Hitachi ZAXIS 350K-3 Operator's Manual
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Hitachi ZAXIS 350K-3 Operator's Manual

Hitachi ZAXIS 350K-3 Operator's Manual

Hydraulic
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EM1U1-1-2
PART NO.
200
200
-3
•
270
240
240LC
-3
•
330
330
-3
•
Hydraulic Excavator
Serial No.
ZAXIS200
class
-3
ZAXIS270
class
-3
(Except 270
, 270LC
-3
ZAXIS270
, 270LC
-3
ZAXIS330
class
-3
-3
200LC
210H
-3
•
-3
250H
-3
-3
•
-3
330LC
350H
-3
•
)
-3
-3
class
210LCH
-3
•
class
250LCH
250K
-3
•
•
class
350LCH
-3
•
200001 and up
020001 and up
020002 and up
051405 and up
210K
-3
-3
•
•
250LCK
270
-3
-3
•
•
350K
-3
-3
•
•
210LCK
-3
270LC
-3
-3
•
350LCK
-3

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  • Page 1 EM1U1-1-2 PART NO. class 200LC 210H 210LCH 210K 210LCK • • • • • class 240LC 250H 250LCH 250K 250LCK 270LC • • • • • • • class 330LC 350H 350LCH 350K 350LCK • • • • • Hydraulic Excavator Serial No.
  • Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support pro- service your machine correctly. Failure to do so could re- gram for customers who operate and maintain their sult in personal injury or machine damage.

  • Page 3: Machine Numbers

    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 4: Travel Motor

    MACHINE NUMBERS TRAVEL MOTOR TYPE: MFG. NO.: M178-07-047 SWING MOTOR TYPE: MFG. NO.: M178-07-014...

  • Page 5: Hydraulic Pump

    MACHINE NUMBERS HYDRAULIC PUMP TYPE: MFG. NO.: M157-00-004...
  • Page 6 MACHINE NUMBERS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 7: Table Of Contents

    CONTENTS MACHINE NUMBERS Beware of Exhaust Fumes ............S-27 Precautions for Welding and Grinding ......... S-27 Avoid Heating Near Pressurized Fluid Lines ....... S-28 SAFETY Avoid Applying Heat to Lines Containing Recognize Safety Information ........... S-1 Flammable Fluids ..............S-28 Understand Signal Words ............
  • Page 8 Installing Fire Extinguisher ............1-56 Pilot Control Shut-off Lever ............1-57 Control Lever (Iso Pattern) ............5-1 Engine Stop Switch ..............1-57 Control Lever (HITACHI Pattern) ..........5-2 Fuse Box ...................1-58 Attchement Pedal (Hydraulic Breaker) ........5-3 Auto Air Conditioner ..............1-59 Attchement Pedal (Hydraulic Crusher) ........5-4 Cab Heater Operation ..............1-62...
  • Page 9 CONTENTS Maintenance Guide ............... 7-9 Remove the Travel Levers ...........7-72 A. Greasing ..................7-14 Check and Replace Seat Belt Check ........7-72 Front Joint Pins ...............7-14 Check Windshield Washer Fluid Level ......7-73 Swing Bearing .................7-16 Check Track Sag ..............7-74 Swing Internal Gear ..............7-17 Clean and Replace Air Conditioner Filter B.
  • Page 10 CONTENTS Shoe Types and Applications (ZAXIS250K 250LCK ) ................12-17 Bucket Types and Applications (ZAXIS250K , 250LCK ) ........... 12-18 Specifications (ZAXIS270 , 270LC ) ........12-19 Working Ranges (ZAXIS270 , 270LC ) ......12-20 Shoe Types and Applications (ZAXIS270 , 270LC ) ..

  • Page 11: Safety

    SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS...

  • Page 12: Follow Safety Instructions

    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 13: Wear Protective Clothing

    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 14: General Precautions For Cab

    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 15: Use Handholds And Steps

    SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. •...

  • Page 16: Fasten Your Seat Belt

    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 17: Operate Only From Operator's Seat

    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 18: Precautions For Operations

    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 19: Investigate Job Site Beforehand

    SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from fall- ing and to prevent the ground, stockpiles, or banks from collapsing.

  • Page 20: Equipment Of Head Guard, Rops, Fops

    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 21: Drive Machine Safely

    SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine.
  • Page 22 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 23: Avoid Injury From Rollaway Accidents

    SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. •...

  • Page 24: Avoid Injury From Back-Over And Swing Accidents

    SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: •...

  • Page 25: Keep Person Clear From Working Area

    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 26: Avoid Tipping

    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 27: Dig With Caution

    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 28: Avoid Power Lines

    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 29: Protect Against Flying Debris

    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 30: Transport Safely

    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 31: Practice Safe Maintenance

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

  • Page 32: Warn Others Of Service Work

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

  • Page 33: Prevent Parts From Flying

    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 34: Prevent Burns

    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 35: Avoid High-Pressure Fluids

    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 36: Prevent Fires

    SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

  • Page 37: Evacuating In Case Of Fire

    SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF po- sition if there is time. • Use a fire extinguisher if there is time. •...

