Professional Documents
Culture Documents
Zx135us Workshop Manual
Zx135us Workshop Manual
: KM-187E
Vol. No. : W187E-02
110 125US
120 135US
135UR
Excavator
Service Manual (Manual No. KM-187E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO187E
Technical Manual (Troubleshooting) : Vol. No. TT187E
Workshop Manual : Vol. No. W187E
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
UNITS USED
2
• SI Units (International System of Units) are used in 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 To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume 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
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688
SA-688
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 re-
placed when necessary.
• If a safety sign or this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other
replacement parts (be sure to state machine
model and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel to SA-003
SA-2
SAFETY
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 at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
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
SA-434
INSPECT MACHINE
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all
dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operator’s
work boots the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you mounting and dismounting the ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• 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 mounting and dis-
mounting the machine.
SA-439
008-E01B-0439
009-E01A-0378
SA-6
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 SA-237
is in operation to minimize the chance of injury
from an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
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 in the operator’s manual.
• 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.
S013-E01A-0032
SA-8
SAFETY
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 the operator should be on the machine.
Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0379
SA-379
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-9
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the
direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay
around the machine while traveling.
SA-387
SA-388
019-E01D-0492
SA-590
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control 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.
SA-392
020-E08A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440
unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
• 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-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-14
SAFETY
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
SA-432
033-E09B-0390
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.
034-E01A-0496
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.
S035-E08A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious
injury.
• Before performing any work on the machine,
attach a “Do Not Operate” tag on the control
lever.
S501-E01A-0287
SA-287
502-E01A-0026
SA-026
SA-20
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 away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot. SA-344
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
504-E01A-0034 SA-034
SA-040
S522-E01A-0040
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
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.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
• If a 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.
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
SA-405
513-E01A-0405
S515-E01A-0309
SA-29
SAFETY
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
can damage the Earth’s atmosphere. SA-226
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.
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology ......... W1-1-7
Group 3 Painting
Painting (ZAXIS110, 110-E, 120, 120-E,
125US, 135US) ................................... W1-3-1
Painting (ZAX135UR) ............................. W1-3-3
187W-1-1
(Blank)
187W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and 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 mo-
clean and dry.
tor 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.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
uneven wear.
b b
a=b a≠b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
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
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
W1-2-1
GENERAL / Tightening
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
W162-01-01-001
W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
GENERAL / Tightening
Service Recommendations for Split Flange
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
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
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
W1-2-6
GENERAL / Tightening
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types of 30°
screw fittings are used.
M114-07-043 M114-07-042
W1-2-8
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic in-
spection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual in-
spection alone. For this reason, replace these parts at the
intervals shown in the table below. However, if any of these
parts are found to be defective, replace before starting op-
eration, regardless of the interval.
Also, when replacing hoses, check the clamps for defor-
mation, cracks, or other deterioration, and replace as nec-
essary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) 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
Swing hose Every 2 years
Hydraulic
Travel 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
W1-2-10
GENERAL / Painting
ZAXIS110, 120
Cab Inside and Outside Unit: mm
Mirror Stay
W1SE-01-03-001
Main Surface of Tool Box Cover 350 Bed Cover 900 Main Surface of
Upperstructure Upperstructure
Cab Inside and Outside
ZAXIS125US, 135US Right
Window
Beam
Right
Ladder
Rail
Mirror Stay
W1SE-01-03-002
Main Surface of Cover Side Bed Cover
350 675 Main Surface of
Upperstructure Control Valve Upperstructure
W1-3-1
GENERAL / Painting
ZAXIS110, 120 ZAXIS125US, 135US
A Out Surface of Hinge
YR-01 A
Swing Portion Out Surface of Hinge
(TAXI Yellow) YR-01
YR-01 (TAXI Yellow) Swing Portion
185 (TAXI Yellow) 190 YR-01 (TAXI Yellow)
B B
720
W178-01-03-003 820 W1CC-01-03-006
5 Section B
Section A
Mask Garnished Portion
Door
Panel Behind the
Door
YR-01 (TAXI Yellow)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Tool Box
N1.0 (Black) W1SE-01-03-003
W178-01-03-007
Upper
Side of
Frame
W178-01-03-006
W1-3-2
GENERAL / Painting
Unit: mm
Ladder Rail on Right Side of Upperstructure
(High-Grade Black)
W187-01-03-002
Bed Cover
W1-3-3
GENERAL / Painting
W187-01-03-004
Tool Box (Black)
W187-01-03-003
Section B
5
Section A
Mask Garnished Portion
Door
Panel Behind the
Door
YR-01 (TAXI Yellow)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
W1-3-4
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 5 Control Valve
Remove and Install Cab ..............................W2-1-1 Remove and Install Control Valve................ W2-5-1
Dimensions of the Cab Glass ....................W2-1-17 Disassemble Control Valve
4-Spool Section.......................................... W2-5-4
Group 2 Counterweight Disassemble Control Valve
Remove and Install Counterweight ..............W2-2-1
5-Spool Section........................................ W2-5-10
Group 3 Main Frame Separate and Combine
Remove and Install Main Frame ..................W2-3-1 4-Spool and 5-Spool Control Valve .......... W2-5-16
Assemble Control Valve
Group 4 Pump Device 4-Spool Section........................................ W2-5-18
Remove and Install Pump Device................W2-4-1 Assemble Control Valve
Remove and Install Pilot Pump and 5-Spool Section........................................ W2-5-24
Regulator....................................................W2-4-4 Disassemble Blade Control Valve
Disassemble Pump Device ..........................W2-4-8 (ZAXIS 135UR Only) ............................... W2-5-30
Assemble Pump Device.............................W2-4-16 Assemble Blade Control Valve
Disassemble Regulator..............................W2-4-28 (ZAXIS 135UR Only) ............................... W2-5-32
Assemble Regulator...................................W2-4-30
Disassemble Solenoid Valve......................W2-4-32 Group 6 Swing Device
Assemble Solenoid Valve...........................W2-4-34 Remove and Install Swing Device ............... W2-6-1
Disassemble and Assemble Pilot Disassemble Swing Device ......................... W2-6-4
Pump (ZAXIS 110,120,125US,135US) ....W2-4-36 Assemble Swing Device ............................ W2-6-10
Disassemble and Assemble Gear Disassemble Swing Motor ....................... W2-6-18
Pump (ZAXIS 135UR Only) .....................W2-4-38 Assemble Swing Motor.............................. W2-6-22
Maintenance Standard ...............................W2-4-40 Disassemble Valve Unit............................. W2-6-28
Assemble Valve Unit.................................. W2-6-30
Maintenance Standard............................... W2-6-32
187W-2-1
Group 7 Pilot Valve Group 10 Solenoid Valve
Remove and Install Right Pilot Valve Remove and Install Solenoid Valve Unit.... W2-10-1
(ZAXIS 110,120,125US,135US).................W2-7-1 Disassemble Proportional
Remove and Install Left Pilot Valve Solenoid Valve ......................................... W2-10-6
(ZAXIS 110,120,125US,135US).................W2-7-5 Assemble Proportional Solenoid Valve...... W2-10-8
Remove and Install Front / Swing Pilot Valve Remove and Install Emergency Stop Solenoid
(ZAXIS 135UR) ..........................................W2-7-8 Valve Unit (ZAXIS 135UR Only) ............ W2-10-11
Disassemble Right and Left Disassemble and Assemble Selector
Pilot Valves ...............................................W2-7-10 Valve ...................................................... W2-10-14
Assemble Right and Left Disassemble and Assemble Unloading
Pilot Valves ...............................................W2-7-14 Valve ...................................................... W2-10-16
Remove and Install Travel
Pilot Valve.................................................W2-7-19 Group 11 Holding Valve
Disassemble Travel Pilot Valve ..................W2-7-22 Remove and Install Holding Valve ............. W2-11-1
Assemble Travel Pilot Valve.......................W2-7-26 Holding Valve (ZAXIS 135UR Only) .......... W2-11-4
Remove and Install Offset Pilot Valve
(ZAXIS 135UR) ........................................W2-7-32
Remove and Install Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-34
Disassemble Offset / Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-36
Assemble Offset / Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-38
187W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal (ZAXIS110, 120)
1. Remove seat mounting nuts (2) to remove seat
(1).
: 17 mm
W178-02-01-001
3
3. Raise duct (5) to remove it.
4
5
W178-02-01-012
W178-02-01-013
W2-1-1
UPPERSTRUCTURE / Cab
5. Disconnect cable connectors (10, 11, 12, and 13)
on the right back side in the cab and ground (9) at
rear inside of the cab.
10
11
12
13
W178-02-01-014
14
W178-02-01-015
15
W178-02-01-016
19
W178-02-01-017
20 21
W2-1-2
UPPERSTRUCTURE / Cab
22
W178-02-01-018
24
W157-02-01-010
W157-02-01-001
W2-1-3
UPPERSTRUCTURE / Cab
Removal (ZAXIS125US, 135US)
1 2
1. Remove seat mounting bolts (2) (4 used) and
bolts (3) (2 used) under the seat belt, to remove
seat (1).
: 17 mm, 16 mm
W1SE-02-01-001
1
3
W1SE-02-01-004
W2-1-4
UPPERSTRUCTURE / Cab
4. Remove bolts (12) (4 used) behind the cab to
remove cover (11) from rear cover (10). 10
: 13 mm
12
11
W1SE-02-01-005
14
15
W1SE-02-01-006
17
W1SE-02-01-007
7. Remove screw (20) (2 used) to remove duct (21)
from duct (18) and duct (19).
18 19
20
21
W1SE-02-01-008
W2-1-5
UPPERSTRUCTURE / Cab
8. Separate radio antenna feeder (22).
Remove screw (23) to remove ground (24). Re-
move connectors (25) (6 used). Pull out junction 22
box (26). Remove bolts (27) (2 used) to remove
23
ground (28).
: 13 mm
24
25
26
27
28
W1SE-02-01-09
W1SE-02-01-011
31
W1SE-02-01-10
W157-02-01-001
W2-1-6
UPPERSTRUCTURE / Cab
Removal (ZAXIS135UR) 1
6
5 7
5. Remove caps (9) (4 used) from duct cover (8)
with a screwdriver. Remove screws (10) (4 used)
to remove the duct cover.
M196-09-021
12, 13
W1CF-02-01-001
14
W2-1-7
UPPERSTRUCTURE / Cab
8. Remove nuts (16) (4 used) and bolts (17) (9
used) (bolt: 5 used, socket bolt: 4 used) from the
cab bottom plate.
: 8 mm Cab
Mounting
: 17 mm Holes
: 24 mm (9 used)
Lubber
17 Mounting
Holes
16 (4 used)
15
W1CF-02-01-002
18
9. Remove the vinyl hose from cab (18).
W1CF-02-01-018
W2-1-8
UPPERSTRUCTURE / Cab
Installation (ZAXIS110, 120)
CAUTION: Cab weight: 290 kg (640 lb)
W157-02-01-001
24
W157-02-01-010
7
3. Install duct (8) to the rear console of the cab with
screws (7). Install filter (6) into duct (8).
: 4.9 N・m (0.5 kgf・m, 3.6 Ibf・ft)
8
W178-02-01-013
13
W178-02-01-014
W2-1-9
UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
4
7. Install rear box (3) with bolt (4). 5
: 17 mm
: 50 N・m (5.1 kgf・m, 37 Ibf・ft)
W178-02-01-012
8. Install duct (20) with bolt (21). Install duct (19) into
duct (20) and fix them with bolt (18).
: 17 mm
: 50 N・m (5.1 kgf・m, 37 Ibf・ft)
18
Matching Surface of Duct
19
W178-02-01-017
20 21
W2-1-10
UPPERSTRUCTURE / Cab
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
W178-02-01-001
W2-1-11
UPPERSTRUCTURE / Cab
Installation (ZAXIS125US、135US)
CAUTION: Cab weight: 270 kg (595 lb)
31
3. Connect grounds (28) with bolt (27).
Put junction box (harness side) (26) onto the W1SE-02-01-10
junction box.
Install connectors (25) (6 used).
Install ground (24) with screw (23).
22
Connect radio antenna feeders (22).
: 13 mm 23
: 10 N・m (1.0 kgf・m, 7.4 Ibf・ft)
24
25
4. Install duct (21) into duct (18) and duct (19) with
26
screws (20) (2 used).
27
28
W1SE-02-01-09
18 19
20
21
W1SE-02-01-008
W2-1-12
UPPERSTRUCTURE / Cab
5. Install vinyl hose (17) at the bottom of washer
tank (16) behind the cab.
16
17
W1SE-02-01-007
14
15
W1SE-02-01-006
12
11
W1SE-02-01-005
8. Install duct (8) into duct (7) with screws (9) (2
used).
: 3 N・m (0.3 kgf・m, 2.2 Ibf・ft)
7
W1SE-02-01-004
W2-1-13
UPPERSTRUCTURE / Cab
9. Install duct cover (5) with screws (4). Install caps
(6) onto duct cover (5).
: 3 N・m (0.3 kgf・m, 2.2 Ibf・ft)
4
W1SE-02-01-003
1 2
W1SE-02-01-001
1
3
W1SE-02-01-002
W2-1-14
UPPERSTRUCTURE / Cab
Installation (ZAXIS135UR)
W190-02-03-009
Cab
Mounting
Holes
(7 used)
3. Install nuts (16) (4 used), bolts (17) (9 used) and
earth wire.
: 24 mm
: 206 N・m (21 kgf・m, 151 lbf・ft)
Lubber
: 17 mm Mounting
17
: 50 N・m (5.1 kgf・m, 37 Ibf・ft) Holes
: 8 mm 16 (4 used)
: 50 N・m (5.1 kgf・m, 37 Ibf・ft)
15
W1CF-02-01-002
11
W1CF-02-01-001
14
W2-1-15
UPPERSTRUCTURE / Cab
6. Install duct cover (8) with screws (10) (4 used).
Install caps (9) (4 used) to duct cover. 1
9, 10
7. Install foot rest (5) and floor mat (7) with bolts (6) 2
(2 used). 8
: 17 mm
: 50 N・m (5.1 kgf・m, 37 Ibf・ft) 3, 4
M196-09-021
W2-1-16
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
(ZAXIS 110, 120)
A
Chamfer Here
NOTE: Unit: mm
67 303.5
(1 mm=0.039 in) 11 Chamfer along the
R2 periphery unless
otherwise specified
R98 R35
0
4-φ13 -1
R3018
405 30 Chamfer both
Section A W178-02-01-019
sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
R58
R58
R11508
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-17
UPPERSTRUCTURE / Cab
NOTE: Unit: mm
(1 mm=0.039 in)
Chamfer Here Chamfer
Chamfer Here along the
85.4 periphery
unless
343.3 213 otherwise
specified
R105
R72 R10
R105
(4 mm)
Chamfer along the periphery
unless otherwise specified
39.5 D
733 733
C R2465 Section C +0.5
2-φ12.2 -0
and D
(4 mm) W178-02-01-019
40 6.754°
289.5
3-R4 50
2-R4
86.9 50
50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
R2002
872
R123
R115
888.58
W178-02-01-010
W2-1-18
UPPERSTRUCTURE / Cab
(ZAXIS125US, 135US)
NOTE: Unit: mm
(1 mm=0.039 in)
R5
27.3
36 (Specified)
110 R2929 R30
R293.5
R129
36
532.5
(5 mm) R75
770.5
36
1081.1
R2929 193.6 R5
Section A W178-02-01-019 189 39 58±5
R30 (Specified)
R20 R542
52.8
(Fillet) 1044.4
R1910
R5
39 415.1
322.1 1164.4
W1SE-02-01-013
Chamfer
Here
2-R20 34 2-R105
2-R15 32.5
4-R73
W1SE-02-01-012 40
39.5
42.3 (4 mm) φ13.5±0.2 557
40
R2 320±0.5 2-R15
2-R20 B
2-φ13.5±0.2
48±5
112±0.2 23.5
54.8±0.2
697.5±0.5
291±0.2
Stop R Here
803
W1SE-02-01-014
Section B W178-02-01-019
W2-1-19
UPPERSTRUCTURE / Cab
FREE R 9±5
32±5
(5 mm) 92.8
27.4
342.7
55.1
W1SE-02-01-018
W1SE-02-01-012
444.2±1
200 152.9±1
194.6
597±1
(5 mm)
(5 mm)
C D
597±1
R2916.2 41.5
Chamfer
Here
40 Chamfer
Here
2-φ13 +1 0
101±5 167
10±5
50.2
4-R5 4-R5
109.6
R2937 2-φ18±0.5
(4 mm)
412
244±0.5 50±0.5 Section C and D
63.5±0.5 W178-02-01-019
R114
67.5±0.5
R551.5 372.5
40
96
490.5 40 R9
637
652
W1SE-02-01-015
W2-1-20
UPPERSTRUCTURE / Cab
(ZAXIS135UR)
Unit: mm (1 mm=0.039 in)
NOTE: JIS R3211
R 1727.8 R 1717.9
4 4
280.2
823.6
R26936.5
R5
W1CF-02-01-018
R67.5
302.7 300.5
R67.5 W1CF-02-01-009 W1CF-02-01-010
R148
42.1 61.2
39.5
R9998 44.5 38.1
195.1 20.9
108.9
2.5
71.5 φ82
3-R10 436.3
58
5-R20
291.8
165 400.3 27.7 17.8 19.9
24.6 22.5
989
262.4 70
3-R13
36
35.5 521 36.5 667
W1CF-02-01-011
593
596.1 R32
W1CF-02-01-012
W2-1-21
UPPERSTRUCTURE / Cab
Unit: mm (1 mm=0.039 in) 193 255 41
33
R82.5 R82.5
52.5
540 400
φ25
532
548
(4 mm)
984.5
614
9-φ18
2-R80 8 33 2-R60
51 590
589 W1CF-02-01-017
W1CF-02-01-015 1022.3
21.5 25.9
R91 R71
666
(4 mm)
520
8 8
20
50 R9126.7 R22862.3
615.8
81.1
R5 R91
+1
φ12 -0
21.4
462 (4 mm)
334.8 R306
21 21 R71
R65 28 R65
W197-02-01-005
W2-1-22
UPPERSTRUCTURE / Cab
Remove Cab Glass (ZAXIS110, 120)
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section
W178-02-01-004
W2-1-23
UPPERSTRUCTURE / Cab
Procedures to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the
A
glass when air is entered between cab and
mounting rubber.
Cab
W178-02-01-002
Glass
Mounting Rubber
W178-02-01-005
W2-1-24
UPPERSTRUCTURE / Cab
Cab Glass Installation Procedure
Left-Hand Cab Glass
(ZAXIS110, 120)
Procedure of installing the left-hand cab glass, the
lower glass of the door and the upper front glass:
A
1. Install the seal rubber on the left-hand cab glass CSE Braid
and lower glass of the door.
Section A
Seal Rubber
W178-02-01-021
5
W178-02-01-023 A
CSE Braid
Seal Rubber
W178-02-01-022
W178-02-01-004
W2-1-25
UPPERSTRUCTURE / Cab
Procedures of installing right-hand cab glass: Mounting Rubber Section
W178-02-01-005
W2-1-26
UPPERSTRUCTURE / Cab
Method for Removing Cab Glass
(ZAXIS125US, 135US)
Garnish
Cab
2. Pierce a hole in adhesive with awl (or cutter, etc). Glass
Awl
Adhesive W1SE-02-01-033
Piano Wire
(Iron Wire)
W1SE-02-01-034
W2-1-27
UPPERSTRUCTURE / Cab
4. Wind both ends of the piano wire to drivers. Saw
down the adhesive by sawing back and forth.
Remove the glass from the cab. (Outside of
Cab the Cab)
NOTE: Saw down from the middle of adhesive
between glass and cab. Glass
There is a danger that piano wire may
break as it is heating in local part. Always
change the part used in sawing for cooling.
Adhesive
(Inside of the Cab)
W1SE-02-01-035
W2-1-28
UPPERSTRUCTURE / Cab
Method for Installing Cab Glass
(ZAXIS125US, 135US)
Right-Hand Glass
Procedures for installing right-hand cab glass, rear
left-hand glass and lower glass of the door are as
follows:
Cab
W2-1-29
UPPERSTRUCTURE / Cab
IMPORTANT: Shake primer (35) vigorously for 11. Lift the glass by a suction lifter (rubber suction
about 1 minute to mix thoroughly plate 4355282, refer to W2-1-23) within 5 minutes
before loosening its cap. to adhere onto the cab.
It should be used quickly when
NOTE: Press fit the glass onto the cab when lo-
opened and sealed immediately
cating it by the spacer adhered on the
when applying is finished.
glass. The other surface where applied
It should be used within 3 days after
with adhesive, except the mating surface,
being opened. (It can be wasted in 2
should be cleaned with white gasoline be-
hours if left it opened.)
fore the adhesive takes.
5. Apply glass primer (SUNRISE MSI Primer 35)
onto the glass where it needs to be coated with
12. The glass should be secured with gummed tape
the adhesive. Wait for 15 minutes or so to let the
to prevent it from moving until the adhesive be-
coating dry itself.
comes solid.
(As for the position where glass primer 35 should
be applied, refer to W2-1-23) NOTE: Time required for adhesive (SUNRISE MSI
SR Seal U90 4463876) becoming solid: 8
6. Peel the paper from the spacer and put on adhe- hours (Just for reference).
sive at the place where the paper was instead. Right-Hand Glass
Gummed Tape
Then put the adhesive tape on the glass. 500
(As for the position to install spacers a, b and c, 350
refer to W2-1-23)
500
W1SE-02-01-027
8. Remove the seal from the cartridge end to install 200
V cut nozzle on it.
500
Remove
Seal
200
W1SE-02-01-040
Adhesive
Cartridge
150
Lower Glass of the Door
150
W1SE-02-01-028
9. Caulk the cut ridge onto hand cauking gun.
50
10. When applying primer, it should be applied onto 150
the glass evenly in V-bead-shape at the position
200
where adhesive should be coated.
150
(As for the position to apply adhesive, refer to
W2-1-24) W1SE-02-01-041
W2-1-30
UPPERSTRUCTURE / Cab
Unit: mm Right-Hand Glass
B
Spacer a (4458466) B
20
Spacer b 700
R7 Spacer c
10.9 Lift Par-
8.7 tially 160
0.5 5 c
305 Spacer a
8.5
A
Concave W1SE-02-01-030
W1SE-02-01-019
D
20
400
Spacer c
R6
9.3 10.5
30
5
650
8.5
Convex
60
123
W1SE-02-01-031
Lower Glass of
W1SE-02-01-021
the Door
Spacer c (4458470)
20 286
5 Spacer c
225
Flat 7
62
W1SE-02-01-032
Adhesive Tape
445 Spacer b
on Both Side
W1SE-02-01-020
Section A-A Section B-B Section C-C Section D-D
Glass
Adhesive
W2-1-31
UPPERSTRUCTURE / Cab
Glass
Coat Adhesive
4 to 5 mm
Bead Here
Spacer a or
9.0
Spacer b
Adhesive Tape
5.5 5.0 on Both Side
5.5 to 5.9
4.9 3.6
Cab
12.0
Unit: mm W1SE-02-01-022
W2-1-32
UPPERSTRUCTURE / Cab
Install upper door glass as follows
Garnish
2. Insert glass A and glass B into the sash slot. In-
sert glass C into the mounting rubber.
Glass A Glass B
W1SE-02-01-044
Glass C
3. Install the sash assembly with glass onto the door
from outside of the cab. Secure the sash assem- Mounting Rubber
bly inside of the cab with the garnish. Mounting Rubber
Sash Slot
Glass A and
Glass B
W1SE-02-01-045
W2-1-33
UPPERSTRUCTURE / Cab
Install rear glass as follows
1 5 9 W1SE-02-01-046
W2-1-34
UPPERSTRUCTURE / Cab
Install upper front glass as follows
1 1
Lower Glass
Lower Glass
W1SE-02-01-047
W2-1-35
UPPERSTRUCTURE / Cab
Remove Cab Glass (ZAXIS135UR)
Procedures to remove left-hand cab glass, lower
glass of the door.
Mounting Rubber Section
W1CF-02-01-003
W2-1-36
UPPERSTRUCTURE / Cab
Method to remove upper front glass, right-hand cab Mounting Rubber Section
glass and rear side cab glass
1. Remove stopper (groove rubber) with a flat-head
screwdriver. Glass
Mounting Rubber
A
3. Tap glass from the side in cab by palm of the A
hand to take the glass off. Two men are required Cab
to do the work.
W216-02-01-003
W1CF-02-01-005
W2-1-37
UPPERSTRUCTURE / Cab
Cab Glass Installation Method (ZAXIS135UR)
Mounting Rubber Section
Procedure of installing left-side cab glass and
lower glass of the door Mounting-Rubber
1. Install the mounting rubber on cab glass. Put and
fasten mounting rubber onto the mounting face of Glass
cab.
NOTE: Rubber aging will cause the contraction of Mounting Rubber Section
rubber, be sure to leave a little bit longer,
and compress mounting rubber when in- Mounting Rubber Glass
stall it to cab.
Cab
W216-02-01-003
W2-1-38
UPPERSTRUCTURE / Cab
Procedures to Install Upper Door Glass
B
Procedures to Install Upper Door Glass
A
W1CF-02-01-003
Section A Rail
Rail
W1CF-02-01-022
Section D
Garnish
Glass
Inside Cab
W1CF-02-01-024
Section B Cab
Sash
Garnish
W1CF-02-01-023
Glass
W2-1-39
UPPERSTRUCTURE / Cab
(Blank)
W2-1-40
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal (ZAXIS110, 120)
Sling Bolt
W178-02-02-002
3. Remove mounting bolts (2) from the counter-
weight. Hoist to remove the counterweight by
crane.
: 41 mm
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Removal (ZAXIS125US, 135US, 135UR) Right-Hand Cover 1
CAUTION: Counterweight weight:
3150 kg (6950 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
Left-Hand 2
Cover
1. Remove harness (1) and vinyl hose (2) from the
washer tank.
W1SE-02-02-005
3
4
Engine Cover
W1SE-02-02-001
W2-2-2
UPPERSTRUCTURE / Counterweight
Sling Bolt
W1SE-02-02-002
W1SE-02-02-003
W2-2-3
UPPERSTRUCTURE / Counterweight
Installation (ZAXIS110, 120)
CAUTION: Counterweight weight:
1800 kg (3970 Ib) (ZAXIS110)
2450 kg (5400 Ib) (ZAXIS120)
W178-02-02-003
Torque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
W2-2-4
UPPERSTRUCTURE / Counterweight
Installation (ZAXIS125US, 135US, 135UR)
CAUTION: Counterweight weight:
3150 kg (6950 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
W1SE-02-02-001
W2-2-5
UPPERSTRUCTURE / Counterweight
4. Install mirror (3) onto the engine cover with bolts
(4) (2 used). 3
4
Engine Cover
W1SE-02-02-006
5. Install harness (1) and vinyl hose (2) into the
washer tank.
