W1lse 00

Manual No.
: KM-1LSE
Vol. No. : W1LSE-00
30 35 40 50 Excavator Workshop Manual

Workshop Manual
30 40
35 50
Excavator
Service Manual (Manual No. KM-1LSE) consists of the following two separate volumes;
Technical Manual : Vol. No. T1LSE
Workshop Manual : Vol. No. W1LSE
PRINTED IN SINGAPORE (PS)
Zaxis30/35/40/50-Wsh 1 25/4/03, 3:00 PM

INTRODUCTION
TO THE READER
• 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 manual.
• Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us-
product information and service procedures. 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
• Technical Manual of the Crawler Crane
• Workshop Manual of the Crawler Crane
• Operator’s Manual of the Crawler Crane
• Parts Catalog of the Crawler Crane
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : C-5
Consecutive Page Number for Each Group

Section
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 could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.
This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention NOTE:
to component/part weights.
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.
IN-01
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS 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 Quantity To Convert 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
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min 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
All information, illustrations and specifications in this

manual are based on the latest product information
available at the time of publication. The right is re-
served to make changes at any time without notice
COPYRIGHT (C) 2003

Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in this

manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001-2
SA-001
UNDERSTAND SIGNAL WORDS

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

which, if not avoided, will result in death or serious
injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• CAUTION also calls attention to safety messages in this
manual.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to SA-1223
the machine.
• NOTE indicates an additional explanation for an

element of information.
002-E01A-0461-6
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and

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

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

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

operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you may
encounter. If you have any questions, you should first
consult your supervisor before operating or performing
maintenance work on the machine.
003-E01A-0003-5
PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• Establish emergency procedure guidelines to cope
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
SA-437
004-E01A-0437-3
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask. SA-438
Be sure to wear the correct equipment and clothing for

the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438-4
PROTECT AGAINST NOISE

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

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.
006-E01A-0434-2
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.
007-E01A-0435-2
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine.
SA-439
008-E01A-0439-3
ADJUST THE OPERATOR'S SEAT

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

operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers with
his back against the seat back.
•If not, move the seat forward or backward, and check
again.
SA-378
009-E01A-0378-3
SA-4
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may
become injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident. SA-237
010-E02A-0237-3
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate
hand signals before starting the machine.
SA-659
011-E01A-0529-4
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT
• Inappropriate engine starting procedure may cause the
machine to runaway, possibly resulting in serious injury
or death.
• Start the engine only from 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
levers are in neutral.
SA-444
012-E01A-0444-3
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow

the instructions shown in the “OPERATING THE
ENGINE” chapter.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
SA-032
machine.
013-E01A-0032-3
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the
machine.
• Only allow the operator on the machine. Keep riders

off.
• Riders also obstruct the operator’s view, resulting in
the machine being operated in an unsafe manner.
014-E01A-0530-2
SA-660
SA-6
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
• Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling SA-661
stones or debris exist.

• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes loose
and slippery.
015-E01A-0531-5
PROTECT AGAINST FALLING STONES AND

DEBRIS
• Confirm that your machine is FOPS cab equipped before
working in areas where the possibility of falling stones or
debris exist.
016-E01A-0510-2
SA-7
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s
directions.
018-E01A-0481-2
SA-481
CONFIRM DIRECTION OF MACHINE TO

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

the undercarriage in relation to the operator’s
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0532-2
SA-662
SA-8
SAFETY
DRIVE MACHINE SAFELY
• Before moving the machine, confirm which way to
move travel pedals/levers for the corresponding
direction you wish to go.
• Pushing the travel levers forward moves the

machine towards the idlers. (Refer to the Driving
the Machine “Travel Levers” section for correct
travel operation.)
• Traveling on a grade may cause the machine to slip SA-663
or to overturn, possibly resulting in serious injury or

death.
• When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 200
to 300 mm (8 to 12 in) (A) above the ground.
• If machine starts to skid or becomes unstable,
lower the bucket immediately.
SA-664
• Traveling across the face of slope or steering on a

slope may cause the machine to skid or to
turnover. If the direction must be changed, move
the machine to level ground, then, change the
direction to ensure safe operation.
019-E02A-0547-8
SA-441
SA-442
SA-9
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 to the ground.
• Run the engine at slow idle speed without load for
5 minutes to cooling it.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot controls shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground, thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E01A-0548-4 SA-666
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when backing
or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:

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

OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings SA-384
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.
021-E01A-0494-8
SA-11
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
• A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
• Keep all persons clear from the area of operation and

machine movement.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
022-E01A-0537-3
SA-667
NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
SA-668
023-E01A-0538-2
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if the
footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.
• If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.
024-E01A-0539-2
SA-669
SA-12
SAFETY
AVOID TIPPING
• The danger of tipping is always present when operating
on a grade, possibly resulting in serious 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.
• Point the tracks uphill to avoid tipping.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging SA-670
loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E01A-0540-4
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0541-2
SA-671
SA-13
SAFETY
DIG WITH CAUTION
• Accidental severing of underground cables or gas lines
may cause an explosion and/or fire, possibly resulting in
• Before digging check the location of cables, gas lines,

and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in
serious eye injury.
• Contact your local "diggers hot line" if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-672
027-E01A-0542-2
OPERATE WITH CAUTION

• If the front attachment or any other part of the machine
hits against an overhead obstacle, such as a bridge, both
the machine and the overhead obstacle will be damaged,
and personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the

boom or arm.
028-E01A-0543-2
SA-673
AVOID POWER LINES

• Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric
lines.
• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the site. SA-674
029-E01A-0544-2
SA-14
SAFETY
DO NOT USE FOR CRANING OPERATION
• This machine is not equipped with any devices that could
allow the machine to be used for craning operation. If the
machine is used for craning operation, the machine may
tip over and/or lifted load may fall, possibly resulting in
• NEVER use the machine for craning operation.
030-E01A-0014-2
SA-014
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,
serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
031-E01A-0432-2
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a level surface.
• Lower bucket and blade to the ground.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
SA-675
033-E01A-0545-4
SA-15
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possibly
resulting in serious injury or death.
• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are

flammable.
• Store flammable fluids well away from fire hazards. SA-018
• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn
spontaneously.
034-E01A-0496-4
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when loading/unloading
the machine onto/from a truck or trailer bed.
• Be sure to observe local regulations when transporting

the machine on public roads.
• Provide an appropriate truck or trailer for transporting
the machine.
Take the following precautions when loading/unloading

the machine: SA-676
1. Select firm level ground.

2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/
unloading the machine.
4. Be sure to load/unload the machine at slow speed.
5. Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
6. Do not operate any levers besides the travel levers
when driving up or down the ramp.
7. The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
8. Prevent possible injury from machine tipping while the
upperstructure is rotating.
9. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
10. Securely fasten chain or cables to the machine frame.
Refer to "transporting" chapter in this manual for
details.
035-E01A-0546-6
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Run the engine at slow idle speed without load for 5
minutes.
4. Turn the key switch to OFF to stop engine. SA-028
5. Relieve the pressure in the hydraulic system by

moving the control levers several times.
6. Remove the key from the switch.
7. Attach a “Do Not Operate” tag on the control lever.
8. Pull the pilot control shut-off lever to the LOCK
position.
9. Allow the engine to cool.
• 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 of this manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken SA-527
parts. Remove any buildup of grease, oil, or debris.

• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before welding on
the machine.
500-E02A-0497-8
SA-18
SAFETY
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without securing
the machine first.
• Always lower the attachment to the ground before you

work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a
jack.
519-E01A-0527-3
SA-527
STAY CLEAR OF MOVING PARTS

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

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating
parts.
502-E01A-0026-2
SA-026
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious
injury.
• Before performing any work on the machine, attach a

“Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
502-E01A-0026-2
SS2045102
SA-19
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and face
away from valve.
• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face SA-344
away from AIR RELEASE PLUG to avoid injury. GEAR

OIL is hot. Wait for gear oil to cool, then gradually
loosen the air release plug to release pressure.
503-E01A-0344-4
STORE ATTACHMENTS SAFELY

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

falling. Keep children and bystanders away from
storage areas.
504-E01A-0034-2
SA-034
SA-20
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 prevent 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 release before removing the SA-039
cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
• Wait for the oil and components to cool before starting SA-225
any maintenance or inspection work.
505-E01A-0498-5
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and abrasion.
It is very difficult to gauge the extent of deterioration due
to aging, fatigue, and abrasion of rubber hoses by
inspection alone.
• Periodically replace the rubber hoses.
• Failure to periodically replace rubber hoses may cause a

fire, fluid injection into skin, or the front attachment to fall
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death. SA-019
506-E01A-0019-3
SA-21
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under pressure
can penetrate the skin or eyes causing serious injury,
blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Relieve the pressure by moving the control levers
several times.
Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care SA-031
to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
507-E01A-0499-5
SA-044
SA-22
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for 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, for oil
leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
SA-019
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
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.
Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
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.
508-E04A-0019-8
SA-23
SAFETY
EVACUATING IN CASE OF FIRE
• If fire breaks out, evacuate the machine in the
following way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door or front window can

not be opened, break the front or rear window panes SA-393
with the emergency evacuation hammer to escape

from the cab.
Refer to the explanation pages on the Emergency
Evacuation Method. (Cab-Equipped Machines Only)
518-E02B-0393-2
SS-1510
BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016-2
SA-016
SA-24
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials before engaging in welding, soldering, SA-030
etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain
flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01A-0030-4
REMOVE PAINT BEFORE WELDING OR

HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator. SA-029
2. If you use solvent or paint stripper, remove stripper

with soap and water before welding. Remove solvent
or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least
15 minutes before welding or heating.
511-E01A-0029-4
SA-25
SAFETY
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away from

the top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 °C (60 °F) first.
• Do not continue to use or charge the battery when the
electrolyte level is lower than specified. Explosion of
the battery may result.
SA-032
• Battery electrolyte is poisonous. If the battery should

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

electrolyte specific gravity.
512-E01A-0032-4
SA-26
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment. SA-309
• See your authorized dealer for MSDS’s (available

only in English) on chemical products used with your
machine.
515-E01A-0309-4
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
SA-226
can damage the Earth’s atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your authorized dealer.
516-E01A-0226-4
SA-27
SAFETY
(Blank)
SA-28
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Group 2 Tightening
Tightening Torque Specification .............. W1-2-1
Torque Chart .......................................... W1-2-3
Piping Joint ............................................ W1-2-6
Periodic Replacement of Parts ............. W1-2-10
Group 3 Bleeding Air

Bleed Air from Hydraulic Oil Tank ........... W1-3-1
Group 4 Painting
Painting .................................................. W1-4-1
1LSW-1-1
（Blank）
1LSW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
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.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

area for disassembling work.
W1-1-1
• 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 instal-
replace part. lation of the pump, swing motor, travel motor or cyl-
• Dirt or debris on the contact or sliding surfaces inder is done, bleed air from the hydraulic system in
may shorten the service life of the machine. Take 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 motor
• If an anti-corrosive agent has been used on a
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, damage
• Be sure to use the designated tools to assemble 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.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary. T570-06-03-011
W1-1-3
Floating Seal Precautions A
1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for tears, breaks,

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

Correct
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
Incorrect
compressed air.
(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it W105-03-05-020
is installed correctly on the seal ring. Correct D Incorrect
a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
a=b a≠b
W110-03-05-004
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. 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
MAINTENANCE STANDARD TERMINOLOGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATIONS
ZAXIS30, 35
Bolt Dia. Wrench Size Torque
No. Descriptions Q’ty
mm mm N⋅m (kgf⋅m) (lbf⋅ft)
1. Engine cushion rubber mounting bolt 12 4 19 88 (9) (65)
Engine bracket mounting bolt (Front) 10 8 17 49 (5) (36)
2.
Engine bracket mounting bolt (Rear) 10 6 17 49 (5) (36)
Hydraulic oil tank and Fuel tank
3. 10 5 17 49 (5) (36)
mounting bolt
PF 1/4 19 29.5 (3) (22)
4. Fitting for hydraulic hoses and piping PF 3/8 22 39 (4) (29)
PF 1/2 27 64 (6.5) (47)
5. Pump mounting bolt 12 2 19 88 (9) (65)
6. Pump cover mounting bolt 10 6 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
7.
Control valve base mounting bolt 10 5 17 49 (5) (36)
8. Swing device mounting bolt 14 6 22 137 (14) (101)
8 2 13 9.8 (1) (7.2)
9. Battery mounting bolt
10 2 17 49 (5) (36)
10. Cab/Canopy mounting bolt 10 13 17 49 (5) (36)
11. Floor mounting bolt 16 4 24 205 (21) (152)
Swing bearing mounting bolt to up-
12 22 19 108 (11) (80)
perstructure
12.
Swing bearing mounting bolt to un-
12 20 19 108 (11) (80)
dercarriage
13. Travel device mounting bolt 12 22 19 128 (13) (94)
14. Sprocket mounting bolt 12 22 19 128 (13) (94)
15. Upper roller mounting bolt 12 2 19 88 (9) (65)
16. Lower roller mounting bolt 14 16 22 245 (25) (181)
8 13 9.8 (1) (7)
17. Cover mounting bolt 10 17 49 (5) (36)
12 19 88 (9) (65)
18. Counterweight mounting bolt 22 2 32 540 (55) (400)
NOTE 1. Apply lubricant (e.g. white zinc B

dissolved into spindle oil) to bolts and
nuts to reduce friction coefficient of them.
2. Make sure bolt and nut threads are clean
before installing.
W1-2-1
ZAXIS40, 50
Bolt Dia. Wrench Size Torque
No. Descriptions Q’ty
mm mm N⋅m (kgf⋅m) (lbf⋅ft)
Engine cushion rubber mounting nut 14 4 22 137 (14) (101)
1.
Engine cushion rubber mounting bolt 16 2 24 205 (21) (152)
Engine bracket mounting bolt (Front) 12 8 19 88 (9) (65)
2.
Engine bracket mounting bolt (Rear) 10 8 17 49 (5) (36)
Hydraulic oil tank and Fuel tank
3. 10 5 17 49 (5) (36)
mounting bolt
PF 1/4 19 29.5 (3) (22)
4. Fitting for hydraulic hoses and piping PF 3/8 22 39 (4) (29)
PF 1/2 27 64 (6.5) (47)
5. Pump mounting bolt 12 2 10 108 (11) (80)
6. Pump cover mounting bolt 10 6 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
7.
Control valve base mounting bolt 10 5 17 49 (5) (36)
8. Swing device mounting bolt 16 8 24 205 (21) (152)
8 2 13 9.8 (1) (7.2)
9. Battery mounting nut
10 2 17 49 (5) (36)
10. Cab/Canopy mounting bolt 10 13 17 49 (5) (36)
11. Floor mounting bolt 16 4 24 205 (21) (152)
Swing bearing mounting bolt to up-
14 22 22 175 (18) (130)
perstructure
12.
Swing bearing mounting bolt to un-
12 20 19 108 (11) (80)
dercarriage
13. Travel device mounting bolt 12 26 19 128 (13) (94)
14. Sprocket mounting bolt 12 24 19 128 (13) (94)
15. Upper roller mounting bolt 14 2 22 137 (14) (101)
16. Lower roller mounting bolt 18 16 27 451 (46) (332)
8 13 9.8 (1) (7)
17. Cover mounting bolt 10 17 49 (5) (36)
12 19 88 (9) (65)
18. Counterweight mounting bolt 18 3 27 295 (30) (217)
NOTE 1. Apply lubricant (e.g. white zinc B

dissolved into spindle oil) to bolts and
nuts to reduce friction coefficient of them.
2. Make sure bolt and nut threads are clean
before installing.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or compo-

nents.
Specified Tightening Torque Chart
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)
W1-2-3
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.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Equally tighten upper and lower Tighten from center and diagonally
alternately Tighten diago-
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
W1-2-4
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
WRONG
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008
an air wrench often causes RIGHT WRONG

tightening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• 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
W105-01-01-009
holes in the bolt and nut while tight-
RIGHT RIGHT WRONG
ening, not while loosening.
• 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
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°
30°
IMPORTANT: 1. Do not over-tighten nut (3). 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
2. Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,28.5)
27 27 64 (6.5,47)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,28.5)
27 22 64 (6.5,47)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.
W1-2-6
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to

seal pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 1
in O-ring groove (e). Tightening M104-07-033
nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (8) or sealing surface mm mm
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,22)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14,101)
place O-ring (6) with a new one 36 30,32 175 (18,129)
and check that O-ring (6) is cor- 41 36 205 (21,151)
rectly seated in place, tighten nut 46 41 205 (21,151)
(9).
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018
Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Seal tape is used to seal clearances between male Internal Thread

and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap. External Thread
Clearance
• Application Procedure
W105-01-01-019
Confirm that the thread surface is clean and, free of Leave one to two pitch threads uncovered
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
T-Bolt Type Band Clamp: M114-07-041
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
Worm Gear Type Band Clamp:
T-Bolt Type Worm Gear Type
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-8
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 ma-
chine.
Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose rup-
ture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
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
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, 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, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Basic Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front-End Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-10
GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Loosen the hydraulic oil tank cap to re-
lease any remaining pressure.
M570-07-005
Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.
2. Stop the engine. Loosen the hydraulic oil tank (2) 1

cap (1) to release any remaining pressure.
3. Remove hydraulic oil tank (2) cap (1). 2
4. Connect a vacuum pump with the hole removed

cap (1) to maintain negative pressure in the hy-
draulic oil tank.
NOTE: Be sure to run the vacuum pump continu-
ously while working.
W1LD-01-03-001
Vacuum Pump
Hose
Adapter
W1LD-01-03-002
W1-3-1
GENERAL / Bleeding Air
(Blank)
W1-3-2
GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Colour
• Upperstructure Outer cover [Except resinated covers] 2.5GYO. 12/1.0D (SP-424) [Dark Gray]
Boom swing post, Boom swing cylinder 2.5GYO. 12/1.0D (SP-424)
Counterweight, Skirt 2.5GYO. 12/1.0D (SP-424)
Canopy except Roof 2.5GYO. 12/1.0D (SP-424)
Control lever [Travel, Blade] 2.5GYO. 12/1.0D (SP-424)
Stay, Swing pedal 2.5GYO. 12/1.0D (SP-424)
Seat base, Floor plate 2.5GYO. 12/1.0D (SP-424)
Upperstructure resinated covers, Tank YR-01 [TAXY Yellow]
• Undercarriage Track frame, Blade 2.5GYO. 12/1.0D (SP-424) [Dark Gray]
• Front attachment Boom, Arm, Bucket and Link YR-01 [TAXY Yellow]
(Including cylinder)
TAXI Yellow
Dark Gray Except
Seat and Console
Highgrade Beige
TAXI Yellow
Dark
Gray TAXI Yellow
Dark
Gray
Dark Gray Dark Gray Dark Gray Dark Gray Dark Gray Dark Gray
Blade Including Undercarriage Boom Swing Post
CYL. Including Swing Including CYL.
Bearing
W1LS-01-04-001
W1-4-1
GENERAL / Painting
(Blank)
W1-4-2
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Canopy Group 5 Swing Device
Remove and Install Canopy............... W2-1-1 Remove and Install
Swing Device................................... W2-5-1
Group 2 Counterweight Disassemble Swing
Remove and Install Reduction Gear (ZAXIS30, 35) ........ W2-5-4
Counterweight ................................. W2-2-1 Assemble Swing
Reduction Gear (ZAXIS30, 35) ........ W2-5-6
Group 3 Pump Device Disassemble Swing
Remove and Install Motor (ZAXIS30, 35)........................ W2-5-8
Pump Device ................................... W2-3-1 Assemble Swing
Disassemble Pump Motor (ZAXIS30, 35)...................... W2-5-10
Device (ZAXIS30, 35) ...................... W2-3-4 Disassemble Swing
Assemble Pump Reduction Gear (ZAXIS40, 50) ...... W2-5-14
Device (ZAXIS30, 35) ...................... W2-3-6 Assemble Swing
Disassemble Pump Reduction Gear (ZAXIS40, 50) ...... W2-5-16
Device (ZAXIS40, 50) .................... W2-3-10 Disassemble Swing
Assemble Pump Motor (ZAXIS40, 50)...................... W2-5-22
Device (ZAXIS40, 50) .................... W2-3-14 Assemble Swing
Maintenance Standards ................... W2-3-18 Motor (ZAXIS40, 50)...................... W2-5-24
Maintenance
Group 4 Control Valve Standards (ZAXIS30, 35) ............... W2-5-28
Remove and Install Maintenance
Control Valve ................................... W2-4-1 Standards (ZAXIS40, 50) ............... W2-5-29
Disassemble and Assemble
Control Valve (ZAXIS30, 35) ............ W2-4-6 Group 6 Pilot Valve
Disassemble and Assemble Remove and Install Pilot Valves........... W2-6-1
Control Valve (ZAXIS40, 50) .......... W2-4-10 Disassemble Travel Pilot Valve............ W2-6-6
Disassemble and Assemble Body.... W2-4-14 Assemble Travel Pilot Valve .............. W2-6-10
Disassemble Boom Anti-Drift Valve . W2-4-16 Disassemble Front/Swing
Assemble Boom Anti-Drift Valve ...... W2-4-18 Pilot Valve ....................................... W2-6-14
Disassemble and Assemble Spool ... W2-4-20 Assemble Front/Swing Pilot Valve ..... W2-6-18
Disassemble and Assemble Arm
Regenerative Valve, Check Valve
and Orifice..................................... W2-4-22
1LSW-2-1
Group 7 Solenoid Valve
Remove and Install Solenoid Valve......... W2-7-1
Solenoid Valve...................................... W2-7-3
1LSW-2-2
UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal
1. Attach a nylon sling to canopy (1).

1
CAUTION: Canopy (1) weight: 90 kg (200 lb)

Cab weight: 175 kg (390 lb)
2. Remove bolts (2) (4 used), spring washers (3) (4

used), stoppers (4) (4 used), lubbers (6) (4used)
and spacers (5) (4 used) to remove canopy (1)
from main frame (8) by crane.
3. Remove lubbers (7) (4 used) from main frame (8).

W1LN-02-01-001
Installation 2
3
4
1
CAUTION: Canopy (1) weight: 90 kg (200 lb)
Cab weight: 175 kg (390 lb) 5
6
1. Lift canopy (1) by crane.
2. Install lubbers (7) (4 used), spacers (5) (4 used) 7

and lubbers (6) (4 used) to canopy (1).
3. Put canopy (1) onto main frame (8).

8
4. Install stoppers (4) (4 used) to lubbers (6) (4 used)
W1LN-02-01-002
and tighten it with spring washers (3) (4 used) and
bolts (2) (4 used).
W2-1-1
UPPERSTRUCTURE / Canopy
(Blank)
W2-1-2
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT 1
Removal
1. Remove bolts (2) (4 used) to remove engine 2

cover (1).
2. Remove bolts (3) (ZAXIS30, 35: 2 used, ZAXIS40,

50: 4 used) to remove latch (4).
CAUTION: Counterweight weight:

175 kg (390 Ib) (ZAXIS 30)
350 kg (770 lb) (ZAXIS 35)
295 kg (650 Ib) (ZAXIS 40)
550 kg (1210 Ib) (ZAXIS 50)
M577-05-014
4 3
3. Install eye bolts (A-12, M12, Pitch 1.75) into the
hole where the bolt (3) was removed from. Eye Bolt
Attach a wire rope to the eyebolt and hold it by
crane.
4. (ZAXIS30, 35)
Remove bolts (6) (2 used) and washers (7) (2
used). Lift counterweight (5) off.
: 22 mm
5. (ZAXIS40, 50)
Remove the mounting bolts (8) (6 used) from
counterweight (5). Lift counterweight (5) off.
: 10 mm
: 18 mm
W577-02-02-001
7 6 5
W507-02-02-001
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
1
CAUTION: Counterweight weight:
175 kg (390 Ib) (ZAXIS 30)
350 kg (770 lb) (ZAXIS 35)
295 kg (650 Ib) (ZAXIS 40) 2
550 kg (1210 Ib) (ZAXIS 50)
1. (ZAXIS30, 35)
Install counterweight (5) with bolts (6) (2 used)
and washers (7) (2 used).
: 22 mm
: 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft )
2. (ZAXIS40, 50)
Install counterweight (5) with bolts (8) (6 used).
: 10 mm 4 3
M577-05-014
: 50 N⋅m (5 kgf⋅m, 360 Ibf⋅ft )

: 18 mm Eye Bolt
: 295 N⋅m (30 kgf⋅m, 215 Ibf⋅ft )
3. Install latch (4) with bolts (3) (ZAXIS30, 35: 2

used, ZAXIS40, 50: 4 used).
4. Install engine cover (1) with bolts (2) (4 used).
W577-02-02-001
7 6 5
W507-02-02-001
W2-2-2
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
IMPORTANT: Be sure to release any pressure in
4
the hydraulic oil tank before doing
5
any work. (Refer to W1-3-1)
2
Removal
1. Remove bolts (4) (4 used), nuts (1) (4 used),

washers (2) (8 used) and spring washers (5) (4
used) to remove covers (3, 6). 6
3
2
1
W1LS-02-03-004
IMPORTANT: Tag hose and piping to aid in

re-assembly.
2. Disconnect all hoses and pipes from pump device
(8). Cap all open ends.
CAUTION: Pump device (8) weight:

20 kg (44 lb) (ZAXIS30, 35),
24 kg (53 lb) (ZAXIS40, 50) 7
3. Attach a nylon sling onto the center of gravity in

pump device (8) to lift it. 8
4. Remove socket bolts (7) (2 used) to lift pump

device (8) off.
W1LS-02-03-005
W2-3-1
Installation
1. Install pump device (8) with socket bolts (7) (2

used).
2. Connect all hoses and pipes onto pump device

(8).
W1LS-02-03-005
3. Install covers (3, 6) with bolts (4) (4 used) nuts (1) 4

(4 used), washers (2) (8 used) and spring 5
washers (5) (4 used).
2
IMPORTANT: Be sure to bleed air in the pump

device.(Refer to W1-1-2.) After
connecting the hoses, check the 6
hydraulic oil level. Start the engine
and check the hoses for oil leaks.
3
2
1
W1LS-02-03-004
W2-3-2
(Blank)
W2-3-3
DISASSEMBLE PUMP DEVICE (ZAXIS30,
35)
5
28 4
26
25 3
23
24
23 2
22 1
20
19
18
14
27 13
12
11
10
8
7
21 6
47 17
46 16
11
45
44
43 41
40 9
37
36
35
34
31
42
30
29
39
33
32
W575-02-03-001
1- Retaining Ring 13 - Rod 25 - Retaining Ring 36 - Bolt
2- Oil Seal 14 - Swash Plate 26 - Valve Plate 37 - Nut
3- Shaft 16 - Stopper Pin B 27 - Spring Pin 39 - Socket Bolt (5 Used)
4- Ball Bearing 17 - Ceramic Ball (2 Used) 28 - Needle Bearing 40 - O-Ring
5- Retaining Ring 18 - Plunger (10 Used) 29 - Spring Holder 41 - O-Ring
6- O-Ring 19 - Retainer 30 - Spring 42 - O-Ring
7- Plug 20 - Holder 31 - Spring Guide 43 - Collar
8- Pin (2 Used) 21 - Needle (3 Used) 32 - Pin 44 - Coupling
9- Housing S 22 - Cylinder Block 33 - O-Ring 45 - Gear Pump
10 - Packing 23 - Retainer (2 Used) 34 - Housing H 46 - Spring Washer (2 Used)
11 - Coned Disc Spring (4 Used) 24 - Spring 35 - Seal Washer 47 - Socket Bolt (2 Used)
12 - Stopper Pin A
W2-3-4
Disassemble Pump Device (ZAXIS30, 35) 7. Remove spring guide (31), spring (30), spring
• Read PRECAUTIONS FOR DISASSEMBLING holder (29) and cylinder block (22) assembly from
AND ASSEMBLING (W1-1-1) carefully before housing S (9).
disassembling.
IMPORTANT: The setting of the pump delivery 8. Remove plungers (18) (10 used), retainer (19),
flow rate changes by turning bolt holder (20) and needles (21) (3 used) from
(36). Be careful not disassemble bolt cylinder block (22).
(36) and nut (37).
1. Loosen socket bolts (47) (2 used), then remove
gear pump (45).
CAUTION: Make sure to push spring (24)
: 6 mm
with a press when removing retaining ring
(25).
If retaining ring (25) is removed without
2. Remove O-rings (40), (41), (42), collar (43) and
pressing spring (24), spring (24) may fly out,
coupling (44) from housing H (34).
possibly causing serious injury.
CAUTION: Use a bolt (M10, length 65 mm) 9. Remove retaining ring (25) from cylinder block
for temporary assembly when removing (22), then remove retainer (23), spring (24) and
housing H (34). retainer (23) in this order.
If a bolt for temporary assembly is not used,
spring (30) may fly out, possibly causing
serious injury. 10. Remove swash plate (14) from housing S (9),
then remove ceramic balls (17) (2 used).
3. Remove upper two of socket bolts (39) (5 used),

then install bolts (M10, length 65 mm) for 11. Remove stopper pin A (12), stopper pin B (16),
temporary assembly in the same place. coned disc springs (11) (4 used), and rod (13).
: 8 mm
IMPORTANT: Never remove ball bearing (4) unless

4. Remove other three socket bolts (39). replacing it.
: 8 mm 12. Remove retaining ring (1) from housing S (9). Tap
shaft assembly (3) lightly with a plastic hammer,
then remove oil seal (2), retaining ring (5) and ball
5. Turn bolts (2 used) for temporary assembly bearing (4).
alternately, then remove them from housing H
(34).
IMPORTANT: Be careful not to drop valve plate

(26) when removing housing H (34).
6. Remove housing H (34), then remove packing
(10), pins (8) (2 used) and valve plate (26) in this
order.
W2-3-5
ASSEMBLE PUMP DEVICE (ZAXIS30, 35)
12 29 6 7 19 20 22 18 24 23 10 30 31 34,39 35 37
36
8,9 43
44
13 45,46,47
17
4
T565-03-01-001
5
16 11 14 21 25 28 26 27 32 33 42 40
1- Retaining Ring 13 - Rod 25 - Retaining Ring 36 - Bolt

