Workshop Manual 110 & 120 PDF

Manual No.
: KM-187E
Vol. No. : W187E-03
110 110M 120 130 130LCN 125US 135US 135UR Excavator Workshop Manual
Workshop Manual
110 125US
110M 135US
120 135UR
130
130LCN
Excavator
Service Manual (Manual No. KM-187E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO187E
Technical Manual (Troubleshooting) : Vol. No. TT187E
Workshop Manual : Vol. No. W187E
PRINTED IN SINGAPORE (PS) 2003.11
Zaxis110...135UR-WSh 1 30/10/03, 7:37 PM

Workshop Manual
Vol No.: W187E-03

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 cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
INTRODUCTION
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
SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS
• CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which
signal words are used to alert the reader to the could, if not avoided, result in personal injury or
potential for personal injury of machine damage. 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 know-how.
heavy parts.
IN-02
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-03
INTRODUCTION
(Blank)
IN-04
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
designated signal words above after the safety
alert symbol are occasionally used on this
machine. SA-1223
• 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

machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
• If a safety sign or this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other
replacement parts (be sure to state machine
model and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel SA-003
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
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437
posted near your telephone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask. SA-438
Be sure to wear the correct equipment and clothing

for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all

dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operator’s
work boots the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified lo-
cations.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount
or dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
SA-439
008-E01B-0439
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-6
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly
examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt 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
machine. SA-426
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control SA-444
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
could result in a battery explosion or a runaway SA-032
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.
Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0379
SA-379
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 coordi-
nate 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
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0491
SA-491
SA-9
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the
direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay
around the machine while traveling.
SA-387
• 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, approxi-
mately 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-388
• Driving across the face of a slope or steering on SA-441
a slope may cause the machine to skid or turn-

over. If the direction must be changed, move the
WRONG
machine to level ground, then, change the direc-
tion to ensure sage operation.
019-E01D-0492
SA-590
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.

• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
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 SA-012
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440
unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
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
position. SA-390
• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.
033-E09B-0390
SA-15
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are

flammable. SA-018
• 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-16
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

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

unloading the machine:
1) Select firm level ground. SA-395
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-17
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.
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.
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
inside the machine.

• Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without
securing the machine first.
• Always lower the attachment to the ground
before you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on
cinder blocks, hollow tires, or props that may
crumble under continuous load. Do not work
under a machine that is supported solely by a
SA-527
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-20
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot. SA-344
• Wait for GEAR OIL to cool, then gradually loosen

AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.
504-E01A-0034 SA-034
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-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become
hot during operation.
The engine, hoses, lines and other parts become
hot as well.
• Wait for the oil and components to cool before
starting any maintenance or inspection work.
505-E01B-0498 SA-225
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.)
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019
attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031
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-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
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.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
Check Emergency Engine Stop Switch:

• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hamper-
ing fire fighting.
• Check the emergency engine stop switch func-
tion 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
pressurized air inside the hydraulic oil tank is
released (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
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the
OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door and/or the front SA-393
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
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
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
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
hoses or other materials before engaging in
SA-030
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-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the
dust. SA-029
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
object 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. Ex-
plosion of the battery may result. SA-032
• 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-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with your machine include such items as
lubricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know
exactly what the risks are and how to do the job SA-309
safely. Then follow procedures and use

recommended equipment.
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids.
Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth’s atmosphere. SA-226
Government regulations may require a certified

air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
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-30
SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Solenoid Valve
Group 11 Holding 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 Upper and Lower Roller
All information, illustrations and speci-
fications in this manual are based on Group 7 Track
the latest product information available
at the time of publication. The right is SECTION 4 FRONT ATTACHMENT
reserved to make changes at any time
without notice.
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
COPYRIGHT(C)2002
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Front Control System Group 6 Signal Control Valve
Group 3 Hydraulic System Group 7 Others (Upperstructure)
Group 4 Electrical System Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
Group 5 Component Test Group 6 Troubleshooting D
Group 6 Adjustment Group 7 Electrical System Inspection
Group 8 ICX
SECTION 1
GENERAL
 CONTENTS 
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................. T1-1-1
Maintenance Standard Terminology .......... T1-1-7
Group 2 Tightening Torque

Tightening Torque Specification ............... W1-2-1
Torque Chart ............................................ W1-2-3
Piping Joint .............................................. W1-2-6
Periodic Replacement of Parts............... W1-2-10
Group 3 Painting
Painting (ZAXIS110, 110-E, 120, 120-E,
125US, 135US) .................................... W1-3-1
Painting (ZAX135UR) .............................. W1-3-3
187W-1-1
(Blank)
187W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

area for disassembling work.
W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

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

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

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

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

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

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

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

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

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

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOLOGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

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

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

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
Bolt Dia Wrench Torque
No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion rubber mounting nut 14 4 22 140 (14.3) (101)
1
Engine cushion rubber mounting bolt 16 2 24 235 (24) (175)
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
2
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
3 19 30 (3.1) (22)
1− −12UNF
16 22 40 (4.1) (30)
5 ORS fittings for hydraulic hoses and piping 27 95 (9.7) (70)
7 32 140 (14.3) (105)
1− −12UNF
16 36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 6 22 140 (14.3) (105)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 10 30 500 (51) (370)
10 Swing motor mounting bolt 10 7 8
64 (6.5) (47)
(Hex. Wrench)
11 Battery mounting nut 10 2 17 20 (2.0) (14.5)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 18 30 27 400 (41) (295)
13
Swing bearing mounting bolt to undercarriage 16 36 24 270 (27.5) (200)
ZAXIS110, 120, 130, 130LCN,
16 28 24 300 (30.5) (220)
Travel device mounting bolt 130H, 130K
ZAXIS110M 16 32 24 300 (30.5) (220)
14 ZAXIS110M 14 6 22 180 (18.4) (135)
Travel reduction device cover ZAXIS110, 120, 130, 130LCN,
14 4 22 180 (18.4) (135)
mounting bolt 130H, 130K
ZAXIS135UR
ZAXIS110, 120, 130, 130LCN,
16 32 24 270 (27.5) (200)
15 Sprocket mounting bolt 130H, 130K
ZAXIS110M 20 32 30 460 (47) (340)
ZAXIS110, 120, 130, 130LCN,
12 8 19 100 (10) (70)
16 Upper roller mounting bolt 130H, 130K
ZAXIS110M 16 16 24 270 (27.5) (200)
ZAXIS110 16 48 24 300 (30.5) (220)
Lower roller mounting bolt ZAXIS120, 130, 130LCN, 130H,
16 56 24 300 (30.5) (220)
17 130K
Lower roller and track guard Lower roller 18 − 27 450 (46) (330)
ZAXIS110M
mounting bolt Track guard 18 8 27 500 (51) (370)
ZAXIS110 16 328 24 410 (42) (300)
ZAXIS120, 130, 130LCN, 130H,
18 Track shoe bolt 16 352 24 410 (42) (300)
130K
ZAXIS110M 18 336 27 560 (57) (410)
19 Track guard mounting bolt ZAXIS110M 18 8 27 500 (51) (370)
6 － 10 10 (1) (7.4)
20 Cover mounting bolt 10 － 17 50 (5.1) (37)
12 － 19 90 (9.2) (66)
21 Flexible master coupling of piping (1.05 to (7.59 to
8 4 pairs 13 10.3 to 12.4
1.26) 9.11)
22 T-bolt clamp of low pressure piping － 11 6.0 (0.6) (4.3)
W1-2-1
NOTE 1.Apply lubricant (e.g. white zinc B dis-

solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
3.Apply LOCTITE to threads before in-
stalling and tightening swing bearing
mounting bolts and lower roller mounting
bolts.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

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

Four different types and grades of bolt are employed. SA-040
Make sure to employ correct bolts and tighten them

correctly when assembling the machine or compo-
nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt H Bolt, Socket bolt M Bolt
Dia. Size Wrench
Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

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

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

tightening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
RIGHT RIGHT WRONG

ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

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

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°
30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
2. Scratches or other damage to

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

Description mm Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 93 (9.5, 69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 93 (9.5, 69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.
W1-2-6
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with a

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

O-ring (6), resulting in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10). Wrench Size Wrench Size Tightening Torque
Damage to O-ring (6) will cause oil mm mm
leakage. Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
4. If nut (9) is loose and oil is leaking, 19 17 29.5 (3.0, 21.5)
do not re-tighten nut (9). Replace 22 19 69 (7.0, 51)
O-ring (6) with a new one and check 27 22 93 (9.5, 69)
that O-ring (6) is correctly seated in 32 27 137 (14.0,101)
place, tighten nut (9). 36 30,32 175 (18.0,129)
41 36 205 (21.0,151)
46 41 205 (21.0,151)
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types 30°
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 using any Male Tapered Thread Male Straight Thread
screw-in connection.
W105-01-01-018
Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5, 25)
22 29.5 (3.0, 21.5) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16,116)
41 108 (11, 80) 205 (21,151)
50 157 (16,116) 320 (33, 235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male and
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of 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 de-

pending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-8
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
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 rub-
bing against each other.
W105-01-01-012
Take care so that hoses do not come into contact

WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic in-
spection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual in-
spection alone. For this reason, replace these parts at the
intervals shown in the table below. However, if any of
these parts are found to be defective, replace before
starting operation, regardless of the interval.
Also, when replacing hoses, check the clamps for defor-
mation, cracks, or other deterioration, and replace as
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Basic Machine Pump delivery hose Every 2 years
Swing hose Every 2 years
Hydraulic
Travel hose Every 2 years
System
Boom cylinder line hose Every 2 years
Front-End Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-10
GENERAL / Painting
PAINTING (ZAXIS110,110M, 120, 130, 130LCN, 125US, 135US)
Surfaces to Be Painted Painting Colour

• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover High-Grade Beige
Tool box cover High-Grade Black (ZAXIS110, 120)
Inner face Grey
• Front attachment YR01 [TAXI yellow]
• Track (undercarriage) N1.0 [Black]
• Floor plate M/F cation colour
• Rear left portion of cab YR-01 [TAXI yellow]
Final painted colour

• Inside and outside surface of cab High-Grade Beige
[KASAI PAINT LF-113-230B
• Right window beam
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) N2.0 (Black)
• Lever (Travel, lock, foot rest) N2.0 (Black)
• Cover side control valve High-Grade Black (ZAXIS125US, 135US)
• Engine cover High-Grade Black (ZAXIS110, 120)
• Ladder rail on right side of upperstructure High-Grade Black
• Mirror stay High-Grade Black
KASAI PAINT Amilack 1400 deep black.
• Antislip cover (Refer to W1-3-2)
(ZAXIS125US, 135US)
• Tool box (Refer to W1-3-2) N1.0 [Black] (ZAXIS125US, 135US)
ZAXIS110, 110M, 120, 130, 130LCN

Cab Inside and Outside Unit: mm
Engine Cover Right Engine Cover

Window
Beam
Right
Ladder
Rail
Mirror Stay
W1SE-01-03-001
Main Surface of Tool Box Cover 350 Bed Cover 900 Main Surface of
Upperstructure Upperstructure
Cab Inside and Outside
ZAXIS125US, 135US Right
Window
Beam
Right
Ladder
Rail
Mirror Stay
W1SE-01-03-002
Main Surface of Cover Side Bed Cover
350 675 Main Surface of
Upperstructure Control Valve Upperstructure
W1-3-1
GENERAL / Painting
ZAXIS110, 110M, 120, 130, 130LCN ZAXIS125US, 135US
Out Surface of Hinge
YR-01 A A
Swing Portion Out Surface of Hinge
(TAXI Yellow) YR-01
YR-01 (TAXI Yellow) Swing Portion
185 (TAXI Yellow) 190 YR-01 (TAXI Yellow)
B B
Door Catch Cover

YR-01 (TAXI Yellow)
720
W178-01-03-003 820 W1CC-01-03-006
5 Section B
Section A
Mask Garnished Portion
Door
Panel Behind the
Door
YR-01 (TAXI Yellow)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
ZAXIS125US, 135US ZAXIS110, 110M, 120, 130, 130LCN

Front Attachment Antislip Cover
YR-01 (TAXI Yellow) KASAI PAINT
Amilack 1400
Deep Black
Tool Box
N1.0 (Black) W1SE-01-03-003
W178-01-03-007
Upper
Side of
Frame
W178-01-03-006
IMPORTANT: When cleaning arm, cylinder, etc. Track (Undercarriage)

N1.0 (Black)
fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
shall be controlled under 70°C when
painting and drying.
W178-01-03-008
W1-3-2
GENERAL / Painting
PAINTING (ZAXIS135UR only)
Surfaces to Be Painted Painting Colour

• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover High-Grade Beige
Inner face Grey
• Front attachment YR01 [TAXI yellow]
• Track N1.0 [Black]
• Floor plate M/F cation colour
• Rear left portion of cab YR-01 [TAXI yellow]
High-Grade Beige
Final painted colour

• Inside and outside surface of cab High-Grade Beige, YR-01 [TAXI yellow]
[KASAI PAINT LF-113-230B
• Right window beam, U bolt
(Charcoal series black, half glossy)]
• Seat Stand N2.0 (Black)
• Lever (Travel, lock, foot rest) N2.0 (Black)
• Cab rear cover High-Grade Beige
• Seat stand cover High-Grade Beige
High-Grade Beige
Unit: mm
Ladder Rail on Right Side of Upperstructure
(High-Grade Black)
Cover Side Control Valve
(High-Grade Black) 400 665
W187-01-03-002
Bed Cover
W1-3-3
GENERAL / Painting
Out Surface of Hinge

YR-01 Swing Portion YR-01
(TAXI Yellow) A (TAXI Yellow)
W187-01-03-004
Tool Box (Black)
W187-01-03-003
Section B
5
Section A
Mask Garnished Portion
Door
Panel Behind the
Door
YR-01 (TAXI Yellow)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
shall be controlled under 70°C when
painting and drying.
W1-3-4
MEMO
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SECTION 2
UPPERSTRUCTURE
 CONTENTS 
Group 1 Cab Group 5 Control Valve
Remove and Install Cab ..............................W2-1-1 Remove and Install Control Valve ............... W2-5-1
Dimensions of the Cab Glass ....................W2-1-17 Disassemble Control Valve
4-Spool Section ......................................... W2-5-4
Group 2 Counterweight Disassemble Control Valve
Remove and Install Counterweight..............W2-2-1
5-Spool Section ....................................... W2-5-10
Group 3 Main Frame Separate and Combine
Remove and Install Main Frame..................W2-3-1 4-Spool and 5-Spool Control Valve.......... W2-5-16
Assemble Control Valve
Group 4 Pump Device 4-Spool Section ....................................... W2-5-18
Remove and Install Pump Device................W2-4-1 Assemble Control Valve
Remove and Install Pilot Pump and 5-Spool Section ....................................... W2-5-24
Regulator....................................................W2-4-4 Disassemble Blade Control Valve
Disassemble Pump Device..........................W2-4-8 (ZAXIS 135UR Only) ............................... W2-5-30
Assemble Pump Device.............................W2-4-16 Assemble Blade Control Valve
Disassemble Regulator..............................W2-4-28 (ZAXIS 135UR Only) ............................... W2-5-32
Assemble Regulator ..................................W2-4-30
Disassemble Solenoid Valve .....................W2-4-32 Group 6 Swing Device
Assemble Solenoid Valve ..........................W2-4-34 Remove and Install Swing Device............... W2-6-1
Disassemble and Assemble Pilot Disassemble Swing Device......................... W2-6-4
Pump (ZAXIS 110,120,125US,135US) ....W2-4-36 Assemble Swing Device............................ W2-6-10
Disassemble and Assemble Gear Disassemble Swing Motor ....................... W2-6-18
Pump (ZAXIS 135UR Only) .....................W2-4-38 Assemble Swing Motor.............................. W2-6-22
Maintenance Standard...............................W2-4-40 Disassemble Valve Unit............................. W2-6-28
Assemble Valve Unit ................................. W2-6-30
Maintenance Standard .............................. W2-6-32
187W-2-1
Group 7 Pilot Valve Group 10 Solenoid Valve
Remove and Install Right Pilot Valve Remove and Install Solenoid Valve Unit ... W2-10-1
(ZAXIS 110,120,125US,135US) ................W2-7-1 Disassemble Proportional
Remove and Install Left Pilot Valve Solenoid Valve ......................................... W2-10-6
(ZAXIS 110,120,125US,135US) ................W2-7-5 Assemble Proportional Solenoid Valve ..... W2-10-8
Remove and Install Front / Swing Pilot Valve Remove and Install Emergency Stop Solenoid
(ZAXIS 135UR) ..........................................W2-7-8 Valve Unit (ZAXIS 135UR Only) .............W2-10-11
Disassemble Right and Left Disassemble and Assemble Selector
Pilot Valves...............................................W2-7-10 Valve ...................................................... W2-10-14
Assemble Right and Left Disassemble and Assemble Unloading
Pilot Valves...............................................W2-7-14 Valve ...................................................... W2-10-16
Remove and Install Travel
Pilot Valve.................................................W2-7-19 Group 11 Holding Valve
Disassemble Travel Pilot Valve..................W2-7-22 Remove and Install Holding Valve..............W2-11-1
Assemble Travel Pilot Valve ......................W2-7-26 Holding Valve (ZAXIS 135UR Only) ...........W2-11-4
Remove and Install Offset Pilot Valve
(ZAXIS 135UR) ........................................W2-7-32
Remove and Install Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-34
Disassemble Offset / Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-36
Assemble Offset / Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-38
Group 8 Pilot Shut-Off Valve

Remove and Install Pilot Shut-Off
Valve...........................................................W2-8-1
Disassemble Pilot Shut-Off Valve
(ZAXIS 110,120).......................................W2-8-10
(ZAXIS 125US,135US,135UR) ................W2-8-12
Assemble Pilot Shut-Off Valve
(ZAXIS 110,120).......................................W2-8-14
(ZAXIS 125US,135US,135UR) ................W2-8-16
Group 9 Signal Control Valve

Remove and Install Signal
Control Valve..............................................W2-9-1
187W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal (ZAXIS110, 120)
1. Remove seat mounting nuts (2) to remove seat
(1).
: 17 mm
W178-02-01-001
2. Remove bolt (4) behind the cab to remove rear

box (3).
: 17 mm
3
3. Raise duct (5) to remove it.
4
5
W178-02-01-012
4. Remove filter (6) with a screwdriver to remove

screw (7), then remove duct (8) from the cab. 6
W178-02-01-013
W2-1-1
5. Disconnect cable connectors (10, 11, 12, and 13)
on the right back side in the cab and ground (9)
at rear inside of the cab.
10
11
12
13
W178-02-01-014
6. Remove washer vinyl hose (14) at rear inside of

the cab.
14
W178-02-01-015
7. Remove cap (15) from duct cover (17) with a 16

screwdriver. Use a screwdriver to loosen screws
(16) to remove duct cover (17). 17
15
W178-02-01-016
8. Remove screw (18) and bolt (21) to remove duct

(19) and duct (20).
: 17 mm
18
Matching Surface of Duct
19
W178-02-01-017
20 21
W2-1-2
CAUTION: Cab weight: 290 kg (640 Ib)
9. Attach lifting straps (22) to the cab top.
22
W178-02-01-018
10. Remove cab mounting bolts (23) and nut (24).

: 17 mm
: 24 mm
23
: 8 mm
24
W157-02-01-010
11. Carefully hoist the cab to remove it.
W157-02-01-001
W2-1-3
Removal (ZAXIS125US, 135US)
1 2
1. Remove seat mounting bolts (2) (4 used) and
bolts (3) (2 used) under the seat belt, to remove
seat (1).
: 17 mm, 16 mm
W1SE-02-01-001
1
3
2. Use a screwdriver to remove cap (6) from duct

W1SE-02-01-002
cover (5).
Remove screws (4) to remove duct cover (5).
4
3. Remove screws (9) from duct (7), then remove

duct (8). W1SE-02-01-003
W1SE-02-01-004
W2-1-4
4. Remove bolts (12) (4 used) behind the cab to
remove cover (11) from rear cover (10). 10
: 13 mm
12
11
W1SE-02-01-005
5. Remove clamp (14) behind rear cover (10) to

remove air conditioner hose (15) from air condi-
tioner hose (13). 10
13
14
15
W1SE-02-01-006
6. Remove vinyl hose (17) from washer tank (16).

16
17
W1SE-02-01-007
7. Remove screw (20) (2 used) to remove duct (21)

from duct (18) and duct (19).
18 19
20
21
W1SE-02-01-008
W2-1-5
8. Separate radio antenna feeder (22).
Remove screw (23) to remove ground (24). Re-
move connectors (25) (6 used). Pull out junction 22
box (26). Remove bolts (27) (2 used) to remove
23
ground (28).
: 13 mm
24
25
26
27
28
W1SE-02-01-09
CAUTION: Cab weight: 270 kg (595 lb) 29
9. Attach lifting straps (29) to cab top (4 places).
W1SE-02-01-011
10. Remove cab mounting bolts (30) (9 used) and

nuts (31) (4 used) from the frame.
: 17 mm
: 24 mm
: 8 mm
30
31
W1SE-02-01-10
11. Carefully hoist the cab to remove it from the

frame.
W157-02-01-001
W2-1-6
Removal (ZAXIS135UR) 1
1. Remove screws (4) (3 used) to remove cover (3).

9, 10
2
2. Remove seat-mounting bolts (2) (4 used) to re- 8
move seat (1).
: 17 mm 3, 4
3. Remove connectors (7 used) at the lower side of

seat (1) and earth wire.
: 10 mm, 17 mm
4. Remove floor mat and bolts (6) (2 used) to re-

move foot rest (5). W1CF-02-01-020
: 17 mm
6
5 7
5. Remove caps (9) (4 used) from duct cover (8)
with a screwdriver. Remove screws (10) (4 used)
to remove the duct cover.
M196-09-021
6. Remove screws (11) (3 used) to remove duct

(14).
11
7. Remove bolts (13) (2 used) to remove filter as-

sembly (12).
: 17 mm
12, 13
W1CF-02-01-001
14
W2-1-7
8. Remove nuts (16) (4 used) and bolts (17) (9
used) (bolt: 5 used, socket bolt: 4 used) from the
cab bottom plate.
: 8 mm Cab
Mounting
: 17 mm Holes
: 24 mm (9 used)
Lubber
17 Mounting
Holes
16 (4 used)
15
W1CF-02-01-002
Earth Wire Mounting Position
Bracket (at 4 places)
18
9. Remove the vinyl hose from cab (18).
CAUTION: Cab weight: 218 kg (480 lb)
10. Attach wire rope to brackets on top of the cab (at

4 places).
Hoist the cab by crane and remove it.
Vinyle Hose
W1CF-02-01-018
W2-1-8
Installation (ZAXIS110, 120)
1. Attach the cab with lifting straps to hoist it by

crane, then place the cab on the frame.
W157-02-01-001
2. Install cab mounting bolts (23) and nut (24).

: 17 mm 23
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
: 24 mm
: 205 N･m (21 kgf･m, 152 Ibf･ft)
: 8 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
24
W157-02-01-010
7
3. Install duct (8) to the rear console of the cab with
screws (7). Install filter (6) into duct (8).
: 4.9 N･m (0.5 kgf･m, 3.6 Ibf･ft)
8
W178-02-01-013
4. Install harness connectors (10, 11, 12 and 13) at

the right inside of the cab and install ground (9) in 9
the cab.
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft) 10
11
12
13
W178-02-01-014
W2-1-9
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
W178-02-01-015
6. Align the mounting hole for duct (5), while press-

ing it to install the hose into the hole.
4
7. Install rear box (3) with bolt (4). 5
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
W178-02-01-012
8. Install duct (20) with bolt (21). Install duct (19)

into duct (20) and fix them with bolt (18).
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
18
Matching Surface of Duct
19
W178-02-01-017
20 21
W2-1-10
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17). 16
17
15
W178-02-01-016
10. Secure seat (1) with nut (2).

: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
W178-02-01-001
W2-1-11
Installation (ZAXIS125US, 135US)
1. Attach lifting straps to top of the cab (4 places).

Hoist the cab by crane and place it on the frame.
2. Install cab mounting bolts (30) and nuts (31). W157-02-01-001
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
: 24 mm
: 210 N･m (21.5 kgf･m, 155 Ibf･ft)
: 8 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
30
31
3. Connect grounds (28) with bolt (27).
Put junction box (harness side) (26) onto the W1SE-02-01-10
junction box.
Install connectors (25) (6 used).
Install ground (24) with screw (23).
22
Connect radio antenna feeders (22).
: 13 mm 23
: 10 N･m (1.0 kgf･m, 7.4 Ibf･ft)
24
25
4. Install duct (21) into duct (18) and duct (19) with
26
screws (20) (2 used).
27
28
W1SE-02-01-09
18 19
20
21
W1SE-02-01-008
W2-1-12
5. Install vinyl hose (17) at the bottom of washer
tank (16) behind the cab.
16
17
W1SE-02-01-007
6. Push air conditioner hose (15) upward to install

air conditioner hose (13).
Secure the hose as its connecting position with 10
clamp (14). 13
14
15
W1SE-02-01-006
7. Install cover (11) onto rear cover (10) with bolts

(12) (4 used). 10
: 13 mm
: 10 N･m (1.0 kgf･m, 7.4 Ibf･ft)
12
11
W1SE-02-01-005
8. Install duct (8) into duct (7) with screws (9) (2
used).
: 3 N･m (0.3 kgf･m, 2.2 Ibf･ft)
7
W1SE-02-01-004
W2-1-13
9. Install duct cover (5) with screws (4). Install caps
(6) onto duct cover (5).
: 3 N･m (0.3 kgf･m, 2.2 Ibf･ft)
4
W1SE-02-01-003
1 2
10. Secure seat (1) with seat mounting bolts (2) (4

used) and bolts (3) (2 used) under the seat belt.
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
: 16 mm
: 70 N･m (7.1 kgf･m, 51 Ibf･ft)
W1SE-02-01-001
1
3
W1SE-02-01-002
W2-1-14
Installation (ZAXIS135UR)
CAUTION: Cab weight: 218 kg (480 lb) Bracket

(at 4 places)
1. Attach wire rope to brackets on top of the cab (at
4 places). Hoist the cab by crane and put it on
the frame carefully. 18
2. Connect the vinyl hose.
W190-02-03-009
Cab
Mounting
Holes
(7 used)
3. Install nuts (16) (4 used), bolts (17) (9 used) and
earth wire.
: 24 mm
: 206 N･m (21 kgf･m, 151 lbf･ft)
Lubber
: 17 mm Mounting
17
: 50 N･m (5.1 kgf･m, 37 Ibf･ft) Holes
: 8 mm 16 (4 used)
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
15
W1CF-02-01-002
Earth Wire Mounting Position
11
4. Install filter assembly (12) with bolts (13) (2

used). 12, 13
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
5. Install duct (14) with screws (11) (3 used).

W1CF-02-01-001
14
W2-1-15
6. Install duct cover (8) with screws (10) (4 used).
Install caps (9) (4 used) to duct cover. 1
9, 10
7. Install foot rest (5) and floor mat (7) with bolts (6) 2
(2 used). 8
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft) 3, 4
8. Install connectors (7 used) at the lower side of

seat (1) and earth wire.
: 10 mm (Connectors set bolt)
: 2.9 to 49 N･m
(0.3 to 5.0 kgf･m, 2 to 36 lbf･ft)
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
9. Install seat (1) with bolts (2) (4 used).

: 17 mm 6
: 50 N･m (5.1 kgf･m, 37 Ibf･ft) 5 7
10. Install cover (3) with screws (4) (3 used).
M196-09-021
W2-1-16
DIMENSIONS OF THE CAB GLASS
(ZAXIS 110, 120)
A
Chamfer Here
NOTE: Unit: mm
67 303.5
(1 mm=0.039 in) 11 Chamfer along the
R2 periphery unless
otherwise specified
R98 R35
4-φ13 0-1
R3018
405 30 Chamfer both
Section A W178-02-01-019
sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
Suitable for the standard machine

Along the Along the W178-02-01-002 after March in 2002
Periphery Periphery B
c1 c1
(60.3) 261.6±1
(9.4)
R42
R72
Section C W178-02-01-019
366
R2992
C
546±1
14
733
R92
(4 mm)
R58
R58
170.6
R11508
70
50
R1808 R42
882.5 997
321.9±1
W178-02-01-024
(4 mm)
Remove sharp
edges along the
R308 R1898
periphery
R258
100
150 Section B W178-02-01-019

943
W178-02-01-007
W2-1-17
NOTE: Unit: mm
(1 mm=0.039 in)
Chamfer Here Chamfer
Chamfer Here along the
85.4 periphery
unless
343.3 213 otherwise
specified
R105
R72 R10
R105
(4 mm)
Chamfer along the periphery
unless otherwise specified
39.5 D
733 733
C R2465 Section C 2-φ12.2 +0.5-0
and D
(4 mm)
W178-02-01-019 6.754°
40
Polish chamfer the

both fringes
289.5
3-R4 50
2-R4
86.9 50
50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
(5 mm) Chamfer along

the Periphery
982.7
W178-02-01-004
R2002
872
R123
R5 for 3 Places 38.2

R14
364.7 51
R2475 470.6
Chamfer along the W178-02-01-009
(5 mm) periphery
R115
888.58
W178-02-01-010
W2-1-18
Suitable for the standard machine after March in
2002
W178-02-01-005
A
753
R63
R63
610.5
490
(4 mm)
R115 R115
R167
50
50
512.5
R167
W178-02-01-025
Remove sharp
edges along the
periphery
Section A
W178-02-01-019
W2-1-19
(ZAXIS125US, 135US)
NOTE: Unit: mm
(1 mm=0.039 in)
Along the Along the

A
Periphery Periphery
C1 C1 75.6
1110.5
R5
27.3
36 (Specified)
110 R2929 R30
R293.5
R129
36
532.5
(5 mm) R75
770.5
36
1081.1
R2929 193.6 R5
Section A W178-02-01-019 189 39 58±5
R30 (Specified)
R20 R542
52.8
(Fillet) 1044.4
R1910
R5
39 415.1
322.1 1164.4
W1SE-02-01-013
Chamfer
Here
Chamfer along the Periphery

2-R5 unless Otherwise Specified.
2-R20 34 2-R105
2-R15 32.5
4-R73
W1SE-02-01-012 40
39.5
42.3 (4 mm) φ13.5±0.2 557
40
R2 320±0.5 2-R15
2-R20 B
2-φ13.5±0.2
48±5
112±0.2 23.5
54.8±0.2
697.5±0.5
291±0.2
Stop R Here
803
W1SE-02-01-014
Section B W178-02-01-019
W2-1-20
NOTE: Unit: mm (1 mm=0.039 in)

R2852.4 R55.8
FREE R 9±5
32±5
(5 mm) 92.8
27.4
342.7
55.1
W1SE-02-01-018
W1SE-02-01-012
444.2±1
200 152.9±1
194.6
Chamfer along the

Periphery unless
Chamfer along
Otherwise Speci-
the Periphery
fied
unless Other-
wise Specified
597±1
(5 mm)
(5 mm)
C D
597±1
R2916.2 41.5
Chamfer
Here
40 Chamfer
Here
+1
2-φ13 0
101±5
10±5 167
50.2
4-R5 4-R5
109.6
249.7±1 347.4±1 50.2

69.7
W1SE-02-01-017
W1SE-02-01-016

596.5
537±0.5 2-R5
371
R2937 2-φ18±0.5
(4 mm)
412
244±0.5 50±0.5 Section C and D
63.5±0.5 W178-02-01-019
R114
67.5±0.5
R551.5 372.5
40
96
490.5 40 R9
637
652
W1SE-02-01-015
W2-1-21
(ZAXIS135UR)
Unit: mm (1 mm=0.039 in)
NOTE: JIS R3211
R 1727.8 R 1717.9
4 4
280.2
R65.5 R5 R10 R65.5
823.6
R26936.5
R5 W1CF-02-01-018
R67.5
302.7 300.5
R67.5 W1CF-02-01-009 W1CF-02-01-010
R148
42.1 61.2
39.5
R9998 44.5 38.1
195.1 20.9
108.9
2.5
71.5 φ82
3-R10 436.3
58
5-R20
36.6 357.7
36.1 R400
4.7 462.5
R900 R2300 (4 mm)
86.7
291.8
165 400.3 27.7 17.8 19.9
24.6 22.5
989
262.4 70
100
334.2 258.8
φ82
78.1 9
208.7 206.1
119
36
397.5 61.2 72
R68 2.5
R182 R130 W1CF-02-01-013

R49 561
375.8 467.8
219.1 165.6 4-R30 150
3-R13
36
35.5 521 36.5 667
W1CF-02-01-011
593
596.1 R32
W1CF-02-01-012
W2-1-22
Unit: mm (1 mm=0.039 in) 193 255 41
33
R82.5 R82.5
52.5
540 400
φ25
532
548
(4 mm)
984.5
614
9-φ18
487 2-R50 2-R80 107

37 33
41
2-R80 8 2-R60
51 590
589
W1CF-02-01-017
W1CF-02-01-015 1022.3
21.5 25.9
R91 R71
666
520 (4 mm)
8 8
20
50 R9126.7 R22862.3
615.8
81.1
R5 R91
+1
φ12 -0
21.4
462 (4 mm)
334.8 R306
21 21 R71
R65 28 R65
17.6 221.6 559.6 288.5
W1CF-02-01-016
W1CF-02-01-014
W197-02-01-005
W2-1-23
Remove Cab Glass (ZAXIS110, 120)
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section
Mounting Rubber Glass

CAUTION: When removing broken or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or similar
should be used to tape the broken or
cracked glass ready to reinforce them so as Cab
to prevent injury from occurring. Be sure to Seal Rubber
remove all glass fragments.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal. W178-02-01-022
W178-02-01-004
1. Insert bamboo spatula into position A in mounting

rubber to pry the mounting rubber apart along all A
periphery. It is easier to remove glass when air is
entered between cab and mounting rubber.
2. Tap glass from the side in cab by palm of hand to
take the glass off. Two men are required to do
the work.
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special Cab
bonding agent. The cab glass may
Seal Rubber
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
W178-02-01-022
assembly.
The upper front glass is
arched-fringed. If this glass needs
to be replaced, contact with the
nearest HITACHI Office to replace it
as an assembly.
W2-1-24
Procedures to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the
A
glass when air is entered between cab and
mounting rubber.
Cab
2. Tap glass from the side in cab by palm of the

W216-02-01-005
hand to take the glass off. Two men are required
to do the work.
W178-02-01-002
Glass
Mounting Rubber
Method to remove rear side cab glass

Cab Inside Stopper
1. Remove stopper (groove rubber) with a minus
(Groove Rubber)
screwdriver.
A
A
2. Insert a bamboo spatula into position A in Cab
mounting rubber to pry the mounting rubber apart
along all periphery. W216-02-01-003

to do the work.
W178-02-01-005
W2-1-25
Cab Glass Installation Procedure
Left-Hand Cab Glass
(ZAXIS110, 120)
Procedure of installing the left-hand cab glass, the
lower glass of the door and the upper front glass:
A
1. Install the seal rubber on the left-hand cab glass CSE Braid
and lower glass of the door.
Section A
Seal Rubber
Put connect end in center of

glass edge and then adhere it.
W178-02-01-021
Lower Glass of Door

50
5
W178-02-01-023 A
CSE Braid
Seal Rubber
2. When the mounting rubber is already on the 10 10

glass, pull and fasten the mounting rubber onto
the mounting face of cab.
Mounting Rubber Section W178-02-01-020

mounting rubber using the special
adhesive. The cab glass may fall if Cab Glass Mounting
the special adhesive is not used. Rubber
The cab glass assembly cannot be
replaced individually. Be sure to re-
place the cab glass as an assembly.
The upper front glass is
arched-fringed. If this glass needs Cab
to be replaced, replace it as an Seal Rubber
assembly.
W178-02-01-022
W178-02-01-004
W2-1-26
Procedures of installing right-hand cab glass: Mounting Rubber Section
1. Install the mounting rubber into the surrounding

Mounting
of the cab glass. Bond the connectors of the Rubber Cab Glass
mounting rubber with the adhesive (Cemedine
366 Standard or equivalent).
Cab
NOTE: Rubber aging will cause the contraction of
the rubber, be sure to leave a little extra,
install by pressing with hands.
W216-02-01-005
2. Put and fasten the mounting rubber on the

mounting face of the cab after installing the rub-
ber.
W178-02-01-002
Procedures of installing rear cab glass:
1. Insert the mounting rubber around the cab glass. Mounting Rubber Section
Install the connectors or the mounting rubber with
the adhesive (Cemedine 366 Standard or equiva- Cab Glass
Mounting
lent). Rubber
NOTE: Rubber aging will cause the contraction of Stopper

the rubber, be sure to leave a little extra,
install by pressing with hands.
2. After installing the glass assembly on the cab, Cab

insert the stopper into the rubber.
W216-02-01-003
IMPORTANT: The rear side glass is

arched-fringed type. If this glass
needs to be replaced, replace it as
an assembly.
W178-02-01-005
W2-1-27
Method for Removing Cab Glass
(ZAXIS125US, 135US)
Procedures for removing right-hand cab glass, rear

left-hand glass and lower glass of the door are as fol-
lows:
Right-Hand Glass

cracked glass, there is a danger of severe
injury from glass shards.
Before removing, bind the broken area and
crack positions with gummed tape to prevent
the danger from occurring. Fallen glass
shards must be removed. Garnish
Garnish
1. Remove resin panel, garnish, spacer, and etc. Resin Panel

around the glass. Lower Glass Rear Left-Hand
of the Door Glass
W1SE-02-01-042
Cab
2. Pierce a hole in adhesive with awl (or cutter, etc). Glass
Awl
Adhesive W1SE-02-01-033
3. Pass a piano wire or iron wire through the

through hole.
Piano Wire
(Iron Wire)
W1SE-02-01-034
W2-1-28
4. Wind both ends of the piano wire to drivers. Saw
down the adhesive by sawing back and forth.
Remove the glass from the cab. (Outside of
Cab the Cab)
NOTE: Saw down from the middle of adhesive
between glass and cab. Glass
There is a danger that piano wire may
break as it is heating in local part. Always
change the part used in sawing for cooling.
Adhesive
(Inside of the Cab)
W1SE-02-01-035
W2-1-29
Method for Installing Cab Glass
(ZAXIS125US, 135US)
Right-Hand Glass
Procedures for installing right-hand cab glass, rear
left-hand glass and lower glass of the door are as
follows:
1. Remove the adhesive left at the cab side all

around by about 1 to 2 mm (0.04 to 0.08 in) with
cutter.
NOTE: Take care not to scratch the cab painting.
Lower Glass Rear Left-Hand

of the Door Glass
W1SE-02-01-042
Cab
Cutter
2. Clean the adhesive surface at cab side with the
white gasoline.
Cut the Adhesive Down
by 1 to 2 mm Deep
W1SE-02-01-036
IMPORTANT: Shake primer (24) vigorously for

about 1 minute to mix thoroughly
Cab
before loosening its cap. Apply Primer (24)
It should be used quickly when Evenly
opened and sealed immediately Adhesive Cut Face
when applying is finished. at Cab Side
It should be used within 3 days after
being opened. (It can be wasted in 2
hours if left it opened.) W1SE-02-01-038
3. Apply coating primer (SUNRISE MSI Primer 24)

onto the adhesive cut face at cab side evenly.
Wait for 15 minutes or so to let the coating dry by
itself.
NOTE: Apply the coating evenly, neither too much,

nor too little.
4. Clean the surface for installing new glass with

clean waste cloth after fully soaking it in alcohol.
W2-1-30
IMPORTANT: Shake primer (35) vigorously for 11. Lift the glass by a suction lifter (rubber suction
about 1 minute to mix thoroughly plate 4355282, refer to W2-1-32) within 5 minutes
before loosening its cap. to adhere onto the cab.
It should be used quickly when
opened and sealed immediately NOTE: Press fit the glass onto the cab when lo-
when applying is finished. cating it by the spacer adhered on the
It should be used within 3 days after glass. The other surface where applied
being opened. (It can be wasted in 2 with adhesive, except the mating surface,
hours if left it opened.) should be cleaned with white gasoline be-
5. Apply glass primer (SUNRISE MSI Primer 35) fore the adhesive takes.
onto the glass where it needs to be coated with
the adhesive. Wait for 15 minutes or so to let the 12. The glass should be secured with gummed tape
coating dry itself. to prevent it from moving until the adhesive be-
(As for the position where glass primer 35 should comes solid.
be applied, refer to W2-1-32) NOTE: Time required for adhesive (SUNRISE MSI
SR Seal U90 4463876) becoming solid: 8
6. Peel the paper from the spacer and put on adhe- hours (Just for reference).
sive at the place where the paper was instead. Right-Hand Glass
Gummed Tape
Then put the adhesive tape on the glass. 500
(As for the position to install spacers a, b and c, 350
refer to W2-1-32)
500
7. Cut the nozzle of adhesive cartridge (SUNRISE 450

MSI SR Seal U90 4463876) in V-shape.
200
8 to 9 mm
200
Cut Nozzle End 13 to 15 mm 100

500
into V-Shape
W1SE-02-01-039
200
Rear Left-Hand Glass 150
W1SE-02-01-027
8. Remove the seal from the cartridge end to install 200

V cut nozzle on it.
500
Remove
Seal
200
W1SE-02-01-040
Adhesive
Cartridge
150
Lower Glass of the Door
150
W1SE-02-01-028
9. Caulk the cut ridge onto hand cauking gun.

50
10. When applying primer, it should be applied onto 150
the glass evenly in V-bead-shape at the position
200
where adhesive should be coated.
150
(As for the position to apply adhesive, refer to
W2-1-32) W1SE-02-01-041
W2-1-31
Unit: mm Right-Hand Glass
B
Spacer a (4458466) B
20
Spacer b 700
R7 Spacer c
10.9 Lift Par-
8.7 tially 160
0.5 5 c
305 Spacer a
1 3.6 Adhesive Tape A

110 85
on Both Side
52 450
6
8.5
A
Concave W1SE-02-01-030
W1SE-02-01-019
Rear Left-Hand Glass

Spacer b (4458469) D
D
20
400
Spacer c
R6
9.3 10.5
30
5
650
0.5 Adhesive Tape

3.6 Spacer a
on Both Side
1 6 290
8.5
Convex
60
123
W1SE-02-01-031
Lower Glass of
W1SE-02-01-021
the Door
Spacer c (4458470)
20 286
5 Spacer c
225
Flat 7
62
W1SE-02-01-032
Adhesive Tape
445 Spacer b
on Both Side
W1SE-02-01-020
Section A-A Section B-B Section C-C Section D-D
Glass
Adhesive
Install Spacer with Spacer b

Its Concave Face
Adhesive
Facing Adhesive
Spacer c
Spacer a Spacer c
Install Spacer with

Glass Adhesive Adhesive
Its Convex Face
Facing Adhesive
W1SE-02-01-023 18
W1SE-02-01-024
W1SE-02-01-025 18
W1SE-02-01-026
W2-1-32
Glass
Coat Adhesive
4 to 5 mm
Bead Here
Spacer a or
9.0
Spacer b
Adhesive Tape
5.5 5.0 on Both Side
5.5 to 5.9
4.9 3.6
Cab
12.0
Unit: mm W1SE-02-01-022
13. The quantity of adhesive and primer should be

used.(Just for reference)
Adhesive: SUNRISE MSI SR Seal Primer: SUNRISE MSI

U90 Primer 24 (for coating)
Glass
(4463876) Primer 35 (for glass)
320 mL Cutridge 150 mL in Each Bottle
Right-Hand Glass (1 Piece) 1 used 1/10 used for each Bottle
Rear Left-Hand Glass (1 Piece) 1/2 used 1/20 used for each Bottle
Lower Glass for the Door (1 Piece) 1/3 used 1/50 used for each Bottle
IMPORTANT: Rear left-hand glass is

arched-fringed type. If this glass
needs to be replaced, contact the
nearest HITACHI Office to replace it
as a unit.
W2-1-33
Install upper door glass as follows
1. Before installing the glass, remove the garnish

from the outside of the sash assembly in the cab
for easier installing. Push the sash assembly out
of the cab and remove it by hand.
Sash Assembly Glass C
Garnish
2. Insert glass A and glass B into the sash slot. In-
sert glass C into the mounting rubber.
Glass A Glass B
W1SE-02-01-044
Glass C
3. Install the sash assembly with glass onto the
door from outside of the cab. Secure the sash Mounting Rubber
assembly inside of the cab with the garnish. Mounting Rubber
Sash Slot
Glass A and
Glass B
W1SE-02-01-045
W2-1-34
Install rear glass as follows
1. Align rear glass (1) with the mounting position at

the rear of cab.
2. Secure the glass with screws (3) (2 used), wash-

ers (4) (4 used) and nuts (5) (2 used) for hinges
(2) (2 used) temporarily. 3 7
3. Secure the glass with screws (7), washers (8) 2

and nuts (9) for catch handle (6) temporarily.
1
4. Tighten screws (3) (2 used) and screw (7) after 6
leveling.
5. Adjust glass positions on the cab at both right

and left with screw (10) of hinge (2).
5
IMPORTANT: Rear glass is arched-fringed type. If 8
this glass needs to be replaced, 4
9
contact the nearest HITACHI Office 10 2 3 6 7
to replace it as an assembly.
4 8
1 5 9 W1SE-02-01-046
W2-1-35
Install upper front glass as follows
1. The glass is adhered with mounting rubber. Draw Adhered with

the mounting rubber and secure to the cab Mounting Rubber (All
Around the Glass)
mounting surface. (All around the glass) Frame
2. Adhere seal (1) to the lower side the upper front

glass with POS seal.
Adhere both right and left ends (the part turning
thicker after bringing together) of seal (1) with
adhesive POS seal to secure them together.
Adhere the lip in the center of seal (1) with POS
Upper Glass
seal. No visible bending or folds can be found.
NOTE: POS seal:

TOSHIBA SILICON POS Seal (black)
Tube adhesive in glue form
IMPORTANT: The glass and mounting rubber

should be adhered with special ad- 1
hesive. Failure to do so, may result
in the glass dropping out. Therefore, Lower Glass
if the glass needs to be replaced,
replace the glass and mounting
rubber as an assembly.
Upper front glass is arched-fringed
type. If this glass needs to be re- Upper Glass
placed, contact the nearest HITACHI
Office to replace it as an assembly.
Adhere POS POS Seal

Seal
1 1
Lower Glass
Lower Glass
W1SE-02-01-047
W2-1-36
Remove Cab Glass (ZAXIS135UR)
Procedures to remove left-hand cab glass, lower
glass of the door.

cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or similar
should be used to tape the broken or
cracked glass to reinforce them so as to Cab
prevent injry from occurring. Be sure to re- Seal Rubber
move all glass fragments.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal. W178-02-01-022
W1CF-02-01-003
1. Insert bamboo spatula into position A in mounting

rubber to pry the mounting rubber apart along all A
periphery. It is easier to remove glass when air is
entered between cab and mounting rubber.

to do the work.

Cab
fall if the special bonding agent is Seal Rubber
not used. The cab glass assembly
can’t be replaced individually. Be
sure to change the cab glass as an
assembly. W178-02-01-022
W2-1-37
Method to remove upper front glass, right-hand cab Mounting Rubber Section
glass and rear side cab glass
1. Remove stopper (groove rubber) with a flat-head
screwdriver. Glass
Mounting Rubber
2. Insert a bamboo spatula into position A in

mounting rubber to pry the mounting rubber apart Cab Inside Stopper
along all periphery. (Groove Rubber)
A
3. Tap glass from the side in cab by palm of the A
hand to take the glass off. Two men are required Cab
to do the work.
W216-02-01-003
W1CF-02-01-005
W2-1-38
Cab Glass Installation Method (ZAXIS135UR)
Procedure of installing left-side cab glass and
lower glass of the door Mounting-Rubber
1. Install the mounting rubber on cab glass. Put and
fasten mounting rubber onto the mounting face of Glass
cab.
IMPORTANT: Be sure to install the cab glass and Cab

Seal-Rubber
fall if the special bonding agent is
not used. The cab glass and
mounting rubber cannot be replaced
individually. Be sure to change the W216-02-01-004
cab glass as an assembly.
Procedure Of Installing Upper Front Glass,

Right-Side Cab Glass and Rear Side Cab Glass
W197-02-01-005
1. Install mounting rubber on the surrounding of cab
glass. Joint the mounting rubber with the bonding
agent (Cemedine 366 Standard or equivalent)
NOTE: Rubber aging will cause the contraction of Mounting Rubber Section
rubber, be sure to leave a little bit longer,
and compress mounting rubber when in- Mounting Rubber
Glass
stall it to cab.
2. After installing glass assembly on the cab, insert

Stopper
the stopper into the mounting rubber.
Cab
W216-02-01-003
W2-1-39
Procedures to Install Upper Door Glass
B
A
1. Before installing the glass, remove the garnish
around sash assembly from the side in the cab. F
C
Press sash assembly down by hand and push
the sash outside to remove it.
D
2. Assemble glass C and glass F into sash grooves.
W1CF-02-01-003
Section A Rail
3. Install the sash assembly, which is with glass

ready fitted, onto the door from the outside of cab.
Then secure the sash assembly at the inside of
Glass Sash
cab with garnish.
Section E W1CF-02-01-021
Rail
W1CF-02-01-022
Section D
Garnish
Glass
Inside Cab
W1CF-02-01-024
Section B Cab
Sash
Garnish
W1CF-02-01-023
Glass
W2-1-40
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
1
Removal (ZAXIS110, 110M, 120, 130, 130LCN)
1. Remove caps (1) from the counterweight. Install

sling bolts (Fleno Ring Bolt: B-30: M30, Pitch 3.5)
to the counterweight.
CAUTION: Counterweight weight:

1800 kg (3970 lb) (ZAXIS110, 110M)
2450 kg (5400 lb) (ZAXIS120, 130, 130LCN)
W178-02-02-001
2. Attach wire ropes to sling bolts using shackles.

Take out slack of wire ropes by applying tension Wire Rope
slowly by crane.
Sling Bolt
W178-02-02-002
3. Remove mounting bolts (2) from the counter-
weight. Hoist to remove the counterweight by
crane.
: 41 mm
W178-02-02-003
W2-2-1
Removal (ZAXIS125US, 135US, 135UR) Right-Hand Cover 1
3150 kg (6950 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
Left-Hand 2
Cover
1. Remove harness (1) and vinyl hose (2) from the
washer tank.
2. Remove bolts (4) (2 used) from the engine cover

to remove mirror (3).
W1SE-02-02-005
3
4
Engine Cover
3. Remove caps (5, 6) (each 2 used) and install

W1SE-02-02-006
sling bolts (Fleno Ring Bolts: B-27: M27, Pitch 5
3.0 mm and B-36: M36, Pitch 4.0 mm) to the
counterweight.
6
W1SE-02-02-001
W2-2-2
CAUTION: Counterweight weight: Wire Rope

3150 kg (6950 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
4. Attach wire ropes to sling bolts using shackles.

