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Hitachi Zaxis 33U-5A, Operator'S Manual

The Hitachi Zaxis 33U-5A Operator's Manual is now available for free download on our website. This comprehensive manual provides essential information and instructions for operating and maintaining your machine effectively. Get your copy now and unleash the full potential of your Hitachi Zaxis 33U-5A.

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CONTENTS

A. Greasing

 ......................................................................................

7-1

9

Front Joint Pins

 ........................................................................

7-1

9

Bucket

 .........................................................................................

7-1

9

Swing Post and Others

 ..........................................................

7-1

9

Blade Pins

 ...................................................................................

7-2

1

Swing Bearing

 ..........................................................................

7-2

2

Swing Internal Gear

................................................................

7-23

Control Lever Universal Joint ..............................................

7-23

B. Engine

 ..........................................................................................

7-2

4

Engine Oil Level

 .......................................................................

7-2

4

Change Engine Oil 

 .................................................................

7-2

5

Replace Engine Oil Filter

 .......................................................

7-2

5

C. Transmission ..............................................................................

7-28

Travel Reduction Gear

 ...........................................................

7-28

D. Hydraulic System

 .....................................................................

7-3

1

Inspection and Maintenance of Hydraulic  

Equipment

 ...........................................................................

7-3

1

Check Hydraulic Oil Level

 ....................................................

7-3

5

Drain Hydraulic Oil Tank Sump

 ..........................................

7-36

Change Hydraulic Oil

 .............................................................

7-37

Suction Filter Cleaning

 ..........................................................

7-37

Replace Full-Flow Filter

 .........................................................

7-4

1

Replace Pilot Oil Filter Element

 ..........................................

7-43

Check Hoses and Lines

 .........................................................

7-4

5

E. Fuel System

 ................................................................................

7-5

2

Recommended Fuel

 ...............................................................

7-5

2

Check Fuel Level

 ......................................................................

7-53

Check Water Separator 

 ........................................................

7-5

4

Bleed Air from Fuel System

 .................................................

7-5

4

Drain Fuel Tank Sump

 ............................................................

7-5

5

Replace Fuel Main Filter Element

 ......................................

7-56

Replace Fuel Pre-Filter Element (Optional)

 ....................

7-57

Check Fuel Hoses

 ....................................................................

7-5

9

F. Air Cleaner ...................................................................................

7-6

0

Clean Air Cleaner Outer Element

 ......................................

7-6

0

Replace Air Cleaner Outer and Inner Elements

 ............

7-6

0

Replace Air Cleaner Inner Element (Optional)

 ..............

7-6

0

G. Cooling System

 ........................................................................

7-6

2

Check Coolant Level

 ..............................................................

7-63

Check and Adjust Fan Belt Tension 

 ..................................

7-6

4

Change Coolant .......................................................................

7-67

Clean Radiator/Oil Cooler Core

 ..........................................

7-6

9

Clean Air Conditioner Condenser  ....................................

7-7

0

Clean Air Conditioner Condenser Front Screen

 ...........

7-7

0

H. Electrical System

 ......................................................................

7-7

1

Batteries

 .....................................................................................

7-7

1

Check Electrolyte Specific Gravity

 ....................................

7-7

4

Replacing Fuses

 .......................................................................

7-7

5

I. Miscellaneous .............................................................................

7-76

Check and Replace Bucket Teeth

 ......................................

7-76

Change Bucket

 .........................................................................

7-78

Adjust Track Sag (Rubber Crawler) and Check for 

Damage 

................................................................................

7-7

9

Check Rubber Track for Damage

 .......................................

7-7

9

Replace Rubber Crawler 

 ......................................................

7-8

1

Removing Rubber Crawler

 ..................................................

7-8

1

Installing Rubber Crawler

 ....................................................

7-8

2

Check Track Sag (Steel Crawler) (Optional)

 ....................

7-83

Converting the Track

 .............................................................

7-8

5

Check and Replace Seat Belt

 ...............................................

7-86

Check Air Conditioner (Cab equipped machine)

 ........

7-87

Clean and Replace Heater / Air Conditioner Filter

 ......

7-9

0

Clean Circulating Air Filter ...................................................

7-9

0

Replace Circulating Air Filter

 ...............................................

7-9

0

Clean Fresh Air Filter ..............................................................

7-9

2

Replace Fresh Air Filter

 ..........................................................

7-9

2

Clean Fresh Air Filter ..............................................................

7-93

Replace Fresh Air Filter

 ..........................................................

7-93

Clean Cab Floor........................................................................

7-9

4

Check, Clean and Function Check of Injection 

 

Nozzle  ...................................................................................

7-9

5

Inspect and Adjust Valve Clearance 

 ................................

7-9

5

Check and Adjust Injection Timing 

 .................................

7-9

5

Measure Engine Compression Pressure 

.........................

7-9

5

Check Starter and Alternator

 ..............................................

7-9

5

Check Crankcase Breather 

 ..................................................

7-9

5

Check Radiator Cap 

 ...............................................................

7-9

5

Tightening and Retightening Torque of Bolts and 

 

Nuts ........................................................................................

7-96

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL 
CONDITIONS

 ....................................................................................

9-

1

Maintenance Under Special Environmental Conditions

 ...

9-

1

STORAGE

 ........................................................................................

10-

1

Storing the Machine

 ....................................................................

10-

1

TROUBLESHOOTING

 .................................................................

11-

1

Troubleshooting ...........................................................................

11-

1

SPECIFICATIONS

 .........................................................................

12-

1

Std. Specification

 ..........................................................................

12-

1

Working Ranges

 ............................................................................

12-

2

Shoe Types and Applications

 ...................................................

12-3

Bucket Types and Applications ZX33U-5A

 ..........................

12-

4

Std. Specification

 ..........................................................................

12-

5

Working Ranges

 ............................................................................

12-6

Shoe Types and Applications

 ...................................................

12-7

Bucket Types and Applications ZX38U-5A

 ..........................

12-8

Std. Specification

 ..........................................................................

12-

9

Working Ranges

 ..........................................................................

12-1

0

Shoe Types and Applications

 .................................................

12-1

1

Bucket Types and Applications ZX48U-5A

 ........................

12-1

2

Std. Specification

 ........................................................................

12-13

Working Ranges

 ..........................................................................

12-1

4

Shoe Types and Applications

 .................................................

12-1

5

Bucket Types and Applications ZX55U-5A

 ........................

12-16

Std. Specification

 ........................................................................

12-17

Working Ranges

 ..........................................................................

12-18

Shoe Types and Applications

 .................................................

12-1

9

Bucket Types and Applications ZX65USB-5A

 ...................

12-2

0

Summary of Contents for Zaxis 33U-5A

Page 1: ... ZX65USB 5A 020001 and up PRINTED IN JAPAN E 2014 12 ZX33U 5A 38U 5A 48U 5A 55U 5A 65USB 5A HYDRAULIC EXCAVATOR OPERATOR S MANUAL ENMADC 1 3 Hydraulic Excavator URL http www hitachi c m com 33U 5A 38U 5A 48U 5A 55U 5A 65USB 5A ENMADC 1 3 PART NO Operator s Manual This book is printed on recycled paper ...

Page 2: ...for detailed information Warranty is provided as a part of Hitachi s support program for customers who operate and maintain their equipment as described in this manual The warranty is explained on the warranty certificate which you should have received from your dealer This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period In so...

Page 3: ...TOR S STATION BREAK IN OPERATINGTHE ENGINE DRIVINGTHE MACHINE OPERATINGTHE MACHINE TRANSPORTING MAINTENANCE MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONAL ATTACHMENT INDEX INDEX ENMADC 1 3 GETTINGON OFFTHEMACHINE ...

Page 4: ......

Page 5: ...rom Attachment Falling Accident S 28 Prevent Burns S 29 Replace Rubber Hoses Periodically S 30 Avoid High Pressure Fluids S 30 Prevent Fires S 31 Evacuating in Case of Fire S 33 Beware of Exhaust Fumes S 33 Precautions for Welding and Grinding S 34 Avoid Heating Near Pressurized Fluid Lines S 35 Avoid Applying Heat to Lines Containing Flammable Fluids S 35 Precautions for Handling Accumulator and ...

Page 6: ...ional 4 1 Travel Mode Switch 4 3 Traveling 4 4 Traveling on Soft Ground 4 5 Raise One Track by Using Boom and Arm 4 6 Towing Machine 4 7 Operating in Water or Mud 4 8 Precautions for Traveling on Slopes 4 9 Parking the Machine on Slopes 4 10 Parking the Machine 4 10 OPERATING THE MACHINE 5 1 Control Lever ISO Pattern 5 1 Boom Swing Pedal 5 2 Blade Lever 5 3 Precautions for Blade Operation 5 4 Pilo...

Page 7: ... 79 Check Rubber Track for Damage 7 79 Replace Rubber Crawler 7 81 Removing Rubber Crawler 7 81 Installing Rubber Crawler 7 82 Check Track Sag Steel Crawler Optional 7 83 Converting the Track 7 85 Check and Replace Seat Belt 7 86 Check Air Conditioner Cab equipped machine 7 87 Clean and Replace Heater Air Conditioner Filter 7 90 Clean Circulating Air Filter 7 90 Replace Circulating Air Filter 7 90...

Page 8: ...Precautions for Crusher Operation 13 10 AUX Function Lever for Extra Piping Optional 13 13 Auxiliary Flow Rate Control Optional 13 14 Control Lever H pattern HITACHI Excavator Pattern 13 15 Control Lever SAE backhoe Pattern 13 16 Fuel Feed Device Optional ZX48U 5A 55U 5A 65USB 5A 13 17 Numeric Keypad Lock Optional 13 18 Additional Counterweight 13 25 Cab Tilting Mechanism 13 26 Maintenance 13 33 C...

Page 9: ...hine and or components Fill these serial Nos in the blank spaces in this group to immediately make them available upon request Machine MODEL TYPE PRODUCT IDENTIFICATION NUMBER Product Identification Number PRODUCT IDENTIFICATION NUMBER NOTE HCMADC00X00050002 PRODUCT IDENTIFICATION NUMBER PIN Marks to indicate the start and end of the PIN MADB 00 002 MADB 00 003 MADB 00 002 ZX33U 5A 38U 5A ZX48U 5A...

Page 10: ...MACHINE NUMBERS 2 Engine TYPE MFG NO Travel Motor TYPE MFG NO MADB 00 020 MADC 00 010 M1M0 00 004 ...

Page 11: ...MACHINE NUMBERS 3 Swing Motor TYPE MFG NO ZX65USB 5A ZX33U 5A 38U 5A 48U 5A 55U 5A MADB 00 005 MADC 00 001 ...

Page 12: ...MACHINE NUMBERS 4 Hydraulic Pump TYPE MFG NO MADB 00 006 ZX48U 5A 55U 5A ZX33U 5A 38U 5A MADB 00 021 ZX65USB 5A MADC 00 002 ...

Page 13: ...otentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs do not use any of the designated signal words above after ...

Page 14: ...ailure to do so may deteriorate the part safety function and or service life In addition personal accident machine trouble and or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy Do not use attachments and or optional parts or equipment not authorized by Hitachi Failure to do so may deteriorate the safety function and or service life of the machine In addit...

Page 15: ...ctors ambulance service hospital and fire department posted near your telephone Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing fo...

Page 16: ...s to protect against objectionable or uncomfortably loud noises Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury In the walk around inspection be sure to cover all points described in the Inspect Machine Daily Before Starting section in the operator s manual SA 434 SAFETY S 4 SA 435 ...

Page 17: ...ntrol shut off lever or control levers which may result in serious injury or death Avoid storing transparent bottles in the cab Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight possibly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while operating the machine Keep all flammable object...

Page 18: ...ial such as oil grease or mud is present on steps handrails or platforms thoroughly remove such material Adjust the Operator s Seat A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machine The operator should be able to fully depress the pedals and to c...

Page 19: ...OCK position Turn the key switch OFF to stop the engine Before leaving the machine close all windows doors and access covers and lock them up Fasten Your Seat Belt If the machine should overturn the operator may become injured and or thrown from the cab Additionally the operator may be crushed by the overturning machine resulting in serious injury or death Prior to operating the machine thoroughly...

Page 20: ...faulty illumination is present immediately repair it Ensure the cab door windows doors and covers are securely locked Check the mirrors for problems If there is replace the problem part s or clean the mirror Operate Only from Operator s Seat Inappropriate engine starting procedures may cause the machine to runaway possibly resulting in serious injury or death Start the engine only when seated in t...

Page 21: ... starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine Keep Riders off Machine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine Only the operator should be on the machine Keep riders off Riders also obstruct ...

Page 22: ...ation and machine movement Do not permit persons other than the operator to enter areas where there is danger such as flying objects Always beware of the surroundings while operating When working in a small area surrounded by obstacles take care not to hit the upperstructure against obstacles When loading onto trucks bring the bucket over the truck beds from the rear side Take care not to swing th...

Page 23: ... edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground before starting work ...

Page 24: ...ound first using large pieces of steel plates strong and firm enough to easily support the machine Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes Prevent machine tipping over from occurring When operating on rough terrain or on slopes Reduce the engine speed Select slow travel speed mode Operate the machine slowly and be cautious with mac...

Page 25: ...al person to coordinate the job site Make sure that all personnel obey the signal person s directions Confirm Direction of Machine to Be Driven Incorrect travel pedal lever operation may result in serious injury or death Before driving the machine confirm the position of the undercarriage in relation to the operator s position If the travel motors are located in front of the cab the machine will m...

Page 26: ...ep the bucket facing the direction of travel approximately 0 2 to 0 3 m A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover If the direction must be changed move the machine to level ground then change the direction to ensure safe ...

Page 27: ...n the inside surface of the side frame to indicate the machine front direction Select a travel route that is as flat as possible Steer the machine as straight as possible making small gradual changes in direction Before traveling on them check the strengths of bridges and road shoulders and reinforce if necessary Use wood plates in order not to damage the road surface Be careful of steering when o...

Page 28: ...urn the auto idle switch OFF and the power mode switch E or P Run the engine at slow idle speed without load for 5 minutes to cool down the engine Stop the engine and remove the key from the key switch Pull the pilot control shut off lever to LOCK position Block both tracks and lower the bucket to the ground Thrust the bucket teeth into the ground if you must park on a grade Position the machine t...

Page 29: ... BEFORE MOVING MACHINE USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED ALWAYS KEEP THE SIGNAL PERSON IN VIEW Use hand signals which conform to your local regulations when work conditions require a signal person No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and markings used on the job and c...

Page 30: ...ISSION sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area Check that all personnel or obstacles other than the signal person are not present in the working area before operating the machine Never Position Bucket Over Anyone Never lift move or swing bucket above anyone or a truck cab Serious injury or machine damage may result due to...

Page 31: ...TER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade possibly resulting in serious injury or death To avoid tipping Be extra careful before operating on a grade Prepare machine operating area flat Keep the bucket low to the ground and close to the machine Reduce operating speeds to avoid tipping or slipping Avoid changing direction when...

Page 32: ...d water lines If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury Contact your local diggers hot line if available in your area and or the utility companies directly Have them mark all underground utilities Operate with Caution If the front attachment or any other part of the machine hits against an overhead obstacle such as a br...

Page 33: ... the machine If lightning comes close immediately stop the operation and take the following action When you are around the machine or operating cab less machine evacuate to a safe place far away from the machine When you are in the cab stay in the cab until lightning has passed and safety is secured Close the cab doors and windows Lower the bucket to the ground and stop the engine Put your hands o...

Page 34: ...d carefully Never move it suddenly Keep all persons well away from the load Never move a load over a person s head Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth They may come off causing the load to fall Protect Against Flying Debris If flying debris hit eyes or any other par...

Page 35: ...rtments Handle Fluids Safely Avoid Fires Handle fuel with care it is highly flammable If fuel ignites an explosion and or a fire may occur possibly resulting in serious injury or death Do not refuel the machine while smoking or when near open flame or sparks Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flammable Sto...

Page 36: ...ng the machine Always ensure that travel mode display 3 on the monitor is before traveling the machine 5 Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp 6 Never steer the machine while on the ramp If the traveling direction must be changed while the ramp unload the machine from the ramp reposition the machine on ...