2- Oil Seal 14 - Swash Plate 26 - Valve Plate 37 - Nut
3- Shaft 16 - Stopper Pin B 27 - Spring Pin 39 - Socket Bolt (5 Used)
4- Ball Bearing 17 - Ceramic Ball (2 Used) 28 - Needle Bearing 40 - O-Ring
5- Retaining Ring 18 - Plunger (10 Used) 29 - Spring Holder 41 - O-Ring
6- O-Ring 19 - Retainer 30 - Spring 42 - O-Ring
7- Plug 20 - Holder 31 - Spring Guide 43 - Collar
8- Pin (2 Used) 21 - Needle (3 Used) 32 - Pin 44 - Coupling
9- Housing S 22 - Cylinder Block 33 - O-Ring 45 - Gear Pump
10 - Packing 23 - Retainer (2 Used) 34 - Housing H 46 - Spring Washer (2 Used)
11 - Coned Disc Spring (4 Used) 24 - Spring 35 - Seal Washer 47 - Socket Bolt (2 Used)
12 - Stopper Pin A
W2-3-6
Assemble Pump Device (ZAXIS30, 35)
• Read PRECAUTIONS FOR DISASSEMBLING 8. Install ceramic balls (17) (2 used) on swash plate
AND ASSEMBLING (W1-1-1) carefully before (14), then install swash plate (14) in housing S
assembling. (9).
NOTE: Apply grease onto ceramic balls (17) to
IMPORTANT: If ball bearing (4) has been replaced, prevent them from falling off.
press ball bearing (4) onto shaft (3)
beforehand, then install retaining
ring (5). 9. Install cylinder block (22) assembly in housing S
1. Insert shaft (3) in housing S (9). Drive in oil seal (9), then insert spring holder (29), spring (30) and
(2), then install retaining ring (1). spring guide (31).
2. Install retainer (23), spring (24) and retainer (23) 10. Install valve plate (26) in housing H (34).
in cylinder block (22) in this order.
NOTE: Apply grease onto the housing H (34) side
in valve plate (26).
3. Push retainer (23) and spring (24) with a press,
then install retaining ring (25).
11. Install pins (8) (2 used) and packing (10) in
housing S (9).
4. Install needle (21) in cylinder block (22), then
install holder (20) on needle (21).
12. Install housing H (34) on housing S (9), then
tighten mounting bolt on spring (30) side with
temporary assembly bolts (2 used) (M10, length
5. Install plungers (18) (10 used) and retainer (19) in
65 mm).
cylinder block (22).
: 8 mm
6. Install coned disc springs (11) (2 used) on stopper

13. Tighten lightly socket bolts (39) (3 used).
pin A (12), then install them in housing S (9).
: 8 mm
IMPORTANT: The length of stopper pin A (12) and

stopper pin B (16) differs to each
other. Install them with referring to
the assembly diagram.
7. Install coned disc springs (11) (2 used) on stopper
pin B (16), then install them in housing S (9).
Install rod (13) in housing S (9).
W2-3-7
34,39
43
44
45,46,47
T565-03-01-001
42 40
NOTE: As for the O-ring (41), refer to W2-3-4.
W2-3-8
14. Remove one bolt which is temporary assembled
in step 12. Install socket bolt (39) in the same
place, then tighten it lightly. Remove the other bolt,
then install socket bolt (39) and tighten it lightly,
similar to the above.
: 8 mm
15. Tighten socket bolts (39) (5 used) securely which

are tighten lightly in steps 13 and 14.
: 8 mm
: 54 to 64 N⋅m
(5.5 to 6.5 kgf⋅m, 40 to 47 lbf⋅ft)
16. Install collar (43), coupling (44), O-rings (40), (41)

and (42) on gear pump (45).
17. Install gear pump (45) on housing H (34), then

tighten socket bolts (47) (2 used) and spring
washers (46) (2 used).
: 6 mm
: 10 to 14 N⋅m
(1.0 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
W2-3-9
DISASSEMBLE PUMP DEVICE (ZAXIS40,
50)
21
20
19
18
17 1
16
15 2
14 3
13 4
12 5
11
10
9
39 8
38
37 7
36 6
40 35
41 34
56 33
42
32
22
55 23
43 31 24
44 30 25
45 29
46 28
47
48 27
26
49
50
51
52
53
54
W1LS-02-03-003
1- Shaft 15 - Holder 29 - Pin 43 - Bolt

2- Oil Seal 16 - Needle (3 Used) 30 - Spring Guide 44 - O-Ring
3- O-Ring 17 - Cylinder Block 31 - Pin (2 Used) 45 - Socket Bolt (2 Used)
4- Seal Holder 18 - Retainer 32 - Body H 46 - Sleeve
5- Retaining Ring 19 - Spring 33 - Seal Washer 47 - O-Ring
6- Ball Bearing 20 - Retainer 34 - Bolt 48 - Rod
7- Seal Washer 21 - Retaining Ring 35 - Nut 49 - Spring Pin
8- Retaining Ring 22 - Spring Washer (8 Used) 36 - O-Ring 50 - Needle Bearing
9- Body S 23 - Socket Bolt (8 Used) 37 - O-Ring (2 Used) 51 - Valve Plate
10 - Packing 24 - Bolt 38 - Collar 52 - Bearing
11 - Thrust Bushing (2 Used) 25 - Nut 39 - Coupling 53 - Bearing
12 - Thrust Plate 26 - Spring Holder 40 - Bolt (2 Used) 54 - Control Piston
13 - Plunger (10 Used) 27 - Spring 41 - Washer (2 Used) 55 - Rod
14 - Retainer 28 - Spring 42 - Gear Pump 56 - O-Ring
W2-3-10
Disassemble Pump Device (ZAXIS40, 50)
• Read PRECAUTIONS FOR DISASSEMBLING IMPORTANT: Never remove seal holder (4) unless
AND ASSEMBLING (W1-1-1) carefully before replacing it.
disassembling. 7. Remove retaining ring (5) from housing S (9). Pull
shaft (1) assembly out with a plastic hammer.
IMPORTANT: The setting of the pump delivery
flow rate changes by turning bolts
(24, 34, 43). Be careful not 8. Remove seal holder (4), O-ring (3), oil seal (2),
disassemble bolts (24, 34, 43) and retaining ring (8) and ball bearing (6) from shaft
nuts (25, 35). (1).
1. Loosen bolts (40) (2 used), then remove gear
pump (42).
: 6 mm 9. Remove thrust plate (12) from housing H (32).
2. Remove O-rings (37, 56, 36), collar (38) and 10. Remove spring holder (26), springs (27, 28), pin
coupling (39) from housing H (32). (29), spring guide (30), the cylinder block (17)
assembly and valve plate (51) from housing H
(32).
CAUTION: Use a bolt (M10, length 65 mm)
for temporary assembly when removing
11. Remove plungers (13) (10 used), retainer (14),
housing S (9).
holder (15) and needles (16) (3 used) from
If a bolt for temporary assembly is not used,
springs (27, 28) may fly out, possibly causing
serious injury.
CAUTION: Make sure to push spring (19)

3. Remove upper four of socket bolts (23) (8 used), with a press when removing retaining ring
then install bolts (M10, length 65 mm) for (21).
temporary assembly in the same place. If retaining ring (21) is removed without
: 8 mm pressing spring (19), spring (19) may fly out,
possibly causing serious injury.
4. Remove other four socket bolts (23).

: 8 mm 12. Remove retaining ring (21) from cylinder block
(17), then remove retainer (20), spring (19) and
retainer (18) in this order.
5. Turn bolts (4 used) for temporary assembly
alternately, then remove them from housing S (9).
IMPORTANT: Never remove bearings (52, 53)
unless replacing it.
6. Remove the housing S (9) assembly, then remove 13. Remove control piston (54) and bearings (52, 53)
packing (10) and pins (31) (2 used). from housing H (32).
W2-3-11
32
55
45
46
47
48
W1LS-02-03-003
W2-3-12
14. Remove socket bolts (45) (2 used) to remove the
sleeve (46) assembly from housing H (32).
15. Remove O-ring (47) and rods (48, 55) from sleeve
(46).
W2-3-13
ASSEMBLE PUMP DEVICE (ZAXIS40, 50)
35 33 30 28 27 21 13 16 15 14 10 26 12 9 8
34 3
29 5
32 4
36 2
39
1
38
6
40
24
41 42 50 49 55 43 44 46 48 47 20 54 52 53 19 18 11 7 25
W1LS-02-03-002
1- Shaft 15 - Holder 29 - Pin 43 - Bolt

2- Oil Seal 16 - Needle (3 Used) 30 - Spring Guide 44 - O-Ring
3- O-Ring 17 - Cylinder Block 31 - *Pin (2 Used) 45 - *Socket Bolt (2 Used)
4- Seal Holder 18 - Retainer 32 - Body H 46 - Sleeve
5- Retaining Ring 19 - Spring 33 - Seal Washer 47 - O-Ring
6- Ball Bearing 20 - Retainer 34 - Bolt 48 - Rod
7- Seal Washer 21 - Retaining Ring 35 - Nut 49 - Spring Pin
8- Retaining Ring 22 - *Spring Washer (8 Used) 36 - O-Ring 50 - Needle Bearing
9- Body S 23 - *Socket Bolt (8 Used) 37 - *O-Ring (2 Used) 51 - Valve Plate
10 - Packing 24 - Bolt 38 - Collar 52 - Bearing
11 - Thrust Bushing (2 Used) 25 - Nut 39 - Coupling 53 - Bearing
12 - Thrust Plate 26 - Spring Holder 40 - Bolt (2 Used) 54 - Control Piston
13 - Plunger (10 Used) 27 - Spring 41 - Washer (2 Used) 55 - Rod
14 - Retainer 28 - Spring 42 - Gear Pump 56 - *O-Ring
NOTE: As for the parts with * mark, refer to

W2-3-10.
W2-3-14
Assemble Pump Device (ZAXIS40, 50)
• Read PRECAUTIONS FOR DISASSEMBLING 8. Install valve plate (51), the cylinder block (17)
AND ASSEMBLING (W1-1-1) carefully before assembly and the thrust plate (12) assembly in
assembling. housing H (32).
1. Install rods (48, 55) and O-ring (47) onto sleeve

(46). 9. Insert spring guide (30), pin (29), springs (28, 27)
and spring holder (26) into housing H (32).
2. Install the sleeve (46) assembly to housing H (32)

with socket bolts (45) (2 used). 10. Install pins (31) (2 used) and packing (10) in
housing H (32).
3. Press bearings (52, 53) into housing H (32), then

install control piston (54). 11. Install oil seal (2) and O-ring (3) to seal holder (4).
4. Install retainer (18), spring (19) and retainer (20) IMPORTANT: If ball bearing (6) has been replaced,
in cylinder block (17) in this order. press ball bearing (6) onto shaft (1)
beforehand, then install retaining
ring (8).
5. Push retainer (20) and spring (19) with a press, 12. Insert shaft (1) in housing S (9). Install seal holder
then install retaining ring (21). (4) and retaining ring (5).
6. Install needles (16) (3 used) in cylinder block (17), 13. Install housing S (9) on housing H (32), then
then install holder (15) on needle (16). tighten mounting bolt on spring (28) side with
temporary assembly bolts (4 used) (M10, length
65 mm).
7. Install plungers (13) (10 used) and retainer (14) in : 8 mm
14. Tighten lightly spring washers (22) (4 used) and

socket bolts (23) (4 used).
: 8 mm
W2-3-15
32
36
39
38
40
41 42
W1LS-02-03-002
NOTE: As for the socket bolts (23, 45) spring

washer (22) and O-ring (37, 56), refer to
W2-3-10.
W2-3-16
15. Remove two bolt which is temporary assembled.
Install spring washers (22) (2 used) and socket
bolt (23) in the same place, then tighten it lightly.
Remove the other bolt, then install spring washers
(22) (2 used) and socket bolt (23) and tighten it
lightly, similar to the above.
: 8 mm
16. Tighten socket bolts (23) (8 used).

: 8 mm
: 54 to 64 N⋅m
(5.5 to 6.5 kgf⋅m, 40 to 47 lbf⋅ft)
17. Install collar (38), coupling (39) and O-rings (36,

56, 37) (2 used) on gear pump (42).
18. Install gear pump (42) on housing H (32) with

bolts (40) (2 used) and spring washers (41) (2
used).
: 6 mm
: 10 to 14 N⋅m
(1.0 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)
W2-3-17
MAINTENANCE STANDARDS
1. The clearance between the plunger diameter and Cylinder
the cylinder block bore diameter. Block
(D-d): 0.050 mm (0.00197 in) or less.

D d
W507-02-04-009
Plunger
2. The clearance between the plunger and the shoe. δ
δ: 0.2 mm (0.00787 in) or less.
W107-02-06-141
3. The wear amount of the oil seal mounting
surfaces.
Make sure that there are no damage and / or
abnormal wear.
W507-02-04-010
(D0-D1): 0.025 mm (0.000984 in) or less. D0 D1
W2-3-18
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
1 Joint Part
IMPORTANT: Be sure to release air in the hydrau-
lic oil tank before starting the work.
(Refer to W1-3-1)
Removal
2
1. Remove the canopy. 3
NOTE: Refer to “REMOVE AND INSTALL CAN-
OPY”.
2. Remove bolts (2) (4 used) to remove cover (3)

W1LS-02-05-006
from side cover (1).
4
IMPORTANT: Tag hose and connector to aid in
re-assembly.
3. Disconnect all pilot hoses at the joint part. Cap all
open ends.
Disconnect all connectors.
5
4. Attach a nylon sling onto seat (5).
CAUTION: Floor plate (4) assembly weight:

160 kg (360 lb) A
IMPORTANT: Keep the stopper (9) of A part well in

order to reassemble it to original
W1LS-02-05-005
position.
5. Remove bolts (7) (4 used), spring washers (8) (4 7
used) and stoppers (9) (4 used) to lift the floor
8
plate (4) assembly off.
9
6. Remove rubbers (11) (4 used), spacers (10) (4 10
used) and rubbers (12) (4 used) from floor plate 4 11
(4).
12
W1LS-02-05-007
W2-4-1
IMPORTANT: Tag hose and piping to aid in
re-assembly. 13 Cap 14 15
7. Disconnect all hoses and pipes from control valve
(14). Cap all open ends.
CAUTION: Control valve (14) weight:

35 kg (77 lb) (ZAXIS30, 35)
48.5 kg (110 lb) (ZAXIS40, 50)
8. Remove bolts (15) (5 used) from main frame (16).
9. Attach a nylon sling under the both caps on con-

trol valve.
Lift control valve (14) with plate (13) off main
frame (16).
W1LS-02-04-001
Cap
10. Remove bolts (17) (4 used) to control valve (14) 14

from plate (13).
13
W1LA-02-04-003
17 16
W2-4-2
Installation
14
CAUTION: Control valve (14) weight:
35 kg (77 lb) (ZAXIS30, 35)
48.5 kg (110 lb) (ZAXIS40, 50) 13
1. Install plate (13) to control valve (14) with bolts

(17) (4 used).
2. Attach a nylon sling under the both caps on con-

W1LA-02-04-003
trol valve.
Hoist control valve (14) with plate (13) onto main 17 16
frame (16).
13 Cap 14 15
3. Install control valve (14) to main frame (16) with
bolts (15) (4 used).
4. Connect all hoses and pipes to control valve (7).
W1LS-02-04-001
Cap
W2-4-3
5. Install rubbers (12) (4 used), spacers (10) (4 used)
4
and rubbers (11) (4 used) onto floor plate (4).

5

160 kg (360 lb)
7. Install the floor plate (4) assembly with stoppers

(9) (4 used), spring washers (8) (4 used) and bolts
(7) (4 used) onto frame (6).
W1LS-02-05-005
8. Connect all the pilot hoses at the joint part. Con- 7

nect all the connectors. 8
9
10
4 11
9. Install cover (3) onto side cover (1) with bolts (2)
(4 used).
12
10. Install the canopy. 6

NOTE: Refer to “REMOVE AND INSTALL CAN-
OPY”.
W1LS-02-05-007
1 Joint Part
IMPORTANT: When the installation is completed,
check the oil level. Start the engine
and check for any oil leaks.
2
3
W1LS-02-05-006
W2-4-4
(Blank)
W2-4-5
DISASSEMBLE AND ASSEMBLE
CONTROL VALVE (ZAXIS30, 35)
1
3
6 7
8
5 1
4 15 14
3
1a 16
9 17 19
18 20
3
2 21
1 10
1
11
3 15
12 14
16 3
13 14 1b 9
17
1 22 18
19
21 20
21 79
20
13 1
3 15
14 16 14
1c 3
1 9 17
23 18
24 19
21 20
25
20 21
13
3
14 28 1
1 1d
26 9
21 27
15
20 16
3 3 19
13 17
2 15
18 30 1
1 16 20
1e 17 27 21
29
31
21
9
20 19
13 14
30 3
14 3
1 1f
32
21
20
13 W1LS-02-04-002
W2-4-6
1a - Body (Flow Combiner 12 - Spring Seat 35 - Orifice 57 - Piston

Valve)
1b - Body (Blade) 13 - Cover (12 Used) 36 - O-Ring 58 - Spring
1c - Body (Swing) 14 - Spring (18 Used) 37 - Check Valve (3 Used) 59 - Plug
1d - Body (Boom Swing) 15 - Plug (7 Used) 38 - Plug 60 - O-Ring
1e - Body (Flow Combining 16 - O-Ring (7 Used) 39 - Check Valve 61 - Spool
Switch)
1f - Body (Auxiliary) 17 - Spring (9 Used) 40 - Spring 62 - Sleeve
1g - Body (Arm) 18 - Check Valve (4 Used) 41 - O-Ring 63 - Backup Ring
1h - Body (Right Travel) 19 - Cover (10 Used) 42 - Plug 64 - O-Ring
1i - Body (Inlet) 20 - Spring Seat (19 Used) 43 - Spool 65 - O-Ring
1j - Body (Left Travel) 21 - Spring Seat (19 Used) 44 - Spring 66 - Backup Ring
1k - Body (Boom) 22 - Spool 45 - Check Valve 67 - Check Valve
1l - Body (Bucket) 23 - Spool 46 - Spool 68 - Spring Seat
1 - Socket Bolt (46 Used) 24 - Spring 47 - Main Relief Valve (P1, P2) 69 - Spring
2 - Spring (2 Used) 25 - Check Valve 48 - Backup Ring (2 Used) 70 - Socket Bolt (5 Used)
3 - O-Ring (24 Used) 26 - Spool 49 - Spool 71 - Body
4 - Main Relief Valve (P3) 27 - Plug (2 Used) 50 - Plate (2 Used) 72 - Backup Ring
5 - Nut (8 Used) 28 - Plug (4 Used) 51 - Spool 73 - Spring
6 - Plug 29 - Spool 52 - Plug 74 - Check Valve
7 - Filter 30 - Plug (2 Used) 53 - O-Ring 75 - Spool
8 - Cover 31 - Check Valve 54 - Spacer 76 - Check Valve
9 - O-Ring (11 Used) 32 - Spool 55 - O-Ring (2 Used) 77 - Rod (4 Used)
10 - Spool 33 - Overload Relief Valve (6 56 - Plug 78 - Spool
Used)
11 - Spring Seat 34 - O-Ring 79 - Make-Up Valve
W2-4-7
1
15 20
21
35 36 16 33
34
17
9 19
37 14
33
3
39 38
40 1
14 3 41
13 14
1 1 42 3
43 28
9
21 19
20
20 21
3
14 1
1 47 56
45 28
1 44 57
46 50
58
21 9
59
20 48
13 1 60
47 3
14 61
3 9 62
1 3 63
1i 28
19 64
49 44 20 65
48 45 21 66
50 15 67
3 9 16 55 68
14
17 53 54 69
1 1j 52 37
51
70
21
71
20 20
13 33 14
21
73 72 3 1
33 74 15 14
3
9 16 33
1 14 15
1k 17
16 76
17 19
75 20
3 37 21
21
20 33
13
3
14 1l
1
78 5
21
20
13 77
W1LS-02-04-003
W2-4-8
1a - Body (Flow Combiner 12 - Spring Seat 35 - Orifice 57 - Piston

Valve)
1b - Body (Blade) 13 - Cover (12 Used) 36 - O-Ring 58 - Spring
1c - Body (Swing) 14 - Spring (18 Used) 37 - Check Valve (3 Used) 59 - Plug
1d - Body (Boom Swing) 15 - Plug (7 Used) 38 - Plug 60 - O-Ring
1e - Body (Flow Combining 16 - O-Ring (7 Used) 39 - Check Valve 61 - Spool
Switch)
1f - Body (Auxiliary) 17 - Spring (9 Used) 40 - Spring 62 - Sleeve
1g - Body (Arm) 18 - Check Valve (4 Used) 41 - O-Ring 63 - Backup Ring
1h - Body (Right Travel) 19 - Cover (10 Used) 42 - Plug 64 - O-Ring
1i - Body (Inlet) 20 - Spring Seat (19 Used) 43 - Spool 65 - O-Ring
1j - Body (Left Travel) 21 - Spring Seat (19 Used) 44 - Spring 66 - Backup Ring
1k - Body (Boom) 22 - Spool 45 - Check Valve 67 - Check Valve
1l - Body (Bucket) 23 - Spool 46 - Spool 68 - Spring Seat
1 - Socket Bolt (46 Used) 24 - Spring 47 - Main Relief Valve (P1, P2) 69 - Spring
2 - Spring (2 Used) 25 - Check Valve 48 - Backup Ring (2 Used) 70 - Socket Bolt (5 Used)
3 - O-Ring (24 Used) 26 - Spool 49 - Spool 71 - Body
4 - Main Relief Valve (P3) 27 - Plug (2 Used) 50 - Plate (2 Used) 72 - Backup Ring
5 - Nut (8 Used) 28 - Plug (4 Used) 51 - Spool 73 - Spring
6 - Plug 29 - Spool 52 - Plug 74 - Check Valve
7 - Filter 30 - Plug (2 Used) 53 - O-Ring 75 - Spool
8 - Cover 31 - Check Valve 54 - Spacer 76 - Check Valve
9 - O-Ring (11 Used) 32 - Spool 55 - O-Ring (2 Used) 77 - Rod (4 Used)
10 - Spool 33 - Overload Relief Valve (6 56 - Plug 78 - Spool
Used)
11 - Spring Seat 34 - O-Ring 79 - Make-Up Valve
W2-4-9
DISASSEMBLE AND ASSEMBLE
CONTROL VALVE (ZAXIS40, 50)
1
15 3
16 1
5
8 12
4 14
15 11
3 16 3
2 17 19
1a
1 10 9 18
11
12 14
13
14 19
1b
22
14
50
14 19
1c
23
24
25
79
6
50
14 7
1d
26 20
14
50 31 19
2
1e
29
14
31
33
13 19
14
1f
32
33
50 14
1g
21
50 W1LS-02-04-005
W2-4-10
1a - Body (Flow Combiner 4- Main Relief Valve (P3) 21 - Spool 38 - Plug

Valve)
1b - Body (Blade) 5- Nut (8 Used) 22 - Spool 39 - O-Ring
1c - Body (Swing) 6- Plug 23 - Spool 40 - Boom Anti-Drift Valve
1d - Body (Boom Swing) 7- O-Ring 24 - Spring (3 Used) 43 - Spool
1e - Body (Flow Combining 8- Cover 25 - Check Valve (3 Used) 46 - Spool
Switch)
1f - Body (Auxiliary) 9- O-Ring (13 Used) 26 - Spool 47 - Main Relief Valve (P1, P2)
1g - Body (Arm 1) 10 - Spool 27 - Plug 49 - Spool
1h - Body (Boom 2) 11 - Spring Seat (23 Used) 28 - O-Ring 50 - Cover (10 Used)
1i - Body (Right Travel) 12 - Spring Seat (23 Used) 29 - Spool 51 - Spool
1j - Body (Inlet) 13 - Cover (2 Used) 30 - Cover (2 Used) 70 - Socket Bolt (5 Used)
1k - Body (Left Travel) 14 - Spring (21 Used) 31 - Valve (2 Used) 75 - Spool
1l - Body (Boom 1) 15 - Plug (16 Used) 32 - Spool 77 - Rod (4 Used)
1m - Body (Bucket) 16 - O-Ring (16 Used) 33 - Overload Relief Valve (6 78 - Spool
Used)
1n - Body (Arm 2) 17 - Spring (11 Used) 34 - Plug 79 - Make-Up Valve
1- Socket Bolt (54 Used) 18 - Check Valve (10 Used) 35 - O-Ring
2- Spring (2 Used) 19 - Cover (5 Used) 36 - Spool
3- O-Ring (28 Used) 20 - Cover 37 - Check Valve
W2-4-11
15 27 1
16
17 28
18
50 1
9 3
3 12
11 14
15 11
14 3
12 16 50
1h
1
43 25 34 47
24
35
20 1i 30
46
47
1j 50
50
49
70
30
38 40
1k
51 39
33
33
37
50 50
1l
75
50 1m
50
78
50 1n
77
36
5
50 W1LS-02-04-004
W2-4-12
1a - Body (Flow Combiner 4- Main Relief Valve (P3) 21 - Spool 38 - Plug

Valve)
1b - Body (Blade) 5- Nut (8 Used) 22 - Spool 39 - O-Ring
1c - Body (Swing) 6- Plug 23 - Spool 40 - Boom Anti-Drift Valve
1d - Body (Boom Swing) 7- O-Ring 24 - Spring (3 Used) 43 - Spool
1e - Body (Flow Combining 8- Cover 25 - Check Valve (3 Used) 46 - Spool
Switch)
1f - Body (Auxiliary) 9- O-Ring (13 Used) 26 - Spool 47 - Main Relief Valve (P1, P2)
1g - Body (Arm 1) 10 - Spool 27 - Plug 49 - Spool
1h - Body (Boom 2) 11 - Spring Seat (23 Used) 28 - O-Ring 50 - Cover (10 Used)
1i - Body (Right Travel) 12 - Spring Seat (23 Used) 29 - Spool 51 - Spool
1j - Body (Inlet) 13 - Cover (2 Used) 30 - Cover (2 Used) 70 - Socket Bolt (5 Used)
1k - Body (Left Travel) 14 - Spring (21 Used) 31 - Valve (2 Used) 75 - Spool
1l - Body (Boom 1) 15 - Plug (16 Used) 32 - Spool 77 - Rod (4 Used)
1m - Body (Bucket) 16 - O-Ring (16 Used) 33 - Overload Relief Valve (6 78 - Spool
Used)
1n - Body (Arm 2) 17 - Spring (11 Used) 34 - Plug 79 - Make-Up Valve
1- Socket Bolt (54 Used) 18 - Check Valve (10 Used) 35 - O-Ring
2- Spring (2 Used) 19 - Cover (5 Used) 36 - Spool
3- O-Ring (28 Used) 20 - Cover 37 - Check Valve
W2-4-13
DISASSEMBLE AND ASSEMBLE BODY
NOTE: The figure below shows ZAXIS30, 35. 33
33 47 (P1)
A B
Front
P3 P2 P1
4 33 47(P2) 33 T1LA-03-03-001
Cross Section A Cross Section B (Blade)

(Flow Combiner Valve)
18
6
15
17
16
T1LA-03-03-016
T1LA-03-03-015
4 - Main Relief Valve (P3) 15 - Plug 17 - Spring 33 - Overload Relief Valve (6
Used)
6 - Plug 16 - O-Ring 18 - Check Valve 47 - Main Relief Valve (P1, P2)
W2-4-14
Disassemble Body Assemble Body
• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before
disassembling. assembling.
1. Remove main relief valves (4) and (47) (2 used). 1. Install main relief valves (4) and (47) (2 used).
: 24 mm : 24 mm
: 59 to 69 N⋅m
2. Remove overload relief valves (33) (6 used). (6.0 to 7.0 kgf⋅m, 43 to 51 Ibf⋅ft)
: 24 mm
2. Install overload relief valves (33) (6 used).
IMPORTANT: Take care not to drop off O-rings (9, : 24 mm
34 and 36), check valves (25, 45), : 59 to 69 N⋅m
and springs (24, 44). (6.0 to 7.0 kgf⋅m, 43 to 51 Ibf⋅ft)
3. Remove nuts (5) (4 used) and rods (77) (4 used)
to divide the control valve into each section. 3. Install check valves (25, 45), O-rings (9, 34 and
: 13 mm 36) into each section. Install springs (24, 44) onto
the inner bore of check valve.
4. Remove O-rings (9, 34 and 36) to remove springs NOTE: As for O-rings (9, 34 and 36), check valves
(24, 44) and check valves (25, 45) with a magnet. (25, 45) and springs (24, 44), refer to
NOTE: As for O-rings (9, 34 and 36), check valves W2-4-6 to 13.
(25, 45) and springs (24, 44), refer to
4. Put bodies (1a to 1l) in each section as before
W2-4-6 to 13.
disassembling. Attach rods (77) (4 used) and
tighten them with nuts (5) (8 used).
: 13 mm
: 26.5 to 29.4 N⋅m
(2.7 to 2.9 kgf⋅m, 20 to 21 Ibf⋅ft)
W2-4-15
DISASSEMBLE BOOM ANTI-DRIFT VALVE
NOTE: The figure below shows ZAXIS30, 35.
56
57
58
59
60
61
62
63
64
65
66
67
68
55
69
70
3 71
W1LA-02-04-007
3- O-Ring 59 - Plug 64 - O-Ring 68 - Spring Seat

55 - O-Ring (2 Used) 60 - O-Ring 65 - O-Ring 69 - Spring
56 - Plug 61 - Spool 66 - Backup Ring 70 - Socket Bolt (5 Used)
57 - Piston 62 - Sleeve 67 - Check Valve 71 - Body
58 - Spring 63 - Backup Ring
W2-4-16
Disassemble Boom Anti-Drift Valve
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before
disassembling.
1. Clamp the body (71) assembly in a vise. Remove

plug (56) from body (71).
: 24 mm
2. Remove piston (57) and spring (58) from body

(71) with a screwdriver.
3. Remove plug (59) and O-ring (60) from body (71).

