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TROUBLESHOOTING

11-3

Control Lever

Problem Cause Solution

Lever is heavy to operate. Rusted joint * Lubricate or repair

Worn pusher * Replace

Does not move smoothly. Worn pusher * Repair or replace

Faulty pilot valve * Replace

Does Not Return to Neutral. Faulty pilot valve * Replace

The lever is tilted in the neutral position

due to increase in play.

Worn joint * Repair or replace

Faulty pilot valve * Replace

Items with * mark: Consult your authorized dealer.

Table of Contents5
Machine Numbers12
Safety17
Recognize Safety Information17
Understand Signal Words17
Follow Safety Instructions18
Prepare for Emergencies19
Wear Protective Clothing19
Protect against Noise20
Inspect Machine20
General Precautions for the Cab21
Use Handholds and Steps22
Adjust the Operator's Seat22
Ensure Safety before Rising from or Leaving Operator's Seat23
Fasten Your Seat Belt23
Move and Operate Machine Safely24
Operate Only from Operator's Seat24
Jump Starting25
Keep Riders off Machine25
Precautions for Operations26
Investigate Job Site Beforehand27
Install OPG Guard28
Restriction of Attachment Installation28
Provide Signals for Jobs Involving Multiple Machines29
Confirm Direction of Machine to be Driven29
Drive Machine Safely30
Avoid Injury from Rollaway Accidents32
Avoid Injury from Back-Over and Swing Accidents33
Keep People Clear from Working Area34
Never Position the Bucket over Anyone34
Avoid Undercutting35
Avoid Tipping35
Never Undercut a High Bank36
Dig with Caution36
Operate with Caution36
Avoid Power Lines37
Precautions for Lightning37
Object Handling38
Protect against Flying Debris and Falling Object39
Park Machine Safely40
Handle Fluids Safely−Avoid Fires40
Transport Safely41
Practice Safe Maintenance42
Warn Others of Service Work43
Support Machine Properly43
Stay Clear of Moving Parts44
Prevent Parts from Flying44
Avoid Injury from Attachment Falling Accident45
Prevent Burns45
Replace Rubber Hoses Periodically46
Avoid High-Pressure Fluids46
Prevent Fires47
Evacuating in Case of Fire49
Beware of Exhaust Fumes49
Precautions for Welding and Grinding50
Avoid Heating Near Pressurized Fluid Lines51
Avoid Applying Heat to Lines Containing Flammable Fluids51
Precautions for Handling Accumulator and Gas Damper51
Remove Paint before Welding or Heating52
Beware of Asbestos and Silica Dust and Other Contamination52
Prevent Battery Explosions53
Service Air Conditioning System Safely53
Handle Chemical Products Safely54
Dispose of Waste Properly54
Never Ride Attachment55
Notes on Aftertreatment Device55
Precautions for Communication Terminal56
Precautions for Communication Terminal Equipment56
Notes on Protection of Operator's Station When the Machine Rolls over58
Visibility Map59
Safety Signs65
Name of Components75
Getting on and off the Machine76
Operator's Station77
About Aftertreatment Device77
Cab Features80
Multi Function Monitor82
Default Setting83
Basic Screen85
How to Use Screens85
Displaying Basic Screen85
Hour Meter88
Clock88
Fuel Gauge88
Def/Adblue® Gauge89
Def/Adblue® Level Alarm89
Coolant Temperature Gauge90
Operating Status Icon Display90
Security Functions (Optional)91
Input Password91
Extending Password Duration Time92
Alarm Occurrence Screen93
Remedy95
Urea SCR System Remedy98
Aftertreatment Device100
Aftertreatment Device Condition Display100
Aftertreatment Device Manual Regeneration Request101
Manual Regeneration Procedure102
Main Menu103
Engine Output Restriction Suspend104
Urea SCR System Troubleshooting106
