110125US 110M135US 120135UR
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
• 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.
(Note: Do not tear off the form. Copy it for usage.):
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.
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• 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.
• 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
• Operation Manual of the Engine
• Parts Catalog of the Engine
• Hitachi Training Material
• 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.
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual W: Workshop Manual
• 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
SAFETY ALERT SYMBOL AND HEADLINE
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.
This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.
• CAUTION:
Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.
• IMPORTANT:
Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or know-how.
Hitachi 120 EXCAVATOR Service Repair Manual
120 - Volvo Service Manual
120 - Volvo Repair Pdf
Instant Access Hitachi 120 Excavator Service Manual
Hitachi 130 EXCAVATOR Service Repair Manual
130 - Hitachi Service Manual
130 - Hitachi Repair Pdf
Instant Access Hitachi Excavator Service Manual
Hitachi 125US 135US EXCAVATOR Service Repair Manual
125US 135US - Hitachi Service Manual
125US 135US - Hitachi Repair Pdf
Instant Access Hitachi 125US 135US Excavator Service Manual
• SI Units (International System of Units) are used in this manual.
MKSA system units and English units are also indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposees.
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
(Operational Principle)
Group 2 Front Control System
Group 3 Hydraulic System
Group 4 Electrical System
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 PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT(C)2003
Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening Torque
Group 3 Painting
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
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Troubleshooting D
Group 7 Electrical System Inspection
Group 8 ICX
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Solenoid Valve
Group 11 Holding 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
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
ZAXIS110, 110M
Type of Front-End Attachment
m (7 ft 5 in) Arm
m (7 ft 5 in) Arm Bucket Capacity (Heaped) m3 (yd3)
(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)
B : Cab Height
C : Rear End Swing Radius
D : Minimum Ground Clearance mm (ft in)
E : Counterweight Clearance mm (ft in)
F : Engine Cover Height
G : Overall Width of Upperstructure mm (ft in)
H : Undercarriage Length
I : Undercarriage Width mm (ft in)
J : Sprocket Center to Idle Center
K : Track Shoe Width mm (ft in)
(Grouser Shoe) (20″)
(Grouer Shoe) (28″) Ground Pressure kPa
NOTE: H/P mode * The dimensions do not include the height of the shoe lug.
ZAXIS120
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)
Engine ISUZU CC-4BG1TC 63 kW/1950 min-1 (85 PS/1950 rpm) 66 kW/2150 min-1 (90 PS/2150 rpm)
A: Overall Width (Excluding back mirrors) 2500 mm (8 ft 2 in)
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
* The dimensions do not include the height of the shoe lug.
ZAXIS130, 130LCN
Std.
Model ZAXIS130 ZAXIS130LCN
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
Bucket Capacity (Heaped) m3 (yd3) PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Operating Weight kg (lb) 12400 (27300) 12500 (27600)
Basic Machine Weight kg (lb) 9700 (21400) 9900 (21800)
Engine ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min 1 (rpm) 66 kW (90 PS)/2150 min 1 (rpm)
A : Overall Width (Excluding Rearview Mirrors) mm (ft in) 2500 (8′ 2″)
B : Cab Height mm (ft in) 2750 (9′ 0″)
C : Rear End Swing Radius mm (ft in) 2130 (7′ 0″)
D : Minimum Ground Clearance mm (ft in) *440 (1′ 5″)
E : Counterweight Clearance mm (ft in) *890 (2′ 11″)
F : Engine Cover Height mm (ft in) *2010 (6′ 7″)
G : Overall Width of Upperstructure mm (ft in) 2460 (8′ 1″)
H : Undercarriage Length mm (ft in) 3590 (11′ 9″) 3760 (12′ 4″)
I : Undercarriage Width mm (ft in) 2490 (8′ 2″)
J : Sprocket Center to Idle Center mm (ft in) 2880 (9′ 5″) 3050 (10′ 0″)
K : Track Shoe Width mm (ft in) 500 (Grouser Shoe) (20″)
Ground Pressure kPa (kgf/cm2) (psi)
(0.38) (5.4) Swing Speed min 1 (rpm) 13.7 (13.7)
Travel Speed (fast/slow) km/h (mph) 5.5/3.4 (3.4/2.1)
Gradeability degree (%) 35 (70)
NOTE: H/P mode
* The dimensions do not include the height of the shoe lug.