Page 37: ...ever to the LOCK position 10 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave the machine unattended If the machine must be raised maintain a 90 to 110 angle between the boom and arm Securely support any machine elements that must be raised for service work Inspect certain parts periodically and repair or replace as necessary Refer to the s...

Page 38: ...quired to work under the floor support the raised operator s station with the fall prevention bars red color to ensure safety When the inspection maintenance work is complete tilt the operator s station downward after housing the fall prevention bars Be sure to slowly lower the operator s station at the time Be careful not to allow the operator s station to tilt down without first stowing the fall...

Page 39: ... or attachment Do not support the machine on cinder blocks hollow tires or props that may crumble under continuous load Do not work under a machine that is supported solely by a jack Stay Clear of Moving Parts Entanglement in moving parts can cause serious injury To prevent accidents care should be taken to ensure that hands feet clothing jewelry and hair do not become entangled when working aroun...

Page 40: ...personal injury or death Travel reduction gears are under pressure As pieces may fly off be sure to keep body and face away from AIR RELEASE PLUG to avoid injury GEAR OIL is hot Wait for GEAR OIL to cool then gradually loosen AIR RELEASE PLUG to release pressure Avoid Injury from Attachment Falling Accident Stored attachments such as buckets hydraulic hammers and blades can fall and cause serious ...

Page 41: ...tor cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be released before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure before removing the cap Hot fluids and surfaces Engine oil gear oil and hydraulic oil also become hot during operation The engine hoses lines and other parts become hot as well Wait for th...

Page 42: ...n severe burns gangrene or otherwise serious injury or death Avoid High Pressure Fluids Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury blindness or death Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard ta...

Page 43: ...Never install bent or damaged lines pipes or hoses Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance Check for Shorts Short circuits can cause fires Clean and tighten all electrical connections Check before each shift or after eight 8 to ten 10 hours operation for loose kinked hardened or frayed electrical cables and wires Check before...

Page 44: ...s dead leaves from entering However flammable materials which have passed through the wire screen may cause fires Check and clean the machine every day and immediately remove accumulated flammable materials Check Key Switch If a fire breaks out failure to stop the engine will escalate the fire hampering fire fighting Always check key switch function before operating the machine every day 1 Start t...

Page 45: ...reak the front or rear window panes with the emergency evacuation hammer to escape from the cab Refer to the explanation pages on the Emergency Evacuation Method Beware of Exhaust Fumes Prevent asphyxiation Engine exhaust fumes can cause sickness or death If you must operate in a building be sure there is adequate ventilation Either use an exhaust pipe extension to remove the exhaust fumes or open...

Page 46: ...ore starting welding Only qualified personnel should perform welding Never allow an unqualified person to perform welding Grinding on the machine may create fire hazards Store flammable objects in a safe place before starting grinding After finishing welding and grinding recheck that there are no abnormalities such as the area surrounding the welded area still smoldering SA 818 SAFETY S 34 ...

Page 47: ...taining Flammable Fluids Do not weld or flame cut pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting them Precautions for Handling Accumulator and Gas Damper High pressure nitrogen gas is sealed in the accumulator and the gas damper Inappropriate handling may cause explosion possibly resulting in serious injury or death Stri...

Page 48: ...ilicon Dust and Other Contamination Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust or other contamination may cause sickness Depending on the work site conditions the risk of inhaling asbestos fiber silicon dust or other contamination may exist Spray water to prevent asbestos fibers silicon dust or oth...

Page 49: ...ll terminals Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire Battery electrolyte is poisonous If the battery should explode battery electrolyte may be splashed into eyes possibly resulting in blindness Be sure to wear eye protection when checking electrolyte specific gravity Service Air Conditioning System Safely If spilled onto s...

Page 50: ...cts used with your machine Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with HITACHI equipment includes such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour wa...

Page 51: ...s practice Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal SAFETY S 39 ...

Page 52: ...r and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipments E GSM900 0 573 W Kg 914 80 MHz DCS 1800 0 130 W Kg 1710 20 MHz WCDMA Band I 0 271 W Kg 1950 00 MHz This data was measured by having each type of communic...

Page 53: ...ire to the base machine or to the communication terminal When required to remove or install the communication terminal consult your nearest Hitachi dealer Do not pinch or forcibly pull cables cords or connectors Failure to do so may cause short circuit or broke circuit that may result in damage and or fire to the base machine or to the communication terminal ...

Page 54: ...e machine operation Always keep the safety signs clean In case a safety sign is broken or lost immediately obtain a new replacement and affix it again in position on the machine Use the part No indicated under the right corner of each safety sign illustration when ordring it at your authorized dealer S 42 SAFETY SIGNS MADG 00 002 ZX65USB 5A ZX33U 5A 38U 5A 48U 5A 55U 5A MADG 00 018 SS3079466 SS438...

Page 55: ...SAFETY SIGNS S 43 SS4642518 MADG 00 002 ZX65USB 5A ZX33U 5A 38U 5A 48U 5A 55U 5A MADG 00 018 SS3090482 MADG 00 006 CAB CANOPY MADG 00 019 ...

Page 56: ...SAFETY SIGNS S 44 SS 024 MADG 00 005 CANOPY SS 259 MADG 00 004 MADG 00 004 CAB ZX33U 5A 38U 5A 48U 5A 55U 5A CAB ZX65USB 5A MADC 00 016 ...

Page 57: ...SAFETY SIGNS S 45 SS4604981 MADG 00 007 ZX33U 5A 38U 5A ZX65USB 5A ZX48U 5A 55U 5A MADB 00 010 MADC 00 012 ...

Page 58: ...pped Machines SAFETY SIGNS S 46 ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A 2 Way Multi Lever Equipped Machines SS 1832 SS 2641 MADG 00 009 MADG 00 018 SS4605065 MADG 00 002 ...

Page 59: ...SAFETY SIGNS S 47 MADB 00 027 SS4433590 MADG 00 011 ZX65USB 5A ZX33U 5A 38U 5A ZX48U 5A 55U 5A ZX33U 5A 38U 5A ZX48U 5A 55U 5A MADG 00 020 MADB 00 026 MADB 00 012 ...

Page 60: ...SAFETY SIGNS S 48 ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A SS4430516 MADB 00 017 MADG 00 012 SSYD00005435 MADB 00 019 ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A MADG 00 016 ...

Page 61: ...ZX65USB 5A SAFETY SIGNS S 49 CAB ZX33U 5A 38U 5A 48U 5A 55U 5A CANOPY SS3088058 MADB 00 014 MADB 00 015 MADG 00 015 ...

Page 62: ...e device such as a cardiac pacemaker please read the instruction manual carefully and follow the instructions before using this machine SAFETY SIGNS S 50 ZX33U 5A 38U 5A ZX48U 5A 55U 5A ZX65USB 5A SS4439187 MADG 00 020 MADG 00 008 MADB 00 012 MADB 00 025 SSYD00006176 ...

Page 63: ...y the cab floor when using the floor tilt mechanism causing serious injury or death Read the operator s manual for safe and proper operation CANOPY CAB ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A CAB SSYD00003167 MADB 00 029 MADB 00 030 MADC 00 018 ...

Page 64: ... Cab Equipped Machine MADB 00 015 MADG 00 013 SS4642980 ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A SAFETY SIGNS S 52 ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A SS4387344 MADG 00 005 MADC 00 013 ...

Page 65: ...ROPS FOPS ROPS FOPS ROPS FOPS MADG 00 015 CANOPY CAB CAB ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A SAFETY SIGNS S 53 MADB 00 029 MADB 00 030 SS 3546 SS 3547 SS 3548 SS 3549 SS 3550 ...

Page 66: ...SAFETY SIGNS S 54 MEMO ...

Page 67: ... 4 Arm Cylinder 5 Work Light 6 Boom 7 Boom Cylinder 8 Boom Swing Cylinder 9 Canopy 10 Counterweight 11 Track Shoe 12 Travel Device 13 Track Frame 14 Front Idler 15 Blade 16 Blade Cylinder Components Name 10 11 9 8 7 6 5 4 3 2 1 16 15 14 13 12 MADB 01 001 ...

Page 68: ...s Take extra care not to contact to door striker 2 dWARNING Never attach a wire on handrails 4 and door striker 2 to lift the cab or main body or while transporting the machine on a truck or trailer as it is dangerous Door knob 6 handle 5 on the front window and release lever 7 are not a handrail Do not use them as a handrail when getting on and off the machine Do not hold control lever 3 or pilot...

Page 69: ...el Lever 3 Right Travel Lever 4 Swing Pedal 5 Monitor 6 Right Control Lever Horn Switch 7 Arm Rest Optional 8 Seat Back Box 9 Operator s Seat 10 Auxiliary Pedal Optional 11 Seat Belt 12 Drink Holder 13 Tool Box MADB 01 002 MADB 01 003 10 8 9 1 12 11 2 3 4 5 6 7 13 ...

Page 70: ...e Lever Cab equipped machine 21 Door Opener Cab equipped machine 22 Pilot Control Shut Off Lever 23 Fresh Air Filter Cab equipped machine 24 FM AM Radio Cab equipped machine Optional 25 Circulating Air Filter Cab equipped machine 26 Fuse Box 27 2 Way Multi Lever Optional ZX65USB 5A ZX33U 5A 38U 5A 48U 5A 55U 5A 17 23 26 26 18 19 24 14 15 16 20 21 25 22 25 27 MADB 01 005 MADC 01 001 MADC 01 002 MAD...

Page 71: ...The washer operates together with the wiper 6 Travel Mode Switch Push side of switch 6 to select the fast speed mode When travel load increases the travel mode automatically shifts to slow speed mode Push side of switch 6 to select the slow speed mode dCAUTION When the fast speed mode is set and load becomes heavy the travel mode will automatically shift slow speed mode while displaying However wh...

Page 72: ...1 6 Monitor Feature The monitor displays various meters warning indicators and work mode selection Screen Configuration The monitor consists of the following screens Basic Screen MENU Alarm List Brightness ADJ Clock Trip ...

Page 73: ...Clock 7 Security Status Indicator Optional 8 Auxiliary 9 Fuel Gauge 10 Hour Meter 11 Overload Alarm Selector Set Switch 12 ECO PWR Mode Selector Selector Switch 13 Auto Idle Selector Switch 14 Menu Return Switch 15 Coolant Temperature Gauge 16 Travel Mode Indicator 17 Work Light Indicator 18 Auxiliary 18 17 16 15 6 7 8 9 10 1 2 3 4 5 12 14 11 13 MADC 01 010 ...

Page 74: ...ultaneously When the red light comes ON and the buzzer sounds immediately stop the engine check the engine oil system and the oil level Alternator Indicator 3 This indicator warns abnormality of the electric system while running the engine When the alternator voltage falls out of the specified range the red light comes ON Check the alternator and the battery system Fuel Level Indicator 4 When the ...

Page 75: ... that the basic screen will be displayed IMPORTANT When the key switch is turned to the ON position engine oil pressure indicator 2 and alternator indicator 3 will be lit Until the alternator starts generating power after the engine starts the alternator alarm is displayed on the screen Until the engine oil pressure exceeds the given pressure the engine oil indicator 2 will stay lit Starting Scree...

Page 76: ...OPERATOR S STATION 1 10 Display of Meters Items to be displayed 6 Clock 9 Fuel Gauge 10 Hour Meter 15 Coolant Temperature Gauge MADB 01 011 15 9 6 10 ...

Page 77: ...cted Refer to the Numeric Key Pad Lock section ECO PWR Mode Selector Switch 11 Two engine speed modes ECO and PWR modes are selected and displayed by operating this mode switch ECO Economy Mode Although production is slightly reduced than in the PWR mode the fuel consumption and noise levels are reduced allowing the machine to operate efficiently PWR Power Mode Operate the machine in this mode whe...

Page 78: ... Switch 14 When the auto idle switch is turned ON the indicator displays ON and the function is enabled Travel Mode Indicator 16 The travel mode selected by the travel mode switch located on the end of the blade lever is displayed Work Light Indicator 17 The indicator is displayed while the work light switch on the switch panel is turned ON and the work lights on the front side of the boom and the...

Page 79: ...If all segments flash the machine is abnormal Immediately consult your authorized Hitachi dealer Coolant Temperature Gauge Indicates the engine coolant temperature Normally the segment shows around the center of the scale during operation All segments will flash when the coolant temperature sensor malfunctions or the CAN data can not be received fNOTE When the coolant temperature is 20 or lower th...

Page 80: ... condition push menu switch 7 to turn off warning mark 5 and return to basic screen 8 Once the warning mark 5 is displayed it will remain on the top left of screen 9 until the abnormality is resolved To check the description of alarm push menu switch 7 on basic screen 8 to display alarm list 13 fNOTE Up to 3 alarm marks are displayed on the top left of screen 9 If 4 or more alarms occur check alar...

Page 81: ...rm occurs Alarm list 13 contains only currently generated alarms 1 Push menu switch 7 on basic screen 8 to display MENU screen 12 2 Select Alarm List 13 on MENU screen 12 Push set switch 14 3 The currently generated alarm is displayed The alarm mark is displayed on the left side and the warning code is displayed next to the alarm mark Refer to Contents of Alarms on the next page for contents of th...

Page 82: ...speed to lower the coolant temperature W 2202 Engine Oil Pressure Alarm Engine oil pressure has decreased Immediately stop the engine Check the engine oil system and oil level W 1206 Air Filter Restriction Alarm Air filter elements are clogged Clean or replace air cleaner element W 1207 Coolant Temperature Sensor Failure Coolant temperature sensor is malfunction or abnormal Repair or replace W 230...

Page 83: ... replace W 1303 Combustion Temperature Sensor Failure Engine or engine related parts are abnormal Consult your authorized Hitachi dealer W 1310 CAN Communication Failure CAN communication device is abnormal Stop operation Check the sensors and controllers for any abnormalities W 2310 EEPROM Failure Communication system is abnormal Consult your authorized Hitachi dealer ...

Page 84: ...or low voltage 00470 03 ECU temperature sensor error high voltage 00470 02 ECU temperature sensor intermittent failure 00470 00 ECU temperature rise alarm 0006E 04 Cooling water temperature sensor error low voltage 0006E 03 Cooling water temperature sensor error high voltage 0006E 02 Cooling water temperature sensor intermittent failure 0006E 00 Cooling water temperature rise alarm 00437 04 Sensor...

Page 85: ...ature 7F853 00 Air cleaner clogging alarm 000BE 00 Overspeed error 0027E 04 Rack actuator error low current 0027E 03 Rack actuator error high current 0027E 07 Rack actuator mechanical failure 0027E 02 Engine error 0027F 0C CAN communication error 00276 02 ECU internal EEPROM error checksum 00276 0C ECU internal EEPROM error read write error 00274 0C ECU internal flash ROM error checksum A 00274 02...

Page 86: ...nu switch 2 while displaying basic screen 1 to display main menu MENU screen 3 Main menu screen 3 contains the items shown in the right figure Alarm list 4 is displayed only when an alarm is generated 3 4 1 2 MADB 00 007 MADB 01 028EN MADB 01 069EN ...

Page 87: ...k Adjustment 1 Push menu switch 2 while displaying basic screen 1 to display MENU 3 2 Select Clock 7 by pushing switch 4 or 5 3 Push set switch 6 to display Clock Setting screen 8 MADB 01 035 1 2 4 5 3 7 8 6 MADB 01 036EN MADB 01 037EN ...

Page 88: ...5 and then push set switch 6 to make the change 5 Push switch 4 or 5 to adjust the clock Push switch 4 to adjust the number downward and push switch 5 to increase it 6 Push set switch 6 to end the time setting procedure 9 4 4 5 5 6 6 MADB 01 037EN MADB 01 038EN MADB 01 039EN ...

Page 89: ...itch 4 or 5 and then push set switch 6 to make the change 2 Each time switch 4 or 5 is pushed Display 11 is changed as follows 24h 12h No display 3 Push switch 6 to make the change 4 Push menu switch 2 to return to MENU 3 and reflect the setting 10 4 5 6 11 4 5 6 3 2 8 MADB 01 040EN MADB 01 041EN MADB 01 042EN ...

