INTRODUCTION

TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this 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 usage.):
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 two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.

• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance and
delivery, operation and activation of all devices repair of the machine, tools and devices needed
and systems, operational performance tests, and for maintenance and repair, maintenance stan-
troubleshooting procedures. dards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.

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

UNITS USED

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

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
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

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.

001-E01A-0688 SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.

• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.

• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.

• DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.

• Some safety signs don’t use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.

• CAUTION also calls attention to safety messages in

this manual.

• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.

• NOTE indicates an additional explanation for an

element of information.

002-E01C-1223

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the ma-

chine 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 miss-

ing, order a replacement from your authorized
dealer in the same way you order other replace-
ment parts (be sure to state machine model and
serial number when ordering).
SA-003

• Learn how to operate the machine and its controls

correctly and safely.

• Allow only trained, qualified, authorized personnel to

operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.

• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003

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- SA-437

lance service, hospital, and fire department

posted near your telephone.

004-E01A-0437

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.

• Operating equipment safely requires the full

attention of the operator. Do not wear radio or music
headphones while operating the machine.

005-E01A-0438

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

• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.

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

points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.

S007-E01A-0435
SA-435

SA-3
 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 op-

erator’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-4
 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.
SA-439
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.

008-E01B-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.

• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again. SA-378

009-E01A-0378

SA-5
 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 SA-237
securely fastened at all times when the machine 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

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-659
machine.

011-E01A-0426

SA-6
 SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT

• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.

• Start the engine only when seated in the

operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals. SA-444
• Before starting the engine, confirm that all control
levers are in neutral.

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 SA-032
could result in a battery explosion or a runaway
machine.

S013-E01A-0032

SA-7
 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-660

PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person’s directions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN

• Incorrect travel pedal/lever operation may result in

serious injury death.

• Before driving the machine, confirm the position of

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.

SA-662
017-E01A-0491

SA-8
 SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection 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-663

• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.

SA-664

• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
SA-441
to ensure sage operation.

019-E01D-0492

SA-589

SA-9
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

• Death or serious injury may result if you attempt to

mount or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the
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. SA-666

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

020-E08A-0493

SA-10
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.

To avoid back-over and swing accidents:

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

• USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person. SA-384

• No machine motions shall be made unless signals

are clearly understood by both signalman and
operator.

• Learn the meanings of all flags, signs, and

markings 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-11
 SAFETY
AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT

MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

To avoid tipping: SA-670

• 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
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-12
 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
SA-674
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.

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
SA-014
safely and securely situated on supporting 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-13
 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.

SA-432
031-E01A-0432

PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
SA-675
position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.

033-E09B-0390

SA-14
 SAFETY
ҥAVOID FIRES
HANDLE FLUIDS SAFELYҥ

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are SA-018

flammable.

• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.

034-E01A-0496
SA-019

SA-15
 SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
SA-676
• Be sure to observe local regulations when
transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.

Take the following precautions when loading /

unloading the machine:
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.

S035-E08A-0395

SA-16
 SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:

• Understand service procedures before doing

work.
• Keep work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from power-
driven parts.

• Before servicing the machine:

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.

• If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527

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
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.

S500-E02B-0497

SA-17
 SAFETY
• 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
inside the machine.
• Always use a work light protected with a guard. In SA-037

case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497

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

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

• Always lower the attachment to the ground before

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

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.

502-E01A-0026
SA-026

SA-18
 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.

SA-344
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.

• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.

SA-034

504-E01A-0034

USE TOOLS PROPERLY

• Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)

SA-040
S522-E01A-0040

SA-19
 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 SA-039
stop. Allow all pressure to be released before
removing the cap.
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225

• Wait for the oil and components to cool before

starting any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES

PERIODICALLY

• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the

page of “Periodic replacement of parts” in the
operator’s manual.)
SA-019
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
result in severe burns, gangrene, or otherwise
serious injury or death.

S506-E01A-0019

SA-20
 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
SA-031
care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA-292

507-E03A-0499

SA-044

SA-21
 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- SA-019
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

Clean up Flammables:

• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.

Check Key Switch:

• If 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-22
 SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S508-E02B-0019

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.

SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.

518-E02B-0393

SS-1510

SA-23
 SAFETY
BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

509-E01A-0016
SA-016

PRECAUTIONS FOR WELDING AND

GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
• After finishing welding and grinding, recheck that SA-818

there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

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

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that

contain flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030

SA-24
 SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.

• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.

511-E01A-0029

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal ob-
ject across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

512-E01C-0032

SA-25
 SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY

• If spilled onto skin, refrigerant may cause a cold

contact burn.

• Refer to the freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405

513-E01A-0405

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.

• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.

S515-E01A-0309

SA-26
 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 SA-226
can damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.

S516-E01A-0226

BEFORE RETURNING THE MACHINE TO

THE CUSTOMER

• After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced

S517-E01A-0435 SA-435

SA-27
 SAFETY
(Blank)

SA-28
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air
SECTION 2 UPPERSTRUCTURE
Group 1 Canopy
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE

All information, illustrations and speci-

fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.

COPYRIGHT(C)2002
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Hydraulic System Group 5 Component Test
Group 2 Electrical System SECTION 5 TROUBLESHOOTING
SECTION 3 COMPONENT OPERATION Group 1 Diagnosing Procedure
Group 1 Pump Device Group 2 Troubleshooting A
Group 2 Swing Device Group 3 Troubleshooting B
Group 3 Control Valve Group 4 Electrical System Inspection
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
 SECTION 1
GENERAL INFORMATION

CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1

Group 2 Tightening
Tightening Torque Specification............... W1-2-1
Torque Chart............................................ W1-2-2
Piping Joint.............................................. W1-2-5

Group 3 Painting
Painting ................................................... W1-3-1

Group 4 Bleeding Air

Bleed Air from Hydraulic Oil Tank ............ W1-4-1

1LAW-1-1
（Blank）

1LAW-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling

• Clean the Machine • Precautions for Disassembling

Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help • If a part or component cannot be removed after
avoid incorrect disassembling of components as removing its securing nuts and bolts, do not
well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.

• Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the

area for disassembling work.

W1-1-1
 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 cylin-
• Dirt or debris on the contact or sliding surfaces der 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, oil seals, trapped in the hydraulic pump hous-
and floating seals with new ones once they are ing, damage to the pump may result.
disassembled. Apply a film of grease before If the hydraulic motor is operated
installing.
with air trapped in the hydraulic mo-
• Be sure that liquid-gasket-applied surfaces are
tor housing, damage to the motor
clean and dry.
may result.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to If the cylinder is operated with air
remove the agent. trapped in the cylinder tube, damage
• Utilize matching marks when assembling. to the cylinder may result.
• Be sure to use the designated tools to assemble Be sure to bleed air before starting
bearings, bushings and oil seals. the engine.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is • Bleeding Air from Hydraulic Pump
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the • Remove the air bleeding plug from the top of the
assembled machine. pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.

W1-1-2
 GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

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

W1-1-3
 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:

(1) Keep seal rings together as a matched set with

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

(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

Correct
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
Incorrect
compressed air. Twist of O-Ring

(2) Clean the floating seal and seal mounting

Bent of O-Ring
bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it B

W105-03-05-020

is installed correctly on the seal ring. Correct

D Incorrect

a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating. A

b b

a=b a≠b

W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

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

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
 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.

2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the
“Allowable Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS

Wrench Torque
Bolt Dia
No. Descriptions Q'ty Size
mm N･m (kgf･m) (Ibf⋅ft)
mm
1 Engine cushion rubber mounting bolt 12 4 19 88 (9) (65)
Engine bracket mounting bolt (Front) 10 8 17 49 (5) (36)
2
Engine bracket mounting bolt (Rear) 10 6 17 49 (5) (36)
3 Hydraulic oil tank mounting bolt 12 4 19 88 (9) (65)
4 Fuel tank mounting nut 10 2 17 20 (2) (15)
PF 1/8 19 29.5 (3) (22)
5 Hydraulic hoses and union joints PF 3/8 22 39 (4) (29)
PF 1/2 27 64 (6.5) (47)
6 Pump mounting bolt 12 2 19 88 (9) (65)
27u 10 6 17 49 (5) (36)
7 Pump cover mounting bolt
30u, 35u 10 8 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
8
Control valve bracket mounting bolt 10 4 17 49 (5) (36)
9 Swing device mounting bolt 14 6 22 137 (14) (101)
10 Battery mounting nut 6 2 10 5 (0.5) (3.7)
11 Canopy mounting bolt 16 4 24 205 (21) (151)
12 Cab mounting bolt 16 4 24 205 (21) (151)
Swing Device 12 24 19 108 (11) (80)
13 Swing bearing mounting bolt
Track 12 20 19 108 (11) (80)
27u 12 18 19 108 (11) (80)
14 Travel device mounting bolt 30u 12 22 19 108 (11) (80)
35u 12 22 19 128 (13) (94)
27u 12 18 19 108 (11) (80)
15 Sprocket mounting bolt 30u 12 22 19 108 (11) (80)
35u 12 22 19 128 (13) (94)
16 Upper roller mounting bolt 12 1 19 88 (9) (65)
17 Lower roller mounting bolt 14 16 22 245 (25) (180)
6 10 5 (0.5) (3.7)
18 Cover mounting bolt 8 13 9.8 (1) (7.2)
10 17 49 (5) (36)
19 Counterweight mounting bolt 22 2 32 540 (55) (400)
10 17 49 (5) (36)
12 19 88 (9) (65)
20 Front attachment stopper pin 14 22 137 (14) (101)
16 24 205 (21) (151)
18 27 390 (40) (289)
21 Side cutter mounting bolt 14 6 22 175 (18) (130)

NOTE: (1) Apply lubricant (i.e. white zinc B

dissolved into spindle oil) to reduce
their friction coefficients.
(2) Remove rust, dirt, and dust before
installing fasteners.

W1-2-1
 GENERAL INFORMATION / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
correct size tools. Otherwise, tightening
tools may slip, potentially causing personal
injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed. SA-040

Make sure to employ correct bolts and tighten them

correctly when assembling the machine or
components.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Hexagon T Bolt, Socket bolt H Bolt M Bolt
Bolt Wrench
Wrench
Dia. Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
Size
M 6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3)
M 8 13 6 29.5 (3) (22) 19.5 (2) (14.5) 9.8 (1) (7.2)
M 10 17 8 64 (6.5) (47) 49 (5) (36) 19.5 (2) (14.5)
M 12 19 10 108 (11) (80) 88 (9) (65) 34 (3.5) (25.5)
M 14 22 12 175 (18) (130) 137 (14) (101) 54 (5.5) (40)
M 16 24 14 265 (27) (195) 205 (21) (152) 78 (8) (58)
M 18 27 14 390 (40) (290) 295 (30) (220) 118 (12) (87)
M 20 30 17 540 (55) (400) 390 (40) (290) 167 (17) (123)
M 22 32 17 740 (75) (540) 540 (55) (400) 215 (22) (159)
M 24 36 19 930 (95) (690) 690 (70) (505) 275 (28) (205)
M 27 41 19 1370 (140) (1010) 1030 (105) (760) 390 (40) (290)
M 30 46 22 1910 (195) (1410) 1420 (145) (1050) 540 (55) (400)
M 33 50 24 2550 (260) (1880) 1910 (195) (1410) 740 (75) (540)
M 36 55 27 3140 (320) (2310) 2400 (245) (1770) 930 (95) (690)

W1-2-2
 GENERAL INFORMATION / 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
lubricant.
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
application.
5. Make sure that nut and bolt
threads are clean before
installing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally

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

W1-2-3
 GENERAL INFORMATION / Tightening
Service Recommendations for Spilt Flange

IMPORTANT: 1. Be sure to clean and Inspect

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

an air wrench often causes RIGHT WRONG

tightening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round

Nut and Bolt Locking

RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while W105-01-01-009

tightening, not while loosening. RIGHT RIGHT WRONG

• 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

W1-2-4
 GENERAL INFORMATION / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a
different torque is given for a
specific application.
M202-07-051
Joint Body
Union Joint

Metal sealing surfaces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°

30°
IMPORTANT: 1. Do not over-tighten nut (3).
Excessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to
specifications. W105-01-01-017

2. Scratches or other damage to

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

Wrench Size Wrench Size Tightening

Description mm mm Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, Ibf⋅ft)
30°male 17 17 24.5 (2.5, 18)
19 19 29.5 (3, 22)
22 22 39 (4, 29)
27 27 64 (6.5, 47)
32 32 137 (14, 101)
36 36 175 (18, 130)
41 41 205 (21, 152)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3, 22)
22 19 39 (4, 29)
27 22 64 (6.5, 47)
32 27 137 (14, 101)
36 32 175 (18, 130)
41 36 205 (21, 152)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.

W1-2-5
 GENERAL INFORMATION / Tightening
O-ring Seal Joint 7 6 9

O-ring (6) seats against the end face of adaptor (7) to

seal pressure oil.

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10
in O-ring groove (8). Tightening M104-07-033

nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening
groove (8) or sealing surface mm mm Torque
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, Ibf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3, 27)
oil leakage. 22 19 69 (7, 51)
4. If nut (9) is loose and oil is 27 22 93 (9.5, 69)
leaking, do not re-tighten nut (9). 32 27 137 (14, 101)
Replace O-ring (6) with a new 36 30, 32 175 (18, 130)
one and check that O-ring (6) is 41 36 205 (21, 152)
correctly seated in place, tighten 46 41 205 (21, 152)
nut (9).

W1-2-6
 GENERAL INFORMATION / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

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

Male Tapered Thread

Wrench Size mm Tightening
Torque
Hose Fittings N⋅m (kgf⋅m, Ibf⋅ft)
17,19 59 (6, 44)
19,22 98 (10, 72)
27,22 118 (12, 87)
36,32 235 (24, 173)
41 295 (30, 218)
50 490 (50, 362)
60 670 (68, 494)
70 980 (100, 723)
Seal Tape Application

Seal tape is used to seal clearances between male Internal Thread

and female threads, so as to prevent any leaks
between threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap. External Thread
Clearance

• Application Procedure
W105-01-01-019

Confirm that the thread surface is clean and, free of

Leave one to two pitch threads uncovered
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
T-Bolt Type Band Clamp: 4.4 N･m ( 0.45 kgf･m, M114-07-041
3.25 lbf･ft )
Worm Gear Type Band Clamp:5.9 to 6.9 N･m (0.6 to
T-Bolt Type Worm Gear Type
0.7 kg･m, 4.3 to 5.1 lbf･ft)

M114-07-043 M114-07-042

W1-2-7
 GENERAL INFORMATION / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the
machine.

Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012

WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-8
 GENERAL INFORMATION / Tightening
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire
hazards. It is very difficult to gauge the extent of
deterioration, fatigue, or weakening of the parts listed
below simply by visual inspection 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
operation, regardless of the interval.
Also, when replacing hoses, check the clamps for
deformation, cracks, or other deterioration, and
replace if necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct
replacement.

Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Basic Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front-End Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-9
 GENERAL INFORMATION / Tightening
(Blank)

W1-2-10
 GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Colour
• Upperstructure Outer cover [Except resinated covers] 2.5GYO. 12/1.0D (SP-424) [Dark Gray]
Boom swing post, Boom swing cylinder 2.5GYO. 12/1.0D (SP-424)
Counterweight, Skirt 2.5GYO. 12/1.0D (SP-424)
Canopy except Roof 2.5GYO. 12/1.0D (SP-424)
Control lever [Travel, Blade] 2.5GYO. 12/1.0D (SP-424)
Stay, Swing pedal 2.5GYO. 12/1.0D (SP-424)
Seat base, Floor plate 2.5GYO. 12/1.0D (SP-424)
Upperstructure resinated covers 2.5GYO. 12/1.0D (SP-424) [TAXY Yellow]
• Undercarriage Track frame, Blade 2.5GYO. 12/1.0D (SP-424) [Dark Gray]
• Front attachment Boom, Arm, Bucket and Link (Including cylin- YR-01 [TAXY Yellow]
der)

TAXI Yellow

TAXI Yellow
Dark Gray Except Sparkling White
Seat and Console
TAXI Yellow
Dark Gray
Dark Gray TAXI Yellow

TAXI TAXI Yellow

Yellow
TAXI Yellow
Dark Gray Dark Gray
Dark Gray
TAXI Yellow

TAXI Yellow

Black Dark Gray Under- W1LA-01-04-001

Dark Gray
Dark Gray carriage Including
Swing Bearing Dark Gray Boom
Including Swing Post
Dark Gray
Front Skirt Including CYL.

W1-3-1
 GENERAL / Painting
(Blank)

W1-3-2
 GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Loosen the hydraulic oil tank cap to re-
lease any remaining pressure.

M1CC-07-002

Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank (2)

cap (1) to release any remaining pressure.

3. Remove hydraulic oil tank (2) cap (1).

4. Connect a vacuum pump with the hole removed

cap (1) to maintain negative pressure in the hy- 1
draulic oil tank (2).
2 M1CC-00-008

NOTE: Be sure to run the vacuum pump continu-

ously while working.
Vacuum Pump

Hose

Adapter

2
W562-02-03-008

W1-4-1
 GENERAL / Bleeding Air
(Blank)

W1-4-2
 MEMO

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 MEMO

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 SECTION 2
UPPERSTRUCTURE

CONTENTS
Group 1 Canopy Group 6 Pilot Valve
Remove and Install Canopy ............... W2-1-1 Remove and Install Pilot Valve .............W2-6-1
Disassemble Travel Pilot Valve ...........W2-6-10
Group 2 Counterweight Assemble Travel Pilot Valve................W2-6-14
Remove and Install Disassemble Front Pilot Valve ............W2-6-18
Counterweight .................................. W2-2-1 Assemble Front Pilot Valve .................W2-6-22
Disassemble Blade and Boom Swing
Group 3 Pump Device Pilot Valve .........................................W2-6-26
Remove and Install Assemble Blade and Boom Swing
Pump Device .................................... W2-3-1 Pilot Valve .........................................W2-6-28
Disassemble Pump Device (27u) ....... W2-3-5
Assemble Pump Device (27u) ............ W2-3-9 Group 7 Solenoid Valve
Disassemble Pump Device Remove and Install Solenoid Valve.......... W2-7-1
(30u, 35u) ....................................... W2-3-13 Disassemble and Assemble
Assemble Pump Device Solenoid Valve ....................................... W2-7-3
(30u, 35u) ....................................... W2-3-15
Maintenance Standard ..................... W2-3-19

Group 4 Control Valve

Remove and Install
Control Valve .................................... W2-4-1
Disassemble And Assemble
Control Valve .................................... W2-4-6

Group 5 Swing Device

Remove and Install
Swing Device.................................... W2-5-1
Disassemble Swing
Reduction Gear ................................ W2-5-6
Assemble Swing
Reduction Gear .............................. W2-5-10
Disassemble Swing Motor ................ W2-5-14
Assemble Swing Motor ..................... W2-5-16
Maintenance Standards.................... W2-5-20

1LAW-2-1
（Blank）

1LAW-2-2
 UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal 2

CAUTION: Canopy weight: 32kg (71 lb)

1. Attach sling belt (2) to canopy (1). Hoist it by 1

crane.

W1LD-02-01-001

2. Loosen screws (3) (2 used) to remove cover (4)

from canopy (1).

4 W1LD-02-01-002
3

1
3. Loosen bolts (5) to remove canopy (1) from the
frame.
: 24 mm

5
W1LD-02-01-003

W2-1-1
 UPPERSTRUCTURE / Canopy
Installation

2
CAUTION: Canopy weight: 32 kg (71 lb)

1. Attach sling belt (2) to canopy (1).

Hoist the canopy onto the frame by crane. 1

W1LD-02-01-001

2. Install canopy (1) with bolts (5) (2 used).

: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
5

W1LD-02-01-003

3. Install cover (4) onto canopy (1) with screws (3)

(2 used).

4
3 W1LD-02-01-002

W2-1-2
 UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
2
Removal
1
1. Remove bolts (2) (3 used) and (3) (2 used) to re-
move cover (1).
: 13 mm

2. Open covers (4) and (5).

3

3. Remove plugs (7) (2 used) from counterweight

(6).
W1LA-04-02-006

CAUTION: Counterweight weight:

299 kg (659 lb) (ZAXIS27u, 30u)
570 kg (1257 lb) (ZAXIS35u) 4 5

4. Attach eyebolt (M16, Pitch 2.0) into the plug (7)

hole.
Attach a wire onto the eyebolt and hoist it by
crane.

W1LA-02-02-001
7

5. Remove bolts (8) (2 used) and washers (9) (2

used). 8、9
Hoist to remove counterweight (6) by crane.
: 32 mm

W574-02-02-003

W2-2-1
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight weight: 8、9

299 kg (659 lb) (ZAXIS27u, 30u)
570 kg (1257 lb) (ZAXIS35u)

1. Install counterweight (6) with bolts (8) (2 used)

and washers (9) (2 used).
: 32 mm
: 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft)

W574-02-02-003

2. Install cover (1) with bolts (2) (3 used) and (3) (2 2

used). 1
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

W1LA-04-02-006

4 5
3. Install plugs (7) (2 used) to the eyebolt hole.

4. Close covers (4) and (5).

W1LA-02-02-001
7

W2-2-2
 UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Removal(ZAXIS27u)

IMPORTANT: Be sure to release any pressure in

1
the hydraulic oil tank before any
work.
2
1. Remove bolts(2)(2 used),(3)(3 used) to remove
3
cover(1).
: 13 mm

IMPORTANT: Attach the identification tags to the

disconnected hoses for
W1LA-02-03-001
reassembling. 6

2. Disconnect hoses(4) and (6)(3 used) from pump

device(9). Attach a cap onto the disconnected
hoses.
: 22 mm, 27 mm

3. Remove socket bolts(8)(4 used) to remove

suction pipe(7).
: 10 mm
5
CAUTION: Pump device weight : 20 kg (44
4
lb)

4. Attach a nylon sling onto the center of gravity in

pump device(9) to hoist it by crane.

5. Remove bolts(16)(2 used). Hoist to remove pump

device(9) by crane.
: 19 mm

O-Ring
9
Flange Groove

8
7

W567-02-03-001

W2-3-1
 UPPERSTRUCTURE / Pump Device
Removal(ZAXIS30u , 35u)

1. Remove bolts(2)(2 used) and (3)(3 used) to

remove cover(1).
: 13 mm 1

IMPORTANT: Attach the identification tags to the 2

disconnected hoses for
reassembling. 3

2. Disconnect hoses(4)(3 used) and (6) from pump

device(7). Attach a cap onto the disconnected
hoses.
: 22 mm, 27 mm W1LA-02-03-001
5
4
3. Remove socket bolts(9)(4 used) to remove
suction pipe(8).
: 8 mm
CAUTION: Pump device weight : 21 kg (46
lb) 6

4. Attach a nylon sling onto the center of gravity in

pump device(7) to hoist it by crane.

5. Remove bolts(5)(2 used). Hoist to remove pump

device(7) by crane.
: 19 mm

8
9

W1LA-02-03-002

W2-3-2
 UPPERSTRUCTURE / Pump Device
Installation(ZAXIS27u)

1. Install pump device(9) with blots(5)(2 used). 6

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)

IMPORTANT: Apply grease onto O-ring(10).

2. Install O-ring(10) to the flange groove in suction

pipe(7). Install suction pipe(7) to pump device(9)
with socket bolts(8)(4 used).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
5

3. 3.Connect hoses(4) and(6)(3 used) onto pump 4

device(9).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

4. Install bolts(2)(2 used) and (3)(3 used) to

cover(1).
: 13 mm
10
: 20 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
9
Flange Groove

IMPORTANT: Be sure to bleed air in the pump

device.(Refer to W1-1-2.) After
connecting the hoses, check the 8
7
hydraulic oil level. Start the engine
and check the hoses for oil leaks.

W567-02-03-001

2
3

W1LA-02-03-001

W2-3-3
 UPPERSTRUCTURE / Pump Device
Installation(ZAXIS30u , 35u)
5
1. Install pump device(7) with blots(5)(2 used). 4
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)

IMPORTANT: Apply grease onto O-ring(10).

6
2. Install O-ring(10) to the flange groove in suction
pipe(8). Install suction pipe(8) to pump device(7)
with socket bolts(9)(4 used).
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

3. 3.Connect hoses(4)(3 used) and(6) onto pump

device(7).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft) 10 7

4. Install bolts(2)(2 used) and (3)(3 used) to 8

9
cover(1).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) W1LA-02-03-002

IMPORTANT: Be sure to bleed air in the pump

device.(Refer to W1-1-2.) After
connecting the hoses, check the
hydraulic oil level. Start the engine 1
and check the hoses for oil leaks.
2
3

W1LA-02-03-001

W2-3-4
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE (ZAXIS27u)
28
27
26
25
24
23
22
21

36
12 35
11 34
33
10 32
9 31
8 51
30 50
6
29
5 48
4
3 47
2 46
1 45
7 44
20 43
19 41
18 49
17
16
15
14 40
13
38
37

42

39

W574-02-03-003

1- Housing 14 - Sleeve 27 - Set Screw 40 - Cover

2- Oil Seal 15 - Shim 28 - Nut 41 - Socket Bolt (5 Used)
3- Bearing 16 - Distance Piece 29 - Plunger (10 Used) 42 - Relief Valve
4- Shim 17 - Coned Disc Spring 30 - Retainer 43 - Side Plate
5- Ring 18 - O-Ring 31 - Holder 44 - Gear
6- Shaft 19 - Piston 32 - Cylinder Block 45 - Side Plate
7- Key 20 - O-Ring 33 - Pin (3 Used) 46 - O-Ring
8- Retaining Ring 21 - Spring Seat 34 - Retainer 47 - Plate
9- Shim 22 - Guide 35 - Spring 48 - Housing
10 - Guide (2 Used) 23 - Spring 36 - Retaining Ring 49 - Socket Bolt (3 Used)
11 - Bushing (2 Used) 24 - Spring 37 - Packing 50 - Socket Bolt (2 Used)
12 - Swash Plate 25 - Shim 38 - Valve Plate 51 - Gear Pump
13 - Pin 26 - Spring Seat 39 - Bearing

W2-3-5
 UPPERSTRUCTURE / Pump Device
Disassemble Pump Device (ZAXIS27u)

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
disassembling.

1. Loosen socket bolts (50) (2 used), then remove

gear pump (51).
: 8 mm

2. Loosen socket bolts (49) (3 used), then remove

housing (48) and side plate (43). At this time gear
(44) is removed together.
: 4 mm

3. Remove gear (44), side plate (45), O-ring (46)

and plate (47) from housing (48).

4. Remove key (7) from shaft (6).

ST 7222 Set Screw with Hexagon Hole

CAUTION: Use special tool (ST 7222) to

remove cover (40).
If it is removed without using special tool (ST
7222), spring (24) may fly out potentially
causing serious injury.

IMPORTANT: The setting of the pump delivery

flow rate changes by turning set
screw (27). Be careful not to turn the
set screw.

5. Install the special tool (ST 7222) on set screw

(27), then remove socket bolts (41) (5 used).
: 6 mm W574-02-03-004

IMPORTANT: Be careful not to drop valve plate

(38) when removing cover (40).

6. Gradually loosen the set screw with a hexagon

hole of the special tool, then remove cover (40).

7. Remove valve plate (38) and spring sheet (26)

from cover (40).

W2-3-6
 UPPERSTRUCTURE / Pump Device

25
24
23
22
21

36
12 35
34
33
10 32
9 31
8 30
6 29

3
2
1

19
17
16
14
13

37

W574-02-03-003

W2-3-7
 UPPERSTRUCTURE / Pump Device
8. Remove packing (37), shim (25), springs (23),
(24), guide (22) and spring seat (21) from housing
(1).

9. Remove shim (9), retaining ring (8) from shaft (6),

then remove cylinder block (32) assembly.

10. Remove plungers (29) (10 used), retainer (30)

and holder (31) from cylinder block (32).

CAUTION: Make sure to push spring (35)

with a press when removing retaining ring
(36).
If retaining ring (36) is removed without
pressing spring (35), spring (35) may fly out,
possibly causing serious injury.

11. Remove retaining ring (36) from cylinder block

(32), then remove spring (35), retainer (34) and
pins (33) (3 used) in this order.

12. Remove shaft (6), swash plate (12) and guides

(10) (2 used) from housing (1).

13. Remove shim (4) and ring (5) from shaft (6).

14. Remove piston (19), coned disc spring (17),

distance piece (16), sleeve (14) and pin (13) from
housing (1).