ZAXIS125US
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
ZAXIS125US
2.26 m (7 ft 5 in) Arm
PCSA 0.45 m3 (0.59 yd3), CECE 0.4 m3
Operating Weight 12400 kg (27300 lb)
Basic Machine Weight 9900 kg (21800 lb)
Engine
T1SE-01-01-001
ISUZU BB-4BG1T 59 kW/1950 min-1 (80 PS/1950 rpm) 63 kW/2150 min-1 (85 PS/2150 rpm)
A: Overall Width (Excluding back mirrors) 2490 mm (8 ft 2 in)
B: Cab Height 2740 mm (9 ft 0 in)
C: Rear End Swing Radius 1465 mm (4 ft 10 in)
D: Minimum Ground Clearance *440 mm (1 ft 5 in)
E: Counterweight Clearance *890 mm (2 ft 11 in)
F: Engine Cover Height *2020 mm (6 ft 8 in)
G: Overall Width of Upperstructure 2470 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 39 kPa (0.40 kgf/cm2, 5.7 psi)
Swing Speed 13.9 min-1 (13.9 rpm)
Travel Speed (fast/slow) 5.3/3.2 km/h (3.2/2.0 mph)
Gradeability 35 degree (70 %)
NOTE: HP mode
* The dimensions do not include the height of the shoe lug.
ZAXIS135US
Model
Type of Front-End Attachment
ZAXIS135US
2.52 m (8 ft 3 in) Arm
Bucket Capacity (Heaped) PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Operating Weight 13200 kg (29100 lb)
Basic Machine Weight 10600 kg (23400 lb)
Engine
T1SE-01-01-001
ISUZU CC-4BG1TC 63 kW/1950 min-1 (85 PS/1950 rpm) 66 kW/2150 min-1 (90 PS/2150 rpm)
A: Overall Width (Excluding back mirrors) 2490 mm (8 ft 2 in)
B: Cab Height 2740 mm (9 ft 0 in)
C: Rear End Swing Radius 1465 mm (4 ft 10 in)
D: Minimum Ground Clearance *440 mm (1 ft 5 in)
E: Counterweight Clearance *890 mm (2 ft 11 in)
F: Engine Cover Height *2020 mm (6 ft 8 in)
G: Overall Width of Upperstructure 2470 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 41 kPa (0.42 kgf/cm2, 5.4 psi)
Swing Speed 13.7 min-1 (13.7 rpm)
Travel Speed (fast/slow) 5.0/3.0 km/h (3.4/2.1 mph)
Gradeability 35 degree (70 %)
NOTE: HP mode
* The dimensions do not include the height of the shoe lug.
ZAXIS135UR
Model ZAXIS135UR
Type of Front-End Attachment Offset Type
Bucket Capacity (Heaped) PCSA 0.45 m3 (0.59 yd3), CECE 0.40 m3
Operating Weight 14400 kg (31800 lb)
Basic Machine Weight 11100 kg (24500 lb)
Engine ISUZU BB-4BG1T 59 kW/1950 min-1 (80 PS/1950 rpm) 63 kW/2150 min-1 (85 PS/2150 rpm)
A: Overall Width (Excluding back mirrors) 2490 mm (8 ft 2 in)
B: Cab Height 2780 mm (4 ft 1 in)
C: Rear End Swing Radius 1465 mm (4 ft 10 in)
D: Minimum Ground Clearance 500 mm (1 ft 8 in)
E: Counterweight Clearance 960 mm (3 ft 2 in)
F: Engine Cover Height *2080 mm (6 ft 10 in)
G: Overall Width of Upperstructure 2460 mm (8 ft 1 in)
H: Undercarriage Length 3670 mm (12 ft 1 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) (Pad Crawler)
Ground Pressure 45 kPa (0.46 kgf/cm2, 6.5 psi)
Swing Speed 13.9 min-1 (13.9 rpm)
Travel Speed (fast/slow) 4.6/2.7 km/h (2.9/1.7 mph)
Gradeability 35 degree (70 %)
NOTE: HP mode
* The dimensions do not include the height of the shoe lug.
ZAXIS130, 130LCN (2-piece Boom)
Model
ZAXIS130 2-piece Boom
ZAXIS130LCN 2-piece Boom
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
Bucket Capacity (Heaped) m3 (yd3)PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Operating Weight kg (lb)12800 (28200) 13000 (28700)
Basic Machine Weight kg (lb)9700 (21400) 9900 (21800)
Engine ISUZU CC-4BG1TC, 63 kW (85 PS)/1950 min 1 (rpm) 66 kW (90 PS)/2150 min 1 (rpm)
A : Overall Width (Excluding Rearview Mirrors) mm (ft in) 2500 (8′ 2″)
B : Cab Height mm (ft in) 2750 (9′ 0″)
C : Rear End Swing Radius mm (ft in) 2130 (7′ 0″)
D : Minimum Ground Clearance mm (ft in) * 440 (1′ 5″)
E : Counterweight Clearance mm (ft in) * 890 (2′ 11″)
F : Engine Cover Height mm (ft in) * 2010 (6′ 7″)
G : Overall Width of Upperstructure mm (ft in) 2460 (8′ 1″)
H : Undercarriage Length mm (ft in)3590 (11′ 9″)
I : Undercarriage Width mm (ft in) 2490 (8′ 2″)
J : Sprocket Center to Idle Center mm (ft in)2880 (9′ 5″)
K : Track Shoe Width mm (ft in)
Ground Pressure kPa (kgf/cm2) (psi)40 (0.41) (5.8)
500 (Grouser Shoe) (20″)
3760 (2’ 4”)
3050 (10’ 0”)
38 (0.39) (5.5) Swing Speed min 1 (rpm)13.7 (13.7)
Travel Speed (fast/slow) km/h (mph)
5.5/3.4 (3.4/2.1)
Gradeability degree (%)35 (70)
NOTE: H/P mode
* The dimensions do not include the height of the shoe lug.
