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Hitachi Construction Machinery Co., Ltd.
URL:http://www.hitachi-c-m.com
This book is printed on recycled paper.
PRINTED IN JAPAN (K) 2013, 09
PART NO.
EM1U4-2-6
Operator's Manual
135US
135US-
• 135USK-
3
3
225US
225US-
• 225USLC-
3
3
225USR
225USR-
• 225USRLC-
3
Hydraulic Excavator
Serial No.
ZX135US
class
080003 and up
-3
ZX225US
class
200001 and up
-3
ZX225USR
class
200001 and up
-3
-3 class
• 135USL-
3
-3 class
-3 class
• 225USRK-
• 225USRLCK-
3
3
3
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Table of Contents
Related Manuals for Hitachi ZX225USR-3
Summarization of Contents
SAFETY
RECOGNIZE SAFETY INFORMATION
Understand safety alert symbols and follow recommended precautions for personal injury prevention.
UNDERSTAND SIGNAL WORDS
Learn the meaning of DANGER, WARNING, CAUTION, IMPORTANT, and NOTE signal words used on machine safety signs.
FOLLOW SAFETY INSTRUCTIONS
Read and follow all safety signs and messages; keep signs clean and maintained; order replacements if damaged.
PREPARE FOR EMERGENCIES
Keep first aid kit and fire extinguisher on hand; establish emergency procedures for fires and accidents.
WEAR PROTECTIVE CLOTHING
Wear appropriate safety equipment like hard hats, safety shoes, glasses, gloves, and hearing protection.
PROTECT AGAINST NOISE
Use hearing protection like earmuffs or earplugs to prevent hearing impairment from prolonged exposure to loud noise.
INSPECT MACHINE
Perform a walk-around inspection daily or shift-wise to identify potential issues and avoid personal injury.
GENERAL PRECAUTIONS FOR CAB
Keep the cab clean, avoid flammable objects, do not use phones/headphones while operating, and use proper floor mats.
USE HANDHOLDS AND STEPS
Maintain a three-point contact when entering/exiting; never jump on/off or mount/dismount a moving machine.
ADJUST THE OPERATOR'S SEAT
Adjust seat for operator comfort and correct control operation to prevent fatigue and misoperations.
ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT
Lower attachment, lock pilot control shut-off lever before exiting; stop engine and close all openings before leaving.
FASTEN YOUR SEAT BELT
Always fasten the seat belt securely when operating the machine to minimize injury from accidents.
MOVE AND OPERATE MACHINE SAFELY
Be aware of bystanders, keep travel alarm/horn functional, use signal persons in congested areas, and ensure proper illumination.
HANDLE STARTING AIDS SAFELY
Keep sparks and flames away from starting fluid; store containers properly and do not incinerate or puncture them.
OPERATE ONLY FROM OPERATOR'S SEAT
Start the engine only when seated in the operator's seat; never start by shorting terminals or while standing on ground.
JUMP STARTING
Follow instructions carefully; operator must be in seat; never use a frozen battery; avoid battery explosion.
KEEP RIDERS OFF MACHINE
Only the operator should be on the machine; riders are subject to injury and obstruct operator's view.
PRECAUTIONS FOR OPERATIONS
Investigate worksite, wear appropriate clothing, clear personnel/obstacles, be aware of surroundings, and avoid hitting upperstructure.
INVESTIGATE JOB SITE BEFOREHAND
Check ground conditions and configuration to prevent tipping, falling, or collapsing; make a work plan and reinforce ground.
EQUIPMENT OF HEAD GUARD, ROPS, FOPS
Equip head guard, ROPS, or FOPS in areas with potential falling stones or debris.
PROVIDE SIGNALS FOR JOBS INVOLVING MUL- TIPLE MACHINES
Use commonly known signals, appoint a signal person, and ensure all personnel obey directions for coordinated work.
CONFIRM DIRECTION OF MACHINE TO BE DRIVEN
Confirm undercarriage position relative to operator; incorrect pedal/lever operation can lead to serious injury or death.
DRIVE MACHINE SAFELY
Confirm travel lever direction, detour obstructions, avoid traveling over obstructions, be cautious on slopes, and fasten seat belt.
AVOID INJURY FROM ROLLAWAY ACCIDENTS
Do not mount or stop a moving machine; park on level ground, lower tools, and secure the machine to prevent rolling.
AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS
Always look around before backing/swinging; be sure bystanders are clear; use signal person if view is obstructed.
KEEP PERSON CLEAR FROM WORKING AREA
Keep all persons clear from operation and movement areas; set up barriers to prevent entry into work area.
NEVER POSITION BUCKET OVER ANYONE
Never lift, move, or swing bucket over anyone or a truck cab to avoid injury or damage.
AVOID UNDERCUTTING
When retreating from excavation edge, position undercarriage perpendicular to edge with travel motors rearward.
AVOID TIPPING
Do not jump clear of tipping machine; operate on grade with extreme care, prepare area flat, keep bucket low.
NEVER UNDERCUT A HIGH BANK
Edges may collapse or landslide occur, causing serious injury or death; confirm area stability before working.
DIG WITH CAUTION
Check for underground cables/gas lines before digging; maintain legal distance; contact utility companies to mark underground utilities.
OPERATE WITH CAUTION
Avoid hitting overhead obstacles like bridges with the boom or arm to prevent damage and injury.
AVOID POWER LINES
Maintain safe distance from electric lines; never move machine or load closer than 3m plus twice line insulator length.
