Front Attachment: Section 4

SECTION 4
FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment
Remove and Install Front Attachment.... W4-1-1
Maintenance Standard ........................... W4-1-8
Standard Dimensions for
Arm and Bucket Connection............... W4-1-11
Standard Dimensions for
Arm and Boom Connection ................ W4-1-12
Group 2 Cylinder
Remove and Install Cylinder .................. W4-2-1
Hydraulic Circuit Pressure
Release Procedure............................. W4-2-15
Disassemble Cylinder........................... W4-2-16
Assemble Cylinder ............................... W4-2-22
Maintenance Standard ......................... W4-2-26
1HHW-4-1
(Blank)
1HHW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
CAUTION: Escaping fluid under pressure

may penetrate the skin, causing serious in-
jury. Avoid this hazard by relieving pressure
before disconnecting hydraulic or other
lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off if re-
moved without releasing accumulated pres-
sure first. Push the air release valve on top of
the hydraulic oil tank to release any remain-
ing pressure.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Ȁ
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau- W105-04-02-001
lic oil tank.
NOTE: Be sure to run the vacuum pump continu-
ously while working on the hydraulic sys-
tem.
W4-1-1
Removal
1. Remove lubrication pipe (1) from the adapter on
the boss at the boom cylinder rod side. 1
(2 places on both left and right)
: 19 mm
Adapter
2. Remove nuts (4) and stopper pin (6) from boom Boom Cylinder
cylinder rod front pin (3). Then remove stopper
(5).
(2 places on both left and right)
: 30 mm
W105-04-01-002
CAUTION: Boom cylinder weight: 3 2

315 kg (690 lb)
Prevent personal injury.
Metal fragments may fly off when
a hammer is used to remove pins.
Be sure to wear necessary protec- 6 Boom Cylinder
tion, such as goggles, hard hat,
etc.
3. Hoist the boom cylinder by crane. With a bar and

a hammer drive pin (3) into the position where
5
thrust plate (2) can be removed. Remove thrust
plate (2). 4
W178-04-01-004
NOTE: When pin (3) is impossible to pull out. Start

the engine, slightly operate the boom lever
and align the boom cylinder rod pin hole.
W4-1-2
IMPORTANT: Insert a plate which does not come
in contact with the grease fitting in
the boom cylinder.
4. Insert a plate between the boom cylinder and
main frame. Hold the boom cylinder and lower it
by crane.
5. Remove the boom cylinder.

Refer to “Remove Boom Cylinder” (W4-2-10).
6. Remove other boom cylinder in the same proce-

dures as steps 3, 4, 5.
7. After stopping the engine, push the air bleeding Plate

valve on the top of hydraulic oil tank to release
W157-04-01-005
any remaining pressure. Then remove the cap.
Completely release the residual pressure from the
Air Bleeding Valve
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”.
Refer to page W4-2-15.
8. Disconnect hoses (7), (8) for the bucket cylinder

and arm cylinder, to cap all openings of disas-
sembled hoses and pipes.
: 36, 41, 50 mm
M157-07-173
7 8
W157-04-01-001
W4-1-3
9. Remove bolt (12), spring washer (13), plate (11)
and block (10) from the plate of boom foot pin (9). 9
: 27 mm
10
CAUTION: Front attachment weight: 11

ZAXIS330, 330LC: 6440 kg (14200 lb) 12
ZAXIS350, 350LCH: 7050 kg (15540 lb)
13
ZAXIS370MTH: 7120 kg (15700 lb)
W178-04-01-001
10. Attach a wire rope to the boom.

Slightly hoist it to take up any wire rope slack by
crane.
11. Insert a bar between the plate of boom foot pin (9)
and the bracket, slightly pull the plate out.
12. Turn the plate upward by hand and turn it left and
right to pull boom foot pin (9) out. (Adjust the posi-
tion of the boom foot pin hole, hoisting/lowering
the front attachment.)
W105-04-01-008
13. After hoisting the front attachment, move the ma-

9
chine backward.
14. Place the front attachment on wooden blocks.
Plate
Insert Bar
Bracket
W178-04-01-001
W178-04-01-005
W4-1-4
Install Attachment
CAUTION: Front attachment weight:
ZAXIS330, 330LC: 6440 kg (14200 lb)
ZAXIS350, 350LCH: 7050 kg (15540 lb)
ZAXIS370MTH: 7120 kg (15700 lb)
1. Hoist the front attachment by crane.

