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Title: ZX135US-6 HYDRAULIC EXCAVATOR Operator's Manual
Part Number: ENMDAS-1-1
Printed: In Japan, September 2023
Serial Number: 508600 and up
Introduction:
The manual provides guidance on how to operate and service the ZX135US-6 hydraulic excavator.
It emphasizes the importance of reading the manual carefully to prevent personal injuries or damage to the machine.
The standard specification machine is designed to operate under specific conditions, including atmospheric temperatures ranging from –20°C to 40°C and altitudes from 0m to 2000m.
If the machine is to be used under different conditions, consultation with an authorized Hitachi Construction Machinery dealer is advised.
The manual is an integral part of the machine and should remain with it if sold.
The machine and manual use metric measurements and recommend the use of metric hardware and tools. PDF Contents: MACHINE NUMBERS..........................................................1
SAFETY...........................................................................S-1
Recognize Safety Information.....................................................S-1
Understand Signal Words..............................................................S-1
Follow Safety Instructions.............................................................S-2
Prepare for Emergencies................................................................S-3
Wear Appropriate Clothing..........................................................S-3
Inspect Machine...............................................................................S-4
General Precautions for the Cab.................................................S-4
Use Handholds and Steps.............................................................S-5
Adjust the Operator's Seat............................................................S-5
Ensure Safety Before Leaving or Standing up from Operator’s Seat............................................................................S-6
Fasten Your Seat Belt.......................................................................S-6
Move and Operate Machine Safely............................................S-7
Operate Only from Operator's Seat...........................................S-7
Jump Starting....................................................................................S-8
Keep Riders off Machine................................................................S-8
Precautions for Operations...........................................................S-9
Investigate Job Site Beforehand..............................................S-10
Install OPG Guard..........................................................................S-11
Restriction of Attachment Installation..................................S-11
Provide Signals for Jobs Involving Multiple Machines....S-12
Confirm Direction of Machine to Be Driven.........................S-12
Drive Machine Safely....................................................................S-13
Avoid Injury from Rollaway Accidents...................................S-15
Avoid Injury from Back-Over and Swing Accidents..........S-16
Keep People Clear from Working Area..................................S-17
Never Position the Bucket Over Anyone...............................S-17
Avoid Undercutting......................................................................S-18
Avoid Tipping..................................................................................S-18
Never Undercut a High Bank.....................................................S-19
Dig with Caution............................................................................S-19
Operate with Caution..................................................................S-19
Avoid Power Lines.........................................................................S-20
Precautions for Lightning...........................................................S-20
Object Handling............................................................................S-21
Protect Against Flying Debris and Falling Object..............S-22
Park Machine Safely......................................................................S-23
Handle Fluids Safely.Avoid Fires............................................S-23
Transport Safely.............................................................................S-24
Practice Safe Maintenance.........................................................S-25
Warn Others of Service Work....................................................S-26
Support Machine Properly.........................................................S-26
Stay Clear of Moving Parts.........................................................S-27
Prevent Parts from Flying...........................................................S-27
Avoid Injury from Attachment Falling Accident................S-28
Prevent Burns..................................................................................S-28
Replace Rubber Hoses Periodically.........................................S-29
Avoid High-Pressure Fluids........................................................S-29
Prevent Fires....................................................................................S-30
Evacuating in Case of Fire...........................................................S-32
Beware of Exhaust Fumes..........................................................S-32
Precautions for Welding and Grinding..................................S-33
Avoid Heating Near Pressurized Fluid Lines........................S-34
Avoid Applying Heat to Lines Containing Flammable
Fluids............................................................................................S-34
Precautions for Handling Accumulator and Gas
Damper........................................................................................S-34
Remove Paint Before Welding or Heating............................S-35
Beware of Asbestos and Silica Dust and Other Contamination..........................................................................S-35
Prevent Battery Explosions........................................................S-36
Service Air Conditioning System Safely................................S-36
Handle Chemical Products Safely............................................S-37
Dispose of Waste Properly..........................................................S-37
Never Ride Attachment...............................................................S-38
Notes on Aftertreatment Device.............................................S-38
Precautions for Communication Terminal............................S-38
Precautions for Communication Terminal Equipment....S-39
Notes on Protection of Operator’s Station when the Machine Rolls Over..................................................................S-41
VISIBILITY MAP............................................................S-42
SAFETY SIGNS..............................................................S-45
NAME OF COMPONENTS...............................................1-1
Name of Components....................................................................1-1
GETTING ON AND OFF THE MACHINE..........................1-2
OPERATOR’S STATION...................................................1-3
About Aftertreatment Device......................................................1-3
Cab Features.......................................................................................1-6
Cab Features (Demolition Machine)..........................................1-7
Multi Function Monitor..................................................................1-8
