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Hitachi 090001, Operator'S Manual

The Hitachi 090001 Operator's Manual is the essential companion for anyone using this powerful product. It provides detailed instructions and safety guidelines to ensure optimal performance. The manual is available for free download at manualshive.com so users can access it easily and conveniently.

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CONTENTS

Console and Seat Fore-aft Adjustment .........................1-128

Seat Fore-Aft Adjustment ..................................................1-128

Suspension Adjustment .....................................................1-129

Fore-Aft Position Adjustment of Seat Surface ............1-129

Angle Adjustment of Seat Surface..................................1-129

Backrest Adjustment ...........................................................1-129

Armrest Adjustment ............................................................1-129

Console Height Adjustment ...................................................1-130

Adjusting Procedures ..........................................................1-130

Installation and Adjustment of Mirrors ..............................1-131

Seat Belt .........................................................................................1-132

Battery Disconnect Switch ......................................................1-133

Switch Operation ..................................................................1-133

BREAK-IN ....................................................................... 2-1

Observe Engine Operation Closely ...........................................2-1

Every 8 Hours or Daily ....................................................................2-1

After the First 50 Hours .................................................................2-1

After the First 100 Hours ...............................................................2-1

OPERATING THE ENGINE .............................................. 3-1

Inspect Machine Daily Before Starting ....................................3-1

Before Starting Engine ..................................................................3-2

Starting the Engine .........................................................................3-3

Check Instruments After Starting ..............................................3-7

Using Booster Batteries .................................................................3-8

Stopping the Engine ...................................................................3-10

Engine Auto-Stop in Extremely Low Temperature ...........3-11

DRIVING THE MACHINE ................................................ 4-1

Drive the Machine Carefully ........................................................4-1

Steering the Machine Using Pedals ..........................................4-2

Steering the Machine Using Levers ..........................................4-3

Travel Mode Switch ........................................................................4-4

Travel Alarm .......................................................................................4-4

Operating on Soft Ground ...........................................................4-5

Raise One Track Using Boom and Arm ....................................4-5

Towing Machine a Short Distance .............................................4-6

Operating in Water or Mud ..........................................................4-7

Parking the Machine on Slopes ..................................................4-8

Parking the Machine ......................................................................4-8

OPERATING THE MACHINE ........................................... 5-1

Control Lever (ISO Pattern) ..........................................................5-1

Attachment Pedal (Hydraulic Breaker) (Optional) ...............5-2

Attachment Pedal (Hydraulic Crusher) (Optional) ...............5-3

Pilot Control Shut-Off Lever ........................................................5-4

Warming Up Operation .................................................................5-5

Engine Speed Control ....................................................................5-6

Auto-Idle .............................................................................................5-7

Auto Shut-Down ..............................................................................5-9

Muffler Filter Manual Regeneration .......................................5-12

Work Mode .....................................................................................5-14

Power Boost Switch .....................................................................5-17

Power Mode ...................................................................................5-18

Operating Backhoe ......................................................................5-19

Shovel ...............................................................................................5-20

Grading Operation .......................................................................5-21

Do Not Strike the Ground with Bucket Teeth .....................5-22

Avoid Hammer Work ...................................................................5-22

Avoid Abusive Operation ..........................................................5-23

Avoid Side Load the Bucket ......................................................5-23

Do Not Use Wide Track Shoes on Rough Ground. ............5-24

Hydraulic Breaker, Hydraulic Crusher and  

Quick Coupler...........................................................................5-25

Piping for Breaker and Crusher ...............................................5-26

Operational Procedures for Stop Valves and  

Selection Valve. ........................................................................5-26

Secondary Relief Pressure Adjustment ................................5-27

Precautions for Breaker Operation .........................................5-28

Change Hydraulic Oil and Replace Full-Flow Filter  

Element ......................................................................................5-32

Precautions for Crusher Operation ........................................5-33

Attachment .....................................................................................5-36

Attachment Connection Parts .................................................5-40

Precaution for Arm Roll-In/Bucket Roll-In Combined 

Operation ...................................................................................5-42

Shackle Hole Usage .....................................................................5-42

Pilot Accumulator Functions ....................................................5-43

How to Lower Boom in Case of Emergency and  

When Engine Stops ................................................................5-44

Precautions for After Operations ............................................5-45

TRANSPORTING ............................................................ 6-1

Transporting by Road ....................................................................6-1

Loading/Unloading on a Trailer .................................................6-2

Fastening Machine for Transporting ........................................6-5

Unloading ..........................................................................................6-5

Lifting Machine ................................................................................6-7

MAINTENANCE .............................................................. 7-1

Correct Maintenance and Inspection Procedures ...............7-1

Check the Hour Meter Regularly ................................................7-3

Preparations for Inspection and Maintenance .....................7-6

Hood and Access Covers ...............................................................7-7

Daily Check ........................................................................................7-9

Maintenance Guide .....................................................................7-10

Periodic Replacement of Parts .................................................7-15

Kind of Oils ......................................................................................7-16

Recommended Engine Oil ...................................................7-16

A. Greasing ......................................................................................7-19

Front Joint Pins ........................................................................7-19

Swing Bearing ..........................................................................7-21

Swing Internal Gear................................................................7-22

B. Engine ..........................................................................................7-23

Engine Oil Level .......................................................................7-23

Change Engine Oil  .................................................................7-25

Replace Engine Oil Filter .......................................................7-25

Check and Clean Around the Engine ...............................7-27

C. Transmission ..............................................................................7-28

Pump Transmission  ...............................................................7-28

Swing Reduction Gear ..........................................................7-29

Travel Reduction Gear ...........................................................7-30

D. Hydraulic System .....................................................................7-32

Inspection and Maintenance of Hydraulic Equipment ...7-32

Summary of Contents for 090001

Page 1: ...XCAVATOR OPERATOR S MANUAL URL http www hitachi c m com ENMDCN 1 1 PART NO Operator s Manual PRINTED IN JAPAN E 2015 12 135US 5B 225US 5B 225USLC 5B Serial No ZX135US 5B 090001 and up ZX225US 5B 300001 and up ZX225USLC 5B 300001 and up Hydraulic Excavator ...

Page 2: ...olid contamination includes dust If the fuel specified above is not used exhaust gas that exceeds the regulation values may be discharged causing serious problem on the engine Consult your nearest Hitachi dealer Warranty is provided as a part of Hitachi s support program for customers who operate and maintain their equipment as described in this manual The warranty is explained on the warranty cer...

Page 3: ...E MACHINE OPERATOR S STATION BREAK IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE HYDRAULICCIRCUITANDELECTRICALCIRCUIT MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE TROUBLESHOOTING SPECIFICATIONS INDEX OPTIONALATTACHMENTSANDDEVICES INDEX ...

Page 4: ......

Page 5: ...28 Replace Rubber Hoses Periodically S 29 Avoid High Pressure Fluids S 29 Prevent Fires S 30 Evacuating in Case of Fire S 32 Beware of Exhaust Fumes S 32 Precautions for Welding and Grinding S 33 Avoid Heating Near Pressurized Fluid Lines S 34 Avoid Applying Heat to Lines Containing Flammable Fluids S 34 Precautions for Handling Accumulator and Gas Damper S 34 Remove Paint Before Welding or Heatin...

Page 6: ... 95 Overload Alarm Switch Optional 1 95 Seat Heater Switch 1 96 Revolving Light Switch Optional 1 96 Electrical Control Main Switch Optional 1 96 Key Switch 1 97 Power Boost Switch 1 97 Horn Switch 1 97 Electrical Control Main Switch Optional 1 98 Cigar Lighter 1 100 Using Cigar Lighter 1 100 Using Cigar Lighter Port as External Power Source 1 100 Cab Light Switch 1 101 Installing Fire Extinguishe...

Page 7: ...st Switch 5 17 Power Mode 5 18 Operating Backhoe 5 19 Shovel 5 20 Grading Operation 5 21 Do Not Strike the Ground with Bucket Teeth 5 22 Avoid Hammer Work 5 22 Avoid Abusive Operation 5 23 Avoid Side Load the Bucket 5 23 Do Not Use Wide Track Shoes on Rough Ground 5 24 Hydraulic Breaker Hydraulic Crusher and Quick Coupler 5 25 Piping for Breaker and Crusher 5 26 Operational Procedures for Stop Val...

Page 8: ...rter and Alternator 7 107 Check and Replace EGR Device 7 107 Clean EGR Cooler 7 107 Check Turbocharger 7 107 Check Gas Damper 7 108 Tightening and Retightening Torque of Nuts and Bolts 7 108 J Muffler Filter 7 123 Check and Clean Filter Element of Muffler Filter 7 123 Check and Clean Muffler Filter 7 123 HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT 8 1 Hydraulic Circuit 8 1 Electrical Circuit 8 2 MAIN...

Page 9: ...CONTENTS Bucket Teeth Transverse Type Pin Used Type 13 18 INDEX 14 1 ...

Page 10: ...CONTENTS MEMO ...

Page 11: ...he machine and or components Fill these serial Nos in the blank spaces in this group to immediately make them available upon request Machine TYPE PRODUCT IDENTIFICATION NUMBER Product Identification Number fNOTE HCMDCN20L00030001 Engine TYPE MFG NO M157 00 001 MDAA 00 001 ZX225US 5B 225USLC 5B ZX135US 5B Marks to indicate the start and end of the PIN PRODUCT IDENTIFICATION NUMBER PIN M157 12 008 M...

Page 12: ...MACHINE NUMBERS 2 Muffler Filter TYPE MFG NO DOC Diesel Oxidation Catalyst TYPE MFG NO Travel Motor TYPE MFG NO Swing Motor TYPE MFG NO M178 07 047 M178 07 086 MDAA 00 002 MDAA 00 002 ...

Page 13: ...MACHINE NUMBERS 3 Hydraulic Pump ZX135US 5B TYPE MFG NO ZX225US 5B 225USLC 5B TYPE MFG NO MDAA 00 003 MDAA 07 072 ...

Page 14: ...MACHINE NUMBERS 4 MEMO ...

Page 15: ...jury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs do not use any of the designated...

Page 16: ...age to material caused by unauthorized modifications will void Hitachi Warranty Policy Never attempt to modify or disassemble the inlet exhaust parts and the muffler filter Avoid giving shocks on the muffler filter by striking elements with other objects or dropping the elements Failure to do so may affect the exhaust gas purifying device possibly damaging it or lowering its performance Do not use...

Page 17: ... emergency numbers for doctors ambulance service hospital and fire department posted near your telephone Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct ...

Page 18: ...armuffs or earplugs to protect against objectionable or uncomfortably loud noises Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury In the walk around inspection be sure to cover all points described in the Inspect Machine Daily Before Starting section in the operator s manual SA 434 ...

Page 19: ...ls pilot control shut off lever or control levers which may result in serious injury or death Avoid storing transparent bottles in the cab Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight possibly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while operating the machine Keep all flamm...

Page 20: ...tion repair the damage to the steps and or handrails Retighten loose bolts Never get on and off the machine with tools in your hands Adjust the Operator s Seat A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machine The operator should be able to fully...

Page 21: ...off lever to the LOCK position Turn the key switch OFF to stop the engine Before leaving the machine close all windows doors and access covers and lock them up Fasten Your Seat Belt If the machine should overturn the operator may become injured and or thrown from the cab Additionally the operator may be crushed by the overturning machine resulting in serious injury or death Prior to operating the ...

Page 22: ... it Ensure the cab door windows doors and covers are securely locked Check the mirrors and the monitor in the cab for problems If there is replace the problem part s or clean the mirror camera and the monitor Refer to Rear View Monitor section on the cleaning of the camera and the monitor Operate Only from Operator s Seat Inappropriate engine starting procedures may cause the machine to runaway po...

Page 23: ...rol when the engine starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine Keep Riders off Machine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine Only the operator should be on the machine Keep riders off Ri...

Page 24: ...cles from the area of operation and machine movement Do not permit persons other than the operator to enter areas where there is danger such as flying objects Always beware of the surroundings while operating When working in a small area surrounded by obstacles take care not to hit the upperstructure against obstacles When loading onto trucks bring the bucket over the truck beds from the rear side...

Page 25: ...te Reinforce ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground be...

Page 26: ...e to tip over When working on soft ground is required be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes Prevent machine tipping over from occurring When operating on rough terrain or on slopes Reduce the engine speed ...

Page 27: ...point a signal person to coordinate the job site Make sure that all personnel obey the signal person s directions Confirm Direction of Machine to Be Driven Incorrect travel pedal lever operation may result in serious injury or death Before driving the machine confirm the position of the undercarriage in relation to the operator s position If the travel motors are located in front of the cab the ma...

Page 28: ...ng in serious injury or death Never attempt to ascend or descend 35 degrees or steeper slopes Gradeability differ depending on the specification Be sure to fasten the seat belt When driving up or down a slope keep the bucket facing the direction of travel approximately 0 2 to 0 3 m A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and s...

Page 29: ...hine forward towards the idlers An arrow mark seal is stuck on the inside surface of the side frame to indicate the machine front direction Select a travel route that is as flat as possible Steer the machine as straight as possible making small gradual changes in direction Before traveling on them check the strengths of bridges and road shoulders and reinforce if necessary Use wood plates in order...

Page 30: ... and or other work tools to the ground Turn the auto idle switch OFF Run the engine at slow idle speed without load for 5 minutes to cool down the engine Stop the engine and remove the key from the key switch Pull the pilot control shut off lever to LOCK position Block both tracks and lower the bucket to the ground Thrust the bucket teeth into the ground if you must park on a grade Position the ma...

Page 31: ... SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED ALWAYS KEEP THE SIGNAL PERSON IN VIEW Use hand signals which conform to your local regulations when work conditions require a signal person No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and mark...

Page 32: ...t up barriers and or put a NO ADMISSION sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area Before operating the machine confirm that there are no obstacles or person other than signal person from working area Never Position Bucket Over Anyone Never lift move or swing bucket above anyone or a truck cab Serious injury or machine damag...

Page 33: ... 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 To avoid tipping Be extra careful before operating on a grade Prepare machine operating area flat Keep the bucket low to the ground and close to the machine Reduce operating speeds to avoid tipping or slipping Avoid changing direction ...

Page 34: ...gas lines and water lines If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury Contact your local diggers hot line if available in your area and or the utility companies directly Have them mark all underground utilities Operate with Caution If the front attachment or any other part of the machine hits against an overhead obstacle ...

Page 35: ...ghtning Lightning may strike the machine If lightning comes close immediately stop the operation and take the following action When you are around the machine or operating cab less machine evacuate to a safe place far away from the machine When you are in the cab stay in the cab until lightning has passed and safety is secured Close the cab doors and windows Lower the bucket to the ground and stop...

Page 36: ...t suddenly Keep all persons well away from the load Never move a load over a person s head Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth They may come off causing the load to fall Protect Against Flying Debris If flying debris hit eyes or any other part of the body serious in...

Page 37: ...ndle Fluids Safely Avoid Fires Handle fuel with care it is highly flammable If fuel ignites an explosion and or a fire may occur possibly resulting in serious injury or death Do not refuel the machine while smoking or when near open flame or sparks Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flammable Store flammab...

Page 38: ...witch OFF 4 Always select the slow speed mode with the travel mode switch 5 Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp 6 Never steer the machine while on the ramp If the traveling direction must be changed while the ramp unload the machine from the ramp reposition the machine on the ground then try loading a...

Page 39: ... Pull the pilot control shut off lever to the LOCK position 10 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave the machine unattended If the machine must be raised maintain a 90 to 110 angle between the boom and arm Securely support any machine elements that must be raised for service work Inspect certain parts periodically and repair or r...

Page 40: ...ing any work on the machine attach a Do Not Operate tag on the control lever This tag is available from your authorized dealer Support Machine Properly Never attempt to work on the machine without securing the machine first Always lower the attachment to the ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment Do not su...

Page 41: ...th Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY Do not attempt to remove grease fitting securing cover As pieces may fly off be sure to keep body and face away from valve Never attempt to disassemble the track adjuster Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off possibly resulting in severe personal injury or death Travel reduction g...

Page 42: ...r or steam is contained in the engine radiator and heater lines Skin contact with escaping hot water or steam can cause severe burns To avoid possible injury from hot spraying water DO NOT remove the radiator cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be released before removing the cap The hydraulic oil tank is pressurized Again be sure to rele...

Page 43: ... which may result in severe burns gangrene or otherwise serious injury or death 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 disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a pi...

Page 44: ...igh pressure lines Never install bent or damaged lines pipes or hoses Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance Check for Shorts Short circuits can cause fires Clean and tighten all electrical connections Check before each shift or after eight 8 to ten 10 hours operation for loose kinked hardened or frayed electrical cables and...

Page 45: ...rials such as dead leaves from entering However flammable materials which have passed through the wire screen may cause fires Check and clean the machine every day and immediately remove accumulated flammable materials Check Key Switch If a fire breaks out failure to stop the engine will escalate the fire hampering fire fighting Always check key switch function before operating the machine every d...

Page 46: ...evacuation hammer to escape from the cab Refer to the explanation pages on the Emergency Evacuation Method Beware of Exhaust Fumes Prevent asphyxiation Engine exhaust fumes can cause sickness or death If you must operate in a building be sure there is adequate ventilation Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the...

Page 47: ...nnel should perform welding Never allow an unqualified person to perform welding Turn the battery disconnect switch to the OFF position before performing welding operation on the machine Grinding on the machine may create fire hazards Store flammable objects in a safe place before starting grinding After finishing welding and grinding recheck that there are no abnormalities such as the area surrou...

Page 48: ...eat to Lines Containing Flammable Fluids Do not weld or flame cut pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting them Precautions for Handling Accumulator and Gas Damper High pressure nitrogen gas is sealed in the accumulator and the gas damper Inappropriate handling may cause explosion possibly resulting in serious inju...

Page 49: ...e of Asbestos and Silicon Dust and Other Contamination Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust or other contamination may cause sickness Depending on the work site conditions the risk of inhaling asbestos fiber silicon dust or other contamination may exist Spray water to prevent asbestos fibers ...

Page 50: ... sparks Securely tighten all terminals Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire Battery electrolyte is poisonous If the battery should explode battery electrolyte may be splashed into eyes possibly resulting in blindness Be sure to wear eye protection when checking electrolyte specific gravity Service Air Conditioning Syste...

Page 51: ... on chemical products used with your machine Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with HITACHI equipment includes such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from t...

Page 52: ...ne running and filter regeneration burning PM Keep away from the direction of the exhaust piping and its vicinity during the filter regeneration Be careful not to let your skin contact with any hot gas from the exhaust piping It may cause severe burns Do not directly touch water coming out of the muffler filter The water is mildly acidic by oxidation catalyst mounted in the muffler filter If filte...

Page 53: ...al waves This machine is equipped with a communication terminal type A or type B Consult your nearest authorized dealer for the type of communication terminal Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipments Type A Type B E GSM900 0 573 W Kg 914 8 MHz 0 12 W Kg 897 6 MHz DCS 1800 0 130 W Kg 1710 2 MHz 0 06 W Kg 1748 0 MHz WCDMA Band I 0 271 W Kg 1950 0 MH...

Page 54: ...y cause damage or fire on the machine and the communication terminal Before removing or installing the communication terminal consult your authorized Hitachi dealer Do not pinch or forcibly pull cables cords and connectors Failure to do so may cause damage or fire on the machine and the communication terminal due to short broken circuit ...

