Hitachi Zaxis 110 110M 120 130 125US 135US 135UR Excavator Operational Principle+Troubleshooting+Parts+Workshop Manual – PDF DOWNLOAD

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Hitachi Zaxis 110 110M 120 130 125US 135US 135UR Excavator Operational Principle+Troubleshooting+Parts+Workshop Manual

FILE DETAILS:

Hitachi Zaxis 110 110M 120 130 125US 135US 135UR Excavator Operational Principle+Troubleshooting+Parts+Workshop Manual

This Listing includes all of the manuals mentioned below:

1. Hitachi 110 120 200 225USR 230 270 330 Electrical Circuit Diagram
2. Hitachi Zaxis 110 110-E 120 120-E 125US 135US Excavator Operational Principle Manual
3. Hitachi Zaxis 110 110-E 120 120-E 125US 135US Excavator Performance Check Manual
4. Hitachi Zaxis 110 110M 120 130 125US 135US 135UR 130LCN Excavator Operational Principle Manual
5. Hitachi Zaxis 110 110M 120 130 125US 135US 135UR 130LCN Excavator Troubleshooting Manual
6. Hitachi Zaxis 110 110M 120 130 125US 135US 135UR 130LCN Excavator Workshop Manual
7. Hitachi Zaxis 110 120 125US 135US 135UR Excavator Workshop Manual
8. Hitachi Zaxis 110 120-E 130 130-H 130K 130LCN Excavator Parts Catalog Manual

DESCRIPTION:

Hitachi Zaxis 110 110M 120 130 125US 135US 135UR Excavator Operational Principle+Troubleshooting+Parts+Workshop Manual

INTRODUCTION:

TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.

ADDITIONAL REFERENCES:

• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material

MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

TABLE OF CONTENTS:

Hitachi Zaxis 110 110M 120 130 125US 135US 135UR Excavator Operational Principle+Troubleshooting+Parts+Workshop Manual

• Hitachi Zaxis 110 110-E 120 120-E 125US 135US Excavator Performance Check Manual

SECTION 4 OPERATIONAL PERFORMANCE
TEST
Group 1 Introduction
Group 2 Engine Test
Group 3 Excavator Test
Group 4 Component Test
Group 5 Standard
SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX

• Hitachi Zaxis 110 110M 120 130 125US 135US 135UR 130LCN Excavator Operational Principle Manual

SECTION 1
GENERAL
Group 1 Specifications
Specifications T1-1-1
Working Ranges T1-1-8
Group 2 Component Layout
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
SECTION 2
SYSTEM
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
SECTION 3
COMPONENT OPERATION
Group 1 Pump Device
Outline T3-1-1
Main Pump T3-1-2
Regulator T3-1-4
Solenoid ValveT3-1-20
Blade Pump (ZAXIS135UR Only)
and Pilot Pump T3-1-22
N Sensor (Engine Speed Sensor) T3-1-22
Pump Delivery Pressure Sensor T3-1-22
Pump Control Pressure Sensor T3-1-23
Group 2 Swing Device
Outline T3-2-1
Swing Reduction Gear T3-2-2
Swing Motor T3-2-3
Swing Parking BrakeT3-2-4
Valve Unit T3-2-6
Group 3 Control Valve
Outline T3-3-1
Hydraulic Circuit T3-3-12
Flow Combiner Valve T3-3-20
Main Relief ValveT3-3-22
Overload Relief ValveT3-3-24
Regenerative Valve T3-3-26
Anti-Drift ValveT3-3-28
Flow Rate Control Valve T3-3-30
Bypass Shut-Out Valve T3-3-32
Auxiliary Flow Combining Valve T3-3-34
Group 4 Pilot Valve
Outline T3-4-1
OperationT3-4-4
Group 5 Travel Device
OutlineT3-5-1
Travel Reduction GearT3-5-2
Travel Motor T3-5-4
Parking Brake T3-5-6
Travel Mode Control T3-5-10
Travel Brake Valve T3-5-18
Group 6 Signal Control Valve
OutlineT3-6-1
Pilot Port T3-6-2
Shuttle Valve T3-6-6
Shockless Valve T3-6-10
Pump 1 and Pump 2 Flow Rate
Control Valves T3-6-12
Bucket Flow Rate Control Valve,
Flow Combiner Valve Control Spool,
Swing Parking Brake Release Spool T3-6-14
Group 7 Others (Upperstructure)
Pilot Shut-Off ValveT3-7-1
Solenoid Valve UnitT3-7-3
Offset Anti-Drift Valve (ZAXIS135UR Only) T3-7-8
Holding Valve T3-7-10
Pilot Relief Valve T3-7-14
EC Motor T3-7-14
Group 8 Others (Undercarriage)
Swing BearingT3-8-1
Center JointT3-8-2
Track Adjuster T3-8-4