  • Page 38: Avoid Heating Near Pressurized Fluid Lines

    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 39: Beware Of Asbestos Dust

    • 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 40: Handle Chemical Products Safely

    • 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 41: Safety Signs

    Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. RIGHT WINDOW SS-2818...
  • Page 42 SAFETY SIGNS/Oceania Model Only 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.
  • Page 43 SAFETY SIGNS/Oceania Model Only If the machine should overturn, the operator may become injured and/or throw from the cab and/or crushed by the overturning machine. SS3088058 Do not extend your hands or head from the window. Your hands or head may come in contact with the boom. SS-859 SS3106039 Sign indicates a hazard of being hit by the working device...
  • Page 44 SAFETY SIGNS/Oceania Model Only 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. SS-408 Sign indicates a burn hazard from compressed air and spurt- ing hot oil if the oil inlet is uncapped during or right after operation.
  • Page 45 SAFETY SIGNS/Oceania Model Only 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 46 SAFETY SIGNS/Oceania Model Only 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 47 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-2811...
  • Page 48 SAFETY SIGNS/Asia/Middle and Near East Model Only WARNING! Prior to operation, maintenance, disassembling, and trans- portation of the machine, be sure to read and understand the Operator’s Manual. SS-1616 If the parked machine is unexpectedly moved, serious injury or death due to crushing may result. Be sure to lower the front attachment to the ground, lock the control levers, and remove the engine key before leaving the machine unat- tended.
  • Page 49 SAFETY SIGNS/Asia/Middle and Near East Model Only When moving the seat height/tilt lever downward, press the lever grip with a palm from the top side. Do not grasp the lever grip to operate the lever, possibly resulting in pinch of your fingers into the seat stand.
  • Page 50 SAFETY SIGNS/Asia/Middle and Near East Model Only SS3106039 Sign indicates a hazard of being hit by the working device of the machine. Keep away from machine during operation. SS3089581 Sign indicates a hazard of a flying plug from track adjuster that could cause injury.
  • Page 51 SAFETY SIGNS/Asia/Middle and Near East Model Only 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. SS4459928 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
  • Page 52 SAFETY SIGNS/Asia/Middle and Near East Model Only Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine. SS-1614 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
  • Page 53 SAFETY SIGNS/Asia/Middle and Near East Model Only Sign indicates an electrical hazard from handing the cable. Read manual for sase and proper handing. SS4459714 Sign indicates an explosion hazard. Keep fire and open flames away from this area. SS4460067 Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness.
  • Page 54 SAFETY SIGNS/Asia/Middle and Near East Model Only MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 55: Components Name

    COMPONENTS NAME COMPONENTS NAME 1- Bucket 2- Bucket Cylinder 3- Arm 4- Arm Cylinder 5- Boom Cylinder 6- Boom 7- Fuel Tank 8- Hydraulic Oil Tank 9- Engine 10- Counterweight 11- Travel Device 12- Track 13- Front Idler 14- Cab M1U1-01-005...

  • Page 56: Operator's Station

    OPERATOR'S STATION CAB FEATURES Std. Model 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 57 OPERATOR'S STATION CAB FEATURES K. Model 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- Attachment Pedal (Optional) 7- Right Control Lever/Power Boost Switch 8- Multi Function Monitor Panel 9- Switch Panel 10- Key Switch...

  • Page 58: Multi Function Monitor

    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 59: Outline

    OPERATOR'S STATION OUTLINE 1 - Work Mode Display 2 - Auto-Idle Display 3 - Overload Alarm Display (Optional) 4 - Auxiliary 5 - Auxiliary 6 - Preheat Display 7 - Work Mode Display 8 - Hour Meter 9 - Auxiliary 10 - Fuel Gauge 11 - Mail Display (Optional) 12 - Auxiliary...
  • Page 60 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. M1U1-01-112 Digging Mode T1V1-05-01-108 Attachment Mode Breaker...
  • Page 61 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. Overload Alarm Display (3) (optional) T1V1-05-02-002 The system measures the load of suspended load from the bottom pressure of boom cylinder.

  • Page 62: Menu Screen (23)

    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). T1V5-05-01-019...

  • Page 63: Hour Meter

    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 64: Menu Key

    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 : Mail (Optional)

  • Page 65: Coolant Temperature Gauge

    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 66 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 67 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. T1V5-05-01-093 Password Input Screen T1V5-05-01-002 Determination Key Delete Key 2. Return to the password input screen, by pushing the back key.
  • Page 68 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 69 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 70: Alarm Occurrence Screen

    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 T1V1-05-01-095 • When the number of alarms is three or more T1V1-05-01-096 1-16...
  • Page 71 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. T1V1-05-01-095 Push a Relevant Key T1V5-05-01-013 1-17...

  • Page 72: Contents Of Alarms

    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 73 OPERATOR'S STATION • Fuel Sensor Error Display Fuel Sensor Error Coolant Temperature 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 74: Clock Setting

    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- T1V1-05-01-123 ed under...

  • Page 75: Attachment Selection (Only Machines Equipped With Optional Parts)

    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 76 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 77 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 78 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 79: Pump 2 Flow Rate Adjustment (Only Machines Equipped With Optional Parts)

    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 80: Displaying Operating Conditions

    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 81: Fuel Rate Display/No Display

    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 T1V1-05-01-123 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 82 OPERATOR'S STATION 4. Push key 6 , and the fuel rate display will be added to basic screen. T1V5-05-01-119 Key 6 T1V1-05-01-007 Fuel Rate 1-28...
  • Page 83 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 T1V1-05-01-007 2. Select fuel rate display/No display from main menu by using keys 1 and 2 .
  • Page 84 OPERATOR'S STATION 4. Push key 6 , and return to the basic screen. T1V5-05-01-164 Key 6 Basic Screen T1V1-05-01-123 1-30...
  • Page 85 • Overload Alarm (Only machines equipped with optional parts) IMPORTANT: When using overload alarm, consult your nearest Hitachi dealer. When the overload alarm switch is turned ON, the system measures load of the suspended load from bottom pressure of the boom cylinder. An alarm message is displayed and buzzer is rung, if overload is detected.
  • Page 86 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 T1V1-05-01-123 2. Select password change from main menu by using keys 1 and 2. Push the determination key. Then, the password change screen displays.
  • Page 87 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. T1V5-05-01-044 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 88 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. T1V5-05-01-132 Determination Key T1V5-05-01-133 Delete Key 9.

