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Hitachi ZX27U-2, Operator'S Manual

The Hitachi ZX27U-2 Operator's Manual is available for free download at manualshive.com. This comprehensive manual provides detailed instructions and essential information for operating and maintaining the Hitachi ZX27U-2. Easy to navigate and download, it ensures users have access to the necessary guidance to optimize their experience with this exceptional product.

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CONTENTS 

 

Using Booster Batteries .......................................3-5 
Stopping the Engine ............................................3-6 
 

DRIVING THE MACHINE 

Travel Levers and Pedals....................................4-1 
Travel Mode Switch .............................................4-3 
Traveling on Soft Ground.....................................4-4 
Raise One Track Using Boom and Arm ..............4-4 
Towing Machine...................................................4-5 
Driving In Water or on Soft Ground .....................4-6 
Precautions for Traveling on Slopes....................4-7 
Parking and Stopping on Slopes .........................4-8 
Parking on Slopes................................................4-8 
 

OPERATING THE MACHINE 

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

(H-Pattern: HITACHI Excavator Pattern).......5-2 

Control Lever (SAE-Backhoe Pattern)   
 

--- If Equipped (2 Way Multi Valve) ...............5-3 

Boom-Swing Pedal ............................................5-4 
Auxiliary Pedal (Optional) ....................................5-5 
Blade Lever..........................................................5-6 
Precautions for Blade Operation .........................5-7 
Pilot Control Shut-Off Lever.................................5-8 
Warming Up Operation ........................................5-9 
Warming Up in Cold Weather..............................5-9 
Auto-Idle Control (Except ZX27U

-2

) ..................5-10 

Operating Backhoe ............................................5-11 
Grading Operation .............................................5-12 
Avoid Driving Bucket Teeth Into Ground ...........5-12 
Avoid Abusive Operation ...................................5-12 
Avoid Striking with Bucket .................................5-13 
Avoid Excavation Using Upperstructure   
 

and/or Boom Swing Power ..........................5-13 

Use Correct Track Shoe ....................................5-13 
Avoid Other than Specified Machine   
 Operations ...................................................5-14 
Boom Cylinder May Hit Blade............................5-15 
Avoid Hitting Blade with Bucket.........................5-16 
Avoid Colliding Blade Against Rocks.................5-16 
Avoid Colliding Boom Cylinder with Track.........5-16 
Precautions for Installing Wide Bucket 
 

or Special Type Bucket................................5-16 

Using Rubber Crawler .......................................5-17 
Hydraulic Breaker (Optional) .............................5-19 
Crusher Operation (Optional) ............................5-22 
Precautions for After Operating the Machine ....5-23 
Auxiliary Flow Rate Control   
 

(Optional) (Except ZX27U

-2

)........................5-24 

Emergency Boom Lowering Procedure.............5-25 
 

TRANSPORTING 

Transporting by Road ..........................................6-1 
Trailer Loading/Unloading ...................................6-1 
Loading ................................................................6-2 

Securing the Machine to the Trailer   
 for 

Transportation.......................................... 6-3 

Unloading ............................................................ 6-4 
Lifting Machine with Crane.................................. 6-5 
 

MAINTENANCE 

Procedures........................................................... 7-1 
Prepare Machine for Inspection/Maintenance .... 7-2 
Opening/Closing Engine Access Covers ............ 7-3 
Opening/Closing Tank Covers ............................ 7-4 
Daily Inspection ................................................... 7-5 
Periodic Replacement of Parts............................ 7-6 
Maintenance Guide ............................................. 7-7 
The Brand Names of Recommended 
 

Oils and Lubricants ..................................... 7-10 

A. Greasing...................................................... 7-11 
 Front 

Joint Pins ........................................... 7-11 

 

Bucket and Link Pins................................... 7-14 

 Blade 

Pins ................................................... 7-14 

 

Precautions for Front Attachment and 

 

   Blade Removal ...................................... 7-14 

 Swing 

Bearing ............................................. 7-15 

 Swing 

Internal Gear .................................... 7-16 

 

Control Lever Universal Joint...................... 7-16 

 Tilt 

Mechanism ............................................ 7-17 

B. Engine ......................................................... 7-18 
 Engine 

Oil.................................................... 7-18 

 Change 

Engine 

Oil ...................................... 7-18 

 Replace 

Engine 

Oil Filter ............................ 7-18 

C. Transmission............................................... 7-20 
 Travel 

Reduction Gear................................ 7-20 

D. Hydraulic System ........................................ 7-22 
 

Inspection and Maintenance of 

 

   Hydraulic Equipment ............................. 7-22 

 Check 

Hydraulic Oil Level........................... 7-23 

 

Drain Hydraulic Oil Tank Sump................... 7-24 

 Change 

Hydraulic Oil .................................. 7-25 

 Clean 

Suction 

Filter..................................... 7-28 

 

Replace Full Flow Filter Element ................ 7-29 

 

Replace Pilot Filter Element........................ 7-30 

 Check 

Hoses 

and Lines .............................. 7-32 

E. Fuel System ................................................ 7-37 
 Check 

Water 

Separator .............................. 7-38 

 

Drain Fuel Tank Sump ................................ 7-38 

 Replace 

Fuel Filter ...................................... 7-39 

 Check 

Fuel 

Hoses....................................... 7-40 

F. Air Cleaner .................................................. 7-41 
 

Clean the Air Cleaner Element ................... 7-41 

 

Replace the Air Cleaner Element................ 7-41 

G. Cooling System ........................................... 7-42 
 Check 

Coolant Level................................... 7-43 

 

Check and Adjust Fan Belt Tension............ 7-44 

 Change 

Coolant .......................................... 7-45 

 Clean 

Radiator Core ................................... 7-46 

H. Electrical System......................................... 7-47 
 Batteries ...................................................... 7-47 

Summary of Contents for ZX27U-2

Page 1: ......

Page 2: ...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 some circumstances Hitachi also provides field improvements often without charge to the customer even if ...

Page 3: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 4: ...S NAME OPERATOR S STATION BREAK IN OPERATING THE ENGINE DRIVING THE MACHINE TRANSPORTING MAINTENANCE CONSUMABLE PARTS LIST MAINTENENCEUNDERSPECIALENVIRONMENTALCONDITIONS OPERATING THE MACHINE STORAGE TROUBLESHOOTING SPECIFICATIONS REFERENCE INDEX ...

Page 5: ...fely S 24 Prevent Burns S 24 Replace Rubber Hoses Periodically S 25 Avoid High Pressure Fluids S 25 Prevent Fires S 26 Evacuating in Case of Fire S 28 Beware of Exhaust Fumes S 28 Beware of Asbestos Dust S 28 Precautions for Welding and Grinding S 29 Avoid Heating Near Pressurized Fluid Lines S 29 Avoid Applying Heat to Lines Containing Flammable Fluids S 29 Remove Paint before Welding or Heating ...

Page 6: ... Machine 5 23 Auxiliary Flow Rate Control Optional Except ZX27U 2 5 24 Emergency Boom Lowering Procedure 5 25 TRANSPORTING Transporting by Road 6 1 Trailer Loading Unloading 6 1 Loading 6 2 Securing the Machine to the Trailer for Transportation 6 3 Unloading 6 4 Lifting Machine with Crane 6 5 MAINTENANCE Procedures 7 1 Prepare Machine for Inspection Maintenance 7 2 Opening Closing Engine Access Co...

Page 7: ...zzle 7 66 Check and Adjust Valve Clearance 7 66 Check Injection Timing 7 66 Measure Engine Compression Pressure 7 66 Check Starter and Alternator 7 67 Check Radiator Cap 7 67 Check Tightening Torque of Bolts and Nuts 7 68 Check Tilt Mechanism Fulcrum Bolts for Looseness 7 71 Preparation for Inspection and Maintenance 7 72 Tilting Floor Down 7 74 CONSUMABLE PARTS LIST 8 1 MAINTENANCE UNDER SPECIAL ...

Page 8: ...CONTENTS MEMO ...

Page 9: ...any information on the machine and or components Fill these serial Nos in the blank spaces in this group to immediately make them available upon request MACHINE MODEL TYPE PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER NOTE HCM1M700X00010001 PRODUCT IDENTIFICATION NUMBER PIN M1M7 00 001 M1M7 00 002 Marks to indicate the start and end of the PIN ...

Page 10: ...MACHINE NUMBERS MEMO ...

Page 11: ...ARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs don t use any of the designated signal...

Page 12: ...messages in this SAFETY chapter are in tended to illustrate basic safety procedures of machines However it is impossible for these safety messages to cover every possible hazardous situation you may en counter If you have any questions concerning safety you should first consult your supervisor and or your au thorized dealer before operating or performing mainte nance work on the machine SA 003 PRE...

Page 13: ...evers or other parts of the machine Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while oper ating the machine SA 438 PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably lou...

Page 14: ...ng a fire Do not wear radio or music headphones and do not use a cell phone while traveling or operating the machine Never allow hazardous materials such as combustible and or explosive material in the operator s space Do not leave cigarette lighters in the cab If the tem perature in the cab increases the lighter may explode USE HANDHOLDS AND STEPS Falling is one of the major causes of personal in...

Page 15: ...nexpectedly move when a body part unintentionally comes in contact with a control lever possibly resulting in serious personal injury or death Before leaving the machine be sure to first lower the front attachment to the ground and then move the pilot control shut off lever to the LOCK position Turn the key switch OFF to stop the engine Before leaving the machine close all windows doors and access...

Page 16: ...ore starting to move or operate the machine sound the travel alarm and horn to alert bystanders Use a signal person when moving swinging or oper ating the machine in congested areas Locate the signal person so that the operator can always witness the signal person Coordinate the meanings of all safety signs hand signals and marks before starting the machine Ap point a person who is responsible to ...

Page 17: ...could result in a battery explosion or a runaway machine If the engine must be jump started be sure to follow the instructions shown in the OPERATING THE EN GINE chapter The operator must be seated in the operator s seat so that the machine will be under control when the engine starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedu...

Page 18: ...e machine Keep all bystanders and unnecessary objects out of and away from the machine working areas Always beware of the surroundings while operating the ma chine Take care not to allow the rear part of the up perstructure to come in contact with objects when swinging the machine in a small area When loading a dump truck bring the bucket from the rear side of the dump truck to avoid moving the bu...