Page 90: ...s different from the Total Accumulated Machine Operation Time displayed on the hour meter fNOTE Once the Trip meter is set it will continuously count the machine operation time regardless of the LCD display 1 status When the machine operation hour reaches the preset hours the Trip mark on LCD display 1 blinks If Trip mark is displayed on the monitor screen when Trip mark starts blinking Trip mark ...

Page 91: ...urn the key switch to ON position Push menu switch 2 while displaying basic screen 1 to display MENU 3 2 Select Trip 7 by pushing switch 4 or 5 3 Push set switch 6 to display Trip Setting screen 8 3 7 4 5 6 8 MADB 00 007 1 2 MADB 01 043EN MADB 01 044EN ...

Page 92: ...ll be changed as follows Hour Trip 1 Trip 2 If Hour is selected the hour meter is displayed on the basic screen If Trip 1 is selected the set time for Trip 1 is displayed and if Trip 2 is selected the set time for Trip 2 is displayed 6 Push switch 6 to make the change 9 4 5 6 MADB 01 047 Example Trip 1 is set on the display screen 4 5 6 MADB 01 044EN MADB 01 046EN ...

Page 93: ... When menu switch 2 is held down Trip will be displayed on short cut key 4 When switch 3 is pushed while holding down menu switch 2 the display will change to Trip 1 5 Each time switch 3 is pushed while menu switch 2 is held down the display will change as follows Trip 2 Hour Meter Trip 1 Trip 2 MADB 00 007 1 2 MADB 01 050 4 2 3 5 2 3 MADB 01 051 ...

Page 94: ... Turn the key switch to ON position Push menu switch 2 while displaying basic screen 1 to display MENU 3 2 Select Trip 7 by pushing switch 4 or 5 3 Push set switch 6 to display Trip Setting screen 8 MADB 00 007 1 2 3 4 5 7 8 6 MADB 01 043EN MADB 01 044EN ...

Page 95: ... follows 50 100 150 200 250 300 400 500 750 1000 1250 1500 2000 2500 3000 7 When the display item is set for Trip 1 or Trip 2 while displaying the desired set time the time displayed on the basic screen will be reset to the set time IMPORTANT When the setting is changed the operation time is counted from the point at which it is reset Please note that displayed time does not indicate the accumulat...

Page 96: ...ment 1 Push menu switch 2 while displaying basic screen 1 to display MENU 3 2 Select Brightness Adjusment 7 by pushing switch 4 or 5 3 Push set switch 6 to display Brightness Adjustment 8 MADB 00 007 1 2 4 5 6 7 3 8 MADB 01 053EN MADB 01 054EN ...

Page 97: ...n push set switch 6 to make the change The brightness is adjusted in 5 levels High Low 5 4 3 2 1 5 Night mode can be set on Brightness Adjustment screen 8 by performing steps 1 through 4 after turning the work light switch ON 9 4 5 6 8 9 MADB 01 055EN MADB 01 056EN MADB 01 057EN ...

Page 98: ...e Control Switch The set temperature decreases each time the down arrow switch is pushed and increases each time the up arrow switch is pushed 9 Defroster Switch Air will blow out of right front vents 4 and 5 10 Mode Switch The air vent location is selected Each time switch 10 is pushed mode indicator 12 changes in the order shown below Air will blow out of right front vents 4 5 and right rear ven...

Page 99: ...ture in the cab by operating temperature control switch 8 Control blower speed by using blower switch 7 Defroster Operation Select the right front vent by operating defroster switch 9 Adjust the louvers on right front vent 5 as required Control blower speed by using blower switch 7 Control the air temperature in the cab by using temperature control switch 8 10 7 9 8 MADB 01 073 5 MADB 01 003 ...

Page 100: ...n keeping the windows clear When the atmosphere is very damp and if the heater has run excessively outside of the windows may become clouded If this happens turn OFF the heater to adjust the temperature in the cab IMPORTANT Keep open flames away from the control panel Refer to the item Clean and Replace Heater Air Conditioner Filter in the Maintenance Section for maintenance of filters ...

Page 101: ... to 3 levels from low to high 9 Temperature Control Switch The set temperature decreases each time the down arrow switch is pushed and increases each time the up arrow switch is pushed 10 Defroster Switch Air will blow out of right front vents 4 and 5 11 Mode Switch The air vent location is selected Each time switch 11 is pushed mode indicator 13 changes in the order shown below Air will blow out ...

Page 102: ...control switch 9 to set the temperature display leftward Control the air temperature in the cab by operating temperature control switch 9 Control the blower speed by using blower switch 8 When air conditioner switch 7 is turned ON cool air will blow out of the right front vent Defroster Operation Select the right front vent by operating defroster switch 10 Adjust the louvers on right front vent 5 ...

Page 103: ...becomes clouded during rainy season or on humid days operate the air conditioner to aid in keeping the windows clear When the atmosphere is very damp and if the air conditioner has run excessively outside of the windows may become clouded If this happens turn OFF the air conditioner to adjust the temperature in the cab Off Season Air Conditioner Maintenance To protect each part of the compressor f...

Page 104: ...OPERATOR S STATION 1 38 Radio Cab equipped machine Optional 1 Radio Clock 1 MADB 01 005 ...

Page 105: ...y 6 Display Switch DISP Push this switch to switch over the display between radio wave frequency and time 7 Preset Switch PRESET One FM and MW AM station per button can be preset using these respective buttons 8 Volume Control Button VOL Push this switch to adjust the volume Push the button to increase the volume in a step by step manner Push the button to decrease the volume in a step by step man...

Page 106: ...s the PRESET button No flashes 3 times and frequency display becomes ON 3 Repeat steps 1 and 2 for other PRESET buttons 7 Station Auto Presetting Procedure Pushing SOUND control switch 2 long with the radio switch ON will search for the optimum receiving radio frequency stations and automatically allocate each station in preset memory buttons 1 to 6 fNOTE Performing auto presetting operation will ...

Page 107: ... the TRE state treble level is increased by one step When DOWN button 3 is pressed with the TRE state treble level is decreased by one step Sound Adjustment Bass Control When UP button 3 is pressed with the Bas state bass level is increased by one step When DOWN button 3 is pressed with the Bas state bass level is decreased by one step Digital Clock Setting Procedure Pushing DISP button 6 long in ...

Page 108: ...se Lever Cab equipped machine dCAUTION Open the door all the way until it securely locks in the latch on the side of the cab To unlock the door push down door lock release lever 1 located at the left side of the operator s seat 1 MADB 03 001 ...

Page 109: ...w to prevent the wiper from operating when the front window is opened Before closing the front window ensure that the wiper switch is turned OFF When opening the front window ensure that the left and right locks are definitely activated 3 Close the upper front window by following steps 1 and 2 in the reverse order Removing and Storing Lower Front Window 1 Open the upper front window beforehand whe...

Page 110: ...er bar 1 horizontally Move the seat backward and forward Seat fore aft is adjustable in 120mm range in 6 steps 20mm per step Tool Box The tool box is located at the right side in cover 2 Seat Back Box Pocket 4 is located at the back side of the seat Put the operator s manual inside 1 2 MADB 01 062 4 MADB 01 071 ...

Page 111: ...open the upper front window Escape through the window See page OPENING UPPER FRONT WINDOW for the opening method of the upper front window dCAUTION Take care not to be injured by pieces of broken window glass 3 If the front window can not be opened break the window glass by using the emergency evacuation tool 1 located at the cab rear Then escape through the broken window 4 If the front window is ...

Page 112: ...earance Seat Belt 1 Confirm that seat belt 1 is not twisted Securely insert the end of seat belt 1 into buckle 2 Lightly pull on the belt to confirm that the buckle latches securely 2 Push button 3 on buckle 2 to unfasten seat belt 1 Replace the seat belt if it is damaged or worn out or if the seat belt has external damage due to accident Room Lamp Cab equipped machine Push switch 4 on the cab lig...

Page 113: ...tly affecting the service life of the machine Thoroughly perform the break in operation The service life and the performance of the machine can be greatly affected by operation and maintenance of the machine during the initial stage of operation Perform the break in operation with the engine output less than 80 of the maximum output for the first 50 hours ...

Page 114: ...BREAK IN 2 2 MEMO ...

Page 115: ...eaks and damage to pipe lines and hoses Deformation break and abnormal noise of upper structure Looseness and missing of mounting bolts and nuts Washer Fluid Undercarriage Sag wear and break of crawler Oil leaks and wear on upper lower rollers and front idlers Oil leaks from travel devices Looseness and missing of mounting bolts and nuts Working Device Check cylinders pipe lines and hoses for oil ...

Page 116: ...a warning lamp burned out the alarm will not be displayed even if any abnormality occurs on the machine Accordingly in case any of the indicator bulbs or the warning lamps do not come ON immediately contact your authorized dealer for repair If any of alternator 4 or engine oil pressure 3 indicator fails to light after the basic screen is displayed the machine may have trouble Immediately contact y...

Page 117: ...15 seconds at a time If engine fails to start return key switch to OFF Wait for more than 30 seconds then try again Failure to do so may cause damage to the starter and or discharging the batteries This machine adopts the starter energizing time restriction control The starter power will be automatically cut after running 30 seconds 7 Release key switch 2 immediately after the engine has started K...

Page 118: ...ndicator 4 goes OFF turn key switch 2 to START position to rotate the starter IMPORTANT Never operate the starter for more than 15 seconds at a time If engine fails to start return key switch to OFF Wait for more than 30 seconds then try again Failure to do so may cause damage to the starter and or discharging the batteries This machine adopts the starter energizing time restriction control The st...

Page 119: ... engine oil pressure indicator 1 stays ON immediately stop the engine Inspect the engine oil pressure system and the oil level IMPORTANT In case any abnormality is found on the monitor unit immediately stop the engine Inspect the cause of the trouble Check engine noise and exhaust gas color Check that the engine noise and exhaust gas color are normal fNOTE Check the exhaust gas color as follows Af...

Page 120: ...ted start the engine using booster battery as shown below Connecting the booster batteries 1 Stop the engine of the machine on which booster battery is mounted 2 Connect one end of red cable 1 to the positive terminal of the machine battery and the other end to the positive terminal of the booster battery 3 Connect one end of black cable 2 to the negative terminal of the booster battery and then c...

Page 121: ...first 2 Disconnect the other end of black booster negative cable 2 from the booster battery 3 Disconnect red booster positive cable 1 from the booster battery 4 Disconnect red booster positive cable 1 from the machine battery To hinge 3 of the machine tank cover Red Booster Battery Machine Battery Black 1 2 M503 03 002 Disconnect First ...

Page 122: ...cept for special cases before stopping the engine lower the bucket and the blade to the ground 2 Pull pilot control shut off lever 1 to LOCK position 3 Turn the engine control dial to the slow idle position and run the engine for 5 minutes to cool the engine 4 Turn key switch 2 OFF to stop the engine ...

Page 123: ...s caused by increase in oil viscosity which is not abnormal Forward Reverse Travel Move both levers or pedals forward together to travel forward Pull the levers or pedals back together to travel in reverse The travel speed can be controlled by adjusting the lever or pedal operating stroke Ascending Descending Slopes The machine gradeability is 30 58 Slowly operate the travel levers or pedals when ...

Page 124: ...site directions Push one lever or pedal forward and pull the other back at the same time dWARNING During pivot or spin turn machine operations the base machine may shake When turning the machine in a tight area slowly operate the machine while taking care not to allow the machine to come in contact with the surrounding objects Spin Turn Pivot Turn M104 04 005 M104 04 007 M1M7 04 012 M1M7 04 013 ...

Page 125: ...e when the machine is traveling with travel mode switch 1 in the fast travel mode position the slow travel mode may not automatically be selected even if the traveling loads increase This symptom is not abnormal Drive the machine after conducting sufficient warm up operation The slow travel mode will automatically be selected if the traveling loads increase is displayed on the monitor Return fast ...

Page 126: ...r not to damage the road surface Be careful of steering when operating on asphalt roads in summer When crossing train tracks use wooden plates in order not to damage them Do not make contact with electric wires or bridges When crossing a river measure the depth of the river using the bucket and cross slowly Do not cross the river when the depth of the river is deeper than the upper edge of the upp...

Page 127: ...m to evacuate the machine Operate the boom the arm and the travel levers simultaneously at this time to prevent the machine from being loaded abnormally If the track frame bottom comes in contact with the ground or if mud and or grabbles are tightly packed into the undercarriage the machine may become impossible to travel Raise each track above the ground with the boom and arm extended remove mud ...

Page 128: ...e bucket s round side on the ground 1 Swing the upperstructure 90 2 Position the boom and the arm so that the angle between them becomes 90 to 110 Push the ground with the round part of the bucket bottom to raise the track off the ground 3 Do not raise the track with the boom and the arm when the boom is swung 4 Place blocks under the machine frame to support the machine 90 to 110 º M1M7 04 006 ...

Page 129: ...e track frames of both machines as illustrated To prevent the wire ropes from being damaged place some protective material between the track frame and the wire ropes IMPORTANT On some machines a bracket is provided on the track frame to install a shackle for towing a lightweight object Never attempt to tow the machine by using this lightweight object towing bracket Breaking the towing bracket may ...

Page 130: ...center joint IMPORTANT If the swing bearing swing gears and center joint are submerged in water or mud by mistake premature wearing on parts such as the swing bearing may result Grease must be changed or overhauling will be required immediately Stop operating the machine as soon as possible and contact your authorized dealer Swing Internal Gear Grease Capacity Model Grease Capacity ZX33U 5A 38U 5A...

Page 131: ...to skid or becomes unstable lower the bucket immediately Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover If the direction must be changed move the machine to level ground then change the direction to ensure safe operation Avoid swinging the upperstructure on slopes Never attempt to swing the upperstructure downhill The machine may tip over If swi...

Page 132: ...de to the ground 3 Turn the auto idle switch off IMPORTANT Turbocharger may be damaged if the engine is not properly shut down 4 Turn the engine control dial counterclockwise to the slow idle position Run the engine at slow idle speed for approximately 5 minutes to cool the engine 5 Turn the key switch to OFF Remove key 2 from the key switch 6 Pull pilot control shut off lever 1 to the LOCK positi...

Page 133: ...ng Do not change the control lever operation pattern Failure to do so may result in operation mistake of the machine A label showing the control patterns of the levers and pedals is attached on the right side in the cab When a lever is released it will automatically return to neutral and that machine function will stop 1 Arm Roll Out 2 Arm Roll In 3 Swing Left 4 Swing Right 5 Boom Lower 6 Boom Rai...

Page 134: ... at the operator s right foot as illustrated to the right Boom Swing Operation 1 Turn cover 2 for boom swing pedal 1 forward 2 Step on the left side of boom swing pedal 1 to swing left Step on the right side of pedal 1 to swing right 3 Turn cover 2 backward over boom swing pedal 1 when boom swing operation is no longer required 3 Swing Left 4 Swing Right 3 4 2 1 Unlock Position 2 Lock Position MAD...

Page 135: ... on the operator s right to raise and lower the blade When blade lever 1 is released it automatically returns to neutral holding the blade in the present position until lever 1 is operated again 2 Blade Raise 3 Blade Lower 2 3 1 MADB 05 002 MADB 05 005 2 3 ...

Page 136: ...ure to do so may result in damage to the blade and the undercarriage When jacking up the machine with this blade the surface beneath the blade comes under high pressure increasing the risk of surface collapse Always be sure that the surface is strong enough to support the weight of the machine before jacking up the machine Avoid dangerous uneven distribution of weight to the blade by maintaining e...

Page 137: ...ion always hold and push pilot control shut off lever 1 down Never attempt to lower raised console 2 or control lever 3 to reactivate all control lever function without holding pilot control shut off lever 1 When leaving the machine always stop the engine Then pull the pilot control shut off lever 1 up to the LOCK position Always check to be sure that the pilot control shut off lever 1 is pulled u...