Take out slack of wire ropes by applying tension
slowly by crane in order to keep balance of wire
ropes (4 used).
Sling Bolt
W1SE-02-02-002
5. Remove mounting bolts (7) (4 used) and washers

(8) (4 used) from the counterweight.
Hoist to remove the counterweight by crane.
: 50 mm
W1SE-02-02-003
W2-2-3
Installation (ZAXIS110, 110M, 120, 130, 130LCN)
1800 kg (3970 Ib) (ZAXIS110, 110M)
2450 kg (5400 Ib) (ZAXIS120, 130, 130LCN)
1. Hoist counterweight (3) and install it onto the

frame by crane.
Install washer (4) and tighten mounting bolt (2) to
the counterweight temporarily.
: 41 mm
3
2
4
W178-02-02-003
2. Remove wire ropes. Tighten the bolts with a

power wrench and torque wrench.
: 41 mm
: 1150 N･m (115 kgf･m, 830 Ibf･ft)
Torque Wrench
Power Wrench W178-02-02-004
3. Remove the sling-bolts. Install caps (1) to the 1

counterweight.
W178-02-02-001
W2-2-4
Installation (ZAXIS125US, 135US, 135UR)
3150 kg (6950 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
1. Hoist counterweight (9) and install it onto the

frame in order to keep its balance.
Install washers (8) (4 used) into mounting bolts
(7) (4 used) and tighten bolts (7) (4 used) to the 9
counterweight temporarily.
: 50 mm 8
2. Remove wire ropes (4 used).

Tighten the mounting bolts (4 used) with a power
wrench and torque wrench.
W1SE-02-02-003
: 50 mm
: 2250 N･m (230 kgf･m, 1660 Ibf･ft)
7 Wire Rope
3. Remove the sling bolts (4 used).

Install caps (5) (6) (each 2 used) to the counter-
weight. Torque Wrench
Power Wrench
W1SE-02-02-004
W1SE-02-02-001
W2-2-5
4. Install mirror (3) onto the engine cover with bolts
(4) (2 used). 3
4
Engine Cover
W1SE-02-02-006
5. Install harness (1) and vinyl hose (2) into the

washer tank.
1
Left-Hand 2
Cover
W1SE-02-02-005
W2-2-6
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious in-
jury. 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 any work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on

top of the hydraulic oil tank to release any re-
maining pressure.
3. Remove the hydraulic oil tank cap. Connect a

vacuum pump to maintain negative pressure in
the hydraulic oil tank.
Be sure to run the vacuum pump continuously
while working.
M104-07-021
W2-3-1
Removal
CAUTION: Cab weight:
290 kg (640 lb) (ZAXIS110, 110M, 120, 130,
130LCN)
270 kg (600 lb) (ZAXIS125US, 135US)
218 kg (481 lb) (ZAXIS135UR)
1. Remove the cab (Refer to “Remove and Install

Cab” in this section.).
: 24 mm, 17 mm
: 8 mm
W157-02-01-001
ZAXIS110, 110M, 120, 130LCN

1800 kg (3970 Ib) (ZAXIS110, 110M)
2450 kg (5400 Ib) (ZAXIS120, 130, 130LCN)
3150 kg (6940 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
2. Remove the counterweight.

(Refer to “Remove and Install Counterweight” in
this section.)
: 41 mm
W178-02-02-002
(ZAXIS110, 110M, 120, 130, 130LCN)
: 50 mm (ZAXIS125US, 135US, 135UR)
ZAXIS125US, 135US, 135UR
W1SE-02-03-001
W2-3-2
CAUTION: Front attachment assembly

weight:
1800 kg (3970 lb) (ZAXIS110, 110M, 125US)
2000 kg (4400 lb) (ZAXIS120, 130, 130LCN,
135US)
3300 kg (7275 lb) (ZAXIS135UR)
3. Remove the front attachment assembly.

(Refer to “Remove and Install of Front Attach-
ment” in this section.)
: 10, 17, 19, 24, 27, 36 mm W105-02-03-002
4. Remove all hoses from upper side of the center

joint. Then remove the stopper.
: 17 mm, 19 mm, 27 mm
: 22 mm (ZAXIS135UR only)
CAUTION: Upperstructure weight:

2600 kg (5730 lb) (ZAXIS110, 110M)
2700 kg (5950 lb) (ZAXIS120, 130, 130LCN)
3000 kg (6610 lb) (ZAXIS125US, 135US,
135UR)
W102-03-03-001
5. Attach wire ropes to the rear (counterweight
bracket) of the frame and the boom bracket. Take
up slack of wire ropes.
If chain block (1) is used, it is not only easy to
adjust the length of wire rope, but also easy to
level the frame.
Rear
IMPORTANT: Make sure rear slings not to touch
engine. W105-02-03-004
Front
W105-02-03-005
W157-02-03-001
W2-3-3
6. Put matching marks on the upperstructure and the
outer race of the swing bearing.
Loosen and remove mounting bolts (2) (30 used)
of the swing bearing.
: 27 mm
NOTE: The mounting angle of the swing bearing is

specified. (Refer to W3-1-1).
7. Chain block (1) shall be used to adjust and level W102-02-03-004
the frame, then hoist it slightly to remove it from

the undercarriage by crane. 1
W157-02-03-002
W2-3-4
Installation
CAUTION: Upperstructure weight:
2600 kg (5730 lb) (ZAXIS110, 110M)
2700 kg (5950 lb) (ZAXIS120, 130, 130LCN)
1
3000 kg (6610 lb) (ZAXIS125US, 135US,
135UR)
1. Fasten wire ropes to the main frame. Level the

main frame by adjusting chain block (1).
Hoist it by crane to install it to the undercarriage.
W157-02-03-002
2. Align the matching mark on the outer race of the

upperstructure and the swing bearing.
Install mounting bolt (2) to the swing bearing and
tighten it temporarily. Remove wire ropes and
tighten the mounting bolts to the swing bearing to
specification.
: 27 mm
: 390 N･m (40 kgf･m, 290 lbf･ft)
3. Install all hoses to the center joint. 2

: 17 mm W102-02-03-004
: 25 N･m (2.5 kgf･m, 18 Ibf･ft)
: 19 mm
: 30 N･m (3 kgf･m, 21.5 Ibf･ft)
: 27 mm
: 93 N･m (9.5 kgf･m, 69 Ibf･ft)
: 22 mm (ZAXIS135UR only)
: 57 N･m (6 kgf･m, 43 Ibf･ft)
4. Install stopper (4) to the center joint with bolt (3).

: 19 mm
: 90 N･m (9.2 kgf･m, 67 Ibf･ft)
(ZAXIS110, 120)
: 110 N･m (11.2 kgf･m, 81 Ibf･ft)
(ZAXIS125US, 135US) 3
: 88 N･m (9 kgf･m, 65 Ibf･ft)
(ZAXIS135UR) 4
Machine Front
W102-03-03-001
W2-3-5
CAUTION: Cab weight:

290 kg (640 lb) (ZAXIS110, 110M, 120, 130,
130LCN)
270 kg (600 lb) (ZAXIS125US, 135US) 5
218 kg (481 lb) (ZAXIS135UR)
5. Install cab (5).

(Refer to “Remove and Install Cab” in this sec-
tion.)
: 24 mm
: 205 N･m (21 kgf･m, 159 Ibf･ft)
: 17 mm W157-02-01-001
: 50 N･m (5.1 kgf･m, 36.89 Ibf･ft)
: 8 mm
: 50 N･m (5.1 kgf･m, 36.89 Ibf･ft) ZAXIS110, 120

1800 kg (3970 lb) (ZAXIS110, 110M)
2450 kg (5400 lb) (ZAXIS120, 130, 130LCN)
3150 kg (6940 lb) (ZAXIS125US, 135UR)
3670 kg (8090 lb) (ZAXIS135US)
6. Install counterweight (6).

(Refer to “Remove and Install Counterweight” in
this section.)
: 41 mm (ZAXIS110, 110M, 120, 130LCN)
: 1150 N･m (115 kgf･m, 830 Ibf･ft) W178-02-02-002
: 50 mm (ZAXIS125US, 135US, 135UR)

: 2250 N･m (230 kgf･m, 1660 Ibf･ft) ZAXIS125US, 135US, 135UR
W1SE-02-03-001
W2-3-6
CAUTION: Front attachment assembly

weight:
1800 kg (3970 lb) (ZAXIS110, 110M, 125US)
2000 kg (4400 lb) (ZAXIS120, 130, 130LCN,
135US)
3300 kg (7275 lb) (ZAXIS135UR)
7. Install front attachment assembly (7). Then, fill

with hydraulic oil.
(Refer to “Remove and Install Front Attachment”
in this section.)
: 5 mm
: 9.8 N･m (1.0 kgf･m, 7.2 Ibf･ft)
7
(ZAXIS135UR Angle sensor for boom foot)
: 17 mm W105-02-03-002
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)

: 19 mm
: 29.5 N･m (3 kgf･m, 21.5 Ibf･ft)
: 24 mm
: 270 N･m (27.5 kgf･m, 190 Ibf･ft)
: 27 mm
: 400 N･m (41 kgf･m, 295 Ibf･ft)
(Stopper bolt for boom foot pin)
: 27 mm M104-07-021
: 93 N･m (7.5 kgf･m, 54 Ibf･ft)
(Hydraulic line fitting for boom foot)
: 36 mm
: 175 N･m (18 kgf･m, 130 Ibf･ft)
(Hydraulic line fitting for boom foot)
8. Start the engine and set the front attachment in

posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if there
is any oil leakage.
W2-3-7
(Blank)
W2-3-8
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

starting any work.
pressure.
Preparation

maining pressure.

M104-07-021
NOTE: Be sure to run the vacuum pump continu-

ously while working.
W2-4-1
Removal (ZAXIS110, 110M, 120, 130, 130LCN)
2
1. Disconnect connectors.
CAUTION: Pump device weight: 95 kg 1 3

(210 lb) 4
2. Disconnect hoses (1 to 10 and 12) and pipe (11)
5
from the pump device.
: 17 mm, 19 mm, 27 mm, 36 mm
: 8 mm, 10 mm
3. Attach eyebolts (M12, Pitch 1.75 mm, Length 22 6

mm) (ST 0002) to the pump device, then connect 13 7
to a hoist.
4. Remove pump device mounting bolts (13) (8

used) to remove the pump device.
: 17 mm
11
12
Installation
1. Install eyebolt (ST 0002) on the pump device and
hoist it by crane.
2. Insert the drive shaft of the pump device into the 10

coupling, and install it with pump device mounting 9
bolts (13) (8 used). 8
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
W187-02-04-001
3. Connect hoses (1 to 10 and 12) and pipe (11).
4. Connect connectors.
Tightening Torque
Wrench Size (mm) Remark
N･m kgf･m (Ibf･ft)
: 27 93 9.5 (69) Hose
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 50 5.1 (37) Bolt
: 8 50 5.1 (37) Bolt
: 19 29.5 3 (21.5) Hose
: 17 9.8 1 (7.2) Hose
IMPORTANT: Bleed the air from the pump. (Refer

to W1-1-2).
Be sure to check hydraulic oil level
and that no oil leaks after assem-
bling.
: 27 mm
: 49 N･m (5 kgf･m, 36 Ibf･ft)
W2-4-2
Removal (ZAXIS125US, 135US, 135UR)
1. Disconnect connectors. 1 2
2. Disconnect hoses (1 to 10 and 12) and pipe (11) 3

Eyebolt (ST 0002)
from the pump device. Mounting
: 17 mm, 19 mm, 27 mm, 36 mm Position
: 8 mm, 10 mm
6
CAUTION: Pump device weight: 95 kg (210 13

lb) 7
3. Attach eyebolts (M12, Pitch 1.75 mm, Length 22
mm) (ST 0002) to the pump device, then hoist by
crane (Refer to W2-4-5).
12 Eyebolt
4. Remove pump device mounting bolts (13) (8 (ST 0002)
Mounting
used) to remove the pump device. Position
: 17 mm
8
Installation
1. Install eyebolts (ST 0002) on the pump device
and hoist by crane.
11
2. Insert the drive shaft of the pump device into the 10

coupling, and install it with pump device mounting
bolts (13) (8 used).
: 17 mm
: 50 N･m (5.1 kgf･m, 37 Ibf･ft)
3. Connect hoses (1 to 10 and 12) and pipe (11).

W1SE-02-04-001
4. Connect connectors. NOTE: The figure above shows for ZAXIS 125US
/ 135US.
Tightening Torque
As for ZAXIS 135UR, the blade pump
Wrench Size (mm) Remark (gear pump) is equipped at the end of pilot
N･m kgf･m (Ibf･ft)
Pump.
: 27 93 9.5 (69) Hose
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 50 5.1 (37) Bolt
: 8 65 6.6 (47.7) Bolt
: 19 29.5 3 (21.5) Hose
: 17 9.8 1 (7.2) Hose
IMPORTANT: Bleed the air from the pump. (Refer

to W1-1-2).
Be sure to check hydraulic oil level
and that no oil leaks after assem-
bling.
: 27 mm
: 49 N･m (5 kgf･m, 36 Ibf･ft)
W2-4-3
REMOVE AND INSTALL PILOT PUMP AND
REGULATOR
6 7 8 9 10
11
12
13
14
15
4
3
2
16
1
17
W176-02-04-004
1- Pilot Pump 6- Socket Bolt (2 Used) 10 - Socket Bolt (4 Used) 14 - Elbow

2- Socket Bolt (2 Used) 7- Socket Bolt (2 Used) 11 - Fitting 15 - O-Ring
3- Spring Washer (2 Used) 8- Socket Bolt (2 Used) 12 - O-Ring 16 - Pump Casing
4- Washer (2 Used) 9- Front Regulator 13 - Pipe 17 - Rear Casing
5- Rear Regulator
NOTE: The figure above shows for ZAXIS 125US

/ 135US.
As for ZAXIS 135UR, the blade pump
(gear pump) is equipped at the end of pilot
pump.
W2-4-4
• Pump device consists of the following parts illus-
trated below.
2. Remove socket bolts (2) (2 used) from rear cas-
ing (17), then remove pilot pump (1).
Rear Regulator Front Regulator : 8 mm
NOTE: The pilot pump mounting surface has been

coated with THREEBOND.
3. Loosen union nuts at both ends of pipe (13), re-

move the pipe from front regulator (9) and rear
regulator (5).
: 17 mm
4. Remove socket bolts (6) (8) (each 2 used) from

rear regulator (5).
W176-02-04-003 : 8 mm
Gear Rear Rear Front Front

Pump Casing Pump Pump Casing NOTE: Socket bolt (7) is used for installing the
solenoid valve on the rear regulator.
IMPORTANT: Be sure not to allow the O-ring be-

tween rear regulator (5) and pump
Removal casing (16) to come off.
CAUTION: Pump device weight: 5. Raise and remove rear regulator (5) from pump
95 kg (210 Ib) casing (16).
1. Install eyebolts (M12, pitch 1.75 mm, length 22
mm) (ST 0002) (2 used) to the pump assembly NOTE: After the rear regulator is raised, pull out
and hoist it, place it on sleepers, approximately the rear regulator obliquely toward pipe
100 mm (4 in) in width and thickness. (13) direction.
6. Remove socket bolts (10) (4 used) from front

Eyebolt (ST 0002) Mounting Position
regulator (9).
: 8 mm
IMPORTANT: Be sure not to allow the O-ring be-

tween rear regulator (9) and pump
casing (16) to come off.
7. By the same procedure as step 5, remove front
regulator (9) from pump casing (16).
W176-02-04-002
Sleeper
W2-4-5
6 8 9 10
11
12
13
14
15
4
3
2
16
1
17
W176-02-04-004
W2-4-6
Installation
IMPORTANT: Confirm that both the front regulator 3. Install O-ring (12) into fitting (11).
and its mounting surface have 8 Apply grease to fitting threads, then install the
O-rings installed on each. fitting into pipe (13).
1. Install front regulator (9) onto pump casing (16) : 17 mm
as follows. : 34.5 N･m (3.5 kgf･m, 25 Ibf･ft)
• Adjust the sleeve position so that the 2-sleeve
grooves inside front regulator are aligned. 4. Install O-ring (15) into elbow (14).
• Place the front regulator onto the pump casing, Apply grease to elbow threads, then install the
then put the feedback link pin into the 2-sleeve elbow into rear regulator (5).
grooves. : 17 mm
• Adjust the front regulator’s position so that the : 34.5 N･m (3.5 kgf･m, 25 Ibf･ft)
knock pin out of pump casing is inserted into the
front regulator. 5. Install pipe (13) into elbow (14).
• Install the front regulator onto the pump casing : 17 mm
with socket bolts (10) (4 used). : 34.5 N･m (3.5 kgf･m, 25 Ibf･ft)
: 8 mm
: 49 N･m (5 kgf･m, 36 lbf･ft) 6. Apply THREEBOND #1215 to the flange face of
pilot pump (1) (contact face with rear casing
(17)).
Feedback Link Pin Sleeve Knock Pin
9 IMPORTANT: As for the pilot pump, its suction

port (with larger diameter) should
face upwards.
7. Install pilot pump (1) into rear casing (17) with
socket bolts (2) (2 used), spring washers (3) (2
16 used) and washers (4) (2 used).
: 8 mm
: 49 N･m (5 kgf･m, 36 lbf･ft)
W176-02-04-008
IMPORTANT: Note that the lengths of socket bolts

(6) and (8) are different.
2. Install rear regulator (5) onto pump casing (16)
with socket bolts (6) (2 used) and (8) (2 used).
: 8 mm
: 49 N･m (5 kgf･m, 36 lbf･ft)
NOTE: Main items of installation are the same as

for that of front regulator (9).
W2-4-7
DISASSEMBLE PUMP DEVICE
10
9
8
27 28
7
6
5 26 29
4
3 25
30 32
2 24 31
1
22
11
7 23
12
13
14 33
22
34
21
20
19
18
17 2
16 35 1
15 36
37
38 47
46
39 4
40 44
45
41
44
43
9
11
49 48
42 5
16 14
13
17 12
50
19 51
20
21
10
38
41
40
18
W176-02-04-005
W2-4-8
1- Socket Bolt (12 Used) 14 - Restrictor Pin (2 Used) 27 - O-Ring (2 Used) 40 - Plate (2 Used)
2- Spring Washer (12 Used) 15 - Swash Plate R 28 - O-Ring (10 Used) 41 - Knock Pin (2 Used)
3- Rear Casing 16 - Servo Piston (6 Used) 29 - O-Ring (4 Used) 42 - Swash Plate F
4- Knock Pin (2 Used) 17 - Spring (6 Used) 30 - Pin (2 Used) 43 - Inner Race
5- Pin (4 Used) 18 - Plunger (18 Used) 31 - Feedback Link (2 Used) 44 - Retaining Ring (2 Used)
6- O-Ring 19 - Retainer (2 Used) 32 - Spring Pin (4 Used) 45 - Roller Bearing
7- Retaining Ring (2 Used) 20 - Bushing (2 Used) 33 - Valve Plate F 46 - Oil Seal
8- Roller Bearing 21 - Disc Spring (8 Used) 34 - Needle Bearing 47 - Retaining Ring
9- O-Ring (4 Used) 22 - Knock Pin (4 Used) 35 - Pump Casing 48 - Front Casing
10 - Socket Bolt (8 Used) 23 - Spring Pin (2 Used) 36 - Needle Bearing 49 - O-Ring
11 - Cradle Plate (2 Used) 24 - Link Pin (2 Used) 37 - Valve Plate R 50 - Drive Shaft
12 - O-Ring (4 Used) 25 - Pin (2 Used) 38 - Rotor (2 Used) 51 - Retaining Ring
13 - Backup Ring (4 Used) 26 - Spring Pin (2 Used) 39 - Shaft
W2-4-9
33
35 1
44
45
44
43
11
42 48
14
50
19
20
21
10
38
40
18
W176-02-04-005
W2-4-10
Disassemble Pump Device
• The pump cosists of the front and rear pumps. 4. With rotor (38) side upward, put front casing (48)
on sleepers, over 30 mm (1.18 in) in width and
• Disassemble front pump side thickness.
IMPORTANT: The valve plate F (33) side of rotor

CAUTION: Front casing weight: 27 kg (60 Ib) (38) is a slide face. Be sure not to
damage it.
1. Install eyebolt (M12) into front casing (48) and 5. Reach out for swash plate F (42) and pull out the
hoist it to take up a slack. rotor (38) assembly from drive shaft (50). Then
place swash plate F (42) with valve plate F (33)
facing downward.
Eyebolt Mounting Position
6. Reach out under retainer (19), remove the re-
tainer with plunger (18) from rotor (38).
7. Remove bushing (20) and disc springs (21) (4

used) from rotor (38).
8. Remove plate (40) from swash plate F (42).

NOTE: With plate (40) upward, slightly tap the
yoke, and the plate will float up.
W176-02-04-015
9. Loosen socket bolts (10) (4 used) on cradle plate
(11), remove the cradle plate from front casing
(48).
2. Remove socket bolts (1) (6 used) from front cas- : 5 mm
ing (48).
: 10 mm 10. Pull out drive shaft (50) by hand with roller bear-
ing (45) from front casing (48).
IMPORTANT: Inner race (43) on drive shaft (50)
cannot be replaced. Be sure not to NOTE: If it is difficult to pull it out, tap the front
damage it. casing side of drive shaft with a plastic
3. Pull out the front casing (48) assembly from hammer.
pump casing (35), at the same time pulling out
drive shaft (50), rotor (38) assembly and restric- IMPORTANT: When removing retaining rings (44),
tor pin (14) with the front casing. be sure not to damage the seal lip
contact surface of drive shaft (50).
NOTE: When pulling out front casing (48), slightly 11. Remove retaining rings (44) (2 used) from drive
raise and pull out pump casing (35) to shaft (50).
prevent rotor (38) from coming off.
NOTE: Do not remove restrictor pin (14) unless
necessary.
W2-4-11
10
8
7
3
31
1
11
14 33
34
35
38
39
45
16
17
50
W176-02-04-005
W2-4-12
IMPORTANT: Be sure to insert the large diameter • Disassemble Rear Pump Side
side of the drive shaft to the special
tool. IMPORTANT: Although the front pump is similar
12. Insert drive shaft (50), of which the large diame- to the rear pump, the parts used are
ter side goes first, to special tool (ST 7266). not exchangeable. Keep parts sepa-
Tap the end of special tool to pull out roller bear- rate after disassembling.
ing (45) from the drive shaft. 1. Romove socket bolts (1) (6 used) from rear cas-
NOTE: When replacing the inner race, replace ing (3). Remove rear casing (3) from pump cas-
with drive shaft (50) assembly. ing (35). At this time, shaft (39) and rotor (38)
assembly are removed with the rear casing.
: 10 mm
50 ST 7266
2. Keep rotor (38) assembly rotor side facing down-
ward, place it on the sleeper, over 80 mm (3 in) in
45 width and thickness.
3. Remove retaining ring (7) from shaft (39).
4. Remove the inner ring plate from roller bearing

(8).
5. Remove rear casing (3) from shaft (39). At this

time, the outer race of roller bearing (8), restrictor
pin (14) and cradle plate (11) are removed with
W176-02-04-009
the rear casing.
NOTE: Do not remove restrictor pin (14) unless
necessary.
13. Remove servo pistons (16) (3 used) and springs
(17) (3 used) from pump casing (35). 6. Remove socket bolts (10) (4 used). Remove cra-
dle plate (11) from rear casing (3).
14. Remove valve plate F (33) from pump casing : 5 mm
(35).
NOTE: Needle bearing (34) remains in pump cas-
ing (35). After the rear pump is disassem-
bled, push out the needle bearing by tap-
ping at the back.
15. Remove the feedback link (31) assembly from

pump casing (35).
NOTE: Do not disassemble feedback link (31)
unless necessary.
W2-4-13
3
31
34
21
20
19
18
17 35
16
15 36
37
38
39
40
W176-02-04-005
W2-4-14
7. Remove the outer race of roller bearing (8) from 15. Remove valve plate R (37) from pump casing
rear casing (3). (35).
NOTE: Insert finger into the outer race to pull up
directly. 16. Remove servo pistons (16) (3 used) and springs
(17) (3 used) from pump casing (35).
IMPORTANT: Retaining ring (7) is located under
the roller bearing. Do not hang 17. Remove the feedback link (31) assembly from
puller pawl on the retaining ring. pump casing (35).
8. Install guide (ST 7267) into the hole of shaft (39) NOTE: Do not disassemble the feedback link
end, to remove the inner race of roller bearing (8) unless necessary.
with a small puller.
18. The outer races of needle bearings (34) and (36)
remain in pump casing (35). Do not remove them
unless necessary.
When removing, tap the outer races out at the
ST 7267
back with a bar and hammer.
39
7 W176-02-04-010
10. Remove swash plate R (15) from shaft (39).
11. Remove plate (40) from swash plate R (15).

NOTE: With the plate upward, slightly tap the yoke,
and the plate will float up.
12. Remove retainer (19) with plunger (18) from shaft

(39).
13. Remove bushing (20) and disc springs (21) (4

used) from shaft (39).
14. Remove rotor (38) from shaft (39).
W2-4-15
ASSEMBLE PUMP DEVICE
2 15 16 17 22 35 17 16 42
4
1
4
47
44
10 46
14
10
40 14
21 20 18 37 36 51 43 34 33 18 20 21 40
48
6 24 25 31 26 23 30 23 26 31 25 24
11 49
3 11
7 45
8
9
9
5 41 19 39 38 38 50 19 41
W176-02-04-011
1
2
W2-4-16
1- Socket Bolt (12 Used) 14 - Restrictor Pin (2 Used) 27 - O-Ring (2 Used) 40 - Plate (2 Used)
2- Spring Washer (12 Used) 15 - Swash Plate R 28 - O-Ring (10 Used) 41 - Dowel Pin (2 Used)
3- Rear Casing 16 - Servo Piston (6 Used) 29 - O-Ring (4 Used) 42 - Swash Plate F
4- Knock Pin (2 Used) 17 - Spring (6 Used) 30 - Pin (2 Used) 43 - Inner Race
5- Pin (4 Used) 18 - Plunger (18 Used) 31 - Feedback Link (2 Used) 44 - Retaining Ring (2 Used)
6- O-Ring 19 - Retainer (2 Used) 32 - Spring Pin (4 Used) 45 - Roller Bearing
7- Retaining Ring (2 Used) 20 - Bushing (2 Used) 33 - Valve Plate F 46 - Oil Seal
8- Roller Bearing 21 - Disc Spring (8 Used) 34 - Needle Bearing 47 - Retaining Ring
9- O-Ring (4 Used) 22 - Knock Pin (4 Used) 35 - Pump Casing 48 - Front Casing
10 - Socket Bolt (8 Used) 23 - Spring Pin (2 Used) 36 - Needle Bearing 49 - O-Ring
11 - Cradle Plate (2 Used) 24 - Link Pin (2 Used) 37 - Valve Plate R 50 - Drive Shaft
12 - O-Ring (4 Used) 25 - Pin (2 Used) 38 - Rotor (2 Used) 51 - Retaining Ring
13 - Backup Ring (4 Used) 26 - Spring Pin (2 Used) 39 - Shaft
NOTE: For items 12, 13, refer to W2-4-18 and

W2-4-22.
For 27, 28, 29 and 32, refer to W2-4-24.
W2-4-17
15 16 17 22 35
40
21 20 18 37 36 34
24 31 30
3
7
19 39 38
W176-02-04-011
W2-4-18
Assemble Pump Device
• Assemble rear pump side IMPORTANT: Pay attention to the direction of disc
spring (21) and retainer (19).
1. Install needle bearings (34) (36), with their 5. Use the steps below to compose rotor (38) into
stamped marks on the outer race facing outward the assembly by the same procedure below.
respectively into pump casing (35) with special • Place the rotor with the center lug upward.
tool (ST 7262) and a hammer. • Compose disc springs (21) (4 used) to align the
outer circle with outer circle and inner circle with
IMPORTANT: As for valve plate R (37), assemble it inner circle. Then place them onto the center lug
with the long hole oriented down- of the rotor.
ward.
2. Apply the grease to the flat surface of valve plate
R (37), then assemble it to align with knock pin 21
(22) of pump casing (35).
20
3. Install spring (17) into servo piston (16) and then

38
install them into pump casing (35). (3 places)
IMPORTANT: Pay attention to the direction of as-

sembling feedback link (31) assem-
bly. W176-02-06-015
4. Align feedback link (31) assembly with pin (30)

groove of pump casing (35). At this time link pin • Cover disc spring (21) with bushing (20).
(24) faces rear casing (3). • Insert plungers (18) (9 used) into retainer (19)
NOTE: Both sides of pin (30) are parallel. Install from the flat surface, then install into the rotor.
the pin into the groove with the parallel
side aligned to it. IMPORTANT: The inner race for needle bearing
(36) is positioned at the large di-
30 ameter side of shaft (39). Take care
31
35
not to damage it.
6. Insert shaft (39) into the rotor (38) assembly.
7. Apply a film of grease to knock pin hole side of

plate (40), then align with knock pin (41) of
Parallel Side
swash plate R (15) to install.
Parallel Side W176-02-04-016
8. Install swash plate R (15) onto shaft (39).
9. Install retaining ring (7) into the inner link groove,

which is one of the two grooves on shaft (39).
W2-4-19
2 15
10
14
6 24 31
11
3
7
8
9
5 39
W176-02-04-011
W2-4-20
IMPORTANT: Pay attention to the direction of the 12. Level cylindrical surface of cradle plate (11) to
inner race for roller bearing (8). that of swash plate R (15) evenly, then assemble
10. Using special tool (ST 7265) and guide (ST 7267), rear casing (3) assembly onto shaft (39).
drive the inner race of roller bearing (8) into shaft At this time, the concave portion of feedback link
(39) with the inner race flange facing inside with (31) on the swash plate R and the threaded hole
a hammer. for lifting on the rear casing are in the same di-
rection.
ST 7265 NOTE: Because the roller of roller bearing (8) is
tilted, it is difficult to install the shaft, make
8 clean cloth into a ball and stuff it into the
ST 7267
bore of roller bearing so as to install the
39 shaft easily.
Concave Connect Portion

7 15
W176-02-04-012
11. Install rear casing (3) into the assembly as follow.

• Install the outer race of roller bearing (8), with the
W176-02-04-018
stamp mark facing front, into the rear casing.
NOTE: If inserting straight while aligning, the shaft
13. Place the inner race plate of roller bearing (8)
can be installed by hand.
with the stamp side outside, then install the inner
race plate of roller bearing (8) onto shaft (39).
• Install O-rings (9) (2 used) into the rear casing.
• Install cradle plate (11) and dowel pin (5) into the 14. Install retaining ring (7) into shaft (39).
rear casing after aligning their positions, then
assemble them with socket bolts (10) (4 used). IMPORTANT: Insert the pin of feedback link (31)
: 5 mm into the concave connect portion on
: 9.8 N･m (1 kgf･m, 7.2 Ibf･ft) swash plate R (15).
15. Align the concave connect portion of swash plate
• When restrictor pin (14) is removed, install R (15) with the position of link pin (24) to fit the
backup rings (13) (2 used) and O-rings (12) (2 rear casing (3) assembly into pump casing (35).
used) into the restrictor pin. Install the restrictor
pin into the rear casing from the orifice side. 16. Using socket bolts (1) (6 used) and spring wash-
ers (2) (6 used), install rear casing (3) into pump
12 casing (35).
: 10 mm
3 14
: 108 N･m (11 kgf･m, 79.6 Ibf･ft)
W176-02-04-013
Orifice 13
• Install O-ring (6) into the rear casing.
W2-4-21
22 35 17 16
47
44
51 43 33
48
30 31 24
45
38 50
W176-02-04-011
W2-4-22
• Assemble front pump side
6. Install retaining ring (51) into drive shaft (50).
IMPORTANT: When assembling valve plate F (33),
keep the long hole oriented down- IMPORTANT: Take care not to damage the slide
ward. face of oil seal (47) of drive shaft
1. Apply a film of grease to the flat surface of valve (50).
plate F (33), then align it with knock pin (22) of 7. Install retaining ring (44) into the nearer groove to
pump casing (35), to assemble. the shaft end, which is one of two grooves on
drive shaft (50).
2. Install spring (17) into servo piston (16), then as-
semble the servo piston into pump casing (35). (3 8. Using special tool (ST 7266) and a hammer, tap
places) roller bearing (45), with the stamp mark forward,
into drive shaft (50).
IMPORTANT: Pay attention to the direction of the
feedback link assembling. 9. Install the inner race plate of roller bearing (45)
3. Align the feedback link (31) assembly with the into drive shaft (50) with the stamp mark forward.
groove for pin (30) of pump casing (35), then as-
semble. At this time, keep link pin (24) toward the 10. Install retaining ring (44) into drive shaft (50).
front casing (48) side.
NOTE: Both sides of pin (30) are parallel. Align the 11. Install the front casing (48) into the assembly as
parallel side with the groove to assemble. follows.
• Place the front casing with pump casing (35) side
30 downward.
31
35 • Apply a film of grease to the bore of oil seal (46).
• Using special tool (ST 7263) and a plastic ham-
mer, tap the oil seal evenly into the front casing.
• Install retaining ring (47) into the front casing.
• Turn the front casing over and put on sleepers,
Parallel Side
over 30 mm in width and thickness.
Parallel Side W176-02-04-016
• Install drive shaft (50) into the front casing. At this
moment just tap drive shaft (50) slightly with a
plastic hammer, roller bearing (45) can be in-
4. The rear pump assembling, Install rotor (38) into stalled.
the assembly by the same procedure as step 5 • Install O-rings (9) (2 used) into the front casing.
for the rear pump assembling.
5. Using special tool (ST 7264), tap inner race (43)

evenly into drive shaft (50) with a hammer.
W2-4-23
35 42
10
14
18 40
48
24
49
11
39 38 50 41
W176-02-04-011
W2-4-24
• Align cradle plate (11) with knock pin (5) and in-
stall it into the front casing, then tighten with CAUTION: Front casing assembly weight:
socket bolts (10) (4 used). 24 kg (53 Ib)
: 5 mm 14. Install eyebolt (M12) to front casing (48).
: 9.8 N･m (1 kgf･m, 7.2 lbf･ft) Position the front casing assembly approximately
• Install O-ring (49) into the front casing. vertical and hold this position.
• If restrictor pin (14) is removed, install backup NOTE: If the front casing is turned over, swash
rings (13) (2 used) and O-rings (12) (2 used) into plate F (42) comes off.
the restrictor pin. Then install the restrictor pin
into the front casing. At this time, keep the orifice
side on the restrictor pin toward inside to install. Eyebolt
12
48
3 14
W176-02-04-013
W176-02-04-017
Orifice 13
15. Install the rotor (38) assembly to the front casing

12. Apply a film of grease to the hole of knock pin (48) assembly, take care not to cause plunger
(41) for plate (40), then match it with the knock (18) to fall from the rotor assembly.
pin and install to swash plate F (42).
IMPORTANT: When installing, keep the connec- CAUTION: Front casing assembly weight:
tion part of link pin (24) for swash 27 kg (60 Ib)
plate F (42) upward (regulator 16. Sling the front casing (48) assembly.
mounting side). NOTE: As the gravity center of the front casing is
13. Apply a film of grease to the cylindrical surface of at the rotor (38) side be sure not to tilt it. If
swash plate F (42). Align the cylindrical surfaces the front casing is tilted, the rotor may fall
of swash plate F and cradle plate (11) and install down.
to the front casing (48) assembly.
IMPORTANT: Put link pin (24) into the concave
portion of feedback link (31) on
42 Connection swash plate F (42).
Part of Link Pin
17. Align the front casing (48) assembly with link pin
(24), assemble the front casing (48) assembly
into pump casing (35).
NOTE: When the spline of drive shaft (50) is not
engaged with that of shaft (39), either ro-
W176-02-04-018 tate drive shaft, or use tool (ST 3315) to
rotate the shaft.
W2-4-25
35
48
W176-02-04-011
1
2
W2-4-26
18. Tighten front casing (48) to pump casing (35)
with socket bolts (1) (6 used) and spring washers
(2) (6 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
19. Install O-rings (27) (2 used), (28) (10 used), (29)

(4 used) and spring pins (32) (4 used) into pump
casing (35).
27 32 28 29
35
W176-02-04-014
W2-4-27
DISASSEMBLE REGULATOR
1 2 3
Regulator for Front Pump Regulator for Rear Pump
6 7 8 9 10 11 12 13 14 15
5 16
4 17
18
19
33
W176-02-04-001
32
31 30 29 28 27 26 25 24 23 22 21 20
1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing
W2-4-28
Disassemble Regulator
• The regulators are used for the front pump and 5. Pull out springs (23) (24) from casing (9).
rear pump. The regulator’s inner structure is fully
identical, and difference is only in its accessories. 6. Insert a round bar into the hole on casing (9), push
Here is the description of the rear regulator. spool (26) end, push out cylinder (22), sleeve
(25) and spool from the casing. At this time, pis-
IMPORTANT: If adjusting screws (4, 5, 16, 17, 18, ton (27) is removed with the cylinder.
19) are disassembled, their set val-
ues will be changed. So, not to dis- 7. Pull out piston (27) from cylinder (28).
assemble them.
When disassembling must be done, 8. Remove spring (8) from casing (9).
after assembling, carry out adjust-
ment according to the procedure of 9. Insert a round bar into the hole on casing (9) to
performance test. push the spool (10) end, push out cylinder (13),
1. Install casing (9) in a vise, then remove pipe (1) sleeve (11) and spool. At this time, piston (12) is
from the casing. removed with the cylinder.
: 17 mm
10. Pull out piston (12) from cylinder (13).
2. Remove socket bolts (2) (2 used) and remove
solenoid valve (3) from the casing.
IMPORTANT: Do not loosen set bolt (16), lock

nuts (17), (18), (19). If loosened, the
set values will be changed.
3. Remove socket bolts (20) (4 used), then remove
cover (15) from casing (9). At this time, the cover
is still with set bolt (16) and stopper assembly
(21) on it.
: 6 mm
IMPORTANT: Don’t loosen lock nuts (4) and (5). If

loosened, set values will be
changed.
4. Remove socket bolts (32) (4 used), then remove
cover (33) from casing (9). At this time, stopper
assembly (6) is removed with the cover.
: 6 mm
W2-4-29
ASSEMBLE REGULATOR
1 2 3
Regulator for Front Pump Regulator for Rear Pump
6 7 8 9 10 11 12 13 14 15
5 16
4 17
18
19
33
W176-02-04-001
32
31 30 29 28 27 26 25 24 23 22 21 20
1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing
W2-4-30
Assemble Regulator
IMPORTANT: Two sleeve holes for casing (9) have 9. Install O-ring (22) and springs (23) (24) to stop-
identical bore, and the shapes of per assembly (21) on cover (15) , then install it on
various parts are very similar. Pay casing (9) with socket bolts (20) (4 used).
attention not to misassemble them. : 6 mm
Perform assembling as illustrated. : 19.5 N･m (2 kgf･m, 14.5 Ibf･ft)
1. Clean all parts neatly and apply hydraulic oil.
10. Using socket bolts (2) (2 used), install solenoid
IMPORTANT: Pay attention to the direction for valve (3) onto casing (9).
assembling sleeve (11) and spool : 8 mm
(10). : 49 N･m (5 kgf･m, 36 Ibf･ft)
2. Insert spool (10) into sleeve (11), using a round
bar, assemble it at the position closed to the cas- 11. Apply a film of grease to the threads portion of
ing (9) center. pipe (1). Install pipe (1) to casing (9).
: 17 mm
3. Install O-ring (14) onto cylinder (13). : 34 N･m (3.5 kgf･m, 25 Ibf･ft)
4. Insert piston (12) into cylinder (13), then assem-

ble on casing (9).
IMPORTANT: Pay attention to the direction for

assembling sleeve (25) and spool
(26).
5. Insert spool (26) into sleeve (25), using a round
bar to assemble it near the center position of cas-
ing (9).
6. Install O-rings (29) (31) and backup ring (30)

onto cylinder (28).
7. Insert piston (27) into cylinder (28) and then in-

stall on casing (9).
8. Install O-ring (7) and spring (8) to stopper as-

sembly (6) on cover (33), then assemble on cas-
ing (9) with socket bolts (32) (4 used).
: 6 mm
: 19.6 N･m (2 kgf･m, 14.5 Ibf･ft)
W2-4-31
DISASSEMBLE SOLENOID VALVE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
W178-02-04-050
1- Socket Bolt 7- Spring 13 - Orifice 19 - O-Ring

2- Solenoid 8- O-Ring 14 - Plate 20 - Filter
3- Spring 9- O-Ring 15 - Wave Washer 21 - O-Ring
4- O-Ring 10 - O-Ring 16 - Filter
5- Diaphragm 11 - Sleeve 17 - Body
6- Retaining Ring 12 - Spool 18 - O-Ring
W2-4-32
Disassemble Solenoid Valve IMPORTANT: Do not remove orifice (13) from
• Be sure not to damage the mating surface of the spool (12).
regulator.
• When replacing the inner parts, replace the so- 4. Remove retaining ring (6), then remove spring (7)
lenoid valve as an assembly. and spool (12).
• Pay attention not to hit the solenoid portion.
• When removing the connector, do not pry, but NOTE: Spring (7) and spool (12) should be pulled
pull out straight and even. out from the opposite direction.
1. Remove socket bolt (1), then remove solenoid (2) 5. Remove filters (16) (20) from body (17).
and O-ring (4). : 6 mm
: 4 mm
NOTE: When cleaning filter (16), first blow the fil-
NOTE: When solenoid (2) is removed, O-ring (4) ter with air from both surfaces, and finally
and spring (3) come off occasionally, pay blow the filter with air from outer side
attention to them. (threaded side).
2. Using special tool (ST 2953), pull out the sleeve

(11) assembly from body (17).
NOTE: When pulling out sleeve (11) (14) and

wave washer (15) may come off occasion-
ally, therefore pay attention to them.
ST 2953
W178-02-04-052
3. Remove plate (14) and wave washer (15) from

body (17).
W2-4-33
ASSEMBLE SOLENOID VALVE
2 1 5 6 7 11 12 13 14 15 17 16
8 9 10
21 20
19
18
W178-02-04-051
1- Socket Bolt 7- Spring 13 - Orifice 19 - O-Ring

2- Solenoid 8- O-Ring 14 - Plate 20 - Filter
3- *Spring 9- O-Ring 15 - Wave Washer 21 - O-Ring
4- *O-Ring 10 - O-Ring 16 - Filter
5- Diaphragm 11 - Sleeve 17 - Body
6- Retaining Ring 12 - Spool 18 - O-Ring
NOTE: As for parts with ‘*’ mark, refer to W2-4-32.
W2-4-34
Assemble Solenoid Valve IMPORTANT: When installing sleeve (11), keep the
1. Install filters (16) (20) onto body (17). sleeve end and the body end in the
: 6 mm same position.
: 10+3 N･m (1+0.3 kgf･m, 7.2+2.2 Ibf･ft) In addition, when installing the
sleeve, be sure not to pry and cause
2. Install wave washer (15) and plate (14) onto body damage to O-ring.
(17). 5. Using special tool (ST 2953), install sleeve (11)
NOTE: When body (17) is horizontally inserted, assembly to body (17).
apply a film of grease to wave washer (15) NOTE: When there is no special tool (ST 2953
and plate (14) to prevent them from com- available, tighten solenoid (2) alternately
ing off. After assembling, check for straight with socket bolts (1) (2 used), sleeve (11)
position of plate (14). end and body (17) end should be placed in
the same position. Install the solenoid.
3. Install O-rings (8), (9) and (10) to sleeve (11). ST 2953
4. Insert spool (12) into sleeve (11), then install

spring (7), retaining ring (6) and diaphragm (5)
onto spool (12).
NOTE: Install diaphragm (5) in the original direc-
tion.
After installing, check that spool (12)
moves smoothly.
W178-02-04-052
6. Install solenoid (2) to body (17) with socket bolt

(1).
: 4 mm
: 5+2 N･m (0.5+0.2 kgf･m, 3.6+1.4 Ibf･ft)
W2-4-35
DISASSEMBLE AND ASSEMBLE PILOT
PUMP (ZAXIS110, 110M, 120, 130, 130LCN,
125US, 135US)
27
13
26
10
1
12
9
6
26
14
27
6
9
2
3
5
16
15
7
W137-02-04-034
12
W2-4-36
IIMPORTANT: The housing is made of aluminium. Be sure not to damage it. Besides, take extreme care to
control tightening torgue.

Key No. Part Name Q’ty Remarks
(mm) N･m kgf･m (Ibf･ft)
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply a film of grease
to bushing when installing.
5 Retaining Ring 1
6 Seal 2 Apply a film of grease
when installing.
7 Cover 1
9 Backup Ring 2 Apply a film of grease
when installing.
10 Key 2
12 O-Ring 2 Apply a film of grease
when installing.
13 Gear 1
14 Gear 1
15 Washer 4
4 to 4.5
16 Bolt 4 : 17 39 to 44 (29 to 32.5)
26 Bushing 2 Apply a film of hydraulic
oil when installing.
W2-4-37
DISASSEMBLE AND ASSEMBLE GEAR
PUMP (ZAXIS135UR ONLY)
28
26
15
25
34
34
4
10
28
9 1
8
25
13
26
8
31 9
7
6
26
28 15
25
29 34
30
5
10 34
28
9
8
25
14
26
8
9
10
3 W212-02-04-006
10
27
W2-4-38
IIMPORTANT: The housing is made of aluminium. Be sure not to damage it. Besides, take extreme care to
control tightening torgue.

(mm) N･m kgf･m (Ibf･ft)
1 Flange 1
2 Housing 1
3 Flange 1
4 Housing 1
5 Cover 1
6 Retaining Ring 1
7 Oil Seal 1 Apply a film of grease
when installing.
8 Seal 4 Apply a film of grease
to bushing when installing.
9 Backup Ring 4 Apply a film of grease
when installing.
10 O-Ring 4 Apply a film of grease
when installing.
13 Gear 1
14 Gear 1
15 Gear 2
27 Coupling 1
28 Pin 6
29 Washer 4
30 Bolt 4
31 Nut 4 4 to 4.5
: 17 39 to 44 (29 to 32.5)
34 Key 4
W2-4-39
MAINTENANCE STANDARD
Pump Device
1. Drive shaft: Outer diameter of shaft.
A
Standard Allowable Limit
A 35 mm (1.38 in) 34.8 mm (1.37 in)
W176-02-04-019
2. Plunger Assembly: Thickness of shoe. B

B 5.5 mm (0.22 in) 5.2 mm (0.20 in)
W176-02-04-020
3. Plunger: Clearance between shoe and plunger. c

C 0.15 mm (0.006 in) 0.4 mm (0.016 in)
4. Cyinder Block: Clearance between plunger outer W176-02-04-020
diameter and cylinder block bore.

D
0.033 mm 0.07 mm
(D-a)
(0.0013 in) (0.0028 in)
a
W176-02-04-021
b
5. Clearance between housing inner diameter and
servo piston outer diameter.
E
0.06 mm 0.12 mm
(E-b)
(0.002 in) (0.005 in)
W176-02-04-022
W2-4-40
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

may penetrate the skin, causing serious in-
jury. Avoid this hazard by relieving pressure
starting any repair work.
moved without releasing accumulated pres-
sure first. Push the air release valve on top
of the hydraulic oil tank to release any
remaining pressure.
Preparation

maining pressure. Refer to "bleed pressure from
hydraulic circuit" on page W4-2-15.

NOTE: Be sure to run the vacuum pump continu- M104-07-021
ously while working on the hydraulic sys-

tem.
W2-5-1
Removal Swing Arm1 Boom2
Auxiliary
IMPORTANT: Cap the ends of all disconnected (ZAXIS135UR:
hoses and pipes, and attach labels Arm2 Offset)
or tags to the hoses for reassem-
bling. Left Travel
Boom1
1. Disconnect all hoses, pipes and connectors from Bucket Machine For-
the control valve. ward
: 17 mm ZAXIS125US
Right Travel
ZAXIS135US
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft) ZAXIS135UR
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) T176-03-03-038
: 6 mm Machine Forward
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) ZAXIS110, 110M,
: 8 mm ZAXIS120, 130, 130LCN
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
Swing
Machine
Forward
ZAXIS125US
ZAXIS135US
ZAXIS135UR
Machine
Forward
ZAXIS110,110M
ZAXIS120, 130, 130LCN
T176-03-03-036
Blade Control Valve

(ZAXIS135UR Only)
W191-02-05-002
W2-5-2
CAUTION: Control valve weight:

132 kg (291 Ib)
ZAXIS110, 110M,
2. Remove control valve mounting bolts (1). ZAXIS120, 130,
4 used: (ZAXIS110, 110M, 120, 130LCN) ZAXIS130LCN
6 used: (ZAXIS125US, 135US, 135UR)
Remove bolt (2) (2 used) of blade control valve.
(ZAXIS135UR only)
(Control Valve)
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 lbf⋅ft)
(Blade Control Valve)
1 W187-02-05-003
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
ZAXIS125US
Installation ZAXIS135US
NOTE: Refer to "removal" section above for ZAXIS135UR
wrench sizes and tightening torques.
1. Install the control valve to the frame and tighten
bolts (1).
4 used: (ZAXIS110, 110M, 120, 130LCN)
6 used: (ZAXIS125US, 135US, 135UR)
1
2. Connect all hoses, pipes and connectors to the W1SE-02-05-001
control valve. Install the blade control valve with

bolts (2) (2 used). (ZAXIS135UR only)
Blade Control Valve
IMPORTANT: After completing installation: check
the hydraulic oil level. Add oil as (ZAXIS135UR Only)
necessary. Run the engine. Check
the component for any oil leaks.
W191-02-05-002
W2-5-3
DISASSEMBLE CONTROL VALVE
4-SPOOL SECTION
X
41
1
2
42
3 29 43
4 23 51
5 30
44 52
6
24 31
7
8 45
Arm Re- 25 53
9 generative
32
Valve
10 (Switch 26 54
Boom
Anti- Valve) 46
36 33
Drift 55
Valve
11 27
19
12 34
20
13 57
21 28 56
14
37 47 58 Check Valve
15 35
59 (Main Relief
16 22 38 48 Circuit)
60
17 49
39 50 61
18
40
66 73
64 67
65 68
69 74
75 W
72
62
70
63
71
X 76 W176-02-05-010
1- O-Ring 20 - Washer 39 - O-Ring 58 - Backup Ring
2- Screw 21 - O-Ring 40 - Plug 59 - O-Ring
3- Backup Ring 22 - Spool 41 - O-Ring 60 - Spring
4- O-Ring 23 - O-Ring 42 - Bolt 61 - Poppet
5- O-Ring 24 - Bolt 43 - Spring Seat 62 - Cap
6- O-Ring 25 - Spring Seat 44 - Spring 63 - Nut
7- Backup Ring 26 - Spring 45 - Spring Seat 64 - Plug
8- Backup Ring 27 - Spring Seat 46 - Main Spool 65 - O-Ring
9- O-Ring 28 - Main Spool 47 - Poppet 66 - Cap
10 - Sleeve 29 - O-Ring 48 - Spring 67 - Retaining Ring
11 - Spool 30 - Screw 49 - O-Ring 68 - Shim
12 - Washer 31 - O-Ring 50 - Plug 69 - Nut
13 - Spring 32 - Bolt 51 - O-Ring 70 - Pilot Housing
14 - Backup Ring 33 - Spring Seat 52 - Bolt 71 - Socket Bolt (11 Used)
15 - O-Ring 34 - Spring 53 - Spring Seat 72 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Spring 73 - Overload Relief Valve
17 - Spring 36 - Main Spool 55 - Spring Seat 74 - Backup Ring
18 - Poppet 37 - Poppet 56 - Main Spool 75 - O-Ring
19 - Spring 38 - Spring 57 - Plug 76 - Housing
W2-5-4
Disassemble Control Valve
4-Spool Upper Section
• Be sure to thoroughly read precautions for dis- IMPORTANT: Remove main spool assemblies (28,
assembly and assembly on page W1-1-1 before 36, 46 and 56) while carefully mov-
starting the disassembly work. ing them. If they stick, even a little,
• Attach identification tags to the spool and mount- try it again instead of pulling
ing positions in the housing in order to avoid dis- roughly.
assembling. 8. Remove main spool assemblies (28, 36, 46 and
56) and O-rings (23, 31, 41 and 51) from housing
1. Remove socket bolts (71) (11 used) from housing (76).
(76), and then remove pilot housing (70).
: 8 mm IMPORTANT: Make alignment marks on main
spools (28, 36, 46 and 56) and
2. Remove boom anti-drift valve assembly (5 to 16) housing (76) in order to avoid con-
from pilot housing (70). Remove O-ring (4), and fusion during reassembling.
backup ring (3) from housing (76). 9. Clamp main spools (28, 36, 46 and 56) on a vise
NOTE: Pry the boom anti-drift valve assembly by with padded wooden pieces, then remove bolts
hand and remove it from pilot housing (70). (24, 32, 42 and 52), spring seats (25, 33, 43 and
53), springs (26, 34, 44 and 54) and spring seats
3. Remove plug (16), O-ring (15), backup ring (14), (27, 35, 45 and 55).
spring (13), washer (12), and spool (11) from : 17 mm
sleeve (10).
10. Remove plugs (40, 50), O-rings (39, 49), springs
4. Remove O-rings (4, 5, 6 and 9) and backup rings (38, 48), poppets (37, 47) from spools (36, 46).
(3, 7 and 8) from sleeve (10). : 17 mm
5. Remove spring (17) and poppet (18) from the

housing (76). 11. Remove spring (19), washer (20), O-ring (21) and
spool (22) from housing (76).
6. Remove cap (66), retaining ring (67), shim (68)
and nut (69) from pilot housing (70). 12. Remove plug (57), backup ring (58), O-ring (59),
Remove screw (30) from pilot housing (70), then spring (60) and poppet (61) from housing (76).
O-ring (29) from screw (30). : 14 mm
: 17 mm
: 4 mm 13. Remove overload relief valves (72, 73) from
housing (76).
7. Remove cap (62) and nut (63) from pilot housing : 27 mm
(70).
Remove screw (2) from pilot housing (70), then
O-ring (1) from screw (2).
: 17 mm
: 4 mm
W2-5-5
76
Bypass Shut-Out Valve
83
82
81 87
80 86
85
Check Valve 84
79 Orifice (Arm 1
91
78 90
Parallel Circuit) 89
77 Load Check
(Arm 2 Tandem 88 102
Circuit) 101
100
99
98
97 Bucket Flow Rate
96 Control Valve
95 (Poppet Valve)
94
93
92 112
103
113
111
Bucket Flow Rate Control Valve

(Switch Valve)
106
104 107
108
105 109
110 W176-02-05-012
76 - Housing 86 - Poppet 96 - O-Ring 106 -Spool

77 - Plug 87 - Bushing 97 - Spring 107 -Washer
78 - O-Ring 88 - O-Ring 98 - Plug 108 -Spring
79 - Plug 89 - Backup Ring 99 - O-Ring 109 -O-Ring
80 - O-Ring 90 - Spring 100 -Spring 110 -Plug
81 - Spring 91 - Check Valve 101 -Poppet 111 -O-Ring
82 - Seat 92 - O-Ring 102 -Valve Seat 112 -O-Ring
83 - Spool 93 - Backup Ring 103 -Pilot Plate 113 -Backup Ring
84 - Plug 94 - Bushing 104 -Socket Bolt (3 Used)
85 - Spring 95 - Backup Ring 105 -Socket Bolt (7 Used)
W2-5-6
4-Spool Side Section
14. Remove plug (110) from pilot plate (103), then
spring (108), washer (107), spool (106) and
O-ring (109).
: 36 mm
15. Loosen socket bolts (104 and 105) (10 used) to

remove pilot plate (103). Remove O-ring (111 and
112) and backup ring (113) from the pilot plate.
16. Remove bushing (94) from pilot plate (103), then

O-rings (92 and 96), backup ring (93 and 95) and
spring (97) from bushing (94).
17. Remove plug (98) from housing (76).

