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Hitachi ZX135US 6 Hydraulic Excavator workshop Manual – PDF DOWNLOAD
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Hitachi ZX135US 6 Hydraulic Excavator workshop Manual
Part No : WDAS50-EN-00
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Description
Hitachi ZX135US 6 Hydraulic Excavator workshop Manual
File details:
Hitachi ZX135US 6 Hydraulic Excavator workshop Manual
Language : English
Pages : 807
Size : 41.7 MB
Downloadable : Yes
Format : PDF
Part No : WDAS50-EN-00
HITACHI ZX135US 6 HYDRAULIC EXCAVATOR WORKSHOP MANUAL – PDF DOWNLOAD:
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Table of Contents:
Hitachi ZX135US 6 Hydraulic Excavator workshop Manual
WDAS50-EN-00..................................................................................... 1 CONTENTS..................................................................................... 3 SECTION 1 GENERAL........................................................................ 3 SECTION 2 MAINTENANCE STANDARD........................................................... 5 SECTION 3 UPPERSTRUCTURE................................................................. 7 SECTION 4 UNDERCARRIAGE.................................................................. 9 SECTION 5 FRONT ATTACHMENT............................................................... 11 INTRODUCTION................................................................................. 13 To The Reader............................................................................ 13 Additional References.................................................................... 13 Manual Composition....................................................................... 13 Page Number.............................................................................. 13 Trademark................................................................................ 13 Safety Alert Symbol and Headline Notations............................................... 14 Units Used............................................................................... 14 SYMBOL AND ABBREVIATION...................................................................... 15 SAFETY....................................................................................... 17 Recognize Safety Information............................................................. 17 Understand Signal Words.................................................................. 17 Follow Safety Instructions............................................................... 18 Prepare for Emergencies.................................................................. 19 Wear Protective Clothing................................................................. 19 Protect Against Noise.................................................................... 20 Inspect Machine.......................................................................... 20 General Precautions for the Cab.......................................................... 21 Use Handholds and Steps.................................................................. 22 Adjust the Operator's Seat............................................................... 22 Ensure Safety Before Rising from or Leaving Operator’s Seat.............................. 23 Fasten Your Seat Belt.................................................................... 23 Move and Operate Machine Safely.......................................................... 24 Operate Only from Operator's Seat........................................................ 24 Jump Starting............................................................................ 25 Keep Riders off Machine.................................................................. 25 Precautions for Operations............................................................... 26 Investigate Job Site Beforehand.......................................................... 27 Install OPG Guard........................................................................ 28 Restriction of Attachment Installation................................................... 28 Provide Signals for Jobs Involving Multiple Machines..................................... 29 Confirm Direction of Machine to Be Driven................................................ 29 Drive Machine Safely..................................................................... 30 Avoid Injury from Rollaway Accidents..................................................... 32 Avoid Injury from Back-Over and Swing Accidents.......................................... 33 Keep People Clear from Working Area...................................................... 34 Never Position the Bucket Over Anyone.................................................... 34 Avoid Undercutting....................................................................... 35 Avoid Tipping............................................................................ 35 Never Undercut a High Bank............................................................... 36 Dig with Caution......................................................................... 36 Operate with Caution..................................................................... 36 Avoid Power Lines........................................................................ 37 Precautions for Lightning................................................................ 37 Object Handling.......................................................................... 38 Protect Against Flying Debris............................................................ 38 Park Machine Safely...................................................................... 39 Handle Fluids Safely−Avoid Fires......................................................... 39 Transport Safely......................................................................... 40 Practice Safe Maintenance................................................................ 41 Warn Others of Service Work.............................................................. 42 Support Machine Properly................................................................. 42 Stay Clear of Moving Parts............................................................... 43 Prevent Parts from Flying................................................................ 43 Avoid Injury from Attachment Falling Accident............................................ 44 Prevent Burns............................................................................ 44 Replace Rubber Hoses Periodically........................................................ 45 Avoid High-Pressure Fluids............................................................... 45 Prevent Fires............................................................................ 46 Evacuating in Case of Fire............................................................... 48 Beware of Exhaust Fumes.................................................................. 48 Precautions for Welding and Grinding..................................................... 49 Avoid Heating Near Pressurized Fluid Lines............................................... 50 Avoid Applying Heat to Lines Containing Flammable Fluids................................. 50 Precautions for Handling Accumulator and Gas Damper...................................... 50 Remove Paint Before Welding or Heating................................................... 51 Beware of Asbestos and Silica Dust and Other Contamination............................... 51 Prevent Battery Explosions............................................................... 52 Service Air Conditioning System Safely................................................... 52 Handle Chemical Products Safely.......................................................... 53 Dispose of Waste Properly................................................................ 53 Never Ride Attachment.................................................................... 54 Notes on Aftertreatment Device........................................................... 54 Precautions for Communication Terminal................................................... 