PRECAUTIONS FOR LIGHTNING
In electrical storms, stop operation, lower bucket, evacuate to safe place; check safety devices after storm.
OBJECT HANDLING
Comply with local regulations; do not use damaged chains/ropes; keep persons away from load; secure load properly.
PROTECT AGAINST FLYING DEBRIS
Wear goggles or safety glasses to protect eyes from flying debris; keep bystanders away from working area.
PARK MACHINE SAFELY
Park on firm, level surface; lower bucket; turn off auto-idle/power mode; run engine for 5 min; stop engine; lock controls.
HANDLE FLUIDS SAFELY−AVOID FIRES
Handle fuel with care; it's flammable. Do not refuel while smoking or near flames; fill tank outdoors.
TRANSPORT SAFELY
Take care machine does not turn over when loading/unloading; observe regulations; select appropriate trailer; use signal person.
PRACTICE SAFE MAINTENANCE
Understand procedures, keep area clean/dry, avoid water inside cab, keep away from power-driven parts.
WARN OTHERS OF SERVICE WORK
Attach a 'Do Not Operate' tag to control lever before performing service work to prevent unexpected movement.
SUPPORT MACHINE PROPERLY
Never work without securing machine; support lifted machine/attachment securely; do not use jacks alone.
STAY CLEAR OF MOVING PARTS
Prevent entanglement of hands, feet, clothing, jewelry, or hair in rotating parts to avoid serious injury.
PREVENT PARTS FROM FLYING
Grease in track adjuster is under high pressure; keep body/face away from valve; do not disassemble adjuster.
STORE ATTACHMENTS SAFELY
Secure attachments to prevent falling; keep children and bystanders away from storage areas.
PREVENT BURNS
Engine coolant and hot fluids are pressurized; allow components to cool before maintenance; do not remove radiator cap when hot.
REPLACE RUBBER HOSES PERIODICALLY
Periodically replace hoses to prevent fire, fluid injection, or attachment failure due to aging or fatigue.
AVOID HIGH-PRESSURE FLUIDS
High-pressure fluids can penetrate skin, causing serious injury or death; relieve pressure before disconnecting lines.
PREVENT FIRES
Check for oil leaks; clean electrical connections; ensure cables are secure; keep flammable materials away from flames.
EVACUATING IN CASE OF FIRE
Stop engine if time permits; use extinguisher; exit machine; break window if necessary for escape.
BEWARE OF EXHAUST FUMES
Prevent asphyxiation; ensure adequate ventilation when operating in buildings; use exhaust pipe extension.
PRECAUTIONS FOR WELDING AND GRINDING
Perform welding/grinding in ventilated area; store flammable objects safely; only qualified personnel should perform.
AVOID HEATING NEAR PRESSURIZED FLUID LINES
Do not heat near pressurized fluid lines or flammable materials; install temporary fire-resistant guards.
AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS
Do not weld or flame cut pipes containing flammable fluids; clean thoroughly with nonflammable solvent first.
REMOVE PAINT BEFORE WELDING OR HEATING
Avoid toxic fumes from heated paint; work outside or in ventilated area; dispose of paint/solvent properly.
BEWARE OF ASBESTOS DUST
Avoid inhaling asbestos dust; spray water to prevent airborne fibers; wear a mask rated for asbestos inhalation.
PREVENT BATTERY EXPLOSIONS
Keep sparks/flames away from batteries; do not charge frozen batteries; check electrolyte level regularly.
SERVICE AIR CONDITIONING SYSTEM SAFELY
Handle refrigerant carefully; use recovery system to avoid leaks; never touch refrigerant; follow container instructions.
HANDLE CHEMICAL PRODUCTS SAFELY
Check MSDS for hazards and safety procedures; follow procedures and use recommended equipment for chemicals.
DISPOSE OF WASTE PROPERLY
Dispose of waste properly to protect environment; use leakproof containers for fluids; inquire about recycling options.
PRECAUTION FOR COMMUNICATION TERMINAL EQUIPMENT
Be aware of potential effects on medical devices; maintain distance or consult dealer to disable equipment.
NOTES ON PROTECTION OF OPERATOR’S STATION WHEN THE MACHINE ROLLS OVER (OPTIONAL)
ROPS cab protects operator; ensure machine mass does not exceed certification limits; always fasten seat belt.
OPERATOR'S STATION
CAB FEATURES
Identifies and describes the various controls and features within the operator's cab for different models.
MULTI FUNCTION MONITOR
Provides an overview and instructions on using the multi-function monitor for various machine operations.
OUTLINE
Details the layout and function of various displays and indicators on the multi-function monitor.
Hour Meter
Displays accumulated machine operation hours, essential for tracking maintenance intervals.
Fuel Gauge
Indicates the fuel level in the tank; refuel before the needle reaches 'E'.
Clock
Displays the current time, which can be set by the operator.
Back Monitor Selector
Allows switching the display between the front view and rear view monitor screens.
Menu Key
Used to shift from the basic screen to the main menu screen for accessing various functions.
Optional Function Key
Allows selection of preset optional functions like Work Mode, Auxiliary, and Mail.
Return to Basic Screen Key
Allows exiting from any screen and returning to the basic display.
Alarm Light
Indicates when an abnormality occurs; comes ON when any abnormality occurs.
Optional Function Display
Displays the functions preset by the optional function keys on the monitor.
Coolant Temperature Gauge
Indicates the engine coolant temperature; normally centered during operation.
