INTRODUCTION

ADDITIONAL REFERENCES

Please refer to the other materials (operator’s

manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.

MANUAL COMPOSITION

This manual consists the Technical Manual and the
Workshop Manual.
• Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, operational performance tests, and
troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

In this manual, the following safety alert symbol and CAUTION:

signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.

UNITS USED

SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C 1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION

These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

this manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.

SA-688

UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
• Some safety signs do not use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
SA-1223
To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.

NOTE indicates an additional explanation for an

element of information.

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

Carefully read and follow all safety signs on the machine

as well as all safety messages in this manual.
Safety signs must be installed, maintained and replaced
if damaged.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure
to state machine model and serial number when or-
dering).
Allow only properly trained, qualified, authorized per-
SA-003
sonnel to operate the machine.
Learn how to correctly operate and service the machine.
Keep your machine in proper working condition.
Always operate the machine within the specification.
• Unauthorized modifications of the machine may impair
the functions and/or safety and affect machine life and
the warranty will become void.
The safety 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.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on
the fire extinguisher and use it properly.
• To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extin-
guisher at the recommended intervals as specified in
the fire-extinguisher manual.
• Establish emergency procedure guidelines to cope
with any fire or accidents which may occur. SA-437

• Keep emergency numbers for doctors, ambulance

service, hospitals, and fire department posted near
your telephone.

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety belt
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.

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 loud noises.

SA-434

INSPECT MACHINE

If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.

• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

SA-435

SA-3
 SAFETY
TIDY UP INSIDE OPERATOR’S SPACE

Always keep inside the cab clean by observing instruc-

tions below, to prevent any personal accidents from oc-
curring.
Remove mud and/or oily material from the shoe soles
before entering the operator’s space. If pedals are oper-
ated without removing mud or oily matter, the foot may
slip off the pedal, possibly creating a hazardous situa-
tion.
Do not leave parts and/or tools around the operator’s
seat.
Do not keep a transparent water bottle in the cab. The
transparent water bottle may concentrate the sun light
like a lens, possibly causing 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 injury.

• When you get on and off the machine, always face the
machine.
• 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.
• In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms, SA-439

thoroughly remove such material.

SA-4
 SAFETY
ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to
mis-operation of the machine.

• The seat should be adjusted whenever the operator for

the machine changes.
• The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back firmly against the seat back.
• If not, readjust the seat forward or backward, and
check again. SA-378

ENSURE SAFETY BEFORE RISING FROM OR

LEAVING OPERATOR’S SEAT

Before rising from the operator’s seat to open/close cab

front window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position.
Failure to do so may allow the machine to unexpectedly
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 covers and lock them up.

FASTEN YOUR SEAT BELT

If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

• Be sure to remain seated with the seat belt securely

fastened whenever operating the machine.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine. Replace the seat belt at
least once every 3 years regardless of appearance SA-237

SA-5
 SAFETY
MOVE AND OPERATE MACHINE SAFELY

Always be aware that there is a potential danger around

the machine while operating the machine.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped).
• Before 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- SA-1291

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 make a signal
and/or guidance.
• Never allow any persons or obstacles to enter the
machine operation areas.
• Use appropriate illuminations.

SA-6
 SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.

• Start the engine only when seated in the operator's

seat.
• NEVER start the engine while standing on the tracks or
on ground.
• Do not start engine by shorting across starter terminals.
A hazardous situation may be created and/or possible
damage to the machine may result. SA-444

• Before starting the engine, confirm that all control lev-

ers are in neutral.

JUMP STARTING

Failure to follow correct jump starting procedures 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.
SA-032
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.

KEEP RIDERS OFF MACHINE

Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the
machine.

• Riders also obstruct the operator’s view, resulting in

the machine being operated in an unsafe manner.
• Only allow the operator is allowed on the machine.
Keep riders off.

SA-1292

SA-7
 SAFETY
PRECAUTIONS FOR OPERATIONS

Thoroughly make certain safety at the work site before

starting operations. Especially always observe the fol-
lowing points.

• Be sure to wear close fitting clothing and required

safety items, such as a hard hat, when operating the
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 bucket
over the dump truck cab or over any co-workers.

M586-12-012

SA-8
 SAFETY
INVESTIGATE JOB SITE BEFOREHAND

When working at the edge of an excavation or on a road

shoulder, the machine could tip over due to collapse of
the ground, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as nec-
essary. Keep the machine well back from the edges of
excavations and road shoulders.
SA-1293
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Never allow bystanders to enter the working area such
as swing radius or traveling range.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing may become
loose and slippery.
• When operating the machine near open flame, sparks,
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 more easily
evacuate if the cliff face collapses.
• If working at the bottom of a cliff or on a high bank is
required, be sure to investigate the area first and con-
firm that no danger of the cliff or bank collapsing exists.
If any possibility of cliff or bank collapsing exists, do
not work in that area.
M586-05-021
• Soft ground may collapse when operating the machine
on it, possibly causing the machine to tip over. When
working on a soft ground is required, be sure to rein-
force the ground first using large pieces of steel plates
strong enough and firm to easily support the machine.
• Note that there is always a possibility of machine tip-
ping over when working on rough terrain or on slopes.
Prevent machine tipping over from occurring. Operate
the machine slowly to ensure safe operation.

