Zx330 Workshop w1hh e 01 PDF

Manual No.
: KM-1HH-E
Vol. No. : W1HH-E-01
330 • 330LC • 350H • 350LCH • 370MTH Excavator Workshop Manual

Workshop Manual
330 • 330LC
350H • 350LCH
370MTH
Excavator
Service Manual (Manual No. KM-1HH-E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO1HH-E
Technical Manual (Troubleshooting) : Vol. No. TT1HH-E
Workshop Manual : Vol. No. W1HH-E
PRINTED IN SINGAPORE (PS) 2005.06
Zaxis330/350/370-WSM 1 1/7/05, 16:28

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7173
FAX: 81-29-831-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center

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

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

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

• On machine safety signs, signal words designating
the degree or level of hazard - DANGER, WARN-
ING, 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.
SA-1223
• Some safety signs don’t 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 per-

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

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

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

replaced when necessary.
• If a safety sign or this manual is damaged or

missing, order a replacement from your author-
ized dealer in the same way you order other
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 ma-
chine 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 au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

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

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

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other

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

tion 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 im-

pairment 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 per-
sonal injury.
• In the walk-around inspection be sure to cover all

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

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

operator’s seat. Store them in their specified lo-
cations.
• Avoid storing transparent bottles in the cab. Don’t

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

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

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

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

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

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

or dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,

steps, and handrails when mounting and dis-
mounting the machine.
008-E01B-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for

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

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

become injured and/or thrown from the cab. Addi-
tionally the operator may be crushed by the over-
turning machine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly

examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine

is in operation to minimize the chance of injury
from an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders.

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

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

levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway

machine.
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

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

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

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

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

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

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

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

travel levers/pedals direction corresponds to the
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. Don’t allow personnel to stay
around the machine while traveling.
SA-387
• Driving on a slope may cause the machine to slip or

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

bucket facing the direction of travel, approxi-
mately 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 turn-
over. If the direction must be changed, move the
machine to level ground, then, change the direc-
tion to ensure sage operation.
019-E01D-0492 SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.

• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the ma-
chine may hit or run over that person, resulting in
serious injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
SA-383
• Keep the travel alarm in working condition (if

equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP

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

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

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

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

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

the operator’s manual.
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

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

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

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

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

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

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

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

be struck by the falling load or may be crushed un-
derneath 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
SA-014
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
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

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

or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position. SA-390
• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

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

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

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

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

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

unloading the machine: SA-395
1) Select firm level ground.

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

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

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

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

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

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

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without se-
curing the machine first.
• Always lower the attachment to the ground

before you work on the machine.
• If you must work on a lifted machine or
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
SA-527
under a machine that is supported solely by a
jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious
injury.
• To prevent accidents, care should be taken to

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

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

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

SA-344
• As pieces may fly off, be sure to keep body and

face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY

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

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

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
stop. Allow all pressure to be released before

removing the cap.
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.
SA-225
• Wait for the oil and components to cool before

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

PERIODICALLY
• Rubber hoses that contain flammable fluids under

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

page of “Periodic replacement of parts” in the
operator’s manual.)
SA-019
• Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front at-
tachment to fall on a person nearby, which may re-
sult in severe burns, gangrene, or otherwise serious
injury or death.
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

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

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

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

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

clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and SA-019
oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.

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

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

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

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

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

them before operating the machine.
S508-E02B-0019
SA-22
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hamper-
ing fire fighting.
• Check the emergency engine stop switch func-
tion 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.
SA-393
• In an emergency, if the cab door and/or the front

window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

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

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

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

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

FLUID LINES
• Flammable spray can be generated by heating near

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

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

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that
contain flammable fluids.
• Clean them thoroughly with nonflammable
solvent before welding or flame cutting them.
510-E01B-0030
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

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

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

from the top of battery.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery
when electrolyte level is lower than specified. Ex- SA-032
plosion of the battery may result.

• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery

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

electrolyte specific gravity.
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when

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

• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with your machine include such items as lu-
bricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know

exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the en-

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

Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air SA-226
can damage the Earth’s atmosphere.

Government regulations may require a certified
air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete, con-

firm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
All information, illustrations and speci- SECTION 4 FRONT ATTACHMENT
fications in this manual are based on
the latest product information available Group 1 Front Attachment
at the time of publication. The right is
reserved to make changes at any time
Group 2 Cylinder
without notice. SECTION 5 ENGINE
COPYRIGHT(C)2005
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Others (Upperstructure)
Group 3 Electrical System Group 7 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)

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

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

area for disassembling work.
W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation M104-07-021
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set

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

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

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting Correct

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

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

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

seal ring surface (C) is parallel with seal
C
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.
b b
a=b a≠b
W110-03-05-004
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
2. Before using a nylon sling, visually check the ny- Scuffing
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

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

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

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

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

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

Four different types and grades of bolt are employed. SA-040
Make sure to employ correct bolts and tighten them

correctly when assembling the machine or compo-
nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt H Bolt, Socket bolt M Bolt
Dia. Size Wrench
Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M 8 13 6 29.5 (3) (22) 19.5 (2) (14.5) 9.8 (1) (7.2)
M 10 17 8 64 (6.5) (47) 49 (5) (36) 19.5 (2) (14.5)
M 12 19 10 108 (11) (80) 88 (9) (65) 34 (3.5) (25.5)
M 14 22 12 175 (18) (130) 137 (14) (101) 54 (5.5) (40)
M 16 24 14 265 (27) (195) 205 (21) (152) 78 (8) (58)
M 18 27 14 390 (40) (290) 295 (30) (220) 118 (12) (87)
M 20 30 17 540 (55) (400) 390 (40) (290) 167 (17) (123)
M 22 32 17 740 (75) (540) 540 (55) (400) 215 (22) (159)
M 24 36 19 930 (95) (690) 690 (70) (505) 275 (28) (205)
M 27 41 19 1370 (140) (1010) 1030 (105) (760) 390 (40) (290)
M 30 46 22 1910 (195) (1410) 1420 (145) (1050) 540 (55) (400)
M 33 50 24 2550 (260) (1880) 1910 (195) (1410) 740 (75) (540)
M 36 55 27 3140 (320) (2310) 2400 (245) (1770) 930 (95) (690)
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diago-
Equally tighten upper and lower alter- Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
WRONG
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008
an air wrench often causes tight- RIGHT WRONG

ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
RIGHT RIGHT WRONG

ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

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

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size mm Tightening

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

new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly in Hose Fittings
8 1
O-ring groove (e). Tightening nut (9) M104-07-033
with O-ring (6) displaced will damage

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

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male and
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of dirt or
damage.
Apply seal tape around threads as shown. Wrap seal tape
in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs de-

pending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-8
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
Each Other
If hoses rub against each other, wear to the
hoses will result, leading to hose rupture. Take
necessary measures to protect hoses from rub-
bing against each other.
W105-01-01-012
Take care so that hoses do not come into contact

WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic in-
spection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual in-
spection 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 defor-
mation, cracks, or other deterioration, and replace as nec-
essary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings
and gaskets, when replacing hoses.
W1-2-10
GENERAL / Painting
PAINTING
Surfaces to Be Painted Painting Colour

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

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

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

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

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

The ambient temperature shall be Track (Undercarriage)
N1.0 (Black)
controlled under 70°C when painting
and drying.
W178-01-03-008
W1-3-2
MEMO
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SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Cab Group 5 Control Valve
Remove and Install Cab.............................W2-1-1 Remove and Install Control Valve ............. W2-5-1
Dimensions of the Cab Glass.....................W2-1-8 Disassemble Control Valve (1) .................. W2-5-4
Assemble Control Valve (1) ....................... W2-5-6
Group 2 Counterweight Disassemble Control Valve (2) .................. W2-5-8
Remove and Install Assemble Control Valve (2) ..................... W2-5-10
Counterweight..........................................W2-2-1 Disassemble Control Valve (3) ................ W2-5-12
Assemble Control Valve (3) ..................... W2-5-14
Group 3 Main Frame Disassemble Control Valve (4) ................ W2-5-18
Remove and Install Assemble Control Valve (4) ..................... W2-5-20
Main Frame..............................................W2-3-1 Disassemble Control Valve (5) ................ W2-5-22
Assemble Control Valve (5) ..................... W2-5-24
Group 4 Pump Device Disassemble Control Valve (6) ................ W2-5-26
Remove and Install Pump Device ..............W2-4-1 Assemble Control Valve (6) ..................... W2-5-28
Disassemble Pump Device ........................W2-4-2 Structure of Valves .................................. W2-5-30
Assemble Pump Device .............................W2-4-8
Disassemble Main Pump ........................W2-4-16 Group 6 Swing Device
Assemble Main Pump ............................W2-4-24 Remove and Install Swing Device ............. W2-6-1
Disassemble Regulator............................W2-4-38 Disassemble Swing Device ....................... W2-6-4
Assemble Regulator.................................W2-4-40 Assemble Swing Device .......................... W2-6-14
Disassemble and Assemble Disassemble Swing Motor ....................... W2-6-22
Pilot Pump .............................................W2-4-42 Assemble Swing Motor............................ W2-6-26
Maintenance Standard .............................W2-4-46 Disassemble and Assemble
Parking Brake Release Valve ................ W2-6-30
Maintenance Standard ............................ W2-6-31
1HHW-2-1
Group 7 Pilot Valve Group 10 Solenoid Valve
Remove and Install Right Remove and Install
Pilot Valve ................................................W2-7-1 Solenoid Valve Unit ............................... W2-10-1
Remove and Install Left Disassemble Propotional Solenoid
Pilot Valve ................................................W2-7-5 Valves (SC, SI and SG) ......................... W2-10-4
Remove and Install Assemble Propotional Solenoid
Travel Pilot Valve .....................................W2-7-9 Valves (SC, SI and SG) ......................... W2-10-6
Disassemble Right and Left Pilot Valves Disassemble Proportional Solenoid
(Up to serial No.320880) ........................W2-7-12 Valves (Torque Control Solenoid Valve,
Disassemble Right and Left Pilot Valves Maximum Pump2 Flow Rate Limit
(Serial No.320881 and up) .....................W2-7-16 Solenoid Valve) ..................................... W2-10-8
Assemble Right and Left Pilot Valves Assemble Proportional Solenoid
(Up to serial No.320880) ........................W2-7-20 Valves (Torque Control Solenoid Valve,
Assemble Right and Left Pilot Valves Maximum Pump2 Flow Rate Limit
(Serial No.320881 and up) .....................W2-7-24 Solenoid Valve) ................................... W2-10-10
Disassemble Travel Pilot Valve (Suitable for the Disassemble and Assemble
machine before March in 2003)..............W2-7-28 Pilot Relief Valve ................................. W2-10-12
Disassemble Travel Pilot Valve (Suitable for the
machine after April in 2003.) ..................W2-7-32
Assemble Travel Pilot Valve (Suitable for the
machine before March in 2003)..............W2-7-36
Assemble Travel Pilot Valve (Suitable for the
machine after April in 2003.) ..................W2-7-42
Group 8 Pilot Shut-Off Valve

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

Remove and Install
Shockless Valve .......................................W2-9-1
Disassemble and Assemble
Shockless Valve .......................................W2-9-2
1HHW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB ZAXIS330, 330LC, 350H, 350LCH:
Removal
1. Remove nuts (2) to remove seat (1).
: 17 mm 2
W178-02-07-006
2. Remove bolts (4) behind the cab to remove rear ZAXIS370MTH:

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

1
W1HH-02-01-004
4
5
W178-02-01-012
W2-1-1
4. Remove filter (6) to remove screws (7) with a
screwdriver, then remove duct (8) from the cab. 6
W178-02-01-013
5. Disconnect harness connectors (10, 11, 12, and
13) on the right side in the cab and remove bolt
to remove ground (9) at rear inside of the cab.
: 17 mm
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 17
(16) to remove duct cover (17).
15
W178-02-01-016
W2-1-2
8. Remove screws (18) and bolts (21) to remove
duct (19) and duct (20).
: 17 mm
18
Mating Surface of Duct
19
W178-02-01-017
20 21
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
W1HH-02-01-003
Section A-A
Lifting Strap
W1HH-02-01-002
W2-1-3
10. Remove cab mounting bolts (23) and nut (24)
from the cab.
: 17 mm
: 24 mm 23
: 8 mm
24
W157-02-01-010
11. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-4
Installation

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
1. Attach the cab with lifting straps to hoist it by

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

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm 24
: 205 N⋅m (21 kgf⋅m, 150 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
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 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
8
W178-02-01-013
4. Install harness connectors (10, 11, 12 and 13) at

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

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

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

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

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2
ZAXIS370MCH: W178-02-07-006
W1HH-02-01-004
W2-1-7
DIMENSIONS OF THE CAB GLASS
A
Chamfer Here
NOTE: Unit: mm
67 303.5
(1 mm=0.039 in) 11 Chamfer along the
R2 periphery unless
otherwise specified
R98 R35
4-φ13 0-1
R3018
405 30 Chamfer both
Section A W178-02-01-019
sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
Suitable for the standard machine

Along the Along the W178-02-01-002 after March in 2002
Periphery Periphery B
c1 c1
(60.3) 261.6±1
(9.4)
R42
R72
Section C W178-02-01-019
366
R2992
C
546±1
14
733
R92
(4 mm)
R58
R58
170.6
R11508
70
50
R1808 R42
882.5 997
321.9±1
W178-02-01-024
(4 mm)
Remove sharp
edges along the
R308 R1898
periphery
R258
100
150 Section B W178-02-01-019

943
W178-02-01-007
W2-1-8
Unit: mm
Chamfer Here Chamfer
Slightly
Chamfer Here
85.4 unless the
Periphery
343.3 213 Polish
Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the Pe-
riphery Polish Chamfered
39.5 D
733
733
C R2465 +0.5
2-φ12.2 -0
(4 mm) Section C 40 6.754°

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

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

R14
364.7 51
R2475 470.6
Chamfer along the W178-02-01-009
(5 mm) Periphery
R115
888.58
W178-02-01-010
W2-1-9
Suitable for the standard machine after March in
2002
W178-02-01-005
A
753
R63
R63
610.5
490
(4 mm)
R115 R115
R167
50
50
512.5
R167
W178-02-01-025
Remove Sharp
edges along the
periphery
Section A
W178-02-01-019
W2-1-10
Remove Cab Glass
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section
Mounting Rubber Glass

CAUTION: When removing broken or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or similar
should be used to tape the broken or
cracked glass ready to reinforce them so as Cab
to prevent injury from occurring. Be sure to Seal Rubber
remove all glass fragments.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal. W178-02-01-022
1. Insert bamboo spatula into position A in mounting W178-02-01-004
rubber to pry the mounting rubber apart along all

periphery. It is easier to remove glass when air is
entered between cab and mounting rubber.
A
2. Tap glass from the side in cab by palm of hand to

take the glass off. Two men are required to do
the work. Mounting Rubber Glass
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 Cab
cannot be replaced individually. Be Seal Rubber
sure to change the cab glass as an
assembly.
The upper front glass is
arched-fringed. If this glass needs W178-02-01-022
to be replaced, contact with the

nearest HITACHI Office to replace it
as an assembly.
W2-1-11
Procedures to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the
A
glass when air is entered between cab and
mounting rubber.
Cab
2. Tap glass from the side in cab by palm of the

W216-02-01-005
hand to take the glass off. Two men are required
to do the work.
W178-02-01-002
Glass
Mounting Rubber
Method to remove rear side cab glass

Cab Inside Stopper
1. Remove stopper (groove rubber) with a minus
(Groove Rubber)
screwdriver.
A
A
2. Insert a bamboo spatula into position A in Cab
mounting rubber to pry the mounting rubber apart
along all periphery. W216-02-01-003
3. Tap glass from the side in cab by palm of the

hand to take the glass off. Two men are required
to do the work.
W178-02-01-005
W2-1-12
Cab Glass Installation Procedure
Left-Hand Cab Glass
Procedure of installing left-hand cab glass, lower
glass of the door and upper front glass.
IMPORTANT: Be sure to install the cab glass and A

mounting rubber using the special CSE Braid
not used. The cab glass assembly
can’t be replaced individually. Be Seal Rubber
assembly.
arched-fringed. If this glass needs
to be replaced, replace it as an Put Connect End in Center of
assembly. Glass Edge and Then Stick It.
W178-02-01-021
1. Install the seal rubber on the left-hand cab glass Lower Glass of Door
and lower glass of the door.
50
Section A
A
CSE Braid
Seal Rubber
10 10
Mounting Rubber Section W178-02-01-020
Mounting
Rubber Cab Glass
5
W178-02-01-023
Cab
2. When the mounting rubber is already on the Seal Rubber
glass, pull and fasten the mounting rubber onto
the mounting face of cab.
W178-02-01-022
W178-02-01-004
W2-1-13
Procedures of installing right-hand cab glass Mounting Rubber Section
IMPORTANT: Be sure to install the cab glass and

Cab Glass Mounting
Rubber
not used. The cab glass assembly
can’t be replaced individually. Be Cab
assembly.
W216-02-01-005
to be replaced, replace it as an
assembly.
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).
NOTE: Rubber aging will cause the contraction of

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

Cab Glass
Mounting
Rubber
Procedures of installing rear cab glass
IMPORTANT: Be sure to install the cab glass and Stopper

not used. The cab glass assembly Cab
can’t be replaced individually. Be
W216-02-01-003
assembly.
to be replaced, replace it as an
assembly.
1. Insert mounting rubber around the cab glass. In-
stall the connectors or mounting rubber with the
bonding agent (Cemedine 366 Standard or
equivalent).
NOTE: Rubber aging will cause the contraction of

rubber, be sure to leave a little extra, install
by pressing with hands. W178-02-01-005
2. After installing the glass assembly on the cab,

insert the stopper into rubber.
W2-1-14
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal 3
CAUTION: Counterweight weight:
ZAXIS330, 330LC: 6800 kg (15000 lb)
ZAXIS350H, 350LCH 370MTH:
7550 kg (16650 lb)
1. Remove caps (1) from counterweight (3) top. In-

stall sling bolts (FLENO RINK BOLT B-42, M42,
W178-02-02-001
Pitch 4.5) to counterweight (3).
Wire Rope
Sling Bolt
2. Attach wire ropes to the sling bolts as illustrated.
Take up slack of wire ropes.
W178-02-02-002
3. Remove bolts (2) and washers (4). Hoist and

remove counterweight (3).
3
ZAXIS330, 330LC:
: 50 mm
ZAXIS350H, 350LCH, 370MTH:
4
: 55 mm
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation

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

frame.
Install washers (4) and tighten bolts (2) to coun-
terweight (3) temporarily. 3
2
ZAXIS330, 330LC: 4
: 50 mm
ZAXIS350H, 350LCH, 370MTH: W178-02-02-003
: 55 mm
2. Remove the wire ropes. Tighten bolts (2) by us-

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

terweight (3).
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work. 5
(Refer to BLEED AIR FROM HY-
DRAULIC OIL TANK on W1-4-1.)
Removal

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS 370MTH: 395kg (870 lb)
W157-02-01-001
1. Remove cab (5). (Refer to “Remove and Install

Cab” in this section.)
: 24 mm, 17 mm, 13 mm
: 8 mm
6

ZAXIS330, 330LC: 6800 kg (15000 lb)
W178-02-02-002
7550 kg (16650 lb)
2. Remove counterweight (6).

(Refer to “Remove and Install Counterweight” in
this section.)
ZAXIS330, 330LC:
: 50 mm
: 55 mm
W2-3-1
CAUTION: Front attachment weight:

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350H, 350LCH: 7050 kg (15540 lb)
ZAXIS 370MTH: 7120 kg (15700 lb) 7
3. Remove front attachment assembly (7).

(Refer to “Remove and Install 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. Remove stopper (4) and bolts (3) from the 3
center joint.
: 17, 22, 27, 41 mm
4
CAUTION: Upperstructure weight:

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

bracket) of main frame and boom bracket. Take
W173-03-03-001
up slack of wire ropes.
If chain block (1) is used, it is not only easy to
adjust the length of wire rope, but also easy to
level the main frame.
Rear of Main Frame

W105-02-03-004
W105-02-03-005
Boom Bracket
1
W157-02-03-001
W2-3-2
6. The mounting angle of swing bearing is specified.
(Refer to W3-1.) Put the matching marks on the
upperstructure and the outer race of swing bear-
ing.
Remove bolt (2) from the swing bearing.
: 41 mm
W105-02-03-007
7. Adjust chain block (1) in order to level the main

frame. Hoist and remove the main frame from the
1
undercarriage.
W157-02-03-002
W2-3-3
Installation
CAUTION: Upperstructure weight:

6560 kg (14460 lb)
1
1. Attach wire ropes to the main frame. Adjust chain
block (1) in order to level the main frame.
Hoist and install the main frame to the undercar-
riage.
As for lifting method, refer to the “Removal”
section.
W157-02-03-002
2. Align the matching marks on the upperstructure

and the outer race of swing bearing.
Install and temporarily tighten bolts (2) to the
swing bearing. Remove wire ropes and tighten
bolts (2) to the swing bearing.
: 41 mm 2
: 1226 N⋅m (125 kgf⋅m, 900 lbf⋅ft)
W105-02-03-007
3. Install all hoses to the center joint.

: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
3
: 27 mm
4
: 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft)
: 41 mm
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
4. Install stopper (4) to the center joint with bolts (3).

: 22 mm
: 54 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)
W173-03-03-001
W2-3-4

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

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

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

(Refer to “Remove and Install Counterweight” in
this section.)
ZAXIS330, 330LC: 6
: 50 mm
: 2260 N⋅m (230 kgf⋅m, 1660 lbf⋅ft) W178-02-02-002
: 55 mm
: 2840 N⋅m (290 kgf⋅m, 2100 lbf⋅ft)
W2-3-5
CAUTION: Front attachment assembly weight:

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

draulic oil.
(Refer to “Remove and Install Front Attachment”
in this section.)
: 19 mm
: 44 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
: 27 mm
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft) 7
: 30 mm W105-02-03-002
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
8. Start the engine. Set the front attachment in pos-

ture for checking hydraulic oil level in its tank.
Check the hydraulic oil level and any oil leakage.
M104-07-021
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
lic oil tank before doing any work.
Air Bleed Plug
Removal
1. Remove the connectors from the pump device.
CAUTION: Pump device weight: 205 kg

(452 lb)
2. Remove all hoses and pipes from the pump

device.
: 17 mm, 27 mm, 36 mm
: 10 mm
W110-02-04-002
3. Install eyebolts (M12, Pitch 1.75 mm) to the
pump device and hold the pump device.
Wrench Tightening Torque
4. Remove the pump device mounting bolts and Remarks
Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
remove the pump device.
: 36 175 (18) (130) Hose
: 17 mm
: 27 93 (9.5) (69) Hose
: 10 88 (9) (65) Bolt
Installation : 17 49 (5) (36) Bolt
1. Install eyebolts on the pump device. Hoist the

pump device.
2. Install the pump device with the pump device

mounting bolts.
3. Install all hoses and pipes to the pump device.
4. Install the connectors to the pump device.
5. Remove the air bleed plugs (2 used) on top of

the regulators. Fill hydraulic oil. (Refer to
W1-1-2.)
6. After completing the work, check hydraulic oil

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

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

(3).
: 5 mm
2. Remove P sensors (46) (2 used).

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

(29). Remove insert (H) from hub (A).
: 6 mm
4. Remove screws (B) (2 used) from hub (A). 46

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

D A G
pins (C) and bolts (G).
F C
5. Remove drain plug (43) and drain gear oil. E
: 22 mm
CAUTION: Pump device weight: 205 kg (452

lb)
6. Secure the pump device assembly on a

workbench.
Workbench : ST 5050
B H W110-02-04-006
W2-4-3
14
20
12
18
15
17
16
19
10
9
11
19
36
32
33
31
34
35
41
40
W1HH-02-04-004
W2-4-4
7. Remove bolt (15). Remove nut (16), washer (17),
and clamp (18) from the pipe.
: 13 mm
8. Remove pipes (12, 14, 19, 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). Remove pilot
pump (35).
: 8 mm
11. Remove bolts (10) (4 used), spring washers (9),

and seal washers (31).
: 24 mm
CAUTION: Main pump weight: 67 kg (148 lb)
12. Install eyebolt (M12, Pitch 1.75 mm) to main

pump (11). Hoist and remove main pump (11).
13. Remove the other main pump in the same pro-

cedures as steps 11 and 12.
14. Remove socket bolts (41) (2 used) and remove

pipe (40).
: 6 mm
W2-4-5
23
45
28
38
24
44
27
25
30
26
W1HH-02-04-004
W2-4-6
CAUTION: Flange assembly weight: 48 kg

(106 lb)
15. Remove flange (23) from the workbench. Turn

over flange (23). Place flange (23) on the
workbench. Remove retaining ring (26) from
flange (23).
16. Remove seal cover (25) from flange (23).
17. Remove oil seal (27) from seal cover (25) by

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)
19. Turn over flange (23). Place flange (23) onto the
press. Remove center shaft (28) and bearing (24) ST 1236
from flange (23) by using special tool (ST 1236).
20. Remove center gear (38) from flange (23).
W173-02-04-003
21. Remove bearing (45) from flange (23) by using

special tool (ST 1235).
ST 1235
22. Remove bearing (24) from center shaft (28) by

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

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

Install bearing (45) by using special tool (ST
2307).
2. Insert center gear (38) into flange (23) from the

main pump mounting hole. Set center gear (38)
onto bearing (45).
3. Place flange (23) on a press. Align center shaft

(28) with the center gear (38) spline. Install
W173-02-04-005
center shaft (28) into bearing (45).
4. Install bearing (24) into flange (23) and center ST 2308

shaft (28) by using special tool (ST 2308) and a
press.
W173-02-04-006
CAUTION: Flange assembly weight: 48 kg

(106 lb)
5. Remove flange (23) from a press. Place flange

(23) on the workbench. Install retaining ring (44)
onto center shaft (28). Install O-ring (30) into
flange (23).
6. Install oil seal (27) into seal cover (25) by using

7. Insert special tool (ST 2280) onto center shaft

(28) and install seal cover (25) into flange (23).
8. Install retaining ring (26) into flange (23).
W2-4-11
W1HH-02-04-001
11 10 9
23
36 35 32, 33, 34 31
W1HH-02-04-002
W2-4-12
9. Turn over flange (23) and place flange (23) on
the workbench. Apply THREEBOND #1215 onto
the pump mounting surface.
Workbench : ST 5050
10. Install eyebolt (M12, Pitch 1.75 mm) to main

pump (11). Hoist and install main pump (11) to
flange (23).
11. Tighten bolts (10) (4 used) with spring washers

(9) and seal washes (31).
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
12. Install the other main pump in the same proce-

dures as steps 10 and 11.
13. Apply THREEBOND #1215 onto the pilot pump

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

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

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
W2-4-13
20
19
18
17, 16, 15
14
W1HH-02-04-001
12
37
28
46
W1HH-02-04-002
W2-4-14
16. Install pipes (12, 14, 19, 20).
: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
: 22 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
17. Install clamp (18) with bolt (15), nut (16), and
washer (17).
: 13 mm
: 3 N⋅m (0.3 kgf⋅m)
Assemble Coupling
D A G
18. Place the pump device horizontal. Install hub (A) F C
to center shaft (28) with screws (B) (2 used).
E
: 8 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
19. Install inserts (H, D) to hub (A) with bolts (E) (4

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

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

: 27 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
CAUTION: Pump device weight: 205 kg

(452 lb)
22. Place the pump device horizontally. Remove plug

(37). Add engine oil.
Engine oil : 1.4 L (0.37 US gal.)
23. Install the pump device with the plug (37) hole
facing to the counterweight.
: 17 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
W2-4-15
DISASSEMBLE MAIN PUMP
47, 48
4
41 31 6
43
42 31
1
3
10
11 16 5
14
15
17
49
44 30
24
25
25
23
39
19 40 37
7 22 34 38
25 46
31 45
21 29
27
13 20 25
25
33 32
18
21
9 12 25
8 20 28
22
2
26
48
36
35
40
39
W173-02-04-026
1- Casing 14 - Oil Seal 27 - Servo Pin 40 - Spring Washer (8 Used)

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

1. Remove retaining ring (11) from the main pump.
2. Remove drive gear (10) by using a puller.
3. Secure the main pump on the workbench (ST

5050).
4. Remove bolts (47) (4 used) and spring washer

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

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

(33). 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. Remove cylinder block (8) upward and remove

valve plate (18) and link (19).
10. Remove spring (12).
W2-4-17
16
14
15
17
13
W173-02-04-026
W2-4-18
11. Remove center shaft (9). Do not lose pin (13).
12. Incline plungers (7) (7 used) to the center of drive

disc (2). Remove plungers (7) upward.
13. Place casing (1) on the workbench. Remove re-

taining ring (17).
14. Place casing (1) on the workbench with the drive 14

disc side upward. Remove seal cover (15) by
using a screwdriver.
15. Remove oil seal (14) from seal cover (15) by us-
ing a screwdriver.
16. Remove O-ring (16) from casing (1).
W173-02-04-007
17. Turn over casing (1) and place casing (1) on a

press. Remove drive disc (2) and the bearing by
using a press and special tool (ST 1239).
ST 1239
W173-02-04-008
W2-4-19
4
6
3
5
W173-02-04-026
W2-4-20
18. Place drive disc (2) on special tool (ST 5905) as
illustrated in order to remove bearing nut (6). 2
ST 5905
W173-02-04-009
19. Install special tool (ST 3054) on the spline of

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

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

ing special tool (ST 1271). ST 1271
W173-02-04-012
W2-4-21
39
40 37
38
27
29
28
2
26
36
35
40
39
W173-02-04-026
W2-4-22
24. Install special tool (ST 1272) between drive disc
(2) and roller bearing (3). Clamp the assembly in
a vise. Adjust the clearance in order to use a
ST 1272 3
puller.
2
W173-02-04-013
25. Set a puller. Remove roller bearings (3) (2 used)

from drive disc (2) at the same time.
Puller
3
(40) (4 used) from stopper S (37). W173-02-04-014
Remove O-ring (38) and stopper S (37) from

head cover (29).
: 6 mm

(40) (4 used) from stopper L (35).
Remove O-ring (36) and stopper L (35) from
head cover (29).
: 6 mm
28. Remove set screw (28) from servo piston (26)

and remove servo pin (27) from head cover (29).
: 8 mm
NOTE: LOCTITE #829 is applied to set screw (28).

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

stall servo pin (27) into the servo piston (26) hole
from the suction port in head cover (29). Apply
LOCTITE #829 to the thread part of set screw
(28). Tighten set screw (28) and secure servo pin
(27).
: 8 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
2. Install O-ring (38) on stopper S (37). Install stop-

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

ber side of head cover (29). Set servo piston (26)
so that servo pin (27) is at the center of the suc-
tion port.
CAUTION: The inner race becomes too hot.

Avoid being burned.
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, 4) inside.
ST 7923
W173-02-04-015
W2-4-27
3 5 4 6 2
W1HH-02-04-005
W2-4-28
5. Place drive disc (2) on a workbench with the
spline side up. Install roller bearings (3) (2 used)
on drive disc (2).
Apply hydraulic oil to the bearing race surfaces.
6. Install the outer race of roller bearing (4) to

spacer (5) by using special tool (ST 2408).
ST 2408
7. Install roller bearing (4) and spacer (5) on drive W173-02-04-016

disc (2).
Check that roller bearings (3, 4) are securely in-

stalled on drive disc (2) after they have cooled
down to atmosphere temperature.
Apply hydraulic oil to the bearing race surfaces.
ST 7102
Install the inner race of roller bearing (4) by using
8. Place drive disc (2) on special tool (ST 5905). In-

stall bearing nut (6) on the thread part in drive
disc (2). Tighten bearing nut (6) until it contacts
bearing (4).
Apply lubricating oil to the thread part in bearing W173-02-04-017
nut (6).
6
ST 5905
W173-02-04-018
W2-4-29
1 3 4 6 2
15
16 14 W1HH-02-04-005
W2-4-30
9. Insert special tool (ST3054) into the spline in
drive disc (2). Turn drive disc (2) and tighten
bearing nut (6). ST 3054
When tightening bearing nut (6), tighten counter-
clockwise.
W173-02-04-023
10. Measure the preload of roller bearings (3, 4). Set

special tool (ST5905). Install a torquemeter and
adapter (ST 3055) on the spline of drive disc (2).
Rotate drive disc (2) two or three times before
recording, for smoother movement of drive disc ST 3055
(2) and make a record of the torque.
Starting Torque Specification:

2.94±0.49 N⋅m (0.30±0.05 kgf⋅m, 2.17±0.36 lbf⋅ft)
ST 5905
CAUTION:
Casing (1) becomes too hot. When applying
grease, avoid being burned.
11. Heat casing (1) to 50 to 80 °C (122 to 176 °F). W173-02-04-024

Apply grease to the inside of casing (1).
12. Install drive disc (2) into casing (1).
Check that drive disc (2) is securely installed in

casing (1) after the casing has cooled down to
atmosphere temperature.
13. Install O-ring (16) into the groove on casing (1).

Apply grease to O-ring (16).
ST 2409
14. Install oil seal (14) into seal cover (15) by using
special tool (ST 2409). Apply grease to the oil
seal (14) lip.
15
W173-02-04-019
W2-4-31
23 19 1
15
12 7 9 13 17 W1HH-02-04-005
18
W1HH-02-04-006
W2-4-32
15. Install special tool (ST 2410) on the spline of 14
drive disc (2). Install seal cover (15) in casing (1).
Tap seal cover (15) into casing (1) by using a
plastic hammer until the retaining ring (17)
groove on casing (1) is visible.
16. Install retaining ring (17) to casing (1).

15
Check that retaining ring (17) seats well in the
groove after installing. ST 2410
17. Turn over casing (1) and place casing (1) on a

workbench with the drive disc side down. Apply
hydraulic oil to the spherical surface of drive disc
(2). Incline plunger (7) to the center of drive disc
W173-02-04-020
(2). Install plungers (7).
18. Apply grease in order not to fall off pin (13) and
install pin (13) to center shaft (9).
19. Install center shaft (9) on drive disc (2).
20. Install spring (12) on center shaft (9).
21. Connect link (19) to valve plate (18). Place valve

plate (18) on casing (1) inside. Insert pin (23) in
link (19) to the mounting end for the casing (1)
regulator.
W2-4-33
23 19 1
27
29
49 7 8 9 13 W1HH-02-04-005
18 30
W1HH-02-04-006
W2-4-34
22. Install plungers (7) (7 used) and center shaft (9)
into cylinder block (8).
Install pin (13) into the groove of cylinder block
while rotating the end of center shaft (9) by using
a radio plier.
23. Apply hydraulic oil to the speherical surfaces of

valve plate (18) and cylinder block (8). Face the
spherical surface of valve plate (18) to cylinder
block (8) and insert into the end of center shaft
(9) into the hole on value plate (18).
24. Apply grease to O-rings (31) (3 used). Install

O-rings (31) (3 used) and packing (49) on casing
(1).
NOTE: As for O-rings (31), refer to W2-4-16.
1
25. Install special tool (ST 7094) on the drain port of

casing (1). Secure valve plate (18) at the center 18
position.
26. Align servo pin (27) on head cover (29) with the
valve plate (18) hole.
ST 7094
27. Align the holes of spring pins (30). Install head
cover (29) on casing (1). Tighten bolts (32) (8 W173-02-04-021
used) with spring washers (33) (8 used).

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

(31) (5 used) and O-ring (42) onto the regulator
mounting surface of casing (1).
NOTE: Check that spring pins (43) (2 used) are W173-02-04-022
installed. As for O-rings (31), refer to

W2-4-16.
CAUTION: Main Pump weight: 67 kg (148 lb)
30. Align feedback pin (24) in the pump with the

notches on sleeves (2 used) in regulator (41).
Install regulator (41) to casing (1).
31. Install bolts (47) (4 used) and spring washers

(48) (4 used) to regulator (41).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
32. Install drive gear (10) into drive disc (2).
33. Install retaining ring (11) into drive disc (2).
W2-4-37
DISASSEMBLE REGULATOR
25
26
27
11
12
24
20
23
22
21
18
30
19
14
31 2
28
6
15
1
29
4
17
16 3
13
15
7 5
8
2
2
14
26
25
12 32
11 10
W173-02-04-029
9
1- Stopper 9- Nut 17 - Spring 25 - Socket Bolt (8 Used)
2- O-Ring (3 Used) 10 - Screw 18 - Sleeve 26 - Spring Washer (8 Used)
3- Sleeve 11 - Nut (2 Used) 19 - Spool 27 - Front Cover
4- Spool 12 - Nut (2 Used) 20 - Cylinder 28 - Bolt (4 Used)
5- Casing 13 - Stopper 21 - Piston 29 - Spring Washer (4 Used)
6- Spring 14 - Stopper (2 Used) 22 - O-Ring 30 - Air Bleed Plug
7- Piston 15 - O-Ring (2 Used) 23 - Backup Ring 31 - O-Ring
8- Cylinder 16 - Spring 24 - O-Ring 32 - Rear Cover
W2-4-38
UPPERSTRUCTURE/Pump Device
Disassemble Regulator
1. Clamp casing (5) in a vise.
2. Remove air bleed plug (30) and O-ring (31) from

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

cover (27) and rear cover (32).
: 6 mm
IMPORTANT: If loosening stoppers (1, 13, 14),

nuts (9, 11, 12), and screw (10), the
regulator setting will change. Do not
loosen stoppers (1, 13, 14), nuts (9,
11, 12), and screw (10).
4. Remove springs (16, 17) from the rear cover (32)

side in casing (5).
5. Push spool (19). Remove cylinder (20) from the

front cover (27) side in casing (5).
6. Remove piston (21), O-ring (22), and backup ring

(23) from cylinder (20).
7. Remove sleeve (18) and spool (19) from the front

cover (27) side in casing (5).
8. Remove spool (19) from sleeve (18).
9. Remove spring (6) from the front cover (27) side

in casing (5).
10. Push spool (4). Remove piston (7) and cylinder

(8) from the rear cover (32) side in casing (5).
11. Remove piston (7) and O-ring (2) from cylinder

(8).
12. Remove sleeve (3) and spool (4) from the front
cover (27) side in casing (5). Remove spool (4)
from sleeve (3) .
W2-4-39
ASSEMBLE REGULATOR
6 1 4 3 5 7 8 2 9 10
24 23 22 21 20 19 18 17 16 15 14 13 12 11 T173-03-01-005
25, 26 27 28, 29 30 31 32
W173-02-04-001
1- Stopper 9- Nut 17 - Spring 25 - Socket Bolt (8 Used)

2- O-Ring (3 Used) 10 - Screw 18 - Sleeve 26 - Spring Washer (8 Used)
3- Sleeve 11 - Nut (2 Used) 19 - Spool 27 - Front Cover
4- Spool 12 - Nut (2 Used) 20 - Cylinder 28 - Bolt (4 Used)
5- Casing 13 - Stopper 21 - Piston 29 - Spring Washer (4 Used)
6- Spring 14 - Stopper (2 Used) 22 - O-Ring 30 - Plug
7- Piston 15 - O-Ring (2 Used) 23 - Backup Ring 31 - O-Ring
8- Cylinder 16 - Spring 24 - O-Ring 32 - Rear Cover
W2-4-40
Assemble Regulator
1. Clamp casing (5) in a vise.
2. Install spool (19) into sleeve (18).
3. Install sleeve (18) and spool (19) from the front

cover (27) side in casing (5).
4. Install spool (4) into sleeve (3). Install sleeve (3)

from the front cover (27) side in casing (5).
5. Install piston (7) into cylinder (8).
6. Install O-ring (2) to cylinder (8). Apply grease to

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

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

(21) to cylinder (20).
9. Apply grease to O-ring (22). Install cylinder (20)

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

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

plug (30).
12. Tighten plug (30).