Default Setting..................................................................................1-9
Basic Screen.....................................................................................1-10
How to Use Screens......................................................................1-11
Displaying Basic Screen.........................................................1-11
Hour Meter.................................................................................1-14
Clock.............................................................................................1-14
Fuel Gauge.................................................................................1-14
DEF Gauge..................................................................................1-15
DEF Level Alarm........................................................................1-15
Coolant Temperature Gauge...............................................1-16
Operating Status Icon Display.............................................1-16
Security Functions (Optional)...................................................1-17
Input Password.........................................................................1-17
Extending Password Duration Time..................................1-18
Alarm Occurrence Screen...........................................................1-19
Remedy.............................................................................................1-21
Urea SCR System Remedy..........................................................1-24
Aftertreatment Device.................................................................1-26
Aftertreatment Device Condition Display......................1-26
Aftertreatment Device Manual Regeneration
Request..................................................................................1-27
Manual Regeneration Procedure.......................................1-28
Main Menu.......................................................................................1-29
Engine Output Restriction Suspend.......................................1-30
Urea SCR System Troubleshooting..........................................1-32
Air Conditioner...............................................................................1-34
Circulation Air Mode...............................................................1-34
Air Conditioner ON/OFF........................................................1-34
Radio..................................................................................................1-35
Work Mode......................................................................................1-36
Attachment Selection............................................................1-36
Mail (Optional)................................................................................1-37
Setting Menu..................................................................................1-39
Date and Time................................................................................1-40
Time Adjustment.....................................................................1-40
Date Adjustment......................................................................1-42
Display Mode Setting.............................................................1-44
Attachment Adjustment.............................................................1-46
Flow Rate Adjustment............................................................1-46
Priority (arm roll-out)..............................................................1-48
Attachment Name Input.............................................................1-50
Auto Shut-Down............................................................................1-52
Auto Shut-Down: ON/OFF....................................................1-52
Auto Shut-Down: Setting Time...........................................1-53
Aftertreatment Device Regeneration Inhibited.................1-54
Setting Procedure....................................................................1-54
Password Change (Optional).....................................................1-56
Sub Meter.........................................................................................1-60
Rear View Camera Monitor........................................................1-62
Rear View Camera ON (Factory Setting: ON)..................1-62
Brightness Adjustment................................................................1-64
Language Settings........................................................................1-66
Lists of Display Language...........................................................1-68
Unit Selection.................................................................................1-69
Display Item Selection (Rear View Camera OFF)................1-71
Main Menu Sequence Change.................................................1-73
Information Menu.........................................................................1-75
Operation.........................................................................................1-76
Fuel Consumption...................................................................1-76
Breaker Operation...................................................................1-78
Attachment Operation...........................................................1-80
Travel Operation.......................................................................1-82
Actual operation......................................................................1-84
Maintenance...................................................................................1-86
Remaining Time and Maintenance Interval...................1-88
Monitoring.......................................................................................1-90
Switch Panel....................................................................................1-92
Return to Previous Screen Switch (Monitor)..................1-93
Return to Basic Screen Switch (Monitor).........................1-93
Selector Knob (Monitor)........................................................1-93
Temperature Control Switch/Mode Switch (Air Conditioner).........................................................................1-93
AUTO/OFF Switch/Fan Switch (Air Conditioner)...........1-93
AM/FM Selector/Tuning Switch (Radio)...........................1-94
Power Switch/Volume Control Knob (Radio).................1-94
Engine Control Dial.................................................................1-94
Auto-Idle Switch.......................................................................1-95
Travel Mode Switch.................................................................1-95
Power Mode Switch................................................................1-96
Work Light Switch....................................................................1-96
Wiper/Washer Switch.............................................................1-97
Skylight Wiper/Washer Switch (Demolition
Machine Hi-Grade Specification)..................................1-98
Numeric Keypad.......................................................................1-98
USB Power Supply Port..........................................................1-99
Switch Panel (for Optional Equipments).............................1-101
Travel Alarm Deactivation Switch (Optional)...............1-102
Swing Alarm Switch (Optional).........................................1-102
Rear Light Switch (Optional)..............................................1-102
Perimeter Lights Switch (Optional).................................1-102
Seat Heater Switch (Optional)...........................................1-103
Electrical Control Main Switch (Optional).....................1-104
ON and OFF Style Operation Main Switch
