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Manual de Taller Excavadora Hitachi Zx200 225 230 270 PDF
Manual de Taller Excavadora Hitachi Zx200 225 230 270 PDF
: KM-178E
Vol. No. : W178-E-02
200·225USR·225US·230·270
Workshop Manual
200
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance
delivery, operation and activation of all devices and repair of the machine, tools and devices
and systems, operational performance tests, and needed for maintenance and repair, maintenance
troubleshooting procedures. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting Indicates supplementary technical information or
heavy parts. know-how.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688
SA-688
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
PREPARE FOR EMERGENCIES
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
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 operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-6
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• 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
012-E01B-0444
JUMP STARTING
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
014-E01B-0379
SA-379
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-9
SAFETY
DRIVE MACHINE SAFELY
SA-387
SA-388
019-E01D-0492
SA-590
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• 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 SA-391
020-E08A-0493
SA-11
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.
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 SA-384
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 operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
injury or death.
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 SA-440
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-13
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
033-E09B-0390
SA-15
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-18
SAFETY
• 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 operator’s 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
SA-028
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.
• 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 SA-527
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
SS2045102
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
504-E01A-0034 SA-034
SA-040
S522-E01A-0040
SA-21
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. SA-039
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-23
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 SA-019
hoses.
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated 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.
SA-24
SAFETY
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-25
SAFETY
EVACUATING IN CASE OF FIRE
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• 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 SA-818
SA-27
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.
511-E01A-0029
512-E01C-0032
SA-28
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
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE
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 Signal Control 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
All information, illustrations and speci-
fications in this manual are based on Group 6 Upper and Lower Roller
the latest product information available
at the time of publication. The right is
Group 7 Track
reserved to make changes at any time
without notice.
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
COPYRIGHT(C)2004
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
Group 5 Component Test Group 6 Electrical System Inspection
Group 6 Adjustment 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 3 Painting
Painting.................................................... W1-3-1
178W-1-1
(Blank)
178W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic
clean and dry.
motor housing, damage to the mo-
• If an anti-corrosive agent has been used on a
tor may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • 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 en-
gine 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.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
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:
uneven wear.
b b
a=b a≠b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
W1-2-1
GENERAL / Tightening
W1-2-2
GENERAL / Tightening
W1-2-3
GENERAL / Tightening
TORQUE CHART
Bolt Types
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-4
GENERAL / Tightening
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 lu-
bricant.
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 ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-5
GENERAL / Tightening
Service Recommendations for Spilt Flange
• 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 Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-6
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
W1-2-7
GENERAL / Tightening
O-ring Seal Joint 9
7 6
W1-2-8
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
M114-07-043 M114-07-042
W1-2-9
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
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.
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-10
GENERAL / Tightening
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 haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place 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, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, 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 replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Oil filter hose (Engine to oil filter) Every 2 years or Every 6000 hours
Engine Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hours
Heater hose (Heater to engine) Every 2 years or Every 6000 hours
Pump suction hose Every 2 years or Every 6000 hours
Basic Machine Pump delivery hose Every 2 years or Every 6000 hours
Swing hose Every 2 years or Every 6000 hours
Hydraulic
Travel hose Every 2 years or Every 6000 hours
System
Boom cylinder line hose Every 2 years or Every 6000 hours
Front-End Arm cylinder line hose Every 2 years or Every 6000 hours
Attachment Bucket cylinder line hose Every 2 years or Every 6000 hours
Pilot hose Every 2 years or Every 6000 hours
W1-2-11
GENERAL / Tightening
(Blank)
W1-2-12
GENERAL / Painting
PAINTING
(ZAXIS200, 200-E)
Right Ladder
Rail
Mirror Stay
900 720
350
Bed Cover W178-01-03-001
Main Surface of Tool Box Cover Main Surface of
Upperstructure Upperstructure
W178-01-03-002
W1-3-1
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01 (TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
Antislip Cover
W178-01-03-004
KASAI PAINT
Amilack 1400
Deep Black
Front Attachment
YR-01 (TAXI Yellow)
W178-01-03-006
W178-01-03-008
W1-3-2
GENERAL / Painting
(ZAXIS225USR)
Right
Window Beam
Right
Ladder Rail
Mirror Stay
W178-01-03-010
600 900 720
W1-3-3
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01 (TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Antislip Cover
KASAI PAINT
Amilack 1400
Front Attachment Deep Black
YR-01 (TAXI Yellow)
Upper Side
W178-01-03-007
of Frame
W178-01-03-012
W1-3-4
GENERAL / Painting
(ZAXIS225US)
Right
Window Beam
Right
Ladder Rail
Mirror Stay
W178-01-03-010
785 675 720
W1-3-5
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01(TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Antislip Cover
KASAI PAINT
Amilack 1400
Front Attachment Deep Black
YR-01 (TAXI Yellow)
Upper Side
W178-01-03-007 of Frame
W178-01-03-012
W1-3-6
GENERAL / Painting
(ZAXIS230, 270)
Right Ladder
Rail
Mirror Stay
900 720
350
Bed Cover W178-01-03-001
Main Surface of Tool Box Cover Main Surface of
Upperstructure Upperstructure
W178-01-03-002
W1-3-7
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01 (TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
Antislip Cover
W178-01-03-004
KASAI PAINT
Amilack 1400
Deep Black
Front Attachment
YR-01 (TAXI Yellow)
W178-01-03-006
W178-01-03-008
W1-3-8
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
Preparation
1. Place the machine on a firm, level surface.
M104-07-021
Pressure Release Button
M157-07-173
Vacuum Pump
Hose
3. Remove hydraulic oil tank cap. Connect a vac-
uum pump to maintain negative pressure in the
hydraulic oil tank. Adapter
W562-02-03-008
W1-4-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 6 Swing Device
Remove and Install Cab ..............................W2-1-1 Remove and Install Swing Device............... W2-6-1
Dimensions of the Cab Glass ....................W2-1-13 Disassemble Swing Device (ZAXIS200,
200-E, 225US, 225USR, 230) ................... W2-6-4
Group 2 Counterweight Disassemble Swing Device (ZAXIS270) ... W2-6-10
Remove and Install Counterweight..............W2-2-1 Assemble Swing Device (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-16
Group 3 Main Frame Assemble Swing Device (ZAXIS270)........ W2-6-24
Remove and Install Main Frame..................W2-3-1 Disassemble Swing Motor (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-30
Group 4 Pump Device Disassemble Swing Motor (ZAXIS270)..... W2-6-34
Remove and Install Pump Device................W2-4-1
Assemble Swing Motor (ZAXIS200,
Disassemble Pump Device..........................W2-4-2
200-E, 225US, 225USR, 230) ................. W2-6-38
Assemble Pump Device.............................W2-4-10
Assemble Swing Motor (ZAXIS270).......... W2-6-42
Disassemble Regulator..............................W2-4-22
Disassemble and Assemble Parking
Assemble Regulator ..................................W2-4-24
Release Valve (ZAXIS270)...................... W2-6-46
Disassemble Solenoid Valve .....................W2-4-26
Maintenance Standard .............................. W2-6-47
Assemble Solenoid Valve ..........................W2-4-28
Disassemble and Assemble Pilot Group 7 Pilot Valve
Pump ........................................................W2-4-30 Remove and Install Right Pilot Valve .......... W2-7-1
Maintenance Standard...............................W2-4-32 Remove and Install Left Pilot Valve............. W2-7-5
Remove and Install Travel
Group 5 Control Valve Pilot Valve .................................................. W2-7-8
Remove and Install Control Valve................W2-5-1
Disassembe Right and Left
Disassemble Control Valve
Pilot Valves .............................................. W2-7-10
4-Spool Section ..........................................W2-5-8
Assemble Right and Left
Disassemble Control Valve
Pilot Valves .............................................. W2-7-18
5-Spool Section ........................................W2-5-14
Disassemble Travel Pilot Valve ................. W2-7-26
Disassemble and Assemble
Assemble Travel Pilot Valve ...................... W2-7-34
4-Spool and 5-Spool Section ...................W2-5-20
Assemble Control Valve
4-Spool Section ........................................W2-5-22
Assemble Control Valve
5-Spool Section ........................................W2-5-30
178W-2-1
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off Valve ......W2-8-1
Disassemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270).......W2-8-4
Disassemble Pilot Shut-Off Valve
(ZAXIS225US) ...........................................W2-8-6
Assemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270).....W2-8-8
Assemble Pilot Shut-Off Valve
(ZAXIS225US) .........................................W2-8-10
178W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
W178-02-07-006
4
3. Raise duct (5) to remove it. 5
W178-02-01-013
W2-1-1
UPPERSTRUCTURE / Cab
5. Disconnect cable connectors (10, 11, 12 and 13)
on the right side in the cab and ground (9) at rear
side in the cab.
10
11
12
13
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a
screwdriver. Remove screw (16) with a screw- 17
driver to remove duct cover (17).
15
W178-02-01-016
19
W178-02-01-017
20 21
W2-1-2
UPPERSTRUCTURE / Cab
22
W178-02-01-018
24
W157-02-01-010
W157-02-01-001
W2-1-3
UPPERSTRUCTURE / Cab
1 2
Removal (ZAXIS225US)
1. Remove seat mounting bolts (2) (4 used) and
bolts (3) (2 used) for seat belt to remove seat (1).
: 17 mm, 16 mm
W1SE-02-01-001
1
3
(7).
W1SE-02-01-004
W2-1-4
UPPERSTRUCTURE / Cab
4. Remove bolts (12) (4 used) at rear side of the
cab to remove cover (11) from rear cover (10). 10
: 13 mm
12
11
W1SE-02-01-005
14
15
W1SE-02-01-006
16
6. Disconnect washer vinyl hose (17) from washer
tank (16) at the bottom rear side of the cab.
17
W1SE-02-01-007
20
21
W1SE-02-01-008
W2-1-5
UPPERSTRUCTURE / Cab
8. Hold and shake the connector of radio antenna
feeder (22) to right and left to remove the connec-
tor. 22
Remove screw (23) to remove ground (24).
Disconnect connectors (25) (6 used). 23
Remove junction box (26).
Remove bolts (27) (2 used) to remove ground 24
(28).
: 13 mm 25
26
27
28
W1SE-02-01-09
W1SE-02-01-011
W1SE-02-01-10
11. Lift the cab by crane and remove the cab from
the frame carefully.
W157-02-01-001
W2-1-6
UPPERSTRUCTURE / Cab
Installation (ZAXIS200, 200-E, 225USR, 230, 270)
W157-02-01-001
W157-02-01-010
W178-02-01-013
10
11
12
13
W178-02-01-014
W2-1-7
UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
4
5
W178-02-01-012
19
W178-02-01-017
20 21
W2-1-8
UPPERSTRUCTURE / Cab
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
W178-02-07-006
W2-1-9
UPPERSTRUCTURE / Cab
Installation (ZAXIS225US)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
30
31
W1SE-02-01-10
27
28
W1SE-02-01-09
21
W1SE-02-01-008
W2-1-10
UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (17) to the bottom
side of washer tank (16) at rear side of the cab.
16
17
W1SE-02-01-007
14
15
W1SE-02-01-006
12
11
W1SE-02-01-005
8. Insert duct (8) into duct (7) and fix them with
screws (9) (2 used). 7
: 3 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft)
8
W1SE-02-01-004
W2-1-11
UPPERSTRUCTURE / Cab
9. Install duct cover (5) to the cab with screw (4)
and install cap (6).
: 3 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft)
4
W1SE-02-01-003
1 2
10. Install seat (1) with seat mounting bolts (2) (4 used)
and seat belt bolts (3) (2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 16 mm
: 70 N⋅m (7.1 kgf⋅m, 51 Ibf⋅ft)
W1SE-02-01-001
1
3
W1SE-02-01-002
W2-1-12
UPPERSTRUCTURE / Cab
DIMENTIONS OF THE CAB GLASS
(ZAXIS200, 200-E, 225USR, 230, 270)
Unit: mm
R2 A Chamfer Here
R98 R35
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
(9.4)
R42
R72
Section C W178-02-01-019
366
C R2992
14
733
546±1
R92
R58
R58 (4 mm)
R11508
170.6
70
R1808 50
882.5 997
R42
(4 mm)
321.9±1
W178-02-01-024
Chamfer along the
periphery
R308 R1898
R258
100
150
943
W178-02-01-007
Section B W178-02-01-019
W2-1-13
UPPERSTRUCTURE / Cab
Unit: mm
Chamfer Here
Chamfer Here
85.4
Chamfer Slightly
343.3 213 unless the periphery
Polish Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the
Periphery Polish Chamfered 39.5 D
733
733
C R2465 +0.5
2-φ12.2 -0
W178-02-01-019
Polish Chamfer
Both Sides
289.5
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
R2002
872
R123
R115
888.58
W178-02-01-010
W2-1-14
UPPERSTRUCTURE / Cab
Applied to the standard machines produced in
March, 2002 and after.
W178-02-01-005
753
R63
R63
610.5
490
(4 mm)
R115 R115
R167
50
50
512.5
R167
W178-02-01-025
Section A W178-02-01-019
W2-1-15
UPPERSTRUCTURE / Cab
(ZAXIS225US)
Unit: mm
Along the Along the
Periphery Periphery
C1 C1
A
75.6
1110.5
R5
27.3
R20 R542
52.8
(R First) 1044.4
R1910
R5
39 415.1
322.1 1164.4
W1SE-02-01-013
Chamfer Here
Chamfer along the Periphery
unless Otherwise Specified
2-R5
2-R20
W1SE-02-01-012 2-R15 34 2-R105 32.5
4-R73
40
R2 42.3 39.5
φ13.5±0.2 557
(4 mm) 40
320±0.5
2-R15
2-R20
B
2-φ13.5±0.2
48±5
112±0.2 23.5
W2-1-16
UPPERSTRUCTURE / Cab
Unit: mm
FREE R 9±5
32±5
(5 mm) 92.8
27.4
342.7
55.1
W1SE-02-01-018
W1SE-02-01-012
444.2±1
200
152.9±1
194.6
C
(5 mm)
D
597±1
R2916.2
Chamfer 41.5
Here
40 Chamfer
Here
+1
101±5 2-φ13 0
10±5 167
50.2
4-R5
4-R5
109.6
R2937 2-φ18±0.5
(4 mm)
412
50±0.5
63.5±0.5
244±0.5
R114
Section C and D W178-02-01-019
67.5±0.5 372.5
R551.5
96 40
490.5 40 R9
637
652
W1SE-02-01-015
W2-1-17
UPPERSTRUCTURE / Cab
Remove Cab Glass (ZAXIS200, 200-E, 225USR,
230, 270)
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass Mounting Rubber Section
W178-02-01-004
W2-1-18
UPPERSTRUCTURE / Cab
Procedures to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the
A
glass when air is entered between cab and
mounting rubber.
Cab
W178-02-01-002
Glass
Mounting Rubber
W178-02-01-005
W2-1-19
UPPERSTRUCTURE / Cab
Method to remove cab glass (ZAXIS225US)
Procedures to remove right-hand glass, rear left
glass and lower door glass
Right-Hand Glass
CAUTION: When removing broken or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or some-
thing like should be used to paste the broken
or cracked glass ready to reinforce them so
as to prevent hurt from occurring. Be sure to
remove glass pieces away. Garnish
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal. Garnish
Resin Panel
Cab
Glass
Awl
Adhesive W1SE-02-01-033
Piano Wire
(or Metal Wire)
3. Pass a piano wire (or a wire) through the pricked
hole.
W1SE-02-01-034
W2-1-20
UPPERSTRUCTURE / Cab
4. Tie both ends of piano wire to two screwdrivers.
Draw the wire back and forth to cut the bonding
agent between cab and glass to remove the
glass from the cab. Cab (Outside of Cab)
Glass
NOTE: Be sure to cut off the bonding agent be-
tween glass and cab just in the middle.
Piano wire is easily broken if a part of it
turns hot. Be sure to change the portion
used while cutting the bonding agent.
Bonding Agent
(Inside of Cab)
W1SE-02-01-035
W2-1-21
UPPERSTRUCTURE / Cab
Left-Hand Cab Glass
Cab Glass Installation Procedure
(ZAXIS200, 200-E, 225USR, 230, 270)
Procedure for installing left-hand cab glass, lower
glass of the door and upper front glass A
CSE Braid
1. Install the seal rubber on the left-hand cab glass
and lower glass of the door.
5 A
W178-02-01-023 CSE Braid
Seal Rubber
10 10
W178-02-01-020
W178-02-01-004
W2-1-22
UPPERSTRUCTURE / Cab
Method for Installing Right-Hand Cab Glass Mounting Rubber Section
Cab
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
W216-02-01-005
W178-02-01-002
W178-02-01-005
W2-1-23
UPPERSTRUCTURE / Cab
Method for Installing Cab Glass (ZAXIS225US)
Right-Hand Glass
Procedures for right-hand glass, rear left-hand glass
and lower door glass
Cab
W2-1-24
UPPERSTRUCTURE / Cab
4. Clean the mating edge of new glass being in- 11. After applying agent, suck the glass (with sucker
stalled with clean rag and ethylalcohol. lifter 4355282, refer to W2-1-25) up to adhere it to
the cab within 5 minutes.
IMPORTANT: Primer 35 should be shaken for
about 1 minute to mix thoroughly NOTE: Mount the glass with its spacer being fit
before opening. ready to the cab while taking the spacer as
With cap off, apply Primer 24 as matching mark. Press to install the glass.
quickly as possible, then replace Remove all bonding agent, except where
cap immediately after use. All the on the mounting face, before solidifying
contents should be used within 3 with white spirit.
days after opening (or 2 hours with
cap off). 12. The glass should be adequately secured with
gummed tape till the bonding agent becomes
solid to prevent them from being mispositioned or
5. Apply glass primer (sunrise MSI primer 35) all coming off.
around where glass bonding agent should be ap-
plied. Wait for about 15 minutes for drying. (As
NOTE: Time for the bonding agent (sunrise MSI
for the position to apply primer 35, refer to
SR seal U90 4463876) to turn into a solid:
W2-1-25)
8 hours (just for reference)
500
7. Cut the nozzle of bonding agent cartridge (sun-
450
rise MSI SR seal U90 4463876) into V-shaped
with a knife. (Refer to W2-1-25) 200
200
8. Remove the seal of cartridge end to fix the cut
V-shaped nozzle on. 100
500
W1SE-02-01-039
200
Rear Left-Hand Glass 150
9. Install the cartridge to the manual cocking gun.
200
W1SE-02-01-040
150
Lower Door Glass
150
50
150
200
150
W1SE-02-01-041
W2-1-25
UPPERSTRUCTURE / Cab
R7
10.9 R6
8.7 0.5
5 10.5 Flat 7
9.3
5
0.5
1 3.6 Apply Adhesive to
3.6 Apply Adhesive Apply Adhesive W1SE-02-01-032
Concave Both Sides
6 1 to Both Sides to Both Sides
Convex 6
8.5
8.5 W1SE-02-01-031
W1SE-02-01-030
Lower Door Glass
Left-Hand Glass Left-Hand Glass D
B D
286
B
400 Spacer c
Spacer c 225
700
Spacer b
Spacer c
30
650
Sucker 160 62
305 c Spacer a Lifter
Spacer a
c
Spacer b
A 445
110 85 290
52 450
60
A 123 W1SE-02-01-020
W1SE-02-01-019
W1SE-02-01-021
Bonding Agent
Apply Adhesive
to Both Sides
5.5 5.0 W1SE-02-01-027
5.5~5.9
W1SE-02-01-043
Remove the
Seal Glass
4.9 3.6
Cab
12.0
Agent Cartridge
W1SE-02-01-022
W1SE-02-01-028
W2-1-26
UPPERSTRUCTURE / Cab
13. The required amount (just for reference) of bonding agent and primer
W2-1-27
UPPERSTRUCTURE / Cab
Procedures to Install Upper Door Glass
Garnish
2. Assemble glass A and glass B into sash grooves.
Insert glass C into the mounting rubber.
Glass A Glass B
W1SE-02-01-044
Sash Groove
W1SE-02-01-045
W2-1-28
UPPERSTRUCTURE / Cab
Procedures to Install Rear Glass
1 5 9 W1SE-02-01-046
W2-1-29
UPPERSTRUCTURE / Cab
Procedures to Install Upper Front Glass
Lower Glass
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
can’t be replaced individually. Be Upper Glass
sure to change the cab glass as an
assembly.
The upper front glass is Slick POS POS Seal
arched-fringed. If this glass needs
Seal Here
to be replaced, contact the nearest
HITACHI Office to replace it as an
assembly.
1 1
Lower Glass
Lower Glass
W1SE-02-01-047
W2-1-30
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal
CAUTION: Counterweight weight:
ZAXIS200, 200-E 4250 kg (9370 lb)
ZAXIS225USR 6710 kg (14790 lb)
ZAXIS225US 7600 kg (15550 lb)
ZAXIS230 5400 kg (11910 lb)
ZAXIS270 6100 kg (13450 lb)
Wire Rope
NOTE: Sling bolt specification
ZAXIS200, 200-E (B-36: M36, Pitch 4.0
mm) Sling Bolt
ZAXIS225US, 225URS, 230, 270 (B-42:
M42, Pitch 4.5 mm)
W178-02-02-002
: 46 mm
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight weight:
ZAXIS200, 200-E 4250 kg (9370 lb)
ZAXIS225USR 6710 kg (14790 lb)
ZAXIS225US 7600 kg (15550 lb)
ZAXIS230 5400 kg (11910 lb)
ZAXIS270 6100 kg (13450 lb)
W178-02-02-001
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work.
(Refer to BLEED AIR FROM HY-
DRAULIC OIL TANK on W1-4-1.)
Removal
CAUTION: Cab weight:
290 kg (640 lb)
(ZAXIS200, 200-E, 225USR, 230, 270)
250 kg (550 lb) (ZAXIS225US)
W157-02-01-001
W2-3-1
UPPERSTRUCTURE / Main Frame
W105-02-03-005
W157-02-03-001
W2-3-2
UPPERSTRUCTURE / Main Frame
6. Put matching marks on the outer race of the upper-
structure and outer race of the swing bearing.
Loosen and remove mounting bolt (2) of the
swing bearing.
(ZAXIS200, 200-E, 225US, 225USR)
: 30 mm
(ZAXIS230, 270)
: 32 mm
W105-02-03-007
1
7. Chain block (1) shall be used to adjust and level
the frame, then lift it slightly to remove it from the
undercarriage.
W157-02-03-002
W2-3-3
UPPERSTRUCTURE / Main Frame
Installation
CAUTION: Upperstructure weight:
4650 kg (10250 lb) (ZAXIS200, 200-E)
4850 kg (10690 lb) (ZAXIS225US)
1
4750 kg (10470 lb) (ZAXIS225USR)
5090 kg (11220 lb) (ZAXIS230)
5270 kg (11630 lb) (ZAXIS270)
Track section:
640 N⋅m (65 kgf⋅m, 470 Ibf⋅ft)
W2-3-4
UPPERSTRUCTURE / Main Frame
4. Install stopper (4) to the center joint with bolt (3).
3
: 22 mm
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft) 4
: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) W157-02-01-001
W178-02-02-002
W2-3-5
UPPERSTRUCTURE / Main Frame
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
: 30 mm
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
M104-07-021
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
1 2 3 4 5
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work.
(Refer to BLEED AIR FROM HY- 12
DRAULIC OIL TANK on W1-4-1.)
Removal 11
1. Disconnect connectors (4 places).
CAUTION: Pump device weight: 170 kg
(375 lb)
Installation
1. Install eyebolt (M12, Pitch 1.75) (ST 0002) on the
pump device and lift by crane.
2. Insert the drive shaft of pump device into the
pump mission, and install it with pump device
mounting bolts (5) (8 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
3. Connect hoses (1 to 4 and 6, 7, 9 to 12) and pipe
(8). W178-02-04-019
4. Connect connectors.
Wrench size Tightening torque
Remark
(mm) N⋅m kgf⋅m(Ibf⋅ft)
: 27 93 9.5 (69) Hose
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 50 5.1 (37) Bolt
:8 50 5.1 (37) Bolt
: 19 29.5 3 (21.5) Hose
W2-4-1
UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
4
3 5
1 2
17
16
15
14
18
13
6
12
11
10
9
56
7
55
8 17
54 16
14
53 15
52 19
12
51
20
11
49 10
9
21
22
23
50 24
49 21
48 22
28
27
26
25
47
33
35
29
46 26
45 34
36
37
32 38
31 30
39
40
41
42
43
44 W178-02-04-004
42
W2-4-2
UPPERSTRUCTURE / Pump Device
68
69
70
67
67
66
71
65
64
63
60 61 72
58 62 61 74
58 73
58 61
59
78 77 61 75
60
57 76
58 68
59
58 78
58
79
57
58
79 W178-02-04-005
W2-4-3
UPPERSTRUCTURE / Pump Device
4
3 5
1 2
68
6 69
66
71
51
76
68
25
47
33 35
34 36
32
30
39
W178-02-04-010
W2-4-4
UPPERSTRUCTURE / Pump Device
1. Remove plug (25) from gear casing (47). 8. Remove socket bolts (71) (12 used) from selector
: 17 mm head (66).
2. Remove plug (30) from gear casing (47) to drain : 10 mm
gear oil. (Approx 1.0 L, 0.2642 US gal)
: 22 mm NOTE: When loosening the socket bolts, the se-
3. Remove socket bolts (1) (4 used) to remove right lector head will jump out due to the force of
regulator (2) from pump casing (51). spring (16). Be sure to record the clearance
: 8 mm between pump casing (51) and the selector
head to ensure the internal parts of pump
NOTE: Pry up the right regulator to the selector casing is in correct position when reas-
head (66) side for easy removal. sembling.
W178-02-04-055
W2-4-5
UPPERSTRUCTURE / Pump Device
18
17
16
15
13
17
53 15
19
51
28
27
26
66 71
47
29 64
26 63
60 72
61
58 62
61 73
74
58
61
77
78 61
60
78
79 58
60
79 W178-02-04-011
W2-4-6
UPPERSTRUCTURE / Pump Device
11. Remove set screw (72) out of servo piston (73), 17. Remove bolts (53) (6 used) from gear casing (47).
then remove pins (74). (2 places) : 24 mm
NOTE: LOCTITE has been applied to the set CAUTION: Pump casing weight: 105 kg
screw. Heat it with a drier etc. for easy re- (230 lb)
moval.
: 6 mm 18. Install eye bolt (M12, Pitch 1.75) to the threaded
hole for socket bolt (71) of pump casing (51), lift it
12. Pull out servo piston (73) from selector head (66). up by crane, remove the pump casing from gear
(2 places) casing (47). At this time, shafts (13) and (19),
gears (27), (29) and etc. are removed with the
13. Remove backup ring (63) and O-ring (64) from pump casing.
pump casing (51). Place the pump casing with the mounting surface
of the regulator facing up.
IMPORTANT: Both valve plates (62, right), (77, left)
are very similar. Their installation 19. Remove gasket (28) from gear casing (47).
direction are determined. Record
their position and direction before IMPORTANT: The position where the gears en-
disassemble. gaging is determined. Make aligning
marks on the gears for easy reas-
14. Remove retaining rings (58) (8 used) from pins sembling.
(61) (4 used) and (78) (4 used) to remove levers
(60) (4 used) and valve plates (62, right) and (77, 20. Make aligning marks on meshed position of
left) from links (79) (2 used). splines on shafts (13) (19) and gears (27) (29).
And make aligning marks on meshed position of
NOTE: Pin (61) has been attached on valve plates gears (27) and (29).
(62) and (77) with LOCTITE. Do not re-
move it unless necessary. 29
27
15. Remove rotor (18), spring (16), center shaft (15)
and plunger (17) from pump casing (51) in order.
(Both right and left)
W137-02-04-007
IMPORTANT: If link (79) is distorted, the pump
performance will be changed. Don’t
21. Remove retaining rings (26) from shafts (13) and
apply excess loads.
(19), and then remove gears (27) and (29).
W2-4-7
UPPERSTRUCTURE / Pump Device
13
12
11
10
9
19
12
51
20
11
49 10
9
50 24
49
47
46
45
40
41
42
43
44 W178-02-04-004
42
W2-4-8
UPPERSTRUCTURE / Pump Device
22. Remove stopper (24) from pump casing (51). 27. Remove bearings (10) and (12) as well as ring
(11) from shafts (13) and (19) with a press.
CAUTION: Pump casing weight: 70 kg (154 lb)
CAUTION: Pump casing weight: 42 kg (93 lb)
23. Attach a nylon sling to pump device (51), lift it up
and place the pump casing on the wooden blocks 28. Attach a nylon sling to pump casing (51), lift it up
with mission side facing down. Wooden block by crane and position the regulator with the
size: 100 mm or more in width and height. mounting surface facing up.
