7-1. Disassembly and Assembly

SECTION 7 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ------------------------------------------------------------------------------------------------------ 7-1

Group 2 Tightening Torque ------------------------------------------------------------------------------------------ 7-4
Group 3 Pump Device -------------------------------------------------------------------------------------------------- 7-7
Group 4 Main Control Valve ----------------------------------------------------------------------------------------- 7-33
Group 5 Swing Device ------------------------------------------------------------------------------------------------- 7-47
Group 6 Travel Device -------------------------------------------------------------------------------------------------- 7-63
Group 7 RCV Lever ------------------------------------------------------------------------------------------------------ 7-90
Group 8 Turning Joint --------------------------------------------------------------------------------------------------- 7-104
Group 9 Boom, Arm and Bucket Cylinder ------------------------------------------------------------------- 7-109
Group 10 Undercarriage ------------------------------------------------------------------------------------------------ 7-128
Group 11 Work Equipment -------------------------------------------------------------------------------------------- 7-141
SECTION 7 DISASSEMBLY AND ASSEMBLY
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15 Taper 1/8
14 14 11.5 18
øD ød
16 16 13.5 20
18 18 15 22
L
20 20 17 25
22 22 18.5 28
24 24 20 30
27 27 22.5 34
7-1
2. INSTALL WORK
1) Tighten all bolts and nuts (sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound (LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove (check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100 mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (the air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
※ the work equipment.
Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
7-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.
7-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt (engine-Bracket) M10 × 1.5 6.0±1.4 43±10.0
2 Engine mounting bolt (bracket-Frame) M12 × 1.75 12.3±1.5 89±10.9
Engine
3 Radiator mounting bolt, nut M10 × 1.5 6.9±1.4 50±10.0
4 Coupling mounting bolt M12 × 1.75 9.25±0.25 67±1.8
5 Main pump mounting bolt M12 × 1.75 9.5±1.9 69±14.0
6 Main control valve mounting bolt M10 × 1.5 6.9±1.4 50±10.0
Hydraulic
7 Fuel tank mounting bolt M12 × 1.75 12.8±3.0 93±22.0
system
8 Hydraulic oil tank mounting bolt M12 × 1.75 12.8±3.0 93±22.0
9 Turning joint mounting bolt, nut M10 × 1.5 6.9±1.4 50±10.0
10 Swing motor mounting bolt M14 × 2.0 19.6±2.9 142±21.0
11 Swing bearing upper mounting bolt M12 × 1.75 13.3±2.0 96.2±14.5
Power
12 train Swing bearing lower mounting bolt M12 × 1.75 12.8±2.0 93±14.5
system
13 Travel motor mounting bolt M12 × 1.75 13.8±2.0 100±14.0
14 Sprocket mounting bolt M12 × 1.75 12.3±1.2 89±8.7
15 Under Carrier roller mounting bolt, nut M12 × 1.75 12.3±1.2 89±8.7
16 carriage Track roller mounting bolt M18 × 2.0 41.3±3.0 299±22.0
17 Counter weight mounting bolt M20 × 2.5 57.9±8.7 419±62.9
18 Others Cab mounting bolt, nut M12 × 1.75 12.8±3.0 92±22.0
19 Operator's seat mounting bolt M 8 × 1.25 2.5±0.5 18.1±3.6
※ For tightening torque of engine and hydraulic components, see each component disassembly and assembly.
7-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
7-5
2) PIPE AND HOSE (FLARE type)
Thread size (PF) Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE (ORFS type)

Thread size (UNF) Width across flat (mm) kgf·m lbf·ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
7-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping
(3) Loosen the breather slowly to release the 13031GE18
pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury. 48
47
(4) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic A1
A2
79
tank.
· Hydraulic tank quantity : 37ℓ A3
(9.8 U.S.gal) 80 A4
54
(5) Disconnect hoses (79, 80) and remove 28
connectors (47, 48).
21
(6) Disconnect pilot line hoses (21, 90) and 49 9
remove connectors (49, 50). 90
(7) Remove socket bolts (28) and disconnect
pump suction tube (9). R35Z77MP101
※ When pump suction tube is disconnected,

the oil inside the piping will flow out, so
catch it in oil pan.
(8) Sling the pump assembly and remove the
pump mounting bolts.
· Weight : 25 kg (55 lb)
※ Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.
7-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug (1EA).
② Tighten plug lightly.
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling (3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
7-8
2. MAIN PUMP
1) STRUCTURE (TYPE 1)
1-8 9-6
1-5
9-2
1-6
1-1 9-5
21
1-4
1-7
12 5-9 4-4
11 5-4
8 5-8 9-8 9-9
9-4
14-4 4-1 9-3
14-1 5-8
9-1
14-3
14-2 5-3 9-7
14-11
14-11 5-7
4-9
14-10 5-2 16-5
5-54 16-2 7-30
5-44 16-6
5-34 16-3
4-7 16-4
19
16-1 7-21
4-6 4-12
18 7-16
3-8 7-21
3-5 7-14
5-10 7-11
3-6 3-7 4-3 4-6
5-1 4-2 4-10 7-10 7-4
4-10
7-7
3-2
2-1 3-4 6-7
6-21 7-17
6-8 4-5
3-3 6-4 7-5
2-3 6-9
3-1 6-3
2-2 6-22 7-19
7-17
6-20
6-1 7-3
7-6
6-2
7-15 7-7
2-5
2-4 22
7-12
7-18 R35Z77MP102
1 Shaft assy 3 Rotary group 4-4 Socket head screw 5-8 Socket head screw 6-9 Coned disc spring 7-14 O-ring 14-2 Distance piece 9-7 Thrust plate
1-1 Shaft 3-1 Piston assy 4-5 Packing 5-9 Hex nut 6-20 Shim 7-15 O-ring 14-3 Coned disc spring 9-8 Spring pin
1-4 Ring 3-2 Cylinder block 4-6 Plug 5-10 Guide 6-21 Shim 7-16 Square ring 14-4 Retaining ring 9-9 Plate
1-5 Ring retaining 3-3 Retainer 4-7 Bearing 5-34 Shim 6-22 Shim 7-17 Square ring 14-5 Shim 16 Relief valve assy
1-6 Key 3-4 Guide 4-9 Socket head screw 5-44 Shim 7 Gear pump 7-18 O-ring 14-6 Shim 16-1 Spool
1-7 Shim 3-5 Spring 4-10 plug 5-54 Shim 7-3 Housing 7-19 Bolt 14-7 Shim 16-2 Adjust screw
1-8 Shim 3-6 Pressure pin 4-12 Orifice 6 Control piston assy 7-4 Cover 7-21 Socket head screw 9 Trochoid pump assy 16-3 O-ring
2 Swash plate assy 3-7 Spring seat 5 Spring seat assy 6-1 Sleeve 7-5 Gear 7-30 Name plate 9-1 Gear 16-4 Spring
2-1 Swash plate 3-8 Retaining ring 5-1 Spring seat 6-2 Parallel pin 7-6 Gear 8 Housing assy 9-2 Case 16-5 Nut
2-2 Suction side guide 4 Port plate assy 5-2 Spring seat 6-3 Distance piece 7-7 Thrust plate assy 11 Oil seal 9-3 Thrust plate 16-6 Spring seat
2-3 Suction side bushing 4-1 Port plate 5-3 Cover 6-4 Piston 7-10 Plate 12 Bearing 9-4 O-ring 18 Spring
2-4 Delivery side guide 4-2 Control plate 5-4 Adjusting screw 6-7 O-ring 7-11 Guide 14 Stopper assy 9-5 Spring pin 19 Spring
2-5 Delivery side bushing 4-3 Parallel pin 5-7 O-ring 6-8 O-ring 7-12 Coupling 14-1 Guide 9-6 Socket head screw 21 Air vent valve
22 Plug
7-9
STRUCTURE (TYPE 2)
25 33 18 39 51 8 7 9 6 4 14 24 13 15 19 2,44 62 61 60 69 67 66 65,68,70
1,20,42,43
22
21
12
34
32
30
36 26 33 10 11 35 31 5 56 27 40 49 71 72
35Z9A7MP102
1 Body S 10 Swash plate 21 Rod G 33 Dish spring 49 Plug 68 Screw

2 Body H 11 Needle 22 Rod C 34 Snap ring 51 Plug 69 O-ring
3 Shaft 12 Ball 24 Retainer 35 Snap ring 56 Spring pin 70 Washer
4 Cylinder barrel 13 Packing 25 Stopper pin A 36 Snap ring 60 Screw 71 O-ring
5 Valve plate 14 Spring C 26 Stopper pin B 39 O-ring 61 Nut 72 O-ring
6 Piston 15 Spring T1 27 Pin 40 O-ring 62 Seal washer
7 Shoe 18 Spring holder 30 Ball bearing 42 Plug 65 Gear pump
8 Shoe holder 19 Spring guide 31 Needle bearing 43 O-ring 66 Coupling
9 Barrel holder 20 Pin 32 Oil seal 44 Screw 67 Collar
7-9-1
7-10
- DISASSEMBLY AND ASSEMBLY (TYPE 1) : Refer
Refer to page 7-10~7-32.
2) NECESSARY TOOLS AND JIGS
The following tools and jigs are necessary to disassemble and reassemble the pump.
(1) Tools
Tool name Size Quantity

Hexagon socket screw key One each 4, 6, 8, 10
Spanner One each 14, 24
Plastic hammer 1 Medium size
Pliers for retaining ring 1 For hole (retaining ring for 22)
Pliers for retaining ring 1 For shaft (retaining ring for 20)
Wrench which can tighten at the
Torque wrench -
specified torque
Grease Small amount -
Adhesives Small amount Loctite (high tack sealant #98)
(2) Jigs
① Disassemble table 110 or more
35 ~ 55
This is a plate to stand the pump facing
downward.
A square block may be used instead of 55 or more
the shaft and does not contact.
R35Z77MP98
② Jigs for disassemble the port plate

Jigs are necessary to protect the shaft,
when disassembly and assembly the Hexagon socket
port plate. set screw
17
Disassembly 20
When hexagon socket head cap screws
(4 pieces of size M12) are removed, the 135
jig is necessary to prevent the port plate 15
8
from lifting up diagonally due to the
control spring. 66 320
Assembly
The jig is necessary to install the port 130
plate parallel to the housing mounting
surface.
The structure of the jig is shown as right. 55 or more
It can hold the port plate by means of 103 ~ 105
applying the machined edge* of the
hexagon socket set screw (M16×150) to
the adjusting screw. R35Z77MP99
※ When the hex socket set screw is used,

apply the machining work on the edge to
shape it in size the dia of 8 mm from the
top edge to 15 mm position.
7-10
3) CAUTIONS DURING DISASSEMBLING AND ASSEMBLING
(1) Cautions for disassembling
① Never attempt operating the adjusting screw unless absolutely necessary.
② Take utmost care during disassembly not to knock or drop each part.
(2) Cautions for disassembling
① Wash each part thoroughly.
② During assembling, take utmost care not to damage the part or allow foreign materials to enter.
③ As a rule, the O-ring and oil seal should not be reused.
④ In our assembly work, the torque wrench is used to control the torque.
Be sure to use torque wrench.
7-11
3. DISASSEMBLING PROCEDURE
1) DISASSEMBLING THE GEAR PUMP
(1) Remove the hexagon socket head cap
screw. (M10×25, 2 pieces)
Hexagon socket screw key (8 mm)
※ Be careful because the O-ring (at 2
pieces) are provided to the housing.
R35Z77MP01
(2) Remove the coupling.
R35Z77MP02
2) DISASSEMBLING THE TROCHOID

PUMP
R35Z77MP03
(2) Remove the case, the side plate (A), and

the gear.
Use the hexagon socket head cap
screws.
For example : M5×90, 2 pieces
M5
R35Z77MP04
7-12
(3) Remove the gear from the case.
R35Z77MP06
(4) Remove the side plate (A) from the case.
R35Z77MP07
(5) Remove the side plate (B) from the port

plate.
R35Z77MP08
(6) Remove the key of the shaft.
R35Z77MP09
7-13
3) DISASSEMBLING THE MAIN PUMP
(1) Remove the port plate since the force of
the control spring is strong, remove the
hexagon socket head cap screws holding
the port plate by means of the jigs.
(M12×40, 3 pieces), (M12×55, 1 piece)
Hexagon socket
R35Z77MP10
set screw
(2) Remove the cover.

Use the jig to hold the port in a horizontal
condition, and unloosen the hexagon
socket set screw of the jig slowly, to
remove the port plate.
※ Be careful because the control plate is
provided to the backside.
Hexagon socket
set screw
R35Z77MP11
(3) This photo shows the state with the port

plate removed.
R35Z77MP12
7-14
(4) Remove the packing.
R35Z77MP13
(5) Remove the control spring and the spring

seat.
Remove the two springs (inner and outer),
and the guide.
R35Z77MP14
(6) Remove the spring seat.
R35Z77MP15
(7) Remove the rotary group.

Remove the shim and the retaining ring.
(for shafts ; 20)
Pliers for retaining rings.
(for shafts ; retaining ring for 20)
Shaft
Shim
Retaining ring
R35Z77MP16
Cylinder block
7-15
(8) Push down sideways the pump. And takes
out the rotary group from the shaft.
R35Z77MP17
(9) Remove the shaft.

The protective taping around the spline
part, and pull out straight the shaft, taking
care not to damage the oil seal.
R35Z77MP18
(10) Remove the swash plate assembly.

Remove the swash plate.
R35Z77MP19
(11) Remove the guide.

