Hitachi Zaxis75US-A 75UR 135UR Technical Manual Troubleshooting – PDF Download

Description

The Hitachi Zaxis75US-A 75UR 135UR Technical Manual Troubleshooting is the dedicated troubleshooting and performance testing volume from Hitachi Construction Machinery’s technical documentation set. This manual covers the Zaxis75US-A, Zaxis75UR, and Zaxis135UR excavators and gives technicians a structured method for measuring machine performance, interpreting fault codes, and tracing the root cause of operational problems across the engine, hydraulic, electrical, and control systems.

File Details

• Manual Type: Technical Manual (Troubleshooting)
• Brand: Hitachi Construction Machinery
• Models Covered: Zaxis75US-A, Zaxis75UR, Zaxis135UR (also referenced as EX75US-A and EX75UR in performance tables)
• Language: English
• Page Count: 322 pages
• File Format: PDF
• Copyright: 2002 Hitachi Construction Machinery Co., Ltd., Tokyo, Japan

Chapters Covered

This manual is divided into two main sections: Section 4 (Operational Performance Test) and Section 5 (Troubleshooting), plus a set of attached hydraulic and electrical circuit diagrams.

• Section 4 — Operational Performance Test
  • Group 1: Introduction — Operational Performance Tests, Preparation for Performance Tests
  • Group 2: Standard — Operational Performance Standard Table, Main Pump 1 and 2 P-Q Diagram, Main Pump 3 P-Q Diagram, Injection Pump, Dr. EX Monitor Indicating Values, Sensor Activating Range
  • Group 3: Engine Test — Engine Speed, Engine Compression Pressure, Valve Clearance Adjustment, Nozzle Check, Injection Timing
  • Group 4: Excavator Test — Travel Speed, Track Revolution Speed, Mistrack Check, Travel Parking Function Check, Swing Speed, Swing Function Drift Check, Swing Motor Leakage, Maximum Swingable Slant Angle, Swing Bearing Play, Hydraulic Cylinder Cycle Time, Dig Function Drift Check, Control Lever Operating Force, Control Lever Stroke, Boom Raise/Swing Combined Operation Check
  • Group 5: Component Test — Primary Pilot Pressure, Secondary Pilot Pressure, Travel Speed Changeover Solenoid Valve Set Pressure, Main Pump Delivery Pressure, Main Relief Valve Set Pressure, Overload Relief Valve Set Pressure, Main Pumps 1 and 2 Flow Rate Measurement, Main Pump 3 Flow Rate Measurement, Swing Motor Drainage, Travel Motor Drainage
  • Group 6: Adjustment — Engine Speed Adjustment and Engine Learning, Governor Lever and Fuel Cut Lever Position, Assembly and Adjustment of Link for Arm Angle Sensor (ZAXIS75UR), Adjusting Method of Front Acceleration Speed and Deceleration Speed (ZAXIS75UR)
• Section 5 — Troubleshooting
  • Group 1: General — Introduction, Diagnosing Procedure, Built-In Diagnosing System Operation, Built-In Diagnosing Function Display List, Dr. EX Operation, Dr. EX Fault Code List (MC), Dr. EX Fault Code List (Auto-MARCCINO Controller), Dr. EX Monitoring Item List, Dr. EX Special Function, Dr. EX Service Mode
  • Group 2: Component Layout — Main Components, Electrical System (Overall System), Electrical System (Front Attachment), Electrical System (Monitor and Switches), Electrical System (Battery), Electrical System (Pressure Sensor), Solenoid Valve, Pump Device, Travel Device, Swing Device, Control Valve
  • Group 3: Troubleshooting A — Fault Code List, Fault Code 01/02/03, Fault Code 04, Fault Code 06, Fault Code 07, Fault Code 18
  • Group 4: Troubleshooting B — Relationship between Machine Trouble Symptoms and Related Parts, Correlation between Trouble Symptoms and Part Failures, Engine System Troubleshooting, All Actuator System Troubleshooting, Front Attachment System Troubleshooting, Swing System Troubleshooting, Travel System Troubleshooting, Blade System Troubleshooting, Other System Troubleshooting, Exchange Inspection, Emergency Boom Lowering Procedure
  • Group 5: Troubleshooting C — Malfunction of Coolant Temperature Gauge, Fuel Gauge, Indicator Light Check System, Alternator Indicator, Engine Oil Pressure Indicator, Overheat Indicator, Air Filter Restriction Indicator, Buzzer, LCD, Hour Meter, Hydraulic Oil Filter Indicator
  • Group 6: Troubleshooting D (ZAXIS75UR Only) — Auto-MARCCINO Controller Fault Code List, Fault Codes 05 through 92, Assembly and Adjustment of Link for Arm Angle Sensor, Initial Setting of Angle Sensor, Initializing the Depth Limit Control System
  • Group 7: Electrical System Inspection — Precautions for Inspection and Maintenance, Instructions for Disconnecting Connectors, Fuse Inspection, Fusible Link Inspection, Battery Voltage Check, How to Troubleshoot Alternator Malfunctions, Continuity Check, Voltage and Current Measurement, Check by False Signal, Test Harness
  • Group 8: ICX — Outline, ICX Fault Code List, Satellite Terminal Fault Code List, Troubleshooting and Setting of ICX and Satellite Terminal Using Dr. EX, Satellite Communication System
• Attached Diagrams
  • ZAXIS75US-A/70 (STD) Hydraulic Circuit Diagram
  • ZAXIS75UR Hydraulic Circuit Diagram
  • ZAXIS75US-A/75US/70 Electrical Circuit Diagram (1)
  • ZAXIS75US-A/75US/70 Electrical Circuit Diagram (2)
  • ZAXIS75UR/135UR Electrical Circuit Diagram
  • ZAXIS75UR/135UR Connectors
  • ZAXIS75US-A Cab Harness
  • ZAXIS75UR Cab Harness
  • ZAXIS75US-A Engine Harness
  • ZAXIS75UR Engine Harness

