Professional Documents
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Read this manual carefully to learn how to operate This warranty provides you the assurance that Hitachi
and service your machine correctly. Failure to do so will back its products where defects appear within the
could result in personal injury or machine damage. warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to
This manual should be considered a permanent the customer, even if the product is out of warranty.
part of your machine and should remain with the Should the equipment be abused, or modified to
machine when you sell it. change its performance beyond the original
factory specifications, the warranty will become
This machine is of metric design. Measurements in void and field improvements may be denied.
this manual are metric. Use only metric hardware and Setting fuel delivery above specifications or otherwise
tools as specified. overpowering machines will result in such action.
Right-hand and left-hand sides are determined by Only qualified, experienced operators officially
facing in the direction of forward travel. licensed (according to local law) should be allowed to
operate the machine. Moreover, only officially licensed
Write product identification numbers in the personnel should be allowed to inspect and service
Machine Numbers section. Accurately record all the the machine.
numbers to help in tracing the machine should it be
stolen. Your dealer also needs these numbers when Prior to operating this machine in a country other than
you order parts. If this manual is kept on the machine, a country of its intended use, it may be necessary to
also file the identification numbers in a secure place make modifications to it so that it complies with the
off the machine. local standards (including safety standards) and
requirements of that particular country. Please do not
Warranty is provided as a part of Hitachi's support operate this machine outside of the country of its
program for customers who operate and maintain their intended use until such compliance has been
equipment as described in this manual. The warranty confirmed. Please contact Hitachi Construction
is explained on the warranty certificate which you Machinery Co., Ltd. or any of our authorized distributor
should have received from your dealer. or dealer if you have any questions concerning
compliance.
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication. The right is reserved to make changes at any time without notice.
MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:
PRODUCT
IDENTIFICATION
NUMBER:
NOTE:
Marks to indicate the start and
1HDP010001 end of the PIN
PRODUCT IDENTIFICATION
NUMBER (PIN)
M157-12-008
TYPE:
MFG. NO.:
M178-00-001
TRAVEL MOTOR TYPE AND SERIAL
NUMBER
TYPE:
MFG. NO.:
M178-07-047
MACHINE NUMBERS
SWING MOTOR TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.:
NUMBER
TYPE:
MFG. NO.:
M157-00-004
CONTENTS
MACHINE NUMBERS Remove Paint Before Welding or Heating........ S-26
Prevent Battery Explosions............................... S-27
SAFETY Service Air Conditioning System Safely............ S-27
Recognize Safety Information ............................. S-1 Handle Chemical Products Safely .................... S-28
Understand Signal Words ................................... S-1 Dispose of Waste Properly ............................... S-28
Follow Safety Instructions ................................... S-2
Prepare for Emergencies .................................... S-2 SAFETY SIGNS................................... S-29
Wear Protective Clothing .................................... S-3
Protect Against Noise.......................................... S-3 COMPONENTS NAME .......................... 1-1
Inspect Machine .................................................. S-3
General Precautions for Cab............................... S-4 OPERATOR’S STATION
Use Handholds and Steps................................... S-5 Cab Features .......................................................1-2
Adjust the Operator’s Seat .................................. S-5 Monitor Panel.......................................................1-3
Fasten Your Seat Belt ......................................... S-6 Coolant Temperature Gauge .......................1-4
Move and Operate Machine Safely ..................... S-6 Fuel Gauge ..................................................1-4
Handle Starting Aids Safely................................. S-6 Auto-Idle Indicator..........................................1-4
Operate Only from Operator’s Seat .................... S-7 Auto-Acceleration Indicator ...........................1-4
Jump Starting ...................................................... S-7 Fuel Level Indicator .......................................1-5
Keep Riders Off Machine .................................... S-7 Air Filter Restriction Indicator ........................1-5
Investigate Job Site Beforehand ......................... S-8 Overheat Indicator .........................................1-5
Protect Against Falling Stones and Debris.......... S-8 Engine Oil Pressure Indicator ........................1-5
Provide Signals for Jobs Involving Multiple Alternator Indicator ........................................1-5
Numbers of Machines ................................... S-9 Engine Oil Level Indicator..............................1-6