Page 19: ...arks and or dead grass a fire may easily break out Use special care not to cause a fire Make sure the work site ground has sufficient strength to firmly support the machine When working close to an excavation or on road shoulders operate the ma chine with the tracks positioned perpendicular to the cliff face with travel motors at the rear and with the blade at the front so that the machine can mor...

Page 20: ... multiple numbers of machines provide signals commonly known by all personnel involved Also appoint a signal person to coordinate the job site Make sure that all personnel obey the signal person s direc tions SA 481 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal lever operation may result in seri ous injury or death Before driving the machine confirm the position of the undercarr...

Page 21: ... driving up or down a slope keep the bucket facing the direction of travel approximately 200 to 300 mm 8 to 12 in A above the ground If machine starts to skid or becomes unstable imme diately 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 th...

Page 22: ...ving the machine When crossing a river drive the machine slowly while measuring the depth of the river using the bucket Do not cross the river when the depth of the river is deeper than the upper track shoe surface Reduce the engine speed when traveling on rough terrains Select a slow travel speed Slower speed will reduce possible damage to the machine Drive the machine so that the travel motors d...

Page 23: ... stop a moving machine Park the machine in compliance with the safe parking procedures described on page S 19 to prevent the ma chine from running away Block both tracks and lower the bucket to the ground thrust the bucket teeth into the ground if you must park on a grade Park a reasonable distance from other machines SA 1297 ...

Page 24: ...DERS 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 a...

Page 25: ...before operating the machine SA 667 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 bucket load spill or due to collision with the bucket Never allow the bucket to pass over anyone to avoid personal injury or death SA 668 AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the foot...

Page 26: ...speeds to avoid tipping or slipping Avoid changing direction when traveling on grades NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable Reduce swing speed as necessary when swinging loads Be careful when working on frozen ground Temperature increases will cause the ground to become soft and make ground travel unstable 025 E01A 0540 4 SA 1301 NEVER ...

Page 27: ...TE WITH CAUTION If the front attachment or any other part of the machine hits against an overhead obstacle such as a bridge both the machine and the overhead obstacle will be damaged and personal injury may result as well Take care to avoid hitting overhead obstacles with the boom or arm SA 673 AVOID POWER LINES Serious injury or death can result if the machine or front attachments are not kept a ...

Page 28: ...e machine may tip over and or lifted load may fall possibly resulting in serious injury or death This machine has been exclusively designed to engage in excavation and loading works This machine is not equipped with any of the necessary safety devices that could allow the machine to be used for craning operation SA 014 PROTECT AGAINST FLYING DEBRIS If flying debris such as soil rock fragments or m...

Page 29: ...peed without load for 5 minutes Turn key switch to OFF to stop engine Remove the key from the key switch Before leaving the machine close all windows roof vent and cab door Lock all access doors and compartments SA 1306 HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care it is highly flammable If fuel ig nites an explosion and or a fire may occur possibly re sulting in serious injury or death D...

Page 30: ...urn the auto idle switch 13 OFF Ex cept ZX27U 2 6 Slowly drive the machine 7 Avoid steering while driving up or down the ramp as it is extremely dangerous If steering is unavoidable first move back to the ground or flatbed modify traveling direction and begin to drive again 8 The top end of the ramp where it meets the flatbed is a sudden bump Take care when traveling over it 9 Wedge the front and ...

Page 31: ...emperatures have cooled down to the safety range In case inspection maintenance must be performed with the engine runnning be sure to appoint an overseer Never lubricate or service the machine while moving it Repair the cracked windowpane before servicing the machine Failure to do so may cause personal injury When raising the machine above the ground using the front attachment function maintain th...

Page 32: ...e 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 op erator s station at the time Be careful not to allow the operator s station to tilt down without first stowing the fall prevention bars Damag...

Page 33: ...ts care should be taken to ensure that hands feet clothing jewelry and hair do not become entangled when working around rotating parts SA 026 PREVENT PARTS FROM FLYING Grease in the track adjuster is under high pressure Failure to follow the precautions below may result in serious injury blindness or death Do not attempt to remove GREASE FITTINGS or VALVE ASSEMBLIES As pieces of parts may fly off ...

Page 34: ...eam can cause severe burns To prevent possible injury from hot spraying water stop the engine Begine to work after the engine and radiator are sufficiently cooled DO NOT remove the radiator cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be release before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure by ...

Page 35: ...ult in severe burns gangrene or otherwise serious injury or death SA 019 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 Make sure that all connectors are completely connected before applying pressure Se...

Page 36: ...or damaged clamps lines hoses oil cooler and oil cooler flange bolts Do not bend or strike high pressure lines Never install bent or damaged lines pipes or hoses 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 e...

Page 37: ...rature parts such as a muffler or exhaust pipe Check Heat Shield Covers around Engine Compartment If the engine compartment heat shield cover becomes broken or lost fire may break out If the engine compartment heat shield cover becomes broken or lost repair or replace it before operating the machine Check Key Switch If fire breaks out failure to stop the engine will escalate the fire hampering fir...

Page 38: ...ust operate the machine in a building be sure there is adequate ventilation Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area SA 016 BEWARE OF ASBESTOS DUST Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Depending on the wok site conditions the ri...

Page 39: ...oldering SA 818 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install temporary ...

Page 40: ...rs and other flammable material from area SA 029 PREVENT BATTERY EXPLOSIONS Battery gas can explode Keep sparks lighted matches and flame away from the top of battery Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Do not charge a frozen battery it may explode Warm the battery to 16 C 60 F first Do not continue to use or charge the battery when t...

Page 41: ... refrigerant SA 405 HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with your machine include such items as lubricants electrolyte coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response tech...

Page 42: ...coolant brake fluid filters and batteries When draining fluid use a leakproof container with a capacity larger than the drained fluid volume to receive it Do not pour waste onto the ground down a drain or into any water source Inquire on the proper way to dispose of harmful waste such as oil fuel coolant brake fluid filters and batteries from your local environmental or recycling center SA 226 ...

Page 43: ...s affixed on the machine to ensure safe 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 illustra tion when placing an order of it to your authorized dealer SS3079466 SS 2640 SS4642518 M1M7 03 002 ...

Page 44: ...SAFETY SIGNS S 34 SS 259 SS 2684 SS 2652 SS 024 SS 2639 SS3090482 M1M7 07 021 CANOPY CAB ...

Page 45: ...SAFETY SIGNS S 35 SS3088058 SS 2651 M1M7 01 021 SS4433590 SS 2636 SS 2753 CAB CANOPY ZX30U 2 ZX35U 2 ZX40U 2 ZX50U 2 ZX27U 2 ...

Page 46: ...SAFETY SIGNS S 36 SS4604981 SS 2685 SS4642517 SS 2685 SS4430516 SS 2686 SS 2687 ZX27U 2 ZX30U 2 ZX35U 2 ZX40U 2 ZX50U 2 ...

Page 47: ...oved or in stalled by unauthorized personnel mismatch to ROPS may occur Remove bolts not covered with resin caps in the rear section of the operator s seat Be careful When bolts are removed the canopy or the cab may come off the floor SS4644686 SS4664139 M1M7 07 063 SS 2798 SS4664709 SS 2927 CAB CANOPY ...

Page 48: ...SAFETY SIGNS S 38 Cab Equipped Machines SS4642980 M1M7 01 020 Cab Equipped Machines SS 1832 M1M7 01 013 2Way Multi Lever Equipped Machines SS4605065 SS 2640 ...

Page 49: ...e Damaged Roll Over Protective Structure ROPS Tip Over Protective Structure TOPS Falling Object Protective Structure FOPS must be replaced not repaired or revised Any alternation to the ROPS or TOPS or FOPS must be approved by the manufacturer SS3107469 SS3107610 ROPS FOPS SS3107593 SS 2651 SS 2652 CANOPY ROPS FOPS ROPS FOPS CAB ...

Page 50: ...SAFETY SIGNS S 40 MEMO ...

Page 51: ...cket 2 Arm 3 Bucket Cylinder 4 Arm Cylinder 5 Work Light 6 Boom 7 Boom Cylinder 8 Canopy 9 Track Shoe 10 Counterweight 11 Travel Device 12 Track Frame 13 Front Idler 14 Blade Cylinder 15 Blade 16 Boom Swing Cylinder 8 9 10 11 14 12 16 13 15 1 4 5 6 3 2 7 ...

Page 52: ...35U 2 ZX40U 2 ZX50U 2 Engine Control Lever ZX27U 2 8 Operator s Seat 9 Boom Swing Pedal 10 Monitor Panel 11 Pilot Control Shut Off Lever 12 Door Lock Release Lever Cab equipped machine 13 Switch Panel 14 Tool Box 15 Operator s Manual Box 16 Attachment Pedal Optional M1M7 01 034 M1M7 01 002 M1M7 01 003 2 3 4 10 8 11 1 9 5 7 13 15 14 12 16 6 ZX30U 2 ZX35U 2 ZX40U 2 ZX50U 2 2 3 4 1 9 5 7 6 ZX27U 2 10...

Page 53: ...ioner Control Panel Cab equipped machine 18 Ash Tray Cab equipped machine 19 Radio AM FM Cab equipped machine 20 Cup Holder 21 Fuse Box M1M7 01 035 M1M7 01 004 M1LA 01 005 21 20 17 19 18 ZX30U 2 ZX35U 2 ZX40U 2 ZX50U 2 20 19 18 17 ZX27U 2 ...

Page 54: ...mode will automatically be selected Press the turtle mark side of switch 6 to select the slow travel mode 7 Wiper Switch Cab equipped machine Three operation positions are provided on this switch OFF Both the wiper and washer do not operate Center The wiper operates WASHER The washer operates together with the wiper 8 Auxiliary Flow Control Switch Optional Except ZX27U 2 The hydraulic oil flow in ...

Page 55: ...l NOTE When the coolant temperature is lower than 20 C 68 F the first segment will flash Fuel Gauge The gauge segment position indicates the fuel level Re fill the fuel before only the E marked segment comes ON NOTE Even though the key switch is OFF when the display control switch is continuously pressed for more than 0 5 seconds the fuel level is dis played As long as the display control switch i...