What This Manual Gives a Technician

This Hitachi Zaxis75US-A 75UR 135UR Technical Manual Troubleshooting is written for the experienced technician who needs to move beyond guesswork. Rather than listing parts, it teaches a measurement-driven diagnostic process: test the machine against the published performance standard, compare the measured data, and then follow the correct troubleshooting flow for the symptom or fault code shown. That approach is what separates a fast, accurate repair from a parts-swapping loop.

The performance test section covers the full range of checks a technician will actually perform in the field — engine speed and compression, valve clearance, nozzle and injection timing, travel and swing speed, mistrack, swing drift, hydraulic cylinder cycle times, dig function drift, control lever force and stroke, and combined boom raise/swing operation. The standard table gives the acceptable values and the allowable tolerances, so the technician knows whether the machine is within specification or not, not just whether it runs.

The troubleshooting section then takes over when the machine is outside specification or a fault code appears. Troubleshooting A deals with fault codes displayed by the main controller, covering codes 01, 02, 03, 04, 06, 07, and 18. Troubleshooting B handles diagnosis when no fault code is present — starting from the symptom, such as slow travel on one side, weak front attachment power, engine stall, swing drift, or blade problems. Troubleshooting C covers the monitor system: gauges, indicators, buzzer, LCD, and hour meter. Troubleshooting D is specific to the ZAXIS75UR and the Auto-MARCCINO front attachment control, covering fault codes 05 through 92 and the angle sensor initialisation and depth limit control reset procedures.

The electrical system inspection group is a practical reference for anyone tracing wiring faults on these machines. It covers fuse and fusible link inspection, battery voltage checks, alternator troubleshooting, continuity and short-circuit checks, voltage and current measurement at specific circuit points, and the use of test harnesses. The ICX group covers the information controller and satellite terminal diagnostics for machines equipped with those systems.

The manual also includes a fault-code reference for both the main controller and the Auto-MARCCINO controller (ZAXIS75UR), a Dr. EX monitoring item list, and the built-in diagnosing system display list, so the technician can use the machine’s own self-diagnostic functions alongside the manual’s procedures.

Who This Manual Is For

This Hitachi Zaxis75US-A 75UR 135UR Technical Manual Troubleshooting is intended for experienced technicians, field service engineers, and owners who maintain their own Zaxis75US-A, Zaxis75UR, or Zaxis135UR excavator. It assumes access to the machine and to the tools and test equipment referenced in the procedures, including pressure gauges, flow testers, a tachometer, a multimeter, and Dr. EX or the built-in diagnosing system. It is the troubleshooting companion to the Operational Principle manual and the Workshop Manual; the three together form the complete technical documentation set for these machines.

Why This Manual Matters

An excavator that is out of specification costs money — in fuel, in cycle times, in premature component wear, and in unplanned downtime. The performance standards in this manual are the reference point for deciding whether a machine needs repair, adjustment, or replacement. The troubleshooting flow charts then prevent the two most expensive diagnostic mistakes: replacing a good part because the symptom pointed the wrong way, and missing the actual fault because a related fault code or monitoring item was not checked.

For the ZAXIS75UR, the Auto-MARCCINO controller and front attachment control system add a layer of electronic diagnostics that is not intuitive to troubleshoot without the fault code list and the flow charts in Troubleshooting D. Having these procedures on hand saves hours of guesswork and helps prevent damage to the angle sensors, solenoid valves, and controller.

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The Hitachi Zaxis75US-A 75UR 135UR Technical Manual Troubleshooting is delivered as an instant PDF download after purchase. There is no shipping, no waiting for a physical book, and no restriction on which device you use to read it. You can view it on a laptop, tablet, or smartphone, print the pages you need for the workshop, and keep the full manual on file for future reference. The PDF format makes it easy to search, zoom in on diagrams, and print specific procedures without carrying the entire manual around the job site.