INTRODUCTION
©2004 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
Read this manual carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or machine damage.
This standard specification machine can be
operated under the following conditions without being
modified.
Atmospheric Temperature: ! 20 " C to 40 " C ( ! 4 " F to
104 " F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other
than described above, consult your nearest Hitachi
dealer.
This manual should be considered a permanent
part of your machine and should remain with the
machine when you sell it.
This machine is of metric design. Measurements in
this manual are metric. Use only metric hardware and
tools as specified.
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the
Machine Numbers section. Accurately record all the
numbers to help in tracing the machine should it be
stolen. Your dealer also needs these numbers when
you order parts. If this manual is kept on the machine,
also file the identification numbers in a secure place
off the machine.
Warranty is provided as a part of Hitachi's support
program for customers who operate and maintain their
equipment as described in this manual. The warranty
is explained on the warranty certificate which you
should have received from your dealer.
This warranty provides you the assurance that Hitachi
will back its products where defects appear within the
warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to
the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original
factory specifications, the warranty will become
void and field improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
Only qualified, experienced operators officially
licensed (according to local law) should be allowed to
operate the machine. Moreover, only officially licensed
personnel should be allowed to inspect and service
the machine.
Prior to operating this machine in a country other than
a country of its intended use, it may be necessary to
make modifications to it so that it complies with the
local standards (including safety standards) and
requirements of that particular country. Please do not
operate this machine outside of the country of its
intended use until such compliance has been
confirmed. Please contact Hitachi Construction
Machinery Co., Ltd. or any of our authorized distributor
or dealer if you have any questions concerning
compliance.
Hitachi machine models are classified into 7 classes and 2 models as shown in
the table below. When referring to the texts and/or illustrations indicated with the
applicable machine class names in this manual, check that the machine models
concerned are included using this table.
Class
ZX120 Class ZAXIS110, 110M, 120, 130H, 130K, 130L
ZX180 Class ZAXIS160LC, 180LC, 180LCN
ZX200 Class ZAXIS200, 200LC, 210H, 210LCH, 210K, 210LCK,
ZX225 Class ZAXIS225USR, 225USRLC, 225USRK, 225USRLCK
ZX270 Class ZAXIS230, 230LC, 240H, 240LCH, 240K, 240LCK, 270, 270LC
ZX330 Class ZAXIS330, 330LC, 350H, 350LCH, 370MTH, 350K, 350LCK
Model
Std. Model ZAXIS110, 110M, 120, 130H, 160LC, 180LC, 180LCN, 200, 200LC, 210H, 210LCH,
225USR, 225USRLC, 230, 230LC, 240H, 240LCH, 270, 270LC, 330, 330LC, 350H,
350LCH, 370MTH
K Model ZAXIS130K, 210K, 210LCK, 225USRK, 225USRLCK, 240K, 240LCK 350K, 350LCK
L Model ZAXIS130L
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.
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
1. MODEL/TYPE
2. Product Identification Number
3. Year of Manufacturing
4. Operating mass (standard version)
5. Engine power in kW according to ISO9249
PRODUCT IDENTIFICATION NUMBER
PRODUCT
IDENTIFICATION
NUMBER:
NOTE:
! HCM1G600L00100001 !
PRODUCT IDENTIFICATION
NUMBER (PIN)
ENGINE
TYPE:
MFG. NO.:
M157-00-001
M157-12-008
M175-00-001
M178-00-001
M1HH-07-001
Marks to indicate the
start and end of the
PIN
Serial Number
Engine Type
ZX120, 180 class
ZX200, 225, 270 class
ZX330 class
MACHINE NUMBERS
TRAVEL MOTOR
TYPE:
MFG. NO.:
SWING MOTOR
TYPE:
MFG. NO.:
M178-07-047
M175-00-002
M178-07-014
M1HH-07-002
ZX120, 180 class
ZX200, 225, 270 class
ZX330 class
MACHINE NUMBERS
HYDRAULIC PUMP
TYPE:
MFG. NO.:
M175-00-003
M1F1-00-001
M157-00-004
M1HH-07-003
ZX120 class
ZX180 calss
ZX200, 225, 270 class
ZX330 class
MACHINE NUMBERS
MEMO
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
CONTENTS
MACHINE NUMBERS
SAFETY
Recognize Safety Information ............................. S-1
Understand Signal Words ................................... S-1
Follow Safety Instructions ................................... S-2
Prepare for Emergencies .................................... S-2
Wear Protective Clothing .................................... S-3
Protect Against Noise .......................................... S-3
Inspect Machine .................................................. S-3
General Precautions for Cab ............................... S-4
Use Handholds and Steps ................................... S-5
Adjust the Operator’s Seat .................................. S-5
Fasten Your Seat Belt ......................................... S-6
Move and Operate Machine Safely ..................... S-6
Handle Starting Aids Safely ................................. S-6
Operate Only from Operator’s Seat .................... S-7
Jump Starting ...................................................... S-7
Keep Riders Off Machine .................................... S-7
Investigate Job Site Beforehand ......................... S-8
Protect Against Falling Stones and Debris .......... S-8
Provide Signals for Jobs Involving Multiple
Numbers of Machines ................................... S-9
Confirm Direction of Machine to be Driven ......... S-9
Drive Machine Safely ......................................... S-10
Avoid Injury from Rollaway Accidents ............... S-11
Avoid Injury from Back-Over