Clamp the step portion of plug (98) with wooden
pieces and secure it to a vise. Then remove valve
seat (102), poppet (101), spring (100) and O-ring
(99) from plug (98).
18. Remove O-ring (88), backup ring (89), spring (90)

and poppet (91) from housing (76). (two places)
19. Remove plug (84), spring (85), poppet (86) and

bushing (87) from housing (76).
20. Remove plug (79), O-ring (80), spring (81), seat

(82) and spool (83) from housing (76).
W2-5-7
76
135
130 144
136
137
131
138
132 Check Valve (Flow
133 Conbiner Circuit) 146
134
Auxiliary Flow
Rate Control
Valve
154
150
W176-02-05-014
76 - Housing 134 -Plug 144 -Overload Relief Valve

130 -Poppet 135 -Poppet 146 -O-Ring
131 -Spring 136 -Spring 150 -Socket Bolt (9 Used)
132 -O-Ring 137 -O-Ring 154 -Pilot Housing (5 Used)
133 -Backup Ring 138 -Plug
W2-5-8
4-Spool Lower Section
21. Remove overload relief valve (144) from housing
(76).
: 27 mm
22. Remove socket bolts (150) (5 used) from housing

(76), then remove pilot housing (154) and O-ring
(146) (4 used).
: 8 mm
23. Remove plug (138), O-ring (137), spring (136)

and poppet (135) from housing (76).
: 14 mm
24. Remove plug (134), backup ring (133), spring

(131) and poppet (130) from housing (76).
: 14 mm
W2-5-9
DISASSEMBLE CONTROL VALVE
5-SPOOL SECTION
216
215
155 217
156
187
157
188
158 181
159 218
160 189
161 182
162 190
197
163 183
176 191
164 203
Arm Anti-Drift 184
Valve 166 177 198
167 165 178 209
168 185 192 199 204
169 179
175
170 173 200 205
210
180 186
171
201 206 211
172
193
174 207
194 212
195 202
213
196 208
214
219
W176-02-05-011
155 -Backup Ring 172 -Poppet 189 -Spring Seat 206 -Spring
156 -O-Ring 173 -Backup Ring 190 -Spring 207 -Spring Seat
157 -Plug 174 -O-Ring 191 -Spring Seat 208 -Main Spool
158 -O-Ring 175 -Overload Relief Valve 192 -Main Spool 209 -O-Ring
159 -O-Ring 176 -Plug 193 -Poppet 210 -Bolt
160 -O-Ring 177 -O-Ring 194 -Spring 211 -Spring Seat
161 -Backup Ring 178 -Backup Ring 195 -O-Ring 212 -Spring
162 -Backup Ring 179 -O-Ring 196 -Plug 213 -Spring Seat
163 -O-Ring 180 -Main Relief Valve 197 -O-Ring 214 -Main Spool
164 -Sleeve 181 -O-Ring 198 -Bolt 215 -Socket Bolt (10 Used)
165 -Spool 182 -Bolt 199 -Spring Seat 216 -Plug
166 -Washer 183 -Spring Seat 200 -Spring 217 -O-Ring
167 -Spring 184 -Spring 201 -Spring Seat 218 -Pilot Housing
168 -Backup Ring 185 -Spring Seat 202 -Main Spool 219 -Housing
169 -O-Ring 186 -Main Spool 203 -O-Ring
170 -Plug 187 -O-Ring 204 -Bolt
171 -Spring 188 -Bolt 205 -Spring Seat
W2-5-10
5-Spool Upper Section
1. Removing socket bolts (215) (10 used) from
housing (219), then remove pilot housing (218).
: 8 mm
2. Remove arm anti-drift valve assembly (157 to

170), O-ring (156) and backup ring (155) from
pilot housing (218).
NOTE: Pry out arm anti-drift valve assemblies by
hand from pilot housing (218).
3. Remove plug (170), O-ring (169), backup ring

(168), spring (167), washer (166), spool (165)
from sleeve (164).
4. Remove plug (157), O-rings (158, 159, 160 and

163) and backup rings (161 and 162) from sleeve
(164).
5. Remove spring (171) and poppet (172) from

housing (219).
6. Remove main spool assemblies (186, 192, 202,

208 and 214) and O-rings (181, 187, 197, 203
and 209) from housing (219).
IMPORTANT: Make alignment marks on main

spools (186, 192, 202, 208 and 214)
and housing (219) in order to avoid
confusion during reassembling.
7. Clamp main spools (186, 192, 202, 208 and 214)

in a vise, then remove bolts (182, 188, 198, 204
and 210), spring seats (183, 189, 199, 205 and
211), springs (184, 190, 200, 206 and 212) and
spring seats (185, 191, 201, 207 and 213).
: 17 mm
8. Remove plug (196), O-ring (195), spring (194)

and poppet (193) from main spool (192).
: 17 mm
9. Remove overload relief valve (175), main relief

valve (180) from housing (219).
: 27 mm
W2-5-11
Load Check Load Check

Valve (Arm 1 245 Valve (Arm 2
Aux. Flow Rate 229 Parallel Circuit) 246 Parallel Circuit)
Control Valve
(Poppet Valve)
230 247
231 240
241 248
232
233 242
Load Check 234 243
223 Valve (Travel 235 244
Parallel Circuit) 225 236
224 226 237
227 238
228 239
220
221
222
219
255
256
254
257
Aux. Flow Rate Con- 258
trol Valve (Switch
Valve)
253
252
251
250 W176-02-05-013
249
219 -Housing 229 -O-Ring 239 -Valve Seat 249 -Plug

220 -Socket Bolt (4 Used) 230 -Backup Ring 240 -O-Ring 250 -O-Ring
221 -Cover 231 -Bushing 241 -Backup Ring 251 -Spring
222 -O-Ring 232 -Backup Ring 242 -Plug 252 -Washer
223 -Socket Bolt (6 Used) 233 -O-Ring 243 -Spring 253 -Spool
224 -Pilot Plate 234 -Spring 244 -Poppet 254 -Socket Bolt (6 Used)
225 -O-Ring 235 -Plug 245 -O-Ring 255 -Socket Bolt (4 Used)
226 -Backup Ring 236 -O-Ring 246 -Backup Ring 256 -Pilot Plate
227 -Spring 237 -Spring 247 -Spring 257 -O-Ring
228 -Poppet 238 -Poppet 248 -Poppet 258 -O-Ring
W2-5-12
10. Remove plug (249) from pilot plate (256),
then disassemble O-ring (250), spring (251),
washer (252) and spool (253).
: 36 mm
11. Remove socket bolts (254 and 255) (10

used), then disassemble pilot plate (256) and
O-rings (257 and 258).
: 6 mm, 8 mm
12. Remove bushing (231) from pilot plate (256),

then remove O-rings (229 and 233), backup rings
(230 and 232) and spring (234).
13. Remove plug (235) from the pilot plate (256)

mounting surface of housing (219).
Clamp the stepped portion of plug (235) with
wood pieces in a vise, then remove valve seat
(239), poppet (238), spring (237) and O-ring
(236).
14. Remove O-ring (225), backup ring (226),

spring (227) and poppet (228) from the pilot plate
(256) mounting surface of housing (219).

(256) mounting surface of housing (219). (3
places)
16. Remove socket bolts (223) (6 used) from

housing (219), then remove pilot plate (224).
: 6 mm

plug (242), spring (243) and poppet (244) from
the pilot plate (224) mounting surface of housing
(219). (2 places)

(224) mounting surface of housing (219).
W2-5-13
219
140
122
139 141
114 123 142
115 124
143
116
125 146
117
145
126
118 127
119 128 153
120
129
Flow
121 Combiner
Valve
Auxiliary Flow
Combiner
147 151
Valve
148 152
149
W176-02-05-014
114 -Plug 122 -Plug 139 -Overload Relief Valve 147 -Socket Bolt (9 Used)
115 -Spring 123 -Spring 140 -O-Ring 148 -O-Ring
116 -Poppet 124 -Poppet 141 -Backup Ring 149 -Plug
117 -Spool 125 -Spool 142 -O-Ring 151 -O-Ring
118 -O-Ring 126 -O-Ring 143 -Plug 152 -Plug
119 -Washer 127 -Washer 145 -O-Ring (5 Used) 153 -Pilot Housing
120 -Spring 128 -Spring 146 -O-Ring (4 Used) 219 -Housing
121 -Bolt 129 -Bolt
W2-5-14
19. Remove overload relief valve (139) from
housing (219).
: 27 mm
20. Remove socket bolts (147) (9 used) from

housing (219), then disassemble pilot housing
(153) and O-ring (145) (5 used).
: 8 mm
21. Remove O-rings (118 and 126), flow com-

biner valve assemblies (122 to 129), and auxil-
iary flow combiner valve assemblies (114 to 121)
from housing (219).
IMPORTANT: Do not remove plug (114), spring

(115), and poppet (116) from spool
(117). When replacing these parts,
replace them as assembly.
22. Clamp spool (117) with wood pieces in a

vise, then remove bolt (121), spring (120) and
washer (119).
: 17 mm
IMPORTANT: Do not remove plug (122), spring

(123) and poppet (124) from spool
(125). When replacing these parts,
replace them as assembly.
23. Clamp spool (125) with wood pieces in a

vise, then remove bolt (129), spring (128) and
washer (127).
: 17 mm
W2-5-15
SEPARATE AND COMBINE 4-SPOOL AND
5-SPOOL CONTROL VALVE
219
266
265
260
261
263
262
76 264
267
268
269
259 270 271
272
273
274
275
276
277 281
279 280
278
W176-02-05-015
76 - Housing 264 -O-Ring 270 -O-Ring 276 -O-Ring

219 -Housing 265 -O-Ring 271 -Backup Ring 277 -Backup Ring
259 -Socket Bolt (9 Used) 266 -Backup Ring 272 -O-Ring 278 -O-Ring
260 -O-Ring 267 -O-Ring 273 -O-Ring 279 -Backup Ring
261 -O-Ring 268 -Backup Ring 274 -O-Ring 280 -O-Ring
262 -O-Ring 269 -O-Ring 275 -O-Ring 281 -Backup Ring
263 -Backup Ring
W2-5-16
Disassemble 4-Spool and 5-Spool Sections Assemble 4-Spool and 5-Spool Sections
1. Install O-rings (260 to 262, 264, 265, 267, 269,
CAUTION: Housing (76) weight: 45 kg (99 Ib) 270, 272 to 276, 278 and 280) and backup rings
Housing (219) weight: 49 kg (108 Ib) (263, 266, 268, 271, 277, 279 and 281) into
housing (219).
1. Remove socket bolts (259) (9 used), then disas-
semble housing (76) and housing (219).
: 12 mm CAUTION: Housing (76) weight: 45 kg (99 Ib)
Housing (219) weight: 49 kg (108 Ib)
2. Remove O-rings (260 to 262, 264, 265, 267, 269,
270, 272 to 276, 278 and 280) and backup rings 2. Connect housing (76) to housing (219) with
(263, 266, 268, 271, 277, 279 and 281) from socket bolt (259).
housing (219). : 12 mm
: 108 + 9.8 N⋅m (11+1 kgf⋅m, 157 + 7 lbf⋅ft)
W2-5-17
ASSEMBLE CONTROL VALVE Main Spool Main Spool
4-SPOOL SECTION (28, 56) (36, 46)
A
25, 53 33, 43
23 31 41 51 26, 54
34, 44
24, 52 32, 42
19
20 27, 55 35, 45
21
57
22
58, 59
60
61
28, 56 36, 46
76
37, 48
38, 48
39, 49
40, 50
W176-02-05-020
Section A Boom 1
W176-02-05-024
67, 68 Boom Anti-Drift Valve

66
5
69
70 10
29
6
11
30
62
7
63
1 8
2 14 9
12
Boom
15 13
Anti-Drift
Valve 16
17
18
W176-02-05-025
W176-02-05-022
1- O-Ring 20 - Washer 39 - O-Ring 58 - Backup Ring
2- Screw 21 - O-Ring 40 - Plug 59 - O-Ring
3- Backup Ring 22 - Spool 41 - O-Ring 60 - Spring
4- O-Ring 23 - O-Ring 42 - Bolt 61 - Poppet
5- O-Ring 24 - Bolt 43 - Spring Seat 62 - Cap
6- O-Ring 25 - Spring Seat 44 - Spring 63 - Nut
7- Backup Ring 26 - Spring 45 - Spring Seat 64 - Plug
8- Backup Ring 27 - Spring Seat 46 - Main Spool 65 - O-Ring
9- O-Ring 28 - Main Spool 47 - Poppet 66 - Cap
10 - Sleeve 29 - O-Ring 48 - Spring 67 - Retaining Ring
11 - Spool 30 - Screw 49 - O-Ring 68 - Shim
12 - Washer 31 - O-Ring 50 - Plug 69 - Nut
13 - Spring 32 - Bolt 51 - O-Ring 70 - Pilot Housing
14 - Backup Ring 33 - Spring Seat 52 - Bolt 71 - Socket Bolt
15 - O-Ring 34 - Spring 53 - Spring Seat 72 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Spring 73 - Overload Relief Valve
17 - Spring 36 - Main Spool 55 - Spring Seat 74 - Backup Ring
18 - Poppet 37 - Poppet 56 - Main Spool 75 - O-Ring
19 - Spring 38 - Spring 57 - Plug 76 - Housing
W2-5-18
4-Spool Upper Section IMPORTANT: When replacing sleeve (10) or spool
1. Clamp main spools (36 and 46) with wood pieces (11), replace them together.
in a vise, then install poppets (37 and 47), 6. Assemble O-ring (15), backup ring (14), spring
springs (38 and 48), O-rings (39 and 49) and (13), washer (12), and spool (11) onto plug (16),
plugs (40 and 50). then install them onto sleeve (10).
: 17 mm NOTE: When assembling washer (12), the cham-
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) fer side shall face the spring side.
2. Install spring seats (27, 35, 45 and 55), springs 7. Install arm anti-drift valve assemblies (5 to 16)
(26, 34, 44 and 54), spring seats (25, 33, 43 and onto pilot housing (70).
53) and bolts (24, 32, 42 and 52) onto main
spools (28, 36, 46 and 56) respectively. IMPORTANT: When replacing housing (76) or
: 17 mm poppet (18), tap poppet (18) with a
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) steel bar.
8. Install poppet (18) and spring (17) into housing
3. Install screw (30) and O-ring (29) onto pilot (76).
housing (70), then install nut (69), shim (68), re-
taining ring (67) and cap (66). 9. Install spool (22), O-ring (21), washer (20) and
: 4 mm spring (19) into housing (76).
: 17 mm
NOTE: When assembling washer (20), the cham-
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
fer side shall face the spring side.
4. Install screw (2) and O-ring (1) onto pilot housing
10. Install poppet (61), spring (60), O-ring (59),
(70), then install nut (63) and cap (62) onto screw
backup ring (58) and plug (57) into housing (76).
(2).
: 14 mm
: 4 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
: 17 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
11. Install main spool assemblies (28, 36, 46 and 56),
O-rings (4, 23, 31, 41 and 51) and backup ring
5. Install backup rings (7 and 8), and O-rings (5, 6
(3) into housing (76) respectively.
and 9) onto sleeve (10).
NOTE: Pay attention to the assembling location of
back up rings (7 and 8) and O-rings (6 and
9).
9 8 7 6
W176-02-05-023
W2-5-19
A
B
70 C
Section B Arm 2 Arm 1
76 73
73 Load Check Valve (Arm

2 Tandem Circuit)
72
90 91
104
105
103
D
71
Section D 110 109 108 107 106 T176-03-03-038
Bucket Flow Rate

Control Valve
84 85 86 87
(Switch Valve) Check Valve Orifice
(Arm 1 Parallel Cir-
cuit)
T176-03-03-006
98
92
97
93
Section C Boom 1
94 99
95 100 Boom 2
96
101
102
Bucket Flow Rate Control
Valve (Poppet Valve)
W176-02-05-026
Section A Swing
88, 89
79 90
78 91
Load Check Valve
77 (Boom 1 Parallel
Circuit)
80 81 82 83 T176-03-03-005
Bypass Shut-Out Valve T176-03-03-007
70 - Pilot Housing 83 - Spool 94 - Bushing 105 -Socket Bolt (7 Used)

71 - Socket Bolt (11 Used) 84 - Plug 95 - Backup Ring 106 -Spool
72 - Overload Relief Valve 85 - Spring 96 - O-Ring 107 -Washer
73 - Overload Relief Valve 86 - Poppet 97 - Spring 108 -Spring
76 - Housing 87 - Bushing 98 - Plug 109 -O-Ring
77 - Plug 88 - O-Ring 99 - O-Ring 110 -Plug
78 - O-Ring 89 - Backup Ring 100 -Spring 111 -O-Ring*
79 - Plug 90 - Spring 101 -Poppet 112 -O-Ring*
80 - O-Ring 91 - Poppet 102 -Valve Seat 113 -Backup Ring*
81 - Spring 92 - O-Ring 103 -Pilot Plate
82 - Seat 93 - Backup Ring 104 -Socket Bolt (3 Used)
NOTE: As for the item with a mark ‘*’ refer to W2-5-6.
W2-5-20
12. Install pilot housing (70) onto housing (76) with 17. Install poppet (91), spring (90), O-ring (88),
socket bolts (71) (11 used). Install overload relief backup ring (89) into housing (76). (2 places)
valves (72 and 73) onto housing (76).
: 8 mm 18. Install bushing (87), poppet (86), spring (85) and
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) plug (84) into housing (76).
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 Ibf⋅ft) 19. Install O-rings (111 and 112) and backup ring
NOTE: Apply grease onto the O-rings of overload (113) into housing (76). Install pilot plate (103)
relief valves (72 and 73). (In order to pro- with socket bolts (104 and 105) (10 used).
tect O-rings from the breakage). : 6 mm
: 25 N⋅m (2.5 kgf･m, 18 Ibf⋅ft)
Assemble Control Valve : 8 mm
4-Spool Side Section : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
13. Install spool (106), washer (107), spring (108)
and O-ring (109) onto pilot plate (103), then in- 20. Tighten plug (110) which has been temporarily
stall plug (110) (Temporarily tighten it). tightened in step 13.
: 36 mm : 36 mm
: 200 N⋅m (20 kgf⋅m, 145 Ibf⋅ft)
NOTE: ･ Tighten plug (110), after installation of
pilot plate (103) to housing(76). Pay at-
21. Install spool (83), seat (82), spring (81), O-ring
tention to the plugs identification because
(80), and plug (79) into housing (76).
plug (110) and plug (249) have different
: 27 mm
length of screw thread.
: 180+3 N⋅m (18+0.3 kgf⋅m, 130.2+2.2
･ As for plug (249), refer to W2-5-26.
Ibf⋅ft)
14. Install poppet (101), spring (100), O-ring (99) and NOTE: Install seat (82) with the chamfered side
plug (98) onto valve seat (102). facing spring side.
15. Install O-rings (92 and 96) and backup rings (93
and 95) onto bushing (94).
16. Install valve seat (102), assembly spring (97) and

bushing (94) into housing (76).
W2-5-21
Section A
76
9
150
B 144 T176-03-03-036
W176-02-05-020
146 146 146 146
Section B
130
131
132, 133
135
Check 136
Valve
(Flow 137
Combiner
Circuit)
138 134
Aux. Flow Rate T176-03-03-002
Control Valve
76 - Housing 134 -Plug 144 -Overload Relief Valve (2 Used)

130 -Poppet 135 -Poppet 146 -O-Ring (4 Used)
131 -Spring 136 -Spring 150 -Socket Bolt (5 Used)
132 -O-Ring 137 -O-Ring 154 -Pilot Housing
133 -Backup Ring 138 -Plug
W2-5-22
22. Install O-rings (146) (4 used) onto housing (76),
then install pilot housing (154) with socket bolts
(150) (5 used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
23. Install poppet (135), spring (136), O-ring (137)

and plug (138) into housing (76).
: 14 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)

backup ring (133) and plug (134) into housing
(76).
: 14 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
25. Install overload relief valves (144) (2 used) onto

housing (76).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
NOTE: Apply grease to the O-ring of overload re-
lief valve. (In order to protect the O-ring
from the breakage.)
W2-5-23
ASSEMBLE CONTROL VALVE Main Spool Main Spool
5-SPOOL SECTION (186, 202, 208, 214) (192)
209 203 197 187 181 183, 199,
189
Section A 205, 211
190
184, 200,
206, 212
188
182, 198,
204, 210
191
185, 201,
207, 213
192
186, 202,
208, 214
193
194
195
Arm Anti-Drift Valve
B
W176-02-05-021 196
A
W176-02-05-024
175 Section B Arm Anti-Drift Valve
164 157
158 159
218 160
215 161
165
180 162
219 163
168
166
169
167
170
171
172
W176-02-05-027
T176-03-03-038
155 -Backup Ring* 172 -Poppet 189 -Spring Seat 206 -Spring
156 -O-Ring* 173 -Backup Ring 190 -Spring 207 -Spring Seat
157 -Plug 174 -O-Ring 191 -Spring Seat 208 -Main Spool
158 -O-Ring 175 -Overload Relief Valve 192 -Main Spool 209 -O-Ring
159 -O-Ring 176 -Plug 193 -Poppet 210 -Bolt
160 -O-Ring 177 -O-Ring 194 -Spring 211 -Spring Seat
161 -Backup Ring 178 -Backup Ring 195 -O-Ring 212 -Spring
162 -Backup Ring 179 -O-Ring 196 -Plug 213 -Spring Seat
163 -O-Ring 180 -Main Relief Valve 197 -O-Ring 214 -Main Spool
164 -Sleeve 181 -O-Ring 198 -Bolt 215 -Socket Bolt (10 Used)
165 -Spool 182 -Bolt 199 -Spring Seat 216 -Plug
166 -Washer 183 -Spring Seat 200 -Spring 217 -O-Ring
167 -Spring 184 -Spring 201 -Spring Seat 218 -Pilot Housing
168 -Backup Ring 185 -Spring Seat 202 -Main Spool 219 -Housing
169 -O-Ring 186 -Main Spool 203 -O-Ring
170 -Plug 187 -O-Ring 204 -Bolt
171 -Spring 188 -Bolt 205 -Spring Seat
W2-5-24
5-Spool Upper Section 5. Install arm anti-drift valve assembly (157 to 170)
1. Clamp main spool (192) with wood pieces in a onto pilot housing (218).
vise. Install poppet (193), spring (194), O-ring
(195) and plug (196). IMPORTANT: Tap poppet (172) with a steel bar
: 17 mm when replacing housing (219) or
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) poppet (172).
2. Install spring seats (185, 191, 201, 207 and 213), 6. Install poppet (172) and spring (171) onto hous-
springs (184, 190, 200, 206 and 212), spring ing (219).
seats (183, 189, 199, 205 and 211), and bolts
(182, 188, 198, 204 and 210) onto main spools 7. Install main spool assemblies (186, 192, 202, 208,
(186, 192, 202, 208 and 214) respectively. and 214), O-rings (156, 181, 187, 197, 203 and
: 17 mm 209) and backup ring (155) into housing (219).
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
8. Install pilot housing (218) onto housing (219) with
3. Install backup rings (161 and 162) and O-rings socket bolts (215) (10 used). Then install over-
(159, 160 and 163) onto sleeve (164). Install load relief valve (175) and main relief valve (180)
O-ring (158) onto plug (157). onto housing (219).
NOTE: Pay attention to the mounting location of : 8 mm
backup rings (161 and 162) and O-rings : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
(160 and 163). : 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 lbf⋅ft)
163 162 161 160
W176-02-05-023
IMPORTANT: When replacing sleeve (164) or

spool (165), replace them together.
4. Install O-ring (169), backup ring (168), spring
(167), washer (166) and spool (165) into plug
(170), then install them onto sleeve (164).
NOTE: Assemble washer (166) with the cham-
fered side facing spring side.
W2-5-25
223 Section B Travel (Left) Boom 2 Section C
224 219
255
254
256
Load Check Valve
(Travel Tandem Cir-
cuit)
248
E
D 248
247
C 247
Aux. Flow
B 245, 246
Rate A
Control Load
Valve 225, Check
226 Valve
T176-03-03-036
249 250 251 (Boom 2
252 253
Parallel
Aux. Flow Rate Circuit)
227
Control Valve
(Switch Valve) 228
Load Check
235 Valve (Travel
229
234 Parallel Cir- W176-02-05-029
230 cuit)
Section D Arm 1 Swing Section E
231 236
232 237
233
238
239 Load Check
Aux. Flow Rate Control Valve
Valve (Poppet Valve) Load Check (Swing Cir-
Valve (Arm 1 cuit)
W176-02-05-026
Parallel Circuit)
Section A
248 248
248
247 247
247 240,
245,
241
245, 246 246
242
Check Valve
(Main Circuit)
242
240,
241
243
244
Load Check
Valve (Arm 1
Tandem Cir-
cuit)
W176-02-05-030
W176-02-05-028
219 -Housing 229 -O-Ring 239 -Valve Seat 249 -Plug
220 -Socket Bolt 230 -Backup Ring 240 -O-Ring 250 -O-Ring
221 -Cover 231 -Bushing 241 -Backup Ring 251 -Spring
222 -O-Ring 232 -Backup Ring 242 -Plug 252 -Washer
223 -Socket Bolt 233 -O-Ring 243 -Spring 253 -Spool
224 -Pilot Plate 234 -Spring 244 -Poppet 254 -Socket Bolt (6 Used)
225 -O-Ring 235 -Plug 245 -O-Ring (3 Used) 255 -Socket Bolt (4 Used)
226 -Backup Ring 236 -O-Ring 246 -Backup Ring (3 Used) 256 -Pilot Plate
227 -Spring 237 -Spring 247 -Spring (5 Used) 257 -O-Ring*
228 -Poppet 238 -Poppet 248 -Poppet (5 Used) 258 -O-Ring*
W2-5-26
9. Install spool (253), washer (252), spring (251)
and O-ring (250) into pilot plate (256), then install
plug (249) (temporarily).
: 36 mm
NOTE: Tighten plug (249) after installing pilot plate
(256) onto housing (219). Pay attention to
the length of threaded portion because the
thread length of plug (249) and plug (110)
is different.
10. Install poppet (238), spring (237), O-ring (236) and

plug (235) onto valve seat (239).
11. Install O-rings (229 and 233) and backup rings

(230 and 232) onto bushing (231).
12. Install the valve seat (239) assembly, spring (234)

and bushing (231) into housing (219).

and backup ring (246) into housing (219). (3
places)
14. Install poppet (228), spring (227), backup ring

(226), and O-ring (225) into housing (219).
15. Installing O-rings (257 and 258) onto housing (29),

Install pilot plate (256) into housing (219) with
socket bolts (254 and 255).
: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
16. Tighten plug (249) which is temporarily tightened

in step 9.
: 36 mm
: 200 N⋅m (20 kgf⋅m, 145 lbf⋅ft)
17. Install poppet (244), spring (243), plug (242),

backup ring (241) and O-ring (240) into housing
(219). (2 places)
18. Install poppet (248), spring (247), backup ring

(246) and O-ring (245) into housing (219).
19. Install pilot plate (224) onto housing (219) with

socket bolt (223).
: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W2-5-27
Section B
219
147
153
A
139
T176-03-03-036 W176-02-05-021
145 145 145 145 145
Section A
114
122
123 115
Flow 124
Combiner 116 Auxiliary Flow Com-
Valve biner Valve
125
117
126, 127
118, 119
128
120
129
121
W176-02-05-028
114 - Plug 122 - Plug 115 - Bolt 147 - Socket Bolt (9 Used)
115 - Spring 123 - Spring 139 - Overload Relief Valve 148 - O-Ring*
116 - Poppet 124 - Poppet 140 - O-Ring* 149 - Plug*
117 - Spool 125 - Spool 141 - Backup Ring* 151 - O-Ring*
118 - O-Ring 126 - O-Ring 142 - O-Ring* 152 - Plug*
119 - Washer 127 - Washer 143 - Plug* 153 - Pilot Housing
120 - Spring 128 - Spring 145 - O-Ring (5 Used) 219 - Housing
121 - Bolt
W2-5-28
IMPORTANT: Overall dimensions of spool (117)
have been determined. When dis-
assembling or replacing poppet
(116), spring (115) and plug (114),
replace them as an assembly.
20. Clamp spool (117) with wood pieces in a vise,
then install washer (119), spring (120) and bolt
(121).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
IMPORTANT: Overall dimensions of spool (125)

have been determined. When dis-
assembling or replacing poppet
(124), spring (123) and plug (122),
replace them as an assembly.
21. Clamp spool (125) with wood pieces in a vise,
then install washer (127), spring (128) and bolt
(129).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
22. Install O-rings (118 and 126), flow combiner valve

assembly (122 to 129) and auxiliary flow combiner
valve assembly (114 to 121) onto housing (219).
23. Install O-rings (145) (5 used) onto housing (219).

Then install pilot housing (153) with socket bolts
(147) (9 used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
24. Install overload relief valve (139) onto housing

(219).
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
NOTE: Apply grease on the O-ring of overload re-
lief valve (139). (In order to protect the
O-ring from breakage.)
W2-5-29
DISASSEMBLE BLADE CONTROL VALVE 19
20
(ZAXIS135UR ONLY) 10 21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1
37
38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11 44
56 45
55
54
53 46
52 47
51
48
62
61
60
50
49
59
58
57
W198-02-05-001
1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Valve 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt 60 - Drive Screw
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring
W2-5-30
Disassemble Blade Control Valve
• Be sure to thoroughly read all precautions for 5. Remove sleeve assembly (37 to 42) from hous-
disassembly/assembry work on page W1-1-1 ing (62).
before starting any repair work. : 36 mm
1. Loosen socket bolts (45) (2 used), (48), and (49)
to remove covers (46, 50) and O-rings (47, 56). 6. Pull out spring (43) and valve (44) from housing
: 6 mm (62).
2. Remove spool assembly (51 to 59) from housing 7. Secure seat (37) in a vice. Remove sleeve (41),
(62). spring (40), valve (39), and O-rings (38, 42).
: 36 mm
NOTE: When removing the spool assembly, be NOTE: As plate (61) is installed with drive screw
sure to pull it out straight to prevent it from (60), be sure not to disassemble the plate.
damaging spool (57) inside housing (62).
3. Secure spool (57) with wooden pieces in a vice.

Remove end spool (51), seat (52), springs (53,
54), and seat (55). Remove plug (59) and O-ring
(58).
: 5 mm
: 8 mm
IMPORTANT: As the set pressure may be changed,

be sure not to disassemble overload
relief valve assemblies (1 to 18) and
(19 to 36).
4. Remove overload relief valve assembly (1 to 18)

and (19 to 36) from housing (62).
: 32 mm
NOTE: As each set pressure is different, be sure

to install overload relief valve assemblies
(1 to 18) and (19 to 36) correctly.
W2-5-31
ASSEMBLE BLADE CONTROL VALVE
(ZAXIS135UR ONLY) Cross Section
X-X 37 39 40 38
41
43
62
42
44
1～18 A1 B1 19～36
A1 B1
X X
W198-02-05-003
W198-02-05-002
57
Cross Section
W-W
54 53 55 56 62
50 51 52 47
48 45
W W
W198-02-05-004
49
57 59 58 46
W198-02-05-005
1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Valve 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Drive Screw
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring
W2-5-32
Assemble Blade Control Valve
1. Secure seat (37) in a vice. Install O-ring (38), 6. Insert spool assembly (51 to 59) to housing (62)
valve (39), spring (40), sleeve (41), and O-ring through port A1 side.
(42).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) NOTE: When installing the spool assembly, be
sure to install it straight to prevent it from
2. Install valve (44) and spring (43) into housing damaging spool (57) inside housing (62).
(62).
7. Install O-ring (56) to cover (50) and O-ring (47) to
3. Install sleeve assembly (37 to 42) to housing cover (46). Install them to housing (62) with
(62). socket bolts (45) (2 used), (48), and (49).
: 36 mm : 6 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) : 25.5 N⋅m (2.6 kgf⋅m, 18.8 lbf⋅ft)
IMPORTANT: As each set pressure is different, be

sure to install overload relief valve
assemblies (1 to 18) and (19 to 36)
correctly.
4. Install overload relief valve assembly (1 to 18)
and (19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
5. Secure spool (57) with wooden pieces in a vice.

Install O-ring (58) to plug (59). Install it to spool
(57). Install seat (55), springs (53, 54), seat (52),
and end spool (51). Install it to spool (57).
: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
: 8 mm
: 18.6 N⋅m (1.9 kgf⋅m, 13.7 lbf⋅ft)
W2-5-33
(Blank)
W2-5-34
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

remaining pressure.
Preparation

maining pressure.


ously while working on the hydraulic sys- M104-07-021
tem.
W2-6-1
Removal
ZAXIS110, 110M, 120, 130LCN
1. Disconnect hoses (1, 3 to 6) and harness (2).
: 36 mm 1 2 3 4 5 6
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 6 mm Front
: 20 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft)
NOTE: Attach caps to the hoses.
2. Attach nylon slings to swing motor (8) so as to

hoist it by crane.
Nylon sling (eye-type at both ends): 2 piece. 7
CAUTION: Swing device weight: M175-00-002
130 kg (290 Ib) ZAXIS125US,135US, 135UR

3. Remove bolt (7), hoist the swing device
1 5
assembly by crane. 2
: 30 mm
: 500 N⋅m (51 kgf⋅m, 370 Ibf⋅ft)
3
Installation
6
NOTE: Refer to “Removal” section above for 4
wrench sizes and tightening torques. 7
1. Install the swing device to the frame and tighten
bolts (7).
IMPORTANT: Before installing the swing device,

apply the liquid packing to both M1SE-07-020
mounting surfaces on the swing

Nylon Sling
device and frame.
2. Connect hoses (1, 3 to 6) and harness (2).
IMPORTANT: Be sure to fill the swing motor with

hydraulic oil after installing it. After
installation, check the hydraulic oil
level. Add oil as necessary. Run the
engine and check the component
for any oil leaks.
W176-02-06-002
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING DEVICE
22
23 1
24
2
3
32 21
25 4
31 5
20 6
26 7
19
8
27
18 9
28 10
17
11
29
16
12
30 15 13
14
W176-02-06-003
1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing
2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-4
Disassemble Swing Device
4. Remove pipe (32) from housing (25).
CAUTION: Swing device weight: : 18 mm
130 kg (290 Ib)
5. Put alignment marks at the jointed portion be-
1. Secure the swing device body with nylon slings, tween swing motor (1) and ring gear (24), be-
then hoist it by crane. tween ring gear (24) and housing (25).
Nylon Sling
CAUTION: Swing motor weight: 34 kg (75 Ib)
6. Remove swing motor (1) from ring gear (24).
: 8 mm
NOTE: THREEBOND has been applied on the
joint faces. Insert a screw driver into the
gap between the swing motor and the ring
gear. Then pry it up for easy removing.
7. Remove first stage sun gear (2) from first stage

carrier (21).
8. Remove first stage carrier (21) assembly from

ring gear (24).
9. Remove ring gear (24) from housing (25).

NOTE: THREEBOND has been applied on the
joint faces. Insert a screw driver into the
gap between the ring gear and the housing.
W176-02-06-002 Then pry it up for easy removing.
: 12 mm
2. Install the swing device on the bracket (ST 5098).
Secure it with bolts (M20) (2 used). Insert the 10. Remove second stage sun gear (20) from sec-
stopper located at the bottom of the bracket into ond stage carrier (18).
the middle of two teeth of the pinion gear. Secure
the bracket on a working bench. 11. Remove second stage carrier (18) assembly from
: 30 mm shaft (30).
Swing Device
ST 5098
Stopper
W178-02-06-012
3. Remove drain plug (31), then drain oil.

: 8 mm
W2-6-5
23
25 21
4
26 7
18
28
17
11
16
30 15
14
W176-02-06-003
W2-6-6
IMPORTANT: The hole for the spring pin located
on the first stage carrier does not CAUTION: Housing assembly weight: 63 kg
continue through. Pay attention to (140 lb)
the drive-in distance when driving
spring pin in. 20. Install eye bolt (M14) into the bolt (23) hole of
12. Drive spring pin (5) in the first stage carrier (21) housing (25). Hoist it by crane. Remove bracket
assembly into pin (4) with special tool (ST 1462). (ST 5098) which has been installed at the pinion
Do not drive spring pin (5) to the end. gear side.
: 30 mm
13. Remove pin (4), planetary gear (7), needle bear-
ing (6) and thrust plate (8) from first stage carrier CAUTION: Before pressing shaft (30), pro-
(21). vide a protection cover (outer diameter: 290
mm (11.4”), inner diameter: 90 mm (3.5”),
14. Remove remaining two sets of pin (4), planetary thickness: 25 to 30 mm).
gear (7), needle bearing (6) and thrust plate (8) Then, use the press to remove the shaft
from first stage carrier (21) according to the re- while covering housing (25) and bearing (14)
moval procedure in step 12, step 13. with the protection cover may result in per-
sonal injury due to metal fragments flying
15. Remove thrust plate (3) from first stage carrier out if the housing and/or bearing break.
(21). Use a press of capacity less than 30 tons
(66000 lb). Be sure to degrease the housing
IMPORTANT: The surface of the pin except for inside before heating the bearing. Failure to
both ends is a rotating surface for degrease may cause a fire.
the needle bearing. 21. Install the protection cover on housing (25). Push
Pay attention not to damage it. the upper end of shaft (30) with a press and re-
16. Clamp pin (4) with a vise. Push spring pins (5) (3 move it from the housing. The inner race of roller
used) out using special tool (ST 1462). bearing (26) and sleeve are removed with the
shaft. Shaft (30) Roller Bearing
17. Disassemble the second stage carrier (18) (14)
Housing (25)
assembly according to the removal procedure for
first stage carrier (21) assembly. Be sure that the
number of thrust plates (11) is 6.
Protection
Cover
18. Remove bolt (17). Remove lock plate (16) for
bearing nut (15).
: 17 mm
19. Remove bearing nut (15) from shaft (30) using

special removing tool for nut (ST 2927).
W157-02-06-010
ST 2927
15 Press
Protection
Cover
W178-02-06-008
W157-02-06-011
W2-6-7
25
26
27
28
29
30 15
14
W176-02-06-003
W2-6-8
22. Attach the shaft (30) assembly to the special tool IMPORTANT: Be sure to use the guide when
bearing removal set. pushing shaft (30) with a press.
Then, remove the shaft using a press.
Press
NOTE: Use the following parts as the special tool
set for removing bearing (26).
Part Size Remarks
Shaft Length: 200 mm 8 used. All should be Roller Bearing Shaft
or Bolt (8 in) identical in length with no (26) Inner Race
Diameter: 19 mm wear and deformation on
(3/4 in) both ends. Sleeve (28)
Material: S35C (JIS),
1035 (AISI)
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2” (Appli-
Guide
cable Diameter:
185 to 215 mm)
Guide Height: 160 mm
(6.3 in)
Outer Diameter: W157-02-06-014
230 mm (9.06 in)

Inner Diameter: 23. Push the spline side of shaft (30) with a press
210 mm (8.27 in) and remove it from the housing. The inner race of
roller bearing (26) and sleeve (28) are removed
Bearing Removal Tool from the shaft.
Shaft 24. Remove O-ring (29) from sleeve (28).
Hose Clamp
25. Insert a round bar into the oil passage in housing
(25). Tap the outer race of roller bearing (26) out.
Oil Passage
Outer Race
W157-02-06-012
Shaft
Inner Race of W178-02-06-001
Roller Bearing
(26)
Sleeve (28) CAUTION: Housing (25) weight: 36 kg (79 Ib)
26. Secure housing (25) body with nylon sling, hoist
it by crane. Turn the up side of the housing down.
27. Insert a screw driver into the notch on housing

(25) where oil seal (27) is mounted. Remove the
oil seal.
Shaft NOTE: THREEBOND has been applied on the
W157-02-06-013
periphery of oil seal. Thus, it cannot be
Guide reused.
IMPORTANT: Push the shaft of the special tool 28. Insert a bar at the back side of the outer race of
into the gully side of the pinion. roller bearing (14). Remove the outer race from
Secure the shaft with the hose housing (25) while tapping with a bar and ham-
clamp in order not to loosen and mer.
separate.
W2-6-9
ASSEMBLE SWING DEVICE
5
3
22
21
7
24
6
20
18
4
19
8
10
23
11
13
12
11
17 9
15
16 14
32
25
26
31
27
28 30
29
W176-02-06-004
1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-10
Assemble Swing Device
1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put the oil seal evenly on housing
IMPORTANT: Pay attention to the mounting direc- (25) and push it in gently. Then place seal
tion for the sleeve and the inner mounting tool (ST 2928) on the oil seal and tap it
race. with a hammer directly.
2. Install sleeve (28), and the inner race of roller
ST 2928
with a bearing (26) into shaft (30). Press the
sleeve and inner race using bearing mounting 27
tool (ST 2929).
NOTE: Press-in distance of the bearing inner race 25
can be assured by using the bearing
mounting tool.
W176-02-06-006
Press
NOTE: According to following steps, oil seal (27)
can be replaced without removing shaft
(30).
• Drain oil out inside of the reduction gear.
ST 2929 • Place the swing device horizontally.
• Remove the oil seal with a screw driver.
26 • Clean off from housing (25).
28 • Apply THREE BOND #1215 onto the outer sur-
face of the oil seal and apply grease onto its
30 inner surface.
• Install the oil seal into the housing by pushing
with hand gently.
• Place the oil seal mounting tool guide (ST
W178-02-06-013
7247) onto the pinion gear.
• Cover the oil seal mounting tool (ST 2928) by
the mounting tool guide (ST 7247), then push it
to the oil seal upper side.
• Install the oil seal into the housing while tap-
CAUTION: Housing weight: 36 kg (79 Ib)
ping the oil seal mounting tool (ST 2928) with a
3. Secure the housing (25) body with the nylon sling,
hammer.
then hoist it by crane. Place sleeve (28) with the
mounting side upward.
Pinion Gear
4. Tap the outer race of roller bearing (26) evenly 27

with a mounting bar and hammer while installing
the outer race into housing (25). Check if installa-
tion is completed by the tapping sound.
ST 7247
ST 2928
25 W176-02-06-005
W2-6-11
24
23
15
14
25
27
28 30
W176-02-06-004
W2-6-12
6. Apply grease all around the inner face of oil seal 11. Screw in bearing nut (15) to shaft (30). Tighten
(27). Apply grease onto the outer surface of as much as is possible by hand.
sleeve (28) on shaft (30). NOTE: Avoid shaft (30) falling down when lifting
NOTE: Apply the grease carefully when installing housing (25).
the shaft to avoid accidental curling of the
seal lip from the shaft.
CAUTION: Housing + shaft + bearing weight:
59 kg (130 Ib)
CAUTION: Housing +outer race weight: 12. Hoist housing (25) by crane and eyebolt (M14)
37 kg (82 Ib) installed in step 9. Place it on a press.
7. Secure the housing (25) body with the nylon sling
and hoist it by crane. Place ring gear (24) with 13. Remove bearing nut (15) from shaft (30).
the mounting side upward.
14. Place mounting tool (ST 2930) onto the inner
8. Tap the outer race of roller bearing (14) evenly race of roller bearing (14). Push the inner race
with a mounting bar and hammer. When installing down using a press.
the outer race into housing (25). Check if installa- NOTE: Press-in distance of the inner race can be
tion is completed by the tapping sound. assured by using the mounting tool.
ST 2930
CAUTION: Housing + outer races (2 used)
weight: 38 kg (84 Ib)
14
IMPORTANT: Pay attention to the problem of curl-
ing the oil seal lip.
9. Install eyebolt (M14) into the ring gear mounting
bolt (23) hole in housing (25). Then hoist and
place it on shaft (30) by crane slowly. Check and
align carefully to protect the oil seal lip from curl-
ing while mounting it.
W178-02-06-011
10. Tap inner race of roller bearing (14) into shaft

(30) with a mounting bar and hammer. Tap the
inner race until two threads lengths of the shaft
bearing nut (15) inner race must appear.
NOTE: The fitting between the inner race and the
shaft is tight.
W2-6-13
18
19
10
11
13
12
11
17 9
15
16 14
25
30
W176-02-06-004
W2-6-14
15. Hoist the housing (25) assembly and place it on 17. Install lock plate (16) onto bearing nut (15) with
bracket (ST 5098) by crane. Secure it with bolts bolt (17). In case the spline of lock plate and that
(M20) (2 used) while the stopper at the bottom of of shaft (30) are not aligned, tighten the bearing
bracket is located at the middle of two teeth of nut in tightening direction until both splines are
the pinion gear. Secure the bracket on a working aligned.
bench. : 17 mm
: 30 mm : 50 N⋅m (5 kgf⋅m, 36.2 lbf⋅ft)
25 IMPORTANT: Pay attention to the mounting direc-

tion of the spring pin and thrust
plate (19).
18. Assemble second stage carrier (18) according to
ST 5098 following steps.
Stopper
Install needle bearing (12) into planetary gear
(13). Clamp planetary gear (13) with two
pieces of thrust plates (11), then install them
together into second stage carrier (18).
When mounting needle bearing (12), the
W178-02-06-012
spring pin hole (in mounting pin (9)) should be
facing out and align the spring pin hole in
second stage carrier (18) and that in pin (9).
IMPORTANT: Pay attention to the mounting direc- Tap spring pin (10) into second stage carrier
tion of bearing nut (15). (18) using the special tool (ST 1462). At this
16. Apply some grease on the thread surface of time, the slit of the spring pin should face the
bearing nut (15), then install it onto shaft (30) with end of pin (9).
the stepped side of the bearing nut facing roller
bearing (14). Tighten the bearing nut using 10
mounting tool (ST 2927).
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) 9
NOTE: Grease must be applied for assuring cor- Slit

rect tightening torque.
W178-02-06-002
Install thrust plate (19) into second stage car-

ST 2927 15 rier (18), while the oil groove of thrust plate
(19) is facing upward.
Install needle bearings (12) (2 used), thrust
plates (14) (4 used), pins (9) (2 used) and
spring pins (10) (2 used) into two remaining
holes of the second stage carrier according to
the same procedure mentioned above.
W178-02-06-008
W2-6-15
5
3
22
21
24 7
20 6
18
4
23
16
32
25
31
30
W176-02-06-004
W2-6-16
IMPORTANT: Pay attention to the mounting loca- 24. Install the first stage carrier (21) assembly onto
tion of thrust plate (8). the spline of second stage sun gear (20).
19. Assemble the following parts to form the first
stage carrier (21) assembly. According to the IMPORTANT: Pay attention to the mounting direc-
procedure mentioned for the second stage carrier tion of first stage sun gear (2).
assembly, install planetary gears (7) (3 used), 25. Install first stage sun gear (2) into the first stage
needle bearings (6) (3 used), thrust plates (8) (3 carrier (21) assembly with the stepped side of
used), pins (4) (3 used), spring pins (5) (3 used) sun gear facing downward.
and thrust plate (3) (1 used) together. Thrust
plate (8) is installed under needle bearing (6). 26. Wind sealing tape on the threaded part of pipe
(32). Install pipe (32) into housing (25) with the
IMPORTANT: Pay attention to the mounting direc- pipe facing downward.
tion of second stage carrier (18). : 18 mm
20. Install the second stage carrier (18) assembly
onto the spline of shaft (30), while the concave 27. Wind the sealing tape on drain plug (31), then
portion of the boss in bottom side of the carrier install it into pipe (32).
comes in contact with lock plate (16). : 8 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
Concave
18
Portion 28. Fill the gear oil into ring gear (24) until the middle
16 part of first stage sun gear (2) is submerged in.
30 (Approx. 3.2 L)
29. Clean off old THREEBOND, then apply new

THREEBOND #1102 onto the swing motor (1)
mounting face of ring gear (24).
CAUTION: Swing motor weight: 34 kg (75 Ib)

W178-02-06-014 30. Secure swing motor (1) body with the nylon sling
and hoist it by crane. Align the mating marks,
21. Install second stage sun gear (20) into the sec- then fasten the swing motor and ring gear (24)
ond stage carrier (18) assembly with the small with bolts (22) (7 used).
diameter part of sun gear facing upward. : 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 Ibf⋅ft)
22. Clean off old THREEBOND and apply new
THREEBOND #1215 onto the ring gear (24)
mounting surface in housing (25).
23. Fasten ring gear (24) and housing (25) with bolts
(23) (12 used) aligning the marks which were
added in disassembling.
: 12 mm
: 140 N⋅m (15 kgf⋅m, 109 Ibf⋅ft)
W2-6-17
DISASSEMBLE SWING MOTOR
34 1
33 2
32 3
4
31
5
30
6
29
28 7
27
26
8
25
9
24
10
23
11
22
23 12
13
22
14
23
15
22
23
22 16
17
21 18
19
20
W176-02-06-008
1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring
W2-6-18
Disassemble Swing Motor
CAUTION: Swing motor weight: 34 kg (75 Ib) 6. Supply air through the parking brake oil port of
1. Secure the swing motor body with the nylon sling. casing (20). Lift piston (25) and remove it.
Then hoist it by crane. Place it with the valve unit NOTE: In case it is impossible to lift, push the pi-
(32) side upward. Shaft (7) extends out of casing son back and pull it out again using piston
(20) at bottom side. Place the swing motor on a mounting tool (ST 2921, ST 2922). As for
square block of height of more than 50 mm (2 in). the operation of the tool, refer to the
explanation for swing motor assembling.
IMPORTANT: Pay attention to valve plate (27)
when removing valve unit (32). It
has a tendency to fall.
2. Loosen and dismount socket bolt (34). Remove 20
valve unit (32) from casing (20). Oil Port
: 14 mm
3. Wind vinyl tape at front end of shaft (7) for pro-

tection.
NOTE: The front end of shaft (7) becomes the
rotating surface of the needle bearing.
W176-02-06-009
4. Remove needle bearing (30) from valve unit (32).