Confirm Direction of Machine to be Driven ......... S-9 Coolant Level Indicator .................................. 1-6
Drive Machine Safely......................................... S-10 Preheat Indicator ...........................................1-6
Avoid Injury from Rollaway Accidents ............... S-11 Work Light Indicator ......................................1-6
Avoid Injury from Back-Over Hydraulic Oil Filter Restriction Indicator.........1-6
and Swing Accidents ................................... S-12 Liquid Crystal Display (LCD)..........................1-7
Keep Personnel Clear from Working Area........ S-13 Display Selection Switch................................1-7
Never Position Bucket Over Anyone ................. S-13 Hour Meter..................................................... 1-7
Avoid Undercutting ............................................ S-13 Trip Meter 1 and Trip Meter 2........................1-8
Avoid Tipping..................................................... S-14 User’s Mode ..................................................1-8
Never Undercut a High Bank............................. S-14 Set Switch......................................................1-9
Dig with Caution ................................................ S-15 Work Mode Switch ......................................1-10
Operate with Caution......................................... S-15 Switch Panel ....................................................1-11
Avoid Power Lines............................................. S-15 Engine Control Dial......................................1-11
Object Handling................................................. S-16 Auto-Idle/Acceleration Selector ...................1-12
Protect Against Flying Debris ............................ S-16 Power Mode Switch .....................................1-13
Park Machine Safely ......................................... S-17 Travel Mode Switch .....................................1-13
Handle Fluids Safely Avoid Fires.................... S-17 Work Light Switch........................................1-14
Practice Safe Maintenance ............................... S-18 Wiper/Washer Switch ..................................1-15
Warn Others of Service Work ........................... S-19 Switch Panel (Optional) .....................................1-16
Support Machine Properly................................. S-19 Key Switch .........................................................1-18
Stay Clear of Moving Parts................................ S-19 Power Boost Switch ...........................................1-18
Prevent Parts from Flying ................................ S-20 Horn Switch........................................................1-18
Store Attachments Safely.................................. S-20 Lighter ...............................................................1-19
Prevent Burns.................................................... S-21 Cab Light............................................................ 1-20
Replace Rubber Hoses Periodically.................. S-21 Installing Fire Extinguisher.................................1-20
Avoid High-Pressure Fluids............................... S-22 Pilot Control Shut-Off Lever...............................1-21
Prevent Fires ..................................................... S-23 Engine Stop Knob ..............................................1-21
Evacuating in Case of Fire ................................ S-24 Fuse Box............................................................ 1-22
Beware of Exhaust Fumes ................................ S-24 Air Conditioner Operation ..................................1-23
Precautions for Welding and Grinding .............. S-25 Cab Heater Operation........................................1-27
Avoid Heating Near Pressurized Fluid Lines ..... S-26 Cooling Operation ..............................................1-28
Avoid Applying Heat to Lines Containing Defroster Operation ...........................................1-28
Flammable Fluids........................................ S-26 Tips for Optimal Air Conditioner Usage .............1-30
CONTENTS
Cab Heater Operation ....................................... 1-31 Work Mode ........................................................5-10
Cab Heater Operation ....................................... 1-33 Power Boost.......................................................5-10
Defroster Operation........................................... 1-34 Power Mode.......................................................5-11
AM/FM Radio Operation.................................... 1-35 Precautions for Operations ................................5-12
Digital Clock Setting Procedure......................... 1-36 Operate the Machine Safely ..............................5-13
Cab Door Release Lever................................... 1-38 Operating Backhoe ............................................5-14
Opening Upper Front Window........................... 1-38 Grading Operation .............................................5-14
Closing Upper Front Window ............................ 1-39 Face Shovel Operation ......................................5-15
Removing and Storing Lower Avoid Abusive Operation ...................................5-15
Front Window.............................................. 1-40 Operating Tips ...................................................5-16