1
Left-Hand 2
Cover
W1SE-02-02-005
W2-2-6
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
Preparation
1. Place the machine on a firm, level surface.
M104-07-021
W2-3-1
UPPERSTRUCTURE / Main Frame
Removal
CAUTION: Cab weight:
290 kg (640 lb) (ZAXIS110, 120)
270 kg (600 lb) (ZAXIS125US, 135US)
218 kg (481 lb) (ZAXIS135UR)
W157-02-01-001
ZAXIS110, 120
W1SE-02-03-001
W2-3-2
UPPERSTRUCTURE / Main Frame
W105-02-03-004
Front
W105-02-03-005
W157-02-03-001
W2-3-3
UPPERSTRUCTURE / Main Frame
6. Put matching marks on the upperstructure and the
outer race of the swing bearing.
Loosen and remove mounting bolts (2) (30 used)
of the swing bearing.
: 27 mm
W102-02-03-004
7. Chain block (1) shall be used to adjust and level
the frame, then hoist it slightly to remove it from
the undercarriage by crane. 1
W157-02-03-002
W2-3-4
UPPERSTRUCTURE / Main Frame
Installation
CAUTION: Upperstructure weight:
2600 kg (5730 lb) (ZAXIS110)
2700 kg (5950 lb) (ZAXIS120)
1
3000 kg (6610 lb) (ZAXIS125US, 135US,
135UR)
W157-02-03-002
Machine Front
W102-03-03-001
W2-3-5
UPPERSTRUCTURE / Main Frame
W1SE-02-03-001
W2-3-6
UPPERSTRUCTURE / Main Frame
W2-3-7
UPPERSTRUCTURE / Main Frame
(Blank)
W2-3-8
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Preparation
1. Place the machine on a firm, level surface.
W2-4-1
UPPERSTRUCTURE / Pump Device
Removal (ZAXIS110, 120)
2
1. Disconnect connectors.
4. Connect connectors.
Tightening Torque
Wrench Size (mm) Remark
N・ m kgf・ m (Ibf・ ft)
: 27 93 9.5 (69) Hose
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 50 5.1 (37) Bolt
: 8 50 5.1 (37) Bolt
: 19 29.5 3 (21.5) Hose
: 17 9.8 1 (7.2) Hose
: 27 mm
: 49 N・m (5 kgf・m, 36 Ibf・ft)
W2-4-2
UPPERSTRUCTURE / Pump Device
Removal (ZAXIS125US, 135US, 135UR)
1. Disconnect connectors. 1 2
Installation
1. Install eyebolts (ST 0002) on the pump device
and hoist by crane.
11
4. Connect connectors. NOTE: The figure above shows for ZAXIS 125US /
135US.
Tightening Torque
As for ZAXIS 135UR, the blade pump (gear
Wrench Size (mm) Remark pump) is equipped at the end of pilot
N・ m kgf・ m (Ibf・ ft)
Pump.
: 27 93 9.5 (69) Hose
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 50 5.1 (37) Bolt
: 8 65 6.6 (47.7) Bolt
: 19 29.5 3 (21.5) Hose
: 17 9.8 1 (7.2) Hose
: 27 mm
: 49 N・m (5 kgf・m, 36 Ibf・ft)
W2-4-3
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PILOT PUMP AND
REGULATOR
6 7 8 9 10
11
12
13
14
15
4
3
2
16
1
17
W176-02-04-004
W2-4-4
UPPERSTRUCTURE / Pump Device
• Pump device consists of the following parts illus-
trated below.
2. Remove socket bolts (2) (2 used) from rear cas-
ing (17), then remove pilot pump (1).
Rear Regulator Front Regulator : 8 mm
W176-02-04-002
Sleeper
W2-4-5
UPPERSTRUCTURE / Pump Device
6 8 9 10
11
12
13
14
15
4
3
2
16
1
17
W176-02-04-004
W2-4-6
UPPERSTRUCTURE / Pump Device
Installation
IMPORTANT: Confirm that both the front regulator 3. Install O-ring (12) into fitting (11).
and its mounting surface have 8 Apply grease to fitting threads, then install the
O-rings installed on each. fitting into pipe (13).
1. Install front regulator (9) onto pump casing (16) : 17 mm
as follows. : 34.5 N・m (3.5 kgf・m, 25 Ibf・ft)
• Adjust the sleeve position so that the 2-sleeve
grooves inside front regulator are aligned. 4. Install O-ring (15) into elbow (14).
• Place the front regulator onto the pump casing, Apply grease to elbow threads, then install the
then put the feedback link pin into the 2-sleeve elbow into rear regulator (5).
grooves. : 17 mm
• Adjust the front regulator’s position so that the : 34.5 N・m (3.5 kgf・m, 25 Ibf・ft)
knock pin out of pump casing is inserted into the
front regulator. 5. Install pipe (13) into elbow (14).
• Install the front regulator onto the pump casing : 17 mm
with socket bolts (10) (4 used). : 34.5 N・m (3.5 kgf・m, 25 Ibf・ft)
: 8 mm
: 49 N・m (5 kgf・m, 36 lbf・ft) 6. Apply THREEBOND #1215 to the flange face of
pilot pump (1) (contact face with rear casing (17)).
W176-02-04-008
W2-4-7
UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
10
9
8
27 28
7
6
5 26 29
4
3 25
30 32
2 24 31
1
22
11
7 23
12
13
14 33
22
34
21
20
19
18
17 2
16 35 1
15 36
37
38 47
46
39 4
40 44
45
41
44
43
9
11
49 48
42 5
16 14
13
17 12
50
19 51
20
21
38 10
41
40
18
W176-02-04-005
W2-4-8
UPPERSTRUCTURE / Pump Device
1- Socket Bolt (12 Used) 14 - Restrictor Pin (2 Used) 27 - O-Ring (2 Used) 40 - Plate (2 Used)
2- Spring Washer (12 Used) 15 - Swash Plate R 28 - O-Ring (10 Used) 41 - Knock Pin (2 Used)
3- Rear Casing 16 - Servo Piston (6 Used) 29 - O-Ring (4 Used) 42 - Swash Plate F
4- Knock Pin (2 Used) 17 - Spring (6 Used) 30 - Pin (2 Used) 43 - Inner Race
5- Pin (4 Used) 18 - Plunger (18 Used) 31 - Feedback Link (2 Used) 44 - Retaining Ring (2 Used)
6- O-Ring 19 - Retainer (2 Used) 32 - Spring Pin (4 Used) 45 - Roller Bearing
7- Retaining Ring (2 Used) 20 - Bushing (2 Used) 33 - Valve Plate F 46 - Oil Seal
8- Roller Bearing 21 - Disc Spring (8 Used) 34 - Needle Bearing 47 - Retaining Ring
9- O-Ring (4 Used) 22 - Knock Pin (4 Used) 35 - Pump Casing 48 - Front Casing
10 - Socket Bolt (8 Used) 23 - Spring Pin (2 Used) 36 - Needle Bearing 49 - O-Ring
11 - Cradle Plate (2 Used) 24 - Link Pin (2 Used) 37 - Valve Plate R 50 - Drive Shaft
12 - O-Ring (4 Used) 25 - Pin (2 Used) 38 - Rotor (2 Used) 51 - Retaining Ring
13 - Backup Ring (4 Used) 26 - Spring Pin (2 Used) 39 - Shaft
W2-4-9
UPPERSTRUCTURE / Pump Device
33
35 1
44
45
44
43
11
42 48
14
50
19
20
21
38 10
40
18
W176-02-04-005
W2-4-10
UPPERSTRUCTURE / Pump Device
Disassemble Pump Device
• The pump cosists of the front and rear pumps. 4. With rotor (38) side upward, put front casing (48)
on sleepers, over 30 mm (1.18 in) in width and
• Disassemble front pump side thickness.
W2-4-11
UPPERSTRUCTURE / Pump Device
10
8
7
3
31
1
11
14 33
34
35
38
39
45
16
17
50
W176-02-04-005
W2-4-12
UPPERSTRUCTURE / Pump Device
IMPORTANT: Be sure to insert the large diameter • Disassemble Rear Pump Side
side of the drive shaft to the special
tool. IMPORTANT: Although the front pump is similar
12. Insert drive shaft (50), of which the large diameter to the rear pump, the parts used are
side goes first, to special tool (ST 7266). not exchangeable. Keep parts sepa-
Tap the end of special tool to pull out roller bear- rate after disassembling.
ing (45) from the drive shaft. 1. Romove socket bolts (1) (6 used) from rear cas-
NOTE: When replacing the inner race, replace with ing (3). Remove rear casing (3) from pump cas-
drive shaft (50) assembly. ing (35). At this time, shaft (39) and rotor (38)
assembly are removed with the rear casing.
: 10 mm
50 ST 7266
2. Keep rotor (38) assembly rotor side facing down-
ward, place it on the sleeper, over 80 mm (3 in) in
45 width and thickness.
W2-4-13
UPPERSTRUCTURE / Pump Device
3
31
34
21
20
19
18
17
16 35
15 36
37
38
39
40
W176-02-04-005
W2-4-14
UPPERSTRUCTURE / Pump Device
7. Remove the outer race of roller bearing (8) from 15. Remove valve plate R (37) from pump casing
rear casing (3). (35).
NOTE: Insert finger into the outer race to pull up
directly. 16. Remove servo pistons (16) (3 used) and springs
(17) (3 used) from pump casing (35).
IMPORTANT: Retaining ring (7) is located under
the roller bearing. Do not hang 17. Remove the feedback link (31) assembly from
puller pawl on the retaining ring. pump casing (35).
8. Install guide (ST 7267) into the hole of shaft (39) NOTE: Do not disassemble the feedback link
end, to remove the inner race of roller bearing (8) unless necessary.
with a small puller.
18. The outer races of needle bearings (34) and (36)
remain in pump casing (35). Do not remove them
unless necessary.
When removing, tap the outer races out at the
ST 7267
back with a bar and hammer.
39
7 W176-02-04-010
W2-4-15
UPPERSTRUCTURE / Pump Device
2 15 16 17 22 35 17 16 42
4
1
4
47
44
10 46
14
10
40 14
21 20 18 37 36 51 43 34 33 18 20 21 40
48
6 24 25 31 26 23 30 23 26 31 25 24
11 49
3 11
7 45
8
9
9
5 41 19 39 38 38 50 19 41 W176-02-04-011
1
2
W2-4-16
UPPERSTRUCTURE / Pump Device
1- Socket Bolt (12 Used) 14 - Restrictor Pin (2 Used) 27 - O-Ring (2 Used) 40 - Plate (2 Used)
2- Spring Washer (12 Used) 15 - Swash Plate R 28 - O-Ring (10 Used) 41 - Dowel Pin (2 Used)
3- Rear Casing 16 - Servo Piston (6 Used) 29 - O-Ring (4 Used) 42 - Swash Plate F
4- Knock Pin (2 Used) 17 - Spring (6 Used) 30 - Pin (2 Used) 43 - Inner Race
5- Pin (4 Used) 18 - Plunger (18 Used) 31 - Feedback Link (2 Used) 44 - Retaining Ring (2 Used)
6- O-Ring 19 - Retainer (2 Used) 32 - Spring Pin (4 Used) 45 - Roller Bearing
7- Retaining Ring (2 Used) 20 - Bushing (2 Used) 33 - Valve Plate F 46 - Oil Seal
8- Roller Bearing 21 - Disc Spring (8 Used) 34 - Needle Bearing 47 - Retaining Ring
9- O-Ring (4 Used) 22 - Knock Pin (4 Used) 35 - Pump Casing 48 - Front Casing
10 - Socket Bolt (8 Used) 23 - Spring Pin (2 Used) 36 - Needle Bearing 49 - O-Ring
11 - Cradle Plate (2 Used) 24 - Link Pin (2 Used) 37 - Valve Plate R 50 - Drive Shaft
12 - O-Ring (4 Used) 25 - Pin (2 Used) 38 - Rotor (2 Used) 51 - Retaining Ring
13 - Backup Ring (4 Used) 26 - Spring Pin (2 Used) 39 - Shaft
W2-4-17
UPPERSTRUCTURE / Pump Device
15 16 17 22 35
40
21 20 18 37 36 34
24 31 30
3
7
19 39 38 W176-02-04-011
W2-4-18
UPPERSTRUCTURE / Pump Device
Assemble Pump Device
• Assemble rear pump side IMPORTANT: Pay attention to the direction of disc
spring (21) and retainer (19).
1. Install needle bearings (34) (36), with their 5. Use the steps below to compose rotor (38) into
stamped marks on the outer race facing outward the assembly by the same procedure below.
respectively into pump casing (35) with special • Place the rotor with the center lug upward.
tool (ST 7262) and a hammer. • Compose disc springs (21) (4 used) to align the
outer circle with outer circle and inner circle with
IMPORTANT: As for valve plate R (37), assemble it inner circle. Then place them onto the center lug
with the long hole oriented down- of the rotor.
ward.
2. Apply the grease to the flat surface of valve plate
R (37), then assemble it to align with knock pin 21
(22) of pump casing (35).
20
W2-4-19
UPPERSTRUCTURE / Pump Device
2 15
10
14
6 24 31
11
3
7
8
9
5 39 W176-02-04-011
W2-4-20
UPPERSTRUCTURE / Pump Device
IMPORTANT: Pay attention to the direction of the 12. Level cylindrical surface of cradle plate (11) to
inner race for roller bearing (8). that of swash plate R (15) evenly, then assemble
10. Using special tool (ST 7265) and guide (ST 7267), rear casing (3) assembly onto shaft (39).
drive the inner race of roller bearing (8) into shaft At this time, the concave portion of feedback link
(39) with the inner race flange facing inside with a (31) on the swash plate R and the threaded hole
hammer. for lifting on the rear casing are in the same direc-
tion.
ST 7265 NOTE: Because the roller of roller bearing (8) is
tilted, it is difficult to install the shaft, make
8 clean cloth into a ball and stuff it into the
ST 7267
bore of roller bearing so as to install the
39 shaft easily.
W176-02-04-012
W176-02-04-013
Orifice 13
W2-4-21
UPPERSTRUCTURE / Pump Device
22 35 17 16
47
44
51 43 33
48
30 31 24
45
38 50 W176-02-04-011
W2-4-22
UPPERSTRUCTURE / Pump Device
• Assemble front pump side
6. Install retaining ring (51) into drive shaft (50).
IMPORTANT: When assembling valve plate F (33),
keep the long hole oriented down- IMPORTANT: Take care not to damage the slide
ward. face of oil seal (47) of drive shaft
1. Apply a film of grease to the flat surface of valve (50).
plate F (33), then align it with knock pin (22) of 7. Install retaining ring (44) into the nearer groove to
pump casing (35), to assemble. the shaft end, which is one of two grooves on
drive shaft (50).
2. Install spring (17) into servo piston (16), then as-
semble the servo piston into pump casing (35). (3 8. Using special tool (ST 7266) and a hammer, tap
places) roller bearing (45), with the stamp mark forward,
into drive shaft (50).
IMPORTANT: Pay attention to the direction of the
feedback link assembling. 9. Install the inner race plate of roller bearing (45)
3. Align the feedback link (31) assembly with the into drive shaft (50) with the stamp mark forward.
groove for pin (30) of pump casing (35), then as-
semble. At this time, keep link pin (24) toward the 10. Install retaining ring (44) into drive shaft (50).
front casing (48) side.
NOTE: Both sides of pin (30) are parallel. Align the 11. Install the front casing (48) into the assembly as
parallel side with the groove to assemble. follows.
• Place the front casing with pump casing (35) side
30 downward.
31
35 • Apply a film of grease to the bore of oil seal (46).
• Using special tool (ST 7263) and a plastic ham-
mer, tap the oil seal evenly into the front casing.
• Install retaining ring (47) into the front casing.
• Turn the front casing over and put on sleepers,
Parallel Side
over 30 mm in width and thickness.
Parallel Side W176-02-04-016
• Install drive shaft (50) into the front casing. At this
moment just tap drive shaft (50) slightly with a
plastic hammer, roller bearing (45) can be in-
4. The rear pump assembling, Install rotor (38) into stalled.
the assembly by the same procedure as step 5 • Install O-rings (9) (2 used) into the front casing.
for the rear pump assembling.
W2-4-23
UPPERSTRUCTURE / Pump Device
35 42
10
14
18 40
48
24
49
11
39 38 50 41 W176-02-04-011
W2-4-24
UPPERSTRUCTURE / Pump Device
• Align cradle plate (11) with knock pin (5) and in-
CAUTION: Front casing assembly weight:
stall it into the front casing, then tighten with
24 kg (53 Ib)
socket bolts (10) (4 used).
14. Install eyebolt (M12) to front casing (48).
: 5 mm
Position the front casing assembly approximately
: 9.8 N・m (1 kgf・m, 7.2 lbf・ft)
vertical and hold this position.
• Install O-ring (49) into the front casing.
• If restrictor pin (14) is removed, install backup NOTE: If the front casing is turned over, swash
rings (13) (2 used) and O-rings (12) (2 used) into plate F (42) comes off.
the restrictor pin. Then install the restrictor pin
into the front casing. At this time, keep the orifice
side on the restrictor pin toward inside to install. Eyebolt
12
48
3 14
W176-02-04-013
W176-02-04-017
Orifice 13
IMPORTANT: When installing, keep the connec- CAUTION: Front casing assembly weight:
tion part of link pin (24) for swash 27 kg (60 Ib)
plate F (42) upward (regulator 16. Sling the front casing (48) assembly.
mounting side). NOTE: As the gravity center of the front casing is
13. Apply a film of grease to the cylindrical surface of at the rotor (38) side be sure not to tilt it. If
swash plate F (42). Align the cylindrical surfaces the front casing is tilted, the rotor may fall
of swash plate F and cradle plate (11) and install down.
to the front casing (48) assembly.
IMPORTANT: Put link pin (24) into the concave
portion of feedback link (31) on
42 Connection swash plate F (42).
Part of Link Pin
17. Align the front casing (48) assembly with link pin
(24), assemble the front casing (48) assembly
into pump casing (35).
NOTE: When the spline of drive shaft (50) is not
engaged with that of shaft (39), either ro-
W176-02-04-018 tate drive shaft, or use tool (ST 3315) to
rotate the shaft.
W2-4-25
UPPERSTRUCTURE / Pump Device
35
48
W176-02-04-011
1
2
W2-4-26
UPPERSTRUCTURE / Pump Device
18. Tighten front casing (48) to pump casing (35) with
socket bolts (1) (6 used) and spring washers (2)
(6 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
27 32 28 29
35
W176-02-04-014
W2-4-27
UPPERSTRUCTURE / Pump Device
DISASSEMBLE REGULATOR
1 2 3
6 7 8 9 10 11 12 13 14 15
5 16
4 17
18
19
33
W176-02-04-001
32
31 30 29 28 27 26 25 24 23 22 21 20
W2-4-28
UPPERSTRUCTURE / Pump Device
Disassemble Regulator
• The regulators are used for the front pump and 5. Pull out springs (23) (24) from casing (9).
rear pump. The regulator’s inner structure is fully
identical, and difference is only in its accessories. 6. Insert a round bar into the hole on casing (9), push
Here is the description of the rear regulator. spool (26) end, push out cylinder (22), sleeve (25)
and spool from the casing. At this time, piston
IMPORTANT: If adjusting screws (4, 5, 16, 17, 18, (27) is removed with the cylinder.
19) are disassembled, their set val-
ues will be changed. So, not to dis- 7. Pull out piston (27) from cylinder (28).
assemble them.
When disassembling must be done, 8. Remove spring (8) from casing (9).
after assembling, carry out adjust-
ment according to the procedure of 9. Insert a round bar into the hole on casing (9) to
performance test. push the spool (10) end, push out cylinder (13),
1. Install casing (9) in a vise, then remove pipe (1) sleeve (11) and spool. At this time, piston (12) is
from the casing. removed with the cylinder.
: 17 mm
10. Pull out piston (12) from cylinder (13).
2. Remove socket bolts (2) (2 used) and remove
solenoid valve (3) from the casing.
W2-4-29
UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR
1 2 3
6 7 8 9 10 11 12 13 14 15
5 16
4 17
18
19
33
W176-02-04-001
32
31 30 29 28 27 26 25 24 23 22 21 20
W2-4-30
UPPERSTRUCTURE / Pump Device
Assemble Regulator
IMPORTANT: Two sleeve holes for casing (9) have 9. Install O-ring (22) and springs (23) (24) to stopper
identical bore, and the shapes of assembly (21) on cover (15) , then install it on
various parts are very similar. Pay casing (9) with socket bolts (20) (4 used).
attention not to misassemble them. : 6 mm
Perform assembling as illustrated. : 19.5 N・m (2 kgf・m, 14.5 Ibf・ft)
1. Clean all parts neatly and apply hydraulic oil.
10. Using socket bolts (2) (2 used), install solenoid
IMPORTANT: Pay attention to the direction for valve (3) onto casing (9).
assembling sleeve (11) and spool : 8 mm
(10). : 49 N・m (5 kgf・m, 36 Ibf・ft)
2. Insert spool (10) into sleeve (11), using a round
bar, assemble it at the position closed to the cas- 11. Apply a film of grease to the threads portion of
ing (9) center. pipe (1). Install pipe (1) to casing (9).
: 17 mm
3. Install O-ring (14) onto cylinder (13). : 34 N・m (3.5 kgf・m, 25 Ibf・ft)
W2-4-31
UPPERSTRUCTURE / Pump Device
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
W178-02-04-050
W2-4-32
UPPERSTRUCTURE / Pump Device
Disassemble Solenoid Valve IMPORTANT: Do not remove orifice (13) from
• Be sure not to damage the mating surface of the spool (12).
regulator.
• When replacing the inner parts, replace the sole- 4. Remove retaining ring (6), then remove spring (7)
noid valve as an assembly. and spool (12).
• Pay attention not to hit the solenoid portion.
• When removing the connector, do not pry, but pull NOTE: Spring (7) and spool (12) should be pulled
out straight and even. out from the opposite direction.
1. Remove socket bolt (1), then remove solenoid (2) 5. Remove filters (16) (20) from body (17).
and O-ring (4). : 6 mm
: 4 mm
NOTE: When cleaning filter (16), first blow the filter
NOTE: When solenoid (2) is removed, O-ring (4) with air from both surfaces, and finally blow
and spring (3) come off occasionally, pay the filter with air from outer side (threaded
attention to them. side).
W178-02-04-052
W2-4-33
UPPERSTRUCTURE / Pump Device
ASSEMBLE SOLENOID VALVE
2 1 5 6 7 11 12 13 14 15 17 16
8 9 10
21 20
19
18
W178-02-04-051
W2-4-34
UPPERSTRUCTURE / Pump Device
Assemble Solenoid Valve IMPORTANT: When installing sleeve (11), keep the
1. Install filters (16) (20) onto body (17). sleeve end and the body end in the
: 6 mm same position.
: 10+3 N・m (1+0.3 kgf・m, 7.2+2.2 Ibf・ft) In addition, when installing the
sleeve, be sure not to pry and cause
2. Install wave washer (15) and plate (14) onto body damage to O-ring.
(17). 5. Using special tool (ST 2953), install sleeve (11)
NOTE: When body (17) is horizontally inserted, assembly to body (17).
apply a film of grease to wave washer (15) NOTE: When there is no special tool (ST 2953
and plate (14) to prevent them from coming available, tighten solenoid (2) alternately
off. After assembling, check for straight po- with socket bolts (1) (2 used), sleeve (11)
sition of plate (14). end and body (17) end should be placed in
the same position. Install the solenoid.
3. Install O-rings (8), (9) and (10) to sleeve (11). ST 2953
W2-4-35
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE PILOT
PUMP (ZAXIS110, 120, 125US, 135US)
27
13
26
10
1
12
9
6
26
14
27
6
9
2
3
5
16
15
7
W137-02-04-034
12
W2-4-36
UPPERSTRUCTURE / Pump Device
IIMPORTANT: The housing is made of aluminium. Be sure not to damage it. Besides, take extreme care to
control tightening torgue.
W2-4-37
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE GEAR
PUMP (ZAXIS135UR ONLY)
28
26
15
25
34
34
4
10
28
1
9
8
25
13
26
8
31 9
7
6
26
28 15
25
29 34
30
5
10 34
28
9
8
25
14
26
8
9
10
3 W212-02-04-006
10
27
W2-4-38
UPPERSTRUCTURE / Pump Device
IIMPORTANT: The housing is made of aluminium. Be sure not to damage it. Besides, take extreme care to
control tightening torgue.
W2-4-39
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
Pump Device
1. Drive shaft: Outer diameter of shaft.
A
Standard Allowable Limit
A 35 mm (1.38 in) 34.8 mm (1.37 in)
W176-02-04-019
W176-02-04-020
W176-02-04-021
b
5. Clearance between housing inner diameter and
servo piston outer diameter.
Standard Allowable Limit
E
0.06 mm 0.12 mm
(E-b)
(0.002 in) (0.005 in)
W176-02-04-022
W2-4-40
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Preparation
1. Place the machine on a firm, level surface.
W2-5-1
UPPERSTRUCTURE / Control Valve
Removal Swing Arm1 Boom2
Auxiliary
IMPORTANT: Cap the ends of all disconnected (ZAXIS135UR:
hoses and pipes, and attach labels Arm2 Offset)
or tags to the hoses for reassem-
bling. Left Travel
Boom1
1. Disconnect all hoses, pipes and connectors from Bucket Machine For-
the control valve. ward
: 17 mm ZAXIS125US
Right Travel
ZAXIS135US
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft) ZAXIS135UR
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) Machine For-
: 36 mm ward
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) ZAXIS110
ZAXIS120
: 6 mm T176-03-03-038
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
: 8 mm Swing
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) Machine
Forward
ZAXIS125US
ZAXIS135US
ZAXIS135UR
Machine
Forward
ZAXIS110
ZAXIS120
T176-03-03-036
W191-02-05-002
W2-5-2
UPPERSTRUCTURE / Control Valve
ZAXIS125US
Installation ZAXIS135US
NOTE: Refer to "removal" section above for ZAXIS135UR
wrench sizes and tightening torques.