  • Page 89: Back Monitor Settings

    OPERATOR'S STATION BACK MONITOR SETTINGS IMPORTANT: Image displayed on the back monitor is of auxiliary nature at best. When the machine is operated pay thorough attention to sur- rounding situation. Auto-Control: ON Image on the monitor unit when traveling is automatically switched to that of the back monitor.
  • Page 90 OPERATOR'S STATION Auto-Control: OFF Set automatic switching function of images between moni- tor unit and back monitor when traveling to OFF. 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen T1V1-05-01-123 2.

  • Page 91: Maintenance Settings

    OPERATOR'S STATION MAINTENANCE SETTINGS 1. When the basic screen diplays, push the menu key and display main menu. Menu Key Basic Screen T1V1-05-01-123 2. Select maintenance settings from main menu by using keys 1 and 2 . Push the determination key. Then, the maintenance settings screen displays.
  • Page 92 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 93 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 94 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 95 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 96: Mail (Optional)

    IMPORTANT: This function is available only to a ma- chine equipped with a satellite terminal. When using the mail function, consult your nearest Hitachi dealer. 1. When the basic screen displays, push mail selection key F3 and display mail screen.
  • Page 97 OPERATOR'S STATION NOTE: When satellite terminal could not receive the mail, the message “Mail delivery failed.” is displayed on the screen. T1V5-05-01-040 1-43...

  • Page 98: Language Settings

    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 99 OPERATOR'S STATION Lists of Display Language Display Languages 1 Language Screen Display Japanese T1V1-05-01-141 English T1V1-05-01-142 Chinese (Simplified) T1V1-05-01-143 Chinese (Traditional) T1V1-05-01-144 Korean T1V1-05-01-145 Indonesian T1V1-05-01-146 Thai T1V1-05-01-147 Vietnamese T1V1-05-01-148 Myanmarese T1V1-05-01-149 Arabic T1V1-05-01-150 Persian T1V1-05-01-151 Turkish T1V1-05-01-152 Display Languages 2 Language Screen Display English...

  • Page 100: Switch Panel

    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 7- Overhead Window Washer Switch (Optional) 8- Overhead Window Wiper Switch (Optional) M1U1-01-015 Std. Model M1U1-01-006 M1U1-01-016 1-46...

  • Page 101: Engine Control Dial

    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 102: Power Mode Switch

    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 103: Work Light Switch

    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 104: Wiper/Washer Switch

    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 105 OPERATOR'S STATION • Washer (K Model) (Overhead Window) As long as the wiper washer switch (1) is held down, washer fluid will be squirted from the nozzles on the front window and overhead window. Continue holding the wiper washer switch (1) for more than 2 seconds to automatically operate the front window wiper.

  • Page 106: Switch Panel (Optional)

    OPERATOR'S STATION SWITCH PANEL (Optional) NOTE: • The optional switch 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 107 OPERATOR'S STATION Electrical Control Main Switch (Optional) 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 108: Key Switch

    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 109: Cigar Lighter

    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 110: Cab Light

    Turn the cab light ON or OFF by using switch (1). M178-01-022 INSTALLING FIRE EXTINGUISHER (Optional) A fire extinguisher (2) can be installed at the right rear corner inside the cab. Consult your nearest HITACHI dealer to install a fire extinguisher. M1U1-01-021 1-56...

  • Page 111: Pilot Control Shut-Off Lever

    OPERATOR'S STATION PILOT CONTROL SHUT-OFF LEVER Pilot control shut-off lever (1) functions to prevent the machine from being mistakenly operated when the operator is getting on or off the machine. WARNING: • Pilot control will not be shut-off unless pilot con- trol shut-off lever (1) is completely pulled-up to the LOCK position.

  • Page 112: Fuse Box

    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 113: Auto Air Conditioner

    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 114 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 115 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 116: Cab Heater Operation

    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 117: Cooling Operation

    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 118 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 119: Tips For Optimal Air Conditioner Usage

    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 120: Cab Heater (Optional)

    OPERATOR'S STATION CAB HEATER (Optional) Part Name and Location 1- Front Vent 2- Foot Vent 3- Defroster Vent 4- Rear Vent 5- Control Panel 6- Mode Switch 7- Fresh Air Vent Switch 8- Temperature Control Switch 9- Blower Switch 10- OFF Switch M1U1-01-025 NOTE: Air flow direction can be changed by controlling the louvers at all air vents except for the foot vents.

  • Page 121: Cab Heater Operation

    OPERATOR'S STATION • Blower Switch (9) The blower speed is controlled from Lo to Hi in 4 steps. When the button is pressed first, the blower starts running in the HI mode. Then, each time the but- ton is pressed, the blower speed is reduced by one step. The blower speed indicator corresponding to the blower speed is lit.

  • Page 122: Defroster Operation

    OPERATOR'S STATION DEFROSTER OPERATION Press mode switch (6) (either the front or front/rear vent mode switch). Set temperature control switch (8) to the heat operation position. Press fresh air mode switch (7). Press blower switch (9). Warm air will blow out from the front or front/ rear vents.

  • Page 123: Am/Fm Radio Operation

    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 124: Digital Clock Setting Procedure

    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 125: Cab Door Release Lever

    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 126: Closing Upper Front Window

    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 127: Removing And Storing Lower Front Window

    OPERATOR'S STATION REMOVING AND STORING LOWER FRONT WINDOW CAUTION: Take care not to pinch yours fingers when handling the lower front window. 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 128: Opening/Closing Overhead Window

    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 129: Emergency Exit

    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 130: Adjusting The Seat

    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 131 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 132: Adjusting The Air-Suspension Seat (Optional)

    OPERATOR'S STATION ADJUSTING THE AIR-SUSPENSION SEAT (Optional) 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 133 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 134: Adjusting Console Height

    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 135: Seat Belt

    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 136 OPERATOR'S STATION MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-82...