ZAXIS110, 110M
B : Maximum Digging
C : Maximum Cutting Height
NOTE:
A: Maximum Digging
B: Maximum Digging Depth
C: Maximum Cutting Height
D: Maximum Dumping Height
E: Transport Height
F: Overall Transport Length
G: Minimum Swing Radius
mm (7 ft 7 in)
NOTE: * The dimensions do not include the height of the shoe lug. ** The dimensions are for transport pin position.
shovel (Reversed hoe bucket)
ZAXIS130, 130LCN
A : Maximum Digging
B : Maximum Digging Depth
C : Maximum Cutting Height
D : Maximum Dumping Height
E : Transport Height
F : Overall Transport Length
G : Minimum Swing Radius
NOTE: * The dimensions do not include the height of the shoe lug.
** The dimensions asterisked are for transport pin position.
ZAXIS125US T1SE-01-01-002 M1SE-12-001
NOTE: *1 The dimensions do not include the height of the shoe lug. *2 The dimensions asterisked are for transport pin position.
ZAXIS135US
B
NOTE: *1 The dimensions do not include the height of the shoe lug. *2 The dimensions asterisked are for transport pin position.
ZAXIS135UR
Category Item 2.14 m (7 ′ 0 ″ ) arm (Standard) 2.44 m (8 ′ 0 ″ ) Long arm
A: Maximum Digging Reach 7590 mm (24 ft 11 in)7920 mm (25 ft 12 in)
B: Maximum Digging Depth
C: Maximum Cutting Height
D: Maximum Dumping Height
E: Transport Height
F: Overall Transport Length
G: Minimum Swing Radius (Front Attachment)
mm (15 ft 9 in)
(28 ft 5 in)
mm (9 ft 1 in)
mm (16 ft 9 in)
(29 ft 6 in)
(21 ft 5 in)
mm (9 ft 1 in)
mm (23 ft 10 in)7300 mm (23 ft 11 in)
mm (4 ft 4 in)
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 of Front end Attachment) Left (Cab side) 1130 mm (3 ft 9 in) Right 1130 mm (3 ft 9 in)
K: Approach Angle 30 degree
T1SM-01-01-002
ZAXIS130, 130LCN (2-piece Boom) M1G6-13-011
A : Maximum Digging Reach mm (ft in)
*1 B : Maximum Digging Depth mm (ft in)
(16′ 3″)
130LCN 2-piece Boom
(17′ 6″)
(19′ 2″) *1 C : Maximum Cutting Height mm (ft in)
*1 D : Maximum Dumping Height mm (ft in)
E : Transport Height mm (ft in)
F : Overall Transport Length mm (ft in)
(29′ 9″)
(9′ 0″)
(24′ 9″)
G : Minimum Swing Radius mm (ft in) - -
NOTE: * The dimensions do not include the height of the shoe lug. ** The dimensions asterisked are for transport pin position.
(9′ 0″)
• Pressure Sensor (Travel)
• Pressure Sensor (Swing) Refer to the Signal Control Valve group.
• Pressure Sensor (Boom Raise)
• Pressure Sensor (Arm Roll-In)
to the Control Valve group.
N
• Pump 2 Flow Rate Control Solenoid Valve
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
Refer to the Pump Device group.
• Pressure Sensor (Boom Raise)
• Pressure Sensor (Arm Roll-In)
Refer to the Control Valve group
• Pressure Sensor (Travel)
• Pressure Sensor (Swing)
Refer to the Signal Control Valve group
•
•
• 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 Refer to the Pump Device group.
2
3
5 -
• Pressure Sensor (Boom Raise)
ELECTRICAL SYSTEM (Relays and Related Equipment)
ZAXIS110/110M/120/130/130LCN
T178-01-02-006
T178-01-02-007 1- Mail Switch (Satellite Navigation System Equipped Machines only)
Download Connector (Not connected on Satellite Navigation System equipped machines)
ZAXIS125US/135US
T1GF-01-02-003
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 connected on Satellite Navigation System equipped machines) 9 - Learning Switch 14 - Load Damp Relay (R1)
5 - Diode D1, D2, D3 and D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)