Subject: ZX120-5A ZX870-5A-201

Page 1 of 6
SERVICE BULLETIN CODE

DESCRIPTION
3 2016 0005
FILING LOCATION
ZX120-5A～
SUBJECT ZX870-5A-201
HIGH-ALTITUDE OPERATION OF ZX-5A
OUTLINE
This Service Bulletin is to provide you with information on the modifications that should be taken to
operate the machine at a high-altitude work site, 2000m or higher. We ask that you follow this
Service Bulletin to explain to your customers before undertaking the modifications.
Changes to the oil replacement interval, inactivation of HP mode, pump torque lowering,
maintenance enforcement
＊ Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.
＊ After replacing the main hydraulic equipment or engine or after post-assembling the aforementioned as an
option, be sure to change and register the post-assembled device serial number on Global e-Service (MMR,
HR, MME, G-Claim).
APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX120-5A ～ ZX870-5A
Machine Serial Nos.: ZX120-5A/ZX170-5A/ZX200-5A/ZX240-5A/ZX300-5A/ZX330-5A/

ZX470-5A/ZX670-5A/ZX870-5A
STD. LABOR HOURS

―
EXPENSES AND THE TIME TO BE CHARGED

―
PARTS
―
DESCRIPTION
Refer to the following page(s).
DWN
CHKD
SA/GI: ZX-5(All)-117 APPD
Page 2 of 6
DESCRIPTION
3 2016 0005
FILING LOCATION
ZX120-5A～
ZX870-5A-201
CONTENTS
1 Outline …………………….………………………………………………………………… 3
2 Modification details ……………….…………………………………………………………… 3
2-1 Engine oil replacement interval …………………….……………………………… 3
2-2 Inactivation of HP mode (for details, refer to page 5.) ……....………………… 3, 5
2-3 Lowering the pump torque (for details, refer to page 6). ………..............…… 3, 6
2-4 Enforcement of water drainage from the hydraulic oil tank ………………… 4
2-5 Cleaning of air cleaner ……………………………………………………………… 4

Page 3 of 6
DESCRIPTION
3 2016 0005
FILING LOCATION
ZX120-5A～
High altitude operation of ZX-5A ZX870-5A-201
1 Outline
For high-altitude (2000m or higher) operation, follow the modifications that are explained in the
“2. Modification details” section to maintain machine reliability and prevent failure development.
Modifications in this Service Bulletin can cause risks of deteriorated operation, decrease in work volume
and drop in convenience. Before undertaking the modifications, explain the above together with the risks
of high altitude operation to your customers.
2 Modification details
2-1 Engine oil replacement interval

In high-altitude sites, black fumes can increase due to low air density, resulting in premature engine oil
deterioration.
To prevent this problem, set the engine oil replacement interval to half the mandated replacement
interval.
Example: If the replacement interval setting is 500 hours, it should be changed to 250 hours.
If 250 hours, it should be changed to 125 hours.
For the brand name of engine oil and replacement method, refer to the section in engine oil/engine oil
filter replacement in “Maintenance” in the operator’s manual.
2-2 Inactivation of HP mode (for details, refer to page 5.)

In high-altitude sites, lag down and engine stalling can occur due to pump torque mismatch. This
occurs when the engine turbo charger rotates excessively due to low air density and output drop.
Prohibit the use of HP mode and guide your customers to use the machine at either ECO or PWR
mode. Or else, inactivate the HP mode by following the directions on page 5.
For some models, the HP mode has already been disabled in the initial setting.
2-3 Lowering the pump torque (for details, refer to page 6).
In high altitude sites, the engine output can drop and lag down and engine stalling can occur due
to pump torque mismatch.
Lower the pump torque if necessary by following the directions on page 6.
Page 4 of 6
DESCRIPTION
3 2016 0005
FILING LOCATION
ZX120-5A～
ZX870-5A-201
2-4 Enforcement of water drainage from the hydraulic oil tank