15. Remove bearing (3) and oil seal (2) from housing
(1).

W2-3-8
 UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE (ZAXIS27u)

6,7 2 3 1 21 30 31 22 23 29 32 24 33 34 37 25 26 35 36 28 38 27 8

45
49
47
48

50,51

T574-03-01-001

10,11 4 5 12 13 14 15 16 17 18 19 20 40,41,42 39 43 44 46

1- Housing 14 - Sleeve 27 - Set Screw 40 - Cover

2- Oil Seal 15 - Shim 28 - Nut 41 - *Socket Bolt (5 Used)
3- Bearing 16 - Distance Piece 29 - Plunger (10 Used) 42 - *Relief Valve
4- Shim 17 - Coned Disc Spring 30 - Retainer 43 - Side Plate
5- Ring 18 - O-Ring 31 - Holder 44 - Gear
6- Shaft 19 - Piston 32 - Cylinder Block 45 - Side Plate
7- *Key 20 - O-Ring 33 - Pin (3 Used) 46 - O-Ring
8- Retaining Ring 21 - Spring Seat 34 - Retainer 47 - Plate
9- Shim 22 - Guide 35 - Spring 48 - Housing
10 - *Guide (2 Used) 23 - Spring 36 - Retaining Ring 49 - Socket Bolt
11 - *Bushing (2 Used) 24 - Spring 37 - Packing 50 - Socket Bolt (3 Used)
12 - Swash Plate 25 - Shim 38 - Valve Plate 51 - Gear Pump (2 Used)
13 - Pin 26 - Spring Seat 39 - Bearing

NOTE: As for items with “∗”, refer to W2-3-5.

W2-3-9
 UPPERSTRUCTURE / Pump Device
Assemble Pump Device (ZAXIS27u)

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
assembling.

1. Drive in oil seal (2) into housing (1), then install

bearing (3).

2. Install shim (4) and ring (5) to shaft (6).

3. Install guides (10) (2 used), swash plate (12) and

shaft (6) in housing (1).

NOTE: Apply grease onto guides (10) (2 used) to

prevent them from falling off.

4. Install pins (33) (3 used), retainer (34), and spring

(35) in cylinder block (32). Push spring (35) with a
press, then install retaining ring (36).

5. Turn over cylinder block (32). Install holder (31),

plungers (29) (10 used) and retainer (30) in
cylinder block (32).

6. Install cylinder block (32) assembly, retaining ring

(8), and shim (9) to shaft (6).

7. Install spring seat (21), guide (22), springs (23),

(24), shim (25) and packing (37) in housing (1).

8. Install pin (13), sleeve (14), shim (15), distance

piece (16), coned disc spring (17) and piston (19)
into housing (1).

9. Install valve plate (38) in cover (40).

NOTE: Apply grease to the back of valve plate (38)

to prevent it from falling.

W2-3-10
 UPPERSTRUCTURE / Pump Device

6,7 1

45
49
47
48

50,51

T574-03-01-001

40,41 43 44 46

W2-3-11
 UPPERSTRUCTURE / Pump Device
IMPORTANT: The setting of the pump delivery
flow rate changes by turning set ST 7222 Set Screw with Hexagon Hole
screw (27). Be careful not to turn the
set screw.

10. Install cover (40) on housing (1), then tighten

socket bolts (41) (5 used) using special tool (ST
7222).
: 6 mm
: 28 to 35 N⋅m
(2.9 to 3.6 kgf⋅m, 21 to 26 lbf⋅ft)

11. Install key (7) on shaft (6).

12. Install side plate (43), gear (44), side plate (45),
O-ring (46), plate (47) and housing (48) in cover
(40), with socket bolts (49) (3 used). W574-02-03-004

: 4 mm
: 6.9 to 8.3 N⋅m
(0.7 to 0.8 kgf⋅m, 5 to 5.8 lbf⋅ft)

13. Install gear pump (51) on cover (40), then tighten

socket bolts (50) (2 used).
: 8 mm
: 55 to 69 N⋅m
(5.6 to 7.0 kgf⋅m, 40 to 50 lbf⋅ft)

W2-3-12
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE (ZAXIS30u, ZAXIS35u)
5
28 4
26
25 3
23
24
23 2
22 1
20
19
18
14
27 13
12
11
10
8
7
21 6

47 17
46 16
11
45

44
43
41 9
40
37
36
35
34

31
42 30
29

39

33
32

W575-02-03-001
1- Retaining Ring 13 - Rod 25 - Retaining Ring 36 - Bolt
2- Oil Seal 14 - Swash Plate 26 - Valve Plate 37 - Nut
3- Shaft 16 - Stopper Pin B 27 - Spring Pin 39 - Socket Bolt (5 Used)
4- Ball Bearing 17 - Ceramic Ball (2 Used) 28 - Needle Bearing 40 - O-Ring
5- Retaining Ring 18 - Plunger (10 Used) 29 - Spring Holder 41 - O-Ring
6- O-Ring 19 - Retainer 30 - Spring 42 - O-Ring
7- Plug 20 - Holder 31 - Spring Guide 43 - Collar
8- Pin (2 Used) 21 - Needle (3 Used) 32 - Pin 44 - Coupling
9- Housing S 22 - Cylinder Block 33 - O-Ring 45 - Gear Pump
10 - Packing 23 - Retainer (2 Used) 34 - Housing H 46 - Spring Washer (2 Used)
11 - Coned Disc Spring (4 Used) 24 - Spring 35 - Seal Washer 47 - Socket Bolt (2 Used)
12 - Stopper Pin A

W2-3-13
 UPPERSTRUCTURE / Pump Device
Disassemble Pump Device (ZAXIS30u, 35u) 7. Remove spring guide (31), spring (30), spring
• Read PRECAUTIONS FOR DISASSEMBLING holder (29) and cylinder block (22) assembly from
AND ASSEMBLING (W1-1-1) carefully before housing S (9).
disassembling.

1. Loosen socket bolts (47) (2 used), then remove 8. Remove plungers (18) (10 used), retainer (19),
gear pump (45). holder (20) and needles (21) (3 used) from
: 6 mm cylinder block (22).

2. Remove O-rings (40), (41), (42), collar (43) and

coupling (44) from housing H (34). CAUTION: Make sure to push spring (24)
with a press when removing retaining ring
(25).
IMPORTANT: The setting of the pump delivery If retaining ring (25) is removed without
flow rate changes by turning bolt pressing spring (24), spring (24) may fly out,
(36). Be careful not disassemble bolt possibly causing serious injury.
(36) and nut (37).
9. Remove retaining ring (25) from cylinder block
CAUTION: Use a bolt (M10, length 65 mm) for (22), then remove retainer (23), spring (24) and
temporary assembly when removing housing retainer (23) in this order.
H (34).
If a bolt for temporary assembly is not used,
spring (30) may fly out, possibly causing 10. Remove swash plate (14) from housing S (9),
serious injury. then remove ceramic balls (17) (2 used).

3. Remove upper two of socket bolts (39) (5 used), 11. Remove stopper pin A (12), stopper pin B (16),
then install bolts (M10, length 65 mm) for coned disc springs (11) (4 used), and rod (13).
temporary assembly in the same place.
: 8 mm
IMPORTANT: Never remove ball bearing (4) unless
replacing it.
4. Remove other three socket bolts (39).
: 8 mm
12. Remove retaining ring (1) from housing S (9). Tap
shaft assembly (3) lightly with a plastic hammer,
5. Turn bolts (2 used) for temporary assembly then remove oil seal (2), retaining ring (5) and ball
alternately, then remove them from housing H bearing (4).
(34).

IMPORTANT: Be careful not to drop valve plate

(26) when removing housing H (34).

6. Remove housing H (34), then remove packing

(10), pins (8) (2 used) and valve plate (26) in this
order.

W2-3-14
 UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE (ZAXIS30u, ZAXIS35u)

12 29 6 7 19 20 22 18 24 23 10 30 31 34,39 35 37

36

8,9 43

44

13 45,46,47

17

4
T565-03-01-001
5

16 11 14 21 25 28 26 27 32 33 42 40

1- Retaining Ring 13 - Rod 25 - Retaining Ring 36 - Bolt

2- Oil Seal 14 - Swash Plate 26 - Valve Plate 37 - Nut
3- Shaft 16 - Stopper Pin B 27 - Spring Pin 39 - Socket Bolt (5 Used)
4- Ball Bearing 17 - Ceramic Ball (2 Used) 28 - Needle Bearing 40 - O-Ring
5- Retaining Ring 18 - Plunger (10 Used) 29 - Spring Holder 41 - O-Ring
6- O-Ring 19 - Retainer 30 - Spring 42 - O-Ring
7- Plug 20 - Holder 31 - Spring Guide 43 - Collar
8- Pin (2 Used) 21 - Needle (3 Used) 32 - Pin 44 - Coupling
9- Housing S 22 - Cylinder Block 33 - O-Ring 45 - Gear Pump
10 - Packing 23 - Retainer (2 Used) 34 - Housing H 46 - Spring Washer (2 Used)
11 - Coned Disc Spring (4 Used) 24 - Spring 35 - Seal Washer 47 - Socket Bolt (2 Used)
12 - Stopper Pin A

W2-3-15
 UPPERSTRUCTURE / Pump Device
Assemble Pump Device (ZAXIS30u, 35u) 8. Install ceramic balls (17) (2 used) on swash plate
• Read PRECAUTIONS FOR DISASSEMBLING (14), then install swash plate (14) in housing S
AND ASSEMBLING (W1-1-1) carefully before (9).
assembling. NOTE: Apply grease onto ceramic balls (17) to
prevent them from falling off.
IMPORTANT: If ball bearing (4) has been replaced,
press ball bearing (4) onto shaft (3)
beforehand, then install retaining 9. Install cylinder block (22) assembly in housing S
ring (5). (9), then insert spring holder (29), spring (30) and
spring guide (31).

1. Insert shaft (3) in housing S (9). Drive in oil seal

(2), then install retaining ring (1). 10. Install valve plate (26) in housing H (34).
NOTE: Apply grease onto the housing H (34) side
in valve plate (26).
2. Install retainer (23), spring (24) and retainer (23)
in cylinder block (22) in this order.
11. Install pins (8) (2 used) and packing (10) in
housing S (9).
3. Push retainer (23) and spring (24) with a press,
then install retaining ring (25).
12. Install housing H (34) on housing S (9), then
tighten mounting bolt on spring (30) side with
4. Install needle (21) in cylinder block (22), then
temporary assembly bolts (2 used) (M10, length
install holder (20) on needle (21).
65 mm).
: 8 mm
5. Install plungers (18) (10 used) and retainer (19) in
cylinder block (22).
13. Tighten lightly socket bolts (39) (3 used).
: 8 mm
6. Install coned disc springs (11) (2 used) on stopper
pin A (12), then install them in housing S (9).
14. Remove one bolt which is temporary assembled
in step 12. Install socket bolt (39) in the same
place, then tighten it lightly. Remove the other bolt,
IMPORTANT: The length of stopper pin A (12) and
then install socket bolt (39) and tighten it lightly,
stopper pin B (16) differs to each
similar to the above.
other. Install them with referring to
: 8 mm
the assembly diagram.

15. Tighten socket bolts (39) (5 used) securely which

7. Install coned disc springs (11) (2 used) on stopper
are tighten lightly in steps 13 and 14.
pin B (16), then install them in housing S (9).
: 8 mm
Install rod (13) in housing S (9).
: 54 to 64 N⋅m
(5.5 to 6.5 kgf⋅m, 40 to 47 lbf⋅ft)

16. Install collar (43), coupling (44), O-rings (40), (41)

and (42) on gear pump (45).

W2-3-16
UPPERSTRUCTURE / Pump Device

34

45,46,47

T565-03-01-001

W2-3-17
 UPPERSTRUCTURE / Pump Device
17. Install gear pump (45) on housing H (34), then
tighten socket bolts (47) (2 used) and spring
washers (46) (2 used).
: 6 mm
: 10 to 14 N⋅m
(1.0 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft)

W2-3-18
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARDS

1. The clearance between the plunger diameter and Cylinder

the cylinder block bore diameter Block

(D-d): 0.050 mm (0.00197 in) or less.

D d

W507-02-04-009
Plunger

2. The clearance between the plunger and the shoe δ

δ: 0.2 mm (0.00787 in) or less.

W107-02-06-141
3. The wear amount of the oil seal mounting
surfaces
Make sure that there are no damage and / or
abnormal wear.

(D0-D1): 0.025 mm (0.000984 in) or less. D0 D1

W507-02-04-010

W2-3-19
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-20
 UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
1, 2 3
Removal

IMPORTANT: Be sure to release any pressure in

the hydraulic oil tank before any
work. (Refer to W1-4-1.)
1. Remove bolts (2) (2 used) and (3) (3 used) to re-
move cover (1).

4 SS-29.

IMPORTANT: Attach a cap on all the disconnected

hoses for assembling.
2. Disconnect actuator pipes (4) (22 used) from con-
7
trol valve (7).
: 19 mm, 22 mm, 27 mm
NOTE: Pipes: Oil cooler pipe: 1 used
Main pipes: 3 used
Front attachment pipes : 8 used
Swing pipes: 4 used
Travel pipes: 6 used

W1LA-02-04-001

3. Remove clip bands (5) (5 used) from pilot pipes

(6).

4. Disconnect pilot pipes (6) (10 used) and the con- 6 7

nectors from control valve (7).
: 19 mm
NOTE: Pipes : Solenoid valve pipes : 2 used 5
Travel pipes: 4 used
Blade pipes: 2 used
Boom swing pipes: 2 used
5
6
5

W1LA-02-04-009

5 6

W2-4-1
 UPPERSTRUCTURE / Control Valve

CAUTION: Control valve weight: 35 kg (77 lb) Cap 7

5. Remove bolts (9) (4 used) from main frame (10).

: 17 mm 8

6. Attach a nylon sling under the both caps on con-

trol valve.
Hoist control valve (7) with plate (8) by crane to
remove main frame (10).
9

W1LA-02-04-004

Cap

7. Remove bolts (11) (4 used) to control valve(7) 7

from plate (8).
: 17 mm 8

W1LA-02-04-003

11 10

W2-4-2
 UPPERSTRUCTURE / Control Valve
Installation

CAUTION: Control valve weight: 35 kg (77 Ib) 7

1. Install plate (8) to control valve (7) with bolts (11)

8
(4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

2. Attach a nylon sling under the both caps on con-

trol valve. 11 10 11 W1LA-02-04-003

Hoist control valve (7) with plate (8) by crane onto

main frame (10). Cap

3. Install control valve (7) to main frame (10) with 8

bolts (9) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W1LA-02-04-004

7 Cap

4
4. Connect actuator pipes (4) (22 used) to control
valve (7).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)

W1LA-02-04-001

W2-4-3
 UPPERSTRUCTURE / Control Valve
6 7
5. Connect pilot pipes (6) (10 used) to control valve
(7).
: 19 mm
5
: 29.5 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)

6. Attach clip bands (5) (5 used) onto pilot pipes (6).

5
6
5

W1LA-02-04-009

5 6

1, 2 3
7. Install cover (1) to main frame (10) with bolts (2)
(2 used) and (3) (3 used).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

IMPORTANT: After connecting the pipes, check

the hydraulic oil level. Start the en-
gine and check the connections for
oil leaks.

SS-29.

W2-4-4
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-5
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE
CONTROL VALVE
1
3

6 7

8
5 1

4 15 14
3
1a 16
9 17 19
18 20
3
2 21
1 10
1
11
3 15
12 14
16 3
13 14 1b 9
17
1 22 18
19
21 20
20 21
13 1
15
3
14 16 14
1c 3
1 9 17
23 18
24 19
21 20
25
20 21
13
3
14 28 1
1 1d
26 9

21 27
15
20 16
3 19
13 3 17
2 15
18 30 1
1 16 20
1e 17 27 21
29
31
21
9 19
20
13 14
30 3

14 3
1 1f
32
21
20
13 W1LA-02-04-005

W2-4-6
 UPPERSTRUCTURE / Control Valve

1a - Body (Flow Combiner 12 - Spring Seat 35 - Orifice 57 - Piston

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

W2-4-7
 UPPERSTRUCTURE / Control Valve

1
15 20
21
35 36 16 33
34
17
9 19
37 14
33
3
39 38
40 1
14 3 41
13 14
1 1g 42 3
43 28
9
21 19
20
20 21
3
14 48
1 47 1 56
45 28
1h 44 57
46
58
21 9
59
20
13 19 1 60
47 3
14 61
3 9 62
1 3 63
1i 28
19 64
49 44 20 65
45 21 66
13 15
48 50 67
3 9 16 55 68
14
17 53 54 69
1 1j 52 37
51
70
21
71
20 20
13 33 14
21
73 72 3 1
33 74 19 14
3
9 18 33
1 14 19
1k 17
18 76
17 19
75 20
3 37 21
21
20 33
13
3
14 1l
1
78 5
21
20
13 77

W1LA-02-04-006

W2-4-8
 UPPERSTRUCTURE / Control Valve

1a - Body (Flow Combiner 12 - Spring Seat 35 - Orifice 57 - Piston

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

W2-4-9
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BODY
33 47(P1)
A B 33

Front

P3 P2 P1

4 33 47(P2) 33 T1LA-03-03-001

Cross Section A Cross Section B (Blade)

(Flow Combiner Valve)
18

6 15

17

16

T1LA-03-03-016
T1LA-03-03-015
4 - Main Relief Valve (P3) 15 - Plug 17 - Spring 33 - Overload Relief Valve (6
Used)
6 - Plug 16 - O-Ring 18 - Check Valve 47 - Main Relief Valve (P1, P2)

W2-4-10
 UPPERSTRUCTURE / Control Valve
Disassemble Body Assemble Body

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.

1. Remove main relief valves (4) and (47) (2 used). 1. Install main relief valves (4) and (47) (2 used).
: 24 mm : 24 mm
: 59 to 69 N⋅m
2. Remove overload relief valves (33) (6 used). (6.0 to 7.0 kgf⋅m, 43 to 51 Ibf⋅ft)
: 24 mm
2. Install overload relief valves (33) (6 used).
IMPORTANT: Take care not to drop off O-rings (9, : 24 mm
34 and 36), check valves (25, 45), : 59 to 69 N⋅m
and springs (24, 44). (6.0 to 7.0 kgf⋅m, 43 to 51 Ibf⋅ft)
3. Remove nuts (5) (4 used) and rods (77) (4 used)
to divide the control valve into each section. 3. Install check valves (25, 45), O-rings (9, 34 and
: 13 mm 36) into each section. Install springs (24, 44) onto
the inner bore of check valve.
4. Remove O-rings (9, 34 and 36) to remove springs NOTE: As for O-rings (9, 34 and 36), check valves
(24, 44) and check valves (25, 45) with a magnet. (25, 45) and springs (24, 44), refer to W2-
NOTE: As for O-rings (9, 34 and 36), check valves 4-6 to 9.
(25, 45) and springs (24, 44), refer to W2-
4. Put bodies (1a to 11) in each section as before
4-6 to 9.
disassembling. Attach rods (77) (4 used) and
tighten them with nuts (5) (8 used).
: 13 mm
: 26.5 to 29.4 N⋅m
(2.7 to 2.9 kgf⋅m, 20 to 21 Ibf⋅ft)

W2-4-11
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE BOOM ANTI-DRIFT VALVE

56

57

58

59

60
61

62

63
64
65
66
67

68
55
69

70
3 71

W1LA-02-04-007

3- O-Ring 59 - Plug 64 - O-Ring 68 - Spring Seat

55 - O-Ring (2 Used) 60 - O-Ring 65 - O-Ring 69 - Spring
56 - Plug 61 - Spool 66 - Backup Ring 70 - Socket Bolt (5 Used)
57 - Piston 62 - Sleeve 67 - Check Valve 71 - Body
58 - Spring 63 - Backup Ring

W2-4-12
 UPPERSTRUCTURE / Control Valve
Disassemble Boom Anti-Drift Valve
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before
disassembling.

1. Clamp the body (71) assembly in a vise. Remove

plug (56) from body (71).
: 24 mm

2. Remove piston (57) and spring (58) from body

(71) with a screwdriver.

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

: 24 mm

4. Remove spool (61) from sleeve (62).

5. Pull the sleeve (62) assembly out of body (71).

6. Remove check valve (67), spring seat (68), and

spring (69) from body (71) with a magnet.

7. Remove backup rings (63, 66) and O-rings (64,

65) from sleeve (62).

8. Remove socket bolts (70) (5 used) to remove

body (71).
: 5 mm

9. Remove O-rings (3) and (55) (2 used) from body

(71).

W2-4-13
 UPPERSTRUCTURE / Control Valve
ASSEMBLE BOOM ANTI-DRIFT VALVE
56

59

57

61
58
60
62
63
64
65
55 66
68
69

W1LA-02-04-008
1k 71 67

3- *O-Ring 1k - Body 63 - Backup Ring 68 - Spring Seat

55 - O-Ring (2 Used) 59 - Plug 64 - O-Ring 69 - Spring
56 - Plug 60 - O-Ring 65 - O-Ring 70 - *Socket Bolt (5 Used)
57 - Piston 61 - Spool 66 - Backup Ring 71 - Body
58 - Spring 62 - Sleeve 67 - Check Valve

NOTE: As for items with a marks “ * ”, refer to W2-

14-14.

W2-4-14
 UPPERSTRUCTURE / Control Valve
Assemble Boom Anti-Drift Valve
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before as-
sembling.
• Apply grease onto the seals.

1. Install backup rings (63, 66) and O-rings (64, 65)

to sleeve (62).

2. Install check valve (67) into sleeve (62).

3. Install spring seat (68) and spring (69) to the

sleeve (62) assembly.

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

the O-ring (55) mounting surface upward.

5. Install O-rings (55) (2 used) and (3) to body (71).

6. Clamp body (1k) in a vise to install body (71) with

socket bolts (70) (5 used).
: 5 mm
: 7.3 to 10 N⋅m
(0.7 to 1.0 kgf⋅m, 5.1 to 7.2 Ibf⋅ft)

7. Install O-ring (60) to plug (59) to install them into

body (71).
: 24 mm
: 29.4 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)

8. Install spool (61) and spring (58) to sleeve (62).

9. Install piston (57) and plug (56) to plug (59).

: 24 mm
: 29.4 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)

W2-4-15
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE SPOOL

NOTE: The illustration shows the arm.

Load Check Valve

20 19 3
21 14 13

14 3 20
1 21 T577-03-03-005

1g 43
Arm Regenerative Valve

1g - Body 13 - Cover 19 - Cover 21 - Spring Seat (2 Used)

1 - Socket Bolt (4 Used) 14 - Spring (2 Used) 20 - Spring Seat (2 Used) 43 - Spool
3 - O-Ring (2 Used)

W2-4-16
 UPPERSTRUCTURE / Control Valve
Disassemble Spool Assemble Spool

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before as-
AND ASSEMBLING (W1-1-1) carefully before sembling.
disassembling.
1. Install spool (43) to body (1g).
1. Remove socket bolts (1) (4 used) from body (19)
to remove covers (13, 19) and O-rings (3) (2 2. Install spring seats (21) (2 used) to spool (43).
used).
: 5 mm
3. Install O-rings (3) (2 used), springs (14) (2 used),
and spring seats (21) (2 used) into covers (13,
19).
2. Remove springs (14) (2 used) and spring seats
(20) (2 used) from covers (13, 19). 4. Install the covers to body (1g) with socket bolts
(1) (4 used).
3. Remove spring seats (21) (2 used) from spool : 5 mm
(43). : 7.3 to 10 N⋅m
(0.7 to 1.0 kgf⋅m, 5.1 to 7.2 Ibf⋅ft)
4. Pull spool (43) out of body (1g).
NOTE: When removing covers (13, 19), take care
not to drop off spring (14) and spring seats
(20, 21).

W2-4-17
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE ARM REGENERATIVE VALVE,
CHECK VALVE, AND ORIFICE

17 15 16
37

Arm Regenerative Valve Arm Spool

36
1g

34

39

40
35

41 T577-03-03-006

42

1g - Body 17 - Spring 36 - O-Ring 40 - Spring

15 - Plug 34 - O-Ring 37 - Check Valve 41 - O-Ring
16 - O-Ring 35 - Orifice 39 - Check Valve 42 - Plug

W2-4-18
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.

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

4. Install spring (40) to body (1g) with plug (42).

Take care not to drop off check valve (39).
: 6 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)

W2-4-19
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-20
 UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
2
Removal

IMPORTANT: Be sure to bleed air from the

hydraulic oil tank before any work.
(Refer to W1-3-1.) 1

CAUTION: Canopy weight: 32 kg (71 Ib)

1. Attach a sling belt onto canopy (1) to hold it.

W1LD-02-01-001

2. Loosen screw (3) to remove cover (4).

4 W1LD-02-01-002
3
3. Remove bolt (5) to hoist and remove canopy (1).
1
: 24 mm

5
W1LD-02-01-003

W2-5-1
 UPPERSTRUCTURE / Swing Device
4. Remove bolts (6) (6 used) and (8) (4 used) to
remove covers (5, 7).
7
: 13 mm, 17 mm 8

6
5. Remove bolts (10) (5 used) and (11) (3 used) to
remove covers (9, 12).
: 13 mm 9
5

6. Disconnect all the pilot pipes and connectors in 10

the pilot valve. Attach a cap onto all the open
ends.
14
11

CAUTION: Floor plate (13) assembly weight: 12

95 kg (209 lb)
13 W1LA-02-05-001
7. Remove bolts (14) (6 used). Attach a rope onto
the seat and hoist it to remove floor plate (13) with
the seat by crane. 15
: 13 mm

CAUTION: Swing device (17) weight:

ZAXIS27u: 33 kg (73 lb)
ZAXIS30u, 35u : 38 kg (84 lb)

8. Disconnect hoses (15) (3 used) from swing 18

device (17). Attach a cap onto all the open ends.
: 22 mm
Hole Part

9. Disconnect hose (18) on the swing device.

: 19 mm, 22 mm

10. Remove bolts (16) (6 used). Float swing device 17 16 W1LA-02-05-003

(17) using the hole (M16, pitch 2.0). Attach a rope

onto the body to hoist swing device (17).
: 22 mm

W2-5-2
 UPPERSTRUCTURE / Swing Device
Installation

CAUTION: Swing device (17) weight:

ZAXIS27u: 33 kg (73 Ib) 15
ZAXIS30u, 35u: 38 kg (84 Ib)

1. Hoist to install swing device (17) by crane and

tighten bolts (16) (6 used).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
18
2. Connect hoses (15) (3 used) and (18) to swing
device (17).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.7 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
17 16 W1LA-02-05-003

3. Hoist to install the floor plate (13) assembly with

the seat onto the uppperstructure with bolts (14)
(6 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

4. Connect the pilot hoses and connectors in the

pilot valve to the floor plate (13) assembly.

5. Install covers (9, 12) with bolts (11) (3 used) and 9

(10) (5 used).
: 13 mm 10
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

11 14

12

13 W1LA-02-05-001

W2-5-3
 UPPERSTRUCTURE / Swing Device
7
8
6. Install covers (5, 7) with bolts (6) (6 used) and (8)
(4 used). 6
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
: 17 mm 5
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W1LA-02-05-001

7. Attach a sling belt onto canopy (1) to hoist it on

2
the frame by crane.

W1LD-02-01-001

8. Install canopy (1) with bolts (5) (2 used). 1

: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)

W1LD-02-01-003

9. Install cover (4) with screws (3) (2 used).

4
3 W1LD-02-01-002

W2-5-4
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-5-5
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING REDUCTION GEAR
ZAXIS27u 7

1 8

26

25

24

23

22
21
20

19

10
9

W565-02-05-001
1 - Shaft 6- Oil Seal 19 - Carrier 23 - Planetary Gear (3 Used)
2 - Collar 7- Bearing 20 - Thrust Plate 24 - Thrust Plate
3 - Plate 8- Socket Bolt (2 Used) 21 - Inner Race (3 Used) 25 - Drive Gear
4 - Bearing 9- Plate (2 Used) 22 - Needle Bearing (3 Used) 26 - O-Ring
5 - Housing 10 - Collar

W2-5-6
 UPPERSTRUCTURE / Swing Device

ZAXIS30u, 35u 7
6

3 8

1
18
17
16
15
14
13
12

11
10
9
26

25
24

23
22
21
20

19

W575-02-05-001
1 - Shaft 8 - Socket Bolt (2 Used) 15 - Second Stage Planetary 21 - Inner Race (4 Used)
Gear (4 Used)
2 - Collar 9 - Plate (2 Used) 16 - Thrust Plate 22 - Needle Bearing (4 Used)
3 - Plate 10 - Collar 17 - Flat Countersunk Head 23 - First Stage Planetary Gear
Screw (4 Used) (4 Used)
4 - Bearing 11 - Second Stage Carrier 18 - Second Stage Sun Gear 24 - Thrust Plate
5 - Housing 12 - Thrust Plate (4 Used) 19 - First Stage Carrier 25 - First Stage Sun Gear
6 - Oil Seal 13 - Inner Race (4 Used) 20 - Thrust Plate (4 Used) 26 - O-Ring
7 - Bearing 14 - Needle Bearing (4 Used)

W2-5-7
 UPPERSTRUCTURE / Swing Device
(The illustration shows ZAXIS30u and 35u)
NOTE: The second stage carrier and second stage
planetary gear are not provided for ZAXIS27u. 7
6

3 8

1
18
17
16
15
14
13
12

11
10
9
26

25
24

23
22
21
20

19

W575-02-05-001
1 - Shaft 8 - Socket Bolt (2 Used) 15 - Second Stage Planetary 21 - Inner Race (4 Used)
Gear (4 Used)
2 - Collar 9 - Plate (2 Used) 16 - Thrust Plate 22 - Needle Bearing (4 Used)
3 - Plate 10 - Collar 17 - Flat Countersunk Head 23 - First Stage Planetary Gear
Screw (4 Used) (4 Used)
4 - Bearing 11 - Second Stage Carrier 18 - Second Stage Sun Gear 24 - Thrust Plate
5 - Housing 12 - Thrust Plate (4 Used) 19 - First Stage Carrier 25 - First Stage Sun Gear
6 - Oil Seal 13 - Inner Race (4 Used) 20 - Thrust Plate (4 Used) 26 - O-Ring
7 - Bearing 14 - Needle Bearing (4 Used)

W2-5-8
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Reduction Gear

• This is the procedure for ZAXIS30u and 35u.

• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before
disassembling.

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

(4), oil seal (6), bearing (7), plates (9)
(2 used), collar (10) , and O-ring (26)
can not be disassembled from
housing (5). Replace them with a
housing assembly.
CAUTION: Swing motor weight: 20 kg (44 Ib)

1. Remove socket bolts (8) (2 used) from the swing

device, then remove the swing motor.
: 10 mm

2. Remove first stage sun gear (25), thrust plate (24),

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

3. Remove the second stage carrier (11) assembly

from housing (5).

4. Loosen flat countersunk head screws (17) (4

used), then remove thrust plate (16), second
stage planetary gears (15) (4 used), needle
bearings (14) (4 used), inner races (13) (4 used)
and thrust plates (12) (4 used) in this order.
: 3 mm

W2-5-9
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING REDUCTION GEAR
ZAXIS27u

27

22

16 8

23
25

21
24
20

26

7
10
5

9 6

3 2

T565-03-02-001

1 - Shaft 6- Oil Seal 19 - Carrier 24 - Thrust Plate

2 - Collar 7- Bearing 20 - Thrust Plate 25 - Drive Gear
3 - Plate 8- Socket Bolt (2 Used) 21 - Inner Race (3 Used) 26 - O-Ring
4 - Bearing 9- Plate (2 Used) 22 - Needle Bearing (3 Used) 27 - Swing Motor
5 - Housing 10 - Collar 23 - Planetary Gear (3 Used)

W2-5-10
 UPPERSTRUCTURE / Swing Device

ZAXIS30u, 35u

27

23

8
24
22
26
21
25
20
16
19
15
18
14
17 13
12
9
11

7 10

4 5

3 2

T575-03-02-001

1 - Shaft 8 - Socket Bolt (2 Used) 15 - Second Stage Planetary 22 - Needle Bearing (4 Used)
Gear (4 Used)
2 - Collar 9 - Plate (2 Used) 16 - Thrust Plate 23 - First Stage Planetary Gear
(4 Used)
3 - Plate 10 - Collar 17 - Flat Countersunk Head 24 - Thrust Plate
Screw (4 Used)
4 - Bearing 11 - Second Stage Carrier 18 - Second Stage Sun Gear 25 - First Stage Sun Gear
5 - Housing 12 - Thrust Plate (4 Used) 19 - First Stage Carrier 26 - O-Ring
6 - Oil Seal 13 - Inner Race (4 Used) 20 - Thrust Plate (4 Used) 27 - Swing Motor
7 - Bearing 14 - Needle Bearing (4 Used) 21 - Inner Race (4 Used)

W2-5-11
 UPPERSTRUCTURE / Swing Device

(The illustration shows ZAXIS30u and 35u)

27

23

8
24
22
26
21
25
20
16
19
15
18
14
17 13
12
9
11

7 10

4 5

3 2

T575-03-02-001

1 - Shaft 8 - Socket Bolt (2 Used) 15 - Second Stage Planetary 22 - Needle Bearing (4 Used)
Gear (4 Used)
2 - Collar 9 - Plate (2 Used) 16 - Thrust Plate 23 - First Stage Planetary Gear
(4 Used)
3 - Plate 10 - Collar 17 - Flat Countersunk Head 24 - Thrust Plate
Screw (4 Used)
4 - Bearing 11 - Second Stage Carrier 18 - Second Stage Sun Gear 25 - First Stage Sun Gear
5 - Housing 12 - Thrust Plate (4 Used) 19 - First Stage Carrier 26 - O-Ring
6 - Oil Seal 13 - Inner Race (4 Used) 20 - Thrust Plate (4 Used) 27 - Swing Motor
7 - Bearing 14 - Needle Bearing (4 Used) 21 - Inner Race (4 Used)

W2-5-12
 UPPERSTRUCTURE / Swing Device
Assemble Swing Reduction Gear

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
assembling.

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

with its chamfered surface facing
upward (motor side).
Apply LOCTITE #242 to flat
countersunk head screws (17) (4
used).
1. Install thrust plates (12) (4 used), inner races (13)
(4 used), needle bearings (14) (4 used), second
stage planetary gears (15) (4 used), and thrust
plate (16) on second stage carrier (11), then
secure them with flat countersunk head screws
(17) (4 used).
: 3 mm
: 3.9±0.4 N⋅m
(0.4±0.04 kgf⋅m, 3±0.3 Ibf⋅ft)

2. Install the second stage carrier (11) assembly into

housing (5).

3. Install second stage sun gear (18).

4. Install thrust plates (20) (4 used), inner races (21)

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

5. Install the first stage carrier (19) assembly into

housing (5).

6. Install first stage sun gear (25) into housing (5).

CAUTION: Swing motor weight: 20 kg (44 Ib)

7. Install O-ring (26) on swing motor (27), then

install swing motor (27) onto housing (5) with
socket bolts (8) (2 used).
: 10 mm
: 128±7 N⋅m
(13.1±0.7 kgf⋅m, 94±5 Ibf⋅ft)

W2-5-13
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR
(The illustration shows ZAXIS27u) 8
7
6
5
4
3
2
1

17
16
15

14
13
12
11
10
9

26
25
24
23
22
21
19
20
19 27

18
28

W565-02-05-002

1 - Housing 8- Holder 15 - Disc Plate 22 - Valve Plate

2 - Socket Bolt (2 Used) 9- Pin (3 Used) 16 - O-Ring 23 - Pin
3 - Bearing 10 - Rotor 17 - O-Ring 24 - Bearing
4 - Shaft 11 - Collar 18 - Brake Piston 25 - Pin
5 - Swash Plate 12 - Spring 19 - Spring Seat (2 Used) 26 - Cover
6 - Plunger (9 Used) 13 - Washer 20 - Disc Spring (2 Used) 27 - Socket Bolt (5 Used)
7 - Retainer 14 - Retaining Ring 21 - O-Ring 28 - O-Ring (2 Used)

W2-5-14
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor

• Read PRECAUTIONS FOR DISASSEMBLING CAUTION: Always press spring (12) with a
AND ASSEMBLING (W1-1-1) carefully before press when removing retaining ring (14).
disassembling. If retaining ring (14) is removed without
pressing spring (12), washer (13) and spring
(12) may fly out, possibly causing serious
NOTE: The swing motors for ZAXIS27u, 30u and injury.
35u have identical structures.
8. Remove retaining ring (14) to remove washer
IMPORTANT: Be careful not to allow valve plate (13), spring (12) and collar (11) from rotor (10).
(22) to fall when removing cover
(26). 9. Remove shaft (4) from housing (1) by tapping
1. Loosen socket bolt (27), then remove cover (26), shaft (4) with a plastic hammer.
valve plate (22) and O-ring (21).
: 10 mm 10. Remove bearing (3) from shaft (4) with a press.

2. Remove bearing (24) and O-rings (28) (2 used)

from cover (26).

3. Remove disc springs (20) (2 used) and spring

seats (19) (2 used) from housing (1).

4. Remove brake piston (18) from housing (1).

5. Remove O-rings (16, 17) from brake piston (18).

IMPORTANT: Take care not to damage the

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

7. Remove plungers (6) (9 used), retainer (7),

holder (8) and pins (9) (3 used) from rotor (10).

W2-5-15
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
(The illustration shows ZAXIS27u)

27 19 22 12 26 14 13 24 4 23 20 25

21

28 10

18
11
17
15
16
6
9 1

7 2

5
8

T565-03-02-001

1 - Housing 8- Holder 15 - Disc Plate 22 - Valve Plate

2 - Socket Bolt (2 Used) 9- Pin (3 Used) 16 - O-Ring 23 - Pin
3 - Bearing 10 - Rotor 17 - O-Ring 24 - Bearing
4 - Shaft 11 - Collar 18 - Brake Piston 25 - Pin
5 - Swash Plate 12 - Spring 19 - Spring Seat (2 Used) 26 - Cover
6 - Plunger (9 Used) 13 - Washer 20 - Disc Spring (2 Used) 27 - Socket Bolt (5 Used)
7 - Retainer 14 - Retaining Ring 21 - O-Ring 28 - O-Ring (2 Used)

W2-5-16
 UPPERSTRUCTURE / Swing Device
Assemble Swing Motor

• Read PRECAUTIONS FOR DISASSEMBLING 6. Install plungers (6) and retainer (7) assembly
AND ASSEMBLING (W1-1-1) carefully before into rotor (10).
assembling.
IMPORTANT: Insert swash plate (5) with its
beveling surface facing downward.
IMPORTANT: Install bearing (3) with its retaining 7. Install swash plate (5) into housing (1).
ring comes to the upper side as
shown in the illustration. 8. Install rotor (10) and plunger (6) assembly into
1. Press bearing (3) onto shaft (4). housing (1).

Retaining Ring

W565-02-05-003

IMPORTANT: Stop pressing bearing (3) onto

shaft (4) when the retaining ring of
bearing (3) touches housing (1). If
the bearing is pressed further, the
retaining ring may deform.
2. Press assembly of shaft (4) and bearing (3) into
housing (1).

IMPORTANT: Insert collar (11) with its beveling

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

4. While depressing washer (13) and spring (12)

with a press, install retaining ring (14).

5. Apply grease to pins (9) (3 used), then install

pins (9) into rotor (10). Install holder (8) on pins
(9).

W2-5-17
 UPPERSTRUCTURE / Swing Device

(The illustration shows ZAXIS27u)

27 19 22 26 24 20
21

28

18

17

16

T565-03-02-001

W2-5-18
 UPPERSTRUCTURE / Swing Device
9. Install O-rings (16) and (17) onto brake piston
(18), then install them into housing (1).

IMPORTANT: Install spring seat (19) and disc

spring (20) in the direction shown
in the illustration.
10. Install spring seats (19) (2 used) and disc
springs (20) (2 used) into housing (1).

19

20

19

W565-02-05-004

11. Install O-ring (21) into housing (1).

12. Press bearing (24) onto cover (26).

13. Install O-rings (28) (2 used) and valve plate (22)

onto cover (26).
NOTE: Apply grease to valve plate (22) before
attaching it to cover (26) in order to
prevent if from falling.

14. Install cover (26) onto housing (1), then tighten

socket bolts (27) (5 used).
: 10 mm
: 128 N⋅m(13 kgf⋅m, 94 Ibf⋅ft)

W2-5-19
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARDS

1. The clearance between the plunger diameter

and the rotor bore diameter
Rotor
(D-d): 0.04 mm (0.00157 in) or less

D d

W507-02-04-009

2. The clearance between the plunger and the

shoe
δ: 0.4 mm (0.0157 in) or less

W107-02-06-140

W107-02-06-141

W2-5-20
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT/ SWING 4
PILOT VALVE
Removal
IMPORTANT: Be sure to release any pressure in
the hydraulic oil tank before any
work. (Refer to W1-4-1.)

1. Remove screws (1) (6 used) from the lever stand

to remove covers (2 and 3 ).

2. Remove clip band (10) and plug (11) on the left

lever stand only.
2 1 3
3. Raise boots (4) (2 used) to remove screws (16) (8 Fast Speed Travel Pedal M1LA-01-006
used) and plates (15 )(4 used).

4. Raise boots (4) on the left lever to remove clip

band (9). 5

6
5. Raise boots (4) (2 used) and loosen lock nuts (8) 7
(2 used) to remove levers (7) (2 used) with grip
Pilot Shut-Off 8
(5) together. Lever
: 22 mm 9
10
11
6. Remove boots (4) (2 used).
16
15
IMPORTANT: Attach the identification tag onto the
disconnected hoses for assembling.

7. Disconnect hoses (12) (12 used) from pilot valves 14

(13) (2 used).
: 19 mm 13
Left Stand Pilot-Off Switch
12 T532-02-06-002
IMPORTANT: Put the matching marks on pilot
valve (13) and stand to aid in re-as-
sembly.

8. Remove bolts (14) (8 used) to remove pilot valves

(13) (2 used) from the stand.
: 13 mm

W2-6-1
 UPPERSTRUCTURE / Pilot Valve
Installation
5
1. Insert pilot valves (13) (2 used) into the lever 6
stand and align the matching marks made when
7
disassembling.
Pilot Shut-Off 8
Lever
2. Install pilot valves (13) (2 used) to the stand with 9
bolts (14) (8 used). 10
: 13 mm 11
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) 16
15
3. Connect hoses (12) (12 used) to pilot valves (13)
(2 used).
: 19 mm
14
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
13
4. Insert levers (7) (2 used) (with grip (5)) into boots Left Stand Pilot-Off Switch
(4) (2 used). Install levers (7) (2 used) into pilot 12 T532-02-06-002

valves (13) (2 used). When installing, lever (7)

with horn button should be installed on the left 4
side.

5. Secure levers (7) (2 used) to pilot valves (13) (2

used) with lock nuts (8) (2 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

6. Raise boot (4) to install clip band (9).

7. Install clip band (10) and plug (11) to pilot valve

(13) on the left stand only.
2 1 3
8. Install boots (4) (2 used) with plates (15) (4 used)
Fast Speed Travel Pedal
and screws (16) (8 used). M1LA-01-006

9. Install covers (2 and 3) with screws (1) (6 used)

on the stands.

IMPORTANT: After the complete work, check the

hydraulic oil level. Start the engine
and check the connection for oil
leaks.

W2-6-2
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL TRAVEL PILOT
VALVE

Removal

IMPORTANT: Be sure to release any pressure in

the hydraulic oil tank before any
1
work. (Refer to W1-4-1.)
1. Remove bolts (2) (2 used) and (3) (2 used) to re-
move cover (1) from the main frame.
: 13 mm, 17 mm

2. Remove pedal mounting socket bolts (6) (4 used)

to remove pedals (5) (2 used) and levers (4) (2
used). 2, 3
: 6 mm
W1LA-02-05-006

IMPORTANT: Attach the identification tag onto the

disconnected hoses for assembling.
3. Disconnect pilot hoses (9) (6 used) from pilot
valve (10). Attach a cap onto the open ends. 4

4. Loosen mounting bolts (7) (4 used) for pilot valve 5

(10). 6
: 13 mm

5. remove bolts (11) (4 used) to remove the cover 11

(8) assembly from the floor.
: 13 mm
7

6. Remove bolts (7) (4 used) to remove pilot valve 8

(10) from cover (8).
: 13 mm
W1LA-02-06-004
10 9

W2-6-3
 UPPERSTRUCTURE / Pilot Valve

Installation

1. Install pilot valve (10) to cover (8) with bolts (7) (4

used) temporarily.
: 13 mm

2. Install the cover (8) assembly to the floor with

bolts (11) (4 used). 4
: 13 mm
5
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
6
3. Connect hoses (9) (6 used) onto pilot valve (10).
: 19 mm
: 34 N⋅m (3.4 kgf⋅m, 25 lbf⋅ft) 11

4. Tighten mounting bolts (7) (4 used) for pilot valve 7

(10).
8
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)

5. Install levers (4) (2 used) and pedals (5) (2 used) W1LA-02-06-004

to pilot valve (10) with socket bolts (6) (4 used). 10 9
: 6 mm
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft)

6. Install cover (1) to the floor in the main frame with

bolts (2) (2 used) and (3) (2 used).
: 13 mm 1
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil
level. Start the engine and check the 2, 3
connections for oil leaks.
W1LA-02-05-006

W2-6-4
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BLADE PILOT VALVE
Removal

IMPORTANT: Be sure to release any pressure in

the hydraulic oil tank before any 4
work. (Refer to W1-4-1.)

1. Remove bolts (2) (4 used) to remove cover (1).

: 13 mm

2. Remove bolts (3) (2 used) to remove lever (4)

from pilot valve (6).

3. Loosen bolts (5) (2 used).

: 13 mm

4. Remove bolts (8) (2 used) to remove the bracket

(9) assembly from the floor.
1, 2 M1LA-05-004

IMPORTANT: Attach the identification tag onto the

disconnected hoses for assembling. 4
3
5. Disconnect hoses (7) (4 used) from pilot valve (6).
Attach a cap onto the open ends.
: 19 mm 5
NOTE: Hold hoses (7) (4 used) with a wire to pre- 9
6
vent them from falling down.

6. Remove bolts (5) (2 used) to remove pilot valve

(6).
: 13 mm
8

W1LA-02-06-005

W2-6-5
 UPPERSTRUCTURE / Pilot Valve
Installation

1. Install pilot valve (6) to bracket (9) with bolts (5) (2

used). 3 4
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
5
2. Connect hoses (7) (4 used) onto pilot valve (6). 9
6
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

3. 3.Install the bracket (9) assembly to the floor with

bolts (8) (2 used).
8
4. Install lever (4) with bolts (3) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)

5. Install cover (1) with bolts (2) (4 used).

: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft) W1LA-02-06-005

7
IMPORTANT: After connecting the hoses and
connectors, check the hydraulic oil
level. Start the engine and check the
4
connections for oil leaks.

1, 2 M1LA-05-004

W2-6-6
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BOOM SWING PILOT
VALVE
Removal

IMPORTANT: Be sure to release any pressure in

the hydraulic oil tank before any
work. (Refer to W1-4-1.) 1
1. Remove bolts (2) (2 used) and (3) (2 used) to re- Floor
move cover (1).
: 13 mm , 17 mm

2. Remove bolts (4) (2 used) to remove cover (5)

from plate (10).
: 13 mm
2, 3

3. Remove socket bolts (6) (2 used) to remove

W1LA-02-05-006
pedal (7) from pilot valve (12).
: 6 mm
4

4. Remove mounting bolts (8) (2 used) from pilot

valve (12). 6
: 13 mm 5

5. Remove bolts (9) (2 used) in plate (10).

7
IMPORTANT: Attach the identification tag onto the
disconnected hoses for assembling. 9 8
6. Disconnect hoses (11) (4 used) from pilot valve
(12). Attach a cap onto the open ends.
: 19 mm
12
7. Remove pilot valve (12) from bracket (8).

10

11
11

W1LA-02-06-003

W2-6-7
 UPPERSTRUCTURE / Pilot Valve
Installation

1. Install pilot valve (12) to plate (10) with bolts (8) (2 4

used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft) 6
5

2. Connect hoses (11) (4 used) onto pilot valve (12).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft) 7

3. Install the pilot valve (12) assembly to the floor 9 8

with bolts (9) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
12
4. Install pedal (7) to pilot valve (12) with socket
bolts (6) (2 used).
: 6 mm 10
: 30 N⋅m (3.1 kg⋅m, 22 lbf⋅ft)

5. Install cover (5) with bolts (4) (2 used).

: 6 mm
11
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft) 11

6. Install cover (1) to the floor in the main frame with

W1LA-02-06-003
bolts (2) (2 used) and (3) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
: 17 mm
1
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) Floor

IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil
level. Start the engine and check the
connections for oil leaks.

2, 3

W1LA-02-05-006

W2-6-8
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-9
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE

18 19

20
19
21
7 8 17 20 22
9 21
10 22 23
11 18
16
5 23
17
6 15
7 24
14
16 24 25
5 35
15
12 25
4
14
3 34
4 13
2 3
2 33
1 32
1

26
27
28
29
30
31
W585-02-06-006

1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)

W2-6-10
 UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
• Thoroughly read the Precautions for Disassem- IMPORTANT: As the spool (23) assemblies (4
bling and Assembling (W1-1-1) prior to disas- used) are adjusted by the pressure
sembling. of shim (21), they had better not be
• As casing (34) and spool (23) can not be disas- disassembled. If disassembling the
sembled, they can not be replaced with the new spool (23) assemblies, record the
one by one. number and thickness of shim (21).
• Put identification tags on the disassembled parts
by port to aid when re-assembling. 7. Remove spool (23) assemblies (2 used), O-rings
(25) (4 used) and (35) (2 used), and springs (24)
IMPORTANT: Put the mating marks onto cam (10), (4 used) from casing (34).
pin (11), cover (12), and casings (13,
34) before disassembling. 8. Remove spring guides (19) (4 used), springs (20)
(4 used), shims (21) (4 used), and washers (22)
1. Clamp the pilot valve in a vise to remove boot (8) (4 used) from spool (23) assemblies (4 used).
from cover (12).

2. Remove set screw (9) from cam (10). Pull pin (11)
out to remove cam (10) from cover (12).
: 2 mm

NOTE: LOCTITE is applied onto the set screw.

Steel ball (6) can not be removed from
cam(10).

3. Loosen and remove socket bolts (7) (2 used) al-

ternately. Remove covers (12) (2 used) and cas-
ing (13) assembly from casing (34).
: 6 mm

IMPORTANT: Put identification tags on the disas-

sembled parts by port.

4. Remove grease cups (4) (4 used), push rods (18)

(4 used), and bushing (2) assemblies (4 used)
from casing (13) assembly.

5. Remove pistons (17) (4 used), springs (16) (4

used), spring seats (15) (4 used), and steel balls
(14) (12 used) from casing (13).

6. Remove packings (3) (4 used) and O-rings (1) (4

used) from bushing (2) assemblies (4 used).

W2-6-11
 UPPERSTRUCTURE / Pilot Valve

5
12

34

26
27
28
29
30
31
W585-02-06-006

W2-6-12
 UPPERSTRUCTURE / Pilot Valve
9. Remove plug (31) and O-ring (30) from casing
(34).
: 6 mm

10. Remove seat (29), steel ball (28), bushing (27)

and seat (26) from casing (34) with a magnet.

IMPORTANT: Be sure not to remove bushing (5)

from cover (12) unless bushing (5) is
damaged.
11. Pull bushings (5) (4 used) out of covers (12) (2
used).

W2-6-13
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE

9 5
8 11
6 10
18 4
3
2
7
12
1
17
35
16

15 13
19
14
31
25
30
20
21
24
22
32
33
23 C C
34
27 W585-02-06-008

29 28
26

Cross
Section C-C

W585-02-06-007

1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)

W2-6-14
 UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
• Thoroughly read the Precautions for disassem- 7. Install push rods (18) (4 used) and bushing (2)
bling and Assembling (W1-1-1) prior to assem- assemblies (4 used) to casing (13).
bling.
• Clean the parts and put them by port for assem- 8. Install bushings (5) (4 used) to covers (12) (2
bling. used).

1. Install seats (26) (2 used), bushings (27) (2 used), 9. Clamp casing (34) in a vise. Tighten casing (13)
steel balls (28) (2 used) and seats (29) (2 used) assembly and cover (12) with socket bolts (7) (4
to casing (34). used).
: 6 mm
2. Install O-rings (30) (2 used) to plugs (31) (2 used). : 23.5 N⋅m (2.4 kgf⋅m, 17 lbf⋅ft)
Install them to casing (34).

IMPORTANT: Be sure to install shim (21) to the

original condition.
3. Install washers (22) (4 used), shims (21) (4 used),
springs (20) (4 used), and spring guides (19) (4
used) to spools (23) (4 used) in this order.

IMPORTANT: Be sure to install the spool (23) as-

sembly into the original hole when
disassembling.
4. Install springs (24) (4 used), spool (23) assem-
blies (4 used), and O-rings (25) (4 used) and (35)
(2 used) to casing (34).

5. Install steel balls (14) (12 used), spring seats (15)

(4 used), springs (16) (4 used), and pistons (17)
(4 used) to casing (13).

6. Install O-rings (1) (4 used) and packings (3) (4

used) to bushings (2) (4 used).

W585-02-06-005
Lip part

W2-6-15
 UPPERSTRUCTURE / Pilot Valve

9
11
8
10
18 4

12

C C

W585-02-06-008

Cross
Section C-C

W585-02-06-007

W2-6-16
 UPPERSTRUCTURE / Pilot Valve
10. Install grease cups (4) (4 used) to push rods (18)
(4 used).

11. Install cams (10) (2 used) to cover (12) with pins

(11) (2 used).

12. Apply LOCTITE #241 onto set screws (9) (2

used). Install set screws (9) (2 used) to cams (10)
(2 used) with pins (11) (2 used).
: 2 mm
: 5 N⋅m (0.5 kgf⋅ m)

13. Install boots (8) (2 used) to covers (12) (2 used).

W2-6-17
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE FRONT ATTACHMENT PI-
LOT VALVE

13

12

14

11
15

11
10

8
8
7
9
21
6 20
16 21
5
20
4 5
19
3 6

3 18
2
4
1

17

W567-02-06-002

1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)

W2-6-18
 UPPERSTRUCTURE / Pilot Valve
Disassemble Front Attachment 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, be careful while handling 4. Pull push rods (8) (2 used) and (9) (2 used) out of
them. block (10).

IMPORTANT: As spool (17) has been selected to 5. With a bamboo spatula, remove oil seals (15) (4
match the hole of housing (18), they used) from block (10).
must be replaced in a set. In addition, NOTE: If a metal bar is used, the mating part of oil
the dimensions of balance springs A seal may be damaged.
(3), B (4) and return springs A (5), B
(6) as well as those of push rods A IMPORTANT: Retaining ring (7) may come off
(8), B (9) are different. For this rea- while disassembling. Take care not
son, be sure to indicate the port to drop it.
number from which it is removed. 6. Press springs using special tool (ST 7257) from
Port numbers are stamped on hous- the top of spring guide (16). Retaining ring (7) will
ing (18). appear. Remove it with a screw driver or similar
tool (4 places).
IMPORTANT: Do not clamp housing (18) in a vise
to remove the screw joint (13) be-
7
cause the screw joint may be dam-
aged.
1. Secure screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm

2. Clamp the flat surface of housing (18) in a vise

16
slightly. Remove cam (12) from universal joint
(14). ST 7257
: 32 mm
NOTE: The universal joint has been secured on
block (10) with LOCTITE. Do not remove it
unless necessary.
W176-02-07-005
3. Remove socket bolts (11) (2 used) to remove
block (10). At this time, push rods (8) (2 used)
IMPORTANT: The number of shims (2) has been
and (9) (2 used) are in place.
determined for each port during the
: 6 mm
performance testing at the factory.
Take care not to lose them. Keep
them carefully to install them to
each former port when reassembly.
7. Remove spring guides (16) (4 used), balance
springs (3) (2 used) and (4) (2 used), return
springs (5) (2 used) and (6) (2 used), shim (2)
and spacers (1) (4 used) from spools (17) (4
used).

W2-6-19
UPPERSTRUCTURE / Pilot Valve

21
20
21

20

19

18

17

W567-02-06-002

W2-6-20
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: As the spool has been selected to
match the hole of the housing, keep
them carefully to install them to the
former port when reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it.
NOTE: The spool and housing must be replaced
as an assembly.

9. Remove O-rings (19) and (21) (2 used) from

housing (18). Do not remove dowel pins (20) (2
used) unless necessary.

W2-6-21
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE FRONT ATTACHMENT PILOT
VALVE

13
14

12

10 11 15 8, 9

7
16

3, 4
21 5, 6
2

19
20 1

17

W567-02-06-001

18

1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)

W2-6-22
 UPPERSTRUCTURE / Pilot Valve
Assemble Front Attachment Pilot Valves

IMPORTANT: The pilot valve is susceptible to con- IMPORTANT: Install spring guide (16), with the
tamination. Keep parts clean when protrusion facing up.
assembling. 3. Install spring guides (16) (4 used) onto the return
springs (3) (2 used) or (4) (4 used).
NOTE: Table below shows the relations between
each port and the components. Take care 4. Install retaining ring (7) onto ring holder (ST
not to confuse them when assembling. 7255).

Port Spool Shim Push rods ST 7255

No. (17) (2) (8), (9) 7
1 with outer
Same to Same to groove
2 the former the former without outer
one one groove W176-02-07-008

3 with outer
groove 5. Insert the spool (17) head into the hole of spring
4 without outer using special tool (ST 7257) to press the spring
groove from the top of spring guide (16). Install retaining
ring (7) with the ring holder (ST 7255) onto the
Port Return Springs Blance Springs head of the spool.
No. (5), (6) (3), (4) 7
1 short short ST 7257 ST 7255
2 long long
3 short short 17
4 long long 16

IMPORTANT: Make sure of the port hole number

Packing Material
and insert spool (17) to the former
port.
1. Insert the thinner end of spools (17) (4 used) to W176-02-07-009

housing (18), then push the spools rotating it. NOTE: Put approx. dia.8 mm, length 10 mm of
NOTE: The spool has been selected to match the packing material, into the port hole not only
hole of the housing. The spool and housing to make the work easy to do, but also to
must be replaced as an assembly. prevent the spool from lowering to the bot-
tom when compressing the spring.
IMPORTANT: Refer to the table above to assemble
them correctly. 6. Assemble the remained spools (17) (3 used) into
2. Install spacers (1) (4 used), shim (2), balance housing (18) in the same procedures as step 2 to
springs (3) (2 used) or (4) (2 used), return springs 5.
(5) (2 used) or (6) (2 used) onto spool (17) in-
stalled in housing (18). 7. Install O-rings (19) and (21) (2 used) on to hous-
ing (18).

