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Hitachi ZAXIS 135US-5B Operator's Manual

Hydraulic excavator
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Table of Contents
URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (E) 2015, 12
ENMDCN-1-1
PART NO.
Operator's Manual
135US
-5B
225US
-5B
225USLC
Hydraulic Excavator
Serial No.
ZX135US
090001 and up
-5B
ZX225US
300001 and up
-5B
ZX225USLC
300001 and up
-5B
-5B

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  Summary of Contents for Hitachi ZAXIS 135US-5B

  • Page 1 ENMDCN-1-1 PART NO. Operator's Manual 135US 225US 225USLC Hydraulic Excavator URL:http://www.hitachi-c-m.com Serial No. ZX135US 090001 and up ZX225US 300001 and up ZX225USLC 300001 and up PRINTED IN JAPAN (E) 2015, 12...
  • Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or machine damage.
  • Page 3 MACHINE NUMBERS INDEX SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT MAI N TENANCE UNDER SPECI A L ENVI R ONMENTAL CONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS...

  • Page 5: Table Of Contents

    CONTENTS MACHINE NUMBERS ............1 Avoid Applying Heat to Lines Containing Flammable Fluids ..............S-34 SAFETY ................S-1 Precautions for Handling Accumulator and Recognize Safety Information ............S-1 Gas Damper ................S-34 Understand Signal Words .............S-1 Remove Paint Before Welding or Heating ......S-35 Follow Safety Instructions ............S-2 Beware of Asbestos and Silicon Dust and Other Prepare for Emergencies ...............S-3...
  • Page 6 CONTENTS Date Adjustment ..............1-35 Revolving Light Switch (Optional) ........1-96 Display Mode Setting ............1-37 Electrical Control Main Switch (Optional) ...... 1-96 Attachment Adjustment ............1-39 Key Switch ..................1-97 Flow Rate Adjustment ............1-39 Power Boost Switch ..............1-97 Priority (arm roll-out) .............
  • Page 7 CONTENTS Console and Seat Fore-aft Adjustment ......1-128 Do Not Strike the Ground with Bucket Teeth ..... 5-22 Seat Fore-Aft Adjustment ..........1-128 Avoid Hammer Work ..............5-22 Suspension Adjustment .............1-129 Avoid Abusive Operation ............5-23 Fore-Aft Position Adjustment of Seat Surface ....1-129 Avoid Side Load the Bucket ............
  • Page 8 CONTENTS Check Hydraulic Oil Level ............ 7-36 J. Muffler Filter ................7-123 Change Hydraulic Oil ............. 7-37 Check and Clean Filter Element of Muffler Filter ..7-123 Air Bleeding Procedures ............7-39 Check and Clean Muffler Filter .........7-123 Suction Filter Cleaning ............7-40 HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT ..
  • Page 9 CONTENTS Bucket Teeth (Transverse-Type-Pin-Used Type) ....13-18 INDEX ................14-1...
  • Page 10 CONTENTS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 11 MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

  • Page 12: Machine Numbers

    MACHINE NUMBERS Muffler Filter TYPE MFG. NO. MDAA-00-002 DOC (Diesel Oxidation Catalyst) TYPE MFG. NO. MDAA-00-002 Travel Motor TYPE MFG. NO. M178-07-047 Swing Motor TYPE MFG. NO. M178-07-086...
  • Page 13 MACHINE NUMBERS Hydraulic Pump (ZX135US-5B) TYPE MFG. NO. MDAA-07-072 (ZX225US-5B, 225USLC-5B) TYPE MFG. NO. MDAA-00-003...
  • Page 14 MACHINE NUMBERS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 15: Safety

    SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words ...

  • Page 16: Follow Safety Instructions

     Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...

  • Page 17: Prepare For Emergencies

    SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...

  • Page 18: Protect Against Noise

    SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...

  • Page 19: General Precautions For Cab

    SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

  • Page 20: Use Handholds And Steps

    SAFETY Use Handholds and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as hand-holds. ...

  • Page 21: Ensure Safety Before Rising From Or Leaving Operator's Seat

    SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position.

  • Page 22: Move And Operate Machine Safely

    SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).

  • Page 23: Jump Starting

    SAFETY Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

  • Page 24: Precautions For Operations

    SAFETY Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.  Clear all persons and obstacles from the area of operation and machine movement.

  • Page 25: Investigate Job Site Beforehand

    SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.

  • Page 26: Install Opg Guard

    Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, install the Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. In order not to impair operator protective structure: Replace damaged OPG guard.

  • Page 27: Restriction Of Attachment Installation

    SAFETY Restriction of Attachment Installation  Do not install an attachment which exceeds specified weight for the machine structure. Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site.

  • Page 28: Drive Machine Safely

    SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine.
  • Page 29 SAFETY  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground.

  • Page 30: Avoid Injury From Rollaway Accidents

    SAFETY Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways:  Select level ground when possible to park the machine.  Do not park the machine on a grade. ...

  • Page 31: Avoid Injury From Back-Over And Swing Accidents

    SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: ...

  • Page 32: Keep Person Clear From Working Area

    SAFETY Keep Person Clear from Working Area  A person around the operating machine may be hit severely by the swinging front attachment or counterweight, be caught in other objects, and/or be struck by flying objects, resulting in serious injury or death. ...

  • Page 33: Avoid Undercutting

    SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic.

  • Page 34: Never Undercut A High Bank

    SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-489 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

  • Page 35: Avoid Power Lines

    SAFETY Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.

  • Page 36: Object Handling

    SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.

  • Page 37: Park Machine Safely

    SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket and blade to the ground.  Turn auto-idle switch OFF.  Run engine at slow idle speed without load for 5 minutes. ...

  • Page 38: Transport Safely

    SAFETY Transport Safely  Take care, the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to be transported.

  • Page 39: Practice Safe Maintenance

    SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving. ...

  • Page 40: Warn Others Of Service Work

    SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

  • Page 41: Stay Clear Of Moving Parts

    SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 SA-2294 Prevent Parts from Flying...

  • Page 42: Avoid Injury From Attachment Falling Accident

    SAFETY Avoid Injury from Attachment Falling Accident  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  To avoid possible personal injury from attachment falling accident, use a platform when replacing an attachment. ...

  • Page 43: Replace Rubber Hoses Periodically

    SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. ...

  • Page 44: Prevent Fires

    SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil cooler, and loose oil cooler flange bolts.
  • Page 45 SAFETY Clean up Flammable Materials:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately.

  • Page 46: Evacuating In Case Of Fire

    SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time. ...

  • Page 47: Precautions For Welding And Grinding

    SAFETY Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.

  • Page 48: Avoid Heating Near Pressurized Fluid Lines

     Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. S-34...

  • Page 49: Remove Paint Before Welding Or Heating

     Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts. S-35...

  • Page 50: Prevent Battery Explosions

    SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...

  • Page 51: Handle Chemical Products Safely

     Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 52: Never Ride Attachment

    SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice. Notes for Muffler Filter Muffler Filter The muffler filter removes particulate matters (PM) in the exhaust gas. The muffler filter traps PM, and it is automatically regenerated by burning PM when the set amount of PM is accumulated in the filter.

  • Page 53: Precaution For Communication Terminal Equipment

    SAFETY Precaution for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the driver's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.
  • Page 54 Failure to do so may cause damage or fire on the machine and the communication terminal. (Before removing or installing the communication terminal, consult your authorized Hitachi dealer.)  Do not pinch or forcibly pull cables, cords and connectors.

  • Page 55: Notes On Protection Of Operator's Station When The Machine Rolls Over

    In order to ensure the protective structure, follow the instructions below.  Consult your authorized Hitachi dealer before welding parts or drilling a hole on the cab, which possibly reduces the cab strength.

  • Page 56: Safety Signs

    Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. (ZX135US-5B) (ZX135US-5B)
  • Page 57 SAFETY SIGNS WARNING! Prior to operation, maintenance, disassembling, and transportation of the machine, be sure to read and understand the Operator’s Manual. SS4420332 If the parked machine is unexpectedly moved, serious injury or death due to crushing may result. Be sure to lower the front attachment to the ground, lock the control levers, and remove the engine key before leaving the machine unattended.
  • Page 58 SAFETY SIGNS When moving the seat height/tilt lever downward, press the lever grip with a palm from the top side. Do not grasp the lever grip to operate the lever, possibly resulting in pinch of your fingers into the seat stand. SS4371371 If the machine should overturn, the operator may become injured and/or throw from the cab and/or crushed by the...
  • Page 59 SAFETY SIGNS Sign indicates a hazard of a flying plug from track adjuster that could cause injury. Read manual before adjusting track for safe and proper handling. SS3086091 Sign indicates a burn hazard from compressed air and spurting hot oil if the oil inlet is uncapped during or right after operation.
  • Page 60 SAFETY SIGNS Sign indicates a hazard of falling off the fender or hood. Never stand close to the edge. SS3092125 Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine. SS3086090 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic oil tank is uncapped while hot.
  • Page 61 SAFETY SIGNS Sign indicates a hazard of rotating parts, such as belt. Turn off before inspection and maintenance. SS3092127 SSYA00008776 S-47...
  • Page 62 SAFETY SIGNS Sign indicates an electrical hazard from handling the cable. Read manual for safe and proper handling. SS4459714 Sign indicates an explosion hazard. Keep fire and open flames away from this area. SS4460067 Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness.
  • Page 63 SAFETY SIGNS SSYA00000341 WARNING IT CONTAINS NITROGEN UNDER HIGH PRESSURE. DON’T ALLOW FIRE OR HEAT NEAR IT. DON’T TRY TO SS-3212 DISASSEMBLE IT. WEAR EYE PROTECTION AND CAREFULLY DRILL A HOLE AT THE POINT MARKED × TO RELEASE GAS PRESSURE BEFORE DISPOSAL.
  • Page 64 SAFETY SIGNS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................S-50...

  • Page 65: Components Name

    COMPONENTS NAME Components Name 1- Bucket 2- Bucket Cylinder 3- Arm 4- Arm Cylinder 5- Boom Cylinder 6- Boom 7- Fuel Tank 8- Hydraulic Oil Tank 9- Engine 10- Muffler Filter 11- Counterweight 12- Travel Device 13- Track 14- Front Idler 15- Cab NOTE: A typical model is shown in the right.

  • Page 66: Getting On/Off The Machine

    GETTING ON/OFF THE MACHINE Getting ON/OFF the Machine Foot holds (1) and handrails (2) are provided in and around the machine. These are used to get on and off the cab safely as well as to do inspection and maintenance of the machine safely. Never jump on or off the machine as it is very dangerous.

  • Page 67: Operator's Station

     Use only genuine Hitachi engine oil. Using engine oil other than the genuine Hitachi oil may shorten the muffler cleaning interval and increase the fuel consumption rate.
  • Page 68 OPERATOR'S STATION  Do not modify the machine without authorization. Never attempt to modify the air inlet and exhaust parts such as the air duct, muffler filter and the exhaust outlet. Also never attempt to disassemble the muffler filter. Avoid giving shocks on the muffler filter by striking elements with other objects or dropping the elements.
  • Page 69 OPERATOR'S STATION  If the previous regeneration is not completed, the muffler filter regeneration request will be lit on the monitor after 10 hours and 30 minutes from the previous one. (refer to 1-24) 12 hours after the previous regeneration, the muffler filter regeneration request alarm flashes on the monitor (refer to 1-24), the engine power derates and the buzzer sounds interruptedly.

  • Page 70: Cab Features (Std. Model)

    OPERATOR'S STATION Cab Features (Std. Model) 1- Left Control Lever/Horn Switch 2- Left Travel Pedal 3- Left Travel Lever 4- Right Travel Lever 5- Right Travel Pedal 6- Right Control Lever/Power Boost Switch 7- Multi Function Monitor Panel 8- Switch Panel 9- Key Switch 10- Regeneration Switch 11- Operator's Seat...

  • Page 71: Multi Function Monitor

    OPERATOR'S STATION Multi Function Monitor Feature The multi function monitor displays various meters, indicators, radio and air conditioner, numeric keypad lock function, rearview camera image, work mode selection and maintenance screen. Screen Configuration The multi function monitor consists of the following screens.

  • Page 72: Default Setting

    OPERATOR'S STATION Default Setting Function Item Default Auto Shut-Down ON/OFF of Auto Shut-down Setting Time 1 min Muffler Filter Regeneration Regeneration Inhibited Inhibited NOTE: Typical functions are shown in the table. Check the initial values of other functions on each monitor screen.
  • Page 73 OPERATOR'S STATION Basic Screen 1- Work Mode Display 2- Muffler Filter 3- Power Mode Display 4- Hour Meter, Clock 5- Auxiliary 6- Auxiliary 7- Preheat Display 8- Seat Belt Display 9- Fuel Gauge 10- Sub Meter 11- Radio Display 12- Air Conditioner Display 13- Coolant Temperature Gauge 14- Auxiliary 15- Overload Alarm Display (Optional)

  • Page 74: Basic Screen

    OPERATOR'S STATION How to Use Screens Displaying Basic Screen IMPORTANT: Start the engine after the basic screen is displayed. When the key switch is turned to the ACC or ON position, the starting screen displays for about two seconds. When the key switch is kept in ACC position, only hour meter, clock and radio will be displayed.
  • Page 75 OPERATOR'S STATION  Display of Meters Work Mode Items to be displayed 4- Hour Meter, Clock 9- Fuel Gauge 13- Coolant Temperature Gauge  Work Mode Display The attachments being used are displayed. Digging Mode MDAA-01-001 Attachment Mode Breaker Pulverizer Crusher Vibrating Hammer Grapple...
  • Page 76 OPERATOR'S STATION  Muffler Filter Display (2) Displays condition of the muffler filter.  Power Mode Display (3) Displays the power mode selected from the switch panel.  Preheat Display (7) While the current is being supplied to the glow plug, the indicator is displayed.

  • Page 77: Hour Meter

    OPERATOR'S STATION  Auto-Idle Display (18) When the auto-idle is selected from the switch panel, the auto-idle display (18) displays. When the key switch is turned ON while the auto-idle switch is also ON, the auto-idle display blinks for 10 seconds.

  • Page 78: Coolant Temperature Gauge

    OPERATOR'S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. Normally the needle is around the center of the scale during operation. M1U1-01-047 Operating Status Icon Display Displays icons indicating the current status of the attachment (1) selected from the work mode selection screen, muffler filter display (2), power mode (3), preheat indicator (4), travel mode (5), auto shut-down (6) ON and auto-idle (7) ON selected from the switch panel, when these...

  • Page 79: Security Functions (Optional)

    Security Functions (Optional) Input Password IMPORTANT:  When required to activate the numeric keypad function, consult your nearest Hitachi dealer.  If the password is forgotten, the machine must be modified. Be extremely careful not to forget the password. Starting Screen MDAA-01-003 1.

  • Page 80: Extending Password Duration Time

    OPERATOR'S STATION Extending Password Duration Time IMPORTANT: This operation is applicable only to those machines that require a password. By using the password duration screen, password duration time can be set. When restarting the machine, a password is not needed within the specified time. 1.

  • Page 81: Alarm Occurrence Screen

    OPERATOR'S STATION Alarm Occurrence Screen In case any abnormality occurs, alarm marks (1) are displayed on the basic screen. If six or more alarms are generated, the alarm marks (1) can be scrolled by rotating switch (2). MDAA-01-316 Indicator MDCD-01-026 1-17...
  • Page 82 OPERATOR'S STATION Follow the procedure below to display detailed information for an alarm. Push selector knob (1) on the basic screen to display the main menu. Rotate selector knob (1) to select the alarm list, and push selector knob (1). Rotate selector knob (1) to select a required alarm from the alarm list, and push selector knob (1).

