SERVICE BULLETIN CODE

DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
SUBJECT (Revised)
INSTALLATION AND REMOVAL METHOD OF ZX120 ∼ 330 SERIES
MAIN PUMP COUPLING

REVISED
CORRECTION OF ERRORS

There are several corrections in Service Bulletin 3 2017 0092 which we previously issued.

Please replace page 8 of 8 with the attached revised version.

[Reason for revision to the Service Bulletin]

The following shows the changes/additions to the setting method explanation.

[Page 7] To avoid the mix-up of type 1 and type 3, the “MODEL” name of the 20t “PUMP MODEL
CODE” has been changed.

[Page 7] The Japanese character (katakana) identifications of the parts used in the “Illustration of
the coupling” have been changed to alphabetical identifications.

[Page 7] “Remarks” are added to outside the column below the torque chart.

CHKD
APPD
 Page 1 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
SUBJECT (Revised)
INSTALLATION AND REMOVAL METHOD OF ZX120 ∼ 330 SERIES
MAIN PUMP COUPLING

OUTLINE
This Service Bulletin is to inform you how to install and remove the ZX120 ∼ 330 series pump
coupling (current style: glasses shape hole type hub) and to provide you with a list of tightening
torques of clamp screws by model.

The coupling removal method is generally the same for all models. However, you will need to pay
greater attention during installation. The jig that you will need and the tightening torque of the
clamping screw vary by the model.

＊ Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.
＊ After replacing the main hydraulic equipment or engine or after post-assembling the aforementioned as an
option, be sure to change and register the post-assembled device serial number on Global e-Service (MMR,
HR, MME, G-Claim).

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX120 ∼ 330 series (All), JD120 ∼ 330 series (All)
Machine Serial Nos.: Initial serial number ∼
Verify details of the applicable models and serial numbers on Global e-Service
S/B (Service Bulletin) system.

STD. LABOR HOURS

―

EXPENSES AND THE TIME TO BE CHARGED

―

PARTS
―

DESCRIPTION
Refer to the following page(s).

CHKD
SA/GI: KISB-036 APPD
 Page 2 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
(Revised)

CONTENTS

1 List of tools to be used for installation and removal …………………………………… 3

2 Coupling removal method and its cautionary remarks ………………………………… 3

3 Coupling installation method and its cautionary remarks …………………………… 4

 Page 3 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
Installation and removal method of engine-pump coupling (Revised)
This Service Bulletin summarizes the cautionary remarks for the coupling
installation and removal work.
Follow the cautionary remarks below when you carry out the work.

1 List of tools to be used for installation and removal

・Hex wrench and torque wrench (refer to chart 1 for wrench size.)
・Clamping hub removal tool (puller)
・Other tools to be used to remove and install covers and pump device (refer to the Workshop Manual.)

2 Coupling removal method and its cautionary remarks

[Work procedure]
1. Remove the pump device.
※ To remove and install the pump device, follow the “Installation and removal of the pump device”
instructions in the Workshop Manual.
・Pump removed state

Hub on the pump side Stopper installation bolt (8 bolts)

Stopper
Element

<Model with no stopper> <Model that comes with a stopper>

2. Remove the eight bolts that are used to install the stopper
(applicable only to the model to which a stopper is installed).

Use a hex wrench.

3. Remove the stopper (applicable only to the model to which a stopper is installed).

4. Remove the coupling element.

 Page 4 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
5. Mark the position of the clamping screw of the hub on the pump side. (Revised)
Mark along the edge of the input shaft.

Clamping screw

Mark along the edge of the input

shaft (on the clamping screw side).

6. Remove the two clamping screws on the pump side.

Use a hex wrench.

7. Use a puller to remove the hub on the pump side.

Use a puller to remove the hub. (To prevent oil leak,

do not use a driver, etc. for the removal. Doing that
can damage the oil seal and shaft seal surfaces.).