24. Remove shafts (13) and (19) from pump casing 29. Remove retaining rings (50) (2 used), oil seals
(51) with special tool (ST 1470) (ST 1471). At this (49) (2 used) from pump casing (51).
time, bearings (10) and (12) are removed with the
shafts. 30. Remove retaining ring (40) from gear casing (47)
and remove retaining ring (41) from gear shaft
Special Tool
ST 1470 (44).
Special Tool
ST 1471 31. Pull out upper ball bearing (42) and gear shaft
(44) from gear casing (47) using special tool (ST
13 1393).
19
44
51
42
W178-02-04-054
26. Remove bearing nut (9) from shafts (13) and (19) W178-02-04-009
34. Remove retaining ring (45), oil seal (46) from gear
casing (47).
W137-02-04-023
W2-4-9
UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
77 64 63 18 16 15 17 12 20 11 10 9 49 29
26
19
50
13
26
27
62 58,61 60 18 78 16 15 17 12 11 9 49
10
68 69 67 70 8 7 54 55 59 58
57 56 51
66
73
72
74
76 79 14 24 23
21
65 22 W178-02-04-003
75
68
W2-4-10
UPPERSTRUCTURE / Pump Device
32, 33, 34
30, 31 39 36, 37, 38 25 6 5 4 35 3 41 40 43 42
44
45
46
48
47
W178-02-04-002
71 2 1 53 52 28
W2-4-11
UPPERSTRUCTURE / Pump Device
30, 31 25 41 40 42 43
42
44
47
W178-02-04-002
51 12 20 11 10
19
13
12 11 10 9 W178-02-04-013
W2-4-12
UPPERSTRUCTURE / Pump Device
1. With a guide bar and hammer, tap the inside ball 10. Set the pre-loads of bearings (10) and (12) installed
bearing (42) into gear casing (47), with the stamp on shaft (13) according to the following proce-
mark facing inside. dures.
• Apply a film of hydraulic oil to bearing nut (9)
NOTE: Tap the bearing and listen to ring to confirm threads. Tighten bearing nut (9) until it comes in
installation is completed. contact with bearing (10) using special tool (ST
3058).
2. Put gear (43) to ball bearing (42), insert gear shaft ST 3058
(44) while aligning the spline.
9
10
3. With a guide bar and hammer, tap the outside ball
bearing (42) into gear casing (44), with the stamp
mark facing outward.
4. Install retaining ring (40) onto gear casing (47), • Attach special tool (ST 3070) on bearing (10),
and install retaining ring (41) onto gear shaft (44). rotate bearing (10) 2 to 3 turns and measure the
starting torque.
5. Install O-ring (31) onto plug (30) and install them
to gear casing (47). ST 3070
: 22 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 10
W2-4-13
UPPERSTRUCTURE / Pump Device
12 20 10 49
19
50
13
49
51
24 23 W178-02-04-003
W2-4-14
UPPERSTRUCTURE / Pump Device
13. Heat pump casing (51) to 50 to 80 °C (122 to 176 19. Install special tools (ST 2649), (ST 2650) over the
°F). spline parts of shafts (13) and (19).
CAUTION: Use special tool to insert the shaft NOTE: If the special tools are not available, wind
(19) assembly, because pump casing (51) has vinyl tape and etc. over spline part of the
been heated. shaft to protect the oil seal (49) from being
damaged.
14. Apply a film of hydraulic oil to the outside of bear-
ings (10), (12) installed on shaft (19), install shaft
(19) to pump casing (51) using the special tool.
If it is difficult to insert, tap in shaft (19) with a
ST 2650
guide bar, etc.
49
Special Tool
51
19 W157-02-04-022
ST 2649
15. Install shaft (13) into pump casing (51), using the 21. Remove special tool (ST 2649), (ST 2650) from
same procedure as above step 14. shafts (13) and (19).
16. Wait for pump casing (51) cooling down to the 22. Install retaining rings (50) (2 used) to pump casing
temperature lower than 40 °C (104 °F). (51).
W2-4-15
UPPERSTRUCTURE / Pump Device
42
44
47
48
W178-02-04-002
71 53 52 28
66 60 58, 78 79 15 14 17 51 29
26
19
13
26
60 58, 78 79 15 14 17 27 W178-02-04-013
W2-4-16
UPPERSTRUCTURE / Pump Device
23. Install gears (27) and (29) onto shafts (13) and 26. Apply THREEBOND #1215 to the mounting sur-
(19), aligning the matching marks made when face of pilot pump (39), install the pilot pump to
disassembling, and install retaining rings (26) (2 gear casing (47) with socket bolts (36), spring
used). washers (37), washers (38) (2 for each).
When replacing the shafts and gears, install the : 8 mm
gear according to the following procedure. : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
• Secure the special tool (ST 7934) to the mounting
surface of shafts (13) and (19) for plunger (17) . 27. Install gasket (32), pipe (34) to gear casing (47).
Tighten them with socket bolts (33) (2 used).
19 : 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 Ibf⋅ft)
ST 7934 13
28. Install levers (60), pins (78), retaining rings (58) (4
for each) to links (79) (2 used).
• Turn shafts (13) and (19) clockwise, viewed from 29. Install the link (79) assemblies (2 used), aligning
the mounting side of gears (27) and (29), until it the groove for pin (57) in pump casing (51). At this
comes into contact with the special tool. (To re- time, lever (60) faces selector head (66).
move the play in periphery direction)
• Install gear (27) and retaining ring (26) to the NOTE: Both surfaces of pin (57) are parallel to
spline of shaft (13). each other. Insert the pin aligning the par-
• Install gear (29) onto the spline of shaft (19), with allel face with the groove.
engaging to gear (27). If it does not engage, turn
57
shaft (19) in the play range of special tool to find 79
the engaging position. 51
• Install retaining ring (26) to the spline of shaft
(19).
• Remove the special tool.
24. Tap spring pins (48) (2 used) into gear casing (47), Parallel Face Parallel Face W176-02-04-016
and install gasket (28).
30. Apply hydraulic oil to the plunger (17) mounting
CAUTION: Pump casing weight: 70 kg (154 lb) surface of shafts (13) and (19).
25. Install eye bolts (M12, Pitch 1.75) (2 used) to the 31. Insert plungers (17) (7 for each) into shafts (13)
threaded hole for socket bolt (71) in pump casing and (19).
(51), lift it up by crane.
Engaging gear (43) and gear (29), install the 32. Apply a film of grease to pins (14) (2 used), and
gears into gear casing (47). Install the gear casing then install them to center shafts (15) (2 used).
to the pump casing with bolts (53), spring wash-
ers (52) (6 for each). 33. Apply a film of grease to the spherical surface of
: 24 mm center shafts (15) (2 used), and then install them
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft) to shafts (13) and (19).
W2-4-17
UPPERSTRUCTURE / Pump Device
58 60 18 16 79 18 15 14 17 51
61
77
W178-02-04-013
62 58, 61 60 18 58, 78 79 16 15 14 17
8 7 54 55 59 56
5 6 3
66
72
74
73
2 1
64 63 W178-02-04-018
W2-4-18
UPPERSTRUCTURE / Pump Device
34. Install springs (16) (2 used) to center shafts (15) 41. Install right regulator (2) into pump casing (51),
(2 used). according to the following procedure.
• Adjust the sleeve position so that the grooves in
35. Insert center shafts (15) (2 used) and plungers both sleeves on the right regulator are in a line.
(17) (14 used) into rotors (18) (2 used). • Put the right regulator on the pump casing, install
pin (59) for link (79) into the both grooves in the
36. Insert a file’s shank etc. into the center hole of sleeve.
center shaft (15), rotate the center shaft to install • Move the right regulator, so that spring pin (54)
pin (14) into the groove of rotor (18). (Both right extended from the pump casing can enter into the
and left pump) right regulator.
• Install the right regulator into the pump casing
NOTE: If the pin does not enter into the groove of with socket bolts (1) (4 used).
the rotor, selector head (66) cannot be as- : 8 mm
sembled to pump casing (51). : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
59
37. Apply a film of LOCTITE LI829 to the threads of 2 Sleeve
pins (61) (4 used), and then install the pins to
valve plates (62, right) and (77, left).
: 7 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
W178-02-04-014
45. Install pin (74) into servo piston (73), fix the servo
piston with set screw (72). (Both right and left
IMPORTANT: Pay attention to the mounting direc- servo pistons)
tion of left regulator (77). Beforehand, apply a film of LOCTITE LI829 to the
threads of the set screw.
39. Insert pins (61) (2 used) for left valve plate (77) : 6 mm
into the hole of levers (60) (2 used) for left regu- : 34.3 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
lator (6), and install retaining rings (58) (2 used).
W2-4-19
UPPERSTRUCTURE / Pump Device
25 35 34
45
46
47
W178-02-04-002
71
68 67 69 70 18 51
19
66
74
Mounting Surface
for Suction Pipe
W178-02-04-016
75 68 62 76 65 14
W2-4-20
UPPERSTRUCTURE / Pump Device
46. Install spring pins (65) (2 used) into selector head
CAUTION: Pump device weight: 160 kg
(66).
(350 lb)
CAUTION: Selector head weight: 29 kg (64 lb) 52. Install eye bolts (M12, Pitch 1.75) (4 used) to the
threaded hole for suction pipe in selector head
47. Install eye bolts (M12, pitch 1.75) (2 used) into the (66). Lift the selector head up by crane and posi-
threaded hole for suction pipe in selector head tion it with the regulator mounting side upward.
(66), lift it up by crane.
Install the selector head on pump casing (51), 53. Insert special tool (ST 2650) on shaft (19). Apply a
while aligning the selector head with spring pin film of grease to oil seal (46) and install the oil
(65). seal to shaft (19).
Pull out the special tool, tap oil seal (46) into the
NOTE: Measure the clearance between the se- gear casing.
lector head and pump casing. Compare it
with the clearance which was recorded NOTE: If special tool (ST 2650) is not available,
during disassembling. If it is larger, pin (14) wind vinyl tape etc. over the spline parts of
can’t be inserted into the groove in rotor shaft (19) to protect the oil seal from being
(18), or pin (14) can’t be inserted into the damaged, and then install the oil seal.
holes in valve plates (62) and (77). Please ST 2650
confirm it.
56. Wind the plug (25) with seal tape and install it to
gear casing (47).
: 17 mm
: 39.5 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
W2-4-21
UPPERSTRUCTURE / Pump Device
DISASSEMBLE REGULATOR
1 2 3
6 7 8 9 10 11 12 13 14 15
5 16
4 17
18
19
33
W176-02-04-001
32
31 30 29 28 27 26 25 24 23 22 21 20
W2-4-22
UPPERSTRUCTURE / Pump Device
Disassemble Regulator
• Regulators are used for right pump and left pump. 5. Pull out springs (23) and (24) from casing (9).
The regulator’s inner structure is fully identical,
and the difference is only in its accessories. Here 6. Insert a round bar into the hole of casing (9). Push-
is the description of left regulator. ing the spool (26) end, push out cylinder (28),
sleeve (25) and the spool from the casing. At this
IMPORTANT: If adjusting screws (4, 5, 16, 17, 18 time, piston (27) is removed with the cylinder.
and 19) are disassembled, their set
values will change. So, do not 7. Pull out piston (27) from cylinder (28).
disassemble them.
When these adjusting screws must 8. Remove spring (8) from casing (9).
be disassembled, carry out adjust-
ment according to the procedure of 9. Insert a round bar into the hole of casing (9).
performance test after assembling. Pushing the spool (10) end, push out cylinder (13),
sleeve (11) and the spool. At this time, piston (12)
1. Clamp casing (9) in a vise, then remove pipe (1) is removed with the cylinder.
from the casing.
: 17 mm 10. Pull out piston (12) from cylinder (13).
W2-4-23
UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR
1 2 3
6 7 8 9 10 11 12 13 14 15
5 16
4 17
18
19
33
W176-02-04-001
32
31 30 29 28 27 26 25 24 23 22 21 20
W2-4-24
UPPERSTRUCTURE / Pump Device
Assemble Regulator
IMPORTANT: Two holes for sleeve in casing (9) 9. Install O-ring (22) and springs (23), (24) to stop-
are with identical bores, and the per assembly (21) on cover (15). Install the cover
shapes of various parts are very on casing (9) with socket bolts (20) (4 used).
similar. Pay attention not to misas- : 6 mm
semble them. Perform assembling : 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
as illustrated.
10. With socket bolts (2) (2 used), install solenoid
1. Clean all parts neatly and apply hydraulic oil. valve (3) onto casing (9).
: 8 mm
IMPORTANT: Pay attention to the direction for : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
sleeve (11), spool (10) and piston
(12) when assembling. 11. Apply a film of grease to the threaded part of pipe
(1). Install pipe (1) to casing (9).
2. Insert spool (10) into sleeve (11). With a round bar, : 17 mm
assemble it at the position closed to the center of : 34 N⋅m (3.5 kgf⋅m, 25.3 Ibf⋅ft)
casing (9).
W2-4-25
UPPERSTRUCTURE / Pump Device
DISASSEMBLE SOLENOID VALVE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
W178-02-04-050
W2-4-26
UPPERSTRUCTURE / Pump Device
Disassemble Solenoid Valve IMPORTANT: Do not remove orifice (13) from
• Be sure not to damage the mating surface for the spool (12).
regulator.
• When replacing inner parts, replace solenoid 4. Remove retaining ring (6), then remove spring (7)
valve as an assembly. and spool (12).
• Pay attention not to hit the solenoid part.
• When removing the connector, do not pry, but pull NOTE: Spool (7) and spool (12) should be pulled
out straight. out from the opposite direction.
1. Remove socket bolt (1), then remove solenoid (2) 5. Remove filters (16), (20) from body (17).
and O-ring (4). : 6 mm
: 4 mm
NOTE: When cleaning filter (16), first blow the filter
NOTE: When solenoid (2) is removed, O-ring (4) with air from both surfaces, and finally blow
and spring (3) may come off occasionally. the filter with air from outer side (threaded
side).
2. Using special tool (ST 2953), pull out the sleeve
(11) assembly from body (17).
W178-02-04-052
W2-4-27
UPPERSTRUCTURE / Pump Device
ASSEMBLE SOLENOID VALVE
2 1 5 6 7 11 12 13 14 15 17 16
3 4 8 9 10
21 20
19
18
W178-02-04-051
W2-4-28
UPPERSTRUCTURE / Pump Device
Assemble Solenoid Valve IMPORTANT: When installing sleeve (11), keep the
1. Install filters (16), (20) onto body (17). sleeve end and body (17) end in the
: 6 mm same position.
: 10+3 N⋅m (1+0.3 kgf⋅m, 7.2+2.2 Ibf⋅ft) In addition, when installing the
sleeve, be sure not to pry and cause
2. Install wave washer (15) and plate (14) on body damage to O-ring.
(17).
5. Using special tool (ST 2953), install sleeve (11)
NOTE: When body (17) is horizontally inserted, assembly to body (17).
apply a film of grease to wave washer (15)
and plate (14) to prevent them from coming NOTE: When there is no special tool (ST 2953)
off. available, tighten solenoid (2) alternately
After assembling, check for straight posi- with socket bolts (1) (2 used). Then sleeve
tion of plate (14). (11) end and body (17) end should be
placed in the same position. Install the so-
3. Install O-rings (8), (9) and (10) to sleeve (11). lenoid.
W178-02-04-052
W2-4-29
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
27
13
26
10
10
1
12
9
6
26
14
27
6
9
2
3
5
16
15
7
W137-02-04-034
12
W2-4-30
UPPERSTRUCTURE / Pump Device
IMPORTANT: The housing is made of aluminum.
Be sure not to damage it. Besides,
take extreme care to control tight-
ening torque.
W2-4-31
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
Pump Device
Unit: mm (in)
Standard Allowable Limit Remedy
Gear Backlash 0.68 (0.027) 1.5 (0.059) Replace
Main Pump
1. Drive Disc: Spline tooth thickness.
Unit: mm (in)
Standard Allowable Limit 1
W157-02-04-017
W2-4-32
UPPERSTRUCTURE / Pump Device
5. Plunger clearance between connecting rod and
plunger
Unit: mm (in)
Standard Allowable Limit
0.15 (0.0059) 0.4 (0.0157) Plunger
Conneting Rod
D-a D
a Large Diameter
End
8. Clearance between servo pin and valve plate D W157-02-04-018
D-a
Unit: mm (in)
Standard Allowable Limit
0.051 (0.0020) 0.3 (0.0118)
D a
W157-02-04-019
W2-4-33
UPPERSTRUCTURE / Pump Device
(Blank)
W2-4-34
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE Lifting Tool Mounting Part Arm 2 Swing
Arm 1
(M10, Pitch 1.5 mm)
Boom 2
IMPORTANT: Release any pressure in the hydrau- Auxiliary
lic oil tank before doing any work. Travel
(Refer to BLEED AIR FROM HY- Left
DRAULIC OIL TANK on W1-4-1.)
Travel
Right
Removal (ZAXIS200, 200-E)
Boom 1
NOTE: Control valves of ZAXIS225US, 225USR
are installed in different direction, even if Bucket
their bodies look same.
IMPORTANT: Attach labels or tags, to aid in reas- Lifting Tool Mounting Part
(M10, Pitch 1.5 mm)
sembling.
W178-02-05-001
W2-5-1
UPPERSTRUCTURE / Control Valve
Installation Lifting Tool Mounting Part Arm 2 Swing
Arm 1
(M10, Pitch 1.5 mm)
NOTE: Refer to "Removal" section above for Boom 2
wrench sizes and tightening torques. Auxiliary
Travel
Left
CAUTION: Control valve weight: 183 kg (400 lb) Travel
Right
1. Install the control valve with bolts (1) (4 used).
Swing
Arm 1
Boom 2
Auxiliary
Arm 2
Travel Left
Boom 1
Bucket
Travel Right W178-04-02-007
W178-02-05-001
W2-5-2
UPPERSTRUCTURE / Control Valve
Removal (ZAXIS225US, 225USR)
W178-02-05-032
W2-5-3
UPPERSTRUCTURE / Control Valve
Installation
NOTE: For wrench sizes and tightening torques,
refer to "Removal" section.
1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) into Travel Left Lifting Tool Mounting
control valve, lift and place the control valve onto Auxiliary
Part (M10, Pitch 1.5 mm)
bracket (2) by crane.
Boom 2
2. Install control valve onto bracket (2) with bolts (1) Arm 1
(4 used). Swing
W178-02-05-032
W2-5-4
UPPERSTRUCTURE / Control Valve
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work.
(Refer to BLEED AIR FROM HY-
Body Front Side
DRAULIC OIL TANK on W1-4-1.)
Travel Right
Bucket
Removal (ZAXIS230, 270)
Boom 1
Travel Left Arm 2
NOTE: Control valves of ZAXIS200, 200-E, 225UR, Lifting Tool
Main Relief Valve
225USR are installed in different direction, Mounting Part
even if their bodies look same. Lifting Tool (M10, Pitch 1.5 mm)
Mounting Part
(M10, Pitch 1.5 mm)
IMPORTANT: Attach labels or tags to aid in reas-
sembling. Auxiliary
Boom 2
IMPORTANT: Cap the ends of all disconnected Arm 1
hoses and pipes.
Swing
1. Disconnect all hoses, pipes and connectors from
the control valve.
: 17 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
Swing Makeup W178-02-05-035
: 19 mm Port
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
W178-02-05-036
W2-5-5
UPPERSTRUCTURE / Control Valve
Installation (ZAXIS 230, 270)
NOTE: For wrench sizes and tightening torques, Body Front Side
refer to "Removal" section. Travel Right
Bucket
Boom 1
CAUTION: Control valve weight: 160kg (350 lb)
Travel Left Arm 2
Lifting Tool
1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) into Main Relief Valve
Mounting Part
control valve, lift and place the control valve onto Lifting Tool (M10, Pitch 1.5 mm)
bracket (2) by crane. Mounting Part
(M10, Pitch 1.5 mm)
2. Install control valve onto bracket (2) with bolts (1) Auxiliary
(4 used).
Boom 2
W178-02-05-036
W2-5-6
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-7
UPPERSTRUCTURE / Control Valve
DISASSEMBLE CONTROL VALVE
4-SPOOL SECTION
9
8
10
3 4
2 11
5
Boom Anti-Drift
6 Valve (Switch
7 13
Valve)
14
12 15
1 16
17
18
19
20
55 19 21
22
54
29 23
53 24
35
52 30 25
47 36 26
37 31 27
51 46 39
45 38 32 28
50 44 Check
43 Valve (Arm 33
42 Regenerative
49 41 Arm Regenerative Valve
Circuit)
40
48 34
Flow Combiner Valve W178-02-05-013
W2-5-8
UPPERSTRUCTURE / Control Valve
• Be sure to thoroughly read “Precautions for 7. Remove overload relief valves (2, 7) from housing
Disassembly and Assembly” (W1-1-1) before (1).
starting the disassembly work. : 32 mm
• Attach identification tags to the spool and mount-
ing positions in the housing in order to avoid mis- 8. Remove socket bolts (40, 42, 44, 46) from hous-
assembling. ing (1) to remove caps (41, 43, 45, 47) and O-ring
(39).
1. Remove socket bolt (5) from housing (1), and : 8 mm
remove pilot housing (4) and O-rings (3, 6).
: 8 mm 9. Remove plug (38), O-ring (37), spring (36), and
poppet (35) from housing (1).
IMPORTANT: Remove spools (8, 9, 10, 11) while : 6 mm
carefully moving them. If they stick,
even a little, try it again instead of 10. Remove socket bolt (48) from housing (1) to
pulling roughly. remove cap (49), O-ring (50) and the spool (55)
Make identification marks on spools assembly.
(8, 9, 10, 11) and housing (1) in order : 4 mm
to avoid confusion during reassem-
bling. 11. Clamp spool (55) with wooden pieces in a vise.
Remove bolt (51), spring seat (52), spring (53)
2. Remove spool assemblies (8, 9, 10, 11), spring and spring seat (54).
(29) and the spool (33) assembly from housing : 8 mm
(1).
12. Remove overload relief valve (34) from housing
NOTE: Don’t disassemble the spool (33) assembly (1).
unless necessary. : 32 mm
W2-5-9
UPPERSTRUCTURE / Control Valve
56 60 75 87
57 61 76 88
89
58 62 77
90
59 63 78
64 79
91
65 80
66 81
8
67
92
68
93
69
10
9
11
82
83
84
70
71 85
72 86
73
74
W178-02-05-016
W2-5-10
UPPERSTRUCTURE / Control Valve
• Disassemble spool (travel right) • Disassemble boom 1 spool
13. Clamp spool (8) with wooden pieces in a vise. 19. Clamp spool (10) with wooden pieces in a vise.
Remove bolt (56), spring seat (57), spring (58), Remove bolt (75), spring seat (76), spring (77)
and spring seat (59). and spring seat (78).
: 8 mm : 8 mm
• Disassemble bucket spool 20. Heat the plug (79) part of spool (10) with a drier to
14. Clamp spool (9) with wooden pieces in a vise. melt LOCTITE. Remove plug (79) using tool (ST
Remove bolt (60), spring seat (61), spring (62) 5909).
and spring seat (63).
ST 5909
: 8 mm
15. Heat the plug (64) part of spool (9) with a drier to
melt LOCTITE. Remove plug (64) using tool (ST
5909). W157-02-05-049
ST 5909
21. Turn over spool (10) and clamp it in a vice. Heat
the plug (86) part of spool (10) with a drier to melt
LOCTITE. Remove plug (86) using tool (ST
5909).
W157-02-05-049
ST 5909
17. Turn over spool (9) and clamp it in a vice. Heat W157-02-05-049
W2-5-11
UPPERSTRUCTURE / Control Valve
142
141
140
W178-02-05-011
W2-5-12
UPPERSTRUCTURE / Control Valve
24. Loosen plug (102) from body (107).
: 36 mm
W2-5-13
UPPERSTRUCTURE / Control Valve
DISASSEMBLE CONTROL VALVE
5-SPOOL SECTION
151
152
150
149
153
148
154
155
147
193
W178-02-05-012
W2-5-14
UPPERSTRUCTURE / Control Valve
• Be sure to thoroughly read “Precautions for Dis- 7. Remove plug (173), spring (176) and poppet
assembly and Assembly” (W1-1-1) before starting (177) from housing (145).
the disassembly work.
• Attach identification tags to the spool and mount- 8. Remove overload relief valve (178) and main re-
ing positions in the housing in order to avoid mis- lief valve (147) from housing (145).
assembling. : 32 mm
1. Remove socket bolt (148) from housing (145). 9. Remove socket bolts (184, 186, 188, 190, 192)
Remove pilot housing (150) and O-ring (149). from housing (145). Remove caps (183, 185, 187,
: 8 mm 189, 191) and O-ring (182) from housing (145).
: 8 mm
IMPORTANT: Remove spools (151, 152, 153, 154,
155) while carefully moving them. If 10. Remove socket bolt (193) from housing (145).
they stick, even a little, try it again Remove cap (194), O-ring (195), spring washer
instead of pulling roughly. (196), spring (197) and spool (198) from housing
Make identification marks on spools (145).
(151, 152, 153, 154, 155) and housing : 4 mm
(1) in order to avoid confusion dur-
ing reassembling. 11. Remove overload relief valve (181) from housing
(145).
2. Remove spool (151, 152, 153, 154, 155) assem- : 32 mm
blies from housing (145).
W2-5-15
UPPERSTRUCTURE / Control Valve
151 -Spool (Travel Left) 201 -Spring 208 -Spring Seat 215 -Bolt
152 -Spool (Auxiliary) 202 -Spring Seat 209 -Spring 216 -Spring Seat
153 -Spool (Boom 2) 203 -Bolt 210 -Spring Seat 217 -Spring
154 -Spool (Arm 1) 204 -Spring Seat 211 -Bolt 218 -Spring Seat
155 -Spool (Swing) 205 -Spring 212 -Spring Seat
199 -Bolt 206 -Spring Seat 213 -Spring
200 -Spring Seat 207 -Bolt 214 -Spring Seat
W2-5-16
UPPERSTRUCTURE / Control Valve
• Disassemble spool (travel left)
12. Clamp spool (151) with wooden pieces in a vise.
Remove bolt (199), spring seat (200), spring (201)
and spring seat (202).
: 8 mm
W2-5-17
UPPERSTRUCTURE / Control Valve
226
225 Arm Anti-Drift Valve
224 (Poppet Valve)
223
222
221
220
219
227
145
228
Check Valve (Auxiliary
Flow Combining Circuit) 233
232
231
230 Load Check Valve
229 (Travel Parallel Circuit)
Auxiliary Flow Control Valve 253
252
234 251
235 250
243
236 244
237
238 249 284
239 248 285
240 247
246
245
277
241 276
259
242 275
258
257 268
260 269 282
256 261
255 281
Load Check Valve 262 280
254
(Boom 2 Parallel 263 274 279
Circuit)
264 273 278 Load Check Valve
272 (Swing)
265 271
270
266
267
W2-5-18
UPPERSTRUCTURE / Control Valve
17. Remove socket bolt (229) from housing (145) to 25. Remove sleeve (244), spring (245), plug (246),
remove flange (230), O-ring (231), spring (232) spring (247) and poppets (248, 249) from housing
and poppet (233). (145).
: 8 mm
26. Loosen plug (259) of body (264).
18. Remove plug (250), O-ring (251), spring (252) : 36 mm
and poppet (253) from housing (145).
: 6 mm 27. Remove socket bolt (265) from housing (145) to
remove the body (264) assembly and O-ring
19. Remove socket bolt (222) from housing (145) to (268).
remove flange (223), O-ring (224), spring (225) : 8 mm
and poppet (226).
: 8 mm 28. Remove plug (259), O-ring (260), spring seat
(261), spring (262), and spool (263) from body
20. Remove socket bolt (254) from housing (145) to (264).
remove flange (255), O-ring (256), spring (257)
and poppet (258). 29. Remove sleeve (269), spring (270), plug (271),
: 8 mm spring (272) and poppets (273, 274) from housing
(145).
21. Remove socket bolt (278) from housing (145) to
remove flange (279), O-ring (280), spring (281)
and poppet (282).
: 8 mm
W2-5-19
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE
CONTROL VALVE
4-SPOOL AND 5-SPOOL SECTIONS 302
301
Check Valve 300
(Main Relief Circuit) 299
292
293 298
294 297
295 303
296
304
Check Valve (Orifice) 305
(Boom Circuit) 306
288 1
Check Valve 289 291
(Flow Combiner Valve Circuit) 290
283
284
285
286
287
307
308
Check Valve 309
(Main Relief Valve) 310
311
312
318 313
321
322 314 317
323 319 315
316
324
320
325
326
327
328
329
Load Check Valve 330
(Travel Tandem Circuit)
145
W178-02-05-014
331
W2-5-20
UPPERSTRUCTURE / Control Valve
• Be sure to thoroughly read “Precautions for Dis-
assembly and Assembly” (W1-1-1) before starting
the disassembly work.