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

2- Flange 6- Cover 10 - Gear 14 - Bushing (2 Used)
3- Oil Seal 7- Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4- Retaining Ring 8- Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
W2-4-42
Disassemble Pilot Pump
1. Clamp flange (2) in the pilot pump in a vise with

cover (6) up.
2. Remove bolts (13) (4 used).

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

screwdriver.
9. Remove seal (5) and backup ring (7) from bush-

ings (14, 15) in cover (6) side.
10. Lightly push drive gear (11). Remove bushings

(14, 15) in cover (6) side from housing (1).
Do not fall off the key between the bushings.
11. Remove seal (5) and backup ring (7) in flange (2)
side from bushings (14, 15).
12. Remove bushings (14, 15) in frange (2) side from

housing (1). Remove gear (10) and drive gear
(11) from housing (1).
W2-4-43
14
10
15
12
13
6
8 9
1
16
7
5
15
11
14
5
7
9
4 3 2
W110-02-04-022
1- Housing 5- Seal (2 Used) 9- O-Ring (2 Used) 13 - Bolt (4 Used)

2- Flange 6- Cover 10 - Gear 14 - Bushing (2 Used)
3- Oil Seal 7- Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4- Retaining Ring 8- Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
W2-4-44
Assemble Pilot Pump
1. Install oil seal (3) into flange (2) by using special

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

housing (1) with the seal groove side down.
4. Install gear (10) and drive gear (11) to housing

(1).
5. Install bushings (14, 15) in flange (2) side to

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

Clamp the flange in a vise. Do not fall off the
bushings and gears when turning over. Install
seal (5) and backup ring (7) into the seal groove
on bushings.
10. Install O-ring (9) on cover (6).
11. Install cover (6) on housing (1).
12. Tighten washers (12) and bolts (13).

: 17 mm
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 29 to 32.5 lbf⋅ft)
W2-4-45
MAINTENANCE STANDARD
Pump Device
Unit : mm (in)
Standard Allowable Limit Remedy
Gear backlash 0.48 (0.019) 1.5 (0.059) Replace
Main Pump
1. Drive disc: Spline tooth thickness
Unit : mm (in)
Standard Allowable Limit
4.9 (0.193) 3.5 (0.138)
2. Drive disc: Oil seal outer diameter
Unit : mm (in)
60.0 (2.362) 59.8 (2.354)
3. Spherical joint: Clearance between plunger and

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

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

a
D-a 0.044 (0.0017) 0.08 (0.0031)
W157-02-04-017
W2-4-46
5. Plunger: Clearance between plunger and
connecting rod
Unit : mm (in)
0.1 (0.0039) 0.4 (0.0016)
W157-02-04-033
6. Clearance between center shaft and valve plate
Unit : mm (in)
a
D-a 0.081 (0.0032) 0.3 (0.012) Center Shaft
W110-02-04-013
Valve Plate
7. Clearance between small chamber inner D W110-02-04-014
diameter and servo piston a
Unit : mm (in)
D-a 0.089 (0.0035) 0.2 (0.0079)
8. Clearance between large chamber inner

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

Unit : mm (in) D a

D-a 0.051 (0.0020) 0.3 (0.012)
W157-02-04-019
W2-4-47
(Blank)
W2-4-48
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Arm 2
IMPORTANT: Release any pressure in the hydrau- Boom 1 4-Spool Section
Bucket 5-Spool Section
Right Travel
Main Swing
Relief Arm 1
Removal valve Boom 2
Auxiliary
1. Remove all hoses, pipes, and connectors from Left Travel
the control valve.
Attach identification tags to the removed hoses
for reassembling. Cap all the removed hoses and
pipes.
: 17 mm, 19 mm, 27 mm, 41 mm
: 8 mm, 10 mm
Machine Front T1HH-01-02-005
CAUTION: Control valve weight: 210 kg

(460 lb)
2. Remove bolts (1) and remove the control valve.

: 24 mm
W1HH-02-05-001
1
W2-5-1
Installation
Arm 2
1. Install the control valve on the main frame with Boom 1 4-Spool Section
Bucket 5-Spool Section
bolts (1).
Right Travel
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
Main Swing
Relief Arm 1
2. Install all hoses, pipes, and connectors to the valve Boom 2
control valve. Auxiliary
Left Travel
3. After completing the work, check hydraulic oil
level. Start the engine and check for any oil leaks.
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm Machine Front T1HH-01-02-005
: 93 N⋅m (9.5 kgf⋅m, 68.5 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
W1HH-02-05-001
1
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE CONTROL VALVE (1)
13 4 4 43
12 41
5
7
46 4
12a
13a
15 6
32 17
35 15 4
15 4
30 15 42
31
14
29 5 4
38 47
25
28 17
37
23
33
14 15
30 34 12
20
31
21
27
22
19
2 24
10
18 26
15
35 45 1
44
16
31
8 11
40
8 15
17
15
39
8
16 8
36
9
31 8 9
5
17
3
W173-02-05-021
1- Casing A 13 - Needle Valve 25 - Spool: Bypass Shut-Off 38 - Spring (7 Used)
2- Casing B 13a - O-Ring (3 Used) 26 - Spool: Auxiliary 39 - Spring
3- Plug 14 - O-Ring (10 Used) 27 - Spool: Right Travel 40 - Spring
4- Plug (4 Used) 15 - O-Ring (11 Used) 28 - Spring (2 Used) 41 - Plug
5- O-Ring (6 Used) 16 - O-Ring (8 Used) 29 - Spring (2 Used) 42 - Plug
6- Spring Cover A 17 - Socket Bolt (32 Used) 30 - Spring Seat (4 Used) 43 - Plug
7- Spring Cover B 18 - Spool: Left Travel 31 - Spring Seat (16 Used) 44 - Plug
8- Spool Cover (5 Used) 19 - Spool: Arm 1 32 - Spacer Bolt (2 Used) 45 - O-Ring
9- Spool Cover (2 Used) 20 - Spool: Boom 1 33 - Stopper (2 Used) 46 - Socket Bolt (4 Used)
10 - Spool Cover: Arm 2 21 - Spool: Bucket 34 - Stopper (7 Used) 47 - Socket Bolt (4 Used)
11 - Spool Cover: Boom 1 22 - Spool: Swing 35 - Spacer Bolt (8 Used)
12 - Anti-Drift Valve (2 Used): 23 - Spool: Arm 2 36 - Stopper
Boom Bottom, Arm Rod
12a - O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used)
W2-5-4
Disassemble control valve (1)
• Anti-drift Valve and Needle Valve • Spool Cover

1. Remove socket bolt (46). Remove needle valve 10. Put the matching marks in order not to make a
(13) and anti-drift valve (12) from spring cover B mistake when assembling casing and spool cover.
(7).
: 5 mm 11. Remove socket bolts (17) (2 used) and remove
spool cover (11) from casing B (2).
2. Remove socket bolt (47) and remove anti-drift : 6 mm
valve (12) from spring cover A (6).
: 5 mm 12. Disassemble spool covers (8) to (10) in the same
procedures.
• Spring Cover : 6 mm
spring cover A (6) from casing A (1). Remove
spring cover B (7) from casing B (2).
: 6 mm
• Spool
IMPORTANT: Turn and remove the spools. If the
spools stick even a little, try again
instead of pulling roughly.
4. As spool and hole of casing are a matched fit, put
the matching marks for reassembling.
5. Remove the spool (18) assembly from casing A

(1).
6. Remove the spool (19) to (27) assemblies in the

same procedures.
7. Clamp spool (18) in a vise.
8. Remove spacer bolt (32) and disassemble spring

seat (30), springs (28, 29), and stopper (33).
: 10 mm
9. Disassemble the spool (19) to (27) assemblies in

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

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

IMPORTANT: Install spool covers (8) to (11) while 10. Install O-rings (14) (5 used) and O-rings (15) (4
aligning the matching marks. used) to spring cover A (6)
1. Install O-rings (15, 16) to spool cover (11).
11. Install spring cover A (6) to casing A (1) with
2. Install spool cover (11) to casing B (2) with socket socket bolts (17) (7 used).
bolts (17) (2 used) while aligning the matching : 6 mm
marks. : 24 to 34 N⋅m
: 6 mm (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)
: 24 to 34 N⋅m
(2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) 12. Install spring cover B (7) in the same procedures.
: 6 mm
3. Install spool covers (8) to (10) in the same pro- : 24 to 34 N⋅m
cedures. (2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft)
: 6 mm
: 24 to 34 N⋅m • Anti-drift Valve and Needle Valve
(2.5 to 3.5 kgf⋅m, 18 to 25.5 lbf⋅ft) 13. Install O-rings (12a) (3 used) to anti-drift valve
(12). Install anti-drift valve (12) to spring cover A
• Spool (6) with socket bolts (47) (4 used).
4. Clamp spool (18) in a vise. : 5 mm
: 9.8 to 14 N⋅m
5. Clean the thread part of spacer bolt (32) and ap- (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
ply LOCTITE #262.
14. Install O-rings (12a) (3 used) to anti-drift valve
6. Install spring seat (30), springs (28, 29), stopper (12). Install O-rings (13a) (3 used) to needle
(33), and spacer bolt (32) to spool (18). valve (13). Install needle valve (13) and anti-drift
valve (12) to spring cover B (7) with socket bolts
7. Tighten spacer bolt (32). (46) (4 used).
: 10 mm : 5 mm
: 15 to 18 N m : 9.8 to 14 N⋅m
(1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft) (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
8. Assemble the spool (18) to (27) assemblies while

aligning the matching marks.
: 10 mm
: 15 to 18 N⋅m
(1.6 to 1.8 kgf⋅m, 11.5 to 13 lbf⋅ft)
9. Install the spool (18) to (27) assemblies to casing

A (1) and casing B (2) respectively.
W2-5-7
1
22 12
23
5 6
13 19
18
20
24
21a
11 4 21
9 14
14 9
8
25
16
Casing A 25 11 17
10
15
W173-02-05-022
1 - Anti-Drift Valve Assembly: 8 - O-Ring (2 Used) 15 - Plug 21a - O-Ring

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

1. Put the matching marks in order to install cor-
rectly.

casing 2 (2) from casing 4 (4).
: 10 mm

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

casing 3 (3) from casing 2 (2).
: 5 mm
6. Remove plug (15). Remove poppet (16) and

spring (17) from casing 2 (2).
: 17 mm
IMPORTANT: Do not loosen the lock nut.

7. Remove relief valve (21) from casing 3 (3).
: 22 mm
8. Remove plug (13). Remove pistons (23, 22) from

casing 3 (3). Check the order when removing pis-
tons (22, 23).
: 10 mm
9. Remove plug (12). Remove bushing (20), spool

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

Arm Bottom Side
2 - Casing 2 9- O-Ring (2 Used) 16 - Poppet 22 - Piston
3 - Casing 3 10 - O-Ring 17 - Spring 23 - Piston
4 - Casing 4 11 - O-Ring (2 Used) 18 - Spool 24 - Socket Bolt (4 Used)
5 - O-Ring 12 - Plug 19 - Spring 25 - Socket Bolt (8 Used)
6 - O-Ring 13 - Plug 20 - Bushing
7 - O-Ring (3 Used) 14 - Plug (2 Used) 21 - Relief Valve
W2-5-10
• Arm Anti-Drift Valve 10. Install casing 3 (3) to casing 2 (2) with socket
1. Install O-rings (7) (3 used) to bushing (20). bolts (24) (4 used).
: 5 mm
2. Install O-ring (6) to plug (12). : 9.8 to 13.5 N⋅m
(1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
3. Install bushing (20), spool (18), and spring (19)
into casing 3 (3). Install plug (12). 11. Install O-ring (11) to casing 4 (4).
: 22 mm
: 69 to 79 N⋅m 12. Install casing 4 (4) to casing A with socket bolts
(7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft) (25) (4 used).
: 10 mm
4. Install O-ring (5) to plug (13). : 98 to 118 N⋅m
(10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)
5. Install pistons (22, 23) into casing 3 (3). Install
plug (13). 13. Install O-ring (11) to casing 2 (2).
: 10 mm
: 127 to 147 N⋅m 14. Install casing 2 (2) to casing 4 (4) with socket
(13 to 15 kgf⋅m, 94 to 108 lbf⋅ft) bolts (25) (4 used).
: 10 mm
6. Install O-ring (21a) to relief valve (21). Tighten : 98 to 118 N⋅m
and install relief valve (21) in casing 3 (3). (10 to 12 kgf⋅m, 72 to 87 lbf⋅ft)
: 22 mm
: 69 to 79 N⋅m
(7 to 8 kgf⋅m, 50.5 to 58 lbf⋅ft)
IMPORTANT: Do not tighten relief valve (21) by

using the lock nut.
7. Install O-ring (10) to plug (15).
8. Install poppet (16) and spring (17) into casing 2

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

2 - Plug 12 - Flange (2 Used) 20 - Spring (2 Used) 29 - Overload Relief Valve:
Arm Side
3 - Plug 13 - Travel Flow Rate Control 21 - Spring 29a - O-Ring
Valve Assembly
4 - Plug (2 Used) 13a - O-Ring 22 - Spacer 30 - Pump Control Valve:
5-Spool Section
5- Plug (3 Used) 14 - Blank Flange Assembly 23 - Plug (3 Used) 30a - O-Ring
6- O-Ring (4 Used) 14a - O-Ring (2 Used) 24 - Plug 30b - O-Ring
7- O-Ring 15 - Socket Bolt (4 Used) 25 - O-Ring (5 Used) 30c - O-Ring
8- O-Ring (2 Used) 16 - Poppet (4 Used) 26 - O-Ring 31 - Socket Bolt (8 Used)
9- O-Ring (3 Used) 17 - Poppet (2 Used) 27 - O-Ring (2 Used) 32 - Socket Bolt (4 Used)
10 - Cover 18 - Poppet 28 - Overload Relief Valve: 33 - Socket Bolt (4 Used)
Boom Side
W2-5-12
• P3 Cover • Overload Relief Valve

1. Remove socket bolts (32) (4 used) and remove 9. Check that there are two kinds of overload relief
P3 cover (11). valves.
: 8 mm Put the matching marks on to each port and part.
2. Remove poppet (16), spring (19), and spacer IMPORTANT: Loosen the valve of overload relief
(22) from casing A. valve. If loosening the lock nut and
adjusting screw, the set pressure
• Blank Flange Assembly will change. Do not loosen the lock
3. Remove socket bolts (33) (4 used) and remove nut and adjusting screw.
blank flange assembly (14).
: 8 mm 10. Remove overload relief valves (28, 29) from cas-
ing B by using the tool below.
4. Remove poppet (17) and spring (20) from casing : 32 mm
A.
• Travel Flow Rate Control Valve Assembly
(Wrench Size: 32 mm)

5. Remove the plug. Remove the piston, sleeve,
(12.7 mm)
(43 mm)
poppet, and spring from casing A.
32 mm
: 32 mm
• Arm Anti-Drift Check Valve (45 mm)

6. Remove plug (24). Remove spring (21) and pop-
pet (18) from casing A. (80 mm) W1HH-02-05-002
: 12 mm
• Left Travel, Boom 2, Swing Load Check Valve • Pump Control Valve (5-Spool Section)
(common to three places) 11. Remove pump control valve (30).
: 36 mm
7. Put the matching marks onto each port and part.

spring (19) from casing A.
: 12 mm
W2-5-13
Machine Front
X
B
5
C C
D D
F F
W1HH-02-05-003
G
30 30a 30c 30b
Casing A Section B
T1HH-03-03-002
X
Auxiliary Bucket
31
Left Travel Right Travel
12
27
16
13a
19
22
13 2
23 25
32
11
8
25
19 27
16 31 T1HH-03-03-005
12
Section C-C T1HH-03-03-004
Section D-D
W2-5-14
Boom 2 Boom 1 Arm 1 Arm 2
1 6
18
28
29 21
24
25 28a
29a
17
25 20
14
23 14a
33 28a
19
16
28
3
7 Section F-F
T1HH-03-03-006 T1HH-03-03-007
29a Section E
29
15 10 9, 26 4 9
Swing
Left
Travel
Auxiliary
16
19 Boom 2
23
Arm 1
25 Swing
W1HH-02-05-004
Section G T1HH-03-03-006 Section X-X
1 - Plug (4 Used) 11 - Cover 19 - Spring (4 Used) 28a - O-Ring

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

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

1. Install O-rings (30a, 30b, 30c) to pump control 7. Install O-ring (25) to plug (24).
valve (30). Tighten and install pump control valve
(30). 8. Install poppet (18) and spring (21) into casing A.
: 36 mm Install plug (24).
: 69 to 78 N⋅m : 12 mm
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft) : 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Overload Relief Valve
• Travel Flow Rate Control Valve Assembly
2. Check that there are two kinds of overload relief 9. Install O-ring (13a) to the plug. Install the piston,
valves. Align the matching marks. sleeve, poppet, and spring into casing A. Install
the plug.
3. Install O-ring (28a) to overload relief valve (28). : 32 mm
Install O-ring (29a) to overload relief valve (29). : 147 to 177 N⋅m
Tighten and install overload relief valves (28, 29) (15 to 18 kgf⋅m, 108 to 130 lbf⋅ft)
by using special tool below.
: 32 mm • Blank Flange Assembly
: 69 to 78 N⋅m 10. Install O-rings (14a) (2 used) to blank flange (14).
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft) Install poppet (17) and spring (20) into casing A.
Install blank flange assembly (14) with socket
bolts (33) (4 used).
: 8 mm
: 49 to 65 N⋅m
(12.7 mm)
(5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)

32 mm
43 mm
• P3 Cover
11. Install O-rings (8) to cover (11).
(45 mm)
(80 mm) W1HH-02-05-002
12. Install poppet (16), spring (19), and spacer (22)
into casing A. Install P3 cover (11) with socket
• Left Travel, Boom 2, Swing Load Check Valve : 8 mm
(common to 3 places) : 49 to 65 N⋅m
(5 to 6.6 kgf⋅m, 36 to 48 lbf⋅ft)
4. Align the matching marks and install it.
6. Install poppet (16) and spring (19) into casing A.

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

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

switch valve (9).
: 8 mm
2. Remove poppet valve (10) from casing B.
• Arm 2 Load Check Valve (with Orifice)

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

(common to 2 places)
IMPORTANT: Put the matching marks to each port

and part.
spring (15) from casing B.
: 12 mm
• Boom Anti-Drift Check Valve

: 12 mm
• Check Valve with Orifice (Bucket Combination)

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

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

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

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

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

Install plug (19).
: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Boom 1, Arm 2 Load Check Valve

IIMPORTANT: Align the matching marks and in-

stall it.
6. Install poppet (12) and spring (15) into the casing.

Install plug (18).
: 12 mm
: 226 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
• Arm 2 Load Check Valve (with Orifice)

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

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

flow combiner valve assembly (1).
: 14 mm
2. Clamp block (2) in a vise.
3. Remove main relief valve (21) from block (2).

: 32 mm
4. Remove plug (9). Remove spool (16), stopper

(14), and springs (12, 13) from block (2).
: 32 mm
5. Put the matching marks onto each port and part.

spring (18) from block (2). (common to 3 places)
: 12 mm
7. Remove plug (3).

: 5 mm
8. Remove orifices (15) (2 used) from block (2).

: 4 mm
W2-5-23
Machine Lower
Machine Front
3, 8, 15 22
T1HH-03-03-002
W1HH-02-05-007
Control Valve Upper View Control Valve Front View
15 16 10 9 12 13
14
20
7
19
6
18
17 20
4 19
11
2
18
17
21a
21
Section A W1HH-02-05-010
1 - Flow Combiner Valve As- 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used)

sembly
2 - Block 8- O-Ring 14 - Stopper 20 - O-Ring (3 Used)
3 - Plug 9- Plug 15 - Orifice (2 Used) 21 - Main Relief Valve
4 - Plug 10 - O-Ring 16 - Spool 21a - O-Ring
5 - O-Ring (3 Used) 11 - O-Ring 17 - Poppet (3 Used) 22 - Socket Bolt (5 Used)
6 - O-Ring (4 Used) 12 - Spring 18 - Spring (3 Used) 23 - Name Plate
W2-5-24
• Flow Combiner Valve

1. Clamp block (2) in a vise. 10. Install O-rings (5) (3 used), O-rings (6) (4 used),
O-rings (7) (2 used), and O-ring (11) to block (2).
2. Install orifices (15) (2 used) in block (2).
: 4 mm 11. Install flow combiner valve assembly (1) with
: 7.8 to 9.8 N⋅m socket bolt (22) (5 used).
(0.8 to 1.0 kgf⋅m, 5.8 to 7.2 lbf⋅ft) : 14 mm
: 215 to 255 N⋅m
3. Install O-ring (8) to plug (3). (22 to 26 kgf⋅m, 159 to 188 lbf⋅ft)
4. Install plug (3).

: 5 mm
: 12.7 to 16.7 N⋅m
(1.3 to 1.7 kgf⋅m, 9.4 to 12.3 lbf⋅ft)
6. Install poppet (17) and spring (18) into block (2).

Align the matching marks and install plug (19).
: 12 mm
: 225 to 265 N⋅m
(23 to 27 kgf⋅m, 166 to 195 lbf⋅ft)
8. Install spool (16), stopper (14), and springs (12,

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

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

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

1. Remove pump control valve (9).
: 36 mm
2. Check that there are two kinds of overload relief

valve.
Put the matching marks on to each port and part.
IMPORTANT: Loosen the valve of overload relief

valve. If loosening the lock nut and
adjusting screw, the set pressure
will change. Do not loosen the lock
nut and adjusting screw.
3. Remove overload relief valve (7, 8) from casing B

by using special tool below.
: 32 mm
(12.7 mm)
32 mm
43 mm
(45 mm)
(80 mm) W1HH-02-05-002
• Casing
IMPORTANT: Do not disassemble socket bolts (10,

11) unless necessary.
4. Remove socket bolt (10) and socket bolts (11) (8
used). Disassemble casing A and casing B.
: 12 mm
W2-5-27
Boom 2 Boom 1
Machine Front 10
5
C C
D D 6
E
4
F F
Control Valve Upper View T1HH-03-03-002

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

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

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

Bucket Bottom Side
2 - Plug 6 - O-Ring (5 Used) 8a - O-Ring 9c - O-Ring
3 - O-Ring (2 Used) 7 - Overload Relief Valve 9 - Pump Control Valve: 10 - Socket Bolt
(3 Used): Bucket Rod, Arm (4-Spool Section)
Bottom, Boom Bottom Side
4 - O-Ring (6 Used) 7a - O-Ring (3 Used) 9a - O-Ring 11 - Socket Bolt (8 Used)
W2-5-28
• Casing
1. Install O-rings (4) (6 used), O-rings (5) (6 used),
and O-rings (6) (5 used) to casing B.
2. Connect casing A and casing B. Tighten socket

bolt (10) and socket bolts (11) (8 used).
: 12 mm
: 137 to 177 N⋅m
(14 to 18 kgf⋅m, 101 to 130 lbf⋅ft)
3. Check that there are two kinds of overload relief

valve. Align the matching marks and install it.
4. Install O-ring (7a) to overload relief valve (7). In-

stall O-ring (8a) to overload relief valve (8). Install
overload relief valves (7, 8) by using special tool
below.
: 32 mm
: 69 to 78 N⋅m
(12.7 mm)
32 mm
43 mm
(45 mm)
(80 mm) W1HH-02-05-002
• Pump Control Valve (4-Spool Section)

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

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

1 Name Plate 1
A A 2 Socket Bolt 5
3 Main Relief 1
4 O-Ring 3
20 5 ROMH Plug 3
6 Spring 3
W1HH-02-05-013
7 Poppet 3
8 Spool 1
18 17 13 18 19 19 19
9 Orifice 2
10 Stopper 1
18
11 Spring 1
12 Spring 1
18
13 O-Ring 1
14 O-Ring 1
17
15 Plug 1
16 O-Ring 1
17 O-Ring 2
18 O-Ring 4
19 O-Ring 3
20 Plug 1
W1HH-02-05-014 21 ROH Plug 1

22 Block 1
W2-5-31
Switch Valve (Bucket Flow Rate Control Valve)
2 1 4 3
9 ITEM PART NAME QTY

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

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

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

B
4
2 ITEM PART NAME QTY

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

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

A
ITEM PART NAME QTY

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

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

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

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

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

1 Lock Nut 1
2 O-Ring 1
3 Adjusting Plug 1
4 Spring 1
5 Spool 1
6 O-Ring 1
7 O-Ring 1
8 O-Ring 1
9 Body 1
W2-5-38
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
7
IMPORTANT: Release any pressure in the hydrau- 6
1
2
Removal
1. Remove hoses (1 to 3 and 5 to 7).
: 41 mm, 19 mm, 17 mm
: 8 mm
5
2. Cap the removed hoses and pipes.
Attach a nylon sling to the swing motor.
Nylon sling (eye-type at both ends): 2 pieces 3
4
CAUTION: Swing device weight: 390 kg W1HH-02-06-001
(800 Ib)
3. Remove bolt (4). Hoist and remove the swing Nylon Sling
device.
: 32 mm
: 640 N⋅m (65 kgf⋅m, 470 Ibf⋅ft)
W176-02-06-002
W2-6-1
Installation
7
NOTE: Refer to “Removal” section for wrench
sizes and tightening torques. 6
1. Apply THREEBOND #1102 to both mounting 1

surfaces on the swing device and main frame. 2
Install the swing device with bolts (4).
2. Install hoses (1 to 3 and 5 to 7).

: 41 mm
: 205 N⋅m (21 kgf⋅m)
: 19 mm 5
: 29.5 N⋅m (3 kgf⋅m)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m) 3
: 8 mm 4
: 50 N⋅m (5.1 kgf⋅m) W1HH-02-06-001
3. After completing the work, fill the swing motor

with hydraulic oil. Check hydraulic oil level. Start
the engine and check for any oil leaks.
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING DEVICE
32
22
2
23
4
5
31
6
21
7
30 8
24 18
29 9
25 20
7
28 10
19
11
27 12
18 13
17 14
26 16
13
15 12
W1HH-02-06-002
1 - Socket Bolt (12 used) 9 - First Stage Planetary Gear 17 - Bolt (2 Used) 25 - Drain Plug
(3 used)
2- Motor 10 - Pin (3 Used) 18 - Thrust Plate (2 used) 26 - Shaft
3- Retaining Ring 11 - Spring Pin (3 Used) 19 - Second Stage Carrier 27 - O-Ring
4- First Stage Sun Gear 12 - Thrust Plate (6 used) 20 - Second Stage Sun Gear 28 - Oil Seal
5- Pin (3 Used) 13 - Needle Bearing (6 Used) 21 - First Stage Carrier 29 - Sleeve
6- Spring Pin (3 Used) 14 - Second Stage Planetary 22 - Ring Gear 30 - Roller Bearing
Gear (3 used)
7 - Thrust Plate (6 used) 15 - Nut 23 - Roller Bearing 31 - Housing
8 - Needle Bearing (3 Used) 16 - Lock Plate 24 - Pipe 32 - Socket Bolt (12 used)
W2-6-4
Disassemble Swing Device
CAUTION: Swing device weight: 390 kg CAUTION: Ring gear (22) weight: 34 kg
(860 lb) (75 lb)
1. Attach a nylon sling to the swing motor. Hoist the 7. Remove socket bolt (32). Install eyebolt (M12,
swing device. Pitch 1.75 mm) to the motor mounting thread po-
sition of ring gear (22). THREEBOND has been
applied on the jointed surfaces between housing
2. Place the swing device on bracket (ST 5100).
(31) and ring gear (22). Insert a screwdriver into
Secure the swing device with bolts (M22) (2
the notch between jointed portion. Hoist and re-
used). Secure the bracket on a workbench.
move ring gear (22) from housing (31).
: 32 mm
Swing Device : 17 mm
CAUTION: Second stage sun gear (20)

ST 5100 weight: 42 kg (93 lb)
8. Remove second stage sun gear (20) and the

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

: 8 mm
4. Remove pipe (24) from housing (31).

: 18 mm
CAUTION: Motor (2) weight: 71 kg (160 lb)
5. Put the matching marks at the jointed portions

between motor (2) and ring gear (22), between
ring gear (22) and housing (31).
Remove socket bolt (1). Hoist and remove motor
(2).
: 10 mm
NOTE: Insert the screwdriver between motor (2)
and ring gear (22). Float motor (1). Re-
move 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
W2-6-5
31
17
26
16
15
W1HH-02-06-002
W2-6-6
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) by using special

tool (ST 3167).
ST 3167 15
W178-02-06-008
W2-6-7
32
23
31
30
29
26
W1HH-02-06-002
W2-6-8
11. Install eyebolt (M20, Pitch 2.5 mm) into the bolt
(32) hole of housing (31). Remove bolts (M22) (2 CAUTION: If pushing shaft (26) by using a
used) securing the housing and bracket. Hoist press, provide a protection cover (outer di-
the housing (31) assembly and remove the ameter: 369 mm (14.5 in), inner diameter: 90
bracket. mm (3.5 in), thickness: 25 to 30 mm (1.0 to
1.2 in)). Push shaft (26) with the protection
12. Set the blocks on the press. Set the housing (31) cover on by using a press. When housing
assembly on the blocks. (31) and/or roller bearing (23) are broken and
flown off, the metal fragments may result in
personal injury. Use a press with the capac-
ity less than 30 tons (66000 lb). Degrease the
3 housing inside before heating roller bearing
(23). Failure to degrease may cause a fire.
13. Put the protection cover onto housing (31) and

remove shaft (26) by using a press. The inner
race of roller bearing (30) and sleeve (29) are
removed with shaft (26) together.
Shaft (26)
Roller Bearing (23)
W1HH-02-06-012 Housing (31)
Block
Protection Cover
W157-02-06-010
Press
Protection Cover
Special Tool W157-02-06-011
14. Remove the inner race of roller bearing (23) from

housing (31).
W2-6-9
31
30
29
27
26
W1HH-02-06-002
W2-6-10
15. Set special tool to the shaft (26) assembly.
CAUTION: When pushing shaft (26) by using
a press, set the shaft into the guide.
NOTE: Use the following parts as special tool for
roller bearing (30). 16. Set shaft (26) with special tool to a press. Re-
move roller bearing (30).
Part Size Remarks
Shaft Length: 220 mm 8 used. All should be Press
or Bolt (8.7 in) identical in length with no
Diameter: 19 mm wear and deformation on
(3/4 in) both ends.
Material: S35C Shaft (26)
Hose Standard Diame- 2 used. Roller
Clamp ter: 8-1/2” (Appli- Bearing (30)
cable Diameter:
Sleeve (29)
185 to 215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter: Guide
292 mm (11.5 in)
Inner Diameter:
272 mm (10.7 in)
W157-02-06-014
Shaft 17. Remove sleeve (29) from shaft (26). Remove

Hose Clamp O-ring (27) from sleeve (29).
18. Insert a round bar into the oil passage in housing

(31). Tap and remove the outer race of roller
bearing (30).
Oil Passage
W157-02-06-012
Outer Race
Shaft (26)
Roller Bearing (30)
W1HH-02-06-007
Sleeve (29) Hose

Clamp
Shaft
Guide
W157-02-06-01
W2-6-11
23
31 5
21
6
7
8
10
28
19 11
18
14
13
12
W1HH-02-06-002
W2-6-12
CAUTION: Housing (31) weight: 104 kg

(230 lb)
19. Fasten the housing (31) body by using a nylon

sling. Hoist and turn over housing (31).
Insert a screwdriver into the notch on housing
(31) where oil seal (28) is mounted. Remove oil
seal (28).
THREEBOND has been applied on the periphery
of oil seal (28). The oil seal cannot be reused.
20. Remove the outer race of roller bearing (23) from

housing (31) by using a bar and hammer.
21. Remove spring pin (6) from first stage carrier (21)
by using 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).
23. Remove thrust plates (18) from first stage carrier

(21).
24. Remove spring pin (11) from second stage carrier

(19) by using a round bar and hammer.
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).
W2-6-13
ASSEMBLE SWING DEVICE
3
5
6
2 1
4
7
8
21
9
7
18 11
12
20 13
32
19
22 14
10
18
17
16
15 23
30
24
31
25
26
27
28
29
T1HH-03-02-001
1 - Socket Bolt (12 used) 9 - First Stage Planetary Gear 17 - Bolt (2 Used) 25 - Drain Plug
(3 used)
2- Motor 10 - Pin (3 Used) 18 - Thrust Plate (2 used) 26 - Shaft
3- Retaining Ring 11 - Spring Pin (3 Used) 19 - Second Stage Carrier 27 - O-Ring
4- First Stage Sun Gear 12 - Thrust Plate (6 used) 20 - Second Stage Sun Gear 28 - Oil Seal
5- Pin (3 Used) 13 - Needle Bearing (6 Used) 21 - First Stage Carrier 29 - Sleeve
6- Spring Pin (3 Used) 14 - Second Stage Planetary 22 - Ring Gear 30 - Roller Bearing
Gear (3 used)
7 - Thrust Plate (6 used) 15 - Nut 23 - Roller Bearing 31 - Housing
8 - Needle Bearing (3 Used) 16 - Lock Plate 24 - Pipe 32 - Socket Bolt (12 used)
W2-6-14
Assemble Swing Device
1. Install needle bearing (8) in first stage planetary 8. Install sleeve (29) and the inner race of roller
gears (9) (3 used) respectively. bearing (30) into shaft (26). Install sleeve (29)
and the inner race by using special tools (ST
2. Install thrust plates (18) in first stage carrier (21) 7289, ST 7292) and a press.
with the oil groove up.
3. Install first stage planetary gears (9) (3 used) and

Press
thrust plates (7) (6 used) into first stage carrier
(21).
4. Align the hole on pin (5) with spring pin hole on ST 7292
first stage carrier (21). Install pins (5) (3 used) by
using a hammer. ST 7289 30
5. Face the slit of spring pin (6) to the end of pin (5). 29
Install spring pin (6) into first stage carrier (21)
and pin (5) by using a hammer. 26
6
5
WIHH-02-06-008
Slit
NOTE: In case only oil seal (29) is replaced, be
W178-02-06-002 sure to use the special tool (ST 7300 or ST
7296).
6. Assemble second stage carrier (19) in the same
procedures as steps 1 to 5. Assemble second
stage planetary gears (14) (3 used), needle CAUTION: Housing (31) weight: 104 kg
bearings (13) (6 used), thrust plates (12) (6 used), (230 lb)
(18), pins (10) (3 used), and spring pins (11) (3
used). 9. Fasten the housing (31) body by using a nylon
sling. Hoist and place housing (31) with the
7. Install O-ring (27) onto sleeve (29). sleeve (29) mounting side up.
10. Tap and install the outer race of roller bearing

(30) into housing (31) by using a bar and ham-
mer evenly. Tap and listen to ring in order to
check if the installation is completed.
W2-6-15
32
22
15 23
31
26
28
29
T1HH-03-02-001
W2-6-16
11. Apply THREEBOND #1102 on the outer surface 19. Place special tool (ST 7290) onto the inner race
of oil seal (28). Place oil seal (28) flat on housing of roller bearing (23). Install the inner race by us-
(31) and push the oil seal in gently by hand. ing a press.
Place special tool (ST 7291) on oil seal (28). Tap
in special tool by using a hammer directly.
23
ST 7291
28 ST 7290
31
WIHH-02-06-009
WIHH-02-06-010
12. Apply grease to the inner surface of oil seal (28).

Apply grease to the outer surface of sleeve (29)
on shaft (26).
(32) hole in housing (31). Hoist and place hous-
ing (31) on shaft (26). Check and align carefully
in order to prevent the oil seal (28) lip from curl-
ing.
14. Tap and install the outer race of roller bearing

(23) into housing (31) by using a bar and ham-
mer evenly. Tap and listen to ring in order to
check if the installation is completed.
15. Tap and install the inner race of roller bearing

(23) into shaft (26) by using a bar and hammer.
Tap the inner race until two threads of shaft for
nut (15) appear.
16. Tighten nut (15) to shaft (26) by hand.

