Zx330 Workshop w1hh e 01

Manual No.
: KM-1HH-E
Vol. No.
: W1HH-E-01
330 330LC 350H 350LCH 370MTH Excavator Workshop Manual
Workshop Manual
330 330LC
350H 350LCH
370MTH
Excavator
Service Manual (Manual No. KM-1HH-E) consists of the following three separate volumes;
Technical Manual (Operational Principle)
: Vol. No. TO1HH-E
Technical Manual (Troubleshooting)
: Vol. No. TT1HH-E
Workshop Manual
: Vol. No. W1HH-E
PRINTED IN SINGAPORE (PS) 2005.06
Zaxis330/350/370-WSM
1/7/05, 16:28
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain

and repair this machine.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you

found any errors regarding the contents of this
manual, please contact using Service Manual
Revision Request Form at the end of this manual.
(Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7173
FAX: 81-29-831-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
The Operators Manual

The Parts Catalog
Operation Manual of the Engine

Parts Catalog of the Engine
Hitachi Training Material
MANUAL COMPOSITION
This manual consists of three portions: the Techni-
Information included in the Technical Manual

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

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

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

Manual (Troubleshooting) and the Workshop Manual.
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains

the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.
CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
Indicates a situation which, if not conformed to the

instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
SI Units (International System of Units) are used in

this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft
A table for conversion from SI units to other system

units is shown below for reference purposees.
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev
Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
SAFETY
RECOGNIZE SAFETY INFORMATION
This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.
001-E01A-0688
SA-688
UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating
the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert
symbol.
DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.
DANGER or WARNING safety signs are

located near specific hazards. General
precautions are listed on CAUTION safety signs.
Some safety signs dont use any of the

designated signal words above after the safety
alert symbol are occasionally used on this
machine.
CAUTION also calls attention to safety messages in

this manual.
To avoid confusing machine protection with per-
sonal safety messages, a signal word IMPORTANT

indicates a situation which, if not avoided, could
result in damage to the machine.
NOTE indicates an additional explanation for an element of information.

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

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

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

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

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

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

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

Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached on the fire extinguisher to use it properly.
To ensure that a fire-extinguisher can be always

used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
Establish emergency procedure guidelines to
cope with fires and accidents.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department
posted near your telephone.
004-E01A-0437
SA-2
SA-437
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
SA-438
Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full atten-
tion of the operator. Do not wear radio or music

headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such

as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal injury.
In the walk-around inspection be sure to cover all

points
described
in
the
PRE-START
INSPECTION chapter in the operators manual.
S007-E01A-0435
SA-3
SA-435
SAFETY
GENERAL PRECAUTIONS FOR CAB
Before entering the cab, thoroughly remove all
dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operators
work boots the operators foot may slip off the
pedal, possibly resulting in a personal accident.
Dont leave parts and/or tools lying around the

operators seat. Store them in their specified locations.
Avoid storing transparent bottles in the cab. Dont

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

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

away from the machine.
After using the ashtray, always cover it to extinguish the match and/or tobacco.
Dont leave cigarette lighters in the cab. When

the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you mounting and dismounting the machine, always face the machine and maintain a
three-point contact with the steps and handrails.
Do not use any controls as hand-holds.

Never jump on or off the machine. Never mount
or dismount a moving machine.
Be careful of slippery conditions on platforms,
SA-439
steps, and handrails when mounting and dismounting the machine.

008-E01B-0439
ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing

the operator for the machine.
The operator should be able to fully depress the

pedals and to correctly operate the control levers
with his back against the seat back.
If not, move the seat forward or backward, and
check again.
009-E01A-0378
SA-5
SA-378
SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may
become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.
Prior to operating the machine, thoroughly

examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimize the chance of injury
from an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
SA-237
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

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

cause the machine to runaway, possibly resulting in
serious injury or death.
Start the engine only when seated in the

operator's seat.
NEVER start the engine while standing on the

track or on ground.
Do not start engine by shorting across starter

terminals.
Before starting the engine, confirm that all control
SA-444
levers are in neutral.

012-E01B-0444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
follow the instructions shown in the OPERATING
THE ENGINE chapter in the operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SA-032
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as
being struck by foreign objects and being thrown off

the machine.
Only the operator should be on the machine.

Keep riders off.
Riders also obstruct the operators view, resulting

in the machine being operated in an unsafe
manner.
014-E01B-0379
SA-379
PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES

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

BE DRIVEN
Incorrect travel pedal/lever operation may result in
serious injury death.
Before driving the machine, confirm the position

of the undercarriage in relation to the operators
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-491
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the
direction you wish to drive.
Be sure to detour around any obstructions.

Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Dont allow personnel to stay
around the machine while traveling.
SA-387
Driving on a slope may cause the machine to slip or

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

bucket facing the direction of travel, approximately 200 to 300 mm (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
Driving across the face of a slope or steering on

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

mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-391
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the machine may hit or run over that person, resulting in
serious injury or death.
To avoid back-over and swing accidents:

Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
Keep the travel alarm in working condition (if
SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP

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

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

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

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

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

the operators manual.
S021-E01A-0494
SA-11
SA-384
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
SA-012
To avoid tipping:
Be extra careful before operating on a grade.

Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or

slipping.
Avoid changing direction when traveling on

grades.
NEVER attempt to travel across a grade steeper

than 15 degrees if crossing the grade is
unavoidable.
Reduce swing speed as necessary when
swinging loads.
Be careful when working on frozen ground.

Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-12
SA-440
SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or
front attachments are not kept a safe distance from

electric lines.
When operating near an electric line, NEVER

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

be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,

sables, slings, or ropes.
Before craning, position the upperstructure with

the travel motors at the rear.
Move the load slowly and carefully. Never move it

suddenly.
Keep all persons well away from the load.

Never move a load over a person's head.
Do not allow anyone to approach the load until it
is safely and securely situated on supporting
blocks or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SA-014
SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
Guard against injury from flying pieces of metal

or debris; wear goggles or safety glasses.
Keep bystanders away from the working area

before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle / acceleration selector and H/P
mode switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.
033-E09B-0390
SA-14
SA-390
SAFETY
HANDLE FLUIDS SAFELYAVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when

near open flame or sparks.
Always stop the engine before refueling the

machine.
Fill the fuel tank outdoors.

All fuels, most lubricants, and some coolants are
SA-018
flammable.
Store flammable fluids well away from fire

hazards.
Do not incinerate or puncture pressurized

containers.
Do not store oily rags; they can ignite and burn

spontaneously.
Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-15
SA-019
SAFETY
SAFETY TRANSPORTING
The danger of tipping is present when load-
ing/unloading the machine onto/from a truck or

trailer bed.
Be sure to observe local regulations when

transporting the machine on public roads.
Provide an appropriate truck or trailer for

transporting the machine.
Take the following precautions when loading /
unloading the machine:
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation
of a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the
ramp as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SA-395
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before doing

work.
Keep work area clean and dry.

Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from

power-driven parts.
Before servicing the machine:

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Park the machine on a level surface.

Lower the bucket to the ground.
Turn the auto-idle / acceleration selecltor off.
Run the engine at slow idle speed without load
for 5 minutes.
Turn the key switch to OFF to stop engine.
Relieve the pressure in the hydraulic system by
moving the control levers several times.
Remove the key from the switch.
Attach a Do Not Operate tag on the control
lever.
Pull the pilot control shut-off lever to the LOCK
position.
Allow the engine to cool.
SA-028
If a maintenance procedure must be performed
with the engine running, do not leave machine

unattended.
If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Never work under a machine raised by the boom.
Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the MAINTENANCE
chapter in the operators manual.
Keep all parts in good condition and properly
installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SA-527
SAFETY
Use a portable safety light for working inside or
under the machine.
Make sure that the bulb is enclosed by a wire

cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.
SA-037
S500-E02B-0497
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, attach a Do Not Operate tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing the machine first.
Always lower the attachment to the ground

before you work on the machine.
If you must work on a lifted machine or

attachment, securely support the machine or
attachment. Do not support the machine on
cinder blocks, hollow tires, or props that may
crumble under continuous load. Do not work
under a machine that is supported solely by a
jack.
SA-527
519-E01A-0527
STAY CLEAR OF MOVING PARTS

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

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

serious injury, blindness, or death.
Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
As pieces may fly off, be sure to keep body and

face away from valve.
Travel reduction gears are under pressure.

As pieces may fly off, be sure to keep body and
SA-344
face away from AIR RELEASE PLUG to avoid

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

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

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

Use tools appropriate for the work to be done.
Makeshift tools, parts, and procedures can create
safety hazards.
For loosening and tightening hardware, use the

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

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

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap.
The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
SA-039
Hot fluids and surfaces:
Engine oil, gear oil and hydraulic oil also become
hot during operation.

The engine, hoses, lines and other parts become
hot as well.
Wait for the oil and components to cool before
SA-225
starting any maintenance or inspection work.

505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and

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

page of Periodic replacement of parts in the
operators manual.)
Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious
injury or death.
S506-E01A-0019
SA-20
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or
goggles for eye protection.
If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-031
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to

fires.
Check for oil leaks due to missing or loose

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

Clean and tighten all electrical connections.
Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
Check before starting work for missing or

damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wires

are loose, kinked, etc..
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris, ac-
cumulated coal dust, and other flammables may

cause fires.
Prevent fires by inspecting and cleaning the

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

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

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

them before operating the machine.
S508-E02B-0019
SA-22
SA-019
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air

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

EMERG. STOP position.
3)
Confirm that both engines stop and that

pressurized air inside the hydraulic oil tank is
released (a hissing sound should be heard).
If any abnormalities are found, be sure to repair

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

Damaged or missing heat shields must be
repaired or
machine.
replaced
before
operating
the
S508-E02B-0019
EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the
following way:
Stop the engine by turning the key switch to the

OFF position if there is time.
Use a fire extinguisher if there is time.

Exit the machine.
In an emergency, if the cab door and/or the front
SA-393
window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on EMERGENCY
EXIT in Operators Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be sure there is

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

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

FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a

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

CONTAINING FLAMMABLE FLUIDS
Do not weld or flame cut pipes or tubes that
contain flammable fluids.
them thoroughly with nonflammable
solvent before welding or flame cutting them.
Clean
510-E01B-0030
SA-24
SA-030
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If

inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.

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

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

Battery gas can explode.
Keep sparks, lighted matches, and flame away
from the top of battery.
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode.
Warm the battery to 16 C ( 60 F ) first.
Do not continue to use or charge the battery
when electrolyte level is lower than specified. Explosion of the battery may result.
Loose terminals may produce sparks. Securely
tighten all terminals.
Battery electrolyte is poisonous. If the battery

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

electrolyte specific gravity.
512-E01C-0032
SA-25
SA-032
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the freon container for proper use when

servicing the air conditioning system.
Use a recovery and recycling system to avoid

venting freon into the atmosphere.
Never let the freon stream make contact with the

skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals

used with your machine include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a

hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SA-309
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the en-
vironment and ecology. Potentially harmful waste

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

Do not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain,
or into any water source.
Air conditioning refrigerants escaping into the air
can
damage
the
Earths
atmosphere.
Government regulations may require a certified
air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
SA-226
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

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

CONTENTS
SECTION 1 GENERAL INFORMATION

Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
All information, illustrations and specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2005
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 4 FRONT ATTACHMENT

Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
TECHNICAL MANUAL (Operational Principle)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings
safely.
Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a load
with a temperature of 100 C (212 F) or more,
reduce the load weight.
Do not lift acid or alkali chemicals.
Take care not to allow the sling to become wet.
The load may slip.
When required to use more than one sling, use
slings with the same width and length to keep the
lifted load balanced.
When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
Avoid using twisted, bound, connected, or
hitched slings.
Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal object.
When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
Store the nylon slings indoors so they wont deteriorate with heat, sun light, or chemicals.
Correct Eyehole
Lifting Method
W102-04-02-016
Incorrect Eyehole
Lifting Method
W105-04-01-008
Bent Sling
W1-1-5
W162-01-01-009

CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may result. Be sure to visually check the nylon sling
for any damage before using.
Damaged Appearance
2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
Broken Sewing Thread
W162-01-01-002
Scuffing
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Scoring
Fuzz
Separation of
Belt
Scuffing
W162-01-01-006
W162-01-01-007
Broken Warp
W162-01-01-008
W1-1-6

MAINTENANCE STANDARD TERMINOLOGY
Standard
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification.
Allowable Limit
1. Normal machine performance cannot be accomplished after exceeding this limit.
2. Repair or adjustment is impossible after exceeding this limit.
3. Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the Allowable Limit.
W1-1-7

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

TIGHTENING TORQUE SPECIFICATION
No.
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Descriptions
Engine cushion rubber mounting bolt
(Fan Side)
Engine bracket mounting bolt
(Pump Side)
Engine oil filter mounting bolt
Radiator mounting bolt
Hydraulic oil tank mounting bolt
Fuel tank mounting bolt
ORS fittings for hydraulic hoses and piping
Pump mounting bolt

Control valve mounting bolt
Control valve bracket mounting bolt
Swing device mounting bolt
Swing motor mounting bolt
Battery mounting nut
Cab mounting nut
Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
ZAXIS330, 330LC, 350H,
Travel device
350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC, 350H,
Sprocket
350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC, 350H,
Upper roller
350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC
Lower roller
ZAXIS350H, 350LCH
mounting bolt
ZAXIS370MTH
ZAXIS330, 330LC
Track shoe bolt ZAXIS350H, 350LCH
ZAXIS370MTH
ZAXIS330, 330LC
Track guard
ZAXIS350H, 350LCH
mounting bolt
ZAXIS370MTH
Coupling, Jubilee and T-bolt clamp of low
pressure piping
23
Front pin-retaining bolt and nut
24
Counterweight
mounting bolt
Bolt Dia
Wrench
Qty
Size (mm)
mm
18
4
27
10
10
17
12
8
19
10
4
17
16
4
24
18
4
27
16
6
24
3
12UNF
1
36
16
7
12UNF
1
41
16
11
12UNF
1
50
16
10
8
17
16
4
24
16
4
24
22
12
32
12
12
10
10
2
17
16
4
24
27
36
36
27
36
36
ZAXIS330, 330LC
ZAXIS350H, 350LCH, 370MTH
Nxm
400
60
90
50
210
300
210
Torque
(kgfxm)
(41)
(6)
(9)
(5.1)
(21)
(30.5)
(21)
(lbfxft)
(300)
(43)
(65)
(37)
(151)
(220)
(151)
175
(18)
(130)
210
(21.5)
(155)
255
(26)
(188)
50
210
210
640
90
50
210
1226
1226
(5.1)
(21.5)
(21.5)
(65)
(9.2)
(5.1)
(21.5)
(125)
(125)
(37)
(155)
(155)
(470)
(66)
(37)
(155)
(905)
(905)
20
40
30
620
(63)
(460)
22
40
32
740
75
(540)
20
32
30
490
(50)
(360)
22
48
32
740
75
(540)
16
16
24
270
(27.5)
(200)
18
20
20
22
22
22
24
20
20
22
8
6
18
20
22
32
36
16
64
72
64
360
384
392
8
24
28
4
4
27
30
30
32
30
30
32
30
30
32
13
11
27
30
32
50
55
390
670
670
740
1130
1130
1370
620
620
740
40
(68)
(68)
75
(115)
(115)
(140)
(63)
(63)
(75)
(290)
(490)
(490)
(540)
(830)
(830)
(1010)
(460)
(460)
(540)
NOTE 1.Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to
W1-2-1
10.3 to 12.4 (1.05 to 1.26) (7.59 to 9.11)
5.9
400
550
750
2260
2840
(0.6)
(41)
(56)
(76.5)
230
290
(4.3)
(300)
(405)
(550)
(1665)
(2100)
reduce friction coefficient of them.

(Except for Sprocket mounting bolt.)

2.Make sure bolt and nut threads are clean
before installing.
W1-2-2

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

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

(lbfft)
(22)
(47)
(80)
(130)
(195)
(290)
(400)
(540)
(690)
(1010)
(1410)
(1880)
(2310)
Nm
19.5
49
88
137
205
295
390
540
690
1030
1420
1910
2400
W1-2-3
(kgfm) (lbfft)
(2)
(14.5)
(5)
(36)
(9)
(65)
(14)
(101)
(21)
(152)
(30)
(220)
(40)
(290)
(55)
(400)
(70)
(505)
(105)
(760)
(145) (1050)
(195) (1410)
(245) (1770)
M Bolt
Nm
9.8
19.5
34
54
78
118
167
215
275
390
540
740
930
(kgfm)
(1)
(2)
(3.5)
(5.5)
(8)
(12)
(17)
(22)
(28)
(40)
(55)
(75)
(95)
(lbfft)
(7.2)
(14.5)
(25.5)
(40)
(58)
(87)
(123)
(159)
(205)
(290)
(400)
(540)
(690)

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

Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and Inspect
sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tightening of one bolt fully before
tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
WRONG
RIGHT
Nut and Bolt Locking
Do not bend it round
Bend along edge sharply
RIGHT
WRONG
RIGHT
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while loosening.
Bend along edge sharply
RIGHT
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
RIGHT
RIGHT
WRONG
Loosen
W105-01-01-009
WRONG
Tighten
W105-01-01-010
W1-2-5

PIPING JOINT
IMPORTANT: The torques given in the chart are

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

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

W105-01-01-017
Wrench Size
mm
Union Nut
17
19
22
27
32
36
41
17
19
22
27
32
36
41
Wrench Size mm
Hose Fittings
17
19
22
27
32
36
41
14
17
19
22
27
32
36
Tightening
Torque
Nm (kgfm, lbfft)
24.5 (2.5,18)
29.5 (3.0,21.5)
39 (4.0,28.5)
93 (9.5,69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
24.5 (2.5,18)
29.5 (3.0,21.5)
39 (4.0,28.5)
93 (9.5,69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
NOTE: Tightening torque of 37male coupling without union is similar

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

O-ring Seal Joint
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with a
new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly in
O-ring groove (e). Tightening nut (9)
with O-ring (6) displaced will damage
O-ring (6), resulting in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10).
Damage to O-ring (6) will cause oil
leakage.
4. If nut (9) is loose and oil is leaking,
do not re-tighten nut (9). Replace
O-ring (6) with a new one and check
that O-ring (6) is correctly seated in
place, tighten nut (9).
W1-2-7
Wrench Size
mm
Union Nut
19
22
27
32
36
41
46
Wrench Size
mm
Hose Fittings
17
19
22
27
30,32
36
41
Hose Fittings
M104-07-033
Tightening Torque
Nm (kgfm, lbfft)
29.5 (3.0,21.5)
69 (7.0,51)
93 (9.5,69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
205 (21.0,151)

Screw-In Connection
Depending on types of screw and sealing, different types
of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread pitch
and thread type (tapered or straight) are
the correct type before using any
screw-in connection.
PT
30
Male Tapered Thread
PF
Male Straight Thread
W105-01-01-018
Wrench Size
mm
Hose Fittings
19
22
27
36
41
50
60
Male Tapered Thread

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

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

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

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

Connecting Hose
RIGHT
WRONG
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being
kinked.
W105-01-01-011
RIGHT
WRONG
Rubbing Against
Each Other
If hoses rub against each other, wear to the

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

with moving parts or sharp objects.
WRONG
Clamp
RIGHT
Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG
Rubbing Against
Each Other
RIGHT
Clamp
W105-01-01-014
W1-2-9

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

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

and gaskets, when replacing hoses.
W1-2-10
Replacement
Intervals
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
GENERAL / Painting
PAINTING
Surfaces to Be Painted
Main surface of upperstructure
Bed cover
Tool box cover
Inner face
Front attachment
Track (undercarriage)
Floor plate
Rear left portion of cab
Painting Colour
YR-01 [TAXI yellow]
High Grade Beige
YR-01 [TAXI yellow]
Grey
YR01 [TAXI yellow]
N1.0 [Black]
M/F cation colour
YR-01 [TAXI yellow]
Final painted colour

Inside and outside surface of cab
High Grade Beige

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

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

High Grade Black
High Grade Black
KASAI PAINT Amilack 1400 deep black.
Cab Inside and Outside
Engine Cover
Engine Cover
Right Window
Beam
Right Ladder
Rail
Mirror Stay
900
350
Main Surface of
Upperstructure
Tool Box Cover
Bed Cover
W178-01-03-002
W1-3-1
720
Main Surface of
Upperstructure
W178-01-03-001
GENERAL / Painting
A
YR-01
(TAXI Yellow)
Out Surface of Hinge Swing

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

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

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

fitted with HN bushing, care not to
pour washing liquid directly on them.
The ambient temperature shall be
controlled under 70C when painting
and drying.
W1HH-01-03-001
Track (Undercarriage)
N1.0 (Black)
W178-01-03-008
W1-3-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Remove and Install Cab.............................W2-1-1

Dimensions of the Cab Glass.....................W2-1-8
Group 2 Counterweight
Remove and Install
Counterweight..........................................W2-2-1
Group 3 Main Frame

Remove and Install
Main Frame..............................................W2-3-1
Group 4 Pump Device

Remove and Install Pump Device ..............W2-4-1
Disassemble Pump Device ........................W2-4-2
Assemble Pump Device .............................W2-4-8
Disassemble Main Pump ........................W2-4-16
Assemble Main Pump ............................W2-4-24
Disassemble Regulator............................W2-4-38
Assemble Regulator.................................W2-4-40
Disassemble and Assemble
Pilot Pump .............................................W2-4-42
Maintenance Standard .............................W2-4-46
Remove and Install Control Valve ............. W2-5-1

Disassemble Control Valve (1) .................. W2-5-4
Assemble Control Valve (1) ....................... W2-5-6
Disassemble Control Valve (2) .................. W2-5-8
Assemble Control Valve (2) ..................... W2-5-10
Disassemble Control Valve (3) ................ W2-5-12
Structure of Valves .................................. W2-5-30

Remove and Install Swing Device ............. W2-6-1
Disassemble Swing Device ....................... W2-6-4
Assemble Swing Device .......................... W2-6-14
Disassemble Swing Motor ....................... W2-6-22
Assemble Swing Motor............................ W2-6-26
Parking Brake Release Valve ................ W2-6-30
Maintenance Standard ............................ W2-6-31
1HHW-2-1
Group 7 Pilot Valve
Group 10 Solenoid Valve
Remove and Install Right

Pilot Valve ................................................W2-7-1
Remove and Install Left
Pilot Valve ................................................W2-7-5
Remove and Install
Travel Pilot Valve .....................................W2-7-9
Disassemble Right and Left Pilot Valves
(Up to serial No.320880) ........................W2-7-12
(Serial No.320881 and up) .....................W2-7-16
Assemble Right and Left Pilot Valves
(Up to serial No.320880) ........................W2-7-20
(Serial No.320881 and up) .....................W2-7-24
Disassemble Travel Pilot Valve (Suitable for the
machine before March in 2003)..............W2-7-28
Disassemble Travel Pilot Valve (Suitable for the
machine after April in 2003.) ..................W2-7-32
Assemble Travel Pilot Valve (Suitable for the
machine before March in 2003)..............W2-7-36
Assemble Travel Pilot Valve (Suitable for the
machine after April in 2003.) ..................W2-7-42
Remove and Install

Solenoid Valve Unit ............................... W2-10-1
Disassemble Propotional Solenoid
Valves (SC, SI and SG) ......................... W2-10-4
Assemble Propotional Solenoid
Valves (SC, SI and SG) ......................... W2-10-6
Disassemble Proportional Solenoid
Valves (Torque Control Solenoid Valve,
Maximum Pump2 Flow Rate Limit
Solenoid Valve) ..................................... W2-10-8
Assemble Proportional Solenoid
Valves (Torque Control Solenoid Valve,
Maximum Pump2 Flow Rate Limit
Solenoid Valve) ................................... W2-10-10
Pilot Relief Valve ................................. W2-10-12
Group 8 Pilot Shut-Off Valve

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

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

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

1
W1HH-02-01-004
3
4
5
W178-02-01-012
W2-1-1
4. Remove filter (6) to remove screws (7) with a
screwdriver, then remove duct (8) from the cab.
7
8
W178-02-01-013
5. Disconnect harness connectors (10, 11, 12, and

13) on the right side in the cab and remove bolt
to remove ground (9) at rear inside of the cab.
: 17 mm
9
10
11
12
13
W178-02-01-014
6. Remove washer vinyl hose (14) at rear inside of

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

screwdriver. Use a screwdriver to loosen screws
(16) to remove duct cover (17).
17
15
W178-02-01-016
W2-1-2
8. Remove screws (18) and bolts (21) to remove
duct (19) and duct (20).
: 17 mm
18
Mating Surface of Duct
19
20
CAUTION: Cab weight:

ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
21
W178-02-01-017
ZAXIS330, 330LC, 350H, 350LCH
22
9. Attach the cab upside with lifting straps (22).
W178-02-01-018
ZAXIS370MTH:
A
A
W1HH-02-01-003
Section A-A
Lifting Strap
W1HH-02-01-002
W2-1-3
10. Remove cab mounting bolts (23) and nut (24)
from the cab.
: 17 mm
: 24 mm
: 8 mm
23
24
W157-02-01-010
11. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-4
Installation
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS370MTH:
395 kg (870 lb)
1. Attach the cab with lifting straps to hoist it by
crane.
W157-02-01-001
23
2. Install bolts (23) and nuts (24) to the cab.

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

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

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

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

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

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

: 17 mm
: 50 Nm (5.1 kgfm, 37 Ibfft)
ZAXIS370MCH:
W178-02-07-006
W1HH-02-01-004
W2-1-7
DIMENSIONS OF THE CAB GLASS
A
NOTE: Unit: mm
(1 mm=0.039 in)
Chamfer Here
67
303.5
Chamfer along the

periphery unless
otherwise specified
11
R2
R35
R98
4-13 0-1
R3018
30
405
Section A
Chamfer both
sides
W178-02-01-019
375
238
612
51
R118
(5 mm)
343.5
148.5
196
100
50
R70
370.5
W178-02-01-006
Along the
Periphery
c1
Along the
Periphery
W178-02-01-002
Suitable for the standard machine

after March in 2002
B
c1
(60.3)
261.61
(9.4)
R42
R72
Section C
W178-02-01-019
366
R2992
5461
14
733
R92
(4 mm)
R58
R58
170.6
R11508
70
50
R1808
882.5
R42
997
321.91
(4 mm)
R308
W178-02-01-024
Remove sharp
edges along the
periphery
R1898
R258
100
150
Section B
943
W178-02-01-007
W2-1-8
W178-02-01-019
Unit: mm
Chamfer
Slightly
unless the
Periphery
Polish
Chamfered
Chamfer Here
Chamfer Here
85.4
343.3
213
R105
R10
R72
R105
(4 mm)
Chamfer Slightly unless the Periphery Polish Chamfered
39.5
D
733
733
R2465
2-12.2
Section C
and D
(4 mm)
+0.5
-0
6.754
40
W178-02-01-019
Polish Chamfer the

Both Fringes
289.5
50
3-R4
2-R4
86.9
50
50
556.3
50
W178-02-01-011
423
W178-02-01-008
366.1
R12
104.5
R95
(5 mm)
982.7
Chamfer along
the Periphery
W178-02-01-004
R2002
872
R123
R5 for 3 Places
38.2
51
364.7
R2475
(5 mm)
Chamfer along the

Periphery
R115
888.58
W178-02-01-010
W2-1-9
R14
470.6
W178-02-01-009
Suitable for the standard machine after March in
2002
W178-02-01-005
A
753
R63
R63
610.5
490
(4 mm)
R115
R115
R167
50
50
512.5
R167
W178-02-01-025
Remove Sharp
edges along the
periphery
Section A
W2-1-10
W178-02-01-019
Remove Cab Glass
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section
Mounting Rubber
CAUTION: When
removing
broken
or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or similar
should be used to tape the broken or
cracked glass ready to reinforce them so as
to prevent injury from occurring. Be sure to
remove all glass fragments.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal.
Cab
Seal Rubber
W178-02-01-022
1. Insert bamboo spatula into position A in mounting

rubber to pry the mounting rubber apart along all
periphery. It is easier to remove glass when air is
entered between cab and mounting rubber.
2. Tap glass from the side in cab by palm of hand to
take the glass off. Two men are required to do
the work.
Glass
W178-02-01-004
Mounting Rubber
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
assembly.
The
upper
front
glass
is
arched-fringed. If this glass needs
to be replaced, contact with the
nearest HITACHI Office to replace it
as an assembly.
W2-1-11
Glass
Cab
Seal Rubber
W178-02-01-022
Procedures to Remove Right-Hand Cab Glass

Cab Inside
1. Insert a bamboo spatula into position A in

mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the
glass when air is entered between cab and
mounting rubber.
Glass
Mounting Rubber
A
Cab
2. Tap glass from the side in cab by palm of the

hand to take the glass off. Two men are required
to do the work.
W216-02-01-005
W178-02-01-002

Mounting Rubber
Method to remove rear side cab glass

1. Remove stopper (groove rubber) with a minus
screwdriver.
Glass
Cab Inside
A
2. Insert a bamboo spatula into position A in

mounting rubber to pry the mounting rubber apart
along all periphery.
Stopper
(Groove Rubber)
A
Cab
W216-02-01-003
3. Tap glass from the side in cab by palm of the

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

cant be replaced individually. Be
assembly.
The
upper
front
glass
is
to be replaced, replace it as an
assembly.
CSE Braid
Seal Rubber
Put Connect End in Center of

Glass Edge and Then Stick It.
W178-02-01-021
1. Install the seal rubber on the left-hand cab glass

and lower glass of the door.
Lower Glass of Door

50
Section A
A
CSE Braid
Seal Rubber
10
10
Mounting
Rubber
W178-02-01-020
Cab Glass
5
W178-02-01-023
Cab
2. When the mounting rubber is already on the

glass, pull and fasten the mounting rubber onto
the mounting face of cab.
Seal Rubber
W178-02-01-022
W178-02-01-004
W2-1-13
Procedures of installing right-hand cab glass

assembly.
The
upper
front
glass
is
assembly.
1. Install the mounting rubber into the surrounding
of cab glass. Bond the connectors of mounting
rubber with the bonding agent (Cemedine 366
Standard or equivalent).
Cab Glass
Mounting
Rubber
Cab
W216-02-01-005
NOTE: Rubber aging will cause the contraction of

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

assembly.
The
upper
front
glass
is
assembly.
1. Insert mounting rubber around the cab glass. Install the connectors or mounting rubber with the
bonding agent (Cemedine 366 Standard or
equivalent).
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
2. After installing the glass assembly on the cab,
insert the stopper into rubber.
W2-1-14
Cab Glass
Stopper
Cab
W216-02-01-003
W178-02-01-005
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Removal
CAUTION: Counterweight weight:

ZAXIS330, 330LC: 6800 kg (15000 lb)
ZAXIS350H, 350LCH 370MTH:
7550 kg (16650 lb)
1. Remove caps (1) from counterweight (3) top. Install sling bolts (FLENO RINK BOLT B-42, M42,
Pitch 4.5) to counterweight (3).
W178-02-02-001
Wire Rope
Sling Bolt
2. Attach wire ropes to the sling bolts as illustrated.

Take up slack of wire ropes.
W178-02-02-002
3. Remove bolts (2) and washers (4). Hoist and

remove counterweight (3).
ZAXIS330, 330LC:
: 50 mm
ZAXIS350H, 350LCH, 370MTH:
: 55 mm
4
2
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
1. Hoist and install counterweight (3) onto the main
frame.
Install washers (4) and tighten bolts (2) to counterweight (3) temporarily.
3
2
ZAXIS330, 330LC:
: 50 mm
: 55 mm
4
W178-02-02-003
2. Remove the wire ropes. Tighten bolts (2) by using a power wrench and torque wrench.
ZAXIS330, 330LC:
: 50 mm
: 2260 Nm (230 kgfm, 1660 lbfft)
: 55 mm
: 2840 Nm (290 kgfm, 2100 lbfft)
Torque Wrench
Power Wrench
W178-02-02-004
W178-02-02-001
3. Remove the sling bolts. Install caps (1) to counterweight (3).
W2-2-2
UPPERSTRUCTURE / Main Frame

REMOVE AND INSTALL MAIN FRAME
IMPORTANT: Release any pressure in the hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
ZAXIS330, 330LC, 350H, 350LCH:
290 kg (640 lb)
ZAXIS 370MTH: 395kg (870 lb)
W157-02-01-001
1. Remove cab (5). (Refer to Remove and Install

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

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

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

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

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

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

6560 kg (14460 lb)
5. Attach wire ropes to the rear (counterweight
bracket) of main frame and boom bracket. Take
up slack of wire ropes.
If chain block (1) is used, it is not only easy to
adjust the length of wire rope, but also easy to
level the main frame.
W173-03-03-001
Rear of Main Frame
Boom Bracket
W105-02-03-004
W105-02-03-005
W157-02-03-001
W2-3-2

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

frame. Hoist and remove the main frame from the
undercarriage.
W157-02-03-002
W2-3-3

Installation
CAUTION: Upperstructure weight:
6560 kg (14460 lb)
1. Attach wire ropes to the main frame. Adjust chain

block (1) in order to level the main frame.
Hoist and install the main frame to the undercarriage.
As for lifting method, refer to the Removal
section.
W157-02-03-002
2. Align the matching marks on the upperstructure

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

: 17 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
: 27 mm
: 118 Nm (12 kgfm, 87 lbfft)
: 41 mm
: 295 Nm (30 kgfm, 220 lbfft)
3
4
4. Install stopper (4) to the center joint with bolts (3).

: 22 mm
: 54 Nm (5.6 kgfm, 41 lbfft)
W173-03-03-001
W2-3-4

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

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

ZAXIS330, 330LC: 6800 kg (15000 lb)
7550 kg (16650 lb)
6. Install counterweight (6).
(Refer to Remove and Install Counterweight in
this section.)
6
ZAXIS330, 330LC:
: 50 mm
: 2260 Nm (230 kgfm, 1660 lbfft)
: 55 mm
: 2840 Nm (290 kgfm, 2100 lbfft)
W178-02-02-002
W2-3-5

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

REMOVE AND INSTALL PUMP DEVICE
Air Bleed Plug
Removal
1. Remove the connectors from the pump device.
CAUTION: Pump device weight: 205 kg
(452 lb)
2. Remove all hoses and pipes from the pump
device.
: 17 mm, 27 mm, 36 mm
: 10 mm
W110-02-04-002
3. Install eyebolts (M12, Pitch 1.75 mm) to the

pump device and hold the pump device.
4. Remove the pump device mounting bolts and
remove the pump device.
: 17 mm
Installation
1. Install eyebolts on the pump device. Hoist the
pump device.
2. Install the pump device with the pump device
mounting bolts.
3. Install all hoses and pipes to the pump device.
4. Install the connectors to the pump device.
5. Remove the air bleed plugs (2 used) on top of
the regulators. Fill hydraulic oil. (Refer to
W1-1-2.)
6. After completing the work, check hydraulic oil
level and any oil leakage.
W2-4-1
Wrench
Size (mm)
: 36
: 27
: 10
: 17
Tightening Torque
Remarks
Nm (kgfm) (lbfft)
175
(18) (130)
Hose
93
(9.5)
(69)
Hose
88
(9)
(65)
Bolt
49
(5)
(36)
Bolt

DISASSEMBLE PUMP DEVICE
14
13
20
12
13
22
15
13
21
18
17
16
22
19
10
9
7
8
22
11
6
5
3
4
2
37
19
36
32
23
33
10
31
1
39
22
34
35
42
40
41
28
45
38
24
43
26 30
25
27
44
29
W1HH-02-04-004
12345678910 11 12 -
Drive Gear (2 Used)

Retaining Ring (2 Used)
N Sensor
O-Ring
Washer
Socket Bolt
Socket Bolt
Spring Washer
Spring Washer (4 Used)
Bolt (8 Used)
Main Pump (2 Used)
Pipe
13 14 15 16 17 18 19 20 21 22 23 24 -
Fitting (4 Used)
Pipe
Bolt
Nut
Washer
Clamp (2 Used)
Pipe (2 Used)
Pipe
Fitting
Fitting (5 Used)
Flange
Bearing
25 26 27 28 29 30 31 32 33 34 35 -
W2-4-2
Seal Cover
Retaining Ring
Oil Seal
Center Shaft
Coupling Assembly
O-Ring
Seal Washer (4 Used)
Socket Bolt (2 Used)
Washer (2 Used)
Pilot Pump
36 37 38 39 40 41 42 43 44 45 46 -
Adapter
Plug
Center Gear
Level Gauge
Pipe
Packing
Drain Plug
Retaining Ring
Bearing
P Sensor (2 Used)

Disassemble Pump Device
1. Remove socket bolts (6, 7) and remove N sensor
(3).
: 5 mm
2. Remove P sensors (46) (2 used).
: 27 mm
3. Remove bolts (E) (4 used) of coupling assembly
(29). Remove insert (H) from hub (A).
: 6 mm
4. Remove screws (B) (2 used) from hub (A).
Remove hub (A) and insert (D) from center shaft
(28).
: 8 mm
46
W173-02-04-002
NOTE: Inserts (F) are installed by using spring

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

lb)
6. Secure the pump device
workbench.
Workbench : ST 5050
assembly
on
a
B
W2-4-3
W110-02-04-006
14
20
12
18
16
19
15
17
10
9
11
19
36
32
33
31
34
35
40
41
W1HH-02-04-004
W2-4-4

7. Remove bolt (15). Remove nut (16), washer (17),
and clamp (18) from the pipe.
: 13 mm
8. Remove pipes (12, 14, 19, 20).
: 19 mm, 22 mm
9. Remove adapter (36) from pilot pump (35).
: 27 mm
10. Remove socket bolts (32) (2 used), spring
washers (33), and washers (34). Remove pilot
pump (35).
: 8 mm
11. Remove bolts (10) (4 used), spring washers (9),
and seal washers (31).
: 24 mm
CAUTION: Main pump weight: 67 kg (148 lb)
12. Install eyebolt (M12, Pitch 1.75 mm) to main
pump (11). Hoist and remove main pump (11).
13. Remove the other main pump in the same procedures as steps 11 and 12.
14. Remove socket bolts (41) (2 used) and remove
pipe (40).
: 6 mm
W2-4-5
23
28
45
38
24
26
30
25
27
44
W1HH-02-04-004
W2-4-6

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

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

using a press or puller.
W173-02-04-004
W2-4-7

ASSEMBLE PUMP DEVICE
1
22
21
20
19
A
18
B
B
17, 16, 15
3, 4
5, 6
14
7, 8
13
W1HH-02-04-001
12
10
11
37
Section B-B
45
38
23
24
25
26
44
27
28
29
46
30
36
35
32, 33, 34
31
W1HH-02-04-002
W2-4-8
View A
W1HH-02-04-003
41, 42
43
12345678910 11 12 -
Drive Gear (2 Used)

N Sensor
O-Ring
Washer
Socket Bolt
Socket Bolt
Spring Washer
Bolt (8 Used)
Main Pump (2 Used)
Pipe
13 14 15 16 17 18 19 20 21 22 23 24 -
Fitting (4 Used)
Pipe
Bolt
Nut
Washer
Clamp (2 Used)
Pipe (2 Used)
Pipe
Fitting
Fitting (5 Used)
Flange
Bearing
25 26 27 28 29 30 31 32 33 34 35 -
W2-4-9
40
Seal Cover
Retaining Ring
Oil Seal
Center Shaft
Coupling Assembly
O-Ring
Seal Washer (4 Used)
Washer (2 Used)
Pilot Pump
39
36 37 38 39 40 41 42 43 44 45 46 -
Adapter
Plug
Center Gear
Level Gauge
Pipe
Packing
Drain Plug
Retaining Ring
Bearing
P Sensor (2 Used)

45
38
23
24
25
26
44
27
28
46
30
W1HH-02-04-002
W2-4-10

Assemble Pump Device
CAUTION: Flange weight: 39kg (86 lb)
ST 2307
1. Face input shaft side of flange (23) upward.

