Page 1 PART NO. EM1V1-NA1-1 Operator’s Manual 240LC 270LC 350LC Hydraulic Excavator Serial No. ZAXIS240LC 020001 and up ZAXIS270LC 030002 and up ZAXIS350LC 050002 and up...
Page 3 PINK 用切り抜き位置 (PDF 割付後削除) MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE MAINTENENCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS STORAGE TROUBLESHOOTING SPECIFICATIONS INDEX...
Page 5 CONTENTS MACHINE NUMBERS Precautions for Welding and Grinding ......... S-27 Avoid Heating Near Pressurized Fluid Lines ....... S-28 Avoid Applying Heat to Lines Containing SAFETY Flammable Fluids ..............S-28 Recognize Safety Information ........... S-1 Remove Paint Before Welding or Heating ......S-28 Understand Signal Words ............
Page 6 CONTENTS Engine Stop Switch ..............1-50 Work Mode ..................5-8 Fuse Box ...................1-51 Work Mode Select ................5-9 Auto Air Conditioner ..............1-52 Power Boost ...................5-10 Cab Heater Operation ..............1-55 Power Mode ..................5-11 Cooling Operation ...............1-56 Operating Backhoe ..............5-12 Defroster Operation ..............1-56 Grading Operation ...............5-12 Tips for Optimal Air Conditioner Usage .......1-58 Face Shovel Operation ...............5-13...
Page 7 CONTENTS Travel Reduction Gear ............7-23 Check Tightening Torque of Bolts and Nuts ....7-81 D. Hydraulic System ..............7-25 MAINTENANCE UNDER SPECIAL Inspection and Maintenance of Hydraulic Equipment ...7-25 ENVIRONMENTAL CONDITIONS Breaker Maintenance ..............7-27 Check Hydraulic Oil Level ...........7-28 Maintenance Under Special Environmental Conditions .. 9-1 Change Hydraulic Oil ............7-29 STORAGE Suction Filter Cleaning ............7-29...
Page 8 CONTENTS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 9 MACHINE NUMBERS The manufacturing Nos. explained in this group is the individ- ual 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 10 MACHINE NUMBERS TRAVEL MOTOR TYPE: MFG. NO.: M178-07-047 SWING MOTOR TYPE: MFG. NO.: M178-07-014...
Page 11 MACHINE NUMBERS HYDRAULIC PUMP TYPE: MFG. NO.: M157-00-004...
Page 12 MACHINE NUMBERS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 13 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. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS...
Page 14 Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equip- ment 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 trouble,...
Page 15 SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropri- ate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing SA-438 Wet weather gear Respirator or filter mask.
Page 16 SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/ or oil 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 ac- cident.
Page 17 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 18 SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the opera- tor may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine web- bing, buckle and attaching hardware.
Page 19 SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground.
Page 20 SAFETY PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equip- ment appropriate for the job, such as a hard hat, etc. when operating the machine. • Clear all persons and obstacles from area of operation and machine movement.
Page 21 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 fall- ing and to prevent the ground, stockpiles, or banks from collapsing.
Page 22 SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure SA-490...
Page 23 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 24 SAFETY • Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direc- tion must be changed, move the machine to level ground, then, change the direction to ensure safe operation. •...
Page 25 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 machine. • Do not park the machine on a grade. •...
Page 26 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 27 SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attach- ment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and ma- chine movement.
Page 28 SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA- CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.
Page 29 SAFETY 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. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines.
Page 30 SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front at- tachments 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 31 SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before strik- ing any object.
Page 32 SAFETY TRANSPORT SAFELY • Take care the machine may turn over when loading or un- loading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe trans- portation. • Select an appropriate truck or trailer for the machine to be transported.
Page 33 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 34 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 35 SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE AS- SEMBLY.
Page 36 SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. •...
Page 37 SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnect- ing hydraulic or other lines. •...
Page 38 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 39 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 po- sition if there is time. • Use a fire extinguisher if there is time. •...
Page 40 SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pres- surized fluid lines, resulting in severe burns to yourself and bystanders. • Do no heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 41 • Keep bystanders out of the work site during operation. SA-029 • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.
Page 42 • Improperly disposing of waste can threaten the environ- ment 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 43 Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. RIGHT WINDOW SS-2818...
Page 44 SAFETY SIGNS WARNING! Prior to operation, maintenance, disassembling, and trans- portation of the machine, be sure to read and understand the Operator’s Manual. SS-1616 Sign indicates an electrocution hazard if machine is brought too near electric power lines. Keep a safe distance from electric power lines. SS-862 Sign indicates a hazard form falling window.
Page 45 SAFETY SIGNS SS3106039 Sign indicates a hazard of being hit by the working device of the machine. Keep away from machine during operation. SS3092349 Sign indicates a hazard of a flying plug from track adjuster that could cause injury. Read manual before adjusting track for safe and proper handing.
Page 46 SAFETY SIGNS Sign indicates a burn hazard from compressed air and spurt- ing hot oil if the oil inlet is uncapped during or right after operation. Read manual for safe and proper handing. SS4371799 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
Page 47 SAFETY SIGNS Sign indicates a hazard of falling off the fender or hood. Never stand close to the edge. SS3092350 Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine. SS-024 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
Page 48 SAFETY SIGNS Sign indicates an explosion hazard. Keep fire and open flames away from this area. Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte. SS-411 SS4467093 S-36...
Page 49 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- Counterweight 11- Travel Device 12- Track 13- Front Idler 14- Cab M1U1-01-005...
Page 50 OPERATOR'S STATION CAB FEATURES 1- Left Control Lever/Horn Switch (On Top of Lever) 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- Air Conditioner Panel...
Page 51 OPERATOR'S STATION MULTI FUNCTION MONITOR How To Use Screens Displaying Basic Screen IMPORTANT: Start the engine after the basic screen is dis- played. When the key switch is turned to the ON position, the starting screen displays for about two seconds and the basic screen displays.
Page 52 OPERATOR'S STATION OUTLINE 1 - Work Mode Display 2 - Auto-Idle Display 3 - Auxiliary 4 - Auxiliary 5 - Auxiliary 6 - Preheat Display 7 - Work Mode Display 8 - Hour Meter 9 - Auxiliary 10 - Fuel Gauge 11 - Auxiliary 12 - Auxiliary 13 - Fuel Rate Display...
Page 53 OPERATOR'S STATION • Display of Meters Items to be displayed Work Mode 8. Hour Meter 10. Fuel Consumption Gauge 14. Clock 16. Menu 22. Coolant Temperature Gauge • Work Mode Display The attachments being used are displayed. M1U1-01-062 Digging Mode T1V1-05-01-108 Attachment Mode Breaker...
Page 54 OPERATOR'S STATION • Auto-Idle Display(2) When selecting auto-idle from the switch panel, the auto- idle display (2) is displayed. When the key is turned ON, the data blinks for 10 seconds. Preheat Display (6) • While the current is supplying to the glow plug, or the air heater the date is displayed.
Page 55 OPERATOR'S STATION Menu Screen (23) Press menu key (16) on the basic screen to display main menu screen (23). Select the desired menu by operating key (25) lo- cated under keys on icon display area (24). M1U1-01-063...
Page 56 OPERATOR'S STATION Hour Meter Total (accumulated) machine operation hours counted since the machine started working, are displayed in the unit of HOUR (h). One digit after the decimal point indicates the tenths of an hour (6 minutes). M1U1-01-038 Fuel Gauge The fuel amount in the fuel tank is indicated.
Page 57 OPERATOR'S STATION Menu Key Shifts the basic screen to the menu screen. M1U1-01-042 Optional Function Key The desired preset optional function can be selected by oper- ating these keys even though the menu key is not operated. F1 : Work Mode Selection F2 : Auxiliary M1U1-01-043 F3 : Auxiliary...
Page 58 OPERATOR'S STATION Coolant Temperature Gauge Indicates the engine coolant temperature. 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 at the work mode selection screen and operation modes such as the auto-idle system (2) and preheat display (3), etc when these systems are activated.
Page 59 Displaying Basic Screen by Password Input (Optional) IMPORTANT: When required to activate the TEN-key func- tion (ignition block system), consult your nearest Hitachi dealer. If the password ever escapes the customer’s memory, the machine must be modified. Be extra careful not to forget the password.
Page 60 OPERATOR'S STATION In Case of Inputting an Incorrect Password 1. If inputting an incorrect password, the message “Pass- word is incorrect. ” displays by pushing the determination key. M1U1-01-067 Password Input Screen M1U1-01-066 Determination Key Delete Key 2. Return to the password input screen, by pushing the back key.
Page 61 OPERATOR'S STATION 3. If inputting an incorrect password three times, a screen displays informing that the security lock has been ap- plied, and a buzzer rings for thirty seconds. During that time, the buzzer does not stop ringing even if turning of the key switch ON/OFF.
Page 62 OPERATOR'S STATION Extending Password Duration Time IMPORTANT: This operation is applicable only to those machines that display the basic screen based upon password input. By using the password duration screen, password duration time can be set. When you restarting the machine, a password need not be input within that timeframe.