Air Conditioner108
Circulation Air Mode108
Air Conditioner ON/OFF108
Radio109
Work Mode110
Attachment Selection110
Mail (Optional)111
Setting Menu113
Date and Time114
Time Adjustment114
Date Adjustment116
Display Mode Setting118
Attachment Adjustment120
Flow Rate Adjustment120
Priority (Arm Roll-Out)122
Priority (Arm Roll-In) (Except ZX135US-6)124
Attachment Name Input126
Auto Shut-Down128
Auto Shut-Down: ON/OFF128
Auto Shut-Down: Setting Time129
Aftertreatment Device Regeneration Inhibited130
Setting Procedure130
Password Change (Optional)132
Sub Meter136
Push Selector Knob (2) While Displaying Basic Screen136
To Display Main Menu Screen (3)136
Brightness Adjustment138
Mdc1-01-001138
MDCD-01-026138
Language Settings140
Lists of Display Language142
Unit Selection143
Rotate Selector Knob (2) to Highlight Setting Menu143
Display Item Selection (Rear View Camera OFF)145
Main Menu Sequence Change147
Information Menu149
Operation150
Fuel Consumption150
Breaker Operation152
Attachment Operation154
Travel Operation156
Actual Operation158
Maintenance160
Remaining Time and Maintenance Interval162
Monitoring164
Switch Panel166
Return to Previous Screen Switch (Monitor)167
Return to Basic Screen Switch (Monitor)167
Selector Knob (Monitor)167
Temperature Control Switch/Mode Switch (Air Conditioner)167
AUTO/OFF Switch/Fan Switch (Air Conditioner)167
AM/FM Selector/Tuning Switch (Radio)168
Power Switch/Volume Control Knob (Radio)168
Engine Control Dial168
Auto-Idle Switch169
Travel Mode Switch169
Power Mode Switch170
Work Light Switch170
Wiper/Washer Switch171
USB Power Supply Port172
Numeric Keypad173
Switch Panel (for Optional Equipments)174
Travel Alarm Deactivation Switch (Optional)175
Rear Light Switch175
Perimeter Lights Switch (Optional)175
Seat Heater Switch (Optional)176
Electrical Control Main Switch177
Key Switch178
Power Boost Switch178
Horn Switch178
Electrical Control Main Switch179
AUX Function Lever 1180
Cigar Lighter181
Using Cigar Lighter181
Cab Light Switch182
Pilot Control Shut-Off Lever183
Control Lever Auto-Lock184
Engine Stop Switch185
Fuse Box186
Auto Air Conditioner187
Features187
Name of Components188
Controller Part Name and Function189
Cab Heater Operation191
Cooling Operation192
Defroster Operation193
Cool Head/Warm Feet Operation193
Tips for Optimal Air Conditioner Usage194
For Rapid Cooling194
When Windows Become Misty194
Off-Season Air Conditioner Maintenance194
AM/FM Radio Operation195
Controls on the Radio195
Tuning Procedure195
Station Presetting Procedure196
Station Auto-Presetting Procedure197
TONE Control198
Audio Input199
Aerial Angle Monitor200
Switching the Screen Display202
Description of Images203
Cab Door Release Lever207
Opening/Closing and Removing Cab Inside Window208
Opening Upper Front Window209
Removing and Storing Lower Front Window210
Opening Side Window211
Opening and Closing the Roll Screen (for Front and Right Windows) (Optional)212
How to Use on the Front Window212
How to Store on Right Window Side214
How to Use on Right Window Side214
How to Clean the Screen214
Opening/Closing Overhead Window (Clear Hatch)215
Emergency Exit216
Opening and Closing the OPG Front Guard (Optional)217
Adjusting Operator's Seat218
Seat Height and Angle Adjustment218
Console and Seat Fore-Aft Adjustment218
Seat Fore-Aft Adjustment218
Suspension Adjustment218
Backrest Adjustment219
Armrest Adjustment219
Adjusting Operator's Seat (Optional)220
Adjusting Seat Height220
Console and Seat Fore-Aft Adjustment220
Seat Fore-Aft Adjustment220
