Page 1 of 14

SERVICE BULLETIN CODE

DESCRIPTION
2 2015 0053
FILING LOCATION

SUBJECT ZX190-5 ∼ ZX870-5-201

ZH200-A/5B-203
ZX-5 HOT & COOL (H&C) BOX TEMPERATURE FAILURE
MODIFICATION - AIR CONDITIONER (A/C) UNIT MODIFICATION
PROCEDURE

OUTLINE
This Service Bulletin is to inform you that there have been incidents on the ZX-5 machines that are
mounted with Denso air conditioner. When the air conditioner is used, warm air is sent into the H&C
box. This is due to the structure that makes it easy for the warm air inside the air conditioner unit to
enter the H&C box vent. It happens when the temperature inside the cab is close to the set air
conditioner temperature. In the event of failure, we ask that you undertake modifications by
following this Service Bulletin.
Below you will find directions on how to install the guide in order to make it easier to send cold air
into the H&C box. To install the guide, you will need to remove the internal covers. Remove the
parts while referring to the “2. Internal removal” section on page 7.
＊ Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.
＊ After replacing the main hydraulic equipment or engine or after post-assembling the aforementioned as an
option, be sure to change and register the post-assembled device serial number on Global e-Service (MMR,
HR, MME, G-Claim).

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX190-5 ∼ ZX870-5, ZH200-A/5B
Machine Serial Nos.: Refer to “List of target models” on pages 4 to 6.
Verify details of the target models on Global e-Service S/B (Service Bulletin).

WHEN TO PERFORM SERVICE STD. LABOR HOURS

Whenever a malfunction occurs. 1.5 Hours / one person

EXPENSES AND THE TIME TO BE CHARGED

The expenses stated in the agreement will be borne by Hitachi, provided that the machines standard
warranty period has not expired.

PARTS
The A/C unit duct/installation guide are scheduled to be stocked at the central parts depot from
January, 2016.

The following codes are to be written in the Warranty Claim Application report:
Unit: 803 ; Type of failure: 81 ; Type of repair: 360 .
DESCRIPTION
Please refer to the following page(s).

DWN
SA/GI: ZX-5(All)-114, ZH200-059
CHKD
SA/KU: According to the claim no. by model APPD
 Page 2 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
ZH200-A/5B-203

CONTENTS

1 Modification parts …………………………………………………………………………… 3

2 Internal removal ……………………………………………………………………………… 7

2-1 Removing the rear cover …………………………………………………………… 7

2-2 Removing the right cover ………………………………………………………… 8

3 Removal of duct ……………………………………………………………………………… 9

4 Installation of H&C port guide ……………………………………………………………… 10

5 Installation of new duct (for H&C guide-attached type) ……………………………… 11

6 Internal installation …………………………………………………………………………… 12

6-1 Installing the cover ………………………………………………………………… 12

6-2 Installing the rear cover …………………………………………………………… 13

7 Confirmation items …………………………………………………………………………… 14

 Page 3 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
1 Modification parts ZH200-A/5B-203

Below you will find directions on how to install the guide in order to make it easier to send cold air into the
H&C box.
Have modification parts shown on Chart 1.1 and Fig. 1.2 ready before beginning the work.

Chart 1.1 List of modification parts for H&C box

Item No. Part No. Part Name Q’ty Remarks
00 YA00045626 Guide 1 H&C port guide
01 YA40018525 Duct 1 For guide-attached type

※ Machine mounted with “modification air conditioner unit (with guide) P/No. YA00042254”
The machines that have been produced after the serial numbers that are listed on Chart 1.2 are
already mounted with air conditioner units with new guides (00). Therefore, they do not have to be
modified as described in this Service Bulletin.

H&C box

Duct (H&C)