SA-9
 SAFETY
PROTECT AGAINST FALLING STONES AND
DEBRIS

Confirm that your machine is FOPS cab equipped before

working in areas where the possibility of falling stones or
debris exist.

PROVIDE SIGNALS FOR JOBS INVOLVING

MULTIPLE NUMBERS OF MACHINES

In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.

For jobs involving 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

undercarriage in relation to the operator’s position.
• If the travel motors are located towards the front of the
cab, the machine will move in the reverse direction
when travel pedals/levers are operated.

SA-1294

SA-10
 SAFETY
DRIVE MACHINE SAFELY

Use a signal person when traveling the machine along

road shoulders or in congested areas.

Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to A
property.

Before driving the machine, always confirm that the

travel pedals/levers direction corresponds to the direc-
tion you wish to drive.
SA-1295

• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Do not allow personnel to stay around the
machine while traveling.
Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.

• Never attempt to ascend or descend 30 degrees or

steeper slopes.
• Be sure to fasten the seat belt.
A
• When driving up or down a slope, keep the bucket SA-1296
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, then, change the direction to ensure safe op-
eration.
• Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow SA-441
speed.
• If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neu-
tral. Then, restart the engine.
• Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not
warmed up sufficiently, sufficient performance may not
be obtained.

SA-589

SA-11
 SAFETY
• Traveling down a slope in the fast mode requires a
longer time to stop the machine. When traveling down
a slope, place travel mode switch (1) in the TURTLE
position.
• Select a travel route that is as flat as possible. Steer
the machine as straight as possible, making small
gradual changes repeatedly in direction. 1

• Check the strengths of bridges and road shoulders

before traveling on them, and reinforce if necessary.
• When the machine is equipped with steel shoes, cover ZX27U-3 (Canopy) M1M7-01-033
the road surface with wood plates in order not to
damage the road surface. Be careful of steering when
operating on asphalt roads in summer.
• When crossing train tracks, lay wood plates over the 1
tracks not to allow the machine to ride on only the
rails.
• Check that the machine can pass under a bridge and
electric lines before driving the machine.
• When crossing a river, drive the machine slowly while
measuring the depth of the river using the bucket. Do ZX30U-3, 35U-3, 40U-3, 50U-3 (Canopy) M1M7-01-032
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 do not
come in contact with loose rocks. If the machine
crosses over an obstruction, abnormally large loads Travel Motor
may be loaded on the machine. Avoid contact with an
obstruction while traveling the machine.
M104-05-008

• During freezing weather, always clean snow and ice

from track shoes before driving the machine on snowy
and/or frozen roads, or loading and unloading the
machine for transportation, to prevent the machine
from slipping.

SA-673

M586-05-002

SA-12
 SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS

Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.

Park the machine in compliance with the safe parking

procedures described on page SA-19 to prevent the
machine 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

SA-13
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals are SA-384

clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494-8

SA-14
 SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

If a person is present near the operating machine, the

person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
• Make sure that no personnel other than the signal
person or no obstacles are present in the working area
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

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.

SA-1300

SA-15
 SAFETY
AVOID TIPPING

The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.

To avoid tipping:
Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable. SA-1301

• 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

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur

causing serious injury or death.

SA-1302

SA-16
 SAFETY
DIG WITH CAUTION

Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in
serious injury or death.

• Before digging check the location of cables, gas lines,

and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in seri-
ous eye injury.
• Contact your local “diggers hot line” if available in your SA-672

area, and/or the utility companies directly.

Have them mark all underground utilities.

OPERATE WITH CAUTION

If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a 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 safe distance from electric
lines.

• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
SA-1305
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.

SA-17
 SAFETY
PRECAUTIONS FOR LIGHTNING

The machine is vulnerable to lightning strikes.

• In the event of an electrical storm, immediately stop

operation, and lower the bucket to the ground.
Evacuate to a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only
after repairing them.

SA-1805

DO NOT USE FOR CRANING OPERATIONS

NEVER use the machine for craning operations. If the

machine is used for craning operations, the 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 metal

pieces hit eyes or any other part of the body, serious
injury may result.

• Guard against such injuries when working in a job site

where possibility of flying pieces of metal or debris
exist, or when removing or installing pins using a
hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432

SA-18
 SAFETY
PARK MACHINE SAFELY

Unless the machine is not correctly parked, any haz-

ardous situations such as running away of the machine
or damage by vandalism may result, causing the ma-
chine to operate unsafely when the engine is re-started.
Follow instructions described below when parking the
machine.