: 24 mm
4. Remove spool (61) from sleeve (62).
5. Pull the sleeve (62) assembly out of body (71).
6. Remove check valve (67), spring seat (68) and

spring (69) from body (71) with a magnet.
7. Remove backup rings (63, 66) and O-rings (64,

65) from sleeve (62).
8. Remove socket bolts (70) (5 used) to remove

body (71).
: 5 mm
9. Remove O-rings (3) and (55) (2 used) from body

(71).
W2-4-17
ASSEMBLE BOOM ANTI-DRIFT VALVE
NOTE: The figure below shows ZAXIS30, 35. 56
59
57
61
58
60
62
63
64
65
55 66
68
69
W1LA-02-04-008
1k 71 67
3- *O-Ring 1k - Body 63 - Backup Ring 68 - Spring Seat

55 - O-Ring (2 Used) 59 - Plug 64 - O-Ring 69 - Spring
56 - Plug 60 - O-Ring 65 - O-Ring 70 - *Socket Bolt (5 Used)
57 - Piston 61 - Spool 66 - Backup Ring 71 - Body
58 - Spring 62 - Sleeve 67 - Check Valve
NOTE: As for items with a marks “ * ”, refer to

W2-4-16.
W2-4-18
Assemble Boom Anti-Drift Valve
assembling.
• Apply grease onto the seals.
1. Install backup rings (63, 66) and O-rings (64, 65)

to sleeve (62).
2. Install check valve (67) into sleeve (62).
3. Install spring seat (68) and spring (69) to the

sleeve (62) assembly.
4. Install body (71) to the sleeve (62) assembly with

the O-ring (55) mounting surface upward.
5. Install O-rings (55) (2 used) and (3) to body (71).
6. Clamp body (1k) in a vise to install body (71) with

: 5 mm
: 7.3 to 10 N⋅m
(0.7 to 1.0 kgf⋅m, 5.1 to 7.2 Ibf⋅ft)
7. Install O-ring (60) to plug (59) to install them into

body (71).
: 24 mm
: 29.4 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)
8. Install spool (61) and spring (58) to sleeve (62).
9. Install piston (57) and plug (56) to plug (59).

: 24 mm
: 29.4 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)
W2-4-19
DISASSEMBLE AND ASSEMBLE SPOOL
Load Check Valve
20 19 3
21 14 13
14 1 21 1g 43 3 20
Arm Regenerative Valve
T577-03-03-005
1g - Body 13 - Cover 19 - Cover 21 - Spring Seat (2 Used)

1 - Socket Bolt (4 Used) 14 - Spring (2 Used) 20 - Spring Seat (2 Used) 43 - Spool
3 - O-Ring (2 Used)
W2-4-20
Disassemble Spool Assemble Spool
1. Remove socket bolts (1) (4 used) from body (19) 1. Install spool (43) to body (1g).
to remove covers (13, 19) and O-rings (3) (2
used). 2. Install spring seats (21) (2 used) to spool (43).
: 5 mm
3. Install O-rings (3) (2 used), springs (14) (2 used)

2. Remove springs (14) (2 used) and spring seats and spring seats (21) (2 used) into covers (13,
(20) (2 used) from covers (13, 19). 19).
3. Remove spring seats (21) (2 used) from spool 4. Install the covers to body (1g) with socket bolts (1)
(43). (4 used).
: 5 mm
4. Pull spool (43) out of body (1g). : 7.3 to 10 N⋅m
NOTE: When removing covers (13, 19), take care (0.7 to 1.0 kgf⋅m, 5.1 to 7.2 Ibf⋅ft)
not to drop off spring (14) and spring seats
(20, 21).
W2-4-21
DISASSEMBLE AND ASSEMBLE ARM REGENERATIVE VALVE,
CHECK VALVE, AND ORIFICE
17 15 16 37
Arm Regenerative Valve Arm Spool
36
1g
34
39
40
35
41 T577-03-03-006
42
1g - Body 17 - Spring 36 - O-Ring 40 - Spring

15 - Plug 34 - O-Ring 37 - Check Valve 41 - O-Ring
16 - O-Ring 35 - Orifice 39 - Check Valve 42 - Plug
W2-4-22
Disassemble Assemble
1. Remove plug (42) from body (1g) to remove 1. Install orifice (35) to body (1g).
check valve (39) and spring (40). O-ring (41) is : 2.5 mm
removed plug (42) together at this time. : 2 N⋅m (0.2 kgf⋅m, 1.4 Ibf⋅ft)
: 6 mm
IMPORTANT: Apply grease onto O-rings (34, 36).
2. Remove plug (15) from body (1g) to remove 2. Install O-rings (34, 36) to plugs (15, 42).
spring (17) and check valve (37) with a magnet.
: 14 mm 3. Install check valve (37) and spring (17) to body
(1g) to install plug (15).
3. Remove orifice (35) from body (1g). : 14 mm
: 2.5 mm : 29.4 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)
4. Install spring (40) to body (1g) with plug (42). Take

care not to drop off check valve (39).
: 6 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)
W2-4-23
(Blank)
W2-4-24
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
1 Joint Part
IMPORTANT: Be sure to release air in the
hydraulic oil tank before starting the
work. (Refer to W1-3-1)
Removal
2
1. Remove the canopy. 3
NOTE: Refer to “REMOVE AND INSTALL
CANOPY”.

W1LS-02-05-006
from side cover (1).
4
IMPORTANT: Tag hose and connector to aid in
re-assembly.
3. Disconnect all the pilot hoses at the joint part. Cap
all open ends.
Disconnect all the connectors.
5

160 kg (360 lb) A
IMPORTANT: Keep the stopper (9) of A part well in

order to reassemble it to original
W1LS-02-05-005
position.
5. Remove bolts (7) (4 used), spring washers (8) (4 7
used) and stoppers (9) (4 used) to lift the floor
8
plate (4) assembly off.
9
6. Remove rubbers (11) (4 used), spacers (10) (4 10
used) and rubbers (12) (4 used) from floor plate 4 11
(4).
12
W1LS-02-05-007
W2-5-1
IMPORTANT: Tag hose to aid in re-assembly.
7. Disconnect all hoses from swing device (13). Cap
all open ends.
13
8. Attach a nylon sling onto swing device (13).
6
CAUTION: Swing device (13) weight:

32.5 kg (72 lb) (ZAXIS30, 35)
47 kg (105 lb) (ZAXIS40, 50)
9. Remove bolts (14) [6 used (ZAXIS30, 35), 8 used W1LD-02-05-003

(ZAXIS40, 50)] to lift swing device (13) off frame 14
(6).
Installation
1. Attach a nylon sling onto swing device (13).

13
CAUTION: Swing device (13) weight: 6

32.5 kg (72 lb) (ZAXIS30, 35)
47 kg (105 lb) (ZAXIS40, 50)
2. Install swing device (13) onto frame (6) with bolts

(14) [6 used (ZAXIS30, 35), 8 used (ZAXIS40,
50)]. W1LD-02-05-003
14
3. Connect all hoses to swing device (13).
W2-5-2
4. Install rubbers (12) (4 used), spacers (10) (4
4
used) and rubbers (11) (4 used) onto floor plate
(4).
5. Attach a nylon sling onto seat (5). 5

160 kg (360 lb)
6. Install the floor plate (4) assembly with stoppers

(9) (4 used), spring washers (8) (4 used) and
bolts (7) (4 used) onto frame (6).
W1LS-02-05-005
7
7. Connect all the pilot hoses at the joint part. 8
Connect all the connectors. 9
10
4 11
8. Install cover (3) onto side cover (1) with bolts (2)
(4 used). 12
6
9. Install the canopy.
NOTE: Refer to “REMOVE AND INSTALL
CANOPY”. W1LS-02-05-007
1 Joint Part
IMPORTANT: When the installation is completed,

check the oil level. Start the engine
and check for any oil leaks.
2
3
W1LS-02-05-006
W2-5-3
DISASSEMBLE SWING REDUCTION
GEAR (ZAXIS30, 35) 7
6
3 8
1
18
17
16
15
14
13
12
11
10
9
26
25
24
23
22
21
20
19
W575-02-05-001
1- Shaft 8 - Socket Bolt (2 Used) 15 - Second Stage Planetary 21 - Inner Race (4 Used)
Gear (4 Used)
2- Collar 9 - Plate (2 Used) 16 - Thrust Plate 22 - Needle Bearing (4 Used)
3- Plate 10 - Collar 17 - Flat Countersunk Head 23 - First Stage Planetary
Screw (4 Used) Gear (4 Used)
4 - Bearing 11 - Second Stage Carrier 18 - Second Stage Sun Gear 24 - Thrust Plate
5 - Housing 12 - Thrust Plate (4 Used) 19 - First Stage Carrier 25 - First Stage Sun Gear
6 - Oil Seal 13 - Inner Race (4 Used) 20 - Thrust Plate (4 Used) 26 - O-Ring
7 - Bearing 14 - Needle Bearing (4 Used)
W2-5-4
Disassemble Swing Reduction Gear (ZAXIS30, 35)

disassembling.
IMPORTANT: Shaft (1), collar (2), plate (3), bearing

(4), oil seal (6), bearing (7), plates (9)
(2 used), collar (10), and O-ring (26)
cannot be disassembled from
housing (5). Replace them with a
housing assembly.
1. Remove socket bolts (8) (2 used) from the swing

device, then remove the swing motor.
: 10 mm
2. Remove first stage sun gear (25), thrust plate (24),

first stage planetary gears (23) (4 used), needle
bearings (22) (4 used), inner races (21) (4 used),
thrust plates (20) (4 used), first stage carrier (19)
and second stage sun gear (18) from housing (5).
3. Remove the second stage carrier (11) assembly

from housing (5).
4. Loosen flat countersunk head screws (17) (4

used), then remove thrust plate (16), second
stage planetary gears (15) (4 used), needle
bearings (14) (4 used), inner races (13) (4 used)
and thrust plates (12) (4 used) in this order.
: 3 mm
W2-5-5
ASSEMBLE SWING REDUCTION GEAR
(ZAXIS30, 35)
27
23
8
24
22
26
21
25
20
16
19
15
18
14
17 13
12
9
11
7 10
4 5
3 2
T575-03-02-001
1- Shaft 8 - Socket Bolt (2 Used) 15 - Second Stage Planetary 22 - Needle Bearing (4 Used)
Gear (4 Used)
2- Collar 9 - Plate (2 Used) 16 - Thrust Plate 23 - First Stage Planetary
Gear (4 Used)
3- Plate 10 - Collar 17 - Flat Countersunk Head 24 - Thrust Plate
Screw (4 Used)
4 - Bearing 11 - Second Stage Carrier 18 - Second Stage Sun Gear 25 - First Stage Sun Gear
5 - Housing 12 - Thrust Plate (4 Used) 19 - First Stage Carrier 26 - O-Ring
6 - Oil Seal 13 - Inner Race (4 Used) 20 - Thrust Plate (4 Used) 27 - Swing Motor
7 - Bearing 14 - Needle Bearing (4 Used) 21 - Inner Race (4 Used)
W2-5-6
Assemble Swing Reduction Gear (ZAXIS30, 35)

assembling.
IMPORTANT: Install thrust plates (16) and (24)

with its chamfered surface facing
upward (motor side).
Apply LOCTITE #242 to flat
countersunk head screws (17) (4
used).
1. Install thrust plates (12) (4 used), inner races (13)

(4 used), needle bearings (14) (4 used), second
stage planetary gears (15) (4 used), and thrust
plate (16) on second stage carrier (11), then
secure them with flat countersunk head screws
(17) (4 used).
: 3 mm
: 3.9±0.5 N⋅m
(0.4±0.05 kgf⋅m, 3±0.3 Ibf⋅ft)
2. Install the second stage carrier (11) assembly into

housing (5).
3. Install second stage sun gear (18).
4. Install thrust plates (20) (4 used), inner races (21)

(4 used), needle bearings (22) (4 used), first
stage planetary gears (23) (4 used), and thrust
plate (24) on first stage carrier (19) in this order.
5. Install the first stage carrier (19) assembly into

housing (5).
6. Install first stage sun gear (25) into housing (5).
7. Install O-ring (26) on swing motor (27), then

install swing motor (27) onto housing (5) with
: 10 mm
: 128±7 N⋅m
(13.1±0.7 kgf⋅m, 94±5 Ibf⋅ft)
W2-5-7
DISASSEMBLE SWING MOTOR (ZAXIS30,
35) 8
7
6
5
4
3
2
1
17
16
15
14
13
12
11
10
9
26
25
24
23
22
21
19
20
19 27
18
28
W565-02-05-002
1 - Housing 8- Holder 15 - Disc Plate 22 - Valve Plate

2 - Socket Bolt (2 Used) 9- Pin (3 Used) 16 - O-Ring 23 - Pin
3 - Bearing 10 - Rotor 17 - O-Ring 24 - Bearing
4 - Shaft 11 - Collar 18 - Brake Piston 25 - Pin
5 - Swash Plate 12 - Spring 19 - Spring Seat (2 Used) 26 - Cover
6 - Plunger (9 Used) 13 - Washer 20 - Disc Spring (2 Used) 27 - Socket Bolt (5 Used)
7 - Retainer 14 - Retaining Ring 21 - O-Ring 28 - O-Ring (2 Used)
W2-5-8
Disassemble Swing Motor (ZAXIS30, 35)
• Read PRECAUTIONS FOR CAUTION: Always press spring (12) with a

DISASSEMBLING AND ASSEMBLING press when removing retaining ring (14).
(W1-1-1) carefully before disassembling. If retaining ring (14) is removed without
pressing spring (12), washer (13) and spring
IMPORTANT: Be careful not to allow valve plate (12) may fly out, possibly causing serious
(22) to fall when removing cover injury.
(26).
1. Loosen socket bolts (27) (5 used), then remove 8. Remove retaining ring (14) to remove washer
cover (26), valve plate (22) and O-ring (21). (13), spring (12) and collar (11) from rotor (10).
: 10 mm
9. Remove shaft (4) from housing (1) by tapping
2. Remove bearing (24) and O-rings (28) (2 used) shaft (4) with a plastic hammer.
from cover (26).
10. Remove bearing (3) from shaft (4) with a press.
3. Remove disc springs (20) (2 used) and spring

seats (19) (2 used) from housing (1).
4. Remove brake piston (18) from housing (1).
5. Remove O-rings (16, 17) from brake piston (18).
IMPORTANT: Take care not to damage the

sliding surface of swash plate (5).
6. Remove rotor (10), plunger (6) assembly, swash
plate (5) and disc plate (15) from housing (1).

holder (8) and pins (9) (3 used) from rotor (10).
W2-5-9
ASSEMBLE SWING MOTOR (ZAXIS30,
35)
27 19 22 12 26 14 13 24 4 23 20 25
21
28 10
18
11
17
15
16
6
9 1
7 2
5
8
T565-03-02-001
1 - Housing 8- Holder 15 - Disc Plate 22 - Valve Plate

2 - Socket Bolt (2 Used) 9- Pin (3 Used) 16 - O-Ring 23 - Pin
3 - Bearing 10 - Rotor 17 - O-Ring 24 - Bearing
4 - Shaft 11 - Collar 18 - Brake Piston 25 - Pin
5 - Swash Plate 12 - Spring 19 - Spring Seat (2 Used) 26 - Cover
6 - Plunger (9 Used) 13 - Washer 20 - Disc Spring (2 Used) 27 - Socket Bolt (5 Used)
7 - Retainer 14 - Retaining Ring 21 - O-Ring 28 - O-Ring (2 Used)
W2-5-10
Assemble Swing Motor (ZAXIS30, 35)
• Read PRECAUTIONS FOR DISASSEMBLING 6. Install plungers (6) and retainer (7) assembly into
AND ASSEMBLING (W1-1-1) carefully before rotor (10).
assembling.
IMPORTANT: Insert swash plate (5) with its
beveling surface facing downward.
IMPORTANT: Install bearing (3) with its retaining 7. Install swash plate (5) into housing (1).
ring comes to the upper side as
shown in the illustration. 8. Install rotor (10) and plunger (6) assembly into
1. Press bearing (3) onto shaft (4). housing (1).
Retaining Ring
W565-02-05-003
IMPORTANT: Stop pressing bearing (3) onto shaft

(4) when the retaining ring of
bearing (3) touches housing (1). If
the bearing is pressed further, the
retaining ring may deform.
2. Press assembly of shaft (4) and bearing (3) into
housing (1).
IMPORTANT: Insert collar (11) with its beveling

surface facing downward.
3. Install collar (11), spring (12) and washer (13) into
rotor (10).
4. While depressing washer (13) and spring (12)

with a press, install retaining ring (14).
5. Apply grease to pins (9) (3 used), then install pins

(9) into rotor (10). Install holder (8) on pins (9).
W2-5-11
27 19 22 26 24 20
21
28
18
17
16
T565-03-02-001
W2-5-12
9. Install O-rings (16) and (17) onto brake piston
(18), then install them into housing (1).
IMPORTANT: Install spring seat (19) and disc

spring (20) in the direction shown in
the illustration.
10. Install spring seats (19) (2 used) and disc springs
(20) (2 used) into housing (1).
19
20
19
W565-02-05-004
11. Install O-ring (21) into housing (1).
12. Press bearing (24) onto cover (26).
13. Install O-rings (28) (2 used) and valve plate (22)

onto cover (26).
NOTE: Apply grease to valve plate (22) before
attaching it to cover (26) in order to prevent
if from falling.
14. Install cover (26) onto housing (1), then tighten

: 10 mm
: 128 N⋅m(13.1 kgf⋅m, 94 Ibf⋅ft)
W2-5-13
DISASSEMBLE SWING REDUCTION
GEAR (ZAXIS40, 50)
20
21
1 Swing Motor
22
23 2
4
29
24 5
25 6
7
26
8
9
27
10
11
28 12
13
14
15
19
16
17
18
W571-02-05-005
1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-14
Disassemble Swing Reduction Gear (ZAXIS40, 9. Remove shaft (28) from housing (23) with a
50) press.
• Read PRECAUTIONS FOR DISASSEMBLING 10. Remove the inner race of roller bearing (24),
AND ASSEMBLING (W1-1-1) carefully before spring plate (25), thrust plate (26) and plate (27)
disassembling. from shaft (28) with a press.
1. Remove socket bolts (1) (4 used) from the swing IMPORTANT: Do not remove the outer races of
motor, then remove the swing motor. roller bearings (21) and (24) from
: 6 mm housing (23). Failure to follow these
instructions will shorten service life
2. Remove socket bolts (17) (9 used) from ring gear of the bearings as press-fit force of
(18). roller bearing (21 and 24) outer
: 8 mm races is reduced. Always replace
housing (23) with a new one if the
3. Remove ring gear (18), first stage carrier (8) bearings are removed.
assembly, second stage sun gear (10) and 11. Remove oil seal (22) from housing (23).
second stage carrier (13) assembly from housing
(23).
Remove retaining ring (9) from second stage sun
gear (10).
4. Remove retaining rings (3) (3 used), plate (4),

first stage sun gear (5), first stage planetary gears
(6) (3 used) and needle bearings (7) (3 used)
from first stage carrier (8) assembly.
5. Drive spring pins (19) (4 used) at second stage

carrier (13) assembly into pin (12) with a round
bar (length: 100 mm or more, diameter: 5 mm).
6. Remove pins (12) (4 used), second stage

planetary gears (14) (4 used), needle bearings
(15) (4 used), thrust plates (16) (4 used) and
plate (11) from second stage carrier (13)
assembly.
7. Securely hold shaft (28). Remove nut (20) from

shaft (28) using a special tool (ST 7313).
(ST 7313)
W1LD-02-05-001
8. Remove plug (29) from housing (23).

: 5 mm
W2-5-15
ASSEMBLE SWING REDUCTION GEAR
(ZAXIS40, 50)
30
2
3
17
6
4
7
5
8
18
15
9
14
10
12 11
16 13
19 20
23 21
22 29
25 24
26
27
28
W571-02-05-004
1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal 30 - Swing Motor
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-16
Assemble Swing Reduction Gear (ZAXIS40, 50)

assembling.
IMPORTANT: Install oil seal (22) with the lip of the

oil seal facing upward (motor side).
1. Install oil seal (22) into housing (23).
2. If roller bearings (21 and 24) are replaced with

new ones together with housing (23), press the
outer race of roller bearings (21) and (24) into
housing (23).
3. Press plate (27), thrust plate (26), spring plate

(25) and the inner race of roller bearing (24) onto
shaft (28).
IMPORTANT: Be careful not to damage oil seal

(22) by shaft (28) during installation.
Also, make sure that plug (29) has
been removed. If plug (29) is not
removed, distortion of oil seal (22)
may result.
4. Install shaft (28) assembly into housing (23).
IMPORTANT: Install nut (20) with the grooved face

upward (motor side).
5. Install the inner race of roller bearing (21) into
shaft (28), and temporarily tighten nut (20).
6. Install plug (29).

: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
W2-5-17
3
17
6
4
7
5
8
18
15
14 10
12
11
16
13
20
23
28
W571-02-05-004
W2-5-18
7. Adjust the roller bearing pre-load. 7-5. Tighten nut (20) onto shaft (28) using a special
tool (ST 7313).
: 152 N⋅m (15.5 kgf⋅m, 112 lbf⋅ft)
Starting Torque
(ST7313)
W1LD-02-05-001
17
7-6. After turning housing (23) in both directions
several times, measure rotation starting torque
(B) of housing (23) at socket bolt (17).
23 20 7-7. Confirm that the measured torque value is

within standards.
(If not, repeat procedure from 7-1).
＊ Torpue difference Standard value

B-A +1.0 to +3.3 kgf
IMPORTANT: Install retaining ring (3) with the

chamfered corner facing toward
plate (4).
8. Install needle bearings (7) (3 used), first stage
planetary gears (6) (3 used), first stage sun gear
28 (5), plate (4) and retaining ring (3) onto first stage
W571-02-05-008 carrier (8).
7-1. Securely hold shaft (28), then loosen nut (20). 9. Install thrust plates (11), (16) (4 used), needle
bearings (15) (4 used), second stage planetary
7-2. Tap the outer diameter of housing (23) (shown gears (14) (4 used) and pins (12) (4 used) onto
with * to the illustration) 3 to 4 turns with a second stage carrier (13).
plastic hammer.
7-3. Install one socket bolt (17) into housing (23).
7-4. After turning housing (23) to both directions

several times, measure rotation starting torque
(A) of housing (23) at socket bolt (17).
W2-5-19
30
2
17
8
18
12 10
13
19 20
23
28
W571-02-05-004
W2-5-20
IMPORTANT: Drive in spring pins (19) (4 used) IMPORTANT: Install retaining ring (9) with its
with its slit facing upward (motor chamfered corner facing upwards.
side). 12. Install retaining ring (9) onto second stage sun
10. Align pin holes on second stage carrier (13) and gear (10). Install second stage sun gear (10) into
pins (12) (4 used), then drive spring pins (19) (4 second stage carrier (13).
used) into the carrier.
13. Install first stage carrier (8) assembly into second
stage carrier (13) assembly.
14. Apply THREEBOND #1215 to the counter bore on

the housing (23). Install ring gear (18) into
12 housing (23), and tighten it with socket bolts (17)
(9 used).
: 8 mm
19 : 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
W571-02-05-007
IMPORTANT: Install second stage carrier (13) 15. Add approx. 0.7 litter (0.185 US gal) of hydraulic
aligning splines so that the pin on oil into the swing reduction gear.
second stage carrier (13) is inserted
into the hole of nut (20). Confirm 16. Install O-ring (2) onto swing motor (30). Install the
dimension A shown in the swing motor onto ring gear (18). Tighten socket
illustration is approx. 18.5 mm. If bolts (1) (4 used).
dimension A is approx. 27.5 mm, it : 6 mm
indicates that pin is not inserted into : 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
the hole on nut (20) properly.
13
Pin
Ａ
20
W571-02-05-006
11. Install second stage carrier (13) assembly onto

shaft (28) aligning the holes on nut (20) with the
pin.
W2-5-21
DISASSEMBLE SWING MOTOR (ZAXIS40,
50) 8
6
5
4
13
14
15
16
17
18
19
20
21
22
11
10
9
30
29
28
27
26
25
24
23
W1LD-02-05-005
1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover
2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring
W2-5-22
Disassemble Swing Motor (ZAXIS40, 50)
CAUTION: Always use a special tool on
washer (20) to press spring (19) when
removing retaining ring (21). If retaining ring
(21) is removed without pressing, washer
disassembling.
(20) and spring (19) may fly out, possibly
causing serious injury.
IMPORTANT: Be careful not to allow valve plate
(27) to fall when removing cover
7. Press washer (20) and spring (19) using a special
(24).
tool (ST 7314). Remove retaining ring (21) to
1. Put matching marks on cover (24) and case (7).
remove washer (20), spring (19) and collar (18)
Loosen socket bolts (23) (3 used). Remove cover
from rotor (17).
(24) and valve plate (27) in this order.
: 12 mm
2. Remove springs (28) (22 used) and O-ring (6) (ST7314)

from case (7).
CAUTION: When removing brake piston (29) 21

using compressed air, be sure to cover the
brake piston with rags to prevent the piston
from flying out. 20
19
3. Remove brake piston (29) and O-ring (30) from
18
case (7) by applying compressed air into the pilot
port on case (7).
4. Remove collar (9), and O-rings (10),(11).

W1LD-02-05-004
5. Remove rotor (17) assemblies (13 to 21), swash 8. Remove shaft (4) from case (7) by tapping shaft
plate (3), friction plates (1) (2 used) and disc (4) with a plastic hammer.
plates (2) (2 used) .
9. Remove O-ring (8) from case (7).
NOTE: Take care not to damage the sliding
surface of swash plate (3).

holder (15) and pins (16) (3 used) from rotor
assemblies (13 to 21).
W2-5-23
ASSEMBLE SWING MOTOR (ZAXIS40, 50)
22 23 28 27 21 20 26 24
25
30
29
17
10
11
19 9
18
1
16
2
7
13
8
15 5 4 3 14
W555-02-05-003
1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover

2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring
W2-5-24
Assemble Swing Motor (ZAXIS40, 50)
8. Install friction plates (1) (2 used) and disc plates
• Read PRECAUTIONS FOR DISASSEMBLING (2) (2 used) to rotor (17) one by one alternately in
AND ASSEMBLING (W1-1-1) carefully before place.
assembling.
IMPORTANT: Do not tap collar (9) with a plastic
IMPORTANT: If ball bearing (5) has been removed, hammer or similar instrument to
press bearing (5) onto shaft (4) install collar (9). Collar (9) and / or
beforehand. case (7) may be damaged. Use a
Press ball bearing (5) until the end press to install collar (9) into case
of ball bearing (5) is flush with the (7).
end surface of case (7). 9. Install O-rings (10) and (11) onto collar (9), and
1. Press shaft (4) and ball bearing (5) assembly into press them into case (7).
case (7).
2. Install collar (18), spring (19) and washer (20) into

rotor (17).
3. While depressing washer (20) and spring (19)

using a special tool (ST 7314), install retaining
ring (21) into rotor (17).
(ST7314)
21
20
19
17
W1LD-02-05-004
4. Install pins (16) (3 used) into rotor (17). Put holder

(15) onto pins (16).
5. Install plungers (13) (9 used) and retainer (14)

into rotor (17).
6. Install swash plate (3) into case (7).
7. Install rotor (17) assemblies (13 to 21) into case

(7).
W2-5-25
23 28 27 24
30
29
W555-02-05-003
W2-5-26
IMPORTANT: Do not tap brake piston (29) with a
plastic hammer or similar
instrument to install brake piston 29
(29). Brake piston (29) and / or case
(7) may be damaged. Use a press to
install brake piston (29) into case (7)
as the illustration.
10. Install O-ring (30) onto brake piston (29). Press
brake piston (29) into case (7).
11. Install springs (28) (22 used) and O-ring (6) into
case (7).
12. Attach valve plate (27) to cover (24). Install cover

(24) on case (7) while aligning the matching
M6 Threaded Hole
marks on cover (24) and case (7). Tighten socket
bolts (23) (3 used).
W527-02-05-003
: 12 mm
: 177±10 N⋅m (18±1 kgf⋅m, 131±7.4 lbf⋅ft)
NOTE: Apply grease to valve plate (27) before

attaching it to cover (24) in order to prevent
it from falling.
W2-5-27
MAINTENANCE STANDARDS (ZAXIS30,
35)
1. The clearance between the plunger diameter and

the rotor bore diameter Rotor
(D-d): 0.04 mm (0.00157 in) or less
D d
W507-02-04-009
2. The clearance between the plunger and the shoe

δ: 0.4 mm (0.0157 in) or less
W107-02-06-140
W107-02-06-141
W2-5-28
50)
1. The clearance between the plunger diameter and
the rotor bore diameter Rotor
(D-d): 0.40 mm or less.
D d
W507-02-04-009
2. The clearance between the plunger and the shoe

δ: 0.4 mm or less.
W107-02-06-140
3. The wear amount of the oil seal mounting

surfaces no damage and / or wear is allowed. D0 D1
(D0 - D1): 0.25 mm or less.

W509-02-04-010
W2-5-29
(Blank)
W2-5-30
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE
Removal and Install Front/Swing Pilot Valve
10
any work. (Refer to W1-3-1) 9 11
8
Removal
• The removal procedure in the left console is
12
shown.
7
1. Raise boot (12) to remove screws (7) (4 used) and
plates (6) (2 used). 6
13
2. Raise boot (12) to remove clip band (15) and plug
(11). 5
NOTE: Clip band (15) and plug (11) are not used in 1
the left console. 4
14
3. Raise boot (12) and loosen lock nut (8) to remove
lever (9) with grip (10) together.
15
4. Remove boot (12). 3
5. Remove screws (1) (4 used) to remove covers (2

and 13) from stand (14).
2
IMPORTANT: Attach the identification tag onto the
disconnected hoses for
re-assembling. 1
1
6. Disconnect all hoses from pilot valve (3).
IMPORTANT: Put the matching marks on pilot

W1LN-02-06-004
valve (3) and stand (14) to aid in
re-assembly.
7. Remove bolts (5) (left console: 3 used, right NOTE: The figure above shows left console.
console: 4 used) and (4) to remove pilot valve (3)
from stand (14).
NOTE: Bolt (4) is not used in the left console.
W2-6-1
Installation
• The installation procedure in the left console is
shown.
10
1. Insert pilot valve (3) into stand (14) and align the
matching marks made when disassembling.
9 11
2. Install pilot valve (3) to stand (14) with bolts (5)
8
(left console: 3 used, right console: 4 used) and
(4).
12
NOTE: Bolt (4) is not used in the left console.
7
3. Connect all hoses to pilot valve (3).
6
4. Install covers (2 and 13) onto stand (14) with 13
screws (1) (4 used).
5
5. Insert lever (9) (with grip (10)) into boot (12). 1
Install lever (9) into pilot valve (3). When installing, 4
lever (9) with horn button should be installed on
14
the left side.
6. Secure lever (9) to pilot valve (3) with lock nuts 15

(8). 3
7. Raise boot (12) to install clip band (15) and plug

(11).
2
NOTE: Clip band (15) and plug (11) are not used in
the left console.
8. Install boot (12) with plates (6) (2 used) and 1 1

screws (7) (4 used).
IMPORTANT: After the complete work, check the W1LN-02-06-004

hydraulic oil level. Start the engine
and check the connection for oil
leaks. NOTE: The figure above shows left console.
W2-6-2
Removal and Install Travel Pilot Valve

the hydraulic oil tank before any
work. (Refer to W1-3-1.)
Removal
1. Remove bolts (4) (5 used). Lift up floor plate (2) a

little to remove the connector of pedal (3).
2. Remove floor plate (2) from main frame (1).

