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Hitachi ZX135-6 Excavator Operators Manual

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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






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