  • Page 137: Break-In

    BREAK-IN OBSERVE ENGINE OPERATION CLOSELY IMPORTANT: Be extra cautious during the first 50 hours, until you become thoroughly familiar with the sound and feel of your new machine. 1. Operate the machine only in economy (E) mode and limit the engine horsepower up to about 80 % of full load. 2.
  • Page 138 BREAK-IN MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 139: Operating The Engine

    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 140: Before Starting Engine

    ON position, return key switch to OFF. Wait for more than 30 seconds (the buzzer stopped), then try again. If the security lock screen is displayed again, contact your nearest HITACHI dealer. Security Lock Screen T1V5-05-01-005...

  • Page 141: Starting The Engine In Ordinary Temperature

    Unless the TEN-key function (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 M1U1-01-033 M178-01-049 Password Input Screen...
  • Page 142 OPERATING THE ENGINE NOTE: When maintenance information display is ON with maintenance setting, the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds. Then, the basic screen displays. 7. The basic screen will be displayed on the monitor. Check that the preheat indicator (4) is OFF at this time.

  • Page 143: Starting In Cold Weather

    Unless the TEN-key function (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 M1U1-01-033 M178-01-049 Password Input Screen...
  • Page 144 OPERATING THE ENGINE NOTE: When maintenance information display is ON with maintenance setting, the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds. Then, the basic screen displays. 7. The basic screen will be displayed on the monitor. The machine will automatically check if preheating is required or not.

  • Page 145: Check Instruments After Starting

    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 146: Using Booster Batteries

    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 ventilated area. Do not continue to use or charge the battery when electrolyte level is lower than specified.
  • Page 147 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 148: Stopping The Engine

    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 149: Driving The Machine

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

  • Page 150: Steering The Machine Using Pedals

    DRIVING THE MACHINE STEERING THE MACHINE USING PEDALS WARNING: In the standard travel position, the front Front Idler idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are positioned at the front of the machine, the control ac- tions of the travel pedals will be reversed.

  • Page 151: Steering The Machine Using Levers

    DRIVING THE MACHINE STEERING THE MACHINE USING LEVERS WARNING: In the standard travel position, the front Front Idler idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are positioned at the front of the machine, the control ac- tions of the travel levers will be reversed.

  • Page 152: Travel Mode Switch

    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 153: Operating On Soft Ground

    DRIVING THE MACHINE OPERATING ON SOFT GROUND • Avoid traveling on very soft ground that does not have sufficient strength to firmly support the machine. • If the machine is operated on very soft ground or be- comes stuck, it may be necessary to clean the track frame area.

  • Page 154: Towing Machine A Short Distance

    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 155: Operating In Water Or Mud

    DRIVING THE MACHINE OPERATING IN WATER OR MUD The machine can be operated in water up to the upper edge of the upper rollers only if worksite footing has sufficient strength to prevent the machine from sinking past the upper edge of the upper roller, and only if the water is flowing slowly.

  • Page 156: Parking The Machine On Slopes

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

  • Page 157: Operating The Machine

    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 158: Control Lever (Hitachi Pattern)

    OPERATING THE MACHINE CONTROL LEVER (HITACHI 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 159 OPERATING THE MACHINE ATTACHMENT PEDAL (HYDRAULIC BREAKER) (K Model) 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 160 OPERATING THE MACHINE ATTACHMENT PEDAL (HYDRAULIC CRUSHER) (K Model) 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 161: Pilot Control Shut-Off Lever

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

  • Page 163: Engine Speed Control

    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 164: Auto-Idle

    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 165: Work Mode

    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 166: Work Mode Select

    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 167: Power Boost

    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 5-11...

  • Page 168: Power Mode

    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 169: Operating Backhoe

    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 170: Face Shovel Operation

    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 171: Operating Tips

    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 172: Hydraulic Breaker And Hydraulic Crusher

    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 173: Pipings For Breaker And Crusher

    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 174: Secondary Relief Pressure Adjustment

    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 175: Precautions For Breaker Operation

    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 176 OPERATING THE MACHINE • Do not operate the breaker in water. Doing so will cause WRONG rust and seal damage, resulting in damage to the hydrau- lic 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 177 OPERATING THE MACHINE • Do not operate breaker with the arm positioned vertically. Excessive vibration to the arm cylinder will occur, causing WRONG 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 178: Breaker Maintenance

    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 changing intervals are shown below. (For filter replace- become contaminated faster and to quickly deteriorate the hy- ment and oil changing intervals are shown below.(For fil- draulic oil.

  • Page 179: Precautions For Crusher Operation

    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 180 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 181: Attachment

    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 182 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 183 Thoroughly read and understand the Always contact your nearest HITACHI dealer before installing attachments shown with this mark *. base machine operator’s manual and the attachment manual to prevent accidents.
  • Page 184 OPERATING THE MACHINE Crusher (ZX200 Class) SANGO Maker HITACHI NPK ✽ Sakado Oosumi STK ✽ JYUKI Model HSC100 HSC160 TS850RCD S-22XA SPAC80R-3 MR1100-2 CX1100 2430 2300 2000 2000 1640 2100 2350 Weight kg (lb) (5360) (5070) (4410) (4410) (3620) (4630)

  • Page 185: Attachment Connection Parts

    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 186: Precaution For Arm Roll-In/Bucket Roll-In Combined Operation

    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 187: Shackle Hole Usage

    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 188: Emergency Boom Lowering Procedure (Without Hose-Rupture Safety Valve)

    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 189: Object Handling

    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 190 OPERATING THE MACHINE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 191: Transporting

    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 192 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 193 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 194 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 195: Machine Lifting Procedure

    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 196 TRANSPORTING MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 197: Maintenance

    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 198: Check The Hour Meter Regularly

    MAINTENANCE Hitachi machine models are classified into 3 classes and 2 models as shown in the table below. When referring to the texts and/or illustrations indicated with the applicable machine class names in this manual, check that the machine models concerned are included using this table.