• Park the machine on solid level surface to prevent the

machine from running away.
• Lower the bucket and/or blade to the ground.
SA-1306

• Pull the pilot control shut-off lever to the LOCK

position.
• Turn the auto-idle switch OFF. Failure to do so may
create a hazarduos condition as the engine speed
may unexpectedly increase. (Except ZX27U-3)
• Run engine at slow idle speed 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

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.

• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

All fuels, most lubricants, and some coolants are flam- SA-018
mable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
• Securely tighten the fuel and oil filler cap.

SA-019

SA-19
 SAFETY
SAFETY TRANSPORTING

The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads. SA-1307

• Provide an appropriate truck or trailer for transporting

the machine.
• Be sure to have a signal person.
• Take the following precautions when
loading/unloading the machine.
1. Select firm level ground.
2. Be sure to use a loading dock or ramp strong enough
to support the machine weight.
13
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have a gradient ZX27U-3
ZX30U-3, 35U-3
of less than 15 degrees. 40U-3, 50U-3
M1M7-01-031
M1M7-01-028
5. Be sure to turn the auto-idle switch (13) OFF. (Except
ZX27U-3)
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 rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
10. Do not operate any levers besides the travel levers
when driving up or down the ramp. ZX27U-3 (Canopy) M1M7-01-033

11. Prevent possible injury from machine tipping while the

upperstructure is rotating.
12. Keep the arm tucked under and rotate the upper-
structure slowly for best stability.

Refer to "transporting" chapter in the operator’s manual

for details.

ZX30U-3, 35U-3, 40U-3, 50U-3 M1M7-01-032

(Canopy)

SA-20
 SAFETY
PRACTICE SAFE MAINTENANCE

Inspection/maintenance work may produce hazardous

situations by contacting and/or accessing a part of body
to a moving, high pressure, and/or high temperature part
of the machine. To avoid serious personal injury or death,
follow the instructions described below.
• Thoroughly coordinate the working procedures to be
taken hereafter with the co-workers before beginning
work such as inspecting/servicing the machine, or
replacing the attachiment .
• Safely park the machine in accordance with the
instructions for “Park Machine Safely.”
• Keep the work area clean and orderly.
• Attach a “DO NOT OPERATE” tag in an easy-to-see SA-028
location such as on a door or a control lever.
• If moisture permeates into the electrical system,
malfunction and/or erroneous movement of the
machine may result. Do not clean sensors, cable
connectors, and the cab inside using water and/or
steam.
• Wait to begin to work until the engine and hydraulic oil
temperatures have cooled down to the safety range. 90 to 110
• 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. M1M7-04-006

• 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 the angle between
the boom and the arm in the range of 90 to 110 .
Never allow anyone to enter under the machine raised
with the front attachment function.
• In case working under the machine raised above the
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to support
the machine weight.
• Never work under the raised bucket.
• Keep all parts in good condition and properly installed. SA-527

• Always use the specified tools correctly.

• Always use a clean tool.
• Fix any damage found immediately. Replace worn or
broken parts.
• Remove any buildup of grease, oil, or debris.
• When cleaning parts, use a non-combustible cleaning
solvent. Never use an inflammable fluid such as
dieasel fuel, or gasoline.

SA-21
 SAFETY
• Disconnect battery ground cable ( ) before making
adjustments to electrical systems or before welding on
the machine.
• Sufficiently illuminate the work site. Use a
maintenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, antifreeze
fluid, or window washer fluid may catch fire.
• When the floor tilt mechanism check and/or mainte- SA-037

nance is conducted, the operator’s station is tilted

upward. Before conducting maintenance work, refer to
page 7-76 in the operator’s manual for the detailed
operation procedures and correctly operate the ma-
chine.
• When required to work under the floor, support the
raised operator’s station with the fall prevention bars
(red color) to ensure safety.
• When the inspection/maintenance work is complete,
tilt the operator’s station downward after housing the
fall prevention bars. Be sure to slowly lower the 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.
M1MW-07-031
Damage to the tilt mechanism may result.

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine, attach a

“Do Not Operate” tag in an easy-to-see place such as
on the cab door or control lever.
• Never attempt to operate the machine with a “Do Not
Operate” tag attached.
• Make it a rule for the inspection/service person to hold
the engine start key during inspection/service work.
SA-287

SS2045102

SA-22
 SAFETY
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing

the machine first.

• Always lower the attachment to the ground before you

work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment with stays
or blocks strong enough to support the machine
and/or attachment weight.

SA-527

STAY CLEAR OF MOVING PARTS

Contact with moving parts can cause serious injury or

death due to amputation or entanglement.

• To prevent accidents, 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, be sure to keep body
and face away from the valve.

Travel reduction gears are under pressure.

SA-344

• As pieces of parts may fly off, be sure to keep body

and face away from AIR RELEASE PLUG to avoid
injury.
• GEAR OIL is hot. Wait for gear oil to cool, then
gradually loosen the air release plug to release
pressure.

SA-23
 SAFETY
STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent

falling accidents.
• Keep children and bystanders away from storage
areas.