※ Put the mark on the guides, to know the
correct direction, and between right and
left side.
Marking
R35Z77MP20
Delivery side Suction side
7-16
(12) Disassemble the port plate assembly.
Remove the control plate.
R35Z77MP21

screws (M8×30, 2 pieces), in order to
remove the cover of the spring seat
assembly.
R35Z77MP26
(14) Remove the spring seat.
R35Z77MP27
(15) Disassemble the control piston assembly.

Remove the piston, the coned disk
springs, the distance piece and the shim.
R35Z77MP28
7-17
(16) Remove the parallel pin and the sleeve.
R35Z77MP29
(17) Remove the minimum flow stopper.

Remove the retaining ring. (for holes ; 22)
(for holes ; retaining ring for 22)
R35Z77MP30
(18) Remove the guide, the coned disk

springs, the distance piece, and shim.
R35Z77MP31
(19) Remove the relief valve.

Remove the hexagon nut.
Spanner (24 mm)
※ Since the pressure has set, you may
remove this assembly, only when
necessary.
R35Z77MP32
7-18
(20) Remove the adjustment screw.
Spanner (14 mm)
※ Be careful because the shim is inserted.
R35Z77MP33
(21) Remove the spring.
R35Z77MP34
(22) Remove the spool.
R35Z77MP35
4) DISASSEMBLING THE GEAR PUMP

(GSP2)
screws.
(M10×20, 4 pieces)
R35Z77MP36
7-19
R35Z77MP37
(3) Remove the square ring.
R35Z77MP38
(4) Remove the plate, the guides, and the

O-rings.
R35Z77MP39
(5) Remove the drive gear, the idle gear, and

the side plates.
R35Z77MP40
7-20
5. ASSEMBLING PROCEDURE
1) ASSEMBLE THE MAIN PUMP
(1) Assemble the minimum flow stopper.
Install the guide, the coned disk springs,
the distance piece, and the shim into the
housing.
* Pay attention to the direction of the
coned disk spring.
Guide R35Z77MP41
Coned disk
spring
Shim
Assembling
direction
(2) Install the retaining ring. (for holes ; 22)

(for holes; retaining ring for 22)
R35Z77MP43
(3) Install the parallel pin and the sleeve into

the housing.
R35Z77MP44
7-21
(4) Install the piston, the coned disk springs,
the distance piece, and the shim into the
housing.
※ Pay attention to the direction of the coned
disk springs.
Piston
Coned disk
spring
R35Z77MP45
Shim
Assembling
direction
(5) Assemble the swash plate.

Install the guides into the housing.
※ Assemble the guides into the housing,
taking care on the marking, which was
put on during disassembling work.
Marking
R35Z77MP47
Delivery side Suction side
(6) Install the swash plate.
R35Z77MP48
7-22
(7) Assemble the shaft.
The protective taping around the spline
part, and install the shaft vertically, taking
care not to damage the oil seal.
※ Confirm that the shim is installed above
the bearing.
Shim
Bearing
R35Z77MP49
(8) Assemble the rotary group.

Install the pistons (10 pistons) into the
retainer.
R35Z77MP50
(9) Apply the grease to the spherical portion

of the guide.
R35Z77MP51
(10) Insert the guide between the retainer and

the cylinder block and assemble the
piston into the hole of the cylinder block.
※ Apply grease to the end of the shoes.
R35Z77MP44
7-23
(11) Install the rotary group.
Assemble the rotary group along the shaft
spline.
R35Z77MP53
(12) Install the retaining ring (for shafts ; 20),

and install the shim.
(for shafts ; retaining ring for 20)
Shim Shaft
Retaining
ring
R35Z77MP54
Cylinder block
(13) Assemble the control spring.

Apply grease to the spherical portion of
the spring seat before assembling.
R35Z77MP55
(14) Assemble the two springs (inner and

outer) and the guide.
R35Z77MP56
7-24
(15) Assemble the port plate.
Assemble the spring seat into the port
plate.
R35Z77MP57
(16) Assemble the cover of the spring seat

assembly, and fix it with hexagon socket
head cap screws. (M8×30, 2 pieces)
·Tightening torque : 3.6 kgf·m
(21~26 lbf·ft)
R35Z77MP58
(17) Apply grease to the backside of the

control plate (to prevent dislodgement),
and assembly it to the port plate while
matching the knock hole.
R35Z77MP59
(18) Assemble the relief valve.

Install the spool into the port plate.
R35Z77MP60
7-25
(19) Assemble the spring.
R35Z77MP61
(20) Install the shim into the adjustment screw.
R35Z77MP62
(21) Assemble the adjustment screw.

Spanner (14 mm)
R35Z77MP63
(22) Tighten the hexagon nut.

※ After assembling, set the pressure and
tighten the nut.
Spanner (24 mm)
·Tightening torque : 1.0 kgf·m
(7.2 lbf·ft)
R35Z77MP64
7-26
(23) Assemble the port plate.
Install the packing.
R35Z77MP65
(24) Holding the cover in parallel condition, by

using the jig, tightens slowly the hexagon
socket set screw of the jigs, in order to
install the port plate.
Hexagon socket
set screw
R35Z77MP66
(25) Fix the port plate with the hexagon socket

head cap screws.
(M12×40, 3 pieces)
(M12×55, 1 pieces)
·Tightening torque : 10~12.5 kgf·m
(72.3~91 lbf·ft)
R35Z77MP67
2) ASSEMBLE
SSEMBLE THE TROCHOID PUMP
(1) Install the key into the shaft.
Trochoid pump side
R part
Cover side
Install the key so that R side position in the

R35Z77MP68
trochoid pump side.
7-27
(2) Install the side plate (B) into the port plate.
R35Z77MP69
(3) Install the gear (inner rotor) into the shaft.

※ The surface of matching mark should be
positioned in the side plate (B) side.
Matching mark
R35Z77MP70
Inner rotor
Outer rotor
(4) Install the side plate (A) into the case.
R35Z77MP71
(5) Install the gear (outer rotor) into the case.

※ The surface of matching mark should be
positioned in the side plate (B) side.
R35Z77MP72
7-28
(6) Install the case into the port plate.
R35Z77MP73
(7) Tighten the hexagon socket head cap

·Tightening torque : 0.7~0.8 kgf·m
(5.1~6.1 lbf·ft)
R35Z77MP74
3) ATTACH THE GEAR PUMP

(1) Install the coupling to the shaft end on the
main pump.
R35Z77MP75
(2) Connect the main pump and the gear

pump.
And fix the gear pump with the hexagon
socket head cap screws.
(M10×25, 2 pieces)
(41~51 lbf·ft)
R35Z77MP76
7-29
4) ASSEMBLE THE GEAR PUMP
(1) Assemble the gear pump (GSP2)
Assemble the square ring into the side
plate.
Pay attention to the suction and delivery
directions.
Suction Delivery
side side
R35Z77MP77
Suction Delivery
side side
Square ring
inserting direction
(2) Assemble the drive gear and the idle gear

to the side plates.
R35Z77MP78
(3) Assemble the drive gear, the idle gear

and the side plates in the housing.
R35Z77MP79
7-30
(4) Insert the O-rings into the guides, then
insert them into the plate.
Side with
large R Guide
R35Z77MP80
(5) Assemble the plate, guides and O-rings.

Pay attention to the suction and delivery
directions.
Suction Delivery
side side
R35Z77MP81
(6) Install the square ring.
R35Z77MP82
(7) Assemble the housing and the cover.
R35Z77MP83
7-31
(8) Fix the housing and the cover with the
hexagon socket head cap screws.
(M10×20, 4 pieces)
(41~51 lbf·ft)
R35Z77MP84
7-32
- DISASSEMBLY AND ASSEMBLY (TYPE 2) : Refer
Refer to page 7-32-1~7-32-11.
1) General precautions
(1) Before disassembling, it is important to have fully understood the internal structure of the pump.
※ The gasket (13), oil seal (32) and O-rings will be probably damaged when you disassemble it, so
be sure to have prepared spares.
(2) After having drained oil inside the pump, wash the pump and put it on a working bench covered
with clean paper, cloth, or rubber mat for disassembling and assembling. Then, disassemble and
assemble the pump slowly and carefully with necessary tools. Use care not to scratch even
slightly, and take proper measures to prevent foreign matters from entering the assembly.
2) Tools
Tool name Size Quantity
Hexagon wrench 4, 6, 8 mm 1 each
Circlip player For hole 1
Spanner wrench 13 mm 1
45N (JIS B 4650) 1
Torque wrench
90N (JIS B 4650) 1
Resin hammer - 1
Special tooling for oil seal See below 1
Seal kit - 1 set
Grease - Small amount
51
31
52
70
Special tooling for oil seal
R27Z97MP98
7-32-1
7-33
3) DISASSEMBLING
(1) Disassembling of gear pump
Remove two screws (68) with spanner
wrench 13 mm, and after that remove gear
pump (65), collar (67) and coupling (66).
※ Coupling (66) and collar (67) may be
attached with gear pump kit (65).
R27Z97MP01
(2) Remove the adjustment screw

Loose hexagon nut (61) with spanner
w r e n c h 1 3 mm, t h e n r e m ove t h e
adjustment screw (60) with hexagon
wrench 4 mm.
※ Suggest you to measure the outside

length of the adjustment screw. Because
it is a good help when you readjust it after
R27Z97MP02
reassembling.
(3) Separation of body S and body H

Remove five screws (44) with hexagon
wrench 8 mm.
R27Z97MP03
※ If you tap the part of inserted spring of

body H with hummer softly, it is easy for
separation.
R27Z97MP04
7-32-2
7-34
(4) Disassembling of body S kit
Remove spring T1 (15) from body S kit,
then take off spring holder (18).
R27Z97MP05

Remove cylinder barrel kit.
R27Z97MP06

Remove swash plate (10) and two balls
(12).
R27Z97MP07

Remove stopper pin A (25), stopper pin B
(26), dish springs (33), rod G (21) and rod
C (22).
※ The length of the stopper pin A and B is

different. Pay attention not to swap when
reassembling.
R27Z97MP08
7-32-3
7-35
Remove snap ring (34) from body S (1).
R27Z97MP09

Tap the end of shaft (3) with hammer,
then oil seal (32) and shaft with bearing
(30) come off.
R27Z97MP10
(10) Disassembling of body H kit

Remove spring guide (19) and valve plate
(5) from body H.
R27Z97MP11
7-32-4
7-36
(11) Disassembling of cylinder barrel kit
Remove shoe holder (8) on which piston
shoe assemblies (6) and (7) are set and
disassemble it in the order of barrel holder
(9) and needle (11).
Also, take off snap ring (35), retainer (24),
spring C (14) and retainer (24), which are
set in the cylinder barrel (4) in this order.
R27Z97MP12
R27Z97MP13
35
24
14
24 4
9
8
7
11
6
R27Z97MP14
7-32-5
7-37
4) ASSEMBLING
(1) Precautions during assembling
Reverse the above procedures for assembling.
When assembling, be very careful to wash parts in clean oil, to prevent dusts and water from
adhering to parts entering assemblies and not to scratch on the sliding surfaces of all parts.
※ Apply small quantity of grease to the periphery of O-rings to be set in socket and spigot joints to
prevent the O-rings from being damaged.
(2) Assembling of cylinder barrel kit

35
Set retainer (24), spring C (14), retainer 24
14
(24) and snap ring (35) in the shaft center 24 4
hole of cylinder barrel (4) in this order,
and carefully set shoe holder (8), on 9
which needle (11), barrel holder (9) and 8
ten piston shoe assemblies have already

been set, in cylinder barrel from the
opposite side. 7
11
6
R27Z97MP14
R27Z97MP15
R27Z97MP16
7-32-6
7-38
(3) Assembling of body S kit
Set shaft (3) with bearing (30), oil seal
(32) and snap ring (34) in this order into
body S (1).
ఐ Use new oil seal for assembling. Before
assembling, apply a small quantity of
grease to the periphery of oil seal lip and
tap it together with the special tooling with
hammer. R27Z97MP17
When assembling, put body S (1) onto

body H (2) tentatively for easy work.
R27Z97MP18

Set each four dish springs (33) to stopper
pin A (25) and stopper pin B (26), then set Stopper pin A
them into body S (1).
ఐ Pay attention to the direction of the dish
Dish springs
washer.
ఐ Pin A and pin B have different length. Set
them to the original position. Otherwise,
Stopper pin B
pump displacement changes, and engine
stall or insufficient speed can occur.
R27Z97MP19

Set rod G (21) and rod C (22) into body S
(1).
※ Pay attention to the direction of the rod G
and rod C. (See cross section drawing for
the direction.)
R27Z97MP20
7-32-7
7-39
Put two balls (12) in the hole of swash
plate (10) and install it in body S.
ఐ Apply grease on the balls if they drop out.
R27Z97MP21

Assemble cylinder barrel kit into the body
S (1).
R27Z97MP22

Set spring T1 (15) to spring holder (18),
then set them together into the hole on
swash plate (10).
R27Z97MP23
(9) Assembling of body H kit

Set spring guide (19) in body H (2).
R27Z97MP24
7-32-8
7-40
(10) Assembling of body H kit
Place valve plate (5) slowly on body H (2)
by positioning it with spring pin (56).
ఐ V notch copper alloy side of valve plate
slides with cylinder barrel (4) and be
careful not to set the valve plate to a
wrong direction.
R27Z97MP25
(11) Assembling of body S kit with body H kit

Place O-ring (40) on body S.
ఐ Use new O-ring for assembling.
R27Z97MP26

Pin
Set pin (20) and pin (27) on body S.
ఐ Pay attention to the position of each pin.
Pin (27) has a hole.
Pin with hole
R27Z97MP27