  • Page 83: Remedy

    OPERATOR'S STATION Remedy Display Contents of Alarms Remedy Muffler Filter Alarm* Muffler filter is abnormal. Immediately set the machine in the park (Blinking) (Red) position, stop the engine and contact your authorized dealer. Muffler Filter Regeneration The muffler filter needs immediate regeneration. Otherwise damage Request to the filter may result.
  • Page 84 OPERATOR'S STATION Display Contents of Alarms Remedy Engine Trouble Alarm Engine or engine related parts are abnormal. Contact your nearest authorized dealer. Engine Oil Pressure Alarm* Engine oil pressure has decreased. Immediately stop the engine. Check the engine oil system and oil level.
  • Page 85 OPERATOR'S STATION Display Contents of Alarms Remedy Fuel Temperature Alarm Fuel temperature has abnormally increased. Stop operation. Check fuel cooler for any malfunction such as clogging. Hydraulic Oil Filter Restriction The hydraulic oil filter is clogged. Alarm Replace hydraulic oil filter element. Air Cleaner Restriction Alarm Air filter elements are clogged.
  • Page 86 OPERATOR'S STATION  Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error Display If the fuel sensor is faulty, the color of the fuel mark changes Sensor Error Display and the needle disappears. If the harness between the fuel sensor and the controller unit is broken, the needle disappears.

  • Page 87: Muffler Filter

    OPERATOR'S STATION Muffler Filter Muffler Filter Condition Display Muffler Filter Display (1) displays the condition of the muffler filter. This mark indicates that the exhaust temperature is high during the muffler filter regeneration. It lights while auto-regeneration is in process.) NOTE: ...

  • Page 88: Muffler Filter Manual Regeneration Request

    This mark indicates that the muffler filter has over collected particulate matter. Immediately stop operation, park the machine in a safe (Blinking, location. Then, contact your nearest Hitachi Red) dealer. This mark indicates that the muffler filter regeneration is inhibited. It is displayed when the manual regeneration request arises while muffler filter regeneration is inhibited.

  • Page 89: Manual Regeneration Procedure

    OPERATOR'S STATION Manual Regeneration Procedure When manual regeneration is needed, screen (1) as shown in the right will be displayed. When this screen is displayed, you need to perform manual regeneration. Before starting manual regeneration, be sure to check the following. If the rear view camera is equipped on the machine and the camera is enabled, screen (1) is displayed only when the pilot control shut-off lever is in LOCK position.

  • Page 90: Main Menu

    OPERATOR'S STATION Main Menu Press selector knob (2) while displaying basic screen (1) to display main menu screen (3). The main menu screen contains the items shown in the figure to the right. The alarm list is displayed only when an alarm is generated.

  • Page 91: Air Conditioner

    When the function is OFF, the mark "" is displayed in gray. IMPORTANT: If mark (10) is displayed on the air conditioner display, communication between the air conditioner and the monitor is abnormal. Consult your nearest Hitachi dealer. MDAA-01-089EN MDAA-01-091EN MDAA-01-226 1-27...

  • Page 92: Radio

    IMPORTANT: If mark (7) is displayed on the radio display, communication between the radio and the monitor is abnormal. Consult your nearest Hitachi dealer. Press the numeric keypad of 1 to 8 while the radio is ON, the radio station will switch to memorized channel of 1 to 8. (Refer...

  • Page 93: Work Mode

    OPERATOR'S STATION Work Mode Front attachment is selected in the Work Mode screen under the Work Mode menu in the main menu. Attachment Selection 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2.

  • Page 94: Mail (Optional)

    IMPORTANT: This function is available only to a machine equipped with a communication terminal. When using the mail function, consult your nearest Hitachi dealer. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
  • Page 95 OPERATOR'S STATION 6. While mail information is sent to the communication terminal, the message "Wait." is displayed on the screen. MDAA-01-111EN 7. When the communication terminal completes receiving mail information, the message "Request Is Accepted." is displayed on the screen. Push the back key to return to the Mail screen.

  • Page 96: Setting Menu

    OPERATOR'S STATION Setting Menu Setting menu consists of date and time setting, attachment adjustment, attachment name, auto shut-down setting, change password, selecting sub meter, brightness adjustment of back monitor and screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).

  • Page 97: Date And Time

    OPERATOR'S STATION Date and Time Time, date and display mode can be set on this screen. Year- month-day format and 24h/12h display mode are selected in the display setting. Time Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
  • Page 98 OPERATOR'S STATION 5. Press selector knob (2) to display Date and Time screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Time Setting (8). 7. Press selector knob (2) to display Time Setting screen (9). MDAA-01-117EN 8. Rotate selector knob (2) to highlight Hour or Minute and push selector knob (2).

  • Page 99: Date Adjustment

    OPERATOR'S STATION Date Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5).
  • Page 100 OPERATOR'S STATION 5. Press selector knob (2) to display Date and Time screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Date Setting (8). 7. Press selector knob (2) to display Date Setting screen (9). MDAA-01-122EN 8. Rotate selector knob (2) to highlight Year, Month or Day and push selector knob (2).

  • Page 101: Display Mode Setting

    OPERATOR'S STATION Display Mode Setting 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5).
  • Page 102 OPERATOR'S STATION 5. Press selector knob (2) to display Date and Time screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Display Form (8). MDAA-01-228EN 7. Press selector knob (2) to display Display Form screen (9). 8. Rotate selector knob (2) to highlight Date (10) and push selector knob (2).

  • Page 103: Attachment Adjustment

    OPERATOR'S STATION Attachment Adjustment The supply flow rate to an attachment, the operational priority for combined operation of an attachment and arm roll-in/arm roll-out can be adjusted on the Attachment Adjust screen. The attachment adjustment can be done when the work mode is set to an attachment other than the bucket.
  • Page 104 OPERATOR'S STATION 5. Press selector knob (2) to display Attachment Adjustment screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Pump Flow Rate (8). MDAA-01-129EN 7. Press selector knob (2) to display Pump Flow Rate screen (9). 8. Rotate selector knob (2) clockwise or counterclockwise to adjust the pump flow rate.

  • Page 105: Priority (Arm Roll-Out)

    OPERATOR'S STATION Priority (arm roll-out) Select an attachment other than the bucket on the work mode screen. (Refer to 1-29) 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3.
  • Page 106 OPERATOR'S STATION 5. Press selector knob (2) to display Attachment Adjustment screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Priority (Arm Roll- Out) (8). MDAA-01-235EN 7. Press selector knob (2) to display Priority (Arm Roll-Out) screen (9). 8. Rotate selector knob (2) clockwise to increase flow rate to the attachment.

  • Page 107: Priority (Arm Roll-In)

    OPERATOR'S STATION Priority (arm roll-in) Select an attachment other than the bucket on the work mode screen. (Refer to 1-29) 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3.
  • Page 108 OPERATOR'S STATION 5. Press selector knob (2) to display Attachment Adjustment screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Priority (Arm Roll-In) (8). 7. Press selector knob (2) to display Priority (Arm Roll-In) screen (9). MDAA-01-236EN 8. Rotate selector knob (2) clockwise to increase flow rate to the attachment.

  • Page 109: Attachment Name Input

    OPERATOR'S STATION Attachment Name Input Attachment name can be changed on this screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5).
  • Page 110 OPERATOR'S STATION 5. Press selector knob (2) to display Attachment Name Input screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight desired attachment name (8). MDAA-01-134EN 7. Press selector knob (2) to display Name Change screen (9). 8. Rotate selector knob (2) right and left to highlight a character, and push selector knob (2).

  • Page 111: Auto Shut-Down

    OPERATOR'S STATION Auto Shut-Down WARNING: This function automatically stops the engine. Take extra care on the work and work environment when using this function. The auto shut-down function can be set in this screen. Set the auto shut-down time and enable (ON) the function beforehand.

  • Page 112: Acting Time Setting

    OPERATOR'S STATION 5. Press selector knob (2) to display Auto Shut-Down screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight ON (8). 7. Press selector knob (2) to set the auto shut-down function ON. Press selector knob (2) again to turn the auto shut-down function OFF.

  • Page 113: Muffler Filter Regeneration Inhibited

    OPERATOR'S STATION Muffler Filter Regeneration Inhibited IMPORTANT: The muffler filter regeneration can be inhibited at this screen to prevent auto regeneration while operating the machine in a dusty area or indoors. Setting Procedure 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
  • Page 114 OPERATOR'S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Muffler Filter Regeneration Inhibited (6). 5. Press selector knob (2) to display Muffler Filter Regeneration Inhibited screen (7). 6. Rotate selector knob (2) to highlight (8), and press selector knob (2) to display Muffler Filter Regeneration Inhibited screen (9).

  • Page 115: Password Change (Optional)

    OPERATOR'S STATION Password Change (Optional) 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MDAA-01-001EN MDCD-01-026 2. Rotate selector knob (2) to highlight Setting Menu (4). MDAA-01-114EN 1-51...
  • Page 116 OPERATOR'S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Password Change (6). MDAA-01-156EN 5. Press selector knob (2) to display Password Change screen (7). MDCD-01-026 MDAA-01-157EN 6. Input current password from the numeric keypad. Current Password MDAA-01-158EN 1-52...
  • Page 117 OPERATOR'S STATION 7. Input the new password and push selector knob (2). 3 to 8 digits can be input for password. MDAA-01-159EN New Password MDAA-01-160EN 1-53...
  • Page 118 OPERATOR'S STATION 8. Input the new password again to confirm it and push selector knob (2). MDAA-01-161EN MDAA-01-162EN MDCD-01-026 9. The password has changed. MDAA-01-163EN 1-54...

  • Page 119: Sub Meter

    OPERATOR'S STATION Sub Meter A sub meter selection menu that can be added to the fuel meter is selected on this screen. OFF, Fuel Consumption Indicator and Breaker Hour Meter are provided. The breaker Sub Meter hour meter indicates the breaker operation time. 1.
  • Page 120 OPERATOR'S STATION 5. Press selector knob (2) to display Sub Meter Selection screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight desired sub meter (8). (Selecting OFF will not display a sub meter.) 7. Press selector knob (2) to enable the changes. NOTE: ...

  • Page 121: Rear View Camera Monitor

    OPERATOR'S STATION Rear View Camera Monitor IMPORTANT: The image displayed on the rear view monitor is meant only as an aid. Actual position and distance of people and objects in the rear view monitor will be different. When operating the machine, pay thorough attention to the surrounding situation.
  • Page 122 OPERATOR'S STATION 5. Press selector knob (2) to display Rear View Camera Monitor screen (7). MDCD-01-026 6. Press selector knob (2) to turn the rear view camera monitor ON/OFF. 7. When the rear view camera monitor is ON, rear view image is continuously displayed on the basic screen.

  • Page 123: Brightness Adjustment

    OPERATOR'S STATION Brightness Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MDAA-01-001EN MDCD-01-026 2. Rotate selector knob (2) to highlight Setting Menu (4). MDAA-01-114EN 3. Press selector knob (2) to display Setting Menu screen (5).
  • Page 124 OPERATOR'S STATION 5. Press selector knob (2) to display Brightness Adjustment screen (7). MDCD-01-026 6. Rotate selector knob (2) clockwise to make the screen brighter, counterclockwise to make the screen darker. MDAA-01-172EN NOTE: When the light is turned ON, the monitor screen changes to night mode and mark (8) is displayed.

  • Page 125: Language Settings

    OPERATOR'S STATION Language Settings 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MDAA-01-001EN MDCD-01-026 2. Rotate selector knob (2) to highlight Setting Menu (4). MDAA-01-114EN 3. Press selector knob (2) to display Setting Menu screen (5).
  • Page 126 OPERATOR'S STATION 5. Press selector knob (2) to display screen (7). 6. Rotate selector knob (2) to highlight the desired MDCD-01-026 language. Press selector knob (2) to make the change. NOTE: When a display is selected, the mark "" is displayed in green.

  • Page 127: Lists Of Display Language

    OPERATOR'S STATION Lists of Display Language Language Screen Display Language Screen Display Japanese Indonesian English Thai Spanish Vietnamese Italian Myanmarese French Arabic German Persian Dutch Turkish Russian Danish Portuguese Esthonian Finnish Polish Greek Icelandic Swedish Croatian Norwegian Slovenian Chinese (Simplified) Romanian Chinese (Traditional) Bulgarian...

  • Page 128: Unit Selection

    OPERATOR'S STATION Unit Selection Unit system displayed on the monitor can be selected in this screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MDAA-01-001EN MDCD-01-026 2. Rotate selector knob (2) to highlight Setting Menu (4). MDAA-01-114EN 3.
  • Page 129 OPERATOR'S STATION 5. Press selector knob (2) to display Unit Selection screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight desired unit system. Press selector knob (2) to set the unit (Metric or US system). MDAA-01-182EN 7. Before changing °C and °F, turn the blower of the air conditioner ON.

  • Page 130: Display Item Selection (Rear View Camera Off)

    OPERATOR'S STATION Display Item Selection (Rear View Camera OFF) The display under the meters can be set to OFF (disable), Logo or Operational information. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MDAA-01-001EN MDCD-01-026 2.
  • Page 131 OPERATOR'S STATION 5. Press selector knob (2) to display Display Item Selection screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight desired display (8). Press selector knob (2) to set the image. (Selecting OFF sets non-display.) NOTE: When a display is selected, the mark "" is displayed in green.

  • Page 132: Main Menu Sequence Change

    OPERATOR'S STATION Main Menu Sequence Change Menu sequence of Air Conditioner, Radio, Work Mode and Mail can be changed in this screen. Frequently used menu can be located on top of the screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
  • Page 133 OPERATOR'S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Main Menu Sequence Change (6). MDAA-01-186EN 5. Press selector knob (2) to display Main Menu Sequence Change screen (7). MDCD-01-026 6.

  • Page 134: Information Menu

    OPERATOR'S STATION Information Menu The information menu includes Operation, Maintenance and Monitoring. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5).

  • Page 135: Operation

    OPERATOR'S STATION Operation The Operation screen displays Fuel Consumption, Breaker Operation, Attachment Operation, Travel Operation, and Actual Operation menus. The Fuel Consumption screen displays fuel consumption, operating hours, and fuel consumption rate from resetting of the monitoring unit. The Breaker Operation screen displays breaker operating hours, machine operating hours and operating rate from resetting the monitoring unit.
  • Page 136 OPERATOR'S STATION 5. Press selector knob (2) to display Operation screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Fuel Consumption (8). 7. Press selector knob (2) to display Fuel Consumption screen (9). MDAA-01-193EN The Machine Operation Hours, Fuel consumption, and Average Fuel Consumption rate can be checked on this screen.

  • Page 137: Breaker Operation

    OPERATOR'S STATION Breaker Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4.
  • Page 138 OPERATOR'S STATION 5. Press selector knob (2) to display Operation Screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Breaker Operation (8). 7. Press selector knob (2) to display Breaker Operation screen (9). MDAA-01-196EN Operating Time, Machine Operation Hours and Operation Ratio can be checked in this screen.

  • Page 139: Attachment Operation

    OPERATOR'S STATION Attachment Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4.
  • Page 140 OPERATOR'S STATION 5. Press selector knob (2) to display operation screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Attachment Operation (8). MDAA-01-199EN 7. Press selector knob (2) to display Attachment Operation screen (9). The attachment Operating Time can be checked in this screen.

  • Page 141: Travel Operation

    OPERATOR'S STATION Travel Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4.
  • Page 142 OPERATOR'S STATION 5. Press selector knob (2) to display operation screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Travel Operation (8). 7. Press selector knob (2) to display Travel Operation screen (9). MDAA-01-202EN Total Travel Operation Time can be checked in this screen. Push selector knob (2) to return to the previous screen.