Page 63 OPERATOR'S STATION ALARM OCCURRENCE SCREEN In case any abnormality occurs, the alarm marks are displayed on the basic screen. • When the number of alarms is two or less M1U1-01-071 • When the number of alarms is three or more M1U1-01-072 1-15...
Page 64 OPERATOR'S STATION In case any abnormality occurs, push the key located under the alarm mark. The monitor displays the corrective action to the alarm situation. M1U1-01-071 Push a Relevant Key M1U1-01-073 1-16...
Page 65 Stop operation. Run the engine at slow idle speed o lower the coolant temperature. M178-01-036 Engine Warning Alarm Engine or engine related parts are abnormal. Consult your nearest Hitachi dealer. M183-01-080 Engine Oil Pressure Alarm Engine oil pressure has decreased. Immediately stop engine. Check engine oil system and oil level.
Page 66 OPERATOR'S STATION • Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error Sensor Error Display Display When the fuel sensor is faulty or if the harness between fuel sensor and monitor unit is broken, the fuel sensor error dis- play is displayed on the fuel gauge. •...
Page 67 OPERATOR'S STATION Clock Setting Press menu key (2) on basic screen (1) to display main menu screen (3). Select time set menu (4) by pressing the key located under keys on icon display area and adjust the clock set. Time Adjustment After selecting time set menu (4) by pressing the key locat- M1U1-01-059 ed under...
Page 68 OPERATOR'S STATION ATTACHMENT SELECTION (Only Machines Equipped with Optional Parts) IMPORTANT: Select the attachments from the work mode screen. In order to display the work mode screen, push work mode selection key F1 after basic screen displays, or select from main menu. Selecting an Attachment by Using Work Mode Selection Key F1 1.
Page 69 OPERATOR'S STATION Selecting an Attachment from Main Menu 1. When the basic screen displays, push the menu key and display main menu. 2. Select work mode from main menu by using keys 1 and 2 . Push determination key. Then, the work mode screen displays.
Page 70 OPERATOR'S STATION Attachment Specification Screen Maximum Pump 2 Flow Rate Breaker 1 Maximum Engine Speed Accumulator Control Solenoid Valve: Secondar y Relief Selec tor Control Solenoid Valve: ON Three way Valve Control Solenoid Valve: The three way valve is connected to the hydraulic oil tank.
Page 71 OPERATOR'S STATION Pulverizer 1 Maximum Pump 1 and 2 Flow Rate Maximum Engine Speed Accumulator Control Solenoid Valve: Secondar y Relief Selec tor Control Solenoid Valve: OFF Three way Valve Control Solenoid Valve: The three way valve is connected to the control valve.
Page 72 OPERATOR'S STATION PUMP 2 FLOW RATE ADJUSTMENT (Only Machines Equipped with Optional Parts) IMPORTANT: This operation is effective when attachments are used. 1. When the basic screen displays, push the menu key and display main menu. 2. Select attachment adjustment from main menu by using keys 1 and 2 .
Page 73 OPERATOR'S STATION DISPLAYING OPERATING CONDITIONS 1. When the basic screen displayed, push the menu key and display main menu. 2. Select operating conditions from main menu by using keys 1 and 2. Push the determination key. Then, the oper- ating conditions screen displays. 3.
Page 74 OPERATOR'S STATION FUEL RATE DISPLAY/NO DISPLAY Fuel Rate Display 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen M1U1-01-059 2. Select fuel rate display/No display from main menu by using keys 1 and 2. Push the determination key. Then, the fuel rate display/No display screen displays.
Page 75 OPERATOR'S STATION 4. Push key 6 , and the fuel rate display will be added to basic screen. M1U1-01-088 Key 6 M1U1-01-089 Fuel Rate 1-27...
Page 76 OPERATOR'S STATION Fuel Rate No Display 1. When the basic screen displays, push the menu key and display main menu. Fuel Gauge Menu Key Basic Screen M1U1-01-089 2. Select fuel rate display/No display from main menu by using keys 1 and 2 .
Page 77 OPERATOR'S STATION 4. Push key 6 , and return to the basic screen. M1U1-01-087 Key 6 Basic Screen M1U1-01-059 1-29...
Page 78 OPERATOR'S STATION Password Change (Optional) 1. After the basic screen is displayed, push the menu key in order to display the main menu. Menu Key Basic Screen M1U1-01-059 2. Select password change from main menu by using keys 1 and 2. Push the determination key. Then, the password change screen displays.
Page 79 OPERATOR'S STATION NOTE: If inputting an incorrect password after pushing the determination key, the message “Password is incorrect.” displays. Push the back key and go back to the previous screen, Input the password again. M1U1-01-093 Back Key 5. The message “Enter password to be registered. ” displays. Then, input a new password with three or four digits and push the determination key.
Page 80 OPERATOR'S STATION 7. The message “Re-enter password. ” displays. Then, input a new password again and push the determination key. 8. If inputting the password again, push the delete key in order to delete the entered characters. M1U1-01-096 Determination Key M1U1-01-097 Delete Key 9.
Page 81 OPERATOR'S STATION MAINTENANCE SETTINGS 1. When the basic screen diplays, push the menu key and display main menu. Menu Key Basic Screen M1U1-01-059 2. Select maintenance settings from main menu by using keys 1 and 2 . Push the determination key. Then, the maintenance settings screen displays.
Page 82 OPERATOR'S STATION Change Interval Settings IMPORTANT: Change interval can only be set when main- tenance information display is set to ON. 1. Select change interval by using keys 1 and 2 2. Set time for change interval by using keys 3 and 4 Key 1 3.
Page 83 OPERATOR'S STATION Resetting Data If data is reset, push key 5 on the Interval ON/OFF set- tings screen. The message “Reset Data. OK?” displays. Then, push the de- termination key. The value of remaining hours is reset to that of change in- terval.
Page 84 OPERATOR'S STATION Screen Display when Maintenance Information Display is ON • When only one item displays 1. If turning the key switch to the ON position, the starting screen displays. Then, the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds.
Page 85 OPERATOR'S STATION • When more than two items apply 1. If turning the key switch to the ON position, the starting screen displays. Then, the scheduled maintenance screen for the items whose change interval has expired displays for three to ten seconds. Finally the basic screen displays. NOTE: For a machine which the basic screen is displayed ac- cording to a password on, the scheduled maintenance screen for the items whose change interval has expired...
Page 86 OPERATOR'S STATION LANGUAGE SETTINGS 1. When the basic screen displayed, push the menu key and display main menu. 2. Select language from main menu by using keys 1 . Push the determination key. Then, the language settings screen displays. 3. Select a desired language by using keys 1 and 2 Push the determinaion key.
Page 87 OPERATOR'S STATION Lists of Display Language Language Screen Display English T1V10501142 Spanish T1V10501153 Italian T1V10501154 French T1V10501155 German T1V10501156 Dutch T1V10501157 Russian T1V10501158 Portuguese T1V10501159 Finnish T1V10501160 Swedish T1V10501161 Norwegian T1V10501162 Danish T1V10501163 1-39...
Page 88 OPERATOR'S STATION SWITCH PANEL 1- Engine Control Dial 2- Auto-Idle Switch 3- Power Mode Switch 4- Travel Mode Switch 5- Work Light Switch 6- Wiper/Washer Switch M1U1-01-015 1-40...
Page 89 OPERATOR'S STATION ENGINE CONTROL DIAL Use engine control dial (1) to adjust engine speed. Fast Idle Turn it clockwise to increase engine speed or counterclockwise to decrease engine speed. • The fully clockwise position : Fast idle Slow Idle • The fully counterclockwise position : Slow idle M1U1-01-033 AUTO-IDLE SWITCH The auto-idle Switch (2) sets the engine speed control mode to...
Page 90 OPERATOR'S STATION POWER MODE SWITCH Three engine speed modes, E, P, and H/P modes, are selected by operating the power mode switch. • E (Economy) Mode Although production is slightly reduced more than in the P mode, the fuel consumption and noise levels are reduced, allowing the machine to operate efficiently.
Page 91 OPERATOR'S STATION WORK LIGHT SWITCH Work light switch has the following positions: • 1 Position Work light (1) on the base machine will light. Also, the in- strument panel illumination will light. • 2 Position Work light (2) will light in addition. M178-01-015 •...
Page 92 OPERATOR'S STATION WIPER/WASHER SWITCH The wiper and the window washer are operated using the Fast wiper/washer switch. • Wiper Turn the wiper/washer switch to the specified position to operate the wiper. Slow OFF Position: The wiper stops and is retracted. INT Position: The wiper operates intermittently at the interval selected by the switch position as described below.
Page 93 OPERATOR'S STATION SWITCH PANEL Armrest NOTE: • The switch panel locations differ depending on the kinds of optional devices are equipped. Before using the switches on the switch panel, make sure what kind of optional devices are equipped. All available optional devices are shown below.