• Hitachi Zaxis 110 110M 120 130 125US 135US 135UR 130LCN Excavator Troubleshooting Manual

SECTION 4
OPERATIONAL
PERFORMANCE TEST
Group 1 Introduction
Operational Performance TestsT4-1-1
Preparation for Performance TestsT4-1-2
Group 2 Standard
ZAXIS110 Operational Performance
Standard TableT4-2-1
ZAXIS110M Operational Performance
Standard TableT4-2-5
ZAXIS120/130/130LCN Operational
Performance Standard TableT4-2-9
ZAXIS125US Operational Performance
Standard TableT4-2-13
ZAXIS135US Operational Performance
Standard TableT4-2-17
ZAXIS135UR Operational Performance
Standard TableT4-2-21
Main Pump P-Q Diagram T4-2-26
Injection PumpT4-2-28
ZAXIS110 Dr ZX Monitor Indicating
Values T4-2-30
ZAXIS110M Dr ZX Monitor Indicating
Values T4-2-34
ZAXIS120/130/130LCN Dr ZX Monitor
Indicating Values T4-2-38
ZAXIS125US Dr ZX Monitor Indicating
Values T4-2-42
ZAXIS135US Dr ZX Monitor Indicating
Values T4-2-46
ZAXIS135UR Dr ZX Monitor Indicating
Values T4-2-50
Sensor Operational Range Table T4-2-56
Group 3 Engine Test
Engine Speed T4-3-1
Engine Compression Pressure T4-3-4
Valve Clearance Adjustment T4-3-6
Nozzle Check T4-3-8
Injection Timing T4-3-10
Lubricant Consumption T4-3-12
Group 4 Excavator Test
Travel Speed T4-4-1
Track Revolution Speed T4-4-2
Mistrack Check T4-4-3
Travel Parking Function Check T4-4-4
Swing Speed T4-4-5
Swing Function Drift Check T4-4-6
Swing Motor Leakage T4-4-8
Maximum Swingable Slant Angle T4-4-10
Swing Bearing Play T4-4-11
Hydraulic Cylinder Cycle Time T4-4-12
Dig Function Drift Check T4-4-14
Control Lever Operating Force T4-4-18
Control Lever Stroke T4-4-20
Bucket/Cab Collision Prevention System
(ZAXIS135UR Only) T4-1-22
Combined Boom Raise/Swing
Function Check T4-4-24
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General
Introduction T5-1-1
Diagnosing Procedure T5-1-2
Built-In Diagnosing System Operation T5-1-6
Built-In Diagnosing Function Display List T5-1-7
Dr ZX Operation T5-1-8
Dr ZX Fault Code List (MC) T5-1-10
Dr ZX Fault Code List
(Auto-MARCCINO Controller) T5-1-12
Dr ZX Monitoring Item List (MC) T5-1-16
Dr ZX Monitoring Item List
(Auto-MARCCINO Controller) T5-1-18
Dr ZX Special Function T5-1-19
Dr ZX Service Mode (MC) T5-1-20
Adjustment Data List T5-1-32
Group 2 Component Layout
Main Component Layout T5-2-1
Electrical Component Layout (Overview) T5-2-4
Electrical System
(Relays and Related Equipment) T5-2-7
Electrical System
(Monitors and Switches) T5-2-10
Pump Device T5-2-12
Swing Device T5-2-13
Control Valve T5-2-13
Signal Control Valve T5-2-13
Solenoid Valve Unit T5-2-13
Travel Device T5-2-14
8-Spool Solenoid Valve T5-2-14
Blade Control Valve T5-2-14
Positioning Control Valve T5-2-14
Components in Control Valve T5-2-16
Signal Control Valve
Port Location T5-2-26
Group 3 Troubleshooting A
Troubleshooting A Procedure T5-3-1
Fault Code List T5-3-2
Fault Code 01, 02, 03T5-3-3
Fault Code 04T5-3-3
Fault Code 06T5-3-4
Fault Code 07T5-3-5
Fault Code 10, 11T5-3-6
Fault Code 12, 13T5-3-7
Fault Code 14, 15, 16, 18T5-3-8
Fault Code 19T5-3-9
Group 4 Troubleshooting B
Troubleshooting B ProcedureT5-4-1
Relationship between Machine Trouble
Symptoms and Related Parts T5-4-2
Correlation between Trouble
Symptoms and Part Failures T5-4-20
Engine System TroubleshootingT5-4-33
All Actuator System TroubleshootingT5-4-54
Front Attachment System
TroubleshootingT5-4-60
Swing System Troubleshooting T5-4-72
Travel System Troubleshooting T5-4-75
Blade System TroubleshootingT5-4-82
Other System Troubleshooting T5-4-86
Exchange Inspection T5-4-112
Emergency Boom Lowering
Procedure T5-4-114
187T-5-2
Group 5 Troubleshooting C
Troubleshooting C Procedure T5-5-1
Malfunction of Coolant
Temperature Gauge T5-5-2
Malfunction of Fuel Gauge T5-5-4
Malfunction of Indicator Light
Check System T5-5-6
Malfunction of Preheat Indicator T5-5-7
Malfunction of Engine Oil Level
Indicator T5-5-8
Malfunction of Coolant Level
Indicator T5-5-10
Malfunction of Alternator Indicator T5-5-12
Malfunction of Engine Oil Pressure
Indicator T5-5-14
Malfunction of Overheat Indicator T5-5-16
Malfunction of Air Filter Restriction
Indicator T5-5-18
Malfunction of Buzzer T5-5-20
Malfunction of LCD T5-5-22
Malfunction of Hour Meter T5-5-23
Malfunction of Hydraulic Oil Filter
Indicator (Optional) T5-5-24
Group 6 Troubleshooting D (ZAXIS 135
UR Only)
Troubleshooting D Procedure T5-6-1
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
Fault Code 92T5-6-22
Group 7 Electrical System Inspection
Precautions for Inspection and
MaintenanceT5-7-1
Instructions for Disconnecting
ConnectorsT5-7-3
Fuse InspectionT5-7-4
Fusible Link InspectionT5-7-6
Battery Voltage CheckT5-7-7
How to Troubleshoot Alternator
Malfunctions T5-7-8
Continuity Check T5-7-9
Voltage and Current Measurement T5-7-11
Check by False SignalT5-7-17
Test Harness T5-7-18
Group 8 ICX
Outline T5-8-1
ICX Fault Code List T5-8-6
Satellite Terminal Fault Code List T5-8-6
Fault Code 1 to 4 and 6T5-8-7
Fault Code 7 to 10T5-8-7
Some Parts of Data in Daily Report,
Frequency Distribution, Cumulative
Operation Hours are not RecordedT5-8-8