Place O-ring (40) on body H.
R27Z97MP28
7-32-9
7-41
Place packing (13), position it with
locating pin (27) on body S.
ఐ Use new packing for assembling.
R27Z97MP29

Set two screws (M10×65) into the upper
side two screw holes, and tighten them
until the distance between body S and
body H comes to 5 to 10 mm.
Then set three screws (44) into the three
screw holes, after that, replace the upper
side two screws (M10×65) to the regular
size screws (44) and fix them.
R27Z97MP30

(37.6~47.7 lbf·ft)
(16) Installation of the adjusting screw

Fasten the adjusting screw (60) with
hexagon wrench 4 mm, then adjust the
outside length of adjusting screw and fix
locknut (61) with spanner wrench 13 mm.
At that time, change the seal washer (62) Set the screw with
to new one. the original length,
otherwise engine
stall can occur.
(10.8~14.5 lbf·ft) R27Z97MP31
(17) Installation of gear pump kit

Place O-r ing (69, 71, 72) on the
P7
installation side of body H.
G55 P8
R27Z97MP32
7-32-10
7-42
Set collar (67) and coupling (66).
R27Z97MP33

Install gear pump kit (65) and fix it by two
screws (68) and washers (70) with
spanner wrench 13 mm.
(14.5~17.3 lbf·ft)
R27Z97MP34
(20) Inspection of assembling

After completed the assembling of pump, make sure that pump shaft rotates smoothly by hand.
7-32-11
7-43
GROUP 4 MAIN CONTROL VALVE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
pressure in the hydraulic piping.

penetrate the skin causing serious injury.
※ When pipes and hoses are disconnected,
(4) Disconnect hydraulic hose.
(5) Disconnect pilot line hoses.
(6) Sling the control valve assembly and
remove the control valve mounting bolt. R35Z77MCV01
·Weight : 25 kg (55 lb)

(7) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
to removal.
(2) Bleed the air from below items.
① Cylinder (boom, arm, bucket)
② Swing motor R35Z77MCV02
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and
recheck the hydraulic oil leak or not.
R35Z77MCV03
7-33
2. STRUCTURE (1/3)
4-10
4-11 14
4-6
4-5 4-10 4-9
4-12
4-4 4-11
4-8
4-3
4-2
3-6 3-10
3-5 3-8 15
4-7
3-4
4-7 3-3
4-13
4-16 2-6 2-10
4-14 3-7 2-5 2-8
2-4
22
2-3
4-15 1-6
4-17 1-5 1-8
4-18 3-7 15 2-7 1-4
3-2 1-3
1-10
2-7 15 1-7
3-9
3-10 2-2
1-7
2-9
1-2 23
2-10
1-9 24
1-10 R35Z72MCV03
1 Dozer work block 2-9 Cover-pilot 4-6 Plug

1-1 Body-work 2-10 Bolt-soc head w/washer 4-7 O-ring
1-2 Spool assy 3 Swing work block 4-8 Cover-pilot
1-3 Poppet 3-1 Body-work 4-9 Bolt-soc head w/washer
1-4 Spring 3-2 Spool assy 4-10 Plug
1-5 O-ring 3-3 Poppet 4-11 O-ring
1-6 Plug 3-4 Spring 4-12 Plug
1-7 O-ring 3-5 O-ring 4-13 Piston
1-8 Cover-pilot 3-6 Plug 4-14 O-ring
1-9 Cover-pilot 3-7 O-ring 4-15 Body-pilot
1-10 Bolt-soc head w/washer 3-8 Cover-pilot 4-16 Bolt-soc head w/washer
2 Boom swing work block 3-9 Cover-pilot 4-17 Orifice
2-1 Body-work 3-10 Bolt-soc head w/washer 4-18 Filter-coin type
2-2 Spool assy 4 Connecting block 14 Relief valve
2-3 Poppet 4-1 Body-work 15 Overload relief valve
2-4 Spring 4-2 Spool assy 17 O-ring
2-5 O-ring 4-3 Poppet 22 O-ring
2-6 Plug 4-4 Spring 23 Bolt-tie
2-7 O-ring 4-5 O-ring 24 Nut-hex
2-8 Cover-pilot
7-34
STRUCTURE (2/3)
13
7-8
7-6 15
7-4
13
7-3
6-6 6-10
6-5 6-8
7-5
6-4
6-3
19 15
5-6
6-7 5-5
7-5 15
5-4
18 5-3
7-2
5-10
6-7 15 5-7 5-8
7-7 18
6-2
7-8
6-9 5-7
18
5-2
6-10
5-9
5-10
R35Z92MCV04
5 PTO work block 6-2 Spool assy 7-4 Plug

5-1 Body-work 6-3 Poppet 7-5 O-ring
5-2 Spool assy 6-4 Spring 7-6 Cover-pilot
5-3 Poppet 6-5 O-ring 7-7 Cover-pilot
5-4 Spring 6-6 Plug 7-8 Bolt-soc head w/washer
5-5 O-ring 6-7 O-ring 8 Inlet work block
5-6 Plug 6-8 Cover-pilot 13 Relief valve
5-7 O-ring 6-9 Cover-pilot 15 Overload relief valve
5-8 Cover-pilot 6-10 Bolt-soc head w/washer 17 O-ring
5-9 Cover-pilot 7 Travel work block 18 O-ring
5-10 Bolt-soc head w/washer 7-1 Body work 19 O-ring
6 Arm work block 7-2 Spool assy
6-1 Body-work 7-3 O-ring
7-35
STRUCTURE (3/3)
117
15
115
119 113
12-10 112
12-6 118 116
12-5 12-8 11-6 114
12-4 12-7 111 112
11-2
12-3 110 120
11-5 107
11-4 102
11-11 101
11-9 104
15 11-12 106 108 109
103
105
10-6 10-10
12-7 11-10
15 10-5 10-8
18 10-4
12-2 10-3
9-6
9-10
9-5 9-8
12-9 11-7 9-4
11-2 11-1 10-7
18 11-8 9-3
11-3
12-10 15
9-7
10-7 18
10-2
9-7
10-9 19
9-2
10-10
9-9
9-10
R35Z72MCV05
9 Travel work block 10-7 O-ring 12-1 Body-work 103 Seal

9-1 Body-work 10-8 Cover-pilot 12-2 Spool assy 104 Filter
9-2 Spool assy 10-9 Cover-pilot 12-3 Poppet 105 Spacer
9-3 Poppet 10-10 Bolt-soc head w/washer 12-4 Spring 106 Ring-retaining
9-4 Spring 11 Boom lock valve 12-5 O-ring 107 Spring A-lock valve
9-5 O-ring 11-1 Body-work 12-6 Plug 108 Spring seat
9-6 Plug 11-2 O-ring 12-7 O-ring 109 Pin
9-7 O-ring 11-3 Plug 12-8 Cover-pilot 110 Poppet
9-8 Cover-pilot 11-4 Poppet 12-9 Cover-pilot 111 Ring-retaining
9-9 Cover-pilot 11-5 Spring 12-10 Bolt-soc head w/washer 112 O-ring
9-10 Bolt-soc head w/washer 11-6 Plug 15 Overload relief valve 113 Guide-piston
10 Boom work block 11-7 O-ring 17 O-ring 114 Piston A1
10-1 Body-work 11-8 Plug 18 O-ring 115 Piston B
10-2 Spool assy 11-9 O-ring 19 O-ring 116 O-ring
10-3 Poppet 11-10 O-ring 20 O-ring 117 Connector
10-4 Spring 11-11 Plug 21 O-ring 118 Ball-steel
10-5 O-ring 11-12 O-ring 101 Cover-lock valve 119 Plug
10-6 Plug 12 Bucket work block 102 Lock valve 120 Bolt-hex. socket head
7-36
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components are manufactured to a high precision. Consequently, before
disassembling and assembling them, it is essential to select an especially clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be remove from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working. Spread
paper or a rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying or transferring the control valve. Do not lift by
the exposed spool, end cover section etc.
(5) After disassembling and assembling of the component it is desired to carry out various tests (for
the relief characteristics, leakage, flow resistance, etc.), but hydraulic test equipment is necessary
for these tests. Therefore, even when its disassembling can be carried out technically, do not
disassemble such components that cannot be tested, adjusted, and so on. Additionally one
should always prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size (mm)
Vice mounted on bench (soft jaws) 1 unit
Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 5 and 6
Spanner Each 1 piece 13, 21 and 30
Rod 1 piece Less than 10×250
7-37
3) DISASSEMBLY
(1) Disassembly of spools (pilot type)
8
7
① Loosen hexagon socket head bolts (10)
with washer.
10
(Hexagon wrench : 5 mm)
② Remove the pilot cover (8).
※ Pay attention not to lose the O-ring (7)
under the pilot cover. R35Z77MCV04
③ Remove the spool assembly (2) from the

body by hand slightly.
※ When extracting each spool from its
body, pay attention not to damage the 2
body.
※ When extracting each spool assembly, it
must be extracted from spring side only.
※ When any abnormal parts are found,
replace it with completely new spool
assembly.
R35Z77MCV05
※ When disassembled, tag the
components for identification so that they
can be reassembled correctly.
7-38
(2) Disassembly of holding valve (boom 1)
① Loosen hexagon socket head bolts
(120). 120
(Hexagon wrench : 5 mm)
② Remove the holding valve.
※ Pay attention not to lose the O-ring and
the poppet under the pilot cover.
※ Pay attention not to damage the "piston R35Z77MCV13
A" under pilot cover.
replace it with completely new holding
valve assembly.
※ When disassembled, tag the Holding valve
components for identification so that they
can be reassembled correctly.
R35Z77MCV14
7-39
(3) Disassembly of the load check valve
and the negative relief valve
6
① The load check valve
a. Fix the body to suitable work bench.
※ Pay attention not to damage the body.
b. Loosen the plug (6)
(Hexagon wrench : 10 mm).
c. Remove the O-ring (5), spring (4) and R35Z77MCV11
the load check valve (3) with pincers or

magnet.
5
4
3
R35Z77MCV12
7-40
(4) Disassembly of the main and overload
relief valve
① Fix the body to suitable work bench. 14
② Remove the main relief valve (14).

(Spanner : 30 mm)
③ Remove the overload relief valve (15).
(Spanner : 22 mm)
※ When disassembled, tag the relief valve R35Z77MCV09
for identification so that they can be

reassembled correctly.
※ Pay attention not to damage seat face.
replace it with completely new relief valve 15
assembly.
R35Z77MCV10
7-41
(5) Disassembly of the block assembly
① Fix the body to suitable work bench.
② Remove the nut (24).
(Spanner : 13 mm)
24
R35Z77MCV15
※ Do not removed the tie bolt (23).
23
R35Z77MCV16
7-42
(6) Inspection after disassembly
Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air.
Then, place them on clean papers or cloths for inspection.
① Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the body, if any, by lapping.
※ Pay careful attention not to leave any lapping agent within the body.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and path's
are free foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When a relief valve does not function properly, repair it, following it's the prescribed disassembly
and assembly procedures.
g. Replace all seals and O-rings with new ones.
② Relief valve
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and show
uniform and consistent contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
d. Confirm that springs are free from breakage, deformation, and wear.
e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
f. Replace all O-rings with new ones.
g. When any light damage is found in above inspections, correct it by lapping.
h. When any abnormal part is found, replace it with a completely new relief valve assembly.
7-43
4) ASSEMBLY
(1) General precaution
① In this assembly section, explanation
only is shown.
For further understanding, please refer to
the figures shown in the previous
structure & disassembly section.
② Pay close attention to keeping all seals
free from handling damage and inspect
carefully for damage before using them.
③ Apply clean grease or hydraulic oil to the
seal so as to ensure it is fully lubricated
before assembly.
④ Do not stretch seals so much as to
deform them permanently.
⑤ In fitting O-rings, pay close attention not
to roll them into their final position in
addition, a twisted O-ring cannot easily
untwist itself naturally and could thereby
cause inadequate sealing and thereby
both internal and external oil leakage.
⑥ Tighten fitting bolts for all sections with a
torque wrench adjusted to the respective
tightening torque.
⑦ Do not reuse removed O-rings and
seals.
5
(2) Load check valve 4
3
① Assemble the load check valve (3) and
O-ring (5), spring (4).
② Put O-rings on to plug (6).
③ Tighten plug to the specified torque.
·Hexagon wrench : 8 mm
·Tightening torque : 3.7 kgf·m R35Z77MCV12
(26.7 lbf·ft)
R35Z77MCV11
7-44
(3) Main relief, port relief valves
① Install the main relief valve (14).
·Spanner : 30 mm 14
·Tightening torque : 6 kgf·m (43.4 lbf·ft)
② Install the over load relief valve (15).
·Spanner : 22 mm
·Tightening torque : 4 kgf·m (28.9 lbf·ft)
R35Z77MCV09
15
R35Z77MCV10
(4) Main spools

① Carefully insert the previously assembled
spool assemblies into their respective 2
bores within of body.
※ Fit spool assemblies into body
carefully and slowly. Do not under any
circumstances push them forcibly in.
R35Z77MCV05
(5) Covers of pilot type

① Fit spool covers (8) tighten the hexagonal
8
socket head bolts (10) with washer to the 7
specified torque.
·Hexagon wrench : 5 mm 10
·Tightening torque : 1~1.1 kgf·m
(7.2~7.9 lbf·ft)
※ Confirm that O-rings (7) have been fitted.
R35Z77MCV04
7-45
(6) Holding valve
① Fit the holding valve to the body and
tighten hexagon socket head bolt (120) Holding valve
to specified torque.
·Hexagon wrench : 5 mm
·Tightening torque :1.1 kgf·m (7.9 lbf·ft)
R35Z77MCV14
120
R35Z77MCV13
7-46
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