Prevent shaft (26) from falling off when hoisting
housing (31).
CAUTION: Housing (31) + shaft (26) +

bearing (23) weight: 193 kg (425 lb)
(32) hole in housing (31). Hoist and place hous-
ing (31) on a press.
18. Remove nut (15) from shaft (26).
W2-6-17
20
19
22
17
16
15 23
31
26
T1HH-03-02-001
W2-6-18
20. Hoist and place the housing (31) assembly on
bracket (ST 5100). Install the housing (31) as- CAUTION: Second stage carrier weight:
sembly with bolts (M22) (2 used). Insert the 42 kg (93 lb)
stopper at the bottom of bracket between teeth of
the pinion gear. Secure the bracket on a work- 23. Install the second stage carrier (19) assembly
bench. onto the spline of shaft (26). The concave part of
: 32 mm 31 the boss in bottom side of the carrier comes in
contact with lock plate (16).
ST 5100
Concave 19
Stopper
16
26
W178-02-06-012
21. Apply a firm of grease on the thread part of nut

(15). Install nut (15) on shaft (26) with the
stepped side facing to roller bearing (23). Tighten W178-02-06-014
nut (15) by using special tool (ST 3167).

: 735 N⋅m (75 kgf⋅m, 540 lbf⋅ft) 24. Install second stage sun gear (20) into the
second stage carrier (19) assembly.
NOTE: Apply grease for keeping correct tightening
torque. 25. Clean off old adhesive. Apply THREEBOND #1215
onto the ring gear (22) mounting surface of hous-
ST 3167
15 ing (31).
W178-02-06-008
22. Install lock plate (16) onto nut (15) with bolt (17).
In case the spline of lock plate (16) and that of
shaft (26) are not aligned, tighten nut (15) in
tightening direction until both splines are aligned.
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W2-6-19
21
20
32
22
24
31
25
T1HH-03-02-001
W2-6-20
CAUTION: Ring gear weight: 34 kg (75 lb)
26. Install eyebolt (M12, Pitch 1.75 mm) to the motor

mounting thread part on ring gear (22). Hoist and
install ring gear (22) on housing (31) while align-
ing the matching marks. Tighten socket bolts (32)
(12 used).
: 17 mm
: 390 N⋅m (40 kgf⋅m)
27. Install the first stage carrier (21) assembly onto

the spline of second stage sun gear (20).
28. Install first stage sun gear (4) into the first stage
carrier (21) assembly with the stepped side
down.
29. Wind the seal tape onto the thread part of pipe
(24). Install pipe (24) into housing (31) with the
pipe down.
: 18 mm
30. Wind the seal tape onto drain plug (25). Install
drain plug (25) into pipe (24).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
31. Add gear oil. Geal oil: 16.3 L (4.31 US gal)
32. Apply THREEBOND #1215 onto the motor

mounting surface of ring gear (22).
CAUTION: Motor weight: 71 kg (160 Ib)
33. Hoist motor (2). Align the matching marks and

install motor (2) into ring gear (22) with socket
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W2-6-21
DISASSEMBLE SWING MOTOR
12
11
10
9
8
7
6 13
3
5
2 4
1 21
22 26
23 27
24 28
25
20
24
23
22
19 21
18 29
17
16 W1HH-02-06-005
15
14
1 - Casing 9 - Plate 17 - Spring (24 Used) 24 - Poppet (2 Used)

2 - Parking Brake 10 - Retainer 18 - Valve Plate 25 - Valve Casing
Release Valve
3 - Socket Bolt (3 Used) 11 - Rotor 19 - Bearing 26 - Socket Bolt (4 Used)
4 - Oil Seal 12 - Friction Plate (3 Used) 20 - O-Ring 27 - O-Ring
5 - Bearing 13 - Plate (4 Used) 21 - Plug (2 Used) 28 - Plug (2 Used)
6 - Shaft 14 - O-Ring 22 - O-Ring 29 - Relief Valve (2 Used)
7 - Shoe Plate 15 - O-Ring 23 - Spring (2 Used)
8 - Plunger (9 Used) 16 - Brake Piston
W2-6-22
Disassemble Swing Motor
CAUTION: Swing motor assembly weight: 7. Attach special tool (ST 7288) onto the brake
70 kg (155 Ib) piston (16) groove and hoist brake piston (16).
26
IMPORTANT: Do not disassemble relief valve (29).
1. Remove relief valves (29) (2 used) from valve
casing (25). ST 7288
: 41 mm
16
2. Remove plugs (21) (2 used) from valve casing
(25).
: 17 mm
1
3. Remove springs (23) (2 used) and poppets (24)
(2 used) from valve casing (25).
4. Remove socket bolts (3) (3 used) from casing (1). W1HH-02-06-006
Remove parking brake release valve (2).

: 5 mm 8. Remove O-rings (14, 15) from casing (1).
5. Put the matching marks on the mounting

surfaces between valve casing (25) and casing
(1). Remove socket bolts (26) (4 used). Remove
valve casing (25) from casing (1).
: 17 mm
NOTE: Check that valve casing (25) is floated by

spring (17). Valve plate (18) may be
removed with valve casing (25). When
removing valve casing (25), do not fall off
valve plate (18).
IMPORTANT: Do not damage the mating surfaces
when separating valve plate (18)
from valve casing (25) or rotor (11)
by using a screwdriver.
6. If valve plate (18) is still attached with the rotor in
step 5, remove valve plate (18) from the rotor.
Remove springs (17) (24 used).
W2-6-23
12
11
10
9
8
7
6 13
5
4
1
25
19
W1HH-02-06-005
W2-6-24
IMPORTANT: Do not damage the slide surfaces
of rotor (11) and plunger (8).
9. Place casing (1) horizontally. Remove rotor (11)
from shaft (6). Remove retainer (10), plate (9),
and plungers (8) (9 used) from shaft (6).
10. Remove plates (13) (4 used) and friction plates

(12) (3 used) from casing (1).
11. Remove shoe plate (7) from casing (1). Do not

damage the slide surface of shoe plate (7).
12. When removing shaft (6), the spline damages the

oil seal. Wind the tape onto the spline of shaft (6)
before removing shaft (6). Tap and remove shaft
(6) from casing (1) by using a plastic hammer
lightly.
13. Remove oil seal (4) from casing (1).
14. Remove the outer race of bearing (5) from casing

(1) by using a bar and plastic hammer.
15. Remove the inner race of bearing (5) from shaft

(6) by using a press.
16. Remove bearing (19) from valve casing (25) by

using a bearing puller.
W2-6-25
ASSEMBLE SWING MOTOR
24
23
22
21
26
28
27
T1HH-03-02-003
25
29
17
16
15
19
14
20
18
12
3 13
2 8
10
11
7
9 5
4 6
T1HH-03-02-002
1 - Casing 9 - Plate 17 - Spring (24 Used) 24 - Poppet (2 Used)
2 - Parking Brake 10 - Retainer 18 - Valve Plate 25 - Valve Casing
Release Valve
3 - Socket Bolt (3 Used) 11 - Rotor 19 - Bearing 26 - Socket Bolt (4 Used)
4 - Oil Seal 12 - Friction Plate (3 Used) 20 - O-Ring 27 - O-Ring
5 - Bearing 13 - Plate (4 Used) 21 - Plug (2 Used) 28 - Plug (2 Used)
6 - Shaft 14 - O-Ring 22 - O-Ring 29 - Relief Valve (2 Used)
7 - Shoe Plate 15 - O-Ring 23 - Spring (2 Used)
8 - Plunger (9 Used) 16 - Brake Piston
W2-6-26
Assemble Swing Motor
1. Install the inner races of bearings (5, 19) into 10. Install brake piston (16) into casing (1).
shaft (6) by using a press.
Install the inner race of bearing (5) with the flange 11. If it is not easy to install brake piston (16) due to
facing to the stepped side of shaft (6). the resistant force from O-rings (14, 15), tap
O-rings evenly by using a plastic hammer. Install
2. Push oil seal (4) into casing (1) by using a plate. springs (17) (24 used) onto brake piston (16).
Install oil seal (4) with the lip facing to the bearing
(5) mounting side.
3. Install the outer race of bearing (5) into casing (1)

by using a bar.
4. Wind the tape onto the spline at the end of shaft

(6) in order not to damage the lip of oil seal (4).
Place casing (1) horizontally. Install shaft (6) into
casing (1).
5. Place casing (1) with the valve casing (25)

mounting side up. Install shoe plate (7).
6. Align the notches on retainer (10) and plate (9).

Assemble plate (9) and retainer (10). Install
plungers (8) (9 used).
Apply hydraulic oil onto the plunger hole in rotor
(11). Instert the plunger (8) assembly into rotor
(11).
7. Place casing (1) horizontally. Install the rotor (11)

assembly onto shaft (6).
IMPORTANT: 4 notches are on the outer side of

plate (13). 4 notches are at the
spline teeth side of friction plate (12).
Align each notch at the same place
when installing.
8. Place casing (1) vertically. Alternately install
plates (13) (4 used) and friction plates (12) (3
used) into casing (1).
9. Apply a film of grease to O-rings (14, 15).

Install O-rings (14, 15) onto casing (1).
W2-6-27
24
23
22
21
26
T1HH-03-02-003
25
29
19
20
18
T1HH-03-02-002
W2-6-28
12. Install the outer race of bearing (19) into valve
casing (25) by using a bar and plastic hammer.
Tap the bearing type indicated surface by using
a plastic hammer and install bearing (19).
13. Install O-ring (20) onto valve casing (25). Apply

grease onto valve plate (18) in order not to fall off.
Install valve plate (18) to value casing (25).
14. Align the matching marks on valve casing (25)

and casing (1). Install valve casing (25) with
socket bolts (26) (4 used).
: 17 mm
: 431 N⋅m (44 kgf⋅m, 320 lbf⋅ft)
15. 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 N⋅m (55 kgf⋅m, 400 lbf⋅ft)
16. Install relief valves (29) (2 used) into valve casing

(25).
: 41 mm
: 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
17. Install parking brake release valve (2) into casing

(1) with socket bolts (3) (3 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.68 lbf⋅ft)
W2-6-29
DISASSEMBLE AND ASSEMBLE
PARKING BRAKE RELEASE VALVE
10 4 9 11
3
7
12
6
5 2
1 13
W110-02-06-005
1- Casing 5 - Bushing 8 - Orifice 11 - O-Ring (2 used)

2- Spool 6 - Filter 9 - Spring 12 - Steel Ball
3- Spring 7 - Spacer 10 - O-Ring 13 - Bolt (3 used)
4- Plunger
W2-6-30
Swing Motor
d
1. Clearance between piston outer diameter and
rotor inner bore.
Unit:m (in)
D-d 0.028 (0.001) 0.058 (0.002)
W107-02-06-138
Use the piston and rotor for the motor.

D D
Use the plunger and cylinder block for the pump.
W107-02-06-139
2. Clearance between piston and shoe

Unit: mm (in)
δ 0 (0) 0.3 mm (0.0118)
δ
W107-02-06-140
W107-02-06-141
W2-6-31
3. Shoe thickness
Unit: mm (in)
t 5.5 (0.22) 5.3 (0.21)
4. Friction plate thickness

Unit: mm (in) W107-02-06-142

t 2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-32
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE

Removal
1. Remove seat mounting bolts (2) (4 used). Re-
move seat (1) (with seat stand).
: 17 mm 2
W178-02-07-006
2. Remove screws (24) (4 used) and cover (23).

Move boot (29) up. 30
: 17 mm
3
29
4
3. Remove caps (17) (2 used) from cover (18). 28
27 5
4. Remove screws (21)(4 used) and (16) (2 used). 26 6
Move cover (18) up. Remove each harness for 25 7
key switch (20), air controller (19), and grip (3). 8
Remove cover (18). Remove screws (22, 15, 13) 9
24 10
and remove cover (14). 11
23 12
5. Remove the connector and bolt (11) for switch 21
20
box (12). Remove switch box (12).
19
: 13 mm 22
18
17
16
15
14
13
W178-02-07-001
W2-7-1
6. Remove hoses (31 to 36). Attach identification
tags onto the removed hoses for reassembling.
Cap the ends of all removed hoses. 30
: 19 mm
3
29
7. Remove nut (4) and remove crips (5, 27). Re- 4
28
move connector (6) and remove grip (3) (with the 27 5
harness).
Remove nut (28). Remove lever (30), washers 26 6
(25, 26), and boot (29). 25 7
8
: 22 mm 9
: 19 mm 24 10
11
23 12
8. Remove bolts (9) (3 used) and (8) (with spring 21
pin (7)) from pilot valve (10). Remove pilot valve 20
(10). 19
22
: 13 mm 18
17
16
15
14
13
W178-02-07-001
31
36
35 32
33
34
W178-02-07-002
31 - Hose T6: (To pilot shut-off valve)

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

of spring pin (7), the harness makes
contact with the moving part of the
pilot valve and the harness is dam-
aged. Arrange the harness to the
W178-02-07-002
outside of spring pin (7).
30
3. Temporarily tighten nut (28) to lever (30) and in-
stall washers (25, 26). Install lever (30) onto pilot 3
29
valve (10) with nut (28). Install boot (29).
4
Temporarily tighten nut (4) to lever (30) and in- 28
stall grip (3) with nut (4). 27 5
Pass the harness of grip (3) through the upper
26 6
hole of boot (29) and install lever (30) with clips
25 7
(5, 27). Arrange the harness to the outside of 8
spring pin (7) over bolt (8) head. 9
Install connector (6). 24 10
11
: 22 mm 23 12
: 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 21
: 19 mm 20
: 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 19
22
18
17
16
15
14
13
W178-02-07-001
W2-7-3
4. Install switch box (12) with bolt (11). Install the
connector. 30
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 29 3
4
5. Install each harness of key switch (20) and air 28
controller (19). 27 5
26 6
6. Install cover (14) with screws (22, 15, 13). 7
25
Install cover (18) with screws (21) (4 used) and 8
(16) (2 used). 9
Install caps (17) (2 used) onto cover (18). 24 10
11
23 12
7. Install boot (29) and cover (23) with screws (24) 21
(4 used). 20
19
22
18
17
16
15
14
13
W178-02-07-001
8. Install seat (1) (with the seat stand) with bolts

(2) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
9. After completing the work, check the oil level.

Start the engine and check for any oil leaks.
2
W178-02-07-006
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE
DRAULIC OIL TANK on W1-4-1.) 1
Removal
1. The console is at the most front position. Re-
move screws (2) (4 used) and cover (3). Move
boot (1) up.
: 17 mm 10
2
9 Radio
2. Remove screws (7, 8) and remove cover (9). 3
8
4
3. Remove cap (10) from cover (6).
4. Remove screws (4) (3 used) and (5). Move cover

(6) up. Remove the radio connector and remove
cover (6). 7
6
5
W178-02-07-003
11
16
15 12
13
5. Remove hoses (11 to 16).
Cap the ends of all removed hoses. 14
Attach an identification tag onto the removed
hoses to for reassembling.
: 19 mm
W178-02-07-004
11 - Hose T5 : (To pilot shut-off valve)
12 - Hose F : (To shockless valve port F for right swing)
13 - Hose C : (To shockless valve port C for arm roll-out)
14 - Hose P2 : (From pilot shut-off valve)
15 - Hose E : (To shockless valve port E for left swing)
16 - Hose D : (To shockless valve port D for arm roll-in)
NOTE: Piping location shows that of JIS pattern.
W2-7-5
6. Remove nut (18). Remove clips (29, 21). Re-
move connector (28) and remove grip (17) (with
the harness). 17
Remove nut (20). Remove lever (19), washers
(25, 26), and boot (1).
: 22 mm 29
: 19 mm 18
19
7. Remove bolts (24) and (23) (with pin (22)). Re- 28
move pilot valve (27). 1
: 13 mm 20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6
Installation
1. Install pilot valve (27) with bolts (24) and (23)
(with pin (22)).
: 13 mm 17
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
2. Install hoses (11 to 16). 29

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 18
19
28
IMPORTANT: If the harness is arranged to the in-
1
side of spring pin (22), the harness 20
makes contact with the moving part 21
of pilot valve and the harness is 22
damaged. Arrange the harness to 23
the outside of spring pin (22). 24
8 9 10 25
3. Temporarily tighten nut (20) to lever (19) and in- 26
stall washers (25, 26). Install lever (19) onto pi- 27
lot valve (27) with nut (20). Install boot (1).
Temporarily tighten nut (18) to lever (19) and in- 2
stall grip (17) with nut (18). 3
Pass the harness of grip (17) through the upper
4
hole of boot (1) and install lever (19) with grips
(29, 21). Arrange the harness to the outside of 5
spring pin (22) over bolt (23) head. Install con-
nector (28).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
: 22 mm 7 6 W178-02-07-003
: 55 N⋅m (5.6 kgf⋅m, 40.5 lbf⋅ft)

: 19 mm
: 35 N⋅m (3.6 kgf⋅m, 26 lbf⋅ft)
W2-7-7
4. Install the connector of radio. Install cover (6)
with screws (4) (4 used) and (5). Install cap (10).
17
Install cover (9) with screws (7, 8).
5. Install boot (1) and cover (3) with screws (2) (4

used). 29
18
6. After completing the work, check the oil level. 19
Start the engine and check for any oil leaks. 28
1
20
21
22
23
24
8 9 10 25
26
27
2
3
4
5
7 6 W178-02-07-003
W2-7-8
REMOVE AND INSTALL TRAVEL PILOT
VALVE

Removal
1. Remove floor mat (1).
WIHH-02-07-001
2. Remove bolts (3) (6 used) from the swing frame.

Remove under cover (2).
: 17 mm
3. Remove bolts (4) (2 used). Remove pedals (5) (2

used) and levers (16, 17). 2
: 17 mm 3
4. Remove pipes (6, 7) and hoses (8 to 11).

Cap the ends of all removed pipes and hoses.
Attach an identification tag onto the removed WIHH-02-07-002
pipes and hoses for reassembling.

: 17 mm, 19 mm
5. Remove socket bolt (14), spring washer (13), and 4

plain washer (12). Remove pilot valve (15). 17
16
: 8 mm 5
5
15
14
14
13
13
12
12 6
7
11
10
9
8
W178-02-07-005
6- Pipe T4: (To pilot shut-off valve)
7- Pipe P1: (From pilot shut-off valve)
8- Hose 11: (To control valve port RF for right travel (forward))
9- Hose 12: (To control valve port RR for right travel (reverse))
10 - Hose 10: (To control valve port LR for left travel (reverse))
11 - Hose 9: (To control valve port LF for left travel (forward))
W2-7-9
Installation
1. Install pilot valve (15) with socket bolt (14), spring
washer (13), and plain washer (12).
: 8 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 1
2. Install pipes (6, 7) and hoses (8 to 11).

: 17 mm
: 35 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
WIHH-02-07-001
3. Install pedal (5) and levers (16, 17) with bolts (4).
: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft)
4. Install under cover (2) with bolts (3) (6 used).

2
: 17 mm 3
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft)
5. Install floor mat (1).

WIHH-02-07-002
6. After completing the work, check the oil level.
Start the engine and check for any oil leaks.
4
17
16
5
5
15
14
14
13
13
12
12 6
7
11
10
9
8
W178-02-07-005
12 - Pipe T4: (To pilot shut-off valve)
13 - Pipe P1: (From pilot shut-off valve)
14 - Hose 11: (To control valve port RF for right travel (forward))
15 - Hose 12: (To control valve port RR for right travel (reverse))
16 - Hose 10: (To control valve port LR for left travel (reverse))
17 - Hose 9: (To control valve port LF for left travel (forward))
W2-7-10
(Blank)
W2-7-11
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13 ZAXIS330, 330LC: Up to serial No. 320880
ZAXIS350
ZAXIS350LCH
ZAXIS370MTH
12
14
11
15
11
10
8
8
7 9
21
6
21 20
16
5
20
4 5
19
3 6
3
2 18
4
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Knock Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-12
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are 4. Remove push rods (8, 9) from block (10).
made of aluminium. Too strong a Two kinds of push rods are used. They must be
force can deform or damage them. handled in order of port number after removing.
Be careful while handling them.
5. By using a bamboo spatula, remove oil seals (15)
IMPORTANT: Spool (17) has been selected to (4 used) from block (10).
match the hole of housing (18). The
dimensions of balance springs A (3), 6. Push the springs by using special tool (ST 7257)
B (4) and return springs A (5), B (6) from the top of spring guide (16). Retaining ring
as well as those of push rods A (8), (7) will appear. Remove retaining ring (7) by us-
B (9) are different. Indicate the port ing a screwdriver or similar tool. (4 places)
number from which it is removed. 7
Port numbers are stamped on
housing (18).
IMPORTANT: Do not remove screw joint (13) while

clamping housing (18) in a vise. The
strong torque may act on the screw
joint. 16
ST 7257
1. Clamp screw joint (13) in a vise. Turn cam (12)
by using a spanner. Remove screw joint (13).
: 19 mm, 32 mm
2. Clamp the flat surface of housing (18) in a vise

W176-02-07-005
slightly. Remove cam (12) from universal joint
(14).
: 32 mm NOTE: The number of shims has been determined
for each port during the performance test-
NOTE: Universal joint (14) has been secured on ing at the factory.
block (10) by using LOCTITE. Do not re- Do not lose shims. Keep shims carefully in
move universal joint (14) unless neces- order to install shims to each former port
sary. when reassembing.
3. Remove socket bolt (11) and remove block (10). 7. Remove spring guide (16), balance springs (3, 4),
Push rods (8, 9) are removed with the block to- return springs (5, 6), shim (2), and spacer (1)
gether. from spool (17).
: 6 mm
W2-7-13
21
20
21
20
19
18
17
W176-02-07-001
W2-7-14
8. Remove spool (17) from housing (18). Slowly
turn and remove spool (17).
As spool (17) has been selected to match the
hole in housing (18), keep spool (17) carefully in
order to install spool (17) to the former port when
reassembling.
9. Remove O-rings (19, 21) from housing (18).

Do not remove knock pin (20) unless necessary.
W2-7-15
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
17
ZAXIS330, 330LC: Serial No.320881 and up
16 ZAXIS350H
ZAXIS350LCH
ZAXIS370MTH
15
14
13
12
11
10
9 22
7
6 21
5 20
4 19
3 18
W178-02-07-064
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Retaining Ring

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Plug
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Spool (4 Used)
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Casing
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)
W2-7-16
Disassemble Right and Left Pilot Valves
IMPORTANT: Casing (22) is made of aluminium. IMPORTANT: Insert a soft rubber between sleeve
As too strong a force can deform, or (12) and the tool in order not to
damage them, handle them with damage the surface of sleeve (12).
care. Oil seal (11) cannot be removed
from sleeve (12).
IMPORTANT: Spool (21) has been selected to Sleeve (12) and oil seal (11) must be
match the hole of casing (22). The replaced as an assembly.
dimensions of balance springs A (3), 5. Pull out sleeve (12) upward by using a pair of
B (4) and return springs A (5), B (6) plier.
as well as those of pushers A (9), B
(10) are different. Indicate the port IMPORTANT: As pushers (9, 10) are used for ports
number from which it is removed. 1, 3 and for ports 2, 4, the dimen-
Port numbers are stamped on cas- sions are different. Indicate the port
ing (22). number from which it is removed in
order to keep by the port number.
IMPORTANT: Do not remove screw joint (17) while 6. Remove pushers (9, 10) from casing (22).
clamping casing (22) in a vise. The
strong torque may act on the screw
joint.
1. Clamp screw joint (17) in a vise. Turn cam (16)
by using a spanner. Remove screw joint (17).
: 19 mm, 32 mm
2. Clamp the flat surface of casing (22) in a vise

lightly. Remove cam (16) from universal joint
(15).
: 32 mm
3. Attach a spanner onto the upper surface and re-

move universal joint (15).
: 17 mm
NOTE: Universal joint (15) has been secured on
casing (22) by using LOCTITE.
4. Remove plate (14).
W2-7-17
17
16
22
7
6 21
5
4 19
3 18
W178-02-07-064
W2-7-18
7. Install special tool (ST 4146) to the port hole on IMPORTANT: Spool (21) has been selected to
casing in order not to lower the spool when push- match the hole of casing (22). Re-
ing the spring. place spool (21) and casing (22) as
: 6 mm an assembly.
11. Remove special tool (ST 4145) from casing (22).
8. Install special tool (ST 4146) to the pusher hole Slowly turn and remove spool (21).
on casing (22). Push special tool (ST 4146) and
push the spring. Tighten special tool (ST 4146) IMPORTANT: Retaining ring (18) may come off
by using bolt (M14, Pitch 2 mm). while disassembling. Do not fall off
: 12 mm retaining ring (18) inside the casing.
If falling off retaining ring (18) inside
the casing, remove retaining ring
ST 4146 (18). Retaining ring (18) cannot be
reused.
12. Remove retaining ring (18) by using a screw-
driver. Install bolt (M8, Pitch 1.25 mm) and re-
move plug (19).
22
: 13 mm
W178-02-07-048
ST 4145
IMPORTANT: The quantity of shims (2) has been
determined for each port during the
performance testing at the factory.
Do not lose shims. Keep shims
carefully in order to install shims to
each former port when reas-
sembing.
9. Remove special tool (ST4146). Remove spring
guides (7) (4 used), balance springs A (3) (2
used), B (4) (2 used), return springs A (5) (2
used) and B (6) (2 used).
10. Remove shim (2) and spacer (1) (4 used) from

spool (21).
W2-7-19
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
ZAXIS330, 330LC: Up to serial No.320880
ZAXIS350H
ZAXIS350LCH
ZAXIS370MTH
13 14
10
12
15
11
8, 9
7
16
3, 4
5, 6
19
17
W176-02-07-006
21 20 18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Knock Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-7-20
Assemble Right and Left Pilot Valves
NOTE: Table below shows the relations between 4. Install retaining ring (7) onto ring holder (ST
each port and the components. Do not 7255).
confuse them when assembling.
ST 7255
7
Port Spool Shim Push Rods
No. (17) (2) (8, 9)
With outer
1 W176-02-07-008
Same to Same to groove

the former the former Without outer 5. Insert the spool (17) head into the hole of special
2
one one groove tool (ST 7257). Push the spring from the top of
With outer spring guide (16). Install retaining ring (7) with the
3
groove ring holder (ST 7255) onto the head of spool.
Without outer
4
groove ST 7257 ST 7255
Port Return Springs Balance Springs 17

No. (5, 6) (3, 4)
1 43 mm 29.9 mm
2 48 mm 30.1 mm Packing Material
3 43 mm 29.9 mm
4 48 mm 30.1 mm W176-02-07-009
NOTE: Insert approx. dia.8 mm, length 10 mm of

1. Insert the thinner end of spool (17) to housing packing material into the port hole in order
(18) while rotating. to not only make the work easy to do, but
Check the port hole number and insert the spool also prevent spool (17) from lowering to
to the former port. the bottom when compressing the spring.
NOTE: Spool (17) has been selected to match the
port hole. Spool (17) and housing (18)
must be replaced as an assembly.
IMPORTANT: Refer to the table in order to assem-

ble them correctly.
2. Install spacer (1), shim (2), balance spring (3) or
(4), and return spring (5) or (6) onto spool (17)
installed in housing (18).
3. Install spring guide (16) onto return spring (3) or

(4) with the protrusion up.
W2-7-21
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-22
6. Assemble other spools (17) (3 used) into housing IMPORTANT: Check the tightness of cam.
(18) in the same procedures as step 2 to 5.
13. Clamp housing (18) carefully in a vise. Install
7. Install O-rings (19) and (21) (2 used) to housing cam (12) to universal joint (14).
(18). Tighten universal joint (14) so that the clearance
between cam (12) and push rods (8, 9) become 0
8. Apply grease to the inner surface of oil seals to 0.2 mm.
(15) (4 used). Install the oil seals (4 used) into : 19 mm, 32 mm
block (10) by using a bamboo spatula. : 88.2 N⋅m (9 kgf⋅m)
NOTE: Insert push rods (8, 9) first as illustrated in IMPORTANT: Do not clamp housing (18) in a vise
order to prevent oil seal (15) from coming when operating. The strong torque
into the endmost of hole during operating. may act on the screw joint (13).
Oil Seal 14. Clamp screw joint (13) in a vise. Tighten univer-
Mounting Hole
sal joint (14). Tighten cam (12) by using a span-
8, 9 ner.
10
: 32 mm
: 88.2 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W176-02-07-007
9. Install push rods (8, 9) to block (10). Install the

push rods with outer groove to ports # 1 and # 3.
Install the push rods without outer groove to ports
# 2 and # 4.
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 knock pin (20). Install the

block (10) assembly to housing (18) with socket
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
W2-7-23
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
ZAXIS330, 330LC: Serial No.32088 and up

ZAXIS350H
ZAXIS350LCH
ZAXIS370MTH
17
16 15
11 9, 10
14
12
13
8
7
3, 4
5, 6
2
19
1
19
22 21
18
W178-02-06-055
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Retaining Ring

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Plug
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Spool (4 Used)
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Casing
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)
W2-7-24
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to IMPORTANT: Refer to the table in order to
contamination. Keep the parts clean assemble them correctly.
when assembling. 3. Install spacer (1), shim (2) and balance springs (3,
4) to spool (21). Install return springs (5, 6) to
NOTE: Table below shows the relations between casing (22).
each port and the components. Do not
confuse them when assembling. 4. Install spring guide (7) onto return springs (5, 6)
with the protrusion facing upward.
Port Spool Shim Pushers A, B 5. Install special tool (ST 4146) to the pusher hole
No. (21) (2) (9, 10) on casing. Push special tool (ST 4146) and push
Outer grooves the spring. Tighten special tool (ST 4146) by using
1 bolt (M14, Pitch 2 mm).
Same to Same to (3 Used)
the former the former Without outer : 12 mm
2 one one groove
ST 4146
Outer grooves
3
(3 Used)
ST 4144
Without outer
4
groove
Port Return Springs Balance Springs A, B

No. (5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long W178-02-07-049
ST 4145
1. Check the port hole number and insert spool (21) 6. Install retaining ring (8) to ring holder (ST 4144).
to the original port. Insert the thinner end of spool
(21) to the port hole in casing (22) while rotating.
port hole. Spool (21) and casing (22) must
be replaced as an assembly.
2. Install special tool (ST 4145) to the port hole on

casing (22) in order not to lower the spool when
pushing the spring.
: 6 mm
W2-7-25
17
16 15
11 9, 10
14
12
13
8
3, 4
22
W178-02-06-055
W2-7-26
7. Install retaining ring (8) on ring holder (ST 4144) IMPORTANT: Align the bolt hole of plate (14) with
to the groove on the head of spool (21) out of the screw hole on casing (22)
special tool (ST 4146) completely.
14. Place plate (14) onto casing (22) and tighten
IMPORTANT: Check the mounting positions of universal joint (15).
pushers (9, 10). : 17 mm
8. Install pushers (9, 10). : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
Push pushers (9, 10) by hand and remove
pushers (9, 10). Check if retaining ring (8) falls off IMPORTANT: Check the tightness of cam (16).
or the positions of balance springs (3, 4) are 15. Install cam (16) to universal joint (15). The
correct. clearance between cam (16) and pushers (9, 10)
After checking, install pushers (9, 10) to casing should be 0 to 0.2 mm.
(22).
16. Secure cam (16) by using a spanner. Tighten
9. Apply grease to the ball at the ends of pushers (9, screw joint (17) by using a spanner.
10). : 19 mm, 32 mm
: 68.4 N⋅m (7.0 kgf⋅m, 50 Ibf⋅ft)
10. Apply grease to the joint part of universal joint
(15).
11. Apply grease to the inner surface of oil seals (11)

(4 used).
NOTE: Sleeve (12) and oil seal (11) must be

replaced as an assembly.
12. Install oil seal (11) and sleeve (12). Push sleeve
(12) until O-ring (13) is inserted into the hole on
casing.
13. Clamp casing (22) in a vise lightly.
W2-7-27
DISASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine before March in 2003.
1
35 2
34
33
32
31
30
3
4
5
6
29
28 7
27
8
9
10
26
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-28
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolt (1) and 8. Place a stand under bracket (26).
remove cover (2) from holder (10). The hole insides of spring pins (24, 25) in bracket
: 10 mm (26) are in stepped-shape. The spring pin can
only be removed in one direction.
2. Remove socket bolts (8) (2 places). Remove Remove both spring pins (24, 25) from bracket
holder (10) from casing (14). (26) at the same time by using special tool (ST
: 8 mm 1237). Remove bracket (26) from pin (3). (2
places)
3. Remove pusher (23) from casing (14). (4 places) Do not remove spring pin (27) with bracket unless
Bushing (13) and oil seal (11) are removed with necessary.
pusher (23) together. The outside end of spring pin (27) has been
caulked.
4. Remove pusher (23) from bushing (13). By using a
bamboo spatula, remove oil seal (11). (4 places)
24, 25
5. Turn and remove the spool (17) assembly from 26
casing (14). (4 places) 3 27
Spring guide (22), balance spring (21), shim (20),
and spacer (19) are removed with spool (17) Caulked Here
together.
Put the marks on spools (17) (4 used) in order to Stand
easily install spools (17) to their former position.
6. Push balance spring (21). Remove spring guide

(22), balance spring (21), shim (20), and spacer W176-02-07-019
(19) from spool (17). (4 places)
The number of shims (20) has been determined
during the performance testing at the factory.
They must be kept together with spool (17). 9. Remove socket bolts (28) (2 used). Remove
damper (6) and rubber seat (7) from pin (3).
7. Remove spring (18) from casing (14). (4 places) O-ring (4) is removed together. (2 places)
: 5 mm
IMPORTANT: Place a stand under bracket (26) and
form an reaction force. If holder (10)
bears the reaction force, a strong
force acts on pin (3) and pin (3) may
be deformed.
W2-7-29
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-30
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mounting

surface up.
IMPORTANT: As the holes for spring pins (34, 35)

in cam (32) are stepped-shape, tap
the bottom of cam.
12. Remove spring pins (34, 35) from cam (32) at the
same time by using special tool (ST 1237). (2
places)
As the holes of spring pins (34, 35) are caulked,

spring pins (34, 35) may feel tight when removing.
13. Remove pin (3) by using a bar and hammer. At

the same time cam (32) is also removed. (2
places)
Do not remove bushings (31) (4 used) left on
holder (10) unless necessary. When removing,
tap bushing (31) by using special tool (ST7256).
14. Remove lock nuts (33) (2 used) from cam (32).

Remove adjusting bolts (30) (2 used). (2 places)
: 13 mm
: 4 mm
W2-7-31
DISASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine after April in 2003.
3
4
35
7 34
33
32
8
9 31
30
10
29
11
28
14 27
26
12
13 15
25
16
24
17
18
23
19
20
21 22
W178-02-07-063
1- Bolt (2 Used) 10 - Spring Pin 19 - O-Ring (2 Used) 28 - Oil Seal (2 Used)

2- Cover 11 - Bracket (2 Used) 20 - Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring (4 Used) 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)
W2-7-32
Disassemble Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminium. IMPORTANT: The quantity of shim has been
As too strong a force can deform, or determined during the performance
damage them, handle them with testing at the factory. Keep the shim
care. together with the spool.
6. Push balance spring (18). Remove spring guide
IMPORTANT: Spool (24) has been selected to (17), balance spring (18), shim (27) and spacer
match the hole of casing. (26) from spool (24) (4 places).
Indicate the port number from which
it is removed. 7. Remove spring (25) from casing (23). (4 places)
Port numbers are stamped on the
periphery of casing (23).
1. Clamp casing (23) in a vise. Remove bolts (1) (2
used), and remove cover (2) from holder (7).
: 10 mm
2. Remove socket bolt (30) (2 places), and remove

spring washer (29) (2 places). Remove holder (7)
from casing (23).
: 8 mm
3. Remove pushers (16) (4 used) from casing (23)

(4 places).
4. Remove pusher (16) from bushing (15). By using

a bamboo spatula, remove oil seal (28) (4 places).
Remove O-ring (14) from bushing (15).
IMPORTANT: Put the mark on spools (24) (4 used)

in order to easily install spool (24)
into the original hole.
5. Turn and remove the spool (24) assembly from
casing (23) (4 places).
Spring guide (17), balance spring (18), shim (27)
and spacer (26) are removed with spool (24)
together.
hole of casing (23). Replace spool (24) and
casing (23) as an assembly.
W2-7-33
3
4
6
3
4
5 10
11
5 12
6 13
6
35
7 34
33
32
9 31
10
31
11 32
33
34
35
12
13
23
19
20
21 22
W178-02-07-063
W2-7-34
IMPORTANT: Place a stand under bracket (11) and 10. Remove O-ring (33) from pin (35) (2 places).
form a reaction force. If holder (7)
bears the reaction force, a strong 11. Place holder (7) with the casing (23) mounting
force acts on pin (35) and pin (35) surface up.
may be deformed.
8. Place a stand under bracket (11).
The hole insides of spring pins (12, 13) in bracket 12. Remove spring pins (3, 4) from cam (5) at the
(11) are in stepped-shape. The spring pin can same time by using special tool (ST 1237) (2
only be removed in one direction. places). The hole insides for spring pins (3, 4) on
Remove both spring pins (12, 13) from bracket cam (5) are the stepped-shape. Tap the bottom of
(11) at the same time by using special tool (ST cam (5). As the holes of spring pins (3, 4) are
1237). Remove bracket (11) from pin (35) (2 crimped, spring pins (3, 4) may feel tight when
places). removing.
Do not remove spring pin (10) on bracket (11)
unless necessary. 13. Remove pin (35) by using a round bar and
The outside end of spring pin (10) has been hammer. At the same time cam (5) is also
crimped. removed (2 places). Do not remove bushings (6)
(4 used) in holder (7) unless necessary. When
removing, tap bushing (6) by using special tool
(ST7256).
12, 13
14. Remove plug (20) from casing (23) (2 places).
11 O-ring (19) is removed with plug (20) together.
35 10
Crimped 15. Remove plug (21) from casing (23) (2 places).
Here
O-ring (22) is removed with plug (21) together.
Stand
W176-02-07-019
9. Remove socket bolts (9) (2 used). Remove

damper (32) and rubber seat (31) from pin (35).
O-ring (34) is removed together (2 places).
: 5 mm
W2-7-35
ASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine before March in 2003.
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12 18
23
20
19
17
14
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-36
Assemble Travel Pilot Valve
1. Assemble spool (17) into the assembly. (4 used) • Install bushing (31) on the opposite side in the
Insert spacer (19), shim (20), and balance same procedure.
spring (21) into spool (17) in this order. Install
31
the shim (20) as the same condition before 10
disassmbling. ST 7256
Push balance spring (21) by hand. Install spring
guide (22) to spool (17) with the stepped-end
down.
2. Insert spring (18) to casing (14). (4 places) W176-02-07-015
3. Insert the spool (17) assembly into the former port. • Install bushing (31) in near side as illustrated.
Turn and install the spool (17) assembly into Stop tapping when the bushing (31) end is flush
casing (14). (4 places) with the outside of holder (10).
4. Assemble pusher (23) into the assembly. (4 used)

Install oil seal (11) onto bushing (13). 31
Apply grease to the inner surface on oil seal 10 ST 7256
(11).
Install O-ring (12) to bushing (13).
Insert pusher (23) to bushing (13). Outside of
Holder
Apply grease to the head of pusher (23).
W176-02-07-014
5. Insert the pusher (23) assembly to holder (10). (4
places)
• Install bushing (31) in the near and opposite side
as illustrated.
6. If bushing (31) has been removed from holder
31
(10), install bushing (31) on holder (10) by using 10
special tool (ST 7256) in the following procedures. ST 7256
• Insert bushing (31) into special tool (ST 7256).