SA-034

PREVENT BURNS

Hot spraying fluids:

After operation, engine coolant is hot and under pressure.
Hot water or steam is contained in the engine, radiator
and heater lines.

Skin contact with escaping hot water or steam 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 SA-039

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 slowly removing the cap.

Hot fluids and surfaces:

Engine oil, gear oil and hydraulic oil also becomes hot
during operation.
The engine, hoses, lines and other parts become hot as
well.

• Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-225

SA-24
 SAFETY
REPLACE RUBBER HOSES PERIODICALLY

Rubber hoses that contain flammable fluids such as

hydraulic oil or fuel under pressure may break due to
aging, fatigue, and abrasion. It is very difficult to gauge
the extent of deterioration due to aging, fatigue, and
abrasion of rubber hoses by visual inspection alone.

• Periodically replace the rubber hoses.(Refer to the

Periodical Replacement Parts section in the operator’s
manual.)

Failure to periodically replace rubber hoses may cause a SA-019

fire, fluid injection into skin, or the front attachment to fall
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. Make sure that
all connectors are completely connected before
applying pressure.
• Search for leaks with a piece of cardboard; take care SA-031

to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-25
 SAFETY
PREVENT FIRES

Check for Oil Leaks:

Fuel, hydraulic oil and lubricant leaks can lead to fires,
possibly resulting in personal injury or death.

• Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damage to
the oil-cooler, and loose oil-cooler flange bolts, for oil
leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and SA-019

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 each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc.

SA-26
 SAFETY
Precautions for Handling Flammables
Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated
flammables immediately.
• Do not store flammable fluid near open flames.
• Do not burn or crush a pressurerized container.
• Do not store oily cloths. They are liable to catch fire.
• Do not wind easy-to-absorb-oil material around
high-temperature 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 fire fighting.

• Always check key switch function before operating the

machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to confirm
that the engine has stopped.
• If any abnormalities are found, be sure to repair them
before operating the machine.

SA-27
 SAFETY
EVACUATING IN CASE OF FIRE

If fire breaks out during machine operation, evacuate the

machine in the following way:

• Stop the engine by turning the key switch to the OFF

position.
• Use a fire extinguisher if there is time.
• Exit the machine using handrails and/or steps.
• In an emergency, if the cab door or front or rear win- SA-393

dow can not be opened, break the front or rear window

panes with the emergency evacuation hammer to es- (Cab-Equipped Machines)
cape from the cab.
Refer to the explanation pages on the Emergency
Evacuation Method in the operator’s manual.

SS4642980

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must 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 risk of in-
haling asbestos fiber may exist. Spray water to pre-
vent asbestos from becoming airborne. Do not use
compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated
to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
SA-029
Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.

SA-28
 SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
Grinding on the machine may create a fire hazard. Store
flammable objects in a safe place before starting grind-
ing.

After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the
welded area still smoldering.

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 fire resistant guards to protect hoses or
other materials before engaging in welding, soldering, SA-030
etc.

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain
flammable fluids.
• Remove flammable fluids thoroughly with
nonflammable solvent before welding or flame cutting
pipes or tubes that contained flammable fluids.

SA-29
 SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

• Remove paint before welding or heating.

• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Allow fumes to disperse at least 15 minutes after
welding or heating. SA-029

• Use attention to the following points when removing

paint.
1. If you sand or grind paint, avoid breathing the dust
which is created.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding.
3. Remove solvent or paint stripper containers and
other flammable material from area.

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 the
electrolyte level is lower than specified. Explosion of
the battery may result. SA-032

• When a terminal becomes loose, it may induce sparks.

Securely tighten all terminals.

Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness. If electrolyte is splashed
into eyes, flush your eyes continuosly with water for
about 15 minutes. Seek medical attention immediately.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

SA-30
 SAFETY
PRECAUTIONS FOR HANDLING REFRIG-
ERANT

If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.

• Refer to the precautions described on the refrigerant

container for handling refrigerant.
• Use a recovery and recycling system to avoid venting
refrigerant into the atmosphere.
• Never allow the skin to directly come in contact with
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 techniques.
• Check the MSDS before you start any job using a
hazardous chemical. Then follow the correct
procedures and use recommended equipment. SA-309

• See your authorized dealer for MSDS.

SA-31
 SAFETY
DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.

• 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
SA-226
such as oil, fuel, coolant, brake fluid, filters, and
batteries from your local environmental or recycling
center.