Page 56: ...he engine oil pressure system and the oil level for any abnormality Overheat Indicator If the coolant temperature rises extremely high this in dicator operates If the red light comes ON the buzzer sounds at the same time Immediately stop machine operation and reduce engine speed to the slow idle speed to lower the coolant tem perature Fuel Level Indicator When the fuel level indicator comes ON whi...

Page 57: ...ator and or battery system Preheat Indicator When the key switch is turned to the HEAT position or ange indicator will light Light will turn off after approx 15 seconds has passed Fast Travel Mode Indicator When the rabbit mark fast mode side of the travel mode switch on the switch panel is pressed the indicator comes ON M178 01 038 M178 01 041 M1M7 01 022 ...

Page 58: ... While the machine is operating the decimal point flashes NOTE Even though the key switch is OFF the hour meter reading can be checked by depressing and holding display selection switch 5 for more than 0 5 seconds The hour meter reading can be displayed as long as display selection switch 5 is held and disappears as soon as the switch is released Trip Meter Display Trip Meter 1 and Trip Meter 2 Th...

Page 59: ...n case information other than the trip meter is being indicated on the LCD the trip mark will be extinguished after the flashing ceases Trip Meter Setting 1 Turn the key switch ON Display either trip meter 1 or trip meter 2 by operating display selection switch 5 NOTE Trip meter 1 and trip meter 2 can be independ ently set by different operation hours 2 Each time set switch 4 is pressed the set ho...

Page 60: ...ch is pressed for more than 2 sec onds the set hour will be quickly shifted 4 After the time you wish to change to is displayed press display selection switch 5 to reset the trip meter IMPORTANT Once the set time is changed the trip meter restarts counting down the time Accordingly note that the displayed time is different from the operation hours counted from the first set time When no trip meter...

Page 61: ... auto idle switch 13 the engine speed is reduced to the slow idle speed approx 4 seconds after returning all control levers to neutral Thereby the fuel consumption is reduced When the auto idle mode is selected auto idle indicator 14 on the monitor panel lights M1CF 01 002 M1M7 01 028 14 13 ...

Page 62: ...switch 6 to turn the air condi tioner and indicator 11 ON 7 Mode Switch The air vent location is selected Each time mode switch 7 is pressed the mode indicator 10 changes in the order shown below Air will blow out from right front vents 1 2 and 2 3 Air will blow out from right front vents 1 2 and 2 3 and the foot vent 4 Air will blow out from the foot vent 4 8 Temperature Control Switch The set te...

Page 63: ...ion After selecting the foot vent by operating vent mode switch 7 press temperature control switch 8 to set the tempera ture indicator toward the left end side Adjust the inside cab temperature using temperature control switch 8 The blower speed can be adjusted manually using blower switch 9 When air conditioner switch 6 is turned ON during cooling operation cool air will also blow out from the ri...

Page 64: ...in the cab become high Operate the air conditioner to keep the windows clear When the atmosphere is very damp the outside of the windows may become clouded if the air conditioner is operated for long periods In this case stop the air conditioner and or adjust the air temperature in the cab When the air conditioner is not used When the air conditioner is not used to protect each part of the compres...

Page 65: ...OPERATOR S STATION 1 15 RADIO Cab Equipped Machines 1 Radio Clock M1M7 01 004 1 ...

Page 66: ...ive the station under normal state scan is interrupted Press and hold this button for 2 seconds to automatically store the station 6 Station Preset Buttons 1 to 6 One FM and MW AM station per button can be preset using these respective buttons 7 Seek Button Press this button to automatically seek the next re ceivable station When a station is received the auto seeking function is deactivated 8 Ban...

Page 67: ... NOTE After presetting is complete if the preset button is pressed again and held for more than 2 seconds the preset station is changed Auto Storing Press and hold the AST button 5 for more than 2 seconds with the radio switch ON preset buttons 1 to 6 automatically search receivable frequency stations in the selected frequency band AM or FM and memorize each station in one button NOTE When auto st...

Page 68: ...4 press TUNE H button to change the hour display Release the CLOCK button 4 to resume the original mode CAB DOOR RELEASE LEVER Cab equipped machines CAUTION Open the cab door all the way until the two latches on the side of the cab securely lock To unlock the door push down on lever 1 located on the left side of the operator s seat M1M7 01 012 M1M7 01 003 M1M7 01 027 While pressing CLOCK button Mi...

Page 69: ...AUTION When closing the front window slowly lower the window Be alert not to pinch your fingers Switch 2 is provided on the front window frame to prevent the wiper from operating when the front window is opened Before closing the front window check that the wiper switch is OFF After opening the front window check that both side lock levers are securely engaged in the window frame 3 When closing th...

Page 70: ... posi tion can be adjusted at the interval of 20 mm 0 8 in in 6 steps 120 mm 5 in in total TOOL AND OPERATOR S MANUAL BOXES Tool box 2 4 and operator s manual box 3 are located under the operator s seat under the floor mat and behind the backrest of the operator s seat respectively M1M7 01 016 M1M7 01 017 M1M7 01 018 1 4 2 3 ...

Page 71: ...g method of the front window WARNING Be sure to wear safety glasses when require to break the windowpane 2 In case opening the front window is impossible break the front window glass with emergency evacuation hammer 1 provided on the rear side in the cab to escape through the broken window 3 If the front window is not available for escaping break the rear window glass with emergency evacuation ham...

Page 72: ... appearance Seat Belt 1 Confirm that seat belt 1 is not twisted and securely insert the end of seat belt 1 into buckle 2 Lightly pull on the belt to confirm that the buckle latches securely 2 Adjust tightness of the seat belt 1 so that the belt is snug but comfortable 3 Push button 3 on buckle 2 to unfasten seat belt 1 CAB LIGHT cab equipped machines Move cab light switch 4 to turn the cab light O...

Page 73: ...equently affecting the service life of the machine Thoroughly perform break in operation The service life and performance of the machine can be greatly affected by operation and maintenance of the ma chine during the initial stage of operation Perform break in operation with the engine output less than 80 of the maximum output for the first 50 hours ...

Page 74: ...BREAK IN 2 2 MEMO ...

Page 75: ...en if any abnormality occurs on the machine Accordingly in case any of the indicator bulbs or the warning lamps doesn t come ON imme diately contact your authorized dealer for repair If any of alternator 3 or en gine oil pressure 4 fails to light after indicator light check is completed the machine may have trouble Immediately contact your authorized dealer for repair 4 Adjust the seat position so...

Page 76: ... Never run the starter for more than 20 seconds at a time If the engine fails to start return the key switch to OFF Wait for more than 30 seconds then try again 5 Release key switch 2 immediately after the engine has started It will automatically return to the ON po sition NOTE The horn sounds even though the key switch is turned OFF The engine doesn t start unless the pilot control shut off lever...

Page 77: ...starter damage and or battery over discharge Never run the starter for more than 20 seconds at a time If the engine fails to start return the key switch to OFF Wait for more than 30 seconds then try again 6 Release key switch 2 immediately after the engine has started It will automatically return to the ON po sition NOTE Set the engine control dial or lever to the fast idle position to start the e...

Page 78: ...monitor 1 Check that alternator indicator 3 is OFF In case alternator indicator 3 stays ON immediately stop the engine Then check the alternator and or battery system for any abnormality 2 Check that engine oil pressure indicator 2 is OFF In case engine oil pressure indicator 2 stays ON immediately stop the engine Then check the engine oil pressure system and or the oil level for any ab normality ...

Page 79: ...tive terminal of the booster battery 3 After connecting one end of the black cable 2 to the negative terminal of the booster battery connect the other end to hydraulic oil tank cover hinge 3 on the machine Be alert to sparks that may be produced in the last connection to the hydraulic oil tank cover hinge 4 After securely connecting the booster cables start the engine of the booster battery machin...

Page 80: ...ket and blade to the ground unless specified 2 Return the engine control dial or the engine control lever to the slow idle position and keep the engine running at slow idle speed for 5 minutes 3 Turn the key switch 2 OFF to stop the engine 4 Pull up pilot control shut off lever 1 to the LOCK po sition M1M7 01 007 M1M7 03 001 2 1 ...

Page 81: ...vel lever or pedal will become heavy to operate This is 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 ad justing the lever or pedal operating stroke Ascending Descending Slopes The machine gradeability is...

Page 82: ...posite directions each other Move one lever or pedal forward and pull the other back at the same time CAUTION During pivot or spin turn machine operations the base machine may shake When turning the machine in a tight area slowly oper ate the machine while taking care not to allow the machine to come in contact with the surrounding objects M1M7 04 012 M104 04 005 M1M7 04 013 M104 04 007 Pivot Turn...

Page 83: ...ing loads increase Press the TURTLE mark side on travel mode switch 1 to select the slow travel mode WARNING In cold weather season when the machine is traveling with the travel mode switch 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 op...

Page 84: ...to the undercarriage the machine may become im possible to travel Raise one side track above the ground with the boom and arm extended remove mud and or grabbles from the track Then evacuate the machine Rotate the raised track in forward or reverse directions alternately to remove the packed rocks and or mud from the track Tow the machine with other machine if the machine becomes stuck in soft gro...

Page 85: ...he machine using another machine Be sure to attach the wire ropes around the track frames To prevent the wire ropes from being damaged place pieces of soft protective material between the wire ropes and the edge corners of the frame IMPORTANT Do not tow the machine using the light weight part towing holes provided on the blade Damage to the towing holes may result M104 05 010 Wire Ropes ...

Page 86: ... mud 2 The machine may enter deeper areas gradually Check the machine s position often Reposition the machine if necessary 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 possibl...

Page 87: ...ing 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 op eration Avoid swinging the upperstructure downhill The ma chine may tip over If swinging uphill is unavoidable carefully operate the upperstructure and boom at slow speed If the engine stalls on a slope immediately lower the blade to...

Page 88: ... PARKING ON SLOPES 1 Park the machine on a level solid surface Position the arm vertically and lower the bucket and blade to the ground 2 Turn the engine control dial or the engine control lever to the slow idle position Run the engine at the slow idle speed for approx 5 minutes to cool the en gine 3 Turn the key switch to OFF to stop the engine Re move the key from the switch 4 Pull pilot control...

Page 89: ...e care not to come into contact with the control levers when turning and looking be hind the machine Labels showing the lever control pattern are provided on the operator s right As illustrated below the labels indicate the ISO Excavator Pattern M588 05 050 When a control lever is released it automatically returns to neutral stopping the function in that position 1 Arm Roll Out 2 Arm Roll In 3 Swi...