• Hitachi Zaxis 110 120 125US 135US 135UR Excavator Workshop Manual

SECTION 1
GENERAL
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 ChartW1-2-3
Piping JointW1-2-6
Periodic Replacement of PartsW1-2-10
Group 3 Painting
Painting (ZAXIS110, 110-E, 120, 120-E,
125US, 135US) W1-3-1
Painting (ZAX135UR) W1-3-3
SECTION 2
UPPERSTRUCTURE
Group 1 Cab
Remove and Install Cab W2-1-1
Dimensions of the Cab Glass W2-1-17
Group 2 Counterweight
Remove and Install Counterweight W2-2-1
Group 3 Main Frame
Remove and Install Main Frame W2-3-1
Group 4 Pump Device
Remove and Install Pump DeviceW2-4-1
Remove and Install Pilot Pump and
RegulatorW2-4-4
Disassemble Pump DeviceW2-4-8
Assemble Pump DeviceW2-4-16
Disassemble RegulatorW2-4-28
Assemble RegulatorW2-4-30
Disassemble Solenoid ValveW2-4-32
Assemble Solenoid ValveW2-4-34
Disassemble and Assemble Pilot
Pump (ZAXIS 110,120,125US,135US) W2-4-36
Disassemble and Assemble Gear
Pump (ZAXIS 135UR Only) W2-4-38
Maintenance Standard W2-4-40
Group 5 Control Valve
Remove and Install Control ValveW2-5-1
Disassemble Control Valve
4-Spool SectionW2-5-4
Disassemble Control Valve
5-Spool SectionW2-5-10
Separate and Combine
4-Spool and 5-Spool Control Valve W2-5-16
Assemble Control Valve
4-Spool SectionW2-5-18
Assemble Control Valve
5-Spool SectionW2-5-24
Disassemble Blade Control Valve
(ZAXIS 135UR Only) W2-5-30
Assemble Blade Control Valve
(ZAXIS 135UR Only) W2-5-32
Group 6 Swing Device
Remove and Install Swing Device W2-6-1
Disassemble Swing Device W2-6-4
Assemble Swing DeviceW2-6-10
Disassemble Swing Motor W2-6-18
Assemble Swing MotorW2-6-22
Disassemble Valve UnitW2-6-28
Assemble Valve UnitW2-6-30
Maintenance StandardW2-6-32
SECTION 3
UNDERCARRIAGE
Group 1 Swing Bearing
Remove and Install Swing Bearing W3-1-1
Disassemble Swing Bearing W3-1-4
Assemble Swing Bearing W3-1-6
Group 2 Travel Device
Remove and Install Travel Device W3-2-1
Disassemble Travel DeviceW3-2-4
Assemble Travel Device W3-2-10
Disassemble Travel Motor W3-2-16
Assemble Travel Motor W3-2-20
Disassemble Travel Brake Valve W3-2-26
Assemble Travel Brake Valve W3-2-28
Maintenance Standard W3-2-30
Group 3 Center Joint
Remove and Install Center JointW3-3-1
Disassemble Center Joint W3-3-4
Assemble Center JointW3-3-7
Maintenance Standard W3-3-11
Group 4 Track Adjuster
Remove and Install Track Adjuster W3-4-1
Disassemble Track Adjuster W3-4-2
Assemble Track Adjuster W3-4-10
Group 5 Front Idler
Remove and Install Front Idler W3-5-1
Disassemble Front Idler W3-5-2