BEFORE RETURNING THE MACHINE TO THE

CUSTOMER

After maintenance or repair work is complete, confirm

that:

• The machine is functioning properly, especially the

safety systems.
• Worn or damaged parts have been repaired or
replaced

SA-435

S517-E01A-0435

SA-32
 SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL Group 5 Floor-Tilting Device
SECTION 2 UPPERSTRUCTURE
Group 1 Canopy and Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
TECHNICAL MANUAL
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Troubleshooting A
Group 3 Troubleshooting B
Group 4 Troubleshooting C
Group 5 Electrical System Inspection
SECTION 1
GENERAL

CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology......... W1-1-7

Group 2 Tightening
Tightening Torque Specifications ............. W1-2-1
Torque Chart............................................ W1-2-2
Piping Joint.............................................. W1-2-5
Periodic Replacement of Parts .............. W1-2-10

Group 3 Painting
Painting ................................................... W1-3-1

Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleed Air from Hydraulic Oil Tank ............ W1-4-1

Group 5 Floor-Tilting Device

Floor-Tilting Device Operation
Procedure .............................................. W1-5-1
Procedure for Floor Tilting up .................. W1-5-2
Procedure for Floor Tilting down.............. W1-5-5

1NDW-1-1
(Blank)

1NDW-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if
any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Apply suitable lubricant onto parts in order to
prevent them from seizing.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
 GENERAL / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A

1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W178-02-11-001
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.

(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

Correct
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
Incorrect
compressed air.

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it W178-02-11-002
is installed correctly on the seal ring. D Incorrect
Correct

(4) After installing the floating seal, check that a a

seal ring surface (A) is parallel with seal C
mating face (C) by measuring the distances
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating.

b b

a=b a b

W178-02-11-003

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a load
with a temperature of 100 C (212 F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY

“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia. Wrench Size Torque

No. Descriptions Q’ty
mm mm Nm (kgf m) (lbf ft)
1. Engine cushion rubber mounting bolt 12 4 19 90 (9) (65)
2. Engine bracket mounting bolt (Front) 10 8 17 50 (5) (36)
3. Hydraulic oil tank mounting bolt 12 4 19 90 (9) (65)
4. Fuel tank mounting nut 10 3 17 20 (2) (15)
7/16-20UNF 17 25 (2.5) (18)
19 30 (3) (22)
Metal face seal fit- 9/16-18UNF
22 40 (4) (29)
Union joints ting for hydraulic
hoses and piping 3/4-16UNF 27 65 (6.5) (47)
for hydraulic
5. 1-1/16-12UNF 36 180 (18) (129)
hoses and
pipes 1-5/16-12UNF 41 210 (21) (151)
9/16 UNF 19 30 (3) (22)
ORS 11/16 UNF 22 70 (7) (52)
13/16 UNF 27 95 (9.5) (69)
6. Pump mounting bolt 12 2 19 90 (9) (65)
7. Pump cover mounting bolt 10 8 17 50 (5) (36)
Control valve mounting bolt 10 4 17 50 (5) (36)
8.
Control valve base mounting bolt 10 4 17 50 (5) (36)
9. Swing device mounting bolt 14 6 22 140 (14) (101)
10. Battery mounting nut 6 3 10 5 (0.5) (3.5)
12 5 19 90 (9) (65)
11. Canopy mounting bolt
10 5 17 50 (5) (36)
12 5 19 90 (9) (65)
12. Cab mounting bolt
10 5 17 50 (5) (36)
Swing bearing Upperstructure 12 22 19 110 (11) (80)
13.
mounting bolt Undercarriage 12 20 19 110 (11) (80)
14. Travel device mounting bolt 12 24 19 110 (11) (83)
15. Sprocket mounting bolt 12 24 19 110 (11) (83)
16. Upper roller mounting bolt 16 2 24 270 (27) (199)
17. Lower roller mounting bolt 14 16 22 180 (18) (130)
6 10 5 (0.5) (3.5)
18. Cover mounting bolt 8 13 10 (1) (7)
10 17 50 (5) (36)
19. Counterweight mounting bolt 22 3 32 550 (55) (398)
10 17 50 (5) (36)
12 19 90 (9) (65)
20. Front pin lock plate bolt 14 22 140 (14) (101)
16 24 210 (21) (152)
18 27 400 (40) (290)
21. Side-cutter mounting bolt 14 6 22 180 (18) (130)
22. Track roller guard mounting bolt 14 12 22 180 (18) (130)
23. Tilt mechanism floor connection pin 10 1 17 50 (5) (36)
24. Tilt mechanism support-holding bolt 10 2 17 50 (5) (36)
Tilt mechanism support connection
25. 8 1 13 10 (1) (7)
pin

NOTE: (1) Apply lubricant (i.e. white zinc B dis-

solved into spindle oil) to reduce their
friction coefficients.
(2) Remove rust, dirt, and dust before in-
stalling fasteners.

W1-2-1
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed. SA-040

Make sure to employ correct bolts and tighten them

correctly when assembling the machine or compo-
nents.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092

Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (22.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)

W1-2-2
 GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.

Tighten from center and diagonally

Equally tighten upper and lower alternately Tighten diagonally

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-3
 GENERAL / Tightening
Service Recommendations for Split Flange

IMPORTANT: 1. Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent. W105-01-01-015

2. Be sure to use only specified WRONG

O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to W105-01-01-016
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes W105-01-01-008

tightening of one bolt fully before RIGHT WRONG

tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts.