Page 94 OPERATOR'S STATION Electrical Control Main Switch When the ( ) mark side of electrical control main switch (4) is pressed, the electrical control (grip switch) system be- comes operable. When there is no need to use the electrical control (grip switch) system, press the ( ) mark side of the main switch to avoid mis-operation.
Page 95 OPERATOR'S STATION KEY SWITCH 1- OFF (Engine Off ) 2- ACC (Horn, Radio etc.) 3- ON (Engine On) 4- START (Engine Start) M178-01-049 POWER BOOST SWITCH Power boost switch (5) is used to gain maximum digging pow- er, and is located on the top of the right control lever. M1J1-01-024 HORN SWITCH Horn switch (6) is provided on the top of the left control lever.
Page 96 IMPORTANT: In case cigar lighter (2) doesn’t pop out au- tomatically 30 seconds after pushing cigar lighter (2) in, pull out cigar lighter (2) manu- ally. Then, consult the your nearest Hitachi dealer. 1. Turn key switch (1) to the ACC or ON position.
Page 97 OPERATOR'S STATION CAB LIGHT Turn the cab light ON or OFF by using switch (1). M178-01-022 1-49...
Page 98 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: • Pilot control will not be shut-off unless pilot con- trol shut-off lever (1) is completely pulled-up to the LOCK position.
Page 99 OPERATOR'S STATION FUSE BOX 10- CONTROLLER 20- OPTION3 9- BACKUP 19- SW. BOX 8- ECM 18- POWER ON 7- LUBRICATOR 17- AIRCON 6- OPTION2 16- GLOW. R M1U1-01-026 5- OPTION1 15- AUXILIARY 4- SOLENOID 14- FUEL PUMP 3- HEATER 13- LIGHTER 2- WIPER 12- RADIO 1- LAMP...
Page 100 OPERATOR'S STATION AUTO AIR CONDITIONER Distinctive Feature • 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 moving the temperature control switch to the full right or left re- spectively.
Page 101 OPERATOR'S STATION Control Panel Designation and Function • Mode Switch (14): Selects the air vent. The selected air vent is indicated on LCD (7). Air flows out of front vent and the defroster vents. Air flows out of the front and rear vents and M178-01-074 the defroster vents.
Page 102 OPERATOR'S STATION • When the “FH” symbol is displayed on LCD (7), air flow-in temperature at the vent, air vent (front and rear vents) lo- cations, fresh air suction port, and blower speed are main- tained at the highest heating conditions. However, in case the circulation indicator is ON before the “FH”...
Page 103 OPERATOR'S STATION • Air Conditioner (A/C) Switch (8) A/C Indicator Press A/C switch (8) to turn the air conditioner and the A/C indicator ON. However, unless the blower is running (the fan display of blower switch (6) is lit), the air conditioner will not be turned ON.
Page 104 OPERATOR'S STATION COOLING OPERATION 1. Press AUTO Switch (9) The AUTO and the A/C indicators come ON. Then, the air temperature at the vent, blower speed, vent locations, and air suction ports are automatically controlled by the air conditioner amplifier according to signals sent from various sensors.
Page 105 OPERATOR'S STATION Cool Head / Warm Feet Operation Cool and warm air is simultaneously supplied to the head vents and feet vents respectively. 1. Press blower switch (6) to adjust the blower speed. 2. Press MODE switch (14) to display the front and rear vent mark on the liquid crystal panel.
Page 106 OPERATOR'S STATION TIPS FOR OPTIMAL AIR CONDITIONER USAGE 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 107 OPERATOR'S STATION AM/FM RADIO OPERATION Controls on the radio 1- Power Switch/Volume Control Knob 2- Tone Adjustment Ring 3- AM/FM Switch 4- Station Presets 5- Tuning Switches 6- Display Mode Change Switch 7- Digital Display 8- Time Set Switches M1G6-01-026 Tuning Procedure •...
Page 108 OPERATOR'S STATION Station Presetting Procedure 1. Select the desired station using tuning switches (5). (Refer to the “Tuning Procedure” section.) 2. Press and hold one station preset (4) for more than 1 sec- ond until an electronic tone is heard. Now, the selected station is preset for the selected station preset.
Page 109 OPERATOR'S STATION CAB DOOR RELEASE LEVER CAUTION: Open the cab door all the way until it se- curely locks in the latch on the side of the cab. To unlock the door from this position, push down on lever (1). OPENING UPPER FRONT WINDOW M1J1-07-051 WARNING: Open or close the upper-front cab window...
Page 110 OPERATOR'S STATION CLOSING UPPER FRONT WINDOW CAUTION: Avoid possible injury while closing window. Upper front window comes down very forcefully. Close window only when sitting in the operator's seat. Guide window down slowly. 1. Pull out lock pin (3) to unlock window. 2.
Page 111 OPERATOR'S STATION REMOVING AND STORING LOWER FRONT WINDOW CAUTION: Take care not to pinch yours fingers when handling the lower front window. 1. Open the upper front window beforehand when remov- ing the lower front window. 2. While pulling the lower front widow inward, raise it to re- move.
Page 112 OPERATOR'S STATION OPENING/CLOSING OVERHEAD WINDOW (Std. Model) Opening 1. Move lock levers (1) toward center of window. 2. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in posi- tion by dampers (3). Closing 1.
Page 113 OPERATOR'S STATION EMERGENCY EXIT If the operator’s cab door should not open in an emergency, escape in the following methods: 1. Open the front windows. Escape through the windows. NOTE: See page “OPENING UPPER FRONT WINDOWS” for the opening method of the front windows. CAUTION: Take care not be injured with pieces of broken glass.
Page 114 OPERATOR'S STATION ADJUSTING THE SEAT Seat Height and Angle Adjustment Seat height adjustment range is 60 mm (2.4 in) with steps every 15 mm (0.6 in) (5 positions in total). Moreover, the height of the front part and the rear part of the seat are ad- justed independently, thus allowing the angle of the seat to be adjusted.
Page 115 OPERATOR'S STATION Armrest Adjustment Armrest (6) can be pulled upright by hand to get on and off the machine easily. The angle of armrest (6) can be adjusted to the desired posi- tion by turning adjusting dial (7) located on the bottom of armrest (6).
Page 116 OPERATOR'S STATION ADJUSTING CONSOLE HEIGHT Adjust the console height to the operator’s comfort and/or work conditions. Adjusting console height can be achieved us- ing 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 117 OPERATOR'S STATION SEAT BELT CAUTION: Be sure to use the seat belt when operat- ing the machine. Before operating the machine, be sure to examine seat belt (1), buckle (2), and attaching hardware. Re- place seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn.
Page 118 OPERATOR'S STATION MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-70...
Page 119 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 (E) mode and limit the engine horsepower up to about 80 % of full load. 2.
Page 120 BREAK-IN MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 121 OPERATING THE ENGINE INSPECT MACHINE DAILY BEFORE STARTING ELECTRICAL SYSTEM Check for worn or frayed wires and loose connections. BOOM, BUCKET, SHEET METAL, TRACKS Check for bent, broken or missing parts. HARDWARE Check for loose or missing parts. FUEL SYSTEM Drain water and deposits from fuel tank.
Page 122 OPERATING THE ENGINE BEFORE STARTING ENGINE 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. Adjust the seat to allow full pedal and control levers stroke with operator’s back against the backrest.
Page 123 IMPORTANT: When required to activate the TEN-key func- tion (ignition block system), consult your nearest Hitachi dealer. Slow Idle 7. The basic screen will be displayed on the monitor. Check that the preheat indicator (4) is OFF at this time.
Page 124 (ignition block system) is activated, this screen is not dis- played. IMPORTANT: When required to activate the TEN-key func- tion (ignition block system), consult your nearest Hitachi dealer. Slow Idle 7. The basic screen will be displayed on the monitor. The machine will automatically check if preheating is required...
Page 125 OPERATING THE ENGINE CHECK INSTRUMENTS AFTER STARTING Checking lnstruments through Monitor Functions. After starting the engine, check the following points through the monitor functions. Check that 1. Alternator indicator (1) is off. 2. Engine oil pressure indicator (2) is off. 3.
Page 126 OPERATING THE ENGINE USING BOOSTER BATTERIES WARNING: • An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Charge the batteries in a well ven.tilated area. Do not continue to use or charge the battery when electrolyte level is lower than specified.
Page 127 OPERATING THE ENGINE Disconnecting the booster batteries 1. Disconnect black negative (–) cable (2) from the machine (Red) frame first. 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 128 OPERATING THE ENGINE STOPPING THE ENGINE Engine stop procedure 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn engine control dial (1) to the slow idle position and SA-390 run the engine for 5 minuets to cool the engine. IMPORTANT: Turbocharger may be damaged if the engine is not properly shut down.
Page 129 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 130 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 ac- tions of the travel pedals will be reversed.
Page 131 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 ac- tions of the travel levers will be reversed.
