Hitachi Ex135usr Excavator Service Manual Set

Description

📘 COMPREHENSIVE DOCUMENT OVERVIEW

Unlock the full potential of your Hitachi EX135USR Excavator with this definitive two-volume Technical Service Manual set (Manual No. KM-194E). This comprehensive digital resource is meticulously designed for service professionals, experienced mechanics, and equipment owners, providing unparalleled detail on both the operational principles and in-depth troubleshooting procedures for your machine. 🚜

Volume 1: Operational Principle (Vol. No. TO194E-00) serves as your foundational guide to understanding every aspect of the EX135USR. It encompasses:

• Section 1: General 📋
  • Exhaustive Specifications: Covering machine dimensions, working ranges, transportation data, and detailed component specifications for the powerful ISUZU A-4BG1T engine, along with its cooling, lubrication, starting, alternator, and fuel systems.
  • Component Layouts: Clear, labeled diagrams identifying main components, the overall electrical system, relays, monitor and switch panels, pump and related parts (including main and pilot pumps), and other critical elements of the excavator.
• Section 2: System 🔧
  • Control System: Detailed explanations of the outline, engine control (including normal, HP, E modes, auto-idle, auto-warming up, and engine learning), pump control (spool regulated, lever regulated, max displacement angle restriction, speed sensing, pump learning), valve control (swing priority, arm regenerative, travel motor swash angle), and other specialized control functions.
  • Hydraulic System: In-depth schematics and operational descriptions for the main circuit, pilot circuit, neutral circuit, single actuator operations, and complex combined operations such as swing & boom raise, and travel & arm roll-in.
  • Electrical System: Comprehensive coverage of the electrical architecture, including the main electric power circuit, bulb check system, preheat circuit, starting circuit, charging system, surge voltage prevention, accessory circuits, and the engine stop circuit.
• Section 3: Component Operation ⚙️
  • Pump Device: Detailed breakdown of the main pump (HPV050FW), regulator functions (flow rate control, summation control), pilot pump, N sensor (engine speed), pump pressure sensor, and A sensor (pump displacement angle).
  • Swing Device: Operational principles of the swing motor (AP5S67), valve unit (relief valve, make-up valve), swing parking brake, and swing reduction gear.
  • Control Valve: Thorough analysis of the 4-spool and 5-spool sections, hydraulic circuit, flow combiner valve, main relief valve, overload relief valve, pump control valve, variable restriction, arm regenerative valve, boom/arm anti-drift valves, bucket flow control, and travel/boom lower selector valve.
  • Pilot Valve: Operation of front attachment/swing and travel pilot valves.
  • Travel Device: Functionality of the travel motor (HMV075CF-18A), travel brake valve (counterbalance, check, overload relief), parking brake, and travel reduction gear.
  • Other Upperstructure Components: Pilot shut-off valve, shockless valve, solenoid valve unit (VC & PC), and EC motor.
  • Other Undercarriage Components: Swing bearing, center joint, and track adjuster.

Volume 2: Troubleshooting & Performance Test (Vol. No. TT194E-00) is your essential companion for diagnostics, maintenance, and repair. This volume includes:

• Safety Information ⚠️: Critical safety precautions to ensure safe working practices.
• Section 4: Operational Performance Test 📊
  • Comprehensive testing procedures for: Introduction to performance testing, Engine Tests (speed, compression, valve clearance, nozzle check, injection timing), Excavator Tests (travel speed, track revolution, mistrack check, travel parking function, swing speed, swing function drift, swing motor leakage, swing bearing play, maximum swingable slant angle, hydraulic cylinder cycle time, dig function drift, control lever operating force/stroke, combined boom raise/swing), and Component Tests (primary/secondary pilot pressure, solenoid valve set pressure, main pump delivery pressure, main/overload relief valve set pressures, main pump flow test, swing/travel motor drainage). Includes standard performance values for benchmarking.
• Section 5: Troubleshooting 🛠️
  • Diagnosing Procedures: Step-by-step guidance, including the use of the Dr.EX diagnostic tool for fault code analysis and real-time monitoring.
  • Component Layouts: Quick reference diagrams for easy component identification.
  • Troubleshooting A (Fault Code Based): Detailed flowcharts for diagnosing issues based on specific Dr.EX fault codes (e.g., EEPROM failures, sensor malfunctions – N sensor, EC sensor, pump displacement/delivery/control pressure sensors, pilot pressure sensors, hydraulic oil temperature sensor).
  • Troubleshooting B (Symptom Based): Addressing issues based on observed symptoms for the Engine System, Actuator Control System, Front Attachment, Swing System, Travel System, and other functions (e.g., wiper issues). Includes engine/pump learning procedures and A-sensor adjustment.
  • Troubleshooting C (Monitor Panel): Diagnosing malfunctions of gauges (coolant temperature, fuel) and indicators.
  • Electrical System Inspection: Detailed procedures for checking harnesses, connectors, fuses, fusible links, battery voltage, alternator performance, and relay replacement.
  • Harness Check: Specific instructions for testing harness continuity.
  • Includes extensive Electrical Circuit Diagrams, Connector Pinouts, and Harness Layouts.