  • Page 199: Layout

    MAINTENANCE LAYOUT Arm Cylinder Boom Center Joint Tool Box Bucket Cylinder Swing Bearing Swing Device Work Light Link B Fuel Tank Boom Cylinder Control Valve Link A Hydraulic Oil Tank Muffler Bucket Fuel Filter Pilot Filter Side Cutter Tooth Engine Oil Filter Control Lever Pump Engine...

  • Page 200: Maintenance Guide Table

    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 201 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 202: Prepare Machine For Maintenance

    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 203: Hood And Access Covers

    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 204: Periodic Replacement Of Parts

    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 205: Maintenance Guide

    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...
  • Page 206 MAINTENANCE D. HYDRAULIC SYSTEM (See Page 7-25) Interval (hours) Parts Quantity 500 1000 1500 2500 5000 1. Check Hydraulic Oil Level 200L ZX200 Class ✸ ✸ ✸ ✸ (52.8 US gal) 243 L 2. Change Hydraulic Oil ZX270 Class ✸ ✸...
  • Page 207 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 208 ✸ 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 209 –10 to 40°C Temp. (–4 to 104°F) (14 to 104°F) (–4 to 104°F) (–4 to 104°F) (14 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 210: Greasing

    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 211 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 212: Swing Bearing

    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 213: Swing Internal Gear

    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 214: Engine

    MAINTENANCE B. ENGINE 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 215: Change Engine Oil

    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. Replace Engine Oil Filter --- every 500 hours IMPORTANT: Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more.
  • Page 216 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 217: Transmission

    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 218: Swing Reduction Gear

    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 219: Travel Reduction Gear

    MAINTENANCE Air Release Plug 1 3 Travel Reduction Gear (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 220 MAINTENANCE Chenge 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 221: Hydraulic System

    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 222 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 223: Breaker Maintenance

    MAINTENANCE BREAKER MAINTENANCE Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter Hydraulic breaker operation subjects the hydraulic system to related hydraulic system components. Recommended changing intervals are shown below. (For filter replace- become contaminated faster and to quickly deteriorate the hy- ment and oil changing intervals are shown below.(For fil- draulic oil.

  • Page 224: Check Hydraulic Oil Level

    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 225: Change Hydraulic Oil

    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 226 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 227 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 228: Replace Hydraulic Tank Oil Filter

    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 229: Replace Pilot Oil Filter

    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 230: Replace Air Breather Element

    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 231: Check Hoses And Lines

    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 232 (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 233 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 234: Service Recommendations For Hydraulic Fittings

    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 235 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 236: Fuel System

    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- T1V1-05-01-123 gine is not properly shut down.
  • Page 237 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 ZX200 Class 400 L (106 US gal) ZX270 Class 500 L (132 US gal) ZX330 Class...

  • Page 238: Drain Fuel Tank Sump

    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 239: Check Water Separator

    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 240 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 241 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 242 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 243: Replace Fuel Main Filter Element

    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 244: Replace Fuel Pre-Filter Element

    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 245: Clean Fuel Solenoid Pump Strainer

    MAINTENANCE 5 CLEAN FUEL SOLENOID PUMP STRAINER: --- every 500 hours Cleaning When the strainer is disassembled, be sure to replace the gasket. Install the cover and the magnet only after suffi- ciently cleaning them. After being assembled, closely check the air-tightness of the strainer.

  • Page 246: Check Fuel Hoses

    (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 247: Air Cleaner

    MAINTENANCE F. AIR CLEANER Clean the Air Cleaner Outer Element --- every 250 hours or when the restriction indicator comes ON Replace the Air Cleaner Outer and Inner Elements --- after cleaning six times or after one year 1. Park the machine on a level surface. 2.
  • Page 248 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 249: Cooling System

    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 250 MAINTENANCE LLC Mixing Table (ZX200 , 270 Class) Refill capacities Mixing Air temperature ratio Soft water ° C ° F liters liters –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 –30 –22 13.0...

  • Page 251: Check Coolant Level

    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 252: Check And Adjust Fan Belt Tension

    MAINTENANCE 2 Check and Adjust Fan Belt Tension Deflection --- every 100 hours (first time after 50 hours) 5~6 mm 98 N (10 kgf ) IMPORTANT: Loose fan belt may result in insufficient bat- tery charging, engine overheating as well as a rapid, abnormal belt wear.

  • Page 253: Change Coolant

    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 Long-Life Coolant (LLC) mixed by 30 to 50 %. ZX200...

  • Page 254: Clean Radiator, Oil Cooler Core And Inter Cooler

    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 Cooler Front Screen --- every 500 hours 7 Clean Air Conditioner Condenser --- every 500 hours 8 Clean Fuel Oil Cooler --- every 500 hours Radiator...

  • Page 255: Electrical System

    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 256 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 257 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 258: Replace Batteries

    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 259: Remove And Installing Battery

    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 260 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 261: Miscellaneous

    MAINTENANCE I. MISCELLANEOUS 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 ZX200 Class 200 (7.9)
  • Page 262 MAINTENANCE 3. Clean shank (6) surface. 4. Install rubber pin lock (4) into shank (6) hole as shown. RIGHT WRONG WRONG M104-07-060 5. Position new tooth (1) over shank (6). RIGHT WRONG WRONG M104-07-061 6. Drive locking pin (5) fully into the hole as shown. RIGHT WRONG M104-07-062...
  • Page 263 MAINTENANCE Check Bucket Teeth for H and BE Type Front or Super V Type Bucket Teeth (ZX 200 , 330 Class) ----- 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 264 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 265: Change Bucket

    MAINTENANCE 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 266: Convert Bucket Connection Into Face Shovel

    MAINTENANCE Convert Bucket Connection Into Face Shovel O-Ring Shift CAUTION: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris; wear goggles or safety glasses, and safety equipment appropriate to the job. IMPORTANT: Provide ample space for turning the bucket Bucket Boss 180°.

