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Hitachi Zaxis 200LC, Operator'S Manual

The Hitachi Zaxis 200LC Operator's Manual is available for free download on our website. This comprehensive manual provides detailed instructions and essential information to safely and efficiently operate the Hitachi Zaxis 200LC excavator. Get your hands on this valuable resource at manualshive.com and unlock the full potential of your machine.

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Safety—Safety Signs

OUT4001,0000293

–19–07MAY07–5/13

T124177

–19–09SEP99

T146003

–UN–02NOV01

1—Attachment Can Hit Cab Caution Decal Location—

Located on the Front Window Frame of All
Foresters

Continued on next page

1-5-5

081407

PN=27

Summary of Contents for Zaxis 200LC

Page 1: ...PART NO OMT200293 Operator s Manual 200LC 250 350 FORESTER ...

Page 2: ......

Page 3: ... are known to the State of California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The State of California requires the above two warnings Worldwide Construction And Forestry Division LITHO ...

Page 4: ...Hitachi s support program for customers who operate and maintain their equipment as described in this manual The warranty is explained on the warranty certificate which you should have received from your dealer This warranty provides you assurance that Hitachi will back its products where defects appear within the warranty period In some circumstances Hitachi also provides field improvements often...

Page 5: ...Introduction TX14740 0001FA5 19 11DEC02 3 3 T124916 19 22FEB05 081407 PN 3 ...

Page 6: ...Introduction 081407 PN 4 ...

Page 7: ...try Cab Door Release Lever 2 1 14 Use and Maintain Seat Belt 1 3 1 Rear Entry Cab Door Handles 2 1 15 Prevent Unintended Machine Movement 1 3 2 Secondary Exit 2 1 16 Avoid Work Site Hazards 1 3 3 Adjusting the Seat 2 1 17 Keep Riders Off Machine 1 3 3 Fire Extinguisher 2 1 18 Avoid Backover Accidents 1 3 4 Hydraulic Oil Tank Pressure Vent 2 1 19 Avoid Machine Tip Over 1 3 4 Use Special Care When L...

Page 8: ...nt Test Kit 3 2 4 m 9 ft 7 in Track Width Rear Entry Maintenance and Repair Record Cab 2 2 26 Keeping System 3 2 5 Shipping Dimensions Zaxis 200LC Forester Articulated Grapple Rear Entry Cab 2 2 28 Maintenance As Required Shipping Dimensions Zaxis 250 Clean Fuel Tank Inlet Screen 3 3 1 Forester Road Builder Side Entry Cab 2 2 30 Drain Fuel Tank Sump 3 3 1 Shipping Dimensions Zaxis 250 Clean Radiat...

Page 9: ...llaneous Operational Checkout Change Swing Gearbox Oil 3 10 1 Operational Checkout 4 2 1 Replace Hydraulic Tank Oil Filter 3 10 2 Operator Station Checks Key Switch On Replace Pilot System Oil Filter 3 10 4 Engine Off 4 2 1 Change Pump Drive Gearbox Oil 3 10 5 Operator Station Checks Engine On 4 2 2 Replace Air Cleaner Elements 3 10 6 Miscellaneous Checks 4 2 12 Replace Air Cleaner Dust Valve 3 10...

Page 10: ...is 200LC Forester Live Heel Grapple 9 ft 2 in Track Width Lift Capacity kg lb 4 6 15 Zaxis 200LC Forester Live Heel Grapple 9 ft 7 in Track Width Lift Capacity kg lb 4 6 16 Zaxis 200LC Forester Articulated Grapple 9 ft 2 in Track Width Lift Capacity kg lb 4 6 17 Zaxis 200LC Forester Articulated Grapple 9 ft 7 in Track Width Lift Capacity kg lb 4 6 18 Zaxis 250 Forester Road Builder Machine Specifi...

Page 11: ...chine 5 Steps Wide slip resistant steps make entry and exit easier Steps also provide a place to clean shoes 6 Engine Fan Guard A secondary fan guard inside the engine compartment helps prevent contact with the engine fan blades 7 Bypass Start Protection Shielding over the starter helps prevent dangerous bypass starting 8 Travel Alarm Alerts bystanders of machine movement when travelling 9 Swing B...

Page 12: ... messages in this manual and on the machine Follow these warnings and instructions carefully Review them frequently Keep safety signs in good condition Be sure new equipment components and repair parts include the current safety signs Be sure all operators of this machine understand every safety message Replace operator s manual and safety signs immediately if missing or damaged Replacement safety...

Page 13: ...any damage or failures resulting from their use are not covered by any John Deere warranty Modifications of this machine or addition of unapproved products or attachments may affect machine stability or reliability and may create a hazard for the operator or others near the machine The installer of any modification which may affect the electronic controls of this machine is responsible for establi...

Page 14: ... Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgicall...

Page 15: ...or working on hydraulic system If hydraulic oil penetrates your skin see a doctor immediately Injected oil must be removed surgically within hours or gangrene may result Contact a knowledgeable medical source or the Deere Company Medical Department in Moline Illinois U S A OUT1739 00001BC 19 05AUG02 1 1 Beware of Exhaust Fumes T133546 UN 24AUG00 Prevent asphyxiation Engine exhaust fumes can cause ...

Page 16: ...ent Maintain Hoses and Wiring Replace hydraulic hoses immediately if they begin to leak and clean up any oil spills Examine electrical wiring and connectors frequently for damage Keep A Fire Extinguisher Available Always keep a multi purpose fire extinguisher on or near the machine Know how to use extinguisher properly OUT1739 00001BE 19 05AUG02 1 1 Prevent Battery Explosions TS204 UN 23AUG88 Batt...

Page 17: ...133567 UN 25AUG00 Improper disposal of waste can threaten the environment Fuel oils coolants filters and batteries used with this machine may be harmful if not disposed of properly Never pour waste onto the ground down a drain or into any water source Air conditioning refrigerants can damage the atmosphere Government regulations may require using a certified service center to recover and recycle u...

Page 18: ...ted machine movement Start engine only while sitting in operator s seat Ensure all controls and working tools are in proper position for a parked machine Never attempt to start engine from the ground Do not attempt to start engine by shorting across the starter solenoid terminals OUT1739 00001C4 19 16JUN06 1 1 Use and Maintain Seat Belt T133716 19 14SEP00 Use seat belt when operating machine Remem...

Page 19: ...resent Pull pilot control shut off lever to locked position during work interruptions Pull pilot control shut off lever to locked position and stop engine before allowing anyone to approach machine Always lower work equipment to the ground and pull pilot control shut off lever to locked position before standing up or leaving the operator s seat Stop engine before exiting 1 3 2 081407 PN 15 ...

Page 20: ... and pedestrians away Use a signal person if moving machine in congested areas or where visibility is restricted Always keep signal person in view Coordinate hand signals before starting machine Operate only on solid footing with strength sufficient to support machine When working close to an excavation position travel motors away from the hole Reduce machine speed when operating with tool on or n...

Page 21: ...at all times Do not jump if the machine tips You will be unlikely to jump clear and the machine may crush you Load and unload from trucks or trailers carefully Be sure truck is wide enough and on a firm level surface Use loading ramps and attach them properly to truck bed Avoid trucks with steel beds because tracks slip more easily on steel Be careful on slopes Use extra care on soft rocky or froz...

Page 22: ...on Use tether lines to guide loads and prearranged hand signals to communicate with co workers OUT1739 00001CB 19 16JUN06 1 1 Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer Adding unapproved attachments may affect machine stability or reliability and may create a hazard for others near the machine Ensure that a qualified person is...

Page 23: ...ld etc to minimize hazards from whipping or intruding objects To maintain OPS protection replace damaged parts immediately The protection offered by OPS will be impaired if OPS is subjected to structural damage is involved in an overturn incident or is altered by welding bending drilling or cutting Damaged OPS components should be replaced not reused Keep all bolts and attaching hardware tight 1 3...

Page 24: ...pport machine with boom arm or other hydraulically actuated attachments Do not support machine with cinder blocks or wooden pieces that may crumble or crush Do not support machine with a single jack or other devices that may slip out of place Understand service procedures before beginning repairs Keep service area clean and dry Use two people whenever the engine must be running for service work OU...

Page 25: ...n approved respirator before heating or welding If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating Do not use a chlorinated solven...

Page 26: ...not let heat go beyond work area to nearby pressurized lines Remove paint properly Do not inhale paint dust or fumes Use a qualified welding technician for structural repairs Make sure there is good ventilation Wear eye protection and protective equipment when welding OUT1739 00001D1 19 05AUG02 1 1 Drive Metal Pins Safely T133738 UN 14SEP00 Always wear protective goggles or safety glasses and othe...

Page 27: ...afety Signs OUT4001 0000293 19 07MAY07 1 13 Safety Signs T135956 19 14DEC00 T156790 UN 17JUL02 Rear Entry Cab T148391 UN 28NOV01 Side Entry Cab 1 Danger Decal Location Continued on next page 1 5 1 081407 PN 23 ...

Page 28: ...d window frame It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged If window is missing or broken replace immediately FFSB110771 T148542 T148542 19 10MAY02 T156792 UN 17JUL02 Rear Entry Cab T148392 UN 28NOV01 Side Entry Cab 1 Warning Decal Location Continued on next page 1 5 2 081407 PN 24 ...

Page 29: ...fety Safety Signs OUT4001 0000293 19 07MAY07 3 13 T102888 19 23AUG96 T156791 UN 17JUL02 Rear Entry Cab T148393 UN 28NOV01 Side Entry Cab 1 Caution Decal Location Continued on next page 1 5 3 081407 PN 25 ...

Page 30: ...ty Signs OUT4001 0000293 19 07MAY07 4 13 T122370 19 26JUL99 T156789 UN 17JUL02 Rear Entry Cab T148395 UN 28NOV01 Side Entry Cab 1 Cab Riser Hold Down Bolts Decal Location Continued on next page 1 5 4 081407 PN 26 ...

Page 31: ...Signs OUT4001 0000293 19 07MAY07 5 13 T124177 19 09SEP99 T146003 UN 02NOV01 1 Attachment Can Hit Cab Caution Decal Location Located on the Front Window Frame of All Foresters Continued on next page 1 5 5 081407 PN 27 ...

Page 32: ...Safety Safety Signs OUT4001 0000293 19 07MAY07 6 13 T135976 19 14DEC00 T148396 UN 21NOV01 Side Entry Cab Only Continued on next page 1 5 6 081407 PN 28 ...

Page 33: ...Safety Safety Signs OUT4001 0000293 19 07MAY07 7 13 T122375 19 26JUL99 T158320 UN 02AUG02 1 Pinch Point Caution Decal Location Continued on next page 1 5 7 081407 PN 29 ...

Page 34: ...Safety Safety Signs OUT4001 0000293 19 07MAY07 8 13 T7972AP 19 22MAR93 T147152B UN 02NOV01 Continued on next page 1 5 8 081407 PN 30 ...

Page 35: ...Safety Safety Signs OUT4001 0000293 19 07MAY07 9 13 T7748DC 19 14OCT92 T148477B UN 26NOV01 1 Warning Decal Location 2 places Continued on next page 1 5 9 081407 PN 31 ...

Page 36: ...Safety Safety Signs OUT4001 0000293 19 07MAY07 10 13 T148698 19 20JUL06 T152309B UN 19MAR02 1 Caution Decal Location Continued on next page 1 5 10 081407 PN 32 ...

Page 37: ...Keep engine compartment and other machine areas free of trash and debris Clean daily Check for fuel or oil leaks every day Repair and clean up spills immediately Keep fire extinguishers on machine and properly maintained Recharge immediately after use T185097 T154569 19 10MAY02 1 1 OPEN OPEN T154570 UN 03MAY02 1 Decal location 2 places Continued on next page 1 5 11 081407 PN 33 ...

Page 38: ...Safety Safety Signs OUT4001 0000293 19 07MAY07 13 13 T137264 UN 26JAN01 T137263 UN 26JAN01 1 Hot Surface Decal Location 1 5 12 081407 PN 34 ...

Page 39: ...ft Control Lever Horn 5 Right Travel Pedal 8 Switch Panel 12 Radio Switch on top of lever 6 Right Control Lever Power 9 Key Switch 13 Pilot Control Shut Off 2 Left Travel Pedal Boost Switch on top of 10 Air Conditioner Panel Lever 3 Left Travel Lever lever 11 Cab Door Release Lever 4 Right Travel Lever 7 Monitor Panel side entry cab only 2 1 1 081407 PN 35 ...