54 Precautions for Communication Terminal Equipment......................................... 55 Notes on Protection of Operator’s Station when the Machine Rolls Over.................... 57 Before Returning the Machine to the Customer............................................. 58 SECTION AND GROUP CONTENTS................................................................... 59 SECTION 1 GENERAL............................................................................ 63 Group 1 Precautions for Disassembling and Assembling..................................... 65 Precautions for Disassembling and Assembling......................................... 65 Group 2 Tightening....................................................................... 71 Tightening Bolts and Nuts............................................................ 71 Piping Joint......................................................................... 74 Group 3 Painting......................................................................... 81 Painting............................................................................. 81 Group 4 Bleeding Air..................................................................... 83 Bleeding Air from Hydraulic System................................................... 83 Bleeding Air from Fuel System........................................................ 84 Air Bleeding from the DEF Defrosting Piping.......................................... 86 Group 5 Preparation...................................................................... 89 Preparation before Inspection and Maintenance........................................ 89 Hydraulic Circuit Pressure Release Procedure......................................... 91 Pressure Release from Hydraulic Oil Tank............................................. 92 Pressure Release from Expansion Tank................................................. 93 SECTION 2 MAINTENANCE STANDARD............................................................... 97 Group 1 Upperstructure................................................................... 99 Pump Device.......................................................................... 99 Swing Motor..........................................................................101 Swing Parking Brake..................................................................103 Group 2 Undercarriage....................................................................105 Travel Motor.........................................................................105 Parking Brake........................................................................107 Sprocket.............................................................................108 Front Idler..........................................................................109 Upper Roller.........................................................................111 Lower Roller.........................................................................112 Track................................................................................113 Group 3 Front Attachment.................................................................117 Pin and Bushing......................................................................117 Side Cutter (2015428, 2015429).......................................................119 Point (963228).......................................................................120 Standard Dimensions for Arm and Bucket Connection....................................121 Standard Dimensions for Arm and Boom Connection......................................122 Cylinder.............................................................................123 SECTION 3 UPPERSTRUCTURE.....................................................................127 Group 1 Cab..............................................................................129 Removal and Installation of Cab......................................................129 Dimensions of Cab Glass..............................................................171 Group 2 Counterweight....................................................................191 Removal and Installation of Counterweight............................................191 Group 3 Main Frame.......................................................................197 Removal and Installation of Main Frame...............................................197 Group 4 Engine...........................................................................215 Removal and Installation of Engine...................................................215 Group 8 Pump Device......................................................................261 Removal and Installation of Pump Device..............................................261 Removal and Installation of Coupling.................................................275 Disassembly of Pump Device...........................................................277 Assembly of Pump Device..............................................................284 Disassembly of Regulator.............................................................293 Assembly of Regulator................................................................295 Disassembly of Solenoid Valve Unit...................................................297 Assembly of Solenoid Valve Unit......................................................299 Structure of Pilot Pump and Blade Pump...............................................301 Group 9 Control Valve....................................................................303 Removal and Installation of Control Valve............................................303 Removal and Installation of Blade Control Valve......................................331 Disassembly of Housing...............................................................335 Assembly of Housing..................................................................337 Disassembly of A-Side Control Valve..................................................339 Assembly of A-Side Control Valve.....................................................347 Disassembly of B-Side Control Valve..................................................357 Assembly of B-Side Control Valve.....................................................368 Disassembly of Blade Control Valve...................................................381 Assembly of Blade Control Valve......................................................383 Group 10 Swing Device....................................................................385 Removal and Installation of Swing Device.............................................385 Disassembly of Swing Reduction Gear..................................................391 Assembly of Swing Reduction Gear.....................................................396 Disassembly of Swing Motor...........................................................403 Assembly of Swing Motor..............................................................406 Disassembly of Valve Unit............................................................413 Assembly of Valve Unit...............................................................415 Group 11 Pilot Valve.....................................................................417 Removal and Installation of Pilot Valve (Left).......................................417 Removal and Installation of Pilot Valve (Right)......................................429 Removal and Installation of Travel Pilot Valve.......................................445 Removal and Installation of Blade Pilot Valve........................................449 Disassembly of Pilot Valves (Right and Left).........................................459 Assembly of Pilot Valves (Right and Left)............................................462 Disassembly of Travel Pilot Valve....................................................465 Assembly of Travel Pilot Valve.......................................................469 Disassembly of Blade and Positioning Pilot Valves....................................475 Assembly of Blade and Positioning Pilot Valves.......................................478 