W2-6-23
 UPPERSTRUCTURE / Pilot Valve

13
14
12

10

11 15 8, 9

20

W567-02-06-001

18

W2-6-24
 UPPERSTRUCTURE / Pilot Valve
8. Apply the grease to the inner face of oil seals (15) IMPORTANT: Make sure of the tighteness of cam.
(4 used), then install the oil seals (4 used) into 13. Clamp housing (18) carefully in a vise and then
block (10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, inserting push rods (8) Tighten the universal joint so that the clearance
and (9) first, then installing oil seal (15). between the cam and push rods (8) (2 used) and
This prevents the oil seal from entering into (9) (2 used) become 0 to 0.2 mm.
the hole. : 32 mm

Oil Seal Mounting Hole IMPORTANT: Do not clamp housing (18) in a vise
because screw joint (13) may be
damaged.
10 14. Clamp screw joint (13) in a vise to tighten univer-
8, 9 sal joint (14). Tighten cam (12) with a spanner.
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

W176-02-07-007

IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods (8) (2 used) and (9) (2 used) to
block (10). When installing the push rods, install
the push rods with groove to ports # 1 and # 3,
the ones without groove to ports # 2 and # 4, re-
spectively.

10. Apply grease to the ball at the ends of push rods

(8) (2 used) and (9) (2 used).

11. Apply grease to the joint part of universal joint

(14).

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

stall the block (10) assembly to housing (18) with
socket bolts (11) (2 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W2-6-25
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE BOOM SWING AND
BLADE PILOT VALVE

20

7 20

8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15

15
4
11 14

14
3

3 12
13
2
2

21
1
1

W1LA-02-06-001

1 - O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2 - Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3 - Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4 - Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6 - Socket Bolt (2 Used)

W2-6-26
 UPPERSTRUCTURE / Pilot Valve
Disassemble Boom Swing and Blade Pilot Valve
• Thoroughly read the Precautions for Disassem- 7. Remove spring guides (19) (2 used), springs (18)
bling and Assembling (W1-1-1) prior to disas- (2 used), washers (16) (2 used), and shims (17)
sembling. (2 used) from spool (15) assemblies (2 used).
• As casing (21) and spool (15) cannot be disas-
sembled, they cannot be replaced with new ones IMPORTANT: As the spool (15) assemblies (2
one by one. used) are adjusted by the pressure
• Put identification tags on the disassembled parts of shim (17), they had better not be
by port to aid when re-assembling. disassembled. If disassembling the
spool (15) assemblies, record the
IMPORTANT: Put the mating marks onto cam (9), number and thickness of shim (17).
pin (10), cover (11), and casing (21)
before disassembling. IMPORTANT: Be sure not to remove bushing (4)
1. Clamp the pilot valve in a vise to remove boot (7) from cover (11) unless bushing (4) is
from cover (11). damaged.
8. Pull bushings (4) (2 used) out of cover (11).
2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm

NOTE: LOCTITE is applied onto the set screw.

Steel ball (5) cannot be disassembled from
cam (9).

3. Loosen and remove socket bolts (6) (2 used) al-

ternately. Remove cover (11) from casing (21).
: 6 mm

4. Remove pusher (20) assemblies (2 used) from

casing (21).

5. Remove bushings (2) (2 used) from pusher (20)

assembly. Remove O-rings (1) (2 used) and pack-
ings (3) (2 used) from bushings (2) (2 used).

IMPORTANT: Put identification tags on the disas-

sembled parts by port.
6. Remove spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).

W2-6-27
 UPPERSTRUCTURE / Pilot Valve
A SSEMBLE BOOM SWING AND BLADE
PILOT VALVE
8 10
7
9
5

20

3
6
2

11

19

18

14

17

16

12

13

15 W1LA-02-06-002

21

1 - O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2 - Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3 - Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4 - *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6 - Socket Bolt (2 Used)

NOTE: As for the item with mark “*”, refer to W2-

6-26.

W2-6-28
 UPPERSTRUCTURE / Pilot Valve
Assemble Boom Swing and Blade Pilot Valve
• Thoroughly read the Precautions for disassem-
bling and Assembling (W1-1-1) prior to assem-
bling.
• Clean the parts and put them by port for assem-
bling.

1. Install bushings (4) (2 used) to cover (11).

IMPORTANT: Be sure to install shim (17) to the

original condition.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used), and spring guides (19) (2
used) to spools (15) (2 used) in this order.

IMPORTANT: Be sure to install the spool (15) as-

sembly into the original hole when
disassembling.
3. Install springs (14) (2 used) and spool (15) as-
semblies (2 used) to casing (21).

4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3

W585-02-06-005
Lip Part

5. Install pushers (20) (2 used) to bushing (2) as-

semblies (2 used). Install them to casing (21).

6. Clamp casing (21) in a vise. Tighten cover (11)

with socket bolts (6) (2 used).
: 6 mm
: 23.5 N⋅m (2.4 kgf⋅m, 17 lbf⋅ft)

7. Install cam (9) to cover (11) with pin (10).

8. Apply LOCTITE #241 onto set screw (8). Install

set screw (8) to cam (9) with pin (10).
: 2 mm
: 5 N⋅m (0.5 kgf⋅m, 4 lbf⋅ft)

9. Install boot (7) to cover (11).

W2-6-29
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-30
 UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
1, 2
3
Removal

IMPORTANT: Be sure to release any pressure in

the hydraulic oil tank before any
work. (Refer to W1-4-1.)
1. Remove bolts (2) (2 used) and wing bolts (3) (3
used) to remove cover (1).
: 13 mm

SS-29.

2. Disconnect connectors (7, 8) in solenoid valve (5).

IMPORTANT: Attach the identification tag onto the 7

disconnected hoses for assembling.
3. Disconnect hoses (4) (7 used) from solenoid
valve (5). Attach a cap onto the open ends. 8
: 19 mm, 22 mm

4. Remove bolts (6) (2 used) to remove solenoid

valve (5) from the bracket.
: 17 mm

W1LA-02-07-002

5, 6

T1LA-04-04-001

W2-7-1
 UPPERSTRUCTURE / Solenoid Valve
Installation

1. Install solenoid valve (5) to the bracket with bolts

(6) (2 used).
: 17 mm
4
: 50 N⋅m (5.1 kgf⋅m)

2. Connect hoses (4) (7 used) to solenoid valve (5).

: 19 mm
: 34 N⋅m (3.5 kgf⋅m)
: 22 mm
: 39 N⋅m (3.9 kgf⋅m)

5, 6

T1LA-04-04-001

3. Connect connectors (7, 8) in solenoid valve (5). 7

W1LA-02-07-002

4. Install cover (1) with bolts (2) (2 used) and wing 1, 2

3
bolts (3) (3 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m)

IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil
level. Start the engine and check the
connections for oil leaks.

SS-29.

W2-7-2
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE

1 3 2

W574-02-07-001

1 - ON-OFF Solenoid Valve 2 - ON-OFF Solenoid Valve 3 - Relief Valve 4 - Housing

(Pilot Control (Travel Speed Selector)
Shut-off Lever)

W2-7-3
 UPPERSTRUCTURE / Solenoid Valve

7
1

8
3

6
9

10

11

12

13

W574-02-07-002

1 - Guide 5 - Washer 8 - Solenoid 11 - Spool

2 - O-Ring 6 - Spool 9 - Tube 12 - Spring
3 - Washer 7 - Nut 10 - O-Ring 13 - Housing
4 - Spring

W2-7-4
 UPPERSTRUCTURE / Solenoid Valve
Disassemble Solenoid Valve Assemble Solenoid Valve

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.

1. Loosen nuts(7) (2 used), hen remove solenoids 1. Install spool (6), washer (5), spring (4) and
(8) (2 used). washer (3) into housing (13).
: 19 mm
2. Install O-ring (2) into guide (1).

2. Remove tubes (9) (2 used), spools (11) (2 used) 3. Install guide (1) into housing (13).
and springs (12) (2 used) from housing (13). : 24 mm
: 21 mm : 74 to 88 N⋅m
(7.5 to 9.0 kgf⋅m, 54 to 65 lbf⋅ft)
3. Remove O-ring (10) from tube (9).
4. Install spring (12) and spool (11) into housing
4. Remove guide (1) from housing (13). (13).
: 24 mm
5. Install O-ring (10) into tube (9).

5. Remove washer (3), spring (4), washer (5) and 6. Install tube (9) into housing (13).
spool (6) from housing (13). : 21 mm
: 47 to 74 N⋅m
6. Remove O-ring (2) from guide (1). (4.8 to 7.6 kgf⋅m, 35 to 55 lbf⋅ft)

7. Install solenoid (8) onto tube (9) with nut (7).

: 19 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)

W2-7-5
 UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-7-6
 MEMO

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 MEMO

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 SECTION 3
UNDERCARRIAGE

CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing .......... W3-1-1 Remove and Install Lower Roller ............. W3-6-1
Disassemble and Assemble
Group 2 Travel Device Lower Roller........................................... W3-6-4
Remove and Install Travel Device ........... W3-2-1 Maintenance Standards ........................... W3-6-6
Disassemble Travel Device (27u) ............ W3-2-6
Assemble Travel Device (27u)................. W3-2-8 Group 7 Track
Disassemble Travel Motor (27u)............ W3-2-12 Remove and Install Rubber Crawler ........ W3-7-1
Assemble Travel Motor (27u).....................3-2-14 Maintenance Standards ........................... W3-7-3
Disassemble Brake Valve (27u)............. W3-2-18
Assemble Brake Valve (27u) ................. W3-2-20
Disassemble Travel Device
(30u, 35u) ............................................ W3-2-22
Assemble Travel Device (30u, 35u) ....... W3-2-26
Disassemble and Assemble
Brake Valve (30u, 35u) ........................ W3-2-32
Maintenance Standards......................... W3-2-34

Group 3 Center Joint

Remove and Install Center Joint.............. W3-3-1
Disassemble Center Joint........................ W3-3-8
Assemble Center Joint .......................... W3-3-10

Group 4 Track Adjuster

Remove and Install Track Adjuster .......... W3-4-1
Disassemble Track Adjuster .................... W3-4-2
Assemble Track Adjuster ......................... W3-4-8

Group 5 Front Idler

Remove and Install Front Idler................. W3-5-1
Disassemble and Assemble Front Idler ... W3-5-2
Maintenance Standards........................... W3-5-4

1LAW-3-1
（Blank）

1LAW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING

The procedures described below starts after removing

the upper structure.

Removal 1
Mating Mark

1. Make mating marks on inner race (3) of swing

bearing (1) and track frame (2).

3 2 W105-03-01-001

2. Remove swing bearing (1) inner race (3)

mounting bolts (4) (20 used).
: 19 mm 4
3

CAUTION: Swing bearing weight

39 kg (86 lb) (ZAXIS27u)
41 kg (90 lb) (ZAXIS30u, 35u)

3. Install the eyebolt with nut into bolt hole (5) W507-02-03-002

(Diameter: 13.5 mm, Depth: 40 mm) on swing

bearing (1). Hoist swing bearing (1) by crane to
remove it.

W507-03-01-001

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation

Clean the mating surfaces of the track frame and

swing bearing.

1. Apply THREEBOND #1102 onto the swing

bearing mating surfaces of track frame.

CAUTION: Swing bearing weight

39 kg (86 lb) (ZAXIS27u) Front Side
41 kg (90 lb) (ZAXIS30u, 35u) ″S″
(the soft zone)
Marking Position

IMPORTANT: Align the marks correctly. Other-

wise, the soft zone position will be
dislocated. B
A

2. Hoist the swing bearing by crane. Align the marks

on the track frame and swing bearing inner race.
S (the soft zone) marking position
A (outer race): 12°
B (inner race): 11.15°

W565-03-01-001

3. Tighten swing bearing (1) inner race (3) mounting 1

bolts (4) (20 used).
4

: 19 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

W507-02-03-002

W3-1-2
 UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
1
IMPORTANT: Be sure to release any pressure in
the hydraulic oil tank before any
work. (Refer to W1-4-1)

Removal

1. Remove bolts (1) (3 used) to remove cover (2).

: 8 mm

2 W507-03-02-001

12
ZAXIS27u 13
Front Side
IMPORTANT: Attach the identification tags onto
the disconnected hoses for
assembling. 8 11
2. Disconnect hoses (6 to 13) from travel device (5). 9 10
Cap all disconnected hose end.
: 19 mm, 22 mm
7
3
6
4

W1LA-03-02-005

12 13
ZAXIS30u、35u
11
10
6 7 8 9

W1LA-03-02-006

W3-2-1
 UNDERCARRIAGE / Travel Device

CAUTION: Travel device weight: 44 kg (97 lb) 12

13
3. Attach a nylon sling onto travel device (5) to hold Front Side
it by crane.
8 11
4. Remove socket bolts (4). Remove travel device 10
9
(5) by crane.
: 19 mm
7
3
NOTE: Socket bolt (4) 6
4
ZAXIS27u :9 used
ZAXIS30u、35u :11 used

W1LA-03-02-005

W507-03-02-004

W3-2-2
 UNDERCARRIAGE / Travel Device
Installation

CAUTION: Travel device weight: 44 kg(97 lb)

IMPORTANT: Apply LOCTITE #262 onto socket 5

bolt (4).
1. Install travel device (5) with socket bolts (4) by
crane.
ZAXIS27u:
: 19 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
ZAXIS30u, 35u:
: 19 mm
: 128 N⋅m (13 kgf⋅m, 94 lbf⋅ft)

NOTE: Socket bolt (4) W507-03-02-004

ZAXIS27u: 9 used
12
ZAXIS30u, 35u: 11 used
ZAXIS27u 13

2. Connect hoses (6 to 13) to travel device (5). Front Side

: 19 mm
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft) 8 11
: 22 mm 9 10
: 40 N⋅m (4.1 kgf⋅m, 30 lbf⋅ft)

7
3
6
4

W1LA-03-02-005
12 13
ZAXIS30u、35u

11
10
6 7 8 9

W1LA-03-02-006

W3-2-3
 UNDERCARRIAGE / Travel Device
3. Install cover (2) with bolts (1) (3 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

1
IMPORTANT: After connecting the hoses, check
the hydraulic oil level. Start the
engine and check the hoses for oil
leaks.
To prevent the travel motor from
seizing, be sure to perform break-in
operation after installation.

Break-in operation conditions 2

1.Engine speed: Slow idle speed W507-03-02-001

2.Travel pedal : Slow speed range

3.Operating duration: 2 minutes or
more

W3-2-4
 UNDERCARRIAGE / Travel Device
(Blank)

W3-2-5
 UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL REDUCTION
GEAR (27u)

1
2
3
4

6
19 7
8
15
18 9
10
17 11
20 16
15
21 14

22
23
24
13
25 12

26
27
28
29
30
31
32
33

W1LA-03-02-004

1- Sun Gear 10 - O-Ring (2 Used) 19 - Spring Pin (3 Used) 27 - Thrust Washer (4 Used)
2- Thrust Washer 11 - Plug (2 Used) 20 - Floating Seal 28 - Inner Race (4 Used)
3- Carrier 12 - Plug 21 - Floating Seal 29 - Needle Bearing (4 Used)
4- Retaining Ring 13 - O-Ring 22 - Bearing 30 - Second Stage Planetary
Gear (4 Used)
5- Drive Gear 14 - Retaining Ring (3 Used) 23 - Retaining Ring 31 - Thrust Washer (4 Used)
6- Slide Ring 15 - Thrust Washer (6 Used) 24 - Bearing 32 - Retaining Ring (4 Used)
7- O-Ring 16 - Pin (3 Used) 25 - Ring Gear 33 - Body
8- Cover 17 - Needle Bearing (3 Used) 26 - Retaining Ring
9- Stopper Ring 18 - First Stage Planetary Gear
(3 Used)

W3-2-6
 UNDERCARRIAGE / Travel Device
Disassemble Travel Reduction Gear
7. Remove retaining ring (32). Remove thrust
• Read PRECAUTIONS FOR DISASSEMBLING washer (31), second stage planetary gear (30),
AND ASSEMBLING (W1-1-1) before needle bearing (29), inner race (28), thrust
disassembling. washer (27) from ring gear (25). Remove others
• This indicates the procedure before Disassemble by the same procedure.
Travel Motor (W3-2-10) and before Disassemble
Brake Valve (W3-2-16). 8. Install the squill vices to the flange parts in body
CAUTION: Travel device weight: 36 kg (33) and ring gear (25). Tighten the squill vices to
remove retaining ring (26) from body (33).
1. Remove plugs (11) (2 used) from cover (8).
Discharge gear oil from the travel device.
25
: 8 mm

NOTE: Gear oil : 0.6 L

Squill Vice
2. Remove stopper ring (9) to remove cover (8) from Squill Vice
ring gear (25).

3. Remove O-ring (7),plug (12), and slide ring (6)

33
from cover (8).
: 5 mm W571-03-02-006

IMPORTANT: Do not disassemble the carrier (3) IMPORTANT: Do not remove bearings (22, 24)
assembly (1 to 4 and 14 to 19) unless necessary. If removing them,
unless necessary. Replace the replace them with new ones.
carrier with an assembly. 9. Remove ring gear (25) assembly (22 to 5) from
4. Remove drive gear (5), carrier (3) assembly, and body (33).
thrust washer (2) from ring gear (25) in this order.
IMPORTANT: For handling of floating seals (20,
NOTE: Retaining rings (4, 11) can be replaced one 21), refer to the section “Precautions
by one. for Floating Seal Handling” on page
W1-1-4.
IMPORTANT: Spring pin (19) and pin (16) cannot 10. Remove floating seal (20) from body (33)side and
be disassembled because they are floating seal (21) from ring gear (25) side.
compressed into carrier (3).
5. Remove retaining rings (14) (3 used) from carrier
(3). Remove thrust washers (15) (3 used), first
stage planetary gears (18) (3 used), needle
bearings (17) (3 used), and thrust washers (15) (3
used) in this order.

6. Remove retaining ring (4) to remove sun gear (1).

W3-2-7
 UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL REDUCTION GEAR
(27u)

33 1 2 3 4 5

13
12

14
15
10
11
9

20 21 22 23 24 26 25 27 28 29 30 31 32 19 16 17 18
W1LA-03-02-008

1- Sun Gear 10 - O-Ring (2 Used) 19 - Spring Pin (3 Used) 27 - Thrust Washer (4 Used)
2- Thrust Washer 11 - Plug (2 Used) 20 - Floating Seal 28 - Inner Race (4 Used)
3- Carrier 12 - Plug 21 - Floating Seal 29 - Needle Bearing (4 Used)
4- Retaining Ring 13 - O-Ring 22 - Bearing 30 - Second Stage Planetary
Gear (4 Used)
5- Drive Gear 14 - Retaining Ring (3 Used) 23 - Retaining Ring 31 - Thrust Washer (4 Used)
6- Slide Ring 15 - Thrust Washer (6 Used) 24 - Bearing 32 - Retaining Ring (4 Used)
7- O-Ring 16 - Pin (3 Used) 25 - Ring Gear 33 - Body
8- Cover 17 - Needle Bearing (3 Used) 26 - Retaining Ring
9- Stopper Ring 18 - First Stage Planetary Gear
(3 Used)

W3-2-8
 UNDERCARRIAGE / Travel Device
Assemble Travel Reduction Gear
4. Secure the flange parts of body (33) and ring gear
• Read PRECAUTIONS FOR DISASSEMBLING (25) with the squill vices. Tighten the squill vices
AND ASSEMBLING (W1-1-1) before assembling. to install retaining ring (26) to body (33).
• This indicates the procedure after Assemble NOTE: Check if ring gear (25) can turn. If not,
Travel Motor (W3-2-12) and after Assemble disassemble and assemble them again
Brake Valve (W3-2-18). because bearings (22, 24) or floating seals
(20, 21) are not installed correctly.
IMPORTANT: Install bearings (22, 24) with the
thinner side of them facing retaining
ring (23). 25
1. Install bearing (24), retaining ring (23), and
bearing (22) in this order from the flange side of
ring gear (25).
Squill Vice Squill Vice

IMPORTANT: For handling of floating seals (20,

21), refer to the section
“ Precautions for Floating Seal
Handling” on page W1-1-4.
2. Install floating seal (20) to body (33) side and 33
floating seal (21) to ring gear (25) side.
W571-03-02-006

3. Align ring gear (25) with body (33). Tap around

ring gear (25) with a plastic hammer to install ring 5. Install inner races (28) (4 used), thrust washers
gear (25) to body (33). (27) (4 used), second stage planetary gears (30)
(4 used), needle bearings (29) (4 used), and
thrust washers (31) (4 used) to body (33) in this
order. Secure them with retaining rings (32) (4
used).

6. Install sun gear (1) to carrier (3) with retaining ring

(4).

7. Install thrust washers (15) (3 used), first stage

planetary gears (18) (3 used), needle bearings
(17) (3 used), thrust washers (15) (3 used) to
carrier (3) in this order. Secure them with
retaining rings (14) (3 used).

8. Place thrust washer (2) on the step part on sun

gear (1) to install carrier (3) assembly and drive
gear (5).

W3-2-9
UNDERCARRIAGE / Travel Device

13
12

10
11
9
7

25
W1LA-03-02-008

W3-2-10
 UNDERCARRIAGE / Travel Device
IMPORTANT: Apply grease onto O-ring (7).

9. Install O-ring (7) to ring gear (25). Apply gear oil

(0.6 L).

IMPORTANT: Apply grease onto slide ring (6).

Secure it to cover (6). Align the plug
(11) hole on cover (8) with the notch
on ring gear (25).
10. Install slide ring (6) to cover (8). Install cover (8)
assembly and stopper ring (9) to ring gear (25).
NOTE: Install cover (8) while tapping the edge on
stopper ring (9) with a screw diver and
hammer.

11. Install O-rings (10) (2 used) to plugs (11) (2 used)

and o-rings (13) to plug (12).

12. Install plug (11) assemblies (2 used) and plug

(12) assembly to cover (8).
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 38 lbf⋅ft)
: 5 mm
: 12 to 22 N⋅m
(1.2 to 2.3 kgf⋅m, 8.9 to 16 lbf⋅ft)

W3-2-11
 UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR

4
5
6

23

22
21
20
19
18
17

16
15
13
14
13
12
11
10
9 W1LA-03-02-007

1- Swash Plate 7- Body 13 - Washer (2 Used) 19 - Bearing

2- Steel Ball (2 Used) 8- Plunger (9 Used) 14 - Spring 20 - Spring Pin
3- Shaft 9- Retainer 15 - Retaining Ring 21 - O-Ring
4- Bearing 10 - Holder 16 - Valve Plate 22 - Valve Body
5- Oil Seal 11 - Pin (3 Used) 17 - O-Ring 23 - Socket Bolt (7 Used)
6- Piston 12 - Cylinder Block 18 - Pin

W3-2-12
 UNDERCARRIAGE / Travel Device
Disassemble Travel Motor
6. Remove plungers (8) (9 used) from retainer (9).
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) before IMPORTANT: Be sure not to disassemble cylinder
disassembling. block (12) assembly (12 to 15)
• This indicates the procedure after Disassemble unless it is abnormal.
Travel Reduction Gear (W3-2-4) and before
Disassemble Brake Valve (W3-2-16).
CAUTION: When removing retaining ring
IMPORTANT: When removing socket bolts (23) (7 (15), be sure to washer (13) and spring (14)
used), valve body (22) is floated by with a press to prevent them from flying off.
the reacting force of spring (14). At
this time record the clearance 7. Remove retaining ring (15) from cylinder block
between valve body (22) and body (12). Remove washer (13), spring (14), and
(7) or the flange part of valve body washer (13) in this order.
(22) and body (7) end for
assembling. IMPORTANT: Be sure not to remove bearing (4)
1. Loosen to remove socket bolts (23) (7 used) from from shaft (3) unless necessary. If
valve body (22). removing it, replace it with a new
: 8 mm one.
8. Tap the bore spline of shaft (3) from body (7)
IMPORTANT: When removing valve body (22), take reduction gear side with a bar and plastic hammer
care not to drop off valve plate (16) to remove shaft assembly (3, 4).
because it may be removed with
valve body (22). 9. Remove oil seal (5) from body (7).
2. Remove valve body (22) from body (7).

IMPORTANT: Be sure not to remove bearing (19)

and spring pin (20) unless
necessary.
3. 3.Remove O-ring (17), O-ring (21) from valve
body (22).

IMPORTANT: Replace the cylinder (12) assembly

with a cylinder assembly (8 to 16)
including valve plate (16).
4. Remove valve plate (16), cylinder block assembly
(12 to 15), pins (11) (3 used), holder (10), and
plunger assembly (8, 9) from body (7) in this
order.

5. Remove swash plate (1), steel balls (2 ) (2 used),

and piston (6) from body (7) in this order.

W3-2-13
 UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR

22 16 21 19 7 14 13 8 3 10 4 6 5

23 20 17 15 12 11 9 1 2

W1LA-03-02-008

1- Swash Plate 7- Body 13 - Washer (2 Used) 19 - Bearing

2- Steel Ball (2 Used) 8- Plunger (9 Used) 14 - Spring 20 - Spring Pin
3- Shaft 9- Retainer 15 - Retaining Ring 21 - O-Ring
4- Bearing 10 - Holder 16 - Valve Plate 22 - Valve Body
5- Oil Seal 11 - Pin (3 Used) 17 - O-Ring 23 - Socket Bolt (7 Used)
6- Piston 12 - Cylinder Block 18 - *Pin

NOTE: As for the item with the mark “*”, refer to

W3-2-12.

W3-2-14
 UNDERCARRIAGE / Travel Device
Assemble Travel Motor
IMPORTANT: Apply hydraulic oil the plunger (8)
• Read PRECAUTIONS FOR DISASSEMBLING mounting hole on cylinder block
AND ASSEMBLING (W1-1-1) before assembling. (12).
• This indicates the procedure after Assemble 6. Install plungers (8) (9 used) to retainer (9). Install
Brake Valve (W3-2-16) and before Assemble plunger (8) assembly (8, 9) to cylinder block (12).
Travel Reduction Gear (W3-2-6).
IMPORTANT: Take care not to drop of retainer (9)
IMPORTANT: Apply grease between lip parts in oil and plunger (8).
seal (5). Install the oil seal (5) lip 7. Place body (7) horizontally. Align the splines of
parts with them facing bearing (4). shaft (3) and cylinder block (12) to install cylinder
1. Attach a round bar onto oil seal (5). Tap a round block (12) assembly (8 to 15) to body (7).
bar to install oil seal (5) to body (7).
IMPORTANT: Apply grease onto O-rings (17) and
2. Tap shaft assembly (3, 4) with a plastic hammer (21).
to install shaft assembly (3, 4) to body (7). 8. Install O-rings (17, 21) to valve body (22).

IMPORTANT: Apply hydraulic oil and grease onto IMPORTANT: Apply hydraulic oil onto the sliding
the sliding surface on swash plate surface on valve plate (16). Apply
(1). grease onto the contact surface on
3. Install piston (6) , steel balls (2) (2 used), and valve body (22).
swash plate (1) to body (7). 9. 9.Install valve plate (16) to valve body (22).

CAUTION: As spring (14) may fly off, be sure

to install retaining ring (15) to cylinder block
(12) with a press.
4. Install washer (13), spring (14), washer (13) to
cylinder block (12) in this order. Secure them with
retaining ring (15) and a press.

IMPORTANT: Apply grease onto pins (11) (3 used)

to prevent them from coming off.
5. Install pins (11) (3 used) to cylinder block (12),
and then install holder (10).

W3-2-15
 UNDERCARRIAGE / Travel Device

22 16 7

23

W1LA-03-02-008

W3-2-16
 UNDERCARRIAGE / Travel Device
IMPORTANT: When placing valve body (22) onto
body (7), check if the clearance
between body (7) and valve body
(22) is equal to that recorded when
disassembling. If not, disassemble
and assemble again because each
part is not installed correctly.

10.Fill hydraulic oil in body (7).

Hydraulic oil : 0.2 L

IMPORTANT: When aligning valve body (22), take

care not to drop off valve plate (16)
to prevent each part from being
damaged.
11. Align valve body (22) with body (7). Tighten
socket bolts (23) (7 used) diagonally.
: 8 mm
: 51 to 65 N⋅m
(5.1 to 6.6 kgf⋅m, 38 to 48 lbf⋅ft)

W3-2-17
 UNDERCARRIAGE / Travel Device
DISASEMBLE BRAKE VALVE

10

9
8
7
6
5
4
3 11
2
1
15

16
17
12
18 13
14
W1LA-03-02-009

1- Plug (2 Used) 6- O-Ring (2 Used) 11 - Choke 16 - Spring

2- O-Ring (2 Used) 7- Spring (2 Used) 12 - Shuttle 17 - O-Ring (2 Used)
3- Spring (2 Used) 8- Check Valve (2 Used) 13 - O-Ring (2 Used) 18 - Plug (2 Used)
4- Spring Seat (2 Used) 9- Spool 14 - Plug (2 Used)
5- Spool (2 Used) 10 - Body 15 - Spool

W3-2-18
 UNDERCARRIAGE / Travel Device
Disassemble Brake Valve

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) before
disassembling.
• This indicates the procedure after the brake valve
is removed.