Disassemble Assemble
1. Remove socket bolts (283, 292) from housing (1) 1. Install O-rings (297 to 320) onto the mounting sur-
to remove flanges (284, 293), O-rings (285, 294), face of the housing.
springs (286, 295) and poppet (287, 296).
: 8 mm
CAUTION: Housing (1) weight: 75 kg (165 lb)
2. Remove plug (288), O-ring (289), spring (290) Housing (145) weight: 74 kg (163 lb)
and poppet (291) from housing (1).
: 6 mm 2. Connect housing (1) and housing (145) with
socket bolt (331).
3. Remove socket bolts (321, 326) from housing : 14 mm
(145) to remove flanges (322, 327), O-rings (323, : 167 to 177 N⋅m
328), springs (324, 329) and poppets (325, 330). (17 to 18 kgf⋅m, 123 to 130 Ibf⋅ft)
: 8 mm
3. Install poppets (325, 330), springs (324, 329),
O-rings (323, 328), flanges (322, 327) and socket
CAUTION: Housing (1) weight: 75 kg (165 lb) bolts (321, 326) into housing (145).
Housing (145) weight: 74 kg (163 lb) : 8 mm
: 61±3 N⋅m
4. Remove socket bolt (331), and separate housing (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)
(1) and housing (145).
: 14 mm 4. Install poppet (291), spring (290), O-ring (289)
and plug (288) into housing (1).
5. Remove O-rings (297 to 320) from the mounting : 6 mm
surface of the housing. : 76±3 N⋅m
(7.8±0.3 kgf⋅m, 56.4±2.2 Ibf⋅ft)
W2-5-21
UPPERSTRUCTURE / Control Valve
ASSEMBLE CONTROL VALVE 4-SPOOL 115
SECTION 120
114
121
118
B
A
C 117 119
139
116
123
122
111 112 113 124
W178-02-05-022
108
1
W178-02-05-017
Section B Section C
T178-03-03-009
Section D
99 98 97 96 95 94
130 102
131
103
132 105
104
128 106
129 109
127
133 126
134 110 107 101 100 T178-03-03-013
125
W178-02-05-020
1 - Housing 106 -Spool 119 -O-Ring 132 -O-Ring
94 - Poppet 107 -Body 120 -Nut 133 -Flange
95 - Poppet 108 -Socket Bolt 121 -Nut 134 -Socket Bolt
96 - Spring 109 -O-Ring 122 -Socket Bolt 135 -Spool
97 - Plug 110 -Plug 123 -O-Ring 136 -Spring
98 - Spring 111 -Poppet 124 -Plug 137 -O-Ring
99 - Sleeve 112 -Spring 125 -Poppet 138 -Flange
100 -O-Ring 113 -O-Ring 126 -Spring 139 -Socket Bolt
101 -O-Ring 114 -O-Ring 127 -O-Ring
102 -Plug 115 -O-Ring 128 -Flange
103 -O-Ring 116 -Body 129 -Socket Bolt
104 -Spring Seat 117 -O-Ring 130 -Poppet
105 -Spring 118 -Screw 131 -Spring
W2-5-22
UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly and
Assembly” (W1-1-1) before starting the assembly
work.
1. Install spool (135), spring (136), O-ring (137), 5. Install poppet (95), spring (96), plug (97), spring
flange (138) and socket bolt (139) into housing (98) and sleeve (99) into poppet (94).
(1).
: 8 mm 6. Install spool (106), spring (105) and spring seat
: 61±3 N⋅m (104) onto body (107). Tighten plug (102) tem-
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft) porarily.
: 36 mm
2. Install poppet (130), spring (131), O-ring (132),
flange (133) and socket bolt (134) into housing 7. Install the poppet (94) assembly into housing (1).
(1). Install body (107) onto the housing with socket
: 8 mm bolt (108).
: 61±3 N⋅m : 8 mm
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft) : 61±3 N⋅m
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)
3. Install poppet (125), spring (126), O-ring (127),
flange (128) and socket bolt (129) into housing 8. Completely tighten plug (102) which was tempo-
(1). rarily tightened in step 6.
: 8 mm : 36 mm
: 61±3 N⋅m : 98 N⋅m (10 kgf⋅m, 72.3 Ibf⋅ft)
(6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)
W2-5-23
UPPERSTRUCTURE / Control Valve
W178-02-05-017
87 75 60 56
88 76 61 57
89
91 77 62 58
90
92
93 78 63 59
79 64
80 65
81 66 6
67
69
11 10 9 8
82 70
71
83
72
84
85 73
86 74
W178-02-05-023
8- Spool (Travel Right ) 63 - Spring Seat 74 - Plug 85 - Backup Ring
9- Spool (Bucket) 64 - Plug 75 - Bolt 86 - Plug
10 - Spool (Boom 1) 65 - Backup Ring 76 - Spring Seat 87 - Bolt
11 - Spool (Arm 2) 66 - O-Ring 77 - Spring 88 - Spring Seat
56 - Bolt 67 - Sleeve 78 - Spring Seat 89 - Spring Seat
57 - Spring Seat 68 - Spring 79 - Plug 90 - Spring
58 - Spring 69 - Poppet 80 - Backup Ring 91 - Spring
59 - Spring Seat 70 - Poppet 81 - O-Ring 92 - Spring Seat
60 - Bolt 71 - Spring 82 - Poppet 93 - Spring Seat
61 - Spring Seat 72 - O-Ring 83 - Spring
62 - Spring 73 - Backup Ring 84 - O-Ring
W2-5-24
UPPERSTRUCTURE / Control Valve
• Assemble spool (travel right) • Assemble spool (boom 1)
9. Clamp spool (8) with wooden pieces in a vise. In- 17. Clamp spool (10) with wooden pieces in a vise,
stall spring seat (59), spring (58), spring seat (57) with the plug (86) side facing up.
and bolt (56). Install poppet (82), and spring (83) into spool (10).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft) 18. Install O-ring (84) and backup ring (85) into plug
(86). Apply LOCTITE #271 on the threaded part of
• Assemble spool (bucket) the plug.
10. Clamp spool (9) with wooden pieces in a vise,
with the plug (74) side facing up. 19. Install plug (86) into spool (10) with tool (ST
Install poppet (70) and spring (71) into spool (9). 5909).
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
11. Install O-ring (72) and backup ring (73) onto plug
(74). Apply LOCTITE #271 on thread part of plug. 20. Turn spool (10) over, then clamp it in a vise. Install
O-ring (81) and backup ring (80) into plug (79).
12. Install plug (74) onto spool (9) with tool (ST 5909). Apply LOCTITE #271 on the threaded part of the
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft) plug.
13. Turn over spool (9), then clamp it in a vise. Install 21. Install plug (79) into spool (10) with tool (ST
poppet (69), spring (68), and sleeve (67). 5909).
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
14. Install O-ring (66) and backup ring (65) onto plug
(64). Apply LOCTITE #271 on the threaded part of 22. Install spring seat (78), spring (77), spring seat
the plug. (76) and bolt (75) into spool (10).
: 8 mm
15. Install plug (64) onto spool (9) with tool (ST 5909). : 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
• Assemble spool (arm 2)
16. Install spring seat (63), spring (62), spring seat 23. Clamp spool (11) with wooden pieces in a vise.
(61) and bolt (60) onto spool (9). Install spring seats (93, 92), springs (91, 90),
: 8 mm spring seats (89, 88), and bolt (87).
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft) : 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
W2-5-25
UPPERSTRUCTURE / Control Valve
Section E
12
E
G
55
54
53
50
48 52
1
49 51
W178-02-05-025
Section G
W178-02-05-017
13
14
15 17
25
16
18 20
19 26
21
22
23
24
27
28
W178-02-05-021
W2-5-26
UPPERSTRUCTURE / Control Valve
24. Clamp spool (55) with wooden pieces in a vise.
Install spring seat (54), spring (53), spring seat
(52) and bolt (51).
: 4 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
27. Install backup rings (21, 24) and O-rings (22, 23)
onto sleeve (20).
29. Install spring (16) and piston (15) onto body (17).
Install plug (13) with O-ring (14) onto the body
temporarily.
: 38 mm
W2-5-27
UPPERSTRUCTURE / Control Valve
H
7
F
5
2 1
4
1
34
W178-02-05-018
W178-02-05-017
Section H Section F
6 3 11 3 10 3 9 3 8 29
6
33
T178-03-03-018
T178-03-03-042
W2-5-28
UPPERSTRUCTURE / Control Valve
IMPORTANT: After installing spools (8, 9, 10, 11)
into housing (1), push them by hand
to confirm smoothness.
33. Install O-rings (3, 6), pilot housing (4) and socket
bolt (5) into housing (1).
: 8 mm
: 42±2 N⋅m (4.3±0.2 kgf⋅m, 31.1±1.4 Ibf⋅ft)
W2-5-29
UPPERSTRUCTURE / Control Valve
ASSEMBLE CONTROL VALVE 5-SPOOL Section A Section B
SECTION
145 226
222 225
265
240 224
223
W178-02-05-018
246, 271 248, 273
245, 270 249, 274
244, 269
234, 259
235, 260
237, 262
236, 261
238, 263
241, 266
283, 284
W2-5-30
UPPERSTRUCTURE / Control Valve
• Be sure to read “Precautions for Disassembly and
Assembly” (W1-1-1) before starting assembly
work.
W2-5-31
UPPERSTRUCTURE / Control Valve
145 Section C
278
254
282
229 281
C
280
D
E
278
279
W178-02-05-018
Section E Section D W178-02-05-028
253
252 Section F
251
250
258
257
233 256 T178-03-03-044
232
231
254
255
230
W178-02-05-026
145 -Housing 233 -Poppet 254 -Socket Bolt 278 -Socket Bolt
229 -Socket Bolt 234 -Plug 255 -Flange 279 -Flange
230 -Flange 235 -O-Ring 256 -O-ring 280 -O-Ring
231 -O-Ring 252 -Spring 257 -Spring 281 -Spring
232 -Spring 253 -Poppet 258 -Poppet 282 -Poppet
W2-5-32
UPPERSTRUCTURE / Control Valve
10. Install poppet (282), spring (281), O-ring (280),
flange (279) and socket bolt (278) into housing
(145).
: 8 mm
: 61±3 N⋅m (6.3±0.3 kgf⋅m, 45.6±2.2 Ibf⋅ft)
W2-5-33
UPPERSTRUCTURE / Control Valve
Section E
198
195
197
W178-02-05-018
196 194
Section G
W178-02-05-024
151 -Spool (Travel Left) 196 -Spring Washer 204 -Spring Seat 212 -Spring Seat
152 -Spool (Auxiliary) 197 -Spring 205 -Spring 213 -Spring
153 -Spool (Boom 2) 198 -Spool 206 -Spring Seat 214 -Spring Seat
154 -Spool (Arm 1) 199 -Bolt 207 -Bolt 215 -Bolt
155 -Spool (Swing) 200 -Spring Seat 208 -Spring Seat 216 -Spring Seat
193 -Socket Bolt 201 -Spring 209 -Spring 217 -Spring
194 -Cap 202 -Spring Seat 210 -Spring Seat 218 -Spring Seat
195 -O-Ring 203 -Bolt 211 -Bolt
W2-5-34
UPPERSTRUCTURE / Control Valve
• Assemble spool (travel left)
14. Clamp spool (151) with wooden pieces in a vise.
Install spring seat (202), spring (201), spring seat
(200) and bolt (199).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 Ibf⋅ft)
W2-5-35
UPPERSTRUCTURE / Control Valve
147
178
150
148 184
181
156 186
I
188
190
192
183
145 G 185
187
M178-05-003 189
Section G 191
149 151 149 152 149 153 149 154 155 149 W178-02-05-018
Section H
157
158
161 159
169
160
164
174, 175 162
170
173 163
176 165
177 166
167
168
171
172
T178-03-03-041
W2-5-36
UPPERSTRUCTURE / Control Valve
20. Install O-ring (182), caps (183, 185, 187, 189, 26. Install poppet (177), spring (176) and plug (173)
191) and socket bolts (184, 186, 188, 190, 192) onto housing (145).
into housing (145).
: 8 mm IMPORTANT: After installing spools (151, 152, 153,
: 42±2 N⋅m (4.4±0.2 kgf⋅m, 31.8±1.4 Ibf⋅ft) 154, 155) into housing (145), push
them by hand to confirm smooth-
21. Install backup rings (165, 168), and O-rings (166, ness.
167) onto sleeve (164).
27. Install the spools (151, 152, 153, 154, 155) as-
IMPORTANT: Be sure to place spool (169) with the sembly into housing (145).
hole side facing poppet (170) when
installing the spool. 28. Install O-ring (149), pilot housing (150) and socket
bolt (148) into housing (145).
22. Install spool (169), poppet (170), spring washer : 8 mm
(171) and spring (172) into sleeve (164). Then in- : 42±2 N⋅m (4.4±0.2 kgf⋅m, 31.8±1.4 Ibf⋅ft)
stall the sleeve assembly into housing (145).
29. Install main relief valve (147) and overload relief
NOTE: Apply more grease on spring washer (171) valves (178, 181) into housing (145).
and spring (172) to prevent them from : 32 mm
coming off. : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61.5±3.6 Ibf⋅ft)
W2-5-37
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-38
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
7 8 1 2
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work.
(Refer to BLEED AIR FROM HY-
DRAULIC OIL TANK on W1-4-1.)
Front
Removal
1. Disconnect hoses (1 to 4 , 8) and cable (7).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 8 mm W178-02-06-016
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) Plug 6 5 4 3
(for Pull-Out Hole)
W2-6-1
UPPERSTRUCTURE / Swing Device
Installation
NOTE: Refer to “Removal” section above for 7 8 1 2
wrench sizes and tightening torques.
6 5 4 3
necessary. Run the engine and (for Pull-Out Hole)
check the component for any oil
leaks.
W2-6-2
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-3
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING DEVICE
(ZAXIS200, 200-E, 225US, 225USR, 230)
22
23 1
24
2
3
32 21
25 4
31 5
20 6
26 7
19
8
27
18 9
28 10
17
11
29
16
12
30 15 13
14
W178-02-06-004
W2-6-4
UPPERSTRUCTURE / Swing Device
Disassemble Swing Device
(ZAXIS200, 200-E, 225US, 225USR, 230)
CAUTION: Swing device weight: 215 kg CAUTION: Motor weight: 47 kg (100 Ib)
(470 lb)
CAUTION: When hoisting the swing device, 6. Remove motor (1) from ring gear (24).
don’t string the rope suddenly. : 10 mm
1. Install eyebolts (M10) (2 used) to the swing de- NOTE: THREEBOND has been applied on the
vice, then lift it by crane. joint surface. Insert a screwdriver into the
Eyebolt gap between the swing motor and ring
Mounting gear. Then pry it up for easy removing.
Position
7. Remove 1st stage sun gear (2) from 1st stage
carrier (21).
11. Remove 2nd stage sun gear (20) from 2nd car-
rier (18).
W178-02-06-012
12. Remove the 2nd stage carrier (18) assembly
from shaft (30).
3. Remove drain plug (31), then drain off oil.
: 8 mm
W2-6-5
UPPERSTRUCTURE / Swing Device
23
25 21
4
18
10
17
11
16
12
30 15
W178-02-06-004
W2-6-6
UPPERSTRUCTURE / Swing Device
IMPORTANT: The hole for the spring pin located 20. Remove bearing nut (15) from shaft (30) using
on the 1st stage carrier is not a special nut removing tool (ST 2926).
through one. Pay attention to the
tapping-in distance when tapping
the spring pin in. ST 2926
15
13. Tap spring pin (5) on the 1st stage carrier (21)
assembly into pin (4) using special tool (ST 1462).
Stop tapping when the spring pin is driven to the
middle of the pin hole. Don’t try to tap spring pin
(5) to the end.
W178-02-06-006
W2-6-7
UPPERSTRUCTURE / Swing Device
25
26
27
28
29
30
14
W178-02-06-004
W2-6-8
UPPERSTRUCTURE / Swing Device
23. Push the upper end of shaft (30) with a press and 26. Push spline side on propeller shaft (30) with
remove it from housing (25). The inner race of press and remove inner race of roller bearing
roller bearing (26) and sleeve (28) are removed (26) and sleeve (28).
with the shaft.
27. Remove O-ring (29) from sleeve (28).
24. Place pulling tool B (ST 1460) of roller bearing
(26) onto the stepped part of pulling tool A (ST 28. Insert a round bar into the oil passage in housing
1461) for roller bearing (26). (25), tap the outer race of roller bearing (26) out.
ST 1460
Insert Round
Outer Race Bar Here
ST 1461
W178-02-06-001
W178-02-06-010
Press
NOTE: THREEBOND has been applied on the
periphery of oil seal. Thus, it can’t be re-
used.
26
ST 1460 28
ST 1461
W178-02-06-009
W2-6-9
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING DEVICE (ZAXIS270)
34
3
33
4
22
32
21 7
8
20 9
31 23
19 7
24 18
30 10
15
25 11
17
29
26
28
16
12
15
27 13
14
W178-02-06-040
1- Motor 10 - Second Stage Carrier 19 - Pin (3 Used) 27 - Shaft
2- Socket Bolt (12 Used) 11 - O-Ring 20 - Thrust Plate 28 - Sleeve
3- First Stage Sun Gear 12 - Socket Bolt (12 Used) 21 - Second Stage Sun Gear 29 - Bolt (10 Used)
4- Thrust Plate 13 - Ring Gear 22 - First Stage Carrier 30 - Cover
5- Pin (3 Used) 14 - O-Ring 23 - Pipe 31 - Spherical Bearing
6- Spring Pin (3 Used) 15 - Thrust Plate (6 Used) 24 - Drain Plug 32 - Housing
7- Thrust Plate (6 Used) 16 - Planetary Gear (3 Used) 25 - Oil Seal 33 - Spherical Bearing
8- Needle Bearing (3 Used) 17 - Bushing (3 Used) 26 - O-Ring 34 - Retaining Ring
9- Planetary Gear (3 Used) 18 - Spring Pin (3 Used)
W2-6-10
UPPERSTRUCTURE / Swing Device
Disassemble Swing Device (ZAXIS270)
CAUTION: Swing device weight: 5. Put alignment marks at the jointed portion be-
Approx. 357 kg (790 Ib) tween motor (1) and ring gear (13), between ring
gear (13) and housing (32).
CAUTION: When hoisting the swing device,
don’t string the rope suddenly. CAUTION: Motor weight: 66 kg (150 Ib)
1. Install eyebolts (M33, Pitch 2.0 mm) to the swing 6. Remove socket bolts (2) (12 used), then lift and
device, then lift it by crane. remove motor (1) from ring gear (13).
Eyebolt Mounting : 10 mm
Position
W178-02-06-018
Wooden Blocks
11. Remove second stage sun gear (21) from sec-
ond stage carrier (10).
3. Remove drain plug (24) from pipe (23), then 12. Remove second stage carrier (10) assembly from
drain off oil. shaft (27).
: 10 mm
W2-6-11
UPPERSTRUCTURE / Swing Device
34
33
4
22
32
7
8
9
31 19 7
18
30 10
15
25
17
29
28
16
12
15
27
W178-02-06-040
W2-6-12
UPPERSTRUCTURE / Swing Device
IMPORTANT: The hole for the spring pin located
on the 1st stage carrier is not a CAUTION: Housing (32) assembly weight:
through one. Pay attention to the 196 kg (430 Ib)
tapping-in distance when tapping
the spring pin in. 20. Turn housing (32) assembly over, remove mount-
ing bolts (29) (10 used) on cover (30) to remove
cover (30).
13. Tap spring pin (6) on the 1st stage carrier (22)
assembly into pin (5) using special tool (ST 1462).
Stop tapping when the spring pin is driven to the 21. Install eyebolts (M20, Pitch 2.5 mm) into the hole
middle of the pin hole. Don’t try to tap spring pin for bolt (12) in housing (32). Lift it by crane, then
(6) to the end. place the housing on the upper side of the block
which has been installed at the press stand.
14. Remove pin (5), planetary gear (9), needle bear-
ing (8), thrust plates (7) (2 used) from 1st stage Press
carrier (22).
17. Clamp the pin (5) with a vise. Push the spring pin Blocks
out using special removing tool (ST 1462). (3
places) 22. Push the upper end of shaft (27) with a press and
remove it from housing (32). At this time, spheri-
18. Disassemble the 2nd stage carrier (10) assem- cal bearing (31) and sleeve (28) are removed
bly according to the removing procedure for the with the shaft.
1st stage carrier (22) assembly. However, use ST
1463 as the extractor for spring pin (9). More-
over, do not remove bushing (17) unless neces- 23. Turn housing (32) over to remove spherical
sary. bearing (33).
W2-6-13
UPPERSTRUCTURE / Swing Device
33
32
31
26
28
27
W178-02-06-040
W2-6-14
UPPERSTRUCTURE / Swing Device
CAUTION: Shaft + sleeve + bearing weight: CAUTION: When pressing shaft (27) with
75 kg (170 Ib) press, it should be carried out inside of the
guide.
25. Set the special tool onto shaft (27) assembly.
26. Set shaft (27) with special tool onto a press, then
Bearing Pulling Tool
pull bearing (31) out.
Hose Plug Round Bar Press
Bearing (31)
Sleeve (28)
W157-02-06-012 Guide
Shaft
Bearing (31)
W157-02-06-014
Sleeve
27. Pull sleeve (28) out from shaft (27) and remove
O-ring (26) from sleeve (28).
W2-6-15
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING DEVICE
(ZAXIS200, 200-E, 225US, 225USR, 230)
1
2 4
3 5
22
21 6
20
7
18
24
8
19 10
11
23
13
12
11
17
9
16
32
15
14
26
29 25 31
27
28
30
W178-02-06-003
W2-6-16
UPPERSTRUCTURE / Swing Device
Assemble Swing Device
(ZAXIS200, 200-E, 225US, 225USR, 230) 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put the oil seal flat on housing
1. Install O-ring (29) onto sleeve (28). (25) and push it in gently. Then place seal
mounting tool (ST 2925) on tne oil seal and tap it
in by hammering directly.
CAUTION: Shaft + sleeve + outer race
weight: 36 kg (80 Ib)
NOTE: If special tool (ST 2925) is used to replace
2. Install sleeve (28) and the inner race of roller the seal, no need to remove the sleeve.
bearing (26) into shaft (30). Press sleeve and in-
ner race using bearing mounting tool (ST 2923). ST 2925
27
Press
W178-02-06-007
W2-6-17
UPPERSTRUCTURE / Swing Device
24
23
15
14
25
27
30
W178-02-06-003
W2-6-18
UPPERSTRUCTURE / Swing Device
14. Place mounting tool (ST 2924) onto the inner
CAUTION: Housing + outer races (2 used) race of roller bearing (14). Push the inner race
weight: 65 kg (140 Ib) down using a press.
9. Install eyebolt (M16) into the ring gear mounting
bolt (23) hole in housing (25). Then lift and place NOTE: Press-in distance of the inner race can be
it on shaft (30) by crane slowly. Check and align assured by using the mounting tool.
carefully to protect the oil seal (27) lip from curl-
ing while mounting it.
ST 2924
10. Tap the inner race of roller bearing (14) into shaft
(30) with a bar and hammer. Tap the inner race 14
until two threads of shaft bearing nut (15) appear.
NOTE: Prevent shaft (30) from falling down when 15. Lift the housing (25) assembly and place it on
lifting housing (25). bracket (ST 5097) by crane. Secure it with 2 bolts
(M20) while the stopper at the bottom of bracket
CAUTION: Housing + shaft + bearing weight: is located at the middle of two teeth of the pinion
110 kg (240 Ib) gear. Secure the bracket on a work bench.
: 30 mm
25
12. Lift housing (25) of ring gear (24) by crane and
eyebolt (M16).
Place it on a press.
ST 5097
Stopper
13. Remove bearing nut (15) from shaft (30).
W178-02-06-012
W2-6-19
UPPERSTRUCTURE / Swing Device
3 5
22
21 6
7
18
8
10
11
13
12
11
17
9
16
15
30
W178-02-06-003
W2-6-20
UPPERSTRUCTURE / Swing Device
IMPORTANT: Pay attention to the direction of the IMPORTANT: Pay attention to the direction of the
bearing nut. spring pin.
16. Apply a film of grease on the threaded surface of 20. Tap spring pin (10) into 2nd stage carrier (18)
bearing nut (15), then install it on shaft (30) with using tool (ST 1463). At this time, the slit of the
the stepped side of bearing nut facing roller spring pin should face to the end of pin (9).
bearing (14). Tighten the bearing nut using
mounting tool (ST 2926).
: ZAXIS200, 225UR, 225US: 10
490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
9
ZAXIS230:
590 N⋅m (60 kgf⋅m, 435 Ibf⋅ft)
Slit
W2-6-21
UPPERSTRUCTURE / Swing Device
22
21
20
18
24
23
16
32
25 31
30
W178-02-06-003
W2-6-22
UPPERSTRUCTURE / Swing Device
IMPORTANT: Pay attention to the mounting direc- IMPORTANT: Pay attention to the mounting direc-
tion of the 2nd stage carrier. tion of the sun gear.
24. Install the 2nd stage carrier (18) assembly onto 29. Install 1st stage sun gear (2) into the 1st stage
the spline of shaft (30), while the concave part of carrier (21) assembly with the stepped side of the
the boss in bottom side of the carrier comes in sun gear facing down.
contact with lock plate (16).
Concave Part 30. Install pipe (32) into housing (25) with seal tape
18
wound on the threaded part of the pipe.
16 : 18 mm
30
31. Wind seal tape on drain plug (31), then install it
into pipe (32).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
32. Fill gear oil into ring gear (24) until the middle
W178-02-06-014 part of the 1st stage sun gear (2) is submerged.
(Approx. 6.7 L, 1.77 Us gal)
25. Install 2nd stage sun gear (20) into the 2nd stage
carrier (18) assembly with the small diameter part 33. Clean off the old THREEBOND, then apply new
of the 2nd stage sun gear facing up. THREEBOND #1212 onto the motor (1) mount-
ing surface of ring gear (24).
26. Clean off old THREEBOND and apply new
THREEBOND #1215 onto the mounting surface CAUTION: Motor weight: 47 kg (100 Ib)
of ring gear (24) inside of housing (25).
27. Install eyebolt (M12) to the motor mounting 34. Install eyebolt (M10) to motor (1), and lift it up by
threaded hole on ring gear (24). Lift the ring gear crane. Align the mating marks, then fasten the
up by crane, to install it on housing (25) with swing motor and ring gear (24) with bolts (22) (8
socket bolts (23) (12 used) while aligning the used).
matching marks made when disassembling. : 10 mm
: 10 mm : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
28. Install the 1st stage carrier (21) assembly onto Eyebolt Mounting
the spline of 2nd stage sun gear (20). Position
W178-02-06-005
W2-6-23
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING DEVICE (ZAXIS270)
4 3
1 5
22 6
2 7
11 8
21 9
10 18
15
13
19
17
12
16
14
34
20
32
33
23
27
31
24
25
26 28 30 29
W178-02-06-017
W2-6-24
UPPERSTRUCTURE / Swing Device
Assemble Swing Device (ZAXIS270)
1. Install O-ring (26) onto sleeve (28). 6. Tap spherical bearing (33) evenly with a bar and
hammer while installing it into housing (32). Tap
the bearing and listen to ring to confirm if installa-
CAUTION: Shaft + sleeve + bearing weight: tion is completed.
75 kg (170 Ib)
7. Install retaining ring (34) onto shaft (16).
2. Install sleeve (28) and spherical ring (31) into
shaft (27). Press the sleeve and bearing using
bearing mounting tool (ST 7937). CAUTION: Housing assembly weight: 195 kg
(430 lb)
NOTE: Press-in distance of the bearing inner race
can be assured by using the bearing 8. Secure housing (32) body with a nylon sling and
mounting tool. lift it up by crane. Place cover (30) with the
mounting side up.
Press
9. Apply THREEBOND #1215 on the outer surface
of oil seal (25). Put the oil seal flat on cover (30)
and push it in gently. Tap the oil seal all around
evenly with a plastic hammer, install it on cover
ST 7937
(30).
27
IMPORTANT: Pay attention as the seal lip of oil
seal (25) is curling up.
