Description

Hitachi ZX135UR Excavator Operator’s Manual (EM1SM-1-1)

Hitachi ZX135UR Excavator Index:

MACHINE NUMBERS
SAFETY
Recognize Safety Information ……………………………S-1
Understand Signal Words …………………………………S-1
Follow Safety Instructions …………………………………S-2
Prepare for Emergencies…………………………………..S-2
Wear Protective Clothing…………………………………..S-3
Protect Against Noise……………………………………….S-3
Inspect Machine ………………………………………………S-3
General Precautions for Cab……………………………..S-4
Use Handholds and Steps…………………………………S-5
Adjust the Operator’s Seat ………………………………..S-5
Fasten Your Seat Belt ………………………………………S-6
Move and Operate Machine Safely …………………….S-6
Operate Only from Operator’s Seat…………………….S-7
Jump Starting ………………………………………………….S-7
Keep Riders Off Machine ………………………………….S-7
Investigate Job Site Beforehand ………………………..S-8
Protect Against Falling Stones and Debris…………..S-8
Provide Signals for Jobs Involving
Multiple Numbers of Machines ……………………..S-9
Confirm Direction of Machine to be Driven…………..S-9
Drive Machine Safely………………………………………S-10
Avoid Injury from Rollaway Accidents ……………….S-11
Avoid Injury from Back-Over and Swing Accidents ..S-12
Keep Person Clear from Working Area ……………..S-13
Never Position Bucket Over Anyone …………………S-13
Avoid Undercutting …………………………………………S-13
Avoid Tipping…………………………………………………S-14
Never Undercut a High Bank……………………………S-14
Dig with Caution …………………………………………….S-15
Operate with Caution………………………………………S-15
Avoid Power Lines………………………………………….S-15
Object Handling ……………………………………………..S-16
Protect Against Flying Debris …………………………..S-16
Park Machine Safely……………………………………….S-17
Handle Fluids Safely－Avoid Fires ……………………S-17
Safety Transporting ………………………………………..S-18
Practice Safe Maintenance………………………………S-19
Warn Others of Service Work…………………………..S-20
Support Machine Properly……………………………….S-20
Stay Clear of Moving Parts………………………………S-20
Prevent Parts from Flying ………………………………..S-21
Store Attachments Safely ………………………………..S-21
Prevent Burns ………………………………………………..S-22
Replace Rubber Hoses Periodically………………….S-22
Avoid High-Pressure Fluids ……………………………..S-23
Prevent Fires …………………………………………………S-24
Evacuating in Case of Fire ………………………………S-25
Beware of Exhaust Fumes ………………………………S-25
Precautions for Welding and Grinding……………….S-26
Avoid Heating Near Pressurized Fluid Lines………S-27
Avoid Applying Heat to Lines
Containing Flammable Fluids ……………………..S-27
Remove Paint Before Welding or Heating………….S-27
Prevent Battery Explosions…………………………….. S-28
Service Air Conditioning System Safely……………. S-28
Handle Chemical Products Safely …………………… S-29
Dispose of Waste Properly …………………………….. S-29
SAFETY SIGNS ………………………………………..S-31
COMPONENTS NAME
Components Name …………………………………………..1-1
OPERATOR’S STATION
Cab Features …………………………………………………..1-2
Cab Right Panel and Rightconsole ……………………..1-3
Monitor Panel and Switch Panel …………………………1-4
Coolant Temperature Gauge ……………………………..1-5
Fuel Gauge ……………………………………………………..1-5
Remaining Fuel Indicator …………………………………..1-5
Air Filter Restriction Indicator……………………………..1-5
Overheat Indicator…………………………………………….1-6
Engine Oil Pressure Indicator …………………………….1-6
Alternator Indicator……………………………………………1-6
Preheat Indicator………………………………………………1-6
Hydraulic Oil Filter Restriction Indicator (Optional)..1-6
Liquid Crystal Display (LCD),
Display Selection Switch, and Set Swicth……….1-7
How to Operate Trip Meter ………………………………..1-8
Power Mode Switch ………………………………………..1-10
Travel Mode Switch…………………………………………1-10
Auto-Idle/Acceleration Selector…………………………1-11
Auto-Marccino Mode Switch …………………………….1-12
Work Light Switch …………………………………………..1-13
Wiper/Washer Switch………………………………………1-14
Offset Switch ………………………………………………….1-15
Emergency Deactivation Switch ……………………….1-16
Horn Switch……………………………………………………1-17
Cab Light……………………………………………………….1-17
Drinks Holder …………………………………………………1-17
Key Switch …………………………………………………….1-18
Engine Speed Control Dial……………………………….1-18
Engine Stop Knob …………………………………………..1-18
Pilot Control Shut-Off Lever ……………………………..1-19
Cigar Lighter…………………………………………………..1-20
Fuse Box ……………………………………………………….1-21
AM/FM Radio Operation ………………………………….1-22
Digital Clock Setting Procedure ………………………..1-23
Air Conditioner Operation ………………………………..1-24
Tips for Air Conditioner Usage………………………….1-26
Cab Door Release Lever …………………………………1-27
Opening Upper Front Windows…………………………1-27
Closing Upper Front Window……………………………1-28
Removing and Storing Lower Front Window ………1-29
Opening Cab Door Window ……………………………..1-29
Emergency Exit ………………………………………………1-30
Adjusting Operator’s Seat ………………………………..1-31
Seat Belt………………………………………………………..1-31