  • Page 143: Actual Operation

    OPERATOR'S STATION Actual Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4.
  • Page 144 OPERATOR'S STATION 5. Press selector knob (2) to display operation screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Actual Operation (8). 7. Press selector knob (2) to display Actual Operation screen (9). MDAA-01-205EN The actual Operating Time can be checked in this screen. Push selector knob (2) to return to the previous screen.

  • Page 145: Maintenance

    OPERATOR'S STATION Maintenance The maintenance screen includes maintenance notice, remaining hours until the next maintenance, and maintenance intervals. Maintenance Items  Engine Oil  Engine Oil Filter  Hydraulic Oil  Hydraulic Oil Pilot Filter  Hydraulic Oil Full-Flow Filter ...
  • Page 146 OPERATOR'S STATION 5. Press selector knob (2) to display Maintenance screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight Maintenance Notice (8). 7. Press selector knob (2) to turn the Maintenance Notice ON. Press selector knob (2) again to turn the Maintenance Notice OFF.

  • Page 147: Remaining Time And Maintenance Interval

    OPERATOR'S STATION Remaining Time and Maintenance Interval 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5).
  • Page 148 OPERATOR'S STATION 5. Press selector knob (2) to display Maintenance screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight a maintenance item to be checked (8). (In the right example, Engine Oil is selected.) 7. Press selector knob (2) to display the time remaining for the selected maintenance item.

  • Page 149: Monitoring

    OPERATOR'S STATION Monitoring Engine speed and PM (particulate matter) accumulation in the muffler filter can be checked in this screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4).
  • Page 150 OPERATOR'S STATION 5. Press selector knob (2) to display Monitoring screen (7). NOTE:  When the "PM Accumulation" bar reaches the right end, auto-regeneration takes place. However, auto- regeneration may not be performed depending on the machine condition.  The PM Accumulation is not displayed during regeneration. MDCD-01-026 MDAA-01-221EN 1-86...

  • Page 151: Switch Panel

    OPERATOR'S STATION Switch Panel 1- Return to Previous Screen 2- Return to Basic Screen 3- Selector Knob 4- Temperature Control Switch/Mode Switch 5- AUTO/OFF Switch/Fan Switch 6- AM/FM Selector/Tuning Switch 7- Power Switch/Volume Control Knob 8- Engine Control Dial 9- Auto-Idle Switch 10- Travel Mode Switch 11- Power Mode Switch 12- Work Light Switch...

  • Page 152: Return To Previous Screen (Monitor)

    OPERATOR'S STATION Return to Previous Screen (Monitor) Push this switch to return to the previous screen. MDAA-01-010 Return to Basic Screen (Monitor) Allows to return to the basic screen from any screen. MDAA-01-011 Select/Confirm Switch (Monitor) Push : Push this switch while the basic screen is displayed, the menu screen opens.

  • Page 153: Am/Fm Selector/Tuning Switch (Radio)

    OPERATOR'S STATION AM/FM Selector/Tuning Switch (Radio) Push : AM/FM is selected. Rotate : Adjusting radio frequency. MDAA-01-014 Power Switch/Volume Control Knob (Radio) Push : Turns power ON/OFF. Rotate : Adjusting the volume. MDAA-01-016 Engine Control Dial Fast Idle Use engine control dial (1) to adjust engine speed. The fully clockwise position : Fast Idle The fully counterclockwise position : Slow Idle...

  • Page 154: Auto-Idle Switch

    OPERATOR'S STATION Auto-Idle Switch The auto-idle switch (2) sets the engine speed control mode to either Auto-Idle ON or OFF.  Auto-Idle Speed When auto-idle switch (2) is turned to ON position, the engine speed decreases to the idle after approximately 4 seconds at the state in which the work lever is turned to MDAA-01-017 neutral.

  • Page 155: Power Mode Switch

    OPERATOR'S STATION Power Mode Switch Two engine speed modes, ECO and PWR modes are selected by operating the power mode switch. MDAA-01-274  ECO (Economy) Mode Operate the machine in this mode when performing normal work. ECO is displayed on Power Mode Display (1). MDAA-01-001EN ...

  • Page 156: Wiper/Washer Switch

    OPERATOR'S STATION Wiper/Washer Switch The wiper and the window washer are operated using the Middle Fast wiper/washer switch. Slow  Wiper Turn the wiper/washer switch to the specified position to operate the wiper. The wiper stops and is retracted. INT Position The wiper operates intermittently at the interval selected by the switch position as described below.

  • Page 157: Overhead Window Wiper And Washer Switch (Optional)

    OPERATOR'S STATION Overhead Window Wiper and Washer Switch (Optional)  Wiper Turn the wiper/washer switch to the specified position to Fast Middle operate the wiper. Slow The wiper stops and is retracted. INT Position The wiper operates intermittently at the interval selected by the switch position as described below.

  • Page 158: Switch Panel (For Optional Equipment)

    OPERATOR'S STATION Switch Panel (for Optional Equipment) Optional Switch Armrest Adjustment Location NOTE: The optional switch locations differ depending on the kinds of optional devices are equipped. Before using the switches, make sure what kinds of optional devices are equipped. Raise the armrest when operating the optional switch.

  • Page 159: Travel Alarm Deactivation Switch

    OPERATOR'S STATION Travel Alarm Deactivation Switch The travel alarm buzzer sounds during travel operation. When pushing the mark of travel alarm deactivation switch (1), the travel alarm buzzer function is deactivated. M1U1-01-035 Swing Alarm Deactivation Switch (Optional) The swing alarm system sounds the buzzer and turns the beacon light ON during swing operation.

  • Page 160: Seat Heater Switch

    OPERATOR'S STATION Seat Heater Switch When seat heater switch (6) is turned ON, the seat surface is heated so that the seat section becomes warm. When the temperature of the seat section is raised to the specified temperature, heating is automatically stopped. M1U1-01-011 Revolving Light Switch (Optional) When revolving light switch (7) is turned ON, the revolving...

  • Page 161: Key Switch

    OPERATOR'S STATION Key Switch 1- OFF (Engine Off ) 2- ACC (Horn, Radio etc.) 3- ON (Engine ON) 4- START (Engine Start) MDCD-01-030 Power Boost Switch Power boost switch (5) is provided on the top of the right control lever. While pressing power boost switch (5), the maximum digging power is boosted within approximately 8 seconds to increase work capacity.

  • Page 162: Electrical Control Main Switch (Optional)

    OPERATOR'S STATION Electrical Control Main Switch (Optional)  Attachment Switch (Assist Operation) or (Main Operation) This switch is mainly used for optional devices and attachments having rotary or tilt function. The attachment becomes operable when ON of electrical control main switch (1) is pushed and main switch indicator (2) is lit.
  • Page 163 Right Control Lever  These switches are provided for operating MCGB-01-029 MCGB-01-030 attachments of this machine. HITACHI does not bear responsibility on any human injury, malfunction and/or physical loss or damage incurred by unauthorized application or use of unauthorized attachments, optional parts or modified switch, which will void Hitachi Warranty Policy.

  • Page 164: Cigar Lighter

    IMPORTANT: In case the cigar lighter does not pop out automatically 30 seconds after pushing the cigar lighter in, pull out the cigar lighter manually. Then, consult your nearest Hitachi dealer. 1. Turn key switch (1) to the ACC or ON position. MDCD-01-030 2.

  • Page 165: Cab Light Switch

    (The light turns ON while the key switch is OFF.) MDCN-01-007 DOOR MCGB-01-023 Installing Fire Extinguisher (Optional) A fire extinguisher can be installed at the left rear corner inside the cab. Consult your nearest HITACHI dealer to install a fire extinguisher. MDCN-01-007 Fire Extinguisher 1-101...

  • Page 166: Pilot Control Shut-Off Lever

    OPERATOR'S STATION Pilot Control Shut-Off Lever Pilot control shut-off lever (1) functions to prevent the machine from being mistakenly operated when the operator is getting on or off the machine. WARNING:  Always pull pilot control shut-off lever (1) into the full LOCK position.

  • Page 167: Fuse Box

    OPERATOR'S STATION Fuse Box 10- CONTROLLER 20- OPTION3 9- BACKUP 19- HORN 10 A 10 A 8- ECM 18- IDLE STOP 30 A 7- START 17- POWER ON 6- OPTION2 16- GLOW. R 20 A MDCN-01-010 5- OPTION1 15- AUXILIARY 10 A 4- SOLENOID 14- MONITOR...

  • Page 168: Auto Air Conditioner

    OPERATOR'S STATION Auto Air Conditioner Features:  Full Auto-Temperature Control: Automatically controls the cab temperature to maintain the temperature set by the temperature control switch regardless of outside air temperature and insolation.  Max. Cooling and Heating: Maximum cooling or heating can be obtained by rotating the temperature control switch clockwise (32 °C) or counterclockwise (18 °C) respectively.

  • Page 169: Components Name

    OPERATOR'S STATION Components Name 1- Front Vent 2- Foot Vent 3- Defroster Vent 4- Rear Vent 5- Temperature Control Switch/Mode Switch 6- AUTO/OFF Switch/Fan Switch NOTE: Air flow direction can be changed by controlling the louvers at all air vents except for foot vents (2). In addition, MDCN-01-008 the louvers on front vent (1) and defroster vent (3) can be completely opened and closed by hand.

  • Page 170: Controller Part Name And Function

    OPERATOR'S STATION Controller Part Name and Function  Mode Switch (5) Selects the air vent. The selected air vent is indicated on monitor (7). Air flows out of front vent and the defroster vents. (Including defroster vent) Air flows out of the front, rear and the defroster vents.
  • Page 171 OPERATOR'S STATION  Blower Switch (6)  When the AUTO indicator (8) is ON, the blower speed is automatically controlled.  When AUTO indicator (8) is OFF, the blower speed is controlled in 6 steps. Rotate blower switch (6) clockwise to increase blower speed.

  • Page 172: Cab Heater Operation

    OPERATOR'S STATION Cab Heater Operation 1. AUTO switch (6): According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow-in vents, air suction ports, and air flow-in temperature at the vent, and controls the blower speed. 2.

  • Page 173: Cooling Operation

    OPERATOR'S STATION Cooling Operation 1. AUTO switch (6): Press AUTO switch (6) to set the air conditioner in AUTO mode. According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow-in vents, air suction ports, and air flow-in temperature at the vent, and controls the blower speed.

  • Page 174: Defroster Operation

    OPERATOR'S STATION Defroster Operation 1. Press AUTO Switch (6) to blow out temperature- controlled air. During cold weather season when starting the engine, the engine coolant temperature and air temperature in the cab are low. The Heater Start- Operation Control System controls the blow rate to the minimum (LO) in order to restrict cool air from flowing into the cab.

  • Page 175: Tips For Optimal Air Conditioner Usage

    OPERATOR'S STATION Tips for Optimal Air Conditioner Usage Air Conditioner Sensor For Rapid Cooling Temperature in the cab may rise over 80 °C (176 °F) when the machine is exposed to sun light in the summer. In this case, ventilate air in the cab first by opening the windows for rapid cooling.

  • Page 176: Am/Fm Radio Operation

    OPERATOR'S STATION AM/FM Radio Operation CAUTION: Refrain from listening to the radio in the cab while operating the machine Controls on the Radio 1- AM/FM Selector/Tuning Switch "FM" and "AM" are switched over alternately each time the switch is pressed. Rotate the tuning knob clockwise to increase frequency, counterclockwise to decrease frequency.

  • Page 177: Station Presetting Procedure

    OPERATOR'S STATION Station Presetting Procedure Setting from Monitor 1. Select the desired station. Refer to the "Tuning Procedure" in the previous section. 2. Press selector knob (1) while displaying basic screen (2) to display main menu screen (3). Rotate selector knob (1) to highlight radio (4).

  • Page 178: Station Auto-Presetting Procedure

    OPERATOR'S STATION Station Auto-Presetting Procedure Receivable stations can be automatically sought and preset to the memory. 1. Press selector knob (1) while displaying basic screen (2) to display main menu screen (3). 2. Rotate selector knob (1) to highlight Radio (4). Press selector knob (1) to display Radio screen (5).

  • Page 179: Tone Control

    OPERATOR'S STATION TONE Control 1. Press selector knob (1) while displaying basic screen (3) to display main menu screen (4). 2. Rotate selector knob (1) to highlight Radio (5). Press selector knob (1) to display Radio screen (6). 3. Rotate selector knob (1) to highlight TONE (7). 4.

  • Page 180: Audio Input (Optional)

    OPERATOR'S STATION Audio Input (Optional) IMPORTANT: This function is available only to a machine equipped with an audio input (optional). Use this function with proper sound volume. Audio Input Selection Attach the audio input (optional) device and push AM/FM Switch/Tuning Switch (1) to display AM and FM screen as well as AUX input screen (3).

  • Page 181: Side Monitor (Optional)

    OPERATOR'S STATION Side Monitor (Optional) An image captured by side camera (5) or rear view camera (4) is displayed on side monitor (1) located in the cab. IMPORTANT: Image displayed on the side monitor is of auxiliary nature at best. Actual position and distance of people and objects in the monitor will be different.

  • Page 182: Cab Door Release Lever

    OPERATOR'S STATION Cab Door Release Lever CAUTION:  Open the cab door all the way until it securely locks in the latch on the side of the cab.  Do not unlock the cab door when the machine is parked on a slope or while the wind is blowing hard. The cab door may close accidently, possibly resulting in personal injury.

  • Page 183: Opening/Closing And Removing Cab Inside Window

    OPERATOR'S STATION Opening/Closing and Removing Cab Inside Window WARNING:  Open, close or remove the upper-front cab window, overhead window, cab door window or lower-front window only after lowering the front attachment to the ground and pulling up pilot control shut-off lever (1) to the LOCK position.

  • Page 184: Opening Upper Front Window

    OPERATOR'S STATION Opening Upper Front Window Opening Upper Front Window 1. Press lock release lever (1) at the upper center to release the upper front window lock. 2. Holding lock release lever (1) at the upper center and lower handle (4) on the upper front window as illustrated, pull the upper front window up and back until auto locks (3) at both sides of the upper front window securely catches into the strikers on the ceiling.

  • Page 185: Removing And Storing Lower Front Window

    OPERATOR'S STATION Removing and Storing Lower Front Window CAUTION: Take care not to pinch yours fingers when handling the lower front window. Removing and Storing Lower Front Window 1. Open the upper front window beforehand when removing the lower front window. 2.

  • Page 186: Opening Side Windows

    OPERATOR'S STATION Opening Side Windows Hold handle (1) and slide rear pane to open the side window. M178-01-061 Side Window 1-122...

  • Page 187: Opening/Closing Overhead Window (Std. Model)

    OPERATOR'S STATION Opening/Closing Overhead Window (Std. Model) Move lock levers (1) toward center of window. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in position by dampers (3). Hold handle (2) and pull window down until "click" sound is heard from left and right locks (1).

  • Page 188: Opening/Closing Overhead Window (Clear Hatch: If Equipped)

    OPERATOR'S STATION Opening/Closing Overhead Window (Clear Hatch: If Equipped) Move lock levers (1) toward center of window. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in position by dampers (3).

  • Page 189: Emergency Exit

    OPERATOR'S STATION Emergency Exit Escape from the cab in emergency in the following methods: CAUTION: The danger of downfall is always present when escaping from the cab in emergency, possibly resulting in serious personal injury. Escape from the cab as safely as possible, depending on the posture of machine and the outside situation.