NOTE: Extend finger into the needle bearing. 7. Remove rotor (1) from casing (20). Plate (23) and
Raise the bearing up straightly while rotat- friction plate (22) are removed with the rotor.
ing it. If it can not be pulled out, push it
back, then pull out again using assembling 8. Hold two pieces of plunger (5) located at diago-
tool (ST 2899). As for the operation of the nal side, then remove them from casing (20).
tool, refer to the swing motor assembling. Disc spring (2), bushing (3) and retainer (4) are
removed with the plungers.
5. Remove disc spring (29) from casing (20).
9. Remove remaining plunger (5) from casing (20).
W2-6-19
10
11
12
14
15
16
17
19
20
W176-02-06-008
W2-6-20
10. Hang two feet of tool (ST 1458) on the internal IMPORTANT: When removing roller bearing (9)
diameter side of swash plate (6). Pull it out of from shaft (7), hold the shaft by
casing (20). hand to prevent it from dropping. If
dropped, needle bearing (30) rotat-
ST 1458 ing face of the shaft will be dam-
6 aged.
16. Clamp bearing extractor (ST 1459) in a vise. In-
20 stall shaft (7) with the spline end facing upward.
Tap the spline end with a plastic hammer, to re-
move roller bearing (9) from the shaft.
W176-02-06-011
ST 1459
11. Remove retaining ring (8) from casing (20).
12. Place casing (20) horizontally.
13. Tap the shaft (7) head at spline side with a plastic
hammer. Remove the shaft from casing (20) with
roller bearing (9).
W176-02-06-021
14. Remove oil seal (11) with a screw driver. As
THREEBOND was applied on the outer surface
of the oil seal, it cannot be reused. 17. Remove plug (12) from casing (20). Pull out
spring (14) and poppet (15).
IMPORTANT: Pay attention to the oil seal (11) lip : 6 mm
contact surface of shaft (7). Do not
damage it. 18. Remove plug (19) from casing (20). Pull out
15. Remove retaining ring (10) from shaft (7). spring (17) and plunger (16).
: 6 mm
NOTE: The reinforced mesh and filter are

mounted inside of the plunger. Do not re-
move it unless necessary. When removing,
clamp the plunger in a vice, then remove
the plug by 3 mm hex wrench. When in-
stalling, degrease for the plunger and plug
first, then apply LOCTITE #242 to the
threaded part of the and plug. Tighten it
with torque 5.9 N⋅m (0.6 kgf⋅m, 4.3 Ibf⋅ft).
W2-6-21
ASSEMBLE SWING MOTOR
34
32
33
30
28
29
27
16 17 19 18
15 31
14
25
13
26
12
24
23
22
5
Parking Brake Release Block
4
21
8
6
9
2
20
3
10 11 W176-02-06-012
7
1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring
W2-6-22
Assemble Swing Motor
1. Place casing (20) onto a 50 mm (2 in) square IMPORTANT: Pay attention to the mounting direc-
block with valve unit (32) mounting side upward. tion of the roller bearing.
2. Install spring (17) onto plunger (16) and insert it 7. Install roller bearing (9). Stamped marks on the
into the hole of the parking brake release block. outer race, inner race and inner race plate should
be facing upward.
3. Install O-ring (18) onto plug (19). Install it into the
hole of the parking brake release block.
Stamped Mark on Outer Race Stamped Mark on Inner Race
: 6 mm
: 34.3 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
4. Install spring (14) onto poppet (15). Insert the

spring into the hole of the parking brake release W176-02-06-014
block. Stamped Mark on Inner Race Plate
5. Install O-ring (13) onto plug (12), then install it in

the hole of the parking brake release block. IMPORTANT: Pay attention to the mounting direc-
: 6 mm tion of the roller bearing.
: 34.3 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft) 8. Insert roller bearing (9) to the spline side of shaft
(7) with the inner race plate side first. Then push
6. Clean off remaining THREEBOND in the oil seal it to the front end of the engaged part of the shaft.
(11) mounting part of casing (20). Apply Pay attention to the seal lip contact surface of the
THREEBOND #1104 or #1215 on the outer sur- shaft. Do not damage it.
face of oil seal. Install it into the casing using as-
sembling tool (ST 2897 and ST 2898). 9. Insert the spline side of shaft (7) into bearing
mounting tool (ST 2896). Tap the opposite side of
the shaft with a plastic hammer while installing
roller bearing (9) on the shaft.
ST 2898
7
11
ST 2897
9
20
ST 2896
W176-02-06-010
W176-02-06-018
10. Install retaining ring (10) onto shaft (7). Pay at-
tention not to cause any damage the seal lip
contact surface of the shaft.
W2-6-23
32
25
26
24
23
22
5
4
21
8
6
20
3
11 W176-02-06-012
7
W2-6-24
11. Apply grease onto the seal lip contact surface of Install retainer (4) onto bushing (3) with the
shaft (7) and the inner surface of oil seal (11). chamfer side facing downward.
4
12. Insert shaft (7) into casing (20). After alignment,
push it in while tapping the end of shaft with a
plastic hammer. Check if mounting is completed
by the tapping sound.
Chamfer Side
13. Install retaining ring (8) into housing (20).
3 W176-02-06-016
14. Apply grease onto the chamfer side and outer

surface of swash plate (6). Align the plunger hole of retainer (4) and that of
rotor (1). Insert plungers (5) (9 used) into the
15. Install swash plate (6) into casing (20) with the holes.
chamfer side facing downward.
NOTE: Rotate the swash plate after installing it in 17. Place casing (20) horizontally with drain plug (21)
casing. In case of sticking or not possible facing downward.
to move, re-install it.
18. Install the rotor (1) assembly and shaft (7) into
IMPORTANT: The flat surface of the rotor is a casing (20) while matching their splines.
slide surface for the valve plate. Pay
attention not to damage it. IMPORTANT: The shaft extends out of casing (20)
16. Assemble the rotor (1) assembly. at bottom side. Place the casing on
Place the rotor with the flat surface downward. a square block of height of more
Install 4 pieces of disc spring (2) into the pro- than 50 mm (2 in).
jecting portion of the rotor. Make sure the disc 18. Place casing (20) with the valve unit (32) mount-
springs are contacted as outer collar to outer ing side up.
collar and inner collar to inner collar. Cover
bushing (3) on the disc spring. Pay attention to IMPORTANT: Pay attention to the mounting order
the spring mounting direction as below. of the plate and the friction plate.
20. Install plates (23) (4 used), friction plates (22) (4
used) into casing (20).
2 3 Mounting order: Install the friction plate into the
casing first, then install the plates and the friction
plates alternately.
1
21. Install O-rings (24) and (26) to piston (25).
W176-02-06-015
W2-6-25
34
32
33
30
28
29
27
31
25
20
W176-02-06-012
W2-6-26
22. Place piston (25) on casing (20) horizontally. 25. Install O-ring (31) into valve unit (32).
Cover the piston with piston mounting tool (ST
2921 and ST 2922). Tap the piston in with a 26. Apply grease on the flat surface of valve plate
hammer. (27).
NOTE: Apply grease on the valve plate to protect
ST 2922 it from falling when installing the valve unit
into the motor.
ST 2921 IMPORTANT: Pay attention to the valve plate as it

may fall down.
25 27. Install valve plate (27) while aligning with knock
20
pin (28) for valve unit (32). Turn the valve unit up
side down, then place it on casing (20).
28. Install valve unit (32) into casing (20) with spring
washers (33) (4 used) and socket bolts (34) (4
used).
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
W176-02-06-020
IMPORTANT: Pay attention to the mounting direc-

tion of the disc spring.
23. Install disc spring (29) into casing (20) to contacts
the outer circle of disc spring (29) on piston (25).
24. Install needle bearing (30) into valve unit (32)

using bearing mounting tool (ST 2899).
ST 2899
30
32
W176-02-06-019
W2-6-27
DISASSEMBLE VALVE UNIT
7
6
1 2 3 4 5 9
10
11
12
4
3
2
1
13
14
15
16
W176-02-06-007
16
15
14
13
1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Ring (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)
W2-6-28
Disassemble Valve Unit
As for the procedure to remove the valve unit IMPORTANT: Take care not to damage the inner
from the swing motor, refer to “Disassemble and surface of the valve housing (5).
Assemble Swing Motor” section. 6. Insert a round bar into valve housing (5) to push
spool (12) to the other side. There is a ring (4) (1
IMPORTANT: The lower section of the valve hous- used) with the spool. When feeling a little tight,
ing is the contact surface for the insert a round bar from the other side to push the
valve plate. Take care not to damage spool back. Repeat this action as needed.
it.
1. Put valve housing (5) on a work bench with a rag 7. Remove ring (4) (1 used) left in valve housing (5)
or a shop cloth. with a magnet.
IMPORTANT: Do not turn the lock nut. The

set-pressure may be changed.
2. Turn the cartridge of relief valve (8) to remove it
from valve housing (5). (2 places)
: 32 mm
Cartridge
Lock Nut
W176-02-06-017
4. Remove plug (13). Then remove spring (15) and

poppet (16) from valve housing (5) with a magnet.
(2 places)
: 12 mm
5. Remove plug (1). Then remove spring (3) from

valve housing (5). (2 places)
: 8 mm
W2-6-29
ASSEMBLE VALVE UNIT
10
11
13
14
15
16
2 1 3 4 12 4 3 1
2
Section E
W176-02-06-013
1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Ring (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)
W2-6-30
Assemble Valve Unit
1. Install O-ring (9) to relief valves (8) (2 used). 6. Install O-ring (14) to plug (13) and then install
them to valve housing (5) (2 places).
IMPORTANT: Pay attention to the assembling or- : 12 mm
der of the O-ring and the backup : 235 N⋅m (24 kgf⋅m, 174 Ibf⋅ft)
ring.
2. Install O-ring (7), and backup ring (10) to relief 7. Install ring (4) on one side of spool (12). Then
valves (8) (2 used). insert the other side of the spool to valve housing
(5). Push the spool until the spool comes in mid-
IMPORTANT: Pay attention to the assembling or- dle of valve housing (5). Take care not to drop the
der of the O-ring and backup ring. ring into the valve housing.
3. Install backup ring (6), O-ring (11) to relief valves
(8) (2 used). 8. Push spool (12) until the end of the spool just
comes out of the opposite hole of valve housing
IMPORTANT: If the lock nut of the relief valve is (5). When pressing too much, ring (4) in the
turned, the set-pressure may be spool will come off in the valve housing.
changed. Do not turn the lock nut.
4. Turn the cartridge of relief valve (8) to install it to 9. Install ring (4) to the end of spool (12) which
valve housing (5). (2 places) comes out from valve housing (5), and then push
: 32 mm the ring to the stepped part of the spool with
: 235 N⋅m (24 kgf⋅m, 174 lbf⋅ft) spring (3).
10. Push spool (12) back to the middle of valve hous-

Cartridge Lock Nut
ing (5) and install spring (3) from the other hole.
11. Install O-ring (2) to plug (1) and install them to

valve housing (5). (2 places)
: 8 mm
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
W176-02-06-017
5. Install spring (15) to poppet (16) and install them

to valve housing (5) (2 places).
W2-6-31
MAINTENANCE STANDARD Shoe
Swing Motor
1. Clearance between plunger and shoe at the

caulked position. : ε
ε
Plunger
Standard Allowable limit
0 0.2 mm (0.0079 in)
W105-02-06-130
ε ≤ 0.2 mm
2. Clearance between outer diameter of plunger

and inner bore of rotor. : D-d D
Rotor
Standard Allowable limit
0 0.05 mm (0.0020 in)
D-d ≤ 0.05 mm
W105-02-06-134
Plunger Assembly
d
Rotor
W105-02-06-135
W2-6-32
Parking brake
W176-02-06-022
C Unit: mm (in)
Allowable
Parts Name Standard Remedy
Limit
A Friction Plate Thickness 2.4 (0.094) 2.35 (0.093)
B Disc Spring (Overall height) 6.8 (0.268) 6.7 (0.263)
C Piston Thickness* 41.0 (1.614) −
D Plate Thickness 1.4 (0.055) 1.35 (0.053)
Remarks Piston does not slide, so no wearing to it.
NOTE: Thickness of pistion shows the thickness

between the disc spring receiving surface
and the pushing plate surface.
Plunger
W155-03-02-007
Unit: mm (in)
Standard Allowable Limit Remedy
A 5.5 (0.217) 5.3 (0.209) Replace
W2-6-33
(Blank)
W2-6-34
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE (ZAXIS110, 110M, 120, 130, 130LCN,
125US, 135US)

before disconnecting hydraulic or other lines. M104-07-021

and may spurt, possibly causing severe ZAXIS110, 110M, 120, 130, 130LCN
pressure.
1
Preparation
2
the top of the hydraulic oil tank to release any
remaining pressure. ZAXIS125US, 135US W178-02-01-001
1 2
Removal
1. (ZAXIS110, 110M, 120, 130, 130LCN)
Remove seat mounting nut (2) to remove seat (1)
with seat stand.
: 17 mm
(ZAXIS125US, 135US)
Remove seat mounting bolts (2) (4 used) and
bolts (3) (2 used) under the seat bolt to remove
seat (1).
: 17 mm, 16 mm
W1SE-02-01-001
ZAXIS125US, 135US
1
3
W1SE-02-01-002
W2-7-1
2. Remove screws (28) (4 used), cover (27) to more
boot (7) upward.
3. Remove screws (25) (4 used), caps (21) (2 used) 4

and screws (20) (2 used) to move cover (22)
upward. Disconnect each harness connectors for 5
key switch (24) and air conditioner controller (23), 6
then remove cover (22). Remove screw (26), (16)
7
(17), (19) and rubber (14) to remove cover (18).
8
4. Remove connector (13) and bolts (11) (3 used) of 28
switch box (12) to remove switch box (12). 27 9
: 13 mm 26 11
10 12
25
IMPORTANT: Attach identification tags on all dis- 24
connected hoses to aid in reassem- 23
bly. 22 13
5. Disconnect hoses (29 to 34). 21
: 19 mm
NOTE: Attach a cap on all disconnected hose
ends.
20
6. Loosen nut (5) to remove grip (4) 14
Loosen nut (8) to remove lever (6), and boot (7).
: 22 mm 15
: 19 mm
16
7. Remove bolts (9) (4 used) to remove valve (10). 19 17

: 13 mm
18
Installation W1CC-02-07-001
1. Install valve (10) with bolts (9) (4 used).

: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf·ft)
29
34
33 30
31
32
W178-02-07-002
29 - Hose T6: (To the pilot shut-off valve)
30 - Hose H: (To the signal control valve port H (bucket roll-out))
31 - Hose A: (To the signal control valve port A (boom raise))
32 - Hose P3: (From the pilot shut-off valve)
33 - Hose G: (To the signal control valve port G (bucket roll-in))
34 - Hose B: (To the signal control valve port B (boom lower))
NOTE: Piping location shows that of ISO pattern.
W2-7-2
2. Connect hoses (29 to 34).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
3. Temporarily tighten nut (8) to the lever, then in- 29

stall lever (6) onto valve (10) with nut (8). Install 34
33 30
boot (7).
Temporarily tighten nut (5) to the lever (6), then 31
install grip (4) with nut (5). 32
: 22 mm
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
: 19 mm
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
4. Install switch box (12) with bolt (11), then connect W178-02-07-002
connector (13).
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft) 4
5. Connect each harness of key switch (24) and air 5

conditioner controller (23). 6
6. Install cover (18) with screws (26), (16) and (19). 7

Install rubber (14).
8
Install cover (22) with screws (25) (4 used) and 28
(20) (2 used). Install caps (21) (2 used). 27 9
26 11
7. Install cover (27) with screws (28) (4 used). 25 10 12
24
23
22 13
21
20
14
15
16
19 17
18
W1CC-02-07-001
W2-7-3
8. (ZAXIS110, 110M, 120, 130, 130LCN)
Install seat (1) (with the seat stand) with nut (2). ZAXIS110, 110M, 120, 130, 130LCN
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: After installation, check the oil level,
start the engine and check for oil
leaks.
(ZAXIS125US、135US)
Install seat (1) with seat mounting bolts (2) (4 1
used) and bolts (3) (2 used) under the seat belt.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2
: 16 mm
: 70 N⋅m (7.1 kgf⋅m, 51 lbf⋅ft) W178-02-01-001
IMPORTANT: After installation, check the oil level, 1 2

start the engine and check for oil ZAXIS125US, 135US
leaks.
W1SE-02-01-001
ZAXIS125US, 135US
1 3
W1SE-02-01-002
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE (ZAXIS110, 110M, 120, 130, 130LCN,
125US, 135US)

remaining pressure.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to the ground.

the hydraulic oil tank to release any pressure
remaining in the hydraulic tank.
M104-07-021
Removal
1. Remove screw (2) and cover (3) to move boot (1)
upward. At this time, the console is at the most
front position.
: 17 mm
2. Remove screws (7) and (8) to remove cover (9).

Remove screws (4) and (5) to move cover (6)
upward. Disconnect the radio connector, then
remove cover (6).
1
2
9 Radio
3
8
4
7
6
5
W178-02-07-003
W2-7-5
IMPORTANT: Attach identification tags on all dis-
connected hoses for reassembly.
3. Disconnected hoses (10 to 15).
: 19 mm
NOTE: Attach a cap on each disconnected hose
end. 10
15
14 11
4. Loosen nut (17). Remove clips (28) and (20) and
12
disconnect connector (27) to remove grip (16)
(with harness). 13
Loosen nut (19) to remove lever (18), washers
(24) and (25) and boot (1).
: 22 mm
: 19 mm
5. Remove bolts (23) and (22) (with pin (21)) to re-

move valve (26).
: 13 mm W178-02-07-004
10 - Hose T5: (To the pilot shut-off valve)
11 - Hose D: (To the signal control valve port D (arm roll-in))
Installation 12 - Hose E: (To the signal control valve port E (left swing))
1. Install valve (26) with bolts (23) and (22) (with pin 13 - Hose P2: (From the pilot shut-off valve)
14 - Hose C: (To the signal control valve port C (arm roll-out))
(21)). 15 - Hose F: (To the signal control valve port F (right swing))
: 13 mm
: 10 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
NOTE: Piping location shows that of ISO pattern.
2. Connect hoses (10 to 15). 16
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
28
17
18
27
1
19
20
21
22
23
24
25
26
W178-02-07-003
W2-7-6
IMPORTANT: If the harness is arranged to the in-
side of spring pin (21), it may make
contact with the moving part of the
pilot valve damaging it. Be sure to 16
arrange harness to the outside of
spring pin (21).
3. Temporarily tighten nut (19) to lever (18), then in- 28
stall washers (24) and (25).
17
4. Install lever (18) onto valve (26) with nut (19). 18
27
1
5. Install boot (1). 19
Temporarily tighten nut (17) to lever (18), then 20
secure grip (16) with nut (17). 21
22
6. Pass the harness of grip (16) through the upper
hole of boot (1), then connect it to lever (18) with 24
clips (28) and (20). 25
26
7. Arrange the harness to the outside of spring pin 9 Radio 2
(21) over bolt (22) head connect connector (27). 8 3
: 22 mm 4
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
: 19 mm
: 26 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)
8. Connect the radio connector and install cover (6) 7

6
with screws (4) and (5). 5
Install cover (9) with screws (7) and (8).
W178-02-07-003
9. Install cover (3) with screw (2).

IMPORTANT: After installation, check the oil level.
Start the engine and check for oil
leaks.
W2-7-7
REMOVE AND INSTALL FRONT/ SWING
PILOT VALVE (ZAXIS135UR) 4
ZAXIS135UR
Removal
IMPORTANT: Be sure to release any pressure in
the hydraulic oil tank before any
work. (Refer to W1-4-1.)
1. Remove screws (1) (6 used) from the lever stand

to remove covers (2 and 3).
2. Remove clip band (9) and plug (10) on the left

2
lever stand only.
3. Raise boots (4) (2 used) to remove screws (15)

(8 used) and plates (14)(4 used). M1CF-03-001
1 3
4. Raise boots (4) on the left lever to remove clip
band (8).
5. Raise boots (4) (2 used) and loosen lock nuts (7) 5

(2 used) to remove levers (6) (2 used) with grip
6
(5) together.
: 22 mm 7
Lock Lever
4
6. Remove boots (4) (2 used).
8
IMPORTANT: Attach the identification tag onto the 15 9
disconnected hoses for assembling. 13
7. Disconnect hoses (11) (12 used) from pilot valves 10
15
(12) (2 used). Attach a cap onto all the open
12
ends.
14
: 19 mm
1
IMPORTANT: Put the matching marks on pilot 11 W1CF-02-07-008
valve (12) and stand to aid in re-as-

sembly.
8. Remove bolts (13) (8 used) to remove pilot
valves (12) (2 used) from the stand.
: 13 mm
W2-7-8
Installation
5
1. Insert pilot valves (12) (2 used) into the lever 6

stand and align the matching marks made when
7
disassembling. Lock Lever
4
2. Install pilot valves (12) (2 used) to the stand with 8
bolts (13) (8 used). 15 9
: 13 mm 13
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) 10
15
12
3. Connect hoses (11) (12 used) to pilot valves (12)
(2 used). 14
: 19 mm
1
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
11 W1CF-02-07-008
4. Insert levers (6) (2 used) (with grip (5)) into boots

(4) (2 used). Install levers (6) (2 used) into pilot
valves (12) (2 used). When installing, lever (6)
with horn button should be installed on the left
side.
4
ZAXIS135UR
5. Secure levers (6) (2 used) to pilot valves (12) (2
used) with lock nuts (7) (2 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
6. Raise boot (4) to install clip band (8).
7. Install clip band (9) and plug (10) to pilot valve

(12) on the left stand only. 2
8. Install boots (4) (2 used) with plates (14) (4 used)

and screws (15) (8 used).
M1CF-03-001
1 3
9. Install covers (2 and 3) with screws (1) (6 used)
on the stands.
IMPORTANT: After completing the work, check

the hydraulic oil level. Start the en-
gine and check the connection for
oil leaks.
W2-7-9
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
12
14
11
15
11
10
8
8
7
9
21
6
16 20
21
5
20
4 5
19
3 6
3 18
2
4
1
17
W176-02-07-001
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim 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 - Knock 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)
W2-7-10
Disassemble Right and Left Pilot Valves
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage them. port number after removing.
Therefore, handle with care.
4. Pull push rods (8) and (9) out of block (10).
IMPORTANT: As spool (17) has been selected to
match the hole of housing (18), they 5. Using a bamboo spatula, remove oil seals (15) (4
must be replaced as a set. In addi- used) from block (10).
tion, the dimensions of balance NOTE: If a metal bar is used, the mating part of oil
springs A (3), B (4) and return seal may be damaged.
springs A (5), B (6) as well as those
of push rods A (8), B (9) are different. IMPORTANT: The retaining ring may come off
For this reason, be sure to indicate while disassembling. Take care not
the port number from which each is to drop it.
removed. Port numbers are stamped 6. Press springs with special tool (ST 7257) from
on housing (18). the top of spring guide (16). Retaining ring (7) will
appear. Remove it with a screw driver or similar
IMPORTANT: Do not clamp housing (18) in a vise tool. (4 places)
to remove the screw joint because 7
the strong torque may act on the
screw joint.
1. Secure screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm
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 bolt (11) to remove block (10). At

this time, push rods (8) and (9) are still on the IMPORTANT: The number of shims (2) has been
block side. determined for each port during the
: 6 mm performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when reassem-
bly.
7. Remove spring guide (16), balance springs (3)
and (4), return springs (5) and (6), shim (2) and
spacer (1) from spool (17).
W2-7-11
21
20
21
20
19
18
17
W176-02-07-001
W2-7-12
IMPORTANT: As spool (17) has been selected to
match the hole of housing (18), keep
them carefully so as to install them
to the former port when reassem-
bling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it slowly.
NOTE: The spool and the housing must be re-
placed as an assembly.
9. Remove O-rings (19) and (21) (2 used) from

housing (18). Do not remove knock pins (20) (2
used) unless necessary.
W2-7-13
ASSEMBLE RIGHT AND LEFT PILOT
VALVES
13
14
10
12
15
11
8, 9
7
16
3, 4
5, 6
19
17
W176-02-07-006
21 20 18
1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim 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 - Knock 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)
W2-7-14
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to IMPORTANT: Install spring guide (16), with the
contamination. Keep parts clean protrusion facing upward.
when assembling. 3. Install spring guides (16) (4 used) onto return
springs (3) (2 used) or (4) (2 used).
NOTE: Table below shows the relations between
each port and the components. Take care 4. Install retaining ring (7) onto ring holder (ST
not to confuse them when assembling. 7255).
ST 7255
Port Spool Shim Push rods 7
No. (17) (2) (8), (9)
1 with outer
Same to Same to groove
W176-02-07-008
2 the former the former without outer
one one groove
5. Insert the spool (17) head into the hole of spring
3 with outer
special tool (ST 7257) to press the spring from
groove
the top of spring guide (16). Install retaining ring
4 without outer
(7) with the ring holder (ST 7255) onto the head
groove
of the spool.
7
Port Return Springs Blance Springs ST 7255
ST 7257
No. (5), (6) (3), (4)
1 short short
17
2 long long
3 short short 16
4 long long
Packing Material
IMPORTANT: Make sure of the port hole number
and insert spool (17) to the former
W176-02-07-009
port.
NOTE: Put approx. dia. 8 mm, length 10 mm of
1. Insert the thinner end of spools (17) (4 used) to
packing material into the port hole, to not
housing (18), then push the spool rotating it.
only make the work easy to do, but also
NOTE: The spool has been selected to match the prevent the spool from lowering to the bot-
hole of the housing. The spool and hous- tom when compressing the spring.
ing must be replaced as an assembly.
6. Assemble the remained spools (17) (3 used) into
IMPORTANT: Refer to the table above to assemble housing (18) in the same procedures as step 2 to
them correctly. 5.
2. Install spacers (1) (4 used), shim (2), balance
springs (3) (2 used) or (4) (2 used), return 7. Install O-rings (19) and (21) (2 used) on to hous-
springs (5) (2 used) or (6) (2 used) onto spools ing (18).
(17) (4 used) installed in housing (18).
W2-7-15
13 14
10
12
15
11
8, 9
W176-02-07-006
20 18
W2-7-16
8. Apply grease to the inner face of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block 13. Clamp housing (18) carefully in a vise and then
(10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, inserting push rods (8) Tighten the universal joint so that the clearance
and (9) first, then installing oil seal (15). between the cam and push rod (8) and (9)
This prevents the oil seal from entering becomes 0 to 0.2 mm.
into the hole. : 32 mm
Oil Seal Mounting Hole IMPORTANT: Do not clamp housing (18) in a vise
because the strong torque may act
on screw joint (43).
10 14. Clamp screw joint (13) in a vise to tighten uni-
versal joint (14). Tighten cam (12) with a spanner.
8, 9
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
W176-02-07-007
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 knock 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 Ibf⋅ft)
W2-7-17
(Blank)
W2-7-18
REMOVE AND INSTALL TRAVEL PILOT
VALVE

remaining pressure. M104-07-021
Preparation ZAXIS110, 110M, 120, 130, 130LCN


remaining in the hydraulic tank. 2
Removal 1
1. Loosen bolts (1) (6 used) to remove under cover
(2). W1SE-02-08-001
: 17 mm ZAXIS125US, 135US
2
1
W1SE-02-08-002
ZAXIS135UR
W187-02-07-001
W2-7-19
2. Loosen bolt (3) to remove pedal (4), levers (15)
and (16).
: 17 mm
IMPORTANT: Attach identification tags on all dis-

connected hoses for reassembly.
3. Disconnect pipes (5 and 6) and hoses (7 to 10). 3
: 19 mm 16
15
4
NOTE: Attach a cap on each disconnected hose
end.
4. Remove socket bolt (13), spring washer (12) and 3

plain washer (11) to remove pilot valve (14).
: 8 mm
4
14
Installation 13
1. Install pilot valve (14) with socket bolt (13), spring 13
12
washer (12) and plain washer (11). 12
: 8 mm 11
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft) 11 5
6
2. Connect pipe (5 and 6), hoses (7 to 10).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
10
9
3. Install pedal (4), lever (15) and (16) with bolt (3). 8
7
: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
IMPORTANT: After installation, check the oil level. W178-02-07-005
Start the engine and check for oil

leaks.
5- Pipe: (To the pilot shut-off valve)

6- Pipe: (From the pilot shut-off valve)
7- Hose K: (To the signal control valve port K (right travel
forward))
8 - Hose L: (To the signal control valve port L (right travel
reverse))
9 - Hose J: (To the signal control valve port J (left travel
reverse))
10 - Hose I: (To the signal control valve port I (left travel
forward))
W2-7-20
4. Install under cover (2) with bolts (1) (6 used).
: 17 mm ZAXIS110, 110M, 120, 130, 130LCN
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
W1SE-02-08-001
ZAXIS125US, 135US
2
1
W1SE-02-08-002
ZAXIS135UR
W187-02-07-001
W2-7-21
DISASSEMBLE TRAVEL PILOT VALVE
35 2
34
33
32
31
30
3
4
5
6
29
28 7
27
8
9
10
26
11
12
25 13
24 23
22
21
20
19
18
14
17
15
16
W176-02-07-002
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-22
Disassemble Travel Pilot Valve
1. Clamp casing (14) in a vise. Remove bolts (1) (2 7. Remove spring (18) from casing (14). (4 places)
used) to remove cover (2) from holder (10).
: 10 mm IMPORTANT: Put a stand under bracket (26). If
holder (10) bears the reaction force,
2. Remove socket bolts (8) (2 places) and spring a strong force acts on pin (3) and
washers (9) (2 used), to remove holder (10) from the pin may deform.
casing (14).
: 8 mm IMPORTANT: The inside of the spring pins (24)
and (25) holes in brackets (26) (2
3. Pull out pusher (23) from casing (14) (4 places). used) is stepped-shape. Therefore,
Bushing (13) and oil seal (11) are removed with the spring pin can only be pulled
the pusher. out in one direction.
8. Put a stand under bracket (26).
4. Pull out pusher (23) from bushing (13), with a Push out spring pins (24) and (25) from the
bamboo spatula to remove oil seal (11). (4 bracket at the same time using special tool (ST
places) 1237). Remove the bracket from pin (3). (2
places)
IMPORTANT: Make marks on spools (17) (4 used) Do not remove spring pin (27) from the bracket
so as to easily install them to their unless necessary.
former position.
NOTE: The outside end of the spring pin has been
5. Pull out the spool (17) assembly from casing (14)
caulked.
turning the spool.(4 places)
Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with the spool.
24,25
NOTE: The spool has been selected to match the
hole of the casing. The spool and casing 26
must be replaced as an assembly. 3 27
Caulked
IMPORTANT: The number of shims (20) has been
determined during the performance
testing at the factory. They must be Stand
kept together with their spool.
6. Compress balance spring (21). Remove spring
guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17). (4 places) W176-02-07-019
9. Remove socket bolts (28) (2 used) to remove

damper (6) and rubber seat (7) from pin (3).
O-ring (4) is removed with them. (2 places)
: 5 mm
W2-7-23
35
34
33
32
31
30
10
14
W176-02-07-002
W2-7-24
10. Remove O-ring (5) from pin (3). (2 places)
11. Place holder (10) with the casing (14) matching

surface facing upward.
IMPORTANT: The holes for spring pins (34) and

(35) of cam (32) is stepped-shape.
Therefore the pins shall be removed
from the bottom of the cam.
12. Pull out spring pins (34) and (35) from cam (32)
at the same time using special puller (ST 1237).
(2 places)
NOTE: The spring pin is a double-pin.
NOTE: The spring pin is caulked in its hole, so it

may feel tight when removing.
13. Remove pin (3) with a round bar and hammer. At

this time cam (32) is also removed. (2 places)
NOTE: Do not remove bushings (31) (4 used) left
on holder (10) unless necessary. When
removal is necessary, the bushing special
tool (ST 7256) should be used to tap it out.
14. Remove lock nuts (33) (2 used) from cam (32) to

remove adjusting bolts (30) (2 used).(2 places)
: 13 mm
: 4 mm
W2-7-25
ASSEMBLE TRAVEL PILOT VALVE
26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9
13
22
4
28
5 11 21
29 12
18
23
20
19
14 17
W176-02-07-010
15, 16
1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjust Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)
W2-7-26
Assemble Travel Pilot Valve
IMPORTANT: Pay attention to the mounting direc- 6. If bushing (31) removes from holder (10), install it
tion of spring guide (22). on the holder using special tool (ST 7256) in the
following procedures.
IMPORTANT: Install the former number of shims NOTE: The bushings (4 used) are identical.
(20).
1. Assemble spool (17) into an assembly. (4 used) • Insert the bushing into special tool (ST 7256),
• Insert spacer (19), shim (20), balance spring (21) then tap on the special tool (ST 7256) to install
into the spool in order. the bushing into the hole of holder.
• Press the balance spring by hand. Install spring Stop tapping when the bushing end is flush with
guide (22) to the spool with the stepped-end fac- the Inside wall.
ing downward. Inside Wall
ST 7256
10
2. Insert spring (18) to casing (14). (4 places)
IMPORTANT: Insert the spool (17) assembly into

the former port.
3. Turn and install the spool (17) assembly into cas- 31
ing (14). (4 places) Inmost Hole
W176-02-07-016
• Install the bushing on the opposite side in the

4. Assemble pusher (23) into an assembly (4 used).
same procedure. 31
• Install oil seal (11) onto bushing (13).
10
• Apply grease to the inner face of the oil seal. ST 7256
• Install O-ring (12) to the bushing.
• Insert pusher (23) to the bushing.
• Apply grease to the pusher head section.
5. Insert the pusher (23) assembly to holder (10). (4

W176-02-07-015
places).
• Install the bushing in the right side as shown bel-
low. Stop tapping when the bushing end is flush
with the outside of holder.
31
10 ST 7256
Outside of
Holder
W176-02-07-014
• Install the bushing in the left side as shown be-

low.
31
10
ST 7256
W176-02-07-013
W2-7-27
3 10 32 30 33 34, 35 8 9
23
14
W176-02-07-010
W2-7-28
7. Insert adjust bolt (30) to cam (32). Tighten the IMPORTANT: Do not adjust the adjust bolt (30)
bolt by hand, and then lightly secure it temporar- while pressing the pusher (23) head
ily with lock nut (33). (2 places) with the adjust bolt. The standard
clearance between the adjust bolt
NOTE: Adjust the dimensions later. and pusher must be 0 to 0.2 mm (0
to 0.008 in).
8. Apply grease on the head (matching surface for 13. Adjust bolt (30) as the following procedures. (2
pusher (23)) of adjust bolt (30) (2 places). places)
: 13 mm
9. Install O-ring (5) to pin (3), then assemble the pin : 4 mm
to holder (10) with cam (32) (2 places). • Loosen lock nut (33).
• Move cam (32) to check whether there is play. If
IMPORTANT: Take care of the inserting direction none, turn the adjust bolt to adjust.
of spring pins (34, 35). • Turn both adjust bolts on the left and right alter-
natively to keep the cam horizontal.
IMPORTANT: Tap the spring pin in until it makes • Measure dimensions A and B from both left and
contact with the stepped-shape in right caves on the cam to holder (10). Fine adjust
hole. the adjust bolt to get same distance for both left
10. Install spring pins (34), (35) to cam (32) using and right.
special tool (ST 1237), then secure the cam and • Secure the adjust bolt by using a hexagon-head
pin (3). The spring pins shall be displaced with wrench. Tighten the lock nut to specified torque
their slits at 90°. first, securing the adjust bolt.
• When adjustment is finished, move the cam to
3 3 Slit Slit check that is a little play. If there is no play, the
pusher may be in compressed condition, and
adjustment should be carried out again.
: 10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
30 33 32 10
A B
W176-02-07-017
11. Caulk the hole edge of cam (32), where spring

pins (34) and (35) are inserted, with a punch. (2
places)
12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used) and
spring washers (9) (2 used). W176-02-07-003
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W2-7-29
26 6 7 1 2 3 25 27 24 10
4
28
5
29
W176-02-07-010
W2-7-30
14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under bracket (26). If
holder (10) bears the reaction force,
15. Apply grease to O-ring (5). (2 places) strong force acts on the pin and the
pin may deform.
IMPORTANT: Pay attention to the direction of
damper (6). IMPORTANT: The inside of the hole of spring pins
(24, 25) in the bracket is
IMPORTANT: The inner bore of damper (6) is stepped-shape. Make sure of the
edged-shape. If the damper is pried direction to insert the spring pin.
upward, O-ring (5) will be damaged.
16. With the lever upward, install damper (6) to pin IMPORTANT: Make sure of the direction of the
(3) straight without prying. (2 places) spring pin.
20. Put a stand under bracket (26).
17. Secure damper (6) to holder (10) with socket Tap spring pins (24) and (25) into the bracket un-
bolts (28) (2 used) and spring washers (29) (2 til the spring pin comes to the stepped end using
used). (2 places) special tool (ST 1237). The spring pins shall be
: 8 mm displaced with their slits at 90°.
: 7 N⋅m (0.7 kgf⋅m, 5.1 Ibf⋅ft)
18. Apply grease to O-ring (4), then press it to the

absolute most end of pin (3). (2 places)
Caulked Here Caulked Here
IMPORTANT: As for the direction to install bracket

26 3
(26), refer to the figure in the
disassemble section (W2-7-22). Take
care not to misassemble it.
19. Install pin (3) into bracket (26), then align the in-
Stand 24, 25
serting holes of spring pins (24) and (25) to fix
pin on the bracket.
W176-02-07-011
21. Caulk the hole edge of bracket (26), where spring

pins (24) and (25) are inserted, with a punch. (2
places)
(Refer to the figure above.)
22. Install pin (3) on other bracket (26) as in step 19

to 21.
23. Install cover (2) to holder (10) with bolts (1) (2

used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
24. Apply grease to the spring pin (27) contact part of

damper (6). (2 places)
W2-7-31
REMOVE AND INSTALL OFFSET PILOT
VALVE (ZAXIS135UR ONLY)
Removal

work. (Refer to W1-4-1.) 2
1. Remove bolts (1) (6 used) to remove under cover
(2).
: 17 mm
1
IMPORTANT: Attach identification tags to the hy-
draulic hoses for re-assembly.
2. Disconnect hoses (4 to 7) from pilot valve (3).
Attach a cap onto all the open ends.
W187-02-07-001
: 19 mm
9
3. Open cover (11) and remove rubber (12) from 10
pilot valve (3). 8
4. Remove bolts (9) (2 used) to remove pedal (8).

: 17 mm
3
5. Loosen socket bolts (10) (2 used) to remove pilot
valve (3).
: 8 mm
7
6
5
W197-02-07-002
4- Hose OR : To 8-Spool Solenoid Valve
5- Hose OL : To 8-Spool Solenoid Valve
6- Hose OP : From Pilot Shut-Off Valve
7- Hose OT : To Pilot Shut-Off Valve
11
12
W197-02-07-003
W2-7-32
Installation
9
1. Install pilot valve (3) with socket bolts (10) (2 10
used). 8
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
2. Install pedal (8) with bolt (9) (2 used) into pilot 3

valve (3) and install rubber (12).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
7
3. Connect hoses (4 to 7) to pilot valve (3).
: 19 mm 4
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
4. Install under cover (2) with bolts(1) (6 used).

: 17 mm
6
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
5
W197-02-07-002
IMPORTANT: After installing, check the hydraulic 4- Hose OR : To 8-Spool Solenoid Valve
oil level, start engine and check all 5- Hose OL : To 8-Spool Solenoid Valve
6- Hose OP : From Pilot Shut-Off Valve
hoses for oil leaks.
7- Hose OT : To Pilot Shut-Off Valve
11
12
W197-02-07-003
W187-02-07-001
W2-7-33
REMOVE AND INSTALL BLADE PILOT
VALVE (ZAXIS135UR)
Removal

(2). 2
: 17 mm
W187-02-07-001
3 4 5
IMPORTANT: Do not turn the rod end, or adjust- 7

6
ment is necessary.
2. Disconnect hoses (4 to 7) (4 used) from pilot W191-02-07-004
valve (3). Attach a cap onto all the open ends.

: 19 mm 4- Hose IA ： To Control Valve (Blade Raise)
5- Hose 2B ： To Control Valve (Blade Lower)
6- Hose BT ： To Hydraulic Oil Tank
3. Remove bolts (8) (2 used) to remove bolts (9) (2 7- Hose BP ： From Pilot Shut-Off Valve
used) and pilot valve (3).
: 17 mm
10
W191-02-07-005
W2-7-34
Installation
1. Install pilot valve (3) with bolt (9). Install cable

(10) with bolt (8). 9
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (4 to 7) (4 used) to pilot valve (3). 3

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
8
IMPORTANT: After installing, check the hydraulic
oil level, start the engine and check
all hoses for oil leaks. 10
3. Install cover (2) with bolts (1) (6 used).
W191-02-07-005
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 3 4 5
7
6
W191-02-07-004
4- Hose IA ： To Control Valve (Blade Raise)

5- Hose 2B ： To Control Valve (Blade Lower)
6- Hose BT ： To Hydraulic Oil Tank
7- Hose BP ： From Pilot Shut-Off Valve
W187-02-07-001
W2-7-35
DISASSEMBLE OFFSET / BLADE PILOT
VALVES (ZAXIS135UR)
17 18 1
16
15
3
4
14
5
7
13
8
12
11
10
W1CF-02-07-001
1- Spacer (2 Used) 6- Spring Guide (2 Used) 11 - Casing 16 - Pin

2- Cam 7- Balance Spring (2 Used) 12 - O-Ring (2 Used) 17 - Bushing (2 Used)
3- Socket Bolt (2 Used) 8- Return Spring (2 Used) 13 - Bushing (2 Used) 18 - Set Screw
4- Boot 9- Spacer (2 Used) 14 - Oil Seal (2 Used)
5- Holder 10 - Spool (2 Used) 15 - Pusher (2 Used)
W2-7-36
Disassemble Offset / Blade Pilot Valves
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work.
1. Remove boot (4) from holder (5).
2. Clamp the pilot valve in a vise. Loosen set screw

(18) and remove pin (16) with a bar. Remove the
cam (2) assembly from holder (5).
: 3 mm
: 8 mm or less
IMPORTANT: Record the positions, related to cas-

ing (11), of the disassembled parts.
Slowly remove socket bolts (3) and
holder (5) as pusher (15) assemblies
may fly out by the force of springs
(8).
3. Alternately loosen and remove socket bolts (3) (2

used). Remove holder (5) and the pusher (15)
assemblies (2 used) from casing (11).
: 6 mm
4. Remove bushings (13) (2 used), O-rings (12) (2

used) and oil seals (14) (2 used) from pushers
(15) (2 used).
IMPORTANT: In order to avoid mixing them up, be

sure to indicate the port number
from which each disassembled part
came.
5. Remove the spool (10) assemblies (2 used) and
return springs (8) (2 used) from each port of cas-
ing (11).
6. Compress balance spring (7) to remove spring

guides (6) (2 used) and balance springs (7) (2
used) from spool (10).
Remove spacers (9) (2 used) from the spool (2
places).
W2-7-37
ASSEMBIE OFFSET / BLADE PILOT
VALVES (ZAXIS135UR)
17 18 1
16
15
3
4
14
5
7
13
8
12
11
10
W1CF-02-07-001
1- Spacer (2 Used) 6- Spring Guide (2 Used) 11 - Casing 16 - Pin

2- Cam 7- Balance Spring (2 Used) 12 - O-Ring (2 Used) 17 - Bushing (2 Used)
3- Socket Bolt (2 Used) 8- Return Spring (2 Used) 13 - Bushing (2 Used) 18 - Set Screw
4- Boot 9- Spacer (2 Used) 14 - Oil Seal (2 Used)
5- Holder 10 - Spool (2 Used) 15 - Pusher (2 Used)
W2-7-38
Assemble Offset / Blade Pilot Valves
• Be sure to read “Precautions for Disassembly and 4. Place the pusher (15) assemblies (2 used) and
Assembly” thoroughly on page W1-1-1 before holder (5) onto each spool (10) assemblies (2
starting the disassembly work. used). Alternately tighten socket bolts (3) (2
used) to install the cover on casing (11).
IMPORTANT: Install spring guide (6) with its : 5 mm
groove side facing to the spring. : 11.5 to 21.5 N⋅m
Do not compress balance spring (7) (1.2 to 2.2 kgf⋅m, 8.7 to 16 lbf⋅ft)
with spring guide (6) more than 4
mm (0.157 in) when installing 5. Install cam (2) on holder (5) with pin (16).
spring. : 5 mm
1. Install spacers (9) (2 used) and springs (7) (2
used) on spools (10) (2 used). Compress springs IMPORTANT: Apply LOCTITE #241 to set screw
(7) (2 used) to install spring guide (6) (2 used) to (18).
spool (10). 6. Install set screw (18) into cam (2).
: 2.5 mm
IMPORTANT: Be sure to confirm the port number : 7.0±1 N⋅m
before inserting each spool (10) as- (0.7 ± 0.1 kgf⋅m, 5.1 ± 0.7 lbf⋅ft)
sembly, to be sure that the spool
assembly is inserted into its correct 7. Tilt cam (2) and apply a film of grease to the
port. pushers (15) (2 used) heads.
2. Insert return springs (8) (2 used) and spool (10)
(2 places) assemblies (2 used) into casing (11). 8. Install boot (4) and spacers (1) (2 used) on
holder (5).
IMPORTANT: Install oil seals (14) (2 used) in their
correct directions. Apply a film of
grease to the lips of the oil seal and
to the inside of bushing (13).
3. Install oil seals (14) (2 used) and O-rings (12) (2
used) on bushings (13) (2 used). Insert pushers
(15) (2 used) into the bushing.
Use one of the following greases:

• Apolloil Autorex C (Idemitsu)
• Ocean 7 (Nihon Ore Louve)
• Screw Bar L60 (NOK)
W2-7-39
(Blank)
W2-7-40
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

remaining pressure.
Preparation
1. Park the machine on a firm, level surface.

remaining pressure.

NOTE: Be sure to run the vacuum pump

con-tinuously while working on the hydrau- M104-07-021
lic system.
W2-8-1
Removal
(ZAXIS110, 110M, 120, 130, 130LCN)

(2).
: 17 mm
2. Remove spring (5).

2
IMPORTANT: Attach tags to hoses for assembly.
3. Disconnect hoses (8 to 15) and pipes (16 and

17).
: 19 mm
1
4. Remove spring pin (7) to remove lever (3).
W1SE-02-08-001
5. Remove bolt (4) to remove pilot shut-off valve (6).

: 17 mm
3
8- Hose DP: (To oil tank)
9- Hose PI: (To signal control valve)
10 - Hose PH: (To signal control valve)
11 - Hose PF: (To solenoid valve unit) 4
12 - Hose T6: (To right pilot valve) 5
13 - Hose P2: (To left pilot valve) 7
14 - Hose P3: (To right pilot valve)
15 - Hose T5: (To left pilot valve) 6
16 - Pipe P1: (To travel pilot valve)
17 - Pipe T4: (To travel pilot valve)
W178-02-08-001
15 16 4
14 17
13
6
12
9
10
11 W178-02-08-002
W2-8-2
Removal
(ZAXIS125US, 135US, 135UR)

(2).
: 17 mm
IMPORTANT: Be sure not to turn rod end (6), or

2
the rod end will need adjusting.
If the rod end is adjusted, operate
1
the lever checking the pilot shut-off
valve
2. Remove socket bolt (3), plane washer (4),nut (8)

and spring washer (7)
: 10 mm W1SE-02-08-002
: 5mm
6
8
7
4
3
W1SE-02-08-004
W2-8-3
3. Remove the hoses and pipes (10 to 19) from pilot ZAXIS125US, 135US
shut-off valve (5). Attach the cap to all the dis-
connected hoses and pipes. Attach the tags to 10
them to aid in assembly. 11
: 19, 22 mm (ZAXIS125US, 135US) 12
: 19 mm (ZAXIS135UR) 5
13
14
4. Loosen socket bolts (9) (2 used) to remove pilot
shut-off valve (5).
: 8 mm
19
18
17 16 15 9 W1SE-02-08-003
9- Socket Bolt (2 Used)

11 - Hose: (To travel pilot valve)
12 - Hose P2: (To left pilot valve)
13 - Hose T5: (From left pilot valve)
14 - Hose PI: (To signal control valve)
15 - Pipe: (From travel pilot valve)
16 - Hose T6: (From right pilot valve)
18 - Hose DP: (To oil tank)
19 - Hose PF: (To solenoid valve)
ZAXIS135UR
11 12
5
9
13
10
9 14
15
16
18
17
W157-02-08-001
9- Socket Bolt(2 Used)
10 - Hose A3 : (To signal control valve)
11 - Hose A2 : (To emergency stop solenoid valve)
12 - Hose A1 : (To blade/ travel pilot valves)
13 - Hose T4 : To hydraulic oil tank)
14 - Hose P : (From pilot pump)
15 - Hose T3 : (To offset/ right pilot valves)
16 - Hose T2 : (To blade/ travel pilot valves)
17 - Hose T1 : (To emergency stop solenoid valve/ left pilot
valve)
18 - Hose A4 : (To signal control valve/ 8-spool solenoid valve)
W2-8-4
Installation (ZAXIS110, 110M, 120, 130, 130LCN)
1. Install pilot shut-off valve (6) with bolt (4).
: 17 mm
3
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Install lever (3) with spring pin (7).