BREAK-IN
Observe Engine Operation Closely ……………………. 2-1
Every 8 Hours or Daily……………………………………… 2-1
After the First 50 Hours ……………………………………. 2-1
After the First 100 Hours ………………………………….. 2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting ……………….. 3-1
Before Starting Engine …………………………………….. 3-2
Starting the Engine in Ordinary Temperature………. 3-3
Starting in Cold Weather ………………………………….. 3-4
Check Instruments After Starting……………………….. 3-5
Bucket/Cab Collision Prevention System and
Auto-Marccino System Function Check ………… 3-6
Using Booster Batteries……………………………………. 3-8
Stopping the Engine ………………………………………. 3-10
DRIVING THE MACHINE
Drive the Machine Carefully ……………………………… 4-1
Steering the Machine Using Levers and Pedals ….. 4-2
Travel Mode Switch …………………………………………. 4-3
Travel Alarm (Optional) ……………………………………. 4-3
Traveling………………………………………………………… 4-4
Operating on Soft Ground ………………………………… 4-5
Raise One Track Using Boom and Arm……………… 4-5
Towing Machine a Short Distance……………………… 4-6
Operating in Water or Mud ……………………………….. 4-7
Precautions for Traveling on Slopes ………………….. 4-8
Parking the Machine on Slopes…………………………. 4-9
Parking the Machine………………………………………… 4-9
OPERATING THE MACHINE
Control Lever (ISO Pattern)………………………………. 5-1
Control Lever (Hitachi Pattern)(Optional) ……………. 5-2
Offset Pedal and Offset Switch………………………….. 5-3
Blade Lever…………………………………………………….. 5-6
Precautions for Blade Operation ……………………….. 5-6
Pilot Control Shut-Off Lever………………………………. 5-7
Engine Speed Control ……………………………………. 5-10
Auto-Idle ………………………………………………………. 5-11
Auto Acceleration ………………………………………….. 5-12
Power Mode………………………………………………….. 5-14
Precautions for Operating the Control System…… 5-15
Bucket/Cab Collision Prevention System………….. 5-16
Auto-Marccino Mode System ………………………….. 5-18
Emergency Deactivation Switch………………………. 5-20
Emergency Stop ……………………………………………. 5-20
Precautions for Operations……………………………… 5-21
Operate the Machine Safely ……………………………. 5-22
Operating Backhoe………………………………………… 5-23
Grading Operation …………………………………………. 5-23
Avoid Abusive Operation ………………………………… 5-24
Operating Tips ………………………………………………. 5-25
Select Correct Track Shoes…………………………….. 5-25
Shackle Hole Usage ………………………………………. 5-26
Avoid Hitting Blade with Front-End Attachment …. 5-27
Avoid Hitting Blade with Bucket ………………………..5-27
Avoid Striking the Blade Into a Rock………………….5-27
Avoid Hitting Cab with Bucket…………………………..5-28
Using Rubber Crawler……………………………………..5-29
Traveling and Other Cautions …………………………..5-30
Emergency Boom Lowering Procedure ……………..5-32
Overnight Storage Instructions …………………………5-33
TRANSPORTING
Transporting by Road………………………………………..6-1
Loading/Unloading on a Trailer…………………………..6-1
Machine Lifting Procedure …………………………………6-5
MAINTENANCE
Correct Maintenance and Inspection Procedures….7-1
Check the Hour Meter Regularly…………………………7-2
Use Correct Fuels and Lubricants ………………………7-2
Prepare Machine for Maintenance………………………7-3
Hood and Access Covers ………………………………….7-4
Daily Inspection………………………………………………..7-5
Periodic Replacement of Parts …………………………..7-6
Maintenance Guide…………………………………………..7-7
A. Greasing ……………………………………………………7-12
Front Joint Pins …………………………………………7-12
Swing Bearing …………………………………………..7-14
Swing Internal Gear …………………………………..7-15
Blade Joint Pins ………………………………………..7-16
B. Engine……………………………………………………….7-17
Engine Oil Level ………………………………………..7-17
Change Engine Oil …………………………………….7-17
Replace Engine Oil Filter ……………………………7-17
C. Transmission ……………………………………………..7-19
Swing Reduction Gear ……………………………….7-19
Travel Reduction Gear ……………………………….7-20
D. Hydraulic System………………………………………..7-22
Inspection and Maintenance of
Hydraulic Equipment…………………………….7-22
Replacement of Hydraulic Oil and Filter ……….7-23
Check Hydraulic Oil Level …………………………..7-24
Drain Hydraulic Tank Sump………………………..7-25
Change Hydraulic Oil …………………………………7-26
Suction Filter Cleaning……………………………….7-26
Replace Full-Flow Filter ……………………………..7-29
Replace Pilot Oil Filter ……………………………….7-30
Replace Air Breather Element …………………….7-31
Check Hoses and Lines ……………………………..7-32
Service Recommendations
for Hydraulic Fittings …………………………….7-35
E. Fuel System……………………………………………….7-37
Drain Fuel Tank Sump ……………………………….7-39
Check Water Separator………………………………7-39
Replace Fuel Filter …………………………………….7-41
Clean Feed Pump Strainer …………………………7-42
Check Fuel Hoses……………………………………..7-43
F. Air Cleaner…………………………………………………7-44
Clean the Air Cleaner Outer Element …………..7-44