  • Page 190: Adjusting Operator's Seat

    OPERATOR'S STATION Adjusting Operator's Seat WARNING: Adjust the seat only after lowering the front attachment on the ground and pulling up the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to move unexpectedly if a control lever or pedal is touched with a part of the body by mistake, possibly resulting in personal injury or death.

  • Page 191: Backrest Adjustment

    OPERATOR'S STATION Backrest Adjustment Pull up lever (5) to release backrest lock. Move backrest to the desired position and release lever (5). MDAA-01-331 Armrest Adjustment Armrest (6) can be pulled upright by hand 90°. Pull the armrest upright by hand to get on and off the machine easily.

  • Page 192: Adjusting Operator's Seat (Optional)

    OPERATOR'S STATION Adjusting Operator's Seat (Optional) WARNING: Adjust the seat only after lowering the front attachment on the ground and pulling up the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to move unexpectedly if a control lever or pedal is touched with a part of the body by mistake, possibly resulting in personal injury or death.

  • Page 193: Suspension Adjustment

    OPERATOR'S STATION Suspension Adjustment Rotate knob (5) to adjust the suspension. Rotate knob (5) clockwise to decrease suspension stiffness. Rotate knob (5) counterclockwise to increase suspension stiffness. Fore-Aft Position Adjustment of Seat Surface Pull lever (6) upward to adjust the seat angle. Seat and console fore-aft adjustment range is 60 mm with steps every 15 mm.

  • Page 194: Console Height Adjustment

    OPERATOR'S STATION Console Height Adjustment Adjust the console height to the operator's comfort and/or work conditions. Adjusting console height can be achieved using three positions provided vertically at 20 mm intervals. CAUTION: Before loosening the console, support the console. Otherwise, the console may suddenly drop, possibly causing personal injury.

  • Page 195: Installation And Adjustment Of Mirrors

    OPERATOR'S STATION Installation and Adjustment of Mirrors WARNING: Adjust the mirrors before operating the machine. Improper adjustment of the mirrors provides poor visibility, which may cause serious human injury or death. IMPORTANT: The image displayed on the rear view monitor is meant only as an aid. When operating the machine, pay thorough attention to the surrounding situation.

  • Page 196: Seat Belt

    OPERATOR'S STATION Seat Belt WARNING:  Be sure to use seat belt (1) when operating the machine.  Before operating the machine, be sure to examine seat belt (1) and attaching hardware for any failure. If any damage and/or wear are found, replace the part concerned.

  • Page 197: Battery Disconnect Switch

    OPERATOR'S STATION Battery Disconnect Switch IMPORTANT: Do not turn the disconnect switch OFF while engine is running or the key switch is other than the OFF position. Failure to do so may damage the electrical system. The disconnect switch differs from the engine start key switch. When the disconnect switch is turned OFF, the electrical system is cut off, so no electric current flows into the entire circuit.
  • Page 198 OPERATOR'S STATION MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-134...

  • Page 199: Break-In

    BREAK-IN Observe Engine Operation Closely IMPORTANT: Be extra cautious during the first 50 hours, until you become thoroughly familiar with the sound and feel of your new machine. 1. Operate the machine only in economy (ECO) mode and limit the engine horsepower up to about 80 % of full load.
  • Page 200 BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 201: Operating The Engine

    OPERATING THE ENGINE Inspect Machine Daily Before Starting Perform the required daily check before starting the engine.  Refer to "Maintenance" chapter for detailed information. Check Points Check Points 1. Level and contamination of engine oil and coolant 1. Sag, wear and break of crawler 2.

  • Page 202: Before Starting Engine

    OPERATING THE ENGINE Before Starting Engine 1. If the machine is equipped with the battery disconnect switch, confirm that the battery disconnect switch is ON position. 2. Confirm that pilot control shut-off lever (1) is in the LOCK position. 3. Confirm that all control levers are placed in neutral. 4.

  • Page 203: Starting The Engine

    Unless the numeric keypad function (ignition block system) is activated, this screen is not displayed. IMPORTANT: When required to activate the numeric keypad function (ignition block system), consult your nearest Hitachi dealer. Slow Idle MDCD-01-030 M1P1-01-068 Password Input Screen...
  • Page 204 OPERATING THE ENGINE NOTE: When the key switch is turned ON, the maintenance notification (4) for the item whose maintenance interval has expired displays for ten seconds. Press Return switch (5) or turn the pilot control shut-off lever to UNLOCK position while the rear view camera is enable to delete the notification.
  • Page 205 Unless the numeric keypad function (ignition block system) is activated, this screen is not displayed. IMPORTANT: When required to activate the numeric keypad function (ignition block system), consult your nearest Hitachi dealer. Slow Idle MDCD-01-030 M1P1-01-068 Password Input Screen...
  • Page 206 OPERATING THE ENGINE NOTE: When the key switch is turned ON, the maintenance notification (4) for the item whose maintenance interval has expired displays for ten seconds. Press Return switch (5) or turn the pilot control shut-off lever to UNLOCK position while the rear view camera is enable to delete the notification.

  • Page 207: Check Instruments After Starting

    OPERATING THE ENGINE Check Instruments After Starting Checking instruments through monitor functions After starting the engine, check the following points through the monitor functions. 1. Check that alternator alarm indicator (1) is OFF. In case alternator alarm indicator (1) stays ON, immediately stop the engine.

  • Page 208: Using Booster Batteries

    OPERATING THE ENGINE Using Booster Batteries IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Use only 24 volt booster batteries with sufficient capacity. WARNING:  An explosive gas is produced while batteries are in use or being charged. Keep open flames and sparks away from the battery area.
  • Page 209 OPERATING THE ENGINE Disconnecting the booster cables Battery Disconnect Switch 1. Disconnect black negative (-) cable (2) from the machine frame first. (Red) 2. Disconnect the other end of black negative (-) cable (2) from the booster batteries. 3. Disconnect red positive (+) cable (1) from the booster batteries.

  • Page 210: Stopping The Engine

    OPERATING THE ENGINE Stopping the Engine Engine Stop Procedure 1. Except for special cases, before stopping the engine, lower the bucket to the ground. 2. Pull pilot control shut-off lever (3) to LOCK position. 3. Turn engine control dial (1) to the slow idle position and SA-390 run the engine for 5 minutes to cool the engine.

  • Page 211: Engine Auto-Stop In Extremely Low Temperature

    OPERATING THE ENGINE Engine Auto-Stop in Extremely Low Temperature WARNING: This function automatically stops the engine. Take extra care on the work and work environment when using this function. IMPORTANT: If the machine is left without operation under -20 °C or lower environment for long period of time, exhaust gas component may accumulate in the muffler filter, damage to the muffler filter may result.
  • Page 212 OPERATING THE ENGINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 213: Driving The Machine

    DRIVING THE MACHINE Drive the Machine Carefully IMPORTANT: During freezing weather, park machine on a hard surface to prevent tracks from freezing to the ground. Clean debris from tracks and track frame. If tracks are frozen to the ground, raise tracks using boom, move machine carefully to prevent damage to drive train and tracks.

  • Page 214: Steering The Machine Using Pedals

    DRIVING THE MACHINE Steering the Machine Using Pedals WARNING: In the standard travel position, the front Front Idler idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are positioned at the front of the machine, the control actions of the travel pedals will be reversed.

  • Page 215: Steering The Machine Using Levers

    DRIVING THE MACHINE Steering the Machine Using Levers WARNING: In the standard travel position, the front Front Idler idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are positioned at the front of the machine, the control actions of the travel levers will be reversed.

  • Page 216: Travel Mode Switch

    DRIVING THE MACHINE Travel Mode Switch WARNING: Tipping-over accidents can cause serious personal injury. Do not change travel mode switch (1) while traveling; especially, changing to fast mode (2) when descending slopes will create a very dangerous situation. Always stop the machine before changing the travel speed mode.

  • Page 217: Operating On Soft Ground

    DRIVING THE MACHINE Operating on Soft Ground • Avoid traveling on very soft ground that does not have sufficient strength to firmly support the machine. • If the machine is operated on very soft ground or becomes stuck, it may be necessary to clean the track frame area. • Swing the upperstructure 90 ° and lower the bucket to raise one track off the ground. Make sure to keep the angle between the boom and arm 90 to 110 °...

  • Page 218: Towing Machine A Short Distance

    DRIVING THE MACHINE Towing Machine a Short Distance RIGHT Soft Protector CAUTION: Cables, straps, or ropes can break causing serious injury. Do not tow machine with damaged chains, frayed cables, slings, straps, or wire ropes. Always wear gloves when handling cable, straps or wire ropes.

  • Page 219: Operating In Water Or Mud

    DRIVING THE MACHINE Operating in Water or Mud The machine can be operated in water up to the upper edge of the upper rollers only if worksite footing has sufficient strength to prevent the machine from sinking past the upper edge of the upper roller, and only if the water is flowing slowly.

  • Page 220: Parking The Machine On Slopes

    DRIVING THE MACHINE Parking the Machine on Slopes WARNING: Avoid parking machine on slopes. The machine may tip over, possibly resulting in personal injury. If parking the machine on a slope is unavoidable:  Thrust the bucket teeth into the ground. ...

  • Page 221: Operating The Machine

    OPERATING THE MACHINE Control Lever (ISO Pattern) WARNING:  Never place any part of the body beyond window frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. Never remove the window sash bar. ...

  • Page 222: Attachment Pedal (Hydraulic Breaker) (Optional)

    OPERATING THE MACHINE Attachment Pedal (Hydraulic Breaker) (Optional) The Breaker can be operated using attachment pedal (1) located on the right front of the seat, as illustrated. CAUTION: Be sure to lock attachment pedal (1) with pedal lock (2) when the attachment pedal is not in use.

  • Page 223: Attachment Pedal (Hydraulic Crusher) (Optional)

    OPERATING THE MACHINE Attachment Pedal (Hydraulic Crusher) (Optional) The crusher can be operated using attachment pedal (1) located on the right front of the seat, as illustrated. CAUTION: Be sure to lock attachment pedal (1) with pedal lock (2) when the attachment pedal is not in use.

  • Page 224: Pilot Control Shut-Off Lever

    OPERATING THE MACHINE Pilot Control Shut-Off Lever Pilot control shut-off lever (1) functions to prevent misoperation of the machine from occurring if the control levers are accidentally moved when leaving the operator's seat or when entering the cab. WARNING: Always pull pilot control shut-off lever (1) into the full LOCK position.

  • Page 225: Warming Up Operation

    OPERATING THE MACHINE Warming Up Operation In cold weather, warm up the machine until coolant and hydraulic oil temperature increases to the appropriate operating temperature. Slow Idle IMPORTANT:  The appropriate hydraulic oil operating temperature on this machine is 50 to 80 °C. Hydraulic components may be seriously damaged if the machine is operated with low temperature hydraulic oil.

  • Page 226: Engine Speed Control

    OPERATING THE MACHINE Engine Speed Control Increase and decrease the engine speed using engine control dial (1) located on the switch panel, as illustrated.  Turn engine control dial (1) clockwise to increase the engine speed. Turn engine control dial (1) counterclockwise to decrease the engine speed.

  • Page 227: Auto-Idle

    OPERATING THE MACHINE Auto-Idle Auto-Idle Function With auto-idle selector (3) turned to the A/I ON position, approximately 4 seconds after all control levers are returned to neutral, the engine speed decreases to the auto-idle setting to save fuel consumption. The engine speed will immediately increase to the speed set by engine control dial (2) when any control lever is operated.
  • Page 228 OPERATING THE MACHINE Auto-Idle ON/OFF Note that auto-idle function can be turned ON or OFF by using auto-idle selector (3) only when the key switch is in ON position. Always check if the auto-idle function is turned ON or OFF with auto-idle indicator (1).

  • Page 229: Auto Shut-Down

    Failure to do so may discharge the batteries.  When the key switch is turned to OFF position while the auto shut-down function is ON, the setting will be reset. When it is required to keep the setting, consult your nearest Hitachi dealer.
  • Page 230 OPERATING THE MACHINE IMPORTANT:  Even if the auto shut-down function is ON, the engine will not stop during the regeneration of the muffler filter.  When the auto shut-down activates, the air conditioner will also stop. Setting the Auto Shut-Down Function Auto Shut-Down: On/Off 1.
  • Page 231 OPERATING THE MACHINE 5. Press selector knob (2) to display Auto Shut-Down screen (7). MDCD-01-026 6. Rotate selector knob (2) to highlight ON (8). 7. Press selector knob (2) to display Auto Shut-Down screen (7). Press selector knob (2) again to turn the auto shut- down function OFF.

  • Page 232: Muffler Filter Manual Regeneration

    OPERATING THE MACHINE Muffler Filter Manual Regeneration Manual Regeneration Procedure When the manual regeneration is needed, screen (1) as shown in the right will be displayed. When this screen is displayed, you need to perform the manual regeneration. Before starting the manual regeneration, be sure to check the following.
  • Page 233 OPERATING THE MACHINE 6. When the regeneration is finished, "Regeneration Has Completed." message will be displayed. If "Regeneration Has Failed." message is displayed, start over the regeneration process again. Failure of regeneration process may happen in the conditions other than above (such as malfunction of a sensor that affects regeneration at low ambient temperature).

  • Page 234: Work Mode

    OPERATING THE MACHINE Work Mode Select Work Mode in the main menu, and choose the appropriate hydraulic circuit and pump flow rate for the front attachment at Work Mode screen. When the engine is started, the digging mode is automatically set.
  • Page 235 NOTE: 36 work modes shown above are designated as the standard specifications. Up to 11 attachment modes other than the digging mode can be designated. Consult your nearest Hitachi dealer for adding or changing the designation of the attachment modes. MDAA-01-001EN...
  • Page 236 OPERATING THE MACHINE Attachment Selection 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Work Mode (4). 3. Press selector knob (2) to display Work Mode screen (5). 4.

  • Page 237: Power Boost Switch

    OPERATING THE MACHINE Power Boost Switch Power boost switch (4) is located on the top of the right control lever. When power boost switch (4) is pushed, increased front attachment power will be supplied for about 8 seconds. MDAA-01-292 5-17...

  • Page 238: Power Mode

    OPERATING THE MACHINE Power Mode Two engine speed modes, ECO and PWR modes are selected by operating the power mode switch (1). ECO (Economy) Mode Operate the machine in this mode when performing normal work. ECO is displayed on Power Mode Display (2). PWR (Power) Mode Use PWR (Power) mode when extra horsepower is needed.

  • Page 239: Operating Backhoe

    OPERATING THE MACHINE Operating Backhoe  Use the appropriate arm and bucket for the work. (Refer to the "Bucket Types and Applications" in the Specifications section.)  Pull the bucket toward the machine using the arm as the main digging force. ...

  • Page 240: Shovel

    OPERATING THE MACHINE Shovel WRONG Backhoe operation digs the ground using the bucket in a roll- in motion. On the other hand, face shovel operation digs the ground using the arm cylinder in a scraping motion. WARNING: Take care not to hit the cab when rolling in the arm with the reversed-installed bucket.

  • Page 241: Grading Operation

    OPERATING THE MACHINE Grading Operation Operate the boom, arm, and the bucket in such a way so that the bucket teeth move horizontally, constantly keeping them perpendicular to the ground at the grading operation. IMPORTANT: Do not pull or push dirt with the bucket when traveling.

  • Page 242: Do Not Strike The Ground With Bucket Teeth

    OPERATING THE MACHINE Do Not Strike the Ground with Bucket Teeth WARNING: Forcibly striking the bucket teeth on the ground may result in personal injury by the flying debris. Also, this operation will shorten the service life of each part on the front attachment. If the bucket teeth are forcibly struck on the ground, it shortens the service life of the front attachment parts (especially the bucket).