Move the machine forward, aligning the boom foot
pin holes.
Insert the thrust plates into boom left and right
W178-04-01-005
sides and adjust the clearance between the plate 9
and frame within 1 mm.
(Adjust the boom foot pin hole, hoisting / lowering
the front attachment.)
CAUTION: Prevent personal injury. Metal

10
fragments may fly off when a hammer is used
to remove pins. Be sure to wear necessary 11
protection, such as goggles, hard hats, etc. 12
13
2. Drive in boom foot pin (9). Install stopper bolt (12),
washer (13), plate (11) and block (10). W178-04-01-001
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
3. Remove the caps from hoses and pipings. Install 8

7
bucket cylinder hoses and arm cylinder hoses (7),
(8).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 50 mm
: 255 N⋅m (26 kg f⋅m) W157-04-01-001
CAUTION: Boom cylinder weight:

315 kg (690 lb)
4. Install the boom cylinder.

Refer to “Install Boom Cylinder” (W4-2-12).
Boom Cylinder
W105-04-02-040
W4-1-5

fragments may fly off when a hammer is used.
Be sure to wear necessary protection, such
as goggles, hard hats, etc. 3 2
5. Hoist the boom cylinder by crane. Insert thrust

plates (2) (2 used), then drive in pin (3), to install 6 Boom Cylinder
the boom cylinders to both sides.
6. Install stopper (5) and secure it with stopper pin 5

(6) and nuts (4) (2 used). (2 places on both left
4
and right)
: 30 mm W178-04-01-004
: 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)

1
7. Install lubrication pipe (1) onto the boom cylinder

rod side boss. (2 places on both left and right)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W105-04-01-002
8. Apply grease to the boom cylinder rod side, bot-

tom side and boom foot side. Boom Cylinder
Rod Side
Boom Foot
Side
M157-07-155
IMPORTANT: After filling hydraulic oil to specified

level, start the engine, check the
connections for any oil leakage.
IMPORTANT: After all work is completed, run each

cylinder several times to stroke end
to bleed air from the circuit.
Boom Cylinder M157-07-156

Bottom Side
W4-1-6
IMPORTANT: When the arm has been removed
from the boom, perform the follow-
ing steps when installing the arm.
9. Install thrust plates (14) into arm left and right

sides. Adjust total clearance of left and right within 14 14
1.5 mm or less.
10. After the arm is installed, apply grease to grease

fitting (15) on the boom connecting boss of the
arm.
IMPORTANT: For handling of HN bushing for the 15 15

front attachment, pay attention to
the following.
Precautions for pressing the bushing in:

If a hammer is used to drive the bushing in, the
bushing may be damaged. Use a press.
M157-07-157
Precautions when reinforcing the arm:

Welding heat for arm reinforcement may cause oil
leakage from the bushing and decrease lubrication
performance.
If oil leak occur, replace the bushing.
IMPORTANT: Pull the bushing out or press it with

special tool (ST 1478).
W4-1-7
MAINTENANCE STANDARD
Pin ⋅ Bushing
F E
G
C
H
D J
A
I
K
B
W105-04-01-018
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 110 (4.33) 109.0 (4.31)
A
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
B Boss (Main Frame) 110 (4.33) 111.5 (4.39)
Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
C Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
Boss (Boom) 110 (4.33) 111.5 (4.39)
Replace
Pin 110 (4.33) 109.0 (4.31)
D
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
E Boss (Arm) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.31)
F Boss (Boom) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
W4-1-8
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 90 (3.54) 89.0 (3.50)
G Boss (Arm) 90 (3.54) 91.5 (3.60)
Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60)
Pin 100 (3.94) 99.0 (3.90)
H Bushing 100 (3.94) 101.5 (4.00)
Bushing (Bucket Cylinder) 100 (3.94) 101.5 (4.00)
Replace
Pin 90 (3.54) 89.0 (3.50)
I
Bushing 90 (3.54) 91.5 (3.60)
Pin 100 (3.94) 99.0 (3.90)
J
Bushing 100 (3.94) 101.5 (4.00)
Pin 100 (3.94) 99.0 (3.90)
K
Bushing 100 (3.94) 101.5 (4.00)
IMPORTANT: When replacing HN bushing for the