A/C unit

Fig. 1.1 Installation locations of H&C box, A/C unit and duct

(01)YA40018525 ∼ 1 H&C port

Duct

A/C unit
(00)YA00045626 ∼ 1
Guide

Fig. 1.2 Structure of A/C unit with guide

 Page 4 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
Chart 1.2 List of target models (1/3)
ZH200-A/5B-203
Model Remarks Model Name Model Code Target S/No.
ZX190LCN-5B(DRM) DBJ5X
ZX190-5B ∼ 100002
ZX190LC-5B(DRM) DBJ5Y
ZX190-5B -AMS ZX190-5B(UPS) DBJ5Z ∼ 500084
ZX210-5B(UPS) DCK5Z
ZX200-5B -AMS ZX210LCN-5B(UPS) DCL5Z ∼ 700596
ZX240N-5B(UPS) DCL5Y
ZX210-5B DCK51
ZX210LC-5B DCK50
ZX210LCN-5B DCL50
ZX240N-5B DCL51
ZX200-5B DCKA0
ZX200LC-5B DCKA1
ZX200-5B ∼ 303755
ZX210H-5B DCKA2
ZX210K-5B DCKA6
ZX210KB-5B DCKA4
ZX210LCH-5B DCKA3
ZX210LCK-5B DCKA7
ZX210LCKB-5B DCKA5
ZX200-5G DCD90
ZX200LC-5G DCD91
ZX210H-5G DCD92
ZX200-5G ∼ 304191
ZX210LCH-5G DCD93
ZX210K-5G DCD94
ZX210LCK-5G DCD95
ZX200-5A DCX90
ZX200LC-5A DCX91
ZX210H-5A DCX92
ZX200-5A ∼ 300017
ZX210K-5A DCX94
ZX210LCH-5A DCX93
ZX210LCK-5A DCX95
ZH210-A DCF90
ZH210LC-A DCF91
ZH200-A ∼ 010516
ZH200-A DCFA0
ZH200LC-A DCFA1
ZH210LC-5B DCS51
ZH200-5B DCSA0
ZH200-5B ZH200LC-5B DCSA1 ∼ 020358
ZH210K-5B DCSA2
ZH210LCK-5B DCSA3
 Page 5 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
Chart 1.2 List of target models (2/3)
ZH200-A/5B-203
Model Remarks Model Name Model Code Target S/No.
ZX240-5B DCAA0
ZX240LC-5B DCAA1
ZX250H-5B DCAA2
ZX250LCH-5B DCAA3
ZX240-5B ∼ 030550
ZX250K-5B DCAA4
ZX250LCK-5B DCAA5
ZX250LC-5B DCA50
ZX250LCN-5B DCA51
ZX240-5G DCE90
ZX240LC-5G DCE91
ZX250H-5G DCE92
ZX240-5G ZX250LCH-5G DCE93 ∼ 030890
ZX250K-5G DCE94
ZX250LCK-5G DCE95
ZX250L-5G DCE96
ZX240-5A DCY90
ZX240LC-5A DCY91
ZX240-5A ZX250H-5A DCY92 ∼ 030002
ZX250K-5A DCY94
ZX260LCH-5A DCYJ0
ZX280-5B DDAA0
ZX280LC-5B DDAA1
ZX270-5B ∼ 040496
ZX290LC-5B DDA50
ZX290LCN-5B DDA51
ZX280-5G DDF90
ZX270-5G ZX280LC-5G DDF91 ∼ 040268
ZX290L-5G DDF92
ZX300-5A DDW90
ZX300-5A ∼ 060002
ZX300LC-5A DDW91
ZX330-5B DDDA0
ZX330LC-5B DDDA1
ZX350H-5B DDDA2
ZX350LCH-5B DDDA3
ZX330-5B
ZX350K-5B DDDA4 ∼ 071335
ZX350LCK-5B DDDA5
ZX350LC-5B DDD50
ZX350LCN-5B DDD51
ZX400R-5B ZX400R-5B DDDA6
ZX330-5G DDE90
ZX330LC-5G DDE91
ZX350H-5G DDE92
ZX330-5G ZX350LCH-5G DDE93 ∼ 042465
ZX350K-5G DDE94
ZX350LCK-5G DDE95
ZX400L-5G DDE96
ZX330-5A DDK90
ZX330LC-5A DDK91
ZX350H-5A DDK92
ZX330-5A ∼ 070006
ZX350K-5A DDK94
ZX350LCH-5A DDK93
ZX350LCK-5A DDK95
 Page 6 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
Chart 1.2 List of target models (3/3)
ZH200-A/5B-203
Model Remarks Model Name Model Code Target S/No.
ZX470LCH-5B JAA50
ZX470LC-5B JAA70
ZX470-5B JAAA0
ZX470LC-5B JAAA1
ZX470H-5B JAAA2
ZX470-5B ∼ 031056
ZX470LCH-5B JAAA3
ZX470R-5B JAAA4
ZX470LCR-5B JAAA5
ZX520LCH-5B JAD40
ZX520LCH-5B JADA0
ZX470-5G JAC90
ZX470LC-5G JAC91
ZX470H-5G JAC92
ZX470-5G ∼ 051082
ZX470LCH-5G JAC93
ZX470R-5G JAC94
ZX470LCR-5G JAC95
ZX670LCH-5B JBA41
ZX670-5B ZX670LCR-5B JBA42 ∼ 030128
ZX670LC-5B JBA70
ZX670LC-5G JBF90
ZX670-5G ZX670LCH-5G JBF91 ∼ 050164
ZX670LCR-5G JBF92
ZX870LCH-5B JBC41
ZX870-5B ZX870LCR-5B JBC42 ∼ 030151
ZX870LC-5B JBC70
ZX870-5G JBE90
ZX870LC-5G JBE91
ZX870-5G ZX870H-5G JBE92 ∼ 050271
ZX870LCH-5G JBE93
ZX870LCR-5G JBE94
 Page 7 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
2 Internal removal ZH200-A/5B-203

Make space to modify the A/C unit.