Page 90: ...contact with the control levers when looking back Labels displaying the available lever control patterns are provided at the right of the operator As illustrated below the labels with H pattern mark at the right bottom corner indicate the HITACHI Excavator Pattern M1LA 05 014 When a control lever is released it automatically returns to neutral stopping the function in that position 1 Swing Right 2...

Page 91: ...dy may come into contact with the control lever s Take care not to come into contact with the control levers when looking back Labels showing the SAE BACKHOE pattern are provided on the operator s right M1M7 05 028 When a control lever is released it automatically returns to neutral stopping the function in that position 1 Boom Lower 2 Boom Raise 3 Swing Left 4 Swing Right 5 Arm Roll Out 6 Arm Rol...

Page 92: ...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 the pedal 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 M1M7 05 005 M1M7 05 006 M571 01 001 2 3 4 ...

Page 93: ... the right to operate hydraulic breaker crusher etc Operation 1 Turn auxiliary pedal cover 1 forward 2 Step on the right or the left side of the auxiliary pedal 2 to operate the front end attachment such as a hy draulic breaker 3 When the auxiliary pedal 2 is not used turn cover 1 backward on the pedal M1M7 05 007 M1M7 05 008 2 1 1 ...

Page 94: ...1 on the operator s right to raise and lower the blade When the lever is released it automatically returns to neu tral holding the blade in the present position until the lever is operated again 2 Blade Raise 3 Blade Lower M1M7 05 009 M1M7 04 004 2 3 3 2 1 ...

Page 95: ...re to do so may result in damage to the blade and the un dercarriage 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 96: ... chine after each shift Pilot Control Shut off Lever Operation Before Leaving the Machine 1 Park the machine on a firm level surface Lower the bucket and blade to the ground Return all control levers to neutral Stop the engine 2 To deactivate control lever 3 function be sure to pull pilot control shut off lever 1 and raise console 2 to the fully locked position Before Starting Operation WARNING Ne...

Page 97: ...l times and lightly operate the swing and travel motors to warm up them WARMING UP IN COLD WEATHER IMPORTANT In case the hydraulic oil temperature is low never operate the machine until all actuator speeds become normal after warming up operation 1 Run the engine at intermediate speed for 5 minutes longer if the air temperature is extremely low 2 Do not run the engine at either slow or fast speed ...

Page 98: ...ays be aware of engine control dial setting before starting operation to prevent the engine speed from increasing unexpectedly When unexpected machine movement could be dangerous such as when loading unloading the machine for transportation or when the machine is engaging in lifting work turn auto idle switch 1 OFF to ensure safe opera tion Use the auto idle function only after warm up operation i...

Page 99: ...hine backward to continue the trench Operate each cylinder with a slight allowance left at both stroke ends IMPORTANT Do not dig the ground in the diagonal direction toward the track frame Failure to do so may cause the bucket teeth to come in contact with the crawler When lowering the boom avoid sudden stops that may create shock load damage to the ma chine Always smoothly lower the boom so that ...

Page 100: ...tioned above AVOID DRIVING BUCKET TEETH INTO GROUND WARNING If the bucket teeth are forcedly driven into the ground crushed material may spatter possibly resulting in injury of the operator and or co workers around the machine Furthermore the service lifetimes of all front attachment parts may be shortened If the bucket teeth are forcedly driven into the ground the service lifetime of all front at...

Page 101: ...age to the front attachment or shortening of the service life of the swing systems may result USE CORRECT TRACK SHOE Never use rubber crawlers or wide track shoes on rough terrain with scattered rocks gravel or boulders Failure to do so may cause breakages of rubber crawlers shoe bending looseness of shoe bolts or damage to track parts such as track links or rollers Refer to the table for Types an...

Page 102: ...chine to become unstable possibly result ing in tipping accident When lifting a load carefully swing the ma chine not to cause the lifting load to come in contact with personnel working near the ma chine 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 load lifting is unavoidable reduce...

Page 103: ...5 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 M586 05 016 M586 05 017 ...

Page 104: ...strated the boom cylinder may acci dentally 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 equipped machine with a bucket wider than shown to the right installed the bucket will come in contact with the cab Be sure to install a specially ...

Page 105: ... 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 WARNING The rubber crawler machine is less stable than the steel crawler machine as the edge of the rubber crawler is easier to deform more than steel crawler Pay attention when operating the machine a...

Page 106: ...awler has a thin rubber film shown in doted line on its roller tread During operation of a new machine or immediately after the rubber crawl ers 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 shor...

Page 107: ...s and plugs Always keep the auxiliary parts in the tool box Check that the pipe clamp bolts are tight and no oil is leaking from the pipe and hose joints before operating the hydraulic breaker Precautions for Hydraulic Breaker Operation WARNING When the hydraulic breaker is in stalled machine stability is reduced as the breaker is much heavier than the bucket In addi tion soil broken pieces of roc...

Page 108: ...e to rusting of the breaker possibly allowing rust dust and or water to enter the hydraulic circuit so that damage to the hydraulic components on the base machine may result 5 Do not use the breaker to lift objects Serious acci dents may result due to the machine tipping over and or the lifted load coming off 6 Do not operate the breaker over the side of the ma chine The machine stability is reduc...

Page 109: ...ge hydraulic oil and replace the full flow filter element at the inter vals shown in the table below especially to extend the service life of the hydraulic pump Refer to the Hdraulic System group in the Maintenance Section Hydraulic Oil change and Full Flow Filter Element Replacement Intervals Hours M1M7 05 027 9 Greasing Front Attachment When using a hydraulic breaker grease all lubrication point...

Page 110: ...ken pieces of rock or metals may be scattered during crusher opera tion potentially creating a hazardous situation Take protective measures to prevent the machine tipping over and or the scattering of hard materi als and observe the precautions described below to ensure safe operation Do not raise the base machine off the ground with the bucket cylinder fully retracted or extended Damage to the fr...

Page 111: ...become contaminated Change the hydraulic oil and replace the full flow filter element at the same intervals as applied to the hydraulic breaker Before transporting the machine on a trailer remove the crusher from the front attachment Position the bucket cylinder so that the cylinder is not fully ex tended during transportation During transportation the machine may be raised off the trailer deck fl...

Page 112: ... 45 L 12 US gal min Maximum Flow Rate 66 L 17 US gal min 85 L 22 US gal min 53 L 14 US gal min Flow Rate Control Selector 8 LOW sets to the minimum flow rate HIGH sets to the maximum flow rate When shifting the flow rate from the LOW to HIGH op erate the switch while pulling the lock knob toward the arrow mark NOTE When shifting the flow rate from the HIGH to LOW no lock knob operation is required...

Page 113: ...m lowering procedure stated below 1 Remove the cover above the hydraulic oil tank Loosen filler cap 1 on the hydraulic oil tank to re lease air pressure from the hydraulic oil tank WARNING Be sure to work only after oil tem perature is low or before operation Failure to do so may allow high temperature oil to spray pos sibly causing severe burns 2 Remove bolts 2 from the front and left side of cov...

Page 114: ...in overload relief valve and adjusting screw in the boom raise circuit cylinder bottom side WARNING 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 Tool 17 mm Lock Nut Torque 27 to 31 N m 2 8 to 3 2 kgf m 20 to 23 lbf ft 3 After checking that the boom is completely lower...

Page 115: ...OADING UNLOADING Always load and unload the machine on a firm level sur face WARNING Be sure to use a loading dock or a ramp when loading unloading the machine Ramp Loading Dock 1 Thoroughly clean the ramp and flatbed Dirty flatbed ramps contaminated with oil mud or ice can be slippery and dangerous 2 Wedge the trailer wheels with blocks so that the trailer doesn t move 3 Ramps must be sufficient ...

Page 116: ...lity 1 Load the machine on the trailer so that the centerline of the machine aligns with the centerline of the flat bed 2 Drive the machine onto the ramp slowly 3 Position the bucket above the flatbed Operate the front attachment so that the angle between the boom and the arm is maintained at 90 to 110 4 The machine tips forward when the machine travels over the top end of the ramp Lower the bucke...

Page 117: ...tighten the base machine and the front at tachment to the flatbed with wire ropes Transporting the machine equipped with rubber crawlers When securing the machine to the flatbed do not directly tighten the rubber crawler with wire ropes As illustrated below attach wire ropes to the tie down brackets to se curely tighten the machine to the flatbed before trans porting the machine M1LA 06 003 Wire R...

Page 118: ... machine in good stability IMPORTANT During loading operation maintain the angle between the boom and the arm at 90 to 110 If the machine is unloaded with the arm fully rolled in damage to the base machine may result 1 Before moving the machine from the flatbed rear end to the ramp position the front attachment so that the angle between the boom and the arm becomes into the range of 90 to 110 Whil...

Page 119: ...d the boom arm and bucket cylinders as illustrated to the right Pull the pilot control shut off lever to LOCK position 4 Position the boom straight ahead of the upperstruc ture Apply the boom swing pedal lock 5 Attach shackles to the boom and blade hooks Se curely thread wire ropes through the shackles 6 Slowly lift the machine so that shock loads will not be applied to the machine Take sufficient...

Page 120: ...TRANSPORTING 6 6 MEMO ...

Page 121: ...and lines Walk around machine checking general appearance noise heat etc Check for loose or missing parts If there is any problem with your machine repair it before operating or contact your authorized dealer IMPORTANT Use only recommended fuel and lu bricants Use only genuine HITACHI parts Failure to use recommended fuel lu bricants and genuine Hitachi parts will result in loss of Hitachi product...

Page 122: ...X27U 2 4 Run the engine at slow idle speed without load for approx 5 minutes to cool down the engine 5 Turn the key switch OFF Remove the key from the switch If inspection maintenance must be performed with the engine running be sure to place a lookout to prevent the machine from being operated mistakenly by other personnel 6 Be sure to place pilot control shut off lever 1 in the LOCK position 7 A...

Page 123: ... cover After checking that stopper 4 provided on the left link is placed in LOCK position 5 remove your hand from the cover Cover 1 will be locked in place When closing cover 1 while raising cover 1 push stopper 4 at the arrowed position Ö to disengage the lock While pushing stopper 4 lower the cover When the cover is lowered by the 1 4 stroke leave stopper 4 Then lower cover 1 further to complete...