Page 55: ...Hitachi dealer before welding parts or drilling a hole on the cab which possibly reduces the cab strength Be sure to always fasten the seat belt when operating the machine If the machine rolls over without operator fastening the seat belt the operator may become injured may be thrown out from the cab and or may become crushed under the machine even though the cab has the protective structure The R...

Page 56: ...se a safety sign is broken or lost immediately obtain a new replacement and affix it again in position on the machine Use the part No indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer S 42 SAFETY SIGNS 11 5 14 15 15 17 6 8 2 4 1 18 7 20 9 19 16 16 10 12 12 13 13 ZX135US 5B ZX225US 5B 225USLC 5B ZX135US 5B ZX135US 5B ZX225US 5B 225US...

Page 57: ...sure to lower the front attachment to the ground lock the control levers and remove the engine key before leaving the machine unattended 3 Sign indicates an electrocution hazard if machine is brought too near electric power lines Keep a safe distance from electric power lines 4 Sign indicates a hazard from falling window After raising window be sure to lock it in place with lock pins SAFETY SIGNS ...

Page 58: ...should overturn the operator may become injured and or throw from the cab and or crushed by the overturning machine 7 Do not extend your hands or head from the window Your hands or head may come in contact with the boom Keep away from machine during operation 8 Sign indicates a hazard of being hit by the working device of the machine Keep away from machine during operation SAFETY SIGNS S 44 SS4371...

Page 59: ...hot oil if the oil inlet is uncapped during or right after operation Read manual for safe and proper handling Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic oil tank is uncapped while hot Allow radiator or hydraulic oil tank to cool before removing cap 11 Sign indicates a hazard of falling Do not stand on this place SAFETY SIGNS S 45 A B SS3086091 SS4459928 SS...

Page 60: ...ard by rotation of upper structure of the machine Keep away from swinging area of machine 14 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic oil tank is uncapped while hot Allow radiator or hydraulic oil tank to cool before removing cap SAFETY SIGNS S 46 SS4420336 SS3086090 SS3092125 ...

Page 61: ...15 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance SAFETY SIGNS S 47 SS3092127 SSYA00008776 ...

Page 62: ...er handling 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 17 SAFETY SIGNS S 48 A C B SS4459714 SS4460067 SS4460056 SS4467093 ...

Page 63: ... PROTECTION AND CAREFULLY DRILL A HOLE AT THE POINT MARKED TO RELEASE GAS PRESSURE BEFORE DISPOSAL 20 Communication terminal can cause accidental bombing at the blasting site Keep the machine apart from the blasting site and an electric detonator to maintain a safe distance SAFETY SIGNS S 49 SS 3212 SSYA00040417 SSYA00000341 ...

Page 64: ...MEMO SAFETY SIGNS S 50 ...

Page 65: ...7 Fuel Tank 8 Hydraulic Oil Tank 9 Engine 10 Muffler Filter 11 Counterweight 12 Travel Device 13 Track 14 Front Idler 15 Cab fNOTE A typical model is shown in the right Some parts may differ depending on the model of the machine COMPONENTS NAME 1 2 3 4 5 6 7 8 9 10 11 12 14 13 15 MDCN 01 001 ...

Page 66: ...n or off the machine as it is very dangerous dWARNING Never attach a wire on the foot holds 1 to lift the cab or main body or while transporting the machine on a truck or trailer as it is dangerous The door handle 3 is not a handrail Do not use the door handle 3 as a handrail when getting on and off the machine Do not hold the control levers 4 or pilot control shut off lever 5 when getting on and ...

Page 67: ...it may cause fire Before maintaining the machine stop the engine and make sure the engine has sufficiently cooled down in order to prevent burns Be sure to use fuel that complies with JIS K 2204 EN 590 and ASTM D 975 which contents 15 ppm or lower sulfur If the fuel described above is not used exhaust gas that exceeds the regulation values may be discharged and serious problem may arise on the eng...

Page 68: ...eneration The auto regeneration is performed at random times depending on the machine operating condition The auto regeneration may start during operation of the machine you can continue to operate the machine refer to 1 23 Turning the pilot control shut off lever to LOCK position while performing auto regeneration may change the engine sound and may increase the engine speed this is not a malfunc...

Page 69: ...performing manual regeneration the muffler filter may be damaged Immediately move the machine to a safe area and perform manual regeneration When approximately 13 hours has passed from the previous regeneration without manual regeneration being carried out the muffler filter alarm and the engine trouble alarm will be displayed on the monitor and the buzzer sounds refer to 1 24 Consult your authori...

Page 70: ...r Panel 8 Switch Panel 9 Key Switch 10 Regeneration Switch 11 Operator s Seat 12 Cab Door Release Lever 13 Pilot Control Shut Off Lever 14 Fuse Box 15 Cigar Lighter 16 Switch Panel for Optional Equipments Glove Compartment without Optional Equipments 17 Glove Compartment Hot and Cool Box 18 Engine Stop Switch 19 Level Indicator 1 2 3 7 9 10 14 11 18 12 13 17 15 8 16 4 5 6 MDCF ML1 009 19 MDCN 01 0...

Page 71: ...onsists of the following screens There are 7 menus and a further 16 sub menus Basic Screen Main Menu Alarm List Radio Air Conditioner Work Mode Mail Optional Setting Menu Information Menu Date and Time Operation Muffler Filter Regeneration Inhibited Attachment Name Input Sub Meter Selection Attachment Adjustment Maintenance Password Change Optional Brightness Adjustment Unit Selection Auto Shut Do...

Page 72: ...em Default Auto Shut Down ON OFF of Auto Shut down OFF Setting Time 1 min Muffler Filter Regeneration Inhibited Regeneration Inhibited OFF fNOTE Typical functions are shown in the table Check the initial values of other functions on each monitor screen ...

Page 73: ... 6 Auxiliary 7 Preheat Display 8 Seat Belt Display 9 Fuel Gauge 10 Sub Meter 11 Radio Display 12 Air Conditioner Display 13 Coolant Temperature Gauge 14 Auxiliary 15 Overload Alarm Display Optional 16 Travel Mode Indicator 17 Auto Shut Down Display 18 Auto Idle Display 2 1 3 8 10 11 12 13 14 15 16 17 18 9 4 5 6 7 MDAA 01 020 ...

Page 74: ...ACC position only hour meter clock and radio will be displayed When the key switch is turned from ACC to ON position the basic screen will be displayed IMPORTANT When the key switch is turned to ON position the alternator alarm will be displayed on the basic screen Until the alternator starts generating power after the engine starts the alternator alarm is displayed on the basic screen Basic Scree...

Page 75: ...displayed 4 Hour Meter Clock 9 Fuel Gauge 13 Coolant Temperature Gauge Work Mode Display The attachments being used are displayed Digging Mode Attachment Mode Breaker Pulverizer Crusher Vibrating Hammer Grapple Clamshell Others Work Mode 4 9 13 MDAA 01 001 ...

Page 76: ... displayed Radio Display 11 Displays the radio panel Air Conditioner Display 12 Displays the air conditioner panel Overload Alarm Display 15 Optional The system measures the load of suspended load from the bottom pressure of boom cylinder When overload is detected an alarm is displayed Travel Mode Display 16 Displays the travel mode selected from the switch panel Auto Shut Down Display 17 When the...

Page 77: ...l accumulated machine operation hours counted since the machine started working are displayed in hours h One digit after the decimal point indicates tenths of an hour 6 minutes Clock Indicates the present time 24 h 12 h display can be selected Refer to Date and Time for switching the display mode Fuel Gauge The remaining fuel amount is indicated by the needle Refuel before the needle reaches E 2 3...

Page 78: ...ing operation Operating Status Icon Display Displays icons indicating the current status of the attachment 1 selected from the work mode selection screen muffler filter display 2 power mode 3 preheat indicator 4 travel mode 5 auto shut down 6 ON and auto idle 7 ON selected from the switch panel when these systems are activated 2 1 7 6 5 3 4 M1U1 01 047 MDAA 01 023 ...

Page 79: ...tch the basic screen displays The engine is ready to run If an incorrect password is input three times a buzzer sounds for thirty seconds During that time the buzzer does not stop even if the key switch is turned ON OFF fNOTE If you make a mistake while entering the password push the CLEAR key in order to erase the entered characters 4 After thirty seconds if the key switch is turned to the ON pos...

Page 80: ...While the password duration screen is still displayed rotate selector knob 1 to highlight the relevant time Pushing selector knob 1 sets the password duration time Duration time 0 minute Duration time 30 minute Duration time 60 minute Duration time 90 minute Duration time 120 minute fNOTE If the password duration time is not set explicitly a duration of 0 is assumed 3 If turning the key switch to ...

Page 81: ...rm Occurrence Screen In case any abnormality occurs alarm marks 1 are displayed on the basic screen If six or more alarms are generated the alarm marks 1 can be scrolled by rotating switch 2 1 Indicator MDCD 01 026 2 MDAA 01 316 ...

Page 82: ...to select the alarm list and push selector knob 1 Rotate selector knob 1 to select a required alarm from the alarm list and push selector knob 1 Detailed information of the selected alarm will be displayed dCAUTION The main menu displays the alarm list only when an alarm occurs dCAUTION The alarm list contains only currently generated alarms 1 MDAA 01 077EN MDAA 01 078EN MDAA 01 079EN MDAA 01 004 ...

Page 83: ... Pull the pilot control shut off lever to the LOCK position run the engine at slow idle speed and turn the muffler filter switch to REGENERATION position Muffler Filter Regeneration Inhibited Alarm Lighting Yellow Regeneration is inhibited Move the machine to a safe area turn regeneration inhibition OFF and perform manual regeneration Muffler Filter Auto Regeneration Inhibited Alarm Lighting Yello...

Page 84: ...ne emergency switch is ON the engine cannot start Boost Temperature Alarm Engine intake air temperature has abnormally increased Stop operation Check intercooler for clogging and intake air piping for disconnection Exhaust Temperature Alarm Exhaust temperature is abnormally high Stop machine operation and check the exhaust lines Muffler Filter Alarm Muffler filter is abnormal Contact your nearest ...

Page 85: ...lter element System Failure Alarm Communication system is abnormal Contact your nearest authorized dealer Pilot Control Shut Off Lever Alarm Pilot control shut off lever system is abnormal Contact your nearest authorized dealer Electric Lever Alarm Electric lever system is abnormal Contact your nearest authorized dealer fNOTE The hydraulic oil filter alarm lights only when the high performance ele...

Page 86: ...mark changes and the needle disappears If the harness between the temperature sensor and the controller unit is broken the needle disappears Engine Speed Control Display Engine warming up operation due to low coolant temperature The engine speed can not be changed during this operation While the time is controlling the engine speed mark 2 is displayed on monitor 1 When the control completes mark 2...

Page 87: ...eed this is not a malfunction Do not stop the engine during regeneration unless absolutely necessary When the manual regeneration switch is pushed during the auto regeneration process the message Minimal Exhaust Restriction Exhaust Filter Cleaning Not Available will be displayed on monitor 2 Regeneration may not be completed according to the operating conditions of the machine In this case muffler...

Page 88: ...ed particulate matter Immediately stop operation park the machine in a safe location Then contact your nearest Hitachi dealer Blinking Red This mark indicates that the muffler filter regeneration is inhibited It is displayed when the manual regeneration request arises while muffler filter regeneration is inhibited Move the machine to a safe place Perform manual regeneration following the below pro...

Page 89: ...eneration switch 2 5 When pushing the muffler filter regeneration switch screen 3 as shown in the right will be displayed and the manual regeneration starts Bar graph on the screen indicates progress of the regeneration process dCAUTION The regeneration does not start unless the pilot control shut off lever is in the LOCK position and the engine control dial is in slow idle When touching the pilot...

Page 90: ... screen 1 to display main menu screen 3 The main menu screen contains the items shown in the figure to the right The alarm list is displayed only when an alarm is generated Mail optional menu will not be displayed unless they are set beforehand 2 1 3 MDAA 01 001EN MDAA 01 077EN MDAA 01 190EN ...

Page 91: ... knob 2 to highlight 8 mark 4 Press selector knob 2 to set the circulation mode 5 Press selector knob 2 again to switch the fresh air mode Air Conditioner ON OFF 1 Rotate selector knob 2 to highlight A C 9 2 Press selector knob 2 to turn the air compressor ON 3 Press selector knob 2 again to turn the air compressor OFF fNOTE When the function is ON the mark is displayed in green When the function ...

Page 92: ...u screen 5 2 Rotate selector knob 2 to highlight Radio 6 3 Press selector knob 2 to display the radio screen Refer to the page 1 112 IMPORTANT If mark 7 is displayed on the radio display communication between the radio and the monitor is abnormal Consult your nearest Hitachi dealer Press the numeric keypad of 1 to 8 while the radio is ON the radio station will switch to memorized channel of 1 to 8...

Page 93: ...nob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Work Mode 4 3 Press selector knob 2 to display Work Mode screen 5 4 Rotate selector knob 2 to highlight the desired front attachment In the right example Bucket is highlighted 5 Press selector knob 2 to enable the changes 2 1 3 5 4 6 MDAA 01 001EN MDAA 01 100EN MDAA 01 101EN ...

Page 94: ...playing Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Mail 4 3 Press selector knob 2 to display Mail screen 5 4 Rotate selector knob 2 to highlight desired request 5 Press selector knob 2 to send mail information to the comunication terminal General Request Fuel Replenishment Request Service Maintenance Request Forwarding Request 2 1 3 4 5 MDCD 01 026 MDAA 01 0...

Page 95: ...essage Request Is Accepted is displayed on the screen Push the back key to return to the Mail screen 8 Then a mail is sent from the communication terminal to the central server fNOTE Depending on the machine s operating environment the mail may not be sent fNOTE When the communication terminal could not receive the mail the message Failed is displayed on the screen MDAA 01 111EN MDAA 01 112EN MDAA...

Page 96: ...down setting change password selecting sub meter brightness adjustment of back monitor and screen 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 2 1 3 4 5 MDAA 01 001EN MDAA 01 114EN MDAA 01 115EN ...

Page 97: ...n the display setting Time Adjustment 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Date and Time 6 1 3 4 5 6 MDCD 01 026 2 MDAA 01 001EN MDAA 01 114EN MDAA 01 115EN ...

Page 98: ...selector knob 2 to highlight Hour or Minute and push selector knob 2 9 Rotate selector knob 2 to adjust the clock Rotate clockwise to adjust the number upwards and counterclockwise to decrease it 10 Push selector knob 2 to end the Time setting procedure 11 Rotate selector knob 2 to highlight 11 Push selector knob 2 to make the change 2 7 9 8 10 11 MDCD 01 026 MDAA 01 117EN MDAA 01 118EN MDAA 01 12...

Page 99: ...ing Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Date and Time 6 2 1 3 4 5 6 MDCD 01 026 MDAA 01 001EN MDAA 01 114EN MDAA 01 115EN ...

Page 100: ...elector knob 2 to highlight Year Month or Day and push selector knob 2 9 Rotate selector knob 2 to adjust the date Rotate clockwise to adjust the number upwards and counterclockwise to decrease it 10 Push selector knob 2 to end the date setting procedure 11 Rotate selector knob 2 to highlight 11 Push selector knob 2 to make the change 7 9 8 10 11 MDCD 01 026 2 MDAA 01 122EN MDAA 01 123EN MDAA 01 1...

Page 101: ...laying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Date and Time 6 1 3 4 5 6 MDCD 01 026 2 MDAA 01 001EN MDAA 01 114EN MDAA 01 115EN ...

Page 102: ...e selector knob 2 to highlight Date 10 and push selector knob 2 Time Each time selector knob 2 is pushed the time format is changed as follows 12 h 24 h 12 h Date Each time selector knob 2 is pushed the date format is changed as follows YYYY MM DD MM DD YYYY DD MM YYYY YYYY MM DD 8 7 9 10 MDAA 01 233EN MDAA 01 234EN MDCD 01 026 2 MDAA 01 228EN MDAA 01 229EN MDAA 01 230EN MDAA 01 232EN MDAA 01 231E...

Page 103: ...ode is set to an attachment other than the bucket Select an attachment other than the bucket on the work mode screen Refer to Work Mode Flow Rate Adjustment 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Attachmen...

Page 104: ...nt Adjustment screen 7 6 Rotate selector knob 2 to highlight Pump Flow Rate 8 7 Press selector knob 2 to display Pump Flow Rate screen 9 8 Rotate selector knob 2 clockwise or counterclockwise to adjust the pump flow rate 2 9 7 8 MDCD 01 026 MDAA 01 129EN MDAA 01 130EN ...

Page 105: ...29 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Attachment Adjustment 6 2 1 3 4 5 6 MDCD 01 026 MDAA 01 001EN MDAA 01 114EN MDAA 01 128EN ...

Page 106: ... to highlight Priority Arm Roll Out 8 7 Press selector knob 2 to display Priority Arm Roll Out screen 9 8 Rotate selector knob 2 clockwise to increase flow rate to the attachment Rotate selector knob 2 counterclockwise to increase flow rate to the arm roll out circuit 9 7 8 MDCD 01 026 2 MDAA 01 235EN MDAA 01 132EN ...

Page 107: ...9 1 Press selector knob 2 while displaying basic screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Attachment Adjustment 6 2 1 3 4 5 6 MDCD 01 026 MDAA 01 001EN MDAA 01 114EN MDAA 01 128EN ...

Page 108: ...2 to highlight Priority Arm Roll In 8 7 Press selector knob 2 to display Priority Arm Roll In screen 9 8 Rotate selector knob 2 clockwise to increase flow rate to the attachment Rotate selector knob 2 counterclockwise to increase flow rate to the arm roll in circuit 9 7 8 MDCD 01 026 2 MDAA 01 236EN MDAA 01 131EN ...

Page 109: ...r knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Attachment Name Input 6 1 3 4 5 6 MDCD 01 026 2 MDAA 01 114EN MDAA 01 133EN MDAA 01 001EN ...

Page 110: ...light a character and push selector knob 2 9 After inputting the new name rotate selector knob 2 to highlight SET Push selector knob 2 to finalize the setting fNOTE In order to delete the last entered character turn selector knob 2 to highlight BS Back Space and then push selector knob 2 In order to delete all entered characters rotate selector knob 2 to highlight ALL CLEAR Push selector knob 2 2 ...

Page 111: ...eases to the idling speed and then stops after 15 seconds When the pilot control shut off lever is pushed before stopping the engine the auto shut down is disabled and the engine will not stop IMPORTANT When the engine stops by the auto shut down function turn the key switch to ACC or OFF once and then turn it to START to restart the engine Turn the key switch OFF after auto shut down when leaving...

Page 112: ...ON the mark is displayed in green When the function is OFF the mark is displayed in gray Acting Time Setting 1 On the Auto Shut Down screen rotate selector knob 2 to highlight Setting Time 9 and push selector knob 2 2 Rotate selector knob 2 to adjust Auto Shut Down acting time 3 Press selector knob 2 to make the change fNOTE 30 seconds before the engine stops the monitor will display Engine Shut D...

Page 113: ...inhibited at this screen to prevent auto regeneration while operating the machine in a dusty area or indoors Setting Procedure 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 2 1 3 4 MDCD 01 026 MDAA 01 114EN MDAA 01 001EN ...