This two-volume set, originally copyrighted in 1998, provides a timeless and exhaustive resource for maintaining the Hitachi EX135USR Excavator at peak operational efficiency. It is an indispensable tool for any technician or owner dedicated to the proper care and repair of this machine.

🔧 TECHNICAL SPECIFICATIONS & COVERAGE

• Equipment Models Covered: Hitachi EX135USR Excavator. The manual’s detailed component data (engine, pumps, etc.) helps confirm applicability.
• Engine Specifications:
  • Model: ISUZU A-4BG1T (Diesel, 4-cycle, vertical, 4-cylinder inline, water-cooled, direct injection).
  • Displacement: 4329 cm³ (264 in³).
  • Rated Output: 62.5 kW/2100 min⁻¹ (Normal); 66.2 kW/2200 min⁻¹ (HP Mode).
  • Fuel System: Bosch A-type injection pump, RSV governor.
  • Detailed specs on cooling, lubrication, starting, and alternator systems.
• Hydraulic System Details:
  • Main Pump: HPV050FW (Variable displacement plunger type), Max flow: 105 L/min x2.
  • Pilot Pump: HY/ZFS 11/16.8 (Fixed displacement gear type).
  • Control Valve: Pilot pressure operated (4-spool + 5-spool design).
  • Swing Motor: AP5S67 (Fixed-displacement swash-plate type).
  • Travel Motor: HMV075CF-18A (Variable displacement bent-axis type).
  • Comprehensive data on cylinder dimensions, relief pressures, and specialized valve units (PC & VC Solenoids).
• Electrical System Information:
  • System Voltage: 24V.
  • Key Components: Battery Relay (24V-100A), Glow Relay, detailed monitor panel functions, Dr.EX diagnostic interface.
  • Full circuit diagrams for power, starting, charging, preheat, and control systems.
• Transmission and Drivetrain Coverage: Planetary reduction gears for swing and travel devices are detailed within their respective sections.
• Special Tools and Equipment Requirements: Frequent mention of the Dr.EX diagnostic tool for fault analysis and performance monitoring. Standard mechanical tools, pressure gauges, tachometers, and specific test harnesses (e.g., ST 7129) are also indicated.

📋 MANUAL SECTIONS & PROCEDURES

• Service Procedures and Maintenance Schedules: Includes comprehensive operational performance tests for all major systems, engine/pump learning procedures, and A-sensor voltage adjustments.
• Repair Instructions and Troubleshooting Guides:
  • Fault Code Diagnostics (Troubleshooting A)
  • Symptom-Based Diagnostics (Troubleshooting B) for Engine, Actuators, Attachments, Swing, Travel.
  • Monitor Panel Troubleshooting (Troubleshooting C) for gauges and indicators.
• Parts Identification and Replacement Procedures: Extensive component layouts and detailed operational descriptions of major assemblies (Pump, Swing, Control Valve, Pilot Valve, Travel Devices) guide identification and implicitly support replacement. Relay replacement procedures are explicitly detailed.
• Assembly and Disassembly Instructions: While not a standalone assembly manual, the “Component Operation” sections offer exploded views and functional descriptions essential for these tasks.
• Adjustment and Calibration Procedures: Valve clearance, injection timing, pilot pressures, relief valve settings (main, swing, travel, overload), solenoid valve pressures, regulator adjustments, and sensor calibrations.
• Safety Procedures and Precautions: A dedicated, extensive section covering a wide range of safety topics from general machine operation to specific maintenance tasks.
• Electrical Schematics and Harness Checks: Full electrical circuit diagrams, connector lists, and harness routing information.

❌ WHAT’S NOT INCLUDED

• A physical, printed version of the manual (this is a digital PDF download).
• Direct, real-time technical support or consultation services.
• Warranty coverage for repairs or guarantees on parts.