Suspension Adjustment221
Fore-Aft Position Adjustment of Seat Surface221
Angle Adjustment of Seat Surface221
Backrest Adjustment221
Armrest Adjustment221
Console Height Adjustment222
Adjusting Procedures222
Installation and Adjustment of Mirrors223
Mirror Installation Diagram224
Seat Belt231
Battery Disconnect Switch232
Switch Operation234
Break-In235
Observe Engine Operation Closely235
Every 8 Hours or Daily235
After the First 50 Hours235
After the First 100 Hours235
Operating the Engine237
Inspect Machine Daily before Starting237
Before Starting Engine239
Starting the Engine240
Check Instruments after Starting246
Using Booster Batteries247
Stopping the Engine249
Engine Auto-Stop in Extremely Low Temperature250
Driving the Machine251
Travel Levers and Pedals251
Travel Mode Switch253
Travel Alarm (Optional)253
Operating on Soft Ground254
Raising the Machine with Boom and Arm254
Retrieval255
Operating in Water or Mud256
Parking the Machine on Slopes257
Parking the Machine257
Prohibition of Sudden Control Operations When Traveling at High Speed258
Prohibition of Traveling for Long Periods258
Operating the Machine259
Control Lever (ISO Pattern)259
Pilot Control Shut-Off Lever260
Warming-Up Operation261
Engine Speed Control262
Auto-Idle263
Auto-Idle Function263
Auto-Idle ON/OFF264
Auto Shut-Down265
Aftertreatment Device Manual Regeneration268
Work Mode270
Power Boost Switch273
Power Mode274
Operating Backhoe275
Shovel276
Grading Operation277
Do Not Strike the Ground with Bucket Teeth278
Avoid Hammer Work278
Avoid Abusive Operation279
Never Move an Object Sideways with the Bucket279
Retracting the Arm and Bucket280
Do Not Use Wide Track Shoes on Rough Ground280
Shackle Hole Usage281
Pilot Accumulator Functions (Optional)282
How to Lower Boom in Case of Emergency and When Engine Stops283
Precautions for after Operations284
Transporting285
Transporting by Road285
Loading/Unloading on a Trailer286
Fastening Machine for Transporting289
Unloading290
Lifting Machine291
Maintenance293
Correct Maintenance and Inspection Procedures293
Layout295
Check the Hour Meter Regularly297
Maintenance Guide Table298
Preparations for Inspection and Maintenance302
Hood and Access Covers303
Maintenance Guide306
Periodic Replacement of Parts312
Kind of Oils313
Brand Names of Recommended Grease313
Recommended Engine Oil313
Brand Names of Recommended Oil314
Brand Names of Recommended Hydraulic Oil314
Recommended Oil Viscosity315
List of Consumable Parts316
Greasing322
Front Joint Pins322
Swing Bearing324
Swing Internal Gear325
Electric Grease Gun (Nickel-Cadmium Battery) (Only ZX345US-6 Class)327
Electric Grease Gun329
Components Name330
Battery Charger Operation331
Charger Lamps331
Electric Grease Gun (Lithium-Ion Battery)336
(Only ZX345US-6 Class)336
Electric Grease Gun338
Components Name339
Battery Charger Operation340
Charger Lamps340
Engine345
Check Engine Oil Level345
Change Engine Oil347
Replace Engine Oil Filter347
Sampling the Engine Oil (Only ZX225USLC-6)350
Check and Clean Around the Engine351
Replace Oil Separator Element (Only ZX135US-6)351
Transmission352
Pump Transmission (Except ZX135US-6)352
Swing Reduction Gear353
Travel Reduction Gear354
Hydraulic System356
Inspection and Maintenance of Hydraulic Equipment356
Check Hydraulic Oil Level359
Change Hydraulic Oil360
Sampling the Engine Oil361
Bleed Air from the Hydraulic System362
Suction Filter Cleaning363
Replace Full-Flow Filter364
Replace Pilot Oil Filter365
Replace Air Breather Element366
Check Hoses and Lines367
Fuel System371