Page 132 DRIVING THE MACHINE TRAVEL MODE SWITCH WARNING: Tipping-over accidents can cause serious personal injury. Do not change travel mode while traveling; especially, changing to the fast mode when descending slopes will create a very dangerous situ- ation. Always stop the machine before changing the travel speed mode.
Page 133 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 be- comes stuck, it may be necessary to clean the track frame area.
Page 134 DRIVING THE MACHINE TOWING MACHINE A SHORT DISTANCE RIGHT 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 135 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 136 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 137 OPERATING THE MACHINE OPERATING THE MACHINE CONTROL LEVER (ISO PATTERN) WARNING: Never place any part of body beyond win- dow frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. If window is missing or broken, replace im- mediately.
Page 138 OPERATING THE MACHINE ATTACHMENT PEDAL (HYDRAULIC BREAKER) (OPTIONAL) The breaker can be operated using attachment pedal (1) lo- cated 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 139 OPERATING THE MACHINE ATTACHMENT PEDAL (HYDRAULIC CRUSHER) (OPTIONAL) Machine stability, applicable hydraulic oil pressure and oil quantity for crusher, etc. must be examined when selecting a crusher. Be sure to consult your authorized dealer when selecting a crusher. For operational instructions, refer to the crusher instruction manual.
Page 140 OPERATING THE MACHINE PILOT CONTROL SHUT-OFF LEVER Pilot control shut-off lever (1) functions to prevent misopera- tion of the machine from occurring if the control levers are accidentally moved when leaving the operator's seat or when entering the cab. WARNING: •...
Page 141 OPERATING THE MACHINE Warming-up Operation In cold weather, warm up the machine until coolant and hydraulic oil temperature increases to the appropriate oper- ating temperature. IMPORTANT: The appropriate hydraulic oil operating tem- Slow Idle perature 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 142 OPERATING THE MACHINE ENGINE SPEED CONTROL Increase and decrease the engine speed using engine control dial (1) located on the right console, as illustrated. • Turn engine control dial (1) clockwise to increase the en- gine speed. Turn engine control dial (1) counterclockwise to decrease the engine speed.
Page 143 OPERATING THE MACHINE AUTO-IDLE With auto-idle selector (3) turned to the A/I ON position, ap- proximately 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 144 NOTE: Five work modes shown above are designated as the standard specifications. Up to five attachment modes other than the digging mode can be designated. Con- sult your nearest Hitachi dealer for adding or changing the designation of the attachment modes.
Page 145 OPERATING THE MACHINE WORK MODE SELECT Press menu key (3) on basic screen (1) to display main menu screen (4). Select work mode (5) by operating key on menu screen (4). Then, press determination key (6). Select the work mode matching the work to be done by pressing bottom key (8) on work mode selection screen (7).
Page 146 OPERATING THE MACHINE POWER BOOST The power boost switch (4) is used to gain maximum digging power, and is located on the top of the right control lever. When the power boost switch (4) is pushed, increased front at- tachment power will be supplied for about 8 seconds. M1J1-01-024 5-10...
Page 147 OPERATING THE MACHINE POWER MODE One of three engine speed modes, E, P or H/P mode, can be selected using power mode switch (1). • E (Economy) Mode Even if the engine speed is reduced in the E mode, digging force remains unchanged from that in the P mode.
Page 148 OPERATING THE MACHINE OPERATING BACKHOE 1. Place the bucket teeth on the ground with the bottom of the bucket at a 45 degree angle to the ground. 2. Pull the bucket toward the machine using the arm as the main digging force. 3.
Page 149 OPERATING THE MACHINE FACE SHOVEL OPERATION WRONG WARNING: Take care not to hit the cab when rolling in the arm with the reversed-installed bucket. • For face shovel operation, dig the ground using the arm cylinder in a scraping motion. •...
Page 150 OPERATING THE MACHINE OPERATING TIPS WRONG Do not hit the track with the bucket when digging. Whenever possible, position your machine on a level surface. Do not use the bucket as a hammer or pile driver. Do not at- tempt to shift rocks and break walls using swing motion. IMPORTANT: To avoid damaging cylinders, do not strike the ground with the bucket nor use the bucket for tamping with the bucket cylinder...
Page 151 OPERATING THE MACHINE HYDRAULIC BREAKER AND HYDRAULIC CRUSHER Select a breaker or crusher that is the correct size and weight for your machine. See your authorized dealer for correct break- er information. Carefully study the operation manuals of the machine, breaker and crusher, and perform the required checks and/or inspec- tion before connecting the breaker or the crusher to the arm.
Page 152 OPERATING THE MACHINE PIPINGS FOR BREAKER AND CRUSHER Operational procedures for stop valves and selection valve. Close A Stop Valves Open M1U1-05-007 Stop Valves A Close : When not using attach- ment or is detached. Open : When using attachment MAIN BODY ATTACHMENT BOOM...
Page 153 1. Measuring the pressure at the relief valve : Pressure is set to A when shipped from HITACHI. (1) Attach a pressure gauge to the pressure gauge connection port (see the figure below)
Page 154 OPERATING THE MACHINE PRECAUTIONS FOR BREAKER OPERATION WRONG 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 155 OPERATING THE MACHINE • Do not operate the breaker in water. Doing so will WRONG cause rust and seal damage, resulting in damage to the hydraulic system components. M104-05-059 WRONG • Do not use breaker for lifting operation. The machine tip- ping over and/or breaker damage may result.
Page 156 OPERATING THE MACHINE • Do not operate breaker with the arm positioned vertically. WRONG Excessive vibration to the arm cylinder will occur, causing oil leakage. M147-05-013 • Press the breaker so that the chisel (the axis) is positioned and thrusted perpendicular to the object. WRONG RIGHT M147-05-014...
Page 157 OPERATING THE MACHINE BREAKER MAINTENANCE Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter Hydraulic breaker operation subjects the hydraulic system to related hydraulic system components. Recommended become contaminated faster and to quickly deteriorate the changing intervals are shown below. (For filter replace- hydraulic oil.
Page 158 OPERATING THE MACHINE PRECAUTIONS FOR CRUSHER OPERATION Prevent machine tipping over and damage to the front attach- ment. Observe the following precautions for crusher opera- tion. WARNING: Machine stability is reduced as crusher is much heavier than bucket. When operating with a crusher, the machine is more apt to tip over.
Page 159 OPERATING THE MACHINE When operating the crusher up high with the boom fully WRONG raised, be careful of falling objects. M107-05-048 • When operating the crusher on a floor in a building, first WRONG confirm that the floor has sufficient strength to support the load caused by crushing, in addition to the machine weight.
Page 160 OPERATING THE MACHINE ATTACHMENT Allowable Weight Limits of Installed Attachment • When an attachment other than the standard bucket is installed on the machine, the machine stability will be dif- ferent. If a heavy attachment is used, not only will controlla- bility be affected but also machine stability will be reduced, possibly causing safety hazard.
Page 161 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 manufacturers’ breaker models while referring to the table on the next page.
Page 162 Before installing them, damage not only the attachment but to the base ma- sufficiently coordinate with the attachment manufacture. Always contact your nearest HITACHI dealer before installing chine may result. Thoroughly read and understand the base machine operator’s manual and the attachment attachments shown with this mark *.
Page 163 OPERATING THE MACHINE Crusher (ZAXIS240LC , 270LC SANGO Maker HITACHI Sakado Oosumi JYUKI Model HSC100 HSC160 TS110RCD S-26V SPAC70R-3 MR1300 CX1100 2300 2300 2750 2500 1640 2700 2350 Weight kg (lb) (5070) (5070) (6060) (5510) (3620) (5950) (5180) 2340 2600...
Page 164 OPERATING THE MACHINE ATTACHMENT CONNECTION PARTS The attachment hydraulic line and connection parts are locat- ed 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 165 OPERATING THE MACHINE PRECAUTION FOR ARM ROLL-IN/BUCKET ROLL-IN COMBINED OPERATION --- If Headguard-Integrated Cab or Raingard is Equipped WARNING: The bucket teeth will hit the headguard or raingard if the bucket is rolled in with the arm fully rolled in, as illustrated. When performing combined operation of long arm roll-in/bucket roll-in or when rolling in the bucket with the arm fully retracted, be careful not to hit the headguard or raingard with the...
Page 166 OPERATING THE MACHINE SHACKLE HOLE USAGE Shackle hole for towing light weight objects. A shackle hole is provided on the track frame to tow light Track Frame weight objects as specified below. IMPORTANT: Be sure to conform to the restrictions and precautions stated below when towing a light weight object using the shackle hole Wire Rope...
Page 167 OPERATING THE MACHINE EMERGENCY BOOM LOWERING PROCEDURE (Without hose-rupture safety valve) WARNING: Prevent personal injury. Confirm that no one is under the front attachment before starting the Front-attachment Side procedure below. If the engine stalls and cannot be restarted, lower the boom to lower the bucket to the ground referring to the emergency boom lowering procedure stated below.
Page 168 OPERATING THE MACHINE OBJECT HANDLING --- IF EQUIPPED WARNING: When you use machine for object han- dling, be sure to comply with all local regulations. Cables, straps, or ropes can break, causing serious injury. Do not use damaged chains, frayed cables, slings, straps, or ropes to crane.