Operating Status Icon Display
Displays icons indicating status of attachment, auto-idle system, and preheat display when activated.
Displaying Basic Screen by Password Input (Optional)
Procedure for activating TEN-key function and entering password to access the basic screen.
In Case of Inputting an Incorrect Password
Details the process when an incorrect password is entered, including error messages and returning to input screen.
Extending Password Duration Time
Allows setting password duration time to avoid repeated input within a timeframe.
ALARM OCCURRENCE SCREEN
Displays alarm marks on the basic screen when abnormalities occur.
CONTENTS OF ALARMS
Lists various alarms, their causes, and recommended remedies for quick troubleshooting.
CLOCK SETTING
Procedure to set the machine's internal clock, including time adjustment and saving the setting.
ATTACHMENT SELECTION
Guide on selecting attachments from the work mode screen to optimize hydraulic circuit and pump flow rate.
Selecting an Attachment from Main Menu
Step-by-step instructions to select an attachment from the main menu via the work mode screen.
Attachment Specification Screen
Displays specifications for various attachments like Breaker, Pulverizer, and Crusher.
PUMP 2 FLOW RATE ADJUSTMENT (Only Machines Equipped with Optional Parts)
Procedure to adjust pump 2 flow rate for attachments like breakers, pulverizers, and crushers.
DISPLAYING OPERATING CONDITIONS
Instructions to view total fuel consumption and fuel consumption rate based on operating environment.
FUEL RATE DISPLAY/NO DISPLAY
Guide on how to enable or disable the fuel rate display on the basic screen.
FUEL RATE NO DISPLAY
Instructions on how to disable the fuel rate display on the basic screen.
Overload Alarm (Only machines equipped with optional parts)
Explains how the overload alarm system works and advises consulting the dealer for usage.
Password Change (Optional)
Procedure for changing the existing password for machine access.
BACK MONITOR SETTINGS
Instructions on setting up the back monitor auto-control function for traveling or stationary views.
MAINTENANCE SETTINGS
Guide on setting maintenance intervals and display options for various machine components.
Change Interval Settings
Procedure for changing maintenance intervals, requiring maintenance information display to be ON.
Resetting Data
Instructions on resetting maintenance data, which updates remaining hours and previous date/time.
Screen Display when Maintenance Information Display is ON
Explains how scheduled maintenance screens appear when intervals have expired, with or without password.
Mail (Optional)
Details the machine's mail function, sending information to ICF and confirming delivery status.
LANGUAGE SETTINGS
Procedure to select the display language for the monitor unit from available options.
Lists of Display Language
Provides a comprehensive list of available display languages for the monitor unit.
SWITCH PANEL
Identifies and describes the functions of various switches on the operator's panel.
ENGINE CONTROL DIAL
Explains how to use the engine control dial to adjust engine speed clockwise or counterclockwise.
AUTO-IDLE SWITCH
Sets engine speed control to Auto-Idle mode to save fuel; auto-idle indicator shows status.
POWER MODE SWITCH
Selects engine speed modes (E, P, H/P) for economy, normal work, or high power requirements.
TRAVEL MODE SWITCH
Selects travel modes (FAST/SLOW) by turning the switch to the desired position.
WORK LIGHT SWITCH
Controls work lights on the machine and instrument panel illumination.
WIPER/WASHER SWITCH
Operates the wiper and window washer; includes settings for OFF, INT (slow, mid, fast), and ON positions.
Washer (K Model) (Overhead Window)
Details operation of the overhead window washer and wiper for K Model, including important warnings.
Wiper Switch (2) (K Model) (Overhead Window)
Describes the ON and OFF positions for the overhead window wiper on K Model machines.
SWITCH PANEL (Optional)
Location and use of optional switches like Travel Alarm Deactivation, Swing Alarm, and Rear Light.
Electrical Control Main Switch (Optional)
Enables or disables the electrical control (grip switch) system; press specific marks to activate/deactivate.
KEY SWITCH
Controls machine power: OFF (engine off), ACC (radio), ON (engine on), START (engine start).
HORN SWITCH
Activates the horn; sounds continuously as long as the switch is pressed.
CIGAR LIGHTER
Operation of the cigar lighter and its use as an external power source for 24V accessories.
CAB LIGHT
Allows turning the cab light ON or OFF using a switch.
INSTALLING FIRE EXTINGUISHER (Optional)
Information on installing a fire extinguisher inside the cab; consult dealer for installation.
PILOT CONTROL SHUT-OFF LEVER
Functions to prevent machine misoperation; must be pulled to LOCK position for safety.
ENGINE STOP SWITCH
Emergency switch to stop the engine if the key switch fails; move downward to stop and return upward.
FUSE BOX
Location and identification of fuses behind the operator's seat for electrical equipment protection.
AUTO AIR CONDITIONER
Describes automatic temperature control features, max cooling/heating, and preheating function.
COOLING OPERATION
Instructions for operating the air conditioner in cooling mode, including AUTO, temperature, and mode controls.
DEFROSTER OPERATION
Procedure for operating the defroster function, including setting temperature and selecting vents.
Cool Head / Warm Feet Operation
Explains how cool and warm air are simultaneously supplied to head and feet vents.
TIPS FOR OPTIMAL AIR CONDITIONER USAGE
Provides advice for rapid cooling, clearing clouded windows, and off-season maintenance of the air conditioner.
CAB HEATER (Optional)
Details the parts and functions of the optional cab heater system, including controls and operation.