front attachment, press it with a
press.
W4-1-9
Side Cutter
C
D
W105-04-01-019
Unit: mm (in)
Standard Allowable Limit Remedy
A 258 (10.2) 168 (6.61)
B 300 (11.8) 
Replace
C 400 (15.7) 
D 300 (11.8) 
Point
B C
W105-04-01-020
Unit: mm (in)
Standard Allowable Limit Remedy
A 240 (9.45) 120 (4.72)
B 96 (3.78) 
Replace
C 130 (5.12) 
D 105 (4.13) 
W4-1-10
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section A Section B
T137-01-03-001
Unit : mm (in)
ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5
a 575 (22.6) ұ ұ ұ
b 10 (0.39) ұ ұ ұ
c 700 (27.6) ұ ұ ұ
d 695 (27.4) ұ ұ ұ
e ҥ ҥ ҥ ҥ
f 1661 (65.4) 1666 (65.6) ұ 1661 (65.4)
g 581 (22.9) ұ ұ 573 (22.6)
h 442 (17.4) ұ ұ ұ
i 100 (3.94) ұ ұ ұ
j 578 (22.7) ұ ұ ұ
k 90 (3.54) ұ ұ ұ
l 581 (22.9) ұ ұ 573 (22.6)
m 420 (16.5) ұ ұ ұ
n 100 (3.94) ұ ұ ұ
o 8.85° ұ ұ ұ
p 8.85° ұ ұ ұ
q 592 (23.3) 600 (23.6) ұ 592 (23.3)
W4-1-11
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5

s 90 (3.5) ← ← ←
t 418.5 (16.5) ← ← ←
u 571 (22.5) ← ← ←
IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals of the previous
model machine.
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
CAUTION: Escaping fluid under pressure

may penetrate the skin, causing serious in-
jury. Avoid this hazard by relieving pressure
before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe
burns. Be sure to wait for oil to cool before
starting any repair work.
The hydraulic oil tank cap may fly off if re-
moved without releasing accumulated pres-
sure first. Push the air release valve on top of
the hydraulic oil tank to release any remain-
ing pressure.
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Ȁ
3. Release pressure from hydraulic oil circuit accor-
ding to the introduction on page W4-2-15.
W105-04-02-001
W4-2-1
Remove Bucket Cylinder
1. Insert wooden block (3) between bucket cylinder
(1) and arm (2).
1
2. After stopping the engine, push the air release
valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release the bucket circuit pressure. 3
Refer to “Hydraulic Circuit Pressure Release Pro-
cedure” on page W4-2-15. 2
3
W554-04-02-006
CAUTION: Secure links A and B with a wire

to prevent them from falling down before
pushing pin (7) out.

fragments may fly off when a hammer is
used.
as goggles, hard hats, etc.
Link A 4 5
3. Remove nuts (6) (2 used) and stopper pin (4).

Push out pin (7) with a round bar.
Remove thrust plates (5).
6
: 32 mm
Link B
7
1 W158-04-02-006
8
4. To prevent rod (8) of bucket cylinder (1) from
stretching, pass wire (9) through the cylinder rod
hole and secure it to the bucket cylinder (1) tube.
9
W102-04-02-005
W4-2-2
5. Disconnect bucket cylinder hoses (12) (2 used) at
the bucket cylinder (1) bottom. Cap all openings.
: 41 mm
10
CAUTION: Bucket cylinder weight:
255 kg (560 lb)
11
15
fragments may fly off when a hammer is
used.
as goggles, hard hats, etc. 13
1
6. Hoist bucket cylinder (1) by crane, to remove nuts
(13) (2 used) and stopper pin (15). Push pin (11)
out.
Remove thrust plate (10).
: 30 mm W1HH-04-02-009
12
7. Remove bucket cylinder (1).
W4-2-3
Install Bucket Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may be
damaged. Use a press.
CAUTION: Bucket cylinder weight: 10