Page 114: ...gain to turn Muffler Filter Regeneration Inhibited OFF 9 When ON is selected the regeneration inhibited icon will be displayed on the monitor Refer to 1 24 fNOTE When the function is ON the mark is displayed in green When the function is OFF the mark is displayed in gray IMPORTANT When the machine is operated with the muffler filter regeneration inhibited the muffler filter becomes clogged When th...

Page 115: ...N 1 51 Password Change Optional 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 2 1 3 4 MDCD 01 026 MDAA 01 114EN MDAA 01 001EN ...

Page 116: ...tting Menu screen 5 4 Rotate selector knob 2 to highlight Password Change 6 5 Press selector knob 2 to display Password Change screen 7 6 Input current password from the numeric keypad 2 7 Current Password 5 6 MDCD 01 026 MDAA 01 157EN MDAA 01 156EN MDAA 01 158EN ...

Page 117: ...OPERATOR S STATION 1 53 7 Input the new password and push selector knob 2 3 to 8 digits can be input for password New Password MDAA 01 159EN MDAA 01 160EN ...

Page 118: ...OPERATOR S STATION 1 54 2 MDCD 01 026 MDAA 01 161EN MDAA 01 162EN MDAA 01 163EN 8 Input the new password again to confirm it and push selector knob 2 9 The password has changed ...

Page 119: ... The breaker hour meter indicates the breaker operation time 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Sub Meter Selection 6 2 1 Sub Meter 3 4 5 6 MDCD 01 026 MDAA 01 114EN MDAA 01 164EN MDAA 01 315EN ...

Page 120: ...2 to highlight desired sub meter 8 Selecting OFF will not display a sub meter 7 Press selector knob 2 to enable the changes fNOTE Only one sub meter can be selected at a time When a display is selected the mark is displayed in green When not selected the mark is displayed in gray 2 7 8 MDCD 01 026 MDAA 01 165EN ...

Page 121: ...n operating the machine pay thorough attention to the surrounding situation Rear View Camera ON OFF 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Rear View Camera Monitor 6 2 1 3 4 5 6 MDCD 01 026 MDAA 01 114EN M...

Page 122: ...basic screen IMPORTANT In order to obtain a clear image clean the lens and the monitor display before operating the machine fNOTE The monitor and camera lens surface is a resin product Lightly wipe the surface with a wet clean cloth Never use an organic solvent IMPORTANT Never attempt to change the mounting position of the rear view camera Consult your authorized dealer if any abnormality is found...

Page 123: ...ng Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Brightness Adjustment 6 2 1 3 4 5 6 MDCD 01 026 MDAA 01 114EN MDAA 01 171EN MDAA 01 001EN ...

Page 124: ...make the screen darker fNOTE When the light is turned ON the monitor screen changes to night mode and mark 8 is displayed Brightness can be adjusted for day mode and night mode respectively fNOTE Even if the light is turned ON during daytime you can activate the daytime screen by pushing 0 9 on the numeric keypad 2 7 8 9 MDCD 01 026 MDAA 01 173EN MDAA 01 018 MDAA 01 172EN ...

Page 125: ... displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight 6 2 1 3 4 5 6 MDCD 01 026 MDAA 01 114EN MDAA 01 001EN MDAA 01 176EN ...

Page 126: ...play screen 7 6 Rotate selector knob 2 to highlight the desired language Press selector knob 2 to make the change fNOTE When a display is selected the mark is displayed in green When not selected the mark is displayed in gray 2 7 MDCD 01 026 MDAA 01 177EN ...

Page 127: ...ish Italian French German Dutch Russian Portuguese Finnish Greek Swedish Norwegian Chinese Simplified Chinese Traditional Korean Language Screen Display Indonesian Thai Vietnamese Myanmarese Arabic Persian Turkish Danish Esthonian Polish Icelandic Croatian Slovenian Romanian Bulgarian Lithuanian ...

Page 128: ...ess selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Unit Selection 6 2 1 3 4 5 6 MDAA 01 114EN MDAA 01 181EN MDAA 01 001EN MDCD 01 026 ...

Page 129: ...2 to set the unit Metric or US system 7 Before changing C and F turn the blower of the air conditioner ON Rotate selector knob 2 to highlight desired unit system C or F Press selector knob 2 to set the unit When pressing selector knob 2 Wait will be will be displayed and then the change will be completed 2 7 MDAA 01 183EN MDAA 01 184EN MDAA 01 182EN MDCD 01 026 ...

Page 130: ...nal information 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Display Item Selection 6 2 1 3 4 5 6 MDAA 01 114EN MDAA 01 237EN MDAA 01 001EN MDCD 01 026 ...

Page 131: ...or knob 2 to highlight desired display 8 Press selector knob 2 to set the image Selecting OFF sets non display fNOTE When a display is selected the mark is displayed in green When not selected the mark is displayed in gray 2 7 Logo Operation Information MDAA 01 239EN MDAA 01 222EN MDAA 01 238EN MDCD 01 026 ...

Page 132: ...ork Mode and Mail can be changed in this screen Frequently used menu can be located on top of the screen 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 2 1 3 4 MDAA 01 114EN MDAA 01 001EN MDCD 01 026 ...

Page 133: ...r knob 2 to highlight Main Menu Sequence Change 6 5 Press selector knob 2 to display Main Menu Sequence Change screen 7 6 Rotate selector knob 2 to highlight a menu to be on the top of the screen Press selector knob 2 to set the menu to the top of the screen 2 7 MDAA 01 187EN MDAA 01 186EN MDCD 01 026 ...

Page 134: ...nance and Monitoring 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 2 1 3 4 5 MDAA 01 190EN MDAA 01 191EN MDAA 01 001EN MDCD 01 026 ...

Page 135: ...s machine operating hours and operating rate from resetting the monitoring unit The Attachment Operation screen displays total operating hours of front attachment travel and all operation from resetting the monitoring unit Fuel Consumption 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector ...

Page 136: ...r knob 2 to return to the basic screen To clear the Fuel Consumption and Machine Operation Hours rotate selector knob 2 to highlight CLEAR 10 and then push selector knob 2 IMPORTANT Total fuel consumption and fuel consumption rate depend on the operating environment and the operation method of the machine The values shown on the screen are just for reference A difference could arise between actual...

Page 137: ...ng Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Operation 6 2 1 3 4 5 6 MDAA 01 190EN MDAA 01 191EN MDAA 01 001EN MDCD 01 026 ...

Page 138: ...display Breaker Operation screen 9 Operating Time Machine Operation Hours and Operation Ratio can be checked in this screen Pushing selector knob 2 to return to the basic screen To reset the Operation Time and Machine Operation Hours data rotate selector knob 2 to highlight CLEAR 10 and then push selector knob 2 2 7 9 8 10 MDAA 01 197EN MDAA 01 196EN MDCD 01 026 ...

Page 139: ...ying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Operation 6 2 1 3 4 5 6 MDAA 01 190EN MDAA 01 191EN MDAA 01 001EN MDCD 01 026 ...

Page 140: ...8 7 Press selector knob 2 to display Attachment Operation screen 9 The attachment Operating Time can be checked in this screen Push selector knob 2 to return to the previous screen To reset the Operating Time data rotate selector knob 2 to highlight CLEAR 10 and then push selector knob 2 2 7 9 8 10 MDAA 01 200EN MDAA 01 199EN MDCD 01 026 ...

Page 141: ...ng Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Operation 6 2 1 3 4 5 6 MDAA 01 190EN MDAA 01 191EN MDAA 01 001EN MDCD 01 026 ...

Page 142: ... 8 7 Press selector knob 2 to display Travel Operation screen 9 Total Travel Operation Time can be checked in this screen Push selector knob 2 to return to the previous screen To reset the Operating Time data rotate selector knob 2 to highlight CLEAR 10 and then push selector knob 2 2 7 9 8 10 MDAA 01 203EN MDAA 01 202EN MDCD 01 026 ...

Page 143: ...ng Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Operation 6 2 1 3 4 5 6 MDAA 01 190EN MDAA 01 191EN MDAA 01 001EN MDCD 01 026 ...

Page 144: ... Operation screen 9 The actual Operating Time can be checked in this screen Push selector knob 2 to return to the previous screen To reset the Operating Time data rotate selector knob 2 to highlight CLEAR 10 and then push selector knob 2 fNOTE The Operating Time includes travel operation hours as well as all other operations 2 7 9 8 10 MDAA 01 206EN MDAA 01 205EN MDCD 01 026 ...

Page 145: ...evice Oil Swing Bearing Grease Air Cleaner Filter Fuel Filter Change Air Conditioner Filter Muffler Filter Line Filter Optional Water Separator Optional User Setting 1 User Setting 2 Maintenance Notice 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu scr...

Page 146: ... required interval is reached an information message is displayed on the screen OFF No notification message is displayed fNOTE When the required interval for an item is reached screen 9 is displayed for 10 seconds when the key is switched ON Press Return button to delete the notification When checking the maintenance items from the menu an item where the set time has been reached are marked with a...

Page 147: ...e displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Maintenance 6 2 1 3 4 5 6 MDAA 01 190EN MDAA 01 223EN MDAA 01 001EN MDCD 01 026 ...

Page 148: ...b 2 to highlight RESET 9 and then push selector knob 2 The value of the remaining hours is reset to that of the change interval The previous change date hour is updated with the current date and time Maintenance Interval Setting To change the maintenance interval rotate selector knob 2 to highlight 11 and then press selector knob 2 The background color of Maintenance Interval 10 changes then turn ...

Page 149: ...is screen 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Monitoring 6 2 1 3 4 5 6 MDAA 01 190EN MDAA 01 220EN MDAA 01 001EN MDCD 01 026 ...

Page 150: ...ing screen 7 fNOTE When the PM Accumulation bar reaches the right end auto regeneration takes place However auto regeneration may not be performed depending on the machine condition The PM Accumulation is not displayed during regeneration 2 7 MDAA 01 221EN MDCD 01 026 ...

Page 151: ...F Switch Fan Switch 6 AM FM Selector Tuning Switch 7 Power Switch Volume Control Knob 8 Engine Control Dial 9 Auto Idle Switch 10 Travel Mode Switch 11 Power Mode Switch 12 Work Light Switch 13 Wiper Washer Switch 14 Numeric Keypad 15 Overhead Window Wiper Washer Switch Optional Optional Std Model 2 3 6 8 7 9 10 13 15 11 12 14 1 4 5 MDAA 01 241 MDCD 01 027 ...

Page 152: ...menu screen opens Push this switch after the menu screen the action is confirmed Rotate Moving the cursor Temperature Control Switch Mode Switch Air Conditioner Push Air vent is selected Rotate Setting the temperature AUTO OFF Switch Fan Switch Air Conditioner Push Push this switch while the air conditioner OFF it turns AUTO Push this switch while operating the air conditioner it turns OFF Rotate ...

Page 153: ...quency Power Switch Volume Control Knob Radio Push Turns power ON OFF Rotate Adjusting the volume Engine Control Dial Use engine control dial 1 to adjust engine speed The fully clockwise position Fast Idle The fully counterclockwise position Slow Idle 1 Slow Idle Fast Idle MDAA 01 014 MDAA 01 016 M1P1 01 068 ...

Page 154: ...onds at the state in which the work lever is turned to neutral This function saves fuel consumption When the auto idle mode is selected auto idle indicator 3 on the monitor panel lights fNOTE Auto idle control may not work completely until the end of the warm up Travel Mode Switch Two travel modes FAST and SLOW are selected by turning the travel mode switch to either position Mark Fast Speed Mode ...

Page 155: ... if necessary Work Light Switch Work light switch has the following positions 1 Position Work light 1 on the base machine will light Also the switch panel illumination will light 2 Position Work light 2 mounted on the boom and work light 1 on the right side of the machine will light At the same time the switch panel illumination will light The monitor changes to night mode OFF Work lights 1 2 and ...

Page 156: ... and washer will not operate If the front window is opened while operating the wiper the wiper stops Washer Press and hold the wiper washer switch to squirt washer fluid onto the front window When the wiper washer switch is pressed for more than 2 seconds the wiper operates until the switch is released When the wiper washer switch is released the wiper automatically retracts While operating the wi...

Page 157: ...hold the wiper washer switch to squirt washer fluid onto the front window When the wiper washer switch is pressed for more than 2 seconds the wiper operates until the switch is released When the wiper washer switch is released the wiper automatically retracts While operating the wiper in the INT mode when the wiper washer switch is pressed the wiper operation mode is changed to the continuous oper...

Page 158: ...re using the switches make sure what kinds of optional devices are equipped Raise the armrest when operating the optional switch All available optional devices are shown below Travel Alarm Deactivation Swing Alarm Rear Work Light Overload Alarm Device Switch Seat Heat Switch Rotating Lamp Electrical Control Optional Switch Location Armrest Adjustment MDAA 01 327 ...

Page 159: ...shing the mark of swing alarm deactivation switch 2 the swing alarm buzzer function is deactivated Rear Light Switch Optional When rear light switch 3 is turned ON the rear light at the rear of the cab roof comes ON Overload Alarm Switch Optional During lifting load work with overload alarm switch 4 ON if overloading is detected the buzzer sounds and overload alarm indicator 5 on the multi monitor...

Page 160: ...the rear on the cab roof comes ON Electrical Control Main Switch Optional Turn the pilot control shut off lever to UNLOCK position The electrical control grip switch system becomes operable by pushing ON of the electrical control main switch 8 It becomes OFF by pressing the switch again It also becomes OFF when the key switch is turned OFF or the pilot control shut off lever is turned to LOCK posi...

Page 161: ...ided on the top of the right control lever While pressing power boost switch 5 the maximum digging power is boosted within approximately 8 seconds to increase work capacity Horn Switch Horn switch 6 is provided on the top of the left control lever The horn continuously sounds as long as the switch is pressed 5 6 MDAA 01 292 MDAA 01 293 1 3 2 4 MDCD 01 030 ...

Page 162: ...t Indicator 2 will not light unless the pilot control shut off lever is in UNLOCK position Besides the indicator 2 light turns OFF and the attachment switch becomes inoperable when the pilot control shut off lever is placed in LOCK position while indicator 2 is lit To operate the attachment switch place the pilot control shut off lever in UNLOCK position and then push ON of electrical control main...

Page 163: ...thorized application or use of unauthorized attachments optional parts or modified switch which will void Hitachi Warranty Policy Before using this switch thoroughly read the operation manual of the corresponding attachment and check the operation of each function in a safe area Before operating an attachment with this switch confirm the requirements on safe and proper mounting and operation of th...

Page 164: ... Cigar Lighter Port as External Power Source Use the cigar lighter port to supply power to lighting equipment for servicing the machine IMPORTANT Only 24 V electric power is available from the cigar lighter port on this machine Never connect accessories that use power other than 24 V Damage to the batteries and accessories may result Do not supply power to accessories for a long time without runni...

Page 165: ...t goes OFF DOOR The room lamp goes ON when the cab door is opened The lamp automatically goes off after 30 seconds The light turns ON while the key switch is OFF Installing Fire Extinguisher Optional A fire extinguisher can be installed at the left rear corner inside the cab Consult your nearest HITACHI dealer to install a fire extinguisher 1 ON OFF DOOR MCGB 01 023 MDCN 01 007 MDCN 01 007 Fire Ex...

Page 166: ...ilot control shut off lever 1 up to the LOCK position Always pull pilot control shut off lever 1 up to the LOCK position before transporting the machine and leaving the machine Confirm that pilot control shut off lever 1 is in the LOCK position before starting the engine The engine will not start in other than the LOCK position Engine Stop Switch In case the engine does not stop even if the key sw...

Page 167: ...30 A 18 IDLE STOP 5 A 7 START 5 A 17 POWER ON 5 A 6 OPTION2 20 A 16 GLOW R 5 A 5 OPTION1 5 A 15 AUXILIARY 10 A 4 SOLENOID 20 A 14 MONITOR 5 A 3 HEATER 20 A 13 LIGHTER 10 A 2 WIPER 10 A 12 RADIO 5 A 1 LAMP 20 A 11 FUEL PUMP 5 A 1 11 4 14 7 17 2 12 5 15 8 18 3 13 6 16 9 19 10 20 M1GR 01 003 MDCN 01 010 ...

Page 168: ...oling and Heating Maximum cooling or heating can be obtained by rotating the temperature control switch clockwise 32 C or counterclockwise 18 C respectively Preheating During preheating the cab in winter with the foot vent selected the air volume is reduced to Low until the coolant temperature rises to prevent cool air from entering the cab fNOTE Even in the summer season the high idle speed may b...

Page 169: ...trol Switch Mode Switch 6 AUTO OFF Switch Fan Switch fNOTE Air flow direction can be changed by controlling the louvers at all air vents except for foot vents 2 In addition the louvers on front vent 1 and defroster vent 3 can be completely opened and closed by hand 5 6 1 MDCN 01 008 MDCN 01 003 2 3 4 MDCD 01 026 ...

Page 170: ... foot and the defroster vents Including defroster vent Foot Vent Mode Each time mode switch 5 is pressed the vent location can be changed in four stages as illustrated below AUTO When switch 6 is selected in AUTO The air vent location is automatically selected Temperature Control Switch 5 Sets temperature in the cab Temperature in the cab can be set from 18 0 to 32 0 C by rotating temperature cont...

Page 171: ...in 6 steps Rotate blower switch 6 clockwise to increase blower speed Rotate blower switch 6 counterclockwise to decrease blower speed The monitor 7 indicates the corresponding blower fan speed AUTO OFF Switch 6 Push AUTO OFF Switch 6 while the air conditioner is OFF it turns into AUTO mode Press AUTO OFF switch 6 while operating the air conditioner it stops operating 7 8 5 6 MDAA 01 001EN ...

Page 172: ...ure control switch 5 so that 25 0 is indicated on the monitor Control air temperature inside cab using this switch as necessary 3 As Necessary Operate Mode switch 5 to manually select the air vent Operate blower switch 6 to manually control the blower speed Operate the air conditioner setting screen on the monitor to maintain the air vent in the fresh air mode or circulation mode Usually the cab h...

Page 173: ... Switch 5 Adjust temperature control switch 5 so that 25 0 is indicated on the monitor Control air temperature inside the cab using this switch as necessary 3 As Necessary Operate Mode switch 5 to manually select the air vent Operate blower switch 6 to manually control the blower speed Operate the air conditioner setting screen on the monitor to maintain the air vent in the fresh air mode or circu...

Page 174: ...and rear vents using mode switch 5 Control air flow direction by adjusting the louvers at the front vent 1 and the defroster vent 3 Control air temperature in the cab by using temperature control switch 5 If the windowpanes become clouded in rainy season or wanted to eliminate moisture turn A C to ON at the air conditioner screen on the monitor Cool Head Warm Feet Operation Cool and warm air is si...

Page 175: ...itioner to aid in keeping the windows clear When the atmosphere is very damp and if the air conditioner has run excessively the outside of the windows may become clouded If this happens turn off the air conditioner to adjust the temperature in the cab Off Season Air Conditioner Maintenance To protect each part of the compressor from a lack of lubricant operate the air conditioner at least once a m...

Page 176: ...it counterclockwise to decrease the sound volume Tuning Procedure Manual Tuning Procedure Rotate tuning switch 1 until the desired station is reached Automatic Search Function 1 Press selector knob 3 while displaying basic screen 4 to display main menu screen 5 2 Rotate selector knob 3 to highlight Radio 6 Press selector knob 3 to display the radio screen Rotate selector knob 3 to highlight seek 8...