(Optional)............................................................................1-104
Key Switch......................................................................................1-105
Power Boost Switch....................................................................1-105
Horn Switch...................................................................................1-105
Electrical Control Main Switch (Optional)..........................1-106
ON and OFF Style Operation Switch (Optional)...............1-108
Cigar Lighter..................................................................................1-109
Using Cigar Lighter................................................................1-109
Cab Light Switch..........................................................................1-110
Installing Fire Extinguisher (Optional).................................1-110
Pilot Control Shut-Off Lever....................................................1-111
Control Lever Auto-Lock...........................................................1-112
Engine Stop Switch.....................................................................1-113
Fuse Box..........................................................................................1-114
Auto Air Conditioner..................................................................1-115Features:....................................................................................1-115
Name of Components..........................................................1-116
Controller Part Name and Function................................1-117
Cab Heater Operation..........................................................1-119
Cooling Operation.................................................................1-120
Defroster Operation..............................................................1-121
Cool Head/Warm Feet Operation.....................................1-121
Tips for Optimal Air Conditioner Usage..............................1-122
For Rapid Cooling..................................................................1-122
When Windows Become Misty.........................................1-122
Off-Season Air Conditioner Maintenance.....................1-122
AM/FM Radio Operation...........................................................1-123
Controls on the Radio...........................................................1-123
Tuning Procedure..................................................................1-123
Station Presetting Procedure.............................................1-124
Station Auto-Presetting Procedure.................................1-125
TONE Control...........................................................................1-126
Audio Input (Optional)..............................................................1-127
Side View Camera System........................................................1-128
Content of Monitor Display.....................................................1-131
Adjusting the Position of the Side Camera Monitor.......1-132
Aerial Angle Monitor..................................................................1-133
Switching the Screen Display.................................................1-135
Description of Images................................................................1-136
Cab Door Release Lever............................................................1-143
Opening/Closing and Removing Cab Inside
Window.....................................................................................1-144
Opening Upper Front Window...............................................1-145
Removing and Storing Lower Front Window....................1-146
Opening Side Window...............................................................1-147
Opening/Closing Overhead Window...................................1-148
Opening/Closing Overhead Window (Clear Hatch)........1-149
Emergency Exit............................................................................1-150
Opening and Closing the OPG Front Guard
(Optional)..................................................................................1-151
Adjusting the Operator's Seat.................................................1-152
Seat Height and Seat Cushion Angle Adjustment.....1-152
Console and Seat Fore-Aft Adjustment.........................1-152
Seat Only Fore-Aft Adjustment.........................................1-152
Backrest Adjustment............................................................1-152
Armrest Adjustment.............................................................1-153
Adjusting Operator's Seat (Optional)...................................1-154
Seat Height and Angle Adjustment................................1-154
Console and Seat Fore-aft Adjustment..........................1-154
Seat Fore-Aft Adjustment...................................................1-154
Suspension Adjustment......................................................1-154
Backrest Adjustment............................................................1-155
Armrest Adjustment.............................................................1-155
Console Height Adjustment....................................................1-156
Adjusting Procedures...........................................................1-156
Installation and Adjustment of Mirrors...............................1-157
Mirror Installation Locations..............................................1-158
Seat Belt..........................................................................................1-160
Battery Disconnect Switch.......................................................1-161
Switch Operation...................................................................1-162
BREAK-IN........................................................................2-1
New Machine Break-in....................................................................2-1
OPERATING THE ENGINE...............................................3-1
Inspect Machine Daily Before Starting.....................................3-1
Before Starting Engine...................................................................3-3
Starting the Engine..........................................................................3-4
Check Instruments After Starting............................................3-10
Using Booster Batteries...............................................................3-11
Stopping the Engine....................................................................3-13
Engine Auto-Stop in Extremely Low Temperature............3-14
DRIVING THE MACHINE.................................................4-1
Travel Levers and Pedals................................................................4-1
Travel Mode Switch.........................................................................4-3
Travel Alarm (Optional)..................................................................4-4
Operating on Soft Ground............................................................4-5
Raising the Machine with Boom and Arm...............................4-5
Retrieval...............................................................................................4-6
Operating in Water or Mud...........................................................4-7
Parking the Machine on Slopes...................................................4-8
Parking the Machine.......................................................................4-8
Prohibition of Sudden Control Operations when
Traveling at High Speed...........................................................4-9
Prohibition of Traveling for Long Periods................................4-9
OPERATING THE MACHINE............................................5-1