Page 169 TRANSPORTING TRANSPORTING BY ROAD When transporting the machine on public roads, be sure to first understand and follow all local regulations. • When transporting using a trailer, check the width, height, length and weight of the trailer with the machine loaded. Note that transporting the weight and dimensions may vary depending on the type of shoe or front attachments M1V1-06-001...
Page 170 TRANSPORTING Loading/Unloading WARNING: • Always turn the auto-idle/acceleration switch OFF and the power mode switch OFF when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever. • Always select the slow speed mode with the travel mode switch.
Page 171 TRANSPORTING 4. Stop the engine. Remove key from switch. 5. Move the control levers several times until hydraulic pres- sure in the cylinders is released. 6. Pull pilot control shut-off lever to LOCK position. 7. Close cab windows, roof vent and door, and cover the ex- haust opening, to prevent entry of wind and water.
Page 172 TRANSPORTING Transporting WARNING: 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. 2. Fasten each corner of the machine and front attachment M1V1-06-001 to the trailer with a chain or cable.
Page 173 TRANSPORTING MACHINE LIFTING PROCEDURE WARNING: • Lifting wire ropes and other lifting tools can break, possibly causing serious personal injury. Do not use damaged or deteriorated wire ropes or lifting tools. • Be sure to contact your authorized dealer for cor- rect lifting procedure, and size and kinds of lifting wire ropes and lifting tools.
Page 174 TRANSPORTING MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 175 IMPORTANT: • Use only recommended fuel and lubri- cants. • Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown. • Use only genuine HITACHI parts.
Page 176 (see page 7-4 and 7-5). USE CORRECT FUELS AND LUBRICANTS IMPORTANT: Always use recommended fuels and lubri- cants. Failure to do so will result in machine dam- age and loss of Hitachi product warranty.
Page 177 MAINTENANCE LAYOUT Arm Cylinder Boom Center Joint Tool Box Bucket Cylinder Swing Bearing Swing Device Work Light Link B Fuel Tank Boom Cylinder Link A Control Valve Hydraulic Oil Tank Muﬄ er Bucket Fuel Filter Pilot Filter Side Cutter Tooth Engine Oil Filter Control Lever Pump...
Page 178 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 mainte- nance can be performed regularly. •...
Page 179 MAINTENANCE Maintenance Guide Table Lubrication Interval M1G6-07-012 Item Page Item Page Engine Oil 7-18 Hydraulic Oil Filter (Pilot) 7-33 Coolant (Long-Life Coolant) 7-53 Hydraulic Oil Filter (Air Breather) 7-34 Grease 7-16 Engine Oil Filter 7-19 Grease 7-14 Gear Oil (Pump Transmission) 7-21 Grease 7-17...
Page 180 MAINTENANCE PREPARE MACHINE FOR MAINTENANCE Before performing the maintenance procedures given in the following chapters, park the machine as described below, un- less otherwise specified. 1. Park the machine on a level surface. M104-07-021 2. Lower the bucket to the ground. 3.
Page 181 MAINTENANCE HOOD AND ACCESS COVERS 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 cov- ers may close accidentally, possibly resulting in personal injury.
Page 182 MAINTENANCE PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspec- tion of the machine. In addition, the parts listed below, if de- fective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone.
Page 183 3. Engine Oil Filter Replacement NOTE: ★ Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more. Consult your nearest Hitachi dealer for the details. C. TRANSMISSION (See Page 7-21) Interval (hours) Parts Quantity...
Page 184 MAINTENANCE D. HYDRAULIC SYSTEM (See Page 7-25) Interval (hours) Parts Quantity 100 1000 1500 2500 5000 1. Check Hydraulic Oil Level ZX240 243 L ✸ ✸ ✸ ✸ 270LC (64.2 US gal) 2. Change Hydraulic Oil 298 L ✸ ✸ ✸...
Page 185 IMPORTANT: Use fresh water or normal tap 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 %. H. ELECTRICAL SYSTEM (See Page 7-59) I.
Page 186 ✸ 1 Front Joint Pin and Swing Bearing ✸ 2 Swing Gear Recommended Engine Oil IMPORTANT: Use only genuine Hitachi engine oil as shown below or engine oil equivalent to DH-1 spec- ified in JASO. Failure to do so may deterio- rate the engine performance and/or shorten the engine service life.
Page 187 –10 to 40°C Temp. (–4 to 104°F) (14 to 104°F) (–4 to 104°F) (14 to 104°F) (–4 to 104°F) (14 to 104°F) Manufacturer Hitachi Super EX 46HN Idemitsu Kosan Super Hydro 46 WRHU British Petroleum Bartran HV46 Rando Oil Caltex Oil HD46 Rando Oil Texaco INC.
Page 188 MAINTENANCE A. GREASING 1 Front Joint Pins • Bucket --- every 250 hours • Link Pins --- every 500 hours M178-07-007 Others --- every 500 hours • Boom Cylinder Bottom M157-07-156 • Boom Foot M157-07-155 7-14...
Page 189 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. (Centralized greasing system) M157-07-155 7-15...
Page 190 MAINTENANCE 2 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 bear- ing, clear the area of all persons. Each time you leave the cab •...
Page 191 MAINTENANCE 3 Swing Internal Gear --- every 500 hours CAUTION: Adding or changing swing internal gear grease and rotating the upperstructure must be done by one person. Before you start, clear the area of all persons. Each time you leave the cab Lower the bucket to the ground.
Page 192 MAINTENANCE B. ENGINE 1 Engine Oil Level --- check daily IMPORTANT: For most accurate readings, check the oil level every day before starting the machine. Be sure the machine is on a level surface. 1. Remove dipstick (1). Wipe oil off with a clean cloth. Rein- sert dipstick (1).
Page 193 2 Change Engine Oil --- every 500 hours IMPORTANT: Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more. Consult your nearest Hitachi dealer for the details. 3 Replace Engine Oil Filter--- every 500 hours M1U1-07-044...
Page 194 MAINTENANCE 14. Open the right access cover and secure the cover with rod. 15. Remove the filter cartridges of engine oil filter (6) by turn- ing it counterclockwise with the filter wrench. 16. Clean the filter gasket contact area on the engine. 17.
Page 195 MAINTENANCE C. TRANSMISSION 1 Pump Transmission 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 en- gine is not properly shut down.
Page 196 MAINTENANCE 2 Swing Reduction Gear 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 en- gine is not properly shut down.
Page 197 MAINTENANCE 3 Travel Reduction Gear Air Release Plug 1 (Oil Supply Plug) Check Oil Level --- every 250 hours 1. Park the machine on a level surface. Oil Level Check Plug 2 2. Rotate the travel motor until the imaginary line through plug (1) and plug (3) is vertical.
Page 198 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 199 MAINTENANCE D. HYDRAULIC SYSTEM INSPECTION AND MAINTENANCE OF HYDRAULIC EQUIPMENT CAUTION: During operation, the parts of the hydrau- lic system become very hot. Allow the machine to cool down before beginning in- spection or maintenance. 1. Be sure that the machine is parked on a level, firm surface before servicing hydraulic equipment.
Page 200 MAINTENANCE 5. When adding hydraulic oil, always use the same brand of oil; do not mix brands of oil. As the machine is filled with Super EX 46HN when it is shipped from the factory, use it as a general rule. When selecting to use another brand of oil listed in the table “Brand names of recommended hydraulic oil”, be sure to completely replace the oil in the system.
Page 201 MAINTENANCE BREAKER MAINTENANCE Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter related hydraulic system components. Recommended Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to quickly deteriorate the hy- changing intervals are shown below. (For filter replace- draulic oil.
Page 202 MAINTENANCE 1 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 203 MAINTENANCE 2 Change Hydraulic Oil 3 Suction Filter Cleaning --- every 5000 hours, 2500 hours or 1500 hours CAUTION: Hydraulic oil may be hot. Wait for oil to M104-07-117 cool before starting work. IMPORTANT: Hydraulic oil changing intervals differ ac- cording to kind of hydraulic oils used.
Page 204 MAINTENANCE 12. Remove drain plug (3). Allow oil to drain. 13. Remove suction filter and rod assembly (4). 14. Clean the filter and tank interior. If the filter is to be re- placed, install new filter on the rod as shown. Tighten nut to 14.5 to 19.5 N•m (1.5 to 2.0 kgf•m, 11.0 to 14.5 lbf•ft).
Page 205 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 206 MAINTENANCE 4 Replace Hydraulic Tank 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. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.
Page 207 MAINTENANCE 5 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. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. 4.
Page 208 MAINTENANCE 6 Replace Air Breather Element --- every 4000 hours CAUTION: Hydraulic oil may be hot just after opera- tion. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. M104-07-021 Replacement Procedures 1.
Page 209 MAINTENANCE 7 Check Hoses and Lines --- daily --- every 250 hours CAUTION: Escaping fluid under pressure can pen- etrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard. Take care to protect hands and body from high-pres- sure fluids.
