Part of the Hitachi Repair Manuals.
This is the full Hitachi service set for the Zaxis 110, 110M, 120, 130, 130LCN and the short tail 125US, 135US and 135UR: the Technical Manual for operational principle (TO187E), the Troubleshooting volume (TT187E), the Workshop Manual (W187E) under publication KM-187E, plus the fold out electrical and hydraulic circuit sheets printed per model and the supplementary technical set for the 110, 120, 125US and 135US. You get the theory (HIOS pump control, pilot circuit, signal control valve), the numbers (relief pressures, drainage limits, torques), the test procedures to prove a component bad before you pull it, and the teardown steps for pumps, motors, the swing device and the entire undercarriage. Written for the Isuzu 4BG1 powered machines, with model specific spec tables throughout.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Manual: General | 1-58 | Machine Model Designations, Component Layout, Serial Number Locations, Standard Maintenance Intervals, Dimensions Against the Earlier EX Series |
| Technical Manual: System | 59-176 | Hydraulic System Layout, Pilot Circuit, Pump Control, HIOS Controller Behaviour, Electrical System Architecture, Engine Control |
| Technical Manual: Component Operation | 177-318 | Main Pump, Pilot Valve, Control Valve, Swing Device, Travel Device, Signal Control Valve, Solenoid Valve Unit |
| Operational Performance Test | 319-503 | Test Standards, Engine Test, Excavator Test, Component Test, Adjustment Procedures |
| Troubleshooting | 504-773 | Component Layout, Fault Diagnosis Flowcharts a to D, Electrical System Inspection, ICX Diagnostics |
| Attached Circuit Diagrams | 774-824 | Electrical Circuit Diagrams per Model, Connector Charts, Cab Harness, Engine Harness, Monitor Harness, Hydraulic Circuit Diagrams, Quick Hitch and Overload Alarm Sheets |
| Workshop Manual: General | 825-888 | Precautions for Disassembling and Assembling, Tightening Torque Specifications, Torque Chart, Piping Joint Standards |
| Workshop Manual: Upperstructure | 889-1140 | Swing Device, Main Pump, Control Valve, Pilot Valve, Swing Motor, Cab and Covers Removal and Installation |
| Workshop Manual: Undercarriage | 1141-1268 | Travel Device, Centre Joint, Track Adjuster, Idler, Track Roller, Sprocket, Track Chain |
| Workshop Manual: Front Attachment | 1269-1344 | Boom, Arm, Bucket, Cylinders, Bushings and Pins, Front Joint Disassembly |
| Workshop Manual: Engine and Accessory | 1345-1572 | Engine Removal and Installation, Cooling Package, Fuel System, Air Conditioner, Accessory Drive |
| Supplementary Technical Manual (110, 120, 125US, 135US): General | 1573-1612 | Component Layout for the Supplemented Machines, Serial Coverage, Specification Tables |
| Supplementary Technical Manual (110, 120, 125US, 135US): System | 1613-1692 | Pump Delivery and Pilot Circuit Routing, Signal Control Valve Behaviour, Solenoid Valve Unit, Monitor Inputs |
| Supplementary Technical Manual (110, 120, 125US, 135US): Component Operation | 1693-1789 | Pump, Valve and Motor Operation for the Supplemented Machines |
| Supplementary Performance Check (110, 120, 125US, 135US) | 1790-1905 | Performance Check Safety, Test Standards, Engine and Excavator Tests |
| Supplementary Troubleshooting (110, 120, 125US, 135US) | 1906-2121 | Adjustment Data List, Sensor Activating Ranges, Connector Charts, Fault Diagnosis Flowcharts |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main relief valve set pressure - boom, arm, bucket | 34.3 MPa (350 kgf/cm2, 4980 psi), tolerance +2.0 / -0.5 | p. 363 |
| Relief pressure when relieving swing | 33.5 MPa (340 kgf/cm2, 4835 psi), tolerance +2.0 / -0.5 | p. 363 |
| Relief pressure when relieving travel | 34.5 MPa (350 kgf/cm2, 4980 psi), tolerance +2.0 / -0.5 | p. 363 |
| Overload relief - boom, arm roll-in, bucket roll-in | 37.3 MPa (380 kgf/cm2, 5400 psi), tolerance +1.0 / -0 | p. 363 |
| Overload relief - arm roll-out, bucket roll-out | 39.2 MPa (400 kgf/cm2, 5690 psi), tolerance +1.0 / -0 | p. 363 |
| Primary pilot pressure at fast idle | 4.0 MPa (40 kgf/cm2, 570 psi), tolerance +1.0 / -0.5 | p. 362 |
| Secondary pilot pressure | 3.4 to 4.0 MPa (34 to 40 kgf/cm2, 483 to 570 psi) | p. 362 |
| Main pump maximum flow, theoretical | 100 L/min (26.4 US gpm) x 2 | p. 43 |
| Swing motor drainage at constant maximum speed | 0.4 L/min or less | p. 363 |
| Swing motor drainage with the motor relieved | 1.6 L/min or less | p. 363 |
| Travel motor drainage with the track jacked up | 0.3 to 1.2 L/min | p. 363 |
| Travel motor drainage with the motor relieved | 0.3 to 1.9 L/min | p. 363 |
| Slow idle speed | 1000 +/- 100 min-1 | p. 360 |
| Fast idle speed, normal | 1915 +/- 50 min-1 | p. 360 |
| Engine compression pressure after warm-up | 2.95 MPa (30.0 kgf/cm2, 427 psi) | p. 360 |
| Valve clearance, inlet and exhaust | 0.4 mm | p. 360 |
| Nozzle injection pressure | 18.1 MPa (185 kgf/cm2, 2630 psi) | p. 360 |
| Hydraulic oil temperature for measurement | 50 +/- 5 C (122 +/- 9 F) | p. 457 |
| Swing device mounting bolt torque | 500 N.m (51 kgf.m, 370 lbf.ft) | p. 873 |
| Track shoe bolt torque | 410 N.m (42 kgf.m, 300 lbf.ft) | p. 873 |