Page 177: ...b 1 to display Radio screen 5 4 Rotate selector knob 1 to highlight a CH to preset a station CH1 to CH8 5 Press and hold selector knob 1 for more than 1 second The current station is preset to the selected CH Setting from numeric keypad 1 Select the desired station Refer to the Tuning Procedure in the previous section 2 Press and hold one numeric keypad 1 to 8 for more than 1 second The current st...

Page 178: ...b 1 to highlight Radio 4 Press selector knob 1 to display Radio screen 5 3 Rotate selector knob 1 to highlight AUTO PRESET 6 4 Press selector knob 1 to start AUTO PRESET process The AUTO PRESET scans reception frequency allocate sought stations to CH1 to CH8 from sensitive station AM will be preset to CH1 to 4 FM will be preset to CH5 to 8 Operating the radio during scan stops the AUTO PRESET 1 MD...

Page 179: ... Radio 5 Press selector knob 1 to display Radio screen 6 3 Rotate selector knob 1 to highlight TONE 7 4 Press selector knob 1 to adjust TONE control Rotate selector knob 1 clockwise to boost treble Rotate selector knob 1 counterclockwise to boost bass Press selector knob 1 to enable the changes 3 4 5 7 6 1 2 MDAA 01 001EN MDAA 01 092EN MDAA 01 096EN MDCD 01 026 ...

Page 180: ...audio cable IMPORTANT Use Φ3 5 mm stereo plug for the connection of audio input terminal IMPORTANT Put AUX IN cap 4 when the audio input is not in use Volume Control of audio device Turn the volume down to the minimum beforehand and then turn volume control knob 2 clockwise to adjust the volume IMPORTANT If volume control knob 2 has been set to the maximum you will hear an overwhelming sound so se...

Page 181: ...e displayed on side monitor 1 Press screen changeover switch 2 while the side monitor is ON image displayed on the side monitor switches There are three image patterns Each time screen changeover switch 2 is pressed the image is switched Image of Rear View Camera 4 Image of Side Camera 5 Image of Rear View Camera 4 and Side Camera 5 displayed side by side IMPORTANT In order to obtain a clear image...

Page 182: ...cab Do not unlock the cab door when the machine is parked on a slope or while the wind is blowing hard The cab door may close accidently possibly resulting in personal injury When opening or closing the cab door take extra care not to catch fingers between the base machine and the cab door To unlock the door push down on lever 1 1 MDCN 01 012 ...

Page 183: ...f the body by mistake possibly resulting in personal injury or death Park the machine on a level and solid ground and stop the engine before opening and closing the upper front window To open the upper front window hold the window by hands hold it until the window is locked When closing the window it may accidently fall by its own weight Hold the window by hands until it is completely closed Since...

Page 184: ...ed the wiper and washer are inoperable dCAUTION Slowly close the upper front window so that not to catch your fingers Always secure lock pin 2 in the lock position after the upper front window is opened Always pull pilot control shut off lever 5 to the LOCK position before opening or closing the upper front window 4 To close the upper front window hold lock release lever 1 at the upper center and ...

Page 185: ...ower Front Window 1 Open the upper front window beforehand when removing the lower front window 2 While pulling the lower front window inward raise it to remove 3 Store the removed windowpane in the storing position After inserting the windowpane into rubbers 2 and 3 slide it sideways securely into rubber 4 Then push fastener 1 to lock 3 4 3 2 1 MDCN 01 015 MDCN 01 016 ...

Page 186: ...OPERATOR S STATION 1 122 Side Window 1 Opening Side Windows Hold handle 1 and slide rear pane to open the side window M178 01 061 ...

Page 187: ...old handle 2 and lift window until it rises upright With the window positioned upright it will be secured in position by dampers 3 Hold handle 2 and pull window down until click sound is heard from left and right locks 1 Note that the overhead window can be used as an emergency exit 1 2 3 MDAA 01 302 MDAA 01 303 ...

Page 188: ...that the overhead window can be used as an emergency exit IMPORTANT Replace the clear hatch with a new one every 5 years even if undamaged In case it was remarkably damaged or has received severe shock loads replace it even if it has been not in use for 5 years When cleaning the clear hatch use a neutral detergent If acidic or alkaline detergent is used the clear hatch may become discolored or cra...

Page 189: ... the front window glass the glass can be broken However if decal 3 is not affixed to the front window glass the glass cannot be broken with emergency evacuation hammer 1 Take care not to be injured with pieces of broken glass 3 If upper front window should be difficult to open check the decal 3 affixed to the window glass If decal 3 is affixed to the front window glass break the front window glass...

Page 190: ...t adjustment range is 60 mm with steps every 15 mm 5 positions in total Push down lever 1 to adjust front part of the seat Pull up lever 1 to adjust rear part of the seat Console and Seat Fore aft Adjustment Operate console and seat slide lever 2 to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers Seat and console fore aft adjustment range is 8...

Page 191: ...the desired position and release lever 5 Armrest Adjustment Armrest 6 can be pulled upright by hand 90 Pull the armrest upright by hand to get on and off the machine easily The angle of armrest 6 can be adjusted to the desired position by turning adjusting dial 7 located on the bottom of armrest 6 6 7 M1G6 01 017 5 ...

Page 192: ... lever 1 upward to fill air and raise the seat Push lever 1 downward to release air and lower the seat When the seat is properly adjusted for your weight indicator 2 is in the green zone Console and Seat Fore aft Adjustment Operate console and seat slide lever 3 to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers Seat and console fore aft adjus...

Page 193: ... every 15 mm Angle Adjustment of Seat Surface Pull lever 7 upward to adjust the seat angle Height of the seat end is adjustable in 4 steps Backrest Adjustment Pull up lever 8 to release backrest lock Move backrest to the desired position Move backrest to the desired position and release lever 8 Armrest Adjustment Armrest 9 can be pulled upright by hand 90 Pull the armrest upright by hand to get on...

Page 194: ...ON Before loosening the console support the console Otherwise the console may suddenly drop possibly causing personal injury Adjusting Procedures 1 Lower the bucket to the ground Stop the engine 2 Move the pilot control shut off lever to the LOCK position 3 Remove left and right console holding bolts 1 Loosen bolts 2 to adjust the console height 4 After adjusting tighten bolts 1 and 2 Tightening T...

Page 195: ...age displayed on the rear view monitor is meant only as an aid When operating the machine pay thorough attention to the surrounding situation Adjust the mirrors so that persons standing within 1 m from the machine or object with height of 1 5 m and 30 cm in diameter can be recognized from the operator s seat IMPORTANT If a modification that may restrict operator s visibility is made determine the ...

Page 196: ...he part concerned Replace seat belt 1 every 3 years regardless of appearance Seat Belt 1 Confirm that seat belt 1 is not twisted Securely insert the end of seat belt 1 into buckle 2 Lightly pull on the belt to confirm that the buckle latches securely 2 Push button 3 on buckle 2 to unfasten seat belt 1 Replace the seat belt if it is damaged or worn or if the seat belt has external damage such as an...

Page 197: ...the electrical system When the disconnect switch is turned to OFF to ON the preset data of the radio or clock may be initialized Set the radio and clock again Use the disconnect switch for the following purposes only Before maintaining or servicing the electrical system Before storing the machine for long period of time preventing the battery discharge Before welding operation on the machine body ...

Page 198: ...OPERATOR S STATION 1 134 MEMO ...

Page 199: ... gauges frequently during operation Every 8 Hours or Daily 1 Perform 8 hour or daily service See Maintenance guide 8 hours 2 Watch for fluid leaks 3 Lubricate working tool pivots every 8 hours for the first 50 hours and every 8 hours when working in mud and water After the First 50 Hours 1 Perform 50 hour service See Maintenance guide 50 hours 2 Check accessible hardware torque See Hardware Torque...

Page 200: ...BREAK IN 2 2 MEMO ...

Page 201: ...nd damage of the bucket 5 Looseness and missing of mounting bolts and nuts 3 Check bucket teeth for looseness wear and missing Upperstructure 1 Fuel level leaks and contamination of fuel in tank 4 Lubrication state of the working device 2 Hydraulic oil level leaks and contamination of hydraulic oil tank 5 Check for pin anti extraction pins stoppers rings and bolts for damage 3 Movement play and op...

Page 202: ...d switch 3 with the engine stopped IMPORTANT Always check the machine on a firm level surface Never attempt to start the engine while checking the machine If engine oil level 4 green is displayed the status is normal 5 Adjust the seat to allow full pedal and control levers stroke with operator s back against the backrest Fasten the seat belt fNOTE The monitor surface is a resin product When the su...

Page 203: ...yed on the monitor for 2 seconds Regardless of pilot control shut off lever 1 position the engine can not be cranked during this moment 6 When the password input screen is displayed on the monitor input the password Unless the numeric keypad function ignition block system is activated this screen is not displayed IMPORTANT When required to activate the numeric keypad function ignition block system...

Page 204: ...has started Key switch 2 will automatically return to ON position fNOTE Because of the engine speed control function the engine speed will be kept to slow idle speed for about 3 to 6 seconds right after the engine starts When the coolant temperature or hydraulic oil temperature is low the time will be longer The engine speed will be kept to slow idle speed even if the engine control dial 3 is not ...

Page 205: ...it screen nothing is displayed is displayed on the monitor for 2 seconds Regardless of pilot control shut off lever 1 position the engine can not be cranked during this moment 6 When the password input screen is displayed on the monitor input the password Unless the numeric keypad function ignition block system is activated this screen is not displayed IMPORTANT When required to activate the numer...

Page 206: ...gain Failure to do so may cause damage to the starter and or discharging the batteries 9 Release key switch 2 immediately after the engine has started Key switch 2 will automatically return to ON position fNOTE Because of the engine speed control function the engine speed will be kept to slow idle speed for about 3 to 6 seconds right after the engine starts When the coolant temperature or hydrauli...

Page 207: ...ds immediately stop the engine Inspect the engine oil pressure system and the oil level IMPORTANT In case any abnormality is found on the monitor unit immediately stop the engine Inspect the cause of the trouble Check engine noise and exhaust gas color Check that the engine noise and exhaust gas color is normal fNOTE Check the exhaust gas color as follows After warm up operation run the engine wit...

Page 208: ...top the engine of the machine on which booster batteries are mounted 2 Turn the battery disconnect switch to the OFF position 3 Connect one end of red cable 1 to the positive terminal of the machine batteries and the other end to the positive terminal of the booster batteries 4 Turn the battery disconnect switch to the ON position 5 Connect one end of black cable 2 to the negative terminal of the ...

Page 209: ...r Cable from Frame First Disconnecting the booster cables 1 Disconnect black negative cable 2 from the machine 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 4 Disconnect red positive cable 1 from the machine batteries 1 Battery Disconnect Switch MDC1 03 001 ...

Page 210: ...siccate due to the intense heat present inside the turbocharger possibly causing damage to the turbocharger 4 Turn key switch 2 OFF to stop the engine If the engine does not stop even if the key switch is turned to the OFF position Emergency Stop In case the engine does not stop even if key switch 2 is turned OFF due to failure of the machine move engine stop switch 4 downward to stop the engine T...

Page 211: ...that engine will be stopped 1 and the indicator starts flashing Also the buzzer sounds The buzzer sounds once at 30 seconds before then continuously sounds from 15 seconds The engine speed decreases to the idling speed and then stops after 15 seconds When the control shut off lever is pushed down before stopping the engine the auto shut down is disabled and the engine will not stop IMPORTANT When ...

Page 212: ...OPERATING THE ENGINE 3 12 MEMO ...

Page 213: ...tracks using boom move machine carefully to prevent damage to drive train and tracks Select a route that is as flat as possible Steer machine as straight as possible making small gradual changes in direction When driving over rough terrain reduce the engine speed to lessen possibility of undercarriage damage fNOTE An arrow mark seal is stuck on the inside surface of the side frame to indicate the ...

Page 214: ...t A of both pedals REVERSE TRAVEL Push down on rear B of both pedals NEUTRAL POSITION C When the travel pedals are placed in neutral travel brakes automatically will stop and or hold the machine RIGHT TURN Push down on front of left pedal LEFT TURN Push down on front of right pedal SHORT TURN Spin turn Push down the front of one pedal and the rear of the other fNOTE For long term traveling push do...

Page 215: ...VEL Push both levers forward A REVERSE TRAVEL Pull both levers rearward B NEUTRAL POSITION C When the travel levers are placed in neutral travel brakes automatically will stop and or hold the machine RIGHT TURN Push left lever forward LEFT TURN Push right lever forward SHORT TURN Spin turn Push one lever forward and pull the other rearward fNOTE For long term traveling push down on pedal tabs D an...

Page 216: ... Travel Alarm During travel operation the travel alarm sounds to warn the people near the machine that the machine is traveling Deactivating Travel Alarm More than 12 seconds after starting to travel the machine raise the armrest and push the travel alarm deactivation switch to stop the travel alarm Within 12 seconds the travel alarm deactivation switch is inoperable Once the machine stops traveli...

Page 217: ...functions to pull the machine toward firm ground Tow the machine if the machine becomes stuck but only if the engine is still operating Be sure to attach a tow line correctly Refer to the TOWING MACHINE A SHORT DISTANCE section on the next page Raise One Track Using Boom and Arm dWARNING Keep the angle between boom and arm 90 to 110 and position the bucket s round side on the ground Swing the uppe...

Page 218: ...rames of both machines as illustrated To prevent the wire ropes from being damaged place some protective material between the track frame and the wire ropes IMPORTANT Do not use the shackle holes on the track frame for towing the machine A center shackle hole on the track frame is provided to pull only lightweight objects The shackle holes on the bottom of the track frame are used to secure the ma...

Page 219: ...tions check the machine s position often Reposition the machine if necessary Avoid submerging the swing bearing swing gears and center joint If the swing bearing swing gears and center joint are submerged remove the drain plug to drain mud and water Clean swing area Install plug Lubricate swing internal gear and swing bearing Swing Internal Gear Capacity ZX135US 5B 9 L ZX225US 5B 225USLC 5B 17 L L...

Page 220: ...ound 3 Turn the auto idle switch off IMPORTANT Turbocharger may be damaged if the engine is not properly shut down 4 Turn engine control dial 1 counterclockwise to the stop the slow idle position Run the engine approximately 5 minutes to cool the engine 5 Turn the key switch to OFF Remove the key from the key switch 6 Pull pilot control shut off lever 2 to the LOCK position IMPORTANT Protect cab e...

Page 221: ... operating Do not change the control lever operation pattern Failure to do so may result in operation mistake of the machine A label showing the control patterns of the levers and pedals is attached on the right side in the cab When a lever is released it will automatically return to neutral and that machine function will stop 1 Arm Roll Out 2 Arm Roll In 3 Swing Right 4 Swing Left 5 Boom Lower 6 ...

Page 222: ... breaker icon on monitor work mode selection screen 3 Refer to the descriptions about the work mode on page 5 14 for work mode setting procedures 2 Move pedal lock 2 forward to the UNLOCK position 3 Push down on attachment pedal 1 to operate the breaker Loosen stopper bolt 4 until stopper bolt 4 comes in contact with the bracket in attachment pedal 1 neutral to prevent attachment pedal 1 from bein...

Page 223: ... to the LOCK position 1 Select the proper hydraulic crusher icon on work mode selection screen 3 Refer to the descriptions about the work mode on page 5 14 for work mode setting procedures 2 Move pedal lock 2 forward to the UNLOCK position 3 Push down on attachment pedal 1 either forward or backward to open or close the crusher 4 Remove foot from attachment pedal 1 to stop the crusher 5 Always kee...

Page 224: ...hine 1 Park the machine on a firm level surface Lower the bucket to the ground Return all control levers to neutral Properly shut down the engine 2 Pull pilot control shut off lever 1 up into the full LOCK position Before Starting Operation Confirm that pilot control shut off lever 1 is pulled up to the LOCK position before starting the engine The engine will not start in other than the LOCK posit...

Page 225: ...owly to each stroke end several times If the machine equipped with various attachments operate the attachment function slowly to allow hydraulic oil to circulate through the system 4 Operate the travel and swing functions slowly to allow hydraulic oil to circulate through the systems 5 Warming up operation ends after the above operation is completed fNOTE Because of the engine speed control functi...

Page 226: ... stop the engine fNOTE Because of the engine speed control function the engine speed will be kept to slow idle speed for about 3 to 6 seconds right after the engine starts When the coolant temperature or hydraulic oil temperature is low the time will be longer The engine speed will be kept to slow idle speed even if engine control dial 1 is not set in the slow idle position fNOTE The warm up syste...

Page 227: ...ed Always be aware of engine control dial 2 setting when auto idle selector 3 is turned to the A I ON position If the engine speed is set high with engine control dial 2 and if the operator is not aware of the high engine speed setting the engine speed will unexpectedly increase when any control lever is operated causing unexpected machine movement thus possibly resulting in serious personal injur...

Page 228: ... Idle Indicator 1 OFF Auto Idle Function OFF When auto idle selector 3 is turned OFF with auto idle indicator 1 ON indicator 1 will go OFF and the auto idle system is deactivated Even if the engine is stopped by turning the key switch with auto idle selector 3 in the A I ON position indicator 1 ON the auto idle system is not deactivated When the engine is restarted the auto idle system remains act...

Page 229: ...wn is disabled and the engine will not stop IMPORTANT Ensure the ON or OFF status of auto shut down indicator 1 If the indicator is ON the auto shut down function will be activated Operating Condition The engine is running The pilot control shut off lever is in the LOCK position Coolant and hydraulic oil temperature are not high The muffler filter is not in regenerating process IMPORTANT When the ...

Page 230: ...itioner will also stop Setting the Auto Shut Down Function Auto Shut Down On Off 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Auto Shut Down 6 1 3 5 4 6 MDAA 01 114EN MDAA 01 147EN 2 MDAA 01 001EN MDCD 01 026 ...

Page 231: ... ON the mark is displayed in green When the function is OFF the mark is displayed in gray Acting Time Setting 1 On the Auto Shut Down screen rotate selector knob 2 to highlight Setting Time 9 2 Push selector knob 2 Rotate selector knob 2 to adjust the auto shut down acting time 3 Press selector knob 2 to make the change fNOTE 30 seconds before the engine stop the monitor will display Engine Shut D...

Page 232: ...1 Park the machine in a safe place Lower the front attachment onto the ground 2 Pull the pilot control shut off lever to the LOCK position 3 Set the engine control dial to slow idle 4 Push the muffler filter regeneration switch 2 5 When pushing the muffler filter regeneration switch 2 screen 3 as shown in the right will be displayed and the manual regeneration starts Bar graph on the screen indica...

Page 233: ...tion time varies depending on the ambient temperature White smoke may temporarily be generated from the tail pipe during the regeneration process due to the burning of particulate matter PM but it is not a malfunction Manual regeneration process completes earlier right after the engine has been running than when it is cold Coolant temperature may increase during the manual regeneration IMPORTANT I...

Page 234: ...ircuit and pump flow rate for the front attachment at Work Mode screen When the engine is started the digging mode is automatically set Following six work modes can be selected from the Work Mode screen Digging Mode Breaker 1 Mode Breaker 2 Mode Pulverizer 1 Mode Crusher 1 Mode Grapple 1 Mode 1 2 MDAA 01 001EN ...

Page 235: ...pulverizer Crusher 1 to 5 Mode Select this mode when using crusher Vibrating Hammer 1 to 5 Mode Select this mode when using vibrating hammer Grapple 1 to 5 Mode Select this mode when using grapple Clamshell 1 to 5 Mode Select this mode when using clamshell Others 1 to 5 Mode Select this mode when other than the above attachment is used fNOTE 36 work modes shown above are designated as the standard...

