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Hitachi ZX135US-5B Hydraulic Excavator Technical Workshop Manual (WDAE-EN-00) – PDF Download
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- Hitachi ZX135US-5B Hydraulic Excavator Technical Workshop Manual
- Part No:WDAE-EN-00
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Description
Hitachi ZX135US-5B Hydraulic Excavator Technical Workshop Manual (WDAE-EN-00)
File Details:
Hitachi ZX135US-5B Hydraulic Excavator Technical Workshop Manual (WDAE-EN-00)
- Manual Language:English
- Downloadable:Yes
- Pages: 599
- Size: 7.51 MB
- Format:PDF
HITACHI ZX135US-5B HYDRAULIC EXCAVATOR TECHNICAL WORKSHOP MANUAL (WDAE-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZX135US-5B Hydraulic Excavator Technical Workshop Manual (WDAE-EN-00)
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Table Of Contents:
Hitachi ZX135US-5B Hydraulic Excavator Technical Workshop Manual (WDAE-EN-00)
WDAE-EN-00...................................................................... 1 INTRODUCTION................................................................ 3 To The Reader........................................................... 3 Additional References................................................... 3 Manual Composition...................................................... 3 Page Number............................................................. 3 Safety Alert Symbol and Headline Notations.............................. 4 Units Used.............................................................. 4 SYMBOL AND ABBREVIATION..................................................... 5 SAFETY...................................................................... 7 Recognize Safety Information............................................ 7 Understand Signal Words................................................. 7 Follow Safety Instructions.............................................. 8 Prepare for Emergencies................................................. 9 Wear Protective Clothing................................................ 9 Protect Against Noise................................................... 10 Inspect Machine......................................................... 10 General Precautions for Cab............................................. 11 Use Handholds and Steps................................................. 12 Adjust the Operator's Seat.............................................. 12 Ensure Safety Before Rising from or Leaving Operator’s Seat............. 13 Fasten Your Seat Belt................................................... 13 Move and Operate Machine Safely......................................... 14 Operate Only from Operator's Seat....................................... 14 Jump Starting........................................................... 15 Keep Riders off Machine................................................. 15 Precautions for Operations.............................................. 16 Investigate Job Site Beforehand......................................... 17 Install OPG Guard....................................................... 18 Provide Signals for Jobs Involving Multiple Machines.................... 19 Confirm Direction of Machine to Be Driven............................... 19 Drive Machine Safely.................................................... 20 Avoid Injury from Rollaway Accidents.................................... 22 Avoid Injury from Back-Over and Swing Accidents......................... 23 Keep Person Clear from Working Area..................................... 24 Never Position Bucket Over Anyone....................................... 24 Avoid Undercutting...................................................... 25 Avoid Tipping........................................................... 25 Never Undercut a High Bank.............................................. 26 Dig with Caution........................................................ 26 Operate with Caution.................................................... 26 Avoid Power Lines....................................................... 27 Precautions for Lightning............................................... 27 Object Handling......................................................... 28 Protect Against Flying Debris........................................... 28 Park Machine Safely..................................................... 29 Handle Fluids Safely−Avoid Fires........................................ 29 Transport Safely........................................................ 30 Practice Safe Maintenance............................................... 31 Warn Others of Service Work............................................. 32 Support Machine Properly................................................ 32 Stay Clear of Moving Parts.............................................. 33 Prevent Parts from Flying............................................... 33 Store Attachments Safely................................................ 34 Prevent Burns........................................................... 34 Replace Rubber Hoses Periodically....................................... 35 Avoid High-Pressure Fluids.............................................. 35 Prevent Fires........................................................... 36 Evacuating in Case of Fire.............................................. 38 Beware of Exhaust Fumes................................................. 38 Precautions for Welding and Grinding.................................... 39 Avoid Heating Near Pressurized Fluid Lines.............................. 40 Avoid Applying Heat to Lines Containing Flammable Fluids................ 40 Precautions for Handling Accumulator and Gas Dumper..................... 40 Remove Paint Before Welding or Heating.................................. 41 Beware of Asbestos and Silicon Dust and Other Contamination............. 41 Prevent Battery Explosions.............................................. 42 Service Air Conditioning System Safely.................................. 42 Handle Chemical Products Safely......................................... 