W178-02-06-021
11. Install cover (30) onto housing (32) with bolts (29)
3. Place shaft (27) with pressed sleeve (28) and (10 used).
spherical bearing (31) on flat surface. : 19 mm
: 34.5 N·m (3.5 kgf·m, 25.5 Ibf⋅ft)
4. Install eyebolts (M16, Pitch 2.0) into the socket
bolt (12) mounting hole in housing (32).
CAUTION: Housing assembly + cover
weight: 200 kg (440 Ib)
CAUTION: Housing weight: 107 kg (240 Ib)
12. Secure housing (32) body with a nylon sling and
5. Lift housing (32) by crane and place the housing
lift it up by crane. Place ring gear (13) with the
on the spherical ring (31). Tap the flange of hous-
mounting side up.
ing (32) evenly by using a bar and hammer
while installing the flange into shaft (27). Tap the
bearing and listen to ring to confirm if installation
is completed.
W2-6-25
UPPERSTRUCTURE / Swing Device
4 5
22 6
7
8
9
10 18
15
19
17
16
20
W178-02-06-017
W2-6-26
UPPERSTRUCTURE / Swing Device
13. Clamp the planetary gear (16) assembly with IMPORTANT: Pay attention to the mounting loca-
thrust plates (15) (2 used), then install it onto tion of thrust plate (7).
second stage carrier (10).
18. Assemble the following parts to form the 1st
14. When planetary gear (16) has been installed onto stage carrier (22) assembly according to the
second stage carrier (10), install pin (19) with the same procedures for the 2nd stage carrier as-
spring pin hole facing front. At this time, the sembly: planetary gear (9) (3 used), needle bear-
spring pin holes both in second stage carrier (10) ings (8) (3 used), thrust plates (7) (6 used), pins
and pin (19) should be in one line. (5) (3 used), spring pins (6) (3 used) and thrust
plate (4).
IMPORTANT: Pay attention to the direction of the Special tool (ST 1462) should be used as the
spring pin. extractor for the spring pin.
15. Tap spring pin (18) into 2nd stage carrier (10) by
using tool (ST 1463). At this time, the slit of the
spring pin should face to the end of pin (19).
18
19
Slit
W178-02-06-002
16. Install thrust plate (20) into 2nd stage carrier (10)
with its oil groove facing upward.
W2-6-27
UPPERSTRUCTURE / Swing Device
3
1
22
21
10
13
12
14
32
23 27
24
W178-02-06-017
W2-6-28
UPPERSTRUCTURE / Swing Device
IMPORTANT: Pay attention to the mounting direc- IMPORTANT: Pay attention to the mounting direc-
tion of the stage carrier. tion of the sun gear.
24. Install 1st stage sun gear (3) into the 1st stage
CAUTION: Second stage carrier assembly carrier (22) assembly with the stepped side of the
weight: 35 kg (80 Ib) sun gear facing down.
19. Install second stage carrier (10) assembly onto
the spline of shaft (27). 25. Install pipe (23) into housing (32) with seal tape
wound on the threaded part of the pipe.
: 18 mm
20. Install 2nd stage sun gear (21) into the 2nd stage
carrier (10) assembly with the small diameter part
of the second stage sun gear facing up. 26. Wind seal tape on drain plug (24), then install it
into pipe (23).
: 10 mm
21. Install O-ring (14) into housing (32). Clean off old : 90 N·m (9.2 kgf·m, 66.5 Ibf⋅ft)
THREEBOND and apply new THREEBOND
#1215 onto the ring gear (13) mounting surface
inside of housing (32). 27. Pour gear oil into ring gear (13) until the middle
part of the 1st stage sun gear (3) is submerged.
(Approx. 17.0 L, 4.49 US gal)
22. Install eyebolt (M12, Pitch 1.75) to the motor
threaded mounting hole on ring gear (13). Lift the
ring gear up by crane, to install it on housing (32) 28. Clean off the old THREEBOND, then apply new
with bolts (12) (12 used) while aligning the THREEBOND #1212 onto the motor (1) mount-
matching marks made when disassembling. ing surface of ring gear (13).
: 17 mm
: 400 N·m (41.0 kgf·m, 300 Ibf⋅ft) CAUTION: Motor weight: 66 kg (150 Ib)
23. Install the 1st stage carrier (22) assembly onto 29. Install eyebolt (M13, Pitch 2.0 mm) to motor (1),
the spline of 2nd stage sun gear (21). and lift it up by crane. Fastening the swing motor
and ring gear (13) with bolts (2) (12 used), while
aligning their mating marks.
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
Eyebolt Mounting
Position
W178-02-06-005
W2-6-29
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR
(ZAXIS200, 200-E, 225US, 225USR, 230)
11
8
7
6
5
4 10
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
W2-6-30
UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
(ZAXIS200, 200-E, 225US, 225USR, 230) IMPORTANT: Be sure not to damage the mating
• Be sure to thoroughly read “Precautions for surface when separating valve plate
Disassembly and Assembly Work” on page (21) from valve casing (28) or rotor
W1-1-1 before starting the disassembly work. (9) with a screwdriver. (Be sure not
to mismatch the surfaces of the
valve plate when installing.)
CAUTION: Swing motor assembly weight:
55 kg (120 Ib) 6. If valve plate (21) is still on rotor (9) in step 5,
remove the valve plate from the rotor. Remove
Relief valve springs (20) (24 used).
IMPORTANT: Don’t disassemble relief valve (32).
1. Remove relief valves (32) (2 used) from valve CAUTION: Another method is to float fload
casing (28). the brake piston by blowing air from port B.
: 41 mm However, piston (13) may fly out when
blowing air. Don’t use this method.
2. Remove plugs (24) (2 used) from valve casing
(28). 7. Install tool (ST 1468) into notch A of brake piston
: 14 mm (19), then pull it out from casing (1).
3. Remove springs (26) (2 used) and poppets (27)
(2 used) from valve casing (28).
T178-03-02-003
W2-6-31
UPPERSTRUCTURE / Swing Device
10
8
7
6
5
4 11
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
W2-6-32
UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care not to damage the slide IMPORTANT: Filter and orifice are mounted inside
surface of rotor (9) and plunger (6). of piston (13). Do not disassemble
them unless they are clogged or
9. Place casing (1) horizontally. Remove rotor (9), deformed. Disassemble them only
retainer (8), plate (7) and plungers (6) (9 used) when absolutely needed.
from shaft (4). If the inner parts need to be
replaced, replace them as an
10. Remove plates (10) (4 used), friction plates (11) assembly.
(3 used) from casing (1).
16. Remove piston (13) from casing (1) with pliers.
IMPORTANT: Take care not to damage the slide
surface of shoe plate (5).
17. Remove spring (14) and ball (15) from casing (1).
11. Remove shoe plate (5) from casing (1).
W2-6-33
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR (ZAXIS270)
6
4 5 7 8
3
2
21
1
20
9
19
10 11
12
13
22
16 15 14 23
17 24
25
26
18 27
28 46
45
29
30 44 47
31 43
32
33
34
35
42
41
40
39
38
37 48
36
49
W178-02-06-027
W2-6-34
UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor (ZAXIS270)
• Be sure to thoroughly read “Precautions for IMPORTANT: Be sure not to damage the matching
Disassembly and Assembly Work” on page surface when separating valve plate
W1-1-1 before starting the disassembly work. (22) and valve casing (2) or rotor
(30) with a screwdriver. (Be sure not
to mismatch the surfaces of the
CAUTION: Swing motor assembly weight: valve plate when installing.)
66 kg (150 Ib)
7. If valve plate (22) is still attached on rotor (30) in
IMPORTANT: Don’t disassemble or turn the step 6, remove valve plate (22) from the rotor.
adjustment screw of relief valve Remove springs (21) (22 used).
(14).
8. Install tool (ST 1468) into notch A of brake piston
1. Remove relief valves (14) (2 used) from valve (23), then pull it out from casing (43).
casing (2).
: 36 mm A
23
2. Remove plugs (13) (2 used) from valve casing
(2). 43
: 17 mm
4. Remove plate (5), O-rings (4), (9) (4 used) and 9. Remove O-rings (20 and 24) from casing (43).
socket bolts (6) (4 used) from valve casing (2).
: 6 mm
W2-6-35
UPPERSTRUCTURE / Swing Device
19
25
26
18 27
28
29
30
43
34
35
42
41
40
39
38
37 48
36
49
W178-02-06-027
W2-6-36
UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care not to damage the slide
surface of rotor (30) and plunger
(18).
15. Install front cover (37) into a vise, remove oil seal
(38) with a minus driver and hammer.
W2-6-37
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
(ZAXIS200, 200-E, 225US, 225USR, 230)
27 26 25 24
12
13
14
15
16
29
T178-03-02-003
T178-03-02-004
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
W2-6-38
UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
(ZAXIS200, 200-E, 225US, 225USR, 230)
IMPORTANT: Be sure to install the inner race of 8. Place casing (1) horizontally. Install the rotor (9)
bearing (3) with the flange facing assembly onto shaft (4).
the stepped side of shaft (4).
IMPORTANT: 4 notchs are on the outer side of
1. Push the inner races of bearings (3), (22) into plate (10). And 4 notchs are on the
shaft (4) with a press. spline teeth side of friction plate (11).
Be sure to align each notch at the
IMPORTANT: Push oil seal (2) in, with its lip same place when installing.
facing up.
9. Place casing (1) vertically. Alternately install
2. Push oil seal (2) into casing (1) with a guide plate. plates (10) (4 used), friction plates (11) (3 used)
into casing (1).
3. Install the outer race of bearing (3) into casing (1)
with a guide bar. 10. Install O-ring (17) and (18) onto casing (1).
W2-6-39
UPPERSTRUCTURE / Swing Device
27 26 25 24
12
13
14
15
16
29
T178-03-02-004 T178-03-02-003
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
W2-6-40
UPPERSTRUCTURE / Swing Device
IMPORTANT: If the inner parts of piston (13) need 18. Install valve casing (28) onto casing (1) with
to be replaced, replace the piston as socket bolts (29) (4 used).
an assembly. : 17 mm
Be sure to align the end face of the : 430 N⋅m (44 kgf⋅m, 320 Ibf⋅ft)
piston with that of casing (1).
19. Install poppets (27) (2 used) and springs (26) ( 2
13. Install ball (15), spring (14) and piston (13) into used) into valve casing (28). Tighten plug (24)
casing (1). with O-ring (25) attached.
: 14 mm
IMPORTANT: Tap the bearing type indicated : 330 N⋅m (34 kgf⋅m, 245 Ibf⋅ft)
surface with a plastic hammer while
installing roller bearing (22). 20. Install relief valves (32) (2 used) into valve casing
(3).
14. Tap the outer race of bearing (22) with a plastic : 41 mm
hammer while installing it into valve casing (28). : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
W2-6-41
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR (ZAXIS270)
22
6 9 4 5 16
2 15
17 23
26 20
27
24
1
21 19
28
25
29
45 30
44 33
34
18
31 35
32
48
49 43
41
39
40 42 38 36
37
11
10
14
12
13
W164-02-06-002
W2-6-42
UPPERSTRUCTURE / Swing Device
Assemble Swing Motor (ZAXIS270)
IMPORTANT: Wind tape on the spline at the end 9. Install spacer (32), bushing (33) into rotor (30).
of shaft (42) to prevent oil seal (38)
from being damaged. 10. Install plungers (18) (9 used) into retainer plate
CAUTION: Casing weight: 21 kg (50 Ib) (34).
1. Place casing (43) with valve casing (2) side fac- IMPORTANT: Apply hydraulic oil into the plunger
ing down. hole in rotor (30).
When installing retainer plate (34),
2. Apply grease to the part of bearing (41) being be sure to place it with its spherical
inserted into casing (43). surface facing bushing (33).
W2-6-43
UPPERSTRUCTURE / Swing Device
6 9 4 5
22
2
17
45 30
44
43
42
11
10
14
12
13
W164-02-06-002
W2-6-44
UPPERSTRUCTURE / Swing Device
IMPORTANT: Tap the bearing at type indicated 21. Install valve casing (2) onto casing (43) with
surface with a plastic hammer while socket bolts (3) (4 used).
installing roller bearing (17). : 17 mm
: 400 N·m (41 kgf·m, 300 Ibf⋅ft)
17. Install bearing (17) into valve casing (2) by
tapping the outer race of bearing (17) evenly 22. Install poppets (10) (2 used), springs (11) (2
with a plastic hammer. used) into valve casing (2). Tighten plug (13) with
O-ring (12) attached.
: 17 mm
IMPORTANT: Pay attention to the surface of valve : 400 N·m (41 kgf·m, 300 Ibf⋅ft)
plate (22). (Install the valve plate
with the notch in the port facing 23. Install relief valves (14) (2 used) into valve casing
rotor (30).) (2).
: 36 mm
18. Install O-ring (1) onto valve casing (2), then : 175 N·m (18 kgf·m, 130 Ibf⋅ft)
install valve plate (22).
24. Install O-rings (4) (2 used), (9) (2 used) onto
NOTE: Apply grease onto valve plate (22) to avoid plate (5) with socket bolt (6).
it coming off from valve casing (2). : 6 mm
: 20 N·m (2.0kgf·m, 14.5 Ibf⋅ft)
19. Apply grease to the needle part of bearing (17).
25. Install parking brake releasing valve (2) onto cas-
NOTE: Press the needle with grease, so it is easy ing (43) with socket bolts (1) (3 used).
to install shaft (42) into bearing (17). : 5 mm
20. Align the matching marks in valve casing (2) and 26. Remove the cap of fitting from valve casing (2),
casing (1), while placing the valve casing onto fill hydraulic oil into casing (43).
casing (43). Be sure to confirm that the clearance
between valve casing (2) and casing (43) is
same with that when disassembling. If the
clearance is larger than that of when
disassembling, reinstallation shall be carried out
from step 5.
W2-6-45
UPPERSTRUCTURE / Swing Device
DISASSEMBLE AND ASSEMBLE PARKING
BEAKE RELEASING VALVE
(ZAXIS270)
1 2 3 4
12
5
11
10
9
6
8 7
W178-02-06-025
W2-6-46
UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
Swing Motor
D D
W107-02-06-139
W107-02-06-140
W2-6-47
UPPERSTRUCTURE / Swing Device
3. Thickness of shoe
Unit: mm (in)
Standard Allowable Limit
5.5 (0.22) 5.3 (0.21)
W107-02-06-142
4. Thickness of friction plate
Unit: mm (in)
Standard Allowable Limit
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-48
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE
Removal
2
W178-02-07-006
W2-7-1
UPPERSTRUCTURE / Pilot Valve
2. Remove screws (24) (4 used) and cover (23).
Move boot (29) up.
: 17 mm 30
3
3. Remove caps (17) (2 used) from cover (18). 29
4
28
4. Remove screws (21) (4 used) and (16) (2 used). 5
27
Move cover (18) up. Remove each connector for
key switch (20), air controller (19) and grip (3). 26 6
Remove cover (18). Remove screws (22, 15, 13). 25 7
8
Remove cover (14).
9
24 10
11
5. Remove the connector and bolts (11) (2 used) for 23 12
switch box (12). Remove switch box (12). 21
: 13 mm 20
19
22
6. Remove hoses (31 to 36). Attach an identification 18
tag onto the removed hoses for assembling. Cap
the removed hoses. 17
: 19 mm
16
7. Remove nut (4). Remove clips (5, 27). Remove
connector (6). Remove grip (3) (with harness).
Remove nut (28). Remove lever (30), washers (25, 15
26), and boot (29).
14
: 22 mm, 19 mm
13
8. Remove bolts (9) (3 used) and (8) (with spring pin
(7)) from pilot valve (10). Remove pilot valve (10). W178-02-07-001
: 13 mm
31
36
35 32
33
34
W178-02-07-002
W2-7-2
UPPERSTRUCTURE / Pilot Valve
Installation
1. Install bolt (9) and (8) (with spring pin (7)) to pilot
valve (10).
: 13 mm 31
: 10 N⋅m (1.0 kgf⋅m, 7.4 Ibf·ft) 36
35 32
W178-02-07-001
W2-7-3
UPPERSTRUCTURE / Pilot Valve
8. Install seat (1) (with the seat stand) with bolts (2)
(4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf·ft)
W178-02-07-006
W2-7-4
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL LEFT PILOT
VALVE
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
7
6
5
W178-02-07-003
W2-7-5
UPPERSTRUCTURE / Pilot Valve
5. Remove hoses (11 to 16). Attach an identification
tag onto the removed hoses for assembling. Cap
the removed hoses.
: 19 mm
Installation W178-02-07-004
11 - Hose T3: (To pilot shut-off valve)
12 - Hose F: (To the signal control valve port F for swing right)
1. Install pilot valve (27) with bolts (24) and (23) (with 13 - Hose C: (To the signal control valve port C for arm roll-out)
spring pin (22)). 14 - Hose A2: (From pilot shut-off valve)
: 13 mm 15 - Hose E: (To the signal control valve port E for swing left
16 - Hose D: (To the signal control valve port D for arm roll-in)
: 10 N⋅m (1.0 kgf⋅m, 7.4 Ibf·ft)
29
18
19
28
1
20
21
22
23
24
25
26
27
W178-02-07-003
W2-7-6
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Do not arrange the harness to the
inside of spring pin (21) as the
harness makes contact with the
moving part of pilot valve (27) and is 17
damaged.
3. Temporarily tighten nut (20) to lever (19). Install
washers (25, 26) onto lever (19). Install lever (19) 29
onto pilot valve (27) with nut (20). Install boot (1).
Temporarily tighten nut (18) to lever (19). Secure 18
grip (17) with nut (18). 19
28
Pass the harness of grip (17) through the upper
1
hole of boot (1), then connect it to lever (19) via 20
grips (29). Arrange the harness to the outside of 21
spring pin (22) over bolt (23) head. Install 22
connector (28). 23
: 13 mm 24
: 10 N⋅m (1.0 kgf⋅m, 7.4 Ibf·ft) 25
: 22 mm 26
: 26 N⋅m (2.7 kgf⋅m, 19 Ibf·ft) 27
: 19 mm 9 2
: 26 N⋅m (2.7 kgf⋅m, 19 Ibf·ft) 8 3
4
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).
7
5. Install boot (1) and cover (3) with screws (2) (4 6
used). 5
6. After completing the work, check the oil level. Start W178-02-07-003
W2-7-7
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL TRAVEL PILOT
VALVE
Removal
1
1. Remove floor mat (1).
5
15
14
14
13
13
12
12 6
7
11
10
9
8
W178-02-07-005
W2-7-8
UPPERSTRUCTURE / Pilot Valve
Installation
3. Install pedal (5), levers (16) and (17) with bolts (4).
: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf·ft)
5
15
14
14
13
13
12
12 6
7
11
10
9
8
W178-02-07-005
W2-7-9
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
17
W176-02-07-001
W2-7-10
UPPERSTRUCTURE / Pilot Valve
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of pushers are used.
made of aluminium. As too strong a 4. Remove pushers (8, 9) from block (10). Keep the
force can deform, or damage them, pusher in order of port number.
handle them with care.
5. By using a bamboo spatula, remove oil seals (15)
IMPORTANT: Spool (17) has been selected to (4 used) from block (10). Do not use the metal bar
match the hole of housing (18). The as the mating part of oil seal (15) may be
dimensions of balance springs A (3), damaged.
B (4) and return springs A (5), B (6)
as well as those of pusher A (8), B 6. Push the spring by using special tool (ST 7257)
(9) are different. Indicate the port from the top of spring guide (16). Remove
number from which it is removed. retaining ring (7) by using a screwdriver or similar
Port numbers are stamped on tool. (4 places) Retaining ring (7) may come off
housing (18). while disassembling. Do not lose retaining ring
(7).
7
IMPORTANT: Do not remove screw joint (13) while
clamping housing (18) in a vise. The
strong torque may act on the screw
joint.
1. Clamp screw joint (13) in a vise. Turn cam (12) by
using a spanner. Remove screw joint (13).
: 19 mm, 32 mm
16
2. Clamp the flat surface of housing (18) in a vise ST 7257
lightly. Remove cam (12) from universal joint (14).
: 32 mm
NOTE: Universal joint (14) has been secured on
block (10) by using LOCTITE. Do not
remove universal joint (14) unless
necessary.
W2-7-11
UPPERSTRUCTURE / Pilot Valve
21
20
21
20
19
18
17
W176-02-07-001
W2-7-12
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Spool (17) has been selected to
match the hole of housing (18). Keep
spool (17) and housing (18) carefully
in order to install them to the
original port when assembling.
8. Slowly turn and remove spool (17) from housing
(18).
NOTE: Spool (17) and housing (18) must be
replaced as an assembly.
W2-7-13
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE RIGHT AND LEFT PILOT VALVES
17
ZAXIS200 : Serial No109562 and up
16 ZAXIS200E : Serial No 109562 and up
ZAXIS225USR : Serial No 109556 and up
ZAXIS225US : Serial No 109546 and up
15
ZAXIS230 : Serial No 11231 and up
ZAXIS270 : Serial No 20336 and up
14
13
12
11
10
9 22
7
6 21
5 20
4 19
3 18
W178-02-07-064
W2-7-14
UPPERSTRUCTURE / Pilot Valve
Disassemble Right and Left Pilot Valves
IMPORTANT: Casing (22) is made of aluminium. IMPORTANT: Insert a soft rubber between sleeve
As too strong a force can deform, or (12) and the tool in order not to
damage them, handle them with damage the surface of sleeve (12).
care. Oil seal (11) cannot be removed from
sleeve (12).
IMPORTANT: Spool (21) has been selected to Sleeve (12) and oil seal (11) must be
match the hole of casing (22). The replaced as an assembly.
dimensions of balance springs A (3), 5. Pull out sleeve (12) upward by using a pair of
B (4) and return springs A (5), B (6) plier.
as well as those of pushers A (9), B
(10) are different. Indicate the port IMPORTANT: As pushers (9, 10) are used for ports
number from which it is removed. 1, 3 and for ports 2, 4, the
Port numbers are stamped on dimensions are different. Indicate
casing (22). the port number from which it is
removed in order to keep by the port
IMPORTANT: Do not remove screw joint (17) while number.
clamping casing (22) in a vise. The 6. Remove pushers (9, 10) from casing (22).
strong torque may act on the screw
joint. 7. Install special tool (ST 4146) to the port hole on
1. Clamp screw joint (17) in a vise. Turn cam (16) by casing in order not to lower the spool when
using a spanner. Remove screw joint (17). pushing the spring.
: 19 mm, 32 mm : 6 mm
2. Clamp the flat surface of casing (22) in a vise 8. Install special tool (ST 4146) to the pusher hole
lightly. Remove cam (16) from universal joint (15). on casing (22). Push special tool (ST 4146) and
: 32 mm push the spring. Tighten special tool (ST 4146) by
using bolt (M14, Pitch 2 mm).
3. Attach a spanner onto the upper surface and : 12 mm
remove universal joint (15).
: 17 mm
ST 4146
NOTE: Universal joint (15) has been secured on
casing (22) by using LOCTITE.
W178-02-07-048
ST 4145
W2-7-15
UPPERSTRUCTURE / Pilot Valve
17
16
22
7
6 21
5
4 19
3 18
W178-02-07-064
W2-7-16
UPPERSTRUCTURE / Pilot Valve
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) from spool (21).
W2-7-17
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
13 14
10
12
8, 9
15
11
7
16
3, 4
5, 6
2
19
1
17
W176-02-07-006
18
21 20
W2-7-18
UPPERSTRUCTURE / Pilot Valve
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to 3. Install spring guide (16) onto return spring (3) or
contamination. Keep the parts clean (4) with the protrusion facing upward.
when assembling.
4. Install retaining ring (7) onto ring holder (ST
NOTE: Table below shows the relations between 7255).
each port and the components. Do not ST 7255
confuse them when assembling. 7
1 Short Short
2 Long Long
Packing Material
3 Short Short
4 Long Long
W176-02-07-009
IMPORTANT: Refer to the table above in order to 6. Assemble other spools (17) (3 used) into housing
assemble them correctly. (18) in the same procedures as step 2 to 5.
2. Install spacer (1), shim (2), balance spring (3) or
(4), and return spring (5) or (6) onto spool (17) 7. Install O-rings (19) and (21) (2 used) to housing
installed in housing (18). (18).
W2-7-19
UPPERSTRUCTURE / Pilot Valve
13 14
10
12
8, 9
15
11
W176-02-07-006
18
20
W2-7-20
UPPERSTRUCTURE / Pilot Valve
8. Apply grease to the inner surface of oil seals IMPORTANT: Check the tightness of cam (12).
(15) (4 used). Install oil seals (15) (4 used) into 13. Clamp housing (18) in a vise lightly. Install cam
block (10) by using a bamboo spatula. (12) to universal joint (14). Tighten universal joint
NOTE: As illustrated, insert pushers (8, 9) first in (14) so that the clearance between cam (12) and
order to prevents oil seal (15) from entering pushers (8, 9) becomes 0 to 0.2 mm.
into the hole. : 19 mm, 32 mm
: 88.2 N⋅m (9.0 kgf⋅m, 65 Ibf·ft)
Oil Seal (15)
Mounting Hole IMPORTANT: Do not clamp housing (18) in a vise.
Screw joint (13) may be damaged.
10 14. Clamp screw joint (13) in a vise. Tighten universal
joint (14). Tighten cam (12) by using a spanner.
: 32 mm
: 88.2 N⋅m (9.0 kgf⋅m, 65 Ibf·ft)
8, 9
W176-02-07-007
W2-7-21
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE RIGHT AND LEFT PILOT VALVES
17
16 15
11 9, 10
14
12
13
8
7
3, 4
5, 6
2
19
1
19
22 21
18
W178-02-06-055
W2-7-22
UPPERSTRUCTURE / Pilot Valve
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to IMPORTANT: Refer to the table in order to
contamination. Keep the parts clean assemble them correctly.
when assembling. 3. Install spacer (1), shim (2) and balance springs (3,
4) to spool (21). Install return springs (5, 6) to
NOTE: Table below shows the relations between casing (22).
each port and the components. Do not
confuse them when assembling. 4. Install spring guide (7) onto return springs (5, 6)
with the protrusion facing upward.
Port Spool Shim Pushers A, B 5. Install special tool (ST 4146) to the pusher hole
No. (21) (2) (9, 10) on casing. Push special tool (ST 4146) and push
Outer grooves the spring. Tighten special tool (ST 4146) by using
1 bolt (M14, Pitch 2 mm).
Same to Same to (3 Used)
Without outer : 12 mm
the former the former
2
one one groove
ST 4146
Outer grooves
3
(3 Used)
ST 4144
Without outer
4
groove
1. Check the port hole number and insert spool (21) 6. Install retaining ring (8) to ring holder (ST
to the original port. Insert the thinner end of spool
(21) to the port hole in casing (22) while rotating. 4144).
NOTE: Spool (21) has been selected to match the
port hole. Spool (21) and casing (22) must
be replaced as an assembly.
W2-7-23
UPPERSTRUCTURE / Pilot Valve
17
16 15
11 9, 10
14
12
13
8
3, 4
22
W178-02-06-055
W2-7-24
UPPERSTRUCTURE / Pilot Valve
7. Install retaining ring (8) on ring holder (ST 4144) IMPORTANT: Align the bolt hole of plate (14) with
to the groove on the head of spool (21) out of the screw hole on casing (22)
special tool (ST 4146) completely.
14. Place plate (14) onto casing (22) and tighten
IMPORTANT: Check the mounting positions of universal joint (15).
pushers (9, 10). : 17 mm
8. Install pushers (9, 10). : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
Push pushers (9, 10) by hand and remove
pushers (9, 10). Check if retaining ring (8) falls off IMPORTANT: Check the tightness of cam (16).
or the positions of balance springs (3, 4) are 15. Install cam (16) to universal joint (15). The
correct. clearance between cam (16) and pushers (9, 10)
After checking, install pushers (9, 10) to casing should be 0 to 0.2 mm.
(22).
16. Secure cam (16) by using a spanner. Tighten
9. Apply grease to the ball at the ends of pushers (9, screw joint (17) by using a spanner.
10). : 19 mm, 32 mm
: 68.4 N⋅m (7.0 kgf⋅m, 50 Ibf⋅ft)
10. Apply grease to the joint part of universal joint
(15).
W2-7-25
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE
31
30 3
4
5
6
29 7
28
27 8
9
26 10
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)
2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-26
UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolt (1) and 7. Remove spring (18) from casing (14). (4 places)
remove cover (2) from holder (10).
: 10 mm IMPORTANT: Place a stand under bracket (26) and
form a reaction force. If holder (10)
2. Remove socket bolt (8) (2 places), and remove bears the reaction force, a strong
holder (10) from casing (14). force acts on pin (3) and pin (3) may
: 8 mm be deformed.