1. Install the control valve to the frame and tighten
bolts (1).
4 used: (ZAXIS110, 120)
6 used: (ZAXIS125US, 135US, 135UR)
1
2. Connect all hoses, pipes and connectors to the W1SE-02-05-001
W191-02-05-002
W2-5-3
UPPERSTRUCTURE / Control Valve
DISASSEMBLE CONTROL VALVE
4-SPOOL SECTION
X
41
1
2
42
3 29
23 43 51
4
5 30
44 52
6
24 31
7
8 45
Arm Re- 25 53
9 generative
32
Valve
10 (Switch 26
Boom 54
Anti- Valve) 46
36 33
Drift 55
Valve 11 27
19
12 34
20
13 57
21 28 56
14
37 47 58 Check Valve
15 35
59 (Main Relief
16 22 38 48 Circuit)
60
17 49
39 50 61
18
40
66 73
64 67
65 68
69 74
75 W
72
62
70
63
71
X 76 W176-02-05-010
1- O-Ring 20 - Washer 39 - O-Ring 58 - Backup Ring
2- Screw 21 - O-Ring 40 - Plug 59 - O-Ring
3- Backup Ring 22 - Spool 41 - O-Ring 60 - Spring
4- O-Ring 23 - O-Ring 42 - Bolt 61 - Poppet
5- O-Ring 24 - Bolt 43 - Spring Seat 62 - Cap
6- O-Ring 25 - Spring Seat 44 - Spring 63 - Nut
7- Backup Ring 26 - Spring 45 - Spring Seat 64 - Plug
8- Backup Ring 27 - Spring Seat 46 - Main Spool 65 - O-Ring
9- O-Ring 28 - Main Spool 47 - Poppet 66 - Cap
10 - Sleeve 29 - O-Ring 48 - Spring 67 - Retaining Ring
11 - Spool 30 - Screw 49 - O-Ring 68 - Shim
12 - Washer 31 - O-Ring 50 - Plug 69 - Nut
13 - Spring 32 - Bolt 51 - O-Ring 70 - Pilot Housing
14 - Backup Ring 33 - Spring Seat 52 - Bolt 71 - Socket Bolt (11 Used)
15 - O-Ring 34 - Spring 53 - Spring Seat 72 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Spring 73 - Overload Relief Valve
17 - Spring 36 - Main Spool 55 - Spring Seat 74 - Backup Ring
18 - Poppet 37 - Poppet 56 - Main Spool 75 - O-Ring
19 - Spring 38 - Spring 57 - Plug 76 - Housing
W2-5-4
UPPERSTRUCTURE / Control Valve
Disassemble Control Valve
4-Spool Upper Section
• Be sure to thoroughly read precautions for disas- IMPORTANT: Remove main spool assemblies (28,
sembly and assembly on page W1-1-1 before 36, 46 and 56) while carefully mov-
starting the disassembly work. ing them. If they stick, even a little,
• Attach identification tags to the spool and mount- try it again instead of pulling
ing positions in the housing in order to avoid dis- roughly.
assembling. 8. Remove main spool assemblies (28, 36, 46 and
56) and O-rings (23, 31, 41 and 51) from housing
1. Remove socket bolts (71) (11 used) from housing (76).
(76), and then remove pilot housing (70).
: 8 mm IMPORTANT: Make alignment marks on main
spools (28, 36, 46 and 56) and
2. Remove boom anti-drift valve assembly (5 to 16) housing (76) in order to avoid con-
from pilot housing (70). Remove O-ring (4), and fusion during reassembling.
backup ring (3) from housing (76). 9. Clamp main spools (28, 36, 46 and 56) on a vise
NOTE: Pry the boom anti-drift valve assembly by with padded wooden pieces, then remove bolts
hand and remove it from pilot housing (70). (24, 32, 42 and 52), spring seats (25, 33, 43 and
53), springs (26, 34, 44 and 54) and spring seats
3. Remove plug (16), O-ring (15), backup ring (14), (27, 35, 45 and 55).
spring (13), washer (12), and spool (11) from : 17 mm
sleeve (10).
10. Remove plugs (40, 50), O-rings (39, 49), springs
4. Remove O-rings (4, 5, 6 and 9) and backup rings (38, 48), poppets (37, 47) from spools (36, 46).
(3, 7 and 8) from sleeve (10). : 17 mm
W2-5-5
UPPERSTRUCTURE / Control Valve
76
83
82
81 87
80 86
85
Check Valve 84
79 Orifice (Arm 1
91
78 90
Parallel Circuit) 89
77 Load Check
(Arm 2 Tan- 88
102
dem Circuit) 101
100
99
98
97 Bucket Flow Rate
96 Control Valve
95 (Poppet Valve)
94
93
92 112
103 113
111
106
104 107
108
105 109
110 W176-02-05-012
W2-5-6
UPPERSTRUCTURE / Control Valve
Disassemble Control Valve
4-Spool Side Section
14. Remove plug (110) from pilot plate (103), then
spring (108), washer (107), spool (106) and
O-ring (109).
: 36 mm
W2-5-7
UPPERSTRUCTURE / Control Valve
76
135
130 144
136
137
131
138
132 Check Valve (Flow
133 Conbiner Circuit) 146
134
Auxiliary Flow
Rate Control
Valve
154
150
W176-02-05-014
W2-5-8
UPPERSTRUCTURE / Control Valve
Disassemble Control Valve
4-Spool Lower Section
21. Remove overload relief valve (144) from housing
(76).
: 27 mm
W2-5-9
UPPERSTRUCTURE / Control Valve
DISASSEMBLE CONTROL VALVE
5-SPOOL SECTION
216
215
155 217
156
187
157
188
158 181
159 218
160 189
161 182
162 190
163 197
183
176 191
164 203
Arm Anti-Drift 184
Valve 166 177 198
167 165 178 209
168 185 192 199 204
169 179
175
173 205
170 200 210
180 186
171
201 206 211
172
193
174 207
194 212
195 202
213
196 208
214
219
W176-02-05-011
155 -Backup Ring 172 -Poppet 189 -Spring Seat 206 -Spring
156 -O-Ring 173 -Backup Ring 190 -Spring 207 -Spring Seat
157 -Plug 174 -O-Ring 191 -Spring Seat 208 -Main Spool
158 -O-Ring 175 -Overload Relief Valve 192 -Main Spool 209 -O-Ring
159 -O-Ring 176 -Plug 193 -Poppet 210 -Bolt
160 -O-Ring 177 -O-Ring 194 -Spring 211 -Spring Seat
161 -Backup Ring 178 -Backup Ring 195 -O-Ring 212 -Spring
162 -Backup Ring 179 -O-Ring 196 -Plug 213 -Spring Seat
163 -O-Ring 180 -Main Relief Valve 197 -O-Ring 214 -Main Spool
164 -Sleeve 181 -O-Ring 198 -Bolt 215 -Socket Bolt (10 Used)
165 -Spool 182 -Bolt 199 -Spring Seat 216 -Plug
166 -Washer 183 -Spring Seat 200 -Spring 217 -O-Ring
167 -Spring 184 -Spring 201 -Spring Seat 218 -Pilot Housing
168 -Backup Ring 185 -Spring Seat 202 -Main Spool 219 -Housing
169 -O-Ring 186 -Main Spool 203 -O-Ring
170 -Plug 187 -O-Ring 204 -Bolt
171 -Spring 188 -Bolt 205 -Spring Seat
W2-5-10
UPPERSTRUCTURE / Control Valve
Disassemble Control Valve
5-Spool Upper Section
1. Removing socket bolts (215) (10 used) from
housing (219), then remove pilot housing (218).
: 8 mm
W2-5-11
UPPERSTRUCTURE / Control Valve
Load Check Load Check
Valve (Arm 1 245 Valve (Arm 2
Aux. Flow Rate 229 Parallel Circuit) 246 Parallel Circuit)
Control Valve
(Poppet Valve)
230 247
231 240
241 248
232
233 242
Load Check 234 243
223 Valve (Travel 235 244
Parallel Circuit) 225 236
224 226 237
227 238
228 239
220
221
222
219
255
256
254
257
Aux. Flow Rate 258
Control Valve
(Switch Valve)
253
252
251
250 W176-02-05-013
249
W2-5-12
UPPERSTRUCTURE / Control Valve
Disassemble Control Valve
5-Spool Side Section
10. Remove plug (249) from pilot plate (256), then
disassemble O-ring (250), spring (251), washer
(252) and spool (253).
: 36 mm
W2-5-13
UPPERSTRUCTURE / Control Valve
219
140
122
139 141
114 123
142
115 124
116 143
125 146
117
145
126
118 127
119 128 153
120
129
Flow
121 Combiner
Valve
Auxiliary Flow
Combiner
147 151
Valve
148 152
149
W176-02-05-014
114 -Plug 122 -Plug 139 -Overload Relief Valve 147 -Socket Bolt (9 Used)
115 -Spring 123 -Spring 140 -O-Ring 148 -O-Ring
116 -Poppet 124 -Poppet 141 -Backup Ring 149 -Plug
117 -Spool 125 -Spool 142 -O-Ring 151 -O-Ring
118 -O-Ring 126 -O-Ring 143 -Plug 152 -Plug
119 -Washer 127 -Washer 145 -O-Ring (5 Used) 153 -Pilot Housing
120 -Spring 128 -Spring 146 -O-Ring (4 Used) 219 -Housing
121 -Bolt 129 -Bolt
W2-5-14
UPPERSTRUCTURE / Control Valve
Disassemble Control Valve
5-Spool Lower Section
19. Remove overload relief valve (139) from housing
(219).
: 27 mm
W2-5-15
UPPERSTRUCTURE / Control Valve
SEPARATE AND COMBINE 4-SPOOL AND
5-SPOOL CONTROL VALVE
219
266
265
260
261
263
262
76 264
267
268
269
259 270 271
272
273
274
275
276
277 281
279 280
278
W176-02-05-015
W2-5-16
UPPERSTRUCTURE / Control Valve
Disassemble 4-Spool and 5-Spool Sections Assemble 4-Spool and 5-Spool Sections
1. Install O-rings (260 to 262, 264, 265, 267, 269,
CAUTION: Housing (76) weight: 45 kg (99 Ib)
270, 272 to 276, 278 and 280) and backup rings
Housing (219) weight: 49 kg (108 Ib)
(263, 266, 268, 271, 277, 279 and 281) into hous-
ing (219).
1. Remove socket bolts (259) (9 used), then disas-
semble housing (76) and housing (219).
: 12 mm CAUTION: Housing (76) weight: 45 kg (99 Ib)
Housing (219) weight: 49 kg (108 Ib)
2. Remove O-rings (260 to 262, 264, 265, 267, 269,
270, 272 to 276, 278 and 280) and backup rings 2. Connect housing (76) to housing (219) with
(263, 266, 268, 271, 277, 279 and 281) from socket bolt (259).
housing (219). : 12 mm
: 108 + 9.8 N⋅m (11+1 kgf⋅m, 157 + 7 lbf⋅ft)
W2-5-17
UPPERSTRUCTURE / Control Valve
ASSEMBLE CONTROL VALVE Main Spool Main Spool
4-SPOOL SECTION (28, 56) (36, 46)
A
25, 53 33, 43
23 31 41 51 26, 54
34, 44
24, 52 32, 42
19
20 27, 55 35, 45
21
57
22
58, 59
60
61
28, 56 36, 46
76
37, 48
38, 48
39, 49
40, 50
W176-02-05-020
Section A Boom 1
W176-02-05-024
W176-02-05-025
W176-02-05-022
1- O-Ring 20 - Washer 39 - O-Ring 58 - Backup Ring
2- Screw 21 - O-Ring 40 - Plug 59 - O-Ring
3- Backup Ring 22 - Spool 41 - O-Ring 60 - Spring
4- O-Ring 23 - O-Ring 42 - Bolt 61 - Poppet
5- O-Ring 24 - Bolt 43 - Spring Seat 62 - Cap
6- O-Ring 25 - Spring Seat 44 - Spring 63 - Nut
7- Backup Ring 26 - Spring 45 - Spring Seat 64 - Plug
8- Backup Ring 27 - Spring Seat 46 - Main Spool 65 - O-Ring
9- O-Ring 28 - Main Spool 47 - Poppet 66 - Cap
10 - Sleeve 29 - O-Ring 48 - Spring 67 - Retaining Ring
11 - Spool 30 - Screw 49 - O-Ring 68 - Shim
12 - Washer 31 - O-Ring 50 - Plug 69 - Nut
13 - Spring 32 - Bolt 51 - O-Ring 70 - Pilot Housing
14 - Backup Ring 33 - Spring Seat 52 - Bolt 71 - Socket Bolt
15 - O-Ring 34 - Spring 53 - Spring Seat 72 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Spring 73 - Overload Relief Valve
17 - Spring 36 - Main Spool 55 - Spring Seat 74 - Backup Ring
18 - Poppet 37 - Poppet 56 - Main Spool 75 - O-Ring
19 - Spring 38 - Spring 57 - Plug 76 - Housing
W2-5-18
UPPERSTRUCTURE / Control Valve
Assemble Control Valve
4-Spool Upper Section IMPORTANT: When replacing sleeve (10) or spool
1. Clamp main spools (36 and 46) with wood pieces (11), replace them together.
in a vise, then install poppets (37 and 47), springs 6. Assemble O-ring (15), backup ring (14), spring
(38 and 48), O-rings (39 and 49) and plugs (40 (13), washer (12), and spool (11) onto plug (16),
and 50). then install them onto sleeve (10).
: 17 mm NOTE: When assembling washer (12), the cham-
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) fer side shall face the spring side.
2. Install spring seats (27, 35, 45 and 55), springs 7. Install arm anti-drift valve assemblies (5 to 16)
(26, 34, 44 and 54), spring seats (25, 33, 43 and onto pilot housing (70).
53) and bolts (24, 32, 42 and 52) onto main
spools (28, 36, 46 and 56) respectively. IMPORTANT: When replacing housing (76) or
: 17 mm poppet (18), tap poppet (18) with a
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) steel bar.
8. Install poppet (18) and spring (17) into housing
3. Install screw (30) and O-ring (29) onto pilot hous- (76).
ing (70), then install nut (69), shim (68), retaining
ring (67) and cap (66). 9. Install spool (22), O-ring (21), washer (20) and
: 4 mm spring (19) into housing (76).
: 17 mm
NOTE: When assembling washer (20), the cham-
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
fer side shall face the spring side.
4. Install screw (2) and O-ring (1) onto pilot housing
10. Install poppet (61), spring (60), O-ring (59),
(70), then install nut (63) and cap (62) onto screw
backup ring (58) and plug (57) into housing (76).
(2).
: 14 mm
: 4 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
: 17 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
11. Install main spool assemblies (28, 36, 46 and 56),
O-rings (4, 23, 31, 41 and 51) and backup ring (3)
5. Install backup rings (7 and 8), and O-rings (5, 6
into housing (76) respectively.
and 9) onto sleeve (10).
NOTE: Pay attention to the assembling location of
back up rings (7 and 8) and O-rings (6 and
9).
9 8 7 6
W176-02-05-023
W2-5-19
UPPERSTRUCTURE / Control Valve
A
B
70 C
Section B Arm 2 Arm 1
76 73
103
D
71
98
92
97
93
Section C Boom 1
94 99
95 100 Boom 2
96
101
102
Bucket Flow Rate Control
Valve (Poppet Valve)
W176-02-05-026
Section A Swing
88, 89
79 90
78 91
Load Check Valve
77 (Boom 1 Parallel
Circuit)
80 81 82 83 T176-03-03-005
Bypass Shut-Out Valve T176-03-03-007
W2-5-20
UPPERSTRUCTURE / Control Valve
12. Install pilot housing (70) onto housing (76) with 17. Install poppet (91), spring (90), O-ring (88),
socket bolts (71) (11 used). Install overload relief backup ring (89) into housing (76). (2 places)
valves (72 and 73) onto housing (76).
: 8 mm 18. Install bushing (87), poppet (86), spring (85) and
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) plug (84) into housing (76).
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 Ibf⋅ft) 19. Install O-rings (111 and 112) and backup ring
NOTE: Apply grease onto the O-rings of overload (113) into housing (76). Install pilot plate (103)
relief valves (72 and 73). (In order to pro- with socket bolts (104 and 105) (10 used).
tect O-rings from the breakage). : 6 mm
: 25 N⋅m (2.5 kgf・m, 18 Ibf⋅ft)
Assemble Control Valve : 8 mm
4-Spool Side Section : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
13. Install spool (106), washer (107), spring (108) and
O-ring (109) onto pilot plate (103), then install 20. Tighten plug (110) which has been temporarily
plug (110) (Temporarily tighten it). tightened in step 13.
: 36 mm : 36 mm
: 200 N⋅m (20 kgf⋅m, 145 Ibf⋅ft)
NOTE: ・ Tighten plug (110), after installation of pi-
lot plate (103) to housing(76). Pay atten-
21. Install spool (83), seat (82), spring (81), O-ring
tion to the plugs identification because
(80), and plug (79) into housing (76).
plug (110) and plug (249) have different
: 27 mm
length of screw thread.
: 180+3 N⋅m (18+0.3 kgf⋅m, 130.2+2.2 Ibf⋅ft)
・ As for plug (249), refer to W2-5-26.
NOTE: Install seat (82) with the chamfered side
14. Install poppet (101), spring (100), O-ring (99) and facing spring side.
plug (98) onto valve seat (102).
15. Install O-rings (92 and 96) and backup rings (93
and 95) onto bushing (94).
W2-5-21
UPPERSTRUCTURE / Control Valve
Section A
76
9
150
Section B
130
131
132, 133
135
Check 136
Valve
(Flow 137
Combiner
Circuit)
138 134
Aux. Flow Rate T176-03-03-002
Control Valve
W2-5-22
UPPERSTRUCTURE / Control Valve
Assemble Control Valve
4-Spool Lower Section
22. Install O-rings (146) (4 used) onto housing (76),
then install pilot housing (154) with socket bolts
(150) (5 used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W2-5-23
UPPERSTRUCTURE / Control Valve
ASSEMBLE CONTROL VALVE Main Spool Main Spool
5-SPOOL SECTION (186, 202, 208, 214) (192)
209 203 197 187 181 183, 199,
189
Section A 205, 211
190
184, 200,
206, 212
188
182, 198,
204, 210
191
185, 201,
207, 213
192
186, 202,
208, 214
193
194
195
Arm Anti-Drift Valve
B
W176-02-05-021 196
A
W176-02-05-024
175 Section B Arm Anti-Drift Valve
164 157
158 159
218 160
215 161
165
180 162
219 163
168
166
169
167
170
171
172
W176-02-05-027
T176-03-03-038
155 -Backup Ring* 172 -Poppet 189 -Spring Seat 206 -Spring
156 -O-Ring* 173 -Backup Ring 190 -Spring 207 -Spring Seat
157 -Plug 174 -O-Ring 191 -Spring Seat 208 -Main Spool
158 -O-Ring 175 -Overload Relief Valve 192 -Main Spool 209 -O-Ring
159 -O-Ring 176 -Plug 193 -Poppet 210 -Bolt
160 -O-Ring 177 -O-Ring 194 -Spring 211 -Spring Seat
161 -Backup Ring 178 -Backup Ring 195 -O-Ring 212 -Spring
162 -Backup Ring 179 -O-Ring 196 -Plug 213 -Spring Seat
163 -O-Ring 180 -Main Relief Valve 197 -O-Ring 214 -Main Spool
164 -Sleeve 181 -O-Ring 198 -Bolt 215 -Socket Bolt (10 Used)
165 -Spool 182 -Bolt 199 -Spring Seat 216 -Plug
166 -Washer 183 -Spring Seat 200 -Spring 217 -O-Ring
167 -Spring 184 -Spring 201 -Spring Seat 218 -Pilot Housing
168 -Backup Ring 185 -Spring Seat 202 -Main Spool 219 -Housing
169 -O-Ring 186 -Main Spool 203 -O-Ring
170 -Plug 187 -O-Ring 204 -Bolt
171 -Spring 188 -Bolt 205 -Spring Seat
NOTE: As for the item with a mark ‘*’ refer to W2-5-10.
W2-5-24
UPPERSTRUCTURE / Control Valve
Assemble Control Valve
5-Spool Upper Section 5. Install arm anti-drift valve assembly (157 to 170)
1. Clamp main spool (192) with wood pieces in a onto pilot housing (218).
vise. Install poppet (193), spring (194), O-ring
(195) and plug (196). IMPORTANT: Tap poppet (172) with a steel bar
: 17 mm when replacing housing (219) or
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) poppet (172).
2. Install spring seats (185, 191, 201, 207 and 213), 6. Install poppet (172) and spring (171) onto housing
springs (184, 190, 200, 206 and 212), spring (219).
seats (183, 189, 199, 205 and 211), and bolts
(182, 188, 198, 204 and 210) onto main spools 7. Install main spool assemblies (186, 192, 202, 208,
(186, 192, 202, 208 and 214) respectively. and 214), O-rings (156, 181, 187, 197, 203 and
: 17 mm 209) and backup ring (155) into housing (219).
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
8. Install pilot housing (218) onto housing (219) with
3. Install backup rings (161 and 162) and O-rings socket bolts (215) (10 used). Then install
(159, 160 and 163) onto sleeve (164). Install overload relief valve (175) and main relief valve
O-ring (158) onto plug (157). (180) onto housing (219).
NOTE: Pay attention to the mounting location of : 8 mm
backup rings (161 and 162) and O-rings : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
(160 and 163). : 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 lbf⋅ft)
163 162 161 160
W176-02-05-023
W2-5-25
UPPERSTRUCTURE / Control Valve
223 Section B Travel (Left) Boom 2 Section C
224 219
255
254
256
Load Check Valve
(Travel Tandem Cir-
cuit)
248
E
D 248
247
C 247
Aux. Flow
B 245, 246
Rate A
Control Load
Valve 225, Check
226 Valve
T176-03-03-036
249 (Boom 2
250 251 252 253
Parallel
Aux. Flow Rate Circuit)
227
Control Valve
(Switch Valve) 228
Load Check
235 Valve (Travel
229
234 Parallel Cir- W176-02-05-029
230 cuit)
Section D Arm 1 Swing Section E
231 236
232 237
233
238
239 Load
Aux. Flow Rate Control Check
Valve (Poppet Valve) Load Check Valve
Valve (Arm 1 (Swing Cir-
W176-02-05-026
Parallel Cir-
Section A
cuit)
248 248
248
247 247
247 240,
245,
241
245, 246 246
242
Check Valve
(Main Circuit)
242
240,
241
243
244
Load Check
Valve (Arm 1
Tandem Cir-
cuit)
W176-02-05-030
W176-02-05-028
219 -Housing 229 -O-Ring 239 -Valve Seat 249 -Plug
220 -Socket Bolt 230 -Backup Ring 240 -O-Ring 250 -O-Ring
221 -Cover 231 -Bushing 241 -Backup Ring 251 -Spring
222 -O-Ring 232 -Backup Ring 242 -Plug 252 -Washer
223 -Socket Bolt 233 -O-Ring 243 -Spring 253 -Spool
224 -Pilot Plate 234 -Spring 244 -Poppet 254 -Socket Bolt (6 Used)
225 -O-Ring 235 -Plug 245 -O-Ring (3 Used) 255 -Socket Bolt (4 Used)
226 -Backup Ring 236 -O-Ring 246 -Backup Ring (3 Used) 256 -Pilot Plate
227 -Spring 237 -Spring 247 -Spring (5 Used) 257 -O-Ring*
228 -Poppet 238 -Poppet 248 -Poppet (5 Used) 258 -O-Ring*
NOTE: As for the item with a mark ‘*’ refer to W2-5-12.
W2-5-26
UPPERSTRUCTURE / Control Valve
Assemble Control Valve
5-Spool Side Section
9. Install spool (253), washer (252), spring (251) and
O-ring (250) into pilot plate (256), then install plug
(249) (temporarily).
: 36 mm
NOTE: Tighten plug (249) after installing pilot plate
(256) onto housing (219). Pay attention to
the length of threaded portion because the
thread length of plug (249) and plug (110)
is different.
W2-5-27
UPPERSTRUCTURE / Control Valve
Section B
219
147
153
A
139
T176-03-03-036 W176-02-05-021
145 145 145 145 145
Section A
114
122
123
115
Flow 124
Combiner 116 Auxiliary Flow Com-
Valve biner Valve
125
117
126, 127
118, 119
128
120
129
121
W176-02-05-028
114 - Plug 122 - Plug 115 - Bolt 147 - Socket Bolt (9 Used)
115 - Spring 123 - Spring 139 - Overload Relief Valve 148 - O-Ring*
116 - Poppet 124 - Poppet 140 - O-Ring* 149 - Plug*
117 - Spool 125 - Spool 141 - Backup Ring* 151 - O-Ring*
118 - O-Ring 126 - O-Ring 142 - O-Ring* 152 - Plug*
119 - Washer 127 - Washer 143 - Plug* 153 - Pilot Housing
120 - Spring 128 - Spring 145 - O-Ring (5 Used) 219 - Housing
121 - Bolt
NOTE: As for the item with a mark ‘*’ refer to W2-5-14.
W2-5-28
UPPERSTRUCTURE / Control Valve
Assemble Control Valve
5-Spool Lower Section
IMPORTANT: Overall dimensions of spool (117)
have been determined. When dis-
assembling or replacing poppet
(116), spring (115) and plug (114),
replace them as an assembly.
20. Clamp spool (117) with wood pieces in a vise,
then install washer (119), spring (120) and bolt
(121).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
NOTE: Assemble washer (119) with the chamfered
side facing spring side.
W2-5-29
UPPERSTRUCTURE / Control Valve
DISASSEMBLE BLADE CONTROL VALVE 19
20
(ZAXIS135UR ONLY) 10 21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1
37
38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11
44
56 45
55
54
53 46
52 47
51
48 62
61
60
50
49
59
58
57
W198-02-05-001
W2-5-30
UPPERSTRUCTURE / Control Valve
Disassemble Blade Control Valve
• Be sure to thoroughly read all precautions for 5. Remove sleeve assembly (37 to 42) from housing
disassembly/assembry work on page W1-1-1 (62).
before starting any repair work. : 36 mm
2. Remove spool assembly (51 to 59) from housing 7. Secure seat (37) in a vice. Remove sleeve (41),
(62). spring (40), valve (39), and O-rings (38, 42).
: 36 mm
NOTE: When removing the spool assembly, be NOTE: As plate (61) is installed with drive screw
sure to pull it out straight to prevent it from (60), be sure not to disassemble the plate.
damaging spool (57) inside housing (62).