Install bearing (45) by using special tool (ST
2307).
2. Insert center gear (38) into flange (23) from the
main pump mounting hole. Set center gear (38)
onto bearing (45).
3. Place flange (23) on a press. Align center shaft
(28) with the center gear (38) spline. Install
center shaft (28) into bearing (45).
4. Install bearing (24) into flange (23) and center
shaft (28) by using special tool (ST 2308) and a
press.
W173-02-04-005
ST 2308
W173-02-04-006
CAUTION: Flange assembly weight: 48 kg

(106 lb)
5. Remove flange (23) from a press. Place flange
(23) on the workbench. Install retaining ring (44)
onto center shaft (28). Install O-ring (30) into
flange (23).
6. Install oil seal (27) into seal cover (25) by using
7. Insert special tool (ST 2280) onto center shaft
(28) and install seal cover (25) into flange (23).
8. Install retaining ring (26) into flange (23).
W2-4-11
W1HH-02-04-001
11
10
23
36
35
W2-4-12
32, 33, 34
31
W1HH-02-04-002

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

: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
W2-4-13
20
19
18
17, 16, 15
3
14
W1HH-02-04-001
12
37
28
46
W1HH-02-04-002
W2-4-14

16. Install pipes (12, 14, 19, 20).
: 19 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
: 22 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
17. Install clamp (18) with bolt (15), nut (16), and
washer (17).
: 13 mm
: 3 Nm (0.3 kgfm)
Assemble Coupling
18. Place the pump device horizontal. Install hub (A)

to center shaft (28) with screws (B) (2 used).
: 8 mm
: 108 Nm (11 kgfm, 80 lbfft)
G
F
19. Install inserts (H, D) to hub (A) with bolts (E) (4

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

: 27 mm
CAUTION: Pump device weight: 205 kg
(452 lb)
22. Place the pump device horizontally. Remove plug
(37). Add engine oil.
Engine oil : 1.4 L (0.37 US gal.)
23. Install the pump device with the plug (37) hole
facing to the counterweight.
: 17 mm
W2-4-15
W110-02-04-006

DISASSEMBLE MAIN PUMP
47, 48
4
31
41
43
42
31
1
3
10
11
17
15
16
14
30
44
49
24
25
25
23
39
40
19
7
22
34
25
21
20
13
37
38
46
31 45
29
27
25
25
33 32
18
9
12
8
21
25
20
22
28
26
48
36
35
40
39
W173-02-04-026
12345678910 11 12 13 -
Casing
Drive Disc
Roller Bearing (2 used)
Roller Bearing
Spacer
Bearing Nut
Plunger (7 used)
Cylinder Block
Center Shaft
Drive Gear
Retaining Ring
Spring
Pin
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Oil Seal
Seal Cover
O-Ring
Retaining Ring
Valve Plate
Link
Lever (2 Used)
Pin (2 Used)
Pin (2 Used)
Pin
Feedback Pin
Servo Piston
27 28 29 30 31 32 33 34 35 36 37 38 39 -
Servo Pin
Set Screw
Head Cover
Spring Pin (2 Used)
O-Ring (10 Used)
Bolt (8 Used)
Plug
Stopper L
O-Ring
Stopper S
O-Ring
Bolt (8 Used)
W2-4-16
40 41 42 43 44 45 46 47 48 49 50 -

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

Disassemble Main Pump
Remove Drive Gear
1. Remove retaining ring (11) from the main pump.
2. Remove drive gear (10) by using a puller.
3. Secure the main pump on the workbench (ST
5050).
4. Remove bolts (47) (4 used) and spring washer
(48). Remove regulator (41).
: 8 mm
5. Remove O-rings (31) (5 used), O-ring (42), and
spring pins (43) (2 used).
6. Remove bolts (32) (8 used) and spring washers
(33). Remove head cover (29).
: 10 mm
7. Remove O-rings (31) (3 used) from casing (1).
8. Place valve plate (18) on casing (1).
9. Remove cylinder block (8) upward and remove
valve plate (18) and link (19).
10. Remove spring (12).
W2-4-17
1
16
17
15
14
13
9
2
W173-02-04-026
W2-4-18

11. Remove center shaft (9). Do not lose pin (13).
12. Incline plungers (7) (7 used) to the center of drive
disc (2). Remove plungers (7) upward.
13. Place casing (1) on the workbench. Remove retaining ring (17).
14. Place casing (1) on the workbench with the drive
disc side upward. Remove seal cover (15) by
using a screwdriver.
14
15. Remove oil seal (14) from seal cover (15) by using a screwdriver.
16. Remove O-ring (16) from casing (1).
W173-02-04-007
17. Turn over casing (1) and place casing (1) on a

press. Remove drive disc (2) and the bearing by
using a press and special tool (ST 1239).
ST 1239
W173-02-04-008
W2-4-19
4
6
3
5
W173-02-04-026
W2-4-20

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

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

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

23. Remove roller bearing (4) from spacer (5) by using special tool (ST 1271).
ST 1271
W173-02-04-012
W2-4-21
39
40
37
38
27
29
28
2
26
36
35
40
39
W173-02-04-026
W2-4-22

24. Install special tool (ST 1272) between drive disc
(2) and roller bearing (3). Clamp the assembly in
a vise. Adjust the clearance in order to use a
puller.
ST 1272
2
W173-02-04-013
25. Set a puller. Remove roller bearings (3) (2 used)

from drive disc (2) at the same time.
Puller

(40) (4 used) from stopper S (37).
Remove O-ring (38) and stopper S (37) from
head cover (29).
: 6 mm
(40) (4 used) from stopper L (35).
Remove O-ring (36) and stopper L (35) from
head cover (29).
: 6 mm
28. Remove set screw (28) from servo piston (26)
and remove servo pin (27) from head cover (29).
: 8 mm
NOTE: LOCTITE #829 is applied to set screw (28).
Heat set screw (28) before disassembling.
W2-4-23
3
W173-02-04-014

ASSEMBLE MAIN PUMP
39, 40
37
31
43
47, 48
41
42 24
23
19
38
10
11
A
28
27
15
26
29
35
36
Section B-B
49
18
30
44
12
21 25
20
22
13
16
17
14
W1HH-02-04-005
W1HH-02-04-006
W2-4-24
45
46
View A
34
50
32, 33
W173-02-04-002
12345678910 11 12 13 -
Casing
Drive Disc
Roller Bearing (2 used)
Roller Bearing
Spacer
Bearing Nut
Plunger (7 used)
Cylinder Block
Center Shaft
Drive Gear
Retaining Ring
Spring
Pin
14 15 16 17 18 19 20 21 22 23 24 25 26 -
Oil Seal
Seal Cover
O-Ring
Retaining Ring
Valve Plate
Link
Lever (2 Used)
Pin (2 Used)
Pin (2 Used)
Pin
Feedback Pin
Servo Piston
27 28 29 30 31 32 33 34 35 36 37 38 39 -
Servo Pin
Set Screw
Head Cover
Spring Pin (2 Used)
O-Ring (10 Used)
Bolt (8 Used)
Plug
Stopper L
O-Ring
Stopper S
O-Ring
Bolt (8 Used)
W2-4-25
40 41 42 43 44 45 46 47 48 49 50 -

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

Assemble Main Pump
1. Insert servo piston (26) into head cover (29). Install servo pin (27) into the servo piston (26) hole
from the suction port in head cover (29). Apply
LOCTITE #829 to the thread part of set screw
(28). Tighten set screw (28) and secure servo pin
(27).
: 8 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
2. Install O-ring (38) on stopper S (37). Install stopper S (37) to head cover (29) with bolts (39) (4
used) and spring washers (40) (4 used).
: 6 mm
: 30 Nm (3.1 kgfm, 22.4 lbfft)
3. Install special tool (ST 7923) on the large chamber side of head cover (29). Set servo piston (26)
so that servo pin (27) is at the center of the suction port.
CAUTION: The inner race becomes too hot.
Avoid being burned.
4. Heat roller bearings (3) (2 used) and the inner
race of bearing (4) to 50 to 80 C (122 to 176 F).
Apply hydraulic oil to roller bearings (3, 4) inside.
ST 7923
W173-02-04-015
W2-4-27
W1HH-02-04-005
W2-4-28

5. Place drive disc (2) on a workbench with the
spline side up. Install roller bearings (3) (2 used)
on drive disc (2).
Apply hydraulic oil to the bearing race surfaces.
6. Install the outer race of roller bearing (4) to
spacer (5) by using special tool (ST 2408).
ST 2408
7. Install roller bearing (4) and spacer (5) on drive

disc (2).
W173-02-04-016
Check that roller bearings (3, 4) are securely installed on drive disc (2) after they have cooled
down to atmosphere temperature.
Apply hydraulic oil to the bearing race surfaces.
ST 7102
Install the inner race of roller bearing (4) by using

8. Place drive disc (2) on special tool (ST 5905). Install bearing nut (6) on the thread part in drive
disc (2). Tighten bearing nut (6) until it contacts
bearing (4).
Apply lubricating oil to the thread part in bearing
nut (6).
W173-02-04-017
6
ST 5905
W173-02-04-018
W2-4-29
15
16
W2-4-30
14
W1HH-02-04-005

9. Insert special tool (ST3054) into the spline in
drive disc (2). Turn drive disc (2) and tighten
bearing nut (6).
When tightening bearing nut (6), tighten counterclockwise.
ST 3054
W173-02-04-023
10. Measure the preload of roller bearings (3, 4). Set

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

2.940.49 Nm (0.300.05 kgfm, 2.170.36 lbfft)
ST 5905
CAUTION:
Casing (1) becomes too hot. When applying
grease, avoid being burned.
11. Heat casing (1) to 50 to 80 C (122 to 176 F).
Apply grease to the inside of casing (1).
W173-02-04-024
12. Install drive disc (2) into casing (1).

Check that drive disc (2) is securely installed in
casing (1) after the casing has cooled down to
atmosphere temperature.
13. Install O-ring (16) into the groove on casing (1).
Apply grease to O-ring (16).
ST 2409
14. Install oil seal (14) into seal cover (15) by using
special tool (ST 2409). Apply grease to the oil
seal (14) lip.
15
W173-02-04-019
W2-4-31
23
19
15
12
13
17
W1HH-02-04-005
18
W1HH-02-04-006
W2-4-32

15. Install special tool (ST 2410) on the spline of
drive disc (2). Install seal cover (15) in casing (1).
Tap seal cover (15) into casing (1) by using a
plastic hammer until the retaining ring (17)
groove on casing (1) is visible.
16. Install retaining ring (17) to casing (1).
Check that retaining ring (17) seats well in the
groove after installing.
17. Turn over casing (1) and place casing (1) on a
workbench with the drive disc side down. Apply
hydraulic oil to the spherical surface of drive disc
(2). Incline plunger (7) to the center of drive disc
(2). Install plungers (7).
18. Apply grease in order not to fall off pin (13) and
install pin (13) to center shaft (9).
19. Install center shaft (9) on drive disc (2).
20. Install spring (12) on center shaft (9).
21. Connect link (19) to valve plate (18). Place valve
plate (18) on casing (1) inside. Insert pin (23) in
link (19) to the mounting end for the casing (1)
regulator.
W2-4-33
14
15
ST 2410
W173-02-04-020
23
19
27
29
49
18
13
W1HH-02-04-005
30
W1HH-02-04-006
W2-4-34

22. Install plungers (7) (7 used) and center shaft (9)
into cylinder block (8).
Install pin (13) into the groove of cylinder block
while rotating the end of center shaft (9) by using
a radio plier.
23. Apply hydraulic oil to the speherical surfaces of
valve plate (18) and cylinder block (8). Face the
spherical surface of valve plate (18) to cylinder
block (8) and insert into the end of center shaft
(9) into the hole on value plate (18).
24. Apply grease to O-rings (31) (3 used). Install
O-rings (31) (3 used) and packing (49) on casing
(1).
NOTE: As for O-rings (31), refer to W2-4-16.
25. Install special tool (ST 7094) on the drain port of
casing (1). Secure valve plate (18) at the center
position.
18
26. Align servo pin (27) on head cover (29) with the
valve plate (18) hole.
27. Align the holes of spring pins (30). Install head

cover (29) on casing (1). Tighten bolts (32) (8
used) with spring washers (33) (8 used).
: 12 mm
: 110 Nm (11 kgfm, 80 lbfft)
ST 7094
W173-02-04-021
32, 33
W173-02-04-002
W2-4-35
47, 48
43 41
42
24
39, 40
2
10
11
29
35
W1HH-02-04-005
36
44
W2-4-36

28. Remove special tool (ST 7094) from casing (1).
Install plug (44).
Remove special tool (ST 7923) from head cover
(29). Install O-ring (36) on stopper L (35). Install
stopper L (35) with spring washers (40) (4 used)
and bolts (39) (4 used).
: 6 mm
: 20 Nm (2 kgfm, 14.5 lbfft)
: 8 mm
: 49 Nm (5 kgfm, 36.2 lbfft)
29. Apply grease to O-rings (31, 42). Install O-rings
(31) (5 used) and O-ring (42) onto the regulator
mounting surface of casing (1).
NOTE: Check that spring pins (43) (2 used) are
installed. As for O-rings (31), refer to
W2-4-16.
CAUTION: Main Pump weight: 67 kg (148 lb)
30. Align feedback pin (24) in the pump with the
notches on sleeves (2 used) in regulator (41).
Install regulator (41) to casing (1).
31. Install bolts (47) (4 used) and spring washers
(48) (4 used) to regulator (41).
: 8 mm
32. Install drive gear (10) into drive disc (2).
33. Install retaining ring (11) into drive disc (2).
W2-4-37
35, 36
39, 40
44
ST 7923
ST 7094
W173-02-04-022

DISASSEMBLE REGULATOR
25
26
27
11
12
20
22
24
23
21
18
30
19
31
28
15
14
29
17
16
13
15
8
2
14
26
25
11
12
10
32
W173-02-04-029
9
12345678-
Stopper
O-Ring (3 Used)
Sleeve
Spool
Casing
Spring
Piston
Cylinder
910 11 12 13 14 15 16 -
Nut
Screw
Nut (2 Used)
Nut (2 Used)
Stopper
Stopper (2 Used)
O-Ring (2 Used)
Spring
17 18 19 20 21 22 23 24 -
Spring
Sleeve
Spool
Cylinder
Piston
O-Ring
Backup Ring
O-Ring
W2-4-38
25 26 27 28 29 30 31 32 -

Front Cover
Bolt (4 Used)
Air Bleed Plug
O-Ring
Rear Cover
UPPERSTRUCTURE/Pump Device
Disassemble Regulator
1. Clamp casing (5) in a vise.
2. Remove air bleed plug (30) and O-ring (31) from
casing (5). Remove elbows (4 used) from casing
(5).
: 19 mm, 41 mm
3. Remove socket bolts (25) (8 used). Remove front
cover (27) and rear cover (32).
: 6 mm
IMPORTANT: If loosening stoppers (1, 13, 14),
nuts (9, 11, 12), and screw (10), the
regulator setting will change. Do not
loosen stoppers (1, 13, 14), nuts (9,
11, 12), and screw (10).
4. Remove springs (16, 17) from the rear cover (32)
side in casing (5).
5. Push spool (19). Remove cylinder (20) from the
front cover (27) side in casing (5).
6. Remove piston (21), O-ring (22), and backup ring
(23) from cylinder (20).
7. Remove sleeve (18) and spool (19) from the front
cover (27) side in casing (5).
8. Remove spool (19) from sleeve (18).
9. Remove spring (6) from the front cover (27) side
in casing (5).
10. Push spool (4). Remove piston (7) and cylinder
(8) from the rear cover (32) side in casing (5).
11. Remove piston (7) and O-ring (2) from cylinder
(8).
12. Remove sleeve (3) and spool (4) from the front
cover (27) side in casing (5). Remove spool (4)
from sleeve (3) .
W2-4-39
ASSEMBLE REGULATOR
24 23
25, 26
27
22
21 20
19
18
17
16
28, 29
15 14 13 12
30
31
10
11
T173-03-01-005
32
W173-02-04-001
12345678-
Stopper
O-Ring (3 Used)
Sleeve
Spool
Casing
Spring
Piston
Cylinder
910 11 12 13 14 15 16 -
Nut
Screw
Nut (2 Used)
Nut (2 Used)
Stopper
Stopper (2 Used)
O-Ring (2 Used)
Spring
17 18 19 20 21 22 23 24 -
Spring
Sleeve
Spool
Cylinder
Piston
O-Ring
Backup Ring
O-Ring
W2-4-40
25 26 27 28 29 30 31 32 -

Front Cover
Bolt (4 Used)
Plug
O-Ring
Rear Cover
Assemble Regulator
1. Clamp casing (5) in a vise.
2. Install spool (19) into sleeve (18).
3. Install sleeve (18) and spool (19) from the front
cover (27) side in casing (5).
4. Install spool (4) into sleeve (3). Install sleeve (3)
from the front cover (27) side in casing (5).
5. Install piston (7) into cylinder (8).
6. Install O-ring (2) to cylinder (8). Apply grease to
O-ring (2). Install cylinder (8) from the rear cover
(32) side in casing (5).
7. Install the rear cover (32) assembly and springs
(16, 17) to casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.6 Nm (2 kgfm, 14.5 lbfft)
8. Install O-ring (22), backup ring (23), and piston
(21) to cylinder (20).
9. Apply grease to O-ring (22). Install cylinder (20)
from the front cover (27) side in casing (5).
10. Install the front cover (27) assembly and spring
(6) into casing (5). Tighten socket bolts (25) (4
used) with spring washers (26).
: 6 mm
: 19.5 Nm (2 kgfm, 14.5 lbfft)
11. Apply grease to O-ring (31). Install O-ring (31) to
plug (30).
12. Tighten plug (30).
: 41 mm
: 78.5 Nm (8 kgfm, 58 lbfft)
13. Install elbows (4 used) to casing (5).
W2-4-41
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
14
10
15
12
13
6
9
8
1
16
5
15
11
14
5
7
9
4
2
W110-02-04-022
1234-
Housing
Flange
Oil Seal
Retaining Ring
5678-
Seal (2 Used)
Cover
Backup Ring (2 Used)
Key (2 Used)
910 11 12 -
O-Ring (2 Used)
Gear
Drive Gear
Washer (4 Used)
W2-4-42
13 14 15 16 -
Bolt (4 Used)
Bushing (2 Used)
Bushing (2 Used)
Knock Pin (2 Used)
Disassemble Pilot Pump
1. Clamp flange (2) in the pilot pump in a vise with
cover (6) up.
2. Remove bolts (13) (4 used).
: 17 mm
3. Remove cover (6) from housing (1).
4. Remove O-ring (9) from cover (6).
5. Remove flange (2) from housing (1).
6. Remove O-ring (9) from flange (2).
7. Remove retaining ring (4) from flange (2).
8. Remove oil seal (3) from flange (2) by using a
screwdriver.
9. Remove seal (5) and backup ring (7) from bushings (14, 15) in cover (6) side.
10. Lightly push drive gear (11). Remove bushings
(14, 15) in cover (6) side from housing (1).
Do not fall off the key between the bushings.
11. Remove seal (5) and backup ring (7) in flange (2)
side from bushings (14, 15).
12. Remove bushings (14, 15) in frange (2) side from
housing (1). Remove gear (10) and drive gear
(11) from housing (1).
W2-4-43
14
10
15
12
13
6
9
8
1
16
5
15
11
14
5
7
9
4
2
W110-02-04-022
1234-
Housing
Flange
Oil Seal
Retaining Ring
5678-
Seal (2 Used)
Cover
Key (2 Used)
910 11 12 -
O-Ring (2 Used)
Gear
Drive Gear
Washer (4 Used)
W2-4-44
13 14 15 16 -
Bolt (4 Used)
Bushing (2 Used)
Bushing (2 Used)
Knock Pin (2 Used)
Assemble Pilot Pump
1. Install oil seal (3) into flange (2) by using special
tool.
2. Install retaining ring (4) to flange (2).
3. Install bushings (14, 15) in cover (6) side to
housing (1) with the seal groove side down.
4. Install gear (10) and drive gear (11) to housing
(1).
5. Install bushings (14, 15) in flange (2) side to
housing (1) with the seal groove side up.
6. Install seal (5) and backup ring (7) into the seal
groove on bushings.
7. Install O-ring (9) on flange (2).
8. Install flange (2) on housing (1).
9. Turn over the housing and flange assembly.
Clamp the flange in a vise. Do not fall off the
bushings and gears when turning over. Install
seal (5) and backup ring (7) into the seal groove
on bushings.
10. Install O-ring (9) on cover (6).
11. Install cover (6) on housing (1).
12. Tighten washers (12) and bolts (13).
: 17 mm
: 39 to 44 Nm
(4 to 4.5 kgfm, 29 to 32.5 lbfft)
W2-4-45
MAINTENANCE STANDARD
Pump Device
Unit : mm (in)
Gear backlash
Standard
Allowable Limit
Remedy
0.48 (0.019)
1.5 (0.059)
Replace
Main Pump
1. Drive disc: Spline tooth thickness
Unit : mm (in)
Standard
Allowable Limit
4.9 (0.193)
3.5 (0.138)
2. Drive disc: Oil seal outer diameter

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

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

diameter and cylinder block bore
D
Unit: mm (in)
D-a
Standard
Allowable Limit
0.044 (0.0017)
0.08 (0.0031)
W157-02-04-017
W2-4-46
5. Plunger: Clearance between plunger and
connecting rod
Unit : mm (in)
Standard
Allowable Limit
0.1 (0.0039)
0.4 (0.0016)
W157-02-04-033
6. Clearance between center shaft and valve plate

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

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

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

D
Unit : mm (in)
D-a
Standard
Allowable Limit
0.051 (0.0020)
0.3 (0.012)
W157-02-04-019
W2-4-47
(Blank)
W2-4-48
UPPERSTRUCTURE / Control Valve

REMOVE AND INSTALL CONTROL VALVE
Arm 2
Boom 1
Bucket
Right Travel
4-Spool Section
5-Spool Section
Main
Relief
valve
Removal
Swing
Arm 1
Boom 2
Auxiliary
Left Travel
1. Remove all hoses, pipes, and connectors from

the control valve.
Attach identification tags to the removed hoses
for reassembling. Cap all the removed hoses and
pipes.
: 17 mm, 19 mm, 27 mm, 41 mm
: 8 mm, 10 mm
Machine Front
T1HH-01-02-005
CAUTION: Control valve weight: 210 kg

(460 lb)
2. Remove bolts (1) and remove the control valve.
: 24 mm
W2-5-1
W1HH-02-05-001

Installation
1. Install the control valve on the main frame with
bolts (1).
: 24 mm
: 205 Nm (21 kgfm, 152 lbfft)
Arm 2
Boom 1
Bucket
Right Travel
Main
Relief
valve
2. Install all hoses, pipes, and connectors to the

control valve.
3. After completing the work, check hydraulic oil
level. Start the engine and check for any oil leaks.
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 68.5 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)
: 8 mm
: 10 mm
4-Spool Section
5-Spool Section
Swing
Arm 1
Boom 2
Auxiliary
Left Travel
Machine Front
T1HH-01-02-005
W2-5-2
W1HH-02-05-001

(Blank)
W2-5-3

DISASSEMBLE CONTROL VALVE (1)
13 4
12
43
41
5
7
46
12a
4
13a
32
35
30
31
29
15
17
15
14
6
4
15
38
25
28
37
47
17
23
33
14
34
30
42
15
15
12
20
31
21
27
22
10
15
35
31
40
44
19
24
26
18
45
16
8
17
11
15
15
39
16
36
8
9
31
17
3
W173-02-05-021
12345678910 11 12 -
Casing A
Casing B
Plug
Plug (4 Used)
O-Ring (6 Used)
Spring Cover A
Spring Cover B
Spool Cover (5 Used)
Spool Cover: Arm 2
Spool Cover: Boom 1
Anti-Drift Valve (2 Used):
Boom Bottom, Arm Rod
12a - O-Ring (6 Used)
13 - Needle Valve
14 - O-Ring (10 Used)
17 - Socket Bolt (32 Used)
18 - Spool: Left Travel
19 - Spool: Arm 1
20 - Spool: Boom 1
21 - Spool: Bucket
22 - Spool: Swing
23 - Spool: Arm 2
25 26 27 28 29 30 31 32 33 34 35 36 -
24 - Spool: Boom 2
37 - Spring (7 Used)
W2-5-4
Spool: Bypass Shut-Off

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

Disassemble control valve (1)
Anti-drift Valve and Needle Valve
1. Remove socket bolt (46). Remove needle valve

(13) and anti-drift valve (12) from spring cover B
(7).
: 5 mm
2. Remove socket bolt (47) and remove anti-drift
valve (12) from spring cover A (6).
: 5 mm
Spring Cover
Spool Cover
10. Put the matching marks in order not to make a

mistake when assembling casing and spool cover.
spool cover (11) from casing B (2).
: 6 mm
12. Disassemble spool covers (8) to (10) in the same

procedures.
: 6 mm

spring cover A (6) from casing A (1). Remove
spring cover B (7) from casing B (2).
: 6 mm
Spool
IMPORTANT: Turn and remove the spools. If the
spools stick even a little, try again
instead of pulling roughly.
4. As spool and hole of casing are a matched fit, put
the matching marks for reassembling.
5. Remove the spool (18) assembly from casing A
(1).
6. Remove the spool (19) to (27) assemblies in the
same procedures.
7. Clamp spool (18) in a vise.
8. Remove spacer bolt (32) and disassemble spring
seat (30), springs (28, 29), and stopper (33).
: 10 mm
9. Disassemble the spool (19) to (27) assemblies in
the same procedures.
: 10 mm
W2-5-5

ASSEMBLE CONTROL VALVE (1)
21
Machine Front
27
15, 14
B
A
16
4
5, 42
8
11
46
12, 12a
13, 13a
47
12
17
35
5, 43
31
5, 41
40
39
T1HH-03-03-002
10
36 31
2
25
Section B-B
23
20
W1HH-02-05-017
Control Valve Upper View

18
Machine Front
26
15, 14
30 33
28
29
30
16
32
8
3
5
44, 45
9
35
15
8
17
Control Valve Lower View
12345678910 11 12 -
Casing A
Casing B
Plug
Plug (4 Used)
O-Ring (6 Used)
Spring Cover A
Spring Cover B
Spool Cover: Arm 2
Spool Cover: Boom 1
Anti-Drift Valve (2 Used)
Boom Bottom, Arm Rod
W1HH-02-05-005
24
19 22
13 - Needle Valve
18 - Spool: Left Travel
19 - Spool: Arm 1
20 - Spool: Boom 1
21 - Spool: Bucket
22 - Spool: Swing
23 - Spool: Arm 2
25 26 27 28 29 30 31 32 33 34 35 36 -
24 - Spool: Boom 2
W2-5-6
Spool: Bypass Shut-Off

Spool: Auxiliary
Spool: Right Travel
Spring (2 Used)
Spring (2 Used)
Stopper (2 Used)
Stopper (7 Used)
Stopper
1
6
Section A-A
38 39 40 41 42 43 44 45 46 47 -
31
38
37 W1HH-02-05-004
31 34
Spring (7 Used)
Spring
Spring
Plug
Plug
Plug
Plug
O-Ring

Assemble Control Valve (1)
Spool Cover
IMPORTANT: Install spool covers (8) to (11) while
aligning the matching marks.
1. Install O-rings (15, 16) to spool cover (11).
2. Install spool cover (11) to casing B (2) with socket
bolts (17) (2 used) while aligning the matching
marks.
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
3. Install spool covers (8) to (10) in the same procedures.
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
Spool
4. Clamp spool (18) in a vise.

5. Clean the thread part of spacer bolt (32) and apply LOCTITE #262.
6. Install spring seat (30), springs (28, 29), stopper
(33), and spacer bolt (32) to spool (18).
7. Tighten spacer bolt (32).
: 10 mm
: 15 to 18 N m
(1.6 to 1.8 kgfm, 11.5 to 13 lbfft)
Spring Cover
10. Install O-rings (14) (5 used) and O-rings (15) (4

used) to spring cover A (6)
11. Install spring cover A (6) to casing A (1) with
socket bolts (17) (7 used).
: 6 mm
: 24 to 34 Nm
(2.5 to 3.5 kgfm, 18 to 25.5 lbfft)
12. Install spring cover B (7) in the same procedures.

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

(12). Install anti-drift valve (12) to spring cover A
(6) with socket bolts (47) (4 used).
: 5 mm
: 9.8 to 14 Nm
(1 to 1.4 kgfm, 7.2 to 10 lbfft)
14. Install O-rings (12a) (3 used) to anti-drift valve
(12). Install O-rings (13a) (3 used) to needle
valve (13). Install needle valve (13) and anti-drift
valve (12) to spring cover B (7) with socket bolts
(46) (4 used).
: 5 mm
: 9.8 to 14 Nm
8. Assemble the spool (18) to (27) assemblies while

aligning the matching marks.
: 10 mm
: 15 to 18 Nm
(1.6 to 1.8 kgfm, 11.5 to 13 lbfft)
9. Install the spool (18) to (27) assemblies to casing
A (1) and casing B (2) respectively.
W2-5-7

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

Arm Bottom Side
2 - Casing 2
3 - Casing 3
4 - Casing 4
5 - O-Ring
6 - O-Ring
7 - O-Ring (3 Used)
8 - O-Ring (2 Used)
15 - Plug
21a - O-Ring
910 11 12 13 14 -
16 17 18 19 20 21 -
22 23 24 25 -
O-Ring (2 Used)
O-Ring
O-Ring (2 Used)
Plug
Plug
Plug (2 Used)
W2-5-8
Poppet
Spring
Spool
Spring
Bushing
Relief Valve
Piston
Piston

Disassemble Control Valve (2)
Arm Anti-Drift Valve
1. Put the matching marks in order to install correctly.

casing 2 (2) from casing 4 (4).
: 10 mm
casing 4 (4) from casing A.
: 10 mm
4. Clamp casings 2 (2) and 3 (3) in a vise.
casing 3 (3) from casing 2 (2).
: 5 mm
6. Remove plug (15). Remove poppet (16) and
spring (17) from casing 2 (2).
: 17 mm
IMPORTANT: Do not loosen the lock nut.

7. Remove relief valve (21) from casing 3 (3).
: 22 mm
8. Remove plug (13). Remove pistons (23, 22) from
casing 3 (3). Check the order when removing pistons (22, 23).
: 10 mm
9. Remove plug (12). Remove bushing (20), spool
(18), and spring (19) from casing 3 (3).
: 22 mm
W2-5-9

Machine Front
14
13
9
14
23
22
F
F
21
21a
20
19
T1HH-03-03-002
18
Section Y-Y
12
W1HH-02-05-006
Arm 1
Arm 2
24
15
17
10
Casing B
16
Casing A
2
1 - Anti-Drift Valve Assembly:
Arm Bottom Side
2 - Casing 2
3 - Casing 3
4 - Casing 4
5 - O-Ring
6 - O-Ring
7 - O-Ring (3 Used)
25 11
25
Section F-F
11
T1HH-03-03-007
8 - O-Ring (2 Used)
15 - Plug
21a - O-Ring
910 11 12 13 14 -
16 17 18 19 20 21 -
22 23 24 25 -
O-Ring (2 Used)
O-Ring
O-Ring (2 Used)
Plug
Plug
Plug (2 Used)
Poppet
Spring
Spool
Spring
Bushing
Relief Valve
W2-5-10
Piston
Piston

10. Install casing 3 (3) to casing 2 (2) with socket

bolts (24) (4 used).
: 5 mm
: 9.8 to 13.5 Nm
1. Install O-rings (7) (3 used) to bushing (20).

2. Install O-ring (6) to plug (12).
3. Install bushing (20), spool (18), and spring (19)
into casing 3 (3). Install plug (12).
: 22 mm
: 69 to 79 Nm
(7 to 8 kgfm, 50.5 to 58 lbfft)
5. Install pistons (22, 23) into casing 3 (3). Install
plug (13).
: 10 mm
: 127 to 147 Nm
(13 to 15 kgfm, 94 to 108 lbfft)
6. Install O-ring (21a) to relief valve (21). Tighten
and install relief valve (21) in casing 3 (3).
: 22 mm
: 69 to 79 Nm
(7 to 8 kgfm, 50.5 to 58 lbfft)
11. Install O-ring (11) to casing 4 (4).

12. Install casing 4 (4) to casing A with socket bolts
(25) (4 used).
: 10 mm
: 98 to 118 Nm
13. Install O-ring (11) to casing 2 (2).
14. Install casing 2 (2) to casing 4 (4) with socket
: 10 mm
: 98 to 118 Nm
IMPORTANT: Do not tighten relief valve (21) by

using the lock nut.
8. Install poppet (16) and spring (17) into casing 2
(2). Install plug (15).
: 17 mm
: 370 to 410 Nm
(38 to 42 kgfm, 275 to 300 lbfft)
9. Install O-rings (8) (2 used) to casing 3 (3).
W2-5-11

16
18
19
21
13
13a
7
25
23
16
17
25
19
20
29 29a
Casing A
1
6
14
22
24
33
14a
6
9
26
8
12
31
32
15
10
27
12
27
11
31
25
28a
28
30a
30b
30c
30
W1HH-02-05-019
1 - Plug (4 Used)
2 - Plug
11 - P3 Cover
12 - Flange (2 Used)
3 - Plug
21 - Spring
4 - Plug (2 Used)
13 - Travel Flow Rate Control

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

16 - Poppet (4 Used)
18 - Poppet
23 24 25 26 27 28 -
Plug (3 Used)
O-Ring (4 Used)
O-Ring
O-Ring (2 Used)
O-Ring (3 Used)
Cover
22 - Spacer
Plug (3 Used)
Plug
O-Ring (5 Used)
O-Ring
O-Ring (2 Used)
Overload Relief Valve:
Boom Side
W2-5-12
28a - O-Ring
29 - Overload Relief Valve:
Arm Side
29a - O-Ring
30 - Pump Control Valve:
5-Spool Section
30a - O-Ring
30b - O-Ring
30c - O-Ring

2. Remove poppet (16), spring (19), and spacer

(22) from casing A.
Blank Flange Assembly

blank flange assembly (14).
: 8 mm
4. Remove poppet (17) and spring (20) from casing
A.
Overload Relief Valve
9. Check that there are two kinds of overload relief

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

valve. If loosening the lock nut and
adjusting screw, the set pressure
will change. Do not loosen the lock
nut and adjusting screw.
10. Remove overload relief valves (28, 29) from casing B by using the tool below.
: 32 mm
32 mm
5. Remove the plug. Remove the piston, sleeve,

poppet, and spring from casing A.
: 32 mm
Arm Anti-Drift Check Valve
(45 mm)
6. Remove plug (24). Remove spring (21) and poppet (18) from casing A.
: 12 mm
Left Travel, Boom 2, Swing Load Check Valve

(common to three places)
(80 mm)
(43 mm)
Travel Flow Rate Control Valve Assembly
(12.7 mm)

P3 cover (11).
: 8 mm
(Wrench Size: 32 mm)
P3 Cover
Pump Control Valve (5-Spool Section)

11. Remove pump control valve (30).
: 36 mm
7. Put the matching marks onto each port and part.

spring (19) from casing A.
: 12 mm
W2-5-13
W1HH-02-05-002

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

Auxiliary
Left Travel
Bucket
31
Right Travel
12
27
16
19
22
2
13a
13
23
25
32
11
8
25
27
19
31
16
Section C-C
T1HH-03-03-004
12
W2-5-14
T1HH-03-03-005
Section D-D

Boom 2
Boom 1
Arm 1
Arm 2
18
21
24
25
17
20
14
29
29a
25
23
28
28a
14a
33
28a
19
16
28
3
7
Section F-F
T1HH-03-03-006
29a
29
T1HH-03-03-007
Section E
15
10
9, 26
Swing
Left
Travel
Auxiliary
16
19
Boom 2
23
Arm 1
25
Swing
W1HH-02-05-004
Section G
Section X-X
T1HH-03-03-006
1 - Plug (4 Used)
2 - Plug
11 - Cover
12 - Flange (2 Used)
3 - Plug
21 - Spring
4 - Plug (2 Used)
13 - Travel Flow Rate Control

Valve Assembly
13a - O-Ring
5678910 -
14 - Blank Flange
18 - Poppet
23 24 25 26 27 28 -
Plug (3 Used)
O-Ring (4 Used)
O-Ring
O-Ring (2 Used)
O-Ring (3 Used)
Cover
22 - Spacer
Plug (3 Used)
Plug
O-Ring (5 Used)
O-Ring
O-Ring (2 Used)
Overload Relief Valve:
Boom Side
W2-5-15
28a - O-Ring
Arm Side
29a - O-Ring
5-Spool Section
30a - O-Ring
30b - O-Ring
30c - O-Ring

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

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

Pump Control Valve
1. Install O-rings (30a, 30b, 30c) to pump control

valve (30). Tighten and install pump control valve
(30).
: 36 mm
: 69 to 78 Nm
(12.7 mm)
43 mm
3. Install O-ring (28a) to overload relief valve (28).

Install O-ring (29a) to overload relief valve (29).
Tighten and install overload relief valves (28, 29)
by using special tool below.
: 32 mm
: 69 to 78 Nm
32 mm

8. Install poppet (18) and spring (21) into casing A.
Install plug (24).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)

valves. Align the matching marks.
(45 mm)
Arm Anti-Drift Check Valve
(80 mm)
9. Install O-ring (13a) to the plug. Install the piston,

sleeve, poppet, and spring into casing A. Install
the plug.
: 32 mm
: 147 to 177 Nm
(15 to 18 kgfm, 108 to 130 lbfft)
Blank Flange Assembly
10. Install O-rings (14a) (2 used) to blank flange (14).

Install poppet (17) and spring (20) into casing A.
Install blank flange assembly (14) with socket
: 8 mm
: 49 to 65 Nm
(5 to 6.6 kgfm, 36 to 48 lbfft)
P3 Cover
11. Install O-rings (8) to cover (11).
W1HH-02-05-002
Left Travel, Boom 2, Swing Load Check Valve

(common to 3 places)
4. Align the matching marks and install it.
12. Install poppet (16), spring (19), and spacer (22)

into casing A. Install P3 cover (11) with socket
: 8 mm
: 49 to 65 Nm
(5 to 6.6 kgfm, 36 to 48 lbfft)

6. Install poppet (16) and spring (19) into casing A.
Install plug (23).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
W2-5-17

3
21
11
11a
18
21
15
12
19
21
16
14
8
5
1
18
6
21
15
12
10
9
23
9a
20
22
17
13
Casing B
W173-02-05-024
1234567-
Plug (2 Used)
Plug
Plug (3 Used)
Plug
Plug (2 Used)
O-Ring (2 Used)
O-Ring
8 - O-Ring (2 Used)
9 - Switch Valve
10 - Poppet Valve
11 - Load Check Valve
11a - O-Ring
13 14 15 16 17 18 19 -
Poppet
Poppet
Spring (2 Used)
Spring
Spring
Plug (2 Used)
Plug
W2-5-18
20 21 22 23 -
Plug
O-Ring (6 Used)
O-Ring

Bucket Flow Rate Control Valve

switch valve (9).
: 8 mm
2. Remove poppet valve (10) from casing B.
Arm 2 Load Check Valve (with Orifice)
3. Remove the plug and remove load check valve

(11) from casing B.
: 12 mm
Boom 1, Arm 2 Load Check Valve

IMPORTANT: Put the matching marks to each port

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

: 12 mm
Check Valve with Orifice (Bucket Combination)

: 10 mm
W2-5-19

Machine Front
Left Travel
Right Travel
13
22
20
17
T1HH-03-03-002
Section C-C
Bucket
Auxiliary
Boom 2
T1HH-03-03-004
Boom 1
6
1
10
9a
23
15
21
12
Section E
Section D-D
Arm 1
14
16
19
21
18
T1HH-03-03-005
T1HH-03-03-006
Swing
Arm 2
11a
11
21
12
15
18
21
4
8
Section G
Section F-F
T1HH-03-03-008
T1HH-03-03-007
1234567-
Plug (2 Used)
Plug
Plug (3 Used)
Plug
Plug (2 Used)
O-Ring (2 Used)
O-Ring
8 - O-Ring (2 Used)
9 - Switch Valve
10 - Poppet Valve
11 - Load Check Valve
11a - O-Ring
13 14 15 16 17 18 19 -
Poppet
Poppet
Spring (2 Used)
Spring
Spring
Plug (2 Used)
Plug
W2-5-20
20 21 22 23 -
Plug
O-Ring (6 Used)
O-Ring

Check Valve with Orifice (Bucket Combination)
Bucket Flow Rate Control Valve
2. Install poppet (13) and spring (17) into the casing.

Install plug (20).
: 10 mm
: 128 to 147 Nm
8. Install O-rings (9a) (2 used) to switch valve (9).

Install poppet valve (10) into the casing. Install
switch valve (9) with socket bolts (23) (4 used).
: 8 mm
: 52 to 62 Nm
(5.3 to 6.3 kgfm, 38 to 46 lbfft)
Boom Anti-Drift Check Valve

Install plug (19).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
Boom 1, Arm 2 Load Check Valve

IIMPORTANT: Align the matching marks and install it.

Install plug (18).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
Arm 2 Load Check Valve (with Orifice)
7. Install O-ring (11a) to the plug. Install load check

valve (11).
: 12 mm
: 226 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
W2-5-21

1
Casing B
21
21a
19
6
20
18
17
5
19
20
18
11
17
7
14
16
6
4
22
23
15
15
17
18
20
19
9
10
12
13
W173-02-05-025
1 - Flow Combiner Valve Assembly

2 - Block
3 - Plug
4 - Plug
5 - O-Ring (3 Used)
6 - O-Ring (4 Used)
7 - O-Ring (2 Used)
13 - Spring
19 - Plug (3 Used)
8910 11 12 -
14 15 16 17 18 -
21 - Main Relief Valve
21a - O-Ring
23 - Name Plate
O-Ring
Plug
O-Ring
O-Ring
Spring
Stopper
Orifice (2 Used)
Spool
Poppet (3 Used)
Spring (3 Used)
W2-5-22

Flow Combiner Valve

flow combiner valve assembly (1).
: 14 mm
2. Clamp block (2) in a vise.
3. Remove main relief valve (21) from block (2).
: 32 mm
4. Remove plug (9). Remove spool (16), stopper
(14), and springs (12, 13) from block (2).
: 32 mm
5. Put the matching marks onto each port and part.
spring (18) from block (2). (common to 3 places)
: 12 mm
7. Remove plug (3).
: 5 mm
8. Remove orifices (15) (2 used) from block (2).
: 4 mm
W2-5-23

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

15
16
10
12
13
14
20
7
19
18
17
20
19
11
2
18
17
5
21a
21
Section A
1 - Flow Combiner Valve Assembly
2 - Block
3 - Plug
4 - Plug
5 - O-Ring (3 Used)
6 - O-Ring (4 Used)
W1HH-02-05-010
7 - O-Ring (2 Used)
13 - Spring
19 - Plug (3 Used)
8910 11 12 -
14 15 16 17 18 -
21 - Main Relief Valve
21a - O-Ring
23 - Name Plate
O-Ring
Plug
O-Ring
O-Ring
Spring
Stopper
Orifice (2 Used)
Spool
Poppet (3 Used)
Spring (3 Used)
W2-5-24

Flow Combiner Valve
1. Clamp block (2) in a vise.
10. Install O-rings (5) (3 used), O-rings (6) (4 used),

O-rings (7) (2 used), and O-ring (11) to block (2).
2. Install orifices (15) (2 used) in block (2).