  • Page 267: Adjust The Bucket Linkage

    MAINTENANCE 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 268: Remove The Travel Levers

    MAINTENANCE 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 269: Check Windshield Washer Fluid Level

    MAINTENANCE 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 270: Check Track Sag

    MAINTENANCE Check Track Sag --- every 50 hours Swing the upperstructure 90° and lower the bucket to raise the track off the ground as shown. 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 271 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 272: Clean And Replace Air Conditioner Filter Clean Filter

    MAINTENANCE 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 so Removing Fresh Air Filter M1U1-07-010...

  • Page 273: Installation

    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 274: Check The Air Conditioner

    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 98 N (10 kgf ) Alternator Pulley 2.

  • Page 275: Clean Cab Floor

    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 276: 12 Retighten Cylinder Head Bolt

    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 277: Check Tightening Torque Of Bolts And Nuts

    MAINTENANCE Check Tightening Torque of Bolts and For tightening nuts and bolts other than specified in the table below, refer to the Tightening Torque Chart Nuts at the end of this section. --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- ing a torque wrench.
  • Page 278 MAINTENANCE Check Tightening Torque of Bolts and For tightening nuts and bolts other than specified in the table below, refer to the Tightening Torque Chart Nuts at the end of this section. --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- ing a torque wrench.
  • Page 279 MAINTENANCE For tightening nuts and bolts other than specified in 16 Check Tightening Torque of Bolts and the table below, refer to the Tightening Torque Chart Nuts at the end of this section. --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- ing a torque wrench.
  • Page 280 MAINTENANCE For tightening nuts and bolts other than specified in 16 Check Tightening Torque of Bolts and the table below, refer to the Tightening Torque Chart Nuts at the end of this section. --- every 250 hours (first time after 50 hours) IMPORTANT: Check and tighten bolts and nuts us- ing a torque wrench.
  • Page 281 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 282 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 7-86...
  • Page 283 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 ZX200 class M1U1-07-073 ZX270 class M1U1-07-056 ZX330 class ZX330 class M1U1-07-055 M1U1-07-057 7-87...
  • Page 284 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 7-88...
  • Page 285 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 7-89...
  • Page 286 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 7-90...
  • Page 287 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 288 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 7-92...
  • Page 289 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 7-93...
  • Page 290 MAINTENANCE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-94...

  • Page 291: Maintenance Under Special Environmental Conditions

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

  • Page 293: Storing The Machine

    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 294: Removing The Machine From Storage

    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 295: Troubleshooting

    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 296: Engine

    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 297 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 298 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 299 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 300: Electrical System

    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 301 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 302: Mode Selection

    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 303: Control Levers

    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 304 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 305 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 306 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 307: Specifications

    SPECIFICATIONS SPECIFICATIONS ZAXIS200 , ZAXIS200LC , ZAXIS210H , ZAXIS210LCH T1V1-01-01-006 Model ZAXIS200 ZAXIS200LC ZAXIS210H ZAXIS210LCH Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm 2.91 m (9 ft 7 in) H Arm Bucket Capacity (Heaped) PCSA 0.8 m (1.05 yd ), CECE 0.7 m Operating Weight...

  • Page 308: Working Ranges (Zaxis200 , Zaxis200Lc Zaxis210H , Zaxis210Lch )

    SPECIFICATIONS WORKING RANGES ZAXIS200 , ZAXIS200LC , ZAXIS210H , ZAXIS210LCH T1V1-01-01-002 Model ZAXIS200-3, 200LC-3 ZAXIS210H-3, 210LCH-3 2.42 m (7 ft 11 in) Arm 2.91 m (9 ft 7 in) Arm 2.91 m (9 ft 7 in) H Arm Category Item ft•in ft•in ft•in...

  • Page 309: Shoe Types And Applications (Zaxis200 Zaxis200Lc , Zaxis210H , Zaxis210Lch )

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS200 600 mm (24”) 700 mm (28”) 800 mm (31”) *600 mm (24”) *900 mm (35”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Triangular Shoe For Ordinary For Weak Foot- For Weak Foot- For Weak Foot- For Paved Road Application...

  • Page 310: Specifications

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS210H 900 mm (35”) 600 mm (24”) 700 mm (28”) 600 mm (24”) Shoe Width Triangular Grouser Shoe Grouser Shoe Flat Shoe Shoe For Ordinary For Weak For Paved For Weak Application Ground Footing Road Footing (Standard) (Option)
  • Page 311 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS200 , ZAXIS200LC , ZAXIS210H , ZAXIS210LCH Bucket Capacity Bucket Width (in) Bucket Application Front-End Attachment (With side cutter) ZAXIS ZAXIS ZAXIS200 ZAXIS200LC 210H 210LCH PCSA CECE 2.42 m 2.91 m 2.42 m 2.91 m 2.91 m 2.91 m (Heaped)

  • Page 312: Specifications

    SPECIFICATIONS SPECIFICATIONS ZAXIS210K , 210LCK T1V1-01-01-001 Model ZAXIS210K-3 ZAXIS210LCK-3 Type of Front-End Attachment 2.91 m (9 ft 7 in) K Arm Bucket Capacity (Heaped) PCSA 0.8 m (1.05 yd ), CECE 0.7 m Operating Weight 21100 kg (46500 lb) 21600 kg (47600 lb) Base Machine Weight 16400 kg (36200 lb) 16800 kg (37000 lb)
  • Page 313 SPECIFICATIONS WORKING RANGES ZAXIS210K , 210LCK T1V1-01-01-002 Model ZAXIS210K , 210LCK 2.91 m (9 ft 7 in) K Arm Category Item ft•in A: Maximum Digging Reach 9920 32’7” B: Maximum Digging Depth *6670 *21’11” C: Maximum Cutting Height *10040 *32’11” D: Maximum Dumping Height *7180 *23’7”...

