Professional Documents
Culture Documents
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
Example : T 1-3-5
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
001-E01A-0688
SA-688
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
PREPARE FOR EMERGENCIES
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-6
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control SA-444
012-E01B-0444
JUMP STARTING
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
014-E01B-0379
SA-379
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-9
SAFETY
DRIVE MACHINE SAFELY
SA-387
SA-388
019-E01D-0492
SA-590
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
020-E08A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440
unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
033-E09B-0390
SA-15
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
SS2045102
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
504-E01A-0034 SA-034
SA-040
S522-E01A-0040
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
511-E01A-0029
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................. T1-1-1
Maintenance Standard Terminology .......... T1-1-7
Group 3 Painting
Painting (ZAXIS110, 110-E, 120, 120-E,
125US, 135US) .................................... W1-3-1
Painting (ZAX135UR) .............................. W1-3-3
187W-1-1
(Blank)
187W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and 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.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A
(3) Check that the O-ring is not twisted, and that it W105-03-05-020
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
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOLOGY
“Standard”
1. Dimension for parts on a new machine.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
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
GENERAL / Tightening
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
W162-01-01-001
W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
GENERAL / Tightening
Service Recommendations for Split Flange
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
W1-2-6
GENERAL / Tightening
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types 30°
of screw fittings are used.
M114-07-043 M114-07-042
W1-2-8
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic in-
spection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards. It is very
difficult to gauge the extent of deterioration, fatigue, or
weakening of the parts listed below simply by visual in-
spection alone. For this reason, replace these parts at the
intervals shown in the table below. However, if any of
these parts are found to be defective, replace before
starting 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
W1-2-10
GENERAL / Painting
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
720
W178-01-03-003 820 W1CC-01-03-006
5 Section B
Section A
Mask Garnished Portion
Door
Panel Behind the
Door
YR-01 (TAXI Yellow)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Tool Box
N1.0 (Black) W1SE-01-03-003
W178-01-03-007
Upper
Side of
Frame
W178-01-03-006
W1-3-2
GENERAL / Painting
Unit: mm
Ladder Rail on Right Side of Upperstructure
(High-Grade Black)
W187-01-03-002
Bed Cover
W1-3-3
GENERAL / Painting
W187-01-03-004
Tool Box (Black)
W187-01-03-003
Section B
5
Section A
Mask Garnished Portion
Door
Panel Behind the
Door
YR-01 (TAXI Yellow)
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
W1-3-4
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 5 Control Valve
Remove and Install Cab ..............................W2-1-1 Remove and Install Control Valve ............... W2-5-1
Dimensions of the Cab Glass ....................W2-1-17 Disassemble Control Valve
4-Spool Section ......................................... W2-5-4
Group 2 Counterweight Disassemble Control Valve
Remove and Install Counterweight..............W2-2-1
5-Spool Section ....................................... W2-5-10
Group 3 Main Frame Separate and Combine
Remove and Install Main Frame..................W2-3-1 4-Spool and 5-Spool Control Valve.......... W2-5-16
Assemble Control Valve
Group 4 Pump Device 4-Spool Section ....................................... W2-5-18
Remove and Install Pump Device................W2-4-1 Assemble Control Valve
Remove and Install Pilot Pump and 5-Spool Section ....................................... W2-5-24
Regulator....................................................W2-4-4 Disassemble Blade Control Valve
Disassemble Pump Device..........................W2-4-8 (ZAXIS 135UR Only) ............................... W2-5-30
Assemble Pump Device.............................W2-4-16 Assemble Blade Control Valve
Disassemble Regulator..............................W2-4-28 (ZAXIS 135UR Only) ............................... W2-5-32
Assemble Regulator ..................................W2-4-30
Disassemble Solenoid Valve .....................W2-4-32 Group 6 Swing Device
Assemble Solenoid Valve ..........................W2-4-34 Remove and Install Swing Device............... W2-6-1
Disassemble and Assemble Pilot Disassemble Swing Device......................... W2-6-4
Pump (ZAXIS 110,120,125US,135US) ....W2-4-36 Assemble Swing Device............................ W2-6-10
Disassemble and Assemble Gear Disassemble Swing Motor ....................... W2-6-18
Pump (ZAXIS 135UR Only) .....................W2-4-38 Assemble Swing Motor.............................. W2-6-22
Maintenance Standard...............................W2-4-40 Disassemble Valve Unit............................. W2-6-28
Assemble Valve Unit ................................. W2-6-30
Maintenance Standard .............................. W2-6-32
187W-2-1
Group 7 Pilot Valve Group 10 Solenoid Valve
Remove and Install Right Pilot Valve Remove and Install Solenoid Valve Unit ... W2-10-1
(ZAXIS 110,120,125US,135US) ................W2-7-1 Disassemble Proportional
Remove and Install Left Pilot Valve Solenoid Valve ......................................... W2-10-6
(ZAXIS 110,120,125US,135US) ................W2-7-5 Assemble Proportional Solenoid Valve ..... W2-10-8
Remove and Install Front / Swing Pilot Valve Remove and Install Emergency Stop Solenoid
(ZAXIS 135UR) ..........................................W2-7-8 Valve Unit (ZAXIS 135UR Only) .............W2-10-11
Disassemble Right and Left Disassemble and Assemble Selector
Pilot Valves...............................................W2-7-10 Valve ...................................................... W2-10-14
Assemble Right and Left Disassemble and Assemble Unloading
Pilot Valves...............................................W2-7-14 Valve ...................................................... W2-10-16
Remove and Install Travel
Pilot Valve.................................................W2-7-19 Group 11 Holding Valve
Disassemble Travel Pilot Valve..................W2-7-22 Remove and Install Holding Valve..............W2-11-1
Assemble Travel Pilot Valve ......................W2-7-26 Holding Valve (ZAXIS 135UR Only) ...........W2-11-4
Remove and Install Offset Pilot Valve
(ZAXIS 135UR) ........................................W2-7-32
Remove and Install Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-34
Disassemble Offset / Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-36
Assemble Offset / Blade Pilot Valve
(ZAXIS 135UR) ........................................W2-7-38
187W-2-2
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