: 4 mm
: 7.8 to 9.8 Nm
(0.8 to 1.0 kgfm, 5.8 to 7.2 lbfft)
11. Install flow combiner valve assembly (1) with

socket bolt (22) (5 used).
: 14 mm
: 215 to 255 Nm
(22 to 26 kgfm, 159 to 188 lbfft)

4. Install plug (3).
: 5 mm
: 12.7 to 16.7 Nm
(1.3 to 1.7 kgfm, 9.4 to 12.3 lbfft)
6. Install poppet (17) and spring (18) into block (2).
Align the matching marks and install plug (19).
: 12 mm
: 225 to 265 Nm
(23 to 27 kgfm, 166 to 195 lbfft)
8. Install spool (16), stopper (14), and springs (12,
13) into block (2). Install plug (9).
: 32 mm
: 68.6 to 78.4 Nm
9. Install O-ring (21a) to main relief valve (21). Install main relief valve (21) in block (2).
: 32 mm
: 68.6 to 78.4 Nm
W2-5-25

9a
10
9
9c
9b
7
11
7a
2
8a
Casing B
1
3
3
Casing A
5
6
4
6
6
7a
7a
7
W173-02-05-026
1 - Plug (2 Used)
5 - O-Ring (6 Used)
2 - Plug
3 - O-Ring (2 Used)
6 - O-Ring (5 Used)
7 - Overload Relief Valve
(3 Used): Bucket Rod, Arm
Bottom, Boom Bottom Side
4 - O-Ring (6 Used)

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


1. Remove pump control valve (9).
: 36 mm

valve.
Put the matching marks on to each port and part.
IMPORTANT: Loosen the valve of overload relief
valve. If loosening the lock nut and
adjusting screw, the set pressure
will change. Do not loosen the lock
nut and adjusting screw.
(80 mm)
(12.7 mm)
(45 mm)
43 mm
32 mm
3. Remove overload relief valve (7, 8) from casing B

by using special tool below.
: 32 mm
W1HH-02-05-002
Casing
IMPORTANT: Do not disassemble socket bolts (10,
11) unless necessary.
4. Remove socket bolt (10) and socket bolts (11) (8
used). Disassemble casing A and casing B.
: 12 mm
W2-5-27

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

Left Travel
Section E
T1HH-03-03-002
Right Travel
Arm 1
T1HH-03-03-006
Arm 2
4
7
7a
5
5
6
4
7a
7
4
Section C-C
Section F-F
T1HH-03-03-004
T1HH-03-03-007
Auxiliary
Bucket
Swing
8
8a
9a
9c
9b
7a
7
Section D-D
1 - Plug (2 Used)
5 - O-Ring (6 Used)
2 - Plug
3 - O-Ring (2 Used)
6 - O-Ring (5 Used)
7 - Overload Relief Valve
(3 Used): Bucket Rod, Arm
Bottom, Boom Bottom Side
4 - O-Ring (6 Used)
Section G
T1HH-03-03-005
T1HH-03-03-008

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

Casing
1. Install O-rings (4) (6 used), O-rings (5) (6 used),

and O-rings (6) (5 used) to casing B.
2. Connect casing A and casing B. Tighten socket
bolt (10) and socket bolts (11) (8 used).
: 12 mm
: 137 to 177 Nm
(14 to 18 kgfm, 101 to 130 lbfft)

valve. Align the matching marks and install it.
(80 mm)
(12.7 mm)
(45 mm)
43 mm
32 mm
4. Install O-ring (7a) to overload relief valve (7). Install O-ring (8a) to overload relief valve (8). Install
overload relief valves (7, 8) by using special tool
below.
: 32 mm
: 69 to 78 Nm
W1HH-02-05-002
5. Install O-rings (9a, 9b, 9c) to pump control valve

(9). Install pump control valve (9).
: 36 mm
: 69 to 78 Nm
W2-5-29

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

1
5
2
10
18
13
15
1
1
Adjusting Screw
1
1
1
21
Poppet
Backup Ring
19
O-Ring
Backup Ring
10
O-Ring
11
Seat
12
Spring
13
Spring
14
Plunger
20
15
Piston
12
16
Filter
17
Filter Stopper
14
18
C-Ring
19
O-Ring
20
O-Ring
21
Plug
22
Body
8
7
O-Ring
Spring
11
17
Lock Nut
Spring Seat
22
16
6
9
QTY
PART NAME
P
W173-02-05-031
W2-5-30

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

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

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

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

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

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

A
12
13
17
21
PL
B1
17
4
12
2
19
24
20
14
18
Section A-A
Dr
Dr
W1HH-02-05-006
W1HH-02-05-008
ITEM+
1
16
11
10
23
22
15
1
A1
W1HH-02-05-009
15
Section B-B
W2-5-35
PART NAME
QTY
Socket Bolt
Socket Bolt
Piston
Piston
Relief Valve
Bushing
Spring
Spool
Spring
10
Poppet
11
Plug
12
Plug
13
Plug
14
Plug
15
O-Ring
16
O-Ring
17
O-Ring
18
O-Ring
19
O-Ring
20
O-Ring
21
O-Ring
22
Casing
23
Casing
24
Casing

Boom 1 Spool Assembly
1
W173-02-05-015
ITEM
PART NAME
QTY
Plug 2
Plug 1
Spring B3
Spring B2
Spring B1
Plunger 3
Plunger 2
Plunger 1
Spool
Arm 2 Spool Assembly

8
10
ITEM
11
PART NAME
12
QTY
Spring Seat (1)
Plug
Plug
Stopper (2)
Stopper (1)
C-Ring
Spring A2
Spring A1
Sleeve (1)
10
Sleeve (2)
11
Sub Spool
12
Spool
W2-5-36
W173-02-05-016

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

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

REMOVE AND INSTALL SWING DEVICE
7
6
1
2
Removal
1. Remove hoses (1 to 3 and 5 to 7).
: 41 mm, 19 mm, 17 mm
: 8 mm
5
2. Cap the removed hoses and pipes.

Attach a nylon sling to the swing motor.
Nylon sling (eye-type at both ends): 2 pieces
3
4
CAUTION: Swing device weight: 390 kg

(800 Ib)
W1HH-02-06-001
3. Remove bolt (4). Hoist and remove the swing

device.
: 32 mm
: 640 Nm (65 kgfm, 470 Ibfft)
Nylon Sling
W176-02-06-002
W2-6-1

Installation
NOTE: Refer to Removal section for wrench
sizes and tightening torques.
7
6
1
1. Apply THREEBOND #1102 to both mounting

surfaces on the swing device and main frame.
Install the swing device with bolts (4).
2. Install hoses (1 to 3 and 5 to 7).
: 41 mm
: 205 Nm (21 kgfm)
: 19 mm
: 29.5 Nm (3 kgfm)
: 17 mm
: 24.5 Nm (2.5 kgfm)
: 8 mm
: 50 Nm (5.1 kgfm)
5
3
4
W1HH-02-06-001
3. After completing the work, fill the swing motor

with hydraulic oil. Check hydraulic oil level. Start
the engine and check for any oil leaks.
W2-6-2

(Blank)
W2-6-3

DISASSEMBLE SWING DEVICE
32
1
22
2
23
3
4
5
31
21
7
30
29
24
18
25
20
9
7
28
10
19
11
27
12
26
18
13
17
14
16
13
12
15
W1HH-02-06-002
1 - Socket Bolt (12 used)

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

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

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

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

Disassemble Swing Device
CAUTION: Ring gear (22) weight: 34 kg
(75 lb)
CAUTION: Swing device weight: 390 kg

(860 lb)
1. Attach a nylon sling to the swing motor. Hoist the
swing device.
2. Place the swing device on bracket (ST 5100).
Secure the swing device with bolts (M22) (2
used). Secure the bracket on a workbench.
: 32 mm
Swing Device
7. Remove socket bolt (32). Install eyebolt (M12,

Pitch 1.75 mm) to the motor mounting thread position of ring gear (22). THREEBOND has been
applied on the jointed surfaces between housing
(31) and ring gear (22). Insert a screwdriver into
the notch between jointed portion. Hoist and remove ring gear (22) from housing (31).
: 17 mm
CAUTION: Second stage
weight: 42 kg (93 lb)
ST 5100
sun
gear
(20)
8. Remove second stage sun gear (20) and the

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

: 8 mm
4. Remove pipe (24) from housing (31).
: 18 mm
CAUTION: Motor (2) weight: 71 kg (160 lb)
5. Put the matching marks at the jointed portions
between motor (2) and ring gear (22), between
ring gear (22) and housing (31).
Remove socket bolt (1). Hoist and remove motor
(2).
: 10 mm
NOTE: Insert the screwdriver between motor (2)
and ring gear (22). Float motor (1). Remove motor (2) easily.
6. Remove first stage sun gear (4) from first stage
carrier (21).
Remove the first stage carrier (21) assembly
from ring gear (22).
: 8 mm
W2-6-5
31
17
26
16
15
W1HH-02-06-002
W2-6-6

CAUTION: Housing (31) assembly weight:
200 kg (440 lb)
9. Remove bolt (17). Remove lock plate (16).
: 17 mm
10. Remove nut (15) from shaft (26) by using special
tool (ST 3167).
ST 3167
15
W178-02-06-008
W2-6-7
32
23
31
30
29
26
W1HH-02-06-002
W2-6-8

11. Install eyebolt (M20, Pitch 2.5 mm) into the bolt
(32) hole of housing (31). Remove bolts (M22) (2
used) securing the housing and bracket. Hoist
the housing (31) assembly and remove the
bracket.
CAUTION: If pushing shaft (26) by using a

press, provide a protection cover (outer diameter: 369 mm (14.5 in), inner diameter: 90
mm (3.5 in), thickness: 25 to 30 mm (1.0 to
1.2 in)). Push shaft (26) with the protection
cover on by using a press. When housing
(31) and/or roller bearing (23) are broken and
flown off, the metal fragments may result in
personal injury. Use a press with the capacity less than 30 tons (66000 lb). Degrease the
housing inside before heating roller bearing
(23). Failure to degrease may cause a fire.
12. Set the blocks on the press. Set the housing (31)
assembly on the blocks.
13. Put the protection cover onto housing (31) and

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

housing (31).
W2-6-9
31
30
29
27
26
W1HH-02-06-002
W2-6-10

15. Set special tool to the shaft (26) assembly.
NOTE: Use the following parts as special tool for
roller bearing (30).
CAUTION: When pushing shaft (26) by using

a press, set the shaft into the guide.
16. Set shaft (26) with special tool to a press. Remove roller bearing (30).
Part
Size
Shaft Length: 220 mm
or Bolt (8.7 in)
Diameter: 19 mm
(3/4 in)
Remarks
8 used. All should be
identical in length with no
wear and deformation on
both ends.
Material: S35C
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2 (Applicable Diameter:
185 to 215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter:
292 mm (11.5 in)
Inner Diameter:
272 mm (10.7 in)
Press
Shaft (26)
Roller
Bearing (30)
Sleeve (29)
Guide
W157-02-06-014
Hose Clamp
17. Remove sleeve (29) from shaft (26). Remove

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

(31). Tap and remove the outer race of roller
bearing (30).
Oil Passage
W157-02-06-012
Outer Race
Shaft (26)
Roller Bearing (30)
W1HH-02-06-007
Sleeve (29)
Guide
Hose
Clamp
Shaft
W157-02-06-01
W2-6-11
23
31
21
6
7
8
9
10
28
19
11
18
14
13
12
W1HH-02-06-002
W2-6-12

CAUTION: Housing (31) weight: 104 kg
(230 lb)
19. Fasten the housing (31) body by using a nylon
sling. Hoist and turn over housing (31).
Insert a screwdriver into the notch on housing
(31) where oil seal (28) is mounted. Remove oil
seal (28).
THREEBOND has been applied on the periphery
of oil seal (28). The oil seal cannot be reused.
20. Remove the outer race of roller bearing (23) from
housing (31) by using a bar and hammer.
21. Remove spring pin (6) from first stage carrier (21)
by using a round bar and hammer.
22. Remove pins (5) (3 used), first stage planetary
gears (9) (3 used), thrust plates (7) (6 used), and
needle bearings (8) (3 used) from first stage
carrier (21).
23. Remove thrust plates (18) from first stage carrier
(21).
24. Remove spring pin (11) from second stage carrier
(19) by using a round bar and hammer.
25. Remove pins (10) (3 used), second stage
planetary gears (14) (3 used), thrust plates (12)
(6 used), and needle bearings (13) (6 used) from
second stage carrier (19).
26. Remove thrust plate (18) from second stage
carrier (19).
W2-6-13

ASSEMBLE SWING DEVICE
3
5
6
1
7
8
21
9
7
18
11
12
20
13
32
19
14
22
10
18
17
16
15
23
30
24
31
25
26
27
28
29
T1HH-03-02-001

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

9 - First Stage Planetary Gear

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

First Stage Carrier
Ring Gear
23 - Roller Bearing
24 - Pipe
W2-6-14
Shaft
O-Ring
Oil Seal
Sleeve
Roller Bearing
31 - Housing

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

bearing (30) into shaft (26). Install sleeve (29)
and the inner race by using special tools (ST
7289, ST 7292) and a press.
3. Install first stage planetary gears (9) (3 used) and

thrust plates (7) (6 used) into first stage carrier
(21).
Press
4. Align the hole on pin (5) with spring pin hole on

first stage carrier (21). Install pins (5) (3 used) by
using a hammer.
ST 7292
ST 7289
29
5. Face the slit of spring pin (6) to the end of pin (5).
Install spring pin (6) into first stage carrier (21)
and pin (5) by using a hammer.
5
30
26
WIHH-02-06-008
Slit
NOTE: In case only oil seal (29) is replaced, be

sure to use the special tool (ST 7300 or ST
7296).
W178-02-06-002
6. Assemble second stage carrier (19) in the same

procedures as steps 1 to 5. Assemble second
stage planetary gears (14) (3 used), needle
bearings (13) (6 used), thrust plates (12) (6 used),
(18), pins (10) (3 used), and spring pins (11) (3
used).
7. Install O-ring (27) onto sleeve (29).

(230 lb)
9. Fasten the housing (31) body by using a nylon
sling. Hoist and place housing (31) with the
sleeve (29) mounting side up.
10. Tap and install the outer race of roller bearing
(30) into housing (31) by using a bar and hammer evenly. Tap and listen to ring in order to
check if the installation is completed.
W2-6-15
32
22
15
23
31
26
28
29
T1HH-03-02-001
W2-6-16

11. Apply THREEBOND #1102 on the outer surface
of oil seal (28). Place oil seal (28) flat on housing
(31) and push the oil seal in gently by hand.
Place special tool (ST 7291) on oil seal (28). Tap
in special tool by using a hammer directly.
ST 7291
19. Place special tool (ST 7290) onto the inner race
of roller bearing (23). Install the inner race by using a press.
28
23
ST 7290
31
WIHH-02-06-009
WIHH-02-06-010
12. Apply grease to the inner surface of oil seal (28).

Apply grease to the outer surface of sleeve (29)
on shaft (26).
(32) hole in housing (31). Hoist and place housing (31) on shaft (26). Check and align carefully
in order to prevent the oil seal (28) lip from curling.
14. Tap and install the outer race of roller bearing
(23) into housing (31) by using a bar and hammer evenly. Tap and listen to ring in order to
check if the installation is completed.
15. Tap and install the inner race of roller bearing
(23) into shaft (26) by using a bar and hammer.
Tap the inner race until two threads of shaft for
nut (15) appear.
16. Tighten nut (15) to shaft (26) by hand.
Prevent shaft (26) from falling off when hoisting
housing (31).
CAUTION: Housing (31) + shaft (26) +
bearing (23) weight: 193 kg (425 lb)
(32) hole in housing (31). Hoist and place housing (31) on a press.
18. Remove nut (15) from shaft (26).
W2-6-17
20
19
22
17
16
23
15
31
26
T1HH-03-02-001
W2-6-18

20. Hoist and place the housing (31) assembly on
bracket (ST 5100). Install the housing (31) assembly with bolts (M22) (2 used). Insert the
stopper at the bottom of bracket between teeth of
the pinion gear. Secure the bracket on a workbench.
31
: 32 mm
CAUTION: Second stage carrier weight:

42 kg (93 lb)
23. Install the second stage carrier (19) assembly
onto the spline of shaft (26). The concave part of
the boss in bottom side of the carrier comes in
contact with lock plate (16).
ST 5100
Concave
Stopper
19
16
26
W178-02-06-012
21. Apply a firm of grease on the thread part of nut

(15). Install nut (15) on shaft (26) with the
stepped side facing to roller bearing (23). Tighten
nut (15) by using special tool (ST 3167).
: 735 Nm (75 kgfm, 540 lbfft)
NOTE: Apply grease for keeping correct tightening
torque.
ST 3167
15
W178-02-06-014
24. Install second stage sun gear (20) into the

second stage carrier (19) assembly.
25. Clean off old adhesive. Apply THREEBOND #1215
onto the ring gear (22) mounting surface of housing (31).
W178-02-06-008
22. Install lock plate (16) onto nut (15) with bolt (17).
In case the spline of lock plate (16) and that of
shaft (26) are not aligned, tighten nut (15) in
tightening direction until both splines are aligned.
: 17 mm
W2-6-19
1
4
21
20
32
22
24
31
25
T1HH-03-02-001
W2-6-20

CAUTION: Ring gear weight: 34 kg (75 lb)
26. Install eyebolt (M12, Pitch 1.75 mm) to the motor
mounting thread part on ring gear (22). Hoist and
install ring gear (22) on housing (31) while aligning the matching marks. Tighten socket bolts (32)
(12 used).
: 17 mm
: 390 Nm (40 kgfm)
27. Install the first stage carrier (21) assembly onto
the spline of second stage sun gear (20).
28. Install first stage sun gear (4) into the first stage
carrier (21) assembly with the stepped side
down.
29. Wind the seal tape onto the thread part of pipe
(24). Install pipe (24) into housing (31) with the
pipe down.
: 18 mm
30. Wind the seal tape onto drain plug (25). Install
drain plug (25) into pipe (24).
: 8 mm
: 50 Nm (5 kgfm, 36 Ibfft)
31. Add gear oil. Geal oil: 16.3 L (4.31 US gal)
32. Apply THREEBOND #1215 onto the motor
mounting surface of ring gear (22).
CAUTION: Motor weight: 71 kg (160 Ib)
33. Hoist motor (2). Align the matching marks and
install motor (2) into ring gear (22) with socket
: 10 mm
W2-6-21

DISASSEMBLE SWING MOTOR
12
11
10
9
8
7
6
3
2
13
5
4
21
22
23
26
24
27
28
25
20
24
16
17
18
23
22
19
21
29
W1HH-02-06-005
15
14
1 - Casing
2 - Parking Brake
Release Valve
4 - Oil Seal
5 - Bearing
6 - Shaft
7 - Shoe Plate
8 - Plunger (9 Used)
9 - Plate
10 - Retainer

18 - Valve Plate
25 - Valve Casing
11 12 13 14 15 16 -
19 20 21 22 23 -
26 27 28 29 -
Rotor
Friction Plate (3 Used)
Plate (4 Used)
O-Ring
O-Ring
Brake Piston
Bearing
O-Ring
Plug (2 Used)
O-Ring
Spring (2 Used)
W2-6-22

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

Disassemble Swing Motor
CAUTION: Swing motor assembly weight:
70 kg (155 Ib)
7. Attach special tool (ST 7288) onto the brake

piston (16) groove and hoist brake piston (16).
26
IMPORTANT: Do not disassemble relief valve (29).

1. Remove relief valves (29) (2 used) from valve
casing (25).
: 41 mm
ST 7288
16
2. Remove plugs (21) (2 used) from valve casing

(25).
: 17 mm
3. Remove springs (23) (2 used) and poppets (24)

(2 used) from valve casing (25).
4. Remove socket bolts (3) (3 used) from casing (1).
Remove parking brake release valve (2).
: 5 mm
W1HH-02-06-006
8. Remove O-rings (14, 15) from casing (1).
5. Put the matching marks on the mounting

surfaces between valve casing (25) and casing
(1). Remove socket bolts (26) (4 used). Remove
valve casing (25) from casing (1).
: 17 mm
NOTE: Check that valve casing (25) is floated by
spring (17). Valve plate (18) may be
removed with valve casing (25). When
removing valve casing (25), do not fall off
valve plate (18).
IMPORTANT: Do not damage the mating surfaces
when separating valve plate (18)
from valve casing (25) or rotor (11)
by using a screwdriver.
6. If valve plate (18) is still attached with the rotor in
step 5, remove valve plate (18) from the rotor.
Remove springs (17) (24 used).
W2-6-23
12
11
10
9
8
7
6
13
5
4
1
25
19
W1HH-02-06-005
W2-6-24

IMPORTANT:
Do not damage the slide surfaces

of rotor (11) and plunger (8).
9. Place casing (1) horizontally. Remove rotor (11)
from shaft (6). Remove retainer (10), plate (9),
and plungers (8) (9 used) from shaft (6).
10. Remove plates (13) (4 used) and friction plates

(12) (3 used) from casing (1).
11. Remove shoe plate (7) from casing (1). Do not
damage the slide surface of shoe plate (7).
12. When removing shaft (6), the spline damages the
oil seal. Wind the tape onto the spline of shaft (6)
before removing shaft (6). Tap and remove shaft
(6) from casing (1) by using a plastic hammer
lightly.
13. Remove oil seal (4) from casing (1).
14. Remove the outer race of bearing (5) from casing
(1) by using a bar and plastic hammer.
15. Remove the inner race of bearing (5) from shaft
(6) by using a press.
16. Remove bearing (19) from valve casing (25) by
using a bearing puller.
W2-6-25

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

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

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

Assemble Swing Motor
1. Install the inner races of bearings (5, 19) into
shaft (6) by using a press.
Install the inner race of bearing (5) with the flange
facing to the stepped side of shaft (6).
2. Push oil seal (4) into casing (1) by using a plate.
Install oil seal (4) with the lip facing to the bearing
(5) mounting side.
10. Install brake piston (16) into casing (1).

11. If it is not easy to install brake piston (16) due to
the resistant force from O-rings (14, 15), tap
O-rings evenly by using a plastic hammer. Install
springs (17) (24 used) onto brake piston (16).
3. Install the outer race of bearing (5) into casing (1)

by using a bar.
4. Wind the tape onto the spline at the end of shaft
(6) in order not to damage the lip of oil seal (4).
Place casing (1) horizontally. Install shaft (6) into
casing (1).
5. Place casing (1) with the valve casing (25)
mounting side up. Install shoe plate (7).
6. Align the notches on retainer (10) and plate (9).
Assemble plate (9) and retainer (10). Install
plungers (8) (9 used).
Apply hydraulic oil onto the plunger hole in rotor
(11). Instert the plunger (8) assembly into rotor
(11).
7. Place casing (1) horizontally. Install the rotor (11)
assembly onto shaft (6).
IMPORTANT: 4 notches are on the outer side of
plate (13). 4 notches are at the
spline teeth side of friction plate (12).
Align each notch at the same place
when installing.
8. Place casing (1) vertically. Alternately install
plates (13) (4 used) and friction plates (12) (3
used) into casing (1).
9. Apply a film of grease to O-rings (14, 15).
Install O-rings (14, 15) onto casing (1).
W2-6-27

24
23
22
21
26
T1HH-03-02-003
25
29
19
20
18
3
2
T1HH-03-02-002
W2-6-28

12. Install the outer race of bearing (19) into valve
casing (25) by using a bar and plastic hammer.
Tap the bearing type indicated surface by using
a plastic hammer and install bearing (19).
13. Install O-ring (20) onto valve casing (25). Apply
grease onto valve plate (18) in order not to fall off.
Install valve plate (18) to value casing (25).
14. Align the matching marks on valve casing (25)
and casing (1). Install valve casing (25) with
: 17 mm
: 431 Nm (44 kgfm, 320 lbfft)
15. Install poppets (24) (2 used) and springs (23) ( 2
used) into valve casing (25). Tighten plug (21)
with O-ring (22) attached.
: 17 mm
: 539 Nm (55 kgfm, 400 lbfft)
16. Install relief valves (29) (2 used) into valve casing
(25).
: 41 mm
: 177 Nm (18 kgfm, 130 lbfft)
17. Install parking brake release valve (2) into casing
(1) with socket bolts (3) (3 used).
: 5 mm
: 12 Nm (1.2 kgfm, 8.68 lbfft)
W2-6-29

DISASSEMBLE AND ASSEMBLE
PARKING BRAKE RELEASE VALVE
10
11
8
3
7
12
6
2
13
W110-02-06-005
1234-
Casing
Spool
Spring
Plunger
5 - Bushing
6 - Filter
7 - Spacer
8 - Orifice
9 - Spring
10 - O-Ring
W2-6-30
11 - O-Ring (2 used)
12 - Steel Ball
13 - Bolt (3 used)

Swing Motor
d
1. Clearance between piston outer diameter and

rotor inner bore.
D-d
Standard
0.028 (0.001)
Unit:m (in)
Allowable Limit
0.058 (0.002)
W107-02-06-138
Use the piston and rotor for the motor.

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

Unit: mm (in)
Standard
Allowable Limit
0 (0)
0.3 mm (0.0118)
W107-02-06-140
W107-02-06-141
W2-6-31

3. Shoe thickness
Standard
5.5 (0.22)
Unit: mm (in)
Allowable Limit
5.3 (0.21)
4. Friction plate thickness
Standard
2.0 (0.08)
Unit: mm (in)
Allowable Limit
1.8 (0.07)
W107-02-06-142
W107-02-06-143
W2-6-32
UPPERSTRUCTURE / Pilot Valve

REMOVE AND INSTALL RIGHT PILOT
VALVE
Removal
1. Remove seat mounting bolts (2) (4 used). Remove seat (1) (with seat stand).
: 17 mm
2
1
W178-02-07-006
2. Remove screws (24) (4 used) and cover (23).

Move boot (29) up.
: 17 mm
30
3
29
3. Remove caps (17) (2 used) from cover (18).
28
5
27
4. Remove screws (21)(4 used) and (16) (2 used).

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

box (12). Remove switch box (12).
: 13 mm
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
W2-7-1

6. Remove hoses (31 to 36). Attach identification
tags onto the removed hoses for reassembling.
Cap the ends of all removed hoses.
: 19 mm
30
3
29
7. Remove nut (4) and remove crips (5, 27). Remove connector (6) and remove grip (3) (with the
harness).
Remove nut (28). Remove lever (30), washers
(25, 26), and boot (29).
: 22 mm
: 19 mm
28
5
27
26
25
6
7
10
24
23
21
20
19
18
8. Remove bolts (9) (3 used) and (8) (with spring

pin (7)) from pilot valve (10). Remove pilot valve
(10).
: 13 mm
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
35
36
31
32
33
34
W178-02-07-002
31 32 33 34 35 36 -
Hose T6: (To pilot shut-off valve)

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

Installation
1. Install bolts (9) (3 used) and (8) (with spring pin
(7)) to pilot valve (10).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 Ibfft)
35
2. Install hoses (31 to 36).

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

of spring pin (7), the harness makes
contact with the moving part of the
pilot valve and the harness is damaged. Arrange the harness to the
outside of spring pin (7).
W178-02-07-002
30
3. Temporarily tighten nut (28) to lever (30) and install washers (25, 26). Install lever (30) onto pilot
valve (10) with nut (28). Install boot (29).
Temporarily tighten nut (4) to lever (30) and install grip (3) with nut (4).
Pass the harness of grip (3) through the upper
hole of boot (29) and install lever (30) with clips
(5, 27). Arrange the harness to the outside of
spring pin (7) over bolt (8) head.
Install connector (6).
: 22 mm
: 26 Nm (2.0 kgfm, 14.5 Ibfft)
: 19 mm
: 26 Nm (2.0 kgfm, 14.5 Ibfft)
29
4
28
5
27
26
25
6
7
10
24
23
21
20
19
18
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
W2-7-3

4. Install switch box (12) with bolt (11). Install the
connector.
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 Ibfft)
30
3
29
4
28
5. Install each harness of key switch (20) and air

controller (19).
27
26
25
6. Install cover (14) with screws (22, 15, 13).

Install cover (18) with screws (21) (4 used) and
(16) (2 used).
Install caps (17) (2 used) onto cover (18).
6
7
10
24
23
21
20
19
18
7. Install boot (29) and cover (23) with screws (24)

(4 used).
8
9
11
12
22
17
16
15
14
13
W178-02-07-001
8. Install seat (1) (with the seat stand) with bolts

(2) (4 used).
: 17 mm
9. After completing the work, check the oil level.
Start the engine and check for any oil leaks.
2
1
W178-02-07-006
W2-7-4

REMOVE
VALVE
AND
INSTALL LEFT
PILOT
Removal
1. The console is at the most front position. Remove screws (2) (4 used) and cover (3). Move
boot (1) up.
: 17 mm
10
9
2. Remove screws (7, 8) and remove cover (9).
Radio
3
4
3. Remove cap (10) from cover (6).

4. Remove screws (4) (3 used) and (5). Move cover
(6) up. Remove the radio connector and remove
cover (6).
5
W178-02-07-003
15
16
11
12
13
5. Remove hoses (11 to 16).

Cap the ends of all removed hoses.
Attach an identification tag onto the removed
hoses to for reassembling.
: 19 mm
14
W178-02-07-004
11 12 13 14 15 16 -
Hose T5 : (To pilot shut-off valve)

Hose F : (To shockless valve port F for right swing)
Hose C : (To shockless valve port C for arm roll-out)
Hose P2 : (From pilot shut-off valve)
Hose E : (To shockless valve port E for left swing)
Hose D : (To shockless valve port D for arm roll-in)
NOTE: Piping location shows that of JIS pattern.
W2-7-5

6. Remove nut (18). Remove clips (29, 21). Remove connector (28) and remove grip (17) (with
the harness).
Remove nut (20). Remove lever (19), washers
(25, 26), and boot (1).
: 22 mm
: 19 mm
7. Remove bolts (24) and (23) (with pin (22)). Remove pilot valve (27).
: 13 mm
17
29
18
19
28
1
20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6

Installation
1. Install pilot valve (27) with bolts (24) and (23)
(with pin (22)).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 Ibfft)
17
2. Install hoses (11 to 16).

: 19 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
29
28
IMPORTANT: If the harness is arranged to the inside of spring pin (22), the harness
makes contact with the moving part
of pilot valve and the harness is
damaged. Arrange the harness to
the outside of spring pin (22).
3. Temporarily tighten nut (20) to lever (19) and install washers (25, 26). Install lever (19) onto pilot valve (27) with nut (20). Install boot (1).
Temporarily tighten nut (18) to lever (19) and install grip (17) with nut (18).
Pass the harness of grip (17) through the upper
hole of boot (1) and install lever (19) with grips
(29, 21). Arrange the harness to the outside of
spring pin (22) over bolt (23) head. Install connector (28).
: 13 mm
: 10 Nm (1.0 kgfm, 7.2 lbfft)
: 22 mm
: 55 Nm (5.6 kgfm, 40.5 lbfft)
: 19 mm
: 35 Nm (3.6 kgfm, 26 lbfft)
W2-7-7
18
19
10
20
21
22
23
24
25
26
27
2
3
4
5
W178-02-07-003

4. Install the connector of radio. Install cover (6)
with screws (4) (4 used) and (5). Install cap (10).
Install cover (9) with screws (7, 8).
17
5. Install boot (1) and cover (3) with screws (2) (4

used).
29

18
19
28
10
20
21
22
23
24
25
26
27
2
3
4
5
W2-7-8
W178-02-07-003

REMOVE AND INSTALL TRAVEL PILOT
VALVE
Removal
1. Remove floor mat (1).
WIHH-02-07-001
2. Remove bolts (3) (6 used) from the swing frame.

Remove under cover (2).
: 17 mm
3. Remove bolts (4) (2 used). Remove pedals (5) (2
used) and levers (16, 17).
: 17 mm
2
3
4. Remove pipes (6, 7) and hoses (8 to 11).

Cap the ends of all removed pipes and hoses.
Attach an identification tag onto the removed
pipes and hoses for reassembling.
: 17 mm, 19 mm
5. Remove socket bolt (14), spring washer (13), and
plain washer (12). Remove pilot valve (15).
: 8 mm
WIHH-02-07-002
17
16
4
5
15
14
14
13
13
12
12
11
10
W178-02-07-005
678910 11 -
W2-7-9
Pipe T4:
Pipe P1:
Hose 11:
Hose 12:
Hose 10:
Hose 9:
(To pilot shut-off valve)

(From pilot shut-off valve)
(To control valve port RF for right travel (forward))
(To control valve port RR for right travel (reverse))
(To control valve port LR for left travel (reverse))
(To control valve port LF for left travel (forward))

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

: 17 mm
: 35 Nm (3.5 kgfm, 25 Ibfft)
: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 Ibfft)
WIHH-02-07-001
3. Install pedal (5) and levers (16, 17) with bolts (4).
: 17 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
4. Install under cover (2) with bolts (3) (6 used).
: 17 mm
: 49 Nm (5.0 kgfm, 36 Ibfft)
2
3
5. Install floor mat (1).

WIHH-02-07-002

4
17
16
4
5
15
14
14
13
13
12
12
11
10
W178-02-07-005
12 13 14 15 16 17 -
W2-7-10
Pipe T4:
Pipe P1:
Hose 11:
Hose 12:
Hose 10:
Hose 9:
(To pilot shut-off valve)

(From pilot shut-off valve)
(To control valve port RF for right travel (forward))
(To control valve port RR for right travel (reverse))
(To control valve port LR for left travel (reverse))
(To control valve port LF for left travel (forward))

(Blank)
W2-7-11

DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
ZAXIS330, 330LC: Up to serial No. 320880
ZAXIS350
ZAXIS350LCH
ZAXIS370MTH
13
12
14
11
15
11
10
9
8
9
21
20
21
16
20
19
3
2
18
17
W176-02-07-001
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 -

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

IMPORTANT: Block (10) and housing (18) are
made of aluminium. Too strong a
force can deform or damage them.
Be careful while handling them.
IMPORTANT: Spool (17) has been selected to
match the hole of housing (18). The
dimensions of balance springs A (3),
B (4) and return springs A (5), B (6)
as well as those of push rods A (8),
B (9) are different. Indicate the port
number from which it is removed.
Port numbers are stamped on
housing (18).
4. Remove push rods (8, 9) from block (10).

Two kinds of push rods are used. They must be
handled in order of port number after removing.
5. By using a bamboo spatula, remove oil seals (15)
(4 used) from block (10).
6. Push the springs by using special tool (ST 7257)
from the top of spring guide (16). Retaining ring
(7) will appear. Remove retaining ring (7) by using a screwdriver or similar tool. (4 places)
7
IMPORTANT: Do not remove screw joint (13) while

clamping housing (18) in a vise. The
strong torque may act on the screw
joint.
16
ST 7257
1. Clamp screw joint (13) in a vise. Turn cam (12)

by using a spanner. Remove screw joint (13).
: 19 mm, 32 mm
2. Clamp the flat surface of housing (18) in a vise
slightly. Remove cam (12) from universal joint
(14).
: 32 mm
W176-02-07-005
NOTE: The number of shims has been determined

for each port during the performance testing at the factory.
Do not lose shims. Keep shims carefully in
order to install shims to each former port
when reassembing.
NOTE: Universal joint (14) has been secured on

block (10) by using LOCTITE. Do not remove universal joint (14) unless necessary.
3. Remove socket bolt (11) and remove block (10).
Push rods (8, 9) are removed with the block together.
: 6 mm
7. Remove spring guide (16), balance springs (3, 4),

return springs (5, 6), shim (2), and spacer (1)
from spool (17).
W2-7-13
21
20
21
20
19
18
17
W176-02-07-001
W2-7-14

8. Remove spool (17) from housing (18). Slowly
turn and remove spool (17).
As spool (17) has been selected to match the
hole in housing (18), keep spool (17) carefully in
order to install spool (17) to the former port when
reassembling.
9. Remove O-rings (19, 21) from housing (18).
Do not remove knock pin (20) unless necessary.
W2-7-15

DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
17
ZAXIS330, 330LC: Serial No.320881 and up

ZAXIS350H
ZAXIS350LCH
ZAXIS370MTH
16
15
14
13
12
11
10
22
9
8
7
6
21
5
4
20
18
19
2
1
W178-02-07-064
123456-
Spacer (4 Used)
Shim (Several)
78910 11 12 -

Pusher A (2 Used)
Pusher B (2 Used)
Oil Seal (4 Used)
Sleeve (4 Used)
13 14 15 16 17 -
W2-7-16
O-Ring (4 Used)
Plate
Universal Joint
Cam
Screw Joint
18 19 20 21 22 -
Retaining Ring
Plug
O-Ring
Spool (4 Used)
Casing

IMPORTANT: Casing (22) is made of aluminium.
As too strong a force can deform, or
damage them, handle them with
care.
match the hole of casing (22). The
dimensions of balance springs A (3),
B (4) and return springs A (5), B (6)
as well as those of pushers A (9), B
(10) are different. Indicate the port
number from which it is removed.
Port numbers are stamped on casing (22).
IMPORTANT: Do not remove screw joint (17) while
clamping casing (22) in a vise. The
strong torque may act on the screw
joint.
1. Clamp screw joint (17) in a vise. Turn cam (16)
by using a spanner. Remove screw joint (17).
: 19 mm, 32 mm
IMPORTANT: Insert a soft rubber between sleeve

(12) and the tool in order not to
damage the surface of sleeve (12).
Oil seal (11) cannot be removed
from sleeve (12).
Sleeve (12) and oil seal (11) must be
replaced as an assembly.
5. Pull out sleeve (12) upward by using a pair of
plier.
IMPORTANT: As pushers (9, 10) are used for ports
1, 3 and for ports 2, 4, the dimensions are different. Indicate the port
number from which it is removed in
order to keep by the port number.
6. Remove pushers (9, 10) from casing (22).
2. Clamp the flat surface of casing (22) in a vise

lightly. Remove cam (16) from universal joint
(15).
: 32 mm
3. Attach a spanner onto the upper surface and remove universal joint (15).
: 17 mm
NOTE: Universal joint (15) has been secured on
casing (22) by using LOCTITE.
4. Remove plate (14).
W2-7-17
17
16
22
7
6
21
5
4
19
18
2
1
W178-02-07-064
W2-7-18

7. Install special tool (ST 4146) to the port hole on
casing in order not to lower the spool when pushing the spring.
: 6 mm
8. Install special tool (ST 4146) to the pusher hole
on casing (22). Push special tool (ST 4146) and
push the spring. Tighten special tool (ST 4146)
by using bolt (M14, Pitch 2 mm).
: 12 mm
ST 4146
22
ST 4145

match the hole of casing (22). Replace spool (21) and casing (22) as
an assembly.
11. Remove special tool (ST 4145) from casing (22).
Slowly turn and remove spool (21).
IMPORTANT: Retaining ring (18) may come off
while disassembling. Do not fall off
retaining ring (18) inside the casing.
If falling off retaining ring (18) inside
the casing, remove retaining ring
(18). Retaining ring (18) cannot be
reused.
12. Remove retaining ring (18) by using a screwdriver. Install bolt (M8, Pitch 1.25 mm) and remove plug (19).
: 13 mm
W178-02-07-048
IMPORTANT: The quantity of shims (2) has been

determined for each port during the
performance testing at the factory.
Do not lose shims. Keep shims
carefully in order to install shims to
each former port when reassembing.
9. Remove special tool (ST4146). Remove spring
guides (7) (4 used), balance springs A (3) (2
used), B (4) (2 used), return springs A (5) (2
used) and B (6) (2 used).
10. Remove shim (2) and spacer (1) (4 used) from
spool (21).
W2-7-19

ASSEMBLE RIGHT AND LEFT PILOT
VALVES
ZAXIS330, 330LC: Up to serial No.320880
ZAXIS350H
ZAXIS350LCH
ZAXIS370MTH
14
13
10
12
15
11
8, 9
7
16
3, 4
5, 6
2
19
1
17
W176-02-07-006
21
123456-
Spacer (4 Used)
Shim (Several)
78910 11 -
20

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

NOTE: Table below shows the relations between
each port and the components. Do not
confuse them when assembling.
4. Install retaining ring (7) onto ring holder (ST

7255).
7
Port
No.
1
2
Spool
(17)
Shim
(2)
Push Rods
(8, 9)
Same to Same to
the former the former
one
one
3
4
ST 7255
With outer
groove
Without outer
groove
With outer
groove
Without outer
groove
Port
No.
Return Springs
(5, 6)
Balance Springs
(3, 4)
1
2
3
4
43 mm
48 mm
43 mm
48 mm
29.9 mm
30.1 mm
29.9 mm
30.1 mm
W176-02-07-008
5. Insert the spool (17) head into the hole of special

tool (ST 7257). Push the spring from the top of
spring guide (16). Install retaining ring (7) with the
ring holder (ST 7255) onto the head of spool.
ST 7255
ST 7257
17
Packing Material
W176-02-07-009
1. Insert the thinner end of spool (17) to housing

(18) while rotating.
Check the port hole number and insert the spool
to the former port.
NOTE: Spool (17) has been selected to match the
port hole. Spool (17) and housing (18)
must be replaced as an assembly.
IMPORTANT: Refer to the table in order to assemble them correctly.
2. Install spacer (1), shim (2), balance spring (3) or
(4), and return spring (5) or (6) onto spool (17)
installed in housing (18).
3. Install spring guide (16) onto return spring (3) or
(4) with the protrusion up.
W2-7-21
NOTE: Insert approx. dia.8 mm, length 10 mm of

packing material into the port hole in order
to not only make the work easy to do, but
also prevent spool (17) from lowering to
the bottom when compressing the spring.
13
14
10
12
15
11
8, 9
W176-02-07-006
20
W2-7-22
18

6. Assemble other spools (17) (3 used) into housing
(18) in the same procedures as step 2 to 5.
IMPORTANT:
Check the tightness of cam.
8. Apply grease to the inner surface of oil seals

(15) (4 used). Install the oil seals (4 used) into
block (10) by using a bamboo spatula.
13. Clamp housing (18) carefully in a vise. Install

cam (12) to universal joint (14).
Tighten universal joint (14) so that the clearance
between cam (12) and push rods (8, 9) become 0
to 0.2 mm.
: 19 mm, 32 mm
: 88.2 Nm (9 kgfm)
NOTE: Insert push rods (8, 9) first as illustrated in

order to prevent oil seal (15) from coming
into the endmost of hole during operating.
IMPORTANT: Do not clamp housing (18) in a vise

when operating. The strong torque
may act on the screw joint (13).
7. Install O-rings (19) and (21) (2 used) to housing

(18).
Oil Seal
Mounting Hole
10
8, 9
14. Clamp screw joint (13) in a vise. Tighten universal joint (14). Tighten cam (12) by using a spanner.
: 32 mm
: 88.2 Nm (9 kgfm, 65 Ibfft)
W176-02-07-007
9. Install push rods (8, 9) to block (10). Install the

push rods with outer groove to ports # 1 and # 3.
Install the push rods without outer groove to ports
# 2 and # 4.
10. Apply grease to the ball at the ends of push rods
(8, 9).
11. Apply grease to the joint part of universal joint
(14).
12. Align the position of knock pin (20). Install the
block (10) assembly to housing (18) with socket
: 6 mm
: 19.6 Nm (2 kgfm, 14.5 Ibfft)
W2-7-23

ASSEMBLE RIGHT AND LEFT PILOT
VALVES
ZAXIS330, 330LC: Serial No.32088 and up
ZAXIS350H
ZAXIS350LCH
ZAXIS370MTH
17
15
16
14
9, 10
11
12
13
8
7
3, 4
5, 6
2
19
19
22
21
18
W178-02-06-055
123456-
Spacer (4 Used)
Shim (Several)
78910 11 12 -

Pusher A (2 Used)
Pusher B (2 Used)
Oil Seal (4 Used)
Sleeve (4 Used)
13 14 15 16 17 -
W2-7-24
O-Ring (4 Used)
Plate
Universal Joint
Cam
Screw Joint
18 19 20 21 22 -
Retaining Ring
Plug
O-Ring
Spool (4 Used)
Casing

IMPORTANT: The pilot valve is susceptible to
contamination. Keep the parts clean
when assembling.
NOTE: Table below shows the relations between
each port and the components. Do not
confuse them when assembling.
Port
No.
1
2
Spool
(21)
Shim
(2)
Same to
the former
one
Same to
the former
one
3
4
Pushers A, B
(9, 10)
Outer grooves
(3 Used)
Without outer
groove
Outer grooves
(3 Used)
Without outer
groove
Port
No.
Return Springs
(5, 6)
Balance Springs A, B
(3, 4)
1
2
3
4
Short
Long
Short
Long
Short
Long
Short
Long
IMPORTANT: Refer to the table in order to

assemble them correctly.
3. Install spacer (1), shim (2) and balance springs (3,
4) to spool (21). Install return springs (5, 6) to
casing (22).
4. Install spring guide (7) onto return springs (5, 6)
with the protrusion facing upward.
5. Install special tool (ST 4146) to the pusher hole
on casing. Push special tool (ST 4146) and push
the spring. Tighten special tool (ST 4146) by using
bolt (M14, Pitch 2 mm).
: 12 mm
ST 4146
ST 4144
ST 4145
1. Check the port hole number and insert spool (21)

to the original port. Insert the thinner end of spool
(21) to the port hole in casing (22) while rotating.
port hole. Spool (21) and casing (22) must
be replaced as an assembly.
W178-02-07-049
6. Install retaining ring (8) to ring holder (ST 4144).
2. Install special tool (ST 4145) to the port hole on

casing (22) in order not to lower the spool when
pushing the spring.
: 6 mm
W2-7-25
17
15
16
14
11
13
9, 10
12
8
3, 4
22
W178-02-06-055
W2-7-26

7. Install retaining ring (8) on ring holder (ST 4144)
to the groove on the head of spool (21) out of
special tool (ST 4146)
IMPORTANT: Check the mounting positions of
pushers (9, 10).
8. Install pushers (9, 10).
Push pushers (9, 10) by hand and remove
pushers (9, 10). Check if retaining ring (8) falls off
or the positions of balance springs (3, 4) are
correct.
After checking, install pushers (9, 10) to casing
(22).
9. Apply grease to the ball at the ends of pushers (9,
10).
10. Apply grease to the joint part of universal joint
(15).
IMPORTANT: Align the bolt hole of plate (14) with

the screw hole on casing (22)
completely.
14. Place plate (14) onto casing (22) and tighten
universal joint (15).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 Ibfft)
IMPORTANT: Check the tightness of cam (16).
15. Install cam (16) to universal joint (15). The
clearance between cam (16) and pushers (9, 10)
should be 0 to 0.2 mm.
16. Secure cam (16) by using a spanner. Tighten
screw joint (17) by using a spanner.
: 19 mm, 32 mm
: 68.4 Nm (7.0 kgfm, 50 Ibfft)
11. Apply grease to the inner surface of oil seals (11)

(4 used).
NOTE: Sleeve (12) and oil seal (11) must be
replaced as an assembly.
12. Install oil seal (11) and sleeve (12). Push sleeve
(12) until O-ring (13) is inserted into the hole on
casing.
13. Clamp casing (22) in a vise lightly.
W2-7-27

DISASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine before March in 2003.
1
2
35
34
33
32
31
30
3
4
5
28
29
27
8
9
10
26
11
12
25
13
23
24
22
21
20
19
18
14
17
15
16
W176-02-07-002
123456789-
Bolt (2 Used)
Cover
Pin (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Damper (2 Used)
Rubber Seat (2 Used)
10 11 12 13 14 15 16 17 18 -
Holder
Oil Seal (4 Used)
O-Ring (4 Used)
Bushing (4 Used)
Casing
O-Ring
Plug
Spool (4 Used)
Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
Spacer (4 Used)
Shim (Several)
Balance Spring (4 Used)
Pusher (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Bracket (2 Used)
Spring Pin (2 Used)
W2-7-28
28 29 30 31 32 33 34 35 -

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

Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolt (1) and
remove cover (2) from holder (10).
: 10 mm
2. Remove socket bolts (8) (2 places). Remove
holder (10) from casing (14).
: 8 mm
3. Remove pusher (23) from casing (14). (4 places)
Bushing (13) and oil seal (11) are removed with
pusher (23) together.
8. Place a stand under bracket (26).