IMPORTANT: The hole insides of spring pins (24,
3. Remove pusher (23) from casing (14) (4 places). 25) in the bracket are in
Bushing (13) and oil seal (11) are removed with stepped-shape. The spring pin can
pusher (23) together. only be removed in one direction.
8. Place a stand under bracket (26).
Remove both spring pins (24, 25) from bracket
4. Remove pusher (23) from bushing (13). By using (26) at the same time by using special tool (ST
a bamboo spatula, remove oil seal (11) (4 places). 1237). Remove bracket (26) from pin (3) (2
places).
IMPORTANT: Put the mark on spools (17) (4 used) Do not remove spring pin (27) from the bracket
in order to easily install spool (17) unless necessary.
into the original hole. NOTE: The outside end of spring pin (27) has been
5. Turn and remove the spool (17) assembly from crimped.
casing (14) (4 places).
Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with spool (17) 24, 25
together.
NOTE: The spool has been selected to match the 26
hole of casing. Replace the spool and 3 27
casing as an assembly. Crimped
Here
W2-7-27
UPPERSTRUCTURE / Pilot Valve
35
34
33
32
31
30 3
10
14
W176-02-07-002
W2-7-28
UPPERSTRUCTURE / Pilot Valve
10. Remove O-ring (5) from pin (3) (2 places).
W2-7-29
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE
ZAXIS200 : Serial No.107149 and up
1 ZAXIS200E : Serial No.107149 and up
ZAXIS225USR : Serial No.107150 and up
ZAXIS225US : Serial No.107198 and up
ZAXIS230 : Serial No.010771 and up
2 ZAXIS270 : Serial No.020234 and up
3
4
35
7 34
33
32
8
9 31
30
10
29
11
28
14 27
26
12
13 15
25
16
24
17
18
23
19
20
21 22
W178-02-07-063
W2-7-30
UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminium. IMPORTANT: The quantity of shim has been
As too strong a force can deform, or determined during the performance
damage them, handle them with testing at the factory. Keep the shim
care. together with the spool.
6. Push balance spring (18). Remove spring guide
IMPORTANT: Spool (24) has been selected to (17), balance spring (18), shim (27) and spacer
match the hole of casing. (26) from spool (24) (4 places).
Indicate the port number from which
it is removed. 7. Remove spring (25) from casing (23) (4 places).
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
W2-7-31
UPPERSTRUCTURE / Pilot Valve
3
4
6
3
4
5 10
11
5 12
6 13
6
35
7 34
33
32
9 31
10
31
11 32
33
34
35
12
13
23
19
20
21 22
W178-02-07-063
W2-7-32
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Place a stand under bracket (11) and 10. Remove O-ring (33) from pin (35) (2 places).
form a reaction force. If holder (7)
bears the reaction force, a strong 11. Place holder (7) with the casing (23) mounting
force acts on pin (35) and pin (35) surface up.
may be deformed.
8. Place a stand under bracket (11).
The hole insides of spring pins (12, 13) in bracket 12. Remove spring pins (3, 4) from cam (5) at the
(11) are in stepped-shape. The spring pin can same time by using special tool (ST 1237) (2
only be removed in one direction. places). The hole insides for spring pins (3, 4) on
Remove both spring pins (12, 13) from bracket cam (5) are the stepped-shape. Tap the bottom of
(11) at the same time by using special tool (ST cam (5). As the holes of spring pins (3, 4) are
1237). Remove bracket (11) from pin (35) (2 crimped, spring pins (3, 4) may feel tight when
places). removing.
Do not remove spring pin (10) on bracket (11)
unless necessary. 13. Remove pin (35) by using a round bar and
The outside end of spring pin (10) has been hammer. At the same time cam (5) is also
crimped. 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).
11 O-ring (19) is removed with plug (20) together.
35 10
Crimped 15. Remove plug (21) from casing (23) (2 places).
Here
O-ring (22) is removed with plug (21) together.
Stand
16. Remove plug (20) from the bottom of casing (23)
(3 places). O-ring (19) is removed with plug (20)
together.
W176-02-07-019
W2-7-33
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12 18
23
20
19
17
14
W176-02-07-010
15, 16
W2-7-34
UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
IMPORTANT: Check the direction to install spring 6. If bushing (31) has been removed from holder
guide (22). (10), install bushing (31) on holder (10) by using
1. Assemble spool (17) into the assembly (4 used). special tool (ST 7256) in the following procedures.
• Insert spacer (19), shim (20), and balance spring NOTE: The bushings (4 used) are identical.
(21) into spool (17) in this order. Install the shim • Insert bushing (31) into special tool (ST 7256).
as the same condition before disassembling. Tap special tool (ST 7256) and install bushing (31)
• Push the balance spring by hand. Install spring into the hole of holder (10) by using a hammer.
guide (22) to spool (17) with the stepped part Stop tapping when bushing (31) end is flush with
facing downward. the inside wall.
ST 7256
10
2. Insert spring (18) to casing (14) (4 places).
4. Assemble plunger (23) into the assembly (4 • Install bushing (31) on the opposite side in the
used). same procedure. 31
• Install oil seal (11) onto bushing (13). 10
ST 7256
• Apply grease to the inner surface on oil seal (11).
• Install O-ring (12) to bushing (13).
• Insert pusher (23) into bushing (13).
• Apply grease to the head of pusher (23).
W176-02-07-015
5. Insert the pusher (23) assembly to holder (10) (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).
31
10 ST 7256
Outside of
Holder
W176-02-07-014
W176-02-07-013
W2-7-35
UPPERSTRUCTURE / Pilot Valve
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-36
UPPERSTRUCTURE / Pilot Valve
7. Install adjusting bolt (30) to cam (32). Tighten IMPORTANT: Do not adjust adjusting bolt (30)
adjusting bolt (30) by hand. Lightly tighten lock while pushing the pusher (23) head.
nut (33) temporarily (2 places). The standard clearance between
NOTE: Adjust the dimensions later. adjusting bolt (30) and pusher (23)
must be 0 to 0.2 mm (0 to 0.008 in).
13. Adjust adjusting bolt (30) in the following
8. Apply grease on the head (mounting surface for procedures (2 places).
pusher (23)) of adjusting bolt (30) (2 places). : 13 mm
: 4 mm
9. Install O-ring (5) to pin (3). Assemble pin (3) to • Loosen lock nut (33).
holder (10) with cam (32) (2 places). • Move cam (32) and check that there is play. If
there is no play, turn and adjust adjusting bolt
10. Install spring pins (34, 35) to cam (32) by using (30).
special tool (ST 1237). Secure cam (32) and pin • Turn both adjusting bolts (30) on the left and right
(3). Spring pins (34, 35) should be displaced with alternatively and keep cam (32) horizontal.
their slits at 90° (2 places). • Measure sizes A and B from both left and right
Tap and install spring pins (34, 35) until spring caves on cam (32) to holder (10). Fine adjust
pins (34, 35) make contact with the stepped part adjusting bolt (30) in order to get same distance
in the hole. on sizes A and B.
• Secure adjusting bolt (30) by using a hexagon
34 35 Slit Slit wrench. Tighten lock nut (33) to the specified
torque. 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 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
30 33 32 10
W176-02-07-017
W2-7-37
UPPERSTRUCTURE / Pilot Valve
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-38
UPPERSTRUCTURE / Pilot Valve
14. Install rubber seat (7) to pin (3) (2 places). IMPORTANT: Place a stand under the bracket and
form a reaction force. If holder (10)
15. Apply grease to O-ring (5) (2 places). bears the reaction force, a strong
force acts on pin (3) and pin (3) may
IMPORTANT: The inner bore of damper (6) is be deformed.
edged-shape. If the damper is pried 20. Place a stand under bracket (26).
when installing, O-ring (5) will be Tap spring pins (24, 25) into bracket (26) until the
damaged. spring pins (24, 25) comes to the stepped end by
16. Install damper (6) to pin (3) with the lever up (2 using special tool (ST 1237). The spring pins (2
places). used) are displaced with their slits in 90°.
W2-7-39
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE
11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30
29
34 15
9 33 28
17
8 18
14
25
27
16
26
24
23
W178-02-06-056
W2-7-40
UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
IMPORTANT: Check the direction to install spring 6. If bushing (6) has been removed from holder (7),
guide (17). install bushing (6) on holder (7) by using special
1. Assemble spool (24) into the assembly (4 used). tool (ST 7256) in the following procedures.
• Insert spacer (26), shim (27), and balance spring NOTE: Bushings (6) (4 used) are identical.
(18) into spool (24) in this order. Install the shim • Insert bushing (6) into special tool (ST 7256). Tap
as the same condition before disassembling. special tool (ST 7256) and install bushing (6) into
• Push the balance spring by hand. Install spring the hole of holder (7) by using a hammer.
guide (17) to spool (24) with the stepped part Stop tapping when bushing (6) end is flush with
facing downward. the inside wall.
ST 7256
7
2. Insert spring (25) to casing (23) (4 places).
4. Assemble pusher (16) into the assembly (4 used). • Install bushing (6) on the opposite side in the
• Install oil seal (28) to bushing (15). same procedure. 6
• Apply grease to the inner surface on oil seal (28). 7
ST 7256
• Install O-ring (14) to bushing (15).
• Insert pusher (16) into bushing (15).
• Apply grease to the head of pusher (16).
Outside of
Holder
W176-02-07-014
W176-02-07-01313
W2-7-41
UPPERSTRUCTURE / Pilot Valve
32 31 35 31 32 7 5 3, 4 30
29
9 34
8 33
23
W178-02-06-056
W2-7-42
UPPERSTRUCTURE / Pilot Valve
7. Install O-ring (33) to pin (35). Assemble pin (35) to 11. Install rubber seat (31) to pin (35) (2 places).
holder (7) with cam (5) (2 places).
12. Apply grease to O-ring (33) (2 places).
IMPORTANT: Check the direction to install spring
pins (3, 4). IMPORTANT: Check the direction of damper (32).
The inner bore of damper (32) is
8. Install spring pins (3, 4) to cam (5) by using edged-shape. If damper (32) is pried
special tool (ST 1237). Secure cam (5) and pin when installing, O-ring (33) will be
(35). Spring pins (3, 4) should be displaced with damaged.
their slits at 90° (2 places). 13. Install damper (32) to pin (35) with the lever up (2
Tap and install spring pins (3, 4) until spring pins places).
(34, 35) make contact with the stepped part in the
hole.
14. Secure damper (32) and rubber seat (31) to
Slit Slit holder (7) with socket bolts (9) (2 used) and spring
3
washers (8) (2 used) (2 places).
: 5 mm
: 7 N⋅m (0.7 kgf⋅m, 5.2 Ibf⋅ft)
W2-7-43
UPPERSTRUCTURE / Pilot Valve
11 32 1 2 35 12 10 13 7 1 1
W178-02-06-056
W2-7-44
UPPERSTRUCTURE / Pilot Valve
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).
Crimped Crimped
Here Here
11 35
Stand 12, 13
W176-02-07-011
W2-7-45
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-46
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
W2-8-1
UPPERSTRUCTURE / Pilot Shut-Off Valve
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work.
(Refer to BLEED AIR FROM HY- 3
DRAULIC OIL TANK on W1-4-1.) 2
1
Removal (ZAXIS225US)
1. Remove ball joint (10).
Installation (ZAXIS225US) 10 9 8 7 6 5
1. Install pilot shut-off valve with bolt (11). W157-02-08-001
3. Install ball joint (10). 1- Hose P2: (From the travel pilot valve)
2- Hose P1: (To the swing, arm pilot valve)
3- Hose P3: (To the boom, bucket pilot valve)
Tightening Torque 4- Hose T6: (From the bucket, boom pilot valve)
Wrench Size (mm) Remark
N⋅m kgf⋅m (Ibf⋅ft) 5- Hose PD: (To the tank port)
6- Hose DP: (From the pilot valve)
: 13 10 1 (7.2) Nut 7- Hose T5: (From the swing, arm pilot valve)
: 22 39 4 (29) Hose 8- Hose T4: (From the travel left and right pilot valve)
9- Hose A4: (To the shuttle valve)
:8 20 2 (14.5) Bolt 10 - Ball Joint
: 17 49 5 (36) Bolt 11 - Bolt
: 19 29 3 (21.5) Hose
W2-8-2
UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)
W2-8-3
UPPERSTRUCTURE / Pilot Shut-Off Valve
3
6
2 7
1
8
9
13 10
11
12
W178-02-08-005
W2-8-4
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270)
• Be sure to thoroughly read all “Precautions for
Disassembly and Assembly Work” on page
W1-1-1 before starting the disassembly work.
W2-8-5
UPPERSTRUCTURE / Pilot Shut-Off Valve
DISASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS225US)
1
2
3
4
5
6
7
8
14
13 12
11
10
W155-02-08-001
W2-8-6
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-off Valve (ZAXIS225US)
• Be sure to thoroughly read all “Precautions for
Disassembly and Assembly Work” on page
W1-1-1 before starting the disassembly work.
W2-8-7
UPPERSTRUCTURE / Pilot Shut-Off Valve
ASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS200, 200-E, 225USR, 230, 270)
12 13 11 4 5 Z
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
W2-8-8
UPPERSTRUCTURE / Pilot Shut-Off Valve
Assemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270)
W2-8-9
UPPERSTRUCTURE / Pilot Shut-Off Valve
ASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS225US)
1 2 3 4 14 5 6 7 8 11 9
12 10 13
W157-02-08-002
W2-8-10
UPPERSTRUCTURE / Pilot Shut-Off Valve
Assemble Pilot Shut-off Valve (ZAXIS225US)
W2-8-11
UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)
W2-8-12
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON- Signal Control Valve
TROL VALVE
Removal
IMPORTANT: Attach tags to hoses and pipes to
aid in assembly.
Pressure Sensor
(Travel) 20 12 SP T178-03-06-015
W2-9-1
UPPERSTRUCTURE / Signal Control Valve
Pilot Valve Side
Port Name Connected To Remark
Port A Right pilot valve Boom raise pilot pressure
Port B Right pilot valve Boom lower pilot pressure
Port C Left pilot valve Arm roll-out pilot pressure
Port D Left pilot valve Arm roll-in pilot pressure
Port E Left pilot valve Left swing pilot pressure
Port F Left pilot valve Right swing pilot pressure
Port G Right pilot valve Bucket roll-in pilot pressure
Port H Right pilot valve Bucket roll-out pilot pressure
Port I Travel pilot valve Left travel forward pilot pressure
Port J Travel pilot valve Left travel reverse pilot pressure
Port K Travel pilot valve Right travel forward pilot pressure
Port L Travel pilot valve Right travel reverse pilot pressure
Port M Auxiliary pilot valve Plug on pilot pressure
Port N Auxiliary pilot valve Plug off pilot pressure
Port SA Pump 1 regulator Pump 1 control pressure
Port SB Pump 2 regulator Pump 2 control pressure
Port PI Pilot shut-off valve Primary pilot pressure
Port PH Pilot shut-off valve Primary pilot pressure (Heat circuit)
Port SH Swing parking brake Brake release pressure
Port DF Hydraulic oil tank Return to hydraulic oil tank
W2-9-2
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE Solenoid Valve Unit
UNIT 2
16 1
3
Removal
1. Disconnect each harness of solenoid valves (9 to
12). 15
14
15
Solenoid Valve Unit
Installation
1. Install solenoid valve unit with bolts (6) (2 used). 13
12
3
2. Connect pilot pipes (1 to 5, 7, 8,13 to 16). 11
10
3. Connect each harness of solenoid valves (9 to 9
12). 8
7
Tight Torque
Wrench Size (mm) Remark 6 4
N⋅m kgf⋅m (Ibf⋅ft) 5
: 17 25 2.5 (18) Pipe, Hose
W178-02-10-001
: 19 30 3 (21.5) Hose
:8 50 5.1 (37) Bolt
1- Hose DD: To the signal control valve port SP
2- Hose: To the control valve (5-spool section)
3- Hose: To the hydraulic oil tank
4- Pipe: To the main relief valve
5- Hose SI: To the center joint
6- Socket bolt
7- Pipe: To the control valve (4-spool section)
8- Pipe: To the control valve (5-spool section)
9- Proportional solenoid valve (SG)
10 - Proportional solenoid valve (SI)
11 - Proportional solenoid valve (SC)
12 - Proportional solenoid valve (SE)
13 - Pipe: To the control valve (4-spool section)
14 - Hose PF: From pilot shut-off valve
15 - Hose PD: From pilot filter
16 - Pipe: To the control valve (5-spool section)
W2-10-1
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVE
2
3
4
5
7
8
9
10
11
12
13 14
15
16
17
18
19
W178-04-05-001
W2-10-2
UPPERSTRUCTURE / Solenoid Valve
Disassemble Proportional Solenoid Valve
1. Loosen socket bolts (1) to remove solenoid (6).
: 3 mm
W2-10-3
UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE PROPORTIONAL SOLENOID
VALVE
4 2 6 1 8 16 13 14 10 15 18
3, 5
9 7 11 12 17
W157-02-11-001
W2-10-4
UPPERSTRUCTURE / Solenoid Valve
Assemble Proportional Solenoid Valve
IMPORTANT: Apply grease to O-rings (13), (14), 2. Install diaphragm (9), washer (11), spring (12) to
(15) and apply a film of hydraulic oil spool (10) and install it into sleeve (16).
to sleeve (16). 10
When inserting the sleeve, be sure
to align the ports of the sleeve with
the ports in the housing. 9
Install sleeve so that the end faces
of sleeve and body come to the
same point.
16
1. Install washer (18), plate (17) into 12
the housing. Install O-rings (13), 11 Housing
(14) and (15) on sleeve (16), then
insert it into the housing. W157-02-11-009
16
15
14
13
10
Housing
W157-02-11-005 W157-02-11-010
1
W157-02-11-011
W2-10-5
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-10-6
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTNS
Group 1 Swing Bearing Group 5 Front Idler
Remove and Install Swing Bearing..............W3-1-1 Remove and Install Front Idler .................... W3-5-1
Disassemble Swing Bearing ........................W3-1-4 Disassemble Front Idler .............................. W3-5-2
Assemble Swing Bearing.............................W3-1-6 Assemble Front Idler ................................... W3-5-6
Maintenance Standard ................................ W3-5-8
Group 2 Travel Device
Remove and Install Travel Device ...............W3-2-1 Group 6 Upper and Lower Roller
Disassemble Travel Device .........................W3-2-4 Remove and Install Upper Roller ................ W3-6-1
Assemble Travel Device ............................W3-2-10 Remove and Install Lower Roller ................ W3-6-5
Disassemble Travel Motor .........................W3-2-20 Disassemble Lower Roller .......................... W3-6-8
Assemble Travel Motor ..............................W3-2-36 Assemble Lower Roller ............................. W3-6-10
Disassemble Travel Brake Valve ...............W3-2-62 Maintenance Standard .............................. W3-6-12
Assemble Travel Brake Valve ....................W3-2-68
Maintenance Standard...............................W3-2-74 Group 7 Track
Remove and Install Track............................ W3-7-1
Group 3 Center Joint Maintenance Standard ................................ W3-7-7
Remove and Install Center Joint..................W3-3-1
Disassemble Center Joint............................W3-3-4
Assemble Center Joint.................................W3-3-6
Maintenance Standard.................................W3-3-9
178W-3-1
(Blank)
178W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstruc-
ture must be removed first. For removal and installa-
tion 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 alignment marks on inner race of swing bear-
Mark
ing (1) and track frame (2).
1 2
W105-03-01-001
W158-03-01-001
ST 0050
W110-03-01-004
4
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the matching surfaces of the frame and swing
bearing.
IMPORTANT: Failure to align the marks may result “S” (Soft Zone)
Marking Position
in misalignment of the inner race
8°
soft zone. Position of Plug
W158-03-01-001
W3-1-2
UNDERCARRIAGE / Swing Bearing
4. After installing the swing bearing, fill the grease
Swing Bearing Grease Level Pinion
bath with grease (Shell Alvania EP2 or equiva-
lent) until the pinion of the swing bearing is
covered 5 mm in grease.
5 mm
W175-03-01-002
Grease Bath
W3-1-3
UNDERCARRIAGE / Swing Bearing
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
W3-1-4
UNDERCARRIAGE / Swing Bearing
Disassemble Swing Bearing
• Be sure to thoroughly read “Precautions for Dis- CAUTION: Swing bearing weight: 220 kg
assembly and Assembly” on page W1-1-1 before (490 lb)
starting the disassembly work.
3. Unseat outer race (1) of swing bearing horizon-
tally and slightly by crane with lifting sling (ST
1. Tap stopper pin (3) of plug (4) up from the bottom 0050). Remove seals (2 and 5).
side.
NOTE: Since pin (3) was caulked after being in- 4. Place the inner race (7) of swing bearing onto
stalled, grind the caulked part with a wooden blocks while holding outer race (1) by
grounder. crane.
1
2
A
W105-03-01-007
7
B
4
W105-03-01-008
9,10 W105-03-01-010
W3-1-5
UNDERCARRIAGE / Swing Bearing
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
W3-1-6
UNDERCARRIAGE / Swing Bearing
Assemble Swing Bearing
IMPORTANT: Be sure to apply grease to balls (6) 2. Tap plug (4) into outer race (1) and then, drive
and to supports (9). pin (3) into the pin hole.
Caulk the head of pin (3) with a punch.
W142-03-01-007
2
3. Install lifting tool (ST 0050) onto outer race (4) lift
it by crane. Thoroughly degrease the slots for
seals (2 and 5). Apply THREEBOND # 1745 (to
seal (2)) and # 1735 (to seal (5)). Then assemble
seals (2 and 5) into the slots.
W142-03-01-006
W3-1-7
UNDERCARRIAGE / Swing Bearing
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Removal
The removal procedure below starts on the premise
that track has been removed. As for the removal of 1
track, refer to W3-7-1.
: 36 mm
: 180 N⋅m (18.5 kgf⋅m, 134 lbf⋅ft)
W3-2-1
UNDERCARRIAGE / Travel Device
Installation
NOTE: Refer to the “Removal” section for wrench
sizes and tightening torque. 4 5
7 W157-03-02-006
W3-2-2
UNDERCARRIAGE / Travel Device
(Blank)
W3-2-3
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL REDUCER
14
13
7
6
12 ZAXIS270
3 15
5 9
4 16 16
3 11
17
10
9 39
38
37
8
2
18
19
1 20
21
22
20
32 33
31
23
24
ZAXIS270
25
26 40
27 30
26 30
25
29 34
28 30
42
41
35
36
W178-03-02-021
W3-2-4
UNDERCARRIAGE / Travel Device
Disassemble Travel Reducer
CAUTION: High pressure may remain in the 5. Remove sun gear (10) from ring gear (13).
travel device. Gradually loosen the air vent
plug to thoroughly release any remaining 6. Remove the second stage carrier (8) assembly
pressure. from ring gear (13).
1. With motor (28) facing upward, secure spacer to 7. Remove sun gear (2) from ring gear (13).
the track frame mounting flange of the motor with
bolts (M20, Pitch 2.5 mm) (2 used). 8. Remove mounting bolt (17) from ring gear (13).
: 30 mm : 24 mm
Spacer
CAUTION: Ring gear weight:
ZAXIS200, 200-E, 225US, 225USR, 230:
40 kg (90 lb)
ZAXIS270: 55 kg (120 lb)
Spacer ST 5090 (ZAXIS200, 200-E, 225US, NOTE: THREEBOND has been applied between
225USR, 230) the drum and ring gear. If it is difficult to
Spacer ST 5102 (ZAXIS270) remove, use a screwdriver to pry them off.
CAUTION: Approx. Travel device weight: CAUTION: The third stage carrier assembly
ZAXIS200, 200-E: 310 kg (680 lb) weight: 31 kg (70 lb)
ZAXIS225US, 225USR, 230: 322 kg (710 lb) (ZAXIS200, 200-E, 225US, 225USR, 230)
ZAXIS270: 480 kg (1060 lb) 52 kg (110 lb): (ZAXIS270)
2. Secure motor (28) body with a nylon sling, then
10. Hook claws (ST 0916) to the third stage carrier (1)
hoist it and turn it over by crane.
and lift it by crane to remove the third stage carrier
assembly from drum (36).
NOTE: Secure spacer tightly to receive the reac-
tion force.
ST 0916
3. Remove cover (16) from ring gear (13).
W3-2-5
UNDERCARRIAGE / Travel Device
32 33
ZAXIS270
40
29
34
28
41 42
35
36
W178-03-02-020
W3-2-6
UNDERCARRIAGE / Travel Device
11. (ZAXIS200, 200-E, 225US, 225USR, 230) 12. Install eyebolts (M16, Pitch 2.0) (2 used) to drum
Using special tools (ST 7248) and (ST 7249), turn (36). Hoist it by crane to remove motor (28) from
and remove bearing nut (34) from the motor (28) the drum.
housing.
Do not remove knock pin (33) unless necessary. NOTE: When it is difficult to remove the motor, turn
sprocket (35).
W157-03-02-005
W3-2-7
UNDERCARRIAGE / Travel Device
7
6
3 9
11
5
4
3
8
18
19
1 20
21
22
20
32
31
23
24
25
26
27
26
25
30
35
36
W178-03-02-002
W3-2-8
UNDERCARRIAGE / Travel Device
18. Tap on the back of each outer race of roller bearing
(30) (2 used) on drum (36) with a bar and hammer
evenly to remove it. However, don’t remove it
unless replacing it.
W3-2-9
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL REDUCER
35 31
32
ZAXIS 270
36 34 33 17 1 2 13 9 8 11 16
37
39
38
10
12
14
21
20
18
19
22
15
ZAXIS270
40
30
28 29 30 25 26 27 24 23 5 6 3 7
41 42
W178-03-02-024
1- Third Stage Carrier 12 - Shaft 23 - Spring Pin (3 Used) 33 - Knock Pin
2- Sun Gear 13 - Ring Gear 24 - Pin (3 Used) 34 - Bearing Nut
3- Thrust Plate (6 Used) 14 - Stopper 25 - Thrust Plate (6 Used) 35 - Sprocket
4- Planetary Gear (3 Used) 15 - Bolt (12 Used) 26 - Needle Bearing (6 Used) 36 - Drum
5- Needle Bearing (3 Used) 16 - Cover 27 - Planetary gear (3 Used) 37 - Retaining Ring
6- Pin (3 Used) 17 - Bolt (24 Used) 28 - Motor 38 - Stopper
7- Spring Pin (3 Used) 18 - Spring Pin (3 Used) 29 - Floating Seal 39 - Ball Bearing
8- Second Stage Carrier 19 - Pin (3 Used) 30 - Roller Bearing (2 Used) 40 - Bearing Nut
9- Spacer (2 Used) 20 - Thrust Plate (6 Used) 31 - Spring Washer (16 Used) 41 - Lock Plate
10 - Sun Gear 21 - Needle Bearing (3 Used) 32 - *Bolt 42 - Bolt (2 Used)
11 - First Stage Carrier 22 - Planetary Gear (3 Used)
W3-2-10
UNDERCARRIAGE / Travel Device
Assemble Travel Reducer
1. If roller bearing (30) on motor (28) has been re- 6. Apply enough grease to the O-ring of floating seal
placed with a new one, the inner race should be (29).
heated to the temperature of 50 to 70°C (122 to Install one side of the floating seal to drum (36).
158 °F) with a heater first, then assemble it to
motor (28). Tap the bearing fully with a bar after it 7. Install eyebolts (M20, Pitch 2.5) to the bolt (32)
cooled. hole of drum (36). Lift it and place the drum with
the motor (28) mounting side facing downward.
NOTE: Tap the bearing and listen to ring to confirm
installation is completed. CAUTION: Approx. Sprocket weight:
ZAXIS200, 200-E, 225US, 225USR, 230:
2. Apply enough grease to the O-ring of floating seal 46 kg (100 lb)
(29). ZAXIS270: 70 kg (150 lb)
Install one side of the floating seal to motor (28).
W3-2-11
UNDERCARRIAGE / Travel Device
35
34
ZAXIS270
40
30
28 30
41 42
W178-03-02-023
W3-2-12
UNDERCARRIAGE / Travel Device
11. Install the inner race of roller bearing (30) to motor 15. After tightening bearing nut (34) or (40) to speci-
(28), tapping it with a bar and hammer. fied torque, reduce play on bearing nut (34) by
tapping sprocket (35) with a hammer. Then rotate
NOTE: It is very stiff to install. Carry out step 10 the sprocket both clockwise and counterclockwise
and 11 repeatedly so that the inner race 4 to 5 turns.
side of the bearing nut (34) comes to the
position that 3 pitches of thread for the 16. Carry out steps 14 and 15 repeatedly.
bearing nut appears.
17. Do step 14 again to tighten bearing nut (34) or
(40) to specified torque.
