Zx48u Operator Manuel PDF
Zx48u Operator Manuel PDF
Zx48u Operator Manuel PDF
ENMADC-2-1
ZX33U-5A
•
Operator’s Manual
38U-5A
•
48U-5A
•
55U-5A
•
65USB-5A HYDRAULIC EXCAVATOR
33U-5A
38U-5A
48U-5A
OPERATOR’S MANUAL
55U-5A
65USB-5A
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
Serial No.
ZX33U-5A 030002 and up
ZX38U-5A 050002 and up
ENMADC-2-1
Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support
service your machine correctly. Failure to do so could program for customers who operate and maintain their
result in personal injury or equipment damage. equipment as described in this manual. The warranty is
explained on the warranty certificate which you should
This standard specification machine can be operated have received from your dealer.
under the following conditions without being modified.
Atmospheric Temperature: −20 °C to 40 °C (−4 °F to 104 °F) This warranty provides you the assurance that Hitachi
Altitude: 0 m to 1500 m (0 ft to 4900 ft) will back its products where defects appear within the
warranty period. In some circumstances, Hitachi also
In case the machine is used under conditions other than provides field improvements, often without charge to
described above, consult your authorized dealer. the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
This manual should be considered a permanent part of change its performance beyond the original factory
your machine and should remain with the machine when specifications, the warranty will become void and field
you sell it. improvements may be denied. Setting fuel delivery
above specifications or otherwise overpowering machines
This machine is of metric design. Measurements in this will result in such action.
manual are metric. Use only metric hardware and tools as
specified. Only qualified, experienced operators officially licensed
• SI Units (International System of Units) are used in this (according to local law) should be allowed to operate
manual. the machine. Moreover, only officially licensed personnel
For reference MKS system units and English units are should be allowed to inspect and service the machine.
also indicated in parentheses after the SI units.
Example : 24.5 MPa (250 kgf/cm², 3560 psi) PRIOR TO OPERATING THIS MACHINE, INCLUDING
COMMUNICATION SYSTEM, IN A COUNTRY OTHER
Right-hand and left-hand sides are determined by THAN A COUNTRY OF ITS INTENDED USE, IT MAY
facing in the direction of forward travel. BE NECESSARY TO MAKE MODIFICATIONS TO IT SO
THAT IT COMPLIES WITH THE LOCAL REGULATORY
Write product identification numbers in the Machine STANDARDS (INCLUDING SAFETY STANDARDS)
Numbers section. Accurately record all the numbers AND LEGAL REQUIREMENTS OF THAT PARTICULAR
to help in tracing the machine should it be stolen. COUNTRY. PLEASE DO NOT EXPORT OR OPERATE
Your dealer also needs these numbers when you order THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS
parts. If this manual is kept on the machine, also file the INTENDED USE UNTIL SUCH COMPLIANCE HAS BEEN
identification numbers in a secure place off the machine. CONFIRMED.
PLEASE CONTACT HITACHI CONSTRUCTION
Use only diesel fuel with quality specified in JIS K-2204, MACHINERY CO., LTD. OR ANY OF OUR AUTHORIZED
EN-590, ASTM D-975, GOST R52368 or GB252. DISTRIBUTOR OR DEALER IF YOU HAVE ANY
Failure to use diesel fuel with quality as specified QUESTIONS CONCERNING COMPLIANCE.
above may allow the engine to emit exhaust gas which
cleanness can not conform to the requests in various
relevant regulations. In addition, serious damage to the
engine may result. Consult with your authorized dealer for
detailed information.
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.
©2018 Hitachi Construction Machinery Co., Ltd.
All Rights Reserved.
MACHINE NUMBERS
INDEX SAFETY
VISIBILITY MAP
SAFETY SIGNS
COMPONENTS NAME
GETTING ON/OFF THE MACHINE
OPERATOR’S STATION
BREAK-IN
OPERATING THE ENGINE
DRIVING THE MACHINE
OPERATING THE MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONST
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
OPTIONAL ATTACHMENT
ENMADC-2-1
INDEX
CONTENTS
MACHINE NUMBERS.........................................................................1 Avoid Heating Near Pressurized Fluid Lines........................ S-32
Avoid Applying Heat to Lines Containing Flammable
SAFETY................................................................................................S-1 Fluids............................................................................................ S-32
Recognize Safety Information.....................................................S-1 Precautions for Handling Accumulator and Gas
Understand Signal Words..............................................................S-1 Damper........................................................................................ S-32
Follow Safety Instructions.............................................................S-2 Remove Paint Before Welding or Heating............................ S-33
Prepare For Emergencies...............................................................S-3 Beware of Asbestos and Silicon Dust and Other
Wear Protective Clothing..............................................................S-3 Contamination.......................................................................... S-33
Protect Against Noise.....................................................................S-4 Prevent Battery Explosions........................................................ S-34
Inspect Machine...............................................................................S-4 Precautions for Handling Refrigerant.................................... S-34
General Precautions for Cab.........................................................S-5 Handle Chemical Products Safely............................................ S-35
Use Handrails and Steps................................................................S-5 Dispose of Waste Properly.......................................................... S-35
Adjust the Operator’s Seat............................................................S-6 Never Ride Attachment............................................................... S-36
Ensure Safety Before Rising From or Leaving Operator’s Precautions for Communication Terminal............................ S-36
Seat..................................................................................................S-6 Precaution for Communication Terminal Equipment...... S-37
Fasten Your Seat Belt.......................................................................S-7
Move and Operate Machine Safely............................................S-7 VISIBILITY MAP............................................................................ S-39
Operate Only From Operator’s Seat...........................................S-8 SAFETY SIGNS............................................................................... S-42
Jump Starting....................................................................................S-8
Keep Riders Off Machine...............................................................S-8 COMPONENTS NAME...................................................................1-1
Precautions for Operations...........................................................S-9 Components Name.........................................................................1-1
Investigate Job Site Beforehand.............................................. S-10
GETTING ON/OFF THE MACHINE............................................1-2
Equipment of OPG........................................................................ S-11
Restriction of Attachment Installation.................................. S-11 Getting ON/OFF the Machine......................................................1-2
Provide Signals for Jobs Involving Multiple Machines.... S-11 OPERATOR'S STATION..................................................................1-3
Confirm Direction of Machine to be Driven........................ S-11 Layout...................................................................................................1-3
Drive Machine Safely.................................................................... S-12 Key Switch.....................................................................................1-5
Avoid Injury From Rollaway Accidents.................................. S-14 Switch Panel ................................................................................1-5
Avoid Injury From Back-over and Swing Accidents.......... S-15 Monitor................................................................................................1-6
Keep Person Clear From Working Area.................................. S-16 Feature............................................................................................1-6
Never Position Bucket Over Anyone...................................... S-16 Screen Configuration................................................................1-6
Avoid Undercutting...................................................................... S-16 Basic Screen........................................................................................1-7
Avoid Tipping.................................................................................. S-17 Indicators.............................................................................................1-8
Never Undercut a High Bank..................................................... S-17 Overheat Indicator (1)...............................................................1-8
Dig With Caution........................................................................... S-18 Engine Oil Pressure Indicator (2)...........................................1-8
Operate With Caution.................................................................. S-18 Alternator Indicator (3).............................................................1-8
Avoid Power Lines......................................................................... S-18 Fuel Level Indicator (4)..............................................................1-8
Precautions for Lightning........................................................... S-19 How to Use Screens.........................................................................1-9
Object Handling............................................................................ S-19 Displaying Basic Screen............................................................1-9
Protect Against Flying Debris................................................... S-20 Hour Meter................................................................................. 1-13
Park Machine Safely...................................................................... S-20 Clock............................................................................................. 1-13
Handle Fluids Safely --- Avoid Fires......................................... S-21 Fuel Gauge................................................................................. 1-13
Safety Transporting...................................................................... S-22 Coolant Temperature Gauge............................................... 1-13
Practice Safe Maintenance......................................................... S-23 Operating Status Icon Display............................................. 1-13
Warn Others of Service Work.................................................... S-24 Alarm Occurrence Screen........................................................... 1-14
Support Machine Properly......................................................... S-25 Error Display Screen................................................................ 1-14
Stay Clear of Moving Parts......................................................... S-25 Warning Display Screen......................................................... 1-14
Prevent Parts From Flying.......................................................... S-26 Alarm List Display.................................................................... 1-15
Avoid Injury from Attachment Falling Accident................ S-26 Contents of Alarms....................................................................... 1-16
Prevent Burns.................................................................................. S-27 Error Code................................................................................... 1-16
Replace Rubber Hoses Periodically......................................... S-28 Warning Codes ........................................................................ 1-16
Avoid High-Pressure Fluids........................................................ S-28 DTC Code List . ............................................................................... 1-18
Prevent Fires.................................................................................... S-29 Main Menu (MENU) ..................................................................... 1-20
Evacuating in Case of Fire........................................................... S-31 Clock.................................................................................................. 1-21
Beware of Exhaust Fumes.......................................................... S-31 Clock Adjustment.................................................................... 1-21
Precautions for Welding and Grinding.................................. S-32 Display Mode Setting............................................................. 1-23
CONTENTS
Trip...................................................................................................... 1-24 Traveling..............................................................................................4-4
Functions of Trip Meter . ....................................................... 1-24 Traveling on Soft Ground..............................................................4-5
Displaying Trip Meter (1) ..................................................... 1-25 Raise One Track by Using Boom and Arm...............................4-6
Displaying Trip Meter (2) ..................................................... 1-27 Towing Machine...............................................................................4-7
Change Trip Meter Set Time . .............................................. 1-28 Operating in Water or Mud...........................................................4-8
Brightness Adjustment................................................................ 1-30 Precautions for Traveling on Slopes..........................................4-9
Heater Operation (ZX33U-5A, 38U-5A, 48U-5A, Parking the Machine on Slopes................................................ 4-10
55U-5A)........................................................................................ 1-32 Parking the Machine.................................................................... 4-10
Name and Function of Each Part of Control Panel....... 1-32
OPERATING THE MACHINE........................................................5-1
Heating Operation ................................................................. 1-33
Defroster Operation................................................................ 1-33 Control Lever (ISO Pattern)...........................................................5-1
Tips for Optimal Heater Usage................................................. 1-34 Boom-Swing Pedal...........................................................................5-2
When Windows Become Clouded..................................... 1-34 Blade Lever.........................................................................................5-3
Air Conditioner Operation (Optional).................................... 1-35 Precautions for Blade Operation.................................................5-4
Name and Function of Each Part of Control Panel....... 1-35 Pilot Control Shut-Off Lever.........................................................5-5
Heating Operation ................................................................. 1-36 Warming Up Operation..................................................................5-7
Cooling Operation................................................................... 1-36 Engine Speed Control.....................................................................5-8
Defroster Operation................................................................ 1-36 Auto-Idle..............................................................................................5-9
Tips for Optimal Air Conditioner Usage................................ 1-37 Auto-Idle ON/OFF.................................................................... 5-10
For Rapid Cooling.................................................................... 1-37 Power Mode.................................................................................... 5-11
When Windows Become Clouded..................................... 1-37 Operating Backhoe....................................................................... 5-13
Off-Season Air Conditioner Maintenance....................... 1-37 Grading Operation........................................................................ 5-14
Radio (Cab equipped machine) (Optional).......................... 1-38 Avoid Abusive Operation........................................................... 5-15
AM/FM Radio Operation (Cab equipped machine) ........ 1-39 Avoid Excavation Using Upperstructure and/or Boom
Part Name and Function ...................................................... 1-39 Swing Power.............................................................................. 5-15
Radio Operation ...................................................................... 1-39 Avoid Driving Bucket Teeth into Ground.............................. 5-16
Tuning Procedure.................................................................... 1-40 Avoid Striking With Bucket........................................................ 5-16
Station Presetting Procedure............................................... 1-40 Boom Cylinder may Hit Blade................................................... 5-17
Deletion of Preset Memory ................................................. 1-40 Avoid Hitting Blade With Bucket.............................................. 5-18
Sound Adjustment.................................................................. 1-41 Avoid Colliding Blade Against Rocks...................................... 5-18
Digital Clock Setting Procedure.......................................... 1-41 Avoid Colliding Boom Cylinder With Track........................... 5-18
Door Lock Release Lever (Cab equipped machine).......... 1-42 Precautions for Installing Wide Bucket or Special Type
Opening Upper Front Window (Cab equipped Bucket.......................................................................................... 5-18
machine) .................................................................................... 1-43 Use Correct Track Shoe................................................................ 5-19
Front Window . ......................................................................... 1-43 Using Rubber Crawler.................................................................. 5-20
Removing and Storing Lower Front Window................ 1-43 Avoid other than Specified Machine Operations.............. 5-22
Adjusting the Seat......................................................................... 1-44 Shackle Bracket Usage................................................................. 5-23
Seat Fore-aft Adjustment...................................................... 1-44 Emergency Boom Lowering Procedure................................ 5-24
Tool Box ........................................................................................... 1-44 Releasing Hose Rupture Valve (Machine Equipped
Seat Back Box.................................................................................. 1-44 with Hose Rupture Valve)................................................ 5-25
Emergency Exit (Cab equipped machine) . ......................... 1-45 Precautions for After Operations............................................. 5-27
Seat Belt............................................................................................ 1-46 TRANSPORTING..............................................................................6-1
Room Lamp (Cab equipped machine)................................... 1-46 Transporting by Road.....................................................................6-1
BREAK-IN............................................................................................2-1 Loading/Unloading on a Truck....................................................6-2
Breaking in New Machine.............................................................2-1 Fastening Machine for Transporting.........................................6-5
Unloading...........................................................................................6-6
OPERATING THE ENGINE.............................................................3-1 Lifting Machine.................................................................................6-7
Inspect Machine Daily Before Starting.....................................3-1
MAINTENANCE................................................................................7-1
Before Starting Engine...................................................................3-2
Starting the Engine..........................................................................3-3 Correct Maintenance and Inspection Procedures................7-1
Check Instruments After Starting Engine................................3-5 Check the Hour Meter Regularly.................................................7-2
Using Booster Battery.....................................................................3-6 Layout...................................................................................................7-3
Stopping the Engine.......................................................................3-8 Maintenance Guide Table..............................................................7-4
Preparations for Inspection and Maintenance......................7-7
DRIVING THE MACHINE...............................................................4-1 Access Covers.....................................................................................7-8
Travel Levers and Pedals (Optional)...........................................4-1 Maintenance Guide...................................................................... 7-11
Travel Mode Switch.........................................................................4-3 Periodic Replacement of Parts.................................................. 7-15
CONTENTS
Kind of Oils....................................................................................... 7-16 Replace Rubber Crawler ....................................................... 7-81
Recommended Engine Oil.................................................... 7-16 Removing Rubber Crawler................................................... 7-81
A. Greasing....................................................................................... 7-19 Installing Rubber Crawler..................................................... 7-82
Front Joint Pins......................................................................... 7-19 Check Track Sag (Steel Crawler) (Optional)..................... 7-83
Bucket.......................................................................................... 7-19 Converting the Track.............................................................. 7-85
Swing Post and Others........................................................... 7-19 Check and Replace Seat Belt................................................ 7-86
Blade Pins.................................................................................... 7-21 Check Air Conditioner (Cab equipped machine)......... 7-87
Swing Bearing........................................................................... 7-22 Clean and Replace Heater / Air Conditioner Filter....... 7-90
Swing Internal Gear................................................................ 7-23 Clean Circulating Air Filter.................................................... 7-90
Control Lever Universal Joint............................................... 7-23 Replace Circulating Air Filter................................................ 7-90
B. Engine........................................................................................... 7-24 Clean Fresh Air Filter............................................................... 7-92
Engine Oil Level........................................................................ 7-24 Replace Fresh Air Filter........................................................... 7-92
Change Engine Oil . ................................................................ 7-25 Clean Fresh Air Filter............................................................... 7-93
Replace Engine Oil Filter........................................................ 7-25 Replace Fresh Air Filter........................................................... 7-93
C. Transmission............................................................................... 7-28 Clean Cab Floor........................................................................ 7-94
Travel Reduction Gear............................................................ 7-28 Check, Clean and Function Check of Injection
D. Hydraulic System...................................................................... 7-31 Nozzle .................................................................................... 7-95
Inspection and Maintenance of Hydraulic Inspect and Adjust Valve Clearance ................................. 7-95
Equipment............................................................................ 7-31 Check and Adjust Injection Timing .................................. 7-95
Check Hydraulic Oil Level..................................................... 7-35 Measure Engine Compression Pressure ......................... 7-95
Drain Hydraulic Oil Tank Sump........................................... 7-36 Check Starter and Alternator............................................... 7-95
Change Hydraulic Oil.............................................................. 7-37 Check Crankcase Breather ................................................... 7-95
Suction Filter Cleaning........................................................... 7-37 Check Radiator Cap . .............................................................. 7-95
Replace Full-Flow Filter.......................................................... 7-41 Tightening and Retightening Torque of Bolts and
Replace Pilot Oil Filter Element........................................... 7-43 Nuts......................................................................................... 7-96
Check Hoses and Lines.......................................................... 7-45
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
E. Fuel System................................................................................. 7-52
CONDITIONS.....................................................................................9-1
Recommended Fuel................................................................ 7-52
Check Fuel Level....................................................................... 7-53 Maintenance Under Special Environmental Conditions....9-1
Check Water Separator ......................................................... 7-54 STORAGE......................................................................................... 10-1
Bleed Air from Fuel System.................................................. 7-54 Storing the Machine..................................................................... 10-1
Drain Fuel Tank Sump............................................................. 7-55
Replace Fuel Main Filter Element....................................... 7-56 TROUBLESHOOTING.................................................................. 11-1
Replace Fuel Pre-Filter Element (Optional)..................... 7-57 Troubleshooting............................................................................ 11-1
Check Fuel Hoses..................................................................... 7-59 SPECIFICATIONS.......................................................................... 12-1
F. Air Cleaner.................................................................................... 7-60 Std. Specification........................................................................... 12-1
Clean Air Cleaner Outer Element....................................... 7-60 Working Ranges............................................................................. 12-2
Replace Air Cleaner Outer and Inner Elements............. 7-60 Shoe Types and Applications.................................................... 12-3
Replace Air Cleaner Inner Element (Optional)............... 7-60 Bucket Types and Applications ZX33U-5A........................... 12-4
G. Cooling System......................................................................... 7-62 Std. Specification........................................................................... 12-5
Check Coolant Level............................................................... 7-63 Working Ranges............................................................................. 12-6
Check and Adjust Fan Belt Tension .................................. 7-64 Shoe Types and Applications.................................................... 12-7
Change Coolant........................................................................ 7-67 Bucket Types and Applications ZX38U-5A........................... 12-8
Clean Radiator/Oil Cooler Core........................................... 7-69 Std. Specification........................................................................... 12-9
Clean Air Conditioner Condenser ..................................... 7-70 Working Ranges...........................................................................12-10
Clean Air Conditioner Condenser Front Screen............ 7-70 Shoe Types and Applications..................................................12-11
H. Electrical System....................................................................... 7-71 Bucket Types and Applications ZX48U-5A.........................12-12
Batteries...................................................................................... 7-71 Std. Specification.........................................................................12-13
Check Electrolyte Specific Gravity..................................... 7-74 Working Ranges...........................................................................12-14
Replacing Fuses........................................................................ 7-75 Shoe Types and Applications..................................................12-15
I. Miscellaneous.............................................................................. 7-76 Bucket Types and Applications ZX55U-5A.........................12-16
Check and Replace Bucket Teeth....................................... 7-76 Std. Specification.........................................................................12-17
Change Bucket.......................................................................... 7-78 Working Ranges...........................................................................12-18
Adjust Track Sag (Rubber Crawler) and Check for Shoe Types and Applications..................................................12-19
Damage ................................................................................ 7-79 Bucket Types and Applications ZX65USB-5A....................12-20
Check Rubber Track for Damage........................................ 7-79 Noise Level Results.....................................................................12-21
CONTENTS
Vibration Level..............................................................................12-21
Electric Fans...................................................................................12-21
Lifting Capacities.........................................................................12-22
OPTIONAL ATTACHMENT........................................................ 13-1
Hydraulic Breaker, Hydraulic Crusher and Quick
Coupler........................................................................................ 13-1
Attachment...................................................................................... 13-2
Piping for Breaker and Crusher (Optional) ......................... 13-3
Attachment Pedal (Hydraulic Breaker) (Optional)............. 13-4
Precautions for Breaker Operation.......................................... 13-5
Attachment Pedal (Hydraulic Crusher) (Optional)............. 13-9
Precautions for Crusher Operation.......................................13-10
AUX Function Lever for Extra Piping 1 (Optional)...........13-13
AUX Function Lever for Extra Piping 2 (Optional)...........13-14
Auxiliary Piping Flow Rate Selector (Optional).................13-15
Control Lever (H-pattern: HITACHI Excavator
Pattern)......................................................................................13-16
Control Lever (SAE-backhoe Pattern)...................................13-17
Fuel Feed Device (Optional) (ZX48U-5A, 55U-5A,
65USB-5A).................................................................................13-18
Numeric Keypad Lock (Optional) ........................................13-19
Additional Counterweight . ...................................................13-26
Cab Tilting Mechanism..............................................................13-27
Maintenance............................................................................13-34
Check Tilt Mechanism Fulcrum Bolts and Working
Screw Lock Nut ................................................................13-34
Greasing....................................................................................13-35
INDEX................................................................................................ 14-1
MACHINE NUMBERS
The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and
hydraulic components. These numbers are requested when
inquiring any information on the machine and/or components.
Fill these serial Nos. in the blank spaces in this group to
immediately make them available upon request.
Machine
SS3097499 MADB-00-002
1. MODEL/TYPE
2. Product Identification Number
3. Year of Manufacturing
4. Operating mass (No additional counter weight version)
5. Mass of additional counter weight
6. Engine power in KW according to ISO 14396: 2002
fNOTE:
Marks to indicate the
*HCM1NE00X00020001* start and end of the PIN
PRODUCT IDENTIFICATION ZX33U-5A, 38U-5A MADB-00-003
NUMBER (PIN)
Engine
TYPE:
MFG. NO.:
MADB-00-020
MADC-00-010
Travel Motor
TYPE:
MFG. NO.:
M1M0-00-004
MACHINE NUMBERS
Swing Motor
TYPE:
MFG. NO.:
ZX65USB-5A MADC-00-001
MACHINE NUMBERS
Hydraulic Pump
TYPE:
MFG. NO.:
ZX65USB-5A MADC-00-002
SAFETY
SA-2644
S-1
SAFETY
S-2
SAFETY
S-3
SAFETY
SA-434
Inspect Machine
If any abnormality is found, be sure to repair it immediately
before operating the machine.
In the walk-around inspection, be sure to cover all
points described in the “Daily Inspection” section in the
operator’s manual.
SA-435
S-4
SAFETY
S-5
SAFETY
SA-378
S-6
SAFETY
S-7
SAFETY
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 ENGINE” chapter.
The operator must be seated in the operator’s seat so
that the machine will be under control when the engine
starts. Jump starting is a two-person operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
SA-1292
S-8
SAFETY
M586-12-012
S-9
SAFETY
S-10
SAFETY
Equipment of OPG
In case the machine is operated in areas where the
possibility of falling stones or debris exists, equip genuine
Hitachi OPG guard. Contact your nearest Hitachi dealer for
installation method of the OPG guard. Depending on the
specifications applied to your machine, modification of the
machine to meet ROPS standards will be possible.
To maintain unimpaired operator protection and
manufacture’s protective structure.
Damaged ROPS, OPG guard must be replaced, not
repaired or revised.
Any alternation to the ROPS or OPG guard must be
approved by the manufacturer.
ROPS : Roll Over Protective Structure
OPG : Operator Protective Guard
SA-490
SA-481
SA-1294
S-11
SAFETY
WRONG
SA-589
S-12
SAFETY
When the machine descends a slope at high speed,
machine weight accelerates descending speed. It may
cause collision accident due to misjudging of braking 1
distance or machine turnover due to running on an
unexpected obstacle.
Always ensure that travel mode display (1) on the monitor
is , and then reduce the engine speed before
descending a slope.
Select a travel route that is as flat as possible. Steer the
machine as straight as possible, making small gradual
changes repeatedly in direction.
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
the road surface with wood plates in order not to damage
the road surface. Be careful of steering when operating
MADH-01-009
on asphalt roads in summer.
When crossing train tracks, lay wood plates over the
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 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
Travel Motor
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 M104-05-008
in contact with loose rocks. If the machine crosses over
an obstruction, abnormally large loads may be loaded
on the machine. Avoid contact with an obstruction while
traveling the machine.
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
S-13
SAFETY
SA-1297
S-14
SAFETY
S-15
SAFETY
SA-667
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 raise the front attachment in a panic.
Lowering the front attachment may be safer in most
cases.
