Hitachi ZAXIS 135US, 135USK, 135USL Excavator operator’s manual SN 062955 and up

INTRODUCTION Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage.

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This standard specification machine can be operated under the following conditions without being modified.

Atmospheric Temperature: 20 C to 40 C ( 4 F to 104 F) Altitude: to 2000 m (0 ft to 6600 ft) In case the machine is used under conditions other than described above, consult your nearest Hitachi dealer.

This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

Right-hand and left-hand sides are determined by facing in the direction of forward travel.

Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of Hitachi's support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.

Prior to operating this machine in a country other than a country of its intended use, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of that particular country. Please do not operate this machine outside of the country of its intended use until such compliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized distributor or dealer if you have any questions concerning compliance.

Hitachi machine models are classified into 2 models as shown in the table below. When referring to the texts and/or illustrations indicated with the applicable machine class names in this manual, check that the machine models concerned are included using this table.

Model Std. Model K Model

ZAXIS125US, 135US, 225US, 225USLC

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

Š2002 Hitachi Construction Machinery Co., Ltd. All rights reserved.

MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

MACHINE

SS3097499

1. MODEL/TYPE

M157-00-001

2. Product Identification Number 3. Year of Manufacturing 4. Operating mass (standard version) 5. Engine power in KW according to ISO9249

PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER: NOTE: HCM1GF00L00100001

Marks to indicate the start and end of the PIN

PRODUCT IDENTIFICATION NUMBER (PIN)

M157-12-008

ENGINE TYPE: MFG. NO.:

M178-00-001

MACHINE NUMBERS TRAVEL MOTOR TYPE: MFG. NO.:

SWING MOTOR M178-07-047

TYPE: MFG. NO.:

HYDRAULIC PUMP

M1GF-07-002

TYPE: MFG. NO.:

M1GF-07-006

CONTENTS 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-30 COMPONENTS NAME .......................... 1-1 OPERATOR’S STATION Cab Features .......................................................1-2 Monitor Panel.......................................................1-4 Coolant Temperature Gauge .......................1-5 Fuel Gauge ..................................................1-5 Auto-Idle Indicator..........................................1-5 Auto-Acceleration Indicator ...........................1-5 Fuel Level Indicator .......................................1-6 Air Filter Restriction Indicator ........................1-6 Overheat Indicator .........................................1-6 Engine Oil Pressure Indicator ........................1-6 Alternator Indicator ........................................1-6 Preheat Indicator ...........................................1-7 Hydraulic Oil Filter Restriction Indicator (K Model) .................................................1-7 Liquid Crystal Display (LCD), Display Selection Switch, Set Switch ...................1-8 Hour Meter..................................................... 1-8 Trip Meter (Trip Meter1 and Trip Meter 2 ......1-9 Engine Speed ................................................1-9 Hydraulic Oil Temperature............................. 1-9 Trip Meter Function .....................................1-10 Work Mode Switch ......................................1-12 Switch Panel ....................................................1-13 Engine Control Dial......................................1-13 Auto-Idle/Acceleration Selector ...................1-14 Power Mode Switch .....................................1-15 Travel Mode Switch .....................................1-15 Work Light Switch........................................1-16 Wiper/Washer Switch ..................................1-17 Switch Panel2 (K Model)....................................1-19 Switch Panel (Optional) .....................................1-20 Key Switch .........................................................1-21 Power Boost Switch ...........................................1-21 Horn Switch........................................................1-21 Cigar Lighter ......................................................1-22 12-V Power Source............................................1-23 Cab Light............................................................ 1-24 Installing Fire Extinguisher (Optional)................1-24 Pilot Control Shut-Off Lever...............................1-25 Engine Stop Knob ..............................................1-25 Fuse Box............................................................ 1-26 Additional Fuse Box (Optional) ..........................1-26 Auto Air Conditioner (optional)...........................1-27 Cab Heater Operation........................................1-32 Cooling Operation ..............................................1-33 Defroster Operation ...........................................1-33 Tips for Optimal Air Conditioner Usage .............1-35 Cab Heater (optional) ........................................1-36

CONTENTS Cab Heater Operation ....................................... 1-37 Defroster Operation........................................... 1-38 AM/FM Radio Operation.................................... 1-39 Digital Clock Setting Procedure......................... 1-40 Cab Door Release Lever................................... 1-41 Opening Upper Front Window........................... 1-41 Closing Upper Front Window ............................ 1-42 Removing and Storing Lower Front Window.............................................. 1-43 Opening Side Windows ..................................... 1-43 Opening/Closing Overhead Window ................. 1-44 Emergency Exit ................................................. 1-45 Sunvisor (Optional)............................................ 1-46 Adjusting the Seat ............................................. 1-47 Adjusting the Seat --- If Equipped ..................... 1-49 Adjusting the Air-Suspension Seat (Optional) ... 1-51 Adjust Console Height....................................... 1-53 Seat Belt ............................................................ 1-54