Page 40: ...witches Road Builder 1 Horn 2 Thumb Close 3 Power Boost 4 Thumb Open OUT1739 00001D5 19 05AUG02 1 1 Control Lever Switches Live Heel Grapple T121780 19 26JUL99 Control Lever Switches Live Heel Grapple 1 Rotate Grapple Counterclockwise 2 Horn 3 Rotate Grapple Clockwise 4 Grapple Close 5 Power Boost 6 Grapple Open 2 1 2 081407 PN 36 ...

Page 41: ...N03 1 1 Monitor Panel DISPLAY SELECT SET WORKMODE 12 13 14 15 16 17 18 3 4 5 6 7 8 10 11 9 19 20 2 1 T136148 UN 06JUN01 1 Engine Coolant Temperature Gauge 2 Fuel Gauge 3 Display Select Switch 4 Set Switch 5 Work Mode Switch 6 Fuel Level Indicator 7 Air Filter Restriction Indicator 8 Alternator Voltage Indicator 9 Not Used 10 Not Used 11 Engine Coolant Level Indicator If Equipped 12 Engine Oil Leve...

Page 42: ...engine oil pressure is low Stop engine immediately NOTE Cold oil low oil level or extreme off level operation may cause indicator to light 14 Pre Heat Indicator Orange indicator will light when the key switch is turned to ON position in cold weather Light will turn off after a few seconds indicating that the preheat is complete 15 Engine Coolant Temperature Indicator IMPORTANT DO NOT stop engine w...

Page 43: ...ront Switch Panel OFF A I A A P H P OFF OFF E 2 1 INT PUSH min 1 ON 6 5 4 3 2 1 T136155 UN 18DEC00 1 Engine RPM Dial 2 Auto Idle Auto Acceleration Switch 3 Power Mode Switch 4 Travel Speed Switch 5 Operating Lights Switch 6 Washer Wiper Switch 2 1 5 081407 PN 39 ...

Page 44: ...ations Turn auto idle auto acceleration switch OFF and set engine rpm dial to improve machine control in difficult work areas loading and unloading 3 Power Mode Switch Move switch to select engine speed mode H P High Power Mode Use H P mode when extra horse power is needed for rolling in the arm in excavation work P Mode Use P mode when general digging work is needed E Economy Mode Use E mode to i...

Page 45: ...ical port for service and maintenance for 24 volt appliances OUT1739 00001DC 19 05AUG02 1 1 Pilot Control Shut Off Lever T148397 UN 21NOV01 Lever In Locked Position Side Entry Cab 1 Pilot Control Shut Off Lever The pilot control shut off lever 1 shuts off hydraulic pilot pressure to all pilot control valves When pilot control shut off lever is in locked Back position the machine will not move if a...

Page 46: ... 19 05AUG02 1 1 Horn T140123 UN 20MAR01 Road Builder Shown 1 T152376 UN 19MAR02 Live Heel Grapple Road Builder 1 T152377 UN 19MAR02 Articulated Grapple Valve In Head 1 Horn Switch Horn switch 1 is located on left control lever 2 1 8 081407 PN 42 ...

Page 47: ...rapple Road Builder 1 T152379 UN 19MAR02 Articulated Grapple Valve In Head 1 Power Boost Switch Press and hold down power boost switch 1 on right control lever for an 8 second increase in hydraulic power Release switch to reset power boost function Power boost is automatically activated when using any front end function except arm 2 1 9 081407 PN 43 ...

Page 48: ...unds when a travel pedal or lever is activated and will continue as long as the tracks are moving When travel motion stops the travel alarm switch is reset After the initial 15 second alarm alarm can be silenced by depressing the travel alarm cancel switch 1 IMPORTANT If alarm is not operating during normal transport or if alarm sounds when engine is running and machine is stationary see your auth...

Page 49: ... port are automatically controlled Blower and A C OFF Switch Press OFF switch to turn blower and A C off When blower OFF switch is pressed the blower and the air conditioner will turn off The blower will turn on if one of the blower switches is pressed whether the air conditioner switch is turned on or off Temperature Control Switches Press switches to set temperature from Full Cool FC to Full Hea...

Page 50: ... blower switches to adjust cab temperature Defroster Operation 1 Press AUTO switch Temperature controlled air blows out 2 Press temperature control switch to set temperature 3 Press fresh air vent switch to select fresh air circulation mode 4 Press Mode switch to select the front vents or the front and rear vents 5 Adjust the louvers on front vent and defroster vent to control air flow direction 6...

Page 51: ...o turn radio on and repeatedly press one of tuning switches 4 until desired station is reached To preset a station select the desired station using tuning switches Press and hold station preset 6 for more than 2 seconds until an electronic tone is heard The frequency of the preset station will be indicated on digital display 7 Setting The Clock NOTE In order to set the clock digital display 7 must...

Page 52: ... 2 Cab Door Handle Outside 3 Cab Door Handle Inside OUT1739 00001E4 19 05AUG02 1 1 Side Entry Cab Door Release Lever T136071B UN 14DEC00 Side Entry Cab Door Release Lever 1 Cab Door Release Lever The cab door can be locked in the open position Open the door all the way until it locks in the latch on the side of the cab To release the door from this locked position push down on lever 1 2 1 14 08140...

Page 53: ...739 00001E5 19 19FEB03 1 1 Rear Entry Cab Door Handles T158066B UN 30JUL02 Rear Entry Cab Door Handle Outside T158067B UN 30JUL02 Rear Entry Cab Door Handle Inside 2 Cab Door Handle Outside 3 Cab Door Handle Inside 2 1 15 081407 PN 49 ...

Page 54: ...y Exit inside view T136074B UN 14DEC00 Side Entry Cab Secondary Exit outside view 1 Latch NOTE Secondary exits can be opened from inside or outside Secondary exit is the rear window of the side entry cab and it is in the roof near door on rear entry cab Release latches 1 and remove rear window pane for side entry cab or remove roof exit panel on rear entry cab 2 1 16 081407 PN 50 ...

Page 55: ...lever Push down lever while sitting on seat to adjust seat to desired angle Release lever Pull up handle 2 to unlock seat Slide seat to desired distance from control levers Release handle Turn knob 3 to adjust seat to weight of operator Squeeze ball 4 to add air for lumbar firmness Press button next to ball to release air Pull up lever 5 to release backrest lock Move backrest to desired position R...

Page 56: ...The fire extinguisher must be replaced after any use Read operating instructions on canister Check gauge If fire extinguisher is not fully charged replace it OUT1739 00001E9 19 05AUG02 2 2 T136085B UN 20DEC00 Side Entry Cab Fire Extinguisher Location T158070B UN 31JUL02 Rear Entry Cab Fire Extinguisher Location 1 Fire Extinguisher 2 1 18 081407 PN 52 ...

Page 57: ... The purpose of this pressure is to maintain a positive pressure on the suction side of the main pumps to prevent pump cavitation The downside effect of this pressure is that hydraulic oil will continue to leak until the operator vents this pressure The system incorporates a hydraulic oil tank pressure vent solenoid 1 that bypasses the cap and provides an electrically controlled method for venting...

Page 58: ...ulic Oil Level 3 Check Coolant Recovery Tank Level 4 Check Engine Oil Level 5 Check Clean Radiator And Oil Cooler Outer Fins Safety and Protective Devices Checks Walk around machine to clear all persons from machine area before starting machine Check condition of guards shields and covers Overall Machine Checks Check for worn or frayed electrical wires and loose or corroded connections Check for b...

Page 59: ...4JAN01 1 Engine Speed Dial Starting The Engine 1 Move engine speed dial 1 to slow idle position 2 Sound horn to alert persons nearby IMPORTANT Prevent starter damage Never operate starter for more than 20 seconds at a time If engine fails to start return key switch to OFF Wait for about 2 minutes then try again After a false start DO NOT turn key switch until engine stops 3 Turn key switch to STAR...

Page 60: ...d and cracking Starting aid fluid is being injected into engine as long as you push switch 1 Turn key switch clockwise to START position 2 After one or two revolutions of engine crankshaft push start aid switch 1 at short intervals Crank engine for 20 seconds maximum then allow 2 minutes between cranking periods Warming The Engine 1 Run engine at 1 3 speed for 30 seconds Do not run engine at fast ...

Page 61: ...l automatically check if preheating is required When preheating is required preheat indicator will light up for approximately 8 seconds If preheat indicator does not light up preheating is not required 2 Turn key switch to ON position 3 As soon as the preheat indicator goes out turn key to the START position to rotate the starter Release the key immediately after the engine has started 2 2 4 08140...

Page 62: ...nd bucket functions by moving cylinders a short distance each direction for the first time 4 Continue cycling cylinders by increasing the travel each cycle until full stroke is obtained 5 Swing upperstructure so boom is perpendicular to tracks CAUTION Prevent possible injury from machine sliding backwards Keep angle between boom and arm 90 110 6 Keeping the angle between boom and arm 90 110 fully ...

Page 63: ...ward 2 NEUTRAL POSITION 3 Travel brakes will automatically stop and hold the machine RIGHT TURN Push down on front of left pedal or push left lever forward LEFT TURN Push down on front of right pedal or push right lever forward SHORT TURN COUNTER ROTATE Push down the front of one pedal and the rear of the other or push one lever forward and pull the other rearward CAUTION Prevent possible injury f...

Page 64: ...each control before operating With this control pattern functions must correspond to the black on white labels located on the control console IMPORTANT Prevent possible machine damage When digging avoid contacting tracks with boom cylinders or bucket When digging over the end of the tracks travel motors should be at the rear to minimize chain and sprocket wear and to maximize machine stability and...

Page 65: ...Operation Operating The Machine OUT1739 00001F1 19 16JUN06 2 2 T122398 19 26JUL99 Control Lever Pattern Road Builder 2 2 8 081407 PN 61 ...

Page 66: ...ible injury from unexpected machine movement Make sure you know the location and function of each control before operating With this control pattern functions must correspond to the black on white labels located on the control console IMPORTANT When operating avoid contact with cab cylinders hoses or tracks with grapple or load 1 Operate control levers to verify that control pattern labels match m...

Page 67: ...Operation Operating The Machine OUT1739 00001F2 19 05AUG02 2 2 T122396 19 26JUL99 Control Lever Pattern Live Heel Grapple 2 2 10 081407 PN 63 ...

Page 68: ...ry from unexpected machine movement Make sure you know the location and function of each control before operating With this control pattern functions must correspond to the black on white labels located on the control console IMPORTANT When operating avoid contact between cab cylinders hoses or tracks and processing head or load 1 Operate control levers to verify that control pattern labels match ...

Page 69: ...Operation Operating The Machine VD76477 0000148 19 18AUG05 2 2 T213345 19 09AUG05 Control Lever Pattern Processor 2 2 12 081407 PN 65 ...

Page 70: ...eration Operating The Machine OUT1739 00001F3 19 16JUN06 1 1 Control Levers Articulated Grapple Valve in Head T146342 19 02NOV01 Control Lever Pattern Articulated Grapple Valve In Head 2 2 13 081407 PN 66 ...

Page 71: ...ed on the machine before operating The machine comes equipped from the factory with the excavator control lever pattern and has the corresponding black on white labels installed on the left and right control consoles When changed to the backhoe control lever pattern the corresponding black on yellow labels must be installed on the left and right control consoles Check the pattern on the labels and...

Page 72: ...lic tank is pressurized Slowly loosen hydraulic cap to vent pressure in the hydraulic tank 3 Vent pressure in hydraulic tank See Vent Hydraulic Oil Tank Pressure in section 3 3 4 Remove panel on top of machine to access pilot signal manifold NOTE DO NOT use manufacturer s hose tags or markings on hose ends to identify hoses for this conversion procedure The conversion must be done on the side of f...

Page 73: ...consoles Additional labels can be purchased from your authorized dealer 7 Tighten hydraulic vent plug A control pattern selector kit is available through service parts When installed it changes the control lever pattern using a solenoid valve OUT1739 00001F6 19 16JUN06 1 1 Operating in Water and Mud T136459 UN 18DEC00 1 Drain Plug Be careful not to operate the machine in water or mud above the upp...

Page 74: ...ush machine using boom and arm cylinder to help travel motors OUT1739 00001F8 19 05AUG02 1 1 Lifting T133649 UN 02NOV00 Without Bucket Loop T135070 UN 02NOV00 With Bucket Loop CAUTION Lifting requires special care Observe these rules when lifting with your machine Never use machine to lift people Do not exceed lift capacity limits Keep everyone clear of raised loads Never attach sling or chain to ...