IMPORTANT: The brake valve need not be

disassembled. Replace it with an
assembly including spring pin (20).

NOTE: As for bearing (19) and spring pin (20),

refer to W3-2-12.

IMPORTANT: When clamping body (10) with an

aluminum plate in a vice to prevent it
from being damaged.
1. Clamp body (10) in a vice with the travel motor
side upward.

2. Remove plugs (1) (2 used) and springs (3) (2

used) from the both sides of body (10).
: 36 mm

IMPORTANT: When pulling out spool assembly (5

to 9), take care not to drop off spring
seat (4).
3. Pull spool assembly (5 to 9) out of the both sides
of body(10) straight. Remove spring seats (4) (2
used) from the spool.

4. Remove plugs (18) (2 used) from the both sides

of body (10). Pull out spool (15) straight. Remove
spring (16) from the spool.
: 8 mm

5. Remove plugs (14) (2 used) and shuttle (12) from

the both sides of body (10).
: 5 mm

W3-2-19
 UNDERCARRIAGE / Travel Device
ASSEMBLE BRAKE VALVE

1 2 7 6 5 8 9 10 4 3

14 13 12 16 15 17 18
W574-03-02-003

1- Plug (2 Used) 6- O-Ring (2 Used) 11 - *Choke 16 - Spring

2- O-Ring (2 Used) 7- Spring (2 Used) 12 - Shuttle 17 - O-Ring (2 Used)
3- Spring (2 Used) 8- Check Valve (2 Used) 13 - O-Ring (2 Used) 18 - Plug (2 Used)
4- Spring Seat (2 Used) 9- Spool 14 - Plug (2 Used)
5- Spool (2 Used) 10 - Body 15 - Spool

NOTE: As for the item with a mark “*”, refer to W3-

2-18.

W3-2-20
 UNDERCARRIAGE / Travel Device
Assemble Brake Valve

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) before assembling.

IMPORTANT: Apply hydraulic oil onto the

surfaces on shuttle (12), spool (15),
and spool (9) before installing them.
1. Insert shuttle (12) into body (10). Install O-rings
(13) (2 used) to plugs (14) (2 used). Install plug
(14) on the both sides of body (10).
: 5 mm
: 11.5 to 21.5 N⋅m
(1.2 to 2.2 kgf⋅m, 8.4 to 16 lbf⋅ft)

2. Install spring (16) into spool (15). Install O-rings

(17) (2 used) to plugs (18) (2 used). Install plug
(18) on the both sides of body (10).
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 38 lbf⋅ft)

3. Install O-rings (2) (2 used) to plugs (1) (2 used).

Install spool (9) assembly (4 to 9) into body (10).
Install spring seats (4) (2 used), springs (3) (2
used), and plugs (1) (2 used) on the both sides of
body (10).
: 36 mm
: 167 to 195 N⋅m
(17 to 20 kgf⋅m, 123 to 144 lbf⋅ft)

W3-2-21
 UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL REDUCTION
GEAR (ZAXIS30u､35u) 15
16
14
7 13
6 12
5 11
10
1
2 8
3 9
4

27
30 17
26
29 18 36 37
19
28
25 35
31
32 24
33 23 22
34 21
20

56
38 55
39 54
40 53
41 52
51
42 50 57
43 49 58
44 48
45
46
59
47 60
61

62

72
63 71
70
69
68
67
66
65
64

W1LA-03-02-010
1 - Plug (2 Used) 19 - Spool 37 - Plug 55 - Thrust Plate
2 - O-Ring (2 Used) 20 - Plug 38 - Spring (2 Used) 56 - Screw (4 Used)
3 - Spring (2 Used) 21 - O-Ring (2 Used) 39 - Control Piston (2 Used) 57 - Plug (3 Used)
4 - Spring Seat (2 Used) 22 - Spring 40 - O-Ring 58 - O-Ring (3 Used)
5 - Plug (2 Used) 23 - Spool 41 - Oil Seal 59 - First Stage Planetary Gear
(3 Used)
6- Plug 24 - Plug (2 Used) 42 - Ball Bearing 60 - Needle Bearing (3 Used)
7- Plug (2 Used) 25 - O-Ring (2 Used) 43 - Shaft 61 - Inner Race (3 Used)
8- Pin (2 Used) 26 - Adapter 44 - Swash Plate 62 - Plug (2 Used)
9- Bearing 27 - Socket Bolt (6 Used) 45 - Plunger (9 Used) 63 - Steel Ball (132 Used)
10 - Valve Plate 28 - O-Ring (3 Used) 46 - Retainer 64 - Ring Gear
11 - Retaining Ring 29 - Body 47 - Holder 65 - Sun Gear
12 - Washer 30 - Socket Bolt (3 Used) 48 - Floating Seal 66 - Retaining
13 - Spring 31 - Check Valve 49 - Bearing 67 - Ring
14 - Spring Seat 32 - Spring 50 - Bearing Nut 68 - First Stage Carrier
15 - Rotor 33 - O-Ring 51 - Thrust Washer (4 Used) 69 - Dive Gear
16 - Pin (3 Used) 34 - Plug 52 - Inner Race 70 - Wire
17 - O-Ring (3 Used) 35 - Steel Ball (2 Used) 53 - Needle Bearing (4 Used) 71 - O-Ring
18 - Valve Body 36 - Body 54 - Second Stage Planetary 72 - Cover
Gear (4 Used)

W3-2-22
 UNDERCARRIAGE / Travel Device
Disassemble Travel Reduction Gear (ZAXIS30u,
35u) CAUTION: Always hold washer (12) and
spring (13) with a press when removing re-
• Read PRECAUTIONS FOR DISASSEMBLING taining ring (11). If retaining ring (11) is re-
AND ASSEMBLING (W1-1-1) carefully before moved without holding washer (12) and
disassembling. spring (13), washer (12) and spring (13) may
fly out potentially causing serious injury.
IMPORTANT: When removing socket bolts(27)(6
used), valve body(18) is floated by
the reacting force of spring(13). At 6. Remove retaining ring (11) from rotor (15), then
this time record the clearance be- remove washer (12), spring (13) and spring seat
tween valve body(18) and body(36) (14).
or between the valve body(18) flange
part and body(36) end for assem- 7. Install eyebolts (M10, pitch: 1.5) into socket bolt
bling. (27) mounting hole on body (36), then hoist body
(36) by crane to turn it over on a wooden block
IMPORTANT: Valve plate (10) may stick to valve (50 mm × 40 mm).
body (18). Take care not to drop
valve plate (10) when removing
valve body (18). 8. Remove plugs (57) (3 used) from cover (72), and
plugs (62) (2 used) from ring gear (64).
: 5 mm [Plug (62)]
CAUTION: Travel device weight: 6 mm [Plug (57)]
ZAXIS27u: 36 kg(79 lb)
ZAXIS30u, 35u: 35 kg(77 lb)
9. Install eyebolts (PF1/4) (2 used) into the plug (57)
1. Removes socket bolts (27) (6 used) to remove mounting holes on cover (72), then insert an steel
valve body (18) and valve plate (10). pipe into the holes on the eyebolts.
: 8 mm

10. While turning cover (72) with an steel pipe, re-

2. Remove pins (8) (2 used) and O-rings (17) (3 move wire (70) from the plug (62) mounting hole
used) from valve body (18). of ring gear (64).

3. Remove O-ring (40) from body (36).

NOTE: Turn cover (72) until wire (70) is seen from
the plug (62) mounting hole. After that pull
4. Remove rotor (15) assembly, swash plate (44), wire (70) out of the hole.
steel balls (35) (2 used), control pistons (39) (2
used) and springs (38) (2 used) from body (36).

5. Remove plungers (45) (9 used), retainer (46),

holder (47) and pins (16) (3 used) from rotor (15).

W3-2-23
UNDERCARRIAGE / Travel Device

37
36

56
55
54
53
41 52
51
42 50
43 49
48

59
60
61

62

72
63 71

69
68
67

65
64

W1LA-03-02-010
Sprocket
Mounting Hole

W3-2-24
 UNDERCARRIAGE / Travel Device
11. Move an eyebolt on cover (72). Hoist to remove IMPORTANT: Attach a bar to shaft (43) assembly.
cover (72) from ring gear (64) by crane. While tapping the end of the bar with
a plastic hammer, remove it. Do not
remove ball bearing (42) unless re-
12. Remove O-ring (71) from cover (72). placement is required.
18. Remove shaft (43) assembly from body (36).

13. Remove thrust plate (69), drive gear (68), first

stage carrier (67) assembly and sun gear (65)
from ring gear (64). 19. Remove plug (37) from bearing nut (50).
: 6 mm

14. Remove first stage planetary gears (59) (3 used),

needle bearings (60) (3 used) and inner races 20. Clamp body (36) in a vise, then remove bearing
(61) (3 used) from first stage carrier (67). nut (50).

15. Remove screws (56) (4 used), thrust plate (55), IMPORTANT: Attach a bar to bearing (49). While
second stage planetary gears (54) (4 used), nee- tapping the end of the bar with a
dle bearings (53) (4 used), inner races (52) (4 hammer, remove it. Replace bearing
used) and thrust washers (51) (4 used) from body (49) with a new one if disassembled.
(36). 21. Remove bearing (49) from body (36).

16. Remove steel balls (132 used) from the plug (62) 22. Remove floating seal (48) from body (36).
mounting hole.

NOTE: Refer to W1-1-4 for precautions for han-

17. Install bolts (M12.pitch: 1.75) (2 or 3 used). dling the floating seal.
Tighten them to remove body (36) from ring gear
(64).
: 19 mm 23. Remove oil seal (41) from body (36).

64

Plate

Wooden
36
Block Wooden Block

W1LA-03-02-011

W3-2-25
 UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL REDUCTION
GEAR (ZAXIS30u､35u)

70 65 66 67 53 52 51 50 38 63 49 39 48 46 36 47 16 15 8 9

69
68

58

57

72

61

11

60 10

71 27

40
62
59
W1LA-03-02-012

56 55 54 41 37 42 64 62 43 44 45 14 13 12 18

1 - Plug (2 Used) 19 - Spool 37 - Plug 55 - Thrust Plate

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

W3-2-26
 UNDERCARRIAGE / Travel Device

19 4 3

1
20

26

23 22 21 W1LA-03-02-002

30 31 32 33

34

29

W1LA-03-02-003

W3-2-27
 UNDERCARRIAGE / Travel Device

70 65 66 67 53 52 51 50 38 63 49 39 48 46 36 47 16 15 8 9

69
68

58

57

72

61

11

60 10

71 27

40
62
59
W1LA-03-02-012

56 55 54 41 37 42 64 62 43 44 45 14 13 12 18

W3-2-28
 UNDERCARRIAGE / Travel Device
Assemble Travel Reduction Gear (ZAXIS30u, 35u) 8. Install sun gear (65) into ring gear (64).

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before as- 9. Install first stage carrier (67) onto sun gear (65).
sembling.

1. Install oil seal (41) into body (36). 10. Install inner races (61) (3 used), needle bearings
(60) (3 used) and first stage planetary gears (59)
(3 used) onto first stage carrier (67) in this order.
2. Install floating seal (48) into body (36).

11. Install drive gear (68) into ring gear (64).

NOTE: Refer to W1-1-4 for precautions for han-
dling the floating seal.
12. Install thrust plate (69) onto first stage carrier
(67).
3. Drive in bearing (49) into body (36), then tighten
bearing nut (50) using special tool (ST3313).
13. Install O-ring (71) onto cover (72).

: 2±0.1 N⋅m (20±1 kgf⋅m, 144±7.2 lbf⋅ft)

14. Install cover (72) onto ring gear (64).

4. Install plug (37) to bearing nut (50).

: 6 mm
: 14.7 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft) 15. Install eyebolts (PF1/4) (2 used) into the plug (57)
mounting hole on cover (72), then insert an steel
5. Install ring gear (64) into body (36) while tapping pipe into the holes of eyebolts.
the ring gear with a plastic hammer.

IMPORTANT: Wrap plug (62) with a seal tape.

IMPORTANT: Wrap plug (62) with a seal tape. 16. Bend wire (70) 90°at approximately 6 mm (0.24
6. Insert steel balls (63) (132 used) into the plug (62) in) from its tip, then insert it into the plug (62)
mounting hole, then tighten plug (62). mounting hole.
: 5 mm While turning cover (72) with an steel pipe, wind
: 7.9±1 N⋅m up wire (70).
(0.8±0.1 kgf⋅m, 5.8±0.7 lbf⋅ft)

17. Install plugs (62) (2 used) to ring gear (64).

IMPORTANT: Apply LOCTITE #262 to screw (56).
7. Install thrust washers (51) (4 used), inner races
(52) (4 used), needle bearings (53) (4 used), sec- 18. Drive in shaft (43) assembly into body (36) with a
ond stage planetary gears (54) (4 used) and plastic hammer.
thrust plate (55) into body (36) in this order, then
tighten them with screws (56) (4 used).
: 6.1±2 N⋅m 19. Install steel balls (35) (2 used), springs (38) (2
(0.62±0.2 kgf⋅m, 4.5±1.4 lbf⋅ft) used), control pistons (39) (2 used) and swash
plate (44) into body (36).

20. Install spring seat (14), spring (13) and washer

(12) into rotor (15) in this order.

W3-2-29
 UNDERCARRIAGE / Travel Device

46 36 47 16 15 8

57

72

11

10

27

40

W1LA-03-02-012

45 13 12 18

W3-2-30
 UNDERCARRIAGE / Travel Device
21. Press washer (12) and spring (13) with a press,
then install retaining ring (11).

22. Install pins (16) (3 used) into rotor (15), then in-
stall holder (47) on pins (16).

23. Install plungers (45) (9 used) and retainer (46)

assembly into rotor (15).

24. Install rotor (15) assembly into body (36).

25. Install O-ring (40) and pins (8) (2 used) into body
(36).

IMPORTANT: Apply grease to the contacting sur-

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

IMPORTANT: When installing valve body (18) on

body (36), check if the clearance be-
tween them is equal to that recorded
when disassembling.
If not, disassemble and assembled
again because they may not be in-
stalled correctly.
27. Install valve body (18) on body (36), then tighten
socket bolts (27) (6 used).
: 8 mm
: 64±4.9 N⋅m
(6.5±0.5 kgf⋅m, 47±3.7 lbf⋅ft)

28. Pour in 0.5 litter (0.52 US qt) of gear oil from the
plug (57) mounting hole on cover (72), then
tighten plug (57).

: 6 mm
: 34±4.9 N⋅m
(3.5±0.5 kgf⋅m, 25±3.7 lbf⋅ft)

NOTE: IDEMITSU APOLLO OIL 21

GEAR 4-90 or equivalent

W3-2-31
 UNDERCARRIAGE / Travel Device
DISASSEMBLE AND ASSEMBLE BRAKE
VALVE (ZAXIS30u、35u)

19 4 3

18

1
20

26

23 22 21 W1LA-03-02-002

30 31 32 33

34

29

W1LA-03-02-003
1- Plug (2 Used) 19 - Spool 23 - Spool 31 - Check Valve
2- O-Ring (2 Used) 20 - Plug 26 - Adapter 32 - Spring
3- Spring (2 Used) 21 - O-Ring (2 Used) 29 - Body 33 - O-Ring
4- Spring Seat (2 Used) 22 - Spring 30 - Socket Bolt (3 Used) 34 - Plug
18 - Valve Body

W3-2-32
 UNDERCARRIAGE / Travel Device
Disassemble Assemble

1. Remove plug (34), spring (32), and check valve 1. Install spool (19), spring(seats (4) (2 sued), and
(31) from body (29). springs (3) (2 used) to valve body (18) with plug
: 8 mm (1).
: 36 mm
: 240±5.0 N⋅m
2. Remove socket bolts (30) (3 used) to remove (24.5±0.5kgf⋅m, 177±3.7 lbf⋅ft)
body (29) from valve body (18).
: 8 mm
2. Install adapter (26) to valve body (18).
: 27 mm
3. Remove plug (20) and spring (22) from valve : 53.9±4.9 N⋅m
body (18). (5.5±0.5kgf⋅m, 40±3.7 lbf⋅ft)
: 8 mm
3. Install spool (23) and spring (22) to valve body
4. Remove adapter (26) and spool (23) from valve (18) with plug (20).
body (18). : 8 mm
: 27 mm : 54±4.9 N⋅m
(5.5±0.5kgf⋅m, 40±3.7 lbf⋅ft)

5. Remove plugs (1) (2 used) from valve body (18)

to remove springs (3) (2 used). 4. Install body (29) to valve body (18) with socket
: 36 mm bolts (30) (3 used).
: 8 mm
: 36.9±1.9 N⋅m
IMPORTANT: Spool (19) assembly cannot be dis- (4.0±0.2kgf⋅m, 27±1.4 lbf⋅ft)
assembled. When pulling out the
spool assembly, take care not to
drop off spring seats (4) (2 used). 5. Install check valve (31) and spring (32) to body
6. Pull out spool (19) assembly in valve body (18) (29) with plug (34).
straight. Remove spring seats (4) (2 used) from : 8 mm
spool (19). : 53.9±4.9 N⋅m
(5.5±0.5kgf⋅m, 40±3.7 lbf⋅ft)

W3-2-33
 UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARDS
Travel Motor

1. The clearance between the plunger diameter and

rotor bore diameter Rotor

(D-d): 0.04 mm (0.00157 in) or less.

D d

W507-02-04-009
Plunger

2. The clearance between the plunger and the shoe

δ: 0.4 mm (0.0157 in) or less.

δ

W107-02-06-140

3. The wear amount of the plunger at its sliding sur- W107-02-06-141

face against the valve plate of the rotor
Make sure that there are no damage, wear, or
seizure.
Damage or wear amount: 0.02 mm (0.000787 in)
or less.

4. The wear amount of the plunger at its sliding sur-

face against the rotor of the valve plate.
Make sure that there are no damage, wear, or
seizure.
Damage or wear amount: 0.02 mm (0.000787 in)
or less.

W3-2-34
 UNDERCARRIAGE / Travel Device

Sprocket

D C B

W503-03-02-004

27u Unit: mm
Allowable
Dimension Standard Remedy
Limit
A 28.5 22.5
B 293.0 287.0
C PCD328.8 - Replace
D 337.5 331.5
E 101.6 -

30u, 35u Unit: mm

Allowable
Dimension Standard Remedy
Limit
A 28.5 22.5
B 309.0 303.0
C PCD344.7 - Replace
D 352.0 346.0
E 101.6 -

NOTE: 1 mm = 0.03937 in

W3-2-35
 UNDERCARRIAGE / Travel Device
（Blank）

W3-2-36
 UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
2
Removal

IMPORTANT: Be sure to release any pressure in

the hydraulic oil tank before any
work. (Refer to W1-4-1.) 1

CAUTION: Canopy weight : 32 kg (71 lb)

1. Attach sling belt (2) onto canopy (1) to hoist it by
crane.

W1LD-02-01-001

2. Loosen screw (3) to remove cover (4).

4 W1LD-02-01-002
3
3. Remove bolt (5) to hoist and remove canopy (1).
1
: 24 mm

5
W1LD-02-01-003

W3-3-1
 UNDERCARRIAGE / Center Joint
4. Remove bolts (6) (6 used) and (8) (4 used) to re-
move covers (5, 7). 8 7
: 13 mm, 17 mm
6

5. Remove bolts (10) (5 used) and (11) (3 used) to

remove covers (9, 12). 9
: 13 mm 5

10

IMPORTANT: Attach the identification tag onto the

11 14
disconnected hoses for assembling.
12
6. Disconnect all the pilot pipes and connectors. At-
tach a cap onto the open ends.
13 W1LA-02-05-001

CAUTION: Floor plate (13) + seat weight :

95 kg (209 lb)
15
7. Remove bolts (14) (6 used). Attach a rope onto
16
the seat and hoist it by crane to remove floor plate
(13) with the seat.
: 13 mm

8. Remove undercover mounting bolts (16) (3 used) W554-03-03-002

17
to remove undercover (15).
: 19 mm

9. Disconnect hoses (17) (4 used) and hoses (18) (6

used) on the spindle side. Attach a cap onto the
open ends.
: 19 mm, 22 mm

18 18

W507-03-03-004

CAUTION: Center joint weight : 16.8 kg 20 21

(37 lb)

10. Disconnect hoses (20) (7 used) and hose (21) on 20

the body side in center joint (19). Attach a cap
onto the open ends.
: 19 mm, 22 mm
19

W507-03-03-001

W3-3-2
 UNDERCARRIAGE / Center Joint
11. Remove mounting bolts (23) (2 used) to remove
to remove stopper (22).
: 19 mm

22
23

19

W1LA-02-05-002

CAUTION: Center joint weight : 16.8 kg

(37lb)
24
12. Remove center joint (19) mounting bolts (24) (4
used) to hoist and remove center joint (19) by
crane.
: 17 mm

W571-03-03-001

W3-3-3
 UNDERCARRIAGE / Center Joint
Installation

CAUTION: Center joint weight: 16.8 kg (37

lb)

1. Install center joint (19) with bolts (24) (4 used). 24

: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W571-03-03-001
17
2. Connect hoses (17) (4 used) and hoses (18) (6
used) to the spindle.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

18 18

W507-03-03-004

3. Install undercover (15) with mounting bolts (16) (3

used).
15
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 16

W554-03-03-002

4. Install stopper (22) to center joint (19) with mount-

ing bolts (23) (2 used).
: 19 mm 22
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
23

19

W1LA-02-05-002

W3-3-4
 UNDERCARRIAGE / Center Joint
5. Connect hoses (20) (7 used) and hose (21) to the
body side.
: 19 mm 20 21
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 20

19

W507-03-03-001

CAUTION: Floor plate (13) assembly weight : 8 7

95 kg (209 lb)
6

6. Hoist floor plate (13) assembly with the seat by

crane to install them onto the upperstructure with 9
bolts (14) (6 used). 5
: 13 mm 10
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

7. Connect the pilot hoses and connectors to floor 11 14

plate (13).
12
8. Install covers (12, 9) with bolts (11) (3 used) and
(10) (5 used). 13 W1LA-02-05-001
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W3-3-5
 UNDERCARRIAGE / Center Joint

8 7
9. Install covers (5, 7) with bolts (6) (6 used) and (8)
(4 used). 6
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
: 17 mm 5
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W1LA-02-05-001

10. Attach sling belt (2) onto canopy (1). Hoist to in-
2
stall canopy (1) onto the frame by crane.

W1LD-02-01-001

1
11. Install canopy (1) with bolts (5) (2 used).
: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W1LD-02-01-003

12. Install cover (4) with screws (3) (2 used).

4
3 W1LD-02-01-002

W3-3-6
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-7
 UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT

12 6

11

10

W565-03-03-001

1 - Bolt 4 - O-Ring 7 - Oil Seal (7 used) 10 - Dust Seal

2 - Cover 5 - Thrust Washer 8 - O-Ring 11 - Spindle
3 - Retaining Ring 6 - Body 9 - Backup Ring

W3-3-8
 UNDERCARRIAGE / Center Joint
Disassemble Center Joint
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before
disassembling.

CAUTION: Center assembly weight: 16.8 kg

(37 lb)

1. Clamp the center joint in a vise.

2. Remove bolts (1) (4 used) from body (6) to re-

move cover (2).
: 13 mm
1
3. Remove O-ring (4), retaining ring (3) and thrust
washer (5) from body (6).
6
4. Install a center joint puller onto body (6) with bolts
(1) (2 used).
: 13 mm

5. Remove body (6) from spindle (11) with a puller. W506-03-03-002

IMPORTANT: Take care not to damage the seal

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

6. Remove oil seals (7) (7 used) from body (6).

IMPORTANT: Use two pins to easily remove oil

seals (7). Take care not to damage
the seal groove with the pins.

7. Remove dust seal (10), backup ring (9) and O-

ring (8) from body (6).
W105-03-03-01

W3-3-9
 UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT

11

10

12

W565-03-03-002

1 - Bolt 4 - O-Ring 7 - Oil Seal (7 used) 10 - Dust Seal

2 - Cover 5 - Thrust Washer 8 - O-Ring 11 - Spindle
3 - Retaining Ring 6 - Body 9 - Backup Ring

W3-3-10
 UNDERCARRIAGE / Center Joint
Assemble Center Joint
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before
disassembling.

IMPORTANT: Before installing kinds of seals into

the seating grooves, coat the seals
with grease or hydraulic oil. After
installing O-ring (8), dust seal (10),
and oil seals (7), coat the lips of
them with grease.

CAUTION: Center joint assembly weight:

16.8 kg (37 lb)

1. Install O-ring (8), backup ring (9), dust seal (10)

and oil seals (7) (7 used) onto body (6).

IMPORTANT: Align the alignment marks when in-

stalling body (6).

2. Place spindle (11) on a work bench, then install

body (6) onto spindle (11).

IMPORTANT: Install body (6) from the upward po-

sition. Push spindle (11) into body
(6) slowly. If spindle (11) is rapidly
pushed in, the seal may be dam-
aged.

3. Install spindle (11) while tapping the outside of

body (6) with a plastic hammer.

4. Install thrust washer (5) onto body (6).

IMPORTANT: Install retaining ring (3) with the

chamfered corner downward. Con-
firm that retaining ring (3) is cor-
rectly seated.

5. Install retaining ring (3) onto spindle (11), then in-

stall O-ring (4) into body (6).

6. Secure cover (2) to body (6) with bolts (1) (4

used).
: 13 mm
: 10.8 N⋅m (1.1 kgf⋅m, 8.0 lbf⋅ft)

W3-3-11
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-12
 UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK
ADJUSTER

CAUTION: Track adjuster weight:

8.5 kg (19 lb) (ZAXIS27u)
12 kg (26 lb) (ZAXIS30u, 35u)

Before removing the track adjuster, the tracks and the

front idler must be removed first. As for removal and
installation of the track and the front idler, refer to
applicable removal and installation sections (W3-7-1)
for tracks and (W3-5-1) for front idler.
In this section, the procedure starts on the premise
2
that the tracks and front idler have already been
removed.

Removal

1. Remove track adjuster (1) from track frame (2).

W507-03-04-001

Installation

IMPORTANT: Be sure that track adjuster (1) does

not cone in touch with spring guide
(3) in track frame (2). Be sure that
track adjuster (1) can be inserted
into plate (4).
1. Install track adjuster (1) to track frame (2) as
illustrated. 3

W507-03-04-002

W507-03-04-003

W3-4-1
 UNDERCARRIAGE / Track Adjuster
DISASSEMBLE TRACK ADJUSTER

2
3

9
10
11

12

13
14
15 W577-03-04-001

1- Valve 5- Spring 9- Retaining Ring 13 - Flange

2- Nut 6- O-Ring 10 - U-Ring 14 - Dust Seal
3- Plug 7- Cylinder 11 - Wear Ring 15 - Socket Bolt (3 Used)
4- Washer 8- Rod 12 - Piston Rod

W3-4-2
 UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
• Be sure to read "precautions for Disassembly and 3. Attach the wire rope to the track adjuster. Hoist it
Assembly" thoroughly on page W1-1-1 before by crane and set it to the special tool cradle.
disassembling.
Track Adjuster

CAUTION: Be sure to use special tool (ST

4943) for assembly / disassembly of the track
adjuster.
As the spring force of the track adjuster is
extremely large, carry out the disassembly
and assembly work carefully. Inspect the tool
for any damage thoroughly.
Cradle
CAUTION: Special tool weight: 225 kg
(496 lb)
1. Place a jack (30 ton) between the cradle and the
base of special tool (ST 4943).
W105-03-04-009

Nut
4. Place the plate (ST 4140) on special tool (ST
4943) such as covering the track adjuster.

Plate (ST 4140)

Cradle

Oil Jack

Track Adjuster

Base
W105-03-04-006

CAUTION: Plate (ST 4140) weight: 36 kg W105-03-04-011

(79 lb) 5. Operate the jack up to the cradle by the specified

2. Loosen nuts (4 used) to remove plate (ST 4140). amount (64 mm) (2.5 in).
: 46 mm NOTE: Specified amount
(Spring free length: 255 mm )
– (Spring set length: 191 mm) =64 mm (2.5 in)
Cradle
Plate (ST 4140)

Oil Jack

W105-03-04-013
W105-03-04-007

W3-4-3
 UNDERCARRIAGE / Track Adjuster

2
3

W577-03-04-001

W3-4-4
 UNDERCARRIAGE / Track Adjuster
IMPORTANT: Loosen and remove valve (1) slowly
because of the pressure of cylinder CAUTION: Plate (ST 4140) weight: 36 kg (79
(7). lb)
6. Remove valve (1) from rod (8). When removing the nut and plate (ST 4140),
: 19 mm be sure to remove it after loosening the oil
jack. Not loosening the oil jack poses a
danger of washer (4) and spring (5) flying off
CAUTION: Plate (ST 4140) weight: 36 kg under the reaction of spring (5).
(79 lb) 9. Remove the nuts (4 used) and the plate (ST
7. Install the nuts (4 used) on the plate (ST 4140), 4140) after loosening the oil jack, and remove
and secure the track adjuster. Operate the oil jack washer (4) from rod (8).
so that the clearance between washer (4) and nut
(2) becomes to about 10 mm.
: 46 mm
Plate (ST 4140)

Nut

4
Plate (ST 4140)
5

W105-03-04-012

W105-03-04-016
8. Remove plug (3), and remove nut (2) from rod
(8).
10. Install eyebolt (M14, pitch: 1.5) to rod (8).
: 5 mm
Remove the spring (5) assembly from special
: 41 mm (ZAXIS27u)
tool.
: 46 mm (ZAXIS30u, 35u)

5
2 8 3

W105-03-04-014

W105-03-04-017

11. Remove spring (5) from cylinder (7).

W3-4-5
 UNDERCARRIAGE / Track Adjuster

9
10
11

12

13
14
15 W577-03-04-001

W3-4-6
 UNDERCARRIAGE / Track Adjuster
12. Remove socket bolts (15) (3 used) from cylinder
(7) to remove flange (13) and dust seal (14).
: 6 mm

13. Remove piston rod (12) from cylinder (7).

14. Remove retaining ring (9), U-ring (10), and wear

ring (11) from piston rod (12).