Page 138: ... all control levers and pedals are in neutral and that no part of the machine is in motion dWARNING If any part of the machine any actuator moves when pilot control shut off lever 1 is lowered to the UNLOCK position despite the fact that all controls are placed in neutral the machine is malfunctioning Immediately pull pilot control shut off lever 1 back to the LOCK position and stop the engine The...

Page 139: ...lant temperature gauge 2 stops flashing and changes to stay ON 2 After the first segment of coolant temperature gauge 2 stops flashing and changes to stay ON turn engine control dial 1 to around medium position 3 Operate the boom arm and bucket cylinders slowly to each stroke end several times If the machine equipped with various attachments operate the attachment function slowly to allow hydrauli...

Page 140: ...nterclockwise to decrease the engine speed Note that the auto idle function will be deactivated if engine control dial 1 is operated while the engine is running at the auto idle setting Before stopping the engine always turn engine control dial 1 counterclockwise to the stop to the slow idle setting Run the engine five minutes to cool the engine Then turn the key switch to OFF position to stop the...

Page 141: ...e function to the OFF position when unexpected machine movement is undesirable especially when loading unloading the machine for transportation The engine speed will increase to the speed set by the engine control dial when any control lever is operated from the neutral position while auto idle display 1 indicates ON If the operator is not aware of the high engine speed setting the engine speed wi...

Page 142: ...with auto idle indicator 1 Auto Idle Switch Auto Idle Indicator 1 ON Auto Idle Function ON Auto Idle Indicator 1 OFF Auto Idle Function OFF After the key switch is turned OFF when the auto idle function is activated with auto idle indicator 1 ON when the engine is restarted auto idle indicator 1 flashes for 10 seconds and the auto idle function becomes activated 1 2 MADB 00 007 ...

Page 143: ...de This mode slightly reduces the engine speed according to the operating condition Digging power is same as the PWR mode Although production is slightly reduced more than in the PWR mode the fuel consumption and noise levels are reduced allowing the machine to operate efficiently PWR Power Mode Operate the machine in this mode when performing normal work 1 2 MADB 00 007 ...

Page 144: ...h selector 2 to turn the overload alarm ON OFF Overload Alarm OFF Overload Alarm ON If the overload alarm is ON the buzzer sounds when the boom bottom pressure sensor 3 detects a defined pressure The buzzer will not sound if the overload alarm is OFF The machine keeps the settings at previous key OFF until the next key ON MADC 01 010 1 2 3 MADC 05 001 ...

Page 145: ...ired depth move the machine as required to continue the trench When operating the arm avoid bottoming the cylinder to prevent cylinder damage IMPORTANT When digging at an angle avoid striking the tracks with the bucket teeth When lowering the boom avoid sudden stops that may cause shock load damage to the machine When digging a deep excavation avoid striking the boom or bucket cylinder hoses again...

Page 146: ... part and the machine may be damaged When grading by operating the boom arm and bucket simultaneously 1 When grading from the forward to the backward slowly roll in the arm while slightly raising the boom As soon as the arm passes the vertical position slowly lower the boom so that the bucket can be horizontally moved 2 When grading from the backward to the forward operate the arm and bucket rolle...

Page 147: ...machine s weight as additional digging force Severe machine damage may result Avoid Excavation Using Upperstructure and or Boom Swing Power Never attempt to move rocks or excavate a cliff face by hitting the bucket using upperstructure and or boom swing power Damage to the front attachment or shortening of the service life of the swing systems may result MZX5 05 002 ...

Page 148: ...cket digging out force Operate the boom arm and bucket simultaneously so that the bucket teeth can be effectively penetrated into the excavation surface Carefully operate the machine to prevent crushed material from spattering possibly resulting in injury to the operator and or co workers around the machine Avoid Striking With Bucket dWARNING The bucket bottom is curved Therefore hammering or pili...

Page 149: ...7 Boom Cylinder may Hit Blade When digging deeply with the blade positioned at the front the boom cylinder or bucket may accidentally hit the blade causing damage Take care to prevent this from happening MZX5 13 014 MZX5 13 015 ...

Page 150: ... blade cylinders may result Avoid Colliding Boom Cylinder With Track When digging deeply with the front attachment positioned at an angle as illustrated the boom cylinder may accidentally collide with the track causing damage Take extra care to prevent this from happening Precautions for Installing Wide Bucket or Special Type Bucket If the boom is fully offset to the left and raised on the cab equ...

Page 151: ...arts such as track links or rollers Refer to the table for Shoe Types and Applications in the specification chapter Soil may easily become packed into the crawler during travel operation on sandy ground If the machine is driven without removing the packed soil from the crawlers the rubber crawlers will be overloaded possibly resulting in breakage of the crawlers Avoid causing the crawlers to becom...

Page 152: ...er of sliding 3 Do not travel the machine while raising one side crawler off the ground with the front attachment Shear or damage to the rubber crawler may result Precautions for Using Rubber Crawlers dWARNING The rubber crawler machine is less stable than the steel crawler machine as the edge of the rubber crawler is easier to deform than steel crawler Pay attention when operating the machine at ...

Page 153: ...rawler has a thin rubber film shown in dotted line on its roller tread During operation of a new machine or immediately after the rubber crawlers are replaced the rubber film may come off due to contact with the rollers This is not abnormal See the right illustration 6 If the rubber crawler is damaged and the rubber crawler core wire rusts the service lifetime of the rubber crawler will become sho...

Page 154: ...e machine to become unstable possibly resulting in tipping accident When lifting a load carefully swing the machine not to cause the lifted load to come in contact with personnel working near the machine Reduce the engine speed to slowly swing the machine Failure to do so may cause the machine to tip over by swing centrifugal force If traveling the machine with a lifted load is unavoidable reduce ...

Page 155: ... on the track frame The track frame and or the shackle bracket may be damaged otherwise The maximum drawbar pull Model Maximum Drawbar Pull ZX33U 5A 9300 N 950 kgf ZX38U 5A 9300 N 950 kgf ZX48U 5A 13200 N 1350 kgf ZX55U 5A 13200 N 1350 kgf ZX65USB 5A 17200 N 1750 kgf Be sure to use a shackle Keep the tow line horizontal straight and parallel to the tracks Select the slow travel mode Slowly drive t...

Page 156: ...d below 1 Remove the cover above the hydraulic oil tank Loosen filler cap 1 on the hydraulic oil tank to release air pressure from the hydraulic oil tank dWARNING Be sure to work only after oil temperature is low or before operation Failure to do so may allow high temperature oil to spray possibly causing severe burns 2 Remove bolts 2 from the front and left side of cover 3 to remove cover 3 3 Low...

Page 157: ...e by following the procedure given below 1 Remove cap 1 from the valve 2 Put the matching marks on plug 2 lock nut 3 and adjustment screw 4 for assembling 3 Loosen lock nut 3 Securely tighten adjustment screw 4 IMPORTANT Note turn number of the adjustment screw It is used for returning the adjustment screw to its original state 4 Lower the front attachment by operating the overload relief valve on...

Page 158: ...bf ft If the front attachment is loaded 1 Put the matching marks on lock nut in overload relief valve and adjusting screw in the boom raise circuit cylinder bottom side dWARNING Loosen the adjusting screw slowly If it is loosened rapidly the boom may also lower rapidly 2 Loosen the lock nut Loosen adjusting screw slowly by checking the movement of boom 3 After checking that the boom is completely ...

Page 159: ... day s operation drive the machine to a firm level ground where no possibility of falling stones ground collapse or floods are present Refer to the group for PARKING THE MACHINE in the DRIVING THE MACHINE section Fully refill the fuel in the fuel tank Clean the machine M1M7 05 024 ...

Page 160: ...OPERATING THE MACHINE 5 28 MEMO ...

Page 161: ...rting weight and dimensions may vary depending on the type of shoe or front attachments installed Investigate beforehand the conditions of the route to be traveled such as dimensional limits weight limits and traffic regulations In some cases getting the permission from the local authority concerned or disassembling the machine to bring it within dimensional limits or weight limits of local regula...

Page 162: ...thoroughly clean the ramps loading dock and flatbed Dirty ramps loading docks and flatbeds with oil mud or ice on them are slippery and dangerous 2 Place blocks against the truck wheels while using a ramp or loading dock 3 Ramps must be sufficient in width length and strength Be sure that the incline of the ramp is less than 15 degrees 4 Loading docks must be sufficient in width and strength to su...

Page 163: ...e to turnover NEVER attempt to change directions whilst positioned on the ramp If repositioning is necessary first move back to the ground or flatbed modify traveling direction and begin to drive again The top end of the ramp where it meets the flatbed is a sudden bump Take care when traveling over it as the balance may be lost Extreme care must be taken when swinging the upper structure when the ...

Page 164: ...ne as illustrated right And then slowly rotate the upperstructure 180 while keeping the arm fully rolled in 6 Reverse the machine to the specified position 7 Rest the front attachment on supports such as wooden blocks placed on the truck flatbed Also lower the blade onto the deck at this time if fitted 8 Stop the engine Remove the key from the key switch 9 Place the pilot control shut off lever in...

Page 165: ...en each corner of the machine and front attachment to the truck with appropriate strength of chains or cables Transporting the machine equipped with rubber crawlers When securing the machine to the flatbed do not directly tighten the rubber crawler with wire ropes Tighten the machine to the trailer flatbed with wire ropes at the travel motor side by using the bracket Tighten the machine firmly to ...

Page 166: ...n traveling over it as the balance may be lost IMPORTANT Make sure that the angle of the boom and the arm is kept at between 90 to 110 when unloading the unit Damage to the unit is possible if the arm is kept in a suspended state during unloading 1 Travel extremely slowly with the bucket on the ground and the angle of the arm and the boom kept at between 90 to 110 when moving from the edge of the ...

Page 167: ...ing lifted resulting in machine damage and or personal injury Do not lift the machine quickly Excessive load will be applied to the lifting wire ropes and or lifting tools possibly causing them to break Do not allow anyone to come close to or under the lifted machine The indicated gravity center is for the standard specification machine The gravity center will vary depending on the kinds of attach...

Page 168: ...top the engine Remove the key from the key switch 7 Set a crane in an appropriate position 8 Attach shackles to the boom and blade hooks Securely thread wire ropes through the shackles 9 Slowly lift the machine so that shock loads will not be applied to the machine Take sufficient care not to lose the balance of the machine ZX33U 5A 2000 mm 79 in ZX38U 5A 2000 mm 79 in ZX48U 5A 1700 mm 67 in ZX55U...

Page 169: ... use only genuine Hitachi parts Failure to do so may result in serious injury or death and or machine breakdown Failure to use recommended fuel lubricants and genuine Hitachi parts will result in loss of Hitachi product warranty Never adjust engine governor or hydraulic system relief valve Protect electrical parts from water and steam Never disassemble electrical components such as main controller...

Page 170: ...ubricants check and adjustment intervals The maintenance guide table is affixed under the seat Refer to page 7 5 Check and maintenance intervals shown in this manual are those for the machines to be operated under normal conditions In case the machine is operated under more severe conditions shorten the intervals ...

Page 171: ...inder 4 Swing Device 5 Fuel Tank 6 Hydraulic Oil Tank 7 Center Joint 8 Air Cleaner 9 Swing Bearing 10 Canopy 11 Control Lever 12 Pump 13 Counterweight 14 Track Link 15 Travel Device 16 Lower Roller 17 Control Valve 18 Upper Roller 19 Track Adjuster 20 Front Idler 21 Blade Cylinder 22 Blade 23 Boom Cylinder 24 Bucket 25 Link 26 Tooth 27 Bucket Cylinder 28 Arm 29 ...

Page 172: ...maintenance can be performed regularly Symbol Marks The following marks are used in the maintenance guide table Grease Front Joint Pin Swing Bearing Swing Gear Hydraulic oil filters Pilot Filter Hydraulic Oil Tank Filter Suction Filter Gear Oil Travel Reduction Device Air Cleaner Element Engine Oil Coolant Long Life Coolant Engine Oil Filter Fuel Filter Fuel Main Filter Pre Filter Hydraulic Oil ...

Page 173: ...7 56 4 Grease Every 100 hours during first time operation up to 500 hours 7 19 13 Air Cleaner Element 7 60 5 Grease Swing Gear 7 23 14 Grease Control Lever 7 23 6 Hydraulic Oil 7 37 15 Grease Bucket 7 19 7 Gear Oil Travel Device 7 29 16 Grease Blade 7 21 8 Hydraulic Oil Filter Suction 7 37 17 Fuel Pre Filter 7 57 9 Hydraulic Oil Filter Full Flow 7 41 5 3 4 16 15 4 4 9 8 6 13 2 1 11 12 14 10 17 7 L...

Page 174: ...ng 7 22 11 Engine Oil Filter 7 25 4 Grease Every 100 hours during first time operation up to 500 hours 7 19 12 Fuel Main Filter 7 56 5 Grease Swing Gear 7 23 13 Air Cleaner Element 7 60 6 Hydraulic Oil 7 37 14 Grease Control Lever 7 23 7 Gear Oil Travel Device 7 29 15 Grease Bucket 7 19 8 Hydraulic Oil Filter Suction 7 37 16 Grease Blade 7 21 6 8 9 6 13 8 2 1 11 12 14 10 7 Lubrication Interval hou...

Page 175: ...en the engine is running in order to prevent the accident If maintenance work while engine running is unavoidable strictly comply with the following items One person should take the operator s seat to be ready to stop the engine any time while communicating with other workers When working around moving parts is unavoidable pay special attention to ensure that hands feet and clothing do not become ...

Page 176: ... After checking that stopper 4 provided on the left link is placed in LOCK position 5 remove your hand from cover 1 Cover 1 will be locked in place When closing cover 1 while raising cover 1 push stopper 4 at the arrowed position a to disengage the lock While pushing stopper 4 lower cover 1 When cover 1 is lowered by the 1 4 stroke leave stopper 4 Then lower cover 1 further to completely close it ...

Page 177: ...er 1 until stopper 3 fits into the lock position on bracket 4 3 Confirm that stopper 3 is in the LOCK position before releasing your hands dCAUTION When closing cover 1 confirm that cover 1 is securely locked 4 When closing cover 1 push stopper 3 while raising cover 1 by hand 5 Lower cover 1 while pushing stopper 3 Release stopper 3 when cover 1 is lowered by 1 4 of its movable distance fNOTE Butt...

Page 178: ... covers may close accidentally possibly resulting in personal injury When opening or closing the access covers take extra care not to catch fingers between the base machine and the access covers Open the radiator front cover until rod 1 fits into the lock position on rail groove 2 Raise rod 1 to release lock before closing the radiator front cover 2 1 MADB 07 022 ...

Page 179: ...e operation up to 500 hours IMPORTANT Grease front joint pins every day until break in operation 50 hours is complete B Engine Parts Quantity Interval hours Page 8 50 100 250 500 1000 2000 1 Engine Oil Check Oil Level 1 7 24 2 Engine Oil Change ZX33U 5A 38U 5A 6 7 L 1 8 US gal ZX48U 5A 55U 5A 7 4 L 2 0 US gal 7 25 ZX65USB 5A 10 5 L 2 8 US gal 3 Engine Oil Filter Replace 1 7 25 As the oil life is s...

Page 180: ...used kind of filter element or average attachment operating availability Refer to the Change Hydraulic Oil and Replace Full Flow Filter Element See recommended oil chart Maintenance required only during first time E Fuel System Parts Quantity Interval hours Page 8 50 100 250 500 1000 2000 1 Check Fuel Level 1 7 53 2 Check Water Separator 1 7 54 3 Drain Fuel Tank Sump 1 As required 7 55 4 Replace F...

Page 181: ...nt LLC is used change every two years or 2000 operating hours whichever comes first IMPORTANT Use soft water as a coolant Do not use strong acid or alkaline water Use the coolant with genuine Hitachi Long Life Coolant LLC mixed by 30 to 50 If a coolant mixed with less than 30 of genuine Hitachi Long Life Coolant LLC is used service life of the cooling parts may be shortened due to damage by freezi...