Recommended Fuel371
Drain Fuel Tank Sump373
Drain Fuel Pre-Filter374
Replace Fuel Main Filter Element377
Replace Fuel Pre-Filter Element379
Check Fuel Hoses381
Air Cleaner382
Clean and Replace Air Cleaner Element (Outer)382
Replace Air Cleaner Element (Inner)384
Cooling System385
Check Coolant Level386
Check and Adjust Fan Belt Tension388
Change Coolant390
Clean Radiator/Oil Cooler/Inter Cooler Core392
Clean Oil Cooler, Radiator and Inter Cooler Front Screen394
Clean Air Conditioner Condenser394
Clean Fuel Oil Cooler394
Drain Intercooler (Only ZX135US-6)395
Electrical System396
Battery397
Replace Battery400
Check Electrolyte Specific Gravity401
Replacing Fuses402
Fuse Box403
Miscellaneous405
Check and Replace Bucket Teeth405
Change Bucket407
Convert Bucket Connection into Face Shovel408
Adjust Bucket Linkage409
Remove Travel Levers410
Check and Replace Seat Belt410
Check Windshield Washer Fluid Level411
Check Track Sag412
Clean and Replace Air Conditioner Filter417
Check Air Conditioner420
Clean Cab Floor422
Retighten Cylinder Head Bolt423
Inspect and Adjust Valve Clearance423
Measure Engine Compression Pressure423
Check Starter and Alternator423
Check and Replace EGR Device423
EGR Cooler Cleaning423
Check Turbo Charger423
Check and Clean Injector424
Check Gas Damper424
Tightening and Retightening Torque of Nuts and Bolts424
Aftertreatment Device453
Check and Clean Aftertreatment Device453
Urea SCR System454
Check Def/Adblue456
Refill Def/Adblue456
Clean Filler Port Strainer459
Change Def/Adblue460
Replace Def/Adblue® Supply Module Main Filter461
Replace Def/Adblue® Tank Water Supply Inlet Filter463
Replace the Def/Adblue® Back Flow Line Filter464
Aerial Angle465
Daily Checks of Aerial Angle Camera Images465
Checking Aerial Angle Camera Images466
Maintenance under Special Environmental Conditions467
Storage469
Bucket Types and Applications482
Specifications482
Working Ranges (Grouser Shoe)484
Shoe Types and Applications485
Bucket Types and Applications486
Specifications486
Working Ranges488
Shoe Types and Applications489
Bucket Types and Applications490
Optional Attachments and Devices491
Using Pad Crawler Shoe491
Traveling and Other Cautions492
Transporting493
Precautions for Transporting Machines with Pad Crawler Shoes493
Long Arm Operation498
Blade Lever499
Avoid Hitting Blade with Front-End Attachment500
Blade Maintenance501
Specifications502
ZX135US-6 with Blade502
Working Ranges503
ZX135US-6 with Blade503
Shoe Types and Applications504
ZX135US-6 with Blade504
Specifications505
ZX225USLC-6 with Blade505
Working Ranges (Grouser Shoe)506
ZX225USLC-6 with Blade506
Shoe Types and Applications507
ZX225USLC-6 with Blade507
Bucket Teeth (Transverse-Type-Pin-Used Type)508
Control Lever (4 Way Multi Valve) (Optional)509
Hydraulic Breaker, Hydraulic Crusher and Quick Coupler510
Piping for Breaker and Crusher511
Operational Procedures for Stop Valves and Selector Valve511
Secondary Relief Pressure Adjustment512
Precautions for Breaker Operation513
Change Hydraulic Oil and Replace Full-Flow Filter Element517
Precautions for Crusher Operation518
Attachment521
Allowable Weight Limits of Installed Attachment521
Attachment Connection Parts523
Precautions for Arm Roll-In/Bucket Roll-In Combined Operation525
Index528

Brand	Hitachi
Model	ZAXIS 135US-6 class
Category	Excavators
Language	English

Hitachi ZAXIS 135US-6 class User Manual

Table of Contents

Questions and Answers:

Hitachi ZAXIS 135US-6 class Specifications

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