📊 COMPREHENSIVE RECOMMENDATION SUMMARY

❓ FREQUENTLY ASKED QUESTIONS

📋 SEO Schema for Google:

💬 Customer Questions & Answers:

Q: What specific models and years does this manual cover?
A: This manual set is specifically for the Hitachi EX135USR Excavator. It covers the operational principles (Manual No. KM-194E, Vol. No. TO194E-00) and troubleshooting/performance testing (Manual No. KM-194E, Vol. No. TT194E-00). The content is based on the 1998 copyright for the operational principle volume.

Q: What types of maintenance and repair procedures are included?
A: It includes comprehensive procedures for operational performance testing of engine, excavator functions, and hydraulic components; fault code diagnostics; symptom-based troubleshooting for all major systems; electrical system inspection; harness checks; and detailed adjustment/calibration procedures for various components.

Q: Is this manual suitable for DIY mechanics or is it for professionals only?
A: Due to its high level of technical detail and the frequent requirement for specialized diagnostic tools like Dr.EX, this manual is primarily aimed at professional service technicians and experienced mechanics. While some information may be useful for advanced DIYers, a strong mechanical background is essential.

Q: What format is this manual in and how do I access it?
A: The manual is a digital PDF file. Upon purchase, you will receive a download link for immediate access. You can save it to your computer or mobile device for permanent offline use.

Q: Are there special tools or diagnostic equipment requirements?
A: Yes, the Hitachi Dr.EX diagnostic tool is frequently mentioned for troubleshooting and performance testing. Additionally, standard workshop tools, pressure gauges, multimeters, and specific Hitachi test harnesses (part numbers sometimes provided) are necessary for many procedures.

Q: Does this manual include wiring diagrams and hydraulic schematics?
A: Yes, the manual contains detailed electrical circuit diagrams, hydraulic system schematics (main circuit, pilot circuit, etc.), connector pinouts, and harness layouts to aid in troubleshooting and understanding system operations.

Q: Is the manual language technical or user-friendly?
A: The language is technical, intended for individuals with a good understanding of heavy machinery systems and service procedures. It is precise and detailed to ensure accuracy in diagnostics and repairs.

Q: Can I print this manual or use it offline?
A: Absolutely. Being a PDF, you can print any sections you need or the entire manual for workshop use. It can also be stored and accessed offline on any device that supports PDF viewing.

🛠️ PROFESSIONAL ASSESSMENT & USABILITY

• Overall Quality Rating: ⭐⭐⭐⭐⭐ (Highly comprehensive and OEM-level detailed)
• Content Classification: Technical Service Manual (Operational Principle & Troubleshooting/Performance Testing) for Hitachi EX135USR Excavator.
• Language & Accessibility: Technical and precise, suitable for trained professionals and experienced mechanics.
• Professional Recommendation: An essential resource for any workshop or technician servicing the Hitachi EX135USR. Indispensable for accurate diagnostics, repairs, and understanding complex system interactions.
• Technical Depth: Extremely thorough, covering system theory, component operation, performance standards, and detailed diagnostic flowcharts.
• Page Count & Scope: 755 pages across two main volumes, offering exhaustive coverage.
• File Quality & Format: High-resolution digital PDF with clear, legible diagrams, schematics, and text.
• Update Status: Based on 1998 copyright for the operational manual; fundamental principles and systems for this model generation are well-covered.

🎯 IDEAL USE CASES & APPLICATIONS

• Professional Service Shop Operations: Core reference for all diagnostics, repairs, and servicing of the EX135USR.
• Equipment Maintenance Planning: Understanding component operation and performance standards aids in proactive maintenance.
• Troubleshooting and Diagnostic Procedures: Step-by-step guidance for both fault-code based and symptom-based problem solving.
• Parts Identification and Ordering: Detailed component layouts and operational descriptions assist in identifying necessary parts.
• Training and Skill Development: Excellent resource for technicians to deepen their understanding of the EX135USR’s systems.
• Equipment Inspection and Safety Compliance: Contains vital safety information and performance standards for inspections.

📋 Original Product Description:

Hitachi Ex135usr Excavator Service Manual Set

DESCRIPTION:

This manual consists oi three portions: the lecnnrcal Manual (Operational Principle), the Technical Man- ual (Troubleshooting) and the Workshop Manual. Information included in the Technical Manual (Operational Principle): technical information needed for redeliver and de- livery, operation and activation of all devices and systems.

IMAGES:

TBLE OF CONTENTS:

Specifications Working Ranges and Machine Dimensions for Transportation Component Specifications main Components Electrical System (Overall System) Electrical System (Relays) t Electrical System (Monitor and Switch Panels) Pump and Related Parts Other Components