Tap special tool (ST 7256) and install bushing (31)
into the hole of holder (10) by using a hammer.
Stop tapping when bushing (31) end is flush with
W176-02-07-013
the inside wall.
ST 7256
10
31
W176-02-07-016
W2-7-37
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-38
7. Install adjusting bolt (30) to cam (32). Tighten IMPORTANT: Do not adjust adjusting bolt (30)
adjusting bolt (30) by hand and lightly secure while pushing the pusher (23) head.
adjusting bolt (30) temporarily with lock nut (33). The standard clearance between
(2 places) adjusting bolt (30) and pusher (23)
must be 0 to 0.2 mm (0 to 0.008 in).
NOTE: Adjust the dimensions later.
13. Adjust adjusting bolt (30) in the following
8. Apply grease on the head (mounting surface for procedures. (2 places)
pusher (23)) of adjusting bolt (30). (2 places) : 13 mm
: 4 mm
9. Apply grease onto pin (3). Install O-ring (5) to pin Loosen lock nut (33).
(3). Assemble pin (3) to holder (10) with cam (32). Move cam (32) and check that there is play. If
(2 places) there is no play, turn and adjust adjusting bolt
(30).
10. Install spring pins (34, 35) to cam (32) by using Turn both adjusting bolts (30) on the left and
special tool (ST 1237). Secure cam (32) and pin right alternatively and keep cam (32) horizontal.
(3). Spring pins (34, 35) should be displaced with Measure sizes A and B from both left and right
their slits at 90°. (2 places) caves on cam (32) to holder (10). Fine adjust
Tap spring pins (34, 35) until they come in contact adjusting bolt (30) in order to get same distance
with the step in hole. for both left and right.
Secure adjusting bolt (30) by using a hexagon
34 35 Slit Slit wrench. Tighten lock nut (33) to specified
torque and secure adjusting bolt (30).
When adjustment is finished, move cam (32)
and check that there is a little play. If there is no
play, pusher (23) may be in compressed
condition. Adjust adjusting bolt (30) again.
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
W176-02-07-017
30 33 32 10
11. Caulk the hole edge of cam (32) where spring

pins (34, 35) are inserted by using a punch. (2
A B
places)
12. Place and install holder (10) on the casing (14)

assembly with socket bolts (8) (2 used) and
spring washers (9) (2 used).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
W176-02-07-003
W2-7-39
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-40
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under bracket (26) and
15. Apply grease to O-ring (5). (2 places) bears the reaction force, a strong
force acts on pin (3) and the pin may
IMPORTANT: The inner bore of damper (6) is be deformed.
edged-shape. If damper (6) is pried
when installing, O-ring (5) will be 20. Place a stand under bracket (26).
damaged. Tap spring pins (24, 25) into bracket (26) until the
spring pins (24, 25) comes to the stepped end by
using special tool (ST 1237). The spring pins (2
16. Install damper (6) to pin (3) with the lever up. (2 used) are displaced with their slits in 90°.
places)
17. Secure damper (6) to holder (10) with socket bolts

Caulked Here Caulked Here
(28) (2 used) and spring washers (29) (2 used). (2
places)
26 3
: 8 mm
: 7 N⋅m (0.7kgf⋅m, 5.1 Ibf⋅ft)
18. Apply grease to O-ring (4). Push O-ring (4) to the

Stand 24, 25
endmost of pin (3). (2 places)
19. As for the direction to install the bracket, refer to

the figure in the disassembly section. Do not W176-02-07-011
misassemble it.
Install bracket (26) to pin (3). Align the inserting 21. Caulk the hole edge of bracket (26) where spring
holes of spring pins (24, 25). pins (24, 25) are inserted by using a punch. (2
places)
(Refer to the figure above.)
22. Install bracket (26) on the opposite side to pin (3)

in the same procedures as steps 19 to 21.
23. Install cover (2) to holder (10) with bolts (1) (2

used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
24. Apply grease to the spring pin (27) contact part of

damper (6). (2 places)
W2-7-41
ASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine after April in 2003.
11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30
29
34 15
9 33 28
17
8 18
14
25
27
16
26
24
23
W178-02-06-056
1- Bolt (2 Used) 10 - Spring Pin 19 - *O-Ring (2 Used) 28 - Oil Seal (2 Used)

2- Cover 11 - Bracket (2 Used) 20 - *Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - *Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - *O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)
NOTE: As for the parts with * mark, refer to

W2-7-32.
W2-7-42
Assemble Travel Pilot Valve
IMPORTANT: Check the direction to install spring 6. If bushing (6) has been removed from holder (7),
guide (17). install bushing (6) on holder (7) by using special
1. Assemble spool (24) into the assembly (4 used). tool (ST 7256) in the following procedures.
• Insert spacer (26), shim (27), and balance spring NOTE: Bushings (6) (4 used) are identical.
(18) into spool (24) in this order. Install the shim • Insert bushing (6) into special tool (ST 7256). Tap
as the same condition before disassembling. special tool (ST 7256) and install bushing (6) into
• Push the balance spring by hand. Install spring the hole of holder (7) by using a hammer.
guide (17) to spool (24) with the stepped part Stop tapping when bushing (6) end is flush with
facing downward. the inside wall.
ST 7256
7
2. Insert spring (25) to casing (23) (4 places).
3. Insert the spool (24) assembly into the former port.

Turn and install the spool (24) assembly into
casing (23) (4 places). 6
W176-02-07-016
4. Assemble pusher (16) into the assembly (4 used). • Install bushing (6) on the opposite side in the
• Install oil seal (28) to bushing (15). same procedure. 6
• Apply grease to the inner surface on oil seal (28). 7
ST 7256
• Install O-ring (14) to bushing (15).
• Insert pusher (16) into bushing (15).
• Apply grease to the head of pusher (16).
5. Insert the pusher (16) assembly into casing (23) W176-02-07-015

(4 places).
• Install bushing (6) in near and opposite side as
illustrated. Stop tapping when the bushing (6) end
is flush with the outside of holder (7).
6
7 ST 7256
Outside of
Holder
W176-02-07-014
• Install bushing (6) in the near and opposite side

as illustrated. 6
7
ST 7256
W176-02-07-01313
W2-7-43
32 31 35 31 32 7 5 3, 4 30
29
9 34
8 33
23
W178-02-06-056
W2-7-44
7. Install O-ring (33) to pin (35). Assemble pin (35) to 11. Install rubber seat (31) to pin (35) (2 places).
holder (7) with cam (5) (2 places).
IMPORTANT: Check the direction of damper (32).
IMPORTANT: Check the direction to install spring The inner bore of damper (32) is
pins (3, 4). edged-shape. If damper (32) is pried
when installing, O-ring (33) will be
8. Install spring pins (3, 4) to cam (5) by using damaged.
special tool (ST 1237). Secure cam (5) and pin 12. Install damper (32) to pin (35) with the lever up (2
(35). Spring pins (3, 4) should be displaced with places).
their slits at 90° (2 places).
Tap and install spring pins (3, 4) until spring pins 13. Secure damper (32) and rubber seat (31) to
(34, 35) make contact with the stepped part in the holder (7) with socket bolts (9) (2 used) and spring
hole. washers (8) (2 used) (2 places).
: 5 mm
3 Slit Slit
: 7 N⋅m (0.7 kgf⋅m, 5.2 Ibf⋅ft)
14. Apply grease to O-ring (34). Push O-ring (34) to

the endmost of pin (35) (2 places).
W178-02-07-050
4
9. Crimp the hole edge of cam (5) where spring pins

(3, 4) are inserted by using a punch.
10. Place holder (7) on the casing (23) assembly.

Install holder (7) with socket bolts (30) (2 used)
and spring washers (29) (2 used).
Check the mark direction and install holder (7).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W2-7-45
11 32 1 2 35 12 10 13 7 1 1
W178-02-06-056
W2-7-46
16. As for the direction to install bracket (11), refer to
the figure in the disassemble section. Install
bracket (11) to pin (35). Align the inserting holes
of spring pins (12, 13).
IMPORTANT: Place a stand under the bracket and

bears the reaction force, a strong
force acts on pin (35) and pin (35)
may be deformed.
17. Place a stand under bracket (11).
Tap spring pins (12, 13) into bracket (11) until the
spring pins (12, 13) comes to the stepped end by
using special tool (ST 1237). The spring pins (2
used) are displaced with their slits in 90°.
Crimped Crimped
Here Here
11 35
Stand 12, 13
W176-02-07-011
18. Caulk the hole edge of bracket (11), where spring

pins (12, 13) are inserted, by using a punch (2
places). (Refer to the figure.)
19. Install bracket (11) on the opposite side to pin (35)

in the same procedures as steps 16 to 18.
20. Install cover (2) to holder (7) with bolts (1) (2

used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.7 Ibf⋅ft)
21. Apply grease to the spring pin (10) contact part of

damper (32) (2 places).
W2-7-47
(Blank)
W2-7-48
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

(Refer to BLEED AIR FROM HY- 1
Removal 2
1. Remove spring (3).
3
2. Remove hoses (6 to 13) and pipes (14, 15). 5
Attach an identification tag to the removed hoses
4
and pipes for reassembling.
: 19 mm
3. Remove spring pin (5) and remove lever (1). W178-02-08-001
4. Remove bolt (2) and remove pilot shut-off valve

(4). 2
: 17 mm
View A
6
10
7
8
9
WIHH-02-08-001
View A 14 13
WIHH-02-08-002
15 12 11
W2-8-1
Installation
1. Install pilot shut-off valve (4) with bolt (2).
2. Install lever (1) with spring pin (5).
3. Install hoses (6 to 13) and pipes (14, 15).

1
4. Install spring (3).
2
3
Wrench Tightening Torque 5
Remark
Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
: 17 49 (5) (36) Bolt 4
: 19 35 (3.6) (26) Pipe
: 19 29.5 (3) (21.5) Hose
W178-02-08-001
6- Hose DP: (To solenoid valve unit (hydraulic oil tank))
7- Hose PF: (To solenoid valve unit)
8- Hose: (To shockless valve)
2
9- Hose PD: (To pilot filter)
10 - Hose T6: (To right pilot valve)
11 - Hose P2: (To left pilot valve)
View A
12 - Hose T5: (To left pilot valve)
13 - Hose P3: (To right pilot valve)
14 - Hose P1: (To travel pilot valve)
15 - Hose T4: (To travel pilot valve)
6
10
7
8
9
WIHH-02-08-001
View A 14 13
WIHH-02-08-002
15 12 11
W2-8-2
(Blank)
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
3
6
2
7
1
8
9
13 10
11
12
W178-02-08-005
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-4
Disassemble Pilot Shut-Off Valve
1. Put the matching marks on body (4) and bracket

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

(3) from body (4).
3. Clamp spool (10) by using wooden pieces in a

vise. Remove socket bolt (13) and bracket (11).
Do not remove pin (12) unless necessary.
: 4 mm
4. Remove socket bolt (5) from body (4).

: 8 mm
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE
12 13 11 4 5 Z
Section Z－Z W178-02-08-006
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

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

socket bolt (5) to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
2. Clamp spool (10) by using wooden pieces in a

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

onto body (4).
4. Apply hydraulic oil to spool (10). Install spool (10)

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

to body (4). Install retaining ring (6) to spool (10).
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL SHOCKLESS
VALVE 14 15 16 17 18 19

13 20
Removal 12 21
1. Remove hoses (1 to 9, 13 to 20). 11

Attach identification tags to the removed hoses
for reassemblig.
: 19, 22 mm
1
2. Remove pressure sensors (11, 12, 21).
10
: 24 mm
3. Remove bolts (10) and remove the shockless 8B 7 8A 6 5 4 3 2

valve.
: 17 mm W173-02-09-001
Installation 1 - Hose (To right swing control valve)

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

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

4
10
Removal 1
1. Remove each harness of solenoid valves from 7
connectors.
8 9
2. Remove pilot lines (1 to 6, 11 to 18, 20 to 23, 25, A
6
and 27). 15 14
View A 13
: 17, 19, 27 mm 16
12
17 11
3. Remove bolts (7, 19) and remove the solenoid
valve unit.
: 6, 8 mm WIHH-02-10-001
20
23
21 18
19
22
25 24
26
27
WIHH-02-10-002
1 - Pipe PF: From pilot shut- 8 - Proportional solenoid valve 15 - Pipe PH: To pump control 22 - Hose PI: To control valve
off valve (SG) valve (5-spool section)
2 - Pipe SC: To arm regenera- 9 - Proportional solenoid valve 16 - Hose PG: To swing parking 23 - Hose TA: To hydraulic oil
tive valve (SI) brake release spool tank
3 - Pipe SG: To main relief 10 - Proportional solenoid valve 17 - Hose DG: From arm 24 - Torque control solenoid
valve (SC) anti-drift valve valve
4 - Hose SI: To travel motor 11 - Pipe DD: From arm regen- 18 - Hose ST: To main pump 1 25 - Hose DI: To hydraulic oil
erative valve tank
5 - Hose DS: To hydraulic oil 12 - Pipe PE: To pump control 19 - Socket bolt 26 - Maximum pump 2 flow rate
tank valve (4-spool section) limit solenoid valve
6 - Hose DP: From pilot shut- 13 - Pipe DE: From bucket flow 20 - Hose SB: To main pump 2 27 - Hose SP: To pump control
off valve rate control valve (valve B) valve (5-spool section)
7 - Socket bolt 14 - Pipe DH: From bucket flow 21 - Hose PD: To pilot shut-off
rate control valve valve
(switch valve A)
W2-10-1
2
Installation
1. Install the solenoid valve unit with bolts (7, 19).
2. Install pilot lines (1 to 6, 11 to 18, 20 to 23, 25

3
and 27).
4
3. Install all harnesses of solenoid valves to con-
nectors. 5
10
1
Remark 7
(mm) N⋅m (kgf⋅m) (Ibf⋅ft)
: 17 24.5 (2.5) (18) Pipe, Hose
8 9
: 19 29 (3) (22) Hose 6
A
: 27 93 (9.5) (43) Hose 15 14
View A 13
16
:6 20 (2) (16) Bolt 12
:8 20 (2) (16) Bolt 17 11
WIHH-02-10-001
20
23
21 18
19
22
25 24
26
27
WIHH-02-10-002
1 - Pipe PF: From 8- Proportional solenoid valve 15 - Pipe PH: To pump control 22 - Hose PI: To con-
pilot shut- off valve (SG) valve (5-spool section) trol valve
2 - Pipe SC: To arm regenera- 9- Proportional solenoid valve 16 - Hose PG: To swing parking 23 - Hose TA: To hydraulic oil
tive valve (SI) brake release spool tank
3 - Pipe SG: To main relief 10 - Proportional solenoid valve 17 - Hose DG: From arm 24 - Torque control solenoid
valve (SC) anti-drift valve valve
4 - Hose SI: To travel motor 11 - Pipe DD: From arm regen- 18 - Hose ST: To main pump 1 25 - Hose DI: To hydraulic oil
erative valve tank
5 - Hose DS: To hydraulic oil 12 - Pipe PE: To pump control 19 - Socket bolt 26 - Maximum pump 2 flow rate
tank valve (4-spool section) limit solenoid valve
6 - Hose DP: From pilot shut- 13 - Pipe DE: From bucket flow 20 - Hose SB: To main pump 2 27 - Hose SP: To pump control
off valve rate control valve (valve B) valve (5-spool section)
7 - Socket bolt 14 - Pipe DH: From bucket flow 21 - Hose PD: To pilot shut-off
rate control valve valve
(switch valve A)
W2-10-2
(Blank)
W2-10-3
DISASSEMBLE PROPORTIONAL
SOLENOID VALVES (SC, SI, and SG)
2
3
4
5
7
8
9
10
11
12
13 14
15
16
17
18
19
W178-04-05-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - O-Ring

2- Lock Nut 7- Spring 12 - Spool 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Orifice 18 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 19 - Wavespring
5- Spring 10 - Washer 15 - O-Ring
W2-10-4
Disassemble Proportional Solenoid Valves (So-
lenoid Valves SC, SI, and SG)
IMPORTANT: Do not disassemble lock nut (2) and

adjusting screw (4).
solenoid (6).
: 3 mm
IMPORTANT: Do not remove orifice (11) from

spool (10).
2. Remove spool (10). Remove diaphragm (9),
washer (10), and spring (11).
3. Remove sleeve (17). Remove O-rings (14,15, 16)

from sleeve (17). Remove plate (18) and
wavespring (19).
W2-10-5
ASSEMBLE PROPORTIONAL SOLENOID
VALVES (SC, SI, and SG)
4 2 6 1 8 17 14 15 12 16 13 19
3, 5 9 7 10 11 18
W157-02-11-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - O-Ring

2- Lock Nut 7- Spring 12 - Spool 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Orifice 18 - Plate
5- Spring 10 - Washer 15 - O-Ring
W2-10-6
Assemble Proportional Solenoid Valve
(Solenoid Valves SC, SI, and SG)
1. Apply grease to O-rings (14, 15, 16) and apply a 2. Install spring (11), washer (10), diaphragm (9) to
film of hydraulic oil to sleeve (17). Install washer spool (12) and install it into sleeve (17).
(10), plate (18) into the housing. Install O-rings Take care not to damage the edge portion in the
(14, 15) and (16) on sleeve (17), then insert it bore of sleeve (17) when inserting the spool (12)
into the housing. When inserting the sleeve, be to sleeve. After inserting spool (12) in, check that
sure to align the ports of the sleeve with the ports the spool (12) slides in and out smoothly without
in the housing. any restriction about 3 to 5 mm (0.12 to 0.20 in).
Install sleeve so that the end faces of sleeve and Apply hydraulic oil to the spool (12).
body come to the same point.
12
17 11
16 10
15 9
14
17
W178-02-10-002
Housing
W157-02-11-005
10
W157-02-11-010
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5) and O-ring (3) are not
separated, so no need to assemble
them.
3. Install solenoid (6) with socket bolts (1) (2 used).
When assembling solenoid (6), take care not to
drop spring (7).
: 3 mm
: 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft)
1
W157-02-11-011
W2-10-7
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVES
(TORQUE CONTROL SOLENOID VALVE,
MAXIMUM PUMP 2 FLOW RATE LIMIT
SOLENOID VALVE)
1
12
13
14
2
4
5
7
8
9
10
11
15
16
17
18 WIHH-02-10-003
19
1- Socket Bolt (2 Used) 6- Solenoid 11 - Spring 16 - Spool

2- Lock Nut 7- Spring 12 - O-Ring 17 - Orifice
3- O-Ring 8- O-Ring 13 - O-Ring 18 - Plate
5- Spring 10 - Retaining Ring 15 - Sleeve
W2-10-8
Disassemble Proportional Solenoid Valves
(Torque Control Solenoid Valve, Maximum Pump
2 Flow Rate Limit Solenoid Valve)
IMPORTANT: Do not lose spring (7) in solenoid hole

when removing solenoid. Do not dis-
assemble lock nut (2) and adjusting
screw (4).

solenoid (6).
: 3 mm
IMPORTANT: Do not remove orifice (17) from

spool (16).
2. Remove spool (16). Remove diaphragm (9), re-

taining ring (10), and spring (11).
3. Remove sleeve (15). Remove O-rings (12, 13,

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

2- Lock Nut 7- Spring 12 - O-Ring 17 - Orifice
3- O-Ring 8- O-Ring 13 - O-Ring 18 - Plate
5- Spring 10 - Retaining Ring 15 - Sleeve
W2-10-10
Assemble Proportional Solenoid Valve
(Torque Control Solenoid Valve Maximum Pump
2 Flow Rate Limit Solenoid Valve)
2. Install spring (11), retaining ring (10), diaphragm
1. Apply grease to O-rings (12, 13, 14) and apply a (9) to spool (16) and install it into sleeve (15).
film of hydraulic oil to sleeve (15). Install Take care not to damage the edge portion in the
wavespring (19), plate (18) into the housing. In- bore of sleeve (15) when inserting the spool (10)
stall O-rings (12, 13) and (14) on sleeve (15), to sleeve. After inserting spool (16) in, check that
then insert it into the housing. When inserting the the spool (16) slides in and out smoothly without
sleeve, be sure to align the ports of the sleeve any restriction about 3 to 5 mm (0.12 to 0.20 in).
with the ports in the housing. Apply hydraulic oil to the spool (16).
Install sleeve so that the end faces of sleeve and
body come to the same point. 16
11
17 10
16 9
15
14
15
W178-02-10-002
Housing
W157-02-11-005
10
W157-02-11-010
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5) and O-ring (3) are not
separated, so no need to assemble
them.
3. Install solenoid (6) with socket bolts (1) (2 used).
When assembling solenoid (6), take care not to
drop spring (7).
: 3 mm
: 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft)
1
W157-02-11-011
W2-10-11
DISASSEMBLE AND ASSEMBLE PILOT
RELIEF VALVE
1
2
3
4
5
6
7
WIHH-02-10-004
1 - Plug 3 - Spring 5 - Poppet 7 - Gasket

2 - Shim 4 - O-Ring 6 - Sleeve 8 - Housing
W2-10-12
Disassemble Pilot Relief Valve Assemble Pilot Relief Valve
NOTE: Do not lose shim (2) in plug (1) when re- 1. Insert gasket (7) into housing (8).
moving plug (1).
2. Insert poppet (5) into sleeve (6). Install spring (3)
1. Remove plug (1) from housing (8). and O-ring (4) into the relief valve. Insert the re-
: 22 mm lief valve assembly into housing (8).
NOTE: Sleeve (6) with poppet (5) attached is pro-
2. Remove spring (3) and O-ring (4) from the relief vided in the relief valve.
valve.
NOTE: Sleeve (6) with poppet (5) attached is pro- 3. Install shim (2) into plug (1). Install plug (1) into
vided in the relief valve. housing (8).
: 22 mm
3. Remove the assembly of poppet (5) and sleeve : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
(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 ZAXIS370MTH
Remove and Install Swing Bearing .......... W3-1-1 Remove and Install Travel Device ..........W3-2-68
Disassemble Swing Bearing .................... W3-1-4 Disassemble Travel Device ....................W3-2-72
Assemble Swing Bearing ......................... W3-1-6 Assemble Travel Device .........................W3-2-78
Disassemble Travel Motor ......................W3-2-86
Group 2 Travel Device Assemble Travel Motor...........................W3-2-90
ZAXIS330, 330LC, 350H, 350LCH Disassemble Brake Valve.......................W3-2-96
Up to Serial No.31357 Assemble Brake Valve ...........................W3-2-98
Remove and Install Travel Device............ W3-2-1 Maintenance Standard ........................W3-2-100
Disassemble Travel Device...................... W3-2-4
Assemble Travel Device ........................ W3-2-10 Group 3 Center Joint
Disassemble Travel Motor ..................... W3-2-18 Remove and Install Center Joint ..............W3-3-1
Assemble Travel Motor .......................... W3-2-22 Disassemble Center Joint ........................W3-3-4
Disassemble Brake Valve ...................... W3-2-30 Assemble Center Joint .............................W3-3-6
Assemble Brake Valve ........................... W3-2-32 Maintenance Standard .............................W3-3-9
Maintenance Standard ......................... W3-2-34
Group 4 Track Adjuster
ZAXIS330, 330LC, 350H, 350LCH ZAXIS330, 330LC, 350H, 350LCH
Serial No.31358 and up Remove and Install Track Adjuster ...........W3-4-1
Remove and Install Travel Device.......... W3-2-35 Disassemble Track Adjuster .....................W3-4-2
Disassemble Travel Device.................... W3-2-38 Assemble Track Adjuster........................W3-4-10
Assemble Travel Device ........................ W3-2-44
Disassemble Travel Motor ..................... W3-2-52 ZAXIS370MTH
Assemble Travel Motor .......................... W3-2-56 Remove and Install Track Adjuster .........W3-4-17
Disassemble Travel Brake Valve............ W3-2-62 Disassemble Track Adjuster ...................W3-4-18
Assemble Travel Brake Valve ................ W3-2-64 Assemble Track Adjuster........................W3-4-24
Maintenance Standard ......................... W3-2-66
1HHW-3-1
Group 5 Front Idler
Remove and Install Front Idler ................. W3-5-1
Disassemble Front Idler ........................... W3-5-2
Assemble Front Idler................................ W3-5-6
Maintenance Standard ........................... W3-5-10
Group 6 Upper and Lower Roller

Remove and Install Upper Roller ............. W3-6-1
Remove and Install Lower Roller ............. W3-6-4
Disassemble Lower Roller ....................... W3-6-8
Assemble Lower Roller .......................... W3-6-10
Maintenance Standard ........................... W3-6-12
Group 7 Track
Remove and Install Track ........................ W3-7-1
Maintenance Standard ............................. W3-7-7
1HHW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstruc-
ture must be removed first. For removal and installa-
tion 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 the matching marks on inner race (1) of
swing bearing and track frame (2).
Matching Mark
1 2
W105-03-01-001
2. Remove bolts (3) (36 used) from the inner race of

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

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

faces of track frame and swing bearing.
CAUTION: Swing bearing weight: 500 kg

(1100 Ib)
2. Hoist the swing bearing. Align the matching

marks on track frame and inner race of swing W110-03-01-004
bearing.
Machine Front “S” (Soft Zone)

Marking Position
Position for Plug
20°
15°
3. Tighten bolts (3) (36 used) to the inner race of Position for
swing bearing. Grease Fitting
: 41 mm 5°
: 1230 N⋅m (125 kgf⋅m, 900 lbf⋅ft)
W110-03-01-001
W158-03-01-001
W3-1-2
4. Add the grease bath with grease (Shell Alvania
EP2 or equivalent) until the pinion of swing bear- Swing Bearing Grease Level Pinion
ing is covered 5 mm in grease.
5 mm
W175-03-01-002
Grease Bath
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (95 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (95 Used)
3 - Pin
W3-1-4
Disassemble Swing Bearing
CAUTION: Swing bearing weight: 500 kg 3

(1100 lb)
1. Place the swing bearing onto the flat workbench.

A
2. Grind off the caulked part of pin (3).

Tap and remove pin (3) from the bottom side of
plug (4). 4
W1HH-03-01-006
3. Install the hand tap (M10, pitch 1.5 mm) into part
A in the hole on plug (4). Install the bolt (M10,
pitch 1.5 mm) into the hole on plug (4). Tap the 4
bolt from its back or pull out plug (4).
W1HH-03-01-001
2
1
CAUTION: Swing bearing outer race (1)
weight: 210 kg (465 lb)
C
4. Hoist outer race (1) of swing bearing horizontally.
Remove seals (2, 5).
6 5 W1HH-03-01-002
5. Rotate outer race (1). Remove balls (6) and sup-

ports (9) from the plug (4) hole.
When removing balls (6), use rod magnet (C).
Use wire (D) and remove support (9). D
9 W1HH-03-01-007
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (95 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (95 Used)
3 - Pin
W3-1-6
Assemble Swing Bearing
2
1. Clean (degrease) the grooves on outer race (1)
and inner race (7) for seals (2, 5). 1
7
Apply THREEBOND #1530D to the groove on
seals (2, 5) in outer race (1) and inner race (7).
Install seals (2, 5).
6
5
W1HH-03-01-003
CAUTION: Swing bearing outer race (1)

2. Hoist the outer race horizontally. Align the outer

race with the inner race coaxially.
Apply grease to balls (6) and supports (9). 9
While rotating the outer race, insert balls (6) and
support (9) into the plug (4) hole one by one by
using a round bar. W1HH-03-01-004
3. Install plug (4) into outer race (1) and install pin 3
(3).
Caulk the head of pin (3) by using a punch. 1
Add grease 0.9 L (Alvania EP2 grease or equiva-
lent) into the swing bearing through the grease
fitting.
W1HH-03-01-005
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
ZAXIS330, 330LC, 350H, 350LCH 4 5
(Up to serial No.31357)

Removal
The procedure starts on the premise that the track
link has already been removed.
3
Refer to page W3-7-1 for track removal.
2
1. Loosen bolts (7) to remove cover (6).
: 22 mm
IMPORTANT: Attach identification tags to aid in

assembling.
6
2. Disconnect hoses (2) to (5).
: 19 mm, 27 mm, 41 mm
NOTE: Install caps on all disconnected hose and 7 W157-03-02-006
line ends.
3. Attach the travel device to a crane with a wire

rope.
CAUTION: Travel device weight: 480 kg

(1060 lb)
4. Remove bolts (1). Remove the travel device by

crane.
: 30 mm
W3-2-1
Installation
1. Install the travel device with bolts (1). 4 5

: 30 mm
: 620 N⋅m (63 kgf⋅m, 460 lbf⋅ft)
2. Connect hoses (2) to (5).

: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) 1
: 27 mm
: 95 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
3
3. Install cover (6) with bolts (7). 2
: 22 mm
: 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
IMPORTANT: After completing travel motor instal-

lation, be sure to fill the travel motor 6
with hydraulic oil (1.3 L (0.34 US
gal.)). After completing installation of
the travel motor or the travel device, 7 W157-03-02-006
be sure to perform test driving to
prevent motor seizure. Test drive as
follows:
Perform break-in operation as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine for two minutes or more.
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL DEVICE 16
ZAXIS330, 330LC, 350H, 350LCH 15
17
13
12 38
14
37
6 11
7 40
3
4 10
5
3
9
23
8
2
1 18
22
19
21
8 20
19
35
31
24
25
26
27
28
27
26
30
41
43
39 42
29
34
33
36
32
31
W1HH-03-02-001
1- Third Stage Carrier 12 - Ring Gear 23 - Second Stage Carrier 34 - Bolt (20 Used)
2- Third Stage Sun Gear 13 - Bolt (28 Used) 24 - Spring Pin (3 Used) 35 - Bearing Nut
3- Thrust Plate (6 Used) 14 - Stopper Pin 25 - Pin (3 Used) 36 - Sprocket
4- Second Stage 15 - Cover 26 - Thrust Plate (6 Used) 37 - Retaining Ring
Planetary Gear (3 Used)
5 - Needle Bearing (3 Used) 16 - Bolt (16 Used) 27 - Needle Bearing (6 Used) 38 - Bearing
6 - Pin (3 Used) 17 - Plug (3 Used) 28 - Third Stage Planetary Gear 39 - O-Ring
(3 Used)
7- Spring Pin (3 Used) 18 - Spring Pin (3 Used) 29 - Motor 40 - Spacer
8- Spacer (2 Used) 19 - Thrust Plate (6 Used) 30 - Floating Seal 41 - Housing
9- Second Stage Sun Gear 20 - Needle Bearing (3 Used) 31 - Roller Bearing (2 Used) 42 - Lock Plate
10 - First Stage Carrier 21 - First Stage Planetary Gear 32 - Drum 43 - Bolt (2 Used)
(3 Used)
11 - Propeller Shaft 22 - Pin (3 Used) 33 - Washer (20 Used)
W3-2-4
Disassemble Travel Device
CAUTION: Pressure may remain in the travel

device. Slowly loosen the air bleed plug to
completely release the residual pressure.
Then, remove the drain plug to drain gear oil
into a container. If the air bleed plug is loos-
ened quickly, the plug may fly off and/or gear
oil may gush out. Position your face and
body away from the plug.
(1060 lb)
1. Turn over the travel device.

Place the travel device securely on a work bench
so that the brake valve does not come into con-
tact 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
12
W107-03-02-008
NOTE: THRREEBOND is applied between cover

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

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

carrier (23) assembly and third stage sun gear (2)
W3-2-5
16
13
12
35
31
30
41
43
42
36
32
31
W1HH-03-02-001
W3-2-6
CAUTION: Ring gear (12) weight: 55 kg 10. Remove the inner race of roller bearing (31) from
(121 lb) drum (31).
NOTE: Do not attempt to remove the inner race of
5. Remove bolts (13) (28 used). Attach eyebolt (M12,
roller bearing (31) which remained in
Pitch 1.75 mm) to bolt (16) hole of ring gear (12).
housing (41) side unless it is to be re-
Remove ring gear (12) from drum (32).
placed.
: 24 mm
11. Remove floating seal (30) from drum (32) and

NOTE: THREEBOND is applied between ring gear
housing (41).
(12) and drum (32). Use the screw driver
for easy removal.
CAUTION: Third stage carrier (1) assembly

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
ST 3051
W157-03-02-005
CAUTION: Drum (32) + sprocket (36) weight:

135 kg (300 lb)
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 mm) to drum (32).

Remove drum (32) from housing (41) by crane.
W3-2-7
6
7 40
3
4 10
5
3
23
8
1 18
22
19
21
20
19
24 31
25
26
27
28
27
26
34
36
32
W1HH-03-02-001
W3-2-8
12. Apply a metal bar to the outer race of roller bear-
ing (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 fol-

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

O-ring, use a bamboo (wooden) spatula to
guide it along the periphery.
IMPORTANT: Be sure to tap only the outer race.

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

pletely by listening to the sound.