W2-5-31
UPPERSTRUCTURE / Control Valve
ASSEMBLE BLADE CONTROL VALVE
(ZAXIS135UR ONLY) Cross Section
X-X 37 39 40 38
41
43
62
42
44
1~18 A1 B1 19~36
A1 B1
X X
W198-02-05-003
W198-02-05-002
57
Cross Section
W-W
54 53 55 56 62
50 51 52 47
48 45
W W
W198-02-05-004
49
57 59 58 46
W198-02-05-005
W2-5-32
UPPERSTRUCTURE / Control Valve
1. Secure seat (37) in a vice. Install O-ring (38), 6. Insert spool assembly (51 to 59) to housing (62)
valve (39), spring (40), sleeve (41), and O-ring through port A1 side.
(42).
: 36 mm
NOTE: When installing the spool assembly, be
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
sure to install it straight to prevent it from
damaging spool (57) inside housing (62).
2. Install valve (44) and spring (43) into housing
(62).
7. Install O-ring (56) to cover (50) and O-ring (47) to
cover (46). Install them to housing (62) with
3. Install sleeve assembly (37 to 42) to housing (62).
socket bolts (45) (2 used), (48), and (49).
: 36 mm
: 6 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
: 25.5 N⋅m (2.6 kgf⋅m, 18.8 lbf⋅ft)
IMPORTANT: As each set pressure is different, be
sure to install overload relief valve
assemblies (1 to 18) and (19 to 36)
correctly.
4. Install overload relief valve assembly (1 to 18)
and (19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
W2-5-33
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-34
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Preparation
1. Place the machine on a firm, level surface.
W2-6-1
UPPERSTRUCTURE / Swing Device
Removal
ZAXIS110,120
1. Disconnect hoses (1, 3 to 6) and harness (2).
: 36 mm 1 2 3 4 5 6
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 6 mm Front
: 20 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft)
NOTE: Attach caps to the hoses.
W176-02-06-002
W2-6-2
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-3
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING DEVICE
22
23 1
24
32 21
25 4
31 5
20 6
26 7
19
8
27
18 9
28 10
17
11
29
16
12
30 15 13
14
W176-02-06-003
1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing
2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-4
UPPERSTRUCTURE / Swing Device
Disassemble Swing Device
4. Remove pipe (32) from housing (25).
CAUTION: Swing device weight:
: 18 mm
130 kg (290 Ib)
5. Put alignment marks at the jointed portion be-
1. Secure the swing device body with nylon slings,
tween swing motor (1) and ring gear (24), be-
then hoist it by crane.
tween ring gear (24) and housing (25).
Nylon Sling
CAUTION: Swing motor weight: 34 kg (75 Ib)
6. Remove swing motor (1) from ring gear (24).
: 8 mm
NOTE: THREEBOND has been applied on the
joint faces. Insert a screw driver into the
gap between the swing motor and the ring
gear. Then pry it up for easy removing.
ST 5098
Stopper
W178-02-06-012
W2-6-5
UPPERSTRUCTURE / Swing Device
23
25 21
4
26 7
18
28
17
11
16
30 15
14
W176-02-06-003
W2-6-6
UPPERSTRUCTURE / Swing Device
IMPORTANT: The hole for the spring pin located
CAUTION: Housing assembly weight: 63 kg
on the first stage carrier does not
(140 lb)
continue through. Pay attention to
the drive-in distance when driving
20. Install eye bolt (M14) into the bolt (23) hole of
spring pin in.
housing (25). Hoist it by crane. Remove bracket
12. Drive spring pin (5) in the first stage carrier (21)
(ST 5098) which has been installed at the pinion
assembly into pin (4) with special tool (ST 1462).
gear side.
Do not drive spring pin (5) to the end.
: 30 mm
13. Remove pin (4), planetary gear (7), needle bear-
ing (6) and thrust plate (8) from first stage carrier CAUTION: Before pressing shaft (30), pro-
(21). vide a protection cover (outer diameter: 290
mm (11.4”), inner diameter: 90 mm (3.5”),
14. Remove remaining two sets of pin (4), planetary thickness: 25 to 30 mm).
gear (7), needle bearing (6) and thrust plate (8) Then, use the press to remove the shaft
from first stage carrier (21) according to the re- while covering housing (25) and bearing (14)
moval procedure in step 12, step 13. with the protection cover may result in per-
sonal injury due to metal fragments flying out
15. Remove thrust plate (3) from first stage carrier if the housing and/or bearing break.
(21). Use a press of capacity less than 30 tons
(66000 lb). Be sure to degrease the housing
IMPORTANT: The surface of the pin except for inside before heating the bearing. Failure to
both ends is a rotating surface for degrease may cause a fire.
the needle bearing. 21. Install the protection cover on housing (25). Push
Pay attention not to damage it. the upper end of shaft (30) with a press and re-
16. Clamp pin (4) with a vise. Push spring pins (5) (3 move it from the housing. The inner race of roller
used) out using special tool (ST 1462). bearing (26) and sleeve are removed with the
shaft. Shaft (30) Roller Bearing
17. Disassemble the second stage carrier (18) as- (14)
Housing (25)
sembly according to the removal procedure for
first stage carrier (21) assembly. Be sure that the
number of thrust plates (11) is 6.
Protection
Cover
18. Remove bolt (17). Remove lock plate (16) for
bearing nut (15).
: 17 mm
ST 2927
15 Press
Protection
Cover
W178-02-06-008
W157-02-06-011
W2-6-7
UPPERSTRUCTURE / Swing Device
25
26
27
28
29
30 15
14
W176-02-06-003
W2-6-8
UPPERSTRUCTURE / Swing Device
22. Attach the shaft (30) assembly to the special tool IMPORTANT: Be sure to use the guide when push-
bearing removal set. ing shaft (30) with a press.
Then, remove the shaft using a press.
Press
NOTE: Use the following parts as the special tool
set for removing bearing (26).
Part Size Remarks
Shaft Length: 200 mm 8 used. All should be Roller Bearing Shaft
or Bolt (8 in) identical in length with no (26) Inner Race
Diameter: 19 mm wear and deformation on
(3/4 in) both ends. Sleeve (28)
Material: S35C (JIS),
1035 (AISI)
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2” (Appli-
cable Diameter: Guide
185 to 215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter: W157-02-06-014
230 mm (9.06 in)
Inner Diameter: 23. Push the spline side of shaft (30) with a press
210 mm (8.27 in) and remove it from the housing. The inner race of
roller bearing (26) and sleeve (28) are removed
Bearing Removal Tool from the shaft.
Shaft 24. Remove O-ring (29) from sleeve (28).
Hose Clamp
Oil Passage
Outer Race
W157-02-06-012
Shaft
Inner Race of W178-02-06-001
Roller Bearing
(26)
Sleeve (28)
CAUTION: Housing (25) weight: 36 kg (79 Ib)
26. Secure housing (25) body with nylon sling, hoist it
by crane. Turn the up side of the housing down.
IMPORTANT: Push the shaft of the special tool 28. Insert a bar at the back side of the outer race of
into the gully side of the pinion. Se- roller bearing (14). Remove the outer race from
cure the shaft with the hose clamp housing (25) while tapping with a bar and ham-
in order not to loosen and separate. mer.
W2-6-9
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING DEVICE
5
3
22
21
7
24
6
20
18
4
19
8
10
23
11
13
12
11
17 9
15
16 14
32
25
26
31
27
28 30
29
W176-02-06-004
W2-6-10
UPPERSTRUCTURE / Swing Device
Assemble Swing Device
1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put the oil seal evenly on housing
IMPORTANT: Pay attention to the mounting direc- (25) and push it in gently. Then place seal
tion for the sleeve and the inner mounting tool (ST 2928) on the oil seal and tap it
race. with a hammer directly.
2. Install sleeve (28), and the inner race of roller with
ST 2928
a bearing (26) into shaft (30). Press the sleeve
and inner race using bearing mounting tool (ST 27
2929).
NOTE: Press-in distance of the bearing inner race 25
can be assured by using the bearing
mounting tool.
W176-02-06-006
Press
NOTE: According to following steps, oil seal (27)
can be replaced without removing shaft
(30).
• Drain oil out inside of the reduction gear.
ST 2929 • Place the swing device horizontally.
• Remove the oil seal with a screw driver.
26 • Clean off from housing (25).
28 • Apply THREE BOND #1215 onto the outer sur-
face of the oil seal and apply grease onto its
30 inner surface.
• Install the oil seal into the housing by pushing
with hand gently.
• Place the oil seal mounting tool guide (ST
W178-02-06-013
7247) onto the pinion gear.
• Cover the oil seal mounting tool (ST 2928) by
the mounting tool guide (ST 7247), then push it
to the oil seal upper side.
• Install the oil seal into the housing while tapping
CAUTION: Housing weight: 36 kg (79 Ib)
the oil seal mounting tool (ST 2928) with a
3. Secure the housing (25) body with the nylon sling,
hammer.
then hoist it by crane. Place sleeve (28) with the
mounting side upward.
Pinion Gear
W2-6-11
UPPERSTRUCTURE / Swing Device
24
23
15
14
25
27
28 30
W176-02-06-004
W2-6-12
UPPERSTRUCTURE / Swing Device
6. Apply grease all around the inner face of oil seal 11. Screw in bearing nut (15) to shaft (30). Tighten as
(27). Apply grease onto the outer surface of much as is possible by hand.
sleeve (28) on shaft (30). NOTE: Avoid shaft (30) falling down when lifting
NOTE: Apply the grease carefully when installing housing (25).
the shaft to avoid accidental curling of the
seal lip from the shaft.
CAUTION: Housing + shaft + bearing weight:
59 kg (130 Ib)
CAUTION: Housing +outer race weight: 12. Hoist housing (25) by crane and eyebolt (M14)
37 kg (82 Ib) installed in step 9. Place it on a press.
7. Secure the housing (25) body with the nylon sling
and hoist it by crane. Place ring gear (24) with the 13. Remove bearing nut (15) from shaft (30).
mounting side upward.
14. Place mounting tool (ST 2930) onto the inner
8. Tap the outer race of roller bearing (14) evenly race of roller bearing (14). Push the inner race
with a mounting bar and hammer. When installing down using a press.
the outer race into housing (25). Check if installa- NOTE: Press-in distance of the inner race can be
tion is completed by the tapping sound. assured by using the mounting tool.
ST 2930
CAUTION: Housing + outer races (2 used)
weight: 38 kg (84 Ib)
14
IMPORTANT: Pay attention to the problem of curl-
ing the oil seal lip.
9. Install eyebolt (M14) into the ring gear mounting
bolt (23) hole in housing (25). Then hoist and
place it on shaft (30) by crane slowly. Check and
align carefully to protect the oil seal lip from curl-
ing while mounting it.
W178-02-06-011
10. Tap inner race of roller bearing (14) into shaft (30)
with a mounting bar and hammer. Tap the inner
race until two threads lengths of the shaft bearing
nut (15) inner race must appear.
NOTE: The fitting between the inner race and the
shaft is tight.
W2-6-13
UPPERSTRUCTURE / Swing Device
18
19
10
11
13
12
11
17 9
15
16 14
25
30
W176-02-06-004
W2-6-14
UPPERSTRUCTURE / Swing Device
15. Hoist the housing (25) assembly and place it on 17. Install lock plate (16) onto bearing nut (15) with
bracket (ST 5098) by crane. Secure it with bolts bolt (17). In case the spline of lock plate and that
(M20) (2 used) while the stopper at the bottom of of shaft (30) are not aligned, tighten the bearing
bracket is located at the middle of two teeth of the nut in tightening direction until both splines are
pinion gear. Secure the bracket on a working aligned.
bench. : 17 mm
: 30 mm : 50 N⋅m (5 kgf⋅m, 36.2 lbf⋅ft)
W178-02-06-008
W2-6-15
UPPERSTRUCTURE / Swing Device
5
3
22
21
24 7
20 6
18
4
23
16
32
25
31
30
W176-02-06-004
W2-6-16
UPPERSTRUCTURE / Swing Device
IMPORTANT: Pay attention to the mounting loca- 24. Install the first stage carrier (21) assembly onto
tion of thrust plate (8). the spline of second stage sun gear (20).
19. Assemble the following parts to form the first
stage carrier (21) assembly. According to the IMPORTANT: Pay attention to the mounting direc-
procedure mentioned for the second stage carrier tion of first stage sun gear (2).
assembly, install planetary gears (7) (3 used), 25. Install first stage sun gear (2) into the first stage
needle bearings (6) (3 used), thrust plates (8) (3 carrier (21) assembly with the stepped side of sun
used), pins (4) (3 used), spring pins (5) (3 used) gear facing downward.
and thrust plate (3) (1 used) together. Thrust plate
(8) is installed under needle bearing (6). 26. Wind sealing tape on the threaded part of pipe
(32). Install pipe (32) into housing (25) with the
IMPORTANT: Pay attention to the mounting direc- pipe facing downward.
tion of second stage carrier (18). : 18 mm
20. Install the second stage carrier (18) assembly
onto the spline of shaft (30), while the concave 27. Wind the sealing tape on drain plug (31), then
portion of the boss in bottom side of the carrier install it into pipe (32).
comes in contact with lock plate (16). : 8 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
Concave
Portion 1 28. Fill the gear oil into ring gear (24) until the middle
1 part of first stage sun gear (2) is submerged in.
3 (Approx. 3.2 L)
23. Fasten ring gear (24) and housing (25) with bolts
(23) (12 used) aligning the marks which were
added in disassembling.
: 12 mm
: 140 N⋅m (15 kgf⋅m, 109 Ibf⋅ft)
W2-6-17
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR
34 1
33 2
32 3
4
31
5
30
6
29
28 7
27
26
8
25
9
24
10
23
11
22
23 12
13
22
14
23
15
22
23
22 16
17
21 18
19
20
W176-02-06-008
W2-6-18
UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
CAUTION: Swing motor weight: 34 kg (75 Ib) 6. Supply air through the parking brake oil port of
1. Secure the swing motor body with the nylon sling. casing (20). Lift piston (25) and remove it.
Then hoist it by crane. Place it with the valve unit NOTE: In case it is impossible to lift, push the pi-
(32) side upward. Shaft (7) extends out of casing son back and pull it out again using piston
(20) at bottom side. Place the swing motor on a mounting tool (ST 2921, ST 2922). As for
square block of height of more than 50 mm (2 in). the operation of the tool, refer to the
explanation for swing motor assembling.
IMPORTANT: Pay attention to valve plate (27)
when removing valve unit (32). It
has a tendency to fall.
2. Loosen and dismount socket bolt (34). Remove 20
valve unit (32) from casing (20). Oil Port
: 14 mm
W2-6-19
UPPERSTRUCTURE / Swing Device
10
11
12
14
15
16
17
19
20
W176-02-06-008
W2-6-20
UPPERSTRUCTURE / Swing Device
10. Hang two feet of tool (ST 1458) on the internal IMPORTANT: When removing roller bearing (9)
diameter side of swash plate (6). Pull it out of from shaft (7), hold the shaft by
casing (20). hand to prevent it from dropping. If
dropped, needle bearing (30) rotat-
ST 1458 ing face of the shaft will be dam-
6 aged.
16. Clamp bearing extractor (ST 1459) in a vise. In-
20 stall shaft (7) with the spline end facing upward.
Tap the spline end with a plastic hammer, to re-
move roller bearing (9) from the shaft.
W176-02-06-011
ST 1459
13. Tap the shaft (7) head at spline side with a plastic
hammer. Remove the shaft from casing (20) with
roller bearing (9).
W176-02-06-021
14. Remove oil seal (11) with a screw driver. As
THREEBOND was applied on the outer surface
of the oil seal, it cannot be reused. 17. Remove plug (12) from casing (20). Pull out
spring (14) and poppet (15).
IMPORTANT: Pay attention to the oil seal (11) lip : 6 mm
contact surface of shaft (7). Do not
damage it. 18. Remove plug (19) from casing (20). Pull out
15. Remove retaining ring (10) from shaft (7). spring (17) and plunger (16).
: 6 mm
W2-6-21
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
34
32
33
30
28
29
27
16 17 19 18
15 31
14
25
13
26
12
24
23
22
5
Parking Brake Release Block
4
21
8
6
9
2
20
3
10 11 W176-02-06-012
7
W2-6-22
UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
1. Place casing (20) onto a 50 mm (2 in) square IMPORTANT: Pay attention to the mounting direc-
block with valve unit (32) mounting side upward. tion of the roller bearing.
2. Install spring (17) onto plunger (16) and insert it 7. Install roller bearing (9). Stamped marks on the
into the hole of the parking brake release block. outer race, inner race and inner race plate should
be facing upward.
3. Install O-ring (18) onto plug (19). Install it into the
hole of the parking brake release block.
Stamped Mark on Outer Race Stamped Mark on Inner Race
: 6 mm
: 34.3 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
ST 2898
7
11
ST 2897
9
20
ST 2896
W176-02-06-010
W176-02-06-018
10. Install retaining ring (10) onto shaft (7). Pay atten-
tion not to cause any damage the seal lip contact
surface of the shaft.
W2-6-23
UPPERSTRUCTURE / Swing Device
32
25
26
24
23
22
5
Parking Brake Release Block
4
21
8
6
20
3
11 W176-02-06-012
7
W2-6-24
UPPERSTRUCTURE / Swing Device
11. Apply grease onto the seal lip contact surface of Install retainer (4) onto bushing (3) with the
shaft (7) and the inner surface of oil seal (11). chamfer side facing downward.
4
12. Insert shaft (7) into casing (20). After alignment,
push it in while tapping the end of shaft with a
plastic hammer. Check if mounting is completed
by the tapping sound.
Chamfer Side
13. Install retaining ring (8) into housing (20).
3 W176-02-06-016
W176-02-06-015
W2-6-25
UPPERSTRUCTURE / Swing Device
34
32
33
30
28
29
27
31
25
20
W176-02-06-012
W2-6-26
UPPERSTRUCTURE / Swing Device
22. Place piston (25) on casing (20) horizontally. 25. Install O-ring (31) into valve unit (32).
Cover the piston with piston mounting tool (ST
2921 and ST 2922). Tap the piston in with a 26. Apply grease on the flat surface of valve plate
hammer. (27).
NOTE: Apply grease on the valve plate to protect it
ST 2922 from falling when installing the valve unit
into the motor.
28. Install valve unit (32) into casing (20) with spring
washers (33) (4 used) and socket bolts (34) (4
used).
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
W176-02-06-020
24. Install needle bearing (30) into valve unit (32) us-
ing bearing mounting tool (ST 2899).
ST 2899
30
32
W176-02-06-019
W2-6-27
UPPERSTRUCTURE / Swing Device
DISASSEMBLE VALVE UNIT
7
6
1 2 3 4 5 9
10
11
12
4
3
2
1
13
14
15
16
W176-02-06-007
16
15
14
13
W2-6-28
UPPERSTRUCTURE / Swing Device
Disassemble Valve Unit
As for the procedure to remove the valve unit IMPORTANT: Take care not to damage the inner
from the swing motor, refer to “Disassemble and surface of the valve housing (5).
Assemble Swing Motor” section. 6. Insert a round bar into valve housing (5) to push
spool (12) to the other side. There is a ring (4) (1
IMPORTANT: The lower section of the valve hous- used) with the spool. When feeling a little tight,
ing is the contact surface for the insert a round bar from the other side to push the
valve plate. Take care not to damage spool back. Repeat this action as needed.
it.
1. Put valve housing (5) on a work bench with a rag 7. Remove ring (4) (1 used) left in valve housing (5)
or a shop cloth. with a magnet.
Cartridge
Lock Nut
W176-02-06-017
W2-6-29
UPPERSTRUCTURE / Swing Device
ASSEMBLE VALVE UNIT
10
11
13
14
15
16
2 1 3 4 12 4 3 1
2
Section E
W176-02-06-013
W2-6-30
UPPERSTRUCTURE / Swing Device
Assemble Valve Unit
1. Install O-ring (9) to relief valves (8) (2 used). 6. Install O-ring (14) to plug (13) and then install
them to valve housing (5) (2 places).
IMPORTANT: Pay attention to the assembling or- : 12 mm
der of the O-ring and the backup : 235 N⋅m (24 kgf⋅m, 174 Ibf⋅ft)
ring.
2. Install O-ring (7), and backup ring (10) to relief 7. Install ring (4) on one side of spool (12). Then in-
valves (8) (2 used). sert the other side of the spool to valve housing
(5). Push the spool until the spool comes in mid-
IMPORTANT: Pay attention to the assembling or- dle of valve housing (5). Take care not to drop the
der of the O-ring and backup ring. ring into the valve housing.
3. Install backup ring (6), O-ring (11) to relief valves
(8) (2 used). 8. Push spool (12) until the end of the spool just
comes out of the opposite hole of valve housing
IMPORTANT: If the lock nut of the relief valve is (5). When pressing too much, ring (4) in the spool
turned, the set-pressure may be will come off in the valve housing.
changed. Do not turn the lock nut.
4. Turn the cartridge of relief valve (8) to install it to 9. Install ring (4) to the end of spool (12) which
valve housing (5). (2 places) comes out from valve housing (5), and then push
: 32 mm the ring to the stepped part of the spool with
: 235 N⋅m (24 kgf⋅m, 174 lbf⋅ft) spring (3).
W176-02-06-017
W2-6-31
UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD Shoe
Swing Motor
ε ≤ 0.2 mm
Rotor
Standard Allowable limit
0 0.05 mm (0.0020 in)
D-d ≤ 0.05 mm
W105-02-06-134
Plunger Assembly
d
Rotor
W105-02-06-135
W2-6-32
UPPERSTRUCTURE / Swing Device
Parking brake
W176-02-06-022
C Unit: mm (in)
Allowable
Parts Name Standard Remedy
Limit
A Friction Plate Thickness 2.4 (0.094) 2.35 (0.093)
B Disc Spring (Overall height) 6.8 (0.268) 6.7 (0.263)
C Piston Thickness* 41.0 (1.614) −
D Plate Thickness 1.4 (0.055) 1.35 (0.053)
Remarks Piston does not slide, so no wearing to it.
Plunger
W155-03-02-007
Unit: mm (in)
Standard Allowable Limit Remedy
A 5.5 (0.217) 5.3 (0.209) Replace
W2-6-33
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-34
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE (ZAXIS110, 120, 125US, 135US)
Preparation
1
1. Place the machine on a firm, level surface.
(ZAXIS125US, 135US)
Remove seat mounting bolts (2) (4 used) and
bolts (3) (2 used) under the seat bolt to remove
seat (1).
: 17 mm, 16 mm
W1SE-02-01-001
ZAXIS125US, 135US
1
3
W1SE-02-01-002
W2-7-1
UPPERSTRUCTURE / Pilot Valve
2. Remove screws (28) (4 used), cover (27) to more
boot (7) upward.
29
34
33 30
31
32
W178-02-07-002
29 - Hose T6: (To the pilot shut-off valve)
30 - Hose H: (To the signal control valve port H (bucket
roll-out))
31 - Hose A: (To the signal control valve port A (boom raise))
32 - Hose P3: (From the pilot shut-off valve)
33 - Hose G: (To the signal control valve port G (bucket roll-in))
34 - Hose B: (To the signal control valve port B (boom lower))
W2-7-2
UPPERSTRUCTURE / Pilot Valve
2. Connect hoses (29 to 34).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
4. Install switch box (12) with bolt (11), then connect W178-02-07-002
connector (13).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft) 4
20
14
15
16
19 17
18
W1CC-02-07-001
W2-7-3
UPPERSTRUCTURE / Pilot Valve
8. (ZAXIS110, 120)
Install seat (1) (with the seat stand) with nut (2). ZAXIS110, 120
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installation, check the oil level,
start the engine and check for oil
leaks.
(ZAXIS125US、135US)
Install seat (1) with seat mounting bolts (2) (4 1
used) and bolts (3) (2 used) under the seat belt.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2
: 16 mm
: 70 N⋅m (7.1 kgf⋅m, 51 lbf⋅ft) W178-02-01-001
W1SE-02-01-001
ZAXIS125US, 135US
1 3
W1SE-02-01-002
W2-7-4
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL LEFT PILOT
VALVE (ZAXIS110, 120, 125US, 135US)
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.
Removal
M104-07-021
1. Remove screw (2) and cover (3) to move boot (1)
upward. At this time, the console is at the most
front position.
: 17 mm
2
9 Radio
3
8
4
7
6
5
W178-02-07-003
W2-7-5
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Attach identification tags on all dis-
connected hoses for reassembly.
3. Disconnected hoses (10 to 15).
: 19 mm
NOTE: Attach a cap on each disconnected hose
end. 10
15
14 11
4. Loosen nut (17). Remove clips (28) and (20) and
12
disconnect connector (27) to remove grip (16)
(with harness). 13
Loosen nut (19) to remove lever (18), washers
(24) and (25) and boot (1).
: 22 mm
: 19 mm
W178-02-07-003
W2-7-6
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: If the harness is arranged to the in-
side of spring pin (21), it may make
contact with the moving part of the
pilot valve damaging it. Be sure to 16
arrange harness to the outside of
spring pin (21).
3. Temporarily tighten nut (19) to lever (18), then in- 28
stall washers (24) and (25).
17
4. Install lever (18) onto valve (26) with nut (19). 18
27
1
5. Install boot (1). 19
Temporarily tighten nut (17) to lever (18), then 20
secure grip (16) with nut (17). 21
22
6. Pass the harness of grip (16) through the upper
hole of boot (1), then connect it to lever (18) with 24
clips (28) and (20). 25
26
7. Arrange the harness to the outside of spring pin 9 Radio 2
(21) over bolt (22) head connect connector (27). 8 3
: 22 mm 4
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
: 19 mm
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
W2-7-7
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT/ SWING
PILOT VALVE (ZAXIS135UR) 4
ZAXIS135UR
Removal
IMPORTANT: Be sure to release any pressure in
the hydraulic oil tank before any
work. (Refer to W1-4-1.)
W2-7-8
UPPERSTRUCTURE / Pilot Valve
Installation
5
W2-7-9
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
1
17
W176-02-07-001
W2-7-10
UPPERSTRUCTURE / Pilot Valve
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage them. port number after removing.
Therefore, handle with care.