24
MU
A
B
(4) Disconnect hose assembly (78, 102, 1
103).
(5) Disconnect pilot line hoses (27, 29, 32). 78
103
(6) Sling the swing motor assembly (1) and 102
remove the swing motor mounting bolts R35Z77SM44
(24).
※ Motor device weight : 39 kg (86 lb)
(7) Remove the swing motor assembly.
※ W h e n r e m ov i n g t h e sw i n g m o t o r
assembly, check that all the piping have
DB
been disconnected. PB
2) INSTALL
(1) Carry out installation in the reverse order 27
to removal.
29 32
(2) Bleed the air from the swing motor.
① Remove the air vent plug. R35Z77SM45
② Pour in hydraulic oil until it overflows from

the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling and
⑤ Tighten plug fully.
7-47
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
2-13 2-25 2-11 2-3 2-12 2-4 2-2 1-37 1-22 1-21 1-19 1-20 1-18 1-14 1-13 1-11 1-12
1-10
2-5
1-35
2-23 1-36
2-24 1-1
2-6
2-7 1-16
2-45
2-22
1-8
2-8
2-46
2-9 1-4
2-38 1-53 2-10

2-18 1-2
2-19
2-15
1-3
2-27
2-38
2-41 1-5
2-21
2-26
2-39 2-40 2-42 2-43 2-44 2-20 2-17 2-28 2-16 2-14 2-1 1-23 1-24 1-15 1-17 1-9 1-7 1-6
R35Z92SM12
1 Gear box 1-11 Thrust washer 1-22 Planetary gear 2-4 Thrust plate 2-15 Brake piston 2-26 O-ring
1-1 Housing 1-12 Inner race 1-23 Thrust plate 2-5 Cylinder block 2-16 O-ring 2-27 Socket head bolt
1-2 Pinion shaft 1-13 Needle bearing 1-24 Drive gear 2-6 Collar 2-17 O-ring 2-28 Orifice
1-3 Plate 1-14 Planetary gear B 1-35 Plug 2-7 Spring 2-18 Spring seat 2-38 Relief valve assy
1-4 Collar 1-15 Thrust plate 1-36 O-ring 2-8 Washer 2-19 Spring 2-39 Check valve
1-5 Tapper roller bearing 1-16 Screw 1-37 O-ring 2-9 Snap ring 2-20 O-ring 2-40 Spring
1-6 Oil seal 1-17 Sun gear B 1-53 Socket bolt 2-10 Pin 2-21 Cover 2-41 Plug
1-7 Tapper roller bearing 1-18 Holder 2 Axial piston motor 2-11 Retainer holder 2-22 Ball bearing 2-42 O-ring
1-8 Plate 1-19 Thrust washer 2-1 Case 2-12 Retainer plate 2-23 Pin 2-43 Plug
1-9 Collar 1-20 Inner race 2-2 Ball bearing 2-13 Piston assy 2-24 Valve plate 2-44 O-ring
1-10 Holder 1-21 Needle bearing 2-3 Shaft 2-14 Disc 2-25 Pin 2-45 Plug
2-46 O-ring
7-48
2) DISASSEMBLY
Disassemble the parts by the following
procedure. 3
(1) Separating the motor and the reduction
gear
Secure the motor assembly in a vice and
remove the socket head bolt (3).
R35Z77SM01
(2) Disassembling the motor

2-21
① Secure the motor assembly in a vice.
Remove the socket head bolts (2-27) 2-27
and separate the cover (2-21).
※ When separating the cover (2-21), be
careful not to drop the valve plate (2-24).
R35Z77SM02
② Remove the valve plate (2-24) and the

pin (2-23).
2-24
※ The valve plate (2-24) may remain on
2-23
the motor side.
R35Z77SM03
③ Remove the bearing (2-22). Remove the

O-ring (2-26).
2-22
2-25 2-26
2-21
R35Z77SM04
7-49
④ Disassemble the check valve.
a. Loosen to remove the plug (2-41).
2-41
R35Z77SM05
b. Remove the spring (2-40) and the

check valve (2-39).
2-39
2-40
R35Z77SM06
⑤ Remove the relief valve.

a. Loosen the plug (2-38-6) to remove the
relief valve assembly (2-38).
※ Do not move the adjuster kit (2-38-7).
Otherwise, the set pressure will change.
※ Do not disassemble the relief valve 2-38-6
assembly (2-38) because it is a function-
al component. 2-38
2-38-7 R35Z77SM07
⑥ Remove the disc spring assembly (2-19)

2-18
and the spring seat (2-18), and utilizing 2-19
the gage port of the case (2-1), remove 2-18
the parking brake piston (2-15).
2-15
※ The piston may be ejected by the air
pressure. Exercise sufficient care during
removal. At the beginning of the work, 2-1
set a lower air pressure and adjust it
while checking the piston for ejection. R35Z77SM08
7-50
⑦ Remove the cylinder block and other
associated parts. 2-5
(2-5) Cylinder block
(2-6) Collar
(2-7) Spring
(2-8) Washer
(2-9) Snap ring
(2-10) Pin
(2-11) Retainer holder
R35Z77SM09
(2-12) Retainer plate
(2-13) Piston assembly
(2-14) Disc(Parking brake spec. only)
⑧ Remove the retainer plate (2-12) and the

piston assembly (2-13).
2-12
2-13
R35Z77SM10
⑨ Remove the pin (2-10) and the retainer

holder (2-11).
2-10
2-11
R35Z77SM11
⑩ While pushing the washer (2-8), remove

the snap ring (2-9). 2-9
⑪ Remove the collar (2-6), the spring (2-7) 2-8
and the washer (2-8). 2-7
2-6
R35Z77SM12
7-51
⑫ Remove the thrust plate (2-4).
2-4
R35Z77SM13
⑬ Lightly strike the end of the shaft (2-3)

2-3
with a plastic hammer to remove the
shaft.
2-2
R35Z77SM14
⑭ Disassemble the ball bearing (2-2) and

the shaft (2-3).
※ The disassembled bearing must not be 2-3
used.
2-2
R35Z77SM15
(3) Disassembling the reduction gear

① Remove the following parts.
(1-37) O-ring 1-23
(1-24) Drive gear 1-20
(1-23) Thrust plate 1-21 1-24
1-22
(1-22) Planetary gear 1-19
(1-21) Needle bearing 1-18
(1-20) Inner race
(1-19) Thrust washer 1-37
(1-18) Holder
R35Z77SM20
7-52
② Remove the sun gear (1-17).
1-17
R35Z77SM21
③ Remove the holder (1-10) and other

associated parts.
1-10
R35Z77SM22
④ Secure the holder (1-10) in a vice and

1-16
loosen the screw (1-16) to remove the
thrust plate (1-15).
1-15
※ The screw is hard to remove because 1-12
loctite was used during assembly. To 1-13
facilitate the removal of the screw, warm
1-14
the screw with a drier.
1-11 1-10
⑤ Remove the following parts.
R35Z77SM23
(1-14) Planetary gear
(1-13) Needle bearing
(1-12) Inner race
※ When replacing the taper roller bearings 1-8

(1-5) and (1-7), the collar (1-9) and the
1-9
plate (1-8), they are to be replaced by
the body assembly.
⑥ Remove the following parts.
(1-8) Plate
(1-9) Collar
R35Z77SM24
7-53
⑦ Remove the pinion shaft (1-2)
※ When removing the shaft, be careful not
to drop it. If it is hard to remove, lightly 1-1
strike it with a plastic hammer.
1-2
R35Z77SM25
⑧ Remove the inner race of the taper roller

1-7
bearing (1-7).
R35Z77SM26
⑨ Break the oil seal (1-6) to remove it.

※ The removed oil seal must not be used 1-6
again.
When removing it, exercise care to
prevent damage to the outer races of the
taper roller bearing (1-8) and (1-6).
R35Z77SM27
⑩ Remove the outer race of the taper roller

1-7
bearing (1-7) and the plug (1-35).
1-35
R35Z77SM28
7-54
3) ASSEMBLY
Assemble the par ts by the following
procedure.
(1) Assembling the motor
① Install the relief valve assembly (2-38).
·Tightening torque : 157±10 N·m
161±1 kgf·m
2-38
R35Z77SM30
② Assemble the check valve (2-39) and the

spring (2-40).
2-39
2-40
R35Z77SM31
③ Install the plug (2-41).

·Tightening torque : 39.2±2.0 N·m
4.0±0.2 kgf·m
2-41
R35Z77SM32
④ Assemble the collar (2-6), the spring

(2-7) and the washer (2-8) in the cylinder
2-8
block (2-5).
2-7
※ Be sure to assemble the collar (2-6) in 2-6
the correct direction.
Tapered side 2-6
Cylinder block
R35Z77SM33
7-55
⑤ While pushing the washer (2-8),
assemble the snap ring (2-9).
2-9
2-8
R35Z77SM35
⑥ Apply grease to the pin (2-10) and

assemble it in the cylinder block (2-5).
⑦ Assemble the retainer holder (2-11).
2-10
2-11
R35Z77SM11
⑧ Set the piston assembly (2-13) on the

retainer plate (2-12) and assemble it in
the cylinder block (2-5).
※ Apply an ample amount of hydraulic fluid
to the sliding part before assembly.
2-12
2-13
R35Z77SM10
⑨ Press-fit the ball bearing (2-2) on the

shaft (2-3).
2-3
※ Press-fit the ball bearing (2-2) with the
attached snap ring facing as shown in
the figure.
2-2
Snap ring
R35Z77SM36
7-56
⑩ Press-fit the shaft (2-3) and the ball
2-3
bearing (2-2) in the case (2-1).
2-2
R35Z77SM14
⑪ Apply grease to the back side of the

thrust plate (2-4) and assemble it. 2-4
※ The thrust plate must be assembled in
the correct direction.
R35Z77SM13
⑫ Assemble the cylinder block (2-5) and

other associated parts.
2-5
※ During assembly, be sure that the pin
(2-10) will not come out.
※ The disc (2-14) is assembled only for the
parking brake spec only.
R35Z77SM09
⑬ Apply grease to the O-ring (2-16) and

the O-ring (2-17) and assemble them on
the brake piston (2-15).
2-15
⑭ While paying attention to the location of
the hole of the pin (2-25), assemble the
2-17
brake piston (2-15) in the case (2-1).
2-16
R35Z77SM37
7-57
⑮ Assemble the spring seat (2-18) and the
2-18
disc spring (2-19) in the correct direction. 2-19
2-18
2-15
2-18
2-19 2-1
2-18
R35Z77SM08
16 Apply grease to the O-ring (2-20) and

assemble it in the case (2-1). 2-20
Check to see if the pin (2-25) can be
assembled in the brake piston and case 2-25
hole. If not, remove the brake piston
(2-15) and re-orient it, then reassemble.
※ Assemble the pin (2-25) while being
attached on the cover.
R35Z77SM39
17 Apply grease to the O-ring (2-26) and

the pin (2-25), then assemble them in the
2-22
cover (2-21).
2-25 2-26
Press-fit the ball bearing (2-22).
2-21
R35Z77SM04
18 Install the pin (2-23), then install the

valve plate (2-24).
2-24
To prevent it from falling, apply grease to
the back side. 2-23
R35Z77SM03
7-58
19 While paying attention to the location of
the pin (2-25), install the cover (2-21) and 2-21
other associated parts to the case (2-1).
2-27
※ Exercise care so that the pin (2-25) and
the valve plate (2-24) will not fall.
20 Loosely tighten the socket head bolts
(2-27), then using a torque wrench,
tighten them to the specified torque.
R35Z77SM02
·Tightening torque : 13±0.7 kgf·m
(94.4±5 lbf·ft)
(2) Assembling the reduction gear
1-6
① Press-fit the oil seal (1-6).
※ Prior to press-fit, apply grease to the oil
seal mounting area of the housing and
the periphery of the oil seal.
R35Z77SM27
② Press-fit the taper roller bearing (1-7)

and install the plug (1-35). 1-7
1-35
R35Z77SM28
③ Apply grease to the inner race of the

taper roller bearing (1-7) assembled on 1-7
the pinion shaft (1-2).
1-2
R35Z77SM41
7-59
④ Install the pinion shaft (1-2) and other
associated parts. Install the taper roller
bearing inner race (1-7). 1-1
※ Prior to assembling the pinion shaft
(1-2), etc. apply grease to the lip of the oil
seal (1-6).
1-2
R35Z77SM25
⑤ Install the collar (1-9) and the plate (1-8).

1-8
1-9
R35Z77SM24
⑥ Install the following parts on the holder.

1-16
(1-10) Holder
(1-12) Inner race 1-12
(1-14) Planetary gear B 1-14
(1-15) Thrust plate 1-10
1-11
(1-16) Screw
R35Z77SM23
※ Apply loctite 242 to the screw prior to

tightening it.
·Tightening torque : 0.4±0.05 kgf·m
2.9±0.3 lbf·ft
⑧ Install the holder (1-10) and other

associated parts.
1-10
R35Z77SM22
7-60
⑨ Install the sun gear (1-17).
※ Install the sun gear (1-17) with the snap
1-17
ring facing as shown in the figure.
R35Z77SM21
⑩ Install the holder (1-18).
1-18
R35Z77SM42
⑪ Install the following parts.