The hole insides of spring pins (24, 25) in bracket
(26) are in stepped-shape. The spring pin can
only be removed in one direction.
Remove both spring pins (24, 25) from bracket
(26) at the same time by using special tool (ST
1237). Remove bracket (26) from pin (3). (2
places)
Do not remove spring pin (27) with bracket unless
necessary.
The outside end of spring pin (27) has been
caulked.
4. Remove pusher (23) from bushing (13). By using a

bamboo spatula, remove oil seal (11). (4 places)
24, 25
5. Turn and remove the spool (17) assembly from

casing (14). (4 places)
Spring guide (22), balance spring (21), shim (20),
and spacer (19) are removed with spool (17)
together.
Put the marks on spools (17) (4 used) in order to
easily install spools (17) to their former position.
6. Push balance spring (21). Remove spring guide
(22), balance spring (21), shim (20), and spacer
(19) from spool (17). (4 places)
The number of shims (20) has been determined
during the performance testing at the factory.
They must be kept together with spool (17).
7. Remove spring (18) from casing (14). (4 places)
26
3
27
Caulked Here
Stand
W176-02-07-019
9. Remove socket bolts (28) (2 used). Remove

damper (6) and rubber seat (7) from pin (3).
O-ring (4) is removed together. (2 places)
: 5 mm
IMPORTANT: Place a stand under bracket (26) and

form an reaction force. If holder (10)
bears the reaction force, a strong
force acts on pin (3) and pin (3) may
be deformed.
W2-7-29
35
34
33
32
31
30
3
5
10
14
W176-02-07-002
W2-7-30

10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) mounting
surface up.
IMPORTANT: As the holes for spring pins (34, 35)
in cam (32) are stepped-shape, tap
the bottom of cam.
12. Remove spring pins (34, 35) from cam (32) at the
same time by using special tool (ST 1237). (2
places)
As the holes of spring pins (34, 35) are caulked,
spring pins (34, 35) may feel tight when removing.
13. Remove pin (3) by using a bar and hammer. At
the same time cam (32) is also removed. (2
places)
Do not remove bushings (31) (4 used) left on
holder (10) unless necessary. When removing,
tap bushing (31) by using special tool (ST7256).
14. Remove lock nuts (33) (2 used) from cam (32).
Remove adjusting bolts (30) (2 used). (2 places)
: 13 mm
: 4 mm
W2-7-31

DISASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine after April in 2003.
2
3
4
5
6
35
34
33
32
31
30
9
10
29
11
28
27
14
12
26
15
13
25
16
24
17
18
23
19
20
21
22
W178-02-07-063
123456789-
Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
10 11 12 13 14 15 16 17 18 -
Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring (4 Used)
Bushing (4 Used)
Pusher (4 Used)
19 20 21 22 23 24 25 26 27 -
W2-7-32
O-Ring (2 Used)
Plug (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Casing
Spool
Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)
28 29 30 31 32 33 34 35 -
Oil Seal (2 Used)

Damper (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Pin

Disassemble Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminium.
As too strong a force can deform, or
damage them, handle them with
care.
match the hole of casing.
Indicate the port number from which
it is removed.
Port numbers are stamped on the
periphery of casing (23).
1. Clamp casing (23) in a vise. Remove bolts (1) (2
used), and remove cover (2) from holder (7).
: 10 mm
IMPORTANT: The quantity of shim has been

determined during the performance
testing at the factory. Keep the shim
together with the spool.
6. Push balance spring (18). Remove spring guide
(17), balance spring (18), shim (27) and spacer
(26) from spool (24) (4 places).
7. Remove spring (25) from casing (23). (4 places)
2. Remove socket bolt (30) (2 places), and remove

spring washer (29) (2 places). Remove holder (7)
from casing (23).
: 8 mm
3. Remove pushers (16) (4 used) from casing (23)
(4 places).
4. Remove pusher (16) from bushing (15). By using
a bamboo spatula, remove oil seal (28) (4 places).
Remove O-ring (14) from bushing (15).
IMPORTANT: Put the mark on spools (24) (4 used)
in order to easily install spool (24)
into the original hole.
5. Turn and remove the spool (24) assembly from
casing (23) (4 places).
Spring guide (17), balance spring (18), shim (27)
and spacer (26) are removed with spool (24)
together.
hole of casing (23). Replace spool (24) and
casing (23) as an assembly.
W2-7-33
3
4
6
3
4
10
11
12
13
35
34
33
32
31
9
10
31
11
32
33
34
35
12
13
23
19
20
21
22
W178-02-07-063
W2-7-34

form a reaction force. If holder (7)
force acts on pin (35) and pin (35)
may be deformed.
The hole insides of spring pins (12, 13) in bracket
(11) are in stepped-shape. The spring pin can
only be removed in one direction.
Remove both spring pins (12, 13) from bracket
(11) at the same time by using special tool (ST
1237). Remove bracket (11) from pin (35) (2
places).
Do not remove spring pin (10) on bracket (11)
unless necessary.
The outside end of spring pin (10) has been
crimped.
10. Remove O-ring (33) from pin (35) (2 places).

11. Place holder (7) with the casing (23) mounting
surface up.
12. Remove spring pins (3, 4) from cam (5) at the
same time by using special tool (ST 1237) (2
places). The hole insides for spring pins (3, 4) on
cam (5) are the stepped-shape. Tap the bottom of
cam (5). As the holes of spring pins (3, 4) are
crimped, spring pins (3, 4) may feel tight when
removing.
13. Remove pin (35) by using a round bar and
hammer. At the same time cam (5) is also
removed (2 places). Do not remove bushings (6)
(4 used) in holder (7) unless necessary. When
removing, tap bushing (6) by using special tool
(ST7256).
12, 13
14. Remove plug (20) from casing (23) (2 places).

O-ring (19) is removed with plug (20) together.
11
35
10
Crimped
Here
15. Remove plug (21) from casing (23) (2 places).

O-ring (22) is removed with plug (21) together.
Stand
W176-02-07-019
9. Remove socket bolts (9) (2 used). Remove

damper (32) and rubber seat (31) from pin (35).
O-ring (34) is removed together (2 places).
: 5 mm
W2-7-35

ASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine before March in 2003.
26
31
25 27
24
10
32
30
34, 35
33
13
22
4
28
29
11
21
12
18
23
20
19
17
14
W176-02-07-010
15, 16
123456789-
Bolt (2 Used)
Cover
Pin (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Damper (2 Used)
10 11 12 13 14 15 16 17 18 -
Holder
Oil Seal (4 Used)
O-Ring (4 Used)
Bushing (4 Used)
Casing
O-Ring
Plug
Spool (4 Used)
Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
Spacer (4 Used)
Shim (Several)
Pusher (4 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Bracket (2 Used)
Spring Pin (2 Used)
W2-7-36
28 29 30 31 32 33 34 35 -

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

Assemble Travel Pilot Valve
1. Assemble spool (17) into the assembly. (4 used)
Insert spacer (19), shim (20), and balance
spring (21) into spool (17) in this order. Install
the shim (20) as the same condition before
disassmbling.
Push balance spring (21) by hand. Install spring
guide (22) to spool (17) with the stepped-end
down.
Install bushing (31) on the opposite side in the

same procedure.
31
ST 7256
2. Insert spring (18) to casing (14). (4 places)
10
W176-02-07-015
3. Insert the spool (17) assembly into the former port.

Turn and install the spool (17) assembly into
casing (14). (4 places)
Install bushing (31) in near side as illustrated.

Stop tapping when the bushing (31) end is flush
with the outside of holder (10).
4. Assemble pusher (23) into the assembly. (4 used)

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

(10), install bushing (31) on holder (10) by using
special tool (ST 7256) in the following procedures.
as illustrated.
31
ST 7256
10
Insert bushing (31) into special tool (ST 7256).

Tap special tool (ST 7256) and install bushing (31)
into the hole of holder (10) by using a hammer.
Stop tapping when bushing (31) end is flush with
the inside wall.
ST 7256
10
31
W176-02-07-016
W2-7-37
W176-02-07-013
10
32
30
33
34, 35
23
14
W176-02-07-010
W2-7-38

7. Install adjusting bolt (30) to cam (32). Tighten
adjusting bolt (30) by hand and lightly secure
adjusting bolt (30) temporarily with lock nut (33).
(2 places)
IMPORTANT: Do not adjust adjusting bolt (30)

while pushing the pusher (23) head.
The standard clearance between
adjusting bolt (30) and pusher (23)
must be 0 to 0.2 mm (0 to 0.008 in).
NOTE: Adjust the dimensions later.

8. Apply grease on the head (mounting surface for
pusher (23)) of adjusting bolt (30). (2 places)
9. Apply grease onto pin (3). Install O-ring (5) to pin
(3). Assemble pin (3) to holder (10) with cam (32).
(2 places)
10. Install spring pins (34, 35) to cam (32) by using
special tool (ST 1237). Secure cam (32) and pin
(3). Spring pins (34, 35) should be displaced with
their slits at 90. (2 places)
Tap spring pins (34, 35) until they come in contact
with the step in hole.
34
35
Slit
Slit
13. Adjust adjusting bolt (30) in the following

procedures. (2 places)
: 13 mm
: 4 mm
Loosen lock nut (33).
Move cam (32) and check that there is play. If
there is no play, turn and adjust adjusting bolt
(30).
Turn both adjusting bolts (30) on the left and
right alternatively and keep cam (32) horizontal.
Measure sizes A and B from both left and right
caves on cam (32) to holder (10). Fine adjust
adjusting bolt (30) in order to get same distance
for both left and right.
Secure adjusting bolt (30) by using a hexagon
wrench. Tighten lock nut (33) to specified
torque and secure adjusting bolt (30).
When adjustment is finished, move cam (32)
and check that there is a little play. If there is no
play, pusher (23) may be in compressed
condition. Adjust adjusting bolt (30) again.
: 9.8 Nm (1 kgfm, 7.2 Ibfft)
W176-02-07-017
11. Caulk the hole edge of cam (32) where spring

pins (34, 35) are inserted by using a punch. (2
places)
30
33
32
10
12. Place and install holder (10) on the casing (14)

assembly with socket bolts (8) (2 used) and
spring washers (9) (2 used).
: 8 mm
W176-02-07-003
W2-7-39
26
25 27
24
10
4
28
29
W176-02-07-010
W2-7-40

14. Install rubber seat (7) to pin (3). (2 places)
15. Apply grease to O-ring (5). (2 places)
IMPORTANT: The inner bore of damper (6) is
edged-shape. If damper (6) is pried
when installing, O-ring (5) will be
damaged.
16. Install damper (6) to pin (3) with the lever up. (2
places)

force acts on pin (3) and the pin may
be deformed.
Tap spring pins (24, 25) into bracket (26) until the
spring pins (24, 25) comes to the stepped end by
using special tool (ST 1237). The spring pins (2
used) are displaced with their slits in 90.
17. Secure damper (6) to holder (10) with socket bolts

(28) (2 used) and spring washers (29) (2 used). (2
places)
: 8 mm
: 7 Nm (0.7kgfm, 5.1 Ibfft)
Caulked Here
26
18. Apply grease to O-ring (4). Push O-ring (4) to the

endmost of pin (3). (2 places)
19. As for the direction to install the bracket, refer to
the figure in the disassembly section. Do not
misassemble it.
Install bracket (26) to pin (3). Align the inserting
holes of spring pins (24, 25).
Stand
Caulked Here
24, 25
W176-02-07-011
21. Caulk the hole edge of bracket (26) where spring

pins (24, 25) are inserted by using a punch. (2
places)
(Refer to the figure above.)
22. Install bracket (26) on the opposite side to pin (3)
in the same procedures as steps 19 to 21.
23. Install cover (2) to holder (10) with bolts (1) (2
used).
: 10 mm
: 5 Nm (0.5 kgfm, 3.6 Ibfft)
24. Apply grease to the spring pin (27) contact part of
damper (6). (2 places)
W2-7-41

ASSEMBLE TRAVEL PILOT VALVE
Suitable for the machine after April in 2003.
11
32
31 1
35
12
10
13
3, 4
29
34
9
15
33 28
30
17
18
14
25
27
16
26
24
23
W178-02-06-056
123456789-
Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
10 11 12 13 14 15 16 17 18 -
Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring
Bushing (4 Used)
Pusher (4 Used)
19 20 21 22 23 24 25 26 27 -
NOTE: As for the parts with * mark, refer to

W2-7-32.
W2-7-42
*O-Ring (2 Used)
*Plug (2 Used)
*Plug (2 Used)
*O-Ring (2 Used)
Casing
Spool (4 Used)
Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)
28 29 30 31 32 33 34 35 -
Oil Seal (2 Used)

Damper (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Pin

Assemble Travel Pilot Valve
IMPORTANT: Check the direction to install spring
guide (17).
1. Assemble spool (24) into the assembly (4 used).
Insert spacer (26), shim (27), and balance spring
(18) into spool (24) in this order. Install the shim
as the same condition before disassembling.
Push the balance spring by hand. Install spring
guide (17) to spool (24) with the stepped part
facing downward.
6. If bushing (6) has been removed from holder (7),

install bushing (6) on holder (7) by using special
tool (ST 7256) in the following procedures.
NOTE: Bushings (6) (4 used) are identical.
Insert bushing (6) into special tool (ST 7256). Tap
special tool (ST 7256) and install bushing (6) into
the hole of holder (7) by using a hammer.
Stop tapping when bushing (6) end is flush with
the inside wall.
ST 7256
2. Insert spring (25) to casing (23) (4 places).

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

same procedure.
ST 7256
W176-02-07-015
Install bushing (6) in near and opposite side as

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

as illustrated.
ST 7256
6
7
W176-02-07-01313
W2-7-43
32
31
35
31 32
3, 4
30
29
9
34
33
23
W178-02-06-056
W2-7-44

7. Install O-ring (33) to pin (35). Assemble pin (35) to
holder (7) with cam (5) (2 places).
IMPORTANT: Check the direction to install spring
pins (3, 4).
8. Install spring pins (3, 4) to cam (5) by using
special tool (ST 1237). Secure cam (5) and pin
(35). Spring pins (3, 4) should be displaced with
their slits at 90 (2 places).
Tap and install spring pins (3, 4) until spring pins
(34, 35) make contact with the stepped part in the
hole.
3
Slit
Slit
11. Install rubber seat (31) to pin (35) (2 places).

IMPORTANT: Check the direction of damper (32).
The inner bore of damper (32) is
edged-shape. If damper (32) is pried
when installing, O-ring (33) will be
damaged.
12. Install damper (32) to pin (35) with the lever up (2
places).
13. Secure damper (32) and rubber seat (31) to
holder (7) with socket bolts (9) (2 used) and spring
washers (8) (2 used) (2 places).
: 5 mm
: 7 Nm (0.7 kgfm, 5.2 Ibfft)
14. Apply grease to O-ring (34). Push O-ring (34) to
the endmost of pin (35) (2 places).
W178-02-07-050
9. Crimp the hole edge of cam (5) where spring pins

(3, 4) are inserted by using a punch.
10. Place holder (7) on the casing (23) assembly.
Install holder (7) with socket bolts (30) (2 used)
and spring washers (29) (2 used).
Check the mark direction and install holder (7).
: 8 mm
: 50 Nm (5.1 kgfm, 37 Ibfft)
W2-7-45
11
32
35
12
10
13
W178-02-06-056
W2-7-46

16. As for the direction to install bracket (11), refer to
the figure in the disassemble section. Install
bracket (11) to pin (35). Align the inserting holes
of spring pins (12, 13).
IMPORTANT: Place a stand under the bracket and
force acts on pin (35) and pin (35)
may be deformed.
Tap spring pins (12, 13) into bracket (11) until the
spring pins (12, 13) comes to the stepped end by
using special tool (ST 1237). The spring pins (2
used) are displaced with their slits in 90.
Crimped
Here
11
Stand
Crimped
Here
35
12, 13
W176-02-07-011
18. Caulk the hole edge of bracket (11), where spring

pins (12, 13) are inserted, by using a punch (2
places). (Refer to the figure.)
19. Install bracket (11) on the opposite side to pin (35)
in the same procedures as steps 16 to 18.
20. Install cover (2) to holder (7) with bolts (1) (2
used).
: 10 mm
: 5 Nm (0.5 kgfm, 3.7 Ibfft)
21. Apply grease to the spring pin (10) contact part of
damper (32) (2 places).
W2-7-47

(Blank)
W2-7-48
UPPERSTRUCTURE / Pilot Shut-Off Valve

REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
Removal
1. Remove spring (3).
2
3
5
2. Remove hoses (6 to 13) and pipes (14, 15).

Attach an identification tag to the removed hoses
and pipes for reassembling.
: 19 mm
3. Remove spring pin (5) and remove lever (1).
W178-02-08-001
4. Remove bolt (2) and remove pilot shut-off valve

(4).
: 17 mm
2
View A
6
10
7
8
WIHH-02-08-001
14
View A
15
W2-8-1
12
13
11
WIHH-02-08-002

Installation
1. Install pilot shut-off valve (4) with bolt (2).
2. Install lever (1) with spring pin (5).
3. Install hoses (6 to 13) and pipes (14, 15).
4. Install spring (3).

2
Wrench
Size (mm)
: 17
: 19
: 19
678910 11 12 13 14 15 -
Tightening Torque
Nm
(kgfm) (lbfft)
49
(5)
(36)
35
(3.6)
(26)
29.5
(3)
(21.5)
3
5
Remark
Bolt
Pipe
Hose
W178-02-08-001
Hose DP: (To solenoid valve unit (hydraulic oil tank))

Hose PF: (To solenoid valve unit)
Hose: (To shockless valve)
Hose PD: (To pilot filter)
Hose T6: (To right pilot valve)
Hose P2: (To left pilot valve)
Hose T5: (To left pilot valve)
Hose P3: (To right pilot valve)
Hose P1: (To travel pilot valve)
Hose T4: (To travel pilot valve)
2
View A
6
10
7
8
WIHH-02-08-001
14
View A
15
W2-8-2
12
13
11
WIHH-02-08-002

(Blank)
W2-8-3

DISASSEMBLE PILOT SHUT-OFF VALVE
5
8
9
13
10
11
12
W178-02-08-005
1234-
Washer
Backup Ring
O-Ring
Body
5678-
Socket Bolt
Retaining Ring
Washer
Backup Ring
910 11 12 -
W2-8-4
O-Ring
Spool
Bracket
Pin
13 - Socket Bolt

Disassemble Pilot Shut-Off Valve
1. Put the matching marks on body (4) and bracket
(11). Remove retaining ring (6), washer (7),
backup ring (8), and O-ring (9) from body (4).
Remove the spool (10) assembly.
2. Remove washer (1), backup ring (2), and O-ring
(3) from body (4).
3. Clamp spool (10) by using wooden pieces in a
vise. Remove socket bolt (13) and bracket (11).
Do not remove pin (12) unless necessary.
: 4 mm
4. Remove socket bolt (5) from body (4).
: 8 mm
W2-8-5

ASSEMBLE PILOT SHUT-OFF VALVE
12 13 11
Section ZZ
10
W178-02-08-006
11
13
T178-03-07-002
1234-
Washer
Backup Ring
O-Ring
Body
5678-
Socket Bolt
Retaining Ring
Washer
Backup Ring
910 11 12 -
W2-8-6
O-Ring
Spool
Bracket
Pin
13 - Socket Bolt

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

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

REMOVE AND INSTALL SHOCKLESS
VALVE
14
15 16
17 18 19
13
20
Removal
21
12
1. Remove hoses (1 to 9, 13 to 20).

Attach identification tags to the removed hoses
for reassemblig.
: 19, 22 mm
11
2. Remove pressure sensors (11, 12, 21).

: 24 mm
10
3. Remove bolts (10) and remove the shockless

valve.
: 17 mm
Installation
1. Apply LOCTITE to bolts (10).
shockless valve with bolts (10).
Install
the
2. Install hoses (1 to 9, 13 to 20).

3. Install pressure sensors (11, 12, 21).
Wrench Size
(mm)
: 17
: 19
: 22
: 24
Tightening Torque
Nm (kgfm) (lbfft)
20
(2)
(14.5)
29.5
(3)
(21.5)
39
(4)
(29)
79
(8)
(58)
Remark
Bolt
Hose
Hose
Pressure
Sensor
8B
8A
2
W173-02-09-001
1 - Hose (To right swing control valve)

2 - Hose (To left swing control valve)
3 - Hose (To bucket roll-in control valve)
4 - Hose (To bucket roll-out control valve)
5 - Hose (To boom lower control valve)
6 - Hose (To boom raise control valve)
7 - Hose (To arm roll-in control valve)
8 A - Hose (To arm roll-out control valve)
8 B - Hose (To arm roll-out control valve)
9 - Hose (From pilot shut-off valve)
10 - Bolt
11 - Pressure Sensor (For boom raise)
12 - Pressure Sensor (For arm roll-in)
13 - Hose (From arm roll-in pilot valve)
14 - Hose (From arm roll-out pilot valve)
15 - Hose (From boom lower pilot valve)
16 - Hose (From boom raise pilot valve)
17 - Hose (From bucket roll-in pilot valve)
18 - Hose (From bucket roll-out pilot valve)
19 - Hose (From right swing pilot valve)
20 - Hose (From left swing pilot valve)
21 - Pressure Sensor (For swing)
W2-9-1

DISASSEMBLE AND ASSEMBLE
SHOCKLESS VALVE
18
17
16
14
15
C
A
E
Section T
Section S
14
15
1
S2
S4
S7
7
S3
Section U
14
S1
Section V
15
Z
3
A4
6
3
Section W
2
12,13 11 10 9
19
Section Z-Z
1
14
15
7
6
5
7 6
Section X
Section Y
W2-9-2
WIHH-02-09-001

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part Name
10. Plug
O-Ring
Steel Ball
Steel Ball
Spring
O-Ring
Plug
Orifice
Spring
Ring
Orifice
Plunger
Plunger Assembly
O-Ring
Plug
Body
Seat
Steel Ball
Plug
Qty
3
4
4
4
4
4
4
1
2
1
1
1
1
4
4
1
1
1
1
Wrench Size
(mm)
:8
Tightening Torque
Nm
(kgfm) (lbfft)
49
(5)
(36.2)
:5
:5
14.7
14.7
(1.5)
(1.5)
(10.8)
(10.8)
:6
24.5
(2.5)
(18.1)
:5
9.8
(1.0)
(7.2)
:8
49
(5)
(36.2)
W2-9-3
Remark
Use LOCTITE #262.

(Blank)
W2-9-4
UPPERSTRUCTURE / Solenoid Valve

REMOVE AND
VALVE UNIT
INSTALL
SOLENOID
3
4
5
10
1
Removal
1. Remove each harness of solenoid valves from
connectors.
7
9
2. Remove pilot lines (1 to 6, 11 to 18, 20 to 23, 25,

and 27).
: 17, 19, 27 mm
View A
16
15
14
6
13
12
11
17
3. Remove bolts (7, 19) and remove the solenoid

valve unit.
: 6, 8 mm
WIHH-02-10-001
20
21
22
23
18
19
24
25
26
27
WIHH-02-10-002
1 - Pipe PF: From pilot shutoff valve
8 - Proportional solenoid valve

(SG)
15 - Pipe PH: To pump control

valve (5-spool section)
22 - Hose PI: To control valve
2 - Pipe SC: To arm regenerative valve

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

(SI)
(SC)
11 - Pipe DD: From arm regenerative valve
12 - Pipe PE: To pump control
13 - Pipe DE: From bucket flow
rate control valve (valve B)
14 - Pipe DH: From bucket flow
rate control valve
(switch valve A)
16 - Hose PG: To swing parking

brake release spool
17 - Hose DG: From arm
anti-drift valve
18 - Hose ST: To main pump 1
23 - Hose TA: To hydraulic oil

tank
24 - Torque control solenoid
valve
25 - Hose DI: To hydraulic oil
tank
26 - Maximum pump 2 flow rate
limit solenoid valve
27 - Hose SP: To pump control
5 - Hose DS: To hydraulic oil

tank
6 - Hose DP: From pilot shutoff valve
7 - Socket bolt
19 - Socket bolt
20 - Hose SB: To main pump 2
21 - Hose PD: To pilot shut-off
valve
W2-10-1

2
Installation
1. Install the solenoid valve unit with bolts (7, 19).
2. Install pilot lines (1 to 6, 11 to 18, 20 to 23, 25
and 27).
3
4
3. Install all harnesses of solenoid valves to connectors.

Wrench Size
(mm)
: 17
: 19
: 27
:6
:8
Tightening Torque
Remark
Nm (kgfm) (Ibfft)
24.5 (2.5)
(18) Pipe, Hose
29
(3)
(22)
Hose
93
(9.5)
(43)
Hose
20
(2)
(16)
Bolt
20
(2)
(16)
Bolt
10
1
7
9
8
View A
16
15
14
6
13
12
11
17
WIHH-02-10-001
20
21
23
18
19
22
24
25
26
27
WIHH-02-10-002
1 - Pipe PF:
From
pilot shut- off valve
8-
Proportional solenoid valve

(SG)
15 - Pipe PH: To pump control

22 - Hose PI:
trol valve
2 - Pipe SC: To arm regenerative valve

3 - Pipe SG: To main relief
valve
4 - Hose SI: To travel motor
9-

(SI)
(SC)
Pipe DD: From arm regenerative valve
Pipe PE: To pump control
Pipe DE: From bucket flow
rate control valve (valve B)
Pipe DH: From bucket flow
rate control valve
(switch valve A)
16 - Hose PG: To swing parking

brake release spool
17 - Hose DG: From arm
anti-drift valve
18 - Hose ST: To main pump 1
23 - Hose TA: To hydraulic oil

tank
24 - Torque control solenoid
valve
25 - Hose DI: To hydraulic oil
tank
26 - Maximum pump 2 flow rate
limit solenoid valve
27 - Hose SP: To pump control
5 - Hose DS: To hydraulic oil

tank
6 - Hose DP: From pilot shutoff valve
7 - Socket bolt
10 11 12 13 14 -
19 - Socket bolt
20 - Hose SB: To main pump 2
21 - Hose PD: To pilot shut-off
valve
W2-10-2
To con-

(Blank)
W2-10-3

DISASSEMBLE PROPORTIONAL
SOLENOID VALVES (SC, SI, and SG)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
W178-04-05-001
12345-

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

Disassemble Proportional Solenoid Valves (Solenoid Valves SC, SI, and SG)
IMPORTANT: Do not disassemble lock nut (2) and
adjusting screw (4).
solenoid (6).
: 3 mm
IMPORTANT: Do not remove orifice (11) from
spool (10).
2. Remove spool (10). Remove diaphragm (9),
washer (10), and spring (11).
3. Remove sleeve (17). Remove O-rings (14,15, 16)
from sleeve (17). Remove plate (18) and
wavespring (19).
W2-10-5

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

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

Assemble Proportional Solenoid Valve
(Solenoid Valves SC, SI, and SG)
1. Apply grease to O-rings (14, 15, 16) and apply a
film of hydraulic oil to sleeve (17). Install washer
(10), plate (18) into the housing. Install O-rings
(14, 15) and (16) on sleeve (17), then insert it
into the housing. When inserting the sleeve, be
sure to align the ports of the sleeve with the ports
in the housing.
Install sleeve so that the end faces of sleeve and
body come to the same point.
2. Install spring (11), washer (10), diaphragm (9) to

spool (12) and install it into sleeve (17).
Take care not to damage the edge portion in the
bore of sleeve (17) when inserting the spool (12)
to sleeve. After inserting spool (12) in, check that
the spool (12) slides in and out smoothly without
any restriction about 3 to 5 mm (0.12 to 0.20 in).
Apply hydraulic oil to the spool (12).
12
14
15
16
11
17
9
10
17
W178-02-10-002
Housing
W157-02-11-005
10
W157-02-11-010
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5) and O-ring (3) are not
separated, so no need to assemble
them.
3. Install solenoid (6) with socket bolts (1) (2 used).
When assembling solenoid (6), take care not to
drop spring (7).
: 3 mm
: 2.9 Nm (0.3 kgfm, 2.2 lbfft)
6
1
W157-02-11-011
W2-10-7

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

Lock Nut
O-Ring
Adjusting Screw
Spring
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Retaining Ring
11 12 13 14 15 -
Spring
O-Ring
O-Ring
O-Ring
Sleeve
W2-10-8
16 17 18 19 -
Spool
Orifice
Plate
Wavespring

Disassemble Proportional Solenoid Valves
(Torque Control Solenoid Valve, Maximum Pump
2 Flow Rate Limit Solenoid Valve)
IMPORTANT: Do not lose spring (7) in solenoid hole
when removing solenoid. Do not disassemble lock nut (2) and adjusting
screw (4).
solenoid (6).
: 3 mm
IMPORTANT: Do not remove orifice (17) from
spool (16).
2. Remove spool (16). Remove diaphragm (9), retaining ring (10), and spring (11).
3. Remove sleeve (15). Remove O-rings (12, 13,
and 14) from sleeve (15). Remove plate (18) and
wavespring (19).
W2-10-9

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

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

Assemble Proportional Solenoid Valve
(Torque Control Solenoid Valve Maximum Pump
2 Flow Rate Limit Solenoid Valve)
1. Apply grease to O-rings (12, 13, 14) and apply a
film of hydraulic oil to sleeve (15). Install
wavespring (19), plate (18) into the housing. Install O-rings (12, 13) and (14) on sleeve (15),
then insert it into the housing. When inserting the
sleeve, be sure to align the ports of the sleeve
with the ports in the housing.
Install sleeve so that the end faces of sleeve and
body come to the same point.
2. Install spring (11), retaining ring (10), diaphragm

(9) to spool (16) and install it into sleeve (15).
Take care not to damage the edge portion in the
bore of sleeve (15) when inserting the spool (10)
to sleeve. After inserting spool (16) in, check that
the spool (16) slides in and out smoothly without
any restriction about 3 to 5 mm (0.12 to 0.20 in).
Apply hydraulic oil to the spool (16).
16
11
14
15
16
17
10
15
W178-02-10-002
Housing
W157-02-11-005
10
W157-02-11-010
IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5) and O-ring (3) are not
separated, so no need to assemble
them.
3. Install solenoid (6) with socket bolts (1) (2 used).
When assembling solenoid (6), take care not to
drop spring (7).
: 3 mm
: 2.9 Nm (0.3 kgfm, 2.2 lbfft)
6
1
W157-02-11-011
W2-10-11

DISASSEMBLE AND ASSEMBLE PILOT
RELIEF VALVE
3
4
5
6
7
WIHH-02-10-004
1 - Plug
2 - Shim
3 - Spring
4 - O-Ring
5 - Poppet
6 - Sleeve
W2-10-12
7 - Gasket
8 - Housing

Assemble Pilot Relief Valve
Disassemble Pilot Relief Valve

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

2. Insert poppet (5) into sleeve (6). Install spring (3)
and O-ring (4) into the relief valve. Insert the relief valve assembly into housing (8).
NOTE: Sleeve (6) with poppet (5) attached is provided in the relief valve.
3. Install shim (2) into plug (1). Install plug (1) into
housing (8).
: 22 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
4. Remove gasket (7) from housing (8).
W2-10-13

(Blank)
W2-10-14
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
ZAXIS370MTH
Remove and Install Swing Bearing .......... W3-1-1
Remove and Install Travel Device ..........W3-2-68
Disassemble Swing Bearing .................... W3-1-4
Disassemble Travel Device ....................W3-2-72
Assemble Swing Bearing ......................... W3-1-6
Assemble Travel Device .........................W3-2-78

Disassemble Travel Motor ......................W3-2-86
Assemble Travel Motor...........................W3-2-90
ZAXIS330, 330LC, 350H, 350LCH
Disassemble Brake Valve.......................W3-2-96
Up to Serial No.31357
Assemble Brake Valve ...........................W3-2-98
Remove and Install Travel Device............ W3-2-1
Maintenance Standard ........................W3-2-100
Disassemble Travel Device...................... W3-2-4

Assemble Travel Device ........................ W3-2-10
Group 3 Center Joint
Disassemble Travel Motor ..................... W3-2-18
Remove and Install Center Joint ..............W3-3-1
Assemble Travel Motor .......................... W3-2-22
Disassemble Center Joint ........................W3-3-4
Disassemble Brake Valve ...................... W3-2-30
Assemble Center Joint .............................W3-3-6
Assemble Brake Valve ........................... W3-2-32
Maintenance Standard .............................W3-3-9
Maintenance Standard ......................... W3-2-34
Group 4 Track Adjuster

ZAXIS330, 330LC, 350H, 350LCH
ZAXIS330, 330LC, 350H, 350LCH
Serial No.31358 and up
Remove and Install Track Adjuster ...........W3-4-1
Remove and Install Travel Device.......... W3-2-35
Disassemble Track Adjuster .....................W3-4-2
Disassemble Travel Device.................... W3-2-38
Assemble Track Adjuster........................W3-4-10
Assemble Travel Device ........................ W3-2-44

Disassemble Travel Motor ..................... W3-2-52
ZAXIS370MTH
Assemble Travel Motor .......................... W3-2-56
Remove and Install Track Adjuster .........W3-4-17
Disassemble Travel Brake Valve............ W3-2-62
Disassemble Track Adjuster ...................W3-4-18
Assemble Travel Brake Valve ................ W3-2-64
Assemble Track Adjuster........................W3-4-24
Maintenance Standard ......................... W3-2-66
1HHW-3-1
Group 5 Front Idler

Remove and Install Front Idler ................. W3-5-1
Disassemble Front Idler ........................... W3-5-2
Assemble Front Idler................................ W3-5-6
Maintenance Standard ........................... W3-5-10
Group 6 Upper and Lower Roller

Remove and Install Upper Roller ............. W3-6-1
Remove and Install Lower Roller ............. W3-6-4
Disassemble Lower Roller ....................... W3-6-8
Assemble Lower Roller .......................... W3-6-10
Maintenance Standard ........................... W3-6-12
Group 7 Track
Remove and Install Track ........................ W3-7-1
Maintenance Standard ............................. W3-7-7
1HHW-3-2
UNDERCARRIAGE / Swing Bearing

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

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

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

(4). Hoist and remove swing bearing (4).
W3-1-1
W110-03-01-004

Installation
Clean the mounting surfaces of track frame and
swing bearing.
1. Apply THREEBOND # 1102 to the mounting surfaces of track frame and swing bearing.
(1100 Ib)
2. Hoist the swing bearing. Align the matching
marks on track frame and inner race of swing
bearing.
W110-03-01-004
Machine Front
S (Soft Zone)
Marking Position
Position for Plug
15
3. Tighten bolts (3) (36 used) to the inner race of

swing bearing.
: 41 mm
: 1230 Nm (125 kgfm, 900 lbfft)
20
Position for
Grease Fitting
5
W110-03-01-001
3
W158-03-01-001
W3-1-2

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

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

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

9 - Support (95 Used)

Disassemble Swing Bearing
3

(1100 lb)
1. Place the swing bearing onto the flat workbench.
2. Grind off the caulked part of pin (3).
Tap and remove pin (3) from the bottom side of
plug (4).
4
W1HH-03-01-006
3. Install the hand tap (M10, pitch 1.5 mm) into part
A in the hole on plug (4). Install the bolt (M10,
pitch 1.5 mm) into the hole on plug (4). Tap the
bolt from its back or pull out plug (4).
W1HH-03-01-001
CAUTION: Swing bearing outer race (1)

4. Hoist outer race (1) of swing bearing horizontally.
Remove seals (2, 5).
5. Rotate outer race (1). Remove balls (6) and supports (9) from the plug (4) hole.
When removing balls (6), use rod magnet (C).
Use wire (D) and remove support (9).
W3-1-5
W1HH-03-01-002
W1HH-03-01-007

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

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

9 - Support (95 Used)

Assemble Swing Bearing
1. Clean (degrease) the grooves on outer race (1)
and inner race (7) for seals (2, 5).
Apply THREEBOND #1530D to the groove on
seals (2, 5) in outer race (1) and inner race (7).
Install seals (2, 5).
2
1
5
W1HH-03-01-003
CAUTION: Swing bearing outer race (1)

2. Hoist the outer race horizontally. Align the outer
race with the inner race coaxially.
Apply grease to balls (6) and supports (9).
While rotating the outer race, insert balls (6) and
support (9) into the plug (4) hole one by one by
using a round bar.
3. Install plug (4) into outer race (1) and install pin
(3).
Caulk the head of pin (3) by using a punch.
Add grease 0.9 L (Alvania EP2 grease or equivalent) into the swing bearing through the grease
fitting.
W1HH-03-01-004
3
1
4
W1HH-03-01-005
W3-1-7

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

REMOVE AND INSTALL TRAVEL DEVICE
ZAXIS330, 330LC, 350H, 350LCH

(Up to serial No.31357)
Removal
The procedure starts on the premise that the track
link has already been removed.
Refer to page W3-7-1 for track removal.
3
2
1. Loosen bolts (7) to remove cover (6).