Page 210 (Use proper bend radius) Hose ends and Deformation or Replace fittings Corrosion (10) NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. M115-07-147 M115-07-148 M115-07-149 Fig.1 7-36...
Page 211 Replace Deformation Replace Loose Retighten NOTE: Refer to the illustrations in Fig.2 for each check point location or for a description of M137-07-007 the abnormality. Use genuine Hitachi parts Fig.2 Table 3. Oil cooler Interval(hours) Check Points Abnormalities Remedies Every 250 hours...
Page 212 MAINTENANCE SERVICE RECOMMENDATIONS FOR HYDRAULIC FITTINGS Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fitting (ORS Fitting) An O-ring is used on the sealing surfaces to prevent oil leak- age. 1. Inspect fitting sealing surfaces (6). They must be free of dirt or defects.
Page 213 MAINTENANCE Metal Face Seal Fittings Fittings are used on smaller hoses and consist of a metal flare and a metal flare seat. 1. Inspect flare (10) and flare seat (9). They must be free of dirt or obvious defects. IMPORTANT: Defects in the tube flare cannot be repaired. Overtightening a defective flare fitting will not stop a leak.
Page 214 MAINTENANCE E. FUEL SYSTEM Recommended Fuel Use high quality DIESEL FUEL only (JIS K-2204) (ASTM 2-D). Kerosene must NOT be used. Refueling 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 en- M1U1-01-059 gine is not properly shut down.
Page 215 MAINTENANCE 8. To avoid condensation, fill the tank at the end of each day’s operation. Take care not to spill fuel on the machine or ground. Model Tank Capacity Yellow Mark ZX240LC , 270LC 500 L (132 US gal) ZX350LC 630 L (166 US gal) Do not fill the tank more than specified.
Page 216 MAINTENANCE 1 Drain Fuel Tank Sump --- daily 1. Park the machine on a level surface with the upperstruc- ture rotated 90° for easier access. 2. Lower the bucket to the ground. 3. Turn the auto-idle off. M104-07-117 IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.
Page 217 MAINTENANCE 2 Check Water Separator --- daily Water separator (4) separates any water that may get mixed with the fuel. Water separator (4) contains a float which rises as water accumulates. Be sure to drain the sediment when the float rises up to the “Drain Water”...
Page 218 MAINTENANCE Draining Procedures (Pre-Filter) 1. Place 0.5 liters or larger capacity container under drain plug (5) to collect the drained water. 2. Shut off the fuel supply by closing cock (5) on the bottom of the fuel tank. 3. Loosen plug (4) on the top of the fuel pre-filter. 4.
Page 219 MAINTENANCE Air Bleeding Procedures IMPORTANT: Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the water separator, replacing the fuel filter, cleaning the fuel solenoid pump strainer or running the fuel tank dry, be sure to bleed the air from the fuel system.
Page 220 MAINTENANCE Air Bleeding by Priming Pump In case air is not bled due to malfunction of the fuel sole- noid pump, operating the priming pump only can bleed air. 1. Check that fuel cock (3) on the bottom of the fuel tank is opened.
Page 221 MAINTENANCE 3 REPLACE FUEL MAIN FILTER ELEMENT --- every 500 hours IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel cartridge and the pre- cartridge. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.
Page 222 MAINTENANCE 4 REPLACE FUEL PRE-FILTER ELEMENT --- every 500 hours IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel cartridge and the pre- cartridge. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.
Page 223 MAINTENANCE 5 CLEAN FUEL SOLENOID PUMP STRAINER: --- every 500 hours Magnet Replacement Procedure When the strainer is disassembled, be sure to replace the strainer together with the gasket. Install the cover and the magnet only after sufficiently cleaning them. After being as- sembled, closely check the air-tightness of the strainer.
Page 224 (Use proper bend radius) Hose ends and fittings Deformation or Replace M137-07-005 Corrosion (7) NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. M137-07-006 Fig. 1 7-50...
Page 225 MAINTENANCE F. AIR CLEANER 1 Clean the Air Cleaner Outer Element --- every 250 hours or when the restriction indicator comes ON 2 Replace the Air Cleaner Outer and Inner Elements --- after cleaning six times or after one year 1.
Page 226 MAINTENANCE 16. When replacing the air cleaner filter element, replace both outer (1) and inner (3) elements together. Remove Air Restriction Switch outer element (1). Clean the filter interior before remov- ing inner element (3). Remove inner element (3). First install inner element (3) and then install outer element (1).
Page 227 Use fresh water or normal tap 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 the air temperature is expected to fall below 0°C (32°F), fill the cooling system with an genuine Hitachi Long-Life Cool- ant (LLC) and soft water mix.
Page 228 MAINTENANCE LLC Mixing Table (ZX240LC , 270LC Refill capacities Mixing Air temperature ratio Soft water ° C ° F liters US gal liters US gal –1 18.2 –4 18.2 –7 18.2 –11 18.2 –15 16.9 –20 –4 10.4 15.6 –25 –13 11.7 14.3...
Page 229 MAINTENANCE 1 Check Coolant Level --- daily CAUTION: Do not loosen radiator filler cap (1) unless the system is cool. Loosen the cap slowly to the stop. Release all pressure before removing the cap. With the engine cold, the coolant level must be between the FULL and LOW marks on coolant reservoir (2), located behind the radiator access door.
Page 230 MAINTENANCE 2 Check and Adjust Fan Belt Tension Deﬂ ection --- every 100 hours (first time after 50 hours) 5~6 mm (0.2 to 0.24 in) 98 N (10 kgf, 22 lbf ) IMPORTANT: Loose fan belt may result in insufficient bat- tery charging, engine overheating as well as a rapid, abnormal belt wear.
Page 231 Release all pressure before removing the cap. IMPORTANT: Use fresh water or normal tap water as a coolant. Don’t use strong acid or alkaline water. Use the coolant with genuine Hitachi M1U1-07-029 Long-Life Coolant (LLC) mixed by 30 to 50 %.
Page 232 MAINTENANCE 5 Clean Radiator, Oil Cooler Core and Inter Oil Cooler Inter Cooler Cooler Outside --- every 500 hours 6 Clean Oil Cooler, Radiator and Inter Coller Front Screen --- every 500 hours 7 Clean Air Conditioner Condenser --- every 500 hours --- every 500 hours 8 Clean Fuel Oil Cooler Radiater...
Page 233 MAINTENANCE H. ELECTRICAL SYSTEM IMPORTANT: Improper radio communication equipment and associated parts, and/or improper installation of radio communication equip- ment effects the machine's electronic parts, causing involuntary movement of the ma- chine. Also, improper installation of electrical equipment’s may cause machine failure and/ or a fire on the machine.
Page 234 MAINTENANCE If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or veg- etable oil. 3. Get medical attention immediately. IMPORTANT: Add water to batteries in freezing weather before you begin operating your machine for the day, or else charge the batteries.
Page 235 MAINTENANCE Electrolyte Level Check --- every one month 1. Check the electrolyte level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte level. 3.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.
Page 236 MAINTENANCE Check electrolyte specific gravity CAUTION: Battery gas can explode. Keep sparks and If you spill acid on yourself: flames away from batteries. Use a flashlight to check 1. Flush your skin with water. the battery electrolyte level. 2. Apply baking soda or lime to help neutralize the acid.
Page 237 MAINTENANCE REMOVE AND INSTALLING BATTERY CAUTION: When removing the battery disconnect the negative (−) terminal (ground) first, while taking care not to cause a short circuit. When installing the battery, connect the positive (+) terminal before con- necting the negative (−) terminal. REPLACING FUSES If any electrical equipment fails to operate, first check the fuses.
Page 238 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 the cause of the trouble. Remove the cover next to the engine coolant reservoir to check the fuse. Replace it if blown. + Side (Red) −...
Page 239 MAINTENANCE I. MISCELLANEOUS 1 Check Bucket Teeth --- daily Check the bucket teeth for wear and looseness Replace teeth (1) if tooth wear exceeds the designated ser- vice limit shown below. Dimension A in mm (in) M104-07-056 Model Limit of Use ZX240LC , 270LC 230 (9.1)
Page 240 MAINTENANCE 3. Clean shank (6) surface. 4. Install rubber pin lock (4) into shank (6) hole as shown. M104-07-060 5. Position new tooth (1) over shank (6). M104-07-061 6. Drive locking pin (5) fully into the hole as shown. M104-07-062 NOTE: Check the bucket teeth periodically to ensure that wear does not exceed the designed service limit.
Page 241 MAINTENANCE Check Bucket Teeth for H and BE Type Front or Super V Type Bucket Teeth (ZX350LC --- daily Check for wearing and looseness of the Bucket tooth points. 1. Replacement intervals When tooth points (1) wear beyond the service limit, replace them.
Page 242 MAINTENANCE Removing the tooth point Turn tooth point (1) to the left, twist and pull it toward you to remove it. Remove the plug, and check if rubber has cracking; if it has, replace the rubber with new one. While the pin and plug can withstand several replace- ments of the tooth point, be sure to check whether they are usable or not when replacing tooth point (1).