(1-20) Inner race 1-20
1-21 1-24
(1-22) Planetary gear A 1-19
(1-23) Thrust plate 1-18
(1-24) Drive gear
1-37
(1-37) O-ring
R35Z77SM20
※ Selection for thrust plate (1-15).

When any consisting parts of reduction
unit were changed, select and install
E
thrust plate corresponding to the

measured value "E" referring to the
below table.
E dimension Less than More than
6.6~7.2
(measured value) 6.6 7.2
Part no. of thrust XJBV-00129 XJBV-00130 XJBV-00131 R35Z77SM43
plate 1-23
(plate thickness) (3.2 mm) (2.8 mm) (2.3 mm)
7-61
(3) Assembling the whole motor assembly
Place the reduction gear assembly on the
motor assembly and loosely tighten the 3
socket head bolt (3), then tighten it to the
specified torque.
(94.4±5 lbf·ft)
R35Z77SM01
7-62
GROUP 6 TRAVEL DEVICE

1) REMOVAL
(1) Swing the work equipment 90。and lower
it completely to the ground.

1
catch it in oil pan. 2
C2
(4) Remove the track shoe assembly. A
Pi
For details, see removal of track shoe B
assembly.
assembly
(6) Remove the hose.
※ Fit blind plugs to the disconnected hoses. R35Z77TM91
(7) Remove the bolts and the sprocket.

(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
7-63
2) STRUCTURE
R35Z72TM01
1 Gear box 1-16 Snap ring 3 Ball bearing 21 Spring 40 Orifice 50-7 O-ring
1-1 Flange holder 1-17 Holder 4 Oil seal 26 Pin 41 Spool 50-8 Socket head bolt
1-2 Floating seal 1-18 Planetary gear (A) 5 Swash plate 27 Ball bearing 42 Spring 51 Name plate
1-3 Angular bearing 1-19 Needle bearing 6 Steel ball 28 O-ring 43 Plug 52 Drive screw
1-4 Ring nut 1-20 Inner race 7 Cylinder block 29 O-ring 44 O-ring 55 Plug
1-5 Plug 1-21 Spring pin 8 Color 30 Base plate 45 Plug 57 O-ring
1-6 Housing 1-22 Drive gear 9 Spring 31 Plunger assy 46 Plug 58 Plug
1-7 Steel ball 1-23 Thrust plate (1.8 t) 10 Washer 31-1 Plunger 47 Orifice 59 Plug
1-8 Plug 1-23 Thrust plate (2.3 t) 11 Snap ring 31-2 Check valve 48 Socket head bolt 61 Disc
1-9 Planetary gear B 1-23 Thrust plate (2.8 t) 12 Pin 31-3 Spring 49 Pin 65 O-ring
1-10 Needle bearing 1-24 Cover 13 Holder 31-4 Plug 50 Valve assy 66 O-ring
1-11 Collar 1-25 O-ring 14 Retainer plate 31-5 O-ring 50-1 Valve body 68 Backup ring
1-12 Thrust washer 1-26 Wire 15 Piston assy 36 Spring seat 50-2 Spool 69 Backup ring
1-13 Thrust plate 1-27 Plug 17 Brake piston 37 Spring 50-3 Spring 71 Spring
1-14 Screw 1-28 Plug 19 Piston assy 38 Cap 50-4 Spring seat 73 Plug
1-15 Sun gear 2 Shaft sub assy 20 Spring 39 O-ring 50-5 Plug 74 O-ring
50-6 O-ring
7-64
3) MAINTENANCE
AINTENANCE INSTRUCTION
(1) Necessary tool to assemble
No. Parts name Applicable components or parts

Plug (1-5), (1-8), (45), (58), Screw (1-14)
1 (230) Orifice (40), (47)
Socket head bolt (50-8)
Torque wrench
Socket head bolt (48)
2 (preset type) (450)
Plug (1-27), (31-4), (43), (46), (50-5)
Housing (1-6), Ring nut (1-4)
3 (1800)
Cap (38)
4 Width across flats 2.0 Orifice (40)
5 Width across flats 2.5 Orifice (47)
6 Width across flats 4.0 Plug (45), Screw (1-14)
7 Hexagon bit for torque wrench Width across flats 5.0 Plug (1-8), (31-4)
Socket head bolt (50-8)
8 Width across flats 6.0 Plug (1-5), (1-27), (31-4), (43), (58)
Socket head bolt (48)
9 Width across flats 8.0 Plug (1-5), (50-5), Housing (1-6)
10 Width across flats 10.0 Socket head bolt (48)
11 Socket for socket wrench Width across flats 22.0 Plug (46)
12 Width across flats 36.0 Cap (38)
Floating seal (1-2)
13 Screw driver Wire (1-26), Base plate (30)
Oil seal (4)
Angular bearing (1-3)
Plug (1-5), Steel ball (1-7)
14 Hammer
Shaft (2), Oil seal (4)
Pin (26)
15 Plastic hammer Base plate (30), Cover (1-24)
16 Cutting pliers Wire (1-26)
17 Snap ring pliers Snap ring (11)
18 Punch Plug (1-5)
7-65
(2) Special Tools
·Table
No. Parts name Applicable components or parts
S-1 Pin Dia. 5.5×30 mm Plug (31-4)

S-2 Eyebolt PF 1/4 Cover (1-24), Wire (1-26)
S-3 Round bar dia. 20×1000 mm Cover (1-24), Wire (1-26)
S-4 Piano wire dia. 0.2×700 mm Steel ball (1-7)
S-5 Housing disassembly jig Housing (1-6)
S-6 Ring nut tightener Ring nut (1-4)
S-7 Round bar dia. 10×150 mm Angular bearing (1-3), Shaft (2)
S-8 Ball bearing disassembly jig Ball bearing (3)
S-9 Floating seal assembly jig Floating seal (1-2)
S-10 Angular bearing press fitting jig Angular bearing (1-3)
S-11 Flange holder press fitting jig Flange holder (1-1)
S-12 Oil seal press fitting jig Oil seal (4)
S-13 Ball bearing press fitting jig Shaft (2), Ball bearing (3)
S-14 Shaft sub assembly press fitting jig Shaft (2), Ball bearing (3)
S-15 Snap ring assembly jig Snap ring (11)
S-16 Ball bearings press fitting jig Ball bearing (27)
※ Refer to page 7-67 for detail figure. (S1~S16)
7-66
· Tools
21 13
4 9
11.2
2.5
5
1.
C
204
265
216
21
25 41
C1 PF1/4
Welding
S-2 Eye bolt S-5 Housing disassembly

+0.3
12.7
30.3+0.1
+0.1
4-16
146
150
90
35
10 107 9 100
S-6 Ring nut tightener S-8 Ball bearing disassembly
15 24
20
170.2 +0.1
169 +0.1
-0.2
-0.2
0
170.2
0
179.5
179.5
173
174
161
158
165
3 7.5
8 +0.5 15
S-9 Floating seal assembly S-10 Angular bearing press fitting
9 110
12 +0.1 12
11+0.1
2
180
23.8 -0.2
0
30
16
47
39
30
S-11 Flange holder press fitting S-12 Oil seal press fitting
60
+0.1
47 +0.05 50
25 10
30
5
26
35
S-13 Ball bearing press fitting S-15 Snap ring assembly

20
40
35
S-16 Ball bearing press fitting
7-67
2. DISASSEMBLY
(1) Before disassembling the TM motors, check the items to be inspected and, for remedy against
trouble, closely examine the nature of the trouble, so that the motor can be disassembled
effectively.
(2) To disassemble the motor, use the disassembling procedures described in section 2-2, and select
a clean place.
(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
(4) During disassembly, give a match mark to the mating surfaces of each part.
(5) Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
(6) Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.
7-68
2) DISASSEMBLE TRAVEL MOTOR BY 50-7
THE FOLLOWING PROCEDURE
(1) Fix the motor with vise.
Loosen socket head bolt (50-7), (50-8)
and remove valve assy (50).
·Tools required :
Torque wrench (No. 1)
Hexagonal bit for torque wrench (No. 7)
R35Z77TM01
(2) Remove cap (38).

·Tools required :
Torque wrench (No. 3) 38
Socket for torque wrench (No. 12)
38
R35Z77TM03
(3) Take out spring (37), spring seat (36).
37
36
36
37
R35Z77TM04
(4) Remove plunger sub assy (31) turning

slowly.
Be careful not to damage around the
plunger.
31
R35Z77TM05
7-69
(5) Disassembly of plunger sub assy is not
required when it operates normally.
Insert pin S-1, dia. 5.5×30, in the through
hole dia.6 of the plunger sub assy, and fix
it with vase.
·Tools required : Steel pin
Pin (S-1) R35Z77TM06
(6) Remove spring (31-3), check valve (31-2).

And store the parts so that the respective 31-3
par ts make a set as it was when 31-2
assembling again, taking care of the
combination of the right and left check
31
valves to the plunger.
R35Z77TM07
(7) Remove plugs (43), (46).

·Tools required :
Socket for torque wrench (No. 11) 43
R35Z77TM08
(8) Removing spring (42), spool assy (41).

Be careful not to damage around the
spool.
41
42
R35Z77TM09
7-70
(9) Remove socket head bolt (48). 48
·Tools required :
※ Points (with parking brake type)
To disassemble the motor easily, socket
head bolt (48) should be loosened evenly
because base plate (30) lift up by the
R35Z77TM10
reactive force of springs (21), (32).
(10) Remove base plate (30).

Then, pay attention so that cylinder block
(7) does not come out. When it is difficult 30
to remove, strike it by use of plastic
hammer. If it is more difficult to remove,
r e m o ve i t b y l i g h t l y p r y i n g w i t h
screwdriver.
·Tools required :
Plastic hammer (No. 15) R35Z77TM11
Screwdriver (No. 13)
(11) With parking brake type. 49 25

Remove pin (26), (49), valve plate (25), 29
O-rings (28, 29). 26
28
R35Z77TM12
(12) This process is the only parking brake 21

type.
Remove spring (21) and brake piston 17
(17). Blow compressed air into parking
brake releasing por t (show the
1-1
photograph with red circle) on flange
holder(1-1).
※ Before working, put rag on all surface of
brake piston because brake piston fly out R35Z77TM13
and oil flies off when working.
7-71
(13) Remove cylinder block sub assy (7), pin
(12), retainer holder (13), retainer plate
(14), piston sub assy (15). Be careful not 15 13
to damage the sliding surface of the
cylinder block. 14 18
Only parking brake type, remove disk 7
plate (18)
12
R35Z77TM14
(14) Remove snap ring (11) by use of plier.

Remove washer (8), spring seat (10) and
spring (9). Be careful not to damage the 10
sliding surface of the cylinder block. 9
·Tools required : 8
11
Snap ring pliers (No. 17)
※ Pay attention not to pinch fingers by the
inside spring when removing the snap
ring. R35Z77TM15
(15) Remove swash plate (5), steel ball (6),

piston sub assy (19) and spring (20).
20
19
5
R35Z77TM16
7-72
(16) Remove plugs (1-27), (1-8). Attach
eyebolt (PF 1/4) to the threaded hole of
plug (1-27) and insert pry-bar (length 1
[m]) in the eye hole, and turn the bar until
wire (1-26) can be seen through the
threaded hole of plug (1-8). Draw the wire
outside when the wire end can be seen.
·Tools required :
Torque wrench (No. 1, No. 2) R35Z77TM17
Eyebolt PF 1/4 (S-2)

Hexagonal bit for torque wrench (No. 7,
No. 8)
Round bar dia. 20×1000 mm (S-3)
Screw driver (No. 13), cutting pliers
(No. 16)
(17) Hook eyebolt and remove cover (1-24)

·Tools required :
Eyebolt PF 1/4 (S-2)
R35Z77TM18
(18) Remove sun gear assy (1-15), holder

(1-17), planetary gear A (1-18), needle
bearing (1-19), inner race (1-20), drive
gear (1-22) and thrust plate (1-23). 1-15 1-17
1-19
1-20
1-18
1-22
1-23
R35Z77TM19
7-73
(19) Remove thrust plate (1-13) and screw
(1-14).
·Tools required :
1-15 1-17
Torque wrench (No. 1) 1-19
1-20
Hexagonal bit for torque wrench (No. 6) 1-18
※ It is easy to remove the screw after
heated fully by heater because screw
1-22
(1-14) is applied loctite.
1-23
R35Z77TM19
(20) Remove planetary gear B (1-9), needle

bearing (1-10), inner race (1-11) and
thrust washer (1-12).
1-12
Be careful not to damage the tooth
1-10
surface of gear and the rolling section of 1-11
the collar. 1-9
R35Z77TM21
(21) Remove plug (1-8).

·Tools required :
R35Z77TM22
(22) Take out steel balls (1-7) from the

threaded hole of plug (1-8). After
decreasing (thinner, white gasoline. etc),
take out them by blowing air. Put piano 1-6
wire through the threaded hole to be sure
that all steel balls (1-7) are taken out. 1-7
·Tools required :
Hammer (No. 14), piano wire (S-4) 1-8
※ When it is difficult to remove, take out R35Z77TM23
steel balls (1-7) striking around housing

(1-6) by hammer.
7-74
(23) Attach jig between flange holder (1-1) and
housing (1-6), and tighten 3 bolts
M14×2.0 uniform from the housing side.
·Tools required : 1-6
Housing disassembly (S-5)
R35Z77TM24
(24) Remove plug (1-5).

·Tools required :
R35Z77TM25
(25) Removing ring nut (1-4).