Replace the Air Cleaner Outer
and Inner Elements …………………………….. 7-44
G. Cooling System…………………………………………. 7-46
Check Coolant Level…………………………………. 7-47
Check and Adjust Fan Belt Tension ……………. 7-48
Change Coolant……………………………………….. 7-49
Clean Radiator Interior………………………………. 7-49
Clean Radiator, and Oil Cooler Core…………… 7-50
Clean Oil Cooler Front Screen …………………… 7-50
Clean Air Conditioner Condenser……………….. 7-51
Clean Air Conditioner Front Screen…………….. 7-51
H. Electrical System ………………………………………. 7-52
Batteries………………………………………………….. 7-52
Replacing Fuses ………………………………………. 7-56
I. Miscellaneous…………………………………………….. 7-57
Check Bucket Teeth …………………………………. 7-57
Change Bucket ………………………………………… 7-59
Adjust the Bucket Linkage …………………………. 7-60
Check and Replace Seat Belt…………………….. 7-61
Check Windshield Washer Fluid Level ………… 7-61
Check Track Sag ……………………………………… 7-62
Clean and Replace Air Conditioner Filter …….. 7-64
Check the Air Conditioner………………………….. 7-67
Cleaning Cab Floor…………………………………… 7-69
Check Injection Nozzle ……………………………… 7-70
Retighten Cylinder Head Bolt …………………….. 7-70
Inspect and Adjust Valve Clearance …………… 7-70
Check Fuel Injection Timing ………………………. 7-70
Measure Engine Compression Pressure……… 7-70
Check Starter and Alternator……………………… 7-70
Change Water Pump Grease …………………….. 7-70
Check Tightening Torque of Bolts and Nuts…. 7-71
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions……………………………. 9-1
STORAGE
Storing the Machine……………………………………….. 10-1
Removing the Machine from Storage……………….. 10-2
TROUBLESHOOTING
Engine………………………………………………………….. 11-1
Electrical System…………………………………………… 11-6
Mode Selection ……………………………………………… 11-8
Control Levers ………………………………………………. 11-9
Hydraulic System…………………………………………… 11-9
SPECIFICATIONS
Specifications………………………………………………… 12-1
Working Ranges ……………………………………………. 12-2
Shoe Types and Applications………………………….. 12-3
Bucket Types and Applications ……………………….. 12-4
INDEX ……………………………………………………….. 14-1

Hitachi