(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 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
W3-2-11
8 1
41
32 36 35 42 43 26 28 27 26 24 W164-03-02-002
W3-2-12
IMPORTANT: Face bearing nut (35) stepped to the 12. Apply LOCTITE #262 to the thread of bolts (43) (2
bearing. Apply grease to the used). Install lock plate (42) to bearing nut (35)
threaded part of bearing nut (35). with bolts (43) (2 used)
7. Install bearing nut (35) to housing (41) and tighten : 19 mm
manually. : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
NOTE: Apply grease to the threaded part of bear- 43

ing nut (35) to tighten the torque to correct 42
specification. 35
8. Hold the travel device securely. Attach the special

tools to bearing nut (35). Then, tighten with a
torque wrench.
W140-03-02-001
Bolt: M16 (60 to 90 mm in length)
×2 pieces
13. Install two needle bearings (27) (2 used) into each
: 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)
third stage planetary gears (28) (3 used).
IMPORTANT: One side of third stage planetary

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

on drum (32) with a plastic hammer to secure
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 N⋅m (80 kgf⋅m, 580 lbf⋅ft)
W3-2-13
12 13 1 2 8 23 9
15
16
41
32 28 25 24 6 4 5 3 7 W164-03-02-002
W3-2-14
15. Insert pins (25) (3 used) into third stage carrier (1)
CAUTION: Ring gear (12) weight: 55 kg
to secure third stage planetary gears (28) (3 used).
At this time align third stage carrier (1) with the (121 lb)
spring pin (24) hole on pin (25).
16. Drive spring pins (24) (3 used) into the spring pin (16) hole on ring gear (12). Hoist ring gear (12).
hole on third stage carrier (1) and pin (25). Be Install ring gear (12) onto drum (32). Apply LOC-
sure that the slit part of spring pin (24) faces to the TITE #262 to bolts (13) (28 used). Tighten bolts
end of pin (25). (13).
: 24 mm
25 24 : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
Slit 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)
W178-02-06-002 following step 13 to 16 above.
CAUTION: Third stage carrier assembly
weight: 52 kg (115 lb) 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
18. Install third stage sun gear (2) into third stage end faces to cover (15).
carrier (1). Be sure that the lower tooth end faces
to cover (15).
Cover (15) Cover (15) 9
2
W166-03-02-001 W166-03-02-002
19. Clean (degrease) ring gear (12) mounting surface

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

gear (12), aligning splines between first stage
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 N⋅m (11.5 kgf⋅m, 83 lbf⋅ft)
29. Wrap seal tape around plugs (17) (3 used). Install

plugs (17) into cover (15).
: 10 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-2-17
DISASSEMBLE TRAVEL MOTOR
ZAXIS330, 330LC, 350H, 350LCH
(Up to serial No.31357) 14
12 13
11
10
9
8
7
Brake Releasing
6 Oil Passage
5
3
4
2 16 15
1
25
26
27
20 18
19
21
17
22
23
28
24
32 29
30
31
40 39 38
37 36
33
34
35 W164-03-02-003
1- O-Ring 11 - Bearing 21 - Link 31 - Knock Pin (2 Used)

2- Disc Spring 12 - Housing 22 - Reamer Bolt 32 - Socket Bolt (4 Used)
3- D-Ring 13 - Oil Seal 23 - Plug (2 Used) 33 - Brake Valve
4- Piston 14 - Retaining Ring 24 - O-Ring (2 Used) 34 - O-Ring
5- D-Ring 15 - O-Ring 25 - Pin 35 - Plug
6- Plate (5 Used) 16 - Bearing Nut 26 - Center Shaft 36 - Servo Piston
7- Spacer 17 - Plunger (7 Used) 27 - Center Spring 37 - Piston Ring (2 Used)
8- Drive Disc 18 - Rotor 28 - Bushing 38 - O-Ring
9- Bearing 19 - Plug (2 Used) 29 - Valve Plate 39 - Cover
10 - Spacer 20 - Friction Plate (4 Used) 30 - Plate 40 - Socket Bolt (4 Used)
W3-2-18
Disassemble Travel Motor
CAUTION: Travel motor weight: 87 kg 4. Remove valve plate (29) from brake valve (33). At
(190 lb) this time, the valve plate is still with link (21)
Brake valve weight: 43 kg (90 lb) attached.
IMPORTANT: Valve plate (29) is easily cracked and NOTE: The valve plate (29) is with bushing (28)
scratched, so handle it with care. attached, but do not remove the bushing
1. Place the travel motor longitudinally. Remove unless necessary.
socket bolts (32) (4 used) to remove brake valve
(33) from housing (12). At this time, the brake 5. Remove plate (30) from brake valve (33).
valve side is still with valve plate (29) attached.
: 14 mm 6. Remove servo piston (36) from brake valve (33).
At this time, the servo piston is still with piston
2. Remove socket bolts (40) (4 used) from brake rings (37) (2 used) attached.
valve (33) to remove cover (39) and O-ring (38).
7. Remove O-Rings (1), (15) from housing (12).
3. Turn brake valve (33) over to remove plug (23)
and O-ring (24), then insert a hexagon wrench 8. Remove disc spring (2) from housing (12).
into the plug (23) hole to remove reamer bolt (22).
: 8 mm, 10 mm
CAUTION: When removing piston (4) from
the housing filled with air, cover the housing
33
with cloth to prevent the brake piston from
22
flying out.
9. Apply 100 to 300 kPa (1 to 3 kgf/cm2, 14 to 43 psi)

23
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
IMPORTANT: Plug (19) has been bound with LOC- sure to place it with the air seat facing up.
TITE. If removing it by force, its
hexagon hole may be damaged. Do Air Seat
not remove plug (19) unless neces-
sary.
4
W178-03-02-009
19 NOTE: Piston (4) is with D-rings (3), (5) attached, do

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

center, the more tilting, the easier remov-
ing.
ST 5904
8
12. Remove spacer (7) from housing (12).
CAUTION: Housing + drive disc (8) + others

W107-03-02-119
CAUTION: Drive disc (8) assembly weight:

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

(158 °F to 194 °F) in a oil bath or drier, and press
the inner race of bearing into drive disc (8) with
special tool (ST 2308) and a press. Tap the inner
race lightly and listen to ring to confirm they are W107-03-02-119
fitting tightly.
CAUTION: Housing (12) weight: 46 kg

IMPORTANT: Apply grease onto bearing nut (16).
(100 lb)
6. Apply grease to the screw part and the side
surface of bearing nut (16). Install bearing nut (16)
8. Place housing (12) with its brake valve mounting
onto drive disc (8), then tighten it by hand.
side facing down.
NOTE: Apply grease to tighten it to the specified IMPORTANT: Apply OCEAN grease #7 to the inner
torque. surface of oil seal (13), and apply
THREEBOND #104 or 1215 to the
outer surface of the oil seal.
9. Tap oil seal (13) evenly and lightly with a plastic
hammer to insert oil seal (13) into housing (12).
The replaced oil seal can be used as a mat then.
10. Install retaining ring (14).
W3-2-23
27 18 2 12 4 18 6 7 8
13
25
Oil Slit (4 Places)
17 3 5 Slit (4 Places) 20 26
W178-03-02-019
W3-2-24
CAUTION: Housing (12) weight: 46 kg 15. Install plungers (17) (7 used) into the spherical
(100 lb) handle hole in drive disc (8) one by one. Be sure
to confirm plungers (17) (7 used) move smoothly.
11. Turn housing (12) over and place it with its oil seal 17 8
(13) side facing down. Tap drive disc (8) assembly
lightly with a plastic hammer and brass bar to in-
stall it into housing (12).
IMPORTANT: Be sure to align the oil slot (slit part) Spherical

in spacer (7) with that in housing Handle Hole
(12).
12. Install spacer (7) into housing (12) with its oil slot
(slit part) facing the travel reduction gear side.
W107-03-02-146
IMPORTANT: Align 5 teeth of plate (6) with the

16. Apply grease to the center shaft (26) spherical
inner grooves in housing (12).
part. Install center shaft (26) into drive disc (8).
In addition, the 4 teeth on friction
Then install center spring (27) onto c enter shaft
plate (20) should be placed at same
(26).
position when installation is carried
out.
17. Apply grease to pin (25) to prevent it from coming
13. Install plates (6) (5 used) and friction plates (20)
off. Then install it into center shaft (26).
(4 used) into housing (12) alternately. Be sure to
align the teethless part (no teeth part ) of plate (6)
18. Put center shaft (26) to rotor (18) shallowly. Ro-
(4 places) with the inner slots inside of housing
tate center shaft (26) so as to align pin (25) just
(12) and install them together.
beneath the slot in rotor (18).
Moreover, the teethless part of friction plate (20)
should be put at same position to form a straight 18
line when installation is carried out.
Groove
NOTE: In case the teethless part or slot position
25
fail to align with each other, heating may be 26
resulted to motor failure.
Groove (4 Places) 12
W178-03-02-015
19. Insert plungers (17) (7 used) into rotor (18).
W178-03-02-018
14. Install D-rings (3, 5) into piston (4), then tap to

install them into housing (12) with a plastic ham-
mer.
W3-2-25
28 29 15 12 2 18
30
31
33
25
36
37
19
23 17 1 26
21
W178-03-02-016
W3-2-26
20. Press plunger (17) slowly and install pin (25) into IMPORTANT: Pay attention to the direction of link
the rotor (18) groove. (21) assembly.
NOTE: If pin (25) can’t be installed into the groove, 29. Install link (21) assembly into brake valve (33)
insert the end of round rotor into the top while aligning the groove in valve plate (29) with
hole of center shaft (26), rotate the center the groove in plate (30). At this time, the sticking
shaft. When doing this work, be sure to part of link (21) should face the brake valve side.
remove the dirt and metallic debris from the
21 29
former rotor first. Rotor (18) Side
21. Install O-rings (1, 15) into housing (12).

Plate (30) Side
IMPORTANT: Install disc spring (2) into housing
(12) with the outer surface side of
W178-03-02-017
the disc spring facing the brake
valve (33) mounting surface.
22. Install disc spring (2) into housing (12). 30. Insert special tool (ST 7131) into the mounting
hole of plug (23), then align the hole of link (21)
23. Fill hydraulic oil into housing (12). with that of servo piston (36).
Hydraulic oil: 1.3 L (0.34 US gal)
ST 7131
24. Install plate (30) onto brake valve (33). 36 21
25. Install piston rings (37) (2 used) onto servo piston

(36).
26. Insert servo piston (36) into brake valve (33).
IMPORTANT: Assemble bushing (28) with the

chamfered side facing inside.
27. Install bushing (28) onto valve plate (29) with a
plastic hammer.
W107-03-02-174
28. Apply LOCTITE #262 on plugs (19) (2 used), then 22
install link (21) onto valve plate (29) with plugs
(19) (2 used).
: 6 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
W3-2-27
33 12
36
38
39
40 23, 24 32
21
W178-03-02-016
22
W3-2-28
31. Apply additive grease, Johnson wax JP103, to the
CAUTION: Brake valve (33) weight: 43 kg
end of reamer bolt (22) in order to prevent it from
seizing. (90 lb)
Install reamer bolt (22) to link (21) and servo pis-
ton (36) through the opposite mounting hole of 36. Hoist and install brake valve (33) onto housing
plug (23). (12), while aligning the hole in removed plug (A)
: 8 mm with special tool (ST 7085).
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
37. Remove special tool (ST 7085) from brake valve
(33).
32. Install O-ring (24) onto plug (23), then install it to
brake valve (33). 38. Install spool (B), spring (C) and plug (A) into brake
: 10 mm valve (33).
: 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft) : 8 mm
: 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft)
33. Install O-ring (38) onto cover (39) and install it to
brake valve (33) with socket bolts (40) (4 used). 39. Install brake valve (33) onto housing (12) with
: 10 mm socket bolts (32) (4 used).
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) : 14 mm
: 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
34. Install special tool (ST 7085) into the end of cen-
ter shaft (26).
ST 7085
26
12
W107-03-02-183
35. Remove plug (A) from brake valve (33) to remove

spool (B) and spring (C).
: 8 mm
W3-2-29
DISASSEMBLE BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
Counter Balance Valve
9 Shuttle Valve for Parking Brake

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

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

2- Overload Relief Valve (2 Used) 7- Poppet (2 Used) 12 - Spool 17 - Plug
3- Casing 8- Plug (2 Used) 13 - Ball (2 Used) 18 - O-Ring
4- Plug (2 Used) 9- O-Ring (2 Used) 14 - Seat (2 Used) 19 - Spool
5- O-Ring (2 Used) 10 - Spring (2 Used) 15 - O-Ring (2 Used) 20 - Spring
W3-2-30
Disassemble Brake Valve
CAUTION: Brake valve weight: 43 kg (90 lb) • Shuttle valve for servo piston and for parking brake
• Counter Balance Valve IMPORTANT: LOCTITE was applied on seat (14).

1. Remove plugs (8) (2 used) from casing (3). Do not remove the seat unless nec-
: 41 mm essary.
6. Remove plugs (16) (2 used) from casing (3) to
2. Remove springs (10) (2 used), stoppers (11) (2 remove balls (13) (2 used) and seats (14) (2
used) from casing (3). used).
: 5 mm, 6 mm
3. Remove spool (12) from casing (3).
• Reducing Valve
7. Remove plug (17) from casing (3) to remove
IMPORTANT: Be sure to loosen and remove over- spool (19) and spring (20).
load relief (2). Do not turn the lock : 8 mm
nut for adjusting screw on overload
relief valve, or its setting pressure
may change.
4. Remove overload relief valves (2) (2 used) from
casing (3).
: 27 mm
Lock Nut
Adjusting Screw
W140-03-02-005
• Check Valve
5. Remove plug (4) from casing (3) to remove

springs (6) (2 used) and poppets (7) (2 used).
: 12 mm
W3-2-31
ASSEMBLE BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
13
14
15
13
14
16
15
Section B 16 Section C
A
2 1 7 6
19 20
17 18
3
4
5
9 B
Section A-A W164-03-02-005
A
12 11 10
1 - O-Ring (2 Used) 6 - Spring (2 Used) 11 - Stopper (2 Used) 16 - Plug (2 Used)

2 - Overload Relief Valve (2 7 - Poppet (2 Used) 12 - Spool 17 - Plug
Used)
3 - Casing 8 - Plug (2 Used) 13 - Ball (2 Used) 18 - O-Ring
4 - Plug (2 Used) 9 - O-Ring (2 Used) 14 - Seat (2 Used) 19 - Spool
5 - O-Ring (2 Used) 10 - Spring (2 Used) 15 - O-Ring (2 Used) 20 - Spring
W3-2-32
• Reducing Valve • Overload Relief Valve

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

metal bar into the plug hole to
poppet (7), then tap the other end of
the bar to obtain tight fitting between
poppet (7) and casing (3).
3. Install springs (6) (2 used) into poppets (7) (2
used) and insert the poppets into casing (3). In-
stall O-rings (5) (2 used) onto plugs (4) (2 used)
and install the plugs into casing (3).
: 12 mm
: 235 N⋅m (24 kgf⋅m, 174 Ibf⋅ft)
W3-2-33
Sprocket
B
C
D
A E
W1HH-03-02-002
Unit: mm (in)
A 87 (3.4) [77 (3.0)]
B 89.15 (3.5) 84.15 (3.3) Cladding by
C 125.75 (5) - welding and
D 133.55 (5.3) 128.55 (5.1) finishing
E 216.0 (8.5) -
NOTE: Values in [ ] is just for reference.
W3-2-34
ZAXIS330, 330LC, 350H, 350LCH 4 5
(Serial No.31358 and up)

Removal
The procedure starts on the premise that the track
link has already been removed.
3
Refer to page W3-7-1 for track removal.
2
1. Loosen bolts (7) to remove cover (6).
: 22 mm
IMPORTANT: Attach identification tags to aid in

assembling.
6
2. Disconnect hoses (2) to (5).
: 19 mm, 27 mm, 50 mm
7 W157-03-02-006
NOTE: Install caps on all disconnected hose and
line ends.
3. Attach the travel device to a crane with a wire

rope.

(1020 lb)
4. Remove bolts (1). Remove the travel device by
crane.
: 30 mm
W3-2-35
Installation
4 5
1. Install the travel device with bolts (1).
: 30 mm
: 620 N⋅m (63 kgf⋅m, 460 lbf⋅ft)
2. Connect hoses (2) to (5).

: 19 mm 1
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
: 27 mm
: 95 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 50 mm
3
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
2
3. Install cover (6) with bolts (7).
: 22 mm
: 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
IMPORTANT: After completing travel motor in- 6

stallation, be sure to fill the travel
motor with hydraulic oil (1.3 L (0.34
US gal.)). After completing installa- 7 W157-03-02-006
tion of the travel motor or the travel
device, be sure to perform test driv-
ing to prevent motor seizure. Test
drive as follows:
slow idle position.
speed position.
3. Test drive the machine for two minutes or more.
W3-2-36
(Blank)
W3-2-37
DISASSEMBLE TRAVEL DEVICE
ZAXIS330, 330LC, 350H, 350LCH
(Serial No. 31358 and up)
17
13
12 38
14
37
6 11
7 40
3
4 10
5
3
9
23
8
2
1 18
22
19
21
8 20
19
35
31
24
25
26
27
28
27
26
30
29 43
42
34
33
36
32
31
W1HH-03-02-004
6 - Pin (3 Used) 17 - Plug (3 Used) 28 - Third Stage Planetary Gear 39 - Spacer
(3 Used)
7- Spring Pin (3 Used) 18 - Spring Pin (3 Used) 29 - Motor 42 - Lock Plate
8- Spacer (2 Used) 19 - Thrust Plate (6 Used) 30 - Floating Seal 43 - Bolt (2 Used)
9- Second Stage Sun Gear 20 - Needle Bearing (3 Used) 31 - Roller Bearing (2 Used)
10 - First Stage Carrier 21 - First Stage Planetary Gear 32 - Drum
(3 Used)
W3-2-38
CAUTION: Pressure may remain in the travel

completely release the residual pressure.
Then, remove the drain plug to drain gear oil
into a container. If the air bleed plug is loos-
ened quickly, the plug may fly off and/or gear
oil may gush out. Position your face and
body away from the plug.
(1020 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 con-
tact with the work bench, with the motor side
downward.
2. Remove bolts (16) to remove cover (15) from ring

gear (12).
: 19 mm 15
NOTE: THRREEBOND is applied between cover 16

(15) and ring gear (12). For easy separa-
tion of cover (15), apply a chisel between 12
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).
W107-03-02-008
4. Remove second stage sun gear (9), second stage

carrier (23) assembly and third stage sun gear (2)
W3-2-39
13
12
35
31
30
43
29
42
36
32
31
W1HH-03-02-004
W3-2-40
CAUTION: Ring gear (12) weight: 55 kg CAUTION: Drum (32) + sprocket (36) weight:
(121 lb) 135 kg (300 lb)
5. Remove bolts (13) (28 used). Attach eyebolt (M12, IMPORTANT: The motor (29) matching surface of
Pitch 1.75 mm) to bolt (16) hole of ring gear (12). drum (32) is the sliding surface.
Remove ring gear (12) from drum (32) by crane. Place the drum assembly onto a
: 24 mm wooden block not to damage it.
NOTE: THREEBOND is applied between ring gear 9. Attach eyebolt (M16, Pitch 2.0 mm) to drum (32).
(12) and drum (32). Use the screw driver Remove drum (32) from housing (41) by crane.
for easy removal.
drum (32).
CAUTION: Third stage carrier (1) assembly
NOTE: Do not attempt to remove the inner race of
6. Remove third stage carrier (1) assembly. roller bearing (31) which remained in
housing (41) side unless it is to be re-
7. Remove bolt (43) and lock plate (42) from bearing placed.
nut (35).
: 19 mm 11. Remove floating seal (30) from drum (32) and
motor (29).
8. Hold the travel device securely. Remove bearing
nut (35) using special tools.
Bolt: M16 (60 to 90 mm in length):2 pieces
ST 3052
ST 3050
35
ST 3051
W157-03-02-005
W3-2-41
6
7 40
3
4 10
5
3
23
8
1 18
22
19
21
20
19
31
24
25
26
27
28
27
26
34
36
32
W1HH-03-02-004
W3-2-42
12. Apply a metal bar to the outer race of roller bear-
ing (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 fol-

lowing 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 bear-
ings (27) (6 used).

(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
NOTE: LOCTITE is applied to bolt (34).
W3-2-43
ZAXIS330, 330LC, 350H, 350LCH
33, 34
29 32 12 13 8 1 2 8 23 9 10
17
40
11
15
14
38
37
19
18
20
22
21
16
30 31 36 35 42 43 28 27 25 26 24 3 6 4 5 3 7
W1HH-03-02-003
6 - Pin (3 Used) 17 - Plug (3 Used) 28 - Third Stage Planetary Gear 40 - Spacer
(3 Used)
7- Spring Pin (3 Used) 18 - Spring Pin (3 Used) 29 - Motor 42 - Lock Plate
8- Spacer (2 Used) 19 - Thrust Plate (6 Used) 30 - Floating Seal 43 - Bolt (2 Used)
9- Second Stage Sun Gear 20 - Needle Bearing (3 Used) 31 - Roller Bearing (2 Used)
10 - First Stage Carrier 21 - First Stage Planetary Gear 32 - Drum
(3 Used)
W3-2-44
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 motor (29). 135 kg (300 lb)
Wait for the bearing to cool. Then, drive it in posi-
tion completely with a metal bar and hammer. 5. Attach eyebolt (M16, Pitch 2.0 mm) to the bolt
(13) hole of drum (32), then hoist and install drum
(32) onto motor (29). At this time check if the
NOTE: Check if the inner race is driven in com- clearance between the motor and drum is equal.
6. Warm the inner race of roller bearing (31) 50 to 70
2. Apply grease to the O-ring outer surface of float- °C (122 to 158 °F) with a heater. Install it between
ing seal (30). Install one half of floating seal (30) drum (32) and motor (29).
on motor (29).
NOTE: For easier insertion of floating seal (30)

O-ring, use a bamboo (wooden) spatula to
guide it along the periphery.
IMPORTANT: Be sure to tap only the outer race.

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


(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 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
W3-2-45
29 8 1
32 36 35 42 43 26 28 27 25 26 24
W1HH-03-02-003
W3-2-46
IMPORTANT: Face bearing nut (35) stepped to the 12. Apply LOCTITE #262 to the thread of bolts (43) (2
bearing. Apply grease to the used). Install lock plate (42) to bearing nut (35)
threaded part of bearing nut (35). with bolts (43) (2 used)
7. Install bearing nut (35) to motor (29) and tighten : 19 mm
manually. : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
NOTE: Apply grease to the threaded part of bear- 43

ing nut (35) to tighten the torque to correct 42
specification. 35
8. Hold the travel device securely. Attach the special

tools to bearing nut (35). Then, tighten with a
torque wrench.
W140-03-02-001
Bolt: M16 (60 to 90 mm in length)
×2 pieces
13. Install two needle bearings (27) (2 used) into each
: 790 N⋅m (80 kgf⋅m, 580 lbf⋅ft)
third stage planetary gears (28) (3 used).
IMPORTANT: One side of third stage planetary

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

on drum (32) with a plastic hammer to secure
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 N⋅m (80 kgf⋅m, 580 lbf⋅ft)
W3-2-47
29 12 13 1 2 8 23 9
15
16
32 28 25 24 6 4 5 3 7
W1HH-03-02-003
W3-2-48
15. Insert pins (25) (3 used) into third stage carrier (1)
CAUTION: Ring gear (12) weight: 55 kg
to secure third stage planetary gears (28) (3 used).
At this time align third stage carrier (1) with the (121 lb)
spring pin (24) hole on pin (25).
16. Drive spring pins (24) (3 used) into the spring pin (16) hole on ring gear (12). Hoist ring gear (12) by
hole on third stage carrier (1) and pin (25). Be crane.
sure that the slit part of spring pin (24) faces to the Install ring gear (12) onto drum (32). Apply LOC-
end of pin (25). TITE #262 to bolts (13) (28 used). Tighten bolts
(13).
25 24 : 24 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
Slit
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
W178-02-06-002 pins (7) (3 used) into second stage carrier (23)
CAUTION: Third stage carrier assembly following step 13 to 16 above.
22. Install second stage carrier (23) assembly into
17. Install third stage carrier (1) assembly, aligning ring gear (12).
splines with motor (29).
23. Install second stage sun gear (9) into second
18. Install third stage sun gear (2) into third stage stage carrier (23). Be sure that the lower tooth
carrier (1). Be sure that the lower tooth end faces end faces to cover (15).
to cover (15).
Cover (15)
2 Cover (15) 9
W166-03-02-001
W166-03-02-002
19. Clean (degrease) ring gear (12) mounting surface

of drum (32). Apply THREEBOND #1389B to the
mounting surface.
W3-2-49
29 12 9 10
17
40
11
15
19
18
20
22
21
16
W1HH-03-02-003
W3-2-50
IMPORTANT: Face the lower tooth height side of
first stage planetary gear (21) to
spacer (40) side.
24. Install spacer (40), first stage planetary gears (21)
(3 used), needle bearings (20) (3 used), thrust
plates (19) (6 used), pins (22) (3 used), spring
pins (18) (3 used) into first stage carrier (10) fol-
lowing step 13 to 16.
25. Install first stage carrier (10) assembly into ring

gear (12), aligning splines between first stage
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 N⋅m (11.5 kgf⋅m, 83 lbf⋅ft)
29. Wrap seal tape around plugs (17) (3 used). Install

plugs (17) into cover (15).
: 10 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-2-51
ZAXIS330, 330LC, 350H, 350LCH
6
Brake Releasing
Oil Passage
5
4
3
Piston Pushing
2 Oil Passage
5 16
28
7 15
8
14
13 17
18
12 19
11 20
10
9
21
22
23
24
25
26
27 W1HH-03-02-005
1- Shaft 8- Roller Bearing 15 - Bushing 22 - Socket Bolt (8 Used)

2- Retaining Ring 9- Disc Spring 16 - Swash Plate 23 - O-Ring
3- Retaining Ring 10 - Brake Piston 17 - Ball (2 Used) 24 - Valve Plate
4- Oil Seal 11 - O-Ring 18 - Plunger (9 Used) 25 - Knock Pin
5- O-Ring (2 Used) 12 - O-Ring 19 - Retainer 26 - Needle Bearing
6- Housing 13 - Plate (4 Used) 20 - Spring (6 Used) 27 - Brake Valve
7- Piston 14 - Rotor 21 - Friction Plate (4 Used) 28 - Spring
W3-2-52
Disassemble Travel Motor
CAUTION: Travel motor weight: 135 kg 6. Remove rotor (14), springs (20) (9 used), bushing
(300 lb) (15), retainer (19) and plungers (18) (9 used) from
housing (6).
IMPORTANT: When removing brake valve (27)
7. Remove plates (13) (4 used) and friction plates
assembly from the motor, valve
(21) (4 used) from housing (6).
plate (24) is also removed with the
brake valve side.
Don’t drop the valve plate as it easily CAUTION: Housing weight: 87 kg (200 lb)
comes off.
1. Place the travel motor longitudinally. After re- 8. Place housing (6) with the brake releasing oil
moving socket bolt (22), remove brake valve (27) passage facing downward and horizontal.
from housing (6).
: 17 mm
NOTE: When the brake releasing oil passage is
IIMPORTANT: The valve plate easily becomes positioned upward, the thick portion of
cracked and scratched, so handle it swash plate (16) faces upward. When
with care. housing (6) is placed horizontally, the
2. Remove valve plate (24) and knock pins (25) from swash plate may come off suddenly.
brake valve (27). Do not remove needle bearing
(26) unless necessary. 9. Remove swash plate (16) from housing (6).
10. With a magnet, remove balls (17) (2 used), piston

NOTE: Even if small removing tool is used for re- (7) and spring (28) from housing (6).
moving the needle bearing, the outer race
may be deformed. 11. Remove retaining ring (2) from housing (6).
Do not reuse the needle bearing.
12. Tap the bottom in the spline bore of shaft (1) using
3. Wrap tape on the needle bearing (26) rotation a bar and plastic hammer to push the shaft out
surface of shaft (1) for protection. with roller bearing (8) from housing (6).
4. Remove disc spring (9) from housing (6).
CAUTION: When removing the brake piston

from the housing filled with air, cover the
housing with cloth to prevent the brake pis-
ton from flying off.
5. Apply pressure air 100 to 300 kPa (1 to 3 kgf/cm2,

14 to 43 psi) to the brake releasing oil passage of
housing (6), so that the brake piston will float up
to be removed.
NOTE: It is possible to using bicycle pump. Do not

pry with a screwdriver, or components will
be damaged.
W3-2-53
4
3
W1HH-03-02-005
W3-2-54
13. Insert a slotted head screwdriver into the shaft (1)
hole of housing (6) and push out oil seal (4).
NOTE: Since the oil seal has been covered with

adhesive, it cannot be used again.
14. Remove retaining ring (3) from shaft (1).
CAUTION: When the shaft is removed from

the roller bearing, be sure to avoid dropping
it.
15. Balance the inner race of roller bearing (8) re-

mained on shaft (1) on a vice. With a bar and
plastic hammer, tap the shaft slightly, to remove
the roller bearing.
Bar
W172-03-02-003
W3-2-55
ZAXIS330, 330LC, 350H, 350LCH
Brake Releasing Oil Passage
27 25 5 23 11 12 10 14 18 16 17 2 8
26 22 24 5 9 13 21 20 15 19 7 28 6
Piston Pushing Oil Passage W1HH-03-02-006
1- Shaft 8- Roller Bearing 15 - Bushing 22 - Socket Bolt (8 Used)

2- Retaining Ring 9- Disc Spring 16 - Swash Plate 23 - O-Ring
3- Retaining Ring 10 - Brake Piston 17 - Ball (2 Used) 24 - Valve Plate
4- Oil Seal 11 - O-Ring 18 - Plunger (9 Used) 25 - Knock Pin
5- O-Ring (2 Used) 12 - O-Ring 19 - Retainer 26 - Needle Bearing
6- Housing 13 - Plate (4 Used) 20 - Spring (6 Used) 27 - Brake Valve
7- Piston 14 - Rotor 21 - Friction Plate (4 Used) 28 - Spring
W3-2-56
Assemble Travel Motor
CAUTION: Housing weight: 87 kg (200 lb) IMPORTANT: Pay attention to assembly direction.
4. Insert the inner ring plate side of roller bearing (8)
1. Place housing (6) with the brake valve (27) mat- into the inner bore spline end of shaft (1) first.
ing surface facing upward. Then push the shaft until the bearing comes into
the tight fitting part. Be sure not to damage the
IMPORTANT: Apply OCEAN grease #7 to the inner seal lip surface of the shaft.
circumference of the oil seal, and
apply THREEBOND #1104 or #1215 5. Insert the inner bore spline end of the shaft into
to the outer circumference of the oil bearing assemble tool (ST 7268). Tap the other
seal. end of the shaft with a plastic hammer to install
2. Neatly clean oil seal (4) fitting part of housing (6). roller bearing (8) onto the shaft.
Using tool (ST 7270, ST 7271), install the oil seal
into the housing. 1
ST 7270
Inner Bore Spline
Inner Ring Plate
4
6 ST 7268 12
W176-03-02-007
ST 7271
W176-03-02-008
IMPORTANT: Pay attention to the direction when

assembling. 6. Install retaining ring (3) on shaft (1), while taking
3. Assemble roller bearing (8) so that all marked care to avoid damaging the oil seal (4) slide sur-
surfaces are on the outer race, inner race, inner face.
ring plate facing outward.
7. Apply grease to the ball (17) surface sufficiently
Inner Race Marked Sur- and assemble balls (2 used) to housing (6).
Outer Race Marked
face
Surface
8. Install spring (28), piston (7) to housing (6) with
the stepped side of the piston facing inside.
W176-02-06-014
Inner Ring Plate Marked

Surface
W3-2-57
27 25 5 23 11 12 10 14 18 16 17 2
5 9 13 21 20 15 19 6
W1HH-03-02-006
W3-2-58
IMPORTANT: The small diameter side of the shaft
CAUTION: Housing weight: 105 kg (240 lb)
is the inner race of the needle bear-
ing. Take care not to damage it.
9. With a plastic hammer, tap shaft (1) lightly to in- 15. Place housing (6) with the brake valve (27)
stall it into housing (6). mounting surface facing upward.
10. Install retaining ring (2) in housing (6) to stop shaft 16. Install plates (13) (4 used) and friction plates (21)
(1). (4 used) on housing (6) alternately. Install the fric-
tion plate (21) first.
NOTE: If keep open the retaining ring and move it 17. Apply grease to O-rings (11), (12). Install them
to the lowest bottom of the housing, instal- into brake piston (10).
lation of the retaining ring becomes easy.
18. Push brake piston (10) into housing (6) with a
11. Apply grease to the ball hole of swash plate (16). plastic hammer by tapping evenly.
Install the swash plate on housing (6), while align NOTE: Since the O-ring is positioned around the
with balls (17) (2 used). brake piston, the brake piston cannot be
fully fitted. When installing brake valve (27),
CAUTION: Housing weight: 95 kg (210 lb) push the brake piston with tightening bolts.
12. Place housing (6) horizontally with its brake re- IMPORTANT: Pay attention to the disc spring as-
leasing oil passage facing downward. sembly direction.
19. Put disc spring (9) on brake piston (10) with the
inner diameter of the disc spring facing the brake
NOTE: If placed opposite, swash plate (16) may piston.
come off.
20. Install O-rings (5) (2 used), (23) onto the brake
IMPORTANT: Pay attention to the retainer direc- valve (27) contact surface of housing (6). Install
tion. O-ring (23) onto the brake valve (27).
13. Install springs (20) (6 used), bushing (15), retainer
(19), plungers (18) (9 used) onto the rotor (14), 21. Fill hydraulic oil into housing (6) until plate (13) is
with the chamfered side of the retainer facing the submerged.
bushing.
IMPORTANT: Pay attention to the knock pin as-
19
sembly direction.
22. Install the large diameter side of knock pins (25)
(2 used) to the knock pin hole of brake valve (27).
Chamfered 15
W172-03-02-001
14. Assemble the rotor (14) assembly into housing

(6).
W3-2-59
27 25
26 22 24 6
W1HH-03-02-006
W3-2-60
IMPORTANT: Pay attention to the needle bearing
assembly direction.
23. Using drive tool (4472142), tap needle bearing
(26) with a hammer into brake valve (27). Face
the mark on the needle bearing outward.
4472142
26
27
W176-03-02-012
24. Apply grease on the flat surface of valve plate

(24). Install the valve plate onto brake valve (27),
aligning knock pin (25).
NOTE: Apply grease sufficiently so that valve plate

adheres to the brake valve. It prevents the
valve plate from coming off while turning
over the brake valve.
IMPORTANT: Take care not to let the valve plate

fall as this can damage it resulting in
oil leaks.
25. Install brake valve (27) to housing (6) and secure
it with socket bolts (22) (8 used).
: 17 mm
: 392 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
W3-2-61
DISASSEMBLE TRAVEL BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
2
3
4
16
3
15
14 2
13 1
8
9 7
10
11 W1HH-03-02-007
12
1- Plug (2 Used) 5- Spool 9- Poppet (2 Used) 13 - Plug

2- O-Ring (2 Used) 6- Valve Housing 10 - Spring (2 Used) 14 - O-Ring
3- Spring (2 Used) 7- Plug 11 - O-Ring (2 Used) 15 - Spring
4- Stopper (2 Used) 8- O-Ring 12 - Overload Relief Valve 16 - Spool
(2 Used)
W3-2-62
Disassemble Travel Brake Valve
1. Remove plug (1) from valve housing (6). (2 6. Remove springs (10), poppets (9) from valve
places). housing (6) with a magnet. (2 places)
: 41 mm
7. Remove plug (13) from valve housing (6).
2. Remove spring (3) and stopper (4) from valve : 6 mm
housing (6) with a magnet. (2 places)
8. Remove spring (15), spool (16) from valve hous-
3. Remove spool (5) from valve housing (6) with a ing (6) with a magnet.
magnet.
4. Remove plug (7) from valve housing (6).

The plug coated with LOCTITE has been inserted
into the hole. Do not remove it unless necessary.
: 6 mm
IMPORTANT: Do not disassemble the overload re-

lief valve. By disassembling it, its
setting pressure may be changed.
IMPORTANT: Do not move the piston on the

overload relief valve, otherwise the
O-ring may be damaged by the hole
of cartridge.
5. Remove relief valves (12) from overload valve
housing (6). (2 places)
: 41 mm
12
W176-03-02-011
Piston
W3-2-63
ASSEMBLE TRAVEL BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
6 1 2 3 4 5 4 3 2 1
13 14 15 16 9 10 11 12 8 7
W1HH-03-02-008
1- Plug (2 Used) 5- Spool 9- Poppet (2 Used) 13 - Plug

2- O-Ring (2 Used) 6- Valve Housing 10 - Spring (2 Used) 14 - O-Ring
3- Spring (2 Used) 7- Plug 11 - O-Ring (2 Used) 15 - Spring
4- Stopper (2 Used) 8- O-Ring 12 - Overload Relief Valve 16 - Spool
(2 Used)
W3-2-64
Assemble Travel Brake Valve
1. Install spool (5) approximately half way into valve 7. Install O-ring (11) (2 used) into overload relief
housing (6). valve (12).
2. Install O-ring (2), spring (3), stopper (4) onto plug 8. Press poppet (9) installed in step 6 with overload
(1) on one side. Install the plug into valve housing relief valve (12) into valve housing (6), while
(6) with pitch a couple of threads left out. slowly rotating the relief valve. (2 places)
: 41 mm
: 440 N⋅m (45 kgf⋅m, 325 lbf⋅ft)
NOTE: If the plug is fully installed, it is difficult to
assemble the plug on other side as spool
IMPORTANT: Pay attention to the assembly spool
(5) may be pushed out.
direction.
9. Install spool (16) into valve housing (6) with the
3. Install O-ring (2), spring (3) and stopper (4) into
hole end facing forward.
other plug (1). Install plug (1) into valve housing
(6). Tighten the plug by hand.
10. Install spring (15) into valve housing (6).
4. Tighten plug (1) on both sides.
11. Install O-ring (14) onto plug (13) into valve hous-
: 41 mm
ing (6).
: 343 N⋅m (35 kgf⋅m, 253 lbf⋅ft)
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
5. Install O-ring (8) into plug (7), then install plug (7)
into valve housing (6).
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
6. Install spring (10) into poppet (9). Install poppet

(9) flush with the hole entrance of valve housing
(6). (2 places)
NOTE: If the poppet is installed into the farthest

end, the spring may come off from the
poppet.
W3-2-65
Sprocket
B
C
D
A E
W1HH-03-02-002
Unit: mm (in)
A 87 (3.4) [77 (3.0)]
B 89.15 (3.5) 84.15 (3.3) Cladding by
C 125.75 (5) - welding and
D 133.55 (5.3) 128.55 (5.1) finishing
E 216.0 (8.5) -
NOTE: Values in [ ] is just for reference.
W3-2-66
Shoe
Travel Motor
1. End play between plunger and shoe.

0 0.2 mm (0.008 in) ε
Plunger
ε ≤ 0.2 mm (0.008 in)
W105-02-06-130
2. The clearance between plunger and rotor bore.