and Swing Accidents ................................... S-12
Keep Person Clear from Working Area ............. S-13
Never Position Bucket Over Anyone ................. S-13
Avoid Undercutting ............................................ S-13
Avoid Tipping ..................................................... S-14
Never Undercut a High Bank ............................. S-14
Dig with Caution ................................................ S-15
Operate with Caution ......................................... S-15
Avoid Power Lines ............................................. S-15
Object Handling ................................................. S-16
Protect Against Flying Debris ............................ S-16
Park Machine Safely ......................................... S-17
Handle Fluids Safely ! Avoid Fires .................... S-17
Practice Safe Maintenance ............................... S-18
Warn Others of Service Work ........................... S-19
Support Machine Properly ................................. S-19
Stay Clear of Moving Parts ................................ S-19
Prevent Parts from Flying ................................ S-20
Store Attachments Safely .................................. S-20
Prevent Burns .................................................... S-21
Replace Rubber Hoses Periodically .................. S-21
Avoid High-Pressure Fluids ............................... S-22
Prevent Fires ..................................................... S-23
Evacuating in Case of Fire ................................ S-24
Beware of Exhaust Fumes ................................ S-24
Precautions for Welding and Grinding .............. S-25
Avoid Heating Near Pressurized Fluid Lines ..... S-26
Avoid Applying Heat to Lines Containing
Flammable Fluids ........................................ S-26
Remove Paint Before Welding or Heating ........ S-26
Prevent Battery Explosions ............................... S-27
Service Air Conditioning System Safely ............ S-27
Handle Chemical Products Safely .................... S-28
Dispose of Waste Properly ............................... S-28
SAFETY SIGNS ................................... S-29
COMPONENTS NAME .......................... 1-1
OPERATOR’S STATION
Cab Features ....................................................... 1-2
Monitor Panel ....................................................... 1-4
Coolant Temperature Gauge ....................... 1-5
Fuel Gauge .................................................. 1-5
Auto-Idle Indicator .......................................... 1-5
Auto-Acceleration Indicator ........................... 1-5
Fuel Level Indicator ....................................... 1-6
Air Filter Restriction Indicator ........................ 1-6
Overheat Indicator ......................................... 1-6
Engine Oil Pressure Indicator ........................ 1-6
Alternator Indicator ........................................ 1-7
Preheat Indicator ........................................... 1-7
Hydraulic Oil Filter Restriction Indicator
(K Model) ................................................. 1-7
Liquid Crystal Display (LCD), Display
Selection Switch, Set Switch ................... 1-8
Hour Meter ..................................................... 1-8
Trip Meter (Trip Meter 1 and Trip Meter 2) .... 1-9
Engine Speed ................................................ 1-9
Hydraulic Oil Temperature ............................. 1-9
Trip Meter Function ..................................... 1-10
Work Mode Switch ...................................... 1-12
Switch Panel .................................................... 1-13
Engine Control Dial ...................................... 1-13
Auto-Idle/Acceleration Selector ................... 1-14
Power Mode Switch ..................................... 1-15
Travel Mode Switch ..................................... 1-15
Work Light Switch ........................................ 1-16
Wiper/Washer Switch .................................. 1-17
Switch Panel (Optional) ..................................... 1-20
Key Switch ......................................................... 1-21
Power Boost Switch ........................................... 1-21
Horn Switch ........................................................ 1-21
Cigar Lighter ...................................................... 1-22
Cab Light ............................................................ 1-23
Installing Fire Extinguisher ................................. 1-23
Pilot Control Shut-Off Lever ............................... 1-24
Engine Stop Knob .............................................. 1-24
Fuse Box ............................................................ 1-25
Auto Air Conditioner (Optional) .......................... 1-26
Cab Heater Operation ........................................ 1-29
Cooling Operation .............................................. 1-30
Defroster Operation ........................................... 1-30
Tips for Optimal Air Conditioner Usage ............. 1-31
Auto Air Conditioner (Optional) .......................... 1-32
CONTENTS
Cab Heater Operation ....................................... 1-36
Cooling Operation ............................................. 1-37
Defroster Operation ........................................... 1-37
Tips for Optimal Air Conditioner Usage ............. 1-39
Cab Heater (Optional) ....................................... 1-40
Cab Heater Operation ....................................... 1-41
Defroster Operation ........................................... 1-42
AM/FM Radio Operation .................................... 1-43
Digital Clock Setting Procedure ......................... 1-44
AM/FM Radio Operation .................................... 1-45