: 22 mm
IMPORTANT: Attach identification tags to aid in
assembling.
2. Disconnect hoses (2) to (5).
: 19 mm, 27 mm, 41 mm
NOTE: Install caps on all disconnected hose and
line ends.
3. Attach the travel device to a crane with a wire
rope.
CAUTION: Travel device weight: 480 kg
(1060 lb)
4. Remove bolts (1). Remove the travel device by
crane.
: 30 mm
W3-2-1
W157-03-02-006

Installation
4
1. Install the travel device with bolts (1).

: 30 mm
: 620 Nm (63 kgfm, 460 lbfft)
2. Connect hoses (2) to (5).
: 19 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
: 27 mm
: 95 Nm (9.5 kgfm, 69 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
3
2
3. Install cover (6) with bolts (7).

: 22 mm
: 180 Nm (18 kgfm, 130 lbfft)
IMPORTANT: After completing travel motor installation, be sure to fill the travel motor
with hydraulic oil (1.3 L (0.34 US
gal.)). After completing installation of
the travel motor or the travel device,
be sure to perform test driving to
prevent motor seizure. Test drive as
follows:
Perform break-in operation as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine for two minutes or more.
W3-2-2
W157-03-02-006

(Blank)
W3-2-3

16
DISASSEMBLE TRAVEL DEVICE

ZAXIS330, 330LC, 350H, 350LCH
15
17
13
12
37
4
3
14
38
11
10
40
5
9
23
18
19
27
26
27
26
25
20
21
19
22
35
31
24
28
30
41
43
39
42
29
34
33
36
31
32
W1HH-03-02-001
1234-
Third Stage Carrier

Third Stage Sun Gear
Thrust Plate (6 Used)
Second Stage
Planetary Gear (3 Used)
6 - Pin (3 Used)
16 - Bolt (16 Used)

17 - Plug (3 Used)
78910 -
18 19 20 21 -
Spring Pin (3 Used)

Spacer (2 Used)
First Stage Carrier
11 - Propeller Shaft
12 13 14 15 -
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
Spring Pin (3 Used)

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

Spring Pin (3 Used)
Pin (3 Used)

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

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

Disassemble Travel Device
CAUTION: Pressure may remain in the travel
device. Slowly loosen the air bleed plug to
completely release the residual pressure.
Then, remove the drain plug to drain gear oil
into a container. If the air bleed plug is loosened quickly, the plug may fly off and/or gear
oil may gush out. Position your face and
body away from the plug.
(1060 lb)
1. Turn over the travel device.
Place the travel device securely on a work bench
so that the brake valve does not come into contact with the work bench, with the motor side
downward.
2. Remove bolts (16) to remove cover (15) from ring
gear (12).
: 19 mm
15
16
12
W107-03-02-008
NOTE: THRREEBOND is applied between cover

(15) and ring gear (12). For easy separation of cover (15), apply a chisel between
cover (15) and ring gear (12) and lightly tap
on the end of the chisel.
Do not remove stopper pin (14) unless it is
damaged or excessively worn.
3. Remove propeller shaft (11) and first stage carrier
(10) assembly from ring gear (12).
4. Remove second stage sun gear (9), second stage
carrier (23) assembly and third stage sun gear (2)
W3-2-5
16
13
12
35
31
30
41
43
42
36
31
32
W1HH-03-02-001
W3-2-6

(121 lb)
5. Remove bolts (13) (28 used). Attach eyebolt (M12,
Pitch 1.75 mm) to bolt (16) hole of ring gear (12).
Remove ring gear (12) from drum (32).
: 24 mm
NOTE: THREEBOND is applied between ring gear
(12) and drum (32). Use the screw driver
for easy removal.

drum (31).
NOTE: Do not attempt to remove the inner race of
roller bearing (31) which remained in
housing (41) side unless it is to be replaced.
11. Remove floating seal (30) from drum (32) and
housing (41).
CAUTION: Third stage carrier (1) assembly

6. Remove third stage carrier (1) assembly.
7. Remove bolt (43) and lock plate (42) from bearing
nut (35).
: 19 mm
8. Hold the travel device securely. Remove bearing
nut (35) using special tools.
Special Tools: ST 3050, ST 3051, ST 3052
Bolt: M16 (60 to 90 mm in length): 2 pieces
ST 3052
ST 3050
35
ST 3051
W157-03-02-005
CAUTION: Drum (32) + sprocket (36) weight:

135 kg (300 lb)
IMPORTANT: The housing (41) matching surface
of drum (32) is the sliding surface.
Place the drum assembly onto a
wooden block not to damage it.
9. Attach eyebolt (M16, Pitch 2.0 mm) to drum (32).
Remove drum (32) from housing (41) by crane.
W3-2-7
40
10
23
8
1
19
20
21
19
22
18
31
24
25
27
26
27
26
28
34
36
32
W1HH-03-02-001
W3-2-8

12. Apply a metal bar to the outer race of roller bearing (31) on drum (32) side, and tap the bar end
with a hammer to drive the outer race out.
13. Apply a round bar to spring pin (18), and tap the
end of the bar to drive spring pin (18) out of first
stage carrier (10) assembly. (3 places)
14. Remove pins (22) (3 used). Remove first stage
planetary gears (21) (3 used), needle bearings
(20) (3 used), and thrust plates (19) (6 used).
15. Remove spacer (40) from first stage carrier (10).
16. Disassemble second stage carrier (23) assembly
following steps 13 to 15 above.
Remove spring pins (7) (3 used), pins (6) (3 used),
second stage planetary gears (4) (3 used), thrust
plates (3) (6 used), needle bearings (5) (3 used),
and spacers (8) (2 used).
17. Disassemble third stage carrier (1) assembly following steps 13 to 15 above.
Remove spring pins (24) (3 used), pins (25) (3
used), thrust plates (26) (6 used), third stage
planetary gears (28) (3 used), and needle bearings (27) (6 used).
CAUTION: Sprocket (36) weight: 68 kg
(150 lb)
18. Loosen and remove bolts (34) (20 used). Remove
sprocket (36) by crane after attaching a nylon
sling to sprocket (36).
: 30 mm
NOTE: LOCTITE is applied to bolt (34).
W3-2-9

ASSEMBLE TRAVEL DEVICE
ZAXIS330, 330LC, 350H, 350LCH
33, 34
32 12 13
29
23
10
39
17
40
11
15
14
38
37
19
18
20
22
21
16
41
30
36
1234-
Third Stage Carrier

Second Stage
6 - Pin (3 Used)
16 - Bolt (16 Used)

17 - Plug (3 Used)
78910 -
18 19 20 21 -
Spring Pin (3 Used)

Spacer (2 Used)
First Stage Carrier
12 13 14 15 -
31
35
42
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
Spring Pin (3 Used)

(3 Used)
22 - Pin (3 Used)
43
28 27 25 26
23 24 25 26 -

Spring Pin (3 Used)
Pin (3 Used)
24

(3 Used)
29 - Motor
30 - Floating Seal
32 - Drum
W3-2-10
34 35 36 37 -
W164-03-02-002
Bolt (20 Used)

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

Assemble Travel Device
1. If replacing roller bearing (31), warm the inner
race (2 used) 50 to 70 C (122 to 158 F) with a
heater, then install one of them into housing (41).
Wait for the bearing to cool. Then, drive it in position completely with a metal bar and hammer.

135 kg (300 lb)
NOTE: Check if the inner race is driven in completely by listening to the sound.
5. Attach eyebolt (M16, Pitch 2.0 mm) to the bolt

(13) hole of drum (32), then hoist and install drum
(32) onto housing (41) with motor (29). At this
time check if the clearance between the motor
and drum is equal.
2. Apply grease to the O-ring outer surface of floating seal (30). Install one half of floating seal (30)
on housing (41).
6. Warm the inner race of roller bearing (31) 50 to 70

C (122 to 158 F) with a heater. Install it between
drum (32) and housing (41).
NOTE: For easier insertion of floating seal (30)

O-ring, use a bamboo (wooden) spatula to
guide it along the periphery.
IMPORTANT: Be sure to tap only the outer race.
3. Install the outer races (2 used) of roller bearing
(31) on drum (32) in position completely with a
metal bar and hammer.
Install the half of floating seal (30) into drum (32).
NOTE: Check if the roller bearing is installed completely by listening to the sound.
(150 lb)
IMPORTANT: Align the chamfered side of sprocket
(36) with drum (32).
4. Attach sprocket (36) with a nylon sling. Hoist it
and place it on drum (32). Apply LOCTITE #262
to bolts (34) (20 used). Tighten bolts (34) and
washers (33) (20 used).
: 30 mm
: 490 Nm (50 kgfm, 360 lbfft)
W3-2-11
41
32
36
35 42 43 26 28 27
W3-2-12
26
24
W164-03-02-002

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

used). Install lock plate (42) to bearing nut (35)
with bolts (43) (2 used)
: 19 mm
43
42
35
NOTE: Apply grease to the threaded part of bearing nut (35) to tighten the torque to correct
specification.
8. Hold the travel device securely. Attach the special
tools to bearing nut (35). Then, tighten with a
torque wrench.
Bolt: M16 (60 to 90 mm in length)
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
13. Install two needle bearings (27) (2 used) into each

third stage planetary gears (28) (3 used).
IMPORTANT: One side of third stage planetary
gear (28) is the marked groove. Install third stage planetary gear (28)
with the side with marked groove
facing to the spring pin (24) hole.
14. Install spacer (8) into third stage carrier (1). Putting thrust plates (26) (6 used) on both ends of
each third stage planetary gears (28) (3 used),
install them into third stage carrier (1).
ST 3052
ST 3050
35
W140-03-02-001
ST 3051
36
W157-03-02-005
9. After tighten bearing nut (35) to specification, tap

on drum (32) with a plastic hammer to secure
appropriate play. Then, rotate sprocket (36) 4 to 5
turns clockwise and then counterclockwise.
10. Repeat step 8 and 9.
11. Repeat step 9 above. Then, tighten bearing nut
(35) to specification.
Special Tools: ST 3050, ST 3051, ST3052,
Bolt: M16 (60 to 90 mm in length):
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
W3-2-13
12 13
23
15
16
41
32
28
W3-2-14
25
24 6
W164-03-02-002

15. Insert pins (25) (3 used) into third stage carrier (1)
to secure third stage planetary gears (28) (3 used).
At this time align third stage carrier (1) with the
spring pin (24) hole on pin (25).
16. Drive spring pins (24) (3 used) into the spring pin
hole on third stage carrier (1) and pin (25). Be
sure that the slit part of spring pin (24) faces to the
end of pin (25).
24
25
Slit
W178-02-06-002
CAUTION: Third stage

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

splines with housing (41).
18. Install third stage sun gear (2) into third stage
carrier (1). Be sure that the lower tooth end faces
to cover (15).
Cover (15)

(121 lb)
(16) hole on ring gear (12). Hoist ring gear (12).
Install ring gear (12) onto drum (32). Apply LOCTITE #262 to bolts (13) (28 used). Tighten bolts
(13).
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)
21. Install spacer (8), second stage planetary gears
(4) (3 used), needle bearings (5) (3 used), thrust
plates (3) (6 used), pins (6) (3 used), and spring
pins (7) (3 used) into second stage carrier (23)
following step 13 to 16 above.
22. Install second stage carrier (23) assembly into
ring gear (12).
23. Install second stage sun gear (9) into second
stage carrier (23). Be sure that the lower tooth
end faces to cover (15).
Cover (15)
W166-03-02-001
19. Clean (degrease) ring gear (12) mounting surface

of drum (32). Apply THREEBOND #1389B to the
mounting surface.
W3-2-15
W166-03-02-002
29
12
10
17
40
11
21
15
22
18
19
16
20
W164-03-02-002
W3-2-16

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

DISASSEMBLE TRAVEL MOTOR
ZAXIS330, 330LC, 350H, 350LCH
12
10
13
14
11
9
8
7
Brake Releasing
Oil Passage
6
3
1
15
16
25
26
27
20
18
19
21
17
22
23
28
24
32
29
30
31
40
39 38
37
36
33
34
35
12345678910 -
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
11 12 13 14 15 16 17 18 19 20 -
W164-03-02-003
Bearing
Housing
Oil Seal
Retaining Ring
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
21 22 23 24 25 26 27 28 29 30 -
Link
Reamer Bolt
Plug (2 Used)
O-Ring (2 Used)
Pin
Center Shaft
Center Spring
Bushing
Valve Plate
Plate
W3-2-18
31 32 33 34 35 36 37 38 39 40 -
Knock Pin (2 Used)

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

Disassemble Travel Motor
CAUTION: Travel motor weight: 87 kg
(190 lb)
Brake valve weight: 43 kg (90 lb)
4. Remove valve plate (29) from brake valve (33). At

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

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

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

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

CAUTION: When removing piston (4) from
the housing filled with air, cover the housing
with cloth to prevent the brake piston from
flying out.
33
22
9. Apply 100 to 300 kPa (1 to 3 kgf/cm2, 14 to 43 psi)

pressure air to brake releasing oil passage in
housing (12), so that brake piston (4) will float up
to be removed.
23
W178-03-02-014
IMPORTANT: Plug (19) has been bound with LOCTITE. If removing it by force, its
hexagon hole may be damaged. Do
not remove plug (19) unless necessary.
NOTE: There is an air seat on brake piston (4). Be

sure to place it with the air seat facing up.
Air Seat
19
W178-03-02-009
NOTE: Piston (4) is with D-rings (3), (5) attached, do

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

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

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

center, the more tilting, the easier removing.
ST 3058
ST 5904
12. Remove spacer (7) from housing (12).

CAUTION: Housing + drive disc (8) + others
W107-03-02-119
CAUTION: Drive disc (8) assembly weight:

7.0 kg (15 lb)
IMPORTANT: As drive disc (8) has tendency to
drop off, keep it with wooden block.
13. Place housing (12) with the brake valve (33)
mounting surface facing downward. Tap and remove drive disc (8) from housing (12) with a plastic hammer lightly. At this time, the drive disc is
still with bearings (9), (11), bearing nut (16), and
spacer (10) attached.
IMPORTANT: The inner race of bearing (9) is left

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

remove oil seal (13) with a screw-driver and
hammer.
8
11
10
9
Thrust Block
W107-03-02-121
W3-2-21

ASSEMBLE TRAVEL MOTOR
ZAXIS330, 330LC, 350H, 350LCH
35, 34
28
15
5 6
30
29
31
33
8
9
10
11
12
13
14
16
18
25
17
20
36
37
38
39
40
23, 24
27
19
26
32
21
W178-03-02-016
22
12345678910 -
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
11 12 13 14 15 16 17 18 19 20 -
Bearing
Housing
Oil Seal
Retaining Ring
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
21 22 23 24 25 26 27 28 29 30 -
Link
Reamer Bolt
Plug (2 Used)
O-Ring (2 Used)
Pin
Center Shaft
Center Spring
Bushing
Valve Plate
Plate
W3-2-22
31 32 33 34 35 36 37 38 39 40 -
Knock Pin (2 Used)

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

CAUTION: Drive disc (8) weight: 4.1 kg (9 lb)
1. Heat the inner race of bearing (9) to 70 to 90C
(158 F to 194 F) in a oil bath or drier. Press the
inner race of bearing (9) into drive disc (8) with
special tool (ST 2155) and a press.
7. Secure drive disc (8) onto special tools (ST 3058,

ST 5904), tighten bearing nut (16) to the specified
torque.
: 3.50.5 Nm
(0.350.05 kgfm, 2.530.36 lbfft)
2. Put the outer race onto the inner race of bearing

(9).
ST 3058
3. Tap and insert the outer race of bearing (11) into

spacer (10) lightly with a plastic hammer.
16
ST 5904
4. Put spacer (10) on the outer race of bearing (9).
5. Heat the inner race of bearing (11) to 70 to 90C

(158 F to 194 F) in a oil bath or drier, and press
the inner race of bearing into drive disc (8) with
special tool (ST 2308) and a press. Tap the inner
race lightly and listen to ring to confirm they are
fitting tightly.
IMPORTANT: Apply grease onto bearing nut (16).
6. Apply grease to the screw part and the side
surface of bearing nut (16). Install bearing nut (16)
onto drive disc (8), then tighten it by hand.
NOTE: Apply grease to tighten it to the specified
torque.
W107-03-02-119

(100 lb)
8. Place housing (12) with its brake valve mounting
side facing down.
IMPORTANT: Apply OCEAN grease #7 to the inner
surface of oil seal (13), and apply
THREEBOND #104 or 1215 to the
outer surface of the oil seal.
9. Tap oil seal (13) evenly and lightly with a plastic
hammer to insert oil seal (13) into housing (12).
The replaced oil seal can be used as a mat then.
10. Install retaining ring (14).
W3-2-23
27
18
12 4
18
13
25
Oil Slit (4 Places)
17
Slit (4 Places)
20 26
W178-03-02-019
W3-2-24

(100 lb)
15. Install plungers (17) (7 used) into the spherical

handle hole in drive disc (8) one by one. Be sure
to confirm plungers (17) (7 used) move smoothly.
11. Turn housing (12) over and place it with its oil seal
(13) side facing down. Tap drive disc (8) assembly
lightly with a plastic hammer and brass bar to install it into housing (12).
17
IMPORTANT: Be sure to align the oil slot (slit part)

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

inner grooves in housing (12).
In addition, the 4 teeth on friction
plate (20) should be placed at same
position when installation is carried
out.
13. Install plates (6) (5 used) and friction plates (20)
(4 used) into housing (12) alternately. Be sure to
align the teethless part (no teeth part ) of plate (6)
(4 places) with the inner slots inside of housing
(12) and install them together.
Moreover, the teethless part of friction plate (20)
should be put at same position to form a straight
line when installation is carried out.
16. Apply grease to the center shaft (26) spherical

part. Install center shaft (26) into drive disc (8).
Then install center spring (27) onto c enter shaft
(26).
17. Apply grease to pin (25) to prevent it from coming
off. Then install it into center shaft (26).
18. Put center shaft (26) to rotor (18) shallowly. Rotate center shaft (26) so as to align pin (25) just
beneath the slot in rotor (18).
18
Groove
NOTE: In case the teethless part or slot position

fail to align with each other, heating may be
resulted to motor failure.
Groove (4 Places)
26
25
12
W178-03-02-015
19. Insert plungers (17) (7 used) into rotor (18).
W178-03-02-018
14. Install D-rings (3, 5) into piston (4), then tap to

install them into housing (12) with a plastic hammer.
W3-2-25
29
28
15
12
18
30
31
33
25
36
37
23
17
19
26
21
W178-03-02-016
W3-2-26

20. Press plunger (17) slowly and install pin (25) into
the rotor (18) groove.
NOTE: If pin (25) cant be installed into the groove,
insert the end of round rotor into the top
hole of center shaft (26), rotate the center
shaft. When doing this work, be sure to
remove the dirt and metallic debris from the
former rotor first.
IMPORTANT: Pay attention to the direction of link

(21) assembly.
29. Install link (21) assembly into brake valve (33)
while aligning the groove in valve plate (29) with
the groove in plate (30). At this time, the sticking
part of link (21) should face the brake valve side.
21
Rotor (18) Side
29
21. Install O-rings (1, 15) into housing (12).

Plate (30) Side
IMPORTANT: Install disc spring (2) into housing

(12) with the outer surface side of
the disc spring facing the brake
valve (33) mounting surface.
22. Install disc spring (2) into housing (12).
23. Fill hydraulic oil into housing (12).
Hydraulic oil: 1.3 L (0.34 US gal)
W178-03-02-017
30. Insert special tool (ST 7131) into the mounting

hole of plug (23), then align the hole of link (21)
with that of servo piston (36).
24. Install plate (30) onto brake valve (33).
36
ST 7131
21
25. Install piston rings (37) (2 used) onto servo piston

(36).
26. Insert servo piston (36) into brake valve (33).
IMPORTANT: Assemble bushing (28) with the
chamfered side facing inside.
27. Install bushing (28) onto valve plate (29) with a
plastic hammer.
28. Apply LOCTITE #262 on plugs (19) (2 used), then
install link (21) onto valve plate (29) with plugs
(19) (2 used).
: 6 mm
W3-2-27
22
W107-03-02-174
12
33
36
38
39
40
23, 24
32
21
W178-03-02-016
22
W3-2-28

31. Apply additive grease, Johnson wax JP103, to the
end of reamer bolt (22) in order to prevent it from
seizing.
Install reamer bolt (22) to link (21) and servo piston (36) through the opposite mounting hole of
plug (23).
: 8 mm
32. Install O-ring (24) onto plug (23), then install it to
brake valve (33).
: 10 mm
: 118 Nm (12 kgfm, 87 lbfft)
33. Install O-ring (38) onto cover (39) and install it to
brake valve (33) with socket bolts (40) (4 used).
: 10 mm
CAUTION: Brake valve (33) weight: 43 kg

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

spool (B) and spring (C).
: 8 mm
W3-2-29

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

Check Valve
10
11
16
12
15
14
13
4
5
6
1, 2
11
10
20
19
13
14
15
16
18
1, 2
17
Shuttle Valve for Servo Piston
Reducing Valve
12345-
O-Ring (2 Used)
Overload Relief Valve (2 Used)
Casing
Plug (2 Used)
O-Ring (2 Used)
W140-03-02-003
678910 -
Spring (2 Used)
Poppet (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
11 12 13 14 15 -
W3-2-30
Stopper (2 Used)
Spool
Ball (2 Used)
Seat (2 Used)
O-Ring (2 Used)
16 17 18 19 20 -
Plug (2 Used)
Plug
O-Ring
Spool
Spring

Disassemble Brake Valve
CAUTION: Brake valve weight: 43 kg (90 lb)
1. Remove plugs (8) (2 used) from casing (3).

: 41 mm
2. Remove springs (10) (2 used), stoppers (11) (2

used) from casing (3).
3. Remove spool (12) from casing (3).
Shuttle valve for servo piston and for parking brake

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

IMPORTANT: Be sure to loosen and remove overload relief (2). Do not turn the lock
nut for adjusting screw on overload
relief valve, or its setting pressure
may change.
4. Remove overload relief valves (2) (2 used) from
casing (3).
: 27 mm
7. Remove plug (17) from casing (3) to remove

spool (19) and spring (20).
: 8 mm
Lock Nut
Adjusting Screw
Check Valve
W140-03-02-005
5. Remove plug (4) from casing (3) to remove

springs (6) (2 used) and poppets (7) (2 used).
: 12 mm
W3-2-31

ASSEMBLE BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
13
14
15
13
14
16
15
16
Section B
Section C
19
17
20
18
3
4
5
C
8
9
Section A-A
A
12
1 - O-Ring (2 Used)
2 - Overload Relief Valve (2
Used)
3 - Casing
4 - Plug (2 Used)
5 - O-Ring (2 Used)
11
10
6 - Spring (2 Used)
7 - Poppet (2 Used)
11 - Stopper (2 Used)
12 - Spool
16 - Plug (2 Used)
17 - Plug
8 - Plug (2 Used)
9 - O-Ring (2 Used)
13 - Ball (2 Used)
14 - Seat (2 Used)
18 - O-Ring
19 - Spool
20 - Spring
W3-2-32
W164-03-02-005

Reducing Valve
1. Insert spring (20) and spool (19) into casing (3).

Install O-ring (18) onto plug (17) to casing (3).
: 8 mm
Shuttle Valve for Servo Piston and for Parking

Brake
(Section B-B, Section C-C)
IMPORTANT: Before inserting ball (13), put ball
(13) on seat (14) and tap on the ball
with a hammer to obtain a tight
fitting between ball (13) and seat (14).
Also, after inserting ball (13) and
before tightening seat (14), insert a
metal bar into the plug hole to ball
(13), then tap the other end of the bar
to obtain tight fitting between ball
(13) and casing (3).
2. Install balls (13) (2 used) with casing (3) titled.
Apply LOCTITE #262 onto seats (14) (2 used)
and install the seats into casing (3). Install O-rings
(15) (2 used) onto plugs (16) (2 used) and install
the plugs into casing (3).
: 5 mm
: 14.5 Nm (1.5 kgfm, 11.0 lbfft)
: 6 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
4. Install overload relief valves (2) (2 used) into casing (3).

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

IMPORTANT: Apply hydraulic oil to spool (12) before assembling. If any resistant
force is felt, move it back and reassemble it. Never assemble it by
force.
5. Insert spool (12) into casing (3). Be sure that
spool (12) can move smoothly in casing (3).
6. Install spring (10) onto stoppers (11) (2 used),
then insert the stoppers into casing (3).
7. Install O-rings (9) (2 used) onto plugs (8) (2 used),
then install the plugs into casing (3).
: 41 mm
: 340 Nm (35 kgfm, 250 lbfft)
Check Valve
IMPORTANT: After inserting poppet (7), insert a
metal bar into the plug hole to
poppet (7), then tap the other end of
the bar to obtain tight fitting between
poppet (7) and casing (3).
3. Install springs (6) (2 used) into poppets (7) (2
used) and insert the poppets into casing (3). Install O-rings (5) (2 used) onto plugs (4) (2 used)
and install the plugs into casing (3).
: 12 mm
: 235 Nm (24 kgfm, 174 Ibfft)
W3-2-33

Sprocket
W1HH-03-02-002
A
B
C
D
E
Standard
Allowable Limit
87 (3.4)
[77 (3.0)]
89.15 (3.5)
84.15 (3.3)
125.75 (5)
133.55 (5.3)
128.55 (5.1)
216.0 (8.5)
-
NOTE: Values in [ ] is just for reference.
W3-2-34
Unit: mm (in)
Remedy
Cladding by
welding and
finishing

ZAXIS330, 330LC, 350H, 350LCH

(Serial No.31358 and up)
Removal
The procedure starts on the premise that the track
link has already been removed.
Refer to page W3-7-1 for track removal.
3
2
1. Loosen bolts (7) to remove cover (6).

: 22 mm
IMPORTANT: Attach identification tags to aid in
assembling.
2. Disconnect hoses (2) to (5).
: 19 mm, 27 mm, 50 mm
NOTE: Install caps on all disconnected hose and
line ends.
3. Attach the travel device to a crane with a wire
rope.
(1020 lb)
4. Remove bolts (1). Remove the travel device by
crane.
: 30 mm
W3-2-35
W157-03-02-006

Installation
1. Install the travel device with bolts (1).

: 30 mm
: 620 Nm (63 kgfm, 460 lbfft)
2. Connect hoses (2) to (5).
: 19 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
: 27 mm
: 95 Nm (9.5 kgfm, 69 lbfft)
: 50 mm
: 205 Nm (21 kgfm, 152 lbfft)
3
2
3. Install cover (6) with bolts (7).

: 22 mm
: 180 Nm (18 kgfm, 130 lbfft)
IMPORTANT: After completing travel motor installation, be sure to fill the travel
motor with hydraulic oil (1.3 L (0.34
US gal.)). After completing installation of the travel motor or the travel
device, be sure to perform test driving to prevent motor seizure. Test
drive as follows:
slow idle position.
speed position.
3. Test drive the machine for two minutes or more.
W3-2-36
W157-03-02-006

(Blank)
W3-2-37

ZAXIS330, 330LC, 350H, 350LCH
(Serial No. 31358 and up)
17
13
12
37
4
3
14
38
11
10
40
5
9
23
8
18
19
27
26
27
26
25
20
21
19
22
35
31
24
28
30
43
29
42
34
33
36
31
32
W1HH-03-02-004
1234-
Third Stage Carrier

Second Stage
6 - Pin (3 Used)
16 - Bolt (16 Used)

17 - Plug (3 Used)
78910 -
18 19 20 21 -
Spring Pin (3 Used)

Spacer (2 Used)
First Stage Carrier
12 13 14 15 -
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
Spring Pin (3 Used)

(3 Used)
22 - Pin (3 Used)

Spring Pin (3 Used)
Pin (3 Used)

(3 Used)
29 - Motor
30 - Floating Seal
32 - Drum
W3-2-38
34 35 36 37 -
Bolt (20 Used)

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

Then, remove the drain plug to drain gear oil
into a container. If the air bleed plug is loosened quickly, the plug may fly off and/or gear
oil may gush out. Position your face and
body away from the plug.
(1020 lb)
1. Turn over the travel device.
Place the travel device securely on a work bench
so that the brake valve does not come into contact with the work bench, with the motor side
downward.
2. Remove bolts (16) to remove cover (15) from ring
gear (12).
: 19 mm
NOTE: THRREEBOND is applied between cover
(15) and ring gear (12). For easy separation of cover (15), apply a chisel between
cover (15) and ring gear (12) and lightly tap
on the end of the chisel.
Do not remove stopper pin (14) unless it is
damaged or excessively worn.
15
16
12
3. Remove propeller shaft (11) and first stage carrier

(10) assembly from ring gear (12).
W107-03-02-008
4. Remove second stage sun gear (9), second stage

carrier (23) assembly and third stage sun gear (2)
W3-2-39
13
12
35
31
30
43
29
42
36
31
32
W1HH-03-02-004
W3-2-40

(121 lb)

135 kg (300 lb)
5. Remove bolts (13) (28 used). Attach eyebolt (M12,

Pitch 1.75 mm) to bolt (16) hole of ring gear (12).
Remove ring gear (12) from drum (32) by crane.
: 24 mm
IMPORTANT: The motor (29) matching surface of

drum (32) is the sliding surface.
Place the drum assembly onto a
wooden block not to damage it.
NOTE: THREEBOND is applied between ring gear

(12) and drum (32). Use the screw driver
for easy removal.
9. Attach eyebolt (M16, Pitch 2.0 mm) to drum (32).

Remove drum (32) from housing (41) by crane.
CAUTION: Third stage carrier (1) assembly


drum (32).
NOTE: Do not attempt to remove the inner race of
roller bearing (31) which remained in
housing (41) side unless it is to be replaced.
6. Remove third stage carrier (1) assembly.

7. Remove bolt (43) and lock plate (42) from bearing
nut (35).
: 19 mm
8. Hold the travel device securely. Remove bearing
nut (35) using special tools.
Bolt: M16 (60 to 90 mm in length):2 pieces
11. Remove floating seal (30) from drum (32) and

motor (29).
ST 3052
ST 3050
35
ST 3051
W157-03-02-005
W3-2-41
4
3
40
10
5
23
8
18
19
27
26
27
26
25
20
21
19
22
31
24
28
34
36
32
W1HH-03-02-004
W3-2-42

12. Apply a metal bar to the outer race of roller bearing (31) on drum (32) side, and tap the bar end
with a hammer to drive the outer race out.
13. Apply a round bar to spring pin (18), and tap the
end of the bar to drive spring pin (18) out of first
stage carrier (10) assembly. (3 places)
14. Remove pins (22) (3 used). Remove first stage
planetary gears (21) (3 used), needle bearings
(20) (3 used), and thrust plates (19) (6 used).
16. Disassemble second stage carrier (23) assembly
following steps 13 to 15 above.
Remove spring pins (7) (3 used), pins (6) (3 used),
second stage planetary gears (4) (3 used), thrust
plates (3) (6 used), needle bearings (5) (3 used),
and spacers (8) (2 used).
17. Disassemble third stage carrier (1) assembly following steps 13 to 15 above.
Remove spring pins (24) (3 used), pins (25) (3
used), thrust plates (26) (6 used), third stage
planetary gears (28) (3 used), and needle bearings (27) (6 used).
(150 lb)
18. Loosen and remove bolts (34) (20 used). Remove
sprocket (36) by crane after attaching a nylon
sling to sprocket (36).
: 30 mm
NOTE: LOCTITE is applied to bolt (34).
W3-2-43

ZAXIS330, 330LC, 350H, 350LCH
33, 34
32 12 13 8
29
23
10
17
40
11
15
14
38
37
19
18
20
22
21
16
30 31 36 35 42 43 28 27 25 26 24 3
4 5
7
W1HH-03-02-003
1234-
Third Stage Carrier

Second Stage
6 - Pin (3 Used)
16 - Bolt (16 Used)

17 - Plug (3 Used)
78910 -
18 19 20 21 -
Spring Pin (3 Used)

Spacer (2 Used)
First Stage Carrier
12 13 14 15 -
Ring Gear
Bolt (28 Used)
Stopper Pin
Cover
23 24 25 26 -
Spring Pin (3 Used)

(3 Used)
22 - Pin (3 Used)

Spring Pin (3 Used)
Pin (3 Used)

(3 Used)
29 - Motor
30 - Floating Seal
32 - Drum
W3-2-44
34 35 36 37 -
Bolt (20 Used)

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

1. If replacing roller bearing (31), warm the inner
race (2 used) 50 to 70 C (122 to 158 F) with a
heater, then install one of them into motor (29).
Wait for the bearing to cool. Then, drive it in position completely with a metal bar and hammer.
NOTE: Check if the inner race is driven in completely by listening to the sound.
2. Apply grease to the O-ring outer surface of floating seal (30). Install one half of floating seal (30)
on motor (29).

135 kg (300 lb)
5. Attach eyebolt (M16, Pitch 2.0 mm) to the bolt
(13) hole of drum (32), then hoist and install drum
(32) onto motor (29). At this time check if the
clearance between the motor and drum is equal.
6. Warm the inner race of roller bearing (31) 50 to 70
C (122 to 158 F) with a heater. Install it between
drum (32) and motor (29).
NOTE: For easier insertion of floating seal (30)

O-ring, use a bamboo (wooden) spatula to
guide it along the periphery.
IMPORTANT: Be sure to tap only the outer race.
3. Install the outer races (2 used) of roller bearing
(31) on drum (32) in position completely with a
metal bar and hammer.
Install the half of floating seal (30) into drum (32).
NOTE: Check if the roller bearing is installed completely by listening to the sound.
(150 lb)
IMPORTANT: Align the chamfered side of sprocket
(36) with drum (32).
4. Attach sprocket (36) with a nylon sling. Hoist it
and place it on drum (32). Apply LOCTITE #262
to bolts (34) (20 used). Tighten bolts (34) and
washers (33) (20 used).
: 30 mm
: 490 Nm (50 kgfm, 360 lbfft)
W3-2-45
29
32 36 35 42 43 26 28 27 25 26 24
W1HH-03-02-003
W3-2-46

IMPORTANT: Face bearing nut (35) stepped to the
bearing. Apply grease to the
threaded part of bearing nut (35).
7. Install bearing nut (35) to motor (29) and tighten
manually.
12. Apply LOCTITE #262 to the thread of bolts (43) (2

used). Install lock plate (42) to bearing nut (35)
with bolts (43) (2 used)
: 19 mm
43
42
35
NOTE: Apply grease to the threaded part of bearing nut (35) to tighten the torque to correct
specification.
8. Hold the travel device securely. Attach the special
tools to bearing nut (35). Then, tighten with a
torque wrench.
Bolt: M16 (60 to 90 mm in length)
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
13. Install two needle bearings (27) (2 used) into each

third stage planetary gears (28) (3 used).
IMPORTANT: One side of third stage planetary
gear (28) is the marked groove. Install third stage planetary gear (28)
with the side with marked groove
facing to the spring pin (24) hole.
14. Install spacer (8) into third stage carrier (1). Putting thrust plates (26) (6 used) on both ends of
each third stage planetary gears (28) (3 used),
install them into third stage carrier (1).
ST 3052
ST 3050
35
W140-03-02-001
ST 3051
36
W157-03-02-005
9. After tighten bearing nut (35) to specification, tap

on drum (32) with a plastic hammer to secure
appropriate play. Then, rotate sprocket (36) 4 to 5
turns clockwise and then counterclockwise.
10. Repeat step 8 and 9.
11. Repeat step 9 above. Then, tighten bearing nut
(35) to specification.
Special Tools: ST 3050, ST 3051, ST3052,
Bolt: M16 (60 to 90 mm in length):
2 pieces
: 790 Nm (80 kgfm, 580 lbfft)
W3-2-47
29
12 13
23
15
16
32
28
25
24
4 5
7
W1HH-03-02-003
W3-2-48

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

(121 lb)
(16) hole on ring gear (12). Hoist ring gear (12) by
crane.
Install ring gear (12) onto drum (32). Apply LOCTITE #262 to bolts (13) (28 used). Tighten bolts
(13).
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)
Slit
W178-02-06-002
CAUTION: Third stage

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

splines with motor (29).
18. Install third stage sun gear (2) into third stage
carrier (1). Be sure that the lower tooth end faces
to cover (15).
Cover (15)
21. Install spacer (8), second stage planetary gears

(4) (3 used), needle bearings (5) (3 used), thrust
plates (3) (6 used), pins (6) (3 used), and spring
pins (7) (3 used) into second stage carrier (23)
following step 13 to 16 above.
22. Install second stage carrier (23) assembly into
ring gear (12).
23. Install second stage sun gear (9) into second
stage carrier (23). Be sure that the lower tooth
end faces to cover (15).
Cover (15)
W166-03-02-001
W166-03-02-002
19. Clean (degrease) ring gear (12) mounting surface

of drum (32). Apply THREEBOND #1389B to the
mounting surface.
W3-2-49
29
12
10
17
40
11
15
19
18
20
22
21
16
W1HH-03-02-003
W3-2-50

IMPORTANT: Face the lower tooth height side of
first stage planetary gear (21) to
spacer (40) side.
24. Install spacer (40), first stage planetary gears (21)
(3 used), needle bearings (20) (3 used), thrust
plates (19) (6 used), pins (22) (3 used), spring
pins (18) (3 used) into first stage carrier (10) following step 13 to 16.
25. Install first stage carrier (10) assembly into ring
gear (12), aligning splines between first stage
carrier (10) and second stage sun gear (9).
26. Add gear oil to ring gear (12).
Gear oil: 9.2 L (2.43 US gal)
27. Insert propeller shaft (11) into the center of carrier.
Be sure that the propeller shaft correctly meshes
with first stage planetary gears (21) and the shaft
of motor (29).
28. Clean (degrease) the cover (15) mounting surface
of ring gear (12). Apply THREEBOND #1389B to
the mounting surface. Install cover (15) to ring
gear (12). Apply LOCTITE #262 to bolts (16) (16
used). Tighten bolts (16) (16 used).
: 19 mm
: 110 Nm (11.5 kgfm, 83 lbfft)
29. Wrap seal tape around plugs (17) (3 used). Install
plugs (17) into cover (15).
: 10 mm
W3-2-51

ZAXIS330, 330LC, 350H, 350LCH
6
Brake Releasing
Oil Passage
5
4
3
Piston Pushing
Oil Passage
2
1
16
28
7
15
14
17
13
19
12
18
20
11
10
9
21
22
23
24
25
26
27
1234567-
Shaft
Retaining Ring
Retaining Ring
Oil Seal
O-Ring (2 Used)
Housing
Piston
8910 11 12 13 14 -
Roller Bearing
Disc Spring
Brake Piston
O-Ring
O-Ring
Plate (4 Used)
Rotor
15 16 17 18 19 20 21 -
Bushing
Swash Plate
Ball (2 Used)
Plunger (9 Used)
Retainer
Spring (6 Used)
W3-2-52
W1HH-03-02-005
22 23 24 25 26 27 28 -

O-Ring
Valve Plate
Knock Pin
Needle Bearing
Brake Valve
Spring

Disassemble Travel Motor
6. Remove rotor (14), springs (20) (9 used), bushing
(15), retainer (19) and plungers (18) (9 used) from
housing (6).
CAUTION: Travel motor weight: 135 kg

(300 lb)
IMPORTANT: When removing brake valve (27)
assembly from the motor, valve
plate (24) is also removed with the
brake valve side.
Dont drop the valve plate as it easily
comes off.
1. Place the travel motor longitudinally. After removing socket bolt (22), remove brake valve (27)
from housing (6).
: 17 mm
IIMPORTANT: The valve plate easily becomes
cracked and scratched, so handle it
with care.
2. Remove valve plate (24) and knock pins (25) from
brake valve (27). Do not remove needle bearing
(26) unless necessary.
NOTE: Even if small removing tool is used for removing the needle bearing, the outer race
may be deformed.
Do not reuse the needle bearing.
3. Wrap tape on the needle bearing (26) rotation
surface of shaft (1) for protection.
7. Remove plates (13) (4 used) and friction plates

(21) (4 used) from housing (6).
CAUTION: Housing weight: 87 kg (200 lb)
8. Place housing (6) with the brake releasing oil
passage facing downward and horizontal.
NOTE: When the brake releasing oil passage is
positioned upward, the thick portion of
swash plate (16) faces upward. When
housing (6) is placed horizontally, the
swash plate may come off suddenly.
9. Remove swash plate (16) from housing (6).
10. With a magnet, remove balls (17) (2 used), piston
(7) and spring (28) from housing (6).
11. Remove retaining ring (2) from housing (6).
12. Tap the bottom in the spline bore of shaft (1) using
a bar and plastic hammer to push the shaft out
with roller bearing (8) from housing (6).
4. Remove disc spring (9) from housing (6).