12. Apply a little grease to the thread of bearing nut : 790 N⋅m (80 kgf⋅m, 580 Ibf⋅ft)
(34).
W157-03-02-005
ST 7248
ST 7249
34
W178-03-02-013
(ZAXIS270)
Install special tools (ST 3053, ST 3050, ST 3052)
to bearing nut (40) with a torque wrench.
: 790 N⋅m (80 kgf⋅m, 580 Ibf⋅ft)
W3-2-13
UNDERCARRIAGE / Travel Device
34 33 1
16
27 26 24 23
ZAXIS270
40
25 30
28
41 42
W178-03-02-023
W3-2-14
UNDERCARRIAGE / Travel Device
18. (ZAXIS200, 200-E, 225US, 225USR, 230) IMPORTANT: There is a mark on one side of third
Align the spline center of motor (28) with that of stage planetary gear (27). Be sure
knock pin (33). If they can’t be aligned well, turn that this marked side faces the hole
bearing nut (34) to tightening direction to align for spring pin (23).
them.
19. Assemble the third stage carrier (1) in the follow-
NOTE: The aim, to do so, is to align the spline of ing steps.
the third stage carrier (1) with knock pin • Install needle bearings (26) (2 used) to planetary
(33). If the work is continued without align- gear (27).
ing, cover (16) can’t be installed as it will • Clamp planetary gear (27) with thrust plates (25)
protrude. (2 used). Insert the planetary gear (27) into third
stage carrier (1).
34 33
• Install pin (24) to third stage carrier (1) to secure
the planetary gear. At this moment, align the
spring pin hole in the carrier with that of in the pin.
• Tap in spring pin (23) to third stage carrier (1). Be
28 sure that the slit in the spring pin faces the pin
(24) end.
23
W176-03-02-004
24 Slit
(ZAXIS270)
Apply LOCTITE #262 to bolts (42) (2 used).
Install lock plate (41) onto bearing nut (40) with W178-02-06-002
bolt (42).
If the bolt hole of lock plate can’t be aligned well, • Install the other two planetary gears (27) to the
turn bearing nut (40) to tightening direction to third stage carrier by same procedures.
align them.
: 19 mm CAUTION: Third stage carrier (1) assembly
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) ZAXIS200, 200-E, 225US, 225USR, 230:
31 kg (70 lb)
42 ZAXIS270: 52 kg (110 lb)
41
CAUTION: When the knock pin fits with the
40 third stage carrier, the third stage carrier will
drop down. Take care not to injure your fin-
gers.
W140-03-02-001
W3-2-15
UNDERCARRIAGE / Travel Device
36 33 17 1 2 13 9 8
28
5 6 3 7 15
W178-03-02-025
W3-2-16
UNDERCARRIAGE / Travel Device
20. Hoist the third stage carrier (1) assembly using 25. Assemble the second stage carrier (8) in the fol-
special tool (ST 0916) and install it to the motor lowing steps.
(28) spline. If alignment work is not carried out as • Install needle bearing (5) to second stage plane-
in step 18, knock pin (33) can’t be inserted into tary gear (4).
the third stage carrier. • Clamp planetary gear (4) with thrust plates (3) (2
used). Install the planetary gear to second stage
carrier (8).
ST 0916 • Install pin (6) to second stage carrier (8), then
align the spring pin (7) hole in the second stage
carrier with that in pin (6).
• Tap in the spring pin (7) to second stage carrier
(8). Be sure that the slit in the spring pin faces pin
Claws
(6) end.
7
6 Slit
W178-03-02-001
CAUTION: Approx. Ring gear weight: • Install spacer (9) to second stage carrier (8).
ZAXIS200, 200-E, 225US, 225USR, 230: • Install the other two planetary gears (4) to second
40 kg (90 lb) stage carrier (8) by same procedures.
ZAXIS270: 55 kg (120 lb)
26. Install the second stage carrier (8) assembly to
22. Install eyebolts (M12, Pitch 1.75) to the bolt (15) ring gear (13).
holes in ring gear (13). Hoist to align the bolt (17)
hole by crane and install it onto drum (36).
23. Install ring gear (13) to drum (36) with bolt (17).
: 24 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
24. Insert sun gear (2) into third stage carrier (1) with
the smaller end facing upward.
W3-2-17
UNDERCARRIAGE / Travel Device
ZAXIS270
2 13 9 8 11 16 37
39
38
10
12
14
15
28
W178-03-02-022
W3-2-18
UNDERCARRIAGE / Travel Device
27. Insert sun gear (10) into second stage carrier (8)
with the smaller outer diameter end facing up-
ward.
30. Insert shaft (12) into the center spline of sun gear
(10). Engage the shaft with the motor (28) spline
and sun gear (2).
34. Install cover (16) to ring gear (13) with bolts (15)
(12 used).
: 19 mm
: 110 N⋅m (11.5 kgf⋅m, 83.2 Ibf⋅ft)
ZAXIS200, 200-E, 225US, 225USR, 230
Bolts (15) (12 used)
ZAXIS270 Bolts (15) (12 used)
W3-2-19
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR
ZAXIS200, 200-E
Brake Releasing Oil Passage
ZAXIS225US (Up to serial No.108985)
Piston Oil Passage
ZAXIS225USR (Up to serial No.108986) Piston Oil Passage
ZAXIS230 (Up to serial No.11128)
6
5
4
2
3 7
2
1 6
15
14
16
13
17
12 18
11 19
10
8 27
26
25
24
23
22 28
21
20
W178-03-02-003
1- Shaft 8- Knock Pin (2 Used) 15 - Swash Plate 22 - Needle Bearing
2- Retaining Ring (2 Used) 9- Valve Plate 16 - Knock Pin 23 - Disc Spring
3- Roller Bearing 10 - Rotor 17 - Plate 24 - O-Ring
4- Oil Seal 11 - Spring (6 Used) 18 - Ball (2 Used) 25 - Brake Piston
5- O-Ring 12 - Bushing 19 - Piston (2 Used) 26 - O-Ring
6- O-Ring (3 Used) 13 - Brake Valve 20 - Plate (4 Used) 27 - Friction Plate (4 Used)
7- Housing 14 - Plunger (9 Used) 21 - Brake Valve 28 - Plate (4 Used)
W3-2-20
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
ZAXIS200, 200-E, 225US, 225USR, 230
CAUTION: Travel motor weight: 92 kg (200 lb) 6. Remove plates (28) and friction plates (27) from
housing (7). (4 used for each)
IMPORTANT: When removing brake valve (21)
from the travel motor, valve plate (9) 7. Remove rotor (10), springs (11) (6 used), bushing
is also removed with the brake valve. (12), retainer (13) and plungers (14) (9 used) from
Do not drop the valve plate as it eas- housing (7).
ily comes off.
CAUTION: Housing weight: 55 kg (120 lb)
1. Place the travel motor longitudinally.
Remove socket bolt (20) to remove brake valve
(21) from housing (7). 8. Place housing (7) with the brake releasing oil
: 14 mm passage facing downward and horizontal.
IMPORTANT: Valve plate (9) is easily cracked and NOTE: When the brake releasing oil passage is
scratched, so handle it with care. positioned up, the thick portion of swash
plate (15) faces upward. When housing (7)
2. Remove valve plate (9) and knock pins (8) (2 is placed horizontally, the swash plate may
used) from brake valve (21). Do not remove nee- come off suddenly.
dle bearing (22) unless necessary.
9. Remove swash plate (15) from housing (7).
NOTE: Even if a small removing tool is used for
removing the needle bearing, the outer NOTE: If the swash plate can’t be removed, apply
race may be deformed. Do not re-use the 100 to 300 kPa (1 to 3 kgf/cm2, 14 to 43
needle bearing. psi) pressure air through the piston pushing
oil passage port, and the swash plate will
3. Wrap tape on the needle bearing (22) rotation be removed with the piston. In order to
surface of shaft (1) for protection. prevent the piston from popping out, cover
it with a cloth. Use a bicycle pump to supply
4. Remove disc spring (23) from housing (7). air.
25
W178-03-02-009
W3-2-21
UNDERCARRIAGE / Travel Device
4
2 7
3
2
W178-03-02-003
W3-2-22
UNDERCARRIAGE / Travel Device
13. Insert a screwdriver into shaft (1) hole in housing
(7) to push out oil seal (4).
W178-03-02-010
W3-2-23
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR
ZAXIS225US (Serial No. 108986 and up)
ZAXIS225USR (Serial No. 108987 and up) Brake Releasing Oil Piston Oil
ZAXIS230 (Serial No. 11129 and up) Passage Passage
6
5
4
2
3 7
1 6
15
14
13
12 18
11 19
10
8 27
26
25
24
23
22 28
21
20
W178-03-02-030
1- Shaft 8- Knock Pin (2 Used) 15 - Swash Plate 24 - O-Ring
2- Retaining Ring 9- Valve Plate 18 - Ball (2 Used) 25 - Brake Piston
3- Roller Bearing 10 - Rotor 19 - Piston 26 - O-Ring
4- Oil Seal 11 - Spring (6 Used) 20 - Socket Bolt(9 Used) 27 - Friction Plate (4 Used)
5- O-Ring 12 - Bushing 21 - Brake Valve 28 - Plate (4 Used)
6- O-Ring (2 Used) 13 - Retainer 22 - Needle Bearing
7- Housing 14 - Plunger (9 Used) 23 - Disc Spring
W3-2-24
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
ZAXIS225US, 225USR, 230
25
W178-03-02-009
W3-2-25
UNDERCARRIAGE / Travel Device
4
2 7
3
W178-03-02-030
W3-2-26
UNDERCARRIAGE / Travel Device
12. Insert a screwdriver into the shaft (1) hole in
housing (7). Remove oil seal (4).
NOTE: Adhesive is applied onto the outer surface
of oil seal (4). Oil seal (4) cannot be used
again.
Bar
3
1
W172-03-02-003
W3-2-27
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR
14
ZAXIS270 (Up to serial No.20226) 12 13
ZAXIS270LCN (Up to serial No.82518)
11
10
9
8
7
Brake Releasing
6 Oil Passage
5
3
4
2 16 15
1
25
26
27
20 18
19
21
17
22
23
28
24
32 29
30
31
40 39 38
37
36
33
34
35 W164-03-02-003
W3-2-28
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
ZAXIS270, 270LCN
CAUTION: Travel motor weight: 90 kg 4. Remove valve plate (29) from brake valve (33). At
(200 lb) this time, the valve plate is still with ring (21)
Brake valve weight: 43 kg (95 lb) attached.
IMPORTANT: Valve plate (29) is easily cracked and NOTE: The valve plate (29) is with bushing (28)
scratched, so handle it with care. attached, but do not remove the bushing
unless necessary.
1. Place the travel motor longitudinally. Remove
socket bolts (32) (4 used) to remove brake valve 5. Remove plate (30) from brake valve (33).
(33) from housing (12). At this time, the brake
valve side is still with valve plate (29) attached. 6. Remove servo piston (36) from brake valve (33).
: 14 mm At this time, the servo piston is still with piston
rings (37) (2 used) attached.
2. Remove socket bolts (40) (4 used) from brake
valve (33) to remove cover (39) and O-ring (38). 7. Remove O-Rings (1), (15) from housing (12).
3. Turn brake valve (33) over to remove plug (23) 8. Remove disc spring (2) from housing (12).
and O-ring (24), then insert a hexagon wrench
into the plug (23) hole to remove reamer bolt (22). CAUTION: When removing brake piston (4)
: 8 mm, 10 mm from the housing filled with air, cover the
housing with cloth to prevent the brake
33 piston from flying out.
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
23
to be removed.
4
W178-03-02-009
W107-03-02-098
W3-2-29
UNDERCARRIAGE / Travel Device
14
12 13
11
10
9
8
7
16
25
26
27
20 18
17
W164-03-02-003
W3-2-30
UNDERCARRIAGE / Travel Device
10. Remove plates (6) (5 used), friction plates (20) (4
CAUTION: Drive disc (8) assembly weight:
used) from housing (12).
8.0 kg (18 lb)
IMPORTANT: When remove center shaft (26), the 15. Install drive disc (8) assembly into special tools
center shaft will be with pin (25) (ST 3058, 5904) to remove bearing nut (16).
attached. Be sure not to lose it.
W107-03-02-121
W3-2-31
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR
ZAXIS270 (Serial No. 20227 and up)
Brake Releasing Oil
ZAXIS270LCN (Serial No. 82519 and up) Passage
8
9
19
18
17
16
15
14
13
12
11
10
27
26
25
24
23
22
21 28
20
W178-03-02-026
1- Shaft 8- Spring 15 - Bushing 22 - O-Ring
2- Retaining Ring 9- Piston 16 - Retainer 23 - Disc Spring
3- Roller Bearing 10 - Needle Bearing 17 - Plunger (9 Used) 24 - O-Ring
4- Retaining Ring 11 - Knock Pin 18 - Swash Plate 25 - Brake Piston
5- Oil Seal 12 - Valve Plate 19 - Ball (2 Used) 26 - O-Ring
6- O-Ring (2 Used) 13 - Rotor 20 - Socket Bolt(8 Used) 27 - Friction Plate (4 Used)
7- Housing 14 - Spring (6 Used) 21 - Brake Valve 28 - Plate (4 Used)
W3-2-32
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
ZAXIS270, 270LCN
CAUTION: When removing brake piston (25), 10. Remove balls (19) (2 used), spring (8) and piston
cover with a cloth in order not to fly out brake (9) from housing (7) by using a magnet.
piston (25).
11. Remove retaining ring (2) from housing (7).
2
5. Apply 100 to 300 kPa (1 to 3 kgf/cm , 14 to 43 psi)
pressure air to brake releasing oil passage in 12. Attach a bar onto the bottom side on inner spline
housing (7). Float and remove brake piston (25). hole of shaft (1). Tap and remove shaft (1) with
roller bearing (3) from housing (7) by using a
NOTE: The upper surface of brake piston (25) is plastic hammer.
the air seat surface. Place brake piston
(25) with the seat surface facing upward.
Air Seat Surface
25
W178-03-02-009
W3-2-33
UNDERCARRIAGE / Travel Device
5
4
3
7
W178-03-02-026
W3-2-34
UNDERCARRIAGE / Travel Device
13. Insert a screwdriver into the shaft (1) hole in
housing (7). Remove oil seal (5).
NOTE: Adhesive is applied onto the outer surface
of oil seal (5). Oil seal (5) cannot be used
again.
Bar
3
1
W172-03-02-003
W3-2-35
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR
ZAXIS200, 200-E
ZAXIS225US (Up to serial No. 108985)
ZAXIS225USR (Up to serial No. 108986)
ZAXIS230 (Up to serial No. 11128)
21 20 8 6 5 25 10 14 13 15 18 19
17
16
22 23 6 24 26 28 27 11 12 19 2
9
W3-2-36
UNDERCARRIAGE / Travel Device
Assemble Travel Motor
ZAXIS200, 200-E, 225US, 225USR, 230
CAUTION: Housing weight: 50 kg (110 lb) 6. Install retaining ring (2) onto shaft (1).
1. Place housing (7) with the brake valve (21) mat- 7. Apply grease to the flat surface of plate (17).
ing surface facing upward. With the greased surface of plate (17) facing
inside, install it into housing (7) while aligning it
IMPORTANT: Apply OCEAN grease #7 to the inner with knock pin (16).
surface of the oil seal, and apply
THREEBOND #1104 or #1215 to the 8. Apply grease to balls (18) (2 used) sufficiently and
outer surface of the oil seal. assemble them to plate (17).
2. Clean the oil seal (4) fitting part of housing (7) NOTE: Without grease applied to the ball, it is
neatly. impossible to hold the ball and swash plate
Tap the oil seal into the housing using special (15).
tools (ST 7270), (ST 7271) and a plastic hammer.
9. Install pistons (19) (2 used) to housing (7) with the
ST 7270
stepped side of the piston facing inside.
3. There are two retaining ring grooves in shaft (1). 11. Apply grease to the ball hole of swash plate (15).
Install retaining ring (2) into the end groove. Install the swash plate on housing (7), aligning it
with 2 balls (18).
4. Install the inner ring plate to roller bearing (3) with
the stamped mark facing the spline of the shaft. CAUTION: Housing weight: 55 kg (120 Ib)
Inner Ring Plate 12. Place housing (7) with the brake releasing oil
3
passage at downward and in horizontal.
W3-2-37
UNDERCARRIAGE / Travel Device
21 6 25 10 14 13
23 6 24 26 28 27 11 12
W178-03-02-006
W3-2-38
UNDERCARRIAGE / Travel Device
IMPORTANT: Pay attention to the retainer direc- IMPORTANT: The upper surface of brake piston
tion. (25) is a seat surface. Take care not
to damage it.
13. Install springs (11) (6 used), bushing (12), retainer
(13), plungers (14) (9 used) onto rotor (10) in that IMPORTANT: Install brake piston (25) with the
order, with the chamfered side of the retainer fac- notch on the disc spring (23)
ing the bushing. mounting surface of the brake
piston facing other side of the brake
releasing oil passage port.
13
18. Tap brake piston (25) into housing (7) using spe-
cial tool (ST 7272), (ST 7273) and a hammer to
push it into the housing.
12
Chamfered Side
W172-03-02-001
NOTE: Since the O-ring is positioned around the
brake piston, the brake piston can’t be fully
fitted. When installing brake valve (21),
push the brake piston with tightening bolts.
14. Assemble the rotor (10) assembly into housing
(7). Brake Releasing Oil
Notch Passage
7 25
CAUTION: Housing weight: 50 kg (110 lb)
19. Put disc spring (23) on brake piston (25) with the
inner diameter of the disc spring facing the brake
piston.
21. Fill hydraulic oil into housing (7) until plate (28) is
submerged.
W3-2-39
UNDERCARRIAGE / Travel Device
21 20 8
22 9
W178-03-02-006
W3-2-40
UNDERCARRIAGE / Travel Device
IMPORTANT: Pay attention to the knock pin (8)
direction.
21 22
W176-03-02-012
W3-2-41
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR
ZAXIS225US (Serial No. 108986and up)
ZAXIS225USR (Serial No. 108987 and afeter)
ZAXIS230 (Serial No. 11129 and after)
Brake Releasing Oil Pas-
sage
21 20 8 6 5 25 10 14 13 15 18
22 23 6 24 26 28 27 11 12 19 2
9
W3-2-42
UNDERCARRIAGE / Travel Device
Assemble Travel Motor
ZAXIS225US, 225USR, 230
W178-03-02-011
W3-2-43
UNDERCARRIAGE / Travel Device
21 6 25 10 14 13
23 6 24 26 28 27 11 12
W178-03-02-029
W3-2-44
UNDERCARRIAGE / Travel Device
IMPORTANT: Face the chamfered side of retainer IMPORTANT: As the upper surface of brake piston
(13) to the bushing (12) side. (25) is an air seat surface, do not
11. Install springs (11) (6 used), bushing (12), retainer damage it.
(13) and plungers (14) (9 used) to rotor (10) in this IMPORTANT: Install brake piston (25) so that the
order. notch on disc spring (23) mounting
surface is located opposite the
13 brake releasing oil passage.
16. Tap and install brake piston (25) into housing (7)
by using special tools (ST 7272, ST 7273) and a
12 hammer.
Chamfered Side NOTE: As O-ring is positioned around brake piston
W172-03-02-001
(25), brake piston (25) cannot be fully in-
serted. When installing brake valve (21),
12. Install the rotor (10) assembly to housing (7). tighten brake piston (25) by using the bolt.
19. Add hydraulic oil into housing (7) until plate (28) is
submerged.
W3-2-45
UNDERCARRIAGE / Travel Device
21 20 8
22 9
W178-03-02-029
W3-2-46
UNDERCARRIAGE / Travel Device
IMPORTANT: Check the direction to install knock
pin (8).
20. Install knock pins (8) (2 used) into brake valve
(21). Insert the large diameter side of knock pin
(8) into the pin hole of brake valve (21).
ST 7269
21 22
W176-03-02-012
W3-2-47
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR
ZAXIS270 (Up to serial No.20226)
ZAXIS270LCN (Up to serial No.82518)
35, 34 28 1 15 2 3 4 5 6 7 8
9
30
10
29
31 11
33
12
13
14
16
18
25
17
36 20
37
38
39
19
40 23, 24 27 32 26
21
W178-03-02-016
22
W3-2-48
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR
ZAXIS270, 270LCN
CAUTION: Drive disc (8) weight: 5.0 kg (11 lb)
1. Heat the inner race of bearing (9) to 70° to 90°C 7. Secure drive disc (8) onto special tools (ST 3058,
(158 °F to 194 °F) in oil bath or drier. Press the ST 5904), tighten bearing nut (16) to the specified
inner race of bearing (9) into drive disc (8) with torque.
special tool (ST 2155) and press. : 3±0.5 N⋅m
(0.3±0.05 kgf⋅m, 2.2 ± 0.37 Ibf⋅ft)
2. Put the outer race onto the inner race of bearing
(9).
ST 3058
fitting tightly.
CAUTION: Housing (12) weight: 46 kg
IMPORTANT: Apply grease onto bearing nut (16). (100 lb)
11. Turn housing (12) over. Tap drive disc (8) assembly
lightly with a plastic hammer and brass bar to in-
stall it into housing (12).
W3-2-49
UNDERCARRIAGE / Travel Device
27 12 4 18 6 7 8
13
25
17 3 5 Slit (4 Places) 20 26
W178-03-02-019
W3-2-50
UNDERCARRIAGE / Travel Device
12. Turn housing (12) over and place it with its oil seal 16. Install plungers (17) (7 used) into the spherical
(13) side facing down. handle hole in drive disc (8) one by one. Be sure
to confirm plungers (17) (7 used) move smoothly.
IMPORTANT: Be sure to align the oil slot (slit part) 17 8
in spacer (7) with that in housing
(12).
13. Install spacer (7) into housing (12) with its oil slot
(slit part) facing the travel reducer side, while Spherical
aligning the oil slot in spacer (7) with the oil slot Handle Hole
inside of housing (12).
25
NOTE: In case the teethless part or slot position 26
fail to align with each other, heating may be
resulted to motor failure.
Groove (4 Places) 12
W178-03-02-015
W3-2-51
UNDERCARRIAGE / Travel Device
28 29 15 12 2
30
31
33
36
37
19
23 1
21
W178-03-02-016
22
W3-2-52
UNDERCARRIAGE / Travel Device
22. Install O-rings (1) (15) into housing (12). IMPORTANT: Pay attention to the direction of ring
(21) assembly.
IMPORTANT: Install disc spring (2) into housing
(12) with the outer surface side of 31. Install link (21) assembly into brake valve (33)
the disc spring facing upward. 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 brake valve side.
23. Install disc spring (2) into housing (12).
29
Rotor (18) Side
24. Fill hydraulic oil into housing (12).
Hydraulic oil: 1.3 L (0.34 US gal)
26. Install plate (30) onto brake valve (33). 32. Insert special tool (ST 7131) into the mounting
hole of plug (23), then align the hole of ring (21)
27. Install piston rings (37) (2 used) onto servo piston with that of servo piston (36).
(36).
ST 7131
28. Insert servo piston (36) into brake valve (33). 36 21
W3-2-53
UNDERCARRIAGE / Travel Device
33 12
36
38
39
40 23, 24 32
21
W178-03-02-016
22
W3-2-54
UNDERCARRIAGE / Travel Device
33. Apply additive grease, Johnson wax JP103, to the
CAUTION: Brake valve weight: 43 kg (90 lb)
end of reamer bolt (22) in order to prevent it from
seizing.
Install reamer bolt (22) to link (21) and servo pis- 38. Lift and install brake valve (33) onto housing (12)
ton (36) through the opposite mounting hole of by crane, while aligning the hole in removed plug
plug (23). (A) with special tool (ST 7085).
: 8 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft) 39. Remove special tool (ST 7085) from brake valve
(33).
34. Install O-ring (24) onto plug (23), then install it to
brake valve (33). (2 Places) 40. Install spool (B), spring (C) and plug (A) into brake
: 10 mm valve (33).
: 118 N⋅m (12 kgf⋅m, 87 Ibf⋅ft) : 8 mm
: 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
35. Install O-ring (38) onto cover (39) and install it to
brake valve (33) with socket bolts (40) (4 used). 41. Install brake valve (33) onto housing (12) with
: 10 mm socket bolts (32) (4 used).
: 88 N⋅m (9.0 kgf⋅m, 65 Ibf⋅ft) : 14 mm
: 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
36. Install special tool (ST 7085) into the end of cen-
ter shaft (26).
ST 7085
26
12
W107-03-02-183
W3-2-55
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR
ZAXIS270 (Serial No. 20227 and up)
ZAXIS270LCN (Serial No. 82519 and up)
27 25 5 23 11 12 10 14 18 16 17 2 8
26 22 24 5 9 13 21 20 15 19 7 28 6
Piston Oil Passage W1HH-03-02-006
W3-2-56
UNDERCARRIAGE / Travel Device
Assemble Travel Motor
ZAXIS270, 270LCN
IMPORTANT: Check the direction to install roller
bearing (8).
CAUTION: Housing (6) weight: 87 kg (190 lb) 4. Insert the inner ring plate side of roller bearing (8)
into the inner bore spline end of shaft (1) until
1. Place housing (6) with the brake valve (27) bearing (8) comes into the tight fitting part. Do not
mounting surface facing upward. damage the seal lip surface of shaft (1).
IMPORTANT: Apply OCEAN grease #7 to the inner 5. Insert the inner bore spline end of shaft (1) into
surface of oil seal (4) and apply special tool (ST 7268). Tap the opposite end of
THREEBOND #1104 or #1215 to the shaft (1) by using a plastic hammer and install
outer surface of oil seal (4). roller bearing (8) to shaft (1).
2. Clean the oil seal (4) mating part of housing (6).
Install oil seal (4) to housing (6) by using special 1
tools (ST 7270, ST7271).
ST 7270 Inner Bore Spline
Inner Ring Plate
4
ST 7268 12
6
W176-03-02-008
W176-03-02-007
ST 7271
IMPORTANT: Check the direction to install roller 6. Install retaining ring (3) on shaft (1). Do not
bearing (8). damage the sliding surface of oil seal (4).
3. Install roller bearing (8) so that all marked sur-
faces on the outer race, inner race and inner ring 7. Apply grease to the ball (17) surface sufficiently.
plate face outside. Install balls (17) (2 used) to housing (6).
Marked Surface on Marked Surface on 8. Install spring (28) and piston (7) to housing (6).
Outer Race Inner Race Face the stepped side of piston (7) inside.
W176-02-06-014
Marked Surface on
Inner Ring Plate
W3-2-57
UNDERCARRIAGE / Travel Device
27 25 5 23 11 12 10 14 18 16 17 2
5 9 13 21 20 15 19 6
W1HH-03-02-006
W3-2-58
UNDERCARRIAGE / Travel Device
IMPORTANT: The smaller diameter side of shaft
CAUTION: Housing (6) weight: 105 kg
(1) is matched with the inner race on
needle bearing (4). Do not damage (230 lb)
the inner race.
9. Tap and install shaft (1) to housing (6) lightly by 15. Place housing (6) with the brake valve (27)
using a plastic hammer. mounting surface facing upward.
10. Install retaining ring (2) to housing (6) and secure 16. Install plates (13) (4 used) and friction plates (21)
shaft (1). (3 used) on housing (6) alternately. Install friction
plate (21) first.
NOTE: If the open part of retaining ring (2) is lo-
cated at the lowest bottom of housing (6), 17. Apply grease to O-rings (11, 12). Install O-rings
retaining ring (2) can be removed and in- (11, 12) to brake piston (10).
stalled easily.
18. Tap and install brake piston (10) into housing (6)
11. Apply grease to the ball (17) hole of swash plate by using a plastic hammer evenly.
(16). Align the positions of pins (17)(2 used) and
install swash plate (16) to housing (6). NOTE: As O-ring is positioned around brake piston
(10), brake piston (10) cannot be fully in-
serted. When installing brake valve (27),
CAUTION: Housing (6) weight: 95 kg (210 lb) tighten brake piston (10) by using the bolt.
12. Place housing (6) horizontally with the brake re- IMPORTANT: Check the direction to install disc
leasing oil passage facing downward. spring (9).
NOTE: If the brake releasing oil passage faces 19. Place disc spring (9) on brake piston (10) with the
upward, swash plate (16) may come off. inner diameter facing to brake piston (10).
IMPORTANT: Face the chamfered side of retainer 20. Install O-rings (5) (2 used) onto the brake valve
(19) to the bushing (15) side. (27) mating surface of housing (6). Install O-ring
13. Install springs (20) (6 used), bushing (15), retainer (23) onto brake valve (27).
(19) and plungers (18) (9 used) to rotor (14) in this
order. 21. Add hydraulic oil into housing (6) until plate (13) is
submerged.
