Description
Factory Workshop Manual in PDF format for Hitachi. Contains detailed illustrations, instructions, and diagrams, step-by-step process for removal and installation, disassembly and assembly, service, inspection, repair, troubleshooting, tuneups.
Features
PDF (Instant Download)
Language: English
Pages: 2121
Number: KM-187E
Bookmarks
Searchable Text
Wiring Diagrams
Hydraulic Diagrams
Models
Hitachi
110, 125US, 110M, 135US, 120, 135UR, 130, 130LCN
Contents
INTRODUCTION
SAFETY
-GENERAL
-PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
Maintenance Standard Terminology
-TIGHTENING TORQUE
Tightening Torque Specification
Torque Chart
Piping Joint
Periodic Replacement of Parts
-PAINTING
Painting (ZAXIS110, 110-E, 120, 120-E, 125US, 135US)
Painting (ZAX135UR)
-UPPERSTRUCTURE
-CAB
Remove and Install Cab
Dimensions of the Cab Glass
-COUNTERWEIGHT
Remove and Install Counterweight
-MAIN FRAME
Remove and Install Main Frame
-PUMP DEVICE
Remove and Install Pump Device
Remove and Install Pilot Pump and Regulator
Disassemble Pump Device
Assemble Pump Device
Disassemble Regulator
Assemble Regulator
Disassemble Solenoid Valve
Assemble Solenoid Valve
Disassemble and Assemble Pilot Pump (ZAXIS 110,120,125US,135US)
Disassemble and Assemble Gear Pump (ZAXIS 135UR Only)
Maintenance Standard
-CONTROL VALVE
Remove and Install Control Valve
Disassemble Control Valve 4-Spool Section
Disassemble Control Valve 5-Spool Section
Separate and Combine 4-Spool and 5-Spool Control Valve
Assemble Control Valve 4-Spool Section
Assemble Control Valve 5-Spool Section
Disassemble Blade Control Valve (ZAXIS 135UR Only)
Assemble Blade Control Valve (ZAXIS 135UR Only)
-SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Device
Assemble Swing Device
Disassemble Swing Motor
Assemble Swing Motor
Disassemble Valve Unit
Assemble Valve Unit
Maintenance Standard
-PILOT VALVE
Remove and Install Right Pilot Valve (ZAXIS 110,120,125US,135US)
Remove and Install Left Pilot Valve (ZAXIS 110,120,125US,135US)
Remove and Install Front / Swing Pilot Valve (ZAXIS 135UR)
Disassemble Right and Left Pilot Valves
Assemble Right and Left Pilot Valves
Remove and Install Travel Pilot Valve
Disassemble Travel Pilot Valve
Assemble Travel Pilot Valve
Remove and Install Offset Pilot Valve (ZAXIS 135UR)
Remove and Install Blade Pilot Valve (ZAXIS 135UR)
Disassemble Offset / Blade Pilot Valve (ZAXIS 135UR)
Assemble Offset / Blade Pilot Valve (ZAXIS 135UR)
-PILOT SHUT-OFF VALVE
Remove and Install Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve (ZAXIS 110,120)
Disassemble Pilot Shut-Off Valve (ZAXIS 125US,135US,135UR)
Assemble Pilot Shut-Off Valve (ZAXIS 110,120)
Assemble Pilot Shut-Off Valve (ZAXIS 125US,135US,135UR)
-SIGNAL CONTROL VALVE
Remove and Install Signal Control Valve
-SOLENOID VALVE
Remove and Install Solenoid Valve Unit
Disassemble Proportional Solenoid Valve
Assemble Proportional Solenoid Valve W2-1D-8
Remove and Install Emergency Stop Solenoid Valve Unit (ZAXIS 135UR Only)
Disassemble and Assemble Selector Valve
Disassemble and Assemble Unloading Valve
-HOLDING VALVE
Remove and Install Holding Valve
Holding Valve (ZAXIS 135UR Only)
-UNDERCARRIAGE
-SWING BEARING
Remove and Install Swing Bearing
Disassemble Swing Bearing
Assemble Swing Bearing
-TRAVEL DEVICE
Remove and Install Travel Device
Disassemble Travel Device (ZAXIS110, 120,130,130LCN,125US,135US,135UR)
Assemble Travel Device (ZAXIS110, 120,130,130LCN,125US,135US,135UR)
Disassemble Travel Motor (ZAXIS110, 120,130,130LCN,125US,135US,135UR)
Assemble Travel Motor (ZAXIS110, 120,130,130LCN,125US,135US,135UR)
Disassemble Travel Brake Valve (ZAXIS110, 120,130,130LCN,125US, 135US135UR)
Assemble Travel Brake Valve (ZAXIS110, 120,130,130LCN,125US, 135US135UR)