Control Lever (ISO Pattern)...........................................................5-1
Pilot Control Shut-Off Lever.........................................................5-2
Warming-Up Operation.................................................................5-3
Engine Speed Control.....................................................................5-4
Auto-Idle..............................................................................................5-5
Auto-Idle ON/OFF.......................................................................5-6
Auto Shut-Down...............................................................................5-7
Aftertreatment Device Manual Regeneration....................5-10
Work Mode......................................................................................5-12
Power Boost Switch......................................................................5-15
Power Mode....................................................................................5-16
Precautions for Digging..............................................................5-17
Operating Backhoe.......................................................................5-18
Shovel................................................................................................5-19
Grading Operation........................................................................5-20
Do Not Strike the Ground with Bucket Teeth......................5-21
Avoid Hammer Work....................................................................5-21
Avoid Abusive Operation...........................................................5-22
Never Move an Object Sideways with the Bucket.............5-22
Retracting the Arm and Bucket................................................5-23
Do Not Use Wide Track Shoes on Rough Ground..............5-23
Shackle Hole Usage......................................................................5-24
Pilot Accumulator Functions.....................................................5-25
How to Lower Boom in Case of Emergency and When Engine Stops..............................................................................5-26
Precautions for After Operations.............................................5-27
TRANSPORTING.............................................................6-1
Transporting by Road.....................................................................6-1
Loading/Unloading on a Trailer..................................................6-2
Fastening Machine for Transporting.........................................6-5
Unloading...........................................................................................6-6
Lifting Machine.................................................................................6-7
MAINTENANCE...............................................................7-1
Correct Maintenance and Inspection Procedures................7-1
Layout...................................................................................................7-3
Check the Hour Meter Regularly.................................................7-4
Maintenance Guide Table........................................................7-5
Preparations for Inspection and Maintenance......................7-7
Hood and Access Covers................................................................7-8
Maintenance Guide.........................................................................7-9
Periodic Replacement of Parts..................................................7-15
Kind of Oils.......................................................................................7-16
Recommended Engine Oil....................................................7-16
List of Consumable Parts............................................................7-19
A. Greasing.......................................................................................7-21
Front Joint Pins.........................................................................7-21
Swing Bearing...........................................................................7-23
Swing Internal Gear................................................................7-24
B. Engine...........................................................................................7-25
Check Engine Oil Level...........................................................7-25
Change Engine Oil...................................................................7-27
Replace Engine Oil Filter........................................................7-27
Check and Clean Around the Engine................................7-29
Replace Oil Separator Element...........................................7-29
C. Transmission...............................................................................7-30
Swing Reduction Gear...........................................................7-30
Travel Reduction Gear............................................................7-31
D. Hydraulic System......................................................................7-33
Inspection and Maintenance of Hydraulic Equipment....7-33
Check Hydraulic Oil Level.....................................................7-37
Change Hydraulic Oil..............................................................7-38
Bleed Air from the Hydraulic System................................7-40
Suction Filter Cleaning...........................................................7-41
Replace Full-Flow Filter..........................................................7-42
Std. Model...................................................................................7-42
Replace Pilot Oil Filter............................................................7-45
Replace Air Breather Element..............................................7-46
Check Hoses and Lines..........................................................7-47
E. Fuel System.................................................................................7-51
Recommended Fuel................................................................7-51
Drain Fuel Tank Sump.............................................................7-53
Drain Fuel Pre-Filter.................................................................7-54
Replace Fuel Main Filter Element.......................................7-57
Replace Fuel Pre-Filter Element..........................................7-59
Check Fuel Hoses.....................................................................7-61
F. Air Cleaner....................................................................................7-62
Clean and Replace Air Cleaner Element (Outer)...........7-62
Replace Air Cleaner Element (Inner).................................7-64
G. Cooling System.........................................................................7-65
Check Coolant Level...............................................................7-66
Check and Adjust Fan Belt Tension....................................7-68
Change Coolant........................................................................7-69
Clean Radiator/Oil Cooler/Inter Cooler Core..................7-71
Clean Oil Cooler, Radiator and Inter Cooler Front
Screen.....................................................................................7-73
Clean Air Conditioner Condenser......................................7-73
Clean Fuel Oil Cooler..............................................................7-73
Drain Intercooler......................................................................7-74
H. Electrical System.......................................................................7-75Battery..........................................................................................7-76