Group 12 Solenoid Valve..................................................................481 Removal and Installation of Pilot Shut-Off Solenoid Valve............................481 Removal and Installation of 4-Spool Solenoid Valve Unit..............................485 Removal and Installation of 2-Spool Solenoid Valve Unit..............................495 Removal and Installation of Maximum Pump 1 Flow Rate Limit Control Solenoid Valve....499 Disassembly of Pilot Shut-Off Solenoid Valve.........................................509 Assembly of Pilot Shut-Off Solenoid Valve............................................511 Structure of 4-Spool Solenoid Valve Unit.............................................513 Structure of 2-Spool Solenoid Valve Unit.............................................515 Structure of Maximum Pump 1 Flow Rate Limit Control Solenoid Valve...................517 Group 13 Signal Control Valve............................................................519 Removal and Installation of Signal Control Valve.....................................519 Structure of Signal Control Valve....................................................525 Group 14 Aftertreatment Device...........................................................529 Removal and Installation of Aftertreatment Device....................................529 Group 15 DEF Tank........................................................................559 Removal and Installation of DEF Tank.................................................559 Group 16 Coolant Control Valve...........................................................581 Removal and Installation of Coolant Control Valve....................................581 Group 17 DEF Supply Module...............................................................585 Removal and Installation of DEF Supply Module........................................585 SECTION 4 UNDERCARRIAGE......................................................................593 Group 1 Swing Bearing....................................................................595 Removal and Installation of Swing Bearing............................................595 Disassembly of Swing Bearing.........................................................601 Assembly of Swing Bearing............................................................604 Group 2 Travel Device....................................................................607 Removal and Installation of Travel Device............................................607 Disassembly of Travel Device.........................................................611 Assembly of Travel Device............................................................615 Disassembly of Travel Motor..........................................................621 Assembly of Travel Motor.............................................................625 Disassembly of Brake Valve...........................................................631 Assembly of Brake Valve..............................................................633 Precautions for Using Floating Seal..................................................635 Group 3 Center Joint.....................................................................637 Removal and Installation of Center Joint (Without Blade).............................637 Removal and Installation of Center Joint (With Blade)................................645 Disassembly of Center Joint (without Blade)..........................................653 Assembly of Center Joint (without Blade).............................................655 Replacement of Body and Spindle......................................................658 Disassembly of Center Joint (with Blade).............................................659 Assembly of Center Joint (with Blade)................................................661 Replacement of Body and Spindle......................................................664 Group 4 Track Adjuster...................................................................665 Removal and Installation of Track Adjuster...........................................665 Disassembly of Track Adjuster........................................................667 Assembly of Track Adjuster...........................................................672 Precautions for Using Floating Seal..................................................675 Group 5 Front Idler......................................................................677 Removal and Installation of Front Idler..............................................677 Disassembly of Front Idler...........................................................679 Assembly of Front Idler..............................................................682 Precautions for Using Floating Seal..................................................685 Group 6 Upper and Lower Rollers..........................................................687 Removal and Installation of Upper Roller.............................................687 Removal and Installation of Lower Roller.............................................693 Disassembly of Lower Roller..........................................................699 Assembly of Lower Roller.............................................................701 Precautions for Using Floating Seal..................................................703 Group 7 Track............................................................................705 Removal and Installation of Track....................................................705 Group 8 Blade Cylinder...................................................................713 Removal and Installation of Blade Cylinder...........................................713 Disassembly of Blade Cylinder........................................................717 Assembly of Blade Cylinder...........................................................720 SECTION 5 FRONT ATTACHMENT...................................................................725 Group 1 Front Attachment.................................................................727 Removal and Installation of Front Attachment.........................................727 Group 2 Cylinder.........................................................................735 Removal and Installation of Boom Cylinder............................................735 Removal and Installation of Arm Cylinder.............................................743 Removal and Installation of Bucket Cylinder..........................................751 Removal and Installation of Positioning Cylinder.....................................755 Disassembly of Boom, Arm and Bucket Cylinders........................................761 Assembly of Boom, Arm and Bucket Cylinders...........................................767 Disassembly of Positioning Cylinder..................................................773 Assembly of Positioning Cylinder.....................................................778 Group 3 Hose Rupture Valve...............................................................785 Removal and Installation of Hose Rupture Valve for Boom Cylinder.....................785 Removal and Installation of Hose Rupture Valve for Arm Cylinder......................789 Removal and Installation of Hose Rupture Valve for Positioning Cylinder..............793 Structure of Hose Rupture Valve for Boom Cylinder (Right)............................797 Structure of Hose Rupture Valve for Boom Cylinder (Left).............................799 Structure of Hose Rupture Valve for Arm Cylinder.....................................801 Structure of Hose Rupture Valve for Positioning Cylinder.............................803 SERVICE MANUAL REVISION REQUEST FORM.........................................................807
Description:
Hitachi ZX135US 6 Hydraulic Excavator workshop Manual
INTRODUCTION:
TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• 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 materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for 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.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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