Page 236: ...en 3 2 Rotate selector knob 2 to highlight Work Mode 4 3 Press selector knob 2 to display Work Mode screen 5 4 Rotate selector knob 2 to highlight the desired front attachment In the right example Bucket 6 is highlighted 5 Press selector knob 2 to make the changes 1 3 2 5 4 6 MDAA 01 100EN MDAA 01 101EN MDAA 01 001EN MDCD 01 026 ...

Page 237: ...HINE 5 17 Power Boost Switch Power boost switch 4 is located on the top of the right control lever When power boost switch 4 is pushed increased front attachment power will be supplied for about 8 seconds 4 MDAA 01 292 ...

Page 238: ...ode Operate the machine in this mode when performing normal work ECO is displayed on Power Mode Display 2 PWR Power Mode Use PWR Power mode when extra horsepower is needed PWR is displayed on Power Mode Display 3 fNOTE ECO mode is set automatically when starting the engine Set PWR mode if necessary 1 MDAA 01 001EN 2 MDAA 01 353 3 MDCD 01 027 ...

Page 239: ...aight line position the tracks parallel to the trench After digging to the desired depth move the machine as required to continue the trench When operating the arm avoid bottoming the cylinder to prevent cylinder damage IMPORTANT When digging at an angle avoid striking the tracks with the bucket teeth When lowering the boom avoid sudden stops that may cause shock load damage to the machine When di...

Page 240: ...ling in the arm with the reversed installed bucket IMPORTANT If a bucket hook is mounted take care not to hit the arm with the hook when rolling in the bucket For face shovel operation dig the ground using the arm cylinder in a scraping motion When underground water is expected make a slope angle of 2 to 3 to drain this water as shown fNOTE Because of the hydraulic cylinder structure digging force...

Page 241: ...dirt with the bucket when traveling Excess force will be applied on each part and the machine may be damaged 1 Operate arm roll in function while slowly raising the boom Once the arm moves past the vertical position slowly lower the boom to allow the bucket to maintain a smooth surface 2 Arm roll out operation is performed in the reverse way of step 1 3 Do the slope finishing work in the same proc...

Page 242: ... parts especially the bucket When digging a hard gravel stratum use dig up force of the bucket Operate the boom arm and the bucket simultaneously so that the bucket teeth efficiently bite into the ground Flying debris may result in personal injury Avoid Hammer Work dWARNING As the bucket body has the curved surface hammer work or piling work is very dangerous Doing so may damage the bucket and fro...

Page 243: ... as additional digging force Severe machine damage may result Avoid Side Load the Bucket Do not side load the bucket For example do not swing the bucket to level material or do not strike objects from the side with the bucket Doing so may damage the front attachment and the swing system WRONG WRONG WRONG WRONG M104 05 018 M161 05 006 ...

Page 244: ...ugh ground such as rocks sand or gravel Wide track shoes are designed for soft ground Failure to do so may result in shoe bending and or shoe bolt loosening and may damage other undercarriage components such as track link and rollers Refer to the Shoe Types and Applications in the Specifications section ...

Page 245: ...he machine hydraulic breaker crusher or quick coupler follow the precautions given below Precautions for Connecting Breaker or Crusher Piping Do not allow impurities to enter into the system when switching the breaker crusher or the quick coupler with the bucket When the breaker crusher or quick coupler is not used apply the cover to the pipe opening on the arm top and install the plug or cap into...

Page 246: ...ment or is detached Open When using attachment A A Stop Valves A Close Open MAIN CONTROLLER MONITOR CONTROLLER MONITOR SWITCH BOX PUMP ATTACHMENT PEDAL SOLENOID VALVE SELECTOR VALVE CONTROL VALVE 2nd RELIEF VALVE ACCUMULATOR Only ZX225US 5B 225USLC 5B CAN ACCUMULATOR STOP VALVE Only ZX225US 5B 225USLC 5B MAIN BODY ATTACHMENT BOOM ARM M1U1 05 007 MDAA 05 006 ...

Page 247: ...ATING THE MACHINE 5 27 Secondary Relief Pressure Adjustment Depending on the breaker model the secondary relief valve relief set pressure differs Consult your nearest Hitachi dealer for installing a breaker ...

Page 248: ...mage to the breaker the front attachment and or the upperstructure Always move lower the breaker slowly to position the tip of the chisel on the object to be broken before starting breaker operation Avoid Moving Objects with Breaker Do not use the breaker and or the bracket to move objects Damage to the boom arm and or breaker may result Do not use the breaker and or the swing function to move obj...

Page 249: ...Operate the Breaker in Water Doing so will cause rust and seal damage resulting in damage to the hydraulic system components Rust dust and water may enter into the hydraulic oil through the broken seal damage to the hydraulic system may result Do Not Use Breaker for Lifting Operation The machine tipping over and or breaker damage may result Do Not Operate the Breaker to the Side of the Machine The...

Page 250: ...ned and Thrusted Perpendicular to the Object Failure to do so may damage the chisel or may cause seized piston Do Not Operate the Breaker Continuously Longer Than One Minute Failure to do so may result in premature wear of the chisel If an object could not be broken within one minute apply the chisel to other locations less than one minute for each location Watch Out Take care not to hit the boom ...

Page 251: ...ont Part of the Undercarriage by Pressing Down the Breaker May Cause Damage to the Front Attachment Never raise the front edge of the undercarriage higher than 150 mm by pressing the breaker down Raising 100 to 150 mm Pressing Down M147 05 016 ...

Page 252: ...e particularly of the hydraulic pump change the hydraulic oil and the full flow filter element Refer to the Hydraulic System in the MAINTENANCE Chapter Replacement intervals differ depending on the brand of hydraulic oil used Refer to the Hydraulic System in the MAINTENANCE Chapter Use the high performance element micro glass on excavators engaged in demolition and logging work fNOTE Full flow fil...

Page 253: ...ed or retracted Failure to do so may result in damage to the front attachment In particular avoid doing so with the bucket cylinder fully extended as the front attachment will be easily damaged Take care to prevent this from happening when dismantling foundation structures using the crusher Using the front attachment do not raise the base machine off the ground with the arm cylinder fully extended...

Page 254: ... high with the boom fully raised be careful of falling objects When operating the crusher on a floor in a building first confirm that the floor has sufficient strength to support the load caused by crushing in addition to the machine weight The load equivalent or higher than the machine weight may be applied on the floor depending on the operation method M107 05 048 M107 05 049 WRONG WRONG WRONG M...

Page 255: ...eaker are used replacing them with each other at intervals impurities are more apt to enter the hydraulic system and the hydraulic oil deteriorates quickly For this reason replace the hydraulic oil tank filter and change the hydraulic oil at the intervals specified in the breaker time sharing diagram in the previous section Always remove the crusher from the excavator before transporting the machi...

Page 256: ...ly will controllability be affected but also machine stability will be reduced possibly causing safety hazard Unit kg Specification Base Machine Breaker Crusher Pulverizer Model Arm Std Weight Max Weight Std Weight Max Weight Std Model ZX135US 5B Std 1000 1100 1200 1400 ZX225US 5B Std 1550 1700 1850 2150 ZX225USLC 5B Std 1750 1950 2100 2450 According to the specifications of installed attachment a...

Page 257: ...roper manufacturer s breaker models while referring to the table on the next page Avoid installing an attachment with a long overall length Damage to the front attachment may result When an attachment of the max weight is installed always operate the attachment over the front or rear side of the machine In addition avoid operating the attachment at the maximum reach Crushers are heavier than break...

Page 258: ...30 80 to 130 70 to 130 50 to 110 Operating Pressure MPa kgf cm2 15 to 17 153 to 173 11 8 to 15 7 120 to 160 13 7 to 15 7 140 to 160 13 7 to 16 7 140 to 170 11 8 to 16 7 120 to 170 13 7 to 17 6 140 to 180 11 3 115 13 7 to 15 7 140 to 160 13 2 to 14 2 135 to 145 11 8 to 16 7 120 to 170 Secondary Relief Valve Set Pressure MPa kgf cm2 17 6 180 20 6 210 17 6 180 17 6 180 19 6 200 11 8 120 17 6 180 15 7...

Page 259: ...25USLC 5B Maker HITACHI Sango Juki NPK Sakato Ohsumi STK Model HSC100 HSC160 TS850RCD S 22XA SDS250 RC MR1000L MR1100 DX 900 Weight kg 2430 2300 2000 2010 2390 1900 2350 2100 Overall Length mm 2340 2600 2400 2326 2425 2200 2250 2380 Rated Pressure MPa kgf cm2 27 9 285 27 9 285 27 5 280 24 5 250 31 4 320 27 5 280 Maximum Opening Width mm 900 850 850 850 1050 1060 1060 900 Swing Method Hydraulic Hyd...

Page 260: ... 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 Adapter tightening torque PF1 210 N m 21 kgf m When the attachment is disconnected Plug Plug Thread Size JIS B2351 O Type PF1 Adapter Plug Hose Cap M175 05 005 ...

Page 261: ... 225USLC 5B left side piping PF1X1 5 16UN 4214444 4222712 4222265 Form Size PF PF30 Female Type ZX135US 5B PF1 PF3 4 4129457 9718916 4222047 ZX225US 5B 225USLC 5B left side piping PF1XPF1 4042034 9718917 4168177 Form Size PF PF30 Male Type ZX135US 5B PF1 PF3 4 4456120 4222715 4222044 ZX225US 5B 225USLC 5B left side piping PF1XPF1 4456118 4222716 4222045 PF PF PF PF PF PF PF PF UNF UNF UNF UNF 37 3...

Page 262: ...is provided on the track frame to tow light 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 provided on the track frame The track frame and or the shackle hole may be damaged otherwise The maximum drawbar pull Model Maximum Drawbar Pull ZX135US 5B 44100 N 4500 kgf or less ZX225U...

Page 263: ...rking position 2 Pull the pilot control shut off lever to the LOCK position Perform items from 3 to 5 within 15 seconds As pressure in the accumulator gradually decreases after stopping the engine pressure in the hydraulic circuit can be released only immediately after stopping the engine 3 Stop the engine Turn the key switch ON 4 Push the pilot control shut off lever to the UNLOCK position 5 Move...

Page 264: ...e off 1 Loosen lock nut 1 in the control valve at the right Loosen screw 2 one half of a turn The boom lowering speed can be somewhat adjusted by loosening screw 2 more IMPORTANT Excessive leakage may result if the screw and the lock nut are tightened insufficiently Be sure to retighten the screw and the lock nut to specifications 2 After the boom is lowered tighten screw 2 and tighten lock nut 1 ...

Page 265: ...ishing the day s operation drive the machine to a firm level ground where no possibility of falling stones ground collapse or floods is present Refer to the group for PARKING MACHINE in the DRIVING MACHINE section Fully refill the fuel in the fuel tank Clean the machine ...

Page 266: ...OPERATING THE MACHINE 5 46 MEMO ...

Page 267: ... the conditions of the route to be traveled such as dimensional limits weight limits and traffic regulations In some cases getting the permission from the local authority concerned or disassembling the machine to bring it within dimensional limits or weight limits of local regulations may become necessary Notify the nearest dealer that you are transporting the unit ZX225US 5B 225USLC 5B IMPORTANT ...

Page 268: ...ry and dangerous 2 Place blocks against the truck and trailer wheels while using a ramp or loading dock 3 Ramps must be sufficient in width length and strength Be sure that the incline of the ramp is less than 15 degrees 4 Loading docks must be sufficient in width and strength to support the machine and have an incline of less than 15 degrees 5 When loading the machine equipped with pat crawler or...

Page 269: ...ramp where it meets the flatbed is a sudden bump Take care when traveling over it as the balance may be lost If the front attachment is not fitted reverse onto the trailer Extreme care must be taken when swinging the upper structure when the machine is on the trailer flatbed If the front attachment is fitted swing slowly with the arm fully roll in underneath the boom being careful not to loose the...

Page 270: ...tructure around 180 3 4 Rest the front attachment on supports such as wooden blocks placed on the trailer flatbed Also lower the blade onto the deck at this time if fitted 4 Stop the engine Remove the key from the key switch 5 Pull the pilot control shut off lever to the LOCK position 6 Close cab windows roof vent and door and cover the exhaust opening to prevent entry of wind and water Place a co...

Page 271: ...f the flatbed where it meets the ramp is a sudden bump Take care when traveling over it IMPORTANT Make sure that the angle of the boom and the arm is kept between 90 to 110 when unloading the unit Damage to the unit is possible if the arm is kept in a suspended state during unloading 1 Travel extremely slowly with the bucket on the ground and the angle of the arm and the boom kept at between 90 to...

Page 272: ...ORTING 6 6 2 The bucket must be on the ground before the machine begins to tip forward 3 As the machine moves forward raise the boom and extend the arm until the machine is completely off the ramp M107 06 015 ...

Page 273: ... or incorrect wire rope attachment will cause the machine to move shift while being lifted resulting in machine damage and or personal injury Do not lift the machine quickly Excessive load will be applied to the lifting wire ropes and or lifting tools possibly causing them to break Do not allow anyone to come close to or under the lifted machine The indicated gravity center is for the standard spe...

Page 274: ...ock all doors and covers 5 Use wire ropes and support bar of sufficient length so that they do not come in contact with the machine while lifting Wrap some protectors around wire ropes and or support bar as required to prevent the machine from being damaged 6 Set a crane in an appropriate position 7 Thread the wire rope through and under both sides of the track frames as illustrated Attach the wir...

Page 275: ...uine Hitachi parts Failure to do so may result in serious injury or death and or machine breakdown Failure to use recommended fuel lubricants and genuine Hitachi parts will result in loss of Hitachi product warranty Never adjust engine governor or hydraulic system relief valve Protect electrical parts from water and steam Never disassemble electrical components such as main controller sensors etc ...

Page 276: ...te the communication terminal however if any abnormality is found consult your nearest Hitachi dealer Before installing any covering attachment such as a head guard consult your nearest Hitachi dealer Never spray water on the communication terminal and the wirings Inquire on the proper way to recycle or dispose of oil fuel coolant filters batteries and other waste from your local environmental or ...

Page 277: ... page This manual recommends grouping the intervals into three categories as follows Daily Check To be conducted daily before operation Monthly check To be regularly conducted once per month Annual check To be regularly conducted once per year Check and maintenance intervals shown in this manual are those for the machines to be operated under normal conditions In case the machine is operated under...

Page 278: ...ance can be performed regularly Symbol Marks The following marks are used in the maintenance guide table Grease Front Joint Pin Swing Bearing Swing Gear Hydraulic oil filters Pilot Filter Hydraulic Oil Tank Filter Suction Filter Gear Oil Pump Transmission Travel Reduction Device Swing Reduction Device Air Cleaner Element Engine Oil Coolant Long Life Coolant Engine Oil Filter Fuel Filter Fuel Main ...

Page 279: ...ery 500 hours Only first time at 250 hours 7 19 13 Gear Oil Pump Transmission 7 28 5 Grease 7 22 14 Fuel Filter Main Pre 7 57 6 Hydraulic Oil 7 37 15 Solenoid Fuel Pump Strainer 7 61 7 Gear Oil Travel Device 7 31 16 Gear Oil Swing Reduction Gear 7 29 8 Hydraulic Oil Filter Suction 7 40 17 Air Cleaner Element 7 66 9 Hydraulic Oil Filter Full Flow 7 41 4 6 11 9 15 10 12 13 14 8 7 4 4 4 1 2 17 16 4 5...

Page 280: ...n the engine is running in order to prevent the accident If maintenance work while engine running is unavoidable strictly comply with the following items One person should take the operator s seat to be ready to stop the engine any time while communicating with other workers When working around moving parts is unavoidable pay special attention to ensure that hands feet and clothing do not become e...

Page 281: ...hen opening or closing the hood and access covers take extra care not to catch fingers between the base machine and the hood or access covers Holding the handle on the access cover raise the cover until the cover is secured with catch 1 After opening the right and or left access cover be sure to insert rod 2 into cover lock hole 3 to hold the cover Left Cover Engine Cover MDCN 07 002 1 Right Cover...

Page 282: ... or closing the hood and access covers take extra care not to catch fingers between the base machine and the hood or access covers Holding the handle on the access cover raise the cover until the cover is secured with catch 1 After opening the right and or left access cover be sure to insert rod 2 into cover lock hole 3 to hold the cover Engine Cover Rear Right Cover Left Cover MDCN 07 003 MDCN 07...

Page 283: ...Hydraulic oil level leaks and contamination of hydraulic oil tank 3 Movement play and operating force of all control levers 4 Operation of all hydraulic components oil leaks and damage to pipe lines and hoses 5 Deformation break and abnormal noise of upper structure 6 Looseness and missing of mounting bolts and nuts 7 Washer Fluid Others 1 Operation of instruments switches lights and buzzer horn 2...

Page 284: ...cket and link pivots every day until break in operation 50 hours is complete When a bucket which does not have clearance adjustment mechanism such as slope finishing bucket or V type bucket or a genuine Hitachi hoe bucket before EX 5 model or an attachment other than genuine Hitachi bucket is used grease two pins every 250 hours B Engine Parts Quantity Interval hours Page 8 50 100 250 500 1000 200...

Page 285: ...1500 2000 2500 5000 1 Check Hydraulic Oil Level 1 7 36 2 Change Hydraulic Oil ZX135US 5B 125 L 7 37 ZX225US 5B 225USLC 5B 185 L 3 Suction Filter Cleaning 1 Each time when hydraulic oil is changed 7 40 4 Replacement of full flow filter Std Model 1 7 41 Demolition and logging work 1 7 42 5 Replace Pilot Oil Filter 1 7 44 6 Replace Air Breather Element 1 7 45 7 Check Hoses and Lines for leaks loose 7...

Page 286: ... Solenoid Fuel Pump Strainer 1 7 61 6 Check Water Separator Optional Drain water 7 63 Replace element 7 64 7 Check Fuel Hoses for leaks cracks 7 65 for cracks bend etc 7 65 F Air Cleaner Parts Quantity Interval hours Page 8 50 100 250 500 1000 2000 1 Air Cleaner Outer Element Clean 1 or when indicator lit 7 66 Replace 1 After cleaning 6 times or 1 year 7 66 2 Air Cleaner Inner Element Optional Rep...

Page 287: ...fe Coolant is used change every two years or 4000 operating hours whichever comes first IMPORTANT Use soft water as a coolant Do not use strong acid or alkaline water Use the coolant with genuine Hitachi Long Life Coolant LLC mixed by 30 to 50 If a coolant mixed with less than 30 of Hitachi Long Life Coolant is used service life of the cooling parts may be shortened due to damage by freezing or co...

Page 288: ...Cab Floor As required 7 106 12 Retighten Cylinder Head Bolt As required 7 107 13 Inspect and Adjust Valve Clearance 7 107 14 Measure Engine Compression Pressure 7 107 15 Check Starter and Alternator 7 107 16 Check and Replace EGR Device 7 107 17 Clean EGR Cooler 7 107 18 Check Turbocharger 7 107 19 Check and Clean Injector 7 108 20 Check Gas Damper As required 7 108 21 Tightening and Retightening ...