Bend along edge sharply Do not bend it round

Nut and Bolt Locking

RIGHT RIGHT WRONG
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while Bend along edge sharply
tightening, not while loosening. W105-01-01-009

RIGHT RIGHT WRONG

Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.

Loosen WRONG
RIGHT

Tighten

W105-01-01-010

W1-2-4
 GENERAL / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint

Metal sealing surfaces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37

30
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017

2. Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.

Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N m (kgf m, lbf ft)
30 male 17 17 24.5 (2.5, 18)
19 19 29.5 (3.0, 22)
22 22 39 (4.0, 28.5)
27 27 64 (6.5, 47)
32 32 137 (14, 101)
36 36 175 (18, 129)
41 41 205 (21, 151)
37 female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 22)
22 19 39 (4.0, 28.5)
27 22 64 (6.5, 47)
32 27 137 (14, 101)
36 32 175 (18, 129)
41 36 205 (21, 151)
NOTE: Tightening torque of 37 male coupling without union is similar
to tightening torque of 37 female.

W1-2-5
 GENERAL / Tightening
Piping Joint

Pipe Joint (Metal Joint) 1 4 5 3 2

(Union Nut Wrench size 17 mm)

Metal sealing surfaces (3) (Metal) of pipe (2) and

adapter (1) seal pressure oil.

Take care not damage sealing surfaces when con-

necting / disconnecting pipe. M1M7-07-005

Tightening Torque Chart

Wrench Size (mm) 17
Nm 39
Tightening
(kgf m) (4.0)
Torque
(lbf ft) (28.5)

O-ring Seal Joint

7 6 9
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.

IMPORTANT: 1. Be sure to replace O-ring (6) with

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly 8 10 Hose Fittings M104-07-033
in O-ring groove (8). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting
in oil leakage. Wrench Size Tightening Torque
3. Take care not to damage O-ring mm
groove (8) or sealing surface Union Nut N m (kgf m, lbf ft)
(10). 19 44 (4.5, 32.5)
Damage to O-ring (6) will cause 22 74 (7.5, 55)
oil leakage. 24 78 (8.0, 58)
4. If nut (9) is loose and oil is leak- 27 103 (10.5, 76)
ing, do not re-tighten nut (9). Re-
place O-ring (6) with a new one
and check that O-ring (6) is cor-
rectly seated in place, tighten nut
(9).

W1-2-6
 GENERAL / Tightening
Quick Coupler

1. Connection Procedure
3 1
• While pulling and fully turning socket ring (1)
counterclockwise, insert socket ring (1) onto plug
(3) until the end face of socket ring (1) comes in
contact with plug (3).
• Release socket ring (1). Check that socket ring
(1) is slightly move backward by the spring force
and the coupler is held in position with balls (2). M1M7-07-006

Be sure to check that socket ring (1) has been 2

moved back fully to the right original position.

2. Disconnection Procedure
• While pulling and fully turning socket ring (1)
counterclockwise, disconnect the coupler. As no
check valve is provided in the coupler, take care
that oil may flow out of the coupler when the cou-
pler is disconnected.
• After the coupler is disconnected, plug the holes
with the exclusively prepared plugs.

CAUTION:

• Take care not to damage the joint surfaces

when disconnecting or connecting the cou-
pler.
• Before disconnecting or connecting the cou-
pler, clean the coupler and its surroundings
with a cleaning solvent and completely wipe
off the cleaning solvent. Use extra care not to
allow foreign matter such as dirt to enter the
coupler.
• Disconnect or connect the coupler in the cor-
rect procedure. Sufficiently check that no oil
leak is present after connecting the coupler.
• After connecting the coupler, check that that
socket ring (1) has been moved back fully to
the right original position.

W1-2-7
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread

Wrench Size Tightening Torque
mm N m (kgf m, lbf ft)
Hose Fittings FC material SS material
19 14.5 (1.5, 10.5) 34 (3.5, 25)
22 29.5 (3.0, 21.5) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16, 116)
41 108 (11, 80) 205 (21, 151)
50 157 (16, 116) 320 (32.5, 235)
60 195 (20, 144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
clearances. Do not overwrap. Clearance

Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N m (0.4 kgf m, 3.2 lbf ft)
Worm Gear Type Band Clamp: T-Bolt Type Worm Gear Type
5.9 to 6.9 N m (0.6 to 0.7 kg m, 4.4 to 5.1 lbf ft)

M114-07-043 M114-07-042

W1-2-8
 GENERAL / Tightening
Connecting Hose
WRONG RIGHT

CAUTION: When replacing hoses, be sure to

use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.
W105-01-01-011
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose WRONG RIGHT
rupture or separation of fitting. Utilize Print
Rubbing Against
marks on hoses when installing to prevent Each Other
hose from being kinked.

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
W105-01-01-012
from rubbing against each other.
WRONG RIGHT
Take care so that hoses do not come into Clamp Clamp
contact with moving parts or sharp objects.