Page 243 MAINTENANCE 2 Change Bucket 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, and safety equipment appropriate to the job. 1. Park the machine on a level surface. Lower the bucket to the ground and position it with the flat surface rest- Bucket Boss ing on the ground.
Page 244 MAINTENANCE 3 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, and safety equipment appropriate to the job. IMPORTANT: Provide ample space for turning the bucket Bucket Boss 180°.
Page 245 MAINTENANCE 4 Adjust the 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. Park the machine on a level surface. Lower the bucket to the ground with the flat side down so that the bucket will not roll.
Page 246 MAINTENANCE 5 Remove the Travel Levers The travel levers may be removed if desired. 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Turn the key switch OFF. Remove the key. 5.
Page 247 MAINTENANCE 7 Check Windshield Washer Fluid Level --- as required. Check fluid in windshield washer tank (1). If the fluid level is low, remove cap (2) and add fluid via the opening. During winter season, use all season windshield washer which will not freeze.
Page 248 MAINTENANCE 8 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. Place blocks under the machine frame to support the machine.
Page 249 MAINTENANCE Loosen the Track 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). IMPORTANT: When gravel or mud is packed between sprockets and track links, remove it before loosening.
Page 250 MAINTENANCE 9 Clean and Replace Air Conditioner Filter Clean Filter Circulating Air Filter --- every 500 hours Fresh Air Filter --- every 500 hours Replace Filter Circulating Air Filter --- After cleaning 6 times or so Fresh Air Filter --- After cleaning 6 times or Removing Fresh Air Filter M1U1-07-010 1.
Page 251 MAINTENANCE CAUTION: Use reduced compressed air pressure (less than 0.2 MPa, 2 kgf/cm ) for cleaning purposes. Clear the area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. Cleaning Clean both the external and internal filters by blowing com- pressed air or washing with water.
Page 252 MAINTENANCE 10 Check the Air Conditioner --- daily Fan Pulley 1. Check pipe connections for refrigerant gas leakage. If oil seepage is found around pipe connections, it indi- cates possible gas leakage. 5 to 6 mm (0.2 to 0.24 in) 98 N (10 kgf, 22 lbf ) Alternator Pulley 2.
Page 253 MAINTENANCE Adjust Compressor Belt Tension Visually check the belt for wear. Replace if necessary. Check compressor belt tension by depressing the midpoint between compressor pulley and crank pulley with the thumb. Deflec- tion must be 9 to 12 mm (0.35 to 0.47 in) with a depressing force of approximately 98 N (10 kgf, 22 lbf ).
Page 254 MAINTENANCE 12 Retighten Cylinder Head Bolt --- as required See your authorized dealer. 13 Inspect and Adjust Valve Clearance --- every 1 000 hours See your authorized dealer. 14 Measure Engine Compression Pressure --- every 1 000 hours See your authorized dealer. 15 Check Starter and Alternator --- every 1 000 hours See your authorized dealer.
Page 255 MAINTENANCE 17 Check Tightening Torque of Bolts and Nuts --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- Check tightness after the first 50 hours then every 250 hours. ing a torque wrench. Tighten to torque shown if any are loose.
Page 256 MAINTENANCE 17 Check Tightening Torque of Bolts and Nuts --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- Check tightness after the first 50 hours then every 250 hours. ing a torque wrench. Tighten to torque shown if any are loose.
Page 257 MAINTENANCE 17 Check Tightening Torque of Bolts and Nuts --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- Check tightness after the first 50 hours then every 250 hours. ing a torque wrench. Tighten to torque shown if any are loose.
Page 258 MAINTENANCE Tightening Torque Chart Wrench Hexagon Bolt Dia. Size Wrench Size M55207091 M55207090 M15707225 Socket Bol N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) (3.1) (22) (2.0) (15.0) (1.0) (7.4) (6.6) (48) (5.1) (37) (2.0) (15.0) (11.0) (81) (9.2) (66) (3.6) (26.0)
Page 259 MAINTENANCE 1. Retighten the engine cushion rubber mounting bolts and nuts. M1U1-07-040 Pump Side M1U1-07-034 Fan Side 2. Retighten the engine bracket mounting bolts. M1U1-07-040 Pump Side M1U1-07-034 Fan Side 7-85...
Page 260 MAINTENANCE 3. Retighten the hydraulic oil tank mounting bolts. M1U1-07-038 4. Retighten the fuel tank mounting bolts. M1U1-07-038 5. Radiator mounting bolt ZX240LC , 270LC M1U1-07-056 ZX350LC M1U1-07-055 M1U1-07-057 7-86...
Page 261 MAINTENANCE 6. Retighten the pump transmission mounting bolts. M1U1-07-021 7. Retighten the control valve mounting bolts. M1U1-07-025 Retighten the control valve bracket mounting bolts. M1U1-07-041 7-87...
Page 262 MAINTENANCE 8. Retighten the swing device mounting bolts. M1U1-07-053 9. Retighten the swing motor mounting bolts. M1U1-07-053 10. Retighten the ORS fittings for hydraulic hoses and piping. M104-07-079 Hycolin tube mounting nut M1U1-07-035 7-88...
Page 263 MAINTENANCE 12. Retighten the battery mounting nuts. M1U1-07-016 13. Retighten the cab mounting nuts. M1U1-07-026 M1U1-07-054 Anchor Bolt Bottm View 7-89...
Page 264 MAINTENANCE 14. Retighten the cover mounting bolts. M1U1-07-042 15. Retighten flexible master coupling. Flexible Master Coupling M1G6-07-008 Retighten, Jubilee and T-bolt clamp T-bolt Clamp M157-07-215 16. Retighten the swing bearing mounting bolts to the up- perstructure. M107-07-088 Retighten the swing bearing mounting bolts to the un- dercarriage.
Page 265 MAINTENANCE 17. Retighten the travel device mounting bolts. M164-07-005 Retighten the travel reduction device cover mounting bolts. M1G6-07-007 Retighten the sprocket mounting bolts. M154-07-050 18. Retighten the upper roller mounting bolts. M157-07-224 7-91...
Page 266 MAINTENANCE 19. Retighten the lower roller mounting bolts. M107-07-092 20. Retighten the shoe mounting bolts. M107-07-093 21. Retighten the track guard mounting bolts. M107-07-094 7-92...
Page 267 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or Before Operation: Check the tightness of plug and all drain cocks. Snowy Weather After Operation: Clean the machine and check for cracks, damaged, loose or missing bolts and nuts.
Page 268 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 269 Precautions for Disconnecting or Connecting Batteries In case the batteries are kept disconnected for more than one month or when the batteries are reconnected, contact your nearest Hitachi dealer. Resetting of the ICF (Information Controller) may be required. 10-1...
Page 270 STORAGE REMOVING THE MACHINE FROM STORAGE CAUTION: Start the engine ONLY in a well-ventilated place. 1. Remove grease from the cylinder rods if coated. 2. Adjust alternator and fan belt tension. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels.
Page 271 STORAGE INSTALLING VANDAL-PROOF COVERS 1. Location of each vandal-proof covers to be installed are shown. 2. In each section, install covers in order of the numbering. 3. Lock covers in each section when finished the installa- tion. NOTE: In case the sunshade is installed on the top of the cab, remove the hatched cover shown below from cab front (1).
Page 272 STORAGE HELP PREVENT CRIME You can help take a bite out of crime by properly documenting ownership and discouraging theft. M107-09-001 RECORD IDENTIFICATION NUMBERS 1. Mark your machines with your own unique numbering system. 2. Record the Product Identification Number (PIN) of the unit and also individual component identification num- bers for engines, axles, pumps, etc.
Page 273 STORAGE WHEN PARKING OUTDOORS Make machines hard to move: • Park in a well-lighted, fenced area. • Lower all equipment to the ground. • Remove ignition key. • Remove battery when unit is storage. • Lock cab doors, windows, and vandal-proof devices. M107-09-003 REDUCE VANDALISM 1.
Page 274 STORAGE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-6...
Page 275 TROUBLESHOOTING IMPOSSIBLE TO START THE ENGINE Problem Cause Solution Starter does not rotate or is Discharged battery Charge or replace battery. not powerful Disconnected, loose, or corroded battery After repairing the corroded terminals area, securely tighten the con- nectors. Lowered pilot control shut-off lever. Pull pilot control shut-off lever Disconnected, loose, or corroded starter After repairing the corroded...
Page 276 TROUBLESHOOTING ENGINE Problem Cause Solution Engine Not Developing Full Air filters plugged Replace filter elements. Power Fuel line restricted Repair or replace fuel line. Contaminated fuel Drain fuel tank and clean outlet screen. Refill. Fuel filters plugged Change filters. Plugged vent in fuel tank cap Clean or install new cap.
