ZX110 - 120 - 130 - 125US - 135US (UR) Full Service Manual PDF

Manual No.
: KM-187E
Vol. No. : TO187-E-04
110 110M 120 130 130LCN 125US 135US 135UR Excavator Technical Manual (Operational Principle)
Technical Manual
(Operational Principle)
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-TM/OP 1 14/11/03, 12:53 PM

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this 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: 81-29-832-7084
FAX: 81-29-831-1162
• This manual contains the revision information
to the 10, June 2008.
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.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
PAGE NUMBER

Example : T 1-3-5

Group Number
Section Number
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
SECTION AND GROUP
SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
TECHNICAL MANUAL Group 2 Front Control System
Group 3 Hydraulic System
(Operational Principle) Group 4 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others(Upperstructure)
Group 8 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
All information, illustrations and speci- Group 3 Engine Test Group 4 Troubleshooting B
fications in this manual are based on Group 4 Excavator Test Group 5 Troubleshooting C
the latest product information available Group 5 Component Test Group 6 Troubleshooting D
at the time of publication. The right is Group 6 Adjustment Group 7 Electrical System Inspection
reserved to make changes at any time Group 8 ICX
without notice.
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMA- Group 8 Pilot Shut-Off Valve
TION Group 9 Signal Control Valve
Group 1 Precautions for Disassem- Group 10 Solenoid Valve
bling and Assembling Group 11 Holding Valve
COPYRIGHT(C)2003 Group 2 Tightening Torque SECTION 3 UNDERCARRIAGE
Hitachi Construction Machinery Co., Ltd. Group 3 Painting Group 1 Swing Bearing
Tokyo, Japan SECTION 2 UPPERSTRUCTURE Group 2 Travel Device
All rights reserved Group 1 Cab Group 3 Center Joint
Group 2 Counterweight Group 4 Track Adjuster
Group 3 Main Frame Group 5 Front Idler
Group 4 Pump Device Group 6 Upper and Lower Roller
Group 5 Control Valve Group 7 Track
Group 6 Swing Device SECTION 4 FRONT ATTACHMENT
Group 7 Pilot Valve Group 1 Front Attachment
Group 2 Cylinder
←これ以下
記載しない
SECTION 1
GENERAL
—CONTENTS—
Group 1 Specifications
Specifications............................................ T1-1-1
Working Ranges ....................................... T1-1-8

Main Component Layout ........................... T1-2-1
Electrical Component Layout .................... T1-2-4
(Overview)
Elecrical System ....................................... T1-2-7
(Relays and Related Equipment)
Electrical System .................................... T1-2-10
(Monitors and Switches)
Pump Device .......................................... T1-2-12
Swing Device .......................................... T1-2-13
Control Valve .......................................... T1-2-13
Signal Control Valve................................ T1-2-13
Solenoid Valve Unit................................. T1-2-13
8-Unit Solenoid Valve Unit .................... T1-2-14
Blade Control Valve ................................ T1-2-14
Positioning Control Valve ...................... T1-2-14
Travel Device .......................................... T1-2-14
Group 3 Component Specifications

ZAXIS110,110M,ZAXIS125US,
ZAXIS135UR......................................... T1-3-1
ZAXIS120,130,130LCN,135US ............... T1-3-11
187T-1-1
(Blank)
187T-1-2
GENERAL / Specifications
SPECIFICATIONS
ZAXIS110, 110M
A
G C
E
D
K J
I H
M175-12-005
Model ZAXIS110 ZAXIS110M

Type of Front-End Attachment 2.26 m (7 ft 5 in) Arm 2.26 m (7 ft 5 in) Arm
Bucket Capacity (Heaped) m3 (yd3) PCSA 0.45 m3 (0.59 yd3), CECE PCSA 0.45 m3 (0.59 yd3), CECE
0.4 m3 0.4 m3
Operating Weight kg (lb) 10700 (23600) 12800 (28200)
Basic Machine Weight kg (lb) 8240 (18200) 10340 (22800)
Engine ISUZU BB-4BG1T, 59 kW (80 PS)/1950 min−1 (rpm)
63 kW (85 PS)/2150 min－1 (rpm)
A : Overall Width (Excluding Rearview Mirrors)
2500 (8′ 2″) 2740 (9′ 0″)
mm (ftxin)
B : Cab Height mm (ftxin) 2740 (9′ 0″) 2950 (9′ 8″)
C : Rear End Swing Radius mm (ftxin) 2130 (7′ 0″) 2130 (7′ 0″)
D : Minimum Ground Clearance mm (ftxin) * 440 (1′ 5″) * 595 (1′ 11″)
E : Counterweight Clearance mm (ftxin) * 890 (2′ 11″) * 1100 (3′ 7″)
F : Engine Cover Height mm (ftxin) * 2000 (6′ 7″) * 2210 (7′ 3″)
G : Overall Width of Upperstructure
2460 (8′ 1″) 2460 (8′ 1″)
mm (ftxin)
H : Undercarriage Length mm (ftxin) 3340 (10′ 11″) 3790 (12′ 5″)
I : Undercarriage Width mm (ftxin) 2490 (8′ 2″) 2740 (9′ 0″)
J : Sprocket Center to Idle Center mm (ftxin) 2620 (8′ 7″) 2990 (9′ 10″)
K : Track Shoe Width mm 500 (Grouser Shoe) 700 (Grouer Shoe)
(ftxin) (20″) (28″)
2
Ground Pressure kPa (kgf/cm ) (psi) 36 (0.37) (5.3) 27 (0.28) (4.0)
Offset Distance mm (ftxin) − −
Swing Speed min−1 (rpm) 13.9 (13.9) 13.9 (13.9)
Travel Speed (fast/slow) km/h 5.5/3.6 4.2/2.4
(mph) (3.4/2.2) (2.6/1.5)
Gradeability degree (%) 35 (70) 35 (70)
NOTE: H/P mode

* The dimensions do not include the height of the shoe lug.
T1-1-1
ZAXIS120
A
G C
F
E
D
K
J
I H
M175-12-001
Model ZAXIS120
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
Bucket Capacity (Heaped) PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Operating Weight 12000 kg (26500 lb)
Basic Machine Weight 9300 kg (20500 lb)
ISUZU CC-4BG1TC 63 kW/1950 min-1 (85 PS/1950 rpm)
Engine
66 kW/2150 min-1 (90 PS/2150 rpm)
A: Overall Width
2500 mm (8 ft 2 in)
(Excluding back mirrors)
B: Cab Height 2740 mm (9 ft 0 in)
C: Rear End Swing Radius 2130 mm (7 ft 0 in)
D: Minimum Ground Clearance *440 mm (1 ft 5 in)
E: Counterweight Clearance *890 mm (2 ft 11 in)
F: Engine Cover Height *2000 mm (6 ft 7 in)
G: Overall Width of Upperstructure 2460 mm (8 ft 1 in)
H: Undercarriage Length 3580 mm (11 ft 9 in)
I: Undercarriage Width 2490 mm (8 ft 2 in)
J: Sprocket Center to Idler Center 2880 mm (9 ft 5 in)
K: Track Shoe Width 500 mm (20 in) (Iron Crawler)
Ground Pressure 38 kPa (0.39 kgf/cm2, 5.5 psi)
Swing Speed 13.7 min-1 (13.7 rpm)
Travel Speed (fast/slow) 5.5/3.4 km/h (3.4/2.1 mph)
Gradeability 35 degree (70 %)
NOTE: HP mode
T1-1-2
ZAXIS130, 130LCN
A
G C
B
F
E
D
K
J
I H
M175-12-001
Std.
Model
ZAXIS130 ZAXIS130LCN
Bucket Capacity (Heaped) m3 (yd3) PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Engine ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min−1 (rpm)
66 kW (90 PS)/2150 min－1 (rpm)
A : Overall Width
2500 (8′ 2″)
(Excluding Rearview Mirrors) mm (ftxin)
B : Cab Height mm (ftxin) 2750 (9′ 0″)
C : Rear End Swing Radius mm (ftxin) 2130 (7′ 0″)
D : Minimum Ground Clearance mm (ftxin) *440 (1′ 5″)
E : Counterweight Clearance mm (ftxin) *890 (2′ 11″)
F : Engine Cover Height mm (ftxin) *2010 (6′ 7″)
G : Overall Width of
2460 (8′ 1″)
Upperstructure mm (ftxin)
H : Undercarriage Length mm (ftxin) 3590 (11′ 9″) 3760 (12′ 4″)
I : Undercarriage Width mm (ftxin) 2490 (8′ 2″)
J : Sprocket Center to Idle Center mm (ftxin) 2880 (9′ 5″) 3050 (10′ 0″)
K : Track Shoe Width mm 500 (Grouser Shoe)
(ftxin) (20″)
2
Ground Pressure kPa (kgf/cm ) (psi) 39 (0.40) (5.7) 37 (0.38) (5.4)
−1
Swing Speed min (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 5.5/3.4
(mph) (3.4/2.1)
Gradeability degree (%) 35 (70)
NOTE: H/P mode

T1-1-3
ZAXIS125US
T1SE-01-01-001
Model ZAXIS125US
ISUZU BB-4BG1T 59 kW/1950 min-1 (80 PS/1950 rpm)
Engine
63 kW/2150 min-1 (85 PS/2150 rpm)
A: Overall Width
2490 mm (8 ft 2 in)
NOTE: HP mode
T1-1-4
ZAXIS135US
T1SE-01-01-001
Model ZAXIS135US
ISUZU CC-4BG1TC 63 kW/1950 min-1 (85 PS/1950 rpm)
Engine
66 kW/2150 min-1 (90 PS/2150 rpm)
A: Overall Width
2490 mm (8 ft 2 in)
NOTE: HP mode
T1-1-5
ZAXIS135UR
A
C
G
B
F
E
D
K J
T1SM-01-01-001
I
Model ZAXIS135UR
Type of Front-End Attachment Offset Type
ISUZU BB-4BG1T 59 kW/1950 min-1 (80 PS/1950 rpm)
Engine
63 kW/2150 min-1 (85 PS/2150 rpm)
A: Overall Width
2490 mm (8 ft 2 in)
D: Minimum Ground Clearance 500 mm (1 ft 8 in)
E: Counterweight Clearance 960 mm (3 ft 2 in)
K: Track Shoe Width 500 mm (20 in) (Pad Crawler)
NOTE: HP mode
T1-1-6
ZAXIS130, 130LCN (2-piece Boom)
A
G C
B
F
E
D
K
J
I H
M175-12-001
Model ZAXIS130 2-piece Boom ZAXIS130LCN 2-piece Boom

3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.50 m (0.65 yd ), CECE 0.45 m
Engine ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min−1 (rpm)
66 kW (90 PS)/2150 min－1 (rpm)
A : Overall Width 2500 (8′ 2″)
(Excluding Rearview Mirrors) mm (ftxin)
B : Cab Height mm (ftxin) 2750 (9′ 0″)
C : Rear End Swing Radius mm (ftxin) 2130 (7′ 0″)
D : Minimum Ground Clearance mm (ftxin) * 440 (1′ 5″)
E : Counterweight Clearance mm (ftxin) * 890 (2′ 11″)
F : Engine Cover Height mm (ftxin) * 2010 (6′ 7″)
G : Overall Width of
Upperstructure mm (ftxin) 2460 (8′ 1″)
H : Undercarriage Length mm (ftxin) 3590 (11′ 9″) 3760 (2’ 4”)
I : Undercarriage Width mm (ftxin) 2490 (8′ 2″)
J : Sprocket Center to Idle Center mm (ftxin) 2880 (9′ 5″) 3050 (10’ 0”)
K : Track Shoe Width mm 500 (Grouser Shoe)
(ftxin) (20″)
Ground Pressure kPa (kgf/cm2) (psi) 40 (0.41) (5.8) 38 (0.39) (5.5)
Swing Speed min−1 (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h 5.5/3.4
(mph) (3.4/2.1)
Gradeability degree (%) 35 (70)
NOTE: H/P mode

T1-1-7
WORKING RANGES
ZAXIS110, 110M
G
G
C
D
C
E
E
D
F
F
A
A
B
M175-12-002
M175-12-003
Backhoe Face shovel (Reversed hoe bucket)
Model ZAXIS110
CategoryI 1.96 m (6′ 5″) Arm 2.26 m (7′ 5″) Arm 2.81 m (9′ 3″) Arm
tem Backhoe Shovel Backhoe Shovel Backhoe Shovel
A : Maximum Digging Reach mm 7430 7580 7700 7850 8180 8330
(ftxin) (24′ 5″) (24′ 10″) (25′ 3″) (25′ 9″) (26′ 10″) (27′ 4″)
B : Maximum Digging Depth mm *4780 *4930 *5080 *5230 *5630 *5780
(ftxin) (15′ 8″) (16′ 2″) (16′ 8″) (17′ 2″) (18′ 6″) (19′ 0″)
C : Maximum Cutting Height mm *7940 *8140 *8110 *8310 *8360 *8570
(ftxin) (26′ 1″) (26′ 8″) (26′ 7″) (27′ 3″) (27′ 5″) (28′ 1″)
D : Maximum Dumping Height mm *5530 *5620 *5700 *5800 *5960 *6060
(ftxin) (18′ 2″) (18′ 5″) (18′ 8″) (19′ 0″) (19′ 7″) (19′ 11″)
E : Transport Height mm 2740 2740 2740 2740 **2740 **2740
(ftxin) (9′ 0″) (9′ 0″) (9′ 0″) (9′ 0″) (9′ 0″) (9′ 0″)
F : Overall Transport Length mm 7220 7220 7220 7220 **7240 **7240
(ftxin) (23′ 8″) (23′ 8″) (23′ 8″) (23′ 8″) (23′ 9″) (23′ 9″)
G : Minimum Swing Radius mm 2310 2310 2340 2340 2600 2600
(ftxin) (7′ 7″) (7′ 7″) (7′ 8″) (7′ 8″) (8′ 6″) (8′ 6″)
Model ZAXIS110M
Category 1.96 m (6′ 5″) Arm 2.26 m (7′ 5″) Arm 2.81 m (9′ 3″) Arm
Item Backhoe Shovel Backhoe Shovel Backhoe Shovel
(ftxin) (24′ 5″) (24′ 10″) (25′ 3″) (25′ 9″) (26′ 10″) (27′ 4″)
(ftxin) (15′ 0″) (15′ 6″) (16′ 0″) (16′ 6″) (17′ 10″) (18′ 3″)
(ftxin) (26′ 8″) (27′ 4″) (27′ 4″) (27′ 11″) (28′ 1″) (28′ 9″)
D : Maximum Dumping Height mm *5730 *5820 *5910 *6010 *6170 *6260
(ftxin) (18′ 10″) (19′ 1″) (19′ 5″) (19′ 9″) (20′ 3″) (20′ 6″)
(ftxin) (9′ 8″) (9′ 8″) (9′ 8″) (9′ 8″) (9′ 8″) (9′ 8″)
(ftxin) (23′ 7″) (23′ 7″) (23′ 7″) (23′ 7″) (23′ 8″) (23′ 8″)
(ftxin) (7′ 7″) (7′ 7″) (7′ 8″) (7′ 8″) (8′ 6″) (8′ 6″)
NOTE: * The dimensions do not include the height of the shoe lug.
** The dimensions are for transport pin position.
T1-1-8
ZAXIS120
G G
C
C
D
D
E
E
F
F
A
A
B
M175-12-002
Backhoe M175-12-003
Face shovel (Reversed hoe bucket)
Category 2.10 m (6 ft 11 in) arm 2.52 m (8 ft 3 in) arm 3.01 m (9 ft 11 in) arm
A: Maximum Digging 7900 mm 8050 mm 8270 mm 8410 mm 8740 mm 8880 mm
Reach (25 ft 11 in) (26 ft 5 in) (27 ft 2 in) (27 ft 7 in) (28 ft 8 in) (29 ft 2 in)
B: Maximum Digging *5150 mm *5300 mm *5570 mm *5710 mm *6060 mm *6200 mm
Depth (16 ft 11 in) (17 ft 5 in) (18 ft 3 in) (18 ft 9 in) (19 ft 11 in) (20 ft 4 in)
C: Maximum Cutting *8370 mm *8560 mm *8570 mm *8770 mm *8900 mm *9100 mm
Height (27 ft 6 in) (28 ft 1 in) (28 ft 1 in) (28 ft 9 in) (29 ft 2 in) (29 ft 10 in)
D: Maximum Dumping *5960 mm *6080 mm *6160 mm *6250 mm *6490 mm *6570 mm
Height (19 ft 7 in) (19 ft 11 in) (20 ft 3 in) (20 ft 5 in) (21 ft 4 in) (21 ft 7 in)
E: Transport Height 2740 mm 2740 mm ** 2740 mm
(9 ft 0 in) (9 ft 0 in) (9 ft 0 in)
F: Overall Transport 7610 mm 7600 mm 7610 mm ** 7620 mm
Length (25 ft 0 in) (24 ft 11 in) (25 ft 0 in) (25 ft 0 in)
G: Minimum Swing 2310 mm 2340 mm 2590 mm
Radius (7 ft 7 in) (7 ft 8 in) (8 ft 6 in)
** The dimensions are for transport pin position.
T1-1-9
ZAXIS130, 130LCN
F
A
Backhoe M175-12-002
Model ZAXIS130, 130 LCN

Item
Backhoe Backhoe Backhoe
A : Maximum Digging Reach mm 7900 8270 8740
(ftxin) (25′ 11″) (27′ 2″) (28′ 8″)
B : Maximum Digging Depth mm *5150 *5570 *6060
(ftxin) (16′ 11″) (18′ 3″) (19′ 11″)
C : Maximum Cutting Height mm *8370 *8570 *8900
(ftxin) (27′ 6″) (28′ 1″) (29′ 2″)
D : Maximum Dumping Height mm *5960 *6160 *6490
(ftxin) (19′ 7″) (20′ 3″) (21′ 4″)
E : Transport Height mm 2750 2750 **2750
(ftxin) (9′ 0″) (9′ 0″) (9′ 0″)
F : Overall Transport Length mm 7610 7610 **7620
(ftxin) (25′ 0″) (25′ 0″) (25′ 0″)
G : Minimum Swing Radius mm 2310 2340 2590
(ftxin) (7′ 7″) (7′ 8″) (8′ 6″)
** The dimensions asterisked are for transport pin position.
T1-1-10
ZAXIS125US
G
G
C C
D
D
E
E
F
F
F
A
B
B A
M1SE-12-001
Backhoe Shovel
T1SE-01-01-002
Model ZAXIS125US
(ftxin) (25′ 6″) (26′ 0″) (26′ 5″) (26′ 11″) (28′ 0″) (28′ 6″)
(ftxin) (16′ 4″) (16′ 10″) (17′ 3″) (17′ 9″) (19′ 1″) (19′ 7″)
(ftxin) (28′ 10″) (29′ 2″) (29′ 7″) (30′ 1″) (30′ 9″) (31′ 3″)
D : Maximum Dumping Height mm *6350 *6600 6570 *6830 *6920 *7180
(ftxin) (20′ 10″) (21′ 8″) (21′ 7″) (22′ 5″) (22′ 8″) (23′ 7″)
(ftxin) (9′ 1″) (9′ 1″) (9′ 1″) (9′ 1″) (9′ 0″) (9′ 0″)
(ftxin) (23′ 9″) (23′ 9″) (23′ 9″) (23′ 9″) (23′ 5″) (23′ 9″)
(ftxin) (6′ 4″) (6′ 4″) (6′ 8″) (6′ 8″) (7′ 9″) (7′ 9″)
NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.
T1-1-11
SPECIFICATIONS
ZAXIS135US
G
G
C C
D
D
E E
F
F
F F
A
B B
A
Backhoe T1SE-01-01-002 Shovel M1SE-12-001
Model ZAXIS135US
(ftxin) (26′ 0″) (26′ 6″) (27′ 3″) (27′ 8″) (28′ 9″) (29′ 3″)
*1 B : Maximum Digging Depth mm *5120 *5270 *5530 *5680 *6020 *6170
(ftxin) (16′ 10″) (17′ 3″) (18′ 2″) (18′ 8″) (19′ 9″) (20′ 3″)
*1 C : Maximum Cutting Height mm *8950 *9100 *9220 *9370 *9610 *9760
(ftxin) (29′ 4″) (29′ 10″) (30′ 3″) (30′ 9″) (31′ 6″) (32′ 0″)
*1 D : Maximum Dumping Height mm *6490 *6790 *6760 *7030 *7150 *7400
(ftxin) (21′ 4″) (22′ 3″) (22′ 2″) (23′ 1″) (23′ 5″) (24′ 3″)
(ftxin) (9′ 4″) (9′ 4″) (9′ 4″) (9′ 4″) (9′ 4″) (9′ 4″)
(ftxin) (23′ 11″) (23′ 11″) (23′ 11″) (23′ 11″) (24′ 0″) (24′ 0″)
(ftxin) (6′ 4″) (6′ 4″) (6′ 9″) (6′ 9″) (7′ 10″) (7′ 10″)
NOTE: *1 The dimensions do not include the height of the shoe lug.
*2 The dimensions asterisked are for transport pin position.
T1-1-12
SPECIFICATIONS
ZAXIS135UR G
J J
E
H
K
I
F
B A
T1SM-01-01-002
Category 2.14 m (7′ 0″) arm 2.44 m (8′ 0″)

Item (Standard) Long arm
A: Maximum Digging Reach 7590 mm (24 ft 11 in) 7920 mm (25 ft 12 in)
B: Maximum Digging Depth 4800 mm (15 ft 9 in) 5100 mm (16 ft 9 in)
C: Maximum Cutting Height 8650 mm (28 ft 5 in) 8980 mm (29 ft 6 in)
D: Maximum Dumping Height 6220 mm (20 ft 5 in) 6530 mm (21 ft 5 in)
E: Transport Height 2780 mm (9 ft 1 in) 2780 mm (9 ft 1 in)
F: Overall Transport Length 7270 mm (23 ft 10 in) 7300 mm (23 ft 11 in)

G: Minimum Swing Radius
(Front Attachment) 1310 mm (4 ft 4 in) 1520 mm (4 ft 12 in)
H: Maximum Blade Raise 550 mm (1 ft 10 in)

I: Maximum Blade Lower 440 mm (1 ft 5 in)
J: Offset Amount (from Center Left (Cab side) 1130 mm (3 ft 9 in)
of Front end Attachment) Right 1130 mm (3 ft 9 in)
K: Approach Angle 30 degree
T1-1-13
SPECIFICATIONS
ZAXIS130, 130LCN (2-piece Boom)

G
A
B
M1G6-13-011
Model ZAXIS130, 130LCN 2-piece Boom

Category 2.10 m (6′11″) Arm 2.52 m (8′3″) Arm 3.01 m (9′11″) Arm
Item Backhoe Backhoe Backhoe
A : Maximum Digging Reach mm (ftxin) 7900 (25′11″) 8270 (27′2″) 8750 (28′8″)
*1
B: Maximum Digging Depth mm (ftxin) *4940 (16′3″) *5340 (17′6″) *5830 (19′2″)
*1
C: Maximum Cutting Height mm (ftxin) *9070 (29′9″) *9390 (30′10″) *9820 (32′3″)
*1
D: Maximum Dumping Height mm (ftxin) *6610 (21′8″) *6930 (22′9″) *7360 (24′2″)
**
E : Transport Height mm (ftxin) 2750 (9′0″) 2750 (9′0″) 2750 (9′0″)
F : Overall Transport Length mm (ftxin) 7550 (24′9″) 7530 (24′9″) 7530 (24′9″)
G : Minimum Swing Radius mm (ftxin) - - -
** The dimensions asterisked are for transport pin position.
T1-1-14
GENERAL / Component Layout
MAIN COMPONENT LAYOUT
ZAXIS110/110M/120/130/130LCN
1
3
4
5
6
7
8
21
10
11
12
13
14
20 15
16
19
18 17
T176-01-02-001
1 - Bucket Cylinder 7 - Fuel Tank 13 - Intercooler 19 - Pilot Shut-Off Valve

(ZAXIS120/130/130LC only)
2 - Arm Cylinder 8 - Hydraulic Oil Tank 14 - Radiator 20 - Travel Pilot Valve
3 - Boom Cylinder 9 - Control Valve 15 - Oil Cooler 21 - Front Attachment/Swing
Pilot Valve
4 - Center Joint 10 - Pilot Filter and Pilot Relief 16 - Battery
Valve
5 - Swing Bearing 11 - Pump Device 17 - Travel Device
6 - Swing Device 12 - Engine 18 - Signal Control Valve
T1-2-1
ZAXIS125US/135US
2 3
1 5
19
6
7
8
18
17
16
9
10
11 T1SE--01-02-001
12
14 13
15
1 - Front Attachment / Swing 6 - Boom Cylinder 11 - Signal Control Valve 16 - Engine

Pilot Valve
2 - Pilot Shut-Off Valve 7 - Hydraulic Oil Tank 12 - Center Joint 17 - Radiator
3 - Travel Pilot Valve 8 - Fuel Tank 13 - Swing Device 18 - Oil Cooler
4 - Arm Cylinder 9 - Control Valve 14 - Pilot Filter / Pilot Relief 19 - Intercooler
Valve (ZAXIS135US only)
5 - Bucket Cylinder 10 - Solenoid Valve Unit 15 - Pump Device
T1-2-2
ZAXIS135UR
2
3
4
1
5
6
7
8
9
10
11
12
13
29
14
28 15
16
17
18
27
26
25
24
23
22 19
21
20 T1SM-01-02-001
1- Bucket Cylinder 9- Solenoid Valve Unit 16 - Pump Device 23 - Emergency Stop Valve
2- Arm Cylinder 10 - Signal Control Valve 17 - Engine 24 - Blade Pilot Valve
3- Offset Cylinder 11 - Fuel Tank 18 - Blade Cylinder 25 - Pilot Shut-Off Valve
4- Offset Anti-Drift Valve 12 - Hydraulic Oil Tank 19 - Radiator 26 - Travel Pilot Valve
5- Boom Cylinder 13 - Pilot Filter / Pilot Relief 20 - Oil Cooler 27 - Travel Device
Valve
6- Blade Signal Switch 14 - Swing Device 21 - Center Joint 28 - Offset Pilot Valve
Valve
7 - Control Valve 15 - Blade Control Valve 22 - Battery 29 - Front Attachment / Swing
Pilot Valve
8- 8-Unit Solenoid Valve
Unit
T1-2-3
ELECTRICAL COMPONENT LAYOUT
(Overview)
ZAXIS110/110M/120/130/130LCN
3
• Pressure Sensor (Front Attachment)
Refer to the Swing Device group. 4
2 • Pressure Sensor
1 (Boom Raise)
• Pressure Sensor
(Arm Roll-In)
Refer to the Control Valve
group.
16
• Pressure Sensor (Travel)

• Pressure Sensor (Swing)
Refer to the Signal Control
Valve group.
15 7
8
14
13 • Pump 1 and 2 Delivery Pressure Sensor

• Pump 1 and 2 Control Pressure Sensor T176-01-02-004
9 • N Sensor
10 • Torque Control Solenoid Valve
12 11 • Pump 2 Flow Rate Control Solenoid Valve
Refer to the Pump Device group.
1 - Horn 5 - Hydraulic Oil Temperature 9 - Overheat Switch 13 - *Coolant Level Switch

Sensor
2 - Work Light 6 - EC Motor and EC Sensor 10 - Coolant Temperature 14 - Battery
Sensor
3 - Fuel Sensor 7 - Engine Oil Pressure Switch 11 - Battery Relay 15 - Air Cleaner Restriction
Switch
4 - Solenoid Valve Unit 8 - *Engine Oil Level Switch 12 - Glow Plug Relay 16 - Wiper Motor
NOTE:* ZAXIS110/110M: Up to serial No.010576
ZAXIS120: Up to serial No.062964
T1-2-4
ZAXIS125US/135US
• Pump 1 and 2 Delivery Pressure Sensor

• Pump 1 and 2 Control Pressure Sensor
• N Sensor
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control Solenoid Valve
1 3
2
4
15
6
7
14
13
8
10
• Pressure Sensor • Pressure Sensor

(Boom Raise) (Travel)
(Arm Roll-In) (Swing)
Refer to the Control Valve Refer to the Signal 11
group Control Valve group 12
T1SE-01-02-002
• Pressure Sensor
(Front Attachment)
Refer to the Swing Device group
1 - EC Motor and EC Sensor 5 - Coolant Temperature 9 - Battery 13 - Solenoid Valve Unit

Sensor
2 - *Engine Oil Level Switch 6 - *Coolant Level Switch 10 - Air Cleaner Restriction 14 - Hydraulic Oil Temperature
Switch Sensor
3 - Engine Oil Pressure Switch 7 - Battery Relay 11 - Wiper Motor 15 - Fuel Sensor
4 - Overheat Switch 8 - Glow Plug Relay 12 - Horn
NOTE:* ZAXIS125US: Up to serial No.010576
ZAXIS135US: Up to serial No.062964
T1-2-5
ZAXIS135UR
1 2
• Pump 1 and 2 Delivery Pressure

Sensor
• Pump 1 and 2 Control Pressure
Sensor
• N Sensor
• Pump 2 Flow Rate Control 18
Solenoid Valve
4
17
16
15
5
6
• Pressure Sensor
(Travel)
• Pressure Sensor
(Swing)
Refer to the Signal
7
Control Valve group 8
14
10
13
12
• Pressure Sensor (Boom Raise)
• Pressure Sensor
(Arm Roll-In) 11
Refer to the Control Valve group. T1SM-01-02-008
1 - Arm Angle Sensor 6- Coolant Temperature 11 - Emergency Stop Solenoid 15 - Fuel Sensor
Sensor Valve
2 - Offset Angle Sensor 7 - Battery Relay 12 - Horn 16 - Hydraulic Oil Temperature
Sensor
3 - Boom Angle Sensor 8- Glow Plug Relay 13 - 8-Unit Solenoid Valve Unit 17 - Pressure Sensor (Front
Attachment)
4 - Engine Oil Pressure Switch 9 - Battery 14 - Solenoid Valve Unit 18 - EC Motor / EC Sensor
5 - Overheat Switch 10 - Air Cleaner Restriction
Switch
T1-2-6
ELECTRICAL SYSTEM
(Relays and Related Equipment) Rear Deck
5
ZAXIS110/110M/120/130/130LCN 4
3
2
10
T178-01-02-006
15
14
18 13
17 12
16 11
T178-01-02-007
1- Mail Switch (Satellite 6- Fuse Box 11- Load Damp Relay (R1) 16- Wiper Relay A (R6)
Navigation System
Equipped Machines only)
2- QOS Controller 7- Learning Switch 12- Washer Relay (R2) 17- Wiper Relay B (R7)
3- ICX (Information Controller) 8- Dr. ZX Connector to MC 13- Work Light Relay 2 (R3) 18- Wiper Relay C (R8)
4- MC (Main Controller) 9- Download Connector (Not connected on 14- Work Light Relay 1 (R4)
Satellite Navigation System equipped
machines)
5-Satellite Terminal (Optional) 10- Dr. ZX Connector to ICX 15- Horn Relay (R5)
T1-2-7
15
ZAXIS125US/135US 4
16
14
17
13
12
11 5
10
T1GF-01-02-003
6
1, 2 3
9 8 7
T1SM-01-02-006
1- ICX (Information Controller) 6- Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
2- MC (Main Controller) 7- Dr.ZX Connector to MC 12 - Work Light Relay 2 (R3) 17 - Wiper Relay C (R8)
3- Satellite Terminal (Optional) 8- Dr.ZX Connector to ICX 13 - Washer Relay (R2)
4- Download Connector (Not 9- Learning Switch 14 - Load Damp Relay (R1)
connected on Satellite
Navigation System equipped
machines)
5 - Diode D1, D2, D3 and D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)
T1-2-8
ZAXIS135UR
Behind Seat
1 2 3
Upward
Speaker
T1CF-01-01-011
T1CF-01-01-012
6
7
5 8
4
9
18
10
17
16
15
14
11
12
13
T1CF-01-01-013
1 - Auto - Marccino Control Unit 6 - Fuse Box 11 - Wiper Relay (R6) 15 - Work Right Relay 1 (R4)
2 - MC (Main Controller) 7 - Emergency Evacuation 12 - MC Relay (Optional) 16 - Work Right Relay 2 (R3)
Switch
3 - ICX (Information Controller) 8 - Learning Switch 13 - Air Bleed Relay 17 - Washer Relay (R2)
(R8) (Optional)
4 - Dr. ZX Connector to ICX 9 - Dr. ZX Connector for UR 14 - Horn Relay (R5) 18 - Load Damp Relay (R1)
5 - Dr. ZX Connector to MC 10 - Personal Computer
Connector to ICX
T1-2-9
ELECTRICAL SYSTEM
ZAXIS110/110M/120/130/130LCN/125US/135US
1 2
20
19
21
18
3
17
22
16 4
15
5 23
14 24
6
13 7
12 8
25
11
9
10
T178-01-01-012
T178-01-01-013
1- Coolant Temperature Gauge 8- Alternator Indicator 15- Digging Mode Indicator 21- Auto-Idle/Acceleration
Selector
2- Fuel Gauge 9- Hydraulic Oil Filter Indicator 16- Attachment Mode Indicator 22- Power Mode Switch
(Optional)
3- Display Selection Switch 10- Coolant Level Indicator 17- Liquid Crystal Display 23- Travel Mode Switch
4- SET Switch 11- Engine Oil Level Indicator 18- Auto-Idle Indicator 24- Work Light Switch
5- Work Mode Switch 12- Engine Oil Pressure 19- Auto-Acceleration Indicator 25- Wiper/Washer Switch
Indicator
6- Fuel Level Indicator 13- Preheat Indicator 20- Engine Control Dial
7- Air Filter Restriction Switch 14- Overheat Indicator
NOTE:* ZAXIS110/110M/125US: Up to serial No.010576
ZAXIS120/135US: Up to serial No.062964
T1-2-10
ZAXIS135UR Monitor 6 7
1
8
2 9
3 10
11
24
4 12
23 13
5
22
14
21 15
T1CF-01-01-003
20 16
19 17
18
T1SM-01-02-014
1- Left Offset Switch 7- Fuel Gauge 13 - Auto-Idle / Acceleration 19 - Preheat Indicator

Selector
2- Right Offset Switch 8 - Liquid Crystal Display 14 - Work Light Switch 20 - Air Filter Restriction Switch
3- Prohibited-Area Release 9 - Set Switch 15 - Auto - Marccino Switch 21 - Alternator Indicator
Switch
4 - Engine Control Dial 10 - Display Selection Switch 16 - Washer Switch 22 - Fuel Level Indicator
5 - Key Switch 11 - Power Mode Switch 17 - Wiper Switch 23 - Overheat Indicator
6 - Coolant Temperature 12 - Travel Mode Switch 18 - Hydraulic Oil Filter 24 - Engine Oil Pressure
Gauge Indicator (Optional) Indicator
T1-2-11
PUMP DEVICE
ZAXIS110/110M/120/130/130LCN/125US/135US
3 4
2 1
T176-03-01-002
7 6 5 10 9 8
T176-03-01-001
ZAXIS135UR
3 4 2 1
T1SM-03-01-002
11 7 6 5 10 9 8
T1SM-03-01-001
1 - Pump 1 4- Pump 2 Control Pressure 7- Max. Pump 2 Flow Rate 10 - Pump 2 Delivery Pressure
Sensor Limit Solenoid Valve Sensor
2 - Pump 2 5 - Pump 1 Control Pressure 8 - N Sensor 11 - Blade Pump
Sensor
3 - Pilot Pump 6 - Torque Control Solenoid 9- Pump 1 Delivery Pressure
Valve Sensor
T1-2-12
SWING DEVICE CONTROL VALVE 3
4
1
T176-01-02-003
T176-01-02-002
SIGNAL CONTROL VALVE SOLENOID VALVE UNIT
8
7
9
T176-03-07-002
T178-03-06-015
1 - Pressure Sensor 4- Main Relief Valve 7- Pressure Sensor (Travel) 9- Solenoid Valve Unit (SI)
(Front Attachment) (Except
Swing Device of
ZAXIS135UR)
2 - Swing Relief Valve 5- Pressure Sensor 8- Solenoid Valve Unit (SC)
(Boom Raise)
3 - Pressure Sensor 6 - Pressure Sensor (Swing)
(Arm Roll-In)
T1-2-13
8-UNIT SOLENOID VALVE UNIT BLADE CONTROL VALVE
(ZAXIS135UR Only) (ZAXIS135UR Only)
POSITIONING CONTROL VALVE
1 (2-piece Boom Only)
2
15 3
4
5
14
6
7
13
8
9
12
16
10
T178-03-03-071
T1SM-01-02-003
11
TRAVEL DEVICE
ZAXIS110, 120, 130, 130LCN, 125US, 135US, ZAXIS110M
135UR
18
17
18
T155-01-01-013
T155-01-01-006
17
1 - Pilot Pressure Sensor (E1: 6 - Pilot Pressure Sensor (E4: 11 - Hydraulic Oil Temperature 15 - Solenoid Valve (C3: Boom
Boom Raise) Left Offset Acceleration) Sensor Lower Deceleration)
2 - Solenoid Valve (C1: Boom 7 - Solenoid Valve (C9: Left 12 - Solenoid Valve (C4: Arm 16 - Overload Relief Valve
Raise Acceleration) Offset Acceleration) Roll - In Deceleration) (Blade), (Positioning)
3 - Pilot Pressure Sensor (E2: 8 - Pilot Pressure Sensor (E5: 13 - Solenoid Valve (C8: Left 17 - Travel Relief Valve
Boom Lower) Arm Roll - Out) Offset Deceleration)
4 - Pilot Pressure Sensor (E6: 9 - Solenoid Valve (C7: Arm 14 - Solenoid Valve (C5: Right 18 - Counterbalance Valve
Right Offset Acceleration) Roll - Out Acceleration) Offset Deceleration)
5 - Solenoid Valve (C6: Right 10 - Pilot Pressure Sensor (E3:
Offset Acceleration) Arm Roll - In)
T1-2-14
GENERAL / Component Specifications
ZAXIS110/110M/125US/135UR
ENGINE
Manufacturer ............................................... ISUZU

Model........................................................... BB-4BG1TRG
Type............................................................. Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore × Stroke ............................... 4-105 mm×125 mm (4.13 in×4.92 in)
Piston Displacement ................................... 4329 cm3 (264 in3)
Rated Output ............................................... 59 kW/1950 min-1 (80 PS/1950 rpm)
HP Mode: 63 kW/2150 min-1 (85 PS/2150 rpm)
Compression Ratio...................................... 18:0
Dry Weight................................................... 361 kg (796 lb)
Firing Order ................................................. 1-3-4-2
Rotation Direction........................................ Clockwise (Viewed from fan side)
COOLING SYSTEM
Cooling Fan .................................................... Dia. 550 mm (21.6 in), 7 Blades (N-Type Blade, Unequal Pitch),
Draw-in Type
Fan Pulley Ratio .......................................... Engine rpm × 0.84
Thermostat .................................................. Cracking Temperature at Atmospheric Pressure: 82 °C (180 °F)
Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F)
Water Pump................................................. Centrifugal Belt Driven Type
LUBRICATION SYSTEM
Lubrication Pump Type................................ Gear Pump
Oil Filter ....................................................... Full-Flow Paper Element Type with Bypass
Oil Cooler .................................................... Water Cooled Integral Type
T1-3-1
STARTING SYSTEM
Motor ........................................................... Magnetic Pinion Shift Reduction Type
Voltage / Output........................................... 24 V / 4.5 kW
PREHEAT SYSTEM
Preheating Method ...................................... Glow Plug (QOS Type)
ENGINE STOP SYSTEM

Stop Method ................................................ Fuel Shut-Off
ALTERNATOR
Type................................................................Regulator Integrated AC Type
Voltage / Output..............................................24 V / 50 A (Brushless)
SUPERCHARGING SYSTEM
Type................................................................Exhaust-Turbocharger Type TD04HL
FUEL SYSTEM
Type............................................................... BOSCH Type (AD Concave Cam)
Governor ....................................................... Centrifugal All Speed Control RSV Type
Injection Nozzle ........................................... Multi-Hole Type
PERFORMANCE
IMPORTANT: This list shows design specifications, which are not servicing standards.
Fuel Consumption Ratio.................................At Full Load: Less than 244 g/kW/h (179 g/PS⋅h)
at 63+4.4-0 kW / 2150 min-1
At Working Load: Less than 242 g/kW/h (178 g/PS⋅h)
at 60+7.4-2.2 kW / 1950 min-1
Injection Timing ..............................................9 ° before T.D.C.
Maximum Output Torque ................................More than 310+20-39 N⋅m (31+2-4 kgf⋅m) at approx. 1600 min-1
Injection Pressure...........................................18.1 MPa (185 kgf/cm2)
Compression Pressure...................................3.0 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust)...................0.4 / 0.4 mm (when cool)
No Load Speed .............................................Slow: at Full Load: 950+50-0 min-1
Fast: at Full Load: 2375±25 min-1
at Working Load: 2175±50 min-1
T1-3-2
Engine Performance Curve (BB-4BG1TRG)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
Torque
Output
KW
N･m
Fuel Consumption
Ratio
g/kW･h
-1
Engine Speed min (rpm) T175-01-03-001
T1-3-3
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type............................................................... Radiator/Oil Cooler Tandem Type Assembly
Weight ........................................................... 57 kg (126 lb)
Radiator Oil Cooler

Cap Opening Pressure...................................49 kPa (0.5 kgf/cm2, 7 psi) −
BATTERY
Capacity..........................................................55 Ah (5-Hour Rate)
Voltage............................................................12 V
Weight ............................................................18 kg (40 lb) × 2
T1-3-4
HYDRAULIC COMPONENT
MAIN PUMP
Model..............................................................HPK055AT-RH17A
Type................................................................Swash Plate Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value)................100 L/min (26.4 US gpm) × 2
REGULATOR
Type................................................................Hydraulic Pressure Operated Type,
BLADE PUMP (ZAXIS135UR Only), PILOT PUMP

Model..............................................................HY / ZFS 11 / 16.8
Type................................................................Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value)................32.8 L/min (8.65 US gpm)
HP Mode: 36.1 L/min (9.53 US gpm)
CONTROL VALVE
Model..............................................................X34
Type................................................................Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure ...............................Normal: 34.3 MPa (350 kgf / cm2, 4980 psi) at
80 L/min (21.1 US gpm)
Overload Relief Set-Pressure ........................37.3 MPa (380 kgf/cm2, 5400 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
39.2 MPa (400 kgf/cm2, 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)
BLADE CONTROL VALVE (ZAXIS135UR Only)

Type................................................................Pilot Pressure Operated Type
Overload Relief Set-Pressure ........................27.5MPa (280 kgf/cm2, 3980 psi) at 50 L/min (13.2 US gpm)
BLADE MAIN RELIEF VALVE (ZAXIS135UR Only)

Set-Pressure ..................................................20.6 MPa (210 kgf/cm2, 2990 psi) at 34.4 L/min (9.1 US gpm)
T1-3-5
SWING DEVICE
Type...........................................................Two-Stage Reduction Planetary Gear
Reduction Gear Ratio................................16.155
SWING MOTOR
Type...........................................................Swash-Plate Type, Fixed Displacement Axial Plunger Motor
VALVE UNIT
Type...........................................................Non Counterbalance Valve Type
Relief Set-Pressure ...................................31.3 MPa (320 kgf/cm2, 4550 psi)
SWING PARKING BRAKE

Type...........................................................Multi-Disc-Wet Negative Type
Release Pressure ....................................1.87 MPa (19.1 kgf/cm2, 271 psi): Cracking pressure
2.52 MPa (25.7 kgf/cm2, 366 psi): Full open
TRAVEL DEVICE
ZAXIS110/125US/135UR
ZAXIS110M
TRAVEL MOTOR
Type...........................................................Swash-Plate Type Variable Displacement Axial Plunger Motor
TRAVEL BRAKE VALVE

Type...........................................................Counter Balance Valve Type
Relief Set Pressure ...................................34.3+2.00 MPa (350+200 kgf/cm2, 4980+2850 psi) at 40 L/min-1
ZAXIS110M
Type...........................................................Counter Balance Valve Type
Relief Set Pressure ...................................35.3+1.00 MPa (360+100 kgf/cm2, 5120+1420 psi) at 37 L/min-1
TRAVEL PARKING BRAKE

Type...........................................................Multi-Disc-Wet Negative Type
ZAXIS110M
Type...........................................................Single-Disc-Wet Negative Type
T1-3-6
CYLINDER
ZAXIS110/110M/125US: Boom Arm Bucket
Rod Diameter ............................................70 mm (2.76”) 75 mm (2.95”) 65 mm (2.56”)
Cylinder Bore.............................................ZAXIS110: 95 mm (3.74”) 105 mm (4.13”) 95 mm (3.74”)
ZAXIS110M: 95 mm (3.74”)
ZAXIS125US: 105 mm (4.13”)
Stroke ........................................................ZAXIS110: 942 mm (3’ 1”) 1040 mm (3’ 5”) 875 mm (2’10”)
ZAXIS110M: 942 mm (3’ 1”)
ZAXIS125US 995 mm (3’ 3”)
Fully Retracted Length ..............................ZAXIS110: 1428 mm (4’ 8”) 1525 mm (5’ 0”) 1350 mm (4’ 5”)
ZAXIS110M: 1428 mm (4’ 8”)
ZAXIS125US: 1503 mm (4’11”)
Plating Thickness ......................................30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18
µin)
Weight .......................................................ZAXIS110: 98 kg (216 lb) 123 kg (271 lb) 91 kg (201 lb)
ZAXIS110M: 98 kg (216 lb)
ZAXIS125US: 107 kg (236 lb)
ZAXIS135UR： Boom Arm Offset

Rod Diameter ............................................70 mm (2.76”) 85 mm (3.55”) 70 mm (2.76”)
Cylinder Bore.............................................105 mm (4.13”) 115 mm (4.53”) 120 mm (4.72”)
Stroke ........................................................1000 mm (3’ 3”) 975 mm (3’ 2”) 455 mm (1’ 6”)
Fully Retracted Length ..............................1520 mm (4’12”) 1442 mm (4’ 9”) 932 mm (3’ 1”)
Plating Thickness ......................................30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight .......................................................109 kg (240 lb) 178 kg (392 lb) 94 kg (207 lb)
Bucket Blade
Rod Diameter ............................................65 mm (2.56”) 70 mm (2.76”)
Cylinder Bore.............................................95 mm (3.74”) 100 mm (3.94”)
Stroke ........................................................875 mm (2’10”) 220 mm (8.66”)
Fully Retracted Length ..............................1350 mm (4’ 5”) 658 mm (2’ 2”)
Plating Thickness ......................................30 µm (1.18 µin) 30 µm (1.18 µin)
Weight .......................................................91 kg (201 lb) 49 kg (108 lb)
FRONT ATTACHMENT PILOT VALVE

Model.........................................................HVP06A-040-101
TRAVEL PILOT VALVE

Model.........................................................HVP05F-040-101
BLADE/OFFSET PILOT VALVE (ZAXIS135UR Only)

Model.........................................................HVP05M-040-101
T1-3-7
SOLENOID VALVE UNIT

Function..........................................................⋅ SC : Arm Regenerative Control
⋅ SI : Travel Motor Swash-Angle Control
PILOT PRESSURE SIGNAL CONTROL VALVE

Function..........................................................⋅ Shock Reducing (Boom Raise)
⋅ Pump Flow Rate Control
⋅ Bucket Flow Rate Control
⋅ Swing Parking Brake Release
⋅ Flow Combiner Valve Control
PILOT SHUT-OFF VALVE

Type................................................................Rotary Type
OIL COOLER BYPASS CHECK VALVE

Cracking Pressure..........................................392 kPa (4 kgf/cm2, 57 psi) at 5 L/min
8-UNIT SOLENOID VALVE UNIT (ZAXIS135UR Only)

Type ..............................................................8-SPOOL Type
Rated Pressure ..............................................3.7 MPa (38 kgf/cm2, 540 psi)
EMERGENCY STOP SOLENOID VALVE (ZAXIS135UR Only)

Rated Pressure ..............................................3.7 MPa (38 kgf/cm2, 540 psi)
T1-3-8
ELECTRICAL COMPONENT
ANGLE SENSOR (ZAXIS135UR Only)

All Resistance Value ...................................... 2k±20%Ω
Available Electrical Angle............................... 180±20 degree
Mechanical Rotation Angle ............................ Boom: 160 degree
Arm/Offset: 360 degree
BATTERY RELAY
Voltage / Current ............................................24 V / 100 A
GLOW PLUG RELAY

Voltage ........................................................... 24 V
HORN
Voltage / Current ............................................ 24 V⋅1.5 A
Sound Pressure ............................................. 113 dB (A)
ILLUMINATION
Specifications ................................................. Work Light : Halogen 24V, 70 W / 60 W
Cab Light : 24 V, 10 W
T1-3-9
AIR CONDITIONER
ZAXIS110/110M:
Refrigerant ....................................................134 a
Cooling Ability.................................................19.3 MJ/h (4600 kcal/h)
Cool Air Volume..............................................550 m3/h or More
Heating Ability.................................................21.0 MJ/h (5000 kcal/h) or More
Warm Air Volume............................................400 m3/h or More
Temperature Adjusting System ......................Electronic Type
Refrigerant Quantity .......................................950±50 g
Compressor Oil Quantity................................180 cm3
ZAXIS125US:
Refrigerant ....................................................134 a
ZAXIS135UR:
Refrigerant ....................................................134 a
Cool Air Volume..............................................38.0 m3/h or More
Temperature Adjusting System ......................Mechanical Type
T1-3-10
ZAXIS120/130/130LCN/135US
ENGINE
Manufacturer ............................................... ISUZU

Model........................................................... CC-4BG1TCG
Type............................................................. Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore × Stroke ............................... 4-105 mm×125 mm (4.13 in×4.92 in)
Piston Displacement ................................... 4329 cm3 (264 in3)
Rated Output ............................................... 63 kW/1950 min-1 (85 PS/1950 rpm)
HP Mode: 66 kW/2150 min-1 (90 PS/2150 rpm)
Compression Ratio...................................... 18:0
Dry Weight................................................... 361 kg (796 lb)
Firing Order ................................................. 1-3-4-2
Rotation Direction........................................ Clockwise (Viewed from fan side)
COOLING SYSTEM
Cooling Fan .................................................... Dia. 550 mm (21.6 in), 7 Blades (N-Type Blade, Unequal Pitch),
Draw-in Type
Fan Pulley Ratio .......................................... Engine rpm × 0.84
Thermostat .................................................. Cracking Temperature at Atmospheric Pressure: 82 °C (180 °F)
Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F)
Water Pump................................................. Centrifugal Belt Driven Type
LUBRICATION SYSTEM
Lubrication Pump Type................................ Gear Pump
Oil Filter ....................................................... Full-Flow Paper Element Type with Bypass
Oil Cooler Water Cooled Integral Type
T1-3-11
STARTING SYSTEM
Motor ..............................................................Magnetic Pinion Shift Reduction Type
Voltage / Output..............................................24 V / 4.5 kW
PREHEAT SYSTEM
Preheating Method .........................................Glow Plug (QOS Type)
ENGINE STOP SYSTEM

Stop Method ...................................................Fuel Shut-Off
ALTERNATOR
Type................................................................Regulator Integrated AC Type
Voltage / Output..............................................24 V / 50 A (Brushless)
SUPERCHARGING SYSTEM
Type................................................................Exhaust-Turbocharger Type TD04HL
FUEL SYSTEM
Type............................................................... BOSCH Type (AD Concave Cam)
Governor ....................................................... Centrifugal All Speed Control RSV Type
Injection Nozzle ........................................... Multi-Hole Type
PERFORMANCE
IMPORTANT: This list shows design specifications, which are not servicing standards.
Fuel Consumption Ratio.................................At Full Load: Less than 244 g/kW/h (179 g/PS⋅h)
at 66+4.4-0 kW / 2150 min-1
At Working Load: Less than 242 g/kW/h (178 g/PS⋅h)
at 63+7.4-2.2 kW / 1950 min-1
Injection Timing ..............................................10 ° before T.D.C.
Maximum Output Torque ................................More than 340+20-39 N⋅m (34+2-4 kgf⋅m) at approx. 1600 min-1
Injection Pressure...........................................18.1 MPa (185 kgf/cm2)
Compression Pressure...................................3.0 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust)...................0.4 / 0.4 mm (when cool)
No Load Speed .............................................Slow: at Full Load: 950+50-0 min-1
Fast: at Full Load: 2375±25 min-1
at Working Load: 2175±50 min-1
T1-3-12
Engine Performance Curve (CC-4BG1TCG)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
Torque
Output
kW
N･m
Fuel Consumption
Ratio
g/kW･h
-1
Engine Speed min (rpm) T176-01-03-001
T1-3-13
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type............................................................... Radiator/Oil Cooler Tandem Type Assembly
Weight ........................................................... 64 kg (141 lb)
Radiator Oil Cooler Intercooler

Cap Opening Pressure...................................49 kPa (0.5 kgf/cm2, 7 psi) − −
BATTERY
Capacity..........................................................55 Ah (5-Hour Rate)
Voltage............................................................12 V
Weight ............................................................18 kg (40 lb) × 2
T1-3-14
HYDRAULIC COMPONENT
MAIN PUMP
Model..............................................................HPK055AT-RH18A
Type................................................................Swash Plate Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value)................105 L/min (27.7 US gpm) × 2
REGULATOR
Type................................................................Hydraulic Pressure Operated Type
PILOT PUMP
Model..............................................................HY / ZFS 11 / 16.8
Type................................................................Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value)................32.8 L/min (8.65 US gpm)
HP Mode: 36.1 L/min (9.53 US gpm)
CONTROL VALVE
Model..............................................................X34
Type................................................................Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure ...............................Normal: 34.3 MPa (350 kgf / cm2, 4980 psi) at
80 L/min (21.1 US gpm)
Overload Relief Set-Pressure ........................37.3 MPa (380 kgf/cm2, 5400 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
(Arm Roll-Out, Bucket Roll-Out)

(2-Piece Boom only)
Type................................................................Pilot Pressure Operated Type
Overload Relief Set-Pressure ........................37.3MPa (380 kgf/cm2, 5400 psi) at 50 L/min (13.2 US gpm)
SWING DEVICE
Type................................................................Two-Stage Reduction Planetary Gear
Reduction Gear Ratio.....................................16.155
SWING MOTOR
Type................................................................Swash-Plate Type, Fixed Displacement Axial Plunger Motor
VALVE UNIT
Type................................................................Non Counterbalance Valve Type
Relief Set-Pressure ........................................32.3 MPa (330 kgf/cm2, psi)
SWING PARKING BRAKE

Type................................................................Multi-Disc-Wet Negative Type
Release Pressure .........................................1.72 MPa (17.6 kgf/cm2, 250 psi): Cracking pressure
2.29 MPa (23.3 kgf/cm2, 331 psi): Full open
T1-3-15
TRAVEL DEVICE
Type........................................................ Two-Stage Reduction Planetary Gear
Reduction Gear Ratio............................. 48.846 (ZAXIS120/130/130LCN)
57.263 (ZAXIS135US)
TRAVEL MOTOR
Type........................................................ Swash-Plate Type Variable Displacement Axial Plunger Motor
TRAVEL BRAKE VALVE

Type........................................................ Counter Balance Valve Type
Relief Set Pressure ................................ 34.8+2.00 MPa (355+200 kgf/cm2, 5050+2850 psi) at 40 L/min-1
TRAVEL PARKING BRAKE

Type........................................................ Multi-Disc-Wet Negative Type
CYLINDER
Boom Arm
Rod Diameter ......................................... 70 mm (2.76”) 80 mm (3.15”)
Cylinder Bore.......................................... 105 mm (4.13”) 115 mm (4.53”)
Stroke ..................................................... 941 mm (3’ 1”) 1135 mm (3’ 9”)
(ZAXIS120/130/130LCN) (ZAXIS120/130/130LCN)
995 mm (3’ 3”) 1127 mm (3’ 8”)
(ZAXIS135US) (ZAXIS135US)
Fully Retracted Length ........................... 1448 mm (4’ 9”) 1650 mm (5’ 5”)
(ZAXIS120/130/130LCN)
1503 mm (4’11”) (ZAXIS135US)
Plating Thickness ................................... 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight .................................................... 107 kg (240 lb) 155 kg (340 lb)
Bucket Positioning (ZAXIS130/130LCN)

Rod Diameter ......................................... 70 mm (2.76”) 95 mm (3.74”)
Cylinder Bore.......................................... 100 mm (3.94”) 140 mm (5.51”)
Stroke ..................................................... 875 mm (2’ 10”) 840 mm (2’ 9”)
Fully Retracted Length ........................... 1350 mm (4’ 5”) 1450 mm (4’ 9”)
Plating Thickness ................................... 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight .................................................... 100 kg (220 lb) 203 kg (450 lb)
T1-3-16
FRONT ATTACHMENT PILOT VALVE
Model...................................................... HVP05P-040-101
TRAVEL PILOT VALVE

Model...................................................... HVP05F-040-101
POSITIONING PILOT VALVE

(2-Piece Boom only)
Model...................................................... HVP05P-040-101
SOLENOID VALVE UNIT

Function.................................................. ⋅ SC : Arm Regenerative Control
⋅ SI : Travel Motor Swash-Angle Control
PILOT PRESSURE SIGNAL CONTROL VALVE

Function.................................................. ⋅ Shock Reducing (Boom Raise)
⋅ Pump Flow Rate Control
⋅ Bucket Flow Rate Control
⋅ Swing Parking Brake Release
⋅ Flow Combiner Valve Control

Type........................................................ Rotary Type
OIL COOLER BYPASS CHECK VALVE

Cracking Pressure.................................. 392 kPa (4 kgf/cm2) at 5 L/min
T1-3-17
ELECTRICAL COMPONENT
BATTERY RELAY
Voltage / Current ........................................... 24 V / 100 A
GLOW RELAY
Voltage............................................................24 V
HORN
Voltage / Current ............................................24 V⋅1.5 A
Sound Pressure..............................................113 dB (A)
ILLUMINATION
Specifications .................................................Work Light : Halogen 24V, 70 W / 60 W
Cab Light : 24 V, 10 W
AIR CONDITIONER
ZAXIS120/130/130LCN:
Refrigerant ....................................................134 a
ZAXIS135US:
Refrigerant ....................................................134 a
T1-3-18
MEMO
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SECTION 2
SYSTEM
—CONTENTS—
Group 1 Control System
Outline ...................................................... T2-1-1
Engine Control .......................................... T2-1-2
Pump Control .......................................... T2-1-21
Valve Control .......................................... T2-1-28
Other Controls ........................................ T2-1-36
Group 2 Front Control System

Outline ...................................................... T2-2-1
Front Movement Control ........................... T2-2-2
Group 3 Hydraulic System

Outline ...................................................... T2-3-1
Pilot Circuit ............................................... T2-3-2
Main Circuit............................................. T2-3-16
Group 4 Electrical System

Outline ...................................................... T2-4-1
Main Circuit............................................... T2-4-2
Electric Power Circuit................................ T2-4-4
Indicator Light Check Circuit ..................... T2-4-6
Accessory Circuit ...................................... T2-4-8
Preheat Circuit ........................................ T2-4-10
Starting Circuit ........................................ T2-4-12
Charging Circuit ...................................... T2-4-16
Engine Stop Circuit ................................. T2-4-20
Serge Voltage Prevention Circuit ............ T2-4-22
187T-2-1
(Blank)
187T-2-2
SYSTEM / Control System
OUTLINE
The main controller (MC) is used to control machine After processing the received signals in the logic circuit,
operations. Electronic signals from the engine control the MC sends out control signals to the EC motor,
dial, various sensors and switches are sent to the MC. solenoid valve units, torque control solenoid valve, and
other control circuits to regulate the engine, pumps,
motors and valves.
Input Signals Output Signals

• EC Sensor → Engine Control (EC Motor)
• Engine Control Dial → Engine Control Dial
• Pump 1 Control Pressure Sensor → HP Mode Control
• Pump 2 Control Pressure Sensor → E mode Control
• Pump 1 Delivery Pressure Sensor → Auto-Idle Control
• Pump 2 Delivery Pressure Sensor → Auto-Acceleration Control
• Pump 3 Delivery Pressure Sensor Auto-Warming Up Control
(Oprtional) → Idle Speed-Up Control
*
• N sensor → Attachment Operation Speed Increase Control
*
• Pressure Sensor (Travel) → Attachment Operation Speed Limit Control
• Pressure Sensor Engine Learning Control
(Front Attachment) →
• Pressure Sensor (Swing) →
• Pressure Sensor (Boom Raise) → Pump Control (Torque Control Solenoid Valve)
• Pressure Sensor (Arm Roll-In) → Speed Sensing Control
• Pressure Sensor (Auxiliary) → Pump 1 Flow Rate Limit Control
• Pressure Sensor (Arm Roll-Out)
(Optional) →
• Hydraulic Oil Temperature Sensor → MC Pump 2 Flow Rate Limit Control
*
• Auto-Idle/Acceleration Selector → Pump 3 Torque Decrease Control
• Power Mode Switch (HP/E/P) →
• Travel Mode Switch (Fast/Slow) → Valve Control (Solenoid Valve Unit)
• Work Mode Switch Arm Regenerative Control
(Digging/Attachment) → Travel Motor Swash Angle Control
*
• Learning Switch → Auxiliary Flow Rate Control
• Key Switch →
• Auxiliary Mode Switch (Optional) → Other Controls
• Boom Bottom Pressure Sensor
(Optional)
Work Mode Control
∗
Travel Alarm Control
∗
Swing Alarm Control
∗
Overload Alarm Control
*
NOTE: :Only on the machines equipped with the
corresponding optional parts or except
ZAXIS135UR.
T2-1-1
ENGINE CONTROL
The engine control system is grouped as follows:
• Engine Control Dial Control • Idle Speed-Up Control

*
• HP Mode Control • Attachment Operation Speed Increase Control
*
• E Mode Control • Attachment Operation Speed Limit Control
• Auto-Idle Control • Engine Learning Control
• Auto-Acceleration Control
• Auto-Warming Up Control
*
NOTE: : Only on the machines with the
ZAXIS135UR.
Engine Control System Layout
Learning Switch Pressure Sensor
Travel
Front Attachment
Pump 2 Pump 1
Swing Delivery Delivery
Key Switch Boom Raise Pressure Pressure
Arm Roll-In Sensor Sensor
Auxiliary (Optional)
Engine EC Sensor
Control Dial
Auto-Idle /
Acceleration
Selector
Auto-Idle
EC Motor
Auto-Acceleration
Power Mode Switch
HP Mode Pump 2 Pump 1

Control Control
Pressure Pressure
E Mode Work Mode Sensor
Sensor
Switch
P Mode Auxiliary Mode Hydraulic Oil
Digging Attachment Switch Temperature
Mode Mode (Optional) Sensor
T178-02-01-001
T2-1-2
(Blank)
T2-1-3
Engine Control Dial Control
Function: Controls the engine speed in response to Engine speed is

the rotation angle of the engine control dial Engine reduced by 200
-1
Speed min when the
and reduces the engine speed by 200 min-1 control levers are in
to reduce fuel consumption and noise level neutral.
when all control levers are in neutral.
Operation: The MC drives the governor lever in

response to the rotation angle of the engine
control dial to regulate the engine speed.
NOTE: Even if the control dial is rotated to the full Engine

speed position, the governor lever doesn’t Control Dial
Slow Fast Position
come in contact with the full speed stopper. Idle Idle
(Refer to the HP mode control.)
When all control levers are turned to neutral (the travel

and front attachment sensors are OFF), the MC drives
the EC motor so that the engine speed is reduced from
the maximum speed by 200 min-1.
NOTE: The engine speed is reduced from the

maximum speed by 200 min-1. Therefore,
when the engine speed set by the engine
control dial is already slower than the
maximum speed by 200 min-1, the engine
speed remains unchanged. This engine
speed reduction control is activated
regardless of whether the auto-idle and/or
auto-acceleration control is activated or
not.
T2-1-4
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
EC Motor
T178-02-01-004
T2-1-5
HP Mode Control
Function: Slightly increases digging power such as

Engine
arm roll-in operation while excavating Speed Maximum
deeply. 1650 min
-1
speed
increases by
-1
200 min .
Operation: The MC drives the EC motor to slightly 1500 min
-1
increase the engine speed set by the

engine control dial when all the following
conditions exist with the power mode
switch is in the HP position.
• Engine Control Dial: Set at 1500 min-1 or faster. Engine

• Boom Raise and/or Arm Roll-In Control: In Control Dial
Slow Fast Position
Operation
Idle Idle
• Average Delivery Pressure of Pumps 1 and 2:
High
NOTE: The engine governor stopper position is

adjusted in the HP mode. Accordingly, the
governor lever doesn’t come in contact with
the stopper in the normal mode.
T2-1-6
Pressure Sensor
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Boom Raise Sensor Sensor
Arm Roll-In
Engine
Control Dial
EC Motor
Power Mode Switch
HP Mode
T178-02-01-005
T2-1-7
E Mode Control
Engine
Speed
Function: Reduce the engine speed by the constant
specified ratio.
Engine speed is
reduced at the
Operation: The MC drives the EC motor to reduce the constant
engine speed set by the engine control dial specified ratio.
when the power mode switch is in the E
mode position. The engine speed is
reduced in proportion to the rotation angle
of the engine control dial.
Engine
Control Dial
Slow Idle Fast Idle Position
Engine
Control Dial
EC Motor
Power Mode Switch
E Mode
T178-02-01-006
T2-1-8
(Blank)
T2-1-9
Auto-Idle Control
Function: Reduces the engine speed when all control

levers are in neutral to reduce fuel
consumption and noise level.
Operation: Approx. 3.5 seconds after all control levers

are return to neutral, the MC drives the EC Engine speed is
motor so that the engine speed is reduced Engine reduced to the
Speed auto-idle speed
to the auto-idle speed. As soon as a control 3.5 seconds later.
lever is operated (the travel and/or front
attachment pressure sensor is turned ON), Fast
Speed
the MC drives the EC motor so that the
engine speed is increased to the original
engine speed (set by the engine control Auto-Idle
Speed
dial).
Auto-Idle System Deactivation Requirements:

• Control Levers: Being operated (either travel or Engine
front attachment control levers with pilot sensor Control Dial
Slow Fast Position
ON) Idle Idle
• Power Mode Switch: When the E mode is
changed to P mode or the P mode is changed to
the E mode.
• Engine Control Dial: When engine speed is
changed.
T2-1-10
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
Auto-Idle/
Acceleration
Selector
Auto-Idle
EC Motor
Power Mode Switch
E Mode
T178-02-01-007
T2-1-11
Auto Acceleration Control
Function: Automatically regulates the engine speed to Engine Speed VS. Control Lever Operations:
meet the machine operating conditions. Engine
When all the control levers are in neutral, Speed
the engine speed is reduced to reduce fuel
consumption and noise level. Engine speed is reduced
Fast Speed from the maximum speed
-1
Operation: When a control lever is operated with the by 400 min .
Auto-
auto-idle / acceleration selector in auto Acceleration Engine speed is reduced
Speed to the auto-idle speed 3.5
acceleration position, the MC calculates the
Auto-Idle seconds later.
most proper engine operating speed
Speed
corresponding to the signals from pressure
sensors (travel, swing, boom raise, and arm Slow Speed
roll-in), the pump control pressure sensors, Engine
and the pump delivery pressure sensors. Slow Fast
Control Dial
Position
Then, the MC drives the EC motor so that Idle Idle
the engine speed is set to the rotation
speed calculated by the MC. Operating Time Progress VS. Engine Speed Change
When all control levers are returned to
neutral, the engine speed is reduced by 400 Control Lever Stroke
min-1 from the maximum speed first. Then,
Full Stroke
3.5 seconds later, the engine speed is
further reduced to the auto-idle speed.
Neutral
NOTE: When all control levers are returned to Position
neutral, the engine speed is reduced by
400 min-1 from the maximum speed. In Time
case the engine speed is set by the engine
control dial and is running at a speed In response to the control
lever stroke and the pump
slower than the maximum speed by 100 Engine Speed delivery pressure, the
min-1, the engine speed will be reduced by optimum engine speed is
selected.
300 min-1. Fast Idle Speed
(P Mode) Auto
Acceleration
Control
Auto-Idle
Engine Speed
Time
T2-1-12
Pressure Sensor
Travel
Pump 2 Pump 1
Pressure Pressure
Boom Raise Sensor
Sensor
Arm Roll-In
Engine
Control Dial
Auto-Idle/
Acceleration
Selector
Auto-Acceler EC Motor
ation
Pump 2 Control Pump 1 Control

Pressure Pressure
Sensor Sensor
T178-02-01-008
T2-1-13
Auto Warming Up Control
Function: Automatically warms up the hydraulic

Engine
system (similar to the auto choke Speed
on automobiles).
Fast
Operation: The MC drives the EC motor in response to Speed
signals from the key switch and the
hydraulic oil temperature sensor to run the
engine at the auto warm up speed for 15 Auto
Warm Up Increasing
minutes after starting the engine. When the Speed Speed
hydraulic oil temperature is below 0°C
Slow
(32°F), the engine keeps running at auto Speed Engine
warm up speed. Control Dial
Slow Idle Fast Idle Position
IMPORTANT: When adjusting the auto-idle speed

deactivate the auto warming up
control function using Dr. ZX, or wait
to adjust until 15 minutes after
starting the engine.
Key Switch
Engine
Control Dial
EC Motor
Hydraulic Oil
Temperature
Sensor
T178-02-01-009
T2-1-14
Idle Speed-Up Control
Engine
Function: Prevents the engine from hunting when Speed
running the engine at slow speed.
Operation: When the travel or front attachment

function is operated while the engine is
running at a speed between the minimum Idle
speed and the Idle Speed-Up Speed, the Speed-Up
MC drives the EC motor so that the engine Speed
Increasing
speed is increased to the Idle Speed-Up Speed
Speed. Engine
Control Dial
Slow Fast Position
Idle Idle
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
EC Motor
T178-02-01-010
T2-1-15
Attachment Operation Speed Increase Control
(Only on the machines equipped with the
When all
auxiliary mode switch (Optional or except Engine
conditions exist,
ZAXIS135UR).) Speed
the maximum
engine speed is
increased to the
Function: Increases the maximum engine speed to speed set by Dr.
the attachment (hydraulic breaker, EX.
secondary crusher, primary crusher or
vibrating hammer) operating engine speed
set by Dr. ZX when the attachment is
operated.
Operation: When the following conditions exist, the

MC drives the EC motor so that the engine Slow Fast Engine
maximum speed is increased to the Idle Idle Control Dial
Position
attachment operating speed set by Dr. ZX
when the attachment is operated.
Operating Conditions:
Dr. ZX: Resets the maximum engine speed to a faster
(+) attachment (hydraulic breaker, secondary crusher,
primary crusher, or vibrating hammer) operating speed
in the service mode.
Engine Control Dial: Maximum Speed Position
Power Mode Switch: HP Mode
Auxiliary: In Operation
Work Mode Switch: Attachment Mode
Auxiliary Mode Switch (Optional): Attachment position
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) reset by Dr. ZX.
NOTE: When the P mode engine speed is preset to

a slower speed in the Dr. ZX service mode,
the maximum engine speed won’t be
increased when operating the attachment.
T2-1-16
Pressure Sensor
Auxiliary(Optional)
Engine
Control Dial
EC Motor
Power Mode Switch
HP Mode
Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T178-02-01-011
T2-1-17
Attachment Operation Speed Limit Control (Only
on the machines equipped with the auxiliary
mode switch (Optional) or except ZAXIS 135UR.) Engine
Speed
When all
conditions exist,
Function: Decreases the maximum engine speed to the maximum
the attachment (hydraulic breaker, engine speed is
secondary crusher, primary crusher or reduced to the
speed set by Dr.
vibrating hammer) operating engine speed ZX.
set by Dr. ZX when the attachment mode is
selected.
Operation: When the following conditions exists, the

MC drives the EC motor so that the engine Engine
Control Dial
maximum speed is reduced to the Position
Slow Fast
attachment operating speed set by Dr. ZX Idle Idle
when the attachment mode is selected.
Dr. ZX: Resets the maximum engine speed to a slower
(−) attachment (hydraulic breaker, secondary crusher,
primary crusher, or vibrator) operating speed in the
service mode.
Work Mode Switch: Attachment Mode
Auxiliary Mode Switch (Optional): Attachment position
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) set by Dr. ZX.
T2-1-18
EC Motor
Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T178-02-01-012
T2-1-19
Engine Learning Control
Function: Inputs the governor lever stopper positions IMPORTANT: Be sure to perform the engine
on both the STOP and FULL sides as the learning if the following repair work
standard data to control the engine. is done. (Refer to the
Troubleshooting Section in T/M.)
Operation:When the learning switch in the rear After performing the engine learning,
console is turned to the engine learning check that the engine learning has
position, the EC motor is driven by the been performed correctly using Dr.
signals from the MC. The EC motor moves ZX.
the governor lever from the IDLE to FULL • After the engine, engine control
and to STOP positions in this order. The EC cable, or EC motor has been
sensor detects the stopper positions of the removed or replaced.
governor lever on both the FULL and STOP • After the MC has been replaced.
sides and sends each stopper position
signal to the MC. The MC stores these NOTE: The engine learning is not required when
signals in its memory. the batteries are replaced.
Learning Switch
Key Switch
EC Sensor
EC Motor
T178-02-01-014
T2-1-20
PUMP CONTROL
The pump control system has the following functions:
• Speed Sensing Control

• *Pump 1 Flow Rate Limit Control
• *Pump 2 Flow Rate Limit Control
• *Pump 3 Flow Torque Decrease Control
NOTE: *Only on the machines equipped with the
ZAXIS135UR.
Pump Control System Layout

Pressure Sensor
Travel
Pump 3
Pump 2 Pump 1 Delivery
Delivery Delivery Pressure
Pressure Pressure Sensor
Sensor Sensor (Optional)
Auxiliary(Optional)
Engine
Control Dial
Torque Control Solenoid Valve
Max. Pump 2 Flow Rate

Limit Solenoid Valve
Max. Pump 1 Flow Rate Limit

Solenoid Valve (Optional)
T178-02-01-002
T2-1-21
Speed Sensing Control
Function: Controls the pump flow rate in response to

engine speed changes due to variations in
load so that the engine output can be utilized
more efficiently. (Engine stall is prevented
when the machine operates under adverse
conditions such as operating at high
altitude.)
Q
Operation:
Flow
1. The target engine operating speed is set by Rate
controlling the engine control dial. Pump P-Q Curve
2. The MC calculates the difference in speed
between the target operating speed and the
actual operating speed monitored by the N sensor.
Then, the MC sends signals to the torque control
solenoid valve.
3. The torque control solenoid valve delivers pilot
pressure oil in response to the signals received
from the MC to the pump regulator, controlling the
pump flow rate.
4. If the engine load increases and the actual engine
operating speed becomes slower than the target Pressure P
operating speed, the pump swash angle is
reduced so that pump flow rate will be reduced.
Therefore, the engine load is reduced, preventing
engine stall.
T2-1-22
N Sensor
Engine
Control Dial
T178-02-01-015
T2-1-23
Pump 1 Flow Rate Limit Control (Only on the Pump 2 Flow Rate Limit Control (Only on the
machines with the auxiliary sensor (Optional) and machines with the auxiliary sensor (Optional) or
max. pump 1 flow rate limit solenoid valve except ZAXIS135UR.)
(Optional) or except ZAXIS135UR.)
Function: Limits the maximum pump 2 flow rate when a
Function: Limits the maximum pump 1 flow rate when a front attachment (mainly a hydraulic breaker)
front attachment (mainly a vibrating hammer) is used.
is used.
Operation:
Operation: 1. When a front attachment is used, the MC receives
1. When a front attachment is used, the MC receives signals from the pressure sensor (auxiliary).
signals from the pressure sensor (auxiliary). 2. In response to the signals arriving from the
2. In response to the signals arriving from the pressure sensor, the MC drives the maximum
pressure sensor, the MC drives the maximum pump 2 flow rate limit solenoid valve to reduce the
pump 1 flow rate limit solenoid valve (optional) to maximum pump flow rate.
reduce the maximum pump flow rate.
NOTE: In proportion to the attachment control
NOTE: In proportion to the attachment control pedal stroke, the maximum pump flow
pedal stroke, the maximum pump flow rated is reduced. The minimum pump
rated is reduced. The minimum pump swash set-angle for a front attachment
swash set-angle for a front attachment (hydraulic breaker, secondary crusher,
(hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) can
primary crusher or vibrating hammer) can be set in the service mode of Dr. ZX.
be set in the service mode of Dr. ZX.
Q
Flow Rate Maximum flow rate is reduced.
Normal P-Q Curve
T2-1-24
Pressure Sensor
Maximum Pump 2 Flow

Rate Limit Control Solenoid
Valve
Maximum Pump 1 Flow Rate

Limit Control Solenoid
Valve (Optional)
T178-02-01-017
T2-1-25
Pump 3 Torque Decrease Control (Only on the
machines equipped with pump 3 (Optional) or
except ZAXIS135UR.) Q
Function: Reduces pump 1 and pump 2 driving Flow Rate P-Q curve is controlled in
torque to prevent the engine from stalling, proportion to pump 3 delivery
pressure.
utilizing the engine output efficiently when
the pump 3 (Optional) driving torque
increases.
Normal P-Q Curve
Operation: When the MC receives signals from pump

3 delivery pressure sensor (optional), the
MC drives the torque control solenoid valve
so that pump 1 and pump 2 flow rates are
reduced. Thereby, the total pump 1, 2, and
3 driving torque is maintained not to
exceed the engine output, utilizing the
engine output efficiently. P
Pump 3
Delivery
Pressure
Sensor
(Optional)
T178-02-01-018
T2-1-26
(Blank)
T2-1-27
VALVE CONTROL
The valve control system functions as follows:
• Arm Regenerative Control

• Travel Motor Swash Angle Control
*
• Auxiliary Flow Rate Control
*
NOTE: : Only on the machines equipped with the
ZAXIS135UR.
T2-1-28
Valve Control System Layout
Pressure Sensor
Learning
Switch
Pump 2 Pump 1
Pressure Pressure
Boom Raise
Sensor Sensor
Key Switch Arm Roll-In
Engine
Control
Dial
Hydraulic Oil
Temperature Sensor
Fast
Slow Pump 2 Control

Pressure Sensor
Travel Mode Switch

Pump 1 Control
Pressure Sensor
Solenoid Valve Unit

SC
SI
Auxiliary Flow
Rate Control
Solenoid Valve
(Optional or
except
ZX135UR)
Auxiliary Flow Rate

Control Valve
Travel Motor
Swash Angle Arm Regenerative

Control Valve Valve (Selector Valve) T176-02-01-002
T2-1-29
Arm Regenerative Control
Function: Accelerates the arm roll-in speed to

prevent arm hesitation during arm roll-in
operation.
Operation: The MC activates the solenoid valve unit

(SC) so that solenoid valve delivers the
pilot pressure oil to shift the arm
regenerative valve (selector valve) when
signals from the pump 2 delivery pressure
sensor, swing pressure sensor, arm roll-in
pressure sensor, and boom raise pressure
sensor meet the following conditions.
When the arm regenerative valve (selector
valve) is shifted, the return circuit from the
arm cylinder rod side to the hydraulic oil
tank is closed. Then, the return oil from the
cylinder rod side is combined with the
pressure oil from the pump and is routed to
the cylinder bottom, accelerating the arm
roll-in speed and preventing arm hesitation.
(Refer to the COMPONENT OPERATION /
Control Valve group.)
Pump 2 Delivery Pressure Sensor: Low pressure.(The
arm doesn’t need much power.)
Arm Roll-In Pressure Sensor: High output (The arm
control lever stroke is large.)
Swing or Boom raise Sensor: Outputting signal
NOTE: To improve arm leveling performance, the

MC gradually activates solenoid valve unit
(SC) when the hydraulic oil temperature is
at 0 to 10 °C (32 to 50 °F).
T2-1-30
Pressure Sensor
Pump 2
Swing
Delivery
Boom Raise Pressure
Arm Roll-In Sensor
Hydraulic Oil
Temperature Sensor
Solenoid Valve Unit
SC
Arm Regenerative Valve T176-02-01-003
(Selector Valve)
T2-1-31
Travel Motor Swash Angle Control
Function: Controls the travel mode.
Operation: When the travel mode switch is in the

SLOW position, the travel motor swash
angle is kept in the maximum angle so that
the travel speed is slow.
When the MC receives the signals from the
travel pressure sensor, pump 1 and 2
delivery pressure sensors, pump 1 and 2
control pressure sensors under the
following conditions with the travel mode
switch in the FAST position, the MC
activates the solenoid valve unit (SI). Then,
the solenoid valve (SI) delivers the pilot
pressure oil to the travel motor swash
angle control valve, reducing the swash
angle to the minimum so that the travel
speed increases.
Travel Pressure Sensor: ON
Front Attachment Pressure Sensor: OFF
Pump 1 and 2 Delivery Pressure Sensor: Either pump
delivery pressures is low.
Pump 1 and 2 Control Pressure Sensor: Either pump
control pressures is high.
NOTE: When one side track is raise off the ground

using the front attachment and is rotated,
the one side pump control pressure
increases, allowing the raised track to
rotate at fast speed.
When the machine is traveling in the fast
mode, even if the front attachment is
operated (the front attachment pressure
sensor is turned ON), the travel mode is
kept unchanged in the fast mode.
T2-1-32
Pressure Sensor
Travel
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Sensor Sensor
Travel Mode Switch
Fast
Mode
Pump 2 Control
Pressure Sensor
Pump 1 Control
Pressure Sensor
Solenoid Valve Unit
SI
Travel Motor
Swash Angle Control Valve

T176-02-01-004
T2-1-33
Auxiliary Flow Rate Control (Only on the
machines equipped with the auxiliary pressure
sensor and auxiliary flow rate control solenoid
valve or except ZAXIS135UR.)
Function: Restricts the oil flow to the auxiliary spool

when the combined operation of the swing,
boom raise, and arm roll-in is made while
operating a front attachment using the
auxiliary spool to maintain controllability of
the combined operation.
Operation: The MC activates the auxiliary flow rate

control solenoid valve (optional) so that the
oil flow to the auxiliary spool is restricted
under the following conditions.
Auxiliary Pressure Sensor: ON
Swing, Boom Raise, Arm Roll-In Pressure Sensors:
ON
T2-1-34
Pressure Sensor
Swing
Boom Raise
Arm Roll-In
Auxiliary Flow
Rate Control
Solenoid Valve
(Optional)
Auxiliary Flow
Rate Control Valve
T176-02-01-005
T2-1-35
OTHER CONTROLS
Work Mode Control

Two work modes, digging and front attachment, are
available by operating the work mode switch.
• Digging Mode:
Normal control is performed.
• *Front Attachment Mode:

Functions only when a front attachment in the
optional kit is operated. The engine speed (refer
to T2-1-16 and 19) and pump flow rate (refer to
T2-1-24) are controlled so as to match the
installed front attachment operation in response to
the movement of the auxiliary valve spool. The
engine speed and pump flow rate control settings
are made by Dr. ZX.
NOTE: *ZAXIS135UR cannot be equipped with a

front attachment.
T2-1-36
Travel Alarm Control (Only on the machines
equipped with the travel alarm device)
Function: Sounds the buzzer (optional) while

traveling.
Operation: As long as the MC receives signals from

the travel pressure sensor when travel
operation is made, the MC sends out
signals to the travel alarm device to sound
the buzzer.
NOTE: After traveling continuously for more than

13 seconds, the buzzer can be stopped by
the buzzer deactivation switch (optional).
Pressure Sensor
Travel
Travel Alarm
Device (Optional)
Buzzer Deactivation
Switch (Optional)
Buzzer (Optional)
T178-02-01-025
T2-1-37
Swing Alarm Control
Function: Sounds the buzzer (optional) rotating the

beacon light during swing operation.
Operation: When swing operation is made, the

pressure sensor (swing) sends a signal to
the MC. As long as this signal is delivered,
the MC outputs the signal to the swing
alarm device, sounding the buzzer and
rotating the beacon light.
NOTE: Operating the buzzer deactivation switch

will deactivate the buzzer.
Pressure Sensor
Swing
Buzzer Deactivation
Switch (Optional)
Swing Alarm
Relay
(Optional)
Buzzer (Optional)
Beacon Light (Optional)
T178-02-01-026
T2-1-38
Overload Alarm Control

(Only on the machine fitted with options)
Function: Sounds the buzzer when lifting the load in

excess of the rated load.
Operation: When lifting the load, the pressure sensor,

provided in the bottom circuit of the boom
cylinder, sends a signal to MC. When a
pressure sensor signal reaches the
specified level, MC sends a signal to the
power transistor, sounding the buzzer.
Overload alarm control can cancel buzzer
warning with an overload alarm switch.
NOTE: For lifting capacities, refer to Operation

Manual.
Pressure Sensor
Boom Bottom (OP)
C16
MC
A28
Power Transistor (OP)
Buzzer
Overload
Relay
Alarm Switch (OP)
(OP) T16R-02-01-001
T2-1-39
(Blank)
T2-1-40
SYSTEM / Front Control System
OUTLINE
The front control is for ZAXIS135UR only.
The auto-MARCCINO control unit with a built-in mi-
crocomputer is used to control the front attachment
operation. Sensing signals from the various sensors,
and switches are sent to the auto-MARCCINO control
unit. After processing the sensing signals in the logic
circuit, the auto-MARCCINO control unit sends out the
control signals to the 8-unit solenoid valve unit and
emergency stop solenoid valve to control the front
attachment operation.
Sensing Signals (Input Signals) Control Signals (Output Signals)

• Pilot Pressure Sensor (Boom Raise, →8-Unit Solenoid Valve ⋅ Front Movement
Boom Raise Acceleration*, Boom Lower, Optional Solenoid Valve Restriction control
Arm Roll-In, Arm Roll-Out Acceleration, (Front Attachment ⋅ Bucket/Cab
Right Offset Acceleration, Left Offset Operation Control) Collision Prevention
Acceleration) → Control
• Angle Sensor (Boom, Arm, Offset) → ⋅ Auto-MARCCINO
Control
• Left Offset Switch → Auto-
• Right Offset Switch → MARCCINO
• Front Movement Control Unit →Emergency Stop ⋅ Front Movement
Restriction Deactivation Switch* → (URX) Solenoid Valve Restriction Control
• Auto-MARCCINO Mode Switch →
• Optional Monitor →Liquid Crystal ⋅ Distance Indication
(Height Limit Switch, Depth Limit Switch, Monitor/Optional Monitor Control*
Offset Limit Switch, Absolute/Relative ⋅ System Failure
Distance Selector, Monitor Display bisplay Control
Selector, Zero Position Set Switch) →
• Emergency Evacuation Switch →
NOTE: *: Machine only with the optional function.