Page 75: ...lve access door CAUTION To avoid injury from escaping oil under pressure stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines Tighten all connections before applying pressure IMPORTANT Never loosen boom manual lower screw more than two turns as screw may come out and oil will escape 2 Loosen nut 1 Loosen boom manual lower screw 2 1 2 turn T...

Page 76: ...d position as valve may come out of housing Tighten valve and nut before applying pressure Prevent possible injury from unexpected machine movement Clear all persons from the area before lowering the boom with the engine stopped 3 Check that the area is clear of all persons before lowering boom Slowly loosen boom manual lower needle valve B 1 2 1 turn The boom will start to lower Turn needle valve...

Page 77: ...ks are frozen in the ground slowly raise the machine using boom to free the tracks Move machine carefully 2 Lower equipment to the ground 3 Turn auto idle auto acceleration switch OFF IMPORTANT Turbocharger can be damaged if procedure to shut down engine is not done properly 4 Run engine with engine rpm dial at 1 3 position without load for 2 minutes 5 Turn engine rpm dial to slow idle position 6 ...

Page 78: ...off 5 Load and unload machine on a level surface 6 Drive machine onto ramps slowly 7 The centerline of the machine should be over the centerline of the trailer IMPORTANT Turbocharger may be damaged if engine is not properly shut down 8 Run engine at 1 2 speed without load for 2 minutes 9 Move engine speed rpm dial to slow idle position 10 Turn key switch to OFF Remove key from switch 11 Pull pilot...

Page 79: ... secure any loose objects inside the cab that can fall when cab is tilted 2 Turn key switch off 3 Close cab door CAUTION To prevent personal injury from falling or from falling objects DO NOT operate CAB TILT controls if cab or riser is occupied 4 Remove the cab riser hold down bolts 3 shown 5 CAB TILT control panel 1 is located in the left side rear battery compartment 6 Tilt cab and riser to tra...

Page 80: ...g objects DO NOT operate CAB TILT controls if anyone is in or near cab and riser area 2 Raise cab up to operating position by pushing and holding RAISE LOWER switch to RAISE 3 Install cab riser hold down bolts Tighten bolts to 678 N m 500 lb ft Specification Cab Hold Down Bolt Torque 678 N m 500 lb ft 2 2 23 081407 PN 76 ...

Page 81: ...aximum Cab Height Clearance 7 Undercarriage Width 3 Track Height 5 Sprocket Center To Sprocket Center Width Item Measurement Specification 1 Machine with counterweight fuel Overall Length 9688 mm 31 ft 10 in tank 2 Maximum Cab Height Transport Height 3387 mm 11 ft 2 in 3 Track Height 910 mm 3 ft 0 in 4 Minimum Ground Clearance Height 445 mm 1 ft 5 1 2 in 5 Sprocket Center To Sprocket Width 2390 mm...

Page 82: ...peration Operating The Machine OUT1739 00001FD 19 08AUG02 2 2 Item Measurement Specification 7 Undercarriage Width 3101 mm 10 ft 2 in 8 Machine Overall Width Width 3871 mm 10 ft 7 in 2 2 25 081407 PN 78 ...

Page 83: ...b Tilted 4 Minimum Ground Sprocket Center Width 8 Cab Height Operating For Transport Clearance 6 Track Shoe Width Position Item Measurement Specification 1 Machine with counterweight fuel Overall Length 1372 mm 45 ft tank 2 Cab Height With Cab Tilted For Transport Height 3307 mm 10 ft 10 in Transport 3 Track Height 1079 mm 3 ft 6 in 4 Minimum Ground Clearance Height 750 mm 2 ft 5 1 2 in 5 Sprocket...

Page 84: ...eration Operating The Machine OUT1739 00001FE 19 08AUG02 2 2 Item Measurement Specification 7 Undercarriage Width 3632 mm 11 ft 11 in 8 Cab Operating Position Height 4711 mm 15 ft 5 in 2 2 27 081407 PN 80 ...

Page 85: ...k Height 5 Sprocket Center To 7 Undercarriage Width 2 Maximum Height With Cab 4 Minimum Ground Sprocket Center Width 8 Cab Height Operating Tilted For Transport Clearance 6 Track Shoe Width Position Item Measurement Specification 1 Machine with counterweight fuel Overall Length 15330 mm 50 ft 4 in With Grapple tank Fully Extended 14080 mm 46 ft 2 in With Grapple Fully Retracted 2 2 28 081407 PN 81...

Page 86: ...ple For Transport Fully Extended 3477 mm 11 ft 5 in With Grapple Fully Retracted 3 Track Height 1079 mm 3 ft 6 in 4 Minimum Ground Clearance Height 750 mm 2 ft 5 1 2 in 5 Sprocket Center To Sprocket Width 2920 mm 9 ft 7 in Center 6 Track Shoe Width 700 mm 28 in 7 Undercarriage Width 3632 mm 11 ft 11 in 8 Cab Operating Position Height 4711 mm 15 ft 5 in 2 2 29 081407 PN 82 ...

Page 87: ...riage Width 3 Track Height 5 Sprocket Center To Sprocket Center Width Item Measurement Specification 1 Overall Length Overall Length 10363 mm 34 ft 2 Maximum Cab Height Transport Height 3658 mm 12 ft 3 Track Height Height 914 mm 3 ft 4 Minimum Ground Clearance Height 610 mm 2 ft 5 Sprocket Center To Sprocket Width 2692 mm 8 ft 10 in Center Width 6 Track Shoe Width Width 700 mm 28 in 7 Undercarriag...

Page 88: ...2 Maximum Cab Height Clearance 7 Undercarriage Width 3 Track Height 5 Sprocket Center To Sprocket Center Width Item Measurement Specification 1 Overall Length Overall Length 10483 mm 34 ft 5 in 2 Maximum Cab Height Transport Height 3769 mm 12 ft 5 in 3 Track Height Height 1250 mm 4 ft 1 in 4 Minimum Ground Clearance Height 700 mm 28 in 5 Sprocket Center To Sprocket Width 2692 mm 8 ft 10 in Center ...

Page 89: ...ation Operating The Machine OUT1739 0000201 19 07AUG02 2 2 Item Measurement Specification 7 Undercarriage Width Width 3403 mm 11 ft 2 in 8 Overall Machine Width Width 3429 mm 11 ft 3 in 2 2 32 081407 PN 85 ...

Page 90: ...15409 mm 50 ft 7 in 2 Maximum Cab Height 48 in Riser 4955 mm 16 ft 3 in 72 in Riser 5455 mm 17 ft 11 in 3 Track Height Height 1250 mm 4 ft 1 in 4 Minimum Ground Clearance Height 737 mm 29 in 5 Sprocket Center To Sprocket Width 2924 mm 9 ft 7 in Center Width 6 Track Shoe Width Width 700 mm 28 in 7 Undercarriage Width Width 3624 mm 11 ft 11 in 8 Overall Machine Width Width 3650 mm 12 ft 9 Cab Transp...

Page 91: ... ft 2 in 2 Maximum Cab Height Height With 48 in Riser 4955 mm 16 ft 3 in Height With 72 in Riser 5455 mm 17 ft 11 in 3 Track Height Height 1250 mm 4 ft 1 in 4 Minimum Ground Clearance Height 737 mm 29 in 5 Sprocket Center To Sprocket Width 2924 mm 9 ft 7 in Center Width 6 Track Shoe Width Width 700 mm 28 in 7 Undercarriage Width Width 3624 mm 11 ft 11 in 8 Overall Machine Width Width 3650 mm 12 ft...

Page 92: ...th 3 Track Height 5 Sprocket Center To Sprocket Center Width Item Measurement Specification 1 Overall Length Overall Length 11114 mm 36 ft 6 in 2 Maximum Cab Height Transport Height 3832 mm 12 ft 7 in 3 Track Height Height 1262 mm 4 ft 2 in 4 Minimum Ground Clearance Height 715 mm 28 in 5 Sprocket Center To Sprocket Width 2690 mm 8 ft 10 in Center Width 6 Track Shoe Width Width 700 mm 28 in 7 Unde...

Page 93: ...rcarriage Width 3 Track Height 5 Sprocket Center To Sprocket Center Width Item Measurement Specification 1 Overall Length Overall Length 11128 mm 36 ft 6 in 2 Maximum Cab Height Transport Height 3796 mm 12 ft 6 in 3 Track Height Height 1262 mm 4 ft 2 in 4 Minimum Ground Clearance Height 700 mm 28 in 5 Sprocket Center To Sprocket Width 2690 mm 8 ft 10 in Center Width 6 Track Shoe Width Width 700 mm...

Page 94: ...671 mm 54 ft 8 in 2 Maximum Cab Height 48 in Riser 4962 mm 16 ft 4 in 72 in Riser 5474 mm 18 ft 0 in 3 Track Height Height 1262 mm 4 ft 2 in 4 Minimum Ground Clearance Height 687 mm 27 in 5 Sprocket Center To Sprocket Width 2913 mm 9 ft 7 in Center Width 6 Track Shoe Width Width 700 mm 28 in 7 Undercarriage Width Width 3613 mm 11 ft 10 in 8 Overall Machine Width Width 3703 mm 12 ft 2 in 9 Cab Tran...

Page 95: ... 8 in 2 Maximum Cab Height Height With 48 in Riser 4962 mm 16 ft 4 in Height With 72 in Riser 5474 mm 18 ft 0 in 3 Track Height Height 1262 mm 4 ft 2 in 4 Minimum Ground Clearance Height 687 mm 27 in 5 Sprocket Center To Sprocket Width 2913 mm 9 ft 7 in Center Width 6 Track Shoe Width Width 700 mm 28 in 7 Undercarriage Width Width 3613 mm 11 ft 10 in 8 Overall Machine Width Width 3703 mm 12 ft 2 i...

Page 96: ...hen disconnecting travel gearboxes When travel gearboxes are disconnected machine has no brakes and can move The machine will roll free on a slope or while being towed 1 Block tracks 2 Drain oil from each travel gearbox See Change Travel Gearbox Oil in section 3 9 3 Remove cover from each gearbox 4 Remove sun gear 1 from each gearbox 5 Install cover Fill gearbox with oil 2 2 39 081407 PN 92 ...

Page 97: ... the service interval for engine oil and filter by 50 DO NOT use diesel fuel with sulfur content greater than 1 0 Bio diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification DO NOT mix used engine oil or any other type of lubricant with diesel fuel OUT1739 0000206 19 05AUG02 1 1 Low Sulfur Diesel Fuel Conditioner When possible use existing fuel formulations ...

Page 98: ...nual Synthetic lubricants may be used if they meet the performance requirements as shown in this manual The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils Re refined base stock products may be used if the finished lubricant meets the performance requirements If alternative hydraulic oils are required the hydraulic system needs to be comp...

Page 99: ...uring the period between oil changes The following oil is allowed Oils meeting MIL L 46167A may be used as artic oil Reduce the service interval by 50 Other oils may be used if they meet one of the following API Service Classification CH 4 If diesel fuel with sulfur content greater than 0 5 is used reduce the service interval by 50 3 1 3 081407 PN 95 ...

Page 100: ... Hours Air Temperature 20 40 C 10 40 C 20 40 C 10 40 C 20 40 C 10 40 C 4 104 F 14 104 F 4 104 F 14 104 F 4 104 F 14 104 F Brand Names Hitachi Super EX 46HNa Apolo U S A Super Hydro 46 WRHU British Petroleum Bartran HV46 Caltex Oil Rando Oil HD46 Texaco INC Rando Oil HD46 Chevron U S A Chevron AW46 INC Esso NUTO H46 Mobil Oil DTE 25 Shell Oil Tellus Oil 46 Remarks Anti wear type hydraulic oil a Fac...

Page 101: ...olube D 3 Essolube D 3 Idemitsu Kosan HE90 15W 40 S 330 S 340 Apollo Gear Apoll oil super wide Apoll oil diesel motive Apoll oil diesel motive Mobil Oil GX90 1330 1340 Mobilube Mobil Delvac Mobil Delvac Nippon Oil SP90a 15W 40b 20 35 C Gear Lube Hidiesel S3 4 95 F 10W 30 Nippon Oil SP80W 90b Gear Lube Shell Oil EP90 30 40 Shell Spirax Rymla zoil white pilot Rymla zoil white pilot super super Remar...

Page 102: ... Grease RECOMMENDED GREASE FOR TRACK ADJUSTER WORKING TOOL PIVOT SWING BEARING AND SWING GEAR Air Temperature 20 40 C 4 104 F Brand Names Nippon Koyu SEP 2a British Petroleum BP Energrease LS EP2 Caltex Oil Multifax EP2 Esso Beacon EP2 Idemitsu Kosan Daphne Coronex EP2 Grease Mobil Oil Mobilux EP2 Nippon Oil Epinoc Grease AP2 Shell Oil Shell Alvania EP2b a Factory fill for swing gear b Factory fil...