2-1 Removing the rear cover

Remove the caps (screw-type), screws and bolts to remove the rear cover (Figs. 2.1 and 2.2).
※ For more information on removal method, refer to the “Cab removal/installation” section in the
Workshop Manual.

Remove the caps Remove the caps (5 locations).

(screw-type) (2 locations). Top cover

Remove the
fuse cover.

Left cover

Details Right cover Tray

Fig. 2.1 Rear cover at the back, inside the cab (rear cover mounted state)

※ Before removing the left cover,

Top cover release the lighter and connector
of the 12V power source socket.
Remove the screw
(9 locations).

Left cover

Remove the bolt.

Tray
Right cover
Remove the bolts and
washers (2 locations).

Fig. 2.2 Rear cover at the back, inside the cab (rear cover removed state)
 Page 8 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
2-2 Removing the right cover ZH200-A/5B-203

Cap
Duct cover

Remove the 1 cap and 1 sems

screw (M6X16) and remove the Duct (A/C unit side)
duct cover.
Duct cover Duct (monitor side)

Duct (A/C unit side)

Duct (monitor side)

Remove the 1 sems bolt (M6X20) and

remove the duct (A/C unit side).

Remove the 3 sems screws (M6X16)

and remove the duct (monitor side).

Fig. 2.3 Removal of right cover and duct (at the monitor)
 Page 9 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
3 Removal of duct ZH200-A/5B-203

Remove the screws and duct (H&C) as shown in Fig. 3.1.

Remove the sems screws

(M6X16) (2 locations).

Floor parts

Duct (H&C)

H&C port

A/C unit

Fig. 3.1 Removal of duct

 Page 10 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
4 Installation of H&C port guide ZH200-A/5B-203

Install guide (00) to the H&C port of the A/C unit.

A/C unit
(with no (00) attached)

(00)YA00045626 ∼ 1 Install in such way so that (00) protrusion

Guide faces the direction of the noon.
Direction of H&C port
the noon

Before installation After installation

Fig. 4.1 Details of H&C port guide installation method

 Page 11 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
5 Installation of new duct (for H&C guide-attached type) ZH200-A/5B-203

Install (01) as shown in Fig. 5.1.

Properly install (01) to the H&C port and install each screw.

Install the sems screws

(M6X16) (2 locations)

Floor parts

(01)YA40018525 ∼ 1
Duct
Properly attach to
the H&C port.

Fig. 5.1 Installation of new duct (for H&C guide-attached type)

With guide (00) stopper

(a) Old shape (b) New shape

Fig. 5.2 Difference between the new and old duct (H&C) shapes
 Page 12 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
6 Internal installation ZH200-A/5B-203

6-1 Installing the cover

Install the duct (A/C unit side), duct (monitor side) and duct cover in the given order as shown in
Fig. 6.1. Install the bolts, screws and caps.

Cap
Duct cover

Install the duct cover and fix with 1

sems screw (M6X16). Install 1 cap. Duct (A/C unit side)
Duct cover Duct (monitor side)

Duct (A/C unit side)

Duct (monitor side)

Install the duct (A/C unit side).

Fix with 1 sems bolt (M8X20).

Install the duct (monitor side).

Fix with 3 sems screws (M6X16).

Fig. 6.1 Installation of right cover and duct (at the monitor)
 Page 13 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
6-2 Installing the rear cover ZH200-A/5B-203

Install the tray, top cover, right cover and left cover in the given order. Install each bolt,
screw, cap, etc. (Figs. 5.8 and 5.9).
※ For more information on installation method, refer to the “Cab removal/installation”
section in the Workshop Manual.

※ Before installing the left cover, properly

Top cover wire the lighter and connector of the
12V power source socket.
Install the screws
(9 locations).

Left cover

Install the bolt.

Tray
Right cover
Install the bolts and
washers (2 locations).

Fig. 6.2 Rear cover at the back, inside the cab (with no cap installed)

Install the caps (screw-type) Install the caps (5 locations).

(2 locations). Top cover

Install the
fuse cover.

Left cover

Details Right cover Tray

Fig. 6.3 Rear cover at the back, inside the cab (with the cap installed)
 Page 14 of 14
SERVICE BULLETIN CODE
DESCRIPTION
2 2015 0053
FILING LOCATION
ZX190-5 ∼ ZX870-5-201
7 Confirmation items ZH200-A/5B-203

Turn the air conditioner ON. Confirm that air is being sent from the vents.
This concludes the work.

Mode switch

ON/OFF
Air volume adjustment switch

Fig. 7.1 Adjustment of switch box

Operate the mode switch and select the one shown

below. Confirm that air is being sent from the vents.

Fig. 7.2 Monitor display