2
1
W1LN-02-04-007
4 3
3. Remove bolts (7) (4 used) to remove the travel 6

lever (6) assembly (2 used) from pilot valve (5).
IMPORTANT: Attach the identification tag onto the

disconnected hoses for 7 8 1
re-assembling.
4. Disconnect all hoses from pilot valve (5). Cap all
disconnected hose openings.
5. Remove bolts (8) (4 used) to remove pilot valve

(5) from main frame (1).
W1LN-02-06-003
W2-6-3
Installation
1. Install pilot valve (5) to main frame (1) with bolts 6

(8) (4 used).
2. Connect all hoses onto pilot valve (5). 7 8 1
3. Install the travel lever (6) assembly (2 used) to

pilot valve (5) with bolts (7) (4 used).
W1LN-02-06-003
4. Connect the connector to pedal (3) under floor

plate (2).
5. Install floor plate (2) onto main frame (1) with bolts
(4) (5 used).
IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil
level. Start the engine and check the 2
connections for oil leaks.
1
W1LN-02-04-007
4 3
W2-6-4
(Blank)
W2-6-5
DISASSEMBLE TRAVEL PILOT VALVE
18 19
20
19
21
7 8 17 20 22
9 21
10 22 23
11 18
16
5 23
17
6 15
7 24
14 24
16 25
5 35
15
4 12 25
14
3 34
4 13
2 3
2 33
1 32
1
26
27
28
29
30
31
W585-02-06-006
1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (Several) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)
W2-6-6
Disassemble Travel Pilot Valve
• Thoroughly read the Precautions for IMPORTANT: As spool (23) has been selected to
Disassembling and Assembling (W1-1-1) prior to match the hole of casing (34), keep
disassembling. them carefully to install them to the
• As casing (34) and spool (23) cannot be original port when reassembling.
disassembled, they cannot be replaced with the 7. Remove spool (23) assemblies (2 used), O-rings
new one by one. (25) (4 used) and (35) (2 used), and springs (24)
• Put identification tags on the disassembled parts (4 used) from casing (34).
by port to aid when re-assembling.
IMPORTANT: As the spool (23) assemblies (4
IMPORTANT: Put the mating marks onto cam (10), used) are adjusted by the pressure
pin (11), cover (12), and casings (13, of shim (21), they had better not be
34) before disassembling. disassembled. If disassembling the
1. Clamp the pilot valve in a vise to remove boot (8) spool (23) assemblies, record the
from cover (12). number and thickness of shim (21).
8. Remove spring guides (19) (4 used), springs (20)
2. Remove set screw (9) from cam (10). Pull pin (11) (4 used), shims (21) (4 used), and washers (22)
out to remove cam (10) from cover (12). (4 used) from spool (23) assemblies (4 used).
: 2 mm
NOTE: LOCTITE is applied onto the set screw.

Steel ball (6) cannot be removed from cam
(10).
3. Loosen and remove socket bolts (7) (2 used)

alternately. Remove covers (12) (2 used) and
casing (13) assembly from casing (34).
: 6 mm
IMPORTANT: Put identification tags on the

disassembled parts by port.
4. Remove grease cups (4) (4 used), push rods (18)
(4 used), and bushing (2) assemblies (4 used)
from casing (13) assembly.
5. Remove pistons (17) (4 used), springs (16) (4

used), spring seats (15) (4 used), and steel balls
(14) (12 used) from casing (13).
6. Remove packings (3) (4 used) and O-rings (1) (4

used) from bushing (2) assemblies (4 used).
W2-6-7
5
12
34
26
27
28
29
30
31
W585-02-06-006
W2-6-8
9. Remove plugs (31) (2 used) and O-rings (30) (2
used) from casing (34).
: 6 mm
10. Remove seats (29) (2 used), steel balls (28) (2

used), bushings (27) (2 used) and seats (26) (2
used) from casing (34) with a magnet.
IMPORTANT: Be sure not to remove bushing (5)

from cover (12) unless bushing (5) is
damaged.
11. Pull bushings (5) (4 used) out of covers (12) (2
used).
W2-6-9
ASSEMBLE TRAVEL PILOT VALVE
9
8 11 5
6 10
18 4
3
2
7
12
1
17
16
35
15 13
19
14
31
25
30
20
21
24
22
32
33
23 C C
34
27
29 28 W585-02-06-008
26
Cross
Section C-C
W585-02-06-007
1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (Several) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)
W2-6-10
Assemble Travel Pilot Valve
• Thoroughly read the Precautions for 7. Install push rods (18) (4 used) and bushing (2)
disassembling and Assembling (W1-1-1) prior to assemblies (4 used) to casing (13).
assembling.
• Clean the parts and put them by port for 8. Install bushings (5) (4 used) to covers (12) (2
assembling. used).
1. Install seats (26) (2 used), bushings (27) (2 used), 9. Clamp casing (34) in a vise. Tighten casing (13)
steel balls (28) (2 used) and seats (29) (2 used) to assembly and covers (12) (2 used) with socket
casing (34). bolts (7) (4 used).
: 6 mm
2. Install O-rings (30) (2 used) to plugs (31) (2 used). : 24 N⋅m (2.4 kgf⋅m, 17 lbf⋅ft)
Install them to casing (34).
IMPORTANT: Be sure to install shim (21) to the

original condition.
3. Install washers (22) (4 used), shims (21) (several),
springs (20) (4 used), and spring guides (19) (4
used) to spools (23) (4 used) in this order.
IMPORTANT: Be sure to install the spool (23)

assembly into the original hole when
disassembling.
4. Install springs (24) (4 used), spool (23)
assemblies (4 used), and O-rings (25) (4 used)
and (35) (2 used) to casing (34).
5. Install steel balls (14) (12 used), spring seats (15)

(4 used), springs (16) (4 used), and pistons (17)
(4 used) to casing (13).
6. Install O-rings (1) (4 used) and packings (3) (4

used) to bushings (2) (4 used).
W585-02-06-005
Lip part
W2-6-11
9
11
8 10
18 4
12
C C
W585-02-06-008
Cross
Section C-C
W2-6-12
10. Install grease cups (4) (4 used) to push rods (18)
(4 used).
11. Install cams (10) (2 used) to covers (12) (2 used)

with pins (11) (2 used).
12. Apply LOCTITE #241 onto set screws (9) (2 used).

Install set screws (9) (2 used) to cams (10) (2
used) with pins (11) (2 used).
: 2 mm
: 5 N⋅m (0.5 kgf⋅ m)
13. Install boots (8) (2 used) to covers (12) (2 used).
W2-6-13
DISASSEMBLE FRONT/SWING PILOT
VALVE
13
12
14
11
15
11
10
8
8
7
9
21
6 20
16 21
5
20
4 5
19
6
3
3 18
2 4
17
W567-02-06-002
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-6-14
Disassemble Front/Swing Pilot Valve
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminum. Too strong a They must be handled in order of
force can deform, or damage them. port number after removing.
Therefore, be careful while handling 4. Pull push rods A (8) (2 used) and B (9) (2 used)
them. out of block (10).
IMPORTANT: As spool (17) has been selected to 5. With a bamboo spatula, remove oil seals (15) (4
match the hole of housing (18), they used) from block (10).
must be replaced in a set. In addition, NOTE: If a metal bar is used, the mating part of oil
the dimensions of balance springs A seal may be damaged.
(3), B (4) and return springs A (5), B
(6) as well as those of push rods A IMPORTANT: Retaining ring (7) may come off
(8), B (9) are different. For this while disassembling. Take care not
reason, be sure to indicate the port to drop it.
number from which it is removed. 6. Press springs using special tool (ST 7257) from
Port numbers are stamped on the top of spring guide (16). Retaining ring (7) will
housing (18). appear. Remove it with a screwdriver or similar
tool (4 places).
IMPORTANT: Do not clamp housing (18) in a vise
to remove the screw joint (13)
7
because screw joint (13) may be
damaged.
1. Secure screw joint (13) in a vise. Then turn cam

(12) with a spanner to remove screw joint (13).
: 32 mm
16
2. Clamp the flat surface of housing (18) in a vise
slightly. Remove cam (12) from universal joint ST 7257
(14).
: 32 mm
NOTE: Universal joint (14) has been secured on
block (10) with LOCTITE. Do not remove it
unless necessary. W176-02-07-005
3. Remove socket bolts (11) (2 used) to remove

IMPORTANT: The number of shims (2) has been
block (10). At this time, push rods A (8) (2 used)
determined for each port during the
and B (9) (2 used) are in place.
performance testing at the factory.
: 6 mm
Take care not to lose them. Keep
them carefully to install them to each
former port when reassembly.
7. Remove spring guides (16) (4 used), balance
springs A (3) (2 used) and B (4) (2 used), return
springs A (5) (2 used) and B (6) (2 used), shims
(2) (several) and spacers (1) (4 used) from
spools (17) (4 used).
W2-6-15
21
20
21
20
19
18
17
W567-02-06-002
W2-6-16
IMPORTANT: As the spool has been selected to
match the hole of the housing, keep
them carefully to install them to the
original port when reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it.
NOTE: The spool and housing must be replaced
as an assembly.
IMPORTANT: Do not remove dowel pins (20) (2

used) unless necessary.
9. Remove O-rings (19) and (21) (2 used) from
housing (18).
W2-6-17
ASSEMBLE FRONT/SWING PILOT VALVE
13
14
12
15 8, 9
10 11
7
16
3, 4
21 5, 6
19
20 1
17
W567-02-06-001
18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)
W2-6-18
Assemble Front/Swing Pilot Valve
IMPORTANT: The pilot valve is susceptible to IMPORTANT: Install spring guide (16), with the
contamination. Keep parts clean protrusion facing up.
when assembling. 3. Install spring guides (16) (4 used) onto the return
springs A (3) (2 used) or B (4) (4 used).
NOTE: Table below shows the relations between
each port and the components. Take care 4. Install retaining ring (7) onto ring holder (ST
not to confuse them when assembling. 7255).
Port Spool Shim Push rods ST 7255

No. (17) (2) (8), (9) 7
with outer
1
Same to Same to groove
the former the former without outer
2
one one groove W176-02-07-008
with outer
3
groove 5. Insert the spool (17) head into the hole of spring
without outer using special tool (ST 7257) to press the spring
4
groove from the top of spring guide (16). Install retaining
ring (7) with the ring holder (ST 7255) onto the
Port Return Springs Blance Springs head of spool (17).
No. (5), (6) (3), (4) 7
1 short short ST 7257 ST 7255
2 long long
3 short short
17
4 long long 16
IMPORTANT: Make sure of the port hole number

Packing Material
and insert spool (17) to the former
port.
1. Insert the thinner end of spools (17) (4 used) to W176-02-07-009
housing (18), then push the spools rotating it. NOTE: Put approx. dia.8 mm, length 10 mm of
NOTE: Spool (17) has been selected to match the packing material, into the port hole not only
hole of housing (18). Spool (17) and to make the work easy to do, but also to
housing must be replaced as an assembly. prevent the spool from lowering to the
bottom when compressing the spring.
IMPORTANT: Refer to the table above to assemble
them correctly. 6. Assemble the remained spools (17) (3 used) into
2. Install spacers (1) (4 used), shims (2) (several), housing (18) in the same procedures as step 2 to
balance springs A (3) (2 used) or B (4) (2 used), 5.
return springs A (5) (2 used) or B (6) (2 used) onto
spool (17) installed in housing (18). 7. Install O-rings (19) and (21) (2 used) on to
housing (18).
W2-6-19
13
14
12
10
11 15 8、9
20
W567-02-06-001
18
W2-6-20
8. Apply the grease to the inner face of oil seals (15) IMPORTANT: Make sure of the tighteness of cam.
(4 used), then install oil seals (15) (4 used) into 13. Clamp housing (18) carefully in a vise and then
block (10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, inserting push rods A (8) Tighten the universal joint so that the clearance
and B (9) first, then installing oil seal (15). between cam (12) and push rods A (8) (2 used)
This prevents oil seal (15) from entering and B (9) (2 used) become 0 to 0.2 mm.
into the hole. : 32 mm
IMPORTANT: Do not clamp housing (18) in a vise

Oil Seal Mounting Hole
because screw joint (13) may be
damaged.
10 14. Clamp screw joint (13) in a vise to tighten
8, 9 universal joint (14). Tighten cam (12) with a
spanner.
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W176-02-07-007
IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods A (8) (2 used) and B (9) (2 used)
to block (10). When installing the push rods,
install the push rods with groove to ports # 1 and
# 3, the ones without groove to ports # 2 and # 4,
respectively.
10. Apply grease to the ball at the ends of push rods

A (8) (2 used) and B (9) (2 used).
11. Apply grease to the joint part of universal joint

(14).
12. Align the position of dowel pins (20) (2 used),

install the block (10) assembly to housing (18)
with socket bolts (11) (2 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W2-6-21
(Blank)
W2-6-22
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
the hydraulic oil tank before any
work. (Refer to W1-3-1.)
Removal
1. Disconnect all hoses from solenoid valve (2). Cap

all open ends.
2. Remove bolts (1) (2 used) to remove solenoid

valve (2) from bracket (3).
3
Installation
2
1. Install solenoid valve (2) to bracket (3) with bolts
1
(1) (2 used).
2. Connect all hoses to solenoid valve (2).

W1LS-02-07-001
3. Connect all electrical cables to solenoid valve (2).
IMPORTANT: After connecting the hoses and con-

nectors, check the hydraulic oil level.
Start the engine and check the con-
nections for oil leaks.
W2-7-1
(Blank)
W2-7-2
DISASSEMBLE AND ASSEMBLE SOLE-
NOID VALVE
1 3 2
W574-02-07-001
1 - ON-OFF Solenoid Valve 2 - ON-OFF Solenoid Valve 3 - Relief Valve 4 - Housing

(Pilot Control (Travel Speed Selector)
Shut-off Lever)
W2-7-3
7
1
8
3
6
9
W574-02-07-002
1 - Guide 5 - Washer 8 - Solenoid 11 - Spool

2 - O-Ring 6 - Spool 9 - Tube 12 - Spring
3 - Washer 7 - Nut 10 - O-Ring 13 - Housing
4 - Spring
W2-7-4
Disassemble Solenoid Valve Assemble Solenoid Valve

1. Loosen nuts(7) (2 used), hen remove solenoids 1. Install spool (6), washer (5), spring (4) and
(8) (2 used). washer (3) into housing (13).
: 19 mm
2. Install O-ring (2) into guide (1).
2. Remove tubes (9) (2 used), spools (11) (2 used) 3. Install guide (1) into housing (13).
and springs (12) (2 used) from housing (13). : 24 mm
: 21 mm : 74 to 88 N⋅m
(7.5 to 9.0 kgf⋅m, 54 to 65 lbf⋅ft)
3. Remove O-ring (10) from tube (9).
4. Install spring (12) and spool (11) into housing
4. Remove guide (1) from housing (13). (13).
: 24 mm
5. Install O-ring (10) into tube (9).
5. Remove washer (3), spring (4), washer (5) and 6. Install tube (9) into housing (13).
spool (6) from housing (13). : 21 mm
: 47 to 74 N⋅m
6. Remove O-ring (2) from guide (1). (4.8 to 7.6 kgf⋅m, 35 to 55 lbf⋅ft)
7. Install solenoid (8) onto tube (9) with nut (7).

: 19 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)
W2-7-5
(Blank)
W2-7-6
SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Upper Roller ............ W3-6-1
Remove and Install Lower Roller ............ W3-6-4
Group 2 Travel Device Disassemble and Assemble
Remove and Install Travel Device .......... W3-2-1 Lower Roller ......................................... W3-6-6
Remove and Install Sprocket .................. W3-2-3 Maintenance Standards .......................... W3-6-8
Disassemble Travel Reduction
Gear (ZAXIS30, 35) .............................. W3-2-4 Group 7 Track
Assemble Travel Reduction Remove and Install Rubber Crawler ....... W3-7-1
Gear (ZAXIS30, 35) .............................. W3-2-8 Maintenance Standards .......................... W3-7-3
Brake Valve (ZAXIS30, 35) ................. W3-2-14
Disassemble Travel
Device (ZAXIS40, 50) ......................... W3-2-16
Assemble Travel
Device (ZAXIS40, 50) ......................... W3-2-20
Maintenance Standards (ZAXIS30, 35) . W3-2-28
Group 3 Center Joint

Remove and Install Center Joint............. W3-3-1
Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6
Group 4 Track Adjuster

Remove and Install Track Adjuster ......... W3-4-1
Disassemble Track Adjuster ................... W3-4-2
Assemble Track Adjuster ........................ W3-4-8
Group 5 Front Idler

Remove and Install Front Idler................ W3-5-1
Disassemble and Assemble Front Idler... W3-5-2
Maintenance Standards (ZAXIS30, 35) ... W3-5-4
Maintenance Standards (ZAXIS40, 50) ... W3-5-5
1LSW-3-1
(Blank)
1LSW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
The procedure below starts on the premise that the
upperstructure has been removed.
Matching Mark
Removal
1. Attach matching mark on inner race (1) of the

swing bearing and track frame (2).
1 2 W105-03-01-001
2. Remove bolts (3) (20 used). 3

: 19 mm
W507-02-03-002
CAUTION: Swing bearing weight:

41 kg (90 lb) (ZAXIS30, 35)
52.5 kg (115 lb) (ZAXIS40, 50)
3. Attach a sling (ST 0050) to the swing bearing and

hoist it by crane.
ST 0050
W507-03-01-001
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Front Side
Thoroughly clean the mounting surfaces of the track ZAXIS30, 35
[S] (Soft Zone)
frame and swing bearing. Marking Portion
1. Apply THREEBOND #1102 on the swing bearing

mounting surface of the track frame. 18°
CAUTION: Swing bearing weight:

41 kg (90 lb) (ZAXIS30, 35)
52.5 kg (115 lb) (ZAXIS40, 50)
1
IMPORTANT: Be careful that if the matching mark
fails to be aligned, the position of W1LS-03-01-001
the softzone of inner race (1) will

misplace. ZAXIS40, 50 Front Side
[S] (Soft Zone)

2. Hoist the swing bearing to align the matching Marking Portion
mark on inner race (1) with that on the track
frame.
3°
W1LS-03-01-002
3
3. Tighten bolts (3) (20 used).
: 19 mm
: 110 N⋅m (11 kgf⋅m, 81 Ibf⋅ft)
W507-02-03-002
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
14
1
any work. (Refer to W1-3-1) 2
Removal

from track frame (14).
W1LN-03-02-001
Front Side
2. Disconnect all hoses from travel device (5). Cap
all open ends.
3. Attach a nylon sling onto travel device (5).
CAUTION: Travel device (5) weight:

44 kg (100 lb) (ZAXIS30, 35)
66 kg (145 lb) (ZAXIS40, 50)
4. Hoist and hold travel device (5). Remove bolts (4)

[22 used (ZAXIS30, 35), 26 used (ZAXIS40, 50)]
and spring washers (3) [22 used (ZAXIS30, 35),
26 used (ZAXIS40, 50)] to lift travel device (5) off 3
track frame (14). 4
5
W577-03-02-014
W3-2-1
Installation
Front Side
CAUTION: Travel device (5) weight:

44 kg (100 lb) (ZAXIS30, 35)
66 kg (145 lb) (ZAXIS40, 50)
1. Attach a nylon sling onto travel device (5).
IMPORTANT: Apply LOCTITE #262 on bolt (4).
2. Hoist and hold travel device (5). Place spring

washers (3) [22 used (ZAXIS30, 35), 26 used
(ZAXIS40, 50)] into bolts (4) [22 used (ZAXIS30,
35), 26 used (ZAXIS40, 50)]. Install travel device 3
(5) onto track frame (14) with bolts (4). 4
5
3. Connect all hoses to travel device (5).
W577-03-02-014
4. Install cover (2) onto track frame (14) with bolts (1)
(3 used). 14
1
IMPORTANT: Be sure to check the hydraulic oil
level after assembling. Start the
2
engine to check each part for any oil
leakage.
Also, running-in should be carried
out as below after assembling to
prevent the travel motor from
burning out.
Condition: 1. Engine running speed: Min running

speed W1LN-03-02-001
2. High speed travel pedal: Low speed

3. Operation time: Above 2 min
W3-2-2
REMOVE AND INSTALL SPROCKET
Removal
CAUTION: Travel device (5) weight: 1

44 kg (100 lb) (ZAXIS30, 35)
66 kg (145 lb) (ZAXIS40, 50)
1. Attach a nylon sling to travel device (1) to lift it by

crane. Place travel device (1) with the travel motor
side downward.
2. Remove bolts (2) [11 used (ZAXIS30, 35), 12

used (ZAXIS40, 50)] and spring washers (3) [11
used (ZAXIS30, 35), 12 used (ZAXIS40, 50)] to
remove sprocket (4) from travel device (1).
: 19 mm W507-03-02-004
Installation 1
CAUTION: Travel device (5) weight: 4

44 kg (100 lb) (ZAXIS30, 35) 2, 3
66 kg (145 lb) (ZAXIS40, 50)
1. Attach a nylon sling to travel device (1) to lift it by

crane. Place travel device (1) with the travel motor
side downward.
IMPORTANT: Apply LOCTITE #262 onto bolt (2).
2. Install sprocket (4) to travel device (1) with bolts

(2) [11 used (ZAXIS30, 35), 12 used (ZAXIS40,
50)] and spring washers (3) [11 used (ZAXIS30,
W1LH-03-02-001
35), 12 used (ZAXIS40, 50)].
: 19 mm
: 127 N⋅m (13 kgf⋅m, 94 lbf⋅ft)
W3-2-3
DISASSEMBLE TRAVEL REDUCTION
GEAR (ZAXIS30, 35) 15
16
14
7 13
6 12
5
10 11
1
2 8
3 9
4
27
30
26 17
29 18 37
36
19
28
25
31 35
32 24 23
33
34 22 21
20
56
55
39 38 54
40 53
41 52
51
42 50 57
43 49 58
44 48
45
46
59
47 60
61
62
72
63 71
70
69
68
67
66
65
64
W1LA-03-02-010
1 - Plug (2 Used) 19 - Spool 37 - Plug 55 - Thrust Plate
2 - O-Ring (2 Used) 20 - Plug 38 - Spring (2 Used) 56 - Screw (4 Used)
3 - Spring (2 Used) 21 - O-Ring (2 Used) 39 - Control Piston (2 Used) 57 - Plug (3 Used)
4 - Spring Seat (2 Used) 22 - Spring 40 - O-Ring 58 - O-Ring (3 Used)
5 - Plug (2 Used) 23 - Spool 41 - Oil Seal 59 - First Stage Planetary
Gear (3 Used)
6- Plug 24 - Plug (2 Used) 42 - Ball Bearing 60 - Needle Bearing (3 Used)
7- Plug (2 Used) 25 - O-Ring (2 Used) 43 - Shaft 61 - Inner Race (3 Used)
8- Pin (2 Used) 26 - Adapter 44 - Swash Plate 62 - Plug (2 Used)
9- Bearing 27 - Socket Bolt (6 Used) 45 - Plunger (9 Used) 63 - Steel Ball (132 Used)
10 - Valve Plate 28 - O-Ring (3 Used) 46 - Retainer 64 - Ring Gear
11 - Retaining Ring 29 - Body 47 - Holder 65 - Sun Gear
12 - Washer 30 - Socket Bolt (3 Used) 48 - Floating Seal 66 - Retaining
13 - Spring 31 - Check Valve 49 - Bearing 67 - Ring
14 - Spring Seat 32 - Spring 50 - Bearing Nut 68 - First Stage Carrier
15 - Rotor 33 - O-Ring 51 - Thrust Washer (4 Used) 69 - Dive Gear
16 - Pin (3 Used) 34 - Plug 52 - Inner Race (4 Used) 70 - Wire
17 - O-Ring (3 Used) 35 - Steel Ball (2 Used) 53 - Needle Bearing (4 Used) 71 - O-Ring
18 - Valve Body 36 - Body 54 - Second Stage Planetary 72 - Cover
Gear (4 Used)
W3-2-4
Disassemble Travel Reduction Gear (ZAXIS30,
CAUTION: Always hold washer (12) and
35)
spring (13) with a press when removing re-
taining ring (11). If retaining ring (11) is re-
moved without holding washer (12) and
spring (13), washer (12) and spring (13) may
disassembling.
fly out potentially causing serious injury.
IMPORTANT: When removing socket bolts (27) (6
used), valve body (18) is floated by
6. Remove retaining ring (11) from rotor (15), then
the reacting force of spring (13). At
remove washer (12), spring (13) and spring seat
this time record the clearance be-
(14).
tween valve body (18) and body (36)
or between the valve body (18)
7. Install eyebolts (M10, pitch: 1.5) into socket bolt
flange part and body (36) end for
(27) mounting hole on body (36), then hoist body
assembling.
(36) by crane to turn it over on a wooden block
(50 mm × 40 mm).
IMPORTANT: Valve plate (10) may stick to valve
body (18). Take care not to drop
valve plate (10) when removing
8. Remove plugs (57) (3 used) from cover (72), and
valve body (18).
plugs (62) (2 used) from ring gear (64).
: 5 mm [Plug (62)]
CAUTION: Travel device weight: 6 mm [Plug (57)]
35 kg (75 lb)
1. Removes socket bolts (27) (6 used) to remove 9. Install eyebolts (PF1/4) (2 used) into the plug (57)
valve body (18) and valve plate (10). mounting holes on cover (72), then insert an steel
: 8 mm pipe into the holes on the eyebolts.
2. Remove pins (8) (2 used) and O-rings (17) (3 10. While turning cover (72) with a steel pipe, remove
used) from valve body (18). wire (70) from the plug (62) mounting hole of ring
gear (64).
3. Remove O-ring (40) from body (36). NOTE: Turn cover (72) until wire (70) is seen from
the plug (62) mounting hole. After that pull
wire (70) out of the hole.
4. Remove the rotor (15) assembly, swash plate
(44), steel balls (35) (2 used), control pistons (39)
(2 used) and springs (38) (2 used) from body
(36).

holder (47) and pins (16) (3 used) from rotor (15).
W3-2-5
37
36
56
55
54
53
41 52
51
42 50
43 49
48
59
60
61
62
72
63 71
69
68
67
65
64
W1LA-03-02-010
Sprocket
Mounting Hole
W3-2-6
11. Move an eyebolt on cover (72). Hoist to remove IMPORTANT: Attach a bar to the shaft (43) assem-
cover (72) from ring gear (64) by crane. bly. While tapping the end of the bar
with a plastic hammer, remove it. Do
not remove ball bearing (42) unless
12. Remove O-ring (71) from cover (72). replacement is required.
18. Remove the shaft (43) assembly from body (36).

13. Remove thrust plate (69), drive gear (68), the first
stage carrier (67) assembly and sun gear (65)
from ring gear (64).
19. Remove plug (37) from bearing nut (50).
: 6 mm
14. Remove first stage planetary gears (59) (3 used),
needle bearings (60) (3 used) and inner races
(61) (3 used) from first stage carrier (67). 20. Clamp body (36) in a vise, then remove bearing
nut (50).
15. Remove screws (56) (4 used), thrust plate (55),

second stage planetary gears (54) (4 used), nee- IMPORTANT: Attach a bar to bearing (49). While
dle bearings (53) (4 used), inner races (52) (4 tapping the end of the bar with a
used) and thrust washers (51) (4 used) from body hammer, remove it. Replace bearing
(36). (49) with a new one if disassembled.
21. Remove bearing (49) from body (36).

16. Remove steel balls (63) (132 used) from the plug
(62) mounting hole.
22. Remove floating seal (48) from body (36).
17. Install bolts (M12, pitch: 1.75) (2 or 3 used).

NOTE: Refer to W1-1-4 for precautions for han-
Tighten them to remove body (36) from ring gear
dling the floating seal.
(64).
: 19 mm
23. Remove oil seal (41) from body (36).
64
Plate
Wooden 36
Block Wooden Block
W1LA-03-02-011
W3-2-7
ASSEMBLE TRAVEL REDUCTION GEAR
(ZAXIS30, 35)
70 65 66 67 53 52 51 50 38 63 49 39 48 46 36 47 16 15 8 9
69
68
58
57
72
61
11
60 10
71 27
40
62
59
W1LA-03-02-012
56 55 54 41 37 42 64 62 43 44 45 14 13 12 18
1 - Plug (2 Used) 19 - Spool 37 - Plug 55 - Thrust Plate

2 - O-Ring (2 Used) 20 - Plug 38 - Spring (2 Used) 56 - Screw (4 Used)
3 - Spring (2 Used) 21 - O-Ring (2 Used) 39 - Control Piston (2 Used) 57 - Plug (3 Used)
4 - Spring Seat (2 Used) 22 - Spring 40 - O-Ring 58 - O-Ring (3 Used)
5 - *Plug (2 Used) 23 - Spool 41 - Oil Seal 59 - First Stage Planetary
Gear (3 Used)
6- *Plug 24 - *Plug (2 Used) 42 - Ball Bearing 60 - Needle Bearing (3 Used)
7- *Plug (2 Used) 25 - *O-Ring (2 Used) 43 - Shaft 61 - Inner Race (3 Used)
8- Pin (2 Used) 26 - Adapter 44 - Swash Plate 62 - Plug (2 Used)
9- Bearing 27 - Socket Bolt (6 Used) 45 - Plunger (9 Used) 63 - Steel Ball (132 Used)
10 - Valve Plate 28 - *O-Ring (3 Used) 46 - Retainer 64 - Ring Gear
11 - Retaining Ring 29 - Body 47 - Holder 65 - Sun Gear
12 - Washer 30 - Socket Bolt (3 Used) 48 - Floating Seal 66 - Retaining
13 - Spring 31 - Check Valve 49 - Bearing 67 - Ring
14 - Spring Seat 32 - Spring 50 - Bearing Nut 68 - First Stage Carrier
15 - Rotor 33 - O-Ring 51 - Thrust Washer (4 Used) 69 - Dive Gear
16 - Pin (3 Used) 34 - Plug 52 - Inner Race (4 Used) 70 - Wire
17 - *O-Ring (3 Used) 35 - *Steel Ball (2 Used) 53 - Needle Bearing (4 Used) 71 - O-Ring
18 - Valve Body 36 - Body 54 - Second Stage Planetary 72 - Cover
Gear (4 Used)
NOTE: As for the items with a mark “*”, refer to
W3-2-4.
W3-2-8
19 4 3
1
20
26
23 22 21 W1LA-03-02-002
30 31 32 33
34
29
W1LA-03-02-003
W3-2-9
70 65 67 53 52 51 50 38 63 49 39 48 36 15
69
68
57
72
61
60
71
62
59
W1LA-03-02-012
56 55 54 41 37 64 62 43 44 14 13 12
W3-2-10
Assemble Travel Reduction Gear (ZAXIS30, 35) 8. Install sun gear (65) into ring gear (64).