Standard Allowable Limit D
0 0.04 mm (0.0016 in)

D-d ≤ 0.04 mm (0.0016 in)
W105-02-06-134
Plunger Assembly
Rotor
W105-02-06-135
Shoe
3. Shoe thickness
5.5 mm (0.22 in) 5.3 mm (0.21 in)
Plunger
W105-02-06-130
W3-2-67
ZAXIS370MTH

1
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
2
page W3-7-1.
that the track have already been removed. W16J-03-02-006
3 Track Frame 4
1. Remove bolts (1) (6 used) to remove cover (2)
from the track frame.
: 22 mm
10
IMPORTANT: Attach identification tags to hoses
for reassembly. 5
2. Disconnect hoses (3 and 4) from travel device (6)
and cap all disconnected hose ends.
: 27 mm, 17 mm
6
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 9 8 7 W16J-03-02-005
hoses.
: 10 mm
W111-03-02-002
W3-2-68
CAUTION: Travel Device weight: 670 kg

3 Track Frame 4
(1480 lb)
4. Attach wire ropes on travel device (6), and hoist

the travel device by crane. 10
5. Put matching marks on travel device (6) and the 5

track frame.
Remove bolts (5) (20 used). Hoist and remove the
travel device by crane.
: 32 mm
6
9 8 7 W16J-03-02-005
W111-03-02-002
W3-2-69
Installation
3 Track Frame 4
(1480 lb)
IMPORTANT: Be sure to align the matching marks 10

made during disassembling. By
failing to do so, it is difficult to install 5
hoses (3 and 4).
1. Install travel device (6) onto the track frame with
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft) 6
2. Connect hoses (9 and 10) to travel device (6) with 9 8 7 W16J-03-02-005
split flanges (7) (4 used) and tighten the split

flange with socket bolts (8) (8 used).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
1
3. Connect hoses (3 and 4) onto travel device (6).
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
4. Install cover (2) onto the track frame with bolts

(1) (6 used).
: 22 mm 2
: 180 N⋅m (18.5 kgf⋅m, 134 Ibf⋅ft)
W16J-03-02-006
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
After completing installation of the
travel device, be sure to perform
running-in to prevent motor seizure.

slow idle position.
speed position
3. Drive the machine for 2 minutes or more
W3-2-70
(Blank)
W3-2-71
DISASSEMBLE TRAVEL DEVICE
ZAXIS370MTH 8
7
6
4
3
1 24
23
22
21
20 25
19
17 18
16
15
14 26
13
27
12
28
29
30
31
10 11 32
9 34 33
35
36
37
38 49
39
40
48
47
46
45
44
43
41
42 W16J-03-02-004
1- Motor 14 - Bolt (24 Used) 26 - Spacer 38 - Needle Bearing (4 Used)
2- O-Ring 15 - 3rd Stage Carrier 27 - 1st Stage Carrier 39 - Needle Bearing (4 Used)
3- Housing 16 - 3rd Stage Sun Gear 28 - Thrust Plate (3 Used) 40 - Thrust Plate (4 Used)
4- Floating Seal 17 - 2nd Stage Carrier 29 - Spring Pin (3 Used) 41 - Shaft
5- Roller Bearing 18 - Spacer 30 - 2nd Stage Planetary Gear (3 Used) 42 - Ring Gear
6- Drum 19 - 2nd Stage Sun Gear 31 - Pin (3 Used) 43 - Bolt (30 Used)
7- Roller Bearing 20 - Thrust Plate (3 Used) 32 - Needle Bearing (3 Used) 44 - Retaining Ring
8- O-Ring 21 - Needle Bearing (3 Used) 33 - Thrust Plate (3 Used) 45 - Stopper Pin
9- Nut 22 - Pin (3 Used) 34 - Thrust Plate (4 Used) 46 - Ball Bearing
10 - Lock Plate 23 - 1st Stage Planetary Gear (3 Used) 35 - 3rd Stage Planetary Gear (4 Used) 47 - Cover
11 - Bolt (2 Used) 24 - Thrust Plate (3 Used) 36 - Spring Pin (4 Used) 48 - Bolt (16 Used)
12 - Sprocket 25 - Spring Pin (3 Used) 37 - Pin (4 Used) 49 - Plug (3 Used)
13 - Washer (24 Used)
W3-2-72
CAUTION: Pressure may remain in the travel CAUTION: Motor (1) weight: 130 kg (300 Ib)
completely release the residual pressure. 2. Put matching marks on the mounting surface of
Then, remove the drain plug and drain the motor (1) and housing (3).
gear oil into a container. Install eyebolts (M12, Pitch 1.75 mm) (2 used)
If the air bleed plug is loosened quickly, the into the motor. Remove bolts (4 used), then hoist
plug may fly off and/or gear oil may spurt. and remove the motor. Remove O-ring (2) from
Keep your face and body away from the plug. the motor.
: 27 mm
CAUTION: Travel device weight: 670 kg 3

(1480 lb) Motor Mounting Bolt
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
(1) facing up.
: 14 mm
49-B
Eyebolt
Mounting Po-
sition
W16J-03-02-002

(1190 Ib)
49-A
3. Attach a wire rope to the middle of drum (6) and
W111-03-02-006
ring gear (42). Hoist the travel device and place it
on the work bench with cover (47) facing up.
CAUTION: Cover (47) weight: 25 kg (55 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 re-
move cover (47) from ring gear (42).
: 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.
W3-2-73
7
6
4
3
24
23
22
21
20 25
19
17 18
16
15
26
12
27
28
29
30
31
10 11 32
9 34 33
35
36
37
38
39
40
48
43
41
42 W16J-03-02-004
W3-2-74
CAUTION: Ring gear (42) weight: 70 kg 10. Install special tool (ST 3136) onto bearing nut (9)
(150 lb) to loosen and remove the bearing nut.
ST 3136
5. Put matching marks on the mating parts of ring
gear (42) and drum (6).
Install eyebolts (M14, Pitch 2.0 mm) into the bolt
(48) holes (2 places) in ring gear (42).
Remove bolts (43) (30 used) to hoist and remove
the ring gear.
Remove O-ring (8) from drum (6).
: 27 mm
6. Remove shaft (41) from first stage carrier (27).

Remove first stage carrier assemblies (20 to 27)
and second stage sun gear (19) from second
stage carrier (17). W111-03-02-018
CAUTION: The second stage carrier (17) CAUTION: Drum (6), sprocket (12) and other
assembly weight: 25 kg (50 Ib) parts weight: 180 kg (400 Ib)
7. Wind nylon slings (2 used) onto second stage IMPORTANT: The mating parts of drum (6) and
carrier (17). Hoist and remove second stage car- housing (3) are sliding seal surface.
rier assemblies (17, 18, 28 to 33). Take care not to damage the sliding
Remove third stage sun gear (16). seal surface and put the removed
drum assembly onto wooden
CAUTION: The third stage carrier (15) as- blocks.
sembly weight: 70 kg (150 Ib)
11. Put matching marks on the mating parts of drum
8. Wind nylon slings (2 used) onto third stage carrier (6) and housing (3).
(15). Hoist and remove third stage carrier as- Install eyebolts (M18, Pitch 2.5 mm) into the bolt
semblies (15 and 34 to 40) by crane. (43) holes (2 places) in the drum.
Hoist and remove the drum assembly from the
9. Remove bolts (11) (2 used) to remove lock plate housing.
(10). At this time, the inner race of roller bearing (7) is
: 19 mm also removed along with it.
12. Remove floating seals (4) from housing (3) and

drum (6).
W3-2-75
7
6
25
17 18
15
14 26
12
27
29
34
35
36
37
38
39
40
W16J-03-02-004
W3-2-76
IMPORTANT: Do not remove the inner race of 17. Pull spring pin (36) out from third stage carrier
roller bearing (5) from housing (3) (15) with a round bar (Dia: 8mm (0.3 in)). Remove
unless necessary. In case the inner pin (37) to remove third stage planetary gear (35)
race of roller bearing (5) has been and thrust plates (34 and 40) from the third stage
removed, it must be replaced with a carrier.
new one. Remove needle bearings (38 and 39) from the
13. Remove the inner race of roller bearing (5) from third stage planetary gear.
housing (3) with a bar and hammer.
18. Remove spring pins (36) (3 used), pins (37) (3
used), third stage planetary gears (35) (3 used),
NOTE: If the inner race of roller bearing (5) can not
thrust plates (34) (3 used) and (40) (3 used), nee-
be removed, it can be cut by gas torch.
dle bearings (38) (3 used) and (39) (3 used) from
However care should be taken to protect
third stage carrier (15) according to the steps in
housing (3) from being damaged while do-
procedure 17.
ing this work.
19. Disassemble the first stage carrier (27) assembly
CAUTION: Sprocket (12) weight: 85 kg and second stage carrier (17) assembly accord-
(190 Ib) ing to the steps in procedures 17 and 18.
The diameter of round bar for spring pin (25):
14. Put matching marks on the mating surface of 4 mm (0.16 in)
sprocket (12) and drum (6). The diameter of round bar for spring pin (29):
Attach nylon slings (2 used) on the sprocket. 5 mm (0.20 in)
Remove bolts (14) (24 used). Hoist and remove
the sprocket. 20. Remove spacer (26) from first stage carrier (27).
: 32 mm Remove spacer (18) from second stage carrier
(17).
IMPORTANT: Do not remove the outer race of
roller bearings (5) and (7) from drum
(6) unless necessary.
If the bearing is pressed in insuffi-
ciently, the service life of the bearing
may be affected. In case the outer
race has been removed, it must be
replaced with a new one.
drum (6) with a bar and hammer.
CAUTION: Drum (6) including other parts

weight: 100 kg (220 Ib)
16. Install eyebolts (M22, Pitch 2.5 mm) into the bolt
(14) holes (2 places) in drum (6) from the motor
(1) side.
Hoist and turn the drum over. Remove the outer
race of roller bearing (7) from the drum with a bar
and hammer.
W3-2-77
12 13 14
ZAXIS370MTH
3 4 6 5 7 9 8
43 42 15 16 18
2 17
1 19
26
27
49
47
44
46
45
41
23
24
25
22
21
20
48
33 30 32 31 28 29
34 36
T16J-03-05-001
10 11 40 35 39 38 37
1- Motor 14 - Bolt (24 Used) 26 - Spacer 38 - Needle Bearing (4 Used)

2- O-Ring 15 - 3rd Stage Carrier 27 - 1st Stage Carrier 39 - Needle Bearing (4 Used)
3- Housing 16 - 3rd Stage Sun Gear 28 - Thrust Plate (3 Used) 40 - Thrust Plate (4 Used)
4- Floating Seal 17 - 2nd Stage Carrier 29 - Spring Pin (3 Used) 41 - Shaft
5- Roller Bearing 18 - Spacer 30 - 2nd Stage Planetary Gear (3 Used) 42 - Ring Gear
6- Drum 19 - 2nd Stage Sun Gear 31 - Pin (3 Used) 43 - Bolt (30 Used)
7- Roller Bearing 20 - Thrust Plate (3 Used) 32 - Needle Bearing (3 Used) 44 - Retaining Ring
8- O-Ring 21 - Needle Bearing (3 Used) 33 - Thrust Plate (3 Used) 45 - Stopper Pin
9- Nut 22 - Pin (3 Used) 34 - Thrust Plate (4 Used) 46 - Ball Bearing
10 - Lock Plate 23 - 1st Stage Planetary Gear (3 Used) 35 - 3rd Stage Planetary Gear (4 Used) 47 - Cover
11 - Bolt (2 Used) 24 - Thrust Plate (3 Used) 36 - Spring Pin (4 Used) 48 - Bolt (16 Used)
12 - Sprocket 25 - Spring Pin (3 Used) 37 - Pin (4 Used) 49 - Plug (3 Used)
13 - Washer (24 Used)
W3-2-78
CAUTION: Housing (3) weight: 90 kg (200 Ib) 5. Install eyebolts (M18, Pitch 2.5 mm) into the bolt
(43) holes (2 places) in drum (6).
1. Wind a nylon sling on housing (3) body. Hoist and Hoist and place the drum (6) with the ring gear
place the housing with motor (1) side facing (42) side facing up.
down. Install the outer race of roller bearing (7) onto the
drum by tapping it with a bar and hammer evenly.
IMPORTANT: For handling of the floating seal, re-
fer to the section “Precautions for NOTE: Tap the bearing and listen to ring to see if
Floating Seal Handling” on page the installation of the outer race is com-
W1-1-4. pleted into drum (6).
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. CAUTION: Sprocket (12) weight: 85 kg
Install the inner race of roller bearing (5) into the (190 lb)
housing by tapping it with a bar and hammer
evenly. 6. Attach nylon slings (2 used) on sprocket (12).
Hoist the sprocket and place it carefully onto drum
NOTE: Tap the bearing and listen to ring to see if (6).
the installation of the inner race is com-
pleted into housing (3). IMPORTANT: Apply LOCTITE #262 on degreased
bolt (14).
7. Install spring washer (13) to each bolts (14) (24
CAUTION: Drum (6) weight: 96 kg (210 Ib) used). Tighten the bolts and install sprocket (12)
onto drum (6).
3. Install eyebolts (M22, Pitch 2.5 mm) into the bolt : 32 mm
(14) holes (2 places) in drum (6) from the motor : 750 N⋅m (75 kgf⋅m, 550 lbf⋅ft)
(1) side.
Hoist and place the drum (6) with the ring gear
(42) side facing down. CAUTION: Drum (6), sprocket (12), plus
Tap the outer race of roller bearing (5) with a bar other parts weight: 180 kg (400 Ib)
and hammer evenly to install it onto the drum(6).
IMPORTANT: Align the matching marks made be-
fore disassembling. Be sure the
NOTE: Tap the bearing and listen to ring to see if clearance all around drum (6) in
the installation of the outer race is com- housing (3) is equal.
pleted into drum (6). 8. Hoist the drum (6) assembly and put it onto
housing (3).
IMPORTANT: Apply grease to the O-ring of float-
ing seal (4) on the drum (6) side. 9. Install the inner race of roller bearing (7) onto the
4. Install one half of floating seal (4) on drum (6). housing by tapping it with a bar and hammer
evenly.
W3-2-79
12
3 6 7 9 8
15
47
34 36
T16J-03-05-001
10 11 40 35 39 38 37
W3-2-80
IMPORTANT: Install bearing nut (9) with the IMPORTANT: If lock plate (10) fails to engage the
stepped part facing roller bearing (7). spline of housing (3), tighten bearing
Apply a film of grease at the nut (9) further in the tightening di-
threaded part of the bearing nut. rection to align with the spline.
10. Install bearing nut (9) onto housing (3) and tighten Apply LOCTITE #262 to bolts (11).
it by hand. 14. Install lock plate (10) onto bearing nut (9) with
degreased bolts (11) (2 used).
: 19 mm
NOTE: Apply a film of grease to the threaded part
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
of bearing nut (9) so as to tighten the nut to
the specified torque.
IMPORTANT: Apply grease on O-ring (8).
15. Install O-ring (8) onto drum (6).
11. Install special tool (ST 3136) onto bearing nut (9)
and tighten it with a wrench.
IMPORTANT: There is an identification groove on
: 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft)
one half of third stage planetary gear
ST 3136 (35). Install the third stage planetary
gear with the identification groove
facing cover (47).
16. Install needle bearings (38) (4 used) and (39) (4
used) onto third stage planetary gears (35) (4
used). Install the third stage planetary gear onto
third stage carrier (15) by clamping it with thrust
plates (34) (4 used) and (40) (4 used).
17. Align the spring pin (36) holes in third stage car-
rier (15) and pins (37) (4 used), then install the
spring pins.
W111-03-02-018
IMPORTANT: When installing spring pin (36), be
sure to let its slit face the end of pin
12. Rotate sprocket (12) both clockwise and counter- (37).
clockwise 4 to 5 turns. Tap on drum (6) with a 18. Install spring pins (36) (4 used) into third stage
plastic hammer to secure appropriate play. carrier (15) and pin (37) with a round bar (Dia: 8
mm (0.3 in)).
13. Perform procedures 11 and 12 twice and tighten
36
bearing nut (9) to the specified torque.
: 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft) 37
Slit
W178-02-06-002
W3-2-81
3 6
43 42 15 16 17 19
26
27
47
41
23
24
25
22
21
20
48
33 30 32 31 28 29
34 36
T16J-03-05-001
40 35 39 38 37
W3-2-82
19. Install spacer (26) to first stage carrier (27).
CAUTION: The second stage carrier (17)
20. Install needle bearings (21) (3 used) onto first assembly weight: 25 kg (60 Ib)
stage planetary gears (23) (3 used). Clamp the
first stage planetary gear with thrust plates (24) (3 25. Wind nylon slings (2 used) onto second stage
used) and (20) (3 used) and install the first stage carrier assemblies (17, 18 and 28 to 33). Hoist the
planetary gear onto first stage carrier (27). second stage carrier assemblies and lower it onto
third stage sun gear (16).
IMPORTANT: When installing spring pin (25), be
sure to let its slit face the end of pin 26. Install second stage sun gear (19) onto second
(22). stage carrier (17) with the smaller end facing
21. Install spring pins (25) (3 used) into first stage cover (47).
carrier (27) and pin (22) by a round bar (Dia: 4 Cover (47) Side
mm (0.16 in)).
25
22
Slit 19 W166-03-02-002
W178-02-06-002 27. Install first stage carrier assemblies (20 to 27)

onto second stage carrier (17).
22. Assemble second stage carrier (17) according to
the procedures 19 to 21. 28. Insert shaft (41) into the center of carrier and be
Round Bar Dia: 5 mm (0.20 in) sure to let it engage with the first stage planetary
gears (23) (3 used).
CAUTION: The third stage carrier (15) as-

sembly weight: 70 kg (150 Ib) CAUTION: Ring gear (42) weight: 70 kg
(150 Ib)
23. Wind nylon slings (2 used) onto third stage carrier
assemblies (15 and 34 to 40). Hoist the third IMPORTANT: Align the matching marks made
stage carrier assemblies and lower it onto hous- when disassembling.
ing (3) carefully. 29. Install eyebolts (M14, Pitch 2.0 mm) into the bolt
(48) hole in ring gear (42). Hoist ring gear by
24. Install third stage sun gear (16) onto third stage crane and lower it to drum (6).
carrier (15) with the smaller end facing cover (47).
IMPORTANT: Apply LOCTITE #262 on degreased
bolt (43).
Cover (47) Side
30. Install ring gear (42) onto drum (6) with bolts (43)
(30 used).
: 27 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
W166-03-02-001
16
W3-2-83
3
42
2
1
49
47
44
46
45
41
48
T16J-03-05-001
W3-2-84
31. Attach a tube bar on ball bearing (46). Tap a tube
CAUTION: Travel reduction gear weight:
bar with a hammer and install the ball bearing
onto cover (47). 540 kg (1190 Ib)
Ball Bearing Inner Diameter: 45 mm (1.77 in)
Outer Diameter: 68 mm (2.68 in) 37. Install eyebolts (M18, Pitch 2.5 mm) into the bolt
holes (2 places) in the housing (3) flange. Hoist
32. Attach a tube bar on stopper pin (45). Tap a tube the travel reduction gear and turn it over.
bar with a hammer to install the stopper pin into
ball bearing (46). 38. Fill gear oil 11.5 L (3.0 US gal.) into the travel re-
Stopper Pin Inner Diameter: 26 mm (1.02 in) duction gear.
Outer Diameter: 50 mm (1.97 in)
39. Install O-ring (2) to motor (1).
IMPORTANT: Install retaining ring (44). Be sure to
let the chamfered part face cover CAUTION: Motor (1) weight: 135 kg (300 Ib)
(47).
33. Install retaining ring (44) onto cover (47). 40. Install eyebolts (M12, Pitch 1.75 mm) (2 used)
into the bolt holes in motor (1). Hoist the motor
CAUTION: Cover (47) weight: 25 kg (55 Ib) and install it onto housing (3) while aligning the
splines on shaft (41) with the splines on the motor.
IMPORTANT: Apply THREEBOND #1389B to the 3
cover (47) mounting surface of ring Motor Mounting Bolt
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 1
(42).
IMPORTANT: Apply LOCTITE #262 on degreased

bolt (48).
35. Install cover (47) onto ring gear (42) with bolts
(48) (16 used). Eyebolt
Mounting Position
: 22 mm
: 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft) W16J-03-02-002
36. Wrap the seal tape to plugs (49) (3 used) and in-
41. Install spring washers to each bolt (4 used), then
stall the plugs into cover (47).
install motor (1) into housing (3) with the bolts
: 14 mm
(4 used).
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
: 27 mm
: 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
W3-2-85
ZAXIS370MTH
4
3
2
1
7
6
2 5
17
15 16
14
13
11 12
10
28
22
27
20
26
25
24
23
19
18
33
32
21
31
30
29
W16J-03-02-001
1- Casing 10 - Piston (9 Used) 18 - Friction Plate 26 - Backup Ring
2- O-Ring (4 Used) 11 - Retainer 19 - Friction Plate 27 - Brake Piston
3- Spring (2 Used) 12 - Holder 20 - Disc Plate (4 Used) 28 - O-Ring
4- Piston (2 Used) 13 - Spring (9 Used) 21 - Friction Plate (3 Used) 29 - Spring (10 Used)
5- Oil Seal 14 - Cylinder Block 22 - Friction Plate 30 - Pin
6- Roller Bearing 15 - Valve Plate 23 - Backup Ring 31 - Pin (4 Used)
7- Shaft 16 - Collar 24 - O-Ring 32 - Valve Housing
8- Steel Ball (2 Used) 17 - Roller Bearing 25 - O-Ring 33 - Socket Bolt (9 Used)
9- Swash Plate
W3-2-86
Disassemble Travel Motor (ZAXIS370MTH)
CAUTION: Valve housing (32) weight: 39 kg IMPORTANT: Fix casing (1) securely.
(90 Ib) 4. Install eyebolts (M12, Pitch 1.75 mm) into the pin
(31) holes (2 places) in brake piston (27). Hoist
IMPORTANT: Loosen socket bolts (33) (9 used) the brake piston and remove it from casing (1).
evenly. When loosening the socket
bolts, valve housing (32) may come 5. Remove O-rings (24 and 25), backup rings (23
up from casing (1) since there is a and 26) from brake piston (27).
spring force coming from springs
(13) and (29). Take down the clear- IMPORTANT: Since friction plates (18, 19, 21 and
ance between the casing and the 22) are different in thickness and the
valve housing. order to install them has been de-
When removing the valve housing termined, they should be kept in or-
from the casing, valve plate (15) will der while removing.
come out with the valve housing, do 6. Remove friction plate (22) from casing (1). Re-
not let the plate come off. move disc plates (20) (4 used) and friction plates
1. Put matching marks on the mating part of valve (21) (3 used) one by one alternately. Remove fric-
housing (32) and casing (1). Install eyebolts (M12, tion plates (19 and 18).
Pitch 1.75 mm) onto the valve housing.
Remove socket bolts (33) (9 used). Hoist the
valve housing and remove it from the casing. CAUTION: The cylinder block (14) assembly
: 14 mm weight: 20 kg (40 Ib)
1 32
IMPORTANT: If cylinder block (14) needs to be re-
33 placed, 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
Eyebolt Mounting slowly.
Position
W16J-03-02-002
8. Remove retainer (11), pistons (10) (9 used),
2. Remove springs (29) (10 used), O-rings (2) (4 holder (12) and springs (13) (9 used) from cylinder
used), pins (31) (4 used) and O-ring (28) from block (14).
casing (1).
IMPORTANT: Do not damage the friction surface
IMPORTANT: Take care not to damage valve plate of swash plate (9).
(15). Piston (4) and steel ball (8) may
3. Remove collar (16) and valve plate (15) from cyl- come out with the swash plate. Be
inder block (14). sure to keep the piston and the steel
ball from dropping.
9. Remove swash plate (9) from casing (1).
W3-2-87
4
3
1
7
6
5
W16J-03-02-001
W3-2-88
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 in-
stalled in the same direction before
disassembling.
casing (1) with a bar and a hammer.
14. Remove oil seal (5) from casing (1).
W3-2-89
ZAXIS370MTH
27
25,26 23,24 22 19 18 7 4 3
33 29
30
16
32
17
1
15
31
5
28
T16J-03-05-003
2 6
Brake Release Circuit 14 10 20 21 13 11 12 9
1- Casing 10 - Piston (9 Used) 18 - Friction Plate 26 - Backup Ring

2- O-Ring (4 Used) 11 - Retainer 19 - Friction Plate 27 - Brake Piston
3- Spring (2 Used) 12 - Holder 20 - Disc Plate (4 Used) 28 - O-Ring
4- Piston (2 Used) 13 - Spring (9 Used) 21 - Friction Plate (3 Used) 29 - Spring (10 Used)
5- Oil Seal 14 - Cylinder Block 22 - Friction Plate 30 - Pin
6- Roller Bearing 15 - Valve Plate 23 - Backup Ring 31 - Pin (4 Used)
7- Shaft 16 - Collar 24 - O-Ring 32 - Valve Housing
8- Steel Ball (2 Used) 17 - Roller Bearing 25 - O-Ring 33 - Socket Bolt (9 Used)
9- Swash Plate
W3-2-90
Assemble Travel Motor
IMPORTANT: Apply grease on inside periphery of IMPORTANT: Align the spherical hole in swash
oil seal (5) for casing (1) at the plate (9) with steel ball (8), then in-
pressed-in part and outside periph- stall the swash plate.
ery of the oil seal. Apply grease to matching part of
In addition, the oil seal should be casing (1) for the swash plate.
pressed in straight to prevent it from 6. Install swash plate (9) onto casing (1) with its
deforming. thicker side facing down.
1. Press oil seal (5) into casing (1).
IMPORTANT: Apply hydraulic oil on the piston (10)
IMPORTANT: Install the outer race of roller bearing mounting hole of cylinder block (14).
(6) with the stamp mark on the outer Pay attention to the mounting direc-
race facing the swash plate (9) side. tion of retainer (11).
2. Tap the outer race of roller bearing (6) evenly with
a bar and hammer while installing the outer race 7. Install springs (13) (9 used) and holder (12) into
into casing (1). cylinder block (14).
Install pistons (10) (9 used) onto retainer (11) and
NOTE: Tap the bearing and listen to ring to confirm install them into the cylinder block.
if installation is completed.
CAUTION: The cylinder block (14) assembly

IMPORTANT: Install the inner race of roller bearing weight: 20 kg (40 Ib)
(6) with its collar facing swash plate
(9). IMPORTANT: Apply hydraulic oil to the piston (10)
3. Tap the inner race of roller bearing (6) evenly with sliding surface of swash plate (9)
a bar and hammer while installing it into shaft (7). and the spherical surface of holder
Tap and install the shaft assembly into casing (1) (12).
with a hammer. There is the inner race for roller
bearing (17) on the tip of shaft (7).
IMPORTANT: Apply hydraulic oil on outside pe- Take care to keep it away from being
riphery of steel ball (8) and piston (4). damaged.
Apply hydraulic oil the piston (4) and Align the shaft splines to those of
the steel ball (8) mounting surfaces cylinder block (14).
of casing (1). 8. Install the cylinder block (14) assembly onto shaft
4. Install springs (3) (2 used), pistons (4) (2 used) (7).
and steel balls (8) (2 used) into casing (1).
CAUTION: The casing (1) assembly weight:

CAUTION: The casing (1) assembly weight: 54 kg (120 Ib)
54 kg (120 Ib)
9. Install eyebolts (M18, Pitch 2.5 mm) into the
5. Install eyebolts (M18, Pitch 2.5 mm) into the bolts socket bolts (33) holes (2 places) in casing (1).
(33) holes in casing (1) (2 places). Hoist the cas- Hoist the casing (1) and place it vertically.
ing (1) assembly up and place it with the brake
release circuit facing down.
W3-2-91
27
29 25, 26 23, 24 22 19 18
30
16
32
17
1
15
31
T16J-03-05-003
14 20 21
W3-2-92
10. Install friction plates (18 and 19) into casing (1). IMPORTANT: As for springs (29) (10 used), there
Then install disc plates (20) (4 used) and friction are twelve spring mounting holes in
plates (21) (3 used) alternately and finally install brake piston (27), so pay attention to
friction plate (22) into the casing. where the spring should be inserted
and not make mistakes.
NOTE: Friction plates (18, 19, 21 and 22) are dif-
ferent in thickness. 27
(18), (22): 4.8 mm (0.2 in) Free Hole
(19): 6.5 mm (0.3 in)
(21): 3 mm (1.0 in)
So they should be installed while aligning 29
with their own notch respectively in casing
(1).
When installing disc plate (20), its inner
splines shall be aligned with those of cyl-
29
inder block (14).
IMPORTANT: Apply grease to O-rings (24 and 25) W16J-03-02-003
and backup rings (23 and 26). Free Hole

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

Notch if the outer race is installed to the most end
of valve housing (32).
IMPORTANT: Apply grease to the mating surfaces

of valve plate (15) and valve housing
(32).
W16J-03-02-003
15. Install collar (16) into valve housing (32). Align the
31 pin holes in pin (30) and valve plate (15) to install
the valve plate into the valve housing (32).
12. Tap brake piston (27) with a plastic hammer to in-
stall it into casing (1).
W3-2-93
33 27
32
31
28
T16J-03-05-003
W3-2-94
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 disassem-
bling. If the value is different, dis-
assemble them and reassemble
again.
IMPORTANT: Align the matching marks made
when disassembling. If the matching
marks cannot be aligned with each
other, brake piston (27) may be in-
stalled in wrong direction.
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
: 440±21.5 N⋅m
(45±2.2 kgf⋅m, 330±16 lbf⋅ft )
NOTE: Tighten socket bolts (33) (9 used) evenly.
1 32
33
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-95
DISASSEMBLE BRAKE VALVE
ZAXIS370MTH
6
1 7
2 8
3 5
4 9
10 Plug
11
10 9
35
Orifice
12
36 13
37 14
38 16 15
39 18
40 20
21
48
17 22
19
24
26 5
47
49
46 28 23
10 30 25
9
41 32
27 33
42 34
43 29
44 31
4
45 3
Orifice
2
1
44
43
36 42
41
50
40
39
35
38
37
W183-03-02-010
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 Used) 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)
W3-2-96
Disassemble Brake Valve
CAUTION: The valve housing (46) assembly IMPORTANT: Do not disassemble overload relief
weight: 39 kg (90 Ib) valves (5) (2 used). The overload re-
lief valve should be replaced as as-
1. Secure the valve housing (46) assembly on a firm sembly. Attach tags on each over-
work bench. load relief valves so that they can be
installed to their original positions.
2. Remove plugs (6 and 15) and O-rings (7 and 14). In addition, do not rotate set screw
Then remove spring (8). (34), or the setting pressure can
: 10 mm change.
5. Loosen plug (32) to remove overload relief valve
IMPORTANT: Remove valve assembly (13) while (5) from valve housing (46). (2 places at right and
rotating it. If a little resistance is felt left)
while removing, do not try to remove : 36 mm
it by force, return to original position
and retry. 6. Press cap (36) while loosening socket bolts (35)
In addition, do not disassemble the (4 used) to remove the cap (36) from valve hous-
valve assembly (13). In case re- ing (46). (2 places at right and left)
placement should be carried out to : 10 mm
any parts of it, be sure to replace it
with the valve housing (46) assembly
including spool assembly (50), valve NOTE: In case cap (36) cannot be removed, a
assembly (13), orifices (11 and 49) plastic hammer can be used to tap the cap,
and the plug. however, the loosened socket bolts (35)
3. Press valve assembly (13) out carefully and rotate should be still on the cap while tapping.
the valve assembly by hand to remove it from
valve housing (46). 7. Remove spring seat (38), spring (39) and spring
seat (40) from valve housing (46). (2 places at
4. Remove plug (1). Then remove O-ring (2), spring right and left)
(3) and check valve (4). (2 places at right and left)
: 14 mm 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).
W3-2-97
ZAXIS370MTH
Overload Relief Valve (5)
16 18 21 26 24 27 31 29 32 33
34
17, 19 20 22 23, 25 28 30
36 38
41
6
37
35 39
42
A A A 7
40
43
8
44
45
13
50
14
48 47
12
15
46
5 2 1 3 4
A-A-A 断面 W183-03-02-016
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 Used) 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- *Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - *O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - *Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - *Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)
NOTE: As for parts with *, refer to W3-2-96.
W3-2-98
Assemble Brake Valve (ZAXIS370MTH)
1. Install O-rings (7 and 14) to plugs (6 and 15) re-
spectively. Install valve assembly (13) and plugs
(6 and 15) into valve housing (46).
: 10 mm
: 64±4.9 N⋅m
(6.5±0.5 kgf⋅m, 47±3.6 lbf⋅ft)
2. Install O-ring (2) to plug (1) and install check valve

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

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

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

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

(38) into valve housing (46). Then install cap (36)
with socket bolts (35) (4 used). (2 places at right
and left)
: 10 mm
: 108±4.9 N⋅m
(11±0.5 kgf⋅m, 80±3.6 lbf⋅ft)
W3-2-99
ZAXIS370MTH
Cylinder
1. The clearance between the inner diameter of cyl- Block
inder block and the outer diameter of the piston:
(D-d): 0.06 mm or less D d
W507-02-04-009
Piston
2. The clearance between the piston and shoe when

Piston
engaging:
δ: 0.4 mm or less
Shoe
δ
W107-02-06-140
Piston
3. The clearance between the inner diameter and
outer diameter at the matching position of casing
and piston: D
(D-d): 0.03 mm or less
Casing
W162-03-02-005
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.
W3-2-100
Sprocket
B
C
D
A E
W1HH-03-02-002
Unit: mm (in)
Standard Dimension Allowable Limit Remedy
A 92 (3.62) [82 (3.23)]
B 86.1 (3.39) 81.1 (3.19) Cladding by
C 122.1 (4.8) - welding and
D 132 (5.2) 127 (5.0) finishing
E 215.9 (8.46) -
NOTE: Value in [ ] is for reference only.
W3-2-101
(Blank)
W3-2-102
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
1 2
Removal
1. Attach an identification tag to all the hoses of

center joint for reassembling.
Remove all the hoses and adapters from the
center joint. Cap all the removed ends of hoses.
: 17 mm, 27 mm, 41 mm
2. Remove bolt (1) from the center joint and remove

stopper plate (2).
3. Install eyebolt to the center joint. Attach a wire W157-03-03-003
rope and hoist the center joint.

CAUTION: Center joint weight: 27 kg (60 lb)
3
4. Remove bolts (3) (3 used). Remove the center
joint.
W105-03-03-003
W3-3-1
Installation
1 2
1. Install the center joint with bolts (3).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
2. Install stopper plate (2) to the center joint with

bolts (1).
: 22 mm
: 140 N⋅m (14.5 kgf⋅m, 105 lbf⋅ft)
3. Install all the hoses to the center joint.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm W157-03-03-003
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) 3
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
4. After completing the work, start the engine and

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

2 - Spindle 5 - Bushing 8 - Cover 11 - Ring
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Bolt (4 Used) 12 - Body
W3-3-4
Disassemble Center Joint
CAUTION: Center joint weight: 26.5 kg IMPORTANT: For easy removal, use the pins (2
(60 lb) used) when removing oil seals (6).
Do not damage the seal groove by
1. Remove bolt (9) from cover (8) diagonally. By the pins.
using eyebolts M10 (Pitch 1.5, Length 18 mm),
hoist and place the center joint on a workbench. 7. Remove oil seals (6) (6 used) and O-ring (4) from
body (12).
2. Put the matching marks on body (12) and spindle
(2).
3. Remove bolts (9) and remove cover (8) from

body (12).
: 17 mm
4. Remove O-ring (7), retaining ring (10), and

O-ring (7) from body (12).
5. Attach special tools (ST 1033, ST 1020) to body

(12) with bolts (9) (2 used).
: 17 mm
ST 1020
ST 1033 W105-03-03-015
8. Remove dust seal (3) from spindle (2).
9. While welding, cover the seal surface in order to

prevent it from being spattered.
When replacing bushing (5), build-up weld at 4
places in its inner diameter by using a welding
rod. Shrink and remove bushing (5).
W506-03-03-002
IMPORTANT: Do not damage the sliding surface

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

2 - Spindle 5 - Bushing 8 - Cover 11 - Ring
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Bolt (4 Used) 12 - Body
W3-3-6
Assemble Center Joint
IMPORTANT: If removing bushing (5), install 4. As the clearance between body (12) and spindle
bushing (5) by using a press first. (2) is approximately 0.1 mm (0.004 in), insert
(Refer to page W3-3-8.) spindle (2) along axis straight and slowly.
Tap and install body (12) by using a plastic ham-
1. Install dust seal (3) into spindle (2) with its lip part mer until surface A of body (12) is flush with that
facing to body (12). of spindle (2).
Surface A 2
0.1 mm
Dust Seal (3) 12
Lip
Body (12)
W105-03-03-024
W178-03-03-002
5. Install ring (11) to body (12) with the chamfered

2. Install oil seals (6) (6 used) and o-ring (4) into
side facing the spindle (2). Install O-ring (7) to
body (12).
body (12).
3. Place spindle (2) onto a workbench. Align the
6. Install retaining ring (10) to spindle (2).
matching marks and install body (12) on spindle
(2).
7. Install cover (8) with bolts (9) (4 used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-3-7
When replacing the body or spindle with the new one,
the following procedures are required.
In case of body (12) In case of spindle (2)
1. Clean body (12) and bushing (5). 1. Clean spindle (2).
2. When pushing bushing (5) into body (12), apply 2. Tap and install plug (1) into spindle (2) by using
grease or molybdenum disulphide to the fitting special tool (ST 2559).
surface.
Push bushing (5) into body (12) by using a press. 3. Tap the balls of plug (1) so that the top of each
Pushing force: 0.5 to 1.5 t (1100 to 3300 lb) ball is 0.4 mm (0.016 in) or more than the respec-
Pushing tool: ST 2558 tive sleeve edge as illustrated in detail D.
1
ST 2558
Sleeve
2
12
0.4 mm
or More
Detail D
W135-03-03-001
W136-03-03-031
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-8
Item Allowable limit (basis for judgment) Remedy

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

and sealed part
Sliding surface of 1) Scored or abnormal wear of more than Replace
body and spindle, 0.1 mm (0.004 in)
except sealed 2) Scored less than 0.1 mm (0.004 in) deep Repair and finish
Body ⋅ Spindle part with oil stone
1) Wear more than 0.5 mm (0.02 in) deep Replace
and abnormal wear
Sliding surface
2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
and ring
3) Scored or abnormal wear less than 0.5 mm Repair and finish
(0.02 in) and repairable.
1) Wear more than 0.5 mm (0.02 in) Replace
Sliding surface 2) Wear less than 0.5 mm (0.02 in) Repair and finish
Cover and ring 3) Scored or abnormal wear less than 0.5 mm Repair and finish
(0.02 in) and repairable.
W3-3-9
(Blank)
W3-3-10
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
Before removing and installing the track adjuster, the
tracks, and the front idler must be removed first. For
removal and installation of the tracks and front idler,
refer to "Remove and Install Front Idler" (W3-5-1) and
"Remove and Install Track" (W3-7-1).
that the tracks and front idler have already been re-
moved.
Removal
CAUTION: Track adjuster weight: 180 kg
(400 lb)
CAUTION: The front idler may fly off due to
the strong spring force when removing
track adjuster (1). Do not stand in the same
direction to track adjuster (1) or where the
track adjuster flies off.
Particularly, a strong spring force is always
applied to the thread part of rod. If the rod
and/or the threads are damaged, metal frag-
2
ments under spring force may fly off.
1
1. Pry and remove track adjuster (1) from track
frame (2) by using a pry bar.
Installation
1. As illustrated, install track adjuster (1) into spring W157-03-04-003
guide (3) on track frame (2). 3 4
Check that the end of track adjuster (1) comes
into contact with that of plate (4).
W157-03-04-002
2 3
Section A
W157-03-04-001
W3-4-1
DISASSEMBLE TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
17
1
2
3
5
6
7
10
16 11
12
15
14
13
W173-03-04-001
1- Socket Bolt (4 Used) 6- U-Ring 10 - Cylinder 14 - Washer

2- Flange 7- Retaining Ring 11 - Plug 15 - Spacer
3- Dust Seal 8- Rod 12 - Valve 16 - Spring
4- Piston Rod 9- O-Ring 13 - Nut 17 - Holder
5- Wear Ring
W3-4-2
Disassemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH)
IMPORTANT: Use special tool (ST 4920) when

assembling and disassembling the
track adjuster.
CAUTION: The spring force of the track ad-

juster is extremely large. Inspect the special
tool for any damage thoroughly in order to
perform the work safely.
Special Tool
CAUTION: Special tool weight: 225 kg (ST 4290)
(496 lb)
1. Place an oil jack (30 t) between the holder and

base.
Holder
Oil Jack
Base
W105-03-04-006
2. Remove the nuts (4 used) of special tool and

remove plate (ST 4036). Plate (ST 4036)
: 46 mm
W105-03-04-007
CAUTION: Track adjuster weight:

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

lustrated.
Hoist and place the track adjuster onto the holder
of special tool.
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.
Plate (ST 4036)
5. Operate an oil jack. W105-03-04-011
Jack up the specified amount (122 m).