  • Page 314: Shoe Types And Applications (Zaxis250K 250Lck )

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS210K 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary For Weak For Weak For Paved Application Ground Footing Footing Road (Standard) (Option)

  • Page 315: Bucket Types And Applications (Zaxis250K , 250Lck )

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS210K-3 ， ZAXIS210LCK Bucket Width Front-End Bucket Capacity (in) Attachment Bucket Application (With side cutter) ZAXIS210K ZAXIS210LCK PCSA CECE 2.91 m (9’7”) 2.91 m (9’7”) (Heaped) (Heaped) K Arm K Arm 0.51 (0.67) 0.45 830 (33”) 0.80 (1.05) HD 1150 (45”) Hoe Bucket...
  • Page 316 SPECIFICATIONS SPECIFICATIONS ZAXIS240 , 240LC , 250H , 250LCH T1V1-01-01-001 Model ZAXIS240 ZAXIS240LC ZAXIS250H ZAXIS250LCH Type of Front-End Attachment 2.96 m (9 ft 9 in) Arm 2.96 m (9 ft 9 in) H Arm Bucket Capacity (Heaped) PCSA 1.0 m (1.3 yd ), CECE 0.9 m Operating Weight...

  • Page 317: Working Ranges

    SPECIFICATIONS WORKING RANGES ZAXIS240 , 240LC , 250H , 250LCH T1V1-01-01-002 ZAXIS250H Model ZAXIS240 , 240LC 250LCH 2.96 m (9 ft 9 in) 3.61m (11 ft 10 in) 2.96 m (9 ft 9 in) Category 2.5 m (8 ft 2 in) Arm H Arm ft•in ft•in...

  • Page 318: Shoe Types And Applications (Zaxis270 , 270Lc )

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS240 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) 760 mm (30”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Triangular Shoe For Ordinary For Weak For Weak For Weak For Paved Road Application Ground...

  • Page 319: Shoe Types And Applications (Zaxis350K , 350Lck Bucket Types And Applications (Zaxis350K , 350Lck )