Page 182: ... 7 90 Replace 1 After cleaning 6 times or so 7 90 Fresh Air Filter Clean 1 7 92 Replace 1 After cleaning 6 times or so 7 92 9 Clean Cab Floor As required 7 94 10 Check Clean and Function Check of Injection Nozzle 7 95 11 Inspect and Adjust Valve Clearance 7 95 12 Check and Adjust Injection Timing 7 95 13 Measure Engine Compression Pressure As required 7 95 14 Check Starter and Alternator 7 95 15 C...

Page 183: ...hours whichever comes first Pump coupling ZX33U 5A 38U 5A 48U 5A 55U 5A Every 5 years or 3000 hours whichever comes first ZX65USB 5A Every 5 years or 4000 hours whichever comes first Hydraulic System Base Machine Pump suction hose Every 2 years or 4000 hours whichever comes first Pump delivery hose Every 2 years or 4000 hours whichever comes first Swing hose Every 2 years or 4000 hours whichever c...

Page 184: ...ASE EP2 Shell Alvania Grease EP2 Shell Gadus S2 V220 2 Cartridge Grease EP2 ExxonMobil Mobilux EP2 KIGNAS Oil KIGNAS MP GREASE No 2 COSMO Oil COSMO GREASE DYNAMAX EP2 BP Energrease LS EP2 Castrol Spheerol EPL2 Chevron Multifax EP2 Recommended Engine Oil IMPORTANT Use only genuine Hitachi engine oil as shown below Or use JASO DH 1 or equivalent engine oil Brand Names of Recommended Engine Oil Kind ...

Page 185: ...I GL4 Class Brand Names of Recommended Hydraulic Oil Kind of Lubricant Hydraulic Oil Where to be applied Manufacturer Hydraulic System 2000 hours Filter paper element 3000 hours High performance element 1000 hours Filter paper element 1500 hours High performance element 20 to 40 C 4 to 104 F Hitachi Super EX 46HN Idemitsu Kosan Super Hydro 46X JX Nippon Oil Energy Corporation SUPER HYRANDO WP46 HY...

Page 186: ...Super Wide DH 1 10W30 Super Wide DH 1 15W40 Travel Device Gear Oil Hitachi Gear Oil GL 4_90 Hydraulic System Hydraulic Oil Tank Hydraulic Oil Super EX46HN Fuel Tank Diesel Fuel ASTM Grade No 2 DS15 ASTM Grade No 2 DS500 ASTM Grade No 1 DS15 ASTM Grade No 1 DS500 Grease Nipple Lithium Grease SEP Grease Radiator Coolant Genuine Hitachi Long Life Coolant LLC ...

Page 187: ... A Greasing Front Joint Pins Bucket every 100 hours Swing Post and Others every 500 hours or every year every 100 hours during first time operation up to 500 hours Lubricate all fittings shown in the figure Bucket Swing Post ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A ...

Page 188: ...MAINTENANCE 7 20 MADB 07 048 M1M7 07 020 M1M7 07 021 M1M7 07 023 Boom Cylinder Bottom Side Boom Foot Boom Swing Cylinder Boom Cylinder Rod Side ...

Page 189: ... 07 006 M585 07 046 MADB 07 008 Arm Cylinder Rod Side Bucket Cylinder Bottom Side Boom and Arm Joint Pin Arm Cylinder Bottom Side Blade Pins every 500 hours or every year Blade Joint Pins Blade Cylinder Rod and Bottom Side ...

Page 190: ... same procedures as described on page 7 7 for preparation for inspection and maintenance 2 Apply grease via grease fitting 1 with a grease gun by two to three strokes 3 Start the engine Push pilot control shut off lever to the UNLOCK position Raise the bucket approx 200 mm 8 in above the ground and rotate the upperstructure 90 1 4 turn 4 Lower the bucket to the ground 5 Repeat the procedure Step 1...

Page 191: ...rease fitting 1 4 Start the engine Push the pilot control shut off lever to the UNLOCK position 5 Raise the bucket 200 mm 8 in off the ground and rotate the upperstructure 90 1 4 turn 6 Lower the bucket to the ground 7 Repeat the procedure Step 1 to 6 four times 8 Apply grease by the quantity shown in the below table If the grease is contaminated remove all old grease and replace with new grease T...

Page 192: ...arting the engine Check oil level before starting the engine Open the engine cover and pull out oil level gauge 1 Wipe oil level gauge 1 with cloth re insert it into the pipe to the end and then pull it out again The oil level should be between the upper and lower marks on oil level gauge 1 If oil level is below the lower limit mark add the recommended engine oil via oil filler 2 If oil level exce...

Page 193: ...cool before starting work 2 Place 10 liter ZX65USB 5A 15 liter container under the engine oil pan Remove oil filler cap 2 3 Remove drain plug 3 to drain oil 4 Then allow oil to drain through a clean cloth into a container 5 After all oil has been drained inspect the cloth for any debris such as small pieces of metal 6 Securely install drain plug 3 Wrench size 19 mm Tightening torque 90 N m 9 kgf m...

Page 194: ...o enter the engine Do not re use engine oil filter 4 Be sure to use only genuine engine oil filter 4 Failure to use genuine parts or replace oil filter 4 may damage the engine 9 Apply a thin layer of clean oil to new oil filter 4 gasket O ring 10 Install new oil filter 4 Turn the filter cartridge clockwise by hand until the gasket touches the contact area Be sure not to damage the gasket when inst...

Page 195: ...S gal ZX65USB 5A 10 5 L 2 8 US gal fNOTE Refer to the recommended oil and grease chart on page 7 16 for the brand names of oils 13 Install oil filler cap 2 14 Start the engine Run the engine at slow idle for 5 minutes 15 Stop the engine Remove the key from the key switch 16 Check for any leakage 17 After 15 minutes check oil level on the dipstick and add or drain oil to maintain proper oil level T...

Page 196: ...release plug to release pressure 4 After gear oil has cooled slowly loosen air release plug 1 to release pressure 5 Remove air release plug 1 and oil level check plug 2 Oil must be up to the bottom of hole 6 If necessary add oil until oil flows out of oil level check plug 2 hole See gear oil chart 7 Clean and install air release plug 1 and oil level check plug 2 Model Tightening Torque ZX33U 5A 38...

Page 197: ...ce dWARNING Keep body and face away from the air release plug Gear oil may be hot just after operation Wait for gear oil to cool and then gradually loosen the air release plug to release pressure 4 After gear oil has cooled slowly loosen air release plug 1 to release pressure and temporarily retighten plug 1 5 Remove drain plug 3 and plug 1 in that order to drain gear oil 6 Clean drain plug 3 Tigh...

Page 198: ...he recommended oil and grease chart on page 7 17 for the brand names of oils 9 Clean and tighten the plugs 1 and 2 Model Tightening Torque ZX33U 5A 38U 5A Plug 1 46 to 51 N m 4 6 to 5 1 kgf m 33 to 36 lbf ft Plug 2 12 to 18 N m 1 2 to 1 8 kgf m 9 to 13 lbf ft ZX48U 5A 55U 5A 65USB 5A Plug 1 22 to 24 N m 2 2 to 2 4 kgf m 16 to 17 lbf ft Plug 2 10 Repeat steps 2 to 9 for the other travel reduction g...

Page 199: ...oving the front attachment for specified time around 10 seconds after stopping the engine 2 2 Bleed air from the hydraulic oil tank to release internal pressure 2 3 Immediately after operation all hydraulic components and hydraulic oil or lubricants are hot and highly pressurized Begin inspection and or maintenance work only after the machine has cooled down Servicing heated and pressurized hydrau...

Page 200: ...hoses to twist when connecting them The life of twisted hoses will be shortened considerably Do not use hydraulic oils other than those listed in the table Brand names of recommended hydraulic oil When adding hydraulic oil always use the same brand of oil do not mix brands of oil When using another manufacturer s hydraulic oil be sure to change the full amount The new machine is filled with hydrau...

Page 201: ...ng on the brand Refer to the Hydraulic System Changing intervals for the high performance element micro glass Breaker Operation Availability 0 10 20 30 40 50 60 70 80 90 100 Full Flow Filter 1000 670 510 410 340 290 250 215 195 180 170 Hydraulic oil 1500 hours life time 1500 1260 1100 980 895 820 760 700 640 600 560 Hydraulic oil 3000 hours life time 3000 2300 1850 1500 1250 1080 935 800 710 630 5...

Page 202: ...life time 2000 1310 980 780 650 550 480 430 385 350 320 Front Greasing When using the hydraulic breaker grease all front joint pins every 50 hours Average Breaker Operation Availability Changing Intervals hour When using filter paper element 0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 10 20 30 40 50 60 70 80 90 100 Element Replacement Intervals Changing Interval when using 1000 hour life tim...

Page 203: ...serious failure in the hydraulic system If the oil level is higher than level gauge 1 remove oil down to the appropriate level using a pump 1 Park the machine following the same procedures as described on page 7 7 for preparation for inspection and maintenance 2 Check oil level with level gauge 1 on hydraulic oil tank Oil must be between marks on gauge 1 If necessary add oil M1M7 05 024 1 MADB 07 ...

Page 204: ...chine until hydraulic oil becomes cool Then bleed air pressure from the hydraulic oil tank ZX33U 5A 38U 5A 48U 5A 55U 5A 3 Slowly loosen drain plug 1 on the bottom of the hydraulic oil tank to drain water and sediment ZX65USB 5A 3 Loosen bolts 2 of drain valve cover 3 Rotate drain valve cover 3 to open the checking port Slowly loosen drain plug 1 on the bottom of the hydraulic oil tank to drain wa...

Page 205: ...es IMPORTANT Do not use hydraulic oils other than listed in the Brand Names of Recommended Hydraulic Oil 1 Park the machine following the same procedures as described on page 7 7 for preparation for inspection and maintenance 2 Open the tank cover Clean the top of the hydraulic oil tank to keep dirt out of the hydraulic system 3 Loosen cap 1 to release pressure from the hydraulic oil tank 4 Remove...

Page 206: ...el Tightening Torque ZX33U 5A 38U 5A 50 N m 5 kgf m 37 lbf ft ZX48U 5A 55U 5A 95 N m 9 5 kgf m 70 lbf ft 11 Add oil until it is between the marks on the oil level gauge 12 Before securing cover 2 with bolts ensure the top edge of the rod assembly 5 is completely inserted into the hole of support 4 Make sure filter and rod assembly 5 are in correct positions Install cover 2 Tighten the bolts to 10 ...

Page 207: ...ert rod assembly 5 into the pipe 10 Clean install and tighten drain plug 3 Model Tightening Torque ZX65USB 5A 95 N m 9 5 kgf m 11 Add oil until it is between the marks on the oil level gauge 12 Before securing cover 2 with bolts ensure the top edge of the rod assembly 5 is completely inserted into the hole of support 4 Make sure filter and rod assembly 5 are in correct positions Install cover 2 Ti...

Page 208: ... dial or lever in the slow idle position 5 Start the engine Wait 5 to 10 seconds Stop the engine 6 Check the hydraulic oil level at the level gauge located on the side of the hydraulic oil tank Add hydraulic oil if necessary 7 Restart the engine Confirm that hydraulic oil level in the hydraulic oil tank is sufficient Run the engine for approximately 1 minute 8 This is the end of the hydraulic pump...

Page 209: ...tely after operation Wait for the oil to cool before starting any maintenance work Procedures 1 Park the machine following the same procedures as described on page 7 7 for preparation for inspection and maintenance 2 Before replacing element 6 be sure to bleed air pressure from the hydraulic oil tank by loosening cap 7 3 Loosen bolts 1 4 used to remove cover 2 and O ring 3 When removing cover 2 sl...

Page 210: ... 5A 10 N m 1 kgf m ZX65USB 5A 50 N m 5 kgf m 9 Bleed air from the hydraulic system and check the hydraulic oil level after replacing the element Refer to the descriptions for Bleed Air from Hydraulic System If the machine is operated with air mixed in the hydraulic circuit damage to the pump may result fNOTE Replace element 6 at the regular interval to keep hydraulic oil clean and to extend the se...

Page 211: ...er operation Wait for the oil to cool before starting any maintenance work 1 Park the machine following the same procedures as described on page 7 7 for preparation for inspection and maintenance 2 Before replacing the element be sure to bleed air pressure from the hydraulic oil tank by loosening cap 1 3 Remove bolts 3 and under cover 2 of rear left side Wrench size 17 mm M1M7 05 024 3 2 1 MADB 00...

Page 212: ...e not to allow dust and or water enter filter case 6 11 Install case 6 into head cover 5 while rotating case 6 clockwise Tightening Torque 25 to 35 N m 2 5 to 3 5 kgf m 18 0 to 26 lbf ft 12 After replacing filter element 7 bleed any remaining air from the hydraulic circuit Check the oil level in the hydraulic oil tank Add oil as needed Refer to the descriptions for Bleed Air from Hydraulic System ...

Page 213: ...to protect hands and body from high pressure fluids If an accident occurs see a doctor familiar with this type of injury immediately Tighten repair or replace any missing loose or damaged clamps hoses and lines Do not bend or strike high pressure lines Never install bent or damaged hoses or lines According to the check points shown below check hoses and lines for oil leaks and damage If any abnorm...

Page 214: ...ck Points Abnormalities Remedies Daily Contact surfaces of flange joints Leak 11 Replace Bolts Loose or leak 11 Retighten or replace O ring Welded surfaces on flange joints Leak 12 Replace Every 250 hours Flange joint neck Crack 13 Replace Welded surfaces on flange joints Crack 12 Replace Clamps Missing or deformation Loose bolts Replace or retighten Oil Cooler Interval hours Check Points Abnormal...

Page 215: ...d flare seat 9 They must be free of dirt or obvious defects 2 Tighten fitting 7 by hand 3 Tighten fitting 7 or nut 8 to the torque values shown Do not allow hose 5 to twist when tightening fittings 10 Wrench size mm 17 19 22 27 36 41 50 Tightening Torque N m 25 30 40 65 180 210 250 kgf m 2 5 3 4 6 5 18 21 25 lbf ft 18 22 29 5 47 130 150 184 7 9 8 10 5 M202 07 051 ...

Page 216: ...e may damage O ring 1 and cause oil leak 3 When assembling fittings take care not to make a dent on O ring groove 3 of adaptor 2 and sealing surface 6 on hose 5 or valve side Failure to do so may result in damage to O ring 1 leading to oil leak 4 If oil leaks from a loose connection of union 4 do not tighten fitting 2 Open the connection replace O ring 1 with a new one and check for correct O ring...

Page 217: ...lve is provided in the coupler take care that oil may flow out of the coupler when the coupler is disconnected 2 2 After the coupler is disconnected plug the holes with the exclusively prepared plugs IMPORTANT Take care not to damage the joint surfaces when disconnecting or connecting the coupler Before disconnecting or connecting the coupler clean the coupler and its surroundings with a cleaning ...

Page 218: ...diagonally applied the coupler may be difficult to disconnect However the coupler may be easily disconnected in this case when oil pressure increases Take care not to diagonally push the coupler Failure to do so damage to the inner parts cause oil leak and or unexpected coupler disconnection may result 2 Disconnecting Coupler Be sure to disconnect the coupler only after removing any foreign matter...

Page 219: ...er Before connecting the coupler be sure to check the coupler surface for any adhered foreign matter Clean to remove the foreign matter if any Adhered foreign matter may cause oil leaks and or disconnection of the coupler When a hose clamping is required put a clamp 200 mm away from the joint edge If the hose is clamped as illustrated to the right the coupler joint may slide as oil pressure change...

Page 220: ...quality or high quality DIESEL FUEL JIS K 2204 ASTM 2 D Kerosene must NOT be used Besides using bad quality fuel drainage agent fuel additives gasoline kerosene or alcohol refueled or mixed with specified fuel may deteriorate performance of fuel filters and cause sliding problem at lubricated contacts in the injector It also affects the engine parts leading to malfunction Using fuel other than ult...

Page 221: ...he monitor panel When necessary to add fuel remove cap 2 and refill fuel IMPORTANT Keep all dirt dust water and other foreign materials out of the fuel system when refilling fuel 3 To avoid condensation fill the tank at the end of each day s operation Take care not to spill fuel on the machine or ground Model Tank Capacity ZX33U 5A 38U 5A 42 L 11 1 US gal ZX48U 5A 55U 5A 70 L 18 5 US gal ZX65USB 5...