255 kg (560 lb)
11
CAUTION: Prevent personal injury. Metal 15

fragments may fly off when a hammer is used 14
to install pin (11). Be sure to wear necessary
protection, such as goggles, hard hats, etc.
1. Hoist bucket cylinder (1) by crane. Align cylinder 13

tube side pin hole with the bucket cylinder mount-
ing hole on arm. Insert thrust plate (10) and install
pin (11).
1
Ȁ
2. Insert stopper pin (15) into arm stopper (14) and
pin (11). Install nuts (13) (2 used).
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) W1HH-04-02-009
12
IMPORTANT: After connecting hoses, fill hydraulic
oil to specified level, start the engine, 1
check the connections for any oil 8
leaks.
3. Connect bucket cylinder hoses (12) (2 used).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
4. Remove wire (9) from rod (8) of bucket cylinder 9 W102-04-02-005

(1).
W4-2-4
CAUTION: Prevent personal injury. Metal 16 4 17 5

5. Start the engine and operate the bucket lever to

align the cylinder rod side pin hole with those of
links (16), (18). Insert thrust plate (5) and pin (7).
7 18 6
W158-04-02-006
19 19
6. Insert stopper pin (4) into stopper (17) and pin (7),
to install nuts (6) (2 used).
: 32 mm
: 550 N⋅m (56.0 kgf⋅m, 405 lbf⋅ft)
IMPORTANT: In case link (18) has been removed

W157-04-01-015
from the arm, never forget to reinsert 18 18
thrust plate (19).
IMPORTANT: After all work is completed, run

bucket cylinder for several times to
stroke end to bleed air from the cir-
cuit.
W4-2-5
Remove Arm Cylinder
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).

valve to release any remaining pressure from the
hydraulic oil tank, then remove the cap.
Release arm circuit pressure.
Refer to “Hydraulic Circuit Pressure Release Pro-
cedure” on page W4-2-15.
4
3. Remove bolt (8) from pin (5) at the arm cylinder
(1) rod side. Remove spring washer (7) and plate
(6).
: 27 mm
1

Be sure to wear necessary protection, such 8 7 6 5 9 2 3 W1HH-04-02-001
4. Push pin (5) out, then remove thrust plate (4).

10
11
5. To prevent arm cylinder (1) rod (9) from extending,

pass a wire through the cylinder rod hole and se-
cure it to the arm cylinder (1) tube.
10
W1HH-04-02-002
6. Disconnect hoses (10) (2 used) from the bottom

of arm cylinder (1) and cap all openings.
: 41 mm, 50 mm
7. Disconnect lubrication pipe (11) from arm cylinder

(1).
: 19 mm
W4-2-6
12
CAUTION: Arm cylinder weight:
460 kg (1010 lb)
1
8. Attach a sling belt at the center of gravity of arm
cylinder (1). Hoist it by crane to take-up sag.

as goggle, hard hats, etc.
13
9. Remove bolt (16) from the tube side pin (13) of 14
arm cylinder (1). Remove spring washer (15) and 15 W1HH-04-02-004
plate (14). Push out pin (13), to remove thrust 16
plates (12) and remove arm cylinder (1).
: 27 mm
W4-2-7
Install Arm Cylinder
IMPORTANT: When pressing the bushing in, if a 12
hammer is used, the bushing may
be damaged. Use a press.
1
CAUTION: Arm cylinder weight:

460 kg (1010 Ib)
1. Attach a sling belt at the center of gravity of arm

cylinder (1). Hoist it by crane. Align the cylinder
tube side hole with the arm cylinder mounting hole
on the boom.
13
fragments may fly off when a hammer is used. 15 W1HH-04-02-004
Be sure to wear necessary protection, such 16
2. Insert thrust plate (12), then install pin (13). Install

1
plate (14) and spring washer (15) into pin (13) with
bolt (16).
: 27 mm 10
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) 11
3. Connect lubrication pipe (11) and arm cylinder (1)

hoses (10) (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
10
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) W1HH-04-02-002
: 50 mm
: 255 N⋅m (26 kgf⋅m, 190 lbf⋅ft)
MPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leaks.
W4-2-8
4. Remove a wire from arm cylinder (1) rod (9). Hoist
arm cylinder (1) by crane. Start the engine, oper- 4
ate arm lever and align the arm cylinder rod side 17
pin hole with the arm cylinder mounting hole on
arm (17).

8 7 6 5 9 W1HH-04-02-001
5. Insert thrust plate (4), then install pin (5).