DEFROSTER OPERATION
Instructions for operating the defroster, including mode switch, temperature, and blower controls.
AM/FM RADIO OPERATION
Describes radio controls, tuning procedures (manual and automatic search), and station presetting.
Digital Clock Setting Procedure
Step-by-step guide to set the digital clock, including time display mode and adjustment.
Sound Adjustment
Explains how to adjust sound settings (Balance, Treble, Bass) using the sound control switch.
CAB DOOR RELEASE LEVER
Operation of the cab door release lever; includes cautions for opening/closing and finger safety.
OPENING UPPER FRONT WINDOW
Procedure for safely opening the upper front cab window, including lock release and securing.
CLOSING UPPER FRONT WINDOW
Procedure for safely closing the upper front cab window, with cautions about forceful closure.
REMOVING AND STORING LOWER FRONT WINDOW
Instructions for removing and storing the lower front window, with caution for finger pinching.
OPENING SIDE WINDOWS
How to open the cab door window by sliding the rear pane to the front.
OPENING/CLOSING OVERHEAD WINDOW (Std. Model, L Model, K Model)
Procedure for opening and closing the overhead window, noting its use as an emergency exit.
OPENING/CLOSING OVERHEAD WINDOW (Clear Hatch: If Equipped)
Procedure for opening/closing the clear hatch overhead window and its emergency exit function.
EMERGENCY EXIT
Methods for escaping the cab in an emergency, including using doors, windows, or overhead exit.
ADJUSTING THE SEAT
Instructions for adjusting seat height, angle, fore-aft position, and backrest for operator comfort.
Armrest Adjustment
How to adjust the armrest angle by turning the adjusting dial located on the bottom of the armrest.
ADJUSTING THE SEAT (Optional)
Guide for optional seat adjustments including height, fore-aft, suspension stiffness, and backrest.
Armrest Adjustment
Details on pulling the armrest upright for entry/exit and adjusting its angle.
ADJUSTING CONSOLE HEIGHT
Procedure to adjust console height for operator comfort and work conditions using four vertical positions.
SEAT BELT
Instructions on using, checking, and replacing the seat belt, buckle, and hardware for proper performance.
BREAK-IN
OBSERVE ENGINE OPERATION CLOSELY
Be cautious during the first 50 hours; operate in economy mode, limit horsepower, avoid idling, and check gauges.
EVERY 8 HOURS OR DAILY
Perform daily service, watch for fluid leaks, and lubricate working tool pivots every 8 hours.
AFTER THE FIRST 50 HOURS
Perform 50-hour service and check accessible hardware torque.
AFTER THE FIRST 100 HOURS
Perform both 50-hour and 100-hour service as per the maintenance guide.
OPERATING THE ENGINE
INSPECT MACHINE DAILY BEFORE STARTING
Check electrical system, boom/bucket/metal parts, hardware, fuel system, hydraulic system, lubrication, and protective devices.
BEFORE STARTING ENGINE
Confirm pilot control shut-off lever is LOCK, control levers are neutral, adjust seat, and fasten seat belt.
STARTING THE ENGINE IN ORDINARY TEMPERA TURE
Procedure for starting engine in normal temperatures: lock lever, set idle, sound horn, turn key ON, input password if required.
STARTING IN COLD WEATHER
Preheating procedure for cold weather: lock lever, set idle position, sound horn, turn key ON, input password if needed.
CHECK INSTRUMENTS AFTER STARTING
Verify alternator indicator, engine oil pressure indicator are OFF, and engine noise/exhaust gas are normal.
USING BOOSTER BATTERIES
Procedure for connecting and disconnecting booster batteries to start an exhausted machine's engine.
STOPPING THE ENGINE
Procedure to safely stop the engine: park on level surface, lower bucket, cool engine, turn key OFF, lock controls.
DRIVING THE MACHINE
DRIVE THE MACHINE CAREFULLY
Park on hard surface in freezing weather, clean tracks; steer straight, reduce speed on rough terrain.
STEERING THE MACHINE USING PEDALS
Instructions for forward, reverse, neutral, right turn, left turn, and short turn using travel pedals.
STEERING THE MACHINE USING LEVERS
Instructions for forward, reverse, neutral, right turn, left turn, and short turn using travel levers.
TRAVEL MODE SWITCH
Selects travel mode (Fast/Slow) by turning the switch; stop machine before changing mode.
TRAVEL ALARM (Optional)
Travel alarm sounds buzzer to warn people; can be deactivated using the deactivation switch.
OPERATING ON SOFT GROUND
Avoid very soft ground; swing upperstructure to lift one track, keep boom/arm angle, use slow travel speed.
RAISE ONE TRACK USING BOOM AND ARM
Procedure to lift one track using boom/arm; keep boom/arm angle, position bucket round side down.
TOWING MACHINE A SHORT DISTANCE
Attach wire ropes to track frames; tow slowly to firm ground; do not use shackle holes on track frame for towing.
OPERATING IN WATER OR MUD
Operate in water up to upper edge of upper rollers only if footing is strong; avoid submerging swing bearing/gears.
PARKING THE MACHINE ON SLOPES
Avoid parking on slopes; if unavoidable, thrust bucket teeth into ground, lock controls, and block tracks.
PARKING THE MACHINE
Park on level surface, lower bucket, turn off auto-idle, run engine for 5 min, stop engine, lock controls, close openings.
OPERATING THE MACHINE
CONTROL LEVER (ISO PATTERN)
Illustrates and explains the ISO pattern control lever functions for arm, swing, boom, and bucket movements.