·Tools required :
1-4
Ring nut tightener (S-6)
※ If fix them by vise, fix around of outside of
flange holder absolutely.
R35Z77TM26
(26) Apply pry-bar to the groove for steel balls

(1-7), and remove angular bearing (1-3)
striking it by hammer.
·Tools required :
Hammer (No. 14)
※ When removing, strike the groove turning. 1-3
If strike the groove on one portion,
R35Z77TM27
angular bearing wouldn't be removed.
7-75
(27) Remove floating seal (1-2) and angular
bearing (1-3).
1-2
1-3
R35Z77TM28
(28) Remove other floating seal (1-2) by use of

two drivers.
·Tools required :
Screw driver (No. 13)
※ Be careful not to damage the sliding
surface of floating seal (1-2).
R35Z77TM29
(29) Apply pre-bar to the hold of spline, and

remove shaft (2) striking it by hammer.
·Tools required :
2
R35Z77TM30
(30) Remove oil seal (4).

·Tools required :
Hammer (No. 14)
4
R35Z77TM31
7-76
(31) Take out ball bearing (3) from shaft (2).
·Tools required :
Ball bearing disassembly jig (S-8)
(32) Completed.
2
R35Z77TM32
7-77
3. REASSEMBLY
(1) Reassemble in a work area that is clean and free from dust and grit.
(2) Handle parts with bare hands to keep them free or linty contaminants.
(3) Repair or replace the damage parts.
Each parts must be free of burrs its corners.
(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.
(5) Wash all parts thoroughly in a suitable solvent.
Dry thoroughly with compressed air
Do not use the cloths.
(6) When reassembling oil motor components of TM motor, be sure to coat the sliding parts of the
motor and valve with fresh hydraulic oil.(NAS class 9 or above).
(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.
7-78
2) ASSEMBLE THE TRAVEL MOTOR BY
THE FOLLOWING PROCEDURE
(1) Apply grease to floating seal (1-2) and

install it on flange holder (1-1). 1-2
·Tools required :
1-1
Floating seal assembly jig (S-9)
R35Z77TM50
(2) Press fit angular bearings (1-3) to housing

(1-6).
·Tools required :
Angular bearings press fitting jig (S-10)
R35Z77TM51
(3) Apply grease to the second floating seal

and place it on the concentric circle. Install
1-2
it on housing (1-6).
·Tools required :
Floating seal assembly jig (S-9)
1-6
R35Z77TM52
(4) Apply lubricating oil on the sliding surface

of floating seal after make the surface
clean by rags.
Install flange holder (1-1) in housing (1-6).
·Tools required :
Flange holder press fitting jig (S-11)
※ If there are foreign articles on the sliding
surface of floating seal (1-2), it causes oil
leak. R35Z77TM53
7-79
(5) Tighten angular bearing (1-3) with ring nut
(1-4)
·Tools required :
Ring nut tightener (S-6)
Tightening torque 23.9±1.0 kgf·m
(173±7.2 lbf·ft)
R35Z77TM54
(6) Tighten plug (1-5).

The seal tape is not allowed to wrap for
assembling of this plug.
·Tools required :
Hexagonal bit for torque wrench (S-9)
(25.2±3.6 lbf·ft)
R35Z77TM55
(7) Caulk plug (1-5) two positions with punch

to lock.
·Tools required :
Hammer (No. 14)
Punch (No. 18)
R35Z77TM56
(8) Place steel balls (1-7) (99 pcs) in.

※ If it is difficult to place steel balls in, beat 1-7
on the side of housing (1-6) by using of
plastic hammer.
R35Z77TM57
7-80
(9) Wrap plug (1-8) with seal tape, and
tighten it.
·Tools required :
(5.8±0.7 lbf·ft)
※ Tighten plug (1-8) until the head of plug is
obscured against the surface of sprocket R35Z77TM58
guide.
(10) Install planetary gear B (1-9), needle

bearing (1-10), inner race (1-11) and
thrust washer (1-12).
1-12
1-10
1-11
1-9
R35Z77TM59
(11) Put thrust plate (1-13) on the trunnion

section of flange holder, apply loctite #262
to screw (1-14) and tighten it. 1-14
Before applying the loctite, decrease the
parts completely and us hardening
accelerator.
·Tools required :
Hexagonal bit for torque wrench (No. 6) R35Z77TM20
(9.4±0.4 lbf·ft)
(12) Install sun gear assy (1-15) with snap ring

(1-16), holder (1-17) with inner race
(1-20), planetary gear A (1-18), needle
bearing (1-19) and drive gear (1-22). 1-15 1-17
1-19
1-20
1-18
1-22
1-23
R35Z77TM19
7-81
(13) Install thrust plate (1-23).
R35Z77TM60
(14) Apply grease to O-ring (1-25), fit the

O-ring on cover (1-24), and install cover 1-24
(1-24) to housing (1-6) matching the
threaded hole of socket plug (1-8) of
housing (1-6) with the U-groove (for piano
wire). 1-6
·Tools required :
Plastic hammer (No. 14)
Eye bolt (S-2) R35Z77TM61
(15) Bend 6 [mm] of the top end of wire (1-26)

at right angle, insert it into the threaded
hole of the housing, and wind the piano
wire turning the cover. Wrap socket plug
(1-8) with seal tape before tightening.
·Tools required :
Eye bolt (S-2)
Round bar dia. 20×1000 [mm] (S-3)
Torque wrench (No. 1) R35Z77TM17
(5.8±0.7 lbf·ft)
(16) Apply grease to oil seal (4) and press fit it

in flange holder.
·Tools required :
4
Oil seal press fitting jig (S-12)
R35Z77TM62
7-82
(17) Press fit ball bearing (3) on shaft (2).
·Tools required :
Ball bearing press fitting jig (S-13)
Shaft sub assembly press fitting jig (S-14)
3
R35Z77TM63
(18) Press fit shaft sub assy (2) in flange

holder (1-1). 2
·Tools required :
Shaft sub assembly press fitting jig (S-14)
1-1
R35Z77TM64
(19) Install steel ball (6), spring (20), piston

assy (19) and swash plate (5) on flange
holder (1-1).
Apply hydraulic oil to the sliding surface of
6
the swash plate.
20
19
5
R35Z77TM16
(20) Install washer (8), spring (11), spring seat

9
(10) and snap ring (9) on cylinder block 8
(7).
11
·Tools required :
Snap ring pliers (No. 17)
10
Snap ring assembly jig (S-16)
R35Z77TM65
7-83
(21) Apply grease to pin (12) install pins in
three holes of cylinder block (7).
12
R35Z77TM66
(22) Install retainer holder (13), retainer plate

(14) and piston sub assy (15). Apply 15 13
hydraulic oil in 99 holes of cylinder block
(7). 14 18
Only parking brake type 7
Install disk plate (18).
R35Z77TM67
(23) Place the motor laterally, and install the

cylinder block sub assy regarding the
spline of the shaft as a guide.
※ Location of spline tooth of cylinder block
(7) should be aligned that of retainer
holder (13) to install them easily.
R35Z77TM68
(24) Push the cylinder block by hand, and

check that the spring contracts and
restores. Apply hydraulic oil to the sliding
surface of the cylinder block.
※ Confirm no foreign articles on surface of
cylinder block, marked a circle. If there are
foreign articles on it, wipe off them.
R35Z77TM69
7-84
(25) Apply grease to O-ring (28), (29) and 49
install pin (49) and them on flange holder 29
(1-1)
28
R35Z77TM70
(26) Press fit ball bearing (27) on base plate

(30).
·Tools required :
Ball bearing press fitting jig (S-16) 27
R35Z77TM71
(27) Apply grease on the back side of valve

plate (25), and install it and pin (26), 25
O-ring (29) on base plate. 26
29
R35Z77TM72
(28) This process is only parking brake type.

Apply grease to O-rings (22), (24) and
install them to brake piston (17).
Install brake piston (17) to flange holder 17
24 22
(1-1) to align pin (61) installed on base
plate in No. 29 with holes on brake piston
(17).
When install it, beat on evenly outside of
brake piston by using of plastic hammer.
R35Z77TM73
·Tools required :
Plastic hammer (No. 15)
7-85
(29) With parking brake type.
Install springs (21), base plate (30), Pin
(49). 30
※ Be careful of installing as springs (21), 49

21
(32) don't fall down.
It's difficult to fall down by greased them.
R35Z77TM74
(30) Tighten socket head bolt (48). 48

·Tools required :
Tightening torque : 13.1±0.7 kgf·m
(94.8±5.1 lbf·ft)
R35Z77TM10
(31) Place spool (41) and spring (42) in.

Place the spool in while turning to prevent
them from sticking.
Apply hydraulic oil to the spool before
installation. 41
42
R35Z77TM09
(32) Tighten plugs (43), (46) with O-ring (44).

·Tools required :
Socket for torque wrench (No. 11) 43
(39.8±3.6 lbf·ft)
R35Z77TM08
7-86
(33) Install check valve (31-2), spring (31-3) 31-4
and plug (31-4) with O-ring (31-5) to 31-5
plunger (31-1). 31-3
Apply a slight grease to the O-ring. 31-2
·Tools required :
(23.5±1.8 lbf·ft) R35Z77TM75
(34) Install plunger assy (31) on base plate

(30).
Install it while turning to prevent it from
sticking.
Apply hydraulic oil to plunger assy (31)
before installation. 31
R35Z77TM05
(35) Place spring (37) and spring seat (36) in.
37
36
36
37
R35Z77TM04
(36) Tighten cap (38) with O-ring (39).

Apply a slight grease to the O-ring.
·Tools required : 38
Hexagonal bit for torque wrench (No. 10) 38
(177±3.7 lbf·ft)
R35Z77TM03
7-87
(37) With parking brake type
Install spool (50-2), spring (50-3) and
spring seat (50-4) in valve body (50-1),
and tighten plug (50-5) 50-2
50-4
·Tools required :
50-5
(39.8±3.6 lbf·ft) R35Z77TM02
(38) Fit O-rings (50-6) or (50-7) to valve body, 50-7

and put valve assy (50) on base plate
(30).
Tighten socket head bolt (50-7), (50-8).
·Tools required :
(27.2±1.4 lbf·ft) R35Z77TM01
(39) Pour the gear oil through the threaded

hole of plug (1-27).
Wind the plug with seal tape before OIL FILL PORT
tightening.
OIL CHECK PORT
·Tools required :
Hexagonal bit for torque wrench (No. 8) OIL DRAIN PORT
(No. 9)
PF 1/4 … Tightening torque wrench R35Z77TM76
3.5±0.5 kgf·m
(25.3±3.6 lbf·ft)
PF 1/4 … Tightening torque wrench
4.0±0.2 kgf·m
(28.9±1.5 lbf·ft)
(40) Completed.
38
38
R35Z77TM03
7-88
3) QUALITY CHECK AFTER REASSEMBLY
(1) Air leak test of reduction unit
Remove one plug (① or ② or ③) of the reduction unit apply compressed air (0.03 [MPa])
through tapped hole of plug in water for two minutes, and observe that are no bubbles.
(2) Air leak test of motor
Seal all piping ports on the motor except one port with plugs, and apply compressed air (0.03
[MPa]) through open port in water for two minutes. Observe that there are no bubbles.
(3) Upon completion of leak test in subparagraphs (1) and (2) above, fill the motor case with new
hydraulic fluid. Run the motor crosswise for two minutes filling hydraulic fluid at flow rate of 20
liters per minute.
Confirm that there is no excessive heat, vibration or noise during running.
7-89
GROUP 7 RCV LEVER

1) REMOVAL

penetrate the skin causing serious injury. 1
(4) Loosen the socket bolt (1).