AND ASSEMBLING (W1-1-1) carefully before 9. Install first stage carrier (67) onto sun gear (65).
assembling.
10. Install inner races (61) (3 used), needle bearings

CAUTION: Travel device weight:
(60) (3 used) and first stage planetary gears (59)
35kg (75 Ib)
(3 used) onto first stage carrier (67) in this order.
1. Install oil seal (41) into body (36).
11. Install drive gear (68) into ring gear (64).
2. Install floating seal (48) into body (36).
12. Install thrust plate (69) onto first stage carrier
(67).
NOTE: Refer to W1-1-4 for precautions for han-
dling the floating seal.
13. Install O-ring (71) onto cover (72).
3. Drive in bearing (49) into body (36), then tighten

bearing nut (50) using special tool (ST 3313).
: 2±0.1 N⋅m (20±1 kgf⋅m, 144±7.2 lbf⋅ft) 14. Install cover (72) onto ring gear (64).
4. Install plug (37) to bearing nut (50).

15. Install eyebolts (PF1/4) (2 used) into the plug (57)
: 6 mm
mounting hole on cover (72), then insert an steel
: 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
pipe into the holes of eyebolts.
5. Install ring gear (64) into body (36) while tapping
the ring gear with a plastic hammer.
IMPORTANT: Wrap plug (62) with a seal tape.
16. Bend wire (70) 90°at approximately 6 mm (0.24

IMPORTANT: Wrap plug (62) with a seal tape.
in) from its tip, then insert it into the plug (62)
mounting hole.
6. Insert steel balls (63) (132 used) into the plug
While turning cover (72) with a steel pipe, wind up
(62) mounting hole, then tighten plug (62).
wire (70).
: 5 mm
: 7.9±1 N⋅m
(0.8±0.1 kgf⋅m, 5.8±0.7 lbf⋅ft)
17. Install plugs (62) (2 used) to ring gear (64).
IMPORTANT: Apply LOCTITE #262 to screw (56).

18. Drive in shaft (43) assembly into body (36) with a
plastic hammer.
7. Install thrust washers (51) (4 used), inner races
(52) (4 used), needle bearings (53) (4 used), sec-
ond stage planetary gears (54) (4 used) and
19. Install steel balls (35) (2 used), springs (38) (2
thrust plate (55) into body (36) in this order, then
used), control pistons (39) (2 used) and swash
tighten them with screws (56) (4 used).
plate (44) into body (36).
: 6.1±2 N⋅m
(0.62±0.2 kgf⋅m, 4.5±1.4 lbf⋅ft)
20. Install spring seat (14), spring (13) and washer
(12) into rotor (15) in this order.
W3-2-11
46 36 47 16 15 8
57
72
11
10
27
40
W1LA-03-02-012
45 13 12 18
W3-2-12
21. Press washer (12) and spring (13) with a press,
then install retaining ring (11).
22. Install pins (16) (3 used) into rotor (15), then in-
stall holder (47) on pins (16).
23. Install plungers (45) (9 used) and the retainer (46)

assembly into rotor (15).
24. Install rotor (15) assembly into body (36).
25. Install O-ring (40) and pins (8) (2 used) into body
(36).
IMPORTANT: Apply grease to the contacting sur-

face of valve body (18) and valve
plate (10) to prevent them from fal-
ling.
26. Install O-ring (17) (3 used) and valve plate (10)

into valve body (18).
IMPORTANT: When installing valve body (18) on

body (36), check if the clearance
between them is equal to that re-
corded when disassembling.
If not, disassemble and assembled
again because they may not be in-
stalled correctly.
27. Install valve body (18) on body (36), then tighten

: 8 mm
: 64±4.9 N⋅m
(6.5±0.5 kgf⋅m, 47±3.7 lbf⋅ft)
28. Pour in 0.5 litter (0.52 US qt) of gear oil from the
plug (57) mounting hole on cover (72), then
tighten plug (57).
: 6 mm
: 34±4.9 N⋅m
(3.5±0.5 kgf⋅m, 25±3.7 lbf⋅ft)
NOTE: IDEMITSU APOLLO OIL 21

GEAR 4-90 or equivalent
W3-2-13
DISASSEMBLE AND ASSEMBLE BRAKE
VALVE (ZAXIS30, 35)
19 4 3
18
1
20
26
23 22 21 W1LA-03-02-002
30 31 32 33
34
29
W1LA-03-02-003
1- Plug (2 Used) 19 - Spool 23 - Spool 31 - Check Valve
2- O-Ring (2 Used) 20 - Plug 26 - Adapter 32 - Spring
3- Spring (2 Used) 21 - O-Ring (2 Used) 29 - Body 33 - O-Ring
4- Spring Seat (2 Used) 22 - Spring 30 - Socket Bolt (3 Used) 34 - Plug
18 - Valve Body
W3-2-14
Disassemble Assemble
1. Remove plug (34), spring (32), and check valve 1. Install spool (19), spring seats (4) (2 sued), and
(31) from body (29). springs (3) (2 used) to valve body (18) with plug
: 8 mm (1).
: 36 mm
: 240±5.0 N⋅m
2. Remove socket bolts (30) (3 used) to remove (24.5±0.5kgf⋅m, 175±3.7 lbf⋅ft)
body (29) from valve body (18).
: 8 mm
2. Install adapter (26) to valve body (18).
: 27 mm
3. Remove plug (20) and spring (22) from valve : 54±4.9 N⋅m
body (18). (5.5±0.5kgf⋅m, 40±3.7 lbf⋅ft)
: 8 mm
3. Install spool (23) and spring (22) to valve body

4. Remove adapter (26) and spool (23) from valve (18) with plug (20).
body (18). : 8 mm
: 27 mm : 54±4.9 N⋅m
(5.5±0.5kgf⋅m, 40±3.7 lbf⋅ft)
5. Remove plugs (1) (2 used) from valve body (18)

to remove springs (3) (2 used). 4. Install body (29) to valve body (18) with socket
: 36 mm bolts (30) (3 used).
: 8 mm
: 37±1.9 N⋅m
IMPORTANT: Spool (19) assembly cannot be dis- (4.0±0.2kgf⋅m, 27±1.4 lbf⋅ft)
assembled. When pulling out the
spool assembly, take care not to
drop off spring seats (4) (2 used). 5. Install check valve (31) and spring (32) to body
(29) with plug (34).
6. Pull out the spool (19) assembly in valve body : 8 mm
(18) straight. Remove spring seats (4) (2 used) : 54±4.9 N⋅m
from spool (19). (5.5±0.5kgf⋅m, 40±3.7 lbf⋅ft)
W3-2-15
1 2
DISASSEMBLE TRAVEL DEVICE (ZAXIS40, 50) 3
29 4
30 5
30
29 6
27 7
28 8
27 9
15 10
18 11
17
26 16
15
25 14
24
23
22
21 13
12
20
19
37 36 W571-03-02-004
55 35
54
53 58 52
51 50 34
49 33
48 32
47 31
46
45
43
44
71 43
42
70 41
40
59 39
57 38
60
56
61
62
63
66 64
67 65
68
50
49 69
52
51 W571-03-02-005
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary Gear 39 - Holder 57 - Choke
(4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2
Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)
W3-2-16
Disassemble Travel Device (ZAXIS40, 50)
9. Remove plungers (38) (9 used), holder (39), bar-
• Read PRECAUTIONS FOR DISASSEMBLING rel holder (40) and pins (41) (3 used) from rotor
AND ASSEMBLING (W1-1-1) carefully before (42).
disassembling.
CAUTION: Travel device weight: CAUTION: Always hold retainer (43) and
50kg (110 Ib) spring (44) with a press when removing re-
taining ring (45). If retaining ring (45) is re-
1. Remove plugs (63) (2 used), spring guides (61) moved without holding retainer (43) and
(2 used), springs (60) (2 used) and balls (59) (2 spring (44), retainer (43) and spring (44) may
used) from body (58). Remove O-rings (62) (2 fly out potentially causing serious injury.
used) from plugs (63) (2 used).
10. Remove retaining ring (45) from rotor (42), then
2. Remove plugs (49) (2 used), springs (51) (2 remove retainer (43), spring (44) and retainer
used), Rings (52) (2 used) and spool (69) from (43).
body (58). Remove O-rings (50) (2 used) from
plugs (49) (2 used). 11. Remove plug (12), O-ring (13), plugs (11) (2
used) and O-rings (10) (2 used) from cover (8).
3. Remove plugs (68) (2 used), spacer (66), spool : 5 mm, 8 mm
(65) and spring (64) from body (58). Remove
O-rings (67) (2 used) from plugs (68) (2 used). 12. Remove stopper ring (9) from cover (8) with a
screwdriver, then remove cover (8) from ring gear
4. Remove socket bolts (55) (4 used), relief valve (26).
assembly (54), O-rings (70) (2 used) and (71)
from body (58).
: 6 mm
CAUTION: Valve plate (46) may stick to body

(58). Take care not to drop valve plate (46)
when removing body (58).
5. Removes socket bolts (53) (7 used) to remove

body (58) and valve plate (46) from body (31).
: 10 mm
6. Remove O-ring (56), bearing (48) and choke (57)

from body (58).
7. Remove O-ring (47) from body (31).
8. Remove the rotor (42) assembly, swash plate

(37), balls (36) (2 used), and control piston (32)
from body (31).
W3-2-17
1
2
3
4
29
30 5
30
29 6
7
27
28 8
27 15
18
17
26 16
15
25
24 14
23
22
21
20
19
W571-03-02-004
35
34
33
31
W571-03-02-005
W3-2-18
13. Remove O-ring (7) and slide ring (6) from cover
(8).
14. Remove drive gear (5), first stage carrier (3) as-
sembly, retaining ring (4) and sun gear (1) from
ring gear (26).
15. Remove retaining rings (14) (3 used), thrust

washers (15) (3 used), first stage planetary gears
(18) (3 used), needle bearings (17) (3 used),
thrust washers (15) (3 used) and pins (16) (3
used) from first stage carrier (3).
16. Remove thrust collar (2), retaining rings (19) (4

used), thrust washers (20) (4 used), second stage
(22) (4 used), rings (23) (4 used) and thrust
washers (24) (4 used) from body (31).
CAUTION: Attach a bar to shaft (35) assem-

bly. While tapping the end of the bar with a
hammer, remove the shaft (35) assembly
from body (31). Do not remove bearing (34)
unless replacement is necessary.
17. Remove shaft (35) from body (31).
18. Remove retaining ring (25) from body (31).
19. Remove body (31) from ring gear (26).
IMPORTANT: Attach a bar to bearing (27). While

tapping the end of the bar with a
hammer, remove bearing (27) from
ring gear (26). Replace bearing (27)
with a new one if removed.
20. Remove seal ring (30), O-ring (29), bearing (27),

retaining ring (28) and bearing (27) from ring gear
(26).
21. Remove O-ring (29) and seal ring (30) from body
(31).
22. Remove oil seal (33) from body (31).
W3-2-19
ASSEMBLE TRAVEL DEVICE (ZAXIS40, 50)
18 17 15 19 20 21 22 24 25 33 28 34 29 37 36 40 41 47 53 44 48
58
15
16
23
14
55
13 54
12
6
8
10
11
9 7 4 3 2 1 5 26 32 27 39 30 38 42 43 31 56 35 57 45 46
T571-03-05-001
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary 39 - Holder 57 - Choke
Gear (4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)
W3-2-20
69 69
52
49
51
50 68
59
60
61
64 62 63 65 66 67
W571-03-02-001
W3-2-21
18 17 15 19 20 21 22 24 25 33 28 29 30
15
16
23
14
13
12
6
8
10
11
9 7 4 3 2 1 5 26 27 31
T571-03-05-001
W3-2-22
Assemble Travel Device (ZAXIS40, 50)
5. Install rings (23) (4 used), thrust washers (24) (4
• Read PRECAUTIONS FOR DISASSEMBLING used), second stage planetary gears (21) (4
AND ASSEMBLING (W1-1-1) carefully before used), needle bearings (22) (4 used) and thrust
assembling. washers (20) (4 used) onto body (31) in this order.
Secure them with retaining rings (19) (4 used),
CAUTION: Travel device weight: then install thrust collar (2).
50kg (110 Ib)
6. Install pins (16) (3 used) onto first stage carrier
1. Install oil seal (33) into body (31). (3). Install sun gear (1) and secure it with retain-
ing ring (4).
2. Install O-ring (29) onto seal ring (30), then install
them into the body (31). 7. Install thrust washers (15) (3 used), first stage
3. Install bearing (27), retaining ring (28), bearing (17) (3 used) and thrust washers (15) (3 used)
(27) and the assembly of seal ring (30) and onto first stage carrier (3) in this order, then install
O-ring (29) into ring gear (26) in this order. retaining rings (14) (3 used).
NOTE: Apply grease to O-ring (29) for easy as- 8. Install the first stage carrier (3) assembly onto
sembling. Degrease the seating surface of ring gear (26), then install drive gear (5) into the
seal ring (30). first stage carrier (3) assembly.
4. Install ring gear (26) into body (31), tapping 9. Install O-ring (7) onto ring gear (26). Add 0.6 litter
around the circumference of ring gear (26) evenly (0.634 US qt) of lubrication oil into ring gear (26).
with a plastic hammer. Install retaining ring (25)
while depressing clearance between the flanges CAUTION: Apply grease to cover (8) and
of body (31) and ring gear (26) with a screw slide ring (6) to hold them. Apply grease to
clamps. O-ring (7), then install it horizontally with
care to avoid damage. Install cover (8) so that
its plug hole aligns with the notch on ring
26 gear (26).
10. Install the assembly of cover (8) and slide ring (6)
onto ring gear (26), then secure them with stop-
Screw Clamp per ring (9).
11. Install plug (11), O-ring (10), plug (12) and O-ring
(13) onto cover (8).
: 5 mm
: 12 to 13 N⋅m
(1.2 to 1.3 kgf⋅m, 8.9 to 9.6 lbf⋅ft)
31
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 38 lbf⋅ft)
W571-03-02-006
W3-2-23
34 37 36 40 41 47 53 44 43 48
58
71
55
54
70
32 39 38 43 42 31 56 35 57 45 46
T571-03-05-001
W3-2-24
IMPORTANT: Do not remove bearing (34) on the
shaft (35) assembly unless replacing
it.
12. Install control piston (32), the shaft (35) assembly,

balls (36) (2 used) and swash plate (37) into body
(31) in this order.
13. Install retainer (43), spring (44) and retainer (43)

into rotor (42) in this order.
14. Depress retainer (43) and spring (44) downward

with a press, and install retaining ring (45).
15. Install pins (41) (3 used) and barrel holder (40)

into rotor (42).
16. Install plungers (38) (9 used) and holder (39) onto

rotor (42).
17. Install the rotor (42) assembly into body (31). Add
0.2 litter (0.211 US qt) of hydraulic oil into body
(31).
18. Install bearing (48), O-ring (47) and valve plate

(46) onto body (58) in this order. Install choke (57)
and O-ring (56).
19. Install body (58) onto body (31), and tighten with
: 10 mm
: 51 to 65 N⋅m
(5.2 to 6.6 kgf⋅m, 38 to 48 lbf⋅ft)
20. Install O-ring (70) (2 used), O-ring (71), relief

valve (54) and socket bolt (55) onto body (58).
: 6 mm
: 25 to 32 N⋅m
(2.6 to 3.3 kgf⋅m, 18.5 to 24 lbf⋅ft)
W3-2-25
69 58 69
52
49
51
50 68
59
60
61
64 63 62 65 66 67
8
W571-03-02-001
W3-2-26
21. Install O-rings (67) (2 used) onto plugs (68) (2
used). Install spring (64), spool (65) and spacer
(66) into body (58), then install plugs (68) (2
used).
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 38 lbf⋅ft)

used). Install spool (69), rings (52) (2 used),
springs (51) (2 used) into body (58), then install
plugs (49) (2 used).
: 36 mm
: 195 to 245 N⋅m
(20 to 25 kgf⋅m, 145 to 180 lbf⋅ft)

used). Install balls (59) (2 used), springs (60) (2
used), spring guides (61) (2 used), plugs (63) (2
used) into body (58) in this order.
: 6 mm
: 5.9 N⋅m (0.6 kgf⋅m, 4.4 lbf⋅ft)
W3-2-27
35)
Travel Motor
1. The clearance between the plunger diameter and Rotor

rotor bore diameter.
(D-d): 0.04 mm (0.00157 in) or less. D d
W507-02-04-009
Plunger
2. The clearance between the plunger and the shoe.
δ: 0.4 mm (0.0157 in) or less. δ
W107-02-06-140
W107-02-06-141
3. The wear amount of the plunger at its sliding sur-
face against the valve plate of the rotor
Make sure that there are no damage, wear, or
seizure.
Damage or wear amount: 0.02 mm (0.000787 in)
or less.
4. The wear amount of the plunger at its sliding sur-

face against the rotor of the valve plate.
Make sure that there are no damage, wear, or
seizure.
Damage or wear amount: 0.02 mm (0.000787 in)
or less.
W3-2-28
Sprocket
D C B
W503-03-02-004
Unit: mm
Dimensio
Standard Allowable Limit Remedy
n
A 28.5 (1.1) 23.5 (0.9)
B 309.0 (12.2) 304.0 (12.0)
C PCD344.7 (13.6) - Replace
D 352.0 (13.9) 347.0 (13.7)
E 101.6 (4.0) -
W3-2-29
50)
Sprocket
B
C
D
A W105-03-07-040
W1SE-03-02-001
Unit: mm (in)
Dimension Standard Allowable Limit Remedy
A 47.6 (1.9) 42.6 (1.7)
B 73.1 (2.9) 68.1 (2.7)
Cladding by
C 96.05 (3.78) 91.05 (3.6) welding and
finishing
C’ PCD92.35 (3.6) -
D 135.0 (5.3) -
W3-2-30
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal

1. Remove the floor plate. 1

NOTE: Refer to "REMOVE AND INSTALL SWING
DEVICE" for removing floor plate.
2. Attach tags to all hoses connected to the body of

center joint (1), to identify for reassembling in the
same positions.
Remove all body side hoses from center joint (1). 3 W507-03-03-001
Cap all disconnected hose ends.

2
3. Remove the bolts (2 used) to remove the lock

plate from the frame.
4. Remove bolts (3) (3 used) to remove under cover

(2) from the frame. W554-03-03-002
Spindle
5. Disconnect all spindle side hoses. Cap all dis-

connected hose ends.
6. Remove bolts (4) (4 used). Lift and remove center W507-03-03-004

joint (1) from the frame by crane.
1
W571-03-03-001
W3-3-1
Installation
1
IMPORTANT: Apply LOCTITE #262 onto bolt (3).
4
1. Hoist center joint (1) by crane. Install center joint

(1) onto the track frame with bolts (4) (4 used).
2. Connect all spindle side hoses. W571-03-03-001
Spindle
3. Install under cover (2) with bolts (3) (3 used).
4. Install the lock plate onto the center joint with the
bolts (2 used).
5. Connect all body side hoses.

3 W507-03-03-004
6. Install the floor plate.

NOTE: Refer to "REMOVE AND INSTALL SWING 2
DEVICE" for installing the floor plate.
IMPORTANT: After connecting the hoses, fill the

hydraulic oil tank to the correct level.
Start the engine and check the hose
connections for oil leaks. W554-03-03-002
W507-03-03-001
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
11
10
12 13
W555-03-03-001
1- Bolt (4 Used) 5- Thrust Washer 8 - O-Ring 11 - Spindle

2- Cover 6- Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7- Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring
W3-3-4
Disassemble Center Joint IMPORTANT: For easy removal, two pins can be
• Read PRECAUTIONS FOR DISASSEMBLING used to pry out oil seals (7). Take
AND ASSEMBLING (W1-1-1) carefully before care not to damage the seal groove
disassembling. with the pins.
1. Clamp the center joint horizontally in a vise. 6. Remove oil seals (7) (7 used) from body (6).
2. Remove bolt (1) (4 used) to remove cover (2)

from body (6).
: 13 mm
Pin
3. Remove O-ring (4), retaining ring (3) and thrust
washer (5) from body (6).
4. Attach special tool (ST 1995) to body (6) with

bolts (1) (2 used).
: 13 mm 7
ST 1995
W105-03-03-015
1
7. Remove dust seal (10), backup ring (9) and
O-ring (8) from body (6).
6
W506-03-03-002
IMPORTANT: Take care not to damage the seal

sliding surface of spindle (11), when
removing spindle (8). When laying
spindle (8) horizontally on the
ground, take extra care not to dam-
age or contaminate the spindle sur-
faces with rough materials such as
sand. Put alignment marks on body
(6) and spindle (11).
5. Screw special tool (ST 1995) to remove spindle

(11) from body (6).
: 13 ㎜
W3-3-5
ASSEMBLE CENTER JOINT
5 2
4
6
8
9
10
11
W555-03-03-002
12 13
1- Bolt (4 Used) 5- Thrust Washer 8 - O-Ring 11 - Spindle

2- Cover 6- Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7- Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring
W3-3-6
Assemble Center Joint
assembling.
IMPORTANT: Before installing various seals into

the seating grooves, coat the seals
with grease or hydraulic oil. After in-
stalling O-ring (8), dust seal (10),
and oil seals (7), coat the lips of
them with grease.
1. Install O-ring (8), backup ring (9), dust seal (10)

and oil seals (7) (7 used) onto body (6).
IMPORTANT: Align the alignment marks when in-

stalling body (6). If body (6) is rap-
idly pushed downward, the seal may
be damaged. Install body (6) onto
spindle (11) while pushing and
turning body (6) slowly.
2. Place spindle (11) on a work bench, then install

body (6) onto spindle (11).
3. Install body (6) until body (6) comes into contact

with spindle (11) flange while tapping the outside
of body (6) with a plastic hammer.
4. Install thrust washer (5) and O-ring (4) onto body

(6).
IMPORTANT: Install retaining ring (3) with the

chamfered side facing cover (2).
Confirm that retaining ring (3) is cor-
rectly seated.
5. Install retaining ring (3) onto spindle (11).
6. Secure cover (2) to body (6) with bolts (1) (4

used).
: 13 mm
: 11 N⋅m (1.1 kgf⋅m, 8.0 lbf⋅ft)
W3-3-7
(Blank)
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
Before removing or installing the track adjuster, the
rubber crawler and front idler must be removed or
installed beforehand. Refer to the corresponding
sections for the removal and installation of the rubber
crawler and front idler
The procedures described below start after the rubber
crawler and front idler are removed.
Removal
1. After removing the front idler assembly, remove

track adjuster (1) from the track frame.
Installation
1
IMPORTANT: Make sure that the track adjuster (1) 2 W507-03-04-001
is not hung on spring guide (3) on
track frame (2) and correctly seated
on the plate (4).
1. Insert track adjuster (1) into track frame (2) as

illustrated.
3 1
W507-03-04-001
3
W507-03-04-003
W507-03-04-002
W3-4-1
DISASSEMBLE TRACK ADJUSTER

1 2
3
5
6
7
10
16
15 13
12
11
14
W1LD-03-04-001
1- Socket Bolt (3 Used) 5- Wear Ring 9- Cylinder 13 - Plug

2- Dust Seal 6- U-Ring 10 - O-Ring 14 - Washer
3- Flange 7- Retaining Ring 11 - Valve 15 - Spring
4- Piston Rod 8- Rod 12 - Nut 16 - Spacer (ZAXIS40, 50 Only)
NOTE: Spacer (16) is not used in ZAXIS30, 35.
W3-4-2
Disassemble Track Adjuster 3. Attach the wire rope to the track adjuster. Lift the
• Be sure to read “Precautions for Disassembly and track adjuster by crane and put the track adjuster
Assembly” thoroughly on page W1-1-1 before on cradle of special tool.
starting any repair work.
Track Adjuster
CAUTION: Special tool weight: 230 kg
(510 lb)
CAUTION: Be sure to use special tool (ST

4943) for assembly / disassembly of the track
adjuster.
The spring force is extremely large, so Cradle of
Special tool
disassembly and assembly work must be
carried out carefully. It is necessary to
inspect the special tool for any damage
thoroughly to ensure safety.
W105-03-04-009
1. Place an oil jack (30 ton) between the cradle and
the base of special tool (ST 4943). CAUTION: Plate (ST 4140) weight: 36 kg
(79 lb)
Nut 4. Install plate (ST 4140) onto special tool (ST 4943)
so that plate (ST 4140) overlies the track adjuster.
Remove valve (11) from rod (8).
Cradle Plate
(ST 4140)
Oil Jack
Track
Base Adjuster
W105-03-04-006
(ST 4943)
CAUTION: Plate (ST 4140) weight: 36 kg

(79 lb)
W105-03-04-011
5. Operate the oil jack to jack up the cradle by the
2. Loosen the nuts (4 used) to remove plate (ST specified amount [66.5 mm (2.6 in) (ZAXIS30, 35),
4140). 82.1 mm (3.2 in) (ZAXIS40, 50)].
: 46 mm
NOTE: Jack up length = Spring free length –
Spring set length
Cradle
Plate (ST 4140)
Oil Jack
W105-03-04-013
W105-03-04-007
W3-4-3
15 13
12
11
14
W1LD-03-04-001
W3-4-4
6. Tighten the nuts onto plate (ST 4140) to secure
CAUTION: Plate (ST 4140) weight:
the track adjuster.
36 kg (79 lb)
Operate the oil jack to compress the track
When removing the nut and plate (ST 4140),
adjuster approximately 10 mm (0.4 in) until a
be sure to remove it after loosening the oil
clearance is observed between washer (14) and
jack. Not loosening the oil jack poses a
nut (12).
danger of washer (14) and spring (15) flying
: 46 mm
off under the reaction of the spring.
8. Lower the oil jack to release the spring force.

Loosen the nuts to remove plate (ST 4140).
Nut
Remove washer (14) from rod (8).
Plate Plate (ST4140)
(ST 4140)
W105-03-04-012
1
7. Remove plug (13) from nut (12). Remove the nut
(12) from rod (8).
: 5 mm
: 46 mm
W105-03-04-016
9. Install eyebolt (M14, pitch 1.5) to the rod (8). Lift

1 8 1
and remove the spring (15) assembly from the
special tool by crane.
Eyebolt
15
W105-03-04-014
W105-03-04-017
CAUTION: Spring weight: 7 kg (15.5 lb)
10. Remove spring (15) from rod (8) after removing

the eyebolt.
W3-4-5

1 2
3
5
6
7
10
16
W1LD-03-04-001
W3-4-6
11. (ZAXIS40, 50 Only)
Remove spacer (16) from rod (8).
12. Remove socket bolts (1) (3 used) from cylinder

(9) to remove flange (3) and dust seal (2).
: 6 mm
13. Remove piston rod (4) from cylinder (9).
14. Remove retaining ring (7), U-ring (6) and wear

ring (5) from piston rod (4).
15. Remove rod (8) and O-ring (10) from cylinder (9).
W3-4-7
ASSEMBLE TRACK ADJUSTER
4 5 6 7 9 10 14
1 3
12 13 8 11
W1LD-03-04-002
A 15 B 16
1- Socket Bolt (3 Used) 5- Wear Ring 9- Cylinder 13 - Plug

2- Dust Seal 6- U-Ring 10 - O-Ring 14 - Washer
3- Flange 7- Retaining Ring 11 - Valve 15 - Spring
4- Piston Rod 8- Rod 12 - Nut 16 - Spacer (ZAXIS40, 50 Only)
NOTE: Spacer (16) is not used in ZAXIS30, 35.
W3-4-8
Assemble Track Adjuster 6. Install spring (15) onto cylinder (9). Install eyebolt
• Be sure to read “Precautions for Disassembly and (M14, pitch 1.5) to the cylinder. Lift the spring
Assembly” thoroughly on page W1-1-1 before assembly by crane. Then set them on special tool
starting any repair work. (ST 4943).
Eyebolt
1. Install O-ring (10) and rod (8) into cylinder (9).
9
IMPORTANT: Install U-ring (6) with the lip facing

retaining ring (7).
Apply the hydraulic oil to wear ring
(5) and the U-ring (6).
ST 4943
2. Install wear ring (5), U-ring (6) and retaining ring
(7) onto piston rod (4).
15
IMPORTANT: Fill chamber (B) in cylinder (9) with
grease. Insert piston rod (4) into the
cylinder to completely bleed air
remaining in the cylinder.
3. Apply grease onto piston rod (4) assembly, and W105-03-04-017
insert it into cylinder (9). 7. Install washer (14) onto rod (8).
IMPORTANT: Fill groove (A) on flange (3) with CAUTION: Plate (ST 4140) weight: 36 kg
grease. (79 lb)
4. Install dust seal (2) into flange (3). Secure the 8. Lift and Install plate (ST 4140) onto the spring.
flange assembly to cylinder (9) with socket bolts Tighten the nuts of the special tool to secure the
(1) (3 used). spring assembly.
ZAXIS30, 35 : 46 mm
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
ZAXIS40, 50 Plate
(ST 4140)
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
Nut
5. Install spacer (16) onto rod (8).