Digital Clock Setting Procedure ......................... 1-46
Cab Door Release Lever ................................... 1-47
Opening Upper Front Window ........................... 1-47
Closing Upper Front Window ............................ 1-48
Removing and Storing Lower
Front Window .............................................. 1-49
Opening Side Windows ..................................... 1-50
Opening/Closing Overhead Window ................. 1-51
Emergency Exit ................................................. 1-52
Adjusting the Seat ............................................. 1-53
Adjusting Console Height .................................. 1-57
Seat Belt ............................................................ 1-58
BREAK-IN
Observe Engine Operation Closely ..................... 2-1
Every 8 Hours or Daily ......................................... 2-1
After the First 50 Hours ....................................... 2-1
After the First 100 Hours ..................................... 2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting ................ 3-1
Before Starting Engine ........................................ 3-2
Starting The Engine in Ordinary Temperature .... 3-3
Starting in Cold Weather ..................................... 3-4
Check Instruments After Starting ........................ 3-5
Using Booster Batteries ....................................... 3-6
Stopping the Engine ............................................ 3-8
DRIVING THE MACHINE
Drive the Machine Carefully ................................ 4-1
Steering the Machine Using Pedals .................... 4-2
Steering the Machine Using Levers .................... 4-3
Travel Mode Switch ............................................. 4-4
Travel Alarm (Optional) ....................................... 4-4
Traveling .............................................................. 4-5
Operating on Soft Ground ................................... 4-6
Raise One Track Using Boom and Arm .............. 4-6
Towing Machine a Short Distance ....................... 4-7
Operating in Water or Mud .................................. 4-8
Precautions for Traveling on Slopes ................... 4-9
Parking the Machine on Slopes ......................... 4-10
Parking the Machine .......................................... 4-10
OPERATING THE MACHINE
Control Lever (ISO Pattern) ............................... 5-1
Control Lever (HITACHI Pattern) ...................... 5-2
Attachment Pedal (Breaker) ................................ 5-3
Attachment Pedal (Hydraulic Crusher) ................ 5-4
Pilot Control Shut-Off Lever ................................. 5-5
Engine Speed Control .......................................... 5-8
Auto-Idle ............................................................... 5-9
Auto Acceleration ............................................... 5-10
Work Mode ........................................................ 5-12
Power Boost ....................................................... 5-12
Power Mode ....................................................... 5-13
Precautions for Operation Using a Bucket ........ 5-14
Precaustions for Operations .............................. 5-15
Operate the Machine Safely .............................. 5-16
Operating Backhoe ............................................ 5-17
Grading Operation ............................................. 5-17
Face Shovel Operation ...................................... 5-18
Avoid Abusive Operation ................................... 5-18
Operating Tips ................................................... 5-19
Select Correct Track Shoes ............................... 5-19
Hydraulic Breaker and Hydraulic Crusher .......... 5-20
Pipings for Breaker and Crusher ....................... 5-21
Secondary Relief Pressure Adjustment ............. 5-23
Precautions for Breaker Operation .................... 5-24
Breaker Maintenance ......................................... 5-27
Precautions for Crusher Operation .................... 5-28
Attachment ......................................................... 5-30
Attachment Connection Parts ............................ 5-35
Precaution for Arm Roll-In/Bucket Roll-In
Combined Operation .................................. 5-36
When Installing an Attachment Longer
than Standard Bucket .................................. 5-36
Shackle Hole Usage .......................................... 5-37
Overnight Storage Instructions .......................... 5-37
Emergency Boom Lowering Procedure ............. 5-38
Object Handling --- If Equipped ......................... 5-42
TRANSPORTING
Transporting by Road .......................................... 6-1
Loading/Unloading on a Trailer ............................ 6-1
Machine Lifting Procedure ................................... 6-5
MAINTENANCE
Correct Maintenance
and Inspection Procedures ............................ 7-1
Check the Hour Meter Regularly ......................... 7-2
Use Correct Fuels and Lubricants ....................... 7-2
Layout ................................................................. 7-3
Maintenance Guide Table .................................... 7-4
Prepare Machine for Maintenance ....................... 7-6
Hood and Access Covers
(ZX120, 180 Class) ........................................ 7-7
Hood and Access Covers
(ZX200, 225, 270, 330 Class) ........................ 7-8
Periodic Replacement of Parts ............................ 7-9
Maintenance Guide ............................................ 7-10
A. Greasing .................................................... 7-15
Front Joint Pins ............................................ 7-15
CONTENTS
Swing Bearing ............................................. 7-18
Swing Internal Gear .................................... 7-19