No good

3 Coupling installation method and its cautionary remarks

[Work procedure]
1. Have a new coupling assembly ready.
2. Install the coupling hub to the input shaft of the pump.
2-1. The hub needs to be installed in a certain direction.
・Install to the pump in such way so that the tool mark is visible (engine-side).
 Page 5 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

2-2. For this work, you will need to go back to the marking that was
ZX120_330-All-201
(Revised)
made along the edge of the input shaft when the coupling was
removed. Turn this marked position by 180 degrees.
Next, match this position with the clamping screw.
※ If this positioning work is not carried out for tightening the screw, friction can increase at the point
where contact is made with the shaft spline. Depending on how much friction develops, it can
result in failure such as that of pump input shaft and engine damage. Be sure to match the
positions correctly.

Install the clamping screw by matching it with

the position that is a 180 degree rotation of the
marking that was made on the input shaft.

Clamping screw

Marking
Install to the pump in such way so that
the tool mark is visible (engine-side).

2-3. Push the hub completely to the end of the input shaft of the pump.

Fully inserted position of the hub

Hub edge in the input shaft of the pump

※ For ZH/ZX200-5B series pumps, use jigs (ST7767, ST7768) for installation. (Refer
to the Workshop Manuals; PUB No. WDCK-EN-00, WDCF-EN-00, WDCS-EN-00.)

a. Washer (M12) b. Nut (M12, pitch 1.75 mm)

 Page 6 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
3. Tighten the two clamping screws. (Revised)
・Use a torque wrench. (For wrench size and tightening torque,
refer to Chart 1.)
・Begin by installing the clamping screw, and complete the work within five minutes.
※ If you are working with pre-coated screws and bolt, you will need to tighten them all at once.
Don’t tightening them halfway and leave them unattended for a long time. The pre-coating
agent can harden and you will not be able to tighten them to the target axial force. This can
then result in failure such as that of input shaft of the pump and engine damage.

Use a torque wrench. (For wrench size

and tightening torque, refer to Chart 1.)
Begin by installing the bolt, and
complete the work within five minutes.

4. Use the bolt to tighten the insert A on the engine flywheel side.
・Make sure to see that the spring pin is attached to the engine flywheel.
・Use a torque wrench. (For wrench size and tightening torque, refer to Chart 1.)
・Begin by installing the bolt, and complete the work within five minutes.
※ If you are working with pre-coated screws and bolt, you will need to tighten them all at once.
Don’t tightening them halfway and leave them unattended for a long time. The pre-coating
agent can harden and you will not be able to tighten them to the target axial force. This can
then result in failure such as that of input shaft of the pump and engine damage.
5. Install the coupling element to the hub on the pump side.
6. Install the stopper (applicable only to the model to which a stopper is installed).
6-1. Positioning of the stopper
・The stopper needs to be assembled in a certain direction.
・Match the bolt hole on the stopper side with the bolt hole on the hub side.
・Confirm the phase of the stopper and element.
Confirm that the stopper is assembled in the correct direction. Match
the bolt hole on the stopper side with the bolt hole on the hub side.

※Stopper assembly direction

Engine side
Coupling hub side

※Phase of stopper and element

Element

Confirm the phase of the

stopper and element.
 Page 7 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
6-2. Install the stopper using eight bolts. (Revised)
・Use a torque wrench. (For wrench size and tightening torque,
refer to Chart 1.)
・Begin by installing the bolt, and complete the work within five minutes.
※ If you are working with pre-coated screws and bolt, you will need to tighten them all at once.
Don’t tightening them halfway and leave them unattended for a long time. The pre-coating
agent can harden and you will not be able to tighten them to the target axial force. This can
then result in failure such as that of input shaft of the pump and engine damage.

Use a torque wrench. (For wrench size

and tightening torque, refer to Chart 1.)
Begin by installing the bolt, and
complete the work within five minutes.

7. Install the pump device.

※ To remove and install the pump device, follow the “Installation and removal of the pump
device” instructions in the Workshop Manual.

8. Releasing the air from the pump

・Release the air from the air release plug at the pump regulator top.
・For the air releasing method, refer to the Workshop Manual and Service Bulletin 2013 0156.
※ Starting the engine without sufficiently releasing the pump air can cause the bearing inside
the pump to seize.

