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

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

This manual provides essential guidance for operators and maintenance personnel to ensure safe, efficient, and reliable machine performance. This comprehensive manual includes detailed operating instructions, safety guidelines, maintenance schedules for the Hitachi ZX135UR Excavator model.

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

Language: English
Format: PDF

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