The restriction deactivation switch is
located on the standard right control
lever with the optional function of
restiction deactivation.
T2-2-1
FRONT MOVEMENT CONTROL
The front movement control has the following
functions:
• Front Movement Restriction Control
• Bucket/Cab Collision Prevention Control
• Auto-MARCCINO Control
• System Abnormality Indication Control
• Restriction Control*
• Distance Indication Control*
NOTE: *: Machine Only with the optional function.

Arm Roll-Out
Acceleration Left Offset Right Offset
Pilot Pres- Boom Raise Acceleration Acceleration
sure Sensor Pilot Pres- Pilot Pres- Pilot Pres-
sure Sensor sure Sensor sure Sensor
Boom Raise Ac- Arm Roll-In Boom Lower

celeration Pilot Pilot Pres- Pilot Pres-
Pressure Sensor sure Sensor sure Sensor
(Optional)
Boom Angle Sensor

8-Unit Solenoid
Valve Unit
Arm Angle Sensor Boom Raise Deceleration
Boom Lower Deceleration

Offset Angle Sensor Arm Roll-In Deceleration
Right Offset Deceleration

Left Offset Switch
Auto-MARCCINO Right Offset Acceleration
Control Unit
Right Offset Switch Arm Roll-Out Acceleration
Left Offset Deceleration

Restriction Deactivation
Switch (Optional) Left Offset Acceleration
Auto-MARCCINO Emergency Stop Solenoid Valve

Mode Switch
Liquid Crystal Monitor
Emergency Evacua- Optional Monitor

tion Switch
Boom Raise Acceleration
Optional Monitor Solenoid Valve (Optional)
(Switch)
Arm Roll-Out Deceleration
Optional Solenoid T1SM-02-03-001
Valve
T2-2-2
Cab Inside System Monitor

4
1
2 3
T1CF-01-01-003
T1SM-01-02-014
Right Front of Seat Optional Monitor
7
11 8
12
10 9
T1CF-02-02-004
T1CF-01-01-004
1 - Right Offset Switch 4 - Liquid Crystal Monitor 7 - Monitor Indication Selector 10 - Offset Limit Switch
2 - Left Offset Switch 5 - Auto-MARCCINO Mode 8 - Height Limit Switch 11 - Zero Position Set Switch
Switch
3 - Front Movement Restriction 6 - Absolute/Relative Dis- 9 - Depth Limit Switch 12 - Evacuation Emergency
Deactivation Switch tance Selector Switch
T2-2-3
(Blank)
T2-2-4
Bucket/Cab Collision Prevention Control
Purpose: To automatically reduce speed or stop Operation: Front movement sensing signals from
the front movement when the bucket the boom angle sensor, arm angle
enters the preset range (deceleration, sensor, and offset angle sensor are
intermediate deceleration, or stop), so sent to the auto-MARCCINO control
that the bucket does not collide with the unit. When the bucket enters the preset
cab. range, the auto-MARCCINO control unit
magnetizes the 8-unit solenoid valve
unit (boom raise deceleration / arm
roll-in deceleration / boom lower
deceleration / left offset deceleration /
right offset deceleration) to reduce or
block the pilot pressure, causing the
front movement to reduce speed or to
stop.
8-Unit Solenoid
Valve Unit
Boom Raise Deceleration
Arm Roll-In Deceleration

Boom Angle Sensor
Right Offset Acceleration

Auto-MARCCINO
Arm Angle Sensor Control Unit Arm Roll-Out Acceleration
Offset Angle Sensor Left Offset Acceleration
Emergency Stop Solenoid

Valve
T1SM-02-03-002
T2-2-5
Restriction Renge:
NOTE: Unit: mm Arm Deceleration
Boom Deceleration
Arm Intermediate Deceleration
Boom Intermediate Deceleration
Boom / Arm Stop Position
950
550
300
235
T1SM-02-02-009
Offset Deceleration
950 Offset Intermediate Deceleration

950
550 Offset Stop Position
300 235 Allowed Boom / Arm
Approaching Range from the
front
450
130
750
220
T1SM-02-02-010
T2-2-6
NOTE: Unit: mm
Arm Deceleration
Offset Deceleration
Arm Intermediate Deceleration
Offset Intermediate Deceleration 950
Boom / Arm Right Offset Stop Position 750
Cover Standard Line 550
235
T1SM-02-02-011
T2-2-7
Auto-MARCCINO Control
• Cab Collision Prevention Control
Function: When the machine is operated in the cab Operation: The auto-MARCCINO control unit moni-
collision prevention mode, if the bucket en- tors the position of the front attachment by
ters the cab collision prevention range while signals from the boom angle sensor, arm
raising the boom such as in a truck loading angle sensor, and offset angle sensor and
operation, all front attachment functions are the front attachment movement by the
stopped. In the auto-MARCCINO control signals from the boom raise pilot pressure
mode, even if the bucket enters the cab col- sensor and arm roll-in pilot pressure sen-
lision prevention range, the bucket can be sor. If the boom is raised when the bucket
moved along the cab collision prevention enters the cab collision prevention range,
control line without stopping the front at- the auto-MARCCINO control unit activates
tachment function, allowing the truck load- the 8-unit solenoid valve (arm roll-in de-
ing work to continue. celeration, and arm roll-out acceleration).
Then, the 8-unit solenoid valve (arm roll-in
deceleration, and arm roll-out accelera-
tion) supplies pilot pressure oil to the con-
trol valve arm spool so that the arm is
rolled out. Thus, the bucket is moved
along the cab collision prevention control
line.
NOTE: How much the arm should be moved (arm

roll-out acceleration command) depends
upon how much the boom is raised (boom
raise pilot pressure sensor) and how far
the bucket has entered the cab collision
prevention range.
Arm Deceleration
Boom Deceleration
Cab Collision Prevention Control Line

Boom / Arm / Left
Offset Stop Position
950
550
235
300
1200
T1SM-02-02-012
T2-2-8
Boom Raise Arm Roll-In

Pilot Pressure Pilot Pressure
Sensor Sensor
8-Unit Solenoid
Valve Unit
Boom Angle Sensor Boom Lower Deceleration
Arm Angle Sensor Right Offset Deceleration

Auto-MARCCINO
Right Offset Acceleration
Control Unit
Offset Angle Sensor Arm Roll-Out Acceleration

Auto-MARCCINO
Mode Switch Left Offset Acceleration
T1SM-02-03-003
T2-2-9
• Offset Control by Offset Switch
Function: Achieves the offset control by operating

the offset switch.
Operation: When the auto-MARCCINO mode

switch is ON and signals from the offset
switch are input to the
auto-MARCCINO control unit, the
auto-MARCCINO control unit activates
the 8-unit solenoid valve (left / right off-
set acceleration). Then, the 8-unit so-
lenoid valve (left / right offset accelera-
tion) supplies a constant pilot pressure
to the control valve offset spool,
achieving the offset operation.
Left Offset Accel- Right Offset Accel-

eration Pilot Pres- eration Pilot Pres-
sure Sensor sure Sensor
8-Unit Solenoid
Valve Unit
Left Offset Switch


Auto-MARCCINO
Right Offset Switch Right Offset Acceleration
Control Unit
Arm Roll-Out Acceleration
Auto-MARCCINO Left Offset Deceleration

Mode Switch
Left Offset Acceleration
T1SM-02-03-004
T2-2-10
(Blank)
T2-2-11
Front Movement Restriction Control
Purpose: In case any abnormal control in front at-

tachment operation occurs, the front at-
tachment movement is restricted in re-
sponse to the location where abnormality
has occurred.
NOTE: When any abnormal control in front at-

tachment operation occurs, the liquid
monitor displays fault codes related to the
defective locations.
Operation: Electrical signals from the various sen-

sors and switches related to the front at-
tachment operation control are sent to
the auto-MARCCINO control unit. If any
abnormal signals from the sensors
and/or switches are sent to the
the 8-unit solenoid valve unit or emer-
gency stop solenoid valve depending on
the abnormal situation. When restricting
the movement of the front attachment
locally, the auto-MARCCINO control unit
restricts the movement of the related ac-
tuators only by activating the 8-unit so-
lenoid valve unit. When restricting all
front attachment movement, the
the emergency stop solenoid valve
blocking the pilot pressure oil so that the
spools in the control valve become un-
controllable. Thereby, all front attachment
functions become inoperative.
T2-2-12
Arm Roll-Out Boom Raise Left Offset Right Offset

Acceleration Pilot Pres- Acceleration Acceleration
Pilot Pressure sure Sensor Pilot Pressure Pilot Pressure
Sensor Sensor Sensor

(Optional)
Boom Angle Sensor

8-Unit Solenoid Valve
Unit


Left Offset Switch
Control Unit
Restriction Deactivation Left Offset Deceleration

Switch (Optional)
Auto-MARCCINO Emergency Stop Solenoid Valve

Mode Switch
Emergency Evacua-
tion Switch Optional Monitor
Boom Raise Acceleration
Optional Monitor Solenoid Valve (Optional)
(Switch)
Optional T1SM-02-03-005
Solenoid Valve
T2-2-13
System Failure Display Control
Purpose: Purpose: In case any abnormalities oc-

Liquid
cur in the front attachment control sys- Crystal
tem, the liquid monitor displays the fault Monitor
codes related to the defective sections.
Operation: Electrical signals are sent to the

auto-MARCCINO control unit from vari-
ous sensors and switches located in the
front attachment control system. When
any abnormal signals are input to the
auto-MARCCINO control unit outputs
signals to the liquid monitor, causing the
liquid monitor to display the fault codes
related to the defective sections.
T1CF-01-01-025
T2-2-14
Left Offset Right Offset

Arm Roll-Out Boom Raise Acceleration Acceleration
Acceleration Pilot Pres- Pilot Pres- Pilot Pres-
Pilot Pressure sure Sensor sure Sensor sure Sensor
Sensor

(Optional)
Boom Angle Sensor

8-Unit Solenoid
Valve Unit


Left Offset Switch
Control Unit
Restriction Deactivation Left Offset Deceleration

Switch (Optional)
Auto-MARCCINO
Mode Switch Emergency Stop Solenoid Valve

Emergency
Evacuation Switch Optional Monitor
Optional Monitor Boom Raise Acceleration

(Switch) Solenoid Valve (Optional)
Optional Sole-
T1SM-02-03-005
noid Valve
T2-2-15
Distance Indication Control (Optional)
Purpose: To display the bucket height, depth, and Operation: Sensing signals from the boom angle
offset amount in both absolute and sensor, arm angle sensor, and offset
relative distance values. angle sensor are input into the
The absolute distance value means the auto-MARCCINO control unit. The
movement distance measured from a auto-MARCCINO control unit calculates
preset-specified standard point. The the bucket tip position using the input
relative distance means the movement signals, allowing the system monitor to
distance measured from a position display the calculation results in
se-lected by the zero position set response to instructions given from the
switch. switches.
Boom Angle Sensor
Arm Angle Sensor
Offset Angle Sensor
Auto-MARCCINO Control
Absolute / Relative Distance Unit
Selector
Optional Monitor Display Selector

(Switch)
Zero Position Set Switch
Optional
Monitor
T1SM-02-03-006
T2-2-16
Distance Display:
• Absolute Distance Display
D
A Standard
Center Line
Standard E
Level
B C Standard Point
M190-05-024 M190-05-025
• Relative Distance Display
Zero
Position
B
Zero Position
M190-05-026 T191-02-02-002
Zero
Position
T191-02-02-003
A - Height C - Reach D - Right Offset E - Left Offset

B - Depth C’ - Reach
T2-2-17
Front Movement Restriction Control (Optional)
Purpose: The height limit switch, depth limit switch,

and offset limit switch are used to preset
the maximum boom top height, maximum
arm top depth, and maximum front at-
tachment offset respectively so that the
front attachment movement is automati-
cally slowed down and stopped at each
preset-position.
Operation: The auto-MARCCINO control unit stores While the front movement restriction control system
the data preset by the height limit switch, is activated, when the front movement restriction
depth limit switch, and offset limit switch. deactivation switch is pressed, the front movement
During operation, the boom angle sensor, restriction control system is temporarily (continu-
arm angle sensor and offset sensor de- ously for 30 seconds) deactivated.
tect the position of the front attachment.
When the front attachment approaches
the preset movement limit position, the
the 8-unit solenoid valve unit (boom raise
deceleration / boom lower deceleration /
arm roll-in deceleration / left offset decel-
eration) and optional solenoid valve unit
(arm roll-out deceleration / boom raise
acceleration) to block the pilot pressure
oil so that the front attachment is stopped
automatically.
8-Unit Solenoid
Valve Unit

Boom Angle Sensor
Arm Angle Sensor
Offset Angle Sensor Right Offset Deceleration

Auto-MARCCINO
Control Unit Right Offset Acceleration
Depth Limit Switch
Arm Roll-Out Acceleration
Offset Limit Switch Left Offset Deceleration

Optional
Monitor Left Offset Acceleration
(Switch) Height Limit Switch
Restriction Boom Raise Acceleration

Deactivation Switch Solenoid Valve (Optional)
Optional Solenoid T1SM-02-03-008

Valve
T2-2-18
Restriction Range :
• Height Limit
M190-05-031
• Depth Limit
M197-05-023
• Offset Limit
M190-05-034
T2-2-19
(Blank)
T2-2-20
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system is broadly divided into two cir-
cuits, the main circuit and the pilot circuit.
Main Circuit:
Power Source Controller Actuator

Main Pumps → Control Valves → Motors
Cylinders
Front Attachments (Optional)
(Except ZAXIS135UR)
Pilot Circuit:
Power Source Controller Pilot Circuit

Pilot Pumps → Pilot Valves → Operation Control Circuit
Pump Regulator Pump Control Circuit
Solenoid Valve Unit Valve Control Circuit
Signal Control Valve Swing Parking Brake Release Circuit
8-Unit Solenoid Valve Travel Motor Swash Angle Control Circuit
(ZAXIS135UR only) Hydraulic Oil Heat Circuit
Emergency Stop Front Attachment Control Circuit
Solenoid Valve (ZAXIS135UR only)
(ZAXIS135UR only)
T2-3-1
PILOT CIRCUIT
Outline: (ZAXIS110, 110M, 120, 130, 130LCN,
125US, 135US)
• Pressure oil from the pilot pump is used to oper-
ate the operation control circuit, pump control
circuit, valve control circuit, swing parking brake
release circuit, travel motor swash angle control
circuit, and hydraulic oil heat circuit.
Operation Control Circuit Swing Parking Brake
Release Circuit
Positioning Pilot Left Pilot Travel Pilot Right Pilot Auxiliary Pilot
Valve Swing Motor
Valve Valve Valve Valve
Pump Control Circuit
To Positioning Maximum Torque
Control Valve Pump 2 Flow Control
Spool Rate Control Solenoid
Solenoid Valve Valve
Pilot Shut-Off
Valve
SB ST
Signal Control Valve
Hydraulic Oil SA
Heat Circuit Maximum Pump 1 Flow
Rate Control Solenoid Valve
To Control Valve (Optional)
Spool 2 1
Pump
Auxiliary Flow Combining
Flow Bucket Flow
Solenoid Valve (When the Combiner Rate Control
Holding Valve auxiliary spool is used.) Valve Valve Regulator
Boom
Boom Anti-Drift Valve
Arm
Arm Anti-Drift Valve
Posi-
tioning Auxiliary Flow Combining
Valve
Bypass Shut-Out Valve

Auxiliary Flow Rate Control Hydraulic
Solenoid Valve (When the Auxiliary Flow Control Valve Oil Tank
auxiliary spool is used.) Valve
Control SC Arm Regenerative Valve
Circuit Suction
SI Control Valve Filter
Solenoid Travel Motor Swash
Valve Unit Angle Control Circuit
Relief Pilot
Travel Travel Valve Pump
Motor Motor
Pilot
Filter
T187-02-03-004
T2-3-2
Outline: (ZAXIS135UR)
• Pressure oil from the pilot pump is used to oper-
ate the operation control circuit, pump control
circuit, valve control circuit, swing parking brake
release circuit, front attachment control circuit,
travel motor swash angle control circuit, and hy-
draulic oil heat circuit. Swing Parking Brake
Operation Control Circuit Release Circuit
Blade Pilot Travel Pilot Left Pilot Right Pilot Offset Pilot Swing Motor
Valve Valve Valve valve Valve
Pump Control
Front Circuit
Emergency 8-Unit Solenoid Valve Attachment
Stop Maximum Pump 2 Torque
Solenoid Control Flow Rate Control Control So-
Valve Circuit Solenoid Valve lenoid Valve
Pilot
Shut-Off
Valve SB ST
Hydraulic Oil SA
Heat Cuicuit
Maximum Pump 1 Flow
To Control Rate Control Solenoid
Valve Spool Valve (Optional) 2 1
Pump
Flow Bucket Flow
Blade Signal Combiner Rate Control
Switch Valve Valve Valve Regulator

Offset Anti-Drift
Valve Arm Anti-Drift Valve

Hydraulic
Oil Tank
Valve
Control SC Arm Regenerative Valve
Circuit Suction
SI Control Valve Filter
Solenoid Valve
Travel Motor Swash
Unit Angle Control Circuit
Relief Pilot
Travel Travel
Valve Pump
Motor Motor
Pilot
Filter
T1SM-02-02-001
T2-3-3
Operation Control Circuit: (ZAXIS110, 110M, 120,
130, 130LCN, 125US, 135US)
• The pilot valves control the pressure oil from the
pilot pump to operate the control valve spools.
• The signal control valve is provided between the

pilot valves and the control valve. The shockless
valve (in the boom lower circuit) built in the signal
control valve dampens quick spool movement in
the control valve. (Refer to the COMPONENT
OPERATION / Signal Control Valve group.)
T2-3-4
Positioning Pilot Valve

(2-piece Boom only) Travel Pilot Valve Pilot Valve (Left) Pilot Valve (Right)
Shockless Valve
13 14
9 10 11 12 4
1
Signal Control Valve 3 2 8 7 6 5
10
9 11
12
7 8
2
1 1
3 3
5 6
13 14
Pilot Control Valve
Valve
Positioning Control Valve

(2-piece Boom only)
T187-02-03-001
1- Boom Raise 5 - Left Swing 9- Left Travel Forward 13 - Positioning Lower
2- Boom Lower 6 - Right Swing 10 - Left Travel Reverse 14 - Positioning Raise
3- Arm Roll-Out 7 - Bucket Roll-In 11 - Right Travel Forward
4- Arm Roll-In 8 - Bucket Roll-Out 12 - Right Travel Reverse
T2-3-5
Operation Control Circuit: (ZAXIS135UR)
• The pilot valves control the pressure oil from the
pilot pump to operate the control valve spools.
• The signal control valve and the 8-unit solenoid

valve are provided between the pilot valves (front
attachment) and the control valve.
• The shockless valve (in the boom lower circuit)
built in the signal control valve dampens quick
spool movement in the control valve. (Refer to
the COMPONENT OPERATION / Signal Control
Valve group.)
• The 8-unit solenoid valve controls the front at-
tachment pilot pressure and the front attachment
operation. (Refer to the SYSTEM / Front Attach-
ment Control System group)
T2-3-6
Blade Pilot Travel Pilot Pilot Valve Pilot Valve Offset Pilot
Valve Valve (Left) (Right) Valve
8-Unit
Solenoid
Valve
18 17
Shockless Valve
Signal
Control
Valve
9 10 11 12 4
3 2 1 8 7 6 5 13 14
10
9 12 11
13 8 17 18
14
7
2
1 1 Blade Control Valve
4
Blade Pump
3 3
6
5
Pilot Control Valve

Pump
T1SM-02-02-002
1- Boom Raise 5- Left Swing 9- Left Travel Forward 13 - Right Offset

2- Boom Lower 6- Right Swing 10 - Left Travel Reverse 14 - Left Offset
3- Arm Roll-Out 7- Bucket Roll-In 11 - Right Travel Forward 17 - Blade Raise
4- Arm Rool-In 8- Bucket Roll-Out 12 - Right Travel Reverse 18 - Blade Lower
T2-3-7
Pump Control Circuit (Refer to the COMPONENT
OPERATION / Pump Device group.)
Pump Flow Rate Control by Flow Rate Control

Pressure Pi
• Pressure oil from the pilot valve is selected by the
shuttle valves in the signal control valve. Then,
the selected pressure oil is routed further to ei-
ther the pump 1 flow rate control valve or the
pump 2 flow rate control valve in the same signal
control valve, shifting either of the flow rate con-
trol valves.
• When either the pump 1 flow rate control valve or

the pump 2 flow rate control valve is shifted, the
pilot pressure oil from the pilot pump is routed to
either main pump 1 or main pump 2 as flow rate
control pressure Pi.
NOTE: When the boom (raise / lower), arm (roll-in

/ out), bucket (roll-in / out), and / or travel
(right) function is operated, flow rate con-
trol pressure Pi is routed to main pump 1.
When the boom (raise), arm (roll-in / out),
swing (right / left), travel (left), and / or off-
set (right / left) (ZAXIS135UR only) func-
tion is operated, flow rate control pressure
Pi is routed to main pump 2.
Torque Control (Speed Sensing) by Torque Control

Solenoid Valve
• After the pilot oil pressure from the pilot pump is
regulated by the torque control solenoid valve,
the regulated pilot oil pressure is routed to main
pump 1 and 2 as speed sensing pressure Ppc.
T2-3-8
Offset
(ZAXIS135U
Travel (Left) Travel (Right) Swing Arm Boom Bucket R only)

(ZAXIS135UR Only)
Signal Control
Valve
Pump 1 Flow Rate

Control Valve
Pump 2 Flow Rate
Control Valve
Control Valve
Torque
Control
Solenoid
Valve
Pump 2 Pump 1
Pilot Pump
T1SM-02-02-003
T2-3-9
Valve Control Circuit: ZAXIS110, 110M, 120,
125US, 130, 130LCN, 135US (Refer to the COM-
PONENT OPERATION / Control Valve and Travel
Device groups.)
The following valves are controlled by pressure oil
from the pilot valves, solenoid valve unit (SC), the
flow combiner valve control spool in the signal con-
trol valve, and the bucket flow rate control valve
control spool.
• Boom Lower Pilot Pressure: Boom Anti-Drift

Valve, Holding Valve (Optional)
• Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve

(Selector Valve), Holding Valve (Optional)
• Auxiliary Pilot Pressure: Auxiliary Flow Combiner

Valve, Bypass Shut-Out Valve (When the auxil-
iary spool is used.)
• Positioning Lower Pilot Pressure (2-piece Boom

only): Bypass Shut-Out Valve, Holding Valve (Op-
tional)
• Positioning Raise Pilot Pressure (2-piece Boom

only): Bypass Shut-Out Valve
• Solenoid Valve SC: Arm Regenerative Valve (Se-

lector Valve)
• Auxiliary Flow Rate Control Solenoid Valve: Aux-

iliary Flow Rate Control Valve (When the auxiliary
spool is used.)
• Auxiliary Flow Combining Solenoid Valve: Boom,

Arm, and Bucket Pilot Pressure
• Flow Combiner Valve Control Spool: Flow Com-

biner Valve
• Bucket Flow Rate Control Valve Control Spool:

Bucket Flow Rate Control Valve
T2-3-10
Positioning
(2-piece Boom only) Travel (Right) Arm Ro-ll-In Boom Lower
Auxiliary
Bucket Flow Rate

13 Control Valve
Control Spool
Flow Combiner Valve

Control Spool
4
2
Auxiliary Flow
Combining Valve
Auxiliary Flow
Auxiliary Combiner Valve
Flow Rate
4 Control Valve Flow Combiner Valve
Holding Valve Bucket Flow Rate
(Arm) Control Valve
Auxiliary Flow
Rate Control Boom Anti-Drift Valve
Solenoid Valve
Arm
Anti-Drift 2
Valve
Solenoid
4
Valve Unit
Holding Valve
(Boom)
SC
Holding Valve
(Positioning)
Pilot
Pump
Arm Regenerative
Valve 13
(Selector Valve)
Positioning
Control Valve
T187-02-03-002
T2-3-11
Valve Control Circuit: ZAXIS135UR (Refer to the
COMPONENT OPERATION / Control Valve and
Travel Device groups.)
• The following valves are controlled by pressure oil
from the pilot valves, solenoid valve unit (SC), the
flow combiner valve control spool in the signal con-
trol valve, the bucket flow rate control valve control
spool, and the blade signal control valve.
• Boom Lower Pilot Pressure: Boom Anti-Drift

Valve
• Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve

(Selector Valve)
• Offset (Right / Left) Pilot Pressure: Offset

Anti-Drift Valve
• Blade Pilot Pressure: Blade Signal Switch Valve
• Blade Signal Control Valve: Flow Combiner Valve,

and Bypass Shut-Out Valve
• Solenoid Valve SC: Arm Regenerative Valve (Se-

lector Valve)
• Flow Combiner Valve Control Spool: Flow Com-

biner Valve
• Bucket Flow Rate Control Valve Control Spool:

T2-3-12
Blade Travel (Right) Arm Roll-In Boom Lower Offset
4
2
Flow Combiner
Valve Control
Spool
Blade
Signal Flow Com- Bucket Flow
Switch biner Rate Control
Valve Valve Valve Control
Spool
Arm
Offset Anti-Drift
Anti-Drift
Valve
Valve
2
Solenoid Bucket Flow Rate Valve

Valve Unit
4 Boom Anti-Drift Valve
SC Bypass Shut-Out Valve
Arm Regenerative Valve

(Selector Valve)
T1SM-02-02-004
T2-3-13
Swing Parking Brake Release Circuit (Refer to
the COMPONENT OPERATION / Swing Device
group.)
• When the front attachment and/or swing function
is operated, the pilot oil pressure selected by the
shuttle valves in the signal control valve shifts the
swing parking brake release spool.
• Consequently, the release signal oil pressure is

routed to the swing motor, releasing the swing
parking brake.
Travel Motor Swash Angle Control Circuit (Refer

to the COMPONENT OPERATION / Travel Device
group.)
• The pilot oil pressure from solenoid valve unit (SI)
regulates the travel motor swash angle control
valve.
Hydraulic Oil Heat Circuit (Refer to the COMPO-

NENT OPERATION / Others (Upperstructure)
group.)
• When the pilot shut-off valve is closed, the pilot
oil pressure is routed to the signal control valve
and 8-unit solenoid valve (ZAXIS135UR only) so
that the hydraulic oil is warmed while passing
through the orifices in the signal control valve,
and 8-unit solenoid valve (ZAXIS135UR only).
• The warmed pilot pressure oil flows to the signal

control valve, 8-unit solenoid valve (ZAXIS
135UR only), and pilot valves so that the pilot
system components are warmed.
T2-3-14
Offset
Positioning (ZAXIS135UR
(2-piece Boom only) Swing Arm Boom Bucket Only)

(ZAXIS135UR only)
Orifice
Orifice

Swing Parking Brake
Release Spool
Travel Motor
Swing Motor
T187-02-02-001
Swash Angle Control Valve
T2-3-15
MAIN CIRCUIT
Outline
• Main pumps (1 and 2) and the blade pump
(ZAXIS135UR only) draw the hydraulic oil from
the hydraulic oil tank. Main pump 1 and main
pump 2 deliver the pressure oil to the 4-spool
side control valve, positioning control valve
(2-piece boom only) and the 5-spool side control
valve respectively. The Blade Pump (ZAXIS
135UR only) delivers the pressure oil to the blade
control valve (ZAXIS135UR only).
• The delivered pressure oil is routed to the mo-

tor(s) or cylinder(s) in response to operation(s) of
the spool(s) in the control valve(s).
• The return oil from the motor(s) and/or cylinder(s)

flows back to the hydraulic oil tank via the control
valve and/or the oil cooler.
NOTE: The return oil from blade control valve

(ZAXIS135UR only) flows back to the hy-
draulic oil tank directly.
• When the oil temperature is low (high viscosity),

the oil flow resistance increases in the oil cooler,
which opens the bypass check valve, allowing
hydraulic oil to return directly to the hydraulic oil
tank without passing through the oil cooler.
T2-3-16
Travel Motor (Left) Travel Motor (Right)
Bucket Cylinder
Front Attachment
(ZAXIS135UR: Offset Cylinder)
Control Valve Boom Cylinder
4-Spool
Arm Cylinder Side
Travel (Left) Travel (Right)
Auxiliary (ZAXIS135 Bucket

UR: Offset)
Boom 2 Boom 1
Arm 1 Arm 2 Blade Cylinder Valve

(ZAXIS135UR Only)
Swing
5-Spool Side
Bypass Check
Valve
Blade Control Valve
(ZAXIS135UR Only)
Swing Motor
Oil Main Pump 2 Main Pump 1 Blade Pump
Cooler (ZAXIS135UR
Positioning Cylinder Only)
(2-piece Boom only)
Suction Filter Hydraulic Oil

Tank
Positioning Control
Valve
(2-piece Boom only)
T2-3-17
Neutral Circuit
• When the control lever is in neutral, the pressure
oil from the main pump passes through the con-
trol valve and returns to the hydraulic oil tank.
Single Operation Circuit

• The pressure oil from main pump 1 is routed to
the 4-spool side control valve and is further
routed to each spool of the travel (right), bucket,
boom 1, and arm 2.
• The pressure oil from main pump 2 is routed to

the 5-spool side control valve and is further
routed to each spool of the swing, arm 1, boom 2,
auxiliary (ZAXIS135UR: offset) and travel (left).
• The boom and the arm are actuated by the pres-

sure oil from two main pumps. The pressure oil
from each main pump is combined and supplied
together.
T2-3-18
Control Valve
Front Attachment Travel Travel

(Left) (Right)
(ZAXIS135UR:
Offset Cylinder)
Bucket Cylinder
Auxiliary
(Offset)
Bucket
Arm Cylinder
Boom 1
Boom Cylinder
Boom 2
Swing Motor
Arm 1
Arm 2
Swing
5-Spool Side
4-Spool Side
Pump 2 Pump 1
T176-02-02-001
T2-3-19
Blade Circuit (ZAXIS 135UR only)
Neutral Circuit
oil from the blade pump is returned to the hydrau-
lic oil tank via the blade control valve.

• When the control lever is operated, the blade
signal selector valve and the bypass cut valve
are shifted.
• When the blade signal selector valve is shifted,
the pilot oil pressure from the blade signal selec-
tor valve shifts the flow combiner valve.
• When the flow combiner valve is shifted, the
pressure oil from pump 1 is combined with the
pressure oil from pump 2 in the control valve and
flows to the blade control valve.
• After the pressure oil from the blade pump is
combined with the pressure oil from pumps 1 and
2 in the blade control valve, the pressure oil flow
to the blade cylinder.
• Due to the above flow combining operation, the
blade cylinder operating speed is increased
NOTE: When combined operation with the blade
is made, actuator speed other than the
blade cylinder must be procured. There-
fore an orifice is provided in the oil flow
combining circuit from pump1 and pump 2.
T2-3-20
Pilot Pressure From

Blade Signal Control
Valve
Flow Combiner
Valve Orifice
Control Valve
Blade
Cylinder
Bypass
Shut-Out
Valve
Blade
Control
Valve
Pump 2 Pump 1
Blade Pump
Pilot Pressure from
Blade Pilot Valve
T1SM-02-02-007
T2-3-21
Positioning Operation Circuit
(2-piece boom only)
Neutral Circuit
oil from pump 1 is returned to the hydraulic oil
tank via the control valve.
Positioning Cylinder

• During positioning operation, the spools in the
bypass shut-out valve and positioning control
valve are shifted.
• The pressurized oil from pump 1 is divided on the
four-spool side, and combined in the positioning
control valve and goes into the positioning cylin-
der.
T178-02-02-014
Combined Operation Circuit

• In combined operations, the pressurized oil from
pump 1 flows into the positioning control valve
through the parallel circuit.
• Even in combined operations, the parallel circuit
allows positioning operation.
T2-3-22
4-Spool Side
Parallel Circuit
Pilot Pres-
sure from Po-Positioning
sitioning PilotCylinder
Valve
Bypass
Shut-Out
Pump 1
Positioning T187-02-03-003
Control Valve
T2-3-23
Swing and Boom Raise Operation
• When the boom is raised while swinging, the pilot
oil pressure shifts the swing, boom 1, and boom
2 spools.
• The pressure oil from pump 1 flows into the

boom cylinders via the parallel circuit and the
boom 1 spool, raising the boom.
• The pressure oil from pump 2 flows into the

swing motor via the swing spool.
• At the same time, the pressure oil from pump 2

flows through the parallel circuit and after being
combined with the pressure oil from pump 1,
flows into the boom cylinders, raising the boom.
T2-3-24
Parallel Circuit
Boom 2
Boom 1
Boom Cylinder
Swing Motor
Swing
Parallel
Circuit
Pump 2 Pump 1
T176-02-02-002
T2-3-25
Travel and Arm Roll-In Operation
• When the arm is rolled in while traveling, the pilot
oil pressure shifts the travel, the arm 1 and 2
spools.
• At the same time, the right travel pilot oil pressure

shifts the flow combiner valve control spool in the
signal control valve. The pressure oil from the
flow combiner valve control spool is routed to the
flow combiner valve, shifting the flow combiner
valve.
• The pressure oil from pump 1 drives the right

travel motor via the right travel spool.
• At the same time, the pressure oil from pump 1

passes through the flow combiner valve and the
left travel spool and drives the left travel motor.
• The pressure oil from pump 2 flows into the arm

cylinder via the arm 1 spool, moving the arm.
• Consequently, the pressure oil from pump 2 is

used only to operate the arm. The pressure oil
from pump 1 is equally routed to both the right
and the left travel motors, ensuring that the ma-
chine can travel straight.
T2-3-26
Travel Motor (Left) Pilot Pressure Travel Motor (Right)

from Flow
Combiner Valve
Control Spool in
Signal Control
Valve
Left
Travel Right
Travel
Arm Cylinder
Arm 1
5-Spool Side 4-Spool Side
Pump 2 Pump 1
T176-02-02-003
T2-3-27
Auxiliary Circuit
(ZAXIS110, 110M, 120, 125US, 130, 130LCN, NOTE: During boom (raise or lower), arm (roll-in
135US) or roll–out), bucket (roll-in or roll–out),
• When a front attachment such as a hydraulic and/or right travel operation, the pilot
breaker is operated, the pilot pressure oil from pressure oil is routed to port SN from the
the hydraulic breaker pilot valve shifts the auxil- signal pilot pressure control valve so that
iary flow combiner valve and the bypass shut-out the auxiliary. flow combiner valve is not
valve. shifted. (Refer to the SYSTEM / Control
System group.)
• Therefore, the neutral circuit in the 4-spool con-
trol valve is blocked so that the pressure oil from
pump1 is routed to the auxiliary spool via the
auxiliary flow combiner valve.
T2-3-28
Pilot Pressure from

Hydraulic Breaker
Pilot Valve
Auxiliary Flow Com-

bining Solenoid Valve
Pilot Pressure from

Auxiliary Flow Signal Control Valve
Combining Valve
SN SM
Front
Attachment
Neutral
Circuit
Auxiliary
Bypass
Shut-Out Valve
Pump 2 Pump 1
T176-02-02-004
T2-3-29
(Blank)
T2-3-30
SYSTEM / Electrical System
OUTLINE
The electrical circuit is broadly divided into the main
circuit, the monitor circuit, and the control circuit.
• Main Circuit
The engine and accessory operation related
circuit.
• Monitor Circuit
The electrical circuit group consists of the
monitors, sensors, and switches, and displays
the machine operation status.
• Control Circuit (Refer to the SYSTEM / Control

System group.)
The control circuit is categorized into the engine,
pump, and valve control circuits. Each circuit
consists of the actuators such as solenoid valves,
MC (main controller), switch boxes, sensors and
pressure switches.
T2-4-1
MAIN CIRCUIT
The major functions and circuits in the main circuit are
as follows.
• Electric Power Circuit: Supplies all electric power

to all electrical systems on this machine. [Key
Switch, Batteries, Fuses (Fuse Boxes, Fusible
Links), and Battery Relay]
• Indicator Light Check Circuit

Checks all indicator bulbs for burning.
• Accessory Circuit
Becomes operative when the key switch is turned
to the ACC position.
• Preheat Circuit
Assists the engine to start in cold weather. [Key
Switch, QOS Controller, Coolant Switch, Glow
Plug Relay, and Glow Plugs]
• Starting Circuit
Starts the engine. [Key Switch, Starter, and Starting
Relay]
• Charging Circuit
Charges the batteries. [Alternator, and Regulator]
• Serge Voltage Prevention Circuit

Prevents the occurrence of serge voltage
developed when stopping the engine. [ Load
Damp Relay]
• Engine Stop Circuit

Stops the engine using the EC motor. [MC, and
EC Motor]
T2-4-2
(Blank)
T2-4-3
ELECTRIC POWER CIRCUIT (KEY
SWITCH: OFF)
The battery ground terminal is connected to the
vehicle frame. The current from the battery plus
terminal flows as (shown) below when the key switch
is OFF.
Battery
→Glow Plug Relay
↓ →Terminal #1: Radio (Backup Power)
(Power)
Fusible Link Monitor (Backup Power)
→Key Switch (B)
ICX Controller (Backup Power)
→Load Damp Relay
→Terminal #2: MC (Power)
→Fuse Box
→Terminal #3: MC (EC Motor Power)
→Terminal #10: Optional
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Key Switch
Fusible Link
Battery
Load
Damp
Relay
Fuse Box
Glow
Plug
Relay
Radio, Monitor,
ICX Controller
Optional
MC
MC (EC) Motor
T187-02-04-001
T2-4-4
ZAXIS135UR
Key Switch
Fusible Link
Battery
Fuse
Box
Load
Damp
Relay
Fuse
Box
Radio, Monitor,
ICX Controller
Glow
Plug
Relay Optional
MC
MC (EC) Motor
T1SM-02-04-001
T2-4-5
INDICATOR LIGHT CHECK CIRCUIT (KEY
SWITCH: ON)
• When the key switch is turned ON, terminal B is
connected to terminals ACC and M in the key
switch.
• The current from key switch terminal M excites

the battery relay.
• Therefore, the battery current enters the monitor

controller via the battery relay and fuse #5 and
checks the indicator bulbs.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Key Switch
Battery
Battery
Relay
Fuse Box
Monitor
Controller
T187-02-04-002
T2-4-6
ZAXIS135UR
Key Switch
Battery
Battery
Relay
Fuse
Box
Monitor
Controller
T1SM-02-04-002
T2-4-7
ACCESSORY CIRCUIT
• When the key switch is turned to the ACC
position, terminal B is connected to terminal ACC
in the key switch.
• The current from key switch terminal ACC flows

to horn, radio, lighter, cab light and auxiliary
through the fuse box, making each accessory
operable.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Key Switch
Fuse
Box
Horn
Radio
Lighter
Cab Light
Auxiliary
T187-02-04-003
T2-4-8
ZAXIS135UR
Key Switch
Fuse
Box
Horn Cab Light
Lighter
Auxiliary
Radio
T1SM-02-04-003
T2-4-9
PREHEAT CIRCUIT (KEY SWITCH: ON /
START)
• When the key switch is turned ON or to the • Accordingly, the glow plug relay is turned ON,
START position, terminal B is connected to routing the current to the glow plugs so that
terminal M in the key switch. The current from preheating begins.
terminal M is routed to QOS controller terminal
#1 through fuse #19 (ZAXIS135UR: fuse #20). • When preheating begins, QOS controller terminal
• When the key switch is ON or in the START #6 is connected to terminal #5 for 8 seconds,
position with the coolant switch OFF (when the turning the preheat indicator ON. (When
coolant temperature is 10 °C (50 °F) or below), preheating is not performed, the preheat indicator
QOS controller terminal #4 is connected to comes ON for 2 seconds for indicator light
terminal #5 (ground). check.)
NOTE: After preheating has been performed,
heating will continue for approx. 30
seconds after the engine starts.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US Monitor
Power
Coolant Temperature
Switch Preheat Indicator
QOS Key Switch
Controller
Fuse
Box
Glow
Plug
Relay
Glow Plug
T187-02-04-004
T2-4-10
ZAXIS135UR
Monitor
Power
Coolant Temperature
Switch Preheat Indicator
QOS Key Switch
Controller
Fuse
Box
Glow
Plug
Relay
Glow Plug
T1SM-02-04-004
T2-4-11
STARTING CIRCUIT (KEY SWITCH:
START)
• When the key switch is turned to the START • Consequently, the relay in the starter is turned
position, terminal B is connected to terminals M ON so that the starter begins rotating.
and ST in the key switch.
• On the other hand, the current from key switch
• As the current from terminal M excites the battery terminal M flows to the MC via fuse #6 as a
relay, the battery current is routed to starter signal indicating that the key switch is in the ON
terminal B and starter relay terminal B via the or START position.
battery relay.
• As soon as the MC receives this signal, the MC
• Key switch terminal ST is connected to starter drives the EC motor, moving the governor lever
relay terminal S so that the current flows through to the engine start position.
the starter relay coil.
• Then, the starter relay is turned ON, allowing the

current to flow from starter relay terminal C to
starter terminal C.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Key Switch
Battery
Battery
Relay
Starter Fuse
Box
C
C
Starter Relay
EC Motor
MC
T187-02-04-005
T2-4-12
ZAXIS135UR
Key Switch
Battery
Battery
Relay
Starter
Fuse
Box
Starter Relay
EC Motor
MC
T1SM-02-04-005
T2-4-13
Starter Relay Operation • When this voltage increases up to 21 to 22 V,

• When the key switch is turned to the START Zener diode (Z) is turned ON so that transistor
position, key switch terminal B is connected to (Q1) is turned ON. Then, current to the base of
terminal ST so that current is routed to the base transistor (Q2) is not routed, turning transistor
in transistor (Q2) through resistance R4 in the (Q2) OFF. At this moment, starter terminal B is
starter relay. Then, transistor (Q2) is turned ON, disconnected from terminal C, stopping the
allowing current to flow to coil (L) in the starter starter.
relay. Therefore, starter terminal B is connected
to terminal C, rotating the starter. Condenser C1 is used to stabilize the operating
voltage and diode D4 protects the circuit in case the
• After the engine starts, the alternator starts battery terminals are reversely connected.
generating electricity, increasing voltage at starter
relay terminal R.
Starter Relay
B
(1) R D3
4 L
C
R3 (2) (1)
R2 Z D2 C
From Alternater R Q2 B
Terminal L Q1
(2)
C1 C Stater
E D4
B
ST Battery
Key Switch
T1CF-02-03-006
T2-4-14
(Blank)
T2-4-15
CHARGING CIRCUIT (KEY SWITCH: ON)
• After the engine starts and the key switch is • When the alternator starts generating electricity,
released, the key switch moves to the ON the current flows from alternator terminal B to the
position. batteries via the battery relay, charging the
batteries.
• Then, key switch terminal B is connected to
terminals ACC and M in the key switch. • The current from alternator terminal L flows to the
monitor controller and the ICX controller, turning
• The Power From Terminal M flows to the battery the alternator indicator OFF.
relay, so that the battery relay keeps ON.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Key Switch
Battery Monitor
Controller
Battery ICX
Relay Controller
Alternator
T187-02-04-006
T2-4-16
ZAXIS135UR
Key Switch
Battery
Battery
Relay
Alternator
Monitor
Controller
ICX
Controller
T1SM-02-04-006
T2-4-17
Alternator Operation
• The alternator consists of field coil FC, stator coil • At the beginning, no current is flowing through
SC, and diodes D. The regulator consists of field coil FC. When the rotor starts turning,
transistors (T1 and T2), Zener diode ZD, and alternate current is generated in stator coil SC by
resistances (R1 and R2). the rotor remanent magnetism.
• Alternator terminal B is connected to base B of • When the current starts to flow through field coil
transistor T1 through the circuit [B → R → RF FC, the rotor is further magnetized so that the
→ (R) → (R1)]. generating voltage increases. Thereby, the
current flowing through field coil FC increases
• When battery relay is ON, the battery voltage is and the generating voltage is increased further, to
applied to base B of transistor T1 so that collector charge the batteries.
C is connected to emitter E. Therefore, field coil
FC is grounded via transistor T1.
Alternator
B R L Regulator
Battery RF
Relay (R) R3 R4 R5
R6
D
ZD
R2
Battery SC B
E
R1 C
T2
FC B
D1 C E
T1
(F)
(E)
E
T157-04-02-008
T2-4-18
Regulator Operation
• When the generating voltage increases more • When the generating voltage decreases lower
than the set-voltage of Zener diode ZD, the than the set-voltage of Zener diode ZD, transistor
current is routed to base B of transistor T2, T2 is turned OFF, causing transistor T1 to turn
connecting collector C to emitter E. ON again.
• Then, the current which was routed to base B of • Then, the current flows through field coil FC,
transistor T1 disappears, turning transistor T1 increasing the generating voltage at the stater
OFF. coil. The above operation is repeated so that the
alternator generating voltage is kept constant.
• Therefore, no current flows through filed coil FC,
reducing the generating voltage at stator coil SC.
Battery RF R3 R4 R5
Relay
R6
ZD
R2
Battery B
SC
A E
C
FC T2
B
R1 C E
T1
(F) D1
(E)
E
T157-04-02-009
T2-4-19
ENGINE STOP CIRCUIT
• When the key switch is turned from the ON
position to the OFF position, the signal current
indicating that the key switch is ON stops flowing
from terminal M to MC terminal #C31
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Key Switch
EC Motor
MC
T187-02-04-008
T2-4-20
ZAXIS135UR
Key Switch
EC Motor
MC
T1SM-02-04-008
T2-4-21
SERGE VOLTAGE PREVENTION CIRCUIT
• When the engine is stopped (key switch: OFF), • When the alternator is generating electricity, the
the current from key switch terminal M is generating current from alternator terminal L
disconnected, turning the battery relay OFF. flows to monitor controller terminal #A-2
(ZAXIS135UR: Terminal #A-13) so that the
• The engine continues to rotate due to inertia monitor controller connects terminal #C-3 to the
force just after the key switch is turned OFF so ground.
that the alternator continues to generate
electricity. • Then, the current flows through the load damp
relay exciting circuit, turning the load damp relay
• As the generating current cannot flow to the ON.
battery, the surge voltage arises in the circuit,
possibly causing failures of the electronic • Accordingly, even if the key switch is turned OFF
components, such as the controller. To prevent while the engine is rotating, the battery current
the occurrence of the surge voltage, the surge continues to excite the battery relay via the load
voltage prevention circuit is provided. damp relay until the alternator stops generating.
Therefore, the battery relay is kept ON, allowing
the generating current to flow to the batteries.
T2-4-22
Key Switch
Battery
Battery
Relay
Load
Damp
Relay
Alternator
Monitor Controller
(135UR: A-13)
T1SM-02-04-007
T2-4-23
(Blank)
T2-4-24
MEMO
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SECTION 3
COMPONENT OPERATION
—CONTENTS—
Group 1 Pump Device Group 5 Travel Device
Outline .......................................................... T3-1-1 Outline...........................................................T3-5-1
Main Pump ................................................... T3-1-2 Travel Reduction Gear..................................T3-5-2
Regulator ...................................................... T3-1-4 Travel Motor ..................................................T3-5-4
Solenoid Valve............................................ T3-1-20 Parking Brake ...............................................T3-5-6
Blade Pump (ZAXIS135UR Only) Travel Mode Control .................................. T3-5-10
and Pilot Pump ....................................... T3-1-22 Travel Brake Valve ..................................... T3-5-18
N Sensor (Engine Speed Sensor) .............. T3-1-22
Pump Delivery Pressure Sensor ................ T3-1-22 Group 6 Signal Control Valve
Pump Control Pressure Sensor ................. T3-1-23 Outline...........................................................T3-6-1
Pilot Port .......................................................T3-6-2
Group 2 Swing Device Shuttle Valve .................................................T3-6-6
Outline .......................................................... T3-2-1 Shockless Valve......................................... T3-6-10
Swing Reduction Gear ................................. T3-2-2 Pump 1 and Pump 2 Flow Rate
Swing Motor.................................................. T3-2-3 Control Valves .......................................... T3-6-12
Swing Parking Brake .................................... T3-2-4 Bucket Flow Rate Control Valve,
Valve Unit ..................................................... T3-2-6 Flow Combiner Valve Control Spool,
Swing Parking Brake Release Spool ....... T3-6-14
Outline .......................................................... T3-3-1 Group 7 Others (Upperstructure)
Hydraulic Circuit ......................................... T3-3-12 Pilot Shut-Off Valve .......................................T3-7-1
Flow Combiner Valve ................................. T3-3-20 Solenoid Valve Unit.......................................T3-7-3
Main Relief Valve........................................ T3-3-22 Offset Anti-Drift Valve (ZAXIS135UR Only) ..T3-7-8
Overload Relief Valve................................. T3-3-24 Holding Valve ............................................. T3-7-10
Regenerative Valve .................................... T3-3-26 Pilot Relief Valve ........................................ T3-7-14
Anti-Drift Valve............................................ T3-3-28 EC Motor .................................................... T3-7-14
Flow Rate Control Valve............................. T3-3-30
Bypass Shut-Out Valve .............................. T3-3-32 Group 8 Others (Undercarriage)
Auxiliary Flow Combining Valve ................. T3-3-34 Swing Bearing...............................................T3-8-1
Center Joint...................................................T3-8-2
Group 4 Pilot Valve Track Adjuster ...............................................T3-8-4
Outline .......................................................... T3-4-1
Operation...................................................... T3-4-4
187T-3-1
(Blank)
187T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of main pump [pump 1 (1) The main pump is a swash plate type variable
and pump 2 (2)], pilot pump (3), and blade pump (4) displacement axial plunger pump. Pump 1 (1) and
(ZAXIS135UR only). The engine output is transmitted pump 2 (2) are integrated as two units in one housing.
to shaft (9) via coupling (10), driving pump 1 (1), pump Pilot pump (3) and blade pump (4) (ZAXIS135UR only)
2 (2), and pilot pump (3), and blade pump (4) are gear pumps. Pump delivery pressure sensors (12
(ZAXIS135UR only). in that order. and 13), pump control pressure sensors (5 and 6), and
N sensor (engine speed sensor) (11) are provided to
control pump and valve operations.
NOTE: ZAXIS135UR is Illustrated below.
4 3 5
2 1
8 7 6
T1SM-03-01-001
10
T1SM-03-01-002
13 12 11
1 - Pump 1 5- Pump 2 Control Pressure 8- Maximum Pump 2 Flow 11 - N Sensor

Sensor Rate Limit Solenoid Valve
2 - Pump 2 6 - Pump 1 Control Pressure 9 - Shaft 12 - Pump 1 Delivery Pressure
Sensor Sensor
3 - Pilot Pump 7 - Torque Control Solenoid 10 - Coupling 13 - Pump 2 Delivery Pressure
Valve Sensor
4 - Blade Pump
(ZAXIS135UR Only)
T3-1-1
MAIN PUMP
The main pump supplies the pressure oil to actuate When cylinder block (1) is rotated, plungers (2)
the hydraulic components such as motors or cylinders. oscillate in the cylinder block due to the inclination of
Each main pump is equipped with a regulator which swash plate (4), suctioning and delivering the
controls the flow rate. Shaft (5) is connected to each hydraulic oil. When the inclination angle of swash plate
pump cylinder block (1) so that the shaft and the (4) is changed by servo piston 1 (3) and servo piston 2
cylinder block rotate together. (6), the stroke of plunger (2) is increased or decreased,
causing the delivery flow rate of the main pump to be
controlled.
NOTE: ZAXIS110, 110M, 120, 130, 130LCN,

125US, and 135US are illustrated below.
4 3 2 1 2 3 4
6 7 8 8 7 6
T176-03-01-004
7 8 8 7
T176-03-01-005
1 - Cylinder Block 3 - Servo Piston 1 (2 used) 5 - Shaft 7 - Feedback Lever

2 - Plunger 4 - Swash Plate 6 - Servo Piston 2 8 - Link
T3-1-2
Flow Rate Control Operation
Servo piston 1 (3) and servo piston 2 (6) are used to 7
change the inclination angle of swash plate (4). The 8
regulator regulates the movements of the servo
pistons. The inclination angle of swash plate (4) is 3
fed back to the regulator via feedback lever (7) and
link (8). 6
NOTE: Refer to the following pages for regulator 4

operation.
• Swash Plate Inclination Control

The center of the swash plate inclination is located T176-03-01-027
at point A as illustrated to the right. The pilot

pressure is constantly supplied to servo piston 2 (6). Minimum Inclination: A
When the circuit to servo piston 1 (3) is opened to
the hydraulic oil tank, therefore, swash plate (4) is 3 6
rotated clockwise around point A. Since two servo
piston 1 (3) units are provided, when the pilot
pressure is supplied to both servo piston 1 (3) and 4
servo piston 2 (6), swash plate (4) is rotated
counterclockwise around point A.
• Feedback Operation
The tip end of feedback lever (7) is inserted into the
T176-03-01-028
protrusion on the side of swash plate (4). When Housing
swash plate (4) is rotated, the protrusion also is
rotated, moving feedback lever (7) at the same time. Maximum Inclination:
For example, when swash plate (4) is rotated from 8 7 A
the minimum to the maximum, the center of
feedback lever (7) is moved from position B to C as
illustrated to the right. Therefore, link (8) is moved
by feedback lever (7), allowing the feedback of the
swash plate inclination angle to go to the regulator.
4
T176-03-01-029
Protrusion Housing
C B
T3-1-3
REGULATOR 1 3 2 4
The regulator controls the main pump flow rate in Dr

response to the various command signal pressures so
that the pump driving power doesn’t exceed the engine
power. Pump 1 and pump 2 are provided with one
Pi
regulator each. The major parts of the regulator are
Air
spring (1), sleeve 1 (2), sleeve 2 (7), spool 1 (3), spool Pd1 Bleed
2 (6), piston (4), load piston (5), inner spring (8), and Circuit
outer spring (9). According to the various command Pps
Dr
signal pressures, the regulator opens or closes the
circuit to servo piston 1 (10), causing the inclination of Pd2
swash plate (11) to change, by which the pump flow
rate is controlled.
5 7 6 Pg
NOTE: The pilot pressure is constantly supplied to
10 12
servo piston 2 (12). Increase Decrease 8、9
Swash Plate Inclination T176-03-01-009
Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

Pressure
Pd2 -Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)
T3-1-4
1 2 3 4
T176-03-01-006
5 6 7 8 9
10 11
12
T176-03-01-004
1- Spring 4- Piston 7 - Sleeve 2 10 - Servo Piston 1

2- Sleeve 1 5- Load Piston 8 - Inner Spring 11 - Swash Plate
3- Spool 1 6- Spool 2 9 - Outer Spring 12 - Servo Piston 2
T3-1-5
Regulator Control Function
The regulator has the following four control
functions.
• Control by Pump Control Pressure

Flow
When a control lever is operated, the pump flow rate Rate (Q)
control valve in the signal control valve regulates
pump control pressure Pi in response to the lever
stroke. Then, when the regulator receives pump
control pressure Pi, the regulator controls the pump
flow rate in proportion to pump control pressure Pi.
When a control lever is operated, pump control
pressure Pi increases. Thereby, the regulator
increases the pump flow rate. When the control
lever is returned to neutral, pump control pressure Pi 0 Pump Control Pressure (Pi)
decreases, causing the regulator to reduce the
pump flow rate.
• Control by Own or Opponent Pump Delivery

Pressure
The regulator receives own pump delivery pressure
Pd1 and opponent pump delivery pressure Pd2 as
control signal pressures. If the two average Flow Pressure Increase
Rate (Q)
pressures increase over the set P-Q line, the
Flow Rate Decrease
regulator reduces both pump flow rates by the
excess pressure from the P-Q line so that the total
pump output is returned to the set P-Q line. Thereby,
the engine is protected from being overloaded. The
P-Q line has been designated to jointly regulate both
pump operations. Therefore, both pump flow rates
are regulated almost equally to each other.
Accordingly, although the higher-pressure side 0 Pressure (P)
pump is loaded more than the lower-pressure side
pump, the total pump output matches with the
engine output. (Total Output Control)
T3-1-6
• Control by Pilot Pressure from Torque Control
Flow
Solenoid Valve Rate (Q)
The main controller (MC) operates based on both
the engine target speed input data and actual speed
information signals and outputs signals to the torque
control solenoid valve. In response to the signals
from the MC, the torque control solenoid valve
delivers torque control pilot pressure Pps to the
regulator. Upon receiving pilot pressure Pps, the
regulator reduces the pump flow rate. (Speed
Sensing Control: Increasing torque at a slow speed) 0 Pressure (P)
(Refer to the CONTROL SYSTEM section.) Flow
Rate (Q)
• Control by Pilot Pressure from Maximum Pump Flow

Rate Control Solenoid Valve
(Pump 2 side only)
When the MC receives signals from the work mode
switch, pressure sensor (auxiliary) or attachment
mode switch (optional), the MC sends signals to the
maximum pump 2 flow rate limit solenoid valve.
Then, in response to the signals from the MC, the 0 Pressure (P)
maximum pump flow rate limit control solenoid valve
reduces pump control pressure Pi, limiting the Flow
maximum pump flow rate. (Pump Flow Rate Limit Rate (Q)
Control)
(Refer to the CONTROL SYSTEM section.)
0 Pump Control Pressure (Pi)

Dr
Pi
Air
Pd1 Bleed
Circuit
Pps
Dr
Pd2
Pg
Increase Decrease

Pressure
Pressure
Dr - Return to Hydraulic Oil Pg - Primary Pilot Pressure
Tank (From Pilot Pump)
T3-1-7
Control by Pump Control Pressure
• Increasing Flow Rate

1. When a control lever is operated, the flow rate
Flow
control valve in the signal control valve is shifted, Rate (Q)
increasing pump control pressure Pi.
2. Piston (4) pushes spool 1 (3) and spring (1) so
that spool 1 (3) is moved to the direction of the
arrow.
3. Then, the circuit from servo piston 1 (10) is
opened to the hydraulic oil tank.
4. The pilot oil pressure is always acting on servo
piston 2 (12). Thereby, swash plate (11) is rotated
in the flow rate increase direction. 0 Pump Control Pressure (Pi)
5. The movement of the swash plate is transmitted
to sleeve 1 (2) via feedback lever/ link (13). Then,
sleeve 1 (2) is moved in the same direction as
spool 1 (3) is moved.
6. When sleeve 1 (2) is moved by the same stroke
as spool 1 (3) is moved, the circuit from servo
piston 1 (10) to the hydraulic oil tank is closed so
that servo piston 1 (10) is stopped, completing
flow rate increase operation.
1 3 2 4
Dr
Pi
Air
Pd1
Bleeding
Circuit
Pps
Dr
Pd2
Pg
10 12
Increase Decrease 13
1- Spring 10 - Servo Piston 1
2- Sleeve 1 11 - Swash Plate
3- Spool 1 12 - Servo Piston 2
4- Piston 13 - Feedback Lever / Link
Pd1 - Pump 1 Delivery Pi - Pump Control Pressure

Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
T3-1-8
To Hydraulic Primary Pilot

1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure
Pd1
Pump 2
Delivery 12
Pressure 13
Pd2 10
11
T176-03-01-010
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure
Pd1
Pump 2
Delivery
13 12
Pressure
Pd2 10
11
T176-03-01-011
T3-1-9
• Decreasing Flow Rate
1. When a control lever is operated, the flow rate
control valve in the signal control valve is returned, Flow
decreasing pump control pressure Pi. Rate (Q)
2. Piston (4) and spool 1 (3) are pushed by spring
(1) so that spool 1 (3) is moved to the direction of
the arrow.
3. Then, the pilot oil pressure is also routed onto
servo piston 1 (10).
4. Two servo pistons 1 (10) are located so that
swash plate (11) is rotated in the flow rate
decrease direction. 0 Pump Control Pressure (Pi)
5. The movement of the swash plate is transmitted
1 3 2 4
spool 1 (3) is moved. Dr
as spool 1 (3) is moved, the circuit to servo piston
1 (10) is closed so that servo piston 1 (10) is
Pi
stopped, completing flow rate decrease operation.
Air
Pd2
Bleeding
Circuit
Pps
Dr
Pd1
Pg
10 12
Increase Decrease 13


Pressure
Pressure
T3-1-10

Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure
Pd1
Pump 2
Delivery 13 12
Pressure
Pd2 10
11
T176-03-01-012
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure
Pd1
Pump 2
Delivery 13 12
Pressure
Pd2 10
11
T176-03-01-013
T3-1-11
Control by Own or Opponent Pump Delivery
Pressure

1. When the pump is loaded by any operation of the
Flow
control levers, either own pump delivery pressure Rate (Q)
Pd1 or opponent pump delivery pressure Pd2
increases. (During operation, pump control
pressure Pi is kept increased.)
2. Load piston (5) moves spool 2 (6), inner spring (8)
and outer spring (9) toward the direction of the
arrow.
3. Due to the movement of spool 2 (6), the pilot
pressure is routed to servo piston 1 (10).
4. Two servo pistons 1 (10) are located so that 0 Pressure (P)
decrease direction. Dr
5. The movement of swash plate (11) is transmitted
Pi
Air
6. When sleeve 2 (7) is moved by the same stroke Pd1
Bleeding
as spool 2 (6) is moved, the circuit to servo piston Circuit
1 (10) is closed so that servo piston 1 (10) is Pps
Dr
Pd2
5 7 6 Pg
10 12
Increase Decrease 8, 9
5- Load Piston 10 - Servo Piston 1

6- Spool 2 11 - Swash Plate
7- Sleeve 2 12 - Servo Piston 2
8- Inner Spring 13 - Feedback Lever / Link
9- Outer Spring

Pressure
Pressure
T3-1-12

5 Oil Tank Pressure 6 7 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
8 9
Pressure
Pd1
Pump 2
Delivery 12
Pressure
13
Pd2 10
11
T176-03-01-014
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure 8 9
Pd1
Pump 2
Delivery 13 12
Pressure
Pd2 10
11
T176-03-01-015
T3-1-13
• Increasing Flow Rate
1. When the pump load is reduced, either own pump
delivery pressure Pd1 or opponent pump delivery
pressure Pd2 decreases. (During operation,
pump control pressure Pi is kept increased.)
2. Load piston (5) and spool 2 (6) are pushed by Flow
Rate (Q)
inner and outer springs (8 and 9) toward the
direction of the arrow.
3. Due to the movement of spool 2 (6), the circuit
from servo piston 1 (10) is opened to the hydraulic
oil tank.
4. Since servo piston 2 (12) is always loaded by the
pilot oil pressure, swash plate (11) is rotated in the
flow rate increase direction.
5. The movement of swash plate (11) is transmitted 0 Pressure (P)
sleeve 2 (7) is moved in the same direction as Dr
1 (10) is closed so that servo piston 1 (10) is Pi
stopped, completing flow rate increase operation. Pd1
Air
Bleeding
Circuit
Pps
Dr
Pd2
5 7 6 Pg
10 12 13 8, 9
Increase Decrease

9- Outer Spring

Pressure
Pressure
T3-1-14

Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
8 9
Pressure
Pd1
Pump 2
Delivery 12
Pressure
13
Pd2 10
11
T176-03-01-016
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
8 9
Pressure
Pd1
Pump 2
Delivery 12
Pressure
13
Pd2 10
11
T176-03-01-017
T3-1-15
Control by Pilot Pressure from Torque Control
Solenoid Valve

1. When the torque control solenoid valve is
activated by the signals from the MC, torque Flow
control pressure Pps increases. Rate (Q)
2. Torque control pressure Pps and either own pump
delivery pressure Pd1 or opponent pump delivery
pressure Pd2 are combined and applied to load
piston (5).
3. Load piston (5) pushes spool 2 (6) and inner
spring (8) and outer spring (9) toward the
direction of the arrow.
4. Due to the movement of spool 2 (6), the pilot 0 Pressure (P)
pressure is routed to servo piston 1 (10).
5. Two servo pistons 1 (10) are located so that Dr
decrease direction.
to sleeve 2 (7) via feedback lever/ link (13). Then, Pi
sleeve 2 (7) is moved in the same direction as Pd1 Air
spool 2 (6) is moved. Bleeding
7. When sleeve 2 (7) is moved by the same stroke Circuit
Pps
as spool 2 (6) is moved, the circuit to servo piston Dr
1 (10) is closed so that servo piston 1 (10) is Pd2
5 7 6 Pg
10 12
Increase Decrease 13 8, 9

9- Outer Spring

Pressure
Pressure
T3-1-16

Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
8 9
Pressure
Pd1
Pump 2
Delivery 12
Pressure
13
Pd2 10
11
T176-03-01-018
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1
Delivery
8 9
Pressure
Pd1
Pump 2
Delivery 12
Pressure
13
Pd2 10
11
T176-03-01-019
T3-1-17
Control by Pilot Pressure from Pump 2 Flow
Rate Limit Solenoid Valve Flow
Rate (Q)
• Limiting Maximum Flow Rate

1. The maximum pump 2 flow rate limit solenoid
valve in the pump control pressure Pi circuit is
activated by the signals from the MC.
2. The maximum pump flow rate limit control
solenoid valve functions as a reducing valve,
limiting pump control pressure Pi.
3. Piston (4) pushes spool 1 (3) and spring (1) 0 Pressure (P)
toward the direction of the arrow.
4. Due to the movement of spool 1 (3), the circuit
from servo piston 1 (10) is opened to the hydraulic Flow
oil tank. Rate (Q)
5. Since servo piston 2 (12) is always loaded by the
pilot oil pressure, swash plate (11) is rotated in the
flow rate increase direction.
7. When sleeve 1 (2) is moved by the same stroke 0 Pump Control Pressure (Pi)
1 (10) is closed so that servo piston 1 (10) is
stopped, completing flow rate increase operation. 1 3 2 4
8. As the pump control pressure is restricted, the Dr
maximum flow rate is reduced more than normal.
Pi
Pd1 Air
Bleeding
Circuit
Pps
Dr
Pd2
Pg
10 12
Increase Decrease


Pressure
Pressure
T3-1-18

Oil Tank Pump Control
1 Pressure 2 3 4
Pressure Pi
Regulated by
Maximum Pump 2
Flow Rate Limit
Solenoid Valve
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure
Pd1
Pump 2
Delivery 12
Pressure
13
Pd2 10
11
T176-03-01-020
Oil Tank Pump Control
1 Pressure 2 3 4
Pressure Pi
Regulated by
Maximum Pump 2
Flow Rate Limit
Solenoid Valve
Torque
Control
Pressure
Pps
Pump 1
Delivery
Pressure
Pd1
Pump 2
Delivery 12
Pressure 13
Pd2 10
11
T176-03-01-021
T3-1-19
SOLENOID VALVE
The torque control solenoid valve and the maximum

pump 2 flow rate limit solenoid valve are provided on
the pump 2 regulator. The torque control solenoid
valve supplies the torque control pressure Pps to both
the pump 1 and pump 2 regulators to reduce the pump
flow rate. The maximum pump 2 flow rate limit
solenoid valve reduces the pump control pressure to
the pump 2 regulator so that the maximum pump flow
rate is limited.
Operation
1. When neutral, port P is connected to the output
port through the notch on the spool.
2. When the current flows to the solenoid from the
MC, the solenoid is magnetized, pushing spring 1.
3. Then, spring 1 pushes the spool so that the output
port is connected to port T through the notch on
the spool.
4. Thereby, the pressure at the output port begins to
decrease.
5. Since the left side spool step flange diameter (A)
is larger than the right side spool step flange
diameter (B), the spool is returned to the left side.
T3-1-20
When Neutral:
Solenoid Spring 1 Spring 2 Sleeve Spool
T176-03-01-030
A Port P Port T B
Output Port
When Operating:
Solenoid Spring 1 Spring 2 Sleeve Spool
T176-03-01-031
A Port P Port T B
Output Port
T3-1-21
BLADE PUMP (ZAXIS135UR ONLY)
Inlet Port
1
PILOT PUMP
2
Drive gear (1) is driven by the engine via the main
pump shaft which in turn rotates driven gear (2) as
they are meshed together.
1 - Drive Gear 2 - Driven Gear
Outlet Port
T137-02-03-005
N SENSOR (ENGINE SPEED SENSOR)

The N sensor detects the engine speed, which is used
to control various operations. The N sensor is located
close to the cylinder block teeth so that the sensor
converts the number of the teeth passing by the 4
sensor into pulse signals, counting the engine rotating
speeds. 5
3 - Tooth 5 - Output
4 - Output
T176-03-01-022
PUMP DELIVERY PRESSURE SENSOR

This sensor detects the pump delivery pressures,
which are used to control various operations. When oil
pressure is applied onto diaphragm (9), the diaphragm T157-02-03-010
is deformed. The deformation of the diaphragm is 6 7 8 9
detected as electrical signals.
6 - Ground 8 - Power Source (5V)

7 - Output 9 - Pressure Receiving Area
(Diaphragm)
T3-1-22
PUMP CONTROL PRESSURE SENSOR

This sensor detects the pump control pressures,
which are used to control various operations. When oil
pressure is applied onto diaphragm (10), the
diaphragm is deformed. The deformation of the T176-03-01-023
diaphragm is detected as electrical signals. 10 11 12 13
10 - Pressure Receiving Area 12 - Output

(Diaphragm)
11 - Ground 13 - Power Source (5V)
T3-1-23
(Blank)
T3-1-24
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit , swing The swing reduction gear converts the swing motor
motor, and swing reduction gear. output to slow large torque to the shaft, rotating the
The valve unit prevents the occurrence of cavitation in upperstructure.
the swing circuit and protects the swing circuit from
being overloaded.
The swing motor is a swash plate type axial plunger
motor (with built-in parking brake) driven by the
pressure oil from the pump and transmits its output to
the swing reduction gear.
Valve Unit
Swing Motor
Swing Reduction Gear
T176-03-02-001
T3-2-1
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary The shaft is meshed with the swing bearing internal
gear type. The ring gear and the housing are one unit gear secured to the undercarriage, causing the
bolted to the upperstructure so that it doesn’t rotate. upperstructure to rotate.
The swing motor shaft rotates the first stage sun gear,
which is transmitted to the second stage sun gear via
the first stage planetary gear and carrier. Rotation of
the second stage sun gear is transmitted to the shaft
via the second stage planetary gear and carrier.
Swing Motor Shaft

First Stage Carrier
First Stage Sun Gear First Stage Planetary Gear
Second Stage Sun Gear Ring Gear
Second Stage Carrier Second Stage Planetary Gear
Shaft
Swing Bearing
T176-03-02-001
Internal Gear
T3-2-2
SWING MOTOR
The swing motor consists of the swash plate, rotor, When the pressure oil from the pump is supplied, the
plungers, valve plate, housing, and parking brake (disc plungers are pushed so that the shoes on the plunger
spring, brake piston, plates, and friction plates). The tips slide along the swash plate as the swash plate is
shaft is splined to the rotor in which the plungers are tilted, causing the rotor to rotate. The shaft end is
located. splined to the first stage sun gear in the swing
reduction gear. Therefore, rotation of the shaft is
transmitted to the swing reduction gear.
Disc Spring
Piston
Valve Plate
Friction Plate
Rotor
Housing Plate
Shoe
Plunger
Retainer
Swash Plate
Shaft
T176-03-02-002
T3-2-3
SWING PARKING BRAKE
The swing parking brake is a wet multi-disc negative

type, which is released only when the brake release
pressure oil is routed into the brake piston chamber.
The brake release pressure oil is supplied from the
pilot pump only when the swing and/or front
attachment function is operated. Unless the swing
and/or front attachment function is operated (including
when the engine is stopped), the brake release
pressure oil is returned to the hydraulic oil tank so that
the brake is automatically applied by the disc spring.
When the brake is released:
When the brake is applied: 1. When the swing and/or front attachment control
1. When the swing and/or front attachment control lever is operated, the swing parking brake release
lever is returned to neutral, the swing parking spool in the signal control valve is shifted.
brake release spool in the signal control valve is Thereby, the pilot pressure oil from the pilot pump
returned to neutral. Then, the pilot pressure at is supplied to port SH.
port SH is reduced. 2. The pilot pressure oil supplied to port SH unseats
2. Therefore, the check valve is closed, allowing the the check valve and flows into the brake piston
brake release pressure to return to the hydraulic chamber.
oil tank via the orifice in the spool. Consequently, the brake piston is pushed upward,
3. Consequently, the spring force is applied to the causing the plates and the friction plate to separated,
plates and friction plates via the brake piston. The releasing the brake.
plates and friction plates are meshed with the
outer diameter of the rotor and the inner diameter
of the motor housing respectively. Accordingly,
the rotor is held by friction force. When the engine
is stopped, no pressure in the pilot signal circuit,
the brake is automatically applied.
T3-2-4
When the brake is applied
Disc Spring
Brake Piston
To Brake Piston
Port SH
(Brake
Release
Pressure)
Check Valve
Friction Plate
To Hydraulic
Spool Oil Tank Orifice
Plate
T176-03-02-004
When the brake is released:
Disc Spring
Brake Piston
To Brake Piston
Port SH
(Brake
Release
Pressure)
Check Valve
Friction Plate
To Hydraulic
Spool Oil Tank Orifice
Plate
T176-03-02-005
T3-2-5
VALVE UNIT
The valve unit consists of the relief valves and the

make-up valves. Relief Valve
The make-up valve prevents the occurrence of
cavitation in the circuit and the relief valve prevents the
occurrence of surge pressure, protecting the circuit
from being overloaded. Make-Up Valve
Make-Up Valve
When the swing motor is driven by inertia force of the
upperstructure when stopping swing operation, the Port C
swing motor is rotated more than the stroke driven by
pressure oil from the pump, causing cavitation in the
swing motor. The make-up valve draws the hydraulic Control Valve
oil by opening the poppet if the oil pressure in the
swing circuit becomes lower than the oil pressure in T107-02-04-013
the return circuit (port C), making up the short oil

supply.
Relief Valve
Poppet
Make-Up Valve Make-Up Valve
T176-03-02-003
Port C
Control Valve
T3-2-6
Relief Valve
When starting or stopping the swing operation, the oil
pressure in the swing circuit increases. The relief
valve prevents the circuit oil pressure from increasing
over the set-pressure.
Operation:
1. The oil pressure in port HP (swing circuit) is
applied to the poppet.
2. When the pressure force in port HP overcomes
the spring set-force, the poppet unseats so that
the pressure oil flows into port LP.
3. Consequently, the oil pressure in the swing circuit
decreases.
4. When the oil pressure in port HP decreases less
than the spring set-force, the poppet is seated by
the spring force.
When Neutral: Poppet Spring
HP
LP
T176-03-02-006
When Operating: Poppet Spring
HP
LP
T176-03-02-007
T3-2-7
(Blank)
T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls oil pressure, flow rate, and The spool arrangements are as follows.
oil flow direction in the hydraulic circuit. The major From the machine front side
parts of the control valve are the main relief valve, (ZAXIS110, 110M, 120, 130, 130LCN)
overload relief valves, flow combiner valve, anti-drift From the machine left side
valves, flow rate control valve, regenerative valve, aux. (ZAXIS125US, 135US, 135UR)
flow combining valves, bypass shut-out valve, and 4-Spool Side: Right Travel, Bucket, Boom 1, Arm 2
spools. Each spool is operated by the pilot oil pressure. 5-Spool Side: Left Travel, Auxiliary (ZAXIS135UR:
Offset), Boom 2, Arm 1, Swing
Swing
Control Valve Arm 1
Boom 2
Auxiliary (ZAXIS135UR: Offset)
Left Travel
Arm 2 Machine Front

ZAXIS125US, 135US, 135UR
Boom 1
5-Spool Side
Bucket
Right Travel
4-Spool Side
T176-03-03-035
Machine Front
Machine Front ZAXIS110, 110M, 120, 130, 130LCN
Blade Control Valve （Positioning）
(ZAXIS135UR Only)
Positioning Control Valve
(2-piece Boom Only)
Machine Front
(Blade)
T178-03-03-071
T3-3-1
Component Layout
1 2 3 4 5 6 7 8 9 10
Bucket
Auxiliary 11 Cylinder
(ZAXIS135UR: Offset)
12
44
13
43
14
42 Boom Cylinder Blade Cylinder
Arm 41 (ZAXIS135UR Only)
Cylinder 40
15
39 16
38 17
22
23
18
Swing Motor 19
20 24
21 25
26
Blade Pump
37 (ZAXIS135UR Only)
36 Main
Pump
35 34 33 32 31 (2-piece Boom Only)
27
28
30 29 T187-03-03-003
T3-3-2
Control Valve
16
Machine Front
35 ZAXIS125US
ZAXIS135US
ZAXIS135UR
4
38
18, 19
5
21
12 Machine Front
9, 10 ZAXIS110
ZAXIS110M
ZAXIS120
ZAXIS130
ZAXIS130LCN T176-03-03-038
1 - Load Check Valve 12 - Overload Relief Valve 23 - Overload Relief Valve (Blade: 34 - Load Check Valve
(Travel Tandem Circuit) (Bucket: Rod Side) Bottom Side) (ZAXIS135UR (Swing Circuit)
Only)
2 - Load Check Valve 13 - Overload Relief Valve 24 - Load Check Valve (Blade) 35 - Arm Regenerative Valve
(Travel Parallel Circuit) (Bucket: Bottom Side) (ZAXIS135UR Only) (Selector Valve)
3 - Check Valve 14 - Load Check Valve 25 - Load Check Valve (Blade 36 - Arm Regenerative Valve
(Main Relief Circuit) (Boom 1 Parallel Circuit) Tandem Circuit) (ZAXIS135UR
Only)
4 - Main Relief Valve 15 - Boom Regenerative Valve 26 - Main Relief Valve (Blade) 37 - Overload Relief Valve
(ZAXIS135UR Only) (Arm: Bottom Side)
5 - Check Valve 16 - Overload Relief Valve 27 - Load Check Valve 38 - Overload Relief Valve
(Main Relief Circuit) (Boom: Bottom Side) (Positioning Circuit) (Arm: Rod Side)
(2-piece Boom Only)
6 - Flow Combiner Valve 17 - Overload Relief Valve 28 - Overload Relief Valve 39 - Arm Anti-Drift Valve
(Boom: Rod Side) (Positioning: Rod Side) (Check Valve)
(2-piece Boom Only)
7 - Check Valve 18 - Boom Anti-Drift Valve 29 - Overload Relief Valve 40 - Arm Anti-Drift Valve
(Flow Combining Circuit) (Check Valve) (Positioning: Bottom Side) (Selector Valve)
(2-piece Boom Only)
8 - Aux. Flow Combining Valve 19 - Boom Anti-Drift Valve 30 - Load Check Valve 41 - Load Check Valve
(Selector Valve) (Positioning Parallel Circuit) (Boom 2 Parallel Circuit)
(2-piece Boom Only)
9 - Bucket Flow Rate Control 20 - Load Check Valve 31 - Check Valve (Orifice) 42 - Aux. Flow Rate Control
Valve (Selector Valve) (Arm 2 Tandem Circuit) (Arm 2 Parallel Circuit) Valve (Poppet Valve)
10 - Bucket Flow Rate Control 21 - Bypass Shut-Out Valve 32 - Load Check Valve 43 - Aux. Flow Rate Control
Valve (Poppet Valve) (Arm 1 Parallel Circuit) Valve (Selector Valve)
11 - Bucket Regenerative 22 - Overload Relief Valve 33 - Load Check Valve 44 - Load Check Valve
Valve (Blade: Rod Side) (Arm 1 Tandem Circuit) (Bucket Parallel Circuit)
(ZAXIS135UR Only)
T3-3-3

1 2 3 4 5 6 7 8 9 10
Bucket
12
44
13
43
14
Cylinder 40
15
39 16
38 17
22
23
18
Swing Motor 19
20 24
21 25
26
Blade Pump
36 Main
Pump
35 34 33 32 31 (2-piece Boom Only)
27
28
30 29 T187-03-03-003
T3-3-4
39, 40
Machine Front
ZAXIS125US
ZAXIS135US
ZAXIS135UR
42, 43
33
Machine Front
ZAXIS110
ZAXIS110M
ZAXIS120
ZAXIS130 17
ZAXIS130LCN
8 T176-03-03-036
13
6 44 7
Only)
Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(ZAXIS135UR Only)
T3-3-5

1 2 3 4 5 6 7 8 9 10
Bucket
12
44
13
43
14
Cylinder 40
15
39 16
38 17
22
23
18
Swing Motor 19
20 24
21 25
26
Blade Pump
36 Main
Pump
35 34 33 32 31 (2-piece Boom Only)
27
F
28
E 30 29 T187-03-03-003
D Cross Section A
C
B
4
A 5
43
8
7
6
T176-03-03-035
T176-03-03-002
T3-3-6
Cross Section B Cross Section C

Travel (Right) Travel (Left) Bucket Auxiliary (ZAXIS135UR: Offset)
12
1
10 42
9 43
2
11
13
T176-03-03-003
T176-03-03-004
Only)
Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(ZAXIS135UR Only)
T3-3-7

1 2 3 4 5 6 7 8 9 10
Bucket
12
44
13
43
14
Cylinder 40
15
39 16
38 17 22
23
18
Swing Motor 19
20 24
21 25
26
Blade Pump
36 Main
Pump
35 34 33 32 31 (2-piece Boom Only)
27
28
30 29 T187-03-03-003
Cross Section D Boom 1 Boom 2
19
16
18
14
41
15
17
T176-03-03-005
T3-3-8
Cross Section E Cross Section F

Arm 2 Arm 1 Swing
40
38
35
39
34
20 32
31
33
36
37 21
T176-03-03-007
T176-03-03-006
Only)
Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(ZAXIS135UR Only)
T3-3-9

1 2 3 4 5 6 7 8 9 10
Bucket
12
44
13
43
14
Cylinder 40
15
39 16
38 17
22
23
18
Swing Motor 19
20 24
21 25
26
Blade Pump
36 Main
Pump
35 34 33 32 31 (2-piece Boom Only)
27
28
30 29 T187-03-03-003
T3-3-10
Blade Control Valve (ZAXIS135UR Only)

Positioning Control Valve (2-piece Boom Only)
Cross Section X-X
X
22, 28
24, 30
25, 27
23, 29
X
T198-03-03-002 T198-03-03-003
Only)
Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(2-piece Boom Only)
(ZAXIS135UR Only)
T3-3-11
HYDRAULIC CIRCUIT
Main Circuit
The pressure oil from main pump 1 flows to the
4-spool side control valve and the pressure oil from
main pump 2 flows to the 5-spool side control valve.
Both right and left main circuits are provided with the
parallel circuits, making combined operations
possible. The boom and arm circuits are provided
with the flow combining circuits so that the pressure
oil from main pump 1 and 2 can be supplied together
to each cylinder when a single operation is made.
The main relief valve is located in the main circuit

(between the pumps and actuators), preventing the
oil pressure in the main circuit from increasing over
the set-pressure during operation (when any control
lever is operated).
The overload relief valves are located in the boom,
arm, and bucket circuits (between the control valve
and actuators), preventing the surge pressure from
being developed by external loads in the actuator
circuits and from increasing over the set-pressure
while the control levers are in neutral.
T3-3-12
Travel Motor (Left) Main Relief 4-Spool Side Travel Motor (Right)
Valve Parallel Circuit
Auxiliary
(ZAXIS135UR:
Offset)
Bucket
Cylinder
Overload
Relief Valve
Arm
Cylinder Overload
Relief Valve
Swing Motor
Boom
Cylinder
Flow Combining
Circuit
5-Spool Side
Parallel Circuit
Pump 2 Pump 1
T176-03-03-032
T3-3-13
Blade Circuit (ZAXIS 135UR only)
Neutral Circuit
oil from the blade pump is returned to the
hydraulic oil tank via the blade control valve.

• When the control lever is operated, the blade
signal switch valve and the bypass cut valve are
shifted.
• When the blade signal switch valve is shifted, the
pilot oil pressure from the blade signal switch
valve shifts the flow combiner valve.
• When the flow combiner valve is shifted, the
pressure oil from pump 1 is combined with the
pressure oil from pump 2 in the control valve and
flows to the blade control valve.
• After the pressure oil from the blade pump is
combined with the pressure oil from pumps 1 and
2 in the blade control valve, the pressure oil flow
to the blade cylinder.
• Due to the above flow combining operation, the
blade cylinder operating speed is increased
NOTE: When combined operation with the blade is

made, actuator speed other than the blade
cylinder must be procured. Therefore an
orifice is provided in the oil flow combining
circuit from pump1 and pump 2.
T3-3-14
Pilot Pressure from Blade

Signal Switch Valve
Orifice
Control Valve
Flow Combiner
Valve
Blade
Cylinder
Bypass
Shut-Out
Valve
Blade
Control
Valve
Pump 2 Pump 1
Blade Pump
Pilot Pressure from
Blade Pilot Valve
T1SM-02-02-007
T3-3-15
Positioning Operation Circuit
(2-Piece Boom Only)
Neutral Circuit
• When the control pedal is in neutral, the pressure
oil from the pump 1 is returned to the hydraulic oil
tank via the control valve.

• During positioning operation, the spools in the
bypass shut-out valve and positioning control
valve are shifted.
• The pressurized oil from pump 1 is divided on the
four-spool side, and combined in the positioning
control valve and goes into the positioning
cylinder.