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS250H 760 mm (30”) 900 mm (35”) 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Triangular Triangular Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Shoe Shoe For Ordinary For Weak For Weak For Paved...
  • Page 320 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS240 , 240LC , 250H , 250LCH Bucket Capacity Front-End Attachment Bucket Width ZAXIS250 ZAXIS250 ZAXIS240 ZAXIS240LC (in) Bucket Application PCSA CECE 2.96 m 2.96 m 2.96 m 2.96 m (With side cut- 2.5 m (8’ 3.61m 2.5 m 3.61m...
  • Page 321 SPECIFICATIONS SPECIFICATIONS ZAXIS250K , 250LCK T1V1-01-01-001 Model ZAXIS250K ZAXIS250LCK Type of Front-End Attachment 2.96 m (9 ft 9 in) K Arm Bucket Capacity (Heaped) PCSA 1.0 m (1.3 yd ), CECE 0.9 m Operating Weight 25400 kg (56000 lb) 26000 kg (57300 lb) Base Machine Weight 19500 kg (43000 lb) 20100 kg (44300 lb)
  • Page 322 SPECIFICATIONS WORKING RANGES ZAXIS250K , 250LCK T1V1-01-01-002 Model ZAXIS250K , 250LCK 2.96 m (9 ft 9 in) K Arm Category Item ft•in A: Maximum Digging Reach 10290 33’9” B: Maximum Digging Depth *6960 *22’10” C: Maximum Cutting Height *10160 *33’4” D: Maximum Dumping Height *7200 *23’8”...
  • Page 323 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS250K 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary For Weak For Weak For Paved Application Ground Footing Footing Road (Standard) (Option)
  • Page 324 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS250K , ZAXIS250LCK Front-End Bucket Width Bucket Capacity Attachment (in) Bucket Application ZAXIS250K ZAXIS250LCK (With side PCSA CECE cutter) 2.96 m (9’9”) 2.96 m (9’9”) (Heaped) (Heaped) K Arm K Arm 0.80 (1.05) 0.70 1080 (42.5”) ●...
  • Page 325 SPECIFICATIONS SPECIFICATIONS ZAXIS270 , 270LC T1V1-01-01-001 Model ZAXIS270 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 27300 kg (60200 lb) 27800 kg (61300 lb) Base Machine Weight 21300 kg (47000 lb) 21800 kg (48100 lb)
  • Page 326 SPECIFICATIONS WORKING RANGES ZAXIS270 , 270LC T1V1-01-01-002 Model ZAXIS270 , 270LC 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”...
  • Page 327 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS270 900 mm (35”) 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Triangular Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe Shoe For Ordinary For Weak For Weak For Paved For Weak Application Ground...
  • Page 328 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS270 , 270LC Bucket Capacity Front-End Attachment Bucket Width (in) ZAXIS270 ZAXIS270LC Bucket Application 2.42 m 3.11 m 3.76m 2.42 m 3.11 m 3.76m PCSA CECE (With side (7’11”) (10’2”) (12’4”) (7’11”) (10’2”) (12’4”) (Heaped) (Heaped) cutter) 1.00 (1.31)
  • Page 329 SPECIFICATIONS SPECIFICATIONS ZAXIS330 , 330LC , 350H , 350LCH T1V7-01-01-004 Model ZAXIS330 ZAXIS330LC ZAXIS350H ZAXIS350LCH Type of Front-End Attachment 3.2 m (10 ft 6 in) Arm 3.2 m (10 ft 6 in) H Arm Bucket Capacity (Heaped) PCSA 1.4 m (1.83 yd ), CECE 1.2 m PCSA 1.38 m...
  • Page 330 SPECIFICATIONS WORKING RANGES ZAXIS330 , 330LC , 350H , 350LCH T1V7-01-01-002 ZAXIS350H Model ZAXIS330 , 330LC 350LCH 3.2 m (10 ft 6 in) Category 2.67 m (8 ft 9 in) Arm 3.2 m (10 ft 6 in) Arm 4.0m (13 ft 2 in) Arm H Arm ft•in ft•in...
  • Page 331 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS330 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary For Weak Footing For Weak Footing For Paved Road Application Ground (Option) (Option)
  • Page 332 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS350H 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary For Weak Footing For Weak Footing For Paved Road Application Ground (Option) (Option)
  • Page 333 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS330 , 330LC , 350H , 350LCH Bucket Capacity Front-End Attachment ZAXIS350 ZAXIS350 Bucket Width (in) ZAXIS330 ZAXIS330LC Bucket Application PCSA CECE (With side cutter) 2.67 m 3.2 m 4.0m 2.67 m 3.2 m 4.0m 3.2 m 3.2 m (Heaped)
  • Page 334 SPECIFICATIONS SPECIFICATIONS ZAXIS350K , 350LCK T1V7-01-01-004 Model ZAXIS350K ZAXIS350LCK Type of Front-End Attachment 3.2 m (10 ft 6 in) K Arm Bucket Capacity (Heaped) PCSA 1.38 m (1.81 yd ), CECE 1.2 m Operating Weight 34400 kg (75800 lb) 35000 kg (77200 lb) Base Machine Weight 26300 kg (58000 lb) 26900 kg (59300 lb)
  • Page 335 SPECIFICATIONS WORKING RANGES ZAXIS350K , 350LCK T1V7-01-01-002 Model ZAXIS350K , 350LCK 3.2 m (10 ft 6 in) K Arm Category Item ft•in A: Maximum Digging Reach 11100 36’5” B: Maximum Digging Depth *7380 *24’3” C: Maximum Cutting Height *10360 *34’0” D: Maximum Dumping Height *7240 *23’9”...
  • Page 336 SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS350K 600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”) Shoe Width Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe For Ordinary For Weak Footing For Weak Footing For Paved Road Application Ground (Option) (Option)
  • Page 337 SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZAXIS350K , ZAXIS350LCK Front-End Bucket Capacity Attachment Bucket Width (in) Bucket Application ZAXIS350K ZAXIS350LCK (With side cutter) PCSA CECE 3.2 m (10’6”) 3.2 m (10’6”) (Heaped) (Heaped) K Arm K Arm 1.15 (1.50) 1.00 1230 (48.4”) ●...
  • Page 338 SPECIFICATIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-32...

  • Page 339: Index

    Confirm Direction of Machine to Be Driven ......S-10 After the First 50 Hours ..............2-1 Contents of Alarms ..............1-18 Air Cleaner ..................7-51 Control Lever (HITACHI Pattern) ..........5-2 Alarm Light ..................1-10 Control Lever (ISO Pattern) ............5-1 Alarm Occurrence Screen ............1-16 Control Levers ................11-9...
  • Page 340 INDEX OPERATOR’S STATION ..............1-2 Object Handling ................S-18 Handle Chemical Products Safely ........... S-30 Object Handling --- If Equipped ..........5-33 Handle Fluids Safely−avoid Fires ..........S-19 Observe Engine Operation Closely .......... 2-1 Handle Starting Aids Safely ............S-6 Opening Side Windows ..............1-78 Hood and Access Covers ..............
  • Page 341 INDEX Remove Paint Before Welding or Heating ......S-28 Travel Alarm (Optional) ..............4-4 Removing and Storing Lower Front Window .....1-78 Travel Mode Switch ............1-53, 4-4 Removing the Machine from Storage ........10-2 Replace Rubber Hoses Periodically ........S-24 Return to Basic Screen Key ............1-10 Understand Signal Words ............
  • Page 343 SPECIFICATIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-32...
  • Page 344 Confirm Direction of Machine to Be Driven ......S-10 After the First 50 Hours ..............2-1 Contents of Alarms ..............1-18 Air Cleaner ..................7-51 Control Lever (HITACHI Pattern) ..........5-2 Alarm Light ..................1-10 Control Lever (ISO Pattern) ............5-1 Alarm Occurrence Screen ............1-16 Control Levers ................11-9...
  • Page 345 INDEX OPERATOR’S STATION ..............1-2 Object Handling ................S-18 Handle Chemical Products Safely ........... S-30 Object Handling --- If Equipped ..........5-33 Handle Fluids Safely−avoid Fires ..........S-19 Observe Engine Operation Closely .......... 2-1 Handle Starting Aids Safely ............S-6 Opening Side Windows ..............1-78 Hood and Access Covers ..............
  • Page 346 INDEX Remove Paint Before Welding or Heating ......S-28 Travel Alarm (Optional) ..............4-4 Removing and Storing Lower Front Window .....1-78 Travel Mode Switch ............1-53, 4-4 Removing the Machine from Storage ........10-2 Replace Rubber Hoses Periodically ........S-24 Return to Basic Screen Key ............1-10 Understand Signal Words ............
  • Page 348 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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