CONTROL LEVER (HITACHI PATTERN)
Illustrates and explains the Hitachi pattern control lever functions for arm, swing, boom, and bucket movements.
CONTROL LEVER (4 Way Multi Valve) (Optional)
Explains the four patterns (Y, H, M, K) selectable via the selector valve for multi-control lever operation.
CONTROL LEVER (2 Way Multi Valve) (Optional)
Explains the two patterns (A, B) selectable via the selector valve for multi-control lever operation.
ATTACHMENT PEDAL (HYDRAULIC BREAKER)
Operation of the attachment pedal for hydraulic breaker; includes cautions and locking procedures.
ATTACHMENT PEDAL (HYDRAULIC CRUSHER)
Operation of the attachment pedal for hydraulic crusher; includes cautions and locking procedures.
PILOT CONTROL SHUT-OFF LEVER
Functions to prevent misoperation; must be pulled to LOCK position when leaving or entering cab.
Warming-up Operation
Procedure for warming up the machine in cold weather until oil temperatures reach appropriate levels.
ENGINE SPEED CONTROL
How to increase or decrease engine speed using the engine control dial, and before stopping the engine.
AUTO-IDLE
How auto-idle reduces engine speed to save fuel; check indicator, be aware of engine speed settings, and turn off when undesirable.
WORK MODE
Selects appropriate hydraulic circuit and pump flow rate for attachments; digging mode is default.
WORK MODE SELECT
Steps to select work modes via the main menu or by pressing the F1 key.
POWER MODE
Selects engine speed modes (E, P, H/P) for efficiency, normal work, or high power demands.
PRECAUTIONS FOR EXCAVATION (K Model)
Specific precautions for K model regarding demolition works, counterweight, bucket cylinder, and link B.
OPERATING BACKHOE
Procedure for backhoe operation: bucket positioning, soil removal, trenching, and avoiding cylinder damage.
GRADING OPERATION
How to perform grading work by positioning arm, raising boom, and maintaining smooth surface with bucket.
FACE SHOVEL OPERATION
Procedure for face shovel operation: dig with arm cylinder scraping motion; make slope for water drainage.
AVOID ABUSIVE OPERATION
Do not use travel as digging force; do not raise rear of machine for digging force to prevent severe damage.
OPERATING TIPS
Do not hit tracks with bucket, position machine on level surface, avoid side loading, do not use bucket as hammer.
SELECT CORRECT TRACK SHOES
Use appropriate track shoes for ground conditions; wide shoes are for soft ground, not rocks or gravel.
HYDRAULIC BREAKER AND HYDRAULIC CRUSHER
Select correct size/weight breaker/crusher; study manuals and perform checks before connecting.
PIPINGS FOR BREAKER AND CRUSHER
Operational procedures for stop valves and selector valve; close valves when not using attachment.
SECONDARY RELIEF PRESSURE ADJUSTMENT
Procedure to install and set secondary relief valve for breakers other than NPK; adjust pressure using screw.
Pressure Measurement
Describes three points to measure pressure: relief valve, arm tip hose, and by Dr.ZX.
PRECAUTIONS FOR BREAKER OPERATION
Breaker reduces machine stability; avoid hitting objects, moving objects with swing function, or fully retracting/extending cylinders.
PRECAUTIONS FOR CRUSHER OPERATION
Prevent tipping and damage; do not support machine weight by cylinder; avoid quick starts/stops; operate parallel to tracks.
ATTACHMENT
Information on allowable weight limits for installed attachments and their effect on machine stability.
ATTACHMENT CONNECTION PARTS
Illustrates hydraulic line connections; install caps/plugs to prevent dust entry when attachment is disconnected.
PRECAUTION FOR ARM ROLL-IN/BUCKET ROLL-IN COMBINED OPERATION
Caution regarding bucket teeth hitting headguard/rainguard during combined arm/bucket roll-in operations.
WHEN INSTALLING AN ATTACHMENT LONGER THAN STANDARD BUCKET
Attachment may contact cab/boom; operate carefully to avoid hitting cab/boom with front attachment tip.
SHACKLE HOLE USAGE
Usage of shackle holes on track frame for towing light objects; adhere to restrictions to prevent damage.
OVERNIGHT STORAGE INSTRUCTIONS
Park on firm, level ground; fill fuel tank; clean machine; drain coolant if necessary; loosen belts; paint to prevent rust.
BUCKET LINK SECURING METHOD (L Model)
Procedure to secure bucket links with link securing parts for suspend-type attachments like logging type.
EMERGENCY BOOM LOWERING PROCEDURE (Without hose-rupture safety valve)
Procedure to lower the boom to the ground if the engine stalls and cannot be restarted.
OBJECT HANDLING --- IF EQUIPPED
Comply with local regulations for object handling; use proper ropes, never move load suddenly or over people.
TRANSPORTING
TRANSPORTING BY ROAD
Understand and follow local regulations for road transport; check trailer dimensions and investigate route conditions.
LOADING/UNLOADING ON A TRAILER
Load/unload on firm, level surface; use ramp/dock; never use front attachment functions on ramp; ensure ramp strength.
Transporting
Fasten chains/cables to machine frame, not hydraulic lines; place blocks; secure attachment with chain/cable.
Unloading
Take care of ramp bump; position arm at 90-110° boom angle; do not hit ground hard with bucket.
MACHINE LIFTING PROCEDURE
Follow correct lifting procedure; use approved ropes/tools; pull pilot control shut-off lever; do not lift quickly.