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-9
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason,
replace these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct replace-
ment.

Periodic Replacement Parts Replacement Interval

Fuel hose (Fuel tank to filter)
Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine)
Engine
Engine rubber vibration insulator
Every 5 years or 3000 hours,
Floor mount rubber
whichever comes first
Pump coupling
Pump suction hose
Pump delivery hose
Base Machine Swing hose
Auxiliary hose
Hydraulic
Oil cooler hose (C/V to oil cooler) Every 2 years
System
Boom cylinder line hose
Arm cylinder line hose
Front Attachment
Bucket cylinder line hose
Pilot hose
Seat Belt Every 3 years

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-10
 GENERAL / Painting
PAINTING

Surfaces to Be Painted Painting Color

Main surface of upperstructure 2.5GYO.12/1.0D (SP-424)
(Except the resinated covers) Dark Gray
Boom swing post, Boom swing cylinder
Counterweight
Cab, Canopy (Including the front panel)
Seat base, Floor plate
(Except the resinated covers)

Track, Blade 2.5GYO.12/1.0D (SP-424)

Dark Gray

Front attachment, Upperstructure cover part YR1-01 TAXI Yellow

Cylinder 2.5GYO.12/1.0D (SP-424)
Dark Gray
Lever (Travel, Blade) N-10[N1.0]
Left stay Black

Dark Gray
(Painted by Manufacture)

Dark Gray

TAXI Yellow
TAXI TAXI Yellow
Yellow Dark Gray
Dark Gray
(Including Seat, Monitor and
Console)

Dark Gray
Dark Gray
Black
TAXI Dark Gray
Yellow TAXI Yellow
Dark Gray
Dark Gray
Dark Gray (Including
Boom Swing CYL)
Dark Gray
(Including
Blade CYL)

Dark Gray Black TAXI Dark Gray Dark Gray TAXI Yellow
Black Yellow W1M7-01-03-001
Black
(Painted by Manufacture)

W1-3-1
 GENERAL / Painting
(Blank)

W1-3-2
 GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal
pressure. Release any remaining pressure
and remove the cap.

Preparation

1. Park the machine on a solid, level surface. Lower

the front attachment onto the ground.

2. Stop the engine. Loosen cap (1) on hydraulic oil

tank (2) and release any remaining pressure. M1M7-05-024
1
3. Remove cap (1) on hydraulic oil tank (2). 2

4. Install a vacuum pump to the hole without cap (1).

Operate the vacuum pump and maintain negative
pressure in the hydraulic oil tank.
Run the vacuum pump continuously while W1M9-01-04-001
working.

Vacuum Pump

Hose

Adapter

W1M9-01-04-002

W1-4-1
 GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)

W1-4-2
 GENERAL / Floor-Tilting Device
FLOOR-TILTING DEVICE OPERATION
PROCEDURE

Preparation
• Park the machine in a flat and solid place.
• Lower the blade.
• Roll-in the arm and bucket, and put them on the
front wooden block or something.

CAUTION: Be careful because interference

of the boom and canopy (cab) takes place
unless the front end attachment is lowered in
advance.
M1M7-07-060
Wooden Block
• Close the door of the cab (optional).

W1-5-1
 GENERAL / Floor-Tilting Device
PROCEDURE FOR FLOOR TILTING UP

CAUTION: If tilting up operation is made with 1

the door open, it interferes with the cover (3).

1. Remove two bolts (2), and remove (3) from the

canopy or cab (1).
: 13 mm
2

IMPORTANT: Near bolts (4), two bolts for fixing the 3

canopy or cab (1) are fitted. Never
4 M1M7-07-061
remove these two bolts in tilting up 4-Pillar Canopy
operation.
A bolt never to be removed can be
identified by the attached cap or red 1
paint.

2. Remove three bolts (4) from the canopy or cab

(1).
: 19 mm

Not to be
removed. M1M7-07-063

Cab (Optional) 4

M1M7-07-064

Not to be
removed.

W1-5-2
 GENERAL / Floor-Tilting Device
IMPORTANT: The operating torque of adjuster 1
screw (5) is 24.5 N m (2.5 kgf m, 18
lbf ft) or lower. In case larger torque
is required, it is probable that bolts
(4) remain not removed. Re-check
from this perspective.

3. Turn adjuster screw (5). Tilt the canopy or cab (1)

assembly toward front. 5
: 17 mm

4. Turn adjuster screw (5) clockwise until disc (6) on

the side face of the tilting device moves to the
M1M7-07-065
farthest end.
4-Pillar Canopy

M1M7-07-066

CAUTION: Do not tilt up cab (1) as far as the Cab (Optional)

striped region. If done so, cab (1) tilts forward
because the center of gravity overhangs the
balancing point, which is dangerous.

5. In cab (1) version machines, stop tilting up 50 mm

before the farthest end (before the striped region
6
(6)).