SA-1300
S-16
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.
Reduce swing speed as necessary when swinging loads.
SA-1302
S-17
SAFETY
SA-673
SA-1305
S-18
SAFETY
Object Handling
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
When using the machine for craning operations, be sure
to comply with all local regulations.
Do not use damaged chains or frayed cables, sables,
slings, or ropes.
Before craning, position the upperstructure with the
travel motors at the rear.
When using the machine for craning operations, always
park the machine on a solid and level ground.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person’s head.
Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the SA-014
ground.
Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
S-19
SAFETY
SA-432
S-20
SAFETY
SA-019
S-21
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.
Provide an appropriate truck or trailer for transporting the
machine. SA-1307
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.
3. Ramps must be sufficient in width, length, and strength. 3
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 of less than
15 degrees. 2
S-22
SAFETY
S-23
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 maintenance
is conducted, the operator’s station is tilted upward.
SA-037
Before conducting maintenance work, refer to page 7-76
in this manual for the detailed operation procedures and
correctly operate the machine.
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 operator’s
station at the time.
Be careful not to allow the operator’s station to tilt down
without first stowing the fall prevention bars. Damage to
the tilt mechanism may result.
M1MW-07-031
SS2045102-4
S-24
SAFETY
SA-527
SA-026
SA-2294
S-25
SAFETY
SA-034
S-26
SAFETY
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. Begin to work after the engine and radiator
are sufficiently cooled
DO NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
The hydraulic oil tank is pressurized. Again, be sure to
release all pressure by slowly removing the cap. SA-039
SA-225
S-27
SAFETY
SA-292
SA-044
S-28
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 oil-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes or hoses.
S-29
SAFETY
Clean up Flammable Materials:
Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause fires.
Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean
high temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
Do not store oily cloths as they are vulnerable to catching
fire.
Keep flammable materials away from open flames.
Do not ignite or crush a pressurized or sealed container.
Wire screens may be provided on openings on the engine
compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.
S-30
SAFETY
SA-393
SS-1510
SA-016
S-31
SAFETY
S-32
SAFETY
S-33
SAFETY
SA-405
S-34
SAFETY
SA-2579
SA-226
S-35
SAFETY
S-36
SAFETY
S-37
SAFETY
Never attempt to disassemble, repair, modify or displace the
communication terminal, antennas or cables. Failure to do
so may result in damage and/or fire to the base machine or
to the communication terminal. (When required to remove
or install the communication terminal, consult your nearest
Hitachi dealer.)
Do not pinch or forcibly pull cables, cords or connectors.
Failure to do so may cause short circuit or broke circuit that
may result in damage and/or fire to the base machine or to
the communication terminal.
S-38
VISIBILITY MAP
This map shows an approximation of the residual masking. This can be used as a guide when conducting a site risk
assessment, utilized for site management and to consider additional visual aids.
Conditions: Driver’s visibility on 1mRB and VTC are evaluated under ISO 5006.
Test Height (on 1mRB): 1.0 m to 1.2 m
(1mRB to VTC/on VTC): Ground Level
Operator eye Height: 1.2 m from the canopy/cab floor
Applicable visual aids: none
MADC-VM-001 MADC-VM-003
Canopy Cab
: Masking area
Machine Position Image
masking area
MADC-VM-002 MADC-VM-004
Canopy Cab
Visibility Map
S-39
VISIBILITY MAP
This map shows an approximation of the residual masking. This can be used as a guide when conducting a site risk
assessment, utilized for site management and to consider additional visual aids.
Conditions: Driver’s visibility on 1mRB and VTC are evaluated under ISO 5006.
Test Height (on 1mRB): 1.0 m to 1.2 m
(1mRB to VTC/on VTC): Ground Level
Operator eye Height: 1.2 m from the canopy/cab floor
Applicable visual aids: none
1.9 m
MADC-VM-005 MADC-VM-007
Canopy Cab
: Masking area
Machine Position Image
masking area
MADC-VM-006 MADC-VM-008
Canopy Cab
Visibility Map
S-40
VISIBILITY MAP
This map shows an approximation of the residual masking. This can be used as a guide when conducting a site risk
assessment, utilized for site management and to consider additional visual aids.
Conditions: Driver’s visibility on 1mRB and VTC are evaluated under ISO 5006.
Test Height (on 1mRB): 1.2 m
(1mRB to VTC/on VTC): Ground Level
Operator eye Height: 1.2 m from the cab floor
Applicable visual aids: none
MADC-VM-009
: Masking area
Machine Position Image
masking area
MADC-VM-010
Visibility Map
S-41
SAFETY SIGNS
All safety signs and their locations affixed on the machine are
illustrated in this group. Make sure of the contents described
in the safety signs through reading actual ones affixed on
the machine to ensure safe machine operation. Always keep
the safety signs clean. In case a safety sign is broken or lost,
immediately, obtain a new replacement and affix it again in
position on the machine. Use the part No. indicated under the
right corner of each safety sign illustration when ordering it at
your authorized dealer.
SS4420332-2
MADB-00-019
S-42
SAFETY SIGNS
SS4420333-2
SS4420334-2
MADG-00-002
Electrocution is possible if the machine is operated too
close to power lines. Always keep a safe distance from
power lines.
S-43
SAFETY SIGNS
Stand clear of the equipment. If
knocked over by the equipment,
serious injury may result.
SS3085503-1 SS-1494
MADC-00-003
SS4392290-1
MADB-00-017
S-44
SAFETY SIGNS
Sign indicates the hazard of
rotating parts, such as fan,
etc. that could cause injury
by being caught. Turn it off
completely before inspection and
maintenance.
SS4425442-1
ZX65USB-5A MADC-00-006
S-45
SAFETY SIGNS
Sign indicates the hazard of
rotating parts, such as belt,
etc. that could cause injury
by being caught. Turn it off
completely before inspection and
maintenance.
SS4425120-1
ZX65USB-5A MADC-00-006
S-46
SAFETY SIGNS
Personal injury may result if the
stored front window slips off.
Always securely lock the window
in the stored position (on the cab
equipped machine).
SS4425121-1
MADC-00-007
SS4392288-2
Serious injury may result if the plug flies off the track
adjuster. Read the Operator’s Manual before loosening
the track, and adjust the track sag following the correct SS-1495
procedure.
S-47
SAFETY SIGNS
SS4425443-1
Possible severe burns. Do not touch the engine ZX33U-5A, 38U-5A MADC-00-004
components while they are hot.
S-48
SAFETY SIGNS
A worker may be crushed by the
cab floor when using the floor
tilt mechanism, causing serious
injury or death. Read the operator's
manual for safe and proper
operation.
SSYD00003167
Canopy MADB-00-029
Cab MADB-00-030
Cab
ZX65USB-5A MADC-00-018
S-49
SAFETY SIGNS
SS3078858-2
SS4408870-2
MADC-00-004
Sign indicates the hazard of rotating parts, such as fan,
etc. that could cause injury by being caught.
Turn it off completely before inspection and maintenance.
S-50
SAFETY SIGNS
Canopy MADB-00-029
SS-3546 SS-3547
ROPS/TOPS/OPG TOP GUARD
Cab MADB-00-030
SS-3548 SS-3549
ROPS/TOPS/OPG TOP GUARD
Cab MADG-00-015
SS-3550
ROPS/TOPS/OPG TOP GUARD ZX65USB-5A
S-51
SAFETY SIGNS
If the machine should overturn, the
operator may become injured and/or
thrown from the cab and/or crushed
by the overturning machine.
Canopy MADC-00-008
SS4448289-1
Cab MADC-00-009
SSYD00006176-1
MADG-00-002
ZX65USB-5A
S-52
COMPONENTS NAME
Components Name
5 6 7
10
11
4
13 12
3 2 1 16 15 14
MADB-01-001
1-1
GETTING ON/OFF THE MACHINE
Foot holds (1) and handrails (4) are provided around the
entrance. These are used to get on and off the cab safely as 6
4
well as to do inspection and maintenance of the machine
safely.
7
Never jump on or off the machine as it is very dangerous. Take
extra care not to contact to door striker (2).
3
dWARNING:
Never attach a wire on handrails (4) and door striker
2
(2) to lift the cab or main body, or while transporting
the machine on a truck or trailer as it is dangerous. 8
Door knob (6), handle (5) on the front window and
release lever (7) are not a handrail. Do not use them MADB-01-065
1
as a handrail when getting on and off the machine.
Do not hold control lever (3) or pilot control shut-off
lever (8) when getting on and off the machine.
1-2
OPERATOR'S STATION
Layout
1- Left Control Lever 1 2 3 4
12 11
13 MADB-01-003
1-3
OPERATOR'S STATION
14- Numeric Keypad Lock System (Optional) 14 15 16
15- Key Switch
16- Heater/Air Conditioner Control Panel (Cab equipped 19
machine)
17- Switch Panel
18- Engine Control Dial 18
23
MADB-01-005
26
25
26
ZX65USB-5A 25
MADC-01-002
1-4
OPERATOR'S STATION
Key Switch 1 2 3
1- OFF (Engine Off )
2- ON
3- START (Engine Start)
Switch Panel
4- Work Light Switch
MADB-01-007
When the upper part of switch (4) is pushed, work lights
(8) located on the front side of the boom and canopy
(cab) come ON.
When the lower part of switch (4) is pushed, work lights
(8) go OFF.
5- Wiper Switch (Cab equipped machine)
Three (operational) positions are provided on this switch.
OFF: Neither the wiper nor the washer operates.
Center: The wiper operates.
WASHER: The washer operates together with the wiper.
6- Travel Mode Switch
4 5 6 7 MADC-01-003
Push side of switch (6) to select the fast speed
mode. When travel load increases, the travel mode
automatically shifts to slow speed mode.
Push side of switch (6) to select the slow speed
mode.
1-5
OPERATOR'S STATION
Monitor
Feature
The monitor displays various meters, warning indicators and
work mode selection.
Screen Configuration
The monitor consists of the following screens.
Clock
Trip
Brightness ADJ.
1-6
OPERATOR'S STATION
Basic Screen
1- Overheat Indicator
2- Engine Oil Pressure Indicator
3- Alternator Indicator 1 2 3 4 5
4- Fuel Level Indicator
5- Preheat Indicator
6- Clock
7- Security Status Indicator (Optional) 18 6
8- Auxiliary
9- Fuel Gauge 17 7
14 13 12 11
MADC-01-023
1-7
OPERATOR'S STATION
Indicators
1 2 3 4
Overheat Indicator (1)
This indicator warns abnormally increased coolant
temperature. The red light comes ON and the buzzer sounds
simultaneously. When the red light comes ON and the
buzzer sounds, immediately stop the machine operation,
run the engine at slow idle speed and lower the coolant
temperature.
1-8
OPERATOR'S STATION
MADH-01-009
1-9
OPERATOR'S STATION
Display of Meters
Items to be displayed
6- Clock
9- Fuel Gauge
6
10- Hour Meter
9
15- Coolant Temperature Gauge 15
10
MADH-01-009
1-10
OPERATOR'S STATION
Preheat Indicator (5)
The machine will automatically check if preheating is 5
required or not. When preheating is required, preheat
indicator (5) is lit automatically. 17
Security Status Indicator (Optional) (7) 7
This indicator is displayed when the immobilizer key or the 16
numeric key pad is connected.
(Refer to the Immobilizer Key and Numeric Key Pad Lock
section.)
: Locked State 11
14
12
: Unlocked State
1-11
OPERATOR'S STATION
Overload Alarm Selector (Optional) (12)
This selector is displayed when the machine is equipped 5
with the overload alarm device. Push selector (12) to turn
the overload alarm ON/OFF. 17
7
16
: Overload Alarm "OFF"
1-12
OPERATOR'S STATION
Hour Meter
Total (accumulated) machine operation hours counted since
the machine started working, are displayed in the unit of
HOUR (h). One digit after the decimal point indicates tenths
MADM-01-014
of an hour (6 minutes).
Clock
Indicates the present time. 24h/12h/No display can be
selected.
(Refer to "Clock" for switching the display mode.)
MADM-01-015
Fuel Gauge
Indicates the remaining fuel amount. Refuel before the
indicator segment reaches "E". When the fuel sensor circuit
is broken or short-circuited, all segments of the fuel gauge
will flash.
MADC-01-024
1 2 3
1-13
OPERATOR'S STATION
The overheat alarm and the engine oil pressure alarm are
separately located on the top of the monitor. If either one 9
8
has failed, the alarm indicator remains ON; thus warning
mark (5) will not be displayed on the top left of screen (9).
However, it will be displayed on alarm list (13).
MADH-01-021
13
12
MADG-01-092
1-14
OPERATOR'S STATION
Alarm List Display
IMPORTANT: Warning code (15) that has "ENG" at the
code top indicates the engine failure. If it is displayed,
immediately consult your authorized Hitachi dealer.
fNOTE:
Alarm list (13) will be displayed on MENU screen (12) only
8
when an alarm occurs.
Alarm list (13) contains only currently generated alarms.
14
MADG-01-092
15
MADC-01-028
1-15
OPERATOR'S STATION
Contents of Alarms
Error Code
Display Code Contents of Remedy
Alarms
E: 1100 Engine Trouble Engine or engine related parts are abnormal.
Alarm Consult your authorized Hitachi dealer.
Warning Codes
Display Code Contents of Remedy
Alarms
W: 1100 Engine Warning Engine or engine related parts are abnormal.
Stop operation, check the detailed code and check the machine.
W: 2201 Overheat Alarm Engine coolant temperature has abnormally increased.
Stop operation. Run the engine at slow idle speed to lower the coolant
temperature.
W: 2202 Engine Oil Engine oil pressure has decreased.
Pressure Alarm Immediately stop the engine. Check the engine oil system and oil level.
W: 1206 Air Filter Air filter elements are clogged.
Restriction Clean or replace air cleaner element.
Alarm
W: 1207 Coolant Coolant temperature sensor is malfunction or abnormal.
Temperature Repair or replace.
Sensor Failure
W: 2304 Fuel Sensor Fuel sensor is malfunction or abnormal.
Failure Repair or replace.
W: 1208 Engine Speed Engine or engine related parts are abnormal.
Sensor Failure Consult your authorized Hitachi dealer.
W: 1304 Engine Control Engine control dial is malfunction or abnormal.
Dial Failure Repair or replace.
W: 2307
1-16
OPERATOR'S STATION
1-17
OPERATOR'S STATION
Monitor
Display Code Error Contents
ENG: 00000-00
004BA-04 Rack position sensor error (low voltage)
004BA-03 Rack position sensor error (high voltage)
0005B-04 Accelerator sensor error (low voltage)
0005B-03 Accelerator sensor error (high voltage)
0005B-02 Accelerator sensor intermittent failure
0001D-04 Spare accelerator sensor error (low voltage)
0001D-03 Spare accelerator sensor error (high voltage)
0001D-02 Spare accelerator sensor intermittent failure
0001D-08 Spare accelerator sensor error (pulse communication)
00470-04 ECU temperature sensor error (low voltage)
00470-03 ECU temperature sensor error (high voltage)
00470-02 ECU temperature sensor intermittent failure
00470-00 ECU temperature rise alarm
0006E-04 Cooling water temperature sensor error (low voltage)
0006E-03 Cooling water temperature sensor error (high voltage)
0006E-02 Cooling water temperature sensor intermittent failure
0006E-00 Cooling water temperature rise alarm
00437-04 Sensor 5V error (low voltage)
00437-03 Sensor 5V error (high voltage)
00437-02 Sensor 5V intermittent failure
0009E-01 Power supply voltage error (low voltage)
0009E-00 Power supply voltage error (high voltage)
00436-04 Speed sensor error
7F8A2-04 Spare speed sensor error
7F801-04 Rack actuator relay error A
7F801-03 Rack actuator relay error B
7F801-02 Rack actuator relay intermittent failure
1-18
OPERATOR'S STATION
Monitor
Display Code Error Contents
ENG: 00000-00
7F803-04 Start assist relay error A
7F803-03 Start assist relay error B
7F803-02 Start assist relay intermittent failure
7F802-04 CSD solenoid valve error A
7F802-03 CSD solenoid valve error B
7F802-02 CSD solenoid valve intermittent failure
00064-04 Oil pressure switch error
00064-01 Oil pressure descend error
000A7-04 Charge switch error
000A7-01 Charge alarm
7F84A-00 Abnormal water temperature
7F853-00 Air cleaner clogging alarm
000BE-00 Overspeed error
0027E-04 Rack actuator error (low current)
0027E-03 Rack actuator error (high current)
0027E-07 Rack actuator mechanical failure
0027E-02 Engine error
0027F-0C CAN communication error
00276-02 ECU internal EEPROM error (checksum)
00276-0C ECU internal EEPROM error (read/write error)
00274-0C ECU internal flash ROM error (checksum A)
00274-02 ECU internal flash ROM error (checksum B)
00274-02 ECU internal flash ROM error (checksum C)
005CD-04 Main relay error
7F9E7-0C ECU internal sub CPU error A
7F9E7-0C ECU internal sub CPU error B
7F9E7-0C ECU internal sub CPU error C
7F9E8-0C ECU internal map format error
1-19
OPERATOR'S STATION
MADH-01-009
MADG-01-095
MADG-01-092
1-20
OPERATOR'S STATION
Clock
Clock Adjustment
1. Push menu switch (2) while displaying basic screen (1) to
display MENU (3).
1
MADH-01-009
2. Select Clock (7) by pushing switch (4) or (5).
4
5
MADC-01-030
1-21
OPERATOR'S STATION
4. Select Hour or Minute (9) by pushing switch (4) or (5),
and then push set switch (6) to make the change.
4
5
6
MADC-01-030
5. Push switch (4) or (5) to adjust the clock. Push switch (4)
to adjust the number downward, and push switch (5) to
increase it.
4
5
MADC-01-032
1-22
OPERATOR'S STATION
Display Mode Setting
1. Display Clock setting screen (8). Select Display (10) by
pushing switch (4) or (5), and then push set switch (6) to 8
make the change.
10
4
5
6
MADC-01-033
2. Each time switch (4) or (5) is pushed, Display (11) is
changed as follows: 24h 12h No display.
11
4
5
6
MADC-01-035
1-23
OPERATOR'S STATION
Trip
Functions of Trip Meter 1
The trip meter allows the operator to know that the
Trip Mark
machine operation hour has reached the preset hour by
blinking the Trip mark (Trip 1 or Trip 2). The Trip mark blinks
for 30 seconds when the machine operation hour reaches Trip Meter
the preset hour. After that, every time the key switch is
turned ON, the Trip meter blinks for 30 seconds until the
meter is reset.
1-24
OPERATOR'S STATION
Displaying Trip Meter (1)
1. Turn the key switch to ON position. Push menu switch (2)
while displaying basic screen (1) to display MENU (3).
MADH-01-009
4
5
6
MADC-01-036
MADC-01-037
1-25
OPERATOR'S STATION
4. Select Display (9) by pushing switch (4) or (5), and then
push set switch (6) to make the change.
4
5
6
MADC-01-037
5. Each time switch (4) or (5) is pushed, the display will be
changed as follows: Hour Trip 1 Trip 2.
MADC-01-038
1-26
OPERATOR'S STATION
Displaying Trip Meter (2)
1. Turn the key switch to ON position. Keep pushing menu
switch (2) while basic screen (1) is displayed.
2
3
MADH-01-041
2
3
MADH-01-042
1-27
OPERATOR'S STATION
Change Trip Meter Set Time
1. Turn the key switch to ON position. Push menu switch (2)
while displaying basic screen (1) to display MENU (3).
MADH-01-009
2. Select Trip (7) by pushing switch (4) or (5).
3
7
4
5
MADC-01-036
MADC-01-037
1-28
OPERATOR'S STATION
4. Select Trip 1 (10) or Trip 2 (11) by pushing switch (4) or
(5), and then push set switch (6) to make the change.
fNOTE: Time for "Trip 1" and "Trip 2" can be set individually. 10
11
4
5. Each time switch (4) or (5) is pushed, the set time will be 5
changed as follows. 6
MADH-01-040
1-29
OPERATOR'S STATION
Brightness Adjustment
1. Push menu switch (2) while displaying basic screen (1) to
display MENU (3).
MADH-01-009
2. Select Brightness Adjustment (7) by pushing switch (4)
or (5).
3
7
4
5
MADC-01-041
1-30
OPERATOR'S STATION
4. Select Brightness (9) by pushing switch (4) or (5), and
then push set switch (6) to make the change.
The brightness is adjusted in 5 levels.
High Low 9
5>4>3>2>1
4
5
6
MADC-01-042
MADC-01-043
MADC-01-044
1-31
OPERATOR'S STATION
7- Blower Switch
The air flow upon heating, can be adjusted to 3 levels
from low to high.
4
8- Temperature Control Switch
The set temperature decreases each time the down
arrow switch is pushed, and increases each time the up
arrow switch is pushed.
9- Defroster Switch 3
MADB-01-003
Air will blow out of right front vents (4) and (5).
10- Mode Switch
The air vent location is selected. Each time switch (10) is
pushed, mode indicator (12) changes in the order shown
below.
Air will blow out of right front vents (4) (5) and 11 12
right rear vent (2).
Air will blow out of right front vents (4) (5), foot
vent (3) and right rear vent (2).
Air will blow out of right front vents (4) (5) and
foot vent (3).
10
9 8 7 6
11- Circulation Air/Fresh Air Selection Switch MADB-01-073
1-32
OPERATOR'S STATION
Heating Operation
Push mode switch (10) to select the vent position, and then
push temperature control switch (8) to the set temperature
display rightward.
Control air temperature in the cab by operating
temperature control switch (8).
Control blower speed by using blower switch (7).
10
Defroster Operation 9 8 7
Select the right front vent by operating defroster switch (9). MADB-01-073
Adjust the louvers on right front vent (5) as required.
Control blower speed by using blower switch (7). Control
5
the air temperature in the cab by using temperature control
switch (8).
MADB-01-003
1-33
OPERATOR'S STATION
IMPORTANT:
Keep open flames away from the control panel.
Refer to the item "Clean and Replace Heater/Air
Conditioner Filter" in the Maintenance Section for
maintenance of filters.
1-34
OPERATOR'S STATION
1- Control Panel
2- Right Rear Vent
3- Foot Vent
4- Right Front Vent 2
1-35
OPERATOR'S STATION
Heating Operation
Push mode switch (11) to select the vent position, and then 7
push temperature control switch (9) to set the temperature
display rightward.
Control the air temperature in the cab by operating
temperature control switch (9).
Control the blower speed by using blower switch (8).
When air conditioner switch (7) is turned ON during heating 11
operation, air in the cab will be dehumidified. 9 8
MADB-01-066
Cooling Operation
Push mode switch (11) to select the vent position, and then
push temperature control switch (9) to set the temperature
display leftward. 7
Control the air temperature in the cab by operating
temperature control switch (9).
Control the blower speed by using blower switch (8).
When air conditioner switch (7) is turned ON, cool air will
blow out of the right front vent.
Defroster Operation 11
10 9 8
Select the right front vent by operating defroster switch
MADB-01-066
(10).
Adjust the louvers on right front vent (5) as required.
Control blower speed by using blower switch (8). Control
the air temperature in the cab by using temperature control
switch (9).
If the windowpanes become clouded in rainy season or 5
when dehumidifying, turn the air conditioner switch (7) ON.
MADB-01-003
1-36
OPERATOR'S STATION
IMPORTANT:
Do not suddenly increase the engine speed. Failure
to do so may damage the compressor.
Keep open flames away from the control panel.
Refer to the item "Clean and Replace Heater/Air
Conditioner Filter" in the Maintenance Section for
maintenance of filters.
1-37
OPERATOR'S STATION
1- Radio/Clock
MADB-01-005
1-38
OPERATOR'S STATION
Radio Operation
1. Turn the engine key switch to ON position. Push radio
power switch (1) ON.
2. Select either MW (AM) or FM by operating AM/FM switch
(5).
3. Select the station according to your preference using
PRESET buttons (7) or UP/DOWN buttons (3).
4. Adjust the volume and tone according to your
preference.
5. When turning the radio OFF, repress power switch (1).
1-39
OPERATOR'S STATION
Tuning Procedure
1. Manual Tuning Procedure
Push UP button (3) to increase the frequency by
one step. Push DOWN button (3) to decrease the
frequency by one step.
2. Automatic Tuning (Auto-Seeking)
Push UP button (3) or DOWN button (3) long to
scan the frequency upward or downward. When a station
3
is received, the auto-seeking function is deactivated so
M1NE-01-003
that the received frequency station is tuned in.
1-40
OPERATOR'S STATION
Sound Adjustment
When SOUND control switch (2) is pressed with the radio
switch ON, It will be in the sound adjustment state.
Each time SOUND control switch (2) is pressed, the
adjustment item can be changed as below.