ST 4943
W105-03-04-012
W3-4-9
12 13 8 11
W1LD-03-04-002
15
W3-4-10
9. Operate the oil jack to compress spring (15) until 12. Attach the wire rope to the track adjuster. Lift the
the specified length (223 mm) (8.8 in) is obtained. track adjuster by crane and remove them from
the special tool.
15
Track Adjuster
Oil Jack
Special Tool
W105-03-04-026
10. Install nut (12) and valve (11) to rod (8). Install
plug (13) to the nut.
W105-03-04-009
: 46 mm
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 10.5 lbf⋅ft) CAUTION: Special tool (ST 4944) weight:
: 19 mm 64 kg (141 lb)
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
IMPORTANT: If only the track adjuster is to be
1 8 1 transported, be sure to use special
tool (ST 4944) to avoid personal
injury.
ZAXIS30, 35
: 24 mm
ZAXIS40, 50
: 30 mm
Track Adjuster
W105-03-04-014
CAUTION: Plate (ST 4140) weight:

36 kg (79 lb)
11. Lower the oil jack to remove the nuts and plate
(ST 4140).
: 46 mm
W105-03-04-028
Special Tool
Plate (ST 4140) (ST 4944)
W105-03-04-011
W3-4-11
(Blank)
W3-4-12
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing the front idler, the track must be re-
moved first. As for removal and installation of the track,
refer to W3-7-1. Here, the procedure starts on the
Track
premise that the tracks have already been removed.
Removal
CAUTION: Front idler (1) assembly weight:

ZAXIS30, 35: 27 kg (60 lb)
ZAXIS40, 50: 42 kg (93 lb)
W507-03-05-001
CAUTION: Front idler (1) may fly out due to
1
strong force from the track adjuster spring 2
when removing it.
Give yourself ample clearance, staying clear
of the front idler line.
1. Insert a bar between the front idler (1) assembly

and track frame (2) to pry it out from the track
frame (2).
IMPORTANT: If it is necessary to keep the front

idler for a while, be sure to place it
horizontal on wooden blocks.
W562-03-05-001
1
Installation
IMPORTANT: Clean the sliding portion between Wooden

track frame (2) and the yoke, then Block
apply the grease on as necessary.
1. Hoist the front idler (1) assembly by crane. Push it

in aligning with the sliding surface on track frame
(2).
W105-03-05-003
Sliding Portion
of Yoke
W507-03-04-003
W3-5-1
DISASSEMBLE AND ASSEMBLE FRONT
IDLER
4 5
6 7
2
8
1
9 W1LD-03-05-001
1 - Axle 4 - Bushing (2 Used) 6 - Yoke (2 Used) 8 - Bolt (4 Used)

2 - Floating Seal (2 Used) 5 - O-Ring (2 Used) 7 - Plate 9 - Spring Pin (2 Used)
3 - Idler
W3-5-2
Disassemble Front Idler Assemble Front Idler
• Be sure to read “Precautions for Disassembly / • Be sure to read “Precautions for Disassembly /
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
CAUTION: Front idler weight: CAUTION: Front idler weight:

ZAXIS30, 35: 25kg (55 Ib) ZAXIS30, 35: 25kg (55 Ib)
ZAXIS40, 50: 40kg (90 Ib) ZAXIS40, 50: 40kg (90 Ib)
1. Remove bolts (8) (4 used) and plate (7) from yoke

CAUTION: Idler weight:
(2).
ZAXIS40, 50: 30kg (65 Ib)
: 19 mm
1. Install bushings (4) (2 used) into idler (3) with a
2. Place the front idler horizontally. Remove spring
press.
pin (9) from yoke (6).
2. Install axle (1) to idler (3).
IMPORTANT: For handling of floating seal (2), re-
fer to the section “Precautions for
3. Install O-ring (5) (2 used) to axle (1).
Floating Seal Handling” on page
W1-1-4.
IMPORTANT: For handling of floating seals (2) (2
3. Remove yoke (6) and floating seal (2) on the side
used), refer to the section “Precau-
removed spring pin (9). Discharge the engine oil
tions for Floating Seal Handling” on
while inclining idler (3).
page W1-1-4.
4. Turn over the front idler.
4. Install floating seal (2) and yoke (6) to idler (3).
Remove spring pin (9), yoke (6) and floating seal
Install spring pin (9) to the yoke.
(2) from yoke (6) in opposite side.
5. Place idler (3) with the installed yoke (6) side
5. Remove O-rings (5) (2 used) from axle(1).
downward.
Apply the engine oil into the idler.
CAUTION: Idler weight: Engine oil: SAE #30 class CD
ZAXIS40, 50: 30kg (65 Ib) ZAXIS 30, 35: 45 mL (0.048 US qt)
Engine oil: API class CD, SAE30
6. Remove axle (1) from idler (3) with a press. ZAXIS 40, 50: 60 mL (0.032 US qt)
IMPORTANT: Do not remove bushings (4) (2 used) 6. Install floating seal (2) and yoke (6) to the side
unless necessary. applied the engine oil.
Install spring pin (9) to the yoke.
7. Remove bushing (4) (2 used) from the idler after
contracting it by overlaying four places, 90 de- 7. Installing plate (7) to yokes (6) (2 used) with bolts
grees apart from each others on the bushing bore (8) (4 used).
with the welding rod, as illustrated. : 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
90°
90°
W105-03-05-012
W3-5-3
MAINTENANCE STANDARDS (ZAXIS30, 35)
D F
A
B
W503-03-05-001
Unit: mm (in)

A 31 (1.2) [25 (1.0)]
B 80 (3.1) -
Cladding by welding
C 39 (1.5) -
and hand finishing,
D 269 (10.6) 272 (10.7) or replace
E 10 (0.4) -
F 307 (12.1) -
Axle and Bushing Unit: mm (in)

Axle Outside Dia. 35 (1.38) 34.2 (1.35)
Bushing Inside Dia. 35 (1.38) 36.0 (1.42) Replace
Flange 2.0 (0.08) 1.2 (0.05)
Thickness
NOTE: Dimensions in parentheses [ ] show the

reference values.
Lubricant Oil: Engine oil SAE30 CD class.
Quantity Oil: 45 mL (0.048 US qt)
W3-5-4
MAINTENANCE STANDARD (ZAXIS40, 50)
C D F
A
B
W503-03-05-001
Unit: mm (in)

A 53 (2.1) [47 (1.9)]
B 92 (3.6) -
Cladding by welding
C 44 (1.7) -
and hand finishing,
D 300 (11.8) 288 (11.3) or replace
E 10 (0.4) -
F 344 (13.5) -
Axle and Bushing Unit: mm (in)

Axle Outside Dia. 40 (1.58) 39.2 (1.54)
Bushing Inside Dia. 40 (1.58) 41.0 (1.61) Replace
Flange 2 (0.08) 1.2 (0.05)
Thickness
NOTE: Dimensions in parentheses [ ] show the

reference values.
Lubrication Oil
Engine Oil Grade: API Class CD, SAE30
Oil Capacity: 60 mL (0.063 US qt)
W3-5-5
(Blank)
W3-5-6
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
1
CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly
or loosen it too much. Valve (1) may fly out or
high pressure grease in the track adjuster
may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2). W105-03-07-002
1 2
IMPORTANT: Clean off gravel or mud packed
between the sprockets and tracks
before loosening valve (1).
It’s enough to turn valve (1) by only
one turn. Do not loosen it over one
turn.
Grease Outlet
1. Slowly loosen track adjuster valve (1) to loosen W1F1-03-07-001
the track tension.

: 19 mm
IMPORTANT: Place pads between track frame (3)

and oil jack (4) when jacking up to
prevent the jack from slipping.
2. Jack up track (6) until the clearance between

track (6) and upper roller (5) is wide enough to
1
remove upper roller (5). Then place wooden
blocks on track frame (3) to support track (6).
3. Loosen bolt (7) and remove upper roller (5). W507-03-06-001

: 24 mm
6 Wooden Blocks 5 7 3
W507-03-06-003
W3-6-1
Installation
6 Wooden Blocks 5 7
IMPORTANT: Apply LOCTITE #262 onto bolt (7). 3
1. Install upper roller (5) onto track frame (3) with

bolt (7).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
2. Remove wooden blocks.

4
3. Lower oil jack (4) to lower track (6).

W507-03-06-003
Remove oil jack (4).
4. Tighten track adjuster valve (1).

: 19 mm
１
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
CAUTION: Securely support the raised ma-

chine with wooden blocks.
5. Jack up the track at the side being adjusted. Put

wooden blocks under the track frame.
W507-03-06-005
90～110º
Wooden Block M570-07-001
W3-6-2
6. Supply grease via grease fitting (2) to adjust the
track tension. 2
Track sag specifications (A):

10 to 15 mm (0.4 to 0.6 in) (Rubber Crawler)
NOTE: The joint part of rubber track should be in

the center when measure the rubber track
tension. At this time turn the track in re-
verse direction so that the track sag faces
downward.
Lower Roller
W507-03-06-005
A
Rubber Crawler
Side (a) M503-05-050
a
7. Jack up the one side track using the front at-
tachment and remove wooden blocks.
M1LG-07-021
Joint Part
M102-07-075
Joint Part
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
CAUTION: Support the raised track securely

using wooden blocks.
1. Raise the one side track off the ground using the
90～110º
front attachment. Then place a wooden block
under track frame to support the machine.
Wooden Block M570-07-001
CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly 1
or loosen it too much. Valve (1) may fly out or
high pressure grease in the track adjuster
may spout. Loosen carefully, keeping body
parts and face well away from valve (1).
Never loosen grease fitting (2).
W105-03-07-002
before loosening valve (1). 1 2
turn.
2. Loosen track adjuster valve (1) slowly to let

grease flow out until the clearance between the
track frame and crawler is wide enough to re- Grease Outlet
move lower roller (3).
: 19 mm W1F1-03-07-001
3. Loosen bolts (4) (2 used) and remove lower roller

1
(3).
: 22 mm (ZAXIS30, 35)
: 27 mm (ZAXIS40, 50)
3
4
W507-03-06-005
W3-6-4
Installation
1 2
CAUTION: Securely support the raised ma-
chine with wooden blocks.
3
1. Install lower roller (3) to the underside of the track 4
frame, aligning the bolt holes.
IMPORTANT: Apply LOCTITE #262 to bolt (4).
2. Install lower roller (3) with bolts (4) (2 used).

ZAXIS30, 35:
: 22 mm
: 245 N⋅m (25 kgf⋅m, 180 lbf⋅ft) W507-03-06-005
ZAXIS40, 50:
: 27 mm
: 460 N⋅m (46 kgf⋅m, 330 lbf⋅ft) 1 2
3. Tighten track adjuster valve (1).

: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
4. Supply grease via grease fitting (2) to adjust the

track tension. Grease Outlet
Track sag specifications (A): W1F1-03-07-001
10 to 15 mm (0.4 to 0.6 in) (Rubber Crawler)
NOTE: The joint part of the rubber track should be

in the center when measuring the rubber
track tension. At this time turn the track in
reverse direction so that the track sag
faces downward. a
Lower Roller
A M1LG-07-021
Joint Part
Rubber Crawler
Side (a) M503-05-050
M102-07-075
Joint Part
5. Jack up the one side track using the front at-
tachment and remove wooden blocks.
W3-6-5
DISASSENBLE AND ASEMBLE LOWER
ROLLER
1 2 3 4 5 6 7
W577-03-06-001
1- Floating Seal 4- Axle 6- Collar 8- Plug

2- Roller 5- Floating Seal 7- O-Ring 9- Stopper Ring
3- Busing (2 Used)
W3-6-6
Disassemble Lower Roller Assemble Lower Roller
• Be sure to read “Precautions for Disassembly and • Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
1. Remove plug (8) from collar (6) to drain engine oil IMPORTANT: For handling of floating seals (1)
from the roller. and (5), refer to the section “Precau-
: 5 mm tions for Floating Seal Handling “ on
page W1-1-4.
IMPORTANT: Collar (6) without plug (8) and axle
(4) cannot be disassembled. Re- 1. Install floating seal (1) to roller (2) and the axle (4)
place them as an assembly. assembly. Press fit the axle assembly in the roller
to the direction of the roller from the side of
2. Remove stopper ring (9) from collar (6). Push out mounting floating seal with a press.
axle (4) assembly from the collar (6) side in roller
(2) with a press. 2. Install floating seal (5) to roller (2) and collar (6).
IMPORTANT: For handling of floating seals (1) 3. Install O-ring (7) to axle (4).
and (5), refer to the section “Precau- Aligning the grooves on axle (4) and collar (6) for
tions for Floating Seal Handling “ on stopper ring (9), install collar (6) and stopper ring
page W1-1-4. (9) onto axle (4).
3. Remove collar (6) from roller (2). Remove floating IMPORTANT: Apply LOCTITE #503 onto plug (8).
seals (1) and (5) from both sides of roller (2).
4. Refill engine oil (SAE #30, API class CD) through
4. Remove O-ring (7) from axle (4). the plug (8) hole on collar (6). Install plug (8) to
the collar.
IMPORTANT: Do not remove bushings (3) (2 used) : 5 mm
from roller (2). In case the bushing : 10 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
must be replaced, replace the roller
(2) assembly. Engine oil
ZAXIS30, 35: 35 mL (0.037 US qt)
ZAXIS40, 50: 45 mL (0.048 US qt)
W3-6-7
Upper Roller
W566-03-06-001
Unit: mm
A 110 (4.33) -
Replace
B 80 (3.15) -
IMPORTANT: Do not disassemble the upper roller.

Replace it as an assembly.
Lubrication oil: Engine oil SAE30 CD class

Quantity oil: 60 mL (0.063 US qt)
W3-6-8
Lower Roller
C D E
B
W577-03-06-001
Unit: mm (in)
Standard Allowable Limit
Remedy
ZAXIS30, 35 / 40, 50 ZAXIS30, 35 / 40, 50
A 31 (1.22) / 53 (2.09) -
B 112 (4.41) / 142 (5.59) -
Build-up weld and fin-
C 34 (1.34) / 39 (1.54) - ishing or replace
D 85 (3.35) / 95 (3.74) 77 (3.03) / 87 (3.43)
E 107 (4.21) / 122 (4.80) -
Axle and Bushing

Unit: mm (in)
Remedy
ZAXIS30, 35 / 40, 50 ZAXIS30, 35 / 40, 50
Outside 29.2 (1.15) / 34.2
Axle 30 (1.18) / 35 (1.39)
Dia (1.35)
Inside Replace
30 (1.18) / 35 (1.39) 31 (1.22) / 36 (1.42)
Bushing Dia
Flange Thickness 2 (0.08) 1.2 (0.05)
Lubrication Oil
Engine Oil SAE30 CD class
Quantity Oil: 35 mL (0.037 US qt) (ZAXIS30, 35)
45 mL (0.048 US qt) (ZAXIS40, 50)
W3-6-9
(Blank)
W3-6-10
UNDERCARRIAGE / Track
REMOVE AND INSTALL RUBBER CRAWLER
Removal
1 2
CAUTION: Grease pressure in the track

adjuster is high. Do not loosen valve (1)
quickly or loosen it too much. Valve (1) may
fly out or high pressure grease in the track
adjuster may spout. Loosen carefully,
keeping body parts and face well away from
Grease Outlet
valve (1). Never loosen grease fitting (2).
If the rod and/or the threads are damaged,
W1F1-03-07-001
metal fragments may fly off when track
adjuster is removed. Take necessary
precautions to prevent any personal injury
from occurring.
CAUTION: Be sure to support the raised

body with wooden block, etc.
90～110º
CAUTION: Rubber crawler weight:
125 kg (280 lb) (ZAXIS30, 35)
205 kg (450 lb) (ZAXIS40, 50)
1. Operate the boom and arm so shat the angle M570-07-001
between them is 90° to 110°, Lower the boom

with the bucket rolled-in to jack up the machine.
Then place a block under track frame to support
the machine.

before loosening valve (1).
turn. 1
2. Slowly loosen track adjuster valve (1) to allow

grease to escape.
: 19 mm
W190-03-06-001
3. Insert steel pipes into the gaps between the
rubber crawler and track frame.
Then, rotate the sprocket in reverse direction.
After the rubber crawler is raised off the front idler Rotate Direction
with the steel pipes, slide the rubber track away
from the track frame and remove it.
Steel pipe
M503-07-062
W3-7-1
Installation
CAUTION: Support the raised track securely

using wooden blocks.
CAUTION: Rubber crawler weight:

125 kg (280 lb) (ZAXIS30, 35)
205 kg (450 lb) (ZAXIS40, 50) 90～110º
1. Using the front attachment, raise the one side

track of the machine off the ground, and place
wooden blocks under the track frame to securely
support the machine. M570-07-001
2. Reinstall the rubber crawler on the sprocket and

hang the other end of the rubber track over the Rotate Direction
front idler.
Rotate the sprocket in the reverse direction to
sufficiently remesh the rubber crawler back onto
the sprocket.
IMPORTANT: Check that the rubber crawler is

securely engaged onto both the Steel pipe
M503-07-063
sprocket and front idler. １ 2
3. After inserting a steel pipe into the gap between

the rubber crawler and track frame, rotate the
sprocket again. Then, completely install the
rubber track onto the front idler.
4. Tighten the track adjuster valve (1). Add grease

into the adjuster cylinder via the grease fitting to
adjust track sag.
Track Sag Specification (A)
Rubber Crawler: 10 to 15 mm (0.4 to 0.6 in)
W507-03-06-005
NOTE: With the joint section of the rubber track
placed just under the lower roller, measure
track sag at the lower center roller as
illustrated.
Roller
A
Joint
Track (Rubber Crawler)

M503-05-050
Joint M102-07-070
M102-07-075
W3-7-2
Outside of Rubber Crawler
1. If there is a crack on lug base (1) with depth of 6
mm (0.2 in) or more, repair crawler. 1
4
If there is a crack between lugs (2) with depth of 6
mm (0.2 in) or more, repair crawler. 5
If there is a crack on rugs (3) or between lugs (2) 2
that reaches to steel code (5) or steel core (4)
with length of 30 mm (1.2 in) or more,
immediately repair crawler. 3
2. Inside of Rubber Crawler (Roller Side)

If there is a crack that reaches to steel code (5) or
steel core (4), immediately repair crawler.
W190-03-07-001
5 W190-03-07-002
Lower Roller
Lug Wear
1. If the lug height (A) is less than 5 mm, replace the Rubber Track
rubber crawler as an assembly.
Lug W190-03-07-003
2. If any portion of steel code (5) appeared on

crawler, replace worn rubber crawler as an
assembly.
5
W190-03-07-004
W3-7-3
Rubber Crawler and Steel Cord Cutting
1. When either of the two rows of the steel cord (5)
has cut, replace rubber crawler as an assembly.
5
W190-03-07-005
Steel Core Separation

1. When any steel core (4) has separated, replace
rubber crawler as an assembly.
W190-03-07-006
W3-7-4
SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Hydraulic Circuit Pressure
Release Procedure ............................... W4-1-1
Remove and Install Front Attachment ..... W4-1-2
Maintenance Standards .......................... W4-1-6
Standard Dimensions for
Arm and Bucket Connection ................. W4-1-9
Standard Dimensions for
Arm and Boom Connection ................. W4-1-10
Group 2 Cylinder
Hydraulic Circuit Pressure
Release Procedure ............................... W4-2-1
Remove and Install Cylinders ................. W4-2-2
Disassemble Boom Cylinder ................. W4-2-16
Assemble Boom Cylinder ..................... W4-2-20
Disassemble Arm Cylinder.................... W4-2-26
Assemble Arm Cylinder......................... W4-2-30
Disassemble Bucket Cylinder ............... W4-2-36
Assemble Bucket Cylinder .................... W4-2-40
Disassemble Boom Swing Cylinder,
Blade Cylinder .................................... W4-2-46
Assemble Boom Swing Cylinder,
Blade Cylinder .................................... W4-2-50
1LSW-4-1
（Blank）
1LSW-4-2
FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE 1
NOTE: Do not start the engine. Operate pilot pump

with the power from battery to deliver pilot
pressure to the spool of control valve.
1. Push pilot control shut-off lever (1) forward

(UNLOCK position).
2. Pull engine stop knob (2) fully out and secure it

using special tool (ST 7334).
IMPORTANT: Battery will deplete. Be sure to op-

erate key switch for short period.
3. Turn the key switch to START position and oper-
ate the left and/or right control lever for releasing M178-01-053
pressure from hydraulic circuit 4 to 5 times.
4. Push engine stop knob (2) in.
M178-01-054
W4-1-1
REMOVE AND INSTALL FRONT AT-
1
TACHMENT 2

the hydraulic oil tank before doing 3
Removal
5
1. Remove bolt (5) to remove cover (4).
4
CAUTION: Boom cylinder (3) weight:
31 kg (70 lb) (ZAXIS30),
W527-04-01-001
34 kg (75 lb) (ZAXIS35),
50 kg (110 lb) (ZAXIS40),
56 kg (125 lb) (ZAXIS50)
2. Attach nylon sling to boom cylinder (3) then hoist

and hold it by crane. Remove bolt (1) to tap out
pin (2) with a hammer and bar.
Wire
3. Operate the boom lever to retract the cylinder rod.
Pass a wire through the rod hole to fix the rod and
prevent it from extending.

W554-02-03-007
4. Disconnect two hoses from boom cylinder (3).

Cap all open ends. Boom
5. Put the boom cylinder rod on a stand.
6. Loosen clip (6) under the head lamp and 6

disconnect connector (7).
Loosen clips (11) (6 used) which fix the light
harness on the rear pipe of the boom. Pass light
harness through the loosened clip band hole.
7
11
W577-04-01-001
W4-1-2
7. Disconnect hoses (4 at rear and 2 at right) from

the boom. Cap all open ends.
Plug: PF3/8 (ZAXIS30, 35)
PF1/2 (ZAXIS40, 50)
Boom
CAUTION: Front attachment weight:

750 kg (1660 lb) (ZAXIS30),
810 kg (1790 lb) (ZAXIS35), W507-04-01-004
1110 kg (2450 lb) (ZAXIS40),

1150 kg (2540 lb) (ZAXIS50)
8. Attach the wire rope to the boom. Find center of

gravity and hold it by crane. Boom
9. Remove nuts (10) (2 used) and bolt (8). Boom 12

W507-04-01-005
8
10. Drive the boom foot pin (9) out with a hammer and
bar.
NOTE: If matching marks have been made on the
boss of swing post and boom foot pin (9), it 9
is easy to align the stopper bolt (8) holes
when assembling.
11. Remove shims (12) (several) from between the 10

boom and swing post.
12. Hoist the front attachment by crane to remove it.

W574-04-01-002
Swing Post Boss
W4-1-3
Installation
CAUTION: Front attachment weight:

750 kg (1660 lb) (ZAXIS30),
Boom
810 kg (1790 lb) (ZAXIS35),
1110 kg (2450 lb) (ZAXIS40),
1150 kg (2540 lb) (ZAXIS50)
1. Attach the wire rope to the boom. Find center of

gravity and hold it by crane.
IMPORTANT: Apply the grease on the surface of

boom foot pin (9).
W507-04-01-005
2. Align the pin hole in the boom with that in the Boom 12
swing post. 8
IMPORTANT: Adjust shim (12) so that the clear-

ance between the boom and swing
post is set to 0.5 mm or less. 9
Swing
Moreover, share these shim (12) to Post
right and left of the pin part evenly.
3. Insert shims (12) (several) between the boom and 10

swing post.
4. Drive the boom foot pin (9) in with a hammer and

bar. W574-04-01-002
IMPORTANT: Apply LOCTITE #262 on nuts (10) (2

used).
When installing nuts, clearance 2 to 3
mm (0.08 to 0.12 in) should be left
between nuts and the boss of the Boom
swing post.
5. Insert bolt (8) and install nuts (10) (2 used).
6. Connect boom hoses (4 at rear and 2 at right).

W507-04-01-004
Boom
7. Pass the light harness through clips (11) (6 used). 6

Connect connector (7) and install clip (6). Fix the
light harness and the boom pipes with clips (11) (6
used).
11
W1LN-04-01-001
W4-1-4
CAUTION: Boom cylinder (3) weight: 1

31 kg (70 lb) (ZAXIS30), 2
34 kg (75 lb) (ZAXIS35),
50 kg (110 lb) (ZAXIS40),
56 kg (125 lb) (ZAXIS50) 3
8. Attach a nylon sling to boom cylinder (3) to hoist it

by crane. Connect two hoses to boom cylinder
(3). 5
9. Remove the wire which is used to secure the rod

part of boom cylinder (3). 4
IMPORTANT: If the air trapped in a cylinder is W527-04-01-001

suddenly compressed, the hydraulic
oil temperature inside of a cylinder
will rise. This may cause damage to
the seals and rings.
10. Start the engine. Operate the cylinder rod to re-

tract fully to the stroke end. Extend the cylinder
rod slowly to align the boom cylinder (3) rod with
the pin (2) hole.
NOTE: When finishing the work in step 10, release
all air from the cylinder to prevent damag-
ing the components.
IMPORTANT: Apply the grease on the surface of

pin (2).
11. Drive pin (2) in with a hammer and bar. Install bolt
(1).
12. Install cover (4) with bolt (5).
IMPORTANT: Fill the hydraulic oil to the specified

level after installation. Operate every
cylinder fully to the stroke end sev-
eral times to release the air from the
circuit and check each connection of
hoses for any oil leakage.
W4-1-5
Pin and Bushing
F
E
M C
G D
L N
A
W577-04-01-003
H I B
J K P
Q
O
W577-04-01-002
Unit：mm (in)

Reme
Part Name ZAXIS40 ZAXIS40,
ZAXIS30/ 35 ZAXIS30/ 35 dy
, 50 50
Pin 45 (1.77) 50 (1.97) 44.0 (1.73) 49.0 (1.93)
A Bushing (Boom) 45 (1.77) 50 (1.97) 46.5 (1.83) 51.5 (2.03)
Bushing (Swing Post) 45 (1.77) 50 (1.97) 46.5 (1.83) 51.5 (2.03)
Pin 40 (1.58) 50 (1.97) 39.0 (1.54) 49.0 (1.93)
B Bushing (Boom Cylinder) 40 (1.58) 50 (1.97) 41.5 (1.63) 51.5 (2.03)
Boss (Swing Post) 40 (1.58) 50 (1.97) 46.5 (1.83) 51.5 (2.03)
Pin 40 (1.58) 50 (1.97) 39.0 (1.54) 49.0 (1.93)
C Bushing (Boom Cylinder) 40 (1.58) 50 (1.97) 41.5 (1.63) 51.5 (2.03)
Boss (Boom) 40 (1.58) 50 (1.97) 46.5 (1.83) 51.5 (2.03) Repla
Pin 40 (1.58)/ 45 (1.77) 50 (1.97) 39 (1.54)/ 44 (1.73) 49.0 (1.93) ce
D Bushing (Arm) 40 (1.58)/ 45 (1.77) 50 (1.97) 41.5(1.63)/ 46.5(1.83) 51.5 (2.03)
Boss (Boom) 40 (1.58)/ 45 (1.77) 50 (1.97) 41.5(1.63)/ 46.5(1.83) 51.5 (2.03)
Pin 40 (1.58) 45 (1.77) 39.0 (1.54) 44.0 (1.73)
E Bushing (Arm Cylinder) 40 (1.58) 45 (1.77) 41.5 (1.63) 46.5 (1.83)
Boss (Arm) 40 (1.58) 45 (1.77) 46.5 (1.83) 46.5 (1.83)
Pin 40 (1.58)/ 45 (1.77) 45 (1.77) 39 (1.54)/ 44 (1.73) 44.0 (1.73)
F Bushing (Arm Cylinder) 40 (1.58)/ 45 (1.77) 45 (1.77) 41.5(1.63)/ 46.5(1.83) 46.5 (1.83)
Boss (Boom) 40 (1.58)/ 45 (1.77) 45 (1.77) 41.5(1.63)/ 46.5(1.83) 46.5 (1.83)
W4-1-6

Part Name Remedy
ZAXIS30, 35 / 40, 50 ZAXIS30, 35 / 40, 50
Pin 40 (1.57) / 45 (1.77) 39.0 (1.54) / 44.0 (1.73)
G Bushing (Bucket Cylinder) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Boss (Arm) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Pin 40 (1.57) / 45 (1.77) 39.0 (1.54) / 44.0 (1.73)
Bushing (Ring A) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
H
Bushing (Bucket Cylinder) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Boss (Ring B) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Pin 40 (1.57) / 45 (1.77) 39.0 (1.54) / 44.0 (1.73)
I Bushing (Arm) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Boss (Ring B) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Pin 40 (1.57) / 45 (1.77) 39.0 (1.54) / 44.0 (1.73)
J Bushing (Ring A) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Boss (Bucket) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Pin 40 (1.57) / 45 (1.77) 39.0 (1.54) / 44.0 (1.73)
K Bushing (Arm) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Boss (Bucket) 40 (1.57) / 45 (1.77) 41.5 (1.63) / 46.5 (1.83)
Pin (2 used) 80 (3.15) / 90 (3.54) 79.0 (3.11) / 89.0 (3.50)
L Bushing (2 used) (Swing Post) 80 (3.15) / 90 (3.54) 81.5 (3.21) / 91.5 (3.60)
Replace
Bushing (Main Frame) 80 (3.15) / 90 (3.54) 81.5 (3.21) / 91.5 (3.60)
Pin 45 (1.77) / 50 (1.97) 44.0 (1.73) / 49.0 (1.93)
Bushing 45 (1.77) / 50 (1.97)
M 46.5 (1.83) / 51.5 (2.03)
(Boom Swing Cylinder)
Boss (Swing Post) 45 (1.77) / 50 (1.97) 46.5 (1.83) / 51.5 (2.03)
Pin 45 (1.77) / 50 (1.97) 44.0 (1.73) / 49.0 (1.93)
Bushing 45 (1.77) / 50 (1.97)
N 46.5 (1.83) / 51.5 (2.03)
(Boom Swing Cylinder)
Boss (Main Frame) 45 (1.77) / 50 (1.97) 46.5 (1.83) / 51.5 (2.03)
Pin 45 (1.77) / 55 (2.17) 44.0 (1.73) / 54.0 (2.13)
O Bushing (Blade) 45 (1.77) / 55 (2.17) 46.5 (1.83) / 56.5 (2.22)
Boss (Track Frame) 45 (1.77) / 55 (2.17) 46.5 (1.83) / 56.5 (2.22)
Pin 45 (1.77) / 55 (2.17) 44.0 (1.73) / 54.0 (2.13)
P Bushing (Blade Cylinder) 45 (1.77) / 55 (2.17) 46.5 (1.83) / 56.5 (2.22)
Boss (Track Frame) 45 (1.77) / 55 (2.17) 46.5 (1.83) / 56.5 (2.22)
Pin 45 (1.77) / 55 (2.17) 44.0 (1.73) / 54.0 (2.13)
Q Bushing (Blade Cylinder) 45 (1.77) / 55 (2.17) 46.5 (1.83) / 56.5 (2.22)
Boss (Blade) 45 (1.77) / 55 (2.17) 46.5 (1.83) / 56.5 (2.22)
IMPORTANT: When replacing HN bushing to the

front attachment, press fit it with a
press.
W4-1-7
Side Cutter
ZAXIS30, 35 ZAXIS40, 50
C C
D D
A A
B B
W505-04-01-001 W1LS-04-01-001
Unit: mm