Page 289: ...ose Heater to engine Every 2 years Differential pressure hose Differential sensor to differential pipe Every 4500 hours Hydraulic System Base Machine Pump suction hose Every 2 years or 4000 hours whichever comes first Pump delivery hose Every 2 years or 4000 hours whichever comes first Swing hose Every 2 years or 4000 hours whichever comes first Travel high pressure hose Every 2 years or 4000 hour...

Page 290: ...il KIGNAS MP GREASE No 2 COSMO Oil COSMO GREASE DYNAMAX EP2 BP Energrease LS EP2 Castrol Spheerol EPL2 Chevron Multifax EP2 Recommended Engine Oil IMPORTANT Use only genuine Hitachi engine oil as shown below or engine oil equivalent to DH 2 specified in JASO Failure to do so may deteriorate the engine and muffler filter performance and or shorten their service life Please be noted that all engine ...

Page 291: ...al GL 4 80W 90 Chevron Thuban SAE 90 DELO 400 Multigrade 15W 30 Remarks API GL4 Class API CD Class JASO DH 1 JASO DH 2 Brand Names of Recommended Hydraulic Oil Kind of Lubricant Hydraulic Oil Where to be applied Change Interval Manufacturer Hydraulic System 5000 hours 2000 hours 20 to 40 C 4 to 104 F Hitachi Super EX 46HN Idemitsu Kosan Super Hydro 46X JX Nippon Oil Energy Corporation SUPER HYRAND...

Page 292: ...10W40 Super Wide DH 2 15W40 Pump Transmission Engine Oil API CD Class Swing Device Travel Device Gear Oil Hitachi Gear Oil GL 4_90 Hydraulic System Hydraulic Oil Tank Hydraulic Oil Super EX46HN Fuel Tank Diesel Fuel EN590 Class A EN590 Class B EN590 Class C EN590 Class D EN590 Class E EN590 Class F Grease fitting Lithium Grease SEP Grease Radiator Coolant Genuine Hitachi LLC Long Life Coolant ...

Page 293: ...MAINTENANCE 7 19 A Greasing Front Joint Pins 500 hours Lubricate all fittings shown in the figure Boom Cylinder Bottom Side Boom Foot M178 07 007 M157 07 156 M178 07 082 ...

Page 294: ...MAINTENANCE 7 20 Boom and Arm Joint Pin Arm Cylinder Rod Pin and Bucket Cylinder Bottom Pin Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin M157 07 157 M178 07 082 ...

Page 295: ...maged if the engine is not properly shut down 4 Run the engine at slow idle speed without load for five minutes 5 Turn the key switch OFF Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position 7 With the upperstructure stationary apply grease via the two grease fittings 8 Start the engine Raise the bucket several inches off the ground and rotate the upperst...

Page 296: ...on 1 Remove cover 1 from upperstructure Check if the swing gear is properly lubricated by grease Add approximately 0 5 kg of grease if required If the grease is contaminated remove grease by opening cover 2 at the undercarriage side and replace with clean grease Model Grease Capacity ZX135US 5B 9 L ZX225US 5B 225USLC 5B 17 L 2 M157 07 161 ZX135US 5B MDCN 07 012 1 1 MDCN 07 013 ZX225US 5B 225USLC 5...

Page 297: ... engine stopped The engine oil indicator 4 must be displayed in green IMPORTANT Do not rely only on the monitor display for checking the machine conditions visually check them yourself as required such as oil level Always check the machine on a firm level surface Never attempt to start the engine while checking the machine fNOTE If the security function is enabled a password is required 2 3 4 MDAA...

Page 298: ...ould be between the upper and lower marks on dipstick 1 If oil level is below the lower limit mark add the recommended engine oil via oil filler 2 If oil level exceeds the upper limit mark remove cap 4 of drain valve 3 at the bottom of the engine oil pan and then open drain valve 3 by turning drainer 5 to drain oil dCAUTION Do not spill oil while changing oil Spilled fuel and oil and trash grease ...

Page 299: ...the bucket to the ground 4 Turn the auto idle switch off IMPORTANT The turbocharger may be damaged if the engine is not properly shut down 5 Run the engine at slow idle speed without load for five minutes 6 Turn the key switch OFF Remove the key from the key switch 7 Pull the pilot control shut off lever to the LOCK position dCAUTION Engine oil may be hot just after operation Take extra care to av...

Page 300: ...valve 3 Install drainer 5 to drain valve 3 10 Screw drainer 5 into drain valve 3 Drain valve 3 will be opened to drain oil 11 Remove oil filler cap 2 Then allow oil to drain through a clean cloth into a container Container 50 liter 12 After all oil has been drained inspect the cloth for any debris such as small pieces of metal 13 Remove drainer 5 Install cap 4 to drain valve 3 3 4 5 M1U1 07 046 M1...

Page 301: ...l pressure indicator on the monitor panel goes out immediately If not stop the engine immediately and find the cause 24 Stop the engine Remove the key from the key switch 25 Check for any leakage at the drain plug 26 Check oil level on the dipstick and add or drain oil to maintain proper oil level The oil level should be between the upper and lower limit marks on the dipstick Refer to 7 24 IMPORTA...

Page 302: ...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 Run the engine at slow idle speed without load for five minutes 5 Stop the engine Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position dCAUTION Oil may be hot just after ...

Page 303: ...the swing device upper cover and add oil Change Gear Oil every 1000 hours dCAUTION Gear oil may be hot just after operation Wait for gear oil to cool before starting work 1 Park the machine on a solid level surface Lower the bucket to the ground Stop the engine 2 Remove the drain plug mounted on the end of drain pipe to drain oil ZX135US 5B 3 Reinstall the drain plug Remove the swing device upper ...

Page 304: ... body and face away from the air release plug Gear oil may be hot just after operation Wait for gear oil to cool and then gradually loosen the air release plug to release pressure 8 After gear oil has cooled slowly loosen air release plug 1 to release pressure 9 Remove air release plug 1 and oil level check plug 2 Oil must be up to the bottom of hole 10 If necessary add oil until oil flows out of ...

Page 305: ...ion Wait for gear oil to cool and then gradually loosen the air release plug to release pressure 8 After gear oil has cooled slowly loosen air release plug 1 to release pressure and temporarily retighten plug 1 9 Remove drain plug 3 and plug 1 in that order to drain oil 10 Clean drain plug 3 Wrap the threads of drain plug 3 with sealing type tape Install plug 3 Tighten plug 3 Tightening Torque 50 ...

Page 306: ...on to be capable of moving the front attachment for specified time around 10 seconds after stopping the engine 3 2 Bleed air from the hydraulic oil tank to release internal pressure 3 3 Immediately after operation all hydraulic components and hydraulic oil or lubricants are hot and highly pressurized Begin inspection and or maintenance work only after the machine has cooled down Servicing heated a...

Page 307: ...wist when connecting them The life of twisted hoses will be shortened considerably IMPORTANT Do not use hydraulic oils other than those listed in the table Brand names of recommended hydraulic oil When adding hydraulic oil always use the same brand of oil do not mix brands of oil When using another manufacturer s hydraulic oil be sure to change the full amount The new machine is filled with hydrau...

Page 308: ...reaker Operation in the OPERATOR S STATION chapter Changing intervals for the high performance element micro glass Breaker Operating Availability 0 10 20 30 40 50 60 70 80 90 100 Full Flow Filter 1000 670 510 410 340 290 250 230 200 190 170 Hydraulic oil 2000 hours life time 2000 1590 1320 1130 990 880 790 710 650 600 560 Hydraulic oil 5000 hours life time 5000 2790 1930 1480 1200 1010 870 760 680...

Page 309: ...030 1270 930 730 600 510 440 390 350 320 fNOTE Full flow filter restriction indicator is optional If a filter paper element is used this indicator does not operate MDAA 07 051 Average Breaker Operating Availability Changing Intervals hour 100 80 90 70 50 30 10 60 20 40 0 0 1000 500 1500 2500 3500 4500 2000 3000 4000 5000 Changing Interval when using 5000 hour life time hydraulic oil Changing Inter...

Page 310: ...FF Remove the key from the key switch 7 Pull the pilot control shut off lever to the LOCK position 8 Open the access door in front of the main pump Check oil level with level gauge 1 on hydraulic oil tank Oil must be between marks on gauge 1 If necessary add oil dCAUTION The hydraulic oil tank is pressurized Push the pressure release button on the tank cap to release pressure and carefully remove ...

Page 311: ... 4 Turn the auto idle switch off IMPORTANT The turbocharger may be damaged if the engine is not properly shut down 5 Run the engine at slow idle speed without load for five minutes 6 Stop the engine Remove the key from the key switch 7 Pull the pilot control shut off lever to the LOCK position 8 Clean the top of the hydraulic oil tank to keep dirt out of the hydraulic system dCAUTION The hydraulic...

Page 312: ...ean install and tighten drain plug 3 14 Add oil until it is between the marks on the oil level gauge 15 Install cover 2 Tighten the bolts to 50 N m 5 kgf m 16 Be sure to bleed air form the system following the procedures shown next page M1U1 07 047 3 M157 07 062 2 4 ...

Page 313: ...lugs 5 slightly until oil flows from plug port to release trapped air completely Tighten air bleed plug 5 Repeat this step for the rest of plugs 5 Tightening torque 95 N m 9 5 kgf m 4 Purge air from the hydraulic system by running the engine at slow idle and operating the control levers slowly and smoothly for 15 minutes 5 Position the machine as illustrated in the oil level checking procedure 6 L...

Page 314: ...inside of the hydraulic oil tank and the suction filter 3 Before installing the suction filter check the dimension of rod assembly 2 shown in figure right Securely insert rod assembly 2 into pipe 3 4 Before securing cover 1 with bolts ensure the top edge of the rod assembly 2 is completely inserted into the hole of support 4 5 Bleed air from the hydraulic system Refer to the descriptions for Bleed...

Page 315: ...s 1 6 used to remove cover 2 and O ring 3 When removing cover 2 slowly remove it while pressing the cover downward so that spring 4 does not fly out 4 Remove the spring 4 and element 5 5 Take extra care never to allow water or dust to enter the filter case 6 Replace element 5 and O ring with new ones Install them into the hydraulic oil tank Be careful not to damage element 5 and O ring 3 Broken el...

Page 316: ...ed kind of filter element or average attachment operating availability IMPORTANT Precautions for the filter element Excavators engaged in demolition and logging work use full flow filter with high performance micro glass element When replacing the element use the same kind of high performance element In case a filter paper element is unavoidably used change hydraulic oil and replace full flow filt...

Page 317: ...raulic oil tank by pressing the air bleed valve on the hydraulic oil tank 3 Loosen bolts 1 6 used to remove cover 2 and O ring 3 When removing cover 2 slowly remove the cover while pressing the cover downward so that spring 4 does not fly off 4 Remove spring 4 and element 5 5 When installing new element 5 into the hydraulic oil tank replace O ring 3 with a new one at the same time 6 Install cover ...

Page 318: ...ank is pressurized Push the pressure release button on the air breather before removing the air breather 7 Remove the filter cartridges of pilot oil filter 2 by turning it counterclockwise with the filter wrench 8 Clean the filter O ring contact area on filter head 1 9 Apply a thin film of clean oil to the gasket of new filter 2 10 Install new filter 2 Turn the filter cartridge clockwise by hand u...

Page 319: ...ssing the air bleed valve on the hydraulic oil tank 3 Rotate cover 2 clockwise approx 1 4 turns Remove cap 1 by rotating it counterclockwise 4 Rotate cover 2 counterclockwise and remove it Remove element 3 5 Install new element 3 Tighten to install cover 2 until cover 2 comes in contact with element 3 Then further tighten the cover 1 4 turn 6 Securely tighten cap 1 clockwise by hand While holding ...

Page 320: ...to protect hands and body from high pressure fluids If an accident occurs see a doctor familiar with this type of injury immediately Tighten repair or replace any missing loose or damaged clamps hoses and lines Do not bend or strike high pressure lines Never install bent or damaged hoses or lines According to the check points shown below check hoses and lines for oil leaks and damage If any abnorm...

Page 321: ... O ring Welded surfaces on flange joints Leak 12 Replace Every 250 hours Flange joint neck Crack 13 Replace Welded surfaces on flange joints Crack 12 Replace Clamps Missing or deformation Loose bolts Replace or retighten Hose and Lines Interval hours Check Points Abnormalities Remedies Daily Check Flexible master coupling Leak 14 Replace or retighten Oil Cooler Interval hours Check Points Abnormal...

Page 322: ...ring 1 out of the groove may damage O ring 1 and cause oil leak 3 When assembling fittings take care not to make a dent on O ring groove 3 of adaptor 2 and sealing surface 6 on hose 5 or valve side Failure to do so may result in damage to O ring 1 leading to oil leak 4 If oil leaks from a loose connection of union 4 do not tighten fitting 2 Open the connection replace O ring 1 with new one and che...

Page 323: ...tions for Use Connect or disconnect fittings with care not to damage seat surfaces 9 and 10 Tightening Torque Tighten fittings to the torque values shown below Wrench size mm 17 19 22 27 Torque N m 25 30 40 80 kgf m 2 5 3 4 8 Bent Tube Tighten bent tube 11 mounted on the control valve to the torque values shown below Wrench size mm 17 19 Tightening torque N m 35 kgf m 3 5 7 9 8 10 5 M202 07 051 11...

Page 324: ...es using bad quality fuel drainage agent fuel additives gasoline kerosene or alcohol refueled or mixed with specified fuel may deteriorate performance of fuel filters and cause sliding problem at lubricated contacts in the injector It also affects the engine parts leading to malfunction Using fuel other than ultra low sulfur or low sulfur diesel fuel has adverse effects on the engine and the muffl...

Page 325: ...ified Stop filling when a yellow mark on fuel level gauge 4 becomes visible Position the oil filler gun so that the gun will not encumber the movement of the level gauge 4 float 4 Immediately after fueling install and lock filler cap 2 to prevent vandalism and loss 5 Install cap 2 of filler port Cap 2 lock procedures If Install cap 2 Turn handle clockwise until cap 2 is locked and push down handle...

Page 326: ... engine at slow idle speed without load for five minutes 5 Turn the key switch OFF Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position 7 Place a container with a capacity of 0 5 liters or larger under drain hose 2 to collect the drained water 8 Open drain valve 1 to drain water and or sediment through the drain hose 9 After draining water securely tighte...

Page 327: ... collect the drained water 2 Rotate drain plug 2 on the bottom of the filter about 4 turns counterclockwise Drain the water accumulated in the filter until float 4 goes to the bottom of case If it is difficult to drain loosen plug 1 on the top of the main filter 3 After draining water securely tighten drain plug 2 and plug 1 4 Start the engine Check drain plug 2 and plug 1 for fuel leaks Wrench si...

Page 328: ...8 goes to the bottom of case If it is difficult to drain loosen plug 7 on the top of the fuel pre filter 3 After draining water securely tighten drain plug 5 and plug 7 4 Start the engine Check drain plug 5 and plug 7 for fuel leaks IMPORTANT After draining water mixed in fuel bleed air from the fuel supply system Wrench size 14 mm Pre Filter 8 5 6 7 MDAA 07 077 MDAA 07 078 Pre Filter Pre Filter M...

Page 329: ...tes starting to bleed air 3 While holding the key switch in the ON position reciprocate fuel main filter priming pump 2 After air is bled from the main filter return priming pump 2 to the original position 4 After the main filter is filled with fuel hold the key switch in the ON position for 30 seconds 5 Start the engine Check the fuel supply system for fuel leaks IMPORTANT Even if air is not thor...

Page 330: ... any spilled fuel 6 Start the engine Check that no fuel leaks are present If the engine does not start repeat the above procedures from step 1 Wrench size 10 mm If Air Mixed After Common Rail In case air mixed in the fuel system due to lack of fuel and the engine is difficult to start release air by following the procedure given below 1 Bleed air until the engine supply pump entrance enough accord...

Page 331: ...eriorate the engine performance and or shorten the engine service life Please be noted that all engine failures caused by using other manufacturers elements are excluded from Hitachi Warranty Policy Take care not to allow dirt and or water to enter the fuel tank Procedures 1 Close cock 1 on the bottom of the fuel tank to next page 1 MDAA 07 007 Pre Filter Pre Filter Main Filter Main Filter MDCN 07...

Page 332: ...ing the exclusive tool 5 When transparent filter case 4 is removed the element is exposed Remove the element by hand 6 Install a new element Replace O ring and tighten transparent filter case 4 to 30 2 N m using the exclusive tool 7 Tighten air bleed plug 1 and drain plug 2 8 Open cock 5 on the bottom of the fuel tank 9 Bleed Air from the Fuel System After replacing the fuel filter element bleed a...

Page 333: ...riorate the engine performance and or shorten the engine service life Please be noted that all engine failures caused by using other manufacturers elements are excluded from Hitachi Warranty Policy Take care not to allow dirt and or water to enter the fuel tank Procedures 1 Close cock 1 on the bottom of the fuel tank to next page 1 MDAA 07 007 Pre Filter Pre Filter Main Filter Main Filter MDCN 07 ...

Page 334: ...sparent filter case 4 is removed the element and O ring for transparent filter case 4 is exposed Remove the element by hand 6 Install a new element Replace O ring and tighten transparent filter case 4 to 30 2 N m using the exclusive tool 7 Tighten air bleed plug 1 and drain plug 2 8 Open cock 5 on the bottom of the fuel tank 9 Bleed Air from the Fuel System After replacing the fuel filter element ...

Page 335: ...trainer is disassembled be sure to replace the gasket Install the cover and the magnet only after sufficiently cleaning them After being assembled closely check the air tightness of the strainer MDCN 07 033 ZX225US 5B 225USLC 5B ZX135US 5B M1U4 07 029 Solenoid Fuel Pump Solenoid Fuel Pump ...

Page 336: ...g a spanner fNOTE Wrench size 17 mm IMPORTANT Only do the cleaning and replacement of the strainer as well as the replacement of gaskets 2 and 4 while servicing the machine Never attempt to disassemble other parts Gasket 4 can get caught with the shaft of pump 5 making it difficult to remove the gasket but do not disassemble the shaft of pump 5 If the gasket is difficult to remove do not disassemb...

Page 337: ... of the fuel tank to stop feeding fuel 2 Place a container with a capacity of 0 5 liters or larger under drain hose 4 to collect the drained water 3 Loosen plug 1 at upper part of water separator 2 Loosen drain plug 3 at lower part of the case to drain water 4 After draining water securely tighten drain plug 1 and plug 3 5 Return the fuel cock to its original position open IMPORTANT After draining...

Page 338: ...ter case 3 using the exclusive tool 5 When transparent filter case 3 is removed the element and O ring for transparent filter case 3 is exposed Remove the element by hand 6 Install a new element Replace O ring and tighten transparent filter case 3 to 30 2 N m using the exclusive tool 7 Tighten air bleed plug 2 and drain plug 4 8 Open cock 1 on the bottom of the fuel tank 9 Bleed Air from the Fuel ...

Page 339: ... bent or damaged hoses According to the check points shown below check hoses for oil leaks and damage If any abnormality is found replace or retighten as instructed in the table Hose Interval hours Check Points Abnormalities Remedies Daily Hose ends Leak 1 Retighten or replace Hose covers Wear crack 2 Replace Every 250 hours Hose covers Crack 3 Replace Hose ends Crack 4 Replace Hose Bend 5 Collaps...