BAL TRE BAS BAL TRE BAS
When SOUND control switch (2) is pressed with the BAS
state, the sound adjustment is deactivated.
M1NE-01-007
1-41
OPERATOR'S STATION
To unlock the door, push down door lock release lever (1)
located at the left side of the operator's seat. 1
MADB-03-001
1-42
OPERATOR'S STATION
MADB-01-058
dCAUTION: 3 6
Slowly close the upper front window so as not to
catch a finger.
Switch (4) is provided on the front window to 1
prevent the wiper from operating when the front
window is opened. Before closing the front window,
ensure that the wiper switch is turned OFF.
When opening the front window, ensure that the left
and right locks are definitely activated.
MADB-01-059
1-43
OPERATOR'S STATION
Tool Box 2
MADB-01-062
1-44
OPERATOR'S STATION
1-45
OPERATOR'S STATION
Seat Belt 1 2
dWARNING:
Be sure to use seat belt (1) when operating the
machine.
Before operating the machine, be sure to examine
seat belt (1) and the hardware attached for any
failure. Replace the seat belt and the hardware
attached if they are damaged and/ or worn.
Replace seat belt (1) every 3 years regardless of its
appearance. M573-01-014
1
Seat Belt
1. Confirm that seat belt (1) is not twisted. Securely insert
the end of seat belt (1) into buckle (2). Lightly pull on the
belt to confirm that the buckle latches securely.
2. Push button (3) on buckle (2) to unfasten seat belt (1).
M107-01-045
M1M7-01-021
1-46
BREAK-IN
2-1
BREAK-IN
MEMO
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2-2
OPERATING THE ENGINE
Engine
Level and contamination of engine oil and coolant
Starting easiness, exhaust gas color, and noise
Oil and water leaks, damage to hoses and pipe lines
Clogging and damage to radiator, oil cooler
Looseness and missing of mounting bolts and nuts
Upperstructure
Fuel level, leaks and contamination of fuel in tank
Hydraulic oil level, leaks and contamination of hydraulic oil tank
Movement, play and operating force of all control levers
Operation of all hydraulic components, oil leaks and damage to pipe lines and hoses
Deformation, break and abnormal noise of upper structure
Looseness and missing of mounting bolts and nuts
Washer Fluid
Undercarriage
Sag, wear and break of crawler
Oil leaks and wear on upper/lower rollers and front idlers
Oil leaks from travel devices
Looseness and missing of mounting bolts and nuts
Working Device
Check cylinders, pipe lines and hoses for oil leaks and damages
Wear and damage of the bucket
Check bucket teeth for looseness, wear and missing
Lubrication state of the working device
Check for pin anti-extraction pins, stoppers, rings and bolts for damage
Looseness and missing of mounting bolts and nuts
Others
Operation of instruments, switches, lights and buzzer/horn
Function of parking brake
Deformation and break of head guard
Abnormal outside appearance of machine
Wear and damage of the seat belt
3-1
OPERATING THE ENGINE
MADB-03-002
4. Adjust the seat to allow full pedal and control levers
stroke with operator's back against the backrest. Fasten
the seat belt.
3 4
fNOTE: The monitor surface is a resin product. When the
surface becomes dusty, lightly wipe the surface with a wet
cloth. Never use an organic solvent.
MADH-01-009
3-2
OPERATING THE ENGINE
fNOTE: The horn sounds even though key switch (2) is turned 3
OFF. The engine does not start unless pilot control shut-off
lever (1) is in the LOCK position.
Slow Idle
MADB-01-067
MADH-01-009
3-3
OPERATING THE ENGINE
Starting in Cold Weather
Preheating
1. Confirm that pilot control shut-off lever (1) is in the LOCK
position. 1
fNOTE:
For a while after the engine starts, the automatic heating Slow Idle
system operates, the engine speed will temporarily
increase.
White smoke may occur for several minutes after the
engine start, but this is not a malfunction. MADB-01-067
MADH-01-009
3-4
OPERATING THE ENGINE
3-5
OPERATING THE ENGINE
dWARNING:
An explosive gas is produced while battery is in use
or being charged. Keep open flames and sparks
away from the battery area. Do not continue to use
or charge the battery when electrolyte level is lower
than specified. Explosion of the battery may result.
Park the machine and a machine with the booster
battery on a dry or concrete surface, not on steel
plates. If the machine is parked on steel plates,
dangerous sparks may be unexpectedly created on SA-032
the machine.
Never connect a positive terminal to a negative
terminal, as a dangerous short circuit will occur.
MADB-07-022
3-6
OPERATING THE ENGINE
Disconnecting the booster cables
1. Disconnect black booster negative (-) cable (2) from
hinge (3) of the machine cover first.
2. Disconnect the other end of black booster negative (-) 1
cable (2) from the booster battery. (Red)
M503-03-002
3-7
OPERATING THE ENGINE
MADB-03-001
MADB-03-002
3-8
DRIVING THE MACHINE
• Forward/Reverse Travel
Move both levers (or pedals) forward together to travel
forward.
Pull the levers (or pedals) back together to travel in
reverse. The travel speed can be controlled by adjusting
the lever (or pedal) operating stroke.
M1LA-04-001
• Ascending/Descending Slopes
The machine gradeability is 30 ° (58 %). Slowly operate the
travel levers (or pedals) when descending a slope. When
the travel levers are placed in neutral, the travel brakes
are automatically applied to stop the machine.
M1M7-04-011 M104-04-003
Forward and Reverse
M1M7-04-010
4-1
DRIVING THE MACHINE
• Pivot Turn
Steer the machine by driving only one side crawler.
Operate either of the travel levers (or pedals).
M1M7-04-012 M104-04-005
Pivot Turn
• Spin Turn
Steer the machine by driving each crawler in the opposite
directions. Push one lever (or pedal) forward and pull the
other back at the same time.
M1M7-04-013
Spin Turn
4-2
DRIVING THE MACHINE
MADH-01-009
4-3
DRIVING THE MACHINE
Traveling
M586-05-002
4-4
DRIVING THE MACHINE
4-5
DRIVING THE MACHINE
4-6
DRIVING THE MACHINE
Towing Machine
IMPORTANT:
On some machines, a bracket is provided on
the track frame to install a shackle for towing a
lightweight object.
Never attempt to tow the machine by using this
lightweight object-towing bracket. Breaking the
towing bracket may result.
Refer to the descriptions on Shackle Bracket Usage
on page 5-23 in “Operating the Machine” section for
usages of the shackle bracket.
In addition, do not tow the machine with the
complete machine lifting holes prepared on the
blade. The lifting holes may be damaged. MZX5-04-001
4-7
DRIVING THE MACHINE
4-8
DRIVING THE MACHINE
SA-441
MZX5-04-002
4-9
DRIVING THE MACHINE
M1M7-04-009
Parking the Machine
1. Park the machine on a level surface. 1
2. Lower the bucket and the blade to the ground.
3. Turn the auto-idle switch off.
7. Close the windows, the roof vent, and the cab door, if the
cab is provided. MADB-03-002
4-10
OPERATING THE MACHINE
dWARNING: 1 5
Never place any part of body beyond window frame.
It could be crushed by the boom if boom control
lever is accidentally bumped or otherwise engaged. 3 4 7 8
Never remove the window sash bar.
Make sure you know the location and function of
2 6
each control before operating.
Do not change the control lever operation pattern.
Failure to do so may result in operation mistake of
the machine.
MADB-01-062
MABA-05-016
4
3
When a lever is released, it will automatically return to neutral,
1
and that machine function will stop.
1- Arm Roll-Out
2- Arm Roll-In
2
3- Swing Left
4- Swing Right
5- Boom Lower M1M7-05-001
6- Boom Raise
7- Bucket Roll-In
8- Bucket Roll-Out 6
5
7
M1M7-05-002
5-1
OPERATING THE MACHINE
Boom-Swing Pedal 1 2
Boom-Swing Operation
1. Turn cover (2) for boom-swing pedal (1) forward.
2. Step on the left side of boom-swing pedal (1) to swing
left. Step on the right side of pedal (1) to swing right.
3. Turn cover (2) backward over boom-swing pedal (1)
when boom-swing operation is no longer required.
3- Swing Left
4- Swing Right Lock Position MADB-05-001
3 4
MADB-00-001
5-2
OPERATING THE MACHINE
Blade Lever
1
Use blade lever (1) on the operator’s right to raise and lower
the blade.
When blade lever (1) is released, it automatically returns to
neutral, holding the blade in the present position until lever (1)
is operated again. 3 2
MADB-05-002
2- Blade Raise
3- Blade Lower
MADB-05-005
5-3
OPERATING THE MACHINE
M586-05-017
5-4
OPERATING THE MACHINE
dWARNING:
To deactivate control lever (3) and pedal functions,
be sure to pull pilot control shut-off lever (1) and
raise console (2) to the fully locked position. To 1 2
reactivate control lever (3) function, always hold
and push pilot control shut-off lever (1) down. Never Lock Position
MADB-05-003
attempt to lower raised console (2) or control lever
(3) to reactivate all control lever function without
holding pilot control shut-off lever (1). 3
Be sure not to touch control lever (3) when operating
pilot control shut-off lever (1). Failure to do so may
allow the machine to unexpectedly move when a
body part unintentionally comes in contact with the
control lever, possibly resulting in serious personal
injury or death.
When leaving the machine, always stop the engine.
Then, pull the pilot control shut-off lever (1) up to
the LOCK position.
Always check to be sure that the pilot control shut-
off lever (1) is pulled up to the LOCK position before
transporting the machine or leaving the machine at
the end of the shift. 1 2
Unlock Position
MADB-01-003
Before Leaving the Machine
1. Park the machine on a firm and level surface. Lower the
bucket and the blade to the ground. Return all control
levers to neutral. Properly shut down the engine.
2. Pull pilot control shut-off lever (1) and raise console (2) to
the full LOCK position.
5-5
OPERATING THE MACHINE
Before Starting Operation:
Confirm that pilot control shut-off lever (1) is pulled up to
the LOCK position before starting the engine.
Slowly push down control shut-off lever (1) to UNLOCK
position before starting operation.
Confirm that all control levers and pedals are in neutral and
that no part of the machine is in motion.
d WARNING: If any part of the machine (any actuator)
moves when pilot control shut-off lever (1) is
lowered to the UNLOCK position despite the fact
that all controls are placed in neutral, the machine is
malfunctioning. Immediately pull pilot control shut-
off lever (1) back to the LOCK position, and stop the
engine. Then, see your authorized dealer.
1
Unlock Position
MADB-01-003
5-6
OPERATING THE MACHINE
Warming Up Operation
In cold weather, warm up the machine until coolant and Fast Idle
hydraulic oil temperature increase to the appropriate
operating temperature.
5-7
OPERATING THE MACHINE
Slow Idle
MADB-01-067
5-8
OPERATING THE MACHINE
Auto-Idle
Auto-Idle Function
With the auto-idle function turned to the ON position,
approximately 4 seconds after all control levers are returned
to neutral, the engine speed decreases to the auto-idle 1
setting to save fuel consumption.
The engine speed will immediately increase to the speed
set by the engine control dial when the engine control
dial is operated with the pilot control shut-off lever pulled,
or when either the control lever or engine control dial is
operated with the pilot control shut-off lever pushed down.
dWARNING:
Prevent the machine from unexpected movement. MADH-01-009
Be sure to turn the auto-idle function to the OFF
position when unexpected machine movement is
undesirable, especially when loading/unloading the
machine for transportation.
The engine speed will increase to the speed set by
the engine control dial when any control lever is
operated from the neutral position while auto-idle
display (1) indicates “ON”. If the operator is not aware
of the high engine speed setting, the engine speed
will unexpectedly increase when any control lever is
operated, causing unexpected machine movement,
thus possibly resulting in serious personal injury.
5-9
OPERATING THE MACHINE
Auto-Idle ON/OFF
Note that auto-idle function can be turned ON or OFF by
pushing auto-idle switch (2).
Check if the auto-idle function is turned ON or OFF with
auto-idle indicator (1).
Auto-Idle Switch 1
Auto-Idle Indicator (1) ON : Auto-Idle Function ON
Auto-Idle Indicator (1) OFF : Auto-Idle Function OFF
5-10
OPERATING THE MACHINE
Power Mode
Two engine speed modes, ECO and PWR modes are selected
by pushing ECO/PWR mode switch (2) while displaying basic
screen (1).
5-11
OPERATING THE MACHINE
Overload Alarm Selector (Optional)
This selector is displayed (1) when the machine is equipped
with the overload alarm device. Push selector (2) to turn the
overload alarm ON/OFF.
The machine keeps the settings at previous key “OFF” until the
next key ON.
MADC-05-001
5-12
OPERATING THE MACHINE
Operating Backhoe
Use the appropriate arm and bucket for the work.
(Refer to the "Bucket Types and Applications" in the
Specifications section.)
Pull the bucket toward the machine using the arm as the
main digging force.
When soil sticks to the bucket, remove it by moving the
arm and/or bucket rapidly back and forth.
Place the bucket teeth on the ground with the bottom of
the bucket at a 45 degree angle to the ground.
When trenching a straight line, position the tracks parallel
M107-05-037
to the trench. After digging to the desired depth, move
the machine as required to continue the trench.
When operating the arm, avoid bottoming the cylinder to
prevent cylinder damage.
IMPORTANT:
When digging at an angle, avoid striking the tracks
with the bucket teeth.
When lowering the boom, avoid sudden stops that
may cause shock load damage to the machine.
When digging a deep excavation, avoid striking the
boom or bucket cylinder hoses against the ground.
When operating the machine with the blade
positioned towards the front, the bucket teeth may
come in contact with the blade if you are not careful.
When the bucket load is dumped with the boom
raised, falling material may hit the base machine
and/or the canopy. Always be aware of loads in the
bucket during operation.
5-13
OPERATING THE MACHINE
Grading Operation
Use the blade for soil refilling and general grading operations
after excavation. Grading operation can be also performed by
operating the boom, arm, and bucket simultaneously.
5-14
OPERATING THE MACHINE
MZX5-05-002
5-15
OPERATING THE MACHINE
If the bucket teeth are forcedly driven into the ground, the
service lifetime of all front attachment parts (especially the
bucket) may be severely shortened. When excavating tightly
fastened gravelly soil, use the bucket digging out force.
Operate the boom, arm, and bucket simultaneously so that the
bucket teeth can be effectively penetrated into the excavation
surface. Carefully operate the machine to prevent crushed
material from spattering, possibly resulting in injury to the
operator and/or co-workers around the machine.
5-16
OPERATING THE MACHINE
MZX5-13-014
MZX5-13-015
5-17
OPERATING THE MACHINE
MZX5-13-015
MZX5-13-016
Avoid Colliding Boom Cylinder With Track
When digging deeply with the front attachment positioned
at an angle, as illustrated, the boom cylinder may accidentally
collide with the track, causing damage. Take extra care to
prevent this from happening.
MZX5-13-018
Precautions for Installing Wide Bucket or Special
Type Bucket
If the boom is fully offset to the left and raised on the cab- ZX33U-5A: 600 mm (24 in)
equipped machine with a bucket wider than shown to the ZX38U-5A: 600 mm (24 in)
right installed, the bucket will come in contact with the cab. Be
sure to install a specially arranged bucket only after consulting ZX48U-5A: 650 mm (26 in)
your authorized dealer to prevent the cab collision with the ZX55U-5A: 650 mm (26 in)
bucket. ZX65USB-5A: 700 mm (28 in)
5-18
OPERATING THE MACHINE
5-19
OPERATING THE MACHINE
Forbidden Operations
1. Do not operate or steer the machine on or near river-
terrace, boulder and boulder mixed ground, crushed-
stone ground, uneven hardpan surfaces, stumps,
reinforcing bars, scraps, and steel plate edges. Failure to
do so may shorten the service life of the rubber crawlers
to a great extent.
M1M7-05-015
2. Do not leave engine oil, fuel, and other kinds of
lubricants remaining on the rubber crawlers, and avoid
traveling on road surface covered with oil to reduce the
danger of sliding.
3. Do not travel the machine while raising one side crawler
off the ground with the front attachment. Shear or
damage to the rubber crawler may result.
5-20
OPERATING THE MACHINE
3. Operating the machine with rubber crawlers sagging
on uneven surfaces can result in derailment of rubber
crawler, possibly causing the rubber crawlers to be
damaged.
M586-05-024
5-21
OPERATING THE MACHINE
dCAUTION:
Precautions for Lifting Work
Operate the machine on level ground. Operating
the machine on a slope may cause the machine
to become unstable, possibly resulting in tipping
accident.
When lifting a load, carefully swing the machine
not to cause the lifted load to come in contact with
personnel working near the machine. Reduce the
engine speed to slowly swing the machine. Failure
to do so may cause the machine to tip over by swing
centrifugal force.
If traveling the machine with a lifted load is
unavoidable, reduce the engine speed to slowly
travel the machine.
Never move the front attachment and/or swing the
machine while traveling the machine with a lifted
load. The lifted load may sway, possibly creating a
hazardous situation.
5-22
OPERATING THE MACHINE
5-23
OPERATING THE MACHINE
2. Remove bolts (2) from the front and left side of cover (3)
1
to remove cover (3).
3. Lower the boom in the procedures on the next page.
MADB-05-005
5-24
OPERATING THE MACHINE
Releasing Hose Rupture Valve (Machine Equipped with
Hose Rupture Valve)
The hose rupture valve prevents sudden falling of the front
attachment in the event of hose breaks during machine
operation. It is located on the rod side of the arm cylinder and Hose Rupture
bottom side of the boom cylinder. Valve for Boom
dWARNING:
Never attempt to operate the hose rupture valve
unless emergency. Failure to do so may result in
serious accident.
Loosen the hose rupture valve slowly. If adjustment
screw (4) is loosened rapidly, the arm or boom may
lower rapidly.
4
MADC-05-004
5-25
OPERATING THE MACHINE
Releasing Overload Relief Valve ZX33U-5A/38U-5A
Torque: 28 to 32 N·m
(2.8 to 3.2 kgf·m, 20 to 23 lbf·ft)
T1M9-03-04-001 M1M0-05-012
Lock Nut
Adjusting screw
T566-03-03-018
5-26
OPERATING THE MACHINE
M1M7-05-024
5-27
OPERATING THE MACHINE
MEMO
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5-28
TRANSPORTING
Transporting by Road
When transporting the machine on public roads, be sure to
first understand and follow all local regulations.
6-1
TRANSPORTING
Loading/Unloading on a Truck
Always load and unload the machine on a firm, level
surface.
Ramp/Loading Dock:
1. Before loading, thoroughly clean the ramps, loading
dock and flatbed. Dirty ramps, loading docks, and
flatbeds with oil, mud, or ice on them are slippery
and dangerous.
2. Place blocks against the truck wheels while using a
ramp or loading dock.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have an incline
of less than 15 degrees.
5. When transporting the machine equipped with a
blade, take care not to hit the blade.
6-2
TRANSPORTING
Loading
dWARNING:
Push auto-idle switch (3) to turn A/I display (2) OFF.
If the machine is operated with A/I display (2) ON, it
may cause the engine speed to suddenly change.
1
Always select the slow speed mode with the travel
mode switch.
Make sure that travel mode display (1) on the
monitor is “ “.
Never steer while driving up or down a ramp as it is 2
extremely dangerous and may cause the machine to
turnover. NEVER attempt to change directions whilst 3
positioned on the ramp. If repositioning is necessary,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
MADH-01-009
The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it as
the balance may be lost.
Extreme care must be taken when swinging the
upper structure when the machine is on the truck
flatbed. If the front attachment is fitted, swing slowly
with the arm fully roll-in underneath the boom being
careful not to loose the balance of the machine.
6-3
TRANSPORTING
1. Load the machine so that the centerline of the machine
aligns with the centerline of the trailer flatbed.
2. Drive the machine onto the ramp slowly.
3. Determine a position for the bucket in line with the
truck. Adjust the angle of the boom and the arm at 90 to
110 °.
4. Lower the bucket onto to the deck of the truck before MADB-06-001
the unit passes over the end of the ramp for support.
5. Move the machine as illustrated right. And then, slowly
rotate the upperstructure 180° while keeping the arm
fully rolled in.
6. Reverse the machine to the specified position.
7. Rest the front attachment on supports such as wooden
blocks placed on the truck flatbed. Also lower the blade MADG-06-001
onto the deck at this time (if fitted).
8. Stop the engine. Remove the key from the key switch.
9. Place the pilot control shut-off lever in the LOCK
position.
10. Cover the openings on the machine to prevent wind
and/or rain from coming in.
6-4
TRANSPORTING
6-5
TRANSPORTING
Unloading
dWARNING:
Always turn the auto-idle switch (2) OFF when
loading or unloading the machine. In the auto-idle
mode, speed may automatically increase. 1
Always select the slow speed mode (1) with the travel
mode switch.
Never steer while driving up or down a ramp as it is
extremely dangerous and may cause the machine to
turnover. NEVER attempt to change directions whilst
positioned on the ramp. If repositioning is necessary,
first move back to the ground or flatbed, modify 2
traveling direction, and begin to drive again.
The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it as MADH-01-009
the balance may be lost.
6-6
TRANSPORTING
Lifting Machine
dWARNING:
Use lifting cables and other lifting tools being free
from any damage and/or aging, and having sufficient
strength.
Consult your nearest Hitachi dealer for correct lifting
procedures, and the size and types of lifting cable
and tools.
Pull the pilot control shut-off lever to the LOCK
position so that the machine does not accidentally
move while being lifted.
Incorrect lifting procedure and/or incorrect wire rope
attachment will cause the machine to move while
being lifted, resulting in machine damage and/or
personal injury.
Do not lift the machine quickly. Excessive load will be
applied to the lifting wire ropes and/or lifting tools,
possibly causing them to break.
Do not allow anyone to come close to or under the
lifted machine.
The indicated gravity center is for the standard
specification machine. The gravity center will vary
depending on the kinds of attachments and/or
optional equipment to be installed or their position
to be taken. Therefore, take care not to lose the
balance of the machine while lifting.
Be sure to set the blade position with the engine
running. Failure to do so may cause the blade to
be moved from the set-position when lifted with a
crane.
6-7
TRANSPORTING
1. Swing the upperstructure so that the blade is positioned ZX33U-5A: 2000 mm (79 in) ZX33U-5A: 4200 mm (165 in)
ZX38U-5A: 2000 mm (79 in) ZX38U-5A: 4200 mm (165 in)
at the rear of the counterweight. ZX48U-5A: 1700 mm (67 in) ZX48U-5A: 4100 mm (161 in)
ZX55U-5A: 1600 mm (63 in) ZX55U-5A: 4100 mm (161 in)
2. Fully retract the blade cylinder. ZX65USB-5A: 1300 mm (51 in) ZX65USB-5A: 3900 mm (154 in)
3. Fully extend the boom, arm and bucket cylinders, as
illustrated to the right.
4. Position the boom straight ahead of the upperstructure.
Apply the boom swing pedal lock.
5. Pull the pilot control shut-off lever to the LOCK position.
6. Stop the engine. Remove the key from the key switch.
7. Set a crane in an appropriate position.
8. Attach shackles to the boom and blade hooks. Securely
thread wire ropes through the shackles.
9. Slowly lift the machine so that shock loads will not be
applied to the machine. Take sufficient care not to lose
the balance of the machine.
MADB-06-006
6-8
MAINTENANCE
IMPORTANT:
Use only recommended fuel and lubricants.
Be sure to use only genuine Hitachi parts. Failure to
do so may result in serious injury or death and/or
machine breakdown.
Failure to use recommended fuel, lubricants, and
genuine Hitachi parts will result in loss of Hitachi
product warranty.
Never adjust engine governor or hydraulic system
relief valve.
Protect electrical parts from water and steam.
Never disassemble electrical components such as
main controller, sensors, etc.
Never adjust parts of engine fuel system or hydraulic
equipment.
Using bad quality fuel, drainage agent, fuel
additives, gasoline, kerosene or alcohol refueled
or mixed with specified fuel may deteriorate
performance of fuel filters and cause sliding problem
at lubricated contacts in the injector. It also affects
the engine, leading to malfunction.
Use genuine Hitachi high performance filter.
7-1
MAINTENANCE
7-2
MAINTENANCE
Layout 10 11
9
8
7
6
12
4
13
3
14
2 15
16
17
18
19
20
21
27 26 25 24 22
29 28 23
MADB-01-001
7-3
MAINTENANCE
Symbol Marks
The following marks are used in the maintenance guide
table.