Page 103: ...ORTANT During cold weather operation low temperature hydraulic oil minimizes filter plugging In addition the antiwear additive and foam inhibitor helps prevent pump cavitation therefore extending pump life For low temperature applications 54 C to 135 C 65 F to 275 F Chevron Aviation Hydraulic Oil A G is recommended DEXRON is a trademark of General Motors Corporation 3 1 7 081407 PN 99 ...

Page 104: ...sted under 250 hours 100 hours 50 hours and 10 hours or daily OUT1739 0000210 19 16JUN06 1 1 Check the Hour Meter Regularly T136354 UN 19DEC00 1 Hour Meter Check the hour meter 1 to determine when your machine needs periodic maintenance Intervals on the periodic maintenance chart are for operating in normal conditions If you operate your machine in difficult conditions you should service it at SHO...

Page 105: ... 16JUN06 1 1 Open Engine Hood for Service T136356 UN 18DEC00 1 Catch CAUTION Prevent possible injury Unlock latch Pull open latches to unlock hood Raise the hood until the end of the bar is securely locked into catch Raise hood using handle on hood until the end of the rod is securely locked into catch 1 OUT1739 0000214 19 12NOV02 1 2 Fuel Tank To avoid condensation fill the fuel tank at the end o...

Page 106: ...xis 250 350 1 Filler Cap CAUTION Handle fuel carefully If the engine is hot or running DO NOT fill the fuel tank DO NOT smoke while you fill fuel tank or work on fuel system Item Measurement Specification Zaxis 200LC Fuel Tank Capacity 1165 L 308 gal Zaxis 250 350 Fuel Tank Capacity 1020 L 269 gal 3 2 3 081407 PN 102 ...

Page 107: ...program is to ensure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical Engine hydraulic power train and coolant samples should be taken from each system on a periodic basis usually prior to a filter and or fluid change interval Certain systems require more frequent sampling Consult your authorized dealer on a maintenance ...

Page 108: ...shield washer fluid level Drain water separator Check hydraulic oil level in cab tilt power pack Check air cleaner dust valve Check oil cooler debris screen Zaxis 200LC Zaxis 250 Every 10 Hours or Daily Check engine oil level Check hydraulic tank oil level Check recovery tank coolant level Grease working tool pivots Every 50 Hours Grease swing bearing After First 50 Hours Check track shoe cap scre...

Page 109: ...1 Zaxis 200LC Zaxis 250 Air Filter Primary AT175223 1 1 1 Zaxis 350 Air Filter Secondary AT280663 1 1 1 Zaxis 200LC Zaxis 250 Air Filter Secondary AT175224 1 1 1 Zaxis 350 Air Cleaner Dust Valve 4453910 1 1 1 Pilot Control Oil Filter AT186554 1 1 1 Supply Oil Filter FFSB114711 1 1 Zaxis 200LC Zaxis 250 Case Drain Oil Filter FFSB114712 1 1 Zaxis 200LC Zaxis 250 Return Oil Filter FFSB114713 1 1 Zaxi...

Page 110: ...s 250 2908 050 148 L 39 0 gal Zaxis 350 2908 050 159 L 42 0 gal Fluid Analysis Kits Diesel Engine Oil AT317904 1 1 1 1 1 Hydraulic Oil AT303189 1 1 1 1 1 Hydrostatic Oil AT303189 3 3 3 3 DieselScan Kit AT180344 1 1 1 1 COOLSCAN PLUS Kit AT183016 1 1 1 1 3 Way Heavy Duty Coolant Test Kit TY16175 1 1 1 1 IMPORTANT If fuel sulfur content exceeds 0 5 percent change the engine oil at 1 2 the normal int...

Page 111: ... Take engine coolant sample Take travel gearbox oil sample Take pump drive gearbox oil sample Take swing gearbox oil sample Take diesel fuel sample Comments Date Hour Meter Reading Maintenance Performed By Every 1000 Hours Change swing gearbox oil Change pump drive gearbox oil Replace hydraulic tank oil filter Replace air cleaner elements Change pilot system oil filter Replace air cleaner dust val...

Page 112: ...Maintenance Periodic Maintenance OUT4001 0000274 19 13AUG07 5 5 Comments Date Hour Meter Reading Maintenance Performed By 3 2 9 081407 PN 108 ...

Page 113: ...6811AJ UN 18OCT88 T136406 UN 18DEC00 1 Drain Valve 1 Park machine on a level surface Rotate upperstructure 90 for easier access 2 Stop engine 3 Remove fuel tank fill cap NOTE Some machines may be equipped with a pipe plug in outlet fitting of drain valve Remove this pipe plug before opening drain valve 4 Open drain valve 1 for several seconds to drain water and sediment into a container Dispose of...

Page 114: ...aning TX14740 0001F8A 19 06DEC02 1 1 Drain Water Separator T147893B UN 15NOV01 1 Fuel Filter water separator Assembly 2 Sediment Bowl 1 Open right access door to access water separator 1 2 Open drain valve 3 and press pump 2 to extract water from fuel system Collect waste in a container and dispose of it properly 3 Close drain valve 4 Bleed fuel system 3 3 2 081407 PN 110 ...

Page 115: ...ce is felt OUT4001 0000278 19 13APR07 1 1 Clean Air Cleaner Dust Valve T136463 UN 18DEC00 1 Air Cleaner Dust Valve IMPORTANT A missing damaged or hardened dust valve will make the dust cup precleaner ineffective causing very short element life Valve should suck closed above 1 3 engine speed Squeeze dust valve 1 to remove dust from the air cleaner If operating in high dust conditions squeeze dust v...

Page 116: ...ture 90 to tracks and position boom arm and front attachment as shown 2 Raise track off ground with boom CAUTION Prevent possible injury from unexpected machine movement Place blocks under machine frame to support machine while measuring track sag 3 Place blocks under machine frame to support machine 4 Rotate track forward two full rotations and then in reverse two full rotations Continued on next...

Page 117: ...itting B Nut C Bleed Hole D Access Hole IMPORTANT Prevent possible damage to track components DO NOT use the grease fitting on the track adjusting cylinder for lubrication Use this fitting ONLY for track adjustment To tighten track connect a grease gun to grease fitting A located through access hole D in track frame Add grease until sag is within recommended limits CAUTION Prevent possible injury ...

Page 118: ...ion 1 Reservoir Fill Cap The cab tilt power pack is located beneath cab on machine frame and is accessible through the left cab access door Remove reservoir fill cap 1 and check hydraulic oil level on dipstick OUT1739 000021E 19 16JUN06 2 2 T136651B UN 20DEC00 Cab Tilt Power Pack Reservoir Dipstick The hydraulic oil in reservoir must show level between marks on dipstick If necessary add oil Use oi...

Page 119: ...urized system can cause serious burns or penetrating injury Relieve pressure by SLOWLY loosening cap 1 1 Insert 4 mm hex wrench 4 into hole 5 and turn counterclockwise to release locking pin 2 SLOWLY turn cap 1 counterclockwise a few degrees to relieve pressure in tank CAUTION Pressure may cause cap to lift off tank 3 To replace cap align notches 2 on cap and case assembly 3 and turn clockwise 3 3...

Page 120: ...AUG05 1 1 Replace Oil Cooler Debris Screen Zaxis 200LC Zaxis 250 T213354A UN 10AUG05 1 Open left access door 2 Remove wing nut securing oil cooler debris screen 3 Replace debris screen and reinstall wing nut 4 Close access door 3 3 8 081407 PN 116 ...

Page 121: ...ing the engine for the day s operation 1 Make sure dipstick 1 is fully seated 2 Remove dipstick to check oil level BEFORE THE ENGINE IS STARTED The engine is full when oil level is in the cross hatch area It is acceptable to run the engine when the oil level is above the ADD mark AFTER THE ENGINE HAS BEEN RUN Allow the oil to drain into the oil pan for 10 minutes before checking the oil level Ten ...

Page 122: ...ble injury from hot spraying water DO NOT remove radiator filler cap unless engine is cool Then turn cap slowly to the stop Release all pressure before you remove cap If recovery tank is empty check for leaks Repair as required Add coolant to the radiator and the recovery tank NOTE If recovery tank is full and radiator is low check for leaks in radiator cap and hose connections between radiator an...

Page 123: ...V01 1 Hydraulic Oil Level Window IMPORTANT Prevent damage to hydraulic system components DO NOT run engine without oil in hydraulic tank 1 Park machine on a level surface and position machine with arm cylinder fully retracted and bucket cylinder fully extended 2 Stop engine 3 Check oil level gauge 1 on hydraulic tank Oil must be between marks on window If necessary add oil 3 4 3 081407 PN 119 Cont...

Page 124: ...sembly 4 Hex Wrench 5 Hole CAUTION High pressure release of oil from pressurized system can cause serious burns or penetrating injury Relieve pressure by SLOWLY loosening cap 1 Vent pressure in hydraulic tank 5 Remove cap 6 Add oil See Section 3 1 7 Install cap to case assembly 3 by aligning notches 2 and turning cap clockwise to lock position 3 4 4 081407 PN 120 ...

Page 125: ...nts T136448 UN 18DEC00 Nine Points T134956 UN 01NOV00 Five Points T134957 UN 01NOV00 Two Points Grease working tool pivots 20 points until grease escapes from joints Grease every 4 hours for first 20 hours Grease every 10 hours during first 30 100 hours and when working in mud and water See Section 3 1 3 4 5 081407 PN 121 ...

Page 126: ... be done by one person Before you lubricate swing bearing clear the area of all persons 1 Park machine on a level surface 2 Stop engine IMPORTANT Watch for grease overflow Do not over grease 3 Lubricate swing bearing with 2 shots of grease at both grease fittings 4 Start engine Raise bucket several inches off the ground and turn upperstructure 45 degrees 5 Repeat steps 2 4 three times NOTE It is n...

Page 127: ...ce Report for each unit placing a copy of this report in the machine file and forwarding a copy to the manufacturers attention 1 Verify that nuts are square with the milled surface of link and there is full contact between nut and milled surface 2 Starting at any cap screw tighten all cap screws in sequence shown to the re torque specification Zaxis 200LC 250 Standard Specification 20 mm Track Sho...

Page 128: ...Apply a light coating of oil to cap screw threads before installing 3 Install nuts with the rounded corners against milled surface of link and chamfered side is away from link Check that nuts are square with the milled surface of link and there is full contact between nut and milled surface As necessary hold the nut so it does not turn 4 Starting at any cap screw tighten all cap screws in sequence...

Page 129: ...l See Section 3 1 4 Check oil level OUT1739 0000228 19 05AUG02 1 1 Drain Hydraulic Tank Sump T136450 UN 18DEC00 1 Sump Plug CAUTION High pressure release of oil from pressurized system can cause serious burns or penetrating injury Relieve pressure by SLOWLY loosening cap 1 1 Vent pressure in hydraulic oil tank 2 Loosen sump plug 1 for several seconds to drain water and sediment into a container Do...

Page 130: ...250 T145091 UN 31AUG01 Zaxis 350 T145092 UN 31AUG01 1 Dipstick 2 Filler Cap 1 Remove dipstick 1 2 Wipe dipstick clean and insert completely into tube 3 Remove dipstick 4 Oil must be approximately halfway below the H level mark To add oil 1 Remove filler cap 2 2 Add oil See Section 3 1 3 Install filler cap 3 8 2 081407 PN 126 ...

Page 131: ...e radiator filler cap 1 unless engine is cool Then turn cap slowly to the stop Release air to relieve all pressure before you remove cap 1 Slowly remove cap 1 Coolant level must be at bottom of the filler neck NOTE If radiator coolant level is low check for leaks on radiator cap and hose connections between radiator and coolant recovery tank 2 Add coolant if necessary 3 Install filler cap 3 8 3 08...

Page 132: ...clothing and cause blindness if splashed into eyes Avoid the hazard by 1 Filling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the...

Page 133: ... running the engine 2 Fill each cell to within specified range with distilled water DO NOT overfill CAUTION Prevent possible injury ALWAYS remove grounded battery clamp first and replace it last 3 Disconnect battery clamps grounded clamp first OUT1739 000022B 19 05AUG02 3 3 T137537 UN 25JAN01 1 Battery Terminal 2 Lubricating Grease 4 Clean battery terminals 1 and clamps with a stiff brush 5 Apply ...

