SECTION 2 MAINTENANCE STANDARD

Group 3 Front Attachment

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
G Pin 71 (2.80) 70.0 (2.76) Replace
Boss (Arm) 71 (2.80) 72.5 (2.85)
Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85)
H Pin 80 (3.15) 79.0 (3.11)
Boss (Link B) 80 (3.15) 81.5 (3.21)
Bushing (Link A) 80 (3.15) 81.5 (3.21)
Bushing (Bucket Cylinder) 80 (3.15) 81.5 (3.21)
I Pin 71 (2.80) 70.0 (2.76)
Boss (Link B) 71 (2.80) 72.5 (2.85)
Bushing (Arm) 71 (2.80) 72.5 (2.85)
J Pin 80 (3.15) 79.0 (3.11)
Boss (Bucket) 80 (3.15) 81.5 (3.21)
Bushing (Link A) 80 (3.15) 81.5 (3.21)
K Pin 80 (3.15) 79.0 (3.11)
Boss (Bucket) 80 (3.15) 81.5 (3.21)
Bushing (Arm) 80 (3.15) 81.5 (3.21)
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.

W2-3-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Side Cutter (2014503, 2014504)

C
D

W155-04-01-002

Unit: mm (in)
Standard Allowable Remedy
Limit
A 278 (10.9) 181 (7.1) Replace
B 295 (11.6) -
C 433 (17.0) -
D 135 (5.3) -

W2-3-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Point (4427919)

B C

W105-04-01-020

Unit: mm (in)
Standard Allowable Remedy
Limit
A 215 (8.5) 107.5 (4.2) Replace
B 95 (3.7) -
C 108 (4.3) -
D 95 (3.7) -

W2-3-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Bucket

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.

WDCD-02-03-005

Section A Section B

WDCD-02-03-003
Unit: mm (in)
ZX200-5G Class ZX200-3 Class
a 450 (17.7) 
b 10 (0.39) 
c 604 (23.8) 
d 580 (22.8) 
e 476 (18.7) 
f 1471 (57.9) 
g 433 (17.0) 
h 305 (12.00) 
i 80 (3.15) 
j 475 (18.7) 
k 31 (1.2) 
l 433 (17.0) 
m 307 (12.1) 
n 80 (3.1) 
o 15 ° -3.7 °
p 15 ° 3.7 °
q 449 (17.7) 

W2-3-1-5
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Boom

Connection

WDCD-02-03-001

Section C
Unit: mm (in)
ZX200-5G Class ZX200-3 Class
s 90 (3.54) 
t 354 (13.93) 352 (13.85)
u 490 (19.3) 

IMPORTANT: If the front attachment of a previous

model machine is used, use the grease intervals
for previous model machine.

WDCD-02-03-004

s- Pin Hole Inner Diameter

W2-3-1-6
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Cylinder

Rod Rod Bend and Run Out

b
a
A

W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1 m (39.4 in)

Unit: mm (in) Unit: mm (in)

Cylinder Name Recommended Size After Re- Bend Run Out Remedy
manufacturing (A) 0.5 (0.020) 1.0 (0.039) Repair
Boom 85-0.012-0.027 (3.35-0.0005-0.001) 1.0 (0.039) 2.0 (0.079) Replace
Arm 95-0.012-0.027 (3.74-0.0005-0.001)
Bucket 80-0.01-0.023 (3.15-0.0004-0.0009)

W2-3-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

(Blank)