CAUTION: When removing the brake piston
from the housing filled with air, cover the
housing with cloth to prevent the brake piston from flying off.
5. Apply pressure air 100 to 300 kPa (1 to 3 kgf/cm2,
14 to 43 psi) to the brake releasing oil passage of
housing (6), so that the brake piston will float up
to be removed.
NOTE: It is possible to using bicycle pump. Do not
pry with a screwdriver, or components will
be damaged.
W3-2-53
4
3
W1HH-03-02-005
W3-2-54

13. Insert a slotted head screwdriver into the shaft (1)
hole of housing (6) and push out oil seal (4).
NOTE: Since the oil seal has been covered with
adhesive, it cannot be used again.
14. Remove retaining ring (3) from shaft (1).
CAUTION: When the shaft is removed from
the roller bearing, be sure to avoid dropping
it.
15. Balance the inner race of roller bearing (8) remained on shaft (1) on a vice. With a bar and
plastic hammer, tap the shaft slightly, to remove
the roller bearing.
Bar
8
1
W172-03-02-003
W3-2-55

ZAXIS330, 330LC, 350H, 350LCH
Brake Releasing Oil Passage
27
25
23
11
12
10
14 18
16
17
3
4
1
26
22
24
13
21
20
15
19
Piston Pushing Oil Passage

1234567-
Shaft
Retaining Ring
Retaining Ring
Oil Seal
O-Ring (2 Used)
Housing
Piston
8910 11 12 13 14 -
Roller Bearing
Disc Spring
Brake Piston
O-Ring
O-Ring
Plate (4 Used)
Rotor
15 16 17 18 19 20 21 -
Bushing
Swash Plate
Ball (2 Used)
Plunger (9 Used)
Retainer
Spring (6 Used)
W3-2-56
28
6
W1HH-03-02-006
22 23 24 25 26 27 28 -

O-Ring
Valve Plate
Knock Pin
Needle Bearing
Brake Valve
Spring

Assemble Travel Motor
1. Place housing (6) with the brake valve (27) mating surface facing upward.
IMPORTANT: Apply OCEAN grease #7 to the inner
circumference of the oil seal, and
apply THREEBOND #1104 or #1215
to the outer circumference of the oil
seal.
2. Neatly clean oil seal (4) fitting part of housing (6).
Using tool (ST 7270, ST 7271), install the oil seal
into the housing.
IMPORTANT: Pay attention to assembly direction.

4. Insert the inner ring plate side of roller bearing (8)
into the inner bore spline end of shaft (1) first.
Then push the shaft until the bearing comes into
the tight fitting part. Be sure not to damage the
seal lip surface of the shaft.
5. Insert the inner bore spline end of the shaft into
bearing assemble tool (ST 7268). Tap the other
end of the shaft with a plastic hammer to install
roller bearing (8) onto the shaft.
1
ST 7270
Inner Bore Spline
Inner Ring Plate
4
6
ST 7268
ST 7271
12
W176-03-02-007
W176-03-02-008
IMPORTANT: Pay attention to the direction when

assembling.
3. Assemble roller bearing (8) so that all marked
surfaces are on the outer race, inner race, inner
ring plate facing outward.
Outer Race Marked
Surface
Inner Race Marked Surface
6. Install retaining ring (3) on shaft (1), while taking

care to avoid damaging the oil seal (4) slide surface.
7. Apply grease to the ball (17) surface sufficiently
and assemble balls (2 used) to housing (6).
8. Install spring (28), piston (7) to housing (6) with
the stepped side of the piston facing inside.
W176-02-06-014
Inner Ring Plate Marked

Surface
W3-2-57
27
25
23
11
12
10
14 18
16
17
13
21
20
15
19
6
W1HH-03-02-006
W3-2-58

IMPORTANT:
The small diameter side of the shaft

is the inner race of the needle bearing. Take care not to damage it.
9. With a plastic hammer, tap shaft (1) lightly to install it into housing (6).

15. Place housing (6) with the brake valve (27)
mounting surface facing upward.
10. Install retaining ring (2) in housing (6) to stop shaft

(1).
16. Install plates (13) (4 used) and friction plates (21)

(4 used) on housing (6) alternately. Install the friction plate (21) first.
NOTE: If keep open the retaining ring and move it

to the lowest bottom of the housing, installation of the retaining ring becomes easy.
17. Apply grease to O-rings (11), (12). Install them

into brake piston (10).
11. Apply grease to the ball hole of swash plate (16).

Install the swash plate on housing (6), while align
with balls (17) (2 used).
12. Place housing (6) horizontally with its brake releasing oil passage facing downward.
NOTE: If placed opposite, swash plate (16) may
come off.
IMPORTANT: Pay attention to the retainer direction.
13. Install springs (20) (6 used), bushing (15), retainer
(19), plungers (18) (9 used) onto the rotor (14),
with the chamfered side of the retainer facing the
bushing.
IMPORTANT: Pay attention to the disc spring assembly direction.

19. Put disc spring (9) on brake piston (10) with the
inner diameter of the disc spring facing the brake
piston.
20. Install O-rings (5) (2 used), (23) onto the brake
valve (27) contact surface of housing (6). Install
O-ring (23) onto the brake valve (27).
21. Fill hydraulic oil into housing (6) until plate (13) is
submerged.
IMPORTANT: Pay attention to the knock pin assembly direction.
22. Install the large diameter side of knock pins (25)
(2 used) to the knock pin hole of brake valve (27).
19
Chamfered
18. Push brake piston (10) into housing (6) with a

plastic hammer by tapping evenly.
NOTE: Since the O-ring is positioned around the
brake piston, the brake piston cannot be
fully fitted. When installing brake valve (27),
push the brake piston with tightening bolts.
15
W172-03-02-001
14. Assemble the rotor (14) assembly into housing

(6).
W3-2-59
27
25
26
22
24
6
W1HH-03-02-006
W3-2-60

IMPORTANT:
Pay attention to the needle bearing

assembly direction.
23. Using drive tool (4472142), tap needle bearing
(26) with a hammer into brake valve (27). Face
the mark on the needle bearing outward.
4472142
27
26
W176-03-02-012
24. Apply grease on the flat surface of valve plate

(24). Install the valve plate onto brake valve (27),
aligning knock pin (25).
NOTE: Apply grease sufficiently so that valve plate
adheres to the brake valve. It prevents the
valve plate from coming off while turning
over the brake valve.
IMPORTANT: Take care not to let the valve plate
fall as this can damage it resulting in
oil leaks.
25. Install brake valve (27) to housing (6) and secure
it with socket bolts (22) (8 used).
: 17 mm
: 392 Nm (40 kgfm, 290 Ibfft)
W3-2-61

DISASSEMBLE TRAVEL BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
1
2
3
4
5
4
16
14
15
13
10
11
W1HH-03-02-007
12
1234-
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Stopper (2 Used)
5678-
Spool
Valve Housing
Plug
O-Ring
910 11 12 -
Poppet (2 Used)
Spring (2 Used)
O-Ring (2 Used)
(2 Used)
W3-2-62
13 14 15 16 -
Plug
O-Ring
Spring
Spool

Disassemble Travel Brake Valve
1. Remove plug (1) from valve housing (6). (2
places).
: 41 mm
2. Remove spring (3) and stopper (4) from valve
housing (6) with a magnet. (2 places)
3. Remove spool (5) from valve housing (6) with a
magnet.
6. Remove springs (10), poppets (9) from valve

housing (6) with a magnet. (2 places)
7. Remove plug (13) from valve housing (6).
: 6 mm
8. Remove spring (15), spool (16) from valve housing (6) with a magnet.
4. Remove plug (7) from valve housing (6).

The plug coated with LOCTITE has been inserted
into the hole. Do not remove it unless necessary.
: 6 mm
IMPORTANT: Do not disassemble the overload relief valve. By disassembling it, its
setting pressure may be changed.
IMPORTANT: Do not move the piston on the
overload relief valve, otherwise the
O-ring may be damaged by the hole
of cartridge.
5. Remove relief valves (12) from overload valve
housing (6). (2 places)
: 41 mm
12
W176-03-02-011
Piston
W3-2-63

ASSEMBLE TRAVEL BRAKE VALVE
ZAXIS330, 330LC, 350H, 350LCH
13
14
15
16
10
11
12
7
W1HH-03-02-008
1234-
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Stopper (2 Used)
5678-
Spool
Valve Housing
Plug
O-Ring
910 11 12 -
Poppet (2 Used)
Spring (2 Used)
O-Ring (2 Used)
(2 Used)
W3-2-64
13 14 15 16 -
Plug
O-Ring
Spring
Spool

Assemble Travel Brake Valve
1. Install spool (5) approximately half way into valve
housing (6).
7. Install O-ring (11) (2 used) into overload relief

valve (12).
2. Install O-ring (2), spring (3), stopper (4) onto plug

(1) on one side. Install the plug into valve housing
(6) with pitch a couple of threads left out.
8. Press poppet (9) installed in step 6 with overload

relief valve (12) into valve housing (6), while
slowly rotating the relief valve. (2 places)
: 41 mm
: 440 Nm (45 kgfm, 325 lbfft)
NOTE: If the plug is fully installed, it is difficult to

assemble the plug on other side as spool
(5) may be pushed out.
3. Install O-ring (2), spring (3) and stopper (4) into
other plug (1). Install plug (1) into valve housing
(6). Tighten the plug by hand.
4. Tighten plug (1) on both sides.
: 41 mm
: 343 Nm (35 kgfm, 253 lbfft)
5. Install O-ring (8) into plug (7), then install plug (7)
into valve housing (6).
: 6 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
IMPORTANT: Pay attention to the assembly spool

direction.
9. Install spool (16) into valve housing (6) with the
hole end facing forward.
10. Install spring (15) into valve housing (6).
11. Install O-ring (14) onto plug (13) into valve housing (6).
: 6 mm
: 34 Nm (3.5 kgfm, 25 lbfft)
6. Install spring (10) into poppet (9). Install poppet

(9) flush with the hole entrance of valve housing
(6). (2 places)
NOTE: If the poppet is installed into the farthest
end, the spring may come off from the
poppet.
W3-2-65

Sprocket
W1HH-03-02-002
A
B
C
D
E
Standard
Allowable Limit
87 (3.4)
[77 (3.0)]
89.15 (3.5)
84.15 (3.3)
125.75 (5)
133.55 (5.3)
128.55 (5.1)
216.0 (8.5)
-
NOTE: Values in [ ] is just for reference.
W3-2-66
Unit: mm (in)
Remedy
Cladding by
welding and
finishing

Shoe
Travel Motor
1. End play between plunger and shoe.
Standard
0
0.2 mm (0.008 in)
Allowable Limit
0.2 mm (0.008 in)
Plunger
W105-02-06-130
2. The clearance between plunger and rotor bore.

Standard
Allowable Limit
0
0.04 mm (0.0016 in)
D-d 0.04 mm (0.0016 in)
W105-02-06-134
Plunger Assembly
d
Rotor
W105-02-06-135
Shoe
3. Shoe thickness
Standard
Allowable Limit
5.5 mm (0.22 in)
5.3 mm (0.21 in)

Plunger
W105-02-06-130
W3-2-67

ZAXIS370MTH
Removal
Before removing the travel device, the tracks must be
removed first. For removal and installation of the
tracks, refer to Remove and Install Tracks section on
page W3-7-1.
that the track have already been removed.
2
W16J-03-02-006
1. Remove bolts (1) (6 used) to remove cover (2)

from the track frame.
: 22 mm
Track Frame
10
IMPORTANT: Attach identification tags to hoses

for reassembly.
2. Disconnect hoses (3 and 4) from travel device (6)
and cap all disconnected hose ends.
: 27 mm, 17 mm
3. Remove socket bolts (8) (8 used) from split
flanges (7) (4 used) to disconnect hoses (9 and
10) from travel device (6). Cap all disconnected
hoses.
: 10 mm
6
9
W16J-03-02-005
W111-03-02-002
W3-2-68

CAUTION: Travel Device weight: 670 kg
(1480 lb)
4. Attach wire ropes on travel device (6), and hoist

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

track frame.
Remove bolts (5) (20 used). Hoist and remove the
travel device by crane.
: 32 mm
6
9
W16J-03-02-005
W111-03-02-002
W3-2-69

Installation
3

(1480 lb)
IMPORTANT: Be sure to align the matching marks
made during disassembling. By
failing to do so, it is difficult to install
hoses (3 and 4).
1. Install travel device (6) onto the track frame with
: 32 mm
: 750 Nm (76.5 kgfm, 550 Ibfft)
2. Connect hoses (9 and 10) to travel device (6) with
split flanges (7) (4 used) and tighten the split
flange with socket bolts (8) (8 used).
: 10 mm
: 90 Nm (9.2 kgfm, 67 Ibfft)
3. Connect hoses (3 and 4) onto travel device (6).
: 27 mm
: 93 Nm (9.5 kgfm, 69 Ibfft)
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 Ibfft)
4. Install cover (2) onto the track frame with bolts
(1) (6 used).
: 22 mm
: 180 Nm (18.5 kgfm, 134 Ibfft)
Track Frame
10
5
6
9
W16J-03-02-005
2
W16J-03-02-006
IMPORTANT: After installation, check the oil level.

Start the engine and check for oil
leaks.
After completing installation of the
travel device, be sure to perform
running-in to prevent motor seizure.
slow idle position.
speed position
3. Drive the machine for 2 minutes or more
W3-2-70

(Blank)
W3-2-71

ZAXIS370MTH
7
5
4
3
2
1
21
22
24
23
20
17
16
15
13
18
25
19
14
26
27
12
28
29
10
11
37
40
39
36
34 33
35
32
31
30
38
49
48
47
44
45
46
43
41
42
12345678910 11 12 13 -
Motor
O-Ring
Housing
Floating Seal
Roller Bearing
Drum
Roller Bearing
O-Ring
Nut
Lock Plate
Bolt (2 Used)
Sprocket
Washer (24 Used)
14 15 16 17 18 19 20 21 22 23 24 25 -
Bolt (24 Used)

3rd Stage Carrier
3rd Stage Sun Gear
2nd Stage Carrier
Spacer
2nd Stage Sun Gear
Pin (3 Used)
1st Stage Planetary Gear (3 Used)
Spring Pin (3 Used)
26 27 28 29 30 31 32 33 34 35 36 37 -
Spacer
1st Stage Carrier
Spring Pin (3 Used)
2nd Stage Planetary Gear (3 Used)
Pin (3 Used)
3rd Stage Planetary Gear (4 Used)
Spring Pin (4 Used)
Pin (4 Used)
W3-2-72
W16J-03-02-004
38 39 40 41 42 43 44 45 46 47 48 49 -

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

Then, remove the drain plug and drain the
gear oil into a container.
If the air bleed plug is loosened quickly, the
plug may fly off and/or gear oil may spurt.
Keep your face and body away from the plug.
CAUTION: Motor (1) weight: 130 kg (300 Ib)

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

(1480 lb)
Motor Mounting Bolt
1. After loosening plug (49-B) 2 to 3 turns, remove

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

(1190 Ib)
49-A
W111-03-02-006
3. Attach a wire rope to the middle of drum (6) and

ring gear (42). Hoist the travel device and place it
on the work bench with cover (47) facing up.
CAUTION: Cover (47) weight: 25 kg (55 Ib)
4. Put matching marks on the mounting surface of
cover (47) and ring gear (42).
Install eyebolts (PT 3/4) into the plug (49) holes.
(2 places)
Remove bolts (48) (16 used), then hoist and remove cover (47) from ring gear (42).
: 22 mm
NOTE: Since THREEBOND has been applied to
the mating surfaces of ring gear (42) and
cover (47), it is better to insert a screw
driver between the ring gear and the cover
to pry the cover up for easier removal.
W3-2-73

8
7
4
3
21
22
24
23
20
17
16
18
25
19
15
26
12
27
28
29
10
11
37
40
39
36
34 33
35
32
31
30
38
48
43
41
42
W3-2-74
W16J-03-02-004

10. Install special tool (ST 3136) onto bearing nut (9)
to loosen and remove the bearing nut.

(150 lb)
ST 3136
5. Put matching marks on the mating parts of ring

gear (42) and drum (6).
Install eyebolts (M14, Pitch 2.0 mm) into the bolt
(48) holes (2 places) in ring gear (42).
Remove bolts (43) (30 used) to hoist and remove
the ring gear.
Remove O-ring (8) from drum (6).
: 27 mm
6. Remove shaft (41) from first stage carrier (27).
Remove first stage carrier assemblies (20 to 27)
and second stage sun gear (19) from second
stage carrier (17).
W111-03-02-018
CAUTION: The second stage carrier (17)

assembly weight: 25 kg (50 Ib)
CAUTION: Drum (6), sprocket (12) and other

parts weight: 180 kg (400 Ib)
7. Wind nylon slings (2 used) onto second stage

carrier (17). Hoist and remove second stage carrier assemblies (17, 18, 28 to 33).
Remove third stage sun gear (16).
IMPORTANT: The mating parts of drum (6) and

housing (3) are sliding seal surface.
Take care not to damage the sliding
seal surface and put the removed
drum assembly onto wooden
blocks.
CAUTION: The third stage carrier (15) assembly weight: 70 kg (150 Ib)
8. Wind nylon slings (2 used) onto third stage carrier
(15). Hoist and remove third stage carrier assemblies (15 and 34 to 40) by crane.
9. Remove bolts (11) (2 used) to remove lock plate
(10).
: 19 mm
11. Put matching marks on the mating parts of drum

(6) and housing (3).
Install eyebolts (M18, Pitch 2.5 mm) into the bolt
(43) holes (2 places) in the drum.
Hoist and remove the drum assembly from the
housing.
At this time, the inner race of roller bearing (7) is
also removed along with it.
12. Remove floating seals (4) from housing (3) and
drum (6).
W3-2-75
1
25
17
18
15
12
14
26
27
29
37
40
39
36
34
35
38
W16J-03-02-004
W3-2-76

IMPORTANT: Do not remove the inner race of
roller bearing (5) from housing (3)
unless necessary. In case the inner
race of roller bearing (5) has been
removed, it must be replaced with a
new one.
housing (3) with a bar and hammer.
NOTE: If the inner race of roller bearing (5) can not
be removed, it can be cut by gas torch.
However care should be taken to protect
housing (3) from being damaged while doing this work.
(190 Ib)
14. Put matching marks on the mating surface of
sprocket (12) and drum (6).
Attach nylon slings (2 used) on the sprocket.
Remove bolts (14) (24 used). Hoist and remove
the sprocket.
: 32 mm
17. Pull spring pin (36) out from third stage carrier
(15) with a round bar (Dia: 8mm (0.3 in)). Remove
pin (37) to remove third stage planetary gear (35)
and thrust plates (34 and 40) from the third stage
carrier.
Remove needle bearings (38 and 39) from the
third stage planetary gear.
18. Remove spring pins (36) (3 used), pins (37) (3
used), third stage planetary gears (35) (3 used),
thrust plates (34) (3 used) and (40) (3 used), needle bearings (38) (3 used) and (39) (3 used) from
third stage carrier (15) according to the steps in
procedure 17.
19. Disassemble the first stage carrier (27) assembly
and second stage carrier (17) assembly according to the steps in procedures 17 and 18.
The diameter of round bar for spring pin (25):
4 mm (0.16 in)
The diameter of round bar for spring pin (29):
5 mm (0.20 in)
Remove spacer (18) from second stage carrier
(17).
IMPORTANT: Do not remove the outer race of

roller bearings (5) and (7) from drum
(6) unless necessary.
If the bearing is pressed in insufficiently, the service life of the bearing
may be affected. In case the outer
race has been removed, it must be
replaced with a new one.
drum (6) with a bar and hammer.
CAUTION: Drum (6) including other parts
weight: 100 kg (220 Ib)
16. Install eyebolts (M22, Pitch 2.5 mm) into the bolt
(14) holes (2 places) in drum (6) from the motor
(1) side.
Hoist and turn the drum over. Remove the outer
race of roller bearing (7) from the drum with a bar
and hammer.
W3-2-77

3
1
13 14
12
ZAXIS370MTH
5
43 42
15 16
18
17
19
26
27
49
47
44
46
45
41
23
24
25
22
21
20
48
33 30 32 31
34
40 35 39 38
10 11
12345678910 11 12 13 -
Motor
O-Ring
Housing
Floating Seal
Roller Bearing
Drum
Roller Bearing
O-Ring
Nut
Lock Plate
Bolt (2 Used)
Sprocket
Washer (24 Used)
14 15 16 17 18 19 20 21 22 23 24 25 -
Bolt (24 Used)

3rd Stage Carrier
3rd Stage Sun Gear
2nd Stage Carrier
Spacer
2nd Stage Sun Gear
Pin (3 Used)
1st Stage Planetary Gear (3 Used)
Spring Pin (3 Used)
26 27 28 29 30 31 32 33 34 35 36 37 -
36
T16J-03-05-001
37
Spacer
1st Stage Carrier
Spring Pin (3 Used)
2nd Stage Planetary Gear (3 Used)
Pin (3 Used)
3rd Stage Planetary Gear (4 Used)
Spring Pin (4 Used)
Pin (4 Used)
W3-2-78
28 29
38 39 40 41 42 43 44 45 46 47 48 49 -

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

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

(43) holes (2 places) in drum (6).
Hoist and place the drum (6) with the ring gear
(42) side facing up.
Install the outer race of roller bearing (7) onto the
drum by tapping it with a bar and hammer evenly.
the installation of the outer race is completed into drum (6).
(190 lb)
6. Attach nylon slings (2 used) on sprocket (12).
Hoist the sprocket and place it carefully onto drum
(6).
IMPORTANT: Apply LOCTITE #262 on degreased
bolt (14).
7. Install spring washer (13) to each bolts (14) (24
used). Tighten the bolts and install sprocket (12)
onto drum (6).
: 32 mm
: 750 Nm (75 kgfm, 550 lbfft)
CAUTION: Drum (6), sprocket (12), plus
other parts weight: 180 kg (400 Ib)
IMPORTANT: Align the matching marks made before disassembling. Be sure the
clearance all around drum (6) in
housing (3) is equal.
8. Hoist the drum (6) assembly and put it onto
housing (3).
9. Install the inner race of roller bearing (7) onto the
housing by tapping it with a bar and hammer
evenly.
W3-2-79
12
3
15
47
34
10 11
40 35 39 38
W3-2-80
37
36
T16J-03-05-001

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

spline of housing (3), tighten bearing
nut (9) further in the tightening direction to align with the spline.
Apply LOCTITE #262 to bolts (11).
14. Install lock plate (10) onto bearing nut (9) with
degreased bolts (11) (2 used).
: 19 mm
IMPORTANT: Apply grease on O-ring (8).
15. Install O-ring (8) onto drum (6).
IMPORTANT: There is an identification groove on
one half of third stage planetary gear
(35). Install the third stage planetary
gear with the identification groove
facing cover (47).
16. Install needle bearings (38) (4 used) and (39) (4
used) onto third stage planetary gears (35) (4
used). Install the third stage planetary gear onto
third stage carrier (15) by clamping it with thrust
plates (34) (4 used) and (40) (4 used).
17. Align the spring pin (36) holes in third stage carrier (15) and pins (37) (4 used), then install the
spring pins.
W111-03-02-018
12. Rotate sprocket (12) both clockwise and counterclockwise 4 to 5 turns. Tap on drum (6) with a
plastic hammer to secure appropriate play.
IMPORTANT: When installing spring pin (36), be

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

bearing nut (9) to the specified torque.
: 785 Nm (80 kgfm, 580 lbfft)
36
37
Slit
W178-02-06-002
W3-2-81
43 42
15 16
17 19
26
27
47
41
23
24
25
22
21
20
48
33 30 32 31
34
40 35 39 38
W3-2-82
37
28 29
36
T16J-03-05-001

19. Install spacer (26) to first stage carrier (27).
20. Install needle bearings (21) (3 used) onto first
stage planetary gears (23) (3 used). Clamp the
first stage planetary gear with thrust plates (24) (3
used) and (20) (3 used) and install the first stage
planetary gear onto first stage carrier (27).
IMPORTANT: When installing spring pin (25), be
sure to let its slit face the end of pin
(22).
21. Install spring pins (25) (3 used) into first stage
carrier (27) and pin (22) by a round bar (Dia: 4
mm (0.16 in)).
CAUTION: The second stage carrier (17)

assembly weight: 25 kg (60 Ib)
25. Wind nylon slings (2 used) onto second stage
carrier assemblies (17, 18 and 28 to 33). Hoist the
second stage carrier assemblies and lower it onto
third stage sun gear (16).
26. Install second stage sun gear (19) onto second
stage carrier (17) with the smaller end facing
cover (47).
Cover (47) Side
25
22
19
Slit
W178-02-06-002
22. Assemble second stage carrier (17) according to

the procedures 19 to 21.
Round Bar Dia: 5 mm (0.20 in)
27. Install first stage carrier assemblies (20 to 27)

onto second stage carrier (17).
28. Insert shaft (41) into the center of carrier and be
sure to let it engage with the first stage planetary
gears (23) (3 used).
CAUTION: The third stage carrier (15) assembly weight: 70 kg (150 Ib)
23. Wind nylon slings (2 used) onto third stage carrier
assemblies (15 and 34 to 40). Hoist the third
stage carrier assemblies and lower it onto housing (3) carefully.
24. Install third stage sun gear (16) onto third stage
carrier (15) with the smaller end facing cover (47).
W166-03-02-002

(150 Ib)
IMPORTANT: Align the matching marks made
when disassembling.
(48) hole in ring gear (42). Hoist ring gear by
crane and lower it to drum (6).
bolt (43).
30. Install ring gear (42) onto drum (6) with bolts (43)
(30 used).
: 27 mm
: 390 Nm (40 kgfm, 290 lbfft)
Cover (47) Side
W166-03-02-001
16
W3-2-83
3
1
42
49
47
44
46
45
41
48
T16J-03-05-001
W3-2-84

31. Attach a tube bar on ball bearing (46). Tap a tube
bar with a hammer and install the ball bearing
onto cover (47).
Ball Bearing Inner Diameter: 45 mm (1.77 in)
Outer Diameter: 68 mm (2.68 in)
32. Attach a tube bar on stopper pin (45). Tap a tube
bar with a hammer to install the stopper pin into
ball bearing (46).
Stopper Pin Inner Diameter: 26 mm (1.02 in)
Outer Diameter: 50 mm (1.97 in)
IMPORTANT: Install retaining ring (44). Be sure to
let the chamfered part face cover
(47).
33. Install retaining ring (44) onto cover (47).
CAUTION: Cover (47) weight: 25 kg (55 Ib)
IMPORTANT: Apply THREEBOND #1389B to the
cover (47) mounting surface of ring
gear (42).
34. Install eyebolts (PT 3/4) into the plug (49) holes (2
places) in cover (47).
Hoist the cover by crane and lower it to ring gear
(42).
CAUTION: Travel reduction gear weight:

540 kg (1190 Ib)
holes (2 places) in the housing (3) flange. Hoist
the travel reduction gear and turn it over.
38. Fill gear oil 11.5 L (3.0 US gal.) into the travel reduction gear.
39. Install O-ring (2) to motor (1).
CAUTION: Motor (1) weight: 135 kg (300 Ib)
40. Install eyebolts (M12, Pitch 1.75 mm) (2 used)
into the bolt holes in motor (1). Hoist the motor
and install it onto housing (3) while aligning the
splines on shaft (41) with the splines on the motor.
3
Motor Mounting Bolt

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

install motor (1) into housing (3) with the bolts
(4 used).
: 27 mm
: 300 Nm (30 kgfm, 220 lbfft)
W3-2-85

ZAXIS370MTH
4
2
7
5
15
16
17
14
13
11
12
10
9
8
28
22
27
20
26
25
24
23
18
19
33
32
21
30
29
123456789-
Casing
O-Ring (4 Used)
Spring (2 Used)
Piston (2 Used)
Oil Seal
Roller Bearing
Shaft
Steel Ball (2 Used)
Swash Plate
10 11 12 13 14 15 16 17 -
Piston (9 Used)
Retainer
Holder
Spring (9 Used)
Cylinder Block
Valve Plate
Collar
Roller Bearing
18 19 20 21 22 23 24 25 -
Friction Plate
Friction Plate
Disc Plate (4 Used)
Friction Plate
Backup Ring
O-Ring
O-Ring
W3-2-86
26 27 28 29 30 31 32 33 -
31
W16J-03-02-001
Backup Ring
Brake Piston
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing

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

4. Install eyebolts (M12, Pitch 1.75 mm) into the pin
(31) holes (2 places) in brake piston (27). Hoist
the brake piston and remove it from casing (1).
5. Remove O-rings (24 and 25), backup rings (23
and 26) from brake piston (27).
IMPORTANT: Since friction plates (18, 19, 21 and
22) are different in thickness and the
order to install them has been determined, they should be kept in order while removing.
6. Remove friction plate (22) from casing (1). Remove disc plates (20) (4 used) and friction plates
(21) (3 used) one by one alternately. Remove friction plates (19 and 18).
CAUTION: The cylinder block (14) assembly
IMPORTANT: If cylinder block (14) needs to be replaced, cylinder block assemblies
(10 to 15) with valve plate (15) should
be replaced.
7. Remove cylinder block (14) assemblies (10 to 15)
from casing (1).
33
NOTE: Hold cylinder block (14) and turn it left and

right lightly by two hands to take it out
slowly.
Eyebolt Mounting
Position
W16J-03-02-002
2. Remove springs (29) (10 used), O-rings (2) (4

used), pins (31) (4 used) and O-ring (28) from
casing (1).
IMPORTANT: Take care not to damage valve plate
(15).
3. Remove collar (16) and valve plate (15) from cylinder block (14).
8. Remove retainer (11), pistons (10) (9 used),

holder (12) and springs (13) (9 used) from cylinder
block (14).
IMPORTANT: Do not damage the friction surface
of swash plate (9).
Piston (4) and steel ball (8) may
come out with the swash plate. Be
sure to keep the piston and the steel
ball from dropping.
9. Remove swash plate (9) from casing (1).
W3-2-87
4
3
7
5
W16J-03-02-001
W3-2-88

10. Remove pistons (4) (2 used), springs (3) (2 used)
and steel balls (8) (2 used) from casing (1).
NOTE: If it is difficult to remove steel ball (8), that
means the ball has been set in casing (1),
so use some kerosene or thinner, etc. to
clean grease first, and then with a magnet
to take it out from casing (1).
IMPORTANT: Do not damage the spline part of
shaft (7) and contact part of oil seal
(5). Oil leakage will occur if they are
damaged.
11. Remove shaft (7) from casing (1). At this moment,
the inner race of roller bearing (6) is connecting
with the shaft.
IMPORTANT: Do not remove the inner race of
roller bearing (6) from shaft (7) and
the outer race of roller bearing (6)
from casing (1) unless necessary.
shaft (7) with a press.
IMPORTANT: Keep the outer race of roller bearing
(6) properly so that it can be installed in the same direction before
disassembling.
casing (1) with a bar and a hammer.
14. Remove oil seal (5) from casing (1).
W3-2-89

ZAXIS370MTH
27
33
29
25,26
23,24
22
19 18
30
16
32
17
1
15
31
5
28
T16J-03-05-003
Brake Release Circuit
123456789-
Casing
O-Ring (4 Used)
Spring (2 Used)
Piston (2 Used)
Oil Seal
Roller Bearing
Shaft
Steel Ball (2 Used)
Swash Plate
10 11 12 13 14 15 16 17 -
14 10 20 21
Piston (9 Used)
Retainer
Holder
Spring (9 Used)
Cylinder Block
Valve Plate
Collar
Roller Bearing
13
18 19 20 21 22 23 24 25 -
11
12
Friction Plate
Friction Plate
Disc Plate (4 Used)
Friction Plate
Backup Ring
O-Ring
O-Ring
W3-2-90
26 27 28 29 30 31 32 33 -
Backup Ring
Brake Piston
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing

Assemble Travel Motor
IMPORTANT: Apply grease on inside periphery of
oil seal (5) for casing (1) at the
pressed-in part and outside periphery of the oil seal.
In addition, the oil seal should be
pressed in straight to prevent it from
deforming.
1. Press oil seal (5) into casing (1).
IMPORTANT: Install the outer race of roller bearing
(6) with the stamp mark on the outer
race facing the swash plate (9) side.
2. Tap the outer race of roller bearing (6) evenly with
a bar and hammer while installing the outer race
into casing (1).
NOTE: Tap the bearing and listen to ring to confirm
if installation is completed.
IMPORTANT: Install the inner race of roller bearing
(6) with its collar facing swash plate
(9).
3. Tap the inner race of roller bearing (6) evenly with
a bar and hammer while installing it into shaft (7).
Tap and install the shaft assembly into casing (1)
with a hammer.
IMPORTANT: Apply hydraulic oil on outside periphery of steel ball (8) and piston (4).
Apply hydraulic oil the piston (4) and
the steel ball (8) mounting surfaces
of casing (1).
4. Install springs (3) (2 used), pistons (4) (2 used)
and steel balls (8) (2 used) into casing (1).
IMPORTANT: Align the spherical hole in swash

plate (9) with steel ball (8), then install the swash plate.
Apply grease to matching part of
casing (1) for the swash plate.
6. Install swash plate (9) onto casing (1) with its
thicker side facing down.
IMPORTANT: Apply hydraulic oil on the piston (10)
mounting hole of cylinder block (14).
Pay attention to the mounting direction of retainer (11).
7. Install springs (13) (9 used) and holder (12) into
cylinder block (14).
Install pistons (10) (9 used) onto retainer (11) and
install them into the cylinder block.
CAUTION: The cylinder block (14) assembly
IMPORTANT: Apply hydraulic oil to the piston (10)
sliding surface of swash plate (9)
and the spherical surface of holder
(12).
There is the inner race for roller
bearing (17) on the tip of shaft (7).
Take care to keep it away from being
damaged.
Align the shaft splines to those of
cylinder block (14).
8. Install the cylinder block (14) assembly onto shaft
(7).
CAUTION: The casing (1) assembly weight:
54 kg (120 Ib)
CAUTION: The casing (1) assembly weight:

54 kg (120 Ib)
5. Install eyebolts (M18, Pitch 2.5 mm) into the bolts
(33) holes in casing (1) (2 places). Hoist the casing (1) assembly up and place it with the brake
release circuit facing down.
9. Install eyebolts (M18, Pitch 2.5 mm) into the

socket bolts (33) holes (2 places) in casing (1).
Hoist the casing (1) and place it vertically.
W3-2-91
27
29 25, 26
23, 24 22
19 18
30
16
32
17
1
15
31
T16J-03-05-003
14
20 21
W3-2-92

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

are twelve spring mounting holes in
brake piston (27), so pay attention to
where the spring should be inserted
and not make mistakes.
NOTE: Friction plates (18, 19, 21 and 22) are different in thickness.
(18), (22): 4.8 mm (0.2 in)
(19): 6.5 mm (0.3 in)
(21): 3 mm (1.0 in)
So they should be installed while aligning
with their own notch respectively in casing
(1).
When installing disc plate (20), its inner
splines shall be aligned with those of cylinder block (14).
IMPORTANT: Apply grease to O-rings (24 and 25)
and backup rings (23 and 26).
11. Install backup rings (26 and 23) and O-rings (25
and 24) onto brake piston (27).
IMPORTANT: Pay attention to the mounting direction for brake piston (27), so that the
notch shall be square to the pin (31)
holes in casing (1).
1
27
27
Free Hole
29
29
W16J-03-02-003
Free Hole
13. Install springs (29) (10 used) onto brake piston

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

of valve plate (15) and valve housing
(32).
15. Install collar (16) into valve housing (32). Align the
pin holes in pin (30) and valve plate (15) to install
the valve plate into the valve housing (32).
12. Tap brake piston (27) with a plastic hammer to install it into casing (1).
W3-2-93
33
27
32
31
28
T16J-03-05-003
W3-2-94

IMPORTANT: Apply grease to O-rings (2 and 28).
16. Install O-rings (28) and (2) (4 used) into casing (1)
and install pins (31) (4 used) to valve housing
(32).
CAUTION: Valve housing (32) weight: 39 kg
(90 Ib)
IMPORTANT: When installing valve housing (32)
into casing (1), be sure to confirm
the clearance value between the
casing and the valve housing is
equal to that noted on disassembling. If the value is different, disassemble them and reassemble
again.
IMPORTANT: Align the matching marks made
when disassembling. If the matching
marks cannot be aligned with each
other, brake piston (27) may be installed in wrong direction.
hole in valve housing (32).
Hoist valve housing (32) to put it onto casing (1)
while aligning the pin (31) hole in brake piston
(27) by crane.
Install the valve housing onto the casing with
: 14 mm
: 44021.5 Nm
(452.2 kgfm, 33016 lbfft )
NOTE: Tighten socket bolts (33) (9 used) evenly.
1
32
33
Eyebolt
Mounting Position
W16J-03-02-002
W3-2-95

DISASSEMBLE BRAKE VALVE
ZAXIS370MTH
1
6
2
10
11
Plug
10
35
Orifice
12
13
36
37
14
38
16
39
15
18
20
40
21
48
17
24
26
47
49
10
9
41
42
23
30
25
28
46
32
27
43
29
44
45
43
34
3
2
36
33
31
Orifice
44
40
22
19
42
41
50
39
38
35
37
W183-03-02-010
12345678910 11 12 13 -
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Plug
O-Ring
Spring
Plug (6 Used)
O-Ring (6 Used)
Orifice
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
O-Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
O-Ring (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 -
W3-2-96
Spring (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Cap (2 Used)
O-Ring (2 Used)
39 40 41 42 43 44 45 46 47 48 49 50 -
Spring (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Spool
Valve Housing
Pin (4 Used)
Pin
Orifice
Spool Assembly

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

valves (5) (2 used). The overload relief valve should be replaced as assembly. Attach tags on each overload relief valves so that they can be
installed to their original positions.
In addition, do not rotate set screw
(34), or the setting pressure can
change.
5. Loosen plug (32) to remove overload relief valve
(5) from valve housing (46). (2 places at right and
left)
: 36 mm
6. Press cap (36) while loosening socket bolts (35)
(4 used) to remove the cap (36) from valve housing (46). (2 places at right and left)
: 10 mm
NOTE: In case cap (36) cannot be removed, a
plastic hammer can be used to tap the cap,
however, the loosened socket bolts (35)
should be still on the cap while tapping.
7. Remove spring seat (38), spring (39) and spring
seat (40) from valve housing (46). (2 places at
right and left)
IMPORTANT: Remove spool assembly (50) while
rotating it. In case a little resistance
is felt while removing, do not try to
remove it by force, return to original
position and retry.
8. Press spool assembly (50) out carefully. Rotate
the spool assembly by hand to remove it from
valve housing (46).
9. Clamp spool assembly (50) in a vice with a chip of
wood inserted at both side.
10. Remove plugs (41) (2 used), then remove springs
(43) (2 used) and check valves (44) (2 used) from
spool (45).
W3-2-97

ZAXIS370MTH
Overload Relief Valve (5)

16
18
21
26
24
27 31
29
32
33
34
17, 19
20
22
23, 25
30
28
36
38
41
37
39
35
42
A
40
43
44
45
13
50
14
48
47
12
15
46
5
12345678910 11 12 13 -
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Plug
O-Ring
Spring
*Plug (6 Used)
*O-Ring (6 Used)
*Orifice
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
O-Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
O-Ring (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 -
NOTE: As for parts with *, refer to W3-2-96.
W3-2-98
A-A-A
Spring (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Cap (2 Used)
O-Ring (2 Used)
4
W183-03-02-016
39 40 41 42 43 44 45 46 47 48 49 50 -
Spring (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Spool
Valve Housing
Pin (4 Used)
Pin
*Orifice
Spool Assembly

Assemble Brake Valve (ZAXIS370MTH)
1. Install O-rings (7 and 14) to plugs (6 and 15) respectively. Install valve assembly (13) and plugs
(6 and 15) into valve housing (46).
: 10 mm
: 644.9 Nm
(6.50.5 kgfm, 473.6 lbfft)
2. Install O-ring (2) to plug (1) and install check valve
(4), spring (3) and the plug into valve housing (46).
(2 places at right and left)
: 14 mm
: 41019.5 Nm
(422 kgfm, 30014.5 lbfft)
IMPORTANT: Install overload relief valve (5) to the
former position before disassembled.
3. Install overload relief valves (5) (2 used) onto
valve housing (46).
: 36 mm
: 41019.5 Nm
(422 kgfm, 30014.5 lbfft)
4. Rotate spool assembly (50) slowly to insert it into
valve housing (46).
5. Install O-ring (37) into cap (36). (2 places at right
and left)
6. Install spring seat (40), spring (39) and spring seat
(38) into valve housing (46). Then install cap (36)
with socket bolts (35) (4 used). (2 places at right
and left)
: 10 mm
: 1084.9 Nm
(110.5 kgfm, 803.6 lbfft)
W3-2-99

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

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

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

Casing
D
4. The wear allowance on the sliding surfaces of

cylinder block and valve plate:
Check there is no abnormal scratch, wear or
score.
The wear allowance shall be within 0.02 mm or
less.
W3-2-100
W162-03-02-005

Sprocket
W1HH-03-02-002
Unit: mm (in)
Standard Dimension Allowable Limit
Remedy
92 (3.62)
[82 (3.23)]
86.1 (3.39)
81.1 (3.19)
Cladding by
122.1 (4.8)
welding and
132 (5.2)
127 (5.0)
finishing
215.9 (8.46)
NOTE: Value in [ ] is for reference only.
W3-2-101

(Blank)
W3-2-102
UNDERCARRIAGE / Center Joint

REMOVE AND INSTALL CENTER JOINT
Removal
1. Attach an identification tag to all the hoses of
center joint for reassembling.
Remove all the hoses and adapters from the
center joint. Cap all the removed ends of hoses.
: 17 mm, 27 mm, 41 mm
2. Remove bolt (1) from the center joint and remove
stopper plate (2).
3. Install eyebolt to the center joint. Attach a wire
rope and hoist the center joint.
W157-03-03-003
CAUTION: Center joint weight: 27 kg (60 lb)

3
4. Remove bolts (3) (3 used). Remove the center

joint.
W105-03-03-003
W3-3-1

Installation
1
1. Install the center joint with bolts (3).