Install plate (6) and spring washer (7) into pin (5)
with bolt (8).
: 27 mm
: 300 N⋅m (30.5 kgf⋅m, 220 lbf⋅ft)
IMPORTANT: When all work is completed, operate

the arm cylinder several times to
cuit.
W4-2-9
Remove Boom Cylinder 1
1. Disconnect lubrication pipes (1) from the boom
cylinder.
: 19 mm

315 kg (690 lb)
2. Attach a wire rope to boom cylinder (2) and hoist it

by crane.
W105-04-02-032
7
3. Remove nuts (5) (2 used), stopper pin (7) and
stopper (6) from the boom cylinder (2) rod to push
pin (4) out.
: 30 mm
6
4. Place boom cylinder (2) on a bracket. Remove the
other boom cylinder by same method. 5 3 4 3 2
W158-04-02-013
5. Operate the boom lever to retract the boom.

To prevent the boom cylinder rod from stretching,
pass the wire through the cylinder rod hole and
secure it to the cylinder tube.

valve to release any remaining pressure from hy-
draulic oil tank. Then remove the cap.
Release the circuit pressure.
Refer to “Release Hydraulic Circuit Pressure Pro- 2
W178-04-02-011
cedure” on page W4-2-15.
W4-2-10
7. Disconnect hoses (12) (4 used) from boom cylin-
der (2) at the boom cylinder bottom. Cap all open-
ings.
: 41 mm

2
Be sure to wear necessary protection, such W178-04-02-011
8. Loosen bolt (8) at the cylinder tube side of main 2

frame, and remove bolt (8), spring washer (9) and 13
plate (10).
Pull pin (11) out.
: 27 mm

315 kg (690 lb)
11 10 9 8
9. Attach a wire rope at the center of gravity of boom
12 W1HH-04-02-003
cylinder (2). Hoist it by crane to remove.
Remove the boom cylinder at other side by the
same method.
W178-04-02-013
2
W4-2-11
Install Boom Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may be
damaged. Use a press.

315 kg (690 lb)
1. Attach a wire rope at the center of gravity of boom

cylinder (2). Hoist it by crane. Align the pin hole at
boom cylinder tube side with the boom cylinder
mounting hole on the main frame.
W178-04-02-013
2
fragments may fly off when a hammer is used. 2
13
2. Insert thrust plate (13) and pin (11). Install spring

washer (9) and plate (10), then tighten with bolt
(8).
: 27 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
3. Install the boom cylinder at other side by the same

method.
11 10 9 8
12 W1HH-04-02-003
4. Connect hoses (12) (4 used) on boom cylinders

(2) (2 used).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
IMPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
connections for any oil leaks.
W4-2-12
5. Hoist boom cylinder (2) by crane. Operate the
boom lever to align the pin hole at cylinder rod
side with the mounting hole of the boom cylinder.

as goggle, hard hats, etc. 7
6. Install thrust plate (3), drive in pin (4) to connect

boom cylinder (2) with the boom.
7. Install stopper (6), stopper pin (7) and nuts (5) (2

used).
6
: 30 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) 5
3 4 3 2
W158-04-02-013
8. Connect lubrication pipes (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
1
9. Install the boom cylinder at other side by the same
method.
IMPORTANT: When all work is completed, run the

boom cylinder for several times to
cuit.
W105-04-02-032
W4-2-13
(Blank)
W4-2-14
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
NOTE: Following method can be used. Do not start

the engine. Operate pilot pump with the
power from battery to deliver pilot pressure
to the spool of control valve.
1. Push the lock lever forward. (Be in OFF condition)
IMPORTANT: Be sure to pull the handle for stop-

ping engine fully out.
Handle to Stop Engine
2. Pull the handle for stopping engine out and secure

it by left foot.
IMPORTANT: Battery will deplete. Be sure to oper-

ate key switch for short period.
3. Turn the key switch to START position and oper-

ate the lever for releasing any pressure from hy-
draulic circuit 4 to 5 times.
IMPORTANT: Push the handle for stopping engine

in.
4. Reset the handle for stopping engine.
W178-04-02-010
W4-2-15
DISASSEMBLE CYLINDER
Boom Cylinder
1 2
3
4
8 5
9 6
10 7
11
12 13
14
15
13
12
17
18
16
W1HH-04-02-007
Bucket Cylinder
1 2
3
4
5
6
7
8
9 10
11
12 13
14
15
13
12
16
17
18
W1HH-04-02-006
1- Piston Rod 6- Bushing 11 - Cushion Ring 15 - Seal Ring

