1999 Hitachi EX135UR Excavator Operator's Manual (P/N EM1ED-EN2-2)

This Hitachi operator’s manual (P/N EM1ED-EN2-2) covers the 1999 EX135UR excavator, serial numbers 002392 and up, with operating instructions, scheduled maintenance procedures and troubleshooting charts.

PDF Bookmarks, Text Search and Diagram Detail

Navigation and small print: Embedded PDF bookmarks provide access to the main sections, but PDF text search is not available. The electrical circuit diagram requires zooming to read small terminal numbers and wire codes; some of the finest characters remain soft when enlarged.

The download contains one printable PDF with 252 pages, including the front and back covers, 11 memo pages and four blank pages.

Excavator Controls, Maintenance and Fault Finding

Beyond the selected topics below, the manual also covers radio and clock setup and seat-belt inspection.

• Operator’s station: Monitor indicators, ISO-pattern control levers, blade controls, the pilot control shut-off lever, cab heating and air-conditioning operation.
• Front-end control systems: Auto-MARCCINO operation, bucket/cab collision prevention checks, bucket-tip monitoring, and height, depth and offset restriction settings.
• Engine and cooling maintenance: Step-by-step procedures for engine oil and filter replacement, fan-belt adjustment, air-cleaner service, coolant changes and fuel-system bleeding.
• Hydraulics and drive lubrication: Hydraulic tank and pilot filter replacement, suction-filter cleaning, pump air bleeding, and pump transmission, swing and travel reduction gear oil service.
• Tracks and bucket: Separate rubber-crawler and optional steel-track adjustment procedures, bucket-tooth replacement, bucket changes and linkage-clearance adjustment.
• Troubleshooting and diagrams: Engine, electrical and hydraulic fault charts, control-system warning patterns, an electrical circuit diagram and a hydraulic piping layout.
• Transport and storage: Trailer loading and securing, short-distance towing, machine lifting, storage preparation, and separate emergency boom-lowering procedures for offset and mono booms.

Hitachi specifies qualified, experienced operators licensed according to local law, and officially licensed personnel for inspection and service.

Operational Systems and Controls

The operator’s station section explains coolant temperature, engine oil pressure, fuel-level and charging indicators, together with auto-idle, economy mode and emergency controls. Start-up instructions include cold-weather starting, booster-battery connections and checks of the bucket/cab collision prevention and Auto-MARCCINO systems.

Auto-MARCCINO coordinates arm movement during boom raising to maintain clearance from the cab. The work-range restriction section explains an important limitation: height and depth settings restrict boom movement, rather than independently stopping the arm and bucket. Front-attachment replacement requires dealer attention to the collision prevention system settings.

Review the included safety alert symbols and signal words before working near power lines, on slopes or around raised attachments and pressurized hydraulics.

Maintenance Procedures and Repair Limits

The maintenance guide organizes lubrication, inspections and replacement work by operating hours, helping plan scheduled service from the hour meter. Illustrated procedures cover water-separator draining, feed-pump strainer cleaning, hydraulic filter service and hose inspection. Hydraulic fitting guidance distinguishes flat-face O-ring seal fittings from metal-face seal fittings, with the associated tightening specifications.

The hydraulic oil-change procedure warns that starting the engine with an unfilled hydraulic pump can damage the pump. The bucket-linkage adjustment instructions also explain how omitted shims can damage the arm end face or adjustment bolts.

Valve-clearance adjustment, injection-timing checks, compression testing, and starter and alternator checks are dealer-service entries rather than detailed repair procedures. Hydraulic and electrical component adjustment, disassembly and repair are also directed to authorized service.

Circuit References and Control Warnings

The Monitor Panel views identify warning indicators, while the Hydraulic Circuit layout locates the main and pilot piping, pumps and control-valve sections. The Electrical Circuit Diagram shows connections for the main controller, Auto-MARCCINO control unit, sensors and solenoids.

The control-system troubleshooting table distinguishes normal automatic stopping from power-source, solenoid-valve and angle-sensor faults through indicator behavior and audible warnings. This helps identify which control warnings require dealer attention. Working Ranges (Offset Boom) drawings and configuration-specific Lifting Capacities charts provide additional operating references.

Selected Track-Sag and Fan-Belt Specifications

Rubber-crawler sag is specified at 20–30 mm, measured between the center lower roller and the track’s inner ridge with the track raised. The optional steel-track procedure specifies 250–280 mm between the underside of the track frame and the back of the shoe; these measurements use different reference points.

In the Cooling System section, fan-belt deflection is 8–12 mm under approximately 98 N (10 kgf), measured midway between the fan and alternator pulleys.