  • Page 243: Avoid Abusive Operation

    OPERATING THE MACHINE Avoid Abusive Operation Do not use travel and do not raise rear of the machine to use the machine's weight as additional digging force. Severe machine damage may result. WRONG WRONG WRONG M104-05-018 Avoid Side Load the Bucket WRONG Do not side load the bucket.

  • Page 244: Do Not Use Wide Track Shoes On Rough Ground

    OPERATING THE MACHINE Do Not Use Wide Track Shoes on Rough Ground. Never use wide track shoes on rough ground such as rocks, sand or gravel. Wide track shoes are designed for soft ground. Failure to do so may result in shoe bending and/or shoe bolt loosening, and may damage other undercarriage components such as track link and rollers.

  • Page 245: Hydraulic Breaker, Hydraulic Crusher And Quick Coupler

    OPERATING THE MACHINE Hydraulic Breaker, Hydraulic Crusher and Quick Coupler Selecting a Breaker or Crusher Select a breaker, crusher or quick coupler with the correct size and weight for your machine, considering the stability of the machine, hydraulic oil pressure and flow rate of the breaker, crusher or quick coupler.

  • Page 246: Piping For Breaker And Crusher

    OPERATING THE MACHINE Piping for Breaker and Crusher Operational Procedures for Stop Valves and Selection Valve. Close Open Stop Valve A Close: When not using attachment or is detached. M1U1-05-007 Open: When using attachment MAIN BODY BOOM ATTACHMENT ATTACHMENT PEDAL 2nd RELIEF CONTROL VALVE...

  • Page 247: Secondary Relief Pressure Adjustment

    OPERATING THE MACHINE Secondary Relief Pressure Adjustment Depending on the breaker model, the secondary relief valve relief set pressure differs. Consult your nearest Hitachi dealer for installing a breaker. 5-27...

  • Page 248: Precautions For Breaker Operation

    OPERATING THE MACHINE Precautions for Breaker Operation WARNING: Machine stability is reduced as the breaker is much heavier than the bucket. When using a breaker, the machine is more apt to tip over. Also, flying objects may hit the cab or other part of the machine.
  • Page 249 Immediately stop the machine operation. Failure to do so may result in serious failure in the hydraulic system Hose jumping including pumps. abnormally Contact your nearest Hitachi dealer. M104-05-058 Do Not Operate the Breaker in Water. Do not operate the breaker in water.
  • Page 250 OPERATING THE MACHINE Operate the Hydraulic Excavator Carefully to Avoid Hitting the Boom. WRONG When the arm rolled in with the breaker equipped, the chisel may come in contact with the boom. Watch Out! Take care not to hit the boom with the crusher M104-05-062 Do Not Operate Breaker with the Arm Positioned...
  • Page 251 OPERATING THE MACHINE Raising the Front Part of the Undercarriage by Pressing Down the Breaker May Cause Damage to the Front Attachment. Never raise the front edge of the undercarriage higher than 150 mm by pressing the breaker down. Pressing Raising Down 100 to 150 mm...

  • Page 252: Change Hydraulic Oil And Replace Full-Flow Filter Element

    OPERATING THE MACHINE Change Hydraulic Oil and Replace Full-Flow Filter Element Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to quickly deteriorate the hydraulic oil. Failure to adhere to proper maintenance intervals may result in damage to the base machine and the breaker. In order to extend the service life particularly of the hydraulic pump, change the hydraulic oil and the full-flow filter element.

  • Page 253: Precautions For Crusher Operation

    OPERATING THE MACHINE Precautions for Crusher Operation Prevent machine tipping over and damage to the front attachment. Observe the following precautions for crusher operation. WARNING: Machine stability is reduced as a crusher is much heavier than a bucket. When operating with a crusher, the machine is more apt to tip over.
  • Page 254 OPERATING THE MACHINE  When the arm rolled in with the crusher equipped, the WRONG crusher may come in contact with the boom. Watch Out! Take care not to hit the boom with the crusher M1G6-05-009  When operating the crusher up high with the boom fully WRONG raised, be careful of falling objects.
  • Page 255 OPERATING THE MACHINE  Always operate the crusher on a stable, level surface, not on a slope or on crushed scraps.  Do not use the crusher to haul or load crushed scraps.  To prevent the attachment from falling accident, use a platform when replacing the attachment.

  • Page 256: Attachment

    OPERATING THE MACHINE Attachment Allowable Weight Limits of Installed Attachment WARNING  Before installing attachments such as hydraulic  According to the specifications of installed breaker, crusher (concrete crusher), or pulverizer, attachment and the base machine, the take machine controllability into account when machine weight may exceed the allowable maximum operating weight of the ROPS, selecting the weight of the attachment by referring...
  • Page 257 OPERATING THE MACHINE  Breaker operation speed is faster than crusher operation so that the recommended breaker max. weights are reduced more than those of the crushers.  The weight is not the only factor to be considered when selecting a breaker. Select proper manufacturer's breaker models while referring to the table on the next page.
  • Page 258 17.6 17.6 10.8 17.6 14.2 13.7 − Relief Valve (180) (180) (180) (180) (180) (110) (180) (145) (140) (kgf/cm Set Pressure NOTE: Size change of return front piping may needed for some MONTABERT breaker. Consult your nearest Hitachi dealer. 5-38...
  • Page 259 24.5 (250) 20.6 (210) 27.4 (280) 31.4 ( 320) 27.4 (280) Maximum Opening Width Swing Method Free Free Free Free Crusher ZX225US-5B, 225USLC-5B Maker HITACHI Sango Juki NPK* Sakato* Ohsumi* STK* Model HSC100 HSC160 TS850RCD S-22XA SDS250 RC MR1000L MR1100...

  • Page 260: Attachment Connection Parts

    OPERATING THE MACHINE Attachment Connection Parts The attachment hydraulic line and connection parts are located as illustrated below. When the attachment is disconnected, be sure to install caps or plugs to the ends of both the arm and attachment side hydraulic lines to prevent dust from entering or from sticking.
  • Page 261 OPERATING THE MACHINE Part No. List (Fill attachment manufacturer's part Nos. in the blank spaces.) Adapter Size Adapter Plug Hose PF-UNF Form / Size 37 ° Male-Type 37 ° 37 ° ZX135US-5B PF1-1-1/16UN 4456399 4222711 4222264 ZX225US-5B, 225USLC-5B left PF1X1-5/16UN 4214444 4222712 4222265...

  • Page 262: Precaution For Arm Roll-In/Bucket Roll-In Combined Operation

    OPERATING THE MACHINE Precaution for Arm Roll-In/Bucket Roll-In Combined Operation WRONG When Installing an Attachment Longer Than Standard Bucket WARNING: When an attachment (such as a hydraulic breaker, crusher or quick coupler), the overall length of which is longer than that of the bucket, is installed, the Watch Out! Take care not to hit the attachment may come in contact with the cab and/or...

  • Page 263: Pilot Accumulator Functions

    OPERATING THE MACHINE Pilot Accumulator Functions The pilot accumulator (1) is a pressure storage reservoir of the control circuit which supplies pressure and enables to operate the control circuit even after stopping the engine. Thus, the front attachment can be lowered with its own weight by using the control lever and pressure in the hydraulic circuit can be released after stopping the engine.

  • Page 264: How To Lower Boom In Case Of Emergency And When Engine Stops

    OPERATING THE MACHINE How to Lower Boom in Case of Emergency and When Engine Stops (Without hose-rupture safety valve) WARNING: Prevent personal injury. Confirm that no one is under the front attachment before starting the procedure below. In case the engine suddenly stops and the engine cannot restart, lower the boom in the following procedures.

  • Page 265: Precautions For After Operations

    OPERATING THE MACHINE Precautions for After Operations  After finishing the day's operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods is present. (Refer to the group for "PARKING MACHINE" in the DRIVING MACHINE section.) ...
  • Page 266 OPERATING THE MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 267: Transporting

    TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations.  When transporting the machine using a trailer, check the width, height, length and weight of the trailer with the machine loaded.

  • Page 268: Loading/Unloading On A Trailer

    TRANSPORTING Loading/Unloading on a Trailer Always load and unload the machine on a firm, level surface. WARNING: Be sure to use a loading dock or a ramp for loading/unloading. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp.
  • Page 269 TRANSPORTING Loading/Unloading WARNING:  Always turn the auto-idle switch OFF when loading or unloading the machine. In the auto-idle mode, speed may automatically increase.  Always select the slow speed mode with the travel mode switch.  Never steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turnover.
  • Page 270 TRANSPORTING 3. When the front attachment is fitted 3.1 Determine a position for the bucket in line with the trailer. Adjust the angle of the boom and the arm at 90 to 110 °. 3.2 Lower the bucket onto to the deck of the trailer before the unit passes over the end of the ramp for support.

  • Page 271: Fastening Machine For Transporting

    TRANSPORTING Fastening Machine for Transporting WARNING: Fasten the machine frame to the deck securely with chains and cables. While traveling, loads may shake around, move forward or backward or to the sides. 1. Place cog stoppers or blocks in front of and behind the tracks to help secure the unit.
  • Page 272 TRANSPORTING 2. The bucket must be on the ground before the machine begins to tip forward. 3. As the machine moves forward, raise the boom and extend the arm until the machine is completely off the ramp. M107-06-015...

  • Page 273: Lifting Machine

     Use lifting cables and other lifting tools being free from any damage and/or aging, and having sufficient strength.  Consult your nearest Hitachi dealer for correct lifting procedures, and the size and types of lifting cable and tools.  Pull the pilot control shut-off lever to the LOCK position so that the machine does not accidentally move while being lifted.
  • Page 274 TRANSPORTING Lifting 1. Fully extend the arm and bucket cylinders. Lower Support Bar the boom until the bucket comes in contact with the ground. 2. Pull the pilot control shut-off lever to the LOCK position. Center of Gravity 3. Stop the engine. Remove the key from the key switch. 4.

  • Page 275: Maintenance

    IMPORTANT:  Use only recommended fuel and lubricants.  Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown.  Failure to use recommended fuel, lubricants, and genuine Hitachi parts will result in loss of Hitachi product warranty.
  • Page 276  Inquire on the proper way to recycle or dispose of oil, fuel, coolant, filters, batteries and other waste from your local environmental or recycling center, or from your authorized dealer.  Hitachi machine models described in this manual are classified as shown in the table below. Model ZX135US-5B Std.

  • Page 277: Check The Hour Meter Regularly

    MAINTENANCE Check the Hour Meter Regularly Refer to the List of Check and Maintenance for information about lubricants, check and adjustment intervals. The maintenance guide table is affixed in the back of the tool box cover. Refer to the next page. This manual recommends grouping the intervals into three categories as follows: Daily Check...
  • Page 278 MAINTENANCE Maintenance Guide Table The maintenance guide table is affixed to the reverse side of the tool box cover. Lubricate and/or service the parts at the intervals as instructed in the table so that all necessary maintenance can be performed regularly. ...
  • Page 279 MAINTENANCE  Maintenance Guide Table Lubrication Interval (hours) MDAA-07-049 Item Page Item Page 1 Engine Oil 7-25 10 Hydraulic Oil Filter (Pilot) 7-44 2 Coolant (Long-Life Coolant) 7-69 11 Hydraulic Oil Filter (Air Breather) 7-45 3 Grease 7-21 12 Engine Oil Filter 7-25 4 Grease (Every 500 hours.

  • Page 280: Preparations For Inspection And Maintenance

    MAINTENANCE Preparations for Inspection and Maintenance Except in special cases, park the machine by following the procedure before servicing the machine. 1. Park the machine on a level surface. 2. Lower the bucket to the ground. M104-07-021 3. Turn the auto-idle switch OFF. 4.

  • Page 281: Hood And Access Covers

    MAINTENANCE Hood and Access Covers ZX135US-5B WARNING:  Do not keep the hood and access covers open when the machine is parked on a slope, or while the wind is blowing hard. The hood or access covers may close accidentally, possibly resulting in personal injury. ...
  • Page 282 MAINTENANCE ZX225US-5B, 225USLC-5B WARNING:  Do not keep the hood and access covers open when the machine is parked on a slope, or while the wind is blowing hard. The hood or access covers may close accidentally, possibly resulting in personal injury. ...

  • Page 283: Daily Check

    MAINTENANCE Daily Check Arm Cylinder Boom Center Joint Tools (ZX135US-5B) Swing Bearing Control Valve Swing Reduction Gear Bucket Cylinder Hydraulic Oil Tank Fuel Tank Work Light Engine Muffler Filter Link B Boom Cylinder Pump Link A Pilot Filter Engine Oil Filter Bucket Counterweight Side Cutter...

  • Page 284: Maintenance Guide

     When a bucket which does not have clearance adjustment mechanism such as slope-finishing bucket or V-type bucket, or a genuine Hitachi hoe bucket before EX-5 model, or an attachment other than genuine Hitachi bucket is used, grease two pins every 250 hours.
  • Page 285 MAINTENANCE C. Transmission Interval (hours) Parts Quantity Page 100 250 500 1000 2000 Check Oil Level 7-28 Pump Change ZX225US-5B, 225USLC-5B 1.6 L 7-28 Transmission Air Breather Cleaning 7-28 Check Oil Level 7-29 Swing Reduction ZX135US-5B 3.2 L Gear Change 7-29 ZX225US-5B, 225USLC-5B 6.2 L...
  • Page 286 MAINTENANCE E. Fuel System Interval (hours) Parts Quantity Page 500 1000 2000 1. Drain Fuel Tank Sump 7-52 2. Drain Fuel Filter 7-53 3. Replace Fuel Main Filter Element 7-57 4. Replace Fuel Pre-Filter Element 7-59 5. Clean Solenoid Fuel Pump Strainer 7-61 Drain water 7-63...
  • Page 287 IMPORTANT:  Use soft water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %. If a coolant mixed with less than 30 % of Hitachi Long-Life Coolant is used, service life of the cooling parts may be shortened due to damage by freezing or corrosion of coolant system parts.
  • Page 288 7-108  Bolts : Maintenance required only during first time check. NOTE: * Contact your nearest Hitachi dealer for maintenance. Instruction plate for the recommended grease and lubricants is affixed inside the tool box cover. J. Muffler Filter Interval (hours)

  • Page 289: Periodic Replacement Of Parts

    MAINTENANCE Periodic Replacement of Parts To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. These parts may cause serious safety/fire hazards due to deterioration, wear, or fatigue being attributed to material aging or repeated operation.

  • Page 290: Kind Of Oils

    Please be noted that all engine failures caused by using engine oil other than specified are excluded from Hitachi Warranty Policy. Consult your nearest Hitachi dealer for the unclear points. Kind of Oil Engine Oil Application Engine Crank Case -20 to 40 ˚C...
  • Page 291 Others Product Conforming to JCMAS HK VG46W NOTE: Consult the nearest Hitachi dealer for the conditions of use and hydraulic oil other than those described above. Refer to Japan Lubricating Oil Society (JALOS) home page for JCMAS HK qualified product.
  • Page 292 Super Wide DH-2 10W40 Super Wide DH-2 15W40 Pump Transmission Engine Oil API CD Class Swing Device Gear Oil Hitachi Gear Oil GL-4_90 Travel Device Hydraulic System Hydraulic Oil Super EX46HN (Hydraulic Oil Tank) EN590 Class A EN590 Class B...

  • Page 293: Greasing

    MAINTENANCE A. Greasing Front Joint Pins --- 500 hours Lubricate all fittings shown in the figure. M178-07-007  Boom Cylinder Bottom Side M157-07-156  Boom Foot M178-07-082 7-19...
  • Page 294 MAINTENANCE  Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket Cylinder Bottom Pin. M157-07-157  Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin. M178-07-082 7-20...