Page 222: ...to drain water If it is difficult to drain water loosen air bleed plug 4 counterclockwise 2 to 3 turns 4 After draining water securely tighten drain plug 3 and plug 4 5 Open cock 2 IMPORTANT After draining water from the water separator bleed air from the fuel supply system Bleed Air from Fuel System Air in the fuel system will cause the engine to start hard and or run roughly Be sure to bleed air...

Page 223: ... valve cover 3 from right front under cover 1 Rotate drain valve cover 3 to open the checking port 3 Place a 0 5 liters or larger capacity container under drain valve 4 to collect the drained water 4 Open drain valve 4 to drain water and or sediment 5 After draining water securely tighten drain valve 4 6 Return drain valve cover 3 to original position and tighten bolts 2 1 2 4 3 MADB 07 024 MADB 0...

Page 224: ...7 for preparation for inspection and maintenance 2 Close cock 1 3 Place a 1 liter or larger capacity container under fuel main filter 2 4 Remove fuel filter 2 using the filter wrench 5 Clean the fuel filter 2 contact area 6 Apply a thin layer of clean fuel to the gasket of new fuel filter 2 7 Turn fuel filter 2 clockwise by hand until fuel filter 2 touches the contact area 8 Tighten fuel filter 2 ...

Page 225: ... elements for the fuel pre filter element Failure to do so may deteriorate the engine performance and or shorten the engine service life Please be noted that all engine failures caused by using other manufacturers elements are excluded from Hitachi Warranty Policy ZX33U 5A 38U 5A 48U 5A 55U 5A ZX65USB 5A Fuel Pre Filter Fuel Pre Filter MADC 07 015 MADC 07 016 ...

Page 226: ... new element Tighten bolt 4 Tightening Torque 30 to 40 N m 3 0 to 4 0 kgf m 22 to 29 lbf ft 9 Tighten air bleed plug 3 and drain plug 2 Tightening Torque Aire Bleed plug 3 30 to 40 N m 3 0 to 4 0 kgf m 22 to 29 lbf ft Drain plug 2 13 to 17 N m 1 3 to 1 7 kgf m 10 to 12 lbf ft 10 Open cock 1 on the bottom of the fuel tank 11 Bleed Air from the Fuel System After replacing the fuel filter element ble...

Page 227: ...er reinstall bent or damaged hoses According to the check points shown below check hoses for oil leaks and damage If any abnormality is found replace or retighten the hose as instructed in the table Hose Interval hours Check Points Abnormalities Remedies Daily Hose ends Leak 1 Retighten or replace Hose covers Wear crack 2 Replace Every 250 hours Hose covers Crack 3 Replace Hose ends Crack 4 Replac...

Page 228: ...ressed air pressure Less than 0 2 MPa 2 kgf cm2 Clear area of bystanders guard against flying chips and wear personal protection equipment including goggles or safety glasses IMPORTANT To clean element 1 avoid giving shocks or striking element 1 with other objects 5 Clean outer element 1 by blowing compressed air less than 0 2 MPa 2 kgf cm2 outward from the inside of the filter element After clean...

Page 229: ...ps 2 10 Start the engine and run at slow idle 11 Check the air filter restriction indicator on the monitor panel If the air filter restriction indicator comes ON stop the engine and replace outer element 1 12 When replacing the air cleaner filter element replace both outer 1 and inner 6 elements together Remove outer element 1 Clean the filter interior before removing inner element 6 Remove inner ...

Page 230: ... 2 15 35 1 8 3 2 2 3 4 2 2 6 4 8 20 40 2 0 3 0 2 6 3 9 3 0 4 4 25 45 2 3 2 7 2 9 3 6 3 3 4 1 30 50 2 5 2 5 3 2 3 3 3 7 3 7 dCAUTION Precautions for handling antifreeze Antifreeze is poisonous Antifreeze is poisonous if ingested it can cause serious injury or death Induce vomiting and get emergency medical attention immediately If antifreeze is accidentally splashed into eyes flush with water for 1...

Page 231: ...sibly causing severe burns After the coolant temperature has lowered slowly loosen cap 1 to release the inside air pressure before removing cap 1 If coolant reservoir 2 is empty add coolant through cap 1 of the radiator When refilling a Long Life Coolant LLC use the same brand product and the same mixture ratio as already used in the machine If only water is refilled the mixture ratio in the Long ...

Page 232: ...kgf 22 lbf Deflection 7 to 9 mm Visually check the belt for wear Replace if necessary Adjust Fan Belt Tension ZX33U 5A 38U 5A 1 Remove bolts 4 from the right side of the seat Remove covers 3 to open the checking port 2 Loosen adjusting bolt 6 and mounting bolt 7 of alternator 5 3 Adjust belt tension by moving alternator 5 forward or backward 4 Securely tighten bolts 6 and 7 IMPORTANT When a new be...

Page 233: ...djust belt tension by moving alternator 5 forward or backward by using adjusting screw 4 4 Securely tighten bolts 6 and nut 3 IMPORTANT When a new belt is installed be sure to re adjust the tension after operating the engine for 3 to 5 minutes at slow idle speed to be sure that the new belt is seated correctly 1 1 2 3 4 5 6 6 MADB 07 050 MADB 07 049 ...

Page 234: ...nsion by moving alternator 5 forward or backward by using adjusting screw 4 4 Securely tighten bolts 6 and nut 3 IMPORTANT When a new belt is installed be sure to re adjust the tension after operating the engine for 3 to 5 minutes at slow idle speed to be sure that the new belt is seated correctly 1 1 1 1 2 1 5 6 3 4 5 6 MADC 07 002 MADC 07 003 MADC 07 004 ...

Page 235: ...irst dCAUTION Do not loosen radiator cap 1 until the system has cooled Hot steam may spout out possibly causing severe burns Loosen the cap slowly to the stop Release all pressure before removing the cap IMPORTANT Use soft water as a coolant Do not use strong acid or alkaline water Use the coolant with genuine Hitachi Long Life Coolant LLC mixed by 30 to 50 ZX33U 5A 38U 5A ZX48U 5A 55U 5A 65USB 5A...

Page 236: ...d slightly higher than slow idle to raise the coolant temperature until the first two segments come on Then run the engine further for about 10 minutes 4 Stop the engine and open radiator drain cock 2 Flush out the cooling system with tap water until draining water is clear This helps remove rust and sediment 5 Close drain cock 2 Fill the radiator with LLC at the specified mixing ratio When adding...

Page 237: ...e remove them before starting the engine IMPORTANT Cover the air cleaner inlet opening to prevent the entry of dust and water while cleaning the radiator If air with pressure of higher than 0 2 MPa 2 kgf cm2 or tap water with high delivery pressure is used for cleaning damage to the radiator oil cooler fins may result Check the core periodically and replace it if necessary when the machine is oper...

Page 238: ...ng If clogged remove clean and reinstall the air conditioner condenser Clean Air Conditioner Condenser Front Screen every 500 hours Optional ZX33U 5A 38U 5A 48U 5A 55U 5A IMPORTANT When operating the machine in a dusty environment check the air conditioner condenser front screen every day for dirt and clogging If clogged remove clean and reinstall the air conditioner condenser front screen ...

Page 239: ...omponents If replacement or modification of such components is required contact your authorized dealer Batteries dWARNING Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check the battery electrolyte level Do not continue to use or charge the battery when electrolyte level is lower than specified Explosion of the battery may result Sulfuric acid in battery el...

Page 240: ...harge the batteries If the battery is used with the electrolyte level lower than the specified lower level the battery may deteriorate quickly Do not refill electrolyte more than the specified upper level Electrolyte may spill damaging the painted surfaces and or corroding other machine parts fNOTE In case electrolyte is refilled more than the specified upper level line or beyond the bottom end of...

Page 241: ...dge the accurate electrolyte level in this case Therefore when the electrolyte level is flush with the U L the level is judged to be proper Then referring to the right illustrations check the level When the electrolyte level is lower than the bottom end of the sleeve refill with distilled water or commercial battery fluid up to the bottom end of the sleeve Be sure to refill with distilled water be...

Page 242: ...dures If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 If splashed in eyes flush with water for 10 to 15 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk 3 Get medical attention immediately IMPORTANT Check the specific gravity of the electrolyte after it...

Page 243: ...A MONITOR B RADIO 20 A CAB SOCKET 25 A LIGHT 5 A OPTION 10 A MAIN RELAY 10 A OPTION 5 A OPT POWER 5 A ENGINE 5 A START 5 A PILOT SHUT OFF 25 A A C 5 A OPT POWER ACC 10 A WIPER WASHER 5 A TRAVEL ILLUMI 20 A POWER SOCKET ZX65USB 5A 5 A MONITOR ACC 5 A HORN 5 A A C PANEL CAB 5 A MONITOR B RADIO 20 A CAB SOCKET 25 A LIGHT 5 A TRAVEL RELAY 10 A MAIN RELAY 10 A OPTION 5 A OPT POWER 5 A ENGINE 5 A START ...

Page 244: ...ety equipment appropriate to the job 1 Use hammer 2 and drift 3 to drive out locking pin 5 Take care not to damage rubber pin lock 4 2 Check lock pin 5 and rubber pin lock 4 Short locking pins and damaged rubber pin locks must be replaced with new ones WRONG 1 2 3 4 A 4 5 5 RIGHT WRONG M104 07 116 M104 07 118 M104 07 058 M104 07 059 M104 07 056 Flush one end of the locking pin to evaluate In this ...

Page 245: ... surface 4 Install rubber pin lock 4 into shank 6 hole as shown 5 Position new tooth 1 over shank 6 6 Drive locking pin 5 fully into the hole as shown RIGHT RIGHT RIGHT WRONG WRONG WRONG 6 6 1 1 5 4 M104 07 060 M104 07 061 M104 07 062 ...

Page 246: ...ound Be sure the bucket will not roll when the pins are removed 2 Slide the O rings out of the way as shown 3 Remove bucket pins A and B to separate the arm and bucket Installation 1 Clean the pins and pin bores Apply sufficient grease to the pins and pin bores 2 Place the new bucket in stable position as shown in the figure 3 Fit the arm and alternate bucket Be sure the bucket will not roll Insta...

Page 247: ...e track area by washing Adjust Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat this procedure to raise the other track Each time be sure to place blocks under the machine frame to support the machine To prevent accident...

Page 248: ...rotate the raised track dCAUTION To prevent accidents care should be taken to ensure that hands feet and any body parts do not become entangled when working around the tracks 4 When proper track sag is obtained turn valve 1 clockwise to the original condition Tightening Torque 90 N m 9 kgf m dCAUTION Consult your authorized dealer if grease is not sufficiently drained Tighten the Track Rubber Craw...

Page 249: ...th may result Be sure to remove the rubber track only after taking appropriate measures to prevent the front idler from coming off Removing Rubber Crawler 1 Lower the bucket and blade to raise one track off ground as shown Place blocks under machine frame to support the machine 2 Slowly turn valve 1 counterclockwise to allow grease to escape from the grease outlet 3 Insert two or three steel pipes...

Page 250: ...erse apply horizontal force to the rubber track to seat it on the idler 5 Insert a steel pipe into gaps among lower rollers track frame and rubber track and rotate the rubber track slowly to correctly seat the rubber track on the idler 6 Confirm that the rubber track is correctly engaged with the sprocket and idler 7 Adjust track sag Refer to Adjust Track Sag 8 After checking that the rubber track...

Page 251: ... 5A 140 to 160 mm 5 5 to 6 3 in fNOTE Check track sag after thoroughly removing soil stuck on the track area by washing Adjust Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat this procedure to raise the other track Each...

Page 252: ...tate the raised track dCAUTION To prevent accidents care should be taken to ensure that hands feet and any body parts do not become entangled when working around the tracks 4 When proper track sag is obtained turn valve 1 clockwise to the original condition Tightening Torque 90 N m 9 kgf m dCAUTION Consult your authorized dealer if grease is not sufficiently drained Tighten the Track Steel Crawler...

Page 253: ...fter the rubber track is removed the front idle will become free to remove If the front idle comes off unexpectedly personal injury and or death may result Be sure to remove the rubber track only after taking an appropriate measure to prevent the front idler from coming off Consult your authorized dealer for converting the track Change the track adjuster whenever converting the steel or rubber tra...

Page 254: ...ng the machine thoroughly examine belt 1 buckle 2 and attaching hardware 3 If any item is damaged or materially worn replace the seat belt or component before operating the machine We recommend that the seat belt be replaced every three years regardless of its apparent condition 1 2 3 MADB 01 003 ...

Page 255: ...vent in the cab Kind of refrigerant and amount when shipping the machine Model Type Amount ZX33U 5A 38U 5A 48U 5A 55U 5A HFC134a 0 65 0 05 kg ZX65USB 5A 0 85 0 05 kg IMPORTANT Do not dispose FREON gas into the atmosphere to prevent depletion of the ozone layer and global warming Check the condenser If the condenser fins become clogged with dirt or insects the cooling effect will be decreased Be su...

Page 256: ... in the cab Kind of refrigerant and amount when shipping the machine Model Type Amount ZX33U 5A 38U 5A 48U 5A 55U 5A HFC134a 0 65 0 05 kg IMPORTANT Do not dispose FREON gas into the atmosphere to prevent depletion of the ozone layer and global warming Check the condenser If the condenser fins become clogged with dirt or insects the cooling effect will be decreased Be sure to keep them clean at all...

Page 257: ... system see your authorized dealer for inspection Adjust Compressor Belt Tension 1 Loosen lock nut 2 of tension pulley 1 2 Move tension pulley 1 by adjusting bolt 3 until tension is correct 3 Securely tighten lock nut 2 of tension pulley 1 Tightening Torque 41 to 50 N m 4 1 to 5 0 kgf m 30 to 37 lbf ft IMPORTANT When a new belt is installed be sure to re adjust the tension after operating the engi...

Page 258: ...when the machine is operated in dusty areas Removing Recirculating Air Filter 1 Open left side panel 1 located under the seat 2 Grasp and pull tab 3 of circulation filter 2 to remove filter 2 Filter 2 can be folded at the middle part Pull the filter while folding it Take care so that it does not interfere with pedals 1 3 2 a 3 2 a 1 MADC 07 006 MADC 07 007 MADC 07 013 MADC 07 014 ZX65USB 5A ZX65US...

Page 259: ...g downward lightly tap the filter 2 frame to let large dirt drop 2 Clean side a of filter 2 by using a vacuum cleaner Installation 1 Install filter 2 with side a facing as illustrated Install tab 3 as illustrated 2 Close panel 1 1 3 2 a 3 2 a 1 MADC 07 006 MADC 07 007 MADC 07 013 MADC 07 014 ZX65USB 5A ZX65USB 5A ZX33U 5A 38U 5A 48U 5A 55U 5A ZX33U 5A 38U 5A 48U 5A 55U 5A ...

Page 260: ...er 1 facing downward lightly tap the filter 1 frame to let large dirt drop 2 Clean side a of filter 1 by using a vacuum cleaner Installation IMPORTANT Inappropriate installation of the filter may cause dust to enter into the heater unit and air conditioner causing malfunction or breakdown of them Before installing the filter element clean off dust around the mounting area install the filter elemen...

Page 261: ...ith side a of filter 1 facing downward lightly tap the filter 1 frame to let large dirt drop 2 Clean side a of filter 1 by using a vacuum cleaner Installation IMPORTANT Inappropriate installation of the filter may cause dust to enter into the heater unit or air conditioner causing malfunction or breakdown of them Before installing the filter element clean off dust around the mounting area install ...

Page 262: ... the ducts 1 2 and 3 1 Park the machine following the same procedures as described on page 7 7 for preparation for inspection and maintenance 2 Sweep the cab floor clean using a brush and brush dust from the cab floor while spraying water Sweep out the mud and dust with a brush as much as possible before applying water 3 When cleaning the floor mat sweep dust water along the grooves on the floor m...