Lubricator .................................................... 7-20
B. Engine ......................................................... 7-22
Engine Oil Level .......................................... 7-22
Change Engine Oil ...................................... 7-23
Replace Engine Oil Filter ............................ 7-23
C. Transmission ............................................. 7-25
Pump Transmission .................................... 7-25
Swing Reduction Gear ................................ 7-26
Travel Reduction Gear ................................ 7-27
D. Hydraulic System ........................................ 7-29
Inspection and Maintenance
of Hydraulic Equipment ......................... 7-29
Replacement of Hydraulic Oil and Filter ...... 7-31
Check Hydraulic Oil Level ........................... 7-32
Drain Hydraulic Tank Sump ........................ 7-33
Change Hydraulic Oil .................................. 7-34
Suction Filter Cleaning ................................ 7-34
Replace Full-Flow Filter .............................. 7-37
Replace Full-Flow Filter (K/L Model) ........... 7-38
Replace Pilot Oil Filter ................................. 7-39
Replace Air Breather Element ..................... 7-41
Check Hoses and Lines .............................. 7-42
Service Recommendations for
Hydraulic Fittings ................................... 7-45
E. Fuel System ................................................ 7-47
Drain Fuel Tank Sump ................................ 7-49
Check Water Separator .............................. 7-50
Replace Fuel Filter ...................................... 7-53
Clean Feed Pump Strainer .......................... 7-54
Check Fuel Hoses ....................................... 7-55
F. Air Cleaner .................................................. 7-56
Clean the Air Cleaner Outer Element .......... 7-56
Replace the Air Cleaner Outer
and Inner Elements ............................... 7-56
G. Cooling System ........................................... 7-59
Check Coolant Level ................................... 7-61
Check and Adjust Fan Belt Tension ............ 7-62
Change Coolant .......................................... 7-63
Clean Radiator Interior ................................ 7-63
Clean Radiator, Oil Cooler Core
and Inter Cooler .................................... 7-64
Clean Oil Cooler Front Screen .................... 7-64
Clean Air Conditioner Condenser ............... 7-64
Clean Inter Cooler Front Screen ................. 7-64
H. Electrical System ....................................... 7-65
Batteries ...................................................... 7-65
Replacing Fuses ......................................... 7-69
Additional Fuse Box (Optional) ................... 7-70
I. Miscellaneous ............................................ 7-71
Check Bucket Teeth .................................... 7-71
Change Bucket .......................................... 7-75
Convert Bucket Connection Into
Face Shovel .......................................... 7-76
Adjust the Bucket Linkage .......................... 7-77
Remove the Travel Levers .......................... 7-78
Check and Replace Seat Belt .................... 7-78
Check Windshield Washer Fluid Level ........ 7-79
Check Track Sag ......................................... 7-80
Adjust Track Sag ......................................... 7-80
Loosen the Track ......................................... 7-81
Tighten the Track ......................................... 7-81
Clean and Replace Air Conditioner
Filter ....................................................... 7-82
Check the Air Conditioner ............................ 7-84
Clean Cab Floor ........................................... 7-85
Check Injection Nozzle ................................ 7-86
Retighten Cylinder Head Bolt ...................... 7-86
Inspect and Adjust Valve Clearance ............ 7-86
Check Fuel Injection Timing ........................ 7-86
Measure Engine Compression
Pressure ................................................ 7-86
Check Starter and Alternator ....................... 7-86
Change Water Pump Grease ...................... 7-86
Check Tightening Torque of Bolts
and Nuts ................................................ 7-87
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions .............................. 9-1
STORAGE
Storing the Machine ........................................... 10-1
Removing the Machine from Storage ................ 10-2
TROUBLESHOOTING
Engine ............................................................... 11-1
Electrical System ............................................... 11-6
Mode Selection .................................................. 11-8
Control Levers ................................................... 11-9
Hydraulic System ............................................... 11-9
SPECIFICATIONS
ZAXIS110, 110M
Specifications ............................................. 12-1
Working Ranges .......................................... 12-2
Shoe Types and Applications ...................... 12-3
Bucket Types
and Applications .................................... 12-4
ZAXIS120, 130H
Specifications ............................................. 12-5
Working Ranges .......................................... 12-6
Shoe Types and Applications ...................... 12-7
Bucket Types and Applications ................... 12-8
ZAXIS130K
Specifications ............................................. 12-9
Working Ranges ........................................ 12-10
Shoe Types and Applications .................... 12-11
Bucket Types and Applications ................. 12-12
You're Reading a Preview
What's Included?
Lifetime Access
Access PDF Contents & Bookmarks
Print one or all pages of your manual