4
3. Connect hoses (8 to 15) and pipes (16 and 17). 5
: 19 mm 7
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 6
4. Install spring (5).
5. Install under cover (2) with bolts (1) (6 used). W178-02-08-001
: 17 mm 15 16 4
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 14 17
13
12
10
11 W178-02-08-002
8- Hose DP: (To oil tank)

9- Hose PI: (To signal control valve)
11 - Hose PF: (To solenoid valve unit)
12 - Hose T6: (To right pilot valve)
18 - Hose T5: (To left pilot valve)
19 - Pipe P1: (To travel pilot valve)
20 - Pipe T4: (To travel pilot valve)
W1SE-02-08-001
W2-8-5
Installation
(ZAXIS125US, 135US, 135UR) ZAXIS125US, 135US
1. Install pilot shut-off valve (5) with socket bolt (9)
(2 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
5
2. Install plane washer (4) to socket bolt (3). Install

ball joint (6) with spring washer (7), nut (8), the
socket bolt.
: 10 mm
: 5 mm
: 20 N·m (2 kgf·m, 14.5 lbf⋅ft)
9 W1SE-02-08-003
ZAXIS135UR
5
9
W157-02-08-001
6
8
7
4
3
W1SE-02-08-004
W2-8-6
3. Connect the hoses and pipes (10 to 19) to pilot ZAXIS125US, 135US
shut-off valve (5).
(ZAXIS125US, 135US) 10
: 19 mm 11
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 12
5
: 22 mm 13
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 14
(ZAXIS135UR)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
19
18
17 16 15 W1SE-02-08-003

11 - Hose: (To travel pilot valve)
13 - Hose T5: (From left pilot valve)
14 - Hose PI: (To signal control valve)
15 - Pipe: (From travel pilot valve)
16 - Hose T6: (From right pilot valve)
18 - Hose DP: (To oil tank)
19 - Hose PF: (To solenoid valve)
ZAXIS135UR
11 12
5
13
10
14
15
16
18
17
W157-02-08-001

10 - Hose A3 : (To signal control valve)
11 - Hose A2 : (To emergency stop solenoid valve)
12 - Hose A1 : (To blade/ travel pilot valves)
13 - Hose T4 : To hydraulic oil tank)
14 - Hose P : (From pilot pump)
15 - Hose T3 : (To offset/ right pilot valves)
16 - Hose T2 : (To blade/ travel pilot valves)
17 - Hose T1 : (To emergency stop solenoid valve/ left pilot
valve)
18 - Hose A4 : (To signal control valve/ 8-spool solenoid valve)
W2-8-7
4. Install under cover (2) with bolts (1) (6 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 lbf⋅ft)
2
1
W1SE-02-08-002
W2-8-8
(Blank)
W2-8-9
DISASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS110, 110M, 120, 130, 130LCN)
3
6
2
7
1
8
9
13 10
11
12
W178-02-08-005
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-10
(ZAXIS110, 110M, 120, 130, 130LCN)
• Be sure to thoroughly read all Precautions for
Disassembly / Assembly work on page W1-1-1
before starting any work.
1. Make the matching mark on body (4) and bracket

(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove the spool (10) assembly.
2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).
3. Clamp the spool (10) with a wooden pieces in a

vise. Remove socket bolt (13) and bracket (11).
: 4 mm
NOTE: Do not remove pin (12) unless necessary.
4. Remove socket bolt (5) from body (4).

: 8 mm
W2-8-11
DISASSEMBLE PILOT SHUT-OFF VALVE
1
2
3
4
5
6
14 7
13
12
9
11
10
W1CC-02-08-001
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Socket Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Steel Ball
3- Backup Ring 7- Washer 11 - Spool 14 - Body
4- O-Ring 8- Retaining Ring
W2-8-12

1. Remove retaining ring (1) and washer (2) to pull

out spool (11).
IMPORTANT: Make the mating mark on the

mounting position on spool (11) and
spring pin (9).
2. Pull spring pin (9) out of spool (11) to remove

lever (10).
3. Remove washer (7) and retaining ring (8) from

spool (11).
4. Remove backup ring (3 and 6) and o-ring (4 and

5) from body (14).
5. Remove socket bolt (12) from body (14).

: 6 mm
W2-8-13
ASSEMBLE PILOT SHUT-OFF VALVE
(ZAXIS110, 110M, 120, 130, 130LCN))
12 13 11 4 5 Z
Section Z-Z W178-02-08-006
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-14
(ZAXIS110, 110M, 120, 130, 130LCN)
1. Apply LOCTITE # 262 on socket bolt (5) and in-
stall it to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)
2. Clamp spool (10) with a wooden pieces in a vise.

Apply LOCTITE #262 on socket bolt (13), then
install bracket (11) onto spool (10).
: 4 mm
: 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft)
3. Install O-ring (3), backup ring (2) and washer (1)

to body (4).
4. Apply hydraulic oil to spool (10) and install it to

body (4).

to body (4), and install retaining ring (6) to spool
(10).
W2-8-15
ASSEMBLE PILOT SHUT-OFF VALVE
1 2 3 4 5 6 7 8 9
13
10
12
14 11
W1CC-02-08-002
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Socket Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Steel Ball
3- Backup Ring 7- Washer 11 - Spool 14 - Body
4- O-Ring 8- Retaining Ring
W2-8-16

IMPORTANT: Apply grease to O-ring (5) and

backup ring (6).
to body (14).
IMPORTANT: Apply hydraulic oil to spool (11).

2. Install spool (11) to body (14). Install retaining
ring (8) to the spool.
IMPORTANT: Apply grease to O-ring (4) and

backup ring (3).
to body (14). Install retaining ring (1) to spool
(11).
5. Install socket bolt (12).

: 6 mm
: 44 N·m (4.5 kgf·m, 32.5 lbf·ft)
W2-8-17
(Blank)
W2-8-18
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE

before disconnecting hydraulic or other
lines.
remaining pressure.
Preparation

remaining pressure.

M104-07-021

tem.
W2-9-1
Removal Signal Control Valve
IMPORTANT: Attach tags to hoses and pipes to
aid in assembly.
NOTE: When removing pipe of signal control valve,

if a SNAP-ON TOOL (GAN850812B: tool Control Valve
size: 19.05 mm) is used, it may be easier
to remove the pipe.
1. Disconnect all hoses and pipes from each port.
2. Remove the pressure sensors (swing, travel).
3. Remove socket bolt (20) to remove the signal

control valve.
: 8 mm
Installation T176-04-04-001
1. Apply LOCTITE to bolt (20) and install the signal Pilot Valve Side
PH
control valve.
A
C M
2. Connect all hoses and pipes to each port.
E B
3. Install the pressure sensor (swing, travel). D SB
H G
Wrench size Tightening Torque Remark F
(mm) N⋅m (kgf⋅m) (Ibf⋅ft) N
PI
: 17 25 (2.5) (18) Hose, pipe
: 19 29.5 (3) (21.5) Hose Pilot Valve
Side
I
: 24 16 (1.6) (11.5) Pressure sensor
K J
:8 50 (5.1) (37) Socket Bolt
DF
SH
SA L 20
T178-03-06-016
Control Valve Side
SM
3
1 5
13
2 4
SK SE
7 8
14
6
Pressure Sensor
(Swing)
9
Control Valve SN
Side
10 11
SL
Pressure Sen-
sor (Travel) 20 12 SP T178-03-06-015
W2-9-2
Pilot Valve Side

Port Name Connected To Remark
Port A Right pilot valve Boom raise pilot pressure
Port B Right pilot valve Boom lower pilot pressure
Port C Left pilot valve Arm roll-out pilot pressure
Port D Left pilot valve Arm roll-in pilot pressure
Port E Left pilot valve Left swing pilot pressure
Port F Left pilot valve Right swing pilot pressure
Port G Right pilot valve Bucket roll-in pilot pressure
Port H Right pilot valve Bucket roll-out pilot pressure
Port I Travel pilot valve Left travel forward pilot pressure
Port J Travel pilot valve Left travel reverse pilot pressure
Port K Travel pilot valve Right travel forward pilot pressure
Port L Travel pilot valve Right travel reverse pilot pressure
Port M Auxiliary pilot valve Auxiliary open pilot pressure
(ZX135UR: Offset pilot valve) (ZX135UR: Left offset pilot pressure)
Port N Auxiliary pilot valve Auxiliary close pilot pressure
(ZX135UR: Offset pilot valve) (ZX135UR: Right offset pilot pressure)
Port SA Pump 1 regulator Pump 1 control pressure
Port SB Pump 2 regulator Pump 2 control pressure
Port PI Pilot shut-off valve Primary pilot pressure
Port PH Pilot shut-off valve Primary pilot pressure (Heat Circuit)
Port SH Swing parking brake Brake release pressure
Port DF Hydraulic oil tank Return to hydraulic oil tank
Control Valve Side

Port Name Connected To Remark
Port 1 Control valve Boom raise pilot pressure
Port 2 Control valve Boom lower pilot pressure
Port 3 Control valve Arm roll-out pilot pressure
Port 4 Control valve Arm roll-in pilot pressure
Port 5 Control valve Left swing pilot pressure
Port 6 Control valve Right swing pilot pressure
Port 7 Control valve Bucket roll-in pilot pressure
Port 8 Control valve Bucket roll-out pilot pressure
Port 9 Control valve Left travel forward pilot pressure
Port 10 Control valve Left travel reverse pilot pressure
Port 11 Control valve Right travel forward pilot pressure
Port 12 Control valve Right travel reverse pilot pressure
Port 13 Control valve Auxiliary open pilot pressure
(ZX135UR: Left offset pilot pressure)
Port 14 Control valve Auxiliary close pilot pressure
(ZX135UR: Right offset pilot pressure)
Port SE – Plug
Port SM Hydraulic oil tank Return to hydraulic oil tank
(ZX135UR: Offset anti-drift valve) (ZX135UR: Offset pilot pressure)
Port SN – Plug
Port SP Solenoid Valve Unit Return to hydraulic oil tank
Port SL Control valve Flow combiner valve control pressure
Port SK Control valve Bucket flow rate control valve control pressure
W2-9-3
(Blank)
W2-9-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID
VALVE UNIT
CAUTION: Escaping fluid under pressure may

penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure be-
fore disconnecting hydraulic or other lines.
remaining pressure.
Preparation

remaining pressure.

NOTE: Be sure to run the vacuum pump continu- M104-07-021

tem.
W2-10-1
Solenoid Valve Unit Solenoid Valve Unit
Removal
1. Disconnect each harness of solenoid valves (8
and 9) from the connector.
2. Disconnect pilot pipes (1 to 6, 10 and 11).
3. Remove socket bolts (7) (2 used) to remove the

solenoid valve unit. 9
: 17, 19 mm
: 8 mm 8
Connector
Installation
1. Install solenoid valve unit with socket bolts (7) (2
used). 11 1
2 W187-02-10-002
2. Connect pilot pipes (1 to 6, 10 and 11)
3. Connect each harness of solenoid valves (8 and

9) to the connector.
10
Tightening Torque 12
Wrench Size (mm) Remark
N⋅m (kgf⋅m) (Ibf⋅ft) 13
: 17 25 (2.5) (18) Pipe, Hose Solenoid Valve
9 Unit
: 19 30 (3) (21.5) Hose
8
: 8 50 (5.1) (37) Socket Bolt
7
: 19 30±3 (3±0.3) (21.5±2.2) Plug
4
5
W187-02-10-001
1 - Pipe : To control valve (4-spool section)
(ZAXIS135UR only: To signal control valve)
2- Hose : To signal control valve port SP
3- Hose : To hydrarulic oil tank
(ZAXIS135UR only: Hose DS: To hydraulic oil tank)
Hose: To switch valve)
4- Hose : To center joint
(ZAXIS135UR only: Hose SI)
5- Pipe : To control valve (4-spool section)
6- Hose : To control valve (5-spool section)
7- Socket Bolt
8- Proportional solenoid valve (SI)
9- Proportional solenoid valve (SC)
10 - Hose (PF): From pilot shut-off valve
11 - Hose: From pilot filter
(ZAXIS135UR only: Hose PD)
12 - Plug (ZAXIS135UR only: Hose PG : To switch valve)
13 - Plug
W2-10-2
8-spool Solenoid Valve (Only ZAXIS135UR)
Removal
1. Open the cover of the machine right side. Set the
lock to secure the cover.
IMPORTANT: Attach the identification tag onto the

disconnected hoses for assembling.
2. Remove the pilot hoses (16 used) from the
8-spool solenoid valve unit. Attach a cap onto the
open ends.
: 17 mm, 19 mm
Cover
W1SE-04-01-002
3. Remove the connectors (15 used) from the
8-spool solenoid valve unit. 8-Spool
Solenoid Valve
4. Remove the bolts (3 used) from plate to remove 1
the 8-spool solenoid valve unit. 2
: 17 mm 15 3
4
5
1 - Pilot Pressure Sensor 9 - Solenoid Valve 14
(E1 : Boom Raise) (C7 : Arm Roll-Out Ac- 6
celeration)
2 - Solenoid Valve 10 - Pilot Pressure Sensor
7
(C1 : Boom Raise (E3 : Arm Roll-In)
13 8
Acceleration)
3 - Pilot Pressure Sensor 11 - Hydraulic Oil Tempera- 9
(E2 : Boom Lower) ture Sensor
4 - Pilot Pressure Sensor 12 - Solenoid Valve 10
12
(E6 : Right Offset Accel- (C4 : Arm Roll-In Decel-
eration) eration)
5 - Solenoid Valve 13 - Solenoid Valve (C8 : Left
(C6 : Right Offset Accel- Offset Deceleration)
eration)
6 - Pilot Pressure Sensor 14 - Solenoid Valve Machine Front
(E4 : Left Offset Accel- (C5 : Right Offset
eration) Deceleration)
11 T1SM-01-02-003
7 - Solenoid Valve 15 - Solenoid Valve
(C9 : Left Offset Accel- (C3 : Boom Raise De- 8-Spool
eration) celeration) Solenoid Unit
8 - Pilot Pressure Sensor
(E5 : Arm Roll-Out)
W187-02-10-003
Plate Bolt
W2-10-3
Installation
1. Install the 8-spool solenoid valve unit to the plate 8-Spool Solenoid
with the bolts (3 used). Valve
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Install the pilot hoses (16 used) to the 8-spool

solenoid valve unit. Hose
: 17 mm
: 44 N⋅m (4.5 kgf⋅m, 32 lbf⋅ft)
: 19 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
W187-02-10-003
3. Install the connectors (15 used) to the 8-spool
Plate Bolt
solenoid valve unit.
4. Unlock the lock on the cover of the machine right

to close the cover. 8-Spool
Solenoid valve
1
2
1 - Pilot Pressure Sensor 9- Solenoid Valve
(E1 : Boom Raise) (C7 : Arm Roll-Out Ac-
15 3
celeration) 4
2 - Solenoid Valve 10 - Pilot Pressure Sensor
(C1 : Boom Raise Accel- (E3 : Arm Roll-In) 5
eration) 14
6
3 - Pilot Pressure Sensor 11 - Hydraulic Oil Tempera-
(E2 : Boom Lower) ture Sensor 7
4 - Pilot Pressure Sensor 12 - Solenoid Valve
(E6 : Right Offset Accel- (C4 : Arm Roll-In Decel- 13 8
eration) eration)
9
5 - Solenoid Valve 13 - Solenoid Valve (C8 : Left
(C6 : Right Offset Accel- Offset Deceleration) 10
eration) 12
6 - Pilot Pressure Sensor 14 - Solenoid Valve
(E4 : Left Offset Accel- (C5 : Right Offset Decel-
eration) eration)
7 - Solenoid Valve 15 - Solenoid Valve
(C9 : Left Offset Accel- (C3 : Boom Raise De-
eration) celeration)
Machine Front
8 - Pilot Pressure Sensor
(E5 : Arm Roll-Out) 11 T1SM-01-02-003
Cover
W1SE-04-01-002
W2-10-4
(Blank)
W2-10-5
DISASSEMBLE PROPORTIONAL SOLENOID VALVE
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W2-10-6
Disassemble Proportional Solenoid Valve
IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Do not disassemble lock nut (2) and
adjusting screw (4).
1. Loosen socket bolts (1) to remove solenoid (6).
: 3 mm
2. Pull out spool (10) and remove diaphragm (9),

washer (11) and spring (12).
3. Pull out sleeve (16) and remove O-rings (13),

(14) and (15), washer (18), and plate (17).
W2-10-7
ASSEMBLE PROPORTIONAL SOLENOID VALVE
4 2 6 1 8 16 13 14 10 15 18
3, 5
9 7 11 12 17
W157-02-11-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W2-10-8
Assemble Proportional Solenoid Valve
IMPORTANT: Apply grease to O-rings (13), (14)

and (15) and apply the hydraulic oil 16
to sleeve (16). 15
14
1. Install washer (18) and plate (17) into the housing.
13
Install O-rings (13), (14) and (15) onto sleeve (16)
and insert it into the housing.
IMPORTANT: Take care not to damage the edge

portion in the bore of sleeve (16)
when inserting the spool (10) as-
sembly. Housing
After inserting the spool, check that
W157-02-11-005
spool (10) slides in and out
smoothly without any restriction 10
about 3 to 5 mm (0.12 to 0.20 in).
Apply hydraulic oil to the spool.
2. Install diaphragm (9), washer (11), and spring
9
(12) to spool (10) and install it into sleeve (16).
16
12
11
W157-02-11-009
IMPORTANT: Lock nut (2), adjust screw (4), spring

(5) and O-ring (3), are not separated, 10
so they need not be assembled.
Take care not to drop solenoid (6)
and spring (7).
3. Install solenoid (6) with bolt (1).
: 3 mm W157-02-11-010
: 2.9 N⋅m (0.3 kgf⋅m, 2.2 Ibf⋅ft) 6
W157-02-11-011
W2-10-9
(Blank)
W2-10-10
REMOVE AND INSTALL EMERGENCY
STOP SOLENOID VALVE UNIT
(ZAXIS135UR ONLY)

sure first. Push the air release valve on top of
the hydraulic oil tank to release any remain-
ing pressure.
Preparation

remaining pressure.

the hydraulic oil tank. M197-07-001

tem.
W2-10-11
Removal
(2).
: 17 mm
2. Disconnect each wiring of emergency stop sole-

noid valve (3) from the connector.
2
3. Disconnect hoses (4) (5 used) from emergency
stop solenoid valve (3). Attach a cap onto the
open end.
: 19 mm
1
4. Remove bolt (5) and washer (6) to remove emer-
gency stop solenoid valve (3).
: 13 mm
Installation W187-02-07-001
1. Install emergency stop solenoid valve (3) with

bolt (5) and washer (6).
5, 6
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) Machine
Front
2. Connect hoses (4) (5 used) to emergency stop

solenoid valve (3).
: 19 mm 4
: 29 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
3. Connect each wiring of emergency stop solenoid

valve (3) to the connector.
4. Install under cover (2) to the machine with bolts

(1) (6 used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
3 Lock Valve
T1SM-03-07-100
(Seen from Floor Bottom)
W2-10-12
(Blank)
W2-10-13
DISASSEMBLE AND ASSEMBLE SELEC-
TOR VALVE
Selector Valve
1
Emergency Stop 2
6 1 Solenoid Valve
3
4
5
6
7
8
9
10
11
12
A W187-02-10-004
T1CF-03-06-003
1 - Socket Bolt (2 Used) 4 - Rod 7 - Spring 10 - O-Ring

2 - Solenoid 5 - Retaining Ring 8 - O-Ring 11 - Sleeve
3 - O-Ring 6 - Spool 9 - O-Ring 12 - Washer
W2-10-14
Disassemble Selector Valve Assemble Selector Valve
• Be sure to thoroughly read precautions for 1. Insert washer (12) into the housing.
disassembly and assembly on page W1-1-1
before any disassembling and assembling work. IMPORTANT: While aligning port hole (A) on
sleeve (11) with the hole on hous-
IMPORTANT: The inside of solenoid (2) cannot be ing., install it.
disassembled. When removing the 2. Install O-rings (8, 9, 10) to sleeve (11). Insert the
solenoid, take care not to lose sleeve into housing.
rod(4) in it.
1. Remove socket bolts (1) (2 used) to remove so- IMPORTANT: Be sure not to damage sleeve (11)
lenoid (2) and O-ring (3). when installing it.
: 4 mm 3. Install spring (7) and retaining ring (5) to spool (6).
Insert it into sleeve (11).
2. Pull spool (6) out of sleeve (11) to remove retain-
ing ring (5) and spring (7) from the sleeve. IMPORTANT: Check if spool (6) can move
NOTE: Be sure to pull spool (6) out slowly. smoothly. If not, replace it.
4. After inserting spool (6), push it 3 to 5 mm by
3. Pull sleeve (11) out of the housing to remove hand.
O-rings (8, 9, 10) from the sleeve.
5. Install O-ring (3) to the housing.
4. Remove washer (12) from the housing.
IMPORTANT: Be sure not to drop off rod (4).
6. Install rod (4) to solenoid (2).
7. Install solenoid (2) with socket bolts (1) (2 used).

: 4 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W2-10-15
DISASSEMBLE AND ASSEMBLE
UNLOADING VALVE
1
2
3
Emergency Stop 4
Solenoid Valve
5
5 6
7
8
9
10
A
W187-02-10-005
3
2 T1CF-03-06-003
Unloading Valve
1
1 - Socket Bolt (4 Used) 4 - Spring 7 - O-Ring 9 - Sleeve

2 - Plate 5 - Spool 8 - O-Ring 10 - Plate
3 - O-Ring 6 - O-Ring
W2-10-16
Disassemble Unloading Valve Assemble Unloading Valve
• Be sure to thoroughly read precautions for 1. Insert plate (10) into the housing.
disassembly and assembly on page W1-1-1
before any disassembling and assembling work. IMPORTANT: While aligning port hole (A) on
sleeve (9) with the hole on housing.
IMPORTANT: When removing plate (2), take care install it.
not to lose spring (4). 2. Install O-rings (6, 7, 8) to sleeve (9). Insert the
1. Remove socket bolts (1) (4 used) from the hous- sleeve into housing.
ing to remove plate (2).
: 4 mm IMPORTANT: Be sure not to damage sleeve (9)
when installing it.
2. Remove O-ring (3) and spring (4) from the hous- 3. Insert spool (5) into sleeve (9). Install spring (4)
ing. to the spool.
3. Pull spool (5) out of sleeve (9). IMPORTANT: Check if spool (5) can move
NOTE: Be sure to pull spool (5) out slowly. smoothly. If not, replace it.
4. After inserting spool (5), push it 3 to 5 mm by
4. Pull sleeve (9) out of the housing to remove hand.
O-rings (6, 7, 8) from the sleeve.
5. Install O-ring (3) to the housing.
5. Remove plate (10) from the housing.
6. Install plate (2) to the housing with socket bolts
(1) (4 used).
: 4 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
W2-10-17
(Blank)
W2-10-18
UPPESTRUCTURE / Holding Valve
REMOVE AND INSTALL HOLDING VALVE
(ZAXIS135UR ONLY)

before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot
hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting any repair work.
The hydraulic oil tank cap may fly off by re-
maining pressure if removed quickly. Slowly
loosen the cap to completely release re-
maining pressure.
Preparation


remaining in the hydraulic tank.

vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
M197-07-001
ously while working
W2-11-1
Removal
IMPORTANT: Attach identification tags to the hy-
draulic hoses and pipes for assem-
bly.
2
1. Disconnect hoses (2,3) from holding valve (6), 1
the hoses (2 used) and pipes (4, 5) from elbows 3
(9, 10).
: 17 mm
: 19 mm
: 27 mm
: 22 mm 5
2. Remove socket bolts (7) (2 used) to remove 10 8

holding valve (6) from clamp (8). 7
: 8 mm 6
W187-02-11-001
9 4
Installation
1. Install holding valve (5) with bolts (6).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (2,3) onto holding valve (6), the

hoses (2 used) and pipes (4,5) onto elbows
(9,10).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18.0 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine. Check the
connections for any oil leakage.
W2-11-2
(Blank)
W2-11-3
HOLDING VALVE
(ZAXIS135UR ONLY)
Port V
Port C
Port Pi
10
18 19 20
Port C
1
21
17
16
2
15 3
Drain Port
4
14
13 5
6
12 7
10
11 10 9 W187-02-11-002
Section A
W2-11-4

(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Housing 1
2 Plug 1
3 O-Ring 2
4 Backup Ring 2
5 O-Ring 1
6 Backup Ring 1
7 Plug 1
8 O-Ring 1
9 Plate 1
10 Socket Bolt 6 :8 50 (5.1) (37)
11 Plug 1
12 Plug 1
13 O-Ring 2
14 Backup Ring 2
15 Holding Valve 1
16 Spring 1
17 Plug 1
18 Holding Valve (Check Valve) 1
19 Plug 1
20 Plug 1
21 Plug 1
W2-11-5
(Blank)
W2-11-6
MEMO
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SECTION 3
UNDERCARRIAGE
 CONTENTS 
Group 1 Swing Bearing Group 3 Center Joint
Remove and Install Swing Bearing..............W3-1-1 Remove and Install Center Joint ................. W3-3-1
Disassemble Swing Bearing ........................W3-1-4 Disassemble Center Joint ........................... W3-3-4
Assemble Swing Bearing.............................W3-1-6 Assemble Center Joint ................................ W3-3-7
Maintenance Standard ...............................W3-3-11
Group 2 Travel Device
Remove and Install Travel Device ...............W3-2-1 Group 4 Track Adjuster
Disassemble Travel Device (ZAXIS110, Remove and Install Track Adjuster.............. W3-4-1
120,130,130LCN,125US,135US,135UR) ....W3-2-4 Disassemble Track Adjuster........................ W3-4-2
Assemble Travel Device (ZAXIS110, Assemble Track Adjuster........................... W3-4-10
120,130,130LCN,125US,135US,135UR) ..W3-2-10
Disassemble Travel Motor (ZAXIS110, Group 5 Front Idler
120,130,130LCN,125US,135US,135UR) ..W3-2-16 Remove and Install Front Idler .................... W3-5-1
Assemble Travel Motor (ZAXIS110, Disassemble Front Idler .............................. W3-5-2
120,130,130LCN,125US,135US,135UR) ..W3-2-20 Assemble Front Idler ................................... W3-5-6
Disassemble Travel Brake Valve Maintenance Standard ................................ W3-5-8
(ZAXIS110, 120,130,130LCN,125US,
135US,135UR)...........................................W3-2-26 Group 6 Upper and Lower Roller
Assemble Travel Brake Valve Remove and Install Upper Roller ................ W3-6-1
(ZAXIS110, 120,130,130LCN,125US, Remove and Install Lower Roller ................ W3-6-5
135US,135UR)...........................................W3-2-28 Disassemble Lower Roller .......................... W3-6-8
Disassemble Travel Reduction Gear Assemble Lower Roller ............................. W3-6-10
(ZAXIS110M) .............................................W3-2-30 Maintenance Standard .............................. W3-6-12
Assemble Travel Reduction Gear
(ZAXIS110M) .............................................W3-2-34 Group 7 Track
Disassemble Travel Motor Remove and Install Tracks .......................... W3-7-1
(ZAXIS110M) .............................................W3-2-38 Maintenance Standard ................................ W3-7-8
Assemble Travel Motor
(ZAXIS110M) .............................................W3-2-42
Disassemble Base Plate
(ZAXIS110M) .............................................W3-2-46
Assemble Base Plate
(ZAXIS110M) .............................................W3-2-48
Maintenance Standard...............................W3-2-50
187W-3-1
(Blank)
187W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure
must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section.
In this section, the procedure starts on the premise
that the upperstructure has already been removed.
Removal
1. Put alignment marks on inner race of swing Mark
bearing (1) and track frame (2).
1 2
W105-03-01-001
2. Remove all bolts (3) (36 used) from inner race of

swing bearing. 3
: 24 mm
W105-03-01-002
CAUTION: Swing bearing weight: 157 kg

(350 lb)
3. Attach lifting tools (ST 0050), hoist swing bearing

(4) and remove it.
ST 0050
W105-03-01-003
4
W3-1-1
Installation
Clean the matching surfaces of the frame and swing
bearing.
1. Apply THREEBOND # 1102 to the matching

surfaces of the track frame and swing bearing.
CAUTION: Swing bearing weight: 157 kg

(350 lb) ST 0050
IMPORTANT: Failure to align the marks may result

in misalignment of the inner race
W105-03-01-003
soft zone.
Position for Grease Front Side
2. Hoist the swing bearing by crane. Align the Fitting
alignment marks both on the track frame and
swing bearing.
6° "S" (Soft Zone)

Marking Position
0.2° Position of
Stop Pin
10°
3. Install the mounting bolts (3) (36 used) to the

inner race of the swing bearing and tighten to
Position for Grease
specification. Fitting
W175-03-01-001
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
W105-03-01-002
W3-1-2
4. After installing the swing bearing, fill the grease
bath with grease (Shell Alvania EP2 or Swing Bearing Grease Level Pinion
equivalent) until the pinion of the swing bearing is
covered 5 mm depth in grease.
5 mm
W175-03-01-002
Grease Bath
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W155-03-01-001
6
9
W105-03-01-011
1 - Outer Race 4 - Plug 6 - Ball (99 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (99 Used)
3 - Pin
W3-1-4
Disassemble Swing Bearing
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly” on page W1-1-1
before starting the disassembly work. 3
1. Grind off caulked part of pin (3).

Tap pin (3) out from the bottom side.
NOTE: After installing pin (3), shave the crimped
part with a grinder.
4
W105-03-01-007
2. Screw bolt into screw hole (M10, pitch 1.5) for

removing plug (4), and then tap the bolt head from
its back to pull the plug out.
4
W105-03-01-008
CAUTION: Swing bearing weight: 2

157 kg (350 lb)
1
3. Using lifting tools (ST 0050), hoist outer race (1)

of the swing bearing horizontally and slightly by A
crane.
Remove seals (2) and (5).
7
4. Place inner race (7) of the swing bearing on a

wooden block, hoist outer race (1) and take up the 6 5 W105-03-01-009
slack.
5. Rotate outer race (1) to remove balls (6) (99

used) and supports (9) (99 used) from the plug (4)
hole.
When removing balls, rod magnet (A) can be B
used. Use wire (B) to remove support (9).
W105-03-01-010
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W155-03-01-001
6
9
W105-03-01-011
1 - Outer Race 4 - Plug 6 - Ball (99 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (99 Used)
3 - Pin
W3-1-6
Assemble Swing Bearing
• Before assembling the swing bearing, refer to
“Precautions of Disassembling and Assembling”
2
(W1-1-1)
1. Thoroughly remove the grease on the seal
grooves for the outer and inner seals (2) and (5).
Apply THREEBOND # 1745 to seal (2) and #1735
to seal (5). Install both seals respectively into
position.
5
W142-03-01-005
IMPORTANT: Be sure to apply grease to balls (6)

and to supports (9).
CAUTION: Swing bearing weight :
157 kg (350 lb)
2. Using lifting tools (ST 0050), hoist the outer race
of the swing bearing horizontally by crane and
match it with the inner race coaxially. 9
Rotating the outer race, insert balls (6), support
(9) into plug (4) hole one by one with a round bar.
W142-03-01-006
3. Tap plug (4) into outer race (1) and, then drive pin
(3) into the pin hole.
Caulk the head of pin (3) with a punch.
Fill grease 0.4 L (Alvania EP2 grease or
equivalent) through the grease fitting.
4
W142-03-01-007
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
The work below starts on the premise that tracks were ZAXIS110, 120, 130, 130LCN, 125US, 135US,
removed already. As for procedures to remove and 135UR:
install tracks, refer to “Remove and Install Tracks” on
page W3-7-1.
4 5
Removal
IMPORTANT: Be sure to bleed air from hydraulic

oil tank, before starting operate. 1
(Refer to “Bleed air from hydraulic 3
oil tank”) 2
1. Remove bolts (7) to remove cover (6).

: 22 mm
2. Disconnect hoses (2 to 5) and cap disconnected

hoses.
ZAXIS110, 120, 130, 130LCN, 125US, 135US,
135UR:
: 17 mm, 19 mm, 27 mm
ZAXIS110M: 6
: 27 mm, 36 mm W155-03-02-009
7
3. Make preparation to hoist the travel device with
wire rope.
ZAXIS110M:
CAUTION: Travel Device Weight:
ZAXIS110, 120, 130, 130LCN, 125US: 4 5
215 kg (475 lb)
ZAXIS135US, 135UR: 223 kg (490 lb)
ZAXIS110M: 280 kg (620 lb)
4. Remove bolt (1), hoist and remove travel device. 1

ZAXIS110M:
: 24 mm
3
2
7 W157-03-02-006
W3-2-1
Installation
1. Install travel device with bolt (1).

: 24 mm ZAXIS110, 120, 130, 130LCN, 125US, 135US,
: 310 N⋅m (31.5 kgf⋅m, 230 lbf⋅ft) 135UR:
2. Connect hoses (2 to 5).

ZAXIS110, 120, 130, 130LCN, 125US, 135US, 4 5
135UR:
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18.1 lbf⋅ft)
: 19 mm 1
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft) 3
: 27 mm
: 95 N⋅m (9.7 kgf⋅m, 70lbf⋅ft) 2
ZAXIS110M:
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18.1 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 36 mm
: 180 N⋅m (18.5 kgf⋅m, 134 lbf⋅ft)
3. Install cover (6) with bolts (7). 6

: 22 mm
W155-03-02-009
: 180 N⋅m (18.5 kgf⋅m, 134 lbf⋅ft) 7
IMPORTANT: After completing travel motor

installation, be sure to fill the travel
ZAXIS110M:
motor with hydraulic oil.
Hydraulic Oil: 0.5 L (0.13 US gal)
After completing installation of the 4 5
travel motor or the travel device, be
sure to perform break-in operation to
prevent motor seizure.
Break-in operation condition: 1

1. Engine control dial: Min. speed
2. Travel mode switch: Low speed
3. Operation duration: Above two minutes
3
2
7 W157-03-02-006
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL DEVICE
(ZAXIS110, 120, 130, 130LCN, 125US,
135US, 135UR) 14
13
12
11
10
8 9
1
7
6
1
5
4
1
2
3
2
1
15
16
20
17
18
19
21
22
23
24
25
26
23
27
28 W176-03-02-001
1- Thrust Plate (12 Used) 8- Pin (3 Used) 15 - Propeller Shaft 22 - Bearing Nut
2- Needle Bearing (6 Used) 9- Spring Pin (3 Used) 16 - Spacer 23 - Roller Bearing (2 Used)
3- Second Stage Planetary Gear (3 Used) 10 - Ring Gear 17 - Firest Stage Carrier 24 - Sprocket
4- Pin (3 Used) 11 - Cover 18 - Sun Gear 25 - Drum
5- Spring Pin (3 Used) 12 - Stopper Pin 19 - Second Stage Carrier 26 - Bolt (16 Used)
6- First Stage Planetary Gear (3 Used) 13 - Bolt (12 Used) 20 - Bolt (16 Used) 27 - Floating Seal
7- Needle Bearing (3 Used) 14 - Plug (3 Used) 21 - Knock Pin 28 - Motor
W3-2-4
Disassemble Travel Device (ZAXIS110, 120, 130,
130LCN, 125US, 135US, 135UR)
5. Remove sun gear (18) from ring gear (10).

CAUTION: High pressure may remain in the
travel device. Gradually loosen the air vent
plug to thoroughly release any remaining
pressure. CAUTION: Second stage carrier assembly
weight:
1. With motor (28) facing upward, secure spacer (ST ZAXIS110, 120, 130, 130LCN, 125US:
5089) to the track frame mounting flange of the 23 kg (51 lb)
motor with bolt (M16, pitch 2.0 mm.). ZAXIS135US, 135UR: 28 kg (62 lb)
: 24 mm
ST 5089 6. Hook claws of special lift tool (ST 0916) to the
second stage carrier (19) assembly and hoist it by
crane to remove the second stage carrier
assembly from ring gear (10).
ST 0916
Claws
W105-03-02-007
CAUTION: Travel device weight:

ZAXIS110, 120, 130, 130LCN, 125US: W178-03-02-001
215 kg (475 lb)

ZAXIS135US, 135UR: 235 kg (490 lb) 7. Using special tools (ST 7248) and (ST 7249), turn
and remove bearing nut (22) from motor (28)
2. Secure motor (28) body with a nylon sling and housing.
hoist it with a crane slowly and turn it over. Do not remove knock pin (21) unless necessary.
NOTE: Secure spacer (ST 5089) tightly to receive

the reaction force.
Bolt M12
3. Remove cover (11) from ring gear (10).
ST 7248
NOTE: THREEBOND has been applied between ST 7249
the cover and the ring gear, install a chisel
between the cover and the ring gear and
lightly tap it with a hammer for easier
removal. 22
Do not remove the stopper pin (12) on the
cover unless necessary.
: 19 mm
W176-03-02-013
4. Remove propeller shaft (15), spacer (16), first

stage carrier (17) assembly from ring gear (10).
W3-2-5
10
8 9
1
7
6
1
20
17
23
24
25
26
23
27
28 W176-03-02-001
W3-2-6
CAUTION: Ring gear + sprocket + drum CAUTION: Ring gear + drum weight:
weight: 95 kg (210 lb) ZAXIS110, 120, 130, 130LCN, 125US:
55 kg (120 lb)
IMPORTANT: The motor side of the drum is the ZAXIS135US, 135UR: 58 kg (130 lb)
sliding surface with the motor.
Place the drum on wooden blocks 12. Install eyebolt (M16) to the hole of mounting
after removal. screw on sprocket (24) of drum (25). Hoist it by
crane and turn ring gear (10) over.
8. Install eye bolts (M12) (2 used) to ring gear (10).
Remove and hoist the ring gear from motor (28) 13. Remove floating seal (27) from drum (25).
housing by crane.
CAUTION: Drum weight: 24 kg (53 lb)
NOTE: If it is difficult to remove, turn sprocket (24).
ST 0002 14. Remove drum (25) from ring gear (10).
10 Remove bolt (26).
Install eye bolt (M16) to the mounting hole on
sprocket and hoist the drum with a crane to place
24 it onto wooden blocks which would be lain in
place for mounting ring gear (10).
: 24 mm
28
NOTE: LOCTITE has been applied on the bolt.
15. Tap on the back of each outer race (2 used) of

W155-03-02-003 roller bearing (23) on drum (25) with a metal bar
and hammer evenly to remove it, However, do not
9. Remove floating seal (27) from motor (28). remove it unless replacing it.
10. Remove the inner race of roller bearing (23) from NOTE: There is no need to replace the inner race
drum (25). of roller bearing (23) on the motor side, so
do not remove it.
CAUTION: Sprocket weight:
ZAXIS110, 120, 130, 130LCN, 125US: 16. Disassemble the first stage carrier (17) assembly.
41 kg (90 lb) Tap spring pin (9) out of the first stage carrier
ZAXIS135US, 135UR: 38 kg (85 lb) (17) using pin (ST 1391). (3 places)
Remove pins (8) (3 used), thrust plates (1) (6
used), planetary gears (6) (3 used), needle
11. Remove sprocket (24) from drum (25). bearings (7) (3 used) from the first stage
Remove bolt (20). carrier (17).
Secure the sprocket with a nylon sling and hoist
it with a crane slowly to remove it.
: 24 mm
NOTE: LOCTITE has been applied on the bolt.
W3-2-7
5
4
1
2
3
2
1
19
W176-03-02-001
W3-2-8
17. Disassemble the second stage carrier (19)
assembly.
Tap spring pin (5) out of the second stage
carrier (19) using pin (ST 1462). (3 places)
Remove pins (4) (3 used), thrust plates (1) (6
used), planetary gears (3) (3 used), needle
bearings (2) (6 used) from the second stage
carrier (19).
W3-2-9
ASSEMBLE TRAVEL DEVICE
(ZAXIS110, 120, 130, 130LCN, 125US,
135US, 135UR)
28 27 23 22 21 10 19 18 17 11
14
16
15
12
6
5
7
9
25 13
4 1 2 3 1
26
20
24
W176-03-02-002
1- Thrust Plate (12 Used) 8- Pin (3 Used) 15 - Propeller Shaft 22 - Bearing Nut
2- Needle Bearing (6 Used) 9- Spring Pin (3 Used) 16 - Spacer 23 - Roller Bearing (2 Used)
3- Second Stage Planetary Gear (3 Used) 10 - Ring Gear 17 - First Stage Carrier 24 - Sprocket
4- Pin (3 Used) 11 - Cover 18 - Sun Gear 25 - Drum
5- Spring Pin (3 Used) 12 - Stopper Pin 19 - Second Stage Carrier 26 - Bolt (16 Used)
6- First Stage Planetary Gear (3 Used) 13 - Bolt (12 Used) 20 - Bolt (16 Used) 27 - Floating Seal
7- Needle Bearing (3 Used) 14 - Plug (3 Used) 21 - Knock Pin 28 - Motor
W3-2-10
Assemble Travel Device (ZAXIS110, 120, 130,
130LCN, 125US, 135US, 135UR)
CAUTION: Sprocket +drum weight:
1. If roller bearing (23) on motor (28) has been
replaced, the inner race should be installed by ZAXIS110, 120, 130, 130LCN, 125US:
first, heating it to the temperature of 50 to 70°C 65 kg (145 lb)
(158 °F) with a heater, then assemble it to motor ZAXIS135US, 135UR: 62 kg (140 lb)
(28). Tap the bearing fully with a bar after it has
cooled. 6. Install eye bolts (ST 0007) (2 used) to bolt (26)
mounting holes of drum (25) from the motor (28)
NOTE: Tap the bearing and listen to ring if installation side, then hoist it by crane and place it
installation is completed. onto ring gear (10).
2. Apply enough grease to the O-ring of floating seal 7. Apply LOCTITE # 262 to bolts (26) (16 used).
(27). Install drum (25) to ring gear (10).
Install one side of the floating seal onto motor : 24 mm
(28). : 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
NOTE: If it is difficult to insert the O-ring of floating
seal to the motor, try to push the O-ring 8. Apply enough grease to the O-ring of floating seal
with a bamboo spatula. (27).
Install one side of the floating seal to drum (25).
IMPORTANT: Do not tap other parts except the
outer race. NOTE: If it is difficult to insert the O-ring of floating
3. Tap the outer race of roller bearing (23) evenly seal to the drum, try to push the O-ring with
with a bar and hammer until it fits snugly into the a bamboo spatula.
drum (25) (2 places).
NOTE: Tap the bearing and listen to ring if
installation is completed. CAUTION: Ring gear + drum + sprocket
weight: 96 kg (210 lb)
CAUTION: Sprocket weight: 9. Secure ring gear (10) with a nylon sling, hoist it by
ZAXIS110, 120, 130, 130LCN, 125US: crane and turn it over slowly. Place square
41 kg (85 lb) wooden blocks to prevent of the motor (28) sliding
ZAXIS135US, 135UR: 38 kg (90 lb) surface of drum (25) from being damaged.
IMPORTANT: Face the chamfer side of sprocket 10. Install eye bolts (ST 0002) (2 used) into bolts (13)
toward the drum. mounting holes of ring gear (10), then hoist the
4. Place sprocket (24) on drum (25). Apply LOCTITE ring gear and put it onto motor (28). Make sure
# 262 to bolts (20) (16 used) and tightening the the motor makes contact with drum (25) evenly.
bolts.
: 24 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
CAUTION: Ring gear weight:

ZAXIS110, 120, 130, 130LCN, 125US:
31 kg (68 lb)
ZAXIS135US, 135UR: 34 kg (75 lb)
5. Remove the old adhesive from ring gear (10) and

drum (25).
With the cover (11) side downward, place the ring
gear. Coat THREEBOND # 1389B to the drum
mating surface.
W3-2-11
28 23 22 21 10 19 11
13
25
1 2 3 1
24
W176-03-02-002
W3-2-12
11. Push ring gear (10) straight down from above into 17. Carry out steps 15 and 16 repeatedly.
motor (28), shaking the ring gear.
18. Do step 15 again to tighten bearing nut (22) to
12. Install the inner race of roller bearing (23) to motor specified torque.
(28), tapping with a bar and hammer. : 790 N⋅m (80 kgf⋅m, 580 Ibf⋅ft)
NOTE: It is very stiff to install. Carry out steps 11 19. Align the spline center of motor (28) with that of
and 12 repeatedly so that the inner race knock pin (21). If they cannot be aligned well, turn
side of the bearing comes to the position bearing nut (22) to tightening direction to align
that the 3 pitches of thread for bearing nut them correctly.
(22) appears. Knock Pin
Center
22
13. Apply a little grease to the thread of bearing nut
(22). 21
NOTE: Apply grease when tightening it to the

specified torque. 28
Spline
Center
IMPORTANT: Assembling the bearing nut with its
stepped port facing inside.
W176-03-02-004
14. Install bearing nut (22) to motor (28) and tighten it
by hand.
NOTE: The aim to do so is to align the spline of the
15. Install special tools (ST 7248, ST 7249) to bearing the second stage carrier (19) with knock
nut (22) with a torque wrench. pin (21). If the work is continued without
: 790 N⋅m (80 kgf⋅m, 580 Ibf⋅ft) aligning, cover (11) cannot be installed to
ring gear (10) as it will protrude.
Bolt M12 20. Install needle bearings (2) (2 used) to second

stage planetary gear (3).
ST 7248
IMPORTANT: There is a mark on one side of
second stage planetary gear (3). Be
ST 7249
sure that this marked side faces the
hole for spring pin (5).
21. Clamp second stage planetary gear (3) with thrust
plates (1) (2 used). Install the second stage
planetary gear to second stage carrier (19).
W176-03-02-013
16. After tightening bearing nut (22) to specified

torque, reduce play on bearing nut (22) by tapping
sprocket (24) with a hammer. Then rotate the
sprocket both clockwise and counterclockwise 4
to 5 turns.
W3-2-13
28 21 10 19 18 17 11
14
16
15
13
4 3 1
W176-03-02-002
W3-2-14
22. Install pin (4) to second stage carrier (19). Align 26. Insert sun gear (18) into second stage carrier (19)
the spring pin (5) hole of second stage carrier with with the smaller end facing upward.
the holes of pin (4).
27. Insert spacer (16) into the center of first stage
IMPORTANT: When aligning spring pin (5), be sure carrier (17).
its slit side faces pin (4) end.
23. Tap spring pin (5) to second stage carrier (19) 28. Install needle bearing (7) to first stage planetary
hole. gear (6).
5
29. Clamp first stage planetary gear (16) with thrust
4 plates (1) (2 used). Install the first stage planetary
gear to first stage carrier (17).
Slit 30. Install pin (8), spring pin (9) to first stage carrier
(17) by the same procedures as in steps 22 to 24.
W178-02-06-002 31. Install first stage carrier (17) assembly to the

spline of sun gear (18).
24. Repeat steps 20 to 23 to install other second 32. Insert propeller shaft (15) into the center spline of
stage planetary gears (3) (2 used) to second sun gear (18). Engage the propeller shaft with
stage carrier (19). motor (28) spline and first stage planetary gear (3),
turning it.
CAUTION: When the knock pin fits with the 33. Thoroughly remove the old bond.
second stage carrier, the second stage Remove the grease on the cover (11) mating
carrier will drop down. Take care not to injure surface of the ring gear, then apply THREEBOND
your fingers. #1215 to it.
25. Using lifting tools (ST 0916) hoist second stage 34. Install cover (11) to ring gear (10) with bolt (13).
carrier (19), and install it to the sprocket of motor : 19 mm
(28). If alignment work is not carried out as in step : 110 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
19, the knock pin (21) cannot be inserted into the
carrier. 35. Remove plug (14). Apply gear oil into ring gear
NOTE: After assembling the second stage carrier, (10).
the distance from the top of the planetary : 19 mm
gear to that of the ring gear is about 35 mm Gear oil: 3.5 L
(1.38 in).
36. Wind sealing tape onto plug (14) and install it to
cover (11).
: 19 mm
ST 0916
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W178-03-02-001
Hang up to Carrier
W3-2-15
DISASSEMBLE TRAVEL MOTOR
(ZAXIS110, 120, 130, 130LCN, 125US,
135US, 135UR)
6
Brake Releasing Oil
Passage
5
4
3
Piston Pushing Oil
2 Passage
5 16
7
8
15
14
13 17
18
12 19
11 20
10
9
21
22
23
24
25
26
W176-03-02-005
27
1- Shaft 8- Roller Bearing 15 - Bushing 22 - Socket Bolt (8 Used)

2- Retaining Ring 9- Disc Spring 16 - Swash Plate 23 - O-Ring
3- Retaining Ring 10 - Brake Piston 17 - Ball (2 Used) 24 - Valve Plate
4- Oil Seal 11 - O-Ring 18 - Plunger (9 Used) 25 - Knock Pin (2 Used)
5- O-Ring (2 Used) 12 - O-Ring 19 - Retainer 26 - Needle Bearing
6- Housing 13 - Plate (4 Used) 20 - Spring (9 Used) 27 - Brake Valve
7- Piston 14 - Rotor 21 - Friction Plate (3 Used)
W3-2-16
Disassemble Travel Motor (ZAXIS110, 120, 130,
130LCN, 125US, 135US, 135UR)
6. Remove rotor (14), springs (20) (9 used), bushing
(15), retainer (19) and plungers (18) (9 used) from
CAUTION: Travel motor weight: 60 kg
housing (6).
(130 lb)
7. Remove plates (13) (4 used) and friction plates
IMPORTANT: When removing brake valve (27) (21) (3 used) from housing (6).
assembly from the motor, valve
plate (24) is also removed with the
brake valve side. CAUTION: Housing weight: 34 kg (75 Ib)
Don’t drop the valve plate as it easily
comes off. 8. Place housing (6) with the brake releasing oil
1. Place the travel motor longitudinally. After passage facing downward and horizontal.
removing socket bolt (22), remove brake valve NOTE: When the brake releasing oil passage is
(27) from housing (6). positioned upward, the thick portion of
: 12 mm swash plate (16) faces upward. When
housing (6) is placed horizontally, the
IIMPORTANT: The valve plate easily becomes swash plate may come off suddenly.
cracked and scratched, so handle it
with care. 9. Remove swash plate (16) from housing (6).
2. Remove valve plate (24) and knock pins (25) (2 NOTE: If the swash plate cannot be removed,
used) from brake valve (27). Do not remove Apply pressure air 100 to 300 kPa (1 to 3
needle bearing (26) unless necessary. kgf/cm2, 14 to 43 psi) through the piston
pushing oil passage port, and the swash
NOTE: Even if small removing tool is used for plate will be removed from the piston. In
removing the needle bearing, the outer order to prevent the piston from popping
race may be deformed. out, cover with cloth. Use a bicycle pump to
Do not reuse the needle bearing. apply air.
3. Wrap tape on the needle bearing (26) rotation 10. With a magnet, remove balls (17) (2 used) and
surface of shaft (1) for protection. piston (7) from housing (6).
4. Remove disc spring (9) from housing (6). 11. Remove retaining ring (2) from housing (6).
12. Tap the bottom in the spline bore of shaft (1) using
CAUTION: When removing the brake piston a bar and plastic hammer to push the shaft out
from the housing filled with air, cover the with roller bearing (8) from housing (6).
housing with cloth to prevent the brake
piston from flying off.
5. Apply pressure air 100 to 300 kPa (1 to 3 kgf/cm2,

14 to 43 psi) to the brake releasing oil passage of
housing (6), so that the brake piston will float up
to be removed.
NOTE: It is possible to using bicycle pump. Do not
pry with a screwdriver, or components will
be damaged.
W3-2-17
4
3
W176-03-02-005
W3-2-18
13. Insert a slotted head screwdriver into the shaft (1)
hole of housing (6) and push out oil seal (4).
NOTE: Since the oil seal has been covered with

adhesive, it cannot be used again.
CAUTION: When the shaft is removed from

the roller bearing, be sure to avoid dropping
it.
15. Balance the inner race of roller bearing (8)

remained on shaft (1) on a vice. With a bar and
plastic hammer, tap the shaft slightly, to remove
the roller bearing.
Bar
W172-03-02-003
W3-2-19
ASSEMBLE TRAVEL MOTOR
(ZAXIS110, 120, 130, 130LCN, 125US,
135US, 135UR)
Brake Releasing Oil Passage
27 25 23 5 11 12 10 14 18 16 17 2 8
26 22 24 5 9 13 21 20 15 19 7
W176-03-02-006
Piston Pushing Oil

Passage
1- Shaft 8- Roller Bearing 15 - Bushing 22 - Socket Bolt (8 Used)

2- Retaining Ring 9- Disc Spring 16 - Swash Plate 23 - O-Ring
3- Retaining Ring 10 - Brake Piston 17 - Ball (2 Used) 24 - Valve Plate
4- Oil Seal 11 - O-Ring 18 - Plunger (9 Used) 25 - Knock Pin (2 Used)
5- O-Ring (2 Used) 12 - O-Ring 19 - Retainer 26 - Needle Bearing
6- Housing 13 - Plate (4 Used) 20 - Spring (9 Used) 27 - Brake Valve
7- Piston 14 - Rotor 21 - Friction Plate (3 Used)
W3-2-20
Assemble Travel Motor (ZAXIS110, 120, 130,
130LCN, 125US, 135US, 135UR)
IMPORTANT: Pay attention to assembly direction.