Page 124: ...en cover 1 Cover 1 will be stopped opening with wire 3 2 Take stopper 4 out of holder 5 Install stopper 4 into lock hollow 6 Cover 1 is held in position 3 When closing cover 1 follow the reverse order of the above procedure CAUTION When closing the cover confirm that the cover securely is locked NOTE Button 2 can be locked with key 7 M1MF 07 030 M1MH 07 003 M1M7 07 018 M1M7 07 019 ZX27U 2 ZX30U 2 ...

Page 125: ...s 3 Oil leaks from travel devices 4 Loose or missing nuts and bolts Front Attachment 1 Damage to or oil leak from cylinders hoses and pipes 2 Damage to or wear on bucket and blade 3 Loose worn or missing bucket teeth 4 Lubrication at greasing points 5 Damage to lock pins stoppers fastener rings and lock bolts for front joint pins 6 Loose or missing nuts and bolts Miscellaneous 1 Malfunction of gau...

Page 126: ...s are found to be defective by inspection immediately replace it regard less of the recommended intervals Consult your authorized dealer for correct replacement Periodic Replacement Parts Replacement Interval Fuel hose Fuel tank to filter Fuel hose Fuel tank to injection pump Heater hose Heater to engine Every 2 years or 4000 hours whichever comes first Engine rubber vibration insulator Floor moun...

Page 127: ... 2 Replace engine oil filter 1 NOTE Ì The oil life is shortened more than normal under high temperature operating shorten the maintenance interval C TRANSMISSION See Page 7 20 Interval hours Parts Quantity 8 50 100 250 500 1000 2000 Check Oil Level ZX27U 2 ZX30U 2 ZX35U 2 0 6 L 0 63 US qt 2 1 Travel Reduction Gear Change ZX40U 2 ZX50U 2 0 9 L 0 95 US qt 2 D HYDRAULIC SYSTEM See Page 7 22 Interval ...

Page 128: ...ter 1 for leaks cracks etc 4 Check Fuel Hoses for cracks bend etc NOTE The fuel filter may become clogged earlier than normal due to contaminated fuel In case the engine power is reduced or black smoke increases shorten the intervals of inspection maintenance F AIR CLEANER See Page 7 41 Interval hours Parts Quantity 8 50 100 250 500 1000 2000 Clean 1 Ì Or clogged 1 Air Cleaner Element Replace 1 Af...

Page 129: ...MISCELLANEOUS See Page 7 51 Interval hours Parts Quantity 8 50 100 250 500 1000 1500 2000 3000 1 Check Bucket Teeth 2 Replace Bucket 1 As required 3 Adjust Track Sag Rubber Crawler and Check for Damage 2 4 Replace Rubber Crawler 2 As required 5 Check Track Sag Steel Crawler Optional 2 6 Check and Replace Seat Belt Every 3 years Replace 7 Check Air Conditioner Cab Equipped Machine Clean 8 Clean and...

Page 130: ...custom wide 15W 40 Apoll oil super wide 15W 40 Apoll oil gear HE90 Mobil Delvac Exxon Mobil Mobilux EP2 1310 1330 1340 Mobilube HD80W 90 Hi diesel S3 Eneos Epinoc Grease Ap2 20 to 35 C 6 to 95 F 10W 30 10 to 40 C 14 to 104 F 15W 40 Hypoid gear 90 Rymla D Shell Oil Shell Alvania EP Grease 2 10W 30 40 Shell Spirax EP 90 Remarks API CD CLASS API GL4 class Hydraulic Oil Fuel Oil Change Interval 2000 h...

Page 131: ...1 Position machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower bucket to the ground the front attachment inspection posi tion All greasing points can be lubricated from the ground 2 Grease all grease fittings illustrated below 1 Boom cylinder rod end 2 Boom cylinder bottom M1M7 05 024 M1M7 07 020 M1M7 07 021 ...

Page 132: ...ANCE 7 12 3 Boom foot 4 Arm cylinder rod end and bucket cylinder bottom 5 Boom and arm joint pin and arm cylinder bottom M1M7 07 022 M1M7 07 058 M571 07 006 M585 07 046 ZX27U 2 ZX30U 2 ZX35U 2 ZX40U 2 ZX50U 2 ...

Page 133: ...MAINTENANCE 7 13 6 Swing cylinder 7 Swing post M1M7 07 023 M1M7 07 024 ...

Page 134: ... pins are removed to replace the front attach ment or blade do not attempt to clean the bore in sides of the bushings 2 Before installing the front attachment or the blade apply grease sufficiently to the pin boss ends or the dust seals of the cylinders 3 Be sure to install at least one shim on both sides of front joint pins 4 When the swing post is disassembled coat the pins and the thrust plates...

Page 135: ...o per sonnel are present around the machine before starting to work Grease via grease fitting 1 1 Lower the bucket and the blade to the ground stop the engine and place the pilot control shut off lever to the LOCK position Add grease with a grease gun by two to three strokes Lower the bucket and blade to the ground 2 Raise the bucket approx 200 mm 8 in above the ground While rotating the upperstru...

Page 136: ...he quantity shown in the table 3 In order to apply grease evenly to the swing gear raise the bucket approximately 200 mm 8 in above the ground While swinging the upperstruc ture at approximately 90 intervals until one full turn is made add grease at each interval Greasing Quantity Total Grease Capacity ZX27U 2 ZX30U 2 ZX35U 2 0 2 L 0 21 US qt 3 0 to 3 3 L 3 1 to 3 5 US qt ZX40U 2 ZX50U 2 0 2 L 0 2...

Page 137: ...50 hours 1 Remove bolts 1 from the top of the tilt mechanism and remove cover 2 2 Coat the full length of operation bolt 3 with grease Recommended grease MOLYKOTE EM 30L manu factured by Dow Corning Toray Co Ltd M1M7 07 077 M1M7 07 078 2 1 3 ...

Page 138: ... Each component of the engine may be hot immediately after operation Allow com ponents to cool before starting to work on them 1 Prepare a 10 liter 2 6 US gal container to receive the drain oil 2 Remove drain plug 2 from engine oil pan 1 to drain the oil 3 Allow oil to drain through a clean cloth to check if any debris such as small pieces of metal are pre sent on the cloth 4 After all oil has dra...

Page 139: ...oil filter 3 may become de formed if excessively tightened NOTE Tightening torque 19 6 to 23 5 N m 2 0 to 2 4 kgf m 14 5 to 17 lbf ft 8 Remove oil filler cap 4 Refill the engine NOTE Refer to the recommended oil and grease chart on page 7 10 for the brand names of oils 9 Check that oil level is between the upper and lower limit marks on the dipstick 5 Start the engine 10 Check that no oil is leaki...

Page 140: ...possibly resulting in personal injury Keep body and face away from the air bleed plug Check Oil Level every 250 hours 1 Park the machine on a level surface 2 Rotate the travel motor until plugs are positioned as illustrated on the right Stop the engine 3 Slowly loosen plug 1 to release pressure 4 Remove plugs 1 and 2 Check that oil flows out of the thread hole for plug 2 If no oil flows out add oi...

Page 141: ...tape Install plug 3 Tightening torque 29 to 39 N m 3 to 4 kgf m 21 5 to 29 lbf ft 6 Supply oil through the thread hole for plug 1 NOTE Refer to the recommended oil and grease chart on page 7 10 for the brand names of oils 7 Remove plug 2 Add oil until oil flows out of the tread hole for plug 2 Oil Quantity ZX27U 2 ZX30U 2 ZX35U 2 0 6 L 0 63 US qt ZX40U 2 ZX50U 2 0 9 L 0 95 US qt 8 After cleaning p...

Page 142: ...Remove plugs and screws only after thoroughly releasing the residual pres sure 3 3 Never attempt to service or inspect the travel and swing motor circuits on slopes Even after air pressure is released from the hydraulic oil tank the machine on a slope will create force to pressurize hydraulic oil in the travel and swing circuit by its own weight IMPORTANT Take special care to keep seal surfaces of...

Page 143: ...the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Check oil level gauge 1 on the side of the hydraulic oil tank Oil must be at the specified level on the gauge M1M7 05 024 M1M7 07 032 M1M7 03 004 1 1 ZX27U 2 ZX30U 2 ZX35U 2 ZX40U 2 ZX50U 2 ...

Page 144: ...chine on a solid level surface Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Leave the machine without operating the machine until hydraulic oil becomes cool Then bleed air pressure from the hydraulic oil tank 3 Slowly loosen drain plug 1 on the bottom of the hy draulic oil tank to drain ...

Page 145: ...nd of hydraulic oil used 1 Park the machine on a solid level surface Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Remove the cover above the hydraulic oil tank Loosen filler cap 1 on the hydraulic oil tank to re lease air pressure from the hydraulic oil tank 3 Remove cap 1 4 Arrange a co...

Page 146: ...Wrench Size 12 mm PT3 8 Square Head Plug Tightening Torque 49 N m 5 kgf m 36 lbf ft ZX40U 2 and ZX50U 2 Wrench Size 27 mm G1 2 Hexagonal Head Plug with O ring Tightening Torque 95 N m 9 7 kgf m 70 lbf ft 7 Supply hydraulic oil via the filler port on the top of the hydraulic oil tank while checking the oil level with level gauge 3 M1M7 07 033 M1M7 07 034 M1M7 03 004 2 3 3 ZX27U 2 ZX30U 2 ZX35U 2 ZX...

Page 147: ...level gauge lo cated on the side of the hydraulic oil tank Add hy draulic oil if necessary 6 Restart the engine Confirm that hydraulic oil level in the hydraulic oil tank is sufficient Run the engine for approximately 1 minute 7 This is the end of the hydraulic pump air bleeding procedure NOTE If the hydraulic pump is left empty overnight or longer be sure to fill the pump with clean hy draulic oi...

Page 148: ... O ring to come off cover 1 at this time 2 Remove suction filter 4 together with rod 3 3 Clean the hydraulic oil tank interior and the suction filter 4 Install suction filter 4 together with rod 3 to the suction pipe 5 Install cover 1 so that rod 3 is securely inserted into support 2 on cover 1 6 Secure cover 1 with four bolts Wrench Size 13 mm Tightening Torque 49 N m 5 kgf m 36 lbf ft ZX27U 2 ZX...