Gear Oil
Air Cleaner Element
(Travel Reduction Device)
Coolant
Engine Oil
(Long-Life Coolant)
Fuel Filter
Engine Oil Filter
(Fuel Main Filter, Pre-Filter)
Hydraulic Oil
7-4
MAINTENANCE
Maintenance Guide Table
Lubrication Interval 8 6
ZX33U-5A, 38U-5A (hours)
9 2
13
5
11
3
12
14
4
10
4 15 4 16 MADC-07-020
7-5
MAINTENANCE
Maintenance Guide Table
ZX48U-5A, 55U-5A, 65USB-5A 9 8 6 8 6 13
11
5
3 12
14
10
MADC-07-021
15 4 16 Lubrication Interval
(hours)
7-6
MAINTENANCE
SA-2294
SA-026
7-7
MAINTENANCE
Access Covers
1 2
Engine Cover
dWARNING:
Do not keep the access covers open when the
machine is parked on a slope, or while the wind
is blowing hard. The access covers may close
accidentally, possibly resulting in personal injury.
When opening or closing the access covers, take
extra care not to catch in fingers between the base
machine and the access covers.
MADB-07-002
Pull up latch (2) to open cover (1). Cover (1) is raised by link
mechanism (3). Be sure to fully raise cover (1). After checking
that stopper (4) provided on the left link is placed in LOCK
position (5), remove your hand from cover (1). Cover (1) will be
locked in place.
When closing cover (1), while raising cover (1), push stopper
(4) at the arrowed position (a) to disengage the lock.
While pushing stopper (4), lower cover (1). When cover (1) is
lowered by the 1/4 stroke, leave stopper (4).
Then, lower cover (1) further to completely close it.
Be sure to completely remove your hand, which is pushing
stopper (4), out of cover (1) at this time. Failure to do so may MADB-00-004
cause your hand to be caught in cover (1), possibly resulting in
severe injury.
3
4
MADB-07-003
Lock Position
4
5
a
M1M7-07-069
7-8
MAINTENANCE
Tank Cover 1 2
dWARNING:
Do not keep the access covers open when the
machine is parked on a slope, or while the wind
is blowing hard. The access covers may close
accidentally, possibly resulting in personal injury.
When opening or closing the access covers, take
extra care not to catch fingers between the base
machine and the access covers.
1. Press button (2) and raise cover (1) to open cover (1). MADB-07-004
2. Raise cover (1) until stopper (3) fits into the lock position
on bracket (4).
3. Confirm that stopper (3) is in the LOCK position before
releasing your hands.
4
dCAUTION: When closing cover (1), confirm that cover
(1) is securely locked.
4. When closing cover (1), push stopper (3) while raising
cover (1) by hand.
3
5. Lower cover (1) while pushing stopper (3). Release
stopper (3) when cover (1) is lowered by 1/4 of its
movable distance.
MADB-07-007
Unlock
Position Lock
Position
MADB-07-005 MADB-07-006
ZX33U-5A, 38U-5A
Unlock
Position
Lock
Position
MADB-07-005 MADB-07-006
ZX48U-5A, 55U-5A, 65USB-5A
7-9
MAINTENANCE
Radiator front Cover
dWARNING:
Do not keep the access covers open when the
machine is parked on a slope, or while the wind
is blowing hard. The access covers may close
accidentally, possibly resulting in personal injury.
When opening or closing the access covers, take
extra care not to catch fingers between the base
machine and the access covers.
Open the radiator front cover until rod (1) fits into the lock
position on rail groove (2).
Raise rod (1) to release lock before closing the radiator front
cover.
MADB-07-022
1 2
7-10
MAINTENANCE
Maintenance Guide
A. Greasing
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
ZX33U-5A, 38U-5A,
Bucket and 5 7-19
48U-5A, 55U-5A
1. Front Joint Pins Link Pins
ZX65USB-5A 6 7-19
Swing Post and Others 10 or every year 7-19
2. Blade Pins 4 or every year 7-21
3. Swing Bearing 2 7-22
4. Swing Internal Gear 1 7-23
5. Control Lever Universal Joint 2 or every year 7-23
: In case excavations are performed in water, grease the pin after operation is complete.
: Grease all pins every 100 hours during first time operation up to 500 hours.
IMPORTANT: Grease front joint pins every day until break-in operation (50 hours) is complete.
B. Engine
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
1. Engine Oil Check Oil Level 1 7-24
6.7 L
ZX33U-5A, 38U-5A
(1.8 US gal)
7.4 L
2. Engine Oil Change ZX48U-5A, 55U-5A 7-25
(2.0 US gal)
10.5 L
ZX65USB-5A
(2.8 US gal)
3. Engine Oil Filter Replace 1 7-25
: As the oil life is shortened more than normal under high temperature operation condition, shorten the
maintenance interval.
C. Transmission
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
Check Oil Level 2 7-28
0.6 L×2
Travel Reduction ZX33U-5A, 38U-5A 7-29
1. (0.63 US qt)
Gear Change
ZX48U-5A, 55U-5A, 0.9 L×2
7-29
65USB-5A (0.95 US qt)
7-11
MAINTENANCE
D. Hydraulic System
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 1500 2000 3000
1. Check Hydraulic Oil Level 1 7-35
2. Drain Hydraulic Oil Tank Sump 1 7-36
43 L
ZX33U-5A, 38U-5A
(13.2 US gal)
66 L
3. Change Hydraulic Oil ZX48U-5A, 55U-5A 7-37
(17.4 US gal)
107.5 L
ZX65USB-5A
(28.4 US gal)
4. Clean Suction Filter 1 Each time when hydraulic oil is changed 7-37
Filter-Paper Element 1 7-41
5. Replace full-flow filter
Element High Performance
1 7-41
Element (Optional)
6. Replace Pilot Oil Filter Element 1 7-43
for leaks, loose − 7-45
7. Check Hoses and Lines
for cracks, bend, etc. − 7-45
: Changing interval differs according to the brand of hydraulic oil used, kind of filter element or average attachment
operating availability.
Refer to the “Change Hydraulic Oil“ and “Replace Full-Flow Filter Element“. See recommended oil chart.
: Maintenance required only during first time.
E. Fuel System
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
1. Check Fuel Level 1 7-53
2. Check Water Separator 1 7-54
3. Drain Fuel Tank Sump 1 As required 7-55
4. Replace Fuel Main Filter Element 1 7-56
5. Replace Fuel Pre-Filter Element (Optional) 1 7-57
for leaks, cracks − 7-59
6. Check Fuel Hoses
for cracks, bend, etc. − 7-59
F. Air Cleaner
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
(or when indicator
Clean 1 7-60
1. Air Cleaner Outer Element is lit)
Replace 1 After cleaning 6 times or 1 year 7-60
2. Air Cleaner Inner Element (Optional) Replace 1 When outer element is replaced 7-60
: Shorten the interval in a dusty work site.
7-12
MAINTENANCE
G. Cooling System
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
1. Check Coolant Level 1 7-63
2. Check and Adjust Fan Belt Tension 1 7-64
5.0 L
ZX33U-5A, 38U-5A
(1.3 US gal)
6.5 L
3. Change Coolant ZX48U-5A, 55U-5A Twice a year * 7-67
(1.7 US gal)
7.4 L
ZX65USB-5A
(2.0 US gal)
Outside 1 7-69
4. Clean Radiator and Oil Cooler
Inside 1 When coolant is changed 7-69
5. Clean Air Conditioner Condenser − 7-70
6. Clean Air Conditioner Condenser Front Screen − 7-70
: Shorten the maintenance interval when the machine is operated in dusty areas.
: Maintenance required only during first time check.
*: When genuine Hitachi Long-Life Coolant (LLC) is used, change every two years or 2000 operating hours, whichever
comes first.
IMPORTANT:
Use soft water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi
Long-Life Coolant (LLC) mixed by 30 to 50 %. If a coolant mixed with less than 30 % of genuine Hitachi Long-
Life Coolant (LLC) is used, service life of the cooling parts may be shortened due to damage by freezing or
corrosion of coolant system parts.
If mineral-rich water is used for coolant, water stain or scale may build up inside the engine or radiator,
causing overheat due to deterioration of coolant performance.
H. Electrical System
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
Check Electrolyte Level 1 Every month 7-73
1. Battery
Check electrolyte specific gravity 1 Every month 7-74
2. Replacing Fuses Replace − As required 7-75
7-13
MAINTENANCE
I. Miscellaneous
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 1500 2000
1. Check and Replace Bucket Teeth − 7-76
2. Change Bucket 1 As required 7-78
Adjust Track Sag (Rubber Crawler) and Check for
3. 2 7-79
Damage
4. Replace Rubber Crawler 2 As required 7-81
5. Check Track Sag (Steel Crawler) (Optional) 2 7-83
6. Check and Replace Seat Belt 1 Every 3 years 7-86
7. Check Air Conditioner (Cab Equipped Machine) − 7-87
Circulating Air Clean 1 7-90
Clean and Replace Filter Replace 1 After cleaning 6 times or so 7-90
8. Heater/ Air Conditioner
Filter Clean 1 7-92
Fresh Air Filter
Replace 1 After cleaning 6 times or so 7-92
9. Clean Cab Floor − As required 7-94
Check, Clean and Function Check of Injection *
10. − 7-95
Nozzle
11. Inspect and Adjust Valve Clearance − * 7-95
12. Check and Adjust Injection Timing − * 7-95
13. Measure Engine Compression Pressure − *As required 7-95
14. Check Starter and Alternator − * 7-95
15. Check Crankcase Breather − * 7-95
16. Check Radiator Cap − * 7-95
Tightening and Retightening Torque of Nuts and
17. − * 7-96
Bolts
: Maintenance required only during first time check.
fNOTE: * Contact your nearest Hitachi dealer for maintenance. Instruction plate for the recommended grease and
lubricants is affixed under the seat.
7-14
MAINTENANCE
Pump delivery hose Every 2 years or 4000 hours whichever comes first
Swing hose Every 2 years or 4000 hours whichever comes first
Auxiliary hose Every 2 years or 4000 hours whichever comes first
Hydraulic System
Oil cooler hose (C/V to Oil cooler) Every 2 years or 4000 hours whichever comes first
Boom cylinder line hose Every 2 years or 4000 hours whichever comes first
Working Device
Arm cylinder line hose Every 2 years or 4000 hours whichever comes first
Bucket cylinder line hose Every 2 years or 4000 hours whichever comes first
7-15
MAINTENANCE
Kind of Oils
Recommended Grease
7-16
MAINTENANCE
Recommended Transmission Oil
fNOTE: A different interval of oil change may be required for Alternative Products.
For details, contact your nearest authorized dealer.
IMPORTANT:
Hitachi Genuine Hydraulic Oils are specially designed and tested to provide optimum performance for the
machine, hence we recommend to use Hitachi Genuine Hydraulic Oils.
If you do not use Hitachi Genuine Hydraulic Oil, use hydraulic oil conforming to JCMAS HK VG46W.
Otherwise, the machine may suffer damage.For the information of JCMAS HK VG46W, refer to JALOS
website.
Do not use oils which do not meet the above specification or requirements. Use of unsuitable oil may lead to
damage which is excluded from Hitachi Warranty Policy.
7-17
MAINTENANCE
Recommended Oil Viscosity
7-18
MAINTENANCE
A. Greasing
Front Joint Pins
Bucket
--- every 100 hours
Swing Post and Others
--- every 500 hours or every year
(every 100 hours during first time operation up to
500 hours)
Lubricate all fittings shown in the figure.
M1M7-05-024
Bucket
ZX65USB-5A
MADC-07-001
Swing Post
M1M7-07-024
7-19
MAINTENANCE
Boom Cylinder Bottom Side
M1M7-07-021
Boom Foot
MADB-07-048
M1M7-07-023
M1M7-07-020
7-20
MAINTENANCE
Arm Cylinder Rod Side, Bucket Cylinder Bottom Side
M571-07-006
M585-07-046
Blade Pins
--- every 500 hours or every year
Blade Joint Pins
Blade Cylinder Rod and Bottom Side
MADB-07-008
7-21
MAINTENANCE
Swing Bearing
--- every 250 hours
7-22
MAINTENANCE
Swing Internal Gear
--- every 500 hours
MADB-07-010
M1M7-07-016
7-23
MAINTENANCE
B. Engine
Engine Oil Level
--- check daily (Before starting the engine)
1 2 MADB-07-011
3 M1M7-07-029
7-24
MAINTENANCE
Change Engine Oil
--- every 500 hours
M104-07-010
3 M1M7-07-029
7-25
MAINTENANCE
7. Remove the filter cartridges of engine oil filter cartridge
(4) by turning it counterclockwise with the filter wrench.
ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
The oil may spill from filter (4) bottom bracket at this
time. Use an empty container to catch the spilled oil.
8. Clean the filter cartridge contact area on the engine.
IMPORTANT:
When filling new oil, take care not to allow foreign
matter to enter the engine.
Do not re-use engine oil filter (4). Be sure to use only
genuine engine oil filter (4). Failure to use genuine
parts or replace oil filter (4), may damage the engine.
9. Apply a thin layer of clean oil to new oil filter (4) gasket 1 4 2 MADB-07-011
(O-ring).
10. Install new oil filter (4). Turn the filter cartridge clockwise
by hand until the gasket touches the contact area. Be
sure not to damage the gasket when installing filter (4).
11. Tighten engine oil filter (4) 3/4 to 1 turn more using the
filter wrench. Be careful not to overtighten.
Tightening torque: 20 to 24 N·m (2.0 to 2.4 kgf·m, 15 to
17 lbf·ft)
7-26
MAINTENANCE
Model Quantity
ZX33U-5A, 38U-5A 6.7 L (1.8 US gal)
ZX48U-5A, 55U-5A 7.4 L (2.0 US gal)
ZX65USB-5A 10.5 L (2.8 US gal)
7-27
MAINTENANCE
C. Transmission
Travel Reduction Gear
Wait for gear oil to cool and then gradually loosen the
air release plug to release pressure.
4. After gear oil has cooled, slowly loosen air release plug 1
(1) to release pressure.
5. Remove air release plug (1) and oil level check plug (2). 2
Oil must be up to the bottom of hole.
6. If necessary, add oil until oil flows out of oil level check
plug (2) hole. (See gear oil chart) 3
7. Clean and install air release plug (1) and oil level check
plug (2).
7-28
MAINTENANCE
Change Gear Oil --- every 1000 hours
IMPORTANT: Do not use gear oils other than those listed
in the "Brand Names of Recommended Oil".
1. Park the machine on a level surface. 1
2. Rotate the travel motor until the plugs are positioned as
illustrated on the right.
2
3. Park the machine following the same procedures as
described on page 7-7 for preparation for inspection and
maintenance.
3
d WARNING: Keep body and face away from the air
release plug. Gear oil may be hot just after operation.
Wait for gear oil to cool and then gradually loosen the
M585-07-080
air release plug to release pressure.
4. After gear oil has cooled, slowly loosen air release plug
(1) to release pressure, and temporarily retighten plug
(1).
5. Remove drain plug (3) and plug (1), in that order, to drain
gear oil.
6. Clean drain plug (3). Tighten plug (3).
7-29
MAINTENANCE
7. Remove oil level check plug (2).
8. Add oil until oil flows out of oil level check plug (2) hole.
7-30
MAINTENANCE
D. Hydraulic System
Inspection and Maintenance of Hydraulic Equipment
IMPORTANT: Never adjust parts of hydraulic equipment.
7-31
MAINTENANCE
IMPORTANT:
When connecting hydraulic hoses and pipes, take
special care to keep seal surfaces free from dirt and
to avoid damaging them.
Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe it out before
reconnecting them.
Only use O-rings that are free of damage or defects.
Be careful not to damage them during reassembly.
Do not allow high pressure hoses to twist when
connecting them. The life of twisted hoses will be
shortened considerably.
Do not use hydraulic oils other than those listed in
the table "Recommended Hydraulic Oil".
When adding hydraulic oil, always use the same
brand of oil; do not mix brands of oil. When using
another manufacturer's hydraulic oil, be sure to
change the full amount.
Never run the engine without oil in the hydraulic oil
tank.
7-32
MAINTENANCE
Change Hydraulic Oil and Replace Full-Flow Filter
Element
Hydraulic breaker operation subjects the hydraulic system
to become contaminated faster and to quickly deteriorate
the hydraulic oil.
Failure to adhere to proper maintenance intervals may
result in damage to the base machine and the breaker.
In order to extend the service life particularly of the
hydraulic pump, change the hydraulic oil and the full-flow
filter element at the specified frequency given below.
(Refer to the "Hydraulic System" in the "MAINTEMANCE"
chapter.)
Changing intervals differ depending on the brand. (Refer to
the "Hydraulic System")
90
Average Breaker Operation Availability (%)
80
Element Replacement Intervals
70
50
Changing Interval when using 3000-hour life time Hydraulic Oil
40
30
20
10
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
MADB-13-043
Changing Intervals (hour)
7-33
MAINTENANCE
Changing intervals for the standard filter paper
Breaker Operation
0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
Availability
Full-Flow Filter 500 180 115 95 85 75 70 65 60 55 50
Hydraulic oil: 1000 hours
1000 720 580 500 450 410 380 360 340 330 320
life time
Hydraulic oil: 2000 hours
2000 1310 980 780 650 550 480 430 385 350 320
life time
90
Average Breaker Operation Availability (%)
80
Element Replacement Intervals
70
50
Changing Interval when using 2000-hour life time Hydraulic Oil
40
30
20
10
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Front Greasing
When using the hydraulic breaker, grease all front joint pins
every 50 hours.
7-34
MAINTENANCE
MADB-07-004
7-35
MAINTENANCE
ZX65USB-5A
2 3
3. Loosen bolts (2) of drain valve cover (3). Rotate drain
valve cover (3) to open the checking port. Slowly loosen
drain plug (1) on the bottom of the hydraulic oil tank to
drain water and sediment.
ZX65USB-5A
MADC-07-009
1
ZX65USB-5A
MADC-07-010
7-36
MAINTENANCE
7-37
MAINTENANCE
ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
6. Slowly loosen drain plug (3). Allow oil to drain. 2
11. Add oil until it is between the marks on the oil level 4
gauge.
12. Before securing cover (2) with bolts, ensure the top edge 5
of the rod assembly (5) is completely inserted into the
hole of support (4). Make sure filter and rod assembly (5) 6
are in correct positions. Install cover (2). Tighten the bolts
to 10 N·m (1 kgf·m, 7.2 lbf·ft).
13. Be sure to do “Bleed Air from Hydraulic System“ shown
7-40 page. MADB-07-014
fNOTE: Replace element (6) at the regular interval to keep ZX48U-5A, 55U-5A
hydraulic oil clean and to extend the service life of the 3
hydraulic components.
MADB-07-012
mm B
Model B C
ZX33U-5A, 38U-5A 465 25 C
ZX48U-5A, 55U-5A 606 39
MZX5-07-001
5
7-38
MAINTENANCE
ZX65USB-5A
6. Loosen bolts (7). Rotate drain valve cover (8) to open
2
the check port. Slowly loosen drain plug (3). Allow oil to
drain.
4
7. Remove rod assembly (5) from the hydraulic oil tank.
IMPORTANT: When changing hydraulic oil, take care not 5
to enter foreign matters such as dirt, water, and/or
sand into the hydraulic oil tank. 6
8. Clean the filter and tank interior. If suction filter (6) is to
be replaced, install new filter on rod (5) as shown.
9. Before installing the suction filter, check the dimension
MADB-07-014
of rod assembly (5) shown in figure below. Securely
insert rod assembly (5) into the pipe. ZX65USB-5A
11. Add oil until it is between the marks on the oil level
gauge.
12. Before securing cover (2) with bolts, ensure the top edge
of the rod assembly (5) is completely inserted into the
hole of support (4). Make sure filter and rod assembly (5)
are in correct positions. Install cover (2). Tighten the bolts
to 50 N·m (5 kgf·m, 36 lbf·ft).
13. Be sure to do “Bleed Air from Hydraulic System“ shown MADC-07-009
7-40 page.
MADC-07-010
mm B
Model B C
ZX65USB-5A 536 20
C
MZX5-07-001
5
7-39
MAINTENANCE
Bleed Air from Hydraulic System 1
MADB-07-004
7-40
MAINTENANCE
Replace Full-Flow Filter
--- every 500 hours (first time after 250 hours)
(when using the filter-paper element)
--- every 1000 hours (first time after 500 hours)
(when using the high performance element)
IMPORTANT: Changing interval differs according to the
brand of hydraulic oil, filter element and attachments
used, kind of filter element or average attachment
operating availability. (Refer to 7-33, 7-34 pages)
M1M7-05-024
d CAUTION: Hydraulic oil becomes hot and pressurized
during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
before starting any maintenance work.
Procedures:
1. Park the machine following the same procedures as 7
described on page 7-7 for preparation for inspection and
maintenance.
2. Before replacing element (6), be sure to bleed air
pressure from the hydraulic oil tank by loosening cap (7).
3. Loosen bolts (1) (4 used) to remove cover (2) and O-ring MADB-00-018
(3). When removing cover (2), slowly remove cover (2)
while pressing cover (2) downward so that spring (4) 1 2 3
does not fly off.
IMPORTANT: Especially when removing the filter, be
aware that the remaining oil in the filter may spill. Use
4
extra care.
4. Remove spring (4), valve (5) and element (6). 5
5. Take extra care never to allow water or dust to enter the
filter case. 6
MADB-07-017
7-41
MAINTENANCE
6. Replace O-ring (3) and element (6) with new ones. Be
careful not to damage element (6) and O-ring (3). 1 2 3
Tightening Torque 5
ZX33U-5A, 38U-5A, 48U-5A, 55U-5A : 10 N·m
(1 kgf·m) 6
ZX65USB-5A : 50 N·m
(5 kgf·m)
9. Bleed air from the hydraulic system and check the
hydraulic oil level after replacing the element.
MADB-07-017
(Refer to the descriptions for "Bleed Air from Hydraulic
System")
If the machine is operated with air mixed in the hydraulic
circuit, damage to the pump may result.
MADB-07-004
7-42
MAINTENANCE
MADB-00-018
MADB-07-018
MADB-07-019
7-43
MAINTENANCE
4. Rotate filter case (6) of pilot filter (4) counterclockwise to
remove filter case (6).
5. While rotating filter element (7), pull to remove filter
element (7) downward.
6. Replace O-ring (8) with a new one.
7. Clean the filter O-ring (8) contact area on filter head (5).
8. Securely install O-ring (8) in the O-ring groove on head
cover (5).
4
9. Coat the seal on new filter element (7) with clean
hydraulic oil. Completely install filter element (7) into
head cover (5) while rotating filter element (7) taking
care not to damage filter element (7). MADB-07-020
10. Take care not to allow dust and/or water enter filter case 5
(6).
11. Install case (6) into head cover (5) while rotating case (6)
clockwise.
Tightening Torque: 25 to 35 N·m 8
(2.5 to 3.5 kgf·m, 18.0 to 26 lbf·ft)
12. After replacing filter element (7), bleed any remaining air 7
from the hydraulic circuit.
Check the oil level in the hydraulic oil tank. Add oil as
needed.
6
(Refer to the descriptions for "Bleed Air from Hydraulic M503-07-031
System")
If the machine is operated with air mixed in the hydraulic
circuit, damage to the pump may result.
13. Install under cover (2).
Wrench size: 17 mm
14. Tighten cap (1).
7-44
MAINTENANCE
Check Hoses and Lines
--- daily
--- every 250 hours
d WARNING:
Hydraulic oil and lubricant leaks can lead to fire that
may result in serious injury. Check for missing or
loose clamps, kinked hoses, lines or hoses that rub
against each other, damaged oil cooler, and loose oil
cooler flange bolts, for leaks.
Escaping oil under pressure can penetrate the skin SA-031
causing serious injury. To avoid this hazard, search
for oil leaks with a piece of cardboard. Take care to
protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor familiar with this
type of injury immediately.
Tighten, repair or replace any missing, loose or
damaged clamps, hoses and lines.
Do not bend or strike high-pressure lines.
Never install bent or damaged hoses or lines.
SA-044
Hose
Interval (hours) Check Points Abnormalities Remedies 3 2
Daily Hose covers Leak (1) Replace
Hose ends Leak (2) Replace 1
Fittings Leak (3) Retighten or replace hose 2
or O-ring 3
M137-07-008
3 2
1
2
3
M115-07-145
7-45
MAINTENANCE
4
Interval (hours) Check Points Abnormalities Remedies
Every 250 Hose covers Damage or leak (4) Replace 5
hours Hose ends Damage or leak (5) Replace
Hose covers Exposed reinforcement (6) Replace
M115-07-146
Hose covers Crack or blister (7) Replace
Hose Bend (8), Collapse (9) Replace 7
Hose ends and Deformation or corrosion (10) Replace 6
Fittings
M115-07-147
M115-07-148
10
Lines M115-07-149
Oil Cooler
15 14
Interval (hours) Check Points Abnormalities Remedies
Every 250 Coupling Leak (14) Retighten or replace
hours Oil Cooler Leak (15) Replace
MADB-07-021
7-46
MAINTENANCE
Metal Face Seal Fittings
7 9 8 10 5
Fittings are used on smaller diameter joint and consist of a
metal flare (10) and a metal flare seat (9).