Remedy
ZAXIS30, 35 / 40, 50 ZAXIS30, 35 / 40, 50
A 104 (4.09) / 127 (5.00) 70 (2.76) / 83 (3.27)
B 138 (5.43) / 165 (6.50) -
Replace
C 153 (6.02) / 223 (8.78) -
D 90 (3.54) / 130 (5.12) -
Point
B C
W554-04-01-003
Unit: mm

Remedy
ZAXIS30, 35 / 40, 50 ZAXIS30, 35 / 40, 50
A 128 (5.04) / 133 (5.24) 64 (2.52) / 67 (2.64)
B 56 (2.20) -
Replace
C 62 (2.44) -
D 51 (2.01) -
W4-1-8
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section A Section B
W1CC-04-01-002
Unit：mm (in)
ZAXIS30, 35 ZAXIS40, 50
a 152 (5.98) 215 (8.46) NOTE: Dimension h: includes the clearance for
shims to adjust bucket clearance.
b 13 (0.51) 10 (0.39)
Dimensions O and P: 90° shown in left ta-
c 250 (9.84) 340 (13.39) ble means the angle for the bolt hole.
d 230 (9.06) 305 (12.01)
e 185 (7.28) 230 (9.06)
f 714 (28.11) 850 (33.46)
g 234 (9.21) 259 (10.20)
h 140 (5.51) 161 (6.34)
i 40 (1.57) 45 (1.77)
j 185 (7.28) 230 (9.06)
k 0 (0) 0 (0)
l 235 (9.25) 259 (10.20)
m 141 (5.55) 161 (6.34)
n 40 (1.57) 45 (1.77)
o 90° 90°
p 90° 90°
q 248.2 (9.77) 284 (11.18)
r 166 (6.54) 186 (7.32)
W4-1-9
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
Section C
W187-04-01-002
Unit：mm (in)
ZAXIS30 / 35 ZAXIS40, 50
s 40 (1.57) / 45 (1.77) 50 (1.97)
t 134 (5.28) / 137 (5.39) 171 (6.73)
u 188 (7.40) / 191 (7.52) 234 (9.21)
W4-1-10
FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE 1
NOTE: Do not start the engine. Operate pilot pump

with the power from battery to deliver pilot
pressure to the spool of control valve.
1. Push pilot control shut-off lever (1) forward

(UNLOCK position).
2. Pull engine stop knob (2) fully out and secure it

using special tool (ST 7334).
IMPORTANT: Battery will deplete. Be sure to op-

erate key switch for short period.
3. Turn the key switch to START position and oper-
ate the left and/or right control lever for releasing M178-01-053
pressure from hydraulic circuit 4 to 5 times.
4. Push engine stop knob (2) in.
M178-01-054
W4-2-1
REMOVE AND INSTALL CYLINDERS
1
Remove Bucket Cylinder
Wooden
Block
1. Insert a wooden block between bucket cylinder

(1) and the arm.
Arm
IMPORTANT: Secure the link with a wire to pre-
vent the link from falling before re- W527-04-02-001
moving pin (3). 3

Link 4
2. Remove ring (3) from the link, then remove pin

(4).
3. Remove pin (5) from the cylinder rod side.
4. Secure the cylinder rod with a wire to prevent the

cylinder rod from extending. 5
W527-04-02-002
CAUTION: Bucket cylinder (1) weight:
ZAXIS30: 23 kg (51 lb)
5. Attach a nylon sling onto bucket cylinder (1) to

hold it by crane. Pass a wire or something similar Wire
through the rod hole of bucket cylinder (1) bind Cylinder Rod
the rod.
W507-04-02-005
W571-04-02-002
W4-2-2
6. Disconnect two hoses from bucket cylinder (1).
Cap two disconnected hose openings.
7. Remove bolt (7) to drive pin (6) out with a ham-

6 7
mer and bar. Remove the shim from both sides of
the cylinder tube boss.
8. Hoist and remove bucket cylinder (1) from the

arm. 1
Arm W1L7-04-02-005
W4-2-3
Install Bucket Cylinder
IMPORTANT: Be sure to insert one shim to both

left and right sides of all pins re-
spectively. And when shims should
be used to adjust the clearance, they
should be inserted at both sides re-
spectively. (Clearance: 0.5 mm (0.02
in) or less)
IMPORTANT: Apply the grease on the lip of the

dust seal for bucket cylinder (1) and
boss side (both bottom and rod
sides).
1. Align both the pin (6) holes in the bucket cylinder

(1) bottom side and the arm. Insert shims to both 6 7
sides of the cylinder tube boss.
IMPORTANT: Apply LOCTITE #262 on bolt (7). 1
2. Drive pin (6) in with a hammer and bar to install

bolt (7).
3. Connect two hoses to bucket cylinder (1). W1L7-04-02-005
Arm
CAUTION: If the air trapped in a cylinder is
suddenly compressed, the temperature in-
side will rise as the temperature of hydraulic
oil will do. This may cause damage to the
seals and rings.
4. Start the engine. Operate the cylinder rod to Cylinder Rod

retract fully to the stroke end. Let the clean
hydraulic oil flow into the bucket cylinder (1) rod
side. Extending the cylinder (1) rod slowly, align
the pin (5) holes both in the bucket cylinder rod
and link B.
NOTE: When the work in step 4 has been carried
out, almost all air in the cylinder has been
released. Link B
5 W527-04-02-002
W4-2-4
IMPORTANT: Align the pin (4) holes in the link B
3
boss and in pin (5). 4
Link B
5. Insert the shims to both sides of the cylinder rod
boss. Drive pin (5) in with a hammer.
6. Install pin (4) and ring (3).

eral times to release the air from the 5 W527-04-02-002
circuit and check each connection

of hoses for any oil leakage.
W4-2-5
Remove Arm Cylinder (ZAXIS30, 35)
1. Insert a wooden block between arm cylinder (1) Wooden

Block 1
and the boom.
Boom
W527-04-02-004
2. Remove bolt (2) to drive pin (3) out with a ham- 2 3

mer and bar. Remove the shims from both sides
of the cylinder rod boss.
NOTE: If it is difficult to pull pin (3) out, raise the

boom a little for pulling it out.
Boom
W1L7-04-02-005
Cylinder Rod Wire

cylinder rod from extending.
W507-04-02-013
W4-2-6
4. Remove bolt (5) and clamp (8) from arm cylinder 6 7
(1).
5
1
IMPORTANT: Attach identification tags to the
disconnected hosed for reassem-
bling.
5. Disconnect two hoses from arm cylinder (1). Cap

two disconnected hose openings.
8
Boom
CAUTION: Arm cylinder (1) weight:
W1L7-04-02-005
6. Attach a nylon sling onto arm cylinder (1). Hoist

and hold it by crane.
7. Remove bolt (7) onto drive pin (6) out with a ham-
1
mer and bar. Remove the shims from both sides
of the cylinder tube boss.
8. Hoist and remove arm cylinder (1).
W571-04-02-006
W4-2-7
Install Arm Cylinder (ZAXIS30, 35)

in) or less).
IMPORTANT: Apply grease on the lip of dust seal 6 7

for arm cylinder (1) and on boss side
(both bottom and rod sides). 5
1
1. Align both the pin (6) holes of arm cylinder (1)
and the boom.
Insert shims to both sides of the cylinder tube
boss.
2. Drive pin (6) in with a hammer. Install bolt (7).
3. Connect two hoses to arm cylinder (1). 8

Boom
4. Secure hose to the arm cylinder (1) rod with W1L7-04-02-005
clamp (8) and bolt (5).
W4-2-8

side will rise as the temperature of the hy-
draulic oil will do. This may cause damage to
the seals and rings. 1

tract fully to the stroke end so as to let the clean
2 3
hydraulic oil flow into the arm cylinder (1) rod.
Slowly extend the cylinder rod. Align the pin (3)
holes both in arm cylinder rod and the arm.
NOTE: When the work in procedure 5 is finished,
almost all air in the cylinder has been re-
leased.
Boom
NOTE: If it is difficult to align the pin (3) holes,
raise the boom a little to align them. W1L7-04-02-005
Arm
6. Insert the shims the both sides of the cylinder rod

boss. Drive pin (3) in with a hammer and install
bolt (2).

eral times to release air from the cir-
cuit and check each connection of
W4-2-9
Remove Arm Cylinder (ZAXIS40, 50)
4 5 1
1. Insert a wooden block between arm cylinder (1)
and boom (2).
2. Remove bolt (4), then remove pin (5).

rod from extending.
4. Disconnect two hoses from arm cylinder (1). Cap

two disconnected hose openings. 3 2
W571-04-02-004
1
CAUTION: Arm cylinder weight:
5. Attach a sling belt onto arm cylinder (1), and hold

it by crane.
W571-04-02-006
6. Remove bolt (7), then remove pin (8).
7. Hoist and remove arm cylinder (1).
8 7 W527-04-02-008
W4-2-10
Install Arm Cylinder
Arm
left and right sides of all pins re- 1
in) or less)
IMPORTANT: Apply the grease on the lip of the

dust seal for bucket cylinder (1) and
boss side (both bottom and rod 8 7
sides). W527-04-02-008

1. Lift arm cylinder (1) by crane. Align the pin (8)

holes on the cylinder tube side and arm.
2. Insert pin (8) and secure it with bolt (7).
3. Connect two hoses to arm cylinder (1).

suddenly compressed, the temperature in- 1
side will rise as the temperature of the hy- 4 5
the seals and rings.

tract fully to the stroke end so as to let the clean
hydraulic oil flow into the arm cylinder (1) rod.
holes both in arm cylinder rod and the arm.
NOTE: When the work in procedure 4 is finished,
3 2
leased.
NOTE: If it is difficult to align the pin (5) holes, W571-04-02-004
raise the boom a little to align them.
5. Insert the shims the both sides of the cylinder rod

boss. Drive pin (5) in with a hammer to install bolt
(4).
W4-2-11
eral times to release air from the cir-
cuit and check each connection of
W4-2-12
Remove Boom Cylinder
3
4
1. Remove bolt (7) to remove cover (2).
CAUTION: Boom cylinder (1) weight:

ZAXIS40: 55 kg (121 lb) 1
ZAXIS50: 60 kg (132 lb) 7
2. Attach a nylon sling onto boom cylinder (1) to hold

it by crane. 2
Remove bolt (3) to pull out pin (4). W527-04-01-001
3. Place end of the cylinder tube on a support. Op-

erate the boom control lever to fully retract the rod.
Thread a piece of wire through the rod hole, and
tie it to the cylinder tube to prevent the cylinder
rod from extending.
4. Disconnect two hoses from boom cylinder (1).

Cap two disconnected hose openings.
1
W554-02-03-007
5. Remove bolt (6) and pin (5). 5

Attach a nylon sling onto boom cylinder (1). Hoist
and remove boom cylinder (1).
W527-04-02-010
W4-2-13
Install Boom Cylinder

in) or less).
IMPORTANT: Apply grease on the lip of the dust

seal for boom cylinder (1) and on
boss side (both bottom and rod
sides).
IMPORTANT: Apply grease on the surface of pin Swing Post

(5). 5
1. Align the pin (5) holes of boom cylinder (1) and

the swing post. Insert the shims to both sides of
the cylinder tube boss.
2. Align the bolt (6) holes of the swing post and pin
(5). Drive pin (5) in with a hammer. 1
IMPORTANT: Apply LOCTITE #262 on bolt (6). 6

When installing nuts, clearance of 3
to 5 mm (0.12 to 0.20 in) should be W527-04-02-010
left between nuts and the boss of
swing post.
3. Attach a nylon sling onto boom cylinder (1) to hold

it by crane.
Align the pin hole on the cylinder bottom side with
the cylinder mounting hole. Insert pin (5). Secure
pin (5) with bolt (6).
1
4. Connect two hoses to boom cylinder (1).
W527-04-02-009
W4-2-14

side will rise as the temperature of the hy-
the seals and rings. 3
4
5. Start the engine. Operate the cylinder rod retract-
ing fully to the stroke end so as to let the clean
hydraulic oil flow into the boom cylinder (1). 1
hole both in boom cylinder rod and the boom.
NOTE: When the work in procedure 5 is finished, Boom
7
leased.
6. Insert the shims into both sides of the cylinder rod 2

boss. Drive pin (3) in with a hammer. Install bolt
W527-04-01-001
(4).
7. Install cover (2) with bolt (7).

eral times to release the air from the
circuit and check each connection
of hoses for any oil leakage.
W4-2-15
DISASSEMBLE BOOM CYLINDER
1
24
23
22
21
20
19
18
17
13
12
28
15
27
26
8
7
6
5
4
3
2
25
W1LS-04-02-001
1- Piston Rod 7- Bushing 18 - Slide Ring 24 - Slide Ring

2- Wiper Ring 8- U-Ring 19 - Piston 25 - Cylinder Tube
3- Cylinder Head 12 - Backup Ring 20 - Steel Ball 26 - Collar
4- O-Ring 13 - O-Ring 21 - Set Screw 27 - Cushion Seal
5- Backup Ring 15 - Spacer 22 - Seal Ring 28 - Holder
6- O-Ring 17 - Cushion Bearing 23 - O-Ring
W4-2-16
Disassemble Boom Cylinder 3. Loosen cylinder head (3) with a hook wrench and
• Be sure to read “Precautions for Disassembly and pull the piston rod (1) assembly (with protective
Assembly” thoroughly on page W1-1-1 before cover on it) out of cylinder tube (25).
starting the disassembly work. Cylinder head (3) diameter:
• The disassembly procedure below starts on the 97 mm (3.8 in) (ZAXIS30),
premise that the hydraulic line has been removed. 105 mm (4.1 in) (ZAXIS35),
110 mm (4.3 in) (ZAXIS40),
115 mm (4.5 in) (ZAXIS50)
CAUTION: Boom cylinder weight:
34.5 kg (76 lb) (ZAXIS30), Hook Wrench
36 kg (80 lb) (ZAXIS35),
55 kg (125 lb) (ZAXIS40),
60 kg (135 lb) (ZAXIS50)
25
IMPORTANT: When draining hydraulic oil from the
cylinder, move piston rod (1) slowly
to prevent the oil from splashing.
1. Clamp the mounting portion (clevis part) of the 3

cylinder tube (25) pin in a vise and secure it
horizontally to drain hydraulic oil from the cylinder.
1 W506-04-02-004
IMPORTANT: The lock washer in cylinder head (3)
is provided on cylinder tube (25) to IMPORTANT: Set screw (21) was crimped with a
form an integral part. Take care not punch in two places after it was
to damage cylinder tube (25) and tightened. Before loosening set
cylinder head (3) when bending and screw (21), cut away the crimped
extending the lock washer. portions.
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to 4. Secure piston rod (1) horizontally and remove set
install a protective cover on piston rod (1) and screw (21) and steel ball (20) from piston (19).
then let the lock washer of cylinder head (3) : 4 mm (ZAXIS30, 35)
protrude out. : 5 mm (ZAXIS40, 50)
Lock Washer 5. Remove piston (19) and cushion bearing (17)

from piston rod (1).
: 55 mm (ZAXIS30, 35)
: 65 mm (ZAXIS40, 50)
2 4
W506-04-02-003
W4-2-17
24
23
22
19
18
13
12
28
15
27
26
8
7
6
5
4
3
2
W1LS-04-02-001
W4-2-18
6. Wind a tape on the screw thread of piston rod (1) 13. Remove O-ring (6), backup ring (5), O-ring (4)
to protect the cylinder head (3) seal, and then from the outer side of cylinder head (3).
remove cylinder head (3) from piston rod (1).
IMPORTANT: Bushing (7) cannot be reused. When
IMPORTANT: Slide rings (18) and (24) cannot be removing the bushing (7), replace
reused. When disassembling the the new one for reassembling.
cylinder, replace with new ones.
14. Remove bushing (7) from the inner side of
7. Secure piston (19) in a vise and remove slide cylinder head (3).
rings (18) and (24) from piston (19).
NOTE: Insert the screwdriver into the bushing (7)
IMPORTANT: When removing the seal parts, take groove to pull bushing (7) out.
care not to damage them.
8. Secure piston (19) in a vise and tap on a

slotted-head screwdriver with a hammer to cut off
seal ring (22) and O-ring (23) to remove them
from piston (19).
19
22, 23
W506-04-02-007
9. Remove the holder (28) assembly from cylinder

head (3).
10. Remove backup ring (12) and O-ring (13) from the
outer side of holder (28).
11. Remove spacer (15) and cushion seal (27) and

collar (26) from the inner side of holder (28).
12. Remove wiper ring (2) and U-ring (8) from the
inner side of cylinder head (3).
W4-2-19
ASSEMBLE BOOM CYLINDER
20 21 18 22, 23 24 19 17 1 25 13 12 28 6 5 4 3
15 27 26 8 7
W1LS-04-02-002
1- Piston Rod 7- Bushing 18 - Slide Ring 24 - Slide Ring

2- Wiper Ring 8- U-Ring 19 - Piston 25 - Cylinder Tube
3- Cylinder Head 12 - Backup Ring 20 - Steel Ball 26 - Collar
4- O-Ring 13 - O-Ring 21 - Set Screw 27 - Cushion Seal
5- Backup Ring 15 - Spacer 22 - Seal Ring 28 - Holder
6- O-Ring 17 - Cushion Bearing 23 - O-Ring
W4-2-20
Assemble Boom Cylinder
• Be sure to read “Precautions for Disassembly and IMPORTANT: Pay attention to the direction when
Assembly” thoroughly on page W1-1-1 before installing U-ring (8).
starting the assembly work.
2. Install U-ring (8) to cylinder head (3).
CAUTION: Boom cylinder weight: 3
34.5 kg (76 lb) (ZAXIS30), 8
36 kg (80 lb) (ZAXIS35),
55 kg (125 lb) (ZAXIS40),
60 kg (135 lb) (ZAXIS50)
IMPORTANT: Apply the hydraulic oil to the inner

side of cylinder head (3). In addition,
after pressing bushing (7) in, be sure
to check that the matching surfaces W506-04-02-011
of the U-ring (8) mounting portion

and bushing (7) are smooth and flat. 3. Install wiper ring (2) to cylinder head (3) using
If they are not, U-ring (8) may be special tool.
damaged by making contact with Special Tool:
bushing (7) when installing it. ST 8046 (ZAXIS30, 35)
3 7 ST 8048 (ZAXIS40, 50)
U-Ring (8)
mounting portion
The matching Special Tool

surfaces here
shall be smooth 3
and flat.
W577-04-02-007
1. Press bushing (7) into cylinder head (3) using

special tool. 2
Special Tool:
ST 7276 (ZAXIS30, 35) W506-04-02-012
ST 7275 (ZAXIS40, 50)

4. Install O-ring (4), backup ring (5) and O-ring (6) to
Special Tool
the outer side of cylinder head (3).
7
3
W506-04-02-010
W4-2-21
18 22, 23 24 19 1 25 13 12 28 3
15 27 26
W1LS-04-02-002
W4-2-22
5. Install collar (26), cushion seal (27) and spacer IMPORTANT: Adjust seal ring (22). If not adjusting,
(15) to the inner side of holder (28). Install O-ring piston (19) cannot be installed to
(13) and backup ring (12) to the outer side of cylinder tube (25).
holder (28).
8. Insert special tool into piston (19) to adjust seal
6. Install the holder (28) assembly to cylinder head ring (22) until it becomes the original one.
(3). Special Tool:
ST 2627 (ZAXIS30)
IMPORTANT: Make sure that O-ring (23) is not ST 2599 (ZAXIS35)
twisted after installing it. ST 2598 (ZAXIS40)
ST 2336 (ZAXIS50)
7. Install O-ring (23) to piston (19), and then install
seal ring (22) using special tools 1 and 2.
Special Tool 1:
22
ST 2623 (ZAXIS30)
ST 2591 (ZAXIS35) 19
ST 2590 (ZAXIS40) Special Tool
ST 2334 (ZAXIS50)
Special Tool 2:
ST 2625 (ZAXIS30)
ST 2595 (ZAXIS35)
ST 2594 (ZAXIS40)
ST 2335 (ZAXIS50) W566-04-02-011
IMPORTANT: When installing slide rings (18) and

Special Tool 2 (24), do not align their split portion.
22 9. Install slide ring (18) and (24) to piston (19).

Special Tool 1
10. Wrap the piston rod (1) screw thread with a
23 protective tape and then install the cylinder head
(3) assembly to piston rod (1) while rotating the
former one.
19
W566-04-02-010
W4-2-23
20 21 18 24 19 17 1 25 3
W1LS-04-02-002
W4-2-24
IMPORTANT: Pay attention to the direction when IMPORTANT: Apply hydraulic oil to the packing
installing cushion bearing (17). parts.
11. Install cushion bearing (17) and the piston (19) 14. Tighten cylinder head (3) to cylinder tube (25) with
assembly to piston rod (1). a hook wrench. Bend the lock washer to prevent it
ZAXIS30: from loosening.
: 55 mm Cylinder head (3) diameter:
: 1110 N･m (115 kgf･m, 830 lbf･ft) ZAXIS30:
ZAXIS35: 97 mm (3.8 in)
: 55 mm : 450 N･m (46 kgf･m, 330 Ibf･ft)
ZAXIS40: 105 mm (4.1 in)
: 65 mm : 490 N･m (50 kgf･m, 360 Ibf･ft)
ZAXIS50: 110 mm (4.3 in)
: 65 mm : 530 N･m (54 kgf･m, 390 Ibf･ft)
115 mm (4.5 in)
IMPORTANT: When the work of installing set : 570 N･m (58 kgf･m, 420 Ibf･ft)
screw (21) is finished, crimp it at two
places with a punch in order to
Hook Wrench
prevent it from loosening.
12. Install steel ball (20) into piston (19) and then
install set screw (21) on it.
ZAXIS30, 35:
: 4 mm
: 16.2 N⋅m (1.7 kgf⋅m, 12.3 lbf⋅ft)
ZAXIS40, 50:
: 5 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23.1 lbf⋅ft) 25
IMPORTANT: Take care not to let slide rings (18) W506-04-02-019
and (24) drop from piston (19) when

inserting the piston rod (1) assembly.
In addition, care should be taken not
to damage the piston rod (1)
assembly and insert the piston rod
(1) assembly straightly. Apply
hydraulic oil to the packing parts.
13. Secure cylinder tube (25) horizontally in a vise,

and then insert the piston rod (1) assembly into
cylinder tube (25).
W4-2-25
DISASSEMBLE ARM CYLINDER
27
1 26
25
24
22
21
20
19
18
17
16
15
11
10
30
13
29
28
8
9
6
5
4
3
2
23
W1LS-04-02-003
1- Piston Rod 9- Bushing 18 - Steel Ball 22 - Cushion Bearing

2- Wiper Ring 10 - Backup Ring 19 - Set Screw 23 - Cushion Seal
3- Cylinder Head 11 - O-Ring 20 - Seal Ring 24 - Stopper
4- O-Ring 13 - Spacer 21 - O-Ring 25 - Collar
5- Backup Ring 15 - Cushion Bearing 22 - Slide Ring 26 - Cushion Seal
6- O-Ring 16 - Slide Ring 23 - Cylinder Tube 30 - Holder
8- U-Ring 17 - Piston 24 - Snap Ring
W4-2-26
Disassemble Arm Cylinder 3. Loosen cylinder head (3) with a hook wrench and
• Be sure to read “Precautions for Disassembly and pull piston rod (1) (with protective cover on it ) out
Assembly” thoroughly on page W1-1-1 before of cylinder tube (23).
starting the disassembly work. Cylinder head (3) diameter:
100 mm (3.9 in) (ZAXIS40, 50)
Hook Wrench
29.5 kg (65 lb) (ZAXIS30),
35 kg (80 lb) (ZAXIS35),
42 kg (93 lb) (ZAXIS40), 23
45 kg (100 lb) (ZAXIS50)
IMPORTANT: When draining off hydraulic oil from

the cylinder, piston rod (1) shall be
moved slowly in order to prevent the
oil from splashing. 3
1. Clamp the cylinder tube (23) pin mounting portion

(clevis part) in a vise and secure it horizontally to 1
W506-04-02-004
drain off hydraulic oil from the cylinder.
IMPORTANT: Set screw (19) was crimped with a
IMPORTANT: The lock washer in cylinder head (3) punch in two places after it was
is provided on cylinder tube (23) to tightened. Before loosening set
form an integral part. Take care not screw (19), cut away the crimped
to damage cylinder tube (23) and portions.
cylinder head (3) when bending and
extending the lock washer. 4. Secure piston rod (1) horizontally and remove set
screw (19) and steel ball (18) from piston (17).
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to : 4 mm
install a protective cover on piston rod (1) and
then let the lock washer in cylinder head (3) 5. Remove piston (17) and cushion bearing (15)
protrude out. from piston rod (1).
: 50 mm (ZAXIS30)
Lock Washer : 55 mm (ZAXIS35)
: 60 mm (ZAXIS40, 50)
6. Remove snap ring (24) from piston rod (1) with a

plastic hammer.
7. Move cushion bearing (25) to the screw side of

piston rod (1) to remove stopper (27) from piston
rod (1).
1 3
W506-04-02-003
W4-2-27
1 26
25
22
21
20
17
16
11
10
30
13
29
28
8
9
6
5
4
3
2
W1LS-04-02-003
W4-2-28
8. Remove cushion bearing (25) and cushion seal 14. Remove wiper ring (2) and U-ring (8) from the
(26) from piston rod (1). inner side of cylinder head (3).
9. Put a cover on the screw threads of piston rod (1) 15. Remove O-ring (6), backup ring (5) and O-ring (4)
to protect the cylinder head (3) seal, and then from the outer side of cylinder head (3).
remove the cylinder head from piston rod (1).
IMPORTANT: Slide rings (16) and (22) cannot be removing bushing (9), replace the
reused. When disassembling the new one for reassembling.
10. Secure piston (17) in a vise and remove slide cylinder head (3).
IMPORTANT: When removing the seal parts, take groove to pull out bushing (9).

from piston (17).
17
20, 21
W506-04-02-007
12. Remove the holder (30) assembly from the outer

side of cylinder head (3).
13. Remove backup ring (10), O-ring (11) from the

outer side of the holder (30) assembly. Remove
spacer (13), cushion seal (29) and collar (28) from
the inner side of holder (30).
W4-2-29
ASSEMBLE ARM CYLINDER
27 25 24 18 19 22 20、21 16 17 15 23 1 11 10 30 6 5 4 3 2
13 29 28 8 9
26
W1LS-04-02-004
1- Piston Rod 9- Bushing 18 - Steel Ball 25 - Cushion Bearing

2- Wiper Ring 10 - Backup Ring 19 - Set Screw 26 - Cushion Seal
3- Cylinder Head 11 - O-Ring 20 - Seal Ring 27 - Stopper
4- O-Ring 13 - Spacer 21 - O-Ring 28 - Collar
5- Backup Ring 15 - Cushion Bearing 22 - Slide Ring 29 - Cushion Seal
6- O-Ring 16 - Slide Ring 23 - Cylinder Tube 30 - Holder
8- U-Ring 17 - Piston 24 - Snap Ring
W4-2-30
Assemble Arm Cylinder 3. Install wiper ring (2) to cylinder head (3) using
• Be sure to read “Precautions for Disassembly and special tool.
Assembly” thoroughly on page W1-1-1 before Special Tool:
starting the assembly work. ST 8045 (ZAXIS30)
ST 8046 (ZAXIS35)
1. Press bushing (9) into cylinder head (3) using ST 8047 (ZAXIS40, 50)
special tool.
Special Tool:
ST 8056 (ZAXIS30)
ST 7276 (ZAXIS35) Special Tool
ST 7325 (ZAXIS40, 50)
3
Special Tool
9
3
W506-04-02-012

W506-04-02-010
IMPORTANT: Pay attention to the direction when 5. Install collar (28), cushion seal (29) and spacer
installing U-ring (8). (13) to the inner side of holder (30). Install backup
ring (10) and O-ring (11) to the outer side of holder
2. Install backup ring (7) and U-ring (8) to cylinder (30).
head (3).
6. Install the holder (30) assembly to cylinder head
3 (3).
8
W506-04-02-011
W4-2-31
27 25 24 22 20、21 16 17 23 1 3
26
W1LS-04-02-004
W4-2-32
IMPORTANT: Make sure that O-ring (21) is not IMPORTANT: Adjust seal ring (20). If not adjusting,
twisted after installing it. piston (17) cannot be installed to
cylinder tube (23).
seal ring (20) using special tools 1 and 2. 8. Insert special tool into piston (17) to adjust seal
Special Tool 1: ring (20) until it becomes the original one.
ST 2592 (ZAXIS30) Special Tool:
ST 2623 (ZAXIS35, 40, 50) ST 2600 (ZAXIS30)
Special Tool 2: ST 2627 (ZAXIS35, 40, 50)
ST 2596 (ZAXIS30)
ST 2625 (ZAXIS35, 40, 50)
20
Special Tool 2 17
Special Tool
20
Special Tool 1
21
W566-04-02-011
17
(22), do not align their split portion.
W566-04-02-010
9. Install slide rings (16) and (22) to piston (17).
IMPORTANT: Pay attention to the direction when

installing cushion bearing (25).
10. Install cushion seal (26) and cushion bearing (25)

onto piston rod (1) with stopper (27).
11. Install snap ring (24) onto piston rod (1) with a
plastic hammer.
12. Wrap the piston rod (1) screw threads with a

protective tape and then install the cylinder head
(3) assembly to piston rod (1) while rotating the
former one.
W4-2-33
18 19 22 16 17 15 23 1 3
W1LS-04-02-004
W4-2-34
IMPORTANT: Pay attention to the direction when IMPORTANT: Apply hydraulic oil to packing parts.
installing cushion bearing (15).
16. Tighten cylinder head (3) to cylinder tube (23) with
13. Install cushion bearing (15) and the piston (17) a hook wrench. Bend the lock washer to prevent it
assembly to piston rod (1). from loosening.
ZAXIS30: Cylinder head (4) diameter:
: 50 mm ZAXIS30:
: 820 N･m (84 kgf･m, 610 lbf･ft) 92 mm (3.6 in)
ZAXIS35: : 430 N･m (44 kgf･m, 320 Ibf･ft)
: 55 mm ZAXIS35:
ZAXIS40, 50: : 450 N･m (46 kgf･m, 333 Ibf･ft)
: 60 mm ZAXIS40, 50:
: 460 N･m (47 kgf･m, 340 Ibf･ft)
IMPORTANT: When the work of installing set
screw (19) is finished, crimp it at two Hook Wrench
places with a punch in order to
prevent it from loosening.
install set screw (19) on it.
: 4 mm
: 16.2 N･m (1.7 kgf･m, 12.3 Ibf･ft)
IMPORTANT: Take care not to let slide rings (16)

inserting the piston rod (1) assembly. 23
In addition, care should be taken not W506-04-02-019

assembly and insert the piston rod

cylinder tube (23).
W4-2-35
DISASSEMBLE BUCKET CYLINDER
1 16
15
14
13
12
11
10
8
9
6
5
4
3
2
17
W1LS-04-02-005
1- Cylinder Rod 5 - Backup Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 6 - O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8 - U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9 - Bushing 13 - Set Screw 17 - Cylinder Tube
W4-2-36
Disassemble Bucket Cylinder 3. Loosen cylinder head (3) with a hook wrench and
• Be sure to read “Precautions for Disassembly and pull piston rod (1) (with protective cover on it) out
Assembly” thoroughly on page W1-1-1 before of cylinder tube (17).
starting the repair work. Cylinder head (3) diameter:
90 mm (3.5 in) (ZAXIS40),
92 mm (3.6 in) (ZAXIS50)
CAUTION: Bucket cylinder weight:
22.5 kg (50 lb) (ZAXIS30), Hook Wrench
25 kg (55 lb) (ZAXIS35),
26 kg (57 lb) (ZAXIS40),
30 kg (66 lb) (ZAXIS50)
17
IMPORTANT: When draining hydraulic oil from the
1. Clamp the pin mounting portion (clevis part) of

cylinder tube (17) in a vise and secure it
horizontally to drain hydraulic oil from the cylinder.
1 3
W506-04-02-004
cylinder head (3) when bending and screw (13) cut away the crimped
extending the lock washer. portions.
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to 4. Secure piston rod (1) horizontally and remove set
install a protective cover on piston rod (1) and screw (13) and steel ball (12) from piston (11).
then let the lock washer in cylinder head (3) : 4 mm
protrude out.
5. Remove piston (11) from piston rod (1).
Lock Washer : 50 mm (ZAXIS30, 35, 40)
: 55 mm (ZAXIS50)
6. Wind a tape on the screw thread of piston rod (1)

to protect the cylinder head (3) seal, and then
2 4
W506-04-02-003
W4-2-37
16
15
14
11
10
8
9
6
5
4
3
2
W1LS-04-02-005
W4-2-38
IMPORTANT: Slide rings (10) and (16) cannot be
reused. When disassembling the
7. Secure piston (11) in a vise and remove slide

IMPORTANT: When removing the seal parts, take


from piston (11).
11
14, 15
W506-04-02-007

10. Remove O-ring (6), backup ring (5) and O-ring (4)
from the outer side of cylinder head (3).

removing bushing (9), replace the
new one for reassembling.

cylinder head (3).

groove to pull bushing (9) out.
W4-2-39
ASSEMBLE BUCKET CYLINDER
12 13 16 14, 15 10 11 17 1 6 5 4 3 2
8 9
W1LS-04-02-006
1- Cylinder Rod 5- Backup Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 6- O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
W4-2-40
Assemble Bucket Cylinder 3. Install wiper ring (2) to cylinder head (3) using
• Be sure to read “Precautions for Disassembly and special tool.
Assembly” thoroughly on page W1-1-1 before Special Tool:
starting the assembly work. ST 8045 (ZAXIS30, 35, 40)
ST 8046 (ZAXIS50)
1. Press bushing (9) into cylinder head (3) using
special tool.
Special Tool:
ST 8056 (ZAXIS30, 35, 40) Special Tool
ST 7276 (ZAXIS50)
3
Special Tool
3
2
W506-04-02-012

W506-04-02-010
IMPORTANT: Pay Attention to the direction when

installing U-ring (8).
2. Install U-ring (8) to cylinder head (3).