Replace Battery.........................................................................7-79
Check Electrolyte Specific Gravity.....................................7-80
Replacing Fuses........................................................................7-81
Fuse Box............................................................................................7-82
I. Miscellaneous..............................................................................7-84
Check and Replace Bucket Teeth.......................................7-84
Change Bucket..........................................................................7-86
Convert Bucket Connection Into Face Shovel...............7-87
Adjust Bucket Linkage...........................................................7-88
Remove Travel Levers.............................................................7-89
Check and Replace Seat Belt................................................7-89
Check Windshield Washer Fluid Level..............................7-90
Check Track Sag........................................................................7-91
Clean and Replace Air Conditioner Filter........................7-95
Check Air Conditioner............................................................7-98
Clean Cab Floor......................................................................7-100
Retighten Cylinder Head Bolt............................................7-101
Inspect and Adjust Valve Clearance................................7-101
Measure Engine Compression Pressure........................7-101
Check Starter and Alternator.............................................7-101
Check and Replace EGR Device........................................7-101
EGR Cooler Cleaning.............................................................7-101
Check Turbo Charger............................................................7-101
Check and Clean Injector....................................................7-102
Check Gas Damper................................................................7-102
Tightening and Retightening Torque of Nuts and
Bolts.......................................................................................7-102
J. Aftertreatment Device...........................................................7-118
Check and Clean Aftertreatment Device.......................7-118
K. Urea SCR System.....................................................................7-119
Check DEF.................................................................................7-121
Refill DEF...................................................................................7-121
Extension Filler Neck.............................................................7-124
Clean Filler Port Strainer......................................................7-125
Change DEF.............................................................................7-126
Replace DEF Supply Module Main Filter........................7-127
Replace DEF Tank Water Supply Inlet Filter..................7-129
Replace the DEF back flow line filter...............................7-130
L. Aerial Angle...............................................................................7-131
Daily Checks of Aerial Angle Camera Images..............7-131
Checking Aerial Angle Camera Images..........................7-132
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS..................................................................9-1
Maintenance Under Special Environmental Conditions....9-1
STORAGE......................................................................10-1
Storing the Machine.....................................................................10-1
TROUBLESHOOTING....................................................11-1
Troubleshooting............................................................................11-1
SPECIFICATIONS..........................................................12-1
Specifications..................................................................................12-1
ZX135US-6..................................................................................12-1
Specifications..................................................................................12-2
ZX135US-6 (High Grade Specification)............................12-2
Working Ranges (Grouser shoe)..............................................12-3
Shoe Types and Uses....................................................................12-4
ZX135US-6..................................................................................12-4
ZX135US-6 (High Grade Specification)............................12-4
Bucket Types and Applications................................................12-5
OPTIONAL ATTACHMENTS AND DEVICES..................13-1
Using Pad Crawler Shoe..............................................................13-1
Traveling and Other Cautions...................................................13-2
Transporting....................................................................................13-3
Precautions for Transporting Machines with Pad
Crawler Shoes............................................................................13-3
Long Arm Operation --- If Equipped.......................................13-7
Blade Lever......................................................................................13-8
Avoid Hitting Blade with Front-End Attachment...............13-9
Blade Maintenance.....................................................................13-10
Specifications................................................................................13-11
ZX135US-6 with Blade.........................................................13-11
Working Ranges...........................................................................13-12
ZX135US-6 with Blade.........................................................13-12
Shoe Types and Applications..................................................13-13
ZX135US-6 with Blade.........................................................13-13
Bucket Teeth (Transverse-Type-Pin-Used Type)...............13-14
Control Levers (Hitachi Construction Machinery
Control Pattern) (Optional).................................................13-15
Attachment Pedal (Hydraulic Breaker) (Optional)...........13-16
Attachment Pedal (Hydraulic Crusher) (Optional)...........13-17
Hydraulic Breaker, Hydraulic Crusher and Quick
Coupler......................................................................................13-18
Piping for Breaker and Crusher..............................................13-19
Operational Procedures for Stop Valves and Selector
Valve...........................................................................................13-19
Secondary Relief Pressure Adjustment...............................13-20
Precautions for Breaker Operation........................................13-21
Change Hydraulic Oil and Replace Full-Flow Filter
Element.....................................................................................13-26
Precautions for Crusher Operation.......................................13-27
Attachment....................................................................................13-30
Allowable Weight Limits of Installed Attachment.....13-30
Attachment Connection Parts................................................13-32
Precautions for Arm Roll-In/Bucket Roll-In Combined Operation..................................................................................13-34
Automatic Refueling Device....................................................13-35
INDEX............................................................................14-1