Specified Amount
122 mm = (Free length of spring: 679 mm) - (Set
Oil Jack
length of spring : 557 mm)
NOTE: 1 mm = 0.03937 in
6. Tighten the nuts of special tool and secure the

track adjuster.
Operate the oil jack and compress the track ad-
juster until a clearance is observed between
washer (14) and nut (13). (Approximately 10 mm W105-03-04-013
(0.4 in))
: 46 mm
7. Remove plug (11) from nut (13). Remove nut (13)

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

(ST 4036) and washer (14). Plate (ST 4036)
1
CAUTION: Spring assembly weight: 168 kg
(370 lb)
10. Install eyebolt (M16, Pitch 1.5) to rod (8).

Hoist the track adjuster and remove the spring W105-03-04-016
(16) assembly from special tool.
Eyebolt
CAUTION: Spring weight: 95 kg (209 lb)
11. Remove eyebolt. Remove spring (16) from rod

(8).
12. Remove spacer (15) from rod (8).
13. Remove socket bolts (1) (4 used). Move flange

(2) to holder (17). Remove flange (2) from cylin-
der (10).
: 8 mm W105-03-04-017
W3-4-7
17
2
3
5
6
7
10
W173-03-04-001
W3-4-8
14. Remove the piston rod (4) assembly from cylin-
der (10). 4
15. Holder (17) is pushed into piston rod (4).

Remove holder (17) from the piston rod (4) as- 5
sembly by using a press.
16. Remove flange (2) from piston rod (4). Remove

dust seal (3) from flange (2).
6
17. Remove rod (8) and O-ring (9) from cylinder (10). 7
18. Remove wear ring (5), retaining ring (7), and W105-03-04-023
U-ring (6) from piston rod (4).
W3-4-9
ASSEMBLE TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
12 11 14 8 15 9 7 5 10 4 1 2
13 16 Chamber B 6 3 17
Chamber A
557 mm (Free Length 679 mm)

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

2- Flange 7- Retaining Ring 11 - Plug 15 - Spacer
3- Dust Seal 8- Rod 12 - Valve 16 - Spring
4- Piston Rod 9- O-Ring 13 - Nut 17 - Holder
5- Wear Ring
W3-4-10
Assemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH) 4
1. Install dust seal (3) on flange (2).
2. Fill chamber (A) of flange (2) with grease. 5

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

Push holder (17) into piston rod (4).
4. Clean all parts.

Install U-ring (6), retaining ring (7), and wear ring
(5) to piston rod (4). W105-03-04-025
10
5. Apply grease to O-ring (9). Install O-ring (9) into
cylinder (10). 6
Install rod (8) into cylinder (10). 5
6. Apply grease to U-ring (6) and wear ring (5). Fill

chamber (B) in cylinder (10) with grease. Apply 4
grease to cylinder (10) and piston rod (4). Install
the piston rod (4) assembly into cylinder (10).
Insert the piston rod (4) assembly and completely
bleed air from chamber (B) and rod (8).
W105-03-04-021
7. Tighten flange (2) with socket bolts (1) (4 used).
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
W3-4-11
14 8 15
16

W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-12
8. Install spacer (15) on rod (8).
8
CAUTION: Spring (16) weight: 95 kg (209 lb)
9. Install spring (16) on rod (8).
CAUTION: Spring (16) assembly weight:

168 kg (370 lb)
10. Install eyebolt (M16, Pitch1.5 mm) into rod (8).

Hoist and place the spring (16) assembly onto
special tool. W105-03-04-017
11. Remove eyebolt. Place washer (14) onto spring

(16). Install plate (ST 4036). Plate (ST 4036)
14
16
W105-03-04-016
12. Tighten the nuts of special tool and secure the

spring assembly.
: 46 mm
W105-03-04-012
W3-4-13
12 11 8
13 16

W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-14
13. Operate the oil jack and compress spring (16) to
the specification.
Specified Length: 557 mm (1 ft 9.9 in)
16
Oil Jack
14. Install nut (13) to rod (8). Install plug (11). W105-03-04-026
: 85 mm
: 5 mm 13 8 11
: 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
W105-03-04-014
15. Install valve (12) to rod (8).

: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) Oil Jack
16. Lower the oil jack.
W105-03-04-013
17. Remove the nuts of special tool and remove plate

(ST 4036). Plate (ST 4036)
: 46 mm
W105-03-04-011
W3-4-15
CAUTION: Track adjuster weight: 180 kg Wire Rope

(397 lb)
18. Attach a wire rope to the track adjuster as illus-

trated. Hoist and remove the track adjuster from
special tool.
CAUTION: If only the track adjusted is

transported, use special tool as illustrated in
order to carry the track adjuster safely.
W105-03-04-009
W105-03-04-028
W3-4-16
REMOVE AND INSTALL TRACK
ADJUSTER
(ZAXIS370MTH)
Before removing and installing the track adjuster, the

tracks and the front idler must be removed first. For
removal and installation of the tracks and front idler,
refer to "Remove and Install Front Idler" (W3-5-1)
and "Remove and Install track" (W3-7-1). In this sec-
tion, the procedure starts on the premise that the
tracks and front idler have already been removed.

the strong force when removing track ad- 2
juster (1). Do not stand in the same direction 1
to track adjuster (1) or where the track ad-
juster flies off.
Particularly, a strong spring force is always
applied to the thread part of rod. If the rod
and/or the threads are damaged, metal frag-
ments under spring force may fly off.
W142-03-04-002
Removal
3 4
(550 lb)
1. Pry and remove track adjuster (1) from track

frame (2) by using a pry bar.
Installation
1. As illustrated, install track adjuster (1) into spring A
guide (3) on track frame (2).
Check that the end of track adjuster (1) comes
into contact with that of plate (4).
W16J-03-04-002
2 3
View W16J-03-04-001
W3-4-17
DISASSEMBLE TRACK ADJUSTER
(ZAXIS370MTH)
1 2 3
5
6
7
10
16
11
15
12
14 W166-03-04-003
13
1- Socket Bolt (4 Used) 5- Wear Ring 9- Cylinder 13 - Nut

2- O-Ring 6- U-Ring 10 - O-Ring 14 - Bracket
3- Guide 7- Retaining Ring 11 - Bolt 15 - Spring
4- Piston Rod 8- Rod 12 - Valve 16 - Spacer
W3-4-18
Disassemble Track Adjuster
(ZAXIS370MTH)
• Use a pump unit which has the maximum pres-

sure of 69 Mpa (700 kgf/cm2, 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
(500 kgf/cm2, 7110 psi) (80 tons) or lower.
IMPORTANT: Use special tool (ST4932) when as-

sembling and disassembling the Track Adjuster
track adjuster.
ST 4932
CAUTION: The spring force of track adjuster

is extremely large. Inspect the special tool
for any damage thoroughly in order to per-
form the work safely.
(550 lb)
1. Hoist and place the track adjuster on the holder

of special tool (ST 4932).
Holder
2. Loosen valve (12). Compress spring (15) of track

adjuster by using special tool (ST 4932) until the W142-03-04-019
clearance between bracket (14) and nut (13) is

approximately 10 mm (0.4 in).
15 Clearance 10 mm (0.39 in)
3. Put the matching marks on rod (8) and nut (13).
: 24 mm
4. Remove valve (12) and bolt (11). Remove nut

(13). 8
: 24 mm, 17 mm, 100 mm 14
13
11
12
W142-03-04-020
W3-4-19
16
15
14 W166-03-04-003
W3-4-20
5. Slowly return the piston of special tool (ST 4932).
Extend spring (15) to its free length.
NOTE: Spring (15) free length: 774 mm (30.5 in)
15 ST 4932

(550 lb)
14
6. Fasten bracket (14) and spring (15) together by
using a wire. Attach a nylon sling to spring (15) in
the track adjuster. Hoist and remove the track
adjuster from special tool (ST 4932).
7. Install eyebolt (M10, Pitch 1.5 mm) onto piston

rod (4). Attach a nylon sling to spring (15) and
pass the nylon sling through eyebolt. Hoist and
W142-03-04-005
place the assembly on the holder as illustrated.
15
Holder
CAUTION: Cylinder (9) assembly weight:
80 kg (180 lb)
8. Hoist and remove the cylinder (9) assembly (1 to W142-03-04-006
10) from spring (15).
CAUTION: Spring weight: 140 kg (310 lb)

9
9. Remove the wire fastening spring (15) and
bracket (14). Hoist and remove spring (15).
CAUTION: Bracket weight: 22 kg (50 lb)
10. Remove spacer (16) and bracket (14) from the 15

holder.
Holder
W142-03-04-007
W3-4-21
1 2 3
5
6
7
10
W166-03-04-003
W3-4-22
guide (3) from piston rod (4).
2
: 12 mm 3
1
12. Remove piston rod (4) from cylinder (9).
4
13. Remove O-ring (2) from guide (3). 10
CAUTION: Cylinder (9) weight: 40 kg (88 lb) 9

Rod (8) weight: 21 kg (50 lb)
14. Install eyebolt (M16, Pitch 2.0 mm) into rod (8). 8
Hoist and remove rod (8) from cylinder (9).
Remove O-ring (10) from the inside of cylinder W142-03-04-010
(9).
4
15. Remove wear ring (5), retaining ring (7), and
U-ring (6) from piston rod (4). 5
6
7
W166-03-04-001
W3-4-23
ASSEMBLE TRACK ADJUSTER
(ZAXIS370MTH)
2 3 9 6 10 16 8 14 11 12
Chamber Chamber B Grease Outlet

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

2- O-Ring 6- U-Ring 10 - O-Ring 14 - Bracket
3- Guide 7- Retaining Ring 11 - Bolt 15 - Spring
4- Piston Rod 8- Rod 12 - Valve 16 - Spacer
W3-4-24
Assemble Track Adjuster
(ZAXIS370MTH)
4
1. Clean all the parts. Apply grease onto wear ring 5

(5) and U-ring (6). Install wear ring (5), U-ring (6),
6
and retaining ring (7) onto piston rod (4). Install 7
U-ring with the lip part facing to rod (8).
CAUTION: Rod (8) weight: 21 kg (50 lb)
2. Apply grease to O-ring (10). Install O-ring (10)

W166-03-04-001
onto cylinder (9). Install eyebolt (M16, Pitch 2.0 10
mm) into rod (8). Hoist and install rod (8) into cyl-
inder (9).
8
CAUTION: Piston rod (4) weight: 16 kg
9
(40 lb)
3. Fill chamber (B) in cylinder (9) with grease. Apply

hydraulic oil to the inner surface of cylinder (9)
and piston rod (4).
Install eyebolt (M10, Pitch 1.5 mm) into piston rod
(4). Hoist and install piston rod (4) into cylinder W142-03-04-012
(9).
Push piston rod (4) and completely release pres-
sure in chamber (B) and rod (8).
2
3
1
4. Fill chamber (A) in guide (3) with grease. Apply
grease to O-ring (2). Apply LOCTITE #262 to
4
Install O-ring (2) onto guide (3). Install guide (3)
onto cylinder (9) with socket bolts (1) (4 used).
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
W142-03-04-018
W3-4-25
9 16 8 14
Grease Outlet
W16J-03-04-003
4 15
W3-4-26
CAUTION: Bracket (14) weight: 22 kg (50 lb)

Spring (15) weight: 140 kg (310 lb)
9
5. Attach a nylon sling onto bracket (14). Hoist and
place bracket (14) and spacer (16) on the holder.
Hoist and place spring (15) onto bracket (14).
Fasten bracket (14) and spring (15) together by
using a wire.
16
CAUTION: Cylinder (9) assembly weight:

60 kg (130 lb) 15
6. Install eyebolt (M10, Pitch 1.5 mm) to piston rod Holder

14
(4). Hoist the cylinder (9) assembly. Align spacer
(16) with bracket (14) and install the cylinder (9)
assembly.
W142-03-04-007
CAUTION: Track adjuster weight:

250 kg (550 lb) 4
7. Attach a nylon sling to spring (15) and pass the

nylon sling through the eyebolt on piston rod (4).
Hoist and place the assembly horizontally and 15
slowly.
W142-03-04-006
8. Hoist and place the track adjuster on special tool

(ST 4932). Set rod (8) with its grease outlet down. ST 4932
Remove eyebolt.
W142-03-04-005
W3-4-27
8 15 14 11 12

Grease Outlet
24.5 in (Free Length 30.5 in) W16J-03-04-003
13
884 mm (35 in)
W3-4-28
9. Operate the cylinder of special tool (ST4932).
Remove a wire from spring (15). Compress
spring (15) until the specified spring length is ob-
tained. Slowly compress spring (15) while align-
ing the center of rod (8) with that of bracket (14)
by using a pry bar. Do not damage the threads 15
on rod (8). (Specified Spring Length: 620 mm
(24.5 in)) ST 4932
10. Align the matching marks made when disassem-

bling. 14
Install nut (13) to rod (8). Install bolt (11).
Check that the grease outlet in rod (8) align with
that in nut (13).
Wire
: 100 mm
: 17 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
11. Tighten valve (12).

: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft) W142-03-04-015
12. Retract the cylinder of special tool (ST 4932).
13
(550 lb) 8
13. Attach a sling belt to the track adjuster.

Hoist and remove the track adjuster from special
tool. 11
12
CAUTION: If only the track adjuster is trans-

ported, use a firm steel box and take any W142-03-04-020
other precautions in order to carry the track
adjuster safely.
W3-4-29
(Blank)
W3-4-30
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 Track” section
(W3-7-1).
that the tracks have already been removed.
Removal
CAUTION: Front idler weight:
W142-03-05-002
ZAXIS330, 330LC: 160 kg (350 lb)
ZAXIS350H, 350LCH: 160 kg (350 lb)
ZAXIS370MTH: 210 kg (460 lb)
CAUTION: The front idler may fly off due to 3
the strong spring force when removing the
track adjuster. Do not stand in the same di-
rection to remove the adjuster or where the
track adjuster flies off.
1
1. Pry and remove the front idler and yoke (2) from
2
track frame (3) by using a pry bar.
4
2. Attach sling belts to bearing (1) and yoke (2) 5 W17P-03-05-001
sections. Hoist and remove the front idler from

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

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

on wooden blocks as illustrated.
W105-03-05-003
Installation
1. Install the front idler in the reverse procedures 3
when removing. Clean and apply grease to the
bearing (1) sliding surface on track frame (3).
W17P-03-05-001
W3-5-1
DISASSEMBLE FRONT IDLER
2
3
6 1
6 8
4
5
4
3
9
1
10
11
W16J-03-05-001
14 13 12
1- Bearing (2 Used) 5- Axle 9 - Guard 12 - Yoke

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

washer (11) (3 used), and (14) (4 used)
are equipped for ZAXIS370MTH only.
W3-5-2
Disassemble Front Idler
1. Remove bolts (10) (3 used) and remove guard IMPORTANT: For handling of floating seal (3), re-
(9) from yoke (12). (ZAXIS370MTH only) fer to the section “Precautions for
: 19 mm Floating Seal Handling” on page
W1-1-4.
6. Remove bearing (1) from the upper side of idler
CAUTION: Yoke (12) weight: (7). Remove floating seals (3) (2 used) from both
ZAXIS330, 330LC, 350H, 350LCH: 25 kg sides of idler (7) and bearing (1).
(55 lb)
2. Attach a nylon sling to yoke (12) and hold yoke 1
(12). Remove bolts (13) (4 used). Remove yoke
(12). 3
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm 7
ZAXIS370MTH:
: 30 mm
3
3. Place idler (7) horizontally. Remove plug (8) from
the lower side and drain oil. 4
: 6 mm
5
4. Remove pin (2) from bearing (1) by using a bar
and hammer.
1
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH: W105-03-05-009
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)
Axle (5) weight: 28 kg (62 lb)
Bearing (1) weight: 14 kg (31 lb)
5. Put the matching marks on bearing (1) and axle

(5). Remove the axle (5) assembly from idler (7)
by using a press.
1 5
W105-03-05-008
W3-5-3
6 1
6
4
5
4
W16J-03-05-001
W3-5-4
CAUTION: Axle (5) assembly weight: IMPORTANT: Do not remove bushing (6) unless
ZAXIS330, 330LC, 350H, 350LCH: 32 kg necessary.
(71 lb) 9. When replacing bushing (6), remove bushing (6)
ZAXIS370MTH: 42 kg (93 lb) by using special tool and a press.
Special tool:
7. Wind a nylon sling onto the axle (5) assembly. ZAXIS330, 330LC, 350H, 350LCH: ST 1425
Hoist and place bearing (1) onto wooden blocks. ZAXIS370MTH: ST 1973
8. Remove pin (2) by using a bar and hammer.

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

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

W3-5-6
Assemble Front Idler
CAUTION: Idler (7) weight: CAUTION: Axle (5) assembly weight:

ZAXIS330, 330LC: 115 kg (250 lb) ZAXIS330, 330LC, 350H, 350LCH: 32 kg
ZAXIS350H, 350LCH: 115 kg (250 lb) (71 lb)
ZAXIS370MTH: 150 kg (330 lb) ZAXIS370MTH: 42 kg (93 lb)
1. Install bushing (6) into idler (7). 5. Wind a nylon sling onto bearing (1) of the axle (5)
assembly. Hoist and insert the axle (5) assem-
bly into idler (7) where floating seal (3) was in-
CAUTION: stalled. Apply LOCTITE #503 to plug (8).
ZAXIS330, 330LC, 350H, 350LCH: Install plug (8) into bearing (1).
Axle (5) weight: 17 kg (37 lb) : 6 mm
Bearing (1) weight: 15 kg (33 lb) : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
ZAXIS370MTH:
Axle (5) weight: 28 kg (62 lb) 7
Bearing (1) weight: 14 kg (31 lb) 3 1
2. Wind a nylon sling onto axle (5). Hoist and place

axle (5) vertically. Install O-ring (4) onto the upper
side of axle (5).
5
bling.
Evenly tap and install bearing (1) into axle (5) by
W157-03-05-006
using a plastic hammer. Insert pin (2) by using a
bar and hammer.
2
5
4 W105-03-05-014
IMPORTANT: For handling of floating seal (3), re-

fer to the section “Precautions for
Floating Seal Handling” on page
W1-1-4.
4. Apply grease to O-ring on floating seal (3). Install

a pair of floating seals (3) into idler (7) and bear-
ing (1).
W3-5-7
1 2 4 3 5 7 8 9 10
11
12
13
W16J-03-05-002
14

W3-5-8
12. Install spring washer (14) onto bolts (13) (4 used)
CAUTION: Idler (7) assembly weight: respectively. (ZAXIS370MTH only) Install yoke
ZAXIS330, 330LC: 115 kg (250 lb) (12) into bearing (1) on both sides with the bolts
ZAXIS350H, 350LCH: 115 kg (250 lb) (4 used).
ZAXIS330, 330LC, 350H, 350LCH:
6. Wind a nylon sling onto the idler (7) assembly. : 24 mm
Hoist and turn over the idler (7) assembly. : 210 N⋅m (21 kgf⋅m, 150 lbf⋅ft)
Install O-ring (4) onto axle (5). ZAXIS370MTH:
: 30 mm
7. Apply grease to O-ring of floating seal (3). Install : 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
the other floating seal (3) into idler (7) and bear-
ing (1). 13. Install spring washer (11) onto bolts (10) (3 used)
respectively. Install guard (9) onto yoke (12) with
1 3 4 7 the bolts (3 used). (ZAXIS370MTH only)
: 19 mm
1 : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W157-03-05-005

bling. Tap the other bearing (1) evenly by using a
plastic hammer. Install bearing (11) into axle (5).
Insert pin (2) by using a bar and hammer.
9. Add engine oil (API CD grade SAE30) through

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

ZAXIS330, 330LC, 350H, 350LCH:
0.3 L (0.32 US gt.)
ZAXIS370MTH:
0.45 L (0.48 US gt.)
10. Apply LOCTITE #503 to plug (8). Install plug (8)

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

ZAXIS330, 330LC, 350H, 350LCH: 25 kg
(55 lb)
11. Wind a nylon sling onto yoke (12). Hoist yoke

(12) and align the bolt (13) holes on yoke (12)
and bearing (1).
W3-5-9
C D
E
A W166-03-05-001
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 102 (402) [80.4 (3.17)] 102 (4.02) [92 (3.62)]
B 200 (7.87) － 200 (7.87) － Cladding by weld-
C 572 (22.51) [550.4 (21.77)] 630 (24.80) 610 (24) ing and finish or
D 617 (24.29) － 675 (26.57) － replace
E 22.5 (0.89) － 22.5 (0.89) －
Axle and Bushing

Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
Axle Outside Dia. 85.0 (3.35) 84.2(3.31) 110 (4.33) 109.2 (4.30)
Inside Dia 85.0 (3.35) 86.0 (3.39) 110 (4.33) 111 (4.37)
Replace
Bushing Flange
2.0 (0.08) 1.2 (0.05) 6.0 (0.24) 5.2 (0.20)
Thickness
NOTE: Values in [ ] are just for reference.
W3-5-10
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or too much as the valve may fly off
or high-pressure grease in the adjusting cyl-
inder may gush out.
Keep body parts and face away from the
valve and loosen the valve carefully.
Do not loosen grease fitting (2).
W105-03-06-001
IMPORTANT: Remove gravel or mud between
sprockets and tracks before loos- １
2
ening 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 and drain
grease.
: 24 mm
Grease Outlet
M116-07-094
Oil Jack 3
CAUTION: Use a nonskid cloth between
track frame (5) and oil jack in order not to
slip.
2. Jack up track (3) in order to get enough clear-

ance between upper roller (4) and track (3).
Nonskid Cloth 5 4
W105-03-06-002
3
3. Insert the wooden blocks between track (3) and
track frame (5).
Wooden Block
W105-03-06-003
W3-6-1
4. Remove bolts (6) (4 used) on upper roller (4).

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

ZAXIS330, 330LC, 350H, 350LCH: 25 kg
(55 lb)
4
5. Remove upper roller (4) from track frame (5).
5
W105-03-06-005
Installation
1. Install upper roller (4) onto track frame (5) with
bolts (6) (4 used).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm 4
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
ZAXIS370MTH:
: 27 mm
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft) 6
5
W157-03-06-001
3
2. Remove the wooden blocks and oil jack between

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

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

firmly by using wooden blocks.
4. Jack up the track to be adjusted. Rotate the track

M116-07-094
in reverse direction slightly.
5. Apply grease through grease fitting (2) and 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)
W157-03-06-002
IMPORTANT: Replace the upper roller as an as-
sembly.
6. Add engine oil (API CD class SAE30) to the plug 7
(8) hole in cover (7).
Engine oil amount:

ZAXIS330, 330LC, 350H, 350LCH:
75 mL (0.079 US gt.)
8
ZAXIS370MTH:
120 mL (0.13 US gt.)
7. Apply LOCTITE #503 to plug (8). Tighten plug

(8).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W158-03-06-001
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove the track guard. Remove bolts (1) (4 5
used) of lower roller (5).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm 1
ZAXIS370MTH:
: 32 mm
W105-03-06-008
2. Jack up one side of the track frame high enough 90° to 110°
(90° to 110° between boom and arm is obtained
when the bucket is lowered with the round bot-
tom contacting with ground). Insert the wooden
blocks under track frame (2) and support the
machine. 2 M104-07-067

or high-pressure grease in the adjusting cyl-
inder may gush out.
valve and loosen the valve carefully.
Do not loosen grease fitting (4). W105-03-06-001
4 3
IMPORTANT: It is enough to loosen valve (3) by 1
to 1.5 turns. Do not loosen the valve
over that degree.
3. Loosen valve (3) on the track adjuster. Drain
grease and adjust the track sag enough to permit
roller (5) to be removed.
: 24 mm
Grease Outlet
M116-07-094
W3-6-4
CAUTION: Lower roller weight:

ZAXIS330, 330LC, 350H, 350LCH:
54 kg (120 lb)
4. Remove lower roller (5) by using a fork lift.
W105-03-06-010
Installation
1. Set lower rollers (5) below track frame (2) by us-
ing a fork lift.
5
W105-03-06-011
2. Lower the machine so that track frame (2) may

keep a little away from collar (6).
6 W105-03-06-012
3. Align the bolt (1) holes and tighten bolts (1) (4

used).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm 1
: 670 N⋅m (68.5 kgf⋅m, 500 lbf⋅ft)
ZAXIS370MTH:
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft)
W105-03-06-008
W3-6-5
4 3
4. Tighten valve (3) on the track adjuster.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
Grease Outlet
M116-07-094
CAUTION: Support the jacked up machine
firmly by using wooden blocks.
5. Jack up the track to be adjusted. Rotate the track

in reverse direction slightly.
6. Apply grease through valve fitting (4) and adjust

tracks tension.
ZAXIS330, 330LC, 350H, 350LCH:

340 to 380 mm (13.4 to 15.0 in)
ZAXIS 370MTH:
380 to 430 mm (15.0 to 16.9 in)
W157-03-06-002
W3-6-6
(Blank)
W3-6-7
DISASSEMBLE LOWER ROLLER
4 5
6
3
3
4
W166-03-06-006
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-8
Disassemble Lower Roller
1. Remove plug (6) from the end of collar (4) and 4. Remove pin (5) from the axle (2) assembly.
drain oil. Remove axle (2) from collar (4) by using a press.
: 6 mm
3 4
2. Put the matching marks on collar (4) and axle (2).
Remove pin (5) from collar (4) at one side by us-
ing a round bar and hammer. Remove axle (2)
from roller (8) by using a press from the side
where pin (5) is removed. The pin and collar at
opposite are removed together.
2
Round Bar:
ZAXIS330, 330LC, 350H, 350LCH:
Dia. 14 mm (0.6 in)
ZAXIS370MTH: Dia. 25 mm (1 in)
4 1 8 1
W105-03-06-027
5. Remove O-rings (3) (2 used) from axle (2).

1
4 6. When replacing bushing (7), remove bushing (7)
by using special tool and a press.
Special tool:
ZAXIS330, 330LC, 350H, 350LCH: ST 1475
ZAXIS370MTH: ST 1955
2
W105-03-06-026
Special
IMPORTANT: For handling of floating seal (1), re- Tool
fer to the section “Precautions for
Floating Seal Handling” on page
W1-1-4.
3. Remove floating seal (1) from both sides of roller
(8) and collars (4) (2 used) respectively.
7
W105-03-06-028
W3-6-9
ASSEMBLE LOWER ROLLER
ZAXIS330, 330LC, 350H, 350LCH:
4 5 6
W1HH-03-06-001
8 2 7 1 3
ZAXIS370MTH:
4 5 6
W162-03-06-002
8 2 7 1 3
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-10
Assemble Lower Roller
1. Install bushings (7) (2 used) onto roller (8). Do 5. Insert axle (2) into roller (8). Install O-ring (3). In-
not dent the flange surface of bushing (7). Apply stall the other collar (4) with pin (5) in the same
grease to O-ring (3). Install O-ring (3) onto axle procedures.
(2).
6. Add engine oil (API CD class SAE30) through the
2. Align the matching marks made when disassem- plug (6) hole in collar (4).
bling.
Install one side of collar (4) onto axle (2) with pin Engine oil amount:
(5). Do not damage O-ring (3). ZAXIS330, 330LC, 350H, 350LCH:
0.42 L (0.44 US gt.)
5 ZAXIS370MTH: 0.5 L (0.53 US gt.)
2
3
into collar (4).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
5 8
4 4
W16J-03-06-001

to one side of collar (4).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W105-03-06-024
IMPORTANT: For handling floating seal (1), refer
to the section “Precautions for Han-
dling Floating Seal” on page W1-1-4.
4. Apply grease to O-ring (3) on floating seal (1). In-

stall floating seal (1) to roller (8) and collar (4).
8 1
1 4
W157-03-06-008
W3-6-11
Upper Roller
C
C
A A
B B
ZAXIS330, 330LC, 350H, 350LCH ZAXIS370MTH
W173-03-06-001
W166-03-06-007
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
A 98 (3.86) − 103 (4.06) −
Cladding by
B 165 (6.50) − 190 (7.48) − welding and fin-
ish or replace
C 120 (4.72) 110 (4.33) 160 (6.30) 150 (5.90)
Axle and Bushing
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
Axle Outside Dia. 45 (1.77) [44.2 (1.74)] 60 (2.36) [59.2 (2.37)]
Inside Dia. 45 (1.77) [46.0 (1.81)] 60 (2.36) [61 (2.37)] Replace

Bushing
Flange Thickness 2 (0.079) [1.2 (0.047)] 4.5 (0.177) [3.7 (0.146)]
W3-6-12
Lower Roller
D D
C A C
C A C
B
B
W1HH-03-06-002 W157-03-06-003
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS 370MTH
350H, 350LCH
Remedy
Standard Allowable Standard Allowable
Limit Limit
A 203(7.99) [229.5 (9.06)] 214 (8.43) [249 (9.80)]
B 256 (10.08) − 284 (11.18) − Cladding by

welding and fin-
C 26.5 (1.04) [13.25 (0.52)] 35 (1.38) [17.5 (0.69)] ish or replace
D 175 (6.89) [157 (6.18)] 200 (7.87) 182 (7.17)
Axle and Bushing
Unit: mm (in)
ZAXIS330, 330LC,
ZAXIS 370MTH
350H, 350LCH
Remedy
Allowable Allowable
Standard Standard
Limit Limit
Axle Outside Dia. 75 (2.95) [74.2 (2.92)] 85 (3.35) [84.2 (3.31)]
Inside Dia. 75 (2.95) [76 (2.99)] 85 (3.35) [86.0 (3.39)] Replace

Bushing
Flange Thickness 2 (0.079) [1.2 (0.047)] 6 (0.24) [5.2 (0.20)]
W3-6-13
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal

or high-pressure grease in the adjusting
cylinder may gush out.
valve and loosen the valve carefully. Do not
loosen grease fitting (2).
5
1. Rotate the tracks so that master pin (3) is
positioned over front idler (4).
Place a wooden block under shoe (5) and 4
support shoe (5).
W105-03-07-006
2. Loosen the track tension. Turn valve (1) in the

adjuster by one turn and drain grease from the 1
grease outlet.
: 24 mm
W105-03-07-002
1
2
Grease Outlet
M116-07-094
W3-7-1

the spring force when removing the track.
Particularly, a strong force is always applied
to the thread part of rod. If the rod and/or the
threads are damaged, metal fragments under
spring force may fly off.
3. ZAXIS330, 330LC, 350LCH: 7

Remove retaining ring (6) to prevent master pin
(3) from coming off.
3
NOTE: If retaining ring (6) interferes with master
link (7), push in master pin (3) in order to
make clearance between retaining ring (6)
and master pin (3). Remove retaining ring
(6). 6
ZAXIS370MTH: ZAXIS330, 330LC, 350H, 350LCH

Remove split pin (8) to prevent master pin (3) W105-03-07-009
from coming off.

NOTE: If split pin (8) interferes with master link (7),
push in master pin (3) in order to make 7
clearance between split pin (8) and master
pin (3). Remove split pin (8). 3
ZAXIS370MTH W166-03-07-001
W3-7-2
IMPORTANT: Master pin (3) is directional. Be sure
ST 1970
to install it in the correct direction.
4. Remove master pin (3) by using special tool (ST
1970).
W105-03-07-008
Direction for Split Pin

removing Corner
the master Direction for
pin. removing the
master pin.
3
3
Retaining Ring
Track Link
Master Link
ZAXIS330, 330LC, 350H 350LCH ZAXIS370MTH

W105-03-07-010
W166-03-07-002
CAUTION: Support the jacked up machine

Boom
firmly by using wooden blocks. Arm
5. Operate the boom and arm so that the angle

between them is 90 to 110 degrees. Lower the 90° to 110°
boom with the round bottom contacting with the
ground. Jack up the machine and remove the
track.
W105-03-07-012
6. Slowly operate the travel lever for the track to be

removed in the reverse direction. Extend and
remove the track.
W105-03-07-011
W3-7-3
Installation
1. Jack up the machine. Set the track under the

lower roller so that the sprocket meshes with the
track end. Sprocket
Check the direction of track. Idler Side Side
W105-03-07-013
2. Hoist and place the track on sprocket (8).
W105-03-07-014
3. With the machine jacked up, slowly operate the

lever for the track to be installed in the forward
direction. Turn travel device (9) and wind the
track. 9
W105-03-07-015
4. Wind the track until the connecting part of track

link reaches front idler (4). Lower the machine.
Place a wooden block under shoe (5) and
support shoe (5).
W105-03-07-016
Wooden Block
W3-7-4
5. Install special tool (ST 1970). Install master pin
ST 1970
(3) by using a hammer. 3
W105-03-07-017
Split Pin
Corner
Direction for
installing the Direction for
master pin. installing the
master pin.
3
3
Retaining Ring
Track Link
Master Link

W166-03-07-002
W105-03-07-010
IMPORTANT: Replace retaining ring (6) and split

pin (8) with new one. 7
6. ZAXIS330, 330LC, 350H, 350LCH:

Install retaining ring (6) to the groove of master
link (7) with the chamfered side for the plier
facing forward.
6
ZAXIS370MTH:
Install split pin (8).
ZAXIS330, 330LC, 350H, 350LCH W105-03-07-009
ZAXIS370MTH W166-03-07-001
W3-7-5
IMPORTANT: If disassembling the links, fill grease Bushing
Seal
(Daphne Epones SR) into the clear-
ance between the pin and bushing. Pin
Apply grease onto the bushing end.
Stand the bushing on a flat plate. Fill
the bushing bore with grease.
Insert the pin into the bushing while
pushing the bushing onto the plate
in order not to move because of
grease. After inserting the pin, wipe
off excess grease. Check the direc-
tion to install the seal. Grease
Do not Apply Do not Apply
Grease Grease
W197-03-07-001
Seal
1
7. Tighten valve (1) on the track adjuster. Apply

grease through grease fitting (2) and adjust the
tracks tension.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
8. Check the track sag after cleaning the track

frame and track.
Grease Outlet
Track sag specifications:
ZAXIS330, 330LC, 350H, 350LCH:
340 to 380 mm (13.4 to 15.0 in) M116-07-094
ZAXIS370MTH:
380 to 430 mm (15.0 to 16.9 in)
W105-03-07-018
W157-03-06-002
W3-7-6
Link
• Measure the length of four links as illustrated.

• Do not measure the master-pin-included part of
the track.
• Measure the length with tension on the track.
W155-03-07-001
Unit: mm (in)
Allowable Allowable
Standard Standard Remedy
Limit Limit
A 865.92 (34.09) 882 (34.72) 863.6 (34.00) 845.6 (33.29) Cladding by

welding and finish
B 116 (4.57) 109 (4.29) 129 (5.08) 122 (4.80) or replace
Master Pin
W105-03-07-021 A
W142-03-07-003
Unit: mm (in)
Allowable Allowable
Limit Limit
A 237 (9.33) − 308 (12.1) −
Replace
B 45 (1.77) [42 (1.65)] 47.3 (1.86) [44.3 (1.40)]
W3-7-7
Master Bushing
W105-03-07-023
Unit: mm (in)
Allowable Allowable
Limit Limit
A 148.3 (5.84) − 160.80 (6.33) −
B 45.45 (1.79) 48.5 (1.91) 47.90 (1.89) 50.90 (2.00) Replace
C 66.91 (2.63) 61.91 (2.44) 71.35 (2.81) 66.35 (2.61)
Grouser Shoe
W105-03-07-024
Unit: mm (in)
Shoe Size 600 mm Grouser Shoe

Allowable Allowable
Limit Limit
A 250 (9.84) − 247 (9.72) −
B 11 (0.43) − 13 (0.51) − Replace
C 30 (1.18) 20 (0.79) 36 (1.42) 21 (0.83)
W3-7-8
Bushing
W105-03-07-023
Unit: mm (in)
Allowable Allowable
Limit Limit
A 158.9(6.26) - 177(6.97) -
B 45.45(1.79) 46.5(1.83) 48.4(1.91) 49.43(1.95) Replace
C 66.91(2.63) 61.9(2.44) 71.35(2.81) 66.35(2.61)
Pin
W105-03-07-020
Unit: mm (in)
Allowable Allowable
Limit Limit
A 242(9.53) - 254(10.00) -
Replace
B 44.69(1.76) 41.7(1.64) 47.57(1.87) 44.57(1.76)
W3-7-9
(Blank)
W3-7-10
MEMO
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SECTION 4
FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment
Remove and Install Front Attachment .........W4-1-1
Maintenance Standard ................................W4-1-7
Standard Dimensions for
Arm and Bucket Connection....................W4-1-10
Standard Dimensions for
Arm and Boom Connection...................... W4-1-11
Group 2 Cylinder
Remove and Install Cylinder........................W4-2-1
Hydraulic Circuit Pressure
Release Procedure ..................................W4-2-13
Up to serial No.33099 and up

Disassemble Cylinder ................................W4-2-14
Assemble Cylinder .....................................W4-2-20
Maintenance Standard...............................W4-2-24
Serial No.33100 and up

Disassemble Cylinder ................................W4-2-26
Assemble Cylinder .....................................W4-2-32
Maintenance Standard...............................W4-2-36
1HHW-4-1
(Blank)
1HHW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT AT-
TACHMENT
1
Adapter
DRAULIC OIL TANK on W1-4-1.) Boom Cylinder
Removal
1. Remove pipe (1) of lubrication pipes to the front
attachment on the boss at the boom cylinder rod
side from the adapter. W105-04-01-002
(2 places on both left and right)

: 19 mm 3 2
2. Remove nuts (4) and stopper pin (6) from boom

cylinder rod front pin (3). Remove stopper (5).
(2 places on both left and right)
6 Boom Cylinder
: 30 mm
CAUTION: Boom cylinder weight:

320 kg (710 lb)
Metal fragments may fly off when
a hammer is used.
5
Wear necessary protection, such
as goggles, hard hat, etc in order 4
to prevent personal injury. W178-04-01-004
Check the direction to remove the

pins as the pins may fly off sud-
denly.
3. Hoist and hold the boom cylinder tube. By using

a bar and hammer tap pin (3) into the position
where thrust plate (2) can be removed. Remove
thrust plate (2).
NOTE: When pin (3) is impossible to remove, start

the engine and slightly operate the boom
lever. Adjust the boom cylinder rod pin
hole while hoisting/lowering the front
attachment.
W4-1-1
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 and lower the boom cylinder.
5. Remove the boom cylinder.