MAINTENANCE
CORRECT MAINTENANCE AND INSPECTION PROCEDURES
Learn and follow correct procedures; inspect daily; check controls, fluids, hoses, and appearance.
CHECK THE HOUR METER REGULARLY
Use hour meter for service intervals; shorten intervals in adverse conditions; lubricate at intervals shown.
USE CORRECT FUELS AND LUBRICANTS
Always use recommended fuels and lubricants; failure may result in machine damage and void warranty.
LAYOUT
Diagram illustrating the location of major machine components like engine, hydraulic tank, and tracks.
MAINTENANCE GUIDE TABLE
Provides a table with symbol marks and corresponding maintenance items and intervals.
PREPARE MACHINE FOR MAINTENANCE
Park on level surface, lower bucket, turn off auto-idle, run engine for 5 min, stop engine, lock controls, attach tag.
HOOD AND ACCESS COVERS
Cautions for opening/closing hood and covers; keep them closed on slopes or in wind; avoid pinching fingers.
PERIODIC REPLACEMENT OF PARTS
Lists parts requiring periodic inspection and replacement based on usage intervals to ensure safety.
A. GREASING
Details greasing points and intervals for front joint pins, swing bearing, swing internal gear, and engine components.
B. ENGINE
Procedures for checking engine oil level, changing engine oil, and replacing the engine oil filter.
C. TRANSMISSION
Procedures for checking and changing oil for the pump transmission and reduction gears.
D. HYDRAULIC SYSTEM
Inspection and maintenance of hydraulic equipment, including cooling down, bleeding air, and hose/pipe connections.
BREAKER MAINTENANCE
Guidelines for changing hydraulic oil and replacing oil tank filter for hydraulic breaker operations.
1 Check Hydraulic Oil Level --- daily
Procedure to check hydraulic oil level using the level gauge, with cautions for pressurized tanks.
2 Change Hydraulic Oil
Procedure for changing hydraulic oil, including cleaning the tank and replacing the suction filter.
3 Suction Filter Cleaning
Instructions for cleaning the suction filter at specified intervals or when changing hydraulic oil.
Air Bleeding Procedures
Steps to bleed air from the hydraulic pump and system after changing hydraulic oil.
4 Replace Hydraulic Oil Tank Filter
Procedure for replacing the hydraulic oil tank filter at specified intervals or when the indicator lights up.
4 Replace Hydraulic Tank Oil Filter (K Model, L Model)
Procedure for replacing the hydraulic tank oil filter for K and L models, with filter restriction indicator notes.
5 Replace Pilot Oil Filter
Procedure for replacing the pilot oil filter at specified intervals; do not reuse the cartridge element.
6 Replace Air Breather Element
Procedure for replacing the air breather element; clean area and use correct tools to avoid damage.
7 Check Hoses and Lines
Daily and 250-hour checks for leaks, kinks, rubs, damage, or corrosion on hoses and lines.
SERVICE RECOMMENDATIONS FOR HYDRAULIC FITTINGS
Guidelines for inspecting and tightening hydraulic fittings, including O-ring replacement and torque specifications.
Metal Face Seal Fittings
Instructions for inspecting and tightening metal face seal fittings to prevent leaks.
Pilot Piping Fittings (For shuttle valve)
Torque specifications for pilot piping fittings used with the shuttle valve.
E. FUEL SYSTEM
Information on recommended fuel, refueling procedures, and checking fuel level.
1 Drain Fuel Tank Sump --- daily
Procedure to drain water and sediment from the fuel tank sump daily.
2 Drain Fuel Filter --- daily
Procedure to drain accumulated water from the fuel filter daily to prevent engine damage.
4 Replace Fuel Pre-Filter Element
Procedure for replacing the fuel pre-filter element, including draining and bleeding air.
5 Clean Fuel Solenoid Pump Strainer
Procedure for cleaning the fuel solenoid pump strainer, including disassembly and reassembly.
Air Bleeding Procedures
Steps to bleed air from the fuel system after draining water, replacing filters, or running the tank dry.
3 Replace Fuel Main Filter Element
Procedure for replacing the main fuel filter element; use only genuine Hitachi elements.
F. AIR CLEANER
Procedures for cleaning and replacing the air cleaner outer and inner elements.
1 Clean Air Cleaner Outer Element
Instructions for cleaning the outer air cleaner element using compressed air or water.
2 Replace Air Cleaner Outer and Inner Elements
Procedure for replacing both outer and inner elements, emphasizing not to reuse the inner element.
G. COOLING SYSTEM
Information on coolant, including use of fresh water or Hitachi Long-Life Coolant (LLC) mixture.
1 Check Coolant Level --- daily
Procedure to check coolant level in the radiator and reservoir; do not loosen cap when system is hot.
2 Check and Adjust Fan Belt Tension
Check belt for wear, replace if necessary; adjust tension by moving alternator bracket.
3 Change Coolant --- twice a year
Procedure for changing coolant, including cleaning radiator interior and bleeding air from the system.
4 Clean Radiator, Oil Cooler Core and Inter Cooler
Instructions for cleaning radiator, oil cooler, and inter cooler components externally and internally.
5 Clean Oil Cooler, Radiator and Inter Cooler Front Screen
Procedure for cleaning the front screen of the oil cooler, radiator, and inter cooler.
6 Clean Air Conditioner Condenser
Instructions for cleaning the air conditioner condenser.