Page 149: ...ing 3 While pressing cover 2 down slowly remove cover 2 so that spring 4 doesn t fly out 4 Remove spring 4 valve 5 and element 6 5 Take care not to allow water and or dirt to enter the filter case 6 Be careful not to damage element 6 and O ring 3 Don t use a broken element 7 Install new element 6 and O ring 3 in the hydraulic oil tank 8 Install cover 2 with four bolts 1 Tightening torque 49 N m 5 ...

Page 150: ...vel surface Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Before replacing the element be sure to loosen the hydraulic oil tank cap 1 to release the air pressure from the hydraulic oil tank 3 Remove bolts 3 to remove under cover 2 from the rear left bottom side of the base machine Wrench ...

Page 151: ...rotating filter element 7 taking care not to damage the filter element 9 Take care not allow dust and or water enter the filter case 10 Install case 6 into head cover 5 while rotating the case clockwise Tightening Torque 25 to 34 N m 2 5 to 3 5 kgf m 18 0 to 25 5 lbf ft 11 After replacing the filter element bleed any remaining air from the hydraulic circuit while running the engine at a slow speed...

Page 152: ...se or damaged clamps hoses and lines Do not bend or strike high pressure lines Never install bent or damaged hoses or lines Check hoses and lines for oil leaks and or damage while referring to the following tables If any abnormality is found repair it as instructed in the remedy column SA 031 SA 292 SA 044 Hoses Interval Hours Check Point Abnormality Remedy Daily Hose surface Hose end Hose connect...

Page 153: ...Replace Every 250 hours Flange type fitting neck Weld joint surfaces on flange type fitting Clamp Crack 13 Crack 12 Omission deformation or loose Replace Replace Replace or retighten Oil cooler Interval Hours Check Point Abnormality Remedy Every 250 hours Hose and hose connection Oil cooler Oil leak 14 Oil leak 15 Retighten or replace Replace M115 07 146 M117 07 147 M117 07 148 M117 07 149 M137 07...

Page 154: ...values shown in the table below 10 Width across flats mm 17 19 22 27 N m 24 5 29 5 39 64 kgf m 2 5 3 4 6 5 Tightening torque lbf ft 18 21 5 29 47 Pipe Metal Seal Fitting Width Across Flats of Union Nut 17 Metal flare seat 4 on adapter 1 and metal flare 5 on pipe 2 ends seal pressure oil Precaution for Application Take care not to damage flare seat 4 and flare 5 when disconnecting or connecting the...

Page 155: ...ngs may result 3 Take care not to make dents on O ring groove 3 of adapter 2 and seal face 6 on the hose or valve side 5 when re assembling fittings Failure to do so may cause damage to O ring 1 and oil leak from fittings 4 If oil leaks from a loose connection of union nut 4 open the connection replace O ring 1 and check that the O ring is correctly seated in O ring groove 3 before re tightening t...

Page 156: ... 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 sol...

Page 157: ...y ZX27U 2 ZX30U 2 ZX35U 2 40 L 10 6 US gal ZX40U 2 ZX50U 2 70 L 18 5 US gal 2 After refilling fuel close tank cover 4 Be sure to lock the cover to prevent vandalism IMPORTANT Take care not to allow water and or dirt to enter the fuel system when refilling fuel 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 from the syst...

Page 158: ...ir bleed plug 4 Drain Fuel Tank Sump as required Park the machine on a solid level surface Loosen bolts 5 to remove drain valve cover 6 from right front cover 7 Rotate drain valve cover 6 to open the checking port Open drain valve 1 on the bottom of the fuel tank and allow the water and sediments to drain from the fuel tank sump M1M7 07 040 M1MF 07 032 M1MF 07 033 4 2 3 7 5 6 1 ...

Page 159: ...g the fuel filter clockwise until the fuel filter comes in contact with the mounting surface Tighten the fuel filter about 1 2 turns more using the filter wrench NOTE Tightening torque 11 8 to 15 6 N m 1 2 to 1 6 kgf m 9 to 11 5 lbf ft 5 Open stop valve 1 6 Turn the key switch ON and hold for 10 to 15 seconds 7 Start the engine and check the fuel system for fuel leaks M1M7 07 040 M1M7 07 007 Tight...

Page 160: ...and or damage while referring to the following tables If any abnormality is found repair it as instructed in the remedy column Hoses Interval Hours Check Point Abnormality Remedy Daily Hose fittings Soutache braid hose surface Leak 1 Rubbed marks 2 Crack 2 Retighten or replace Replace Replace Every 250 hours Soutache braid hose surface Hose fittings Hose Hose ends and fittings Crack 3 Crack 4 Acut...

Page 161: ... suction port If water enters the air cleaner suction port damage to the engine may result When cleaning don t hit element 1 or force the element to collide against other object 3 Clean element 1 by blowing compressed air pressure less than 0 2 MPa 2 kgf cm2 29 psi from the inside of the element After cleaning be sure to check element 1 for damage If any damage is found replace the element with a ...

Page 162: ... 30 the sys tem may develop rust and if it is above 60 the engine may overheat NOTE As for Borax Coolant the mixed ratio 50 is recommended for anti rust LLC Mixing Ratio Mixing ratio 30 35 40 45 50 Air temperature C F 10 14 15 5 20 4 25 13 30 22 Precautions for Handling LLC WARNING LLC is poisonous 1 If ingested Induce vomiting and immediately get emergency medical attention 2 If antifreeze is acc...

Page 163: ... coolant to coolant reservoir 2 WARNING Do not loosen radiator filler cap 1 unless the system is cool Hot steam may escape possibly causing severe burns Loosen the cap 1 slowly to the stop after the coolant becomes cool Release all pressure before removing the cap 1 If coolant reservoir 2 is empty add coolant through ra diator cap 1 M1M7 07 043 ZX27U 2 ZX30U 2 ZX35U 2 M1M7 07 044 ZX40U 2 ZX50U 2 2...

Page 164: ...nd alternator pulley 2 In addition check the fan belt for any damage If the belt has any cracks replace the belt with a new one Adjustment of Fan Belt Tension 1 Remove wing bolt 3 from the right side of the seat and switch box 4 to open the inspection door 2 Loosen mounting bolts 6 of alternator 5 3 Move alternator 5 to correctly adjust the fan belt tension 4 Securely tighten bolts 6 IMPORTANT Whe...

Page 165: ...ter and a ra diator cleaner agent Start the engine and run it at a speed slightly higher than slow idle to raise the cool ant temperature until the needle of the temperature gauge reaches the white zone Then run the engine further for about ten minutes 3 Stop the engine and open radiator drain cock 1 to allow the coolant to drain Flush out the cooling sys tem with fresh water including less impuri...

Page 166: ...nt entry of dust and water while cleaning the radiator High pressure air less than 0 2 MPa 2 kgf cm2 29 psi or water can damage radiator fins Keep the pressure nozzle 500 mm 19 7 in or more away from the core face The radiator and the oil cooler are arranged in series In case dust or dirt should become stuck to the radiator core clean the radiator with compressed air and or water to maintain the c...

Page 167: ... use or charge the battery when the electrolyte level is lower than specified Explosion of the battery may result Charge battery in a well ventilated area Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes IMPORTANT If the battery is used with the electrolyte level lower than the specified low level the...

Page 168: ...he filler port It is difficult to judge the ac curate electrolyte level in this case Check if the electrolyte surface touches the bottom end of the sleeve or not according to the right illustrations When the electrolyte surface 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 After refilling securely tighten the f...

Page 169: ...arks to fly near the batteries Perform battery maintenance only after turning the key switch OFF and removing the battery caps Touching the batteries soon after operation is haz ardous Wait for the batteries to cool During charging batteries generate flammable hy drogen gas Remove the batteries from the base ma chine Then charge the batteries in a well ventilated area only after removing the caps ...

Page 170: ...NANCE 7 50 Replacing Fuses 1 If any electrical equipment fails to operate first check the fuses in the fuse box 2 One each capacity of spare fuses are provided in the fuse box M1M7 07 052 M1M7 07 076 Fuse Box ...

Page 171: ... glasses Procedure of Bucket Teeth Change 1 Use hammer 2 and drift 3 to drive out locking pin 5 Be careful not to damage rubber pin lock 4 while removing locking pin 5 2 Inspect locking pin 5 and rubber pin lock 4 for any damage Replace short or damaged locking pins as illustrated below with new ones M104 07 056 M589 07 017 M104 07 118 M104 07 058 M104 07 059 4 WRONG WRONG RIGHT WRONG 5 Level the ...

Page 172: ...ce 4 Install rubber pin lock 4 into shank 6 hole as shown M104 07 060 5 Position new tooth 1 over shank 6 M104 07 061 6 Drive locking pin 5 fully into the hole as shown M104 07 062 1 5 6 1 6 4 RIGHT WRONG WRONG WRONG WRONG WRONG RIGHT RIGHT ...

Page 173: ...o the ground and position it with the flat sur face resting on the ground Be sure the bucket will not roll when the pins are removed 2 Slide the O rings out of the specified position to the bucket boss side 3 Remove bucket pins A and B to separate the arm and bucket Installation 1 Clean the removed pins and pin bores Apply suffi cient grease to the pins and pin bores 2 Place a new bucket in a stab...

Page 174: ... 0 39 to 0 59 Adjusting Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 Before adjusting track sag lower the bucket and blade to the ground to raise both tracks off the ground Be sure to place blocks under machine frame to support the machine 3 After adjusting track sag of both tracks run the tracks back and forth ...

Page 175: ...fur ther 3 If grease does not drain smoothly raise the track to be loosed off the ground and slowly rotate the track 4 When proper track sag is obtained turn valve 1 clockwise and tighten it to 88 N m 9 kgf m 65 lbf ft Tighten Track Rubber Crawler WARNING In case the track sag is not adjustable this is a very hazardous situation Since the track adjuster spring is excessively loaded the grease pres...

Page 176: ...o 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 both tracks 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 into the gaps among ...

Page 177: ...ntal 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 See page 7 54 8 After checking that the rubber track is correctly en gaged with t...

Page 178: ...round such as mud or gravel these materials may easily become packed into the undercarriage ad just the track sag so that it is slightly loose Adjusting Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat this procedure to ...