Page 134: ...m can cause serious burns Wait for travel gearbox oil to cool Keep body and face away from check plug 2 Gradually loosen check plug to release air to relieve pressure 3 After travel gearbox has cooled slowly loosen check plug to release air to relieve pressure 4 Remove check plug Oil must be to bottom of hole 5 If necessary remove fill plug 1 and add oil until oil flows out of oil level check plug...

Page 135: ... the pleats from inside to outside Be careful not to make a break in the element IMPORTANT A damaged or dirty element may cause engine damage Install a new primary element 1 If the element shows damage 2 If element will not clean 3 After 1000 hours service or annually Install a new secondary element 1 If the primary element is damaged and needs to be replaced 2 If the element is visibly dirty 3 Af...

Page 136: ... Prevent possible burning injury DO NOT touch any part of exhaust system until it is cool 1 Remove the cleanout plug 1 from the bottom of the spark arrester muffler and allow waste to collect into a container 2 Repeatedly tap on the arrester near the cleanout plug This may be enough to begin drainage of the spark trap 3 Enter cab and start engine 4 Run engine for 2 minutes alternating between slow...

Page 137: ... valve on side of engine oil pan Allow oil to drain into a container Dispose of waste oil properly 5 Turn filter counterclockwise to remove Clean mounting surface on base 6 Apply thin film of oil to rubber gasket of new filter 7 Install new filter Turn filter clockwise by hand until gasket touches mounting surface 8 Tighten filter 3 4 1 turn more 9 Install drain plug or close drain valve Continued...

Page 138: ...With Filter Change Capacity 25 0 L 6 6 gal Zaxis 350 Forester Specification Engine Oil With Filter Change Capacity 36 0 L 9 5 gal 11 Fill engine with oil See Section 3 1 12 Install filler cap 2 13 Start engine Engine oil pressure indicator on monitor must go out within 15 20 seconds If not stop engine immediately and find the cause 14 Stop engine Check oil level Check for any leakage at filter Tig...

Page 139: ...e must be 13 25 mm 1 2 1 in deep measured from the bottom of the ring gear The grease must also be free of contamination by dirt and water IMPORTANT If water or mud is found in swing gear area See Operating in Water and Mud in section 2 2 3 If the grease is contaminated remove grease and replace with clean grease Add grease as required When completely dry or after running in mud or water swing bea...

Page 140: ...ing surface 4 Tighten filter 2 3 turn more 5 Bleed air from the fuel system OUT1739 0000233 19 06DEC02 1 1 Replace Water Separator T147893B UN 15NOV01 1 Fuel Filter water separator Assembly 2 Sediment Bowl 1 Turn fuel filter water separator assembly 1 counterclockwise to remove Allow sediment to drain into a container Dispose of waste properly 2 Turn sediment bowl 2 counterclockwise to remove from...

Page 141: ...500 Hours OUT1739 0000235 19 05AUG02 1 1 Check Air Intake Hoses Check air intake hoses for cracks Replace as necessary Check air intake hose clamp condition and torque Replace or tighten as necessary 3 9 5 081407 PN 137 ...

Page 142: ...s 250 Specification Swing Gearbox Oil Capacity 7 6 L 8 0 qt Zaxis 350 Specification Swing Gearbox Oil Capacity 14 0 L 15 0 qt Zaxis 350 Specification Optional 2nd Swing Gearbox Oil Capacity 2 6 L 2 8 qt 1 Remove plug mounted on end of drain pipe to drain oil into a container Dispose of waste oil properly 2 Install plug 3 Remove filler cap 2 and add oil See Section 3 1 4 Install filler cap 5 Check ...

Page 143: ...der fully retracted and bucket cylinder fully extended 2 Stop engine CAUTION High pressure release of oil from pressurized system can cause serious burns or penetrating injury The hydraulic tank is pressurized Relieve pressure by SLOWLY loosening cap 3 Vent pressure in hydraulic oil tank See Section 3 3 4 Hold down filter cover 1 against light spring load when removing the last two cap screws Cont...

Page 144: ...emove element and inspect for metal particles and debris in bottom of filter canister Excessive amounts of brass and steel particles can indicate a hydraulic pump motor or valve malfunction or a malfunction in process A rubber type of material can indicate cylinder packing problem 8 Install filter element valve and spring 9 Install cover 1 with new O ring 6 and tighten cap screws 2 Specification C...

Page 145: ...UG01 Zaxis 350 T136461 UN 19DEC00 1 Filter Canister 2 Filter Element 3 O Ring 1 Vent pressure in hydraulic oil tank See Section 3 3 2 Remove filter canister 1 3 Remove filter element 2 4 Remove O ring 3 5 Install new O ring and filter element Specification Filter Canister Torque 39 N m 29 lb ft 6 Install filter canister 3 10 4 081407 PN 141 ...

Page 146: ...Remove filler plug 2 2 Remove drain plug 3 Allow oil to drain into a container Dispose of waste oil properly 3 Apply Liquid TEFLON Pipe Thread Sealant to drain plug Install plug Specification Pump Drive Gearbox Oil Capacity 1 0 L 1 1 qt 4 Add oil See Section 3 1 5 Remove dipstick 1 and check oil level Oil level must be approximately halfway below H mark 6 Install filler plug Install dipstick 3 10 ...

Page 147: ... Remove secondary element 4 Clean the inside of filter canister 5 Install elements making sure the secondary element is centered in canister 6 Install cover tighten clamps OUT1739 000023B 19 05AUG02 1 1 Replace Air Cleaner Dust Valve T136463 UN 18DEC00 1 Air Cleaner Dust Valve NOTE A missing damaged or hardened dust valve will cause the air filter elements to be ineffective Replace dust valve 1 3 ...

Page 148: ...ey and alternator pulley with the thumb Deflection must be 8 to 12 mm 0 32 to 0 47 in with a depressing force of approximately 98 N 10 kgf 22 lbft Specification Fan Belt Deflection 8 to 12 mm 0 32 to 0 47 in Specification Fan Belt Force 98 N 10 kgf 22 lbft 3 If tension is not within specifications loosen bolts for adjusting plate and alternator bracket Move alternator till tension is correct 4 Tig...

Page 149: ...ecessary 2 Check radiator and oil cooler for dirt grease leaks and loose or broken mountings Clean radiator and oil cooler fins CAUTION Prevent possible injury from hot spraying water DO NOT remove radiator filler cap unless engine is cool Then turn cap slowly to the stop 3 Release air to relieve pressure Remove filler cap Zaxis 200LC 250 Specification Cooling System Approximate Capacity 23 0 L 6 ...

Page 150: ...with quality water Coolants meeting these specifications require use of supplemental coolant additives formulated for heavy duty diesel engines for protection against corrosion and cylinder liner erosion and pitting A 50 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F If protection at lower temperatures is required consult your authorized dealer for recom...

Page 151: ... water Fill Fill radiator to the bottom of the radiator fill neck Fill the recovery tank to FULL mark Deaeration The cooling system requires several warm up and cool down cycles to deaerate It will NOT deaerate during normal operation Only during warm up and cool down cycles will the system deaerate 1 Start engine Run engine until coolant reaches a warm temperature 2 Stop engine Allow coolant to c...

Page 152: ...ecification Travel Gearbox Oil Capacity each 5 2 L 1 4 gal 7 5 L 2 gal High Drawbar Zaxis 350 Specification Travel Gearbox Oil Capacity each 7 5 L 2 0 gal 8 5 L 2 25 gal High Drawbar 4 Remove drain plug 3 Allow oil to drain into a container Dispose of waste oil properly 5 Wrap threads of drain plug with a sealing type tape Install plug Tighten plug to 49 N m 430 lb in 6 Remove oil fill plug 1 7 Ad...

Page 153: ...rain plug 2 and drain oil into a suitable container Dispose of waste properly 3 Turn filter bowl 1 counterclockwise and remove from head assembly 3 4 Remove filter element from inside of bowl and inspect the surface for contamination 5 Discard filter element 6 Inspect filter head assembly and by pass valve 3 for damage Replace as necessary 7 Lubricate o ring seal and install new filter element 8 E...

Page 154: ...ll new filter element 7 Lightly lubricate the threads of the filter bowl and o ring and screw the filter bowl into the head assembly 8 Bleed the system and check for leaks See Section 3 3 VD76477 0000174 19 01SEP05 1 1 Replace Return Oil Filter Zaxis 200LC Zaxis 250 T213353B UN 30AUG05 1 Filter Housing 2 Check Valve 1 Turn off and depressurize system 2 Disconnect hose at base of boom 3 Remove chec...

Page 155: ...c system components DO NOT run engine without oil in the tank Avoid mixing different brands or types of oils Oil manufacturers engineer their oils to meet certain specifications and performance requirements Mixing different oil types can degrade lubricant and machine performance 1 Park machine on level surface with upperstructure rotated 90 for easier access 2 Position machine with arm cylinder fu...

Page 156: ... with suction filter TX14740 0001F41 19 16JUN06 3 5 T136450 UN 18DEC00 1 Drain Plug 7 Remove drain plug 1 Allow oil to drain into a container Dispose of waste oil properly Zaxis 200LC Specification Hydraulic Tank Oil Capacity 130 L 34 0 gal Zaxis 250 Specification Hydraulic Tank Oil Capacity 148 L 39 0 gal Clean inside of tank and suction screen 8 Replace hydraulic oil filter 9 Replace pilot syste...

Page 157: ...29 4 in Suction Screen Rod Nut Torque 14 7 19 6 N m 10 8 14 5 lb ft Hydraulic Cover Cap Screw Torque 49 N m 36 lb ft TX14740 0001F41 19 16JUN06 5 5 T135011 UN 01NOV00 1 Bleed Plug IMPORTANT If the hydraulic pump is not filled with oil it will be damaged when the engine is started 13 Remove air bleed plugs 1 from hydraulic pump until oil flows from bleed holes 14 Install air bleed plugs in hydrauli...

Page 158: ...ut oil in the tank Avoid mixing different brands or types of oils Oil manufacturers engineer their oils to meet certain specifications and performance requirements Mixing different oil types can degrade lubricant and machine performance 1 Park machine on level surface with upperstructure rotated 90 for easier access 2 Position machine with arm cylinder fully retracted and bucket cylinder fully ext...

Page 159: ...tion Hydraulic Tank Oil Capacity 159 L 42 0 gal TX14740 0001F9A 19 16JUN06 3 6 T145090 UN 31AUG01 1 Drain Plug 6 Remove drain plug 1 Allow oil to drain into a container Dispose of waste oil properly TX14740 0001F9A 19 16JUN06 4 6 T135008 UN 01NOV01 1 Hydraulic Oil Cap 2 Hydraulic Oil Tank Cover 7 Remove cover 2 with suction screen 8 Clean inside of tank and suction screen 9 Replace hydraulic oil f...

Page 160: ...een Rod 1 Length 702 mm 27 6 in Suction Screen Rod Nut Torque 14 7 19 6 N m 10 8 14 5 lb ft Hydraulic Cover Cap Screw Torque 49 N m 36 lb ft TX14740 0001F9A 19 16JUN06 6 6 T145146 UN 31AUG01 1 Bleed Plug IMPORTANT If the hydraulic pump is not filled with oil it will be damaged when the engine is started 14 Remove air bleed plugs 1 from hydraulic pump until oil flows from bleed holes 15 Install air...

Page 161: ...e control valves cylinders pumps or motors If these parts need service see your authorized dealer OUT1739 0000245 19 05AUG02 1 1 Precautions for Alternator and Regulator When batteries are connected follow these rules 1 Disconnect negative battery cable when you work on or near alternator or regulator 2 Be sure alternator wires are correctly connected BEFORE you connect batteries 3 Do not ground a...

Page 162: ...ling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention i...

Page 163: ...5 kg 1 lb baking soda in 4 L 1 gal water or 0 47 L 1 pt household ammonia in 4 L 1 gal water IMPORTANT DO NOT overfill the battery cells Check the specific gravity of electrolyte in each battery cell A fully charged battery will have a corrected specific gravity reading of 1 260 If the reading is below 1 200 charge the battery 4 1 3 081407 PN 159 ...

Page 164: ...o 12 volt booster batteries together as shown for 24 volts 1 Connect one end of the positive cable to the positive terminal of the machine batteries A and the other end to the positive terminal of the booster batteries B 2 Connect one end of the negative cable to the negative terminal of the booster batteries Connect the other end of the negative cable to the machine frame as far away from the mac...