CAUTION: Housing weight: 34 kg (75 Ib) 4. Insert the inner ring plate side of roller bearing (8)
into the inner bore spline end of shaft (1) first.
1. Place housing (6) with the brake valve (27) Then push the shaft until the bearing comes into
mating surface facing upward. the tight fitting part. Be sure not to damage the
seal lip surface of the shaft.
IMPORTANT: Apply OCEAN grease #7 to the inner
circumference of the oil seal, and 5. Insert the inner bore spline end of the shaft into
apply THREEBOND #1104 or #1215 bearing assemble tool (ST 2895). Tap the other
to the outer circumference of the oil end of the shaft with a plastic hammer to install
seal. roller bearing (8) onto the shaft.
2. Neatly clean oil seal (4) fitting part of housing (6).
Using tool (ST 2893), install the oil seal into the 1
housing.
ST 2893 Inner Bore Spline
Inner Ring Plate
4
ST 2895 12
6
W176-03-02-007
W176-03-02-008
IMPORTANT: Pay attention to the direction when 6. Install retaining ring (3) on shaft (1), while taking
assembling. care to avoid damaging the oil seal (4) slide
3. Assemble roller bearing (8) so that all marked surface.
surfaces are on the outer race, inner race, inner
ring plate facing outward. 7. Apply grease to the ball (17) surface sufficiently
and assemble balls (2 used) to housing (6).
Inner Race Marked
Outer Race Marked
Surface NOTE: Without the grease applied to the ball, it will
Surface
be impossible to hold the ball and swash
plate (16).
8. Install piston (7) to housing (6) with the stepped

side of the piston facing inside.
W176-02-06-014
Inner Ring Plate Marked

Surface
W3-2-21
27 25 23 5 11 12 10 14 18 16 2
17
5 9 13 21 20 15 19
W176-03-02-006
W3-2-22
IMPORTANT: The small diameter side of the shaft
CAUTION: Housing weight: 40 kg (88 lb)
is the inner race of the needle
bearing. Take care not to damage it.
9. With a plastic hammer, tap shaft (1) lightly to 15. Place housing (6) with the brake valve (27)
install it into housing (6). mounting surface facing upward.
10. Install retaining ring (2) in housing (6) to stop shaft 16. Install plates (13) (4 used) and friction plates (21)
(1). (3 used) on housing (6) alternatelly. Install the
plate first.
NOTE: If keep open the retaining ring and move it
to the lowest bottom of the housing, 17. Apply grease to O-rings (11), (12). Install them
installation of the retaining ring becomes into brake piston (10).
easy.
18. Push brake piston (10) into housing (6) with a
11. Apply grease to the ball hole of swash plate (16). plastic hammer by tapping evenly.
Install the swash plate on housing (6), while align
with balls (17) (2 used). NOTE: Since the O-ring is positioned around the
brake piston, the brake piston cannot be
fully fitted. When installing brake valve (27),
CAUTION: Housing weight: 35 kg (77 Ib) push the brake piston with tightening bolts.
12. Place housing (6) horizontally with its brake IMPORTANT: Pay attention to the disc spring
releasing oil passage facing downward. assembly direction.
NOTE: If placed opposite, swash plate (16) may 19. Put disc spring (9) on brake piston (10) with the
come off. inner diameter of the disc spring facing the brake
piston.
IMPORTANT: Pay attention to the retainer
direction. 20. Install O-rings (5) (2 used), (23) onto the brake
13. Install springs (20) (9 used), bushing (15), retainer valve (27) contact surface of housing (6).
(19), plungers (18) (9 used) onto the rotor (14),
with the chamfered side of the retainer facing the 21. Fill hydraulic oil into housing (6) until plate (13) is
bushing. submerged.
19 IMPORTANT: Pay attention to the knock pin

assembly direction.
22. Install the large diameter side of knock pins (25)
(2 used) to the knock pin hole of brake valve (27).
Chamfered 15
W172-03-02-001
14. Assemble the rotor (14) assembly into housing

(6).
W3-2-23
27 25
26 22 24
W176-03-02-006
W3-2-24
IMPORTANT: Pay attention to the needle bearing
assembly direction.
23. Using drive tool (ST 2894), tap needle bearing
(26) with a hammer into brake valve (27). Face
the mark on the needle bearing outward.
ST 2894
26
27
W176-03-02-012
24. Apply grease on the flat surface of valve plate

(24). Install the valve plate onto brake valve (27),
aligning knock pin (25).
NOTE: Apply grease sufficiently so that valve plate
adheres to the brake valve. It prevents the
valve plate from coming off while turning
over the brake valve.
IMPORTANT: Take care not to let the valve plate

fall as this can damage it resulting in
oil leaks.
25. Install brake valve (27) to housing (6) and secure
it with socket bolts (22) (8 used).
: 12 mm
: 177 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
W3-2-25
DISASSEMBLE TRAVEL BRAKE VALVE
(ZAXIS110, 120, 130, 130LCN, 125US,
135US, 135UR)
2
3
4
16
3
15
14
13 2
1
9 8 7
10
11
W176-03-02-009
12
1- Plug (2 Used) 5- Spool 9- Poppet (2 Used) 13 - Plug

2- O-Ring (2 Used) 6- Valve Housing 10 - Spring (2 Used) 14 - O-Ring
3- Spring (2 Used) 7- Plug 11 - O-Ring (2 Used) 15 - Spring
4- Stopper (2 Used) 8- O-Ring 12 - Relief Valve (2 Used) 16 - Spool
W3-2-26
Disassemble Travel Brake Valve (ZAXIS110, 120,
130, 130LCN, 125US, 135US, 135UR)
6. Remove springs (10), poppets (9) from valve
1. Remove plug (1) from valve housing (6). (2 housing (6) with a magnet. (2 places)
places).
: 36 mm
7. Remove plug (13) from valve housing (6). (2
2. Remove spring (3) and stopper (4) from valve places)
housing (6) with a magnet. (2 places) : 6 mm
3. Remove spool (5) from valve housing (6) with a 8. Remove spring (15), spool (16) from valve
magnet. housing (6) with a magnet.
4. Remove plug (7) from valve housing (6).

The plug coated with LOCTITE has been inserted
into the hole. Do not remove it unless necessary.
: 6 mm
IMPORTANT: Do not disassemble the relief valve.

By disassembling it, its setting
pressure may be changed.
IMPORTANT: Do not move the piston on the relief

valve, otherwise the O-ring may be
damaged by the hole of cartridge.
5. Remove relief valves (12) from valve housing (6).
(2 places)
: 30 mm
12
W176-03-02-011
Piston
W3-2-27
ASSEMBLE TRAVEL BRAKE VALVE
(ZAXIS110, 120, 130, 130LCN, 125US,
135US, 135UR)
1 2 3 4 5 4 3 2 1 6
W176-03-02-010
9 10 11 12 8 7 16 14 13 15
1- Plug (2 Used) 5- Spool 9- Poppet (2 Used) 13 - Plug

2- O-Ring (2 Used) 6- Valve Housing 10 - Spring (2 Used) 14 - O-Ring
3- Spring (2 Used) 7- Plug 11 - O-Ring (2 Used) 15 - Spring
4- Stopper (2 Used) 8- O-Ring 12 - Relief Valve (2 Used) 16 - Spool
W3-2-28
Assemble Travel Brake Valve (ZAXIS110, 120, 130,
130LCN, 125US, 135US, 135UR)
7. Install O-ring (11) (2 used) into relief valve (12).
1. Install spool (5) approximately half way into valve
housing (6).
8. Press poppet (9) installed in step 6 with relief
valve (12) into valve housing (6), while slowly
2. Install O-ring (2), spring (3), stopper (4) onto plug rotating the relief valve. (2 places)
(1) on one side. Install the plug into valve housing : 30 mm
(6) with pitch a couple of threads left out. : 310 N⋅m (32 kgf⋅m, 230 lbf⋅ft)
NOTE: If the plug is fully installed, it is difficult to
assemble the plug on other side as spool
(5) may be pushed out. IMPORTANT: Pay attention to the assembly spool
direction.
9. Install spool (16) into valve housing (6) with the
3. Install O-ring (2), spring (3) and stopper (4) into hole end facing forward.
other plug (1). Install plug (1) into valve housing
(6). Tighten the plug by hand.
10. Install spring (15) into valve housing (6).
4. Tighten plug (1) on both sides.

: 36 mm 11. Install O-ring (14) onto plug (13) into valve
: 440 N⋅m (45 kgf⋅m, 325 lbf⋅ft) housing (6).
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
5. Install O-ring (8) into plug (7), then install plug (7)
into valve housing (6).
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
6. Install spring (10) into poppet (9). Install poppet

(9) flush with the hole entrance of valve housing
(6). (2 places)
NOTE: If the poppet is installed into the farthest
end, the spring may come off from the
poppet.
W3-2-29
DISASSEMBLE TRAVEL REDUCTION
GEAR (ZAXIS110M)
8
7
6
5
4
3
2
1
9
10
11
12
13
14
20
15
16 19
18
17
24
23
22
21
25
26
27
28
29
30
31
W1F1-03-02-005
1- Socket Bolt (16 Used) 9- Thrust Washer (3 Used) 17 - Bearing Nut 25 - Thrust Washer (4 Used)
2- Cover 10 - Inner Race (3 Used) 18 - Bearing 26 - Needle Bearing (4 Used)
3- Thrust Plate 11 - Needle Bearing (3 Used) 19 - Housing 27 - Inner Race (4 Used)
4- Thrust Plate 12 - First Stage Planetary Gear 20 - Bearing 28 - Second Sage Planetary
(3 Used) Gear (4 Used)
5- Drive Gear 13 - Thrust Washer (3 Used) 21 - Floating Seal 29 - Thrust Plate (4 Used)
6- First Stage Holder 14 - Screw (3 Used) 22 - Plug (4 Used) 30 - Spring Pin (4 Used)
7- Retaining Ring 15 - O-Ring (3 Used) 23 - Second Stage Holder 31 - Screw (4 Used)
8- Sun Gear 16 - Plug (3 Used) 24 - Oil Seal
W3-2-30
Disassemble Travel Reduction Gear (ZAXIS110M)
CAUTION: Travel Reduction Gear Weight:

120 kg (265 lb) 5. Remove first stage holder (6) from sun gear (8).
1. Install eyebolts (M16) (2 used) to the screw holes 6. Remove sun gear (8) from second stage holder
on second stage holder (23). Using the eye bolts, (23).
Lift the travel reduction gear by crane. Loosen
plugs (16) (2 used) to drain oil. 7. Loosen and remove screws (31) (4 used).
: 12 mm Remove second stage planetary gear (28) (4
used) and thrust plate (29) (4 used) from second
2. Loosen and remove socket bolts (1) (16 used). stage holder (23).
After tapping the fringe of cover (2) with a plastic : 8 mm
hammer, insert a screwdriver into the mating gap
between housing (19) and cover to remove cover. 8. Remove needle bearing (26) (4 used), inner race
: 8 mm (27) (4 used) and thrust washer (25) (4 used) from
second stage planetary gears (28) (4 used).
IMPORTANT: Remove thrust plate (3), and
measure and record a step distance
between face of housing (19) and
that of thrust plate (4) protruded
from housing (19).
3. Remove thrust plate (3), screw (14) (3 used) and
thrust plate (4) from first stage holder (6).
4. Remove thrust washer (13) (3 used), Planetary

gear (12) (3 used), needle bearing (11) (3 used),
inner race (10) (3 used) and thrust washer (9) (3
used) from first stage holder (6).
W3-2-31
20
19
18
17
24
23
22
21
30
W1F1-03-02-005
W3-2-32
9. Remove plugs (22) (4 used) from second stage 11. Remove the inner race of bearing (18) from
holder (23). Remove bearing nut (17) from housing (19).
housing (19) using special tool (ST 3154).
: 8 mm, 22 mm 12. Remove one side of floating seal (21) from
housing (19).
Socket Wrench 22 mm ST 3154
13. Remove the other side of floating seal (21) from
second stage holder (23).
NOTE: Do not remove the inner race of bearing
(20) remaining on second stage holder (23)
Rotation Handle unless replacement is required.
14. Remove oil seal (24) from second stage holder

(23).
W1F1-03-02-006
15. Tap outer races out of bearings (18) and (20) in

17 22
housing (19), with a bar and plastic hammer.
W1F1-03-02-007
NOTE: Do not remove spring pins (25) unless

required.
CAUTION: Second stage holder weight:

50 kg (110 lb)
10. Remove second stage holder (23) from housing
(19) with a press.
W3-2-33
ASSEMBLE TRAVEL REDUCTION GEAR
(ZAXIS110M)
25 26 27 28 29 9 10 11 12 13
4
6
14
3
7
8
5
31
30
16
24 23 21 20 18 17 22 19 15
W1F1-03-02-008
1- Socket Bolt (16 Used) 9- Thrust Washer (3 Used) 17 - Bearing Nut 25 - Thrust Washer (4 Used)
2- Cover 10 - Inner Race (3 Used) 18 - Bearing 26 - Needle Bearing (4 Used)
3- Thrust Plate 11 - Needle Bearing (3 Used) 19 - Housing 27 - Inner Race (4 Used)
4- Thrust Plate 12 - First Stage Planetary Gear 20 - Bearing 28 - Second Sage Planetary
(3 Used) Gear (4 Used)
5- Drive Gear 13 - Thrust Washer (3 Used) 21 - Floating Seal 29 - Thrust Plate (4 Used)
6- First Stage Holder 14 - Screw (3 Used) 22 - Plug (4 Used) 30 - Spring Pin (4 Used)
7- Retaining Ring 15 - O-Ring (3 Used) 23 - Second Stage Holder 31 - Screw (4 Used)
8- Sun Gear 16 - Plug (3 Used) 24 - Oil Seal
W3-2-34
Assemble Travel Device
CAUTION: Housing weight: 45 kg (100 lb) IMPORTANT: Do not reuse bearing nut (17). Be
sure to replace it with new one.
1. Tap outer races for bearings (18) and (20) into 7. Tighten bearing nut (17) to second stage holder
housing (19), with a bar and hammer. (23) using special tool (ST 3154).
: 22 mm
2. Install oil seal (24) into second stage holder (23). : 1245±137 N⋅m
(127±14 kgf⋅m, 920±100 Ibf⋅ft)
3. Heat inner race for the bearing (20) up to 50° to Socket Wrench 22 mm ST 3154
70°C (122° to 158°F) with a heater, then set it in
second stage holder (23). After bearing is cooled
down, drive it into position, with a bar and
hammer. Rotation Handle
4. Install one side of floating seal (21) into housing

(19) and the other side of it into second stage
holder (23). W1F1-03-02-006
17 23 22
CAUTION: Second stage holder weight:

50 kg (110 lb)
Housing weight: 45 kg (100 lb)
5. Hoist and install housing (19) onto second stage

holder (23) by crane.
W1F1-03-02-007
6. Heat inner race for the bearing (18) up to 50° to IMPORTANT: Re-tap screw holes for plugs (22).
70°C (122° to 158°F) with a heater, then set it in 8. After tightening plugs (22) (4 used) to second
second stage holder (23). After bearing is cooled stage holder (23), crimp plugs (22) (4 used) two
down, drive it into position, with a bar and places with a punch.
hammer. : 8 mm
: 39±4.9 N⋅m
(4±0.5 kgf⋅m, 29±3.6 Ibf⋅ft)
9. Install inner race (27) and needle bearing (26) in

second stage planetary gear (28). Then, install
thrust washer (25) and planetary gear (28) on
second stage holder (23) in this order.
IMPORTANT: Drive spring pin (30) with a slit

directed toward the outer
circumference.
10. Install thrust plate (29) on second stage holder
(23) and drive in spring pins (30). Then tighten
screws (31). Follow the same procedures to install
the other three second stage planetary gears (28).
: 8 mm
: 59±4.9 N⋅m
(6±0.5 kgf⋅m, 43±3.6 Ibf⋅ft)
W3-2-35
28 9 10 11 12 13
4
6
14
3
7
8
5
16
19 W1F1-03-02-008
W3-2-36
11. Install retaining ring (7) in sun gear (8). 18. Apply a film of THREEBOND #1211 to the
Then, install sun gear (8) aligning the gear teeth mounting face on housing (19). Install cover (2)
on second stage planetary gears (28). with socket bolts (1) (16 used).
: 8 mm
12. Install inner race (10) and needle bearing (11) into : 73±3.6 N⋅m
first stage planetary gear (12). (7.4±0.4 kgf⋅m, 54±2.7 Ibf⋅ft)
13. Install thrust washer (9), first stage planetary gear 10. Supply gear oil 3.5 L (0.9 US gal) into a hole
(12) and thrust washer (13) in order onto first of oil supply plug (16) (until oil comes out). Then,
stage holder (6). install oil supply plug (16) and oil level check plug
(16) to cover (2).
14. Follow the same procedures to install the other : 12 mm
two first stage planetary gears (12) onto first stage : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
holder (6).
15. Install first stage holder (6) into housing (19). Oil Supply Plug
Install drive gear (5) aligning gear teeth on first
stage planetary gears (12).
Oil Level
Check Plug
16. Install thrust plate (4) onto first stage holder (6)
with screws (14) (3 used).
IMPORTANT: Before installing thrust plate (3),

W1F1-03-02-009
measure a step distance between
face of housing (19) and that of
thrust plate (4) protruded from
housing (19). Install thrust plate (3)
according to the table below.
(mm)
Measure Step Thrust Plate (3) to be
Distance Used
2.88 to 2.22 2.3
2.21 to 1.84 2.8
1.83 to 1.64 3.0
1.63 to 1.36 3.2
1.35 to 1.12 3.6
17. Measure a step distance between face of housing

(19) and that of thrust plate (4) protruded from
housing (19). Then select thrust plate (3) from the
table above, and install it on first stage holder (6).
W3-2-37
DISASSEMBLE TRAVEL MOTOR
(ZAXIS110M)
10
9
8
5 7
6
4 22
21
3 20
39 19
18
2 17
16
1 15
14
13
12
11
36
35
34
33
32
31
30
29
28
24
23
37
38
W187-03-02-002
1- Bolt (16 Used) 11 - Shaft 21 - Collar 32 - O-ring

2- Spring Washer (16 Used) 12 - Steel Ball (2 Used) 22 - Retaining ring 33 - Backup Ring
3- Sprocket 13 - Thrust Plate 23 - Valve Plate 34 - Ball Bearing
4- Plug (3 Used) 14 - Plunger (9 Used) 24 - Disc Plate 35 - Pin
5- Housing 15 - Retainer Plate 28 - Backup Ring 36 - Base Plate
6- Spring (2 Used) 16 - Holder 29 - O-ring 37 - Socket Bolt (9 Used)
7- Piston (2 Used) 17 - Pin (3 Used) 30 - Piston 38 - Spring (8 Used)
8- O-ring 18 - Rotor 31 - Pin (4 Used) 39 - O-ring (9 Used)
9- Oil Seal 19 - Collar
10 - Ball Bearing 20 - Spring
W3-2-38
Disassemble Travel Motor (ZAXIS110M)
• Be sure to read “Precautions for Disassembly and 5. Remove disc plate (24) from housing (5).
Assembly” thoroughly on page W1-1-1 before
starting the disassembly work. 6. Remove O-rings (29 and 32) and backup rings
(28 and 33) from piston (30).
CAUTION: Travel device weight: 280 kg
7. Remove rotor (18) assembly from housing (5).
(620 lb)
8. Put matching marks on plungers (14) and rotor
1. Lift the travel device by crane, and rest it on a (18) so that they can be reassembled in the same
workbench, with the base plate (36) facing position each other. Remove plungers (14) and
upward. Then secure it in stable position. retainer plate (15).
CAUTION: Base plate weight: 22 kg (49 Ib)
IMPORTANT: When removing base plate (36),

valve plate (23) may come off.
Slowly remove the base plate from
housing (5).
2. Springs (38) (8 used) are pushing base plate (36)
upward.
Loosen socket bolts (37) (9 used) uniformly to
remove the base plate from housing (5).
: 12 mm
3. Remove O-rings (39) (4 used), (8) and springs

(38) (8 used) from housing (5). Remove valve
plate (23), Pins (31) (4 used), (35) from base plate
(36).
CAUTION: When removing piston (30) using

compressed air, be sure to cover the piston
with cloths to prevent the piston from flying
out.
4. Supply compressed air less than 0.3 MPa (3.1

kgf/cm3, 44 psi) into the brake release oil passage
so that piston (30) will float up to be removed.
W3-2-39
10
5 7
6
4 22
3 20
39 19
18
2 17
16
1
13
12
11
36
34
W187-03-02-002
W3-2-40
9. Remove holder (16) and pins (17) (3 used) from
CAUTION: Housing (5) assembly weight:
rotor (18).
120 kg (265 lb)
10. Using a press, compress collar (21) and spring
(20). While holding the press in that position, 16. Turn over housing (5) assembly by crane.
remove retaining ring (22).
Remove collar (21), spring (20) and collar (19) CAUTION: Sprocket weight: 50 kg (110 lb)
from rotor (18) in order while retracting the press.
17. Remove bolts (1) (16 used) and spring washers
IMPORTANT: When removing thrust plate (13), (2) (16 used). Remove sprocket (3) from housing
pistons (7) (2 used) and steel balls (5) by crane.
(12) (2 used) may come out together : 30 mm
with thrust plate (13). Take care not
to drop pistons or steel balls.
11. Remove thrust plate (13) from housing (5).
12. Remove pistons (7) (2 used) and springs (6) (2

used). If steel balls (12) (2 used) are hard to be
removed, clean the balls and their vicinities with
white kerosene or thinner. Then, use a magnet to
draw steel balls (2 used) out of housing (5).
13. Remove shaft (11) from housing (5). Remove ball

bearing (10) from shaft with a press.
14. Remove ball bearing (34) from base plate (36).
CAUTION: Housing (5) assembly weight:

120 kg (265 lb)
15. Install eyebolts (M16) into screw holes on housing

(5). Lift housing (5) by crane.
While lifting the housing by crane, loosen plugs
(4) (2 used) to drain oil.
: 12 mm
W3-2-41
ASSEMBLE TRAVEL MOTOR (ZAXIS110M)
32 28 24 14 17 5
33
8
37
29
31
18
35
23
36 Drive Gear
34
21
22
20
38 4
19 31 30 39 15 16 11 13 12 10 9
W187-03-02-001
1- *Bolt (16 Used) 11 - Shaft 21 - Collar 34 - Ball Bearing

2- *Spring Washer (16 Used) 12 - Steel Ball (2 Used) 22 - Retaining ring 35 - Pin
3- *Sprocket 13 - Thrust Plate 23 - Valve Plate 36 - Base Plate
4- Plug (3 Used) 14 - Plunger (9 Used) 24 - Disc Plate 37 - Socket Bolt (9 Used)
5- Housing 15 - Retainer Plate 28 - Backup Ring 38 - Spring (8 Used)
6- *Spring (2 Used) 16 - Holder 29 - O-Ring 39 - O-Ring (9 Used)
7- *Piston (2 Used) 17 - Pin (3 Used) 30 - Piston
8- O-Ring 18 - Rotor 31 - Pin (4 Used)
9- Oil Seal 19 - Collar 32 - O-ring
10 - Ball Bearing 20 - Spring 33 - Backup Ring
NOTE: As for mark *, refer to W3-2-38.
W3-2-42
Assemble Travel Motor (ZAXIS110M)
CAUTION: Sprocket weight: 50 kg (110 lb) 7. Apply grease to steel balls (12) (2 used), then
insert them into housing (5).
IMPORTANT: Check that the chamfered sprocket
(3) surface faces toward the mating 8. Align the holes on thrust plate (13) with the
surface on housing (5) locations of steel balls (12) (2 used). Then, install
1. Install sprocket (3) onto housing (5) by crane. thrust plate into housing (5).
Tighten sprocket (3) to housing (5) with bolts (1)
(16 used) and spring washer (2) (16 used). 9. Install collar (19), spring (20) and collar (21) into
: 30 mm rotor (18) in order. While pushing collar (21) with a
: 460 N⋅m (47 kgf⋅m, 340 Ibf⋅ft) press, install retaining ring (22) into rotor (18).
10. Install pins (17) (3 used) and holder (16) into rotor
CAUTION: Housing (5) assembly weight: (18).
170 kg (370 lb)
11. Align matching marks put on when disassembling
2. Turn over housing (5) assembly by crane. plungers (14) and rotor (18). Install plungers (14)
(9 used) and retainer plate (15) into rotor (18).
3. Install ball bearing (34) into base plate (36).
Attach a metal bar to ball bearing (34) and tap the
end of the metal bar to completely install the
bearing in position.
4. Install ball bearing (10) on to shaft (11) with a

press.
5. Align spline teeth on both shaft (11) and the drive

gear (drive gear (5) is shown on page W3-2-30).
While tapping the end of shaft (11) with a plastic
hammer, Install shaft (11) with ball bearing (10)
into the drive gear.
6. Apply grease to pistons (7) (2 used). Then, install

spring (6) into each piston. Install piston with
spring into housing (5).
6
7 W1F1-03-02-004
W3-2-43
24
32 5
33
8
37
29
31
18
35
23
36 Drive Gear
38 4
30 39 11
W187-03-02-001
W3-2-44
12. Engage rotor assembly (18) with the spline on
shaft (11) in housing (5).
13. Engage disc plate (24) with spline of the rotor (18)
in housing (5).
14. Attach O-rings (29 and 32) and backup rings (28
and 33) to piston (30). Then, install the piston into
housing (5) while tapping with a plastic hammer.
15. Attach O-rings (39) (4 used) and O-rings (8) to

housing (5). Install springs (38) (8 used) into
piston (30).
CAUTION: Base plate weight: 22 kg (49 Ib)
16. Install pins (31) (4 used) and pin (35) into base
plate (36). Apply a film of grease to valve plate
(23) and install it onto base plate (36), aligning the
pin hole with pin (35).
17. Slowly overturn base plate (36) so that valve plate

(23) does not come off. Install base plate (36)
onto piston (30), aligning the pin (31) (4 used)
holes with pins (31) (4 used).
Equally tighten socket bolts (37) (9 used).
: 12 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
W3-2-45
DISASSEMBLE BASE PLATE (ZAXIS110M)
1 A
B
CD
E
5 F
5 7 G 2
4 A 3
6 B
CD
E D
F
8 GH A
I 9
14 J K 8
15 13 L 10
11
3 13
2
12 13 B
33
16
A
17
B
16
19 34
18 20
13
35
25 21
22
26 23
27 A
B
28 C
D 24
E
D
C 19
B
A 18
23
22
21
20
25
26
28
27
W1F1-03-02-010
1- Spool Assembly 8- Relief Valve (2 Used) 9- O-Ring 23 - Spring Seat (2 Used)
A- Spool A- Poppet 10 - Plug (3 Used) 24 - Plunger Assembly
B- Backup Ring B- Housing 11 - O-Ring (3 used) A- Plug (2 Used)
C- O-Ring C- Piston 12 - Spring B- O-Ring (2 used)
D- O-Ring D- Backup Ring 13 - Plug (9 Used) C- Spring (2 Used)
E- Backup Ring E- O-Ring 14 - Orifice (2 Used) D- Check Valve (2 Used)
F- Filter F- Spring Seat 15 - Orifice (2 Used) E- Plunger
G- Retaining Ring G- Spring 16 - Orifice (2 Used) 25 - Steel Ball (2 Used)
2- O-Ring (2 used) H- Spring Guide 17 - Pin 26 - Spring (2 Used)
3- Plug (2 Used) I- O-Ring 18 - Socket Bolt (8 Used) 27 - O-Ring (2 used)
4- Plug J- Plug 19 - Cap (2 Used) 28 - Plug (2 Used)
5- Backup Ring (2 Used) K- Nut 20 - O-Ring (2 used) 33 - Socket Bolt (9 Used)
6- O-Ring L- Set Screw 21 - Spring Seat (2 Used) 34 - Base Plate
7- Seat 22 - Spring (2 Used) 35 - Pin (2 Used)
W3-2-46
Disassemble base Plate (ZAXIS110M)
• Replace each spool assembly (1), relief valve (8) 7. Remove two plugs (3) (2 used) to remove spring
and plunger assembly (24) as an assembly unit. (12) from base plate (34).
• Spool assembly (1) and plunger assembly (24) : 10 mm
are installed in base plate (34) with selective fit.
Avoid disassembling them unless required. 8. Remove O-rings (2) (2 used) from two plugs (3) (2
When unavoidably disassembled, take care not to used).
damage them.
IMPORTANT: Spool assembly (1) is installed in
1. Remove socket bolts (18) (8 used) to remove base plate (34) with selective fit.
caps (19) (2 used) from base plate (34). When removing spool assembly (1)
: 8 mm from base plate (34), if spool
assembly (1) does not come out
2. Remove plugs (28) (2 used) from caps (19) (2 smoothly, do not try to forcibly
used). Remove O-rings (27) (2 used) springs (26) remove it. Softly tap it with a plastic
(2 used) and steel balls (25) (2 used) from caps hammer to push it back slightly first.
(19) (2 used). Then, after checking that spool
: 14 mm assembly (1) moves smoothly,
remove it while slowly turning it.
3. Remove spring seats (21) (2 used), springs (22) 9. Softly tap the end face of spool assembly (1) to
(2 used) and spring seats (23) (2 used) from base push out the other end of spool assembly (1) from
plate (34). base plate (34). Hold the protruded end of spool
assembly (1) by hand and pull it out of base plate
IMPORTANT: Plunger assembly (24) is installed in (34) while turning the spool assembly.
base plate (34) with selective fit. NOTE: Do not remove plugs (13) (9 used) unless
When removing plunger assembly required.
(24) from base plate (34), if plunger Do not remove orifices (14 (2 used), 15 (2
assembly (24) does not come out used) and 16 (2 used)) as they are crimped
smoothly, do not try forcibly remove with base plate (1).
it. Softly tap it with a plastic hammer
to push it back slightly first. Then,
after checking that plunger
assembly (24) moves smoothly,
remove it while slowly turning it.
4. Softly tap the end face of plunger assembly (24)
to push out the other end of plunger assembly
(24) from base plate (34). Hold the protruded end
of plunger assembly (24) by hand and pull it out of
base plate (34) while turning the plunger.
5. After removing relief valve (8), remove seat (7)

from base plate (34).
6. Remove backup rings (5) (2 used) and O-ring (6)

from seat (7). Remove O-ring (9) from relief valve
(8).
: 27 mm
W3-2-47
ASSEMBLE BASE PLATE (ZAXIS110M)
2 7 6, 5 13 14, 15 1 12 2 3 8 4 33 17
9 10, 11
18
21
19
22
16 34 13 24 23 20 35
18
19
27
25
26
28
W1F1-03-02-011
1- Spool Assembly 8- Relief Valve (2 Used) 16 - Orifice (2 Used) 24 - Plunger Assembly

2- O-Ring (2 used) 9- O-Ring 17 - Pin 25 - Steel Ball (2 Used)
3- Plug (2 Used) 10 - Plug (3 Used) 18 - Socket Bolt (8 Used) 26 - Spring (2 Used)
4- Plug 11 - O-Ring (3 used) 19 - Cap (2 Used) 27 - O-Ring (2 used)
5- Backup Ring (2 Used) 12 - Spring 20 - O-Ring (2 used) 28 - Plug (2 Used)
6- O-Ring 13 - Plug (9 Used) 21 - Spring Seat (2 Used) 33 - Socket Bolt (9 Used)
7- Seat 14 - Orifice (2 Used) 22 - Spring (2 Used) 34 - Base Plate
J- Plug 15 - Orifice (2 Used) 23 - Spring Seat (2 Used) 35 - Pin (2 Used)
W3-2-48
Assemble Base Plate (ZAXIS110M)
IMPORTANT: Spool assembly (1) and plunger 6. After applying a film of hydraulic oil to plunger
assembly (24) are installed in base assembly (24), install it into base plate (34) while
plate (34) with selective fit. turning plunger (24). After installing plunger
Avoid disassembling them unless assembly (24), check plunger assembly (24)
required. When disassembly is smoothly moves.
unavoidable, take care not to
damage them. 7. Install steel balls (25) (2 used) and springs (26) (2
used) into caps (19) (2 used).
CAUTION: Base plate weight: 22 kg (49 lb)
8. Attach O-rings (27) (2 used) to plugs (28) (2used).
Then install plugs (28) (2 used) into caps (19) (2
1. After applying a film of hydraulic oil to spool used).
assembly (1), install it into base plate (34) while : 14 mm
turning spool (1). After installing spool (1) : 21±1 N⋅m
assembly, check spool assembly (1) smoothly (2.1±0.1 kgf⋅m, 15.5±0.7 Ibf⋅ft)
moves.
9. Install spring seats (23), springs (22) and spring
2. Install spring (12) into spool assembly (1). Attach seats (21) in order on the both ends of plunger
O-ring (2) (2 used) to plug (3) (2 used). Then, assembly (24) in base plate (34).
install plugs (3) (2 used) into base plate (34).
: 10 mm 10. Attach O-rings (20) (2 used) to caps (19) (2 used).
: 118±6 N⋅m Then, install caps (19) (2 used) into base plate
(12±0.6 kgf⋅m, 87±4.4 Ibf⋅ft) (34) with socket bolts (18) (8 used).
: 8 mm
3. Attach backup ring (5), O-ring (6) and backup ring : 59±5 N⋅m
(5) to seat (7). (6±0.5 kgf⋅m, 44±3.6 Ibf⋅ft)
4. Attach O-ring (9) to plug (J) of relief valve (8).
Then, install seat (7) into relief valve (8).
5. Install relief valves (8) (2 used) to base plate (34).

: 27 mm
: 370±20 N⋅m
(38±2 kgf⋅m, 275±15 Ibf⋅ft)
W3-2-49
Sprocket
C B
D
A W105-03-07-040
W1SE-03-02-001
ZAXIS110, 120, 130, 130LCN, 125US Unit: mm (in)

A 61.00 (2.4) [51.00 (2.01)]

B 87.35 (3.44) 82.35 (3.24) Build up and
C 122.00 (4.8) 117.00 (4.61) finishing
C’ PCD115.85 (4.56) -
D 171. 45 (6.75) -
NOTE: Valve in [ ] is just for reference.
ZAXIS135US, 135UR Unit: mm (in)

A 61.00 (2.4) [51.00 (2.01)]

B 73.85 (2.91) 68.85 (2.71) Build up and
C 108.50 (4.27) 103.50 (4.08) finishing
C’ PCD102.35 (4.00) -
D 171. 45 (6.75) -
ZAXIS110M Unit: mm (in)

A 70.00 (2.76) [60.00 (2.36)]

B 110.3 (4.34) 105.3 (4.15) Build up and
C 149.7 (5.89) 144.7 (5.70) finishing
C’ PCD142.8 (5.62) -
D 190.0 (7.48) -
W3-2-50
Shoe
Travel Motor
ZAXIS110, 120, 130, 130LCN, 125US, 135US,
135UR:
1. End play between plunger and shoe.

ε
Standard Allowable Limit Plunger
0 0.2 mm (0.008 in)
ε ≤ 0.2 mm (0.008 in) W105-02-06-130
D
2. The clearance between plunger and rotor bore.
0 0.04 mm (0.0016 in)
D-d ≤ 0.04 mm (0.0016 in)
W105-02-06-134
Plunger Assembly
Rotor
W105-02-06-135
Shoe
3. Shoe thickness
5.5 mm (0.22 in) 5.3 mm (0.21 in)
Plunger
W105-02-06-130
W3-2-51
Parking Brake
ZAXIS110, 120, 130, 130LCN, 125US, 135US,
135UR:
B D
C W176-03-02-014
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Friction plate Thickness 2.4 (0.0945) 2.35 (0.0925)
(Overall height)
B Disc spring 6.4 (0.252)
6.5 (0.256)
C Piston Thickness* 40.2 (1.58) −

D Plate Thickness 1.4 (0.055) 1.35 (0.053)
No wearing on the piston because it dues not slide.
Remarks
ZAXIS110M:
W165-03-02-008
Unit: mm (in)
Allowable Limit
Part Name Standard Remedy
(Thickness)
Replace the deformed or damaged
A Spring Free Length :36.2 -
spring.
Replace if scratch depth is 0.02 mm or
B Piston Thickness* :45.7 45.68
more, or surface is capped.
Thickness :3.2 Replace if slide surface is deeply
C Plate - scratched or friction or friction material
is separated.
NOTE: *The piston thickness is shown as the
distance from the contact point of the disc
spring to the contact point of the plate.
W3-2-52
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal

1. Attach tags to all hoses connected to the center

joint for reassembly.
Disconnect all hoses from the center joint. Put a
cap on all disconnected ends.
: 17 mm, 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm, 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft)
: 27 mm, 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
ZAXIS135UR only:
: 22 mm, 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
2. Remove mountings bolts (1) to remove stopper

plate (2) from the center joint.
: 19 mm, 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
(ZAXIS110, 110M, 120, 130, 130LC)
: 19 N⋅m, 110 N⋅m (11.2 kgf⋅m, 81 lbf⋅ft)
(ZAXIS125US, 135US)
: 19 mm, 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
(ZAXIS135UR)
3. Install eye bolt to the center joint to lift the center
joint with a wire rope.
CAUTION: Center joint weight:
19 kg (42 lb) (ZAXIS110, 110M, 120, 130,
130LCN, 125US, 135US)
31 kg (68 lb) (ZAXIS135UR)
4. Remove center joint mounting bolts (3). Then, 1

remove the center joint while holding the center
joint by a crane.
: 17 mm 2
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) Front Side
Installation
NOTE: Refer to “Removal” section above for
W102-03-03-001
wrench sizes and tightening torque.
3
1. Install the center joint using mounting bolts (3).
2. Install stopper plate (2) to the center joint with
mounting bolts (1).
3. Connect all hoses to the center joint.
IMPORTANT: After completion, start engine and
check the component for any oil
leaks.
Front Side W190-03-03-001
W3-3-1
(Blank)
W3-3-2
DISASSEMBLE CENTER JOINT
(ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US)
3
7
10
11
12
W175-03-03-001
1 - Plug (With Ball) 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-3
ZAXIS135UR
13 1
7
3
6
8
10
11
12
W196-03-03-001
1- Plug (With Ball) 5- Bushing 9 - O-Ring 12 - Bolt (4 Used)

2- Spindle 6- Oil Seal (8 Used) 10 - Retaining Ring 13 - Plug (2 Used)
3- Dust Seal 7- Body 11 - Cover
4- O-Ring 8- Ring
W3-3-4
Disassemble Center Joint
before starting the disassembly work.
CAUTION: Center joint weight:

19 kg (42 lb) (ZAXIS110, 110M, 120, 130,
130LCN, 125US, 135US)
1. Remove mounting bolt (12) from cover (11)

diagonally. Using eyebolts M10 (pitch 1.5 mm,
length 18 mm: ST 0001), hoist the center joint,
then secure it on a work bench (ST 5061).
ST 1020
IMPORTANT: Put a matching mark on body (7) and ST 1033

spindle (2).
2. Remove bolts (12) to remove cover (11) from
body (7).
: 17 mm
3. Remove O-ring (9), retaining ring (10) and ring (8)

from body (7).
4. Attach the special tools (ST 1033, ST 1020) to

body (7) with bolts (12) (2 used) on cover (11).
: 17 mm W506-03-03-002
IMPORTANT: Take care not to damage the sliding

surface of the spindle (2) seal.
5. Remove spindle (2) from body (7).
IMPORTANT: For easy removal, two pins can be

used to pry out oil seals (6). Take
care not to damage the seal groove
with the pins.
6. Remove oil seals (6) (6 used) (ZAXIS135UR only:
8 used), dust seal (3) and O-ring (4) from body
(7).
W105-03-03-015
IMPORTANT: While welding, be sure to cover the

seal surface to prevent it from being
spattered.
7. When replacing bushing (5), build-up weld at 4

places in its inner diameter with welding rod,
shrink bushing (5) to pull it out.
W3-3-5
(Blank)
W3-3-6
ASSEMBLE CENTER JOINT
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
7 6
8
10
9
11
12
W175-03-03-002
1 - Plug (With Ball) 4 - O-Ring 7 - Body 10 - Retaining Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - O-Ring 12 - Bolt (4 Used)
W3-3-7
ZAXIS135UR
13
7 6
8 10
9
11
12
W196-03-03-002
1- Plug (With Ball) 5- Bushing 9 - Ring 12 - Bolt (4 Used)

2- Spindle 6- Oil Seal (8 Used) 10 - Retaining Ring 13 - Plug (2 Used)
3- Dust Seal 7- Body 11 - Cover
4- O-Ring 8- Ring
W3-3-8
Assemble Center Joint
IMPORTANT: If bushing (5) is removed, be sure to

reinstall bushing (5) first. Refer to
W3-3-10.
1. Install O-ring (4) and dust seal (3) into body (7).
2. Install oil seals (6) (6 used) (ZAXIS135UR only: 8

used) into body (7).
IMPORTANT: Just before inserting the spindle,

apply molybdenum disulphide to
bushing (5) and coat the seal portion
with grease. Be sure not to damage
them when installing.
3. Place spindle (2) on a work bench. Mount body
(7) on spindle (2) with their matching mark aligned,
which is put before disassembling.
0.1 mm
IMPORTANT: Clearance between body (7) and
spindle (2) is approximately 0.1 mm
(0.004 in), so spindle (2) must be
inserted along axis straight and
slowly.
4. Tap body (7) with a plastic hammer until it touches
the edge of spindle (2).
IMPORTANT: Be sure to install ring (8) with the

chamfered side facing the spindle. W105-03-03-024
5. Install ring (8) and O-ring (9) to body (7).
6. Install retaining ring (10) to spindle (2).
7. Install cover (11) with bolts (12) (4 used).

: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-3-9
When replacing the body or the spindle with new one,
the following procedures are required.
ST 2770
Replacing Body (7)

7
Press bushing (5) into body (7).
1. Clean body (7) and bushing (5). 5
2. Press bushing (5) into body (7), using pressing

tool.
Pressing force: 0.5 to 1.5 t (1100 to 3300 lbf)
Pressing tool: ST 2770
ZAXIS110, 110-E, 120,

120-E, 125US, 135US ZAXIS135UR W105-03-03-029
Replacing Spindle (2) 1

D 1 D 1
1. Clean spindle (2). 2
2. Tap plugs (1) into spindle (2) using special tools

(ST 2559).
3. Drive the balls of plug (1) so that the top of each 2

ball is 0.4 mm (0.016 in) (ZAXIS135UR: 27 mm
(1.06 in)) or more lower than the respective
sleeve edge, as illustrated in Detail D.
Special tool: ST 2559
4. (ZAXIS135UR only)
Install plugs (13) (2 used).
: 6 mm (R1/4)
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W136-03-03-031
W187-03-03-001
ST 2559
0.4 mm
Sleeve
or more
(ZAXIS
135UR:
27 mm
or more)
Ball
W157-03-03-004 Detail D
W135-03-03-001
W3-3-10
Item Allowable limit (basis for judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Scored, abnormal wear Replace
3. Uneven wear (wear range is within 180°) Replace
Wear range is within
one half
Bushing
T157-01-01-040
Sliding surface with Scored or serious damage Replace

sealed part
1) Scored or abnormal wear of more than 0.1 Replace
Sliding surface of
mm (0.004 in)
body and spindle,
2) Scored less than 0.1 mm (0.004 in) deep Repair and finish
except sealed part
Body ⋅ spindle with oil stone
1) Wear more than 0.5 mm (0.02 in) deep Replace
And abnormal wear
Sliding surface
2) Wear less than 0.5 mm (0.02 in) deep Repair and finish
with ring
3) Scored or abnormal worn less than 0.5 Repair and finish
mm (0.02 in) deep and able to be repaired.
1) Wear more than 0.5 mm (0.02 in) Replace
Sliding surface 2) Wear less than 0.5 mm (0.02 in) Repair and finish
Cover with ring 3) Scored or abnormal worn less than 0.5 Repair and finish
mm (0.02 in) and able to be repaired.
W3-3-11
(Blank)
W3-3-12
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
Before removing and adjusting the track adjuster, the
tracks and the front idler must be removed first. For
removal of the tracks and front idler, refer to their Re-
moval / Installation sections.
In this section, the procedure starts on the premise that
the tracks and front idler have already been removed.
Removal
CAUTION: Track adjuster weight:
ZAXIS110: 51 kg (112 lb)
ZAXIS110M: 92 kg (230 lb)
ZAXIS120, 130, 130LCN, 125US:
55 kg (121 lb)
ZAXIS135US, 135UR: 62 kg (137 lb)
CAUTION: The front idler may jump out of

position due to strong spring force when the
tracks is disconnected. Especially, a strong
spring force is always applied to the threaded
part of the rod. If the rod and/or the threads
are damaged, metal fragments may fly off
2
when the track is disconnected.
Take necessary precautions to prevent any
1
personal injury from occurring.
1. After removing the front idler with yoke, remove

track adjuster (1) from track frame (2) by prying it
out with a pry bar.
W157-03-04-003
3 4
Installation
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2).
Check that the end face of track adjuster (1)
comes into contact with the face of plate (4).
W157-03-04-002
2 3
W157-03-04-001
W3-4-1
DISASSEMBLE TRACK ADJUSTER
1
2
4
5
6
7
8
9
3
10
11
12
13
14
15
18
17
W178-03-04-001
16
1- Holder 6- Piston Rod 11 - Cylinder 15 - Valve

2- Dust Seal 7- Wear Ring 12 - O-Ring 16 - Nut
3- Socket Bolt (3 Used) 8- U-Ring 13 - Spacer 17 - Washer
4- Flange 9- Retaining Ring 14 - Plug 18 - Spring
5- Wear Ring 10 - Rod
W3-4-2
Disassemble Track Adjuster
• Be sure to thoroughly read “Precautions for Dis-
assembly and Assembly” on page W1-1-1 before
starting the disassembly work.
CAUTION: Be sure to use special tool (ST

4920) for assembly / disassembly of the track
adjuster.
The spring force is extremly large, so disas-
sembly and assembly work must be carried
out carefully. In addition, it is necessary to
inspect the special tool for any damage
thoroughly to ensure safety.
CAUTION: Special tool weight:

225 kg (500 lb)
1. Place an oil jack (30 t) between the base and Holder

holder.
Base
W105-03-04-006
2. Loosen the nuts from the special tool to remove

plate (ST 4036). Plate (ST 4036)
: 46 mm
W105-03-04-007

ZAXIS110: 51 kg (112 lb)
ZAXIS120, 130, 130LCN, 125US:
55 kg (121 lb)
ZAXIS135US, 135UR: 62 kg (137 lb)
3. Attach a wire rope to the track adjuster as illus-

trated. Lift it up by crane and put it on the holder
of special tool.
W105-03-04-009
W3-4-3
10
14
15
17
16 W178-03-04-001
W3-4-4
4. Install plate (ST 4036) on the track adjuster and
secure them together.
Plate (ST 4036)
W105-03-04-011
5. Operate the oil jack.
W105-03-04-013
6. Tighten the nuts of the special tool to secure the

track adjuster.
Operate the oil jack to compress the track ad-
juster approximately 10 mm (0.4 in) until a clear-
ance is observed between washer (17) and nut
(16).
: 46 mm
W105-03-04-012
7. Remove plug (14) from nut (16). Remove nut (16) 16 10 14

and valve (15) from rod (10).
: 5 mm
: 65 mm
: 24 mm
W105-03-04-014
W3-4-5
3
10
11
13
18
17
W178-03-04-001
W3-4-6
8. Lower the oil jack slowly.
W105-03-04-015
9. Remove the nuts of the special tool to remove

plate (ST 4036) and washer (17). Plate (ST 4036)
17
CAUTION: Spring assembly weight:
ZAXIS110: 47 kg (104 lb)
ZAXIS120, 130, 130LCN, 125US: 51 kg (112 lb)
ZAXIS135US, 135UR: 58 kg (128 lb) W105-03-04-016
10. Install eyebolt (M16, Pitch 1.5) to rod (10) and lift
Eyebolt
the track adjuster up by crane to remove it from
the special tool.
CAUTION: Spring weight:

ZAXIS110: 25 kg (55 lb)
ZAXIS120, 130, 130LCN: 125US: 28 kg (62 lb)
11. After removing the eyebolt, remove spring (18) W105-03-04-017
from rod (10).
12. Remove spacer (13) from rod (10).
13. Remove socket bolts (3) (3 used) and then move

flange (4) in the direction of the holder.
: 6 mm
14. Pull out the piston rod (6) assembly from cylinder
(11).
15. Pull out holder (1) from the piston rod (6) assem-
bly with a press.
: 25 mm
W3-4-7
2
4
5
6
7
8
9
10
11
12
W178-03-04-001
W3-4-8
16. Remove flange (4) from piston rod (6). Remove
dust seal (2) and wear ring (5) from flange (4).
6
17. Remove rod (10) and O-ring (12) from cylinder
(11).
8
18. Remove retaining ring (9), U-ring (8) and wear
ring (7) from piston rod (6). 9
W105-03-04-025
W3-4-9
ASSEMBLE TRACK ADJUSTER
15 14 17 10 13 12 11 9 7 6 A 3 4 1
W178-03-04-002
16 18 B 8 5 2
354 mm (13.94″)(Free Length 425 mm(16.73″))

(ZAXIS110)
373 mm (14.69″)(Free Length 455 mm(17.91″))
(ZAXIS110M)
383.5 mm (15.10″)(Free Length 461 mm(18.15″))
(ZAXIS120, 130, 130LCN, 125US)
407.0 mm(16.02″)(Free Length 478 mm(18.82″))
(ZAXIS135US, 135UR)
506.5 mm (19.94″)(ZAXIS110)
558 mm (21.97″)(ZAXIS110M)
542.0 mm (21.34″)(ZAXIS120,125US)
562.5 mm (22.15″)(ZAXIS135US, 135UR)
1- Holder 6- Piston Rod 11 - Cylinder 15 - Valve