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 the Engine in Cold Weather ................... 3-4 Check Instruments After Starting ........................ 3-5 Using Booster Batteries....................................... 3-6 Stopping the Engine ............................................ 3-8

DRIVING THE MACHINE Drive the Machine Carefully ................................ 4-1 Steering the Machine Using Pedals .................... 4-2 Steering the Machine Using Levers .................... 4-3 Travel Mode Switch............................................. 4-4 Travel Alarm (Optional) ....................................... 4-4 Traveling.............................................................. 4-5 Operating on Soft Ground ................................... 4-6 Raise One Track Using Boom and Arm .............. 4-6 Towing Machine a Short Distance....................... 4-7 Operating in Water or Mud.................................. 4-8 Precautions for Traveling on Slopes ................... 4-9 Parking the Machine on Slopes......................... 4-10 Parking the Machine.......................................... 4-10

OPERATING THE MACHINE Control Lever (ISO Pattern) ............................... 5-1 Attachment Pedal (Breaker)................................ 5-2 Attachment Pedal (Hydraulic Crusher)................ 5-3 Pilot Control Shut-Off Lever ................................ 5-4 Engine Speed Control ......................................... 5-7 Auto-Idle .............................................................. 5-8 Auto Acceleration ................................................ 5-9

Work Mode ........................................................5-11 Power Boost.......................................................5-11 Power Mode.......................................................5-12 Precautions for Operation Using a Bucket ........5-13 Precautions for Operations ................................5-14 Operate the Machine Safely ..............................5-15 Operating Backhoe ............................................5-16 Grading Operation .............................................5-16 Face Shovel Operation ......................................5-17 Avoid Abusive Operation ...................................5-17 Operating Tips ...................................................5-18 Select Correct Track Shoes...............................5-18 Hydraulic Breaker and Hydraulic Crusher.......... 5-19 Pipings for Breaker and Crusher ....................... 5-20 Secondary Relief Pressure Adjustment ............. 5-22 Precautions for Braker Operation ......................5-23 Breaker Maintenance......................................... 5-26 Precautions for Crusher Operation....................5-27 Attachment.........................................................5-29 Precaution for Arm Roll-In/Bucket Roll-In Combined Operation ................................... 5-32 When Installing an Attachment Longer than Standard Bucket ..........................................5-32 Shackle Hole Usage ..........................................5-33 Overnight Storage Instructions .......................... 5-33 Emergency Boom Lowering Procedure .............5-34 Object Handling --- If Equipped ......................... 5-37 Long Arm Operation --- If Equipped...................5-39

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 Layout ................................................................. 7-3 Maintenance Guide Table....................................7-4 Prepare Machine for Maintenance....................... 7-6 Hood and Access Covers ....................................7-7 Periodic Replacement of Parts ............................7-9 Maintenance Guide............................................7-10 A. Greasing ....................................................7-15 Front Joint Pins............................................7-15 Swing Bearing..............................................7-17 Swing Internal Gear .....................................7-18 B. Engine.......................................................... 7-19 Engine Oil Level...........................................7-19 Change Engine Oil.......................................7-19 Replace Engine Oil Filter .............................7-19 C. Transmission .............................................7-21 Pump Transmission.....................................7-21 Swing Reduction Gear................................. 7-22 Travel Reduction Gear ................................7-23 D. Hydraulic System .........................................7-25

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CONTENTS

E.

F.

G.

H.

I.