Page 340: ...sult Clean and replace the air cleaner element when the engine is stopped Do not remove the inner element when cleaning the outer element Replace the inner element when replacing the outer element Do not reuse elements Use clean and dried compressed air When blowing compressed air be sure to keep the air nozzle away from the element Otherwise filter paper may be broken by the pressure of air Clean...

Page 341: ... of filter paper If any damage is found replace the element with new one 6 Press outer element 1 into the air cleaner body straightly by hand Ensure that outer element 1 is properly installed by pushing its bottom edge 7 Install cover and tighten clamps 2 8 In case the air filter restriction indicator lights soon after cleaning outer element 1 even if the cleaning times are less than 6 times repla...

Page 342: ...place Air Cleaner Element Inner Replace When outer element is replaced IMPORTANT Do not clean and reuse the inner element 1 After removing outer element 1 Clean inside the air cleaner body 2 with clean cloth before removing inner element 3 2 Remove inner element 3 Replace it with new one ...

Page 343: ...2 0 10 4 15 6 25 45 9 0 11 0 11 7 14 3 30 50 10 0 10 0 13 0 13 0 Precautions for handling antifreeze dCAUTION Antifreeze is poisonous Antifreeze is poisonous if ingested it can cause serious injury or death Induce vomiting and get emergency medical attention immediately If antifreeze is accidentally splashed into eyes flush with water for 10 to 15 minutes and get emergency medical attention When s...

Page 344: ...l the coolant temperature in the radiator becomes cool Hot steam may spout out possibly causing severe burns After the coolant temperature has lowered slowly loosen cap 1 to release the inside air pressure before removing cap 1 If coolant reservoir 2 is empty add coolant to the radiator and then to coolant reservoir 2 2 MDCN 07 041 MDCN 07 043 MDCN 07 042 MDCN 07 044 ZX135US 5B ZX135US 5B ZX225US ...

Page 345: ...tor pulley by your thumb with a depressing force of approximately 98 N 10 kgf Deflection must be within the value illustrated in the right Visually check the belt for wear Replace if necessary Adjust Drive Belt Tension 1 Loosen lock nut 1 and alternator lower mounting bolt 3 2 Rotate tension adjust bolt 2 to adjust the belt tension 3 After completing adjustment tighten lock nut 1 and alternator lo...

Page 346: ...10 kgf Deflection must be within the value illustrated in the right Visually check the belt for wear Replace if necessary Adjust Drive Belt Tension 1 Loosen lock nut 1 at the top of alternator 3 and lock nut 4 at the bottom of alternator 3 2 Adjust belt tension by moving alternator 3 forward or backward by using adjustment bolt 2 3 Securely tighten lock nut 1 and 4 IMPORTANT When a new belt is ins...

Page 347: ...d level surface Lower the bucket to the ground Stop the engine 2 Remove the under cover Remove the radiator cap Open drain cock 1 on the radiator to allow the coolant to drain completely Remove impurities such as scale at the same time 3 Close drain cock 1 Fill the radiator with soft water containing fewer impurities or tap water and a radiator cleaner agent Run the engine at a speed slightly high...

Page 348: ...gine to sufficiently bleed air from the cooling system It is necessary to bleed air from water lines of EGR Loosen the plug and bleed air 6 After adding coolant operate the engine for several minutes until the temperature gauge stabilizes Check the coolant level again and add coolant if necessary ZX135US 5B is not necessary to bleed air from water lines of EGR ZX225US 5B 225USLC 5B MDAA 07 099 ...

Page 349: ...oil cooler inter cooler fins may result The radiator and the oil cooler are arranged in parallel The inter cooler is arranged in tandem If dirt or dust is accumulated on them cooling system performance decreases Clean the radiator oil cooler inter cooler cores with compressed air pressure less than 0 2 MPa 2 kgf cm2 or tap water It will prevent a reduction in cooling system performance MDCN 07 045...

Page 350: ...s are dropped into the radiator oil cooler inter cooler core remove them before starting the engine Twist screw 1 to open cover 2 and perform cleaning Take care not to break the fin during clean operation Close cover 2 and tighten screw 1 after cleaning IMPORTANT Check the core periodically and replace it if necessary when the machine is operated in dusty areas 1 2 ZX135US 5B ZX225US 5B 225USLC 5B...

Page 351: ...too tight or loose Adjust the tightening torque of the clip nut to hold the screen For rough indication of the tightening torque refer to the below Tightening Torque 0 5 N m or A 23 0 5 mm Clean Air Conditioner Condenser every 500 hours IMPORTANT Check the screen daily and replace it if necessary when the machine is operated in dusty areas Clean Fuel Oil Cooler every 500 hours IMPORTANT Check the ...

Page 352: ... the machine Also improper installation of electrical equipment may cause machine failure and or a fire on the machine Be sure to consult your authorized dealer when installing radio communication equipment or additional electrical parts or when replacing electrical parts Never attempt to disassemble or modify the electrical electronic components If replacement or modification of such components i...

Page 353: ...in clothing and cause blindness if splashed into the eyes Wearing eye protection and rubber gloves IMPORTANT If the battery is used with the electrolyte level lower than the specified lower level the battery may deteriorate quickly Do not refill electrolyte more than the specified upper level Electrolyte may spill damaging the painted surfaces and or corroding other machine parts fNOTE In case ele...

Page 354: ...harged inflammable hydrogen gas is created Remove the battery from the base machine Recharge the battery after removing the caps in a well ventilated area When disconnecting the battery terminals first disconnect the battery minus side terminal When connecting the battery terminals connect the battery minus side terminal last If a piece of metal such as a tool comes in contact with the battery plu...

Page 355: ...of the battery Check the electrolyte level by viewing through the filler port It is difficult to judge the accurate electrolyte level in this case Therefore when the electrolyte level is flush with the U L the level is judged to be proper Then referring to the right illustrations check the level When the electrolyte level is lower than the bottom end of the sleeve refill with distilled water or co...

Page 356: ...before replacing the battery This machine is equipped with two 12V batteries Negative terminal is connected to the ground If one battery is damaged on the 24V system replace the damaged battery with the same type of new battery If a maintenance free battery is damaged replace it with new maintenance free battery Battery charger differs depending on the type of battery If improper battery is connec...

Page 357: ...he limit fNOTE Measure the electrolyte specific gravity when the electrolyte temperature is equal to the atmospheric temperature Do not check the electrolyte specific gravity immediately after operation as the correct value can not be obtained Recommended range of specific gravity by electrolyte temperature 40 C 1 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 Specific gravity of b...

Page 358: ...ial tool for fuse removal is also provided in the fuse box 10 CONTROLLER 5 A 20 OPTION3 5 A 9 BACK UP 10 A 19 HORN 10 A 8 ECM 30 A 18 IDLE STOP 5 A 7 START 5 A 17 POWER ON 5 A 6 OPTION2 20 A 16 GLOW RELAY 5 A 5 OPTION1 5 A 15 AUXILIARY 10 A 4 SOLENOID 20 A 14 MONITOR 5 A 3 HEATER 20 A 13 LIGHTER 10 A 2 WIPER 10 A 12 RADIO 5 A 1 LAMP 20 A 11 FUEL PUMP 5 A 1 11 4 14 7 17 2 12 5 15 8 18 3 13 6 16 9 1...

Page 359: ...ven if the key switch is turned to the START position fusible link may be the cause of the trouble Remove the cover next to the engine coolant reservoir to check the fuse Replace it if blown 21 Side Red 45 A 22 Side Black 65 A M1U1 07 023 MDCN 07 054 ZX135US 5B ZX225US 5B 225USLC 5B 21 22 ...

Page 360: ...s or safety glasses and safety equipment appropriate to the job 1 Use hammer 2 and drift 3 to drive out locking pin 5 Take care not to damage lock rubber 4 2 Check lock pin 5 and lock rubber 4 Short locking pins and damaged rubber pin locks must be replaced with new ones WRONG 1 2 3 4 A 4 5 5 RIGHT WRONG M104 07 116 M104 07 118 M104 07 058 M104 07 059 M104 07 056 Flush one end of the locking pin t...

Page 361: ... surface 4 Install rubber pin lock 4 into shank 6 hole as shown 5 Position new tooth 1 over shank 6 6 Drive locking pin 5 fully into the hole as shown RIGHT RIGHT RIGHT WRONG WRONG WRONG 6 6 1 1 5 4 M104 07 060 M104 07 061 M104 07 062 ...

Page 362: ...imit a hole will be made on the tooth point which makes the nose exposed and worn out and will eventually break or let the tooth point fall off dCAUTION Guard against injury from flying pieces of metal Wear goggles or safety glasses and safety equipment appropriate to the job Procedures Removing the tooth point 1 Preparations for removing tooth point Hit the left and right top ends and the left an...

Page 363: ...adapter 2 Place pin removing jig on the top end of lock pin 3 and hit it with hammer to remove lock pin 3 When driving out the pin first hit with a shorter jig until top end of lock pin 3 comes to the upper end position of the lug of tooth point 1 and then use the longer jig to remove lock pin 3 1 3 3 2 M116 07 126 ...

Page 364: ...s dirt etc are stuck to the adapter nose tooth point 1 will not insert properly and the pin cannot be driven in Insert tooth point 1 slowly until the tooth point comes to the end of the adapter nose while twisting and turning it to the right 2 Inserting the pin Insert lock pin 3 with take up facing toward the adapter nose With tooth point 1 fully inserted onto adapter 2 tap lock pin 3 into tooth p...

Page 365: ...ble to corrosion do not use grease oil and other oily materials when inserting the lock pin 2 In mounting welding type nose and the adapter onto the bucket lock pin 3 should be removed from the nose when preheating and welding Otherwise the rubber will be spoiled ...

Page 366: ... the way as shown 3 Remove bucket pins A and B to separate the arm and bucket Installation 1 Clean the pins and pin bores Apply sufficient grease to the pins and pin bores 2 Place the new bucket in stable position as shown in the figure 3 Fit the arm and alternate bucket Be sure the bucket will not roll Install bucket pins A and B 4 Install the locking pins and snap rings on pins A and B 5 Install...

Page 367: ...e bucket in a stable position 2 Slide the O rings out of the way as shown 3 Remove bucket pins A and B to separate the arm and bucket Clean the pins and pin bores Apply sufficient grease to the pins and pin bores 4 Turn the bucket 180 Be sure the bucket will not roll 5 Fit the arm and alternate bucket Be sure the bucket will not roll Install bucket pins A and B 6 Install the locking pins and snap ...

Page 368: ...nd bucket As shim 2 is a dual partitioning type it can be easily removed by slightly loosening bolt 1 and inserting tip of a screw driver into the contact surface of left and right shims 2 5 Push and hold bolts 1 to remove all clearance a between arm and boss 4 Holding boss 4 against arm increases clearance b Install as many shims 2 into clearance b as possible 6 Install remaining shims 2 into cle...

Page 369: ...m Check and Replace Seat Belt Check daily Replace every 3 years Prior to operating the machine thoroughly examine belt 5 buckle 6 and attaching hardware 7 If any item is damaged or materially worn replace the seat belt or component before operating the machine We recommend that the seat belt be replaced every three years regardless of its apparent condition 2 5 5 7 6 6 7 4 3 1 M178 07 077 M1U1 07 ...

Page 370: ...CE 7 96 Check Windshield Fluid Level Check fluid in windshield washer tank 1 If the fluid level is low remove cap 2 and add fluid via the opening MDCN 07 009 MDCN 07 056 1 ZX135US 5B ZX225US 5B 225USLC 5B 2 1 2 ...

Page 371: ...fNOTE Check track sag after thoroughly removing soil stuck on the track area by washing Adjust Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat this procedure to raise the other track Each time be sure to place blocks un...

Page 372: ... the grease outlet 2 Between 1 to 1 5 turns of valve 1 is sufficient to loosen the track 3 If grease does not drain smoothly slowly rotate the raised track 4 When proper track sag is obtained turn valve 1 clockwise and tighten to 90 N m 9 kgf m 67 lbf ft Tighten the Track dCAUTION It is abnormal if the track remains tight after turning valve 1 counterclockwise or if the track is still loose after ...

Page 373: ...24 grease will escape from the grease outlet 2 Between 1 to 1 5 turns of valve 1 is sufficient to loosen the track When valve 1 comes in contact with stop plate 3 do not loosen valve 1 further 3 If grease does not drain smoothly slowly rotate the raised track dCAUTION To prevent accidents care should be taken to ensure that hands feet and any body parts do not become entangled when working around ...

Page 374: ... the grease in the cylinder is highly pressurized In such cases NEVER ATTEMPT TO DISASSEMBLE the track or track adjuster because of dangerous high pressure grease inside the track adjuster See your authorized dealer immediately To tighten the track connect a grease gun to grease fitting 2 and add grease until the sag is within specifications MDAA 07 057 2 ...

Page 375: ...ter cleaning 6 times or so Fresh Air Filter After cleaning 6 times or so Removing Fresh Air Filter 1 Grasp the upper section of filter cover 1 and pull to remove filter cover 1 2 Grasp the grip on fresh air filter 2 through the opening from which filter cover 1 is removed and pull to remove fresh air filter 2 MDCN 07 009 MDCN 07 057 MDCN 07 058 MDCN 07 059 ZX135US 5B ZX135US 5B ZX225US 5B 225USLC ...

Page 376: ... air filter outside cover 3 by pulling it toward the cab front 3 Remove screws 4 Remove circulating air filter outside 1 by sliding it to the arrow direction Removing Circulating Air Filter Inside 1 Remove circulating air filter inside 5 by holding grip 6 and pulling it toward you through the opening for cover 3 MDCN 07 060 MDCN 07 061 MDCN 07 062 1 2 3 1 4 5 6 ...

Page 377: ... air filter 2 install the filter cover by fitting it with the duct Install the inner element of the air cleaner Secure it with three stoppers Fresh air filter 2 ZX225US 5B 225USLC 5B Install fresh air filter 2 so that the direction of the arrow points inside the cab After installing fresh air filter 2 install the filter cover by fitting it with the duct Circulating Air Filter Inside 7 Install filt...

Page 378: ... and amount when shipping the machine Model Type Amount ZX135US 5B HFC134a 0 85 0 05 kg ZX225US 5B 225USLC 5B 0 85 0 05 kg Check the condenser If the condenser fins become clogged with dirt or insects the cooling effect will be decreased Be sure to keep it clean at all times Refer to Clean Radiator Core in Maintenance Section Check compressor After operating the air conditioner for 5 to 10 minutes...

Page 379: ...ension pulley by adjusting bolt 3 under tension pulley 1 until tension is correct 3 Securely tighten bolt 2 of tension pulley 1 4 Securely tighten adjusting bolt 3 IMPORTANT When a new belt is installed be sure to re adjust the tension after operating the engine for 3 to 5 minutes at slow idle speed to be sure that the new belt is seated correctly ZX225US 5B 225USLC 5B Air Compressor Pulley Fan Pu...

Page 380: ...alled Secure circulating air filter outside cover 4 with screws 3 Remove foot air vent holding screws 6 Attach cover 2 onto the foot air vent and secure it with screws 6 IMPORTANT Never fail to do this preparation work Failure to do so may result in damage failure of the air conditioner 3 Sweep the cab floor clean using a brush and brush dust from the cab floor while spraying water 4 When cleaning...

Page 381: ...d dealer Measure Engine Compression Pressure every 1000 hours See your authorized dealer Check Starter and Alternator every 1000 hours See your authorized dealer Check and Replace EGR Device every 4500 hours See your authorized dealer Clean EGR Cooler every 4500 hours See your authorized dealer Check Turbocharger every 4500 hours See your authorized dealer ...

Page 382: ...s The cover or window can not be opened with normal operating force The cover or window can not maintain its open position Oil or gas leak is found Tightening and Retightening Torque of Nuts and Bolts every 250 hours first time after 50 hours Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table Bolts and nuts should be replaced ...

Page 383: ...tube mounting nut 17 35 3 5 12 Battery mounting nut 10 4 17 50 5 13 Cab mounting nut 16 4 24 210 21 Cab mounting anchor bolt 22 1 32 550 55 Cab cushion rubber mounting bolt 12 8 19 110 11 14 Cover mounting bolt 6 10 8 13 10 17 50 5 12 19 90 9 15 Flexible master coupling of low pressure piping 4 pairs 13 10 3 to 12 4 1 05 to 1 26 11 6 0 6 Jubilee clamp of low pressure piping 7 6 0 6 8 6 0 6 T bolt ...

Page 384: ...10 21 50 260 26 11 Hycolin tube mounting nut 17 35 3 5 12 Battery mounting nut 10 2 17 50 5 13 Cab mounting nut 16 4 24 210 21 Cab mounting anchor bolt 22 1 32 550 55 Cab cushion rubber mounting bolt 12 8 19 110 11 14 Cover mounting bolt 6 10 3 3 to 4 2 0 3 to 0 4 8 13 10 1 10 17 50 5 15 Flexible master coupling of low pressure piping 4 pairs 13 10 3 to 12 4 1 05 to 1 26 11 6 0 6 Jubilee clamp of ...

Page 385: ... 400 40 17 22 750 75 550 55 220 22 32 24 950 95 700 70 280 28 36 27 1400 140 1050 105 400 40 41 30 1950 195 1450 145 550 55 46 33 2600 260 1950 195 750 75 50 36 3200 320 2450 245 950 95 55 dCAUTION If fixing bolts for counterweight are loosened consult your nearest authorized dealer IMPORTANT Apply lubricant e g white zinc B solved into spindle oil to bolts and nuts to stabilize their friction coe...

Page 386: ...g bolt and nut 2 Engine bracket mounting bolt Pump Side Pump Side Fan Side Fan Side M1U1 07 040 M1U1 07 034 M1U1 07 040 M1U1 07 034 M1U4 07 046 ZX135US 5B ZX225US 5B 225USLC 5B ZX225US 5B 225USLC 5B ZX225US 5B 225USLC 5B ZX135US 5B 225US 5B 225USLC 5B ...

Page 387: ...MAINTENANCE 7 113 3 Hydraulic oil tank mounting bolt 4 Fuel tank mounting bolt MDCN 07 064 MDCN 07 064 MDCN 07 065 MDCN 07 065 ZX135US 5B ZX135US 5B ZX225US 5B 225USLC 5B ZX225US 5B 225USLC 5B ...

Page 388: ...MAINTENANCE 7 114 5 Radiator mounting bolt 6 Pump transmission mounting bolt MDCN 07 066 MDCN 07 067 ZX135US 5B ZX225US 5B 225USLC 5B M1U1 07 021 ZX225US 5B 225USLC 5B ZX135US 5B M1U4 07 050 ...

Page 389: ...MAINTENANCE 7 115 7 Control valve mounting bolt Control valve bracket mounting bolt M1U4 07 051 M1U4 07 051 ZX135US 5B ZX135US 5B MDCN 07 068 MDCN 07 068 ZX225US 5B 225USLC 5B ZX225US 5B 225USLC 5B ...

Page 390: ...ng device mounting bolt 9 Swing motor mounting bolt 10 ORS fittings for hydraulic hoses and piping M104 07 079 MDCN 07 018 MDCN 07 018 MDCN 07 069 MDCN 07 069 ZX135US 5B ZX135US 5B ZX225US 5B 225USLC 5B ZX225US 5B 225USLC 5B ...

Page 391: ...MAINTENANCE 7 117 11 Hycolin tube mounting nut 12 Battery mounting nut ZX135US 5B ZX135US 5B M1U1 07 111 MDCN 07 071 MDCN 07 072 MDCN 07 070 ZX225US 5B 225USLC 5B ZX225US 5B 225USLC 5B ...