  • Page 295: Swing Bearing

    MAINTENANCE Swing Bearing --- every 500 hours CAUTION: Lubricating both the swing bearing and gear and rotating the upperstructure must be done by one person. Before you lubricate the swing bearing, clear the area of all persons. Each time you leave the cab ...

  • Page 296: Swing Internal Gear

    MAINTENANCE Swing Internal Gear --- every 500 hours CAUTION: Before lubricating the machine, lower the bucket on the ground, stop the engine and pull the pilot control shut-off lever to the LOCK position. 1. Remove cover (1) from upperstructure. Check if the swing gear is properly lubricated by grease.

  • Page 297: Engine

    MAINTENANCE B. Engine Engine Oil Level --- check daily 1. Confirm that pilot control shut-off lever (1) is in the LOCK position. 2. Confirm that all control levers are placed in neutral. 3. Insert key switch (2). Turn it to ON position. Press and hold switch (3) with the engine stopped.
  • Page 298 MAINTENANCE --- Visual Inspection IMPORTANT: An incorrect engine oil level may cause trouble on the engine (The oil level should be between the upper and lower marks on dipstick (1)). Even if the engine oil level exceeds the upper limit, control the oil level to the proper quantity before starting the engine.

  • Page 299: Change Engine Oil

    MAINTENANCE Change Engine Oil --- every 500 hours Replace Engine Oil Filter --- every 500 hours 1. Run the engine to warm oil. DO NOT run the engine until oil is hot. 2. Park the machine on a level surface. 3.
  • Page 300 MAINTENANCE IMPORTANT: Install drainer (5) to drain valve (3) slowly. Oil may exhaust in large quantities when suddenly tightened. 8. Remove oil filler cap (2). 9. Remove cap (4) from oil pan drain valve (3). Install drainer (5) to drain valve (3). 10.

  • Page 301: Check And Clean Around The Engine

    MAINTENANCE 14. Open the right access cover and secure the cover with rod. 15. Remove the filter cartridges of engine oil filter (6) by turning it counterclockwise with the filter wrench. 16. Clean the filter gasket contact area on the engine. 17.

  • Page 302: Transmission

    MAINTENANCE C. Transmission Pump Transmission (Except ZX135US-5B) Check Oil Level --- every 250 hours 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

  • Page 303: Swing Reduction Gear

    MAINTENANCE Swing Reduction Gear Check Oil Level --- every 500 hours 1. Park the machine on a solid level surface. Lower the bucket to the ground. Stop the engine. ZX135US-5B 2. Turn over the level gauge rubber cover. Check level gauge (1).

  • Page 304: Travel Reduction Gear

    MAINTENANCE Travel Reduction Gear Air Release Plug 1 Check Oil Level --- every 500 hours (Oil Supply Plug) 1. Park the machine on a level surface. Oil Level Check Plug 2 2. Rotate the travel motor until the imaginary line through Horizontal Oil Level plug (1) and plug (3) is vertical.
  • Page 305 MAINTENANCE Change Gear Oil --- every 2000 hours 1. Park the machine on a level surface. 2. Rotate the travel motor until the imaginary line through plug (1) and plug (3) is vertical. 3. Lower the bucket to the ground. 4.

  • Page 306: Hydraulic System

    MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment IMPORTANT: Never adjust parts of engine fuel system or hydraulic equipment. CAUTION: When checking and/or servicing the hydraulic components, pay special attention to the following points. 1. Be sure that the machine is parked on a level, firm surface before servicing hydraulic equipment.
  • Page 307 MAINTENANCE IMPORTANT:  When connecting hydraulic hoses and pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them.  Wash hoses, pipes, and the tank interior with a washing liquid and thoroughly wipe it out before reconnecting them.
  • Page 308 MAINTENANCE Change Hydraulic Oil and Replace Full-Flow Filter Element Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to quickly deteriorate the hydraulic oil. Failure to adhere to proper maintenance intervals may result in damage to the base machine and the breaker. In order to extend the service life particularly of the hydraulic pump, change the hydraulic oil and the full-flow filter element at the specified frequency given below.
  • Page 309 MAINTENANCE Changing intervals for the standard filter paper Breaker Operating 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 % Availability Full-Flow Filter 1000 Hydraulic oil: 2000 hours 2000 1310 life time Hydraulic oil: 5000 hours 5000...

  • Page 310: Check Hydraulic Oil Level

    MAINTENANCE Check Hydraulic Oil Level --- daily IMPORTANT: Never run the engine without oil in hydraulic oil tank. 1. Park the machine on a level surface. M104-07-021 2. Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended. 3.

  • Page 311: Change Hydraulic Oil

    MAINTENANCE Change Hydraulic Oil CAUTION: Hydraulic oil may be hot just after operation. Wait for oil to cool before starting work. IMPORTANT: Hydraulic oil changing intervals differ M104-07-117 according to kind of hydraulic oils used. (See Recommended Oil Chart in this group) 1.
  • Page 312 MAINTENANCE 12. Remove drain plug (3). Allow oil to drain. 13. Clean, install and tighten drain plug (3). 14. Add oil until it is between the marks on the oil level gauge. 15. Install cover (2). Tighten the bolts to 50 N·m (5 kgf·m). 16.

  • Page 313: Air Bleeding Procedures

    MAINTENANCE Air Bleeding Procedures IMPORTANT: If the hydraulic pump is not filled with oil, it will be damaged when the engine is started. The machine is equipped with two main pumps. Bleed air from these pumps after changing hydraulic oil. 1.

  • Page 314: Suction Filter Cleaning

    MAINTENANCE Suction Filter Cleaning ---each time when hydraulic oil is changed The suction filter is located on the bottom of the hydraulic oil tank. Clean the suction filter when changing hydraulic oil. 1. After removing hydraulic oil from the hydraulic oil tank, remove cover (1) and rod assembly (2).

  • Page 315: Replacement Of Full-Flow Filter

    MAINTENANCE Replacement of Full-Flow Filter --- every 1000 hours Std. Model CAUTION: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil M104-07-021 immediately after operation. Wait for the oil to cool before starting any maintenance work.
  • Page 316 MAINTENANCE Replacement of Full-Flow Filter --- every 300 hours Demolition and logging work When the hydraulic oil filter alarm on the monitor panel is lit, immediately replace the filter element. M104-07-021 CAUTION: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation.
  • Page 317 MAINTENANCE Procedures: 1. Park the machine on solid and level ground with the bucket cylinder fully extended and the arm cylinder fully retracted. Lower the bucket on the ground as shown to the right. Stop the engine. 2. Before replacing element (5), be sure to bleed air pressure from the hydraulic oil tank by pressing the air bleed valve on the hydraulic oil tank.

  • Page 318: Replace Pilot Oil Filter

    MAINTENANCE Replace Pilot Oil Filter --- every 1000 hours 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. M104-07-021 IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. 4.

  • Page 319: Replace Air Breather Element

    MAINTENANCE Replace Air Breather Element --- every 5000 hours CAUTION: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

  • Page 320: Check Hoses And Lines

    MAINTENANCE Check Hoses and Lines ---daily --- every 250 hours WARNING:  Hydraulic oil and lubricant leaks can lead to fire that may result in serious injury. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damaged oil cooler, and loose oil cooler flange bolts, for leaks.
  • Page 321 MAINTENANCE Interval (hours) Check Points Abnormalities Remedies Every 250 Hose covers Damage or leak (4) Replace hours Hose ends Damage or leak (5) Replace Hose covers Exposed reinforcement (6) Replace M115-07-146 Hose covers Crack or blister (7) Replace M115-07-147 Hose Bend (8), Collapse (9) Replace Hose ends...
  • Page 322 MAINTENANCE Service Recommendations for Hydraulic Fittings Two hydraulic fitting designs are used on this machine.  Flat Face O-ring Seal Fitting (ORS Fitting) O-ring (1) is used on the sealing surfaces of adapter (2) to prevent oil leakage. Precautions for Use 1.
  • Page 323 MAINTENANCE  Metal Face Seal Fittings Tight contact between metal flares on adaptor (7) and metal connector (8) of hose (5) prevents pressure oil leakage. This type of fittings is used on smaller diameter joint. Precautions for Use Connect or disconnect fittings with care not to damage seat surfaces (9 and 10).

  • Page 324: Fuel System

    MAINTENANCE E. Fuel System CAUTION: Beware of fire. Fuel is flammable. Keep fuel away from fire hazards. Recommended Fuel Use only super high quality or high quality DIESEL FUEL (JIS K-2204) (ASTM D-975) (EN-590). Kerosene must NOT be used. Besides, using bad quality fuel, drainage agent, fuel additives, gasoline, kerosene or alcohol refueled or mixed with specified fuel may deteriorate performance of fuel filters and cause sliding problem at lubricated contacts...

  • Page 325: Refueling

    MAINTENANCE Refueling 1. Park the machine on a level surface. Lower the bucket to the ground. Check the fuel level with fuel gauge (1). If the fuel level is low, stop the engine. Refuel by removing cap (2) on the fuel tank. 2.

  • Page 326: Drain Fuel Tank Sump

    MAINTENANCE Drain Fuel Tank Sump --- daily 1. Park the machine on a level surface with the upperstructure rotated 90 ° for easier access. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. M104-07-117 IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

  • Page 327: Drain Fuel Filter

    MAINTENANCE Drain Fuel Filter --- daily Main Filter IMPORTANT: Drain fuel filter daily before starting operation. The engine may be damaged if you do not drain fuel filter daily. Fuel main filter and pre-filter have water separator functions, Pre-Filter these allow float to rise as water accumulates. Be sure to drain daily the water accumulated in the filter until float (4) goes to the bottom of case.
  • Page 328 MAINTENANCE Draining Procedures (Pre Filter) 1. Place a container with a capacity of 0.5 liters or larger under drain hose (6) to collect the drained water. Main Filter 2. Rotate drain plug (5) on the bottom of the filter counterclockwise. Drain the water accumulated in the filter until float (8) goes to the bottom of case.
  • Page 329 MAINTENANCE Bleed Air from the Fuel System Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the fuel filter, replacing the fuel filter, cleaning the solenoid fuel pump strainer or running the fuel tank dry, be sure to bleed the air from the fuel system.
  • Page 330 MAINTENANCE Air Bleeding by Priming Pump In case air is not bled due to malfunction of the solenoid fuel pump, operating the priming pump only can bleed air. 1. Check that fuel cock (1) on the bottom of the fuel tank is opened.

  • Page 331: Replace Fuel Main Filter Element

    --- every 1000 hours or when fuel filter clogging lamp is lit Main Filter IMPORTANT:  Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine Pre-Filter performance and/or shorten the engine service life.
  • Page 332 MAINTENANCE 2. Place a container with a capacity of 1 liters or larger under drain hose (3) to collect the drained water. 3. Loosen air bleed plug (1) and drain plug (2). Drain fuel until fuel does not flow out of the filter. After draining fuel, remove drain plug (2) and replace O-ring.

  • Page 333: Replace Fuel Pre-Filter Element

    ---every 1000 hours or when fuel filter clogging lamp is lit Main Filter IMPORTANT:  Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine Pre-Filter performance and/or shorten the engine service life.
  • Page 334 MAINTENANCE 2. Place a container with a capacity of 1 liters or larger under drain hose (3) to collect the drained water. Pre-Filter 3. Loosen air bleed plug (1) and drain plug (2). Drain fuel until fuel does not flow out of the filter. After draining fuel, remove drain plug (2) and replace O-ring.

  • Page 335: Clean Solenoid Fuel Pump Strainer

    MAINTENANCE Clean Solenoid Fuel Pump Strainer --- every 1000 hours Solenoid Fuel Pump Cleaning When the strainer is disassembled, be sure to replace the gasket. Install the cover and the magnet only after sufficiently cleaning them. After being assembled, closely check the air-tightness of the strainer.
  • Page 336 MAINTENANCE Disassembling/ Assembling Close the cock on the bottom of the fuel tank. To remove cover (1), loosen with a spanner. After cover (1) is removed, gasket (2), strainer (3), and gasket (4) are easily removed in order. Wash removed strainer (3) with light oil. Install the strainer in the reverse order of disassembling.

  • Page 337: Check Water Separator

    MAINTENANCE Check Water Separator Drain water --- daily Replace Element --- every 2000 hours Water separator (2) is a device designed to separate water from the fuel. There is a float inside the case which buoys when water accumulates. When the float rises to the water draining level, drain water. Drain Procedures 1.
  • Page 338 MAINTENANCE Element replacement procedure 1. Close cock (1) on the bottom of the fuel tank. 2. Place a container with a capacity of 1 liters or larger under drain hose (5) to collect the drained water. MDAA-07-007 3. Loosen air bleed plug (2) and drain plug (4). Drain fuel until fuel does not flow out of the filter.

  • Page 339: Check Fuel Hoses

    MAINTENANCE Check Fuel Hoses ---daily --- every 250 hours CAUTION: Fuel leaks can lead to fires that may result in serious injury.  Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that rub against each other, and any fuel leaks.

  • Page 340: Air Cleaner

    MAINTENANCE F. Air Cleaner Clean and Replace Air Cleaner Element (Outer) Clean --- every 250 hours or when the restriction indicator comes ON Replace --- after cleaning 6 times or after one year CAUTION: When using compressed air pressure (less than 0.69 MPa (7 kgf/cm )), dust may scatter.
  • Page 341 MAINTENANCE 3. At this time, do not remove the inner element. IMPORTANT: Do not hit or clash outer element (1) against other object to clean the element. 4. Allow compressed air pressure [less than 0.69 MPa (7 kgf/cm )] to blow out of the inside of outer element (1) to clean the element.
  • Page 342 MAINTENANCE Replace Air Cleaner Element (Inner) Air Cleaner Restriction Alarm Switch Replace --- When outer element is replaced IMPORTANT: Do not clean and reuse the inner element. Cover 1. After removing outer element (1). Clean inside the air cleaner body (2) with clean cloth before removing inner element (3).

  • Page 343: Cooling System

    Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %. If a coolant mixed with less than 30 % of Hitachi Long-Life Coolant is used, service life of the cooling parts may be shortened due to damage by freezing or corrosion of coolant system parts.

  • Page 344: Check Coolant Level

    MAINTENANCE Check Coolant Level --- daily When the engine is cold, the coolant level must be between the FULL and LOW marks on coolant reservoir (2). If the coolant level is below the low mark, add coolant to coolant reservoir (2). CAUTION: Do not remove cap (1) until the coolant temperature in the radiator becomes cool.

  • Page 345: Check And Adjust Fan Belt Tension

    MAINTENANCE Check and Adjust Fan Belt Tension (ZX135US-5B) 7 to 8 mm 98 N (10 kgf) --- every 250 hours (50 hours at first time only) Fan Pulley IMPORTANT: Loose fan belt may result in insufficient Alternator Pulley battery charging, engine overheating, as well as a rapid, abnormal belt wear.
  • Page 346 MAINTENANCE Check and Adjust Fan Belt Tension 5 to 6 mm (ZX225US-5B, 225USLC-5B) 98 N (10 kgf) Fan Pulley --- every 250 hours (first time after 50 hours) IMPORTANT: Loose fan belt may result in insufficient Alternator Pulley battery charging, engine overheating, as well as premature belt wear.

  • Page 347: Change Coolant

    MAINTENANCE Change Coolant --- twice a year (in spring and autumn) NOTE: When genuine Hitachi Long-Life Coolant is used, change interval is once every two years (in autumn every other year) or every 4000 hours whichever comes first. CAUTION: Do not loosen the radiator cap until the system has cooled.
  • Page 348 MAINTENANCE 5. Close drain cock (1). Fill the radiator with tap water and LLC at the specified mixing ratio. When adding coolant, do so slowly to avoid mixing air bubbles in the system. Run the engine to sufficiently bleed air from the cooling system.