: 19 mm
: 90 Nm (9.2 kgfm, 67 lbfft)
2. Install stopper plate (2) to the center joint with

bolts (1).
: 22 mm
: 140 Nm (14.5 kgfm, 105 lbfft)
3. Install all the hoses to the center joint.
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3.0 kgfm, 21.5 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)
W157-03-03-003
4. After completing the work, start the engine and

check for any oil leaks.
W105-03-03-003
W3-3-2

(Blank)
W3-3-3

DISASSEMBLE CENTER JOINT
1
2
3
4
5
12
11
10
7
W157-03-03-002
1 - Plug (with Ball)

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

Disassemble Center Joint
CAUTION: Center joint weight: 26.5 kg
(60 lb)
1. Remove bolt (9) from cover (8) diagonally. By
using eyebolts M10 (Pitch 1.5, Length 18 mm),
hoist and place the center joint on a workbench.
IMPORTANT: For easy removal, use the pins (2

used) when removing oil seals (6).
Do not damage the seal groove by
the pins.
7. Remove oil seals (6) (6 used) and O-ring (4) from
body (12).
2. Put the matching marks on body (12) and spindle

(2).
3. Remove bolts (9) and remove cover (8) from
body (12).
: 17 mm
4. Remove O-ring (7), retaining ring (10), and
O-ring (7) from body (12).
5. Attach special tools (ST 1033, ST 1020) to body
(12) with bolts (9) (2 used).
: 17 mm
ST 1020
ST 1033
W105-03-03-015
8. Remove dust seal (3) from spindle (2).

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

of spindle (2) seal.
6. Remove spindle (2) from body (12).
W3-3-5

ASSEMBLE CENTER JOINT
1
2
3
4
6
12
11
10
9
W178-03-03-001
1 - Plug (with Ball)

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

Assemble Center Joint
IMPORTANT: If removing bushing (5), install
bushing (5) by using a press first.
(Refer to page W3-3-8.)
1. Install dust seal (3) into spindle (2) with its lip part
facing to body (12).
4. As the clearance between body (12) and spindle

(2) is approximately 0.1 mm (0.004 in), insert
spindle (2) along axis straight and slowly.
Tap and install body (12) by using a plastic hammer until surface A of body (12) is flush with that
of spindle (2).
Surface A
0.1 mm
Dust Seal (3)
12
Lip
Body (12)
W105-03-03-024
W178-03-03-002
2. Install oil seals (6) (6 used) and o-ring (4) into

body (12).
3. Place spindle (2) onto a workbench. Align the
matching marks and install body (12) on spindle
(2).
5. Install ring (11) to body (12) with the chamfered

side facing the spindle (2). Install O-ring (7) to
body (12).
6. Install retaining ring (10) to spindle (2).
7. Install cover (8) with bolts (9) (4 used).
: 17 mm
W3-3-7

When replacing the body or spindle with the new one,
the following procedures are required.
In case of body (12)
In case of spindle (2)
1. Clean body (12) and bushing (5).
1. Clean spindle (2).
2. When pushing bushing (5) into body (12), apply

grease or molybdenum disulphide to the fitting
surface.
Push bushing (5) into body (12) by using a press.
Pushing force: 0.5 to 1.5 t (1100 to 3300 lb)
Pushing tool: ST 2558
2. Tap and install plug (1) into spindle (2) by using

3. Tap the balls of plug (1) so that the top of each
ball is 0.4 mm (0.016 in) or more than the respective sleeve edge as illustrated in detail D.
ST 2558
Sleeve
12
0.4 mm
or More
Detail D
W135-03-03-001
W136-03-03-031
W105-03-03-029
ST 2559
Ball
W157-03-03-004
W3-3-8

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

one half
Bushing
T157-01-01-040
Body Spindle
Cover
Sliding surface
Scored or serious damage
and sealed part
Sliding surface of 1) Scored or abnormal wear of more than
body and spindle,
0.1 mm (0.004 in)
except
sealed 2) Scored less than 0.1 mm (0.004 in) deep
part
1) Wear more than 0.5 mm (0.02 in) deep
and abnormal wear
Sliding surface
2) Wear less than 0.5 mm (0.02 in) deep
and ring
3) Scored or abnormal wear less than 0.5 mm
(0.02 in) and repairable.
1) Wear more than 0.5 mm (0.02 in)
Sliding surface
2) Wear less than 0.5 mm (0.02 in)
and ring
3) Scored or abnormal wear less than 0.5 mm
(0.02 in) and repairable.
W3-3-9
Replace
Replace
Repair and finish
with oil stone
Replace
Repair and finish
Repair and finish
Replace
Repair and finish
Repair and finish

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

REMOVE AND INSTALL TRACK ADJUSTER
(ZAXIS330, 330LC, 350H, 350LCH)
Before removing and installing the track adjuster, the
tracks, and the front idler must be removed first. For
removal and installation of the tracks and front idler,
refer to "Remove and Install Front Idler" (W3-5-1) and
"Remove and Install Track" (W3-7-1).
that the tracks and front idler have already been removed.
Removal
CAUTION: Track adjuster weight: 180 kg
(400 lb)
CAUTION: The front idler may fly off due to
the strong spring force when removing
track adjuster (1). Do not stand in the same
direction to track adjuster (1) or where the
track adjuster flies off.
Particularly, a strong spring force is always
applied to the thread part of rod. If the rod
and/or the threads are damaged, metal fragments under spring force may fly off.
2
1
1. Pry and remove track adjuster (1) from track

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

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

Flange
Dust Seal
Piston Rod
Wear Ring
6789-
U-Ring
Retaining Ring
Rod
O-Ring
10 11 12 13 -
W3-4-2
Cylinder
Plug
Valve
Nut
14 15 16 17 -
Washer
Spacer
Spring
Holder

Disassemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH)
IMPORTANT: Use special tool (ST 4920) when
assembling and disassembling the
track adjuster.
CAUTION: The spring force of the track adjuster is extremely large. Inspect the special
tool for any damage thoroughly in order to
perform the work safely.
Special Tool
(ST 4290)
CAUTION: Special tool weight: 225 kg

(496 lb)
1. Place an oil jack (30 t) between the holder and
base.
Holder
Oil Jack
Base
W105-03-04-006
2. Remove the nuts (4 used) of special tool and

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

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

4. Install plate (ST 4036) on the track adjuster.
Plate (ST 4036)
5. Operate an oil jack.
W105-03-04-011
Jack up the specified amount (122 m).

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

and valve (12) from rod (8).
: 5 mm
: 85 mm
: 24 mm
W105-03-04-012
13
11
W105-03-04-014
W3-4-5
17
1
2
3
4
5
6
10
16
15
14
W173-03-04-001
W3-4-6

8. Lower the oil jack and release the spring force.
Oil Jack
W105-03-04-015
9. Remove the nuts of special tool. Remove plate

(ST 4036) and washer (14).
Plate (ST 4036)
CAUTION: Spring assembly weight: 168 kg

(370 lb)
10. Install eyebolt (M16, Pitch 1.5) to rod (8).
Hoist the track adjuster and remove the spring
(16) assembly from special tool.
W105-03-04-016
Eyebolt
CAUTION: Spring weight: 95 kg (209 lb)

11. Remove eyebolt. Remove spring (16) from rod
(8).
12. Remove spacer (15) from rod (8).
13. Remove socket bolts (1) (4 used). Move flange
(2) to holder (17). Remove flange (2) from cylinder (10).
: 8 mm
W3-4-7
W105-03-04-017
17
2
3
4
5
6
10
W173-03-04-001
W3-4-8

14. Remove the piston rod (4) assembly from cylinder (10).
15. Holder (17) is pushed into piston rod (4).

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

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

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

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

Assemble Track Adjuster
(ZAXIS330, 330LC, 350H, 350LCH)
1. Install dust seal (3) on flange (2).
4
5
2. Fill chamber (A) of flange (2) with grease.

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

Push holder (17) into piston rod (4).
4. Clean all parts.
Install U-ring (6), retaining ring (7), and wear ring
(5) to piston rod (4).
5. Apply grease to O-ring (9). Install O-ring (9) into
cylinder (10).
Install rod (8) into cylinder (10).
6. Apply grease to U-ring (6) and wear ring (5). Fill
chamber (B) in cylinder (10) with grease. Apply
grease to cylinder (10) and piston rod (4). Install
the piston rod (4) assembly into cylinder (10).
Insert the piston rod (4) assembly and completely
bleed air from chamber (B) and rod (8).
7. Tighten flange (2) with socket bolts (1) (4 used).
: 8 mm
: 64 Nm (6.5 kgfm, 47 lbfft)
W3-4-11
W105-03-04-025
10
6
5
W105-03-04-021
14
15
16
W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-12

8. Install spacer (15) on rod (8).
8
CAUTION: Spring (16) weight: 95 kg (209 lb)

9. Install spring (16) on rod (8).
CAUTION: Spring (16) assembly weight:
168 kg (370 lb)
10. Install eyebolt (M16, Pitch1.5 mm) into rod (8).
Hoist and place the spring (16) assembly onto
special tool.
11. Remove eyebolt. Place washer (14) onto spring
(16). Install plate (ST 4036).
W105-03-04-017
Plate (ST 4036)
14
16
W105-03-04-016
12. Tighten the nuts of special tool and secure the

spring assembly.
: 46 mm
W105-03-04-012
W3-4-13
12
13
11
16

W1HH-03-04-001
778 mm (2 ft 6.6 in)
W3-4-14

13. Operate the oil jack and compress spring (16) to
the specification.
Specified Length: 557 mm (1 ft 9.9 in)
16
Oil Jack
14. Install nut (13) to rod (8). Install plug (11).

: 85 mm
: 5 mm
: 14.5 Nm (1.5 kgfm, 11 lbfft)
W105-03-04-026
13
11
W105-03-04-014
15. Install valve (12) to rod (8).

: 24 mm
Oil Jack
16. Lower the oil jack.
W105-03-04-013
17. Remove the nuts of special tool and remove plate

(ST 4036).
: 46 mm
Plate (ST 4036)
W105-03-04-011
W3-4-15

(397 lb)
Wire Rope
18. Attach a wire rope to the track adjuster as illustrated. Hoist and remove the track adjuster from
special tool.
CAUTION: If only the track adjusted is
transported, use special tool as illustrated in
order to carry the track adjuster safely.
W105-03-04-009
W105-03-04-028
W3-4-16

REMOVE AND INSTALL TRACK
ADJUSTER
(ZAXIS370MTH)
Before removing and installing the track adjuster, the
tracks and the front idler must be removed first. For
removal and installation of the tracks and front idler,
refer to "Remove and Install Front Idler" (W3-5-1)
and "Remove and Install track" (W3-7-1). In this section, the procedure starts on the premise that the
tracks and front idler have already been removed.
the strong force when removing track adjuster (1). Do not stand in the same direction
to track adjuster (1) or where the track adjuster flies off.
Particularly, a strong spring force is always
applied to the thread part of rod. If the rod
and/or the threads are damaged, metal fragments under spring force may fly off.
2
1
W142-03-04-002
Removal
(550 lb)
1. Pry and remove track adjuster (1) from track

frame (2) by using a pry bar.
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Check that the end of track adjuster (1) comes
into contact with that of plate (4).
W16J-03-04-002
View
W3-4-17
W16J-03-04-001

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

O-Ring
Guide
Piston Rod
5678-
Wear Ring
U-Ring
Retaining Ring
Rod
910 11 12 -
Cylinder
O-Ring
Bolt
Valve
W3-4-18
13 14 15 16 -
Nut
Bracket
Spring
Spacer

Disassemble Track Adjuster
(ZAXIS370MTH)
Use a pump unit which has the maximum pressure of 69 Mpa (700 kgf/cm2, 9950 psi) and the
flow rate of 8 to 10 liters (2.1 to 2.6 US gal). Be
sure to set the main relief pressure to 49 Mpa
(500 kgf/cm2, 7110 psi) (80 tons) or lower.
IMPORTANT: Use special tool (ST4932) when assembling and disassembling the
track adjuster.
Track Adjuster
ST 4932
CAUTION: The spring force of track adjuster

is extremely large. Inspect the special tool
for any damage thoroughly in order to perform the work safely.
(550 lb)
1. Hoist and place the track adjuster on the holder
of special tool (ST 4932).
Holder
2. Loosen valve (12). Compress spring (15) of track

adjuster by using special tool (ST 4932) until the
clearance between bracket (14) and nut (13) is
approximately 10 mm (0.4 in).
W142-03-04-019
15
3. Put the matching marks on rod (8) and nut (13).

: 24 mm
4. Remove valve (12) and bolt (11). Remove nut
(13).
: 24 mm, 17 mm, 100 mm
14
Clearance 10 mm (0.39 in)
8
13
11
12
W142-03-04-020
W3-4-19
16
15
14
W3-4-20
W166-03-04-003

5. Slowly return the piston of special tool (ST 4932).
Extend spring (15) to its free length.
NOTE: Spring (15) free length: 774 mm (30.5 in)
15
ST 4932

(550 lb)
6. Fasten bracket (14) and spring (15) together by
using a wire. Attach a nylon sling to spring (15) in
the track adjuster. Hoist and remove the track
adjuster from special tool (ST 4932).
14
7. Install eyebolt (M10, Pitch 1.5 mm) onto piston

rod (4). Attach a nylon sling to spring (15) and
pass the nylon sling through eyebolt. Hoist and
place the assembly on the holder as illustrated.
W142-03-04-005
15
Holder
CAUTION: Cylinder (9) assembly weight:

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

9
9. Remove the wire fastening spring (15) and

bracket (14). Hoist and remove spring (15).
CAUTION: Bracket weight: 22 kg (50 lb)
10. Remove spacer (16) and bracket (14) from the
holder.
15
Holder
W142-03-04-007
W3-4-21
3
4
5
7
8
9
10
W166-03-04-003
W3-4-22

guide (3) from piston rod (4).
: 12 mm
3
1
12. Remove piston rod (4) from cylinder (9).

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

CAUTION: Cylinder (9) weight: 40 kg (88 lb)
Rod (8) weight: 21 kg (50 lb)
14. Install eyebolt (M16, Pitch 2.0 mm) into rod (8).
Hoist and remove rod (8) from cylinder (9).
Remove O-ring (10) from the inside of cylinder
(9).
8
W142-03-04-010
15. Remove wear ring (5), retaining ring (7), and

U-ring (6) from piston rod (4).
5
6
W166-03-04-001
W3-4-23

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

O-Ring
Guide
Piston Rod
5678-
Wear Ring
U-Ring
Retaining Ring
Rod
14
Chamber B
11 12
Grease Outlet
W16J-03-04-003
910 11 12 -
15
Cylinder
O-Ring
Bolt
Valve
W3-4-24
13
13 14 15 16 -
Nut
Bracket
Spring
Spacer

Assemble Track Adjuster
(ZAXIS370MTH)
1. Clean all the parts. Apply grease onto wear ring

(5) and U-ring (6). Install wear ring (5), U-ring (6),
and retaining ring (7) onto piston rod (4). Install
U-ring with the lip part facing to rod (8).
5
6
CAUTION: Rod (8) weight: 21 kg (50 lb)

2. Apply grease to O-ring (10). Install O-ring (10)
onto cylinder (9). Install eyebolt (M16, Pitch 2.0
mm) into rod (8). Hoist and install rod (8) into cylinder (9).
W166-03-04-001
10
CAUTION: Piston rod (4) weight: 16 kg

(40 lb)
3. Fill chamber (B) in cylinder (9) with grease. Apply

hydraulic oil to the inner surface of cylinder (9)
and piston rod (4).
Install eyebolt (M10, Pitch 1.5 mm) into piston rod
(4). Hoist and install piston rod (4) into cylinder
(9).
Push piston rod (4) and completely release pressure in chamber (B) and rod (8).
W142-03-04-012
4. Fill chamber (A) in guide (3) with grease. Apply

grease to O-ring (2). Apply LOCTITE #262 to
Install O-ring (2) onto guide (3). Install guide (3)
onto cylinder (9) with socket bolts (1) (4 used).
: 12 mm
: 175 Nm (18 kgfm, 130 lbfft)
2
1
W142-03-04-018
W3-4-25
16
14
Grease Outlet
15
W3-4-26
W16J-03-04-003

CAUTION: Bracket (14) weight: 22 kg (50 lb)
Spring (15) weight: 140 kg (310 lb)
9
5. Attach a nylon sling onto bracket (14). Hoist and

place bracket (14) and spacer (16) on the holder.
Hoist and place spring (15) onto bracket (14).
Fasten bracket (14) and spring (15) together by
using a wire.
16
CAUTION: Cylinder (9) assembly weight:

60 kg (130 lb)
15
6. Install eyebolt (M10, Pitch 1.5 mm) to piston rod

(4). Hoist the cylinder (9) assembly. Align spacer
(16) with bracket (14) and install the cylinder (9)
assembly.
14
Holder
W142-03-04-007
CAUTION: Track adjuster weight:

250 kg (550 lb)
7. Attach a nylon sling to spring (15) and pass the

nylon sling through the eyebolt on piston rod (4).
Hoist and place the assembly horizontally and
slowly.
15
W142-03-04-006
8. Hoist and place the track adjuster on special tool

(ST 4932). Set rod (8) with its grease outlet down.
Remove eyebolt.
ST 4932
W142-03-04-005
W3-4-27
15
14
11 12

24.5 in (Free Length 30.5 in)
884 mm (35 in)
W3-4-28
Grease Outlet
13
W16J-03-04-003

9. Operate the cylinder of special tool (ST4932).
Remove a wire from spring (15). Compress
spring (15) until the specified spring length is obtained. Slowly compress spring (15) while aligning the center of rod (8) with that of bracket (14)
by using a pry bar. Do not damage the threads
on rod (8). (Specified Spring Length: 620 mm
(24.5 in))
10. Align the matching marks made when disassembling.
Install nut (13) to rod (8). Install bolt (11).
Check that the grease outlet in rod (8) align with
that in nut (13).
: 100 mm
: 17 mm
15
ST 4932
14
Wire
11. Tighten valve (12).

: 24 mm
: 147 Nm (15 kgfm, 108 lbfft)
W142-03-04-015
12. Retract the cylinder of special tool (ST 4932).

13

(550 lb)
13. Attach a sling belt to the track adjuster.

Hoist and remove the track adjuster from special
tool.
CAUTION: If only the track adjuster is transported, use a firm steel box and take any
other precautions in order to carry the track
adjuster safely.
W3-4-29
11
12
W142-03-04-020

(Blank)
W3-4-30
UNDERCARRIAGE / Front Idler

REMOVE AND INSTALL FRONT IDLER
Before removing the front idler, the tracks must be
removed first. For removal and installation of the
tracks, refer to Remove and Install Track section
(W3-7-1).
that the tracks have already been removed.
Removal
CAUTION: Front idler weight:
ZAXIS330, 330LC: 160 kg (350 lb)
ZAXIS350H, 350LCH: 160 kg (350 lb)
W142-03-05-002

the strong spring force when removing the
track adjuster. Do not stand in the same direction to remove the adjuster or where the
track adjuster flies off.
1. Pry and remove the front idler and yoke (2) from
track frame (3) by using a pry bar.
1
2
4
5
2. Attach sling belts to bearing (1) and yoke (2)

sections. Hoist and remove the front idler from
track frame (3).
3. Remove bolts (5) and remove guard (4) from
yoke (2). (ZAXIS370MTH only)
: 19 mm
W17P-03-05-001
Wooden Block
4. When storing the front idler, place the front idler

on wooden blocks as illustrated.
W105-03-05-003
Installation
1. Install the front idler in the reverse procedures
when removing. Clean and apply grease to the
bearing (1) sliding surface on track frame (3).
W17P-03-05-001
W3-5-1

DISASSEMBLE FRONT IDLER
2
3
1
6
7
4
5
4
3
2
10
11
W16J-03-05-001
14
1234-
Bearing (2 Used)
Pin (2 Used)
Floating Seal (2 Used)
O-Ring (2 Used)
5678-
12
13
Axle
Bushing (2 Used)
Idler
Plug (2 Used)
9 - Guard
10 - Bolt (3 Used)
11 - Spring Washer (3 Used)
NOTE: Guard (9), bolt (10) (3 used), spring

washer (11) (3 used), and (14) (4 used)
are equipped for ZAXIS370MTH only.
W3-5-2
12 - Yoke
13 - Bolt (4 Used)

Disassemble Front Idler
1. Remove bolts (10) (3 used) and remove guard
(9) from yoke (12). (ZAXIS370MTH only)
: 19 mm
CAUTION: Yoke (12) weight:
ZAXIS330, 330LC, 350H, 350LCH: 25 kg
(55 lb)
2. Attach a nylon sling to yoke (12) and hold yoke
(12). Remove bolts (13) (4 used). Remove yoke
(12).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
ZAXIS370MTH:
: 30 mm
IMPORTANT: For handling of floating seal (3), refer to the section Precautions for
W1-1-4.
6. Remove bearing (1) from the upper side of idler
(7). Remove floating seals (3) (2 used) from both
sides of idler (7) and bearing (1).
3. Place idler (7) horizontally. Remove plug (8) from

the lower side and drain oil.
: 6 mm
4. Remove pin (2) from bearing (1) by using a bar
and hammer.
1
3
7
3
4
5
1
CAUTION:
ZAXIS330, 330LC, 350H, 350LCH:
Idler assembly weight: 115 kg (250 lb)
Axle (5) weight: 17 kg (37 lb)
Bearing (1) weight: 15 kg (33 lb)
W105-03-05-009
ZAXIS370MTH:
Idler assembly weight : 150 kg (330 lb)
5. Put the matching marks on bearing (1) and axle
(5). Remove the axle (5) assembly from idler (7)
by using a press.
1
W105-03-05-008
W3-5-3
6
4
5
4
2
W16J-03-05-001
W3-5-4

CAUTION: Axle (5) assembly weight:
ZAXIS330, 330LC, 350H, 350LCH: 32 kg
(71 lb)
7. Wind a nylon sling onto the axle (5) assembly.
Hoist and place bearing (1) onto wooden blocks.
IMPORTANT: Do not remove bushing (6) unless

necessary.
9. When replacing bushing (6), remove bushing (6)
by using special tool and a press.
Special tool:
ZAXIS330, 330LC, 350H, 350LCH: ST 1425
ZAXIS370MTH: ST 1973
8. Remove pin (2) by using a bar and hammer.

Put the matching marks on bearing (1) and axle
(5). Remove axle (5) from bearing (1) by using a
press.
Remove O-rings (4) (2 used) from axle (5).
Special
Tool
4
1
6
Wooden Block
W105-03-05-011
4
W105-03-05-010
W3-5-5

ASSEMBLE FRONT IDLER
10
11
12
13
14
1234-
Bearing (2 Used)
Pin (2 Used)
Floating Seal (2 Used)
O-Ring (2 Used)
5678-
Axle
Bushing (2 Used)
Idler
Plug (2 Used)
9 - Guard
10 - Bolt (3 Used)

W3-5-6
W16J-03-05-002
12 - Yoke
13 - Bolt (4 Used)

Assemble Front Idler
CAUTION: Axle (5) assembly weight:
ZAXIS330, 330LC, 350H, 350LCH: 32 kg
(71 lb)
CAUTION: Idler (7) weight:

ZAXIS330, 330LC: 115 kg (250 lb)
ZAXIS350H, 350LCH: 115 kg (250 lb)
5. Wind a nylon sling onto bearing (1) of the axle (5)

assembly. Hoist and insert the axle (5) assembly into idler (7) where floating seal (3) was installed. Apply LOCTITE #503 to plug (8).
Install plug (8) into bearing (1).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
1. Install bushing (6) into idler (7).

CAUTION:
ZAXIS330, 330LC, 350H, 350LCH:
ZAXIS370MTH:
7
3
2. Wind a nylon sling onto axle (5). Hoist and place

axle (5) vertically. Install O-ring (4) onto the upper
side of axle (5).
Evenly tap and install bearing (1) into axle (5) by
using a plastic hammer. Insert pin (2) by using a
bar and hammer.
W105-03-05-014
W1-1-4.
4. Apply grease to O-ring on floating seal (3). Install
a pair of floating seals (3) into idler (7) and bearing (1).
W3-5-7
W157-03-05-006
3 5
10
11
12
13
14

W3-5-8
W16J-03-05-002

CAUTION: Idler (7) assembly weight:
ZAXIS330, 330LC:
115 kg (250 lb)
ZAXIS350H, 350LCH:
115 kg (250 lb)
ZAXIS370MTH:
150 kg (330 lb)
12. Install spring washer (14) onto bolts (13) (4 used)

respectively. (ZAXIS370MTH only) Install yoke
(12) into bearing (1) on both sides with the bolts
(4 used).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
: 210 Nm (21 kgfm, 150 lbfft)
ZAXIS370MTH:
: 30 mm
: 390 Nm (40 kgfm, 290 lbfft)
6. Wind a nylon sling onto the idler (7) assembly.

Hoist and turn over the idler (7) assembly.
Install O-ring (4) onto axle (5).
7. Apply grease to O-ring of floating seal (3). Install
the other floating seal (3) into idler (7) and bearing (1).
1
7
1
13. Install spring washer (11) onto bolts (10) (3 used)

respectively. Install guard (9) onto yoke (12) with
the bolts (3 used). (ZAXIS370MTH only)
: 19 mm
5
W157-03-05-005
8. Align the matching marks made when disassembling. Tap the other bearing (1) evenly by using a
plastic hammer. Install bearing (11) into axle (5).
Insert pin (2) by using a bar and hammer.
9. Add engine oil (API CD grade SAE30) through
the plug (8) hole in bearing (1).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
0.3 L (0.32 US gt.)
ZAXIS370MTH:
0.45 L (0.48 US gt.)
10. Apply LOCTITE #503 to plug (8). Install plug (8)
into bearing (1).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
CAUTION: Yoke (12) weight:
ZAXIS330, 330LC, 350H, 350LCH: 25 kg
(55 lb)
11. Wind a nylon sling onto yoke (12). Hoist yoke
(12) and align the bolt (13) holes on yoke (12)
and bearing (1).
W3-5-9

E
A
W166-03-05-001
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
102 (402)
[80.4 (3.17)]
200 (7.87)
572 (22.51) [550.4 (21.77)]

617 (24.29)
22.5 (0.89)
A
B
C
D
E
ZAXIS370MTH
Standard
102 (4.02)
200 (7.87)
630 (24.80)
675 (26.57)
22.5 (0.89)
Allowable
Limit
[92 (3.62)]
610 (24)
Remedy
Cladding by welding and finish or

replace
Axle and Bushing

Unit: mm (in)
Axle
Bushing
Outside Dia.
Inside Dia
Flange
Thickness
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
85.0 (3.35)
84.2(3.31)
85.0 (3.35)
86.0 (3.39)
110 (4.33)
110 (4.33)
Allowable
Limit
109.2 (4.30)
111 (4.37)
2.0 (0.08)
6.0 (0.24)
5.2 (0.20)
1.2 (0.05)
NOTE: Values in [ ] are just for reference.
W3-5-10
ZAXIS370MTH
Standard
Remedy
Replace
UNDERCARRIAGE / Upper And Lower Roller

REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or too much as the valve may fly off
or high-pressure grease in the adjusting cylinder may gush out.
Keep body parts and face away from the
valve and loosen the valve carefully.
Do not loosen grease fitting (2).
W105-03-06-001
IMPORTANT: Remove gravel or mud between

sprockets and tracks before loosening valve (1).
It is enough to loosen the valve by
1 to 1.5 turns.
Do not loosen the valve over that
degree.
1. Loosen valve (1) on the track adjuster and drain
grease.
: 24 mm
Grease Outlet
M116-07-094
Oil Jack
CAUTION: Use a nonskid cloth between

track frame (5) and oil jack in order not to
slip.
2. Jack up track (3) in order to get enough clearance between upper roller (4) and track (3).
Nonskid Cloth
4
W105-03-06-002
3. Insert the wooden blocks between track (3) and

track frame (5).
5
Wooden Block
W105-03-06-003
W3-6-1

4. Remove bolts (6) (4 used) on upper roller (4).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
ZAXIS370MTH:
: 27 mm
W157-03-06-001
CAUTION: Upper roller weight:

ZAXIS330, 330LC, 350H, 350LCH: 25 kg
(55 lb)
4
5. Remove upper roller (4) from track frame (5).
5
W105-03-06-005
Installation
1. Install upper roller (4) onto track frame (5) with
bolts (6) (4 used).
ZAXIS330, 330LC, 350H, 350LCH:
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
ZAXIS370MTH:
: 27 mm
: 400 Nm (41 kgfm, 300 Ibfft)
6
5
3
W157-03-06-001
2. Remove the wooden blocks and oil jack between

track (3) and track frame (5).
5
W105-03-06-002
W3-6-2

3. Tighten valve (1) on the track adjuster.
: 24 mm
: 147 Nm (15 kgfm, 108 Ibfft)
CAUTION: Support the jacked up machine

firmly by using wooden blocks.
Grease Outlet
4. Jack up the track to be adjusted. Rotate the track

in reverse direction slightly.
M116-07-094
5. Apply grease through grease fitting (2) and adjust

tracks tension.
ZAXIS330, 330LC, 350H, 350LCH:
Track sag specifications (A):
340 to 380 mm (13.4 to 15.0 in)
ZAXIS370MTH:
380 to 430 mm (15.0 to 16.9 in)
IMPORTANT: Replace the upper roller as an assembly.

6. Add engine oil (API CD class SAE30) to the plug
(8) hole in cover (7).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
75 mL (0.079 US gt.)
ZAXIS370MTH:
120 mL (0.13 US gt.)
W157-03-06-002
7. Apply LOCTITE #503 to plug (8). Tighten plug

(8).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
W158-03-06-001
W3-6-3

REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove the track guard. Remove bolts (1) (4
used) of lower roller (5).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm
ZAXIS370MTH:
: 32 mm
5
1
W105-03-06-008
2. Jack up one side of the track frame high enough

(90 to 110 between boom and arm is obtained
when the bucket is lowered with the round bottom contacting with ground). Insert the wooden
blocks under track frame (2) and support the
machine.
90 to 110

or high-pressure grease in the adjusting cylinder may gush out.
valve and loosen the valve carefully.
Do not loosen grease fitting (4).
M104-07-067
W105-03-06-001
IMPORTANT: It is enough to loosen valve (3) by 1

to 1.5 turns. Do not loosen the valve
over that degree.
3. Loosen valve (3) on the track adjuster. Drain
grease and adjust the track sag enough to permit
roller (5) to be removed.
: 24 mm
Grease Outlet
M116-07-094
W3-6-4
CAUTION: Lower roller weight:

ZAXIS330, 330LC, 350H, 350LCH:
54 kg (120 lb)
4. Remove lower roller (5) by using a fork lift.
5
W105-03-06-010
Installation
1. Set lower rollers (5) below track frame (2) by using a fork lift.
5
W105-03-06-011
2. Lower the machine so that track frame (2) may

keep a little away from collar (6).
3. Align the bolt (1) holes and tighten bolts (1) (4

used).
ZAXIS330, 330LC, 350H, 350LCH:
: 30 mm
: 670 Nm (68.5 kgfm, 500 lbfft)
ZAXIS370MTH:
: 32 mm
: 750 Nm (76.5 kgfm, 550 Ibfft)
W105-03-06-012
W105-03-06-008
W3-6-5

4
4. Tighten valve (3) on the track adjuster.

: 24 mm
: 147 Nm (15 kgfm, 108 Ibfft)
Grease Outlet

M116-07-094
5. Jack up the track to be adjusted. Rotate the track

in reverse direction slightly.
6. Apply grease through valve fitting (4) and adjust
tracks tension.
ZAXIS330, 330LC, 350H, 350LCH:
340 to 380 mm (13.4 to 15.0 in)
ZAXIS 370MTH:
380 to 430 mm (15.0 to 16.9 in)
W157-03-06-002
W3-6-6

(Blank)
W3-6-7

DISASSEMBLE LOWER ROLLER
7
1
3
4
W166-03-06-006
1 - Floating Seal (2 Used)

2 - Axle
3 - O-Ring (2 Used)
4 - Collar (2 Used)
5 - Pin (2 Used)
6 - Plug (2 Used)
W3-6-8
7 - Bushing (2 Used)
8 - Roller

Disassemble Lower Roller
1. Remove plug (6) from the end of collar (4) and
drain oil.
: 6 mm
4. Remove pin (5) from the axle (2) assembly.

Remove axle (2) from collar (4) by using a press.
3
2. Put the matching marks on collar (4) and axle (2).

Remove pin (5) from collar (4) at one side by using a round bar and hammer. Remove axle (2)
from roller (8) by using a press from the side
where pin (5) is removed. The pin and collar at
opposite are removed together.
2
Round Bar:
ZAXIS330, 330LC, 350H, 350LCH:
Dia. 14 mm (0.6 in)
ZAXIS370MTH: Dia. 25 mm (1 in)
4
1
W105-03-06-027
5. Remove O-rings (3) (2 used) from axle (2).

1
6. When replacing bushing (7), remove bushing (7)

by using special tool and a press.
Special tool:
ZAXIS330, 330LC, 350H, 350LCH: ST 1475
ZAXIS370MTH: ST 1955
2
W105-03-06-026
W1-1-4.
3. Remove floating seal (1) from both sides of roller
(8) and collars (4) (2 used) respectively.
Special
Tool
W105-03-06-028
W3-6-9

ASSEMBLE LOWER ROLLER
ZAXIS330, 330LC, 350H, 350LCH:
4
W1HH-03-06-001
ZAXIS370MTH:
4
W162-03-06-002
1 - Floating Seal (2 Used)

2 - Axle
3 - O-Ring (2 Used)
4 - Collar (2 Used)
5 - Pin (2 Used)
6 - Plug (2 Used)
W3-6-10
7 - Bushing (2 Used)
8 - Roller

Assemble Lower Roller
1. Install bushings (7) (2 used) onto roller (8). Do
not dent the flange surface of bushing (7). Apply
grease to O-ring (3). Install O-ring (3) onto axle
(2).
Install one side of collar (4) onto axle (2) with pin
(5). Do not damage O-ring (3).
5. Insert axle (2) into roller (8). Install O-ring (3). Install the other collar (4) with pin (5) in the same
procedures.
6. Add engine oil (API CD class SAE30) through the
plug (6) hole in collar (4).
Engine oil amount:
ZAXIS330, 330LC, 350H, 350LCH:
0.42 L (0.44 US gt.)
ZAXIS370MTH: 0.5 L (0.53 US gt.)
5
2

into collar (4).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
5
4
W16J-03-06-001

to one side of collar (4).
: 6 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
IMPORTANT: For handling floating seal (1), refer
to the section Precautions for Handling Floating Seal on page W1-1-4.
4. Apply grease to O-ring (3) on floating seal (1). Install floating seal (1) to roller (8) and collar (4).
8
W157-03-06-008
W3-6-11
W105-03-06-024

Upper Roller
C
C
A
B
A
B
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
W173-03-06-001
W166-03-06-007
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
ZAXIS370MTH
Standard
Allowable
Limit
98 (3.86)
103 (4.06)
165 (6.50)
190 (7.48)
120 (4.72)
110 (4.33)
160 (6.30)
150 (5.90)
Remedy
Cladding by
welding and finish or replace
Axle and Bushing

Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
Axle
ZAXIS370MTH
Standard
Allowable
Limit
Outside Dia.
45 (1.77)
[44.2 (1.74)]
60 (2.36)
[59.2 (2.37)]
Inside Dia.
45 (1.77)
[46.0 (1.81)]
60 (2.36)
[61 (2.37)]
Flange Thickness
2 (0.079)
[1.2 (0.047)]
4.5 (0.177)
[3.7 (0.146)]
Bushing
NOTE: Values in [
] are just for reference.
W3-6-12
Remedy
Replace

Lower Roller
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
W1HH-03-06-002
W157-03-06-003
Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
ZAXIS 370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
203(7.99)
[229.5 (9.06)]
214 (8.43)
[249 (9.80)]
256 (10.08)
284 (11.18)
26.5 (1.04)
[13.25 (0.52)]
35 (1.38)
[17.5 (0.69)]
175 (6.89)
[157 (6.18)]
200 (7.87)
182 (7.17)
Remedy
Cladding by
welding and finish or replace
Axle and Bushing

Unit: mm (in)
ZAXIS330, 330LC,
350H, 350LCH
Allowable
Standard
Limit
Axle
ZAXIS 370MTH
Standard
Allowable
Limit
Outside Dia.
75 (2.95)
[74.2 (2.92)]
85 (3.35)
[84.2 (3.31)]
Inside Dia.
75 (2.95)
[76 (2.99)]
85 (3.35)
[86.0 (3.39)]
Flange Thickness
2 (0.079)
[1.2 (0.047)]
6 (0.24)
[5.2 (0.20)]
Bushing
NOTE: Values in [
W3-6-13
Remedy
Replace

(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal
or high-pressure grease in the adjusting
cylinder may gush out.
valve and loosen the valve carefully. Do not
loosen grease fitting (2).
1. Rotate the tracks so that master pin (3) is

positioned over front idler (4).
Place a wooden block under shoe (5) and
support shoe (5).
W105-03-07-006
2. Loosen the track tension. Turn valve (1) in the

adjuster by one turn and drain grease from the
grease outlet.
: 24 mm
W105-03-07-002
1
2
Grease Outlet
M116-07-094
W3-7-1
the spring force when removing the track.
Particularly, a strong force is always applied
to the thread part of rod. If the rod and/or the
threads are damaged, metal fragments under
spring force may fly off.
3. ZAXIS330, 330LC, 350LCH:
Remove retaining ring (6) to prevent master pin
(3) from coming off.
NOTE: If retaining ring (6) interferes with master
link (7), push in master pin (3) in order to
make clearance between retaining ring (6)
and master pin (3). Remove retaining ring
(6).
ZAXIS370MTH:
Remove split pin (8) to prevent master pin (3)
from coming off.
NOTE: If split pin (8) interferes with master link (7),
push in master pin (3) in order to make
clearance between split pin (8) and master
pin (3). Remove split pin (8).
7
3
ZAXIS330, 330LC, 350H, 350LCH
W105-03-07-009
7
3
8
ZAXIS370MTH
W3-7-2
W166-03-07-001
IMPORTANT: Master pin (3) is directional. Be sure
to install it in the correct direction.
4. Remove master pin (3) by using special tool (ST
1970).
ST 1970
W105-03-07-008
Direction for
removing
the master
pin.
Split Pin
Corner
Direction for
removing the
master pin.
Retaining Ring
Track Link
Master Link
ZAXIS370MTH
ZAXIS330, 330LC, 350H 350LCH

W105-03-07-010
W166-03-07-002

5. Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the
boom with the round bottom contacting with the
ground. Jack up the machine and remove the
track.
Boom
Arm
90 to 110
W105-03-07-012
6. Slowly operate the travel lever for the track to be

removed in the reverse direction. Extend and
remove the track.
W105-03-07-011
W3-7-3
Installation
1. Jack up the machine. Set the track under the
lower roller so that the sprocket meshes with the
track end.
Check the direction of track.
Sprocket
Side
Idler Side
W105-03-07-013
2. Hoist and place the track on sprocket (8).
W105-03-07-014
3. With the machine jacked up, slowly operate the

lever for the track to be installed in the forward
direction. Turn travel device (9) and wind the
track.
W105-03-07-015
4. Wind the track until the connecting part of track

link reaches front idler (4). Lower the machine.
Place a wooden block under shoe (5) and
support shoe (5).
5
Wooden Block
W3-7-4
W105-03-07-016
5. Install special tool (ST 1970). Install master pin
(3) by using a hammer.
ST 1970
W105-03-07-017
Split Pin
Corner
Direction for
installing the
master pin.
Direction for
installing the
master pin.
3
Retaining Ring
Track Link
Master Link
ZAXIS370MTH
ZAXIS330, 330LC, 350H, 350LCH
W166-03-07-002
W105-03-07-010
IMPORTANT: Replace retaining ring (6) and split

pin (8) with new one.
6. ZAXIS330, 330LC, 350H, 350LCH:

Install retaining ring (6) to the groove of master
link (7) with the chamfered side for the plier
facing forward.
ZAXIS370MTH:
Install split pin (8).
ZAXIS330, 330LC, 350H, 350LCH
W105-03-07-009
ZAXIS370MTH
W3-7-5
W166-03-07-001
IMPORTANT: If disassembling the links, fill grease
(Daphne Epones SR) into the clearance between the pin and bushing.
Apply grease onto the bushing end.
Stand the bushing on a flat plate. Fill
the bushing bore with grease.
Insert the pin into the bushing while
pushing the bushing onto the plate
in order not to move because of
grease. After inserting the pin, wipe
off excess grease. Check the direction to install the seal.
Bushing
Seal
Pin
Do not Apply
Grease
Grease
Do not Apply
Grease
W197-03-07-001
Seal
7. Tighten valve (1) on the track adjuster. Apply

grease through grease fitting (2) and adjust the
tracks tension.
: 24 mm
: 147 Nm (15 kgfm, 108 lbfft)
8. Check the track sag after cleaning the track
frame and track.
Grease Outlet
Track sag specifications:

ZAXIS330, 330LC, 350H, 350LCH:
340 to 380 mm (13.4 to 15.0 in)
ZAXIS370MTH:
380 to 430 mm (15.0 to 16.9 in)
M116-07-094
W105-03-07-018
W157-03-06-002
W3-7-6
Link
Measure the length of four links as illustrated.
Do not measure the master-pin-included part of
the track.
Measure the length with tension on the track.
A
W155-03-07-001
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
865.92 (34.09)
882 (34.72)
863.6 (34.00)
845.6 (33.29)
116 (4.57)
109 (4.29)
129 (5.08)
122 (4.80)
Remedy
Cladding by
welding and finish
or replace
Master Pin
W105-03-07-021
ZAXIS370MTH
ZAXIS330, 330LC, 350H, 350LCH
W142-03-07-003
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
237 (9.33)
308 (12.1)
45 (1.77)
[42 (1.65)]
47.3 (1.86)
[44.3 (1.40)]
NOTE: Values in [
W3-7-7
Remedy
Replace
Master Bushing
W105-03-07-023
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
ZAXIS370MTH
Standard
Allowable
Limit
Standard
Allowable
Limit
148.3 (5.84)
160.80 (6.33)
45.45 (1.79)
48.5 (1.91)
47.90 (1.89)
50.90 (2.00)
66.91 (2.63)
61.91 (2.44)
71.35 (2.81)
66.35 (2.61)
Remedy
Replace
Grouser Shoe
W105-03-07-024
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
Shoe Size
ZAXIS370MTH
600 mm Grouser Shoe

Standard
Allowable
Limit
Standard
Allowable
Limit
250 (9.84)
247 (9.72)
11 (0.43)
13 (0.51)
30 (1.18)
20 (0.79)
36 (1.42)
21 (0.83)
W3-7-8
Remedy
Replace
Bushing
W105-03-07-023
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
Standard
A
B
C
158.9(6.26)
45.45(1.79)
66.91(2.63)
Allowable
Limit
46.5(1.83)
61.9(2.44)
ZAXIS370MTH
Standard
177(6.97)
48.4(1.91)
71.35(2.81)
Allowable
Limit
49.43(1.95)
66.35(2.61)
Remedy
Replace
Pin
W105-03-07-020
Unit: mm (in)
ZAXIS330, 330LC, 350H, 350LCH
Standard
A
B
242(9.53)
44.69(1.76)
Allowable
Limit
41.7(1.64)
ZAXIS370MTH
Standard
254(10.00)
47.57(1.87)
W3-7-9
Allowable
Limit
44.57(1.76)
Remedy
Replace
(Blank)
W3-7-10
MEMO
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SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment .........W4-1-1
Maintenance Standard ................................W4-1-7
Standard Dimensions for
Arm and Bucket Connection....................W4-1-10
Standard Dimensions for
Arm and Boom Connection...................... W4-1-11
Group 2 Cylinder
Remove and Install Cylinder........................W4-2-1
Hydraulic Circuit Pressure
Release Procedure ..................................W4-2-13
Up to serial No.33099 and up
Disassemble Cylinder ................................W4-2-14
Assemble Cylinder .....................................W4-2-20
Maintenance Standard...............................W4-2-24
Serial No.33100 and up
Disassemble Cylinder ................................W4-2-26
Assemble Cylinder .....................................W4-2-32
Maintenance Standard...............................W4-2-36
1HHW-4-1
(Blank)
1HHW-4-2
FRONT ATTACHMENT / Front Attachment

REMOVE AND
TACHMENT
INSTALL
FRONT
AT1
Adapter
Boom Cylinder
Removal
1. Remove pipe (1) of lubrication pipes to the front
attachment on the boss at the boom cylinder rod
side from the adapter.
(2 places on both left and right)
: 19 mm
W105-04-01-002
2. Remove nuts (4) and stopper pin (6) from boom

cylinder rod front pin (3). Remove stopper (5).
(2 places on both left and right)
: 30 mm
CAUTION: Boom cylinder weight:
320 kg (710 lb)
Metal fragments may fly off when
a hammer is used.
Wear necessary protection, such
as goggles, hard hat, etc in order
to prevent personal injury.
Check the direction to remove the
pins as the pins may fly off suddenly.
3. Hoist and hold the boom cylinder tube. By using
a bar and hammer tap pin (3) into the position
where thrust plate (2) can be removed. Remove
thrust plate (2).
NOTE: When pin (3) is impossible to remove, start
the engine and slightly operate the boom
lever. Adjust the boom cylinder rod pin
hole while hoisting/lowering the front
attachment.
W4-1-1
Boom Cylinder
5
4
W178-04-01-004

IMPORTANT: Insert a plate which does not come
in contact with the grease fitting in
the boom cylinder.
4. Insert a plate between the boom cylinder and
main frame. Hold and lower the boom cylinder.
5. Remove the boom cylinder.
Refer to Remove Boom Cylinder (W4-2-10).
6. Remove the other boom cylinder in the same
procedures as steps 3 to 5.
7. After stopping the engine, push the air bleed
valve on the top of hydraulic oil tank and release
any remaining pressure from the hydraulic oil
tank. Remove the cap.
Completely release the residual pressure from
the hydraulic circuit. Refer to the Hydraulic Circuit Pressure Release Procedure (W4-2-15).
Plate
W157-04-01-005
Air Bleed Valve
8. Remove hoses (7, 8) of the bucket cylinder and

arm cylinder. Cap the removed hoses and pipes.
: 36, 41, 50 mm
M157-07-173
W157-04-01-001
W4-1-2

9. Remove bolt (12), spring washer (13), plate (11),
and block (10) from the plate of boom foot pin (9).
: 27 mm
10
11

ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH:
7120 kg (15700 lb)
12
13
W178-04-01-001
10. Attach a wire rope to the boom.