Opening Side Windows ..................................... 1-41 Select Correct Track Shoes...............................5-16
Opening/Closing Overhead Window ................. 1-42 Precaution for Arm Roll-in/Bucket Roll-in
Emergency Exit ................................................. 1-43 Combined Operation ................................... 5-17
Adjust the Seat .................................................. 1-44 Shackle Hole Usage ..........................................5-17
Adjusting the Seat --- If Equipped ..................... 1-46 Overnight Storage Instructions .......................... 5-17
Adjusting Console Height .................................. 1-48 Emergency Boom Lowering Procedure .............5-18
Seat Belt............................................................ 1-49 Object Handling --- If Equipped ......................... 5-19
BREAK-IN TRANSPORTING
Observe Engine Operation Closely ..................... 2-1 Transporting by Road ..........................................6-1
Every Eight Hours or Daily .................................. 2-1 Loading/Unloading on a Trailer............................6-1
After the First 50 Hours ....................................... 2-1 Machine Lifting Procedure ...................................6-5
After the First 100 Hours ..................................... 2-1
MAINTENANCE
OPERATING THE ENGINE Correct Maintenance
Inspect Machine Daily Before Starting ................ 3-1 and Inspection Procedures............................ 7-1
Before Starting Engine ........................................ 3-2 Check the Hour Meter Regularly .........................7-2
Level Check......................................................... 3-3 Use Correct Fuels and Lubricants .......................7-2
Starting the Engine.............................................. 3-4 Maintenance Guide Table.................................... 7-3
Starting in Cold Weather ..................................... 3-5 Prepare Machine for Maintenance....................... 7-5
Check Instruments After Starting ........................ 3-6 Hood and Access Covers ....................................7-6
Using Booster Batteries....................................... 3-7 Periodic Replacement of Parts ............................7-7
Stopping the Engine ............................................ 3-9 Maintenance Guide..............................................7-8
A. Greasing ....................................................7-11
DRIVING THE MACHINE Front Joint Pins............................................7-12
Drive the Machine Carefully ................................ 4-1 Swing Bearing..............................................7-14
Steering the Machine Using Pedals .................... 4-2 Swing Internal Gear .....................................7-15
Steering the Machine Using Levers .................... 4-3 B. Engine.......................................................... 7-16
Travel Mode Switch............................................. 4-4 Engine Oil Level...........................................7-17
Travel Alarm (Optional) ....................................... 4-4 Change Engine Oil.......................................7-17
Traveling.............................................................. 4-5 Replace Engine Oil Filter .............................7-17
Operating on Soft Ground ................................... 4-6 C. Transmission .............................................7-19
Raise One Track Using Boom and Arm .............. 4-6 Pump Transmission.....................................7-20
Towing Machine a Short Distance....................... 4-7 Swing Reduction Gear................................. 7-21
Operating in Water or Mud.................................. 4-8 Travel Reduction Gear ................................7-22
Precautions for Traveling on Slopes ................... 4-9 D. Hydraulic System .........................................7-24
Parking the Machine on Slopes......................... 4-10 Inspection and Maintenance
Parking the Machine.......................................... 4-10 of Hydraulic Equipment .........................7-25
Check Hydraulic Oil Level............................7-27
OPERATING THE MACHINE Drain Hydraulic Tank Sump.........................7-28
Control Lever (ISO Pattern) ............................... 5-1 Change Hydraulic Oil...................................7-29
Control Lever (HITACHI Pattern) ...................... 5-2 Suction Filter Cleaning................................. 7-29
Pilot Control Shut-Off Lever ................................ 5-3 Replace Hydraulic Tank Oil Filter ................ 7-32
Engine Speed Control ......................................... 5-6 Replace Pilot Oil Filter .................................7-33
Auto-Idle .............................................................. 5-7 Check Hoses and Lines............................... 7-34
Auto Acceleration ................................................ 5-8
CONTENTS
Service Recommendations for MAINTENANCE UNDER SPECIAL
Hydraulic Fittings................................... 7-37 ENVIRONMENTAL CONDITIONS
E. Fuel System ................................................ 7-39 Maintenance Under Special
Drain Fuel Tank Sump ................................ 7-41 Environmental Conditions..............................9-1
Check Water Separator .............................. 7-41