Page 179: ...fur ther 3 If grease does not drain smoothly raise the track to be loosed off the ground and slowly rotate the track 4 When proper track sag is obtained turn valve 1 clockwise and tighten it to 88 N m 9 kgf m 65 lbf ft Tighten Track Steel Crawler WARNING In case the track sag is not adjustable this is a very hazardous situation Since the track adjuster spring is excessively loaded the grease press...

Page 180: ...ter 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 nearest authorized dealer for converting the track Change the track adjuster whenever convert ing the steel or ru...

Page 181: ...r to operating the machine thoroughly examine belt 1 buckle 2 and attaching hardware 3 If any item is damaged or materially worn replace the damaged or worn item s before operating the machine Replace seat belt 1 every three years regardless of its apparent condition M1M7 07 012 2 1 3 ...

Page 182: ... reduced Keep the condenser clean Refer to the descriptions for Clean Radiator in MAINTENANCE section Check the compressor After operating the air conditioner for 5 to 10 minutes touch both high and low pressure pipe lines with your hands Normally the high pressure side should be hot and the low pressure side should be cool Check each bolt for looseness Check that the compressor mounting bolts and...

Page 183: ...commenced maintenance hour is a ref erence value In case the machine is operated in dusty job site replace the filter at a shorter interval Removal of Re circulation Filter 1 Remove floor mat 1 Remove bolts 3 to remove floor plate 2 2 Grasp and pull the grips of re circulation filters 4 5 and 6 upright to remove them M1M7 07 055 M1M7 07 014 M1M7 07 015 M1M7 07 053 M1M7 07 054 1 3 4 5 6 2 ...

Page 184: ...n the filter using tap water 2 Hold the filter in water with a neutral detergent dis solved for about 5 minutes 3 Clean the filter again with water 4 Dry the filter Installation Install the cleaned filters or new filters by following the removal procedure described on the previous page in the reverse order Insert filters 4 and 6 into the grooves on both sides Install filter 5 into the center duct ...

Page 185: ... 2 Sweep the dust out of the cab floor and the pedals with a brush or use a brush while directing water Sweep out the mud and bust with a brush as much as possible before applying water 3 When cleaning the floor mat sweep out the dust and or water along the grooves on the floor mat 4 When cleaning the cab floor with the floor mat re moved remove only the rear mat Then sweep the dust and or water t...

Page 186: ...n and repair Check and Adjust Valve Clearance every 1000 hours or every year Consult your authorized dealer for inspection and repair Check Injection Timing every 2000 hours or every 2 years Consult your authorized dealer for inspection and repair Measure Engine Compression Pressure As required Consult your authorized dealer for inspection and repair ...

Page 187: ...ENANCE 7 67 Check Starter and Alternator every 1000 hours Consult your authorized dealer for inspection and repair Check Radiator Cap every 2000 hours Consult your authorized dealer for inspection and repair ...

Page 188: ... 10 Battery mounting nut 6 6 10 5 0 5 3 5 12 5 19 88 9 65 11 Canopy mounting bolt 10 5 17 49 5 36 12 5 19 88 9 65 12 Cab mounting bolt 10 5 17 49 5 36 Upperstructure 12 22 19 108 11 80 13 Swing bearing mounting bolt Undercarriage 12 20 19 108 11 80 14 Travel device mounting bolt 12 24 19 113 11 5 83 15 Sprocket mounting bolt 12 24 19 113 11 5 83 16 Upper roller mounting bolt 16 2 24 231 23 5 170 1...

Page 189: ...ing nut 6 2 10 5 0 5 3 5 12 5 19 88 9 65 11 Canopy mounting bolt 10 5 17 49 5 36 12 5 19 88 9 65 12 Cab mounting bolt 10 5 17 49 5 36 Upperstructure 12 27 19 108 11 80 13 Swing bearing mounting bolt Undercarriage 12 24 19 108 11 80 14 Travel device mounting bolt 14 24 22 175 18 130 15 Sprocket mounting bolt 14 24 22 175 18 130 16 Upper roller mounting bolt 16 2 24 231 23 5 170 17 Lower roller moun...

Page 190: ... 36 19 5 2 0 14 17 49 5 0 36 8 12 108 11 80 88 9 0 65 34 3 5 25 19 88 9 0 65 10 14 175 18 130 137 14 101 54 5 5 40 22 137 14 101 12 16 265 27 195 205 21 152 78 8 0 58 24 205 21 152 14 18 390 40 289 295 30 217 118 12 87 27 295 30 217 14 20 540 55 398 390 40 290 167 17 123 30 390 40 289 17 22 740 75 542 540 55 398 215 22 159 32 24 930 95 687 690 70 506 275 28 203 36 27 1370 140 1013 1030 105 759 390...

Page 191: ... side Then retighten nut 1 to 49 N m 5 0 kgf m 36 lbf ft M1M7 07 079 2 Tilt the cab floor forward Support the floor with a fall prevention bar Retighten arrowed bolts 3 4 and 5 3 Tightening torque 9 8 N m 1 0 kgf m 7 lbf ft 4 Tightening torque 49 N m 5 0 kgf m 36 lbf ft 5 Tightening torque 49 N m 5 0 kgf m 36 lbf ft M1M7 07 074 M1MW 07 031 M1M7 07 080 M1MH 07 014 1 1 ZX40U 2 ZX50U 2 ZX27U 2 ZX30U ...

Page 192: ...round 4 After rolling the arm and the bucket in lower the bucket a wooden block down to the ground 5 Face the 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 8 After loosening two bolts 2 of cover 1 on the front of the base machine fully slide the cover upward T...

Page 193: ...nce so that it may fall downward potentially creating hazard ous conditions IMPORTANT Don t tilt the canopy or cab using other than the floor tilt mechanism such as a crane Failure to do so may cause damage to the floor tilt mechanism and or floor 12 Raise fall prevention bar 6 in the arrowed direction until it comes in contact with the bracket 7 mounted on the cab floor reverse surface Lock stopp...

Page 194: ...3 Continue to turn adjuster screw 4 counterclockwise until the edge of bracket 13 comes in contact with bearing bracket 7 WARNING If adjuster screw 4 is continuously turned after the floor is completely lowered when the adjuster screw is extended by approx 15 mm 0 6 in washer 10 will come in contact with the end face of pin 11 so that adjuster screw 4 will not turn further Take care that if adjust...

Page 195: ...th three bolts 3 Wrench size 19 mm Tightening torque 90 N m 9 2 kgf m 67 lbf ft CAUTION Unless bolts 3 are tightened to the specification the machine will not meet the standard of the Roll Over Protective Structure ROPS M1M7 07 063 M1M7 07 064 3 3 Cab Canopy ...

Page 196: ...MAINTENANCE 7 76 MEMO ...

Page 197: ...on Filter 4617512 Pilot Filter 4294130 Engine Oil Filter 4626337 4641043 Fuel Filter 4626336 Water Separator 4632694 Air Cleaner Element 4417516 Filter Element ZX40U 2 ZX50U 2 Full Flow Filter 4129280 Hydraulic Oil Suction Filter 4617512 Pilot Filter 4294130 Engine Oil Filter 4641043 Fuel Filter 4626336 Water Separator 4632694 Air Cleaner Element 4417516 ...

Page 198: ... 4354262 2 4354260 2 Bucket Parts ZX40U 2 ZX50U 2 Part No Quantity Tooth 4339865 4 Lock Pin 4339868 4 Tooth Lock Rubber 4339867 4 Side Cutter R 4622021 1 Side Cutter L 4626430 1 Bolt 4317650 6 Spring Washer A590914 6 Side Cutter Nut J951014 6 O ring 4291436 4 Shim 4354258 2 NOTE The quantities shown in the above tables are those required for the one standard bucket The quantities for an optional b...

Page 199: ...while checking for cracks damage and loose bolts and nuts Loosen the tracks a little more than usual Front Attachment Standard attachment may be damaged when digging rocky ground Reinforce the bucket be fore using it or use a heavy duty bucket Freezing Weather Fuel Use high quality fuel suitable for low temperature Lubricant Use high quality low viscosity hydraulic oil and engine oil Engine Coolan...

Page 200: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 2 MEMO ...

Page 201: ...negative battery cable from the ter minal 8 Add an antirust agent to the coolant In cold weather add an antifreeze or drain the coolant completely Be sure to attach a No Water in Radiator tag on a clearly visible location if the system is drained 9 Loosen the alternator belt and fan belt 10 Paint necessary areas to prevent rust 11 Store the machine in a dry protected place If stored outside cover ...

Page 202: ...draulic functions several cycles 6 Carefully check all systems before operating the machine with a full load NOTE When the machine has been stored for a long time be sure to perform the following steps as well a Check the condition of all hoses and con nections b Warm up the engine c Stop the engine d Install new fuel filters Replace the engine oil filter and fill the engine with oil IMPORTANT If ...

Page 203: ...nsufficient engine oil Oil leak at connections Oil pressure switch failure Add oil Repair Replace Engine knocks or runs irregularly Fuel filter restriction Air in the fuel system Air cleaner restriction Clean or replace the filter Re tighten connections and bleed Clean or replace the element Engine overheats Insufficient coolant and or cool ant leak Loose fan belt or oil on fan belt Radiator fins ...

Page 204: ...ly Too tight track sag Foreign matter such as rocks stuck in the tracks Counterbalance valve failure Travel motor performance drop Adjust track sag Remove foreign matter Replace Replace Machine mistracks Track sag is not equal on both sides Hydraulic pump performance drop Oil leak inside control valve Adjust track sag properly and equally on both sides Replace Replace the control valve Insufficien...

Page 205: ...ear End Swing Radius mm ft in 775 2 7 D Minimum Ground Clearance mm ft in 320 1 1 E Counterweight Height mm ft in 560 1 10 F Engine Cover Height mm ft in 1420 4 8 G Undercarriage Length mm ft in 1950 6 5 H Undercarriage Width mm ft in 1550 5 1 I Sprocket Center to Idler Center mm ft in 1490 4 11 J Track Shoe Width mm ft in 300 1 0 Rubber Crawler Ground Pressure kPa kgf cm2 psi 27 0 0 28 4 0 28 0 0...