7 Clean Fuel Oil Cooler
Instructions for cleaning the fuel oil cooler.
8 Clean Air Conditioner Front Screen (Opt.)
Procedure for cleaning the front screen of the air conditioner, with cautions for compressed air usage.
H. ELECTRICAL SYSTEM
Information on radio communication equipment effects and electrical component installation safety.
BATTERIES
Warnings about battery gas explosion; procedures for handling, charging, and avoiding hazards.
Electrolyte Level Check --- every one month
How to check electrolyte level using lines or filler port; refill with distilled water or battery fluid.
Check electrolyte specific gravity --- every one month
Check specific gravity after electrolyte cools; ensure it's within the recommended range for battery health.
REPLACE BATTERIES
Guidelines for replacing batteries, including matching type and avoiding issues with different charge rates.
Remove and Installing Batteries
Procedure for safely removing and installing batteries, emphasizing disconnecting negative terminal first.
REPLACING FUSES
Check fuses when electrical equipment fails; install fuses with correct amperage ratings to prevent damage.
Fusible Link (Main Fuse)
Check fusible link if starter does not rotate; remove cover next to engine coolant reservoir to check fuse.
I. MISCELLANEOUS
Covers various miscellaneous maintenance tasks not fitting other categories.
1 Check Bucket Teeth --- daily
Check bucket teeth for wear and looseness; replace if tooth wear exceeds the service limit.
2 Change Bucket
Procedure for changing the bucket, including pin removal, cleaning, greasing, and checking for movement interference.
3 Convert Bucket Connection Into Face Shovel
Procedure to convert the bucket connection for face shovel operation, including turning the bucket 180°.
4 Adjust Bucket Linkage
System for taking up play in the linkage by removing and installing shims to adjust clearance.
5 Remove Travel Levers
Instructions for removing the travel levers if desired.
6 Check and Replace Seat Belt
Maintain seat belt condition; check for damage/wear; replace every three years regardless of condition.
7 Check Windshield Washer Fluid Level
Check fluid in the washer tank; add fluid if low; use all-season fluid in winter.
8 Check Track Sag
Check track sag every 50 hours by measuring distance 'A'; adjust track if sag is not within specifications.
Loosen the Track
Procedure to loosen the track by turning the valve counterclockwise; keep body parts away from valve.
Tighten the Track
Connect grease gun to fitting and add grease to tighten track; consult dealer if abnormal tightness occurs.
9 Clean and Replace Air Conditioner Filter
Procedures for cleaning and replacing circulating and fresh air filters for the air conditioner.
10 Check Air Conditioner
Check pipe connections for leakage, condenser for clogging, compressor, and belt tension.
Adjust Compressor Belt Tension
Check and adjust compressor belt tension; re-adjust after operating engine for 3-5 minutes with new belt.
11 Clean Cab Floor
Procedure for cleaning the cab floor with tap water; spray floor only, avoid surrounding area, remove moisture.
12 Retighten Cylinder Head Bolt
Retighten cylinder head bolts as required; consult authorized dealer for this procedure.
13 Inspect and Adjust Valve Clearance
Inspect and adjust valve clearance at every 1000 hours; consult authorized dealer for this procedure.
14 Measure Engine Compression Pressure
Measure engine compression pressure at every 1000 hours; consult authorized dealer for this procedure.
15 Check Starter and Alternator
Check starter and alternator at every 1000 hours; consult authorized dealer for this procedure.
16 Check and Replace EGR Device
Check and replace EGR device as required; consult authorized dealer for this procedure.
17 Check Tightening Torque of Bolts and Nuts
Check and tighten bolts/nuts every 250 hours (first 50 hours); replace if loose; use torque wrench.
Tightening Torque Chart
Provides torque specifications for various bolt and socket bolt sizes based on width across flats.
TROUBLESHOOTING
IMPOSSIBLE TO START THE ENGINE
Lists causes and solutions for starter issues, fuel system problems, and preheat system faults preventing engine start.
ENGINE
Troubleshooting guide for engine performance issues like low power, overheating, excessive oil consumption, and smoke.
ELECTRICAL SYSTEM
Troubleshooting guide for electrical system issues including cranking problems, charging indicator, alternator noise, and monitor panel failures.
MODE SELECTION
Troubleshooting for issues with work mode selector, travel speed function, and auto-idle not working.
CONTROL LEVERS
Common problems with control levers such as stiffness, lack of return to neutral, excessive play, or improper vertical position.
HYDRAULIC SYSTEM
Troubleshooting for hydraulic system issues including slow functions, overheating oil, oil foams, low pressure, and function failures.
SPECIFICATIONS
ZX135US-3
Detailed specifications for the ZX135US-3 model, including dimensions, weight, engine, and ground pressure.
WORKING RANGES
Provides digging reach, depth, cutting height, and dumping height dimensions for different arm configurations.
SHOE TYPES AND APPLICATIONS
Details shoe types, applications, operating weight, and ground pressure for various track shoe options.
BUCKET TYPES AND APPLICATIONS
Lists bucket types, capacities, widths, and their applicability to different front-end attachments.
SPECIFICATIONS ZX135USK-3
Detailed specifications for the ZX135USK-3 model, including dimensions, weight, engine, and ground pressure.
WORKING RANGES ZX135USK-3
Provides digging reach, depth, cutting height, and dumping height dimensions for ZX135USK-3 with K arm.
SHOE TYPES AND APPLICATIONS ZX135USK-3
Details shoe types, applications, operating weight, and ground pressure for ZX135USK-3 models.