Page 263: ...Timing every 1500 hours Consult your authorized dealer for inspection and repair Measure Engine Compression Pressure as required Consult your authorized dealer for inspection and repair Check Starter and Alternator every 1000 hours Consult your authorized dealer for inspection and repair Check Crankcase Breather every 1500 hours Consult your authorized dealer for inspection and repair Check Radiat...

Page 264: ...t 50 hours then every 250 hours Tighten to torque shown if any are loose Bolts and nuts should be replaced with those of the same or higher grade For tightening nuts and bolts other than specified in the table below refer to the Tightening Torque Chart at the end of this section IMPORTANT Check and tighten bolts and nuts using a torque wrench ...

Page 265: ...2 11 19 110 11 80 12 Cab mounting bolt 12 5 19 90 9 65 13 Swing bearing mounting bolt Upperstructure 12 22 19 110 11 80 Undercarriage 12 20 19 110 11 80 14 Travel device mounting bolt 12 24 19 110 11 83 15 Sprocket mounting bolt 12 24 19 110 11 83 16 Upper roller mounting bolt 16 2 24 210 21 151 17 Lower roller mounting bolt 14 16 22 220 22 130 18 Cover mounting bolt 6 10 5 0 5 3 5 8 13 10 1 7 10 ...

Page 266: ...Poles 12 11 19 110 11 80 12 Cab mounting bolt 12 5 19 110 11 80 13 Swing bearing mounting bolt Upperstructure 12 27 19 110 11 80 Undercarriage 12 24 19 110 11 80 14 Travel device mounting bolt 14 24 22 180 18 130 15 Sprocket mounting bolt 14 24 22 180 18 130 16 Upper roller mounting bolt 16 2 24 270 27 199 17 Lower roller mounting bolt 16 16 24 270 27 195 18 Cover mounting bolt 6 10 5 0 5 3 5 8 13...

Page 267: ... 18UNF 19 30 3 22 22 40 4 29 3 4 16UNF 27 65 6 5 47 1 1 16 12UNF 36 180 18 130 1 5 16 12UNF 41 210 21 151 1 5 8 12UNF 2 50 250 25 184 ORS 9 16 18UNF 19 30 3 22 11 16 16UNF 22 70 7 52 13 16 16UNF 27 95 9 5 69 1 3 16 12UNF 36 180 18 130 1 7 16 12UNF 2 41 210 21 151 8 T bolt clamp of low pressure piping 1 4 28UNF 4 11 10 1 7 9 Pump mounting bolt 12 4 19 90 9 65 10 Pump cover mounting bolt 10 12 17 50...

Page 268: ...55 22 Shoe bolt optional 12 312 19 165 16 5 121 23 Cover mounting bolt 6 10 5 0 5 3 5 8 13 10 1 7 10 17 50 5 36 24 Counterweight mounting bolt 24 3 36 930 95 685 25 Additional counterweght mounting bolt optional 20 2 30 540 55 398 26 Front pin lock bolts 10 17 50 5 36 12 19 90 9 65 14 22 140 14 103 16 24 210 21 151 18 27 400 40 236 27 Track roller guard mounting bolt optional 16 12 24 270 27 196 ...

Page 269: ...10 220 22 160 M24 36 19 950 95 700 700 70 520 280 28 205 M27 41 19 1400 140 1030 1050 105 770 400 40 295 M30 46 22 1950 195 1440 1450 145 1070 550 55 410 M33 50 24 2600 260 1920 1950 195 1440 750 75 550 M36 55 27 3200 320 2360 2450 245 1810 950 95 700 dCAUTION If fixing bolts for counterweight are loosened consult your nearest authorized dealer IMPORTANT Apply lubricant e g white zinc B solved int...

Page 270: ...MAINTENANCE 7 102 MEMO ...

Page 271: ...vice intervals Radiator Clean the oil cooler screen to prevent clogging of the radiator core Fuel System Clean the filter element and strainer regularly at shorter service intervals Electrical Parts Clean the commutator especially for the starter and alternator Rocky Ground Track Carefully operate while checking for cracks damage and loose bolts and nuts Do not use rubber crawlers Front Attachment...

Page 272: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 2 MEMO ...

Page 273: ...eading NO COOLANT Protection Against Dust and Moisture Store the machine in a dry storage area using a protective cover Tools Inspect and repair then store Lubrication Operation If oil film on the metal surfaces is lost rust may begin possibly causing abnormal wear of the machine when the machine operation is restarted If the machine is stored for a long time operate hydraulic functions for travel...

Page 274: ...STORAGE 10 2 MEMO ...

Page 275: ...lectronic components Engine Consult the nearest Hitachi dealer for the engine troubleshooting Engine Auxiliaries Problem Cause Solution Batteries will not be charged Broken battery separator Replace Faulty regulator Adjust and replace Faulty ground line Repair Faulty alternator Repair or replace Batteries discharge quickly after being charged Shorted cable Repair or replace Shorted battery separat...

Page 276: ...ter rotates No fuel After checking that no fuel is leaking refill fuel Faulty injection pump Repair and adjust Air in the fuel system Bleed air Clogged fuel filter After draining water replace the element Frozen fuel Warm the fuel pump with hot water or wait until the atmospheric temperature rises Faulty preheat system Repair and adjust Even though the engine is started the engine stalls soon Too ...

Page 277: ...orn pusher Replace Does not move smoothly Worn pusher Repair or replace Faulty pilot valve Replace Does not return to neutral Faulty pilot valve Replace The lever is tilted in the neutral position due to increase in play Worn joint Repair or replace Faulty pilot valve Replace Mark Consult your authorized Hitachi dealer ...

Page 278: ...s pilot shut off solenoid valve pilot shut off switch Repair or replace The pilot control shut off lever is in the LOCK position Turn the pilot shut off lever to the UNLOCK position All actuators have no power Malfunction due to worn hydraulic pump Replace Decreased main relief valve set pressure in the control valve Adjust Lack of hydraulic oil Refill Clogged suction strainer in the hydraulic oil...

Page 279: ...ty pilot circuit line Repair or replace Only one cylinder is inoperable or has no power Broken oil seal in cylinder Repair or replace Oil leak due to damage to cylinder rod Repair or replace Faulty pilot valve Replace Faulty pilot circuit line Repair or replace Low set pressure of main or port relief valve boom arm and bucket Adjust and replace Hydraulic oil temperature increases Stained oil coole...

Page 280: ...unter balance valve Replace Does not travel smoothly Overly tensioned or slackened crawler sag Adjust Deformed track frame Repair or replace Embedded foreign matter such as rock fragments Remove Dragged parking brake Repair Faulty counter balance valve Replace Travel speed does not change Faulty travel speed switch Replace Poor contact in connector Repair or replace Damaged wire harness Repair Fau...

Page 281: ...g bearing and bearing balls Repair or replace Lack of grease Refill Low set pressure of swing relief valve Adjust and replace Mark Consult your authorized Hitachi dealer Immediately after the control valve swing motor relief valve and or the swing motor is replaced a noise may be emitted and or operation may not be performed smoothly due to air trapped in the hydraulic line Slowly continue to oper...

Page 282: ...de switch Replace Poor contact in connector Repair or replace Damaged wire harness between ECU and monitor Repair Faulty controller ECU Replace Faulty solenoid valve Repair or replace Auto idle is inoperable or not released Faulty pressure sensor Replace Poor contact in connector Repair or replace Damaged wire harness Repair Faulty controller Replace Mark Consult your authorized Hitachi dealer Oth...

Page 283: ...ht Clearance mm ft in 550 1 10 F Engine Cover Height mm ft in 1530 5 G Undercarriage Length mm ft in 2110 6 11 H Undercarriage Width mm ft in 1550 5 1 I Sprocket Center to Idler Center mm ft in 1660 5 5 J Track Shoe Width mm ft in 300 1 Ground Pressure kPa kgf cm2 psi 30 0 31 4 4 32 0 32 4 5 Swing Speed min 1 rpm 9 1 9 1 Travel Speed fast slow km h mph 4 3 2 8 2 7 1 7 Gradeability 30 tan θ 0 58 fN...

Page 284: ...dius mm ft in 1970 6 6 2090 6 10 2150 7 1 2180 7 2 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position mm ft in 360 1 2 J Blade Bottom Lowest Position mm ft in 320 1 1 K Offset Distance mm ft in L610 2 R735 2 5 L450 1 6 R700 2 4 L610 2 R700 2 4 L450 1 6 R700 2 4 Maximum Boom Swing Angle L72 R62 52 L62 R45 L62 R62 52 L62 R45 fNOTE The dimensions do not include the heig...

Page 285: ...rd For Ordinary Ground Optional For Paved Road Optional For Paved Road Optional Operating Weight kg 3510 3650 3750 3720 Minimum Ground Clearance mm 280 270 310 320 Undercarriage Length mm 2110 2130 2170 2180 Undercarriage Width mm 1550 1550 1550 1550 Ground Pressure kPa 32 33 34 33 kgf cm2 0 32 0 33 0 35 0 34 fNOTE The specifications for the front end attachment are for 1 52 m arm with ISO 0 08 m3...

Page 286: ...eir bulk density shall be less than 1600 kg m as a standard Loading work For loading operation of dried loosened earth and sand Their bulk density shall be less than 1100 kg m as a standard Bucket Types and Applications ZX33U 5A Bucket Bucket Capacity m yd ISO Heaped Bucket Width mm Front End Attachment With side cutter mm in Without side cutter mm in 1 17 m 3 10 Arm 1 52 m 5 0 Arm Hoe Bucket 0 04...

Page 287: ...ight Clearance mm ft in 550 1 10 F Engine Cover Height mm ft in 1530 5 G Undercarriage Length mm ft in 2110 6 11 H Undercarriage Width mm ft in 1740 5 9 I Sprocket Center to Idler Center mm ft in 1660 5 5 J Track Shoe Width mm ft in 300 1 Ground Pressure kPa kgf cm2 psi 34 0 35 4 9 36 0 36 5 2 Swing Speed min 1 rpm 9 1 9 1 Travel Speed fast slow km h mph 4 3 2 8 2 7 1 7 Gradeability 30 tan θ 0 58 ...

Page 288: ...ius mm ft in 2080 6 10 2190 7 2 2240 7 4 2300 7 7 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position mm ft in 360 1 2 J Blade Bottom Lowest Position mm ft in 400 1 4 K Offset Distance mm ft in L610 2 R735 2 5 L450 1 6 R700 2 4 L610 2 R700 2 4 L450 1 6 R700 2 4 Maximum Boom Swing Angle L72 R62 52 L62 R45 L62 R62 52 L62 R45 fNOTE The dimensions do not include the heigh...

Page 289: ...rd For Ordinary Ground Optional For Paved Road Optional For Paved Road Optional Operating Weight kg 3960 4100 4200 4170 Minimum Ground Clearance mm 280 270 310 320 Undercarriage Length mm 2110 2130 2170 2180 Undercarriage Width mm 1740 1740 1740 1740 Ground Pressure kPa 36 37 38 37 kgf cm2 0 36 0 38 0 38 0 38 fNOTE The specifications for the front end attachment are for 1 72 m arm with ISO 0 10 m3...

Page 290: ...e less than 1600 kg m as a standard Loading work For loading operation of dried loosened earth and sand Their bulk density shall be less than 1100 kg m as a standard Bucket Types and Applications ZX38U 5A Bucket Bucket Capacity m yd ISO Heaped Bucket Width mm Front End Attachment With side cutter mm in Without side cutter mm in 1 32 m 4 4 Arm 1 72 m 5 8 Arm Hoe Bucket 0 04 0 052 0 055 0 072 0 065 ...

Page 291: ...weight Clearance mm ft in 610 2 F Engine Cover Height mm ft in 1590 5 3 G Undercarriage Length mm ft in 2500 8 2 H Undercarriage Width mm ft in 1960 6 5 I Sprocket Center to Idler Center mm ft in 2000 6 7 J Track Shoe Width mm ft in 400 1 4 Ground Pressure kPa kgf cm2 psi 27 0 27 3 9 28 0 29 4 1 Swing Speed min 1 rpm 9 0 9 0 Travel Speed fast slow km h mph 4 2 2 5 2 6 1 6 Gradeability 30 tan θ 0 5...

Page 292: ...rall Height mm ft in 2530 8 2 F Overall Length mm ft in 5350 17 7 5390 17 8 5350 17 7 5390 17 8 G Minimum Swing Radius mm ft in 2240 7 4 2370 7 10 2240 7 4 2370 7 10 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position mm ft in 460 1 6 J Blade Bottom Lowest Position mm ft in 365 1 2 K Offset Distance mm ft in L690 2 3 R850 2 10 Maximum Boom Swing Angle L80 R60 fNOTE Th...

Page 293: ...rd For Ordinary Ground Optional For Paved Road Optional For Paved Road Optional Operating Weight kg 4900 5010 5200 5070 Minimum Ground Clearance mm 340 320 360 360 Undercarriage Length mm 2500 2490 2540 2540 Undercarriage Width mm 1960 1960 1960 1960 Ground Pressure kPa 28 28 30 29 kgf cm2 0 28 0 29 0 30 0 29 fNOTE The specifications for the front end attachment are for 1 69 m arm with ISO 0 11 m3...

Page 294: ...earth sand mud and so on Their bulk density shall be less than 1600 kg m as a standard Loading work For loading operation of dried loosened earth and sand Their bulk density shall be less than 1100 kg m as a standard Bucket Types and Applications ZX48U 5A Bucket Bucket Capacity m yd ISO Heaped Bucket Width mm Front End Attachment With side cutter mm in Without side cutter mm in 1 38 m 4 6 Arm 1 69...

Page 295: ...rweight Clearance mm ft in 610 2 F Engine Cover Height mm ft in 1590 5 3 G Undercarriage Length mm ft in 2500 8 2 H Undercarriage Width mm ft in 2000 6 7 I Sprocket Center to Idler Center mm ft in 2000 6 7 J Track Shoe Width mm ft in 400 1 4 Ground Pressure kPa kgf cm2 psi 29 0 29 4 1 29 0 30 4 3 Swing Speed min 1 rpm 9 0 9 0 Travel Speed fast slow km h mph 4 2 2 5 2 6 1 6 Gradeability 30 tan θ 0 ...

Page 296: ... Height mm ft in 2530 8 2 F Overall Length mm ft in 5470 17 11 5520 18 1 5470 17 11 5520 18 1 G Minimum Swing Radius mm ft in 2210 7 3 2300 7 7 2210 7 3 2300 7 7 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position mm ft in 460 1 6 J Blade Bottom Lowest Position mm ft in 365 1 2 K Offset Distance mm ft in L690 2 3 R850 2 10 Maximum Boom Swing Angle L80 R60 fNOTE The di...

Page 297: ...rd For Ordinary Ground Optional For Paved Road Optional For Paved Road Optional Operating Weight kg 5210 5320 5510 5380 Minimum Ground Clearance mm 340 320 360 360 Undercarriage Length mm 2500 2490 2540 2540 Undercarriage Width mm 2000 2000 2000 2000 Ground Pressure kPa 29 30 31 30 kgf cm2 0 30 0 31 0 32 0 31 fNOTE The specifications for the front end attachment are for 1 69 m arm with ISO 0 14 m3...

Page 298: ...earth sand mud and so on Their bulk density shall be less than 1600 kg m as a standard Loading work For loading operation of dried loosened earth and sand Their bulk density shall be less than 1100 kg m as a standard Bucket Types and Applications ZX55U 5A Bucket Bucket Capacity m yd ISO Heaped Bucket Width mm Front End Attachment With side cutter mm in Without side cutter mm in 1 38 m 4 6 Arm 1 69...

Page 299: ... Clearance mm ft in 620 2 F Engine Cover Height mm ft in 1600 5 3 G Undercarriage Length mm ft in 2500 8 2 H Undercarriage Width mm ft in 2000 6 7 I Sprocket Center to Idler Center mm ft in 1990 6 6 J Track Shoe Width mm ft in 400 1 4 Ground Pressure kPa kgf cm2 psi 37 0 37 5 4 Swing Speed min 1 rpm 9 5 9 5 Travel Speed fast slow km h mph 4 8 2 9 3 0 1 8 Gradeability 25 tan θ 0 47 fNOTE The dimens...