2
(5) Remove the cover of the console box.
(6) Disconnect pilot line hoses (3).
3
(7) Remove the pilot valve assembly (2).
※ When removing the pilot valve assembly,
check that all the hoses have been
21078DA06
disconnected.
2) INSTALL
to removal.
7-90
1) STRUCTURE
26
27
28
21
24
25
23
20 22
19 18
11 30
32
14
16 17, 29
15 12
13
5 7
8 6
10 4
3 31
9
2 1
R35Z92RL02
1 Case 9 Spring seat 17 Machine screw 25 Boot

2 Plug 10 Spool 18 Joint assembly 26 Handle
3 O-ring 11 Push rod (1, 3) 19 Swash plate 27 Switch assembly
4 Spring 12 Plug 20 Hex nut 28 Screw
5 Spring seat (1, 3) 13 O-ring 21 Connector 29 Plate (B)
6 Spring seat (2, 4) 14 Rod seal 22 Nut 30 Boot
7 Stopper 15 Plate (A) 23 Nut 31 Spring (2, 4)
8 Spring (1, 3) 16 Bushing 24 Insert 32 Push rod (2, 4)
7-91
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
(L) Hexagonal wrench 10 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5
Torque wrench Capable of tightening with the specified torques
7-92
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports.
(2) Fix pilot valve in a vise with copper (or
lead) sheets.
(3) Remove end of boot (30) from case (1)
and take it out upwards.
1408DA62
※ For valve with switch, remove cord also

through hole of casing.
1408DA63
(4) Loosen lock nut (22) and adjusting nut

(20) with spanners on them respectively,
and take out handle section as one body.
1408DA64
(5) Remove the boot (30).
1408DA61
7-93
(6) Loosen adjusting nut (20) and plate (29)
with spanners on them respectively, and
remove them.
RE04 (140-7)
RE05 (140-7)
(7) Turn joint anticlockwise to loosen it,

utilizing jig (special tool).
※ When return spring (8, 31) is strong in
force, plate (29), plug (12) and push rod
(11, 32) will come up on loosening joint.
Pay attention to this.
RE06 (140-7)
RE07 (140-7)
7-94
(8) Remove plate (29).
RE08 (140-7)
(9) When return spring (8, 31) is weak in

force, plug (12) stays in casing because
of sliding resistance of O-ring.
※ Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
※ During taking out, plug may jump up due
to return spring (8, 31) force.
RE09 (140-7)
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring (8, 31) out of casing.
※ Record relative position of reducing valve
subassembly and return springs.
RE10 (140-7)
(11) Loosen hexagon socket head plug (2)

with hexagon socket screw key.
RE11 (140-7)
7-95
(12) For disassembling reducing valve section,
stand it vertically with spool (10) bottom
placed on flat workbench. Push down
spring seat (5, 6) and remove two pieces
of semicircular stopper (7) with tip of small
minus screwdriver.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat (5,
RE14 (140-7)
6).
※ Do not push down spring seat more than
6 mm.
(13) Separate spool (10), spring seat (5, 6),

spring (8, 31) and spring seat (9)
individually.
※ Until being assembled, they should be
handled as one subassembly group.
RE15 (140-7)
(14) Take push rod (11, 32) out of plug (12).
RE16 (140-7)
(15) Remove O-ring (13) and seal (14) from

plug (12).
Use small minus screwdriver or so on to
remove this seal.
RE17 (140-7)
7-96
RE18 (140-7)
(16) Remove lock nut (22) and then boot (25).
RE19 (140-7)
25038RL02(4)
7-97
(17) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(rough cleaning).
※ If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
※ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
② Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides (finish
cleaning).
※ Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(18) Rust prevention of parts.
Apply rust-preventives to all parts.
※ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
7-98
4) ASSEMBLY
(1) Tighten hexagon socket head plug (2) to
the specified torque.
※ Tighten two bolts alternately and slowly.
RE29 (140-7)
(2) Put spring seat (9), springs (8, 31) and

spring seat (5, 6) onto spool (10) in this
order.
RE30 (140-7)
(3) Stand spool vertically with its bottom

placed on flat workbench, and with spring
seat pushed down, put two pieces of
semicircular stopper (7) on spring seat
without piling them on.
※ Assemble stopper (7) so that its sharp
edge side will be caught by head of spool.
Do not push down spring seat more than
6 mm.
RE31 (140-7)
(4) Assemble spring (8, 31) into casing.

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
RE32 (140-7)
7-99
(5) Assemble O-ring (13) onto plug (12).
RE33 (140-7)
(6) Assemble rod seal (14) to plug (12).

※ Assemble seal in such lip direction as
shown below.
RE34 (140-7)
(7) Assemble push rod (11, 32) to plug (12).

※ Apply working oil on push-rod surface.
RE35 (140-7)
(8) Assemble plug subassembly to casing.

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
RE36 (140-7)
7-100
(9) When return spring is strong in force,
assemble 4 sets at the same time,
utilizing plate (29), and tighten joint (18)
temporarily.
(10) Fit plate (29).
RE37 (140-7)
(11) Tighten joint (18) with the specified torque

to casing, utilizing jig.
RE38 (140-7)
(12) Assemble swash plate (19) to joint (18).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
RE39 (140-7)
(13) Assemble adjusting nut (20), apply

spanner to width across flat of plate (19)
to fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
RE40 (140-7)
7-101
(14) Fit boot (30) to plate.
1408DA61
(15) Fit boot (25) and lock nut (22), and handle
subassembly is assembled completely.
25038RL02(4)
RE48 (140-7)
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60° to 120°
from casing hole.
1408DA66
7-102
(17) Assemble bushing (16) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
1408DA67
(18) Determine handle direction, tighten lock

nut (19) to specified torque to fix handle.
1408DA68
(19) Apply grease to rotating section of joint

and contacting faces of disk and push
rod.
1408DA69
(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
25038RL04
7-103
GROUP 8 TURNING JOINT

1) REMOVAL

(4) Disconnect all hoses.
(5) Sling the turning joint assembly (1) and
remove the mounting bolt (2).
R35Z77TJ01
·Tightening torque : 6.9± 1.4 kgf·m
(49.9± 10.1 lbf·ft)
(6) Remove the turning joint assembly.
※ When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal.
※ Take care of turning joint direction.
1
※ Assemble hoses to their original positions.
※ Confirm the hydraulic oil level and check 2
R35Z77TJ02
7-104
1) STRUCTURE
7
6
9
8
3
12,13 10 11
R35Z77TJ03
1 Hub 5 Slipper seal 9 Retainer ring

2 Shaft 6 O-ring 10 Plug
3 Cover 7 O-ring 11 Plug
4 Spacer 8 O-ring 12 Hexagon bolt
13 Spring washer
7-105
2) DISASSEMBLY
※ Before the disassembly, clean the turning
joint.
(1) Remove bolts (12), washer (13) and cover
(3).
3
13
12
R35Z77TJ04
(2) Remove O-ring (8).

(3) Remove retainer ring (9) and spacer (4).
9
4
8
R35Z77TJ05
(4) Place hub (1) on a V-block and by using a

wood buffer at the shaft end, hit out shaft Secure with hand
Wooden block
(2) to about 1/2 from the body with a
hammer.
※ Take care not to damage the shaft (2)
when remove hub (1) or rest it sideway.
※ Put a fitting mark on hub (1) and shaft (2). V block
Work bench
8-141(3) 210-7
(5) Remove eight slipper seals (5) and O-ring

7
(6, 7) from hub (1). 6
R35Z77TJ06
7-106
3) ASSEMBLY
※ Clean all parts.
※ As a general rule, replace oil seals and
O-ring.
※ Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Fix eight slipper seal (5) and O-ring (6, 7)

7
to hub (1). 6
R35Z77TJ06
(2) Set hub (1) on block, install shaft (2) into

hub (1) by hand.
2
R35Z77TJ07
(3) Fit spacer (4) and retainer ring (9) to shaft

(2).
(4) Fit O-ring (8) to hub (1).
9
4
8
R35Z77TJ05
7-107
(5) Install cover (3) to hub and tighten bolts
(12).
13
12
R35Z77TJ04
7-108
GROUP 9 BOOM, ARM AND BUCKET CYLINDERS

1) BUCKET CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
※ Operate the control levers and pedals
13031GE18
Loosen the breather slowly to release
the pressure inside the hydraulic tank.
Bucket cylinder
injury.
※ Fit blind plugs in the hoses after disconn-
ecting them, to prevent dirt or dust from Arm
entering. Wooden block
① Set block between bucket cylinder and
arm. R35Z77CY03
② Remove bolt (2), nut (3) and pull out pin

(1). 1
2
※ Tie the rod with wire to prevent it from
coming out.
R35Z77CY02
③ Disconnect bucket cylinder hoses (4)

and put plugs (5) on cylinder pipe. 5
4
R35Z77CY04
7-109
④ Sling bucket cylinder assembly (9) and
remove bolt (6) and nut (7) then pull out 7 8
9
pin (8).
⑤ Remove bucket cylinder assembly (9).
·Weight : 30 kg (70 lb) 6
R35Z77CY05
(2) Install
① Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
※ Bleed the air from the bucket cylinder.
※ Confirm the hydraulic oil level and check
7-110
2) ARM CYLINDER
(1) Removal
stop the engine.
13031GE18
Arm cylinder
injury.
Block
ecting them, to prevent dirt or dust from
entering.
① Set block between arm cylinder and
boom.
R35Z77CY06
② Remove bolt and nut (2) and pull out pin

(1).
coming out.
1
R35Z77CY07
③ Disconnect arm cylinder hoses (4) and 4

put plugs on cylinder pipe.
4
R35Z77CY08
7-111
⑤ Sling arm assembly (8) and remove bolt 6
and nut (7) then pull out pin (6).
⑥ Remove arm cylinder assembly (8).
8 7
R35Z77CY09
(2) Install
to removal.
the pin hole.
※ Bleed the air from the arm cylinder.
※ Confirm the hydraulic oil level and check
7-112
3) BOOM CYLINDER
(1) Removal
stop the engine.
13031GE18
injury.
ecting them, to prevent dirt or dust from
entering.
① Sling boom cylinder assembly.
R35Z77CY10
③ Remove bolt and nut (2) and pull out pin

(1).
coming out.
1
2
R35Z77CY11
④ Lower the boom cylinder assembly (3)

on a stand.
R35Z77CY12
7-113
⑤ Disconnect boom cylinder hoses(4) and
put plugs on cylinder pipe.
R35Z77CY13
⑥ Remove bolt (6) and pull out pin (5).

⑦ Remove boom cylinder assembly (3).
5 6
R35Z77CY14
(2) Install
to removal.
the pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
7-114
1) STRUCTURE
(1) Bucket cylinder
21 20
5,4 3 11 7,6 8 9,10 1 2 12 13 14 15 16,17 18,19 23
22
R35Z77CY15
1 Tube assembly 9 O-ring 17 Back-up ring

2 Rod assembly 10 Back-up ring 18 Piston nut
3 Gland 11 O-ring 19 Set screw
4 Dust wiper 12 Piston 20 Pin bushing
5 Snap ring 13 Dust ring 21 Dust seal
6 Rod seal 14 Piston seal 22 Grease nipple
7 Back-up ring 15 Wear ring 23 Grease nipple
8 DU bushing 16 O-ring
7-115
(2) Arm cylinder
21,22,23 24,25
26 4,5 3 11 6,7 8 9,10 1 2 20 12 13 14 15 16,17 18,19 26
R35Z97CY16
1 Tube assembly 10 Back-up ring 19 Set screw

2 Rod assembly 11 O-ring 20 Cushion ring
3 Gland 12 Piston 21 Check valve
4 Dust wiper 13 Dust ring 22 Coil spring
5 Snap ring 14 Piston seal 23 Plug
6 Rod seal 15 Wearring 24 Pin bushing
7 Back-up ring 16 O-ring 25 Dust seal
8 DU bushing 17 Back-up ring 26 Grease nipple
9 O-ring 18 Piston nut
7-116
(3) Boom cylinder
23 21,22 22 21
4,5 3 11 6,7 8 9,10 1 2 20 12 13 14 15 16,17 18,19
24
R35Z77CY17
1 Tube assembly 9 O-ring 17 Back-up ring

2 Rod assembly 10 Back-up ring 18 Piston nut
4 Dust wiper 12 Piston 20 Cushion ring
5 Snap ring 13 Dust ring 21 Pin bushing
6 Rod seal 14 Piston seal 22 Dust seal
8 DU bushing 16 O-ring 24 Grease nipple
7-117
(4) Dozer cylinder
20 19
21 5,4 3 12 6,7 8 10,11 9 2 1 16 14 15 13 17,18 22
R35Z77CY18
1 Tube assembly 8 Buffer ring 15 Wear ring

2 Rod assembly 9 DU bushing 17 Piston nut
4 Dust wiper 11 Back-up ring 19 Pin bushing
5 Snap ring 12 O-ring 20 Dust seal
6 Rod seal 13 Piston 21 Grease nipple
7 Back-up ring 14 Piston seal 22 Grease nipple
7-118
(5) Boom swing cylinder
21 20
4,5 3 11 6,7 8 9,10 1 2 12 13 14 15 16,17 19 18
22
R35Z77CY19
1 Tube assembly 9 O-ring 16 O-ring

2 Rod assembly 10 Back-up ring 17 Back-up ring
3 Gland 11 O-ring 18 Piston nut
4 Dust wiper 12 Piston 19 Set screw
5 Snap ring 13 Dust ring 20 Pin bushing
6 Rod seal 14 Piston seal 21 Dust seal
8 DU bushing
7-119
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8 B
Allen wrench
3
Spanner M22
Hook spanner Suitable size (80~120 mm)
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgf·m lbf·ft
Boom cylinder 3 M90 68±6.8 492±49
Arm cylinder 3 M85 64±6.4 463±46
Gland Bucket cylinder 3 M75 56±5.6 405±41
Dozer cylinder 3 M100 75±7.5 542±54
Boom swing cylinder 3 M85 64±6.4 463±46
Boom cylinder 18 M33 82±8 593±59
Arm cylinder 18 M33 82±8 593±59
Piston Bucket cylinder 18 M29 73±7 528±53
Dozer cylinder 17 M39 150±15 1085±109
Boom swing cylinder 18 M33 93±9 673±67
7-120
3) DISASSEMBLY
※ Procedures are based on the boom
cylinder.
(1) Remove cylinder head and piston rod
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out rod assembly (2) about

200 mm (7.1 in). Because the rod
assembly is rather heavy, finish
m
extending it with air pressure after the oil
0m
20
draining operation.
R35Z77CY20
③ Loosen and remove the gland (3) by

hook spanner.
※ Cover the extracted rod assembly (2) Turn counter
with rag to prevent it from being clockwise Hook spanner
accidentally damaged during operation.
3
Cover here
with rag
R35Z77CY21
④ Draw out cylinder head and rod assembly

together from tube assembly (1). 1
Lift
※ Since the rod assembly is heavy in this
case, lift the tip of the rod assembly (2)
with a crane or some means and draw it Full straight
sideways
out. However, when rod assembly (2)
has been drawn out to approximately
two thirds of its length, lift it in its center to 2 Oil pan
draw it completely.
R35Z77CY22
7-121
Note that the plated surface of rod
assembly (2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
⑤ Place the removed rod assembly on a

wooden V-block that is set level.
※ Cover a V-block with soft rag.
2 Wooden block
R35Z77CY23
(2) Remove piston and gland 20 12 16,17 19 18