Page 206: ... Swing Radius mm ft in 775 2 7 D Minimum Ground Clearance mm ft in 290 11 E Counterweight Height mm ft in 560 1 10 F Engine Cover Height mm ft in 1420 4 8 G Undercarriage Length mm ft in 2100 6 11 H Undercarriage Width mm ft in 1550 5 1 I Sprocket Center to Idler Center mm ft in 1650 5 5 J Track Shoe Width mm ft in 300 1 0 Rubber Crawler Ground Pressure kPa kgf cm2 psi 28 0 0 28 4 0 29 0 0 30 4 3 ...

Page 207: ...Swing Radius mm ft in 870 2 10 D Minimum Ground Clearance mm ft in 290 11 E Counterweight Height mm ft in 560 1 10 F Engine Cover Height mm ft in 1420 4 8 G Undercarriage Length mm ft in 2100 6 11 H Undercarriage Width mm ft in 1740 5 9 I Sprocket Center to Idler Center mm ft in 1650 5 5 J Track Shoe Width mm ft in 300 1 0 Rubber Crawler Ground Pressure kPa kgf cm2 psi 31 0 0 32 4 6 33 0 0 33 4 7 ...

Page 208: ... Swing Radius mm ft in 980 3 3 D Minimum Ground Clearance mm ft in 335 1 1 E Counterweight Height mm ft in 605 2 0 F Engine Cover Height mm ft in 1510 4 11 G Undercarriage Length mm ft in 2540 8 4 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 Rubber Crawler Ground Pressure kPa kgf cm2 psi 27 0 0 27 3 8 28 0 0 28 4 0 ...

Page 209: ... Swing Radius mm ft in 1000 3 3 D Minimum Ground Clearance mm ft in 335 1 1 E Counterweight Height mm ft in 605 2 0 F Engine Cover Height mm ft in 1510 4 11 G Undercarriage Length mm ft in 2540 8 4 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 Rubber Crawler Ground Pressure kPa kgf cm2 psi 29 0 0 30 4 3 30 0 0 30 4 3...

Page 210: ...Overall Transport Length mm ft in 4200 13 9 4280 14 1 G Minimum Swing Radius mm ft in 1950 6 5 2030 6 8 2050 6 9 2090 6 10 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position above ground level 360 1 2 J Blade Bottom Lowest Position above ground level mm ft in 315 1 0 K Offset Distance mm ft in L705 L 2 4 R640 R 2 1 L705 L 2 4 R600 R 1 12 Maximum Boom Swing Angle L72 ...

Page 211: ... Transport Length mm ft in 4450 14 7 4560 15 0 G Minimum Swing Radius mm ft in 1940 6 4 2060 6 9 2140 7 0 2170 7 1 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position above ground level 360 1 2 J Blade Bottom Lowest Position above ground level mm ft in 315 1 0 K Offset Distance mm ft in L705 L 2 4 R640 R 2 1 L705 L 2 4 R600 R 1 12 Maximum Boom Swing Angle L72 R62 L62 ...

Page 212: ...ansport Length mm ft in 4650 15 3 4780 15 8 G Minimum Swing Radius mm ft in 2070 6 10 2170 7 1 2230 7 4 2290 7 6 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position above ground level mm ft in 360 1 2 J Blade Bottom Lowest Position above ground level mm ft in 390 1 0 K Offset Distance mm ft in L705 L 2 4 R640 R 2 1 L705 L 2 4 R600 R 1 12 Maximum Boom Swing Angle L72 R...

Page 213: ... 4 F Overall Transport Length mm ft in 5340 17 6 5380 17 8 G Minimum Swing Radius mm ft in 2190 7 2 2340 7 8 2270 7 5 2390 7 10 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position above ground level mm ft in 425 1 5 J Blade Bottom Lowest Position above ground level mm ft in 335 1 1 K Offset Distance mm ft in L795 L 2 7 R760 R 2 6 Maximum Boom Swing Angle L80 R60 NOTE ...

Page 214: ... 4 F Overall Transport Length mm ft in 5460 17 11 5520 18 1 G Minimum Swing Radius mm ft in 2150 7 1 2260 7 5 2300 7 7 2340 7 8 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position above ground level mm ft in 425 1 5 J Blade Bottom Lowest Position above ground level mm ft in 335 1 1 K Offset Distance mm ft in L795 L 2 7 R760 R 2 6 Maximum Boom Swing Angle L80 R60 NOTE ...

Page 215: ...1550 5 1 Ground Pressure kPa kgf cm2 psi 27 0 0 28 4 0 28 0 0 29 4 1 ZX27U 2 Cab Shoe Width 300 mm 1 0 Rubber Shoe 300 mm 1 0 Grouser Shoe Application For Paved Road Standard For Ordinary Ground Option Operating Weight kg lb 2950 6500 3040 6700 Minimum Ground Clearance mm ft in 320 1 1 310 1 0 Undercarriage Length mm ft in 1950 6 5 1920 6 4 Undercarriage Width mm ft in 1550 5 1 1550 5 1 Ground Pre...

Page 216: ...d Pressure kPa kgf cm2 psi 28 0 0 28 4 0 28 0 0 29 4 1 ZX30U 2 Cab Shoe Width 300 mm 1 0 Rubber Shoe 300 mm 1 0 Grouser Shoe Application For Paved Road Standard For Ordinary Ground Option Operating Weight kg lb 3220 7100 3305 7290 Minimum Ground Clearance mm ft in 290 11 280 11 Undercarriage Length mm ft in 2100 6 11 2120 6 11 Undercarriage Width mm ft in 1550 5 1 1550 5 1 Ground Pressure kPa kgf ...

Page 217: ...nd Pressure kPa kgf cm2 psi 31 0 0 32 4 6 32 0 0 33 4 7 ZX35U 2 Cab Shoe Width 300 mm 1 0 Rubber Shoe 300 mm 1 0 Grouser Shoe Application For Paved Road Standard For Ordinary Ground Option Operating Weight kg lb 3630 8000 3715 8190 Minimum Ground Clearance mm ft in 290 11 280 11 Undercarriage Length mm ft in 2100 6 11 2120 6 11 Undercarriage Width mm ft in 1740 5 9 1740 5 9 Ground Pressure kPa kgf...

Page 218: ...d Pressure kPa kgf cm2 psi 27 0 0 27 3 8 28 0 0 28 4 0 ZX40U 2 Cab Shoe Width 400 mm 1 4 Rubber Shoe 400 mm 1 4 Grouser Shoe Application For Paved Road Standard For Ordinary Ground Option Operating Weight kg lb 4540 10010 4610 10160 Minimum Ground Clearance mm ft in 335 1 1 315 1 0 Undercarriage Length mm ft in 2540 8 4 2490 8 2 Undercarriage Width mm ft in 1960 6 5 1960 6 5 Ground Pressure kPa kg...

Page 219: ...nd Pressure kPa kgf cm2 psi 29 0 0 30 4 3 30 0 0 30 4 3 ZX50U 2 Cab Shoe Width 400 mm 1 4 Rubber Shoe 400 mm 1 4 Grouser Shoe Application For Paved Road Standard For Ordinary Ground Option Operating Weight kg lb 4880 10760 4950 10910 Minimum Ground Clearance mm ft in 335 1 1 315 1 0 Undercarriage Length mm ft in 2540 8 4 2490 8 2 Undercarriage Width mm ft in 2000 6 7 2000 6 7 Ground Pressure kPa k...

Page 220: ...450 18 500 20 550 22 NOTE 1 Symbols in the above table have the fol lowing meanings General excavating Light duty excavating Loading work 2 Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging loading operation of dried loosened earth sand mud so on Their bulk dens...

Page 221: ... 450 18 500 20 550 22 600 24 NOTE 1 Symbols in the above table have the fol lowing meanings General excavating Light duty excavating Loading work 2 Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging loading operation of dried loosened earth sand mud so on Their b...

Page 222: ...0 14 400 16 450 18 500 20 550 22 600 24 650 26 700 28 NOTE 1 Symbols in the above table have the fol lowing meanings General excavating Light duty excavating Loading work 2 Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging loading operation of dried loosened ear...

Page 223: ... 500 20 550 22 600 24 650 26 NOTE 1 Symbols in the above table have the fol lowing meanings General excavating Light duty excavating Loading work 2 Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging loading operation of dried loosened earth sand mud so on Their b...

Page 224: ...SPECIFICATIONS 12 20 MEMO ...

Page 225: ...he counterweight doesn t 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 M20 2 Remove mounting bolts 5 WARNING Take care if the additional counter weight is eccentrically lifted the lifted counter weight may widely sway Place the removed ad ditional counterweight on a level surface Installation 1 Lift the additional counterweight using the li...

Page 226: ...REFERENCE 13 2 MEMO ...

Page 227: ...ge Coolant 7 45 Change Engine Oil 7 18 Change Hydraulic Oil 7 25 Check Air conditioner Machine with Cab 7 62 Check Bucket Teeth for Looseness and or Wear 7 51 Check Coolant Level 7 43 Check Fuel Hoses 7 40 Check Hoses and Lines 7 32 Check Hydraulic Oil Level 7 23 Check Injection Nozzle 7 66 Check Injection Timing 7 66 Check Machine After Starting Engine 3 4 Check Radiator Cap 7 67 Check Starter an...

Page 228: ...Only from Operator s Seat S 7 Operate with Caution S 17 Operating Backhoe 5 11 Overheat Indicator 1 6 P Park Machine Safely S 19 Parking and Stopping on Slopes 4 8 Parking on Slopes 4 8 Pedals Levers and Monitor Panel 1 2 Periodic Replacement of Parts 7 6 Pilot Control Shut Off Lever 5 8 Practice Safe Maintenance S 21 Precautions for After Operating the Machine 5 23 Precautions for Blade Operation...

Page 229: ...Swing Bearing 7 15 Swing Internal Gear 7 16 Switch Panel 1 4 System Failure Indicator 1 6 T The Brand Names of Recommended Oils and Lubricants 7 10 Tidy Up Inside Operator s Space S 4 Tilt Mechanism 7 17 Tilting Floor Down 7 74 Tips for Air Conditioner Usage 1 14 Tool and Operator s manual Boxes 1 20 Towing Machine 4 5 Trailer Loading Unloading 6 1 Transmission 7 20 Transporting by Road 6 1 Travel...

Page 230: ...INDEX 14 4 MEMO ...

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