HITACHI EX135UR Excavator Service Manual SET

INTRODUCTION IN-01 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 cor- rect 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. (Note: Do not tear off the form. Copy it for us- age.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog • Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material MANUAL COMPOSITION • This manual consists of three portions: the Techni- cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man- ual. • 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 per- formance 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 assem- ble/disassemble procedures. PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1 -3 -5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual

INTRODUCTION IN-02 SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts. • CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death. • IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. • NOTE: Indicates supplementary technical information or know-how. UNITS USED • SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees. Quantity To Convert From Into Multiply By MPa kgf/cm 2 10.197 Pressure MPa psi 145.0 kW PS 1.360 Power kW HP 1.341 Temperature °C °F °C×1.8+32 km/h mph 0.6214 Velocity min -1 rpm 1.0 Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0 Quantity To Convert From Into Multiply By mm in 0.03937 Length mm ft 0.003281 L US gal 0.2642 L US qt 1.057 Volume m 3 yd 3 1.308 Weight kg lb 2.205 N kgf 0.10197 Force N lbf 0.2248 N⋅m kgf⋅m 1.0197 Torque N⋅m lbf⋅ft 0.7375

SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout SECTION 2 SYSTEM Group 1 Control System Group 2 Front Control System Group 3 Hydraulic System Group 4 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Others(Upperstructure) Group 7 Others(Undercarriage) TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PER- FORMANCE TEST Group 1 Introduction Group 2 Engine Test Group 3 Excavator Test Group 4 Component Test Group 5 Standard SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Troubleshooting D Group 7 Electrical System Inspection Group 8 Harness Check WORKSHOP MANUAL SECTION 1 GENERAL INFORMA- TION Group 1 Precautions for Disassem- bling and Assembling Group 2 Tightening Torque SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Pilot Shut-Off Valve Group 9 Shockless Valve SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder SECTION 5 ENGINE SECTION AND GROUP CONTENTS TECHNICAL MANUAL (Operational Principle) All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice COPYRIGHT©1997 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

191T-1-1 SECTION 1 GENERAL ―CONTENTS― Group 1 Specification Specifications ............................................ T1-1-1 Working Ranges and Machine Dimensions for Transportation ................ T1-1-2 Component Specifications ........................ T1-1-3 Group 2 Component Layout Main Components ..................................... T1-2-1 Electrical System (Component Layout) ............................... T1-2-2 Electrical System (Relays) ........................ T1-2-3 Electrical System (Monitor and Switch) ............................... T1-2-4 Others ....................................................... T1-2-6

191T-1-2 (Blank)

GENERAL / Specifications T1-1-1 SPECIFICATIONS Machine Model EX135UR Machine Type Cab Mounted Type of Front End Attachment − Offset Type Standard Bucket Capacity (Heaped) m 3 (yd 3 ) 0.45 (0.59): PCSA, 0.40: CECE Operating Weight kg (lb) 14000 (31000) Basic Machine Weight kg (lb) 10900 (24000) Engine − ISUZU 4BG1T, 63 kW/1900 min -1 (85 PS/1900 rpm) A: Overall Width mm (ft in) 2490 (8’ 2”) B: Cab Height mm (ft in) 2800 (9’ 2”) C: Swing Radius mm (ft in) 1370 (4’ 6”) D: Ground Clearance of Undercarriage mm (ft in) 430 (1’ 5”) E: Clearance Height Under Upper mm (ft in) 890 (2’ 11”) F: Height of House mm (ft in) 1980 (6’ 6”) G: Track Length mm (ft in) 3620 (11’ 11”) H: Undercarriage Overall Width mm (ft in) 2490 (8’ 2”) l : Crawler Base mm (ft in) 2900 (9’ 6”) J: Track Shoe Width mm (ft in) 500 (1’ 8”) Ground Pressure kPa (kgf/cm 2 ) 47 (0.48) Maximum Swing Speed min -1 (rpm) 13.4 (13.4) Maximum Travel Speed (Fast/Slow) km/h (mph) 5.0 (3.2)/3.5(2.2) Gradability Degree (%) 35 (70) M191-11-001 Base Machine Dimension Diagram

GENERAL / Specifications T1-1-2 WORKING RANGES AND MACHINE DIMENSIONS FOR TRANSPORTATION M191-11-002 M191-11-004 Working Dimension Arm Size Description 2.21 m 2.51 m A: Maximum Reach mm (ft in) 7540 (24’ 9”) 7830 (25’ 8”) B: Maximum Digging Depth mm (ft in) 4800 (15’ 9”) 5100 (16’ 9”) C: Maximum Height of Cutting Edge mm (ft in) 8550 (28’ 1”) 8790 (28’ 10”) D: Maximum Dumping Height mm (ft in) 6140 (20’ 2”) 6380 (20’ 11”) E: Shipping Height mm (ft in) 2800 (9’ 2”) 2800 (9’ 2”) F: Shipping Length mm (ft in) 7390 (24’ 3”) 7450 (24’ 5”) G: Minimum Radius of Equipment and Attachment mm (ft in) 1240 (4’ 1”) 1470 (4’ 10”) H: Blade Maximum Lifting mm (ft in) 490 (1’ 7”) I : Blade Maximum Lowering mm (ft in) 500 (1’ 8”) J : Offset Right mm (ft in) Offset Left mm (ft in) 1160 (3’ 7”) 1100 (3’ 9”) K: Blade Approach Angle (degree) 30

HITACHI EX135UR Excavator Service Manual SET

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