Page 300: ...l Length mm ft in 5760 18 11 5790 19 G Minimum Swing Radius mm ft in 2450 8 1 2540 8 4 H Boom Swing Pivot Offset Distance mm ft in 45 2 I Blade Bottom Highest Position mm ft in 450 1 6 J Blade Bottom Lowest Position mm ft in 390 1 3 K Offset Distance mm ft in L720 2 4 R850 2 9 Maximum Boom Swing Angle L80 R60 fNOTE The dimensions do not include the height of the shoe lug The dimensions of the mach...

Page 301: ...d Pressure kPa 37 37 37 kgf cm2 0 37 0 38 0 38 fNOTE The specifications for the front end attachment are for 1 85 m arm with ISO 0 22 m3 bucket Rubber shoe rubber pad shoe and pad crawler shoe should be used on paved road Use of rubber crawlers on other than paved road may shorten the service life of the rubber crawlers to a great extent Other than 400 mm grouser shoe should not be used on gravel ...

Page 302: ...igging and loading operation of dried loosened earth sand mud and so on Their bulk density shall be less than 1600 kg m as a standard Loading work For loading operation of dried loosened earth and sand Their bulk density shall be less than 1100 kg m as a standard Bucket Types and Applications ZX65USB 5A Bucket Bucket Capacity m yd ISO Heaped Bucket Width mm Front End Attachment With side cutter mm...

Page 303: ...avoid damaging the machine hydraulic breaker crusher or quick coupler follow the precautions given below Precautions for connecting breaker crusher or quick coupler piping Do not allow impurities to enter into the system when disconnecting connecting hoses of the breaker crusher or the quick coupler with the arm end piping When the breaker crusher or quick coupler is not installed always install c...

Page 304: ...perator Refer to the ROPS certification affixed in the cab for the allowable maximum operating weight Specification Base Machine Breaker Crusher Pulverizer Model Arm Std Weight Max Weight Std Weight Max Weight Zero Tail Swing Model ZX33U 5A Std 200 220 240 280 Long 180 190 210 250 ZX38U 5A Std 250 280 300 350 Long 220 240 260 300 ZX48U 5A Std 320 350 390 450 Long 290 320 350 410 ZX55U 5A Std 370 4...

Page 305: ... 38U 5A ZX65USB 5A B C Stop Valves Pedal Operation and Hydraulic Oil Flow When the pedal is depressed to D side hydraulic oil flows into line B When the pedal is depressed to E side hydraulic oil flows into line C ZX48U 5A 55U 5A C Stop Valves B C Close When not using attachment or is detached Open When using attachment Close Open MADB 13 003 MADB 13 004 MADB 13 002 MADB 13 001 MADC 12 003 MADB 13...

Page 306: ...n cover 1 of attachment pedal 2 forward 2 Depress attachment pedal 2 forward to operate the breaker 3 Remove foot from attachment pedal 2 to stop the breaker 4 Depress attachment pedal 2 forward and lock the pedal to continuously operate the breaker 5 When attachment pedal 2 is locked in the neutral position the breaker does not operate When the breaker is not in use lock the pedal in the neutral ...

Page 307: ... any objects with breaker Doing so will result in damage to the breaker the front attachment and or the upperstructure Always move lower the breaker slowly to position the tip of the chisel on the object to be broken before starting breaker operation Avoid moving objects with breaker Do not use the breaker and or the bracket to move objects Especially do not use the swing function to move objects ...

Page 308: ...s Immediately consult your authorized HITACHI dealer Do not operate the breaker in water Doing so will cause rust and seal damage resulting in damage to the hydraulic system components Rust dust and water may enter into the hydraulic oil through the broken seal causing damage to the hydraulic system Do not use breaker for lifting operation The machine tipping over and or breaker damage may result ...

Page 309: ...hisel the axis is positioned and thrust perpendicular to the object Failure to do so may damage the chisel or may cause seized piston Do not operate the breaker continuously longer than one minute Failure to do so may result in premature wear of the chisel If an object could not be broken within one minute apply the chisel to other locations less than one minute for each location Watch Out Take ca...

Page 310: ...ont attachment Do not raise the front part of the undercarriage 150 mm or more by pressing down the breaker Do not operate breaker with the boom swing operation Do not operate the breaker for long period of time while swinging the boom Failure to do so may shorten the service life of the main frame Raising 10 to 15 cm Pressing Down OK M147 05 016 MADB 13 044 ...

Page 311: ...al 2 when the pedal is not in use 1 Turn cover 1 of attachment pedal 2 forward 2 Depress attachment pedal 2 backward and forward to operate the crusher 3 Remove foot from attachment pedal 2 to stop the crusher 4 When attachment pedal 2 is locked in the neutral position the crusher does not operate When the crusher is not in use lock the pedal in the neutral position 1 2 MADB 13 007 1 Lock Open For...

Page 312: ...t cylinder fully extended or retracted Failure to do so may result in damage to the front attachment In particular avoid doing so with the bucket cylinder fully extended as the front attachment will be easily damaged Take care to prevent this from happening when dismantling foundation structures using the crusher Using the front attachment do not raise the base machine off the ground with the arm ...

Page 313: ...hen operating the crusher up high with the boom fully raised be careful of falling objects When operating the crusher on a floor in a building first confirm that the floor has sufficient strength to support the load caused by crushing in addition to the machine weight The load equivalent or higher than the machine weight may be applied on floor depending on the operation method MZX5 13 010 MZX5 13...

Page 314: ...er and bucket or crusher and breaker are used and replaced with each other at intervals impurities are more apt to enter the hydraulic system the hydraulic oil deteriorates quickly For this reason replace the hydraulic oil tank filter and change the hydraulic oil at the intervals specified in the breaker time sharing diagram in the previous section Always remove the crusher from the excavator befo...

Page 315: ...equirements on safe proper mounting and operation of the attachment with its manufacturer or distributor and observe them The Extra Piping can be operated by using switches provided on right control lever 1 as illustrated AUX Function Lever Right for Extra Piping 1 Attachment such as a breaker can be operated by moving slide switch 2 on right control lever 1 left and right 2 Pushing switch 3 on ri...

Page 316: ...um Flow Rate 40 L 11 US gal min 45 L 12 US gal min Maximum Flow Rate 66 L 17 US gal min 85 L 22 US gal min Flow Rate Control Switch 1 LOW sets to the minimum flow rate HIGH sets to the maximum flow rate When shifting the flow rate from the LOW to HIGH operate switch 1 while pulling the lock knob toward the arrow mark fNOTE When shifting the flow rate from the HIGH to LOW no lock knob operation is ...

Page 317: ...tor s body may come into contact with the control lever s Take care not to come into contact with the control levers when looking back Labels displaying the available lever control patterns are provided at the right of the operator M1LA 05 014 1 3 2 4 5 8 6 7 M1M7 05 001 3 4 2 1 6 5 8 7 M1M7 05 002 When a control lever is released it automatically returns to neutral stopping the function in that p...

Page 318: ...en looking back Whenever changing the pattern stop the engine rotate the selector valve and set to the pattern position Labels showing the lever control pattern are provided around the operator s seat As illustrated below the labels indicate the control patterns Refer to the illustration Lever Control Partern Label Location ZX33U 5A 38U 5A 48U 5A 55U 5A Canopy Roof Cab Right side in the cab ZX65US...

Page 319: ...out hose 7 stored in this device Set the hose end strainer 2 into the fuel tank 4 Remove fuel tank cap 4 of the device IMPORTANT If cap 4 is not removed pressure in the tank will increase and the pump performance will be degraded It will also shorten the service life of the pump 5 Turn power switch 8 of electrical pump 3 to ON position and start fueling 6 Refill fuel while checking the level gauge...

Page 320: ...the customer It is recommended to change the password frequently to prevent snooping If the customer forgets the password contact your authorized Hitachi dealer Keep open flames including burning cigarette away from the numeric keypad Use soft cloth to wipe the surface of the numeric keypad If the machine will not be in use for a long period of time disconnect the battery cables to prevent battery...

Page 321: ...rt IMPORTANT Input the password by using numeric keypad 2 within 15 seconds after all numeric keys 2 are lit After 15 seconds all numeric keys 2 will go off and inputting is not accepted any longer On that occasion redo from the beginning by turning key switch 1 OFF once Locking After key switch 1 is turned OFF the machine will be locked automatically after the lapse of time set user defined for l...

Page 322: ...t is entered at input of password 2 Locking indicator 6 red LED When locked indicator 6 slowly blinks Indicator 6 is lit when the 1st and 3rd digits are entered at the input of password 3 Numeric keys 2 1 9 and 0 Used for inputting the password and making various other kinds of setting 4 Key F 4 Used for function setting 5 Key C 5 Used primarily for cancelling input Besides this key is used to che...

Page 323: ... 3rd digit 5 Similarly input the 4th digit 6 If the input numerals coincide with those of the password the buzzer sounds twice and unlocking is done In this condition when key switch 1 is turned ON the engine will start fNOTE If mis input the password the entered numbers can be cancelled by pushing Key C 3 Alternatively redo from the beginning by turning key switch 1 OFF 2 3 1 MADB 01 007 MADB 13 ...

Page 324: ...cators 4 and 5 blink and the numerals of the new password are lit in turn After blinking the new password the password can be displayed by pushing Key C 6 fNOTE Registration is not made at this stage When the buzzer sounds 8 times and two indicators 4 and 5 alternately blink the input password was incorrect Start from item 3 again 7 Push Key F 2 for more than 2 seconds The buzzer sounds three time...

Page 325: ...vant key to set the lock delay timer List of lock time assigned to each key as timer Key 1 15 seconds Factory default Key 2 3 minutes Key 3 5 minutes Key 4 10 minutes Key 5 15 minutes Key 6 30 minutes Key 7 60 minutes Key 8 90 minutes Key 9 120 minutes Key 0 0 seconds 6 Push Key F 2 for more than 2 seconds The buzzer sounds three times and the change is registered This is the end of the procedure ...

Page 326: ...key switch 1 is turned OFF After that horn and buzzer will sound to warn the operator every time key switch 1 is turned ON until the correct password is input System Error Display In case any abnormality occurs on the system two indicators blink alternately Consult your authorized Hitachi dealer Factory Default Setting Factory default setting is shown below 1 Password 0000 2 Lock delay timer set t...

Page 327: ...that counterweight 1 does not fall Wire Rope 2 2 Breaking load more than 7 kN Pin Shackle 3 2 JIS Nominal size 8 or more Eye bolt 4 2 M16 2 Remove mounting bolts 5 dWARNING Take care if additional counterweight 1 is eccentrically lifted lifted counterweight 1 may widely sway Place removed additional counterweight 1 on a level surface Installation 1 Lift additional counterweight 1 by using the lift...

Page 328: ...peration Do not use the cab tilting device other than the applicable machines Be sure to check that no personnel are present around the machine and in the cab before using the cab tilting device Never attempt to operate the cab tilting device for daily check The daily inspection can be performed through the maintenance cover ports IMPORTANT Never attempt to modify the machine other than the author...

Page 329: ...front attachment straightforward toward the machine without swinging the front attachment at this time 6 Stop the engine Remove the key from the key switch 7 Close the cab optional door IMPORTANT Remove bolt 1 and cover 2 If the floor is tilted up with cover 2 damage to cover 2 floor and the cab tilting device may result 8 Remove bolt 1 and cover 2 9 Remove bolt 3 Loosen bolt 4 and remove cover 5 ...

Page 330: ...me off the floor resulting in unexpected accident Care should be taken that if the floor is tilted upward while raising the front attachment the canopy or cab optional may come in contact with the boom Wrench size 13 mm 17 mm 19 mm Cab 3 positions MADB 13 020 6 MADB 13 023 MADB 13 022 6 6 Canopy 2 positions at the rear Canopy 3 positions at the front ZX33U 5A 38U 5A 48U 5A 55U 5A Cab 4 positions 6...

Page 331: ...device such as a crane Failure to do so may result in breakage of the cab tilting mechanism and or floor 11 Install hose protection rubber 8 while taking care not to damage hose 7 at the cab tilting device mounting area 12 Install cab tilting device 10 through openings 9 on the machine MADB 13 024 9 7 8 MADC 018 MADC 019 10 ...

Page 332: ... 15 contact each other Failure to do so may result in breakage of the cab tilting device and or floor Take care not to entangle hoses or harnesses when installing the cab tilting device 15 Turn adjuster 16 counterclockwise to tilt up the cab until the stoppers 15 contact each other Wrench size 17 mm MADB 13 026 MADB 13 027 MADB 13 025 12 11 14 Set Condition MADB 13 029 MADB 13 028 15 13 ...

Page 333: ...efore starting to work under the tilted cab floor make sure if fall prevention bar 17 does not come off by jolting fall prevention bar 17 by hand dWARNING Fall prevention bar 17 is a redundant safety device to be functioned in case the floor tilt mechanism fails Never attempt to work under the tilted cab floor supported with only fall prevention bar 17 Failure to do so may result in a serious pers...

Page 334: ...y creating hazardous conditions 1 Before tilting the cab floor down check if any tools or workshop towels are not left behind on the base machine or in the operator s cab and fall prevention bar 2 has been stowed in position When stowing fall prevention bar 2 raise fall prevention bar 2 in the arrowed direction and then slide it backward IMPORTANT Do not attempt to tilt down the cab after the stop...

Page 335: ... Fulcrum Bolts and Working Screw Lock Nut Before Use 1 Check tilt mechanism fulcrum bolts 1 for looseness If bolt 1 is loose retighten bolt 1 to 10 N m 1 0 kgf m 2 Check working screw lock nut 2 for looseness If lock nut 2 is loose retighten nut 2 to 140 N m 14kgf m 2 1 MADB 13 035 ...

Page 336: ...NT Greasing Before Use 1 Rotate adjuster 1 counterclockwise to fully extend the tilt device 2 Apply grease all over the thread part of screw 2 of adjuster 1 Recommended grease Dow Corning Toray Co Ltd MOLYKOTE EM 30L 2 1 1 MADB 13 029 MADB 13 036 ...

Page 337: ...Applications ZX33U 5A 12 4 Bucket Types and Applications ZX38U 5A 12 8 Bucket Types and Applications ZX48U 5A 12 12 Bucket Types and Applications ZX55U 5A 12 16 Bucket Types and Applications ZX65USB 5A 12 20 C COMPONENTS NAME 1 1 Cab Tilting Mechanism 13 26 Change Bucket 7 78 Change Coolant 7 67 Change Engine Oil 7 25 Change Hydraulic Oil 7 37 Change Trip Meter Set Time 1 28 Check Air Conditioner ...

Page 338: ...ading Operation 5 14 Greasing 7 19 13 34 H Handle Chemical Products Safely S 38 Handle Fluids Safely Avoid Fires S 23 Heater Operation ZX33U 5A 38U 5A 48U 5A 55U 5A 1 32 Heating Operation 1 33 1 36 Hour Meter 1 13 How to Use Screens 1 9 Hydraulic Breaker Hydraulic Crusher and Quick Coupler 13 1 Hydraulic System 7 31 I Indicators 1 8 Inspect and Adjust Valve Clearance 7 95 Inspect Machine S 4 Inspe...

Page 339: ... Information S 1 Recommended Engine Oil 7 16 Recommended Fuel 7 52 Releasing Hose Rupture Valve Machine Equipped with Hose Rupture Valve Optional 5 25 Remove Paint Before Welding or Heating S 36 Removing and Storing Lower Front Window 1 43 Removing Rubber Crawler 7 81 Replace Air Cleaner Inner Element Optional 7 60 Replace Air Cleaner Outer and Inner Elements 7 60 Replace Circulating Air Filter 7 ...

Page 340: ...nal Words S 1 Unloading 6 6 Use Correct Track Shoe 5 19 Use Handrails and Steps S 6 Using Booster Battery 3 6 Using Rubber Crawler 5 20 W Warming Up Operation 5 7 Warn Others of Service Work S 26 Warning Codes 1 16 Warning Display Screen 1 14 Wear Protective Clothing S 3 When Windows Become Clouded 1 34 1 37 Working Ranges 12 2 12 6 12 10 12 14 12 18 ...

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