2- Dust Seal 7- Wear Ring 12 - O-Ring 16 - Nut
3- Socket Bolt (3 Used) 8- U-Ring 13 - Spacer 17 - Washer
4- Flange 9- Retaining Ring 14 - Plug 18 - Spring
5- Wear Ring 10 - Rod
W3-4-10
Assemble Track Adjuster
1. Clean all parts. Then install dust seal (2) and wear
ring (5) to flange (4) after applying grease on
them. 6
IMPORTANT: Fill (A) portion of flange (4) full with

grease.
8
2. Install flange (4) to piston rod (6).
9
3. Apply grease into holder (1) and press it into pis-
ton rod (6) with a press with special tool (ST
7228). 7
4. Install wear ring (7), U-ring (8), retaining ring (9) W105-03-04-025
onto piston rod (6).
11
5. Apply grease to O-ring (12) and install it on cyl- 8
inder (11). Install rod (10) into cylinder (11). 7
6
IMPORTANT: Fill (B) portion of cylinder (11) with
grease. Push the piston rod (6) as-
sembly into the cylinder to com-
pletely bleed air from (B) portion and
rod (10).
W105-03-04-021
6. Apply grease to U-ring (8) and wear ring (7). In-
stall the piston rod (6) assembly into cylinder (11).
Eyebolt 10
7. Tighten flange (4) with socket bolts (3) (3 used).
: 6 mm, 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8. Install spacer (13) onto rod (10).
CAUTION: Spring weight:

ZAXIS110: 25 kg (55 lb)
ZAXIS120, 130, 130LCN: 125US: 28 kg (62 lb)
W105-03-04-017
9. Install spring (18) onto rod (10).
CAUTION: Spring assembly weight:

ZAXIS110: 47 kg (104 lb)
ZAXIS120, 130, 130LCN: 125US: 51 kg (112 lb)
ZAXIS135US, 135UR: 58 kg (121 lb)
10. Install eyebolt (M16, pitch 1.5 mm) to rod (10). Lift
the spring assembly up by crane and put it on the
special tool.
W3-4-11
14 17 10
W178-03-04-002
16 18
354 mm (13.94″)(Free Length 425 mm(16.73″))

(ZAXIS110)
373 mm (14.69″)(Free Length 455 mm(17.91″))
(ZAXIS110M)
383.5 mm (15.10″)(Free Length 461 mm(18.15″))
(ZAXIS120, 130, 130LCN, 125US)
407.0 mm(16.02″)(Free Length 478 mm(18.82″))
(ZAXIS135US, 135UR)
506.6 mm (19.94″)(ZAXIS110)
558 mm (21.97″)(ZAXIS110M)
542.0 mm (21.34″)(ZAXIS120,125US)
562.5 mm (22.15″)(ZAXIS135US, 135UR)
W3-4-12
11. Remove the eyebolt from rod (10). Put washer
(17) on spring (18) and install plate (ST 4036).
Plate (ST 4036)
17
18
W105-03-04-016
12. Tighten the nuts of the special tool to secure the

spring assembly.
: 46 mm
W105-03-04-012
13. Operate the oil jack to compress spring (18) to

specified length. 18
Specified Length:
354 mm (13.94 in) (ZAXIS110)
373 mm (14.69 in) (ZAXIS110M)
383.5 mm (15.10 in)
(ZAXIS120, 130, 130LCN, 125US)
407.0 mm (16.02 in) (ZAXIS135US, 135UR)
W105-03-04-026
16 10 14
14. Install nut (16) to rod (10), and then install plug
(14).
: 65 mm
: 5 mm
: 15.0 N⋅m (1.5 kgf⋅m, 10.8 lbf⋅ft)
W105-03-04-014L
W3-4-13
15 10
W178-03-04-002
354 mm (13.94″)(Free Length 425 mm(16.73″))

(ZAXIS110)
373 mm (14.69″)(Free Length 455 mm(17.91″))
(ZAXIS110M)
383.5 mm (15.10″)(Free Length 461 mm(18.15″))
(ZAXIS120, 130, 130LCN, 125US)
407.0 mm(16.02″)(Free Length 478 mm(18.82″))
(ZAXIS135US, 135UR)
506.7 mm (19.94″)(ZAXIS110)
558 mm (21.97″)(ZAXIS110M)
542.0 mm (21.34″)(ZAXIS120,125US)
562.5 mm (22.15″)(ZAXIS135US, 135UR)
W3-4-14
15. Install valve (15) to rod (10).
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
16. Lower the oil jack.
W105-03-04-013
17. Remove the nuts of the special tool and plate (ST
4036) Plate (ST 4036)
: 46 mm
W105-03-04-011

ZAXIS110: 51 kg (112 lb)
ZAXIS120, 130, 130LCN: 125US: 55kg (121 lb)
ZAXIS135US, 135UR: 62 kg (137 lb)
18. Attach a wire rope to the track adjuster as illus-

trated. Lift it up by hoist and remove it from the
special tool.
W105-03-04-009
IMPORTANT: If only the spring assembly is to be

transported, be sure to use a special
tool, such as the one illustrated, to
carry the spring assembly safely.
W105-03-04-028
W3-4-15
(Blank)
W3-4-16
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
Before removing the front idler, the tracks must be
removed first. For removal of the tracks, refer to
“Remove and Install Tracks” section.
In this section, the procedure starts on the premise
that the tracks has already been removed.
CAUTION: Front idler weight:

ZAXIS110/120/130/130LCN/
125US/135US/135UR: 82 kg (180 lb)
ZAXIS110M: 116 kg (2561 kg) W110-03-05-001

tracks is disconnected. Especially, a strong
spring force is always applied to the threaded
part of the rod. If the rod and/or the threads
are damaged, metal fragments may fly when 3
the track is disconnected. 1
Take necessary precautions to prevent any
personal injury from occurring.
1. Pry the front idler with a pry bar to move it out from
the track frame (3) with yoke (2).
2
2. Attach the bearing (1) portion and yoke (2) portion
W178-03-05-001
with sling as illustrated and remove the front idler
assembly from track frame (3).
3. If it is necessary to remain the front idler for a time,

be sure to place it on wooden blocks as shown to
keep it stable.
Installation W178-03-05-002
1. Install the front idler according to the reversed

procedures of removal and pay attention to the
following precautions when installation is carried
out. 3
• Clean track frame (3) and the sliding surface of
bearing (1) and apply grease on them.
1
W178-03-05-004
W3-5-1
DISASSEMBLE FRONT IDLER
2
1
3
4
6
7
8
6
4
3
2
1
10
W178-03-05-003
1 - Bearing (2 Used) 4 - Floating Seal (2 Used) 7 - Idler 9 - Yoke

2 - Pin (2 Used) 5 - Axle 8 - Plug (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 6 - Bushing (2 Used)
W3-5-2
Disassemble Front Idler
• Be sure to thoroughly read “Precautions for IMPORTANT: For handling of floating seal (4),
Disassembly and Assembly” on page W1-1-1 refer to the section “Precautions for
before starting the disassembly work. Floating Seal Handling” on page
W1-1-4.
1. Loosen bolts (10) (4 used) to remove yoke (9). 4. Remove floating seal (4) from bearing (1) and
Remove plugs (8) (2 used) from bearing (1) to idler (7).
drain oil into a container.
1
: 24 mm
: 6 mm
4
2. Remove pin (2) from one of bearing (1).
7
: 16 mm
CAUTION: Idler etc. weight:

ZAXIS110/120/130/130LCN/ 4
125US/135US/135UR: 68 kg (150 lb)
ZAXIS110M: 95 kg (215 lb) 3
5
3. Push out axle (5) from bearing (1) with a press.
Bearing (1) in opposite side shall be pushed out
from idler (7) with its axle (5). Remove O-ring (3)
from axle (5). 1
1 5
W105-03-05-009
W105-03-05-008
W3-5-3
3
2
1
W178-03-05-003
W3-5-4
5. Withdraw pin (2) from the bearing (1), and remove
axle (5) with a press.
3
1
W105-03-05-010
6. When replacing bushing (6), special tool can be

used to push it out with a press. Special Tool
Special Tool:
ZAXIS110/120/130/130LCN/
125US/135US/135UR: ST 1955
ZAXIS110M: ST 1425
6
W105-03-05-011
W3-5-5
ASSEMBLE FRONT IDLER
1 2 4 5 6
10
8 9
3
7
W157-03-05-003
1 - Bearing (2 Used) 4 - Floating Seal (2 Used) 7 - Idler 9 - Yoke

2 - Pin (2 Used) 5 - Axle 8 - Plug (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 6 - Bushing (2 Used)
W3-5-6
Assemble Front Idler
1. Install bushing (6) (2 used) into idler (7) from both 2
ends.
1
2. Install O-ring (3) (1 used) onto axle (5). Aligning 5
the pin holes, install axle (5) into bearing (1) at
one side and secure it using pin (2). While doing
this, take care not to damage O-ring (3).
3. Install floating seal (4) (one pair) into idler (7) and 3 W105-03-05-014
into bearing (1).
IMPORTANT: For handling of floating seal (4), 7

refer to the section “Precautions for 4 1
Floating Seal Handling” on page
W1-1-4.
4. Insert axle (5) into idler (7) from the side installed
with floating seal. Install O-ring (3) onto axle (5).
5. Install the other floating seal (4) into idler (7) and 5
into bearing (1).
6. Install bearing (1) onto axle (5), aligning the pin W157-03-05-006
holes of axle (5). Secure them using pin (2).
7. Add engine oil via plug (8) hole on bearing (1).

Apply sealant (LOCTITE # 503 or equivalent) to
plug (8). Tighten plug (8). 7
: 6 mm 1 4 3
1
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
Engine oil: API CD Class SAE 30
Quantity:
ZAXIS110/120/130/130LCN/
125US/135US/135UR: 235 mL
5
ZAXIS110M: 265 mL
W157-03-05-005
8. Install yoke (9) and tighten bolts (10).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
W3-5-7
Front Idler
C D
A
B
W157-03-05-001
Unit: mm (in)
ZAXIS110/120/130/130LCN/125US/
135US/135UR ZAXIS110M
Standard Allowable Limit Standard Allowable Limit Remedy
A 68 (2.68) [52 (2.05)] 84 (3.31) [66 (2.60)]
B 135 (5.32) − 159 (6.26) −

Build-up weld
C 454 (17.87) 442 (17.40) 500 (19.69) 482 (18.98)
and finishing
D 489 (19.25) − 538 (21.18) −
E 17.5 (0.69) 23.5 (0.93) 19 (0.75) 25 (0.98)
Axle and Bushing Unit: mm (in)

ZAXIS110/120/130/130LCN
/125US/135US/135UR ZAXIS110M
Axle Outside Dia. 65.0 (2.56) [64.2 (2.53)] 75.0 (2.95) [74.2 (2.92)]
Inside Dia. 65.0 (2.56) [66 (2.60)] 75.0 (2.95) [76 (2.992)] Replace
Bushing
Flange
2 (0.08) [1.2 (0.05)] 2 (0.08) [1.2 (0.05)]
Thickness
NOTE: Values in [ ] are just for reference.
W3-5-8
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Do not loosen valve (1) quickly or
loosen it too much as high-pressure grease in
the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and face
away from valve (1). Never loosen grease
fitting (2).
W105-03-06-001
IMPORTANT: When gravel or mud is packed 1

between the sprockets and tracks,
remove it before loosening valve (1).
1. Loosen valve (1) of the track adjuster to drain

grease.
: 24 mm
Grease outlet
M104-07-119
3
CAUTION: Use a non-skid cloth between
track frame (5) and an oil jack to prevent
slipping.
2. Jack up tracks (3) high enough to permit upper

roller (4) removal.
Oil Jack 5 4
W105-03-06-002
3. Insert wooden blocks between tracks (3) and track

frame (5).
W105-03-06-003
W3-6-1
4. Loosen mounting bolts (6) of upper roller (4).
ZAXIS110/120/130/130LCN/125US/
135US/135UR:
: 19 mm
ZAXIS110M:
4
: 24 mm
W157-03-06-001
CAUTION: Upper roller weight:

ZAXIS110/120/130/130LCN/125US/
135US/135UR: 12 kg (26 lb)
4
5. Remove upper roller (4) from track frame (5).
Installation
1. ZAXIS110/120/130/130LCN/125US/
5
135US/135UR: W105-03-06-005
Install upper roller (4) onto track frame (5) with
bolts (6).
: 19 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
ZAXIS110M:
: 24 mm 4
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
6
5
2. Remove the wooden blocks and oil jack. W157-03-06-001
Oil Jack
W105-03-06-002
W3-6-2
3. Install valve (1) of the track adjuster. Jack up track
(3) on the side being adjusted a sag, and turn it
slightly towards the reversed direction. Fill grease 1
from grease fitting (2) to make the track being in
tension.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Track sag specifications (A): 2

ZAXIS110/120/130/130LCN/125US/
135US/135UR: 250 to 280 mm (9.84 to 11.02 in) Grease Outlet
ZAXIS110M: 285 to 320 mm (11.22 to 11.60 in)
M104-07-119
CAUTION: The machine jacked up must be

securely supported with wooden blocks.
W157-03-06-002
NOTE: Replace the upper roller as an assembly.

7
4. Add engine oil via plug (8) hole on cover (7).
Tighten plug (8).
Engine oil: API CD class, SAE 30
Quantity:
ZAXIS110/120/130/130LCN/125US/135US: 48 ml 8
ZAXIS110M: 70 mL
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15.0 lbf⋅ft)
Apply LOCTITE # 503 or equivalent to the plug.
W158-03-06-001
W3-6-3
(Blank)
W3-6-4
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove mounting bolts (1) of lower roller (5) after 5
removing the track guard.
ZAXIS110/120/130/130LCN/125US/
135US/135UR: 1
: 24 mm
ZAXIS110M:
: 27 mm
W105-03-06-008
CAUTION: Securely support the raised track 90° to 110°

with wooden blocks.
2. Raise one side of the track frame high enough to

remove the lower roller.
2 M104-07-067

loosen it too much as high-pressure grease in
the adjusting cylinder may spurt out. Loosen
carefully, keeping body parts and face away
from valve (3).
Never loosen grease fitting (4).
W105-03-06-001
IMPORTANT: It’s enough to turn valve (3) by only

1.5 turns. Do not loosen it over 1.5 3
turns.
3. Loosen valve (3) of the track adjuster to maintain
track in such tension that lower roller (5) can be
removed.
: 24 mm
4
Grease Outlet
W178-03-06-001
W3-6-5
CAUTION: Lower roller weight:

ZAXIS110/120/130/130LCN/125US/
135US/135UR: 21 kg (46 lb)
4. Remove lower roller (5) by fork lift, and etc.
W105-03-06-010
Installation
1. Place lower rollers (5) under the tracks (2) as
illustrated by fork lift, etc.
5
W105-03-06-011
2. Lower track frame (2) enough to gain a little

clearance between collar (6) and track frame (2).
6 W105-03-06-012
3. Align the bolt holes and tighten bolt (1).

ZAXIS110/120/130/130LCN/125US/
135US/135UR:
: 24 mm 1
: 300 N⋅m (31 kgf⋅m, 225 lbf⋅ft)
ZAXIS110M:
: 27 mm
: 460 N⋅m (47 kgf⋅m, 340 lbf⋅ft)
W105-03-06-008
W3-6-6
4. Install valve (3) of the track adjuster. Jack up the
track on the side being adjusted a sag, and turn it
slightly towards the reversed direction. Fill grease
from grease fitting (4) to make the track be in 3
tension.
: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Track sag specification (A):

ZAXIS110/120/130/130LCN/125US/ 4
135US/135UR: Grease Outlet
250 to 280 mm (9.84 to 11.02 in)
W178-03-06-001
ZAXIS110M:
285 to 320 mm (11.22 to 12.60 in)
CAUTION: Securely support the raised track

using wooden blocks.
W157-03-06-002
W3-6-7
DISASSEMBLE LOWER ROLLER
3
2
4 1
5
6
5
4
3
2
1
W157-03-06-004
1 - Plug (2 Used) 3 - Pin (2 Used) 5 - Floating Seal (2 Used) 7 - Roller

2 - Collar (2 Used) 4 - O-Ring (2 Used) 6 - Bushing (2 Used) 8 - Axle
W3-6-8
Disassemble Lower Roller
before starting the disassembly work.
1. Remove plug (1) from collars (2), and drain oil.

Push out pin (3) from collar (2) on both side.
: 6 mm
ZAXIS110/120/130/130LCN/125US/
135US/135UR:
: 8 mm
ZAXIS110M:
: 14 mm
2 5 7 5
2. Push out axle (8) with a press.

Remove collar (2) of one side from axle (8).
3. Remove axle (8) from roller (7). 5

Remove O-ring (4) from axle (8). 2
IMPORTANT: For handling of floating seal (5),

refer to the section Precautions For
Floating Seal Handling on page 8
W1-1-4. W105-03-06-026
4. Remove floating seal (5) from roller (7) and collar 4 2
(2).
5. Press axle (8) with a press to remove collar (2) of 8

the other side and O-ring (4) from axle (8).
W105-03-06-027
Special Tool
6. In case of replacing bushing (6), push out bushing

(6) with a with using special tool.
6
Special Tool
ZAXIS110/120/130/130LCN/125US/
135US/135UR: 1928
ZAXIS110M: 1955
W105-03-06-028
W3-6-9
ASSEMBLE LOWER ROLLER
2 7 6 5 4 3 1
W105-03-06-023
1 - Plug (2 Used) 3 - Pin (2 Used) 5 - Floating Seal (2 Used) 7 - Roller

2 - Collar (2 Used) 4 - O-Ring (2 Used) 6 - Bushing (2 Used) 8 - Axle
W3-6-10
Assemble Lower Roller
1. Install bushing (6) (2 used) onto roller (7) with a
press. Take care not to dent the flange surface of
bushing (6).
Apply a coat of grease to O-ring (4) and install it
onto axle (8).
3
2. Install collar (2) of one side onto axle (8), aligning
the pin holes. 8
Secure them using pin (3). Take care not to
damage O-ring (4).
IMPORTANT: Coat grease on O-ring of floating

seal and then install it. 4
2
When installing O-ring, take care not W105-03-06-031
to twist it and install it in the correct 7 5

angle.
For handling of the floating seal,
refer to the section “Precautions for
floating seal handling” on the page
W1-1-4. 5 2
3. Install floating seal (5) to roller (7) and to collar

(2).
W157-03-06-008
2 5 8 7
4. Insert axle (8) into roller (7). Install O-ring (4). The
other collar (2) shall be assembled in the same
4
way. Secure them using pin (3).
W157-03-06-009
3 7
1
5. Add engine oil via the plug (1) hole on collar (2).
Tighten plug (1).
Apply LOCTITE # 503 or equivalent to the plug.
Engine oil: API CD class, SAE 30
Quantity:
2
ZAXIS110/120/130/130LCN/125US/
135US/135UR: 200 mL W105-03-06-024
ZAXIS110M: 260 mL
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W3-6-11
Upper Roller
W105-03-06-032
Unit: mm (in)
ZAXIS110/120/130/130LCN/
ZAXIS110M
ZAXIS125US/135US/135UR
A 72 (2.83) – 84 (3.31) –
B 120 (4.72) – 150 (5.91) – Replace

C 100 (3.94) 90 (3.54) 120 (4.72) [110 (4.33)]
W3-6-12
Lower Roller
W157-03-06-003
Unit: mm (in)
ZAXIS110/120/130/130LCN/
ZAXIS110M
A 146 (5.75) [165.4 (6.51)] 169.0 (6.65) [193.5 (7.62)]
B 186 (7.32) – 218.0 (8.58) – Build-up weld
C 20.5 (0.81) [10.3 (0.41)] 24.5 (0.97) [12.3 (0.48)] and finishing
D 130 (5.12) 112 (4.41) 150.0 (5.90) 132 (5.20)
Axle and Bushing

Unit: mm (in)
ZAXIS110/120/130/130LCN/
ZAXIS110M
Axle Outside Dia. 50 (1.97) [49.2 (1.94)] 65 (2.56) [64.2 (2.53)]
Inside Dia. 50 (1.97) [51 (2.01)] 65 (2.56) [66.0 (2.60)]
Replace
Bushing Flange
2 (0.079) [1.2 (0.05)] 2 (0.079) [1.2 (0.047)]
Thickness
W3-6-13
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal 1
2
loosen too much since high-pressure grease
in the adjusting cylinder may spurt out.
Loosen carefully, keeping body parts and
face away from valve (4). Never loosen
grease fitting (2).
3
Wooden Block
W105-03-07-006
1. Rotate the tracks so that master pin (3) is

positioned over front idler (2). Put a wooden block
under track shoes (1), as shown.
W105-03-07-001
2. Loosen the track tension.

: 24 mm 4
NOTE: To loosen the track tension, slowly turn

valve (4) counterclockwise one turn,
grease will escape from the grease outlet.
W105-03-07-002
Grease Outlet M104-07-119
W3-7-1
3. Remove retaining ring (6), which is used to
prevent the master pin from coming off. 7
NOTE: If retaining ring (6) interferes with master 3

link (7), drive master pin (3) in to make
clearance between retaining ring (6) and
master pin (3), before attempting to remove
retaining ring (6). 6

tracks is disconnected.
Especially, the strong spring force is always W105-03-07-009
applied to the thread portion of the rod. If the

rod and/or thread are damaged, metal
fragments may fly when the tracks is
disconnected. Take necessary precautions to
prevent any personal injury from occurring.
IMPORTANT: Master pin is directional. Be sure to

strike the pin in or pull it out in
correct direction.
4. Remove master pin (3) by using special tool (ST
1970). W105-03-07-005
Corner
Direction for Direction for
installing the removing the
master pin. master pin.
Retaining Ring
Track Link 3
Master Link
W105-03-07-010
ST 1970
W105-03-07-008
W3-7-2
5. Rotate the upperstructure 90° degrees toward the
side of the track to be removed, perpendicular to
the tracks. Operate the boom and arm so that the
angle between them is 90° to 110° degrees.
Lower the boom with the bucket rolled-in to jack
up the machine as illustrated. 90° to 110°
M104-07-067
6. Slowly drive the machine in reverse until the

whole length of the track being removed comes
on the ground.
W105-03-07-011
W3-7-3
Installation
1. Jack up the machine so that sprocket can engage
with track end and put the track under the lower
roller.
Be sure to position the track in correct direction,
as illustrated. Sprocket
Idler Side Side
W105-03-07-013
2. Hoist the track and place it on sprocket (8).
W105-03-07-014
3. With the machine being jacked up, operate the
9
travel lever for the side the track being installed in
forward direction. Wind the track while rotating
travel device (9).
W105-03-07-015
4. Turn the sprocket until end of track (1) comes on 2

front idler (2).
Lower the machine and place a wooden block as
illustrated.
W105-03-07-016
Wooden Block
W3-7-4
IMPORTANT: Master pin (3) is directional. Be
Corner
sure to install it in the correct
Direction for Direction for
direction. installing the removing the
5. Install master pin (3) with a hammer and special master pin master pin
tool (ST 1970).
Retaining Ring
Track Link 3
Master Link
W105-03-07-010
ST 1970
IMPORTANT: Old retaining ring (6) cannot be

reused as it deforms easily. Replace
it with a new one.
6. Retaining ring (6) is directional. Install retaining
ring (6) into master link (7) groove with the flat
side of puller insert hole facing outward. W105-03-07-017
IMPORTANT: If any links have been removed from

the track, be sure to fill the grease
(Daphne Epones SR or equivalent)
into the clearance between the pin
and busing when reconnecting the 6
links.
Stand the bushing on a flat plate. Fill
the bushing bore with grease.
Insert the pin into the bushing while
Bushing W105-03-07-009
pushing the bushing onto the plate Seal
(so that the busing end stays on the
plate). Wipe off excess grease. Pin
Install the seal in the direction as
illustrated.
Grease
Do not Do not
Apply Apply
Grease. Grease.
W197-03-07-001
Seal
W3-7-5
7. Tighten valve (4). Apply grease to fitting (5) to
adjust track link tension.
: 24 mm 5
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Track sag specification (A):
250 to 280 mm (9.84 to 11.02 in)
Grease Outlet M104-07-119
W105-03-07-018
W157-03-06-002
W3-7-6
ZAXIS110M: • Slowly insert the pin into the bushing from above
Assemble Link while turning the pin left and right.
If any links have been removed from the track, • Confirm that grease comes out from a clearance
reconnect in accordance with the following between pin and bushing.
procedure.
Slowly insert the pin into
the bushing while turning
IMPORTANT: Do not apply grease onto dust seal the pin left and right.
Pin
at this stage (step 1)
Confirm that grease comes
IMPORTANT: Be sure install the dust seal into the out from a clearance between
link groove with the flat side of dust Bushing pin and bushing.
seal facing inward.
1. Install the dust seal into the link groove. Grease
(right link and left link)
Push the bushing on to
Link Plate the plate.
Dust Seal
W17P-03-07-002
• Slowly insert the pin into the bushing until the pin
comes in contact with the plate.
• Apply grease to the pin’s surface out of the
bushing.
W17P-03-07-001
• Lay the bushing with pin on the workbench.
• Slowly insert the pin further into the bushing,
IMPORTANT: Fully fill grease (Daphne Epones SR while turning the pin, until the bushing is centered
No.2) into a clearance between pin on the pin.
and bushing.
2. Insert the pin into the bushing in accordance with
the following procedure. 3. Apply grease onto both side of the bushing ends.
• Stand the bushing on flat plate.
• Fill grease into the bushing up to about 1/3 of 4. Apply grease onto surface of dust seal in the link
bushing height. At this time, avoid that air is mixed groove.
into grease. (right link and left link)
• Push the bushing onto the plate so that the Install right link and left link onto right and left
bushing end stays on the plate. sides of pin respectively.
W3-7-7
Link
Measure the length of four links.
• Master pin is not included in measurement.
• Measurement shall be carried out with the track in
tension.
W155-03-07-001
ZAXIS110, 120, 130, 130LCN, 125US, 135US,

135UR:
Unit: mm (in)
A 687.4 (27.06) 707.9 (27.87)

Build-up weld and finishing or replace
B 89 (3.50) 82 (3.23)
ZAXIS110M:
Unit: mm (in)
A 761.8 (29.99) 785.8 (30.94)

Build-up weld and finishing or replace
B 104 (4.09) 97 (3.82)
W3-7-8
Master Bushing
W105-03-07-023
ZAXIS110, 120, 130, 130LCN, 125US, 135US,

135UR:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 107.5 (4.23) –
B 34.1 (1.34) [37.1 (1.46)] Replace

C 50.67 (1.99) [45.67 (1.80)]
ZAXIS110M:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 129.2 (5.09) –
B 38.7 (1.52) [41.7 (1.64)] Replace

C 59 (2.32) [54 (2.13)]
W3-7-9
Master Pin
W105-03-07-021
ZAXIS110, 120, 130, 130LCN, 125US, 135US,

135UR:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 163.9 (6.45) –
Replace
B 33.75 (1.33) [30.75 (1.21)]
ZAXIS110M:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 203 (7.99) –
Replace
B 38.4 (1.51) [35.4 (1.39)]
W3-7-10
Pin
A
W142-03-07-004
ZAXIS110, 120, 130, 130LCN, 125US, 135US,

135UR:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 175 (6.89) –
Replace
B 33.5 (1.32) [30.5 (1.20)]
ZAXIS110M:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 212 (8.35) –
Replace
B 38 (1.496) [35 (1.38)]
W3-7-11
Bushing
W105-03-07-023
ZAXIS110, 120, 130, 130LCN, 125US, 135US,

135UR:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 117.4 (4.62) –
B 34.1 (1.34) [35.1 (1.38)] Replace
C 50.67 (1.99) [45.67 (1.80)]
ZAXIS110M:
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 137.5 (5.41) –
B 38.7 (1.52) [39.7 (1.56)] Replace
C 59 (2.32) [54 (2.13)]
W3-7-12
Grouser shoe
ZAXIS110, 120, 130, 130LCN, 125US, 135US,
135UR:
W105-03-07-024
Unit: mm (in)
Shoe Width 500 mm Grouser
Allowable
Standard Remedy
Limit
A 191.5 (7.54) –
Build-up weld
B 8 (0.32) – and finishing
or replace
C 20 (0.79) 14 (0.55)
A
W187-03-07-001
Unit: mm (in)
A 181 −
B 8 − Replace
C 65 14
NOTE: Check the shoe. Be sure to replace the

shoe before the allowable limit if necessary.
W3-7-13
ZAXIS110M:
W105-03-07-024
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 219 (8.62) − Build-up weld
B 8.5 (0.34) − and finishing
or replace
C 26 (1.02) 18.2 (0.72)
NOTE: Check the shoe. Be sure to replace the

shoe before the allowable limit if necessary.
W3-7-14
MEMO
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SECTION 4
FRONT ATTACHMENT
 CONTENTS 
Group 1 Front Attachment
Remove and Install Front Attachment ........W4-1-1
Maintenance Standard...............................W4-1-10
Standard Dimensions for
Arm and Bucket Connection ....................W4-1-15
Standard Dimensions for
Arm and Boom Connection ................... W4-1-18
Group 2 Cylinder
Removeand Install Cylinder ..................... W4-2-1
Hydraulic Circuit Pressure Release
Procedure ............................................ W4-2-19
Disassemble Cylinder ............................ W4-2-20
Assemble Cylinder ................................. W4-2-36
Maintenance Standard ........................... W4-2-52
187W-4-1
(Blank)
187W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT
ATTACHMENT
Removal
Remove bolts (1) (2 used) to remove cover (2). (2
places on both left and right) 1 2
: 17 mm
W198-04-01-001
2. Remove grease hose (3) from the adapter at the
boom cylinder rod side boss. (2 places on both
left and right) 3
: 17 mm (ZAXIS110, 110M, 120, 130,
130LCN, 125US, 135US)
: 19 mm (ZAXIS135UR) Adapter
3. Remove nuts (6) and bolts (8) from boom cylinder Boom Cylinder
rod pin (4). Then remove stopper (7). (2 places on
both left and right)
: 24 mm
W105-04-01-002
CAUTION: Boom cylinder weight:

100 kg (220 lb) (ZAXIS110, 110M) 4 5
109 kg (240 lb) (ZAXIS120, 130, 130LN, 125US,
135US, 135UR)
CAUTION: Prevent personal injury. Metal
fragments may fly when a hammer is used to 8 Boom Cylinder
remove pins. Be sure to wear necessary
protection, such as goggles, hardhat, etc.
4. Hoist the boom cylinder by crane. Drive pin (4)
into the position where thrust plate (5) can be
removed, with a bar and hammer. Remove the
thrust plate. 7
NOTE: When pin (4) is impossible to pull out, start 6
the engine, slightly operate to align the
W178-04-01-004
boom lever and the boom cylinder rod pin
hole.
5. Place the boom cylinder on a bench of 1 m (39.4

in) height.
Start the engine, operate the boom lever to retract
Boom Cylinder
the boom cylinder. Use a wire to secure the boom
cylinder rod as illustrated.
Stop the engine. Wire
W554-02-03-007
W4-1-1
6. Remove hoses (12) (4 used) from the boom
cylinder at the cylinder bottom. Close all openings Boom Cylinder
with plug (13/16-16 UN). 13 9
: 27 mm

10
fragments may fly when a hammer is used to
remove pins. Be sure to wear necessary 11
7. Loosen nut (11) at the boom cylinder bottom side 10

of the main frame, remove bolt (9).
Pull out pin (10). 11
Remove thrust plate (13). 12 W187-04-02-009
: 24 mm

100 kg (220 lb) (ZAXIS110, 110M)
109 kg (240 lb) (ZAXIS120, 130, 130LCN,
125US, 135US, 135UR)
CAUTION: Attach a wire rope to the boom

cylinder so that the rope does not damage
Boom Cylinder
the boom cylinder while hoisting the cylinder.
8. Attach a wire rope at the center of gravity of boom W187-04-01-001

cylinder, hoist it by crane. ZAXIS110, 110M, 120, 130, 130LCN
Remove other side boom cylinder by the same
Air Release Valve
procedure step 3 to 8.
9. After stopping the engine, push the air release

valve on the top of hydraulic oil tank to release
any remaining pressure. Then remove the cap.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic
Circuit Pressure Release Procedure”.
Refer to page W4-2-15.
M157-07-173
Air Release
Valve
SS-2096
W4-1-2
10. Remove hoses (14) and (15) for the bucket ZAXIS110, 110M, 120, 130, 130LCN
cylinder and arm cylinder. Remove hoses for
offset cylinder. Close all openings with cap.
14 15
: 27, 36 mm
: 19 mm
M154-07-002

15
14
W1SE-04-01-001
11. (ZAXIS110, 110M, 120, 130, 130LCN) ZAXIS110, 110M, 120, 130, 130LCN
Remove mounting bolts (8 used), to remove the
tool box and cover.
Remove mounting bolts (4 used), to remove the
cover.
: 17 mm
Cover
Tool Box
W178-04-01-002
Cover
W1SE-04-01-002
Bolt
12. (ZAXIS135UR only) Socket Bolt
Remove bolts (4 used) from the boom to remove Bolt
the cover of boom angle sensor.
Remove bolts (2 used) and socket bolts (3 used)
to remove the boom angle sensor and connector.
: 17 mm
: 5 mm
Plate
Bolt
Connector
Boom Angle
Sensor
W187-04-01-006
W4-1-3
13. Remove bolt (19), spring washer (20), plate (18)
and block (17) from the plate of boom foot pin 16
(16).
: 27 mm
17
18
19
20
CAUTION: Front attachment weight:
1800 kg (4000 lb) (ZAXIS110, 110M) W178-04-01-001
1900 kg (4190 lb) (ZAXIS125US)

2000 kg (4400 lb) (ZAXIS120, 130, 130LCN,
135US)
3100 kg (6830 lb) (ZAXIS135UR)
14. Attach the front attachment to a crane. Slightly

hoist the front attachment to take up any wire rope
slack.
W105-04-01-008
16
15. Insert a bar between the plate of boom foot pin

(16) and the bracket, slightly pull the plate out.
Plate
Insert Bar
16. Turn the plate upward by hand and turn it left and
right to pull it out. Bracket
(Adjust the position of the boom foot pin hole,
hoisting/lowering the front attachment.)
W187-04-01-004
CAUTION: Boom foot pin (16) weight: 23 kg

(51 lb)
17. After hoisting the front attachment, move the

machine backward.
18. Place the front attachment on wooden blocks.
W178-04-01-005
W4-1-4
Install Attachment
CAUTION: Front attachment weight:
1800 kg (4000 lb) (ZAXIS110, 110M)
1900 kg (4190 lb) (ZAXIS125US)
2000 kg (4400 lb) (ZAXIS120, 130, 130LCN,
135US)
3100 kg (6830 lb) (ZAXIS135UR)
1. Hoist the front attachment by crane. Move the

machine forward, aligning the boom foot pin holes. W178-04-01-005
Insert the thrust plates into boom left and right

16
sides and adjust the clearance between the plate
and frame within 1 mm.
(Adjust the boom foot pin hole, hoisting/lowering
the front attachment.)
17
18
CAUTION: Boom foot pin (16) weight: 23 kg
19
(51 lb)
20
CAUTION: Prevent personal injury. Metal W178-04-01-001
protection, such as goggles, hardhat, etc. Bolt
Socket Bolt
2. Drive in boom foot pin (16). Install stopper bolt Bolt
(19), washer (20), plate (18) and block (17).
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
Plate
Bolt
Install the boom angle sensor and connector to
Connector
the boom and boom foot pin (16) plate with bolts Boom Angle
(2 used) and socket bolts (3 used). Sensor
W187-04-01-006
Install the cover of boom angle sensor to boom
with bolts (4 used). ZAXIS110, 110M, 120, 130LCN
: 5 mm
: 9.8 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
4. (ZAXIS110, 110M, 120, 130, 130LCN)

Install the tool box and cover with bolts (8 used).
Cover
Tool Box
Install the cover with bolts (4 used).
W178-04-01-002
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) ZAXIS125US, 135US, 135UR, 135UR
Cover
W1SE-04-01-002
W4-1-5
5. Remove caps from hoses and pipings. Install ZAXIS110, 110M, 120
bucket cylinder hoses and arm cylinder hoses
(14), (15) and offset cylinder hoses.
: 27 mm
14 15
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
IMPORTANT: When pressing the bushing in, if a

hammer is used, the bushing may be
damaged. Use a press. M154-07-002

100 kg (220 lb) (ZAXIS110, 110M) 14 15
109 kg (240 lb) (ZAXIS120, 125US, 135US,
135UR)

the boom cylinder while hoisting the cylinder.
6. Attach a wire rope at the center of gravity of boom
cylinder hoist it by crane. Align the boom cylinder
bottom side pin hole with the boom cylinder
mounting hole on the main frame. W1SE-04-01-001

7. Insert thrust plate (13) and pin (10). Install bolt (9),
tighten with nut (11).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) Boom Cylinder
8. Install other side boom cylinder by the same

procedure. W187-04-01-001
9. Install hoses (12) (4 used) on the boom cylinders

(2 used). Boom Cylinder
: 27 mm 13 9
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
IMPORTANT: After filling hydraulic oil to specified

level, start the engine and check the
10
connections for any oil leakage.
11
10
11
12 W187-04-02-009
W4-1-6
10. Hoist the boom cylinder by crane. Operate the
boom lever, align the cylinder rod side pin hole
with the boom cylinder mounting hole.
4 5
protection, such as goggles, hardhat, etc. 8 Boom Cylinder
11. Install thrust plate (5), drive in pin (4), connect the
boom cylinder to the boom.
12. Install stopper (7), bolt (8) and nut (6).

: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
7
6
W178-04-01-004
3
13. Install grease hoses (3).
(ZAXIS110, 120, 125US, 135US)
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 71.5 lbf⋅ft)
(ZAXIS135UR)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
14. Install the other side boom cylinder by the same

procedure.
IMPORTANT: When all work is completed, run the W105-04-02-032
boom cylinder several times to

stroke end to bleed air from circuit

Install cover (2) to the boom cylinder with bolts (1)
(2 used). (2 places on both left and right)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
1 2
W198-04-01-003
W4-1-7
ZAXIS110, 110-E, 120, 120-E

16. Add grease to the boom cylinder rod side, bottom
side and boom foot side. Boom Cylinder
Rod Side
Boom Foot
Side
M154-07-002

Boom Cylinder
Rod Side
Boom Foot
Side
M1SE-07-003
IMPORTANT: When the arm has been removed
from the boom, perform the
following steps when installing the
arm.
17. Install thrust plates (21) into arm left and right
sides. Adjust total clearance of left and right within
1.5 mm or less.
18. After the arm is installed, add grease to grease Boom Cylinder M104-07-002
fitting (22) on the boom connecting boss of the Bottom Side

arm.
IMPORTANT: For handling of HN bushing for the

front attachment, pay attention to
the following. 21 21
Precautions for pressing the bushing in:

If a hammer is used to drive the bushing in, the
bushing may be damaged. Use a press.
Precautions when reinforcing the arm:

Welding heat for arm reinforcement may cause oil 22 22
leakage the bushing and decrease lubrication
performance.
If an oil leak occurs, replace the bushing.
Use tool (ST 1454) to pull the bushing out or press it

in.
M157-07-157
W4-1-8
(Blank)
W4-1-9
Pin and Bushing F E G
C H
ZAXIS110, 110M J
ZAXIS120 A D C
B I K
W105-04-01-018
Unit: mm (in)

Part Name Remedy
ZAXIS120 ZAXIS110,110M ZAXIS120 ZAXIS110,110M
Pin 71 (2.8) ← 70.0 (2.8) ←
A
Bushing 71 (2.8) ← 72.5 (2.9) ←
Pin 71 (2.8) ← 70.0 (2.8) ←
B Boss (Main Frame) 71 (2.8) ← 72.5 (2.9) ←
Bushing (Boom Cylinder) 71 (2.8) ← 72.5 (2.9) ←
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
C Bushing (Boom Cylinder) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Boss (Boom) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
D
Bushing 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
E Boss (Arm) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Bushing (Arm Cylinder) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
F Boss (Boom) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Bushing (Arm Cylinder) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6) Replace
Pin 60 (2.36) ← 59.0 (2.32) ←
G Boss (Arm) 60 (2.36) ← 61.5 (2.42) ←
Bushing (Bucket Cylinder) 60 (2.36) ← 61.5 (2.42) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
H Bushing 65 (2.56) ← 66.5(2.62) ←
Bushing (Bucket Cylinder) 65 (2.56) ← 66.5(2.62) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
I
Bushing 65 (2.56) ← 66.5(2.62) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
J
Bushing 65 (2.56) ← 66.5(2.62) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
K
Bushing 65 (2.56) ← 66.5(2.62) ←
W4-1-10
ZAXIS125US
ZAXIS135US
Unit: mm (in)

Part Name ZAXIS ZAXIS ZAXIS ZAXIS Remedy
135US 125US 135US 125US
Pin 71 (2.8) ← 70.0 (2.8) ←
A
Bushing 71 (2.8) ← 72.5 (2.9) ←
Pin 71 (2.8) ← 70.0 (2.8) ←
B Boss (Main Frame) 71 (2.8) ← 72.5 (2.9) ←
Bushing (Boom Cylinder) 71 (2.8) ← 72.5 (2.9) ←
Pin 71 (2.8) ← 70.0 (2.8) ←
C Bushing (Boom Cylinder) 71 (2.8) ← 72.5 (2.9) ←
Boss (Boom) 71 (2.8) ← 72.5 (2.9) ←
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
D
Bushing 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
E Boss (Arm) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Bushing (Arm Cylinder) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Pin 71 (2.8) 65 (2.6) 70.0 (2.8) 64.0 (2.5)
F Boss (Boom) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6)
Bushing (Arm Cylinder) 71 (2.8) 65 (2.6) 72.5 (2.9) 66.5 (2.6) Replace
Pin 60 (2.36) ← 59.0 (2.32) ←
G Boss (Arm) 60 (2.36) ← 61.5 (2.42) ←
Bushing (Bucket Cylinder) 60 (2.36) ← 61.5 (2.42) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
H Bushing 65 (2.56) ← 66.5(2.62) ←
Bushing (Bucket Cylinder) 65 (2.56) ← 66.5(2.62) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
I
Bushing 65 (2.56) ← 66.5(2.62) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
J
Bushing 65 (2.56) ← 66.5(2.62) ←
Pin 65 (2.56) ← 64.0 (2.52) ←
K
Bushing 65 (2.56) ← 66.5(2.62) ←
IMPORTANT: When replacing HN bushing, press

fit it in with a press.
W4-1-11
ZAXIS135UR
D
F
P
R
E O
G Q C
A
S
I
K T
H
B
M
L N W187-04-01-007
Unit: mm (in)
ZAXIS135UR
Part Name Remedy
Pin 71 (2.8) 70.0 (2.8)
A
Boss (Main Frame) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
B Boos (Main Frame) 71 (2.8) 72.5 (2.9)
Bushing (Boom Cylinder) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
C Boss (Boom) 71 (2.8) 72.5 (2.9)
Bushing (Boom Cylinder) 71 (2.8) 72.5 (2.9) Replace
Pin 65 (2.56) 64.0 (2.5)
D
Bushing（Arm） 65 (2.56) 66.5 (2.6)
Pin 71 (2.8) 70.0 (2.8)
E Boom (Arm) 71 (2.8) 72.5 (2.9)
Bushing (Arm Cylinder) 71 (2.8) 72.5 (2.9)
Pin 80 (3.15) 79.0 (3.11)
F
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)
W4-1-12
Unit: mm (in)
ZAXIS135UR
Part Name Remedy
Pin (Bucket Cylinder) 60 (2.36) 59.0 (2.32)
G
Bushing 60 (2.36) 61.5 (2.42)
Pin 65 (2.56) 64.0 (2.52)
H Bushing (Bucket Cylinder) 65 (2.56) 66.5 (2.62)
Bushing (Link) 65 (2.56) 66.5 (2.62)
Pin 65 (2.56) 64.0 (2.52)
I
Bushing (Arm) 65 (2.56) 66.5 (2.62)
Pin 65 (2.56) 64.0 (2.52)
J
Bushing (Link) 65 (2.36) 66.5 (2.62)
Pin 65 (2.56) 64.0 (2.52)
K
Bushing (Arm) 65 (2.56) 66.5 (2.62)
Pin 71 (2.8) 70.0 (2.8)
L
Bushing (Blade) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
M
Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9) Replace
Pin 71 (2.8) 70.0 (2.8)
N
Bushing (Blade Cylinder) 71 (2.8) 72.5 (2.9)
Pin (Lower/Upper Boom) 125 (4.92) 124.0 (4.88)
O
Bushing (Upper Boom) 125 (4.92) 126.5 (4.98)
Pin (Cylinder Stay / Upper Boom) 125 (4.92) 124.0 (4.88)
P
Bushing 125 (4.92) 126.5 (4.98)
Pin (Lower Boom / Offset Cylinder) 60 (2.36) 59.0 (2.32)
Q
Bushing (Offset Cylinder) 60 (2.36) 61.5 (2.42)
Pin (Upper Boom / Offset Cylinder) 60 (2.36) 59.0 (2.32)
R
Bushing (Offset Cylinder) 60 (2.36) 61.5 (2.42)
Pin (Cylinder Stay / Stay) 60 (2.36) 59.0 (2.32)
S
Bushing (Stay) 60 (2.36) 61.5 (2.42)
Pin (Lower Boom / Stay) 60 (2.36) 59.0 (2.32)
T
Bushing (Stay) 60 (2.36) 61.5 (2.42)
W4-1-13
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
A 229 (9.0) 149 (5.9)
B 245 (9.6) -
Replace
C 330 (13.0) -
D 135 (5.3) -
Point
B C
W105-04-01-020
Unit: mm (in)

A 178.5 (7.0) 90 (3.5)
B 79.2 (3.1) -
Replace
C 95.0 (3.7) -
D 81.0 (3.2) -
W4-1-14
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
ZAXIS110, 110M, 125US
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS110, 110M, 125US EX100-5, EX100M-5 EX100-3, EX100M-3 EX100-2, EX100M-2
a 325 (12.8) ← ← ←
b 5 (0.2) ← ← ←
c 505 (19.9) 500 (19.7) ← ←
d 460 (18.1) ← ← ←
e - - - -
f 1230 (48.4) ← ← ←
g 377 (14.8) ← ← ←
h 254 (10.0) ← ← ←
i 65 (2.6) ← ← ←
j 355.2 (14.0) ← ← ←
k 70 (2.8) ← ← ←
l 377 (14.8) ← ← ←
m 255 (10.0) ← ← ←
n 65 (2.6) ← ← ←
o 90° ← ← ←
p 90° ← ← ←
q 391 (15.4) ← ← ←
IMPORTANT: If the front attachment of a previous NOTE: The dimension h: 254 mm (10 in) shows
model machine is used, use the the dimension with the adjustable boss.
grease intervals of the previous
model machine.
W4-1-15
ZAXIS120, 135US
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS120, 130, 130CN, 135US EX120-5, EX135USR EX120-3 EX120-2
a 325 (12.8) ← ← ←
b 5 (0.2) ← ← ←
c 505 (19.9) 500 (19.7) ← ←
d 460 (18.1) ← ← ←
e - - - -
f 1230 (48.4) ← ← ←
g 377 (14.8) ← ← ←
h 254 (10.0) ← ← ←
i 65 (2.6) ← ← ←
j 355.2 (14.0) ← ← ←
k 70 (2.8) ← ← ←
l 377 (14.8) ← ← ←
m 255 (10.0) ← ← ←
n 65 (2.6) ← ← ←
o 90° ← ← ←
p 90° ← ← ←
q 391 (15.4) ← ← ←
IMPORTANT: If the front attachment of a previous NOTE: The dimension h: 254 mm (10 in) shows
model machine is used, use the the dimension with the adjustable boss.
model machine.
W4-1-16
ZAXIS135UR
Section A Section B
W187-04-01-003
Unit: mm (in)
ZAXIS135UR
a 325 (12.8)
b 5 (0.2)
c 505 (19.9)
d 460 (18.1)
e －
f 1230 (48.4)
g 377 (14.8)
h 254 (10.0)
i 65 (2.6)
j 355.2 (14.0)
k 70 (2.8)
l 377 (14.8)
m 255 (10.0)
n 65 (2.6)
o 90°
p 90°
q 391 (15.4)
NOTE: The dimension h: 254 mm (10 in) shows

the dimension with the adjustable boss.
W4-1-17
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
ZAXIS110, 110M, 125US
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS110, 110M EX100-5 EX100-3 EX100-2

125US
s 65 (2.6) ← ← ←
t 260 (10.2) ← ← ←
u 390 (15.4) 374 (14.7) ← ←
IMPORTANT: If the front attachment of a previous

model machine is used, use the
model machine.
W4-1-18
ZAXIS120, 130, 130LCN, 135US
Section C
W187-04-01-002
Unit: mm (in)
ZAXIS120, 130, 130LCN, 135US EX120-5 EX120-3 EX120-2

s 71 (2.8) ← ← ←
t 273 (10.7) ← ← ←
u 403 (15.9) 388 (15.3) ← ←
IMPORTANT: If the front attachment of a previous

model machine is used, use the
model machine.
W4-1-19
ZAXIS135UR
Section C
W187-04-01-008
Unit: mm (in)
ZAXIS135UR
s 71 (2.8)
t 273 (10.7)
u 403 (15.9)
W4-1-20
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Remove Bucket Cylinder
1. Insert wooden block (3) between bucket cylinder 1
(1) and arm (2).

valve to release any remaining pressure from the 3
hydraulic oil tank, then remove the cap.
Release the bucket circuit pressure. 2
Refer to “Release Hydraulic Circuit Pressure”. 3
(W4-2-19)
W554-04-02-006
CAUTION: Use a wire to secure the link to

4 5
prevent it from falling before pushing pin (7)
out.

fragments may fly off when a hammer is
used to remove pins. Be sure to wear nec- 6
essary protection, such as goggles, hardhat,
etc.
3. Remove nut (6) and bolt (4). Push out pin (7). 7
Remove thrust plates (5).
1 W158-04-02-006
: 24 mm 8
4. To prevent bucket cylinder rod (8) from stretching,

pass wire (9) through the cylinder rod hole and
secure it to the bucket cylinder pipe.
9
W102-04-02-005
W4-2-1
5. Disconnect bucket cylinder hoses (12) (2 used)
at the bucket cylinder (1) bottom. Close all open-
ings with cap.
: 27 mm
10
CAUTION: Bucket cylinder weight:

93 kg (205 lb) (ZAXIS110, 125US)
102 kg (225 lb) (ZAXIS120, 135US)
15
CAUTION: Prevent personal injury. Metal 11

fragments may fly when a hammer is used to 13
remove pins. Be sure to wear necessary pro-
tection, such as goggles, hardhat, etc.
6. Hoist bucket cylinder (1) by crane, remove nut

(13) and bolt (15). Push out pin (11). 1
Remove thrust plate (10).
: 24 mm
7. Remove bucket cylinder (1). 12

W187-04-02-004
W4-2-2
Install Bucket Cylinder
hammer is used, the bushing may
be damaged. Use a press.
CAUTION: Bucket cylinder weight:

93 kg (205 lb) (ZAXIS110, 125US)
102 kg (225 lb) (ZAXIS120, 135US)
10
used to install pin (11). Be sure to wear nec-
etc. 15
1. Hoist bucket cylinder (1) by crane. Align the cyl-
inder tube side pin hole with the bucket cylinder
14 11
mounting hole on the arm. Insert thrust plate (10)
and install pin (11). 13
2. Insert bolt (15) into arm stopper (14) and pin (11),
install nut (13).
: 24 mm
1
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
IMPORTANT: After installing hoses, fill hydraulic

oil to specified level, start the en-
gine and check the connections for 12 W187-04-02-004
any oil leakage.