Page 165: ...ilate the area where batteries are being charged Stop or cut back charging rate if battery case feels hot or is venting electrolyte Battery temperature must not exceed 52 C 125 F OUT1739 0000248 19 05AUG02 1 1 Replacing Batteries Your machine has two 12 volt batteries with negative ground Batteries must meet one of the specifications below Specification Battery Cold Cranking Amps At 18 C 0 F 800 B...

Page 166: ...Machine Regularly T6642EJ UN 18OCT88 Remove any grease oil fuel or debris build up to avoid possible injury or machine damage IMPORTANT Directing pressurized water at electronic electrical components or connectors bearings and hydraulic seals fuel injection pumps or other sensitive parts and components may cause product malfunctions Reduce pressure and spray at a 45 to 90 degree angle High pressur...

Page 167: ...ulting in cracks that will weaken the material Never use substances such as Trichloethylene Carbon Tetrachloride or petroleum products Thoroughly rinse the windows after washing and dry with clean soft towels To minimize scratches and improve visibility by filling in existing scratches it is recommended that the windows be waxed regularly Some of the several commercially available waxes that are r...

Page 168: ...us Machine TX14740 0001FA4 19 10DEC02 1 5 Replacing Fuses T158168B UN 30JUL02 Rear Entry Cab T147142C UN 16APR02 Side Entry Cab 1 Main Fuse Block 2 Load Center Fuse Block Continued on next page 4 1 8 081407 PN 164 ...

Page 169: ...ipment 10 Amp Fuse marked OPT 2 ALT F10 Optional Equipment 5 Amp Fuse marked OPT 3 BATT F11 Work and Drive Lights 20 Amp Fuse marked lamp F12 Windshield Wiper And Washer 10 Amp Fuse marked wiper F13 Air Conditioner And Heater 20 Amp Fuse marked heater F14 Horn 10 Amp Fuse Marked Horn not used with air horn option F15 Radio 5 Amp Fuse marked radio F16 Lighter 10 Amp Fuse marked lighter F17 Dome Lig...

Page 170: ...ected 10 Amp Fuse F45 12 Volt Protected 10 Amp Fuse F46 12 Volt Protected 30 Amp Fuse F47 Windshield Wiper rear entry cab 20 Amp Fuse F52 Air Horn 3 Amp Fuse optional F53 Grapple 10 Amp Fuse F54 Not Used 30 amp spare IMPORTANT Install fuse with correct amperage rating to prevent electrical system damage from overload Fuses F35 through F38 F43 through F47 and F52 through F54 are located on fuse blo...

Page 171: ...0 Amp Fuse F48 Battery Power To Cab Tilt 150 Amp Fuse optional F49 Cab Tilt 7 5 Amp Fuse optional F55 Power Condenser 20 Amp Circuit Breaker F58 Air Compressor 30 Amp Circuit Breaker optional F59 Pressure Switch 7 5 Amp Fuse optional IMPORTANT Install fuse with correct amperage rating to prevent electrical system damage from overload Fuses F21 F32 through F34 F39 through F42 F48 F49 F55 F58 and F5...

Page 172: ...d behind the cab TX14740 000001A 19 03FEB03 1 1 Drain Air Compressor Accumulator T164840 UN 31JAN03 1 Drain Valve Approximately once a week open drain valve 1 to drain condensation from accumulator Close drain valve OUT1739 000024E 19 16JUN06 1 3 Adjusting Bucket to Arm Joint T95775 UN 10NOV88 Your machine has a bucket adjustment system to take up play When play increases remove shims as follows 1...

Page 173: ...ral times during a working day due to changing soil type and moisture content Adjust tracks in the actual operating conditions TIGHT TRACK Packing causes a tight track If material packs in the undercarriage adjust tracks with the material packed in the components While the track spring will recoil and the machine can continue to operate with a tight track continued operation will result in excessi...

Page 174: ...1500 2600 1920 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 a Grade 2 applies for hex cap screws not hex bolts up to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 mm long and for all other types of bolts and screws of any length b Lubricated means coated with a lubri...

Page 175: ...580 1160 2000 1475 M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 a Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings b Dry means plain or zinc plate...

Page 176: ...t will allow you or your authorized dealer to pinpoint a specific test or repair needed to restore the machine to design specifications A location will be required which is level and has adequate space to complete the checks No tools or equipment are needed to perform the checkout Complete the necessary visual checks oil levels oil condition external leaks loose hardware linkage wiring etc prior t...

Page 177: ... right Run engine a few minutes to warm coolant before check Engine OFF Key switch ON Does battery relay click Do engine coolant temperature gauge 1 and fuel gauge 2 needles move to the right Do all monitor indicators light during bulb check sequence After 2 3 seconds do only the alternator voltage indicator 3 engine oil pressure indicator 4 and dig mode indicator 5 remain lit Does monitor display...

Page 178: ...ator lights after engine starts of ok go to your authorized dealer 1 1 Work Mode Circuit Checks SET WORKMODE 3 2 1 T137610 UN 02FEB01 1 Mode Selection Switch 2 Dig Mode Indicator 3 Attachment Mode Indicator Auto idle auto acceleration switch OFF Pilot shut off lever in LOCKED position Push work mode selection switch 1 to select desired work mode Do corresponding dig mode 2 or attachment mode 3 ind...

Page 179: ...ine speed decrease after 4 seconds Slowly actuate any dig function control lever Does engine speed return to fast idle YES Go to next check NO Check fuse 1 in fuse box of ok go to your authorized dealer 1 1 Pilot Shut Off Valve Checks CAUTION Machine may move during this check Make sure area is clear and large enough to operate all controls T7351CC UN 22AUG90 Run engine at slow idle Pilot shut off...

Page 180: ...witch Pilot shut off lever in UNLOCKED position forward Push travel pedals or levers forward or pull travel pedals or levers rearward Does travel alarm sound Push travel pedals or levers and allow travel alarm to operate for a minimum of 15 seconds While continuing travel push travel alarm cancel switch 1 Does travel alarm stop sounding YES Go to next check NO Check fuse 19 in fuse box of ok go to...

Page 181: ...n Head T123058 19 29JUL99 Road Builder Engine at slow idle Operate machine in clear area Move pilot shut off lever to UNLOCKED position Slowly move hydraulic levers to all positions on decals Do front attachment boom arm and swing move as decals show YES Go to next check NO Install decals to match pattern Go to your authorized dealer 4 2 6 081407 PN 177 ...

Page 182: ...Engine at slow idle Fill bucket with dirt and position bucket at maximum reach with bucket 2 in 50 mm above ground Observe bucket for 1 minute Does bucket drift down to ground within 1 minute YES Go to your authorized dealer NO Go to next check 1 1 Control Valve Lift Check Test T6292AZ UN 19OCT88 Engine at slow idle Position machine as illustrated Slowly actuate pilot controller to lower boom exte...

Page 183: ...Engine at fast idle Travel speed switch in fast position Drive machine at full speed forward on a flat and level area After machine is moving slowly move the arm control lever from neutral to full actuation to extend the arm Does machine mistrack excessively when the arm is extended NOTE Machine will slow down during this test YES Go to your authorized dealer NO Go to next check 1 1 Travel Speed S...

Page 184: ...nds 2 9 0 3 Boom Lower cylinder retract Cycle Time seconds 2 4 0 3 Arm In cylinder extend Cycle Time seconds 3 6 0 3 Arm Out cylinder retract Cycle Time seconds 2 6 0 3 Bucket Load cylinder extend Cycle Time seconds 3 2 0 3 Bucket Dump cylinder retract Cycle Time seconds 2 1 0 3 Swing Left Or Right For 3 Revolutions From A Running Start Cycle Time seconds 13 5 1 0 Zaxis 200LC Forester Travel Speed...

Page 185: ...ification Track Raised For 3 Revolutions From A Running Start Check In Forward And Reverse With Travel Speed Switch In FAST Position Cycle Time seconds 18 7 1 0 Track Raised For 3 Revolutions From A Running Start Check In Forward And Reverse With Travel Speed Switch In SLOW Position Cycle Time seconds 30 0 2 0 Zaxis 250 Forester Travel Speed High Drawbar Specification Drive 20 m 65 ft From A Runni...

Page 186: ...er extend Cycle Time seconds 6 6 0 3 Boom Lower cylinder retract Cycle Time seconds 6 0 0 3 Arm In cylinder retract Cycle Time seconds 3 8 0 3 Arm Out cylinder extend Cycle Time seconds 6 5 0 3 Swing Left Or Right For 3 Revolutions From A Running Start Cycle Time seconds 15 0 18 0 Swing Left Or Right For 3 Revolutions From A Running Start with optional 2nd swing gearbox Cycle Time seconds 18 1 21 ...

Page 187: ...heck and Adjust Track Sag See Section 3 3 for more detailed information YES Go to your authorized dealer for repair if oil leakage is noted from idlers or rollers NO Go to next check 1 1 Horn Circuit Check T137734 UN 01FEB01 1 Horn Button Key switch ON Press horn button 1 on top of left control lever Does horn sound YES Go to next check NO Check fuse 14 in fuse box of ok go to your authorized deal...

Page 188: ...rd easily Does lever unlock and lock easily to hold seat back in position See Adjusting the Seat See Section 2 1 for more detailed information YES Go to next check NO Inspect linkage and repair Go to your authorized dealer 1 1 Window Checks Pull window up and back until it catches in latch for convenient storage overhead Does pin move smoothly to lock and unlock window Do latches operate freely Do...

Page 189: ...and outside of cab Release latches 1 and remove secondary exit panel Does cover open and close freely YES Go to next check NO Inspect Repair 1 1 Side Entry Cab Secondary Exit Check T136074B UN 14DEC00 Side Entry Cab Secondary rear window Exit 1 Latch NOTE This panel can be opened from both inside and outside of cab Release latches 1 and remove secondary exit panel Does panel open and close freely ...

Page 190: ... Checks Verify the following are working properly and all mounting brackets and hardware are tight All latches and locks Hood and access doors Hoses and clamps Fan shroud and fan guard Fan direction YES Check complete NO Repair or replace if necessary 4 2 15 081407 PN 186 ...

Page 191: ...lest to verify to least likely more difficult to verify When diagnosing a problem use all possible means to isolate the problem to a single component or system Use the following steps to diagnose problems Step 1 Operational Checkout Procedure Step 2 Troubleshooting charts Step 3 Adjustments Step 4 See your authorized dealer 4 3 1 081407 PN 187 ...

Page 192: ...heck water separator primed Water in fuel Check drain and refill Leaks in fuel system Check fuel system connections Contaminated fuel Drain tank Add clean fuel Check water separator Air in fuel system Bleed air Low battery power Charge or install new batteries Slow cranking speed poor electrical Clean and tighten battery and starter connection connections Wrong engine oil Use correct oil Air filte...

Page 193: ...not working correctly or too cool Injection pump Go to your authorized dealer Engine Starts But Will Not Power on POW ON fuse Replace fuse Continue To Run Engine Not Developing Full Air filters clogged Clean or replace filter elements Power Fuel filter clogged Change filter Bleed air Water separator Change Bleed air Contaminated fuel Drain fuel tank Change water separator change fuel filter bleed ...

Page 194: ...backwards Install fan correctly Cooling system passages clogged Flush cooling system Low Engine Oil Pressure Oil level low Add oil Oil filter clogged Install new oil filter Wrong oil Use correct oil Oil leaks Go to your authorized dealer Engine temperature too high Check cooling system Engine Uses Too Much Oil Wrong oil Use correct oil Oil leaks Check engine oil drain plug Engine temperature too h...

Page 195: ... Exhaust Smoke Is White Wrong fuel Use correct fuel Cold engine Run engine until warm Turbocharger Excessively Noisy Air leak in engine intake or exhaust Inspect repair Or Vibrates manifold Oil Dripping From Turbocharger Excessive crankcase pressure Check vent tube to ensure tube is Adapter not clogged Clean Turbocharger oil return line carbon Remove line Inspect clean buildup where line passes ex...

Page 196: ...ld down clamp Loose battery hold down clamp Replace both batteries and install hold down clamp Frozen battery Replace both batteries Keep batteries fully charged in cold weather Low Battery Output Low water level Add water Dirty or wet battery top causing Clean and wipe battery top dry discharge Corroded or loose battery cables Clean and tighten battery cables Broken battery post Wiggle battery po...

Page 197: ...s Key switch malfunction Disconnect battery ground Charging Indicator Light On Loose or glazed alternator belt Check belt Replace if glazed Engine Running Excessive electrical load from added Remove accessories or install higher accessories output alternator Loose or corroded electrical Inspect clean or tighten electrical connections on battery ground connections strap starter or alternator Batter...