1. Inspect flare (10) and flare seat (9). They must be free of
dirt or obvious defects.
2. Tighten fitting (7) by hand.
3. Tighten fitting (7) or nut (8) to the torque values shown.
M202-07-051
Do not allow hose (5) to twist when tightening fittings.
±10%
Wrench size (mm) 17 19 22 27 36 41 50
N·m 25 30 40 65 180 210 250
Tightening
(kgf·m) (2.5) (3) (4) (6.5) (18) (21) (25)
Torque
(lbf·ft) (18) (22) (29.5) (47) (130) (150) (184)
7-47
MAINTENANCE
Service Recommendations for Hydraulic Fittings
Two hydraulic fitting designs are used on this machine.
Tightening Torque:
Tighten fittings to the torque values shown below.
±10 %
Wrench size (mm) 19 22 24 27 36 41
N·m 30 70 80 95 180 210
Tightening
(kgf·m) (3.0) (7.0) (8.0) (9.5) (18) (21)
Torque:
(lbf·ft) (22) (52) (59) (70) (130) (152)
7-48
MAINTENANCE
Quick Coupler
1. Connection Procedure
1.1 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 3 1
with plug (3).
1.2 Release socket ring (1). Check that socket ring (1) is
slightly moved backward by the spring force and that
the coupler is held in position with balls (2). Be sure to
check that socket ring (1) has been moved back fully to
the right original position.
2
M1M7-07-006
2. Disconnection Procedure
2.1 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 coupler is
disconnected.
2.2 After the coupler is disconnected, plug the holes with
the exclusively prepared plugs.
IMPORTANT:
Take care not to damage the joint surfaces when
disconnecting or connecting the coupler.
Before disconnecting or connecting the coupler,
clean the coupler and its surroundings with a
cleaning 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 correct
procedure. Confirm by inspection that no oil leak is
present after connecting the coupler.
After connecting the coupler, check that socket ring
(1) has been moved back fully to the right original
position.
7-49
MAINTENANCE
Quick Coupler
1. Connecting Coupler
Always grasp the coupler by its clamp section. Push the
body straight until the dust prevention cover retracts
approx. 2 mm. Then, pull the clamp section straight to
make sure that the coupler is properly connected and
will not be disconnected.
Dust Prevention Clamp Section
Cover
M1LA-07-016
M1LA-07-017
M1LA-07-018
7-50
MAINTENANCE
Using Screwdriver
WRONG
M1LE-07-006
7-51
MAINTENANCE
E. Fuel System
Recommended Fuel
Use only super high quality or high quality DIESEL FUEL (JIS
K-2204) (ASTM 2-D). Kerosene must NOT be used.
Besides, using bad quality fuel, drainage agent, fuel
additives, gasoline, kerosene or alcohol refueled or mixed
with specified fuel may deteriorate performance of fuel
filters and cause sliding problem at lubricated contacts
in the injector. It also affects the engine parts, leading to
malfunction. Using fuel other than ultra low-sulfur or low-
sulfur diesel fuel has adverse effects on the engine, which
may result in malfunction.
7-52
MAINTENANCE
Check Fuel Level
--- every 8 hours (daily)
2. Check fuel level gauge (3) and fuel gauge (1) of the
monitor panel. When necessary to add fuel, remove cap
(2) and refill fuel.
MADB-07-041
7-53
MAINTENANCE
Check Water Separator
Drain water --- every 8 hours (before starting
operation)
Water separator (1) is a device designed to separate water from
the fuel. There is a float inside the case which buoys when
water accumulates.
When the float rises to the water draining level, drain water.
Drain Procedures
1
1. Park the machine following the same procedures as
described on page 7-7 for preparation for inspection and
maintenance.
2. Place a 0.5 liters or larger capacity container under drain
plug (3) to collect the drained water.
MADB-07-022
3. Close cock (2) at upper part of water separator (1).
Loosen drain plug (3) at lower part of water separator (1)
to drain water. If it is difficult to drain water, loosen air
bleed plug (4) counterclockwise 2 to 3 turns.
2
4. After draining water, securely tighten drain plug (3) and
plug (4).
5. Open cock (2). 4
1
IMPORTANT: After draining water from the water
separator, bleed air from the fuel supply system.
7-54
MAINTENANCE
Drain Fuel Tank Sump
--- As reguired
1
1. Park the machine following the same procedures as
described on page 7-7 for preparation for inspection and
maintenance. 2
MADB-07-025
7-55
MAINTENANCE
Replace Fuel Main Filter Element
--- every 500 hours
IMPORTANT:
Be sure to use only genuine Hitachi elements for
the fuel main filter element. Failure to do so may
deteriorate the engine performance and/or shorten
the engine service life. Please be noted that all 1
engine failures caused by using other manufacturers'
elements are excluded from Hitachi Warranty Policy.
Take care not to allow dirt and/or water to enter the
fuel tank.
Procedures:
1. Park the machine following the same procedures as MADB-07-022
described on page 7-7 for preparation for inspection and
maintenance.
2. Close cock (1).
3. Place a 1 liter or larger capacity container under fuel
main filter (2).
4. Remove fuel filter (2) using the filter wrench.
2
5. Clean the fuel filter (2) contact area.
6. Apply a thin layer of clean fuel to the gasket of new fuel
filter (2).
7. Turn fuel filter (2) clockwise by hand until fuel filter (2)
touches the contact area.
8. Tighten fuel filter (2) 1/2 turn more using the filter
wrench. Be careful not to overtighten.
MADB-07-011
Tightening Torque : 20 to 24 N·m (2.0 to 2.4 kgf·m, 15 to
17 lbf·ft)
9. Open cock (1).
10. Bleed Air from the Fuel System
After replacing the fuel filter element, bleed air from the
fuel supply system.
(Refer to " Bleed Air from the Fuel System".)
7-56
MAINTENANCE
Replace Fuel Pre-Filter Element (Optional)
--- every 500 hours or when fuel filter clogging lamp
is lit
IMPORTANT:
Be sure to use only genuine Hitachi elements for
the fuel pre-filter element. Failure to do so may
deteriorate the engine performance and/or shorten
the engine service life. Please be noted that all
engine failures caused by using other manufacturers'
elements are excluded from Hitachi Warranty Policy.
Fuel Pre-Filter
ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
MADC-07-015
7-57
MAINTENANCE
Procedures:
1. Park the machine following the same procedures as
described on page 7-7 for preparation for inspection and
maintenance.
2. Close cock (1).
3. Place a 1 liter or larger capacity container under drain
plug (2).
4. Loosen air bleed plug (3) and drain plug (2). Drain fuel
until fuel does not flow out of the filter. 1
5. Loosen bolt (4) and remove filter case (5). MADC-07-022
6. Remove filter element (6). ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
1
3
ZX65USB-5A
8 3
5
7
2 M1M0-07-042 M1M0-07-041
4
7-58
MAINTENANCE
Check Fuel Hoses
--- every 8 hours (before starting operation)
--- every 250 hours
Hose
Interval (hours) Check Points Abnormalities Remedies
Daily Hose ends Leak (1) Retighten or replace
Hose covers Wear, crack (2) Replace 1
2
Every 250 Hose covers Crack (3) Replace
hours Hose ends Crack (4) Replace
Hose Bend (5), Collapse (6) Replace 1
Hose fittings Corrosion (7) Replace
M137-07-003
M137-07-004
M137-07-005
7
M137-07-006
7-59
MAINTENANCE
F. Air Cleaner 1
MADB-07-027
7-60
MAINTENANCE
7. Clean the filter interior before installing outer element
(1). 1 Cover
7-61
MAINTENANCE
G. Cooling System
Coolant
IMPORTANT: Use soft water as a coolant. Do not use
strong acid or alkaline water. Use the coolant with
genuine Hitachi Long-Life Coolant (LLC) mixed by 30
to 50 %.
If a coolant mixed with less than 30 % of genuine
Hitachi Long-Life Coolant (LLC) is used, service life of
the cooling parts may be shortened due to damage by
freezing or corrosion of coolant system parts.
If it is above 60 %, the engine may overheat.
7-62
MAINTENANCE
Check Coolant Level
--- daily
With the engine cold, the coolant level must be between the 2
FULL and LOW marks on coolant reservoir (2).
If the coolant level is below the low mark, remove the cap of
coolant reservoir (2) and add coolant to coolant reservoir (2). 1
d CAUTION: Do not loosen cap (1) until the coolant
temperature in the radiator becomes cool. Hot steam
may spout out, possibly causing severe burns. After
the coolant temperature has lowered, slowly loosen
cap (1) to release the inside air pressure before
removing cap (1).
If coolant reservoir (2) is empty, add coolant through cap (1) of ZX33U-5A, 38U-5A MADB-07-028
the radiator.
7-63
MAINTENANCE
Check and Adjust Fan Belt Tension 98 N (10 kgf)
Inspect
Check fan belt tension by depressing the midpoint between
fan pulley (1) and alternator pulley (2) by your thumb with M589-07-014
a depressing force of approximately 98 N (10 kgf, 22 lbf ).
Deflection : 7 to 9 mm 3 4
Visually check the belt for wear. Replace if necessary.
5 MADB-07-031
MADB-07-032
7-64
MAINTENANCE
ZX48U-5A, 55U-5A
1
1. Remove bolts (1) (5 used). Remove cover (2) to open
checking port.
2. Loosen mounting bolts (6) and nut (3) of alternator (5).
3. Adjust belt tension by moving alternator (5) forward or
backward by using adjusting screw (4).
4. Securely tighten bolts (6) and nut (3). 1
2
IMPORTANT: When a new belt is installed, be sure to re-
adjust the tension after operating the engine for 3 to 5
minutes at slow idle speed to be sure that the new belt
is seated correctly.
MADB-07-050
MADB-07-049
7-65
MAINTENANCE
ZX65USB-5A
1. Remove bolts (1) (6 used). Remove cover (2) to open
checking port.
2. Loosen mounting bolts (6) and nut (3) of alternator (5). 1 1
3. Adjust belt tension by moving alternator (5) forward or 1
backward by using adjusting screw (4).
1 2
4. Securely tighten bolts (6) and nut (3).
IMPORTANT: When a new belt is installed, be sure to re-
adjust the tension after operating the engine for 3 to 5 1
minutes at slow idle speed to be sure that the new belt
is seated correctly.
MADC-07-002
MADC-07-003
6 3
MADC-07-004
7-66
MAINTENANCE
Change Coolant
--- twice a year (in spring and autumn)
IMPORTANT: Use fresh water or normal tap water as a ZX33U-5A, 38U-5A MADB-07-028
coolant. Do not use strong acid or alkaline water. Use
the coolant with genuine Hitachi Long-Life Coolant
(LLC) mixed by 30 to 50 %.
7-67
MAINTENANCE
Procedure:
1. Park the machine following the same procedures as
described on page 7-7 for preparation for inspection and
maintenance.
2. Remove the under cover. Remove radiator cap (1). Open
drain cock (2) on the radiator and the drain cock on the
water jacket to allow the coolant to drain completely.
Remove impurities such as scale at the same time.
3. Close drain cock (2) and the drain cock on the water
jacket. Fill the radiator with soft water containing fewer 2
impurities or tap water and a radiator cleaner agent.
Run the engine at a speed slightly higher than slow ZX33U-5A, 38U-5A MADB-07-033
idle to raise the coolant temperature until the first two
segments come on. Then, run the engine further for
about 10 minutes.
4. Stop the engine and open radiator drain cock (2). Flush
out the cooling system with tap water, until draining
water is clear. This helps remove rust and sediment.
5. Close drain cock (2). Fill the radiator with tap water and
LLC at the specified mixing ratio. When adding coolant,
do so slowly to avoid mixing air bubbles in the system.
Run the engine to sufficiently bleed air from the cooling
system. 2 ZX48U-5A, 55U-5A MADB-07-034
ZX65USB-5A MADC-07-005
7-68
MAINTENANCE
Clean Radiator/Oil Cooler Core
Outside --- every 500 hours
Inside --- when coolant is changed
dWARNING:
Entanglement in moving parts can cause serious
injury.
Before servicing, stop the engine and the fan to
prevent any accident.
Never attempt to start the engine when the cover is
open.
In case tools or parts are dropped into the radiator/
oil cooler/inter cooler core, remove them before
starting the engine.
IMPORTANT:
Cover the air cleaner inlet opening to prevent the
entry of dust and water while cleaning the radiator.
If air with pressure of higher than 0.2 MPa (2 kgf/cm2)
or tap water with high delivery pressure is used for
cleaning, damage to the radiator/oil cooler/ fins may
result.
Check the core periodically and replace it if
necessary when the machine is operated in dusty
areas.
7-69
MAINTENANCE
Clean Air Conditioner Condenser
--- every 500 hours
IMPORTANT: When operating the machine in a dusty
environment, check the air conditioner condenser
every day for dirt and clogging. If clogged, remove,
clean and reinstall the air conditioner condenser.
7-70
MAINTENANCE
H. Electrical System
IMPORTANT:
Improper radio communication equipment and
associated parts, and/or improper installation of radio
communication equipment effects the machine's
electronic parts, causing involuntary movement of the
machine.
Also, improper installation of electrical equipments
may cause machine failure and/or a fire on the
machine.
Be sure to consult your authorized dealer when
installing a radio communication equipment or
additional electrical parts, or when replacing electrical
parts.
Never attempt to disassemble or modify the electrical/
electronic components. If replacement or modification
of such components is required, contact your
authorized dealer.
Batteries
dWARNING:
Battery gas can explode. Keep sparks and flames
away from batteries.
SA-036
Do not leave cover (1) removed. Do not keep tools,
metals or flammable materials around the battery
or inside the battery room. If a metal tool is placed
across the battery terminal and a vehicle component
such as the engine block, sparks may be created,
possibly resulting in fire and/or explosion.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of
the battery may result.
Charge the batteries in a well ventilated location.
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into the eyes.
Wearing eye protection and rubber gloves.
7-71
MAINTENANCE
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk.
3. Get medical attention immediately.
IMPORTANT:
Add water to batteries in freezing weather before
you begin operating your machine for the day, or
before charge the batteries.
If the battery is used with the electrolyte level lower
than the specified lower level, the battery may
deteriorate quickly.
Do not refill electrolyte more than the specified
upper level. Electrolyte may spill, damaging the
painted surfaces and/or corroding other machine
parts.
7-72
MAINTENANCE
Electrolyte Level Check
--- every month
1. Check the electrolyte level at least once a month.
2. Park the machine on level ground and stop the engine.
3. Check the electrolyte level.
3.1 When checking the level from the battery side:
U.L (Upper Level)
Clean around the level check lines with a wet towel.
L.L (Lower Level)
Do not use a dry towel. Static electricity may be
developed, causing the battery gas to explode. Check M146-07-109
if the electrolyte level is between U.L (Upper Level)
and L.L (Lower Level). In case the electrolyte level
is lower than the middle level between the U.L and Filler Port
L.L, immediately refill distilled water or commercial
battery fluid. Be sure to refill with distilled water before
recharging (operating the machine). After refilling,
securely tighten the filler plug. Sleeve
Upper Level
3.2 When impossible to check the level from the battery Lower Level
side or no level check mark is indicated on the side: Separator Top
After removing the filler plug from the top of the M146-07-110
battery. Check the electrolyte level by viewing through Proper
the filler port. It is difficult to judge the accurate Since the electrolyte surface touches the bottom end of
electrolyte level in this case. Therefore, when the the sleeve, the electrolyte surface is raised due to surface
tension so that the electrode ends are seen curved.
electrolyte level is flush with the U.L, the level is judged
to be proper. Then, referring to the right illustrations, M146-07-111
Lower
check the level. When the electrolyte level is lower than
the bottom end of the sleeve, refill with distilled water When the electrolyte surface is lower than the bottom
end of the sleeve, the electrode ends are seen straight.
or commercial battery fluid up to the bottom end of
the sleeve. Be sure to refill with distilled water before M146-07-112
recharging (operating the machine). After refilling,
securely tighten the filler plug.
3.3 When an indicator is available to check the level, follow
its check result.
4. Always keep around the battery terminals clean to
prevent battery discharge. Check terminals for loose
and/or rust. Coat terminals with grease or petroleum
jelly to prevent corrosion build up.
M409-07-072
7-73
MAINTENANCE
Check Electrolyte Specific Gravity
--- every month
If you spill acid on yourself:
1. Flush your skin with water.
dWARNING: Battery gas can explode. Keep sparks and
flames away from batteries. Use a flashlight to check 2. Apply baking soda or lime to help neutralize
the battery electrolyte level. the acid.
0 °C
(32 °F)
Fluid temp.
–20 °C
(–4 °F)
–40 °C
(–40 °F)
1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32
7-74
MAINTENANCE
Replacing Fuses
--- as required
If any electrical equipment fails to operate, first check the
fuses.
fNOTE:
One each spare fuse for respective fuse capacities is
provided in the fuse box.
MADB-07-036
ZX65USB-5A
5A MONITOR ACC 5A HORN
5A A/C PANEL, CAB 5A MONITOR B, RADIO
20 A CAB SOCKET 25 A LIGHT
5A TRAVEL RELAY 10 A MAIN RELAY
10 A OPTION 5A OPT. POWER
5A ENGINE 5A START
5A PILOT SHUT OFF 25 A A/C
5A OPT. POWER ACC 10 A WIPER, WASHER
ZX65USB-5A
5A TRAVEL, ILLUMI. MADC-07-012
20 A POWER SOCKET
7-75
MAINTENANCE
I. Miscellaneous 1 4 5
Check and Replace Bucket Teeth
--- daily
Check bucket teeth (1) for wear and looseness.
Replace teeth (1) if tooth wear exceeds the designated service
limit shown below.
New Limit of Use
A
A (mm) 128 65
M104-07-056
Replace
dCAUTION: 2
Guard against injury from flying pieces of metal.
3
Wear hard hat or safety glasses, and safety
equipment appropriate to the job.
1. Use hammer (2) and drift (3) to drive out locking pin (5).
Take care not to damage rubber pin lock (4).
2. Check lock pin (5) and rubber pin lock (4). Short locking
pins and damaged rubber pin locks must be replaced
with new ones.
M104-07-116
RIGHT WRONG
5
WRONG
7-76
MAINTENANCE
3. Clean shank (6) surface.
4. Install rubber pin lock (4) into shank (6) hole as shown.
RIGHT WRONG
6 4
M104-07-060
RIGHT WRONG
6 1
M104-07-061
RIGHT WRONG
1 5
M104-07-062
7-77
MAINTENANCE
Change Bucket
--- as required
Removal
1. Park the machine on a level surface. Lower the bucket to
the ground and position it with the flat surface resting
O-Ring Shift
on the ground. Be sure the bucket will not roll when the
pins are removed.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm and
bucket.
Bucket Boss
Installation
1. Clean the pins and pin bores. Apply sufficient grease to Link
the pins and pin bores.
2. Place the new bucket in stable position as shown in the B
figure. A
3. Fit the arm and alternate bucket. Be sure the bucket will
not roll. Install bucket pins A and B.
4. Install the locking pins and snap rings on pins A and B.
5. Install O-rings to the specified positions.
M104-07-063
6. Apply grease to each pin.
7. Start the engine and run at slow idle. Slowly operate the
bucket in both directions to check for any interference in
bucket movement.
7-78
MAINTENANCE
Roller
Check Rubber Track for Damage
A
Check the rubber track for damage. If any, consult your
authorized dealer for repair.
7-79
MAINTENANCE
Loosen the Track (Rubber Crawler)
7-80
MAINTENANCE
Replace Rubber Crawler
--- as required
d WARNING:
Do not loosen valve (1) too quickly or too much as
high-pressure grease in the adjusting cylinder may
spout out. Loosen carefully, keeping body parts and
face away from valve (1). Never loosen grease fitting
(2).
When removing the rubber track, do not allow
M1M7-04-006
anyone to stand in front of the front idler. During
this procedure, the high power track adjuster may Grease Outlet
1
suddenly release the front idler with extreme force, 2
potentially resulting in personal injury or death.
After the rubber track is removed, the front idle will
become free to remove. If the front idle comes off
unexpectedly, personal injury and/or death may
result. Be sure to remove the rubber track only after
taking appropriate measures to prevent the front M1LA-07-036
idler from coming off.
7-81
MAINTENANCE
Installing Rubber Crawler
Grease Outlet
1. Lower the bucket and blade to raise one track off
1
ground. Place blocks under machine frame to support
the machine.
2. Slowly turn valve (1) counterclockwise to allow grease to
escape from the grease outlet.
3. Engage the rubber track with the sprocket and position
the other end of the rubber track on the front idler. M1LA-07-036
4. While rotating the sprocket in reverse, apply horizontal
force to the rubber track to seat it on the idler.
Direction of Rotation
5. Insert a steel pipe into gaps among lower rollers, track
frame and rubber track and rotate the rubber track
slowly to correctly seat the rubber track on the idler.
6. Confirm that the rubber track is correctly engaged with
the sprocket and idler.
7. Adjust track sag. (Refer to "Adjust Track Sag".)
Steel Pipe
8. After checking that the rubber track is correctly engaged M503-07-063
with the sprocket and idler and the track sag is correctly
adjusted, lower the machine to the ground.
7-82
MAINTENANCE
Check Track Sag (Steel Crawler) (Optional)
--- every 50 hours
Swing the upperstructure 90 ° and lower the bucket to raise
the track off the ground as shown. Measure distance (A) at the
middle of the track frame from the bottom of the track frame
to the back face of the track shoe.
Each time, be sure to place blocks under the machine frame to
support the machine.
7-83
MAINTENANCE
Loosen the Track (Steel Crawler)
7-84
MAINTENANCE
Converting the Track
d WARNING:
Consult your authorized dealer for converting the
track. Extremely strong force is being applied. Do
not allow anyone to stand in front of the front idler.
After the rubber track is removed, the front idle will
become free to remove. If the front idle comes off
unexpectedly, personal injury and/or death may
result. Be sure to remove the rubber track only after
taking an appropriate measure to prevent the front
idler from coming off.
Consult your authorized dealer for converting the track.
Change the track adjuster whenever converting the steel or
rubber track.
7-85
MAINTENANCE
MADB-01-003
7-86
MAINTENANCE
Check Refrigerant
1 MADB-07-038
Start the engine and run at approximately 1500 min-1 (rpm).
Turn the air conditioner switch to ON. Set the blower switch
to HI and set the temperature control switch to the coolest
position (18 °C on the monitor screen). Operate the air
conditioner for 2 to 3 minutes. Check if cool air comes out No Refrigerant Insufficient
Empty Quantity
from the vent in the cab.
Kind of refrigerant and amount when shipping the Almost clear. A few
bubbles may appear
machine Sufficient when the engine
Quantity speed is raised or
Model Type Amount lowered.
ZX33U-5A, 38U-5A,
0.65±0.05 kg
48U-5A, 55U-5A HFC134a
M107-01-050
ZX65USB-5A 0.85±0.05 kg
Check compressor
After operating the air conditioner for 5 to 10 minutes,
touch both the high pressure pipe and the low pressure
pipe.
If normal, the high-pressure side pipe will be hot, and the
low-pressure side cold.
7-87
MAINTENANCE
ZX33U-5A Serial No. 031467 and up
ZX38U-5A Serial No. 050477 and up
ZX48U-5A Serial No. 031087 and up
ZX55U-5A Serial No. 050783 and up
Check pipe connections for refrigerant gas leakage
Pipe
If oil seepage is found around pipe connections, it indicates Connections
possible gas leakage.
Check Refrigerant
Start the engine and run at approximately 1500 min-1 (rpm).
Turn the air conditioner switch to ON. Set the blower switch
to HI and set the temperature control switch to the coolest
position (18 °C on the monitor screen). Operate the air
conditioner for 2 to 3 minutes. Check if cool air comes out
from the vent in the cab. ZX33U-5A, 38U-5A MADB-07-051
7-88
MAINTENANCE
Crank Pulley
Compressor Pulley
M1M7-07-013
3 1 2 M1NE-07-005
Compressor Pulley
7-89
MAINTENANCE
Clean and Replace Heater / Air Conditioner Filter
Clean Circulating Air Filter
--- every 500 hours
Replace Circulating Air Filter
--- After cleaning 6 times or so
2 3
MADC-07-014
ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
1 MADC-07-006
ZX65USB-5A
3 2
MADC-07-007
ZX65USB-5A
7-90
MAINTENANCE
Cleaning
IMPORTANT: Clean filter (2) by using a vacuum cleaner.
Do not clean it by blowing compressed air or washing
with water.
1. With side "a" of filter (2) facing downward, lightly tap the a
filter (2) frame to let large dirt drop.