• In combined operations, the pressurized oil from
pump 1 flows into the positioning control valve
through the parallel circuit.
• Even in combined operations, the parallel circuit
allows positioning operation.
T3-3-16
4-Spool Side
Parallel Circuit
Positioning
Cylinder
Pilot Pressure
from Positioning
Pilot Valve
Bypass Shut-Out
Valve
Pump 1
T187-02-03-003
Positioning
Control Valve
T3-3-17
Pilot Pressure Operation Circuit External Pilot Oil Pressure Control Circuit
The pilot pressure oil (shown by figure letters) from • The arm regenerative valve (selector valve) is
the pilot valve is routed to the spool end faces in the shifted by the pilot pressure oil from solenoid
control valve, moving the spools. Besides moving valve unit (SC).
the spools, the pilot pressure oil operates the control • The flow combiner valve is shifted by the pilot
valve at the same time in the following operations: pressure oil from the flow combiner control spool
• When arm roll-in operation (4) is made, the pilot in the signal control valve.
pressure oil moves the spools and shifts the arm • The bucket flow rate control valve is shifted by the
anti-drift valve selector valve. pilot pressure oil from the bucket flow rate control
• When boom lower operation (2) is made, the pilot valve control spool in the signal control valve.
pressure oil moves the spools and shifts the boom
anti-drift valve selector valve. ZAXIS110, 110M, 120, 130, 130LCN, 125US,
As the air bleed circuit is provided in the upper 135US:
section of the control valve so that any air trapped in • The aux. flow combining valve and bypass
the control valve will automatically be bled. shut-out valve are shifted by the pilot pressure oil
from auxiliary pilot valve.
• The aux. flow rate control valve is shifted by the
pilot pressure oil from the aux. flow rate control
solenoid valve.
• The bypass shut-out valve is shifted by the
positioning pilot pressure.
ZAXIS135UR:
• The flow combiner valve is shifted by the pilot
pressure oil from the blade signal switch valve.
• The bypass shut-out valve is shifted by the blade
pilot pressure.
(Refer to the SYSTEM / Control System group.)
NOTE: The attachment cannot be equipped for

ZAXIS135UR. Therefore, as for
ZAXIS135UR, the auxiliary flow rate control
solenoid valve, auxiliary flow rate control
valve, and flow combining valve are not
operated.
T3-3-18
Pilot Pressure Oil from Flow Combiner Valve
Control Spool in Signal Control Valve and Blade
Signal Switch Valve (ZAXIS135UR Only)
Aux. Flow Combining Valve Pilot Pressure Oil from Aux. Pilot Valve
(Connected to Hydraulic Oil Tank: ZAXIS135UR)
Flow Combiner Valve
Pilot Pressure Oil from Bucket Flow Rate
Valve Control Spool in Signal Control Valve
10
11
9
12
Bucket Flow
Rate Control
Pilot Pressure Oil Valve
from Aux. Flow
Rate Control 8
Solenoid Valve 7
(Connected to
Hydraulic
Oil Tank:
ZAXIS135UR)
Aux. Flow
Rate Control 2
Valve 1
1
Arm Anti-Drift
Valve
Boom
4 Anti-Drift
3 Valve
3
Pilot Pressure
Oil from
Solenoid Valve
Unit (SC)
Pilot
Arm Pressure Oil
Regenerative from Aux.
Valve 6 Pilot Valve
(Selector Valve) 5 Air Bleed Circuit (ZAXIS
135UR:
Blade)
(2-piece
Boom:
Positioning)
T176-03-03-025
1 - Boom Raise 4 - Arm Roll-In 7 - Bucket Roll-In 10 - Left Travel Reverse
2 - Boom Lower 5 - Left Swing 8 - Bucket Roll-Out 11 - Right Travel Forward
3 - Arm Roll-Out 6 - Right Swing 9 - Left Travel Forward 12 - Right Travel Reverse
T3-3-19
FLOW COMBINER VALVE
1. Normally, the pressure oil from pump 1 pushes

the check valve through hole B so that the check
valve is seated.
2. When the front attachment and/or travel function
is operated, the right travel pilot pressure oil shifts
the flow combiner control spool in the signal
control valve, causing the pilot pressure oil to shift
the flow combiner valve spool.
3. Then, the pressure oil from pump 1 enters hole A,
unseats the check valve, and flows into the left
travel spool.
4. Accordingly, the pressure oil from pump 1 is
routed to both the right and left travel spools at
the same time, allowing the pressure oil from
pump 2 to flow to the front attachment and swing
spools. Therefore, even if travel and front
attachment/swing functions are operated at the
same time, the machine can travel straight.
Flow Combiner Valve Pilot Pressure from Flow

Combiner Valve Control Spool
in Signal Control Valve
Pump 1 T176-03-03-026
T3-3-20
When Neutral: When Operating:
To Hydraulic Oil Tank To Hydraulic Oil Tank
To Left Travel Check Valve To Left Travel Check Valve

Spool Spool
Hole B
Pressure Oil Pressure Oil

from Pump 1 from Pump 1
Hole A Hole A
Spool Spool
Pilot Pressure Oil

from Flow
To Flow Combiner Valve
Combiner Valve Control Spool
Control Spool
T176-03-03-008 T176-03-03-009
T3-3-21
MAIN RELIEF VALVE
The main relief valve prevents the oil pressure in the

main circuit and blade circuit (ZAXIS135UR only) from
rising higher than the set-pressure while operating the
actuators such as the motors and cylinders. Thereby,
oil leakage from hoses and pipe joints and damage to
the actuators are prevented.
NOTE: The operations of main relief valves in main

circuit and blade circuit (ZAXIS135UR only)
are same.
Operation
1. The oil pressure in port HP (main circuit) acts on Blade Circuit (ZAXIS135UR only)
the pilot poppet through orifice A in the main
poppet and orifice B in the seat. Sleeve Pilot Poppet
2. When the oil pressure in port HP increases more LP Passage A Spring B
than the spring B set-force, the pilot poppet is Spring A
unseated, allowing the pressure oil to flow to port
LP (hydraulic oil tank) through passage A and
around the outer diameter of the sleeve.
HP
3. At this time, a pressure difference arises between
port HP and the spring chamber due to orifice A.
4. When this pressure difference increases more
than the spring A set-force, the main poppet is
unseated, causing the pressure oil in port HP to Seat
Orifice A
flow to port LP. Orifice B
5. Thereby, the actuator circuit pressure is reduced. Main Poppet Spring Chamber T198-03-03-007
6. When the actuator circuit pressure is reduced to
the specified pressure, the main poppet is closed
by spring A.
T3-3-22
Main Circuit
When Normal:
Main Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-010
Sleeve Spring Chamber Spring A Pilot Poppet
When Relieving:
Main Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-011
Sleeve Spring Chamber Spring A Pilot Poppet
T3-3-23
OVERLOAD RELIEF VALVE Blade Circuit (ZAXIS135UR only)
(with Make-Up Function) Positioning Circuit (2-piece Boom only)
The overload relief valves are located in the boom,

arm, bucket, blade (ZAXIS135UR only) and Spring C Sleeve Spring A Main Poppet
positioning (2-piece boom only) circuits. The overload Seat
Orifice A
relief valve prevents each actuator circuit pressure
from rising excessively when the actuators are moved HP
by external loads. In addition, when the actuator circuit
pressure is reduced, draws the hydraulic oil from the
hydraulic oil tank to prevent the occurrence of
cavitations (make-up function).
NOTE: The operations of overload relief valves in Spring B Pilot Passage A Spring Valve
boom, arm, bucket, blade (ZAXIS135UR Poppet Chamber
LP T198-03-03-006
only) and positioning (2-piece Boom only)
are same.
Make-Up Operation
Relief Operation 1. When the oil pressure in port HP (actuator circuit)
1. Boom, Arm, and Bucket: is reduced lower than the oil pressure in port LP
The oil pressure in port HP (actuator circuit) acts (hydraulic oil tank), the make-up valve (blade and
on the pilot poppet through orifice A in the main positioning: sleeve) is moved to the left.
poppet and orifice B in the seat. 2. Then, the hydraulic oil in port LP flows to port HP,
Blade and Positioning: preventing cavitation.
The oil pressure in port HP (actuator circuit) acts 3. When the oil pressure in port HP increases more
on the pilot poppet through orifice A in the valve. than the specified pressure, the make-up valve
2. When the oil pressure in port HP increases more (blade and positioning: sleeve) is closed by spring
than the spring B set-force, the pilot poppet is C.
unseated, allowing the pressure oil to flow to port
LP (hydraulic oil tank) through passage A and
around the outer diameter of sleeve.
3. At this time, a pressure difference arises between
port HP and the spring chamber due to orifice A.
4. When this pressure difference increases more
than the spring A set-force, the main poppet is
unseated, causing the pressure oil in port HP to
flow to port LP.
5. Thereby, the actuator circuit pressure is reduced.
6. When the actuator circuit pressure is reduced to
the specified pressure, the main poppet is closed
by spring A.
T3-3-24
Boom, Arm, Bucket
Main
When Normal: Sleeve Make-Up Valve Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-012
Spring C Spring Chamber Spring A Pilot Poppet
Main
When Relieving: Sleeve Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-013
Spring Chamber Spring A Pilot Poppet
When Operating Make-Up: Make-Up Valve
HP
LP T176-03-03-014
Spring C
T3-3-25
REGENERATIVE VALVE
The regenerative valves are located in the boom lower,

arm roll-in, and bucket roll-in circuits, accelerating the
cylinder operating speeds, preventing the cylinders Pressure Oil from Pump 1
from making a pose in movement, and improving
machine controllability.
NOTE: Operational principles of each regenerative

valve are almost identical. Therefore, the
bucket regenerative valve is used as an Bucket
Cylinder
example.
Operation
1. When the bucket is rolled in, the return oil from
the cylinder rod side (the bottom side in case of
the boom cylinder) is routed to the check valve via
hole A in the spool. Check Valve
2. At this moment, when the oil pressure in the
T176-03-03-027
cylinder bottom side (the rod side in case of the
boom cylinder) is lower than the rod side, the
check valve is unseated.
3. Then, the return oil from the cylinder rod side
flows into the bottom side so that the return
pressure oil is regenerated, increasing the
cylinder operating speed.
4. When the cylinder is fully stroked or digging loads
increase, the oil pressure in the cylinder bottom
circuit increases, causing the check valve to seat
so that regeneration is stopped.
NOTE: Arm Regenerative Valve (selector valve)

Operation
The arm regenerative valve (selector valve)
is shifted by the pilot pressure oil from
solenoid valve unit (SC) so that the return
oil circuit from the cylinder rod side to the
hydraulic oil tank is blocked. Then, the
return oil from the arm cylinder rod side is
combined with the pressure oil from the
pump and is routed to the arm cylinder
bottom. (Only the arm regenerative valve
(selector valve). Refer to the SYSTEM /
Control system group.)
T3-3-26
When Neutral: When Operating:
Bucket Bucket
Cylinder Cylinder
Spool
Spool
Hole A Hole A
Check Check
Valve Valve
T176-03-03-015 T176-03-03-016
T3-3-27
ANTI-DRIFT VALVE
The anti-drift valves are located in the boom cylinder

bottom and arm cylinder rod side circuits to reduce the
cylinder drift.
NOTE: The boom and arm anti-drift valves are

identical in construction.
Blocking Operation
1. When the control lever (the spool) is in neutral, Boom Cylinder
the anti-drift valve (selector valve) is not shifted.
2. Therefore, the pressure oil in the boom cylinder
bottom (arm cylinder rod side) is applied to the
anti-drift valve check valve via the control valve.
3. Consequently, the check valve is seated, blocking
the return oil circuit from the cylinder so that the
cylinder drift is reduced.
Releasing Operation
1. When rolling the arm in or lowering the boom, the
pressure oil from the pilot valve shifts the anti-drift
valve (selector valve). T176-03-03-028
2. The hydraulic oil in the check valve spring Anti-Drift Valve Anti-Drift Valve
chamber is returned to the hydraulic oil tank via (Selector Valve) (Check Valve)
the orifice in the Selector valve. Pressure Oil To Hydraulic
3. Accordingly, the check valve is unseated, allowing from Pump 1 Oil Tank Boom Cylinder
the return oil from the boom cylinder bottom side
(arm cylinder rod side) to flow to the spool.
From Pilot
Valve
To Hydraulic
Oil Tank
T176-03-03-029
Anti-Drift Valve Anti-Drift Valve

(Selector Valve) (Check Valve)
T3-3-28
When Blocking:
Drain
Boom
Cylinder
To Pilot
Valve
Selector Valve
Sleeve
Spring B
Seat
Spring A
Check Valve
To Spool
T176-03-03-017
When Releasing:
Drain
Boom
Cylinder
From Pilot
Valve
Selector Valve
Sleeve
Pressure Spring B
Oil from
Seat
Pump
Spring A
Check Valve
To Spool
T176-03-03-018
T3-3-29
FLOW RATE CONTROL VALVE
The flow rate control valve is located in the bucket and NOTE: The attachment cannot be equipped for
auxiliary circuits. When a combined operation is made, ZAXIS135UR.
the flow rate control valve restricts the oil flow so that Therefore, as for ZAXIS135UR, the
the other actuators are given priority to operate. auxiliary flow rate control valve is not
operated.
When bucket (auxiliary) single operation is made: NOTE: The bucket flow rate control valve restricts
1. The pressure oil from pump 1 acts on the check the bucket circuit oil flow when the bucket,
valve in the poppet via port P1. boom raise and arm roll-in operations are
2. Normally, the selector valve is kept open so that made simultaneously. The auxiliary flow
the pressure oil from pump 1 unseats the check rate control valve restricts the auxiliary
valve and flows into the main spool through the circuit oil flow when a combined operation
selector valve. with the auxiliary and other front
3. Thereby, the poppet valve is opened, allowing the attachment is made. The bucket flow rate
pressure oil to flow to the bucket spool. control valve is used here as an example.
When the combined operation of the bucket

(auxiliary), boom raise, and arm roll-in is made:
1. When the boom raise and arm roll-in functions are
operated simultaneously, the selector valve is
shifted so that the bucket flow rate control valve in
the signal control valve is shifted by the boom Pressure Oil To Hydraulic
Poppet Valve
from Pump 1 Oil Tank
raise pilot pressure.
2. Then, the oil pressure behind the poppet valve
increases, and the force to close the poppet valve
appears.
3. Consequently, the opening clearance of the
poppet valve is reduced so that oil flow to the Selector
Bucket
Valve
bucket spool is restricted, allowing the pressure Cylinder
oil to be routed to the high pressure side of the
boom raise circuit.
Pilot Pressure T176-03-03-030
from Bucket Flow

Rate Control Pressure Oil To Hydraulic
Valve from Pump 1 Oil Tank
Poppet Valve
Selector
Valve Bucket
Cylinder
T176-03-03-031
T3-3-30
When Normal Operation:
Poppet Check Valve Spring A

Spring B
To Main Spool
To Hydraulic
Oil Tank
Pressure Oil Selector

from Main Valve
Pump 1
Boom Raise
Pilot Pressure
To Main Spool
T176-03-03-019
Plug 2
When Oil Flow is Restricted:
Poppet Check Valve Spring A

Spring B
To Main Spool
To Hydraulic
Oil Tank
Selector
Pressure Oil Valve
from Main
Pump 1
Boom Raise
Pilot Pressure
To Main Spool
T176-03-03-020
Plug 2
T3-3-31
BYPASS SHUT-OUT VALVE
The bypass shut-out valve is located after the 4-spool
side circuit. When the blade (ZAXIS135UR When Neutral:
only)/positioning (2-piece Boom only) is operated, the Spring Spool 4-Spool Side
bypass shut-out valve is shifted, blocking the neutral Neutral Circuit
passage in the 4-spool side circuit.
Operation
1. When the control levers are in neutral, the bypass
shut-out valve is not shifted. The pressure oil from
pump 1 returns back to the hydraulic oil tank
through the neutral passage in the 4-spool side
circuit.
2. When the blade/positioning is operated, the pilot Return to
pressure from the pilot valve is routed to port SJ Hydraulic
Oil Tank
so that the bypass shut-out valve is shifted.
3. (Blade)
Consequently, the neutral passage in the 4-spool
side circuit is blocked, allowing the pressure oil
from pump 1 to flow to the blade control valve.
(Positioning) Port SJ T176-03-03-022
The pressure oil from the pump 1 flows to the

positioning control valve through the neutral and When Operating:
parallel passage in the 4-spool side circuit. Spring Spool 4-Spool Side
Neutral Circuit
Return to
Hydraulic
Oil Tank
Port SJ T176-03-03-024
T3-3-32
Neutral Circuit
Port SJ
From Positioning
Pilot Valve
Positioning
Cylinder
Parallel
Circuit Bypass Shut-Out
Valve
Pump 1
Positioning
T187-02-03-003
Control Valve
(2-piece Boom)
NOTE: 2-piece boom is illustrated here.
T3-3-33
AUXILIARY FLOW COMBINING VALVE
Auxiliary Flow Combining Valve
The auxiliary flow combiner valve is located before the When Neutral:
4-spool side circuit. The auxiliary flow combiner valve Port SN
operates differently depending on whether a single or
combined operation is made. Spring B
To Auxiliary
Spool
NOTE: The auxiliary flow combiner valve operates Check Valve
only on the machines equipped with the
optional auxiliary flow combining system. Pressure Oil
from Pump 1
Normally, port SN and port SM are
connected to the hydraulic oil tank.
NOTE: The attachment cannot be equipped for

ZAXIS135UR. Therefore, as for ZAXIS135 Spool
UR, the auxiliary flow combining valve and
auxiliary combining control solenoid valve
are not operated. Port SN and port SM are
connected to the hydraulic oil tank.
Spring A
Signal Operation
When a single aux. pilot valve operation is made, the Port SM
aux. flow combining valve allows the pressure oil from
pump 1 to flow to the aux. spool together with the
pressure oil from pump 2, increasing the attachment
operating speed.
T176-03-03-021
1. When an aux. pilot valve is operated, the pilot

pressure oil is routed to port SM and port SJ so When Operating:
that both the aux. flow combining valve and Port SN
bypass shut-out valve are shifted. Spring B
2. When the bypass shut-out valve is shifted, the To Auxiliary
neutral circuit in the 4-spool side is blocked. Spool Check Valve
3. At this moment, the aux. flow combiner valve is
also shifted, allowing the pressure oil from the
4-spool side (pump 1) to flow to the aux. spool via Pressure Oil
from Pump 1
the aux. flow combining valve.
4. Therefore, pressure oil from both pumps 1 and 2
is supplied to the attachment, increasing
attachment operation speed.
Spool
Spring A
Port SM
T176-03-03-023
T3-3-34
Pilot Pressure from

Signal Control Valve Aux. Pilot Valve
Aux. Flow Combining Valve
Aux. Flow
Control Solenoid Valve
Combining Valve
Port SN Port SM
Attachment
Neutral Circuit
Auxiliary
Port SJ
4-Spool Side
5-Spool Side
Pump 2 Pump 1
T176-03-03-033
NOTE: The auxiliary flow combining solenoid valve

is installed only on the machines equipped
with the optional auxiliary flow combining
system.
T3-3-35
Combined Operation
Auxiliary Flow Combining Valve
When the auxiliary pilot valve and the boom, arm,
bucket, or travel functions are operated simultaneously, Port SN
the auxiliary flow combining valve is not shifted.
Thereby, the specified operating speed of the boom, Spring B
To Auxiliary
arm, bucket, or travel function is ensured. Spool
However, the combined oil flow is supplied to the Check Valve
auxiliary circuit when the pilot pressure to port SN is
reduced by the reducing valve. Pressure Oil
from Pump 1
1. When the auxiliary pilot valve is operated, the
pilot pressure oil is routed to port SM on the
auxiliary flow combining valve.
2. When the boom, arm, bucket, or travel is
Spool
operated at the same time, the pilot pressure oil
from the signal control valve is routed to port SN.
3. The pressure oil from port SM acts on the
auxiliary flow combining valve spool toward
opening direction. The pressure oil from port SN
Spring A
and spring A act toward the closing direction.
4. Since the force to close the spool is larger than
that to open the spool, the spool is kept closed. Port SM
5. When the pilot pressure to port SN is reduced by
the reducing valve, the pilot pressure in port SM
overcomes the pilot pressure in port SN and
spring (A) force. Then, the auxiliary flow
T176-03-03-037
combining valve is opened. Therefore, the
pressure oil from pump 1 and pump 2 are
combined and supplied together to the auxiliary
spool.
T3-3-36
Pilot Pressure from

Signal Control Valve Aux. Pilot Valve
Aux. Flow Combining Valve
Aux. Flow
Control Solenoid Valve
Combining
Valve
Port SN Port SM
Neutral Circuit
Attachment
Auxiliary
Port SJ
Pump 2 Pump 1
T187-03-03-002
NOTE: The auxiliary flow combining solenoid valve

is installed only on the machines equipped
with the optional auxiliary flow combining
system.
T3-3-37
(Blank)
T3-3-38
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls the pilot oil pressure by which The reducing valves in both the front attachment /
the control valve spools are operated. swing, travel, offset, and blade (ZAXIS135UR only)
Two types of the standard pilot valves are located on pilot valves are identical construction except for the
this machine. Both have four oil ports. One type is pusher moving cam.
used for the front attachment / swing function control.
Another is used for the travel function control. Other
type has two oil ports. This type is used for the offset
and blade (ZAXIS135UR only) function controls.
(ZAXIS110, 110M, 120, 130, 130LCN, 125US, and • Travel Pilot Valve
135US: Two oil ports (Optional)) 1 Right Travel Reverse
2 Right Travel Forward
4 Oil Ports Pilot Valve 3 Left Travel Forward
• Front Attachment / Swing Pilot Valve 4 Left Travel Reverse
Port ISO Control
H Pattern
No. Pattern
1 Bucket Roll-Out ← Hydraulic P T
Symbol
2 Boom Lower ←
Right
3 Bucket Roll-In ←
4 Boom Raise ←
1 Right Swing Arm Roll-In
2 Arm Roll-Out Right Swing 1 3 2 4
Left
3 Left Swing Arm Roll-Out
T105-02-07-020
4 Arm Roll-In Left Swing
Hydraulic P T
Symbol
1 3 2 4 T
T105-02-07-020
3 4
2 1
T178-03-04-002
1
P
T178-03-04-001
3
T3-4-1
2 Oil Ports Pilot Valve
• Offset Pilot Valve
P T
Port No.
1 Right Offset
2 Left Offset
• Blade Pilot Valve

Port No.
1 Blade Lower
2 Blade Raise
1 2 T1CF-03-04-001
T1CF-03-04-002
1 2
T3-4-2
(Blank)
T3-4-3
OPERATION
Spool (6) head comes in contact with the upper face
of spring guide (3) which is kept raised by return
spring (5).
Neutral (Output Diagram: A to B):

1. When neutral, spool (6) totally blocks the
pressure oil in port P (from the pilot pump).The E F
output port is opened to port T (hydraulic oil tank)
through the passage in spool (6). Therefore, the D
oil pressure in the output port (to the control Pilot
valve) is equal to that in port T. Pressure
2. When the control lever is slightly tilted, cam (1) is
tilted, moving pusher (2) downward. Then, C
pusher (2) pushes return spring (5) downward
with spring guide (3). At this time, as the oil
pressure in the output port is equal to that in port A B
Lever Stroke
T, spool (6) moves downward while keeping the T522-02-05-001
under face of the spool head in contact with
spring guide (3).
3. This status continues until hole (7) on spool (6) is
opened to port P.
T3-4-4
Front Attachment / Swing Pilot Valve
1 1
2 2
6
3 3 Port T
4 4
7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
Output Port T178-03-04-005

Travel Pilot Valve

1 1
2 2 Port T
7
Port P
3 3 6
4 4
5 Output Port
5
6
Port T Port T
6
Port P Port P
7 7

1 - Cam 3 - Spring Guide 5 - Return Spring 7 - Hole

2 - Pusher 4 - Balance Spring 6 - Spool
T3-4-5
During Metering or Decompressing (Output
Diagram: C to D)
1. When the control lever is further tilted to move E F
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, the allowing the pressure oil
D
in port P to flow into the output port.
Pilot
2. The oil pressure in the output port acts on the Pressure
bottom face of spool (6) so that spool (6) is
pushed upward.
C
3. However, until the upward force acting on the
bottom face of spool (6) overcomes balance
spring (4) force, balance spring (4) is not A B
Lever Stroke
compressed. Then, spool (6) is not raised,
allowing the oil pressure in the output port to T522-02-05-001
increase.
4. As the oil pressure in the output port increases,
the force to push spool (6) upward increases.
When, this force overcomes balance spring (4)
force, balance spring (4) is compressed so that
spool (6) is moved upward.
5. As spool (6) is moved upward, hole (7) is closed
so that the pressure oil from port P stops flowing
into the output port, stopping the pressure oil in
the output port to increase.
6. As spool (6) is moved downward, balance spring
(4) is compressed, increasing the spring force.
Therefore, the oil pressure in the output port
becomes equal to the oil pressure acting on the
bottom face of spool (6) being balanced in
position with the spring force.
T3-4-6
1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P
Output Port T178-03-04-008 Output Port T178-03-04-009
Travel Pilot Valve

1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
Port P Port P
7 7
Output Port T178-03-04-012 Output Port T178-03-04-013

T3-4-7
Full Stroke (Output Diagram: E to F)
1. When the control lever is fully stroked, pusher (2)
is moved downward until pusher (2) in the front E F
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel D
pilot valve comes in contact with the casing. Pilot
2. At this moment, the bottom of pusher (2) directly Pressure
pushes spool (6). Therefore, even if the oil
pressure in the output port increases further, hole C
(7) on spool (6) is kept open.
3. Consequently, the oil pressure in the output port
is equal to the oil pressure in port P. A B
Lever Stroke
T522-02-05-001
NOTE: Total lever strokes for the front attachment

and swing controls are determined by
stroke dimension (E) of pusher (2). Total
lever stroke for the travel control is
determined by stroke dimension (E) of cam
(1).
T3-4-8
2 2
4
5
6
Port T
7 Port P
T178-03-04-010
Travel Pilot Valve

1
1
E
2
4
5
6
Port T
Port P
7
T178-03-04-006

T3-4-9
(Blank)
T3-4-10
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of the travel motor, travel The travel reduction gear is a two stage reduction
reduction gear, and travel brake valve. The travel planetary gear type, converting rotary power
motor is a swash plate type variable displacement axial transmitted from the travel motor to slow large torque
plunger motor, equipped with parking brake. The travel causing the sprocket and track to rotate. The travel
motor is driven by the pressure oil from the pump and brake valve protects the travel circuit from being
transmits its rotary power to the travel reduction gear. overloaded and prevents the occurrence of cavitation.
NOTE: The parking brake of ZAXIS110, 120, 130,
130LCN, 125US, 135US is wet - multi - disc
negative type.
The parking brake of ZAXIS110M is wet -
single - disc negative type.
ZAXIS110/120/130/130LCN/125US/135US ZAXIS110M
Travel Brake Valve Travel Reduction Gear Travel Brake Valve Travel Reduction Gear
Travel Motor Travel Motor
T176-03-05-001
W187-03-02-001
T3-5-1
TRAVEL REDUCTION GEAR
ZAXIS110/120/130/130LCN/125US/135US
The travel reduction gear is a two-stage reduction Travel motor housing (11) is bolted to the track frame
planetary gear type. The travel motor rotates propeller and is secured to second stage carrier (2) by hub (8).
shaft (5). This rotation is transmitted to ring gear (1) via Ring gear (1) is bolted to drum (10). Drum (10) is
first stage planetary gear (6), first stage carrier (4), sun bolted to sprocket (9). Accordingly, when ring gear (1)
gear (3), second stage planetary gear (7), and second is rotated, drum (10) and sprocket (9) are also rotated.
stage carrier (2).
1 2 3 4
8 7 6
11 10
9
T176-03-05-001
1 - Ring Gear 4 - First Stage Carrier 7 - Second Stage Planetary Gear 10 - Drum
2 - Second Stage Carrier 5 - Propeller Shaft 8 - Hub 11 - Housing
3 - Sun Gear 6 - First Stage Planetary Gear 9 - Sprocket
T3-5-2
ZAXIS110M
The travel reduction gear is a two stage planetary gear Since second stage carrier (2) of the reduction gear
type. and holder (9) of the travel motor are integrated within
The travel motor rotates shaft (6) and this driving force a monoblock, second stage carrier (2) is held
is transmitted to second stage carrier (2) and ring gear stationary.
(1) through first stage planetary gear (5), first stage As ring gear (1) is bolted to sprocket (8), they all rotate
carrier (4), second stage sun gear (3) and second together.
stage planetary gear (7).
1 2 3 4 5
1 2 3 4
6
6
5
Second First
Stage Stage
8 7 T165-03-05-008
T165-03-05-003
9 7
1 - Ring Gear 4 - First Stage Carrier 6 - Shaft 8 - Sprocket

2 - Second Stage Carrier 5 - First Stage Planetary Gear 7 - Second Stage Planetary 9 - Holder (Travel Motor)
Gear
3 - Second Stage Sun Gear
T3-5-3
TRAVEL MOTOR
The travel motor consists of the valve plate, swash The shoes on the tips of the plungers slide along the
plate, rotor, plungers, and shaft. The shaft is splined to swash plate surface due to the inclination of the swash
the rotor, in which the plungers are inserted. When the plate, causing the rotor to rotate.
pressure oil is supplied from the pump, the plungers
are pushed.
ZAXIS110/120/130/130LCN/125US/135US
Shaft Rotor Shoe Swash Plate
Valve Plate Plunger
T176-03-05-002
T3-5-4
ZAXIS110M
Shaft Rotor Shoe
T165-03-05-002
Valve Plunger Swash Plate
T3-5-5
PARKING BRAKE
ZAXIS110/120/130/130LCN/125US/135US
The parking brake is a wet-type multi disc brake. The
brake is a negative type so that it is released only
when the brake release pressure oil is routed into the
brake piston chamber. The parking brake is
automatically applied unless the travel function is
operated. The friction plates and the plates are splined
to the rotor and the housing, respectively.
Releasing Brake Applying Brake

1. When the travel lever is operated, the pressure oil 1. When the travel lever is returned to neutral, the
from the main pump is routed to port AM or BM counterbalance spool in the travel brake valve is
through the control valve. returned to neutral.
2. This pressure oil shifts the counterbalance valve 2. Then, the pressure oil acting on the brake piston
spool and acts on the brake piston via the notch is returned to the drain circuit via the orifice.
on the spool. Therefore, the brake piston is slowly pushed back
3. Then, the brake piston is pushed against the disc by the disc spring.
spring, allowing the plates and friction plates to be 3. Consequently, the spring force is applied to the
freed each other so that the brake is released. plates engaging on the outer diameter of the rotor
and the friction plates engaging on the inner
diameter of the housing via the brake piston,
securing the rotor outer diameter by friction
between the friction plates and the plates.
T3-5-6
When Applying Brake: When Releasing Brake:

Friction Plate Friction Plate
Plate Plate
Disc Spring
Disc Spring Brake Piston Brake Piston
Orifice
To Brake Piston
Counterbalance
Spool
Port BM Port AM
T176-03-05-007
T3-5-7
ZAXIS110M Applying Brake

The parking brake is a negative-type brake which is 1. When returning the travel lever to neutral, the
released when oil pressure acts on parking brake counterbalance spool is returned to its neutral
chamber M. The parking brake is always automatically position, closing the parking brake release port
applied except for travel operation. P3.
The friction plate is connected to the rotor by a spline 2. As parking brake chamber M is connected to the
coupling. When the spring pushes the piston, the drain line.
piston comes in contact with the friction plate, applying 3. The piston is slowly moved to the right by the
the parking brake. spring the until it makes contact securely with
friction plate, applying the parking brake.
Releasing Brake
1. When operating the travel lever, the pressure oil
from the main pump flows into the travel motor
port (P1 or P2) via the control valve.
2. Pressure oil form the travel motor port (P1 or P2)
is routed to parking brake chamber M via the
parking brake release port P3.
3. This pressure oil frees the piston to the left from
the friction plate, releasing the parking brake.
(Refer to the shuttle function on the previous
page.)
T3-5-8
Port P3 Spring Piston M Friction Plate Rotor
T165-05-04-009
T3-5-9
TRAVEL MODE CONTROL
ZAXIS110/120/130/130LCN/125US/135US
The tilt angle of swash plate (7) is changed by piston
(8) movement to select the travel mode.
• Slow Speed Mode

1. When the travel mode switch is in the SLOW
position, the MC (main controller) doesn’t send
signals to solenoid valve unit (SI) so that the pilot
pressure oil is not routed to pilot port (1).
Therefore, spool (3) is kept raised by spring (4).
2. Accordingly, the pressure oil doesn’t act on piston
(8), holding the swash plate angle to the
maximum and increasing the stroke of plunger (6).
Then, the travel motor rotates at slow speed.
T3-5-10
5 6 7 8
T176-03-05-005
1 - Pilot Port 3 - Spool 5 - Orifice 7 - Swash Plate

2 - Piston Control Shuttle Valve 4 - Spring 6 - Plunger 8 - Piston
T3-5-11
• Fast Speed Mode

1. When the travel mode switch is in the FAST
position, the MC sends signals to solenoid valve
unit (SI) in response to change in travel loads.
(Refer to the pages for the Travel Motor Swash
Angle Control in the SYSTEM / Control System
group.) Then, the pilot pressure oil is routed to
port (1), moving spool (3) downward.
2. The pressure oil in the high pressure motor port
(AM or BM) acts on piston (8) through orifice (5).
3. Piston (8) moves swash plate (7) so that the
swash plate (7) angle is reduced. Thereby, the
plunger (6) stroke is reduced, causing the travel
motor to rotate at fast speed.
T3-5-12
5 6 7 8
T176-03-05-006
1 - Pilot Port 3 - Spool 5 - Orifice 7 - Swash Plate

2 - Piston Control Shuttle 4 - Spring 6 - Plunger 8 - Piston
Valve
T3-5-13
ZAXIS110M
Piston (1) is located next to swash plate (3). The
angle of swash plate (3) is changed by
extending/retracting piston (1) so as to change the
travel speed mode.
• Slow Speed Mode

1. When the slow speed travel mode is selected, the
main controller (MC) does not send a control
signal to the solenoid valve unit (SI). For this
reason, the pilot pressure used for travel mode
change is not routed to port PS (4). As a result,
spool (5) is held to the left side by spring (6).
2. Pressure oil from high pressure side motor port
a2 (7) or a1 (8) is blocked by spool (5), draining oil
in the two-speed control piston chamber via spool
(5).
3. The motor plungers push swash plate (3) down,
making the surface (A) of swash plate (3) come in
contact with the casing surface. In this position,
the displacement angle of swash plate (3) is at the
maximum angle, allowing the motor plungers to
reciprocate in maximum stroke, thus achieving
the slow speed travel mode.
T3-5-14
6 4 5 6
T165-03-05-005
Surface (A)
3
2 7 8
Top View of Swash Plate Surface (B) Valve Plate
T165-03-05-010
1 - Piston 3 - Swash Plate 5 - Spool 7 - Port a2

2 - Steel Ball 4 - Port PS 6 - Spring 8 - Port a1
T3-5-15
• Fast Speed Mode

1. With the fast speed travel mode selected, the
main controller (MC) send a control signal to the
solenoid valve unit (SI) when traveling under light
loads. Pilot pressure SH used for travel mode
change is then routed from port PS (4), moving
spool (5) to the right.
2. Pressure oil from high pressure side motor port
a2 (7) or a1 (8), routed via spool (5), acts on
piston (1).
3. Then, piston (1) pushes swash plate (3), making
the surface (B) of swash plate (3) come in contact
with the casing surface. In this position, the
displacement angle of swash plate (3) is at the
minimum angle, allowing the motor plungers to
reciprocate in minimum stroke, thus achieving the
fast speed travel mode.
T3-5-16
6 4 5 6
T165-03-05-007
Surface (A)
3
2 8
7 Valve Plate
Top View of Swash Plate
Surface (B) T165-03-05-011
1 - Piston 3 - Swash Plate 5 - Spool 7 - Port a2

2 - Steel Ball 4 - Port PS 6 - Spring 8 - Port a1
T3-5-17
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor

head, consisting of the following valves.
ZAXIS110/120/130/130LCN/125US/135US
Counterbalance Valve:
Makes starting and stopping travel operations smooth,
prevents the machine from running away while
descending slopes, and routes the travel motor
operating the pressure oil in the high pressure port (AV
or BV) to the parking brake.
Check Valve:
Assists the counterbalance valve operation and
prevents cavitation in the motor circuit.
Overload Relief Valve:

Prevents the occurrence of overload and surge
pressure in the motor circuit and reduces shock loads
developed when stopping travel operation.
Shuttle Valve:
Routes the travel motor operating high pressure oil in
the high pressure port (AM or BM) to the slow or fast
side piston so that the piston is controlled.
Travel Motor Swash Plate Angle Control Valve:

Delivers the pressure oil routed by the piston control
shuttle valve to the slow or fast side piston.
Orifice:
Makes the travel mode change (swash plate angle
control) smooth.
T3-5-18
Counterbalance Valve
Check Valve
Shuttle Valve Orifice

Overload Relief Valve Travel Motor Swash Plate
Angle Control Valve
T176-03-05-004
T3-5-19
While Traveling: While descending:
1. When the pressure oil from the control valve 1. While descending a slope, the travel motor is
enters port BV (8), the pressure oil flows around forcibly rotated by the machine weight so that the
the outer diameter of spool (9), unseats check motor operates like a pump, drawing oil.
valve BC (7), and flows further to motor port BM 2. If the travel motor draws oil, oil pressure in port
(6). BV (8) and chamber B (10) will decrease, causing
2. On the other hand, the return oil from the travel spool (9) to the left so that the return oil flow from
motor is routed to motor port AM (4). However, its the travel motor is restricted.
passage is blocked by check valve AC (3) and 3. Therefore, oil pressure in motor port AM (4) will
spool (9). increase, braking the travel motor.
3. When the oil pressure in port BV (8) increases, 4. Once pressure oil flow is restricted, oil pressure in
the pressure oil is routed into chamber B (10) motor port AM (4) will increase again, moving
through orifice (f) in spool (9), moving spool (9) to spool (9) to the right. As this operation (hydraulic
the right. braking operation) is repeated, the machine is
4. Consequently, the return oil from the travel motor prevented from running away.
flows to port AV (1) through notch (h) on spool (9).
Then, the pressure oil is allowed to flow so that Circuit Protection Operation:
the travel motor starts rotating. 1. When oil pressure in the circuit increases over the
5. When the travel lever is returned to neutral, spool set-pressure of overload relief valve (5), the
(9) is returned to the original position by the spring overload relief valve is opened, allowing the high
force, blocking the oil passage so that the travel pressure oil to relieve to the low pressure side so
motor rotation is stopped. that the travel motor is protected from being
overloaded.
2. In addition, the overload relief valve relieves the
shock loads developed due to inertia force when
stopping the travel motor.
3. If the travel motor draws oil like a pump, check
valve BC (7) is unseated (make-up operation) so
that cavitation is prevented.
T3-5-20
10 8 9 1 2
BV AV
6
4
7 3
T176-03-05-009
1 - Port AV 4 - Motor Port AM 7 - Check Valve BC 9 - Spool (Counterbalance Valve)

2 - Chamber A 5 - Overload Relief Valve 8 - Port BV 10 - Chamber B
3 - Check Valve AC 6 - Motor Port BM
T3-5-21
ZAXIS110M
Counterbalance Valve: Overload Relief Valve (9):
Ensures smooth starts and stops, and prevents Prevents overload and surge pressure in the motor
overrunning when traveling down slopes. circuit.
Check Valve (2): Travel Motor Swash Angle Control Valve (10):
Ensures smooth starts and stops, and prevents Activated by pilot pressure from the solenoid valve
cavitation from occurring in the motor circuit by unit (SI). Routes the travel motor driving pressure to
functioning together with counterbalance valve. the two-speed control piston.
From Control Valve To Control Valve
1 2 3 4 5 6
9 8 10 7
T165-03-05-004
1 - Orifice 4 - Port P1 7 - Port a2 9 - Overload Relief Valve
2 - Check Valve 5 - Port P3 8 - Port a1 10 - Travel Motor Swash Angle
Control Valve
3 - Spool 6 - Port P2
(Counterbalance Valve)
T3-5-22
While Traveling: Circuit Protection Operation:
1. When pressure oil from the control valve is routed 1. If pressure in the circuit exceeds the setting
to port P1 (4), it is then routed to motor port a1 (8) pressure of overload relief valve (9), the valve
after opening check valve (2). opens to relieve peak pressure to the lower
2. On the other hand, return oil from the travel motor pressure side to protect the motor from
returns to motor port a2 (7) but does not flow overloading.
further as it is blocked by the other check valve 2. This valve also functions to release shock
(2). pressure caused by inertial force that develops
3. As supply oil at port P1 (4) increases, it is then when the motor stops.
routed to the left end of spool (3) via orifice (1), 3. When the motor sucks oil as it may happen when
shifting spool (3) to the right. descending, check valve (2) opens to prevent
4. Consequently, return oil from the motor port starts cavitation in the circuit from occurring.
to flow into port P2 (6) via a notch on spool (3),
allowing the travel motor to rotate.
5. When the travel levers are returned to the neutral Shuttle Function:
position, spool (3) is returned to the original 1. When spool (3) is moved from its neutral position,
position by the spring, blocking the motor circuit to port P1 (4) or port P2 (6) is connected to parking
stop motor rotation. brake release port P3 (5), routing pressure oil to
the parking brake chamber to release the parking
brake.
While Descending: 2. When the travel motor stops rotating, spool (3) is
1. When the machine travels down a slope, the returned to the neutral position, closing port P3
travel motors are forcibly driven by the machine (5). Then, oil in the parking brake chamber is
weight so that the motor sucks oil like a pump. drained to the drain port, activating the parking
2. When the motor sucks oil, the oil pressure at port brake.
P1 (4) and the left end of spool (3) decreases,
moving spool (3) to the left to restrict the return oil
flow.
3. For this reason, the pressure at motor port a2 (7)
rises to brake (slow) motor rotation.
4. As the motor rotation is slowed, the pressure at
port P1 (4) rises, moving spool (3) to the right.
Repetition of this return oil restriction and
unrestriction (hydraulic braking) prevents the
machine from overrunning.
T3-5-23
(Blank)
T3-5-24
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit
between the pilot valve and the control valve and con-
trols pilot signal pressure used to regulate the pumps
and various kinds of valves.
The major components of the signal control valve are,
shuttle valves, shockless valve, pump 1 flow rate con-
trol valve, pump 2 flow rate control valve, flow com-
biner valve control spool, bucket flow rate control
valve control spool, and swing parking brake release
spool.
Pilot Valve Side
T178-03-06-016
Cross Section A-A
Shockless Valve
Auxiliary Bucket Flow Rate Control Valve
Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve
Swing Parking Brake Flow Combiner Valve Control Spool

Release Spool
T178-03-06-002
T3-6-1
PILOT PORT
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
T3-6-2
Pilot Valve Side

Port Name Connecting to Note
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
(ZAXIS135UR : Offset Pilot Valve) (ZAXIS135UR : Left Offset Pilot Pressure)
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
(ZAXIS135UR : Offset Pilot Valve) (ZAXIS135UR : 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 (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T3-6-3
Control Valve Side

SM
3
1 5
13
2 4
SK
SE
Pressure Sensor 8
(swing)
14
Control Valve Side 7
9
6
10
SN
SL
11
Pressure Sensor 12 SP T178-03-06-015

(Travel)
T3-6-4
Control Valve Side

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 (ZAXIS135UR: Off- Right Swing Pilot Pressure
set Anti-Drift Valve)
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
(ZAXIS135UR : Left Offset Pilot Pressure)
Port 14 Control Valve Auxiliary Close Pilot Pressure
(ZAXIS135UR : Right Offset Pilot Pressure)
Port SE - Plug
Port SM Hydraulic Oil Tank (ZAXIS135UR : Returning to Hydraulic Oil Tank (ZAXIS135UR :
Offset Anti-Drift Valve) Offset Pilot Pressure)
Port SN - Plug
Port SP Solenoid Valve Unit Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T3-6-5
SHUTTLE VALVE
The shuttle valve selects the pilot pressure used to
perform each operation and routes it to the corre-
sponding flow rate control valves and/or control
spools. The flow rate control valves and/or control
spools corresponding to each operation are as fol-
lows:
Pump 1 Flow Pump 2 Flow Flow Combiner Bucket Flow Rate Swing Parking
Rate Control Rate Control Valve Control Control Valve Brake Release
Valve Valve Spool Control Spool Spool
Boom Raise { { - - {
Boom Lower { - - - {
Arm Roll-In { { - { {
Arm Roll-Out { { - - {
Bucket Roll-In { - - - {
Bucket Roll-Out { - - - {
Right Swing - { - - {
Left Swing - { - - {
Right Travel { - { - -
Left Travel - { - - -
Auxiliary
- { - - {
(ZX135UR : Offset)
T3-6-6
5 6 7 8 9 10 11 12 13
Left Right Swing Arm Boom Bucket Offset
Travel Travel (ZX135UR Only)
1 2 3 4
14
15
16
17
T1SM-03-06-100
Pump 1 Flow Pump 2 Flow Bucket Flow Flow Combiner Swing Parking
Rate Control Rate Control Rate Control Valve Control Brake Release
Valve Valve Valve Control Spool Spool
Spool
T3-6-7
Pilot Valve Side
T178-03-06-016
Cross Section B-B
9
5
8
7
16
17
15 13
11
14
6 10
12
3
1
4
2
T178-03-06-009
1 - Left Travel 6 - Boom/Arm/Bucket/Right 11 - Boom/Arm/Bucket 16 - Swing/Auxiliary

Travel (ZAXIS135UR : Offset)
2 - Left Travel/Right Travel 7 - Boom/Arm 12 - Boom/Arm/Bucket/ 17 - Auxiliary
Swing/Auxiliary (ZAXIS135UR : Offset)
(ZAXIS135UR : Offset)
3 - Right Travel 8 - Boom 13 - Arm/Boom
Raise/Swing/Auxiliary
4 - Boom/Arm/Bucket/ Right 9 - Arm/Boom Raise 14 - Bucket
Travel
5 - Arm 10 - Boom/Arm/Bucket/Left 15 - Swing
Travel/Swing/Auxiliary
T3-6-8
(Blank)
T3-6-9
SHOCKLESS VALVE
The shockless valve is provided in the boom raise
circuit and functions during boom lowering operation.
During Boom Raising Operation: During Boom Lowering Operation (Shock Re-
1. The boom raise pilot pressure is routed from port ducing Operation)
A and acts on the spool. 1. When the boom is lowered, the return oil from the
2. Immediately after the operation is started, the low boom raise spool in the control valve is routed to
pilot pressure oil flows to port 1 via clearance C port 1.
between the spool and the housing, and inner 2. Since the spool blocks the oil passage between
passage 2. port 1 and port A, the return oil cannot flow di-
3. The set-force of spring A is weaker than that of rectly to port A.
spring B. Therefore, when the pilot pressure in- 3. Port 1 is connected to spring A side via inner
creases, the spool is moved to the left. passage 1 and to the oil chamber via inner pas-
4. As the spool is moved to the left, port A is con- sage 2.
nected to port 1, increasing the pressure in port 1 4. The pressure oil in the oil chamber flows out of
so that the spool in the control valve is moved. clearance C between the spool and the housing,
reducing the pressure in the oil chamber. Then,
the spool is moved to the right by the pressure in
the spring A side. Thereby, clearance C between
the spool and the housing is closed, blocking the
pressure oil flow.
5. When clearance C is closed, the pressure in the
oil chamber increases, moving the spool to the
left. Therefore, clearance C is opened again, al-
lowing the pressure oil to flow to port A.
6. As operations in steps (4 and 5) are repeated,
the pressure oil is gradually returned to port A so
that the control spool returns slowly.
T3-6-10
Pilot Valve Side
Port A
Inner Passage 1 C Spool Spring B
Spring A Inner Passage 2 Oil Chamber
Port 1
T178-03-06-013
Control Valve Side
T3-6-11
PUMP 1 AND PUMP 2 FLOW RATE CON-
TROL VALVES
The pump flow rate control valve delivers the pump
control pressure Pi to the pump regulator in response
to the pilot oil pressure from the pilot valve.
1. The pilot pressure from the pilot valve is routed

into the spring chamber side in either the pump 1
or pump 2 flow rate control valve after being se-
lected by the shuttle valves in the signal control
valve.
2. Then, the spool is moved to the right, causing the
primary pilot pressure to flow in either port SA or
SB.
3. Therefore, the pressure in port SA or SB in-
creases.
4. The oil pressure in port SA or SB acts on the right
end of the spool. Thus, the spool is moved back
to the left until the pressure force in port SA or SB
balances with the pilot pressure force in the
spring chamber so that the pressure in port SA or
SB stops increasing.
NOTE: The pump 1 flow rate control valve oper-

ates when the boom (raise or lower), arm
(roll-in or out), bucket (roll-in or out), auxil-
iary, and travel (right) functions are oper-
ated. The pump 2 flow rate control valve
operates when the boom (raise), arm
(roll-in or out), swing (right or left), auxiliary
(ZAXIS135UR : Offset (right / left)), and
travel (left) functions are operated.
T3-6-12
Port SA, SB
Spring Spool
Primary Pilot Pressure
Pilot Pressure
Shuttle Valve
T178-03-06-017
T3-6-13
BUCKET FLOW RATE CONTROL VALVE
CONTROL SPOOL, FLOW COMBINER
VALVE CONTROL SPOOL, SWING PARK-
ING BRAKE RELEASE SPOOL Bucket Flow Rate Control Valve Control Spool:
To Hydraulic Boom Raise Control
Oil Tank Pilot Pressure
NOTE: The three captioned spools are identical in Spool Spring
operational principle.
The bucket flow rate control valve control spool is

shifted by the arm roll-in control pilot pressure, allow-
ing the boom raise pilot pressure to flow to the bucket
flow rate control valve in the control valve. T178-03-06-014
The flow combiner valve control spool is shifted by the Arm Roll-In Pi- To Bucket Flow Rate
right travel pilot pressure, allowing the primary pilot lot Pressure Control Valve
pressure to flow to the flow combiner valve in the con-
trol valve. Flow Combiner Valve Control Spool:
The swing parking brake release spool is shifted by To Hydraulic Primary Pilot
the boom, arm, bucket, or auxiliary (ZAXIS135UR : Oil Tank Pressure
Spool Spring
Offset) pilot pressure, allowing the primary pilot pres-
sure to flow to the swing motor.
T178-03-06-014
Right Travel To Flow Combiner
Pilot Pressure Valve
Swing Parking Brake Release Spool:

Oil Tank Pressure
Spool Spring
T178-03-06-014
Pilot To Swing
Pressure Parking Brake
T3-6-14
COMPONENT OPERATION / Others (Upperstructure)
The pilot shut-off valve is a manual-operated switch
valve. The spool in the pilot shut-off valve is rotated by
moving the pilot control shut-off lever to turn on or off
the pilot oil flow to the pilot valves.
ZAXIS110, 110M, 120, 130, 130LCN, 125US,

135US :
• When Pilot Control Shut-Off Lever is in LOCK
Position. Section Z-Z
The pilot shut-off valve is set in the OFF position.
The pressure oil from the pilot pump does not flow
into the pilot valves, but it is routed to the signal
control valve. The pilot oil on the pilot valve side is
routed to the hydraulic tank. Even if the control
lever is operated, the pilot valve doesn’ t work.
• When Pilot Control Shut-Off Lever is in

UNLOCK Position
The pilot shut-off valve is set in the ON position.
The pressure oil from the pilot pump to flow into the
pilot valves as the drain circuit is blocked. If the To Signal From Pilot
control lever is operated, the pilot valve works and Control Valve Pump T178-03-07-002
the pilot pressure oil flows to the respective

hydraulic cylinders and/or motors.
A2 A1 Z
T1 T2 A3 A4 T4
T3 P
A5 T178-03-07-003
A1 - Right Pilot Valve A4 - Signal Control Valve T1 - Travel Pilot Valve T - Hydraulic Oil Tank
(Port PH)
A2 - Travel Pilot Valve A5 - Signal Control Valve T2 - Left Pilot Valve
(Port PI)
A3 - Left Pilot Valve P - Primary Pilot Pressure T3 - Right Pilot Valve
T3-7-1
ZAXIS135UR :
• When Pilot Control Shut-Off Lever is in LOCK Section Z-Z
Position.
The pilot shut-off valve is set in the OFF position.
The pressure oil from the pilot pump does not flow
into the pilot valves, but it is routed to the signal
control valve and 8-unit solenoid valve. The pilot oil
on the pilot valve side is routed to the hydraulic tank.
Even if the control lever is operated, the pilot valve
doesn’ t work.
• When Pilot Control Shut-Off Lever is in

UNLOCK Position To From Pilot
Hydraulic Pump
The pilot shut-off valve is set in the ON position. Oil Tank
The pressure oil from the pilot pump to flow into the T1SM-03-07-001
pilot valves, emergency stop solenoid valve, and

signal control valve as the drain circuit is blocked. If
the control lever is operated, the pilot valve works
and the pilot pressure oil flows to the respective
hydraulic cylinders and/or motors.
A2 A1
T4
A3
P
Z T3
T2
A4
T1
W157-02-08-001
A1 - Blade / Travel Pilot Valve A4 - Signal Control Valve / T1 - Emergency Stop Solenoid T3 - Offset / Right Pilot Valve
8-Unit Solenoid Valve Valve / Left Pilot Valve
A2 - Emergency Stop Solenoid P - Primary Pilot Pressure T2 - Balde / Travel Pilot Valve T4 - Hydraulic Oil Tank
Valve
A3 - Signal Control Valve
T3-7-2
SOLENOID VALVE UNIT
The solenoid valve unit functions to control the control
valve and travel motor swash angle control valve by
signals from the main controller (MC).
The solenoid valve unit consists of two proportional
solenoid valves (SC) and (SI). (Refer to the Control
System Group in the SYSTEM Section.)
SC : Controls the arm regenerative valve (selector

valve) located in the control valve.
SI : Controls the travel motor swash angle.
(Travel Speed Selection)
SC SI T176-03-07-002
T3-7-3
8-Unit Solenoid Valve (ZAXIS 135UR Only)
The 8-unit solenoid valve consists of proportional
valves, oil temperature sensors, and pressure sen-
sors.
1
• Proportional Solenoid Valve
The proportional valve is regulated by the signal 2
current from the Auto Marccino control unit and
15 3
outputs the oil pressure in proportion to the supplied
current value. The proportional solenoid valves fall 4
into 2 categories, deceleration and acceleration 5
proportional solenoid valves. 14
The deceleration proportional solenoid valve is fully 6
opened when the key switch is turned ON, reducing 7
or blocking the secondary pilot pressure oil from the 13
pilot valve by receiving the current signal from the 8
Auto Marccino control unit. (Refer to the SYSTEM /
9
Control System group.)
The acceleration proportional solenoid valve con- 12
trols the primary pilot pressure oil from the pilot 10
shut-off valve by receiving the current signal from
the Auto Marccino control unit, allowing the pilot
pressure oil to directly flow to the control spools
without routing through the pilot valve.
(Refer to the SYSTEM / Control System group.) T1SM-01-02-003
11
Machine
1 - Pilot Pressure Sensor 5 - Solenoid Valve (C6 : Right 9 - Solenoid Valve (C7 : Arm 13 - Solenoid Valve (C8 : Left
(E1 : Boom Raise) Offset Acceleration) Roll - Out Acceleration) Offset Deceleration)
2 - Solenoid Valve (C1 : Boom 6 - Pilot Pressure Sensor (E4 : 10 - Pilot Pressure Sensor 14 - Solenoid Valve (C5 : Right
Raise Acceleration) Left Offset Acceleration) (E3 : Arm Roll - In) Offset Deceleration)
3 - Pilot Pressure Sensor 7 - Solenoid Valve (C9 : Left 11 - Hydraulic Oil Temperature 15 - Solenoid Valve (C3 : Boom
(E2 : Boom Lower) Offset Acceleration) Sensor Lower Deceleration)
4 - Pilot Pressure Sensor (E6 : 8 - Pilot Pressure Sensor 12 - Solenoid Valve (C4 : Arm
Right Offset Acceleration) (E5 : Arm Roll - Out) Roll - In Deceleration)
T3-7-4
Proportional Solenoid Valve
Upon receiving an electric current signal from the Because of the pressure receiving area difference
MC, and Auto-Marccino control unit (ZAXIS135UR between two step parts (a), the pressure at port S
only) the proportional solenoid valve outputs the acts as a force to push the spool to the right. As
hydraulic pressure proportional to the degree of the the pressure at port S increases, the force to
electric current. push the spool to the right also increases. When
this force overcomes the force to push the spool
• When not energized (In neutral): to the left by the solenoid, the spool moves back
The spring pushes the spool to the right, to the right side, closing the passage between
connecting output port S to tank port T. output port S and port P. As a result, the pressure
increase at port S stops.
• When energized:
The solenoid pushes the spool to the left for a
distance proportional to the electric current
flowing through the solenoid. The pilot oil from
port (P) flows into output port S, increasing the
pressure at output port S. The pressure at port S
acts on step parts (a) on the spool. (See detail
“a.”)
Spool Spring Solenoid

T S P
a
T107-02-07-005
T3-7-5
Emergency Stop Solenoid Valve (ZAXIS 135UR
Only)
The emergency stop solenoid valve consists of a
Machine
selector valve and an unload valve. The emergency Front
stop solenoid valve is regulated by the signal current
from the Auto Marccino control unit so that when any
abnormality in the front attachment control system
occurs, the emergency stop solenoid valve is acti-
vated to block the pilot pressure oil to the pilot valve
(except for travel and blade control system). The
emergency stop solenoid valve is an ON-OFF type
solenoid valve.
Emergency Stop Pilot Shut-Off Valve

Solenoid Valve
T1SM-03-07-100
(Seen from Floor Bottom)
T3-7-6
When neutral:
The pressure oil flows from the pilot relief valve to se-
lector valve port P1 and unload valve port P2. In the
unload valve, port P2 is connected to port A so that
the pressure oil flows from port A to the pilot shut-off
valve. When neutral, selector valve port S is con- Selector
nected to port DR. Port DR is connected to the hy- Valve
draulic oil tank. Spool Port S Port P2
Port P1
Port DR Unload Valve Port A
T1CF-03-06-003
When operated:
When the selector valve solenoid is activated, the
spool is moved, causing port P1 to connect to port S.
Then, the pilot pressure oil in port P1 is routed into the
pilot chamber in the unload valve via port S. The oil Spool
pressure routed into the pilot chamber acts on the Pilot Cham-
Port P1 Port S ber Sleeve
sleeve. When the pilot oil pressure overcomes the
spring force, the sleeve is moved downward. When
the sleeve is moved downward, the pilot pressure oil
flowing to the pilot shut-off valve from port P2 via port
A is blocked by the sleeve.
Spring Port A Port P2
T1CF-03-06-004
T3-7-7
OFFSET ANTI-DRIFT VALVE Port PL
(ZAXIS 135UR ONLY)
Port B
The front attachment may be drifted to the right if the Offset Cylin-
front attachment is taken in such position as its der
self-weight is loaded to the offset cylinder. The
anti-drift valve is provided in the offset cylinder rod Port A
side circuit to prevent the offset cylinder from drifting.
Offset
Anti-Drift Valve Port DR
Left Right
Offset Spool in Control T1CF-03-06-013
Valve
When the offset cylinder control valve spool is in When Neutral : Port A
neutral: (Control Valve)
In case the front attachment self-weight is loaded to
the offset cylinder so that it is extended, the oil
pressure in the offset cylinder rod side increases.
Poppet
The increased oil pressure in the offset cylinder rod Port B
side is routed to port B and flows into the chamber (Offset Cyl-
under the poppet via passages “a” and “b.” Then, the inder Rod
Side)
poppet is pushed upward, closing port A. Therefore,
the pressure oil in the offset cylinder rod side circuit
cannot flow to port A from port B, preventing the off-
Passage b
set cylinder from drifting.
Passage a
T1CF-03-06-008
T3-7-8
When offsetting front attachment to the left:
When the front attachment is offset to the left, the When Operating Left Offset :
system pressure oil from the control valve is routed Port A
to port A. Then, the pressure oil pushes the poppet (Control Valve)
downward so that the pressure oil flows to port B.
The pressure oil from port B is routed into the offset
cylinder rod side, allowing the front attachment to
offset to the left.
Port B
(Offset
Cylinder
Rod Side)
T1CF-03-06-009
When offsetting the front attachment to the right:

When the front attachment is offset to the right, the When Operating Right Offset :
right offset pilot pressure oil is routed to port PL, Port A
(Control Valve)
causing the spool in the anti-drift valve to move up-
ward. Then, the passage C is opened to the drain
passage. Therefore, the pressure oil in the spring
chamber flows to port DR via passages “b, a, and c.” Poppet
Thereby, the return oil from the offset cylinder rod Port B
(Offset Cyl-
can flow from port B to port A while pushing the pop- inder
pet downward. Rod Side)
Passage c
Passage b
Spool
Passage a Drain Pas-

sage
Port PL
(Right Offset
Pilot Pres-
sure)
Port DR
T1CF-03-06-010
T3-7-9
HOLDING VALVE
(Only on the machines equipped with the corre-
sponding optional parts.)
The holding valves function to hold the front attach-

ment in position if any hose for the front attachment is
punctured accidentally. The holding valves are at-
tached to the bottom side of the boom cylinder, the Chamber a Passage c Passage b
rod side of the arm cylinder, and the rod side of the
positioning cylinder.
NOTE: The following explanation will be made
about the holding valve for the boom cyl-
inder as an instance.
• Holding valve operation when the control lever is

in neutral.
Pilot
1. Because the pilot pressure Pi does not act on the Pressure
spool, the spool remains in neutral. Pi
2. The cylinder-holding pressure at the cylinder port Port B Spool
B is applied to the poppet and to the spool
Port A Poppet Passage a
through passage c. To the Spool
3. The cylinder-holding pressure, after passing in the Control T178-03-07-006
Valve
through passage c, is blocked by the spool. The
pressure in the chamber a is applied to the spool
through passage c, but not transmitted to pas-
sage a by blocking with the spool.
4. As a result, the cylinder pressure at cylinder port
B is maintained unchanged. Therefore, even if
any hose at the front attachment is punctured,
the front attachment is held in position to avoid
unintended lowering.
T3-7-10
X Section X-X Passage a
Passage b
Spool
Passage c
Chamber a
Poppet
Port A Port B
X
T178-03-07-008
T3-7-11
• Holding valve operation when the boom lower
control lever is operated The Boom Lower Control Lever: Half Stroke or less
1. When moving the boom lower control lever at half
stroke or less, the pilot pressure Pi acts on the Chamber a Passage c Passage b Relief
spool, and makes the spool move to the orifice B Valve
position.
2. At this time, the spool blocks passage B, so that
the poppet is pushed against the seat.
3. As a result, the pressurized oil from the port B Orifice A
flows through passages c and a in order to lower
Poppet
the boom.
4. When moving the boom lower control lever at half
stroke or more, the pilot pressure Pi acts on the
Pressure
spool, and makes the spool shift to the orifice C Pi
position.
5. Then, passages b and a are connected through Port B
Spool
orifice C. At this time, an oil passage, from port B Port A
to orifice A to chamber a to passage b to orifice C To the Spool
to passage a to port A, is opened. in the Con- Seat Passage a Orifice B
6. The oil from passage c is blocked by the spool, trol Valve T178-03-07-009
so that the oil does not flow into passage a.

7. The pressure in the chamber a lowers, and the
poppet rises accordingly, so that the return oil
from the cylinder port B flows into port A through
the poppet to lower the boom.
The Boom Lower Control Lever: Half Stroke or More
Chamber a Passage c Passage b Relief
Valve
Passage A
Orifice C
Pressure
Pi
Port B
Spool
Port A To the Spool Poppet Passage a

in the Con-
trol Valve T178-03-07-007
T3-7-12
Section X-X
X Relief Valve
Passage a
Orifice B Spool
Pressure Pi
Orifice C Passage b
Passage c Chamber a
Spring
Orifice A
From Port B
Poppet
Port A Port B
X
T178-03-07-008
T3-7-13
PILOT RELIEF VALVE
Pilot Relief
Valve
The pilot relief valve has a pilot filter incorporated.
The pilot relief valve functions to regulate the pilot
P
pump pressure oil routed to port P to a set constant
pressure.
Pilot Filter
T178-03-07-001
Output Output Worm

EC MOTOR Gear Shaft Gear
The EC motor is used to control the engine speed. A

worm gear is incorporated into the EC motor to
prevent a loss of synchronism from occurring. The EC
sensor is provided to detect the degrees of the EC
motor rotation to calculate the governor lever position.
(Refer to the Control System Group in SYSTEM
Section.)
Motor
Sensor EC Worm
Gear Sensor Wheel
T157-02-05-018
T3-7-14
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure and The internal gear of inner race (3) engages with the
allows the upperstructure to rotate smoothly. The output shaft of the swing reduction gear.
bearing is a single-row shear ball-type bearing,
comprising outer race (1), inner race (3), balls (6),
supports (5), and seals (2) and (4). Outer race (1) is
bolted to the upperstructure and inner race (3) is
bolted to the undercarriage.
T135-03-02-001
1 - Outer Race 3 - Inner Race 5 - Support 6 - Ball

2 - Seal 4 - Seal
T3-8-1
CENTER JOINT
The center joint is a 360° rotating joint. When the Hydraulic oil flows to the right and left travel motors
upperstructure is rotated, the center joint avoids and blade cylinder (ZAXIS135UR only) via the spindle
twisting of hoses and allows the hydraulic oil to flow and the oil ports of the body. The seals prevent oil
smoothly to or from the travel motors and blade leaks between the spindle and body into adjacent
cylinder (ZAXIS135UR only). The spindle is attached passages.
to the upperstructure and the body is bolted to the
swing center of the undercarriage.
ZAXIS110, 120, 130, 130LCN, 125US, 135US
Left Travel Right Travel Left Travel Right Travel

Motor (Reverse) Motor (Forward) Motor (Forward) Motor (Forward)
Left Travel Right Travel
Motor (Reverse) Motor (Reverse)
Motor (Forward) Motor (Reverse)
Spindle
Pilot Pressure Pilot Pressure

for Travel Mode Control Drain for Travel Mode
Control
Body
Drain
Drain Seal
Drain
: Forward
: Reverse
: Pilot Pressure
for Travel Mode Control
T157-03-02-004
T3-8-2
ZAXIS135UR
Left Travel Mo- Right Travel

tor (Forward) Motor (Forward)

Motor (Reverse) Motor (Reverse)
Left Travel Mo- Right Travel Mo-

tor (Forward) tor (Forward) Blade Drain
Travel Forward / Blade Raise Lower
Left Travel Motor Right Travel Spindle
Travel Reverse / Blade Lower (Reverse) Motor (Reverse)
Blade
Raise Body
Drain Seal
Pilot Pressure
Blade
Blade Lower
Blade Raise
Blade
Lower Raise
Drain
T1SM-03-08-001
T3-8-3
TRACK ADJUSTER
The track adjuster located on the side frame is
composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.
• Grease is applied through grease fitting into

chamber (a) of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes piston
rod (8) out and decreases track sag.
1
• To increases track sag, loosen valve (1) 1 to 1.5 Grease Fitting
turns counterclockwise to release grease from
the track adjuster cylinder through the grease
discharge hole.
CAUTION: Do not loosen valve (1) quickly or

loosen too much since high-pressure grease
in the adjusting cylinder may spout out.
Loosen carefully, keeping body parts and
face away from valve (1).
Grease Discharge Hole
Never loosen grease fitting.
M104-07-119
3 4 a
1 2 5 6 7 8
W178-03-04-002
1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-8-4
MEMO
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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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PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
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FAX:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

Manual No. : KM-187E
Vol. No. : TT187-E-04
110 110M 120 130 130LCN 125US 135US 135UR Excavator Technical Manual (Troubleshooting)
Technical Manual
(Troubleshooting)
110 125US
110M 135US
120 135UR
130
130LCN
Excavator
Zaxis110..135UR-TM/TSh 1 14/11/03, 12:54 PM

INTRODUCTION
TO THE READER
age.):
TEL: 81-29-832-7084
FAX: 81-29-831-1162
MANUAL COMPOSITION
IN-01
INTRODUCTION
PAGE NUMBER

Example : T 1-3-5

Group Number
Section Number

NOTATIONS
• CAUTION:
heavy parts.
IN-02
INTRODUCTION
UNITS USED
this manual.
From From
mm ft 0.003281 MPa psi 145.0
L US qt 1.057 kW HP 1.341
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
• 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.
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
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).
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 AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Troubleshooting D
Group 7 Electrical System Inspection
Group 8 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications 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
All information, illustrations and speci- Group 2 Front Control System Group 6 Signal Control Valve
fications in this manual are based on Group 3 Hydraulic System Group 7 Others (Upperstructure)
the latest product information available Group 4 Electrical System Group 8 Others (Undercarriage)
at the time of publication. The right is
reserved to make changes at any time WORKSHOP MANUAL
without notice. SECTION 1 GENERAL INFORMA- Group 9 Signal Control Valve
TION Group 10 Solenoid Valve Unit
Group 1 Precautions for Disassem- Group 11 Holding Valve
bling and Assembling SECTION 3 UNDERCARRIAGE
Group 2 Tightening Torque Group 1 Swing Bearing
Group 3 Painting Group 2 Travel Device
SECTION 2 UPPERSTRUCTURE Group 3 Center Joint
COPYRIGHT(C)2003 Group 1 Cab Group 4 Track Adjuster
Hitachi Construction Machinery Co., Ltd. Group 2 Counterweight Group 5 Front Idler
Tokyo, Japan Group 3 Main Frame Group 6 Upper and Lower Roller
All rights reserved Group 4 Pump Device Group 7 Track
Group 5 Control Valve SECTION 4 FRONT ATTACHMENT
Group 6 Swing Device Group 1 Front Attachment
Group 7 Pilot Valve Group 2 Cylinder
Group 8 Pilot Shut-Off Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Operational Performance Tests....................T4-1-1 ZAXIS135UR Dr. ZX Monitor Indicating
Preparation for Performance Tests...............T4-1-2 Values..................................................... T4-2-50
Sensor Operational Range Table............... T4-2-56
Group 2 Standard Group 3 Engine Test
ZAXIS110 Operational Performance Engine Speed............................................... T4-3-1
Standard Table............................................T4-2-1 Engine Compression Pressure .................... T4-3-4
ZAXIS110M Operational Performance Valve Clearance Adjustment........................ T4-3-6
Standard Table............................................T4-2-5 Nozzle Check............................................... T4-3-8
ZAXIS120/130/130LCN Operational Injection Timing .......................................... T4-3-10
Performance Standard Table ......................T4-2-9 Lubricant Consumption.............................. T4-3-12
ZAXIS125US Operational Performance
Standard Table..........................................T4-2-13 Group 4 Excavator Test
ZAXIS135US Operational Performance Travel Speed ................................................ T4-4-1
Standard Table..........................................T4-2-17 Track Revolution Speed............................... T4-4-2
ZAXIS135UR Operational Performance Mistrack Check ............................................ T4-4-3
Standard Table..........................................T4-2-21 Travel Parking Function Check.................... T4-4-4
Main Pump P-Q Diagram ...........................T4-2-26 Swing Speed ................................................ T4-4-5
Injection Pump............................................T4-2-28 Swing Function Drift Check ......................... T4-4-6
ZAXIS110 Dr. ZX Monitor Indicating Swing Motor Leakage .................................. T4-4-8
Values .......................................................T4-2-30 Maximum Swingable Slant Angle .............. T4-4-10
ZAXIS110M Dr. ZX Monitor Indicating Swing Bearing Play.................................... T4-4-11
Values .......................................................T4-2-34 Hydraulic Cylinder Cycle Time................... T4-4-12
ZAXIS120/130/130LCN Dr. ZX Monitor Dig Function Drift Check............................ T4-4-14
Indicating Values ......................................T4-2-38 Control Lever Operating Force .................. T4-4-18
ZAXIS125US Dr. ZX Monitor Indicating Control Lever Stroke .................................. T4-4-20
Values .......................................................T4-2-42 Bucket/Cab Collision Prevention System
ZAXIS135US Dr. ZX Monitor Indicating (ZAXIS135UR Only) ............................... T4-1-22
Values .......................................................T4-2-46 Combined Boom Raise/Swing
Function Check ........................................ T4-4-24
Boom Raise and Arm Roll-In
Combined Operation .............................. T4-4-25
187T-4-1
Group 5 Component Test
Primary Pilot Pressure..................................T4-5-1
Secondary Pilot Pressure.............................T4-5-4
Solenoid Valve Set Pressure........................T4-5-6
Main Pump Delivery Pressure......................T4-5-9
Main Relief Valve Set Pressure..................T4-5-10
Relief Pressure (When reliving Swing).......T4-5-14
Relief Pressure (When reliving Travel).......T4-5-16
Overload Relief Valve Set Pressure...........T4-5-18
Main Pump Flow Rate Measurement.........T4-5-22
Swing Motor Drainage................................T4-5-28
Travel Motor Drainage................................T4-5-32
Group 6 Adjustment
Assembly and Adjustment of Link for Arm
Angle Sensor (ZAXIS135UR Only) ............T4-6-1
Adjusting Method of Front Acceleration/
Deceleration Speed (ZAXIS135UR Only) ..T4-6-2
Initial Setting of Angle Sensor
(ZAXIS135UR Only) ...................................T4-6-3
Initializing Depth Limit Control System
(ZAXIS135UR Only) ...................................T4-6-4
Engine Speed Adjustment and Engine
Learning......................................................T4-6-6
Governor Lever/Fuel Cut Lever Position......T4-6-8
187T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
leaking oil. Use oil pans to catch escaping oil.

Pay special attention to this when removing hy-
draulic pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
ZAXIS110 OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure: NOTE: 1 mm=0.03937 in
ZAXIS110
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 1000±100 Value indicated on Dr.ZX
Fast Idle Speed (Normal) 1915±50 ↑
Fast Idle Speed (With ECO deactivated) 1915±50 ↑
Fast Idle Speed (Relief operation) 1960±50 Extend the boom cylinder to
relieve the boom raise
circuit.
Fast Idle Speed (E mode) 1915±70 Value indicated on Dr.ZX
Fast Idle Speed (HP mode) 2150 or more Extend the boom and arm
cylinder to relieve the boom
raise and arm roll-in circuit.
Auto-Idle Speed 1240±100 Value indicated on Dr.ZX
Auto-Acceleration Speed 1725±70 ↑
Warming Up Speed 1190±100 ↑
ENGINE COMPRESSION PRESSURE 2.95 (30.0, 427) T4-3-4
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) mm 0.4 With the engine cold T4-3-6
NOZZULE INJECTION PRESSURE 18.1 (185, 2630) T4-3-8
2
MPa (kgf/cm , psi)
INJECTION TIMING (Degrees before TDC) deg. 9° T4-3-10
LUBRICANT CONSUMPTION mL/h 40 or less Hour meter: 2000 hours or T4-3-12
less
TRAVEL SPEED sec/10 m T4-4-1
Fast Speed 6.5±0.6
Slow Speed (10.5±1.0)
T4-2-1
ZAXIS110
Reference
Page
Standard)
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 13.8±1.0
MISTRACK mm/20 m 200 or less T4-4-3
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 12.9±1.1 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK mm /180° 860 or less 2.26 m Arm T4-4-6
0.45 m3 (PCSA heaped)
bucket, bucket empty
SWING MOTOR LEAKAGE mm/5 min 0 2.26 m Arm T4-4-8
bucket, bucket loaded
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to 3.05 T4-4-11
MAXIMUM SWINGABLE SLANT ANGLE deg. 21° or possibly Bucket loaded T4-4-10
more
HYDRAULIC CYLINDER CYCLE TIME sec 2.26 m Arm T4-4-12
Bucket, bucket empty
Boom Raise 2.9±0.3
Boom Lower 2.3±0.3
Arm Roll-In 2.9±0.3
Arm Roll-Out 2.2±0.3
Bucket Roll-In 3.3±0.3
Bucket Roll-Out 2.4±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.26 m Arm T4-4-14
Bucket
Boom Cylinder (Maximum Reach Position) 10 or less Bucket loaded
(Arm Roll-In Position) 5 or less Bucket empty
Arm Cylinder (Maximum Reach Position) 20 or less Bucket loaded
Bucket Cylinder (Maximum Reach Position) 15 or less Bucket loaded
Bucket Bottom (Maximum Reach Position) 150 or less Bucket loaded
NOTE: 1 mm=0.03937 in
T4-2-2
ZAXIS110
Reference
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI Lever Pattern T4-4-18
N (kgf, lbf)
Boom Lever 18 (1.8, 4.4) or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 3.3) or less
Bucket Lever 15 (1.5, 3.3) or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 4.4) or less
Travel Lever 28 (2.8, 6.2) or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-20
Boom Lever 105±10
Arm Lever (ISO Lever Pattern: Swing Lever) 84±10
Bucket Lever 84±10
Swing Lever (ISO Lever Pattern: Arm Lever) 105±10
Travel Lever 120±10
BOOM RAISE/SWING (Bucket Empty) sec 2.26 m Arm T4-4-24
3.1±0.3 0.45 m3 (PCSA heaped)
Bucket
(Bucket Teeth Height: H) mm 5400 or more
BOOM RAISE/ARM ROLL-IN (Bucket Empty) 2.26 m Arm T4-4-25
sec 4.3±0.5 0.45 m3 (PCSA heaped)
Bucket
PRIMARY PILOT PRESSURE 2
MPa (kgf/cm , psi) T4-5-1
Engine: Fast Idle 4.0+1.0-0.5
(40 -5, 570+142-71)
+10
Engine: Slow Idle 3.5+1.0-0.5

(35 -5, 500+142-71)
+10
SECONDARY PILOT PRESSURE) Value indicated on T4-5-4

3.4 to 4.0 (34 to 40,
(Engine: Fast Idle and Slow Idel) Dr.ZX
483 to 570)
2
MPa (kgf/cm , psi) (Lever: Full Stroke)
SOLENOID VALVE SET PRESSURE Value Indicated On T4-5-6
2
MPa (kgf/cm , psi) Dr. ZX±0.2 (2, 28)
T4-2-3
ZAXIS110
Reference
Page
Standard)
MAIN PUMP DELIVERY PRESSURE 0.7+1.0-0.7 Value indicated on T4-5-9
2
MPa (kgf/cm , psi) +10 +142 Dr.ZX
(7 -7, 100 -100)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 (350+20-5, Value indicated on
4980+284-71) Dr.ZX
RELIEF PRESSURE 33.5+2.0-0.5 (340+20-5, Value indicated on T4-5-14
2
(When relieving Swing) MPa (kgf/cm , psi) 4835+356-71) Dr.ZX
2
(When relieving Travel) MPa (kgf/cm , psi) 4980+284-71) Dr.ZX
OVERLOAD RELIEF VALVE SET PRESSURE (Reference values T4-5-16
2
MPa (kgf/cm , psi) at 50 L/min)
Boom (Raise/Lower), Arm Roll-In, and 37.3+1.0-0
Bucket Roll-In (380+10-0, 5400+142-0)
Arm Roll-Out, Bucket Roll-Out 39.2+1.0-0
(400+10-0, 5690+142-0)
MAIN PUMP FLOW TEST (L/min) - Refer to page T4-2-26, T4-5-20
27
SWING MOTOR DRAINAGE (L/min) T4-5-26
With constant maximum speed 0.4 or less Allowable Limit: 0.6
With the motor relieved 1.6 or less Allowable Limit: 2.0
TRAVEL MOTOR DRAINAGE (L/min) T4-5-30
With the track jacked up 5 or less Allowable Limit: 5
With the motor relieved 8 or less Allowable Limit: 8
T4-2-4
ZAXIS110M OPERATIONAL
ZAXIS110M
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Fast Idle Speed (Relief operation) 1960±50 Extend the boom cylinder to
relieve the boom raise
circuit.
MPa (kgf/cm , psi)
NOZZULE INJECTION PRESSURE 18.1 (185, 2630) T4-3-8
2
MPa (kgf/cm , psi)
less
Fast Speed 8.7±0.5
T4-2-5
ZAXIS110M
Reference
Page
Standard)
Slow Speed 34.5±2.0
bucket, bucket empty
bucket, bucket loaded
more
Boom Raise 2.9±0.3
Boom Lower 2.3±0.3
Bucket
NOTE: 1 mm=0.03937 in
T4-2-6
ZAXIS110M
Reference
Page
Standard)
N (kgf, lbf)
Boom Lever 105±10
Bucket Lever 84±10
3.1±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
483 to 570)
2
2
T4-2-7
ZAXIS110M
Reference
Page
Standard)
2
MPa (kgf/cm , psi) +10 +142 Dr.ZX
(7 -7, 100 -100)
2
MPa (kgf/cm , psi)
4980+284-71) Dr.ZX
(When relieving Swing) 2
MPa (kgf/cm , psi) 4835+356-71) Dr.ZX
(When relieving Travel) 2
MPa (kgf/cm , psi) 4980+284-71) Dr.ZX
2
Bucket Roll-In (380+10-0, 5400+142-0)
(400+10-0, 5690+142-0)
27
Continuous Pressure 2
MPa (kgf/cm , psi) (0.2 (2.0, 28)) Measured at test stand
Maximum Instantaneous Pressure (0.5 (5.0, 71)) Measured at test stand
2
MPa (kgf/cm , psi)
T4-2-8
ZAXIS120/130/130LCN OPERATIONAL
ZAXIS120/130
ZAXIS130LCN Reference
PERFORMANCE TEST DESIGNATION Remarks
(Performance Page
Standard)
ENGINE SPEED min-1 T4-3-1
Fast Idle Speed (Relief operation) 1960±50 Extend the boom cylinder
to relieve the boom raise
circuit.
cylinder to relieve the
boom raise and arm roll-in
circuit.
(After engine warm-up) MPa (kgf/cm2, psi)
NOZZULE INJECTION PRESSURE 18.1 (185, T4-3-8
MPa (kgf/cm2, psi) 2630)
less
Fast Speed 6.5±0.6
T4-2-9
ZAXIS120/130
(Performance Page
Standard)
Bucket, bucket loaded
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to T4-4-11
3.05
more
Boom Raise 3.1±0.3
Boom Lower 2.2±0.3
HYDRAULIC CYLINDER CYCLE TIME sec ZAXIS130 2P Boom, 2.1m Arm
ZAXIS130 2P Boom + 2.1 m Arm (2P Boom,
2.1 m Arm)
Boom Raise 4.0±0.3
Boom Lower 3.5±0.3
2nd Boom Raise 4.2±0.3
2nd Boom Lower (with HRV) 3.8±0.3
2nd Boom Lower (without HRV) 3.6±0.3
NOTE: 1 mm=0.03937 in
T4-2-10
ZAXIS120/130
(Performance Page
Standard)
Bucket
Positioning Cylinder 2P Boom + 2.1 m Arm
ZAXIS130 2P Boom + 2.1 m Arm only
(Maximum Reach Position) 40 or less
(Arm Roll-In Position) 30 or less
N (kgf, lbf)
Boom Lever 18 (1.8, 4.4) or
less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 3.3) or
less
Bucket Lever 15 (1.5, 3.3) or
less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 4.4) or
less
Travel Lever 28 (2.8, 6.2) or
less
Boom Lever 105±10
Bucket Lever 84±10
3.3±0.3 0.50 m3 (PCSA heaped)
Bucket
(Bucket Teeth Height: H) ZAXIS130 2P Boom 4500 or more ZAXIS130 2P Boom
2.1 m Arm only 2.1 m Arm only
NOTE: 1 mm=0.03937 in
T4-2-11
ZAXIS120/130
(Performance Page
Standard)
Bucket
(40 -5, 570+142-71)
+10
Engine: Slow Idle 3.5+1.0-0

(35 -0, 500+142-0)
+10
SECONDARY PILOT PRESSURE) Value indicated on Dr.ZX T4-5-4

3.4 to 4.0 (34 to
(Engine: Fast Idle and Slow Idel) (Lever: Full Stroke)
2 40, 483 to 570)
MPa (kgf/cm , psi)
SOLENOID VALVE SET PRESSURE Value Indicated T4-5-6
2
MPa (kgf/cm , psi) On Dr. ZX±0.2 (2,
28)
MAIN PUMP DELIVERY PRESSURE 0.7+1.0-0.7 Value indicated on Dr.ZX T4-5-9
2
MPa (kgf/cm , psi) +10 +142
(7 -7, 100 -100)
2
MPa (kgf/cm , psi)
Boom, Arm 34.5+2.0-0.5 Value indicated on Dr.ZX
(350+20-5,
4980+284-71)
Bucket 35.5+2.0-0.5 Value indicated on Dr.ZX
(360+20-5,
5120+284-71)
RELIEF PRESSURE 34.5+2.0-0.5 Value indicated on Dr.ZX T4-5-14
(When relieving Swing) 2
MPa (kgf/cm , psi) (350+20-5,
4980+284-71)
RELIEF PRESSURE T4-5-15
(When relieving Travel) 2
MPa (kgf/cm , psi)
(When relieving both travel levers) 34.5+2.0-0.5 Value indicated on Dr.ZX
(350+20-5,
4980+284-71)
(When relieving one travel lever) 35.5+2.0-0.5 Value indicated on Dr.ZX
(360+20-5,
5120+284-71)
T4-2-12
ZAXIS120/130
(Performance Page
Standard)
2
Bucket Roll-In (380+10-0,
5400+142-0)
(400+10-0,
5690+142-0)
MAIN PUMP FLOW TEST (L/min) － Refer to page T4-2-22, T4-5-20
23
T4-2-13
(Blank)
T4-2-14
ZAXIS125US OPERATIONAL
ZAXIS125US
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 950±100 Value indicated on Dr ZX.
Fast Idle Speed (Relief operation) 1950 or more Extend the boom cylinder
circuit.
ENGINE COMPRESSION PRESSURE 2.95 (30.0, T4-3-4
MPa (kgf/cm , psi) 427)
2
less
Fast Speed 6.9±0.6
T4-2-15
ZAXIS125US
Reference
Page
Standard)
more
Boom Raise 3.8±0.3
Boom Lower 3.2±0.3
Blade Raise 2.4±0.3
Blade Lower 2.6±0.3
Bucket
Blade Cylinder (Maximum Raise Position) 5 or less
NOTE: 1 mm=0.03937 in
T4-2-16
ZAXIS125US
Reference
Page
Standard)
N (kgf, lbf)
Blade Lever 33 (3.3, 24) or less
Boom Lever 105±10
Bucket Lever 84±10
Blade Lever 120±10
3.5±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
483 to 570)
2
T4-2-17
ZAXIS125US
Reference
Page
Standard)
2
2
MPa (kgf/cm , psi) Dr.ZX
(7+10-7, 100+142-100)
2
MPa (kgf/cm , psi)
4980+284-71) Dr.ZX
2
2
2
Bucket Roll-In (380+10-0, 5400+142-0)
(400 -0, 5690+142-0)
+10

27
With the motor relieved 1.6 or less Allowable Limit: 2.0 T4-5-30
TRAVEL MOTOR DRAINAGE (L/min)
T4-2-18
ZAXIS135US OPERATIONAL
ZAXIS135US
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
circuit.
MPa (kgf/cm , psi)
2
less
T4-2-19
ZAXIS135US
Reference
Page
Standard)
more
Boom Raise 3.3±0.3
Boom Lower 2.9±0.3
Bucket
(Arm Roll-In position) 5 or less Bucket empty
NOTE: 1 mm=0.03937 in
T4-2-20
ZAXIS135US
Referenc
e Page
Standard)
N (kgf, lbf)
Boom Lever 105±10
Bucket Lever 84±10
Blade Lever 120±10
3.3±0.3 0.50 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
2 483 to 570)
MPa (kgf/cm , psi)
T4-2-21
ZAXIS135US
Reference
Page
Standard)
2
2
MPa (kgf/cm , psi)
(7+10-7, 100+142-100)
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.5+2.0-0.5 (350+20-5, Value indicated on Dr.ZX
4980+284-71)
RELIEF PRESSURE 33.5+2.0-0.5 (340+20-5, Value indicated on Dr.ZX T4-5-14
2
(When relieving Swing) MPa (kgf/cm , psi) 4835+356-71)
RELIEF PRESSURE 34.5+2.0-0.5 (350+20-5, Value indicated on Dr.ZX T4-5-15
2
(When relieving Travel) MPa (kgf/cm , psi) 4980+427-284)
2
Bucket Roll-In (380+10-0, 5400+142-0)
(400 -0, 5690+142-0)
+10