4. Pull push rods (8) and (9) out of block (10).
IMPORTANT: As spool (17) has been selected to
match the hole of housing (18), they 5. Using a bamboo spatula, remove oil seals (15) (4
must be replaced as a set. In addi- used) from block (10).
tion, the dimensions of balance NOTE: If a metal bar is used, the mating part of oil
springs A (3), B (4) and return seal may be damaged.
springs A (5), B (6) as well as those
of push rods A (8), B (9) are different. IMPORTANT: The retaining ring may come off
For this reason, be sure to indicate while disassembling. Take care not
the port number from which each is to drop it.
removed. Port numbers are stamped 6. Press springs with special tool (ST 7257) from the
on housing (18). top of spring guide (16). Retaining ring (7) will
appear. Remove it with a screw driver or similar
IMPORTANT: Do not clamp housing (18) in a vise tool. (4 places)
to remove the screw joint because 7
the strong torque may act on the
screw joint.
1. Secure screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm
W2-7-11
UPPERSTRUCTURE / Pilot Valve
21
20
21
20
19
18
17
W176-02-07-001
W2-7-12
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: As spool (17) has been selected to
match the hole of housing (18), keep
them carefully so as to install them
to the former port when reassem-
bling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it slowly.
NOTE: The spool and the housing must be re-
placed as an assembly.
W2-7-13
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
14
10
12
15
11
8, 9
7
16
3, 4
5, 6
19
17
W176-02-07-006
21 20 18
W2-7-14
UPPERSTRUCTURE / Pilot Valve
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to con- IMPORTANT: Install spring guide (16), with the
tamination. Keep parts clean when protrusion facing upward.
assembling. 3. Install spring guides (16) (4 used) onto return
springs (3) (2 used) or (4) (2 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).
ST 7255
Port Spool Shim Push rods 7
No. (17) (2) (8), (9)
1 with outer
Same to Same to groove
W176-02-07-008
2 the former the former without outer
one one groove
5. Insert the spool (17) head into the hole of spring
3 with outer
special tool (ST 7257) to press the spring from
groove
the top of spring guide (16). Install retaining ring
4 without outer
(7) with the ring holder (ST 7255) onto the head
groove
of the spool.
7
Port Return Springs Blance Springs ST 7255
ST 7257
No. (5), (6) (3), (4)
1 short short
2 long long 17
3 short short 16
4 long long
Packing Material
IMPORTANT: Make sure of the port hole number
and insert spool (17) to the former
W176-02-07-009
port.
NOTE: Put approx. dia. 8 mm, length 10 mm of
1. Insert the thinner end of spools (17) (4 used) to
packing material into the port hole, to not
housing (18), then push the spool rotating it.
only make the work easy to do, but also
NOTE: The spool has been selected to match the prevent the spool from lowering to the bot-
hole of the housing. The spool and housing tom when compressing the spring.
must be replaced as an assembly.
6. Assemble the remained spools (17) (3 used) into
IMPORTANT: Refer to the table above to assemble housing (18) in the same procedures as step 2 to
them correctly. 5.
2. Install spacers (1) (4 used), shim (2), balance
springs (3) (2 used) or (4) (2 used), return springs 7. Install O-rings (19) and (21) (2 used) on to hous-
(5) (2 used) or (6) (2 used) onto spools (17) (4 ing (18).
used) installed in housing (18).
W2-7-15
UPPERSTRUCTURE / Pilot Valve
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-16
UPPERSTRUCTURE / Pilot Valve
8. Apply grease to the inner face of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block 13. Clamp housing (18) carefully in a vise and then
(10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, inserting push rods (8) Tighten the universal joint so that the clearance
and (9) first, then installing oil seal (15). between the cam and push rod (8) and (9)
This prevents the oil seal from entering into becomes 0 to 0.2 mm.
the hole. : 32 mm
Oil Seal Mounting Hole IMPORTANT: Do not clamp housing (18) in a vise
because the strong torque may act
on screw joint (43).
10 14. Clamp screw joint (13) in a vise to tighten univer-
sal joint (14). Tighten cam (12) with a spanner.
8, 9
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
W176-02-07-007
W2-7-17
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-18
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL TRAVEL PILOT
VALVE
Removal 1
1. Loosen bolts (1) (6 used) to remove under cover
(2). W1SE-02-08-001
: 17 mm ZAXIS125US, 135US
2
1
W1SE-02-08-002
ZAXIS135UR
W187-02-07-001
W2-7-19
UPPERSTRUCTURE / Pilot Valve
2. Loosen bolt (3) to remove pedal (4), levers (15)
and (16).
: 17 mm
W2-7-20
UPPERSTRUCTURE / Pilot Valve
4. Install under cover (2) with bolts (1) (6 used).
: 17 mm ZAXIS110, 110-E, 120, 120-E
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
W1SE-02-08-001
ZAXIS125US, 135US
2
1
W1SE-02-08-002
ZAXIS135UR
W187-02-07-001
W2-7-21
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE
35 2
34
33
32
31
30
3
4
5
6
29
28 7
27
8
9
10
26
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
W2-7-22
UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolts (1) (2 7. Remove spring (18) from casing (14). (4 places)
used) to remove cover (2) from holder (10).
: 10 mm IMPORTANT: Put a stand under bracket (26). If
holder (10) bears the reaction force,
2. Remove socket bolts (8) (2 places) and spring a strong force acts on pin (3) and
washers (9) (2 used), to remove holder (10) from the pin may deform.
casing (14).
: 8 mm IMPORTANT: The inside of the spring pins (24)
and (25) holes in brackets (26) (2
3. Pull out pusher (23) from casing (14) (4 places). used) is stepped-shape. Therefore,
Bushing (13) and oil seal (11) are removed with the spring pin can only be pulled out
the pusher. in one direction.
8. Put a stand under bracket (26).
4. Pull out pusher (23) from bushing (13), with a Push out spring pins (24) and (25) from the
bamboo spatula to remove oil seal (11). (4 bracket at the same time using special tool (ST
places) 1237). Remove the bracket from pin (3). (2
places)
IMPORTANT: Make marks on spools (17) (4 used) Do not remove spring pin (27) from the bracket
so as to easily install them to their unless necessary.
former position.
NOTE: The outside end of the spring pin has been
5. Pull out the spool (17) assembly from casing (14)
caulked.
turning the spool.(4 places)
Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with the spool.
24,25
NOTE: The spool has been selected to match the
hole of the casing. The spool and casing 26
must be replaced as an assembly. 3 27
Caulked
IMPORTANT: The number of shims (20) has been
determined during the performance
Stand
testing at the factory. They must be
kept together with their spool.
6. Compress balance spring (21). Remove spring
guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17). (4 places) W176-02-07-019
W2-7-23
UPPERSTRUCTURE / Pilot Valve
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-24
UPPERSTRUCTURE / Pilot Valve
10. Remove O-ring (5) from pin (3). (2 places)
W2-7-25
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12
18
23
20
19
14 17
W176-02-07-010
15, 16
W2-7-26
UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
IMPORTANT: Pay attention to the mounting direc- 6. If bushing (31) removes from holder (10), install it
tion of spring guide (22). on the holder using special tool (ST 7256) in the
following procedures.
IMPORTANT: Install the former number of shims NOTE: The bushings (4 used) are identical.
(20).
1. Assemble spool (17) into an assembly. (4 used) • Insert the bushing into special tool (ST 7256),
• Insert spacer (19), shim (20), balance spring (21) then tap on the special tool (ST 7256) to install
into the spool in order. the bushing into the hole of holder.
• Press the balance spring by hand. Install spring Stop tapping when the bushing end is flush with
guide (22) to the spool with the stepped-end fac- the Inside wall.
ing downward. Inside Wall
ST 7256
10
2. Insert spring (18) to casing (14). (4 places)
Outside of
Holder
W176-02-07-014
W176-02-07-013
W2-7-27
UPPERSTRUCTURE / Pilot Valve
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-28
UPPERSTRUCTURE / Pilot Valve
7. Insert adjust bolt (30) to cam (32). Tighten the IMPORTANT: Do not adjust the adjust bolt (30)
bolt by hand, and then lightly secure it temporarily while pressing the pusher (23) head
with lock nut (33). (2 places) with the adjust bolt. The standard
clearance between the adjust bolt
NOTE: Adjust the dimensions later. and pusher must be 0 to 0.2 mm (0
to 0.008 in).
8. Apply grease on the head (matching surface for 13. Adjust bolt (30) as the following procedures. (2
pusher (23)) of adjust bolt (30) (2 places). places)
: 13 mm
9. Install O-ring (5) to pin (3), then assemble the pin : 4 mm
to holder (10) with cam (32) (2 places). • Loosen lock nut (33).
• Move cam (32) to check whether there is play. If
IMPORTANT: Take care of the inserting direction none, turn the adjust bolt to adjust.
of spring pins (34, 35). • Turn both adjust bolts on the left and right alterna-
tively to keep the cam horizontal.
IMPORTANT: Tap the spring pin in until it makes • Measure dimensions A and B from both left and
contact with the stepped-shape in right caves on the cam to holder (10). Fine adjust
hole. the adjust bolt to get same distance for both left
10. Install spring pins (34), (35) to cam (32) using and right.
special tool (ST 1237), then secure the cam and • Secure the adjust bolt by using a hexagon-head
pin (3). The spring pins shall be displaced with wrench. Tighten the lock nut to specified torque
their slits at 90°. first, securing the adjust bolt.
• When adjustment is finished, move the cam to
3 3 Slit Slit check that is a little play. If there is no play, the
pusher may be in compressed condition, and ad-
justment should be carried out again.
: 10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
30 33 32 10
A B
W176-02-07-017
W2-7-29
UPPERSTRUCTURE / Pilot Valve
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-30
UPPERSTRUCTURE / Pilot Valve
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under bracket (26). If
holder (10) bears the reaction force,
15. Apply grease to O-ring (5). (2 places) strong force acts on the pin and the
pin may deform.
IMPORTANT: Pay attention to the direction of
damper (6). IMPORTANT: The inside of the hole of spring pins
(24, 25) in the bracket is
IMPORTANT: The inner bore of damper (6) is stepped-shape. Make sure of the di-
edged-shape. If the damper is pried rection to insert the spring pin.
upward, O-ring (5) will be damaged.
16. With the lever upward, install damper (6) to pin IMPORTANT: Make sure of the direction of the
(3) straight without prying. (2 places) spring pin.
20. Put a stand under bracket (26).
17. Secure damper (6) to holder (10) with socket Tap spring pins (24) and (25) into the bracket until
bolts (28) (2 used) and spring washers (29) (2 the spring pin comes to the stepped end using
used). (2 places) special tool (ST 1237). The spring pins shall be
: 8 mm displaced with their slits at 90°.
: 7 N⋅m (0.7 kgf⋅m, 5.1 Ibf⋅ft)
W2-7-31
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL OFFSET PILOT
VALVE (ZAXIS135UR ONLY)
Removal
6
5
W197-02-07-002
4- Hose OR : To 8-Spool Solenoid Valve
5- Hose OL : To 8-Spool Solenoid Valve
6- Hose OP : From Pilot Shut-Off Valve
7- Hose OT : To Pilot Shut-Off Valve
11
12
W197-02-07-003
W2-7-32
UPPERSTRUCTURE / Pilot Valve
Installation
9
1. Install pilot valve (3) with socket bolts (10) (2 10
used). 8
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
IMPORTANT: After installing, check the hydraulic 4- Hose OR : To 8-Spool Solenoid Valve
oil level, start engine and check all 5- Hose OL : To 8-Spool Solenoid Valve
6- Hose OP : From Pilot Shut-Off Valve
hoses for oil leaks.
7- Hose OT : To Pilot Shut-Off Valve
11
12
W197-02-07-003
W187-02-07-001
W2-7-33
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BLADE PILOT
VALVE (ZAXIS135UR)
Removal
W187-02-07-001
3 4 5
10
W191-02-07-005
W2-7-34
UPPERSTRUCTURE / Pilot Valve
Installation
1. Install pilot valve (3) with bolt (9). Install cable (10)
with bolt (8). 9
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
7
6
W191-02-07-004
W187-02-07-001
W2-7-35
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE OFFSET / BLADE PILOT
VALVES (ZAXIS135UR)
17 18 1
16
15
3
4
14
5
7
13
8
12
11
10
W1CF-02-07-001
W2-7-36
UPPERSTRUCTURE / Pilot Valve
Disassemble Offset / Blade Pilot Valves
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work.
W2-7-37
UPPERSTRUCTURE / Pilot Valve
ASSEMBIE OFFSET / BLADE PILOT
VALVES (ZAXIS135UR)
17 18 1
16
15
3
4
14
5
7
13
8
12
11
10
W1CF-02-07-001
W2-7-38
UPPERSTRUCTURE / Pilot Valve
Assemble Offset / Blade Pilot Valves
• Be sure to read “Precautions for Disassembly and 4. Place the pusher (15) assemblies (2 used) and
Assembly” thoroughly on page W1-1-1 before holder (5) onto each spool (10) assemblies (2
starting the disassembly work. used). Alternately tighten socket bolts (3) (2 used)
to install the cover on casing (11).
IMPORTANT: Install spring guide (6) with its : 5 mm
groove side facing to the spring. : 11.5 to 21.5 N⋅m
Do not compress balance spring (7) (1.2 to 2.2 kgf⋅m, 8.7 to 16 lbf⋅ft)
with spring guide (6) more than 4
mm (0.157 in) when installing 5. Install cam (2) on holder (5) with pin (16).
spring. : 5 mm
1. Install spacers (9) (2 used) and springs (7) (2
used) on spools (10) (2 used). Compress springs IMPORTANT: Apply LOCTITE #241 to set screw
(7) (2 used) to install spring guide (6) (2 used) to (18).
spool (10). 6. Install set screw (18) into cam (2).
: 2.5 mm
IMPORTANT: Be sure to confirm the port number : 7.0±1 N⋅m
before inserting each spool (10) as- (0.7 ± 0.1 kgf⋅m, 5.1 ± 0.7 lbf⋅ft)
sembly, to be sure that the spool
assembly is inserted into its correct 7. Tilt cam (2) and apply a film of grease to the
port. pushers (15) (2 used) heads.
2. Insert return springs (8) (2 used) and spool (10)
(2 places) assemblies (2 used) into casing (11). 8. Install boot (4) and spacers (1) (2 used) on
holder (5).
IMPORTANT: Install oil seals (14) (2 used) in their
correct directions. Apply a film of
grease to the lips of the oil seal and
to the inside of bushing (13).
3. Install oil seals (14) (2 used) and O-rings (12) (2
used) on bushings (13) (2 used). Insert pushers
(15) (2 used) into the bushing.
W2-7-39
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-40
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
Preparation
1. Park the machine on a firm, level surface.
W2-8-1
UPPERSTRUCTURE / Pilot Shut-Off Valve
Removal
(ZAXIS110, 120)
3
8- Hose DP: (To oil tank)
9- Hose PI: (To signal control valve)
10 - Hose PH: (To signal control valve)
11 - Hose PF: (To solenoid valve unit) 4
12 - Hose T6: (To right pilot valve) 5
13 - Hose P2: (To left pilot valve)
7
14 - Hose P3: (To right pilot valve)
15 - Hose T5: (To left pilot valve) 6
16 - Pipe P1: (To travel pilot valve)
17 - Pipe T4: (To travel pilot valve)
W178-02-08-001
15 16 4
14 17
13
6
12
9
10
11 W178-02-08-002
W2-8-2
UPPERSTRUCTURE / Pilot Shut-Off Valve
Removal
(ZAXIS125US, 135US, 135UR)
: 5mm
6
8
7
4
3
W1SE-02-08-004
W2-8-3
UPPERSTRUCTURE / Pilot Shut-Off Valve
3. Remove the hoses and pipes (10 to 19) from pilot ZAXIS125US, 135US
shut-off valve (5). Attach the cap to all the dis-
connected hoses and pipes. Attach the tags to 10
them to aid in assembly. 11
: 19, 22 mm (ZAXIS125US, 135US) 12
: 19 mm (ZAXIS135UR) 5 13
14
4. Loosen socket bolts (9) (2 used) to remove pilot
shut-off valve (5).
: 8 mm
19
18
17 16 15 9 W1SE-02-08-003
ZAXIS135UR
11 12
5
9
13
10
9 14
15
16
18
17
W157-02-08-001
9- Socket Bolt(2 Used)
10 - Hose A3 : (To signal control valve)
11 - Hose A2 : (To emergency stop solenoid valve)
12 - Hose A1 : (To blade/ travel pilot valves)
13 - Hose T4 : To hydraulic oil tank)
14 - Hose P : (From pilot pump)
15 - Hose T3 : (To offset/ right pilot valves)
16 - Hose T2 : (To blade/ travel pilot valves)
17 - Hose T1 : (To emergency stop solenoid valve/ left pilot
valve)
18 - Hose A4 : (To signal control valve/ 8-spool solenoid valve)
W2-8-4
UPPERSTRUCTURE / Pilot Shut-Off Valve
Installation (ZAXIS110, 120)
1. Install pilot shut-off valve (6) with bolt (4).
: 17 mm
3
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 17 mm 15 16 4
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 14 17
13
12
10
11 W178-02-08-002
W1SE-02-08-001
W2-8-5
UPPERSTRUCTURE / Pilot Shut-Off Valve
Installation
(ZAXIS125US, 135US, 135UR) ZAXIS125US, 135US
1. Install pilot shut-off valve (5) with socket bolt (9)
(2 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
5
9 W1SE-02-08-003
ZAXIS135UR
5
9
W157-02-08-001
6
8
7
4
3
W1SE-02-08-004
W2-8-6
UPPERSTRUCTURE / Pilot Shut-Off Valve
3. Connect the hoses and pipes (10 to 19) to pilot ZAXIS125US, 135US
shut-off valve (5).
(ZAXIS125US, 135US) 10
: 19 mm 11
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 12
5
: 22 mm 13
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 14
(ZAXIS135UR)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
19
18
17 16 15 W1SE-02-08-003
ZAXIS135UR
11 12
5
13
10
14
15
16
18
17
W157-02-08-001
W2-8-7
UPPERSTRUCTURE / Pilot Shut-Off Valve
4. Install under cover (2) with bolts (1) (6 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 lbf⋅ft)
2
1
W1SE-02-08-002
W2-8-8
UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)
W2-8-9
UPPERSTRUCTURE / Pilot Shut-Off Valve
DISASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS110, 120)
3
6
2 7
1
8
9
13 10
11
12
W178-02-08-005
W2-8-10
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
(ZAXIS110, 120)
• Be sure to thoroughly read all Precautions for
Disassembly / Assembly work on page W1-1-1
before starting any work.
W2-8-11
UPPERSTRUCTURE / Pilot Shut-Off Valve
DISASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS125US, 135US, 135UR)
1
2
3
4
5
6
14 7
13
12
9
11
10
W1CC-02-08-001
W2-8-12
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
(ZAXIS125US, 135US, 135UR)
W2-8-13
UPPERSTRUCTURE / Pilot Shut-Off Valve
ASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS110, 120)
12 13 11 4 5 Z
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
W2-8-14
UPPERSTRUCTURE / Pilot Shut-Off Valve
Assemble Pilot Shut-Off Valve
(ZAXIS110, 120)
1. Apply LOCTITE # 262 on socket bolt (5) and in-
stall it to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)
W2-8-15
UPPERSTRUCTURE / Pilot Shut-Off Valve
ASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS125US, 135US, 135UR)
1 2 3 4 5 6 7 8 9
13
10
12
14 11
W1CC-02-08-002
W2-8-16
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
(ZAXIS125US, 135US, 135UR)
W2-8-17
UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)
W2-8-18
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE
Preparation
1. Park the machine on a firm, level surface.
W2-9-1
UPPERSTRUCTURE / Signal Control Valve
Removal Signal Control Valve
IMPORTANT: Attach tags to hoses and pipes to
aid in assembly.
Installation T176-04-04-001
1. Apply LOCTITE to bolt (20) and install the signal Pilot Valve Side
PH
control valve.
A
C M
2. Connect all hoses and pipes to each port.
E B
3. Install the pressure sensor (swing, travel). D SB
H G
Wrench size Tightening Torque Remark F
(mm) N⋅m (kgf⋅m) (Ibf⋅ft) N
PI
: 17 25 (2.5) (18) Hose, pipe
: 19 29.5 (3) (21.5) Hose Pilot Valve
Side
I
: 24 16 (1.6) (11.5) Pressure sensor
K J
:8 50 (5.1) (37) Socket Bolt
DF
SH
SA L 2
T178-03-06-016
Control Valve Side
SM
3
1 5
1
2 4
SK SE
7 8
1
6
Pressure Sensor
(Swing)
9
Control Valve SN
Side
1 11
SL
Pressure Sen-
sor (Travel) 2 1 SP T178-03-06-015
W2-9-2
UPPERSTRUCTURE / Signal Control Valve
W2-9-3
UPPERSTRUCTURE / Signal Control Valve
(Blank)
W2-9-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
UNIT
Preparation
1. Park the machine on a firm, level surface.
W2-10-1
UPPERSTRUCTURE / Solenoid Valve
Solenoid Valve Unit Solenoid Valve Unit
Removal
1. Disconnect each harness of solenoid valves (8
and 9) from the connector.
Installation
1. Install solenoid valve unit with socket bolts (7) (2
used). 11 1
W187-02-10-002
2
2. Connect pilot pipes (1 to 6, 10 and 11)
Tightening Torque 12
Wrench Size (mm) Remark
N⋅m (kgf⋅m) (Ibf⋅ft) 13
: 17 25 (2.5) (18) Pipe, Hose Solenoid Valve
9 Unit
: 19 30 (3) (21.5) Hose
8
: 8 50 (5.1) (37) Socket Bolt
7
: 19 30±3 (3±0.3) (21.5±2.2) Plug
4
5
W187-02-10-001
1 - Pipe : To control valve (4-spool section)
(ZAXIS135UR only: To signal control valve)
2- Hose : To signal control valve port SP
3- Hose : To hydrarulic oil tank
(ZAXIS135UR only: Hose DS: To hydraulic oil tank)
Hose: To switch valve)
4- Hose : To center joint
(ZAXIS135UR only: Hose SI)
5- Pipe : To control valve (4-spool section)
6- Hose : To control valve (5-spool section)
7- Socket Bolt
8- Proportional solenoid valve (SI)
9- Proportional solenoid valve (SC)
10 - Hose (PF): From pilot shut-off valve
11 - Hose: From pilot filter
(ZAXIS135UR only: Hose PD)
12 - Plug (ZAXIS135UR only: Hose PG : To switch valve)
13 - Plug
W2-10-2
UPPERSTRUCTURE / Solenoid Valve
8-spool Solenoid Valve (Only ZAXIS135UR)
Removal
1. Open the cover of the machine right side. Set the
lock to secure the cover.
W187-02-10-003
Plate Bolt
W2-10-3
UPPERSTRUCTURE / Solenoid Valve
Installation
1. Install the 8-spool solenoid valve unit to the plate 8-Spool Solenoid
with the bolts (3 used). Valve
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
Cover
W1SE-04-01-002
W2-10-4
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-10-5
UPPERSTRUCTURE / Solenoid Valve
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
W2-10-6
UPPERSTRUCTURE / Solenoid Valve
Disassemble Proportional Solenoid Valve
W2-10-7
UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE PROPORTIONAL SOLENOID VALVE
4 2 6 1 8 16 13 14 10 15 18
3,5
9 7 11 12 17
W157-02-11-001
W2-10-8
UPPERSTRUCTURE / Solenoid Valve
Assemble Proportional Solenoid Valve
16
12
11
W157-02-11-009
W157-02-11-011
W2-10-9
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-10-10
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL EMERGENCY
STOP SOLENOID VALVE UNIT
(ZAXIS135UR ONLY)
Preparation
1. Park the machine on a firm, level surface.
W2-10-11
UPPERSTRUCTURE / Solenoid Valve
Removal
1. Remove bolts (1) (6 used) to remove under cover
(2).
: 17 mm
W187-02-07-001
Installation
1. Install emergency stop solenoid valve (3) with bolt
(5) and washer (6).
5, 6
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) Machine
Front
3 Lock Valve
T1SM-03-07-100
(Seen from Floor Bottom)
W2-10-12
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-10-13
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE SELEC-
TOR VALVE
Selector Valve
1
Emergency Stop 2
6 1 Solenoid Valve
3
4
5
6
7
8
9
10
11
12
A W187-02-10-004
T1CF-03-06-003
W2-10-14
UPPERSTRUCTURE / Solenoid Valve
Disassemble Selector Valve Assemble Selector Valve
• Be sure to thoroughly read precautions for 1. Insert washer (12) into the housing.
disassembly and assembly on page W1-1-1
before any disassembling and assembling work. IMPORTANT: While aligning port hole (A) on
sleeve (11) with the hole on housing.,
IMPORTANT: The inside of solenoid (2) cannot be install it.
disassembled. When removing the 2. Install O-rings (8, 9, 10) to sleeve (11). Insert the
solenoid, take care not to lose rod(4) sleeve into housing.
in it.
1. Remove socket bolts (1) (2 used) to remove so- IMPORTANT: Be sure not to damage sleeve (11)
lenoid (2) and O-ring (3). when installing it.
: 4 mm 3. Install spring (7) and retaining ring (5) to spool (6).
Insert it into sleeve (11).
2. Pull spool (6) out of sleeve (11) to remove retain-
ing ring (5) and spring (7) from the sleeve. IMPORTANT: Check if spool (6) can move
NOTE: Be sure to pull spool (6) out slowly. smoothly. If not, replace it.
4. After inserting spool (6), push it 3 to 5 mm by
3. Pull sleeve (11) out of the housing to remove hand.
O-rings (8, 9, 10) from the sleeve.
5. Install O-ring (3) to the housing.
4. Remove washer (12) from the housing.
IMPORTANT: Be sure not to drop off rod (4).
6. Install rod (4) to solenoid (2).
W2-10-15
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE
UNLOADING VALVE
1
2
3
Emergency Stop 4
Solenoid Valve
5
5 6
7
8
9
10
A
W187-02-10-005
3
2 T1CF-03-06-003
Unloading Valve
1
W2-10-16
UPPERSTRUCTURE / Solenoid Valve
Disassemble Unloading Valve Assemble Unloading Valve
• Be sure to thoroughly read precautions for disas- 1. Insert plate (10) into the housing.
sembly and assembly on page W1-1-1 before any
disassembling and assembling work. IMPORTANT: While aligning port hole (A) on
sleeve (9) with the hole on housing.
IMPORTANT: When removing plate (2), take care install it.
not to lose spring (4). 2. Install O-rings (6, 7, 8) to sleeve (9). Insert the
1. Remove socket bolts (1) (4 used) from the hous- sleeve into housing.
ing to remove plate (2).