2. Clean side "a" of filter (2) by using a vacuum cleaner.
Installation
2 3
1. Install filter (2) with side "a" facing as illustrated. Install MADC-07-014
tab (3) as illustrated. ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
2. Close panel (1).
1
MADC-07-013
ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
3 2
MADC-07-007
ZX65USB-5A
1 MADC-07-006
ZX65USB-5A
7-91
MAINTENANCE
Clean Fresh Air Filter
--- every 500 hours
Replace Fresh Air Filter
--- After cleaning 6 times or so
Cleaning MADB-07-045
Installation
IMPORTANT: Inappropriate installation of the filter 1
may cause dust to enter into the heater unit and
air conditioner, causing malfunction or breakdown
of them. Before installing the filter element, clean MADB-07-042
off dust around the mounting area; install the filter
element with extra care.
3 2 1
1. Fresh air filter (1) can be replaced by removing clip band
(2).
2. Install fresh air filter (1) assembly while holding tab (3) of
cover.
a
MADB-07-043
7-92
MAINTENANCE
Clean Fresh Air Filter
--- every 500 hours
Replace Fresh Air Filter
--- After cleaning 6 times or so
ZX65USB-5A
Removing Fresh Air Filter
1. Pull out fresh air filter (1) upward, which is located at
bottom left of the seat. MADC-07-023
Cleaning
IMPORTANT: Clean filter (3) by using a vacuum cleaner.
Do not clean it by blowing compressed air or washing
with water.
1. With side "a" of filter (1) facing downward, lightly tap the
filter (1) frame to let large dirt drop.
2. Clean side "a" of filter (1) by using a vacuum cleaner.
1
Installation
IMPORTANT: Inappropriate installation of the filter
may cause dust to enter into the heater unit or air
conditioner, causing malfunction or breakdown of
them. Before installing the filter element, clean off
dust around the mounting area; install the filter MADC-07-024
element with extra care.
Install the fresh air filter straightly into the fresh air filter 1
mounting case.
a
MADC-07-025
7-93
MAINTENANCE
Clean Cab Floor
--- as required
1 2 3
IMPORTANT: Only the cab floor can be washed with
water. Take care not to splash other parts of the cab
with water. Do not increase the water pressure speed
by squeezing the hose end. Never use steam to clean
the cab floor. Always clean the cab floor only after
closing ducts (1, 2, and 3) to prevent water from
entering the ducts (1, 2, and 3).
7-94
MAINTENANCE
Check, Clean and Function Check of Injection Nozzle
--- every 1500 hours
Consult your authorized dealer for inspection and repair.
7-95
MAINTENANCE
Tightening and Retightening Torque of Bolts and
Nuts
--- every 250 hours (first time after 50 hours)
Check tightness after the first 50 hours then every 250 hours.
Tighten to torque shown if any are loose. Bolts and nuts should
be replaced with those of the same or higher grade.
For tightening nuts and bolts other than specified in the table
below, refer to the Tightening Torque Chart at the end of this
section.
7-96
MAINTENANCE
ZX33U-5A, 38U-5A
Bolt Dia. Wrench Size Torque
No. Descriptions Q’ty
mm mm N·m (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 4 17 50 (5) (36)
7/16-20UNF 17 25 (2.5) (18)
Metal face 19 30 (3) (22)
seal fitting for 9/16-18UNF
22 40 (4) (29)
Union joints for hydraulic hoses 3/4-16UNF 27 65 (6.5) (47)
5. hydraulic hoses and and piping 1-1/16-12UNF 36 180 (18) (129)
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 10 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)
11. Canopy mounting bolt 4 Poles 12 11 19 110 (11) (80)
12. Cab mounting bolt 12 5 19 90 (9) (65)
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 24 210 (21) (151)
17. Lower roller mounting bolt 14 16 22 220 (22) (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 32 750 (75) (553)
10 17 50 (5) (36)
12 19 90 (9) (65)
20. Front pin lock bolts 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)
IMPORTANT:
Before installing, clean the bolt and nut threads to remove soil, rust, and/or dust.
When installing new bolts and/or nuts, apply lubricant (e.g. white zinc B dissolved into spindle oil) to the
screw threads.
Tighten bolts and nuts to the specifications. If tightened with excessively high or inadequate torque,
missing or breakage of bolts and/or nut may result.
In case the counterweight mounting bolts became loose, consult your authorized dealer for retightening.
7-97
MAINTENANCE
ZX48U-5A, 55U-5A
Bolt Dia. Wrench Size Torque
No. Descriptions Q’ty
mm mm N·m (kgf·m) (lbf·ft)
1. Engine cushion rubber mounting bolt 14 4 22 140 (14) (101)
2. Engine bracket mounting bolt (Front) 10 8 17 50 (5) (36)
3. Hydraulic oil tank mounting bolt 12 4 19 110 (11) (80)
4. Fuel tank mounting nut 10 4 17 20 (2) (15)
7/16-20UNF 17 25 (2.5) (18)
Metal face 19 30 (3) (22)
seal fitting for 9/16-18UNF
22 40 (4) (29)
Union joints for hydraulic hoses 3/4-16UNF 27 65 (6.5) (47)
5. hydraulic hoses and and piping 1-1/16-12UNF 36 18 (18) (129)
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 10 (Socket) 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 16 8 24 270 (27) (195)
10. Battery mounting nut 6 4 10 5 (0.5) (3.5)
11. Canopy mounting bolt 4 Poles 12 11 19 110 (11) (80)
12. Cab mounting bolt 12 5 19 110 (11) (80)
Swing bearing Upperstructure 12 27 19 110 (11) (80)
13.
mounting bolt Undercarriage 12 24 19 110 (11) (80)
14. Travel device mounting bolt 14 24 22 180 (18) (130)
15. Sprocket mounting bolt 14 24 22 180 (18) (130)
16. Upper roller mounting bolt 16 2 24 270 (27) (199)
17. Lower roller mounting bolt 16 16 24 270 (27) (195)
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 24 3 36 930 (93) (690)
10 17 50 (5) (36)
12 19 90 (9) (65)
20. Front pin lock bolts 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 16 12 24 270 (27) (196)
IMPORTANT:
Before installing, clean the bolt and nut threads to remove soil, rust, and/or dust.
When installing new bolts and/or nuts, apply lubricant (e.g. white zinc B dissolved into spindle oil) to the
screw threads.
Tighten bolts and nuts to the specifications. If tightened with excessively high or low torque, missing or
breakage of bolts and/or nut may result.
In case the counterweight mounting bolts became loose, consult your authorized dealer for retightening.
7-98
MAINTENANCE
ZX65USB-5A
Bolt Dia. Torque
Q’ty Wrench Size
No. Descriptions mm mm N·m (kgf·m) (lbf·ft)
1. Engine cushion rubber mounting bolt 14 4 22 140 (14) (101)
2. Engine bracket mounting bolt (Front) 10 8 17 65 (6.5) (47)
3. Muffler mounting U-bolt fixing nut (single nut) 10 4 17 10 (1) (7)
4. Muffler mounting U-bolt fixing nuts (double nuts) 10 4 17 35 (3.5) (26)
5. Hydraulic oil tank mounting bolt 16 4 24 270 (27) (195)
6. Fuel tank mounting nut 10 4 17 20 (2) (14)
PF1/8 19 30 (3) (22)
PF3/8 22 40 (4) (29)
PF1/2 27 65 (6.5) (47)
Joint
PF3/4 36 180 (18) (130)
PF1 2 41 210 (21) (151)
PF1-1/4 1 50 250 (25) (184)
7/16-20UNF 17 25 (2.5) (18)
9/16-18UNF 19 30 (3) (22)
Union joints for hydraulic Metal face seal 22 40 (4) (29)
7.
hoses and pipes fitting for hydraulic 3/4-16UNF 27 65 (6.5) (47)
hoses and piping 1-1/16-12UNF 36 180 (18) (130)
1-5/16-12UNF 41 210 (21) (151)
1-5/8-12UNF 2 50 250 (25) (184)
9/16-18UNF 19 30 (3) (22)
11/16-16UNF 22 70 (7) (52)
ORS 13/16-16UNF 27 95 (9.5) (69)
1-3/16-12UNF 36 180 (18) (130)
1-7/16-12UNF 2 41 210 (21) (151)
8. T-bolt clamp of low pressure piping 1/4-28UNF 4 11 10 (1) (7)
9. Pump mounting bolt 12 4 19 90 (9) (65)
10. Pump cover mounting bolt 10 12 17 50 (5) (36)
11. Control valve mounting bolt 10 4 17 50 (5) (36)
12. Control valve base mounting bolt 10 5 17 50 (5) (36)
13. Swing device mounting bolt 16 8 24 270 (27) (196)
14. Battery mounting nut 6 2 10 5 (0.5) (3.5)
15. Cab mounting bolt 12 12 19 110 (11) (80)
16. Cab cushion rubber (rear) mounting bolt 14 2 22 180 (18) (130)
Swing bearing mounting Upperstructure 14 36 22 180 (18) (130)
17.
bolt Undercarriage 14 24 22 180 (18) (130)
18. Travel device mounting bolt 14 24 22 220 (22) (162)
19. Sprocket mounting bolt 14 24 22 220 (22) (162)
7-99
MAINTENANCE
ZX65USB-5A
Bolt Dia. Torque
Q’ty Wrench Size
No. Descriptions mm mm N·m (kgf·m) (lbf·ft)
20. Upper roller mounting bolt 16 2 24 210 (21) (151)
21. Lower roller mounting bolt 20 16 30 620 (62) (455)
22. Shoe bolt (optional) 12 312 19 165 (16.5) (121)
6 10 5 (0.5) (3.5)
23. Cover mounting bolt 8 13 10 (1) (7)
10 17 50 (5) (36)
24. Counterweight mounting bolt 24 3 36 930 (95) (685)
25. Additional counterweight mounting bolt (optional) 20 2 30 540 (55) (398)
10 17 50 (5) (36)
12 19 90 (9) (65)
26. Front pin lock bolts 14 22 140 (14) (103)
16 24 210 (21) (151)
18 27 400 (40) (236)
27. Track roller guard mounting bolt (optional) 16 12 24 270 (27) (196)
7-100
MAINTENANCE
Tightening Torque Chart
Hexagon
Bolt Dia. Wrench Wrench
Size Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft)
M8 13 6 30 (3.0) (22) 20 (2.0) (15) 10 (1.0) (7.4)
M10 17 8 65 (6.5) (48) 50 (5.0) (37) 20 (2.0) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (135) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8.0) (59)
M18 27 14 400 (40) (295) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (295) 170 (17) (125)
M22 32 17 750 (75) (550) 550 (55) (410) 220 (22) (160)
M24 36 19 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 19 1400 (140) (1030) 1050 (105) (770) 400 (40) (295)
M30 46 22 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 24 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 27 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)
IMPORTANT:
Apply lubricant (e. g. white zinc B solved into spindle
oil) to bolts and nuts to stabilize their friction
coefficient.
Remove soil, dust, and/or dirt from the nut and bolt
thread surfaces before tightening.
Tighten nuts and bolts to specifications. If tightened
with excessively low or high torque, missing or
breakage of nuts and/or bolts may result.
7-101
MAINTENANCE
MEMO
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7-102
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
Freezing Weather Fuel/Lubricant Use high quality and low viscosity fuel and oil.
Engine Coolant Be sure to use antifreeze.
Battery Fully charge the batteries at shorter intervals. If not fully charged,
electrolyte may freeze.
Track Keep the track clean. Park the machine on a hard surface to prevent the
tracks from freezing to the ground.
High Altitude Engine Oil Change at 1/2 of normal service interval.
(Altitude: 1500 m or Engine Oil Filter Change at 1/2 of normal service interval.
higher)
When the machine is operated at the altitude 1500 m or higher, the ignition of the engine may deteriorate, possibly
resulting in significant decrease in durability or function. If the machine is unavoidably operated under these conditions,
consult your authorized Hitachi dealer.
9-1
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
MEMO
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9-2
STORAGE
Item Remedy
Machine Cleaning Wash the machine. Remove soil or other debris adhered to the machine.
Lubrication/Greasing Check lubricant's level and contamination. Fill up or change if necessary. Lubricate all grease
points.
Coat grease to exposed metal surfaces which are subject to rust (i.e. cylinder rods etc.).
Battery Remove the batteries and store them in a dry protected place after charging fully. If not
removed, disconnect the negative battery cable from the ( ) terminal.
Coolant Add anti-rusting agent. If storing in extremely cold areas, either add extra anti-freeze or drain
coolant completely to avoid freezing. In this case, place a sign reading "NO COOLANT".
Protection Against Dust Store the machine in a dry storage area using a protective cover.
and Moisture
Tools Inspect and repair, then store.
Lubrication Operation If oil film on the metal surfaces is lost, rust may begin, possibly causing abnormal wear of the
machine when the machine operation is restarted. If the machine is stored for a long time,
operate hydraulic functions for travel, swing and digging two to three times for lubrication,
at least once a month. Be sure to check the coolant level and lubrication conditions before
operating. Charge the batteries at this time.
f NOTE:
Lubricating operation is a series of warm-up, travel, swing and digging operation carried out repeatedly for a few cycles
at slow speed.
Lubricants will deteriorate during long term storage of the machine. Be sure to carefully check the lubricants before
restarting operation of the machine.
Refer to "Using Rubber Crawler" in the OPERATING THE MACHINE section for the machines equipped with rubber crawlers.
10-1
STORAGE
MEMO
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10-2
TROUBLESHOOTING
Troubleshooting
If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary
measures to prevent the reoccurrence of the same trouble.
In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest Hitachi dealer. Never
attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components.
IMPORTANT: Never attempt to disassemble or modify the electrical/electronic components.
Engine
Consult the nearest Hitachi dealer for the engine troubleshooting.
Engine Auxiliaries
11-1
TROUBLESHOOTING
Impossible to Start the Engine
11-2
TROUBLESHOOTING
Control Lever
11-3
TROUBLESHOOTING
Hydraulic System
When the machine is stored without operation, air mixed in hydraulic oil will become separated and will accumulate
in the cylinder upper sections, causing a delay in the response time of the machine movement or weak power
development.
In case these symptoms appear, repeatedly operate all actuators several times.
Problem Cause Solution
No hydraulic Functions Faulty hydraulic pump * Repair or replace
(Noise from pumps) Lack of hydraulic oil Refill
Broken suction pipe and/or hose * Repair or replace
No hydraulic Functions Faulty pilot pump * Replace
(Hydraulic pump noise remains Faulty pilot shut-off solenoid valve * Replace
unchanged.) Faulty wire harness (pilot shut-off solenoid * Repair or replace
valve) pilot shut-off switch
The pilot control shut-off lever is in the LOCK Turn the pilot shut-off lever to
position. the UNLOCK position.
All actuators have no power. Malfunction due to worn hydraulic pump * Replace
Decreased main relief valve set pressure in the * Adjust
control valve
Lack of hydraulic oil Refill
Clogged suction strainer in the hydraulic oil Clean
tank
Absorption of air from the oil suction side Retighten
Only one side lever is inoperable or has Faulty relief valve in the valve * Repair or replace
no power. Broken pipe and/or hose * Repair or replace
Loose pipe line joint Retighten
Broken O-ring at pipe line joint * Replace
Faulty hydraulic pump * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Faulty pilot solenoid valve * Repair or replace
* Mark: Consult your authorized Hitachi dealer.
11-4
TROUBLESHOOTING
11-5
TROUBLESHOOTING
Drive Function
Problem Cause Solution
One or both side tracks are inoperable. Damaged center joint * Repair or replace
Incompletely released parking brake * Repair or replace
Broken travel motor * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Faulty counter balance valve * Replace
Does not travel smoothly. Overly tensioned or slackened crawler sag Adjust
Deformed track frame * Repair or replace
Embedded foreign matter such as rock Remove
fragments
Dragged parking brake * Repair
Faulty counter balance valve * Replace
Travel speed does not change. Faulty travel speed switch. * Replace
Poor contact in connector * Repair or replace
Damaged wire harness * Repair
Faulty solenoid valve * Repair or replace
Faulty motor * Repair or replace
* Mark: Consult your authorized Hitachi dealer.
11-6
TROUBLESHOOTING
Swing Function
Problem Cause Solution
Upperstructure does not swing. Faulty swing parking brake * Repair or replace
Broken swing motor * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Low set pressure of swing relief valve * Adjust and replace
Swing is not smooth. Worn swing gear * Repair or replace
Damaged swing bearing and bearing balls * Repair or replace
Lack of grease Refill
Low set pressure of swing relief valve * Adjust and replace
* Mark: Consult your authorized Hitachi dealer.
Immediately after the control valve, swing motor relief valve and/or the swing motor is replaced, a noise may be
emitted and/or operation may not be performed smoothly due to air trapped in the hydraulic line.
Slowly continue to operate the machine for approx. 10 minutes to bleed air.
After repair work is complete, be sure to check the oil level in the hydraulic oil tank. Refill hydraulic oil as needed.
11-7
TROUBLESHOOTING
Engine Speed
Problem Cause Solution
Even if operating the engine control Blown fuse Replace
dial, the engine speed does not Faulty engine control dial * Replace
change. Poor contact in connector * Repair or replace
Damaged wire harness (between EC dial and * Repair
monitor)
Faulty controller (ECU) * Replace
Work mode does not change. Faulty mode switch * Replace
Poor contact in connector * Repair or replace
Damaged wire harness (between ECU and * Repair
monitor)
Faulty controller (ECU) * Replace
Faulty solenoid valve * Repair or replace
Auto-idle is inoperable or not released. Faulty pressure sensor * Replace
Poor contact in connector * Repair or replace
Damaged wire harness * Repair
Faulty controller * Replace
* Mark: Consult your authorized Hitachi dealer.
Others
The machine may have a noise, excessive vibration, and abnormal smell when any trouble occurs.
Always beware of the machine conditions during operation.
11-8
SPECIFICATIONS
Std. Specification
ZX33U-5A
A C
E
D
J I
H G
MADG-12-001
Model ZX33U-5A
Specification Canopy Cab
Type of Front-End
- Boom Swing Type, 1.52 m (5 ft) Arm
Attachment
Bucket Capacity (Heaped) m (yd )
3 3
0.08 (0.11)
Operating Weight kg (lb) 3330 (7340) 3510 (7740)
Base Machine Weight kg (lb) 2520 (5560) 2700 (5950)
3TNV88
Engine kW/min-1 21.2/2400
(PS/rpm) (28.8/2400)
A: Overall Width mm (ft·in) 1550 (5' 1'')
B: Overall Height mm (ft·in) 2480 (8' 2'')
C: Rear End Swing Radius mm (ft·in) 875 (2' 10")
D: Minimum Ground
mm (ft·in) 280 (11'')
Clearance
E: Counterweight
mm (ft·in) 550 (1' 10'')
Clearance
F: Engine Cover Height mm (ft·in) 1530 (5')
G: Undercarriage Length mm (ft·in) 2110 (6' 11'')
H: Undercarriage Width mm (ft·in) 1550 (5' 1'')
I: Sprocket Center to Idler
mm (ft·in) 1660 (5' 5'')
Center
J: Track Shoe Width mm (ft·in) 300 (1')
kPa 30 32
Ground Pressure
(kgf/cm2, psi) (0.30, 4.4) (0.32, 4.6)
Swing Speed min-1 (rpm) 9.1 (9.1)
Travel Speed (fast/slow) km/h (mph) 4.3/2.8 (2.7/1.7)
Gradeability 30° (tan θ = 0.58)
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.
The specifications include additional counterweight and extra attachment lines.
12-1
SPECIFICATIONS
Working Ranges
ZX33U-5A
K (Left) K (Right)
H
G
D
E
I
J
F
MADC-12-004
ZX33U-5A
Category
Canopy Cab
Item
1.17 m Arm 1.52 m Arm 1.17 m Arm 1.52 m Arm
A: Maximum Digging Reach mm (ft·in) 4890 (16' 1") 5170 (17') 4890 (16' 1") 5170 (17')
B: Maximum Digging Depth mm (ft·in) 2790 (9' 2") 3130 (10' 3") 2790 (9' 2") 3130 (10' 3")
C: Maximum Cutting Height mm (ft·in) 4620 (15' 2") 4700 (15' 5") 4420 (14' 6") 4470 (14' 8")
D: Maximum Dumping Height mm (ft·in) 3200 (10' 6") 3310 (10' 10") 3030 (9' 11") 3100 (10' 2")
E: Overall Height mm (ft·in) 2480 (8' 2")
F: Overall Length mm (ft·in) 4450 (14' 7") 4530 (14' 10") 4450 (14' 7") 4530 (14' 10")
G: Minimum Swing Radius mm (ft·in) 1970 (6' 6") 2090 (6' 10") 2150 (7' 1") 2180 (7' 2")
H: Boom Swing Pivot Offset Distance mm (ft·in) 100 (4")
I: Blade Bottom Highest Position mm (ft·in) 360 (1' 2")
J: Blade Bottom Lowest Position mm (ft·in) 320 (1' 1")
K: Offset Distance mm (ft·in) L610 (2') R735 (2'5") L610 (2') R700 (2'4")
* L450 (1'6") R700 (2'4") * L450 (1'6") R700 (2'4")
Maximum Boom-Swing Angle L72° R62° [52°] L62° R62° [52°]
* L62° R45° * L62° R45°
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
L: Left R: Right
Values in the brackets [ ] are dimension of the machine equipped with the House rupture valve.
* Mark indicates the machine with assist pipes.
12-2
SPECIFICATIONS
ZX33U-5A (Cab)
Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe
Shoe Width
300 mm 300 mm 300 mm 300 mm
For Paved Road For Ordinary Ground For Paved Road For Paved Road
Application
(Standard) (Optional) (Optional) (Optional)
Operating
(kg) 3510 3650 3750 3720
Weight
Minimum
Ground (mm) 280 270 310 320
Clearance
Undercarriage
(mm) 2110 2130 2170 2180
Length
Undercarriage
(mm) 1550 1550 1550 1550
Width
Ground
(kPa) 32 33 34 33
Pressure
(kgf/cm )
2
0.32 0.33 0.34 0.34
fNOTE:
The specifications for the front-end attachment are for 1.52 m arm with ISO 0.08 m3 bucket.
Rubber shoe, rubber pad shoe and pad crawler shoe should be used on paved road. Use of rubber crawlers on other than
paved road may shorten the service life of the rubber crawlers to a great extent.
Other than 300 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground
may cause serious damage to shoe, shoe bolts and other parts such as rollers.
The dimensions do not include the height of the shoe lug.
12-3
SPECIFICATIONS
fNOTE:
Symbols in the above table have the following meanings.
: General excavating
: Light duty excavating
: Loading work
12-4
SPECIFICATIONS
Std. Specification
ZX38U-5A
A C
E
D
J I
H G
MADG-12-001
Model ZX38U-5A
Specification Canopy Cab
Type of Front-End
- Boom Swing Type, 1.72 m (5 ft 8 in) Arm
Attachment
Bucket Capacity (Heaped) m (yd )
3 3
0.10 (0.13)
Operating Weight kg (lb) 3790 (8360) 3960 (8730)
Base Machine Weight kg (lb) 2930 (6460) 3100 (6830)
3TNV88
Engine kW/min-1 21.2/2400
(PS/rpm) (28.8/2400)
A: Overall Width mm (ft·in) 1550 (5' 1'')
B: Overall Height mm (ft·in) 2480 (8' 2'')
C: Rear End Swing Radius mm (ft·in) 980 (3' 3")
D: Minimum Ground
mm (ft·in) 280 (11'')
Clearance
E: Counterweight
mm (ft·in) 550 (1' 10'')
Clearance
F: Engine Cover Height mm (ft·in) 1530 (5')
G: Undercarriage Length mm (ft·in) 2110 (6' 11'')
H: Undercarriage Width mm (ft·in) 1740 (5' 9'')
I: Sprocket Center to Idler
mm (ft·in) 1660 (5' 5'')
Center
J: Track Shoe Width mm (ft·in) 300 (1')
kPa 34 36
Ground Pressure
(kgf/cm2, psi) (0.35, 4.9) (0.36, 5.2)
Swing Speed min-1 (rpm) 9.1 (9.1)
Travel Speed (fast/slow) km/h (mph) 4.3/2.8 (2.7/1.7)
Gradeability 30° (tan θ = 0.58)
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.
The specifications include additional counterweight and extra attachment lines.