Page 277 TROUBLESHOOTING ENGINE Problem Cause Solution Coolant Temperature Too Low Thermostat See your authorized dealer. Temperature gauge or sending unit See your authorized dealer. Low Engine Oil Pressure Engine oil pump or pump drive See your authorized dealer. Low oil level Add oil.
Page 278 TROUBLESHOOTING ENGINE Problem Cause Solution Nothing Works Battery Recharge or replace. Nothing Works Battery relay Replace relay. (Except clock) Batteries Undercharged Loose or corroded connections Clean and tighten or replace batteries. Alternator belt loose Tighten or install new belt. Alternator not charging See your authorized dealer.
Page 279 TROUBLESHOOTING ENGINE Problem Cause Solution Exhaust Gas is White Wrong fuel Drain tank. Use correct fuel. Cold engine Run engine until warm. Thermostat faulty or too “cool” See your authorized dealer. Injection pump out of time See your authorized dealer. Coolant leakage into engine cylinder See your authorized dealer.
Page 280 TROUBLESHOOTING ELECTRICAL SYSTEM Problem Cause Solution Engine Cranks Slowly Battery discharged or will not hold a Replace battery. charge Starter “dragging” See your authorized dealer. Low battery voltage Recharge or replace battery. Starter Motor Continues to Start relay stuck See your authorized dealer. Run After Engine Starts Starter solenoid stuck See your authorized dealer.
Page 281 TROUBLESHOOTING ELECTRICAL SYSTEM Problem Cause Solution No Indicators in Gauge Panel Circuit board See your authorized dealer. Operate Wiring harness See your authorized dealer. Fuse Replace fuse. Indicator Light in Gauge Panel is Bulb Replace bulb. Inoperative Fuse Replace fuse. Sender Do sender check.
Page 282 TROUBLESHOOTING MODE SELECTION Problem Cause Solution Work Mode Selector Mode switches See your authorized dealer. Does Not Work Electrical connector See your authorized dealer. Wire harness (between MC and See your authorized dealer. Monitor) Main controller (MC) See your authorized dealer. Solenoid valve unit See your authorized dealer.
Page 283 TROUBLESHOOTING CONTROL LEVERS Problem Cause Solution Moves Hard Corroded joint See your authorized dealer. Worn out pusher See your authorized dealer. Does Nothing Worn out pusher See your authorized dealer. Pilot valve See your authorized dealer. Does Not Return to Neutral Pilot valve See your authorized dealer.
Page 284 TROUBLESHOOTING HYDRAULIC SYSTEM Problem Cause Solution Hydraulic Oil Overheats Relief valve See your authorized dealer. Contaminated oil Drain oil and refill. Travel motors See your authorized dealer. Improperly adjusted hydraulic See your authorized dealer. components Oil Foams Air leak in line from reservoir to pump Repair leak or see your authorized dealer.
Page 285 TROUBLESHOOTING HYDRAULIC SYSTEM Problem Cause Solution One Control Lever Does Not Relief valve pressure low See your authorized dealer. Work Tube or hose damaged Repair or replace. Hydraulic fittings loose Tighten. Damaged O-rings in fittings Install new O-ring. Hydraulic Pump See your authorized dealer.
Page 286 TROUBLESHOOTING HYDRAULIC SYSTEM Problem Cause Solution Travel is Not Smooth Rocks or mud “jammed” in track frame Remove and repair. Travel brake not releasing See your authorized dealer. Swing Does Not Work Swing brake release valve See your authorized dealer. Swing motor See your authorized dealer.
Page 287 SPECIFICATIONS SPECIFICATIONS ZAXIS240LC T1V1-01-01-001 Model ZAXIS240LC Type of Front-End Attachment 2.96 m (9 ft 9 in) Arm Bucket Capacity (Heaped) PCSA 1.0 m (1.3 yd ), CECE 0.9 m Operating Weight 23900 kg (52700 lb) Base Machine Weight 18400 kg (40600 lb) –1 Engine Isuzu AH-4HK1XYSA-01 132 kW/2000 min...
Page 288 SPECIFICATIONS WORKING RANGES ZAXIS240LC T1V1-01-01-002 Model ZAXIS240LC Category 2.5 m (8 ft 2 in) Arm 2.96 m (9 ft 9 in) Arm 3.61m (11 ft 10 in) Arm ft•in ft•in ft•in Item A: Maximum Digging Reach 9880 32’5” 10290 33’9” 10910 35’10”...
Page 289 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS240LC 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary Ground For Weak Footing For Weak Footing For Paved Road Application (Standard) (Option)
Page 290 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS240LC Bucket Capacity Front-End Attachment Bucket Width ZAXIS240LC-3 Bucket mm (in) Application 2.96 m PCSA CECE (With side cutter) 3.61m 2.5 m (9’9”) (Heaped) (Heaped) (11’10”) (8’2”) Arm Standard ● ● ● 0.80 (1.05) 0.70 1080 (42.5”) ●...
Page 291 SPECIFICATIONS SPECIFICATIONS ZAXIS 270LC T1V1-01-01-001 Model ZAXIS270LC Type of Front-End Attachment 3.11 m (10 ft 2 in) K Arm Bucket Capacity (Heaped) PCSA 1.1 m (1.44 yd ), CECE 1.0 m Operating Weight 27800 kg (61300 lb) Base Machine Weight 21800 kg (48100 lb) –1 Engine...
Page 292 SPECIFICATIONS WORKING RANGES ZAXIS270LC T1V1-01-01-002 Model ZAXIS270LC 2.42 m (7 ft 11 in) Arm 3.11 m (10 ft 2 in) Arm 3.76 m (12 ft 4 in) Arm Category Item ft•in ft•in ft•in A: Maximum Digging Reach 10060 33’0” 10710 35’2”...
Page 293 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS270LC 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary Ground For Weak Footing For Weak Footing For Paved Road Application (Standard) (Option)
Page 294 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS270LC Bucket Capacity Front-End Attachment Bucket Width mm (in) ZAXIS270LC Bucket Application (With side PCSA CECE 2.42 m 3.11 m 3.76m cutter) (Heaped) (Heaped) (7’11”) (10’2”) (12’4”) ● ● ● 1.00 (1.31) 0.90 1260 (49.6”) ●...
Page 295 SPECIFICATIONS SPECIFICATIONS ZAXIS350LC T1V7-01-01-004 Model ZAXIS350LC Type of Front-End Attachment 3.2 m (10 ft 6 in) Arm Bucket Capacity (Heaped) PCSA 1.4 m (1.83 yd ), CECE 1.2 m Operating Weight 32800 kg (71000 lb) Base Machine Weight 25300 kg (54200 lb) –1 Engine Isuzu AH-6HK1XYSA-01 202 kW/1900 min...
Page 296 SPECIFICATIONS WORKING RANGES ZAXIS350LC T1V7-01-01-002 Model ZAXIS350LC Category 2.67 m (8 ft 9 in) Arm 3.2 m (10 ft 6 in) Arm 4.0m (13 ft 2 in) Arm ft•in ft•in ft•in Item A: Maximum Digging Reach 10570 34’8” 11100 36’5” 11860 38’11”...
Page 297 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS350LC 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary Ground For Weak Footing For Weak Footing For Paved Road Application (Standard) (Option)
Page 298 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS350LC Bucket Capacity Front-End Attachment Bucket Width ZAXIS350LC Bucket mm (in) Application PCSA CECE (With side cutter) 2.67 m 3.2 m 4.0m (Heaped) (Heaped) (8’9”) (10’6”) (13’2”) ● ● ● 1.15 (1.50) 1.00 1230 (48.4”) ●...
Page 299 INDEX Check Instruments After Starting ..........3-5 AM/FM Radio Operation ............1-59 Check Starter and Alternator ...........7-80 Adjust the Bucket Linkage ............7-71 Check Tightening Torque of Bolts and Nuts .......7-81 Adjust the Operator’s Seat ............S-5 Check Track Sag ................7-74 Adjusting the Seat ...............1-66 Check Water Pump ...............7-80 Adjusting Console Height ............1-68 Check Water Separator ...............7-43...
Page 300 INDEX Engine Stop Switch ..............1-50 Maintenance Guide ............... 7-9 Ensure Safety Before Rising from or Maintenance Guide Table ............7-4 Leaving Operator’s Seat ............S-5 Maintenance Under Special Environmental Conditions .. 9-1 Equipment of Head Guard, Rops, Fops ........ S-10 Maintenance settings ..............1-33 Evacuating in Case of Fire ............
Page 301 INDEX Precautions for Welding and Grinding ......... S-27 Starting the Engine in Ordinary Temperature ...... 3-3 Prepare Machine for Maintenance ........... 7-6 Stay Clear of Moving Parts ............S-22 Prepare for Emergencies .............. S-2 Steering the Machine Using Levers ......... 4-3 Prevent Battery Explosions ............
Page 302 INDEX MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................14-4...
Page 304 Hitachi Construction Machinery Co., Ltd. Head Office : 5-1, Koraku 2-chome, Bunkyo-ku, Tokyo 112-0004, Japan Recycle This manual is printed on recycled paper.

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