W2-3-2-2
MEMO
MEMO
SECTION 3

UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 11 Pilot Valve
Removal and Installation of Cab...............................W3-1-1-1 Removal and Installation of Pilot Valve
Dimensions of Cab Glass..............................................W3-1-2-1 (Left)............................................................................ W3-11-1-1
Removal and Installation of Pilot Valve
Group 2 Counterweight (Right)......................................................................... W3-11-2-1
Removal and Installation of Counterweight.........W3-2-1-1 Removal and Installation of Travel Pilot Valve... W3-11-3-1
Group 3 Main Frame Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
Removal and Installation of Main Frame................W3-3-1-1 Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Disassembly of Travel Pilot Valve............................ W3-11-5-1
Group 4 Engine Assembly of Travel Pilot Valve................................. W3-11-5-5
Removal and Installation of Engine.........................W3-4-1-1
Group 12 Solenoid Valve
Group 6 Hydraulic Oil Tank Removal and Installation of Pilot Shut-Off
Removal and Installation of Hydraulic Oil Tank...W3-6-1-1 Solenoid Valve......................................................... W3-12-1-1
Group 7 Fuel Tank Removal and Installation of 3-Spool Solenoid
Removal and Installation of Fuel Tank.....................W3-7-1-1 Valve Unit.................................................................. W3-12-2-1
Disassembly of Pilot Shut-Off Solenoid Valve... W3-12-3-1
Group 8 Pump Device Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-3-3
Removal and Installation of Pump Device.............W3-8-1-1 Structure of 3-Spool Solenoid Valve Unit............ W3-12-4-1
Removal and Installation of Coupling.....................W3-8-2-1
Disassembly of Pump Device.....................................W3-8-3-1 Group 13 Signal Control Valve
Assembly of Pump Device...........................................W3-8-3-8 Removal and Installation of Signal Control
Disassembly of Regulator............................................W3-8-4-1 Valve............................................................................ W3-13-1-1
Assembly of Regulator..................................................W3-8-4-3 Structure of Signal Control Valve........................... W3-13-2-1
Disassembly of Solenoid Valve...................................W3-8-5-1
Assembly of Solenoid Valve........................................W3-8-5-3
Structure of Pilot Pump................................................W3-8-6-1
Group 9 Control Valve
Disassembly of Housing...............................................W3-9-2-1
Assembly of Housing.....................................................W3-9-2-3
Disassembly of Control Valve (4-Spool Side)........W3-9-3-1
Assembly of Control Valve (4-Spool Side)..............W3-9-3-8
Disassembly of Control Valve (5-Spool Side)........W3-9-4-1
Assembly of Control Valve (5-Spool Side)..............W3-9-4-8
Group 10 Swing Device
Removal and Installation of Swing Device......... W3-10-1-1
Disassembly of Swing Device.................................. W3-10-2-1
Assembly of Swing Device....................................... W3-10-2-6
Disassembly of Swing Motor................................... W3-10-3-1
Assembly of Swing Motor......................................... W3-10-3-4

DCDW-3-1
(Blank)

DCDW-3-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Removal and Installation of Cab

6 2

5 4 1 WDAA-03-01-023

3 WDAA-03-01-047

IMPORTANT: Cap the open ends in case the hoses 4. Remove floor mat (4).
and pipes have been disconnected. In addition,
5. Remove bolts, washers (5) (4 used). Remove travel
attach an identification tag onto the connectors,
control levers (6) (2 used).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Open door (1).

dCAUTION: Seat (2) weight: 42 kg (93 lb)

3. Remove socket bolts (3) (4 used). Remove seat (2).

l : 6 mm

W3-1-1-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

WDAA-03-01-048

Detail A 7
14 12 WDAA-03-01-050

11 10 11
Detail B

8 7 WDAA-03-01-049
13 WDAA-03-01-051

6. Remove bolts, washers (7) (3 used). Remove bracket

(8).

j : 19 mm
7. Remove cover (9).
8. Disconnect plug (10) and connectors (11) (2 used).
9. Remove bolt, washer (12) and screw (13). Remove
cover (14).

j : 13 mm

W3-1-1-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

15 29 26, 27, 28 68 69 33 31

A B

25

20, 21

20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
17, 18
71 70
Detail A Detail B

WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18

10. Open cover (15). 15. Remove bolts, washers (30) (2 used).
11. Remove caps (16) (2 used). Remove seals (17) (2 j : 17 mm
used) and screws (18) (3 used). Remove cover (19).
16. Remove bolt, washer (31). Remove cover (32).
12. Remove bolts, washers (20) (2 used) and washers
(21) (2 used). j : 13 mm

j : 13 mm 17. Remove screws (68) (2 used). Remove duct (69).

13. Remove caps (22) (3 used). Remove seals (23) (3 18. Remove bolt, washer (70). Remove duct (71).
used) and screws (24) (3 used). Remove cover (25).
j : 13 mm
14. Remove caps (26) (2 used). Remove seals (27) (2
used) and screws (28) (2 used). Remove cover (29)
and duct (33).