Page 198: ...h Panel Switches or Fuse Replace fuse RPM Dial Work OUT1739 0000256 19 05AUG02 1 1 Front Attachments Electrical Controls Live Heel Grapple Thumb Symptom Problem Solution Function Does Not Work Fuse Replace fuse Relay Go to your authorized dealer Solenoid Go to your authorized dealer Connector Clean contacts reconnect Joystick Switch Go to your authorized dealer 4 3 8 081407 PN 194 ...

Page 199: ...aulic tank cap Replace cap Power Boost Does Not Work Fuse Check fuse Hydraulic Oil Overheats Wrong oil Use correct oil Clogged radiator or oil cooler Clean and straighten fins Radiator screen clogged Remove and clean Clogged filters Install new filters Low oil level Fill tank to full mark Contaminated oil Drain oil and refill Oil Foams High or low oil level Correct level Wrong oil Use correct oil ...

Page 200: ...t and correct kinked Travel Is Jerky Track sag adjustment Adjust tension Rocks or mud jammed in track frame Remove and repair Engine Stops When Travel Or Water separator clogged Drain Change element Control Lever Moved NOTE If any other problems are encountered which require special tools or machine knowledge to correct see your authorized dealer 4 3 10 081407 PN 196 ...

Page 201: ...ntil 30 days after receipt of machine have elapsed Paint areas to prevent rust Replace decals where needed 4 Apply waste oil to track chains Run machine back and forth several times Park machine on a hard surface to prevent tracks from freezing to ground 5 Store machine in a dry protected place If stored outside cover with a waterproof material IMPORTANT LPS 3 Rust Inhibitor can destroy painted fi...

Page 202: ...ecord all 10 characters of the Product Identification Number 1 OUT1739 000025A 19 05AUG02 1 1 Record Engine Serial Number T7748EA UN 30OCT92 A Engine Serial Number Engine Serial Number A TX14740 0001D4C 19 11MAY06 1 1 Record Travel Motor Serial Numbers T144978 UN 30AUG01 Travel Motor Serial Number Travel Motor Serial Number NOTE Cover removed for clarity of photograph 4 5 1 081407 PN 198 ...

Page 203: ... take Mark your machine with your own numbering system Take color photographs from several angles of each machine VD76477 00003AC 19 05DEC05 1 1 Keep Machines Secure TS230 UN 24MAY89 1 Install vandal proof devices 2 When machine is in storage Lower equipment to the ground Set wheels to widest position to make loading more difficult Remove any keys and batteries 3 When parking indoors put large equ...

Page 204: ...tem With Full Flow Filter With Bypass Cooling Fan Suction Electrical System 24 Volt Batteries 2 12 Volt 180 Minutes Reserve Capacity Zaxis 250 Engine Specifications 200016 Isuzu CC 6BG1TRA Type Diesel 4 Cycle Turbocharged Watercooled In Line Direct Injection Bore And Stroke 105 x 125 mm 4 13 x 4 92 in Cylinders 6 Displacement 6 5 L 396 cu in Rated Output 118 kW 2000 min 1 160 PS 2000 rpm HP Mode 1...

Page 205: ...ure System With Full Flow Filter With Bypass Cooling Fan Suction Electrical System 24 Volt Batteries 2 12 Volt 180 Minutes Reserve Capacity Zaxis 350 Engine Specifications Isuzu AA 6HK1XQA Type Diesel 4 Cycle Turbocharged Watercooled In Line Direct Injection Bore And Stroke 115 x 125 mm 4 53 x 4 92 in Cylinders 6 Displacement 7 8 L 475 cu in Rated Output 177 kW 1900 min 1 240 PS 1900 rpm HP Mode 1...

Page 206: ...0 qt Travel Gearbox each Oil Capacity 5 2 L 1 4 gal Pump Drive Gearbox Oil Capacity 1 0 L 1 1 qt Zaxis 250 Drain And Refill Capacities Counterweight Fuel Tank Capacity 1020 L 269 gal Cooling System Capacity 23 0 L 6 1 gal With 7 in Riser 24 0 L 6 3 gal With 48 in Riser Engine Oil Capacity Including Filter Change 25 L 6 6 gal Hydraulic Tank Oil Capacity 148 0 L 39 0 gal Hydraulic System Capacity 25...

Page 207: ...in riser Engine Oil Capacity Including Filter Change 36 L 9 5 gal Hydraulic Tank Oil Capacity 159 0 L 42 0 gal Hydraulic System Capacity 328 0 L 87 0 gal Road Builder 450 0 L 119 0 gal Log Loaderr Swing Gearbox Oil Capacity 14 0 L 15 0 qt Optional 2nd Swing Gearbox Oil Capacity 2 6 L 2 8 qt Travel Gearbox each Oil Capacity 7 5 L 2 0 gal Pump Drive Gearbox Oil Capacity 1 0 L 1 3 qt 4 6 4 081407 PN ...

Page 208: ...tice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes full counterweight fuel tank with standard undercarriage 2 91 m 9 ft 7 in arm 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 3660 mm 12 ...

Page 209: ...ft 2 in 7 Minimum Ground Clearance Distance 445 mm 1 ft 5 in 8 Center Of Sprocket To Center Of Distance 2390 mm 7 ft 10 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Undercarriage Width 3209 mm 10 ft 6 in 11 Machine Overall Length 9688 mm 31 ft 10 in Machine Operating Weight 24 578 kg 54 187 lb 4 6 6 081407 PN 205 ...

Page 210: ...out notice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes 2910 mm 9 ft 7 in undercarriage full counterweight fuel tank 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 3660 mm 12 ft 0 in 2 U...

Page 211: ...mm 15 ft 5 in 7 Minimum Ground Clearance Distance 750 mm 2 ft 5 in 8 Center of Sprocket To Center of Distance 2 92 m 9 ft 7 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Track Shoe Height 1079 mm 3 ft 6 in 11 Machine Overall Length 13 72 m 45 ft Machine Operating Weight 31 383 kg 69 187 lb 4 6 8 081407 PN 207 ...

Page 212: ...thout notice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes full counterweight fuel tank 2910 mm 9 ft 7 in undercarriage 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 3660 mm 12 ft 0 in 2...

Page 213: ...rance Distance 750 mm 2 ft 5 in 8 Center Of Sprocket To Center Of Distance 2920 mm 9 ft 7 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Track Shoe Height 1079 mm 3 ft 6 in 11 Machine Overall Length 14080 mm 46 ft grapple fully retracted 15330 mm 50 ft 4 in grapple fully extended Machine Operating Weight 30 929 kg 68 187 lb 4 6 10 081407 PN 209 ...

Page 214: ...Miscellaneous Specifications OUT1739 0000265 19 07AUG02 1 1 Zaxis 200LC Forester Road Builder Working Ranges T147543 UN 21NOV01 4 6 11 081407 PN 210 ...

Page 215: ...Miscellaneous Specifications OUT1739 0000266 19 07AUG02 1 1 Zaxis 200LC Forester Live Heel Grapple Working Ranges T147544 UN 21NOV01 4 6 12 081407 PN 211 ...

Page 216: ...Miscellaneous Specifications OUT1739 0000267 19 07AUG02 1 1 Zaxis 200LC Forester Articulated Grapple Working Ranges T147545 UN 21NOV01 4 6 13 081407 PN 212 ...

Page 217: ... 10 20 7 62 25 6 10 20 3497 7710 a 4 57 15 4028 8880 a 3955 8720 a 3 05 10 6124 13700 a 4908 10820 a 4322 9550 a 1 52 5 8418 18550 a 5942 13100 a 4826 10640 Ground Line 9711 21410 a 6695 14760 4704 10370 1 52 5 6219 13710 a 9997 22040 a 6582 14510 4636 10220 3 05 10 11285 24880 a 9544 21040 a 6577 14500 4658 10270 4 57 15 11304 24920 a 8219 18120 a 5960 13140 a LIFTING OVER SIDE m ft 3 05 10 4 57 ...

Page 218: ...00 a 5897 13000 7 62 25 6532 14400 a 5897 13000 a 4354 9600 1 52 20 6804 15000 a 5987 13200 a 4309 9500 4 57 15 7439 16400 a 6169 13600 4354 9600 3 05 10 8210 18100 a 6033 13300 4354 9600 3266 7200 1 53 5 8664 19100 5897 13000 4309 9500 3221 7100 Ground Line 8346 18400 5761 12700 4173 9200 3175 7000 1 52 5 8165 18000 5625 12400 4128 9100 3 05 10 6849 15100 a 4128 11200 a 3130 6900 a LIFTING OVER S...

Page 219: ... a 5897 13000 7 62 25 6532 14400 a 5897 13000 4354 9600 1 52 20 6804 15000 a 5987 13200 a 4309 9500 4 57 15 7439 16400 a 6169 13600 4354 9600 3 05 10 8210 18100 a 6033 13300 4354 9600 3266 7200 1 53 5 8664 19100 5897 13000 4309 9500 3221 7100 Ground Line 8346 18400 5761 12700 4173 9200 3175 7000 1 52 5 8165 18000 5625 12400 4128 9100 3 05 10 6849 15100 a 4128 9100 a 3130 6900 a LIFTING OVER SIDE m...

Page 220: ...5534 12200 a 7 62 25 5262 11600 a 4717 10400 a 1 52 20 5443 12000 a 4717 10400 a 3719 8200 4 57 15 7348 16200 a 5987 13200 a 4944 10900 a 3719 8200 3 05 10 6668 14700 a 5262 11600 a 3629 8000 1 53 5 7257 16000 a 5126 11300 3538 7800 Ground Line 10795 23800 a 7439 16400 4944 10900 3447 7600 1 52 5 9888 21800 a 6849 15100 a 4763 10500 a 2903 6400 a 3 05 10 7666 16900 a 5307 11700 a 3356 7400 a LIFTI...

Page 221: ... 5534 12200 a 7 62 25 5262 11600 a 4717 10400 a 1 52 20 5443 12000 a 4717 10400 a 3719 8200 4 57 15 7348 16200 a 5987 13200 a 4944 10900 a 3719 8200 3 05 10 6668 14700 a 5262 11600 a 3629 8000 1 53 5 7257 16000 a 5126 11300 3538 7800 Ground Line 10795 23800 a 7439 16400 4944 10900 3447 7600 1 52 5 9888 21800 a 6849 15100 a 4763 10500 a 2903 6400 a 3 05 10 7666 16900 a 5307 11700 a 3356 7400 a LIFT...

Page 222: ...erweight Clearance 7 Minimum Ground Clearance Item Measurement Specification 1 Sprocket Center To Idler Center Distance 3840 mm 12 ft 7 in 4050 mm 13 ft 3 in High Drawbar 2 Undercarriage Length 4645 mm 15 ft 5 in 5018 mm 16 ft 6 in High Drawbar 3 Counterweight Clearance Distance 1090 mm 3 ft 7 in 1448 mm 4 ft 9 in High Drawbar 4 Rear End Swing Radius Distance 3165 mm 10 ft 5 in 3165 mm 10 ft 5 in ...

Page 223: ... Drawbar 8 Center Of Sprocket To Center Of Distance 2692 mm 8 ft 10 in Sprocket 2692 mm 8 ft 10 in High Drawbar 9 Track Shoe Width 700 mm 28 in 700 mm 28 in High Drawbar 10 Undercarriage Width 3403 mm 11 ft 2 in 3403 mm 11 ft 2 in High Drawbar 11 Machine Overall Length 10363 mm 34 ft 10483 mm 34 ft 5 in High Drawbar Machine Operating Weight 29 257 kg 64 500 lb 32 810 kg 72 335 lb High Drawbar 4 6 ...

Page 224: ...t notice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes 2910 mm 9 ft 7 in undercarriage full counterweight fuel tank 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 4050 mm 13 ft 3 in 2 Und...

Page 225: ...5455 mm 17 ft 11 in With 72 in Riser 7 Minimum Ground Clearance Distance 750 mm 2 ft 5 in 8 Center of Sprocket To Center Of Distance 2924 m 9 ft 7 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Track Shoe Height 1250 mm 4 ft 1 in 11 Machine Overall Length 15409 mm 50 ft 7 in Machine Operating Weight 39 995 kg 88 172 lb 4 6 22 081407 PN 221 ...

Page 226: ...ut notice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes 2910 mm 9 ft 7 in undercarriage full counterweight fuel tank 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 4050 mm 13 ft 3 in 2 Un...