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 16 - Set Screw
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 17 - Nut
4- Seal 9- Cylinder Head 14 - Piston 18 - Cylinder Tube
5- Ring 10 - O-Ring
NOTE: Socket bolt (8) (9 used):

boom cylinder only.
W4-2-16
Arm Cylinder
2
3
4
5
8 6
9 7
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
1- Piston Rod 6- Bushing 11 - Cushion Ring 16 - Set Screw

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 17 - Nut
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 18 - Cylinder Tube
4- Seal 9- Cylinder Head 14 - Piston 19 - Cushion Ring
5- Ring 10 - O-Ring 15 - Seal Ring 20 - Plug
W4-2-17
Arm Cylinder
As the other hydraulic oil cylinders are very similar in
construction, disassembling procedures of the arm
cylinder are shown as an example.
2
3
4
5
8 6
9 7
10
11
12
13
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
NOTE: Cushion ring (19) and plug (20) are

equipped to the arm cylinder only.
W4-2-18
Disassemble Cylinders
• Read carefully “Precautions for Disassembly and 3. Pull out cylinder head (9) from cylinder tube (18)
Assembly” (W1-1-1) before starting repair work. by tapping with a plastic hammer.
• To avoid duplication, disassembling procedures of
the arm cylinder are shown below as an example, 4. Secure cylinder rod (1) on special tool (ST5908).
as the other cylinders are very similar in Put matching marks between cylinder rod (1) and
construction. nut (17).
The disassembling procedure below starts on the ST 5908

premise that the hydraulic lines and the line
securing bands have been removed.
CAUTION: Cylinder weight:

Boom cylinder: 315 kg (690 lb)
Bucket cylinder: 255 kg (560 lb)
Arm cylinder: 460 kg (1010 lb)
W158-04-02-022
1. Hoist and securely place the cylinder on a

workbench by crane. Be sure that the cylinder is 5. Remove cushion ring (19) and plug (20) from nut
placed horizontally. Drain hydraulic oil from the (17). (arm cylinder only)
cylinder. : 10 mm
W102-04-02-027
2. Fully extend cylinder rod (1). Secure the rod end

by crane. Remove socket bolts (8) (8 used) from
cylinder head (9).
: 19 mm
(Boom, arm and bucket cylinder)
NOTE: Socket bolts (8) (9 used) are equipped to
the boom cylinder only.
IMPORTANT: Be sure to pull piston rod (1) straight

so as not to damage the sliding
surfaces.
W4-2-19
2
3
4
5
6
9 7
10
11
14
15
13
12
16
17
19
20
18
W1HH-04-02-005
W4-2-20
IMPORTANT: As set screw (16) was mushroomed
with a punch and hammer at two
places after it had been screwed in,
cut away its mushroomed portion
using a drill first.
6. Remove set screw (16).
: 6 mm (Boom, arm and bucket cylinder)
7. Loosen nut (17) with special tool (ST5908).

Remove piston (14).
Nut Turning Special Tools:
Boom cylinder : 120 mm (ST 3267)
Arm cylinder : 125 mm (ST 3268)
Bucket cylinder : 105 mm (ST 3266)
ST 5908
W158-04-02-022
IMPORTANT: When removing the seals, take care

not to damage piston (14).
8. Remove seal ring (15), wear rings (13) (2 used)
and teflon rings (12) (2 used) from piston (14).
9. Remove cushion ring (11) from piston rod (1).
10. Wind tape around the thread part of piston rod (1)
in order to protect the seal of cylinder head (9).
Remove the cylinder head from the piston rod.
11. Remove O-ring (10), retaining rings (2) and (7)

from cylinder head (9). Then remove dust seal (3),
ring (5), seal (4), and bushing (6).
Special tools for bushing removal:
Bucket cylinder : 100 mm (ST 1288)
W4-2-21
ASSEMBLE CYLINDER
Arm Cylinder
As the other hydraulic oil cylinders are very similar in

construction, disassembling procedures of the arm
cylinder are shown as an example.
2 3 4 5 6 12 13 15 13 12 14
16 17
8 7 10 1 18 11
19
20
W1HH-04-02-008
1- Piston Rod 6- Bushing 11 - Cushion Ring 16 - Set Screw