Disassemble Travel Reduction Gear (ZAXIS110M)
Assemble Travel Reduction Gear (ZAXIS110M)
Disassemble Travel Motor (ZAXIS110M)
Assemble Travel Motor (ZAXIS110M)
Disassemble Base Plate (ZAXIS110M)
Assemble Base Plate (ZAXIS110M)
Maintenance Standard
-CENTER JOINT
Remove and Install Center Joint
Disassemble Center Joint
Assemble Center Joint
Maintenance Standard
-TRACK ADJUSTER
Remove and Install Track Adjuster
Disassemble Track Adjuster
Assemble Track Adjuster
-FRONT IDLER
Remove and Install Front Idler
Disassemble Front Idler
Assemble Front Idler
Maintenance Standard
-UPPER AND LOWER ROLLER
Remove and Install Upper Roller
Remove and Install Lower Roller
Disassemble Lower Roller
Assemble Lower Roller
Maintenance Standard
-TRACK
Remove and Install Tracks
Maintenance Standard
-FRONT ATTACHMENT
-FRONT ATTACHMENT
Remove and Install Front Attachment
Maintenance Standard
Standard Dimensions for Arm and Bucket Connection
Standard Dimensions for Arm and Boom Connection
-CYLINDER
Removeand Install Cylinder
Hydraulic Circuit Pressure Release Procedure
Disassemble Cylinder
Assemble Cylinder
Maintenance Standard
-ENGINE AND ACCESSORY
-GENERAL INFORMATION
General Repair Instructions
Notes on the Format of This Manual
Main Data and Specifications
Performance Curve
External View
Tightening Torque Specifications
Angular Nut and Bolt Tightening Method
Major Parts Fixing Nuts and Bolts
Identifications
-MAINTENANCE
Lubricating System
Fuel System
Cooling System
Valve Clearance Adjustment
Injection Timing
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair Kit
Recommended Lubricants
Engine Oil Viscosity Chart
-ENGINE ASSEMBLY 1 (DISASSEMBLY)
External Parts Disassembly Steps
Major Components
Rocker Arm and Rocker Arm Shaft Disassembly Steps
Cylinder Head Disassembly Steps
Piston and Connecting Rod Disassembly Steps
-ENGINE ASSEMBLY 2 (INSPECTION AND REPAIR)
Cylinder Head
Valve Guide
Valve Spring
Tappet
Push Rod
Rocker Arm Shaft and Rocker Arm
Idler Gear and Idler Gear Shaft
Camshaft
Cylinder Body and Liner
Piston and Piston Ring
Piston Pin
Connecting Rod
Crankshaft
Flywheel
Timing Gear Case Cover
-ENGINE ASSEMBLY 3 (REASSEMBLY)
Piston and Connecting Rod Reassembly Steps
Cylinder Head Reassembly Steps
Rocker Arm and Rocker Arm Shaft Reassembly Steps
Major Component Reassembly Steps 1
Major Component Reassembly Steps 2
External Parts Reassembly Steps (Left-Hand Side)
External Parts Reassembly Steps (Right-Hand Side)
Engine Tuning Operation
-LUBRICATING SYSTEM
General Description
Oil Pump
Oil Cooler
-COOLING SYSTEM
General Description
Thermostat
-FUEL SYSTEM
General Description
Injection Nozzle
Injection Pump Calibration Data
-TURBOCHARGER
General Description
Turbocharger Identification
Troubleshooting
Inspection and Repair
-ENGINE ELECTRICALS
Starter Identification
Starter Main Data and Specifications
Starter Sectional View
Performance
Disassembly
Inspection and Repair
Reassembly
Adjustment
Performance Test
Alternator Identification
Main Data and Specifications
Alternator Sectional View
Charging Circuit
Structure
Disassembly
Inspections
Reassembly
Bench Test
Current Output Test
Fault Finding
Specifications
-TROUBLESHOOTING
HARD STARTING
STARTER INOPERATIVE
2STARTER OPERATES BUT
ENGINE DOES NOT TURN OVER
3ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
ENGINE TURNS OVER BUT DOES NOT START-
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption
Excessive Oil Consumption
Overheating
Whity Exhaust Smoke
Dark Exhaust Smoke
Oil Pressure does not Rise
Abnormal Engine Noise
-SPECIAL TOOL LIST
Special Tool List
-REPAIR STANDARDS
Repair Standards
-CONVERSION TABLE
Length
Area
Volume
Mass
Pressure
Torque
Temperature
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