BUCKET TYPES AND APPLICATIONS ZX135USK-3
Lists bucket types, capacities, widths, and their applicability to ZX135USK-3 front-end attachments.
SPECIFICATIONS ZX135USL-3
Detailed specifications for the ZX135USL-3 model, including dimensions, weight, engine, and ground pressure.
WORKING RANGES ZX135USL-3
Provides digging reach, depth, cutting height, and dumping height dimensions for ZX135USL-3 with reinforced arm.
SHOE TYPES AND APPLICATIONS ZX135USL-3
Details shoe types, applications, operating weight, and ground pressure for ZX135USL-3 models.
BUCKET TYPES AND APPLICATIONS ZX135USL-3
Lists bucket types, capacities, widths, and their applicability to ZX135USL-3 front-end attachments.
SPECIFICATIONS ZX225US-3, 225USLC-3
Detailed specifications for ZX225US-3 and ZX225USLC-3 models, including dimensions and weight.
WORKING RANGES ZX225US-3, 225USLC-3
Provides digging reach, depth, cutting height, and dumping height for ZX225US-3 and ZX225USLC-3.
SHOE TYPES AND APPLICATIONS ZX225US-3
Details shoe types, applications, operating weight, and ground pressure for ZX225US-3 models.
BUCKET TYPES AND APPLICATIONS ZX225US-3, 225USLC-3
Lists bucket types, capacities, widths, and their applicability to ZX225US-3/USLC-3 front-end attachments.
SPECIFICATIONS ZX225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3
Detailed specifications for ZX225USR/RLC/RK/LCK-3 models, including dimensions, weight, and engine.
WORKING RANGES ZX225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3
Provides digging reach, depth, cutting height, and dumping height for various ZX225US-3/LC/RK/LCK-3 configurations.
SHOE TYPES AND APPLICATIONS ZX225USR-3
Details shoe types, applications, operating weight, and ground pressure for ZX225USR-3 models.
SHOE TYPES AND APPLICATIONS ZX225USRLCK-3
Details shoe types, applications, operating weight, and ground pressure for ZX225USRLCK-3 models.
BUCKET TYPES AND APPLICATIONS ZX225USR-3, 225USLC-3
Lists bucket types, capacities, widths, and applicability for ZX225USR-3/USLC-3 front-end attachments.
BUCKET TYPES AND APPLICATIONS ZX225USRK-3, 225USRLCK-3
Lists bucket types, capacities, widths, and applicability for ZX225USRK-3/USRLCK-3 front-end attachments.
OPTIONAL ATTACHMENTS AND DEVICES
BUCKET TEETH (Transverse-Type-Pin-Used Type)
Procedure for replacing bucket teeth, including cautions for handling and tool usage.
USING PAD CRAWLER SHOE
Information on pad crawler shoes, forbidden operations, and precautions for handling to avoid damage.
TRAVELING AND OTHER CAUTIONS
Cautions for traveling with pad crawler shoes, including avoiding direct sunlight, reckless steering, and high temperatures.
TRANSPORTING
Instructions for transporting machines with pad crawler shoes, emphasizing secure fastening with ropes and protectors.
PRECAUTIONS FOR TRANSPORTING MACHINES WITH PAD CRAWLER SHOES
Securely fasten track frames to flatbed with ropes and protectors, avoiding direct contact with pad crawler shoes.
Check Track Sag
Procedure to check track sag every 50 hours and adjust if it's not within specifications.
LONG ARM OPERATION --- IF EQUIPPED
Guidelines for operating with the optional long arm, including limitations on works and bucket size for stability.
BLADE LEVER
Operation of the blade lever to raise and lower the blade; lever returns to neutral when released.
PRECAUTIONS FOR BLADE OPERATION
Use blade for dozing only; avoid deep digging, intensive loads, jacking up, or contact with bucket.
AVOID HITTING BLADE WITH FRONT-END AT TACHMENT
Caution to prevent bucket or boom cylinder contact with the blade when operating with front attachment forward.
AVOID HITTING BLADE WITH BUCKET
Be careful not to let the bucket hit the blade when crowding the arm for traveling or transport.
AVOID STRIKING THE BLADE INTO A ROCK
Do not strike large rocks with the blade to prevent damage and shorten operating life of blade and cylinders.
BLADE MAINTENANCE
Greasing intervals for blade joint pins, cylinder rods, and cylinder bottoms.
Transportation Figure for Machine Equipped with Blade
Shows how to position the blade during transport to avoid contact with the front attachment.
SPECIFICATIONS ZX135US-3 with Blade
Detailed specifications for the ZX135US-3 model with blade attachment, including dimensions and weight.
WORKING RANGES ZX135US-3 with Blade
Provides digging reach, depth, cutting height, and dumping height for ZX135US-3 with blade and different arm lengths.
SHOE TYPES AND APPLICATIONS ZX135US-3 with Blade
Details shoe types, applications, operating weight, and ground pressure for ZX135US-3 with blade models.
SPECIFICATIONS ZX135USL-3 with Blade
Detailed specifications for the ZX135USL-3 model with blade attachment, including dimensions and weight.
WORKING RANGES ZX135USL-3 with Blade
Provides digging reach, depth, cutting height, and dumping height for ZX135USL-3 with blade and different arm lengths.
SHOE TYPES AND APPLICATIONS ZX135USL-3 with Blade
Details shoe types, applications, operating weight, and ground pressure for ZX135USL-3 with blade models.
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