3
W506-04-02-011
W4-2-41
16 14, 15 10 11 17 1 3
W1LS-04-02-006
W4-2-42
IMPORTANT: Make sure that O-ring (15) is not IMPORTANT: Adjust seal ring (14). If not adjusting,
twisted after installing it. piston (11) cannot be installed to
cylinder tube (17).
seal ring (14) using special tools 1 and 2. 6. Insert special tool (ST 2479) into piston (11) to
Special Tool 1: adjust seal ring (14) until it becomes the original
ST 2934 (ZAXIS30) one.
ST 2622 (ZAXIS35, 40) Special Tool:
ST 2592 (ZAXIS50) ST 2934 (ZAXIS30)
Special Tool 2: ST 2626 (ZAXIS35, 40)
ST 2934 (ZAXIS30) ST 2600 (ZAXIS50)
ST 2624 (ZAXIS35, 40)
ST 2596 (ZAXIS50)
14
Special Tool 2
11 Special Tool
14
Special Tool 1
15
11 W566-04-02-011

W566-04-02-010
(16), do not align their split portion.
8. Wrap the piston rod (1) screw thread with a

(3) assembly to the piston rod while rotating the
former one.
9. Install the piston (11) assembly to piston rod (1).

ZAXIS30:
: 50 mm
: 590 N･m (60 kgf･m, 430 lbf･ft)
ZAXIS35:
: 50 mm
: 520 N･m (53 kgf･m, 380 lbf･ft)
ZAXIS40:
: 50 mm
: 680 N･m (69 kgf･m, 500 lbf･ft)
ZAXIS50:
: 50 mm
: 870 N･m (89 kgf･m, 640 lbf･ft)
W4-2-43
12 13 16 10 11 17 1 3
W1LS-04-02-006
W4-2-44
IMPORTANT: When the work of installing set IMPORTANT: Apply hydraulic oil to packing parts.
screw (13) is finished, crimp it at two
places with a punch in order to 12. Tighten cylinder head (3) to cylinder tube (17) with
prevent it from loosening. a hook wrench. Bend the lock waser to prevent it
from loosening.
10. Install steel ball (12) into piston (11) and then Cylinder head (3) diameter:
install set screw (13) on it. ZAXIS30:
: 4 mm 82 mm (3.2 in)
: 16.2 N･m (1.7 kgf･m, 12.3 Ibf･ft) : 350 N･m (36 kgf･m, 260 Ibf･ft)
ZAXIS35:
IMPORTANT: Take care not to let slide rings (10) 85 mm (3.3 in)
and (16) drop from piston (11) when : 390 N･m (40 kgf･m, 290 Ibf･ft)
inserting the piston rod (1) assembly. ZAXIS40:
In addition, care should be taken not 90 mm (3.5 in)
to damage the piston rod (1) : 390 N･m (40 kgf･m, 290 Ibf･ft)
assembly and insert the piston rod ZAXIS50:
(1) assembly straightly. Apply 92 mm (3.6 in)
hydraulic oil to the packing parts. : 430 N･m (44 kgf･m, 320 Ibf･ft)
11. Secure cylinder tube (17) horizontally in a vise, Hook Wrench

cylinder tube (17).
17
W506-04-02-019
W4-2-45
DISASSEMBLE BOOM SWING CYLINDER,
BLADE CYLINDER
17
16
15
1 14
13
12
11
8
7
6
5
4
3
2
18
W1LS-04-02-007

3- Cylinder Head 7- Bushing 13 - Steel Ball 17 - Slide Ring
4- O-Ring 8- U-Ring 14 - Set Screw 18 - Cylinder Tube
W4-2-46
Disassemble Boom Swing Cylinder and Blade 3. Loosen cylinder head (3) with a hook wrench and
Cylinder pull piston rod (1) (with protective cover on it) out
• Be sure to read “Precautions for Disassembly and of cylinder tube (18).
Assembly” thoroughly on page W1-1-1 before Cylinder head (3) diameter:
starting any repair work. ZAXIS30, 35:
• The disassembly procedure below starts on the 105 mm (4.1 in) (Boom swing),
premise that the hydraulic line has been removed. 110 mm (4.3 in) (Blade)
ZAXIS40, 50:
115 mm (4.5 in) (Boom swing),
CAUTION: Boom swing cylinder weight:
120 mm (4.7 in) (Blade)
32.5 kg (72 lb) (ZAXIS30, 35),
45 kg (100 lb) (ZAXIS40, 50)
Hook Wrench
Blade cylinder weight:
21.5 kg (47 lb) (ZAXIS30, 35),
35 kg (77 lb) (ZAXIS40, 50)
IMPORTANT: When draining hydraulic oil from the 18

1. Clamp the pin mounting portion (clevis part) of

cylinder tube (18) in a vise and secure it
horizontally to drain hydraulic oil out from the
cylinder.
3
1 W506-04-02-004
cylinder head (3) when bending and screw (14), cut away the crimped
extending the lock washer in portions.
cylinder head (3).
4. Secure piston rod (1) horizontally to remove set
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to screw (14) and steel ball (13) from piston (12).
install a protective cover on piston rod (1) and : 4 mm
then let the lock plate protrude out. : 5 mm (Blade: ZAXIS40, 50)
Lock Washer 5. Remove piston (12) from piston rod (1).

: 55 mm (ZAXIS30, 35)
: 60 mm (Boom swing: ZAXIS40, 50)
: 70 mm (Blade: ZAXIS40, 50)
2 4
W506-04-02-003
W4-2-47
17
16
15
1
12
11
8
7
6
5
4
3
2
W1LS-04-02-007
W4-2-48
6. Wind a tape on the screw thread of piston rod (1)
to protect the cylinder head (3) seal, and then
IMPORTANT: Side rings (11) and (17) cannot be

reused.
When disassembling the cylinder,
replace with new ones.
7. Secure piston (12) in a vise and remove slide

IMPORTANT: When removing the seal parts, take


from piston (12).
12
15, 16
W506-04-02-007

10. Remove O-ring (6), backup ring (5) and O-ring (4)
from the outer side of cylinder head (3).

removing bushing (7), replace the
new one for reassembling.

cylinder head (3).

groove to pull bushing (7) out.
W4-2-49
ASSEMBLE BOOM SWING CYLINDER,
BLADE CYLINDER
13 14 17 15, 16 11 12 18 1 6 5 4 3 2
8 7
W1LS-04-02-006

3- Cylinder Head 7- Bushing 13 - Steel Ball 17 - Slide Ring
4- O-Ring 8- U-Ring 14 - Set Screw 18 - Cylinder Tube
W4-2-50
Assemble Boom Swing Cylinder and Blade
Cylinder IMPORTANT: Pay attention to the direction when
• Be sure to read “Precautions for Disassembly and installing U-ring (8).
Assembly” thoroughly on page W1-1-1 before
starting the assembly work. 2. Install U-ring (8) to the inner side of cylinder head
(3).
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3). In addition, after 3
pressing bushing (7), be sure to
check that the matching surfaces of 8
the U-ring (8) mounting portion and
bushing (7) are smooth and flat. If
they are not, U-ring (8) may be
damaged by making contact with
bushing (7) when installing it.
3 7 U-Ring (8)
mounting portion W506-04-02-011
The matching 3. Install wiper ring (2) to cylinder head (3) using
surfaces here
shall be smooth special tool.
and flat. Special Tool:
Boom swing:
ST 8046 (ZAXIS30, 35)
ST 8047 (ZAXIS40, 50)
W577-04-02-007
Blade:
1. Press bushing (7) into cylinder head (3) using ST 8046 (ZAXIS30, 35)
special tool. ST 8048 (ZAXIS40, 50)
Special Tool:
Boom swing:
ST 7276 (ZAXIS30, 35) Special Tool
ST 7325 (ZAXIS40, 50)
3
Blade:
ST 7276 (ZAXIS30, 35)
ST 7275 (ZAXIS40, 50)
Special Tool
7
2
3
W506-04-02-012
W506-04-02-010
W4-2-51
17 15, 16 11 12 18 1 6 5 4 3
W1LS-04-02-006
W4-2-52
4. Install O-ring (4), backup ring (5) and O-ring (6) to IMPORTANT: Adjust seal ring (15). If not adjusting,
the outer side of cylinder head (3). piston (12) cannot be installed to
cylinder tube (18).
IMPORTANT: Make sure that O-ring (16) is not
twisted after installing it. 6. Insert special tool into piston (12) to adjust seal
ring (15) until it becomes the original one.
seal ring (15) using special tools 1 and 2.
Special Tool 1:
15
Boom swing:
ST 2591 (ZAXIS30, 35)
ST 2334 (ZAXIS40, 50) Special Tool
Blade:
ST 2590 (ZAXIS30, 35)
ST 2593 (ZAXIS40, 50)
12
Special Tool 2:
Boom swing:
ST 2595 (ZAXIS30, 35) W566-04-02-011
ST 2335 (ZAXIS40, 50)

Blade: IMPORTANT: When installing slide rings (11) and
ST 2594 (ZAXIS30, 35) (17), do not align their split portion.
ST 2597 (ZAXIS40, 50)
Special Tool 2 8. Wrap the piston rod (1) screw thread with
15 (3) assembly to piston rod (1) while rotating the
Special Tool 1 former one.
16
12
W566-04-02-010
W4-2-53
13 14 17 11 12 18 1 3
W1LS-04-02-006
W4-2-54
9. Install the piston (12) assembly to piston rod (1). IMPORTANT: Apply hydraulic oil to the packing
ZAXIS30, 35: parts.
(Boom swing)
: 55 mm 12. Tighten cylinder head (3) to cylinder tube (18) with
: 1260 N⋅m (129 kgf⋅m, 930 lbf⋅ft) a hook wrench. Bend the lock washer to prevent it
(Blade) from loosening.
: 55 mm Cylinder head (3) diameter:
: 1130 N⋅m (115 kgf⋅m, 830 lbf⋅ft) ZAXIS30, 35:
ZAXIS40, 50: (Boom swing)
(Boom swing) 105 mm (4.1 in)
: 60 mm : 490 N･m (50 kgf･m, 360 Ibf･ft)
: 1780 N⋅m (185 kgf⋅m, 1340 lbf⋅ft) (Blade)
(Blade) 110 mm (4.3 in)
: 70 mm : 530 N･m (54 kgf･m, 390 Ibf･ft)
: 2170 N⋅m (225 kgf⋅m, 1630 lbf⋅ft) ZAXIS40, 50:
(Boom swing)
IMPORTANT: When the work of installing set 115 mm (4.5 in)
screw (14) is finished, crimp it at two : 570 N･m (58 kgf･m, 420 Ibf･ft)
places with a punch in order to (Blade)
prevent it from loosening. 120 mm (4.7 in)
: 650 N･m (66 kgf･m, 480 Ibf･ft)
install set screw (14) on it. Hook Wrench
: 4 mm
: 16.2 N⋅m (1.7 kgf⋅m, 12.3 lbf⋅ft)
(Blade: ZAXIS40, 50)
: 5 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23.1 lbf⋅ft)
IMPORTANT: Take care not to let slide rings (11)

inserting the piston rod (1) assembly.
In addition, care should be taken not 18
assembly and insert the piston rod W506-04-02-019


cylinder tube (18).
W4-2-55
35)
Piston Rod
W105-04-02-094
Unit: mm (in)
Cylinder name Recommended outer diameter (A) after re-manufacturing
-0.025
Boom 45 -0.064 mm (1.7717 -0.0010
-0.0025 in)
-0.025
Arm (ZAXIS30) 40 -0.064 mm (1.5748 -0.0010
-0.0025 in)
-0.025 -0.0010
(ZAXIS35) 45 -0.064 mm (1.7717 -0.0025 in)
Bucket 40 -0.025
-0.064 mm (1.5748 -0.0010
–0.0025 in)
Boom swing 45 -0.025
-0.064 mm (1.7717 -0.0010
–0.0025 in)
Blade 45 -0.025
-0.064 mm (1.7717 -0.0010
-0.0025 in)
Rod Bend and Run Out

Dial Gauge
Cylinder Rod
W166-04-02-022
1 m (39.4 in)
V Block
Unit: mm (in)
Bend Run out Remedy
Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
W4-2-56
MAINTENANCE STANDARDS (ZAXIS40, 50)
Piston Rod
W105-04-02-094
Unit: mm (in)
Cylinder name Recommended outer diameter (A) after re-manufacturing
+0.023
Boom 55 -0.043 mm (2.1654 +0.0009
-0.0017 in)
Arm 50 +0.023
-0.043 mm (1.9685 +0.0009
–0.0017 in)
+0.023
Bucket (ZAXIS40) 40 -0.043 mm (1.5748 +0.0009
-0.0017 in)
+0.023 +0.0009
(ZAXIS50) 45 -0.043 mm (1.7717 -0.0017 in)
Boom swing 50 +0.023
-0.043 mm (1.9685 +0.0009
–0.0017 in)
Blade 55 +0.023
-0.043 mm (2.1654 +0.0009
-0.0017 in)
Rod Bend and Run Out

Dial Gauge
Cylinder Rod
W166-04-02-022
1 m (39.4 in)
V Block
Unit: mm (in)
Bend Run out Remedy
Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
W4-2-57
(Blank)
W4-2-58
SECTION 5
ENGINE
CONTENTS
Safety Instructions .............................................1 Fuel System ................................................ M-25
Specifications...................................................12 General ..................................................... M-25
Performance Curves ........................................18 Injection Pump .......................................... M-25
Dimensions ......................................................21 Injection Nozzle ......................................... M-31
Fuel Filter .................................................. M-31
Mechanism Governor ................................................... M-33
Feature ......................................................... M-1 Automatic Advance Timer .......................... M-37
Engine Body ................................................. M-3 Electrical System......................................... M-41
Cylinder Block ............................................. M-3 Charging System ....................................... M-41
Cylinder Head ............................................. M-3 Turbo Charger System ................................ M-43
Crank Shaft ................................................. M-5
Piston and Piston Rings .............................. M-5 Servicing
Connecting Rod .......................................... M-7 General ..........................................................S-1
Rocker Arm ................................................. M-7 Engine Identification .....................................S-1
Camshaft .................................................... M-7 General Precautions.....................................S-3
Camshaft .................................................... M-9 Tightening Torques .......................................S-5
Flywheel...................................................... M-9 Troubleshooting............................................S-8
Lubricating System ......................................M-11 Servicing Specifications..............................S-19
General ......................................................M-11 Maintenance Check List .............................S-44
Oil Pump ....................................................M-13 Check and Maintenance .............................S-47
Relief Valve ................................................M-13 Special Tools ............................................S-59
Oil Filter Cartridge......................................M-15 Engine Body.................................................S-73
Oil Pressure Switch....................................M-15 Checking and Adjusting................................S-73
Cooling System............................................M-17 Disassembling and Assembling....................S-75
General ......................................................M-17 Draining Water and Oil ...............................S-77
Water Pump ...............................................M-17 External Components .................................S-77
Thermostat.................................................M-19 Cylinder Head and Valves ..........................S-79
Radiator .....................................................M-19 Gear Case ..................................................S-83
Radiator Cap..............................................M-21 Piston and Connecting Rod ........................S-95
Intake/Exhaust System ................................M-23 Flywheel and Crankshaft ..........................S-101
Air Cleaner .................................................M-23 Servicing ....................................................S-105
Muffler........................................................M-23 Cylinder Head ..........................................S-105
Timing Gear and Camshaft....................... S-115
Piston and Connecting Rod ...................... S-119
Crankshaft................................................S-125
Cylinder ....................................................S-137
1LSW-5-1
Lubricating System .................................... S-141
Checking.................................................... S-141
Servicing .................................................... S-141
Oil Pump .................................................. S-141
Cooling System.......................................... S-145
Checking.................................................... S-145
Fan Belt ................................................... S-145
Radiator ................................................... S-145
Disassembling and Assembling ................. S-147
Fuel System............................................... S-151
Checking and Adjusting ............................. S-151
Injection Pump ......................................... S-151
Injection Nozzle ....................................... S-155
Injection Pump ......................................... S-157
Injection Nozzle ....................................... S-159
Electrical System ....................................... S-161
Checking.................................................... S-161
Starter ...................................................... S-161
Glow Plug ................................................ S-163
Starter ...................................................... S-163
Alternator ................................................. S-165
Servicing .................................................... S-171
Starter ...................................................... S-171
Alternator ................................................. S-175
Turbo Charger System............................... S-181
Checking.................................................... S-181
1LSW-5-2
—TABLE DES MATIERES—
Instructions de Securite .....................................4 Entretien
Caracteristiques...............................................14 Generalites.....................................................S-2
Courbes de Performance .................................18 Identification du Moteur ................................S-2
Dimensions ......................................................21 Precautions Generalites ...............................S-4
Couples de Serrage .....................................S-6
Mecanisme Depannage................................................. S-11
Caracteristiques............................................ M-2 Caracteristiques D’Entretien .....................S-28
Corps du Moteur ........................................... M-4 Liste des Verification D’Entretien ..............S-45
Bloc-Moteur ................................................ M-4 Verification et Entretien ..............................S-48
Culasse....................................................... M-4 Outils Speciaux ..........................................S-60
Vilebrequin .................................................. M-6 Corps du Moteur ..........................................S-74
Piston et Segments ..................................... M-6 Verification et Reglage .................................S-74
Bielle ........................................................... M-8 Demontage et Montage ................................S-76
Arbre a Cames.............................................. M-8 Vidange D’Eau et D’Huile ........................S-78
Culbuteurs .................................................. M-8 Composantes Externes ..............................S-78
Arbre a Came D’Alimentation....................M-10 Culasse et Soupapes .................................S-80
Volant.........................................................M-10 Carter de Distribution .................................S-84
System de Lubrification................................M-12 Piston et Bielle ...........................................S-96
Generalites ................................................M-12 Volant et Vilebrequin ................................S-102
Pompe a Huile ...........................................M-14 Entretien.....................................................S-106
Soupape de Decharge ...............................M-14 Culasse ....................................................S-106
Cartouche de Filter a Huile ........................M-16 Pignon de Distribution et Arbre a Came ... S-116
Manocontact de pression D’Huile .............M-16 Piston et Bielle .........................................S-120
Systeme de Refroidissement .......................M-18 Vilebrequin ...............................................S-126
Generalites ................................................M-18 Cylindre ....................................................S-138
Pompe a Eau .............................................M-18 Systeme de Lubrification ............................S-142
Thermostat.................................................M-20 Verification .................................................S-142
Radiateur ...................................................M-20 Entretien.....................................................S-142
Bouchon du Raidiateur............................. M-22 Pompe a Huile..........................................S-142
Admission et Echappement .........................M-24 Systeme de Refroidissement......................S-146
Filter a Air ..................................................M-24 Verification .................................................S-146
Pot D’Echappement ..................................M-24 Courroie de Ventilateur.............................S-146
System D’Alimentation................................M-26 Radiateur..................................................S-146
Generalites ................................................M-26 Demontage et Montage ..............................S-148
Pompe D’Injection.....................................M-26 Systeme D’Alimentation ............................S-152
Injecteurs ...................................................M-32 Verification et Reglage ...............................S-152
Filtre a Carburant .......................................M-32 Pompe D’Injection ...................................S-152
Regulateur .................................................M-34 Injecteurs .................................................S-156
Minuterie D’Avance a Automatique ...........M-38 Demontage et Montage ..............................S-158
Systeme Electrique ......................................M-42 Pompe D’Injection ...................................S-158
Circuit de Charge .......................................M-42 Injecteurs .................................................S-160
Systeme Turbochargeur...............................M-44
1LSW-5-3
Systeme Electrique .................................... S-162
Verification ................................................. S-162
Demarreur................................................ S-162
Bougie de Prechauffage........................... S-164
Demontage et Montage.............................. S-164
Demarreur................................................ S-164
Alternateur ............................................... S-166
Verification ................................................. S-172
Demarreur................................................ S-172
Alternateur ............................................... S-176
Systeme Turbocharger............................... S-182
Verification ................................................. S-182
Demontage et Montage.............................. S-186
1LSW-5-4
—VERZEICHNIS—
Sicherheit Zuerst................................................8 Wartung
Technische Merkmale ......................................16 Allgemeines ...................................................S-2
Leistungskurven...............................................18 Motor Kennzeichnung...................................S-2
Abmessungen ..................................................21 Allgemeines Vorkehrungen...........................S-4
Anzugsdrehmomente ...................................S-7
Mechanismus Storungssuche ...........................................S-15
Merkmale ...................................................... M-2 Wartungsdaten ...........................................S-35
Motorkorper .................................................. M-4 Wartungs-Checkliste ..................................S-46
Zylinderblock............................................... M-4 Uberprufung und Wartung ..........................S-48
Zylinderkopf ................................................ M-4 Spezialwerkzeuge ......................................S-60
Kurbelwelle ................................................. M-6 Motorkorper..................................................S-74
Kolben und Kolbenrine................................ M-6 Uberprufung und Einstellung ........................S-74
Pleuelstange ............................................... M-8 Ausbau und Einbau ......................................S-76
Kipphebel .................................................... M-8 Ablassen Von Wasser und Ol .....................S-78
Nockenwelle ............................................... M-8 Aussere Bauteile ........................................S-78
Kraftstoff-Nockenwelle ...............................M-10 Zylinderkopf und Ventile .............................S-80
Schwungrad ...............................................M-10 Getriebegehause........................................S-84
Schmierungssystem.....................................M-12 Kolben und Pleuelstange............................S-96
Allgemeines ...............................................M-12 Schwungrad und Kurbelwelle ...................S-102
Olpumpe ....................................................M-14 Wartung......................................................S-106
Uberdruckventil ..........................................M-14 Zylinderkopf..............................................S-106
Olfilterpatrone ............................................M-16 Steuerung und Nockenwelle ..................... S-116
Oldruckschalter ..........................................M-16 Kolben und Pleuelstange..........................S-120
Kuhlungssystem ..........................................M-18 Kurbelwelle...............................................S-126
Allgemeines ...............................................M-18 Zylinder ....................................................S-138
Wasserpumpe ............................................M-18 Schmierungssystem ...................................S-142
Thermostat.................................................M-20 Uberprufung ...............................................S-142
Kuhler ........................................................M-20 Wartung......................................................S-142
Kuhlerverschlusskappe ..............................M-22 Olpumpe...................................................S-142
Ansaug-und Auspuffsystem .........................M-24 Kuhlungssystem .........................................S-146
Luftfilter ......................................................M-24 Uberprufung ...............................................S-146
Auspufftopf.................................................M-24 Lufterriemen .............................................S-146
Kraftstoff-System .........................................M-26 Kuhler.......................................................S-146
Allgemines .................................................M-26 Ausbau und Einbau ....................................S-148
Einspritzpumpe ..........................................M-26 Kraftstoffsystem .........................................S-152
Einspritzduse .............................................M-32 Uberprufung und Einstellung ......................S-152
Kraftstofffilter..............................................M-32 Einspritzpumpe.........................................S-152
Drehzahlregler ...........................................M-34 Einspritzduse............................................S-156
Automatischer Versteller ............................M-38 Ausbau und Einbau ....................................S-158
Electrisches System.....................................M-42 Einspritzpumpe.........................................S-158
Ladesystem................................................M-42 Einspritzduse............................................S-160
Turboladersystem ........................................M-44
1LSW-5-5
Elektrischessystem .................................... S-162
Uberprufung............................................... S-162
Anlasser................................................... S-162
Gluhkerze ................................................ S-164
Ausbau und Einbau.................................... S-164
Anlasser................................................... S-164
Wechselstrom-Lichtmaschine .................. S-166
Uberprufung............................................... S-172
Anlasser................................................... S-172
Wechselstromlicht-Maschine.................... S-176
Turboladersystem ...................................... S-182
Uberprufung............................................... S-182
Ausbau und Einbau.................................... S-186
1LSW-5-6

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Manual No.

30 35 40 50 Excavator Workshop Manual

PRINTED IN SINGAPORE (PS)

Zaxis30/35/40/50-Wsh 1 25/4/03, 3:00 PM

• Each page has a number, located on the center

Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

• SI Units (International System of Units) are used in 2

To Convert Quantity To Convert Into Multiply By

All information, illustrations and specifications in this

COPYRIGHT (C) 2003

• When you see this symbol on your machine or in this

UNDERSTAND SIGNAL WORDS

• DANGER indicates an imminently hazardous situation

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

• Safety signs should be installed, maintained and

• If a safety sign or this manual is damaged or missing,

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher on hand.

You may need:

Be sure to wear the correct equipment and clothing for

• Avoid wearing loose clothing, jewelry, or other items

PROTECT AGAINST NOISE

• Wear a suitable hearing protective device such as

• In the walk-around inspection, be sure to cover all

ADJUST THE OPERATOR'S SEAT

• The seat should be adjusted whenever changing the

• Prior to operating the machine, thoroughly examine

MOVE AND OPERATE MACHINE SAFELY

• Take extra care not to run over bystanders. Confirm

• Start the engine only from the operator's seat.

• If the engine must be jump started, be sure to follow

KEEP RIDERS OFF MACHINE

• Only allow the operator on the machine. Keep riders

• Investigate the configuration and ground conditions of

stones or debris exist.

PROTECT AGAINST FALLING STONES AND

CONFIRM DIRECTION OF MACHINE TO

• Before driving the machine, confirm the position of

• Pushing the travel levers forward moves the

• Traveling on a grade may cause the machine to slip SA-663

or to overturn, possibly resulting in serious injury or

• When traveling up or down a grade, keep the

• Traveling across the face of slope or steering on a

To avoid back-over and swing accidents:

INTO THE WORK AREA. USE THE HORN OR

• Keep all persons clear from the area of operation and

NEVER POSITION BUCKET OVER ANYONE

• If the footing starts to collapse and if retreat is not

• Prepare machine operating area flat.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

NEVER UNDERCUT A HIGH BANK

• Before digging check the location of cables, gas lines,

OPERATE WITH CAUTION

• Take care to avoid hitting overhead obstacles with the

AVOID POWER LINES