W3-1-1-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

A B

WDAA-03-01-063 WDAA-03-01-064

34
Detail A Detail B

34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

19. Remove clip (35).

20. Disconnect connectors (34) (7 used).
21. Remove clip (36).
22. Disconnect connectors (37) (4 used).

W3-1-1-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

1 41

WDCD-03-01-003 WDCD-03-01-002
38 40 39 43 44

Detail A 46 45

42 79 80 WDCD-03-01-001
48 47
TDAA-05-08-006

23. Shut door (1). 29. Remove bolts, washers (43) (2 used). Remove cover
(44).
24. Open cover (38).
25. Remove filter (39). j : 17 mm

26. Remove screws (40) (6 used). Remove filter case (41). 30. Remove bolt (45). Disconnect connector (46).

27. Open engine cover (42). j : 13 mm

28. Remove bolts, washers (79) (5 used). Remove cover 31. Push the lock and shift lever (47). Disconnect
(80). connector (48).

j : 17 mm 32. Open door (1).

W3-1-1-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a a 49

a - Lifting Bracket WDAA-03-01-058 73 72 WDAA-03-13-005

dCAUTION:
(930 lb)
The cab (49) assembly weight: 420 kg

33. Attach nylon slings onto lifting brackets (a) (4

places) of cab (49). Hoist and hold the cab (49)
assembly.

dCAUTION: Remove cover (72) while holding it.

Do not drop cover (72).
34. Remove bolts, washers (73) (6 used). Remove cover
(72).

j : 17 mm

W3-1-1-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

49 55, 56 54 55, 56 52, 53

74, 75, 76 WDAA-03-01-066 54 52, 53 54 55, 56 50, 51 55, 56

WDAA-03-01-059

35. Remove bolt (74), washer (75), and spacer (76) at the
rear side.

j : 32 mm
36. Remove socket bolts (50) (2 used) and washers (51)
(2 used).

l : 8 mm
37. Remove socket bolts (52) (5 used) and washers (53)
(5 used).

l : 8 mm
38. Remove bolts, washers (54) (5 used).

j : 17 mm
39. Remove nuts (55) (4 used) and washers (56) (4 used).
Remove the cab (49) assembly.

j : 24 mm

W3-1-1-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

57 60 61 62 63 Detail A 66

66

64

59
65
WDAA-03-01-061
58

64

57 60 77 62 WDAA-03-01-060

67
WDAA-03-01-067

40. Disconnect connectors (57) (5 used).

41. Remove screws (58) (4 used). Remove monitor
controller (59).
42. Remove bolt, washer (77).

j : 17 mm
43. Remove screws (60) (4 used). Disconnect connector
(61).
44. Remove screws (62) (4 used). Remove cover (63).
45. Remove bolts, washers (64) (4 used). Remove MC
(65).

j : 13 mm

dCAUTION:
(64 lb)
Bracket assembly (67) weight: 29 kg

46. Remove bolts, washers (66) (6 used). Remove

bracket assembly (67).

j : 17 mm

W3-1-1-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

57 60 61 62 63 Detail A 66

66

64

59
65
WDAA-03-01-061
58

64

57 60 77, 78 62 WDAA-03-01-060

67
WDAA-03-01-067

Installation

dCAUTION:
(64 lb)
Bracket assembly (67) weight: 29 kg

1. Install bracket assembly (67) with bolts, washers (66)

(6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Install MC (65) with bolts, washers (64) (4 used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install cover (63) with screws (62) (4 used).
4. Connect connector (61) with screws (60) (4 used).
5. Install clamp (78) with bolt, washer (77).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Install monitor controller (59) with screws (58) (4
used).
7. Connect connectors (57) (5 used).

W3-1-1-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a a 49 55, 56 54 55, 56 52, 53

54 52, 53 54 55, 56 50, 51 55, 56

a - Lifting Bracket WDAA-03-01-058 WDAA-03-01-059

dCAUTION:
(930 lb)
The cab (49) assembly weight: 420 kg

8. Attach nylon slings onto lifting brackets (a) (4

places) of cab (49). Hoist the cab (49) assembly.
9. Install the cab (49) assembly with washers (56) (4
used) and nuts (55) (4 used).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

10. Install bolts, washers (54) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Install washers (53) (5 used) and socket bolts (52) (5
used).

j : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

12. Install washers (51) (2 used) and socket bolts (50) (2
used).

j : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-10