  • Page 349: Clean Radiator/Oil Cooler/Inter Cooler Core

    MAINTENANCE Clean Radiator/Oil Cooler/Inter Cooler Core Outside --- every 500 hours Inter Cooler Inside --- once a year CAUTION: Use reduced compressed air pressure (Less than 0.2 MPa, 2 kgf/cm ) for cleaning purposes. Wear personal protection equipment including eye protection.
  • Page 350 MAINTENANCE WARNING:  Entanglement in moving parts can cause serious injury.  Before servicing, stop the engine and the fan to prevent any accident.  Never attempt to start the engine when the cover is open.  In case tools or parts are dropped into the radiator/ oil cooler/inter cooler core, remove them before starting the engine.

  • Page 351: Clean Oil Cooler, Radiator And Inter Cooler Front Screen

    MAINTENANCE Clean Oil Cooler, Radiator and Inter Cooler Front Screen --- every 500 hours IMPORTANT: Check the screen daily and replace it if necessary when the machine is operated in dusty areas. Pull the clip lever on the screen to remove the screen. Insert the clip into the cover hole and turn over the clip lever MDCN-07-049 to hold the screen.

  • Page 352: Electrical System

    MAINTENANCE H. Electrical System IMPORTANT:  Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment affects the machine's electronic parts, causing involuntary movement of the machine.  Also, improper installation of electrical equipment may cause machine failure and/or a fire on the machine.

  • Page 353: Battery

    MAINTENANCE Battery WARNING:  Battery gas can explode. Keep sparks and flames away from batteries.  Do not leave cover (1) removed. Do not keep tools, metals or flammable materials around the battery or inside the battery room. If a metal tool is placed across the battery terminal and a vehicle component such as the engine block, sparks may be created, SA-032...
  • Page 354 MAINTENANCE Precautions for Handling Batteries  If electrolyte spills on your skin and/or clothes, immediately flush the skin and/or clothes with water and then wash further with soap. If splashed in eyes, flush with water for approximately 15 minutes and seek immediate medical attention. ...
  • Page 355 MAINTENANCE Electrolyte Level Check --- every one month Check the electrolyte level at least once a month. 1. Park the machine on level ground and stop the engine. 2. Check the electrolyte level. 2.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.

  • Page 356: Replace Battery

    MAINTENANCE 3. Always keep around the battery terminals clean to prevent battery discharge. Check terminals for loose and/or rust. Coat terminals with grease or petroleum jelly to prevent corrosion build up. M409-07-072 Replace Battery IMPORTANT: Turn the battery disconnect switch to OFF before replacing the battery.
  • Page 357 MAINTENANCE Check electrolyte specific gravity --- every one month The electrolyte specific gravity varies depending on the electrolyte temperature. The specific gravity should be kept within the range shown below. Charge the battery if the specific gravity is below the limit. Recommended range of specific gravity by electrolyte temperature 40 °...

  • Page 358: Replacing Fuses

    MAINTENANCE Replacing Fuses --- as necessary If any electrical part or component ceases to function, check its fuse first. The fuse box is located behind the operator’s seat. NOTE:  One spare fuse for each capacity is provided in the fuse box. ...
  • Page 359 MAINTENANCE  Fusible Link (Main Fuse) In case the starter won't rotate even if the key switch is turned to the START position, fusible link may be the cause of the trouble. Remove the cover next to the engine coolant reservoir to check the fuse.

  • Page 360: Miscellaneous

    MAINTENANCE I. Miscellaneous Check and Replace Bucket Teeth --- daily Check bucket teeth (1) for wear and looseness. Replace teeth (1) if tooth wear exceeds the designated service limit shown below. A (mm) Model Limit of Use ZX135US-5B M104-07-056 ZX225US-5B, 225USLC-5B Replace CAUTION: ...
  • Page 361 MAINTENANCE 3. Clean shank (6) surface. 4. Install rubber pin lock (4) into shank (6) hole as shown. RIGHT WRONG M104-07-060 5. Position new tooth (1) over shank (6). RIGHT WRONG M104-07-061 6. Drive locking pin (5) fully into the hole as shown. RIGHT WRONG M104-07-062...
  • Page 362 MAINTENANCE Check Bucket Teeth for Super V Type Bucket Teeth (ZX225US-5B, 225USLC-5B) --- daily Check bucket teeth (1) for wear and looseness. When tooth points (1) wear beyond the service limit, replace them. Parts No. Limit of Use 0.8 m Reinforced Hoe Bucket with 4400250...
  • Page 363 MAINTENANCE 2. Driving out locking pin Remove pebbles, dirt, etc., completely from the gap between lock pin (3) and adapter (2). Place pin-removing jig on the top end of lock pin (3) and hit it with hammer to remove lock pin (3). When driving out the pin, first hit with a shorter jig until top end of lock pin (3) comes to the upper end position of the lug of tooth point (1), and then use the longer jig...
  • Page 364 MAINTENANCE 3. Removing the tooth point Turn tooth point (1) to the left, twist and pull it toward you to remove it. IMPORTANT: Check if lock pin (3) has cracks. If it has, replace the rubber with new one. While the pin and plug can withstand several replacements of the tooth point, be sure to check whether they are usable or not when replacing tooth point (1).
  • Page 365 MAINTENANCE Other Precautions 1. Since rubber is susceptible to corrosion, do not use grease, oil and other oily materials when inserting the lock pin. 2. In mounting welding-type nose and the adapter onto the bucket, lock pin (3) should be removed from the nose when preheating and welding.

  • Page 366: Change Bucket

    MAINTENANCE Change Bucket CAUTION: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris. Wear goggles or safety glasses, hard hat and face shield. Before starting converting work, keep bystanders clear of the machine.

  • Page 367: Convert Bucket Connection Into Face Shovel

    MAINTENANCE Convert Bucket Connection Into Face Shovel O-Ring Shift CAUTION: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris. Wear goggles or safety glasses, hard hat and face shield. Converting the bucket connection allows you to use the Bucket Boss machine as a face shovel.

  • Page 368: Adjust Bucket Linkage

    MAINTENANCE Adjust Bucket Linkage The machine is provided with a bucket adjustment system to take up play in the linkage. When play in the linkage increases, remove and install shims as follows: 1. Place the bucket in a stable position. Clearance Adjust Part 2.

  • Page 369: Remove Travel Levers

    MAINTENANCE Remove Travel Levers The travel levers may be removed if desired. Procedure: Remove bolts (1) and (2) to remove travel levers (3) and (4) from brackets. NOTE: Wrench size: 17 mm Tightening Torque: 50 N·m (5 kgf·m) M178-07-077 Check and Replace Seat Belt Check --- daily Replace --- every 3 years Prior to operating the machine, thoroughly examine belt (5),...

  • Page 370: Check Windshield Fluid Level

    MAINTENANCE Check Windshield Fluid Level Check fluid in windshield washer tank (1). If the fluid level is low, remove cap (2) and add fluid via the opening. MDCN-07-009 ZX135US-5B MDCN-07-056 ZX225US-5B, 225USLC-5B 7-96...

  • Page 371: Check Track Sag

    MAINTENANCE Check Track Sag --- every 50 hours Swing the upperstructure 90 ° and lower the bucket to raise the track off the ground as shown. Measure distance (A) at the middle of the track frame from the bottom of the track frame to the back face of the track shoe.
  • Page 372 MAINTENANCE Loosen the Track (ZX135US-5B) CAUTION: The pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or loosen it too much as valve (1) may fly out or high- pressure grease in the adjusting cylinder may spout out.
  • Page 373 MAINTENANCE Loosen the Track (ZX225US-5B, 225USLC-5B) CAUTION: The pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or loosen it too much as valve (1) may fly out or high- pressure grease in the adjusting cylinder may spout out.
  • Page 374 MAINTENANCE Tighten the Track CAUTION: It is abnormal if the track can not be adjusted. The strong force acts on the spring in track adjuster. Therefore, the grease in the cylinder is highly pressurized. In such cases, NEVER ATTEMPT TO DISASSEMBLE the track or track adjuster, because of dangerous high-pressure grease inside the track adjuster.

  • Page 375: Clean And Replace Air Conditioner Filter

    MAINTENANCE Clean and Replace Air Conditioner Filter Clean Circulating/Fresh Air Filters Circulating Air Filter --- every 500 hours Fresh Air Filter --- every 500 hours Replace Circulating/Fresh Air Filters Circulating Air Filter --- After cleaning 6 times or so Fresh Air Filter --- After cleaning 6 times or so MDCN-07-009 ZX135US-5B Removing Fresh Air Filter...
  • Page 376 MAINTENANCE Removing Circulating Air Filter (Outside) 1. Circulating air filter (outside) (1) is located beside the seat stand. 2. Remove screws (2). Remove circulating air filter (outside) cover (3) by pulling it toward the cab front. 3. Remove screws (4). Remove circulating air filter (outside) (1) by sliding it to the arrow direction.
  • Page 377 MAINTENANCE WARNING: When using compressed air pressure, wear safety glasses or goggles. Cleaning Arrow-mark Clean the circulating and fresh air filters. Clean both the external and internal filters by blowing compressed air or washing with water. Washing procedure with water is as follows: 1.

  • Page 378: Check Air Conditioner

    MAINTENANCE Check Air Conditioner Oil Seepage Check pipe connections for refrigerant gas leakage If oil seepage is found around pipe connections, it indicates possible gas leakage. Detail Check Refrigerant Start the engine and run at approximately 1500 min (rpm). −1 M1CD-07-038 Turn the air conditioner switch to ON.
  • Page 379 MAINTENANCE Inspect belt, check and adjust tension Tension Pulley Compressor Pulley --- every 250 hours Fan Pulley Visually check the compressor and fan belts for wear. Check fan belt tension by depressing the midpoint of the belt with the thumb. Deflection must be shown in the right figure with a depressing force of approximately 98 N (10 14.6 to 16.4 mm kgf ).

  • Page 380: Clean Cab Floor

    MAINTENANCE Clean Cab Floor --- as required IMPORTANT: When cleaning the cab floor with tap water, spray the floor only. Take care not to splash the surrounding area. Do not increase water spray speed by restricting the hose end, and do not use high pressure steam for cleaning.

  • Page 381: Retighten Cylinder Head Bolt

    MAINTENANCE Retighten Cylinder Head Bolt --- as required See your authorized dealer. Inspect and Adjust Valve Clearance --- every 1000 hours See your authorized dealer. Measure Engine Compression Pressure --- every 1000 hours See your authorized dealer. Check Starter and Alternator --- every 1000 hours See your authorized dealer.

  • Page 382: Check Gas Damper

    MAINTENANCE Check and Clean Injector --- every 4500 hours See your authorized dealer. Check Gas Damper --- as required CAUTION: The gas damper has been charged with high-pressure nitrogen gas. Inappropriate handling may cause explosion, possibly resulting in serious injury or death. The gas dampers are used in the tool box cover and the cab overhead window.
  • Page 383 MAINTENANCE ZX135US-5B Torque Wrench Descriptions Bolt Dia Q'ty size N·m (kgf·m) Engine cushion rubber mounting bolt and nut (24) Engine bracket mounting bolt (Pump side) (11) Hydraulic oil tank mounting bolt (27) Fuel tank mounting bolt (27) Radiator mounting bolt (Upper side) Radiator mounting bolt (Lower side) Pump transmission mounting bolt (6.5)
  • Page 384 MAINTENANCE ZX225US-5B, 225USLC-5B Torque Wrench Descriptions Bolt Dia Q'ty size N·m (kgf·m) Engine cushion rubber mounting bolt and nut (55) Engine bracket mounting bolt (Pump side) (27) Engine bracket mounting bolt (Fan side) (6.5) Hydraulic oil tank mounting bolt (27) Fuel tank mounting bolt (27) Radiator mounting bolt (Right side, Left side)
  • Page 385 MAINTENANCE Tightening Torque Chart Hexagon Wrench Socket Bolt Bolt Dia. Socket Bolt Wrench size Wrench size N·m (kgf·m) N·m (kgf·m) N·m (kgf·m) N·m (kgf·m) (0.3 to 3.3 to 4.2 0.4) (3.0) (2.0) (1.0) (2.0) (6.5) (5.0) (2.0) (5.0) (11) (3.5) (18) (14) (5.5)
  • Page 386 MAINTENANCE 1. Engine cushion rubber mounting bolt and nut Pump Side M1U1-07-040 M1U4-07-046 ZX135US-5B ZX225US-5B, 225USLC-5B Fan Side M1U1-07-034 ZX225US-5B, 225USLC-5B 2. Engine bracket mounting bolt Pump Side M1U1-07-040 ZX135US-5B, 225US-5B, 225USLC-5B Fan Side M1U1-07-034 ZX225US-5B, 225USLC-5B 7-112...
  • Page 387 MAINTENANCE 3. Hydraulic oil tank mounting bolt ZX135US-5B MDCN-07-064 MDCN-07-065 ZX225US-5B, 225USLC-5B 4. Fuel tank mounting bolt MDCN-07-064 ZX135US-5B MDCN-07-065 ZX225US-5B, 225USLC-5B 7-113...
  • Page 388 MAINTENANCE 5. Radiator mounting bolt MDCN-07-066 ZX135US-5B MDCN-07-067 ZX225US-5B, 225USLC-5B 6. Pump transmission mounting bolt ZX135US-5B M1U4-07-050 ZX225US-5B, 225USLC-5B M1U1-07-021 7-114...
  • Page 389 MAINTENANCE 7. Control valve mounting bolt M1U4-07-051 ZX135US-5B MDCN-07-068 ZX225US-5B, 225USLC-5B Control valve bracket mounting bolt M1U4-07-051 ZX135US-5B MDCN-07-068 ZX225US-5B, 225USLC-5B 7-115...
  • Page 390 MAINTENANCE 8. Swing device mounting bolt MDCN-07-018 MDCN-07-069 ZX135US-5B ZX225US-5B, 225USLC-5B 9. Swing motor mounting bolt MDCN-07-018 MDCN-07-069 ZX135US-5B ZX225US-5B, 225USLC-5B 10. ORS fittings for hydraulic hoses and piping M104-07-079 7-116...
  • Page 391 MAINTENANCE 11. Hycolin tube mounting nut M1U1-07-111 ZX135US-5B MDCN-07-071 ZX225US-5B, 225USLC-5B 12. Battery mounting nut MDCN-07-070 ZX135US-5B MDCN-07-072 ZX225US-5B, 225USLC-5B 7-117...
  • Page 392 MAINTENANCE 13. Cab mounting nut M1U1-07-026 MDCN-07-073 Anchor Bolts 14. Cover mounting bolt MDCN-07-022 7-118...
  • Page 393 MAINTENANCE 15. Flexible master coupling of low pressure piping M1G6-07-008 Flexible Master Coupling T-bolt clamp of low pressure piping MDAA-07-027 M1U4-07-052 ZX135US-5B ZX225US-5B, 225USLC-5B 16. Swing bearing mounting bolt Upperstructure Side M107-07-088 M1U1-07-113 M107-07-089 Undercarriage Side Undercarriage Side ZX135US-5B ZX225US-5B, 225USLC-5B 7-119...
  • Page 394 MAINTENANCE 17. Travel device mounting bolt M164-07-005 Travel reduction device cover mounting bolt M1G6-07-007 Sprocket mounting bolt M154-07-050 18. Upper roller mounting bolt M157-07-224 7-120...
  • Page 395 MAINTENANCE 19. Lower roller mounting bolt M107-07-092 20. Track shoe mounting bolt M107-07-093 21. Track guard mounting bolt MDAA-07-058 Full track guard mounting bolt (Only ZX225US-5B, 225USLC-5B) MDAA-07-059 7-121...
  • Page 396 MAINTENANCE 22. Muffler filter mounting bolt Contact your nearest authorized dealer. MDAA-07-061 23. Front pin-retaining bolt MDCS-07-004 MDCN-07-080 7-122...