When the air pressure is low, water can vaporize, developing air bubbles, even when the hydraulic oil
temperature is normal. As a result, cavitation can occur when negative pressure is sucked in.
To prevent the development of air bubbles, drain the water regularly from the bottom of the hydraulic
oil tank.
Refer to “How to drain the water from the hydraulic oil tank” in the “Maintenance” section in the
operator’s manual on the locations from where and when water needs to be drained.
2-5 Cleaning of air cleaner

In high-altitude sites, the engine turbo charger can rotates excessively due to low air density.
Operating the machine with a clogged air cleaner can affect engine reliability.
When the “clogged” warning lights up, the air cleaner should be cleaned promptly.
For the cleaning method and replacement interval, refer to the air cleaner section in “Maintenance” in
the operator’s manual.
Page 5 of 6
DESCRIPTION
3 2016 0005
FILING LOCATION
ZX120-5A～
2-2 How to inactivation the HP Mode ZX870-5A-201
Use MPDr. to inactivate the HP mode. Follow the steps below.
2-2-1. Operate MPDr. Open the page on Functions → Machine Body → Set →Constant
Change. (Refer to the instruction manual for MPDr.)
2-2-2. From the pull-down menu for “Power Mode Selection,” select an item that does not
include the HP mode and click “[F5] Set.” (As an example, “ECO, PWR Mode” has been
selected.”)
2-2-3. Check to make sure that you get the message as shown on the fig. to the left. Click
“Yes.” Next, the message as shown on the fig. to the right will appear. This completes
the setting change. Click “OK.”
2-2-4. Check to make sure that the details for “Present value” are those selected in 2-2-2.
(Here, the setting is “ECO, PWR Mode.”)
2-2-5. Press the power mode switch on the machine side. If you are able to confirm that you
can only switch to the power mode that was selected in 2-2-4 (you are unable to switch
to HP mode), the setting is complete.
Page 6 of 6
DESCRIPTION
3 2016 0005
FILING LOCATION
ZX120-5A～
2-3 Pump torque lowering procedure ZX870-5A-201
Use MPDr. to lower the pump driving torque. Follow the steps below.
2-3-1. Operate MPDr. Open the page on Functions → Machine Body → Set →Constant
Change. (Refer to the instruction manual for MPDr.)
2-3-2. The pump driving torque can be adjusted by the power mode. (Place a check mark in
“Select“ for “*** Mode Torque Adjustment.” Click “[F4] Present Value.” (“***” refers to
ECO, PWR and other such power modes for adjustment.) (As an example, “PWR Mode”
has been selected.)
2-3-3. Enter the torque to be adjusted in the “Changed value” column and click “[F5] Set.”
※ The torque change range (from min. to max values) and change-units are
pre-determined.
※ Take the work status into account. Adjust by making sure that there will be no engine
lag down, engine stalling or emission of black fumes.
2-3-4. Check to make sure that you get the message as shown on the fig. to the left. Click
“Yes.” Next, the message as shown on the fig. to the right will appear. This completes
the setting change. Click “OK.”
2-3-5. Check to see if the value in the “Present value” column is the same as the value that was
entered. If it is, this concludes the torque adjustment.

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Page 1 of 6

SERVICE BULLETIN CODE

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Serial Nos.: ZX120-5A/ZX170-5A/ZX200-5A/ZX240-5A/ZX300-5A/ZX330-5A/

STD. LABOR HOURS

EXPENSES AND THE TIME TO BE CHARGED

2 Modification details ……………….…………………………………………………………… 3

2-1 Engine oil replacement interval …………………….……………………………… 3

2-2 Inactivation of HP mode (for details, refer to page 5.) ……....………………… 3, 5

2-5 Cleaning of air cleaner ……………………………………………………………… 4

2-1 Engine oil replacement interval

2-2 Inactivation of HP mode (for details, refer to page 5.)

2-4 Enforcement of water drainage from the hydraulic oil tank

2-5 Cleaning of air cleaner

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