Replace Fuel Filter ...................................... 7-44 STORAGE
Clean Feed Pump Strainer.......................... 7-45 Storing the Machine ...........................................10-1
Check Fuel Hoses....................................... 7-47 Removing the Machine from Storage ................10-2
F. Air Cleaner .................................................. 7-48
Clean the Air Cleaner Outer Element.......... 7-48 TROUBLESHOOTING
Replace the Air Cleaner Outer Engine ...............................................................11-1
and Inner Elements............................... 7-48 Electrical System ...............................................11-6
G. Cooling System ........................................... 7-50 Mode Selection ..................................................11-8
Check Coolant Level ................................... 7-52 Control Levers ...................................................11-9
Check and Adjust Fan Belt Tension............ 7-52 Hydraulic System ...............................................11-9
Change Coolant .......................................... 7-53
Clean Radiator Interior ................................ 7-53 SPECIFICATIONS
Clean Radiator and Oil Cooler Core ........... 7-54 ZAXIS230, ZAXIS230LC
Clean Oil Cooler Front Screen .................... 7-54 Specifications .............................................12-1
Clean Air Conditioner Condenser ............... 7-54 Working Ranges..........................................12-2
Clean Inter Cooler Front Screen ................. 7-54 Shoe Types
H. Electrical System ....................................... 7-55 and Applications .................................... 12-3
Batteries ...................................................... 7-55 Bucket Types
Replace Batteries........................................ 7-59 and Applications .................................... 12-5
Replacing Fuses ......................................... 7-59 ZAXIS240H, ZAXIS240LCH
I. Miscellaneous ............................................ 7-60 Specifications .............................................12-6
Check Bucket Teeth.................................... 7-61 Working Ranges..........................................12-7
Change Bucket .......................................... 7-63 Shoe Types
Convert Bucket Connection Into and Applications .................................... 12-8
Face Shovel .......................................... 7-64 Bucket Types
Adjust the Bucket Linkage .......................... 7-65 and Applications ..................................12-10
Remove the Travel Levers .......................... 7-66 ZAXIS270, ZAXIS270LC
Check and Replace Seat Belt ................... 7-67 Specifications ...........................................12-11
Check Windshield Washer Fluid Level ....... 7-67 Working Ranges........................................12-12
Check Track Sag ........................................ 7-68 Shoe Types
Adjust Track Sag......................................... 7-68 and Applications ..................................12-13
Loosen the Track ........................................ 7-69 Bucket Types
Tighten the Track ........................................ 7-69 and Applications ..................................12-15
Clean and Replace Air Conditioner
Filter ...................................................... 7-70 OPTIONAL ATTACHMENTS AND
Check the Air Conditioner ........................... 7-72 DEVICES
Clean Cab Floor .......................................... 7-73 Automatic Lubrication Device ............................ 13-1
Check Injection Nozzle................................ 7-74 Bucket Teeth (Transverse-Type-Pin
Retighten Cylinder Head Bolt ...................... 7-74 Used Type) ................................................13-4
Inspect and Adjust Valve Clearance ........... 7-74 Hydraulic Breaker ..............................................13-5
Check Fuel Injection Timing........................ 7-74 Breaker Operation .............................................13-6
Measure Engine Compression Precautions for Breaker Operation ....................13-7
Pressure................................................ 7-74 Breaker Maintenance.......................................13-10
Check Starter and Alternator....................... 7-74 Hydraulic Crusher ............................................13-11
Change Water Pump Grease ..................... 7-74 Precautions for Crusher Operation.................. 13-12
Check Tightening Torque of Bolts
and Nuts................................................ 7-75 INDEX..............................................................14-1
SAFETY
RECOGNIZE SAFETY INFORMATION
SA-688
001-E01A-0001
CAUTION also calls attention to safety messages in this
manual.
002-E01A-1223
S-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
S-2
SAFETY
WEAR PROTECTIVE CLOTHING
SA-434
006-E01A-0434
INSPECT MACHINE
007-E01A-0435 SA-435
S-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
S-4
SAFETY
USE HANDHOLDS AND STEPS
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.
008-E01A-0439
again.
009-E01A-0378
S-5
SAFETY
FASTEN YOUR SEAT BELT
011-E01A-0426
Starting fluid:
S-6
SAFETY
OPERATE ONLY FROM OPERATOR’S SEAT
012-E01B-0444
JUMP STARTING
S013-E01A-0032
SA-379
014-E01B-0379
S-7
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
SA-490
015-E01A-0380
S-8
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