50 mm
(1.97 in)
W1M9-01-05-001

W1-5-3
 GENERAL / Floor-Tilting Device
IMPORTANT: Do not make tilting up operation by
other means (e.g. by crane) than the
tilting device. Otherwise, the tilting
device or floor could be damaged.
7
6. In case of work done lying under the floor, support
the opening space of the raised floor for security
with fall prevention lever (7).

M1M7-07-067

M1M7-07-081

W1-5-4
 GENERAL / Floor-Tilting Device
PROCEDURE FOR FLOOR TILTING DOWN

1. Return fall prevention lever (7) toward direction of

the arrow while raising lock stopper (14).

14

M1M7-07-082

CAUTION: Do not lower the floor abruptly. If

adjuster screw (5) is rotated abruptly in
lowering the floor, the floor trembles
enormously, which is dangerous.

2. Slowly turn adjuster screw (5) anticlockwise.

: 17 mm
9

3. Turn adjuster screw (5) counterclockwise until the 10

farthest end contacts receiver seat (8).
8

CAUTION: After the floor has been lowered 2 to 5 mm

completely, if adjuster screw (5) is kept (0.1 to 0.2 in)
5 M1M7-07-068
turned, it will not be turned any longer when
unscrewed by about 15 mm because washer 11 12
(11) touches pin (12). Be careful not to turn
adjuster screw (5) further because washer
(11) deforms and gets damaged, causing fall
of bolt (13).

4. When the floor has been lowered completely, 13

adjuster screw (5) is drawn. Make adjustment so
that the clearance between collar (9) of adjuster
screw (5) and contact face (10) becomes 2 to 5
mm (0.1 to 0.2 in).
W1M9-01-05-002

W1-5-5
 GENERAL / Floor-Tilting Device
4
5. Install the canopy or cab (1) with three bolts (4). 4-Pillar Canopy
: 19 mm
: 90 N m (9.2 kgf m, 66 lbf ft)
1

M1M7-07-062

Cab (Optional) 4

M1M7-07-064

W1-5-6
 MEMO

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 MEMO

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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Canopy and Cab
Removal and Installation of
4-Pillar Canopy ...................................... W2-1-1
Removal and Installation of Cab .............. W2-1-7
Dimensions of Cab Glass ...................... W2-1-15
Removal and Installation of
2-Pillar Canopy .................................... W2-1-29
Group 2 Counterweight
Removal and Installation of
Counterweight ....................................... W2-2-1
Group 3 Pump Device
Removal and Installation of
Pump Device ......................................... W2-3-1
Disassembly of Pump Device ................ W2-3-4
Assembly of Pump Device ....................... W2-3-6
Maintenance Standard........................... W2-3-10
Group 4 Control Valve
Removal and Installation of
Control Valve ......................................... W2-4-1
Disassembly and Assembly of
Control Valve ......................................... W2-4-6
Disassembly and Assembly of Body .... W2-4-14
Disassembly of Boom Anti-Drift Valve
(Only ZX30U-3, 35U-3) ........................ W2-4-18
Assembly of Boom Anti-Drift Valve
(Only ZX30U-3, 35U-3) ........................ W2-4-20
Disassembly and Assembly of Spool ..... W2-4-22
Disassembly and Assembly of Arm
Regenerative Valve, Check Valve
and Orifice ........................................... W2-4-24
1NDW-2-1
Group 5 Swing Device
Removal and Installation of
Swing Device ......................................... W2-5-1
Disassembly of Swing Device .................. W2-5-4
Assembly of Swing Device....................... W2-5-8
Disassembly of Swing Motor.................. W2-5-14
Assembly of Swing Motor....................... W2-5-16
Maintenance Standard ........................... W2-5-20
Group 6 Pilot Valve
Removal and Installation of Pilot Valve
(Left) ...................................................... W2-6-1
Removal and Installation of Pilot Valve
(Right) .................................................... W2-6-5
Removal and Installation of
Travel Pilot Valve ................................... W2-6-9
Removal and Installation of
Blade Pilot Valve .................................. W2-6-11
Removal and Installation of
Boom Swing Pilot Valve ....................... W2-6-15
Disassembly of Pilot Valves
(Left and Right) .................................... W2-6-18
Assembly of Pilot Valves
(Left and Right) .................................... W2-6-22
Disassembly of Travel Pilot Valve .......... W2-6-26
Assembly of Travel Pilot Valve ............... W2-6-30
Disassembly of Pilot Valves for
Boom Swing, Blade, and Auxiliary........ W2-6-36
Assembly of Pilot Valves for
Boom Swing, Blade, and Auxiliary........ W2-6-38
Group 7 Solenoid Valve
Removal and Installation of
Solenoid Valve ....................................... W2-7-1
Disassembly of 2-Spool Solenoid Valve... W2-7-4
Assembly of 2-Spool Solenoid Valve ....... W2-7-6
Disassembly of 1-Spool Solenoid
Valve.................................................... W2-7-10
Assembly of 1-Spool Solenoid Valve ..... W2-7-12

1NDW-2-2
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