12-5
SPECIFICATIONS
Working Ranges
ZX38U-5A
K (Left) K (Right)
H
G
D
E
I
J
F
MADC-12-004
ZX38U-5A
Category
Canopy Cab
Item
1.32 m Arm 1.72 m Arm 1.32 m Arm 1.72 m Arm
A: Maximum Digging Reach mm (ft·in) 5210 (17' 1") 5520 (18' 1") 5210 (17' 1") 5520 (18' 1")
B: Maximum Digging Depth mm (ft·in) 3060 (10') 3460 (11' 4") 3060 (10') 3460 (11' 4")
C: Maximum Cutting Height mm (ft·in) 4870 (16') 4950 (16' 3") 4700 (15' 5") 4740 (15' 7")
D: Maximum Dumping Height mm (ft·in) 3460 (11' 4") 3570 (11' 9") 3310 (10' 10") 3390 (11' 2")
E: Overall Height mm (ft·in) 2480 (8' 2")
F: Overall Length mm (ft·in) 4640 (15' 3") 4760 (15' 7") 4640 (15' 3") 4760 (15' 7")
G: Minimum Swing Radius mm (ft·in) 2080 (6' 10") 2190 (7' 2") 2240 (7' 4") 2300 (7' 7")
H: Boom Swing Pivot Offset Distance mm (ft·in) 100 (4")
I: Blade Bottom Highest Position mm (ft·in) 360 (1' 2")
J: Blade Bottom Lowest Position mm (ft·in) 400 (1' 4")
K: Offset Distance mm (ft·in) L610 (2') R735 (2' 5") L610 (2') R700 (2'4")
* L450 (1'6") R700 (2'4") * L450 (1'6") R700 (2'4")
Maximum Boom-Swing Angle L72° R62° [52°] L62° R62° [52°]
* L62° R45° * L62° R45°
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
L: Left R: Right
Values in the brackets [ ] are dimension of the machine equipped with the House rupture valve.
* Mark indicates the machine with assist pipes.
12-6
SPECIFICATIONS
ZX38U-5A (Cab)
Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe
Shoe Width
300 mm 300 mm 300 mm 300 mm
For Paved Road For Ordinary Ground For Paved Road For Paved Road
Application
(Standard) (Optional) (Optional) (Optional)
Operating
(kg) 3960 4100 4200 4170
Weight
Minimum
Ground (mm) 280 270 310 320
Clearance
Undercarriage
(mm) 2110 2130 2170 2180
Length
Undercarriage
(mm) 1740 1740 1740 1740
Width
Ground
(kPa) 36 37 38 38
Pressure
(kgf/cm )
2
0.36 0.38 0.38 0.38
fNOTE:
The specifications for the front-end attachment are for 1.72 m arm with ISO 0.10 m3 bucket.
Rubber shoe, rubber pad shoe and pad crawler shoe should be used on paved road. Use of rubber crawlers on other than
paved road may shorten the service life of the rubber crawlers to a great extent.
Other than 300 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground
may cause serious damage to shoe, shoe bolts and other parts such as rollers.
The dimensions do not include the height of the shoe lug.
12-7
SPECIFICATIONS
fNOTE:
Symbols in the above table have the following meanings.
: General excavating
: Light duty excavating
: Loading work
12-8
SPECIFICATIONS
Std. Specification
ZX48U-5A
A C
E
D
J
I
H
G
MADG-12-003
Model ZX48U-5A
Specification Canopy Cab
Type of Front-End
- Boom Swing Type, 1.69 m (5 ft 7 in) Arm
Attachment
Bucket Capacity (Heaped) m (yd )
3 3
0.11 (0.14)
Operating Weight kg (lb) 4760 (10490) 4890 (10780)
Base Machine Weight kg (lb) 3540 (7800) 3670 (8090)
4TNV88
Engine kW/min-1 28.2/2400
(PS/rpm) (38.3/2400)
A: Overall Width mm (ft·in) 1850 (6' 1'')
B: Overall Height mm (ft·in) 2530 (8' 4'')
C: Rear End Swing Radius mm (ft·in) 1080 (3' 7")
D: Minimum Ground
mm (ft·in) 340 (1' 1'')
Clearance
E: Counterweight
mm (ft·in) 610 (2')
Clearance
F: Engine Cover Height mm (ft·in) 1590 (5' 3'')
G: Undercarriage Length mm (ft·in) 2500 (8' 2'')
H: Undercarriage Width mm (ft·in) 1960 (6' 5'')
I: Sprocket Center to Idler
mm (ft·in) 2000 (6' 7'')
Center
J: Track Shoe Width mm (ft·in) 400 (1' 4'')
kPa 27 28
Ground Pressure
(kgf/cm2, psi) (0.27, 3.9) (0.28, 4.1)
Swing Speed min-1 (rpm) 9.0 (9.0)
Travel Speed (fast/slow) km/h (mph) 4.2/2.5 (2.6/1.6)
Gradeability 30° (tan θ = 0.58)
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.
The specifications include additional counterweight and extra attachment lines.
12-9
SPECIFICATIONS
Working Ranges
ZX48U-5A
G
K (Left) K (Right)
F J
MADC-12-005
ZX48U-5A
Category
Canopy Cab
Item
1.38 m Arm 1.69 m Arm 1.38 m Arm 1.69 m Arm
A: Maximum Digging Reach mm (ft·in) 5760 (18' 11") 6060 (19' 11") 5760 (18' 11") 6060 (19' 11")
B: Maximum Digging Depth mm (ft·in) 3320 (10' 11") 3630 (11' 11") 3320 (10' 11") 3630 (11' 11")
C: Maximum Cutting Height mm (ft·in) 5590 (18' 4") 5820 (19' 1") 5590 (18' 4") 5820 (19' 1")
D: Maximum Dumping Height mm (ft·in) 3910 (12' 10") 4140 (13' 7") 3910 (12' 10") 4140 (13' 7")
E: Overall Height mm (ft·in) 2530 (8' 2")
F: Overall Length mm (ft·in) 5350 (17' 7") 5390 (17' 8") 5350 (17' 7") 5390 (17' 8")
G: Minimum Swing Radius mm (ft·in) 2240 (7' 4") 2370 (7' 10") 2240 (7' 4") 2370 (7' 10")
H: Boom Swing Pivot Offset Distance mm (ft·in) 100 (4")
I: Blade Bottom Highest Position mm (ft·in) 460 (1' 6")
J: Blade Bottom Lowest Position mm (ft·in) 365 (1' 2")
K: Offset Distance mm (ft·in) L690 (2' 3")
R850 (2' 10")
Maximum Boom-Swing Angle L80° R60°
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
L: Left R: Right
12-10
SPECIFICATIONS
ZX48U-5A (Cab)
Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe
Shoe Width
400 mm 400 mm 400 mm 400 mm
For Paved Road For Ordinary Ground For Paved Road For Paved Road
Application
(Standard) (Optional) (Optional) (Optional)
Operating
(kg) 4890 5000 5190 5060
Weight
Minimum
Ground (mm) 340 320 360 360
Clearance
Undercarriage
(mm) 2500 2490 2540 2540
Length
Undercarriage
(mm) 1960 1960 1960 1960
Width
Ground
(kPa) 28 28 29 29
Pressure
(kgf/cm )
2
0.28 0.29 0.30 0.29
fNOTE:
The specifications for the front-end attachment are for 1.69 m arm with ISO 0.11 m3 bucket.
Rubber shoe, rubber pad shoe and pad crawler shoe should be used on paved road. Use of rubber crawlers on other than
paved road may shorten the service life of the rubber crawlers to a great extent.
Other than 400 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground
may cause serious damage to shoe, shoe bolts and other parts such as rollers.
The dimensions do not include the height of the shoe lug.
12-11
SPECIFICATIONS
fNOTE:
Symbols in the above table have the following meanings.
: General excavating
: Light duty excavating
: Loading work
12-12
SPECIFICATIONS
Std. Specification
ZX55U-5A
A C
E
D
J
I
H
G
MADG-12-003
Model ZX55U-5A
Specification Canopy Cab
Type of Front-End
- Boom Swing Type, 1.69 m (5 ft 7 in) Arm
Attachment
Bucket Capacity (Heaped) m (yd )
3 3
0.14 (0.18)
Operating Weight kg (lb) 5070 (11180) 5200 (11460)
Base Machine Weight kg (lb) 3830 (8440) 3960 (8730)
4TNV88
Engine kW/min-1 28.2/2400
(PS/rpm) (38.3/2400)
A: Overall Width mm (ft·in) 1850 (6' 1'')
B: Overall Height mm (ft·in) 2530 (8' 4'')
C: Rear End Swing Radius mm (ft·in) 1100 (3' 7")
D: Minimum Ground
mm (ft·in) 340 (1' 1'')
Clearance
E: Counterweight
mm (ft·in) 610 (2')
Clearance
F: Engine Cover Height mm (ft·in) 1590 (5' 3'')
G: Undercarriage Length mm (ft·in) 2500 (8' 2'')
H: Undercarriage Width mm (ft·in) 2000 (6' 7'')
I: Sprocket Center to Idler
mm (ft·in) 2000 (6' 7'')
Center
J: Track Shoe Width mm (ft·in) 400 (1' 4'')
kPa 29 29
Ground Pressure
(kgf/cm2, psi) (0.29, 4.2) (0.30, 4.2)
Swing Speed min-1 (rpm) 9.0 (9.0)
Travel Speed (fast/slow) km/h (mph) 4.2/2.5 (2.6/1.6)
Gradeability 30° (tan θ = 0.58)
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.
The specifications include additional counterweight and extra attachment lines.
12-13
SPECIFICATIONS
Working Ranges
ZX55U-5A
G
K (Left) K (Right)
F J
MADC-12-005
ZX55U-5A
Category
Canopy Cab
Item
1.38 m Arm 1.69 m Arm 1.38 m Arm 1.69 m Arm
A: Maximum Digging Reach mm (ft·in) 5960 (19' 7") 6260 (20' 7") 5960 (19' 7") 6260 (20' 7")
B: Maximum Digging Depth mm (ft·in) 3530 (11' 7") 3830 (12' 7") 3530 (11' 7") 3830 (12' 7")
C: Maximum Cutting Height mm (ft·in) 5750 (18' 10") 6000 (19' 8") 5750 (18' 10") 6000 (19' 8")
D: Maximum Dumping Height mm (ft·in) 4070 (13' 4") 4310 (14' 2") 4070 (13' 4") 4310 (14' 2")
E: Overall Height mm (ft·in) 2530 (8' 2")
F: Overall Length mm (ft·in) 5470 (17' 11") 5520 (18' 1") 5470 (17' 11") 5520 (18' 1")
G: Minimum Swing Radius mm (ft·in) 2210 (7' 3") 2300 (7' 7") 2210 (7' 3") 2300 (7' 7")
H: Boom Swing Pivot Offset Distance mm (ft·in) 100 (4")
I: Blade Bottom Highest Position mm (ft·in) 460 (1' 6")
J: Blade Bottom Lowest Position mm (ft·in) 365 (1' 2")
K: Offset Distance mm (ft·in) L690 (2'3")
R850 (2'10")
Maximum Boom-Swing Angle L80° R60°
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
L: Left R: Right
12-14
SPECIFICATIONS
ZX55U-5A (Cab)
Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe
Shoe Width
400 mm 400 mm 400 mm 400 mm
For Paved Road For Ordinary Ground For Paved Road For Paved Road
Application
(Standard) (Optional) (Optional) (Optional)
Operating
(kg) 5200 5310 5500 5370
Weight
Minimum
Ground (mm) 340 320 360 360
Clearance
Undercarriage
(mm) 2500 2490 2540 2540
Length
Undercarriage
(mm) 2000 2000 2000 2000
Width
Ground
(kPa) 29 30 31 30
Pressure
(kgf/cm )
2
0.30 0.31 0.32 0.31
fNOTE:
The specifications for the front-end attachment are for 1.69 m arm with ISO 0.14 m3 bucket.
Rubber shoe, rubber pad shoe and pad crawler shoe should be used on paved road. Use of rubber crawlers on other than
paved road may shorten the service life of the rubber crawlers to a great extent.
Other than 400 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground
may cause serious damage to shoe, shoe bolts and other parts such as rollers.
The dimensions do not include the height of the shoe lug.
12-15
SPECIFICATIONS
fNOTE:
Symbols in the above table have the following meanings.
: General excavating
: Light duty excavating
: Loading work
12-16
SPECIFICATIONS
Std. Specification
ZX65USB-5A
A C
E
D
J I
H
G
MADC-12-001
Model ZX65USB-5A
Specification Cab
Type of Front-End
- Boom Swing Type, 1.85 m (4 ft 11 in) Arm
Attachment
Bucket Capacity (Heaped) m (yd )
3 3
0.22 (0.29)
Operating Weight kg (lb) 6160 (13580)
Base Machine Weight kg (lb) 4440 (9790)
4TNV94L
Engine kW/min-1 34.1/2000
(PS/rpm) (46.4/2000)
A: Overall Width mm (ft·in) 1930 (6' 4")
B: Overall Height mm (ft·in) 2540 (8' 4'')
C: Rear End Swing Radius mm (ft·in) 1300 (4' 3")
D: Minimum Ground
mm (ft·in) 335 (1' 1'')
Clearance
E: Counterweight
mm (ft·in) 620 (2')
Clearance
F: Engine Cover Height mm (ft·in) 1600 (5' 3'')
G: Undercarriage Length mm (ft·in) 2500 (8' 2'')
H: Undercarriage Width mm (ft·in) 2000 (6' 7'')
I: Sprocket Center to Idler
mm (ft·in) 1990 (6' 6'')
Center
J: Track Shoe Width mm (ft·in) 400 (1' 4'')
kPa 35
Ground Pressure
(kgf/cm2, psi) (0.36, 5.1)
Swing Speed min-1 (rpm) 9.5 (9.5)
Travel Speed (fast/slow) km/h (mph) 4.8/2.9 (3.0/1.8)
Gradeability 30° (tan θ = 0.58)
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.
The specifications include additional counterweight and extra attachment lines.
12-17
SPECIFICATIONS
Working Ranges
ZX65USB-5A
G K (Left) K (Right)
I
J
F
A
B
MADC-12-002
ZX65USB-5A
Category
Cab
Item
1.50 m Arm 1.85 m Arm
A: Maximum Digging Reach mm (ft·in) 6230 (20' 5") 6560 (21' 6")
B: Maximum Digging Depth mm (ft·in) 3770 (12' 4") 4120 (13' 6")
C: Maximum Cutting Height mm (ft·in) 5960 (19' 7") 6190 (20' 4")
D: Maximum Dumping Height mm (ft·in) 4170 (13' 8") 4410 (14' 6")
E: Overall Height mm (ft·in) 2540 (8' 4")
F: Overall Length mm (ft·in) 5760 (18' 11") 5790 (19')
G: Minimum Swing Radius mm (ft·in) 2450 (8' 1") 2540 (8' 4")
H: Boom Swing Pivot Offset Distance mm (ft·in) 45 (2")
I: Blade Bottom Highest Position mm (ft·in) 450 (1' 6")
J: Blade Bottom Lowest Position mm (ft·in) 390 (1' 3")
K: Offset Distance mm (ft·in) L720 (2' 4")
R850 (2' 9")
Maximum Boom-Swing Angle L80° R60°
fNOTE:
The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
L: Left R: Right
12-18
SPECIFICATIONS
fNOTE:
The specifications for the front-end attachment are for 1.85 m arm with ISO 0.22 m3 bucket.
Rubber shoe, rubber pad shoe and pad crawler shoe should be used on paved road. Use of rubber crawlers on other than
paved road may shorten the service life of the rubber crawlers to a great extent.
Other than 400 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground
may cause serious damage to shoe, shoe bolts and other parts such as rollers.
The dimensions do not include the height of the shoe lug.
12-19
SPECIFICATIONS
fNOTE:
Symbols in the above table have the following meanings.
: General excavating
: Light duty excavating
: Loading work
12-20
SPECIFICATIONS
Unit: dB(A)
Cab Canopy
LwA LpA LwA LpA
ZX33U-5A 95 75 95 −
ZX38U-5A 95 75 95 −
ZX48U-5A 96 75 96 −
ZX55U-5A 96 75 96 −
ZX65USB-5A 97 76 − −
Vibration Level
Hands/Arms: T he acceleration to which the operator's
hands and arms will be exposed is lower than
2.5 m/s².
Electric Fans
We consider our products exempted from EU regulation
327/2011, implementing EU directive 2009/125/EC, based on
the fact that the fans are considered battery powered as the
energy supply recharging the battery is not continuous nor at
a constant level.
12-21
SPECIFICATIONS
Lifting Capacities
fNOTE:
Lifting capacity of the ZX series does not exceed 75 % of
tipping load with the machine on firm, level ground or 87 %
of full hydraulic capacity. (ISO 10567)
Net lifting capacities are equal to the values obtained by
deducting the ATT mass from the values described in the
table below.
ZX33U-5A Z (m)
Boom 2.28 m, Counterweight 560 kg*
*Include additional counterweight 190 kg.
4
Canopy Unit; kg
X MAX 3
Arm 1 2 3 4 Z2
Z REACH [m]
Z2 1160 590 390 370 4.17
2
1.17 m Z1 1010 560 380 4.00
Z3 1860 980 560 470 3.47
Z2 580 390 320 4.50 1
2
Z3
Cab Unit; kg 3
X MAX 0 1 2 3 4 5
Arm 1 2 3 4 X (m)
Z REACH [m]
Z2 1230 620 420 390 4.17 MADC-12-009
12-22
SPECIFICATIONS
ZX38U-5A Z (m)
2
Z3
3
Cab Unit; kg
0 1 2 3 4 5
X MAX X (m)
Arm 1 2 3 4
Z REACH [m]
MADC-12-010
Z2 1610 860 570 480 4.49
1.32 m Z1 1380 830 560 500 4.34
Z3 1870 1530 820 590 3.86
Z2 860 570 420 4.87
1.72 m Z1 1420 810 550 430 4.73
Z3 1430 1490 800 540 490 4.31
12-23
SPECIFICATIONS
ZX48U-5A Z (m)
2 Z3
Cab Unit; kg 3
0 1 2 3 4 5
X MAX
Arm 2 3 4 5 X (m)
Z REACH [m]
MADC-12-006
Z2 1130 760 570 4.91
1.38 m Z1 1100 740 590 4.73
Z3 2130 1100 740 680 4.25
Z2 1130 750 540 510 5.21
1.69 m Z1 1080 720 530 520 5.04
Z3 2070 1070 710 590 4.60
12-24
SPECIFICATIONS
ZX55U-5A Z (m)
2
Z3
Cab Unit; kg 3
X MAX
Arm 2 3 4 5 0 1 2 3 4 5
Z REACH [m]
X (m)
Z2 1320 890 650 630 5.11
MADC-12-007
1.38 m Z1 1290 870 650 4.94
Z3 2510 1290 860 750 4.49
Z2 1320 880 640 570 5.41
1.69 m Z1 1270 850 620 580 5.26
Z3 2280 1260 840 650 4.84
12-25
SPECIFICATIONS
ZX65USB-5A Z (m)
X MAX
Arm 2 3 4 5 4
Z REACH [m]
Z2
Z2 1530 1030 760 690 5.32 3
1.50 m Z1 1480 1000 740 710 5.14
Z3 2900 1490 990 810 4.70 2
Z2 1540 1030 750 620 5.65
1
1.85 m Z1 1460 980 720 640 5.48
Z3 2640 1450 970 720 710 5.08 0 Z1
Z3
3
0 1 2 3 4 5
X (m)
MADC-12-008
12-26
OPTIONAL ATTACHMENT
HYDRAULIC BREAKER, HYDRAULIC CRUSHER AND QUICK COUPLER
13-1
OPTIONAL ATTACHMENT
HYDRAULIC BREAKER, HYDRAULIC CRUSHER AND QUICK COUPLER
Attachment
Allowable Weight Limits of Installed Attachment
dWARNING:
When an attachment other than the standard bucket
is installed on the machine, the machine stability will
be different.
If a heavy attachment is used, not only will
controllability be affected but also machine stability
will be reduced, possibly causing safety hazard.
Before installing attachments such as hydraulic
breaker, crusher (concrete crusher), or pulverizer,
take machine controllability into account when
selecting the weight of the attachment by referring
to the table below.
According to the specifications of installed
attachment and the base machine, the machine
weight may exceed the allowable maximum
operating weight of the ROPS, making the ROPS
unable to assure the protective function for operator.
Refer to the ROPS certification affixed in the cab for
the allowable maximum operating weight.
(Unit: kg)
Base Machine Breaker Crusher/Pulverizer
Specification
Model Arm Std.Weight Max.Weight Std.Weight Max.Weight
Std. 200 220 240 280
ZX33U-5A
Long 180 190 210 250
Std. 250 280 300 350
ZX38U-5A
Long 220 240 260 300
Zero Tail Swing Std. 320 350 390 450
ZX48U-5A
Model Long 290 320 350 410
Std. 370 400 440 510
ZX55U-5A
Long 330 360 400 460
Std. 460 500 550 640
ZX65USB-5A
Long 410 450 490 580
(without additional counterweight)
Breaker operation speed is faster than crusher operation
so that the recommended breaker max. weights are
reduced more than those of the crushers.
Avoid installing an attachment with a long overall length.
Damage to the front attachment may result.
When an attachment of the max. weight is installed,
always operate the attachment over the front or rear
side of the machine. In addition, avoid operating the
attachment at the maximum reach.
Crushers are heavier than breakers. Slowly move the
control lever when operating a crusher.
13-2
OPTIONAL ATTACHMENT
PIPING FOR BREAKER AND CRUSHER
MADB-13-001 MADB-13-002
A: Selection Valve
Remove a rubber cap and change the attachment.
B, C: Stop Valves
Pedal Operation and Hydraulic Oil Flow
When the pedal is depressed to “D” side, hydraulic oil
Close flows into line “B”.
When the pedal is depressed to “E” side, hydraulic oil
flows into line “C”.
MADB-13-005
E D
Open
MADB-13-006
Stop Valves B, C
Close : When not using attachment or is detached.
MADB-13-041
Open : When using attachment.
13-3
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC BREAKER)
Neutral
LOCK
1 MADB-13-040
position
13-4
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC BREAKER)
MZX5-13-003
13-5
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC BREAKER)
MZX5-13-017
MZX5-13-004
Do not operate the breaker to the side of the machine.
The machine may become unstable and undercarriage
component life may shorten as a result from operating the
breaker to the side of the machine.
MZX5-13-005
13-6
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC BREAKER)
M1M7-05-023
MZX5-13-006
Press the breaker so that the chisel (the axis) is
positioned and thrust perpendicular to the object.
Failure to do so may damage the chisel or may cause seized
piston.
MZX5-13-007
13-7
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC BREAKER)
M147-05-016
OK
MADB-13-044
13-8
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC CRUSHER)
Lock
Open
Forward
LOCK
position
Neutral
LOCK
1 MADB-13-040
position
13-9
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC CRUSHER)
MZX5-13-009
13-10
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC CRUSHER)
Watch Out!
Take care not to hit the
boom with the crusher
MZX5-13-010
When operating the crusher up high with the boom fully
raised, be careful of falling objects.
MZX5-13-012
13-11
OPTIONAL ATTACHMENT
ATTACHMENT PEDAL (HYDRAULIC CRUSHER)
13-12
OPTIONAL ATTACHMENT
AUX FUNCTION LEVER FOR EXTRA PIPING 1
2. Auxiliary
3. Breaker Switch
4. Horn Switch
13-13
OPTIONAL ATTACHMENT
AUX FUNCTION LEVER FOR EXTRA PIPING 2
dWARNING: 1
2. Assist Operation
3. Assist Operation (Same as left end)
13-14
OPTIONAL ATTACHMENT
AUXILIARY PIPING FLOW RATE SELECTOR
Extra Piping 1
ZX33U-5A ZX48U-5A ZX65USB-5A
ZX38U-5A ZX55U-5A
LOW 38.4 L/min 45 L/min 45 L/min
HIGH 61.2 L/min 85 L/min 91.5 L/min
fNOTE: Flow rate of the auxiliary pipe line 2 is fixed. Its flow
rate can not be selected with flow rate selector (1).
Extra Piping 2
ZX33U-5A ZX48U-5A ZX65USB-5A
ZX38U-5A ZX55U-5A
22.8 L/min 45 L/min 45 L/min 1
Lock
M1M7-05-025
13-15
OPTIONAL ATTACHMENT
CONTROL LEVER (H-PATTERN: HITACHI EXCAVATOR PATTERN)
MADB-01-062
MADM-13-008
4- Arm Roll-In
M1M7-05-001
5- Boom Lower 6
6- Boom Raise
8
7- Bucket Roll-In
8- Bucket Roll-Out 5
M1M7-05-002
13-16
OPTIONAL ATTACHMENT
CONTROL LEVER (SAE-BACKHOE PATTERN)
dWARNING: 1 5
Make sure you know the location and function
of each control lever before operating. The
upperstructure and/or front attachment may 3 4 7 8
unexpectedly move in an attempt to look back
because a part of operator’s body may come into
contact with the control lever(s). Take care not to 2 6
come into contact with the control levers when
looking back.
Whenever changing the pattern, stop the engine,
rotate the selector valve, and set to the pattern
position.
