2002-era Hitachi ZAXIS 110, 110M, 120, 125US, 130, 130LCN, 135US & 135UR Excavator Workshop & Technical Manuals (P/N W187E-03)

This 2002-era Hitachi ZAXIS manual set covers the 110, 110M, 120, 125US, 130, 130LCN, 135US, and 135UR excavators. It combines Workshop Manual W187E-03, Technical Manual (Troubleshooting) TT187E-04, Technical Manual (Operational Principle) TO187E-04, and ZAXIS Air Conditioner Troubleshooting Manual TT1G6-EAC-00.

• Engine overhaul: Cylinder head and valve work, liner and piston inspection, crankshaft measurements, lubrication and cooling repairs, plus starter and alternator overhaul.

• Hydraulic components: Main and pilot pump repair, regulator adjustment, control valve disassembly, swing device overhaul, and pilot, solenoid, and holding valve service.

• Undercarriage: Travel motor and reduction gear overhaul, swing bearing service, center joint repair, and track adjuster, idler, roller, and track procedures.

• Cab and upper structure: Cab removal, bonded-glass replacement, harness routing, and main frame and counterweight removal and installation.

• Diagnostic procedures: Dr. ZX, MC fault codes, symptom-based troubleshooting, built-in monitor checks, and electrical test-harness procedures.

• Front attachment: Boom, arm, bucket, and cylinder work, with ZAXIS 135UR offset/blade hydraulics and Auto-MARCCINO collision-prevention checks.

• Air conditioning: System-specific troubleshooting, self-diagnostic functions, sensor and servo motor checks, refrigerant evacuation and charging, and leak checks.

The manuals are written for experienced technicians carrying out maintenance, diagnosis, and repair with the required workshop equipment.

Isuzu Engine Repair and Fuel-System Service

The engine section covers BB-4BG1TRG and CC-4BG1TCG engines, including internal inspection and overhaul, timing gear assembly, compression testing, injection timing, and nozzle testing. Turbocharger coverage includes TD04HL inspection.

Injection-pump adjustment and repair are assigned to an authorized ZEXEL or ROBERT BOSCH service outlet. The pump calibration sheets are examples, not universal settings for every engine.

Hydraulic Testing and Model-Specific Repairs

Pump P–Q diagrams accompany relief-pressure, cylinder-drift, travel-performance, and hydraulic-leakage tests. Exploded views and component cross-sections illustrate pump and swing device assemblies.

ZAXIS 110M has separate travel motor and reduction gear instructions. ZAXIS 135UR procedures address its blade gear pump, holding valve, and offset/blade controls.

Air-bleeding instructions cover pump, swing, and travel components, with warnings about damage from trapped air. Hydraulic-hose routing drawings distinguish boom, arm, and bucket connections.

Fault Isolation and Electrical Diagrams

Separate code-based and symptom-based paths help select relevant tests even when a malfunction produces no fault code. Dr. ZX monitoring, MC diagnosis, monitor checks, and ICX information-controller procedures support fault isolation.

Electrical schematics, connector pinouts, and engine/cab harness drawings support circuit tracing. ZAXIS 135UR material includes connector, console-harness, and hydraulic diagrams, but this PDF lacks its standalone full-machine electrical schematic.

Cab Glass, Assembly Data, and Structural Service

Bonded-glass procedures include piano-wire removal, SUNRISE MSI Primer 24 and Primer 35, suction lifter 4355282, and spacer dimensions. Certain panes require complete glass-and-mounting-rubber assemblies; their replacement procedures differ from those for individually bonded panes.

Cab-glass dimensional drawings, piping-joint views, O-ring joint schematics, and nylon-sling lifting illustrations accompany the assembly procedures. Safety coverage addresses heavy-component lifting and high-pressure hydraulics.

Torque tables cover the engine, cab, and control valve in SI and US customary units. ZAXIS 130K information is limited to shared tightening-torque references.

Painting instructions identify upper-structure, undercarriage, and cab paint codes, along with temperature precautions.

Air-Conditioner Variants and Diagnostics

The separate air-conditioner manual distinguishes the 120/180-class and 200/225/270/330-class systems, including different control layouts and diagnostic routines. Coverage of these additional machine classes is specific to their air-conditioning systems.

Examples of Pump Wear Limits and Valve Settings

These pump inspection dimensions and engine settings are a small selection of the workshop specifications.

The main-pump drive shaft has a standard outer diameter of 35 mm at inspection point A, with a 34.8 mm allowable limit. Plunger-shoe thickness at point B is 5.5 mm standard, with a 5.2 mm allowable limit.

For the BB-4BG1TRG and CC-4BG1TCG engines, cold intake and exhaust valve clearance is 0.40 mm (0.016 in).

PDF Navigation, Diagram Detail, and Included Manuals

Search and diagram detail: PDF text search and embedded bookmarks are unavailable. Some diagram sheets require rotation, and dense electrical schematics contain small labels that remain difficult to read when enlarged.

The download is one printable, 1,655-page PDF. It contains the Workshop Manual (733 pages), Troubleshooting Technical Manual (452), Operational Principle Technical Manual (307), Air Conditioner Troubleshooting Manual (130), and 33 diagram pages, including 10 duplicate sheets. The total already includes four title pages, the blank and memo pages, and one service-manual revision request form.