43 Dispose of Waste Properly............................................... 43 Never Ride Attachment................................................... 44 Notes for Muffler Filter................................................ 44 Precautions for Communication Terminal.................................. 44 Precaution for Communication Terminal Equipment......................... 45 Before Returning the Machine to the Customer............................ 46 SECTION AND GROUP CONTENTS.................................................. 47 SECTION 1 GENERAL........................................................... 49 Group 1 Precautions for Disassembling and Assembling.................... 51 Precautions for Disassembling and Assembling........................ 51 Group 2 Tightening...................................................... 57 Tightening Bolts and Nuts........................................... 57 Piping Joint........................................................ 60 Group 3 Painting........................................................ 67 Painting............................................................ 67 Group 4 Bleeding Air.................................................... 69 Bleeding Air from Hydraulic Oil Tank................................ 69 Bleeding Air from Hydraulic System.................................. 70 Bleeding Air from Fuel System....................................... 71 Bleeding Air from Radiator.......................................... 73 Group 5 Pressure Release Procedure...................................... 75 Hydraulic Circuit Pressure Release Procedure........................ 75 Group 6 Preparation..................................................... 77 Preparation before Inspection and Maintenance....................... 77 SECTION 2 MAINTENANCE STANDARD.............................................. 81 Group 1 Upperstructure.................................................. 83 Pump Device......................................................... 83 Swing Motor......................................................... 85 Swing Parking Brake................................................. 87 Group 2 Undercarriage................................................... 89 Travel Motor........................................................ 89 Parking Brake....................................................... 91 Sprocket............................................................ 92 Front Idler......................................................... 93 Upper Roller........................................................ 95 Lower Roller........................................................ 96 Track............................................................... 97 Group 3 Front Attachment................................................101 Pin and Bushing.....................................................101 Side Cutter (2015428, 2015429)......................................103 Point (Z963228).....................................................104 Standard Dimensions for Arm and Bucket Connection...................105 Standard Dimensions for Arm and Boom Connection.....................106 Cylinder............................................................107 SECTION 3 UPPERSTRUCTURE....................................................111 Group 1 Cab.............................................................113 Removal and Installation of Cab.....................................113 Dimensions of Cab Glass.............................................139 Group 2 Counterweight...................................................159 Removal and Installation of Counterweight...........................159 Group 3 Main Frame......................................................161 Removal and Installation of Main Frame..............................161 Group 4 Engine..........................................................175 Removal and Installation of Engine..................................175 Group 8 Pump Device.....................................................199 Removal and Installation of Pump Device.............................199 Removal and Installation of Coupling................................215 Disassembly of Pump Device..........................................217 Assembly of Pump Device.............................................224 Disassembly of Regulator............................................233 Assembly of Regulator...............................................235 Disassembly of Solenoid Valve.......................................237 Assembly of Solenoid Valve..........................................239 Structure of Pilot Pump.............................................241 Group 9 Control Valve...................................................243 Removal and Installation of Control Valve...........................243 Disassembly of Housing..............................................263 Assembly of Housing.................................................265 Disassembly of Control Valve (Housing A Side).......................267 Assembly of Control Valve (Housing A Side)..........................275 Disassembly of Control Valve (Housing B Side).......................283 Assembly of Control Valve (Housing B Side)..........................294 Removal and Installation of Blade Control Valve (Optional)..........305 Disassembly of Blade Control Valve (Optional).......................309 Assembly of Blade Control Valve (Optional)..........................311 Group 10 Swing Device...................................................313 Removal and Installation of Swing Device............................313 Disassembly of Swing Device.........................................319 Assembly of Swing Device............................................324 Disassembly of Swing Motor..........................................331 Assembly of Swing Motor.............................................334 Disassembly of Valve Unit...........................................341 Assembly of Valve Unit..............................................343 Group 11 Pilot Valve....................................................345 Removal and Installation of Pilot Valve (Left)......................345 Removal and Installation of Pilot Valve (Right).....................351 Removal and Installation of Travel Pilot Valve......................359 Removal and Installation of Blade Pilot Valve.......................363 Disassembly of Pilot Valves (Right and Left)........................371 Assembly of Pilot Valves (Right and Left)...........................374 Disassembly of Travel Pilot Valve...................................377 Assembly of Travel Pilot Valve......................................381 Disassembly of Blade Pilot Valve....................................387 Assembly of Blade Pilot Valve.......................................390 Group 12 Solenoid Valve.................................................393 Removal and Installation of Pilot Shut-Off Solenoid Valve...........393 Removal and Installation of 4-Spool Solenoid Valve Unit.............397 Removal and Installation of 2-Spool Solenoid Valve Unit.............405 Disassembly of Pilot Shut-Off Solenoid Valve........................409 Assembly of Pilot Shut-Off Solenoid Valve...........................411 Structure of 4-Spool Solenoid Valve Unit............................413 Structure of 2-Spool Solenoid Valve Unit............................415 Group 13 Signal Control Valve...........................................417 Removal and Installation of Signal Control Valve....................417 Structure of Signal Control Valve...................................425 Group 14 Muffler Filter.................................................427 Removal and Installation of Muffler Filter..........................427 Disassembly of Muffler Filter.......................................435 Assembly of Muffler Filter..........................................437 SECTION 4 UNDERCARRIAGE.....................................................441 Group 1 Swing Bearing...................................................443 Removal and Installation of Swing Bearing...........................443 Disassembly of Swing Bearing........................................449 Assembly of Swing Bearing...........................................452 Group 2 Travel Device...................................................455 Removal and Installation of Travel Device...........................455 Disassembly of Travel Device........................................457 Assembly of Travel Device...........................................461 Disassembly of Travel Motor.........................................467 Assembly of Travel Motor............................................471 Disassembly of Brake Valve..........................................477 Assembly of Brake Valve.............................................479 Precautions for Using Floating Seal.................................481 Group 3 Center Joint....................................................483 Removal and Installation of Center Joint (Without Blade)............483 Removal and Installation of Center Joint (With Blade)...............487 Disassembly of Center Joint (Without Blade).........................491 Assembly of Center Joint (Without Blade)............................493 Replacement of Body (Without Blade).................................496 Disassembly of Center Joint (With Blade)............................497 Assembly of Center Joint (With Blade)...............................499 Replacement of Body (With Blade)....................................502 Group 4 Track Adjuster..................................................503 Removal and Installation of Track Adjuster..........................503 Disassembly of Track Adjuster.......................................505 Assembly of Track Adjuster..........................................510 Group 5 Front Idler.....................................................513 Removal and Installation of Front Idler.............................513 Disassembly of Front Idler..........................................515 Assembly of Front Idler.............................................518 Precautions for Using Floating Seal.................................521 Group 6 Upper and Lower Rollers.........................................523 Removal and Installation of Upper Roller............................523 Removal and Installation of Lower Roller............................527 Disassembly of Lower Roller.........................................531 Assembly of Lower Roller............................................533 Precautions for Using Floating Seal.................................535 Group 7 Track...........................................................537 Removal and Installation of Track...................................537 Group 8 Blade Cylinder..................................................543 Removal and Installation of Blade Cylinder..........................543 Disassembly of Blade Cylinder.......................................547 Assembly of Blade Cylinder..........................................549 SECTION 5 FRONT ATTACHMENT..................................................553 Group 1 Front Attachment................................................555 Removal and Installation of Front Attachment........................555 Group 2 Cylinder........................................................561 Removal and Installation of Boom Cylinder...........................561 Removal and Installation of Arm Cylinder............................565 Removal and Installation of Bucket Cylinder.........................571 Disassembly of Boom, Arm, and Bucket Cylinders......................575 Assembly of Boom, Arm, and Bucket Cylinders.........................582 Group 3 Hose Rupture Valve..............................................587 Removal and Installation of Hose Rupture Valve for Boom Cylinder....587 Removal and Installation of Hose Rupture Valve for Arm Cylinder.....589 Structure of Hose Rupture Valve for Boom Cylinder (Right)...........591 Structure of Hose Rupture Valve for Boom Cylinder (Left)............593 Structure of Hose Rupture Valve for Arm Cylinder....................595 SERVICE MANUAL REVISION REQUEST FORM........................................599
Please Note:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