19
IMPORTANT: Check the direction to install knock
pin (25).
15 22. Install knock pin (25) into brake valve (27). Insert
Chamfered the larger diameter side of knock pin (25) into the
Side W172-03-02-001 pin hole of brake valve (27).
W3-2-59
UNDERCARRIAGE / Travel Device
27 25
26 22 24 6
W1HH-03-02-006
W3-2-60
UNDERCARRIAGE / Travel Device
IMPORTANT: Check the direction to install needle
bearing (26).
23. Lightly tap and install needle bearing (26) to brake
valve (27) by using special tool (4472142) and a
hammer. Face the stamped mark of needle
bearing (22) outside.
4472142
26
27
W176-03-02-012
W3-2-61
UNDERCARRIAGE / Travel Device
DISASSEMBLE BRAKE VALVE
ZAXIS200, 200-E, 225US, 225USR, 230
1
2
3
4
4
15
14 3
13 2
12 1
8
7
9
10
W178-03-02-004
11
W3-2-62
UNDERCARRIAGE / Travel Device
Disassemble Brake Valve
ZAXIS200, 200-E, 225US, 225USR, 230
6. Remove springs (10), poppets (9) from valve
1. Remove plug (1) from valve housing (5). (2 housing (5) with a magnet. (2 places)
places).
: 36 mm 7. Remove plug (12) from valve housing (5). (2
places)
2. Remove spring (3) and stopper (4) from valve : 6 mm
housing (5) using a magnet. (2 places)
8. Remove spring (14), spool (15) from valve hous-
3. Remove spool (6) from valve housing (5) with a ing (5) with a magnet.
magnet.
W176-03-02-011
Piston
W3-2-63
UNDERCARRIAGE / Travel Device
DISASSEMBLE BRAKE VALVE
ZAXIS270 (Up to serial No.20226)
ZAXIS270LCN (Up to serial No.82518)
Counter Balance Valve
12
10
7
21 14
15 9 6
20 1, 2
16 5
8
17
19 4
18
W3-2-64
UNDERCARRIAGE / Travel Device
Disassemble Brake Valve
ZAXIS270, 270LCN
Be sure to thoroughly read “Precautions for Disassem- • Shuttle valve for servo piston and for parking brake
bly and Assembly Work” on page W1-1-1 before start-
ing the disassembly work. IMPORTANT: The LOCTITE was applied on seat
(15). Do not remove the seat unless
necessary.
CAUTION: Brake valve weight: 43 kg (90 Ib)
6. Remove plugs (17) (2 used) from casing (3) to
• Counter Balance Valve remove balls (14) (2 used) and seats (15) (2
1. Remove plugs (8) (2 used) from casing (3). used).
: 41 mm : 5 mm, 6 mm
W140-03-02-005
• Check Valve
W3-2-65
UNDERCARRIAGE / Travel Device
DISASSEMBLE BRAKE VALVE
ZAXIS270 (Serial No. 20227 and up)
ZAXIS270LCN (Serial No. 82519 and up)
2
3
4
16 3
15
14 2
13 1
9 8 7
10
11
W1HH-03-02-007
12
W3-2-66
UNDERCARRIAGE / Travel Device
Disassemble Brake Valve
ZAXIS270, 270LCN
1. Remove plug (1) from valve housing (6). (2 6. Remove spring (10) and poppet (9) from valve
places) housing (6) by using a magnet. (2 places)
: 41 mm
7. Remove plug (13) from valve housing (6).
2. Remove spring (3) and stopper (4) from valve : 6 mm
housing (6) by using a magnet. (2 places)
8. Remove spring (15) and spool (16) from valve
3. Remove spool (5) from valve housing (6) by using housing (6) by using a magnet.
a magnet.
W176-03-02-011
Piston
W3-2-67
UNDERCARRIAGE / Travel Device
ASSEMBLE BRAKE VALVE
ZAXIS200, 200-E, 225US, 225USR, 230
6 5
4 4
3 3
2
2
1
1
15
14
7
9 13
12
10 W178-03-02-005
11 8
W3-2-68
UNDERCARRIAGE / Travel Device
Assemble Brake Valve
ZAXIS200, 200-E, 225US, 225USR, 230
1. Insert spool (6) approximately half way into valve IMPORTANT: Be sure to assemble spool in correct
housing (5). direction.
2. Install O-ring (2), spring (3), stopper (4) onto plug 8. Install spool (15) into valve housing (5) with the
(1) at one side. Install the plug into valve housing hole end facing front.
(5) with a thread left out.
9. Install spring (14) into valve housing (5).
NOTE: If the plug is fully installed, it is difficult to
assemble the plug to other side as spool 10. Install O-ring (13) on plug (12) to valve housing
(6) may be pushed out. (5).
: 6 mm
3. Install O-ring (2), spring (3) and stopper (4) into : 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
another plug (1). Install plug (1) into valve housing
(5). Tighten the plug by hand.
5. Install O-ring (8) into plug (7), then install plug (7)
into valve housing (5).
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
W3-2-69
UNDERCARRIAGE / Travel Device
DISASSEMBLE BRAKE VALVE
ZAXIS270 (Up to serial No.20226)
ZAXIS270LCN (Up to serial No.82518)
14
15
16
14
15
17
16
Section B 17 Section C
A
2 1 7 6
20 21
19
18
3
4
4
9 B
A
13 12 10
W3-2-70
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL BRAKE VALVE
ZAXIS270, 270LCN
2. Install balls (14) (2 used) with casing (3) titled. 6. Install spring (10) onto stoppers (12) (2 used),
Apply LOCTITE #262 onto seats (15) (2 used) then insert the stoppers into casing (3).
and install the seat into casing (3). Install O-rings
(16) (2 used) onto plugs (17) (2 used) and install 7. Install O-rings (5) (2 used) onto plugs (8) (2 used),
the plugs into casing (3). then install the plugs into casing (3).
: 5 mm : 41 mm
: 14.5 N⋅m (1.5 kgf⋅m, 11.0 Ibf⋅ft) : 340 N⋅m (35 kgf⋅m, 250 Ibf⋅ft)
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
• Check Valve
3. Install springs (6) (2 used) into poppets (7) (2
used) and insert the poppet into casing (3). Install
O-rings (5) (2 used) onto plugs (4) (2 used) and
install the plugs into casing (3).
: 12 mm
: 235 N⋅m (24 kgf⋅m, 174 Ibf⋅ft)
W3-2-71
UNDERCARRIAGE / Travel Device
ASSEMBLE BRAKE VALVE
ZAXIS270 (Serial No. 20227 and up)
ZAXIS270LCN (Serial No. 82519 and up)
6 1 2 3 4 5 4 3 2 1
13 14 15 16 9 10 11 12 8 7
W1HH-03-02-008
W3-2-72
UNDERCARRIAGE / Travel Device
Assemble Brake Valve
ZAXIS270, 270LCN
7. Install O-ring (11) into relief valve (12). (2 Used)
1. Install spool (5) approximately half way into valve
housing (6). 8. Push poppet (9) installed in step 6 slowly and in-
stall relief valve (11) into valve housing (6). (2
2. Install O-ring (2), spring (3), and stopper (4) onto places)
plug (1) at one side. Install bolts (1) (4 used) to : 41 mm
valve housing (6). Tighten plug (1) by hand. : 440 N⋅m (45 kgf⋅m, 330 Ibf⋅ft)
3. Install O-ring (2), spring (3), and stopper (4) into NOTE: Check the direction to install spool (15).
plug (1) at other side. Install bolts (1) (4 used) to 9. Install Spool (16) to housing (6) with the end fac-
valve housing (6). Tighten plug (1) by hand. ing forward.
4. Tighten plug (1) on both sides by using a spanner. 10. Insert spring (15) into valve housing (6).
: 41 mm
: 343 N⋅m (35 kgf⋅m, 255 Ibf⋅ft) 11. Install O-ring (14) to plug (13). Install plug (13)
into valve housing (6).
5. Install O-ring (8) to plug (7). Install plug (7) into : 6 mm
housing (6). : 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
W3-2-73
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Sprocket
C’
C
B
D
A
W1SE-03-02-001
W105-03-07-040
ZAXIS200, 200-E, 225US, 225USR, 230 Unit: mm (in) ZAXIS270 Unit: mm (in)
Standard Allowable Limit Standard Allowable Limit
W3-2-74
UNDERCARRIAGE / Travel Device
Travel Motor
Shoe
1. Clearance between plunger and shoe
Unit: mm (in)
Standard Allowable Limit
0 0.2 (0.0079)
ε≤0.2 mm (0.0079 in) ε
Plunger
W105-02-06-134
Plugner Assembly
Rotor
W105-02-06-135
Plunger
W105-02-06-130
W3-2-75
UNDERCARRIAGE / Travel Device
Parking Brake
B D
C W176-03-02-014
ZAXIS270 (Up to Serial No. 20226), ZAXIS270LCN (UP to Serial No. 80518) Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Friction plate Thickness 3.3 (0.13) 3.25 (0.12)
B Disc spring (Overall height) 7.6 (0.30) 7.20 (0.28)
C Piston Thickness 49.6 (1.95) −
D Plate Thickness 1.80 (0.07) 1.75 (0.07)
ZAXIS270 (Serial No. 20227 and up), ZAXIS270LCN (Serial No. 80519 and up) Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Friction plate Thickness 3.0 (0.12) 2.95 (0.12)
B Disc spring (Overall height) 7.5 (0.30) 7.4 (0.29)
C Piston Thickness *42 (1.65) −
D Plate Thickness 2.0 (0.08) 1.95 (0.08)
W3-2-76
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal 1 2
3
2. Remove mounting bolt (1) from the center joint to
remove stopper plate (2).
: 22 mm
: 140 N⋅m (14.5 kgf⋅m, 105 lbf⋅ft)
W3-3-1
UNDERCARRIAGE / Center Joint
Installation
NOTE: Refer to “Removal” section above for 1 2
wrench sizes and tightening torque.
leaks.
W105-03-03-003
W3-3-2
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-3
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT
3
4
10
9
11
12
W157-03-03-002
W3-3-4
UNDERCARRIAGE / Center Joint
Disassemble Center Joint
• Be sure to thoroughly read “Precautions for Dis- IMPORTANT: For easy removal, two pins can be
assembly and Assembly Work” on page W1-1-1 used to pry out oil seals (6). Take
before starting the disassembly work. care not to damage the seal groove
with the pins.
CAUTION: Center joint weight: 26.5 kg (60 lb)
6. Remove oil seals (6) (6 used) and O-ring (4) from
body (7).
1. Remove mounting bolt (12) from cover (11)
diagonally. Using eyebolts M10 (pitch 1.5, length
18 mm), hoist the center joint, then secure it on a
work bench.
ST 1033
7. When replacing bushing (5), build-up weld at 4
places in its inner diameter with welding rod,
shrink bushing (5) to pull it out.
W506-03-03-002
W3-3-5
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT
3
4
6
7
8
10
9
11
12
W178-03-03-001
W3-3-6
UNDERCARRIAGE / Center Joint
Assemble Center Joint
IMPORTANT: If bushing is removed, be sure to IMPORTANT: Clearance between body (7) and
reinstall bushing (5) first. (Refer to spindle (2) is approximately 0.1 mm
page W3-3-8.) (0.004 in), so the spindle must be
inserted along axis straight and
IMPORTANT: Install dust seal (3) with its lip side slowly.
facing body (7).
4. Tap body (7) with a plastic hammer until its sur-
1. Install dust seal (3) to spindle (2). face A is flush with that of spindle (2).
Surface A 2
0.1 mm
Lip
Body (7)
W105-03-03-024
W178-03-03-002
2. Install oil seals (6) (6 used) and o-ring (4) into IMPORTANT: Be sure to install ring (8) with the
body (7). chamfered side facing spindle.
3. Secure spindle (2) to a work bench. Install body 5. Install ring (8) and O-ring (9) to body (7).
(7) on spindle (2) with their matching marks
aligned. 6. Install retaining ring (10) to spindle (2).
W3-3-7
UNDERCARRIAGE / Center Joint
When replacing the body or spindle with new one, the
following procedures are required.
2. Press bushing (5) into body (7), using the press- 3. Tap the balls of plug (1) so that the top of each
ing tool. ball is 0.4 mm (0.016 in) or more lower than the
Pressing force: 0.5 to 1.5 t (1100 to 3300 lb) respective sleeve edge as illustrated in detail D.
Pressing tool: ST 2558
ST 2558
Sleeve
2
0.4 mm
7 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
UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD
Bushing
T157-01-01-040
W3-3-9
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-10
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
Before removing and adjusting the track adjuster, the
tracks and the front idler must be removed first. For
removal of the tracks and front idler, refer to their Re-
moval / Installation sections.
In this section, the procedure starts on the premise that
the tracks and front idler have already been removed.
Removal
CAUTION: Track adjuster weight:
ZAXIS200, 200-E: 120 kg (265 lb)
ZAXIS225US, 225USR, 230: 125 kg (276 lb)
ZAXIS270: 180 kg (400 lb)
CAUTION: The front idler may jump out due
to strong spring force when disconnecting
the tracks adjuster (1). Do not stand in the
same direction as to track adjuster’s (1) re-
moval, nor any vicinity where there may be a
clanged of being injured by the idler flying off.
Particularly, a strong spring force is always
applied to the threaded part of the rod. If the
rod and/or the threads are damaged, metal
2
fragments under spring force may fly off.
Take due care.
1
W157-03-04-002
2 3
Section A
W157-03-04-001
W3-4-1
UNDERCARRIAGE / Track Adjuster
DISASSEMBLE TRACK ADJUSTER
1
2
4
5
6
7
8
9
3
10
11
12
13
14
15
18
17
W178-03-04-001
16
W3-4-2
UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly Work” on page CAUTION: Track adjuster weight:
W1-1-1 before starting the disassembly work. ZAXIS200, 200-E: 120 kg (265 lb)
ZAXIS225US, 225USR, 230: 125 kg (276 lb)
Be sure to use special tool (ST 4920) for assembly / ZAXIS270: 180 kg (400 lb)
disassembly of the track adjuster.
The spring force is extremely large, so disassembly 3. Attach wire rope to the track adjuster as illustrated.
and assembly work must be carried out carefully. In Lift and place it on the holder of special tool by
addition, it is necessary to inspect the special tool for crane.
any damage thoroughly to ensure safety.
W105-03-04-009
Holder
Base
W105-03-04-006
W105-03-04-007
W3-4-3
UNDERCARRIAGE / Track Adjuster
10
14
15
17
W178-03-04-001
16
W3-4-4
UNDERCARRIAGE / Track Adjuster
4. Install plate (ST 4036) on the track adjuster and 7. Operate the oil jack to compress the track ad-
secure them together. juster approximately 10 mm (0.4 in) until a clear-
ance is observed between washer (17) and nut
(16).
Plate (ST 4036) 8. Remove plug (14) from nut (16). Remove nut (16)
and valve (15) from rod (10).
: 5 mm
: 75 mm (ZAXIS 200, 200-E, 225US,
225USR, 230)
: 24 mm
: 85 mm (ZAXIS 270)
16 10 14
W105-03-04-011
W105-03-04-014
W105-03-04-013
W105-03-04-012
W3-4-5
UNDERCARRIAGE / Track Adjuster
3
10
11
13
18
17
W178-03-04-001
W3-4-6
UNDERCARRIAGE / Track Adjuster
9. Lower the oil jack slowly.
CAUTION: Approx. Spring weight:
Nut ZAXIS200, 200-E: 65 kg (144 lb)
ZAXIS225US, 225USR, 230: 72 kg (160 lb)
ZAXIS270: 95 kg (210 lb)
W105-03-04-016
11. Install eyebolt (M16, pitch 1.5 mm) to rod (10) and
lift the track adjuster up by crane to remove it from
the special tool.
Eyebolt
W105-03-04-017
W3-4-7
UNDERCARRIAGE / Track Adjuster
2
4
5
6
7
8
9
10
11
12
W178-03-04-001
W3-4-8
UNDERCARRIAGE / Track Adjuster
17. Remove flange (4) from piston rod (6). Remove
dust seal (2) and wear ring (5) from flange (4).
8
9
W105-03-04-025
W3-4-9
UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER
15 14 17 10 13 12 11 9 7 6 A 3 4 1
W178-03-04-002
16 18 B 8 5 2
Unit: mm (in)
ZAXIS: 200-E, 225US,
ZAXIS: 200 ZAXIS: 270
225USR, 230
507 mm (20) 521 mm (20.5) 557 mm (21.9)
C
Free Length 616 mm (24.3) Free Length 626 mm (24.6) Free Length 679 mm (26.7)
D 698 mm (27.5) 712 mm (28) 778 mm (30.6)
W3-4-10
UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
1. Clean all parts. Then install dust seal (2) and wear 6. Apply grease to U-ring (8), wear ring (7), cylinder
ring (5) to flange (4) after applying grease on (11) and piston rod (6). Install the piston rod (6)
them. assembly into cylinder (11).
W3-4-11
UNDERCARRIAGE / Track Adjuster
9. Install spring (18) onto rod (10).
10. Install eyebolt (M16, pitch 1.5 mm) to rod (10). Lift
the spring assembly up by crane and put it on the
special tool.
Eyebolt
10
W105-03-04-017
W3-4-12
UNDERCARRIAGE / Track Adjuster
(Blank)
W3-4-13
UNDERCARRIAGE / Track Adjuster
14 17 10
W178-03-04-002
16 18
Unit: mm (in)
ZAXIS: 200-E, 225US,
ZAXIS: 200 ZAXIS: 270
225USR, 230
507 mm (20) 521 mm (20.5) 557 mm (21.9)
C
Free Length 616 mm (24.3) Free Length 626 mm (24.6) Free Length 679 mm (26.7)
D 698 mm (27.5) 712 mm (28) 778 mm (30.6)
W3-4-14
UNDERCARRIAGE / Track Adjuster
11. Remove the eyebolt from rod (10). Put washer 14. Install nut (16) to rod (10), and then install plug
(17) on spring (18) and install plate (ST 4036). (14) to nut.
: 75 mm (ZAXIS 200, 200-E,
225US, 225USR, 230)
Plate (ST 4036) : 85 mm (ZAXIS 270)
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 11.0 Ibf⋅ft)
17
16 10 14
18
W105-03-04-016
l
W105-03-04-014
Nut
W105-03-04-012
18
W105-03-04-026
W3-4-15
UNDERCARRIAGE / Track Adjuster
15 10
W178-03-04-002
Unit: mm (in)
ZAXIS: 200-E, 225US,
ZAXIS: 200 ZAXIS: 270
225USR, 230
507 mm (20) 521 mm (20.5) 557 mm (21.9)
C
Free Length 616 mm (24.3) Free Length 626 mm (24.6) Free Length 679 mm (26.7)
D 698 mm (27.5) 712 mm (28) 778 mm (30.6)
W3-4-16
UNDERCARRIAGE / Track Adjuster
15. Install valve (15) to rod (10).
CAUTION: Spring assembly weight:
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) ZAXIS200, 200-E: 115 kg (255 lb)
ZAXIS225US, 225USR, 230: 120 kg (265 lb)
16. Lower the oil jack. ZAXIS270: 180 kg (375 lb)
W105-03-04-013
17. Remove the nuts of the special tool and plate (ST
4036)
: 46 mm
W105-03-04-009
Track Adjuster
W105-03-04-011
W105-03-04-028
Special Tool
(ST 4930)
W3-4-17
UNDERCARRIAGE / Track Adjuster
(Blank)
W3-4-18
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
Before removing the front idler, the tracks must be
removed first. For removal of the tracks, refer to
“Remove and Install Tracks” section.
In this section, the procedure starts on the premise
that the tracks has already been removed.
Installation
1. Install the front idler according to the reversed
procedures of removal and pay attention to the
following precautions when installation is carried
out.
• Clean the sliding surface (a) of yoke (2) and
sliding surface (b) of track frame (3), then apply
grease on them.
W178-03-05-002
(b)
3
(a)
2
W178-03-05-004
W3-5-1
UNDERCARRIAGE / Front Idler
DISASSEMBLE FRONT IDLER
2
1
3
4
6
7
8
6
4
3
2
1
10
W178-03-05-003
W3-5-2
UNDERCARRIAGE / Front Idler
Disassemble Front Idler
• Be sure to thoroughly read “Precautions for 4. Remove floating seal (4) from bearing (1) and
Disassembly and Assembly Work” on page idler (7).
W1-1-1 before starting the disassembly work.
1
1. Loosen bolt (10) to remove yoke (9). Remove 4
plug (8) from bearing (1) to drain oil into a 7
container.
: 24 mm
: 6 mm 4
3
2. Remove pin (2). 5
: 16 mm
1
W105-03-05-009
1 5
W105-03-05-008
W3-5-3
UNDERCARRIAGE / Front Idler
W178-03-05-003
W3-5-4
UNDERCARRIAGE / Front Idler
4. Push axle (5) out from bearing (1) via a press.
Remove O-ring (3) from axle (5).
W105-03-05-010
ST 1425
W105-03-05-011
W3-5-5
UNDERCARRIAGE / Front Idler
ASSEMBLE FRONT IDLER
1 2 4 5 6
10
8 9
3
7
W157-03-05-003
W3-5-6
UNDERCARRIAGE / Front Idler
Assemble Front Idler
1. Install bushing (6) (2 used) into idler (7) from both 5. Install the other floating seal (4) into idler (7) and
ends. into bearing (1).
1 5
5
W157-03-05-005
3. Install floating seals (4) a set into idler (7) and 7. Add engine oil via plug (8) hole on bearing (1).
bearing (1). Apply sealant (LOCTITE # 503 or equivalent) to
plug (8). Tighten plug (8).
: 6 mm
MPORTANT: For handling of floating seal (4), refer
: 20 N⋅m (2 kgf⋅m, 14.5 lb f⋅ft)
to the section “Precautions for
Engine oil: API CD Class SAE 30
Floating Seal Handling” on page
Quantity ZAXIS200, 200-E, 225US, 225USR, 230:
W1-1-4.
265 mL (0.07 US gal)
ZAXIS270:
4. Insert axle (5) into idler (7) from the side installed
300 mL (0.08 US gal)
with floating seal. Install O-ring (3) onto axle (5).
8. Install yoke (9) and tighten bolts (10).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
7
4 1
W157-03-05-006
W3-5-7
UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD
C D
A
B
W157-03-05-001
Unit: mm (in)
Axle Outside Dia. 75.0 (2.95) 85.0 (3.35) [74.2 (2.93)] [84.2(3.31)]
Inside Dia. 75.0 (2.95) 85.2 (3.35) [76 (2.997)] [86.0 (3.39)] Replace
Bushing
Flange Thickness 2 (0.08) 2.0 (0.08) [1.2(0.05)] [1.2 (0.05)]
W3-5-8
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Do not loosen valve (1) quickly or
loosen it too much as high-pressure grease in
the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and face
away from valve (1). Never loosen grease
fitting (2).
W105-03-06-001
W178-03-06-001
5 4
W105-03-06-002
W105-03-06-003
W3-6-1
UNDERCARRIAGE / Upper And Lower Roller
4. Loosen mounting bolts (6) of upper roller (4).
: 24 mm
W157-03-06-001
5
Installation W105-03-06-005
1. Install upper roller (4) onto track frame (5) using
bolts (6).
: 24 mm
: 270 N⋅m (28 kgf⋅m, 200 lbf⋅ft)
6
5
W105-03-06-002
W3-6-2
UNDERCARRIAGE / Upper And Lower Roller
3. Install valve (1) of the track adjuster.
: 24 mm
: 88 N⋅m (9 kgf⋅m,65 lbf・ft)
1
W158-03-06-001
W3-6-3
UNDERCARRIAGE / Upper And Lower Roller
(Blank)
W3-6-4
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove mounting bolts (1) of lower roller (5) after 5
removing the track guard.
: 27 mm
1
(ZAXIS200, 200-E, 225US, 225USR, 230)
: 30 mm (ZAXIS 270)
4
Grease Outlet
W178-03-06-001
W3-6-5
UNDERCARRIAGE / Upper And Lower Roller
W105-03-06-010
Installation
1. Place lower rollers (5) under the tracks (2) as
illustrated using a fork lift, etc.
5
W105-03-06-011
W105-03-06-008
W3-6-6
UNDERCARRIAGE / Upper And Lower Roller
4. Install valve (3) of the track adjuster.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf・ft) 3
W178-03-06-001
6. Fill grease from grease fitting (4) to make the track
be in tension.
W157-03-06-002
W3-6-7
UNDERCARRIAGE / Upper And Lower Roller
DISASSEMBLE LOWER ROLLER
3
2
4 1
5
6
5
4
3
2
1
W157-03-06-004
W3-6-8
UNDERCARRIAGE / Upper And Lower Roller
Disassemble Lower Roller
• Be sure to thoroughly read “Precautions for 5. Remove O-rings (4) (2 used) from axle (8).
Disassembly and Assembly Work” on page
W1-1-1 before starting the disassembly work.
6. In case of replacing bushing (6), push out bushing
(6) via a press and special tools.
1. Remove plug (1) from collars (2) and drain oil.
:6 mm
2 5 7 5 6
5
W105-03-06-028
2
Pulling Tool:
ZAXIS 200, 200-E, 225US, 225USR, 230
ST-1955
8 ZAXIS 270
W105-03-06-026
ST-1475
4 2
W105-03-06-027
W3-6-9
UNDERCARRIAGE / Upper And Lower Roller
ASSEMBLE LOWER ROLLER
2 7 6 5 4 3 1
W105-03-06-023
W3-6-10
UNDERCARRIAGE / Upper And Lower Roller
Assemble Lower Roller
1. Install bushings (6) (2 used) onto roller (7) using a 4. Insert axle (8) into roller (7). Install O-ring (4). The
press. Take care not to dent the flange surface of other collar (2) shall be assembled in the same
bushing (6). way. Secure them with pin (3).
Apply a film of grease to O-ring (4) and install it
onto axle (8). 5. Add engine oil via the plug (1) hole on collar (2).
Tighten plug (1).
2. Install collar (2) of one side onto axle (8), aligning Apply LOCTITE # 503 or equivalent to the plug.
the pin holes. Secure them with pin (3). Take care : 6 mm
not to damage O-ring (4). : 20 N・m (2 kgf・m, 14.5 lbf・ft)
3 Engine oil: API CD class, SAE30
ZAXIS200, 200-E, 225US, 225USR, 230:
8
Quantity: 260 mL (0.069 US gal)
ZAXIS270
Quantity: 420 mL (0.11 US gal)
2 4
W105-03-06-031
7 5
5 2
W157-03-06-008
W3-6-11
UNDERCARRIAGE / Upper And Lower Roller
MAINTENANCE STANDARD
Upper Roller
W105-03-06-032
W3-6-12
UNDERCARRIAGE / Upper And Lower Roller
Lower Roller
W157-03-06-003
Roller
Unit: mm (in)
W3-6-13
UNDERCARRIAGE / Upper And Lower Roller
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal
5
CAUTION: Do not loosen valve (1) quickly or
4
loosen too much since high-pressure grease
in the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and face
away from valve (1). Never loosen grease fit-
ting (2).
W105-03-07-006
W3-7-1
UNDERCARRIAGE / Track
3. Remove retaining ring (6), which is used to pre-
vent the master pin from coming off. 7
3
NOTE: If retaining ring (6) interferes with master
link (7), drive master pin (3) in to make
clearance between retaining ring (6) and
master pin (3) before attempting to remove
retaining ring (6). 6
W105-03-07-008
W3-7-2
UNDERCARRIAGE / Track
5. Operate the boom and arm so that the angle be-
tween them is 90° to 110° . Lower the boom with
the bucket rolled-in to jack up the machine so as
to pull the track out. Then place a block under the
track frame to support the machine.
90° to 110°
M104-07-067
6. Slowly drive the machine in reverse until the
whole length of the track being removed comes on
the ground.
W105-03-07-011
W3-7-3
UNDERCARRIAGE / Track
Installation
1. Jack up the machine and put the track under the
lower roller so that the sprocket teeth mesh with
the end of the track. Be sure to position the track
in correct direction as illustrated.
Sprocket
Idler Side Side
W105-03-07-015
W105-03-07-016
W3-7-4
UNDERCARRIAGE / Track
IMPORTANT: Master pin (3) is directional. Be sure
to install it in the correct direction. Corner
Direction for
Removing the Direction for
Master Pin Installing the
5. Install master pin (3) using special tool (ST 1970). Master Pin
Retainin Ring
Track Llink
3
Master Link
W105-03-07-010
ST 1970
7
6. Install retaining ring (6). Retaining ring (6) is di-
rectional. Install retaining ring (6) into master link
(7) groove with the flat side of puller insert hole
facing outward.