: 4 mm IMPORTANT: Be sure not to damage sleeve (9)
when installing it.
2. Remove O-ring (3) and spring (4) from the hous- 3. Insert spool (5) into sleeve (9). Install spring (4) to
ing. the spool.
3. Pull spool (5) out of sleeve (9). IMPORTANT: Check if spool (5) can move
NOTE: Be sure to pull spool (5) out slowly. smoothly. If not, replace it.
4. After inserting spool (5), push it 3 to 5 mm by
4. Pull sleeve (9) out of the housing to remove hand.
O-rings (6, 7, 8) from the sleeve.
5. Install O-ring (3) to the housing.
5. Remove plate (10) from the housing.
6. Install plate (2) to the housing with socket bolts
(1) (4 used).
: 4 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W2-10-17
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-10-18
UPPESTRUCTURE / Holding Valve
REMOVE AND INSTALL HOLDING VALVE
(ZAXIS135UR ONLY)
Preparation
W2-11-1
UPPESTRUCTURE / Holding Valve
Removal
IMPORTANT: Attach identification tags to the hy-
draulic hoses and pipes for assem-
bly.
2
1. Disconnect hoses (2,3) from holding valve (6), the 1
hoses (2 used) and pipes (4, 5) from elbows (9, 3
10).
: 17 mm
: 19 mm
: 27 mm
: 22 mm 5
W187-02-11-001
9 4
Installation
1. Install holding valve (5) with bolts (6).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W2-11-2
UPPESTRUCTURE / Holding Valve
(Blank)
W2-11-3
UPPESTRUCTURE / Holding Valve
HOLDING VALVE
(ZAXIS135UR ONLY)
Port V
Port C
Port Pi
10
18 19 20
Port C
1
21
17
16
2
15 3
Drain Port
4
14
13 5
6
12 7
10
11 10 9 W187-02-11-002
Section A
W2-11-4
UPPESTRUCTURE / Holding Valve
W2-11-5
UPPESTRUCTURE / Holding Valve
(Blank)
W2-11-6
SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 5 Front Idler
Remove and Install Swing Bearing ..............W3-1-1 Remove and Install Front Idler .................... W3-5-1
Disassemble Swing Bearing ........................W3-1-4 Disassemble Front Idler .............................. W3-5-2
Assemble Swing Bearing .............................W3-1-6 Assemble Front Idler ................................... W3-5-6
Maintenance Standard................................. W3-5-8
Group 2 Travel Device
Remove and Install Travel Device ...............W3-2-1 Group 6 Upper and Lower Roller
Disassemble Travel Device..........................W3-2-4 Remove and Install Upper Roller................. W3-6-1
Assemble Travel Device ............................W3-2-10 Remove and Install Lower Roller................. W3-6-5
Disassemble Travel Motor .........................W3-2-16 Disassemble Lower Roller........................... W3-6-8
Assemble Travel Motor ..............................W3-2-20 Assemble Lower Roller.............................. W3-6-10
Disassemble Travel Brake Valve ...............W3-2-26 Maintenance Standard............................... W3-6-12
Assemble Travel Brake Valve ....................W3-2-28
Maintenance Standard ...............................W3-2-30 Group 7 Track
Remove and Install Tracks .......................... W3-7-1
Group 3 Center Joint Maintenance Standard................................. W3-7-7
Remove and Install Center Joint ..................W3-3-1
Disassemble Center Joint ............................W3-3-4
Assemble Center Joint.................................W3-3-7
Maintenance Standard ............................... W3-3-11
187W-3-1
(Blank)
187W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure
must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section.
In this section, the procedure starts on the premise
that the upperstructure has already been removed.
Removal
1. Put alignment marks on inner race of swing Mark
bearing (1) and track frame (2).
1 2
W105-03-01-001
W105-03-01-002
ST 0050
W105-03-01-003
4
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the matching surfaces of the frame and swing
bearing.
0.2° Position of
Stop Pin
10°
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
W105-03-01-002
W3-1-2
UNDERCARRIAGE / Swing Bearing
4. After installing the swing bearing, fill the grease
bath with grease (Shell Alvania EP2 or Swing Bearing Grease Level Pinion
equivalent) until the pinion of the swing bearing is
covered 5 mm depth in grease.
5 mm
W175-03-01-002
Grease Bath
W3-1-3
UNDERCARRIAGE / Swing Bearing
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W155-03-01-001
6
9
W105-03-01-011
W3-1-4
UNDERCARRIAGE / Swing Bearing
Disassemble Swing Bearing
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly” on page W1-1-1
before starting the disassembly work. 3
4
W105-03-01-007
W105-03-01-008
W105-03-01-010
W3-1-5
UNDERCARRIAGE / Swing Bearing
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W155-03-01-001
6
9
W105-03-01-011
W3-1-6
UNDERCARRIAGE / Swing Bearing
Assemble Swing Bearing
• Before assembling the swing bearing, refer to
“Precautions of Disassembling and Assembling”
2
(W1-1-1)
1. Thoroughly remove the grease on the seal
grooves for the outer and inner seals (2) and (5).
Apply THREEBOND # 1745 to seal (2) and #1735
to seal (5). Install both seals respectively into
position.
5
W142-03-01-005
3. Tap plug (4) into outer race (1) and, then drive pin
(3) into the pin hole.
Caulk the head of pin (3) with a punch.
Fill grease 0.4 L (Alvania EP2 grease or
equivalent) through the grease fitting.
4
W142-03-01-007
W3-1-7
UNDERCARRIAGE / Swing Bearing
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Bolt (7)
: 22 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
Hoses (2 to 5)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 30 N・m (3.1 kgf⋅m, 22 Ibf⋅ft) 6
: 27 mm
W155-03-02-009
: 95 N⋅m (9.7 kgf・m, 70 Ibf⋅ft) 7
Installation
NOTE: Refer to the “Removal” section for wrench
sizes and tightening torque.
W3-2-1
UNDERCARRIAGE / Travel Device
IMPORTANT: After completing travel motor
installation, be sure to fill the travel
motor with hydraulic oil (0.5 L). After
completing installation of the travel
motor or the travel device, be sure to
perform break-in operation to
prevent motor seizure. Test drive as
follows:
Break-in operation condition
1. Engine control dial: slow idle position
2. Travel mode switch: slow speed position
3. Operation time: 2 minutes or more
W3-2-2
UNDERCARRIAGE / Travel Device
(Blank)
W3-2-3
UNDERCARRIAGE / Travel Device
13
12
11
10
8 9
1
7
6
1
5
4
1
2
3
2
1
15
16
20
17
18
19
21
22
23
24
25
26
23
27
28 W176-03-02-001
1- Thrust Plate (12 Used) 8- Pin (3 Used) 15 - Propeller Shaft 22 - Bearing Nut
2- Needle Bearing (6 Used) 9- Spring Pin (3 Used) 16 - Spacer 23 - Roller Bearing (2 Used)
3- Second Stage Planetary Gear (3 Used) 10 - Ring Gear 17 - Firest Stage Carrier 24 - Sprocket
4- Pin (3 Used) 11 - Cover 18 - Sun Gear 25 - Drum
5- Spring Pin (3 Used) 12 - Stopper Pin 19 - Second Stage Carrier 26 - Bolt (16 Used)
6- First Stage Planetary Gear (3 Used) 13 - Bolt (12 Used) 20 - Bolt (16 Used) 27 - Floating Seal
7- Needle Bearing (3 Used) 14 - Plug (3 Used) 21 - Knock Pin 28 - Motor
W3-2-4
UNDERCARRIAGE / Travel Device
Disassemble Travel Device
CAUTION: High pressure may remain in the 5. Remove sun gear (18) from ring gear (10).
travel device. Gradually loosen the air vent
plug to thoroughly release any remaining
pressure.
1. With motor (28) facing upward, secure spacer (ST CAUTION: Second stage carrier assembly
5089) to the track frame mounting flange of the weight: 23 kg (51 lb) (ZAXIS110, 120, 125US)
motor with bolt (M16, pitch 2.0 mm.). 28 kg (62 lb) (ZAXIS135US, 135UR)
: 24 mm 6. Hook claws of special lift tool (ST 0916) to the
ST 5089 second stage carrier (19) assembly and hoist it by
crane to remove the second stage carrier
assembly from ring gear (10).
ST 0916
Claws
W105-03-02-007
W3-2-5
UNDERCARRIAGE / Travel Device
10
8 9
1
7
6
1
20
17
23
24
25
26
23
27
28 W176-03-02-001
W3-2-6
UNDERCARRIAGE / Travel Device
CAUTION: Ring gear + sprocket + drum CAUTION: Ring gear + drum weight:
weight: 95 kg (210 lb) 55 kg (120 lb) (ZAXIS110, 120, 125US)
58 kg (130 lb) (ZAXIS135US, 135UR)
IMPORTANT: The motor side of the drum is the
sliding surface with the motor. 12. Install eyebolt (M16) to the hole of mounting
Place the drum on wooden blocks screw on sprocket (24) of drum (25). Hoist it by
after removal. crane and turn ring gear (10) over.
8. Install eye bolts (M12) (2 used) to ring gear (10). 13. Remove floating seal (27) from drum (25).
Remove and hoist the ring gear from motor (28)
housing by crane.
CAUTION: Drum weight: 24 kg (53 lb)
CAUTION: Sprocket weight: 16. Disassemble the first stage carrier (17) assembly.
41 kg (90 lb) (ZAXIS110, 120, 125US) Tap spring pin (9) out of the first stage carrier
38 kg (85 lb) (ZAXIS135US, 135UR) (17) using pin (ST 1391). (3 places)
Remove pins (8) (3 used), thrust plates (1) (6
used), planetary gears (6) (3 used), needle
11. Remove sprocket (24) from drum (25). bearings (7) (3 used) from the first stage
Remove bolt (20). carrier (17).
Secure the sprocket with a nylon sling and hoist
it with a crane slowly to remove it.
: 24 mm
W3-2-7
UNDERCARRIAGE / Travel Device
5
4
1
2
3
2
1
W176-03-02-001
W3-2-8
UNDERCARRIAGE / Travel Device
17. Disassemble the second stage carrier (19)
assembly.
Tap spring pin (5) out of the second stage
carrier (19) using pin (ST 1462). (3 places)
Remove pins (4) (3 used), thrust plates (1) (6
used), planetary gears (3) (3 used), needle
bearings (2) (6 used) from the second stage
carrier (19).
W3-2-9
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL DEVICE
28 27 23 22 21 10 19 18 17 11
14
16
15
12
5
7
9
25 13
4 1 2 3 1
26
20
24
W176-03-02-002
1- Thrust Plate (12 Used) 8- Pin (3 Used) 15 - Propeller Shaft 22 - Bearing Nut
2- Needle Bearing (6 Used) 9- Spring Pin (3 Used) 16 - Spacer 23 - Roller Bearing (2 Used)
3- Second Stage Planetary Gear (3 Used) 10 - Ring Gear 17 - First Stage Carrier 24 - Sprocket
4- Pin (3 Used) 11 - Cover 18 - Sun Gear 25 - Drum
5- Spring Pin (3 Used) 12 - Stopper Pin 19 - Second Stage Carrier 26 - Bolt (16 Used)
6- First Stage Planetary Gear (3 Used) 13 - Bolt (12 Used) 20 - Bolt (16 Used) 27 - Floating Seal
7- Needle Bearing (3 Used) 14 - Plug (3 Used) 21 - Knock Pin 28 - Motor
W3-2-10
UNDERCARRIAGE / Travel Device
Assemble Travel Device
IMPORTANT: Do not tap other parts except the NOTE: If it is difficult to insert the O-ring of floating
outer race. seal to the drum, try to push the O-ring with
3. Tap the outer race of roller bearing (23) evenly a bamboo spatula.
with a bar and hammer until it fits snugly into the
drum (25) (2 places).
NOTE: Tap the bearing and listen to ring if CAUTION: Ring gear + drum + sprocket
installation is completed. weight: 96 kg (210 lb)
9. Secure ring gear (10) with a nylon sling, hoist it by
crane and turn it over slowly. Place square
CAUTION: Sprocket weight: wooden blocks to prevent of the motor (28) sliding
41 kg (85 lb) (ZAXIS110, 120, 125US) surface of drum (25) from being damaged.
38 kg (90 lb) (ZAXIS135US, 135UR)
10. Install eye bolts (ST 0002) (2 used) into bolts (13)
IMPORTANT: Face the chamfer side of sprocket mounting holes of ring gear (10), then hoist the
toward the drum. ring gear and put it onto motor (28). Make sure
4. Place sprocket (24) on drum (25). Apply LOCTITE the motor makes contact with drum (25) evenly.
# 262 to bolts (20) (16 used) and tightening the
bolts.
: 24 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
W3-2-11
UNDERCARRIAGE / Travel Device
28 23 22 21 10 19 11
13
25
1 2 3 1
24
W176-03-02-002
W3-2-12
UNDERCARRIAGE / Travel Device
11. Push ring gear (10) straight down from above into 17. Carry out steps 15 and 16 repeatedly.
motor (28), shaking the ring gear.
18. Do step 15 again to tighten bearing nut (22) to
12. Install the inner race of roller bearing (23) to motor specified torque.
(28), tapping with a bar and hammer. : 790 N⋅m (80 kgf⋅m, 580 Ibf⋅ft)
NOTE: It is very stiff to install. Carry out steps 11 19. Align the spline center of motor (28) with that of
and 12 repeatedly so that the inner race knock pin (21). If they cannot be aligned well, turn
side of the bearing comes to the position bearing nut (22) to tightening direction to align
that the 3 pitches of thread for bearing nut them correctly.
(22) appears. Knock Pin
Center
22
13. Apply a little grease to the thread of bearing nut
(22). 21
W176-03-02-004
14. Install bearing nut (22) to motor (28) and tighten it
by hand.
NOTE: The aim to do so is to align the spline of the
15. Install special tools (ST 7248, ST 7249) to bearing the second stage carrier (19) with knock
nut (22) with a torque wrench. pin (21). If the work is continued without
: 790 N⋅m (80 kgf⋅m, 580 Ibf⋅ft) aligning, cover (11) cannot be installed to
ring gear (10) as it will protrude.
W176-03-02-013
W3-2-13
UNDERCARRIAGE / Travel Device
28 21 10 19 18 17 11
14
16
15
13
4 3 1
W176-03-02-002
W3-2-14
UNDERCARRIAGE / Travel Device
22. Install pin (4) to second stage carrier (19). Align 26. Insert sun gear (18) into second stage carrier (19)
the spring pin (5) hole of second stage carrier with with the smaller end facing upward.
the holes of pin (4).
27. Insert spacer (16) into the center of first stage
IMPORTANT: When aligning spring pin (5), be sure carrier (17).
its slit side faces pin (4) end.
23. Tap spring pin (5) to second stage carrier (19) 28. Install needle bearing (7) to first stage planetary
hole. gear (6).
5
29. Clamp first stage planetary gear (16) with thrust
4 plates (1) (2 used). Install the first stage planetary
gear to first stage carrier (17).
Slit 30. Install pin (8), spring pin (9) to first stage carrier
(17) by the same procedures as in steps 22 to 24.
24. Repeat steps 20 to 23 to install other second 32. Insert propeller shaft (15) into the center spline of
stage planetary gears (3) (2 used) to second sun gear (18). Engage the propeller shaft with
stage carrier (19). motor (28) spline and first stage planetary gear (3),
turning it.
CAUTION: When the knock pin fits with the 33. Thoroughly remove the old bond.
second stage carrier, the second stage Remove the grease on the cover (11) mating
carrier will drop down. Take care not to injure surface of the ring gear, then apply THREEBOND
your fingers. #1215 to it.
25. Using lifting tools (ST 0916) hoist second stage
carrier (19), and install it to the sprocket of motor 34. Install cover (11) to ring gear (10) with bolt (13).
(28). If alignment work is not carried out as in step : 19 mm
19, the knock pin (21) cannot be inserted into the : 110 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
carrier.
NOTE: After assembling the second stage carrier, 35. Remove plug (14). Apply gear oil into ring gear
the distance from the top of the planetary (10).
gear to that of the ring gear is about 35 mm : 19 mm
(1.38 in). Gear oil: 3.5 L
W178-03-02-001
Hang up to Carrier
W3-2-15
UNDERCARRIAGE / Travel Device
5
4
3
Piston Pushing Oil
2 Passage
5 16
7
8
15
14
13 17
18
12 19
11 20
10
9
21
22
23
24
25
26
W176-03-02-005
27
W3-2-16
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
IMPORTANT: When removing brake valve (27) 7. Remove plates (13) (4 used) and friction plates
assembly from the motor, valve (21) (3 used) from housing (6).
plate (24) is also removed with the
brake valve side.
Don’t drop the valve plate as it easily CAUTION: Housing weight: 34 kg (75 Ib)
comes off. 8. Place housing (6) with the brake releasing oil
1. Place the travel motor longitudinally. After passage facing downward and horizontal.
removing socket bolt (22), remove brake valve NOTE: When the brake releasing oil passage is
(27) from housing (6). positioned upward, the thick portion of
: 12 mm swash plate (16) faces upward. When
housing (6) is placed horizontally, the
IIMPORTANT: The valve plate easily becomes swash plate may come off suddenly.
cracked and scratched, so handle it
with care. 9. Remove swash plate (16) from housing (6).
2. Remove valve plate (24) and knock pins (25) (2 NOTE: If the swash plate cannot be removed,
used) from brake valve (27). Do not remove Apply pressure air 100 to 300 kPa (1 to 3
needle bearing (26) unless necessary. 2
kgf/cm , 14 to 43 psi) through the piston
pushing oil passage port, and the swash
NOTE: Even if small removing tool is used for plate will be removed from the piston. In
removing the needle bearing, the outer order to prevent the piston from popping
race may be deformed. out, cover with cloth. Use a bicycle pump to
Do not reuse the needle bearing. apply air.
3. Wrap tape on the needle bearing (26) rotation 10. With a magnet, remove balls (17) (2 used) and
surface of shaft (1) for protection. piston (7) from housing (6).
4. Remove disc spring (9) from housing (6). 11. Remove retaining ring (2) from housing (6).
12. Tap the bottom in the spline bore of shaft (1) using
CAUTION: When removing the brake piston a bar and plastic hammer to push the shaft out
from the housing filled with air, cover the with roller bearing (8) from housing (6).
housing with cloth to prevent the brake
piston from flying off.
2
5. Apply pressure air 100 to 300 kPa (1 to 3 kgf/cm ,
14 to 43 psi) to the brake releasing oil passage of
housing (6), so that the brake piston will float up
to be removed.
NOTE: It is possible to using bicycle pump. Do not
pry with a screwdriver, or components will
be damaged.
W3-2-17
UNDERCARRIAGE / Travel Device
4
3
W176-03-02-005
W3-2-18
UNDERCARRIAGE / Travel Device
13. Insert a slotted head screwdriver into the shaft (1)
hole of housing (6) and push out oil seal (4).
Bar
W172-03-02-003
W3-2-19
UNDERCARRIAGE / Travel Device
27 25 23 5 11 12 10 14 18 16 17 2 8
26 22 24 5 9 13 21 20 15 19 7
W176-03-02-006
W3-2-20
UNDERCARRIAGE / Travel Device
Assemble Travel Motor
CAUTION: Housing weight: 34 kg (75 Ib) IMPORTANT: Pay attention to assembly direction.
4. Insert the inner ring plate side of roller bearing (8)
1. Place housing (6) with the brake valve (27) into the inner bore spline end of shaft (1) first.
mating surface facing upward. Then push the shaft until the bearing comes into
the tight fitting part. Be sure not to damage the
IMPORTANT: Apply OCEAN grease #7 to the inner seal lip surface of the shaft.
circumference of the oil seal, and
apply THREEBOND #1104 or #1215 5. Insert the inner bore spline end of the shaft into
to the outer circumference of the oil bearing assemble tool (ST 2895). Tap the other
seal. end of the shaft with a plastic hammer to install
2. Neatly clean oil seal (4) fitting part of housing (6). roller bearing (8) onto the shaft.
Using tool (ST 2893), install the oil seal into the
housing. 1
ST 2893
Inner Bore Spline
Inner Ring Plate
4
6 ST 2895 12
W176-03-02-007
W176-03-02-008
W3-2-21
UNDERCARRIAGE / Travel Device
27 25 23 5 11 12 10 14 18 16 2
17
5 9 13 21 20 15 19
W176-03-02-006
W3-2-22
UNDERCARRIAGE / Travel Device
IMPORTANT: The small diameter side of the shaft
CAUTION: Housing weight: 40 kg (88 lb)
is the inner race of the needle
15. Place housing (6) with the brake valve (27)
bearing. Take care not to damage it.
mounting surface facing upward.
9. With a plastic hammer, tap shaft (1) lightly to
install it into housing (6).
16. Install plates (13) (4 used) and friction plates (21)
(3 used) on housing (6) alternatelly. Install the
10. Install retaining ring (2) in housing (6) to stop shaft
plate first.
(1).
NOTE: If keep open the retaining ring and move it 17. Apply grease to O-rings (11), (12). Install them
to the lowest bottom of the housing, into brake piston (10).
installation of the retaining ring becomes
easy. 18. Push brake piston (10) into housing (6) with a
plastic hammer by tapping evenly.
11. Apply grease to the ball hole of swash plate (16).
NOTE: Since the O-ring is positioned around the
Install the swash plate on housing (6), while align
brake piston, the brake piston cannot be
with balls (17) (2 used).
fully fitted. When installing brake valve (27),
push the brake piston with tightening bolts.
CAUTION: Housing weight: 35 kg (77 Ib)
12. Place housing (6) horizontally with its brake IMPORTANT: Pay attention to the disc spring
releasing oil passage facing downward. assembly direction.
NOTE: If placed opposite, swash plate (16) may 19. Put disc spring (9) on brake piston (10) with the
come off. inner diameter of the disc spring facing the brake
piston.
IMPORTANT: Pay attention to the retainer
direction. 20. Install O-rings (5) (2 used), (23) onto the brake
13. Install springs (20) (9 used), bushing (15), retainer valve (27) contact surface of housing (6).
(19), plungers (18) (9 used) onto the rotor (14),
with the chamfered side of the retainer facing the 21. Fill hydraulic oil into housing (6) until plate (13) is
bushing. submerged.
Chamfered 15
W172-03-02-001
W3-2-23
UNDERCARRIAGE / Travel Device
27 25
26 22 24
W176-03-02-006
W3-2-24
UNDERCARRIAGE / Travel Device
IMPORTANT: Pay attention to the needle bearing
assembly direction.
23. Using drive tool (ST 2894), tap needle bearing
(26) with a hammer into brake valve (27). Face
the mark on the needle bearing outward.
ST 2894
26
27
W176-03-02-012
W3-2-25
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL BRAKE VALVE
2
3
4
16
3
15
14
13 2
1
9 8 7
10
11 W176-03-02-009
12
W3-2-26
UNDERCARRIAGE / Travel Device
Disassemble Travel Brake Valve
1. Remove plug (1) from valve housing (6). (2 6. Remove springs (10), poppets (9) from valve
places). housing (6) with a magnet. (2 places)
: 36 mm
2. Remove spring (3) and stopper (4) from valve 7. Remove plug (13) from valve housing (6). (2
housing (6) with a magnet. (2 places) places)
: 6 mm
W176-03-02-011
Piston
W3-2-27
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL BRAKE VALVE
1 2 3 4 5 4 3 2 1 6
W176-03-02-010
9 10 11 12 8 7 16 14 13 15
W3-2-28
UNDERCARRIAGE / Travel Device
Assemble Travel Brake Valve
1. Install spool (5) approximately half way into valve 7. Install O-ring (11) (2 used) into relief valve (12).
housing (6).
W3-2-29
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Sprocket
C B
D
A
W105-03-07-040
W1SE-03-02-001
W3-2-30
UNDERCARRIAGE / Travel Device
Shoe
Travel Motor
W105-02-06-130
W105-02-06-134
Plunger Assembly
Rotor
W105-02-06-135
Shoe
3. Shoe thickness
Standard Allowable Limit
5.5 mm (0.22 in) 5.3 mm (0.21 in)
Plunger
W105-02-06-130
W3-2-31
UNDERCARRIAGE / Travel Device
Parking Brake
B D
C W176-03-02-014
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Friction plate Thickness 2.4 (0.0945) 2.35 (0.0925)
(Overall height)
B Disc spring 6.4 (0.252)
6.5 (0.256)
W3-2-32
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal
: 17 mm 3
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
Installation
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torque.
W3-3-1
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-2
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT
(ZAXIS110, 120, 125US, 135US)
1
3
7
10
11
12
W175-03-03-001
W3-3-3
UNDERCARRIAGE / Center Joint
ZAXIS135UR
13 1
7
3
6
8
10
11
12
W196-03-03-001
W3-3-4
UNDERCARRIAGE / Center Joint
Disassemble Center Joint
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly” on page W1-1-1
before starting the disassembly work.
W105-03-03-015
W3-3-5
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-6
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT
ZAXIS110, 120, 125US, 135US
7 6
8
10
11
12
W175-03-03-002
W3-3-7
UNDERCARRIAGE / Center Joint
ZAXIS135UR
13
7 6
8 10
9
11
12
W196-03-03-002
W3-3-8
UNDERCARRIAGE / Center Joint
Assemble Center Joint
1. Install O-ring (4) and dust seal (3) into body (7).
0.1 mm
IMPORTANT: Clearance between body (7) and
spindle (2) is approximately 0.1 mm
(0.004 in), so spindle (2) must be
inserted along axis straight and
slowly.
4. Tap body (7) with a plastic hammer until it touches
the edge of spindle (2).
W3-3-9
UNDERCARRIAGE / Center Joint
When replacing the body or the spindle with new one,
the following procedures are required.
ST 2770
4. (ZAXIS135UR only)
Install plugs (13) (2 used).
: 6 mm (R1/4)
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W136-03-03-031
W187-03-03-001
ST 2559
0.4 mm
Sleeve
or more
(ZAXIS
135UR:
27 mm
or more)
Ball
W157-03-03-004 Detail D
W135-03-03-001
W3-3-10
UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD
T157-01-01-040
W3-3-11
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-12
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK
ADJUSTER
Before removing and adjusting the track adjuster, the
tracks and the front idler must be removed first. For
removal of the tracks and front idler, refer to their
Removal / Installation sections.
In this section, the procedure starts on the premise
that the tracks and front idler have already been
removed.