15. Remove rod (8) and O-ring (6) from cylinder (7).

W3-4-7
 UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER

1 2 4 5 8 9 12 A 15

T577-03-07-002

3 6 7 B 10 11 13 14

1- Valve 5- Spring 9- Retaining Ring 13 - Flange

2- Nut 6- O-Ring 10 - U-Ring 14 - Dust Seal
3- Plug 7- Cylinder 11 - Wear Ring 15 - Socket Bolt (3 Used)
4- Washer 8- Rod 12 - Piston Rod

W3-4-8
 UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
• Be sure to read "precautions for Disassembly and 6. Install spring (5) on cylinder (7), and install the
Assembly" thoroughly on page W1-1-1 before spring assembly on special tool (ST 4944).
starting any repair work.

1. Install O-ring (6) and rod (8) in cylinder (7).

IMPORTANT: Bring the lips of U-ring (10) facing to

the retaining ring (6) side. Apply
hydraulic oil to the U-ring and wear
ring (11).
2. Install wear ring (11), U-ring (10), and retaining ST 4944
ring (9) on piston rod (12).

IMPORTANT: Fill the grease in chamber B of

cylinder (7), and bleed out the air in
the cylinder completely by pushing
the piston rod (12) assembly. Apply
hydraulic oil to the cylinder and
piston rod.
W105-03-04-017
3. Install the piston rod (12) assembly to cylinder (7). 7. Install washer (4) on rod (8).

4. Install eyebolt (M14, pitch: 1.5) to rod (8).

CAUTION: Plate (ST 4140) weight: 36 kg
IMPORTANT: Fill groove A on flange (13) with the (79 lb)
grease. 8. Hoist plate (ST 4140) by crane. Place the plate
5. Install dust seal (14) on flange (13), and install the (ST 4140) on special tool (ST 4943) such as
flange on cylinder (7) with socket bolts (15) (3 covering the track adjuster and fix it with the nuts
used). (4 used).
: 6 mm : 46 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

Plate (ST 4140)

W105-03-04-012

W3-4-9
 UNDERCARRIAGE / Track Adjuster

2 5 8

T577-03-07-002

W3-4-10
 UNDERCARRIAGE / Track Adjuster
9. Operate the oil jack to compress spring (5) until
the specified length is obtained. CAUTION: Plate (ST 4140) weight: 36 kg
Specified length : ZAXIS27u (79 lb)
: 191 mm 11. Loosening the oil jack, remove the nut (4 used) to
: ZAXIS30u, 35u : 198 mm remove the plate (ST 4140).
: 46 mm

Plate (ST 4140)

5

Oil Jack

W105-03-04-011

12. Attach the wire rope to the track adjuster.

Remove the track adjuster from special tool by
W105-03-04-026 crane.

10. Install nut (2) on rod (8), and install plug (3) on the
nut. Track adjuster
: 41 mm (ZAXIS27u)
: 46 mm (ZAXIS30u, 35u)
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

2 8 3

W105-03-04-027

13. Remove the eyebolt from rod (8). Install valve (1).

CAUTION: Special tool weight: 64 kg (141 lb)

W105-03-04-014 14. If only the track adjuster is to be transported, be
sure to use special tool (ST 4944) to carry the
track adjuster safely.
: 24 mm
Track Adjuster

Special Tool (ST 4944)

W105-03-04-028

W3-4-11
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-12
 UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER

Before removing the front idler, the track must be re-

moved first. As for removal and installation of the track,
refer to W3-7-1. Here, the procedure starts on the
premise that the tracks have already been removed.

Removal

CAUTION: Front idler weight:

ZAXIS27u: 23 kg (51 lb)
ZAXIS30u, 35u: 27 kg (60 lb)
W507-03-05-001
CAUTION: The front idler may fly out due to
strong force from the track adjuster spring 1
when removing it. 3
Give yourself ample clearance, staying clear
of the front idler’s line.
1. Insert a bar between front idler (1) and track
frame (3) to pry it out from the track frame with
yoke (2) attached.

IMPORTANT: If it is necessary to remain the front

idler for a while, be sure to place it
2
horizontal on wooden blocks.

W562-03-05-001

Installation
Wooden
Block
IMPORTANT: Clean the sliding portion between
track frame (3) and yoke (2), then
apply the grease on as necessary.
1. Hoist the front idler (1) assembly by crane. Push
yoke (2) in aligning with the sliding surface on
track frame (3).
Tap front idler (1) into track frame (3) completely W105-03-05-003
with a round bar and hammer.
3

Sliding Portion
of Yoke (2)

W507-03-04-003

W3-5-1
 UNDERCARRIAGE / Front Idler
DISASSEMBLE AND ASSEMBLE FRONT
IDLER

4 5 9

W1LA-03-05-001

1 - Axle 4 - Bushing (2 Used) 6 - Yoke (2 Used) 8 - Bolt (4 Used)

2 - Floating Seal (2 Used) 5 - O-Ring (2 Used) 7 - Plate 9 - Spring Pin (2 Used)
3 - Idler

W3-5-2
 UNDERCARRIAGE / Front Idler
Disassemble Front Idler Assemble Front Idler
• Be sure to read “Precautions for Disassembly / • Be sure to read “Precautions for Disassembly /
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before as-
disassembling. sembling.

1. Remove bolts (8) (4 used) and plate (7) from yoke 1. Install bushings (4) (2 used) into idler (3) with a
(2). press.
: 19 mm
2. Install axle (1) to idler (3).
2. Place the front idler horizontally. Remove spring
pin (9) from yoke (6). 3. Install O-ring (5) (2 used) to axle (1).

IMPORTANT: For handling of floating seal (2), re-

fer to the section “Precautions for IMPORTANT: For handling of floating seals (2) (2
Floating Seal Handling” on page used), refer to the section
W1-1-4. “Precautions for Floating Seal Han-
3. Remove yoke (6) and floating seal (2) on the side dling” on page W1-1-4.
removed spring pin (9). Discharge the engine oil 4. Install floating seal (2) and yoke (6) to idler (3).
while inclining idler (3). Install spring pin (9) to the yoke.

4. Turn over the front idler. 5. Place idler (3) with the installed yoke (6) side
Remove spring pin (9), yoke (6) and floating seal downward.
(2) from yoke (6) in opposite side. Apply the engine oil into the idler.
Engine oil: SAE #30 class CD
5. Remove O-rings (5) (2 used) from axle(1). ZAXIS 27u: 30 cm3
ZAXIS 30u, 35u: 45 cm3
6. Remove axle (1) from idler (3) with a press.
6. Install floating seal (2) and yoke (6) to the side
IMPORTANT: Do not remove bushings (4) (2 used) applied the engine oil.
unless necessary. Install spring pin (9) to the yoke.
7. Remove bushing (4) (2 used) from the idler after
contracting it by overlaying four places, 90 de- 7. Installing plate (7) to yokes (6) (2 used) with bolts
grees apart from each others on the bushing bore (8) (4 used).
with the welding rod, as illustrated. : 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
90°

90°

W105-03-05-012

W3-5-3
 UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD

D F

A
B

W503-03-05-001

Unit: mm (in)

Standard Allowable Limit Remedy

A 31 (25)
B 80 -
C 34 / 39 - Cladding by welding
and hand finishing,
D 269 272 or replace
E 10 -
F 307 -
NOTE: ZAXIS27u / 30u, 35u

Axle and Bushing Unit: mm (in)

Standard Allowable Limit Remedy
Axle Outer Dia. 30 / 35 (29.2) / (34.2)
Bushing Inner Dia. 30 / 35 (30.5) / (35.5) Replace
Flange 2.0 (1.5)
Thickness
NOTE: ZAXIS27u / 30u, 35u

NOTE: Dimensions in parentheses [ ] show the

reference values.

Lubricant Oil: Engine oil SAE30 CD class.

Quantity Oil: 30 mL (30 cm3)

W3-5-4
 UNDERCARRIAGE / Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal

CAUTION: Be sure to support the raised

body with wooden block, etc.

1. Jack up the machine as illustrated.

90～110°

CAUTION: The track adjuster is under high

pressure. Do not loosen valve (1) quickly or
M570-07-001
loosen it too much as high pressure grease
in the track adjuster may spurt out. Loosen it
by 1 turn.
1 2
Loosen carefully, keeping body parts and
face away from the valve . Never loosen
grease fitting (2).

IMPORTANT: When gravel or mud is packed be-

tween sprockets and tracks, remove
it before loosening valve (1).
Grease Outlet
2. Loosen track adjuster valve (1) slowly. Discharge
the grease till the space is enough for removing W1F1-03-07-001
lower roller (4) from the track frame.
: 19 mm

3. Tighten valve (1) as the original condition after

loosening the track.
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

4. Remove bolts (3) (2 used) from lower roller (4) to

remove lower roller (4). 3
: 22 mm

M588-07-052

W3-6-1
 UNDERCARRIAGE / Lower Roller
Installation
• The work should be carried out with the track be-
ing jacked up.
1
1. Install lower roller (4) under the track frame with
bolt (3) aligning with their holes.
2

IMPORTANT: Apply LOCTITE #262 on bolts (3) (2

used).
2. Install lower roller (4) with bolts (3) (2 used).
: 22 mm
: 245 N⋅m (25 kgf⋅m, 181 lbf⋅ft)

3
3. Fill the grease through grease fitting (2) to make
the rubber track in tension.

NOTE:The joint part of the rubber track should be

in the center when measure the rubbeer
track tension. At this time turn the track in M588-07-052

reverse direction so that the track sag faces 4

downward.
Track sag specifications (A)
(Rubber track): 10 to 15 mm (0.4 to 0.6 in)

Lower Roller

Rubber Track
M503-05-050
Side a

W567-03-07-007
4. Remove the wooden blocks under the track frame
Joint Part
by jacking up further.

Joint Part

M102-07-075

W3-6-2
 UNDERCARRIAGE / Lower Roller
(Blank)

W3-6-3
 UNDERCARRIAGE / Lower Roller
DISASSEMBLE AND ASSEMBLE LOWER
ROLLER

1 2 3 4 5 6 7

W577-03-06-001

1 - Floating Seal 4 - Axle 6 - Collar 8 - Plug

2 - Roller 5 - Floating Seal 7 - O-Ring 9 - Stopper Ring
3 - Bushing (2 Used)

W3-6-4
 UNDERCARRIAGE / Lower Roller
Disassemble Lower Roller Assemble Lower Roller
• Be sure to read “Precautions for Disassembly / • Be sure to read “Precautions for Disassembly /
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before as-
disassembling. sembling.

1. Remove plug (8) from collar (6) to drain engine oil IMPORTANT: For handling of floating seals (1) and
from the roller. (5), refer to the section ″Precautions
: 5 mm for floating seal handling” on page
W1-1-4.
IMPORTANT: Replace the axle (4) assembly with- 1. Install floating seal (1) to roller (2) and the axle (4)
out disassembly. assembly. Press fit the axle assembly in the roller
2. Remove stopper ring(9) from collar (6). Pull out to the direction of the roller from the side of
the axle (4) assembly from roller (2) to the direc- mounting floating seal with a press.
tion of roller (2) from collar (6) side with a press.
2. Install floating seal (5) to roller (2) and collar (6).
IMPORTANT: For handling of floating seals (1) and
(5), refer to the section ″Precautions 3. Install O-ring (7) to axle (4). Aligning the axle and
for floating seal handling" on page stopper ring (9) fixing the groove of collar (6), in-
W1-1-4. stall the collar and the stopper ring onto the axle.
3. Remove collar(6) from roller (2). Remove floating
seals (1) and (5) from the both sides of roller (2). 4. Supply engine oil 35 cm3 (SAE30, class CD) via
the plug(8) hole on collar (6).
IMPORTANT: Do not remove bushings (3) (2 used)
from roller (2). In case the bushing IMPORTANT: Apply LOCTITE #503 to plug (8).
must be replaced, replace the roller 5. Install plug (8) to collar (6).
assembly. : 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

W3-6-5
 UNDERCARRIAGE / Lower Roller
MAINTENANCE STANDARD

Lower Roller

C D E

B
W577-03-06-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 31 (23)
B 112 - Cladding by
welding and
C 34 - hand finishing,
D 85 77 or replace
E 107 -

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outer Dia. 30.0 (29.2)
Inner Dia. 30.0 (30.5) Replace
Bushing Flange 2.0 (1.5)
Thickness

NOTE: Dimensions in parentheses [ ] show the

reference values.

Lubricant Oil
Engine Oil SAE30 CD class.
Quantity Oil: 35 mL (35 cm3)

W3-6-6
 UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal
CAUTION: Rubber track weight:
ZAXIS27u, 30u: 125 kg (276 lb)
ZAXIS35u: 138 kg (304 lb)

CAUTION: The track adjuster is under high

pressure. Do not loosen valve (1) quickly or 90～110°
loosen it too much since high pressure
grease in the adjuster may spurt out. Loosen
it by 1 turn.
Loosen carefully, keeping body parts and
face away from the valve . Never loosen
M570-07-001
grease fitting (2).

CAUTION: Be sure to support the raised

body with wooden block, etc.
1. Jack up the machine as illustrated.

IMPORTANT: Remove any gravel or mud packed

between sprockets and tracks, 3
before loosening valve (1).
2. Loosen valve (1) of the track adjuster slowly and
discharge grease.
: 19 mm
4

NOTE: Rotate the sprocket with valve (1) Grease Outlet

loosening and removal and installation of W178-03-06-001

the tracks is easy because the tracks are

loosened more.

3. Insert steel pipes into the gaps between the Rotating

rubber track and the track frame. Rotate the Direction
sprocket in reverse direction.
Due to the steel pipes being inserted, the rubber
track is raised off from the front idler. Slide the
rubber track transversely to remove the rubber
track.
Steel Pipe
M503-07-062

W3-7-1
 UNDERCARRIAGE / Track
Installation

CAUTION: Rubber Track weight:

ZAXIS27u, 30u: 125 kg (276 lb) Rotating
ZAXIS35u: 138 kg (304 lb) Direction

CAUTION: Be sure to support the raised

machine with wooden blocks, etc.

1. Jack up the machine with the front attachment.

Steel Pipe
M503-07-062
2. Mesh the sprocket with the rubber track and
install to the front idler.
Rotate the sprocket in reverse direction and press
fit the rubber track.
1
IMPORTANT: Be sure the rubber track is securely
engaged with the sprocket and the
2
front idler.
3. Wind the rubber track with steel pipes in it and
rotate the sprocket in reverse direction to install
the rubber track completely onto the front idler.

4. Secure valve (1).

: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

5. Fill the grease via grease fitting (2) to adjust the M588-07-052

rubber track tension.

NOTE: The joint part of the rubber track should be

in the center when measure the rubber
track tension. Rotate the track in reverse
direction so that the track sag faces
downward.
Track sag specifications (A)
(Rubber track): 10 to 15 mm (0.4 to 0.6 in)

Lower Roller

A W567-03-07-007

Joint Part

Rubber Track
M503-05-050
Side a
Joint Part

M102-07-075

W3-7-2
 UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Outside of Rubber Track
1
4
1. If there is a crack on lug base (1) with depth of 3
mm (0.12 in) or more, repair track.
If there is a crack between lugs (2) with depth of 3 2 5
mm (0.12 in) or more, repair track.
If there is a crack on rugs (3) or between lugs (2)
that reaches to steel code (5) or steel core (4) 3
with length of 30 mm (1.2 in) or more,
immediately repair track.

W190-03-07-001

4
2. Inside of Rubber Track (Roller Side)
If there is a crack that reaches to steel code (5) or
steel core (4), immediately repair track.

5 W190-03-07-002

Lower Roller
Lug Wear
Rubber Track
1. If the lug height (A) is less than 5 mm (0.2 in),
replace the rubber track as an assembly.

Lug W190-03-07-003

2. If any portion of steel code (5) appeared on track,

replace worn rubber track as an assembly.

5
W190-03-07-004

W3-7-3
 UNDERCARRIAGE / Track
Rubber Track and Steel Code Cutting

1. When either of the two rows of the steel code (5)

has cut, replace rubber track as an assembly.

5
W190-03-07-005

Steel Core Separation

1. When any steel core (4) has separated, replace

rubber track as an assembly.

W190-03-07-006

W3-7-4
 MEMO

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 MEMO

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 SECTION 4
FRONT ATTACHMENT

CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment...... W4-1-1
Maintenance Standards..........................W4-1-11

Group 2 Cylinder
Remove and Install Cylinders .................. W4-2-1
Disassemble Boom Cylinder.................. W4-2-18
Assemble Boom Cylinder ...................... W4-2-22
Disassemble Arm Cylinder .................... W4-2-28
Assemble Arm Cylinder ......................... W4-2-33
Disassemble Bucket Cylinder ................ W4-2-36
Assemble Bucket Cylinder..................... W4-2-40
Disassemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-44
Assemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-50
Maintenance Standards......................... W4-2-56

1LAW-4-1
（Blank）

1LAW-4-2
 FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
1 2
IMPORTANT: Be sure to release any pressure in
the hydraulic oil tank before any
work. (Refer to W1-4-1.)

Removal 3

5
CAUTION: Boom cylinder weight:
28 kg (62 lb) (ZAXIS27u)
31 kg (68 lb) (ZAXIS30u) 4
35 kg (77 lb) (ZAXIS35u) W527-04-01-001

1. Remove bolt (5) to remove cover (4).

: 17 mm

7
2. Attach a nylon sling onto boom cylinder (3) to
hold it by crane. Remove bolt (1) from the boom
cylinder. 8
Pull out pin (2).
: 19 mm

3. Operate the boom lever to retract the boom cylin- Boom

W574-04-01-001

der fully. Thread a piece of wire through the rod

hole and tie it to the cylinder tube so that the cyl-
inder rod can not be extended. 6

3
4. Remove bolts (7) (2 used) to remove cover (8).
: 13 mm

IMPORTANT: Attach the identification tag onto the

disconnected hoses for assembling.
W1L7-04-01-001
5. Disconnect hoses (6) (2 used) on the boom side.
Cap each disconnected hose end.
: 22 mm

6. Place the boom cylinder (3) rod side on the sup- Wire
port.

W554-02-03-007

W4-1-1
 FRONT ATTACHMENT / Front Attachment

9
7. Remove plug (10) on the head light. Loosen clips
(9) (4 used) to secure the pipe on back of boom
and the harness on head light. Thread the har-
ness to the boom foot through clips (9) (4 places). 10

IMPORTANT: Attach the identification tag onto the

disconnected hoses for assembling.
8. Disconnect hoses(4 used at rear, 2 used at right
side). Attach a cap onto the disconnected hoses
Boom
and a plug onto the pipes on the boom side.
: 22 mm W1L7-04-02-005

CAUTION: Front attachment weight:

279 kg (615 lb) (ZAXIS 27u)
311 kg (686 lb) (ZAXIS 30u)
354 kg (780 lb) (ZAXIS 35u)

9. Attach a wire onto the boom to hold it at the cen-

ter of gravity.

W507-04-01-004
10. Remove nuts (13) (2 used) to remove bolt (11).
: 17 mm

11. Pull out boom foot pin (12) with a round bar and
hammer.

NOTE: Put the mating marks on the swing post

boss and boom foot pin(12), and it is easy
to align the bolt(11) holes when assem-
bling.

W507-04-01-005

12. Hoist to remove the front attachment by crane. 11

12

13

W1LA-04-02-008

W4-1-2
 FRONT ATTACHMENT / Front Attachment
Installation
11

IMPORTANT: Be sure to insert a shim to the right

12
and left sides in all the pins. In case
adjusting the clearance, insert the
same number of shim to the right 13
and left sides. (Clearance: 0.5 mm or
less)

CAUTION: Front attachment weight:

279 kg (615 lb) (ZAXIS 27u)
311 kg (686 lb) (ZAXIS 30u)
354 kg (780 lb) (ZAXIS 35u)
W1LA-04-02-008

IMPORTANT: Apply the grease on the surface of

boom foot pin (12).
1. Align the boom foot pin (12) holes on the boom
and swing post.
Insert shims between the boom and swing post
on both sides.
Align the bolt (11) hole in boom foot pin (12) with
that in the boss of swing post. Drive the boom foot
pin (12) in with a hammer.
Boom

IMPORTANT: Apply LOCTITE #262 on nuts (13) (2

used).
When installing nuts, clearance 3 to W507-04-01-004

5 mm (0.12 to 0.20 in) should be left Boom

between nuts and the boss of swing
post.
2. Insert bolt (11) and install nuts (13) (2 used).
: 17 mm Bracket
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

3. Connect boom hoses (4 used at rear). Secure

boom hoses (2 used at right) on the bracket.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

W1L7-04-01-001

Harness 9

4. Pass the light harness through clips (9) (4 used). 10

Install plug (10). Secure the light harness and
boom pipes with the clips (4 used).

Boom
W1L7-04-02-005

W4-1-3
 FRONT ATTACHMENT / Front Attachment

CAUTION: Front attachment weight:

279 kg (615 lb) (ZAXIS 27u)
311 kg (686 lb) (ZAXIS 30u)
354 kg (780 lb) (ZAXIS 35u) 7

8
5. Attach a nylon sling onto boom cylinder (3) to
hoist boom cylinder (3) by crane and connect
hoses (6) (2 used) to the boom cylinder.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

6. Install cover (8) with bolts (7) (2 used).

: 13 mm
W574-04-01-001
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
Boom 2
CAUTION: If the air trapped in a cylinder is
suddenly compressed, the temperature in- 6
side will rise as the temperature of the hy-
draulic oil will do. This may cause damage to
the seals and rings. 3

7. Start the engine. Operate the cylinder rod to re-

tract fully to the stroke end. Extend the cylinder
rod slowly to align the boom cylinder rod with the
pin (2) hole .

NOTE: When finishing the work in step 7, release

all air from the cylinder to prevent damag- W1L7-04-01-001

ing the components.

1
8. Drive pin (2) in with a hammer. Install bolt (1) to 2
secure the pin.
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) 3

9. Install cover (4) with bolt (5).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
5
IMPORTANT: Fill the hydraulic oil to the specified
level after installation. Operate every
cylinder fully to the stroke end sev- 4
eral times to release the air from the
circuit and check each connection W527-04-01-001
of hoses for any oil leakage.

W4-1-4
 FRONT ATTACHMENT / Front Attachment
(Blank)

W4-1-5
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARDS
Pin, Bushing
27u

M N

A
C

B
E D P
I K Q
J
O
G

H
W571-04-01-004
W533-04-01-002

Unit: mm

Key Letter Part Name Standard Allowable Limit Remedy

Pin 45 44.0
A
Bushing (Boom) 45 46.5
Pin 40 39.0
B
Bushing (Boom Cylinder) 40 41.5
Pin 40 39.0
C
Bushing (Boom Cylinder) 40 41.5
Pin 45 44.0
D Replace
Bushing (Arm) 45 46.5
Pin 40 39.0
E
Bushing (Arm Cylinder) 40 41.5
Pin 40 39.0
F
Bushing (Arm Cylinder) 40 41.5
Pin 35 34.0
G
Bushing (Bucket Cylinder) 35 36.5

NOTE: 1 mm = 0.03937 in

W4-1-6
 FRONT ATTACHMENT / Front Attachment

Unit: mm

Key Letter Part Name Standard Allowable Limit Remedy

Pin 35 34.0
Bushing (Bucket Cylinder) 35 36.5
H
Bushing 35 36.5
Link B 35 36.5
Pin 35 34.0
I Bushing (Arm) 35 36.5
Link B 35 36.5
Pin 35 34.0
J
Bushing (Link A) 35 36.5
Pin 35 34.0
K
Bushing (Arm) 35 36.5
Pin 71 70.0
L
Bushing (Main Frame) 71 72.5
Pin 40 39.0 Replace
M Bushing
40 41.5
(Boom Swing Cylinder)
Pin 40 39.0
N Bushing
40 41.5
(Boom Swing Cylinder)
Pin 45 44
O
Bushing (Blade) 45 46.5
Pin 45 44.0
P
Bushing (Blade Cylinder) 45 46.5
Pin 45 44.0
Q
Bushing (Blade Cylinder) 45 46.5

NOTE: 1 mm = 0.03937 in

W4-1-7
 FRONT ATTACHMENT / Front Attachment

30u, 35u

M N

A
C

B
E D P
I K Q
J
O
G
H
W571-04-01-004

W533-04-01-002

Unit: mm

Key Letter Part Name Standard Allowable Limit Remedy

Pin 45 44.0
A
Bushing (Boom) 45 46.5
Pin 40 39.0
B
Bushing (Boom Cylinder) 40 41.5
Pin 40 39.0
C
Bushing (Boom Cylinder) 40 41.5
Pin 45 44.0
D Replace
Bushing (Arm) 45 46.5
Pin 40/45 39.0/44.0
E
Bushing (Arm Cylinder) 40/45 41.5/46.5
Pin 40/45 39.0/44.0
F
Bushing (Arm Cylinder) 40/45 41.5/46.5
Pin 40 39.0
G
Bushing (Bucket Cylinder) 40 41.5
NOTE: 30u/35u
NOTE: 1 mm = 0.03937 in

W4-1-8
 FRONT ATTACHMENT / Front Attachment

Unit: mm

Key Letter Part Name Standard Allowable Limit Remedy

Pin 40 39.0
Bushing (Bucket Cylinder) 40 41.5
H
Bushing 40 41.5
Link B 40 41.5
Pin 40 39.0
I Bushing (Arm) 40 41.5
Link B 40 41.5
Pin 40 39.0
J
Bushing (Link A) 40 41.5
Pin 40 39.0
K
Bushing (Arm) 40 41.5
Pin 80 79.0
L
Bushing (Main Frame) 80 81.5
Pin 45 44.0 Replace
M Bushing
45 46.5
(Boom Swing Cylinder)
Pin 45 44.0
N Bushing
45 46.5
(Boom Swing Cylinder)
Pin 45 44.0
O
Bushing (Blade) 45 46.5
Pin 45 44.0
P
Bushing (Blade Cylinder) 45 46.5
Pin 45 44.0
Q
Bushing (Blade Cylinder) 45 46.5

NOTE: 1 mm = 0.03937 in

W4-1-9
 FRONT ATTACHMENT / Front Attachment
Side Cutter

D
A

W505-04-01-001

Unit: mm

Standard Allowable Limit Remedy

A 104 70
B 138 -
Replace
C 153 -
D 90 -

Point

B C

W554-04-01-003
Unit: mm

Standard Allowable Limit Remedy

A 128 65
B 56 -
Replace
C 62 -
D 51 -

NOTE: 1 mm = 0.03937 in

W4-1-10
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

断面 A 断面 B
W1CC-04-01-002

Unit: mm
ZAXIS27u ZAXIS30u ZAXIS35u
a 152 152 152
b 13 13 13
c 244 244 244
d 230 230 230
e 185 185 185
f 634 714 714
g 235 235 235
h 140 140 140
i 35 40 40
j 185 185 185
k 0 0 0
l 235 235 235
m 141 141 141
n 35 40 40
o 90° 90° 90°
p 90° 90° 90°
q 248.2 248.2 248.2
r 166 166 166
NOTE: Dimension h: 140 mm (5.51 in) includes
the clearance for shims to adjust bucket
clearance.
Dimensions O and P: 90° shown in left ta-
ble means the angle for the bolt hole .

W4-1-11
 FRONT ATTACHMENT / Front Attachment
(Blank)

W4-1-12
 FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
1
Remove Bucket Cylinder

CAUTION: Bucket cylinder weight:

16 kg (35 Ib) (ZAXIS27u)
20 kg (44 Ib) (ZAXIS30u, 35u)
1. Insert a wooden block between bucket cylinder
(1) and the arm to support the bucket cylinder. Wooden
Block Arm W571-04-02-001

IMPORTANT: Before Pulling out pin (4), take care 2 3

not to drop off link B. Secure it with
a wire or something.
2. Remove ring (2). Pull out stopper pin (3). Drive
pin (4) out with a hammer and a bar. Remove
shims from both sides of cylinder rod boss.
NOTE: It is easy to align the stopper pin (3) holes
when assembling if matching marks had Link B
been made on the boss of link B and pin
(4).
4 W527-04-02-002

3. Attach a nylon sling onto bucket cylinder (1) to

hold it. Pass a wire or something similar through 1
the rod hole of bucket cylinder (1) to bind the rod.