Slightly hoist the boom in order to take up any
wire rope slack.
11. Insert a pry bar between the plate of boom foot

pin (9) and the bracket. Slightly pull out the plate.
12. Turn the plate upward by hand. Turn the plate left
and right in order to pull out boom foot pin (9).
(Adjust the position of the boom foot pin hole
while hoisting/lowering the front attachment.)
W105-04-01-008
13. Hoist the front attachment and move the machine

backward.
14. Place the front attachment on wooden blocks.
Plate
Insert Bar
Bracket
W178-04-01-001
W178-04-01-005
W4-1-3

Installation
ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH:
7120 kg (15700 lb)
1. Hoist the front attachment.
Move the machine forward and align the boom
foot pin holes.
Insert the thrust plates into both left and right
sides of boom and adjust the clearance between
the plate and frame within 1 mm.
(Adjust the position of the boom foot pin hole
while hoisting / lowering the front attachment.)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order
10
11
12
2. Install boom foot pin (9). Install stopper bolt (12),

washer (13), plate (11), and block (10).
: 27 mm
: 400 Nm (41 kgfm, 295 lbfft)
3. Remove the caps from hoses and pipes. Install
hoses (7, 8) of the bucket cylinder and arm cylinder.
: 36 mm
: 175 Nm (18 kgfm, 130 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
: 50 mm
: 255 Nm (26 kg fm)
W178-04-01-005
13
W178-04-01-001
W157-04-01-001
CAUTION: Boom cylinder weight: 320 kg

(710 lb)
4. Install the boom cylinder.
Refer to Install Boom Cylinder (W4-2-12).
Boom Cylinder
W105-04-02-040
W4-1-4

5. Hoist and hold the boom cylinder tube. Insert

thrust plates (2) (2 used). Install pin (3) and install
the boom cylinders to both sides.
6. Install stopper (5) with stopper pin (6) and nuts

(4) (2 used). (2 places on both left and right)
: 30 mm
: 550 Nm (56 kgfm, 405 lbfft)
Boom Cylinder
5
4
W178-04-01-004
7. Install lubrication pipe (1) onto the boom cylinder

rod side. (2 places on both left and right)
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
W105-04-01-002
8. Apply grease to the boom cylinder rod side, bottom side, and boom foot side.
Boom Cylinder
Rod Side
Boom Foot
Side
M157-07-155
9. Fill hydraulic oil to specified level. Start the engine and check the connections for any oil leakage.
10. After completing the work, run each cylinder several times to stroke end in order to release any
pressure in the circuit.
Boom Cylinder
Bottom Side
W4-1-5
M157-07-156

IMPORTANT: When removing the arm from the
boom, perform the following steps
when installing the arm.
Install thrust plates (14) into left and right sides of
arm. Adjust total clearance of left and right within
1.5 mm.
14
14
15
15
After installing the arm, apply grease to grease

fitting (15) on the boom connecting boss of arm.
IMPORTANT: For handling of HN bushing for the
front attachment, pay attention to
following requirements.
Precautions for pressing the bushing in:
If a hammer is used to drive the bushing in, the bushing may be damaged. Use a press.
Precautions when reinforcing the arm:
Welding heat for arm reinforcement may cause oil to
leak from the bushing and decrease lubrication performance.
If oil leak occurs because of heated bushing after
welding, replace the bushing.
Special tools should be used to pull the bushing out or
press it in.
Tool: ST 1478
W4-1-6
M157-07-157

Pin and Bushing
E
G
C
D
A
I
J
K
W105-04-01-018
Unit: mm (in)
Parts Name
A
Standard
Allowable Limit
Pin
110 (4.33)
109.0 (4.31)
Bushing
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Boss (Main Frame)
110 (4.33)
111.5 (4.39)
Bushing (Boom Cylinder)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Bushing (Boom Cylinder)
110 (4.33)
111.5 (4.39)
Boss (Boom)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Bushing
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Boss (Arm)
110 (4.33)
111.5 (4.39)
Bushing (Arm Cylinder)
110 (4.33)
111.5 (4.39)
Pin
110 (4.33)
109.0 (4.31)
Boss (Boom)
110 (4.33)
111.5 (4.39)
Bushing (Arm Cylinder)
110 (4.33)
111.5 (4.39)
W4-1-7
Remedy
Replace

Unit: mm (in)
Parts Name
G
I
J
K
Standard
Allowable Limit
Pin
90 (3.54)
89.0 (3.50)
Boss (Arm)
90 (3.54)
91.5 (3.60)
Bushing (Bucket Cylinder)
90 (3.54)
91.5 (3.60)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
Bushing (Bucket Cylinder)
100 (3.94)
101.5 (4.00)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press.
W4-1-8
Remedy
Replace

Side Cutter
B
C
D
A
W105-04-01-019
Unit: mm (in)
Standard
Allowable Limit
258 (10.2)
168 (6.61)
300 (11.8)
400 (15.7)
300 (11.8)
Remedy
Replace
Point
W105-04-01-020
Unit: mm (in)
Standard
Allowable Limit
240 (9.45)
120 (4.72)
96 (3.78)
130 (5.12)
105 (4.13)
W4-1-9
Remedy
Replace

STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section B
Section A
T137-01-03-001
Unit : mm (in)
ZAXIS330
ZAXIS350H
ZAXIS370MTH
EX300-5
575 (22.6)
10 (0.39)
700 (27.6)
695 (27.4)
1661 (65.4)
1666 (65.6)
1661 (65.4)
581 (22.9)
573 (22.6)
442 (17.4)
100 (3.94)
578 (22.7)
90 (3.54)
581 (22.9)
573 (22.6)
420 (16.5)
100 (3.94)
8.85
8.85
592 (23.3)
600 (23.6)
592 (23.3)
W4-1-10

STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS330
ZAXIS350H
ZAXIS370MTH
EX300-5
90 (3.5)
418.5 (16.5)
571 (22.5)
IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals for previous model
machine.
W4-1-11

(Blank)
W4-1-12
FRONT ATTACHMENT / Cylinder

REMOVE AND INSTALL CYLINDER
Remove Bucket Cylinder

1. Insert wooden block (3) between bucket cylinder
(1) and arm (2).
3
2
3
2. Stop the engine. Push the air bleed valve and

release any remaining pressure from the hydraulic oil tank. Remove the cap.
Release the bucket circuit pressure.
Refer to Hydraulic Circuit Pressure Release
Procedure on page W4-2-15.

a hammer is used.
Wear necessary protection, such as goggles,
hard hats, etc in order to prevent personal
injury.
W554-04-02-006
Link A
3. Fasten links A and B by using a wire in order not

to fall off before removing pin (7).
6
4. Remove nuts (6) (2 used) and stopper pin (4).

Remove pin (7) by using a round bar.
Remove thrust plates (5).
: 32 mm
Link B
7
1
W158-04-02-006
5. In order not to extend rod (8) of bucket cylinder

(1), pass wire (9) through the cylinder rod hole
and secure rod (8) to the bucket cylinder (1) tube.
W4-2-1
W102-04-02-005

6. Remove bucket cylinder hoses (12) (2 used) at
the bottom of bucket cylinder (1). Cap all open
ends.
: 41 mm
10
CAUTION: Bucket cylinder (1) weight: 255

kg
(560 lb)
11
15

a hammer is used.
injury.
13
7. Hoist bucket cylinder (1). Remove nuts (13) (2

used) and stopper pin (15). Remove pin (11).
Remove thrust plate (10).
: 30 mm
8. Remove bucket cylinder (1).
W4-2-2
W1HH-04-02-009
12

Install Bucket Cylinder
IMPORTANT: When installing the bushing, if a
hammer is used, the bushing may
be damaged. Use a press.
10
CAUTION: Bucket cylinder (1) weight: 255

kg (560 lb)
11
CAUTION: When installing pin (11), metal

fragments may fly off by using a hammer.
injury.
15
14
1. Hoist bucket cylinder (1). Align the hole on cylinder tube side with the cylinder mounting hole on
arm. Insert thrust plate (10) and install pin (11).
2. Insert stopper pin (15) into arm stopper (14) and
pin (11). Install nuts (13) (2 used).
: 30 mm
: 400 Nm (41 kgfm, 300 lbfft)
13
3. Install bucket cylinder hoses (12) (2 used).

Fill hydraulic oil to specified level. Start the engine and check for any oil leaks
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
W1HH-04-02-009
12
4. Remove wire (9) from rod (8) of bucket cylinder

(1).
W4-2-3
W102-04-02-005

16
17
18
5. Start the engine and operate the bucket lever.

Align the hole on cylinder rod side with those of
links (16, 18). Insert thrust plate (5) and pin (7).
6
W158-04-02-006
19
19
6. Insert stopper pin (4) into stopper (17) and pin (7).
Install nuts (6) (2 used).
: 32 mm
: 550 Nm (56.0 kgfm, 405 lbfft)
7. After completing the work, operate the bucket
cylinder several times to the stroke end and release the pressure in the circuit.
IMPORTANT: In case link (18) has been removed
from the arm, insert thrust plate (19)
when installing.
W4-2-4
18
18
W157-04-01-015

Remove Arm Cylinder
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).
release any remaining pressure in the hydraulic
oil tank. Remove the cap.
Release arm circuit pressure.
3. Remove bolt (8) from pin (5) at the arm cylinder

(1) rod side. Remove spring washer (7) and plate
(6).
: 27 mm
1

4. Remove pin (5). Remove thrust plate (4).
5 9
W1HH-04-02-001
5. In order not to extend rod (9) of arm cylinder (1),

pass a wire through the cylinder rod hole and
secure rod (9) to the arm cylinder (1) tube.
10
11
6. Remove hoses (10) (2 used) at the bottom of arm

cylinder (1). Cap all open ends.
: 41 mm, 50 mm
7. Remove lubrication pipe (11) from arm cylinder
(1).
: 19 mm
W4-2-5
10
W1HH-04-02-002

12
CAUTION: Arm cylinder (1) weight: 460 kg

(1010 lb)
1
8. Attach a sling belt at the center of gravity of arm

cylinder (1). Hoist arm cylinder (1) and take up
sag.
a hammer is used. Wear necessary protection, such as goggle, hard hats, etc in order
9. Remove bolt (16) from tube side pin (13) of arm
cylinder (1). Remove spring washer (15) and
plate (14). Remove pin (13) and remove thrust
plates (12). Remove arm cylinder (1).
: 27 mm
W4-2-6
13
14
15
16
W1HH-04-02-004

12
Install Arm Cylinder

IMPORTANT: When installing the bushing and if a
be damaged. Install the bushing by
using a press.
CAUTION: Arm cylinder (1) weight: 460 kg

(1010 lb)
1. Attach a sling belt at the center of gravity of arm
cylinder (1). Hoist arm cylinder (1). Align the cylinder tube side hole with the cylinder mounting
hole on the boom.
13
14
15
W1HH-04-02-004
16

1
10
2. Insert thrust plate (12) and install pin (13). Install

plate (14) and spring washer (15) into pin (13)
with bolt (16).
: 27 mm
: 400 Nm (41 kgfm, 300 lbfft)
3. Install lubrication pipe (11) and hoses (10) (2
used) of arm cylinder (1).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
: 50 mm
: 255 Nm (26 kgfm, 190 lbfft)
4. Fill hydraulic oil to specified level. Start the engine and check for any oil leaks.
W4-2-7
11
10
W1HH-04-02-002

5. Remove a wire from rod (9) of arm cylinder (1).
Hoist arm cylinder (1). Start the engine and operate arm lever. Align the hole on arm cylinder rod
side with the mounting hole on arm (17).
4
17

6. Insert thrust plate (4) and install pin (5).
Install plate (6) and spring washer (7) into pin (5)
with bolt (8).
: 27 mm
: 300 Nm (30.5 kgfm, 220 lbfft)
7. When completing the work, operate the arm cylinder several times to the stroke end and release
the pressure in the circuit.
W4-2-8
5 9
W1HH-04-02-001

Remove Boom Cylinder
1. Remove lubrication pipes (1) from the boom cylinder.
: 19 mm
CAUTION: Boom cylinder (2) weight: 315 kg

(690 lb)
2. Attach a wire rope onto boom cylinder (2). Hoist
boom cylinder (2).
W105-04-02-032

3. Remove nuts (5) (2 used), stopper pin (7), and
stopper (6) from the boom cylinder (2) rod. Remove pin (4).
: 30 mm
4. Place boom cylinder (2) on a support. Remove
the other boom cylinder in the same procedures.
6
5
2
W158-04-02-013
5. Operate the boom lever and retract the boom

cylinder.
In order not to extend the boom cylinder rod,
pass a wire through the cylinder rod hole and
secure the rod to the cylinder tube.
release any remaining pressure in the hydraulic
oil tank.
Release the circuit pressure.
W4-2-9
W178-04-02-011

7. Remove hoses (12) (4 used) at the bottom of
boom cylinder (2). Cap all open ends.
: 41 mm

8. Remove bolt (8) at the cylinder tube side of main
frame. Remove spring washer (9) and plate (10).
Remove pin (11).
: 27 mm
W178-04-02-011
2
13
CAUTION: Boom cylinder (2)weight: 315 kg

(690 lb)
9. Attach a wire rope at the center of gravity of
boom cylinder (2). Hoist and remove the boom
cylinder.
Remove the other boom cylinder in the same
procedures.
11 10 9
12
W4-2-10
W1HH-04-02-003
W178-04-02-013

Install Boom Cylinder
IMPORTANT: When installing the bushing and if a
be damaged. Install the bushing by
using a press.
CAUTION: Boom cylinder weight: 320 kg
(710 lb)
1. Attach a wire rope at the center of gravity of
boom cylinder (2). Hoist boom cylinder (2). Align
the pin hole at boom cylinder tube side with the
mounting hole on the main frame.
W178-04-02-013
2
2
13
2. Insert thrust plate (13) and pin (11). Install spring

washer (9) and plate (10) with bolt (8).
: 27 mm
: 390 Nm (40 kgfm, 290 lbfft)
3. Install the other boom cylinder in the same procedures.
4. Install hoses (12) (4 used) onto boom cylinders
(2) (2 used).
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
5. Fill hydraulic oil to specified level. Start the engine and check for any oil leaks.
W4-2-11
11 10 9
12
W1HH-04-02-003

6. Hoist boom cylinder (2). Operate the boom lever
and align the pin hole at cylinder rod side with the
mounting hole of boom cylinder.
a hammer is used. Wear necessary protection, such as goggle, hard hats, etc in order
7. Install thrust plate (3). Install pin (4) and connect

boom cylinder (2) with the boom.
8. Install stopper (6), stopper pin (7), and nuts (5) (2
used).
: 30 mm
: 400 Nm (41 kgfm, 300 lbfft)
6
5
2
W158-04-02-013
9. Install lubrication pipes (1).

: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)
10. Install the other boom cylinder in the same procedures.
11. When completing the work, operate the boom

cylinder several times to the stroke end and release the pressure in the circuit.
W105-04-02-032
W4-2-12

HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
NOTE: Do not start the engine. Operate the pilot
pump by using the power from battery and
deliver the pilot pressure to the spool of
control valve.
1. Push the lock lever forward.
2. Pull the handle for stopping engine completely
and secure the handle.
Handle for Stopping Engine
IMPORTANT: Battery will deplete. Operate the key

switch for short period.
3. Turn the key switch to the START position. Operate the lever in order to release any pressure in
hydraulic circuit 4 to 5 times.
4. Reset the handle for stopping engine.
W178-04-02-010
W4-2-13

DISASSEMBLE CYLINDER
Boom Cylinder
Up to serial No.33099
1
10
11
12
13
14
15
13
12
17
18
16
W1HH-04-02-007
Bucket Cylinder
1
9 10
11
12 13
14
15
13
12
16
17
18
W1HH-04-02-006
12345-
Piston Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Cylinder Head
O-Ring
11 12 13 14 -
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
NOTE: Socket bolt (8) (9 used) are equipped for

the boom cylinder only.
W4-2-14
15 16 17 18 -
Seal Ring
Set Screw
Nut
Cylinder Tube

Arm Cylinder
1
2
8
9
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
12345-
Piston Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Cylinder Head
O-Ring
11 12 13 14 15 -
Cushion Ring
Wear Ring (2 Used)
Piston
Seal Ring
W4-2-15
16 17 18 19 20 -
Set Screw
Nut
Cylinder Tube
Cushion Ring
Plug

Arm Cylinder
As the other hydraulic oil cylinders are very similar in
construction, the procedures of arm cylinder are
shown as an example.
1
2
8
9
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
NOTE: Cushion ring (19) and plug (20) are

equipped for the arm cylinder only.
W4-2-16

Disassemble Cylinders
The disassembling procedure starts on the premise
that the hydraulic lines and the bands securing
lines have been removed.
CAUTION: Cylinder weight:
Boom cylinder: 320 kg (710 lb)
Bucket cylinder: 255 kg (560 lb)
Arm cylinder:
460 kg (1010 lb)
3. Tap cylinder head (9) by using a plastic hammer.

Remove cylinder head (9) and piston rod (1) from
cylinder tube (18).
Remove piston rod (1) straight in order not to
damage the sliding surfaces.
4. Secure piston rod (1) on special tool (ST5908).
Put the matching marks on piston rod (1) and nut
(17).
ST 5908
1. Hoist and place the cylinder on a workbench

horizontally. Drain hydraulic oil from the cylinder.
W158-04-02-022
5. Remove cushion ring (19) and plug (20) from nut

(17). (arm cylinder only)
: 10 mm
W102-04-02-027
2. Fully extend piston rod (1). Support the piston

rod (1) end. Remove socket bolts (8) (8 used)
from cylinder head (9).
: 19 mm
(Boom, arm, and bucket cylinder)
NOTE: Socket bolts (8) (9 used) are equipped for
W4-2-17
1
2
9
10
11
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-18

6. As set screw (16) was mushroomed by using a
punch and hammer at two places after set screw
(16) had been screwed in, cut away its
mushroomed part by using a drill first. Remove
set screw (16).
: 6 mm (Boom, arm and bucket cylinder)
7. Remove nut (17) by using special tool (ST5908).
Remove piston (14).
Special tools when turning nut:
Boom cylinder : 120 mm (ST 3267)
Arm cylinder : 125 mm (ST 3268)
Bucket cylinder : 105 mm (ST 3266)
ST 5908
W158-04-02-022
8. Remove seal ring (15), wear rings (13) (2 used),

and teflon rings (12) (2 used) from piston (14).
When removing the seals, do not damage piston
(14).
9. Remove cushion ring (11) from piston rod (1).
10. Wind the tape onto the thread part of piston rod
(1) in order to protect the seal of cylinder head
(9). Remove cylinder head (9) from piston rod
(1).
11. Remove O-ring (10) and retaining rings (2, 7)
from cylinder head (9). Remove dust seal (3),
ring (5), seal (4), and bushing (6).
Special tools when removing bushing (6):
Arm cylinder : 120 mm (ST 1429)
W4-2-19

ASSEMBLE CYLINDER
Arm Cylinder
2
12
10
18
13
11
15
13
16
12
14
17
19
20
W1HH-04-02-008
12345-
Piston Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Cylinder Head
O-Ring
11 12 13 14 15 -
Cushion Ring
Wear Ring (2 Used)
Piston
Seal Ring
NOTE: Cushion ring (19) and plug (20) are

equipped for the arm cylinder only.
Socket bolts (8) (9 used) are equipped for
W4-2-20
16 17 18 19 20 -
Set Screw
Nut
Cylinder Tube
Cushion Ring
Plug

Assemble Cylinder
1. Apply hydraulic oil onto the inside of cylinder
head (9). Install bushing (6) into cylinder head (9).
Special tools when installing bushing:
Arm cylinder
: 110 mm (ST 2393)
2. Face the grooves of ring (5) and seal (4) to piston
(14).
Install ring (5), seal (4), and retaining ring (7) to
cylinder head (9).
3. Install dust seal (3) to cylinder head (9) by using
a plastic hammer.
Special tools when installing dust seal:
Boom cylinder : (ST 2392)
Arm cylinder
: (ST 2672)
Bucket cylinder : (ST 2357)
4. Install O-ring (10) and retaining ring (2) to
cylinder head (9).
5. Install wear rings (13) (2 used), seal ring (15),
teflon rings (12) (2 used) to piston (14).
(1) in order to protect the seal of cylinder head
(9). Install the cylinder head (9) assembly to
piston rod (1).
7. Install cushion ring (11) to piston rod (1) with R
part facing to cylinder head (9). Install the piston
(14) assembly to piston rod (1).
W4-2-21
18
16
17
19
20
W1HH-04-02-008
W4-2-22

8. Secure piston rod (1) on special tool (ST 5908).
Align the matching marks made when
disassembling and tighten nut (17).
Special Tools when turning nut:
: Boom cylinder: 8825883 Nm
(90090 kg fm, 6500650 lbfft)
120 mm (ST 3267)
Arm cylinder: 218672187 Nm
(2230223 kg fm, 161001610 lbfft)
125 mm (ST 3268)
Bucket cylinder: 100031000 Nm
(1020102 kg fm, 7380740 lbfft)
105 mm (ST 3266)
11. Secure cylinder tube (18) horizontally on a

workbench. Align the piston rod (1) assembly
with the center of cylinder tube (18). Insert the
piston rod (1) assembly into cylinder tube (18) in
order to not to damage the rings.
12. Install cylinder head (9) to cylinder tube (18) with
: 19 mm
: 83483 Nm
(858.5 kgfm, 61562 lbfft)
(Boom cylinder, Bucket cylinder)
: 1226123 Nm
(12512.5 kgfm, 90590 lbfft)
(Arm cylinder)
ST 5908
NOTE: Socket bolts (8) (9 used) are equipped for

W158-04-02-022
9. Tighten nut (17) with set screw (16).

Mushroom the head of set screw (16) at two
places by using a punch.
: 6 mm
: 63.76.4 Nm
(6.50.65 kgfm, 474.7 lbfft)
10. Install cushion ring (19) to piston rod (1) with R
part facing to plug (20) by using plug (20). (arm
cylinder only)
: 10 mm
: 109.811 Nm
(11.21.1 kgfm, 1818 lbfft)
W4-2-23

Wear to Outer Diameter of Rod
Rod Bend and Run Out

Dial Gauge
Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
Unit: mm (in)
Cylinder
Name
V Block
Recommended Size After

Re-manufacturing (A)
Boom
105
Arm
115
Bucket
95
-0.036
-0.090
-0.036
-0.090
-0.036
-0.090
(4.13
-0.001
-0.004
(4.53
-0.001
-0.004
(3.74
-0.001
-0.004
Unit: mm (in)
Bend
Allowable
limit
Allowable
limit
Run Out
Remedy
0.5 (0.020) 1.0 (0.039)
Repair
1.0 (0.039) 2.0 (0.079)
Replace
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder
Name
Boom
Standard Inner Diameter (C)

110
Arm
120
Bucket
100
+0.180
+0.115
+0.180
+0.115
+0.165
+0.100
(4.33
(4.72
(4.72
+0.007
+0.005
+0.007
+0.005
+0.006
+0.004
Allowable
Limit
Remedy
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
W4-2-24

(Blank)
W4-2-25

DISASSEMLBE CYLINDER
Boom Cylinder
Bucket Cylinder
Serial No. 33100 and up
12
10
13
12
11
1
15
14
Boom Cylinder
24
20
19
22
16
17
18
17
19
20
21
23
Bucket Cylinder
*24
W1HH-04-02-014
123456-
Piston Rod
Snap Ring
Dust Seal
Slide Ring
Cylinder Head
Buffer Ring
78910 11 12 -
Bushing
Snap Ring
Backup Ring
O-Ring
Collar
13 14 15 16 17 18 -
NOTE: The items without mark * are same.
W4-2-26
O-Ring
Bolt (12 Used)
Washer (12 Used)
Cushion Ring
O-Ring
19 20 21 22 23 24 -
Ring (2 Used)
Wear Ring (2 Used)
Piston Ring
Piston
Set Screw
Cylinder Tube

Arm Cylinder
14
10
11
12
15
16
15
13
9
8
7
6
3
2
1
17
18
27
22
23
25
19
20
21
20
22
23
24
26
W1HH-04-02-012
1234567-
Piston Rod
Cap
Ball (12 Used)
Plunger
Snap Ring
Dust Seal
Slide Ring
8910 11 12 13 14 -
Cylinder Head
Buffer Ring
Bushing
Snap Ring
Backup Ring
O-Ring
Collar
15 16 17 18 19 20 21 -
Backup Ring
O-Ring
Bolt (12 Used)
Washer (12 Used)
Cushion Ring
O-Ring
W4-2-27
22 23 24 25 26 27 -
Ring (2 Used)
Wear Ring (2 Used)
Piston Ring
Piston
Set Screw
Cylinder Tube

Arm Cylinder
construction, the procedures of arm cylinder are shown
as an example
.
16
14
10
11
12
15
15
13
9
8
7
6
3
2
1
17
18
27
22
23
25
19
20
21
20
22
23
24
26
W1HH-04-02-012
NOTE: Cap (2), balls (3) (12 used) and plunger (4)
are equipped for the arm cylinder only.
W4-2-28

Disassemble Cylinder
As the other hydraulic oil cylinders are very
similar in construction, the procedures of arm
cylinder are shown as an example.
The disassembling procedure starts on the premise
that the hydraulic lines and the bands securing lines
have been removed.
IMPORTANT: As set screw (26) was crimped by

using a punch and hammer at two
places after set screw (26) had been
screwed in, cut away its crimped
part by using a drill first.
4. Remove set screw (26).
: 6 mm (Boom, arm and bucket)
5. Remove the piston (25) assembly from piston rod
(1).
CAUTION: Cylinder weight:

Boom cylinder: 320 kg (710 lb)
Arm cylinder: 460 kg (1020 lb)
Bucket cylinder: 255 kg (570 lb)
1. Hoist and place the cylinder on a workbench
horizontally. Drain hydraulic oil from the cylinder.
6. Remove cap (2) from the upper surface of piston

rod (1) end. Remove balls (3) (12 used) from the
open part by using a magnet.
7. Remove plunger (4) from piston rod (1).
W102-04-02-027
2. Fully extend and support piston rod (1). Remove

bolts (17) (12 used) and washers (18) (12 used)
from cylinder head (8).
: 30 mm (Boom, bucket)
: 36 mm (Arm)
IMPORTANT: Remove piston rod (1) straight in
order not to damage the sliding
surfaces.
3. Tap and remove cylinder head (8) with piston rod
(1) together from cylinder tube (27) by using a
plastic hammer.
W4-2-29
10
11
12
13
9
8
7
2
1
25
19
20
21
20
22
23
24
W1HH-04-02-012
W4-2-30

IMPORTANT:
When removing the rings, do not

damage piston (25).
8. Remove piston ring (24), wear rings (23) (2 used)
and rings (22) (2 used) from the piston (25)
assembly.
9. Remove O-ring (21), backup ring (20) and
cushion ring (19) from piston rod (1).
(1) in order to protect the seal of cylinder head (8).
Remove cylinder head (8) from piston rod (1).
11. Remove the collar (14) assembly from piston rod
(1).
12. Remove O-ring (13) and backup rings (12) (2
used) from the collar (14) assembly.
13. Remove the cylinder head (8) assembly from
piston rod (1).
14. Remove O-ring (13), backup ring (12), snap ring
(5), dust seal (6), slide ring (7) and buffer ring (9)
from cylinder head (8). Remove snap ring (11)
and bushing (10) from cylinder head (8).
Special tools when removing bushing:
Boom 110 mm (ST 1399)
Arm
110 mm (ST 1399)
Bucket 100 mm (ST 1288)
W4-2-31

ASSEMBLE CYLINDER
Arm Cylinder
As the other hydraulic oil cylinders are very
similar in construction, the procedures of arm
cylinder are shown as an example.
17, 18
12, 13
10
11 15, 16
22
14
19
23
20, 21
24
23
22
W1HH-04-02-027
1234567-
Piston Rod
Cap
Ball (12 Used)
Plunger
Snap Ring
Dust Seal
Slide Ring
27
8910 11 12 13 14 -
Cylinder Head
Buffer Ring
Bushing
Snap Ring
Backup Ring
O-Ring
Collar
15 16 17 18 19 20 21 -
25 26
Backup Ring
O-Ring
Bolt (12 Used)
Washer (12 Used)
Cushion Ring
O-Ring
W4-2-32
22 23 24 25 26 27 -
Ring (2 Used)
Wear Ring (2 Used)
Piston Ring
Piston
Set Screw
Cylinder Tube

Assemble Cylinder
IMPORTANT: Apply hydraulic oil onto the inside of
cylinder head (8).
1. Install bushing (10) to cylinder head (8).
Special tool when installing bushing:
Boom 110 mm (ST 2393)
Arm
110 mm (ST 2393)
Bucket 100 mm (ST 2360)
2. Install slide ring (7) and buffer ring (9) to cylinder
head (8).
3. Install dust seal (6) to cylinder head (8) by using a
plastic hammer.
Special tools when installing dust seal:
Boom (ST 2392)
Arm
(ST 2672)
Bucket (ST 2357)
4. Install backup ring (12), O-ring (13) and snap
rings (5, 11) to cylinder head (8).
(1) in order to protect the seal of cylinder head (8).
Install the cylinder head (8) assembly to piston
rod (1).
6. Install the cylinder head (8) assembly to piston
rod (1).
7. Install backup ring (15) and O-ring (16) to collar
(14).
8. Install the collar (14) assembly to piston rod (1).
W4-2-33
22
17, 18
19
23
20, 21
24
23
22
W1HH-04-02-027
27
W4-2-34
25

9. Install piston ring (24), wear rings (23) (2 used)
and rings (22) (2 used) to piston (25).
10. Install the piston (25) assembly to piston rod (1).
11. Install cushion ring (19) onto piston rod (1).
12. Install plunger (4), balls (3) (12 used) and O-ring
(21) to piston (25).
13. Install backup rings (20) (2 used) and O-ring (21)
to piston (25).
IMPORTANT: Align with the center of cylinder tube
(18) and insert the piston rod (1)
assembly in order not to damage the
rings.
14. Secure cylinder tube (27) horizontally on a
workbench. Insert the piston rod (1) assembly into
cylinder tube (27).
15. Install cylinder head (8) to cylinder tube (27) with
bolts (17) (12 used) and washers (18) (12 used).
: 30 mm
: 529.778.5 Nm
(54.8 kgfm, 39057.5 Ibfft)
(Boom, bucket)
: 36 mm
: 892137 Nm
(9114 kgfm, 658101Ibfft)
(Arm)
W4-2-35

Wear to Outer Diameter of Rod
Rod Bend and Run Out

Dial Gauge
A
Cylinder Rod
W166-04-02-022
W105-04-02-094
Unit: mm (in)
Cylinder
Name
1m
V Block
Recommended Size After

Re-manufacturing (A)
Boom
105
Arm
115
Bucket
95
-0.036
-0.090
-0.036
-0.090
-0.036
-0.090
(4.134
-0.001
-0.004
(4.528
-0.001
-0.004
(3.74
-0.001
-0.004
Unit: mm (in)
Bend
Allowable
limit
Allowable
limit
Run Out
Remedy
0.5 (0.020) 1.0 (0.039)
Repair
1.0 (0.039) 2.0 (0.079)
Replace
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder
Name
Standard Inner Diameter (C)
Boom
110
Arm
110
Bucket
100
+0.250
+0.050
+0.250
+0.050
+0.250
+0.050
(4.331
+0.01
+0.002
) (4.331
+0.01
+0.01
(3.937
+0.002
+0.02
Allowable
Limit
Remedy
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
) +0.3 (+0.012)
Replace
W4-2-36
MEMO
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SECTION 5
ENGINE AND ACCESSORY

CONTENTS
General Information
Alternator ...................................................6A-13
General Repair Instruction ........................... 0A-1
Injection Pump ...........................................6A-14
Illustration Arrows ........................................ 0A-2
Bearing Case .............................................6A-18
Abbreviations ............................................... 0A-3
Oil Cooler ...................................................6A-20
Nut and Bolt Angular Tightening Method ...... 0A-4
Rocker Arm and Shaft Assembly ................6A-23
Standard Bolt Torque Specifications............. 0A-6
Camshaft....................................................6A-32
Recommended Thread Locking Agents ....... 0A-8
Cylinder Head ............................................6A-39
Main Data and Specifications....................... 0A-9
Crank Pulley and Flywheel .........................6A-62
Performance Curve.................................... 0A-11
Timing Gears..............................................6A-66
External View Drawing ............................... 0A-12
Flywheel Housing .......................................6A-71
Service Standard ....................................... 0A-13
Oil Pan .......................................................6A-76
Torque Specifications ................................. 0A-17
Front Cover ................................................6A-78
Special Tools.............................................. 0A-25
Piston .........................................................6A-82
Troubleshooting ......................................... 0A-26
Crankshaft..................................................6A-94
Lubricant Application.................................. 0A-36
Cylinder Block .......................................... 6A-106
Sealant Application .................................... 0A-36
Engine Cooling
Service Information
Identification ................................................ 0B-1
Lubrication System ...................................... 0B-2
Fuel System................................................. 0B-2
Cooling System............................................ 0B-6
Valve Clearance Adjustment ........................ 0B-6
Compression Pressure Measure.................. 0B-8
Recommended Lubricants ........................... 0B-9
Engine Oil Viscosity Chart ........................... 0B-9
Service Precaution .......................................6B-1

General Description .....................................6B-2
Thermostat ...................................................6B-3
Water Pump .................................................6B-6
Engine Fuel
Service Precaution .......................................6C-1
General Description .....................................6C-2
Fuel Filter .....................................................6C-5
Injection Nozzle............................................6C-7
Engine Mechanical
Service Precautions ..................................... 6A-2
General Description ..................................... 6A-2
Turbocharger ............................................... 6A-4
Exhaust Manifold ......................................... 6A-5
Intake Cover ................................................ 6A-7
Water Pump ................................................. 6A-9
Injection Pump ...........................................6C-17

Injection Pump Calibration Data .................6C-18
Starting and Charging

Service Precaution .....................................6D3-1
Alternator ...................................................6D3-2
Starter Motor ............................................ 6D3-11
1HHW-5-1
Engine Lubrication
Service Precaution.......................................6G-1
General Description .....................................6G-2
Oil Pump ......................................................6G-4
Oil Coolor.....................................................6G-8
Oil Port Cover ............................................ 6G-11
Engine Induction
Service Precaution........................................6J-1
Turbocharger ................................................6J-2
Troubleshooting ............................................6J-4
Inspection and Repair ...................................6J-6
1HHW-5-2
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Hitachi Construction Machinery Co. Ltd

Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
Hitachi Ref. No.
SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY:
MODEL:
PUBLICATION NO.:
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FAX:
(Located at the right top corner in the cover page)
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(Located at the bottom center in the page. If two or more revisions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
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REPLY:
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Manual No.

330 330LC 350H 350LCH 370MTH Excavator Workshop Manual

PRINTED IN SINGAPORE (PS) 2005.06

to provide technical information needed to maintain

If you have any questions or comments, at if you

The Operators Manual

Operation Manual of the Engine

Information included in the Technical Manual

Information included in the Technical Manual

Information included in the Workshop Manual:

cal Manual (Operational Principle), the Technical

lower part of the page, and each number contains

Indicates a situation which, if not conformed to the

SI Units (International System of Units) are used in

A table for conversion from SI units to other system

UNDERSTAND SIGNAL WORDS

DANGER indicates an imminently hazardous

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

DANGER or WARNING safety signs are

Some safety signs dont use any of the

CAUTION also calls attention to safety messages in

To avoid confusing machine protection with per-

sonal safety messages, a signal word IMPORTANT

NOTE indicates an additional explanation for an element of information.

Safety signs should be installed, maintained and

If a safety sign or this manual is damaged or

Learn how to operate the machine and its controls

Allow only trained, qualified, authorized personnel

Keep your machine in proper working condition.

The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of

PREPARE FOR EMERGENCIES

To ensure that a fire-extinguisher can be always

You may need:

Avoid wearing loose clothing, jewelry, or other

Operating equipment safely requires the full atten-

tion of the operator. Do not wear radio or music

PROTECT AGAINST NOISE

Wear a suitable hearing protective device such

walking around it before you start it to avoid personal injury.

In the walk-around inspection be sure to cover all

Dont leave parts and/or tools lying around the

Avoid storing transparent bottles in the cab. Dont

Refrain from listening to the radio, or using music

Keep all flammable objects and/or explosives

Dont leave cigarette lighters in the cab. When

Do not use any controls as hand-holds.

Be careful of slippery conditions on platforms,

steps, and handrails when mounting and dismounting the machine.

ADJUST THE OPERATOR'S SEAT

The seat should be adjusted whenever changing

The operator should be able to fully depress the

Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

Inappropriate engine starting procedures may

Start the engine only when seated in the

NEVER start the engine while standing on the

Do not start engine by shorting across starter

Before starting the engine, confirm that all control

levers are in neutral.

being struck by foreign objects and being thrown off

Only the operator should be on the machine.