Inspection and Maintenance of Hydraulic Equipment ......................... 7-25 Replacement of Hydraulic Oil and Filter...... 7-26 Check Hydraulic Oil Level ........................... 7-27 Drain Hydraulic Tank Sump ........................ 7-28 Change Hydraulic Oil .................................. 7-29 Suction Filter Cleaning ................................ 7-29 Replace Hydraulic Tank Oil Filter................ 7-32 Replace Pilot Oil Filter................................. 7-34 Replace Air Breather Element..................... 7-35 Check Hoses and Lines .............................. 7-36 Service Recommendations for Hydraulic Fittings................................... 7-39 Fuel System ................................................ 7-41 Drain Fuel Tank Sump ................................ 7-43 Check Water Separator .............................. 7-43 Replace Fuel Filter ...................................... 7-46 Clean Feed Pump Strainer.......................... 7-47 Check Fuel Hoses....................................... 7-48 Air Cleaner .................................................. 7-49 Clean the Air Cleaner Outer Element.......... 7-49 Replace the Air Cleaner Outer and Inner Elements............................... 7-49 Cooling System ........................................... 7-51 Check Coolant Level ................................... 7-52 Check and Adjust Fan Belt Tension............ 7-53 Change Coolant .......................................... 7-54 Clean Radiator Interior ................................ 7-54 Clean Intercooler Core (ZAXIS135US, 135USK, 225US, 225USLC), Radiator, and Oil Cooler Core............... 7-55 Clean Oil Cooler Front Screen .................... 7-55 Clean Air Conditioner Condenser ............... 7-56 Clean Inter Cooler Front Screen ................. 7-56 Electrical System ....................................... 7-57 Batteries ...................................................... 7-57 Remove and Installing Battery .................... 7-61 Replacing Fuses ......................................... 7-61 Additional Fuse Box (Optional) ................... 7-61 Miscellaneous ............................................ 7-63 Check Bucket Teeth.................................... 7-63 Change Bucket .......................................... 7-65 Convert Bucket Connection Into Face Shovel .......................................... 7-66 Adjust the Bucket Linkage .......................... 7-67 Remove the Travel Levers .......................... 7-68 Check and Replace Seat Belt ................... 7-69 Check Windshield Washer Fluid Level ....... 7-69 Check Track Sag ........................................ 7-70 Adjust Track Sag......................................... 7-70 Loosen the Track ........................................ 7-71 Tighten the Track ........................................ 7-71 Clean and Replace Air Conditioner Filter ...................................................... 7-72 Check the Air Conditioner ........................... 7-75 Cleaning Cab Floor ..................................... 7-77 Check Injection Nozzle................................ 7-78 Retighten Cylinder Head Bolt ...................... 7-78 Inspect and Adjust Valve Clearance ........... 7-78

Check Fuel Injection Timing ........................7-78 Measure Engine Compression Pressure ................................................ 7-78 Check Starter and Alternator .......................7-78 Change Water Pump Grease ...................... 7-78 Check Tightening Torque of Bolts and Nuts ................................................7-79

HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT Hydraulic Circuit...................................................8-1 Electlical Circuit....................................................8-2 Electrical Circuit Diagram ....................................8-3

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 Installing Vandal-Proof Covers ..........................10-3 Help Prevent Crime ...........................................10-4 Record Identification Numbers ..........................10-4 Keep Proof of Ownership...................................10-4 Park Indoors Out of Sight ..................................10-4 When Parking Outdoors ....................................10-5 Reduce Vandalism............................................. 10-5 Report Thefts Immediately................................. 10-5

TROUBLESHOOTING Engine ...............................................................11-1 Electrical System ...............................................11-6 Mode Selection ..................................................11-8 Control Levers ...................................................11-9 Hydraulic System ...............................................11-9

SPECIFICATIONS ZAXIS125US Specifications .............................................12-1 Working Ranges..........................................12-2 Shoe Types and Applications ...................... 12-3 ZAXIS135US Specifications .............................................12-4 Working Ranges..........................................12-5 Shoe Types and Applications ...................... 12-6 ZAXIS225US, ZAXIS225USLC Specifications .............................................12-7 Working Ranges..........................................12-8 Shoe Types and Applications ...................... 12-9 Sound Level Results (2000/14/EC) .................12-11

CONTENTS OPTIONAL ATTACHMENTS AND DEVICES Bucket Teeth (Transverse-Type-Pin -Used Type) ............................................... 13-1 Blade Lever ....................................................... 13-2 Precautions for Blade Operation ....................... 13-2 Avoid Hitting Blade with Front-End Attachment .................................................. 13-3 Avoic Hitting Blade with Bucket ......................... 13-3 Avoid Striking the Blade into a Rock ................. 13-3 Blade Maintenance............................................ 13-4 ZAXIS125US Specifications ............................................ 13-5 Working Ranges ......................................... 13-6 Shoe Types and Applications...................... 13-7 ZAXIS135US Specifications ............................................ 13-8 Working Ranges ......................................... 13-9 Shoe Types and Applications.................... 13-10 Using Rubber Pad Shoe.................................. 13-11 Traveling and Other Cautions ......................... 13-12 Transporting .................................................... 13-13 Precautions for Transporting Machines with Rubber-Pad Shoes ............................ 13-13 Electronic Key Lock Operation Manual ........... 13-16 Registration/Registration Cancellation of Ordinary Operation Key......................... 13-19 Additional Registration Procedure................... 13-20 Registration Cancellation Procedure............... 13-21 Lifting Capacities ............................................. 13-22

INDEX ............................................................. 14-1