W571-04-02-002

4. Disconnect hoses (7) (2 used) from bucket cylin-

der (1). Cap the discon-nected hoses.
: 22 mm
5 6
7. Remove bolt (6). Drive pin (5) out with a hammer
and bar. Remove the shim from both sides of the 1
cylinder tube boss.
: 19 mm

6. Remove bucket cylinder (1) from the arm.

W1L7-04-02-005

7 Arm

W4-2-1
 FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder

IMPORTANT: Be sure to insert one shim to both

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

IMPORTANT: Apply the grease on the lip of the

dust seal for bucket cylinder (1) and
boss side (both bottom and rod
sides).
1. Align both the pin (5) holes in the bucket cylinder 5 6
(1) bottom side and the arm. Insert shims to both
sides of the cylinder tube boss.
1

2. Drive pin (5) in with a hammer and a bar and

install bolt (6).
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W1L7-04-02-005

3. Connect hoses (7) (2 used) to bucket cylinder (1). 7 アーム

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

CAUTION: If the air trapped in a cylinder is

suddenly compressed, the temperature in-
side will rise as the temperature of hydraulic
oil will do. This may cause damage to the
seals and rings.
4. Start the engine. Operate the cylinder rod to Cylinder Rod
retract fully to the stroke end. Let the clean
hydraulic oil flow into the bucket cylinder (1) rod
side. Extending the cylinder (1) rod slowly, align
the pin (4) holes both in the bucket cylinder rod
and link B.
NOTE: When the work in step 4 has been carried Link B
out, almost all air in the cylinder has been
released.

4 W527-04-02-002

W4-2-2
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Align the stopper pin (3) holes in the
link B boss and in pin (4). 2
3
5. Insert the shims to both sides of the cylinder rod
boss. Drive pin (4) in with a hammer.

Link B

4 W527-04-02-002

6. Install stopper pin (3) and ring (2).

IMPORTANT: Fill the hydraulic oil to the specified

level after installation. Operate every
cylinder fully to the stroke end sev-
eral times to release the air from the
circuit and check each connection
of hoses for any oil leakage.

W4-2-3
 FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1

CAUTION: Arm cylinder weight:

25 kg (55 Ib) (ZAXIS27u)
27 kg (60 Ib) (ZAXIS30u)
35 kg (77 Ib) (ZAXIS35u)
1. Insert wooden blocks between arm cylinder (1)
and the boom to support the arm cylinder.

2. Remove bolt (2). Drive pin (3) out with a hammer

Boom
and bar. Remove the shims from both sides of the Wooden
cylinder rod boss. Block
: 19 mm (ZAXIX27u, 30u) W571-04-02-004
6 7
: 22 mm (ZAXIX35u)
NOTE: If it is difficult to pull pin (3) out, raise the 5
boom a little for pulling it out. 1
4
3. Pass a wire through the rod hole in arm cylinder 3
2
(1) to bind the rod.

8
4. Remove bolt (5). Remove clamp (8). Boom
: 13 mm W1L7-04-02-005

IMPORTANT: Attach identification tags to the dis-

connected hosed for reassembling.
5. Disconnect hoses (4) (2 used) from arm cylinder
(1). Cap the disconnected hoses.
: 22 mm

6. Attach a nylon sling to arm cylinder (1). Hoist and

hold it by crane.

7. Remove bolt (7). Drive pin (6) out with a hammer

and bar. Remove the shims from both sides of the
cylinder tube boss. W577-04-02-008

: 19 mm (ZAXIS27u, 30u)
: 22 mm (ZAXIS35u)

8. Remove arm cylinder (1).

W571-04-02-006

W4-2-4
 FRONT ATTACHMENT / Cylinder
Install Arm Cylinder

IMPORTANT: Be sure to insert one shim to both

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

IMPORTANT: Apply grease on the lip of dust seal

for arm cylinder (3) and on boss side
(both bottom and rod sides).
1. Align both the pin (6) holes of arm cylinder (1) and 6 7
boom. 5
Insert shims to both sides of the cylinder tube
1
boss.
4
2. Drive pin (6) in with a hammer and bar. Install bolt
(7).
ZAXIS27u, 30u
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
ZAXIS35u
8
: 22 mm
Boom
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)
W1L7-04-02-005

3. Connect hoses (4) (2 used) to arm cylinder (1).

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

4. Insert the plane washer into bolt (5). Secure hose

(4) and clamp (8) to the arm cylinder (1) rod with
the bolt.
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W4-2-5
 FRONT ATTACHMENT / Cylinder

CAUTION: If the air trapped in a cylinder is

suddenly compressed, the temperature in-
side will rise as the temperature of the hy-
draulic oil will do. This may cause damage to
the seals and rings.
5. Start the engine. Operate the cylinder rod to re-
tract fully to the stroke end so as to let the clean 1
hydraulic oil flow into the arm cylinder (1) rod.
Slowly extend the cylinder rod. Align the pin (3)
holes both in arm cylinder rod and the arm.
2 3
NOTE: When the work in procedure 5 is finished,
almost all air in the cylinder has been re-
leased.
NOTE: If it is difficult to align the pin (3) holes,
raise the boom a little to align them.
Boom
IMPORTANT: Apply LOCTITE #262 on bolt (2).
6. Insert the shims the both sides of the cylinder rod W1L7-04-02-005
boss. Drive pin (3) in with a hammer and bar and Arm
install bolt (2).
ZAXIS27u, 30u
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
ZAXIS27u, 30u
: 22 mm
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)

IMPORTANT: Fill the hydraulic oil to the specified

level after installation. Operate every
cylinder fully to the stroke end sev-
eral times to release air from the cir-
cuit and check each connection of
hoses for any oil leakage.

W4-2-6
 FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder 1
2

CAUTION: Boom cylinder weight:

28 kg (62 Ib) (ZAXIS 27u) 3
31 kg (68 Ib) (ZAXIS 30u)
35 kg (77 Ib) (ZAXIS 35u)

1. Remove bolt (5) to remove cover (4).

: 17 mm 5

2. Attach a nylon sling to boom cylinder (3) to hoist

and hold it by crane. Remove bolt (1). Drive pin 4
(2) out with a hammer and bar. W527-04-01-001

: 19 mm

3. Remove the shims from both sides of the cylinder

rod boss. Operate the boom lever to retract the
cylinder rod. Pass a wire through the rod hole to
bind the rod.
Wire
IMPORTANT: Attach identification tags to the dis-
connected hoses for reassembling.
4. Disconnect hoses (9) (2 used) from boom cylin-
der (3). Cap the disconnected hoses.
: 22 mm W554-02-03-007

5. Place the boom cylinder (3) rod on a stand. 3 6

6. Remove nuts (8) (2 used) and bolt (6).

: 17 mm

7. Drive pin (7) out with a hammer and bar. Remove 9

shims from both sides of the cylinder tube boss.
NOTE: It is easy to align bolt (6) holes during as-
sembling if matching marks had been
made on the swing post and pin (7) be-
forehand.

8. Hoist and remove boom cylinder (3) by crane.

W1LA-04-02-008
8 7

W4-2-7
 FRONT ATTACHMENT / Cylinder
Install Boom Cylinder

IMPORTANT: Be sure to insert one shim to both

left and right sides of all pins re-
spectively. And when shims should
be used to adjust the clearance, they
should be inserted at both sides re-
3 6
spectively. (Clearance: 0.5 mm (0.02
in) or less).

IMPORTANT: Apply grease on the lip of the dust

seal for boom cylinder (3) and on
9
boss side (both bottom and rod
sides).

IMPORTANT: Apply grease on the surface of pin

(7).
1. Align the pin (7) holes of boom cylinder (3) and
the swing post. Insert the shims to both sides of
the cylinder tube boss.

2. Align the bolt (6) holes of the swing post and pin
(7). Drive the pin in with a hammer and bar.

IMPORTANT: Apply LOCTITE #262 on nuts (8) (2 7 W1LA-04-02-008

8
used).
When installing nuts, clearance of 3
to 5 mm (0.12 to 0.20 in ) should be
left between nuts and the boss of
swing post.
3. Insert bolt (6) and install nuts (8) (2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

4. Hoist boom cylinder (3) by crane and connect

hoses (9) (2 used) to the boom cylinder.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

W4-2-8
 FRONT ATTACHMENT / Cylinder

CAUTION: If the air trapped in a cylinder is

suddenly compressed, the temperature in-
side will rise as the temperature of the hy-
draulic oil will do. This may cause damage to
the seals and rings.
5. Start the engine. Operate the cylinder rod retract-
ing fully to the stroke end so as to let the clean 1
hydraulic oil flow into the boom cylinder (3). 2
Slowly extend the cylinder rod. Align the pin (2)
hole both in boom cylinder rod and the boom.
NOTE: When the work in procedure 5 is finished, 3
almost all air in the cylinder has been re-
leased.

6. Insert the shims into both sides of the cylinder rod 5

boss. Drive pin (2) in with a hammer and a bar.
Install bolt (1).
: 19 mm 4
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) W527-04-01-001

7. Install cover (4) with bolt (5).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

IMPORTANT: Fill the hydraulic oil to the specified

level after installation. Operate every
cylinder fully to the stroke end sev-
eral times to release the air from the
circuit and check each con-nection
of hoses for any oil leakage.

W4-2-9
 FRONT ATTACHMENT / Cylinder
Remove Boom Swing Cylinder
CAUTION: Boom swing cylinder weight:
26 kg (57 Ib) (ZAXIS 27u) 1
32 kg (71 Ib) (ZAXIS 30u, 35u)

1. Remove bolts (2) (4 used) to remove cover (1)

from left side of the machine.
: 13 mm

2. Remove bolts(4) (5 used) and(6) (3 used) to re-

move covers (3, 5).
: 13 mm 2

IMPORTANT : Before removing the fuel tank, W1LA-04-02-006

drain fuel out to make the fuel tank empty.

3. Remove bolts(15) (2 used) to remove cover (14).
: 17 mm

4. Remove bolts (12) and double nuts (13) (2 used)

to remove band (8) from fuel tank (7).
: 17 mm, 19 mm

5. Remove clamps (10) (2 used). Disconnect hoses

(11) (2 used) from the cock.

6. Remove fuel tank (7).

4 5

W1LA-02-05-007
6

7 8

15 14 12、13 10、11 9
W1LA-04-02-007

W4-2-10
 FRONT ATTACHMENT / Cylinder
7. Insert wooden blocks between boom swing cylin-
der (16) and the main frame to support the boom
swing cylinder. Remove nuts (19) (2 used), bolt
(17) and pin (18).
: 17 mm
NOTE: Pin (18) may come off while removing bolt
(17). And it is easy to align bolt (17) holes if 17
matching mark were made on swing post
and pin (18) beforehand.

8. Start the engine. Operate the cylinder rod to re- 19

tract fully to the stroke end. And pass a wire
through the boss of the cylinder rod. Bind the rod 18
to prevent it from stretching.
16
IMPORTANT: Attach identification tags to the dis-
connected hoses for reassembly.
9. Disconnect bottom side hose (21) from the hole in W1LA-04-02-004
under cover (14) and disconnect the rod hose
(20) from the front side.
Cap the disconnected hoses.
: 19 mm

10. Remove bolts(25)(2 used) and plate(24). Pull out 20

pin(22) and spacer(23) to the main frame side. 21
: 19 mm

11. 11.Remove boom swing cylinder(16).

16

W577-04-02-013

22

23

24

25

W1LA-04-02-005

W4-2-11
 FRONT ATTACHMENT / Cylinder
Install Boom Swing Cylinder

IMPORTANT: Apply grease onto the lip of dust

seal for boom swing cylinder (16).
1. Attach a nylon sling to boom swing cylinder (16)
and hoist it by crane.
Put the cylinder tube boss on the main frame. 22
Insert wooden blocks between the boom swing
cylinder and main frame to support the cylinder. 23

16
IMPORTANT: Apply grease on the surface of pin
(22). 24
2. Install spacer (23) to pin (22) and pass them
through the hole. Align the pin (22) holes in boom 25
swing cylinder (16) and the main frame. Install
stopper (24) and secure with bolts (25) (2 used). W1LA-04-02-005

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

3. Connect hose (21) on the bottom of boom swing

cylinder (16). Connect hose (20) on the rod.
: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft)

20
21

16

W577-04-02-013

W4-2-12
 FRONT ATTACHMENT / Cylinder

CAUTION: If the air trapped in a cylinder is

suddenly compressed, the temperature in-
side will rise as the temperature of the hy-
draulic oil will do. This may cause damage to
the seals and rings.
4. Start the engine. Operate the cylinder rod to re-
17
tract fully to the stroke end so as to let the clean
hydraulic oil flow into boom swing cylinder (16).
Slowly extend the cylinder rod. Align pin (8) holes
both in boom swing cylinder rod and the swing 19
post.
NOTE: When the work in procedure 4 is finished,
18
almost all air in the cylinder has been re-
leased.
16

IMPORTANT: Apply the grease on the surface of

pin (18). W1LA-04-02-004
5. Align the bolt (17) holes of swing post and pin
(18). Install pin (18).

IMPORTANT: Apply LOCTITE #262 on nuts (19) (2

used). A clearance 2 to 3 mm (0.08 to
0.12 in) should be left between the
boss of swing post and the nut
when installing the nut.
6. Install bolt (17) and nuts (19) (2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W4-2-13
 FRONT ATTACHMENT / Cylinder
7. Install fuel tank (7) to the main frame.

8. Install bolt (12) and double nuts (13) (2 used) to

band (8) to secure the fuel tank.
: 7 mm 7 8
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

9. Connect hoses (11) (2 used) with clamps (10) (2

used).

10. Install cover (14) with bolts (15) (2 used).

: 17 mm 15 14 12、13 10、11 9
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) W1LA-04-02-007

11. 11.Install covers (3, 5) with bolts (4) (5 used) and

(6) (3 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m 15 lbf⋅ft)

12. 12.Install cover (1) with bolts (2) (4 used).

: 13 mm
: 20 N⋅m (2 kgf⋅m 15 lbf⋅ft)
4 5
IMPORTANT: Fill the hydraulic oil to the specified 3
level after installation. Operate every
cylinder fully to the stroke end sev-
eral times to release the air from the
circuit and check each connection
of hoses for any oil leakage. 6
W1LA-02-05-007

W1LA-04-02-006

W4-2-14
 FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder

CAUTION: Blade cylinder weight:

19 kg (42 Ib) (ZAXIS27u) 1 2
21 kg (46 Ib) (ZAXIS30u)
24 kg (53 Ib) (ZAXIS35u)
1. Remove bolts (1) (2 used) to remove cover (2).
: 17 mm 3

2. Attach a nylon sling to blade cylinder (3). Hoist 9

and hold it by crane.
8 4
3. Remove bolt (8) to drive pin (9) out with a ham-
mer and bar.
: 22 mm 7

4. Start the engine with the cylinder rod retracting 5

fully to the stroke end. And pass a wire through
6
the boss of the cylinder rod to bind the rod with it.

IMPORTANT: Attach identification tags to the dis-

connected hoses for reassembling.
5. disconnect hose (5) on the bottom side in blade
cylinder (3). Disconnect hose (4) on the rod side.
Attach a cap onto the disconnected hoses. W567-04-02-002
: 22 mm
Blade Track Frame
6. Remove bolt (4) from the blade. Drive pin (7) out
with a hammer and bar.
: 22 mm

7. Remove blade cylinder (3) from the blade.

W4-2-15
 FRONT ATTACHMENT / Cylinder
Install Blade Cylinder

IMPORTANT: Apply grease on the inner surface of

bushing for blade cylinder (3) and on
the lip part of the dust seal (both
bottom and rod sides).

IMPORTANT: Apply grease on the surface of pin

(7).
1. Hoist and hold blade cylinder (3) by crane and
align the pin (7) holes of the blade cylinder and
the blade. 3
Drive pin (7) in with a hammer and bar.
Install bolt (6) and secure the pin.
: 22 mm
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)
4
2. Connect hose (5) to the bottom side of blade
cylinder (3) and connect hose (4) to the rod side.
7
: 22 mm
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft) 5

W567-04-02-002

Blade

W4-2-16
 FRONT ATTACHMENT / Cylinder

CAUTION: If the air trapped in a cylinder is

suddenly compressed, the temperature in-
side will rise as the temperature of the hy-
draulic oil will do. This may cause damage to 1 2
the seals and rings.
3. Start the engine. Operate the cylinder rod to re-
tract fully to the stroke end to let the clean hydrau-
lic oil flow into the blade cylinder (3) rod. Slowly 3
extend the cylinder rod. Align blade cylinder rod
with pin (9) hole in the track frame. 9
NOTE: When finishing the work procedure 3, al-
most all air in the cylinder has been re-
8
leased.

IMPORTANT: Apply grease to the surface of pin

(9).
4. Drive pin (9) in with a hammer and bar.
Install bolt (8) to secure the pin.
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

5. Install cover (2) to blade cylinder (3) with bolts (1)

(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) W567-04-02-002

Blade Track Frame

IMPORTANT: Fill the hydraulic oil to the specified
level after installation. Operate every
cylinder fully to the stroke end sev-
eral times to release the air from the
circuit and check each connection
of hoses for any oil leakage.

W4-2-17
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
Boom Cylinder

1
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
25
24
23
22
21
20
19

18

26

W1LA-04-02-002

1- Piston Rod 8- *Backup Ring 15 - Cushion Ring 21 - Steel Ball

2- Wiper Ring 9- U-Ring 16 - Spacer 22 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 23 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 24 - O-Ring
5- Backup Ring 12 - Retainer 19 - Slide Ring 25 - Slide Ring
6- O-ring 13 - Backup Ring 20 - Piston 26 - Cylinder Tube
7- Bushing 14 - O-Ring
NOTE: The item with a mark * is not equipped for ZAXIS27u.

W4-2-18
 FRONT ATTACHMENT / Cylinder
Disassemble Boom Cylinder

• Be sure to read “Precautions for Disassembly and 3. Loosen cylinder head (3) with a hook wrench and
Assembly” thoroughly on page W1-1-1 before pull piston rod (1) (with protective cover on it) out
starting the disassembly work. of cylinder tube (26).
• The disassembly procedure below starts on the Cylinder head (3) diameter:
premise that the hydraulic line has been re- 90 mm (3.5 in) (ZAXIS27u)
moved. 90 mm (3.5 in) (ZAXIS30u)
95 mm (3.7 in) (ZAXIS35u)
Hook Wrench
CAUTION: Boom Cylinder Weight:
28 kg (62 Ib) (ZAXIS27u)
31 kg (68 Ib) (ZAXIS30u)
35 kg (77 Ib) (ZAXIS35u)
IMPORTANT: When draining hydraulic oil from the
25
cylinder, move piston rod (1) slowly
to prevent the oil from splashing.
1. Clamp the mounting portion (clevis part) of the
cylinder tube (26) pin in a vise and secure it hori-
zontally to drain hydraulic oil from the cylinder. 3

IMPORTANT: The lock washer in cylinder head (3)

is provided on cylinder tube (26) to 1 W506-04-02-004
form an integral part. Take care not
to damage the cylinder tube and cyl-
IMPORTANT: Set screw (22) was crimped with a
inder head (3) when bending and ex-
punch in two places after it was
tending the lock washer.
tightened. Before loosening set
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to
screw, cut away the crimped por-
install a protective cover on the piston rod and
tions.
then let the lock washer in cylinder head (3) bend.
4. Secure piston rod (1) horizontally and remove set
screw (22) and steel ball (21) from piston (20).
: 5 mm (ZAXIS27u)
: 6 mm (ZAXIS30u, 35u)
Lock Washer
5. Remove piston (20) and cushion bearing (18)
from piston rod (1).
: 46 mm (ZAXIS27u)
: 55 mm (ZAXIS30u, 35u)

1 3
W506-04-02-003

W4-2-19
 FRONT ATTACHMENT / Cylinder

17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
25
24
23

20
19

W1LA-04-02-002

W4-2-20
 FRONT ATTACHMENT / Cylinder
6. Wind a tape onto the screw thread of piston rod
(1) to protect the cylinder head (3) seal. Remove
cylinder head (3) from piston rod (1).

IMPORTANT: Slide rings(19, 25) cannot be re-used.

When disassembling the cylinders,
replace them with the new ones.
7. Secure piston (20) in a vise and remove slide
rings(19, 25) from the piston.

IMPORTANT: When removing the seal parts, take

care not to damage piston (20).
8. Insert the screwdriver between piston (20) and
seal ring (23) and raise seal ring (23) up. Cut the
seal ring with a pair of pliers to remove the seal
ring from the piston.

9. Remove stopper (11), connector (10), and re-

tainer (12) from cylinder head (3).

10. Remove backup ring (13) and O-ring (14) from

the outer side on retainer (12).

11. Remove stopper (17), spacer (16), and cushion

ring (15) from the inner side of retainer (12).

12. Remove wiper ring (2), U-Ring (9), and backup

ring (8) from the inner side of cylinder head (3).

NOTE: Backup ring (8) is not equipped for

ZAXIS27u.

13. Remove O-ring (6), backup ring (5), and O-ring

(4) from the outer side of cylinder head (3).

IMPORTANT: Bushing (7) cannot be re-used.

When removing the bushing, be
sure to replace it with the new one.
14. Pull bushing (7) out of the inner side of cylinder
head (3).
NOTE: Insert the screwdriver into the bushing (7)
groove to pull the bushing out.

W4-2-21
 FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
Boom Cylinder

3 4 5 6 13 14 26 24 23 22 21

W1LA-04-02-003
2 7 8 9 10 11 12 15 16 17 1 18 19 20 25

1- Piston Rod 8- *Backup Ring 15 - Cushion Ring 21 - Steel Ball

2- Wiper Ring 9- U-Ring 16 - Spacer 22 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 23 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Ring 24 - O-Ring
5- Backup Ring 12 - Retainer 19 - Slide Ring 25 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Piston 26 - Cylinder Tube
7- Bushing 14 - O-Ring
NOTE: The item with a mark * is not equipped for ZAXIS27u.

W4-2-22
 FRONT ATTACHMENT / Cylinder
Assemble Boom Cylinder IMPORTANT: Take care of the mounting direction
• Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before as- 2. Install backup ring (8) and U-ring (9) to cylinder
sembling. head (3).
NOTE: Backup ring (8) is not equipped for
ZAXIS27u.
CAUTION: Boom cylinder weight:
28 kg (62 Ib) (ZAXIS27u) 3
31 kg (68 Ib) (ZAXIS30u)
35 kg (77 Ib) (ZAXIS35u)
IMPORTANT: Apply hydraulic oil to the inner side
8
of cylinder head (3).
Press bushing (7) until the end of
bushing (7) is flush with the end sur-
face of cylinder head (3).
If not flushing, backup ring (8) or U-
ring (9) will be damaged when in-
stalling backup ring (8) or U-ring (9).

7 W506-04-02-011
3
3. Install wiper ring (2) to cylinder head (3) with spe-
cial tool.
ST 8045 (ZAXIS27u)
Flush the surface
ST 8046 (ZAXIS30u, 35u)

Special
W577-04-02-007 Tool

1. Press bushing (7) into cylinder head (3) with spe-

cial tool.
ST 7277 (ZAXIS27u)
ST 7276 (ZAXIS30u, 35u)
2
ST 7277
W506-04-02-012
ST 7276

7 4. Install O-ring (4), backup ring (5) and O-ring (6) to

the outer side of cylinder head (3).
3

5. Install cushion ring (15), spacer (16) and stopper

(16) to the inner side of retainer (12).
Install O-ring (14) and backup ring (13) to the
outer side of retainer (12).

6. Install retainer (12) assembly, connector (10) and

W506-04-02-010
stopper (11) to cylinder head (3).

W4-2-23
 FRONT ATTACHMENT / Cylinder

3 13 14 26 23 24 22 21

W1LA-04-02-003
10 11 12 15 16 1 18 19 20 25

W4-2-24
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that O-ring (24) is not
twisted after installing it. 11. Remove a protective tape from the piston rod (1)
7. Install O-ring (24) to piston (20), and then install screw thread. Install cushion bearing (18) and pis-
seal ring (23) with special tools. ton (20) assembly to piston rod (1).
Special tool 1: ST 2592 (ZAXIS27u, 30u) ZAXIS27u
ST 2623 (ZAXIS35u) : 46 mm
Special tool 2: ST 2596 (ZAXIS27u, 30u) : 686 N⋅m (70 kgf⋅m, 506 lbf⋅ft)
ST 2625 (ZAXIS35u) ZAXIS30u
: 55 mm
: 981 N⋅m (99 kgf⋅m, 723 lbf⋅ft)
Special Too 1
ZAXIS30u
23 : 55 mm
Special Tool 2 : 1079 N⋅m (101 kgf⋅m, 796 lbf⋅ft)
24
20 IMPORTANT: When the work of installing set
screw (22) is finished, crimp it at two
places with a punch in order to pre-
vent it from loosening.
W566-04-02-010
12. Install steel ball (21) into piston (20) and then in-
IMPORTANT: Adjust seal ring (23). If not adjusting, stall set screw (22) on it.
piston (20) can not be installed to ZAXIS27u
cylinder tube (26). : 5 mm
8. Adjust seal ring (23) with special tool. : 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
Special tool : ST 2060 (ZAXIS27u, 30u) ZAXIS30u, 35u
ST 2627 (ZAXIS35u) : 6 mm
: 16.7 N⋅m (1.7 kgf⋅m, 12.3 lbf⋅ft)

IMPORTANT: Take care not to let slide rings (19)

and (25) drop from piston (20) when
23 inserting the piston rod (1) assembly.
In addition, care should be taken not
to damage the piston rod assembly
20 Special and insert the piston rod assembly
Tool
straightly. Apply the hydraulic oil to
the packing parts.
13. Lay cylinder tube (25) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
W566-04-02-011
tube.

IMPORTANT: When installing slide rings (19) and

(25), do not align their split portion.
9. Install slide rings (19) and (25) to piston (20).

10. Wrap the piston rod (1) screw thread with protec-
tive tape and then install the cylinder head (3) as-
sembly to the piston rod while rotating the former
one.

W4-2-25
 FRONT ATTACHMENT / Cylinder

3 26

W1LA-04-02-003
1 19 20 25

W4-2-26
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply the hydraulic oil to the pack-
ing parts.
14. Tighten cylinder head (3) to cylinder tube (26)
with a hook wrench. Bend the lock washer to pre-
vent it from loosening.
Cylinder head (3) diameter:
ZAXIS27u, 30u: 90 mm
: 324 N⋅m (33 kgf⋅m, 239 lbf⋅ft)
ZAXIS35u: 95 mm
: 333 N⋅m (34 kgf⋅m, 246 lbf⋅ft)

Hool Wrench

25
W506-04-02-019

W4-2-27
 FRONT ATTACHMENT / Cylinder
Arm Cylinder

25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2

26

W1LA-04-02-001

1- Piston Rod 8- U-Ring 15 - Cushion Bearing 21 - O-Ring

2- Wiper Ring 9- Bushing 16 - Slide Ring 22 - Slide Ring
3- Cylinder Head 10 - Backup Ring 17 - Piston 23 - Cushion Bearing
4- O-Ring 11 - O-Ring 18 - Steel Ring 24 - Washer
5- Backup Ring 12 - Cushion Ring 19 - Set Screw 25 - Bolt
6- O-ring 13 - Spacer 20 - Seal Ring 26 - Cylinder Tube
7- *Backup Ring 14 - Stopper

NOTE: The item with a mark * is not equipped for

ZAXIS27u.

W4-2-28
 FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
• Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (26).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter:
disassembling. 85 mm (3.3 in) (ZAXIS27u, 30u)
• Start the following procedures after disconnecting 90 mm (3.5 in) (ZAXIS35u)
the lines.
Hook Wrench

CAUTION: Arm cylinder weight:

25 kg (55 Ib) (ZAXIS27u)
27 kg (60 Ib) (ZAXIS30u)
33 kg (73 Ib) (ZAXIS35u) 26

IMPORTANT: When draining off hydraulic oil from

the cylinder, piston rod (1) shall be
moved slowly in order to prevent the 3
oil from splashing.
1. Clamp the pin mounting part (clevis part) of cylin-
der tube (26) and hold it horizontally in a vise to
1
drain hydraulic oil from the cylinder. W506-04-02-004

IMPORTANT: The lock washer in cylinder head (3) IMPORTANT: As set screw (19) head is mush-
is provided on cylinder tube (26) to roomed after being installed, cut the
form on integral part. Take care not mushroomed part with a hand drill
to damage the cylinder tube and cyl- before loosening set screw (19).
inder head (3) when bending and ex- 4. Secure piston rod (1) horizontally.
tending the lock washer. Remove set screw (19) and steel ball (18) from
2. Pull out piston rod (1) approximately 200 mm (7.9 piston (17).
in). Place a protective cover onto the piston rod, : 5 mm (ZAXIS27u, 30u)
extend the lock washer. : 6 mm (ZAXIS35u)

Lock Washer 5. Remove piston (17), cushion bearing (15) from

piston rod (1).
: 46 mm (ZAXIS27u)
: 50 mm (ZAXIS30u)
: 55 mm (ZAXIS35u)

IMPORTANT: Adhesive agent is applied onto

bolt(25). Heat bolt(25) with a burner
for 10 to 15 seconds and remove it.
6. Remove bolt(25) from piston rod(1) to remove
1 3
washer(24) and cushion bearing(23).
W506-04-02-003
8 mm (ZAXIS27u)
10 mm (ZAXIS30u, 35u)

7. Wrap piston rod (1) screw thread with protective

tape to protect the cylinder head (3) seal and then
remove cylinder head (3) from piston rod (1).