4
3
MADG-05-006
1
1- Boom Lower
2- Boom Raise MADG-05-002
3- Swing Left
4- Swing Right
5- Arm Roll-Out
6- Arm Roll-In 5
8
7- Bucket Roll-In
8- Bucket Roll-Out
6
MADG-05-002
13-17
OPTIONAL ATTACHMENT
FUEL FEED DEVICE
13-18
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
13-19
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
Unlocking
1. Turn key switch (1) ON. Then, all numeric keys (2) are lit.
Input the password within 15 seconds.
2. Buzzer will sound and unlocking indicator (3) (green
LED) will be lit. When security indicator (4) is displayed
on the monitor screen, the engine is able to start.
MADB-01-007
Locking
After key switch (1) is turned OFF, the machine will be
locked automatically after the lapse of time set (user
defined) for lock delay timer. While the lock delay timer is 3
working, the machine is locked immediately by pushing
any of numeric keys (1 – 9, 0, F, or C). Besides, while the
lock delay timer is working, unlocking indicator (3) keeps
blinking.
MADB-13-010
MADC-13-006
13-20
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
13-21
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
Unlocking
1. Turn key switch (1) ON. Then, all numeric keys (2) are lit.
2. Input the 1st digit of the four-digit password. 1
3. Similarly, input the 2nd digit.
4. Similarly, input the 3rd digit.
5. Similarly, input the 4th digit.
6. If the input numerals coincide with those of the
MADB-01-007
password, the buzzer sounds twice, and unlocking is
done. In this condition, when key switch (1) is turned ON,
the engine will start.
2
MADB-13-012
MADB-13-013
13-22
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
Change Password
Cancel the registered password, and set a new password.
1
1. Turn key switch (1) to the ON position.
2. Unlock the numeric keypad.
3. Push Key F (2) and Key 1 (3) simultaneously for more
than 2 seconds.
4. Two indicators (4) and (5) blink simultaneously, and the MADB-01-007
buzzer sounds.
5. Input new 4-digit password. After inputting, two
indicators (4) and (5) are lit, and the buzzer sounds twice.
3
6. Once again, re-enter the new password. (the same
password as that in Item 5)
When the new password is properly input, two indicators
(4) and (5) blink, and the numerals of the new password
are lit in turn. After blinking the new password, the
password can be displayed by pushing Key C (6).
5 4
MADB-13-015
5 4
6 2
MADB-13-015
13-23
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
5 4
6
MADB-13-015
13-24
OPTIONAL ATTACHMENT
NUMERIC KEYPAD LOCK
Alarm Function
If an incorrect password is input four times, buzzer and horn
will sound to warn the operator. Horn and buzzer will keep
1
sounding for predetermined period of time even key switch
(1) is turned OFF.
After that, horn and buzzer will sound to warn the operator
every time key switch (1) is turned ON until the correct
password is input.
MADB-01-007
System Error Display
In case any abnormality occurs on the system, two
indicators blink alternately.
Consult your authorized Hitachi dealer.
13-25
OPTIONAL ATTACHMENT
ADDITIONAL COUNTERWEIGHT
Additional Counterweight
The mass values of additional counterweights (1) are shown in
the table below.
Model Weight Overhang from the end of the
base machine
ZX33U-5A 190 kg 100 mm
ZX38U-5A 230 kg 110 mm
ZX48U-5A 200 kg 100 mm
ZX55U-5A 200 kg 100 mm
ZX65USB-5A 270 kg 110 mm
Removal
Remove additional counterweight (1) by following the
procedure below.
Installation 3
13-26
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
dCAUTION:
Wear safety equipments appropriate to the job such as a hard hat, gloves and protective shoes.
Sufficiently illuminate the work site and work under well-lighted area. Work under low light condition can
lead misoperation.
Take care not to allow grease to contact with skin. If grease contacts with skin, wash away with a lot of water
and soap.
Severe burns may result if skin comes in contact with hot parts immediately after operation. Before starting
to work, stop the engine and make sure all parts have sufficiently cooled down.
When checking or servicing the machine by using the cab tilting function, tilt up the cab with the cab tilting
device. Thoroughly read this manual before operating the cab tilting device. Incorrect operation may cause
cab falling, possibly resulting in serious accident.
Do not use the cab tilting device other than cab tilt up/down operation. Do not use the cab tilting device
other than the applicable machines.
Be sure to check that no personnel are present around the machine and in the cab before using the cab
tilting device.
Never attempt to operate the cab tilting device for daily check. The daily inspection can be performed
through the maintenance cover ports.
IMPORTANT: Never attempt to modify the machine other than the authorized personnel. If a bolt is removed/
installed by unauthorized personnel, mismatch to ROPS may occur.
MADC-017
4
3
MADC-013
13-27
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
6. Stop the engine. Remove the key from the key switch.
7. Close the cab (optional) door.
3
4
5
2
ZX33U-5A, 38U-5A MADB-13-018
3 4
5
2 MADB-13-019
ZX48U-5A, 55U-5A, 65USB-5A
13-28
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
10. Remove bolts (6) (not covered with resin caps) in the rear ZX33U-5A, 38U-5A, 48U-5A, 55U-5A
section of the operator's seat.
dCAUTION:
If bolts other than bolt (6) are removed, the canopy
or the cab (optional) may come off the floor,
resulting in unexpected accident.
Care should be taken that if the floor is tilted upward
while raising the front attachment, the canopy or cab
(optional) may come in contact with the boom.
Wrench size: 13 mm
17 mm
19 mm
6
6 Cab (4 positions) MADC-13-002 Canopy (2 positions at the rear) MADB-13-023
13-29
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
11. Install hose protection rubber (8) while taking care not to
damage hose (7) at the cab tilting device mounting area.
12. Install cab tilting device (10) through openings (9) on the
machine. 7
8 MADC-018
MADC-019
10
MADB-13-024
13-30
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
Wrench size: 17 mm
13
Set Condition
MADB-13-026 MADB-13-027
14
15
MADB-13-028
16
MADB-13-029
13-31
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
MADB-13-030
17
19
MADB-13-031
13-32
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
dWARNING:
Be sure to tilt down the cab after checking or Fall Prevention Bar
servicing. At this time, be sure to store the fall
prevention bar first, and then slowly tilt down the
cab. If the fall prevention bar is not stored before
tilting down the cab, the cab tilting device may be
broken.
Perform cab tilt down operation manually. Do not
use compressed air or electrical tools. If adjusting
screw (1) is quickly turned by using compressed air MADC-016
or electrical tool, the floor will rapidly lowered and it
may severely vibrate, potentially creating hazardous
conditions.
Wrench size: 17 mm
MADB-13-032
Storage Condition
MADB-13-033
MADB-13-034
13-33
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
Maintenance
Check Tilt Mechanism Fulcrum Bolts and Working
Screw Lock Nut
--- Before Use
1. Check tilt mechanism fulcrum bolts (1) for looseness. If
bolt (1) is loose, retighten bolt (1) to 10 N·m (1.0 kgf·m).
2. Check working screw lock nut (2) for looseness.
If lock nut (2) is loose, retighten nut (2) to 140 N·m 2
(14kgf·m).
MADB-13-035
13-34
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
Greasing
--- Before Use
1. Rotate adjuster (1) counterclockwise to fully extend the
tilt device.
MADB-13-029
2. Apply grease all over the thread part of screw (2) of
adjuster (1).
Recommended Dow Corning Toray Co., Ltd.
grease: MOLYKOTE® EM-30L
2
1
MADB-13-036
13-35
OPTIONAL ATTACHMENT
CAB TILTING MECHANISM
MEMO
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13-36
INDEX
A Bucket Types and Applications ZX33U-5A .......................... 12-4
Access Covers....................................................................................7-8 Bucket Types and Applications ZX38U-5A .......................... 12-8
Additional Counterweight ....................................................13-26 Bucket Types and Applications ZX48U-5A ........................12-12
Adjust the Operator’s Seat ...........................................................S-6 Bucket Types and Applications ZX55U-5A ........................12-16
Adjust Track Sag (Rubber Crawler) and Check for Bucket Types and Applications ZX65USB-5A ...................12-20
Damage ..................................................................................... 7-79 C
Adjusting the Seat........................................................................ 1-44
COMPONENTS NAME .....................................................................1-1
Air Cleaner ...................................................................................... 7-60
Cab Tilting Mechanism .............................................................13-27
Air Conditioner Operation (Optional) ................................... 1-35
Change Bucket .............................................................................. 7-78
Alarm List Display ......................................................................... 1-15
Change Coolant ............................................................................ 7-67
Alarm Occurrence Screen .......................................................... 1-14
Change Engine Oil ...................................................................... 7-25
Alternator Indicator (3) ..................................................................1-8
Change Hydraulic Oil .................................................................. 7-37
AM/FM Radio Operation (Cab equipped machine) ....... 1-39
Change Trip Meter Set Time .................................................... 1-28
Attachment..................................................................................... 13-2
Check Air Conditioner (Cab equipped machine) .............. 7-87
Attachment Pedal (Hydraulic Breaker) (Optional) ............ 13-4
Check and Adjust Fan Belt Tension ....................................... 7-64
Attachment Pedal (Hydraulic Crusher) (Optional)............ 13-9
Check and Adjust Injection Timing ....................................... 7-95
Auto-Idle .............................................................................................5-9
Check and Replace Bucket Teeth ............................................ 7-76
Auto-Idle ON/OFF......................................................................... 5-10
Check and Replace Seat Belt .................................................... 7-86
AUX Function Lever for Extra Piping 1 (Optional)...........13-13
Check Coolant Level .................................................................... 7-63
AUX Function Lever for Extra Piping 2 (Optional)...........13-14
Check Crankcase Breather ........................................................ 7-95
Auxiliary Piping Flow Rate Selector (Optional) ................13-15
Check Electrolyte Specific Gravity .......................................... 7-74
Avoid Abusive Operation .......................................................... 5-15
Check Fuel Hoses .......................................................................... 7-59
Avoid Applying Heat to Lines Containing Flammable
Check Fuel Level ........................................................................... 7-53
Fluids ........................................................................................... S-32
Check Hoses and Lines ............................................................... 7-45
Avoid Colliding Blade Against Rocks..................................... 5-18
Check Hydraulic Oil Level .......................................................... 7-35
Avoid Colliding Boom Cylinder With Track.......................... 5-18
Check Instruments After Starting Engine ...............................3-5
Avoid Driving Bucket Teeth into Ground ............................. 5-16
Check Radiator Cap .................................................................... 7-95
Avoid Excavation Using Upperstructure and/or Boom
Check Rubber Track for Damage ............................................ 7-79
Swing Power ............................................................................. 5-15
Check Starter and Alternator ................................................... 7-95
Avoid Heating Near Pressurized Fluid Lines ....................... S-32
Check the Hour Meter Regularly................................................7-2
Avoid High-Pressure Fluids ....................................................... S-28
Check Tilt Mechanism Fulcrum Bolts and Working
Avoid Hitting Blade With Bucket............................................. 5-18
Screw Lock Nut ....................................................................13-34
Avoid Injury from Attachment Falling Accident ............... S-26
Check Track Sag (Steel Crawler) (Optional) ......................... 7-83
Avoid Injury From Back-over and Swing Accidents ......... S-15
Check Water Separator .............................................................. 7-54
Avoid Injury From Rollaway Accidents ................................. S-14
Check, Clean and Function Check of Injection Nozzle .. 7-95
Avoid other than Specified Machine Operations ............. 5-22
Clean Air Cleaner Outer Element ............................................ 7-60
Avoid Power Lines ........................................................................ S-18
Clean Air Conditioner Condenser .......................................... 7-70
Avoid Striking With Bucket ....................................................... 5-16
Clean Air Conditioner Condenser Front Screen ................ 7-70
Avoid Tipping................................................................................. S-17
Clean and Replace Heater / Air Conditioner Filter............ 7-90
Avoid Undercutting ..................................................................... S-16
Clean Cab Floor ............................................................................. 7-94
B Clean Circulating Air Filter......................................................... 7-90
BREAK-IN.............................................................................................2-1 Clean Fresh Air Filter......................................................... 7-92, 7-93
Basic Screen .......................................................................................1-7 Clean Radiator/Oil Cooler Core ............................................... 7-69
Batteries ........................................................................................... 7-71 Clock....................................................................................... 1-13, 1-21
Before Starting Engine ..................................................................3-2 Clock Adjustment ......................................................................... 1-21
Beware of Asbestos and Silicon Dust and Other Components Name ........................................................................1-1
Contamination ......................................................................... S-33 Confirm Direction of Machine to be Driven ....................... S-11
Beware of Exhaust Fumes.......................................................... S-31 Contents of Alarms ...................................................................... 1-16
Blade Lever ........................................................................................5-3 Control Lever (H-pattern: HITACHI Excavator
Blade Pins ........................................................................................ 7-21 Pattern) .....................................................................................13-16
Bleed Air from Fuel System ....................................................... 7-54 Control Lever (ISO Pattern) ..........................................................5-1
Boom Cylinder may Hit Blade .................................................. 5-17 Control Lever (SAE-backhoe Pattern)..................................13-17
Boom-Swing Pedal..........................................................................5-2 Control Lever Universal Joint ................................................... 7-23
Breaking in New Machine ............................................................2-1 Converting the Track ................................................................... 7-85
Brightness Adjustment............................................................... 1-30 Coolant Temperature Gauge .................................................... 1-13
Bucket ............................................................................................... 7-19 Cooling Operation ....................................................................... 1-36
14-1
INDEX
Cooling System.............................................................................. 7-62 H
Correct Maintenance and Inspection Procedures................7-1 Handle Chemical Products Safely............................................ S-35
D Handle Fluids Safely --- Avoid Fires......................................... S-21
Heater Operation (ZX33U-5A, 38U-5A, 48U-5A,
DRIVING THE MACHINE..................................................................4-1
55U-5A)........................................................................................ 1-32
Defroster Operation.......................................................... 1-33, 1-36
Heating Operation ........................................................... 1-33, 1-36
Deletion of Preset Memory . ..................................................... 1-40
Hour Meter....................................................................................... 1-13
Dig With Caution........................................................................... S-18
How to Use Screens.........................................................................1-9
Digital Clock Setting Procedure............................................... 1-41
Hydraulic Breaker, Hydraulic Crusher and Quick
Display Mode Setting.................................................................. 1-23
Coupler........................................................................................ 13-1
Displaying Basic Screen.................................................................1-9
Hydraulic System........................................................................... 7-31
Displaying Trip Meter (1) ........................................................... 1-25
Displaying Trip Meter (2) ........................................................... 1-27 I
Dispose of Waste Properly.......................................................... S-35 Indicators.............................................................................................1-8
Door Lock Release Lever (Cab equipped machine).......... 1-42 Inspect and Adjust Valve Clearance ...................................... 7-95
Drain Fuel Tank Sump.................................................................. 7-55 Inspect Machine...............................................................................S-4
Drain Hydraulic Oil Tank Sump................................................. 7-36 Inspect Machine Daily Before Starting.....................................3-1
Drive Machine Safely.................................................................... S-12 Inspection and Maintenance of Hydraulic Equipment.... 7-31
DTC Code List . ............................................................................... 1-18 Installing Rubber Crawler........................................................... 7-82
E Investigate Job Site Beforehand.............................................. S-10
Electric Fans...................................................................................12-21 J
Electrical System............................................................................ 7-71 Jump Starting....................................................................................S-8
Emergency Boom Lowering Procedure................................ 5-24
Emergency Exit (Cab equipped machine) . ......................... 1-45 K
Engine................................................................................................ 7-24 Keep Person Clear From Working Area.................................. S-16
Engine Oil Level............................................................................. 7-24 Keep Riders Off Machine...............................................................S-8
Engine Oil Pressure Indicator (2).................................................1-8 Key Switch...........................................................................................1-5
Engine Speed Control.....................................................................5-8 Kind of Oils....................................................................................... 7-16
Ensure Safety Before Rising From or Leaving Operator’s L
Seat..................................................................................................S-6 Layout.......................................................................................... 1-3, 7-3
Equipment of OPG........................................................................ S-11 Lifting Capacities.........................................................................12-22
Error Code........................................................................................ 1-16 Lifting Machine.................................................................................6-7
Error Display Screen..................................................................... 1-14 Loading/Unloading on a Truck....................................................6-2
Evacuating in Case of Fire........................................................... S-31
M
F
MACHINE NUMBERS............................................................................1
Fasten Your Seat Belt.......................................................................S-7 MAINTENANCE..................................................................................7-1
Fastening Machine for Transporting.........................................6-5 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
Feature.................................................................................................1-6 CONDITIONS.................................................................................9-1
Follow Safety Instructions.............................................................S-2 Main Menu (MENU) ..................................................................... 1-20
For Rapid Cooling.......................................................................... 1-37 Maintenance.................................................................................13-34
Front Joint Pins............................................................................... 7-19 Maintenance Guide...................................................................... 7-11
Front Window ................................................................................ 1-43 Maintenance Guide Table..............................................................7-4
Fuel Feed Device (Optional) (ZX48U-5A, 55U-5A, Maintenance Under Special Environmental Conditions....9-1
65USB-5A).................................................................................13-18 Measure Engine Compression Pressure . ............................. 7-95
Fuel Gauge....................................................................................... 1-13 Miscellaneous................................................................................. 7-76
Fuel Level Indicator (4)...................................................................1-8 Monitor................................................................................................1-6
Fuel System...................................................................................... 7-52 Move and Operate Machine Safely............................................S-7
Functions of Trip Meter .............................................................. 1-24
N
G
Name and Function of Each Part of Control
GETTING ON/OFF THE MACHINE................................................1-2 Panel.................................................................................. 1-32, 1-35
General Precautions for Cab.........................................................S-5 Never Position Bucket Over Anyone...................................... S-16
Getting ON/OFF the Machine......................................................1-2 Never Ride Attachment............................................................... S-36
Grading Operation........................................................................ 5-14 Never Undercut a High Bank..................................................... S-17
Greasing...............................................................................7-19, 13-35 Noise Level Results.....................................................................12-21
Numeric Keypad Lock (Optional) ........................................13-19
14-2
INDEX
O Recommended Fuel..................................................................... 7-52
OPERATING THE ENGINE................................................................3-1 Releasing Hose Rupture Valve (Machine Equipped
OPERATING THE MACHINE............................................................5-1 with Hose Rupture Valve)...................................................... 5-25
OPERATOR’S STATION.....................................................................1-3 Remove Paint Before Welding or Heating............................ S-33
OPTIONAL ATTACHMENT........................................................... 13-1 Removing and Storing Lower Front Window...................... 1-43
Object Handling............................................................................ S-19 Removing Rubber Crawler......................................................... 7-81
Off-Season Air Conditioner Maintenance............................ 1-37 Replace Air Cleaner Inner Element (Optional).................... 7-60
Opening Upper Front Window (Cab equipped Replace Air Cleaner Outer and Inner Elements.................. 7-60
machine) .................................................................................... 1-43 Replace Circulating Air Filter..................................................... 7-90
Operate Only From Operator’s Seat...........................................S-8 Replace Engine Oil Filter............................................................. 7-25
Operate With Caution.................................................................. S-18 Replace Fresh Air Filter..................................................... 7-92, 7-93
Operating Backhoe....................................................................... 5-13 Replace Fuel Main Filter Element............................................ 7-56
Operating in Water or Mud...........................................................4-8 Replace Fuel Pre-Filter Element (Optional).......................... 7-57
Operating Status Icon Display.................................................. 1-13 Replace Full-Flow Filter............................................................... 7-41
Overheat Indicator (1).....................................................................1-8 Replace Pilot Oil Filter Element................................................ 7-43
Replace Rubber Crawler ............................................................ 7-81
P Replace Rubber Hoses Periodically......................................... S-28
Park Machine Safely...................................................................... S-20 Replacing Fuses............................................................................. 7-75
Parking the Machine.................................................................... 4-10 Restriction of Attachment Installation.................................. S-11
Parking the Machine on Slopes................................................ 4-10 Room Lamp (Cab equipped machine)................................... 1-46
Part Name and Function . .......................................................... 1-39
Periodic Replacement of Parts.................................................. 7-15 S
Pilot Control Shut-Off Lever.........................................................5-5 SAFETY.................................................................................................S-1
Piping for Breaker and Crusher (Optional) ......................... 13-3 SAFETY SIGNS................................................................................. S-42
Power Mode.................................................................................... 5-11 SPECIFICATIONS............................................................................. 12-1
Practice Safe Maintenance......................................................... S-23 STORAGE........................................................................................... 10-1
Precaution for Communication Terminal Equipment...... S-37 Safety Transporting...................................................................... S-22
Precautions for After Operations............................................. 5-27 Screen Configuration......................................................................1-6
Precautions for Blade Operation.................................................5-4 Seat Back Box.................................................................................. 1-44
Precautions for Breaker Operation.......................................... 13-5 Seat Belt............................................................................................ 1-46
Precautions for Communication Terminal............................ S-36 Seat Fore-aft Adjustment........................................................... 1-44
Precautions for Crusher Operation.......................................13-10 Shackle Bracket Usage................................................................. 5-23
Precautions for Handling Accumulator and Gas Shoe Types and
Damper........................................................................................ S-32 Applications............................12-3, 12-7, 12-11, 12-15, 12-19
Precautions for Handling Refrigerant.................................... S-34 Sound Adjustment........................................................................ 1-41
Precautions for Installing Wide Bucket or Special Type Starting the Engine..........................................................................3-3
Bucket.......................................................................................... 5-18 Station Presetting Procedure.................................................... 1-40
Precautions for Lightning........................................................... S-19 Stay Clear of Moving Parts......................................................... S-25
Precautions for Operations...........................................................S-9 Std. Specification.......................... 12-1, 12-5, 12-9, 12-13, 12-17
Precautions for Traveling on Slopes..........................................4-9 Stopping the Engine.......................................................................3-8
Precautions for Welding and Grinding.................................. S-32 Storing the Machine..................................................................... 10-1
Preparations for Inspection and Maintenance......................7-7 Suction Filter Cleaning................................................................ 7-37
Prepare For Emergencies...............................................................S-3 Support Machine Properly......................................................... S-25
Prevent Battery Explosions........................................................ S-34 Swing Bearing................................................................................. 7-22
Prevent Burns.................................................................................. S-27 Swing Internal Gear...................................................................... 7-23
Prevent Fires.................................................................................... S-29 Swing Post and Others................................................................ 7-19
Prevent Parts From Flying.......................................................... S-26 Switch Panel ......................................................................................1-5
Protect Against Flying Debris................................................... S-20 T
Protect Against Noise.....................................................................S-4
TRANSPORTING.................................................................................6-1
Provide Signals for Jobs Involving Multiple Machines.... S-11
TROUBLESHOOTING..................................................................... 11-1
R Tightening and Retightening Torque of Bolts and
Radio (Cab equipped machine) (Optional).......................... 1-38 Nuts............................................................................................... 7-96
Radio Operation ........................................................................... 1-39 Tips for Optimal Air Conditioner Usage................................ 1-37
Raise One Track by Using Boom and Arm...............................4-6 Tips for Optimal Heater Usage................................................. 1-34
Recognize Safety Information.....................................................S-1 Tool Box ........................................................................................... 1-44
Recommended Engine Oil......................................................... 7-16 Towing Machine...............................................................................4-7
14-3
INDEX
Transmission................................................................................... 7-28
Transporting by Road.....................................................................6-1
Travel Levers and Pedals (Optional)...........................................4-1
Travel Mode Switch.........................................................................4-3
Travel Reduction Gear................................................................. 7-28
Traveling..............................................................................................4-4
Traveling on Soft Ground..............................................................4-5
Trip...................................................................................................... 1-24
Troubleshooting............................................................................ 11-1
Tuning Procedure.......................................................................... 1-40
U
Understand Signal Words..............................................................S-1
Unloading...........................................................................................6-6
Use Correct Track Shoe................................................................ 5-19
Use Handrails and Steps................................................................S-5
Using Booster Battery.....................................................................3-6
Using Rubber Crawler.................................................................. 5-20
V
VISIBILITY MAP............................................................................... S-39
Vibration Level..............................................................................12-21
W
Warming Up Operation..................................................................5-7
Warn Others of Service Work.................................................... S-24
Warning Codes . ............................................................................ 1-16
Warning Display Screen.............................................................. 1-14
Wear Protective Clothing..............................................................S-3
When Windows Become Clouded................................ 1-34, 1-37
Working Ranges..........................12-2, 12-6, 12-10, 12-14, 12-18
14-4
CONFORMITY
The EU Declaration of Conformity includes the machine
without accessory, unless fitted with accessories approved
by Hitachi Construction Machinery.
The EU Declaration of Conformity will lose its validity for
any modification of the machine without approval.
Aboma bv
Maxwellstraat 49A, PO Box 141, NL-6710 BC Ede
Country : The Netherlands