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 17 - Nut
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 18 - Cylinder Tube
4- Seal 9- Cylinder Head 14 - Piston 19 - Cushion Ring
5- Ring 10 - O-Ring 15 - Seal Ring 20 - Plug
NOTE: Cushion Ring (19) and Plug (20) are

equipped to the arm cylinder only.
Socket Bolts (8) are equipped to the boom
cylinder only.
W4-2-22
Assemble Cylinder
IMPORTANT: Apply hydraulic oil to the inside of

cylinder head (9).
1. Install bushing (6) to cylinder head (9) with a
press.
Special tools for bushing installation:
Bucket cylinder: 100 mm (ST 2360)
IMPORTANT: Install them with ring (5) and seal (4)

grooves facing piston (14).
2. Install ring (5), seal (4), and retaining ring (7) to

cylinder head (9).
3. Install dust seal (3) to cylinder head (9) with a

plastic hammer.
Special tools for dust seal installation:
Boom cylinder : (ST 2392)
Arm cylinder : (ST 2672)
Bucket cylinder: (ST 2357)
4. Install O-ring (10) and retaining ring (2) to cylinder

head (9).
5. Install wear rings (13) (2 used), seal ring (15),

teflon rings (12) (2 used) to piston (14).
6. Wind tape around the thread part of piston rod (1)

in order to protect the seal of cylinder head (9).
Install the cylinder head (9) assembly to piston rod
(1).
IMPORTANT: Be sure to install cushion ring (11)

so that “R” part faces cylinder head
(9).
7. Install cushion ring (11) to piston rod (1). Install

the piston (14) assembly to piston rod (1).
W4-2-23
16 17
8 1 18
19
20
W1HH-04-02-008
W4-2-24
8. Secure piston rod (1) to special tool (ST 5908). IMPORTANT: Be sure to align piston rod (1)
Tighten nut (17) using special tool (ST 5908). assembly with the center of cylinder
Be sure to align the matching marks on the rod tube (18) when inserting, in order to
with that on the nut. Tighten nut (17). avoid damaging the rings.
Nut Turning Special Tools:
: Boom cylinder: 8825 ± 883 N⋅m 11. Secure cylinder tube (18) horizontally on a work
(900 ± 90 kg f⋅m, 6500 ± 650 lbf⋅ft) bench. Insert the piston rod (1) assembly into
120 mm (ST 3267) cylinder tube (18).
Arm cylinder: 21867 ± 2187 N⋅m 12. Install cylinder head (9) to cylinder tube (18).
(2230 ± 223 kg f⋅m, 16100 ± 1610 lbf⋅ft) Tighten socket bolts (8) (8 used).
125 mm (ST 3268)
: 19 mm
Bucket cylinder: 10003 ± 1000 N⋅m : 834 ± 83 N⋅m
(1020 ± 102 kg f⋅m, 7380 ± 740 lbf⋅ft) (85 ± 8.5 kgf⋅m, 615 ± 62 lbf⋅ft)
105 mm (ST 3266) (Boom cylinder, Bucket cylinder)
: 19 mm
ST 5908 : 1226 ± 123 N⋅m
(125 ± 12.5 kgf⋅m, 905 ± 90 lbf⋅ft)
(Arm cylinder)
NOTE: Socket bolts (8) (9 used) are equipped to

the boom cylinder only.
W158-04-02-022
9. Tighten nut (17) with set screw (16).

Mushroom the head of set screw (16) at two
places with a punch and hammer.
: 6 mm
: 63.7 ± 6.4 N⋅m
(6.5 ± 0.65 kgf⋅m, 47 ± 4.7 lbf⋅ft)
IMPORTANT: Install cushion ring (19) with “R”

part facing plug (20)
10. Install cushion ring (19) to piston rod (1) with plug
(20). (arm cylinder only)
: 10 mm
: 109.8 ± 11 N⋅m
(11.2 ± 1.1 kgf⋅m, 181 ± 8 lbf⋅ft)
W4-2-25
MAINTENANCE STANDARD
Wear to Outer Diameter of Rod Rod Bend and Run Out
Dial Gauge
A
Cylinder Rod
W166-04-02-022
W105-04-02-094
1m
Unit: mm (in) V Block
Cylinder Recommended Size After