Page 392: ...MAINTENANCE 7 118 13 Cab mounting nut 14 Cover mounting bolt M1U1 07 026 MDCN 07 073 Anchor Bolts MDCN 07 022 ...

Page 393: ...lamp of low pressure piping 16 Swing bearing mounting bolt Upperstructure Side Undercarriage Side ZX225US 5B 225USLC 5B M107 07 088 M107 07 089 MDAA 07 027 M1U4 07 052 M1G6 07 008 ZX135US 5B Undercarriage Side ZX135US 5B ZX225US 5B 225USLC 5B Flexible Master Coupling M1U1 07 113 ...

Page 394: ...MAINTENANCE 7 120 17 Travel device mounting bolt Travel reduction device cover mounting bolt Sprocket mounting bolt 18 Upper roller mounting bolt M1G6 07 007 M154 07 050 M157 07 224 M164 07 005 ...

Page 395: ...TENANCE 7 121 19 Lower roller mounting bolt 20 Track shoe mounting bolt 21 Track guard mounting bolt Full track guard mounting bolt Only ZX225US 5B 225USLC 5B M107 07 092 M107 07 093 MDAA 07 058 MDAA 07 059 ...

Page 396: ...MAINTENANCE 7 122 22 Muffler filter mounting bolt Contact your nearest authorized dealer 23 Front pin retaining bolt MDAA 07 061 MDCS 07 004 MDCN 07 080 ...

Page 397: ... refer to 9 1 Maintenance Under Special Environmental Conditions Twist screw 2 to open muffler filter maintenance window 1 located at the top of the engine cover Check differential hoses and pipes for disconnection or cracks Check the differential sensors and harnesses of exhaust temperature sensors for abnormality Securely close muffler filter maintenance window 1 Remove muffler upper cover if ne...

Page 398: ...MAINTENANCE 7 124 MEMO ...

Page 399: ...8 1 HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT Hydraulic Circuit MDAA 08 001 ...

Page 400: ...22 AIR CON UNIT 23 WIPER RELAY 24 WIPER MOTOR 25 ECU 26 STARTER SWITCH 27 FUSE 28 SECURITY RELAY 29 SECURITY HORN 30 SECURITY HORN RELAY 31 LIGHTER 32 RADIO 33 SPEAKER R 34 SPEAKER L 35 LIGHTER RELAY1 36 LIGHTER RELAY2 37 WASHER RELAY 38 HORN RELAY 39 HORN SWITCH 40 AUTO SHUT DOWN RELAY 41 CAB LIGHT 42 MONITOR 43 POWER DIGGING SWITCH 44 MC 45 SWITCH BOX 46 AUTO IDLE SWITCH 47 MODE SWITCH 48 TRAVEL...

Page 401: ...1300NP 3 JX Nippon Oil Energy Corporation onto plated part of the cylinder rods Dusty Atmosphere Air Cleaner Clean the element regularly at shorter service intervals Radiator Clean the oil cooler screen to prevent clogging of the radiator core Fuel System Clean the filter element and strainer regularly at shorter service intervals Engine Muffler Clean earlier than the normal interval to prevent du...

Page 402: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 2 MEMO ...

Page 403: ...ve cover Tools Inspect and repair then store Lubrication Operation If oil film on the metal surfaces is lost rust may begin possibly causing abnormal wear of the machine when the machine operation is restarted If the machine is stored for a long time operate hydraulic functions for travel swing and digging two to three times for lubrication at least once a month Be sure to check the coolant level ...

Page 404: ...STORAGE 10 2 MEMO ...

Page 405: ...ronic components Engine Consult the nearest Hitachi dealer for the engine troubleshooting Engine Auxiliaries Problem Cause Solution Batteries will not be charged Broken battery separator Replace Faulty regulator Adjust and replace Faulty ground line Repair Faulty alternator Repair or replace Batteries discharge quickly after being charged Shorted cable Repair or replace Shorted battery separator R...

Page 406: ... the ON position Starter rotates No fuel After checking that no fuel is leaking refill fuel Air in the fuel system Bleed air Clogged fuel filter After draining water replace the element Frozen fuel Warm the fuel pump with hot water or wait until the atmospheric temperature rises Engine stop switch is ON Repair and replace Faulty preheat system Repair and replace Even though the engine is started t...

Page 407: ...pusher Replace Does not move smoothly Worn pusher Repair or replace Faulty pilot valve Replace Does Not Return to Neutral Faulty pilot valve Replace The lever is tilted in the neutral position due to increase in play Worn joint Repair or replace Faulty pilot valve Replace Items with mark Consult your nearest Hitachi dealer ...

Page 408: ...ontrol shut off switch Repair or replace The pilot control shut off lever is in the LOCK position Turn the pilot control shut off lever to the UNLOCK position All actuators have no power Malfunction due to worn hydraulic pump Replace Decreased main relief valve set pressure in the control valve Adjust Lack of hydraulic oil Refill Clogged suction strainer in the hydraulic oil tank Clean Absorption ...

Page 409: ...or replace Faulty pilot solenoid valve Repair or replace Only one cylinder is inoperable or has no power Broken oil seal in cylinder Repair or replace Oil leak due to damage to cylinder rod Repair or replace Faulty pilot valve Replace Faulty pilot circuit line Repair or replace Faulty pilot solenoid valve Repair or replace Hydraulic oil temperature increases Stained oil cooler Clean Insufficient e...

Page 410: ... of lubricant in front idler and or roller Refill Deformed track frame Repair or replace Embedded foreign matter such as rock fragments Remove Dragged parking brake Repair Travel speed does not change Faulty travel mode switch Replace Faulty pressure sensor Replace Pump 1 and 2 delivery pressure sensors Replace Pumps 1 2 control pressure sensors Replace Poor contact in connector Repair or replace ...

Page 411: ...wing bearing and bearing balls Repair or replace Lack of grease Refill Inversion protective valve Repair or replace Items with mark Consult your nearest Hitachi dealer Immediately after the control valve swing motor relief valve and or the swing motor is replaced a noise may be emitted and or operation may not be performed smoothly due to air trapped in the hydraulic line Slowly continue to operat...

Page 412: ...alve Repair or replace Auto idle is inoperable or not released Faulty pressure sensor Replace Poor contact in connector Repair or replace Damaged wire harness Repair Faulty controller Replace Performing manual regeneration Normal control Items with mark Consult your nearest Hitachi dealer Pump Control Problem Cause Solution Front attachment and or travel speed is slow Blown control fuse Replace Po...

Page 413: ...wing Radius 1490 mm D Minimum Ground Clearance 410 mm E Counterweight Clearance 840 mm F Engine Cover Height 2060 mm G Overall Width of Upperstructure 2480 mm H Undercarriage Length 3580 mm I Undercarriage Width 2490 mm J Sprocket Center to Idle Center 2880 mm K Track Shoe Width 500 mm Grouser shoe Ground Pressure 42 kPa 0 43 kgf cm2 Swing Speed 13 3 min 1 rpm Travel Speed fast slow 5 5 3 3 km h G...

Page 414: ...0 B Maximum Digging Depth 5070 5490 5980 C Maximum Cutting Height 9020 9290 9690 D Maximum Dumping Height 6550 6830 7220 E Overall Height 2790 2790 2780 F Overall Length 7360 7370 7390 G Minimum Swing Radius 2000 2110 2450 fNOTE The dimensions do not include height of the shoe lug except Item E The dimensions asterisked are for transport pin position MDCN 12 001 G C D E F A B ...

Page 415: ... 36 kPa 0 37 kgf cm2 31 kPa 0 32 kgf cm2 Shoe Width 500 mm Pad Crawler Shoe 500 mm Rubber Pad Shoe Application For Paved Road Option For Paved Road Option Operating Weight kg 13500 13800 Base Machine Weight kg 10900 11300 Cab Height mm 2830 2830 Minimum Ground Clearance mm 470 470 Undercarriage Length mm 3670 3660 Undercarriage Width mm 2490 2490 Ground Pressure 42 kPa 0 43 kgf cm2 43 kPa 0 44 kgf...

Page 416: ...ty excavating Rock digging Loading work Slope finishing work Not applicable not warrantable Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging and loading operation of dry loosened earth sand mud and so on Their bulk density shall be less than 1 60 t m3 as a stan...

Page 417: ...50 mm C Rear End Swing Radius 1680 mm D Minimum Ground Clearance 450 mm E Counterweight Clearance 990 mm F Engine Cover Height 2490 mm G Overall Width of Upperstructure 2910 mm H Undercarriage Length 4170 mm 4460 mm I Undercarriage Width 2800 mm 2990 mm J Sprocket Center to Idle Center 3370 mm 3660 mm K Track Shoe Width 600 mm Grouser shoe Ground Pressure 53 kPa 0 54 kgf cm2 50 kPa 0 51 kgf cm2 Sw...

Page 418: ...m A Maximum Digging Reach 9620 10110 B Maximum Digging Depth 6120 6620 C Maximum Cutting Height 10790 11230 D Maximum Dumping Height 7860 8290 E Overall Height 3230 3020 F Overall Length 9270 9110 G Minimum Swing Radius 2720 2380 fNOTE The dimensions do not include height of the shoe lug except Item E MDCN 12 003 G C D E F A B ...

Page 419: ...oe 700 mm Grouser Shoe 800 mm Grouser Shoe 900 mm Grouser Shoe Application For Ordinary Ground Standard For Weak Footing Option For Weak Footing Option For Weak Footing Option Operating Weight kg 24300 24700 25000 25500 Base Machine Weight kg 19900 20300 20600 21100 Cab Height mm 2950 2950 2950 2950 Minimum Ground Clearance mm 450 450 450 450 Undercarriage Length mm 4460 4460 4460 4460 Undercarria...

Page 420: ...h fNOTE Symbols in the above table have the following meanings General excavating Light duty excavating Rock digging Loading work Slope finishing work Not applicable not warrantable Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging and loading operation of dry l...

Page 421: ...owing conditions Forbidden Operations Do not operate on sharp rocky uneven surfaces such as river rock gravel etc Do not allow engine oil gasoline etc to remain on the track and avoid traveling in oil in order to reduce the danger of slipping While raising the machine using the front attachment do not allow the other side track to drive possibly causing personal injury damaging or displacing pad c...

Page 422: ... 140 F in temperature as this will cause wear to the shoe as well as damage to the road surface Ease the machine down from the jacked up position Do not let it drop Pad crawler has large friction force Therefore to avoid damaging the pad crawler slowly operate the control levers to gradually turn the machine After raising one side track with the front attachment slowly lower the pad crawler equipp...

Page 423: ...orner of the machine and front attachment to the trailer with a chain or cable Precautions for Transporting Machines with Pad Crawler Shoes When transporting a machine with pad crawler shoes be sure to fasten the right and left track frames securely to the flatbed with wire ropes and soft protectors as shown Do not allow wire ropes to come into direct contact with pad crawler shoes M102 06 004 Fla...

Page 424: ...US 5B 250 to 280 mm 9 8 to 11 0 in ZX225USLC 5B 225USRLC 5B 300 to 335 mm 11 8 to 13 2 in fNOTE Check track sag after thoroughly removing soil stuck on the track area by washing Adjust Track Sag Precautions for Adjusting Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 When adjusting track sag lower the bucket to th...

Page 425: ...cape from the grease outlet 2 Between 1 to 1 5 turns of valve 1 is sufficient to loosen the track 3 If grease does not drain smoothly slowly rotate the raised track 4 When proper track sag is obtained turn valve 1 clockwise and tighten to 90 N m 9 kgf m Tighten the Track dCAUTION It is abnormal if the track remains tight after turning valve 1 counterclockwise or if the track is still loose after c...

Page 426: ...long socket 24 grease will escape from the grease outlet 2 Between 1 to 1 5 turns of valve 1 is sufficient to loosen the track When valve 1 comes in contact with stop plate 3 do not loosen valve 1 further 3 If grease does not drain smoothly slowly rotate the raised track dCAUTION To prevent accidents care should be taken to ensure that hands feet and any body parts do not become entangled when wor...

Page 427: ...er Therefore the grease in cylinder is highly pressurized In such cases NEVER ATTEMPT TO DISASSEMBLE the track or track adjuster because of dangerous high pressure grease inside the track adjuster See your authorized dealer immediately To tighten the track connect a grease gun to grease fitting 2 and add grease until the sag is within specifications MDAA 07 057 2 ...

Page 428: ...hine is in operation Pin bore B when the machine is transported IMPORTANT Connect the arm cylinder rod end to pin bore B only when the machine is transported Do not operate the digging or loading function with the arm cylinder connected to pin bore B as the bucket may hit the cab accidentally with this connection When transporting the machine follow the procedure shown below to convert it into the...

Page 429: ...ly Do not attempt to dig deeply with the blade Doing so will damage not only the blade but the undercarriage as well 2 Do not apply intensive or uneven loads Never apply high speed impact to the blade by running the machine into a load 3 Jacking up the machine with this blade the surface beneath the blade comes under high pressure increasing the risk of surface collapse Always be sure that the sur...

Page 430: ...reful Be sure to prevent this from happening Avoid Hitting Blade with Bucket When crowding the arm into a traveling or transporting position be careful not to let the bucket hit the blade Avoid Striking the Blade into a Rock Do not attempt to strike large rocks with the blade as doing so will damage the blade and the blade cylinders shortening their operating lives WRONG WRONG WRONG M155 14 009 M1...

Page 431: ...inder Rod 2 points Blade Cylinder Bottom 2 points Transportation Figure for Machine Equipped with Blade When transporting the machine equipped with a blade and a long arm front attachment on a trailer place the blade in the opposite position toward the front attachment Otherwise the bucket may come in contact with the blade M175 13 002 M198 07 017 M175 13 005 ...

Page 432: ...ing Radius 1490 mm D Minimum Ground Clearance 410 mm E Counterweight Clearance 840 mm F Engine Cover Height 2060 mm G Overall Width of Upperstructure 2480 mm H Undercarriage Length 3580 mm I Undercarriage Width 2490 mm J Sprocket Center to Idle Center 2880 mm K Track Shoe Width 500 mm Grouser Shoe Ground Pressure 45 kPa 0 46 kgf cm2 Swing Speed 13 3 min 1 rpm Travel Speed fast slow 5 5 3 3 km h Gr...

Page 433: ... Maximum Cutting Height mm 9020 9290 9690 D Maximum Dumping Height mm 6550 6830 7220 E Overall Height mm 2790 2790 2780 F Overall Length mm 7880 7890 7910 G Minimum Swing Radius mm 2000 2100 2450 H Max Raising Height mm 460 I Max Digging Depth mm 540 J Blade Angle degree 28 5 fNOTE The dimensions do not include height of the shoe lug except Item E The dimensions asterisked are for transport pin po...

Page 434: ...00 11900 12300 Cab Height mm 2790 2830 2830 Minimum Ground Clearance mm 410 470 470 Undercarriage Length mm 3580 3670 3660 Undercarriage Width mm 2490 2490 2490 Ground Pressure 45 kPa 0 46 kgf cm2 45 kPa 0 46 kgf cm2 46 kPa 0 47 kgf cm2 fNOTE The specifications for the front end attachment are for a 2 52 m arm with PCSA 0 50 m3 standard bucket 700 mm grouser shoe 500 mm pad crawler shoe and 500 mm...

Page 435: ... mm B Cab Height 2950 mm C Rear End Swing Radius 1680 mm D Minimum Ground Clearance 450 mm E Counterweight Clearance 990 mm F Engine Cover Height 2490 mm G Overall Width of Upperstructure 2910 mm H Undercarriage Length 4460 mm I Undercarriage Width 2990 mm J Sprocket Center to Idle Center 3660 mm K Track Shoe Width 600 mm Grouser shoe Ground Pressure 55 kPa 0 56 kgf cm2 Swing Speed 11 8 min 1 rpm ...

Page 436: ... B Maximum Digging Depth mm 6120 6620 C Maximum Cutting Height mm 10790 11230 D Maximum Dumping Height mm 7860 8290 E Overall Height mm 3230 3020 F Overall Length mm 9270 9110 G Minimum Swing Radius mm 2720 2380 H Max Raising Height mm 570 I Max Digging Depth mm 300 J Blade Angle degree 25 fNOTE The dimensions do not include height of the shoe lug except Item E G C D E F J H I A B MDCN 13 015 ...

Page 437: ...andard Operating Weight kg 26300 Base Machine Weight kg 21900 Cab Height mm 2950 Minimum Ground Clearance mm 450 Undercarriage Length mm 4460 Undercarriage Width mm 2990 Ground Pressure 55 kPa 0 56 kgf cm2 fNOTE The specifications for the front end attachment is for 2 91 m arm with PCSA 0 8 m3 bucket The dimensions do not include the height of the shoe lug ...

Page 438: ...r safety glasses 1 Securely lower the bucket to the ground 2 Use hammer 3 and drift 2 to drive out transverse type locking pin 1 to remove tooth 4 fNOTE Be sure to use a drift 2 thinner than pin 1 3 Clean shank 5 surface Attach a new tooth 4 onto shank 5 Insert pin 1 as deep as it goes Then drive pin 1 using hammer 3 and drift 2 to securely lock tooth 4 M157 14 013 5 1 2 3 4 ...

Page 439: ...een 1 9 Battery 7 79 Battery Disconnect Switch 1 133 Before Starting Engine 3 2 Beware of Asbestos and Silicon Dust and Other Contamination S 35 Beware of Exhaust Fumes S 32 Blade Lever 13 9 Blade Maintenance 13 11 Breaker Operation 1 73 Brightness Adjustment 1 59 Bucket Teeth Transverse Type Pin Used Type 13 18 Bucket Types and Applications 12 4 ZX135US 5B 12 4 ZX225US 5B 225USLC 5B 12 8 C COMPON...

Page 440: ...g in Case of Fire S 32 Every 8 Hours or Daily 2 1 Extending Password Duration Time 1 16 F Fasten Your Seat Belt S 7 Fastening Machine for Transporting 6 5 Features 1 104 Flow Rate Adjustment 1 39 Follow Safety Instructions S 2 For Rapid Cooling 1 111 Fore Aft Position Adjustment of Seat Surface 1 129 Front Joint Pins 7 19 Fuel Consumption 1 71 Fuel Gauge 1 13 Fuel System 7 50 Fuse Box 1 103 G GETT...

Page 441: ...ion Valve 5 26 Overhead Window Wiper and Washer Switch Optional 1 93 Overload Alarm Switch Optional 1 95 P Park Machine Safely S 23 Parking the Machine 4 8 Parking the Machine on Slopes 4 8 Password Change Optional 1 51 Periodic Replacement of Parts 7 15 Pilot Accumulator Functions 5 43 Pilot Control Shut Off Lever 1 102 5 4 Piping for Breaker and Crusher 5 26 Power Boost Switch 1 97 5 17 Power Mo...

Page 442: ...Steering the Machine Using Levers 4 3 Steering the Machine Using Pedals 4 2 Stopping the Engine 3 10 Storing the Machine 10 1 Sub Meter 1 55 Suction Filter Cleaning 7 40 Support Machine Properly S 26 Suspension Adjustment 1 126 1 129 Swing Alarm Deactivation Switch Optional 1 95 Swing Bearing 7 21 Swing Internal Gear 7 22 Swing Reduction Gear 7 29 Switch Operation 1 133 Switch Panel 1 87 Switch Pa...

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