Page 227: ...5455 mm 17 ft 11 in With 72 in Riser 7 Minimum Ground Clearance Distance 750 mm 2 ft 5 in 8 Center of Sprocket To Center Of Distance 2924 m 9 ft 7 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Track Shoe Height 1250 mm 4 ft 1 in 11 Machine Overall Length 14684 mm 48 ft 2 in Machine Operating Weight 40 828 kg 90 011 lb 4 6 24 081407 PN 223 ...

Page 228: ...Miscellaneous Specifications TX14740 0000029 19 26FEB03 1 1 Zaxis 250 Forester Road Builder 9 ft 9 in Arm Working Ranges T165855 UN 26FEB03 4 6 25 081407 PN 224 ...

Page 229: ...Miscellaneous Specifications TX14740 000002A 19 26FEB03 1 1 Zaxis 250 Forester Road Builder 10 ft 2 in Arm Working Ranges T165856 UN 26FEB03 4 6 26 081407 PN 225 ...

Page 230: ...Miscellaneous Specifications TX14740 0000023 19 24FEB03 1 1 Zaxis 250 Forester Live Heel Grapple Working Ranges T165802 UN 25FEB03 4 6 27 081407 PN 226 ...

Page 231: ...Miscellaneous Specifications TX14740 0000024 19 24FEB03 1 1 Zaxis 250 Forester Butt N Top Grapple Working Ranges T165804 UN 25FEB03 4 6 28 081407 PN 227 ...

Page 232: ... 8170 a 4 57 15 4681 10320 a 4413 9730 a 3 05 10 7788 17170 a 5744 12830 a 4953 10920 a 3175 7000 a 1 52 5 10373 22870 a 7057 15560 a 5601 12350 a 4104 9040 a Ground Line 11589 25550 a 7983 17600 a 5565 12270 4082 9000 a 1 52 5 5846 12890 a 11684 25760 a 7838 17280 5465 12050 3 05 10 9384 20690 a 11072 24410 a 7833 17270 5474 12070 4 57 15 12968 28590 a 9616 21200 a 7153 15770 a LIFTING OVER SIDE ...

Page 233: ...40 a 3180 7010 a 3 05 10 9067 19990 a 6668 14700 a 5643 12440 a 4854 10730 a 1 52 5 12220 26940 a 8206 18090 a 6477 14280 a 5248 11570 Ground Line 11009 24270 a 9362 20640 a 6913 15240 5144 11340 1 52 5 5316 11720 a 13876 30590 a 9757 21510 6795 14980 4903 10810 a 3 05 10 10015 22080 a 13336 29400 a 9748 21490 6786 14960 4 57 15 15631 34460 a 11948 26340 a 8954 19740 a 6 1 20 8931 19690 LIFTING OV...

Page 234: ...57 15 6577 14500 a 7802 17200 a 6532 14400 a 5443 12000 a 3 05 10 7076 15600 a 8256 18200 a 6713 14800 a 5489 12100 a 3447 7600 a 1 53 5 10977 24200 a 8573 18900 a 6759 14900 a 5443 12000 a 3674 8100 a Ground Line 11295 24900 a 8573 18900 a 6668 14700 a 5171 11400 a 1 52 5 10569 23300 a 8074 17800 a 6214 13700 a 4536 10000 a 3 05 10 8800 19400 a 6849 15100 a 4627 10200 a 3175 7000 a 4 57 15 4763 1...

Page 235: ...8256 18200 a 6895 15200 a 5851 12900 a 4 57 15 8936 19700 a 9072 20000 a 7258 16000 a 5942 13100 a 3 05 10 9934 21900 a 7666 16900 a 6033 13300 a 4536 10000 a 1 53 5 10478 23100 a 7847 17300 a 5942 13100 a 4173 9200 a Ground Line 14606 32200 a 10297 22700 a 7575 16700 a 5534 12200 a 3266 7200 a 1 52 5 12655 27900 a 9208 20300 a 6668 14700 a 4536 10000 a 3 05 10 9390 20700 a 7031 15500 a 4899 10800...

Page 236: ...erweight Clearance 7 Minimum Ground Clearance Item Measurement Specification 1 Sprocket Center To Idler Center Distance 4050 mm 13 ft 3 in 4050 mm 13 ft 3 in High Drawbar 2 Undercarriage Length 5020 mm 16 ft 6 in 5095 mm 16 ft 9 in High Drawbar 3 Counterweight Clearance Distance 1489 mm 4 ft 11 in 1453 mm 4 ft 9 in High Drawbar 4 Rear End Swing Radius Distance 3580 mm 11 ft 9 in 3580 mm 11 ft 9 in...

Page 237: ...h Drawbar 8 Center Of Sprocket To Center Of Distance 2690 mm 8 ft 10 in Sprocket 2690 mm 8 ft 10 in High Drawbar 9 Track Shoe Width 700 mm 28 in 700 mm 28 in High Drawbar 10 Undercarriage Width 3390 mm 11 ft 2 in 3390 mm 11 ft 2 in High Drawbar 11 Machine Overall Length 11114 mm 36 ft 6 in 11128 mm 36 ft 7 in High Drawbar Machine Operating Weight 28 873 kg 85 700 lb 41 447 kg 91 375 lb High Drawba...

Page 238: ...ut notice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes 2910 mm 9 ft 7 in undercarriage full counterweight fuel tank 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 4050 mm 13 ft 3 in 2 Un...

Page 239: ...5474 mm 18 ft 0 in 72 in Riser 7 Minimum Ground Clearance Distance 687 mm 2 ft 3 in 8 Center Of Sprocket To Center Of Distance 2913 m 9 ft 7 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Track Shoe Height 1262 mm 4 ft 2 in 11 Machine Overall Length 16671 mm 54 ft 8 in Machine Operating Weight 45 790 kg 100 950 lb 4 6 36 081407 PN 235 ...

Page 240: ...ut notice Wherever applicable specifications are in accordance with PCSA and SAE standards Except where otherwise noted these specifications are based on a machine equipped with 700 mm 28 in shoes 2910 mm 9 ft 7 in undercarriage full counterweight fuel tank 79 kg 175 lb operator and standard equipment Item Measurement Specification 1 Sprocket Center To Idler Center Distance 4050 mm 13 ft 3 in 2 Un...

Page 241: ... 5474 mm 18 ft 0 in With 72 in Riser 7 Minimum Ground Clearance Distance 687 mm 2 ft 3 in 8 Center Of Sprocket To Center Of Distance 2913 m 9 ft 7 in Sprocket 9 Track Shoe Width 700 mm 28 in 10 Track Shoe Height 1262 mm 4 ft 2 in 11 Machine Overall Length 15756 mm 51 ft 8 in Machine Operating Weight 44 693 kg 98 530 lb 4 6 38 081407 PN 237 ...

Page 242: ...Miscellaneous Specifications TX14740 0001FB3 19 07JAN03 1 1 Zaxis 350 Forester Live Heel Grapple Working Ranges T163188 UN 17FEB03 4 6 39 081407 PN 238 ...

Page 243: ...Miscellaneous Specifications TX14740 0001FB2 19 07JAN03 1 1 Zaxis 350 Forester Butt N Top Grapple Working Ranges T163189 UN 17FEB03 4 6 40 081407 PN 239 ...

Page 244: ... a 6754 14890 a 3 05 10 14769 32560 a 10242 22580 a 8264 18220 a 7208 15890 a 1 52 5 10373 22870 a 11961 26370 a 9222 20330 a 7380 16270 Ground Line 9634 21240 a 12891 28420 a 9621 21210 7235 15950 1 52 5 7598 16750 a 9004 19850 a 12932 28510 a 9489 20920 7167 15800 3 05 10 11648 25680 a 12120 26720 a 12111 26700 a 9421 20770 a 4 57 15 9548 21050 a 12877 28390 a 10174 22430 a 7498 16530 a LIFTING ...

Page 245: ...338 27200 a 9525 21000 7303 16100 5806 12800 3 05 10 15377 33900 a 12791 28200 9344 20600 7303 16100 5761 12700 a 1 53 5 17509 38600 a 12383 27300 9253 20400 5035 11100 5670 12500 Ground Line 17509 38600 12202 26900 9072 20000 7031 15500 5579 12300 1 52 5 16239 35800 a 11929 26300 8890 19600 6940 15300 4899 10800 a 3 05 10 13562 29900 a 10932 24100 a 8528 18800 a 6078 13400 a 4 57 15 7938 17500 a ...

Page 246: ...9700 a 14651 32300 a 11884 26200 a 8936 19700 6668 14700 3 05 10 16012 35300 a 12020 26500 8709 19200 6532 14400 1 53 5 23678 52200 a 16828 37100 a 11657 25700 8528 18800 6441 14200 Ground Line 22816 50300 a 16511 36400 a 11340 25000 8346 18400 6396 14100 1 52 5 19822 43700 a 14832 32700 a 11203 24700 8255 18200 4944 10900 a 3 05 10 15059 33200 a 11748 25900 a 8754 19300 a 5806 12800 a 4 57 15 793...

Page 247: ...ab 2 1 14 Arm Cab tilt power pack Grease 3 4 5 Oil level check 3 3 6 Armrest Cab forestry Adjustment 2 1 17 Door handles 2 1 14 2 1 15 Articulated grapple valve in head Release handle 2 1 14 Control lever switches 2 1 3 Cab rear entry Control levers 2 2 13 Heater and air conditioner 2 1 13 Attachment mode Carrier roller oil specification 3 1 6 Indicator 2 1 3 Case Drain Auto acceleration Replace F...

Page 248: ...ne oil pressure Shipping Zaxis 250 Forester butt n top Indicator 2 1 3 grapple 2 2 34 Engine RPM dial 2 1 6 Shipping Zaxis 250 Forester live heel Exit secondary 2 1 16 grapple 2 2 33 Shipping Zaxis 250 Forester road builder 2 2 30 Shipping Zaxis 250 Forester road builder high F drawbar 2 2 31 Shipping Zaxis 350 Forester butt n top grapple 2 2 38 Filter Shipping Zaxis 350 Forester live heel Case Dr...

Page 249: ...3 2 1 Left control 2 2 14 Hydraulic Pilot control shut off 2 1 7 Control shut off lever 2 1 7 Right control 2 2 14 Fluid 3 1 4 Steering 2 2 6 Oil level check 3 4 3 Levers Suction screen clean 3 12 1 3 12 4 Location 2 1 1 Sump drain 3 8 1 Lift capacity System troubleshooting 4 3 9 Zaxis 200LC Forester articulated grapple 9 ft 2 Tank filter replace 3 10 2 in 4 6 17 Tank fluid change 3 12 1 3 12 4 Za...

Page 250: ... 4 6 7 Zaxis 200LC Forester road builder 4 6 5 Panels Zaxis 250 Forester butt n top grapple 4 6 23 Location 2 1 1 Zaxis 250 Forester live heel grapple 4 6 21 Parking machine 2 2 20 Zaxis 250 Forester road builder 4 6 19 Pedal Zaxis 350 Forester butt n top grapple 4 6 37 Steering 2 2 6 Zaxis 350 Forester live heel grapple 4 6 35 Pedals Zaxis 350 Forester road builder 4 6 33 Location 2 1 1 Maintenan...

Page 251: ...ontrol lever switches 2 1 2 Storage Road builder Machine 4 4 1 Control levers 2 2 7 Storing fuel 3 1 2 Swing Area cleaning 2 2 16 Gearbox oil level check 3 8 1 S Gearbox oil specification 3 1 5 Swing bearing gear Safety features 1 1 1 Grease 3 5 1 3 9 3 Safety instructions 1 2 1 Swing gearbox Screen Oil change 3 10 1 Radiator air inlet 3 3 2 Switch Seat Auto acceleration 2 1 6 Adjustment 2 1 17 Au...

Page 252: ...torque 3 6 1 3 8 8 Zaxis 200LC Forester road builder 4 6 11 Transporting Zaxis 250 Forester butt n top grapple 4 6 28 Machine 2 2 21 Zaxis 250 Forester live heel grapple 4 6 27 Travel Zaxis 250 Forester road builder 10 ft 2 in Gearbox oil level 3 8 6 arm 4 6 26 Gearbox oil specification 3 1 5 Zaxis 250 Forester road builder 9 ft 9 in Travel alarm 2 1 10 arm 4 6 25 Cancel Switch 2 1 10 Zaxis 350 Fo...

Page 253: ......

Page 254: ...Hitachi Construction Machinery Co Ltd Head Office 5 1 Koraku 2 chome Bunkyo ku Tokyo 112 0004 Japan Recycle This manual is printed on recycled paper ...

Page 255: ...200LC 250 350 Operator s Manual OMT200293 ...

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