Removal
CAUTION: Track adjuster weight:
51 kg (112 lb) (ZAXIS110)
55 kg (121 lb) (ZAXIS120, 125US)
62 kg (137 lb) (ZAXIS135US, 135UR)
Installation W157-03-04-003
3 4
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Check that the end face of track adjuster (1) comes
into contact with the face of plate (4).
W157-03-04-002
2 3
W157-03-04-001
W3-4-1
UNDERCARRIAGE / Track Adjuster
1
2
4
5
6
7
8
9
3
10
11
12
13
14
15
18
17
W178-03-04-001
16
W3-4-2
UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly” on page W1-1-1
before starting the disassembly work.
Base
W105-03-04-006
W105-03-04-007
W3-4-3
UNDERCARRIAGE / Track Adjuster
10
14
15
17
16 W178-03-04-001
W3-4-4
UNDERCARRIAGE / Track Adjuster
4. Install plate (ST 4036) on the track adjuster and
secure them together.
Plate (ST 4036)
7. Remove plug (14) from nut (16). Remove nut (16) W105-03-04-012
W105-03-04-014
W3-4-5
UNDERCARRIAGE / Track Adjuster
3
10
11
13
18
17
W178-03-04-001
W3-4-6
UNDERCARRIAGE / Track Adjuster
8. Lower the oil jack slowly.
W105-03-04-015
17
CAUTION: Spring assembly weight:
47 kg (104 lb) (ZAXIS110)
51 kg (112 lb) (ZAXIS120, 125US)
58 kg (128 lb) (ZAXIS135US, 135UR)
10. Install eyebolt (M16, Pitch 1.5) to rod (10) and lift W105-03-04-016
14. Pull out the piston rod (6) assembly from cylinder
(11).
15. Pull out holder (1) from the piston rod (6)
assembly with a press.
: 25 mm
W3-4-7
UNDERCARRIAGE / Track Adjuster
2
4
5
6
7
8
9
10
11
12
W178-03-04-001
W3-4-8
UNDERCARRIAGE / Track Adjuster
16. Remove flange (4) from piston rod (6). Remove
dust seal (2) and wear ring (5) from flange (4).
6
17. Remove rod (10) and O-ring (12) from cylinder
(11).
8
18. Remove retaining ring (9), U-ring (8) and wear
ring (7) from piston rod (6). 9
W105-03-04-025
W3-4-9
UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER
15 14 17 10 13 12 11 9 7 6 A 3 4 1
W178-03-04-002
16 18 B 8 5 2
W3-4-10
UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
1. Clean all parts. Then install dust seal (2) and wear
ring (5) to flange (4) after applying grease on
them. 6
4. Install wear ring (7), U-ring (8), retaining ring (9) W105-03-04-025
onto piston rod (6).
11
5. Apply grease to O-ring (12) and install it on 8
cylinder (11). Install rod (10) into cylinder (11). 7
6
IMPORTANT: Fill (B) portion of cylinder (11) with
grease. Push the piston rod (6)
assembly into the cylinder to
completely bleed air from (B) portion
and rod (10).
W105-03-04-021
6. Apply grease to U-ring (8) and wear ring (7).
Install the piston rod (6) assembly into cylinder
(11).
Eyebolt 10
7. Tighten flange (4) with socket bolts (3) (3 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
10. Install eyebolt (M16, pitch 1.5 mm) to rod (10). Lift
the spring assembly up by crane and put it on the
special tool.
W3-4-11
UNDERCARRIAGE / Track Adjuster
14 17 10
W178-03-04-002
16 18
W3-4-12
UNDERCARRIAGE / Track Adjuster
11. Remove the eyebolt from rod (10). Put washer
(17) on spring (18) and install plate (ST 4036).
Plate (ST 4036)
17
18
W105-03-04-016
W105-03-04-012
W105-03-04-026
16 10 14
14. Install nut (16) to rod (10), and then install plug
(14).
: 65 mm
: 5 mm
: 15.0 N⋅m (1.5 kgf⋅m, 10.8 lbf⋅ft)
W105-03-04-014L
W3-4-13
UNDERCARRIAGE / Track Adjuster
15 10
W178-03-04-002
W3-4-14
UNDERCARRIAGE / Track Adjuster
15. Install valve (15) to rod (10).
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
W105-03-04-013
17. Remove the nuts of the special tool and plate (ST
4036) Plate (ST 4036)
: 46 mm
W105-03-04-011
W105-03-04-009
W105-03-04-028
W3-4-15
UNDERCARRIAGE / Track Adjuster
(Blank)
W3-4-16
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
Before removing the front idler, the tracks must be
removed first. For removal of the tracks, refer to
“Remove and Install Tracks” section.
In this section, the procedure starts on the premise
that the tracks has already been removed.
Installation
1. Install the front idler according to the reversed
procedures of removal and pay attention to the
following precautions when installation is carried W178-03-05-002
out.
• Clean track frame (3) and the sliding surface of
bearing (1) and apply grease on them.
3
1
W178-03-05-004
W3-5-1
UNDERCARRIAGE / Front Idler
DISASSEMBLE FRONT IDLER
2
1
3
4
6
7
8
6
4
3
2
1
10
W178-03-05-003
W3-5-2
UNDERCARRIAGE / Front Idler
Disassemble Front Idler
• Be sure to thoroughly read “Precautions for IMPORTANT: For handling of floating seal (4),
Disassembly and Assembly” on page W1-1-1 refer to the section “Precautions for
before starting the disassembly work. Floating Seal Handling” on page
W1-1-4.
1. Loosen bolt (10) to remove yoke (9). Remove 4. Remove floating seal (4) from bearing (1) and
plug (8) from bearing (1) to drain oil into a idler (7).
container.
1
: 24 mm
: 6 mm
4
2. Remove pin (2).
7
: 16 mm
1
7
W105-03-05-009
W105-03-05-008
W3-5-3
UNDERCARRIAGE / Front Idler
W178-03-05-003
W3-5-4
UNDERCARRIAGE / Front Idler
5. Push axle (5) out from bearing (1) with a press.
Remove O-ring (3) from axle (5). 3
W105-03-05-010
W105-03-05-011
W3-5-5
UNDERCARRIAGE / Front Idler
ASSEMBLE FRONT IDLER
1 2 4 5 6
10
8 9
3
7
W157-03-05-003
W3-5-6
UNDERCARRIAGE / Front Idler
Assemble Front Idler
1. Install bushing (6) (2 used) into idler (7) from both 2
ends.
1
2. Install O-ring (3) (1 used) onto axle (5). Aligning 5
the pin holes, install axle (5) into bearing (1) at
one side and secure it using pin (2). While doing
this, take care not to damage O-ring (3).
3. Install floating seal (4) (one pair) into idler (7) and 3 W105-03-05-014
5. Install the other floating seal (4) into idler (7) and 5
into bearing (1).
6. Install bearing (1) onto axle (5), aligning the pin W157-03-05-006
W3-5-7
UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD
Front Idler
C D
A
B
W157-03-05-001
Unit: mm (in)
B 135 (5.32) −
Build-up weld
C 454 (17.87) 442 (17.40)
and finishing
D 489 (19.25) −
W3-5-8
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Do not loosen valve (1) quickly or
loosen it too much as high-pressure grease
in the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and
face away from valve (1). Never loosen
grease fitting (2).
W105-03-06-001
Grease outlet
M104-07-119
3
CAUTION: Use a non-skid cloth between
track frame (5) and an oil jack to prevent
slipping.
5 4
W105-03-06-002
W105-03-06-003
W3-6-1
UNDERCARRIAGE / Upper And Lower Roller
4. Loosen mounting bolts (6) of upper roller (4).
: 19 mm
W157-03-06-001
CAUTION: Upper roller weight: 12 kg (26 lb)
5. Remove upper roller (4) from track frame (5).
5
Installation W105-03-06-005
1. Install upper roller (4) onto track frame (5) with
bolts (6).
: 19 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
6
5
W157-03-06-001
W105-03-06-002
W3-6-2
UNDERCARRIAGE / Upper And Lower Roller
3. Install valve (1) of the track adjuster. Jack up track
(3) on the side being adjusted a sag, and turn it
slightly towards the reversed direction. Fill grease 1
from grease fitting (2) to make the track being in
tension.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
M104-07-119
W157-03-06-002
W3-6-3
UNDERCARRIAGE / Upper And Lower Roller
W158-03-06-001
W3-6-4
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove mounting bolts (1) of lower roller (5) after 5
removing the track guard.
: 24 mm
1
W105-03-06-008
Grease Outlet
M104-07-119
W3-6-5
UNDERCARRIAGE / Upper And Lower Roller
W105-03-06-010
Installation
1. Place lower rollers (5) under the tracks (2) as
illustrated by fork lift, etc.
5
W105-03-06-011
2
2. Lower track frame (2) enough to gain a little
clearance between collar (6) and track frame (2).
6 W105-03-06-012
W105-03-06-008
W3-6-6
UNDERCARRIAGE / Upper And Lower Roller
4. Install valve (3) of the track adjuster. Jack up the
track on the side being adjusted a sag, and turn it
slightly towards the reversed direction. Fill grease 3
from grease fitting (4) to make the track be in
tension.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
M104-07-119
W157-03-06-002
W3-6-7
UNDERCARRIAGE / Upper And Lower Roller
DISASSEMBLE LOWER ROLLER
3
2
4 1
5
6
5
4
3
2
1
W157-03-06-004
W3-6-8
UNDERCARRIAGE / Upper And Lower Roller
Disassemble Lower Roller
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly” on page W1-1-1
before starting the disassembly work.
W105-03-06-026
5. Press axle (8) with a press to remove collar (2) of 4 2
the other side and O-ring (4) from axle (8).
W105-03-06-027
W105-03-06-028
W3-6-9
UNDERCARRIAGE / Upper And Lower Roller
ASSEMBLE LOWER ROLLER
2 7 6 5 4 3 1
W105-03-06-023
W3-6-10
UNDERCARRIAGE / Upper And Lower Roller
Assemble Lower Roller
1. Install bushing (6) (2 used) onto roller (7) with a
press. Take care not to dent the flange surface of
bushing (6).
Apply a coat of grease to O-ring (4) and install it
onto axle (8).
3
2. Install collar (2) of one side onto axle (8), aligning
the pin holes. 8
Secure them using pin (3). Take care not to
damage O-ring (4).
4. Insert axle (8) into roller (7). Install O-ring (4). The
other collar (2) shall be assembled in the same
4
way. Secure them using pin (3).
W157-03-06-009
3 7
1
5. Add engine oil via the plug (1) hole on collar (2).
Tighten plug (1).
Engine oil: API CD class, SAE 30
Quantity: 200 mL
: 6 mm 2
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
Apply LOCTITE # 503 or equivalent to the plug. W105-03-06-024
W3-6-11
UNDERCARRIAGE / Upper And Lower Roller
MAINTENANCE STANDARD
Upper Roller
W105-03-06-032
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 72 (2.83) –
W3-6-12
UNDERCARRIAGE / Upper And Lower Roller
Lower Roller
W157-03-06-003
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 146 (5.75) [165.4 (6.51)]
B 186 (7.32) – Build-up weld
C 20.5 (0.81) [10.3 (0.41)] and finishing
W3-6-13
UNDERCARRIAGE / Upper And Lower Roller
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal 1
2
CAUTION: Do not loosen valve (4) quickly or
loosen too much since high-pressure grease
in the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and
face away from valve (4). Never loosen
grease fitting (2).
3
Wooden Block
W105-03-07-006
W105-03-07-001
W105-03-07-002
W3-7-1
UNDERCARRIAGE / Track
3. Remove retaining ring (6), which is used to
prevent the master pin from coming off. 7
Corner
Direction for Direction for
installing the removing the
master pin. master pin.
Retaining Ring
Track Link 3
Master Link
W105-03-07-010
ST 1970
W105-03-07-008
W3-7-2
UNDERCARRIAGE / Track
5. Rotate the upperstructure 90° degrees toward the
side of the track to be removed, perpendicular to
the tracks. Operate the boom and arm so that the
angle between them is 90° to 110° degrees.
Lower the boom with the bucket rolled-in to jack
up the machine as illustrated. 90° to 110°
M104-07-067
W105-03-07-011
W3-7-3
UNDERCARRIAGE / Track
Installation
1. Jack up the machine so that sprocket can engage
with track end and put the track under the lower
roller.
Be sure to position the track in correct direction,
as illustrated. Sprocket
Idler Side Side
W105-03-07-013
W105-03-07-014
3. With the machine being jacked up, operate the
9
travel lever for the side the track being installed in
forward direction. Wind the track while rotating
travel device (9).
W105-03-07-015
W105-03-07-016
Wooden Block
W3-7-4
UNDERCARRIAGE / Track
IMPORTANT: Master pin (3) is directional. Be
Corner
sure to install it in the correct
Direction for Direction for
direction. installing the removing the
5. Install master pin (3) with a hammer and special master pin master pin
tool (ST 1970).
Retaining Ring
Track Link 3
Master Link
W105-03-07-010
ST 1970
Grease
Do not Do not
Apply Apply
Grease. Grease.
W197-03-07-001
Seal
W3-7-5
UNDERCARRIAGE / Track
7. Tighten valve (4). Apply grease to fitting (5) to
adjust track link tension.
: 24 mm 5
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Track sag specification (A):
250 to 280 mm (9.84 to 11.02 in)
W105-03-07-018
W157-03-06-002
W3-7-6
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link
Measure the length of four links.
• Master pin is not included in measurement.
• Measurement shall be carried out with the track in
tension.
W155-03-07-001
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 687.4 (27.06) 707.9 (27.87) Build-up weld and finishing or
B 89 (3.50) 82 (3.23) replace
W3-7-7
UNDERCARRIAGE / Track
Master Bushing
W105-03-07-023
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 107.5 (4.23) –
Master Pin
W105-03-07-021
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 163.9 (6.45) –
Replace
B 33.75 (1.33) [30.75 (1.21)]
W3-7-8
UNDERCARRIAGE / Track
Pin
A
W142-03-07-004
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 175 (6.89) –
Replace
B 33.5 (1.32) [30.5 (1.20)]
Bushing
W105-03-07-023
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 117.4 (4.62) –
B 34.1 (1.34) [35.1 (1.38)] Replace
C 50.67 (1.99) [45.67 (1.80)]
W3-7-9
UNDERCARRIAGE / Track
Grouser shoe
W105-03-07-024
Unit: mm (in)
Shoe Width 500 mm Grouser
Allowable
Standard Remedy
Limit
A 191.5 (7.54) –
Build-up weld
B 8 (0.32) – and finishing
or replace
C 20 (0.79) 14 (0.55)
A
W187-03-07-001
Unit: mm (in)
Shoe Width 500 mm Grouser
A 181 −
B 8 − Replace
C 65 14
W3-7-10
SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment ........W4-1-1
Maintenance Standard ...............................W4-1-10
Standard Dimensions for
Arm and Bucket Connection ....................W4-1-15
Standard Dimensions for
Arm and Boom Connection ................... W4-1-18
Group 2 Cylinder
Removeand Install Cylinder .................... W4-2-1
Hydraulic Circuit Pressure Release
Procedure ........................................... W4-2-19
Disassemble Cylinder ........................... W4-2-20
Assemble Cylinder ................................ W4-2-36
Maintenance Standard .......................... W4-2-52
187W-4-1
(Blank)
187W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT
ATTACHMENT
IMPORTANT: Be sure to release any pressure in
the hydraulic oil tank before any
work. (Refer to W1-4-1.)
Removal
1. (ZAXIS135UR only)
Remove bolts (1) (2 used) to remove cover (2). (2
places on both left and right) 1 2
: 17 mm
W198-04-01-001
2. Remove grease hose (3) from the adapter at the
boom cylinder rod side boss. (2 places on both
left and right) 3
: 17 mm (ZAXIS110, 120, 125US, 135US)
: 19 mm (ZAXIS135UR)
Adapter
3. Remove nuts (6) and bolts (8) from boom cylinder
rod pin (4). Then remove stopper (7). (2 places on Boom Cylinder
both left and right)
: 24 mm
W554-02-03-007
W4-1-1
FRONT ATTACHMENT / Front Attachment
6. Remove hoses (12) (4 used) from the boom
cylinder at the cylinder bottom. Close all openings Boom Cylinder
with plug (13/16-16 UN). 13 9
: 27 mm
: 24 mm
Air Release
Valve
SS-2096
W4-1-2
FRONT ATTACHMENT / Front Attachment
10. Remove hoses (14) and (15) for the bucket ZAXIS110, 120
cylinder and arm cylinder. Remove hoses for
offset cylinder. Close all openings with cap.
14 15
: 27, 36 mm
: 19 mm
M154-07-002
W1SE-04-01-001
Cover
W1SE-04-01-002
Bolt
12. (ZAXIS135UR only) Socket Bolt
Remove bolts (4 used) from the boom to remove Bolt
the cover of boom angle sensor.
Remove bolts (2 used) and socket bolts (3 used)
to remove the boom angle sensor and connector.
: 17 mm
: 5 mm
Plate
Bolt
Connector
Boom Angle
Sensor
W187-04-01-006
W4-1-3
FRONT ATTACHMENT / Front Attachment
13. Remove bolt (19), spring washer (20), plate (18)
and block (17) from the plate of boom foot pin 16
(16).
: 27 mm
17
18
19
20
CAUTION: Front attachment weight:
1800 kg (4000 lb) (ZAXIS110) W178-04-01-001
W105-04-01-008
16
16. Turn the plate upward by hand and turn it left and Plate
Insert Bar
right to pull it out.
(Adjust the position of the boom foot pin hole, Bracket
hoisting/lowering the front attachment.)
W187-04-01-004
CAUTION: Boom foot pin (16) weight: 23 kg
(51 lb)
W178-04-01-005
W4-1-4
FRONT ATTACHMENT / Front Attachment
Install Attachment
CAUTION: Front attachment weight:
1800 kg (4000 lb) (ZAXIS110)
1900 kg (4190 lb) (ZAXIS125US)
2000 kg (4400 lb) (ZAXIS120, 135US)
3100 kg (6830 lb) (ZAXIS135UR)
4. (ZAXIS110, 120)
Install the tool box and cover with bolts (8 used).
(ZAXIS125US, 135US, 135UR)
Cover
Install the cover with bolts (4 used).
Tool Box
: 17 mm
W178-04-01-002
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
ZAXIS125US, 135US, 135UR, 135UR
Cover
W1SE-04-01-002
W4-1-5
FRONT ATTACHMENT / Front Attachment
5. Remove caps from hoses and pipings. Install ZAXIS110, 120
bucket cylinder hoses and arm cylinder hoses
(14), (15) and offset cylinder hoses.
: 27 mm
14 15
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
7. Insert thrust plate (13) and pin (10). Install bolt (9),
tighten with nut (11).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) Boom Cylinder
10
11
12 W187-04-02-009
W4-1-6
FRONT ATTACHMENT / Front Attachment
10. Hoist the boom cylinder by crane. Operate the
boom lever, align the cylinder rod side pin hole
with the boom cylinder mounting hole.
4 5
CAUTION: Prevent personal injury. Metal
fragments may fly when a hammer is used to
remove pins. Be sure to wear necessary
protection, such as goggles, hardhat, etc. 8 Boom Cylinder
11. Install thrust plate (5), drive in pin (4), connect the
boom cylinder to the boom.
3
13. Install grease hoses (3).
(ZAXIS110, 120, 125US, 135US)
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 71.5 lbf⋅ft)
(ZAXIS135UR)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
1 2
W198-04-01-003
W4-1-7
FRONT ATTACHMENT / Front Attachment
Boom Foot
Side
M154-07-002
Boom Foot
Side
M1SE-07-003
IMPORTANT: When the arm has been removed
from the boom, perform the
following steps when installing the
arm.
17. Install thrust plates (21) into arm left and right
sides. Adjust total clearance of left and right within
1.5 mm or less.
18. After the arm is installed, add grease to grease Boom Cylinder M104-07-002
W4-1-8
FRONT ATTACHMENT / Front Attachment
(Blank)
W4-1-9
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin and Bushing F E G
C H
ZAXIS110 J
ZAXIS120 A D C
B I K
W105-04-01-018
Unit: mm (in)
W4-1-10
FRONT ATTACHMENT / Front Attachment
ZAXIS125US
ZAXIS135US
Unit: mm (in)
W4-1-11
FRONT ATTACHMENT / Front Attachment
ZAXIS135UR
D
F
P
R
E O
G Q C
A
S
I
K T
H
B
M
L N W187-04-01-007
Unit: mm (in)
ZAXIS135UR
Part Name Remedy
Standard Allowable Limit
Pin 71 (2.8) 70.0 (2.8)
A
Boss (Main Frame) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
B Boos (Main Frame) 71 (2.8) 72.5 (2.9)
Bushing (Boom Cylinder) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
C Boss (Boom) 71 (2.8) 72.5 (2.9)
Bushing (Boom Cylinder) 71 (2.8) 72.5 (2.9) Replace
Pin 65 (2.56) 64.0 (2.5)
D
Bushing(Arm) 65 (2.56) 66.5 (2.6)
Pin 71 (2.8) 70.0 (2.8)
E Boom (Arm) 71 (2.8) 72.5 (2.9)
Bushing (Arm Cylinder) 71 (2.8) 72.5 (2.9)
Pin 80 (3.15) 79.0 (3.11)
F
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)
W4-1-12
FRONT ATTACHMENT / Front Attachment
Unit: mm (in)
ZAXIS135UR
Part Name Remedy
Standard Allowable Limit
Pin (Bucket Cylinder) 60 (2.36) 59.0 (2.32)
G
Bushing 60 (2.36) 61.5 (2.42)
Pin 65 (2.56) 64.0 (2.52)
H Bushing (Bucket Cylinder) 65 (2.56) 66.5 (2.62)
Bushing (Link) 65 (2.56) 66.5 (2.62)
Pin 65 (2.56) 64.0 (2.52)
I
Bushing (Arm) 65 (2.56) 66.5 (2.62)
Pin 65 (2.56) 64.0 (2.52)
J
Bushing (Link) 65 (2.36) 66.5 (2.62)
Pin 65 (2.56) 64.0 (2.52)
K
Bushing (Arm) 65 (2.56) 66.5 (2.62)
Pin 71 (2.8) 70.0 (2.8)
L
Bushing (Blade) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
M
Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9) Replace
Pin 71 (2.8) 70.0 (2.8)
N
Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9)
Pin (Lower/Upper Boom) 125 (4.92) 124.0 (4.88)
O
Bushing (Upper Boom) 125 (4.92) 126.5 (4.98)
Pin (Cylinder Stay / Upper Boom) 125 (4.92) 124.0 (4.88)
P
Bushing 125 (4.92) 126.5 (4.98)
Pin (Lower Boom / Offset Cylinder) 60 (2.36) 59.0 (2.32)
Q
Bushing (Offset Cylinder) 60 (2.36) 61.5 (2.42)
Pin (Upper Boom / Offset Cylinder) 60 (2.36) 59.0 (2.32)
R
Bushing (Offset Cylinder) 60 (2.36) 61.5 (2.42)
Pin (Cylinder Stay / Stay) 60 (2.36) 59.0 (2.32)
S
Bushing (Stay) 60 (2.36) 61.5 (2.42)
Pin (Lower Boom / Stay) 60 (2.36) 59.0 (2.32)
T
Bushing (Stay) 60 (2.36) 61.5 (2.42)
W4-1-13
FRONT ATTACHMENT / Front Attachment
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
Standard Allowable Limit Remedy
A 229 (9.0) 149 (5.9)
B 245 (9.6) -
Replace
C 330 (13.0) -
D 135 (5.3) -
Point
B C
W105-04-01-020
Unit: mm (in)
B 79.2 (3.1) -
Replace
C 95.0 (3.7) -
D 81.0 (3.2) -
W4-1-14
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
ZAXIS110, 125US
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS110, 125US EX100-5, EX100M-5 EX100-3, EX100M-3 EX100-2, EX100M-2
a 325 (12.8) ← ← ←
b 5 (0.2) ← ← ←
c 505 (19.9) 500 (19.7) ← ←
d 460 (18.1) ← ← ←
e - - - -
f 1230 (48.4) ← ← ←
g 377 (14.8) ← ← ←
h 254 (10.0) ← ← ←
i 65 (2.6) ← ← ←
j 355.2 (14.0) ← ← ←
k 70 (2.8) ← ← ←
l 377 (14.8) ← ← ←
m 255 (10.0) ← ← ←
n 65 (2.6) ← ← ←
o 90° ← ← ←
p 90° ← ← ←
q 391 (15.4) ← ← ←
IMPORTANT: If the front attachment of a previous NOTE: The dimension h: 254 mm (10 in) shows
model machine is used, use the the dimension with the adjustable boss.
grease intervals of the previous
model machine.
W4-1-15
FRONT ATTACHMENT / Front Attachment
ZAXIS120, 135US
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS120, 135US EX120-5, EX135USR EX120-3 EX120-2
a 325 (12.8) ← ← ←
b 5 (0.2) ← ← ←
c 505 (19.9) 500 (19.7) ← ←
d 460 (18.1) ← ← ←
e - - - -
f 1230 (48.4) ← ← ←
g 377 (14.8) ← ← ←
h 254 (10.0) ← ← ←
i 65 (2.6) ← ← ←
j 355.2 (14.0) ← ← ←
k 70 (2.8) ← ← ←
l 377 (14.8) ← ← ←
m 255 (10.0) ← ← ←
n 65 (2.6) ← ← ←
o 90° ← ← ←
p 90° ← ← ←
q 391 (15.4) ← ← ←
IMPORTANT: If the front attachment of a previous NOTE: The dimension h: 254 mm (10 in) shows
model machine is used, use the the dimension with the adjustable boss.
grease intervals of the previous
model machine.
W4-1-16
FRONT ATTACHMENT / Front Attachment
ZAXIS135UR
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS135UR
a 325 (12.8)
b 5 (0.2)
c 505 (19.9)
d 460 (18.1)
e -
f 1230 (48.4)
g 377 (14.8)
h 254 (10.0)
i 65 (2.6)
j 355.2 (14.0)
k 70 (2.8)
l 377 (14.8)
m 255 (10.0)
n 65 (2.6)
o 90°
p 90°
q 391 (15.4)
W4-1-17
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
ZAXIS110, 125US
Section C
W187-04-01-002
Unit: mm (in)
W4-1-18
FRONT ATTACHMENT / Front Attachment
ZAXIS120, 135US
Section C
W187-04-01-002
Unit: mm (in)
W4-1-19
FRONT ATTACHMENT / Front Attachment
ZAXIS135UR
Section C
W187-04-01-008
Unit: mm (in)
ZAXIS135UR
s 71 (2.8)
t 273 (10.7)
u 403 (15.9)
W4-1-20
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Remove Bucket Cylinder
1. Insert wooden block (3) between bucket cylinder 1
(1) and arm (2).