  • Page 397: Muffler Filter

    MAINTENANCE J. Muffler Filter Check and Clean Filter Element of Muffler Filter --- every 4500 hours Contact your nearest authorized dealer. Check and Clean Muffler Filter --- as required IMPORTANT: Check and clean flammable objects on the area around the muffler filter. ZX135US-5B MDCN-07-076 Do not disassemble the base machine support parts, sensors,...
  • Page 398 MAINTENANCE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-124...

  • Page 399: Hydraulic Circuit And Electrical Circuit

    HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT Hydraulic Circuit MDAA-08-001...

  • Page 400: Electrical Circuit

    HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT Electrical Circuit Electrical Diagram 1. FUSIBLE LINK 37. WASHER RELAY 2. BATTERY 38. HORN RELAY 3. BATTERY RELAY 39. HORN SWITCH 4. STARTER 40. AUTO SHUT DOWN RELAY 5. STARTER RELAY 41. CAB LIGHT 6. ALTERNATOR 42.

  • Page 401: Maintenance Under Special Environmental Conditions

    Reinforce the bucket before using it, or use a heavy duty bucket. Falling Stones Cab Head Guard : Provide a cab guard to protect the machine from falling stones. Consult your nearest Hitachi dealer. Freezing Weather Fuel/Lubricant : Use high quality and low viscosity fuel and oil.

  • Page 402: Maintenance Under Special Environmental Conditions

    MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 403: Storage

    In case the batteries are kept disconnect for more than one month or the battery disconnect switch is turned off, data in the information controller or preset data of the radio may be initialized. Contact your nearest Hitachi dealer before restarting operation of the machine after the batteries are disconnected for one month or more.
  • Page 404 STORAGE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-2...

  • Page 405: Troubleshooting

    If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest Hitachi dealer. Never attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components.
  • Page 406 * Repair and replace Water or air in the fuel system Drain water or bleed air Faulty engine control system * Repair and replace Clogged muffler filter * Repair and replace Items with * mark: Consult your nearest Hitachi dealer. 11-2...
  • Page 407 Does Not Return to Neutral Faulty pilot valve * Replace The lever is tilted in the neutral position Worn joint * Repair or replace due to increase in play Faulty pilot valve * Replace Items with * mark: Consult your nearest Hitachi dealer. 11-3...
  • Page 408 * Replace Faulty hydraulic pump * Repair or replace Faulty pilot valve * Replace Faulty pilot circuit line * Repair or replace Faulty pilot solenoid valve * Repair or replace Items with * mark: Consult your nearest Hitachi dealer. 11-4...
  • Page 409 Hydraulic oil temperature increases Stained oil cooler Clean Insufficient engine fan belt tension Adjust Oil leak from low pressure hose Loose clamps Retighten Faulty suction manifold * Repair or replace Items with * mark: Consult your nearest Hitachi dealer. 11-5...
  • Page 410 Poor contact in connector * Repair or replace Damaged wire harness * Repair Faulty controller (MC) * Replace Faulty solenoid valve * Repair or replace Faulty motor * Repair or replace Items with * mark: Consult your nearest Hitachi dealer. 11-6...
  • Page 411 Inversion protective valve * Repair or replace Items with * mark: Consult your nearest Hitachi dealer. Immediately after the control valve, swing motor relief valve and/or the swing motor is replaced, a noise may be emitted and/or operation may not be performed smoothly due to air trapped in the hydraulic line.
  • Page 412 * Repair or replace Damaged wire harness * Repair Faulty controller * Replace Performing manual regeneration (Normal control) Items with * mark: Consult your nearest Hitachi dealer. Pump Control Problem Cause Solution Front attachment and/or travel speed Blown control fuse...
  • Page 413 SPECIFICATIONS Specifications ZX135US-5B MDCN-12-006 Model ZX135US-5B Type of Front-End Attachment 2.52 m Arm Bucket Capacity (Heaped) PCSA 0.50 m , CECE 0.45 m Operating Weight 13400 kg Base Machine Weight 10800 kg Engine ISUZU AM-4JJ1XZSA-03 73.4 kW/2000 min (100 PS/2000 rpm) Overall Width 2490 mm (Excluding back mirrors)

  • Page 414: Specifications

    SPECIFICATIONS Working Ranges (Grouser shoe) ZX135US-5B MDCN-12-001 2.10 m Arm 2.52 m Arm 3.01 m Arm Category Backhoe Backhoe Backhoe Item A: Maximum Digging Reach 8020 8390 8860 B: Maximum Digging Depth 5070 5490 5980 C: Maximum Cutting Height 9020 9290 9690 D: Maximum Dumping Height...

  • Page 415: Zx135Us-5B

    SPECIFICATIONS Shoe Types and Applications ZX135US-5B 500 mm 600 mm 700 mm Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe For Ordinary For Weak Footing For Weak Footing Application Ground (Option) (Option) (Standard) 13400 13700 13900 Operating Weight 10800 11100 11300 Base Machine Weight 2790...

  • Page 416: Zx135Us-5B

    SPECIFICATIONS Bucket Types and Applications ZX135US-5B Bucket Capacity Bucket Width Front-End Attachment Bucket PCSA CECE With Side Without Side 2.10 m Arm 2.52 m Arm 3.01 m Arm (Heaped) (Heaped) Cutters Cutters 0.19 0.17    0.30 0.25  ...
  • Page 417 SPECIFICATIONS Specifications ZX225US-5B, 225USLC-5B MDCN-12-002 Model ZX225US-5B ZX225USLC-5B Type of Front-End Attachment 2.91 m Arm Bucket Capacity (Heaped) PCSA 0.80 m , CECE 0.70 m Operating Weight 23800 kg 24300 kg Base Machine Weight 19400 kg 19900 kg Engine ISUZU AM-4HK1XZSA-03 122 kW/2000 min (166 PS/2000 rpm) A: Overall Width (Excluding back mirrors) 2910 mm...

  • Page 418: Working Ranges (Grouser Shoe)

    SPECIFICATIONS Working Ranges (Grouser shoe) ZX225US-5B, 225USLC-5B MDCN-12-003 2.42 m Arm 2.91 m Arm Category Backhoe Backhoe Item A: Maximum Digging Reach 9620 10110 B: Maximum Digging Depth 6120 6620 C: Maximum Cutting Height 10790 11230 D: Maximum Dumping Height 7860 8290 E: Overall Height...

  • Page 419: Shoe Types And Applications

    SPECIFICATIONS Shoe Types and Applications ZX225US-5B 600 mm 700 mm 800 mm Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe For Ordinary For Weak For Weak Application Ground Footing Footing (Standard) (Option) (Option) Operating Weight 23800 24200 24500 Base Machine 19400 19800 20100...

  • Page 420: Bucket Types And Applications

    SPECIFICATIONS Bucket Types and Applications ZX225US-5B, 225USLC-5B Bucket Capacity Bucket Width Front-End Attachment Bucket Application PCSA CECE (With side cutter) 2.42 m Arm 2.91 m Arm (Heaped) (Heaped) 0.51 0.45   0.80 HD 1150   0.80 1140  ...

  • Page 421: Optional Attachments And Devices

    OPTIONAL ATTACHMENTS AND DEVICES Using Pad Crawler Shoe Pad crawler is a tract link on which a rubber pad is installed so the machine does not damage road surfaces when traveling. Be sure to observe all precautions for handling pad crawler. Avoid operating the machine in the following conditions: Forbidden Operations Do not operate on sharp, rocky, uneven surfaces, such as...

  • Page 422: Traveling And Other Cautions

    After raising one side track with the front attachment, slowly lower the pad crawler equipped machine. If the pad crawler becomes severely damaged, contact your nearest Hitachi Dealer for replacement. 13-2...

  • Page 423: Transporting

    OPTIONAL ATTACHMENTS AND DEVICES Transporting Transporting CAUTION: Fasten chains or cables to the machine frame. Do not place chains or cables over or against the hydraulic lines or hoses. 1. Place blocks in front of and behind the tracks. M107-06-013 2.
  • Page 424 OPTIONAL ATTACHMENTS AND DEVICES Check Track Sag --- every 50 hours Swing the upperstructure 90 ° and lower the bucket to raise the track off the ground as shown. Keep the angle between the boom and arm 90 to 110 ° and position the bucket’s round side on the ground.
  • Page 425 OPTIONAL ATTACHMENTS AND DEVICES Loosen the Track (ZX135US-5B) CAUTION: Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2).
  • Page 426 OPTIONAL ATTACHMENTS AND DEVICES Loosen the Track (ZX225USLC-5B, 225USRLC-5B) CAUTION: The pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or loosen it too much as valve (1) may fly out or high- pressure grease in the adjusting cylinder may spout out.
  • Page 427 OPTIONAL ATTACHMENTS AND DEVICES Tighten the Track CAUTION: It is abnormal if the track can not be adjusted. The strong force acts on the spring in track adjuster. Therefore, the grease in cylinder is highly pressurized. In such cases, NEVER ATTEMPT TO DISASSEMBLE the track or track adjuster, because of dangerous high-pressure grease inside the track adjuster.

  • Page 428: Long Arm Operation

    OPTIONAL ATTACHMENTS AND DEVICES Long Arm Operation --- If Equipped ZX135US-5B 1. The optional [3.01 m] long arm is only for light works such as loam loading, sludge handling, etc.. Do not use it for heavy works such as digging gravel. When the arm is used for digging, apply shallow cut to the ground to avoid tough digging, or arm damage may result.

  • Page 429: Blade Lever

    OPTIONAL ATTACHMENTS AND DEVICES Blade Lever ZX135US-5B, 225USLC-5B Use blade lever (1) on the operator’s right to raise and lower the blade. When the lever is released, it automatically returns to neutral, keeping the blade in its position until the lever is operated again.

  • Page 430: Avoid Hitting Blade With Front-End Attachment

    OPTIONAL ATTACHMENTS AND DEVICES Avoid Hitting Blade with Front-End Attachment WRONG When operating the machine with the blade positioned towards the front, the bucket or boom cylinder may come into contact with the blade if you are not careful. Be sure to prevent this from happening.

  • Page 431: Blade Maintenance

    OPTIONAL ATTACHMENTS AND DEVICES Blade Maintenance Greasing --- every 250 hours Lubricate all fittings shown in the figure.  Blade Joint Pins (4 points)  Blade Cylinder Rod (2 points)  Blade Cylinder Bottom (2 points) M175-13-002 M198-07-017 Transportation Figure for Machine Equipped with Blade When transporting the machine equipped with a blade and a long arm front attachment on a trailer, place the blade in the opposite position toward the front attachment.

  • Page 432: Specifications

    OPTIONAL ATTACHMENTS AND DEVICES Specifications ZX135US-5B with Blade MDCN-13-002 Model ZX135US-5B with Blade Type of Front-End Attachment 2.52 m Arm Bucket Capacity (Heaped) PCSA 0.50 m , CECE 0.45 m Operating Weight 14400 kg Base Machine Weight 11800 kg Engine ISUZU AM-4JJ1XZSA-03 73.4 kW/2000 min (100 PS/2000 rpm) A: Overall Width (Excluding back mirrors)

  • Page 433: Working Ranges

    OPTIONAL ATTACHMENTS AND DEVICES Working Ranges ZX135US-5B with Blade MDCN-13-004 Model ZX135US-5B with Blade Category 2.10 m Arm 2.52 m Arm 3.01 m Arm Item A: Maximum Digging Reach 8020 8390 8860 B: Maximum Digging Depth 5070 5490 5980 C: Maximum Cutting Height 9020 9290 9690...

  • Page 434: Shoe Types And Applications

    OPTIONAL ATTACHMENTS AND DEVICES Shoe Types and Applications ZX135US-5B with Blade 500 mm 500 mm 500 mm Shoe Width Grouser Shoe Pad Crawler Shoe Rubber Pad Shoe For Ordinary For Paved Road For Paved Road Application Ground (Option) (Option) (Standard) Operating Weight 14400 14500...

  • Page 435: Specifications

    OPTIONAL ATTACHMENTS AND DEVICES Specifications ZX225USLC-5B with Blade MDCN-13-014 Model ZX225USLC-5B with Blade Type of Front-End Attachment 2.91 m Arm Bucket Capacity (Heaped) PCSA 0.80 m , CECE 0.70 m Operating Weight 26300 kg Base Machine Weight 21900 kg Engine ISUZU AM-4HK1XZSA-03 122 kW/2000 min (166 PS/2000 rpm) A: Overall Width (Excluding back mirrors)

  • Page 436: Working Ranges (Grouser Shoe)

    OPTIONAL ATTACHMENTS AND DEVICES Working Ranges (Grouser shoe) ZX225USLC-5B with Blade MDCN-13-015 Model ZX225USLC-5B with Blade Category 2.42 m Arm 2.91 m Arm Item A: Maximum Digging Reach 9620 10110 B: Maximum Digging Depth 6120 6620 C: Maximum Cutting Height 10790 11230 D: Maximum Dumping Height...

  • Page 437: Shoe Types And Applications

    OPTIONAL ATTACHMENTS AND DEVICES Shoe Types and Applications ZX225USLC-5B with Blade 600 mm Shoe Width Grouser Shoe For Ordinary Application Ground (Standard) Operating Weight 26300 Base Machine 21900 Weight Cab Height 2950 Minimum Ground *450 Clearance Undercarriage 4460 Length Undercarriage 2990 Width 55 kPa...
  • Page 438 OPTIONAL ATTACHMENTS AND DEVICES Bucket Teeth (Transverse-Type-Pin-Used Type) Replacement Procedure CAUTION: Guard against injury from flying pieces of metal. Wear goggles or safety glasses. 1. Securely lower the bucket to the ground. 2. Use hammer (3) and drift (2) to drive out transverse-type locking pin (1) to remove tooth (4).
  • Page 439 INDEX Beware of Asbestos and Silicon Dust and Other Contamination ................. S-35 Acting Time Setting ..............1-48 Beware of Exhaust Fumes............S-32 Actual Operation ................1-79 Blade Lever ..................13-9 Adjust Bucket Linkage ..............7-94 Blade Maintenance ..............13-11 Adjust the Operator’s Seat ............S-6 Breaker Operation ................
  • Page 440 INDEX Clock....................1-13 Fore-Aft Position Adjustment of Seat Surface ....1-129 Components Name ............1-1, 1-105 Front Joint Pins ................7-19 Confirm Direction of Machine to Be Driven ......S-13 Fuel Consumption ................ 1-71 Console and Seat Fore-aft Adjustment ....1-126, 1-128 Fuel Gauge ..................
  • Page 441 INDEX MAINTENANCE .................7-1 Overload Alarm Switch (Optional) ......... 1-95 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ................9-1 Park Machine Safely ..............S-23 Mail (Optional) ................1-30 Parking the Machine ..............4-8 Main Menu ..................1-26 Parking the Machine on Slopes ..........4-8 Main Menu Sequence Change ..........1-68 Password Change (Optional) ............
  • Page 442 INDEX Removing and Storing Lower Front Window ....1-121 Swing Alarm Deactivation Switch (Optional) ..... 1-95 Replace Air Breather Element ..........7-45 Swing Bearing ................7-21 Replace Battery ................7-82 Swing Internal Gear ..............7-22 Replace Engine Oil Filter ............7-25 Swing Reduction Gear ..............

This manual is also suitable for:

Zaxis 225us-5bZaxis 225uslc-5b090001300001

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