27
T4-2-22
ZAXIS135UR OPERATIONAL
ZAXIS135UR
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
circuit.
cylinder to relieve the
boom raise and arm roll-in
circuit.
ENGINE COMPRESSION PRESSURE 2.95 (30.0, T4-3-4
2
less
Fast Speed 7.9±0.6
T4-2-23
ZAXIS135UR
Reference
Page
Standard)
TRAVEL MOTOR LEAK mm/5 min 0 T4-4-4
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to T4-4-11
3.05
more
Boom Raise 4.0±0.3
Boom Lower 3.3±0.3
Left Offset (Offset Switch) 2.7±0.5
(5.0±2.5)
Right Offset (Offset Switch) 3.4±0.5
(5.0±2.5)
NOTE: 1 mm=0.03937 in
T4-2-24
ZAXIS135UR
Reference
Page
Standard)
Bucket
Blade Cylinder 5 or less
Blade Lower Amount 20 or less
Offset Cylinder 10 or less
N (kgf, lbf)
Offset Pedal 150 (15.3, 133.8) or
less
Boom Lever 105±10
Bucket Lever 84±10
Blade Lever 50±15
Offset Pedal 14±10
T4-2-25
ZAXIS135UR
Reference
Page
Standard)
3.3±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
BUCKET/CAB COLLISION PREVENTION SYSTEM mm T4-4-22
Cab Front (235)
Side of Cab (220)
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
2 483 to 570)
MPa (kgf/cm , psi)
2
2
MPa (kgf/cm , psi) +10 +142
(7 -7, 100 -100)
T4-2-26
ZAXIS135UR
Reference
Page
Standard)
2
MPa (kgf/cm , psi)
4980+284-71) Dr.ZX
2
2
Blade 20.6+2.0-0.5 (210+20-5
2990+284-71)
Offset 28.4+3.0-0.5 (290+30-5,
4120+427-71)
2
Bucket Roll-In (380 -0, 5400+142-0)
+10

(400 -0, 5690+142-0)
+10
Blade Raise 27.5+1.0-0

(280 -0, 3980+142-0)
+10
Blade lower 39.2+1.0-0

(400 -0, 5960+142-0)
+10

27
T4-2-27
MAIN PUMP P-Q DIAGRAM
• Hydraulic P-Q Control
(REFERENCE: Measured at Test Stand)
• Rated Pump Speed: 1950 min-1 (rpm)

(This pump device is not equipped with a trans-
mission so that the pump speed is equal to the
engine speed. Therefore, measure the pump flow
rate with the engine running at the rated pump
speed.)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-20.
• ZAXIS110/110M/125US/135UR Points on P-Q Line • ZAXIS120/130/130LCN/135US Points on P-Q Line

Delivery Pressure Flow Rate Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm) 2
MPa (kgf/cm , psi) L/min (gpm)
A 3.9 (40, 570) 100±2 (26.4±0.5) A 3.9 (40, 570) 105±2 (27.7±0.5)
B 14.7 (150, 2135) [99 (26.1)] B 15.5 (158, 2250) [104 (27.5)]
C 17.2 (175, 2490) 86±4 (22.7±1.0) C 17.2 (175, 2490) 94±4 (24.8±1.0)
D 19.2 (196, 2790) [73 (19.3)] D 20.1 (205, 2915) [78 (20.6)]
E 23.0 (235, 3345) 63±4 (16.6±1.0) E 24.5 (250, 3555) 66±4 (17.4±1.0)
F 34.3 (350, 4780) [30±6 (7.9±1.6)] F 34.3 (350, 4780) [35±6 (9.2±1.6)]
The value indicated in parentheses is only a reference The value indicated in parentheses is only a reference
value. value.
L/min A
B
Flow D
Rate
Delivery Pressure MPa (kgf/cm2)

T178-04-05-001
T4-2-28
• P-Q Control by Pump Control Pilot Pressure Sig-
nal
∗ (REFERENCE: Measured at Test Stand)
• Rated Pump Speed: 1950 min-1 (rpm)

(This pump device is not equipped with a trans-
mission so that the pump speed is equal to the
engine speed. Therefore, measure the pump flow
rate with the engine running at the rated pump
speed.)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-22.
• ZAXIS110/110M/125US/135UR Points on P-Q Line • ZAXIS120/130/130LCN/135US Points on P-Q Line

Pump Control Flow Rate Pump Control Flow Rate
pressure L/min (gpm) pressure L/min (gpm)
MPa (kgf/cm2, psi) MPa (kgf/cm2, psi)
A Q minimum 35±2 (9.2±0.5) A Q minimum 35±2 (9.2±0.5)
1.96±0.05 (20±0.5, 55±1 (14.5±0.3) 1.96±0.05 (20±0.5, 55±1 (14.5±0.3)
B B
284±7) 284±7)
2.9+0−0.3 2.9+0−0.3
C 100±2 (26.4±0.5) C 105±2 (27.7±0.5)
(30 −3, 427+0−43)
+0
(30 −3, 427+0−43)
+0
The valve indicated in parentheses is only a reference The valve indicated in parentheses is only a reference
valve. valve.
L/min
C
Flow
Rate
2
Pump Control Pressure MPa (kgf/cm )
T178-04-05-002
T4-2-29
INJECTION PUMP
ZAXIS110/110M/125US/135UR
Test Conditions:
1. Injection pump: PES4A 101041-8900 8. Transfer pump pressure:
2. Governor: EP/RSV 105419-4040 157 kPa (1.6 kgf/cm2, 23 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 127 kPa (1.3
EF8511/9) kgf/cm2, 18.5 psi)
6. Nozzle opening pressure: NOTE: The nozzle test injection pressure is 17.2
17.2 MPa (175 kgf/cm2, 2490 psi) MPa (175 kgf/cm2, 2490 psi). However,
7. Test fuel: ISO 4113 or SAE J967d actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
-1 Strokes Rate Between Cylinders Fixed Remarks
Point (mm ) (mm) 3
(cm /1000 Stroke) (%)
A 1100 8.4 80±1.1 ±2 Lever Basic
C 475 Approx. 6.0 8.8±1.4 ±14 Rack
D 100 - 125±5 - Lever Rack limit
Governor adjustment
Above 14.0
13.0
Rack Limit
Idle-Sub Spring Setting

D
9.5 Governor Spring Setting
9.1±0.1 A
Pack Position
(mm)
8.4
7.9±0.1
6.5 C
6.0
5.7±0.3
300 475 (1115)

145±30 350 (440) 1125 1210
T175-04-05-001
-1
Pump Speed min (rpm)
T4-2-30
ZAXIS120/130/130LCN/135US
Test Conditions:
1. Injection pump: PES4A 101041-8900 8. Transfer pump pressure:
2. Governor: EP/RSV 105419-4040 157 kPa (1.6 kgf/cm2, 23 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 127 kPa (1.3
EF8511/9) kgf/cm2, 18.5 psi)
6. Nozzle opening pressure: NOTE: The nozzle test injection pressure is 17.2
17.2 MPa (175 kgf/cm2, 2490 psi) MPa (175 kgf/cm2, 2490 psi). However,
7. Test fuel: ISO 4113 or SAE J967d actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
-1 Strokes Rate Between Cylinders Fixed Remarks
Point (mm ) (mm) 3
(cm /1000 Stroke) (%)
A 1100 8.5 81±1.1 ±2 Lever Basic
C 475 Approx. 6.0 8.8±1.4 ±14 Rack
D 100 - 125±5 - Lever Rack limit
Governor adjustment
Above 14.0
13.0
Rack Limit
Idle-Sub Spring Setting

D
Governor Spring Setting
9.5
Pack Position 9.1±0.1 A
(mm)
8.5
8.0±0.1
6.5 C
6.0
6.0±0.3
300 475 (1115)

145±30 1130 1210
350 (430) (1120)
T176-04-05-001
-1
Pump Speed min (rpm)
T4-2-31
ZAXIS110 DR.ZX MONITOR INDICATING
VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
Reference Measured Value

Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral∗ 0.5

Boom Raise∗ 35.5 When relieving
∗
Boom Lower -
∗
Arm Roll-In 35.5 When relieving
∗
Arm Roll-Out 35.7 When relieving
∗
Bucket Roll-Out 35.7 When relieving
Bucket Roll-In* 36.0 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 35.2 When relieving
∗
Operation
∗
Control Lever in Neutral 0.5
∗
Boom Raise 35.5 When relieving
∗
Boom Lower -
∗
∗
∗
∗
Bucket Roll-In 0.8 When relieving
∗
Operation
T4-2-32

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)

∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
Boom Raise + Arm Roll-In +
Bucket Roll-In Combined 3.51 When relieving
∗
Operation
T4-2-33

Item Remarks
TARGET ENGINE SPEED (min )
-1
Fast Idle∗ 1750

Fast Idle
(When operating a control lever)∗ 1950
∗
Fast Idle (HP Mode) 2150 When reliev-
ing boom
raise circuit
∗
Fast Idle (E Mode) 1750
∗
Auto-Idle 1050
∗
Slow Idle 800
ACTUAL ENGINE SPEED (min )
-1
∗
Fast Idle 1930
Fast Idle
(When operating a control lever)
∗ 2000
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1190
∗
Slow Idle 920
ENGINE SPEED DEVIATION
-1
(min )
∗
Fast Idle 186
Fast Idle
∗ 56
∗
ing boom
raise circuit
∗
∗
Auto-Idle 134
∗
Slow Idle 128
EC ANGLE (Volt)
∗
Minimum 2.55
∗
Maximum 3.12
DIAL ANGLE (Volt)
∗
Minimum 0.44
∗
Maximum 4.25
T4-2-34

Item Remarks
BOOM RAISE PILOT
∗ 4.03 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
TRAVEL PILOT CONTROL
PRESSURE
∗∗
(MPa)
4.00
FRONT ATTACHMENT “ON-OFF” is dis-
CONTROL PRESSURE
∗
(MPa)
- played
Pump 2 Proportional Valve Lever in Neutral
Output (MPa)
3.92
Main Pump Torque Engine Slow Idle
Proportional Valve 3.73 + Travel
Output (MPa)
ARM REGENERATIVE PRO-
PORTIONAL VALVE OUTPUT
(MPa)
Lever in Neutral 1.47
Swing, Arm Roll-In, and Boom
Raise Combined Operation 2.45
TRAVEL MOTOR CONTROL Traveling, Travel
PRESSURE (MPa) 2.92 Mode Switch:
Fast
EC MOTOR POSITION (Step) When relieving
360 arm roll-in circuit
T4-2-35
ZAXIS110M DR.ZX MONITOR INDICATING
VALUES

Item Remarks

∗
Boom Lower -
∗
∗
∗
∗
Operation
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-36

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)

∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
Boom Raise + Arm Roll-In +
Bucket Roll-In Combined 3.80 When relieving
∗
Operation
T4-2-37

Item Remarks
TARGET ENGINE SPEED (min )
-1
Fast Idle∗ 1750

Fast Idle
(When operating a control lever)∗ 1950
∗
ing boom
raise and arm
roll-in circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
ACTUAL ENGINE SPEED (min )
-1
∗
Fast Idle 1970
Fast Idle
∗ 2060
∗
ing boom
raise and arm
roll-in circuit
∗
∗
Auto-Idle 1290
∗
Slow Idle 1040
-1
(min )
∗
Fast Idle 220
Fast Idle
∗ 112
∗
ing boom
raise and arm
roll-in circuit
∗
∗
Auto-Idle 248
∗
Slow Idle 244
EC ANGLE (Volt)
∗
Minimum 2.61
∗
Maximum 3.14
DIAL ANGLE (Volt)
∗
Minimum 0.52
∗
Maximum 4.33
T4-2-38

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
PRESSURE
∗∗
(MPa)
3.91
CONTROL PRESSURE
∗
(MPa)
- played
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
T4-2-39
ZAXIS120/130/130LCN DR.ZX MONITOR
INDICATING VALUES
∗
Unless specified, test under the following conditions. built-in diagnosing system.
Engine Speed: Fast Idle ∗∗
Work Mode Switch: Digging Mode

Item Remarks

∗
Boom Lower -
∗
∗
∗
Boom Raise + Arm
Roll-In + Bucket Roll-In 33.8 When relieving
∗
Combined Operation
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
Boom Raise + Arm
∗
Combined Operation
T4-2-40

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-41

Item Remarks
TARGET ENGINE SPEED -1
(min )
Fast Idle∗ 1750

Fast Idle (When operating a
control lever)∗ 1950
Fast Idle (HP Mode)∗ 2000 When reliev-
ing boom
raise circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
ACTUAL ENGINE SPEED -1
(min )
∗
Fast Idle 1890
Fast Idle
(When operating a control 1910
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1150
∗
Slow Idle 870
-1
(min )
∗
Fast Idle 142
Fast Idle
(When operating a control -34
∗
lever)
∗
Fast Idle (HP Mode) -30 When reliev-
ing boom
raise circuit
∗
∗
Auto-Idle 100
∗
Slow Idle 72
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.08
DIAL ANGLE (Volt)
Minimum∗ 0.58
Maximum∗ 4.37
T4-2-42

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
PRESSURE
∗∗
(MPa)
3.98
CONTROL PRESSURE
∗
(MPa)
- played
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
T4-2-43
ZAXIS125US DR.ZX MONITOR INDICATING
VALUES

Item Remarks

∗
Boom Lower -
∗
∗
∗
Boom Raise + Arm
∗
Combined Operation
Boom Lower∗ -
Arm Roll-In∗ 35.7 When relieving
Arm Roll-Out∗ 35.7 When relieving
Bucket Roll-Out∗ 0.8 When relieving
Bucket Roll-In∗ 0.8 When relieving
Boom Raise + Arm
Combined Operation∗
T4-2-44

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-45

Item Remarks
(min )
Fast Idle∗ 1750

∗
ing boom
raise circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
(min )
∗
Fast Idle 1950
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1250
∗
Slow Idle 1030
-1
(min )
∗
Fast Idle 192
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 208
∗
Slow Idle 236
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.12
DIAL ANGLE (Volt)
Minimum∗ 0.46
Maximum∗ 4.37
T4-2-46

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
4.62
PRESSURE
∗∗
(MPa)
4.58
CONTROL PRESSURE
∗
(MPa)
- played
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
EC MOTOR POSITION (Step)
Slow Idle (Lever in Neutral) 0.0

Fast Idle (Lever in Neutral) 280
Fast Idle (When relieving arm
344
roll-in circuit)
T4-2-47
ZAXIS135US DR.ZX MONITOR INDICATING
VALUES

Item Remarks

∗
Boom Lower -
∗
∗
∗
Boom Raise + Arm
∗
Combined Operation
Boom Lower∗ -
Boom Raise + Arm
T4-2-48

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-49

Item Remarks
(min )
Fast Idle∗ 1750

ing boom
raise circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
(min )
∗
Fast Idle 1920
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1220
∗
Slow Idle 980
-1
(min )
∗
Fast Idle 168
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 168
∗
Slow Idle 178
EC ANGLE (Volt)
Minimum∗ 2.51
Maximum∗ 3.10
DIAL ANGLE (Volt)
Minimum∗ 0.50
Maximum∗ 4.37
T4-2-50

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
4.05
PRESSURE
∗∗
(MPa)
4.03
CONTROL PRESSURE
∗
(MPa)
- played.
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
Slow Idle (Lever in Neutral) 0

roll-in circuit: ) 348
T4-2-51
ZAXIS135UR DR.ZX MONITOR INDICATING
VALUES
Measuring MC

Item Remarks

∗
Boom Lower -
∗
∗
∗
Blade Raise 35.5 When relieving
Bade Lower 35.5 When relieving
Boom Raise + Arm
∗
Combined Operation
Boom Lower∗ -
Blade Lower 0.5 When relieving
Boom Raise + Arm
T4-2-52

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-53

Item Remarks
(min )
Fast Idle∗ 1750

ing boom
raise circuit
∗
∗
Auto-Idle 1080
∗
Slow Idle 830
(min )
Fast Idle∗ 1850

ing boom
raise circuit
Fast Idle (E Mode)∗ 1880
Auto-Idle∗ 1170
Slow Idle∗ 930
-1
(min )
∗
Fast Idle 100
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 100
∗
Slow Idle 100
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.12
DIAL ANGLE (Volt)
∗
Minimum 0.42
∗
Maximum 4.47
T4-2-54

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
PRESSURE
∗∗
(MPa)
4.19
CONTROL PRESSURE
∗
(MPa)
- played.
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
Slow Idle (Lever in Neutral) 8

376
roll-in circuit: )
T4-2-55
Measuring Auto-Marccino Controller

Unless specified, test under the following conditions.
Engine Speed: Fast Idle
Auto-MARCCINO Switch: ON
Item Remarks
ANGLE SENSOR VOLTAGE (V) When in
Stroke End
Boom Raise 0.761
Boom Lower -
Arm Roll-In 4.140
Arm Roll-Out 0.703
Left Offset 3.671
Right Offset 1.210
SOLENOID VALVE CURRENT When in Neu-
(mA) tral
Boom Raise Deceleration 461
Boom Lower Deceleration 461
Arm Roll-In Deceleration 423
Arm Roll-Out Deceleration 423
Left Offset Deceleration 423
Boom Raise Acceleration 0
Arm Roll-Out Acceleration 0
Left Offset Acceleration 0
(Offset Switch) (359)
Right Offset Acceleration 0
(Offset Switch) (351)
Right Offset Deceleration 423
PILOT PRESSURE (MPa) When reliev-
ing
Boom Raise 4.18
Arm Roll-In 4.13
ANGLE SENSOR VALUE
BEFORE CORRECTING (V)
Boom 0.761
Arm 4.140
Offset 2.128
ANGLE SENSOR STANDARD
VALUE (V)
Boom 0.722
Arm 4.199
Offset 2.187
T4-2-56
SENSOR OPERATIONAL RANGE TABLE
1. Checking Method
• Hydraulic Oil Temperature: 50 ± 5 °C
• Unless specified:
Auto-Idle
Engine Power ∗
Work Mode /Auto-Accelera
Control Mode
Switch tion
Dial Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
*: The work mode switch is not equipped for
ZAXIS135UR.
• Monitor by Dr.ZX.
2. Sensor Operational Range
Sensor Operation Specification

Minimum Speed 0.3 to 1.0 V
Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Maximum Speed (Power Mode Switch: P) 3.3 to 3.7 V
EC Sensor
Maximum Speed (Power Mode Switch: HP) Maximum Speed
(Mode Switch: OFF) +0.2 V or more
Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm2)
Pilot Control Shut-Off Lever: LOCK
Pressure Sensor
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm2)
Pilot Control Shut-Off Lever: UNLOCK
Pump Control Control Lever: Neutral 1 to 1.6 MPa (10 to 16 kgf/cm2)
Pressure Sensor Control Lever: Full Stroke 2.9 to 3.9 MPa (30 to 40 kgf/cm2)
N Sensor 20°C (Between Ground to Signal) 810 ± 240 Ω
T4-2-57
(Blank)
T4-2-58
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure engine speed with the built-in diagnos-
ing system (Refer to the TROUBLESHOOTING /
General group) or Dr. ZX. If the built-in diagnos-
ing system or Dr. ZX is not available, use an en-
gine speed meter.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before

performing all other tests to check that the
engine speed meets specification.
Because, if the engine speed is not
adjusted correctly, all other performance
data will be unreliable.
Preparation: 2
1. Select the monitor function of the built-in
1
diagnosing system (or Dr.ZX). When using an
engine speed meter, install speed pickup (2) to
injection pipe (1).
2. Warm up the machine until the engine coolant

temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50±5 °C (122±9 °F).
IMPORTANT: Never attempt to the readjust

stopper (3).
T107-06-02-002
T107-06-02-001
T4-3-1
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), and fast idle (in Refer to T5-4 Troubleshooting B.
the HP mode).
NOTE: *: The work mode switch is not equipped
2. Select the switch positions and the test condi- for ZAXIS135UR.
tions corresponding to the engine speed to be
NOTE: ECO stands for the auto engine speed re-
measured as shown in the table below.
duction system by 200 min-1.
Engine Power Auto-Idle/ Auto- * Work

Control Mode Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle (Nor- Digging
Max. Speed P OFF
mal) Mode
Fast Idle Check in the Dr. ZX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle Digging Check the engine speed while
Max. Speed P OFF
(Relief operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Auto- Digging
Max. Speed P Auto-Acceleration within 3 seconds after returning
Acceleration Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Min. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
T4-3-2
ZAXIS110/110M/120/130/125US/135US
Monitor Panel Switch Panel
Engine Control Dial
Auto-Idle/
Acceleration Selector
Power Mode Switch
Work Mode
Switch
T178-01-01-003
T178-01-01-004
ZAXIS135UR Monitor Panel
Power Mode
Switch
Auto-Idle/
Acceleration
Engine Control Selector
Dial
T1CF-01-01-003
T1SM-01-02-014
T4-3-3
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a decline in engine power.
2. Check exhaust gas color and the amount of

blow-by gas from the crankcase. Keep track of
engine oil consumption.
3. Check for abnormalities in the intake system,

including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature

gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each T105-06-02-001
cylinder.
NOTE: Unless the fuel delivery pipes are discon-

nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase.
5. Install an adaptor (Isuzu 5-85317-001-0) and

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adaptor and compression gauge to prevent air
leakage.)
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each

cylinder and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to engine shop manual.
T4-3-4
(Blank)
T4-3-5
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting work, clean the head cover

mounting area to avoid contamination in the
engine.
Preparation:
1. Locate the top dead center (TDC) in the Top Mark
compression stroke.
Align the TDC mark on the crank pulley with the
TDC Mark
pointer located on the timing gear case as
illustrated. Piston No.1(or piston No.6) is now
positioned at the TDC in its compression stroke. Timing Gear
Case
NOTE: When rotating the crank pulley, remove the Crank Pulley
fan guard. Then, rotate the fan while hold-
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the head cover.
3. Move push rods for the intake and exhaust

valves on the No.1 cylinder up and down by hand.
If any clearances on the both ends of the push
rods are found, piston No.1 is positioned at TDC
in the compression stroke. (If the exhaust valve
of cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.4) positioned at TDC in the compression
stroke.
Measurement:
1. Insert a thickness gauge into the clearance
between the rocker arm and the valve stem end
to measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to

No.4 in that order, as viewed from the fan
side .
T107-02-12-005
T4-3-6
2. When the measurement is started from No.1
cylinder, perform the same measurement to all
valves indicated with the mark “○” in the table
below. (When the measurement is started from
No.4 cylinder, perform the measurement in the
valves shown with mark “×”.)
Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
{ { { {
started from No.1 cylinder
When the measurement is
× × × ×
started from No.4 cylinder
3. Rotate the crankshaft 360°. Align the TDC mark

with the pointer. Then, continue measurement of
other valves in the same way.
Evaluation:
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
1. Loosen the adjusting screw lock nuts for the

rocker arms. Insert the thickness gauge set at 0.4
mm, adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the

specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 25.5±4.9 N⋅m
(2.6±0.5 kgf⋅m, 18.8±3.6 lbf⋅ft)
T4-3-7
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray
pattern with a nozzle tester.
2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the
engine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection
pipings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel
penetrates into the blood stream, it may
cause blood toxication.
1. Injection pressure
After attaching the nozzle holder to the nozzle T107-06-02-006
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at
approx. 60 time strokes a minute, measure the
fuel injection pressure.
If adjustment is required, loosen the lock nuts
and adjust the adjusting screws. Turn clockwise
to increase the pressure, and counterclockwise
to decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to
bypass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray
pattern.
3. Oil tight condition

Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
NOTE: Use clean diesel fuel.
T4-3-8
Evaluation:
1. Standard Injection Pressure:
Normal
2. Spray Pattern
• Large-size spray should not be visible to the
naked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be

fine and injected intermittently.
• There should be no drips found.

T102-02-11-005
• Injection spray angle must be normal.
3. Oil Tight Condition Abnormal

No fuel leaks.
T102-02-11-006
Adjustment:
• To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw.
Turn clockwise to increase the pressure, and
counterclockwise to decrease the pressure.
• After adjusting, retighten the lock nuts.
T107-06-02-007
T4-3-9
INJECTION TIMING Timing Mark
Inspection: Top Mark

1. Position No.1 piston to the top dead center. Turn
the crank pulley in the direction of rotation
TDC Mark
(clockwise as seen from the front of the engine)
to set a “TDC” mark on the crank pulley under
the “Top mark”, located on the timing gear case. Timing Gear
Case
NOTE: When rotating the crank pulley, remove the Crank Pulley
fan guard. Then, rotate the fan while hold-
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the timing check hole cover on the front Gear Case
Projection
section of the fuel injection pump.
When the mark on the injection pump is set
under the projection of the gear case, No.1 piston
is positioned at the top dead center. If the mark is
not set under the projection, keep turning to Check
adjust. Hole
NOTE: The alignment mark on the injection pump Injection Pump

cannot be directly seen through the check Alignment Mark
hole. Use a mirror for checking.
T107-02-12-007
3. Remove the injection piping from No.1 cylinder. Gear Case

Projection
4. Remove the delivery valve holder for No.1
cylinder from the injection pump to pull the
delivery valve and the spring out. Reinstall the
delivery valve holder.
: 39 to 43 N⋅m
(4 to 4.4 kgf⋅m, 28.9 to 31.8 lbf⋅ft)
5. Turn the crank pulley at approx. 30 degrees

counterclockwise.
Injection Pump
Alignment Mark
T107-02-12-008
T4-3-10
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel
cannot be seen from the top of the delivery valve
hole. This is the position where the injection
starts.
7. Check the “TDC” mark, located on the crank
pulley for what degrees the “TDC” mark
indicates.
Adjustment:
1. Turn the crank pulley so that the “TDC” mark
comes just above the correct timing position on
the timing gear case.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump
outward against the cylinder block. T107-02-12-009
When delaying timing, tilt the injection pump
inward against the cylinder block.
T4-3-11
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
IMPORTANT: Make sure to keep the ma-

chine-leaving time in Step 1 above.
5. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
6. Record the read-out B (unit: hour) of the hour
meter.
7. Replenish the lubricant up to the high-level
gauge while measuring the oil-replenishing vol-
ume C.
NOTE: For measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the fol-

lowing equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]
Evaluation:
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure both the slow and fast speeds of the
a 10 m (32.8 ft) test track. machine.
2. Select the following switch positions:
Preparation:
Travel Engine Power * Work Auto-Idle/
1. Adjust the track sag on both side tracks equally.
Mode Control Mode Mode Acceleration
2. Prepare a flat and solid test track 10 m (32.8 ft) in Switch Dial Switch Switch Selector
length with extra length of 3 to 5 m (9.8 to 16 ft) Slow Digging
on both ends for machine acceleration and de- Fast Idle P Mode OFF
Mode Mode
celeration. Fast Digging
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Mode Mode
the ground with the arm and bucket rolled in. * : The work mode switch is not equipped for
ZAXIS135UR.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). 3. Start traveling the machine in the acceleration
zone with the travel levers to full stroke.
4. Measure the time required to travel 10 m (32.8
ft).
5. After measuring the forward travel speed, turn
Arm Rolled-In, Bucket Rolled-In the upperstructure 180° and measure the reverse
End
Bucket Height: 0.3 to 0.5 m travel speed.
6. Repeat steps 4. to 5. three times in each direc-
Start
10 m Deceleration
tion and calculate the average values.
Zone
3 to 5 m
Acceleration Evaluation:
Zone Refer to T4-2 Operational Performance Standard.
3 to 5 m
T105-06-03-001
Remedy:
Refer to T5-4 Troubleshooting B.
T4-4-1
TRACK REVOLUTION SPEED
Measure the track revolution cycle time with the 1. Measure both the slow and fast travel speeds.
track raised off ground. 2. Select the following switch positions:
Travel Engine Power * Work Auto-Idle/
Preparation: Mode Control Mode Mode Acceleration
1. Adjust the track sag of both side tracks to be Switch Dial Switch Switch Selector
equal. Slow Digging
2. On the track to be measured, mark one shoe with Fast Idle P Mode OFF
Mode Mode
chalk. Fast Digging
3. Swing the upperstructure 90° and lower the Fast Idle P Mode OFF
Mode Mode
bucket to raise the track off ground. Keep the * : The work mode switch is not equipped for
boom-arm angle between 90 to 110° as shown. ZAXIS135UR.
Place blocks under the machine frame. 3. Operate the travel control lever of the raised
CAUTION: Securely support the raised track track to full stroke.
using wooden blocks. 4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
4. Maintain the hydraulic oil temperature at 50±5 °C speed is obtained.
(122±9 °F). 5. Raise the other side and repeat the above
procedures.
6. Repeat steps 3. to 5. three times and calculate
the average values.
90 to 110° Evaluation:
Refer to T4-2 Operational Performance Standard
Table.
M104-07-067
NOTE: The measurement data obtained through
Mark the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20
m travel speed check described before is
more recommendable.
Remedy:
T4-4-2
MISTRACK CHECK
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure the amount of mistracking in both fast,
Measure the maximum tread deviation from the and slow travel speeds.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points to check the performance Travel Engine Power * Work Auto-Idle/
equilibrium between both sides of the travel Mode Control Mode Mode Acceleration
device systems (from the main pump to the travel Switch Dial Switch Switch Selector
motor). Slow Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode Mode
deviation has a trend to decrease. Fast Digging
Mode Mode
Preparation: * : The work mode switch is not equipped for
1. Adjust the track sag of both tracks to be equal. ZAXIS135UR.
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft) 3. Start traveling the machine in the acceleration
on both ends for machine acceleration and zone with the travel levers at full stroke.
deceleration. 4. Measure the maximum distance between a
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above straight 20 m (65.6 ft) tread chord line and the
the ground with the arm and bucket rolled in. tread made by the machine.
4. Maintain the hydraulic oil temperature at 50±5 °C 5. After measuring the tracking in forward travel,
(122±9 °F). turn the upperstructure 180° and measure in
reverse travel.
the average values.
Maximum Distance
Evaluation:
Acceleration Table.
Zone:
3 to 5 m
20 m Remedy:
T105-06-03-022
T4-4-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a speci-
fied slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T105-06-03-004
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine.
4. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation: Alignment marks on the track

Refer to T4-2 Operational Performance Standard side frame and shoe when the
machine comes to a stop.
Table.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-4-4
SWING SPEED
Summary: CAUTION: Prevent personal injury. Always
Measure the time required to swing three complete make sure that the area is clear and that
turns. co-workers are out of the swing area before
starting the measurement.
Preparation:
1. Check the lubrication of the swing gear and Measurement:
swing bearing. 1. Select the following switch positions:
2. Place the machine on flat, solid ground with Auto-Idle/
ample space for swinging. Do not conduct this Engine Con- Power Mode *Work Mode
Acceleration
test on slopes. trol Dial Switch Switch
Selector
3. With the arm rolled out and bucket rolled in, hold Digging
the bucket so that the height of the bucket pin is Fast Idle P Mode OFF
Mode
the same as the boom foot pin. The bucket must * : The work mode switch is not equipped for
be empty. ZAXIS135UR.
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
The same height as the direction and measure the time required for 3
boom foot pin height
turns.
T105-06-03-013
the average values.
NOTE: In case a sufficient space for the meas-
urement is difficult to find, carry out the
Evaluation:
measurement with the boom fully raised
and the arm fully rolled-in.
Remedy:
Refer to T5-4 Troubleshooting B in Group T5-4.
T178-04-03-001

(122±9 °F).
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180° full-speed
swing.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with
Two Check Marks
ample space for swinging. Do not conduct this
test on a slope. T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).
T105-06-03-009
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
T4-4-6
Measurement:
Auto-Idle/
Engine Con- Power Mode *Work Mode
Acceleration
trol Dial Switch Switch Measure Difference Between Marks
Selector
Digging
Mode
* : The work mode switch is not equipped for
ZAXIS135UR.
2. Operate the swing control lever fully and return it Marking on the Track Frame
to the neutral position when the mark on the
upperstructure aligns with that on the track frame Marking on the Swing Bearing
after swinging 180° .
3. Measure the distance between the two marks. T105-06-03-010
4. Align the marks again, swing 180°, then test in

the opposite direction.
5. Repeat steps 3. to 5. three times each and
calculate the average values.
Evaluation:
Remedy:
Refer to T5-4 Troubleshooting B in Group T5-4.
T4-4-7
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=675 kg (1490 lb): ZAXIS110/110M/125US/ T105-06-03-011
ZAXIS135UR
750 kg (1655 lb): ZAXIS120/130/130LCN/
ZAXIS135US
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122±9 °F).
T4-4-8
Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode *Work Mode
Acceleration
Switch Switch Measure Difference Between Marks
Selector
P Mode Digging Mode OFF
ZAXIS135UR.
2. Maintain the engine at slow idle. After five

Marking on the Track Frame
minutes, measure the difference between the
marks along the swing bearing periphery and the Marking on the Swing Bearing
track frame.
3. Perform the measurement in both right and left T105-06-03-010
swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
Remedy:
T4-4-9
MAXIMUM SWINGABLE SLANT ANGLE
With the upperstructure swung 90° to the slope, 1. Select the following switch positions:
check the maximum slant angle on which the upper- Engine Auto-Idle/
structure can swing to the uphill side. Control Acceleration
Switch Switch
Dial Selector
Preparation: Fast Idle P Mode Digging Mode OFF
1. Check that the swing gear and bearing are well
lubricated. * : The work mode switch is not equipped for
ZAXIS135UR.
weight (W) of the following specification can be 2. Operate the swing lever to full stroke to swing the
used. upperstructure to the uphill side.
W=675 kg (1490 lb): ZAXIS110/110M/125US/ 3. If the machine can swing, measure the cab floor
ZAXIS135UR slant angle.
750 kg (1655 lb): ZAXIS120/130/130LCN/ 4. Increase the slope angle and repeat steps 2. and
ZAXIS135US 3. Check both clockwise and counterclockwise.
3. With the arm cylinder fully retracted and the 5. Perform the measurement three times.
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin Evaluation:
height. Refer to T4-2 Operational Performance Standard.
4. Climb a slope and swing the upperstructure 90°
to the slope. Remedy:
5. Maintain the hydraulic oil temperature at 50±5 °C Refer to T5-4 Troubleshooting B.
(122±9 °F).
T105-06-03-011
T4-4-10
SWING BEARING PLAY
Summary:
Measure the swing bearing play with a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
Magnetic Dial
3. Install a dial gauge on the track frame as shown, Base Gauge
using a magnetic base. T105-06-03-014
4. Position the upperstructure so that the boom

aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty. Round Trunk
NOTE: The measured value will vary depending

on where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the round T105-06-03-015
trunk as possible.
Measurement: Measurement: (h1)

1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to
The same height
raise the front idler 0.5 m (20 in). Record the dial as the boom foot
gauge reading (h2). pin height
3. Calculate bearing play (H) from this data (h1 and

h2) as follows: T105-06-03-007
H=h2-h1
Measurement: (h2)
Evaluation:
T105-06-03-017
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME Boom Cylinder
Summary:
Measure the cycle time of the boom, arm, and
bucket cylinders.
Preparation:
1. When measuring the boom cylinders: With the
arm rolled out and the empty bucket rolled in,
lower the bucket to the ground, as shown. T105-06-03-018
Arm Cylinder
2. When measuring the cycle time of the arm
cylinder: With the empty bucket rolled in, position
the arm so that it is vertical to the ground. Lower
the boom until the bucket is 0.5 m (20 in) above
the ground.
3. When measuring the bucket cylinder: The empty

0.5 m
bucket should be positioned at mid-stroke
between roll-in and roll-out, so that the sideplate
T105-06-03-019
edges are vertical to the ground. Bucket Cylinder
4. When measuring the offset cylinder (ZAXIS
135UR):
Set the offset cylinder in either the right or left
offset stroke end position. (Be sure that the
bucket is out of the collision prevention range.)
5. When measuring the blade cylinder (ZAXIS

135UR):
Lower the bucket to the ground to raise the ma-
chine front off the ground and secure the height
space to allow the blade to move up-and-down
full stroke.
T105-06-03-020

Offset Cylinder
(122±9 °F).
M190-05-034
Blade Cyliner
T191-04-03-009
T4-4-12
Measurement:
Engine Auto-Idle/
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
ZAXIS135UR.
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone.)
2-1. Measuring boom cylinders:
Measure the time it takes to raise the boom,
and the time it takes to lower the boom. To do
so, position the boom at one stroke end, then
move the control lever to the other stroke end
as quickly as possible.
2-2. Measuring arm cylinder:
Measure the time it takes to roll in the arm,
and the time it takes to roll out the arm. To do
so, position the arm at one stroke end, then
move the control lever to the other stroke end
as quickly as possible.
2-3. Measuring bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To
do so, position the bucket at one stroke end,
then move the control lever to the other stroke
end as quickly as possible.
2-4. Measuring the Offset Cylinder (ZAXIS135UR):
Measure the time required to Offset the front
atttachment from right to left or vice versa
while operating the offset pedal full stroke.
2-5. Measuring the blade cylinder (ZAXIS135UR):
Measure the time required to raise or lower
the blade while operating the blade control
lever full stroke.
3. Repeat each measurement three times and

Evaluation:
Remedy:
T4-4-13
DIG FUNCTION DRIFT CHECK
• Maximum Reach Position
Summary:
1. Measure dig function drift, which can be caused
by oil leakage in the control valve and boom, arm,
and bucket cylinders, with the loaded bucket.
2. When testing the dig function drift just after
cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end to purge Extended
Retracted
air. Distance
Distance
Retracted
Distance
Preparation:
Same Height
weight (W) of the following specification can be
used.
W=675 kg (1490 lb): ZAXIS110/110M/125US/ Bucket Bottom
ZAXIS135UR
750 kg (1655 lb): ZAXIS120/130/130LCN/
ZAXIS135US T105-06-03-021
2. Position the arm cylinder with the rod 50 mm (2

Arm Cylinder Extension
in) extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin. Mark
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
T110-06-03-001
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and Boom and Bucket Cylinder Retraction
bucket cylinders.
Mark Mark
3. Repeat step 2. three times and calculate the
average values.
Evalution:
Remedy: T110-06-03-002
T4-4-14
• Arm Roll-In Position
Summary:
1. Measure dig function drift, which can be caused
by oil leakage in the control valve and boom, arm,
and bucket cylinders.
2. When testing the dig function drift just after
cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end to purge
air.
Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position. 1m
4. With the arm rolled in and the bucket rolled in. T173-04-03-001
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
(122±9 °F).
Measurement:
1. Stop the engine.
Cylinder Retraction
measure the change in the position of the bottom Mark Mark
of the arm tip, as well as the boom, arm and
bucket cylinders.
average values.
Evalution:
T110-06-03-002
Remedy:
T4-4-15
Offset Cylinder (ZAXIS135UR)
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Extended Distance
weight (675 kg) of the following specification can
be used.
2. Position the arm, Bucket, boom Cylinders with
the fuly extended position. Position the offset
Cylinder with the rod 100 mm retracted from the
fully extended position (right offset).
(122±9 °F).
Measurement:
1. Stop the engine.
2. 1 hour after the engine has been stopped,
measure the change in the position of the bottom Blade Bottom
of the offset cylinders.
T197-04-03-001

average values.
Blade Cylinder (ZAXIS135UR) Offset Cylinder Extension
Preparation:
1. Position the blade cylinder with the fully extended
position.
Mark
2. Record the height between the blade tip and
thegroud.
(122±9 °F).
T110-06-03-001
Blade Bottom
A B
T197-04-03-002
T4-4-16
Measurement:
1. Stop the engine.
measure the change in the position of the bottom
of the blade tip calculate the difference between
the before and after data.
average values.
Evalution:
Remedy:
T4-4-17
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T107-06-03-003
T107-06-03-004
T4-4-18
Measurement:
1. Measure each control lever.
Engine Auto-Idle/
Switch Switch
Dial Selector
ZAXIS135UR.
3. Operate each boom (raise), arm and bucket lever

to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the
maximum operating force with the boom (lower)
relieved by jacking up the machine in a safe
area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force required. When finished, lower the track
and then jack-up the other track.
the average values.
Evalution:
Refer to T4-2 Orerational Performance Standard
T4-4-19
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T107-06-03-005
Measurement:
1. Stop the engine.
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step (2) three times and calculate the
average values.
Evalution:
Refer to T4-2 Orerational Performance Standard.
T4-4-20
(Blank)
T4-4-21
BUCKET/CAB COLLISION PREVENTION Intrusion Prevention to the Cab Front
SYSTEM (ZAXIS135UR ONLY)
Summary:
Check that the interference prevention device cor-
rectly functions.
Preparation:
1. If an Optional arm or bucket is used, check that
the front or bucket setting is made correctly.
2. Position the front attachment as follows.
2-1. Intrusion prevention to the cab front Position
the upperstructure with the boom cylinder ver-
tical and the bucket at the bucket face the cab M191-03-003
front face.
2-2. Intrusion prevention to the cab side
Position the upperstructure with the boom fully
raised and the arm fully rolled in so that the
bucket is positioned by the cab side.
3. Maintain the hydraulic oil temperature at 50±5 °C.
(122±9 °F)
Bucket Tooth Tip Bumper End
T191-04-03-014
Intrusion Prevention to the Cab Side
M190-03-007
Side Cutter Side Face Cab Right Side Face
T191-04-03-015
T4-4-22
Measurement:
Auto- Auto-Idle/
Engine Con- Power Mode
MARCCINO Acceleration
trol Dial Switch
Mode Switch Selector
Fast Idle OFF P Mode OFF
2. Procedures for the measurement are as follows:

2-1. Intrusion prevention to the cab front Roll the
arm in until it stops. Measure the clearance
between the bucket teeth and the bumper
under the cab.
2-2. Intrusion prevention to the cab side
Operate the left offset function until the front
attachment stops. Measure the clearance be-
tween the bucket side cutter side face and the
cab side.
3. Repeat each measurement three times and cal-
culate the average values.
Evalution:
Refer to T4-2 Performance Standard.
Remedy:
Refer to T5-6 Troubleshooting D.
T4-4-23
COMBINED BOOM RAISE/SWING
FUNCTION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. With the arm fully rolled out and bucket fully
rolled in, lower the bucket to the ground. The
bucket must be empty.
T107-06-03-009

(122±9 °F).

Measurement:
Engine Auto-Idle/
Switch Switch
Dial Selector
T107-06-03-010
ZAXIS135UR.
2. Raise the boom and swing simultaneously, both

at full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height(H) of H
the bucket teeth.
the average values.
T107-06-03-011
Evalution:
Remedy:
T4-4-24
BOOM RAISE AND ARM ROLL-IN COM-
BINED OPERATION
Summary:
1. Performance of boom raise and arm roll-in com-
bined operation is checked.
2. Make sure that the cylinders don’t hesitate while Arm Mounting
Pin
operating the cylinder with the engine running at
fast idle.
Preparation:
1. Retract the arm cylinder fully and extend the
bucket cylinder so that the bucket teeth and arm
mounting pin are on a straight line. Adjust the
boom cylinder so that the bucket tooth tip height
is 0.5 m (1 ft 8 in) above the ground. (The bucket 0.5 m
must be empty.)
2. Maintain the hydraulic oil temperature at 50 ± 5
T107-06-03-006
°C (122±9 °F).
Measurement:
1. Select the switch positions as follows.
Engine Auto-Idle/
Switch Switch
Dial Selector
ZAXIS135UR.
2. Raise the boom and roll the arm in full stroke at

the same time.
3. Measure the time required for the arm to reach
the stroke end with the bucket empty.
4. Repeat the measurement three times and calcu-
T107-06-03-008
late the average value.
Evaluation:
Remedy:
T4-4-25
(Blank)
T4-4-26
OPERATIONL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on the top of the
hydraulic oil tank to release any remaining
pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST 6942)
to the removed plug hole (pressure check port).
Plug
: 14 mm
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
T178-03-07-001
(122±9 °F).
Measurement:
Auto-Idle /
Engine Power Mode *Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Mode
Digging
Slow Idle P Mode OFF
Mode
ZAXIS135UR.
2. Measure the pilot pressure in each specified

setting above.
3. Repeat the measurement three times and
Evaluation:
Refer to T4-2 Operational Performane Standard.
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set-pressure as necessary.
: 41 mm
Relief Valve
T178-03-07-001
1. Remove plug (1) from the relief valve.

: 41 mm 1 2 3 4
: 12 mm
2. Remove spring (2), shims (3), and plunger (4)

from the relief valve.
3. Install the estimated number of shims (3) onto
plunger (4).
4. Install plunger (4), shims (3), and spring (2) into T178-04-04-002
the relief valve. Tighten plug (1).
: 68±6.8 N･m (7±0.7 kgf･m, 50±5 lbf･ft)
5. Check the set-relief pressure.
NOTE: Standard Change in Pressure (Reference)

Shim Thickness Change in Relief Pressure
(mm) kPa (kgf/cm2) (psi)
0.2 61.8 (0.63) (9)
0.4 124.6 (1.27) (18)
0.8 249.2 (2.54) (36)
T4-5-2
(Blank)
T4-5-3
SECONDARY PILOT PRESSURE
Preparation:
hydraulic oil tank to release any remaining Signal Control Valve
pressure.
3. Measure the pressure by either of the following
methods.
NOTE: When disconnecting the pilot lines from the

signal control valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) to easily Control
disconnect the lines. Valve
• Measure pressure at the location between the

pilot valve and the signal control valve:
Disconnect the pilot circuit hose to be meas-
ured from the signal control valve. Connect
hose (7/16-20UNF approx. 400 mm long) to the
signal control valve. Install tee (ST 6450) and
pressure gauge (ST 6942) between the hoses.
• Measure pressure at the location between the
control valve and the signal control valve:
Disconnect the pilot circuit line to be measured
between the signal control valve and the control
valve. Connect hose to the signal control valve.
Install tee (ST 6451) and pressure gauge (ST
6942) between the hose and the control valve.
: 14 mm, 17 mm
4. Start the engine. Confirm that no oil leakage is T176-04-04-001

(122±9 °F).
T157-05-04-011
T4-5-4
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
ZAXIS135UR.
2. Measure the pilot pressure in each specified
setting above with the corresponding control
lever operated full stroke.
Evaluation:
Remedy:
T4-5-5
SOLENOID VALVE SET PRESSURE
Measure solenoid valve set pressure with both the
Dr.ZX and the pressure gauge.
Preparation:
pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453), SC
tee (ST 6451), adapter (ST 6461), and pressure SI
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated. T176-03-07-002
: 17 mm, 19 mm, 22 mm
Connect Dr.ZX to the machine for solenoid valve Solenoid Valve Unit
set pressure monitoring.
Pressure Gauge
1
(122±9 °F).
Hose Tee Adapter T157-05-04-002
T4-5-6
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
ZAXIS135UR.
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SC: Perform a combined
operation of boom raise and arm roll-in.
Solenoid Valve SI: Travel the machine, then stop
the machine.
3. Read the values on both Dr.ZX and the pressure
gauge.
Evaluation:
Refer to T4-2 Operational performance Standard.
T4-5-7
Solenoid Valve Set Pressure Adjustment 7
Procedure
IMPORTANT: Do not loosen the adjusting screw 8

excessively.
The O-ring on the threads may come
off the sealing surface if loosening
the screw 2 turns or more, causing
oil leakage. T107-06-04-020
The distance between the lock

nut end and screw end should
1. Loosen lock nut (7). Turn adjusting screw (8) to be 2.0 mm (0.079 in) or less.
adjust the set pressure of the solenoid valve.
2. Retighten lock nut (7).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
: 3 mm

Screw Turns 1/4 1/2 3/4 1 8
Change kPa 78 156 234 312 7
in (kgf/cm2) (0.8) (1.6) (2.4) (3.2) T107-06-05-001
Pressure (psi) (11) (23) (34) (46)
3. Check the set pressure of the solenoid valve.

Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be
measured with the built-in diagnosing system or
Dr.ZX.
Preparation:
pressure.
3. Remove the plug from the pump delivery port.
Install adapter (ST 6648), hose (ST 6943) and
pressure gauge (ST 6941) on the port.
: 6 mm
Select the monitoring function of the built-in

diagnosing system (or Dr.ZX).
observed at the pressure gauge connection. Pump 2 Delivery Pump 1 Delivery
Pressure Port Pressure Port
5. Maintain the hydraulic oil temperature at 50±5 °C T176-03-01-001
(122±9 °F).
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
ZAXIS135UR.
2. Measure the pressure with the control levers in

neutral.
Evaluation:
Remedy:
T4-5-9
MAIN RELIEF VALVE SET PRESSURE
Main Circuit
The main relief pressure can also be measured with
the built-in diagnosing system or Dr.ZX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
2. Press the air release valve on top the of the
pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6648), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Select the monitoring function of the built-in

diagnosing system (or Dr.ZX).
Pump 2 Delivery Pump 1 Delivery
observed at the pressure gauge connection. Pressure Port Pressure Port
T176-03-01-001
(122±9 °F).
T4-5-10
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
ZAXIS135UR.
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
3. As for the swing function, secure the
upper-structure so it is immovable. Slowly
operate the swing lever to relieve the swing
function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.
Evaluation:
T4-5-11
Blade Circuit
Summary: Blade Pump

Measure the main relief valve pressure setting at the
blade pump delivery port.
Preparation:
1. Stop the engine.
2. Press the air release valve on the hydraulic oil
tank to bleed air.
3. Disconnect the delivery line on blade pump.
Install adapter (ST 6291), hose (ST 6943) and
pressure gauge (ST 6941) to inspection port.
: 24mm, 27 mm
4. Start the engine. Confirm that no oil leakage is T1SM-03-01-001

(122±9 °F).
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
ZAXIS135UR.
2. Slowly operate bucket control lever until the

cylinder rod reaches both stroke ends to relieve
the function.
Evaluation:
Refer to T4-2 Performance Standard Table.
T4-5-12
NOTE: If the measure pressures for all functions
(except the blade) are lower than the Main Circuit
Lock Nut
specified range, the probable cause is a Adjusting
Screw
decrease of the main relief valve setting
pressure (in main circuit).
If the relief pressure in blade circuit is lower,
the probable cause is a decrease of the
main relief valve setting pressure (in blade
circuit).
Main Relief Pressure Setting Adjustment

W105-02-05-151
Procedure
Adjusting
Adjustment: Screw
1. Loosen the lock nut.
2. Turn the adjustiing screw to adjust the main relief

pressure setting referring to the table below. Pressure Pressure
Increase Decrease

Main Circuit:
: 17 mm T105-06-05-002
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
Blade Circuit: Blade Circuit
: 6 mm Adjusting
: 24 mm Screw
: 9.82 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
4. Recheck the set pressures.
•Main Circuit
Screw Turns 1/4 1/2 3/4 1
Lock Nut
Change in MPa 2.79 5.59 8.36 11.2
Relief (kgf/cm2) (28.5) (57) (85.2) (114)
T198-04-04-007
Pressure (psi) (405) (811) (1212) (1620)
•Blade circuit Adjusting

Screw
Screw Turns 1
Change in MPa 13.5
Relief (kgf/cm2) (138)
Pressure (psi) (1960) Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
RELIEF PRESSURE (When relieving Swing Relief
Swing) Valve
1. Loosen lock nut (1).

: 24 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Turn adjustiing screw (2) to adjust the swing relief

pressure setting referring to the table below.
: 8 mm

Change in MPa 0.9 2.0 2.9 3.9
2
Relief (kgf/cm ) (10) (20) (30) (40)
Pressure (psi) (142) (284) (427) (570)
T176-01-02-002
1 2
T176-04-04-004
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-14
(Blank)
T4-5-15
RELIEF PRESSURE (When relieving
Travel)
ZAXIS110/120/130/130LCN/125US/135US
1. Remove the travel relief valve.
: 30 mm
2. Remove sleeve (1) and poppet (3).
3. Install shims (5) between poppet (3) and spring Travel Relief
Valve
guide (4) to adjust the set-pressure.
4. Install the travel relief valve.

: 310 N⋅m (32 kgf⋅m, 230 lbf⋅ft)
T155-01-01-006
5. Check the set-pressure.
1 2 5
Shim Change in Relief
Thickness Parts No. Pressure
(mm) kPa (kgf/cm2) (psi)
0.5 4305162 785 (8) (114)
3 4
T135-06-04-001
T4-5-16
ZAXIS110M
1. Loosen lock nut (2).
: 19 mm
2. Turn adjusting screw (1) to adjust the set pres-

sure referring to the table below.
: 6 mm

: 44 N⋅m (4.5 kgf⋅m, 32.5 lbf⋅ft)
Travel Relief
4. Check the set-pressure. Valve
NOTE: Standard Change in Relief Pressure (Ref- T155-01-01-013
erence)
Screw Turns 1
kPa 8.6 2
(kgf/cm2) (88)
(psi) (1250)
1
T133-06-04-002
Adjusting
Screw
Pressure Pressure
Increase Decrease
T105-06-05-002
T4-5-17
OVERLOAD RELIEF VALVE SET
PRESSURE
Summary: Preparation:
1. The circuit pressure must be increased by 1. Properly shut down the engine.
applying an external force while blocking the 2. Press the air release valve on the top of the
return circuit from the control valve. This hydraulic oil tank to release any remaining
measuring method is hazardous and the results pressure.
obtained with this method are unreliable. 3. Main Circuit :
2. The oil flow rate used to set the overload relief Remove the plug from the main pump delivery
pressure is far less than that used to set the main port. Install adapter (ST 6648), hose (ST 6943)
relief pressure. Therefore, measuring the over- and pressure gauge (ST 6941) on the port.
load pressure in the main circuit by increasing the : 6 mm
main relief set-pressure more than the overload
valve set-pressure is not a proper method. In ad- Blade Circuit (ZAXIS 135 UR Only):
dition, in case a main relief valve designed to Disconnect the lines of blade pump. Install
leak a small quantity of oil before reliving is used, adapter (ST 6291), hose (ST 6943), and pressure
its pre-leaking start pressure must be increased gauge (ST 6941).
more than the overload relief valve set-pressure. : 24 mm, 27 mm
However, the pre-leaking start pressure is not
always increased more than the overload relief 4. Select the monitoring function of the built-in
valve set-pressure as the adjustable upper limit diagnosing system (or Dr.ZX).
of the main relief valve set-pressure is provided. Start the engine. Confirm that no oil leakage is
Accordingly, the overload relief valve assembly observed at the pressure gauge connection.
should be removed from the machine and NOTE: When measuring the blade circuit , use the
checked on a specified test stand at a correct oil pressure gauge only.
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil 5. Maintain the hydraulic oil temperature at 50±5 °C
passage. When this type of overload relief valve (122±9 °F).
is checked, the control valve body must be pre-
cisely finished as the test unit. Provide one con-
trol valve other than that on the machine as a test
kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
T4-5-18
Measurement:
Auto-Idle /
Acceleration Blade Pump
Selector
Digging
Mode
ZAXIS135UR.
2. Slowly operate bucket, arm, and boom control

levers to the stroke ends to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement : Pump 2 Delivery Pump 1 Delivery
Pressure Port Pressure Port
calculate the average value for each front T1SM-03-01-001
function.
T4-5-19
Evaluation:
Performance of the overload relief valves are normal Main Circuit Adjusting
if the measured main relief pressures (in main circuit Lock Nut Screw
or blade circuit) are within the specified value range.
Overload Relief Valve Set Pressure Adjusting

Procedure
NOTE: In principle, adjust the overload relief valve

T176-04-04-003
set pressure on a test stand.
Adjustment:
Adjusting
1. Loosen the lock nut. Screw
Main Circuit :
: 17 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23.1 lbf⋅ft)
Pressure Pressure
Increase Decrease
Blade Circuit :
: 17 mm
: 19.6 N⋅m (2 kgf⋅m, 14.4 lbf⋅ft)
: 6 mm T105-06-05-002
2. Turn adjustiing screw (2) to adjust the overload

relief pressure setting referring to the table below. Blade Circuit
Lock Nut
•Main Circuit
Screw Turns 1/4 1/2 3/4 1 Adjusting Screw
T198-04-04-008
Change in MPa 2.79 5.59 8.36 11.2
2
Relief (kgf/cm ) (28.5) (57) (85.2) (114)
Pressure (psi) (405) (811) (1212) (1620) Lock Nut
Adjusting Screw
•Blade Circuit
Change in MPa 4.9 9.9 14.9 19.8
Relief (kgf/cm2) (50.5) (101.0) (151.4) (201.9)
Pressure (psi) (718) (1436) (2153) (2811) Pressure Pressure
Increase Decrease
T505-06-04-007
T4-5-20
(Blank)
T4-5-21
MAIN PUMP FLOW RATE MEASUREMENT
•P-Q Control (Torque Control) 5. Install a pressure gauge to the main pump to be
Summary: measured. (Refer to T4-5-8 Main Relief Pressure
Main pump performance is checked by measuring Check.)
the pump flow rate with a hydraulic tester installed at : 6 mm
the main pump delivery port (one side) to be meas-
ured. Use Dr. ZX and a pressure gauge at the same 6. Disconnect pipe (12) from the regulator. Connect
time. plug (PF 1/4) to the disconnected pipe.
: 17 mm
IMPORTANT: This measurement procedure is a 7. Disconnect the N sensor connector. Connect the
simple method. The measured data pulse counter to the N sensor.
will be lower by approx. 5 % than 8. Disconnect the vacuum pump. Loosen plug (11)
the accurately measured value. To on the top of the pump casing to bleed air from
measure accurately, disconnect the the main pump casing until oil only comes out of
return circuit from the control valve the plug clearance.
and connect it to the hydraulic oil 9. Fully open the loading valve of the hydraulic
tank. tester.
10. Start the engine. Check the pressure gauge con-
Preparation: nection for any oil leaks. Install Dr. ZX and select
1. Stop the engine. Push the air bleed valve to the monitor function.
bleed air. Connect a vacuum pump to the oil filler
port. Measurement:
NOTE: Operate the vacuum pump while connect- 1. Measure the maximum flow rate.
ing the pump flow rate test line.
2. Select each switch position as follows:
2. Disconnect the delivery hose from the main pump Auto-Idle /
(one side) to be measured. Connect pipe (1) to Acceleration
the pump delivery port using the split flanges and Selector
bolts which were used to connect the discon- Digging
nected delivery hose. Mode
: 41 mm : 10 mm * : The work mode switch is not equipped for
ZAXIS135UR.
3. Connect pipe (1) to hydraulic tester (4) using test 3. Adjust the main relief valve set-pressure in the
hose (2) and adapter (3). Connect adapter (5), control valve to each pressure point specified
joint (6), test hose (7) and flange (8) to hydraulic along the main pump P-Q curve. (Refer to
tester (4). T4-2-22) Slowly close the loading valve of the
: 41 mm : 10 mm hydraulic tester while relieving the pressure in the
4. Connect the delivery hose to flange (8) with split arm roll-in circuit. Measure the flow rates and en-
flanges (9) and bolts (10). gine speeds at the pressure points specified in
: 10 mm the P-Q curve.
4. Repeat each measurement three times and cal-
culate the average values.
T4-5-22
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las:
NOTE: When actually measuring, install pipe (1)
Qc = (Ns × Q) ⁄ Ne only to the pump to be measured.
Qc : Converted Flow Rate

Q: Measured Flow Rate
Ns : Specified Pump Speed (1950 min-1)
Ne : Measured Engine Speed
Pulse Numbers (Hz)×60/21
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control
Valve)
T173-04-04-002
11
N Sensor T176-03-01-002
12
T176-03-01-001
1 - Pipe (ST 6192) 4 - Hydraulic Tester (ST 6299) 7 - Test Hose (ST 6320) 10 - Bolt (ST 6409) (4 Used)
2 - Test Hose (ST 6145) 5 - Adapter PF1 × UNF1-7/8 8 - Flange (ST 6118) 11 - Plug
(ST 6146)
3 - Adapter PF1 × UNF1-7/8 6 - Joint (ST 6330) 9 - Split Flange (ST 6130) 12 - Pipe
(ST 6146)
T4-5-23
• Pilot Characteristics
Summary: 8. Disconnect the vacuum pump. Loosen plug (11)

Main pump performance is checked by measuring on the top of the pump casing. Bleed air from the
the pump flow rate with a hydraulic tester installed at pump casing until oil only comes out of the plug.
the main pump delivery port (one side) to be meas- 9. Fully open the loading valve of the hydraulic
ured. Use Dr. ZX and a pressure gauge at the same tester.
time. 10. Start the engine. Check the line connections for
any oil leaks.
IMPORTANT: This measurement procedure is a
simple method. The measured data Measurement:
will be lower by approx. 5 % than 1. The pump flow rate in response to the external
the accurately measured value. To command pilot pressure is measured.
measure accurately, disconnect the 2. Select each switch position as follows:
return circuit from the control valve Auto-Idle /
and connect it to the hydraulic oil Engine Power Mode *Work Mode
Acceleration
tank. Control Dial Switch Switch
Selector
Preparation:
Digging
1. Referring to steps 1 to 4 on page T4-5-16, con- Fast Idle P Mode OFF
Mode
nect a hydraulic tester to the main pump to be
measured.
ZAXIS135UR.
2. Disconnect the hose from regulator port Pi of the
pump to be measured. Connect plug (ST 6213) 3. Adjust the reducing valve set-pressure to each
to the disconnected hose. pressure point specified along the main pump
: 6 mm, 19 mm P-Q curve. (Pilot Characteristics) (Refer to
3. Install adapters (14) (3 used) to reducing valve T4-2-18) Measure the flow rates and engine
(15). Remove plug M from the pilot filter. Then, speeds at the pressure points specified in the
install adapter (12) and hose (13) to the pilot filter. P-Q curve.
Connect the other end of hose (13) to regulator 4. Repeat each measurement three times and cal-
port P1 on reducing valve (15). culate the average values.
: 19 mm
4. Install tee (16) to port P2 on reducing valve (15). Evaluation:
Connect pressure gauge (17) and hose (13) to 1. Convert the measured flow rates to those at the
tee (16). Connect hose (13) to the regulator. specified pump speed using the following formu-
: 19 mm las:
5. Connect hose (18) and adapter (19) to port T on
reducing valve (15). Remove plug L from the re- Qc = (Ns × Q) / Ne
turn pipe. Connect hose (18) to the plug L port.
: 19 mm, 22 mm Qc : Converted Flow Rate
6. Disconnect pipe (20) from the regulator. Connect Q: Measured Flow Rate
plug (PF 1/4) to the disconnected pipe. Ns : Specified Pump Speed (1950 min-1)
: 17 mm Ne : Measured Engine Speed
7. Disconnect the N sensor connector. Connect the Pulse Numbers (Hz)×60/21
pulse counter to the N sensor.
2. Standard Flow Rate
T4-5-24
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control
Valve)
T173-04-04-002
11
20
Port Pi N Sensor T176-03-01-002
T176-03-01-001
Reducing Valve
Port Position
Reducing Return Pipe
Valve
T Plug M
L 19
17
18
P1 P2
14
To Regulator To Pilot
Port Pi Filter
13 16 14 14 13 12
15
T178-03-07-001
T178-04-04-004
1 - Pipe (ST 6192) 6 - Joint (ST 6330) 11 - Plug 16 - Tee UNF7/16 × UNF7/16×
PF1/4 (ST 6451)
2 - Test Hose (ST 6145) 7 - Test Hose (ST 6320) 12 - Adapter UNF7/16 × PF1/4 17 - Pressure Gauge (ST 6931)
(ST 6069)
3 - Adapter PF1 × UNF1-7/8 8 - Flange (ST 6118) 13 - Hose UNF7/16 × UNF7/16 18 - Hose UNF7/16 × UNF7/16
(ST 6146) (4334309) (4334309)
4 - Hydraulic Tester 9 - Split Flange (ST 6130) 14 - Adapter PF3/8 × UNF7/16 19 - Adapter PF3/8 × UNF7/16
(ST 6299) (4200465) (4200465)
5 - Adapter PF1 × UNF1-7/8 10 - Bolt (ST 6409) (4 Used) 15 - Reducing Valve (4325439) 20 - Pipe
(ST 6146)
T4-5-25
Regulator Adjustment
6 5 1 2
10
4 3
7 8
T178-03-01-006
1 - Lock Nut 4 - Adjusting Screw 7 - Lock Nut 9 - Lock Nut
(For Minimum Flow Ad- (For Maximum Flow Ad- (For P-Q Control Adjust- (For P-Q Control Adjust-
justment) justment) ment) ment)
2 - Adjusting Screw 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
(For Minimum Flow Ad- (For Pilot Pressure Char- (For P-Q Control Adjust- (For P-Q Control Adjust-
justment) acteristic Adjustment) ment) ment)
3 - Lock Nut 6 - Adjusting Screw
(For Maximum Flow Ad- (For Pilot Pressure Char-
justment) acteristic Adjustment)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (1) and turn ad- 1) Do not turn the adjusting screw
justing screw (2). more than two turns.
Q Rotating adjusting screw (2) 1/4 2) Securely retighten lock nut (1) after
a turn clockwise increases the the adjustment.
minimum pump flow rate by 3.45
cm3/rev. (0.21 in3/rev).
: 17 mm
: 19.6 N⋅m
(2 kgf⋅m, 14.4 lbf⋅ft)
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn ad- 1) Do not turn the adjusting screw
justing screw (4). more than two turns.
Q Rotating adjusting screw (4) 1/4 2) Do not increase the maximum flow
a turn clockwise decreases the rate.
maximum pump flow rate by In other words, do not turn the
2.88 cm3/rev. (0.18 in3/rev). adjusting screw counterclockwise.
: 13 mm 3) Securely retighten lock nut (3) after
: 9.8 N⋅m the adjustment.
(1 kgf⋅m, 7.2 lbf⋅ft)
Pd
T4-5-26
Adjustment Item Adjustment Procedure Remarks

3. Pilot Pressure Characteristics Loosen lock nut (5) and turn 1) Do not turn the adjusting screw
ad-justing screw (6). more than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
a turn clockwise decreases the clockwise, the maximum flow rate
Q
flow rate by 5.75 cm3/rev (0.35 will also be decreased.
in3/rev). To maintain the maximum flow rate
: 30 mm unchanged, turn adjusting screw (4)
: 29.4 N⋅m counterclockwise twice as much as
(3 kgf⋅m, 21.7 lbf⋅ft) adjusting screw (6) is turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1
(adjusting screw (6) clockwise turn)
Pi is to counterbalance.
3) Securely retighten lock nut (5) after
the adjustment.
4. P-Q Control A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws
(Torque Adjustment) adjusting screw (8). more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws
Q 1/4 a turn clockwise increases watching the engine performance.
the flow rate by 5.75 cm3/rev 3) Securely retighten lock nut (7) or (9)
A (0.35 in3/rev.). after the adjustment.
B: Loosen lock nut (9) and turn
adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise increases
the flow rate by 1.24 cm3/rev.
Pd (0.08 in3/rev).
Pd
T4-5-27
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on hydraulic
oil temperature.
1
Also, take care not to fall off the machine
while the measurement.
Preparation:
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
T157-05-04-014
2. Properly shut down the engine. Press air release
valve (1) on the top of the hydraulic oil tank to
release any remaining pressure. 2
3. Disconnect swing motor drain hose (2) at the

hydraulic oil tank end. Install plug (ST 6213) to
the disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
Preconditions for Measurement:

Auto-Idle /
Acceleration
Selector
Digging
Mode
T176-04-04-005
ZAXIS135UR.
T4-5-28
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Be sure that the bucket is
empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil The same height as
measurement after the swing speed reaches boom foot pin height
a constant maximum speed. The measuring
time should be more than 45 seconds. T105-06-03-013
(3) Repeat the measurement at least three times

in both clockwise and counterclockwise
directions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
T107-06-06-005
hose end. The measuring time should be
more than 45 seconds.
in both clockwise and counterclockwise
directions, and calculate the average values.
T107-06-05-008
T4-5-29
Evaluation:
Table.
∗ Conversion of the amount of drain oil measured

into the per-minute value
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
△Q = 60 × q / t
Where:
△Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-30
(Blank)
T4-5-31
TRAVEL MOTOR DRAINAGE
ZAXIS110/120/130/130LCN/125US/135US
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side
track jacked up.
NOTE: The amount of drain oil from the travel

motor will change depending on hydraulic
1
oil temperature.
Travel motor operational performance must
be judged from travel speed, mistrack, and
so on.
Preparation:
(122±9 °F). Rotate the travel motor to warm the
2. Properly shut down the engine. Press air release

valve (1) on top of the hydraulic oil tank to
release any remaining pressure. T157-05-04-014
3. Disconnect travel motor drain hose (2) at the

travel motor end. Install plug (ST 6637) to the 2
disconnected end. Connect the drain hose
(3/4-16UN) to the travel motor.
: 22 mm, 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

Auto-Idle /
Acceleration
Selector
Digging
Mode
* : The work mode switch is not equipped for T155-05-04-004
ZAXIS135UR.
T4-5-32
Measurement:
1. Amount of Oil Drained While Rotating Travel
Motor
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
90 to 110°
CAUTION: Securely support the raised track
using wooden blocks. When working around
moving parts is unavoidable, pay special
attention to ensure that hands, feet, and
clothing do not become entangled. M104-07-067
(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil
measurement after the track rotation speed
reaches a constant maximum speed. The
measuring time should be more than 45
seconds.

in both forward and reverse directions, and
Evaluation:
∗ Conversion of the amount of drain oil measured

into the per-minute value
T157-05-04-019
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
△Q = 60 × q / t
Where:
△Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-33
ZAXIS110M
Summary:
1. To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side
track jacked up.
2. Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of
the swing area before starting the measurement.
3. Operational performance of the travel motor
should be totally evaluated taking test results on
the travel speed and mistrack into consideration.
4. The amount of drain oil from the travel motor will
change depending on hydraulic oil temperature.
Travel motor operational performance must be
judged from travel speed, mistrack, and so on.
Preparation:
(122±9 °F). Rotate the travel motor to warm the
2. Properly shut down the engine. Press the air
release valve on top of the hydraulic oil tank to
release any remaining pressure.
3. Remove plug (1) in the travel motor and install
pressure gauge (ST 6925) and adapter (ST
6053).
: 10 mm
T133-06-04-003
T4-5-34
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Selector
Digging 90 to 110°
Fast Idle P OFF
Mode
Measurement:
1. Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
M104-07-067

using wooden blocks. When working around
moving parts is unavoidable, pay special
attention to ensure that hands, feet, and
clothing do not become entangled.
2. Rotate the raised track with the travel lever

operated full stroke. Measure the drain oil
pressure.
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
T4-5-35
(Blank)
T4-5-36
OPERATIONAL PERFORMANCE TEST / Adjustment
ASSEMBLY AND ADJUSTMENT OF LINK
FOR ARM ANGLE SENSOR (ZAXIS135UR
ONLY) 3
2 2
IMPORTANT: Compared to other angle sensors, it
is more difficult to assemble or
adjust the link for the arm angle
1 1
sensor. When replacing the arm
4
angle sensor, follow the assembly
and adjustment procedures below.
Assembling and Adjusting the Link
IMPORTANT: In the case of pressing–in of a

bushing, vertically press the bushing
T187-04-06-100
by using protective plate so that the
surrounding areas are not damaged. 1 5 Angle Sensor
1. Press bushing (2) into link (1) (2 used).
2. Press bushing (3) into the arm side. 5 4 5
3. Install end rod (5) to lever (4). Turn and adjust

lever (4) so that the clearance between pins is 250
mm.
250 mm
4. Install lever (4) with the edge of angle sensor
lining with the end rod side. Angle Sensor
20 mm
IMPORTANT: Before attaching the link, apply
grease generously to sliding and
rotating areas. Be sure to replace
cotter pins (9, 10) with new ones and
wind them.
5. Attach the link to the front attachment as shown at
right. (Cylinder:
Stay Side)
NOTE: When replacing the arm, replace it after 5
removing pin (10).
4
1- Link 6- Pin
2- Bushing 7- Spacer Aligning Surfaces
3- Bushing 8- Spacer
4- Lever 9- Cutter Pin
5- End Rod 10 - Pin
10 7 8 9
7
(Arm Side)
6 8 7 9
T187-04-06-101
T4-6-1
ADJUSTING METHOD OF FRONT
ACCELERATION SPEED AND Lock Nut
DECELERATION SPEED (ZAXIS135UR
ONLY) Adjusting
Screw
Adjust solenoid valve set pressure to change front
acceleration or deceleration.
Repeat adjusting pressure and operating front.
IMPORTANT: Do not adjust arm acceleration

solenoid valve (for cab collision
prevention control). T107-06-05-001
1. Select the following switch positions: Lock Nut Adjusting Screw

Engine Control Power Mode Auto-MARCCINO
Dial Switch Mode Switch
Fast Idle P ON
2. Paint matching marks on adjusting screw and lock Pressure Pressure

nut before working. (Note do not paint on threads Increase Decrease
of adjusting screw)
W107-02-05-129
3. Loosen lock nut and adjust by adjusting screw.
Clockwise : acceleration
8-Unit Solenoid Valve Layout
Counterclockwise : deceleration
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 0.08 lbf⋅in) 1
8
: 3 mm
2
Reference: Standard Pressure Change 7
kPa 78 156 234 312 3
(kgf/cm2) 0.8 1.6 2.4 3.2 6
(psi) 11.3 22.6 33.9 45.2
4
5
4. Tighten lock nut.
T1SM-01-02-003
1 - Solenoid Valve 5- Solenoid Valve
(C1 : Boom Raise (C4 : Arm Roll-In
Acceleration) Deceleration)
2 - Solenoid Valve 6 - Solenoid Valve
(C6 : Right Offset (C8 : Left Offset
(C9 : Left Offset (C5 : Right Offset
(C7 : Arm Roll-Out (C3 : Boom Lower
T4-6-2
INITIAL SETTING OF ANGLE SENSOR
(ZAXIS135UR ONLY)
Initial setting of the angle sensor is required when the Side Cutter Cab Right
angle sensor or the front attachment (boom, arm) is Side Face Side Face
replaced.
1. Set the front attachment in the following standard

position.
Standard position:
Boom : Fully raised
(with the boom cylinder fully extended)
Arm : Fully rolled in
(with the arm cylinder fully extended) T191-04-03-015
Offset : Set the offset position by referring to the

below table.
Clearance between the
side cutter of the bucket
Bucket Type
and the operator’s cab.
(Unit: mm)
Standard
220
or Optional Bucket
2. Stop the engine. Turn the key switch into OFF.
3. Wait for 10 seconds.
4. Connect the initial setting connector.

Initiol Setting Connector
5. Turn the key switch into ON. At this time the (With Initial Setting Label)
engine must stop.
6. Disconnect the initial setting connector again. The

setting is complete if the buzzer sounds a short
(beep).
7. Turn the key switch into OFF.
IMPORTANT: If the buzzer sounds continuously,

the initial setting is failed. Check the
angle sensor system for
abnormalities and repair if necessary.
Then, perform the initial setting
again.
T1CF-05-01-002
T4-6-3
INITIALIZING THE DEPTH LIMIT CONTROL
SYSTEM (ZAXIS135UR ONLY)
It is required to initialize the Depth Limit Control
System in the following case:
• The front attachment, angle sensor, link for angle
sensor, 8-unit solenoid valve, 2-unit solenoid valve
(optional), or auto-MARCCINO control unit is
exchanged.
CAUTION: When initializing the depth limit

control system, the front attachment will be
automatically moved through the
auto-MARCCINO control unit. Therefore, the
initialization must be carried out on firm level
ground in a wide space so that work crew is
not hit or injured by the moving front
attachment.
IMPORTANT: If initialization is interrupted, stop

the engine, and reset Dr. ZX to
restart initialization.
Depth Limit Control System Initializing

Procedures Service Switch
(Plug)
1. Connect Dr. ZX to the auto-MARCCINO control

unit, and connect the service switch. Confirm that
hydraulic oil temperature is 20ºC or higher. (Refer
to T5-1-16.)
2. Choose the Target Digging Range Correction from

the Service Modes of Dr. ZX. Follow the
instructions on the window of Dr. ZX.
サービス
3. Choose the Boom Metering Adjustment from the

サービス
Service Modes of Dr. ZX. Follow the instructions

on the window of Dr. ZX.
T1CF-05-01-001
Dr.ZX Connector
(Auto-MARCCINO Controller)
(Stamped Position : UR)
T4-6-4
4. Choose the Arm Metering Adjustment from the
Service Modes of Dr. ZX. Follow the instructions
on the window of Dr. ZX.
5. Choose the Auto Adjustment Of Level Crowd

Operation (for Optional Monitor) from the Service
Modes of Dr. ZX. Follow the instructions on the
window of Dr. ZX.
6. Stop the engine.
Operational Check
1. With Dr. ZX connected, start the engine.
NOTE: If Dr.ZX is not connected to the

auto-MARCCINO control unit, or the
service switch is not connected, setting the
depth to plus side cannot be made.
2. Set the depth to ‘‘+0.1’’ m on the system monitor.
3. Align the bucket teeth with an extension

straight-line passing through the boom top pin and
arm top pin, and make full boom lowering and arm
roll-in at the same time.
Evaluation
Setting is OK when the bucket tooth tip can be

level-crowded at height of 0.1 m above the ground, T197-05-06-005
without touching the ground, in the above operation.
T4-6-5
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
After removing and/or replacing the components as

described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
• Removal of the engine, engine control cable, or

EC motor
• Replacement of MC
Adjustment of Engine Speed:

1. Turn the key switch to the START position to start
the engine.
NOTE: Turn the air conditioner OFF.
2. Rotate the engine control dial to the minimum

speed position. (The output voltage from the EC
sensor is 2.5 V.)
3. Deactivate the auto warming up and ECO control

systems by Dr. ZX.
4. When Dr. ZX is not available, keep the engine

running for about 15 minutes to warm coolant
temperature to more than 30 °C (86 F°) until the
auto warming up control system is deactivated.
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
7. Tighten the lever holding bolt to secure the control

lever to the motor output shaft.
: 30 N⋅m (3 kgf⋅m, 22.1 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
8. Perform engine learning.
T4-6-6
Engine Learning: ZAXIS110/110M/120/130/130LCN
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesn’t stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the learning switch OFF.
7. Check the engine speed. T178-01-02-006
ZAXIS125US/135US
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T1SM-01-02-006
T1CC-05-01-001
Learning Switch Dr.ZX Connector
to MC
ZAXIS135UR
Dr.ZX Connector
to MC
Learning Switch
T1CF-01-01-004
T4-6-7
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
• Governor Lever and Fuel Cut Lever
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Motor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T4-6-8
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
A B
STOP FULL
FULL
T105-07-04-003
STOP
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T4-6-9
(Blank)
T4-6-10
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General
Introduction ............................................... T5-1-1 Components in Control Valve ..................T5-2-16
Diagnosing Procedure .............................. T5-1-2 Signal Control Valve
Built-In Diagnosing System Operation ...... T5-1-6 Port Location .........................................T5-2-26
Built-In Diagnosing Function Display List .. T5-1-7
Dr. ZX Operation ....................................... T5-1-8
Group 3 Troubleshooting A
Troubleshooting A Procedure ....................T5-3-1
Dr. ZX Fault Code List (MC).................... T5-1-10
Fault Code List ..........................................T5-3-2
Dr. ZX Fault Code List
Fault Code 01, 02, 03................................T5-3-3
(Auto-MARCCINO Controller) ............. T5-1-12
Fault Code 04............................................T5-3-3
Dr. ZX Monitoring Item List (MC)............. T5-1-16
Fault Code 06............................................T5-3-4
Dr. ZX Monitoring Item List
Fault Code 07............................................T5-3-5
(Auto-MARCCINO Controller) ............. T5-1-18
Fault Code 10, 11 ......................................T5-3-6
Dr. ZX Special Function .......................... T5-1-19
Fault Code 12, 13......................................T5-3-7
Dr. ZX Service Mode (MC) ...................... T5-1-20
Fault Code 14, 15, 16, 18..........................T5-3-8
Adjustment Data List............................... T5-1-32
Fault Code 19............................................T5-3-9
Group 4 Troubleshooting B
Main Component Layout ........................... T5-2-1
Troubleshooting B Procedure ....................T5-4-1
Electrical Component Layout (Overview) .. T5-2-4
Relationship between Machine Trouble
Electrical System
Symptoms and Related Parts ..................T5-4-2
(Relays and Related Equipment) ............ T5-2-7
Correlation between Trouble
Electrical System
Symptoms and Part Failures .................T5-4-20
(Monitors and Switches)........................ T5-2-10
Engine System Troubleshooting ..............T5-4-33
Pump Device .......................................... T5-2-12
All Actuator System Troubleshooting .......T5-4-54
Swing Device .......................................... T5-2-13
Front Attachment System
Control Valve .......................................... T5-2-13
Troubleshooting.....................................T5-4-60
Signal Control Valve................................ T5-2-13
Swing System Troubleshooting ...............T5-4-72
Solenoid Valve Unit................................. T5-2-13
Travel System Troubleshooting ...............T5-4-75
Travel Device .......................................... T5-2-14
Blade System Troubleshooting................T5-4-82
8-Spool Solenoid Valve ........................... T5-2-14
Other System Troubleshooting ................T5-4-86
Blade Control Valve ................................ T5-2-14
Exchange Inspection ............................. T5-4-112
Positioning Control Valve ........................ T5-2-14
Emergency Boom Lowering
Procedure............................................ T5-4-114
187T-5-1
Group 5 Troubleshooting C Fault Code 92..........................................T5-6-22
Troubleshooting C Procedure ................... T5-5-1
Malfunction of Coolant Group 7 Electrical System Inspection
Temperature Gauge ................................ T5-5-2 Precautions for Inspection and
Malfunction of Fuel Gauge ........................ T5-5-4 Maintenance............................................T5-7-1
Malfunction of Indicator Light Instructions for Disconnecting
Check System ......................................... T5-5-6 Connectors ..............................................T5-7-3
Malfunction of Preheat Indicator ............... T5-5-7 Fuse Inspection.........................................T5-7-4
Malfunction of Engine Oil Level Fusible Link Inspection..............................T5-7-6
Indicator .................................................. T5-5-8 Battery Voltage Check...............................T5-7-7
Malfunction of Coolant Level How to Troubleshoot Alternator
Indicator ................................................ T5-5-10 Malfunctions ............................................T5-7-8
Malfunction of Alternator Indicator .......... T5-5-12 Continuity Check .......................................T5-7-9
Malfunction of Engine Oil Pressure Voltage and Current Measurement.......... T5-7-11
Indicator ................................................ T5-5-14 Check by False Signal.............................T5-7-17
Malfunction of Overheat Indicator ........... T5-5-16 Test Harness ...........................................T5-7-18
Malfunction of Air Filter Restriction
Indicator ................................................ T5-5-18 Group 8 ICX
Malfunction of Buzzer ............................. T5-5-20 Outline ......................................................T5-8-1
Malfunction of LCD ................................. T5-5-22 ICX Fault Code List ...................................T5-8-6
Malfunction of Hour Meter....................... T5-5-23 Satellite Terminal Fault Code List ..............T5-8-6
Malfunction of Hydraulic Oil Filter Fault Code 1 to 4 and 6.............................T5-8-7
Indicator (Optional) ............................... T5-5-24 Fault Code 7 to 10.....................................T5-8-7
Some Parts of Data in Daily Report,
Group 6 Troubleshooting D (ZAXIS 135
UR Only) Frequency Distribution, Cumulative
Troubleshooting D Procedure ................... T5-6-1 Operation Hours are not Recorded..........T5-8-8
Auto-MARCCINO Controller
Fault Code List........................................ T5-6-2
Fault Code 05 ........................................... T5-6-6
Fault Code 06 ........................................... T5-6-6
Fault Code 07 ........................................... T5-6-7
Fault Code 08 ........................................... T5-6-7
Fault Code 11 to 13, 17............................. T5-6-8
Fault Code 14 to 16, 19 to 22 ................. T5-6-10
Fault Code 37, 38, 40 to 42, 44............... T5-6-12
Fault Code 43, 45, 47, 48 ....................... T5-6-13
Fault Code 50 to 52 ................................ T5-6-14
Fault Code 53 ......................................... T5-6-16
Fault Code 60 to 63 ................................ T5-6-18
Fault Code 80 to 83 ................................ T5-6-19
Fault Code 90 ......................................... T5-6-20
Fault Code 91 ......................................... T5-6-21
187T-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- • Troubleshooting C (monitor diagnosis)
dures after any machine trouble has occurred. The Refer to these procedures when gauges and/or
inspection and troubleshooting procedures are pre- indicators are malfunctioning.
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution. Example: Malfunction of fuel gauge
The troubleshooting section in this manual consists of • Troubleshooting D (troubleshooting of the front
8 groups; General, Component Layout, Troubleshoot- attachment operational control using fault codes
ing A (base machine diagnosis using fault codes), (ZAXIS135UR).
Troubleshooting B (base machine diagnosis starting Use there charts when the self-diagnosing func-
with inspection of abnormal operational status), Trou- tion of Dr.ZX shows any fault codes in diagnosing
bleshooting C (monitor diagnosis), Troubleshooting D the Auto-MARCCINO Control Unit. Some fault
(Auto-Marccino diagnosis), Electrical System Inspec- codes may be displayed on the standard monitor.
tion, and ICX.
Example;
• General Dr. ZX : Fault Code 11 ---
Arm Roll-Out Malfunction
• Component Layout Standard Monitor : Fault Code UE11 ---
Arm Roll-Out Malfunction
• Troubleshooting A (base machine diagnosis using
fault codes) • Electrical System Inspection
Refer to these procedures if any fault codes are Refer to this group when required to obtain pre-
displayed when the main controller (MC) is diag- cautions and/or information for the electrical sys-
nosed with Dr. ZX. (or the built-in diagnosing system inspection.
tem)
(MC self-diagnosing function retains a record of Example: Fuse Inspection
the electrical signal system malfunction in the
form of fault codes.) • ICX
Refer to these procedures after any fault code is
Example: Fault Code 06: Abnormal EC Sensor displayed after diagnosing ICX (Information Con-
troller) or the satellite terminal (optional) with Dr.
• Troubleshooting B (base machine diagnosis ZX. (The controller self-diagnosing function re-
starting with inspection of abnormal operational tains a record of the electrical signal system mal-
status) function in the form of fault codes.)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with Example: ICX Fault Code 7: MC Communication
Dr. ZX (or the built-in diagnosing system). Trace Time Out
the cause of trouble based on the inspected result
of the abnormal symptom. In addition, information on the following items is
described in this group.
Example: Even if the engine control dial is oper- (1) Trouble shooting and setting procedures of
ated, engine speed remains unchanged. ICX and satellite terminal using Dr. ZX.
(2) Information on the satellite communication
system
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator T107-07-01-001
Before inspecting, get the full story of

malfunctions from your star witness --- the
operator.
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear
suddenly for the first time?
(d) Did the machine have any other troubles

previously? If so, which parts were repaired
before?
T107-07-01-002
T5-1-2
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Be sure to check for blown fuses
before troubleshooting. Even if a fuse looks
normal by visual inspection, a fine crack is difficult
to find. Always use a tester when checking the
fuses.
T107-07-01-003
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses.
T5-1-3
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
Perform diagnosis by connecting Dr. ZX to the

machine or by operating the built-in diagnosing
system. In case any fault code has been dis-
played by diagnosis using Dr. ZX (or the built-in T107-07-01-005
diagnosing system), delete the fault code once

and retry self-diagnosis again. If the fault code is
displayed again, check the cause of the trouble by
referring to Troubleshooting A in this section (As
for ZAXIS135UR, refore to Trouble shooting D).
After the machine trouble has been corrected, the
fault code (displayed by the built-in diagnosing
function) will be deleted. Therefore, in case prob-
lems which are not easily re-predicable are en-
countered, use Dr. ZX to display the fault code. In
case no fault codes are displayed, check all re-
lated parts/component operating condition using
the monitor function of Dr. ZX (or the built-in di-
agnosing system) while referring to troubleshoot-
ing B in this section.
T107-07-01-006
※ Note that the fault codes displayed do not

necessarily indicate machine trouble. The
controller stores even temporary electrical
malfunctions, such as a drop in battery output
voltage or disconnections of the switches, sensors,
etc., for inspections.
For this reason, the “RETRIAL” is required to
erase the accumulated fault codes from the
controller memory and to confirm if any fault
codes are indicated after the “RETRIAL”.
6. Trace possible causes

Before reaching a conclusion, check the most
T107-07-01-007
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-4
(Blank)
T5-1-5
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the ZAXIS110/110M/120/130/130LCN/125US/135US
HITACHI Dealer Only. Don’t explain
this system function to the customer.
In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. ZX.
Display
Built-In Diagnosing System Activation Selection
1. While pressing the monitor SET switch, turn the Switch
key switch ON.
SET Switch
Built-In Diagnosing System Operation
1. Each time the display selection switch is pressed,
the displayed item will be changed as shown on
next page.
LCD
NOTE: The fault code is indicated in the display
order 8. All fault codes (18 in total) can be
indicated. In case more than one fault code
is indicated, they will be displayed with an
interval of 1 second in order. After the ma-
chine malfunction has been repaired, the
fault codes are automatically deleted. Ac-
T178-01-01-003
cordingly, if any trouble, which is not re-
producible, is encountered, it is recom- ZAXIS135UR
mended to use Dr. ZX.
• The LCD in the service mode displays only the item LCD
No. on the left and the monitored result on the right.
The item description is not displayed. SET Switch
Display
Selection
Switch
T1SM-01-02-014
T5-1-6
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
4 Engine Actual Speed n {{{{ -1 User Mode (Required to set
min
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 {{{ － Display Purpose Only
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ －
9 ML Switch** 1 {{ 0: Switch OFF
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa
sure
11 Pump 2 Delivery Pres- 3 {{ MPa
sure
12 Pump 1 Pump (Flow) 4 {{ MPa
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa
Control Pressure
14 Engine Target Speed 6 {{ -1
min
15 EC Angle 7 {{ V
16 Dial Angle 8 {{ V
17 Boom Raise Pilot Pres- 9 {{ MPa
sure
18 Arm Roll-In Pilot Pres- A {{ MPa
sure
19 Swing Control Pilot b {{ MPa
Pressure
20 Travel Control Pilot c {{ MPa
Pressure
21 Front Att. Operation d {{ 0: Not Operating
1: Operating
22 Att. Control Pressure E {{ MPa
23 Work Mode F {{ 0: Digging
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
NOTE: *: Refer to T5-1-8 for the Fault Codes.