① Remove set screw (19)
② Remove piston nut (18).
※ Since piston nut (18) is tightened to a
high torque, use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the piston nut (18).
③ Remove piston assembly (12), back up

R35Z77CY24
ring (17), O-ring (10) and cushion ring
(20).
④ Remove the gland assembly from rod
assembly (2). Plastic
hammer
※ If it is too heavy to move, move it by
Lift with a crane
striking the flanged part of gland with a
plastic hammer.
Pull straight
※ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the
lip of DU bushing (8) and packing
R5577CY35
(4,5,6,7,9,10) by the threads of rod
assembly (2).
7-122
(3) Disassemble the piston assembly
① Remove wear ring (15). 13 14 15
② Remove dust ring (13) and piston seal
(14).
※ Exercise care in this operation not to
damage the grooves.
R35Z77CY25
(4) Disassemble gland assembly

① Remove back up ring (10) and O-ring (9).
4,5 3 6,7 8 9,10
② Remove snap ring (5), dust wiper (4).
③ Remove back up ring (7), rod seal (6).
④ Remove the cushion ring (8).
※ Exercise care in this operation not to
damage the grooves.
※ Do not remove seal and ring, if does not
damaged.
R35Z77CY26
7-123
4) ASSEMBLY
(1) Assemble cylinder head assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
R5577CY38
② Coat dust wiper (4) with grease and fit

Press here
dust wiper (4) to the bottom of the hole of (Straight down)
dust seal. Metal
At this time, press a pad metal to the 4
metal ring of dust seal.
③ Fit retain ring (5) to the stop face.
R35Z77CY29
④ Fit back up ring (7), rod seal (6) to

corresponding grooves, in that order.
※ Coat each packing with hydraulic oil
before fitting it. Wrong Right
※ Insert the backup ring until one side of it
is inserted into groove.
8-157(3) 210-7
※ Rod seal (6) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
※ Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
R35Z77CY35
7-124
⑤ Fit back up ring (10) to gland (3).
※ Put the backup ring in the warm water of 3 9,10
30~50°C .
⑥ Fit O-ring (9) to gland (3).
R35Z77CY27
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston (16) with
hydraulic oil.
R35Z77CY28
② Fit piston seal (14) to piston.

※ Put the piston seal in the warm water of 14
60~100°C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.
R35Z77CY30
③ Fit wear ring (15) and dust ring (13) to

piston (12). 12 13 15
R35Z77CY31
7-125
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench.
Gland assembly
② Apply hydraulic oil to the outer surface of
Rod assembly
rod assembly (2), the inner surface of
piston and gland.
③ Insert gland assembly to rod assembly.
R5577CY45
④ Insert cushion ring (20) to rod assembly.

※ Note that cushion ring (20) has a
20
direction in which it should be fitted.
Insert
R35Z77CY32
⑤ Fit piston assembly to rod assembly.

Piston assembly
R35Z77CY34
⑥ Fit piston nut (18) and set screw (19).

· Tightening torque :
19 18
Item kgf·m lbf·ft
Boom 18 82±8 593±59
Arm 18 82±8 593±59
Bucket 18 73±7 528±53
Dozer 17 150±15 1085±109
Boom swing 18 93±9 673±67 R35Z77CY33
7-126
(3) Overall assemble Fix with a bar
① Place a V-block on a rigid work bench.
Mount the tube assembly (1) on it and
Lift
fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
② Insert the rod assembly in to the tube
assembly, while lifting and moving the
Appply liquid packing
rod assembly with a crane.
2 R5577CY49
※ Be careful not to damage piston seal by
thread of tube assembly.
③ Match the bolt holes in the cylinder head Hook spanner
flange to the tapped holes in the tube
assembly and tighten socket bolts to a Turn clockwise
specified torque.
※ Refer to the table of tightening torque.
Cover here
with rag R5577CY50
7-127
GROUP 10 UNDERCARRIAGE
1. RUBBER
RUBBER TRACK
1) REMOVAL
Grease valve Frame
(1) Loosen tension of the rubber track.
※ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
R35Z77TR04
(2) Remove the rubber track from lower

frame using pry.
Pry
R35Z77TR22
2) INSTALL
to removal.
※ Adjust the tension of the rubber track.
90 ~ 110
R35Z77TR03
7-128
2. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden block
Master pin
as shown.
(2) Loosen tension of the track link.
※ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
Block
8-161(1) 140-7
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
※ Jack up the machine and put wooden
block under the machine.
※ Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet.
1
R35Z77TR01
2) INSTALL
to removal.
※ Adjust the tension of the track link.
90 ~ 110
R35Z77TR02
7-129
3. CARRIER ROLLER
Grease valve Frame
1) REMOVAL
(1) Loosen tension of the track link.
R35Z77TR04
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller

R35Z77TR05
(3) Loosen the bolt and nut (1) 1

(4) Open bracket (2) with a screwdriver, push
2
out from inside, and remove carrier roller
assembly.
·Weight : 5 kg (11 Ib) 1
R35Z77TR06
2) INSTALL
to removal.
7-130
4. TRACK ROLLER
Grease valve Frame
1) REMOVAL
(1) Loosen tension of the rubber track.
R35Z77TR04
(2) Using the work equipment, push up track

frame on side which is to be removed.
※ After jack up the machine, set a block
under the unit.
90 ~ 110
R35Z77TR02
(3) Remove the mounting bolt (1) and draw

out the track roller (2).
·Weight : 8 kg (17.5 lb)
2 R35Z77TR07
2) INSTALL
to removal.
7-131
5. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link
link.
(2) Sling the idler (1) and pull out idler and
1
recoil spring assembly from track frame,
using a pry.
R35Z77TR08
(3) Pull out yoke and spring weld assembly

from track frame, using a pry.
R35Z77TR09
(4) Sling the recoil spring (3) and pull out

recoil spring (3) from track frame.
R35Z77TR10
2) INSTALL
to removal.
※ Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
8-164(4) 140-7
7-132
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
5 8
7 3
6 1
4
4
6 5
3
R35Z77TR11
1 Shell 4 Ball bearing 7 Spring pin

2 Shaft 5 Bracket 8 Plug
3 Seal assembly 6 Snap ring
7-133
(2) Disassembly Press
① Remove plug and drain oil.
② Draw out the spring pin (7), using a
press.
7
R35Z77TR17
③ Remove brackets (5) from shaft.
1
R35Z77TR18
④ Remove seal assembly (3) from shell (1)

by pry.
※ Do not reuse seal assembly after
removal. 3
6
⑤ Remove snap ring (6) from shell (1)
1 6
3
R35Z77TR19
⑥ Draw out the ball bearing (4) with shaft

(2) using press.
⑦ Remove the ball bearing (4) from shaft, 1 4
using a special tool.
※ Only remove ball bearing if replacement
is necessity.
2
R35Z77TR20
7-134
(3) Assembly
※ Before assembly, clean the parts.
※ Coat the sliding surfaces of all parts with
oil.
① Do not press it at the normal temperature,
assemble ball bearing (4) to shaft by
press.
4
2
R35Z77TR21
② Insert shaft (2) with ball bearing (4)

assembly to shell (1).
1 4
2
R35Z77TR20
③ Assembly snap ring (6) and seal

assembly (3).
3
6
1 6
3
R35Z77TR19
④ Assemble bracket (5) to shell (1).
1
R35Z77TR18
7-135
⑤ Install bracket (5) attached with seal (3).
8-168(1) 140-7
⑥ Knock in the spring pin (7) with a Press

hammer.
7
R35Z77TR17
⑦ Lay bracket (5) on its side.

5
Supply engine oil to the specified level,
and tighten plug.
8-168(3) 140-7
7-136
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
10
8
9 7
1
5
6
R35Z77TR12
1 Body assy 5 Nut 8 O-ring

2 Rod 6 Split pin 9 Back-up ring
3 Tension spring 7 Grease valve 10 Packing
4 Cap
7-137
(2) Disassembly
① Apply pressure on cap (4) with a press.
※ The spring is under a large installed load. 5, 6
This is dangerous, so be sure to set
properly. 4
· Spring set load : 2700 kg (6000 lb)
② Remove split pin (6) and nut (5). 3
Take enough notice so that the press
which pushes down the spring, should
not be slipped out in its operation.
③ Lighten the press load slowly and
remove cap (4) and spring (3).
R35Z77TR13
⑤ Remove rod (2) from body (1).

⑥ Remove grease valve (7) from rod (2).
2
1
7
R35Z77TR14
⑦ Remove packing (10), back-up ring (9)

and O-ring (8) from body (1).
10
8
9
1
R35Z77TR15
7-138
(3) Assembly
① Install O-ring (8), back-up ring (9), and 10
8
packing (10) body (1). 9
1
R35Z77TR15
② Pour grease into body (1), then push in

rod (2) by hand. 2
After take grease out of grease valve
mounting hole, let air out.
1
※ If air letting is not sufficient, it may be 7
difficult to adjust the tension of crawler.
③ Fit grease valve(7) to rod(2).
(72.4±3. 6 lbf·ft)
R35Z77TR14
④ Install rod (2) to body (1).

2
R35Z77TR23
7-139
⑤ Install spring (3) and cap (4) to body (1).
⑥ Apply pressure to spring (3) with a press
and tighten nut (5).
※ During the operation, pay attention 5, 6
specially to prevent the press from
slipping out. 4
⑦ Tighten nut (5) and insert split pin (6).
3
R35Z77TR13
⑧ Lighten the press load and confirm the

set length of spring (2).
· Spring length : 233.5 mm
233.5mm
R35Z77TR16
7-140
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
C
C
B E
B
A
A
E
SECTION A-A SECTION B-B
SECTION C-C SECTION D-D SECTION E-E
R27Z97AT01
7-141
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
ground with back of bucket facing down.
R27Z97AT02
② Remove nut (1), bolt (2) and draw out the

pin (4).
R35Z77AT03
③ Remove nut (1), bolt (2) and draw out the

pin (3) then remove the bucket assembly.
R35Z77AT04
(2) Install
to removal.
the pin hole.
※ Adjust the bucket clearance.
For detail, see operator's manual.
R35Z77AT05
7-142
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket R5577AT06
assembly.
② Disconnect bucket cylinder hose (4).
Fit blind plugs (5) in the piping at the
chassis end securely to prevent oil from
spurting out when the engine is started.
③ Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
coming out.
④ For details, see removal of arm cylinder
assembly.
R35Z77AT04
Place a wooden block under the cylinder
and bring the cylinder down to it.
⑤ Remove bolt (1) and pull out the pin (2)
then remove the arm assembly.
※ When lifting the arm assembly, always lift
the center of gravity.
1,2
R5577AT07
(2) Install
① Carry out installation in the reverse
order to removal.
When lifting the arm assembly, always lift
※ Bleed the air from the cylinder.
7-143
3) BOOM CYLINDER
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. R5577AT08
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose (2)
and arm cylinder hose (1). 1,2
※ When the hose are disconnected, oil
may spurt out.
⑤ Sling boom assembly (3).
R5577AT10
⑥ Remove bolt (3), nut (4) and pull out the 3,4,5
pin (5) then remove boom assembly.
※ When lifting the boom assembly always
lift the center of gravity.
R5577AT09
(2) Install
to removal.
When lifting the arm assembly, always lift
※ Bleed the air from the cylinder.
R35Z77AT06
7-144

7-1. Disassembly and Assembly

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7-1. Disassembly and Assembly

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SECTION 7 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution ------------------------------------------------------------------------------------------------------ 7-1

Use following table for unspecified torque.

1) BOLT AND NUT

(1) Coarse thread

(2) Fine thread

3) PIPE AND HOSE (ORFS type)

Thread size Width across flat (mm) kgf·m lbf·ft

1. REMOVAL AND INSTALL

(3) Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

※ When pump suction tube is disconnected,

1 Body S 10 Swash plate 21 Rod G 33 Dish spring 49 Plug 68 Screw

Tool name Size Quantity

② Jigs for disassemble the port plate

※ When the hex socket set screw is used,

(2) Remove the coupling.

2) DISASSEMBLING THE TROCHOID

(2) Remove the case, the side plate (A), and

(4) Remove the side plate (A) from the case.

(5) Remove the side plate (B) from the port

(6) Remove the key of the shaft.

(2) Remove the cover.

(3) This photo shows the state with the port

(5) Remove the control spring and the spring

(6) Remove the spring seat.

(7) Remove the rotary group.

(9) Remove the shaft.

(10) Remove the swash plate assembly.

(11) Remove the guide.

Delivery side Suction side

(13) Remove the hexagon socket head cap

(14) Remove the spring seat.

(15) Disassemble the control piston assembly.

(17) Remove the minimum flow stopper.

(18) Remove the guide, the coned disk

(19) Remove the relief valve.

(21) Remove the spring.

(22) Remove the spool.

4) DISASSEMBLING THE GEAR PUMP

(3) Remove the square ring.

(4) Remove the plate, the guides, and the

(5) Remove the drive gear, the idle gear, and

(2) Install the retaining ring. (for holes ; 22)

(3) Install the parallel pin and the sleeve into

(5) Assemble the swash plate.

Delivery side Suction side

(6) Install the swash plate.

(8) Assemble the rotary group.

(9) Apply the grease to the spherical portion

(10) Insert the guide between the retainer and

(12) Install the retaining ring (for shafts ; 20),

(13) Assemble the control spring.

(14) Assemble the two springs (inner and

(16) Assemble the cover of the spring seat

(17) Apply grease to the backside of the

(18) Assemble the relief valve.

(20) Install the shim into the adjustment screw.

(21) Assemble the adjustment screw.