IMPORTANT: Do not reuse slide rings (16) and (22).

When dissembling the cylinder, re-
place them with new ones.
8. Clamp piston (17) and hold it horizontally in a vise
to remove slide rings (16) and (22) from piston
(17).

W4-2-29
 FRONT ATTACHMENT / Cylinder

25
24
23
22
21
20

17
16

14
13
12
11
10
9
8
7
6
5
4
3
2

W1LA-04-02-001

W4-2-30
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (17)
when removing seals.
9. Insert a screwdriver between piston (17) and seal
ring (20). Raise seal ring (20) with screwdriver.
Cut off seal ring (20) with cutting pliers to remove
seal ring (20) from piston (17).
Remove O-ring (21) in the same procedure.

10. Remove backup ring (10) and O-Ring (11) from

the outer side of cylinder head (3).

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

12. Remove stopper (14) from the inner side of cylin-

der head (3). Remove spacer (13) and cushion
ring (12).

13. Remove wiper ring (2), U-ring (8) and backup ring
(7) from the inner side of cylinder head (3).
NOTE: Backup ring (7) is not equipped for
ZAXIS27u.

IMPORTANT: Do not reuse bushing (9).

Replace it with new one when dis-
assembling the cylinder.
14. Remove bushing (9) from the inner side of cylin-
der head (3).
NOTE: Insert a screwdriver into the bushing (9)
grove to pull it out.

W4-2-31
 FRONT ATTACHMENT / Cylinder

Arm Cylinder

3 4 5 6 10 11 26 15 17 16 22 19 18

25

W567-04-02-005
2 7 8 9 12 13 14 1 21 20 23 24

1- Piston Rod 8- U-Ring 15 - Cushion Bearing 21 - O-Ring

2- Wiper Ring 9- Bushing 16 - Slide Ring 22 - Slide Ring
3- Cylinder Head 10 - Backup Ring 17 - Piston 23 - Cushion Bearing
4- O-Ring 11 - O-Ring 18 - Steel Ring 24 - Washer
5- Backup Ring 12 - Cushion Ring 19 - Set Screw 25 - Bolt
6- O-Ring 13 - Spacer 20 - Seal Ring 26 - Cylinder Tube
7- *Backup Ring 14 - Stopper
NOTE: The item with a mark * is not equipped for ZAXIS27u.

W4-2-32
 FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder 3. Install wiper ring (2) to cylinder head (3) with spe-
• Read PRECAUTIONS FOR DISASSEMBLING cial tool.
AND ASSEMBLING (W1-1-1) carefully before as-
sembling.

CAUTION: Arm cylinder weight: Special Tool

25 kg (55 Ib) (ZAXIS 27u)
3
27 kg (60 Ib) (ZAXIS 30u)
33 kg (73 Ib) (ZAXIS 35u)
1. Press bushing (9) into cylinder head (3) with spe-
cial tool.
Special tool 1: ST 8056 (ZAXIS27u, 30u)
ST 7276 (ZAXIS35u)
2
W506-04-02-012
Special Tool

9 IMPORTANT: Make sure that O-ring (21) is not

twisted after installing it.
3
6. Install O-ring (21) to piston (17), and then install
seal ring (20) with special tools.
Special tool 1: ST 2624 (ZAXIS27u, 30u)
ST 2596 (ZAXIS35u)
Special tool 2: ST 2622 (ZAXIS27u, 30u)
ST 2592 (ZAXIS35u)

W506-04-02-010

Special Tool 1
IMPORTANT: Take care of the mounting direction
of U-ring (8). 20
2. Install backup ring (7) and U-ring (8) to cylinder
Special Tool 2
head (3).
NOTE: Backup ring (7) is not equipped for 21
ZAXIS27u.

17
3
8
W566-04-02-010

W506-04-02-011

W4-2-33
 FRONT ATTACHMENT / Cylinder

3 26 15 17 16 22 19 18

25

W567-04-02-005
1 21 20 23 24

W4-2-34
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Adjust seal ring (20). If not adjusted, IMPORTANT: When the work of installing set
piston (17) can not be installed to screw (19) is finished, crimp it at two
cylinder tube (26). places with a punch in order to pre-
7. Adjust seal ring (20) with special tool. vent it from loosening.
Special tool: ST 2626 (ZAXIS27u, 30u) 12. Install steel ball (18) into piston (17) and then in-
ST 2600 (ZAXIS35u) stall set screw (19) on it.
ZAXIS27u, 30u
: 5 mm
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
ZAXIS35u
20 : 6 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23 lbf⋅ft)
Special
Tool IMPORTANT: Take care not to let slide rings (16)
and (22) drop from piston (17) when
17 inserting the piston rod (1) assembly.
In addition, care should be taken not
W566-04-02-011 to damage the piston rod assembly
straightly. Apply the hydraulic oil to
IMPORTANT: When installing slide rings (16) and the packing parts.
(22), do not align their split portion. 13. Lay cylinder tube (26) horizontally in a vise, and
8. Install slide rings (16) and (22) to piston (17). insert the piston rod (1) assembly into the cylinder
tube.

9. Wrap the piston rod (1) screw thread with protec-

tive tape and then install the cylinder head (3) as- IMPORTANT: Apply the hydraulic oil to the pack-
sembly to the piston rod while rotating the former ing parts.
one. 14. Tighten cylinder head (3) to cylinder tube (26)
with a hook wrench. Bend the lock washer to pre-
vent it from loosening.
10. Install piston (17) assembly to piston rod (1). Cylinder head (3) diameter:
ZAXIS27u ZAXIS27u, 30u
: 46 mm : 304 N⋅m (31 kgf⋅m, 224 lbf⋅ft)
: 588 N⋅m (60 kgf⋅m, 434 lbf⋅ft) ZAXIS35u
ZAXIS30u : 324 N⋅m (33 kgf⋅m, 239 lbf⋅ft)
: 50 mm
: 834 N⋅m (95 kgf⋅m, 615 lbf⋅ft) Hook Wrench
ZAXIS35u
: 55 mm
: 980 N⋅m (100 kgf⋅m, 723 lbf⋅ft)

IMPORTANT: Apply adhesive agent onto bolt(25).

Install cushion bearing(23) with the
side without slit facing to piston(17).

11. Install cushion bearing(23), washer(24), and

bolt(25) to piston rod(1).
ZAXIS27u, 30u 26
: 5 mm W506-04-02-019
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
ZAXIS35u
: 6 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23 lbf⋅ft)

W4-2-35
 FRONT ATTACHMENT / Cylinder
BUCKET CYLINDER

16
15
14
13
12
11
10

9
8
7
6
5
4
3
2

17

W566-04-02-005

1- Piston Rod 6- O-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- *Backup Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
NOTE: The item with a mark * is not equipped for ZAXIS27u.

W4-2-36
 FRONT ATTACHMENT / Cylinder
Disassemble Bucket Cylinder 3. Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
• Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (17).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter:
disassembling. 73 mm (2.9 in) (ZAXIS27u)
• Start the following procedures after disconnecting 78 mm (3.1 in) (ZAXIS30u, 35u)
the lines.
Hook Wrench

CAUTION: Bucket cylinder weight:

16 kg (35 Ib) (ZAXIS27u)
20 kg (44 Ib) (ZAXIS30u, 35u)
17
IMPORTANT: When draining off hydraulic oil from
the cylinder, piston rod (1) shall be
moved slowly in order to prevent the
oil from splashing. 3
1. Clamp the pin mounting part (clevis part) of cylin-
der tube (17) and hold it horizontally in a vise to
drain hydraulic oil from the cylinder.
1 W506-04-02-004

IMPORTANT: The lock washer in cylinder head (3)

is provided on cylinder tube (17) to IMPORTANT: As set screw (13) head is mush-
from on integral part. Take care not roomed after being installed, cut the
to damage the cylinder tube and cyl- mushroomed part with a hand drill
inder head (3) when bending and ex- before loosening set screw (13).
tending the lock washer. 4. Secure piston rod (1) horizontally.
2. Pull out piston rod (1) approximately 200 mm (7.9 Remove set screw (13) and steel ball (12) from
in). Place a protective cover onto the piston rod, piston (11).
extend the lock washer. : 5 mm

Lock Washer 5. Remove piston (11) from piston rod (1).

: 46 mm

6. Wrap piston rod (1) screw thread with protective

tape to protect cylinder head (3) seal and then
remove cylinder head (3) from piston rod (1).

IMPORTANT: Do not reuse slide rings (10) and (16).

When dissembling cylinder, replace
1 3 them with new ones.
W506-04-02-003 7. Clamp piston (11) and hold it horizontally in a vise
to remove slide rings (10) and (16) from piston
(11).

W4-2-37
 FRONT ATTACHMENT / Cylinder

16
15
14
13
12
11
10

9
8
7
6
5
4
3
2

17

W566-04-02-005

W4-2-38
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver between piston (11) and seal
ring (14). Raise seal ring (14) with a screwdriver.
Cut off seal ring (14) with cutting pliers to remove
seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.

9. Remove wiper ring (2), U-ring (8) and backup ring

(7) from the inner side of cylinder head (3).

NOTE: Backup ring (7) is not equipped for

ZAXIS27u.
10. Remove O-ring (6), backup ring (5) and O-ring (4)
from the outer side of cylinder head (3).

IMPORTANT: Do not reuse bushing (9).

Replace it with new one when dis-
assembling the cylinder.
11. Remove bushing (9) from the inner side of cylin-
der head (3).
NOTE: Install a screwdriver into the bushing (9)
groove to pull it out.

W4-2-39
 FRONT ATTACHMENT / Cylinder
BUCKET CYLINDER

3 4 5 6 17 10 16 13 12

W571-04-02-011
2 7 8 9 1 11 14 15

1- Piston Rod 6- O-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- *Backup Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
NOTE: The item with a mark * is not equipped for ZAXIS27u.

W4-2-40
 FRONT ATTACHMENT / Cylinder
Assemble Bucket Cylinder 3. Install wiper ring (2) to cylinder head (3) with spe-
• Read PRECAUTIONS FOR DISASSEMBLING cial tool (ST 8044).
AND ASSEMBLING (W1-1-1) carefully before as-
sembling.

CAUTION: Bucket cylinder weight: ST 8044

16 kg (35 Ib) (ZAXIS27u)
3
20 kg (44 Ib) (ZAXIS30u, 35u)
1. Press bushing (9) into cylinder head (3) with spe-
cial tool (ST 8055).

ST 8055
2
9
W506-04-02-012

3
4. Install O-ring (4), backup ring (5) and O-ring (6) to
the outer side of cylinder head (3).

IMPORTANT: Make sure that O-ring (15) is not

twisted after installing it.
7. Install O-ring (15) to piston (11), and then install
W506-04-02-010
seal ring (14) with special tools.
Special tool 1: ST 2478 (ZAXIS27u)
ST 2482 (ZAXIS30u, 35u)
IMPORTANT: Take care of the mounting direction Special tool 2: ST 2477 (ZAXIS27u)
of U-ring (8). ST 2481 (ZAXIS30u, 35u)
2. Install backup ring (7) and U-ring (8) to cylinder
head (3).
NOTE: Backup ring (7) is not equipped for Special Tool 1
ZAXIS27u.
14
3 Special Tool 2
8
15

11

W566-04-02-010

W506-04-02-011

W4-2-41
 FRONT ATTACHMENT / Cylinder

3 17 14 15 13 12

W571-04-02-011
1 10 11 16

W4-2-42
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Adjust seal ring (14). If not adjusted, IMPORTANT: Take care not to let slide rings (10)
piston (11) can not be installed to and (16) drop from piston (11) when
cylinder tube (17). inserting the piston rod (1) assembly.
7. Adjust seal ring (14) with special tool. In addition, care should be taken not
Special tool: ST 2479 (ZAXIS27u) to damage the piston rod assembly
ST 2483 (ZAXIS30u, 35u) straightly. Apply the hydraulic oil to
the packing parts.
11. Lay cylinder tube (17) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
tube.
14
IMPORTANT: Apply the hydraulic oil to the pack-
ing parts.
11 Special 12. Tighten cylinder head (3) to cylinder tube (17)
Tool
with a hook wrench. Bend the lock washer to pre-
vent it from loosening.
Cylinder head (3) diameter:
ZAXIS27u: 73 mm
: 286 N⋅m (29 kgf⋅m, 211 lbf⋅ft)
W566-04-02-011
ZAXIS30u, 35u: 78 mm
: 294 N⋅m (30 kgf⋅m, 217 lbf⋅ft)
IMPORTANT: When installing slide rings (10) and
(16), do not align their split portion. Hook Wrench
7. Install slide rings (10) and (16) to piston (11).

8. Wrap the piston rod (1) screw thread with protec-

tive tape and then install the cylinder head (3) as-
sembly to the piston rod while rotating the former
one.

9. Install piston (11) assembly to piston rod (1).

ZAXIS27u
: 540 N⋅m (55 kgf⋅m, 398 lbf⋅ft) 17
ZAXIS30u, 35u
: 638 N⋅m (65 kgf⋅m, 471 lbf⋅ft) W506-04-02-019

IMPORTANT: When the work of installing set

screw (13) is finished, crimp it at two
places with a punch in order to pre-
vent it from loosening.
10. Install steel ball (12) into piston (11) and then in-
stall set screw (13) on it.
: 5 mm
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)

W4-2-43
 FRONT ATTACHMENT / Cylinder
BOOM SWING CYLINDER

17
16
15
14
13
12
11

10
9
8
7
6
5
4
3

18

W1L7-04-02-003

1- Piston Rod 6- O-Ring 11 - Slide Ring 15 - Seal Ring

2- Wiper Ring 7- Bushing 12 - Piston 16 - O-Ring
3- Cylinder Head 8- U-Ring 13 - Steel Ball 17 - Slide Ring
4- O-Ring 9- Backup Ring 14 - Set Screw 18 - Cylinder Tube
5- Backup Ring 10 - Retaining Ring

W4-2-44
 FRONT ATTACHMENT / Cylinder

Blade Cylinder

17
16
15
14
13
12
11

10
9
8
7
6
5
4
3

18

W567-04-02-011

1- Piston Rod 6- O-Ring 11 - Slide Ring 15 - Seal Ring

2- Wiper Ring 7- Bushing 12 - Piston 16 - O-Ring
3- Cylinder Head 8- U-Ring 13 - Steel Ball 17 - Slide Ring
4- O-Ring 9- Backup Ring 14 - Set Screw 18 - Cylinder Tube
5- Backup Ring 10 - Retaining Ring

W4-2-45
 FRONT ATTACHMENT / Cylinder

NOTE: The construction of the boom Swing cylin-

der and Blade cylinder is the same. The il-
lustration shows the blade cylinder.

17

14
13

12
11

18

W567-04-02-011

W4-2-46
 FRONT ATTACHMENT / Cylinder
Disassemble Boom Swing Cylinder and Blade 3. Loosen cylinder head (3) with a hook wrench and
Cylinder pull piston rod (1) (with protective cover on it) out
of cylinder tube (18).
Cylinder head (3) diameter:
• Read PRECAUTIONS FOR DISASSEMBLING Boom Swing Cylinder
AND ASSEMBLING (W1-1-1) carefully before 90 mm (ZAXIS27u)
disassembling. 100 mm (ZAXIS30u, 35u)
• Start the following procedures after disconnecting Blade Cylinder
the lines. 100 mm (ZAXIS27u)
105 mm (ZAXIS30u)
110 mm (ZAXIS35u)
CAUTION: Boom Cylinder weight: Hook Wrench
26 kg (57 Ib) (ZAXIS27u)
32 kg (71 Ib) (ZAXIS30u, 35u)
Blade Cylinder weight:
19 kg (42 Ib) (ZAXIS27u)
20 kg (44 Ib) (ZAXIS30u) 18
24 kg (53 Ib) (ZAXIS35u)
IMPORTANT: When draining off hydraulic oil from
the cylinder, piston rod (1) shall be
moved slowly in order to prevent the 3
oil from splashing.
1. Clamp the pin mounting part (clevis part) of cylin-
der tube (18) and hold it horizontally in a vise to
drain hydraulic oil from the cylinder. 1 W506-04-02-004

IMPORTANT: The lock washer in cylinder head (3) IMPORTANT: As set screw (14) head is mush-
is provided on cylinder tube (18) to roomed after being installed, cut the
form an integral part. Take care not mushroomed part with a hand drill
to damage the cylinder tube and cyl- before loosening set screw (14).
inder head (3) when bending and ex- 4. Secure piston rod (1) horizontally.
tending the lock washer. Remove set screw (14) and steel ball (13) from
2. Pull out piston rod (1) approximately 200 mm (7.9 piston (12).
in). Place a protective cover onto the piston rod, ZAXIS35u (Blade Cylinder only)
extend the lock washer. : 6 mm
Others
: 5 mm
Lock Washer
5. Remove piston (12) from piston rod (1).
Boom Swing Cylinder
ZAXIS27u, 30u
: 46 mm
ZAXIS30u, 35u
: 50 mm
Blade Cylinder
ZAXIS27u, 30u, 35u
1 3 : 55 mm
W506-04-02-003
6. Wrap piston rod (1) screw thread with protective
tape to protect cylinder head (3) seal and then
remove cylinder head (3) from piston rod (1).

IMPORTANT: Do not reuse slide rings (11) and (17).

When dissembling the cylinder, re-
place them with new ones.
7. Clamp piston (12) and hold it horizontally in a vise
to remove slide ring (11) and (17) from piston
(12).

W4-2-47
 FRONT ATTACHMENT / Cylinder

17
16
15

12
11

10
9
8
7
6
5
4

W567-04-02-011

W4-2-48
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (12)
when removing seals.
8. Insert a screwdriver between piston (12) and seal
ring (15). Raise seal ring (15) with a screwdriver.
Cut off seal ring (15) with cutting pliers to remove
seal ring (15) from piston (12).
Remove O-ring (16) in the same procedure.

9. Remove wiper ring (2),retaining ring (10), U-ring

(8) and backup ring (9) from the inner side of cyl-
inder head (3).

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

IMPORTANT: Do not reuse bushing (7).

Replace it with new one when dis-
assembling the cylinder.
11. Remove bushing (7) from the inner side of cylin-
der head (3).
NOTE: Insert a screwdriver into the bushing (7)
groove to pull it out.

W4-2-49
 FRONT ATTACHMENT / Cylinder
BOOM SWING CYLINDER AND BLADE
CYLINDER

NOTE: The cross section of boom swing cylinder

and the cross section of blade cylinder are
the same.

3 7 8 9 17 11 10 16 13 12

W1LD-04-02-009

2 7 5 6 1 14 15

1- Piston Rod 6- O-Ring 11 - Slide Ring 15 - Seal Ring

2- Wiper Ring 7- Bushing 12 - Piston 16 - O-Ring
3- Cylinder Head 8- U-Ring 13 - Steel Ball 17 - Slide Ring
4- O-Ring 9- Backup Ring 14 - Set Screw 18 - Cylinder Tube
5- Backup Ring 10 - Retaining Ring

W4-2-50
 FRONT ATTACHMENT / Cylinder
Assemble Boom Swing Cylinder and Blade Cyl- IMPORTANT: Take care of the mounting direction
inder of U-ring (8).
• Read PRECAUTIONS FOR DISASSEMBLING 2. Install backup ring (9), U-ring (8), and retaining
AND ASSEMBLING (W1-1-1) carefully before as- ring (10) to the inner side of cylinder head (3).
sembling. 3
8
CAUTION: Boom Cylinder weight:
26 kg (57 Ib) (ZAXIS27u)
32 kg (71 Ib) (ZAXIS30u, 35u)
Blade Cylinder weight:
19 kg (42 Ib) (ZAXIS27u)
20 kg (44 Ib) (ZAXIS30u)
24 kg (53 Ib) (ZAXIS35u)
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3). Press bushing
(7) until the end of bushing (7) is W506-04-02-011
flush with the end surface of cylin-
der head (3). If not flush, U-ring (8) 3. Install wiper ring (2) to cylinder head (3) with spe-
will be damaged when installing U- cial tool.
ring (8.) Special Tool (Boom Swing Cylinder)
ST 8045 (ZAXIS27u)
ST 8046 (ZAXIS30u, 35u)
7
3 Special Tool (Blade Cylinder)
ST 8046 (ZAXIS27u, 30u)
ST 8047 (ZAXIS35u)

Check if bushing is
installed properly.

Special
Tool

3
W577-04-02-007

1. Press bushing (7) into cylinder head (3) with spe-

cial tool.
Special Tool (Boom Swing Cylinder)
ST 8056 (ZAXIS27u) 2
ST 7276 (ZAXIS30u, 35u) W506-04-02-012

Special Tool (Blade Cylinder) 4. Install O-ring (4), backup ring (5) and O-ring (6) to
ST 7276 (ZAXIS27u, 30u) the outer side of cylinder head (3).
ST 7325 (ZAXIS35u)

Special Tool

7
3

W506-04-02-010

W4-2-51
 FRONT ATTACHMENT / Cylinder

3 4 5 6 18 15 16

2 12 W571-04-02-012

W4-2-52
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that O-ring (16) is not 8. Wrap the piston rod (1) screw thread with protec-
twisted after installing it. tive tape and then install the cylinder head (3) as-
Install O-ring (16) to piston (12), and then install sembly to the piston rod while rotating the former
seal ring (14) with special tool. one.
Special Tool 1
Boom Swing Cylinder
ST 2596 (ZAXIS27u) 9. Install piston (12) assembly to piston rod (1).
ST 2595 (ZAXIS30u, 35u) Boom Swing Cylinder
Blade Cylinder ZAXIS27u
ST 2595 (ZAXIS27u) : 46 mm
ST 2594 (ZAXIS30u) : 687 N⋅m (69 kgf⋅m, 507 lbf⋅ft)
ST 2335 (ZAXIS35u) ZAXIS30u, 35u
Special Tool 2 : 50 mm
Boom Swing Cylinder : 980 N⋅m (98 kgf⋅m, 723 lbf⋅ft)
ST 2592 (ZAXIS27u) Blade Cylinder
ST 2591 (ZAXIS30u, 35u)
ZAXIS27u, 27u
Blade Cylinder
ST 2591 (ZAXIS27u) : 55 mm
ST 2590 (ZAXIS30u) : 981 N⋅m (98 kgf⋅m, 724 lbf⋅ft)
ST 2334 (ZAXIS35u) ZAXIS27u, 30u
: 55 mm
: 1128 N⋅m (114 kgf⋅m, 832 lbf⋅ft)
Special Tool 1 ZAXIS30u,35u
15 : 55 mm
Special Tool 2 : 1373 N⋅m (140 kgf⋅m, 1013 lbf⋅ft)
16
IMPORTANT: When the work of installing set
screw (14) is finished, crimp it at two
places with a punch in order to pre-
12
vent it from loosening.
W566-04-02-010 10. Install steel ball (13) into piston (12) and then in-
stall set screw (14) on it.
IMPORTANT: Adjust seal ring (15). If not adjusted, ZAXIS35u (Blade Cylinder only)
piston (12) can not be installed to : 6 mm
cylinder tube (18). : 31.5 N⋅m (3.2 kgf⋅m, 23.2 lbf⋅ft)
6. Adjust seal ring (15) with special tool. Others
Special Tool (Boom Swing Cylinder) : 5 mm
ST 2600 (ZAXIS27u) : 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
ST 2599 (ZAXIS30u, 35u)
Special Tool (Blade Cylinder)
ST 2599 (ZAXIS27u) IMPORTANT: Take care not to let slide rings (11)
ST 2590 (ZAXIS30u) and (17) drop from piston (12) when
ST 2334 (ZAXIS35u) inserting the piston rod (1) assembly.
In addition, care should be taken not
to damage the piston rod assembly
and insert the piston rod assembly
15
straightly. Apply the hydraulic oil to
the packing parts.
11. Lay cylinder tube (18) horizontally in a vise, and
Special
Tool
insert the piston rod (1) assembly into the cylinder
tube.
12

W566-04-02-011

IMPORTANT: When installing slide rings (11) and

(17), do not align their split portion.
7. Install slide rings (11) and (17) to piston (12).

W4-2-53
 FRONT ATTACHMENT / Cylinder

3 18 14 13

1 11 12 17 W571-04-02-012

W4-2-54
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply the hydraulic oil to the pack-
ing parts.
12. Tighten cylinder head (3) to cylinder tube (18) with
a hook wrench. Bend the lock washer to prevent it
from loosening.
Cylinder head (3) diameter:
Boom Swing Cylinder
ZAXIS27u: 90 mm
: 324 N⋅m (33 kgf⋅m, 239 lbf⋅ft)
ZAXIS30u, 35u: 100 mm
: 343 N⋅m (34 kgf⋅m, 253 lbf⋅ft)
Blade Cylinder
ZAXIS27u, 27u: 100 mm
: 343 N⋅m (34 kgf⋅m, 253 lbf⋅ft)
ZAXIS30u: 105 mm
: 363 N⋅m (36 kgf⋅m, 268 lbf⋅ft)
ZAXIS35u: 110 mm
: 373 N⋅m (37 kgf⋅m, 275 lbf⋅ft)

Hook Wrench

18
W506-04-02-019

W4-2-55
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD

Rod Rod Bend and Run Out

A Dial Gauge
Cylinder Rod

W105-04-02-094 W166-04-02-022
ZX27u unit: mm (in)
1m
Recommended Size After
Cylinder Name V Block
Re-manufacturing (A)
+0.025 (1.5 +0.001 unit: mm (in)
Boom 40 ) Bend Run out Remedy
-0.064 8 −0.003
+0.025 (1.5 +0.001 Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Arm 40 ) Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
-0.064 8 −0.003
+0.025 (1.3 +0.001
Bucket 35 )
-0.064 8 −0.003
+0.025 (1.5 +0.001
Boom Swing 40 )
-0.064 8 −0.003
+0.025 (1.7 +0.001
Blade 45 )
-0.064 7 −0.003

ZX30u unit: mm (in)

Recommended Size After
Cylinder Name
Re-manufacturing (A)
+0.025 (1.7 +0.001
Boom 45 )
-0.064 7 −0.003
+0.025 (1.5 +0.001
Arm 40 )
-0.064 8 −0.003
+0.025 (1.5 +0.001
Bucket 40 )
-0.064 8 −0.003
+0.025 (1.7 +0.001
Boom Swing 45 )
-0.064 7 −0.003
+0.025 (1.7 +0.001
Blade 45 )
-0.064 7 −0.003

ZX35u unit: mm (in)

Recommended Size After
Cylinder Name
Re-manufacturing (A)
+0.025 (1.7 +0.001
Boom 45 )
-0.064 7 −0.003
+0.025 (1.7 +0.001
Arm 45 )
-0.064 7 −0.003
+0.025 (1.5 +0.001
Bucket 40 )
-0.064 8 −0.003
+0.025 (1.7 +0.001
Boom Swing 45 )
-0.064 7 −0.003
+0.025 (1.7 +0.001
Blade 45 )
-0.064 7 −0.003

W4-2-56
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 SECTION 5
ENGINE

CONTENTS
SECTION 1 General Information SECTION 5 Fuel System
GENERAL REPAIR INSTRUCTION................... 2 FUEL CIRCULATION SYSTEM DIAGRAM ......86
NOTES ON THE FORMAT GOVERNOR ....................................................87
OF THIS MANUAL ........................................... 2 NOZZLE HOLDER ASSEMBLY .......................95
APPEARANCE .................................................. 5
MAIN DATA AND SPECIFICATIONS ................. 6 SECTION 6 Troubleshooting
TIGHTENING TORQUE SPECIFICATIONS....... 7
ANGULAR NUT AND BOLT SECTION 7 Special Tool
TIGHTENING METHOD .................................. 9
TIGHTENING TORQUE ON SECTION 8 Service Standard
MAJOR COMPONENTS ................................ 11
GASKET LOCATION ....................................... 16 SECTION 9 Conversion Table
MAINTENANCE............................................... 19 LENGTH ........................................................107
RECOMENDED LUBRICATION OIL................ 24 AREA .............................................................109
VOLUME........................................................109
SECTION 2 Engine MASS ............................................................ 111
DISASSEMBLY................................................ 27 PRESSURE ................................................... 112
INSPECTION AND REPAIR ............................ 40 TORQUE ....................................................... 113
REASSEMBLY................................................. 54 TEMPERATURE ............................................ 114

SECTION 3 Lubrication System

LUBRICATION OIL CIRCULATION
SYSTEM DIAGRAM....................................... 76
OIL PUMP ....................................................... 77

SECTION 4 Cooling System

COOLING WATER CIRCULATION
SYSTEM DIAGRAM....................................... 80
WATER PUMP................................................. 81
THERMOSTAT ................................................ 84

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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162

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