Name Re-manufacturing (A) Unit: mm (in)
-0.036 -0.001
Boom 105 -0.090 (4.13 ) Bend Run Out Remedy
-0.004
-0.036 -0.001 Allowable
Arm 115 (4.53 ) 0.5 (0.020) 1.0 (0.039) Repair
-0.090 -0.004 limit
-0.036 -0.001 Allowable
Bucket 95 (3.74 ) 1.0 (0.039) 2.0 (0.079) Replace
-0.090 -0.004 limit
Wear to Inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder Allowable
Standard Inner Diameter (C) Remedy
Name Limit
+0.180 +0.007
Boom 110 (4.33 ) +0.3 (+0.012) Replace
+0.115 +0.005
C
+0.180 +0.007
Arm 120 (4.72 ) +0.3 (+0.012) Replace
+0.115 +0.005
+0.165 +0.006
Bucket 100 (4.72 ) +0.3 (+0.012) Replace
+0.100 +0.004
W4-2-26

Front Attachment: Section 4

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SECTION 4

CAUTION: Escaping fluid under pressure

2. Stop the engine. Push the air release valve on top

CAUTION: Boom cylinder weight: 3 2

3. Hoist the boom cylinder by crane. With a bar and

NOTE: When pin (3) is impossible to pull out. Start

5. Remove the boom cylinder.

6. Remove other boom cylinder in the same proce-

7. After stopping the engine, push the air bleeding Plate

8. Disconnect hoses (7), (8) for the bucket cylinder

CAUTION: Front attachment weight: 11

10. Attach a wire rope to the boom.

13. After hoisting the front attachment, move the ma-

14. Place the front attachment on wooden blocks.

1. Hoist the front attachment by crane.

CAUTION: Prevent personal injury. Metal

3. Remove the caps from hoses and pipings. Install 8

CAUTION: Boom cylinder weight:

4. Install the boom cylinder.

CAUTION: Prevent personal injury. Metal

5. Hoist the boom cylinder by crane. Insert thrust

6. Install stopper (5) and secure it with stopper pin 5

: 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)

7. Install lubrication pipe (1) onto the boom cylinder

8. Apply grease to the boom cylinder rod side, bot-

IMPORTANT: After filling hydraulic oil to specified

IMPORTANT: After all work is completed, run each

Boom Cylinder M157-07-156

9. Install thrust plates (14) into arm left and right

10. After the arm is installed, apply grease to grease

IMPORTANT: For handling of HN bushing for the 15 15

Precautions for pressing the bushing in:

Precautions when reinforcing the arm:

IMPORTANT: Pull the bushing out or press it with

IMPORTANT: When replacing HN bushing for the

ZAXIS330 ZAXIS350H ZAXIS370MTH EX300-5

IMPORTANT: If the front attachment of a previous

CAUTION: Escaping fluid under pressure

2. Stop the engine. Push the air release valve on top

CAUTION: Secure links A and B with a wire

CAUTION: Prevent personal injury. Metal

3. Remove nuts (6) (2 used) and stopper pin (4).

CAUTION: Bucket cylinder weight: 10

CAUTION: Prevent personal injury. Metal 15

1. Hoist bucket cylinder (1) by crane. Align cylinder 13

3. Connect bucket cylinder hoses (12) (2 used).

4. Remove wire (9) from rod (8) of bucket cylinder 9 W102-04-02-005

CAUTION: Prevent personal injury. Metal 16 4 17 5

5. Start the engine and operate the bucket lever to

IMPORTANT: In case link (18) has been removed

IMPORTANT: After all work is completed, run

2. After stopping the engine, push the air release

CAUTION: Prevent personal injury. Metal

4. Push pin (5) out, then remove thrust plate (4).

5. To prevent arm cylinder (1) rod (9) from extending,

6. Disconnect hoses (10) (2 used) from the bottom

7. Disconnect lubrication pipe (11) from arm cylinder

CAUTION: Prevent personal injury. Metal

CAUTION: Arm cylinder weight:

1. Attach a sling belt at the center of gravity of arm

2. Insert thrust plate (12), then install pin (13). Install

3. Connect lubrication pipe (11) and arm cylinder (1)

MPORTANT: After filling hydraulic oil to specified