3. Remove nut (6) and bolt (4). Push out pin (7).
Remove thrust plates (5). 7
: 24 mm 1 W158-04-02-006
8
9
W102-04-02-005
W4-2-1
FRONT ATTACHMENT / Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used) at
the bucket cylinder (1) bottom. Close all openings
with cap.
: 27 mm
10
W4-2-2
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may
be damaged. Use a press.
10
CAUTION: Prevent personal injury. Metal
fragments may fly off when a hammer is used
to install pin (11). Be sure to wear necessary
protection, such as goggles, hardhat, etc.
1. Hoist bucket cylinder (1) by crane. Align the cyl- 15
inder tube side pin hole with the bucket cylinder
mounting hole on the arm. Insert thrust plate (10)
14 11
and install pin (11).
13
2. Insert bolt (15) into arm stopper (14) and pin (11),
install nut (13).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
1
9 W102-04-02-005
W4-2-3
FRONT ATTACHMENT / Cylinder
6. Insert bolt (4) into stopper (17) and pin (7), install
nut (6).
: 4 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
7 18 6
IMPORTANT: In case link (18) has been removed W158-04-02-006
from the arm, do not forget to
re-insert thrust plate (19).
19 19
IMPORTANT: When all work is completed, run the
bucket cylinder several times to
stroke end to bleed air from the cir-
cuit.
W157-04-01-015
18 18
W4-2-4
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder (ZAXIS110, 120, 125US,
135US)
1. Insert wooden block (3) into space between arm 1
cylinder (1) and boom (2).
3. Remove nut (8) and bolt (10) from pin (5) at the 4
10 5
arm cylinder (1) rod side.
: 24 mm (ZAXIS110, 125US) 1
: 30 mm (ZAXIS120, 135US)
boom gently.
6 1
12
W102-04-02-014
W4-2-5
FRONT ATTACHMENT / Cylinder
15
W187-04-02-007
W4-2-6
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
(ZAXIS110, 120, 125US, 135US)
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may
be damaged. Use a press.
11
3. Install grease hose (12) and arm cylinder hoses
(11) (2 used). 1
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
12
IMPORTANT: After filling hydraulic oil to specified
level, start the engine and check the
connections for any oil leaks.
W102-04-02-014
W4-2-7
FRONT ATTACHMENT / Cylinder
4. Remove wire (7) from arm cylinder rod (6). Start
the engine, operate the arm lever, align the arm 6 1
cylinder rod side pin hole with the arm cylinder
mounting hole on arm (18).
18
W4-2-8
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder (ZAXIS 135UR)
2. Remove nut (2) and bolt (3) to pull out pin (4).
Pull the thrust plate between arm cylinder (1) rod 1
and the arm.
: 30 mm 9
7, 8
3. Secure arm cylinder (1) with a wire to prevent the
arm cylinder rod from extending. 5
4
4. Remove hoses (5) (2 used) at the bottom part of
6
arm cylinder (1). Attach the cap onto the hoses.
: 36 mm
2, 3
W4-2-9
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder (ZAXIS 135UR)
W4-2-10
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder
Boom Cylinder
W187-04-02-008
W4-2-11
FRONT ATTACHMENT / Cylinder
8. Remove hoses (12) (4 used) from the boom
cylinder at the cylinder bottom. Close all openings
with plug (13/16-16 UN). Boom Cylinder
: 27 mm 13 9
Boom Cylinder
W187-04-01-001
W4-2-12
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder
IMPORTANT: When pressing the bushing in, if a
hammer is used, the bushing may
be damaged. Use a press.
CAUTION: Boom cylinder weight:
100 kg (220 lb) (ZAXIS110)
109 kg (240 lb)
(ZAXIS120, 125US, 135US, 135UR)
W187-04-01-001
W4-2-13
FRONT ATTACHMENT / Cylinder
5. Hoist the boom cylinder by crane. Operate the
boom lever, align the cylinder rod side pin hole
with the boom cylinder mounting hole.
4 5
CAUTION: Prevent personal injury. Metal
fragments may fly off when a hammer is used
to remove pins. Be sure to wear necessary
protection, such as goggles, hardhat, etc.
8
Boom Cylinder
6. Install thrust plate (5), drive in pin (4), connect the
boom cylinder to the boom.
3
8. Install grease hoses (3).
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.7 lbf⋅ft)
Boom Cylinder
W105-04-02-032
W4-2-14
FRONT ATTACHMENT / Cylinder
Remove Offset Cylinder (ZAXIS 135UR)
4
CAUTION: Offset cylinder weight: 100 kg
2, 3
(220 lb)
1. Attach a wire onto the offset cylinder. Hoist it by
crane. 1
2. Remove nut (9) and bolt (10) to pull out pin (8). 5
Pull thrust plate (7) between the offset cylinder (1)
rod and the upper boom.
: 24 mm 7 M1SM-07-003
5. Remove nut (2) and bolt (3) to pull out pin (4).
Remove thrust plate (5) between the offset cylin-
der (1) cylinder part and the lower boom.
: 24 mm
W4-2-15
FRONT ATTACHMENT / Cylinder
Install Offset Cylinder (ZAXIS 135UR)
W4-2-16
FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder (ZAXIS135UR)
10 9 9
W198-04-02-001
W4-2-17
FRONT ATTACHMENT / Cylinder
Install Blade Cylinder (ZAXIS135UR)
10 9 9
W198-04-02-001
W4-2-18
FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
W178-04-02-010
W4-2-19
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
Boom Cylinder
11 1 2 3 4 8 7 5 6 9 10
19 20 21 24 23 22
W191-04-02-001
14 13 20 19 16 15 17 18 16 12
Bucket Cylinder
11 1 2 3 4 8 7 5 6 9 10
20 21 24 23 22
W191-04-02-002
20 19 16 15 17 18 16 19 12
1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)
2 - Backup Ring 8 - Socket Bolt 14 - Cushion Seal 20 - Slide Ring (2 Used)
(10 Used) (ZAXIS110, 125US, 135UR Bucket
Cylinder)
(12 Used) (ZAXIS120, 135US, Bucket Cylinder)
(10 Used) (ZAXIS110 Boom Cylinder)
(12 Used) (ZAXIS120, 125US, 135US, 135UR
Boom Cylinder)
3 - U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4 - Buffer Ring 10 - O-Ring 16 - Backup Ring (2 22 - Set Screw
Used)
5 - Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6 - Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-20
FRONT ATTACHMENT / Cylinder
Disassemble Boom and Bucket Cylinders
• Be sure to thoroughly read “Precautions for Dis- 4. Secure piston rod (11) on special tool (ST 5908).
assembly and Assembly” on page W1-1-1 before Put matching marks between the piston rod and
starting any disassembling work. nut (24).
W102-04-02-027
: 12 mm
W4-2-21
FRONT ATTACHMENT / Cylinder
Boom Cylinder
11 1 2 3 4 7 5 6 9 10
19 20 21 24 23 22
W191-04-02-001
14 13 20 19 16 15 17 18 16
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
20 21 24 23 22
W191-04-02-002
20 19 16 15 17 18 16 19
W4-2-22
FRONT ATTACHMENT / Cylinder
5. Remove set screw (22) and steel ball (23). 9. Remove O-rings (10), backup rings (9) and (2)
from cylinder head (7). Then remove wiper ring
NOTE: Set screw (22) was crimped with a punch (1), U-ring (3), buffer ring (4), snap ring (6), and
in 2 places after it was tightened. Before bushing (5).
loosing the set screw, cut away the Tool for removing bushing:
crimped portions. Boom
: Boom 70 mm (ST 8017/ST 1284)(ZAXIS110)
8 mm (ZAXIS110) 70 mm (ST 8017/ST 1284)(ZAXIS120, 125US,
10 mm (ZAXIS120, 125US, 135US, 135US, 135UR)
135UR) Bucket
Bucket 65 mm (ST 8015/ST 1283)(ZAXIS110, 125US,
8 mm (ZAXIS110, 125US) 135UR)
8 mm (ZAXIS120, 135US, 135UR) 70 mm (ST 8017/ST 1284)(ZAXIS120, 135US)
ST 5908
W158-04-02-022
W4-2-23
FRONT ATTACHMENT / Cylinder
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
15 16 25 26 28 22 12
14 13
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-24
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• Be sure to thoroughly read “Precautions for Dis- 4. Secure piston rod (11) on special tool (ST 5908).
assembly and Assembly” on page W1-1-1 before Put matching marks between the piston rod (11)
starting any disassembling work. and nut (24).
W102-04-02-027
W4-2-25
FRONT ATTACHMENT / Cylinder
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
15 16 25 26 28 22 12
14 13
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-26
FRONT ATTACHMENT / Cylinder
5. Remove set screw (22) and steel ball (23).
: 10 mm
ST 5908
W158-04-02-022
10. Remove snap ring (25) from piston rod (11) with a
screwdriver. Move cushion bearing (27) to the
snap ring side, remove stopper (28) to remove
cushion bearing (27) and cushion seal (26).
W4-2-27
FRONT ATTACHMENT / Cylinder
Offset Cylinder (ZAXIS135UR Only)
11 1 2 3 4 7 5 6 8 9 10 13 14 15
22 23 24 25 26 12
16 17 18 19 20 21 27 28 29
W198-04-02-002
W4-2-28
FRONT ATTACHMENT / Cylinder
Disassemble Offset Cylinder (ZAXIS135)
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1
before starting any repair work.
• The disassembly procedure below starts on the
premise that hydraulic lines and line securing
bands have been removed.
W102-04-02-027
W158-04-02-022
W4-2-29
FRONT ATTACHMENT / Cylinder
Offset Cylinder (ZAXIS135UR Only)
11 1 2 3 4 7 5 6 8 9 10 13 14 15
22 23 24 25 26
16 17 18 19 20 21 27 28 29
W198-04-02-002
W4-2-30
FRONT ATTACHMENT / Cylinder
5. Remove set screw (29) and steel ball (28). 9. Remove O-rings (15, 13, 9), backup rings (14, 10,
8, 2) from cylinder head (7). Then remove wiper
NOTE: Set screw (29) was crimped with a punch in ring (1), U-ring (3), buffer ring (4), snap ring (6),
2 places after it was tightened. Before and bushing (5).
loosing the set screw, cut away the crimped Tool for removing bushing:
portions. 70 mm (ST 8017)
: 10 mm
10. Remove stopper (25) from piston rod (11) with a
6. Loosen nut (27) using special tool (ST 5908). screwdriver. Remove cushion bearing (24),
Remove piston (18), shim (26) and cushion cushion seal (23) and snap ring (22).
bearing (16).
Tool for turning nuts: 85 mm (ST 3304)
ST 5908
W158-04-02-022
W4-2-31
FRONT ATTACHMENT / Cylinder
Blade Cylinder (ZAXIS135UR Only)
11 1 2 3 4 7 5 6 8 9 10
19 20 21 12
13 14 15 16 17 18 22 23 24 25
W198-04-02-003
W4-2-32
FRONT ATTACHMENT / Cylinder
Disassemble Blade Cylinder (ZAXIS135UR)
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1
before starting any repair work.
• The disassembly procedure below starts on the
premise that hydraulic lines and line securing
bands have been removed.
W4-2-33
FRONT ATTACHMENT / Cylinder
Blade Cylinder (ZAXIS135UR)
11 1 2 3 4 7 5 6 8 9 10
19 20 21
13 14 15 16 17 18 22 23 24 25
W198-04-02-003
W4-2-34
FRONT ATTACHMENT / Cylinder
5. Remove set screw (25) to remove steel ball (24).
: 10 mm
NOTE: Set screw (25) was crimped with a punch in
2 places after it was tightened. Before
loosening the set screw cut away the
crimped portions
7. Remove seal ring (17), slide rings (13, 14, 20, 21),
O-ring (18), and backup rings (15, 19) from piston
(16).
W4-2-35
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
Boom Cylinder
Hole (1 place)
Face the slit toward the piston
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20
21
22, 23
24
Bucket Cylinder
Hole (1 place)
1 2 3 4 5 6 7 8 9, 10
11 12 15 16 17, 18 19 20
21
22, 23
24
W187-04-02-001
W4-2-36
FRONT ATTACHMENT / Cylinder
Assemble Boom and Bucket Cylinders
1. Install bushing (5) to cylinder head (7) with a IMPORTANT: Be sure that the cushion seal slit
press. faces toward the piston and that the
cushion bearing oil groove faces the
Tools for installing bushing installation: correct direction. (Boom cylinder
Boom only.)
70 mm (ST 8017/ST 1284)(ZAXIS110) 7. Install cushion seal (14) to piston rod (11). Install
70 mm (ST 8017/ST 1284)(ZAXIS120, 125US, piston (15) to the piston rod.
135US, 135UR) (For boom cylinder only, install cushion seal (14)
Bucket and cushion bearing (13).)
65 mm (ST 8015/ST 1283)(ZAXIS110, 125US,
135UR)
70 mm (ST 8017/ST 1284)(ZAXIS120, 135US)
W4-2-37
FRONT ATTACHMENT / Cylinder
Boom Cylinder
7 8
11 12 21 22, 23
24
W178-04-02-003
Bucket Cylinder
7 8
11 12 21 22, 23
24
W187-04-02-001
W4-2-38
FRONT ATTACHMENT / Cylinder
8. Install shim (21) to piston rod (11). Tighten nut IMPORTANT: Be sure to align piston rod (11) with
(24) using special tool (ST 5908). the center of cylinder tube (12) when
Be sure to align the matching mark on the rod inserting, in order to avoid
with that on the nut. damaging the rings.
Tool for tightening nut: 10. Secure cylinder tube (12) horizontally on a work
Boom bench. Insert piston rod (11) into the cylinder tube.
75 mm (ST 3271) (ZAXIS110)
80 mm (ST 3262) (ZAXIS120, 125US, 135US, 11. Install cylinder head (7) to cylinder tube (12).
135UR) Tighten socket bolts (8) (10 used for ZAXIS110,
Bucket 125US, 135UR Bucket cylinder, 12 used for
75 mm (ST 3271) (ZAXIS110, 125US, 135UR) ZAXIS120, 135US, 125US, 135UR Boom
75 mm (ST 3271) (ZAXIS120, 135US) cylinder).
Boom cylinder: : 12 mm (Boom, Bucket)
: 2390N⋅m (245 kgf⋅m, 1770 lbf⋅ft) : 171 N⋅m (17.4 kgf⋅m, 126 lbf⋅ft)
(ZAXIS110)
: 3140 N⋅m (320 kgf⋅m, 2320 lbf⋅ft)
(ZAXIS120, 125US, 135US, 135UR)
Bucket cylinder:
: 3580 N⋅m (365 kgf⋅m, 2640 lbf⋅ft)
(ZAXIS110, 125US, 135UR)
: 3970 N⋅m (405 kgf⋅m, 2930 lbf⋅ft)
(ZAXIS120, 135US)
ST 5908
W158-04-02-022
W4-2-39
FRONT ATTACHMENT / Cylinder
Arm Cylinder
NOTE: The figure below shows ZAXIS110.
Although cylinder tube (12) of ZAXIS135
UR is different, the disassembling
procedure is same.
Hole (1 place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26
27
28
W4-2-40
FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder
1. Install bushing (5) to cylinder head (7) with a 8. Install cushion seal (26) to piston rod (11). Install
press. cushion bearing (27) and stopper (28). Slide the
Tool for pressing bushing: cushion bearing to the stopper and install snap
75 mm (ST 8018/ST 1285) (ZAXIS110, 125US) ring (25).
80 mm (ST 8019/ST 1286) (ZAXIS120, 135US)
85 mm (ST 8020) (ZAXIS135UR)
W4-2-41
FRONT ATTACHMENT / Cylinder
Arm Cylinder
7 8 11 12 21 22, 23 24
W1SE-04-02-001
W4-2-42
FRONT ATTACHMENT / Cylinder
9. Install shim (21) to piston rod (11). Using tool (ST
5908), tighten nut (24) in order to align the
matching marks before removal.
Tool for turning nut:
80 mm (ST 3262) (ZAXIS110, 125US)
85 mm (ST 3304) (ZAXIS120, 135US)
90 mm (ST 3263) (ZAXIS135UR)
: 4710 N⋅m
(480 kgf⋅m, 3470 lbf⋅m)
(ZAXIS110, 125US)
: 6180 N⋅m
(630 kgf⋅m, 4560 lbf⋅m)
(ZAXIS120, 135US)
: 6580 N⋅m
(671 kgf⋅m, 4850 lbf⋅m)
(ZAXIS135UR)
ST 5908
W158-04-02-022
W4-2-43
FRONT ATTACHMENT / Cylinder
Offset Cylinder (ZAXIS135UR Only)
25
5 6
W196-04-02-006
Be sure that oil groove face the
correct direction when assembling
W4-2-44
FRONT ATTACHMENT / Cylinder
Assemble Offset Cylinder (ZAXIS135UR only)
1. Press bushing (5) into cylinder head (7). 7. Install the piston (18) assembly and cushion
Bushing Special Tool: 70 mm (ST 8017) bearing (16) into piston rod (11).
2. Install backup ring (2), U-ring (3), buffer ring (4), 8. Install shim (26) into piston rod (11). Tighten nut
and snap ring (6) into cylinder head (7). (27) using special tool (ST 5908) according to the
matching mark.
3. Install wiper ring (1) into cylinder head (7) with a
plastic hammer. Nut Special Tool: 85 mm (ST 3304)
Special tools for wiper ring installation: : 3580 N⋅m (365 kgf⋅m, 2640 lbf⋅ft)
ST 8017 ST 5908
W4-2-45
FRONT ATTACHMENT / Cylinder
Offset Cylinder (ZAXIS135UR)
7 12 11 27 22
29, 28 23
24
25
W196-04-02-006
W4-2-46
FRONT ATTACHMENT / Cylinder
IMPORTANT: Set screw (29) was crimped with a
punch in 2 places after it was
tightened.
9. Align holes on piston rod (11) and nut (27). Install
steel ball (28). Then, tighten set screw (29).
: 10 mm
: 56.9±10.7 N⋅m
(5.8±1.09 kgf⋅m, 42±8 lbf⋅ft)
W4-2-47
FRONT ATTACHMENT / Cylinder
Blade Cylinder (ZAXIS135UR)
1 7 10 8, 9 11 12 17, 18 20 21 22 23
13 14
25
24
W198-04-02-004
2, 3 4 5 6 15 19
1- Wiper Ring 8- Backup Ring 15 - Backup Ring (2 Used) 21 - Slide Ring (2 Used)
2- Backup Ring 9- O-Ring 16 - Piston 22 - Shim
3- U-Ring 10 - O-Ring 17 - Seal Ring 23 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 24 - Steel Ball
5- Bushing 12 - Cylinder Tube 19 - Backup Ring 25 - Set Screw
6- Snap Ring 13 - Slide Ring 20 - Slide Ring (2 Used)
7- Cylinder Head 14 - Slide Ring
W4-2-48
FRONT ATTACHMENT / Cylinder
Assemble Blade Cylinder (ZAXIS135UR)
1. Press bushing (5) into cylinder head (7) with a 7. Install the piston (16) assembly to piston rod (11).
press.
Bushing Special Tool: 70 mm (ST 8017) 8. Install shim (22) into piston rod (11). Tighten nut
(23) using special tool (ST 5908) according to the
IMPORTANT: Be sure to install correctly. matching mark.
Nut Turning Special Tool: 75 mm (ST 3271)
2. Install backup ring (2) and U-ring (3), buffer ring : 2640 N⋅m (269 kgf⋅m, 1950 Ibf⋅ft)
(4) and snap ring (6) into cylinder head (7). ST 5908
W4-2-49
FRONT ATTACHMENT / Cylinder
Blade Cylinder (ZAXIS135UR)
7 11 12 23
25
24
W198-04-02-004
W4-2-50
FRONT ATTACHMENT / Cylinder
IMPORTANT: Set screw (25) should be crimped
with a punch in 2 places after it is
tightened.
9. Align the holes on piston rod (11) and nut (23) to
install steel ball (24). Then, tighten set screw (25).
: 8 mm
: 31.5±5.88 N⋅m
(3.21±0.60 kgf⋅m, 23±4.3 Ibf⋅ft)
W4-2-51
FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
Piston Rod
W105-04-02-094
Unit: mm (in)
Machine Model Cylinder Name Recommended Size After Re-manufacturing (A)
-0.01 -0.00039
Boom 70 -0.023 (2.76 -0.00091 )
ZAXIS110 -0.01 -0.00039
Arm 75 -0.023 (2.95 -0.00091 )
ZAXIS125US
-0.01 -0.00039
Bucket 65 -0.023 (2.56 -0.00091 )
-0.01 -0.00039
Boom 70 -0.023 (2.76 -0.00091 )
ZAXIS120 -0.01 -0.00039
Arm 80 -0.023 (3.15 -0.00091 )
ZAXIS135US
-0.01 -0.00039
Bucket 70 -0.023 (2.76 -0.00091 )
-0.01 -0.00039
Boom 70 -0.023 (2.76 -0.00091 )
-0.012 -0.00047
Arm 85 -0.027 (3.35 -0.00106 )
-0.01 -0.00039
ZAXIS135UR Bucket 65 -0.023 (2.56 -0.00091 )
-0.01 -0.00039
Offset 70 -0.023 (2.76 -0.00091 )
-0.01 -0.00039
Blade 70 -0.023 (2.76 -0.00091 )
Dial Gauge
Piston 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
W4-2-52
SECTION 5
ENGINE AND ACCESSORY
CONTENTS
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual.............. 1-2 Cylinder Head................................................ 4-2
Main Data and Specifications ........................ 1-6 Valve Guide ................................................... 4-3
Performance Curve ....................................... 1-7 Valve Spring .................................................. 4-6
External View ................................................ 1-9 Tappet ........................................................... 4-7
Tightening Torque Specifications ................. 1-13 Push Rod ...................................................... 4-8
Angular Nut and Bolt Tightening Method...... 1-15 Rocker Arm Shaft and Rocker Arm................ 4-8
Major Parts Fixing Nuts and Bolts................ 1-17 Idler Gear and Idler Gear Shaft ..................... 4-9
Identifications .............................................. 1-25 Camshaft..................................................... 4-10
Cylinder Body and Liner............................... 4-11
Maintenance Piston and Piston Ring ................................ 4-17
Lubricating System ........................................ 2-2 Piston Pin .................................................... 4-18
Fuel System .................................................. 2-3 Connecting Rod........................................... 4-19
Cooling System ............................................. 2-6 Crankshaft................................................... 4-21
Valve Clearance Adjustment.......................... 2-6 Flywheel ...................................................... 4-28
Injection Timing ............................................. 2-8 Timing Gear Case Cover ............................. 4-28
Compression Pressure Measurement.......... 2-12
Turbocharger Inspection.............................. 2-13 Engine Assembly 3 (Reassembly)
Engine Repair Kit ........................................ 2-14 Piston and Connecting Rod
Recommended Lubricants ........................... 2-15 Reassembly Steps ....................................... 5-2
Engine Oil Viscosity Chart ........................... 2-15 Cylinder Head Reassembly Steps.................. 5-4
Rocker Arm and Rocker Arm Shaft
Engine Assembly 1 (Disassembly) Reassembly Steps ....................................... 5-7
External Parts Disassembly Steps ................. 3-2 Major Component Reassembly Steps 1 ......... 5-8
Major Components ........................................ 3-6 Major Component Reassembly Steps 2 ....... 5-13
Rocker Arm and Rocker Arm Shaft External Parts Reassembly Steps
Disassembly Steps .................................... 3-10 (Left-Hand Side) ........................................ 5-18
Cylinder Head Disassembly Steps ............... 3-11 External Parts Reassembly Steps
Piston and Connecting Rod (Right-Hand Side) ...................................... 5-21
Disassembly Steps .................................... 3-12 Engine Tuning Operation ............................. 5-25
187W-5-1
Lubricating System Troubleshooting
General Description....................................... 6-2 Hard Starting ............................................... 11-2
Oil Pump ....................................................... 6-3 1) Starter Inoperative................................. 11-2
Oil Cooler ...................................................... 6-5 2) Starter Operates but
Engine does not Turn Over.................... 11-3
Cooling System 3) Engine Turns Over but does not Start
General Description....................................... 7-2 Fuel is Being Delivered to the
Thermostat.................................................... 7-3 Injection Pump ...................................... 11-4
4) Engine Turns Over but does not Start.... 11-5
Fuel System Unstable Low Idling ..................................... 11-6
General Description....................................... 8-2 Insufficient Power ........................................ 11-8
Injection Nozzle ............................................. 8-3 Excessive Fuel Consumption..................... 11-11
Injection Pump Calibration Data .................... 8-8 Excessive Oil Consumption ....................... 11-13
Overheating............................................... 11-14
Turbocharger Whity Exhaust Smoke ............................... 11-16
General Description....................................... 9-2 Dark Exhaust Smoke................................. 11-17
Turbocharger Identification ............................ 9-3 Oil Pressure does not Rise ........................ 11-18
Troubleshooting............................................. 9-5 Abnormal Engine Noise ............................. 11-20
Inspection and Repair ................................... 9-7
Special Tool List
Engine Electricals Special Tool List .......................................... 12-2
Starter Identification .................................... 10-2
Starter Main Data and Specifications........... 10-3 Repair Standards
Starter Sectional View ................................. 10-4 Repair Standards ........................................ 13-1
Performance ............................................... 10-4
Disassembly................................................ 10-5 Conversion Table
Inspection and Repair ................................. 10-8 Length ......................................................... 14-1
Reassembly .............................................. 10-12 Area ............................................................ 14-3
Adjustment ................................................ 10-13 Volume ........................................................ 14-3
Performance Test ...................................... 10-14 Mass ........................................................... 14-5
Alternator Identification.............................. 10-15 Pressure...................................................... 14-6
Main Data and Specifications .................... 10-16 Torque ......................................................... 14-7
Alternator Sectional View........................... 10-17 Temperature ................................................ 14-8
Charging Circuit ........................................ 10-17
Structure ................................................... 10-18
Disassembly.............................................. 10-19
Inspections................................................ 10-22
Reassembly .............................................. 10-24
Bench Test ................................................ 10-25
Current Output Test ................................... 10-26
Fault Finding ............................................. 10-27
Specifications ............................................ 10-27
187W-5-2