3. Install bucket cylinder hoses (12) (2 used).
: 27 mm 1
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) 8
4. Remove wire (9) from bucket cylinder rod (8).
9 W102-04-02-005
W4-2-3

used to remove pins. Be sure to wear nec-
essary protection, such as goggles, hardhat, 16 4 17 5
etc.
5. Start the engine, operate the bucket lever, align

the cylinder rod side pin hole with those of links
(16), (18). Insert thrust plate (5) and pin (7).
6. Insert bolt (4) into stopper (17) and pin (7), install
nut (6).
: 4 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft) 7 18 6
W158-04-02-006
IMPORTANT: In case link (18) has been removed
from the arm, do not forget to
re-insert thrust plate (19). 19 19
IMPORTANT: When all work is completed, run the

bucket cylinder several times to
stroke end to bleed air from the cir-
cuit.
W157-04-01-015
18 18
W4-2-4
Remove Arm Cylinder (ZAXIS110, 120, 125US,
135US)
1. Insert wooden block (3) into space between arm 1
cylinder (1) and boom (2).

valve to release any remaining pressure from the 2
hydraulic oil tank, then remove the cap.
Release arm circuit pressure.
Refer to “Hydraulic Circuit Pressure Release”
3
(W4-2-19)
W187-04-02-005
3. Remove nut (8) and bolt (10) from pin (5) at the 4
10 5
arm cylinder (1) rod side.
: 24 mm (ZAXIS110, 125US) 1
: 30 mm (ZAXIS120, 135US)

etc.
4. Start the engine, slightly operating the boom and 8

the arm to put a wick out and push pin (5) out. W187-04-02-006
Remove thrust plate (4). After that lower the

boom gently. 6 1
5. To prevent arm cylinder rod (6) from extending,

pass wire (7) through the cylinder rod hole and
secure it to the arm cylinder tube. 7
6. Disconnect hoses (11) (2 used) from arm cylinder

W187-04-02-010
(1) at the arm cylinder bottom, and close all
openings with cap. 11
: 36 mm
1
7. Remove grease hose (12) from arm cylinder (1).

: 17 mm
12
W102-04-02-014
W4-2-5
CAUTION: Arm cylinder weight:

125 kg (276 lb) (ZAXIS110, 125US)
157 kg (346 lb) (ZAXIS120, 135US) 1
8. Attach a sling at the center of gravity of arm cyl-

inder (1). Slightly hoist it by crane.

fragments may fly off when a hammer is W102-04-02-016

essary protection, such as goggles, hardhat, 13
17
etc.
1 14
9. Remove nuts (15) and bolt (17) from the arm cyl-
inder (1) tube side. Push out pin (14), remove
thrust plates (13), remove the arm cylinder.
: 24 mm (ZAXIS110, 125US)
: 30 mm (ZAXIS120, 135US)
15
W187-04-02-007
W4-2-6
Install Arm Cylinder
(ZAXIS110, 120, 125US, 135US)
CAUTION: Arm cylinder weight:

125 kg (276 lb) (ZAXIS110, 125US)
157 kg (346 lb) (ZAXIS120, 135US)
1. Attach a sling belt at the center of gravity of arm

cylinder (1). Hoist the arm cylinder by crane.
Align the cylinder tube side hole with the arm
cylinder mounting hole on the boom.
13
17
CAUTION: Prevent personal injury. Metal 1 14
etc.
2. Insert thrust plate (13), then install pin (14). Install 16

15
bolt (17) to the pin and stopper (16) and put nut
(15) on the bolt.
: 24 mm (ZAXIS110, 125US)
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) W187-04-02-007
: 30 mm (ZAXIS120, 135US)
: 550 N⋅m (56 kgf⋅m, 400 lbf⋅ft)
11
3. Install grease hose (12) and arm cylinder hoses 1
(11) (2 used).
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 12

connections for any oil leaks.
W102-04-02-014
W4-2-7
4. Remove wire (7) from arm cylinder rod (6). Start
the engine, operate the arm lever, align the arm 6 1
cylinder rod side pin hole with the arm cylinder
mounting hole on arm (18).
18
CAUTION: Prevent personal injury. Metal 7

used to remove pins. Be sure to wear nec- W187-04-02-010

etc. 4
10 5
5. Insert thrust plate (4), then install pin (5).
9
Insert bolt (10) into the pin and stopper (9), then
put nut (8) on the bolt.
: 24 mm (ZAXIS110, 125US)
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
: 30 mm (ZAXIS120, 135US) 18
: 550 N⋅m (56.0 kgf⋅m, 400 lbf⋅ft)

arm cylinder several times to stroke
end to bleed air from the circuit. 8
W187-04-02-006
W4-2-8
Remove Arm Cylinder (ZAXIS 135UR)
CAUTION: Arm cylinder weight: 178 kg

(390 lb)
1. Attach a wire onto arm cylinder (1). Hoist it by
crane.

etc.
2. Remove nut (2) and bolt (3) to pull out pin (4). 1
Pull the thrust plate between arm cylinder (1) rod
and the arm. 9
: 30 mm 7, 8
3. Secure arm cylinder (1) with a wire to prevent the 5

arm cylinder rod from extending.
4
6
4. Remove hoses (5) (2 used) at the bottom part of
arm cylinder (1). Attach the cap onto the hoses.
2, 3
: 36 mm
5. Remove nuts (7) (2 used) and bolts (8) (2 used)

from both right and left of cylinder stay (6) to pull M1SM-05-009
out pins (9) (2 used).
: 24 mm

(390 lb)
6. After removing pin (9), hoist and remove arm
cylinder (1) by crane. Remove the thrust plate
from both right and left of cylinder stay (6).
W4-2-9
Install Arm Cylinder (ZAXIS 135UR)

(390 lb)
essary protection, such as goggles, hardhat, 1
etc.
9
1. Hoist arm cylinder (1) by crane to align the holes 7, 8
on both cylinder tube and cylinder stay (6). Install
the thrust plate, pins (9) (2 used), bolts (8) (2 5
used), and nuts (7) (2 used) in this order. 4
: 24 mm 6
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
2, 3
IMPORTANT: After filling the hydraulic oil to the
specified level, start the engine.
Check the connections for any oil
leakage. M1SM-05-009
2. Connect hoses (5) (2 used) to arm cylinder (1).

: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
3. Remove a wire from the arm cylinder rod. Start

the engine. Extend arm cylinder (1). Aligning the
holes on both arm cylinder (1) rod and arm, in-
stall the thrust plate. Drive pin (4).
4. Aligning the holes on both stopper and pin (4),

drive bolt (3) and install nut (2).
: 30 mm
: 400 N⋅m (41.0 kgf⋅m, 295 lbf⋅ft)

arm cylinder several times to stroke
end to bleed air from the circuit.
W4-2-10
Remove Boom Cylinder
1. (ZAXIS 135 UR only)

Remove bolts (1) (2 used) to remove cover (2).
(2places on both right and left)
: 17 mm
2. Disconnect grease hoses (3) of boom cylinder.

: 17 mm (ZAXIS 110,120,125US, 135US)
: 19 mm (ZAXIS 135UR)
1 2
CAUTION: Boom cylinder weight: W198-04-01-003
100 kg (220 lb) (ZAXIS110) 3

109 kg (240 lb)
(ZAXIS120, 125US, 135US, 135UR)

the boom cylinder pipe while hoisting the
cylinder.
3. Attach a wire rope to the boom cylinder and hoist

it by crane.
W105-04-02-032
CAUTION: Prevent personal injury. Metal 4 5

etc. 8
Boom Cylinder
4. Remove nut (6), bolt (8) and stopper (7) from the
boom cylinder rod, then push out pin (4).
Remove thrust plate (5).
5. Place a support stand at the front end of the

boom cylinder tube and put the boom cylinder on
it. Place other boom cylinder with the same pro- 7
cedure. 6
W178-04-01-004
6. Operate the boom lever to retract the boom cyl-

inder. To prevent the boom cylinder rod from
stretching, pass the wire through the cylinder rod
Wire
hole and secure it to the cylinder tube.
7. After stopping the engine, push air release valve

to release any remaining pressure from hydraulic
tank. Then remove the cap.
Release the circuit pressure.
Refer to “Hydraulic Circuit Pressure Release”.
(W4-2-20).
Boom Cylinder
W187-04-02-008
W4-2-11
8. Remove hoses (12) (4 used) from the boom
cylinder at the cylinder bottom. Close all open-
ings with plug (13/16-16 UN). Boom Cylinder
: 27 mm 13 9

used to remove pins. Be sure to wear nec- 10
etc. 11
9. Loosen nut (11) at the boom cylinder bottom side
of the main frame, remove bolt (9). 10
Pull out pin (10).
Remove thrust plate (13). 11
: 24 mm 12 W187-04-02-009

100 kg (220 lb) (ZAXIS110)
109 kg (240 lb)
(ZAXIS120, 125US, 135US, 135 UR)

the boom cylinder while hoisting the cylin-
der.
10. Attach a wire rope at the center of gravity of
boom cylinder. Hoist it by crane.
Remove other side boom cylinder with the same
procedure.
Boom Cylinder
W187-04-01-001
W4-2-12
Install Boom Cylinder
100 kg (220 lb) (ZAXIS110)
109 kg (240 lb)
(ZAXIS120, 125US, 135US, 135UR)

the boom cylinder while hoisting the cylin-
der.
1. Attach a wire rope at the center of gravity of

boom cylinder. Hoist it by crane. Align the boom
cylinder bottom side pin hole with the boom cyl-
inder mounting hole on the main frame.
Boom Cylinder
W187-04-01-001

used to remove pins. Be sure to wear nec- Boom Cylinder
essary protection, such as goggles, hardhat, 13 9
etc.
2. Insert thrust plate (13) and pin (10). Install bolt (9),
tighten with nut (11).
10
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) 11
3. Install other side boom cylinder with the same

procedure. 10
4. Install hoses (12) (4 used) on boom cylinders (2 11

used). 12 W187-04-02-009
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

connections for any oil leaks.
W4-2-13
5. Hoist the boom cylinder by crane. Operate the
boom lever, align the cylinder rod side pin hole
with the boom cylinder mounting hole.
4 5
etc. 8
Boom Cylinder
6. Install thrust plate (5), drive in pin (4), connect the

boom cylinder to the boom.
7. Install stopper (7), bolt (8) and nut (6).

: 24 mm 7
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
6
W178-04-01-004
3
8. Install grease hoses (3).
: 17 mm
: 29.5 N⋅m (3 kgf⋅m, 21.7 lbf⋅ft)
9. Install other side boom cylinder with the same

procedure.
Boom Cylinder
W105-04-02-032
10.(ZAXIS 135 UR only)

Install cover (2) onto the boom cylinder with bolts
(1) (2 used). (2 places on both right and left)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
IMPORTANT: When all work is completed, run the 1 2

boom cylinder several times to
stroke end to bleed air from circuit. W198-04-01-003
W4-2-14
Remove Offset Cylinder (ZAXIS 135UR)
4
CAUTION: Offset cylinder weight: 100 kg
2, 3
(220 lb)
1. Attach a wire onto the offset cylinder. Hoist it by
crane. 1

fragments may fly off when a hammer is 8 9, 10
etc. 6
5
2. Remove nut (9) and bolt (10) to pull out pin (8).
Pull thrust plate (7) between the offset cylinder
(1) rod and the upper boom. 7 M1SM-07-003
: 24 mm
3. Start the engine. Retract offset cylinder (1). Se-

cure the offset cylinder with a wire to prevent the
rod from extending. Stop the engine.
4. Remove hoses (6) (4 used) at the bottom part of

offset cylinder (1). Attach the cap onto the hoses.
: 17 mm, 19 mm, 27 mm
5. Remove nut (2) and bolt (3) to pull out pin (4).
Remove thrust plate (5) between the offset cyl-
inder (1) cylinder part and the lower boom.
: 24 mm

(220 lb)
6. Hoist and remove offset cylinder (1) by crane.
W4-2-15
Install Offset Cylinder (ZAXIS 135UR)
CAUTION: Offset cylinder weight: 100 kg 4

(220 lb)
2, 3

fragments may fly off when a hammer is 1
etc. 8 9, 10
1. Hoist offset cylinder (1) by crane to align the
holes on both cylinder tube and lower boom. In-
stall thrust plate (5) and drive pin (4). 6
5
2. Insert bolt (3) while aligning the holes on the
stopper and pin (4). Install nut (2).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 152 lbf⋅ft) 7 M1SM-07-003
3. Connect hoses (6) (4 used) to offset cylinder (1).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.7 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
4. Start the engine. Extend offset cylinder (1). Align-

ing the holes on both offset cylinder (1) rod and
upper boom, install thrust plate (7). Drive pin (8).
5. Aligning the holes on both stopper and pin (8),

install bolt (9) and nut (10).
IMPORTANT: After filling the hydraulic oil to the

specified level, start the engine.
Check the connections for any oil
leakage.

arm cylinder for several times to
stroke end to bleed air from the cir-
cuit.
W4-2-16
Remove Blade Cylinder (ZAXIS135UR)

debris may fly off when a hammer is used to
protection, such as goggles, hard hat, etc.
1. Loosen bolts (1) (4 used) to remove covers (2) (2
used).
: 19 mm
CAUTION: Blade cylinder weight: 49 kg

(110 lb)
2. Attach a wire rope to right blade cylinder (3).
Hoist the blade cylinder and hold it by crane.
1
3. Disconnect hoses (6) (2 used) from right blade
cylinder (3). 2
Cap the disconnected hoses. 5
: 22 mm
5
4. Remove rings (9) (2 used) and stopper pins (8)
(2 used) to pull out pins (7) (2 used). 5 3
Remove thrust plate (5). 8 5
5
4
6
CAUTION: Blade cylinder (3) weight: 49 kg 7 5
(110 lb)
5. Hoist and remove right blade cylinder (3) by
crane.
8
6. Remove left blade cylinder (4) with the same pro-

cedure as step 2 to 5.
7
10 9 9
W198-04-02-001
W4-2-17
Install Blade Cylinder (ZAXIS135UR)
CAUTION: Blade cylinder weight: 49 kg

(110 lb)
1. While slinging right blade cylinder (3) by crane,
align the pin holes on the tube and blade, rod
and track frame.
Insert thrust plate (5). Drive pins (7) (2 used) in
with a bar and hammer. Insert stopper pins (8) (2
1
used) and install rings (9) (2 used).
2
2. Reconnect hoses (6) (2 used) to right blade cyl- 5
inder (3).
5
: 22 mm
: 39 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
5 3
3. Install cover (2) to right blade cylinder (3), then 8 5
secure it with bolts (1) (2 used). 5
4
: 19 mm 6
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) 7 5
4. Install left blade cylinder (4) with the same pro-

cedure as step 1 to 3.
8
IMPORTANT: After completing work, fully stroke
each cylinder several times to bleed
any air remaining in the circuit. 7
10 9 9
W198-04-02-001
W4-2-18
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
NOTE: Following method can be used. Do not

start the engine. Operate pilot pump with
the power from battery to deliver pilot
pressure to the spool of control valve.
1. Push the lock lever forward. (Be in OFF condi-

tion)
IMPORTANT: Be sure to pull the handle for stop-

Handle to Stop Engine
ping engine fully out.
2. Pull the handle for stopping engine out and se-

cure it by left foot.
IMPORTANT: Battery will deplete. Be sure to op-

erate key switch for short period.
3. Turn the key switch to START position and oper-

ate the lever for releasing pressure from
hydraulic circuit 4 to 5 times.
IMPORTANT: Push the handle for stopping engine

in.
4. Reset the handle for stopping engine.
W178-04-02-010
W4-2-19
DISASSEMBLE CYLINDER
Boom Cylinder
11 1 2 3 4 8 7 5 6 9 10
19 20 21 24 23 22
W191-04-02-001
14 13 20 19 16 15 17 18 16 12
Bucket Cylinder
11 1 2 3 4 8 7 5 6 9 10
20 21 24 23 22
W191-04-02-002
20 19 16 15 17 18 16 19 12
1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)
2 - Backup Ring 8 - Socket Bolt 14 - Cushion Seal 20 - Slide Ring (2 Used)
(10 Used) (ZAXIS110, 125US, 135UR Bucket
Cylinder)
(12 Used) (ZAXIS120, 135US, Bucket Cylinder)
(10 Used) (ZAXIS110 Boom Cylinder)
(12 Used) (ZAXIS120, 125US, 135US, 135UR
Boom Cylinder)
3 - U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4 - Buffer Ring 10 - O-Ring 16 - Backup Ring (2 22 - Set Screw
Used)
5 - Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6 - Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-20
Disassemble Boom and Bucket Cylinders
• Be sure to thoroughly read “Precautions for Dis- 4. Secure piston rod (11) on special tool (ST 5908).
assembly and Assembly” on page W1-1-1 before Put matching marks between the piston rod and
starting any disassembling work. nut (24).
• The disassembly procedure below starts on the

premise that the hydraulic line and the line se-
curing bands have been removed. ST 5908
CAUTION: Cylinder weight:

Boom cylinder:
100 kg (220 lb) (ZAXIS110)
109 kg (240 lb) (ZAXIS120, 125US, 135US)
178 kg (390 lb) (ZAXIS135UR)
Bucket cylinder: W158-04-02-022
93 kg (205 lb) (ZAXIS110)

102 kg (225 lb) (ZAXIS120, 125US, 135US)
1. Lift and place the cylinder horizontally on a work

bench by crane and secure. Drain hydraulic oil
from the cylinder.
W102-04-02-027
IMPORTANT: Be sure to pull piston rod (11)

straight so as not to damage the
sliding surfaces.
2. Fully extend piston rod (11). Secure the rod end
by crane. Remove socket bolts (8) from cylinder
head (7).
: 12 mm
3. Pull out cylinder head (7) from cylinder tube (12)

by tapping with a plastic hammer.
W4-2-21
Boom Cylinder
11 1 2 3 4 7 5 6 9 10
19 20 21 24 23 22
W191-04-02-001
14 13 20 19 16 15 17 18 16
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
20 21 24 23 22
W191-04-02-002
20 19 16 15 17 18 16 19
W4-2-22
5. Remove set screw (22) and steel ball (23). 9. Remove O-rings (10), backup rings (9) and (2)
from cylinder head (7). Then remove wiper ring
NOTE: Set screw (22) was crimped with a punch (1), U-ring (3), buffer ring (4), snap ring (6), and
in 2 places after it was tightened. Before bushing (5).
loosing the set screw, cut away the Tool for removing bushing:
crimped portions. Boom
: Boom 70 mm (ST 8017/ST 1284)(ZAXIS110)
8 mm (ZAXIS110) 70 mm (ST 8017/ST 1284)(ZAXIS120, 125US,
10 mm (ZAXIS120, 125US, 135US, 135US, 135UR)
135UR) Bucket
Bucket 65 mm (ST 8015/ST 1283)(ZAXIS110, 125US,
8 mm (ZAXIS110, 125US) 135UR)
8 mm (ZAXIS120, 135US, 135UR) 70 mm (ST 8017/ST 1284)(ZAXIS120, 135US)
6. Loosen nut (24) using special tool (ST 5908).

Remove piston (15), and shim (21). (For the
boom cylinder only, remove cushion bearing (13)
and cushion seal (14).)
Tool for turning nuts:
Boom
75 mm (ST 3271)(ZAXIS110)
80 mm (ST 3262)(ZAXIS120, 125US, 135US,
135UR)
Bucket
75 mm (ST 3271)(ZAXIS110, 125US)
75 mm (ST 3271)(ZAXIS120, 135US, 135UR)
ST 5908
W158-04-02-022
7. Remove seal ring (17), slide rings (19) and (20)

(each 2 used), O-ring (18) and backup rings (16)
(2 used) from piston (15).
8. Remove cylinder head (7) from piston rod (11).
W4-2-23
Arm Cylinder
NOTE: The figure below shows ZAXIS 110. Al-

though cylinder tube (12) of ZAXIS 135 UR
is different, the disassembling procedure is
same.
11 1 2 3 4 7 5 6 9 10
15 16 25 26 28 22 12
14 13
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
1 - Wiper Ring 8 - Socket Bolt 15 - Piston 22 - Set Screw

(12 Used) (ZAXIS110, 125US)
(10 Used) (ZAXIS120, 135US,
135UR)
2- Backup Ring 9 - Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper
W4-2-24
Disassemble Arm Cylinder
• Be sure to thoroughly read “Precautions for Dis- 4. Secure piston rod (11) on special tool (ST 5908).
assembly and Assembly” on page W1-1-1 before Put matching marks between the piston rod (11)
starting any disassembling work. and nut (24).

premise that the hydraulic line and the line se- ST 5908
curing bands have been removed.
CAUTION: Arm Cylinder weight:

125 kg (276 lb) (ZAXIS110, 125US)
157 kg (346 lb) (ZAXIS120, 135US)
178 kg (390 lb) (ZAXIS135UR)
W158-04-02-022
1. Lift and place the cylinder horizontally on a work

bench by crane and secure it.
Drain hydraulic oil from the cylinder.
W102-04-02-027

straight so as not to damage the
sliding surfaces.
2. Fully extend piston rod (11). Secure the rod end
by crane. Remove socket bolts (8) from cylinder
head (7).
: 12 mm (12 used) (ZAXIS110, 125US)
14 mm (10 used) (ZAXIS120, 135US,
135UR)
3. Pull out cylinder head (7) from cylinder tube (12)

by tapping with a plastic hammer.
W4-2-25
Arm Cylinder
NOTE: The figure below shows ZAXIS 110. Al-

though cylinder tube (12) of ZAXIS 135 UR
is different, the disassembling procedure is
same.
11 1 2 3 4 7 5 6 9 10
15 16 25 26 28 22 12
14 13
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-26
5. Remove set screw (22) and steel ball (23).
NOTE: Set screw (22) was crimped with a punch in

2 places after it was tightened. Before
loosing the set screw, cut away the crimped
portions.
: 10 mm
6. Loosen nut (24) to remove piston (15), shim (21),

cushion bearing (13), and cushion seal (14) using
special tool (ST 5908).
Tool for turning nut:
80 mm (ST 3262) (ZAXIS110, 125US)
85 mm (ST 3304) (ZAXIS120, 135US)
90 mm (ST 3263) (ZAXIS135UR)
ST 5908
W158-04-02-022
7. Remove seal ring (17) and slide rings (19),

(20)(each 2 used), O-ring (18) and backup rings
(16) (2 used) from piston (15).
9. Remove O-rings (10), backup rings (9), (2) from

cylinder head (7). Then remove wiper ring (1),
U-ring (3), buffer ring (4), snap ring (6), and
bushing (5).
Tool for removing bushing:

75 mm (ST 8018/ST 1285)
(ZAXIS110, 125US)
80 mm (ST 8019/ST 1286)
(ZAXIS120, 135US)
85 mm (ST 8020) (ZAXIS135UR)
10. Remove snap ring (25) from piston rod (11) with a
screwdriver. Move cushion bearing (27) to the
snap ring side, remove stopper (28) to remove
cushion bearing (27) and cushion seal (26).
W4-2-27
Offset Cylinder (ZAXIS135UR Only)
11 1 2 3 4 7 5 6 8 9 10 13 14 15
22 23 24 25 26 12
16 17 18 19 20 21 27 28 29
W198-04-02-002
1- Wiper Ring 9- O-Ring 17 - Slide Ring 24 - Cushion Bearing

2- Backup Ring 10 - Backup Ring 18 - Piston 25 - Stopper
3- U-Ring 11 - Piston Rod 19 - Seal Ring 26 - Shim
4- Buffer Ring 12 - Cylinder Tube 20 - O-Ring 27 - Nut
5- Bushing 13 - O-Ring 21 - Slide Ring 28 - Steel Ball
6- Snap Ring 14 - Backup Ring 22 - Snap Ring 29 - Set Screw
7- Cylinder Head 15 - O-Ring 23 - Cushion Seal
8- Backup Ring 16 - Cushion Bearing
W4-2-28
Disassemble Offset Cylinder (ZAXIS135)
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1
premise that hydraulic lines and line securing
bands have been removed.

(220 lb)
1. Lift and securely place the cylinder on a
workbench by crane. Drain hydraulic oil from the
cylinder.
W102-04-02-027
2. Extend the detents to unlock cylinder head (7).

Using R wrench (ST 3223), loosen the cylinder
head 1 to 2 turns.

straight out to prevent the sliding
surface from becoming damaged.
3. Fully extend piston rod (11) to hold the rod end by
crane. Remove cylinder head (7) from cylinder
tube (12) to remove the piston rod .
4. Securely place piston rod (11) on special tool (ST

5908). Put matching marks on the piston rod and
nut (27).
ST 5908
W158-04-02-022
W4-2-29
11 1 2 3 4 7 5 6 8 9 10 13 14 15
22 23 24 25 26
16 17 18 19 20 21 27 28 29
W198-04-02-002
W4-2-30
5. Remove set screw (29) and steel ball (28). 9. Remove O-rings (15, 13, 9), backup rings (14, 10,
8, 2) from cylinder head (7). Then remove wiper
NOTE: Set screw (29) was crimped with a punch in ring (1), U-ring (3), buffer ring (4), snap ring (6),
2 places after it was tightened. Before and bushing (5).
loosing the set screw, cut away the crimped Tool for removing bushing:
portions. 70 mm (ST 8017)
: 10 mm
10. Remove stopper (25) from piston rod (11) with a
6. Loosen nut (27) using special tool (ST 5908). screwdriver. Remove cushion bearing (24),
Remove piston (18), shim (26) and cushion cushion seal (23) and snap ring (22).
bearing (16).
Tool for turning nuts: 85 mm (ST 3304)
ST 5908
W158-04-02-022
7. Remove seal ring (19), slide ring (17), O-ring (20)

and slide ring (21).
W4-2-31
Blade Cylinder (ZAXIS135UR Only)
11 1 2 3 4 7 5 6 8 9 10
19 20 21 12
13 14 15 16 17 18 22 23 24 25
W198-04-02-003
1- Wiper Ring 8- Backup Ring 15 - Backup Ring 21 - Slide Ring

2- Backup Ring 9- O-Ring 16 - Piston 22 - Shim
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 24 - Steel Ball
5- Bushing 12 - Cylinder Tube 19 - Backup Ring 25 - Set Screw
6- Snap Ring 13 - Slide Ring 20 - Slide Ring
7- Cylinder Head 14 - Slide Ring
W4-2-32
Disassemble Blade Cylinder (ZAXIS135UR)
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1
premise that hydraulic lines and line securing
bands have been removed.
CAUTION: Blade cylinder weight: 50 kg (110

lb)
1. Lift and securely place the cylinder on a
workbench by crane. Drain hydraulic oil from the
cylinder.
2. Extend the detents to unlock cylinder head (7).

Using R wrench (ST 3221), loosen cylinder head W102-04-02-027
(7) 1 to 2 turns.

straight out to prevent the sliding
ST 5908
surface from becoming damaged.
3. Fully extend piston rod (11) to hold the rod end by
crane. Remove cylinder head (7) from cylinder
tube (12) to remove the piston rod .
4. Securely place piston rod (11) on special tool (ST

5908). Put matching marks on the piston rod and
nut (23). W158-04-02-022
W4-2-33
Blade Cylinder (ZAXIS135UR)
11 1 2 3 4 7 5 6 8 9 10
19 20 21
13 14 15 16 17 18 22 23 24 25
W198-04-02-003
W4-2-34
5. Remove set screw (25) to remove steel ball (24).
: 10 mm
NOTE: Set screw (25) was crimped with a punch in
2 places after it was tightened. Before
loosening the set screw cut away the
crimped portions
6. Remove nut (23) using special tool (ST 5908).

Remove piston (16) and shim (22).
Nut Turning Special Tool: 75 mm (ST 3271)
7. Remove seal ring (17), slide rings (13, 14, 20, 21),
O-ring (18), and backup rings (15, 19) from piston
(16).
9. Remove O-rings (9, 10) and backup rings (8, 2)

from cylinder head (7). Pull out wiper ring (1),
U-ring (3), buffer ring (4), snap ring (6), and
bushing (5).
Bushing Special Tool: 70 mm (ST8017)
W4-2-35
ASSEMBLE CYLINDER
Boom Cylinder
Hole (1 place)
Face the slit toward the piston
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20
21
22, 23
24
Be sure that oil groove faces the

correct direction when assembling. W178-04-02-003
Bucket Cylinder
Hole (1 place)
1 2 3 4 5 6 7 8 9, 10
11 12 15 16 17, 18 19 20
21
22, 23
24
W187-04-02-001
1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt 14 - Cushion Seal 20 - Slide Ring (2 Used)
(10 Used) (ZAXIS110, 125US, 135UR
Bucket Cylinder)
(12 Used)(ZAXIS120, 135US, Bucket
Cylinder)
(10 Used) (ZAXIS110 Boom Cylinder)
135US, 135UR Boom Cylinder)
3- U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-36
Assemble Boom and Bucket Cylinders
1. Install bushing (5) to cylinder head (7) with a IMPORTANT: Be sure that the cushion seal slit
press. faces toward the piston and that the
cushion bearing oil groove faces the
Tools for installing bushing installation: correct direction. (Boom cylinder
Boom only.)
70 mm (ST 8017/ST 1284)(ZAXIS110) 7. Install cushion seal (14) to piston rod (11). Install
70 mm (ST 8017/ST 1284)(ZAXIS120, 125US, piston (15) to the piston rod.
135US, 135UR) (For boom cylinder only, install cushion seal (14)
Bucket and cushion bearing (13).)
65 mm (ST 8015/ST 1283)(ZAXIS110, 125US,
135UR)
70 mm (ST 8017/ST 1284)(ZAXIS120, 135US)
IMPORTANT: Be sure that the rings are installed

correctly.
2. Install U-ring (3), backup ring (2), snap ring (6),
and buffer ring (4) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) with a

plastic hammer.
Tools for installing wiper ring:

Boom
70 mm (ST 8017/ST 1295)(ZAXIS110)
70 mm (ST 8017/ST 1295)(ZAXIS120, 125US,
135US, 135UR)
Bucket
65 mm (ST 8015/ST 1294)(ZAXIS110, 125US,
135UR)
70 mm (ST 8017/ST 1295)(ZAXIS120, 135US)
4. Install O-rings (10) and backup ring (9) to cylinder

head (7).
5. Install O-ring (18), backup rings (16) (2 used),

seal ring (17) slide rings (19), (20) (each 2 used)
to piston (15).
6. Install cylinder head (7) to piston rod (11).

Tool for installing cylinder head:
Boom
70 mm (ST 8017/ST 2361)(ZAXIS110)
70 mm (ST 8017/ST 2361)(ZAXIS120, 125US,
135US, 135UR)
Bucket
65 mm (ST 8015/ST 2346)(ZAXIS110, 125US,
135UR)
70 mm (ST 8017/ST 2361)(ZAXIS120, 135US)
W4-2-37
Boom Cylinder
7 8
11 12 21 22, 23
24
W178-04-02-003
Bucket Cylinder
7 8
11 12 21 22, 23
24
W187-04-02-001
W4-2-38
8. Install shim (21) to piston rod (11). Tighten nut IMPORTANT: Be sure to align piston rod (11) with
(24) using special tool (ST 5908). the center of cylinder tube (12) when
Be sure to align the matching mark on the rod inserting, in order to avoid
with that on the nut. damaging the rings.
Tool for tightening nut: 10. Secure cylinder tube (12) horizontally on a
Boom work bench. Insert piston rod (11) into the cylinder
75 mm (ST 3271) (ZAXIS110) tube.
80 mm (ST 3262) (ZAXIS120, 125US, 135US,
135UR) 11. Install cylinder head (7) to cylinder tube (12).
Bucket Tighten socket bolts (8) (10 used for ZAXIS110,
75 mm (ST 3271) (ZAXIS110, 125US, 135UR) 125US, 135UR Bucket cylinder, 12 used for
75 mm (ST 3271) (ZAXIS120, 135US) ZAXIS120, 135US, 125US, 135UR Boom
Boom cylinder: cylinder).
: 2390N⋅m (245 kgf⋅m, 1770 lbf⋅ft) : 12 mm (Boom, Bucket)
(ZAXIS110) : 171 N⋅m (17.4 kgf⋅m, 126 lbf⋅ft)
: 3140 N⋅m (320 kgf⋅m, 2320 lbf⋅ft)
(ZAXIS120, 125US, 135US, 135UR)
Bucket cylinder:
: 3580 N⋅m (365 kgf⋅m, 2640 lbf⋅ft)
(ZAXIS110, 125US, 135UR)
: 3970 N⋅m (405 kgf⋅m, 2930 lbf⋅ft)
(ZAXIS120, 135US)
ST 5908
W158-04-02-022
IMPORTANT: Crimp 2 places around set screw

(22) top fringe to prevent the set
screw from loosening.
9. Align the holes on piston rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole. If it’s impossible to aligh
the holes, turn the nut to the direction to tighten.
Boom:
: 8 mm (ZAXIS110)
: 31.5±5.88 N⋅m
(3.21±0.6 kgf⋅m, 23.22±4.34 lbf⋅ft)
: 10 mm (ZAXIS120, 125US, 135US,
135UR)
: 56.9±10.7 N⋅m
(5.80±1.09 kgf⋅m, 42.0±7.9 kgf⋅m)
Bucket:
: 8 mm (ZAXIS110, 125US, 135UR)
: 31.5±5.88 N⋅m
(3.21±0.6 kgf⋅m, 23.2±4.3 lbf⋅ft)
: 8 mm (ZAXIS120, 135US)
: 31.5±5.88 N⋅m
(3.21±0.6 kgf⋅m, 23.2±4.3 lbf⋅ft)
W4-2-39
Arm Cylinder
NOTE: The figure below shows ZAXIS110.
Although cylinder tube (12) of ZAXIS135
UR is different, the disassembling
procedure is same.
Face the slit toward the piston.
Hole (1 place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26
27
28
Be sure that oil groove faces the

correct direction when assembling.
W178-04-02-005
1- Wiper Ring 8 - Socket Bolt 15 - Piston 22 - Set Screw

(12 Used) (ZAXIS110, 125US)
135UR)
2- Backup Ring 9 - Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 Used)
W4-2-40
Assemble Arm Cylinder
1. Install bushing (5) to cylinder head (7) with a 8. Install cushion seal (26) to piston rod (11). Install
press. cushion bearing (27) and stopper (28). Slide the
Tool for pressing bushing: cushion bearing to the stopper and install snap
75 mm (ST 8018/ST 1285) (ZAXIS110, 125US) ring (25).
80 mm (ST 8019/ST 1286) (ZAXIS120, 135US)
85 mm (ST 8020) (ZAXIS135UR)
IMPORTANT: Be sure that the rings are installed

correctly.
2. Install U-ring (3), backup ring (2), buffer ring (4),
and snap ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) with a

plastic hammer.
Tool for pressing wiper ring:
75 mm (ST 8018/ST 1296) (ZAXIS110, 125US)
80 mm (ST 8019/ST 1297) (ZAXIS120, 135US)
85 mm (ST 8020) (ZAXIS135UR)
4. Install O-rings (10) and backup ring (9) to cylinder

head (7).
5. Install seal ring (17). O-ring (18), slide rings (19),

(20) (each 2 used) and backup ring (16) (2 used)
to piston (15).
6. Install cylinder head (7) assembly to piston rod

(11).
Tool for installing cylinder head:
75 mm (ST 8018/ST 2344) (ZAXIS110, 125US)
80 mm (ST 8019/ST 2345) (ZAXIS120, 135US)
85 mm (ST 8020) (ZAXIS135UR)
IMPORTANT: Be sure that cushion seal (14) slit

faces toward the piston and that
cushion bearing (13) oil groove
faces the correct direction.
7. Install cushion seal (14) to piston rod (11). Install
cushion bearing (13) and piston (15) assembly to
the piston rod.
IMPORTANT: Be sure that cushion seal (26) slit

faces toward the piston and that
cushion bearing (27) oil groove
faces the correct direction.
W4-2-41
Arm Cylinder
7 8 11 12 21 22, 23 24
W1SE-04-02-001
W4-2-42
9. Install shim (21) to piston rod (11). Using tool (ST
5908), tighten nut (24) in order to align the
matching marks before removal.
Tool for turning nut:
80 mm (ST 3262) (ZAXIS110, 125US)
85 mm (ST 3304) (ZAXIS120, 135US)
90 mm (ST 3263) (ZAXIS135UR)
: 4710 N⋅m
(480 kgf⋅m, 3470 lbf⋅m)
(ZAXIS110, 125US)
: 6180 N⋅m
(630 kgf⋅m, 4560 lbf⋅m)
(ZAXIS120, 135US)
: 6580 N⋅m
(671 kgf⋅m, 4850 lbf⋅m)
(ZAXIS135UR)
ST 5908
W158-04-02-022
IMPORTANT: Crimp 2 places around set screw

(22) top fringe to prevent the set
screw from loosening.
10. Align the holes on piston rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.If it is impossible to align
them, turn the nut to tighten.
: 10 mm
: 56.9±10.7 N⋅m
(5.8±1.09 kgf⋅m, 42.0±7.9 lbf⋅ft)
IMPORTANT: Be sure to keep piston rod (11)

aligned with the center of cylinder
tube (12) when inserting, in order to
avoid damaging the rings.
11. Secure cylinder tube (12) horizontally on a
work bench. Insert piston rod (11) into the cylinder
tube.
12. Install cylinder head (7) to cylinder tube (12).

Tighten socket bolts (8) (12 used for ZAXIS110,
125US, 10 used for ZAXIS120, 135US, 135UR).
: 12 mm (ZAXIS110, 125US)
: 171 N⋅m (17.4 kgf⋅m, 126 lbf⋅ft)
: 14 mm (ZAXIS120, 135US, 135UR).
: 267 N⋅m (27.2 kgf⋅m, 200 lbf⋅ft)
W4-2-43
1 7 15 2, 3 4 8, 9 10, 13, 14 12 11 16 18 17 19, 20 21 26 27 22

29, 28 23
24
25
5 6
With the slit toward the piston
W196-04-02-006
Be sure that oil groove face the
correct direction when assembling
1- Wiper Ring 9- O-Ring 17 - Slide Ring (2 Used) 24 - Cushion Bearing

2- Backup Ring 10 - Backup Ring 18 - Piston 25 - Stopper (2 Used)
3- U-Ring 11 - Piston Rod 19 - Seal Ring 26 - Shim
4- Buffer Ring 12 - Cylinder Tube 20 - O-Ring 27 - Nut
5- Bushing 13 - O-Ring 21 - Slide Ring 28 - Steel Ball
6- Snap Ring 14 - Backup Ring 22 - Snap Ring 29 - Set Screw
7- Cylinder Head 15 - O-Ring 23 - Cushion Seal
8- Backup Ring (3 Used) 16 - Cushion Bearing
W4-2-44
Assemble Offset Cylinder (ZAXIS135UR only)
1. Press bushing (5) into cylinder head (7). 7. Install the piston (18) assembly and cushion
Bushing Special Tool: 70 mm (ST 8017) bearing (16) into piston rod (11).
2. Install backup ring (2), U-ring (3), buffer ring (4), 8. Install shim (26) into piston rod (11). Tighten nut
and snap ring (6) into cylinder head (7). (27) using special tool (ST 5908) according to the
matching mark.
3. Install wiper ring (1) into cylinder head (7) with a
plastic hammer. Nut Special Tool: 85 mm (ST 3304)
Special tools for wiper ring installation: : 3580 N⋅m (365 kgf⋅m, 2640 lbf⋅ft)
ST 8017 ST 5908
4. Install O-ring (13), backup rings (10, 14, 8) and

O-rings (9, 15) into cylinder head (6).
5. Install seal ring (19), O-ring (20), and slide rings

(17, 21) to piston (18).
6. Install cylinder head (7) assembly into piston rod W158-04-02-022

(11).
Cylinder head special tool: ST 8017
IMPORTANT: Install cushion seal (23) with the slit

side facing the piston.
Install cushion bearing (16) with the
oil groove facing the correct
direction.
W4-2-45
Offset Cylinder (ZAXIS135UR)
7 12 11 27 22
29, 28 23
24
25
W196-04-02-006
W4-2-46
IMPORTANT: Set screw (29) was crimped with a
punch in 2 places after it was
tightened.
9. Align holes on piston rod (11) and nut (27). Install
steel ball (28). Then, tighten set screw (29).
: 10 mm
: 56.9±10.7 N⋅m
(5.8±1.09 kgf⋅m, 42±8 lbf⋅ft)
IMPORTANT: Install cushion seal (23) with the slit

facing the piston. Install cushion
bearing (24) with the oil groove
facing the correct direction.
10. Install snap ring (22) and cushion seal (23) into
piston rod (11). Install cushion bearing (24) and
stopper (25).

aligned with the center of cylinder
tube (12) when inserting, in order to
avoid damaging the piston rings.
11. Securely place cylinder tube (12) on a workbench,

insert the piston rod (11) assembly into the
cylinder tube.
12. Tighten cylinder head (7) to cylinder tube (12) with

R wrench (ST 3222). Fold the detents to lock the
cylinder head.
: 1060±235 N⋅m
(108±24 kgf⋅m, 780±170 lbf⋅ft)
W4-2-47
1 7 10 8, 9 11 12 17, 18 20 21 22 23
13 14
25
24
W198-04-02-004
2, 3 4 5 6 15 19
1- Wiper Ring 8- Backup Ring 15 - Backup Ring (2 Used) 21 - Slide Ring (2 Used)
2- Backup Ring 9- O-Ring 16 - Piston 22 - Shim
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 24 - Steel Ball
5- Bushing 12 - Cylinder Tube 19 - Backup Ring 25 - Set Screw
6- Snap Ring 13 - Slide Ring 20 - Slide Ring (2 Used)
7- Cylinder Head 14 - Slide Ring
W4-2-48
Assemble Blade Cylinder (ZAXIS135UR)
1. Press bushing (5) into cylinder head (7) with a 7. Install the piston (16) assembly to piston rod (11).
press.
Bushing Special Tool: 70 mm (ST 8017) 8. Install shim (22) into piston rod (11). Tighten nut
(23) using special tool (ST 5908) according to the
IMPORTANT: Be sure to install correctly. matching mark.
Nut Turning Special Tool: 75 mm (ST 3271)
2. Install backup ring (2) and U-ring (3), buffer ring : 2640 N⋅m (269 kgf⋅m, 1950 Ibf⋅ft)
(4) and snap ring (6) into cylinder head (7). ST 5908
3. Install wiper ring (1) into cylinder head (7) using

ST 8017.
Wiper Ring Special Tool: ST 8017
4. Install O-rings (9), (10) and backup ring (8) to

cylinder head (7).
W158-04-02-022
5. Install seal ring (17), O-ring (18), slide rings (13,

14, 20, 21) and backup rings (15, 19) to piston
(16).
6. Install the cylinder head (7) assembly into piston

rod (11).
Cylinder Head Special Tool: ST 8017
W4-2-49
7 11 12 23
25
24
W198-04-02-004
W4-2-50
IMPORTANT: Set screw (25) should be crimped
with a punch in 2 places after it is
tightened.
9. Align the holes on piston rod (11) and nut (23) to
install steel ball (24). Then, tighten set screw (25).
: 8 mm
: 31.5±5.88 N⋅m
(3.21±0.60 kgf⋅m, 23±4.3 Ibf⋅ft)

aligning with the center of cylinder
tube (12) when inserting in order to
avoid damaging the piston rings.
10. Securely place cylinder tube (12) on a workbench,
insert the piston rod (11) assembly into the
cylinder tube.
11. Tighten cylinder head (7) to cylinder tube (12) with

R wrench (ST 3223). Fold the detents to lock the
cylinder head.
: 647 N⋅m
(66 kgf⋅m, 480 lbf⋅ft)
W4-2-51
Piston Rod
W105-04-02-094
Unit: mm (in)
Machine Model Cylinder Name Recommended Size After Re-manufacturing (A)
-0.01 -0.00039
Boom 70 -0.023
(2.76 -0.00091
)
ZAXIS110 -0.01 -0.00039
Arm 75 -0.023
(2.95 -0.00091
)
ZAXIS125US
-0.01 -0.00039
Bucket 65 -0.023
(2.56 -0.00091
)
-0.01 -0.00039
Boom 70 -0.023
(2.76 -0.00091
)
ZAXIS120 -0.01 -0.00039
Arm 80 -0.023
(3.15 -0.00091
)
ZAXIS135US
-0.01 -0.00039
Bucket 70 -0.023
(2.76 -0.00091
)
-0.01 -0.00039
Boom 70 -0.023
(2.76 -0.00091
)
-0.012 -0.00047
Arm 85 -0.027
(3.35 -0.00106
)
-0.01 -0.00039
ZAXIS135UR Bucket 65 -0.023
(2.56 -0.00091
)
-0.01 -0.00039
Offset 70 -0.023
(2.76 -0.00091
)
-0.01 -0.00039
Blade 70 -0.023
(2.76 -0.00091
)
Piston Rod Run Out
Dial Gauge
Piston Rod
W166-04-02-022
1 m (39.4 in)
V Block
unit: mm (in)
Bend Run out Remedy
Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
W4-2-52
MEMO
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SECTION 5
ENGINE AND ACCESSORY
 CONTENTS 
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual.............. 1-2 Cylinder Head................................................ 4-2
Main Data and Specifications ........................ 1-6 Valve Guide ................................................... 4-3
Performance Curve ....................................... 1-7 Valve Spring .................................................. 4-6
External View ................................................ 1-9 Tappet ........................................................... 4-7
Tightening Torque Specifications ................. 1-13 Push Rod ...................................................... 4-8
Angular Nut and Bolt Tightening Method...... 1-15 Rocker Arm Shaft and Rocker Arm................ 4-8
Major Parts Fixing Nuts and Bolts................ 1-17 Idler Gear and Idler Gear Shaft ..................... 4-9
Identifications .............................................. 1-25 Camshaft..................................................... 4-10
Cylinder Body and Liner............................... 4-11
Maintenance Piston and Piston Ring ................................ 4-17
Lubricating System ........................................ 2-2 Piston Pin .................................................... 4-18
Fuel System .................................................. 2-3 Connecting Rod........................................... 4-19
Cooling System ............................................. 2-6 Crankshaft................................................... 4-21
Valve Clearance Adjustment.......................... 2-6 Flywheel ...................................................... 4-28
Injection Timing ............................................. 2-8 Timing Gear Case Cover ............................. 4-28
Compression Pressure Measurement.......... 2-12
Turbocharger Inspection.............................. 2-13 Engine Assembly 3 (Reassembly)
Engine Repair Kit ........................................ 2-14 Piston and Connecting Rod
Recommended Lubricants ........................... 2-15 Reassembly Steps ....................................... 5-2
Engine Oil Viscosity Chart ........................... 2-15 Cylinder Head Reassembly Steps.................. 5-4
Rocker Arm and Rocker Arm Shaft
Engine Assembly 1 (Disassembly) Reassembly Steps ....................................... 5-7
External Parts Disassembly Steps ................. 3-2 Major Component Reassembly Steps 1 ......... 5-8
Major Components ........................................ 3-6 Major Component Reassembly Steps 2 ....... 5-13
Rocker Arm and Rocker Arm Shaft External Parts Reassembly Steps
Disassembly Steps .................................... 3-10 (Left-Hand Side) ........................................ 5-18
Cylinder Head Disassembly Steps ............... 3-11 External Parts Reassembly Steps
Piston and Connecting Rod (Right-Hand Side) ...................................... 5-21
Disassembly Steps .................................... 3-12 Engine Tuning Operation ............................. 5-25
187W-5-1
Lubricating System Troubleshooting
General Description....................................... 6-2 Hard Starting ............................................... 11-2
Oil Pump ....................................................... 6-3 1) Starter Inoperative................................. 11-2
Oil Cooler ...................................................... 6-5 2) Starter Operates but
Engine does not Turn Over.................... 11-3
Cooling System 3) Engine Turns Over but does not Start
General Description....................................... 7-2 Fuel is Being Delivered to the
Thermostat.................................................... 7-3 Injection Pump ...................................... 11-4
4) Engine Turns Over but does not Start.... 11-5
Fuel System Unstable Low Idling ..................................... 11-6
General Description....................................... 8-2 Insufficient Power ........................................ 11-8
Injection Nozzle ............................................. 8-3 Excessive Fuel Consumption..................... 11-11
Injection Pump Calibration Data .................... 8-8 Excessive Oil Consumption ....................... 11-13
Overheating............................................... 11-14
Turbocharger Whity Exhaust Smoke ............................... 11-16
General Description....................................... 9-2 Dark Exhaust Smoke................................. 11-17
Turbocharger Identification ............................ 9-3 Oil Pressure does not Rise ........................ 11-18
Troubleshooting............................................. 9-5 Abnormal Engine Noise ............................. 11-20
Inspection and Repair ................................... 9-7
Special Tool List
Engine Electricals Special Tool List .......................................... 12-2
Starter Identification .................................... 10-2
Starter Main Data and Specifications........... 10-3 Repair Standards
Starter Sectional View ................................. 10-4 Repair Standards ........................................ 13-1
Performance ............................................... 10-4
Disassembly................................................ 10-5 Conversion Table
Inspection and Repair ................................. 10-8 Length ......................................................... 14-1
Reassembly .............................................. 10-12 Area ............................................................ 14-3
Adjustment ................................................ 10-13 Volume ........................................................ 14-3
Performance Test ...................................... 10-14 Mass ........................................................... 14-5
Alternator Identification.............................. 10-15 Pressure...................................................... 14-6
Main Data and Specifications .................... 10-16 Torque ......................................................... 14-7
Alternator Sectional View........................... 10-17 Temperature ................................................ 14-8
Charging Circuit ........................................ 10-17
Structure ................................................... 10-18
Disassembly.............................................. 10-19
Inspections................................................ 10-22
Reassembly .............................................. 10-24
Bench Test ................................................ 10-25
Current Output Test ................................... 10-26
Fault Finding ............................................. 10-27
Specifications ............................................ 10-27
187W-5-2
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLECATION NO.:
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DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
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Workshop Manual 110 & 120 PDF

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Workshop Manual 110 & 120 PDF

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Manual No.

PRINTED IN SINGAPORE (PS) 2003.11

Zaxis110...135UR-WSh 1 30/10/03, 7:37 PM

Vol No.: W187E-03

• Each page has a number, located on the center

Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

• This is the SAFETY ALERT SYMBOL.

UNDERSTAND SIGNAL WORDS

• CAUTION also calls attention to safety messages in

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the

to operate the machine.

• Be prepared if a fire starts or if an accident occurs.

posted near your telephone.

WEAR PROTECTIVE CLOTHING

Be sure to wear the correct equipment and clothing

• Prolonged exposure to loud noise can cause

• Before entering the cab, thoroughly remove all

• Falling is one of the major causes of personal injury.

ADJUST THE OPERATOR'S SEAT

• If the machine should overturn, the operator may

securely fastened at all times when the machine

MOVE AND OPERATE MACHINE SAFELY

levers are in neutral.

• Battery gas can explode, resulting in serious injury.

• Riders on machine are subject to injury such as

PROVIDE SIGNALS FOR FOBS INVOLV-

• For jobs involving multiple numbers of machines,

CONFIRM DIRECTION OF MACHINE TO

• Incorrect travel pedal/lever operation may result in

• Before driving the machine, always confirm that the

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

• Driving across the face of a slope or steering on SA-441

a slope may cause the machine to skid or turn-

H/P mode switch off.

To avoid back-over and swing accidents:

MACHINE WILL TIP OVER FASTER THAN YOU

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

• Serious injury or death can result if the machine or

• If a lifted load should fall, any person nearby may

• If flying debris hit eyes or any other part of the body,

PARK MACHINE SAFELY

• Close windows, roof vent, and cab door.

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

• All fuels, most lubricants, and some coolants are

• Store flammable fluids well away from fire

• The danger of tipping is present when

Take the following precautions when loading /

2) Be sure to use a loading dock or ramp.

• Understand service procedures before doing

• Before servicing the machine:

inside the machine.

• Unexpected machine movement can cause serious

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS

• Grease in the track adjuster is under high pressure.

• Wait for GEAR OIL to cool, then gradually loosen

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

USE TOOLS PROPERLY

• The hydraulic oil tank is pressurized. Again, be