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

Use the Operational Principle volume to follow system operation, the Troubleshooting volume to isolate a fault, and the Workshop Manual for the component repair. The air-conditioner volume provides separate diagnostic procedures for the listed A/C classes.

For the ZAXIS 135UR, the diagram sheets include connector, console harness, and hydraulic references. The full-machine electrical schematic for that model is listed in the Troubleshooting volume and is absent from this download.

PDF Format and Diagram Readability

Scanned pages and diagrams: The PDF has no searchable text layer or embedded bookmarks. Some diagram sheets are sideways, and small labels on dense electrical schematics can remain difficult to read after rotation and magnification.

The download is one printable PDF with 1,655 pages. That total includes the four title pages, blank and memo pages, one revision request form, and 33 separate diagram sheets, including 10 duplicates.

Engine Overhaul, Hydraulic Repair, and Fault Diagnosis

This selection of procedures covers major workshop jobs. The manuals also include paint codes and application-temperature guidance for the upperstructure, undercarriage, and cab.

• Engine overhaul: Cylinder head and valve service, piston and liner inspection, crankshaft measurements, lubrication and cooling repairs, and starter and alternator overhaul.
• Hydraulic components: Main and pilot pump repair, regulator adjustment, control valve disassembly, swing device overhaul, and service procedures for pilot, solenoid, and holding valves.
• Undercarriage: Travel motor and reduction gear overhaul, swing bearing service, center joint repair, and procedures for track adjusters, idlers, rollers, and tracks.
• Cab and upperstructure: Cab removal, bonded-glass replacement, harness routing, and removal and installation of the main frame and counterweight.
• Electrical diagnosis: Dr. ZX and built-in monitor checks, MC fault codes, symptom-based troubleshooting, and electrical test-harness procedures.
• Front attachment: Boom, arm, bucket, and cylinder procedures, plus ZAXIS 135UR offset and blade hydraulics and Auto-MARCCINO checks.
• Air conditioning: Controller self-diagnosis, sensor and servo motor checks, leak testing, and refrigerant evacuation and charging.

The set is written for experienced technicians performing maintenance, fault isolation, and component repair with workshop and diagnostic equipment.

Isuzu Engine and Fuel-System Service

The engine section covers BB-4BG1TRG and CC-4BG1TCG overhaul, with timing gear assembly, compression testing, injection timing, and injector nozzle checks. The TD04H turbocharger section shows how rotor shaft play is measured.

The manual directs injection pump adjustment and repair to an authorized ZEXEL or Robert Bosch service outlet. The included calibration sheets illustrate example pump configurations.

Hydraulic Testing and Model-Specific Repairs

Pump pressure-flow diagrams support relief-pressure, cylinder-drift, travel-performance, and leakage tests. Hose-routing drawings distinguish boom, arm, and bucket connections. The ZAXIS 110M has dedicated travel motor and reduction gear procedures, while the ZAXIS 135UR has procedures for its blade gear pump and holding valve. The ZAXIS 130 and 130LCN also have dedicated two-piece-boom hydraulic references.

The air-bleeding procedures distinguish the pump, swing motor, travel motor, and cylinders. Air left in a pump or motor housing after service can damage the component at startup.

Fault Isolation and Circuit Tracing

Use the symptom charts to select checks when Dr. ZX or the built-in monitor returns no fault code. Connector pinouts and harness drawings help trace wiring between the controller and the affected component. The Troubleshooting volume also covers ICX information-controller checks.

Cab Glass and Assembly References

The bonded-glass procedures identify piano-wire removal, SUNRISE MSI Primer 24 and Primer 35, suction lifter 4355282, and spacer dimensions. The cab chapter distinguishes individually bonded panes from panes serviced as complete glass-and-rubber assemblies.

Cab-glass drawings, sling lifting views, piping-joint and O-ring illustrations, and tightening tables in SI and US customary units support reassembly. ZAXIS 130K coverage is limited to shared tightening-torque references.

Air-Conditioner Controls and Diagnostics

The A/C volume separates the 120/180-class controls from the 200/225/270/330-class controls so technicians can match the diagnostic routine to the installed system. The additional machine classes are covered for air conditioning only.

Examples of Pump Wear Limits and Valve Clearance

The main pump drive shaft has a standard outside diameter of 35 mm at inspection point A and an allowable limit of 34.8 mm. The plunger shoe has a standard thickness of 5.5 mm at point B and an allowable limit of 5.2 mm.

The Isuzu engine maintenance section specifies 0.40 mm (0.016 in) cold clearance for both intake and exhaust valves on the BB-4BG1TRG and CC-4BG1TCG engines.