Assemble Front Idler W3-5-6
Maintenance StandardW3-5-8
Group 6 Upper and Lower Roller
Remove and Install Upper RollerW3-6-1
Remove and Install Lower RollerW3-6-5
Disassemble Lower RollerW3-6-8
Assemble Lower RollerW3-6-10
Maintenance StandardW3-6-12
Group 7 Track
Remove and Install Tracks W3-7-1
Maintenance StandardW3-7-7
SECTION 4
FRONT ATTACHMENT
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 ConnectionW4-1-18
Group 2 Cylinder
Removeand Install Cylinder W4-2-1
Hydraulic Circuit Pressure Release
ProcedureW4-2-19
Disassemble Cylinder W4-2-20
Assemble CylinderW4-2-36
Maintenance Standard W4-2-52
SECTION 5
ENGINE AND ACCESSORY
General Information
General Repair Instructions 1-2
Notes on the Format of This Manual 1-2
Main Data and Specifications 1-6
Performance Curve 1-7
External View 1-9
Tightening Torque Specifications 1-13
Angular Nut and Bolt Tightening Method 1-15
Major Parts Fixing Nuts and Bolts 1-17
Identifications 1-25
Maintenance
Lubricating System 2-2
Fuel System 2-3
Cooling System 2-6
Valve Clearance Adjustment 2-6
Injection Timing 2-8
Compression Pressure Measurement 2-12
Turbocharger Inspection 2-13
Engine Repair Kit 2-14
Recommended Lubricants 2-15
Engine Oil Viscosity Chart 2-15
Engine Assembly 1 (Disassembly)
External Parts Disassembly Steps 3-2
Major Components 3-6
Rocker Arm and Rocker Arm Shaft
Disassembly Steps 3-10
Cylinder Head Disassembly Steps 3-11
Piston and Connecting Rod
Disassembly Steps 3-12
Engine Assembly 2
(Inspection and Repair)
Cylinder Head4-2
Valve Guide 4-3
Valve Spring 4-6
Tappet 4-7
Push Rod 4-8
Rocker Arm Shaft and Rocker Arm4-8
Idler Gear and Idler Gear Shaft 4-9
Camshaft 4-10
Cylinder Body and Liner 4-11
Piston and Piston Ring 4-17
Piston Pin 4-18
Connecting Rod 4-19
Crankshaft 4-21
Flywheel 4-28
Timing Gear Case Cover 4-28
Engine Assembly 3 (Reassembly)
Piston and Connecting Rod
Reassembly Steps5-2
Cylinder Head Reassembly Steps5-4
Rocker Arm and Rocker Arm Shaft
Reassembly Steps5-7
Major Component Reassembly Steps 1 5-8
Major Component Reassembly Steps 2 5-13
External Parts Reassembly Steps
(Left-Hand Side) 5-18
External Parts Reassembly Steps
(Right-Hand Side) 5-21
Engine Tuning Operation 5-25

• Hitachi Zaxis 110 120-E 130 130-H 130K 130LCN Excavator Parts Catalog Manual

PUMP
MOTOR;OIL
VALVE
CYLINDER
PARTS INDEX

HITACHI ZAXIS 110 110M 120 130 125US 135US 135UR EXCAVATOR OPERATIONAL PRINCIPLE+TROUBLESHOOTING+PARTS+WORKSHOP MANUAL – PDF DOWNLOAD:

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]