W197-03-07-001
Seal
W3-7-5
UNDERCARRIAGE / Track
7. Tighten adjuster valve (1). Apply grease to grease
fitting (2) to adjust the track link tension. 2
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
Track sag specification (A):
ZAXIS200, 200-E, 225US, 225USR, 230:
300 to 335 mm (11.8 to 13.19 in)
ZAXIS 270:
340 to 380 mm (13.39 to 14.96 in) 1
W105-03-07-018
W157-03-06-002
W3-7-6
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link
Measure the length of four links.
• Master pin is not included in measurement part.
• Measurement shall be carried out with the track in
tension.
W155-03-07-001
Grouser shoe
W105-03-07-024
ZAXIS200, 200-E, 225US, 225USR, 230 Unit: mm (in) ZAXIS270 Unit: mm (in)
Allowable Allowable
Standard Remedy Standard Remedy
Limit Limit
W3-7-7
UNDERCARRIAGE / Track
Master Bushing W105-03-07-023
ZAXIS 200, 200-E, 225US, 225USR, 230 Unit: mm (in) ZAXIS 270 Unit: mm (in)
Master Pin
W105-03-07-021
ZAXIS 200, 200-E, 225US, 225USR, 230 Unit: mm (in) ZAXIS 270 Unit: mm (in)
W3-7-8
UNDERCARRIAGE / Track
Pin
A
W142-03-07-004
ZAXIS 200, 200-E, 225US, 225USR, 230 Unit: mm (in) ZAXIS 270 Unit: mm (in)
Bushing
W105-03-07-023
ZAXIS 200, 200-E, 225US, 225USR, 230 Unit: mm (in) ZAXIS 270 Unit: mm (in)
W3-7-9
UNDERCARRIAGE / Track
(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...............................W4-1-10
Standard Dimensions for
Arm and Bucket Connection ....................W4-1-18
Standard Dimensions for
Arm and Boom Connection ................... W4-1-19
Group 2 Cylinder
Removeand Install Cylinder ..................... W4-2-1
Hydraulic Circuit Pressure Release
Procedure ............................................ W4-2-19
Disassemble Cylinder ............................ W4-2-20
Assemble Cylinder ................................. W4-2-38
Maintenance Standard ........................... W4-2-54
178W-4-1
(Blank)
178W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
Preparation
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinders and lower the
bucket to the ground.
W105-04-02-001
Removal
1. Remove grease hose (1) from the adapter on the
boss at the boom cylinder rod side. 1
(2 places on both left and right)
: 17 mm Adapter
2. Remove nuts (4) and bolts (6) from boom cylinder Boom 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:
175 kg (385 lb) 3 2
(ZAXIS200, 200-E, 225US, 225USR)
220 kg (485 lb) (ZAXIS230)
Cylinder No : Up to serial No 881-380 (R)
: Up to serial No 882-380 (L)
210 kg (465 lb) (ZAXIS230) 6 Boom Cylinder
Cylinder No : Serial No 881-381 (R) and up
: Serial No 882-381 (L) and up
280 kg (620 lb) (ZAXIS270)
Prevent personal injury. Metal fragments may
fly when a hammer is used to remove pins. Be
sure to wear necessary protection, such as
5
goggles, hard hat, etc.
4
3. Hoist the boom cylinder. With a bar and a hammer W178-04-01-004
drive pin (3) into the position where thrust plate (2)
can be removed. Remove thrust plate (2).
W4-1-1
FRONT ATTACHMENT / Front Attachment
4. Place the boom cylinder on a bench of 1 m height.
Start engine, operate the boom lever to retract the
boom cylinder, use a wire to secure the boom
cylinder rod as illustrated.
Stop the engine.
Boom Cylinder
5. Remove boom cylinder.
Refer to “Remove Boom Cylinder” (W4-2-10).
Metal Wire
6. Remove other boom cylinder in the same proce-
dures as steps 3, 4, 5.
7. After stopping engine, push the air release valve Air Bleeding Valve
on the top of hydraulic oil tank to release any re-
maining pressure. Then remove the cap.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”.
Refer to page W4-2-15.
M157-07-173
W4-1-2
FRONT ATTACHMENT / Front Attachment
Disconnect hoses (7), (8) for bucket cylinder and arm
cylinder, cover all openings of disassembled hoses and ZAXIS200, 200-E
pipes with cap. ZAXIS230, 270
: 36, 41 mm
7 8
W157-04-01-001
ZAXIS225US, 225USR
W178-04-01-006
ZAXIS225US, 225USR
Side Cover
Assembly Cover Assembly
Cover
Assembly
W178-04-01-008
W4-1-3
FRONT ATTACHMENT / Front Attachment
10. 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:
3670 kg (8090 lb) 11
(ZAXIS200, 200-E, 225US, 225USR) 12
4800 kg (10585 lb) (ZAXIS 230)
13
Cylinder No : Up to serial No 881-380 (R)
: Up to serial No 882-380 (L) W178-04-01-001
W105-04-01-008
9
12. Insert a bar between the plate of boom foot pin (9)
and the bracket, slightly pull the plate out.
13. Turn the plate upward by hand and turn boom foot Plate
Insert Bar
pin (9) left and right to pull it out.
(Adjust the position of the boom foot pin hole by Bracket
hoisting and lowering the front attachment.)
W178-04-01-001
W178-04-01-005
W4-1-4
FRONT ATTACHMENT / Front Attachment
Installation
CAUTION: Front attachment weight:
3670 kg (8090 Ib)
(ZAXIS200, 200-E, 225US, 225USR)
4800 kg (10585 lb) (ZAXIS 230)
Cylinder No : Up to serial No 881-380 (R)
: Up to serial No 882-380 (L)
4770 kg (10515 lb) (ZAXIS230)
Cylinder No : Serial No 881-381 (R) and up
: Serial No 882-381 (L) and up
5230 kg (11530 lb) (ZAXIS 270) W178-04-01-005
9
1. Hoist the front attachment.
Move the machine forward, aligning the boom foot
pin holes.
Insert the thrust plates into boom left and right
sides and adjust the clearance between the plate
and frame within 1 mm. 10
(Adjust the boom foot pin hole by hoisting and 11
lowering the front attachment.) 12
13
CAUTION: Prevent personal injury. Metal W178-04-01-001
fragments may fly when a hammer is used to
remove pins. Be sure to wear necessary pro-
tection, such as goggles, hard hats, etc.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
ZAXIS225US, 225USR
Side Cover
Assembly Cover Assembly
Cover
Assembly
W178-04-01-008
W4-1-5
FRONT ATTACHMENT / Front Attachment
4. Remove caps from hoses and pipings. Install
bucket cylinder hoses (7) and arm cylinder hoses ZAXIS200, 200-E
(8). ZAXIS230, 270
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
: 36 mm 7 8
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
W157-04-01-001
ZAXIS225US, 225USR
W4-1-6
FRONT ATTACHMENT / Front Attachment
1
8. Connect grease pipe (1) onto the boss at boom
cylinder rod side. (2 places on both left and right)
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
Boom Foot
Side
W4-1-7
FRONT ATTACHMENT / Front Attachment
IMPORTANT: When the arm has been removed
from the boom, perform the following
steps when installing the arm.
10. 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.
W4-1-8
FRONT ATTACHMENT / Front Attachment
(Blank)
W4-1-9
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
F E
G
C
H
D J
A
I K
B
W105-04-01-018
Unit: mm (in)
W4-1-10
FRONT ATTACHMENT / Front Attachment
Unit:mm (in)
W4-1-11
FRONT ATTACHMENT / Front Attachment
F E
G
C
H
D J
A
I K
B
W105-04-01-018
Unit:mm (in)
W4-1-12
FRONT ATTACHMENT / Front Attachment
Unit:mm (in)
W4-1-13
FRONT ATTACHMENT / Front Attachment
F E
G
C
H
D J
A
I K
B
W105-04-01-018
Unit:mm (in)
W4-1-14
FRONT ATTACHMENT / Front Attachment
Unit:mm (in)
W4-1-15
FRONT ATTACHMENT / Front Attachment
Side Cutter
(ZAXIS200, 200-E, 225US, 225USR)
C
D
W155-04-01-002
Unit: mm (in)
Standard Allowable Limit Remedy
B 295 (11.6) -
Replace
C 433 (17.0) -
D 135 (5.3) -
Side Cutter
(ZAXIS230, 270)
B
C
D
W155-04-01-002
Unit: mm (in)
Standard Allowable Limit Remedy
B 300 (11.81) -
Replace
C 400 (15.75) -
D 300 (11.81) -
W4-1-16
FRONT ATTACHMENT / Front Attachment
Point
(ZAXIS200, 200-E, 225US, 225USR)
B C
W105-04-01-020
Unit: mm (in)
Standard Allowable Limit Remedy
B 95 (3.7) -
Replace
C 108 (4.3) -
D 95 (3.7) -
Point
(ZAXIS230, 270)
B C
W105-04-01-020
Unit: mm (in)
Standard Allowable Limit Remedy
B 96 (3.78) -
Replace
C 130 (5.12) -
D 105 (4.13) -
W4-1-17
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS EX200-5、 EX200-3
ZAXIS200 EX200-2 ZAXIS230 ZAXIS270
225US EX225USR
a 450 (17.7) ← ← ← ← 460 (18.11) 475 (18.70)
b 0 (0) ← ← ← ← 5 (0.20) 0
c 604 (23.8) ← ← ← ← 620 (24.41) 622 (24.49)
d 580 (22.8) ← ← ← ← 580 (22.83) 600 (23.62)
e - - - - - 470 (18.50) 470 (18.50)
f 1471 (57.9) ← 1460 (57.5) ← ← 1547 (60.91) 1558 (61.34)
g 433 (17.0) ← ← ← ← 549 (21.61) 555 (21.85)
h 305.5 (12.0) ← ← ← ← 430 (16.93) 430 (16.93)
i 80 (3.1) ← ← ← ← 90 (3.54) 90 (3.54)
j 475 (18.7) ← ← ← ← 470 (18.50) 470 (18.50)
k 31 (1.2) ← ← ← ← 69 (2.72) 69 (2.72)
l 433 (17.0) ← ← ← ← 549 (21.61) 555 (21.85)
m 307 (12.1) ← ← ← ← 410 (16.14) 410 (16.14)
n 80 (3.1) ← ← ← ← 90 (3.54) 90 (3.54)
°
o 3.7° ← ← ← ← 8.4 8.4°
p 3.7° ← ← ← ← 8.4° 8.4°
q 449 (17.7) ← ← ← ← 565 (22.24) 571 (22.48)
W4-1-18
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit:mm (in)
ZAXIS225US
ZAXIS200 EX200-5 EX200-3 EX200-2 ZAXIS230 ZAXIS270
ZAXIS225USR
s 90 (3.5) ← 80 (3.1) ← ← 100 (3.94) 100 (3.94)
t 352 (13.9) ← 345 (13.6) ← ← 369 (14.53) 409 (16.10)
u 490 (19.3) ← 482 (19.0) ← ← 532 (20.94) 578 (22.76)
W4-1-19
FRONT ATTACHMENT / Front Attachment
(Blank)
W4-1-20
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Preparation
1. Park the machine on a solid, level surface. Retract
the arm cylinder and bucket cylinder fully. Lower
the boom and place the arm top onto the ground.
2
3
W554-04-02-006
W4-2-1
FRONT ATTACHMENT / Cylinder
7
W158-04-02-006
9
W102-04-02-005
10
5. Disconnect bucket cylinder hoses (12) (2 used)
at the bottom of bucket cylinder (1). Cap the
open ends.
ZAXIS200, 200-E, 225US, 225USR, 230
15
: 36 mm
ZAXIS270
: 41 mm 11
13
12 W187-04-02-004
W4-2-2
FRONT ATTACHMENT / Cylinder
12 W187-04-02-004
W4-2-3
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
IMPORTANT: When installing the bushing and if a
hammer is used, the bushing may be
damaged. Install the bushing by
using a press.
10
2. Insert bolt (15) into stopper (14) and pin (11) in the
arm. Install nut (13).
ZAXIS200, 200-E, 225US, 225USR
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
ZAXIS230, 270
: 32 mm
: 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
W4-2-4
FRONT ATTACHMENT / Cylinder
IMPORTANT: Fill hydraulic oil to specified level.
Start the engine and check for any oil
leaks.
6. Insert bolt (4) into stopper (17) and pin (7). Install
nut (6).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 1220 lbf⋅ft)
W157-04-01-015
18 18
W4-2-5
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1. Insert wooden block (3) between arm cylinder (1)
and boom (2). 1
W187-04-02-010
12
W102-04-02-014
W4-2-6
FRONT ATTACHMENT / Cylinder
7. Disconnect lubrication pipe (12) from arm cylinder ZAXIS230, 270
(1).
1 11
: 17 mm
12
9. Remove nuts (15) and bolt (17) from the tube side
in arm cylinder (1). Remove pin (14). Remove
thrust plate (13) and remove arm cylinder (1).
ZAXIS200, 200-E, 225US, 225USR 13
17
: 30 mm
ZAXIS230, 270 1 14
: 32 mm
15
W187-04-02-007
W4-2-7
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
W4-2-8
FRONT ATTACHMENT / Cylinder
3. Connect lubrication pipe (12) and hoses (11) (2
used) in the arm cylinder.
ZAXIS200, 200-E, 225US, 225USR
: 17 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft) ZAXIS230, 270
: 36 mm
1 11
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
: 41 mm
Lubrication
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) Pipe
ZAXIS230, 270 12
: 17 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
18
W187-04-02-010
10 4
9 5
18
8
W187-04-02-006
W4-2-9
FRONT ATTACHMENT / Cylinder
8
W187-04-02-006
W4-2-10
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-11
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder 1
W105-04-02-035
W4-2-12
FRONT ATTACHMENT / Cylinder
6. Stop the engine. Push the air bleed valve and
release any remaining pressure in the hydraulic oil
tank.
Release the circuit pressure.
Refer to the “Hydraulic Circuit Pressure Release
Procedure” on page W4-2-19.
ZAXIS230, 270 2
11
Plug: 1 7/16-12UN 8
ZAXIS200, 200-E, 225US, 225USR, 230
: 36 mm
ZAXIS270
: 41 mm
9
W105-04-02-040
W4-2-13
FRONT ATTACHMENT / Cylinder
W105-04-02-040
W4-2-14
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-15
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder
W4-2-16
FRONT ATTACHMENT / Cylinder
4. Disconnect hoses (12) (4 used) onto boom
cylinders (2) (2 used). 2
ZAXIS200, 200-E, 225US, 225USR, 230 11
: 36 mm 8
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
ZAXIS270
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
9
IMPORTANT: Fill hydraulic oil to specified level.
Start the engine and check for any oil 9 10
leaks.
10
12
5. Hoist boom cylinder (2). Operate the boom lever W178-04-02-009
7. Insert bolt (7) into pin (4) and stopper (6). Install
nut (5).
: 30 mm
6
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
5
3 4 3 2
8. Connect lubrication pipe (1). W158-04-02-013
: 17 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
W105-04-02-032
W4-2-17
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-18
FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE
W178-04-02-010
W4-2-19
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
Boom Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 881-381 (R) and up, Serial No. 882-381 (L) and up)
11 1 2 3 4 7 5 6 9 10
8
14 13 19 16 20 21 22 12
20 16 15 17 18 19 24 23
W158-04-02-016
Bucket Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 884-391 and up)
11 1 2 3 4 7 5 6 9 10
13 20 19 20 21 22 12
16 15 17 18 16 19 24 23
W158-04-02-018
W4-2-20
FRONT ATTACHMENT / Cylinder
Disassemble Boom and Bucket Cylinders
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(Boom Cylinder
Cylinder No.: Serial No. 881-381 (R) and up, Serial
No. 881-382 (L) and up
Bucket Cylinder
Cylinder No.: Serial No. 884-391 and up)
W102-04-02-027
W4-2-21
FRONT ATTACHMENT / Cylinder
3. Tap and remove cylinder head (7) from cylinder
tube (12) by using a plastic hammer.
W4-2-22
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-23
FRONT ATTACHMENT / Cylinder
Boom Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 19 16 20 21 22
20 16 15 17 18 19 24 23
W158-04-02-016
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
13 20 19 20 21 22
16 15 17 18 16 19 24 23
W158-04-02-018
W4-2-24
FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill
and remove set screw (22). Remove steel ball
(23).
W4-2-25
FRONT ATTACHMENT / Cylinder
Arm Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: 883-431 and up)
1 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22 12
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-26
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 883-431 and up),
W4-2-27
FRONT ATTACHMENT / Cylinder
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-28
FRONT ATTACHMENT / Cylinder
5. Cut away the crimped position by using a hand
drill and remove set screw (22). Remove steel ball
(23).
W4-2-29
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
ZAXIS230
(Boom Cylinder:
Cylinder No.: Up to serial No. 881-380 (R), Up to serial No. 882-380 (L)
Bucket Cylinder
Cylinder No.: Up to serial No. 884-390)
1 2 3 3 5 6 7
8 9 10 11 12 13 14 15 13 12 16
19 18 17
W178-04-02-026
W4-2-30
FRONT ATTACHMENT / Cylinder
Disassemble Boom and Bucket Cylinders
ZAXIS230
(Boom cylinder
Cylinder No.: Up to serial No. 881-380 (R), Up to
serial No. 882-380 (L)
Bucket cylinder
Cylinder No.: Up to serial No 884-390)
W178-04-02-034
W4-2-31
FRONT ATTACHMENT / Cylinder
Boom Cylinder
Bucket Cylinder
1 2 3 4 5 6 7
10 11 12 13 14 15 13 12
19
W178-04-02-026
W4-2-32
FRONT ATTACHMENT / Cylinder
5. Remove the piston (14) assembly, cushion ring
(10) and cylinder head (19) from piston rod (1) in
this order.
W4-2-33
FRONT ATTACHMENT / Cylinder
Arm Cylinder
ZAXIS230
(Cylinder No.: Up to serial No. 883-430)
1 2 3 4 5 7 9 10
6
11 12 13 14
15
22 18 19 21 20 19 18 17 16
W178-04-02-027
W4-2-34
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
ZAXIS230
(Cylinder No.: Up to serial No. 883-430)
W178-04-02-033
W4-2-35
FRONT ATTACHMENT / Cylinder
Arm Cylinder
1 2 3 4 5 7 9
6
11 12 13 14
22 18 19 21 20 19 18
W178-04-02-027
W4-2-36
FRONT ATTACHMENT / Cylinder
5. Remove the piston (21) assembly, cushion ring
(22) and cylinder head (19) from piston rod (1) in
this order.
W4-2-37
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
Boom Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 881-381 (R) and up, Serial No. 882-381 (L) and up)
Hole (1 Place)
Face the slit to the piston.
1 2 3 4 5 6 7 8 9、10
11 12 13 14 15 16 17、18 19 20
21
22, 23
24
Bucket Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 884-391 and up)
Hole (1 Place)
1 2 3 4 5 6 7 8 9、10
11 12 13 15 16 17、18 19 20
21
22, 23
24
W4-2-38
FRONT ATTACHMENT / Cylinder
Assemble Boom and Bucket Cylinders
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
Boom cylinder
(*Cylinder No.: Serial No. 881-381 (R) and up,
Serial No. 882-381(L) and up
Bucket cylinder
*Cylinder No.: Serial No. 884-391 and up)
1. Install bushing (5) into cylinder head (7). IMPORTANT: Face the slit in cushion seal (14) to
Special tool when installing bushing: the piston. Check the direction of oil
Boom 85 mm (ST 8020) groove in cushion bearing (13).
Bucket 80 mm (ST 8019)
7. Install cushion bearing (13) to piston rod (11).
IMPORTANT: Check the direction to install. Install the piston (15) assembly to piston rod (11).
(Boom cylinder only: Install cushion seal (14).)
2. Install U-ring (3), backup ring (2), buffer ring (4)
and snap ring (6) to cylinder head (7).
W4-2-39
FRONT ATTACHMENT / Cylinder
Boom Cylinder
7 8
11 12 21 21, 23
24
W178-04-02-003
Bucket Cylinder
7 8
11 12 21 21, 23
24
W178-04-02-004
W4-2-40
FRONT ATTACHMENT / Cylinder
8. Install shim (21) to piston rod (11). Align the
matching marks made before disassembling and
tighten nut (24) by using special tool (ST 5908).
Special tool when turning nut:
Boom 90 mm (ST 3263)
Bucket 90 mm (ST 3263)
Boom cylinder
: 4780 N⋅m (490 kgf⋅m, 3530 lbf⋅ft)
Bucket cylinder
: 6570 N⋅m (670 kgf⋅m, 3850 lbf⋅ft) Special Tool: ST 5908
W158-04-02-022
W4-2-41
FRONT ATTACHMENT / Cylinder
Arm Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 883-431 and up)
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17、18 19 20 21
22、23
24
25
26
27
28
W4-2-42
FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder
ZAXIS200, 200-E, 225US, 225USR, 230*, 270
(*Cylinder No.: Serial No. 883-431 and up)
W4-2-43
FRONT ATTACHMENT / Cylinder
Arm Cylinder
7 8
11 12 22, 23
24
25
26
27
28
W4-2-44
FRONT ATTACHMENT / Cylinder
9. Align the holes on piston rod (11) and nut (24).
Install steel ball (23) with set screw (22). Crimp
set screw (22) by using a punch (2 places).
: 10 mm
: 56.9±10.7 N⋅m
(5.8±1.1 kgf⋅m, 42±7.9 lbf⋅ft)
W4-2-45
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
ZAXIS230
(Boom Cylinder
Cylinder No.: Up to serial No. 881-381 (R), Up to serial No. 882-380 (L)
Bucket Cylinder
Cylinder No.: Up to serial No. 884-390)
2 3 4 5 6
1 8 9 10 11 12 13 15 13 12
14 17
18
19 16
W178-04-02-035
W4-2-46
FRONT ATTACHMENT / Cylinder
Assemble Boom and Bucket Cylinders
ZAXIS230
(Boom cylinder
Cylinder No.: Up to serial No. 881-381 (R), Up to
serial No 882-380 (L)
Bucket cylinder
Cylinder No.: Up to serial No. 884-390)
W4-2-47
FRONT ATTACHMENT / Cylinder
Boom Cylinder
Bucket Cylinder
1 8
14 17
18
19 16
W178-04-02-035
W4-2-48
FRONT ATTACHMENT / Cylinder
6. Install the piston (14) assembly to piston rod (1).
Tighten socket bolts (17) (6 used) and washers
(18) (6 used) temporarily.
W178-04-02-035
W4-2-49
FRONT ATTACHMENT / Cylinder
Arm Cylinder
ZAXIS230
(Cylinder No.: Up to serial No. 883-430)
1 8 9 10 11 12 13 14 15
22 21 18 19 20 19 18 17 16
2 3 4 5 6 7
W178-04-02-031
W4-2-50
FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder
ZAXIS230
(Cylinder No.: Up to serial No. 883-430)
W4-2-51
FRONT ATTACHMENT / Cylinder
Arm Cylinder
1 8 9 15
21 17 16
W178-04-02-031
W4-2-52
FRONT ATTACHMENT / Cylinder
7. Install the piston (21) assembly to piston rod (1).
Tighten socket bolts (16) (6 used) and washers
(17) (6 used) temporarily.
W178-04-02-032
W4-2-53
FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
W105-04-02-094
W166-04-02-022
ZAXIS270 (Up to serial No.20572) unit: mm (in) ZAXIS270 (Serial No. 20573 and up) unit: mm (in)
W4-2-54
FRONT ATTACHMENT / Cylinder
Wear to The Inner Diameter of Rod Bushing
ZAXIS200, 200-E, 225US, 225USR unit: mm (in)
W4-2-55
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-56
MEMO
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SECTION 5
ENGINE AND ACCESSORY
―CONTENTS―
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual .............. 1-2 Cylinder Head ................................................ 4-2
Main Data and Specifications......................... 1-6 Valve Guide.................................................... 4-3
Performance Curve........................................ 1-7 Valve Spring ................................................... 4-6
External View ................................................. 1-9 Tappet ............................................................ 4-7
Tightening Torque Specifications ..................1-11 Push Rod ....................................................... 4-8
Angular Nut and Bolt Tightening Method...... 1-13 Rocker Arm Shaft and Rocker Arm................. 4-8
Major Parts Fixing Nuts and Bolts ................ 1-15 Idler Gear and Idler Gear Shaft ...................... 4-9
Identifications............................................... 1-26 Camshaft...................................................... 4-10
Cylinder Body and Liner ............................... 4-11
Maintenance Piston and Piston Ring ................................. 4-17
Lubricating System ........................................ 2-2
Piston Pin..................................................... 4-19
Fuel System................................................... 2-3
Connecting Rod ........................................... 4-20
Cooling System.............................................. 2-7
Crankshaft.................................................... 4-22
Valve Clearance Adjustment .......................... 2-7
Flywheel....................................................... 4-29
Injection Timing.............................................. 2-9
Timing Gear Case Cover.............................. 4-29
Compression Pressure Measurement .......... 2-14
Turbocharger Inspection .............................. 2-15 Engine Assembly 3 (Reassembly)
Engine Repair Kit ......................................... 2-16
Piston and Connecting Rod
Recommended Lubricants ........................... 2-17
Reassembly Steps........................................ 5-2
Engine Oil Viscosity Chart ........................... 2-17
Cylinder Head Reassembly Steps .................. 5-4
Rocker Arm and Rocker Arm Shaft
Engine Assembly 1 (Disassembly) Reassembly Steps........................................ 5-7
External Parts Disassembly Steps ................. 3-2
Major Component Reassembly Steps 1.......... 5-8
Major Components......................................... 3-6
Major Component Reassembly Steps 2........ 5-13
Rocker Arm and Rocker Arm Shaft
External Parts Reassembly Steps
Disassembly Steps......................................3-11
(Left-Hand Side) ......................................... 5-18
Cylinder Head Disassembly Steps ............... 3-12
External Parts Reassembly Steps
Piston and Connecting Rod
(Right-Hand Side)....................................... 5-21
Disassembly Steps..................................... 3-13
Engine Tuning Operation.............................. 5-25
178W-5-1
Lubricating System Current Output Test .................................... 10-26
General Description ....................................... 6-2 Fault Finding .............................................. 10-27
Oil Pump ........................................................ 6-3 Specifications ............................................. 10-27
Oil Cooler....................................................... 6-5
Troubleshooting
Cooling System Hard Starting ................................................ 11-2
General Description ....................................... 7-2 1) Starter Inoperative ................................. 11-2
Water Pump ................................................... 7-3 2) Starter Operates but
Thermostat..................................................... 7-8 Engine does not Turn Over .................... 11-3
3) Engine Turns Over but does not Start
Fuel System Fuel is Being Delivered to the
General Description ....................................... 8-2 Injection Pump ....................................... 11-4
Injection Nozzle ............................................. 8-3 4) Engine Turns Over but does not Start .... 11-5
Injection Pump Calibration Data..................... 8-8 Unstable Low Idling ...................................... 11-6
Insufficient Power......................................... 11-8
Turbocharger Excessive Fuel Consumption ......................11-11
General Description ....................................... 9-2 Excessive Oil Consumption........................ 11-13
Turbocharger Identification ............................ 9-3 Overheating ............................................... 11-14
Troubleshooting ............................................. 9-5 Whity Exhaust Smoke ................................ 11-16
Inspection and Repair .................................... 9-7 Dark Exhaust Smoke.................................. 11-17
Oil Pressure does not Rise......................... 11-18
Engine Electricals Abnormal Engine Noise.............................. 11-20
Starter Identification ..................................... 10-2
Starter Main Data and Specifications ........... 10-3 Special Tool List
Starter Sectional View.................................. 10-4 Special Tool List ........................................... 12-2
Performance ................................................ 10-4
Disassembly ................................................ 10-5 Repair Standards
Inspection and Repair .................................. 10-8 Repair Standards ......................................... 13-1
Reassembly ............................................... 10-12
Adjustment................................................. 10-13 Conversion Table
Performance Test....................................... 10-14 Length .......................................................... 14-2
Alternator Identification .............................. 10-15 Area ............................................................. 14-3
Main Data and Specifications..................... 10-16 Volume ......................................................... 14-3
Alternator Sectional View ........................... 10-17 Mass ............................................................ 14-5
Charging Circuit ......................................... 10-17 Pressure....................................................... 14-6
Structure .................................................... 10-18 Torque .......................................................... 14-7
Disassembly .............................................. 10-19 Temperature ................................................. 14-8
Inspections ................................................ 10-22
Reassembly ............................................... 10-24
Bench Test ................................................. 10-25
178W-5-2
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
REPLY: