomed
with a punch and hammer at two
places after it had been screwed in,
cut away its mushroomed portion
using a drill first.
6. Remove set screw (16).
: 6 mm (Boom, arm and bucket cylinder)
7. Loosen nut (17) with special tool (ST5908).
Remove piston (14).
Nut Turning Special Tools:
Boom cylinder : 120 mm (ST 3267)
Arm cylinder : 125 mm (ST 3268)
Bucket cylinder : 105 mm (ST 3266)
ST 5908
W158-04-02-022
IMPORTANT: When removing the seals, take care

not to damage piston (14).
8. Remove seal ring (15), wear rings (13) (2 used)
and teflon rings (12) (2 used) from piston (14).
9. Remove cushion ring (11) from piston rod (1).
10. Wind tape around the thread part of piston rod (1)
in order to protect the seal of cylinder head (9).
Remove the cylinder head from the piston rod.
11. Remove O-ring (10), retaining rings (2) and (7)
from cylinder head (9). Then remove dust seal (3),
ring (5), seal (4), and bushing (6).
Special tools for bushing removal:
Bucket cylinder : 100 mm (ST 1288)
W4-2-21

ASSEMBLE CYLINDER
Arm Cylinder
As the other hydraulic oil cylinders are very similar in
construction, disassembling procedures of the arm
cylinder are shown as an example.
2
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
Cylinder Head
O-Ring
11 12 13 14 15 -
Cushion Ring
Wear Ring (2 Used)
Piston
Seal Ring
NOTE: Cushion Ring (19) and Plug (20) are

equipped to the arm cylinder only.
Socket Bolts (8) are equipped to the boom
cylinder only.
W4-2-22
16 17 18 19 20 -
Set Screw
Nut
Cylinder Tube
Cushion Ring
Plug

Assemble Cylinder
IMPORTANT: Apply hydraulic oil to the inside of
cylinder head (9).
1. Install bushing (6) to cylinder head (9) with a
press.
Special tools for bushing installation:
Bucket cylinder: 100 mm (ST 2360)
IMPORTANT: Install them with ring (5) and seal (4)
grooves facing piston (14).
2. Install ring (5), seal (4), and retaining ring (7) to
cylinder head (9).
3. Install dust seal (3) to cylinder head (9) with a
plastic hammer.
Special tools for dust seal installation:
Boom cylinder : (ST 2392)
Arm cylinder : (ST 2672)
Bucket cylinder: (ST 2357)
4. Install O-ring (10) and retaining ring (2) to cylinder
head (9).
5. Install wear rings (13) (2 used), seal ring (15),
teflon rings (12) (2 used) to piston (14).
6. Wind tape around the thread part of piston rod (1)
in order to protect the seal of cylinder head (9).
Install the cylinder head (9) assembly to piston rod
(1).
IMPORTANT: Be sure to install cushion ring (11)
so that R part faces cylinder head
(9).
7. Install cushion ring (11) to piston rod (1). Install
the piston (14) assembly to piston rod (1).
W4-2-23
18
16
17
19
20
W1HH-04-02-008
W4-2-24

8. Secure piston rod (1) to special tool (ST 5908).
Tighten nut (17) using special tool (ST 5908).
Be sure to align the matching marks on the rod
with that on the nut. Tighten nut (17).
Nut Turning Special Tools:
: Boom cylinder: 8825 883 Nm
(900 90 kg fm, 6500 650 lbfft)
120 mm (ST 3267)
Arm cylinder: 21867 2187 Nm
(2230 223 kg fm, 16100 1610 lbfft)
125 mm (ST 3268)
IMPORTANT: Be sure to align piston rod (1)

assembly with the center of cylinder
tube (18) when inserting, in order to
avoid damaging the rings.
11. Secure cylinder tube (18) horizontally on a work
bench. Insert the piston rod (1) assembly into
cylinder tube (18).
12. Install cylinder head (9) to cylinder tube (18).
Tighten socket bolts (8) (8 used).
: 19 mm
: 834 83 Nm
(85 8.5 kgfm, 615 62 lbfft)
(Boom cylinder, Bucket cylinder)
: 19 mm
: 1226 123 Nm
(125 12.5 kgfm, 905 90 lbfft)
(Arm cylinder)
Bucket cylinder: 10003 1000 Nm

(1020 102 kg fm, 7380 740 lbfft)
105 mm (ST 3266)
ST 5908
NOTE: Socket bolts (8) (9 used) are equipped to

the boom cylinder only.
W158-04-02-022
9. Tighten nut (17) with set screw (16).

Mushroom the head of set screw (16) at two
places with a punch and hammer.
: 6 mm
: 63.7 6.4 Nm
(6.5 0.65 kgfm, 47 4.7 lbfft)
IMPORTANT: Install cushion ring (19) with R
part facing plug (20)
10. Install cushion ring (19) to piston rod (1) with plug
(20). (arm cylinder only)
: 10 mm
: 109.8 11 Nm
(11.2 1.1 kgfm, 181 8 lbfft)
W4-2-25

Wear to Outer Diameter of Rod
Rod Bend and Run Out

Dial Gauge
Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
Unit: mm (in)
Cylinder
Name
Boom
V Block
Recommended Size After

Re-manufacturing (A)
-0.036
105 -0.090
(4.13
-0.001
)
-0.004
Arm
115
-0.036
-0.090
(4.53
-0.001
-0.004
Bucket
95
-0.036
-0.090
(3.74
-0.001
)
-0.004
Unit: mm (in)
Bend
Allowable
limit
Allowable
limit
Run Out
Remedy
0.5 (0.020) 1.0 (0.039)
Repair
1.0 (0.039) 2.0 (0.079)
Replace
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder
Name
Standard Inner Diameter (C)
Allowable
Limit
Remedy
Boom
110
+0.180
+0.115
(4.33
+0.007
+0.005
+0.3 (+0.012)
Replace
Arm
120
+0.180
+0.115
(4.72
+0.007
+0.005
+0.3 (+0.012)
Replace
Bucket
100
+0.165
+0.100
(4.72
+0.006
+0.004
+0.3 (+0.012)
Replace
W4-2-26
MEMO
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SECTION 5
ENGINE AND ACCESSORY

CONTENTS
General Information
Alternator ..................................................6A-13
General Repair Instruction...........................0A-1
Injection Pump ..........................................6A-14
Illustration Arrows........................................0A-2
Bearing Case ............................................6A-18
Abbreviations ..............................................0A-3
Oil Cooler ..................................................6A-20
Nut and Bolt Angular Tightening Method......0A-4
Rocker Arm and Shaft Assembly ...............6A-23
Standard Bolt Torque Specifications ............0A-6
Camshaft...................................................6A-32
Recommended Thread Locking Agents .......0A-8
Cylinder Head............................................6A-39
Main Data and Specifications ......................0A-9
Crank Pulley and Flywheel.........................6A-62
Performance Curve ................................... 0A-11
Timing Gears.............................................6A-66
External View Drawing...............................0A-12
Flywheel Housing ......................................6A-71
Service Standard.......................................0A-13
Oil Pan ......................................................6A-76
Torque Specifications ................................0A-17
Front Cover ...............................................6A-78
Special Tools .............................................0A-25
Piston ........................................................6A-82
Troubleshooting.........................................0A-26
Crankshaft.................................................6A-94
Lubricant Application .................................0A-36
Cylinder Body ..........................................6A-106
Sealant Application....................................0A-36
Engine Cooling
Service Information
Identification................................................0B-1
Lubrication System ......................................0B-2
Fuel System ................................................0B-2
Cooling System ...........................................0B-6
Valve Clearance Adjustment........................0B-6
Compression Pressure Measurement..........0B-8
Recommended Lubricants ...........................0B-9
Engine Oil Viscosity Chart ...........................0B-9
Service Precautions.....................................6B-1
General Description.....................................6B-2
Thermostat ..................................................6B-3
Water Pump ................................................6B-6
Engine Fuel
Service Precautions.................................... 6C-1
General Description.................................... 6C-2
Fuel Filter ................................................... 6C-5
Injection Nozzle Holder............................... 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
Injection Pump ......................................... 6C-17
Starting and Charging

Service Precautions.................................. 6D3-1
Alternator ................................................. 6D3-2
Starter Motor ...........................................6D3-11
1HHW-5-1
Engine Lubrication
Service Precautions ................................... 6G-1
General Description.................................... 6G-2
Oil Pump .................................................... 6G-4
Oil Coolor ................................................... 6G-8
Oil Port Cover ...........................................6G-11
Engine Induction
Service Precaution ...................................... 6J-1
Turbocharger............................................... 6J-2
Troubleshooting........................................... 6J-4
Inspection and Repair ................................. 6J-6
1HHW-5-2
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Hitachi Construction Machinery Co. Ltd
Hitachi Ref. No.
Attn: Publications, Marketing & Product Support

Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM

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MODEL:
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revisions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
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INTRODUCTION

If you have any questions or comments, at if you

Operation Manual of the Engine

The Operators Manual

Information included in the Technical Manual

Information included in the Technical Manual

Information included in the Workshop Manual:

cal Manual (Operational Principle), the Technical

Indicates a situation which, if not conformed to the

SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm , 3560 psi)

A table for conversion from SI units to other system

UNDERSTAND SIGNAL WORDS

CAUTION also calls attention to safety messages in

To avoid confusing machine protection with personal

NOTE indicates an additional explanation for an

Safety signs should be installed, maintained and replaced when necessary.

Learn how to operate the machine and its controls

Allow only trained, qualified, authorized personnel to

Keep your machine in proper working condition.

The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

Avoid wearing loose clothing, jewelry, or other

Operating equipment safely requires the full

PROTECT AGAINST NOISE

ADJUST THE OPERATOR'S SEAT

MOVE AND OPERATE MACHINE SAFELY

Inappropriate engine starting procedures may cause

PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES

CONFIRM DIRECTION OF MACHINE TO

Driving on a slope may cause the machine to slip or

Driving across the face of a slope or steering on a

Death or serious injury may result if you attempt to

The danger of tipping is always present when

Be extra careful before operating on a grade.

Be careful when working on frozen ground.

PARK MACHINE SAFELY

All fuels, most lubricants, and some coolants are

danger of tipping is present when

Take the following precautions when loading /

WARN OTHERS OF SERVICE WORK

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS

Travel reduction gears are under pressure.

STORE ATTACHMENTS SAFELY

USE TOOLS PROPERLY

Makeshift tools, parts, and procedures can create

After operation, engine coolant is hot and under

Hot fluids and surfaces:

Wait for the oil and components to cool before

REPLACE RUBBER HOSES

Failure to periodically replace rubber hoses may

Fuel, hydraulic oil and lubricant leaks can lead to

Short circuits can cause fires.

Spilled fuel and oil, and trash, grease, debris,

If a fire breaks out, failure to stop the engine will

If a fire breaks out, failure to release pressurized air

Turn the emergency engine stop switch to the

If any abnormalities are found, be sure to repair

Damaged or missing heat shields may lead to fires.

Damaged or missing heat shields must be

EVACUATING IN CASE OF FIRE

In an emergency, if the cab door and/or the front

window cannot be opened, break the front or rear