9. Operational check, oil leak check

10. This completes the work.

 Page 8 of 8
SERVICE BULLETIN CODE
DESCRIPTION
3 2017 0092A
FILING LOCATION

ZX120_330-All-201
(Revised)
List of tightening torques of couplings (Chart 1)
1
PUMP MODEL HOLE PART SCREW ADHESIVE TIGHTNING
MODEL COUPLING SYMBOL QTY
CODE PRESENCE NAME SIZE ※ TORQUE(Nm) ※※
Part No. 4464407 B Clamping screw M16x2.0-18 - 2 110
ZX120-5G No
Type CF-H-035-T6 G Bolt M14x2.0-40 ○ 3 140
Part No. 4683953 B Clamping screw M16x2.0-18 - 2 110
ZX120-3 Type CF-H-045-T20 No G Bolt M16x2.0-55 ○ 4 220
Stopper P/No. 3113293 I Bolt M6x1.0-15 ○ 8 10
12t
ZX120-5B Part No. 4721246 B Clamping screw M12x1.75-16 ○ 2 50
ZX120-6 Type CF-H-045-T27 Yes G Bolt M16x2.0-55 ○ 4 220
ZX120-GI Stopper P/No. YB00002184 I Bolt M6x1.0-15 ○ 8 10
Part No. YB00001524 B Clamping screw M12x1.75-16 ○ 2 50
JD120G Yes
Type CF-H-045-T32 G Bolt M16x2.0-55 ○ 4 220
ZX200-3, ZX240-3, ZX270-3
1 ZX170W-3, ZX190W-3, Part No. YB00000114 B Clamping screw M12x1.75-16 ○ 2 50
ZX210W-3, ZX200-5A,
ZX240-5A, ZX160-5G, Yes
ZX180-5G, ZX200-5G,
ZX240-5G, ZX270-5G, Type CF-H-045-T28 G Bolt M16x2.0-55 ○ 4 220
JD200G, JD240G, JD270G
ZX160/180-3 Part No. 4716391 B Clamping screw M12x1.75-16 ○ 2 50
ZX160-5A
Type CF-H-090-T35 Yes G Bolt M16x2.0-60 ○ 4 220
ZX160/180-5B
20t ZX140W-3/5B Stopper P/No. 2059073 I Bolt M6x1.0-15 ○ 8 10
ZX170W/190W/210W-5B Part No. 4716846 B Clamping screw M12x1.75-16 2 50
○
ZX200/240/270-5N
Yes
ZX200/240/270-6N
ZX125W-6 Type CF-H-090-36 G Bolt M16x2.0-55 ○ 4 220

ZX200/240/270-5B Part No. 4713245 B Clamping screw M12x1.75-16 ○ 2 50

ZX200/240-6 Yes
ZH200-5A/5B Type CF-H-090-T31 G Bolt M16x2.0-60 ○ 4 220
Part No. YB00002300 B Clamping screw M12x1.75-16 ○ 2 50
ZH200-6 Yes
Type CF-H-090-T60 G Bolt M16x2.0-65 ○ 4 220
ZX330-3 Part No. YB00003276 B Clamping screw M16x2.0-22 - 2 110
ZX330/300-5A Yes
ZX330-5G Type CF-H-110-T85 G Bolt M18x2.5-65 ○ 4 320
Part No. YB00003277 B Clamping screw M16x2.0-22 - 2 110
30t JD330G Yes
Type CF-H-110-T86 G Bolt M18x2.5-65 ○ 4 320
ZX330-5N/6N Part No. YB00002166 B Clamping screw M16x2.0-22 2 110
-
ZX300-6N
Yes
ZX330-5B
ZX330-6 Type CF-H-130-T11 G Bolt M18x2.5-65 ○ 4 320

※ SCREW AND BOLT WITH ADHESIVE:LESS THAN 5 MINUTES FROM AN INSTALLATION START TO COMPLETION.
※※ TIGHTNING TORQUE ALLOWANCE IS LESS THAN 10%.
[Remarks]
1
The names of the models that are shown on chart 1are leading models. You are advised to check the P/No. of the coupling that is actually mounted.
1 Illustration of the copuling No hole type hub

IDENTIFY MARK ※2

IDENTIFY MARK ※1

Glasses shape hole type hub

INPUT SHAFT SCREW

SECTION Z-Z