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.

1- 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.
1- 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.
1- 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.

1- 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.

1- 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.

1- 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
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
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 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Others (Upperstructure)
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 Electrical System Inspection
Group 6 Adjustment Group 7 ICX
 SECTION 1
GENERAL INFORMATION

CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology ......... W1-1-7

Group 2 Tightening Torque

Tightening Torque Specification ............... W1-2-1
Torque Chart ............................................ W1-2-4
Piping Joint .............................................. W1-2-7
Periodic Replacement of Parts............... W1-2-11

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

Group 4 Bleeding Air

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

178W-1-1
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling

Clean the Machine Precautions for Disassembling

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

Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the

area for disassembling work.

W1-1-1
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and 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
clean and dry. motor housing, damage to the mo-
• If an anti-corrosive agent has been used on a tor may result.
new part, be sure to thoroughly clean the part to If the cylinder is operated with air
remove the agent. trapped in the cylinder tube, dam-
• Utilize matching marks when assembling. age to the cylinder may result.
• Be sure to use the designated tools to assemble Be sure to bleed air before starting
bearings, bushings and oil seals.
the engine.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
Bleeding Air from Hydraulic Pump
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
• Remove the air bleeding plug from the top of the
assembled machine.
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.

Bleeding Air from Travel Motor / Swing Motor

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

motor removed, fill the motor case with hydraulic
oil.

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

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation M104-07-021
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.

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.

(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019

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

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

(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

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a
a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B

b b

a=b a b
W110-03-05-004

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

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a
load with a temperature of 100 C (212 F) or
more, reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
W102-04-02-016
slings with the same width and length to keep the
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
 SECTION 2
UPPERSTRUCTURE

CONTENTS
Group 1 Cab Group 6 Swing Device
Remove and Install Cab ..............................W2-1-1 Remove and Install Swing Device............... W2-6-1
Dimensions of the Cab Glass ....................W2-1-13 Disassemble Swing Device (ZAXIS200,
200-E, 225US, 225USR, 230) ................... W2-6-4
Group 2 Counterweight Disassemble Swing Device (ZAXIS270)... W2-6-10
Remove and Install Counterweight..............W2-2-1 Assemble Swing Device (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-16
Group 3 Main Frame Assemble Swing Device (ZAXIS270)........ W2-6-24
Remove and Install Main Frame..................W2-3-1 Disassemble Swing Motor (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-30
Group 4 Pump Device Disassemble Swing Motor (ZAXIS270)..... W2-6-34
Remove and Install Pump Device................W2-4-1
Assemble Swing Motor (ZAXIS200,
Disassemble Pump Device..........................W2-4-2
200-E, 225US, 225USR, 230) ................. W2-6-38
Assemble Pump Device.............................W2-4-10
Assemble Swing Motor (ZAXIS270).......... W2-6-42
Disassemble Regulator..............................W2-4-22
Disassemble and Assemble Parking
Assemble Regulator ..................................W2-4-24
Release Valve (ZAXIS270)...................... W2-6-46
Disassemble Solenoid Valve .....................W2-4-26
Maintenance Standard .............................. W2-6-47
Assemble Solenoid Valve ..........................W2-4-28
Disassemble and Assemble Pilot Group 7 Pilot Valve
Pump ........................................................W2-4-30 Remove and Install Right Pilot Valve .......... W2-7-1
Maintenance Standard ...............................W2-4-32 Remove and Install Left Pilot Valve............. W2-7-5
Remove and Install Travel
Group 5 Control Valve Pilot Valve .................................................. W2-7-8
Remove and Install Control Valve................W2-5-1
Disassembe Right and Left
Disassemble Control Valve
Pilot Valves .............................................. W2-7-10
4-Spool Section ..........................................W2-5-8
Assemble Right and Left
Disassemble Control Valve
Pilot Valves .............................................. W2-7-18
5-Spool Section........................................W2-5-14
Disassemble Travel Pilot Valve ................. W2-7-26
Disassemble and Assemble
Assemble Travel Pilot Valve ...................... W2-7-34
4-Spool and 5-Spool Section ...................W2-5-20
Assemble Control Valve
4-Spool Section........................................W2-5-22
Assemble Control Valve
5-Spool Section........................................W2-5-30

178W-2-1
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off Valve......W2-8-1
Disassemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270).......W2-8-4
Disassemble Pilot Shut-Off Valve
(ZAXIS225US) ...........................................W2-8-6
Assemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270).....W2-8-8
Assemble Pilot Shut-Off Valve
(ZAXIS225US) .........................................W2-8-10

Group 9 Signal Control Valve

Remove and Install Signal
Control Valve..............................................W2-9-1

Group 10 Solenoid Valve

Remove and Install Solenoid
Valve Unit .................................................W2-10-1
Disassemble Proportional
Solenoid Valve .........................................W2-10-2
Assemble Proportional
Solenoid Valve .........................................W2-10-4

178W-2-2
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