**: ML specification is only available in Japanese domestic market.
T5-1-7
Dr.ZX OPERATION ZAXIS110/110M/120/130/130LCN:
Rear Console Fuse Box
Dr. ZX is a troubleshooting tool to diagnose the elec-
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. ZX is Dr. ZX Connector
(MC)
connected to either the MC or the ICX, it displays
whether the controllers and sensors operate normally
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actuators
such as solenoid valves from the MC and
auto-MARCCINO Controller (ZAXIS135UR) in real
time while operating the machine (Monitor Display
Function).
NOTE: Refer to Group 8 “ICX” for operation of Dr. Dr. ZX Connector

EX connected to the ICX. (ICX)
T178-01-02-006
ZAXIS125US/135US:
Fuse
Box
Dr. ZX Dr. ZX
Connector Connector
to ICX to MC
T1SM-01-02-006
ZAXIS135UR:
Dr. ZX Connector Fuse Box

to MC
Dr. ZX Connector
Dr. ZX Connector
to Auto-Marccino
to ICX
Controller (UR)
T1CF-01-01-013
T5-1-8
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
Palm
tors (MC, ICX and Auto-MARCCINO Controller （Dr. ZX）
(ZAXIS135UR)) located in the cab, using Hot
Sync cable and battery box cable.
Hot Sync Cable
2. Turn the key switch ON, or start the engine.
3. When the palm power is turned ON, palm displays
the following screens in order. Battery Box
3-1. Title Screen Cable
Select the Dr. ZX icon
3-2. Select Kind Screen T178-05-01-167
+ Select the EPVC-Mid
3-3. Menu Screen
Start
Select the Start.
3-4. Model Name Screen
(Example) Model: ZX110
3-5. Function Selection Screen Title Screen
+ Self-Diagnostic Results
+ Monitor Display
+ Special Function Select Kind
Cannot
Screen
NOTE: Special functions allow the ECO and WU Communicate
deactivation. (Refer to T5-1-19)
· Check harness
· Check fuse
4. Select Self-Diagnostic Results. Then, continue to Menu Screen
operate palm by following instructions to be dis-
played at the screen bottom hereafter.
Model Name
NOTE: Refer to the Dr. ZX Operation Manual for Confirmation
the detailed operation of Dr. ZX.
NOT OK
OK ?
OK
Replace software
Self-Diagnosing
Result Display Special
Function Select Monitor Function
function
Self-diagnostic
Result by con- Enter model
troller is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed
Monitored data
is displayed
T5-1-9
Dr.ZX FAULT CODE LIST (MC)
Fault Code Trouble Cause

01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure • Faulty MC
15 Abnormal Boom Raise Pilot Pressure • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure • Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor
T5-1-10
(Blank)
T5-1-11
FAULT CODE LIST (AUTO-MARCCINO
CONTROLLER) (ZAXIS135UR ONLY)
Fault Code
Buzzer System
System Cause of Trouble
Dr. ZX Sound Indicator
Monitor
05 − − ON Faulty monitor (switch box) communication
06 − − ON Abnormal metering correction value
Continuously
07 UE07 ON Abnormal front angle sensor calibration value
sounds
Continuously
08 UE08 ON Abnormal code setting
sounds
11 UE11 Abnormal arm roll-out function
12 UE12 Continuously Abnormal right offset function
ON
13 UE13 sounds Abnormal left offset function
17 UE17 Abnormal boom raise function
14 − − Abnormal arm roll-out acceleration pilot pressure sensor
15 − − Abnormal right offset acceleration pilot pressure sensor
16 − − Abnormal left offset acceleration pilot pressure sensor
19 − − ON Abnormal boom raise acceleration pilot pressure sensor
20 − − Abnormal boom raise pilot pressure sensor
21 − − Abnormal boom lower pilot pressure sensor
22 − − Abnormal arm roll-in pilot pressure sensor
23 − Abnormal auxiliary pilot pressure sensor
37 UE37 Abnormal arm roll-out deceleration proportional solenoid valve

38 UE38 Abnormal 8-unit solenoid valve unit (right offset deceleration)
Long beep
40 UE40 Abnormal 8-unit solenoid valve unit (boom raise deceleration)
sounds in- ON
41 UE41 Abnormal 8-unit solenoid valve unit (arm roll-in deceleration)
termittently
42 UE42 Abnormal 8-unit solenoid valve unit (left offset deceleration)
44 UE44 Abnormal 8-unit solenoid valve unit (boom lower deceleration)
43 − − Faulty 8 unit solenoid valve unit (right offset acceleration)
45 − − Faulty 8 unit solenoid valve unit (arm roll-out acceleration)
47 ON Faulty 8 unit solenoid valve unit (left offset acceleration)
− −
48 − − Faulty boom raise acceleration proportional solenoid valve
NOTE: *Unless the solenoid valve has failed, boom raise operation is correctly controlled in the range lower
than boom foot pin height.
T5-1-12
Trouble on the Machine Corrective Action Group
1) Check harness.
− 2) Replace the controller. G4
3) Replace the system monitor.
1) Abnormal metering correction
Depth limit control stops G4
value.
1) Replace the controller if the con-
* Movement to the cab stops. troller does not operate correctly. G1
1) Input the front and bucket codes

* Movement to the cab stops. G1
again.
1) Check harness.
2) Replace the pilot pressure
All movement stops.(No pilot pressure) sensor. G0
3) Replace the solenoid valve.
Cab collison prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
Offset movement by offset switch stops.
Cab collison prevention control stops, depth limit control stops
Cab collison prevention control stops.
1) Check harness.
G8
2) Replace pilot pressure sensor.
Arm roll-out movement stops. 1) Check harness.
Right offset movement stops. 2) Replace the solenoid valve.
Boom raise movement stops.
G3
Arm roll-in movement stops.
Left offset movement stops.
Boom lower movement stops.
Offset movement by offset switch stops. 1) Check harness.
Cab collison prevention control stops. 2) Replace the solenoid valve.
Offset movement by offset switch stops. G4
Depth limit control stops.
NOTE: If two or more trouble occurs at the same time, the system monitor displays the fault code for the lower
group number only.
T5-1-13
Fault Code
Buzzer System
Monitor
50 UE50 Abnormal boom angle sensor
51 UE51 Abnormal arm angle sensor
52 UE52 Abnormal offset angle sensor
53 UE53 Continuously Abnormal slide arm sensor
ON
sounds
80 UE80 Boom angle sensor deviation

81 UE81 Arm angle sensor deviation
82 UE82 Offset angle sensor deviation
83 UE83 Continuously Slide arm sensor deviation
ON
sounds
60 UE60 Faulty boom angle sensor initial setting.

61 UE61 Continuously Faulty arm angle sensor initial setting.
ON
62 UE62 sounds Faulty offset angle sensor initial setting.
63 UE63 Faulty slide arm sensor initial setting.
Faulty hydraulic oil temperature sensor.
90 − − ON
Abnormal sensor power source.
91 − − ON
Abnormal reference power source. (Abnormal voltage supplied
92 − − −
to Auto-MARCCINO controller)
Complete front attachment angle sensor initial setting.
F0 − − −
Continuously Invasion of hazardous area by emergency evacuation switch.
F2 − −
sounds
Escape out of hazardous area.
F3 − − −
Short beep Invasion of hazardous area by interference prevention mode.
F4 UE00 sounds ON
intermittently
FA − − − Install attachment select switch
FB − − − Remove attachment select switch
FC − − −
group number only.
T5-1-14
Interference prevention control system functions 1) Check harness.

as if boom is raised to the highest position. 2) Replace the angle sensor.
Interference prevention control system functions
as if arm is fully rolled in.
G2
as if the front attachment is fully offset to the left
side.
as if boom is raised to the highest position. 2) Check angle sensor installation.
Interference prevention control system functions 3) Replace the angle sensor.
as if arm is fully rolled in. Interference prevention
G2
control system functions as if the front attach-
ment is fully offset to the left side.
as if slide arm is fully extension.
1) Check harness.
2) Replace the angle sensor

G4
as if oil temperature is lowest. 2) Replace the hydraulic oil temperature sensor.
Depth limit control stops 1) Initialize the angle sensor again.
G4
Cab collison control stops. 2) Replace the angle sensor.
Normal Movement by backup function. 1) Check harness.
G8
* Movement to the cab stops.
G5
− G7
− G8
All movement stops. (No pilot pressure) G0
G8
G8
G8
T5-1-15
Dr.ZX MONITORING ITEM LIST (MC)
Dr. ZX displays the input signals from the switches and
sensors to the MC and the control signals to the ac-
tuators from the MC.
Item Data Unit

Pump 1 Delivery Pressure Input signals from pump 1 delivery pressure sensor MPa
Pump 1 Pump (Flow) Con- Input signals from pump 1control pressure sensor MPa
trol Pressure
Pump 2 Delivery Pressure Input signals from pump 2 delivery pressure sensor MPa
Pump 2 Pump (Flow) Con- Input signals from pump 2control pressure sensor MPa
trol Pressure
Pump 2 Max. Displacement cm3
Engine Target Speed Target speed when loaded. Approx. 150 min differs min-1
-1
from speed when unloaded.

Engine Actual Speed Input signal from N sensor min-1
Deviation in Engine Speed Calculated Value min-1
(Engine Speed Differencial) (Target Engine Speed - Actual Engine Speed)
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (arm roll-in) MPa
Swing Control Pressure Input signal from pressure sensor (swing) MPa
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) FR
Hydraulic Oil Temperature Input signal from oil temperature sensor °C
E/P/HP Mode Switch Power mode switch selection status E, P, HP
Auto-Idle/Auto-Accel Switch Auto-Idle/Acceleration selection status AI, AA
Travel Mode Travel mode switch selection status Lo, Hi
Power Digging (Boost) Power digging switch status Pd
Switch
Work mode Work mode switch selection status STD, ATT
ATT. Mode BU, CS, CL, HB
Engine Learning Status Done, Undone,
Aborted Ky
Pump 2 Proportional Sole- Control signal to max. pump 2 flow rate limit solenoid MPa
noid Valve Output valve
Pump Torque Proportional Control signal to torque control solenoid valve MPa
Solenoid Valve Output
Arm Regenerative Propor- Control signal to solenoid valve SC MPa
tional Solenoid Valve Out-
put
Travel Motor Control Pres- Control signal to solenoid valve SI MPa
sure
EC Motor Position step
T5-1-16
Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sensor MPa
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
Arm Roll-Out Pilot Pressure Input signal from pressure sensor (arm roll-out) MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Offset Angle V
Pump 1 Max. Displacement cm3
Boom Dampener Switch OFF, SOFT, HARD
Pump 1 Proportional Solenoid Valve Control signal to max. pump 1 flow rate limit so- MPa
Output lenoid valve
ATT. Proportional Solenoid Valve MPa
Output
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial *ML Setting Unf, Done, Abrt,
Und
NOTE: ML specification is only available in Japanese domestic market.
T5-1-17
Dr.ZX MONITORING ITEM LIST
(AUTO-MARCCINO CONTROLLER)
(ZAXIS135UR ONLY)
Dr.ZX has a function to monitor the command signals
from the Auto-MARCCINO Controller Unit and input
signals from various switches and sensors.
Data Unit Data Unit

Boom angle sensor voltage V ON/OFF signal from slide arm retracted solenoid Dsd*
Arm angle sensor voltage V valve
Offset angle sensor voltage V ON/OFF signal from slide arm extended sole- Dss*
Slide arm sensor voltage V noid valve
Oil temperature ºC Boom angle sensor value before correction V
Boom raise deceleration solenoid valve current mA Arm angle sensor value before correction V
Boom lower deceleration solenoid valve current mA Offset angle sensor correction value V
Arm roll-in deceleration solenoid valve current mA Slide arm angle sensor correction value V
Arm roll-out deceleration solenoid valve current mA Boom angle sensor standard value V
Left offset deceleration solenoid valve current mA Arm angle sensor standard value V
Boom raise acceleration solenoid valve current mA Offset angle sensor standard value V
Arm roll-out acceleration solenoid current mA Slide arm angle sensor standard value V
Left offset acceleration solenoid valve current mA Monitored height m
Right offset acceleration solenoid valve current mA Monitored reach m
Right offset deceleration solenoid valve current mA Monitored offset amount m
Boom raise pilot pressure MPa ON/OFF signal from breaker switch Sbr *
Boom raise acceleration pilot pressure MPa ON/OFF signal from bucket switch Sbk *
Boom lower pilot pressure MPa ON/OFF signal from breaker lamp LMP*
Arm roll-in pilot pressure MPa Auxiliary pilot pressure MPa
Arm roll-out acceleration pilot pressure MPa NOTE: * White letters (or figures) are shown on
Right offset acceleration pilot pressure MPa the black screen when the switches are
Left offset acceleration pilot pressure MPa ON (connected).
ON/OFF signal from right offset switch Sor *
ON/OFF signal from left offset switch Sol *
ON/OFF signal from prohibited-area release Sav *
switch
ON/OFF signal from interference prevention Sin *
mode switch
ON/OFF signal from emergency evacuation Spr *
switch
ON/OFF signal from initial setting switch Scl *
ON/OFF signal from service switch Ssv *
ON/OFF signal from range limit release switch Slm *
Buzzer output Dbz *
Lock/Unlock signal of pilot pressure Dpi *
T5-1-18
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS110.
Start the service software in the Select a special function

operation mode
If the following screen appears, Select the function you want to
you are in the operation mode. execute.
Select Special Function.
Fig. A Fig. B
T178-05-01-013 T178-05-01-168
Select ESC to return
to Fig. A.
Special function
Select Execute to execute the

function.
WU deactivation ECO control deactivation
Execute Execute
T178-05-01-030 T178-05-01-031 T178-05-01-032 T178-05-01-033

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. B. to Fig. B. to Fig. B. to Fig. B.
T5-1-19
Dr.ZX SERVICE MODE (MC) ZAXIS110/110M/120/130/130LCN
Engine
Dr. ZX has three (3) modes, learning value display, Learning
Switch
parameter change, and monitor display information
setting.
Learning Value Display Dr.ZX

Connector
Displays the values set by learning function. to MC
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.
Monitor Display Information Setting

Items to be displayed on the monitor LCD can be
added.
T178-01-02-006
• Accessing Service Mode
1. After turning the key switch OFF, wait for more ZAXIS125US/135US
than 10 seconds.
2. Connect Dr. ZX to the connector to MC on the
base machine.
3. Turn the engine learning switch to the learning
position (the stamped mark E side).
4. Turn the key switch ON. Don’t start the engine at
this time.
5. Turn Dr. ZX switch ON.
Learning Switch T1SM-01-02-006

Dr.ZX Connector
to MC
ZAXIS135UR
Dr.ZX Connector to
The learning switch is MC
turned to the stamped
mark E
Learning Switch
Stamped
Mark E
T1CC-05-01-001
Learning Switch
T1CF-01-01-004
T5-1-20
(Blank)
T5-1-21
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Offset Angle Sensor Correction Value Display of offset angle sensor correction valve
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation en-
Speed Adjustment gine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjust- Adjustment of lowest pump 1 max. flow rate in breaker opera-
ment tion
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher opera-
tion
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory ham-
mer operation
Hyd. Breaker P2 Max Swash Angle Adjust- Adjustment of lowest pump 2 max. flow rate in breaker opera-
ment tion
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher opera-
tion
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory ham-
mer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Proportional Solenoid Valve Adjustment Adjustment of optional solenoid valve
T5-1-22
Item Data
Boom Lower Dampener Proportional Sole- Adjustment of solenoid valve
noid Valve Adjustment
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
*ML Crane Front Code Change Setting of front att. code for ML models
*ML Crane Bucket Code Change Setting of bucket code for ML models
Max. *ML Crane Speed Adjustment Setting of engine speed in crane mode
*ML Crane Bucket Weight Adjustment
Min, Boom CYL. Bottom Pressure Over Bal-
ance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil tempera-
ture
Overload Alarm Display/No-display Monitor setting of display/no-display of overload alarm.
NOTE: ML specification is only available in Japanese domestic market.
T5-1-23
Displaying Engine Learning Data and Angle Sensor Correction Valve
Start the service software in The service software will

the service mode start in the service mode
Select Start from the Press Correct if the dis- Confirm that you are in the Select Special Function.
EPVC_Mid software menu. played model name is cor- service mode, and select
rect. Rechecked.
Fig. A T178-05-01-006 Fig. B T187-05-01-001 Fig.C T178-05-01-034 Fig. D T178-05-01-035

Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.
Select the function you Learning data items will

want to execute be displayed
The menu will be displayed. Select the item you want to
Select Learning Data Display execute.
from the menu.
Fig. E T178-05-01-036 Fig. F T178-05-01-037

Select ESC to return Select ESC to return
to Fig. D. to Fig. F.
T5-1-24
EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T178-05-01-038 T178-05-01-039 T178-05-01-040 T178-05-01-041

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. F. to Fig. F. to Fig. F. to Fig. F.
T5-1-25
Changing Parameters In The Controller
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password”
section.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the Select Special Function.
EPVC_Mid software menu. model name is correct. service mode, and select Re-
checked.
Fig. A T178-05-01-006 Fig. C T178-05-01-034 Fig. D T178-05-01-035

Fig. B T187-05-01-001 Select ESC to return Select ESC to return
Select ESC to return to Fig. A. to Fig. A
to Fig. A.
Execute the parameter Select a parameter change

change Enter the password
item
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-26
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the Ad- The new value will be displayed
The adjusted value will be dis-
justment space, and press in the Adjustment space. Select
played.
Execution. Execute to change to this value.
T178-05-01-045 T178-05-01-046 T178-05-01-047

to Fig. G. to Fig. G. to Fig. G.
T5-1-27
Changing The User Mode Display on The Monitor Panel
Start the service mode on the condition that the engine learning switch is turned on.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the
EPVC_Mid software menu. model name is correct. service mode, and select Re- Select Special Function.
checked.
Fig. A T178-05-01-006 Fig. B T187-05-01-001 Fig. C T178-05-01-034 Fig. D T178-05-01-035

to Fig. A. to Fig. A. to Fig. A.
Execute the monitor display Select a display change Select Display or

change item No Display
The menu will be displayed. Select the monitor display Select Disp or No Disp.
Select Monitor Display from change item you want to exe-
the menu. cute.
Fig. E T178-05-01-042 Fig. F T178-05-01-048 Fig. G T178-05-01-049

to Fig. D. to Fig. E. to Fig. F.
T5-1-28
Confirm Disp/No Disp Confirm the result

Confirm that the Monitor space
shows Disp or No Disp. If it is It has been changed as shown
correctly displayed, select on-screen. Select ESC.
Execute.
Fig. H T178-05-01-050 Fig. I T178-05-01-051

Select ESC to return
to Fig.F. Select ESC to return to Fig. F.
T5-1-29
• Operational Performance Check After Adjustment
(Check that pump flow rate and engine speed
have been changed.)
IMPORTANT: After adjusting the engine speed and

flow rate to the attachment, turn the
engine learning switch to neutral. If
the engine is started with the engine
learning switch in the engine learn-
ing position, the MC will not control
the engine, pumps, and valves so
that change in the pump flow rate
and the engine speed cannot be
checked.
1. Turn the key switch OFF.

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. ZX. connector (When moni-
toring with Dr. ZX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.
T5-1-30
(Blank)
T5-1-31
ADJUSTMENT DATA LIST
ZAXIS110, 110M, ZAXIS125US

Min. Adjust- Adjustable Range Standard
Adjustment Data Remarks
ment Value Model Range Adjustment
Li Speed 10 min-1 ZX110/110M/125US 0 to 120 0 min-1
WU Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
AI Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
E Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
P Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
Breaker Speed 10 min-1 ZX110/110M/125US -500 to 200 0 min-1
Secondary Crusher ZX110/110M/125US
10 min-1 -500 to 200 200 min-1
(Demolisher) Speed
Crusher Speed 10 min-1 ZX110/110M/125US -500 to 200 200 min-1
Vibro-Hammer Speed 10 min-1 ZX110/110M/125US -500 to 200 0 min-1
Hyd. Breaker P1 Max ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Swash Angle
Secondary (Demolisher) P1 ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Max Crusher Swash Angle
Crusher P1 Max Swash ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Angle
Vibro PI Max Swash Angle 0.6 cm3/rev ZX110/110M/125US 25.8 to 57 57 cm3/rev
Hyd. Breaker P2 Max ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Swash Angle
Secondary Crusher ZX110/110M/125US
(Demolisher) P2 Max 0.6 cm3/rev 25.8 to 57 57 cm3/rev
Swash Angle
Crusher P2 Max Swash ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Angle
Vibro P2 Max Swash Angle 0.6 cm3/rev ZX110/110M/125US 25.8 to 57 57 cm3/rev
Pump PQ Base Torque ZX110/110M/125US
2.45 N･m -78.4 to 0 0 N･m
Adjustment
T5-1-32
Min. Adjust- Standard

Adjustment Data Adjustable Range Remarks
ment Value Adjustment
ATT Proportional Solenoid
0.1 MPa ZX110/110M/125US -0.89 to 0.89 0 MPa
Valve
Boom Lower Dampener ZX110/110M/125US
0.1 MPa -0.89 to 0.89 0 MPa
Proportional Solenoid Valve
ATT Speed Increase Down ZX110/110M/125US
500 ms 0 to 3000 3000 ms
Wait Time
*ML Crane Front Code 1 ZX110/110M/125US 0 to 2 0
*ML Crane Bucket Code 1 ZX110/110M/125US 0 to 1 0
Max. *ML Crane Speed 10 min -1
ZX110/110M/125US -450 to 400 0 min-1
*ML Crane Bucket Weight 4 kg ZX110/110M/125US -512 to 508 0 kg
Min Boom Cyl. Bottom ZX110/110M/125US
0.1 MPa -9.81 to 9.81 0 MPa
Pressure Over Balance
NOTE: 1 MPa = 98.07 kPa

1 kgf⋅m = 9.807 N⋅m
ML specification is only available in Japa-
nese domestic market.
T5-1-33
ZAXIS120, ZAXIS130, ZAXIS130LCN, ZAXIS135US, ZAXIS135UR

Min. Adjustment Adjustable Range Standard
Value Model Range Adjustment
Li Speed ZX120/130/130LCN/
10 min-1 0 to 120 0 min-1
135US/135UR
WU Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
AI Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
E Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
P Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
Breaker Speed ZX120/130/130LCN/
10 min-1 -500 to 200 0 min-1
135US/135UR
Secondary Crusher (De- ZX120/130/130LCN/
10 min-1 -500 to 200 200 min-1
molisher) Speed 135US/135UR
Crusher Speed ZX120/130/130LCN/
10 min-1 -500 to 200 200 min-1
135US/135UR
Vibro-Hammer Speed ZX120/130/130LCN/
10 min-1 -500 to 200 0 min-1
135US/135UR
Hyd. Breaker P1 Max ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Swash Angle 135US/135UR
Secondary (Demolisher)
ZX120/130/130LCN/
P1 Max Crusher Swash 0.6 cm3/rev 27 to 60 60 cm3/rev
135US/135UR
Angle
Crusher P1 Max Swash ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Angle 135US/135UR
Vibro Pi Max Swash Angle ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
135US/135UR
Hyd. Breaker P2 Max ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Swash Angle 135US/135UR
T5-1-34
Min. Adjustment Adjustable Range Standard

Value Model Range Adjustment
Secondary Crusher
ZX120/130/130LCN/
(Demolisher) P2 Max 0.6 cm3/rev 27 to 60 60 cm3/rev
135US/135UR
Swash Angle
Crusher P2 Max Swash ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Angle 135US/135UR
Vibro P2 Max Swash An- ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
gle 135US/135UR
Pump PQ Base Torque ZX120/130/130LCN/
2.45 N･m -78.4 to 0 0 N･m
Adjustment 135US/135UR
ATT Proportional Solenoid ZX120/130/130LCN/
0.1 MPa -0.89 to 0.89 0 MPa
Valve 135US/135UR
Boom Lower Dampener
ZX120/130/130LCN/
Proportional Solenoid 0.1 MPa -0.89 to 0.89 0 MPa
135US/135UR
Valve
ATT Speed Increase ZX120/130/130LCN/
500 ms 0 to 3000 3000 ms
Down Wait Time 135US/135UR
*ML Crane Front Code ZX120/130/130LCN/
1 0 to 2 0
135US/135UR
*ML Crane Bucket Code ZX120/130/130LCN/
1 0 to 1 0
135US/135UR
Max. *ML Crane Speed ZX120/130/130LCN/
10 min-1 -450 to 400 0 min-1
135US/135UR
*ML Crane Bucket Weight ZX120/130/130LCN/
4 kg -512 to 508 0 kg
135US/135UR
Min Boom Cyl. Bottom ZX120/130/130LCN/
0.1 MPa -9.81 to 9.81 0 MPa
Pressure Over Balance 135US/135UR
NOTE: 1 MPa = 98.07 kPa

1 kgf⋅m = 9.807 N⋅m
ML specification is only available in Japa-
T5-1-35
(Blank)
T5-1-36
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
ZAXIS110, 110M, ZAXIS120, ZAXIS130, ZAXIS130LCN
1
3
4
5
6
7
10
11
12
13
14
20 15
16
19
18 17
T176-01-02-001
1 - Bucket Cylinder 7 - Fuel Tank 13 - Intercooler 19 - Pilot Shut-Off Valve

(ZAXIS120,130,130LCN
Only)
2 - Arm Cylinder 8 - Hydraulic Oil Tank 14 - Radiator 20 - Travel Pilot Valve
3 - Boom Cylinder 9 - Control Valve 15 - Oil Cooler 21 - Front Attachment/Swing
Pilot Valve
4 - Center Joint 10 - Pilot Filter and Pilot Relief 16 - Battery
Valve
5 - Swing Bearing 11 - Pump Device 17 - Travel Device
6 - Swing Device 12 - Engine 18 - Signal Control Valve
T5-2-1
ZAXIS125US, ZAXIS135US
2 3
1 5
19
6
7
8
18
17
16
9
10
11 T1SE--01-02-001
12
14 13
15
1 - Front Attachment / Swing 6 - Boom Cylinder 11 - Signal Control Valve 16 - Engine

Pilot Valve
2 - Pilot Shut-Off Valve 7 - Hydraulic Oil Tank 12 - Center Joint 17 - Radiator
3 - Travel Pilot Valve 8 - Fuel Tank 13 - Swing Device 18 - Oil Cooler
4 - Arm Cylinder 9 - Control Valve 14 - Pilot Filter / Pilot Relief 19 - Intercooler (ZAXIS 135US
Valve Only)
5 - Bucket Cylinder 10 - Solenoid Valve Unit 15 - Pump Device
T5-2-2
ZAXIS135UR
2
3
4
1
5
6
7
8
9
10
11
12
13
29
14
28 15
16
17
18
27
26
25
24
23
22 19
21
20 T1SM-01-02-001
1- Bucket Cylinder 9- Solenoid Valve Unit 16 - Pump Device 23 - Emergency Stop Valve
2- Arm Cylinder 10 - Signal Control Valve 17 - Engine 24 - Blade Pilot Valve
3- Offset Cylinder 11 - Fuel Tank 18 - Blade Cylinder 25 - Pilot Shut-Off Valve
4- Offset Anti-Drift Valve 12 - Hydraulic Oil Tank 19 - Radiator 26 - Travel Pilot Valve
5- Boom Cylinder 13 - Pilot Filter / Pilot Relief 20 - Oil Cooler 27 - Travel Device
Valve
6- Blade Signal Switch 14 - Swing Device 21 - Center Joint 28 - Offset Pilot Valve
Valve
7 - Control Valve 15 - Blade Control Valve 22 - Battery 29 - Front Attachment / Swing
Pilot Valve
8- 8-Unit Solenoid Valve
Unit
T5-2-3
ELECTRICAL COMPONENT LAYOUT
(Overview)
3
• Pressure Sensor (Front Attachment)
Refer to the Swing Device group. 4
2 • Pressure Sensor
1 (Boom Raise)
• Pressure Sensor
(Arm Roll-In)
Refer to the Control Valve
group.
16
• Pressure Sensor (Travel)

• Pressure Sensor (Swing)
Refer to the Signal Control
Valve group.
15 7
8
14
13 • Pump 1 and 2 Delivery Pressure Sensor

• Pump 1 and 2 Control Pressure Sensor T176-01-02-004
9 • N Sensor
10 • Torque Control Solenoid Valve
12 11 • Pump 2 Flow Rate Control Solenoid Valve
1 - Horn 5 - Hydraulic Oil Temperature 9 - Overheat Switch 13 - *Coolant Level Switch

Sensor
2 - Work Light 6 - EC Motor and EC Sensor 10 - Coolant Temperature 14 - Battery
Sensor
3 - Fuel Sensor 7 - Engine Oil Pressure Switch 11 - Battery Relay 15 - Air Cleaner Restriction
Switch
4 - Solenoid Valve Unit 8 - *Engine Oil Level Switch 12 - Glow Plug Relay 16 - Wiper Motor
NOTE: * ZAXIS110, 110M: Up to serial No.010576
ZAXIS120: Up to serial No.062964
T5-2-4
• Pump 1 and 2 Delivery Pressure Sensor

• Pump 1 and 2 Control Pressure Sensor
• N Sensor
• Pump 2 Flow Rate Control Solenoid Valve
1 3
2
4
15
6
7
14
13
8
10

(Boom Raise) (Travel)
(Arm Roll-In) (Swing)
Refer to the Control Valve Refer to the Signal 11
group Control Valve group 12
T1SE-01-02-002
• Pressure Sensor
(Front Attachment)
Refer to the Swing Device group
1 - EC Motor and EC Sensor 5 - Coolant Temperature 9 - Battery 13 - Solenoid Valve Unit

Sensor
2 - *Engine Oil Level Switch 6 - *Coolant Level Switch 10 - Air Cleaner Restriction 14 - Hydraulic Oil Temperature
Switch Sensor
3 - Engine Oil Pressure Switch 7 - Battery Relay 11 - Wiper Motor 15 - Fuel Sensor
4 - Overheat Switch 8 - Glow Plug Relay 12 - Horn
NOTE: * ZAXIS125US: Up to serial No.010576
ZAXIS135US: Up to serial No.062964
T5-2-5
ZAXIS135UR
1 2
• Pump 1 and 2 Delivery Pressure

Sensor
• Pump 1 and 2 Control Pressure
Sensor
• N Sensor
• Pump 2 Flow Rate Control 17
Solenoid Valve
4
17
16
15
5
6
• Pressure Sensor
(Travel)
• Pressure Sensor
(Swing)
Refer to the Signal
7
Control Valve group 8
14
10
13
12
• Pressure Sensor (Boom Raise)
• Pressure Sensor
(Arm Roll-In) 11
Refer to the Control Valve group. T1SM-01-02-008
1 - Arm Angle Sensor 6- Coolant Temperature 11 - Emergency Stop Solenoid 16 - Hydraulic Oil Temperature
Sensor Valve Sensor
2 - Offset Angle Sensor 7 - Battery Relay 12 - Horn 17 - Pressure Sensor (Front
Attachment)
3 - Boom Angle Sensor 8 - Glow Plug Relay 13 - 8-Unit Solenoid Valve Unit 18 - EC Motor / EC Sensor
4 - Engine Oil Pressure Switch 9 - Battery 14 - Solenoid Valve Unit
5 - Overheat Switch 10 - Air Cleaner Restriction 15 - Fuel Sensor
Switch
T5-2-6
ELECTRICAL SYSTEM
(Relays and Related Equipment) Rear Deck
5
3 4
2
10
T178-01-02-006
15
14
18 13
17 12
16 11
T178-01-02-007
1- Mail Switch (Satellite 6- Fuse Box 11- Load Damp Relay (R1) 16- Wiper Relay A (R6)
Navigation System
Equipped Machines only)
2- QOS Controller 7- Learning Switch 12- Washer Relay (R2) 17- Wiper Relay B (R7)
3- ICX (Information Controller) 8- Dr. ZX Connector to MC 13- Work Light Relay 2 (R3) 18- Wiper Relay C (R8)
4- MC (Main Controller) 9- Download Connector (Not connected on 14- Work Light Relay 1 (R4)
Satellite Navigation System equipped
machines)
5-Satellite Terminal (Optional) 10- Dr. ZX Connector to ICX 15- Horn Relay (R5)
T5-2-7
15
ZAXIS125US、ZAXIS135US 4
16
14
17
13
12
11 5
10
T1GF-01-02-003
6
1, 2 3
9 8 7
T1SM-01-02-006
1- ICX (Information Controller) 6- Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
2- MC (Main Controller) 7- Dr.ZX Connector to MC 12 - Work Light Relay 2 (R3) 17 - Wiper Relay C (R8)
3- Satellite Terminal (Optional) 8- Dr.ZX Connector to ICX 13 - Washer Relay (R2)
4- Download Connector (Not 9- Learning Switch 14 - Load Damp Relay (R1)
connected on Satellite
Navigation System equipped
machines)
5 - Diode D1, D2, D3 and D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)
T5-2-8
ZAXIS135UR
Behind Seat
1 2 3
Upward
Speaker
T1CF-01-01-011
T1CF-01-01-012
6
7
5 8
4
9
18
10
17
16
15
14
11
12
13
T1CF-01-01-013
1 - Auto - Marccino Control Unit 6 - Fuse Box 11 - Wiper Relay (R6) 15 - Work Right Relay 1 (R4)
2 - MC (Main Controller) 7 - Emergency Evacuation 12 - MC Relay (Optional) 16 - Work Right Relay 2 (R3)
Switch
3 - ICX (Information Controller) 8 - Learning Switch 13 - Air Bleed Relay 17 - Washer Relay (R2)
(R8) (Optional)
4 - Dr. ZX Connector to ICX 9 - Dr. ZX Connector for UR 14 - Horn Relay (R5) 18 - Load Damp Relay (R1)
5 - Dr. ZX Connector to MC 10 - Personal Computer
Connector to ICX
T5-2-9
ELECTRICAL SYSTEM
ZAXIS110/110M/120/130/130LCN/125US/135US
1 2
20
19
21
18
3
17
22
16 4
15
5 23
14 24
6
13 7
12 8
25
11
9
10
T178-01-01-012
T178-01-01-013
1- Coolant Temperature 8- Alternator Indicator 15 - Digging Mode Indicator 21 - Auto-Idle/Acceleration

Gauge Selector
2 - Fuel Gauge 9- Hydraulic Oil Filter 16 - Attachment Mode Indicator 22 - Power Mode Switch
Indicator (Optional)
3- Display Selection Switch 10 - *Coolant Level Indicator 17 - Liquid Crystal Display 23 - Travel Mode Switch
4- SET Switch 11 - *Engine Oil Level Indicator 18 - Auto-Idle Indicator 24 - Work Light Switch
5- Work Mode Switch 12 - Engine Oil Pressure 19 - Auto-Acceleration Indicator 25 - Wiper/Washer Switch
Indicator
6- Fuel Level Indicator 13 - Preheat Indicator 20 - Engine Control Dial
7- Air Filter Restriction Switch 14 - Overheat Indicator
NOTE: * ZAXIS110/110M/125US: Up to serial No.010576

ZAXIS120/135US: Up to serial No.062964
T5-2-10
ZAXIS135UR Monitor 6 7
1
8
2 9
3 10
11
24
4 12
23 13
5
22
14
21 15
T1CF-01-01-003
20 16
19 17
18
T1SM-01-02-014
1- Left Offset Switch 7- Fuel Gauge 13 - Auto-Idle / Acceleration 19 - Preheat Indicator

Selector
2- Right Offset Switch 8 - Liquid Crystal Display 14 - Work Light Switch 20 - Air Filter Restriction Switch
3- Prohibited-Area Release 9 - Set Switch 15 - Auto - Marccino Switch 21 - Alternator Indicator
Switch
4 - Engine Control Dial 10 - Display Selection Switch 16 - Washer Switch 22 - Fuel Level Indicator
5 - Key Switch 11 - Power Mode Switch 17 - Wiper Switch 23 - Overheat Indicator
6 - Coolant Temperature 12 - Travel Mode Switch 18 - Hydraulic Oil Filter 24 - Engine Oil Pressure
Gauge Indicator (Optional) Indicator
T5-2-11
PUMP DEVICE
ZAXIS110/110M/120/130/130LCN/125US/135US
3 4
2 1
T176-03-01-002
7 6 5 10 9 8
T176-03-01-001
ZAXIS135UR
3 4 2 1
T1SM-03-01-002
11 7 6 5 10 9 8
T1SM-03-01-001
1 - Pump 1 4- Pump 2 Control Pressure 7- Max. Pump 2 Flow Rate 10 - Pump 2 Delivery Pressure
Sensor Limit Solenoid Valve Sensor
2 - Pump 2 5 - Pump 1 Control Pressure 8 - N Sensor 11 - Blade Pump
Sensor
3 - Pilot Pump 6 - Torque Control Solenoid 9- Pump 1 Delivery Pressure
Valve Sensor
T5-2-12
SWING DEVICE CONTROL VALVE 3
4
1
T176-01-02-003
T176-01-02-002
SIGNAL CONTROL VALVE SOLENOID VALVE UNIT
8
7
9
T176-03-07-002
T178-03-06-015
1 - Pressure Sensor 4- Main Relief Valve 7- Pressure Sensor (Travel) 9- Solenoid Valve Unit (SI)
(Front Attachment) (Except
Swing Device of
ZAXIS135UR)
2 - Swing Relief Valve 5- Pressure Sensor 8- Solenoid Valve Unit (SC)
(Boom Raise)
3 - Pressure Sensor 6 - Pressure Sensor (Swing)
(Arm Roll-In)
T5-2-13
8-UNIT SOLENOID VALVE UNIT BLADE CONTROL VALVE
(ZAXIS135UR Only) (ZAXIS135UR Only)
1 (2-piece Boom Only)
2
15 3
4
5
14
6
7
13
8
9
12
16
10
T178-03-03-071
T1SM-01-02-003
11
TRAVEL DEVICE
ZAXIS110, 120, 130, 130LCN, 125US, 135US, ZAXIS110M
135UR
18
17
18
T155-01-01-006 T155-01-01-013
17
1 - Pilot Pressure Sensor (E1: 6 - Pilot Pressure Sensor (E4: 11 - Hydraulic Oil Temperature 15 - Solenoid Valve (C3: Boom
Boom Raise) Left Offset Acceleration) Sensor Lower Deceleration)
2 - Solenoid Valve (C1: Boom 7 - Solenoid Valve (C9: Left 12 - Solenoid Valve (C4: Arm 16 - Overload Relief Valve
Raise Acceleration) Offset Acceleration) Roll - In Deceleration) (Blade), (Positioning)
3 - Pilot Pressure Sensor (E2: 8 - Pilot Pressure Sensor (E5: 13 - Solenoid Valve (C8: Left 17 - Travel Relief Valve
Boom Lower) Arm Roll - Out) Offset Deceleration)
4 - Pilot Pressure Sensor (E6: 9 - Solenoid Valve (C7: Arm 14 - Solenoid Valve (C5: Right 18 - Counterbalance Valve
Right Offset Acceleration) Roll - Out Acceleration) Offset Deceleration)
5 - Solenoid Valve (C6: Right 10 - Pilot Pressure Sensor (E3:
Offset Acceleration) Arm Roll - In)
T5-2-14
(Blank)
T5-2-15
COMPONENTS IN CONTROL VALVE
1 2 3 4 5 6 7 8 9 10
11
Auxiliary Bucket Cylinder
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
23
Swing Motor 19
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
T5-2-16
Control Valve
34 Machine Front
31 ZAXIS125US
ZAXIS135US
ZAXIS135UR
4
16
18, 19
5
21
12
9, 10
Machine Front
ZAXIS110/110M
ZAXIS120
ZAXIS130 T176-03-03-038
ZAXIS130LCN
1 - Load Check Valve 11 - Bucket Regenerative 21 - Bypass Shut-Out Valve 31 - Arm Regenerative Valve
(Travel Tandem Circuit) Valve (Selector Valve)
2 - Load Check Valve 12 - Overload Relief Valve 22 - Overload Relief Valve (Blade: 32 - Arm Regenerative Valve
(Travel Parallel Circuit) (Bucket: Rod Side) Rod Side) (ZX135UR Only)
3 - Check Valve 13 - Overload Relief Valve 23 - Overload Relief Valve (Blade: 33 - Overload Relief Valve
(Main Relief Circuit) (Bucket: Bottom Side) Bottom Side) (ZX135UR Only) (Arm: Bottom Side)
4 - Main Relief Valve 14 - Load Check Valve 24 - Load Check Valve (Blade) 34 - Overload Relief Valve
(Boom 1 Parallel Circuit) (ZX135UR Only) (Arm: Rod Side)
5 - Check Valve 15 - Boom Regenerative Valve 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
(Main Relief Circuit) Tandem Circuit) (ZX135UR (Check Valve)
Only)
6 - Flow Combiner Valve 16 - Overload Relief Valve 26 - Main Relief Valve (Blade) 36 - Arm Anti-Drift Valve
(Boom: Bottom Side) (ZX135UR Only) (Selector Valve)
7 - Check Valve 17 - Overload Relief Valve 27 - Check Valve (Orifice) (Arm 2 37 - Load Check Valve
(Flow Combining Circuit) (Boom: Rod Side) Parallel Circuit) (Boom 2 Parallel Circuit)
8 - Aux. Flow Combining Valve 18 - Boom Anti-Drift Valve 28 - Load Check Valve (Arm 1 38 - Aux. Flow Rate Control
(Check Valve) Parallel Circuit) Valve (Poppet Valve)
9 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 29 - Load Check Valve (Arm 1 39 - Aux. Flow Rate Control
Valve (Selector Valve) (Selector Valve) Tandem Circuit) Valve (Selector Valve)
10 - Bucket Flow Rate Control 20 - Load Check Valve 30 - Load Check Valve 40 - Load Check Valve
Valve (Poppet Valve) (Arm 2 Tandem Circuit) (Swing Circuit) (Bucket Parallel Circuit)
T5-2-17
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
T5-2-18
35, 36
Machine Front
ZAXIS125US
ZAXIS135US
ZAXIS135UR
38, 39
33
Machine Front
ZAXIS110/110M
ZAXIS120
ZAXIS130
ZAXIS130LCN 8 17 T176-03-03-036
13
6 40 7
5 - Check Valve 15 - Boom Regenerative Valve 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
Only)
T5-2-19
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
13
39
14 Boom Cylinder
38 15
Arm Cylinder 16
37
36 17
Blade Cylinder
35 18 (ZX135UR Only)
34
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
F 26 (ZX135UR Only)
E T1SM-03-03-001
D Cross Section A
C
B
4
A 5
39
8
7
6
T176-03-03-035
T176-03-03-002
T5-2-20
Cross Section B Cross Section C

Travel (Right) Travel (Left) Bucket Auxiliary (ZX135UR: Offset)
12
1
10 38
9 39
2
11
13
T176-03-03-003
T176-03-03-004
5 - Check Valve 15 - Boom Regenerative 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
(Main Relief Circuit) Valve Tandem Circuit) (ZX135UR (Check Valve)
Only)
T5-2-21
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
Cross Section D Boom 1 Boom 2
19
34
18
14
37
15
17
T176-03-03-005
T5-2-22
Cross Section E Cross Section F

Arm 2 Arm 1 Swing
36
16
31
35
30
20 28
27
29
32
33 21
T176-03-03-007
T176-03-03-006
1- Load Check Valve 11 - Bucket Regenerative 21 - Bypass Shut-Out Valve 31 - Arm Regenerative Valve
5- Check Valve 15 - Boom Regenerative 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
(Main Relief Circuit) Valve Tandem Circuit) (ZX135UR (Check Valve)
Only)
6- Flow Combiner Valve 16 - Overload Relief Valve 26 - Main Relief Valve (Blade) 36 - Arm Anti-Drift Valve
7- Check Valve 17 - Overload Relief Valve 27 - Check Valve (Orifice) (Arm 2 37 - Load Check Valve
8 - Aux. Flow Combining 18 - Boom Anti-Drift Valve 28 - Load Check Valve (Arm 1 38 - Aux. Flow Rate Control
Valve (Check Valve) Parallel Circuit) Valve (Poppet Valve)
T5-2-23
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
T5-2-24
Blade Control Valve (ZAXIS135UR Only)
Positioning Control Valve (2-piece Boom Only)
Cross Section X-X
X
22
24
25
23
X
T198-03-03-002 T198-03-03-003
1- Load Check Valve 11 - Bucket Regenerative 21 - Bypass Shut-Out Valve 31 - Arm Regenerative Valve
5- Check Valve 15 - Boom Regenerative Valve 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
Only)
6- Flow Combiner Valve 16 - Overload Relief Valve 26 - Main Relief Valve (Blade) 36 - Arm Anti-Drift Valve
7- Check Valve 17 - Overload Relief Valve 27 - Check Valve (Orifice) (Arm 2 37 - Load Check Valve
8 - Aux. Flow Combining 18 - Boom Anti-Drift Valve 28 - Load Check Valve (Arm 1 38 - Aux. Flow Rate Control
Valve (Check Valve) Parallel Circuit) Valve (Poppet Valve)
T5-2-25
SIGNAL CONTROL VALVE PORT
LOCATION
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
T5-2-26
Pilot Valve Side

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
(ZAXIS135UR : Offset Pilot Valve) (ZAXIS135UR : Left Offset Pilot Pressure)
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
(ZAXIS135UR : Offset Pilot Valve) (ZAXIS135UR : 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 (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-2-27
Control Valve Side

SM
3
1 5
13
2 4
SK
SE
Pressure Sensor 8
(swing)
14
Control Valve Side 7
9
6
10
SN
SL
11
Pressure Sensor 12 SP T178-03-06-015

(Travel)
T5-2-28
Control Valve Side

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 (ZAXIS135UR: Right Swing Pilot Pressure
Offset Anti-Drift Valve)
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
(ZAXIS135UR : Left Offset Pilot Pressure)
Port 14 Control Valve Auxiliary Close Pilot Pressure
(ZAXIS135UR : Right Offset Pilot Pressure)
Port SE - Plug
Port SM Hydraulic Oil Tank (ZAXIS135UR : Returning to Hydraulic Oil Tank (ZAXIS135UR :
Offset Anti-Drift Valve) Offset Pilot Pressure)
Port SN - Plug
Port SP Solenoid Valve Unit Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T5-2-29
(Blank)
T5-2-30
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using Dr. ZX (or the built-in diagnosing
system).
• How to Read Troubleshooting Flow Charts
YES(OK)
(2)
(1) After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
Instructions, reference, and/or inspection methods and/or measurements are occasionally

・
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
・ Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
box.
・ Use Dr. ZX (or the built-in diagnosing system) for descriptions in the double-line box.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
NOTE: All harness end connectors are seen from

the open-end side.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke • Faulty MC
15 Abnormal Boom Raise Lever Stroke • Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke • Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Oil Temperature Sensor
T5-3-2
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
YES * Faulty MC.
Check if engine and machine

actuators operate normally. · Refer to T4-6-6.
Faulty MC.
NO
· Refer to T4-6-6.
* Even if any fault codes are still displayed after re-
trying, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
YES Faulty sensor.

Disconnect connectors from
all sensors relating to the in-
dicated fault code, and retry. Short-circuited harness be-
Does fault code 04 disappear? tween MC and sensor in
Disconnect all con- section where continuity is
nectors from MC. YES
present.
Is there continuity be-
tween terminals #1 and
NOTE: If fault code 04 #3 of harness at each
(abnormal sensor NO sensor?
voltage) appears,
Faulty MC.
other fault codes
NO
appear at the same · Key switch: OFF
time. · Refer to T4-6-1.
T5-3-3
FAULT CODE 06
(ABNORMAL EC SENSOR)
Faulty harness between

Check harness between YES MC and EC sensor.
MC connector C (31P)
YES terminal #18 and EC
sensor terminal #2 for
breakage or short circuit.
Disconnect EC sensor. Faulty MC.
Check if voltage between
Disconnect EC sensor. Check harness end connectors NO
if resistance between sensor YES #1 and #3 is 5±0.5 V. · Refer to T4-6-6.
side connector terminals #1
and #3 is less than 2.0±0.4 Check if voltage between Broken harness be-
EC sensor harness end YES tween MC and EC
kΩ. Connect test harness
between EC sensor and base connector terminal #1 and sensor terminal #3.
· Key switch: ON vehicle frame matches
machine side harness. Check
if voltage changes in accor- specification.
NO
dance with specifications Broken harness be-
when engine control dial is tween MC and EC
rotated. NO
sensor terminal #1.
· Key switch: ON
· Specification: 5±0.5 V
Faulty EC sensor.
NO
· Test Harness: ST 7129 · Refer to T4-6-6.
· Specification: Refer to the
table below.
EC Sensor Specification Connector (Harness End Connector Viewed from the

Slow Idle 2.5 to 2.7 V Open End Side)
Fast Idle (HP mode 3.3 to 3.7 V
Switch: OFF)
MC Connector C
Fast Idle (HP mode Voltage at Fast Idle (HP Mode
Switch: ON) Switch: OFF) plus 0.2 V or C1 C10
more
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
FAULT CODE 07 Faulty harness be-
(ABNORMAL ENGINE CONTROL DIAL Check harness between MC and engine
ANGLE) tween MC connector C control dial.
(31P) harness end ter- YES
minal #6 and switch
NOTE: The terminal NO. in parenthesis is for
YES panel terminal #3 (#2)
ZAXIS135UR. Disconnect switch for breakage or short
panel. Check if voltage circuit. Faulty MC.
Disconnect switch panel.
Check if resistance be- between harness end
tween switch panel side connector terminals #2 NO
· Refer to 4-6-6.
connector terminals #2 (#1) YES (#1) and #4 (#3) is
and #4 (#3) is 5±0.5 kΩ. 5±0.5 V.
Broken harness be-
Reconnect switch panel. Check if voltage be- YES tween MC and engine
Insert tester probe into tween switch panel control dial terminal
connector terminal #3 (#2) harness end connector #4 (#3).
from the reverse side. terminal #2 (#1) and ve-
Check if voltage varies as · Key switch: ON NO hicle frame matches
specified when engine con- specification.
trol dial is turned.
Broken harness be-
tween MC and engine
NO control dial terminal
#2 (#1).
· Key switch: ON
· Specification: Refer to the Faulty engine control

table below. dial.
NO
Engine Control Dial Specification

Maximum Speed 4.0 to 4.7 V
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#6
C1 C10
C23 C31
Switch Panel #3 #1
#4 #2
T5-3-5
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta- Faulty harness be-
neously, faulty harness may be the cause of this Check harness between MC and pump
problem. tween MC connector C delivery pressure
(31P) harness end ter-
YES sensor.
minal #1 (pump 1) or
#4 (pump 2) and pump
YES delivery pressure sen-
sor terminal #2 for
breakage or short cir-
Faulty MC.
cuit.
Disconnect pump de- NO
livery pressure sensor.
Check if voltage be- · Refer to T4-6-6.
tween harness end
NO connector terminals #1 Broken harness be-
and #3 is 5±0.5 V. tween MC and pump
Check if voltage be- delivery pressure
Check if fault codes are tween pump delivery YES sensor terminal #3.
switched after switching pressure sensor har-
pump 1 delivery pressure ness end connector
sensor with pump 2 de- · Key switch: ON terminal #1 and vehicle
livery pressure sensor frame matches speci-
NO Broken harness be-
and retrying. fication. tween MC and pump
delivery pressure
NO sensor terminal #1.
· Key switch: ON
· Specification: 5±0.5 V Faulty pump delivery
pressure sensor.
YES
MC Connector C
#1 #4
C1 C10
C23 C31
Pump Delivery Pressure Sensor
3 2 1
T5-3-6
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of Check harness be- Faulty harness be-
this problem. tween MC connector C tween MC and pump
(31P) harness end ter- control pressure sen-
minal #7 (pump 1) or
YES sor.
#13 (pump 2) and
pump control pressure
YES sensor terminal #2 for
breakage or short cir-
cuit.
Disconnect pump con- Faulty MC.

trol pressure sensor. NO
Check if voltage be-
tween harness end · Refer to T4-6-6.
NO connector terminals #1
Broken harness be-
and #3 is 5±0.5 V. tween MC and pump
Check if voltage be- control pressure sen-
tween pump control sor terminal #3.
Check if fault codes are pressure sensor har- YES
switched after switching ness end connector
pump 1 control pressure · Key switch: ON terminal #1 and vehicle
sensor with pump 2 con- frame matches specifi-
trol pressure sensor and NO cation. Broken harness be-
retrying. tween MC and pump
NO control pressure sen-
sor terminal #1.
· Key switch: ON
Faulty pump control

pressure sensor.
YES
MC Connector C
#13 #7
C1 C10
C23 C31
Pump Control Pressure Sensor
1 2 3
T5-3-7
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT Check harness be-
Faulty harness be-
PRESSURE) tween MC connector C
(31P) harness end tween MC and
FAULT CODE 18 each corresponding
YES pressure sensor.
(ABNORMAL TRAVEL PILOT PRESSURE) terminal and pressure
YES sensor terminal #2 for
Checking Instruction breakage or short cir-
• All pressure sensors seldom fail at the same time. cuit. Faulty MC.
Accordingly, if fault codes 14, 15, 16, and 18 are NO
displayed simultaneously, faulty harness may be · Refer to T4-6-6.
the cause of this problem.
Connector C Terminal:
Disconnect pressure #14: Pressure Sensor (Swing)
sensor. Check if volt- #2: Pressure Sensor
NO age between harness (Boom Raise)
end connector termi- #5: Pressure Sensor
nals #1 and #3 is 5±0.5 (Arm Roll-In)
V. #3: Pressure Sensor
(Travel)
Check if fault code dis-
Broken harness be-
appears after switching
· Key switch: ON tween MC and
pressure sensor with an-
pressure sensor ter-
other pressure sensor Check if voltage be- minal #3.
and retrying. tween pressure YES
sensor harness end
connector terminal #1
and vehicle frame
NO matches specification. Broken harness be-
tween MC and
Fault Code: pressure sensor ter-
14: Pressure Sensor (Swing) NO
minal #1.
15: Pressure Sensor
(Boom Raise) · Key switch: ON
16: Pressure Sensor · Specification: 5±0.5 V
(Arm Roll-In)
18: Pressure Sensor Faulty pressure sen-
(Travel) sor.
YES
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
Pilot Pressure Sensor
1 2 3
T5-3-8
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)
Connect oil tempera-

ture sensor harness Faulty MC.
YES
end connector terminal
#1 to #2 with a clip.
Remove connector B · Refer to T4-6-6.
(25P) and connector C
(31P) from MC. Check Broken harness be-
Connect MC connec- tween MC and oil
YES for continuity between
tor B (25P) harness YES temperature sensor
connector B harness
end terminal #22 to terminal #1.
end terminal #22 and
vehicle frame. Check
connector C terminal
for continuity between
#24.
Disconnect oil tempera- oil temperature sensor
ture sensor. Check if NO harness end connec-
sensor side connector tor terminal #2 and Broken harness be-
resistance matches vehicle frame. tween MC and oil
specification. temperature sensor
NO terminal #2.
· Specification: Refer to
the table below.
Faulty oil temperature
sensor.
NO
Oil Temperature Specification Connector (Harness End Connector Viewed from the Open End Side)
Oil Temperature Resistance
(°C) (kΩ) MC Connector B
−20 16.2±1.6 B8
B1
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534) B19 B25
80 0.322 #22
MC Connector C
C1 C10
C23 C31
#24
Oil Temperature Sensor
1 2
T5-3-9
(Blank)
T5-3-10
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.ZX (or the built-in diagnosing
system) although the machine’s operation is
abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
• How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 7) in this section.
・ • Use Dr.ZX (or the built-in diagnosing system) function.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
• Moves governor. • Detects minimum governor speed position (2.5
V) only when key switch is turned ON.
• Detects minimum and maximum speed posi-
tion when engine learning is conducted.
Function
• Governor lever doesn’t move. • Engine speed is controlled based on idle posi-
tion set when key switch is turned ON. There-
Symptoms in control fore, engine speed is always controlled with
system when trouble error in idle position setting if set incorrectly.
occurs.
• Even if engine control dial is turned, engine • Error in setting will seldom occur so that
speed doesn’t increase from slow idle speed. change in machine operation will not be no-
• Engine start may be difficult though starter ro- ticed.
tates. • In case error is set on lower side, engine
• Engine will stall if discontinuity occurs in EC speed changes but runs slower than normal
motor while engine is running at more than a through the full range when engine control dial
specified speed. is turned. (Note: In case error is set on upper
• Engine will become uncontrollable if disconti- side, EC motor is driven so that it runs faster
nuity occurs in EC motor while engine is run- than the control range. However, motor, a
ning at lower than a specified speed. Engine worm gear type, holds governor lever at
cannot be stopped with key switch. maximum constant position, preventing engine
Symptoms in machine stall. When engine control dial is turned to
operation when trouble minimum speed position, governor lever is re-
occurs. turned to idle position.)
• When starting engine, engine speed fluctuates.
• Starting engine is occasionally difficult.
By Fault Code Fault code 06 is displayed.


Monitor Item: EC Angle (Displayed by built-in di-
By Monitor agnostic system)

Evalua-
Function
tion • Install lamp harness (ST 7125) to check EC
Using Test output signal and harness for any abnormality.

Harness
Others  
• Engine is stopped by EC motor. (Engine stop • If EC sensor is faulty, engine learning is not
motor is not provided.) performed.
NOTE • Fuel cut-off cable is provided.
Descriptions of Control T2-1 T2-1

(Operational Principle
Section in T/M)
T5-4-2
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
• Indicates governor lever position (engine • Monitors pump control pressure to con- • Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system and travel trol HP mode, auto-acceleration, and
motor swash angle controls. travel motor swash angle controls.
• Engine speed doesn’t change even if • No signals arrive to MC • If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
• If discontinuity or short circuit occurs in
-1
presented by back-up mode function.
engine control dial, low idle of 900 min
is used as back-up value.
• Engine speed is kept unchanged low • Auto-acceleration control is inoperable • HP mode is inoperable.
-1
idle (900 min ). (Engine can be stopped (but not noticeable). • Auto-acceleration control is inoperable.
by key switch.) • Travel speed is kept in slow mode, not • Travel speed is kept in slow mode, not
allowing to automatically change to fast allowing to automatically change to fast
mode. mode.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault codes 10 is displayed.
Monitor Item: Engine Target Speed, Dial Monitor Item: Pump 1 and 2 pump control Monitor Item: Pump 1 delivery pressure
Angle (Displayed by built-in diagnostic pressure (Displayed by built-in diagnostic (Displayed by built-in diagnostic system)
system) system)
⎯ ⎯ ⎯
⎯ ⎯ ⎯
• Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
⎯ Short Circuit: 4.75 V or more ⎯
T2-1 T2-1 T2-1
T5-4-3
Parts Pump 3 Delivery Pressure Sensor

Pump 2 Delivery Pressure Sensor
(Optional)
• Monitors pump delivery pressure to control • Monitors pump delivery pressure to control
HP mode, auto-acceleration, arm regenera- pump 3 torque decrease control.
tive and travel motor swash angle control.
Function
• If pump delivery pressure sensor output is • Engine stalls if pump torque is increased.
Symptoms in control system 0 or 5 V, following symptoms will be pre-
sented by back-up mode function.
when trouble occurs.
• HP mode is inoperable. • Engine stalls if pump torque is increased.

• Auto-acceleration control is inoperable.
• Arm is slow when arm roll-in and swing
combined operation is made.
• Travel speed is kept in slow mode, not al-
lowing to automatically change to fast
mode.
Symptoms in machine opera-

tion when trouble occurs.
By Fault Code Fault codes 11 is displayed. 

Monitor Item: Pump 2 delivery pressure (Dis-
played by built-in diagnostic system)
By Monitor Func-

Evaluation
tion
Using Test Harness  

Others  
NOTE  
Descriptions of Control (Opera- T2-1 T2-1

tional Principle Section in T/M)
T5-4-4
Pressure Sensor
Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
• Monitors travel pilot pressure to control • Monitors front attachment pilot pressure • Monitors swing pilot pressure to control
auto-idle, auto-acceleration, idle to control auto-idle, and idle speed in- arm regenerative systems.
speed-up, and travel motor swash angle crease systems.
controls.
• No signals arrive to MC • No signals arrive to MC • No signals arrive to MC
• Engine speed doesn’t increase even if • Engine speed doesn’t increase even if • Since arm regenerative function is inop-
auto-idle/auto-acceleration selector is any front attachment actuator is oper- erable, when swing/arm roll-in combined
auto-idle position. ated with auto-idle/auto-acceleration se- operation is made, initial arm moving
• Engine speed doesn’t increase even if lector is auto-idle position. speed is slow. (Not remarkable)
auto-idle/auto-acceleration selector is • Occasionally, engine speed hunts while • During arm level crowding operation,
auto-acceleration position. operating front attachment at slow idle. arm speed is slightly slow.
• Occasionally, engine speed hunts while
traveling at slow idle.
• Fast travel mode cannot be selected
even if travel mode switch is turned to
the FAST position.
Fault code 18 is displayed.  Fault code 14 is displayed.

Monitor Item: Travel Control Pressure (dis- Monitor Item: Front Attachment Operation Monitor Item: Swing Control Pressure (dis-
played built-in diagnostic system). (displayed built-in diagnostic system). played built-in diagnostic system).
Monitor pressure change while traveling Monitor pressure change while operating Monitor pressure change while swinging
machine. front attachment. upperstructure.
  
  
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T2-1 T2-1 T2-1
T5-4-5
Parts
Pressure Sensor Pressure Sensor
(Boom Raise) (Arm Roll-In)
• Monitors boom raise pilot pressure to control • Monitors arm roll-in pilot pressure to control
HP mode, auto-acceleration, and arm regen- HP mode, auto-acceleration, and arm regen-
erative controls. erative controls.
Function
• No signals arrive to MC • No signals arrive to MC
Symptoms in control sys-

tem when trouble occurs.
• Even if boom is raised with HP mode switch • Even if boom is raised with HP mode switch
ON, engine speed doesn’t increase. ON, engine speed doesn’t increase.
• Even if boom is raised with • Even if boom is raised with
auto-idle/auto-acceleration selector is auto-idle/auto-acceleration selector is
auto-acceleration position, engine speed auto-acceleration position, engine speed
doesn’t increase. doesn’t increase.
• Arm roll-in speed becomes slightly slower • Arm speed is slow in arm level crowd opera-
Symptoms in machine op- than normal in boom raise and arm roll-in tion.
eration when trouble oc- combined operation as arm regenerative sys-
tem doesn’t work. (Not remarkable)
curs. • Arm roll-in and boom raise speeds become
slightly slower at the beginning stage of arm
level crowd operation.
By Fault Code Fault Code 15 is displayed. Fault code 16 is displayed.
By Monitor Func- Monitor Item: Boom Raise Pilot Pressure (dis- Monitor Item: Arm Roll-In Pilot Pressure (dis-
played built-in diagnosing system). played built-in diagnosing system).
tion Monitor pressure change while raising boom. Monitor pressure change while rolling arm in.
Evalua-
tion
Using Test Har-
 
ness
Others  
• Judge if pressure sensor is faulty or port is • Judge if pressure sensor is faulty or port is
clogged by switching pressure sensor with clogged by switching pressure sensor with
another pressure sensor. another pressure sensor.
NOTE

(Operational Principle Sec-
tion in T/M)
T5-4-6
Pressure Sensor (Auxiliary)

Torque Control Solenoid Valve Solenoid Valve Unit (SC)
(Optional)
• Monitors attachment pilot pressure when • Supplies control pressure to pumps 1 • Routes return oil from arm cylinder rod
attachment is installed to control at- and 2 to control speed sensing. side to bottom side when rolling arm in
tachment operation speed increase, to increase arm speed.
pump 1 and pump 2 flow rate limit, and
auxiliary flow rate controls.
• No signals arrive to MC • If torque control solenoid valve is not • In case solenoid valve unit (SC) is not
activated, output pressure from solenoid activated, pressure at port SC becomes
2 2
valve is 0 MPa (0 kgf/cm ). 0 MPa (0 kgf/cm ). Arm regenerative
valve will not operate at this time.
• Engine speed doesn’t increase when • Even if speed sensing system doesn’t • Solenoid valve unit (SC) is closed:
attachment is operated. work, upper limit power is restricted so • Arm speed is slow in arm level crowd
• When attachment is operated, operation that machine is operable. operation.
speed increases. • Solenoid valve unit (SC) is open:
• As the arm regenerative valve is always
operated, arm speed is fast.
  
Monitor Item: ATT Control Pressure (dis- Monitor Item: Pump Torque Proportional Monitor Item: Arm Regenerative Propor-
played built-in diagnosing system). Solenoid Valve Output tional Sol. Valve Output
Monitor pressure change while operating
attachment.
• Install lamp harness (ST 7226) to check

output signals from MC and harness
  condition.
  
• Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor
with another pressure sensor.
 
T2-1 T2-1 T2-1
T5-4-7
Parts Max. Pump 1 Flow Rate Limit Solenoid

Solenoid Valve Unit (SI)
Valve (Optional)
• When pump delivery pressure is low in fast • When operating attachment, limits maximum
travel mode, travel motor swash angle is re- pump 1 flow rate.
duced to increase travel speed.
Function
• Fast travel mode cannot be selected. • In case max. pump 1 flow rate limit solenoid
valve is not activated, pressure at output port
2
becomes 0 MPa (0 kgf/cm ).
Symptoms in control sys-
tem when trouble occurs.
• Solenoid valve unit (SI) is closed: • Max. pump 1 flow rate limit solenoid valve is
• Even if travel mode switch is turned to FAST closed:
position, fast travel mode cannot be selected. • When operating attachment, operating speed
• Solenoid valve unit (SI) is open: doesn’t decrease.
• Travel speed is always fast. • Max. pump 1 flow rate limit solenoid valve is
open:
• Right travel, bucket, arm and boom speeds
Symptoms in machine op- become slow as the max. flow of pump 1 de-
eration when trouble oc- creases.
curs. • Machine mistracks to the right when traveling.
By Fault Code  
By Monitor
 
Function
Evaluation
Using Test • Install lamp harness (ST 7226) to check out-
put signals from MC and harness condition.
Harness 
Others  
NOTE  
T2-1 T2-1
Descriptions of Control
tion in T/M)
T5-4-8
Max. Pump 2 Flow Rate Auxiliary Flow Rate Control Hydraulic Oil Tempera-
N Sensor
Limit Solenoid Valve Solenoid Valve (Optional) ture Sensor
• When operating attachment, • Restricts oil flow to auxiliary • Monitors engine speed to • Monitors hydraulic oil tem-
limits maximum pump 2 flow spool during a combined op- operate engine speed sens- perature to control
rate. eration to improve operability. ing control. auto-warming up and arm
regenerative control.
• In case max. pump 2 flow rate • In case auxiliary flow rate con- • Speed sensing control is in- • If circuit breakage occurs,
limit solenoid valve is not ac- trol solenoid valve is not acti- operable. system operates as if hy-
tivated, pressure at output vated, pressure at output port draulic oil temperature is
2
port becomes 0 MPa (0 becomes 0 MPa (0 kgf/cm ). 40 °C (Dr. ZX or monitor
2
kgf/cm ). will not indicate 40 °C in
diagnosis operation).
• Max. pump 2 flow rate limit • If valve is bound closed, at- • Engine stalls under adverse • Even if oil temperature is
solenoid valve is closed: tachment speed will become operating conditions such as lower than 0 °C,
• When operating attachment, slow. at high altitude. auto-warming up control
operating speed doesn’t de- • If valve is bound open, boom doesn’t operate so that en-
crease. will not move in 3-combined gine runs at idle speed
• Max. pump 2 flow rate limit operation of boom raise. when engine is started.
solenoid valve is open: • When oil temperature is
• Left travel, arm, boom and lower than 10 °C, arm re-
swing speeds become slow generative control is inop-
as the max. flow of pump 2 erable.
decreases.
• Machine mistracks to the left
when traveling.
Fault code 19 is displayed.

  
Monitor Item: Actual engine Monitor Item: Hydraulic Oil
speed (If N sensor fails, engine Temperature
  speed is not measured.)
   
   
• Even if signals from N sensor
are not delivered due to bro-
ken circuit or poor sensor in-
stallation, few changes in
operational performance oc-
  cur, making troubleshooting 
difficult. Use monitor func-
tion.
T2-1 T2-1 T2-1 T2-1
T5-4-9
Parts
Engine Learning Switch Travel Mode Switch MC
• Starts engine learning. • Changes travel mode. • Controls engine, pump, and
• ON: 0V→Learning • Fast Mode: 0V valve operation.
• OFF: 5V→Normal Control • Slow Mode: 5V
Function
• Engine learning is not per- • Broken Circuit in Switch: Travel • Depending on trouble situations,
formed. speed remains unchanged in control system malfunction may
slow mode (5V). differ. (The following symptoms
• Short Circuit in Switch: Travel in machine operation indicates
speed remains unchanged in that MC logic circuit has failed.)
Symptoms in control fast mode (0V).
system when trouble
occurs.
• Engine learning: • Even if travel mode switch is • Even if key switch is turned ON,
• Machine will operate nor- turned to the FAST position, fast step motor will not move to the
mally problem is caused by travel mode cannot be selected. START position so that engine
broken circuit or discontinu- • Even if travel mode switch is cannot start. Even though en-
ity of switch. (Only learning turned to the slow position, gine starts, speed stays slow.
cannot be performed.) travel speed is fast. • Since pump displacement is
• If short circuit occurs, held at minimum, all actuator
learning mode operation speeds are slow.
Symptoms in machine starts when key switch is
operation when trou- turned ON. Therefore, en-
gine will stall at 2 second or
ble occurs. 20 seconds after engine
starts.
Fault codes 01, 02, and 03 are

By Fault displayed. Other fault codes may
  be displayed.
Code
Evalua- By Monitor Monitor Item: Engine Learning Monitor Item: Travel Mode
tion Function 
Using Test   
Harness
Others   
• Before suspecting a failure in
MC, be sure to check the fuses
in control system. If any sensor
in 5 V system is short-circuited,
NOTE   all sensor fault codes will be dis-
played.
Descriptions of Con- T2-1 T2-1

trol (Operational Prin- 
ciple Section in T/M)
T5-4-10
Auto-Idle/Auto-Acceleratio Auto-Idle/Auto-Acceleration Power Mode Switch Power Mode Switch

n Selector (Auto-Idle) Selector (HP Mode) (E Mode)
• Activates auto-idle control.
(Auto Acceleration)
• Activates auto-acceleration • Activates HP mode control. • Selects E mode.
• ON: 0 V → Auto-idle is oper- control. • ON: 0 V → HP mode is op- • ON: 0 V → E mode
able. • ON: 0 V → Auto-acceleration is erable. • OFF: 5 V → Normal
• OFF: 5 V → Inoperable. operable. • OFF: 5 V → Normal
• OFF: 5 V → Inoperable.
• Broken Circuit: Auto-idle sys- • Broken Circuit: • Broken Circuit: Even if HP • Broken Circuit: Even if E
tem is inoperable. Auto-acceleration control is mode is selected, HP mode mode is selected, engine
• Short Circuit: Even if inoperable. is inoperable. speed doesn’t decrease.
auto-idle/auto-acceleration • Short Circuit: Even if • Short Circuit: Even if HP • Short Circuit: Engine
selector is OFF, auto-idle con- auto-idle/auto-acceleration se- mode switch is turned OFF, speed doesn’t increase to
trol is always performed. lector is OFF, auto-acceleration HP mode system is not de- the maximum. Auto-idle
control is always performed. activated. Attachment speed control is inoperable.
increase control (optional)
becomes inoperable.
• Same as described above. • Same as described above. • Same as described above. • Same as described above
   
Monitor Item: Monitor Item: Monitor Item: E/P/HP Mode Monitor Item: E/P/HP Mode
Auto-Idle/Auto-Accel Switch Auto-Idle/Auto-Accel Switch Switch Switch
   
   
   
T2-1 T2-1 T2-1 T2-1
T5-4-11
Parts Work Mode Switch Work Mode Switch Auxiliary Mode Switch
(Digging Mode) (Attachment Mode) (Optional)
• Allows normal control to be • Functions only when optional • Functions only when optional
performed. attachment kit is equipped. (At- attachment kit is equipped. (At-
tachment operation speed in- tachment operation speed in-
Function crease/limit control) crease/limit control)
• In response to operation of the • In response to operation of the

auxiliary valve, engine speed auxiliary valve, engine speed
related to the attachment is con- related to the attachment is con-
trolled. trolled.
Symptoms in control
system when trouble ―
occurs.
• Even if auxiliary valve is oper- • Even if auxiliary valve is oper-

ated, engine speed doesn’t in- ated, engine speed doesn’t in-
crease. crease.
• Even if attachment mode is se- • Even if attachment mode is se-
lected, maximum engine speed lected, maximum engine speed
doesn’t decrease. doesn’t decrease.
Symptoms in machine
operation when trou- ―
ble occurs.
By Fault   
By Monitor Monitor Item: Work Mode Monitor Item: Work Mode Switch
Switch 
Evalua- Function
tion Using Test   
Harness
Others   
NOTE   
Descriptions of Con- T2-1 T2-1 T2-1

trol (Operational Prin-
T5-4-12
Bucket Flow Rate Con- Auxiliary Flow Rate Boom Regenerative

Flow Combiner Valve
trol Valve Control Valve Valve
• Supplies hydraulic oil to both • Restricts oil flow to bucket • To be shifted by pilot pres- • Prevents boom cylinder hesi-
right and left travel spools during 3-combined operation sure from auxiliary flow rate tation by routing return oil
from pump 1 during com- of bucket, arm roll-in, and control solenoid valve. from boom cylinder bottom
bined operation of travel and boom raise to allow boom to side to rod side.
front/swing. raise.
• During combined operation • If switch valve is bound with • If spool is bound or spring is • If check valve is kept closed,
of travel and front/swing, in- valve activated, bucket cir- broken, orifice doesn’t vary. boom is not smoothly low-
sufficient oil is supplied to left cuit is always restricted. ered.
travel spool. • If check valve is kept open,
machine cannot be raised off
ground with front attachment.
• While traveling, when • If poppet valve is bound at • If bound at fully closed posi- • Same as described above.
front/swing lever is operated, fully closed position or if tion, attachment speed be-
machine mistracks to the left. switch valve is bound when comes slow.
poppet valve is fully closed, • If bound at fully opened posi-
bucket speed becomes slow. tion, boom doesn’t move dur-
• If poppet valve is bound at ing 3-combined operation of
fully opened position or if swing, arm roll-in, and boom
switch valve is bound when raise.
poppet valve is fully opened,
boom doesn’t move during
3-combined operation of
bucket, arm roll-in, and boom
raise.
   
   
   
   
   
T3-3 T3-3 T3-3 T3-3
T5-4-13
Parts
Arm Regenerative Valve Bucket Regenerative Valve Arm Anti-Drift Valve
• To be shifted by pilot pressure • Prevents bucket cylinder hesi- • Prevents arm from drifting
from solenoid valve unit (SC). tation by routing return oil from due to oil leaks in control
• Increases arm speed by rout- bucket cylinder rod side to bot- valve. Check valve in arm
ing return oil from arm cylinder tom side. roll-in return circuit is forcibly
rod side to bottom side. opened to allow arm to move
Function only when arm is rolled in.
• Arm regenerative function is • If check valve is kept closed, • If switch valve is bound,
inoperable. bucket is not smoothly rolled in. check valve doesn’t open.
• If check valve is kept open,
bucket power is weak.
Symptoms in control
system when trouble
occurs.
• Arm speed is extremely slow • Same as described above. • If check valve is kept closed,
during arm level crowd opera- arm roll-in speed becomes
tion while arm regenerative slow.
valve is kept closed. • If check valve is kept opened,
• The lever operated first is front attachment drift in-
given priority during combined creases due to oil leaks in
Symptoms in machine operation of arm roll-in and control valve.
operation when trou- swing while arm regenerative • Arm moves jerky or arm
valve is kept open. speed becomes slow de-
ble occurs. pending on valve bound con-
ditions.
By Fault   
By Monitor
  
Evalua- Function
tion Using Test
  
Harness
Others   
NOTE   

T5-4-14
Boom Anti-Drift Valve Auxiliary Flow Combiner Valve Bypass Cut Valve
• Prevents boom from drifting due to oil • Supplies pressure oil from pump 1 to • Supplies pressure oil from pump 1 to
leaks in control valve. Check valve in auxiliary spool when auxiliary spool is auxiliary spool when auxiliary spool is
boom lower return circuit is forcibly operated. operated.
opened to allow boom to move only
when boom is lowered.
• If switch valve is bound, check valve • If switch valve is kept closed, operating • If spool is bound in the fully opened po-
doesn’t open. speed doesn’t increase in single auxil- sition, single attachment operation
iary operation. speed becomes slow.
• If spool is bound in the fully closed posi-
tion, main relief valve continues to re-
lieve with all control levers positioned in
neutral.
• If spool is bound in opened position,
when all control levers are in neutral,
pump 1 pressure is higher than pump 2
pressure.
• If check valve is kept closed, boom • Same as described above. • Same as described above.
doesn’t lower.
• If check valve is kept opened, front at-
tachment drift increases due to oil leaks
in control valve.
• Boom moves jerky or arm speed be-
comes slow depending on valve bound
conditions.
  
  
  
  
  
T3-3 T3-3 T3-3
T5-4-15
Parts
Pump 1 Flow Control Valve Pump 2 Flow Control Valve
• Supplies flow rate control pressure Pi to pump 1 • Supplies flow rate control pressure Pi to
regulator in response to lever stroke when boom pump 2 regulator in response to lever stroke
(raise/lower), arm (roll out/in), bucket when boom (raise/lower), arm (roll out/in),
(roll-out/in), right travel, or auxiliary is operated. swing (right/left), or left travel is operated.
Function
• If spool is bound in the fully opened position, • If spool is bound in the fully opened position,
even if control lever is in neutral, pump 1 swash even if control lever is in neutral, pump 2
angle is tilted to maximum. (When traveling with swash angle is tilted to maximum. (When
travel levers held in half way stroke, machine traveling with travel levers held in half way
mistracks to the left.) stroke, machine mistracks to the right.)
• If spool is bound in the fully opened position, • If spool is bound in the fully opened position,
pump 1 control pressure sensor indicates the pump 2 control pressure sensor indicates
maximum pressure. the maximum pressure.
• If spool is bound in the fully closed position, • If spool is bound in the fully closed position,
even if control lever is operated, pump 1 swash even if control lever is operated, pump 2
angle is held to minimum. (Right travel is inop- swash angle is held to minimum. (Left travel
erable in single travel operation. Bucket speed is inoperable in single travel operation.
is very slow.) Swing speed is very slow.)
• If spool is bound in the fully closed position, • If spool is bound in the fully closed position,
Symptoms in control sys- pump 1 control pressure sensor can not detect pump 2 control pressure sensor can not
tem when trouble occurs. pump control pressure. (Right travel doesn’t run detect pump control pressure. (Left travel
fast with right track jacked up.) doesn’t run fast with left track jacked up.)
• Same as described above. • Same as described above.

Symptoms in machine op-
eration when trouble oc-
curs.
By Fault Code  
By Monitor
 
Function
Evaluation Using Test
Harness  
Others
 
NOTE ― ―

tion in T/M)
T5-4-16
Flow Combiner Valve Control Swing Parking Brake Bucket Flow Rate Control Valve
Spool Release Spool Control Spool
• Supplies control pressure to flow com- • Supplies swing parking brake release • Supplies boom raise pilot pressure to
biner valve when shifted by right travel pressure when shifted by boom, arm, bucket flow rate control valve when
pilot pressure. bucket, or swing pilot pressure. shifted by arm roll-in pilot pressure.
• If spool is bound in the fully opened po- • If spool is bound in the fully open posi- • If spool is bound in the fully opened po-
sition, when boom, arm, bucket, or tion, swing parking brake is kept re- sition, bucket speed becomes slow
swing is operated, flow combiner valve leased. when boom raise and bucket combined
is shifted. (Machine vibrates while traveling.) operation is made. (Bucket flow rate
• If spool is bound in the fully closed posi- • If spool is bound in the fully open posi- control is inoperable.)
tion, when travel and front/swing com- tion, the pressure sensor (front) is al- • If spool is bound in the fully closed posi-
bined operation is made, machine mis- ways turned into ON. tion, boom doesn’t move during
tracks to the right. (right travel speed is Thus, engine speed doesn’t decrease 3-combined operation of bucket, arm
slow.) when the control lever is in neutral dur- roll-in, and boom raise.
ing auto-idle/acceleration control.
tion, swing parking brake is kept applied.
(Dragging is felt.)
tion, the pressure sensor (front) is al-
ways turned into OFF.
Thus, engine speed doesn’t increase
when the control lever is operated during
auto-idle/acceleration control.
• Same as described above. • Same as described above. • Same as described above.
  
  
  
  
  
T3-6 T3-3 T3-3
T5-4-17
Parts Emergency Stop

Offset Anti-Drift Valve 8-Unit Solenoid Valve
Solenoid Valve
(ZAXIS135UR) (ZAXIS135UR)
(ZAXIS135UR)
• Prevents the offset front at- • To control pilot pressure to con- • If front control fails, the
tachment from being offset by trol front function (Front Move- emergency stop solenoid
its own weight to the right. ment Restriction, Cab collision valve shuts off the pilot pres-
(Being provided in the offset Prevention, Auto-MARCCINO sure to stop all operations.
Function cylinder rod circuit.) control.
• If stuck in the open position, • Front does not move or stop. • When fault code is not dis-
the offset cylinder hold circuit • When front movement restric- played (this is normal state),
is kept released, allowing the tion and cab collison prevention the emergency stop solenoid
front attachment to offset to control deceleration solenoid valve works.
the right depending on the valve spool stuck open causing
stop position of the front at- the front function not to stop or
tachment. decelerate.
• If stuck in the fully closed posi- • Deceleration solenoid valve
tion, the return oil from the spool stuck shut making the
Symptoms in control offset cylinder rod side is front function immovable.
system when trouble
blocked so that the right offset • Acceleration solenoid valve
function becomes inoperable. spool stuck open causing the
occurs. front function not to stop.
• Acceleration solenoid valve
spool stuck shut making the
front function immovable.
• Same as described above. • Same as described above. • If this solenoid valve is stuck
during its operation, it be-
comes inoperative. If stuck
with the solenoid valve open,
the pilot pressure cannot be
Symptoms in machine shut off even if front control
fails.
operation when trou-
ble occurs.
Fault code 40, 41, 43, 45, 47, 48

By Fault is displayed (Auto-MARCCINO
― system) 
Code
Evalua- By Monitor
tion   
Function
Using Test   
Harness
Others   
NOTE   

T5-4-18
Blade Signal Switch Valve Front Angle Sensor Oil Temperature Sensor
(ZAXIS135UR) (ZAXIS135UR) （ZAXIS135UR）
• Shifts the flow combiner valve when the • The position of the bucket is detected by • Detects the hydraulic oil temperature
blade pilot pressure is supplied. angle sensors for the boom, arm and and sends as a signal to the
offset; and the detected data is sent to auto-Marccino control unit.
the auto-MARCCINO control unit.
• Even though the blade control lever is • If one of angle sensors fails, the • The system is controlled based on the
operated, the flow combiner valve is not auto-MARCCINO control unit works to oil temperature at which the trouble had
shifted. input a maximum value as a data on the occurred
failed angle sensor in order to avoid in-
terference.
• If stuck in the closed position, the flow • Part of the front attachment fitted with a • When a trouble occurrs at lower than 10
combiner valve is not shifted so that the sensor that seems to be failed does not °C, deceleration and stop functions in
blade speed becomes slow when a move toward the cab. the cab collision prevention system are
combined operation is made. activated earlier than the normal posi-
tions.
• When a trouble occurrs at 10 °C or
higher, deceleration and stop functions
in the cab collision prevention system
are activated at the normal position
Fault code 90 is displayed.
 
Monitor Item:
Boom Angle, Arm Angle,
 Offset Angle 
  
  
― ― 
T2-3 T2-2

T5-4-19
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
E-1 E-2 E-3
Starter doesn’t ro- Although starter When engine control dial is fully rotated, engine
Trouble tate rotates, engine stalls. Occasionally engine stalls during opera-
Symptom doesn’t start. tion with engine control dial fully rotated and
auto-idle ON. Engine speed is slower than
specification in all operating range. Idle speed is
faster or slower than specification.
Parts
MC (Main Controller) z z
QOS Controller
EC Motor z
EC Sensor { z
Pump 1 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch z
Battery Relay z
Glow Relay
Engine Electrical Equipment z
Engine Unit z z
Governor z z
Swing Parking Brake Release Spool
(Signal Control Valve)
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
replacing engine.
Remarks
T5-4-20
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
E-4 E-5 E-6 E-7 E-8 E-9

Even if engine con- Engine speed Faulty HP mode. Even if key switch is Faulty auto-idle Faulty E mode.
trol dial is rotated, doesn’t increase turned OFF, engine system.
engine speed re- after engine is doesn’t stop.
mains unchanged. started.
z z z { z z
z { {
{ {
{
{
{
{
{
{
z {
z
z
z { z
z {
z {
Check engine con-

trol cable.
z : Related, required to check { : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-21
E-10 E-11 E-12

Faulty auto-acceleration When traveling or operating Engine speed doesn’t in-
Trouble system. front attachment with engine crease even if attachment is
Symptom running at slow idle, engine operated in attachment
hunts. mode.
Parts
MC (Main Controller) z z z
QOS Controller
EC Motor
EC Sensor
Pump 1 Delivery Pressure Sensor {
Pump 1 Control Pressure Sensor {
Pump 2 Control Pressure Sensor {
Pressure Sensor (Travel) {
Pressure Sensor (Front Attachment) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Auxiliary) z
N Sensor
Coolant Temperature Switch
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector z
Power Mode Switch
Work Mode Switch z
Auxiliary Mode Switch z
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit z
Governor
Pump Regulator
Remarks
T5-4-22
E-13 E-14 E-15 E-16

When attachment mode Engine stalls within Engine stalls during Engine is difficult to
is selected, engine several seconds after operation under ad- start at low temperature.
speed doesn’t de- engine has started. verse condition such as
crease. at high altitude.
z z
z
z
z
z
{
Check fuel system for Check batteries.
clogging.
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
T5-4-23
All Actuator System Troubleshooting

A-1 A-2 A-3
All actuator speeds are slow. Left travel is inoperable during Right travel is inoperable dur-
Trouble single travel operation. Single ing single travel operation. Sin-
Symptom swing operation speed is slow. gle bucket operation speed is
Arm is slightly slow during arm slow. Boom is not raised prop-
level crowding. erly during arm level crowding.
Parts
MC (Main Controller) z
Torque Control Solenoid Valve {
N Sensor {
Spool
Main Relief Valve {
Arm Flow Rate Control Valve
Main Pump z z z
Regulator { z z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve z
Pump 2 Flow Rate Control Valve z
Remarks
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently. In case more than one trou-
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.

symptom will be more noticeable so that this component will
not be the direct cause of the trouble concerned.
T5-4-24
A-4 A-5
Actuator doesn’t stop Actuator speed is faster
even if control lever is than normal.
returned to neutral. Machine mistracks when
the travel lever is oper-
ated at half stroke.
Precise control can not
be performed.
z
z
T5-4-25
Front Attachment System Troubleshooting

F-1 F-2 F-3
All front attachment actuator Some cylinder are inoper- Arm speed is slow in a com-
Trouble power is weak. able or speeds are slow. bined operation. Arm speed
Symptom is slow during arm level
crowding.
Parts
MC (Main Controller) z
Solenoid Valve Unit (SC) z
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Spool z
Main Relief Valve z
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Emergency Valve
Shockless Valve (Signal Control Valve) z
Shuttle Valve (Signal Control Valve) z
Bucket Flow Rate Control Valve Control

Spool (Signal Control Valve)
Pilot Valve z
Cylinder
Offset Anti-Drift Valve (ZAXIS135UR)
8-Unit Solenoid Valve Unit (ZAXIS135UR) z
Emergency Stop Solenoid Valve
z
(ZAXIS135UR)
z
(ZAIXS135UR)
Remarks
T5-4-26
scribed provided that each trouble occurs
the same time, find out all faulty compo-
independently.
nents while checking all suspected com-
F-4 F-5 F-6 F-7

Bucket is slow in bucket roll-in When starting to move in com- When starting to move in com- When boom raise or arm roll-out
single operation. Bucket doesn’t bined operation, arm doesn’t bined operation, boom doesn’t is operated, boom or arm starts
move smoothly in bucket roll-in smoothly move. Arm starts to smoothly move. Boom starts to to move after slightly moving
single operation. move slow slightly in arm roll-in move slow slightly in boom downward.
single operation. These troubles lower single operation.
often occur when oil tempera-
ture is low.
z
z
z
z
z
z z
z z

T5-4-27
Front Attachment System Troubleshooting
F-8 F-9 F-10 F-11
Front attachment Offset is slow or Offset cylinder drifts Abnormal front con-
Trouble drifts remarkably. does not move in remarkably. trol (ZAXIS135UR
Symptom offset single opera- (ZAXIS135UR Only) Only)
tion. (ZAIXS135UR
Only)
Parts
MC (Main Controller)
Solenoid Valve Unit (SC)
Pressure Sensor (Boom Raise)
Spool z z z
Main Relief Valve
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Boom Anti-Drift Valve z
Arm Anti-Drift Valve z
Emergency Valve
Shockless Valve (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Bucket Flow Rate Control Valve Control Spool

Pilot Valve z z z
Cylinder z z
Offset Anti-Drift Valve (ZAXIS135UR) z z
8-Unit Solenoid Valve Unit (ZAXIS135UR) z z
(ZAXIS135UR)
Auto-MARCCINO Controller (ZAIXS135UR) z
Remarks

T5-4-28
(Blank)
T5-4-29
Swing/Travel/Blade (ZAXIS135UR) System Troubleshooting

S-1 T-1 T-2
Swing is slow or unmoving. Both right and left tracks do One side track doesn’t rotate
Trouble not rotate or rotate slowly. or rotates slowly. Machine
Symptom mistracks.
Parts
Travel Mode Switch
Pump Device
Spool z
Main Relief Valve
Travel Relief Valve
Overload Relief Valve
Load Check Valve
Flow Combiner Valve
Bypass Cut Valve
Swing Parking Brake Release Spool
z
Pump 1 Flow Control Valve
{
z {
Flow Combiner Control Spool
Shuttle Valve (Signal Control Valve) { {
Swing Device z
Travel Device z
Center Joint z
Pilot Valve z z
Blade Signal Switch Valve
(ZAXIS135UR)
Also, refer to T-5. In case either bucket or swing
is also slow, refer to A-2 or
Remarks A-3.
T5-4-30
T-3 T-4 B-1 B-2

Machine mistracks dur- Fast travel is inoperable. Blade is slow or weak in Blade drifts remarkably.
ing travel and front at- Travel mode does not blade single operation.
tachment combined op- change from slow mode
eration. to fast mode.
z
{
{
{
{
{
z
z
z
z
z z
{
z
z
z

T5-4-31
Other System Troubleshooting

O-1 O-2 O-3
Wiper is inoperable or not Wiper is inoperable. Air Conditioner Malfunction
Trouble retracted. (ZAXIS125US/135US/
Symptom (ZAXIS110/110M/120/130/ 135UR)
130LCN)
Parts
Travel Mode Switch
Pump Device
Spool
Main Relief Valve
Travel Relief Valve
Overload Relief Valve
Load Check Valve
Flow Combiner Valve
Swing Parking Brake
Flow Combiner Control Spool
Shuttle Valve (Signal Control Valve)
Swing Device
Travel Device
Center Joint
Pilot Valve
Blade Signal Switch Valve
Offset Anti-Drift Valve (ZAXIS135UR)
8-Unit Solenoid Valve Unit (ZAXIS 135 UR)
(ZAXIS 135 UR)
(ZAXIS 135 UR)
Remarks
T5-4-32
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesn’t rotate.
Related Fault Code: None
• This trouble has nothing to do with the electronic

control system such as the MC.
• Check for loose harness connections before-
hand. Faulty starter or faulty
harness between
starter and battery re-
Check if voltage at YES lay.
battery relay terminal A
is 24 V.
YES
Faulty battery relay.
Check if both voltages
at key switch terminal
#5 and #6 are 24 V. NO
YES
Faulty key switch.
Check for continuity
Check if battery voltage YES
· Key switch: START between battery posi-
and electrolyte density is tive terminal and key
normal, and fusible link switch terminal #1. Faulty harness be-
(40 A) is not blown.
NO tween battery and key
switch.
NO
· Voltage: More than 24 V
Density: More than 1.26 Faulty battery or fusible
link.
NO
Key Switch Battery Relay

Terminal A
T178-05-04-001
T105-07-04-002
T5-4-33
E-2 Although starter rotates, engine doesn’t
start.
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
hand.
Faulty engine.
YES
· Refer to engine shop manual.
Check if governor lever
moves to the START position
when key switch is turned ON.
YES Faulty EC motor.
· Key switch: ON · Refer to T4-6-6.

Check if EC motor drive
circuit is normal.
NO
Faulty MC.
· Test harness: 4274589 NO
(ST 7125)
• Governor Lever and Fuel Cut Lever · Refer to T4-6-6.
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Mo-
tor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T5-4-34
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
A B
STOP FULL
FULL
T105-07-04-003
STOP
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T5-4-35
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.
Related Fault Code: 06
• In case engine learning has not been performed • Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. • Check for loose harness connections before-
• In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
Return fuel cut

lever to original po-
YES sition.
Check if fuel cut

lever has been
moved up to half YES Faulty EC sensor.
way stroke.
Check if fault code · Refer to T4-6-6.

06 is displayed.
NO YES End.
Check if problem is
corrected after en-
gine learning.
NO
NO Monitor engine
· Refer to T4-6-6 for learning status.
engine learning
procedures.
· Monitor item: En-
gine learning con-
trol
T5-4-36
Faulty engine and/or fuel sys-

YES tem.
Check if governor lever

OK comes in contact with stopper
when performing engine Faulty control cable and/or in-
learning. correctly adjusted engine gov-
ernor lever.
NO
· Adjust engine speed.

(Refer to T4-6-6.)
Faulty MC, faulty learning

switch, or broken harness be-
tween learning switch and MC.
NOT OK
· Refer to T4-6-6.
T5-4-37
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
• If the EC fails, the engine will not stop with the

key switch OFF.
hand.
Faulty engine control dial or

broken harness between en-
gine control dial and MC.
YES
Check if fault code 07 is dis-
played. Using Dr. ZX, monitor
engine control dial angles
(standard voltages). Check if
voltages are normal. Faulty EC motor.
YES
Install test harness (ST 7125)
to EC motor. Check if lamp
comes ON while turning en- · Refer to T4-6-6.
gine control dial.
· Standard voltages NO
Slow idle position: 0.3 to 1 V Faulty MC or broken harness
Fast idle position: 4.0 to 4.7 V between MC and EC motor.
· Possible to display with built-in
diagnosing system. NO
· Refer to T4-6-6.
T5-4-38
E-5 Engine speed doesn’t increase after engine
is started.
• Refer to the pages for the Auto Warming Up Con-

trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
hand.
More than 0 °C
when starting Normal.
Monitor oil tem-

NO perature.
Faulty key switch or

broken harness be-
· Monitor item: Hydraulic oil
YES tween key switch and
temperature Monitor key switch. MC.
· Possible to display with Check if displayed
built-in diagnosing system “ky” is highlighted in
response to key
switch operation.
Check if fault code
19 is displayed. Lower than 0 °C
when starting Faulty MC.
NO
· Refer to T4-6-6.
· Monitor item: Key
switch
Faulty hyd. oil tem-
perature sensor or
broken harness be-
tween oil tempera-
ture sensor and MC.
YES
T5-4-39
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP

mode position, HP mode is inoperable. (General
mode normally operates.)
Related Fault Codes: 10, 11, 15, and 16
• Sensors detect the conditions necessary to oper- • Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to “HP Check if governor
mode”. lever comes in contact YES Faulty engine.
with full-side stopper
while relieving boom
raise circuit pressure.
YES
Check if any fault Faulty MC.
codes are displayed. · Monitor item: E/P/HP
mode switch NO
· Refer to T4-6-6.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
· Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-40
• Although the power mode switch isn’t turned to the
HP mode position, HP mode is operable.
• Boom raise and arm roll-in must be operated

when the average delivery pressures of pump 1
and 2 are high, if HP mode control is performed.
The sensors related to this condition may not be
broken at the same time.
Short circuited harness
between MC and power
YES mode switch.
Monitor the power

Check if the symp- End.
mode switch. Check Check if the governor YES
tom disappears after
if “HP” is displayed. lever comes in contact completing engine
with full side stopper YES learning.
when the key switch is Faulty MC.
turned ON (engine not
running) and the engine NO
· Monitor item: E/P/HP control dial is turned to · Refer to T4-6-6.
mode switch NO
Fast Idle.
· Power mode switch:
P mode Faulty engine.
NO
T5-4-41
E-7 Even if key switch is turned OFF, engine
doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
Related Fault Codes: 06 and 07
• Probably symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Even if engine control dial is rotated, engine
speed remains unchanged” will come up. Per-
form troubleshooting for these symptoms.
T5-4-42
E-8 Faulty auto-idle system
• Even if control lever is turned to neutral. Auto-idle

system is inoperable.
• In case trouble symptoms E1 to E7 are recog- • Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma- Normal (Turn power
chine trouble symptoms and related parts on mode switch to a posi-
page T5-4-2.) YES tion other than the E
mode.)
Check if power mode

switch is in the E
YES mode position. Bound swing parking
brake release spool in
YES the signal control
valve.
Monitor the pressure
sensor (front).
Check if “ON” is dis-
Monitor auto-idle switch.
played.
Check if displayed “AI” is NO
turned OFF or ON in re-
sponse to auto-idle / Faulty MC.
auto- acceleration selec-
tor operation. · Engine: Running NO
· Refer to T4-6-6.
Faulty auto-idle / auto-

acceleration selector
· Monitor item:
or broken harness
Auto-idle / auto-accel
between auto-idle
switch
switch and MC.
NO
• Although the auto-idle / auto-acceleration selector is

turned OFF, the auto-idle control is operated.
• Be sure to separate auto-idle control from Short circuited harness

auto-acceleration control. between MC and auto-idle
/ auto-acceleration selec-
YES tor.
Monitor auto-idle /
auto-acceleration se-
lector. Check if “AI” is
displayed.
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / · Refer to T4-6-6.
auto-acceleration selec-
tor: OFF
T5-4-43
E-9 Faulty E mode
• Even if power mode switch is turned to the E mode

position, engine speed remains unchanged. (En-
gine speed doesn’t decrease.)
• In case trouble symptoms E-1 to E-8 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
hand. Faulty power mode switch or
broken harness between
NO power mode switch and MC.
Monitor power mode switch.
Check if displayed “E Mode” is
turned OFF or ON in re-
sponse to power mode switch
operation.
Faulty MC.
YES
· Monitor item: · Refer to T4-6-6.
E/P/HP mode switch
• Although power mode switch isn’t turned into E

mode, engine speed decrease.
Short circuited harness be-

tween MC and power mode
YES
switch.
Monitor power mode switch.
Check if “E” is displayed.
Faulty MC.
· Monitor item: E/P/HP switch NO
· Power mode switch: P mode
· Refer to T4-6-6.
T5-4-44
E-10 Faulty auto-acceleration system
• Auto-acceleration system is inoperable.
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
• In case trouble symptoms E-1 to E-9 are recog- • Refer to the pages for Auto-Acceleration Control
nized, perform the troubleshooting of these trou- in the SYSTEM / Control System group in the
bles beforehand. T/M (Operational Principle).
• Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and
2 delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.) Faulty auto-idle /
auto-acceleration selector or
broken harness between
Monitor auto-idle / auto-acceleration switch and MC.
NO
auto-acceleration selector.
Check if displayed “AA” is
turned OFF or ON in response
to auto-acceleration switch
operation.
Faulty MC.
YES
· Refer to T4-6-6.
· Monitor item:
Auto-idle/auto-accel
switch
• Although auto-idle / acceleration selector is turned

OFF, the auto-idle acceleration control is operated.
• Be sure to separate the auto-idle control from the

auto-acceleration control. Short circuited harness between
MC and auto-idle /
YES auto-acceleration selector.
Monitor auto-idle / accelera-
tion selector.
Check if “AA” is displayed.
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / auto-acceleration se- · Refer to T4-6-6.
lector:
Auto-idle position
T5-4-45
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
• Although the failure in pressure sensors (travel

and front attachment) will have relevance to mal-
function of the engine speed increase control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES Faulty engine.
Check if engine speed is

faster than increased idle · Refer to the Engine Shop
speed. Manual.
Faulty MC.
· Monitor item: NO
Engine target speed
· Possible to display with built-in · Refer to T4-6-6.
diagnosing system
T5-4-46
E-12 Engine speed doesn’t increase even if at-
tachment is operated in attachment mode.
NOTE: The attachment mode is not equipped for
ZAXIS135UR.
• In case trouble symptoms E-1 to E-11 are recog- • Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
• Although the failure in pressure sensor (auxiliary) • Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Normal (Set to “In-
NO crease (+)”.)
Check if attachment
speed adjustment
has been set to “In-
NO crease (+)” in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to “Decrease” in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
· Monitor item: Att. con-

trol pilot pressure Normal (If set to “De-
crease”, this control
system is deacti-
YES vated.)
YES Faulty MC.

Monitor work mode
switch. Check if display
switches in response · Refer to T4-6-6.
to work mode switch
A operation.
Faulty work mode

switch.
NO
· Monitor item:
Work mode switch
T5-4-47
E-13 When attachment mode is selected, engine
speed doesn’t decrease.
NOTE: The attachment mode is not equipped for
ZAXIS135UR.
• In case trouble symptoms E-1 to E-11 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
hand.
YES Faulty MC.

Monitor work mode
switch. Check if dis-
play switches in re-
sponse to work mode · Refer to T4-6-6.
YES switch operation.
Check if attachment Faulty work mode switch.

speed adjustment has NO
been set to “Decrease
(-)” in Dr. ZX service · Monitor item:
mode. Work mode switch
Normal (Set to “Increase

(+)”.)
NO
T5-4-48
E-14 Engine stalls within several seconds after
engine has started.
• Refer to the pages for Engine Learning Control in

the SYSTEM / Control System group in the T/M
(Operational Principle).
• If the engine-learning switch is turned to the
learning position, the engine will stall in 5 sec-
onds after the engine starts.
hand.
Normal (Return switch to

YES neutral.)
Check if engine learn-

ing switch is turned to
the learning position.
Faulty learning switch, or
short-circuited harness be-
tween learning switch and
MC, or check fuel system for
clogging.
NO
T5-4-49
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
• If speed-sensing control is inoperable, the engine

will stall under adverse operating conditions.
hand.
Disconnect torque control

solenoid valve. Connect
test harness (ST 7226)
Monitor torque control sole- between solenoid valve
noid valve output. Install NO and harness. Check if
pressure gauge to output port test harness lamp comes To A
so that pressure can be ON.
measured by pressure gauge
and Dr. ZX. Check if both
NO measured pressure values by
pressure gauge and Dr. ZX
vary identically.
Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. · Monitor item: Pump torque
proportional solenoid valve
output
· Refer to the Operational Per-
· Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES
Faulty torque control

YES solenoid valve.
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-50
(Blank)
T5-4-51
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesn’t start although pre-heated.)
• Check if electricity is routed to the glow plugs. • Check battery at the same time.
Check the glow plugs for any abnormality. • Check for loose harness connections before-
• The pre-heat system operates only when coolant hand.
temperature is below 10 °C (50 °F). When cool-
ant temperature is higher than 10 °C (50 °F), the
pre-heat system doesn’t operate.
Faulty coolant temperature

YES switch.
Disconnect coolant tempera-

ture switch. Check if voltage at
glow plug is 20 to 24 V.
YES Faulty QOS controller.
Disconnect QOS controller.
Ground harness end connector
· Key switch: ON terminal #4 to vehicle frame.
Check if problem is corrected.
NO
Measure each glow plug re-
sistance.
· Using a clip, ground from the NO
reverse side of the connector
without disconnecting. · Key switch: OFF
· Before measuring, remove
copper plates connecting
each glow plug.
• Measurement of Glow Plug Voltage and Resistance

Voltage Check
Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10 Ω
T105-07-04-006
T105-07-04-007
T5-4-52
Faulty glow plug.

∞Ω
Faulty engine unit, faulty glow

NO plug relay, or broken harness
Disconnect glow plug re- between glow plug relay and
lay. Connect harness end glow plug.
connector terminal #4 to
YES vehicle frame. Check if
voltage is 20 to 24 V. · Refer to the engine shop manual.
Broken harness between glow

plug relay and QOS controller.
Disconnect glow plug re- · Key switch: ON YES
lay. Check if voltage at
glow plug relay harness
end connector terminals
#1 or #3 is 20 to 24 V.
Below 10 Ω
In case voltage at terminal #1
is 0 V, harness between glow
relay and batteries is broken.
· Key switch: ON In case voltage at terminal #3
is 0 V, harness between glow
relay and key switch terminal
NO M is broken.
· Verify that fuse #19

(ZAXIS135UR: #20) is normal.
T5-4-53
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.

ZAXIS135UR:
• Reduction in pump 1 and 2 flow rate due to some • Blade operations use different control valve from
reasons or faulty pilot system may cause this trou- that of front attachment operation. Therefore,
ble. there is a small possibility to have faulty main re-
• Also, check for fuse of the torque control solenoid lief valves of two control valves at the same time.
valve.
• Although speed is satisfactory, in case power is
weak, refer to the troubleshooting for faulty relief
valve (F-1).
• Check for loose harness connections beforehand.
Faulty pilot pump or

YES clogged pilot filter.
Check if same
symptom still ap-
pears after disas-
NO sembling, cleaning,
and adjusting pilot
relief valve.
End.
NO
Check if primary
pilot pressure is Faulty N sensor or
normal. broken harness in N
YES sensor circuit.
· Fully boom raised or arm

roll-in Monitor actual en-
· Monitor item: Boom gine speed. Check
Raise Pilot Pressure, Arm if abnormal speed
YES
Roll-In Pilot Pressure YES is indicated. Monitor torque con-
trol solenoid valve
output. Check if
· Monitor item: Engine torque control sole-
Actual Speed noid valve output is
· Possible to display NO normal.
with monitor service
mode.
· Monitor item:
Pump torque NO
proportional solenoid
valve output
· Refer to the opera-
tional performance
Test section
T5-4-54
Pressure Gauge Torque Control

Mounting Port Solenoid Valve
T176-03-01-001
Faulty pump device.
Install pressure YES
gauge between
YES torque control sole-
noid valve and regu- Faulty torque control solenoid
Check if harness
lator. Check if the valve.
between MC and
pressure changes. NO
torque control so-
lenoid valve is
normal
Faulty harness between torque

control solenoid valve and MC.
· Key Switch: OFF NO
Faulty MC.
· Refer to T4-6-6.
T5-4-55
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
• The pump 2 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the left
travel and swing motors, which are driven by pres-
sure oil from pump 2, moves very slow.
• Pressure oil from pump 1 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the boom prior to the arm so that arm
speed becomes very slow.
• Refer to the SYSTEM / Hydraulic System group in
the T/M (Operational Principle).
Faulty pump 2 regu-

YES lator.
Monitor pump 2
pump control pres-
sure. Check if
pressure in-
creases in propor-
tion to left travel
lever stroke. Bound pump 2 flow
rate control valve in
signal control valve.
NO
· Monitor item: Pump
2 Flow Control
Pressure
· Possible to display
with built-in diag-
nosing system.
T5-4-56
A-3 Right travel is inoperable during single
travel operation. Single bucket operation
speed is slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
• The pump 1 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the right
travel motor and bucket cylinder, which are actu-
ated by pressure oil from pump 1, moves very
slow.
• Pressure oil from pump 2 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the arm prior to the boom so that boom
is scarcely raised.
• Refer to the SYSTEM / Hydraulic System group in
Faulty pump 1 regu-

YES lator.
Monitor pump 1
pump control pres-
sure. Check if
pressure increases
in proportion to
right travel lever
stroke. Bound pump 1 flow
rate control valve in
signal control valve.
NO
· Monitor item: Pump
1 Flow Control
Pressure
with built-in diag-
nosing system.
T5-4-57
A-4 Actuator doesn’t stop even if control lever is
returned to neutral.
• Bound spool in the pilot valve or bound main spool

in the control valve is suspected.
YES Faulty pilot valve.
Check if actuator stops when

· When control lever is in neu-
pilot control shut-off lever is
tral, pilot pressure is routed to
raised.
spool end in control valve.
Faulty control valve.

NO
· Although pilot pressure is not

routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-58
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control can not
be performed.
• The pump 1 or 2 flow rate is maximized due to

some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
doesn’t reach the full stroke.
• The pressure oil from pump 1 makes right travel
perform, and the pressure oil from pump 2 makes
left travel. Perform on the single travel operation.
Different flow rates between pump 1 and pump 2
occur, and the machine mistracks. When the
travel lever is operated at half stroke.
• Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).
Faulty pump regulator.

YES
Monitor pump control pres-
sure of pump 1 and 2. Check
if the pressure changes in re-
sponse to the lever operation.
Bound pump flow rate control
valve in signal control valve.
· Pump 1: Bucket operation NO
· Pump 2: Swing operation
· Monitor item: Pump 1 and 2
pump control pressures
· Possible to display with
built-in diagnosing system.
T5-4-59
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator is weak or
slow.
• In case operating speeds are extremely slow,

pump control may be malfunctioning (A-2 and/or
A-3). Faulty pilot system may also cause this
trouble.
ZAXIS135UR:
• An emergency stop solenoid valve is provided
between the pilot shut-off valve and the front at-
tachment pilot valve to control the front attach-
ment oprtation. In case the unload valve in the
emergency stop solenoid valve should become
stuck, the primary pilot oil pressure to the front
attachment pilot valve will become abnormal, and
the similar symptom may appear.
Main relief valve should be

normal. Find out cause of
trouble by tracing other trou-
34.3 to 36.3 MPa ble symptoms.
(350 to 370 kgf/cm2)
Monitor pump 1 and 2 delivery

pressures.
Adjust main relief valve.
· Monitor item: Pump 1 and 2 De- Less than 34.3 MPa

livery Pressures (350 kgf/cm2)
· Possible to display with built-in
diagnosing system.
· Relieve boom, arm, and bucket
circuits.
· Power Mode Switch: OFF
· Work Mode: Digging
T5-4-60
F-2 Some cylinders are inoperable or speeds
are slow.

ZAXIS135UR:
• When other actuators (travel and swing motors) • When the auto-Marccino fault codes are dis-
operate normally, the pilot pump (primary pilot played, refer to the Troubleshooting D.
pressure) is considered to be normal. • In case only the single offset operation is slow,
• In case single bucket operation speed is slow, refer to F-9 also.
refer to F-4.
• In case single arm roll-in operation speed is slow,
refer to F-5.
• In case single boom lower operation speed is
Bound control valve
slow, refer to F-6.
YES spool or faulty cylinder
(faulty seal kit).
Monitor pump con- Check if overload
trol pressure. Check YES relief pressure is
if pump control pres- normal.
Faulty overload relief
sure changes valve.
smoothly while mov-
NO
ing control lever
YES slowly.
Monitor or meas- Faulty shuttle valve in

ure secondary pilot signal pressure con-
· Monitor item: trol valve.
pressure. Check if · Pump 1 Flow Control NO
secondary pilot Pressure, Pump 2 Flow
pressure is normal. Control Pressure
· Possible to display with Bound shockless
built-in diagnosing sys- YES valve spool.
tem.
· Secondary Pilot
Check if secondary
Pressure: YES
pilot pressure at inlet Bound corresponding
· Refer to Operational Check if secon-
Performance Test NO port to signal control solenoid valve spool ,
valve is normal. dary pilot pres- or bound shuttle valve
Section. sure at inlet port
· Monitor item: Boom in solenoid valve.
to 8-unit solenoid
Raise Pilot Pressure, NO valve is normal.
Arm Roll-In Pilot
Pressure · Check only when
· Possible to display Faulty pilot valve.
boom is not raised. NO
with built-in diagnos- · Check only ZAXIS
In case cylinders
ing system. 135UR. Skip this
other than boom
step and proceed to
are abnormal, skip
the NO line except
this step and pro-
ZAXIS135UR.
ceed to the NO line.
T5-4-61
F-3 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
• Refer to the pages for the Arm Regenerative

Control and the Arm Flow Rate Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
Disconnect solenoid
valve unit (SC). Con-
nect test harness (ST Faulty solenoid valve
7226) between sole- YES unit (SC).
Monitor output from noid valve unit (SC)
solenoid valve unit NO and harness. Check if
(SC). Install pressure test harness lamp
comes ON. Broken harness be-
gauge to port SC.
tween solenoid valve
Compare pressure NO unit (SC) and MC.
measured by Dr. ZX
NO with that measured by
pressure gauge. Check · Perform boom raise and
if both pressure values arm roll-in combined
vary identically. operation.
Faulty arm regenerative

YES valve.
Check if arm regenera-
Check if any fault
· Monitor item: tive valve in 5-spool
codes are dis-
played. · Arm Regenerative Pro- YES section of control valve
portional Solenoid Valve is scored or bound. Find out cause of trou-
Output ble by tracing other
NO trouble symptoms.
· Perform boom raise and
· Fault Codes: arm roll-in combined op-
11: Pump 2 Delivery eration.
Pressure Sensor · Refer to the Operational
14: Pressure Sen- Performance Test.
sor (Swing) Faulty corresponding
15: Pressure Sen- sensor or faulty MC, or
sor (Boom Raise) broken harness be-
16: Pressure Sen- YES tween MC and sensor.
sor (Arm Roll-In)
NOTE: In case other fault · Refer to T4-6-6.

codes are displayed,
perform trouble-
shooting corre-
sponding to the dis-
played fault code.
T5-4-62
F-4 Bucket is slow in bucket roll-in single op-
eration. Bucket doesn’t move smoothly in
bucket roll-in single operation.
• Faulty bucket flow rate control valve or bucket

regenerative valve may cause this trouble. Faulty bucket regen-
• Refer to the COMPONENT OPERATION / Con- erative valve (Disas-
YES semble and clean, or
trol Valve group in the T/M (Operational Princi-
Check if bucket re- replace.)
ple). generative valve in
Install pressure gauge YES bucket spool is
to hose SK connecting bound or scored.
signal control valve to Find out cause of trou-
bucket flow rate con- ble by tracing other
trol valve in control NO trouble symptoms.
valve. Check if relief
NO pressure is approx. 3.9
MPa (40 kgf/cm2)
while performing
Check if bucket flow 3-function combined Bound bucket flow rate
rate control valve in operation of boom control valve control
control valve is raise, arm roll-in, and spool in signal control
bound or scored. bucket roll-in. NO valve.
Faulty bucket flow rate

control valve (Disas-
YES semble and clean, or
replace.)

Bucket Flow Hose (SK)
Rate Control
Valve
T176-05-04-001
T5-4-63
F-5 When starting to move in combined opera-
tion, arm doesn’t smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
• Refer to the COMPONENT OPERATION / Con-

trol Valve group in the T/M (Operational Princi-
ple).
Faulty arm regenerative valve

YES (Disassemble to clean, or re-
Check if arm regenera- place.)
tive valve is bound or
NO
scored.
Check if arm anti-drift valve is
bound or scored. Find out cause of trouble by
tracing other trouble symp-
NO toms.
Faulty arm anti-drift valve

YES (Disassemble to clean, or re-
place.)
F-6 When starting to move in combined opera-

tion, boom doesn’t move smoothly. Boom
starts to move slow slightly in boom lower
single operation.

Find out cause of
• Refer to the COMPONENT OPERATION / Con- trouble by tracing
other trouble symp-
trol Valve group in the T/M (Operational Princi- toms.
ple). NO
Check if boom regen-

erative valve is bound
NO or scored. Faulty boom regen-
erative valve (Disas-
Check if boom semble to clean, or
anti-drift valve is replace.)
YES
bound or scored.
Faulty boom anti-drift

valve (Disassemble to
YES clean, or replace.)
T5-4-64
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
YES Faulty anti-drift valve.

Check if anti-drift
valves (arm and
YES boom) are bound or
scored.
Oil leaks in cylinder.
Check if load check
valve in control NO
valve is normal.
Faulty load check

· Disassemble / valve.
Visual Inspection NO
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve
is malfunctioning, the oil in the bottom (B)
side of the boom cylinder flows back
into the circuit through the load check When the load check
valve, causing the boom cylinder to valve is faulty: (A)
temporarily retract.
2. Since oil pressure and flow rate from
the pump is low, if oil leaks from bottom
side (A) to rod side (B) due to faulty
boom cylinder piston or cylinder barrel,
the boom cylinder is temporarily re-
tracted during the initial stage of opera-
tion. In addition, cylinder force is
reduced, increasing the cylinder drift in T105-07-04-012
this case.
T5-4-65
F-8 Front attachment drifts remarkably.
• In case a large oil leak is detected in the right

offset system (ZAXIS135UR), refer to F-10.
YES Normal.
Correctly adjust
Check if each front
NO emergency valve and
attachment cylin- Check if emergency lock it up.
der drift is within valve at boom 1 sec-
specification. tion in control valve
NO
4-spool section is cor- Check if symptom is
rectly adjusted. deleted when overload
Check if cylinder drift
· Specification: relief valve is tempo-
is reduced when pilot
Refer to YES rarily switched with
shut-off valve is
Operational another overload relief
NO closed.
Performance valve.
Test
Faulty pilot valve.
YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses from the boom cylinder rod T105-07-04-009

side. Drain oil from the hoses and cylinders.
(Plug the disconnected hose ends.)
3. Retract the arm cylinder to lift the bucket off the

ground. If oil flows out of the hose disconnected
pipe ends and the boom cylinders are retracted
at this time, oil leaks in the boom cylinders. In
case no oil flows out of the hose disconnected
pipe ends but the boom cylinders are retracted,
oil leaks in the control valve.
T5-4-66
Emergency
Valve
Scored control 2
valve spool, broken
NO spring, or loose
spool end.
Check if oil
NO leaks in cylin-
ders.
Faulty cylinder
(Replace seal kit.).
YES
Faulty overload
relief valve.
YES T155-06-04-001
Adjustment Procedure:
Turn screw (1) counterclockwise to the stop, then
tighten lock nut (2).
: 4 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft)
T5-4-67
F-9 The single offset operation is slow or im-
movable. (ZAXIS135UR only)
End (Stuck offset

YES anti-drift valve)
Disassemble to clean
offset anti-drift valve.
YES Check if symptom is
Check if pressure at
corrected. Stuck spool in con-
port SM on signal con-
YES trol valve is equal to trol valve.
primary pilot pressure. NO
Stuck shuttle valve

in signal control
Check if primary NO valve
pilot pressure is · Offset front attachment
normal. to right and left.
Faulty 8-unit sole-

Check if secondary YES noid valve (Stuck
· Standard: Refer to pilot pressure at 8-unit spool or shuttle
Operational Per- solenoid valve inlet valve)
formance Test port is normal
section. NO
· Offset front attachment Faulty pilot valve

to right and left.
NO
Control Valve
Port SM (Control Valve Side)
8-Unit Solenoid
Valve
Left Offset Pilot

Pressure
Front
Ring Offset
Pilot Pressure
T1SM-05-04-001
T178-03-06-015
T5-4-68
F-10 Offset cylinder drifts remarkably (right side).
(ZAXIS135UR Only)
YES Faulty pilot valve.
Check if Cylinder
drift is reduced
when pilot shut-off
valve is closed. Faulty offset anti-drift
YES valve.
Disassemble and
clean offset anti-drift
valve. Check if symp-
NO tom disappears. Faulty control valve.
YES
Scored control valve

spool, broken spring or
NO loosened spool end. Faulty cylinder
(internal leakage).
NO
T5-4-69
F-11 Front control (front movement restriction,
cab collision prevention, auto-MARCCINO)
is abnormal. (ZAXIS135UR Only)
• When a fault code is displayed, refer to T5-6

(Trouble shooting D).
• When adjusting front speed, refer to T4-6-2.
hand. End (Binding
8-unit solenoid
YES
valve.)
Disassemble and
clean 8-unit sole-
noid valve.
Reassemble. YES Faulty harness.
Check if trouble is Check 8-unit sole-
corrected. noid valve harness
NO breakage or short Faulty Auto-
circuit. MARCCINO con-
NO
trol unit.
T5-4-70
(Blank)
T5-4-71
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the

main circuit is faulty.
• In case other functions (front attachment and
travel) operate normally, the pilot pump is con-
sidered to be normal. If the pilot system is dis-
playing a problem, the cause of the trouble may
exist in the circuit after the pilot valve.
• In case the left travel speed is also slow, refer to
A-2.
Check if swing parking

Check if swing parking YES brake release valve is
brake release pres- scored or bound.
sure is approx. 3.9
Monitor pump control MPa (40 kgf/cm2).
pressure while slowly YES
operating swing lever.
Check if pump control Faulty swing parking
pressure varies · Relieve arm circuit. brake release spool in
smoothly. · Monitor item: signal control valve.
YES Front Attachment Con- NO
Monitor secondary trol Pilot Pressure.
pilot pressure. · Possible to display with
Check if secondary built-in diagnosing sys- Bound pump 2 flow rate
pilot pressure is · Monitor item: tem. control valve in signal
normal. Pump 2 Flow Control control valve.
Pressure NO
· Possible to display with
built-in diagnosing sys-
tem. Faulty pilot valve.
· Specification: NO
Refer to OPERA-
TIONAL PER-
FORMANCE TEST
Section.
· Monitor item:
Swing Control Pilot
Pressure
with built-in diag-
nosing system.
T5-4-72
Faulty swing reduction

YES
gear.
Check if swing motor
drain oil amount is
YES normal.
Check if swing relief · Measurement: Faulty swing motor.

pressure is normal. Refer to OPERA-
YES NO
TIONAL PER-
FORMANCE TEST
· Relieve swing circuit. Section.
· Monitor item: Pump 2 De-
livery Pressure Faulty swing relief
· Specification: valve.
Refer to OPERATIONAL NO
PERFORMANCE TEST
Section.
Faulty swing motor

NO parking brake release
valve.
T5-4-73
(Blank)
T5-4-74
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
• Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
• In case both travel systems do not operate, the
pilot system, which is applied to both side travel
motors, may be faulty. If the primary pilot pres-
sure is lower than specification, the front attach-
ment operating speed becomes slow as well.
Refer to A-1.
• In case the fast travel mode cannot be selected,
refer to T-5.
T5-4-75
T-2 One side track doesn’t rotate or rotates
slowly. Machine mistracks.
• Check that both side track sags are equally ad- • In one side track only doesn’t rotate, the pilot
justed. valve, control valve, travel motor, or center joint
• Faulty pump control will cause the machine to may be faulty.
mistrack. In this case, other trouble symptoms
such as slow bucket or swing single operation Check if travel motor
YES drain oil amount is nor-
speed, or slow arm roll-in and boom raise speed mal.
in level crowd operation will occur at the same
Check if travel relief
time. If both mistrack and other symptoms as
pressure in slow speed · Specification: Refer
described above occurs at the same time, refer side is normal. to OPERATIONAL
to A-2 and A-3. NO PERFORMANCE
TEST section.
· Relieve travel circuit.
Check if symptom is · Monitor item: Pump 1 and Switch forward travel
reversed when right 2 Delivery Pressure relief valve with reverse
and left travel line · Possible to display with travel one, or right travel
built-in diagnosing system relief valve with left one.
YES hoses are switched · Specification: Check if symptom is
each other at the top of
center joint. Refer to OPERATIONAL reversed.
PERFORMANCE TEST NO
Check if secondary section.
travel pilot pressure
is normal.
Bound control valve
spool.
Measurement: YES
Refer to OPERA-
TIONAL PER- Faulty pilot valve.
FORMANCE NO
TEST section.
Relationship between Faulty Seal Location Seal Location

and Mistrack Direction
Seal When traveling When pivot turn
No. straight: is performed:
2 Blade Lower
（ZAXIS135UR Only）
Blade Raise
1
3 Right Travel
(Reverse)
Left Travel 2
(Reverse) 3
4
Right Travel
(Forward)
Left Travel
(Forward) 4
5
5
T198-05-04-004
NOTE: The figure shows for ZAXIS135UR.
T5-4-76
Faulty travel motor.

NO
YES Faulty travel reduction

Disassemble and clean
gear.
travel motor servo pis-
YES ton. Check if same
Disassemble and symptom occurs.
clean travel motor Faulty travel motor
counterbalance valve. servo piston.
Check if same symp- NO
YES tom occurs.
Faulty counterbalance
valve.
NO
NO Faulty center joint.
Faulty travel relief

valve.
YES
Arrangement of Upper Pipe Line in Center Joint

Front
Dr port
Left Travel
(Forward) Right Travel
(Forward)
Blade Lower
(Reverse) (Reverse)
Blade Raise
Back
T198-05-04-003
T5-4-77
T-3 Machine mistracks during travel and front
attachment combined operation.
Related Fault Code: None Faulty flow combiner

valve control spool in
Disconnect hose (SL), YES signal control valve.
connecting to flow
combiner valve, from
NO signal control valve.
Install pressure gauge Faulty load check
to signal control valve. YES valve.
Check load check
Check flow com- Check if signal pres- valve for any abnor-
biner valve in con- sure is approx. 3.9 mality.
trol valve for any MPa (40 kgf/cm2). NO Find out cause of
abnormality. trouble by tracing
NO other trouble symp-
toms.
Faulty flow combiner

YES valve.
Control Valve
Hose (SL)
T176-05-04-001
T5-4-78
(Blank)
T5-4-79
T-4 Fast travel is inoperable.
Travel mode doesn’t change from slow
mode to fast mode.
• Refer to the pages for the Travel Motor Swash

Angle Control in the SYSTEM / Control section in
Faulty travel mode switch or
• Check for loose harness connections before- broken harness between
hand. travel mode switch and MC.
NO
Monitor travel mode

switch. Check if dis- Check if symptom is re-
played indication is versed when pressure
highlighted in response sensor (travel) is switched
to travel mode switch NO with another pressure sen-
NO operation. sor.
Monitor pressure sen-

sor (travel). Check if
· Monitor item: Monitor travel motor
pressure varies in re-
Travel Mode swash angle. Install pres-
sponse to travel lever
sure gauge to solenoid
operation.
valve unit (SI) output port.
YES Check if pressure meas-
ured by Dr. ZX varies iden-
Check if any fault tically with pressure
· Monitor item: Travel Con- measured by pressure
codes are displayed.
trol Pressure gauge while repeating to
travel and stop.
YES
· Monitor item:
Travel Motor Swash Angle
Control Pressure
· Travel Mode: Fast
· Measurement: Refer to
OPERATIONAL PER-
FORMANCE TEST section.
Faulty corresponding sen-

sor or broken harness be-
YES tween MC and sensor.
· Fault Codes:
10: Pump 1 Delivery Pressure Sen-
sor
11: Pump 2 Delivery Pressure Sen-
sor
12: Pump 1 Control Pressure Sensor
NOTE: In case other fault
codes are displayed,
perform troubleshooting
corresponding to the
displayed fault code.
T5-4-80
Faulty pressure sensor

YES (travel).
Broken harness between

travel pressure sensor and
MC or clogged shuttle
valve in signal pressure
control valve.
NO
Disconnect solenoid
valve unit (SI). Connect Faulty solenoid valve unit
test harness (ST 7226) YES
(SI).
between solenoid valve
NO unit (SI) and harness.
Check if test harness
lamp comes ON. Broken harness between
solenoid valve and MC.
NO
· Travel Mode: Fast YES
Faulty travel motor swash
Check if travel motor angle control valve.
swash angle control
YES valve is bound or
scored. Faulty travel motor or faulty
travel reduction gear.
NO
T5-4-81
BLADE SYSTEM TROUBLESHOOTING
(ZAXIS135UR ONLY)
B-1 Single blade operation is slow or weak in
power.
• Check whether the pilot system or the main cir- • The pressure oil from main pumps 1 and 2 is
cuit system is faulty. jointlysupplied to the blade circuit to increase the
• In case the machine mistracks, a potential cause blade speed. In case only the operation speed is
is sticking of the flow combiner valve or the shut- slow (strong in power), potential cause may be
tle valve between the signal control valve and the faulty main relief valve (in the blade circuit). Even
flow combiner valve. if the main relief valve (in the blade circuit) is
faulty, the oil pressure is maintained by the main
relief valve in the main circuit.
IInstall pressure gauge

to outlet port (P2) on YES
Install tee to port Pi on YES blade signal switch
blade signal switch valve. Check if pres-
valve. Check if pressure is 4 MPa or more.
sure at port Pi is equal Stuck blade signal
YES to secondary pilot switch valve
pressure. NO
Stuck shuttle valve (b)

Check if secondary between blade pilot
pilot pressure is valve and blade signal
normal. NO switch valve
· Standard:
Refer to Operational
Performance Test.
Faulty blade pilot valve
NO
Blade Pilot Circuit
Blade Pilot Valve

Signal Control Valve Shuttle Valve (a)
Shuttle
Shuttle Valve (a)
Valve (b)
Control
Port (P2) Valve
Flow Combiner
Port （Pi） Port
Valve Port
（Pi）
Bypass
Blade Signal Shut-Off
Switch Valve Valve Port
Port
(P2)
Pilot Pump
Blade Signal T1SM-05-04-003
Switch Valve
T1SM-05-04-002
T5-4-82
Stuck bypass shut off

YES valve.
Disassemble to clean by- Remove blade cylin- Faulty center joint or oil
pass shut off valve in con- der. Retract blade cyl- NO leakage in control valve.
trol valve. Check if symp- inder full stroke. Con-
tom is corrected. nect only rod side pipe
line to cylinder. Check
YES if oil flows out of bot-
tom side port when oil
Check if main relief is supplied into cylinder
pressure in blade cir- via rod side oil port.
cuit is normal.
Faulty cylinder seal.
NO
YES
Faulty main relief valve in

blade circuit.
NO
T5-4-83
B-2 Blade Drift is Large.
Checking Instructions
• When the blade does not stop lowering, refer to
A-4. Faulty center joint,
Remove blade cylinder or control valve
and fully retract it. Then, internal leakage.
connect hydraulic line to NO
cylinder rod side only and
NO perform blade raise op-
Check if symptom eration. Check if oil flows
disappears when up- out of cylinder bottom Faulty cylinder
per and lower over- side oil port. seal.
load relief valves are YES
switched.
Faulty overload
relief valve.
NOTE: Be sure to reinstall YES
overload relief valves
to their original posi-
tions since each of
their set pressures is
different.
T5-4-84
(Blank)
T5-4-85
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
(ZAXIS110/110M/120/130)
• The wiper is driven by electric power routed via

the relay circuit controlled by the monitor assem-
bly. In case the wiper is inoperable, first check
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness.
• If the front window is open, the wiper won’t oper-
ate. Check that the front window is securely
closed.
Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
Disconnect front
window open / close Remove test harness
switch. Check if and reconnect circuit to YES Faulty wiper relay.
Connect test har- the original position.
wiper operates. ness (ST 7227) be- Replace wiper relay
tween auxiliary elec- YES one at a time. Check if
tric power (fuse box wiper operates.
· Key switch: ON #19) and wiper motor
as illustrated to the To A
right. Check if wiper NO
NO · Key switch: ON
operates.
Faulty wiper motor or
NO or test har- faulty links.
ness lamp doesn’t
· Key switch: ON light normally.
NOTE: When the wiper motor
is normal, lamp S lights
while the wiper is mov-
ing within the operating End (Faulty monitor).
YES
range. Both lamps B
and S light for a mo-
ment at the same time Replace monitor as-
only when the wiper A sembly. Check if wiper
reaches the intermittent operates. Faulty cab harness.
stop position.
NO
T5-4-86
Test Harness Application Circuit

Fuse Box #19
Lamp S
M B S
Lamp B Wiper Motor
L E
Ground
T178-05-04-004
Wiper Operating Range Intermittent Stop Position
Retracted Position
Operating Range
T178-05-04-005
Test Harness Connection Method
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-87
O-2 Wiper is inoperable
(ZAXIS125US / 135US/ 135UR)
• When the front window is opene, the wiper will

not operate. Make sure that the window is se-
curely closed. Dust on the contact points of the
switch may cause discontinuity in the circuit. Be
sure to carefully inspect wiring connections prior
to troubleshooting.
YES
Faulty wiper relay
Switch wiper relay with Measure voltage at

washer relay. Check if connector terminal S YES Faulty wiper motor
wiper operates. on wiper motor.
Check if voltage varies
0 to 24 V in response
YES to wiper operation in-
Check if voltage at tervals.
Connector terminal B
on wiper motor is 24 V
or more.
NO · Key Switch: ON
· Wiper Switch: ON NO
· Without disconnecting,
· Key Switch: ON
ground the connector to
· Without disconnecting,
vehicle using a clip from
ground the connector to Blown fuse #12 or bro-
the reverse side of the
vehicle using a clip from ken wire between fuse
connector.
the reverse side of the #12 and wiper motor
connector. terminal B.
NO
ZAXIS125US, 135US
Wiper Relay
ZAXIS135UR
Washer Relay
Washer Relay
Wiper Relay
T1SM-01-02-006
T1CF-01-01-013
T5-4-88
Faulty monitor
Check if continuity be- YES
tween wiper relay terminal
#2 and terminals shown
below is present.

· ZAXIS125US, 135US: Con- wiper relay and monitor
nector C terminal #6 NO
· ZAXIS135UR: Connector C
terminal #5
Connector (Harhess End Connector Viewed the Open Side)

ZAXIS125US, 135US
Monitor Connector
10 1 Wiper Motor
1
20 11
T1SM-05-04-004
ZAXIS135UR
Monitor Connector C
Relay
8 1
1
16 9
T1SM-05-04-005
T5-4-89
O-3 Malfunction of Air Conditioner
NOTE: The self-diagnosis function is not equipped
for ZAXIS135UR.
ZAXIS110, ZAXIS110M, ZAXIS120, ZAXIS130,
ZAXIS130LCN
The air conditioner has a self-diagnosis function.
The self-diagnosis functions to:
1) Display Fault Codes
2) Change Displayed Fault Codes
3) Delete Fault Code
4) End Fault Code Display
• Display Fault Code

1. Press the fan OFF switch to turn the fan OFF. Temperature
2. Press and hold both the upper and lower sides of Fan OFF Switch Control Switch
the temperature control switch on the air condi-
tioner control panel at the same time for more
than 3 seconds with the key switch ON.
NOTE: After operation has been performed, the
buzzer will sound.
3. If any fault codes are found, the LCD displays the M178-01-017
fault codes as E{{. LCD
NOTE: If more than one fault code is found, the

lower number fault code will be displayed
first.
T5-4-90
Fault Code List
Fault
Location in Trouble Cause Symptom
Code
Abnormal circulation E11 Broken circuit in air circulation Y value (air flow-in temperature) cannot
air sensor sensor be adjusted in response to the
E12 Short-circuited circulation air set-temperature.
sensor
Abnormal fresh air E13 Broken circuit in fresh air sensor Operation is controlled under such cir-
sensor E14 Short-circuited fresh air sensor cumstance as no fresh air sensor is pro-
vided.
Abnormal solar E18 Short-circuited solar radiation Operation is controlled under such cir-
radiation sensor sensor cumstance as no solar radiation sensor is
provided.
Abnormal evapora- E21 Broken circuit in evaporator sen- Operation is controlled under such cir-
tor sensor sor cumstance as the evaporator temperature
E22 Short-circuited evaporator sen- is set to 10 °C (50 °F).
sor
Abnormal damper E43 Abnormal air vent damper Corresponding damper servo becomes
E44 Abnormal air mix damper inoperable.
E45 Abnormal circulation/fresh air
damper
Water temperature E15 Broken circuit in water tempera- Operation is controlled under such cir-
sensor ture sensor cumstance as the water temperature is
E16 Short-circuited water tempera- set to 60 °C (140 °F). (Warm-up control is
ture sensor not performed.)
Abnormal refrigerant E51 Abnormal high/low refrigerant The compressor clutch is disengaged.
pressure (The compressor stops.)
T5-4-91
• Change Displayed Fault Code
1. When displaying more than one fault code, press Temperature
either the upper or bottom side of the tempera- Control Switch
ture control switch key. The following fault code is
displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.
M178-01-017
LCD
• Delete Fault Code

LCD
1. Press and hold both the circulation air switch and
the fresh air vent switch for more than 3 seconds
at the same time to delete the fault code.
NOTE: After the fault code is deleted, the buzzer
will sound.
2. After the fault code has been deleted, the LCD

displays E{{. M178-01-017
Circulation Fresh Air vent
Air Switch Switch
Fan OFF Switch
• End Fault Code Display

1. Press the fan OFF switch, or press the upper
side of the fan switch key. The self-diagnostic
mode is complete.
M178-01-017
Fan Switch
T5-4-92
The air conditioner operation system has a

self-diagnosing function. This system performs the
diagnosis by 8-steps as shown in the flow chart be-
low: Check Model Confirmation, Display Function
Confirmation, Present Trouble Diagnosing, Past
Trouble Diagnosing, Sensing Temperature Display,
and Component Operation Check, Correction of the
Set Temperature and Selection of Celsius and Fahr-
enheit Temperature Indication.
Normal Operation
Turn key switch ON while pressing air

conditioner switch and mode switch.
Keep pressing OFF switch

for more than 3 seconds. STEP 0
Check Model Confirmation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 1
for more than 3 seconds. Display Function Con-
firmation
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Keep pressing OFF switch STEP 3 Keep pressing air conditioner

for more than 3 seconds. Past Trouble Di- switch for more than 3 seconds.
agnosing
Sensing Temperature
Display
Component Operation Check
Press AUTO switch and Press AUTO Press A/C Press A/C switch and
lower side fan switch. Switch and switch and lower side fan switch.
upper side upper side
fan switch. fan switch.
Keep pressing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
for more than 3 seconds.
Self-Diagnosis
T5-4-93
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing the air condi-
tioner switch and mode switch on air conditioner
control panel.
STEP 0 Check Model Confirmation

The liquid crystal display (LCD) indicates the ma-
chine model name this system can diagnose. T178-05-08-001
Mode Switch OFF Switch

• The LCD will indicate “Sd” as the check model
name (ZAXIS125US/135US).
• Select next step to be performed by operating the
switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
passed after the check model is displayed.
STEP 1 Display Function Confirmation

Turn all indicators ON to check indicator bulbs.
• The LCD panel and all switch indicators light.

• Select the next step to be performed by operating
the switches as follows:
• Press the upper side of the fan switch: To pro-
ceed to “STEP 2.”
• Press the lower side of the fan switch: To return
to “STEP 0.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-94
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
• In case any abnormalities are present, the LCD in-

dicates the fault codes. If more than one fault code
is detected, the following fault code is displayed af-
ter flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient 23 −23
Temperature Sen-
sor
Outdoor Ambient 24 −24
Temperature Sen-
sor
Coolant Tempera-  
ture Sensor
∗
Solar Radiation 26 −26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of breakage.
NOTE: As for coolant temperature sensor, no fault
codes display. In case no failures are pre-
sent, the LCD indicates “20.”
to “STEP 1.”
T5-4-95
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
• In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice. T178-05-08-001
Fault Code OFF Switch
Breakage Short Circuit
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient
Temperature Sen- 23 −23
sor
Outdoor Ambient
Temperature Sen- 24 −24
sor
Coolant Tempera-  
ture Sensor
Solar Radiation −26
Sensor
NOTE: As for coolant temperature sensor, no fault
codes display. In case no failures are pre-
sent, the LCD indicates “30.”
• When the air conditioner switch is kept pressed for
more than 3 seconds, failure records are deleted.
After this operation, the air conditioner switch indi-
cator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are re-
sumed.)
to “STEP 2.”
T5-4-96
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
• The sensing temperature detected by the in-cab

ambient temperature sensor, outdoor ambient tem-
perature sensor, and coolant temperature sensor
are displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001
NOTE: The coolant temperature sensor indicates Fresh Air Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
to “STEP 3.”
T5-4-97
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
• Each time the fresh air vent switch is pressed, the

component to be checked is selected in order.
Check which component has been selected by re-
ferring to No. indicated on the LCD. (See table 1.)
• Operating pattern of the selected component is T178-05-08-001
shifted at an interval of 10 seconds. Operating pat-
Fresh Air Vent switch OFF Switch
tern is cycled. (See table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
• Press the AUTO switch and upper side of the fan
switch: To proceed to “STEP 6-1”.
• Press the air conditioner switch and upper side of
the fan switch: To proceed to “STEP 6-2”.
to “STEP 4.”
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5”, and “H” are
damper: 0% (fully closed) → indicated next to the decimal point
50%*→ 100% (fully opened) respectively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow
M (Lo) → M (Hi) → Hi volume light.
Air Vent Location 53 Selects air vent: Front*→ Indicator corresponding to selected
Front/Rear → Front/Foot → Foot air vent lights.
Fresh/Circulation 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
Air Vent Selection tion* → Fresh mode light.
Air Conditioner 55 Turns air conditioner switch: ON* → ON: Indicator lights.
OFF OFF: Indicator is extinguished.
T5-4-98
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
• Each time when the top or bottom of the tempera-

ture control switch is pressed, temperature correc-
tion, displayed on the LCD window, can be
changed.
• Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is T178-05-08-001
25°C (77 °F) and set temperature correction is -1°C OFF Switch
(-34 °F), the actually controlled temperature be-
comes 24°C (75 °F).
• Press the AUTO switch and lower side of the fan
switch: To return to “STEP 5.”
T5-4-99
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pressed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of the LCD
window as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
C F Fresh Air Vent Switch OFF Switch

• Press the Air Conditioner Switch and lower side
of the fan switch: To return to “STEP 5.”
T5-4-100
∗ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Uncontrollable vent hole
∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Symptom Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-4-101
ZAXIS110, ZAXIS110M, ZAXIS120, ZAXIS130, ZAXIS130LCN:
Refrigerant Quantity ....................... 900±50 g
Compressor Oil Quantity................ 180 cm3
ZAXIS135UR
T5-4-102
(Blank)
T5-4-103
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost forms. Thermistor doesn’t cool.
flow volume is reduced.
Thermistor cools.
T5-4-104
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion Readjust or replace expansion valve.

valve.
Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction

Repair.
type).
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-4-105
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer con-
tact noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-4-106
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-107
Compressor
Compressor doesn’t rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) using gas de-
blower mo- tector. (Refer to NOTE 2 on page T5-4-111.)
tor rotate.
Stain on exterior.
(Refer to NOTE 1
on page T5-4-111.)
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high.
No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through Others

sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-4-104.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-4-108
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesn’t rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-4-104.
Broken valve (See NOTE 3 on page T5-4-111.)
Replace.
Blown gasket (See NOTE 3 on page T5-4-111.)
Check and adjust

Excessive oil. oil level.
T5-4-109
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-4-110
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Saggy belt. Refer to the Cooling Circuit

Troubleshooting Table on
page T5-4-104.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Loose screws. Troubleshooting Table on
page T5-4-104.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high pressure side and low pressure side is 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high pressure side and low pressure side will
disappear within about 10 seconds.
T5-4-111
EXCHANGE INSPECTION
Pump2 Pump1
(5-Spool Side) (4-Spool Side)
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Many sensors and solenoid valves used on this ma-

chine are identical. Therefore, using this switch-check
method, faulty part /component, and/or harness can
be easily found.
Example: Abnormal pump 1 delivery pressure (Fault

code: 10) PP2 PP1
Check Method: Figure A T176-03-01-002
1. Switch two delivery pressure sensors located as

shown in figure A to figure B.
2. Retry troubleshooting. Pump2 Pump1
(5-Spool Side) (4-Spool Side)
Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
In case the pump 1 delivery pressure is abnormal

(fault code 10), the pump 1 delivery pressure sensor
harness is considered to be faulty.
PP1 PP2
Figure B T176-03-01-002
T5-4-112
Applicability of Exchange Inspection Method

Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
10 Abnormal Pump 1 Delivery Pressure Applicable (Harness)
11 Abnormal Pump 2 Delivery Pressure
12 Abnormal Pump 1 Control Pressure Applicable (Harness)
13 Abnormal Pump 2 Control Pressure
14 Abnormal Swing Pilot Pressure Applicable (Harness/Sensor)
15 Abnormal Boom Raise Pilot Pressure
16 Abnormal Arm Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Not Applicable
Sensor
T5-4-113
EMERGENCY BOOM LOWERING PRO- Rear
CEDURE
1 Boom 1
CAUTION: Never allow anyone to come

under the front attachment while performing
the emergency boom lowering procedure.
2
If the engine stalls and cannot be restarted, lower the
boom and the bucket to the ground referring to the
emergency boom lowering procedure stated below.
1. Remove rubber caps (1) and (2) from the boom I

section of the 4-spool control valve.
2. Remove lock nut (8) using a wrench (17 mm). Be

sure to turn the wrench counterclockwise to
remove lock nut (8).
3. Turn socket-head screw (7) clockwise to the stop Control Valve M175-05-001
using an allen wrench (4 mm).
4. Turn lock nut (5) counterclockwise to loosen it, 6

using a wrench (17 mm). 3
4
Loosen socket-head screw (6) clockwise using an 1
allen wrench (4 mm) while closely watching the boom
5
lower. Note that the loosened degree of screw (6)
determines the boom lowering speed. Adjust the
boom lowering speed with the allen wrench as 7
required.
Take care not to remove snap ring (3) and washer (4) 2
at this time. Also, do not loosen screw (6) excessively
or cause washer (4) to be deformed. 8
6. After the bucket is lowered to the ground, turn

screws (6) and (7) counterclockwise to the stop.
Loosen screw (7) 1/8 of a turn clockwise. Tighten
lock nuts (5) and (8).
Tightening Torque: 19.5 N⋅m (2 kgf⋅m) M154-05-001
7. Re-install rubber caps (1) and (2). Be sure to

return them to their original positions.
NOTE: Be sure to work on screw (7) first, then, on

screw (6), as stated above.
T5-4-114
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
• How to Read Troubleshooting Flow Charts
YES (OK)
(2)
After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO (NOT OK)
・ Instructions, reference, and/or instruction methods on inspection and/or measurements

are occasionally described under the box. If incorrectly checked or measured, not only
· Key switch: ON will troubleshooting be unsuccessful but also damage to components may result.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
NOTE: All harness end connector are seen from

the open end side.
Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
hand. YES
Disconnect coolant temperature

Gauge pointer doesn’t move sensor. Ground harness end
Without connecting coolant
at all. terminal to vehicle frame.
temperature sensor, check for
Check if pointer swings to (H)
continuity between terminals
side.
below.
NO
· Key switch: ON
· ZAXIS110/110M/120/130/130LCN/
125US/135US: Disconnect monitor
connector B. Between monitor har-
ness end connector terminal #18 and
coolant temperature sensor terminal.
· ZAXIS135UR: Disconnect monitor
connector A. Between monitor har-
coolant temperature sensor terminal.
YES
Gauge pointer swings over Disconnect coolant tempera-

scale. In case of ZAXIS135 ture sensor. Check if pointer
UR, all the points on gauge returns to zero. Without connecting coolant
are blinking. temperature sensor, check for
continuity between terminals
· Key switch: ON below.
NO
· ZAXIS110/110M/120/130/130LCN/
connector B. Between monitor harness
end connector terminal #18 and vehicle
frame.
connector A. Between monitor harness
end connector terminal #15 and vehicle
frame.
Disconnect coolant tempera-
YES
ture sensor. Ground harness
Gauge pointer keeps moving end terminal to vehicle frame,
unstably. Check if pointer swings and is
stabilized to (H) side.
NO
· Key switch: ON
T5-5-2
Coolant Temperature Gauge Board

(ZAXIS110/110M/120/130/130LCN/125US/135US)
Faulty coolant temperature
sensor.
105 ﾟC
(95 ﾟC)
YES Faulty monitor.

70 ﾟC

monitor and sensor.
NO
Coolant Temperature Gauge Board T157-07-05-001
(ZAXIS135UR)
E F
D
C
Faulty coolant temperature A

sensor.
T1CF-05-05-001
Short-circuited harness be-
YES tween monitor and sensor.
Gauge Point Coolant Temperature
A Blinking 20 ˚C or lower
Faulty monitor. A ON 20 to 39 ˚C
B ON 40 to 59 ˚C
NO C ON 60 to 84 ˚C
D ON 85 to 99 ˚C
E ON 100 to 106 ˚C
F ON 107 ˚C or higher
Coolant Temperature Sensor

Coolant Temperature Resistance (kΩ)
Faulty coolant temperature °C (°F)
sensor. 25 (77) 7.6±0.76
40 (104) 4.0±0.35
50 (122) 2.7±0.22
Faulty monitor. 80 (176) 0.92±0.07
95 (203) 0.56±0.04
105 (221) 0.42±0.03
120 (248) 0.28±0.01
Connector (Harness end connector terminals seen
from the open end side)
ZAXIS110/110M/120/130/130LCN/125US/135US ZAXIS135UR
Monitor Connector B Monitor Connector A
10 1 10 1
18 15
20 11 20 11
T5-5-3
MALFUNCTION OF FUEL GAUGE
hand.
YES
Disconnect fuel sensor. Con-
Fuel gauge pointer doesn’t nect harness end connector
move at all. terminals #1 to terminal #2 with
In case of ZAXIS135UR, all a clip. Check if pointer swings
the points on gauge are Without connecting fuel sensor,
to (FULL) side. check for continuity between
blinking.
terminals below.
· Key switch: ON NO
· ZAXIS110/110M/120/130/130LCN/125US/
135US: Disconnect monitor connector B. Be-
tween monitor harness end connector terminal
#19 and fuel sensor terminal #1.
· ZAXIS135UR: Disconnect monitor connector A.
Between monitor harness end connector termi-
nal #14 and fuel sensor terminal #1.
YES
Fuel gauge pointer swings over Disconnect fuel sensor. Check Without connecting fuel sensor,
scale. if pointer returns to zero. check for continuity between
In case of ZAXIS135UR, all the terminals below.
points on gauge are blinking.
· Key switch: ON
NO
· ZAXIS110/110M/120/130/130LCN/125US/135US:
Disconnect monitor connector B. Between monitor
harness end connector terminal #19 and vehicle
frame.
· ZAXIS135UR: Disconnect monitor connector A.
Between monitor harness end connector terminal
#14 and vehicle frame.
YES
Disconnect fuel sensor. Con-
nect harness end connector
Fuel gauge pointer keeps mov- terminals #1 to #2 with a clip.
ing unstably. Check if pointer swings and is
stabilized to (FULL) side.
NO
· Key switch: ON
T5-5-4
Fuel Sensor
Float
Faulty fuel sensor.
FULL
R370 mm
YES Faulty monitor. 257 mm 3/4
93 mm
monitor and sensor. 70.5 mm
NO 204 mm 1/2
1/4
338 mm
EMPTY
Faulty fuel sensor.
T178-05-05-001
NOTE: 1 mm = 0.03937 in
YES tween monitor and sensor. Float Position Resistance (Ω)
Upper Limit (FULL) 10+0-4
3/4 26
1/2 38±5
Faulty monitor. 1/4 53
NO Warning Level 85±3
Lower Limit (EMPTY) 90+10-0

Faulty fuel sensor. ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector B Fuel Sensor
10 1
2 1
19
Faulty monitor. 20 11
ZAXIS135UR
Monitor Connector A
10 1
14
20 11
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Disconnect monitor
connector C. Check if YES Burnt fuse or faulty
there is continuity monitor.
hand. between harness end
connector terminal
YES #1(power input) and
fuse box terminal
Indicator doesn’t light Broken harness be-
#5(switch box).
when indicator light Check if all indicators tween fuse and
check operation is per- don’t light. monitor.
formed.
NO
Conduct trouble-
shooting of each in-
NO dicator which does
not light.

ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector C
10 1
1
20 11
ZAXIS135UR
Monitor Connector C
8 1
1
16 9
T5-5-6
MALFUNCTION OF PREHEAT INDICATOR
• The preheat system operates only when coolant
temperature is below 10 °C (50 °F), lighting the
preheat indicator for 8 seconds. (Refer to the
SYSTEM /Electrical Circuit group.)
• In case the preheat system malfunctions, refer to
the troubleshooting B for E-16 Engine is difficult
to start at low temperature.
Faulty coolant tem-
hand.
YES perature switch.
Remove connector
Preheat indicator (with black and
lights even though white cables) from Faulty QOS con-
preheat system coolant tempera- YES troller.
doesn’t operate ture switch. Check
if indicator goes Disconnect QOS
(coolant tempera- controller. Check if
ture is more than OFF by grounding Without connecting
harness end con- indicator goes QOS controller, Short-circuited har-
10 °C (50 °F)). OFF. YES ness between QOS
nector to vehicle check for continuity
frame. NO between terminals controller and moni-
below. tor.
· Key switch: ON
NO
· ZAXIS110/110M/120/130/125US/135US: NO Faulty monitor.

· Key switch: ON
Disconnect monitor connector B. Be-
tween monitor harness end connector
terminal #20 and vehicle frame.
· ZAXIS 135UR: Disconnect monitor con-
nector B. Between monitor harness end
Remove connector connector terminal #6 and vehicle frame. Faulty coolant tem-
(with black and YES
Preheat indicator perature switch.
white cables) from
doesn’t light al-
coolant tempera-
though preheat
ture switch. Check
system operates Disconnect QOS Faulty QOS control-
if indicator comes YES
(coolant tempera- controller. Check if ler.
ON.
ture is lower than indicator comes
10 °C (50 °F)). ON by grounding
harness end con-
Connect terminals Broken harness
nector terminal #6
below to vehicle between QOS con-
to vehicle frame. YES
· Key switch: ON frame. Check if troller and monitor.
indicator comes
NO
ON.
NO
Connector (Harness end connector terminals · Key switch: ON Faulty monitor.
· ZAXIS110/110M/120/130/ NO
seen from the open end side) 130LCN/125US/135US: Monitor
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US harness end connector B termi-
nal #20
Monitor Connector B
· ZAXIS135UR: Monitor harness
end connector B terminal #6
10 1 · Without disconnecting connec-
tor, ground connector to vehicle
20 frame with a clip from reverse
11 side of connector.
ZAXIS135UR
Monitor Connector B QOS Controller

8 1
6 1 2 3
4 5 6
16 11
T5-5-7
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
(ZAXIS110/110M/125US: Up to serial No. 010576)
(ZAXIS120/135US: Up to serial
No. 062964)
• Check that indicator light is not burned out.

• Check that all other indicators work correctly.
• Check that machine is parked on level surface.
hand.
YES
Without connecting
connector to engine oil
NO level switch, check for
continuity between
Check if indicator terminals below.
lights by removing
Indicator doesn’t connector (with NO
· Disconnect monitor connector
light even if engine black and white ca- B. Between monitor harness
oil level is lower ble) from engine oil end connector terminal #8 and
than specification. level switch. vehicle frame.
YES
Without connecting
connector to engine oil
Remove connector level switch, check for
(with black and white NO continuity between
Lower than 3.5 mm cables) from engine oil terminals below.
below LOW level mark level switch. Check if
on oil level gauge indicator goes OFF by
grounding harness · Disconnect monitor connector A.
end connector to vehi- Between monitor harness end
cle frame. connector terminal #8 and engine
oil level switch connector.
Indicator comes ON Check oil level with
even if engine oil oil level gauge.
level matches
specification.
YES
Above 3.5 mm
below LOW level mark
on oil level gauge
T5-5-8
Engine Oil Level Switch

tween engine oil level switch
and monitor. Oil Level
Gauge Engine Oil Level
Switch
ON
Faulty monitor. H A (Indicator ON)
L
(Indicator
OFF)
OFF
A: 3.5mm
T107-04-03-010
Faulty engine oil level switch.

YES Faulty monitor. from the open end side)
Monitor Connector B
Broken harness between en-
gine oil level switch and moni- 10 1
NO tor. 8
20 11
Faulty engine oil level switch.
Normal (Lack of engine oil).
T5-5-9
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
(ZAXIS110/110M/125US: Up to serial No. 010576)
(ZAXIS120/135US: Up to serial No. 062964)
• Check that indicator light is not burned out.

• Check that all other indicators work correctly.
• Check that machine is parked on level surface.
hand.
Without connecting YES

connector to coolant
level switch, check for
NO continuity between
Check if indicator terminals below.
Indicator doesn’t
lights by removing
light even if coolant
connector (with NO
level is lower than
gray cable) from
specification. · Disconnect monitor connector B.
coolant level switch.
Between monitor harness end
connector terminal #9 and vehicle
frame.
YES
Without connecting
connector to coolant
Remove connector level switch, check for
(with gray cables) from NO continuity between
coolant level switch. terminals below.
Check if indicator
goes OFF by ground-
NO ing harness end
connector terminal #1
to vehicle frame. · Disconnect monitor connector B.
Indicator comes ON Check if coolant Between monitor harness end
even if coolant level level in coolant res- connector terminal #9 and coolant
matches specifica- ervoir is lower than level switch connector.
tion. LOW mark.
YES
YES
T5-5-10
Coolant Level Switch

tween coolant level switch
and monitor. Reserve Tank
ON
FULL
Faulty monitor.
LOW
Radiator
OFF
T107-04-03-012
Faulty coolant level switch.

Faulty monitor. from the open end side)
YES
coolant level switch and moni-
tor. 1 2
NO
Monitor Connector B
10 1
19
20 11
Faulty coolant level switch.
Normal (Lack of coolant).
T5-5-11
MALFUNCTION OF ALTERNATOR INDI-
CATOR
hand.
NOTE: *Regulator terminals L are water-resistant

type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
Between 13 V
Measure voltage at and 33.5 V
monitor connector A
Between 13 V terminal below.
and 33.5 V
Alternator indicator · ZAXIS110/110M/120/130/130LCN/125US/

Measure voltage at
stays ON after en- ∗
135US: Monitor connector A terminal #2
regulator terminal L.
gine is started. · ZAXIS135UR : Monitor connector A terminal Less than 13 V or
#13 higher than 33.5 V
· Engine: Running
· Engine: Running
Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V
Measure voltage at
regulator terminal L.*
YES
Although alternator Check if indicator
output is low, alter- lights when key
nator indicator switch is turned ON. · Key switch: ON
· Engine: Stopped Less than 10 V or
doesn’t light.
higher than 33.5 V
· Key switch: ON
NO
T5-5-12

Faulty monitor. from the open end side)
Starter Relay
regulator terminal L and moni- E
tor. S R
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US

Faulty regulator or faulty al-
Monitor Connector A
ternator.
8 1
2
16 9
Faulty monitor.
ZAXIS135UR
Monitor Connector A
Faulty regulator. 10 1
13
20 11
Burned out indicator light.
T5-5-13
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
hand.
NOTE: During one or two minutes after the engine

is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.
Disconnect engine oil YES
pressure switch.
Check if indicator lights ZAXIS110/110M/120/130/125US/
when harness end 135US: Reconnect engine oil
YES connector terminal #1 pressure switch connector. Con-
(white and red cable) is nect monitor connector C terminal
grounded to vehicle #18 to the vehicle frame. Check if
frame. the indicator lights.
Indicator doesn’t Check if indicator ZAXIS135UR: Reconnect engine
light even if engine lights when key NO oil pressure switch connector.
oil pressure is low. switch is turned ON. · Key switch: ON Connect monitor connector A ter-
minal #5 to the vehicle frame.
Check if the indicator lights.
· Key switch: ON
· Engine: Stopped
· Key switch: ON
· Without disconnecting con-
nector, ground connector to
vehicle frame with a clip
from reverse side of con-
nector.
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure
started. switch is discon- YES
nected.
Reconnect engine oil
pressure switch. Check
· Check oil filter for
for continuity between
clogging. · Key switch: ON NO terminals below.
· Engine: Stopped
· ZAXIS110/110M/120/130/ NO
125US/135US: Disconnect
monitor connector C. Be-
tween monitor harness end
connector terminal #18 and
vehicle frame.
· ZAXIS135UR: Disconnect
monitor connector A. Between
monitor harness end connec-
tor terminal #5 and vehicle
frame.
T5-5-14
Engine Oil Pressure Switch

Pressure Operation
Faulty engine oil pressure
Approx. 39 kPa
switch.
(0.4 kgf/cm2, 5.7 psi) or ON
less
Approx. 39 kPa
monitor and engine oil pres- (0.4 kgf/cm2, 5.7 psi) or OFF
YES sure switch. higher
Faulty monitor.
NO

ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US

Burnt indicator light.
Monitor Connector C
10 1
Faulty engine oil pressure
switch or faulty engine oil
pressure system, or clogged 18
oil filter. 20 11
ZAXIS135UR
tween monitor and engine oil Monitor Connector A
pressure switch.
10 1
5
Faulty monitor. 20 11
T5-5-15
MALFUNCTION OF OVERHEAT INDICA-
TOR
hand.
Remove connector
(red and blue cable) YES
from overheat switch.
Check if indicator lights
when harness end
YES terminal is grounded to
vehicle frame.
· Key Switch: ON
NO
· Key switch: ON
Indicator doesn’t light Check if indicator
even if engine over- lights when key
heats. switch is turned ON.
· Key switch: ON
NO
Check if indicator
goes OFF when YES
overheat switch is
disconnected.
Indicator lights even
if coolant tempera-
ture is low. Disconnect overheat
switch. Remove con- YES
· Key switch: ON nector below from
· Engine: Stopped monitor. Check for con-
tinuity between con-
NO nector terminal #6 and
vehicle frame.
NO
· ZAXIS110/110M/120/130/130LCN/
125US/135US: Monitor connector B
· ZAXIS135UR: Monitor connector A
T5-5-16
Overheat Switch
Faulty overheat switch. Coolant Temperature Operation
Lower than 105 °C OFF
(221 °F)
Reconnect overheat 105 °C (221 °F) or ON
switch. Check if indi- Broken harness between higher
cator lights when YES monitor and overheat
monitor connector switch.
below terminal #6 is
grounded to vehicle
frame.
Faulty monitor.
NO
· ZAXIS110/110M/120/130/130LCN/
125US/135US: Monitor connector B
· ZAXIS135UR: Monitor connector A Connector (Harness end connector terminals seen
· Key switch: ON
· Without disconnecting connector, ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
ground connector to vehicle frame us-
Monitor Connector B
ing such jumper wire as clip from re-
verse side of connector. 10 1
Burnt indicator light.
6
20 11
ZAXIS135UR
Faulty overheat switch. Monitor Connector A
10 1
6
Short-circuited harness
between monitor and 20 11
overheat switch.
Faulty monitor.
T5-5-17
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
hand.
Disconnect air filter re-

striction switch at plug
receptacle with green YES
and blue cable. Check if
indicator lights when
harness end plug con-
YES nector is grounded to Reconnect air filter re-
vehicle frame. striction switch. Check for
continuity between ter-
minals below.
Check if indicator NO
Even if air filter is lights when key
clogged, indicator switch is turned ON. · Key switch: ON
doesn’t light. · ZAXIS110/110M/120/130/130LCN/
125US/135US: Disconnect monitor con-
nector B. Between monitor harness end
connector terminal #7 and vehicle frame.
· Key switch: ON · ZAXIS135UR: Disconnect monitor con-
nector A. Between monitor harness end
connector terminal #10 and vehicle frame.
NO
YES
Check if indicator
goes OFF when air
Although air filter is
filter restriction switch
not clogged, indi-
is disconnected. Disconnect air filter re-
cator lights.
striction switch at plug YES
receptacle with green
and blue cable from
· Disassemble and monitor. Check for con-
visually inspect. · Key switch: ON tinuity between terminals
· Verify that air filter NO below.
is not moist.
NO
· ZAXIS110/110M/120/130/130LCN/
connector B. Between monitor har-
vehicle frame.
connector A. Between monitor har-
vehicle frame.
T5-5-18
Faulty air filter restriction

switch.
Air Filter Restriction Switch
Pressure Operation
YES Faulty monitor. 5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

monitor and air filter re-
striction switch.
NO

Burned out indicator light.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector B
10 1
7
Faulty air filter restriction
switch.
20 11
Short-circuited harness ZAXIS135UR

between monitor and air
filter restriction switch. Monitor Connector A
10 1
10
20 11
Faulty monitor.
T5-5-19
MALFUNCTION OF BUZZER
hand.
NOTE: *Regulator terminals L are water-resistant

Measure voltage at starter relay 1 terminal
R instead. Check for continuity between
starter relay 1 terminal R and regulator
terminal L beforehand.
Measure voltage at 13 V or higher Faulty regulator.
Buzzer continues monitor connector A
to sound when key terminal below.
switch is turned ON
without starting en-
gine. Faulty monitor.
· ZAXIS110/110M/120/130/
Lower than 13
130LCN/125US/135US:
Monitor harness end connec-
tor terminal #2
· ZAXIS135UR: Monitor har-
ness end connector terminal
#13
· Key switch: ON (without start-
ing engine)
Faulty engine oil pres-

YES sure system.
Buzzer continues to Check if engine oil

sound when engine pressure indicator
is started. lights. YES Overheat of engine.
Check if overheat in-
dicator lights.
NO
Faulty monitor.
NO
NO Normal.
Buzzer doesn’t
sound even if en- Check if engine
gine oil pressure Perform troubleshooting
speed is 900 min-1 NO of indicator staying ON.
indicator or over- (rpm) or faster.
heat indicator lights
with engine running. Check if alternator in-
YES dicator lights. Measure voltage at regu-
lator terminal L.*
YES
· Engine speed: 900 min-1

(rpm) or faster.
T5-5-20

ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector A Starter Relay

8 1
2 E
S R
16 9
ZAXIS135UR
Monitor Connector A
10 1
13
20 11
Lower than 13 V or Faulty regulator or faulty al-

higher than 33.5 V ternator.
Lower than 13 V or Broken harness between

higher than 33.5 V regulator terminal L and moni-
tor.
Measure voltage at monitor
connector A terminal below.
Between 13 V Faulty monitor.
and 33.5 V
· ZAXIS110/110M/120/130/ Between 13 V
130LCN/125US/135US: Moni- and 33.5 V
tor harness end connector ter-
minal #2
· ZAXIS135UR: Monitor harness
end connector terminal #13
· Engine speed: 900 min-1 (rpm)
or faster
T5-5-21
MALFUNCTION OF LCD
• The following items are described:

1 to 3: To be displayed in the standard mode.
4 to 8: To be displayed in the user’s mode.
9 to 24: To be displayed with built-in diagnosing
system
• In case only LCD is abnormal, the machine will
normally operate.
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. ZX doesn’t display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller
7 Load Alarm and monitor.
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller
and monitor.
9 Fault Code In case Dr. ZX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. ZX doesn’t display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode
T5-5-22
MALFUNCTION OF HOUR METER

hand.
∗
NOTE: Regulator terminals L are water-resistant
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
Lower than 13 V or
higher than 33.5 V Faulty regulator or
faulty alternator.
Hour meter
doesn’t count
operating hours Measure voltage at Between 13V
∗
with engine run- regulator terminal L. and 33.5 V Faulty monitor.
ning.
Measure voltage
· Engine speed: 900 min-1
· Engine: Running at monitor con-
(rpm) or faster
nector A terminals
below.
Between 13V
and 33.5 V
· ZAXIS110/110M/120/130/
130LCN/125US/135US: Ter-
minal #2 Broken harness be-
· ZAXIS 135UR: Terminal #13 tween regulator ter-
minal L and monitor.
Connector (Harness end connector terminals seen Lower than 13 V or
from the open end side) higher than 33. 5 V
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector A Starter Relay

8 1
2 E
S R
16 9
ZAXIS135UR
Monitor Connector A
10 1
13
20 11
T5-5-23
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
hand.
Disconnect hydraulic
oil filter restriction
switch at plug recepta-
cle with black and yel-
low cable. Check if in- YES
dicator lights when
YES harness end plug
connector is grounded
to vehicle frame.
Even if hydraulic oil Check if indicator

filter is clogged, indi- lights when key
cator doesn’t light. switch is turned ON. NO
· Key switch: ON
· Key switch: ON
NO
Check if indicator
goes OFF when
hydraulic oil filter YES
Although hydraulic restriction switch at
oil filter is not plug receptacle with
clogged, indicator black and yellow
lights. cable is discon-
nected. Disconnect hydraulic oil
filter restriction switch at
YES
plug receptacle with
black and yellow cable
from monitor. Check for
· Key switch: ON NO continuity between ter-
· Engine: Stopped minals below.
NO
· ZAXIS110/110M/120/130/
130LCN/125US/135US: Dis-
connect monitor connector C.
Between monitor harness end
connector terminal #14 and
vehicle frame.
· ZAXIS135UR: Disconnect
monitor connector A. Between
monitor harness end connector
terminal #9 and vehicle frame.
T5-5-24
Faulty hydraulic oil filter

restriction switch.
Reconnect hydraulic oil

filter restriction switch. Broken harness between Connector (Harness end connector terminals seen
Check if indicator lights YES monitor and hydraulic oil
when monitor connector from the open end side)
filter restriction switch.
is grounded to vehicle
frame. ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector A
NO Faulty monitor.
10 1
· Key switch: ON
· ZAXIS110/110M/120/130/130LCN/ 14
125US/135US: Monitor connector C 20 11
terminal #14
· ZAXIS135UR: Monitor connector A ZAXIS135UR
terminal #9
· Without disconnecting connector, Monitor Connector A
ground connector to vehicle frame
with a clip from reverse side of con- 10 1
nector. Burned out indicator light. 9
20 11
Faulty hydraulic oil filter

restriction switch.
between monitor and hy-
draulic oil filter restriction
switch.
Faulty monitor.
T5-5-25
(Blank)
T5-5-26
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURE
(ZAXIS135UR ONLY)
Troubleshooting D procedures are to be applied to the front
attachment control system.
Use troubleshooting D procedure when fault codes
are shown on Dr. ZX after monitoring the main con-
troller (MC) with Dr. ZX or on the system monitor.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
• After checking or measuring item (1), according to the results
・ (1) select either YES (OK) or NO (NOT OK) and proceed to next
item (2) or (3), as appropriate.
(3)
NO (NOT OK)
・ • Special instructions or reference items are indicated in the space under the box.
Incorrect checking or measuring methods will render the troubleshooting impossi-
· Key switch: ON ble, and may damage components as well.
・ • Use Dr. ZX when the item is shown in a double line frame.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes and locations can be found.
NOTE: For all connector drawings illustrated in

this group, harness end connector
terminals seen from the open end side are
shown.
Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-6-1
FAULT CODE LIST (AUTO-MARCCINO
CONTROLLER) (ZAXIS135UR ONLY)
Fault Code
Buzzer System
Monitor
05 − − ON Faulty monitor (switch box) communication
06 − − ON Abnormal metering correction value
Continuously
07 UE07 ON Abnormal front angle sensor calibration value
sounds
Continuously
08 UE08 ON Abnormal code setting
sounds
11 UE11 Abnormal arm roll-out function
12 UE12 Continuously Abnormal right offset function
ON
13 UE13 sounds Abnormal left offset function
17 UE17 Abnormal boom raise function
14 − − Abnormal arm roll-out acceleration pilot pressure sensor
15 − − Abnormal right offset acceleration pilot pressure sensor
16 − − Abnormal left offset acceleration pilot pressure sensor
19 − − ON Abnormal boom raise acceleration pilot pressure sensor
20 − − Abnormal boom raise pilot pressure sensor
21 − − Abnormal boom lower pilot pressure sensor
22 − − Abnormal arm roll-in pilot pressure sensor
23 − Abnormal auxiliary pilot pressure sensor
37 UE37 Abnormal arm roll-out deceleration proportional solenoid valve

38 UE38 Abnormal 8-unit solenoid valve unit (right offset deceleration)
Long beep
40 UE40 Abnormal 8-unit solenoid valve unit (boom raise deceleration)
sounds in- ON
41 UE41 Abnormal 8-unit solenoid valve unit (arm roll-in deceleration)
termittently
42 UE42 Abnormal 8-unit solenoid valve unit (left offset deceleration)
44 UE44 Abnormal 8-unit solenoid valve unit (boom lower deceleration)
43 − − Faulty 8 unit solenoid valve unit (right offset acceleration)
45 − − Faulty 8 unit solenoid valve unit (arm roll-out acceleration)
47 ON Faulty 8 unit solenoid valve unit (left offset acceleration)
− −
48 − − Faulty boom raise acceleration proportional solenoid valve
T5-6-2
1) Check harness.
− 2) Replace the controller. G4
3) Replace the system monitor.
1) Abnormal metering correction
value.
1) Replace the controller if the con-
* Movement to the cab stops. troller does not operate correctly. G1
1) Input the front and bucket codes

again.
1) Check harness.
2) Replace the pilot pressure
All movement stops.(No pilot pressure) sensor. G0
3) Replace the solenoid valve.
Cab collison prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
Offset movement by offset switch stops.
Depth limit control stops
G4
Cab collison prevention control stops, depth limit control
stops
1) Check harness.
G8
2) Replace pilot pressure sensor.
Arm roll-out movement stops. 1) Check harness.
Right offset movement stops. 2) Replace the solenoid valve.
Boom raise movement stops.
G3
Arm roll-in movement stops.
Left offset movement stops.
Boom lower movement stops.
Offset movement by offset switch stops. 1) Check harness.
Cab collison prevention control stops. 2) Replace the solenoid valve.
Offset movement by offset switch stops. G4
Depth limit control stops.
group number only.
T5-6-3
Fault Code
Buzzer System
Monitor
50 UE50 Abnormal boom angle sensor
51 UE51 Abnormal arm angle sensor
52 UE52 Abnormal offset angle sensor
53 UE53 Continuously Abnormal slide arm sensor
ON
sounds
80 UE80 Boom angle sensor deviation

81 UE81 Arm angle sensor deviation
82 UE82 Offset angle sensor deviation
83 UE83 Continuously Slide arm sensor deviation
ON
sounds
60 UE60 Faulty boom angle sensor initial setting.

61 UE61 Continuously Faulty arm angle sensor initial setting.
ON
62 UE62 sounds Faulty offset angle sensor initial setting.
63 UE63 Faulty slide arm sensor initial setting.
Faulty hydraulic oil temperature sensor.
90 − − ON
Abnormal sensor power source.
91 − − ON
Abnormal reference power source. (Abnormal voltage sup-
92 − − −
plied to Auto-MARCCINO controller)
Complete front attachment angle sensor initial setting.
F0 − − −
Continuously Invasion of hazardous area by emergency evacuation switch.
F2 − −
sounds
Escape out of hazardous area.
F3 − − −
Short beep Invasion of hazardous area by interference prevention mode.
F4 UE00 sounds ON
intermittently
FA − − − Install attachment select switch
FB − − − Remove attachment select switch
The auxiliary pedal is operated without setting the attachment
FC − − − select switch properly
group number only.
T5-6-4

as if boom is raised to the highest position. 2) Replace the angle sensor.
as if arm is fully rolled in.
G2
as if the front attachment is fully offset to the left
side.
as if boom is raised to the highest position. 2) Check angle sensor installation.
Interference prevention control system functions 3) Replace the angle sensor.
as if arm is fully rolled in. Interference prevention
G2
control system functions as if the front attach-
ment is fully offset to the left side.
as if slide arm is fully extension.
1) Check harness.
2) Replace the angle sensor

G4
as if oil temperature is lowest. 2) Replace the hydraulic oil temperature sensor.
Depth limit control stops 1) Initialize the angle sensor again.
G4
Cab collison control stops. 2) Replace the angle sensor.
Normal Movement by backup function. 1) Check harness.
G8
* Movement to the cab stops.
G5
− G7
− G8
All movement stops. (No pilot pressure) G0
G8
G8
G8
T5-6-5
FAULT CODE 05 (FAULT MONITOR
(SWITCH BOX) COMMUNICATION)

hand.
Breakage and/or short circuit

Disconnect connector (B) and connector (EF-4) YES of harness where abnormality
from monitor (switch box) and is found.
auto-MARCCINO controller respectively. Check
if circuits described below have any abnormali-
ties. When optional with front movement Re-
striction system monitor is provided, disconnect
4P connector from optional monitor. Then,
check if harness has any abnormalities.
Faulty auto-MARCCINO
controller.
NO
Machines Equipped with front
Standard Model: movement Restriction System Moni-
Monitor Auto-MARC tor (Optional):
(Switch Box) CINO Optional Auto-MARCCI Monitor Optional
Connector B Controller monitor 4P NO Controller (Switch Box) monitor 4P
Connector Connector(Bla Connector Connector B Connector(Blac
(EF-4) ck) (EF-4) k)
#10 #11 #1 #3 #12 #2
#11 #12 #3 #2 #13 #4

Monitor Connector (B) Auto-MARCCINO Controller Connector (EF-4) Front Movement Restriction Control
5 5 System Monitor 4P Connector (Black)
8 1
2 3
11 12
11 10 2 1
16 9
13 16 4 3
FAULT CODE 06 (ABNORMAL METERING

CORRECTION VALUE)
YES Normal.
Adjust metering by Dr.ZX. Check

if fault code disappears.
NO controller.
T5-6-6
FAULT CODE 07 (ABNORMAL CALIBRA-
TION VALUE)
• Calibration values are input into the

auto-MARCCINO controller beforehand. Accord-
ingly, this fault code is rarely displayed during
machine operation.
YES
Normal.
Check if any fault codes on

system monitor are deleted
when sensor is initialized.
· Refer to T4-6-1
· After initializing, re-start the
engine Faulty auto-MARCCINO con-
NO troller.
FAULT CODE 08 (ABNORMAL CODE SET-

TING)
• When no front attachment or bucket codes are

registered, this fault code is displayed. Register
the front attachment or bucket code.
YES
Normal.
Register front attachment or
bucket code using the Dr. ZX.
Check if fault codes displayed
on system monitor are de-
leted.
· After initializing, restart the

engine. Faulty auto-MARCCINO con-
troller.
T5-6-7
FAULT CODE 11 FAULT CODE 13
(ABNORMAL ARM ROLL-OUT OPERA- (ABNORMAL LEFT OFFSET OPERATION)
TION) FAULT CODE 17
FAULT CODE 12 (ABNORMAL BOOM RAISE)
(ABNORMAL RIGHT OFFSET OPERA-
TION)
• Fault code 11 is displayed when the arm roll-out • Fault code 17 is displayed when the boom raise
pilot-pressure sensor sends a signal corre- acceleration pilot-pressure sensor sends a signal
sponding to a pressure of 0.98 MPa (10 kgf/cm2) corresponding to a pressure of 0.98 MPa (10
or more to the auto-MARCCINO controller while kgf/cm2) or more to the auto-MARCCINO con-
the auto-MARCCINO controller sends no signal troller while the auto-MARCCINO controller
to the 8-unit solenoid valve unit (arm roll-out ac- sends no signal to the 2-unit solenoid valve unit
celeration) by arm keep-off. (boom raise acceleration) by depth limit control.
• Fault codes 12 and 13 are displayed when right • Check for loose harness connections beforehand.
or left offset pilot pressure sensor sends a signal
corresponding to a pressure of 0.98 MPa (10
kgf/cm2) or more to the auto-MARCCINO con-
troller while the offset switch is not depressed.
Sticking solenoid valve or delayed response in
the hydraulic system at very low temperature
may be the cause of these troubles.
With pilot control shut-off lever
held in the LOCK position,
monitor pilot pressure sensor
corresponding to the fault code
using Dr. ZX. Check if 0
With pilot control shut-off lever YES kgf/cm2 pressure is displayed.
held in the UNLOCK position,
monitor pilot pressure sensor
NO corresponding to the fault
code using Dr. ZX. Check if
10 kgf/cm2 or more pressure · Engine: Running
is displayed. · System deactivation switch:
ON
Faulty auto-MARCCINO con-

Check if any fault codes are troller.
deleted when engine is · Engine: Running
re-started. · System deactivation switch: NO
ON · Refer to Countermeasure - 2.
Normal.
YES
· Check operation of the arm
keep-off control, depth limit
control and the offset switch.
T5-6-8
8-Unit Solenoid
Valve
Front
Port P
Faulty solenoid valve.

T1CF-01-01-014
YES
· Refer to Countermeasure -
1.
Faulty pilot pressure sensor.

NO
· Refer to Countermeasure -
2.
CAUTION: Countermeasures 1 and 2 are to
be used only when the machine must be
temporarily operated. Carefully operate the
front attachment by means of these counter
measures as the cab collision prevention
system and the auto-MARCCINO system will
be inoperable.
• Countermeasure-1 • Countermeasure-2
After disconnecting the hose from port P on the Disconnect the emergency stop solenoid valve
8-unit solenoid valve, install plugs to the hose located under the cab.
end and port P. In case the machine is equipped
with the front movement restriction system (op-
tional), disconnect the hose from port P on the
2-unit solenoid valve and install plugs to the hose
end and port P. Thereby, the offset switch be-
comes inactivated.
T5-6-9
(ABNORMAL ARM ROLL-OUT ACCEL- (ABNORMAL BOOM RAISE PILOT
ERATION PILOT PRESSURE SENSOR) PRESSURE SENSOR)
(ABNORMAL RIGHT OFFSET ACCELERA- (ABNORMAL BOOM LOWER PILOT
TION PILOT PRESSURE SENSOR) PRESSURE SENSOR)
(ABNORMAL LEFT OFFSET ACCELERA- (ABNORMAL ARM ROLL-IN PILOT PRES-
TION PILOT PRESSURE SENSOR) SURE SENSOR)
FAULT CODE 19
(ABNORMAL BOOM RAISE ACCELERA-
TION PILOT PRESSURE SENSOR)
• These fault codes are displayed when signal volt-
age from the pilot pressure sensor to the After disconnecting pilot pressure
auto-MARCCINO controller is in the range of sensor, directly connect terminals
#1 and #3 on harness end
0.25 V or less, or 4.75 V or more. connector.
YES
• Check for loose harness connections before- Remove connector (EF-2) from
hand. auto-MARCCINO controller.
After disconnecting pilot Check if continuity between
pressure sensor, directly terminal #19 and #21on the
connect terminals #1 and #3 harness end connector is
NO on harness end connector. present.
Remove connector (EF-2)
from auto-MARCCINO
controller. Check if continuity
between terminal #19 or
#21on the harness end
connector and the vehicle
frame is present.
Switch pilot pressure sensor
with other nornal one. Check if
the fault code is deleted. Broken harness between pilot
pressure sensor (Terminals
NO #1 and #3) and
auto-MARCCINO controller.
Faulty pilot pressure sensor.

YES

Pilot Pressure Sensor Connector (EF-3)
Connector Connector (EF-2)
1 8 1 10
2 5 6
1 2 3
12 15 16 17
19 21
19 25 23 31
T5-6-10
Without reconnecting pilot

pressure sensor Short-circuited harness
Disconnect pilot pressure
andauto-MARCCINO between pilot pressure sensor
sensor and auto-MARCCINO
controller connector (EF-2), (terminal #2) and
controller connector (EF-3).
check if continuity between YES auto-MARCCINO controller.
Check if continuity between
harness end connector sensor harness end connector
terminal #2 and YES terminal #2 and the vehicle
auto-MARCCINO controller frame is present.
connector (EF-3) harness end
NO Faulty auto-MARCCINO con-
terminal
NO troller.
· Terminal #: Broken harness between pilot

Boom raise: #17 pressure sensor terminal #2
Boom raise acceleration NO
and auto-MARCCINO con-
(Optional): #5 troller.
Boom lower: #16
Arm roll-out: #15
Arm roll-in: #6
Right offset: #12
Left offset: #2
between pilot pressure sensor
YES (terminals #1 and 3) and
T5-6-11
FAULT CODE 37 (ABNORMAL ARM FAULT CODE 41 (ABNORMAL 8-UNIT
ROLL-OUT DECELERATION PROPOR- SOLENOID VALVE UNIT (ARM ROLL-IN
TIONAL SOLENOID VALVE) DECELERATION)
FAULT CODE 38 (ABNORMAL 8-UNIT FAULT CODE 42 (ABNORMAL 8-UNIT
SOLENOID VALVE UNIT (RIGHT OFFSET SOLENOID VALVE UNIT (LEFT OFFSET
DECELERATION) DECELERATION)
FAULT CODE 40 (ABNORMAL 8-UNIT FAULT CODE 44 (ABNORMAL 8-UNIT
SOLENOID VALVE UNIT (BOOM RAISE SOLENOID VALVE UNIT (BOOM LOWER
DECELERATION) DECELERATION)
・Check for loose harness connections first.
Disconnect solenoid
valve. Disconnect con-
nector (EF-1) from NO Faulty auto-MARCCINO
auto-MARCCINO con-
troller. Check for continu- controller.
ity between harness con-
nector terminal and vehi-
Disconnect solenoid valve. YES cle.
Connect harness side con-
nector terminals #1 to #2. Short-circuited harness
Remove connector (EF-1) between solenoid valve
· Boom raise : #16, #23 and auto-MARCCINO
from auto-MARCCINO
Arm roll-in : #6, #11 controller.
controller. Check for conti-
YES nuity between harness end Arm roll-out : #15, #22 YES
Right offset : #4, #9
connector terminals.
Left offset : #5, #10
Disconnect solenoid Boom lower : #17, #24
valve. Check if solenoid
valve electrical resis-
tance is approx. 2.24 Broken harness between
kΩ. solenoid valve and
· Boom raise : #16, #23
NO auto-MARCCINO con-
Arm roll-in : #6, #11
troller.
Arm roll-out : #15, #22
Right offset : #4, #9
Left offset : #5, #10
Boom lower : #17, #24

NO

Solenoid Valve Controller Auto-MARCCINO Controller Connector (EF-1)

1 11
1 2 4 5 6 9 10 11
15 16 17 22 23 24
25 32
T5-6-12
(ABNORMAL 8-UNIT SOLENOID VALVE (ABNORMAL 8-UNIT SOLENOID VALVE
UNIT [RIGHT OFFSET ACCELERATION]) UNIT [LEFT OFFSET ACCELERATION])
(ABNORMAL 8-UNIT SOLENOID VALVE (ABNORMAL BOOM RAISE ACCELERA-
UNIT [ARM ROLL-OUT ACCELERATION]) TION SOLENOID VALVE)
・Check for loose harness connections first.
Disconnect solenoid
valve. Check for continu- NO Faulty auto-MARCCINO
ity between controller.
auto-MARCCINO con-
troller connector (EF-1)
harness connector ter-
YES
Disconnect solenoid valve. minal below and vehicle.
Connect harness side con-
nector terminal #1 to #2.
Remove connector (EF-1) Short circuit of harness
from auto-MARCCINO between solenoid valve
controller. Check for · Right offset (#7, #29) YES and auto-MARCCINO
YES
continuity between harness · Arm roll-out (#18, #32) controller.
end connector terminals · Left offset (#19, #30)
With solenoid valve below. · Boom raise (#20, #31)
disconnected, check if
solenoid valve electrical
resistance is approx. Broken harness between
2.24 kΩ. solenoid valve and
· Right offset (#7, #29) auto-MARCCINO con-
· Arm roll-out (#18, #32) NO
troller.
· Left offset (#19, #30)
· Boom raise (#20, #31)

NO

Solenoid Valve Connector Auto-MARCCINO Controller Connector (EF-1)
1 11
1 2 7
18 19 20
30 31 32
25 32
T5-6-13
FAULT CODE 50
(ABNORMAL BOOM ANGLE SENSOR)
FAULT CODE 51
(ABNORMAL ARM ANGLE SENSOR)
FAULT CODE 52
(ABNORMAL OFFSET ANGLE SENSOR)
• Fault codes 50 to 52 are displayed when input

voltage from the angle sensor to the
auto-MARCCINO controller is 0.1 V or less, or
4.9 V or more.
• Check for loose harness connections first.
Disconnect angle sensor.

Check for continuity between
MC connector (MCX-B) har-
YES ness connector terminal #20
or #22 and vehicle.
Disconnect angle sensor.
Connect harness end con-
nector terminals #1 to #3.
YES Disconnect MC connector
(MCX-B).
harness connector terminal
#20 and #22. Broken harness between an-
With angle sensor discon- gle sensor (terminals #1, #3)
nected, check if angle sensor NO and MC.
electrical resistance is 5±1.0
kΩ.
Faulty angle sensor.
NO
· Refer to T4-6 (Adjustment).

Boom Angle Arm/Offset Angle

Sensor Connector MC Connector (MCX-B)
Sensor Connector
B1 B8
1 2 1 2 3
20 22
3
B19 B25
T5-6-14

Disconnect angle sensor con- tween angle sensor (terminal
nector and auto-MARCCINO #2) and auto-MARCCINO
Disconnect angle sensor con- controller connector (EF-3). YES controller.
nector and auto-MARCCINO Check for continuity between
controller connector (EF-3). sensor harness connector
Check for continuity between YES terminal #2 and vehicle.
sensor harness connector
terminal #2 and
auto-MARCCINO controller Faulty auto-MARCCINO con-
harness terminal. NO troller.
NO
Broken harness between an-

· Terminals: gle sensor (terminal #2) and
NO auto-MARCCINO controller.
Boom (Terminal #7)
Arm (Terminal #19)
Offset (Terminal #18)

tween angle sensor (terminals
YES #1, #3) and MC.
Auto-MARCCINO Controller Connector (EF-3)

C1 C10
7
18 19
C23 C31
T5-6-15
FAULT CODE 53
(ABNORMAL SLIDE ARM SENSOR)
• Fault code 53 is displayed when input voltage
from the slide arm sensor to the
auto-MARCCINO controller is 0.5 V or less, or
2.95 V or more.
Disconnect slide arm sensor.

auto-MARCCINO end con-
Disconnect slide arm sensor. troller connector (EF-2) har-
Connect harness end con- YES ness end connector terminals
nector terminals #1 to #3. #19, #22 and vehicle.
Disconnect auto-MARCCINO
Controller connector (EF-2).
YES harness end connector ter-
minals #19 and #22.
Broken harness between slide
arm sensor (terminals #1 and
With slide arm sensor dis- #3) and auto-MARCCINO
connected, check if slide arm controller.
sensor electrical resistance is NO
5±1.0 kΩ.
Faulty slide arm sensor.
NO
· Refer to T4-6 Adjustment.

Angle Sensor Connector Auto-MARCCINO Controller Connector (EF-2)
1 8
1 2
3 19 22
19 25
T5-6-16

tween slide arm sensor (ter-
Disconnect slide arm sensor minal #2) and
connector and YES auto-MARCCINO controller.
auto-MARCCINO controller
connector (EF-3). Check for
YES continuity between sensor
Disconnect slide arm sensor harness end connector ter-
connector and minal #2 and vehicle.
auto-MARCCINO controller Faulty auto-MARCCINO con-
NO connector (EF-3). Check for NO troller.
continuity between sensor
harness end connector ter-
minal #2 and
auto-MARCCINO controller
Broken harness between slide
harness end terminal #11.
arm sensor (terminal #2) and
NO auto-MARCCINO controller.

tween slide arm sensor and
YES auto-MARCCINO controller.

C1 C10
11
C23 C31
T5-6-17
(FAULTY INITIAL SETTING OF BOOM (FAULTY INITIAL SETTING OF OFFSET
ANGLE SENSOR) ANGLE SENSOR)
(FAULTY INITIAL SETTING OF ARM AN- (FAULTY INITIAL SETTING OF SLIDE ARM
GLE SENSOR) SENSOR)
• Fault codes 60 to 62 are displayed when input

voltage from the angle sensor to the
auto-MARCCINO controller is at the deviation of
±0.3 V or more from the specified value.
• Fault code 63 is displayed when input voltage
from the angle sensor to the auto-MARCCINO
controller is at the deviation of ±0.1 V or more
from the specified value .
Measure the voltage at angle Faulty auto-MARCCINO con-

sensor with the front attach- troller.
ment in angle sensor initializa- YES
tion position. Check if signal
voltage is within ±0.3 V of the
specification.
NO
Faulty angle sensor.

· Specifications:
Check if fault codes Boom : 0.664 V ± 0.3 V
disappear when angle Arm : 4.247 V ± 0.3 V NO
sensor is initialized. Offset : 2.153 V ± 0.3 V · Refer to T4-6 Adjust-
· With the connector connected, ment.
ground connector to vehicle
· Refer to T4-6 Adjust- with a clip from the rear side of
ment. the connector.
End.
YES

Boom Angle Sensor/Slide Arm/Offset Angle

Arm Sensor Connectors Sensor Connectors
1 2
1 2 3
3
T5-6-18
(BOOM ANGLE SENSOR DEVIATION) (OFFSET ANGLE SENSOR DEVIATION)
(ARM ANGLE SENSOR DEVIATION) (SLIDE ARM SENSOR DEVIATION)
NOTE: The attachments marked with “*” are op-

tional.
• Check for deformation in the link part of angle

sensor first.
• These fault codes are displayed if the value be-
yond the sensor operating range below is output
to the auto-MARCCINO controller.
Sensor Activating Range

Sensor
Boom Angle Sensor Arm Angle Sensor Offset Angle Sensor *Slide Arm Sensor
Attachment
Standard Arm 0.165 V to 4.305 V 0.265 V to 4.746 V 0.684 V to 4.338 V －
*Long Arm ↑ 0.215 V to 4.480 V ↑ －
*Slide Arm
YES Faulty auto-MARCCINO con-

Measure voltage at terminal troller.
#2 on angle sensor connector
on fault code. Check if voltage
is within sensor operating
range above.
· Using a clip, ground from the Faulty angle sensor installing.

rear side of the connector NO
without disconnecting. · Refer to T4-6 Adjustment.
Connector (Harness end connector terminals seen from the open end side)
Boom Angle Sensor/Slide Arm Arm/Offset Angle

Sensor Connectors Sensor Connectors
1 2
1 2 3
3
T5-6-19
FAULT CODE 90
(FAULTY OIL TEMPERATURE SENSOR)
• The auto-MARCCINO controller activates the Oil Temperature Electrical Resis-
deceleration and stop functions in the cab colli- (°C) tance (kΩ)
sion prevention system earlier than the normal -20 15.0±1.5
positions when the input signals from the oil tem-
perature sensor are lower than 10 °C. 0 (5.74)
• Fault code 90 is displayed when signal voltage 20 2.45±0.24
corresponding to -30° C or lower, or +100° C or
more is sent out of the oil temperature sensor to 40 (1.15)
the auto-MARCCINO controller. 60 (0.584)
hand. 80 0.318±0.031
Disconnect oil tempera-

ture sensor. Short-circuited harness
Check for continuity be- between oil temperature
tween auto-MARCCINO YES sensor and
Disconnect oil tempera- controller connector auto-MARCCINO con-
ture sensor, and connect (EF-2) terminal #21 or troller.
harness end connector
YES connector (EF-4) termi-
terminals No.1 and No.2. nal #4 and vehicle.
Disconnect
auto-MARCCINO con-
troller connector, check
for continuity between NO Faulty auto-MARCCINO
YES harness end terminals controller.
Disconnect oil
temperature sen- below.
sor. Check if oil
temperature sen-
sor electrical re-
oil temperature sensor
sistance is within
and auto-MARCCINO
specification. NO
· Terminals: controller.
Connector (EF-2): #21
Connector (EF-4): #4
Faulty oil temperature

NO sensor.

Oil Temperature Sensor Auto-MARCCINO Controller (EF-2) Auto-MARCCINO Controller (EF-4)

1 8 1 5
4
1 2
21 25
19 13 16
T5-6-20
FAULT CODE 91 (ABNORMAL SENSOR
POWER SOURCE)
• Fault code 91 means that the voltage of the sen-

sor in the auto-MARCCINO control unit is ab-
normal. In case fault code is displayed after the
retrial, replace the auto-MARCCINO control unit.
T5-6-21
FAULT CODE 92 (ABNORMAL REFER-
ENCE POWER SOURCE)
• If reference voltage (5V) delivered from the MC to
the auto- MARCCINO controller is abnormal,
fault code 92 is displayed. Even if any abnormal-
ity occurs, the backup function is activated so
that machine operation is not affected.
Remove connector (MCX-B)

from MC. Connect hatness
end connector terminal #19 to
#21.
Remove connector (EF-3)
from auto-MARCCINO
controller. Check if continuity
Remove connector (EF-3) NO between harness end
from auto-MARCCINO connector terminals #30 and
controller. Check if voltage #31 is present.
between harness end
connector terminals #30 and
NO #31 is 5 ± 0.25 V.
Check if MC fault code 04 is YES controller.
displayed
Conduct the troubleshooting

for MC.
YES
· Refer to T5-3-3.


MC Connector (MCX-B) 1 10
1 8
30 31
19 21 23 31
19 25
T5-6-22
NO Faulty auto-MARCCINO con-

troller.
Without reconnecting con-
nector to MC, check if conti-
nuity between the vehicle
YES frame and terminal #30 or #31
on auto-MARCCINO control-
ler harness end connector is
present.
YES between MC and
Broken harness between MC

NO and auto-MARCCINO
controller.
T5-6-23
(Blank)
T5-6-24
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Be sure to remove the negative terminals from
the batteries first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown inn the table onn the L Blue G Green
right. Or Orange Lg Light
In cases on the design sheet where two colors green
are indicated for one wire, the left initial stands Y Yellow B Black
for the base color, while the right initial stands for Br Brown P Pink
the marking color.
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
T5-7-1
3. Precautions for connecting and disconnecting

terminal connectors.
Right Wrong
1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to “Instructions for
Disconnecting Connector” on page T5-7-3.) T107-07-06-001
2) Water-resistant connectors keep water out

so that if water enters them, water will not
easily drain from them. When checking
water-resistant connectors, take extra care
not to allow water to enter the connectors. In
case water should enter the connectors, Right
reconnect only after the connectors are
Rust
thoroughly dried.
3) Before connecting terminal connectors, Wrong
(Deformation)
check that no terminals are bent or coming
off. In addition, as most connectors are Wrong
made of brass, check that no terminals are (Separation)
rusting. T107-07-06-002
4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock “clicks.” Wind a Piece of Wire Tester Probe
4. Pull the harness near the connector to check if it

is correctly connected.Precaution for using a
circuit tester.
1) Before using a circuit tester, refer to the Sharpen the end of the Wire
T107-07-06-003
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram.
When the connector size is very small, and
the standard probe size is too large to be
used for testing, wind a fine piece of
sharpened wire or a pin around the probe to
make the test easier.
T5-7-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type
NOTE: Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling the
connectors.
The lock is located on female side con-
nector (harness end side).
T107-04-05-002
Locations of This Type Connector

Fuel Gauge N Sensor *Engine Oil Level Switch Radio
Hydraulic Oil Level Switch EC Motor *Coolant Level Switch Speaker
Horn EC Sensor Diode Learning Switch
Cab Harness Pump Delivery Pressure Sensor Key Switch Wiper
Pressure Sensor General Relay Engine Control Dial Monitor
Washer Solenoid Valve
NOTE:* ZAXIS110/110M/125US
: Up to serial No.010576
ZAXIS120/135US:
Up to serial No.062964
• Pull Up to Unlock and Separate Type

Starter Relay
T107-04-05-003
• Pull to Separate Type
IMPORTANT: Generally, the solenoid valve con-

nector has a lock. Always pull to
separate the connector only after
unlocking using a tool such as a
pair of needle nose pliers. T107-04-05-004

Dr.ZX
T5-7-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas- 10 20
ured. (Measurement Range: 0 to 30 V) 9 19
3. Ground the negative probe of the tester to the
vehicle frame. Touch the terminals located away 8 18
from the center of the fuse box with the positive 7 17
probe of the tester one at a time. When normal
continuity of a fuse is intact, the tester will indi- 6 16
cate 20 to 25 volts (battery voltage). 5 15
4 14
3 13
2 12
1 11
M178-07-034
T5-7-4
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor ICX (Backup 11 20 A Work Light Relays 1 and 2
Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio (ZAXIS135UR: Room
(10A) Light, Cigarette Lighter, Radio)
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
(ZAXIS135UR: Auxiliary)
7 5A Air Conditioner Unit 17 5A Room Light (ZAXIS135UR:
URX Controller Power)
8 5A Optional 1 18 10 A Auxiliary (ZAXIS135UR: Sole-
noid Valve Power)
9 10 A Optional 2 19 5A QOS Controller, Glow Plug
(10A) Relay (ZAXIS135UR: Emer-
gency Evacuation Switch)
10 5A Optional 3 20 − Empty (ZX135UR: QOS Con-
(5A) troller, Glow Plug Relay)
T5-7-5
FUSIBLE LINK INSPECTION Battery Relay
Inspection
1. Remove the negative cable from the battery.

2. Loosen bolt M8 holding the cable routed in front
of the fusible link box to move the cable out of the
way of the front cover.
3. Open the fusible link box front cover and visually
inspect the fusible link.
Fusible Link M178-07-049
Fusible Link Cover
Replacement
1. Check that the negative cable is removed from

the battery.
2. Remove bolt M8 to take the fusible link off the T178-05-06-002
battery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten two screws M6 (2 used). Bolt M8
6. Install the fusible link box and the cable to the
battery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-7-6
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging V

system.
T157-07-06-007
T5-7-7
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

position. Confirm that the alternator indicator
comes on.
2. Measure the voltage between the B and E B

terminals of the alternator. If the measured
voltage is around 24 V, the alternator circuit can
be considered normal. If the measured voltage
is low, a shortage in battery capacity or
looseness of the wire connectors of the alternator
circuit might be the cause of the malfunction.
When the voltage is 0 V, the wiring between the
fuse box and alternator might be loose or E
disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
3. Next, start the engine and measure the voltage T157-07-06-003

generated while as the alternator rotates.
As described above, measure the voltage
between terminals B and E on the side of the
alternator. If the voltage is around 28 V, the
alternator is operating normally.
If the rated voltage is not being generated, there
is some trouble with the alternator or the regula-
tor.
T5-7-8
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
Ω
the vehicle
If the ohm-meter reading is: 0 Ω = Continuity frame.
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: Ω frame.
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
T5-7-9
Multi-line continuity check
Disconnect both end connectors of the harness,
and short-circuit two terminals, (A) and (B), at one First short-circuit
end connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector.
A a
If the ohm-meter reading is ∞ Ω, either line (A) - (a), B b
or (B) - (b) is in discontinuity. To find out which line C c
is discontinued, conduct the single line continuity
check on both lines individually, or, after changing Second short-circuit
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
Ω
NOTE: By conducting the multi-line continuity

check twice, it is possible to find out which T107-07-05-004
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity Short-circuit between harnesses.
between terminals (a) and (c).
If the ohm-meter reading is: A
×
a
B b
0 Ω = Line (B) - (b) has discontinuity. C c
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B)
or (C). Ω
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines. T107-07-05-005
T5-7-10
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.
24-Volt Circuit
Start checking the circuit in order up to the location
to be measured from either power source or actua-
tor side. Thereby, the faulty location in the circuit will
be found.
Black Probe (Minus) of Tester: To ground to the
vehicle frame
Red Probe (Plus) of Tester: To touch the location
to be measured
T5-7-11
ZAXIS110/120/130/130LCN/125US/135US
Engine Key Switch Location to be Measured Specification

Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (6) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Volt- 26 to 30 V
Fast Speed ON age (B)/Generating Voltage 26 to 30 V
Between (10) and Ground: Battery Relay / Generating
Fast Speed ON Voltage 26 to 30 V
Between (15) and Ground: Fuse Box / Starter Relay (R)/
Fast Speed ON Generating Voltage 13 to 30 V
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Between (17) and Ground: Monitor
Surge Voltage Pre-
vention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
*Measure after disconnecting the negative cable from the battery.
T5-7-12
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13
Monitor
Starter Relay
16
Alternator
G
lo
w
P
14
Glow Plug
T178-05-06-001
T5-7-13
ZAXIS135UR
Engine Key Switch Location to be Measured Specification

Power Source Circuit
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (6) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Volt- 26 to 30 V
Fast Speed ON age (B)/Generating Voltage 26 to 30 V
Between (10) and Ground: Battery Relay / Generating
Fast Speed ON Voltage 26 to 30 V
Between (15) and Ground: Fuse Box / Starter Relay (R)/
Fast Speed ON Generating Voltage 13 to 30 V
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Between (17) and Ground: Monitor
Surge Voltage Pre-
vention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Room Light/Radio/Cigar 20 to 25 V
Stopped ON Lighter 20 to 25 V
Stopped ON Between (20) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (21) and Ground: Horn 20 to 25 V
Between (9) and Ground: Battery Relay
*Measure after disconnecting the negative cable from the battery
T5-7-14
Key Switch
Battery
1 2 3 5 4 9
6 8
15
Battery Relay
Starter 10 Fuse
Box
11
12 18 Load
Damp
Relay
13
21 20 19
Starter Relay
16
Alternator Glow
Plug
14 Relay
A13 Monitor
7
17
Glow Plug
T1SM-05-07-001
T5-7-15
5 Voltage Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal No.1
Three polarities Power source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.
• Voltage between terminal No.1 and the ground T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two polarities
1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following V
conditions.
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3) T107-07-05-008
• Tester red terminal (positive):
Connected to terminal No.1 Three polarities
1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V
T107-07-05-009
T5-7-16
CHECK BY FALSE SIGNAL
Two-Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the maxi-
mum value is displayed, the MC and the circuit up to
the machine side harness end connector are normal.
When the pressure switch circuits are normal, Dr. ZX Connect
displays “ON.”
IMPORTANT: Don’t connect terminal #1 or #2 to

terminal #3 or to the vehicle frame Three Polarities
T107-07-05-010
(ground) when checking a

three-polarity connector. (Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor) 1 2 3
NOTE: Some kinds of sensors can be monitored (EC Sensor)
by the built-in diagnosing system. (Refer to
the TROUBLESHOOTING / General
group.)
Connect
T107-07-05-011
T5-7-17
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
Parts Number 4283594 (ST 7126)

Use to check a single-line (discontinuity and/or volt-
age).
To Location to be Measured.
During Operation: Lamp is ON. To Ground
T107-07-05-012
Parts Number (ST 7226)

Use to check the solenoid valve unit circuits.
When the corresponding control lever or switch is 4
operated: Lamp is ON. 3 50
(Refer to T5-4-50, 62 and 81.) 150 50 50
1 2 2 1
T107-07-06-015

Use to check the EC motor circuit.
(Refer to T5-4-34 and 38.) 5
6
50
• EC Motor Circuit
When the engine control dial is rotated: 1 2 2 1
150 50
Both lamps ON: Normal 50
Only one lamp ON: Check for continuity of the 4 3 4 3
circuit connected to the lamp OFF. 7 50
Both lamps OFF: Check the harness together 8
with the relay.
Parts Number 4274589 (ST 7125) T107-07-06-024

Use to measure the EC sensor circuit signal line (Red)
voltage (between terminals #2 and #3).
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009
T5-7-18
Use to check the wiper circuit.
(Refer to T5-4-86.)
2
5 1
2 4 7
1
Parts Number (ST 7227) T178-05-06-003
T5-7-19
(Blank)
T5-7-20
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from
various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into “Daily Report Data List”, “Frequency Dis-
tribution Data List”, “Cumulative Operation Hour List”,
“Alarm List”, and “Trouble List” and are recorded in
the ICX.
Data stored in the ICX is downloadable by the PALM.

This data, after being uploaded to a personal com-
puter, can be read with the “data-viewer”, a data read-
ing software. Using the HAU from e-Service, the data
can be uploaded to a server to which customers,
distributor and Hitachi are accessible.
T5-8-1
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours

(Hours are recorded by hour meter signal from monitor.)
6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)
9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
10 Front Attachment Operat- Total front attachment operating hours during daily operation
ing Hours (Hours are recorded by signals from front attachment pressure sensor.)
11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
12 Auxiliary Attachment Ex- Total auxiliary attachment except for breaker operating hours during daily
cept for Breaker Operating operation
Hours (Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
14 Engine Operating Hour Engine operating hour distribution during daily operation
Distribution (Operating hours are recorded only when alternator output signal is con-
tinuously delivered for more than 10 minutes.)
T5-8-2
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.
* ML crane specification is only available in

Japanese domestic market.
Frequency Distribution Data List
Data Details
1 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant tempera-
ture sensor.)
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sensor.)
3 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pressure
sensor.)
4 *ML Operation Hour Cumulative *ML operation hours
(Hours are recorded by signals from crane mode switch.)
NOTE: * ML specification is only available in Japa-

T5-8-3
Alarm List
Code Data Details

86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
NOTE: In case the above alarms are recorded,

check individual item. If malfunction of the
monitor is found, refer to troubleshooting
C.
T5-8-4
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
NOTE: In case the above fault codes are re-

corded, refer to troubleshooting A.
T5-8-5
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout In case MC communication lasted for less than 7 sec-
onds.
8 Monitor Communication Timeout In case monitor communication did not last for more
than 24 seconds.
9* MC Communication Timeout In case MC communication did not last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication did not last for more
than 1 minute.
NOTE: *Fault code 9 may be displayed on only

the machine to which the ICX is installed
later.
SATELLITE TERMINAL FAULT CODE LIST
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data does not match sending data.
T5-8-6
FAULT CODE 1 TO 4 AND 6
YES Faulty ICX
Check if all data are normally

cumulated.
Faulty ICX
NO
* Even if the fault code remains displayed after retry-

ing, the machine can be operated as it is when data
record is normally cumulated.
FAULT CODE 7 TO 10
YES Faulty ICX

ICX and corresponding com-
ponent while referring to the
following table.
Broken harness between ICX
and corresponding compo-
NO nent.
Fault Code ICX terminal # Corresponding component terminal #

7 Connector C terminal #11 MC connector D terminal #10
8 Connector C terminal #1 Monitor connector B terminal #3
10 Connector B terminal #5 Satellite terminal #2
T5-8-7
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
• All necessary data signals may not be input into
the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Related Data Input Signal

Key switch ON and OFF time Key switch
Engine start and stop time, Engine operating hours (Daily report and cu- Alternator
mulative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Coolant temperature distribution in radiator Coolant temperature sensor
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Av- Travel pressure sensor
erage pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment pressure sensor
hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
NOTE: *ML specification is available only in Japa-

T5-8-8
Corrective Action Remarks

Check harness between ICX terminal A5 and key In case engine does not start, refer to troubleshooting
switch terminal M. B.
Check harness between ICX terminal A2 and alterna- In case alternator indicator malfunctions, refer to trou-
tor terminal L. bleshooting C.
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
T5-8-9
Downloading from and Uploading to the
ICX
The data stored in the ICX is downloadable by the
PALM using the “MIC Download” program or the “Dr.
ZX” program. Downloading using each program as
well as uploading to a PC are explained below. For
uploading of the downloaded data to a server using
the e-Service, refer to the “e-Service Manual”.
T5-8-10
THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
ZAXIS110/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM
ZAXIS110/120/130/130LCN CONNECTORS
ZAXIS125US/135US ELECTRICAL CIRCUIT DIAGRAM
ZAXIS125US/135US CONNECTORS
ZAXIS135UR ELECTRICAL CIRCUIT DIAGRAM
ZAXIS135UR CONNECTORS
ZAXIS110/120/130/130LCN CAB HARNESS
ZAXIS125US/135US CAB HARNESS
ZAXIS135UR CAB HARNESS
ZAXIS110/120/130/130LCN ENGINE HARNESS
ZAXIS125US/135US ENGINE HARNESS
ZAXIS135UR ENGINE HARNESS
ZAXIS110/120/130/130LCN MONITOR HARNESS
ZAXIS135UR CONSOLE HARNESS
ZAXIS110/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM
ZAXIS125US/135US HYDRAULIC CIRCUIT DIAGRAM
ZAXIS135UR HYDRAULIC CIRCUIT DIAGRAM

CAUTION: Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing, be sure to consult the Parts Catalog.
Attach to Vol. No. : TT187E-04
ZAXIS110/110M/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM

LUBRICATOR
CAB OUTSIDE CAB INSIDE

OPTION(330)
LUBRICATOR
MONITOR
CAB INSIDE CAB OUTSIDE
CONTROLLER MONITOR
STARTER SWITCH
MONITOR
POWER IN-PUT
BUCK UP POWER IN-PUT POWER
WATER TENP. SWITCH GLOW IN-PUT CIRCUIT HOUR METER DATA COMMUNICATION OUT-PUT
NOT IN SMJ SERIAL COMMUNICATION TXD
COMMUNICATION SW.
SERIAL COMMUNICATION RXD
REG IN-PUT SATELLITE/PC
CONNECTION SW.
INTERIOR
INTERIOR LAMP
POWER ON SIGNAL
LAMP
POWER-IN
REG. IN-PUT
FUSIBLE LINK(45A) BATT.(DIRECT) COOLANT TEMP. FUEL
EC DIAL SIGNAL IN-PUT
EC DIAL SIGNAL IN-PUT(GND)
BUCK UP
WIPER SIGNAL IN-PUT(+5V)
BATTERY 12V X 2 WIPER SIGNAL IN-PUT
ACC(LOAD)
120 GROUP
BATTERY RELAY ALT(LOAD) WIPER SIGNAL IN-PUT(GND)
LIQUID
CRYSTAL PANEL
OVER-HEAT
FUSIBLE LINK(65A)
LOAD DUMP FUSE AIR FILTER
RELAY
FUEL
GLOW
LIGHT
WIPER
HEATER
HORN
RADIO
LIGHTER
ROOM LIGHT
AUX.
GLOW/R
BACK-UP
CONTROLLER
EC MOTOR
SOLENOID
SWITCH BOX
POWER ON SIGNAL
AIR-CON.
STARTER WIRING TOOL WORK LIGHT
DISPLAY CHANGE MAIN
SAFETY RELAY COMPLETED CHARGE
POWER
(120 GROUP) SET ENG. OIL LEVEL CONTROLLER
MONITOR
SPARE 1
ROOM LIGHT WORK MODE MAIN
SPARE 2 GND
WIPER MOTOR ENG. OIL LEVEL
WIRING COMPLETED
120 GROUP
COOLANT LEVEL
AUTO RE-FUELING LIGHTER

HYD.OIL FILTER
SYSTEM SPARE 4 B9:MONITOR COMMUNICATION GND
C10:MCX COMMUNICATION GND
SPARE 5 D11:DIGITAL GND
SPARE 6
SPARE 6 SW. IN-PUT OPTION

ALTERNATOR HYD. OIL FILTER SW. IN-PUT
SPARE 4 EXT. HYD. OIL FILTER WARNING #4448754
GLOW RELAY OPTION
LIGHT 1
LIGHT 2
CHARGE EXT.
SPEAKER R SPARE 2 SW. IN-PUT RADIATOR LEVEL SW. #4153251
WARNING LAMP LOCATION AIR FILTER RESTRICTION SW. IN-PUT
SPARE 5 EXT. AIR CLEANER RESTRICTION SW. #4224238
NO.12 IS OPT., NO.5 IS NOT USE (120 GROUP #4334759)
WORK LIGHT SW. IN-PUT
FUEL
REGULATOR SPEAKER L GLOW EXT.
WIPER
ENG. OIL LEVEL EXT.
RADIO COOLANT LEVEL EXT.
GLOW PLUG
FUEL SIGNAL
COOLANT TEMP. SIGNAL FUEL SENSOR #4257128
AUTO- AUTO-IDLE DIGGING ATTACHMENT COOLANT TEMP SENSOR #4436537
ACCELERATION MODE 1 SIGNAL OUT-PUT
(ONLY ZX200 PASS THROUGH NO.12)
LOAD DUMP RELAY OUT-PUT MODE 2 SIGNAL OUT-PUT
ENG. OIL LEVEL SW.(ON ENG.) #4371903
RELAY DRIVE CIRCUIT

LIGHT 1 RELAY OUT-PUT WIPER, WASHER MOVE SIGNAL OUT-PUT ENG. OIL PRESSURE SW.(ON ENG.) #*******
LIGHT 2 RELAY OUT-PUT
WIPER C RELAY OUT-PUT SPARE 1 SW. IN-PUT
WIPER B RELAY OUT-PUT
ENG. OIL PRESS. SW. IN-PUT
WIPER A RELAY OUT-PUT OVER-HEAT SW. IN-PUT
WASHER RELAY OUT-PUT ENG. OIL LEVEL SW. IN-PUT OVER-HEAT SW. #4371318
COOLANT LEVEL SW. IN-PUT
WIPER WIPER WIPER WIPER AUTO-IDLE SW. IN-PUT AUTO-IDLE
PULL-UP
A/I A/A SW
RELAY A RELAY B RELAY B1 RELAY B2 AUTO-ACCELERATION SW. IN-PUT AUTO-ACCELERATION WASHER SW.
WASHER SW. IN-PUT
LIGHT SW. 2 IN-PUT
LIGHT SW. 1 IN-PUT
LIGHT SW.
WIPER, WASHER EN SW. IN-PUT
BACK-UP EN SW. IN-PUT
HOUR METER GROUND
WASHER RELAY SIGNAL WIPER VR.
INTERIOR LIGHT
INTERIOR LIGHT
POWER IN-PUT
BUZZER SIGNAL
WASHER ENG. SPEED CONTROL DIAL
FRONT WINDOW UP-ON HIGH-SPEED

LOW-SPEED TRAVEL 2-SPEED SW.
LIGHT RELAY 2
NORMAL OPEN HP, P, E MODE SW.
SWITCH BOX
BOOM LIGHT
LIGHT RELAY 1
WORK LIGHT ZX200, ZX225USR ADDITIONAL PUMP ELECTRICAL DIAGRAM
PUMP 3 DELIVERY PRESSURE

PROPORTIONAL SOL-2
PROPORTIONAL SOL-1
ARM DUMP PILOT(S)

PRESSURE
SENSOR (H)
HORN RELAY
HORN SIDE/
MALE ON
BOTH SIDE HORN (H)
HORN SWITCH
ML-CRANE BOOM DUMPING

(JAPANESE DOMESTIC ONLY) (JAPANESE DOMESTIC ONLY) SWING ALARM
HORN (L)
TRAVEL ALARM
BOOM ROD SIDE PRESSURE (S)

TRAVEL ALARM
OPTION
ARM DUMP PILOT (S)

OPTION
INITIAL SETTING SW.
BOOM BOTTOM (S)
BOOM BOTTOM (S)

CRANE MODE SW.
LOAD ALARM: EN
BOOM ANGLE (S)
SWING OUT-PUT
ARM ANGLE (S)
TO MCX CONNECTOR
LEARNING SW.
POWER DIGGING SW. CANCEL SW.
PRESSURE SWITCH
SOLAR RADIATION
GROUP ONLY SENSOR NATURAL
COMPRESSOR
SUB HARNESS
GROUP
MONITOR
KEY MAIN SOLENOID EC MOTOR

SIGNAL POWER POWER POWER
SOLAR RADIATION
SENSOR
CONTROLLER
EC MOTOR
MAIN SOLENOID
AIR-CON. UNIT GND GND
AMBIENT SENSOR
GROUP
BOOM DUMPING
SEALED WIRE
RE-GENERATION
PUMP TORQUE
ANGLE LIMIT
ANGLE LIMIT
PUMP 2 TILT
PUMP 1 TILT
DUMPENER
OIL TEMP. SENSOR

AUX. FLOW
ARM FLOW
DIGGING
2-SPEED
TRAVEL
POWER
BOOM
CONTROL 1
CONTROL 2
PRESSURE
ARM
PUMP
PUMP
SENSOR 2 PRESSURE
CAB INSIDE CAB OUTSIDE SENSOR 1
EC MOTOR EC ANGLE
SENSOR PUMP 2 PUMP 1
N SENSOR PRESSURE PRESSURE ARM BOOM
VALVE SOLENOID PUMP MOTOR TRAVEL SWING FRONT ROLL-IN
SOLENOID SENSOR (L) PRESSURE SENSOR (L) PRESSURE RAISE
SENSOR (H) SENSOR (H)
OPTION
PRESSURE SENSOR (LOW)
Up to serial No. 010576 (ZAXIS110/110M)

OPTION
Up to serial No. 062964 (ZAXIS120)

ZAXIS110/110M/120/130/130LCN CONNECTORS
THESE CONNECTORS ARE THE HARNESS END CAUTION: Parts numbers on the drawing are provided only for reference purpose.
CONNECTORS, UNLESS OTHERWISE SPECIFIED. To order parts on the drawing, be sure to consult the Parts Catalog.
FUEL GAUGE BUZZAR CANCEL SW. AMBIENT SENSOR SOLAR-RADIATION SENSOR

(TRAVEL ALARM) (120 GROUP) (120 GROUP)
YAZAKI YAZAKI
YAZAKI 7323-2064
QOS CONTROLER COMPRESSOR PUMP/H(ENG SIDE) AMBIENT SENSOR SOLAR-RADIATION SENSOR AIR-CON PRESSURE SW.
(200 GROUP) (200 GROUP) (200 GROUP)
LOCK
2P FEMALE
YAZAKI 7123-7464-40 YAZAKI 7323-6214-40 SUMITOMO 6188-0494 SUMITOMO 6189-0533
DIODE SPEAKER PRESSURE SENSOR(L) GLOW RELAY OPTION POWER WWES

SWING ALARM
WATER PROOF PLUG CONNECTOR

MALE SHARE PLUG
YAZAKI 7113-1020
WATER PROOF CAP
YAZAKI 7120-8018
FEMALE RECEPTACLE
YAZAKI YAZAKI GROUND YAZAKI 7115-1050
YAZAKI 7283-1223-30 YAZAKI RV03FB YAZAKI 7323-2044 WATER PROOF CAP
YAZAKI 7120-1157
CONNECTOR
ALTERNATOR LEARNING SW. BOOM DUMPING FLAT TERMINAL
PRESSURE SENSOR(H) SOLENOID WIPER(CAB/H-SIDE) HYD. OIL TEMP. SENSOR WASHER
(ENG. OIL PRESS. SW.)
SCREW TERMINAL FLAT TERMINAL
LOCK WITH LOCK
AMP 172320-2
3P-FEMALE SUMITOMO 6189-0031 (CN. WITH OUT LOCK) YAZAKI 7323-1424-40
RELAY EO LEVEL RAD. LAVEL N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. WIPER
COOLANT TENP. SW. BOOM DUMPING
SUMITOMO 6098-1493 YAZAKI 7323-7414-40 SUMITOMO 6189-0133 ALTERNATOR

*COOLANT LEVEL SW
ML-CRANE WASHER
ENG. OIL PRESSURE SW.
RADIO GLOW RELAY
STARTER RELAY
BATTERY RELAY
DETAIL 1 AIR CLEANER RESTRICTION SW
BODY LIGHT
FUEL GAUGE
DIODE(1, 3)
YAZAKI 7123-1402
EARTH LINE WIPER
HORN SW
MCX-A MCX-B MCX-C MCX-D LEARNING SW
CAB
RADIO
S-REINFORCEMENT PLATE
AUX. POWER
BOOM DUMPING POWER LIGHTER
MONITOR
AIR-CON
TRAVEL ALARM
MONITOR A (CAB/H SIDE) MONITOR B (CAB/H SIDE) MONITOR C (CAB/H SIDE)
ADDITIONAL PUMP ATT1
ADDITIONAL PUMP ATT2 CONTROL SYSTEM
GROUND LINE
POWER DIGGING SW
MONITOR A MONITOR B MONITOR C SATELLITE/PC

DETAIL 2
CAB COVER
FLAME
NOTE : Up to serial No. 010576 (ZAXIS110)

ZAXIS125US/135US ELECTRICAL CIRCUIT DIAGRAM To order parts on the drawing, be sure to consult the Parts Catalog.
CAB OUTSIDE CAB INSIDE CAB INSIDE CAB OUTSIDE

STARTER SWITCH
CONTROLLER
MONITOR
POWER IN-PUT
BUCK UP POWER IN-PUT POWER HOUR METER DATA
WATER TENP. SWITCH GLOW IN-PUT CIRCUIT COMMUNICATION OUT-PUT
COMMUNICATION SW.
CONSOLE SERIAL COMMUNICATION RXD ICX Dr. ZX
CONNECTION SW.
POWER ON SIGNAL
REG IN-PUT INTERIOR SATELLITE/PC
LAMP INTERIOR LAMP
POWER-IN
REG. IN-PUT
FUSIBLE LINK(45A) COOLANT FUEL
BATT.(DIRECT) TEMP
BACK UP
BATTERY WIPER SIGNAL IN-PUT
BATTERY RELAY LIGHT WIPER SIGNAL IN-PUT(GND)
GROUP
FUSIBLE LINK(65A) LIQUID CRYSTAL PANEL
OVER-HEAT
LOAD DUMP FUSE
AIR FILTER
RELAY
FUEL
BACK-UP
CONTROLLER
SOLENOID
SWITCH BOX
POWER ON SIGNAL
AIR-CON.
EC-MOTOR
GLOW
LIGHT
WIPER
HEATER
HORN
RADIO
LIGHTER
ROOM LIGHT
AUX.
GLOW/R
TOOL
WORK LIGHT
STARTER WIRING MAIN
SAFETY RELAY COMPLETED DISPLAY CHANGE CHARGE POWER
GROUP ENG. OIL LEVEL CONTROLLER
SET
SPARE 1 MAIN
ROOM LIGHT WORK MODE GND
WIPER SUB 1 SPARE 2
WIPER MOTOR DOOR SWITCH
WIPER ENG. OIL LEVEL
GROUP
COOLANT LEVEL
HYD. OIL FILTER B9:MONITOR
LIGHTER COMMUNICATION GND
AUTO RE-FUELING SPARE 4
C10:MCX
SPARE 5 COMMUNICATION
GND
CONSOLE
SPEAKER R HYD. OIL FILTER SW. IN-PUT
ALTERNATOR GLOW SPARE 4 EXT.
HYD. OIL FILTER WARNING
RELAY OPTION
LIGHT 1
LIGHT 2
CHARGE EXT.
SPARE 2 SW. IN-PUT
AIR FILTER RESTRICTION SW. IN-PUT
RADIATOR LEVEL SW.
WARNIG LAMP LOCATION AIR CLEANER RESTRICTION SW.
SPARE 5 EXT.
NO.12 IS OPT., NO.5 IS NOT USE WORK LIGHT SW. IN-PUT GROUP
WIPER MOTOR WIPER SUB 2 FUEL EXT.
REGULATOR GLOW EXT.
ENG. OIL LEVEL EXT.
RADIO SPEAKER L COOLANT LEVEL EXT.
GLOW PLUG CONSOLE FUEL SIGNAL
FUEL SENSOR
COOLANT TEMP. SIGNAL COOLANT TEMP. SENSOR
AUTO- AUTO-IDLE DIGGING ATTACHMENT
ENG. OIL LEVEL SW.(ON ENG.)
LIGHT 1 RELAY OUT-PUT ENG. OIL PRESSURE SW.(ON ENG.)
RELAY DRIVE
WIPER, WASHER MOVE SIGNAL OUT-PUT
CIRCUIT
LIGHT C RELAY OUT-PUT SPARE 1 SW. IN-PUT
LIGHT B RELAY OUT-PUT
LIGHT A RELAY OUT-PUT
OVER-HEAT SW. IN-PUT
WASHER RELAY OUT-PUT
ENG. OIL LEVEL SW. IN-PUT OVER-HEAT SW.
PULL-UP
WIPER AUTO-IDLE SW. IN-PUT AUTO-IDLE
RELAY A AUTO-ACCELERATION SW. IN-PUT AUTO-ACCELERATION
A/I A/A SW
WASHER SW. IN-PUT WASHER SW.
LIGHT SW. 2 IN-PUT
LIGHT SW. 1 IN-PUT
BACK-UP EN SW. IN-PUT LIGHT SW.
HOUR METER GROUND
INTERIOR LIGHT
INTERIOR LIGHT
POWER IN-PUT
SIGNAL
WASHER BUZZER
ENG. SPEED
CONTROL DIAL
HIGH-SPEED
LIGHT RELAY 2
NORMAL OPEN HP,P,E MODE SW.

SWITCH BOX
SWITCH BOX
BOOM LIGHT
CONSOLE
LIGHT RELAY 1
WORK LIGHT
PRESSURE SWITCH
CONSOLE
(ASSY)
HORN RELAY
HORN SWITCH
COMPRESSOR
ML-CRANE
HORN SIDE/ (JAPANESE DOMESTIC ONLY)
MALE ON
BOTH SIDE HORN (H) BOOM DUMPING
SEPARATE CONSOLE A2 (JAPANESE DOMESTIC ONLY) SWING ALARM
BOOM ROD SIDE PRESSURE(S)

TRAVEL ALARM
TRAVEL ALARM
OPTION
HORN (L)
ARM DUMP PILOT(S)
INITIAL SETTING SW.

OPTION
CRANE MODE SW.
BOOM BOTTOM(S)
BOOM BOTTOM(S)
LOAD ALARM:EN
SWING OUT-PUT
BOOM ANGLE(S)
ARM ANGLE(S)
LEARNING SW.
POWER DIGGING SW. Dr. ZX
CANCEL SW.
LO
CONSOLE
REGISTER HEATER CONTROLLER
MACHINE
SELECTION
KEY MAIN SOLENOID EC-MOTOR

IN DETAILS:COMMON TO A/C SIGNAL POWER POWER POWER
OPTION
3 IS DIFFERENT
CONTROLLER
MAIN EC-MOTOR
SOLENOID
GND GND
AIR-CON. CONTROLLER
SENSOR
GND
TEMP. BOOM DUMPING
HUSE SEALED
WIRE
CIRC AIR SENSOR
AMBIENT SENSOR
SOLAR
RADIATION
SENSOR
Up to serial No. 010576 (ZAXIS125US)
GENERATION
TORQUE
THERMISTER
DUMPENER
AUX. FOLW
PUMP
PUMP
FLOW
OIL TEMP.
2-SPEED
SENSOR 1
PRESSURE
TILT ANGLE
TRAVEL
ARM RE-
SENSOR
PUMP 1
CONTROL 1
PUMP
CONTROL 2
PUMP
PRESSURE
LIMIT
SENSOR
SENSOR 2
BOOM
LO REGISTER CAB INSIDE CAB OUTSIDE EC

N
PUMP EC-MOTOR ANGLE

VALVE SOLENOID SENSOR
SOLENOID PUMP 2 PUMP 1
MOTOR TRAVEL SWING FRONT ARM BOOM BOOM
PRESSURE PRESSURE PRESSURE PRESSURE ROLL-IN RAISE ANGLE
AIR-CON UNIT SENSOR(L) SENSOR(H) SENSOR(L) SENSOR(H)
OPTION
PRESSURE SENSOR(L) ANGLE SENSOR
ONLY ZAXIS225US
ZAXIS125US/135US CONNECTORS To order parts on the drawing, be sure to consult the Parts Catalog.
THESE CONNECTORS ARE THE HARNESS END

CONNECTORS, UNLESS OTHERWISE SPECIFIED.
YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI
WIPER MOTOR WIPER SUB2 DOOR SW. WIPER SUB1 CANCEL SW. BUZZER CIRC AIR SENSOR
MOTOR SIDE : M MOTOR SIDE : M CAB/H SIDE : F CAB/H SIDE : F TRAVEL ALARM
SUB1
SUB2
ROOF
SUMITOMO YAZAKI NILES YAZAKI YAZAKI GLASS DOOR SW
QOS CONTROLLOR COMPRESSOR PUMP/H(ENG. SIDE) AMBIENT SENSOR SOLAR RADIATION SENSOR A/C PRESSURE SW.
MOTOR
WIPER
LOCK
2P F
YAZAKI YAZAKI SUMITOMO SUMITOMO
DIODE SPEAKER PRESS. SENSOR(L) GLOW RELAY OPT. POWER WWES SWING ALARM
WATER PROOF CONNECTOR

MALE SHARE PLUG
YAZAKI YAZAKI YAZAKI
WATER PROOF CAP
YAZAKI YAZAKI YAZAKI YAZAKI
FEMALE RECEPTACLE
GROUND YAZAKI
PRESS. SENSOR(H) SOLENOID FUEL GAUGE HYD. OIL TEMP. SENSOR WASHER ALTERNATOR LEARNING SW. BOOM DUMPING WATER PROOF CAP
ENG. OIL PRESSURE SW. YAZAKI
LOCK CONNECTOR
FLAT TERMINAL

WITH LOCK
AMP 172320-2
3P F SUMITOMO CN. WITHOUT LOCK YAZAKI
GP RELAY EO LEVEL RAD. LEVEL N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. WIPER
COOLANT TEMP.SW. BOOM DUMPING CAB/H SIDE : F
ALTERNETOR
*RAD. LEVEL SW.
DETAIL 1 WASHER
GLOW RELAY
STARTER RELAY
BATTERY RELAY
AIR CLEANER RESTRICTION SW.
BODY LIGHT
FUEL GAUGE
SUMITOMO YAZAKI YAZAKI
AIR-CON. CONTROLLER(1) AIR-CON. CONTROLLER(2) ML CLANE RADIO DIODE

HEATER CONTROLLER(1) HEATER CONTROLLER(2)
EARTH LINE WIPER
HORN SW.
AIR-CON.
A/C BOX RADIO
YAZAKI AUX. POWER

LIGHTER
POWER
MONITOR
TRAVEL ALARM
ML CLANE
CONTROL SYSTEM GROUND LINE

POWER DIGGING SW.
LEARNING SW.
BOOM DUMPING
CONSOLE A(CAB/H SIDE) CONSOLE C(CAB/H SIDE) SW-BOX
CONSOLE B(CAB/H SIDE)
DETAIL 2
MONITOR A MONITOR B MONITOR C SATELLITE/PC C/U BRACKET
FRAME
NOTE : Up to serial No. 010576 (ZAXIS125US)

ZAXIS135UR ELECTRICAL CIRCUIT DIAGRAM CAUTION: Parts numbers on the drawing are provided only for reference purpose.
COOLANT TEMP. SW.
STARTER SW.
RESISTER S
RESISTER D
EMERGENCY
EVACUATION SW.
K
A
RESISTER
K
STARTER SW.
A
FUSIBLE LINK (45A)
OPT DECEL.
NOT IN SMJ 2-9 OUT 1-32
BATTERY 12V×2 ACC (LOAD) EMERGENCY
BATTERY RELAY
IN 1-18 ACCEL.
ALT (LOAD) EVACUATION
4-2 RECEPTION (+) OUT 1-29
LCD 4-11 TRANSMISSION (+) SW.
FUSIBLE LINK (65A)
IN 1-7 ACCEL.
AUTO LOAD DUMP DISPLAY 4-3 RECEPTION (-)
RE-FUELING 4-12 TRANSMISSION (-) OUT 1-10
SYSTEM RELAY IN 1-5 DECEL.
OUT 1-23
IN 1-16 DECEL.
MONITOR
HORN
LIGHT
WIPER
AIR-CON.
AUX.
ROOM LIGHT, LIGHTER, RADIO

HEATER
BACK-UP
LCD MONITOR
EMERGENCY SW.
GLOW
POWER IN-OUT OUT 1-24
BACK-UP POWER IN-PUT POWER DECEL.
GLOW IN-PUT CIRCUIT
IN 1-17
STARTER SERIAL COMMUNICATION TXD
SAFETY RELAY
GND SERIAL COMMUNICATION RXD OUT 1-11
SERIAL COMMUNICATION 2TXD- IN 1-6 DECEL.
WASHER SERIAL COMMUNICATION 2TXD+
REG IN-PUT SERIAL COMMUNICATION 2RXD+
GLOW RELAY SERIAL COMMUNICATION 2RXD- 3-10 OFFSET-LEFT OUT 1-30
2-2 OFFSET-RIGHT IN 1-19 ACCEL.
WASHER CAB OUT
RELAY 2-14 RESTRICTION SW. OUT 1-31
CAB IN ROOM LIGHT COOLANT
FUEL
IN 1-20
POWER-ON SIGNAL
TEMP. ACCEL.
LIQUID EC DIAL SIGNAL IN-PUT OPT
CRYSTAL EC DIAL SIGNAL IN-PUT (GND) RIGHT CONTROL OUT 1-22
EC MOTOR
PANEL LEVEL IN 1-15 DECEL.
WIPER L1 : LOAD ALARM
RELAY
L2 : STROKE END 2-12 INITIAL SETTING 5V (PRES.) 2-19
××× ×××× ×××× ××
L3 : HOOK
3B
BOOM RAIS. PRES. 3-17 BOOM RAIS. PRES.
ALTERNATOR
L4 : ARM VERTICALITY A 6 GND (PRES.) 2-21
××
L5 : ENG. OIL PRESS.
××
DISPLAY CHANGE
2-3 SERVICE SW. ARM DUMP PRES. 3-15 ARM DUMP PRES. 2
LIGHT
L6 : OVER-HEAT
××××× 1-25 GND (RELAY) ARM ROLL-IN DECEL. PRES. 3-6
××× SET L7 : FUEL
BOOM LOWER DECEL. PRES. 3-16 ARM ROLL-IN DECEL. PRES. 5
K
××× WORK MODE

L8 : CHARGE 1-26 BUZZER
×× L9 : AIR FILTER 2-4 SWING MODE OFFSET RIGHT ACCEL. PRES. 3-12
A
RADIO LIGHT IC/U BUZZER

GLOW PLUG WIPER MOTOR ××× L10 : GLOW
××
L11 : HYD. OIL FILTER
OFFSET LEFT ACCEL. PRES. 3-2 BOOM LOWER DECEL. PRES. 6
AUTO M
L12 : SPARE BOOM RAISE ACCEL. PRES. 3-5
TRAVEL SW
REGULATOR HYD. OIL FILTER SW. IN-PUT OFFSET RIGHT ACCEL. PRES. 7
SPARE
CHARGE EXT
WASHER
AIR FILTER SW. IN-PUT OFFSET LEFT ACCEL. PRES. 8
CRANE MODE SW. 2-13 CONNECT DETECTION
FUEL EXT
WIPER
GLOW EXT
4-9 TRANSMISSION
WARNING LAMP LOCATION 4-10 RECEPTION
BOOM RAISE
HIGH- LOW- ACCEL. PRES.
SPEED SPEED FUEL SIGNAL
HORN RELAY COOLANT TEMP SIGNAL 3-11 SLIDE SENSOR
2-15 ARM RETRACT OPT
AUTO - MARCCINO
135UR ONLY 2-6 ARM EXTEND EMERGENCY HYD. OIL TEMP. SENSOR
HORN SW LIGHT TRAVEL MODE
STOP SOL.
AUTO M WIPER
AUTO - IDLE
SLIDE ARM 2-16
HP MODE EMERGENCY STOP
SOL. VALVE
E MODE
HORN SIDE LOAD DUMP RELAY OUT-PUT AUTO - IDLE
MALE ON SATELLITE / PC LIGHT 1 RELAY OUT-PUT WORK MODE
RELAY DRIVE
HORN WIPER RELAY OUT-PUT

BOTH SIDE WASHER RELAY OUT-PUT ML MODE 1
CURCUIT
LIGHT RELAY 2 ML1 RELAY OUT-PUT BOOM ANGLE SENSOR

ML2 RELAY OUT-PUT
ML3 RELAY OUT-PUT
ML4 RELAY OUT-PUT ARM ANGLE SENSOR
(NORMAL OPEN ML CONNECT)

PULL - UP
ML SWITCH
(BOOM LIGHT) ML - MODE 2 OFFSET ANGLE SENSOR
BUCK UP EN
ENG. OIL PRES. SW. IN-PUT
LIGHT RELAY 1 OVER - HEAT SW. IN-PUT
HOUR METER GND.
ENG. SPEED BOOM ROD
PRESSURE (S)
CONTROL DIAL
INITIAL BOOM BOTTOM

(WORK LIGHT) PRESSURE (S)
SETTING SW.
NORMAL OPEN OPT
ARM ROLL-OUT PRES. (S)

COOLANT TEMP. SENSOR
FUEL SENSOR
OVER-HEAT SW.
HYD. OIL FILTER WARNING (OPT)
LEARNING SW.
ML RELAY
SWING
A NATURAL ALARM
BUCKET LOCK SOL.
ML LIGHT
SOL. PUMP AUTO

AIR BLEED
A
OPTION
SEALED WIRE
CANCEL SW.
PRESSURE SWITCH
HYD. OIL TEMP. SENSOR

ANGLELIMIT
PUMP 1
TORQUE
PUMP
ANGLELIMIT
PUMP 2
AUX. FLOW
OUTSIDE INSIDE N-SENSOR

COMPRESSOR
CONTROL 2
PUMP
CONTROL 1
PUMP
INSIDE OUTSIDE OPTION TRAVEL FRONT SWING SWING ARM BOOM
ROLL-IN RAISE
OPTION
Attach to vol. No. : TT187E-04
CONNECTORS, UNLESS OTHERWISE SPECIFIED
RESISTOR S FUEL GAUGE LCD DISPLAY (2) LCD LAMP (2) CANCEL SW. ML CRANE
(TRAVEL ALARM)
SUMITOMO 6189-4172 SUMITOMO 6189-4171

YAZAKI 7323-2064 SUMITOMO 6242-5061
QOS CONTROLLER MONITOR BUZZER BOOM ANGLE SENSOR INITIAL SETTING RADIO SUB/H. (CAB/H SIDE)
IC/U BUZZER
EFCT SUB/H. (CAB SIDE)
YAZAKI 7123-7464-40 SUMITOMO 6030-2981
DIODE SPEAKER PRESS. SENSOR (L) DR. ZX (MC, UR, ICX) GLOW RELAY OPT. POWER
WWES SWING ALARM
YAZAKI YAZAKI
YAZAKI 7283-1223-30 YAZAKI RV03FB YAZAKI 7323-2044 7323-2228 7323-3010
PRESS. SENSOR (H) SOLENOID FRONT ANGLE SENSOR HYD. OIL TEMP. SENSOR WASHER ALTERNATOR LEARNING SW. CONSOLE B (CAB/H SIDE)
RELAY/H (ENG-OIL PRESSURE SW.)
LOCK
AMP EJ <> 070 YAZAKI 7232-1424-40

3PF SUMITOMO 6189-0031 (CN WITH OUT LOCK)
GP RELAY COOLANT TEMP. SW. N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. SLIDE ARM
ARM ANGLE SENSOR RESISTOR D
OFFSET ANGLE SENSOR
SUMITOMO 6098-1493 YAZAKI 7323-7414-40
AUTO AIR BLEED PT

RADIO
YAZAKI 7123-1402
CONSOLE A (CON A) ; CAB H SIDE
MONITOR - A MONITOR - B MONITOR - C SATELLITE / PC

ZAXIS110/110M/120/130/130LCN CAB HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
LIGHTER
LEARNING SW-2
DIRECTION
PULLING
HARNESS
POWER BOOST SW
TIN PLATE
ML-CRANE-10
MEASURE HERE
ML-CRANE-11
CANCEL SW-1 BLACK RETAINER
CANCEL SW-3 BACK COVER
YAZAKI
MONITOR C-12
ML-CRANE-7
CANCEL SW.
MONITOR A-1
MONITOR A-2
MONITOR A-3
MONITOR A-4
MONITOR A-5
MONITOR A
SWING ALARM-1 MONITOR A-6 INSTALL MONITOR A, B AND C AS FOLLOWS.
RELAY BOX
· TURN BACK CONNECTOR'S SURFACE TO A. SLEEVE MUST BE SHORT LIGHTER
ML-CRANE-8
· VIEW C-C' IS AS FOLLOWS.
MONITOR A, B, C
MONITOR A-16
MONITOR B
RELAY BOX
RELAY BOX
MONITOR A-8
MONITOR A-9 ML-CRANE-6 VIEW C-C'
MONITOR A-7 MONITOR A-10 MONITOR C-9 MONITOR C
LEARNING SW-1 MONITOR A, B, C * MONITOR A, B AND C MUST BE UPPER SIDE
WHEN THE RELAY BOX IS RIGHT SIDE
MONITOR C-11
MONITOR A-12
MONITOR A-13 MONITOR C-10
1. IF NO COMMENT, WIRE 0.3~1.25 MAY BE CAVS AND
MONITOR A-15
WIRE 2~5 MAY BE AVS.
ML-CRANE-3
ML-CRANE-4 MONITOR A-16
MONITOR B-1 HARNESS END OF TAPE 2. PIN ARRANGEMENT OF THIS DRAWING
MONITOR B-2 PULLING INDICATE VIEW POINT FROM THE
DIRECTION MEASURE HERE
MONITOR B-3 OTHER SIDE CONNECTOR.
MONITOR B-4
MONITOR B-5 ALL SIRSUITS MUST BE TIGHTER TOGETHER 3. NO ELECTRIC JOINT MAY BE BETWEEN FH AND KC.
MONITOR B-6
MONITOR B-7
MONITOR B-8
4. PUT THE PART No. LEBEL ON THE HARNESS.
MONITOR B-9
5. PULG CONNECTORS MUST BE BRASS.
MONITOR B-10 6. COLOR SIGN DUE TO JASO D607.
MONITOR B-11 LIGHTER 7. GENERAL EXPRESS ON THE DRAWING DUE TO #X4259303.
MONITOR B-2 8. OUTSIDE DIAMETER OF CORRUGATE TUBE FOR CAB EARTH 1,
MONITOR B-13 CAB EARTH 2, QOS-CON AND G-LIGHTER MUST BE LESS THAN 20mm.
MONITOR B-14
MONITOR B-15
MONITOR B-16
FASTEN
MONITOR C-1 WITH TAPE
MONITOR C-2
MONITOR C-3
MONITOR A-11
1. ICX-A AND B MUST BE ARRANGED AS FOLLOWS 2. ICX-C AND D MMUST BE ARRANGED AS FOLLOWS
MONITOR C-7 BY USING THE TAPE. BY USING THE TAPE.
MONITOR C-15 MONITOR C-13 · TURN BACK CONNECTION'S SUR FACE TO C. · TURN BACK CONNECTOR'S SURFACE TO A.
· ON THE LINE OF ICX-A AND B, FASTEN ICX-A AND B WITH · ON THE LINE OF ICX-C AND D, FASTEN ICX-C AND D WITH
IN 50mm FROM I AND IN BETWEEN MCX-A AND B USING A TAPE. IN 50mm FROM I AND IN BETWEEN MCX-C AND D USING A TAPE.
MONITOR C-14
· VIEW A-A' IS AS FOLLOWS · VIEW B-B' IS AS FOLLOW.
MONITOR C-6
ML-CRANE-1
VIEW B-B'
VIEW A-A'
ML-CRANE-5
* ICX-C AND D MUST BE UPPER SIDE SATELLITE / PC
* ICX-A AND B MUST BE UPPER SIDE WHEN MCX-D IS RIGHT SIDE.
SATELLITE/PC-10 WHEN MCX-A IS RIGHT SIDE.
ML-CRANE-2
SATELLITE/PC-2
SATELLITE/PC-1
LEARNING SW MOVE THIS SIDE
ASS'Y HOUSING CNO4M (N)
SATELLITE/PC-3
INSTALL A PULLER
ALL SIRSUITS MUST BE TIGHTER TOGETHER (YAZAKI 7147-9178) AND
SATELLITE/PC-4 SPARE FUSES 5A, 5A, 10A AND 20A.
SATELLITE/PC-5
HORN-SW.
TIN PLATE
SATELLITE/PC-7 PRINT USAGE AND AMPERE
SATELLITE/PC-8 ON THE COVER.
APPLY RED TAPE
SATELLITE/PC-6
RADIO SWING ALARM

SATELLITE/PC-9
LABEL
SPARE
YAZAKI 7123-2044
ML CRANE ASSY FEMALE PIUG
CN TYPE FLANGE
ZAXIS125US/135US CAB HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
G
CONSOLE LIGHTER
LEANING CONSOLE A ICX-D

RELAY BOX
H 90
B 90
MCX-A DIRECTION FOR
R1
LOCK REMOVING HARNESS
FUSE-BOX
CONSOLE
MEASURE HERE
90
J06FGY ICX DR.EX

DIRECTION FOR
CRANE DR.EX REMOVING HARNESS
CANCEL SW D E
SOLAR RADIATION SENSOR
CONSOLE
90
CRANE WIPER DIRECTION FOR
REMOVING HARNESS FUSE NO.1,11
CANCEL CONSOLE
CANCEL C
LEARNING
SWING ALARM
MONITOR ML CRANE
WIPER CONNECT
CRANE
MONITOR
MONITOR
MONITOR
MONITOR LIGHTER
MONITOR CONSOLE CONSOLE MONITOR
MONITOR CONSOLE
MONITOR CONSOLE
CORRUGATE TUBE 20MM DIA
FASTEN WITH TAPE
SWING ALARM
CRANE
MONITOR
SPEAKER
BUZZER
MONITOR BUZZER
MONITOR BUZZER
CONSOLE MONITOR
CONSOLE MONITOR CRANE ALL SIRSUITS MUST BE
MONITOR MONITOR WIPER TIGHTER TOGETHER
LERNING
CONSOLE WIPER
MONITOR
MONITOR WIPER
CONSOLE MONITOR
CRANE MONITOR
CRANE MONITOR
CONSOLE MONITOR
MONITOR CONSOLE CONSOLE
MONITOR CONSOLE
CONSOLE CONSOLE
MONITOR CONSOLE
MONITOR CONSOLE
CONSOLE MONITOR CONSOLE
MONITOR CONSOLE
CONSOLE MONITOR
MONITOR
MONITOR
MONITOR LIGHTER NOTE
MONITOR 1. UNDER 1.25 WIRE MAY BE CAVS WIRE, IF NO COMMENT.
MONITOR OVER 2 WIRE MAY BE AVS WIRE.
MONITOR
2. PIN ARRANGEMENTS OF THIS DRAWING INDICATE
VIEW POINTS FROM THE OTHER SIDE CONNECTORS.
CONSOLE
MONITOR
CONSOLE 3. NO ELECTRIC TURNING POINT MAY BE BETWEEN AH
CONSOLE MONITOR
AND J-CAB EARTH, K-CAB EARTH.
MONITOR CONSOLE
MONITOR CONSOLE SPEAKER 4. PUT THE PART NO. LABEL ON THE HARNESS.
MONITOR
MONITOR SOLAR RADIATION SENSOR CONSOLE 5. NO PLATE ON THE CB TYPE CONNECTORS.
6. COLOR SIGN DUE TO JASO D607.

7. GENERAL EXPRESS ON THE DRAWING
MONITOR DUE TO # X4259303
CRANE
CRANE
RELAY BOX
SATELLITE
CN
CRANE
SATELLITE
SATELLITE
CN
YAZAKI
LEARNING SWITCH
DIRECTION FOR REMOVING
HARNESS ALL SIRSUITS MUST BE
TIGHTER TOGETHER
MEASURE HERE
SATELLITE
SATELLITE
L02MB
SATELLITE
SATELLITE
SATELLITE
SATELLITE
M04MB
SATELLITE C16MW
LABEL
C010MW AUX.
SATTELLITE
Attach to Vol. No.: TT187E-04
ZAXIS135UR CAB HARNESS CAUTION: Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing,be sure to consult the Parts Catalog.
MONITOR C-2
MONITOR C-3
MONITOR C-4 5V SENSOR
MONITOR C-5 CONSOLE B-3
MONITOR C-6 GND SENSOR
MONITOR C-8
MONITOR C-9
MONITOR C-10
MONITOR C-11
MONITOR C-12
MONITOR C-13 BUZZER 1 CONSOLE B-4
MONITOR C-14
MONITOR C-15
CONSOLE B-2 CONSOLE A-4
SLIDE -2
Dr. ZX-3
Dr. ZX-1
CONSOLE A-8
Dr. ZX-2 AIR BLEED
LEARNING SW -2 AIR BLEED PT-3
SWING ALARM -1 AIR BLEED PT-4
EN LOAD AIR BLEED PT-2
AIR BLEED PT-5
BUZZER 2 CONSOLE A-7
EMERGENCY STOP SW-1
CANCEL SW -1 EMERGENCY STOP SW-4 RESISTOR S
CANCEL SW -3 EMERGENCY STOP SW-2 EF Dr ZX-1
MONITOR B-2 INITIAL SETTING GND-2 EF Dr ZX-3
MONITOR B-3
MONITOR B-4
LEARNING SW -1 WIPER E
MONITOR B-1 SLIDE -2
EF Dr ZX-2
MONITOR A-1 CONSOLE A-11 SATELLITE / PC-10 CONSOLE A-12
MONITOR B-5 MONITOR A-2 CONSOLE A-9
INITIAL SETTING -1 MONITOR A-3 WIPER S
MONITOR A-20 MONITOR A-4 SATELLITE / PC-2 SERVICE -M
MONITOR A-5 SATELLITE / PC-1 WIPER P
MONITOR A-6
MONITOR A-7 WIPER B
MONITOR A-19 MONITOR A-8
MONITOR A-9
MONITOR A-10
CONSOLE A-1 EMERGENCY STOP SW -3
RADIO -3
CONSOLE A-3 MONITOR A-13 ICX DR. ZX-1 RESISTOR D-1
MONITOR A-14 ICX DR. ZX-3 RADIO -8 RESISTOR D-2
AIR BLEED PT-1 MONITOR A-15 SATELLITE / PC-3 RADIO -2 RESISTOR D-3
MONITOR A-16 SATELLITE / PC-4 RADIO -5 RESISTOR D-4
MONITOR A-18 RADIO -4 RESISTOR D-6
ICX DR. ZX-2 RADIO -7
SATELLITE / PC-7
SATELLITE / PC-8 CONSOLE A-10
CONSOLE A-2 LIGHTER ( + )
MONITOR B-6
SATELLITE / PC-6
MONITOR B-8
MONITOR B-10 SERVICE -F
MONITOR B-11
MONITOR B-12
MONITOR B-13 SLIDE 5
CONSOLE A-14 24V EMERGENCY STOP VALVE
MONITOR B-15 SLIDE ARM -1
INITIAL SETTING -2
LIGHTER ( - ) EF Dr ZX-4
CONSOLE A-6
CONSOLE B-1 SLIDE 3
MONITOR C-1 CONSOLE A-13
FUSE NO.1,11
R1
FUSE BOX INSTALL A PULLER
(YAZAKI 7147-9178) AND
SPARE FUSES 5A,5A,10A AND 20A
PRINT USAGE AND AMPERE

ON THE COVER.
#4480089
FASTEN WITH TAPE

EMERGENCY SW.
MEASURE HERE SATELLITE / PC
AUX.
RELAY BOX
YAZAKI 7123-7464-40
R1 : LOAD DUMP
R2 : WASHER
R3 : LIGHT 2
connect R4 : LIGHT 1
MONITOR A R5 : HORN
R6 : WIPER
R7 : ML OPT.
R8 : AIR BLEED SWING ALARM
MONITOR B SERVICE RESISTOR D

RESISTOR S
MONITOR C
YAZAKI 7123-2044
CN TYPE
BUZZER
INITINAL SET. GND
SUMITOMO
6030-2981
EN LOAD
TO_E ９０゜
POINT_A
INITINAL SET. CANCEL SW.
LEARNING
YAZAKI 7123-2044
CN TYPE
ALL SIRSUITS MUST BE TIGHTER

MCX
YAZAKI 7123-2044
CN TYPE
AIR BLEED PT
ICX-C,D
TO_C
ALL SIRSUITS MUST BE TIGHTER MCX
A
FASTEN
WITH TAPE
MCX-A
50mm
AIR BLEED
MCX-B D
1. IF NO COMMENT, WIRE 0.3 1.25 MAY BE CAVS AND
MCX-C ICX-A,B WIRE 2 5 MAY BE AVS.
C
MCX-D 2. PIN ARRANGEMENT OF THIS DRAWING
INDICATE VIEW POINT FROM THE
BY USING THE TAPE. BY USING THE TAPE. OTHER SIDE CONNECTOR.
á TURN BACK CONNECTION'S SUR FACE TO C. á TURN BACK CONNECTOR'S SURFACE TO A.
á ON THE LINE OF ICX-A AND B, FASTEN ICX-A AND B WITH á ON THE LINE OF ICX-C AND D, FASTEN ICX-C AND D WITH
IN 50mm FROM I AND IN BETWEEN MCX-A AND B USING A TAPE. IN 50mm FROM I AND IN BETWEEN MCX-C AND D USING A TAPE. 3. NO ELECTRIC JOINT MAY BE BETWEEN FH AND KC.
á VIEW A-A' IS AS FOLLOWS á VIEW B-B' IS AS FOLLOW.
SLIDE ARM

VIEW B-B'
CONSOLE B
VIEW A-A' 6. COLOR SIGN DUE TO JASO D607.
* ICX-C AND D MUST BE UPPER SIDE 7. GENERAL EXPRESS ON THE DRAWING DUE TO #X4259303.
CONSOLE A WHEN MCX-A IS RIGHT SIDE. 8. OUTSIDE DIAMETER OF CORRUGATE TUBE FOR CAB EARTH 1,
CAB EARTH 2, QOS-CON AND G-LIGHTER MUST BE LESS THAN 20mm.
LIGHTER
SLEEVE MUST BE SHORT
SPEAKER
MEASURE HERE
RADIO
HARNESS PULLING
ROOM LAMP
DIRECTION
ZAXIS110/110M/120/130/130LCN ENGINE HARNESS
090 WATERPROOF SLEEVE 090 WATERPROOF SLEEVE

3P FEMALE 3P FEMALE
YAZAKI FL
AM
EP
RO
OTC
OF
OF
&H
RO
ATP
EA
HE
TP
RO
F&
OO
OF
PR
CO
ME
T YAZAKI
FLA
FLAMEPROOF &
FLA
HEATPROOF COT
ME
TRAVEL ALARM-2
PR
OFO
& HE
ATP
RO
OF
CO
LIGHT GND
(WATERPROOF SLEEVE)
T
(WATERPROOF SLEEVE) FLAM FLAMEPROOF & HEATPROOF COT
E PROO
F & HE
ATPR
OOF
COT
EC MOTOR
170(HEARTPROOFVT)
H TYPE
SUMITOMO
(WATERPROOF SLEEVE)
STARTER RELAY
FLAMEPROOF & HEATPROOF COT (WATERPROOF SLEEVE)
HYD. OIL FILTER
(WATERPROOF SLEEVE)
FLAMEPROOF & HEATPROOF COT
TRAVEL ALARM-4
TRAVEL ALARM-3 FLAMEPROOF & HEATPROOF COT
TRAVEL ALARM-1 T YAZAKI
CO
OF
RO
HEATPROOF COT
P
PLUG AT
FLAMEPROOF &
& HE
F
OO
EPR
WATERPROOF SLEEVE AM
FL
SUMITOMO

FLAMEPROOF &
WATERPROOF JOINT-1 HEATPROOF COT
WATERPROOF JOINT-1
WATERPROOF JOINT-1
WATERPROOF JOINT-1 YAZAKI YAZAKI WATERPROOF SLEEVE

WATERPROOF JOINT-1 SUMITOMO
GLOW PLUG
FLAMEPROOF &
HEATPROOF COT
FLAMEPROOF &
HEATPROOF COT
FLAMEPROOF &
HEATPROOF COT
WATERPROOF JOINT-2
YAZAKI
WATERPROOF JOINT-2
WATERPROOF JOINT-2 YAZAKI COOLANT TEMP. SW
WATERPROOF JOINT-2
LEVEL YAZAKI
WATERPROOF JOINT-2
YAZAKI

SUMITOMO
YAZAKI
WATERPROOF JOINT-1 YAZAKI

WATERPROOF JOINT-2
SUMITOMO
FLAMEPROOF &
HEATPROOF COT
OF &
EPRO COT
FLAMTPROOF
EC MOTOR 1 HEA TERMINAL CAP
EC MOTOR 3
FLAMEPROOF &
EC MOTOR 2 FLAMEPROOF & HEATPROOF COT HEATPROOF COT
EC MOTOR 4
(WATERPROOF SLEEVE)
400mm
DO NOT INSTALL A/C (COMPRESSOR)
JOINT IN THIS AREA. YAZAKI
CLAMP

SUMITOMO
PLUG
ASSEMBLE EMPTY PLUG

HYD. OIL FILTER YAZAKI
CLIP
YAZAKI
or EQUIVALENT YAZAKI
10
CLIP
COOLANT TEMP. SW YAZAKI 7047-3241
or EQUIVALENT RED COLOR TAPE
28
0(
CO
T)
SUMITOMO
SUMITOMO
WHITE COLOR TAPE
BATTERY RELAY
YAZAKI
588 597
(WATERPROOF SLEEVE)
AC GLOW RELAY
AMBIENT SENSOR YAZAKI
YAZAKI 090-Ⅱ
7383-7028
GLOW RELAY
YAZAKI 2 USED
BLACK RETAINER
A/C(COMPRESSOR)
AMBIENT SENSOR-1
SCALE POINT
SUMITOMO
CLIP
AMBIENT SENSOR-2
LIGHT GND
MOVE TO THIS SIDE.
090 WATER PROOF YAZAKI RV03FB

SUMITOMO 6189-0031
090 WATER PROOF

SUMITOMO 6189-0031
YAZAKI RV03FB 090 WATER PROOF
EC MOTOR SUMITOMO 6189-0031 090 WATER PROOF
SUMITOMO 6189-0031
YAZAKI RV03FB YAZAKI RV03FB
TRAVEL-2
YAZAKI RV03FB
AMP EJ(2)3P FEMALE

YAZAKI RV03FB
AMP EJ(2)3P FEMALE
(WATER PROOF SLEEVE)

SUMITOMO
6800-3859
TRAVEL-4
TRAVEL-3 PLUG
TRAVEL-1
WATERPROOF JOINT-1
SUMITOMO 6409-2325
FUEL FILTER
LIGHT GND (WATER PROOF SLEEVE) YAZAKI 7323-1424-40
WATERPROOF JOINT-1 (WATER PROOF SLEEVE) WATERPROOF JOINT-2
WATERPROOF JOINT-1 SUMITOMO 6409-2325
WATERPROOF JOINT-1 GLOW PLUG
WATERPROOF JOINT-1 STARTER RELAY
YAZAKI RV03FB (WATER PROOF)
WATERPROOF JOINT-1
WATERPROOF JOINT-2 WATER TEMP. SW.

WATERPROOF JOINT-2 ENG. OIL LEVEL SW. YAZAKI 7323-4714-40
SUMITOMO 6188-0494
WATERPROOF JOINT-2 YAZAKI 7323-7414-40
WATERPROOF JOINT-2
TRAVEL PLUG
7323-1424-40
PLUG
WATERPROOF JOINT-1
6189-0714 TERMINAL CAP
EC MOTOR 1
EC MOTOR 2
EC MOTOR 3
EC MOTOR 4
AC (COMPRESSOR)
YAZAKI 7323-6214-40
FUEL FILTER AC PRESS

SUMITOMO 6189-0533
YAZAKI 7322-4125-50 YAZAKI 7322-4123-30
ASSY 7323-3525-50 ASSY 7323-3527-30
J06MGY ASSY
SUMITOMO 6098-0852
WATER TEMP. 560

BLUE RETAINER NO JOINT
YAZAKI 7323-2228
SUMITOMO
6270-3963
CLAMP
YAZAKI 7323-3010x2
SUMITOMO 6400-7601 AC AMB SENSOR

ASSY AMP EJ(2)2P FEMALE
SUMITOMO 6409-0033 174352-2
SCALE POINT
AIR_FILT SW.
(WATER PROOF)
AC PRESS. SW-1 BATTERY
YAZAKI 7323-2228
AC PRESS. SW-2
AMB. TEMP.SENSOR-1
591 AIR_ FILT-M
AMB. TEMP.SENSOR-2
LIGHT GND CLAMP POINT
090 WATER PROOF

SLEEVE YAZAKI
RV03FB
SUMITOMO
6189-0031 2
1 3
090 WATER PROOF

SLEEVE
220
SUMITOMO YAZAKI 090 WATERPROOF
( HE
6189-0031 RV03FB EC MOTOR SLEEVE 090 WATERPROOF
2 SUMITOMO 6189-0031 SLEEVE
AT
220 3
(HE 1 SUMITOMO 6189-0031
PR
ATP
O
ROO
LIGHT GND YAZAKI
OF
F VT YAZAKI
) RV03FB
VT
(WATER PROOF SLEEVE) RV03FB
)
2
180 MEPR OF CO
(FLAATPRO
BODY_LIGHT 1 1 3
HE
2
OFF-L-I ARM-D-I (WATER PROOF SLEEVE) 1 3
OFF-R-I
BOOM-U 090 WATER PROOF 090 WATER PROOF 090 WATER PROOF
47
TPR RO 160
090 WATER PROOF SLEEVE & )
OO OF &
SLEEVE
SLEEVE (F 0
OT)
0 OF OT
OOF T)
SLEEVE SUMITOMO
HELAM
SUMITOMO SUMITOMO
14 RO F C
FC
SUMITOMO 6189-0032 6189-0032 6189-0032
6189-0032 AT EP EP OO
HEALAMEP
&
PR RO M
OO OF L A PR
YAZAKI F & (F AT
HE
(F
RV03FB CO
2 220 160 T)
1 3
(FLAMEPROOF & (FLAMEPROOF &
YAZAKI HEATPROOF COT) HEATPROOF COT)
TRAVEL ALARM -2 RV03FB
660 (FLAMEPROOF & HEATPROOF COT)

T)
AMP EJ( ) 3P FEMALE
CO
HEATPROOF COT)
OF
2 FUEL/M
(FLAMEPROOF &
RO
1 3
TP
EA
&H
OF
RO
P
ME
460
A
FL
0(
AMP EJ( ) 3P FEMALE
70
36 LA ATP
(F E
0 ME R
H
P R OO
SUMITOMO
O FC
OIL_TEMP/S
O O
6800-3859
F T
& )
PLUG
WATERPROOF 100
(FL
SLEEVE JOINT-1 A
HEA MEPR
SUMITOMO TPR OOF
OO
6409-2325 FC & 500
OT) (FLAMEPROOF &
160
HEATPROOF COT)
HYD. OIL FILTER (FLAMEPROOF & ENG._OIL_P_SW.
HEATPROOF COT)
(WATERPROOF SLEEVE)
WATERPROOF YAZAKI 7323-1424-40
SLEEVE JOINT-2
HEATPROOF COT)
SUMITOMO
(FLAMEPROOF &
6409-2325
)
GLOW PLUG
OT
TRAVEL ALARM -4
FC
STARTER RELAY
TRAVEL ALARM -3
OO
(WATERPROOF SLEEVE)
PR
TRAVEL ALARM -1
100
AT
(FLAMEPROOF &
HE
210
BOOM ANGLE SENSOR HEATPROOF COT)
AP PLUG
&
HYD. OIL TEMP_S
OF
RO
BOOM-D OFF-R OFF-L ARM-C
ASSENBLE
EP
090 WATER PROOF 090 WATER PROOF 090 WATER PROOF 090 WATER PROOF
EMPTY PLUG
AM
SLEEVE SLEEVE SLEEVE SLEEVE
SUMITOMO
(FL
SUMITOMO SUMITOMO SUMITOMO COOLANT TEMP. SW.
WATER PROOF JOINT -1 6189-0031 6189-0031 6189-0031 6189-0031 HYD. OIL TEMP_S
220

SUMITOMO ENG._OIL_LEVEL_SW. YAZAKI 7323-7414-40
WATER PROOF JOINT -1
TRAVEL PLUG 6188-0494 YAZAKI 7323-7414-40
WATER PROOF JOINT -1 ASSY ASSY ASSENBLE
A/C PRESSURE_SW. -1 EMPTY PLUG YAZAKI 7323-1424-40
(FLAMEPROOF & HEATPROOF COT)

A/C PRESSURE_SW. -2
FASTEN
WITH TAPE
LIGHT GND
OT)
SUMITOMO
WATER PROOF JOINT -2 C 6189-0714 TERMINAL CAP
ARM AND OFFSET O OF
WATER PROOF JOINT -2 ANGLE SENSOR EA TPR
F &H
WATER PROOF JOINT -2 SOL. VALVE B5-2 OO &
EPR OF OT)
360
WATER PROOF JOINT -2 SOL. VALVE B8-2 AM RO
(FL 260 AMEP OOF C
WATER PROOF JOINT -2 33 0 (FL ATPR
SOL. VALVE B4-2
HE
SOL. VALVE B7-2
SOL. VALVE B2-2 470 (FLAMEPROOF & HEATPROOF COT)
SOL. VALVE B3-2
SOL. VALVE B6-2 400 1270
WATER PROOF JOINT -1 SOL. VALVE B9-2 HEATPROOF COT) HEATPROOF COT)
WATER PROOF JOINT -2 SOL. VALVE B7-1
SOL. VALVE B9-2 A/C (COMPRESSOR)
YAZAKI 7323-6214-40

SOL. VALVE B6-1
YAZAKI
RV03FB
EC MOTOR 1 PRES. SENSOR 8-2 2
1 3
EC MOTOR 2 PRES. SENSOR 5-2
EC MOTOR 3 ANGLE SENSOR 1-2
PRES. SENSOR 2-2
PRES. SENSOR 6-2
PRES. SENSOR 1-2 A/C PRESSURE_SW.
ANGLE SENSOR 2-5 SUMITOMO 6189-0533
YAZAKI 7322-4125-50 RED COLOR
ASSY 7323-3525-50 YAZAKI 7322-4123-30
ANGLE SENSOR 2-2 TAPE WHITE COLOR ASSY 7323-3527-30
OIL TEMP. SENSOR 1 TAPE
SOL. VALVE B8-1
SOL. VALVE B2-1
SOL. VALVE B3-1
SOL. VALVE B4-1
SOL. VALVE B5-1
GLOW RELAY
YAZAKI 7323-2228
ANGLE SENSOR 1-3
ANGLE SENSOR 2-1
ANGLE SENSOR 2-4
PRES. SENSOR 1-1 CLAMP
PRES. SENSOR 6-1 SUMITOMO
6810-0184 RAD_LEVEL
PRES. SENSOR 7-1
HYD. OIL FILTER PRES. SENSOR 8-1 GLOW RELAY
PRES. SENSOR 2-1 YAZAKI
7323-3010×2ヶ
PRES. SENSOR 5-1
ANGLE SENSOR 1-1
COOLANT TEMP SW. ANGLE SENSOR 2-3
ANGLE SENSOR 2-6
PRES. SENSOR 1-3
PRES. SENSOR 6-3 AIR FILT. SW.
PRES. SENSOR 7-3 (WATERPROOF SLEEVE)
PRES. SENSOR 8-3
WASHER
PRES. SENSOR 2-3 YAZAKI BATTERY RELAY
PRES. SENSOR 5-3 7323-2228
OIL TEMP. SENSOR 2
CLAMP A, B, C
ZAXIS110/110M/120/130/130LCN MONITOR HARNESS CAUTION: Parts numbers on the drawing are provided only for reference purpose.
MONITOR A-8 CAB A-7
WIPER E CAB C-12
MONITOR A-2 CAB A-1

MONITOR A-3 CAB A-2
MONITOR A-4 CAB A-3
MONITOR A-5 CAB A-4
MONITOR A-6 CAB A-5
MONITOR A-7 CAB A-6
MONITOR A-10
MONITOR A-11 CAB B-16
MONITOR A-14 BUZZER 2

WIPER
MONITOR B-1 CAB A-8

MONITOR B-2 CAB A-9
MONITOR B-3 CAB A-10
MONITOR B-5 CAB C-4 CAB A

MONITOR B-7 CAB A-13 MONITOR A
CONNECT
MONITOR B-11 CAB B-1
MONITOR B-12 CAB B-2 CAB B MONITOR B
MONITOR B-16
MONITOR B-17 MONITOR C
CAB C
MONITOR B-20 CAB B-8 TAPE
MONITOR C-1 CAB B-9

MONITOR C-2 CAB B-10
MONITOR C-5 CAB B-13 BUZZER

MONITOR C-8 CAB C-16
MONITOR C-9 CAB C-1
MONITOR C-12 CAB A-11

WIPER L CAB C-9

WIPER S CAB C-11
WIPER B CAB C-10
WIPER M CAB C-8
SOLAR-RADIATION SENSOR-1 CAB C-13
OFFSET SW-3
RESTRICTION DEACT. SW.-GND
CRANE SW-3
CRANE SW-1
NOTE
1. WIRE SHALLBE CAVS ,IF NO COMMENT.
2. PUT THE LABEL FOR THE HARNESS.

IC/U BUZZER 1
OFFSET SW-2 3. SYMBOL OF THES DROWING DUE TO #4259303
RESTRICTION DEACT. SW.-S
4. NO ELECTRIC TURNING POINT MAY BE BETWEEN
EMERGENCY STOP SOL-1
A-HORN SW ,A-EMERGENCY STOP SOL.
OFFSET SW-1
IC/U BUZZER 2
EMERGENCY STOP SOL.

090 WATER PROOF SLEEVE
SUMITOMO 6189-0031
CRANE SW.
SUMITOMO
6242-5061
RESTRICTION
DEACT. SW.
OFFSET SW
IC/U BUZZER
SUMITOMO
6030-2981
TR/MO TR/MO
SH SW/MO
M
A B
A B A B
SL SN SM SK T3
PROPEL RH 1
RR
RF P1
2
B8
4
LR
T A8
TRAVEL;L
TRAVEL;R
P 12 RR 11 RF
LF
9 LF 10 LR
3 B1
A5
T3 T4
PROPEL LH A1
T1
DK
B7
T2
VALVE
COMB-
FUNCTION
A1 A7
P AUX
A2
7 BKT IN 8 BKT OUT
A3
13 AUX B
14 AUX A
A4
BUCKET
B2
SY
A2
BKT CYL.
DY
PI1 SEC.BOOM
PRIM.BOOM
2 BM DWN 1 BM UP
TO 1
B3
ARM CYL.
A3
B6
PI2
ZAXIS110/110M/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM
A6
PRIM.ARM
4 ARM IN
3 ARM OUT
BOOM CYL.
SC TO 3
PI3
SEC.ARM
A4
SJ
B5
PF
PG A5 A9 DC DH T2
SWING
DY
5 SW L 6 SW R
SC
DD
ARM FLOW
DH
T1 P2
SI
DX
TR. SPEED
DS PD
VALVE SOL.
PD2 PD1
PA
PA
Eng.
PE
PF
PUMP FL PUMP PQ
PG
for the relief valve pressure setting valve.
PC
PD
TA
SB
SA
PC1 PC2
Note:Refer to the PEFORMANCE STANDARD in the technical manual
N 14
SM TR/MO TR/MO
M 13 DB
5
E SW L
BUCKET S3
F SW R 6
3 SH SW/MO
IN
G BKT IN 7
OUT 1 M
H BKT OUT 8
4
SE
UP
T
P A B
SL
DOWN
2
SH
BOOM A BOOM UP 1
ARM SK
3
A B A B
OUT
SB
IN
1
4 B BOOM DWN 2
L C ARM OUT 3
T
P
SP
R SN
2
SWING SL SN SM SK T3
SA
PROPEL RH D
1 ARM IN 4
L
RR
12
RF K 11 P1
2
TR B8
4 J
10
LR
T I A8
9 TRAVEL;L
TRAVEL;R
P 12 RR 11 RF
LF
9 LF 10 LR
PH DF
3 B1
A4
T3 T4
PROPEL LH A1
T1
DK
B7
VALVE
COMB-
T2
FUNCTION
A1 A7
P AUX
A2
7 BKT IN 8 BKT OUT
A3 13 AUX B
14 AUX A
BUCKET
B2
SY
A2
DY
BKT CYL.
PI1 SEC.BOOM
PRIM.BOOM
2 BM DWN 1 BM UP
TO 1
B3
ARM CYL.
A3
B6
PI2
A6
PRIM.ARM
4 ARM IN
3 ARM OUT
BOOM CYL.
SC TO 3
PI3
SEC.ARM
A4
SJ
B5
PF
PG A5 A9 DC DH T2
SWING
DY
5 SW L 6 SW R
SC
DD
ARM FLOW
P2
DH T1
SI
DX
TR. SPEED
DS PD
VALVE SOL.
PD2 PD1
PA
Eng.
PA
PE
PF
PUMP FL PUMP PQ
PG
PC
PD
TA
SB
SA
PC1 PC2
Attach to Vol. No.: TT187E-04 Note:Refer to the PEFORMANCE STANDARD in the technical manual
VALVE SOL.(OPT)
MEMO
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Fax: 81-298-31-1162

PUBLECATION NO.:
PAGE NO.:
FAX:

REPLY:

THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
ZAXIS110/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM
ZAXIS110/120/130/130LCN CONNECTORS
ZAXIS125US/135US ELECTRICAL CIRCUIT DIAGRAM
ZAXIS125US/135US CONNECTORS
ZAXIS135UR ELECTRICAL CIRCUIT DIAGRAM
ZAXIS110/120/130/130LCN CAB HARNESS
ZAXIS125US/135US CAB HARNESS
ZAXIS135UR CAB HARNESS
ZAXIS110/120/130/130LCN ENGINE HARNESS
ZAXIS110/120/130/130LCN MONITOR HARNESS
ZAXIS110/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM

ZAXIS110/110M/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM

LUBRICATOR
CAB OUTSIDE CAB INSIDE

OPTION(330)
LUBRICATOR
MONITOR
CAB INSIDE CAB OUTSIDE
CONTROLLER MONITOR
STARTER SWITCH
MONITOR
POWER IN-PUT
BUCK UP POWER IN-PUT POWER
WATER TENP. SWITCH GLOW IN-PUT CIRCUIT HOUR METER DATA COMMUNICATION OUT-PUT
COMMUNICATION SW.
SERIAL COMMUNICATION RXD
REG IN-PUT SATELLITE/PC
CONNECTION SW.
INTERIOR
INTERIOR LAMP
POWER ON SIGNAL
LAMP
POWER-IN
REG. IN-PUT
FUSIBLE LINK(45A) BATT.(DIRECT) COOLANT TEMP. FUEL
BUCK UP
BATTERY 12V X 2 WIPER SIGNAL IN-PUT
ACC(LOAD)
120 GROUP
BATTERY RELAY ALT(LOAD) WIPER SIGNAL IN-PUT(GND)
LIQUID
CRYSTAL PANEL
OVER-HEAT
FUSIBLE LINK(65A)
LOAD DUMP FUSE AIR FILTER
RELAY
FUEL
GLOW
LIGHT
WIPER
HEATER
HORN
RADIO
LIGHTER
ROOM LIGHT
AUX.
GLOW/R
BACK-UP
CONTROLLER
EC MOTOR
SOLENOID
SWITCH BOX
POWER ON SIGNAL
AIR-CON.
STARTER WIRING TOOL WORK LIGHT
DISPLAY CHANGE MAIN
SAFETY RELAY COMPLETED CHARGE
POWER
(120 GROUP) SET ENG. OIL LEVEL CONTROLLER
MONITOR
SPARE 1
ROOM LIGHT WORK MODE MAIN
SPARE 2 GND
WIPER MOTOR ENG. OIL LEVEL
WIRING COMPLETED
120 GROUP
COOLANT LEVEL
AUTO RE-FUELING LIGHTER

HYD.OIL FILTER
SYSTEM SPARE 4 B9:MONITOR COMMUNICATION GND
C10:MCX COMMUNICATION GND
SPARE 6

ALTERNATOR HYD. OIL FILTER SW. IN-PUT
SPARE 4 EXT. HYD. OIL FILTER WARNING #4448754
GLOW RELAY OPTION
LIGHT 1
LIGHT 2
CHARGE EXT.
SPEAKER R SPARE 2 SW. IN-PUT RADIATOR LEVEL SW. #4153251
WARNING LAMP LOCATION AIR FILTER RESTRICTION SW. IN-PUT
SPARE 5 EXT. AIR CLEANER RESTRICTION SW. #4224238
NO.12 IS OPT., NO.5 IS NOT USE (120 GROUP #4334759)
WORK LIGHT SW. IN-PUT
FUEL
REGULATOR SPEAKER L GLOW EXT.
WIPER
ENG. OIL LEVEL EXT.
RADIO COOLANT LEVEL EXT.
GLOW PLUG
FUEL SIGNAL
COOLANT TEMP. SIGNAL FUEL SENSOR #4257128
AUTO- AUTO-IDLE DIGGING ATTACHMENT COOLANT TEMP SENSOR #4436537
ENG. OIL LEVEL SW.(ON ENG.) #4371903
RELAY DRIVE CIRCUIT

LIGHT 1 RELAY OUT-PUT WIPER, WASHER MOVE SIGNAL OUT-PUT ENG. OIL PRESSURE SW.(ON ENG.) #*******
WIPER C RELAY OUT-PUT SPARE 1 SW. IN-PUT
WIPER B RELAY OUT-PUT
WIPER A RELAY OUT-PUT OVER-HEAT SW. IN-PUT
WASHER RELAY OUT-PUT ENG. OIL LEVEL SW. IN-PUT OVER-HEAT SW. #4371318
WIPER WIPER WIPER WIPER AUTO-IDLE SW. IN-PUT AUTO-IDLE
PULL-UP
A/I A/A SW
RELAY A RELAY B RELAY B1 RELAY B2 AUTO-ACCELERATION SW. IN-PUT AUTO-ACCELERATION WASHER SW.
WASHER SW. IN-PUT
LIGHT SW. 2 IN-PUT
LIGHT SW. 1 IN-PUT
LIGHT SW.
BACK-UP EN SW. IN-PUT
HOUR METER GROUND
INTERIOR LIGHT
INTERIOR LIGHT
POWER IN-PUT
BUZZER SIGNAL
WASHER ENG. SPEED CONTROL DIAL
FRONT WINDOW UP-ON HIGH-SPEED

LIGHT RELAY 2
NORMAL OPEN HP, P, E MODE SW.
SWITCH BOX
BOOM LIGHT
LIGHT RELAY 1
WORK LIGHT ZX200, ZX225USR ADDITIONAL PUMP ELECTRICAL DIAGRAM

PROPORTIONAL SOL-2
PROPORTIONAL SOL-1
ARM DUMP PILOT(S)

PRESSURE
SENSOR (H)
HORN RELAY
HORN SIDE/
MALE ON
BOTH SIDE HORN (H)
HORN SWITCH
ML-CRANE BOOM DUMPING

(JAPANESE DOMESTIC ONLY) (JAPANESE DOMESTIC ONLY) SWING ALARM
HORN (L)
TRAVEL ALARM
BOOM ROD SIDE PRESSURE (S)

TRAVEL ALARM
OPTION
ARM DUMP PILOT (S)

OPTION
INITIAL SETTING SW.
BOOM BOTTOM (S)
BOOM BOTTOM (S)

CRANE MODE SW.
LOAD ALARM: EN
BOOM ANGLE (S)
SWING OUT-PUT
ARM ANGLE (S)
TO MCX CONNECTOR
LEARNING SW.
POWER DIGGING SW. CANCEL SW.
PRESSURE SWITCH
SOLAR RADIATION
GROUP ONLY SENSOR NATURAL
COMPRESSOR
SUB HARNESS
GROUP
MONITOR
KEY MAIN SOLENOID EC MOTOR

SIGNAL POWER POWER POWER
SOLAR RADIATION
SENSOR
CONTROLLER
EC MOTOR
MAIN SOLENOID
AIR-CON. UNIT GND GND
AMBIENT SENSOR
GROUP
BOOM DUMPING
SEALED WIRE
RE-GENERATION
PUMP TORQUE
ANGLE LIMIT
ANGLE LIMIT
PUMP 2 TILT
PUMP 1 TILT
DUMPENER
OIL TEMP. SENSOR

AUX. FLOW
ARM FLOW
DIGGING
2-SPEED
TRAVEL
POWER
BOOM
CONTROL 1
CONTROL 2
PRESSURE
ARM
PUMP
PUMP
SENSOR 2 PRESSURE
CAB INSIDE CAB OUTSIDE SENSOR 1
EC MOTOR EC ANGLE
SENSOR PUMP 2 PUMP 1
N SENSOR PRESSURE PRESSURE ARM BOOM
VALVE SOLENOID PUMP MOTOR TRAVEL SWING FRONT ROLL-IN
SOLENOID SENSOR (L) PRESSURE SENSOR (L) PRESSURE RAISE
SENSOR (H) SENSOR (H)
OPTION
PRESSURE SENSOR (LOW)
Up to serial No. 010576 (ZAXIS110/110M)

OPTION

ZAXIS110/110M/120/130/130LCN CONNECTORS
THESE CONNECTORS ARE THE HARNESS END CAUTION: Parts numbers on the drawing are provided only for reference purpose.
CONNECTORS, UNLESS OTHERWISE SPECIFIED. To order parts on the drawing, be sure to consult the Parts Catalog.
FUEL GAUGE BUZZAR CANCEL SW. AMBIENT SENSOR SOLAR-RADIATION SENSOR

(TRAVEL ALARM) (120 GROUP) (120 GROUP)
YAZAKI YAZAKI
YAZAKI 7323-2064
QOS CONTROLER COMPRESSOR PUMP/H(ENG SIDE) AMBIENT SENSOR SOLAR-RADIATION SENSOR AIR-CON PRESSURE SW.
(200 GROUP) (200 GROUP) (200 GROUP)
LOCK
2P FEMALE
YAZAKI 7123-7464-40 YAZAKI 7323-6214-40 SUMITOMO 6188-0494 SUMITOMO 6189-0533
DIODE SPEAKER PRESSURE SENSOR(L) GLOW RELAY OPTION POWER WWES

SWING ALARM
WATER PROOF PLUG CONNECTOR

MALE SHARE PLUG
YAZAKI 7113-1020
WATER PROOF CAP
YAZAKI 7120-8018
FEMALE RECEPTACLE
YAZAKI YAZAKI GROUND YAZAKI 7115-1050
YAZAKI 7283-1223-30 YAZAKI RV03FB YAZAKI 7323-2044 WATER PROOF CAP
YAZAKI 7120-1157
CONNECTOR
ALTERNATOR LEARNING SW. BOOM DUMPING FLAT TERMINAL
PRESSURE SENSOR(H) SOLENOID WIPER(CAB/H-SIDE) HYD. OIL TEMP. SENSOR WASHER
(ENG. OIL PRESS. SW.)
LOCK WITH LOCK
AMP 172320-2
3P-FEMALE SUMITOMO 6189-0031 (CN. WITH OUT LOCK) YAZAKI 7323-1424-40
RELAY EO LEVEL RAD. LAVEL N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. WIPER
COOLANT TENP. SW. BOOM DUMPING
SUMITOMO 6098-1493 YAZAKI 7323-7414-40 SUMITOMO 6189-0133 ALTERNATOR

*COOLANT LEVEL SW
ML-CRANE WASHER
RADIO GLOW RELAY
STARTER RELAY
BATTERY RELAY
DETAIL 1 AIR CLEANER RESTRICTION SW
BODY LIGHT
FUEL GAUGE
DIODE(1, 3)
YAZAKI 7123-1402
EARTH LINE WIPER
HORN SW
MCX-A MCX-B MCX-C MCX-D LEARNING SW
CAB
RADIO
AUX. POWER
BOOM DUMPING POWER LIGHTER
MONITOR
AIR-CON
TRAVEL ALARM
MONITOR A (CAB/H SIDE) MONITOR B (CAB/H SIDE) MONITOR C (CAB/H SIDE)
ADDITIONAL PUMP ATT1
ADDITIONAL PUMP ATT2 CONTROL SYSTEM
GROUND LINE
POWER DIGGING SW
MONITOR A MONITOR B MONITOR C SATELLITE/PC

DETAIL 2
CAB COVER
FLAME
NOTE : Up to serial No. 010576 (ZAXIS110)

ZAXIS125US/135US ELECTRICAL CIRCUIT DIAGRAM To order parts on the drawing, be sure to consult the Parts Catalog.
CAB OUTSIDE CAB INSIDE CAB INSIDE CAB OUTSIDE

STARTER SWITCH
CONTROLLER
MONITOR
POWER IN-PUT
BUCK UP POWER IN-PUT POWER HOUR METER DATA
WATER TENP. SWITCH GLOW IN-PUT CIRCUIT COMMUNICATION OUT-PUT
COMMUNICATION SW.
CONSOLE SERIAL COMMUNICATION RXD ICX Dr. ZX
CONNECTION SW.
POWER ON SIGNAL
REG IN-PUT INTERIOR SATELLITE/PC
LAMP INTERIOR LAMP
POWER-IN
REG. IN-PUT
FUSIBLE LINK(45A) COOLANT FUEL
BATT.(DIRECT) TEMP
BACK UP
BATTERY WIPER SIGNAL IN-PUT
BATTERY RELAY LIGHT WIPER SIGNAL IN-PUT(GND)
GROUP
FUSIBLE LINK(65A) LIQUID CRYSTAL PANEL
OVER-HEAT
LOAD DUMP FUSE
AIR FILTER
RELAY
FUEL
BACK-UP
CONTROLLER
SOLENOID
SWITCH BOX
POWER ON SIGNAL
AIR-CON.
EC-MOTOR
GLOW
LIGHT
WIPER
HEATER
HORN
RADIO
LIGHTER
ROOM LIGHT
AUX.
GLOW/R
TOOL
WORK LIGHT
STARTER WIRING MAIN
SAFETY RELAY COMPLETED DISPLAY CHANGE CHARGE POWER
GROUP ENG. OIL LEVEL CONTROLLER
SET
SPARE 1 MAIN
ROOM LIGHT WORK MODE GND
WIPER SUB 1 SPARE 2
WIPER MOTOR DOOR SWITCH
WIPER ENG. OIL LEVEL
GROUP
COOLANT LEVEL
HYD. OIL FILTER B9:MONITOR
LIGHTER COMMUNICATION GND
AUTO RE-FUELING SPARE 4
C10:MCX
SPARE 5 COMMUNICATION
GND
CONSOLE
SPEAKER R HYD. OIL FILTER SW. IN-PUT
ALTERNATOR GLOW SPARE 4 EXT.
HYD. OIL FILTER WARNING
RELAY OPTION
LIGHT 1
LIGHT 2
CHARGE EXT.
SPARE 2 SW. IN-PUT
AIR FILTER RESTRICTION SW. IN-PUT
RADIATOR LEVEL SW.
WARNIG LAMP LOCATION AIR CLEANER RESTRICTION SW.
SPARE 5 EXT.
NO.12 IS OPT., NO.5 IS NOT USE WORK LIGHT SW. IN-PUT GROUP
WIPER MOTOR WIPER SUB 2 FUEL EXT.
REGULATOR GLOW EXT.
ENG. OIL LEVEL EXT.
RADIO SPEAKER L COOLANT LEVEL EXT.
GLOW PLUG CONSOLE FUEL SIGNAL
FUEL SENSOR
COOLANT TEMP. SIGNAL COOLANT TEMP. SENSOR
AUTO- AUTO-IDLE DIGGING ATTACHMENT
ENG. OIL LEVEL SW.(ON ENG.)
LIGHT 1 RELAY OUT-PUT ENG. OIL PRESSURE SW.(ON ENG.)
RELAY DRIVE
WIPER, WASHER MOVE SIGNAL OUT-PUT
CIRCUIT
LIGHT C RELAY OUT-PUT SPARE 1 SW. IN-PUT
LIGHT B RELAY OUT-PUT
LIGHT A RELAY OUT-PUT
OVER-HEAT SW. IN-PUT
WASHER RELAY OUT-PUT
ENG. OIL LEVEL SW. IN-PUT OVER-HEAT SW.
PULL-UP
WIPER AUTO-IDLE SW. IN-PUT AUTO-IDLE
RELAY A AUTO-ACCELERATION SW. IN-PUT AUTO-ACCELERATION
A/I A/A SW
WASHER SW. IN-PUT WASHER SW.
LIGHT SW. 2 IN-PUT
LIGHT SW. 1 IN-PUT
BACK-UP EN SW. IN-PUT LIGHT SW.
HOUR METER GROUND
INTERIOR LIGHT
INTERIOR LIGHT
POWER IN-PUT
SIGNAL
WASHER BUZZER
ENG. SPEED
CONTROL DIAL
HIGH-SPEED
LIGHT RELAY 2
NORMAL OPEN HP,P,E MODE SW.

SWITCH BOX
SWITCH BOX
BOOM LIGHT
CONSOLE
LIGHT RELAY 1
WORK LIGHT
PRESSURE SWITCH
CONSOLE
(ASSY)
HORN RELAY
HORN SWITCH
COMPRESSOR
ML-CRANE
HORN SIDE/ (JAPANESE DOMESTIC ONLY)
MALE ON
BOTH SIDE HORN (H) BOOM DUMPING
SEPARATE CONSOLE A2 (JAPANESE DOMESTIC ONLY) SWING ALARM
BOOM ROD SIDE PRESSURE(S)

TRAVEL ALARM
TRAVEL ALARM
OPTION
HORN (L)
ARM DUMP PILOT(S)
INITIAL SETTING SW.

OPTION
CRANE MODE SW.
BOOM BOTTOM(S)
BOOM BOTTOM(S)
LOAD ALARM:EN
SWING OUT-PUT
BOOM ANGLE(S)
ARM ANGLE(S)
LEARNING SW.
POWER DIGGING SW. Dr. ZX
CANCEL SW.
LO
CONSOLE
REGISTER HEATER CONTROLLER
MACHINE
SELECTION
KEY MAIN SOLENOID EC-MOTOR

IN DETAILS:COMMON TO A/C SIGNAL POWER POWER POWER
OPTION
3 IS DIFFERENT
CONTROLLER
MAIN EC-MOTOR
SOLENOID
GND GND
AIR-CON. CONTROLLER
SENSOR
GND
TEMP. BOOM DUMPING
HUSE SEALED
WIRE
CIRC AIR SENSOR
AMBIENT SENSOR
SOLAR
RADIATION
SENSOR
GENERATION
TORQUE
THERMISTER
DUMPENER
AUX. FOLW
PUMP
PUMP
FLOW
OIL TEMP.
2-SPEED
SENSOR 1
PRESSURE
TILT ANGLE
TRAVEL
ARM RE-
SENSOR
PUMP 1
CONTROL 1
PUMP
CONTROL 2
PUMP
PRESSURE
LIMIT
SENSOR
SENSOR 2
BOOM
LO REGISTER CAB INSIDE CAB OUTSIDE EC

N
PUMP EC-MOTOR ANGLE

VALVE SOLENOID SENSOR
SOLENOID PUMP 2 PUMP 1
MOTOR TRAVEL SWING FRONT ARM BOOM BOOM
PRESSURE PRESSURE PRESSURE PRESSURE ROLL-IN RAISE ANGLE
AIR-CON UNIT SENSOR(L) SENSOR(H) SENSOR(L) SENSOR(H)
OPTION
PRESSURE SENSOR(L) ANGLE SENSOR
ONLY ZAXIS225US
ZAXIS125US/135US CONNECTORS To order parts on the drawing, be sure to consult the Parts Catalog.

CONNECTORS, UNLESS OTHERWISE SPECIFIED.
YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI
WIPER MOTOR WIPER SUB2 DOOR SW. WIPER SUB1 CANCEL SW. BUZZER CIRC AIR SENSOR
MOTOR SIDE : M MOTOR SIDE : M CAB/H SIDE : F CAB/H SIDE : F TRAVEL ALARM
SUB1
SUB2
ROOF
SUMITOMO YAZAKI NILES YAZAKI YAZAKI GLASS DOOR SW
QOS CONTROLLOR COMPRESSOR PUMP/H(ENG. SIDE) AMBIENT SENSOR SOLAR RADIATION SENSOR A/C PRESSURE SW.
MOTOR
WIPER
LOCK
2P F
YAZAKI YAZAKI SUMITOMO SUMITOMO
DIODE SPEAKER PRESS. SENSOR(L) GLOW RELAY OPT. POWER WWES SWING ALARM
WATER PROOF CONNECTOR

MALE SHARE PLUG
YAZAKI YAZAKI YAZAKI
WATER PROOF CAP
YAZAKI YAZAKI YAZAKI YAZAKI
FEMALE RECEPTACLE
GROUND YAZAKI
PRESS. SENSOR(H) SOLENOID FUEL GAUGE HYD. OIL TEMP. SENSOR WASHER ALTERNATOR LEARNING SW. BOOM DUMPING WATER PROOF CAP
ENG. OIL PRESSURE SW. YAZAKI
LOCK CONNECTOR
FLAT TERMINAL

WITH LOCK
AMP 172320-2
3P F SUMITOMO CN. WITHOUT LOCK YAZAKI
GP RELAY EO LEVEL RAD. LEVEL N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. WIPER
COOLANT TEMP.SW. BOOM DUMPING CAB/H SIDE : F
ALTERNETOR
*RAD. LEVEL SW.
DETAIL 1 WASHER
GLOW RELAY
STARTER RELAY
BATTERY RELAY
BODY LIGHT
FUEL GAUGE
SUMITOMO YAZAKI YAZAKI
AIR-CON. CONTROLLER(1) AIR-CON. CONTROLLER(2) ML CLANE RADIO DIODE

HEATER CONTROLLER(1) HEATER CONTROLLER(2)
EARTH LINE WIPER
HORN SW.
AIR-CON.
A/C BOX RADIO
YAZAKI AUX. POWER

LIGHTER
POWER
MONITOR
TRAVEL ALARM
ML CLANE
CONTROL SYSTEM GROUND LINE

POWER DIGGING SW.
LEARNING SW.
BOOM DUMPING
CONSOLE A(CAB/H SIDE) CONSOLE C(CAB/H SIDE) SW-BOX
CONSOLE B(CAB/H SIDE)
DETAIL 2
MONITOR A MONITOR B MONITOR C SATELLITE/PC C/U BRACKET
FRAME
NOTE : Up to serial No. 010576 (ZAXIS125US)

ZAXIS135UR ELECTRICAL CIRCUIT DIAGRAM CAUTION: Parts numbers on the drawing are provided only for reference purpose.
COOLANT TEMP. SW.
STARTER SW.
RESISTER S
RESISTER D
EMERGENCY
EVACUATION SW.
K
A
RESISTER
K
STARTER SW.
A
FUSIBLE LINK (45A)
OPT DECEL.
NOT IN SMJ 2-9 OUT 1-32
BATTERY 12V×2 ACC (LOAD) EMERGENCY
BATTERY RELAY
IN 1-18 ACCEL.
ALT (LOAD) EVACUATION
4-2 RECEPTION (+) OUT 1-29
LCD 4-11 TRANSMISSION (+) SW.
FUSIBLE LINK (65A)
IN 1-7 ACCEL.
AUTO LOAD DUMP DISPLAY 4-3 RECEPTION (-)
RE-FUELING 4-12 TRANSMISSION (-) OUT 1-10
SYSTEM RELAY IN 1-5 DECEL.
OUT 1-23
IN 1-16 DECEL.
MONITOR
HORN
LIGHT
WIPER
AIR-CON.
AUX.
ROOM LIGHT, LIGHTER, RADIO

HEATER
BACK-UP
LCD MONITOR
EMERGENCY SW.
GLOW
POWER IN-OUT OUT 1-24
BACK-UP POWER IN-PUT POWER DECEL.
GLOW IN-PUT CIRCUIT
IN 1-17
STARTER SERIAL COMMUNICATION TXD
SAFETY RELAY
GND SERIAL COMMUNICATION RXD OUT 1-11
SERIAL COMMUNICATION 2TXD- IN 1-6 DECEL.
WASHER SERIAL COMMUNICATION 2TXD+
REG IN-PUT SERIAL COMMUNICATION 2RXD+
GLOW RELAY SERIAL COMMUNICATION 2RXD- 3-10 OFFSET-LEFT OUT 1-30
2-2 OFFSET-RIGHT IN 1-19 ACCEL.
WASHER CAB OUT
RELAY 2-14 RESTRICTION SW. OUT 1-31
CAB IN ROOM LIGHT COOLANT
FUEL
IN 1-20
POWER-ON SIGNAL
TEMP. ACCEL.
LIQUID EC DIAL SIGNAL IN-PUT OPT
CRYSTAL EC DIAL SIGNAL IN-PUT (GND) RIGHT CONTROL OUT 1-22
EC MOTOR
PANEL LEVEL IN 1-15 DECEL.
WIPER L1 : LOAD ALARM
RELAY
L2 : STROKE END 2-12 INITIAL SETTING 5V (PRES.) 2-19
××× ×××× ×××× ××
L3 : HOOK
3B
BOOM RAIS. PRES. 3-17 BOOM RAIS. PRES.
ALTERNATOR
L4 : ARM VERTICALITY A 6 GND (PRES.) 2-21
××
L5 : ENG. OIL PRESS.
××
DISPLAY CHANGE
2-3 SERVICE SW. ARM DUMP PRES. 3-15 ARM DUMP PRES. 2
LIGHT
L6 : OVER-HEAT
××××× 1-25 GND (RELAY) ARM ROLL-IN DECEL. PRES. 3-6
××× SET L7 : FUEL
BOOM LOWER DECEL. PRES. 3-16 ARM ROLL-IN DECEL. PRES. 5
K
××× WORK MODE

L8 : CHARGE 1-26 BUZZER
×× L9 : AIR FILTER 2-4 SWING MODE OFFSET RIGHT ACCEL. PRES. 3-12
A
RADIO LIGHT IC/U BUZZER

GLOW PLUG WIPER MOTOR ××× L10 : GLOW
××
L11 : HYD. OIL FILTER
OFFSET LEFT ACCEL. PRES. 3-2 BOOM LOWER DECEL. PRES. 6
AUTO M
L12 : SPARE BOOM RAISE ACCEL. PRES. 3-5
TRAVEL SW
REGULATOR HYD. OIL FILTER SW. IN-PUT OFFSET RIGHT ACCEL. PRES. 7
SPARE
CHARGE EXT
WASHER
AIR FILTER SW. IN-PUT OFFSET LEFT ACCEL. PRES. 8
CRANE MODE SW. 2-13 CONNECT DETECTION
FUEL EXT
WIPER
GLOW EXT
4-9 TRANSMISSION
WARNING LAMP LOCATION 4-10 RECEPTION
BOOM RAISE
HIGH- LOW- ACCEL. PRES.
SPEED SPEED FUEL SIGNAL
HORN RELAY COOLANT TEMP SIGNAL 3-11 SLIDE SENSOR
2-15 ARM RETRACT OPT
AUTO - MARCCINO
135UR ONLY 2-6 ARM EXTEND EMERGENCY HYD. OIL TEMP. SENSOR
HORN SW LIGHT TRAVEL MODE
STOP SOL.
AUTO M WIPER
AUTO - IDLE
SLIDE ARM 2-16
HP MODE EMERGENCY STOP
SOL. VALVE
E MODE
HORN SIDE LOAD DUMP RELAY OUT-PUT AUTO - IDLE
MALE ON SATELLITE / PC LIGHT 1 RELAY OUT-PUT WORK MODE
RELAY DRIVE
HORN WIPER RELAY OUT-PUT

BOTH SIDE WASHER RELAY OUT-PUT ML MODE 1
CURCUIT
LIGHT RELAY 2 ML1 RELAY OUT-PUT BOOM ANGLE SENSOR

ML2 RELAY OUT-PUT
ML3 RELAY OUT-PUT
ML4 RELAY OUT-PUT ARM ANGLE SENSOR
(NORMAL OPEN ML CONNECT)

PULL - UP
ML SWITCH
(BOOM LIGHT) ML - MODE 2 OFFSET ANGLE SENSOR
BUCK UP EN
ENG. OIL PRES. SW. IN-PUT
LIGHT RELAY 1 OVER - HEAT SW. IN-PUT
HOUR METER GND.
ENG. SPEED BOOM ROD
PRESSURE (S)
CONTROL DIAL
INITIAL BOOM BOTTOM

(WORK LIGHT) PRESSURE (S)
SETTING SW.
NORMAL OPEN OPT
ARM ROLL-OUT PRES. (S)

COOLANT TEMP. SENSOR
FUEL SENSOR
OVER-HEAT SW.
HYD. OIL FILTER WARNING (OPT)
LEARNING SW.
ML RELAY
SWING
A NATURAL ALARM
BUCKET LOCK SOL.
ML LIGHT
SOL. PUMP AUTO

AIR BLEED
A
OPTION
SEALED WIRE
CANCEL SW.
PRESSURE SWITCH
HYD. OIL TEMP. SENSOR

ANGLELIMIT
PUMP 1
TORQUE
PUMP
ANGLELIMIT
PUMP 2
AUX. FLOW
OUTSIDE INSIDE N-SENSOR

COMPRESSOR
CONTROL 2
PUMP
CONTROL 1
PUMP
INSIDE OUTSIDE OPTION TRAVEL FRONT SWING SWING ARM BOOM
ROLL-IN RAISE
OPTION
Attach to vol. No. : TT187E-04
CONNECTORS, UNLESS OTHERWISE SPECIFIED
RESISTOR S FUEL GAUGE LCD DISPLAY (2) LCD LAMP (2) CANCEL SW. ML CRANE
(TRAVEL ALARM)

YAZAKI 7323-2064 SUMITOMO 6242-5061
QOS CONTROLLER MONITOR BUZZER BOOM ANGLE SENSOR INITIAL SETTING RADIO SUB/H. (CAB/H SIDE)
IC/U BUZZER
EFCT SUB/H. (CAB SIDE)
YAZAKI 7123-7464-40 SUMITOMO 6030-2981
DIODE SPEAKER PRESS. SENSOR (L) DR. ZX (MC, UR, ICX) GLOW RELAY OPT. POWER
WWES SWING ALARM
YAZAKI YAZAKI
YAZAKI 7283-1223-30 YAZAKI RV03FB YAZAKI 7323-2044 7323-2228 7323-3010
PRESS. SENSOR (H) SOLENOID FRONT ANGLE SENSOR HYD. OIL TEMP. SENSOR WASHER ALTERNATOR LEARNING SW. CONSOLE B (CAB/H SIDE)
RELAY/H (ENG-OIL PRESSURE SW.)
LOCK
AMP EJ <> 070 YAZAKI 7232-1424-40

3PF SUMITOMO 6189-0031 (CN WITH OUT LOCK)
GP RELAY COOLANT TEMP. SW. N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. SLIDE ARM
ARM ANGLE SENSOR RESISTOR D
OFFSET ANGLE SENSOR
SUMITOMO 6098-1493 YAZAKI 7323-7414-40
AUTO AIR BLEED PT

RADIO
YAZAKI 7123-1402
CONSOLE A (CON A) ; CAB H SIDE
MONITOR - A MONITOR - B MONITOR - C SATELLITE / PC

ZAXIS110/110M/120/130/130LCN CAB HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
LIGHTER
LEARNING SW-2
DIRECTION
PULLING
HARNESS
POWER BOOST SW
TIN PLATE
ML-CRANE-10
MEASURE HERE
ML-CRANE-11
CANCEL SW-1 BLACK RETAINER
CANCEL SW-3 BACK COVER
YAZAKI
MONITOR C-12
ML-CRANE-7
CANCEL SW.
MONITOR A-1
MONITOR A-2
MONITOR A-3
MONITOR A-4
MONITOR A-5
MONITOR A
SWING ALARM-1 MONITOR A-6 INSTALL MONITOR A, B AND C AS FOLLOWS.
RELAY BOX
· TURN BACK CONNECTOR'S SURFACE TO A. SLEEVE MUST BE SHORT LIGHTER
ML-CRANE-8
· VIEW C-C' IS AS FOLLOWS.
MONITOR A, B, C
MONITOR A-16
MONITOR B
RELAY BOX
RELAY BOX
MONITOR A-8
MONITOR A-9 ML-CRANE-6 VIEW C-C'
MONITOR A-7 MONITOR A-10 MONITOR C-9 MONITOR C
LEARNING SW-1 MONITOR A, B, C * MONITOR A, B AND C MUST BE UPPER SIDE
WHEN THE RELAY BOX IS RIGHT SIDE
MONITOR C-11
MONITOR A-12
1. IF NO COMMENT, WIRE 0.3~1.25 MAY BE CAVS AND
MONITOR A-15
WIRE 2~5 MAY BE AVS.
ML-CRANE-3
ML-CRANE-4 MONITOR A-16
MONITOR B-1 HARNESS END OF TAPE 2. PIN ARRANGEMENT OF THIS DRAWING
MONITOR B-2 PULLING INDICATE VIEW POINT FROM THE
DIRECTION MEASURE HERE
MONITOR B-3 OTHER SIDE CONNECTOR.
MONITOR B-4
MONITOR B-5 ALL SIRSUITS MUST BE TIGHTER TOGETHER 3. NO ELECTRIC JOINT MAY BE BETWEEN FH AND KC.
MONITOR B-6
MONITOR B-7
MONITOR B-8
MONITOR B-9
MONITOR B-10 6. COLOR SIGN DUE TO JASO D607.
MONITOR B-11 LIGHTER 7. GENERAL EXPRESS ON THE DRAWING DUE TO #X4259303.
MONITOR B-2 8. OUTSIDE DIAMETER OF CORRUGATE TUBE FOR CAB EARTH 1,
MONITOR B-13 CAB EARTH 2, QOS-CON AND G-LIGHTER MUST BE LESS THAN 20mm.
MONITOR B-14
MONITOR B-15
MONITOR B-16
FASTEN
MONITOR C-1 WITH TAPE
MONITOR C-2
MONITOR C-3
MONITOR A-11
MONITOR C-7 BY USING THE TAPE. BY USING THE TAPE.
MONITOR C-15 MONITOR C-13 · TURN BACK CONNECTION'S SUR FACE TO C. · TURN BACK CONNECTOR'S SURFACE TO A.
· ON THE LINE OF ICX-A AND B, FASTEN ICX-A AND B WITH · ON THE LINE OF ICX-C AND D, FASTEN ICX-C AND D WITH
IN 50mm FROM I AND IN BETWEEN MCX-A AND B USING A TAPE. IN 50mm FROM I AND IN BETWEEN MCX-C AND D USING A TAPE.
MONITOR C-14
· VIEW A-A' IS AS FOLLOWS · VIEW B-B' IS AS FOLLOW.
MONITOR C-6
ML-CRANE-1
VIEW B-B'
VIEW A-A'
ML-CRANE-5
* ICX-C AND D MUST BE UPPER SIDE SATELLITE / PC
SATELLITE/PC-10 WHEN MCX-A IS RIGHT SIDE.
ML-CRANE-2
SATELLITE/PC-2
SATELLITE/PC-1
LEARNING SW MOVE THIS SIDE
ASS'Y HOUSING CNO4M (N)
SATELLITE/PC-3
INSTALL A PULLER
ALL SIRSUITS MUST BE TIGHTER TOGETHER (YAZAKI 7147-9178) AND
SATELLITE/PC-4 SPARE FUSES 5A, 5A, 10A AND 20A.
SATELLITE/PC-5
HORN-SW.
TIN PLATE
SATELLITE/PC-7 PRINT USAGE AND AMPERE
SATELLITE/PC-8 ON THE COVER.
APPLY RED TAPE
SATELLITE/PC-6
RADIO SWING ALARM

SATELLITE/PC-9
LABEL
SPARE
YAZAKI 7123-2044
ML CRANE ASSY FEMALE PIUG
CN TYPE FLANGE
ZAXIS125US/135US CAB HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
G
CONSOLE LIGHTER
LEANING CONSOLE A ICX-D

RELAY BOX
H 90
B 90
MCX-A DIRECTION FOR
R1
LOCK REMOVING HARNESS
FUSE-BOX
CONSOLE
MEASURE HERE
90
J06FGY ICX DR.EX

DIRECTION FOR
CRANE DR.EX REMOVING HARNESS
CANCEL SW D E
CONSOLE
90
CRANE WIPER DIRECTION FOR
REMOVING HARNESS FUSE NO.1,11
CANCEL CONSOLE
CANCEL C
LEARNING
SWING ALARM
MONITOR ML CRANE
WIPER CONNECT
CRANE
MONITOR
MONITOR
MONITOR
MONITOR LIGHTER
MONITOR CONSOLE CONSOLE MONITOR
MONITOR CONSOLE
MONITOR CONSOLE
CORRUGATE TUBE 20MM DIA
FASTEN WITH TAPE
SWING ALARM
CRANE
MONITOR
SPEAKER
BUZZER
MONITOR BUZZER
MONITOR BUZZER
CONSOLE MONITOR
CONSOLE MONITOR CRANE ALL SIRSUITS MUST BE
MONITOR MONITOR WIPER TIGHTER TOGETHER
LERNING
CONSOLE WIPER
MONITOR
MONITOR WIPER
CONSOLE MONITOR
CRANE MONITOR
CRANE MONITOR
CONSOLE MONITOR
MONITOR CONSOLE
CONSOLE CONSOLE
MONITOR CONSOLE
MONITOR CONSOLE
CONSOLE MONITOR CONSOLE
MONITOR CONSOLE
CONSOLE MONITOR
MONITOR
MONITOR
MONITOR LIGHTER NOTE
MONITOR 1. UNDER 1.25 WIRE MAY BE CAVS WIRE, IF NO COMMENT.
MONITOR OVER 2 WIRE MAY BE AVS WIRE.
MONITOR
2. PIN ARRANGEMENTS OF THIS DRAWING INDICATE
VIEW POINTS FROM THE OTHER SIDE CONNECTORS.
CONSOLE
MONITOR
CONSOLE 3. NO ELECTRIC TURNING POINT MAY BE BETWEEN AH
CONSOLE MONITOR
AND J-CAB EARTH, K-CAB EARTH.
MONITOR CONSOLE
MONITOR CONSOLE SPEAKER 4. PUT THE PART NO. LABEL ON THE HARNESS.
MONITOR
MONITOR SOLAR RADIATION SENSOR CONSOLE 5. NO PLATE ON THE CB TYPE CONNECTORS.
6. COLOR SIGN DUE TO JASO D607.

7. GENERAL EXPRESS ON THE DRAWING
MONITOR DUE TO # X4259303
CRANE
CRANE
RELAY BOX
SATELLITE
CN
CRANE
SATELLITE
SATELLITE
CN
YAZAKI
LEARNING SWITCH
DIRECTION FOR REMOVING
HARNESS ALL SIRSUITS MUST BE
TIGHTER TOGETHER
MEASURE HERE
SATELLITE
SATELLITE
L02MB
SATELLITE
SATELLITE
SATELLITE
SATELLITE
M04MB
SATELLITE C16MW
LABEL
C010MW AUX.
SATTELLITE
ZAXIS135UR CAB HARNESS CAUTION: Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing,be sure to consult the Parts Catalog.
MONITOR C-2
MONITOR C-3
MONITOR C-4 5V SENSOR
MONITOR C-5 CONSOLE B-3
MONITOR C-8
MONITOR C-9
MONITOR C-10
MONITOR C-11
MONITOR C-12
MONITOR C-13 BUZZER 1 CONSOLE B-4
MONITOR C-14
MONITOR C-15
CONSOLE B-2 CONSOLE A-4
SLIDE -2
Dr. ZX-3
Dr. ZX-1
CONSOLE A-8
Dr. ZX-2 AIR BLEED
LEARNING SW -2 AIR BLEED PT-3
SWING ALARM -1 AIR BLEED PT-4
EN LOAD AIR BLEED PT-2
AIR BLEED PT-5
BUZZER 2 CONSOLE A-7
EMERGENCY STOP SW-1
CANCEL SW -1 EMERGENCY STOP SW-4 RESISTOR S
CANCEL SW -3 EMERGENCY STOP SW-2 EF Dr ZX-1
MONITOR B-2 INITIAL SETTING GND-2 EF Dr ZX-3
MONITOR B-3
MONITOR B-4
LEARNING SW -1 WIPER E
MONITOR B-1 SLIDE -2
EF Dr ZX-2
MONITOR A-1 CONSOLE A-11 SATELLITE / PC-10 CONSOLE A-12
MONITOR B-5 MONITOR A-2 CONSOLE A-9
INITIAL SETTING -1 MONITOR A-3 WIPER S
MONITOR A-20 MONITOR A-4 SATELLITE / PC-2 SERVICE -M
MONITOR A-5 SATELLITE / PC-1 WIPER P
MONITOR A-6
MONITOR A-7 WIPER B
MONITOR A-19 MONITOR A-8
MONITOR A-9
MONITOR A-10
CONSOLE A-1 EMERGENCY STOP SW -3
RADIO -3
CONSOLE A-3 MONITOR A-13 ICX DR. ZX-1 RESISTOR D-1
MONITOR A-14 ICX DR. ZX-3 RADIO -8 RESISTOR D-2
AIR BLEED PT-1 MONITOR A-15 SATELLITE / PC-3 RADIO -2 RESISTOR D-3
MONITOR A-18 RADIO -4 RESISTOR D-6
ICX DR. ZX-2 RADIO -7
SATELLITE / PC-7
CONSOLE A-2 LIGHTER ( + )
MONITOR B-6
SATELLITE / PC-6
MONITOR B-8
MONITOR B-10 SERVICE -F
MONITOR B-11
MONITOR B-12
MONITOR B-13 SLIDE 5
CONSOLE A-14 24V EMERGENCY STOP VALVE
INITIAL SETTING -2
LIGHTER ( - ) EF Dr ZX-4
CONSOLE A-6
CONSOLE B-1 SLIDE 3
MONITOR C-1 CONSOLE A-13
FUSE NO.1,11
R1
FUSE BOX INSTALL A PULLER
(YAZAKI 7147-9178) AND
SPARE FUSES 5A,5A,10A AND 20A
PRINT USAGE AND AMPERE

ON THE COVER.
#4480089
FASTEN WITH TAPE

EMERGENCY SW.
MEASURE HERE SATELLITE / PC
AUX.
RELAY BOX
YAZAKI 7123-7464-40
R1 : LOAD DUMP
R2 : WASHER
R3 : LIGHT 2
connect R4 : LIGHT 1
MONITOR A R5 : HORN
R6 : WIPER
R7 : ML OPT.
R8 : AIR BLEED SWING ALARM
MONITOR B SERVICE RESISTOR D

RESISTOR S
MONITOR C
YAZAKI 7123-2044
CN TYPE
BUZZER
INITINAL SET. GND
SUMITOMO
6030-2981
EN LOAD
TO_E ９０゜
POINT_A
INITINAL SET. CANCEL SW.
LEARNING
YAZAKI 7123-2044
CN TYPE
ALL SIRSUITS MUST BE TIGHTER

MCX
YAZAKI 7123-2044
CN TYPE
AIR BLEED PT
ICX-C,D
TO_C
ALL SIRSUITS MUST BE TIGHTER MCX
A
FASTEN
WITH TAPE
MCX-A
50mm
AIR BLEED
MCX-B D
1. IF NO COMMENT, WIRE 0.3 1.25 MAY BE CAVS AND
MCX-C ICX-A,B WIRE 2 5 MAY BE AVS.
C
MCX-D 2. PIN ARRANGEMENT OF THIS DRAWING
INDICATE VIEW POINT FROM THE
BY USING THE TAPE. BY USING THE TAPE. OTHER SIDE CONNECTOR.
á TURN BACK CONNECTION'S SUR FACE TO C. á TURN BACK CONNECTOR'S SURFACE TO A.
á ON THE LINE OF ICX-A AND B, FASTEN ICX-A AND B WITH á ON THE LINE OF ICX-C AND D, FASTEN ICX-C AND D WITH
IN 50mm FROM I AND IN BETWEEN MCX-A AND B USING A TAPE. IN 50mm FROM I AND IN BETWEEN MCX-C AND D USING A TAPE. 3. NO ELECTRIC JOINT MAY BE BETWEEN FH AND KC.
á VIEW A-A' IS AS FOLLOWS á VIEW B-B' IS AS FOLLOW.
SLIDE ARM

VIEW B-B'
CONSOLE B
VIEW A-A' 6. COLOR SIGN DUE TO JASO D607.
* ICX-C AND D MUST BE UPPER SIDE 7. GENERAL EXPRESS ON THE DRAWING DUE TO #X4259303.
CONSOLE A WHEN MCX-A IS RIGHT SIDE. 8. OUTSIDE DIAMETER OF CORRUGATE TUBE FOR CAB EARTH 1,
CAB EARTH 2, QOS-CON AND G-LIGHTER MUST BE LESS THAN 20mm.
LIGHTER
SLEEVE MUST BE SHORT
SPEAKER
MEASURE HERE
RADIO
HARNESS PULLING
ROOM LAMP
DIRECTION
ZAXIS110/110M/120/130/130LCN ENGINE HARNESS

3P FEMALE 3P FEMALE
YAZAKI FL
AM
EP
RO
OTC
OF
OF
&H
RO
ATP
EA
HE
TP
RO
F&
OO
OF
PR
CO
ME
T YAZAKI
FLA
FLAMEPROOF &
FLA
HEATPROOF COT
ME
TRAVEL ALARM-2
PR
OFO
& HE
ATP
RO
OF
CO
LIGHT GND
(WATERPROOF SLEEVE)
T
(WATERPROOF SLEEVE) FLAM FLAMEPROOF & HEATPROOF COT
E PROO
F & HE
ATPR
OOF
COT
EC MOTOR
170(HEARTPROOFVT)
H TYPE
SUMITOMO
(WATERPROOF SLEEVE)
STARTER RELAY
FLAMEPROOF & HEATPROOF COT (WATERPROOF SLEEVE)
HYD. OIL FILTER
(WATERPROOF SLEEVE)
TRAVEL ALARM-4
TRAVEL ALARM-3 FLAMEPROOF & HEATPROOF COT
TRAVEL ALARM-1 T YAZAKI
CO
OF
RO
HEATPROOF COT
P
PLUG AT
FLAMEPROOF &
& HE
F
OO
EPR
WATERPROOF SLEEVE AM
FL
SUMITOMO

FLAMEPROOF &
WATERPROOF JOINT-1 HEATPROOF COT
WATERPROOF JOINT-1
WATERPROOF JOINT-1
WATERPROOF JOINT-1 YAZAKI YAZAKI WATERPROOF SLEEVE

GLOW PLUG
FLAMEPROOF &
HEATPROOF COT
FLAMEPROOF &
HEATPROOF COT
FLAMEPROOF &
HEATPROOF COT
WATERPROOF JOINT-2
YAZAKI
WATERPROOF JOINT-2
WATERPROOF JOINT-2 YAZAKI COOLANT TEMP. SW
WATERPROOF JOINT-2
LEVEL YAZAKI
WATERPROOF JOINT-2
YAZAKI

SUMITOMO
YAZAKI

WATERPROOF JOINT-2
SUMITOMO
FLAMEPROOF &
HEATPROOF COT
OF &
EPRO COT
FLAMTPROOF
EC MOTOR 1 HEA TERMINAL CAP
EC MOTOR 3
FLAMEPROOF &
EC MOTOR 2 FLAMEPROOF & HEATPROOF COT HEATPROOF COT
EC MOTOR 4
(WATERPROOF SLEEVE)
400mm
DO NOT INSTALL A/C (COMPRESSOR)
JOINT IN THIS AREA. YAZAKI
CLAMP

SUMITOMO
PLUG
ASSEMBLE EMPTY PLUG

HYD. OIL FILTER YAZAKI
CLIP
YAZAKI
or EQUIVALENT YAZAKI
10
CLIP
COOLANT TEMP. SW YAZAKI 7047-3241
or EQUIVALENT RED COLOR TAPE
28
0(
CO
T)
SUMITOMO
SUMITOMO
WHITE COLOR TAPE
BATTERY RELAY
YAZAKI
588 597
(WATERPROOF SLEEVE)
AC GLOW RELAY
AMBIENT SENSOR YAZAKI
YAZAKI 090-Ⅱ
7383-7028
GLOW RELAY
YAZAKI 2 USED
BLACK RETAINER
A/C(COMPRESSOR)
AMBIENT SENSOR-1
SCALE POINT
SUMITOMO
CLIP
AMBIENT SENSOR-2
LIGHT GND
MOVE TO THIS SIDE.
090 WATER PROOF YAZAKI RV03FB

SUMITOMO 6189-0031
090 WATER PROOF

SUMITOMO 6189-0031
YAZAKI RV03FB 090 WATER PROOF
EC MOTOR SUMITOMO 6189-0031 090 WATER PROOF
SUMITOMO 6189-0031
YAZAKI RV03FB YAZAKI RV03FB
TRAVEL-2
YAZAKI RV03FB
AMP EJ(2)3P FEMALE

YAZAKI RV03FB
AMP EJ(2)3P FEMALE

SUMITOMO
6800-3859
TRAVEL-4
TRAVEL-3 PLUG
TRAVEL-1
WATERPROOF JOINT-1
SUMITOMO 6409-2325
FUEL FILTER
LIGHT GND (WATER PROOF SLEEVE) YAZAKI 7323-1424-40
WATERPROOF JOINT-1 (WATER PROOF SLEEVE) WATERPROOF JOINT-2
WATERPROOF JOINT-1 SUMITOMO 6409-2325
WATERPROOF JOINT-1 GLOW PLUG
WATERPROOF JOINT-1 STARTER RELAY
YAZAKI RV03FB (WATER PROOF)
WATERPROOF JOINT-1
WATERPROOF JOINT-2 WATER TEMP. SW.

WATERPROOF JOINT-2 ENG. OIL LEVEL SW. YAZAKI 7323-4714-40
SUMITOMO 6188-0494
WATERPROOF JOINT-2 YAZAKI 7323-7414-40
WATERPROOF JOINT-2
TRAVEL PLUG
7323-1424-40
PLUG
WATERPROOF JOINT-1
6189-0714 TERMINAL CAP
EC MOTOR 1
EC MOTOR 2
EC MOTOR 3
EC MOTOR 4
AC (COMPRESSOR)
YAZAKI 7323-6214-40
FUEL FILTER AC PRESS

SUMITOMO 6189-0533
YAZAKI 7322-4125-50 YAZAKI 7322-4123-30
ASSY 7323-3525-50 ASSY 7323-3527-30
J06MGY ASSY
SUMITOMO 6098-0852
WATER TEMP. 560

BLUE RETAINER NO JOINT
YAZAKI 7323-2228
SUMITOMO
6270-3963
CLAMP
YAZAKI 7323-3010x2
SUMITOMO 6400-7601 AC AMB SENSOR

ASSY AMP EJ(2)2P FEMALE
SUMITOMO 6409-0033 174352-2
SCALE POINT
AIR_FILT SW.
(WATER PROOF)
AC PRESS. SW-1 BATTERY
YAZAKI 7323-2228
AC PRESS. SW-2
AMB. TEMP.SENSOR-1
591 AIR_ FILT-M
AMB. TEMP.SENSOR-2
LIGHT GND CLAMP POINT
090 WATER PROOF

SLEEVE YAZAKI
RV03FB
SUMITOMO
6189-0031 2
1 3
090 WATER PROOF

SLEEVE
220
SUMITOMO YAZAKI 090 WATERPROOF
( HE
6189-0031 RV03FB EC MOTOR SLEEVE 090 WATERPROOF
2 SUMITOMO 6189-0031 SLEEVE
AT
220 3
(HE 1 SUMITOMO 6189-0031
PR
ATP
O
ROO
LIGHT GND YAZAKI
OF
F VT YAZAKI
) RV03FB
VT
(WATER PROOF SLEEVE) RV03FB
)
2
180 MEPR OF CO
(FLAATPRO
BODY_LIGHT 1 1 3
HE
2
OFF-L-I ARM-D-I (WATER PROOF SLEEVE) 1 3
OFF-R-I
BOOM-U 090 WATER PROOF 090 WATER PROOF 090 WATER PROOF
47
TPR RO 160
090 WATER PROOF SLEEVE & )
OO OF &
SLEEVE
SLEEVE (F 0
OT)
0 OF OT
OOF T)
SLEEVE SUMITOMO
HELAM
SUMITOMO SUMITOMO
14 RO F C
FC
SUMITOMO 6189-0032 6189-0032 6189-0032
6189-0032 AT EP EP OO
HEALAMEP
&
PR RO M
OO OF L A PR
YAZAKI F & (F AT
HE
(F
RV03FB CO
2 220 160 T)
1 3
YAZAKI HEATPROOF COT) HEATPROOF COT)
TRAVEL ALARM -2 RV03FB

T)
AMP EJ( ) 3P FEMALE
CO
HEATPROOF COT)
OF
2 FUEL/M
(FLAMEPROOF &
RO
1 3
TP
EA
&H
OF
RO
P
ME
460
A
FL
0(
AMP EJ( ) 3P FEMALE
70
36 LA ATP
(F E
0 ME R
H
P R OO
SUMITOMO
O FC
OIL_TEMP/S
O O
6800-3859
F T
& )
PLUG
WATERPROOF 100
(FL
SLEEVE JOINT-1 A
HEA MEPR
SUMITOMO TPR OOF
OO
6409-2325 FC & 500
OT) (FLAMEPROOF &
160
HEATPROOF COT)
HYD. OIL FILTER (FLAMEPROOF & ENG._OIL_P_SW.
HEATPROOF COT)
(WATERPROOF SLEEVE)
WATERPROOF YAZAKI 7323-1424-40
SLEEVE JOINT-2
HEATPROOF COT)
SUMITOMO
(FLAMEPROOF &
6409-2325
)
GLOW PLUG
OT
TRAVEL ALARM -4
FC
STARTER RELAY
TRAVEL ALARM -3
OO
(WATERPROOF SLEEVE)
PR
TRAVEL ALARM -1
100
AT
(FLAMEPROOF &
HE
210
BOOM ANGLE SENSOR HEATPROOF COT)
AP PLUG
&
HYD. OIL TEMP_S
OF
RO
BOOM-D OFF-R OFF-L ARM-C
ASSENBLE
EP
090 WATER PROOF 090 WATER PROOF 090 WATER PROOF 090 WATER PROOF
EMPTY PLUG
AM
SLEEVE SLEEVE SLEEVE SLEEVE
SUMITOMO
(FL
SUMITOMO SUMITOMO SUMITOMO COOLANT TEMP. SW.
WATER PROOF JOINT -1 6189-0031 6189-0031 6189-0031 6189-0031 HYD. OIL TEMP_S
220

SUMITOMO ENG._OIL_LEVEL_SW. YAZAKI 7323-7414-40
TRAVEL PLUG 6188-0494 YAZAKI 7323-7414-40
WATER PROOF JOINT -1 ASSY ASSY ASSENBLE
A/C PRESSURE_SW. -1 EMPTY PLUG YAZAKI 7323-1424-40
(FLAMEPROOF & HEATPROOF COT)

A/C PRESSURE_SW. -2
FASTEN
WITH TAPE
LIGHT GND
OT)
SUMITOMO
WATER PROOF JOINT -2 C 6189-0714 TERMINAL CAP
ARM AND OFFSET O OF
WATER PROOF JOINT -2 ANGLE SENSOR EA TPR
F &H
WATER PROOF JOINT -2 SOL. VALVE B5-2 OO &
EPR OF OT)
360
WATER PROOF JOINT -2 SOL. VALVE B8-2 AM RO
(FL 260 AMEP OOF C
WATER PROOF JOINT -2 33 0 (FL ATPR
SOL. VALVE B4-2
HE
SOL. VALVE B7-2
SOL. VALVE B2-2 470 (FLAMEPROOF & HEATPROOF COT)
SOL. VALVE B3-2
SOL. VALVE B6-2 400 1270
WATER PROOF JOINT -1 SOL. VALVE B9-2 HEATPROOF COT) HEATPROOF COT)
WATER PROOF JOINT -2 SOL. VALVE B7-1
SOL. VALVE B9-2 A/C (COMPRESSOR)
YAZAKI 7323-6214-40

SOL. VALVE B6-1
YAZAKI
RV03FB
EC MOTOR 1 PRES. SENSOR 8-2 2
1 3
EC MOTOR 3 ANGLE SENSOR 1-2
PRES. SENSOR 2-2
PRES. SENSOR 6-2
PRES. SENSOR 1-2 A/C PRESSURE_SW.
ANGLE SENSOR 2-5 SUMITOMO 6189-0533
YAZAKI 7322-4125-50 RED COLOR
ASSY 7323-3525-50 YAZAKI 7322-4123-30
ANGLE SENSOR 2-2 TAPE WHITE COLOR ASSY 7323-3527-30
OIL TEMP. SENSOR 1 TAPE
SOL. VALVE B8-1
SOL. VALVE B2-1
SOL. VALVE B3-1
SOL. VALVE B4-1
SOL. VALVE B5-1
GLOW RELAY
YAZAKI 7323-2228
ANGLE SENSOR 1-3
ANGLE SENSOR 2-1
ANGLE SENSOR 2-4
PRES. SENSOR 1-1 CLAMP
PRES. SENSOR 6-1 SUMITOMO
6810-0184 RAD_LEVEL
PRES. SENSOR 7-1
HYD. OIL FILTER PRES. SENSOR 8-1 GLOW RELAY
PRES. SENSOR 2-1 YAZAKI
7323-3010×2ヶ
PRES. SENSOR 5-1
ANGLE SENSOR 1-1
COOLANT TEMP SW. ANGLE SENSOR 2-3
ANGLE SENSOR 2-6
PRES. SENSOR 1-3
PRES. SENSOR 6-3 AIR FILT. SW.
PRES. SENSOR 7-3 (WATERPROOF SLEEVE)
PRES. SENSOR 8-3
WASHER
PRES. SENSOR 2-3 YAZAKI BATTERY RELAY
PRES. SENSOR 5-3 7323-2228
OIL TEMP. SENSOR 2
CLAMP A, B, C
ZAXIS110/110M/120/130/130LCN MONITOR HARNESS CAUTION: Parts numbers on the drawing are provided only for reference purpose.
MONITOR A-8 CAB A-7
WIPER E CAB C-12
MONITOR A-2 CAB A-1

MONITOR A-3 CAB A-2
MONITOR A-4 CAB A-3
MONITOR A-5 CAB A-4
MONITOR A-6 CAB A-5
MONITOR A-7 CAB A-6
MONITOR A-10
MONITOR A-11 CAB B-16

WIPER
MONITOR B-1 CAB A-8

MONITOR B-2 CAB A-9
MONITOR B-5 CAB C-4 CAB A

MONITOR B-7 CAB A-13 MONITOR A
CONNECT
MONITOR B-12 CAB B-2 CAB B MONITOR B
MONITOR B-16
MONITOR B-17 MONITOR C
CAB C
MONITOR B-20 CAB B-8 TAPE
MONITOR C-1 CAB B-9

MONITOR C-5 CAB B-13 BUZZER

MONITOR C-9 CAB C-1
MONITOR C-12 CAB A-11

WIPER L CAB C-9

WIPER S CAB C-11
WIPER B CAB C-10
WIPER M CAB C-8
OFFSET SW-3
RESTRICTION DEACT. SW.-GND
CRANE SW-3
CRANE SW-1
NOTE
1. WIRE SHALLBE CAVS ,IF NO COMMENT.
2. PUT THE LABEL FOR THE HARNESS.

IC/U BUZZER 1
OFFSET SW-2 3. SYMBOL OF THES DROWING DUE TO #4259303
RESTRICTION DEACT. SW.-S
4. NO ELECTRIC TURNING POINT MAY BE BETWEEN
A-HORN SW ,A-EMERGENCY STOP SOL.
OFFSET SW-1
IC/U BUZZER 2
EMERGENCY STOP SOL.

090 WATER PROOF SLEEVE
SUMITOMO 6189-0031
CRANE SW.
SUMITOMO
6242-5061
RESTRICTION
DEACT. SW.
OFFSET SW
IC/U BUZZER
SUMITOMO
6030-2981
TR/MO TR/MO
SH SW/MO
M
A B
A B A B
SL SN SM SK T3
PROPEL RH 1
RR
RF P1
2
B8
4
LR
T A8
TRAVEL;L
TRAVEL;R
P 12 RR 11 RF
LF
9 LF 10 LR
3 B1
A5
T3 T4
PROPEL LH A1
T1
DK
B7
T2
VALVE
COMB-
FUNCTION
A1 A7
P AUX
A2
7 BKT IN 8 BKT OUT
A3
13 AUX B
14 AUX A
A4
BUCKET
B2
SY
A2
BKT CYL.
DY
PI1 SEC.BOOM
PRIM.BOOM
2 BM DWN 1 BM UP
TO 1
B3
ARM CYL.
A3
B6
PI2
ZAXIS110/110M/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM
A6
PRIM.ARM
4 ARM IN
3 ARM OUT
BOOM CYL.
SC TO 3
PI3
SEC.ARM
A4
SJ
B5
PF
PG A5 A9 DC DH T2
SWING
DY
5 SW L 6 SW R
SC
DD
ARM FLOW
DH
T1 P2
SI
DX
TR. SPEED
DS PD
VALVE SOL.
PD2 PD1
PA
PA
Eng.
PE
PF
PUMP FL PUMP PQ
PG
PC
PD
TA
SB
SA
PC1 PC2
N 14
SM TR/MO TR/MO
M 13 DB
5
E SW L
BUCKET S3
F SW R 6
3 SH SW/MO
IN
G BKT IN 7
OUT 1 M
H BKT OUT 8
4
SE
UP
T
P A B
SL
DOWN
2
SH
BOOM A BOOM UP 1
ARM SK
3
A B A B
OUT
SB
IN
1
4 B BOOM DWN 2
L C ARM OUT 3
T
P
SP
R SN
2
SWING SL SN SM SK T3
SA
PROPEL RH D
1 ARM IN 4
L
RR
12
RF K 11 P1
2
TR B8
4 J
10
LR
T I A8
9 TRAVEL;L
TRAVEL;R
P 12 RR 11 RF
LF
9 LF 10 LR
PH DF
3 B1
A4
T3 T4
PROPEL LH A1
T1
DK
B7
VALVE
COMB-
T2
FUNCTION
A1 A7
P AUX
A2
7 BKT IN 8 BKT OUT
A3 13 AUX B
14 AUX A
BUCKET
B2
SY
A2
DY
BKT CYL.
PI1 SEC.BOOM
PRIM.BOOM
2 BM DWN 1 BM UP
TO 1
B3
ARM CYL.
A3
B6
PI2
A6
PRIM.ARM
4 ARM IN
3 ARM OUT
BOOM CYL.
SC TO 3
PI3
SEC.ARM
A4
SJ
B5
PF
PG A5 A9 DC DH T2
SWING
DY
5 SW L 6 SW R
SC
DD
ARM FLOW
P2
DH T1
SI
DX
TR. SPEED
DS PD
VALVE SOL.
PD2 PD1
PA
Eng.
PA
PE
PF
PUMP FL PUMP PQ
PG
PC
PD
TA
SB
SA
PC1 PC2
Attach to Vol. No.: TT187E-04 Note:Refer to the PEFORMANCE STANDARD in the technical manual
VALVE SOL.(OPT)
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
Zaxis110...135UR-WSh 1 30/10/03, 7:37 PM

Workshop Manual
Vol No.: W187E-03

INTRODUCTION
TO THE READER
age.):
TEL: 81-298-32-7173
FAX: 81-298-31-1162
MANUAL COMPOSITION
IN-01
INTRODUCTION
PAGE NUMBER

Example : T 1-3-5

Group Number
Section Number

NOTATIONS
• CAUTION:
heavy parts.
IN-02
INTRODUCTION
UNITS USED
this manual.
From From
mm ft 0.003281 MPa psi 145.0
L US qt 1.057 kW HP 1.341
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
• 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
• 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
• 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
• 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.
face away from valve.
• Travel reduction gears are under pressure.
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
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.
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).
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 6 Swing Device
Group 7 Pilot Valve
Group 10 Solenoid Valve
Group 11 Holding Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
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

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

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
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)
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
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

(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
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
(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)
(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
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)
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
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)

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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ZX110 - 120 - 130 - 125US - 135US (UR) Full Service Manual PDF

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ZX110 - 120 - 130 - 125US - 135US (UR) Full Service Manual PDF

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Manual No.

PRINTED IN SINGAPORE (PS) 2003.11

Zaxis110...135UR-TM/OP 1 14/11/03, 12:53 PM

• Each page has a number, located on the center

Consecutive Page Number for Each Group

• Each page has a number, located on the center

Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

Group 2 Component Layout

Group 3 Component Specifications

Model ZAXIS110 ZAXIS110M

NOTE:  H/P mode

NOTE:  H/P mode

ZAXIS130, 130LCN (2-piece Boom)

Model ZAXIS130 2-piece Boom ZAXIS130LCN 2-piece Boom

NOTE:  H/P mode

Face shovel (Reversed hoe bucket)

Model ZAXIS130, 130 LCN

Backhoe T1SE-01-01-002 Shovel M1SE-12-001

Category 2.14 m (7′ 0″) arm 2.44 m (8′ 0″)

A: Maximum Digging Reach 7590 mm (24 ft 11 in) 7920 mm (25 ft 12 in)

B: Maximum Digging Depth 4800 mm (15 ft 9 in) 5100 mm (16 ft 9 in)

C: Maximum Cutting Height 8650 mm (28 ft 5 in) 8980 mm (29 ft 6 in)

D: Maximum Dumping Height 6220 mm (20 ft 5 in) 6530 mm (21 ft 5 in)

E: Transport Height 2780 mm (9 ft 1 in) 2780 mm (9 ft 1 in)

F: Overall Transport Length 7270 mm (23 ft 10 in) 7300 mm (23 ft 11 in)

H: Maximum Blade Raise 550 mm (1 ft 10 in)

ZAXIS130, 130LCN (2-piece Boom)

Model ZAXIS130, 130LCN 2-piece Boom

1 - Bucket Cylinder 7 - Fuel Tank 13 - Intercooler 19 - Pilot Shut-Off Valve

1 - Front Attachment / Swing 6 - Boom Cylinder 11 - Signal Control Valve 16 - Engine

• Pressure Sensor (Travel)

13 • Pump 1 and 2 Delivery Pressure Sensor

1 - Horn 5 - Hydraulic Oil Temperature 9 - Overheat Switch 13 - *Coolant Level Switch

• Pump 1 and 2 Delivery Pressure Sensor

• Pressure Sensor • Pressure Sensor

1 - EC Motor and EC Sensor 5 - Coolant Temperature 9 - Battery 13 - Solenoid Valve Unit

• Pump 1 and 2 Delivery Pressure

1- Left Offset Switch 7- Fuel Gauge 13 - Auto-Idle / Acceleration 19 - Preheat Indicator

SIGNAL CONTROL VALVE SOLENOID VALVE UNIT

Manufacturer ............................................... ISUZU

ENGINE STOP SYSTEM

Radiator Oil Cooler

BLADE PUMP (ZAXIS135UR Only), PILOT PUMP

BLADE CONTROL VALVE (ZAXIS135UR Only)

BLADE MAIN RELIEF VALVE (ZAXIS135UR Only)

SWING PARKING BRAKE

TRAVEL BRAKE VALVE

TRAVEL PARKING BRAKE

ZAXIS135UR： Boom Arm Offset

FRONT ATTACHMENT PILOT VALVE

TRAVEL PILOT VALVE

BLADE/OFFSET PILOT VALVE (ZAXIS135UR Only)

SOLENOID VALVE UNIT

PILOT PRESSURE SIGNAL CONTROL VALVE

PILOT SHUT-OFF VALVE

OIL COOLER BYPASS CHECK VALVE

8-UNIT SOLENOID VALVE UNIT (ZAXIS135UR Only)

EMERGENCY STOP SOLENOID VALVE (ZAXIS135UR Only)

ANGLE SENSOR (ZAXIS135UR Only)

GLOW PLUG RELAY

Manufacturer ............................................... ISUZU

ENGINE STOP SYSTEM

NOTE: H/P mode

NOTE: H/P mode

NOTE: H/P mode