Refer to “Remove Boom Cylinder” (W4-2-10).
6. Remove the other boom cylinder in the same

procedures as steps 3 to 5.
7. After stopping the engine, push the air bleed

valve on the top of hydraulic oil tank and release Plate
any remaining pressure from the hydraulic oil
W157-04-01-005
tank. Remove the cap.
Completely release the residual pressure from
Air Bleed Valve
the hydraulic circuit. Refer to the “Hydraulic Cir-
cuit Pressure Release Procedure” (W4-2-15).
8. Remove hoses (7, 8) of the bucket cylinder and

arm cylinder. Cap the removed hoses and pipes.
: 36, 41, 50 mm
M157-07-173
7 8
W157-04-01-001
W4-1-2
9. Remove bolt (12), spring washer (13), plate (11),
and block (10) from the plate of boom foot pin (9). 9
: 27 mm
10
CAUTION: Front attachment weight: 11

ZAXIS330, 330LC: 6440 kg (14200 lb) 12
ZAXIS350, 350LCH: 7050 kg (15540 lb)
13
ZAXIS370MTH: 7120 kg (15700 lb)
W178-04-01-001
10. Attach a wire rope to the boom.

Slightly hoist the boom in order to take up any
wire rope slack.
11. Insert a pry bar between the plate of boom foot

pin (9) and the bracket. Slightly pull out the plate.
12. Turn the plate upward by hand. Turn the plate left
and right in order to pull out boom foot pin (9).
(Adjust the position of the boom foot pin hole
while hoisting/lowering the front attachment.)
W105-04-01-008
13. Hoist the front attachment and move the machine

backward. 9
14. Place the front attachment on wooden blocks.
Plate
Insert Bar
Bracket
W178-04-01-001
W178-04-01-005
W4-1-3
Installation
CAUTION: Front attachment weight:
ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH: 7120 kg (15700 lb)
1. Hoist the front attachment.

Move the machine forward and align the boom
foot pin holes.
Insert the thrust plates into both left and right
sides of boom and adjust the clearance between W178-04-01-005
9
the plate and frame within 1 mm.
(Adjust the position of the boom foot pin hole
while hoisting / lowering the front attachment.)
CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 10
tion, such as goggles, hard hats, etc in order 11
to prevent personal injury.
12
2. Install boom foot pin (9). Install stopper bolt (12), 13
washer (13), plate (11), and block (10).
: 27 mm W178-04-01-001
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
3. Remove the caps from hoses and pipes. Install

hoses (7, 8) of the bucket cylinder and arm cyl- 7 8
inder.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 50 mm
: 255 N⋅m (26 kg f⋅m)
W157-04-01-001
CAUTION: Boom cylinder weight: 320 kg

(710 lb)
4. Install the boom cylinder.

Refer to “Install Boom Cylinder” (W4-2-12).
Boom Cylinder
W105-04-02-040
W4-1-4

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury. 3 2
5. Hoist and hold the boom cylinder tube. Insert

thrust plates (2) (2 used). Install pin (3) and install
the boom cylinders to both sides.
6 Boom Cylinder
6. Install stopper (5) with stopper pin (6) and nuts

(4) (2 used). (2 places on both left and right)
: 30 mm
5
: 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)
4
W178-04-01-004
7. Install lubrication pipe (1) onto the boom cylinder

1
rod side. (2 places on both left and right)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W105-04-01-002
8. Apply grease to the boom cylinder rod side, bot-
tom side, and boom foot side.
Boom Cylinder
Rod Side
Boom Foot
Side
M157-07-155
9. Fill hydraulic oil to specified level. Start the en-
gine and check the connections for any oil leak-
age.
10. After completing the work, run each cylinder sev-

eral times to stroke end in order to release any
pressure in the circuit.
Boom Cylinder M157-07-156

Bottom Side
W4-1-5
IMPORTANT: When removing the arm from the
boom, perform the following steps
when installing the arm.
• Install thrust plates (14) into left and right sides of

arm. Adjust total clearance of left and right within 14 14
1.5 mm.
• After installing the arm, apply grease to grease

fitting (15) on the boom connecting boss of arm.
IMPORTANT: For handling of HN bushing for the

front attachment, pay attention to 15 15
following requirements.
Precautions for pressing the bushing in:

If a hammer is used to drive the bushing in, the bush-
ing may be damaged. Use a press.
Precautions when reinforcing the arm: M157-07-157
Welding heat for arm reinforcement may cause oil to

leak from the bushing and decrease lubrication per-
formance.
If oil leak occurs because of heated bushing after
welding, replace the bushing.
Special tools should be used to pull the bushing out or

press it in.
Tool: ST 1478
W4-1-6
Pin and Bushing
F E
G
C
H
D J
A
I
K
B
W105-04-01-018
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 110 (4.33) 109.0 (4.31)
A
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
B Boss (Main Frame) 110 (4.33) 111.5 (4.39)
Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
C Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
Boss (Boom) 110 (4.33) 111.5 (4.39)
Replace
Pin 110 (4.33) 109.0 (4.31)
D
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
E Boss (Arm) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
F Boss (Boom) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
W4-1-7
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 90 (3.54) 89.0 (3.50)
G Boss (Arm) 90 (3.54) 91.5 (3.60)
Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60)
Pin 100 (3.94) 99.0 (3.90)
H Bushing 100 (3.94) 101.5 (4.00)
Bushing (Bucket Cylinder) 100 (3.94) 101.5 (4.00)
Replace
Pin 90 (3.54) 89.0 (3.50)
I
Bushing 90 (3.54) 91.5 (3.60)
Pin 100 (3.94) 99.0 (3.90)
J
Bushing 100 (3.94) 101.5 (4.00)
Pin 100 (3.94) 99.0 (3.90)
K
Bushing 100 (3.94) 101.5 (4.00)
IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press.
W4-1-8
Side Cutter
C
D
W105-04-01-019
Unit: mm (in)
A 258 (10.2) 168 (6.61)
B 300 (11.8) 
Replace
C 400 (15.7) 
D 300 (11.8) 
Point
B C
W105-04-01-020
Unit: mm (in)
A 240 (9.45) 120 (4.72)
B 96 (3.78) 
Replace
C 130 (5.12) 
D 105 (4.13) 
W4-1-9
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section A Section B
T137-01-03-001
Unit : mm (in)
ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5
a 575 (22.6) ← ← ←
b 10 (0.39) ← ← ←
c 700 (27.6) ← ← ←
d 695 (27.4) ← ← ←
e －－－－
f 1661 (65.4) 1666 (65.6) ← 1661 (65.4)
g 581 (22.9) ← ← 573 (22.6)
h 442 (17.4) ← ← ←
i 100 (3.94) ← ← ←
j 578 (22.7) ← ← ←
k 90 (3.54) ← ← ←
l 581 (22.9) ← ← 573 (22.6)
m 420 (16.5) ← ← ←
n 100 (3.94) ← ← ←
o 8.85° ← ← ←
p 8.85° ← ← ←
q 592 (23.3) 600 (23.6) ← 592 (23.3)
W4-1-10
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5

s 90 (3.5) ← ← ←
t 418.5 (16.5) ← ← ←
u 571 (22.5) ← ← ←
IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals for previous model
machine.
W4-1-11
(Blank)
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
lic oil tank before doing any work. 1
Remove Bucket Cylinder 3

1. Insert wooden block (3) between bucket cylinder
(1) and arm (2). 2
3
2. Stop the engine. Push the air bleed valve and
release any remaining pressure from the hydrau- W554-04-02-006
lic oil tank. Remove the cap.

Release the bucket circuit pressure.
Refer to “Hydraulic Circuit Pressure Release
Procedure” on page W4-2-15.

a hammer is used.
Wear necessary protection, such as goggles,
hard hats, etc in order to prevent personal Link A 4 5
injury.
3. Fasten links A and B by using a wire in order not

to fall off before removing pin (7).
6
4. Remove nuts (6) (2 used) and stopper pin (4).

Remove pin (7) by using a round bar.
Link B
Remove thrust plates (5).
7
: 32 mm
1 W158-04-02-006
8
5. In order not to extend rod (8) of bucket cylinder
(1), pass wire (9) through the cylinder rod hole
and secure rod (8) to the bucket cylinder (1) tube.
9
W102-04-02-005
W4-2-1
6. Remove bucket cylinder hoses (12) (2 used) at
the bottom of bucket cylinder (1). Cap all open
ends.
: 41 mm
10
CAUTION: Bucket cylinder (1) weight: 255

kg 11
(560 lb)
15

a hammer is used.
Wear necessary protection, such as goggles, 13
hard hats, etc in order to prevent personal
injury.
1
7. Hoist bucket cylinder (1). Remove nuts (13) (2

used) and stopper pin (15). Remove pin (11).
Remove thrust plate (10). W1HH-04-02-009
: 30 mm 12
8. Remove bucket cylinder (1).
W4-2-2
Install Bucket Cylinder
IMPORTANT: When installing the bushing, if a
hammer is used, the bushing may
be damaged. Use a press.
CAUTION: Bucket cylinder (1) weight: 255 10

kg (560 lb)
CAUTION: When installing pin (11), metal 11
fragments may fly off by using a hammer.
Wear necessary protection, such as goggles, 15
hard hats, etc in order to prevent personal 14
injury.
1. Hoist bucket cylinder (1). Align the hole on cylin-

der tube side with the cylinder mounting hole on 13
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). 1
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft)
3. Install bucket cylinder hoses (12) (2 used). W1HH-04-02-009
Fill hydraulic oil to specified level. Start the en- 12

gine and check for any oil leaks
: 41 mm 1
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) 8
4. Remove wire (9) from rod (8) of bucket cylinder

(1).
9 W102-04-02-005
W4-2-3
CAUTION: Metal fragments may fly off when 16 4 17 5

5. Start the engine and operate the bucket lever.

Align the hole on cylinder rod side with those of
links (16, 18). Insert thrust plate (5) and pin (7).
7 18 6
W158-04-02-006
19 19
6. Insert stopper pin (4) into stopper (17) and pin (7).
Install nuts (6) (2 used).
: 32 mm
: 550 N⋅m (56.0 kgf⋅m, 405 lbf⋅ft)
W157-04-01-015
7. After completing the work, operate the bucket 18 18
cylinder several times to the stroke end and re-
lease the pressure in the circuit.
IMPORTANT: In case link (18) has been removed

from the arm, insert thrust plate (19)
when installing.
W4-2-4
Remove Arm Cylinder
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).

release any remaining pressure in the hydraulic
oil tank. Remove the cap.
Release arm circuit pressure.
Refer to “Hydraulic Circuit Pressure Release
4
3. Remove bolt (8) from pin (5) at the arm cylinder
(1) rod side. Remove spring washer (7) and plate
(6).
: 27 mm
1

tion, such as goggles, hard hats, etc in order 8 7 6 5 9 2 3 W1HH-04-02-001
4. Remove pin (5). Remove thrust plate (4). 1
5. In order not to extend rod (9) of arm cylinder (1),

10
pass a wire through the cylinder rod hole and
secure rod (9) to the arm cylinder (1) tube. 11
6. Remove hoses (10) (2 used) at the bottom of arm

cylinder (1). Cap all open ends.
: 41 mm, 50 mm
10
7. Remove lubrication pipe (11) from arm cylinder
(1). W1HH-04-02-002
: 19 mm
W4-2-5
12
CAUTION: Arm cylinder (1) weight: 460 kg
(1010 lb)
1
8. Attach a sling belt at the center of gravity of arm
cylinder (1). Hoist arm cylinder (1) and take up
sag.

tion, such as goggle, hard hats, etc in order
13
14
9. Remove bolt (16) from tube side pin (13) of arm 15 W1HH-04-02-004
cylinder (1). Remove spring washer (15) and 16

plate (14). Remove pin (13) and remove thrust
plates (12). Remove arm cylinder (1).
: 27 mm
W4-2-6
Install Arm Cylinder 12
IMPORTANT: When installing the bushing and if a

hammer is used, the bushing may 1
be damaged. Install the bushing by
using a press.
CAUTION: Arm cylinder (1) weight: 460 kg

(1010 lb)
1. Attach a sling belt at the center of gravity of arm

cylinder (1). Hoist arm cylinder (1). Align the cyl- 13
inder tube side hole with the cylinder mounting 14
hole on the boom. 15 W1HH-04-02-004
16

10
2. Insert thrust plate (12) and install pin (13). Install
plate (14) and spring washer (15) into pin (13) 11
with bolt (16).
: 27 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft)
3. Install lubrication pipe (11) and hoses (10) (2 10

used) of arm cylinder (1).
: 19 mm W1HH-04-02-002
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 50 mm
: 255 N⋅m (26 kgf⋅m, 190 lbf⋅ft)

gine and check for any oil leaks.
W4-2-7
5. Remove a wire from rod (9) of arm cylinder (1).
Hoist arm cylinder (1). Start the engine and oper- 4
ate arm lever. Align the hole on arm cylinder rod
17
side with the mounting hole on arm (17).

a hammer is used. Wear necessary protec- 1
6. Insert thrust plate (4) and install pin (5).

Install plate (6) and spring washer (7) into pin (5)
with bolt (8).
: 27 mm 8 7 6 5 9 W1HH-04-02-001
: 300 N⋅m (30.5 kgf⋅m, 220 lbf⋅ft)
7. When completing the work, operate the arm cyl-

inder several times to the stroke end and release
the pressure in the circuit.
W4-2-8
Remove Boom Cylinder 1
1. Remove lubrication pipes (1) from the boom cyl-
inder.
: 19 mm
CAUTION: Boom cylinder (2) weight: 315 kg

(690 lb)
2. Attach a wire rope onto boom cylinder (2). Hoist

boom cylinder (2).
W105-04-02-032
7
3. Remove nuts (5) (2 used), stopper pin (7), and
stopper (6) from the boom cylinder (2) rod. Re-
move pin (4).
Remove thrust plate (3).
: 30 mm
6
4. Place boom cylinder (2) on a support. Remove
the other boom cylinder in the same procedures. 5 3 4 3 2
W158-04-02-013
5. Operate the boom lever and retract the boom

cylinder.
In order not to extend the boom cylinder rod,
pass a wire through the cylinder rod hole and
secure the rod to the cylinder tube.

release any remaining pressure in the hydraulic
oil tank.
Release the circuit pressure.
Refer to “Hydraulic Circuit Pressure Release 2
W178-04-02-011
W4-2-9
7. Remove hoses (12) (4 used) at the bottom of
boom cylinder (2). Cap all open ends.
: 41 mm

to prevent personal injury. 2
W178-04-02-011
8. Remove bolt (8) at the cylinder tube side of main

frame. Remove spring washer (9) and plate (10). 2
Remove pin (11). 13
Remove thrust plate (13).
: 27 mm
CAUTION: Boom cylinder (2)weight: 315 kg

(690 lb)
9. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist and remove the boom
cylinder.
Remove the other boom cylinder in the same 11 10 9 8
procedures. 12 W1HH-04-02-003
W178-04-02-013
2
W4-2-10
Install Boom Cylinder
IMPORTANT: When installing the bushing and if a

hammer is used, the bushing may
be damaged. Install the bushing by
using a press.
CAUTION: Boom cylinder weight: 320 kg

(710 lb)
1. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist boom cylinder (2). Align
the pin hole at boom cylinder tube side with the
mounting hole on the main frame.
W178-04-02-013
2
2. Insert thrust plate (13) and pin (11). Install spring

washer (9) and plate (10) with bolt (8).
: 27 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
3. Install the other boom cylinder in the same pro-

cedures.
11 10 9 8
4. Install hoses (12) (4 used) onto boom cylinders
12 W1HH-04-02-003
(2) (2 used).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

gine and check for any oil leaks.
W4-2-11
6. Hoist boom cylinder (2). Operate the boom lever
and align the pin hole at cylinder rod side with the
mounting hole of boom cylinder.

tion, such as goggle, hard hats, etc in order
7. Install thrust plate (3). Install pin (4) and connect

boom cylinder (2) with the boom.
8. Install stopper (6), stopper pin (7), and nuts (5) (2

used).
6
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) 5
3 4 3 2
W158-04-02-013
9. Install lubrication pipes (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
1
10. Install the other boom cylinder in the same pro-
cedures.
11. When completing the work, operate the boom

cylinder several times to the stroke end and re-
lease the pressure in the circuit.
W105-04-02-032
W4-2-12
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
NOTE: Do not start the engine. Operate the pilot

pump by using the power from battery and
deliver the pilot pressure to the spool of
control valve.
1. Push the lock lever forward.
2. Pull the handle for stopping engine completely

and secure the handle.
Handle for Stopping Engine
IMPORTANT: Battery will deplete. Operate the key

switch for short period.
3. Turn the key switch to the START position. Oper-

ate the lever in order to release any pressure in
hydraulic circuit 4 to 5 times.
4. Reset the handle for stopping engine.
W178-04-02-010
W4-2-13
DISASSEMBLE CYLINDER
Boom Cylinder
Up to serial No.33099
1 2
3
4
8 5
9 6
10 7
11
12
13
14
15
13
12
17
18
16
W1HH-04-02-007
Bucket Cylinder
1 2
3
4
5
6
7
8
9 10
11
12 13
14
15
13
12
16
17
18
W1HH-04-02-006
1- Piston Rod 6- Bushing 11 - Cushion Ring 15 - Seal Ring

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 16 - Set Screw
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 17 - Nut
4- Seal 9- Cylinder Head 14 - Piston 18 - Cylinder Tube
5- Ring 10 - O-Ring
NOTE: Socket bolt (8) (9 used) are equipped for

the boom cylinder only.
W4-2-14
Arm Cylinder
2
3
4
5
8 6
9 7
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
1- Piston Rod 6- Bushing 11 - Cushion Ring 16 - Set Screw

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 17 - Nut
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 18 - Cylinder Tube
4- Seal 9- Cylinder Head 14 - Piston 19 - Cushion Ring
5- Ring 10 - O-Ring 15 - Seal Ring 20 - Plug
W4-2-15
Arm Cylinder
As the other hydraulic oil cylinders are very similar in
construction, the procedures of arm cylinder are
shown as an example.
2
3
4
5
8 6
9 7
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
NOTE: Cushion ring (19) and plug (20) are

equipped for the arm cylinder only.
W4-2-16
Disassemble Cylinders
As the other hydraulic oil cylinders are very similar in 3. Tap cylinder head (9) by using a plastic hammer.
construction, the procedures of arm cylinder are Remove cylinder head (9) and piston rod (1) from
shown as an example. cylinder tube (18).
Remove piston rod (1) straight in order not to
The disassembling procedure starts on the premise damage the sliding surfaces.
that the hydraulic lines and the bands securing
lines have been removed. 4. Secure piston rod (1) on special tool (ST5908).
Put the matching marks on piston rod (1) and nut
(17).
CAUTION: Cylinder weight:
Boom cylinder: 320 kg (710 lb)
ST 5908
Bucket cylinder: 255 kg (560 lb)
Arm cylinder: 460 kg (1010 lb)
1. Hoist and place the cylinder on a workbench

horizontally. Drain hydraulic oil from the cylinder.
W158-04-02-022
5. Remove cushion ring (19) and plug (20) from nut

(17). (arm cylinder only)
: 10 mm
W102-04-02-027
2. Fully extend piston rod (1). Support the piston

rod (1) end. 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 for
W4-2-17
2
3
4
5
6
9 7
10
11
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-18
6. As set screw (16) was mushroomed by using a
punch and hammer at two places after set screw
(16) had been screwed in, cut away its
mushroomed part by using a drill first. Remove
set screw (16).
: 6 mm (Boom, arm and bucket cylinder)
7. Remove nut (17) by using special tool (ST5908).

Remove piston (14).
Special tools when turning nut:
Boom cylinder : 120 mm (ST 3267)
Arm cylinder : 125 mm (ST 3268)
Bucket cylinder : 105 mm (ST 3266)
ST 5908
W158-04-02-022
8. Remove seal ring (15), wear rings (13) (2 used),

and teflon rings (12) (2 used) from piston (14).
When removing the seals, do not damage piston
(14).
9. Remove cushion ring (11) from piston rod (1).
10. Wind the tape onto the thread part of piston rod
(1) in order to protect the seal of cylinder head
(9). Remove cylinder head (9) from piston rod
(1).
11. Remove O-ring (10) and retaining rings (2, 7)

from cylinder head (9). Remove dust seal (3),
ring (5), seal (4), and bushing (6).
Special tools when removing bushing (6):
W4-2-19
ASSEMBLE CYLINDER
Arm Cylinder

construction, the procedures of arm cylinder are
shown as an example.
2 3 4 5 6 12 13 15 13 12 14
16 17
8 7 10 1 18 11
19
20
W1HH-04-02-008
1- Piston Rod 6- Bushing 11 - Cushion Ring 16 - Set Screw

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 17 - Nut
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 18 - Cylinder Tube
4- Seal 9- Cylinder Head 14 - Piston 19 - Cushion Ring
5- Ring 10 - O-Ring 15 - Seal Ring 20 - Plug
NOTE: Cushion ring (19) and plug (20) are

equipped for the arm cylinder only.
Socket bolts (8) (9 used) are equipped for
W4-2-20
Assemble Cylinder
1. Apply hydraulic oil onto the inside of cylinder

head (9). Install bushing (6) into cylinder head (9).
Special tools when installing bushing:
2. Face the grooves of ring (5) and seal (4) to piston

(14).
Install ring (5), seal (4), and retaining ring (7) to
cylinder head (9).
3. Install dust seal (3) to cylinder head (9) by using

a plastic hammer.
Special tools when installing dust seal:
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).

(1) in order to protect the seal of cylinder head
(9). Install the cylinder head (9) assembly to
piston rod (1).
7. Install cushion ring (11) to piston rod (1) with “R”

part facing to cylinder head (9). Install the piston
(14) assembly to piston rod (1).
W4-2-21
16 17
8 1 18
19
20
W1HH-04-02-008
W4-2-22
8. Secure piston rod (1) on special tool (ST 5908). 11. Secure cylinder tube (18) horizontally on a
Align the matching marks made when workbench. Align the piston rod (1) assembly
disassembling and tighten nut (17). with the center of cylinder tube (18). Insert the
Special Tools when turning nut: piston rod (1) assembly into cylinder tube (18) in
: Boom cylinder: 8825±883 N⋅m order to not to damage the rings.
(900±90 kg f⋅m, 6500±650 lbf⋅ft)
120 mm (ST 3267) 12. Install cylinder head (9) to cylinder tube (18) with
Arm cylinder: 21867±2187 N⋅m : 19 mm
(2230±223 kg f⋅m, 16100±1610 lbf⋅ft) : 834±83 N⋅m
125 mm (ST 3268) (85±8.5 kgf⋅m, 615±62 lbf⋅ft)
(Boom cylinder, Bucket cylinder)
Bucket cylinder: 10003±1000 N⋅m : 1226±123 N⋅m
(1020±102 kg f⋅m, 7380±740 lbf⋅ft) (125±12.5 kgf⋅m, 905±90 lbf⋅ft)
105 mm (ST 3266) (Arm cylinder)
ST 5908
NOTE: Socket bolts (8) (9 used) are equipped for
W158-04-02-022
9. Tighten nut (17) with set screw (16).

Mushroom the head of set screw (16) at two
places by using a punch.
: 6 mm
: 63.7±6.4 N⋅m
(6.5±0.65 kgf⋅m, 47±4.7 lbf⋅ft)
10. Install cushion ring (19) to piston rod (1) with “R”
part facing to plug (20) by using plug (20). (arm
cylinder only)
: 10 mm
: 109.8±11 N⋅m
(11.2±1.1 kgf⋅m, 181±8 lbf⋅ft)
W4-2-23
Wear to Outer Diameter of Rod Rod Bend and Run Out
Dial Gauge
A
Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
Unit: mm (in) V Block
Cylinder Recommended Size After

Name Re-manufacturing (A) Unit: mm (in)
-0.036 -0.001
Boom 105 (4.13 ) Bend Run Out Remedy
-0.090 -0.004
-0.036 -0.001 Allowable
Arm 115 (4.53 ) 0.5 (0.020) 1.0 (0.039) Repair
-0.090 -0.004 limit
-0.036 -0.001 Allowable
Bucket 95 (3.74 ) 1.0 (0.039) 2.0 (0.079) Replace
-0.090 -0.004 limit
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder Allowable
Standard Inner Diameter (C) Remedy
Name Limit
+0.180 +0.007
Boom 110 ) (4.33 ) +0.3 (+0.012) Replace
+0.115 +0.005
C
+0.180 +0.007
Arm 120 ) (4.72 ) +0.3 (+0.012) Replace
+0.115 +0.005
+0.165 +0.006
Bucket 100 ) (4.72 ) +0.3 (+0.012) Replace
+0.100 +0.004
W4-2-24
(Blank)
W4-2-25
DISASSEMLBE CYLINDER
Boom Cylinder 12
Bucket Cylinder 13
12
Serial No. 33100 and up 11
10
9
8
7
6
5
4
3
2
15
14
Boom Cylinder
24
19
20
22
21
20
19
17
18
17
16
23
Bucket Cylinder
*24
W1HH-04-02-014
1- Piston Rod 7- Bushing 13 - O-Ring 19 - Ring (2 Used)

2- Snap Ring 8- Snap Ring 14 - Bolt (12 Used) 20 - Wear Ring (2 Used)
3- Dust Seal 9- Backup Ring 15 - Washer (12 Used) 21 - Piston Ring
4- Slide Ring 10 - O-Ring 16 - Cushion Ring 22 - Piston
5- Cylinder Head 11 - Collar 17 - Backup Ring (2 Used) 23 - Set Screw
6- Buffer Ring 12 - Backup Ring (2 Used) 18 - O-Ring 24 - Cylinder Tube
NOTE: The items without mark * are same.
W4-2-26
Arm Cylinder
Serial No. 33100 and up
15
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
18
17
27
22
23
25
24
23
22
20
21
20
19
26
W1HH-04-02-012
1- Piston Rod 8- Cylinder Head 15 - Backup Ring 22 - Ring (2 Used)

2- Cap 9- Buffer Ring 16 - O-Ring 23 - Wear Ring (2 Used)
3- Ball (12 Used) 10 - Bushing 17 - Bolt (12 Used) 24 - Piston Ring
4- Plunger 11 - Snap Ring 18 - Washer (12 Used) 25 - Piston
5- Snap Ring 12 - Backup Ring 19 - Cushion Ring 26 - Set Screw
6- Dust Seal 13 - O-Ring 20 - Backup Ring (2 Used) 27 - Cylinder Tube
7- Slide Ring 14 - Collar 21 - O-Ring
W4-2-27
Arm Cylinder
Serial No. 33100 and up

construction, the procedures of arm cylinder are shown
15
as an example 16
.
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
18
17
27
22
23
25
24
23
22
20
21
20
19 26
W1HH-04-02-012
NOTE: Cap (2), balls (3) (12 used) and plunger (4)
are equipped for the arm cylinder only.
W4-2-28
Disassemble Cylinder
• As the other hydraulic oil cylinders are very IMPORTANT: As set screw (26) was crimped by
similar in construction, the procedures of arm using a punch and hammer at two
cylinder are shown as an example. places after set screw (26) had been
screwed in, cut away its crimped
The disassembling procedure starts on the premise part by using a drill first.
that the hydraulic lines and the bands securing lines 4. Remove set screw (26).
have been removed. : 6 mm (Boom, arm and bucket)
CAUTION: Cylinder weight: 5. Remove the piston (25) assembly from piston rod
Boom cylinder: 320 kg (710 lb) (1).
Arm cylinder: 460 kg (1020 lb)
Bucket cylinder: 255 kg (570 lb) 6. Remove cap (2) from the upper surface of piston
rod (1) end. Remove balls (3) (12 used) from the
1. Hoist and place the cylinder on a workbench open part by using a magnet.
horizontally. Drain hydraulic oil from the cylinder.
7. Remove plunger (4) from piston rod (1).
W102-04-02-027
2. Fully extend and support piston rod (1). Remove

bolts (17) (12 used) and washers (18) (12 used)
from cylinder head (8).
: 30 mm (Boom, bucket)
: 36 mm (Arm)
IMPORTANT: Remove piston rod (1) straight in

order not to damage the sliding
surfaces.
3. Tap and remove cylinder head (8) with piston rod

(1) together from cylinder tube (27) by using a
plastic hammer.
W4-2-29
13
12
11
10
9
8
7
6
5
4
3
2
25
24
23
22
20
21
20
19
W1HH-04-02-012
W4-2-30
IMPORTANT: When removing the rings, do not
damage piston (25).
8. Remove piston ring (24), wear rings (23) (2 used)
and rings (22) (2 used) from the piston (25)
assembly.
9. Remove O-ring (21), backup ring (20) and

cushion ring (19) from piston rod (1).
(1) in order to protect the seal of cylinder head (8).
Remove cylinder head (8) from piston rod (1).
11. Remove the collar (14) assembly from piston rod

(1).
12. Remove O-ring (13) and backup rings (12) (2

used) from the collar (14) assembly.
13. Remove the cylinder head (8) assembly from

piston rod (1).
14. Remove O-ring (13), backup ring (12), snap ring

(5), dust seal (6), slide ring (7) and buffer ring (9)
from cylinder head (8). Remove snap ring (11)
and bushing (10) from cylinder head (8).
Special tools when removing bushing:
Boom 110 mm (ST 1399)
Arm 110 mm (ST 1399)
Bucket 100 mm (ST 1288)
W4-2-31
ASSEMBLE CYLINDER
Arm Cylinder
As the other hydraulic oil cylinders are very
similar in construction, the procedures of arm
cylinder are shown as an example.
5 6 7 9 10 22 23 24 23 22
17, 18 12, 13 11 15, 16 14 19 20, 21 2 3
W1HH-04-02-027
1 8 27 25 26 4
1- Piston Rod 8- Cylinder Head 15 - Backup Ring 22 - Ring (2 Used)

2- Cap 9- Buffer Ring 16 - O-Ring 23 - Wear Ring (2 Used)
3- Ball (12 Used) 10 - Bushing 17 - Bolt (12 Used) 24 - Piston Ring
4- Plunger 11 - Snap Ring 18 - Washer (12 Used) 25 - Piston
5- Snap Ring 12 - Backup Ring 19 - Cushion Ring 26 - Set Screw
6- Dust Seal 13 - O-Ring 20 - Backup Ring (2 Used) 27 - Cylinder Tube
7- Slide Ring 14 - Collar 21 - O-Ring
W4-2-32
Assemble Cylinder
IMPORTANT: Apply hydraulic oil onto the inside of

cylinder head (8).
1. Install bushing (10) to cylinder head (8).
Special tool when installing bushing:
Boom 110 mm (ST 2393)
Arm 110 mm (ST 2393)
Bucket 100 mm (ST 2360)
2. Install slide ring (7) and buffer ring (9) to cylinder

head (8).
3. Install dust seal (6) to cylinder head (8) by using a

plastic hammer.
Special tools when installing dust seal:
Boom (ST 2392)
Arm (ST 2672)
Bucket (ST 2357)
4. Install backup ring (12), O-ring (13) and snap

rings (5, 11) to cylinder head (8).

(1) in order to protect the seal of cylinder head (8).
Install the cylinder head (8) assembly to piston
rod (1).
6. Install the cylinder head (8) assembly to piston

rod (1).
7. Install backup ring (15) and O-ring (16) to collar

(14).
8. Install the collar (14) assembly to piston rod (1).
W4-2-33
22 23 24 23 22
17, 18 19 20, 21 2 3
W1HH-04-02-027
1 8 27 25 4
W4-2-34
9. Install piston ring (24), wear rings (23) (2 used)
and rings (22) (2 used) to piston (25).
10. Install the piston (25) assembly to piston rod (1).
11. Install cushion ring (19) onto piston rod (1).
12. Install plunger (4), balls (3) (12 used) and O-ring
(21) to piston (25).
13. Install backup rings (20) (2 used) and O-ring (21)

to piston (25).
IMPORTANT: Align with the center of cylinder tube

(18) and insert the piston rod (1)
assembly in order not to damage the
rings.
14. Secure cylinder tube (27) horizontally on a

workbench. Insert the piston rod (1) assembly into
cylinder tube (27).
15. Install cylinder head (8) to cylinder tube (27) with

bolts (17) (12 used) and washers (18) (12 used).
: 30 mm
: 529.7±78.5 N⋅m
(54.8± kgf⋅m, 390±57.5 Ibf⋅ft)
(Boom, bucket)
: 36 mm
: 892±137 N⋅m
(91±14 kgf⋅m, 658±101Ibf⋅ft)
(Arm)
W4-2-35
Wear to Outer Diameter of Rod Rod Bend and Run Out
Dial Gauge
A Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
V Block
Unit: mm (in)
Cylinder Recommended Size After
Name Re-manufacturing (A) Unit: mm (in)
-0.036 -0.001 Bend Run Out Remedy
Boom 105 (4.134 -0.004
)
-0.090
Allowable
Arm 115
-0.036
(4.528
-0.001
) 0.5 (0.020) 1.0 (0.039) Repair
-0.090 -0.004 limit
Allowable
Bucket 95
-0.036
(3.74
-0.001
) 1.0 (0.039) 2.0 (0.079) Replace
-0.090 -0.004 limit
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder Allowable
Standard Inner Diameter (C) Remedy
Name Limit
+0.250 +0.01
Boom 110 ) (4.331 ) +0.3 (+0.012) Replace
+0.050 +0.002
C
+0.250 +0.01
Arm 110 ) (4.331 ) +0.3 (+0.012) Replace
+0.050 +0.002
+0.250 +0.01
Bucket 100 ) (3.937 ) +0.3 (+0.012) Replace
+0.050 +0.02
W4-2-36
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 Block .......................................... 6A-106
Sealant Application .................................... 0A-36
Engine Cooling
Service Information Service Precaution .......................................6B-1
Identification ................................................ 0B-1
General Description .....................................6B-2
Lubrication System ...................................... 0B-2
Thermostat ...................................................6B-3
Fuel System................................................. 0B-2
Water Pump .................................................6B-6
Cooling System............................................ 0B-6
Valve Clearance Adjustment ........................ 0B-6 Engine Fuel
Compression Pressure Measure.................. 0B-8
Service Precaution .......................................6C-1
Recommended Lubricants ........................... 0B-9
General Description .....................................6C-2
Engine Oil Viscosity Chart ........................... 0B-9
Fuel Filter .....................................................6C-5
Injection Nozzle............................................6C-7
Engine Mechanical Injection Pump ...........................................6C-17
Service Precautions ..................................... 6A-2
Injection Pump Calibration Data .................6C-18
General Description ..................................... 6A-2
Turbocharger ............................................... 6A-4 Starting and Charging
Exhaust Manifold ......................................... 6A-5
Service Precaution .....................................6D3-1
Intake Cover ................................................ 6A-7
Alternator ...................................................6D3-2
Water Pump ................................................. 6A-9
Starter Motor ............................................ 6D3-11
1HHW-5-1
Engine Lubrication
Service Precaution.......................................6G-1
General Description .....................................6G-2
Oil Pump ......................................................6G-4
Oil Coolor.....................................................6G-8
Oil Port Cover ............................................ 6G-11
Engine Induction
Service Precaution........................................6J-1
Turbocharger ................................................6J-2
Troubleshooting ............................................6J-4
Inspection and Repair ...................................6J-6
1HHW-5-2
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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
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
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What is the purpose of this manual?

What is the purpose of this manual?

What safety symbols are used in the manual?

What safety symbols are used in the manual?

Manual No.

330 • 330LC • 350H • 350LCH • 370MTH Excavator Workshop Manual

PRINTED IN SINGAPORE (PS) 2005.06

Zaxis330/350/370-WSM 1 1/7/05, 16:28

• Each page has a number, located on the center

Consecutive Page Number for Each Group

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are

• Some safety signs don’t use any of the

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with per-

• NOTE indicates an additional explana-

• Carefully read and follow all safety signs on the

• Safety signs should be installed, maintained and

• If a safety sign or this manual is damaged or

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

• Wear close fitting clothing and safety equipment

You may need:

Respirator or filter mask.

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full atten-

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause im-

• Wear a suitable hearing protective device such

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

• Before entering the cab, thoroughly remove all

• Don’t leave parts and/or tools lying around the

• Avoid storing transparent bottles in the cab. Don’t

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

• After using the ashtray, always cover it to extin-

• Don’t leave cigarette lighters in the cab. When

• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount

• Be careful of slippery conditions on platforms,

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly