ZX350H-5A Operation Manual

PART NO.
ENMDAK-2-5
ZX120-5 • 160-5 • 200-5 • 240-5 • 300-5 • 330-5 class

Operator's Manual
120-5 class
HYDRAULIC EXCAVATOR
130-5A
160-5 class
160LC-5A
200-5 class
OPERATOR'S MANUAL
200-5A · 200LC-5A · 210H-5A · 210LCH-5A · 210K-5A · 210LCK-5A
240-5 class
240-5A · 240LC-5A · 250H-5A · 250LCH-5A · 250K-5A· 250LCK-5A
300-5 class
300-5A · 300LC-5A
URL:http://www.hitachi-c-m.com 330-5 class

330-5A · 330LC-5A · 350H-5A · 350LCH-5A · 350K-5A · 350LCK-5A
Hydraulic Excavator
Serial No.
ZX120-5 class 090001 and up
ENMDAK-2-5

This book is printed on recycled paper. PRINTED IN JAPAN (E) 2017, 12 ZX300-5 class 060001 and up
INTRODUCTION
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 machine 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 2000 m (0 ft to 6600 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 the
described above, consult your authorized dealer. 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
This machine is of metric design. Measurements in this overpowering machines will result in such action.
manual are metric. Use only metric hardware and tools as
specified. Only qualified, experienced operators officially licensed
(according to local law) should be allowed to operate
Right-hand and left-hand sides are determined by the machine. Moreover, only officially licensed personnel
facing in the direction of forward travel. should be allowed to inspect and service the machine.
Write product identification numbers in the Machine PRIOR TO OPERATING THIS MACHINE, INCLUDING
Numbers section. Accurately record all the numbers COMMUNICATION SYSTEM, IN A COUNTRY OTHER
to help in tracing the machine should it be stolen. THAN A COUNTRY OF ITS INTENDED USE, IT MAY
Your dealer also needs these numbers when you order BE NECESSARY TO MAKE MODIFICATIONS TO IT SO
parts. If this manual is kept on the machine, also file the THAT IT COMPLIES WITH THE LOCAL REGULATORY
identification numbers in a secure place off the machine. STANDARDS (INCLUDING SAFETY STANDARDS)
AND LEGAL REQUIREMENTS OF THAT PARTICULAR
Be sure to use fuel that complies with JIS K-2204, EN-590, COUNTRY. PLEASE DO NOT EXPORT OR OPERATE
ASTM D-975 or GB252. THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS
Also use fuel that complies with solid contamination level INTENDED USE UNTIL SUCH COMPLIANCE HAS
of class 18/16/13 of ISO4406-1999 (solid contamination BEEN CONFIRMED. PLEASE CONTACT HITACHI
includes dust). If the fuel specified above is not used, CONSTRUCTION MACHINERY CO., LTD. OR ANY OF
exhaust gas that exceeds the regulation values may be OUR AUTHORIZED DISTRIBUTOR OR DEALER IF YOU
discharged, causing serious problem on the engine. HAVE ANY QUESTIONS CONCERNING COMPLIANCE.
Consult your authorized dealer.
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.
©2017 Hitachi Construction Machinery Co., Ltd.

All rights reserved.
INDEX MACHINE NUMBERS
SAFETY
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 T
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
OPTIONAL ATTACHMENTS AND DEVICES
INDEX
ENMDAK-2-5
CONTENTS
MACHINE NUMBERS..........................................................1 Avoid Applying Heat to Lines Containing Flammable
Fluids............................................................................................ S-34
SAFETY........................................................................... S-1 Precautions for Handling Accumulator and Gas
Recognize Safety Information.....................................................S-1 Damper........................................................................................ S-34
Understand Signal Words..............................................................S-1 Remove Paint Before Welding or Heating............................ S-35
Follow Safety Instructions.............................................................S-2 Beware of Asbestos and Silicon Dust and Other
Prepare for Emergencies................................................................S-3 Contamination.......................................................................... S-35
Wear Protective Clothing..............................................................S-3 Prevent Battery Explosions........................................................ S-36
Protect Against Noise.....................................................................S-4 Service Air Conditioning System Safely................................ S-36
Inspect Machine...............................................................................S-4 Handle Chemical Products Safely............................................ S-37
General Precautions for Cab.........................................................S-5 Dispose of Waste Properly.......................................................... S-37
Use Handholds and Steps.............................................................S-6 Never Ride Attachment............................................................... S-38
Adjust the Operator's Seat............................................................S-6 Precautions for Communication Terminal............................ S-38
Ensure Safety Before Rising from or Leaving Operator’s Precautions for Communication Terminal Equipment.... S-39
Seat..................................................................................................S-7 Notes on Protection of Operator’s Station when the
Fasten Your Seat Belt.......................................................................S-7 Machine Rolls Over.................................................................. S-41
Move and Operate Machine Safely............................................S-8
Operate Only from Operator's Seat...........................................S-8 SAFETY SIGNS/Oceania Model Only.......................... S-42
Jump Starting....................................................................................S-9 SAFETY SIGNS/Asia/Middle and Near East Model
Keep Riders off Machine................................................................S-9 Only.............................................................................. S-49
Precautions for Operations........................................................ S-10
Investigate Job Site Beforehand.............................................. S-11 COMPONENTS NAME..................................................... 1-1
Install OPG Guard.......................................................................... S-12 Components Name.........................................................................1-1
Restriction of Attachment Installation.................................. S-13
GETTING ON/OFF THE MACHINE.................................. 1-2
Provide Signals for Jobs Involving Multiple Machines.... S-13
Confirm Direction of Machine to Be Driven......................... S-13 OPERATOR’S STATION................................................... 1-3
Drive Machine Safely.................................................................... S-14 Cab Features .....................................................................................1-3
Avoid Injury from Rollaway Accidents................................... S-16 Std. Model......................................................................................1-3
Avoid Injury from Back-Over and Swing Accidents.......... S-17 Cab Features .....................................................................................1-4
Keep Person Clear from Working Area.................................. S-18 K. Model.........................................................................................1-4
Never Position Bucket Over Anyone...................................... S-18 Multi Function Monitor..................................................................1-5
Avoid Undercutting...................................................................... S-19 Default Setting..................................................................................1-6
Avoid Tipping.................................................................................. S-19 Basic Screen........................................................................................1-7
Never Undercut a High Bank..................................................... S-20 How to Use Screens.........................................................................1-8
Dig with Caution............................................................................ S-20 Displaying Basic Screen............................................................1-8
Operate with Caution.................................................................. S-20 Hour Meter................................................................................. 1-11
Avoid Power Lines......................................................................... S-21 Clock............................................................................................. 1-11
Precautions for Lightning........................................................... S-21 Fuel Gauge................................................................................. 1-11
Never Allow Machine to Engage in Crane Work................ S-22 Coolant Temperature Gauge............................................... 1-11
Protect Against Flying Debris................................................... S-22 Operating Status Icon Display............................................. 1-11
Park Machine Safely...................................................................... S-23 Security Functions (Optional)................................................... 1-12
Handle Fluids Safely−Avoid Fires............................................. S-23 Input Password......................................................................... 1-12
Transport Safely............................................................................. S-24 Extending Password Duration Time.................................. 1-13
Practice Safe Maintenance......................................................... S-25 Alarm Occurrence Screen........................................................... 1-14
Warn Others of Service Work.................................................... S-26 Remedy............................................................................................. 1-16
Support Machine Properly......................................................... S-26 Main Menu....................................................................................... 1-19
Stay Clear of Moving Parts......................................................... S-27 Air Conditioner............................................................................... 1-20
Prevent Parts from Flying........................................................... S-27 Circulation Air Mode............................................................... 1-20
Avoid Injury from Attachment Falling Accident................ S-28 Air Conditioner ON/OFF........................................................ 1-20
Prevent Burns.................................................................................. S-28 Radio.................................................................................................. 1-21
Replace Rubber Hoses Periodically......................................... S-29 Work Mode...................................................................................... 1-22
Avoid High-Pressure Fluids........................................................ S-29 Attachment Selection............................................................ 1-22
Prevent Fires.................................................................................... S-30 Mail (Optional)................................................................................ 1-23
Evacuating in Case of Fire........................................................... S-32 Setting Menu.................................................................................. 1-25
Beware of Exhaust Fumes.......................................................... S-32 Date and Time................................................................................ 1-26
Precautions for Welding and Grinding.................................. S-33 Time Adjustment..................................................................... 1-26
Avoid Heating Near Pressurized Fluid Lines........................ S-34
CONTENTS
Date Adjustment...................................................................... 1-28 Power Boost Switch...................................................................... 1-84
Display Mode Setting............................................................. 1-30 Horn Switch..................................................................................... 1-84
Attachment Adjustment............................................................. 1-32 Electrical Control Main Switch (Optional)............................ 1-85
Flow Rate Adjustment............................................................ 1-32 ON/OFF Operation Switch (Optional).................................... 1-86
Priority (arm roll-out) (Except ZX330-5A class)............. 1-34 AUX Function Lever 3............................................................. 1-86
Attachment Name Input............................................................. 1-36 Cigar Lighter.................................................................................... 1-87
Auto Shut-Down............................................................................ 1-38 Using Cigar Lighter ................................................................ 1-87
Auto Shut-Down: ON/OFF.................................................... 1-38 Using Cigar Lighter Port as External Power Source..... 1-87
Acting Time Setting................................................................ 1-39 Cab Light Switch............................................................................ 1-88
Password Change (Optional)..................................................... 1-40 Installing Fire Extinguisher (Optional)................................... 1-88
Sub Meter......................................................................................... 1-44 Pilot Control Shut-Off Lever...................................................... 1-89
Rear View Camera Monitor........................................................ 1-46 Engine Stop Switch....................................................................... 1-89
Rear View Camera ON (Factory Setting: ON).................. 1-46 Fuse Box............................................................................................ 1-90
Brightness Adjustment................................................................ 1-48 Auto Air Conditioner.................................................................... 1-91
Language Settings........................................................................ 1-50 Features:...................................................................................... 1-91
Lists of Display Language........................................................... 1-52 Components Name................................................................. 1-92
Unit Selection................................................................................. 1-53 Controller Part Name and Function.................................. 1-93
Main Menu Sequence Change................................................. 1-55 Cab Heater Operation............................................................ 1-96
Information Menu......................................................................... 1-57 Cooling Operation................................................................... 1-97
Operation......................................................................................... 1-58 Defroster Operation................................................................ 1-98
Fuel Consumption................................................................... 1-58 Cool Head/Warm Feet Operation....................................... 1-98
Breaker Operation................................................................... 1-60 Tips for Optimal Air Conditioner Usage................................ 1-99
Attachment Operation........................................................... 1-62 For Rapid Cooling.................................................................... 1-99
Travel Operation....................................................................... 1-64 When Windows Become Clouded..................................... 1-99
Actual operation...................................................................... 1-66 Off-Season Air Conditioner Maintenance....................... 1-99
Maintenance................................................................................... 1-68 AM/FM Radio Operation...........................................................1-100
Remaining Time and Maintenance Interval................... 1-70 Controls on the Radio...........................................................1-100
Monitoring....................................................................................... 1-72 Tuning Procedure..................................................................1-100
Switch Panel.................................................................................... 1-74 Station Presetting Procedure.............................................1-101
Return to Previous Screen Switch (Monitor).................. 1-75 Station Auto-Presetting Procedure.................................1-102
Return to Basic Screen Switch (Monitor)......................... 1-75 TONE Control...........................................................................1-103
Selector Knob (Monitor)........................................................ 1-75 Audio Input (Optional)..............................................................1-104
Temperature Control Switch/Mode Switch (Air Side View Camera System (Optional)...................................1-105
Conditioner)......................................................................... 1-75 Content of Monitor Display.....................................................1-107
AUTO/OFF Switch/Fan Switch (Air Conditioner)........... 1-75 Adjusting the Position of the Side Camera Monitor.......1-108
AM/FM Selector/Tuning Switch (Radio)........................... 1-76 Cab Door Release Lever............................................................1-109
Power Switch/Volume Control Knob (Radio)................. 1-76 Opening/Closing and Removing Cab Inside
Engine Control Dial................................................................. 1-76 Window.....................................................................................1-110
Auto-Idle Switch....................................................................... 1-77 Opening Upper Front Window...............................................1-111
Travel Mode Switch................................................................. 1-77 Removing and Storing Lower Front Window....................1-112
Power Mode Switch................................................................ 1-78 Opening Side Window...............................................................1-113
Work Light Switch.................................................................... 1-78 Opening/Closing Overhead Window (Std. Model).........1-114
Wiper/Washer Switch............................................................. 1-79 Opening/Closing Overhead Window (Clear Hatch: If
Overhead Window Wiper and Washer Switch Equipped).................................................................................1-115
(K Model)............................................................................... 1-80 Emergency Exit............................................................................1-116
Numeric Keypad....................................................................... 1-80 Adjusting Operator's Seat........................................................1-117
Switch Panel (for Optional Equipment)................................. 1-81 Seat Height and Angle Adjustment................................1-117
Travel Alarm Deactivation Switch (Optional)................. 1-82 Console and Seat Fore-aft Adjustment..........................1-117
Swing Alarm Deactivation Switch (Optional)................ 1-82 Seat Fore-Aft Adjustment...................................................1-117
Rear Light Switch (Optional)................................................ 1-82 Backrest Adjustment............................................................1-117
Overload Alarm Switch (Optional)..................................... 1-82 Armrest Adjustment.............................................................1-118
Seat Heater Switch ................................................................. 1-83 Adjusting Operator's Seat (Optional)...................................1-119
Rotating Lamp Switch (Optional)....................................... 1-83 Seat Height and Angle Adjustment................................1-119
Electrical Control Main Switch (Optional)....................... 1-83 Console and Seat Fore-aft Adjustment..........................1-119
ON/OFF Operation Switch (Optional)............................... 1-83 Seat Fore-Aft Adjustment...................................................1-119
Key Switch........................................................................................ 1-84 Suspension Adjustment......................................................1-119
CONTENTS
Backrest Adjustment............................................................1-120 Shovel................................................................................................ 5-17
Armrest Adjustment.............................................................1-120 Grading Operation........................................................................ 5-18
Adjusting Operator's Seat (Optional)...................................1-121 Do Not Strike the Ground with Bucket Teeth...................... 5-19
Adjusting Seat Height..........................................................1-121 Avoid Hammer Work.................................................................... 5-19
Console and Seat Fore-aft Adjustment..........................1-121 Avoid Abusive Operation........................................................... 5-20
Seat Fore-Aft Adjustment...................................................1-121 Avoid Side Load the Bucket....................................................... 5-20
Suspension Adjustment......................................................1-122 Retracting the Arm and Bucket................................................ 5-21
Fore-Aft Position Adjustment of Seat Surface.............1-122 Do Not Use Wide Track Shoes on Rough Ground.............. 5-21
Angle Adjustment of Seat Surface..................................1-122 Shackle Hole Usage...................................................................... 5-22
Backrest Adjustment............................................................1-122 Pilot Accumulator Functions (Optional)................................ 5-23
Armrest Adjustment.............................................................1-122 How to Lower Boom in Case of Emergency and When
Console Height Adjustment....................................................1-123 Engine Stops.............................................................................. 5-24
Adjusting Procedures...........................................................1-123 Precautions for After Operations............................................. 5-25
Installation and Adjustment of Mirrors...............................1-124
TRANSPORTING............................................................. 6-1
Mirror Installation Diagram................................................1-125
Seat Belt..........................................................................................1-126 Transporting by Road.....................................................................6-1
Battery Disconnect Switch.......................................................1-127 Loading/Unloading on a Trailer..................................................6-2
How to operate the disconnect switch..........................1-127 Fastening Machine for Transporting.........................................6-5
Unloading...........................................................................................6-5
BREAK-IN........................................................................ 2-1 Lifting Machine.................................................................................6-7
Observe Engine Operation Closely............................................2-1
MAINTENANCE............................................................... 7-1
Every 8 Hours or Daily.....................................................................2-1
After the First 50 Hours..................................................................2-1 Correct Maintenance and Inspection Procedures................7-1
After the First 100 Hours................................................................2-1 Layout...................................................................................................7-3
Check the Hour Meter Regularly.................................................7-4
OPERATING THE ENGINE............................................... 3-1 Preparations for Inspection and Maintenance......................7-7
Inspect Machine Daily Before Starting.....................................3-1 Hood and Access Covers................................................................7-8
Before Starting Engine...................................................................3-2 Maintenance Guide...................................................................... 7-11
Starting the Engine..........................................................................3-3 Periodic Replacement of Parts.................................................. 7-16
Check Instruments After Starting...............................................3-8 Kind of Oils....................................................................................... 7-17
Using Booster Batteries..................................................................3-9 Recommended Engine Oil.................................................... 7-17
Stopping the Engine.................................................................... 3-11 A. Greasing....................................................................................... 7-20
Front Joint Pins......................................................................... 7-20
DRIVING THE MACHINE................................................. 4-1
Swing Bearing........................................................................... 7-22
Drive the Machine Carefully.........................................................4-1 Swing Internal Gear................................................................ 7-23
Steering the Machine Using Pedals...........................................4-2 Electric Grease Gun (Only ZX330-5 class)........................ 7-24
Steering the Machine Using Levers...........................................4-3 Electric Grease Gun................................................................. 7-26
Travel Mode Switch.........................................................................4-4 Components Name................................................................. 7-27
Travel Alarm (Optional)..................................................................4-4 Battery Charger Operation................................................... 7-28
Operating on Soft Ground............................................................4-5 Charger Lamp............................................................................ 7-29
Raise One Track Using Boom and Arm.....................................4-5 B. Engine........................................................................................... 7-35
Towing Machine a Short Distance..............................................4-6 Engine Oil Level........................................................................ 7-35
Operating in Water or Mud...........................................................4-7 Change Engine Oil . ................................................................ 7-37
Parking the Machine on Slopes...................................................4-8 Replace Engine Oil Filter........................................................ 7-37
Parking the Machine.......................................................................4-8 Check and Clean Around the Engine................................ 7-40
OPERATING THE MACHINE............................................ 5-1 C. Transmission............................................................................... 7-41
Control Lever (ISO Pattern)...........................................................5-1 Pump Transmission ................................................................ 7-41
Pilot Control Shut-Off Lever.........................................................5-2 Swing Reduction Gear........................................................... 7-42
Warming-Up Operation.................................................................5-3 Travel Reduction Gear............................................................ 7-43
Engine Speed Control.....................................................................5-4 D. Hydraulic System...................................................................... 7-45
Auto-Idle..............................................................................................5-5 Inspection and Maintenance of Hydraulic
Auto Shut-Down...............................................................................5-7 Equipment............................................................................ 7-45
Work Mode...................................................................................... 5-10 Check Hydraulic Oil Level..................................................... 7-49
Power Boost Switch...................................................................... 5-13 Change Hydraulic Oil.............................................................. 7-50
Power Mode.................................................................................... 5-14 Air Bleeding Procedures........................................................ 7-52
Precautions for Excavation (K. Model)................................... 5-15 Suction Filter Cleaning........................................................... 7-53
Operating Backhoe....................................................................... 5-16 Replacement of Full-Flow Filter.......................................... 7-54
CONTENTS
Replace Pilot Oil Filter............................................................ 7-57 STORAGE...................................................................... 10-1
Replace Air Breather Element.............................................. 7-58 Storing the Machine..................................................................... 10-1
Replace Line Filter Element (Optional)............................. 7-59
Check Hoses and Lines.......................................................... 7-61 TROUBLESHOOTING.................................................... 11-1
E. Fuel System................................................................................. 7-65 Troubleshooting............................................................................ 11-1
Recommended Fuel................................................................ 7-65 SPECIFICATIONS.......................................................... 12-1
Drain Fuel Tank Sump............................................................. 7-67 Specifications.................................................................................. 12-1
Drain Fuel Pre-Filter................................................................. 7-68 ZX130-5A.................................................................................... 12-1
Replace Fuel Main Filter Element....................................... 7-71 Working Ranges (Grouser shoe).............................................. 12-2
Replace Fuel Pre-Filter Element.......................................... 7-73 ZX130-5A.................................................................................... 12-2
Replace Fuel Solenoid Pump Filter Element.................. 7-75 Shoe Types and Applications.................................................... 12-3
Check Fuel Hoses..................................................................... 7-77 ZX130-5A.................................................................................... 12-3
F. Air Cleaner.................................................................................... 7-78 Bucket Types and Applications................................................ 12-4
Clean and Replace Air Cleaner Element (Outer)........... 7-78 ZX130-5A.................................................................................... 12-4
Clean or replace the outer element.................................. 7-78 Specifications.................................................................................. 12-5
Replace Air Cleaner Element (Inner)................................. 7-80 ZX160LC-5A............................................................................... 12-5
G. Cooling System......................................................................... 7-81 Working Ranges (Grouser shoe).............................................. 12-6
Check Coolant Level............................................................... 7-82 ZX160LC-5A............................................................................... 12-6
Check and Adjust Fan Belt Tension .................................. 7-84 Shoe Types and Applications.................................................... 12-7
Change Coolant........................................................................ 7-86 ZX160LC-5A............................................................................... 12-7
Clean Radiator/Oil Cooler/Inter Cooler Core.................. 7-88 Bucket Types and Applications................................................ 12-8
Clean Oil Cooler, Radiator and Inter Cooler Front ZX160LC-5A............................................................................... 12-8
Screen..................................................................................... 7-90 Specifications.................................................................................. 12-9
Clean Air Conditioner Condenser...................................... 7-90 ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A................... 12-9
Clean Fuel Oil Cooler.............................................................. 7-90 Working Ranges (Grouser shoe)............................................12-10
H. Electrical System....................................................................... 7-91 ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A.................12-10
Battery.......................................................................................... 7-92 Shoe Types and Applications..................................................12-11
Replace Battery......................................................................... 7-95 ZX200-5A..................................................................................12-11
Replacing Fuses........................................................................ 7-97 Shoe Types and Applications..................................................12-12
Fuse Box...................................................................................... 7-98 ZX200LC-5A.............................................................................12-12
I. Miscellaneous............................................................................7-100 Shoe Types and Applications..................................................12-13
Check and Replace Bucket Teeth.....................................7-100 ZX210H-5A...............................................................................12-13
Change Bucket........................................................................7-106 Shoe Types and Applications..................................................12-14
Convert Bucket Connection Into Face Shovel.............7-107 ZX210LCH-5A..........................................................................12-14
Adjust Bucket Linkage.........................................................7-108 Bucket Types and Applications..............................................12-15
Remove Travel Levers...........................................................7-109 ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A.................12-15
Check and Replace Seat Belt..............................................7-109 Specifications................................................................................12-16
Check Windshield Fluid Level............................................7-110 ZX210K-5A, 210LCK-5A........................................................12-16
Check Track Sag......................................................................7-111 Working Ranges (Grouser shoe)............................................12-17
Clean and Replace Air Conditioner Filter......................7-115 ZX210K-5A, 210LCK-5A........................................................12-17
Check Air Conditioner..........................................................7-117 Shoe Types and Applications..................................................12-18
Clean Cab Floor......................................................................7-119 ZX210K-5A................................................................................12-18
Retighten Cylinder Head Bolt............................................7-120 ZX210LCK-5A...........................................................................12-18
Inspect and Adjust Valve Clearance................................7-120 Bucket Types and Applications..............................................12-19
Measure Engine Compression Pressure........................7-120 ZX210K-5A, 210LCK-5A........................................................12-19
Check Starter and Alternator.............................................7-120 Specifications................................................................................12-20
Check and Replace EGR Device........................................7-120 ZX240-5A, 240LC-5A.............................................................12-20
Check Gas Damper................................................................7-121 Specifications................................................................................12-21
Tightening and Retightening Torque of Nuts and ZX250H-5A, 250LCH-5A.......................................................12-21
Bolts.......................................................................................7-121 Specifications................................................................................12-22
List of Consumable Parts..........................................................7-143 ZX250K-5A, 250LCK-5A........................................................12-22
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL Working Ranges...........................................................................12-23
CONDITIONS.................................................................. 9-1 ZX240-5A, 240LC-5A.............................................................12-23
Maintenance Under Special Environmental Conditions....9-1 Working Ranges...........................................................................12-24
ZX250H-5A, 250LCH-5A, 250K-5A, 250LCK-5A............12-24
Shoe Types and Applications..................................................12-25
CONTENTS
ZX240-5A..................................................................................12-25 Specifications................................................................................13-10
Shoe Types and Applications..................................................12-26 ZX130-5A with Blade............................................................13-10
ZX240LC-5A.............................................................................12-26 Working Ranges...........................................................................13-11
ZX250H-5A...............................................................................12-27 Shoe Types and Applications..................................................13-12
ZX250LCH-5A..........................................................................12-28 Bucket Teeth (Transverse-Type-Pin-Used Type)...............13-13
Shoe Types and Applications..................................................12-29 Attachment Pedal (Hydraulic Breaker) (Optional)...........13-14
ZX250K-5A................................................................................12-29 Attachment Pedal (Hydraulic Crusher) (Optional)...........13-15
ZX250LCK-5A...........................................................................12-29 Hydraulic Breaker, Hydraulic Crusher and Quick
Bucket Types and Applications..............................................12-30 Coupler......................................................................................13-16
ZX240-5A, 240LC-5A.............................................................12-30 Piping for Breaker and Crusher..............................................13-17
ZX250H-5A, 250LCH-5A, 250K-5A, 250LCK-5A............12-31 Operational Procedures for Stop Valves and Selection
Specifications................................................................................12-32 Valve...........................................................................................13-17
ZX300-5A, 300LC-5A.............................................................12-32 Secondary Relief Pressure Adjustment...............................13-18
Working Ranges...........................................................................12-33 Precautions for Breaker Operation........................................13-19
ZX300-5A, 300LC-5A.............................................................12-33 Change Hydraulic Oil and Replace Full-Flow Filter
Shoe Types and Applications..................................................12-34 Element.....................................................................................13-23
ZX300-5A..................................................................................12-34 Precautions for Crusher Operation.......................................13-24
ZX300LC-5A.............................................................................12-34 Attachment....................................................................................13-27
Bucket Types and Applications..............................................12-35 Allowable Weight Limits of Installed Attachment.....13-27
ZX300-5 class...........................................................................12-35 Attachment Connection Parts................................................13-29
Specifications................................................................................12-36 Precaution for Arm Roll-In/Bucket Roll-In Combined
ZX330-5A, 330LC-5A.............................................................12-36 Operation..................................................................................13-31
Specifications................................................................................12-37
INDEX............................................................................ 14-1
ZX350H-5A, 350LCH-5A.......................................................12-37
Specifications................................................................................12-38
ZX350K-5A, 350LCK-5A........................................................12-38
Working Ranges...........................................................................12-39
ZX350-5A, 350LC-5A.............................................................12-39
Working Ranges...........................................................................12-40
ZX350H-5A, 350LCH-5A, 350K-5A, 350LCK-5A............12-40
ZX330-5A..................................................................................12-41
ZX330LC-5A.............................................................................12-41
ZX350H-5A...............................................................................12-42
ZX350LCH-5A..........................................................................12-42
ZX350K-5A................................................................................12-43
ZX350LCK-5A...........................................................................12-43
Bucket Types and Applications..............................................12-44
ZX330-5 class...........................................................................12-44
Sound Level Results....................................................................12-45
Vibration Level..............................................................................12-45
Electric Fans...................................................................................12-45
OPTIONAL ATTACHMENTS AND DEVICES.................. 13-1
Using Pad Crawler Shoe.............................................................. 13-1
Traveling and Other Cautions................................................... 13-2
Transporting.................................................................................... 13-3
Precautions for Transporting Machines with Pad
Crawler Shoes............................................................................ 13-3
Control Lever (Hitachi Pattern) (Optional)............................ 13-6
Blade Lever...................................................................................... 13-7
Avoid Hitting Blade with Front-End Attachment............... 13-8
Blade Maintenance....................................................................... 13-9
CONTENTS
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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
1
MZX5-00-001EN-EU
5 3 M157-00-001
1. MODEL/TYPE
2. Product Identification Number
3. Year of Manufacturing
4. Operating mass (standard version)
5. Engine power in kW according to ISO14396 ; 2002
Product Identification Number
fNOTE: Marks to indicate the

*HCMDCY90K00030001* start and end of the PIN
PRODUCT IDENTIFICATION NUMBER (PIN)
M157-12-008
1
MACHINE NUMBERS
Engine
(ZX120-5,
TYPE : 160-5 class)
MFG. NO. :
M178-00-002
(ZX300-5,
330-5 class)
(ZX200-5,
240-5 class)
MDAA-00-001
Travel Motor
TYPE :
MFG. NO. :
M178-07-047
Swing Motor
TYPE :
MFG. NO. :
M178-07-086
2
MACHINE NUMBERS
Hydraulic Pump
(ZX120-5 class)
TYPE :
MFG. NO. :
MDAA-07-072
(ZX160-5 class)
TYPE :
MFG. NO. :
(ZX200-5, 240-5, 300-5, 330-5 class) MDAK-00-001
TYPE :
MFG. NO. :
TYPE :
MFG. NO. :
MDAK-00-003
3
MACHINE NUMBERS
MEMO
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4
SAFETY
Recognize Safety Information

 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.
SA-2644
Understand Signal Words

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

element of information.
S-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine.
 Keep your machine in proper working condition. SA-003
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
S-2
SAFETY
Prepare for Emergencies

 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone. SA-437
Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing SA-438
Wet weather gear
Respirator or filter mask
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
S-3
SAFETY
Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
S-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
S-5
SAFETY
Use Handholds and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
 Do not use any controls as hand-holds.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
 Before getting on or off the machine, check the condition
of the steps and handrails for sticking of slippery material
like grease or mud. Thoroughly remove such material if
stuck. In addition, repair the damage to the steps and/or
SA-439
handrails. Retighten loose bolts.
 Never get on and off the machine with tools in your
hands.
Adjust the Operator's Seat

 A poorly adjusted seat for either the operator or the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.
S-6
SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
 Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
 Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt is replaced every three
years regardless of its apparent condition.
S-7
SAFETY
Move and Operate Machine Safely

 Bystanders can be run over.
 Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or
 Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
 Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Use appropriate illumination. Check that all lights are SA-426
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the cab for
problems.
If there is, replace the problem part(s) or clean the mirror,
camera lens and the monitor display.
Refer to "Rear View Monitor" section on the cleaning of
the camera lens and the monitor display.
Operate Only from Operator's Seat

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or the
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444
S-8
SAFETY
Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be 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
Keep Riders off Machine

 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders
off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-379
S-9
SAFETY
Precautions for Operations

 Investigate the work site before starting operations.
 Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
 Clear all persons and obstacles from the area of operation
and machine movement. Do not permit persons
other than the operator to enter areas where there is
danger such as flying objects. Always beware of the
surroundings while operating. When working in a small
area surrounded by obstacles, take care not to hit the
upperstructure against obstacles.
 When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M178-05-007
S-10
SAFETY
Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
S-11
SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.
Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, install the Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
In order not to impair operator protective structure:
Replace damaged OPG guard. Never attempt to repair or
modify the guard.
OPG: Operator Protective Guard
SA-490
S-12
SAFETY
Restriction of Attachment Installation

 Do not install an attachment which exceeds specified
weight for the machine structure.
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
SA-481
Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or death.
 Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.
SA-491
S-13
SAFETY
Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do A
not allow personnel to stay around the machine while
traveling.
 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
SA-441
WRONG
SA-590
S-14
SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
S-15
SAFETY
Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle switch OFF.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
 Pull the pilot control shut-off lever to LOCK position.
SA-391
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-2273
S-16
SAFETY
Avoid Injury from Back-Over and Swing

Accidents
 If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
 Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
 Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
 USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW. SA-383
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
 No machine motions shall be made unless signals are
clearly understood by both signal person and operator.
 Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
 Keep windows, mirrors, and lights clean and in good
condition.
 Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
 Read and understand all operating instructions in the SA-384
operator’s manual.
S-17
SAFETY
Keep Person Clear from Working Area

 A person around the operating machine may be hit severely
by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects,
resulting in serious injury or death.
 Set up barriers and/or put a NO ADMISSION sign at the
machine operating site and areas exposed by flying
objects to prevent anyone from entering the work area.
 Before operating the machine, confirm that there are
no obstacles or person other than signal person from
working area.
SA-386
Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
SA-487
S-18
SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.
SA-488
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 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 SA-012
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.
 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-440
S-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-489
Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
 Before digging check the location of cables, gas lines, and
water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
 Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
SA-382
Have them mark all underground utilities.
Operate with Caution

 If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
 Take care to avoid hitting overhead obstacles with the
boom or arm.
SA-389
S-20
SAFETY
Avoid Power Lines

 Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric lines.
 When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
 Check and comply with any local regulations that may
apply.
 Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381
Precautions for Lightning

 Lightning may strike the machine.
If lightning comes close, immediately stop the operation,

and take the following action.
 When you are around the machine or operating cab-
less machine, evacuate to a safe place far away from the
machine.
 When you are in the cab, stay in the cab until lightning
has passed and safety is secured. Close the cab doors and
windows. Lower the bucket to the ground, and stop the
engine. Put your hands on your lap to avoid contact with
any metal surfaces. Never go out of the cab.
SA-2715
If lightning strikes the machine or near the machine, check
all of the machine safety devices for any failure after
lightning has passed and safety is secured. If any trouble is
found, operate the machine only after repairing it.
S-21
SAFETY
Never Allow Machine to Engage in Crane Work

 Never allow the machine to engage in crane work. Possibly,
serious personal injury or death may result.
 This machine is designed for digging and loading
operation.
 This machine is not equipped with a lifting device and
safety devices required for crane work.
SA-014
Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.
SA-432
S-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle switch OFF.
 Run engine at slow idle speed without load for 5 minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
 Pull the pilot control shut-off lever to the LOCK position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.
SA-390
Handle Fluids Safely−Avoid Fires

 Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
 Do not refuel the machine while smoking or when near
open flame or sparks.
 Always stop the engine before refueling the machine.
 Fill the fuel tank outdoors.
 All fuels, most lubricants, and some coolants are flammable.

 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers.
 Do not store oily rags; they can ignite and burn SA-018
spontaneously.
 Securely tighten the fuel and oil filler caps.
SA-019
S-23
SAFETY
Transport Safely
 Take care, the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395
3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck
or trailer using the front attachment functions when
driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the

"TRANSPORTING" chapter.
S-24
SAFETY
Practice Safe Maintenance

To avoid accidents:
 Understand service procedures before starting work.
 Keep the work area clean and dry.
 Do not spray water or steam inside cab.
 Never lubricate or service the machine while it is moving.
 Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving
the control levers several times. SA-028
7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of this manual. SA-527
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Turn the battery disconnect switch to OFF before
adjusting the electrical systems or performing welding on
the machine.
S-25
SAFETY
 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.
SA-037
Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102-4 SS3076175
Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you
work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
S-26
SAFETY
Stay Clear of Moving Parts

 Entanglement in moving parts can cause serious injury.
 To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
SA-026
SA-2294
Prevent Parts from Flying

 Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious
injury, blindness, or death.
 Do not attempt to remove GREASE FITTING or VALVE
ASSEMBLY.
 Do not attempt to remove grease fitting securing cover.
 As pieces may fly off, be sure to keep body and face away
from valve.
 Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly SA-344
resulting in severe personal injury or death.
 Travel reduction gears are under pressure.

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
S-27
SAFETY
Avoid Injury from Attachment Falling Accident

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 To avoid possible personal injury from attachment falling
accident, use a platform when replacing an attachment.
 Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
SA-034
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 Avoid possible injury from hot spraying water. DO NOT
remove the expansion tank 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 SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
S-28
SAFETY
Replace Rubber Hoses Periodically

 Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
 Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
 Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
S-29
SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to 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.
 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.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.
S-30
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 muffler
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.
Check Key Switch:

 If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
 If any abnormalities are found, be sure to repair them
Check Heat Shields:

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as muffler may cause fire. Always close the engine cover
while operating the machine.
S-31
SAFETY
Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window pane with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method.
SS-1510
Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
SA-016
S-32
SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable materials in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Turn the battery disconnect switch to the OFF position
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are SA-818
no abnormalities such as the area surrounding the welded
area still smoldering.
S-33
SAFETY
Avoid Heating Near Pressurized Fluid Lines

 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc.
SA-030
Avoid Applying Heat to Lines Containing

Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.
Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your authorized dealer.
S-34
SAFETY
Remove Paint Before Welding or Heating

 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
 Avoid potentially toxic fumes and dust.
 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable materials from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contaminations
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contaminations may exist. Spray water to prevent
asbestos fibers, silicon dust or other contaminations from
becoming airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contaminations SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contaminations.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
S-35
SAFETY
Prevent Battery Explosions

 Battery gas can explode.
 Keep sparks, lighted matches, and flame away from the
top of battery.
 Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 ˚C ( 60 ˚F ) first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.
 Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
 Be sure to wear eye protection when checking electrolyte
specific gravity.
Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for
proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.
SA-405
S-36
SAFETY
Handle Chemical Products Safely

 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
 A Safety Data Sheet (SDS) provides specific details on
chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
 Check the SDS before you start any job using a hazardous
chemical. That way you will know exactly what the risks
are and how to do the job safely. Then follow procedures
and use recommended equipment.
 See your authorized dealer for SDS’s (available only in SA-2579
English) on chemical products used with your machine.
Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations SA-226
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
S-37
SAFETY
Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.
S-38
SAFETY
Precautions for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside the rear tray situated
at the back of the operator's seat. There is a possibility that
a medical device, including an implantable device such as a
cardiac pacemaker, could be affected and malfunction due the
electrical waves emitted from the communication terminal
equipment.
Any person fitted with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.7 inches) apart
at all times. If this condition cannot be met, please contact
your authorized dealer and have the person in charge stop
the communication terminal equipment from functioning
completely, and confirm that it is not emitting electrical waves.
This machine is equipped with a communication terminal type
A or type B.
Consult your nearest authorized dealer for the type of
communication terminal.
Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
Type A Type B
E-GSM900 0.573 W/kg (914.8 MHz) 0.12 W/kg (897.6 MHz)
DCS-1800 0.130 W/kg (1710.2 MHz) 0.06 W/kg (1748.0 MHz)
WCDMA Band I 0.271 W/kg (1950.0 MHz) 0.05 W/kg (1950.0 MHz)
WCDMA Band VIII - 0.10 W/kg (892.6 MHz)
 This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this
machine, and a human body set apart by 3 cm.
 SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application
such as a mobile phone.
In Japan: Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).
In EU member nation: Under the "Council Recommendation

1999/519/EC 12 July 1999", the maximum SAR value is 2 W/kg.
In US: Under the "Federal Communications Commission (FCC)

Guidelines (FCC 1997)", the maximum SAR value is 1.5 W/kg.
In Canada: Under the "Canada's Radio Standards Specification

(RSS) -102", the maximum SAR value is 1.5 W/kg.
S-39
SAFETY
 Do not attempt to disassemble, repair, modify and displace
of the communication terminal, antenna and cables. Failure
to do so may cause damage or fire on the machine and the
communication terminal. (Before removing or installing the
communication terminal, consult your authorized dealer.)
 Do not pinch or forcibly pull cables, cords and connectors.

Failure to do so may cause damage or fire on the machine
and the communication terminal due to short/broken
circuit.
S-40
SAFETY
Notes on Protection of Operator’s Station when

the Machine Rolls Over
The cab corresponds to the structure to protect the operator
by absorbing impact energy when the machine rolls over (Roll-
Over Protective Structure (ROPS)).
However, when the machine mass exceeds the maximum
operating mass described in the ROPS certification by
modifying the machine or installing a special attachment,
the cab can not fulfill its protective function, possibly causing
In order to ensure the protective structure, follow the

instructions below.
 Consult your authorized dealer before welding parts or
drilling a hole on the cab, which possibly reducing the cab SS-3636
strength.
 Be sure to always fasten the seat belt when operating
the machine. IIf the machine rolls over without operator
fastening the seat belt, the operator may become injured,
may be thrown out from the cab and/or may become
crushed under the machine even though the cab has the
protective structure.
The ROPS certification is valid under the following conditions.

 The machine mass is lower than the maximum operating
mass described in the ROPS certification.
 The ROPS is properly installed.
 No modification is made to the ROPS.
 The ROPS is free from damages.
Maximum operating
Applicable Machine Model Number mass assuring the ROPS
SS-3944
Certificate number ROPS Model
of the ROPS Number
S-41
SAFETY SIGNS/Oceania Model Only
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 placing an
order of it to the Hitachi dealer.
3
7
18
9
5
1 2
10
RADIATOR CAP 12
14
8 11
19 12
13
15
OPEN
16
ZX330-5 class
17
16
7
SS-4021
S-42
1.
WARNING!
Prior to operation, maintenance, disassembling, and
transportation of the machine, be sure to read and
understand the Operator’s Manual.
SS4420332-2
2.
Sign indicates an electrocution hazard if machine is brought
too near electric power lines.
Keep a safe distance from electric power lines.
SS-862
3.
Sign indicates a hazard from falling window.
After raising window, be sure to lock it in place with lock
pins.
SS-863
S-43
4.
When moving the seat height/tilt lever downward, press the
lever grip with a palm from the top side. Do not grasp the
lever grip to operate the lever, possibly resulting in pinch of
your fingers into the seat stand.
SS4371371-3
5.
If the machine should overturn, the operator may become
injured and/or throw from the cab and/or crushed by the
overturning machine.
SS3088058
6.
Do not extend your hands or head from the window. Your
hands or head may come in contact with the boom.
SS-859
S-44
7.
Sign indicates a hazard of being hit by the working device of
the machine.
Keep away from machine during operation.
SS3092845
8.
Sign indicates a hazard of a flying plug from track adjuster
that could cause injury.
Read manual before adjusting track for safe and proper
handling.
SS-408
9.
Sign indicates a burn hazard from spurting hot water or oil if
radiator or hydraulic oil tank is uncapped while hot.
Allow radiator or hydraulic oil tank to cool before removing
cap.
SS-864
S-45
10.
Sign indicates a hazard of falling.
Do not stand on this place.
SS3092351
11.
Sign indicates a hazard of falling off the fender or hood.
Never stand close to the edge.
SS3092350
12.
Sign indicates a crush hazard by rotation of upper structure
of the machine.
Keep away from swinging area of machine.
SS-024
S-46
13.
Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic oil tank is uncapped while hot. Allow
radiator or hydraulic oil tank to cool before removing cap.
SSYA00036802-1
14.
Do not touch or open the radiator cap. When the cap is
opened, replace the cap with a new one.
SS-3590
15.
Sign indicates a hazard of rotating parts, such as belt.
Turn off before inspection and maintenance.
SS3092352
S-47
16.
Sign indicates a hazard of rotating parts, such as fan.
SSYA00008686
17.
Sign indicates an explosion hazard.
Keep fire and open flames away from this area.
Skin contact with electrolyte will cause burns. Splashed
electrolyte into eyes will cause blindness. Take care not to
touch electrolyte.
SS-411
18.
SS4467093-2
19.
SS-3212
S-48
SAFETY SIGNS/Asia/Middle and Near East Model Only
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 placing an
order of it to the Hitachi dealer.
3 4
1
20
8
23
19 10
11
2 6 7
12
14
RADIATOR CAP 13
16 9 14
15 22
OPEN
ZX330-5 class 18
21
17
8
SS-4033
S-49
1.
WARNING!
Prior to operation, maintenance, disassembling, and
transportation of the machine, be sure to read and
understand the Operator’s Manual.
SS4420332-2
2.
If the parked machine is unexpectedly moved, serious injury
or death due to crushing may result. Be sure to lower the
front attachment to the ground, lock the control levers,
and remove the engine key before leaving the machine
unattended.
SS4420333-2
3.
Sign indicates an electrocution hazard if machine is brought
too near electric power lines.
Keep a safe distance from electric power lines.
SS4420334-2
4.
Sign indicates a hazard from falling window.
After raising window, be sure to lock it in place with lock
pins.
SS4420335-2
S-50
5.
When moving the seat height/tilt lever downward, press the
lever grip with a palm from the top side. Do not grasp the
lever grip to operate the lever, possibly resulting in pinch of
your fingers into the seat stand.
SS4371371-3
6.
If the machine should overturn, the operator may become
injured and/or throw from the cab and/or crushed by the
overturning machine.
SS4654287-1
7.
Do not extend your hands or head from the window. Your
hands or head may come in contact with the boom.
SS4459990-2
8.
Sign indicates a hazard of being hit by the working device of
the machine.
SS3089581-1
S-51
9.
Sign indicates a hazard of a flying plug from track adjuster
that could cause injury.
Read manual before adjusting track for safe and proper
handling.
SS3086091-4
10.
Sign indicates a burn hazard from compressed air and
spurting hot oil if the oil inlet is uncapped during or right
after operation.
Read manual for safe and proper handling.
SS4459928-1
11.
Sign indicates a burn hazard from spurting hot water or oil if
radiator or hydraulic oil tank is uncapped while hot.
Allow radiator or hydraulic oil tank to cool before removing
cap.
SS4420336-2
12.
Sign indicates a hazard of falling.
Do not stand on this place.
SS3092126-1
S-52
13.
Sign indicates a hazard of falling off the fender or hood.
Never stand close to the edge.
SS3092125-2
14.
Sign indicates a crush hazard by rotation of upper structure
of the machine.
Keep away from swinging area of machine.
SS3086090-2
15.
Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic oil tank is uncapped while hot. Allow
radiator or hydraulic oil tank to cool before removing cap.
SSYA00036802-1
16.
Do not touch or open the radiator cap. When the cap is
opened, replace the cap with a new one.
SS-3590
S-53
17.
Sign indicates a hazard of rotating parts, such as belt.
SS3092127-1
18.
Sign indicates a hazard of rotating parts, such as fan.
SSYA00008776-2
19.
Use the handle only to open or close the front window. Do
not use the handle to enter or leave the cab. If the window
is not locked, it may move possibly causing you to lose your
balance and fall.
SSYA00040415
20.
To those persons fixed with any medical device. Including
implantable device such as a cardiac pacemaker. Please read
the instruction manual carefully and follow the instructions
before using this machine.
SSYA00040416
S-54
21. A
Sign indicates an electrical hazard from handling the cable.
Read manual for safe and proper handling.
SS4459714-1
Sign indicates an explosion hazard. B

Keep fire and open flames away from this area.
SS4460067-1
Skin contact with electrolyte will cause burns. Splashed C

electrolyte into eyes will cause blindness. Take care not to
touch electrolyte.
SS4460056-1
S-55
22.
WARNING
IT CONTAINS NITROGEN UNDER HIGH PRESSURE.
DON’T ALLOW FIRE OR HEAT NEAR IT. DON’T TRY TO
DISASSEMBLE IT. SS-3212
WEAR EYE PROTECTION AND CAREFULLY DRILL A HOLE AT
THE POINT MARKED × TO RELEASE GAS PRESSURE BEFORE
DISPOSAL.
23.
Communication terminal can cause accidental bombing at
the blasting site. Keep the machine apart from the blasting
site and an electric detonator to maintain a safe distance.
SSYA00040417
S-56
COMPONENTS NAME
Components Name
1- Bucket
2- Bucket Cylinder 4
3- Arm 3
4- Arm Cylinder 2
5- Boom Cylinder 5
6- Boom
6
7- Fuel Tank
8- Hydraulic Oil Tank 7
8
9- Engine 9
1
10- Counterweight
11- Travel Device
12- Track 14
13- Front Idler
14- Cab 13
15- Expansion Tank 10

12
16- Battery Disconnect Switch 15
16
fNOTE: A typical model is shown in the right. Some parts may 11
MDC1-07-056
differ depending on the model of the machine.
1-1
GETTING ON/OFF THE MACHINE
Getting ON/OFF the Machine 4 5 3
Foot holds (1) and handrails (2) are provided in and around the
machine.
These are used to get on and off the cab safely as well as to do
inspection and maintenance of the machine safely.
Never jump on or off the machine as it is very dangerous.
2
dWARNING:
 Never attach a wire on foot holds (1) to lift the cab or
main body or while transporting the machine on a
truck or trailer as it is dangerous. 1 MDAA-01-329
 Door handle (3) is not a handrail. Do not use door
handle (3) as a handrail when getting on and off the
machine.
 Do not hold control levers (4) or pilot control shut-off
lever (5) when getting on and off the machine.
MDAA-01-338
1-2
OPERATOR'S STATION
Cab Features
1 2 3 4 5 6
Std. Model 7
1- Left Control Lever/Horn Switch

2- Left Travel Pedal
3- Left Travel Lever 13
8
4- Right Travel Lever
5- Right Travel Pedal
9
6- Right Control Lever/Power Boost Switch
7- Multi Function Monitor Panel
10
8- Switch Panel 12
9- Key Switch
10- Switch Panel (for Optional Equipments)
Glove Compartment (without Optional Equipments)
11- Operator's Seat
12- Cab Door Release Lever 11 MDAA-01-335
13- Pilot Control Shut-Off Lever
14- Glove Compartment
14
15- Fuse Box 18 16
16- Cigar Lighter 15
18- Glove Compartment (Hot and Cool Box)
19- Engine Stop Switch 17
MDAA-01-289
19 MDAA-01-290
1-3
OPERATOR'S STATION
Cab Features
1 2 3 4 5 6 7
K. Model 8
1- Left Control Lever/Horn Switch

2- Left Travel Pedal
3- Left Travel Lever 14
9
4- Right Travel Lever
5- Right Travel Pedal
10
6- Attachment Pedal
7- Right Control Lever/Power Boost Switch
8- Multi Function Monitor Panel 11
13
9- Switch Panel
10- Key Switch
12- Operator's Seat 12 MDAA-01-339
13- Cab Door Release Lever
14- Pilot Control Shut-Off Lever
15
15- Glove Compartment 19 17
16- Fuse Box 16
17- Cigar Lighter
19- Glove Compartment (Hot and Cool Box)
20- Engine Stop Switch 18
MDAA-01-289
20 MDAA-01-290
1-4
OPERATOR'S STATION
Multi Function Monitor

Feature
The multi function monitor displays various meters,
indicators, radio and air conditioner, numeric keypad lock
function, rearview camera image, work mode selection and
maintenance screen.
Screen Configuration
The multi function monitor consists of the following
screens.
There are 7 menus, and a further 14 sub menus.
Basic Screen Main Menu Alarm List
Air Conditioner
Radio
Work Mode
Mail (Optional)
Setting Menu Date and Time
Attachment Adjustment
Attachment Name Input
Auto Shut-Down
Password Change (Optional)
Sub Meter Selection
Rear View Camera Monitor
Brightness Adjustment
Unit Selection
Main Menu Sequence Change
Information Menu Operation
Maintenance
Monitoring
1-5
OPERATOR'S STATION
Default Setting
Function Item Default

Auto Shut-Down ON/OFF of Auto Shut-down OFF
Setting Time 1 min
fNOTE: Typical functions are shown in the table. Check the initial values of other functions on each monitor screen.
1-6
OPERATOR'S STATION
Basic Screen
1 2 3 4 5 6 7
1- Work Mode Display
2- Auto-Idle Display
3- Power Mode Display
18 8
4- Hour Meter, Clock
5- Auxiliary 9
17
6- Auxiliary
16
7- Preheat Display
15
8- Seat Belt Display 10
14
9- Fuel Gauge
13
10- Sub Meter Display
11- Radio Display
12- Air Conditioner Display
13- Coolant Temperature Gauge
14- Auxiliary
15- Overload Alarm Display (Optional)
16- Travel Mode Display 12 11
17- Auto Shut-Down Display

18- Auxiliary MDEB-01-020EN
1-7
OPERATOR'S STATION
How to Use Screens

Displaying Basic Screen
IMPORTANT: Start the engine after the basic screen is
displayed.
When the key switch is turned to the ACC or ON position,

the starting screen displays for about 2 seconds. When the
key switch is kept in ACC position, only hour meter, clock
and radio will be displayed. When the key switch is turned
from ACC to ON position, the basic screen will be displayed.
Starting Screen MDAA-01-003
Basic Screen MDAA-01-001
IMPORTANT: When the key switch is turned to ON

position, the alternator alarm will be displayed on the
basic screen. Until the alternator starts generating
power after the engine starts, the alternator alarm is
displayed on the basic screen.
Alternator Alarm
MDAA-01-042
1-8
OPERATOR'S STATION
 Display of Meters Work Mode 4
Items to be displayed
4- Hour Meter, Clock
9- Fuel Gauge
13- Coolant Temperature Gauge 9
 Work Mode Display 13

The attachments being used are displayed.
Digging Mode
Attachment Mode MDAA-01-001

Breaker
Pulverizer
Crusher
Vibrating Hammer
Grapple
Clamshell
Others
1-9
OPERATOR'S STATION
 Auto-Idle Display (2) 2 3
When the auto-idle is selected from the switch panel, the
auto-idle display (2) displays. 7
When the key switch is turned ON while the auto-idle
switch is also ON, the auto-idle display blinks for 10 8
seconds.
17
10
 Power Mode Display (3) 16
Displays the power mode selected from the switch panel. 15
 Preheat Display (7)

While the current is being supplied to the glow plug, the
indicator is displayed. 12 11
 Seat Belt Display (8) MDEB-01-286EN

Turns ON when the key switch is in the ON position, and
turns OFF 5 seconds after the engine starts.
 Sub Meter Display (10)

Fuel consumption or breaker hour meter is displayed.
 Radio Display (11)

Displays the radio panel.
 Air Conditioner Display (12)

Displays the air conditioner panel.
 Overload Alarm Display (15) (Optional)

The system measures the load of suspended load from
the bottom pressure of boom cylinder. When overload is
detected, an alarm is displayed.
 Travel Mode Display (16)

Displays the travel mode selected from the switch panel.
 Auto Shut-Down Display (17)

When the auto shut-down is turned ON from the menu
screen, auto shut-down display (17) displays.
When the key switch is turned ON while the auto shut-
down is enabled, auto shut-down display (17) blinks for 10
seconds.
1-10
OPERATOR'S STATION
Hour Meter
Total (accumulated) machine operation hours counted since
the machine started working, are displayed in hours (h).
One digit after the decimal point indicates tenths of an hour
(6 minutes).
MDAA-01-021
Clock
Indicates the present time.
24-h/12-h display can be selected.
(Refer to "Date and Time" for switching the display mode.)
Fuel Gauge
The remaining fuel amount is indicated by the needle.
Refuel before the needle reaches "E".
MDAA-01-276
Coolant Temperature Gauge

The engine coolant temperature is indicated with a needle.
Normally the needle is around the center of the scale during
operation.
M1U1-01-047
Operating Status Icon Display 1 2 3

Displays icons indicating the current status of attachment
(1) selected from the work mode selection screen, auto-idle
(2) ON, power mode (3), preheat indicator (4), travel mode 4
(5) and auto shut-down (6) ON selected from the switch
panel, when these systems are activated.
MDED-01-501
6 5
1-11
OPERATOR'S STATION
Security Functions (Optional)

Input Password
IMPORTANT:
When required to activate the numeric keypad

function, consult your authorized dealer.
If the password is forgotten, the machine must be

modified. Be extremely careful not to forget the
password.

1. Turn the key switch ON. After the starting screen is
displayed, the password input screen will be displayed.
2. Input a password by using the numeric keypad.
3. The monitor unit matches the input password to the

registered one. If they match, the basic screen displays.
The engine is ready to run. If an incorrect password is
input 3 times, a buzzer sounds for 30 seconds. During
that time, the buzzer does not stop even if the key switch MDAA-01-085EN
is turned ON/OFF. Password Input Screen
fNOTE: If you make a mistake while entering the password,

push the CLEAR key in order to erase the entered characters.
4. After 30 seconds, if the key switch is turned to the ON

position, the starting screen displays and the password
input screen displays again. Then the password can be
input again.
5. If an incorrect password is input again, the buzzer
sounds for a further 30 seconds.
MDAA-01-086EN
1-12
OPERATOR'S STATION
Extending Password Duration Time
IMPORTANT: This operation is applicable only to those
machines that require a password.
By using the password duration screen, password duration

time can be set. When restarting the machine, a password
need not be input within the specified timeframe.
1. When turning the key switch from ON to ACC position,

the monitor unit displays the password duration screen
for 10 seconds.
MDAA-01-087EN
Password Duration Screen (Key Switch: OFF)
2. While the password duration screen is still displayed,
rotate selector knob (1) to highlight the relevant time.
Pushing selector knob (1) sets the password duration 1
time.
Duration time 0 minute
fNOTE: If the password duration time is not set explicitly, a

duration of 0 is assumed.
MDCD-01-026
3. If turning the key switch to the ON position within the
password duration time, the monitor unit displays the
basic screen after the starting screen.
MDAA-01-001
1-13
OPERATOR'S STATION
Alarm Occurrence Screen

In case any abnormality occurs, alarm marks (1) are displayed
on the basic screen.
If 6 or more alarms are generated, alarm marks (1) can be
scrolled by rotating switch (2).
Indicator MDCD-01-021
MDCD-01-026
1-14
OPERATOR'S STATION
Follow the procedure below to display detailed information for
an alarm.
Push selector knob (1) on the basic screen to display the

main menu.
Rotate selector knob (1) to select the alarm list, and push
selector knob (1).
Rotate selector knob (1) to select a required alarm from the

alarm list, and push selector knob (1).
Detailed information of the selected alarm will be displayed. MDCD-01-003
MDCD-01-026
fNOTE:
 The main menu displays the alarm list only when an alarm
occurs.
 The alarm list contains only currently generated alarms.
MDAA-01-077EN
MDCD-01-006EN MDCD-01-007EN
1-15
OPERATOR'S STATION
Remedy
Display Contents of Alarms Remedy

Engine Oil Level Alarm Check engine oil level and refill oil.
Overheat Alarm** Engine coolant temperature has abnormally increased.

Stop operation. Run the engine at slow idle speed to lower the coolant
temperature.
Hydraulic Oil Overheat Alarm Hydraulic oil temperature is above normal.

(Only ZX330-5 class) Stop operation, check hydraulic oil level, check for leaks etc.
Coolant Level Alarm Check coolant level and add coolant if necessary.
Engine Trouble Alarm Engine or engine related parts are abnormal.

Contact your nearest authorized dealer.
Engine Oil Pressure Alarm* Engine oil pressure has decreased.

Immediately stop the engine. Check the engine oil system and oil
level.
Engine Start Disabled As the pilot shut-off lever is lowered, the engine cannot start.
Engine Start Disabled As the engine emergency switch is ON, the engine cannot start.
Alternator Alarm Electrical system is abnormal.

Check alternator and battery system.
fNOTE:
 *Alarm mark is displayed and buzzer will sound.
 **Alarm mark is displayed and buzzer will sound. Turn engine control dial to the slow idle position, and buzzer will stop.
1-16
OPERATOR'S STATION
Display Contents of Alarms Remedy

Fuel Level Alarm Fuel level is low.
Refill fuel as soon as possible.
Air Cleaner Restriction Alarm Air filter elements are clogged.

Clean or replace air filter elements.
Hydraulic Oil Filter Restriction Hydraulic oil filter is clogged.

Alarm (Optional)** Replace hydraulic oil filter element.
Fuel Filter Restriction Alarm* Fuel filter is clogged.

Replace fuel filter element.
Water Separator Alarm Water separator is full.

Drain water.
System Failure Alarm Communication system is abnormal.

Contact your nearest authorized dealer.
Electric Lever Alarm (Optional) Electric Lever System Is Abnormal.

Contact Your Nearest Authorized Dealer.
Pilot Control Shut-Off Lever Pilot control shut-off lever system is abnormal.
Alarm Contact your nearest authorized dealer.
fNOTE:
 *If the indicator comes ON immediately after replacing the fuel filter, air mixed in the system during replacement may be
the cause. Be sure to bleed air from the fuel system when replacing the fuel filter. (When air is bled, the indicator will go
OFF.)
 **The hydraulic oil filter alarm lights only when the high performance element (optional) is used.
1-17
OPERATOR'S STATION
 Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error Display
If the fuel sensor is faulty, the color of the fuel mark changes Sensor Error Display
and the needle disappears. If the harness between the
fuel sensor and the controller unit is broken, the needle
disappears.
 Coolant Temperature Sensor Error Display

If the coolant temperature sensor is faulty, color of the
temperature mark changes and the needle disappears.
If the harness between the temperature sensor and the
controller unit is broken, the needle disappears.
MDAA-01-024EN
 Engine Speed Control Display

Engine warming-up operation due to low coolant
temperature. The engine speed can not be changed during
this operation. While the time is controlling the engine
speed, mark (2) is displayed on monitor (1). When the
control completes, mark (2) goes OFF and the engine speed
becomes adjustable. 2 1
MDAA-01-355
1-18
OPERATOR'S STATION
Main Menu
Push selector knob (2) while displaying Basic Screen (1) to 1
display Main Menu screen (3).
The Main Menu screen contains the items shown in the figure
to the right. The alarm list is displayed only when an alarm is
generated.
Mail (optional) menu will not be displayed unless they are set
beforehand.
MDAA-01-001EN
MDCD-01-026
MDAA-01-077EN
MDAA-01-190EN
1-19
OPERATOR'S STATION
Air Conditioner
1
Most air conditioner functions are operated by using switches
(3) and (4), however air vent selection and turning A/C ON and
OFF are performed from the air conditioner setting screen in
the menu. (Refer to the page 1-90)
Circulation Air Mode

1. Push selector knob (2) while displaying Basic Screen (1)
to display Main Menu screen (5).
2. Rotate selector knob (2) to highlight Air Conditioner (6).
MDAA-01-001EN
3. Push selector knob (2) to display Air Conditioner screen
(7).
2
Rotate selector knob (2) to highlight (8) mark. 3
4. Push selector knob (2) to set the circulation air mode. 4
5. Push selector knob (2) again to switch the fresh air mode.
Air Conditioner ON/OFF

1. Rotate selector knob (2) to highlight A/C (9).
2. Push selector knob (2) to turn the air compressor ON.
MDCD-01-026
3. Push selector knob (2) again to turn the air compressor
OFF.
fNOTE: When the function is ON, the mark "" is displayed in 5

green. When the function is OFF, the mark "" is displayed in
gray.
6
IMPORTANT: If mark (10) is displayed on the air
conditioner display, communication between the air
conditioner and the monitor is abnormal. Consult your
authorized dealer.
MDAA-01-089EN
8
9
MDAA-01-091EN
10
MDAA-01-226
1-20
OPERATOR'S STATION
Radio
Most radio functions are operated by using switches (3) and 1
(4), however memory channel setting, seek function, TONE
adjustment, and AUTO PRESET are done at the radio screen in
the main menu.

2. Rotate selector knob (2) to highlight Radio (6).
3. Push selector knob (2) to display the radio screen.
(Refer to the page 1-101) MDAA-01-001EN
IMPORTANT: If mark (7) is displayed on the radio display,

communication between the radio and the monitor is 2
abnormal. Consult your authorized dealer.
3
Push the numeric keypad of 1 to 8 while the radio is ON, the 4
radio station will switch to memorized channel of 1 to 8. (Refer
to 1-82 and 1-102)
MDCD-01-026
MDAA-01-092EN
MDAA-01-227
1-21
OPERATOR'S STATION
Work Mode
Front attachment is selected in Work Mode screen (5) under 1
the Work Mode menu in the main menu.
Attachment Selection
2. Rotate selector knob (2) to highlight Work Mode (4).
3. Push selector knob (2) to display Work Mode screen (5).
4. Rotate selector knob (2) to highlight the desired front
MDAA-01-001EN
attachment.
(In the right example, "Bucket" is highlighted.)
5. Push selector knob (2) to enable the changes. 2
MDCD-01-026
MDAA-01-100EN
MDAK-01-101EN
1-22
OPERATOR'S STATION
Mail (Optional)
IMPORTANT: This function is available only to a machine 1
equipped with a communication terminal. When using
the mail function, consult your authorized dealer.

2. Rotate selector knob (2) to highlight Mail (4).
3. Push selector knob (2) to display Mail screen (5).
4. Rotate selector knob (2) to highlight desired request.
MDAA-01-001EN
5. Push selector knob (2) to send mail information to the
comunication terminal.
 General Request 2
 Fuel Replenishment Request
 Service Maintenance Request
 Forwarding Request
MDCD-01-026
MDAA-01-109EN
MDAA-01-110EN
1-23
OPERATOR'S STATION
6. While mail information is sent to the communication
terminal, the message "Wait." is displayed on the screen.
MDAA-01-111EN
7. When the communication terminal completes receiving

mail information, the message "Request Is Accepted." is
displayed on the screen.
Push the return to previous screen switch to return to
the Mail screen.
8. Then, a mail is sent from the communication terminal to

the central server.
fNOTE:
 Depending on the machine's operating environment, the
mail may not be sent. MDAA-01-112EN
 When the communication terminal could not receive the

mail, the message "Failed." is displayed on the screen.
MDAA-01-113EN
1-24
OPERATOR'S STATION
Setting Menu
Setting menu consists of date and time setting, attachment 1
adjustment, attachment name, auto shut-down setting,
change password, selecting sub meter, brightness adjustment
of rear view camera monitor and screen.

2. Rotate selector knob (2) to highlight Setting Menu (4).
3. Push selector knob (2) to display Setting Menu screen
(5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
MDAK-01-128EN
1-25
OPERATOR'S STATION
Date and Time

Time, date and display mode can be set on this screen. Year- 1
month-day format and 24h/12h display mode are selected in
the display setting.
Time Adjustment
(5). MDAA-01-001EN
4. Rotate selector knob (2) to highlight Date and Time (6).
MDCD-01-026
MDAA-01-114EN
MDAK-01-115EN
1-26
OPERATOR'S STATION
5. Push selector knob (2) to display Date and Time screen
(7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Time Setting (8).

7. Push selector knob (2) to display Time Setting screen (9). 7
MDAA-01-117EN
8. Rotate selector knob (2) to highlight Hour or Minute (10)
and push selector knob (2).
9. Rotate selector knob (2) to adjust the clock. Rotate 9
clockwise to adjust the number upwards, and
counterclockwise to decrease it..
10. Push selector knob (2) to end the Time setting 10
procedure.
11
11. Rotate selector knob (2) to highlight (11). Push
selector knob (2) to make the change.
MDAA-01-118EN
MDAA-01-121EN
1-27
OPERATOR'S STATION
Date Adjustment
to display Main Menu screen (3). 1

(5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
MDAK-01-115EN
1-28
OPERATOR'S STATION
(7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Date Setting (8).

7. Push selector knob (2) to display Date Setting screen (9). 7
MDAA-01-122EN
8. Rotate selector knob (2) to highlight Year, Month or Day
(10) and push selector knob (2).
9. Rotate selector knob (2) to adjust the date. Rotate 9
clockwise to adjust the number upwards, and
counterclockwise to decrease it.
10. Push selector knob (2) to end the date setting procedure. 10
11. Rotate selector knob (2) to highlight (11). Push

selector knob (2) to make the change. 11
MDAA-01-123EN
MDAA-01-127EN
1-29
OPERATOR'S STATION
Display Mode Setting

(5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
MDAK-01-115EN
1-30
OPERATOR'S STATION
(7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Display Form (8).
MDAA-01-228EN
7. Push selector knob (2) to display Display Form screen (9).

8. Rotate selector knob (2) to highlight Time or Date (10) 9
and push selector knob (2).
Time : Each time selector knob (2) is pushed, the time 10
format is changed as follows: 12 h  24 h  12 h.
Date : Each time selector knob (2) is pushed, the date
format is changed as follows: YYYY/MM/DD 
MM/DD/YYYY  DD/MM/YYYY  YYYY/MM/DD.
MDAA-01-229EN
MDAA-01-230EN
MDAA-01-231EN
MDAA-01-232EN
MDAA-01-233EN
MDAA-01-234EN
1-31
OPERATOR'S STATION
Attachment Adjustment
The supply flow rate to an attachment, the operational priority 1
for combined operation of an attachment and arm roll-in/arm
roll-out can be adjusted on the Attachment Adjust screen.
The attachment adjustment can be done when the work
mode is set to an attachment other than the bucket. Select an
attachment other than the bucket on the work mode screen.
(Refer to "Work Mode".)
Flow Rate Adjustment

to display Main Menu screen (3). MDAA-01-001EN

2
(5).
4. Rotate selector knob (2) to highlight Attachment
Adjustment (6).
MDCD-01-026
MDAA-01-114EN
MDAK-01-128EN
1-32
OPERATOR'S STATION
5. Push selector knob (2) to display Attachment Adjustment
screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Pump Flow Rate (8).
MDAK-01-129EN
7. Push selector knob (2) to display Pump Flow Rate screen

(9).
8. Rotate selector knob (2) clockwise or counterclockwise 9
to adjust the pump flow rate.
MDAA-01-130EN
1-33
OPERATOR'S STATION
Priority (arm roll-out) (Except ZX330-5A class)
Select an attachment other than the bucket on the work
mode screen. (Refer to 1-22) 1

(5).
Adjustment (6).
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
MDAK-01-128EN
1-34
OPERATOR'S STATION
5. Push selector knob (2) to display Attachment Adjustment
screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Priority (Arm Roll-

Out) (8).
7
MDAK-01-235EN
7. Push selector knob (2) to display Priority (Arm Roll-Out)

screen (9).
8. Rotate selector knob (2) clockwise to increase flow 9
rate to the attachment. Rotate selector knob (2)
counterclockwise to increase flow rate to the arm roll-
out circuit.
MDAA-01-132EN
1-35
OPERATOR'S STATION
Attachment Name Input

Attachment name can be changed on this screen. 1

(5).
4. Rotate selector knob (2) to highlight Attachment Name
Input (6).
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
MDAK-01-133EN
1-36
OPERATOR'S STATION
5. Push selector knob (2) to display Attachment Name
Input screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight desired attachment

name (8).
7
MDAK-01-134EN
7. Push selector knob (2) to display Name Change screen
(9).
8. Rotate selector knob (2) right or left to highlight a 9
character, and push selector knob (2).
9. After inputting the new name, rotate selector knob (2)
to highlight "SET". Push selector knob (2) to finalize the
setting.
fNOTE: In order to delete the last entered character, rotate

selector knob (2) to highlight "BS" (Back Space), and then push
selector knob (2). In order to delete all entered characters,
rotate selector knob (2) to highlight "ALL CLEAR". Push selector
knob (2). MDAA-01-137EN
MDAA-01-145EN
1-37
OPERATOR'S STATION
Auto Shut-Down
dWARNING: This function automatically stops

the engine. Take extra care on the work and work
1
environment when using this function.
The auto shut-down function can be set in this screen. Set

the auto shut-down time and enable (ON) the function
beforehand. The engine automatically stops after the preset
time at the state in which the pilot control shut-off lever
is pulled. 30 seconds before the engine stop, the monitor
displays a message that engine will be stopped and the
indicator starts flashing. The buzzer also sounds. The buzzer MDAA-01-001EN
sounds once at 30 seconds before, and then continuously
sounds from 15 seconds. The engine speed decreases to the
idling speed, and then stops after 15 seconds. When the pilot
2
control shut-off lever is pushed before stopping the engine,
the auto shut-down is disabled and the engine will not stop.
IMPORTANT: When the engine stops by the auto shut-

down function, turn the key switch to ACC or OFF once
and then turn it to START to restart the engine. Turn
the key switch OFF after auto shut-down when leaving
the machine for long period of time. Do not leave the
machine after auto shut-down. Failure to do so may
discharge the batteries.
MDCD-01-026
Auto Shut-Down: ON/OFF

3
(5).
4. Rotate selector knob (2) to highlight Auto Shut-Down (6).
MDAA-01-114EN
MDAK-01-147EN
1-38
OPERATOR'S STATION
5. Push selector knob (2) to display Auto Shut-Down screen
(7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight ON (8).

7. Push selector knob (2) to set the auto shut-down 7
function ON. Push selector knob (2) again to turn the
auto shut-down function OFF. 8
fNOTE: When the function is ON, the mark "" is displayed in

gray.
MDAA-01-148EN
Acting Time Setting
1. On Auto Shut-Down screen (7), rotate selector knob (2)
to highlight Setting Time (9) and push selector knob (2).
2. Rotate selector knob (2) to adjust Auto Shut-Down
acting time.
9
3. Push selector knob (2) to make the change.
fNOTE: 30 seconds before the engine stops, the monitor will

display "Engine Shut-Down Soon." message (10).
MDAA-01-150EN
10
MDAA-01-146EN
1-39
OPERATOR'S STATION
Password Change (Optional)

1. Push selector knob (2) while displaying Basic Screen (1) 1
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
1-40
OPERATOR'S STATION
(5).
5
4. Rotate selector knob (2) to highlight Password Change
(6). 6
MDAA-01-156EN
5. Push selector knob (2) to display Password Change
screen (7). 2
MDCD-01-026
MDAA-01-157EN
6. Input current password from the numeric keypad.
Current Password
MDAA-01-158EN
1-41
OPERATOR'S STATION
7. Input the new password and push selector knob (2). 3 to
8 digits can be input for password.
MDAA-01-159EN
New Password
MDAA-01-160EN
1-42
OPERATOR'S STATION
8. Input the new password again to confirm it and push
selector knob (2).
MDAA-01-161EN
MDAA-01-162EN
MDCD-01-026
9. The password has been changed.
MDAA-01-163EN
1-43
OPERATOR'S STATION
Sub Meter
A sub meter selection menu that can be added to the fuel 1
meter is selected on this screen. OFF, Fuel Consumption
Indicator and Breaker Hour Meter are provided. The breaker
Sub Meter
hour meter indicates the breaker operation time.

(5).
MDAA-01-315EN
4. Rotate selector knob (2) to highlight Sub Meter Selection
(6).
2
MDCD-01-026
MDAA-01-114EN
MDAA-01-164EN
1-44
OPERATOR'S STATION
5. Push selector knob (2) to display Sub Meter Selection
screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight desired sub meter

(8). (Selecting OFF will not display a sub meter.)
7
7. Push selector knob (2) to enable the changes.
8
fNOTE:
 Only one sub meter can be selected at a time.

 When a display is selected, the mark "" is displayed in

green. When not selected, the mark "" is displayed in gray.
MDAA-01-165EN
1-45
OPERATOR'S STATION
Rear View Camera Monitor
dWARNING: 1
 Switching the rear view camera monitor OFF may
result in serious personal injury or damage to the
machine, due to being unable to see the view from
the rear of the machine. If the image from the rear
view camera is not displayed on Basic Screen (1) of
the monitor, follow the instructions on this page to
display it.
 The image displayed on the rear view monitor is
meant only as an aid. Actual position and distance MDAA-01-001EN
of people and objects in the rear view monitor will
be different. When operating the machine, pay
thorough attention to the surrounding situation.
2
Rear View Camera ON (Factory Setting: ON)
(5).
4. Rotate selector knob (2) to highlight Rear View Camera
Monitor (6). MDCD-01-026
MDAA-01-114EN
MDAA-01-168EN
1-46
OPERATOR'S STATION
5. Push selector knob (2) to display Rear View Camera
Monitor screen (7).
2
MDCD-01-026
6. Push selector knob (2) to turn the rear view camera

monitor ON.
7
IMPORTANT:
In order to obtain a clear image, clean the lens and

the monitor display before operating the machine.
Never attempt to change the mounting position of

the rear view camera.
Consult your authorized dealer if any abnormality is

found on the rear view image.
MDAA-01-169EN
fNOTE: The monitor display and camera lens surface are resin
product. Lightly wipe the surface with a wet clean cloth. Never
use an organic solvent.
1-47
OPERATOR'S STATION
Brightness Adjustment
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
(5).
4. Rotate selector knob (2) to highlight Brightness 5
Adjustment (6).
MDAA-01-171EN
1-48
OPERATOR'S STATION
5. Push selector knob (2) to display Brightness Adjustment
screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) clockwise to make the screen

brighter, counterclockwise to make the screen darker.
7
MDAA-01-172EN
fNOTE:
 When the light is turned ON, the monitor screen changes
to night mode and mark (8) is displayed. Brightness can be
adjusted for day mode and night mode respectively.
8
 Even if the light is turned ON during daytime, you can
activate the daytime screen by pushing "0" (9) on the
numeric keypad.
MDAA-01-173EN
MDAA-01-018
1-49
OPERATOR'S STATION
Language Settings
MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN

(5).
4. Rotate selector knob (2) to highlight (6). 5
MDAA-01-176EN
1-50
OPERATOR'S STATION
5. Push selector knob (2) to display screen (7).

2
6. Rotate selector knob (2) to highlight the desired MDCD-01-026

language. Push selector knob (2) to make the change.
fNOTE: When a display is selected, the mark "" is displayed

in green. When not selected, the mark "" is displayed in gray.
7
MDAA-01-177EN
1-51
OPERATOR'S STATION
Lists of Display Language
Language Screen Display Language Screen Display

Japanese Indonesian
English Thai
Spanish Vietnamese
Italian Myanmarese
French Arabic
German Persian
Dutch Turkish
Russian Danish
Portuguese Estonian
Finnish Polish
Greek Icelandic
Swedish Croatian
Norwegian Slovenian
Chinese (Simplified) Romanian
Chinese (Traditional) Bulgarian
Korean Lithuanian
1-52
OPERATOR'S STATION
Unit Selection
Unit system displayed on the monitor can be selected in this 1
screen.

MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
(5).
4. Rotate selector knob (2) to highlight Unit Selection (6). 5
MDAA-01-181EN
1-53
OPERATOR'S STATION
5. Push selector knob (2) to display Unit Selection screen
(7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight the desired unit

system. Push selector knob (2) to set the unit (Metric or
US system). 7
MDAA-01-182EN
7. Before changing °C and °F, turn the blower of the air

conditioner ON.
Rotate selector knob (2) to highlight desired unit system
(°C or °F). Push selector knob (2) to set the unit.
When pressing selector knob (2), "Wait." will be will be
displayed and then the change will be completed.
MDAA-01-183EN
MDAA-01-184EN
1-54
OPERATOR'S STATION
Main Menu Sequence Change

Menu sequence of Air Conditioner, Radio and Work Mode 1
can be changed in this screen. Frequently used menu can be
located on top of the screen.

MDAA-01-001EN
MDCD-01-026
MDAA-01-114EN
1-55
OPERATOR'S STATION
(5).
4. Rotate selector knob (2) to highlight Main Menu 5
Sequence Change (6).
MDAA-01-186EN
5. Push selector knob (2) to display Main Menu Sequence

Change screen (7). 2
MDCD-01-026
6. Rotate selector knob (2) to highlight a menu to be on the

top of the screen. Push selector knob (2) to set the menu
to the top of the screen.
7
MDAA-01-187EN
1-56
OPERATOR'S STATION
Information Menu
The information menu includes Operation, Maintenance and 1
Monitoring.

2. Rotate selector knob (2) to highlight Information Menu
(4).
3. Push selector knob (2) to display Information Menu
screen (5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
MDAA-01-191EN
1-57
OPERATOR'S STATION
Operation
The Operation screen displays Fuel Consumption, Breaker 1
Operation, Attachment Operation, Travel Operation, and
Actual Operation menus. The Fuel Consumption screen
displays fuel consumption, operating hours, and fuel
consumption rate from resetting of the monitoring unit. The
Breaker Operation screen displays breaker operating hours,
machine operating hours and operating rate from resetting
the monitoring unit. The Attachment Operation screen
displays total operating hours of front attachment, travel and
all operation from resetting the monitoring unit.
MDAA-01-001EN
Fuel Consumption
2
(4).
screen (5).
4. Rotate selector knob (2) to highlight Operation (6).
MDCD-01-026
MDAA-01-190EN
5
6
MDAA-01-191EN
1-58
OPERATOR'S STATION
5. Push selector knob (2) to display Operation screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Fuel Consumption

(8).
7. Push selector knob (2) to display Fuel Consumption 7
screen (9).
8
MDAA-01-193EN
The Machine Operation Hours, Fuel consumption, and

Average Fuel Consumption rate can be checked on this
screen. 9
Push selector knob (2) to return to the previous screen. To
clear the Fuel Consumption and Machine Operation Hours,
rotate selector knob (2) to highlight CLEAR (10), and then
push selector knob (2).
IMPORTANT: Total fuel consumption and fuel

consumption rate depend on the operating 10
environment and the operation method of the
machine.
The values shown on the screen are just for reference. MDAA-01-194EN
A difference could arise between actual fuel
consumption and fuel consumption as displayed on
the monitor unit.
1-59
OPERATOR'S STATION
Breaker Operation

(4).
screen (5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
5
6
MDAA-01-191EN
1-60
OPERATOR'S STATION
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Breaker Operation

(8).
7. Push selector knob (2) to display Breaker Operation 7
screen (9).
MDAA-01-196EN
Operating Time, Machine Operation Hours and Operation

Ratio can be checked in this screen.
Push selector knob (2) to return to the previous screen. To 9
clear the Operation Time and Machine Operation Hours
data, rotate selector knob (2) to highlight CLEAR (10), and
then push selector knob (2).
10
MDAA-01-197EN
1-61
OPERATOR'S STATION
Attachment Operation

(4).
screen (5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
5
6
MDAA-01-191EN
1-62
OPERATOR'S STATION
2
MDCD-01-026

Operation (8).
7
MDAA-01-199EN
7. Push selector knob (2) to display Attachment Operation
screen (9).
9
The attachment Operating Time can be checked in this
screen.
Push selector knob (2) to return to the previous screen. To
clear the Operating Time data, rotate selector knob (2) to
highlight CLEAR (10), and then push selector knob (2).
10
MDAA-01-200EN
1-63
OPERATOR'S STATION
Travel Operation

(4).
screen (5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
5
6
MDAA-01-191EN
1-64
OPERATOR'S STATION
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Travel Operation (8).

7. Push selector knob (2) to display Travel Operation screen
(9). 7
MDAA-01-202EN
Total Travel Operating Time can be checked in this screen.

Clear selector knob (2) to return to the previous screen. To
reset the Operating Time data, rotate selector knob (2) to 9
10
MDAA-01-203EN
1-65
OPERATOR'S STATION
Actual operation

(4).
screen (5).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
5
6
MDAA-01-191EN
1-66
OPERATOR'S STATION
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Actual Operation

(8). 7
7. Push selector knob (2) to display Actual Operation screen
(9).
MDAA-01-205EN
The actual Operating Time can be checked in this screen.

Clear selector knob (2) to return to the previous screen. To
reset the Operating Time data, rotate selector knob (2) to 9
fNOTE: The Operating Time includes travel operation hours

as well as all other operations.
10
MDAA-01-206EN
1-67
OPERATOR'S STATION
Maintenance
The maintenance screen includes maintenance notice, 1
remaining hours until the next maintenance, and maintenance
intervals.
Maintenance Items
 Engine Oil
 Engine Oil Filter
 Hydraulic Oil
 Hydraulic Oil Pilot Filter
 Hydraulic Oil Full-Flow Filter
 Pump Transmission Oil
MDAA-01-001EN
 Travel Device Oil
 Swing Device Oil
 Swing Bearing Grease 2
 Air Cleaner Filter
 Fuel Filter
 Air Conditioner Filter
 Line Filter (Optional)
 User Setting 1
 User Setting 2
Maintenance Notice
to display Main Menu screen (3). MDCD-01-026

(4).
3. Push selector knob (2) to display Information Menu 3
screen (5).
4. Rotate selector knob (2) to highlight Maintenance (6).
MDAA-01-190EN
MDAA-01-223EN
1-68
OPERATOR'S STATION
5. Push selector knob (2) to display Maintenance screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight Maintenance Notice

(8).
7. Push selector knob (2) to turn the Maintenance 7
Notice ON. Push selector knob (2) again to turn the
Maintenance Notice OFF.
ON : When the required interval is reached, an
information message is displayed on the screen.
OFF : No notification message is displayed.
8
MDAK-01-208EN
fNOTE: When the required interval for an item is reached,

screen (9) is displayed for 10 seconds when the key is switched
ON. Push Return button to delete the notification. When
checking the maintenance items from the menu, an item
where the set time has been reached are marked with a
spanner.
MDAA-01-213EN
MDAA-01-214EN
1-69
OPERATOR'S STATION
Remaining Time and Maintenance Interval

(4).
screen (5).
4. Rotate selector knob (2) to highlight Maintenance (6).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
MDAA-01-223EN
1-70
OPERATOR'S STATION
5. Push selector knob (2) to display Maintenance screen (7).
2
MDCD-01-026
6. Rotate selector knob (2) to highlight a maintenance item

to be checked (8). (In the right example, Engine Oil is
selected.) 7
7. Push selector knob (2) to display the time remaining for
the selected maintenance item. 8
MDAA-01-336EN
Resetting Data
To reset the remaining time data, rotate selector knob (2) to
highlight RESET (9), and then push selector knob (2).
The value of the remaining hours is reset to that of the
change interval. The previous change date/hour is updated
with the current date and time.
Maintenance Interval Setting

To change the maintenance interval, rotate selector knob (2)
9
to highlight (11), and then push selector knob (2).
The background color of Maintenance Interval (10) changes,
then rotate selector knob (2) to adjust the time, and then
push selector knob (2) to enable the change.
MDAA-01-210EN
10
11
MDAA-01-212EN
1-71
OPERATOR'S STATION
Monitoring
Engine speed can be checked in this screen. 1

(4).
screen (5).
4. Rotate selector knob (2) to highlight Monitoring (6).
MDAA-01-001EN
MDCD-01-026
MDAA-01-190EN
MDAA-01-220EN
1-72
OPERATOR'S STATION
5. Push selector knob (2) to display Monitoring screen (7).
2
MDCD-01-026
MDAK-01-221EN
1-73
OPERATOR'S STATION
Switch Panel
1 2
1- Return to Previous Screen Switch
2- Return to Basic Screen Switch 3
3- Selector Knob
4- Temperature Control Switch/Mode Switch 4
5- AUTO/OFF Switch/Fan Switch 6

6- AM/FM Selector/Tuning Switch 5
7- Power Switch/Volume Control Knob
7
8- Engine Control Dial
9- Auto-Idle Switch 8
10- Travel Mode Switch 13
11- Power Mode Switch 9

12- Work Light Switch
10
13- Wiper/Washer Switch
11
14- Numeric Keypad
12
15- Overhead Window Wiper/Washer Switch (K Model)
14 MDCD-01-027
15
(K Model)
MDAA-01-241
1-74
OPERATOR'S STATION
Return to Previous Screen Switch (Monitor)
Push this switch to return to the previous screen.
MDAA-01-010
Return to Basic Screen Switch (Monitor)

Allows to return to the basic screen from any screen.
MDAA-01-011
Selector Knob (Monitor)

Push : Push this switch while the basic screen is displayed,
the menu screen opens.
Push this switch after the menu screen, the action
is confirmed.
Rotate : Moving the cursor.
MDAA-01-012
Temperature Control Switch/Mode Switch (Air

Conditioner)
Push : Air vent is selected.
Rotate : Setting the temperature.
MDAA-01-013
AUTO/OFF Switch/Fan Switch (Air Conditioner)

Push : Push this switch while the air conditioner OFF, it
turns AUTO. Push this switch while operating the
air conditioner, it turns OFF.
Rotate : Adjusting the blower speed.
MDAA-01-015
1-75
OPERATOR'S STATION
AM/FM Selector/Tuning Switch (Radio)
Push : AM/FM is selected.
Rotate : Adjusting radio frequency.
MDAA-01-014
Power Switch/Volume Control Knob (Radio)

Push : Turns power ON/OFF.
Rotate : Adjusting the volume.
MDAA-01-016
Engine Control Dial

Use engine control dial (1) to adjust engine speed. Fast Idle
The fully clockwise position : Fast Idle

The fully counterclockwise position : Slow Idle 1
Slow Idle
M1P1-01-068
1-76
OPERATOR'S STATION
Auto-Idle Switch
Auto-idle switch (2) sets the engine speed control mode to
either Auto-Idle ON or OFF.
2
 Auto-Idle Speed
When auto-idle switch (2) is turned to ON position, the
engine speed decreases to the idle after approximately 4
seconds at the state in which the control lever is turned to 3 MDAA-01-017
neutral.
This function saves fuel consumption.
When the auto-idle mode is selected, auto-idle indicator (3)
on the monitor panel lights.
fNOTE: Auto-idle control may not work completely until the

end of the warm-up.
MDCD-01-020SC
Travel Mode Switch
Two travel modes, FAST and SLOW, are selected by turning
the travel mode switch to either position.
Mark (Fast Speed Mode)

Mark (Slow Speed Mode)
MDCD-01-028
1-77
OPERATOR'S STATION
Power Mode Switch
Two engine speed modes, ECO and PWR modes are selected
by operating the power mode switch.
 ECO (Economy) Mode MDAA-01-274

1
Operate the machine in this mode when performing normal
work.
ECO is displayed on Power Mode Display (1).
MDAA-01-001EN
 PWR (Power) Mode 2
Use PWR (Power) mode when extra horsepower is needed.
PWR is displayed on Power Mode Display (2).
fNOTE: ECO mode is set automatically when starting the

engine. Set PWR mode if necessary.
MDAA-01-353
Work Light Switch
Work light switch has the following positions.
1 Position : Work light (3) on the base machine will light.

Also, the switch panel illumination will light.
2 Position : Work light (4) mounted on the boom and
work light (3) on the right side of the machine
MDCD-01-029
will light. At the same time, the switch panel
illumination will light. The monitor changes to
night mode.
OFF : Work lights (3), (4), and the switch panel
illumination will turn off.
fNOTE: When the key switch is turned OFF while the work 4
light switch is in 2-position, work light (4) turns ON for 30
seconds.
3
M157-01-146
1-78
OPERATOR'S STATION
Wiper/Washer Switch
The wiper and the window washer are operated using the Middle
Fast
wiper/washer switch. Slow
 Wiper
Turn the wiper/washer switch to the specified position to
operate the wiper.
OFF The wiper stops and is retracted.

INT Position The wiper operates intermittently at the
interval selected by the switch position as
described below. INT has three positions of MBFM-01-005
operating speed as shown below.
INT (Slow): The wiper operates at 8-second interval.
INT (Mid): The wiper operates at 6-second interval. Wiper
INT (Fast): The wiper operates at 3-second interval.
ON The wiper operates continuously.
fNOTE: When the front window (upper) is opened, the wiper

and washer will not operate. If the front window is opened
while operating the wiper, the wiper stops.
 Washer
Press and hold the wiper/washer switch to squirt washer
fluid onto the front window. When the wiper/washer switch
is pressed for more than 2 seconds, the wiper operates until
the switch is released. When the wiper/washer switch is
released, the wiper automatically retracts.
While operating the wiper in the INT mode, when the
wiper/washer switch is pressed, the wiper operation mode
is changed to the continuous operation mode.
fNOTE: The wiper motor protection control stops wiper

operation to prevent it from becoming immovable when
it operates long period of time under high load. When the M1U1-01-018
wiper stops, do not change the arm position and wait several
minutes until the wiper starts operating again.
1-79
OPERATOR'S STATION
Overhead Window Wiper and Washer Switch (K Model)
 Wiper Middle Fast
Turn the wiper/washer switch to the specified position to Slow
operate the wiper.
OFF The wiper stops and is retracted.

INT Position The wiper operates intermittently at the
interval selected by the switch position as
described below. INT has three positions of
operating speed as shown below.
MDAA-01-275
INT (Slow): The wiper operates at 8-second interval.
INT (Mid): The wiper operates at 6-second interval.
INT (Fast): The wiper operates at 3-second interval.
ON The wiper operates continuously.
 Washer
Press and hold the wiper/washer switch to squirt washer
fluid onto the front window. When the wiper/washer switch
is pressed for more than 2 seconds, the wiper operates until Wiper
the switch is released. When the wiper/washer switch is
released, the wiper automatically retracts.
While operating the wiper in the INT mode, when the
wiper/washer switch is pressed, the wiper operation mode
is changed to the continuous operation mode.
M157-01-081
Numeric Keypad
Used for inputting password.
Press the numeric keypad of 1 to 8 while the radio is ON,
the radio station will switch to memorized channel of 1 to 8.
When the light is turned ON, the monitor changes to night
mode screen.
Even if the light is turned ON, you can activate the daytime
screen by pushing "0" on the numeric keypad.
MDAA-01-018
1-80
OPERATOR'S STATION
Switch Panel (for Optional Equipment) Optional Switch Armrest

Location
fNOTE: The optional switch locations differ depending on

the kinds of optional devices are equipped. Before using
the switches, make sure what kinds of optional devices are
equipped. Raise the armrest when operating the optional
switch. All available optional devices are shown below.
 Travel Alarm Deactivation

 Swing Alarm Deactivation
 Rear Light
 Overlord Alarm
 Seat Heater
 Revolving
 Electrical Control Main MDAA-01-327
 ON/OFF Operation
1-81
OPERATOR'S STATION
Travel Alarm Deactivation Switch (Optional) 1
The travel alarm buzzer sounds during travel operation.

When pushing the mark of travel alarm deactivation
switch (1), the travel alarm buzzer function is deactivated.
M1U1-01-035
Swing Alarm Deactivation Switch (Optional) 2
The swing alarm system sounds the buzzer and turns the
beacon light ON during swing operation.
When pushing the mark of swing alarm deactivation
switch (2), the swing alarm buzzer function is deactivated.
M1U1-01-036
Rear Light Switch (Optional) 3
When rear light switch (3) is turned ON, the rear light at the
rear of the cab roof comes ON.
M1P1-01-070
4
Overload Alarm Switch (Optional)
During lifting load work with overload alarm switch (4) ON,
if overloading is detected, the buzzer sounds and overload
alarm indicator (5) on the multi-monitor comes ON. Turn
overload alarm switch (4) OFF to deactivate the overload
alarm system function.
M1U1-01-010
MDEB-01-286EN
1-82
OPERATOR'S STATION
Seat Heater Switch 6
When seat heater switch (6) is turned ON, the seat surface
is heated so that the seat section becomes warm. When the
temperature of the seat section is raised to the specified
temperature, heating is automatically stopped.
M1U1-01-011
7
Rotating Lamp Switch (Optional)
When rotating lamp switch (7) is turned ON, the rotating
lamp provided at the rear on the cab roof comes ON.
M1U1-01-012
Electrical Control Main Switch (Optional) 8

Turn the pilot control shut-off lever to UNLOCK position. The
electrical control (grip switch) system becomes operable
by pushing ON of the electrical control main switch (8). It
becomes OFF by pressing the switch again. It also becomes
OFF when the key switch is turned OFF or the pilot control
shut-off lever is turned to LOCK position.
MDAA-01-311
d CAUTION: When there is no need to use the electrical

control (grip switch) system, turn OFF the main switch
to avoid misoperation.
9
ON/OFF Operation Switch (Optional)

When the ( ) mark side of ON/OFF operation main switch
(9) is pressed, the ON/OFF operation (grip switch) system
becomes operable.
dCAUTION: When there is no need to use the ON/OFF

operation (grip switch) system, press the ( ) mark side MDAA-01-356
of the main switch to avoid misoperation.
1-83
OPERATOR'S STATION
Key Switch 1
2
1- OFF (Engine Off )
2- ACC (Horn, Radio etc.)
3
3- ON (Engine ON)
4- START (Engine Start) 4
MDCD-01-030
Power Boost Switch

Power boost switch (5) is provided on the top of the right
control lever.
While pressing power boost switch (5), the maximum digging
power is boosted within approximately 8 seconds to increase
work capacity.
5
MDAA-01-292
Horn Switch
Horn switch (6) is provided on the top of the left control lever.
The horn continuously sounds as long as the switch is pressed.
6
MDAA-01-293
1-84
OPERATOR'S STATION
Electrical Control Main Switch (Optional) 1

 Attachment Switch (Assist Operation) (Main Operation)
This switch is mainly used for optional devices and
attachments having rotary or tilt function. The attachment 2
becomes operable when ON of electrical control main
switch (1) is pushed and main switch indicator (2) is lit.
IMPORTANT: The attachment switch is operable only MDAA-01-311

when indicator (2) of electrical control main switch (1)
is lit. Indicator (2) will not light unless the pilot control
shut-off lever is in UNLOCK position. Besides, the
indicator (2) light turns OFF and the attachment switch
becomes inoperable when the pilot control shut-off
lever is placed in LOCK position while indicator (2) is
lit. To operate the attachment switch, place the pilot
control shut-off lever in UNLOCK position, and then
push ON of electrical control main switch (1) to turn on
indicator (2) light.
AUX Function Lever 1

1. Auxiliary 6 4 3 1
2. Power Boost Switch
5 2
3. Attachment Switch (Assist Operation)
4. Auxiliary
5. Horn Switch
6. Auxiliary
Left Control Lever Right Control Lever

MDAA-01-337 MCGB-01-030
1-85
OPERATOR'S STATION
ON/OFF Operation Switch (Optional)

 Attachment Switch (Assist Operation)
This switch is mainly used for optional devices and
attachments having rotary or tilt function. The attachment
moves only when the switch is pressed.
IMPORTANT: When the ( ) mark side of ON/OFF

operation main switch (1) is pressed, the attachment MDAA-01-356
switch becomes operable.
AUX Function Lever 3

2. Power Boost Switch
3. Auxiliary
4. Auxiliary
5. Horn
dCAUTION:
 These switches are provided for operating
attachments of this machine. HITACHI does not bear
responsibility on any human injury, malfunction 6 4 3 1
and/or physical loss or damage incurred by
unauthorized application or use of unauthorized 5 2
attachments, optional parts or modified switch,
which will void Hitachi Warranty Policy.
 Before using this switch, thoroughly read the
operation manual of the corresponding attachment
and check the operation of each function in a safe
area.
 Before operating an attachment with this switch,
confirm the requirements on safe and proper Left Control Lever Right Control Lever
mounting and operation of the attachment with its MDAA-01-337 MDAA-01-337
manufacturer or distributor and observe them.
1-86
OPERATOR'S STATION
Cigar Lighter
Using Cigar Lighter 1
IMPORTANT: In case the cigar lighter does not pop out
automatically 30 seconds after pushing the cigar
lighter in, pull out the cigar lighter manually. Then,
consult your authorized dealer.
1. Turn key switch (1) to the ACC or ON position.

MDCD-01-030
2. Push and release the cigar lighter knob.
3. The cigar lighter knob will return to the original position
when the lighter becomes usable. Pull the cigar lighter
out to use. Cigar Lighter
4. After using the cigar lighter, insert the cigar lighter into
the panel until the knob is seated in the original position.
Using Cigar Lighter Port as External Power Source

Use the cigar lighter port to supply power to lighting
equipment for servicing the machine.
IMPORTANT: Only 24 V electric power is available from

the cigar lighter port on this machine.
Never connect accessories that use power other than MDAA-01-297
24 V. Damage to the batteries and accessories may
result.
Do not supply power to accessories for a long time
without running the engine. Failure to do so may
1. Pull the cigar lighter knob out.

2. Correctly insert the accessory socket into the cigar
lighter port.
3. Turn key switch (1) to the ACC or ON position. Power is
supplied to the connected accessory.
4. After using the accessory, disconnect the accessory
socket and insert the cigar lighter into the port.
1-87
OPERATOR'S STATION
Cab Light Switch 1

Push switch (1) on the cab light to turn the cab light ON.
ON : The cab light comes ON and stays ON.

(The light does not turn ON while the key is in OFF
position.)
OFF : The cab light goes OFF.
Neutral : The room lamp goes ON when the cab door is
opened.
The cab light automatically goes off after 30
seconds.
(The cab light turns ON while the key switch is
OFF.) MDAA-01-305
MDAA-01-318
Installing Fire Extinguisher (Optional)

A fire extinguisher can be installed at the left rear corner
inside the cab. Consult your authorized dealer to install a fire
extinguisher.
MDAA-01-319
Fire Extinguisher
1-88
OPERATOR'S STATION
Pilot Control Shut-Off Lever 1
Pilot control shut-off lever (1) functions to prevent the

machine from being mistakenly operated when the operator is
getting on or off the machine.
dWARNING:
 Always pull pilot control shut-off lever (1) into the
full LOCK position. Unless pilot control shut-off lever
(1) is fully moved to the LOCK position, the control
lever is not locked, possibly creating a hazardous
situation.
 When leaving the machine, always stop the engine. LOCK position MDAA-01-295
Then, pull pilot control shut-off lever (1) up to the
LOCK position. 1
 Always pull pilot control shut-off lever (1) up to the
LOCK position before transporting the machine and
leaving the machine.
 Confirm that pilot control shut-off lever (1) is in the
LOCK position before starting the engine. The engine
will not start in other than the LOCK position.
UNLOCK Position MDAA-01-296
Engine Stop Switch

In case the engine does not stop even if the key switch is
turned OFF due to failure of the machine, move switch (2)
located at the front-left side of the seat stand downward to
stop the engine.
After operating switch (2), be sure to return the switch back to
the upward position.
MDAA-01-290
2
1-89
OPERATOR'S STATION
Fuse Box
A
10- CONTROLLER 20- OPT.3 (ALT)

5A 5A
9- BACKUP 19- HORN
10 A 10 A
A
8- ECM 18- IDLE STOP B
30 A 5A
7- START 17- POWER ON
5A 5A
6- OPT.2 (ALT) 16- GLOW RELAY
MDAA-01-297
20 A 5A
5- OPT.1 (ALT) 15- AUX A
5A 10 A
10 20
4- SOLENOID 14- MONITOR
9 19
20 A 5A
8 18
3- HEATER 13- LIGHTER
20 A 10 A 7 17
2- WIPER 12- RADIO 6 16
10 A 5A 5 15
1- LAMP 11- FUEL PUMP 4 14
20 A 5A 3 13
2 12
B
1 11
30- - 40- -

29- - 39- -
M1GR-01-003
28- SENSOR_UNIT 38- -
10 A
B
27- AUX.3 37-
5A 30 40
26- QUICK HITCH 36- 29 39
5A 28 38
25- IMMOBI 35- DCU 27 37
5A 20 A 26 36
24- 12VUNIT 34- AUX.2 25 35
10 A 10 A 24 34
23- CAB LAMP REAR 33- WARNING LAMP
23 33
10 A 10 A
22 32
22- CAB LAMP FRONT 32- CAB LAMP FRONT +2
10 A 10 A 21 31
21- SEAT HEATER 31- SEAT COMPR.

10 A 10 A
M1GR-01-003
1-90
OPERATOR'S STATION
Auto Air Conditioner

Features:
 Full Auto-Temperature Control:
Automatically controls the air temperature in the cab to
maintain the temperature set by the temperature control
switch regardless of outside air temperature and insolation.
 Max. Cooling and Heating:

Maximum cooling or heating can be obtained by rotating
the temperature control switch clockwise (32 °C) or
counterclockwise (18 °C) respectively.
 Preheating:
During preheating the cab in winter with the foot vent
selected, the air volume is reduced to Low until the coolant
temperature rises to prevent cool air from entering the cab.
f NOTE: Even in the summer season, the high idle speed may
be higher than the normal speed due to the above control
system.
 Heater Start-Operation Control System:

In winter or in cold weather, when starting the engine, the
engine coolant is cool and air temperature inside the cab is
low. Then, cool air is restricted not to flow in the cab to the
minimum (LO) until the coolant is warmed when the front
foot vent and/or foot vent is selected.
1-91
OPERATOR'S STATION
Components Name
1
1- Front Vent
2- Foot Vent
3- Defroster Vent
4- Rear Vent
5- Temperature Control Switch/Mode Switch
6- AUTO/OFF Switch/Fan Switch
fNOTE: Air flow direction can be changed by controlling the

louvers at all air vents except for foot vents (2). In addition,
the louvers on front vents (1) and defroster vent (3) can be MDAA-01-295
3 2
completely opened and closed by hand.
MDAA-01-289
MDCD-01-026
1-92
OPERATOR'S STATION
Controller Part Name and Function
ZX120-5, 160-5 class
 Mode Switch (5)
5
Selects the air vent. The selected air vent is indicated on
monitor (7). 6
Air flows out of front vent and the defroster vents.
Air flows out of the front, rear and the defroster

vents.
Air flows out of the front, foot and the defroster

vents. MDCD-01-026
Foot Vent Mode
Each time mode switch (5) is pressed, the vent location can be
changed in four stages as illustrated below.
AUTO   
 When switch (6) is selected in AUTO:

The air vent location is automatically selected.
 Temperature Control Switch (5):

Sets temperature in the cab.
Temperature in the cab can be set from 18.0 to 32.0 °C by
MDAA-01-001
rotating temperature control switch (5). Temperature can be
7
set by 0.5 °C increments.
The set-temperature is displayed on monitor (7).
1-93
OPERATOR'S STATION
ZX200-5, 240-5, 300-5, 330-5 class
 Mode Switch (5)
Selects the air vent. The selected air vent is indicated on
monitor (7). 5
Air flows out of the front and defroster vents. 6
(Including defroster vent)
Air flows out of the front, rear and defroster vents.
Air flows out of the front, rear, foot and defroster
vents.
MDCD-01-026
Air flows out of the foot vents.
Each time mode switch (5) is pressed, the vent mode can be
changed in 4 stages as illustrated below.
AUTO   
 When switch (6) is selected in AUTO:

The air vent mode is automatically selected.
 Temperature Control Switch (5):

Sets the air temperature in the cab.
Temperature in the cab can be set from 18.0 to 32.0 °C by
rotating temperature control switch (5). Temperature can be
set by 0.5 °C increments.
The set temperature is displayed on monitor (7).
MDAA-01-001EN
7
1-94
OPERATOR'S STATION
 Fan Switch (6)
 When AUTO indicator (8) is ON, the blower speed is
automatically controlled.
 When AUTO indicator (8) is OFF,
the blower speed is controlled in 6 steps. 6
Rotate blower switch (6) clockwise to increase blower
speed. Rotate blower switch (6) counterclockwise to
decrease blower speed.
Monitor (7) indicates the corresponding blower speed.
 AUTO/OFF Switch (6)

Push AUTO/OFF Switch (6) while the air conditioner is OFF,
MDCD-01-026
it turns into AUTO mode. Press AUTO/OFF switch (6) while
operating the air conditioner, it stops operating.
MDAA-01-001EN
7
1-95
OPERATOR'S STATION
Cab Heater Operation
1. AUTO/OFF switch (6):
According to signals sent from various sensors, the air
5
conditioner amplifier automatically selects the air flow-in
vents, air suction ports, and air flow-in temperature at 6
the vent, and controls the blower speed.
2. Temperature Control Switch (5):
Adjust temperature control switch (5) so that "25.0" is
indicated on the monitor. Control air temperature inside
cab using this switch (5) as necessary.
3. As Necessary: MDCD-01-026
 Operate Mode switch (5) to manually select the air vent.
 Operate Fan switch (6) to manually control the blower
speed.
 Operate the air conditioner setting screen on the
monitor to maintain the air vent in the fresh air mode or
circulation air mode.
Usually the cab heater turns the dehumidifier function OFF,

however, it turns ON by switching the A/C to ON at the air
conditioner setting screen.
1-96
OPERATOR'S STATION
Cooling Operation
1. AUTO/OFF switch (6):
5
Push AUTO/OFF switch (6) to set the air conditioner in
AUTO mode. According to signals sent from various 6
sensors, the air conditioner amplifier automatically
selects the air flow-in vents, air suction ports, and air
flow-in temperature at the vent, and controls the blower
speed.
2. Temperature Control Switch (5):
Adjust temperature control switch (5) so that "25.0" is
indicated on the monitor. Control air temperature inside MDCD-01-026
the cab using this switch (5) as necessary.
3. As Necessary:
 Operate Mode switch (5) to manually select the air vent.
 Operate Fan switch (6) to manually control the blower
speed.
 Operate the air conditioner setting screen on the
monitor to maintain the air vent in the fresh air mode or
circulation air mode.
In case the front window (lower) becomes clouded,

manually close the defroster vent (3).(It can be closed
manually.)
3 MDAA-01-295
1-97
OPERATOR'S STATION
Defroster Operation
1. Push AUTO/OFF Switch (6) to blow out temperature-
controlled air. During cold weather season when 5
starting the engine, the engine coolant temperature
6
and air temperature in the cab are low. The Heater Start-
Operation Control System controls the blow rate to the
minimum (LO) in order to restrict cool air from flowing
into the cab.
2. Adjust temperature control switch (5) so that "25.0" is
indicated on the monitor. Set the fresh air mode from air
conditioner setting screen on the monitor.
MDCD-01-026
3. Select the front vents or the front and rear vents
using mode switch (5).
1
Control air flow direction by adjusting the louvers at front

vents (1) and defroster vent (3).
Control air temperature in the cab by using temperature

control switch (5).
If the windowpanes become clouded in rainy season
or wanted to eliminate moisture, turn A/C ON at the air
conditioner screen on the monitor.
Cool Head/Warm Feet Operation

Cool and warm air is simultaneously supplied to the head MDAA-01-295
3
vents and feet vents respectively.
ZX120-5, 160-5 class

1. Push Fan switch (6) to adjust the blower speed.
2. Push MODE switch (5) to display the front and rear vent
mark on the monitor.
Turn A/C ON from the air conditioner setting screen on
the monitor.
ZX200-5, 240-5, 300-5, 330-5 class

1. Push Fan switch (6) to adjust the blower speed.
2. Push MODE switch (5) to display the front and rear vent
mark on the monitor.
Turn A/C ON from the air conditioner setting screen on
the monitor.
Control air temperature inside the cab by using temperature

control switch (5).
1-98
OPERATOR'S STATION
Tips for Optimal Air Conditioner Usage

Air Conditioner Sensor
For Rapid Cooling
Temperature in the cab may rise over 80 °C (176 °F) when
the machine is exposed to sun light in the summer.
In this case, ventilate air in the cab first by opening the
windows for rapid cooling.
After starting the engine, press AUTO/OFF switch (6). Set
temperature to "18.0" on the monitor by using temperature
control switch (5). Turn circulation air mode ON from air
conditioner setting screen on the monitor.
Close the windows when the cab cools down to the
ambient temperature.
MDAA-01-292
When Windows Become Clouded

If the insides of the windows become clouded during rainy
weather or on humid days, operate the air conditioner to aid
in keeping the windows clear.
When the atmosphere is very damp, and if the air
conditioner has run excessively, the outside of the windows
may become clouded. If this happens, turn off the air
conditioner to adjust the temperature in the cab.
Off-Season Air Conditioner Maintenance

To protect each part of the compressor from a lack of
lubricant, operate the air conditioner at least once a month
for several minutes with the engine running at a slow speed
during off-season.
IMPORTANT:
Do not suddenly increase the engine speed. Failure

to do so may damage the compressor.
Refer to the item "Check Air Conditioner Filter" in

the Maintenance Chapter for maintenance of the air
conditioner filters.
Always clean the auto air conditioner sensor for

effective air conditioner performance. Avoid placing
any obstructions around the sensor.
1-99
OPERATOR'S STATION
AM/FM Radio Operation
dCAUTION: Refrain from listening to the radio in the cab

while operating the machine. 3 1
Controls on the Radio 2
1- AM/FM Selector/Tuning Switch

"FM" or "AM" is switched over alternately each time the
switch is pressed. Rotate tuning switch (1) clockwise
to increase frequency, counterclockwise to decrease
frequency. MDCD-01-026
2- Power Switch/Volume Control Knob
Push: Turns power switch (2) ON/OFF. Rotate volume 4
control knob (2) clockwise to increase the sound volume.
Rotate it counterclockwise to decrease the sound
volume.
Tuning Procedure
 Manual Tuning Procedure
Rotate tuning switch (1) until the desired station is
reached.
MDAA-01-001EN
 Automatic Search Function
5
Push selector knob (3) to display the radio screen.
Rotate selector knob (3) to highlight seek (8). Push
selector knob (3) to go to the next higher frequency
station. Push selector knob (3). 6
Rotate selector knob (3) to highlight seek (7). Push

selector knob (3) to go to the next lower frequency
station. Push selector knob (3).
MDAA-01-092EN
7
8
MDAA-01-095EN
1-100
OPERATOR'S STATION
Station Presetting Procedure
Setting from Monitor
1. Select the desired station. Refer to the "Tuning
Procedure" in the previous section. 1
2. Push selector knob (1) while displaying basic screen (2)
to display Main Menu screen (3). Rotate selector knob (1)
to highlight Radio (4).
3. Push selector knob (1) to display Radio screen (5).
4. Rotate selector knob (1) to highlight a CH to preset a
station. (CH1 to CH8)
5. Push and hold selector knob (1) for more than 1 second.
The current station is preset to the selected CH.
Setting from numeric keypad

1. Select the desired station. Refer to the "Tuning
Procedure" in the previous section.
MDCD-01-027
2. Push and hold one numeric keypad (1 to 8) for more 2
than 1 second. The current station is preset to the
selected number of CH.
MDAA-01-001EN
MDAA-01-092EN
MDAA-01-093EN
1-101
OPERATOR'S STATION
Station Auto-Presetting Procedure
Receivable stations can be automatically sought and preset 1
to the memory.
1. Push selector knob (1) while displaying basic screen (2)
Push selector knob (1) to display Radio screen (5).
3. Rotate selector knob (1) to highlight AUTO PRESET (6).
4. Push selector knob (1) to start AUTO PRESET process. The
AUTO PRESET scans reception frequency, allocate sought
MDCD-01-026
stations to CH1 to CH8 from sensitive station. AM will be
preset to CH1 to CH4, FM will be preset to CH5 to CH8.
Operating the radio during scan stops the AUTO PRESET.
MDAA-01-001EN
MDAA-01-092EN
MDAA-01-099EN
1-102
OPERATOR'S STATION
TONE Control
1. Push selector knob (1) while displaying basic screen (2) 1
Push selector knob (1) to display Radio screen (5).
3. Rotate selector knob (1) to highlight TONE (6).
4. Push selector knob (1) to adjust TONE control. Rotate
selector knob (1) clockwise to boost treble. Rotate
selector knob (1) counterclockwise to boost bass. Push
selector knob (1) to enable the changes.
MDCD-01-026
MDAA-01-001EN
MDAA-01-092EN
MDAA-01-096EN
1-103
OPERATOR'S STATION
Audio Input (Optional)

IMPORTANT: This function is available only to a machine
equipped with an audio input (optional). Use this
1
function with proper sound volume.
2
Audio Input Selection
Attach the audio input (optional) device and push AM/FM
Selector/Tuning Switch (1) to display AM and FM screen as
well as AUX input screen (3).
Connecting audio device MDCD-01-026
By removing AUX IN Cap (4), the audio input terminal

appears.
Connect your audio device to the audio input terminal of
the machine with your audio cable.
IMPORTANT:
Use Φ3.5 mm stereo plug for the connection of audio

input terminal.
Put AUX IN cap (4) when the audio input is not in use.

Volume Control of audio device

3
Turn the volume down to the minimum beforehand, and
then turn volume control knob (2) clockwise to adjust the MDAA-01-340
volume.
IMPORTANT:
If volume control knob (2) has been set to the

maximum, you will hear an overwhelming sound; so
set volume control knob (2) to the minimum first and
then turn it clockwise to increase it. Adjust volume
control knob (2) on the audio device if the sound is 4
too low even volume control knob (2) is set at top.
Operate your audio device to play or stop the sound.

MDAA-01-341
1-104
OPERATOR'S STATION
Side View Camera System (Optional)

Images from side camera (right side of machine) (4) and side
camera (left side) (5) can be displayed on the side camera
monitor (1) inside the cab.
dWARNING
 Check visibility before operating the machine.
When visibility is poor, the field of vision cannot be
ensured, which may lead to damage and/or serious
injury.
1
 Do not make any alterations, such as changing the
position of side cameras (right side of machine) (4)or
side camera (left side) (5).
 If the quality of the image on side camera monitor (1)
is poor, clean the camera(s) and/or monitor to make
the image clearer. Always ensure good footing when
cleaning the cameras. MDC1-01-561
 If it is difficult to see side camera monitor (1), adjust
the angle of the monitor and/or the position of the
seat so it is easy to see. (Refer to the sections on
Adjusting the Position of the Side Camera Monitor
and Adjust the Operator's Seat.)
fNotes: The surface of side camera monitor (1) and camera

lenses are made of plastic. When cleaning them, use a clean,
water-dampened cloth and wipe lightly. Never use an organic
solvent.
4
IMPORTANT:
The images displayed on side camera monitor (1)

MDAK-01-504
are only meant as aids. People and objects displayed
on the monitor may appear differently from their
actual positions or distances. Before moving the
machine, always check the area around the machine
thoroughly before moving it.
When the door of the cab is fully open, the door

appears in the image from side camera (left side) (5).
If the field of vision is insufficient, ensure visibility
using the operator seat mirror. 5
If there are any problems with the image in side

camera monitor (1), contact your nearest authorised
dealer.
MDC1-01-563
1-105
OPERATOR'S STATION
Device Layout
1. Side camera monitor
1
2. Image toggle switch
3. Brightness adjustment switch
4. Side camera (right side of machine)
5. Side camera (left side of machine)
Operating the Camera

Once the key switch is turned to its ON position, side 2 3
camera monitor (1) comes ON and an image is displayed on
it.
Once the key switch is turned to its OFF position, side
camera monitor (1) turns OFF and no image is displayed.
There are 2 patterns for displaying the images and the MDC1-01-564
system switches between them each time image toggle
switch (2) is pressed.
Images (side by side images) from side camera (right side)

(4) and side camera (left side) (5)
4
Image from side camera (right side) (4)
There are 4 levels of brightness, which can be adjusted with

MDAK-01-504
each push of brightness adjustment switch (3).
fNotes: If work light switch (6) is put in position 2, the monitor
screen switches to Night Mode.
5
MDC1-01-563
MDCD-01-026
1-106
OPERATOR'S STATION
Content of Monitor Display 8 7

Image (7) from side camera (right side) and Image (8) from side
camera (left side) Front of
Machine
Image Orientation
MDC1-01-565
7
Image (7) from side camera (right side)
IMPORTANT: When the image is only from side camera
(right side), use the operator seat mirror to ensure the
field of vision on the left side of the machine.
Image Orientation MDC1-01-566

Front of Machine
Display of Camera Guide Icon

Camera guide icon (9) is normally displayed on the monitor
and it indicates the orientations of the camera images and the
machine.
The direction of the

arrow indicates the
front of the machine. In
this case it is indicating
9 the front of the B
machine is pointing up.
Detail B
MDC1-01-567
Indicates the direction
the camera is facing. In MDC1-01-568
this case it indicates the
image is of the left side
of the machine.
1-107
OPERATOR'S STATION
Adjusting the Position of the Side Camera

Monitor
The position of the monitor can be adjusted using axes (10)
and (11) of the monitor bracket.
IMPORTANT: When opening/closing the cab window,

move the monitor to position A on the operator’s
side. If the position is not changed, the monitor will
interfere with the cab’s front window.
10
11
MDC1-01-569
MDC1-01-570
1-108
OPERATOR'S STATION
Cab Door Release Lever
dCAUTION:
 Open the cab door all the way until it securely locks
in the latch on the side of the cab.
 Do not unlock the cab door when the machine is
parked on a slope or while the wind is blowing hard.
The cab door may close accidently, possibly resulting
in personal injury.
 When opening or closing the cab door, take extra
care not to catch fingers between the base machine
and the cab door.
1 MDAA-01-320
To unlock the door, push down on lever (1).
1-109
OPERATOR'S STATION
Opening/Closing and Removing Cab Inside

Window
dWARNING: 1
 Open, close or remove the upper front cab window,

overhead window, cab door window or lower front
window only after lowering the front attachment
to the ground and pulling up pilot control shut-off
lever (1) to the LOCK position. Failure to do so may
allow the machine to move unexpectedly if a control
lever or pedal is touched with a part of the body
by mistake, possibly resulting in personal injury or
death.
 Park the machine on a level and solid ground and
stop the engine before opening and closing the
upper front window. MDAA-01-295
 When opening the upper front window, hold the

window by hands, hold it until the upper front
window is locked.
 When closing the upper front window, it may
accidently fall by its own weight. Hold the upper
front window by hands until it is completely closed.
Since the window stops before it completely closes,
do not operate the machine at the position with the
window being stopped. The upper front window is
not locked at that position, having the possibility of
suddenly dropping.
1-110
OPERATOR'S STATION
Opening Upper Front Window

1
Opening Upper Front Window
1. Press lock release lever (1) at the upper center to release
the upper front window lock.
2. Holding lock release lever (1) at the upper center
and lower handle (4) on the upper front window as
illustrated, pull the upper front window up and back
until auto locks (3) at both sides of the upper front
window securely catches into the strikers on the ceiling.
3. After confirming that the window securely catches into
5
auto locks (3), slide lock pin (2) into the left bracket boss
hole to lock the window in position.
4
fNOTE: When the upper front window is opened, the wiper
MDAA-01-358
and washer are inoperable.
dCAUTION:
 Slowly close the upper front window so that not to
catch your fingers.
 Always secure lock pin (2) in the lock position after
the upper front window is opened.
 Always pull pilot control shut-off lever (5) to the
LOCK position before opening or closing the upper
front window.
4. To close the upper front window, hold lock release lever

(1) at the upper center and lower handle (4) on the upper
front window as illustrated, and follow the steps 1 to 3 in
the reverse order. The window stops before it completely
MDAA-01-359
closes, so close the front window by pushing release
lever (1) upward.
Push lock release lever (1) downward to release auto lock
(3).
fNOTE: Unless the upper front window is securely closed, the 2

wiper and washer will not operate.
3 MDAA-01-306
MDAA-01-360
1-111
OPERATOR'S STATION
Removing and Storing Lower Front Window
dCAUTION: Take care not to pinch yours fingers when

handling the lower front window.
Removing and Storing Lower Front Window

1. Open the upper front window beforehand when
removing the lower front window.
2. While pulling the lower front window inward, raise it to
remove.
3. Store the removed windowpane in the storing position.
After inserting the windowpane into rubbers (2 and 3), MDAA-01-298
slide it sideways securely into rubber (4). Then, push
4 1
fastener (1) to lock.
3
2
MDAA-01-299
1-112
OPERATOR'S STATION
Opening Side Window 1
Hold handle (1) and slide windowpane to open the side

window.
Side Window M178-01-061
1-113
OPERATOR'S STATION
Opening/Closing Overhead Window (Std. Model) 1

Move locks (1) toward center of window. Hold handle (2) and
lift window until it rises upright. With the window positioned
upright, it will be secured in position by dampers (3).
Hold handle (2) and pull window down until "click" sound is
heard from left and right locks (1).
Note that the overhead window can be used as an emergency
exit.
2
MDAA-01-302
MDAA-01-303
1-114
OPERATOR'S STATION
Opening/Closing Overhead Window (Clear 1

Hatch: If Equipped)
Move locks (1) toward center of window. Hold handle (2) and
lift window until it rises upright. With the window positioned
upright, it will be secured in position by dampers (3).
Hold handle (2) and pull window down until "click" sound is
heard from left and right locks (1).
Note that the overhead window can be used as an emergency
exit.
IMPORTANT:
 Replace the clear hatch with a new one every 5
years even if undamaged. In case it was remarkably
2
damaged or has received severe shock loads, replace MDAA-01-302
it even if it has been not in use for 5 years.
 When cleaning the clear hatch, use a neutral
detergent.
If acidic or alkaline detergent is used, the clear hatch
may become discolored or crack. 3
 Keep organic solvent away from the clear hatch.
Failure to do so may cause the clear hatch to become
discolored or crack.
MDAA-01-303
1-115
OPERATOR'S STATION
Emergency Exit
1
Escape from the cab in emergency in the following methods:
dCAUTION: The danger of downfall is always present

when escaping from the cab in emergency, possibly
resulting in serious personal injury. Escape from the
cab as safely as possible, depending on the posture of
machine and the outside situation.
1. Open the cab door. Escape through the door.

2. If the cab door should be difficult to open or use, open
the upper front window. Escape through the window.
MDAA-01-321
fNOTE: Emergency exit decals (2) are affixed to the front and
rear windows. See page "OPENING UPPER FRONT WINDOW"
for the opening method of the upper front window.
dCAUTION: If decal (3) is affixed to the front

windowpane, the windowpane can be broken.
However if decal (3) is not affixed to the front
windowpane, the glass cannot be broken with
emergency evacuation hammer (1). Take care not to be
injured with pieces of broken glass.
3 2
3. If upper front window should be difficult to open, check

the decal (3) affixed to the windowpane.
M1U4-01-012
If decal (3) is affixed to the front windowpane, break the 3 2
front windowpane using the emergency evacuation tool
(1) installed the cab left side. Then escape through the
broken windowpane.
4. If decal (3) is not affixed to the front windowpane, or if
the front window is not available for escaping, break the
rear windowpane using emergency evacuation hammer
(1). Then escape through the broken windowpane.
5. If neither of front and rear windows are available for
emergency exit, open the overhead window to escape
from the cab.
MDAA-01-322
1-116
OPERATOR'S STATION
Adjusting Operator's Seat
dWARNING: Adjust the seat only after lowering the

front attachment on the ground and pulling up the
pilot control shut-off lever to the LOCK position.
Failure to do so may allow the machine to move
unexpectedly if a control lever or pedal is touched with
a part of the body by mistake, possibly resulting in
dCAUTION: Avoid possible injury while operating

height/tilt lever (1). When pushing down lever (1), do SS4371371-3
not grab it. Fingers may be pinched between lever (1)
and the seat stand. Be sure to push on the upper face
of lever (1) by your palm.
4
Seat Height and Angle Adjustment
Seat height adjustment range is 60 mm with steps every 15
mm (5 positions in total).
Push down lever (1): to adjust front part of the seat.
Pull up lever (1): to adjust rear part of the seat.
Console and Seat Fore-aft Adjustment 3
Operate console and seat slide lever (2) to adjust the seat
and both right and left consoles to desired distance from
the travel pedals and levers. Seat and console fore-aft 2 1 MDAA-01-290
adjustment range is 160 mm with steps every 20 mm.
Seat Fore-Aft Adjustment

Operate seat slide lever (3) to adjust the seat to desired
distance from the travel pedals and levers. Seat fore-aft
Backrest Adjustment
Pull up lever (4) to release backrest lock. Move backrest to
the desired position and release lever (4).
1-117
OPERATOR'S STATION
Armrest Adjustment
Armrest (5) can be pulled upright by hand 90°. Pull armrest
(5) upright by hand to get on and off the machine easily.
The angle of armrest (5) can be adjusted to the desired 5
position by turning adjusting dial (6) located on the bottom
of armrest (5). 6
M1G6-01-017
1-118
OPERATOR'S STATION
Adjusting Operator's Seat (Optional)

dCAUTION: Avoid possible injury while operating

height/tilt lever (1). When pushing down lever (1), do SS4371371-3
not grab it. Fingers may be pinched between lever (1)
and the seat stand. Be sure to push on the upper face
of lever (1) by your palm.
Seat Height and Angle Adjustment

Seat height adjustment range is 60 mm with steps every 15 1
mm (5 positions in total).
Push down lever (1): to adjust front part of the seat.
Pull up lever (1): to adjust rear part of the seat.
Console and Seat Fore-aft Adjustment

4
the travel pedals and levers. Seat and console fore-aft 2 4 3 MDAA-01-331

Suspension Adjustment
Rotate knob (4) to adjust the suspension.
Rotate knob (4) clockwise (+ direction) to increase
suspension stiffness.
Rotate knob (4) counterclockwise (- direction) to decrease
suspension stiffness.
1-119
OPERATOR'S STATION
Backrest Adjustment
the desired position and release lever (5).
5
MDAA-01-331
Armrest Adjustment
Armrest (6) can be pulled upright by hand 90°. Pull armrest
(6) upright by hand to get on and off the machine easily.
The angle of armrest (6) can be adjusted to the desired
6
position by turning adjusting dial (7) located on the bottom
of armrest (6).
7
M1G6-01-017
1-120
OPERATOR'S STATION
Adjusting Operator's Seat (Optional)

Adjusting Seat Height

IMPORTANT: The seat is an air suspension type.
Pull lever (1) upward to fill air and raise the seat. Push lever
(1) downward to release air and lower the seat. When the
seat is properly adjusted for your weight, indicator (2) is in
the green zone.
4
Console and Seat Fore-aft Adjustment
the travel pedals and levers. Seat and console fore-aft
adjustment range is 160 mm with steps every 20 mm. 4
3 1 2 MDAA-01-333
1-121
OPERATOR'S STATION
Suspension Adjustment
Rotate knob (5) to adjust the suspension.
Rotate knob (5) clockwise to decrease suspension stiffness.
Rotate knob (5) counterclockwise to increase suspension
stiffness.
Fore-Aft Position Adjustment of Seat Surface

Pull lever (6) upward to adjust the seat angle. Seat and
console fore-aft adjustment range is 60 mm with steps
every 15 mm.
Angle Adjustment of Seat Surface

Pull lever (7) upward to adjust the seat angle. Height of the
seat end is adjustable in 4 steps.
Backrest Adjustment
the desired position. Move backrest to the desired position 7
and release lever (8). 6
8
MDAA-01-333
Armrest Adjustment
Armrest (9) can be pulled upright by hand 90 °. Pull armrest
(9) upright by hand to get on and off the machine easily. The
angle of armrest (9) can be adjusted to the desired position
by turning adjusting dial (10) located on the bottom of 9
armrest (9).
10
M1G6-01-017
1-122
OPERATOR'S STATION
Console Height Adjustment

Adjust the console height to the operator's comfort and/or
work conditions.
Adjusting console height can be achieved using 3 positions
provided vertically at 20 mm (0.8 in) intervals.
dCAUTION: Before loosening the console, support the

console. Otherwise, the console may suddenly drop,
possibly causing personal injury.
Adjusting Procedures
1. Lower the bucket to the ground. Stop the engine. 1
2. Move the pilot control shut-off lever to the LOCK

position.
3. Remove left and right console holding bolts (1). Loosen
bolts (2) to adjust the console height.
4. After adjusting, tighten bolts (1) and (2).
Tightening Torque: 50 N·m (5 kgf·m)
2 M1U1-01-030
1-123
OPERATOR'S STATION
Installation and Adjustment of Mirrors
dWARNING:
 Adjust the mirrors, referring to the field of vision in
the mirrors in the "VISIBILITY MAP" chapter.
Perform adjustment with the machine position as
shown.
 If the mirrors are adjusted improperly, the field of
vision cannot be ensured and/or will be obstructed,
which may result in serious personal injury. MDFT-VM-001
Machine Position Image
 Check the field of vision in the mirrors every day
before starting work.
 If any of the mirrors are dirty, clean them.
 Ensure appropriate footing when adjusting or
cleaning mirrors.
IMPORTANT:
Mirrors and cameras only act as aids. Before

operating the machine, always check the area
around the machine thoroughly.
If a modification is made that could restrict the field

of vision, it may result in an obstruction to the field
of vision, so check the field of vision again.
1-124
OPERATOR'S STATION
Mirror Installation Diagram
The mirror installation locations (1, 2) on this machine are
shown in the right. 1 2
Adjust the installation locations of each mirror by following
the instructions below to ensure safety.
Installation angle and dimension varies depending on the
model.
1- Operator's Seat Mirror

2- Handrail Mirror for Getting ON/OFF the Machine
MDFT-01-004
 Operator's Seat Mirror (1)

Adjust the mirror to the specified position.
75°
110°
MDC1-01-549
 Handrail Mirror for Getting ON/OFF the Machine (2)

Adjust the mirror so that the side of the machine appears
on the mirror as shown in the right.
Adjust the mirror so that a range of at least 1 m from the
right side of the machine can be seen from the operator’s
seat.
MDC1-01-550
1-125
OPERATOR'S STATION
Seat Belt
2 1
d WARNING:
 Be sure to use seat belt (1) when operating the
machine.
 Before operating the machine, be sure to examine
seat belt (1) and attaching hardware for any failure. If
any damage and/or wear are found, replace the part
concerned.
 Replace seat belt (1) every 3 years regardless of
appearance.
Seat Belt M1U1-01-031
1. Confirm that seat belt (1) is not twisted. Securely insert 2 1

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).
Replace seat belt (1) if it is damaged or worn, or if seat belt

(1) has external damage such as an accident.
3
M1U1-01-032
1-126
OPERATOR'S STATION
Battery Disconnect Switch

IMPORTANT: Never turn disconnect switch (2) OFF
while the engine is running or the key switch is in the
position other than OFF. Failure to do so may damage
the electrical system.
Battery disconnect switch (2) is different from the engine

start key switch. When battery disconnect switch (2) is turned
OFF, the electrical system will completely be isolated from
the battery. No current will flow through the whole electrical
system.
Before turning battery disconnect switch (2) OFF, be sure

to turn the key switch OFF and wait 1 minute or more after MDAK-01-501
the engine stops. If battery disconnect switch (2) is turned
OFF within 1 minute after the engine stops, it may result in
malfunction of the electrical system. When turning battery
disconnect switch (2) from OFF to ON, preset radio station and
1
the clock may be reset. Set them again.
Use battery disconnect switch (2) only for the following

purposes; otherwise, turn it ON.
 Before maintaining and repairing the electrical system
 Before storing the machine for long period (Discharge
prevention)
 Before performing welding operation on the machine.
 Before replacement the batteries.
MDAK-01-502
How to operate the disconnect switch 2 ON Position
1. When lever (1) is set in a horizontal direction, disconnect

switch (2) is turned ON. Lever (1) can not be removed
from switch (2) in this condition.
1
2. When lever (1) is rotated counterclockwise to
perpendicular direction, disconnect switch (2) is turned
OFF. Lever (1) can be removed from switch (2) in this
condition.
MDAK-01-503
2 OFF Position
1-127
OPERATOR'S STATION
MEMO
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1-128
BREAK-IN
Observe Engine Operation Closely

IMPORTANT: Be extra cautious during the first 50 hours,
until you become thoroughly familiar with the sound
and feel of your new machine.
1. Operate the machine only in economy (ECO) mode and

limit the engine horsepower up to about 80 % of full
load.
2. Avoid excess engine idling.
3. Check indicator lights and gauges frequently during
operation.
Every 8 Hours or Daily

1. Perform 8-hour or daily service.
2. Watch for fluid leaks.
3. Lubricate working tool pivots every 8 hours for the first
50 hours, and every 8 hours when working in mud and
water.
After the First 50 Hours

1. Perform 50-hour service.
2. Check accessible hardware torque. (See Hardware Torque
Specifications in Maintenance chapter.)
After the First 100 Hours

Perform 50-hour and 100-hour service.
2-1
BREAK-IN
MEMO
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2-2
Inspect Machine Daily Before Starting

Perform the required daily check before starting the engine.
Engine
 Level 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 and
intercooler
 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 hoses
 Deformation, break, and abnormal noise at each part
 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
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
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*
fNOTE: Item with *mark: Refer to “Maintenance“ section for

detailed information.
3-1
Before Starting Engine 1
1. Ensure that the battery disconnect switch is in the ON

position.
2. Confirm that pilot control shut-off lever (1) is in the LOCK
position.
3. Confirm that all control levers are placed in neutral.
4. Insert key (2) to the key switch. Turn it to ON position.
Press and hold switch (3) with the engine stopped.
IMPORTANT: Always check the machine on a firm, level
surface. Never attempt to start the engine while
checking the machine. MDAA-01-295
LOCK Position
If engine oil level (4) (green) and coolant level (5) (green)
is displayed, the status is normal.
5. Adjust the seat to allow full control pedals and levers 2
stroke with operator's back against the backrest. Fasten
the seat belt.
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.
MDCD-01-030
MDCD-01-026
MDAK-01-043
3-2
Starting the Engine 1
Starting the Engine in Ordinary Temperature

position.
2. Turn engine control dial (3) to the slow idle position.
3. Sound horn to alert bystanders
5. "Wait-screen (nothing is displayed)" is displayed on the
monitor for 2 seconds. Regardless of pilot control shut-
off lever (1) position, the engine can not be cranked
during this moment. LOCK Position MDAA-01-295
6. When the Password Input screen is displayed on the

monitor, input the password. Unless the numeric keypad
function (ignition block system) is activated, this screen
is not displayed.
2
IMPORTANT: When required to activate the numeric
keypad function (ignition block system), consult your
authorized dealer.
Slow Idle
3
MDCD-01-030 M1P1-01-068
Password Input Screen MDAA-01-085EN
3-3
fNOTE: When the key switch is turned ON, the maintenance

notification (4) for the item whose maintenance interval
has expired displays for 10 seconds. Push Return to Previous
Screen switch (5) or turn the pilot control shut-off lever to the
UNLOCK position while the rear view camera is enabled to
delete the notification.
4
7. The Basic Screen will be displayed on the monitor. Check
that the preheat indicator (6) is OFF at this time.
8. Turn key switch to the START position to rotate the
starter. The engine will start.
IMPORTANT: Never operate the starter for more than 10 MDAA-01-213EN
seconds at a time. If the engine fails to start, return
the key switch to the OFF position. Wait for more than 5
30 seconds, then try again. Failure to do so may cause
damage to the starter and/or discharge the batteries.
MDCD-01-026
3-4
9. Release key switch (2) just after the engine has started.
Key switch (2) will automatically return to the ON 2
position.
fNOTE:
 The engine speed will be kept to slow idle speed just after
the engine starts. When engine speed control indicator (7)
is displayed, slow idle speed will be maintained. When the
MDCD-01-030
coolant temperature or hydraulic oil temperature is low, the
time will be longer. The engine speed will be kept to slow
idle speed even if engine control dial (3) is not set in the
slow idle position.
 After the slow idle speed is maintained, the warm-up

system automatically operates and the engine speed will
temporarily increase even if engine control dial (3) is set to
the slow idle position.
dCAUTION: Do not attempt to operate the machine

when engine speed control indicator (7) is lit. The 3
engine speed may change after the slow idle period
and operation speed of work device may suddenly
increase, which may cause a serious accident.
fNOTE: White smoke may be emitted for several minutes after

the engine start, this is not a malfunction.
MDCD-01-026
MDAA-01-355
3-5
Starting in Cold Weather
1
Preheating
position.
2. Turn engine control dial (3) to around the middle
between the L and H position.
3. Sound the horn to alert bystanders.
5. "Wait-screen (nothing is displayed)" is displayed on the
monitor for 2 seconds. Regardless of pilot control shut-
off lever (1) position, the engine can not be cranked
LOCK position MDAA-01-295
during this moment.
6. When the Password Input screen is displayed on the
monitor, input the password. Unless the numeric keypad
function (ignition block system) is activated, this screen
is not displayed. 2
IMPORTANT: When required to activate the numeric
keypad function (ignition block system), consult your
authorized dealer.
Slow Idle
3
MDCD-01-030 M1P1-01-068
Password Input Screen MDAA-01-085EN
3-6
fNOTE: When the key switch is turned ON, maintenance

notification (4) for the item whose maintenance interval
has expired displays for 10 seconds. Press Return to Previous
Screen switch (5) or turn the pilot control shut-off lever to
UNLOCK position while the rear view camera is enable to
delete the notification.
4
7. The Basic Screen will be displayed on the monitor.
The machine will automatically check if preheating is
required or not. When preheating is required, preheat
indicator (6) is lit for automatically.
fNOTE: In case, preheat indicator (6) does not come ON, MDAA-01-213EN
preheating is not required. Follow the "Starting the Engine in
Ordinary Temperature" section. 5
8. As soon as preheat indicator (6) goes OFF, turn key

switch to START position to rotate the starter.
IMPORTANT: Never operate the starter for more than 10
seconds at a time. If engine fails to start, return key
switch to OFF. Wait for more than 30 seconds, then
try again. Failure to do so may cause damage to the
starter and/or discharging the batteries.
9. Release key switch just after the engine has started. Key
switch will automatically return to ON position.
MDCD-01-026
fNOTE:
 Because of the engine speed control function, the engine 6
speed will be kept to slow idle speed for about 3 to 10
seconds just after the engine starts. When the coolant
temperature or hydraulic oil temperature is low, the time
will be longer. The engine speed will be kept to slow idle
speed even if the engine control dial (3) is not set in the slow
idle position.
 The warm-up system automatically operates after keeping
slow idle speed, and the engine speed will temporarily
increase even if the engine control dial is set in the slow idle
position.
dCAUTION: Do not attempt to operate the machine for

10 seconds after starting the engine. The engine speed
may change after the slow idle period and operation

speed of work device may suddenly increase, which
may cause serious accident.
fNOTE: White smoke may occur for several minutes after the
engine start, this is not a malfunction.
3 M1P1-01-068
3-7
Check Instruments After Starting

Checking instruments through monitor functions
After starting the engine, check the following points
through the monitor functions. 1
1. Check that alternator alarm indicator (1) is OFF. In case

alternator alarm indicator (1) stays ON, immediately stop 2
the engine. Inspect the alternator and battery system for
any abnormality.
2. Check that engine oil pressure indicator (2) is OFF and
the alarm buzzer does not sound.
In case engine oil pressure indicator (2) stays ON and the
buzzer sounds, immediately stop the engine. Inspect the
engine oil pressure system and the oil level. MDAA-01-041
IMPORTANT: In case any abnormality is found on the
monitor unit, immediately stop the engine. Inspect the
cause of the trouble.
Check engine noise and exhaust gas color:

Check that the engine noise and exhaust gas color is
normal.
f NOTE:
 Check the exhaust gas color as follows. (After warm-up
operation, run the engine with no loads.)
Clear or : Normal (Perfect combustion)
Light Blue
Black : Abnormal (Imperfect combustion, abnormal
fuel system)
White : Abnormal (Oil is leaking into the combustion
chamber, abnormal fuel system)
 White smoke may occur for several minutes after the
engine start, this is not a malfunction.
3-8
Using Booster Batteries

IMPORTANT: The machine electrical system is a 24 volt
negative (-) ground. Use only 24 volt booster batteries
with sufficient capacity.
dWARNING:
 An explosive gas is produced while batteries are 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.
SA-032
 Park the machine and a machine with the booster
batteries 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
the machine.
 Never connect a positive terminal to a negative
terminal, as a dangerous short circuit will occur.
When the machine batteries are exhausted, start the engine

using booster batteries as shown below.
Connecting the booster cables

1. Stop the engine of the machine on which booster
batteries are mounted.
2. Turn the battery disconnect switch to the OFF position. Battery Disconnect Switch
3. Connect one end of red cable (1) to the positive (+) 1 Connect First
terminal of the machine batteries, and the other end to
the positive (+) terminal of the booster batteries.
(Red)
4. Turn the battery disconnect switch to the ON position.
5. Connect one end of black cable (2) to the negative (-)
terminal of the booster batteries, and then make ground
connection to the frame of the machine to be started
with the other end of black (-) cable (2). In the last
connection to frame, sparks may fly. Be sure to connect
the cable end as far away from the machine batteries as Booster Batteries Machine Batteries
possible.
(Black)
6. After securely connecting the booster cables, start the To Upperstructure Frame of the
engine of the machine on which booster batteries are 2 Machine
mounted. Connecting the booster cables MDC1-03-001
7. Start the engine of the troubling machine.

8. After the engine starts, disconnect cables (2) and (1),
following the procedure below.
3-9
Disconnecting the booster cables Battery Disconnect Switch
1. Disconnect black negative (-) cable (2) from the machine 1

frame first.
2. Disconnect the other end of black negative (-) cable (2) (Red)
from the booster batteries.
3. Disconnect red positive (+) cable (1) from the booster
batteries.
4. Disconnect red positive (+) cable (1) from the machine
batteries.
Booster Batteries Machine Batteries
(Black)
To Upperstructure Frame of the Machine
2 Disconnect Booster Cable from Frame First
MDC1-03-001
Disconnecting the booster cables
3-10
Stopping the Engine

Engine Stop Procedure
1. Except for special cases, before stopping the engine,
lower the bucket to the ground.
2. Pull pilot control shut-off lever (3) to LOCK position.
3. Turn engine control dial (1) to the slow idle position and
run the engine for 5 minutes to cool the engine. SA-390
3
IMPORTANT: If the engine equipped with a turbocharger

is stopped without first performing the cool down
operation, the lubricant on the turbocharger bearing
surfaces may desiccate due to the intense heat present
inside the turbocharger, possibly causing damage to
the turbocharger.
4. Turn key switch (2) OFF to stop the engine.
If the engine does not stop, even if the key switch is MDAA-01-295
turned to the OFF position. (Emergency Stop)
In case the engine does not stop even if key switch (2) is
turned OFF due to failure of the machine, move engine stop
switch (4) downward to stop the engine. The engine will 1
stop. Return engine stop switch (4) to its original position
(upward). Slow Idle
d CAUTION: Do not use engine stop switch (4) unless

absolutely necessary. When the machine stops due
to the machine failure, do not start the machine until
repair is completed.
M1P1-01-068
MDCD-01-030
4 MDAA-01-290
3-11
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3-12
DRIVING THE MACHINE
Drive the Machine Carefully

IMPORTANT: During freezing weather, park machine on
a hard surface to prevent tracks from freezing to the
ground. Clean debris from tracks and track frame.
If tracks are frozen to the ground, raise tracks using
boom, move machine carefully to prevent damage to
drive train and tracks.
Select a route that is as flat as possible. Steer machine

as straight as possible making small, gradual changes in
direction.
When driving over rough terrain, reduce the engine speed to

lessen possibility of undercarriage damage.
fNOTE: An arrow-mark seal is stuck on the inside surface of

the side frame to indicate the machine front direction.
Arrow-mark
M178-03-001
4-1
DRIVING THE MACHINE
Steering the Machine Using Pedals
dWARNING: In the standard travel position, the front

idlers are positioned at the front of the machine and Cab
Front Idler
the travel motors at the rear. If the travel motors are

positioned at the front of the machine, the control
actions of the travel pedals will be reversed. Be sure
to confirm the position of the travel motors before
traveling.
 FORWARD TRAVEL
Travel Motor
Push down on front (A) of both pedals.
M104-01-038
 REVERSE TRAVEL
Push down on rear (B) of both pedals.
 NEUTRAL POSITION (C)
When the travel pedals are placed in neutral, travel
brakes automatically will stop and/or hold the
machine. A
D
 RIGHT TURN
A C
Push down on front of left pedal. B
D
 LEFT TURN
C
Push down on front of right pedal. B
Forward and Reverse
M104-04-009 M104-04-003
 SHORT TURN (Spin turn)
Push down the front of one pedal and the rear of the
other.
fNOTE: For long-term traveling, push down on pedal tabs (D)

and rest feet on the footrests.
Pivot Turn
M104-04-010 M104-04-005
Spin Turn M104-04-007

M104-04-011
4-2
DRIVING THE MACHINE
Steering the Machine Using Levers
dWARNING: In the standard travel position, the front

idlers are positioned at the front of the machine and Cab
Front Idler
the travel motors at the rear. If the travel motors are

positioned at the front of the machine, the control
actions of the travel levers will be reversed. Be sure
to confirm the position of the travel motors before
traveling.
 FORWARD TRAVEL
Travel Motor
Push both levers forward (A).
M104-01-038
 REVERSE TRAVEL A
A
Pull both levers rearward (B). C
 NEUTRAL POSITION (C)
C
When the travel levers are placed in neutral, travel B
brakes automatically will stop and/or hold the B
machine.
D
 RIGHT TURN
Push left lever forward.
D
 LEFT TURN
Push right lever forward.
Forward and Reverse
M104-04-009 M104-04-003
 SHORT TURN (Spin turn)
Push one lever forward and pull the other rearward.
fNOTE: For long-term traveling, push down on pedal tabs (D)

and rest feet on the footrests.
Pivot Turn
M104-04-010 M104-04-005
Spin Turn M104-04-007
M104-04-011
4-3
DRIVING THE MACHINE
Travel Mode Switch
dWARNING: Tipping-over accidents can cause serious

personal injury. Do not change travel mode switch (1)
while traveling; especially, changing to fast mode (2)
when descending slopes will create a very dangerous
situation. Always stop the machine before changing
the travel speed mode.
1
Turn travel mode switch (1) on the switch panel to the
specified position to select the travel mode (Fast/Slow).
MDCD-01-026
• Fast Mode: Turn travel mode switch (1) to mark (2)
position.
• Slow Mode: Turn travel mode switch (1) to mark (3) 3 2
position.
Mark (Fast Speed Mode) 1

Mark (Slow Speed Mode)
MDCD-01-028
Travel Alarm (Optional)

During travel operation, the travel alarm sounds to warn the
people near the machine that the machine is traveling.
Deactivating Travel Alarm

More than 12 seconds after starting to travel the machine,
raise the armrest and push the travel alarm deactivation
switch to stop the travel alarm. (Within 12 seconds, the
travel alarm deactivation switch is inoperable.)
Once the machine stops traveling and when restarting to Optional Switch
travel, the travel alarm will sound again. If desired to stop
the alarm, operate the deactivation switch once more.
T1V1-05-02-004
fNOTE: The optional switch locations differ depending on

what kinds of optional devices are equipped. Before using
the switches, make sure what kinds of optional devices are
equipped.
4-4
DRIVING THE MACHINE
Operating on Soft Ground

• Avoid traveling on very soft ground that does not have
sufficient strength to firmly support the machine.
• If the machine is operated on very soft ground or
becomes stuck, it may be necessary to clean the track
frame area.
• Swing the upperstructure 90 ° and lower the bucket
to raise one track off the ground. Make sure to keep
the angle between the boom and arm 90 to 110 ° and
position the bucket’s round side on the ground.
• Rotate the raised track back and forth to remove mud and
dirt.
• After lowering the track to the ground, select slow travel
speed. Carefully move the machine to firm ground.
• Utilize the boom and arm functions to pull the machine M104-05-012
toward firm ground.
• Tow the machine if the machine becomes stuck but only
if the engine is still operating. Be sure to attach a tow line
correctly. (Refer to the “Towing Machine a Short Distance”
section on the next page.)
Raise One Track Using Boom and Arm
dWARNING: Keep the angle between boom and arm

90 to 110 ° and position the bucket’s round side on the
ground.
90 to 110 ˚
Swing the upperstructure 90 ° and lower the bucket to raise
track off ground. Do not dig bucket teeth into the ground
when using the hoe bucket reversed.
Place blocks under machine frame to support the machine.
IMPORTANT: When the machine is modified as a face

90 to 110 ˚
shovel by installing the hoe bucket in reverse, avoid
raising the machine above the ground using the front
attachment with the bucket cylinder fully extended.
Excessive loads will be applied to the pins around the
bucket and the bucket cylinder, resulting in breakage M104-05-013
of the pins.
MZX5-04-003
4-5
DRIVING THE MACHINE
Towing Machine a Short Distance

Soft Protector
dCAUTION: Cables, straps, or ropes can break causing

serious injury. Do not tow machine with damaged
chains, frayed cables, slings, straps, or wire ropes.
Always wear gloves when handling cable, straps or
wire ropes.
When your machine becomes stuck but the engine is still

operational, attach wire ropes to the machine as illustrated Wire Rope
at right, and slowly tow your machine to firm ground using
another machine. M104-05-010
Be sure to attach the wire ropes around the track frames of
both machines as illustrated. Shackle hole
for towing
To prevent the wire ropes from being damaged, place some lightweight
protective material between the track frame and the wire objects.
ropes.
IMPORTANT: Do not use the shackle holes on the track

frame for towing the machine. Wire Rope
A center shackle hole on the track frame is provided
to pull only lightweight objects. The shackle holes on
the bottom of the track frame are used to secure the
machine for transportation. Refer to the instructions Shackle
on page 5-22 for using the center shackle hole
MZX5-04-004
appropriately. Tie down
brackets for
transporting.
Wire Rope
Shackle
MZX5-04-005
4-6
DRIVING THE MACHINE
Operating in Water or Mud

The machine can be operated in water up to the upper edge of
the upper rollers only if worksite footing has sufficient strength
to prevent the machine from sinking past the upper edge of
the upper roller, and only if the water is flowing slowly.
When operating in such conditions, check the machine’s

position often. Reposition the machine if necessary. A
Avoid submerging the swing bearing, swing gears and center M104-05-009
joint.
Model A
If the swing bearing, swing internal gear and center joint are
ZX120-5 Class 660 mm (26 in)
submerged, remove the drain plug to drain mud and water.
Clean swing area. Install plug. Lubricate swing internal gear ZX160-5 Class
and swing bearing. ZX200-5 Class 770 mm (30 in)
ZX240-5 Class
Swing Internal Gear Capacity ZX300-5 Class
860 mm (34 in)
ZX120-5 Class: 9 L (2.4 US gal) ZX330-5 Class
ZX160-5, 200-5, 240-5, 300-5 Class: 17 L (4.5 US gal)
ZX330-5 Class: 19 L (5.0 US gal)
Lubricate swing bearing. (See Maintenance Guide, 500 hours)
4-7
DRIVING THE MACHINE
Parking the Machine on Slopes
dWARNING: Avoid parking machine on slopes. The

machine may tip over, possibly resulting in personal
injury.
If parking the machine on a slope is unavoidable:

 Thrust the bucket teeth into the ground.
 Return the control levers to neutral and pull pilot control
shut-off lever (2) to the LOCK position.
 Block both tracks.
SA-2273
Parking the Machine
1. Park the machine on a firm level surface.
1
3. Turn the auto-idle switch off. Slow Idle
IMPORTANT: Turbocharger may be damaged if the

engine is not properly shut down.
4. Turn engine control dial (1) counterclockwise to the stop M1P1-01-068

(the slow idle position). Run the engine approximately 5
minutes to cool the engine.
5. Turn the key switch to OFF. Remove the key from the key
switch.
6. Pull pilot control shut-off lever (2) to the LOCK position.
2
IMPORTANT: Protect cab electrical components from bad
weather. Always close windows, roof vent and cab door
when parking the machine.
7. Close windows, roof vent, and cab door.

8. Lock all access doors and compartments.
Lock Position M1U1-01-025
4-8
Control Lever (ISO Pattern)
dWARNING:
 Never place any part of the body beyond window
frame. It could be crushed by the boom if boom 1 5
control lever is accidentally bumped or otherwise
engaged. Never remove the window sash bar.
4 3 7 8
 Make sure you know the location and function of
each control before operating.
 Do not change the control lever operation pattern. 2 6
Failure to do so may result in operation mistake of
the machine.
A label showing the control patterns of the levers and pedals is

attached on the right side in the cab.
When a lever is released, it will automatically return to neutral,

and that machine function will stop.
1- Arm Roll-Out
2- Arm Roll-In
MDAA-01-288
3- Swing Right
4- Swing Left
5- Boom Lower
6- Boom Raise
3
1
7- Bucket Roll-In
4
8- Bucket Roll-Out
2
M104-05-001
7 5
8
M104-05-002
5-1
Pilot Control Shut-Off Lever 1
Pilot control shut-off lever (1) functions to prevent

misoperation of the machine from occurring if the control
levers and pedals are accidentally moved when leaving the
operator's seat or when entering the cab.
dWARNING: Always pull pilot control shut-off lever

(1) into the full LOCK position. Unless pilot control
shut-off lever (1) is fully moved to the LOCK position,
the all control levers are not locked, possibly creating
a hazardous situation. When leaving the machine,
always stop the engine. Then, pull pilot control shut-
off lever (1) up to the LOCK position. Always check to
be sure that pilot control shut-off lever (1) is pulled up LOCK position MDAA-01-295
to the LOCK position before transporting the machine
or leaving the machine at the end of the shift.
Before Leaving the Machine

1. Park the machine on a firm, level surface. Lower the
bucket to the ground. Return all control levers to neutral.
Properly shut down the engine.
2. Pull pilot control shut-off lever (1) up into the full LOCK
position. 1
Before Starting Operation:

Confirm that pilot control shut-off lever (1) is pulled up to
the LOCK position before starting the engine. The engine UNLOCK Position
MDAA-01-296
will not start in other than the LOCK position.
Slowly push down pilot 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.
dWARNING: 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 control
levers and pedals 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.
5-2
Warming-Up Operation
In cold weather, warm up the machine until coolant and
hydraulic oil temperature increases to the appropriate
operating temperature. 1
Slow Idle
IMPORTANT: The appropriate hydraulic oil operating
temperature on this machine is 50 to 80 °C. Hydraulic
components may be seriously damaged if the machine
is operated with low temperature hydraulic oil. In case
warming up the machine by relieving the hydraulic
M1P1-01-068
system, continuously relieve the relief valve for 10 to
15 seconds while taking a pause for 5 to 10 seconds.
1. Even after the engine starts, leave engine control dial (1)
in slow idle position.
(Do not operate the machine until the needle of coolant
temperature gauge (2) starts swinging.)
2. After the needle of coolant temperature gauge (2) starts 2
swinging, turn engine control dial (1) to approx. medium
position.
3. Operate the boom, arm and bucket cylinders slowly to
each stroke end several times. If the machine equipped
with various attachments, operate the attachment
MDAA-01-001EN
function slowly to allow hydraulic oil to circulate through
the system.
4. Operate the travel and swing functions slowly to allow
hydraulic oil to circulate through the systems.
5. Warming-up operation ends after the above operation is
completed.
fNOTE:
coolant temperature or hydraulic oil temperature is low, the M1P1-05-003
slow idle position.
increase even if engine control dial (1) is in the slow idle
position.
7
when engine speed control indicator (7) is lit. The
MDAA-01-355
5-3
Engine Speed Control

Increase and decrease the engine speed using engine control
dial (1) located on the switch panel, as illustrated.
 Turn engine control dial (1) clockwise to increase the engine

speed. Turn engine control dial (1) counterclockwise to 1
decrease the engine speed.
 Note that the auto-idle function will be deactivated if

engine control dial (1) is operated while the engine is
running at the auto-idle setting.
MDCD-01-026
 Before stopping the engine, always turn engine control dial
(1) counterclockwise to the stop (to the slow idle setting).
Run the engine five minutes to cool the engine. Then, turn Fast Idle
the key switch to OFF position to stop the engine.
fNOTE: 1
Slow Idle
coolant temperature or hydraulic oil temperature is low, the
M1P1-01-068
slow idle position.
increase even if engine control dial (1) is set in the slow idle
position.

when engine speed control indicator (7) is lit. The
7
MDAA-01-355
5-4
Auto-Idle 1
Auto-Idle Function
With auto-idle switch (3) turned to the A/I ON position,
approximately 4 seconds after all control levers are returned
to neutral, the engine speed decreases to the auto-idle
setting to save fuel consumption.
The engine speed will immediately increase to the speed
set by engine control dial (2) when any control lever is
operated.
IMPORTANT:
Always check if auto-idle indicator (1) is turned ON or

OFF before starting operation. If indicator (1) is ON, MDCD-01-020SC
the auto-idle function will be activated.
Always be aware of engine control dial (2) setting

when auto-idle switch (3) is turned to the A/I ON
position. If the engine speed is set high with engine
control dial (2), and 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.
2
dmovement.
WARNING: Prevent the machine from unexpected
Be sure to turn auto-idle switch (3) to the
3
A/I OFF position when unexpected machine movement

is undesirable, especially when loading/unloading the
MDCD-01-026
machine for transportation.
fNOTE: Auto-idle control may not work completely until the

end of the warm-up.
5-5
Auto-Idle ON/OFF 1
Note that auto-idle function can be turned ON or OFF by

using auto-idle switch (3) only when the key switch is in ON
position.
Always check if the auto-idle function is turned ON or OFF
with auto-idle indicator (1).
Auto-Idle Indicator (1) ON : Auto-Idle Function ON

Auto-Idle Indicator (1) OFF : Auto-Idle Function OFF
 When auto-idle switch (3) is turned OFF with auto-idle

indicator (1) ON, indicator (1) will go OFF and the auto-idle
system is deactivated.
MDCD-01-020SC
 Even if the engine is stopped by turning the key switch with
auto-idle switch (3) in the A/I ON position [indicator (1) ON],
the auto-idle system is not deactivated. When the engine is
restarted, the auto-idle system remains activated, allowing
auto-idle indicator (1) to flash for 5 seconds and stay ON
later.
MDCD-01-026
5-6
Auto Shut-Down
dthe
WARNING: This function automatically stops
engine. Take extra care on the work and work
environment when using this function.
When the auto shut-down function is turned ON, the engine

automatically stops after the preset time at the state in which 2
the pilot control shut-off lever is pulled. 30 seconds before
the engine stop, monitor (2) displays a message that engine
will be stopped and indicator (1) starts flashing. Also the
buzzer sounds. The buzzer sounds once at 30 seconds before,
then continuously sounds from 15 seconds. The engine
MDAA-01-146EN
speed decreases to the idling speed, and then stops after 15
seconds. When the pilot control shut-off lever is pushed before
stopping the engine, the auto shut-down is disabled and the
engine will not stop.
IMPORTANT: Ensure the ON or OFF status of auto shut-

1
down indicator (1). If the indicator is ON, the auto shut-
down function will be activated.
Operating Condition
 The engine is running.
 The pilot control shut-off lever is in the LOCK position.
 Coolant and hydraulic oil temperature are not high.
IMPORTANT:
When the engine stops by the auto shut-down

function, turn the key switch to ACC or OFF once and
then turn it to START to restart the engine. Turn the MDAK-01-020
key switch OFF after auto shut-down when leaving
the machine for long period of time. Do not leave the
machine after auto shut-down. Failure to do so may
When the key switch is turned to OFF position while

the auto shut-down function is ON, the setting will
be reset. When it is required to keep the setting,
consult your authorized dealer.
5-7
IMPORTANT: When the auto shut-down activates, the air
conditioner will also stop.
1
Setting the Auto Shut-Down Function

Auto Shut-Down: On/Off
1. Press selector knob (2) while displaying Basic Screen (1)
3. Press selector knob (2) to display Setting Menu screen
(5). MDAA-01-001EN
4. Rotate selector knob (2) to highlight Auto Shut-Down (6).

2
MDCD-01-026
MDAA-01-114EN
MDAK-01-101EN
5-8
5. Push selector knob (2) to display Auto Shut-Down screen
(7). 2
MDCD-01-026
6. Rotate selector knob (2) to highlight ON (8).

7. Push selector knob (2) to display Auto Shut-Down screen 7
(7). Push selector knob (2) again to turn the auto shut- 8
down function OFF.
fNOTE: When the function is ON, the mark "" is displayed in

gray.
Acting Time Setting

MDAA-01-148EN
1. On Auto Shut-Down screen (7), rotate selector knob (2)
to highlight Setting Time (9).
2. Push selector knob (2). Rotate selector knob (2) to adjust
the auto shut-down acting time.
3. Push selector knob (2) to make the change.
9
fNOTE: 30 seconds before the engine stop, the monitor will

display "Engine Shut-Down Soon." message (10).
MDAA-01-150EN
10
MDAA-01-146EN
5-9
Work Mode
Select Work Mode in the main menu, and select the
appropriate hydraulic circuit and pump flow rate for the front
attachment at Work Mode screen.
When the engine is started, the digging mode is automatically

set. Following 6 work modes can be selected from the Work
Mode screen.
 Digging Mode
 Breaker 1 Mode
 Pulverizer 1 Mode
 Crusher 1 Mode
 Grapple 1 Mode MDAA-01-001
5-10
The selected work mode is indicated by attachment mode
indicator (2) of Basic Screen (1).
Select the work mode corresponding to the work in which the
machine is engaged while referring to the table below.
Work Mode Description
Digging Mode Select this mode when using bucket.
Breaker 1 to 5 Mode Select this mode when using breaker.
Pulverizer 1 to 5 Mode Select this mode when using pulverizer.
Crusher 1 to 5 Mode Select this mode when using crusher.
Vibrating Hammer 1 to 5
Select this mode when using vibrating hammer.
Mode
Grapple 1 to 5 Mode Select this mode when using grapple.
Clamshell 1 to 5 Mode Select this mode when using clamshell.
Others 1 to 5 Mode Select this mode when other than the above attachment is used.
fNOTE: 36 work modes shown above are designated as the

1
standard specifications. Up to 11 attachment modes other
2
than the digging mode can be designated. Consult your
authorized dealer for adding or changing the designation of
the attachment modes.
MDAA-01-001EN
5-11
Attachment Selection
1. Press selector knob (2) while displaying Basic Screen (1)
2. Rotate selector knob (2) to highlight Work Mode (4).
3. Press selector knob (2) to display Work Mode screen (5).
4. Rotate selector knob (2) to highlight the Desired Front
Attachment.
(In the right example, Bucket (6) is highlighted.)
5. Press selector knob (2) to make the changes.
MDAA-01-001EN
MDCD-01-026
MDAA-01-100EN
MDAK-01-101EN
5-12
Power Boost Switch

Power boost switch (4) is located on the top of the right
control lever.
When power boost switch (4) is pushed, increased front

attachment power will be supplied for about 8 seconds. 4
MDAA-01-292
5-13
Power Mode
Two engine speed modes, ECO or PWR mode is selected by
operating the power mode switch (1).
ECO (Economy) Mode

Operate the machine in this mode when performing normal
work.
ECO is displayed on Power Mode Display (2).
PWR (Power) Mode

Use PWR (Power) mode when extra horsepower is needed.
PWR is displayed on Power Mode Display (3).
fNOTE: ECO mode is set automatically when starting the

engine. Set PWR mode if necessary.
MDCD-01-027
MDAA-01-001EN
MDAA-01-353
5-14
Precautions for Excavation (K. Model)

This model has been exclusively designed to applications for
demolition works. Therefore, the points described below are
remarkably different from those of the standard specifications.
Do not allow the machine to engage in a bucket work severer
than handling crushed material. Never apply the machine to
heavy duty excavation works.
Increase in Counterweight
IMPORTANT: According to the provision that the
machine is equipped with an attachment Model Increased weight (kg)
heavier than the standard bucket, the ZX210K-5A 400
counterweight is increased as shown in ZX250K-5A 950
the right table. Therefore, the machine ZX350K-5A 1250
stability in bucket works decreases. Avoid
applying this machine to excavation works.
In addition, avoid quick operation of the
front attachment such as dropping the front
attachment at fast speed, possibly resulting
in damage to the frame.
Link B
Change in Specifications of Bucket Cylinder and Link B
Overall length of a breaker and/or crusher to be attached
to this machine is longer than the standard bucket.
Accordingly, the roll-in operation angle of them is reduced
than the standard machine to prevent the breaker/
crusher from coming in contact with the front attachment
structures, possibly causing damage to the front
attachment structures. As mentioned above. When a bucket
is operated on this machine, the roll-in operation angle of
Demolition type model
the bucket is reduced. Therefore, the soil volume loaded in Standard type mode Reduction in bucket roll-in angle
the bucket decrease. Thereby, this machine is inadequate to
use as an excavator. M104-05-051
Precautions to be Taken When Using the Machine as an Model Reduction in bucket roll-in angle
Excavator ZX210K-5A,
13 °
Modify the machine in the following points when 250K-5A
exclusively using this machine as an excavator. Consult with ZX350K-5A 15 °
your nearest Hitachi dealer for the detailed information.
 Replace the counterweight with one for the standard

specification machine.
 Replace link B with one for the standard specification
machine.
 In case the bypass pipe lines are mounted on the arm,
remove the bypass pipe lines.
5-15
Operating Backhoe
 Use the appropriate arm and bucket for the work.
(Refer to the "Bucket Types and Applications" in the
Specifications Chapter.)
 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 (if

equipped) positioned towards the front, the bucket
teeth may come in contact with the blade if you are
not careful.
5-16
Shovel
Backhoe operation digs the ground using the bucket in a roll-
in motion. On the other hand, face shovel operation digs the
ground using the arm cylinder in a scraping motion.
dthe
WARNING: Take care not to hit the cab when rolling in
arm with the reversed-installed bucket.
Watch out!
(Take care not to hit
IMPORTANT: If a bucket hook is mounted, take care the cab with bucket)
not to hit the arm with the hook when rolling in the
bucket.
MZX5-05-003
 For face shovel operation, dig the ground using the arm
cylinder in a scraping motion.
 When underground water is expected, make a slope
angle of 2 to 3° to drain this water as shown.
fNOTE: Because of the hydraulic cylinder structure, digging

force of the face shovel operation is smaller than the backhoe
operation.
2 to 3 °
M104-05-020
5-17
Grading Operation
Operate the boom, arm, and the bucket in such a way so that
the bucket teeth move horizontally, constantly keeping them
perpendicular to the ground at the grading operation.
IMPORTANT: Do not pull or push dirt with the bucket

when traveling. Excess force will be applied on each
part, and the machine may be damaged.
1. Operate arm roll-in function while slowly raising the

boom. Once the arm moves past the vertical position,
slowly lower the boom to allow the bucket to maintain a M104-05-017
smooth surface.
2. Arm roll-out operation is performed in the reverse way of
step 1.
3. Do the slope finishing work in the same procedure as
described in steps 1 and 2.
5-18
Do Not Strike the Ground with Bucket Teeth
dground
WARNING: Forcibly striking the bucket teeth on the
may result in personal injury by the flying
debris. Also, this operation will shorten the service life
of each part on the front attachment.
If the bucket teeth are forcibly struck on the ground, it

shortens the service life of the front attachment parts
(especially the bucket).
When digging a hard gravel stratum, use dig up force of the
bucket. Operate the boom, arm and the bucket simultaneously
so that the bucket teeth efficiently bite into the ground.
Flying debris may result in personal injury.
Avoid Hammer Work
dhammer
WARNING: As the bucket body has the curved surface,
work or piling work is very dangerous. Doing
so may damage the bucket and front attachment.
Do not attempt to use the bucket for hammer work and piling
work.
Doing so may damage the bucket and front attachment,
causing personal injury.
MZX5-05-004
5-19
Avoid Abusive Operation

Do not use travel and do not raise rear of the machine to use
the machine's weight as additional digging force. Severe
machine damage may result.
MZX5-05-005
Avoid Side Load the Bucket

Do not side load the bucket. For example, do not swing the
bucket to level material or do not strike objects from the side
with the bucket.
Doing so may damage the front attachment and the swing
system.
MZX5-05-006
5-20
Retracting the Arm and Bucket

Pay attention to the following when installing cab equipment
(optional) such as OPG (level 2) front guard, OPG (level 2) head
guard, rain visor, cab top lights (4 lights), etc.
dCAUTION: When the machine is equipped with

the cab equipment mentioned above, the teeth of
the bucket may hit the cab equipment if the arm
is retracted excessively. Be careful not to hit the
cab equipment with the teeth of the bucket when
retracting the arm.
M107-05-072
Do Not Use Wide Track Shoes on Rough Ground

Never use wide track shoes on rough ground such as rocks,
sand or gravel. Wide track shoes are designed for soft ground.
Failure to do so may result in shoe bending and/or shoe bolt

loosening, and may damage other undercarriage components
such as track link and rollers.
(Refer to the "Shoe Types and Applications" in the
Specifications section.)
5-21
Shackle Hole Usage

A shackle hole is provided on the track frame to tow light Shackle hole for towing light
weight objects as specified below. weight objects.
IMPORTANT: Be sure to conform to the restrictions and

precautions stated below when towing a light weight
object using the shackle hole provided on the track
frame. The track frame and/or the shackle hole may be
damaged otherwise. Wire Rope
 The maximum drawbar pull.

Shackle
Model Maximum Drawbar Pull
ZX120-5 Class 44100 N (4500 kgf ) or less
ZX160-5 Class 53900 N (5500 kgf ) or less M104-05-011
ZX200-5 Class
ZX240-5 Class
73600 N (7500 kgf ) or less
ZX300-5 Class
ZX330-5 Class
 Be sure to use a shackle.

 Keep the tow line horizontal, straight, and parallel to the
tracks.
Select the slow travel mode. Slowly drive the machine when
towing.
5-22
Pilot Accumulator Functions (Optional)

The pilot accumulator (1) is a pressure storage reservoir of the
control circuit which supplies pressure and enables to operate
the control circuit even after stopping the engine.
1
Thus, the front attachment can be lowered with its own weight
by using the control lever and pressure in the hydraulic circuit
can be released after stopping the engine.
Pressure Release Procedure of Hydraulic Circuit

1. Set the machine in the parking position.
MDAA-05-009
Perform items from 3 to 5 within 15 seconds.
As pressure in the accumulator gradually decreases after
stopping the engine, pressure in the hydraulic circuit can be
released only immediately after stopping the engine.
3. Stop the engine. Turn the key switch ON.

4. Push the pilot control shut-off lever to the UNLOCK
position.
5. Move the control levers and attachment pedals forward
and rearward or left and right to release pressure from
the hydraulic circuit.
6. Pull the pilot control shut-off lever to the LOCK position
and turn the key switch OFF.
5-23
How to Lower Boom in Case of Emergency and 2 1

When Engine Stops
(Without hose-rupture safety valve)
dWARNING: Prevent personal injury. Confirm that no

one is under the front attachment before starting the
procedure below.
In case the engine suddenly stops and the engine cannot

restart, lower the boom in the following procedures.
IMPORTANT: Never loosen screw (2) more than 2 turns. MDAA-05-008

Screw (2) may come off. ZX120-5 Class
1. Loosen lock nut (1) in the emergency valve at the right. 2
Loosen screw (2) one half of a turn. The boom lowering
speed can be somewhat adjusted by loosening screw (2) Front
more. Attachment Side
1
IMPORTANT: Excessive leakage may result if screw (2)
and lock nut (1) are tightened insufficiently. Be sure to
retighten screw and the lock nut to specifications.
2. After the boom is lowered, tighten screw (2) and tighten
lock nut (1) to the specifications below.
T1V1-03-03-073
Locknut (1)
ZX160-5, 200-5, 240-5, 300-5, 330-5 Class
Tightening Torque: 13 N·m (1.3 kgf·m)
Screw (2)
Tightening Torque: 7 N·m (0.7 kgf·m)
Emergency Valve
1
2
T1V1-03-03-038
5-24
Precautions for After Operations

 After finishing the day's operation, drive the machine to
a firm, level ground where no possibility of falling stones,
ground collapse, or floods is present.
(Refer to the group for "PARKING MACHINE" in the
DRIVING MACHINE Chapter.)
 Fully refill the fuel in the fuel tank.
 Clean the machine.
5-25
MEMO
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5-26
TRANSPORTING
Transporting by Road
When transporting the machine on public roads, be sure to
first understand and follow all local regulations.
 When transporting the machine using a trailer, check

the width, height, length and weight of the trailer with
the machine loaded. Note that transporting weight and
dimensions may vary depending on the type of shoe or M1V1-06-001
front attachments installed.
 Investigate beforehand the conditions of the route to be
traveled, such as dimensional limits, weight limits, and
traffic regulations.
In some cases, getting the permission from the local authority

concerned or disassembling the machine to bring it within
dimensional limits or weight limits of local regulations may
become necessary.
Notify your authorized dealer that you are transporting the
machine.
ZX120-5 Class
IMPORTANT: The auxiliary bar attached to the rear
section of the hand rail can be installed in two
positions to adjust its height. Install the auxiliary bar
in the transportation position when transporting the
machine. After transporting the machine, reinstall the
auxiliary bar in the normal operation position before
Transportation Position MDAA-06-001
MDAA-06-002
Normal Operation Position
6-1
TRANSPORTING
Loading/Unloading on a Trailer
Always load and unload the machine on a firm, level
surface.
dWARNING: Be sure to use a loading dock or a ramp

for loading/unloading. Never load or unload the
machine onto or off a truck or trailer using the front
attachment functions when driving up or down the
ramp.
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 and trailer 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 loading the machine equipped with pat
crawler or rubber pad shoes, take sufficient care not
to allow the machine to slip since the surface of the
rubber pad shoe is flat.
Load the machine only after removing soil or clay
adhered to the machine.
6. When transporting the machine equipped with a
blade, take care not to hit the blade.
6-2
TRANSPORTING
Loading/Unloading
dWARNING:
 Always turn the auto-idle switch OFF when loading
or unloading the machine. In the auto-idle mode,
speed may automatically increase.
 Always select the slow speed mode 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
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 the balance may be lost. If the front attachment is
not fitted, reverse onto the trailer.
 Extreme care must be taken when swinging the
upper structure when the machine is on the trailer
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.
Loading
If the front attachment is fitted, load with the front faced
towards the front, if the front attachment is not fitted,
reverse onto the trailer.
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.
15 ° or less
M1G6-06-002
15 ° or less
M107-06-018
6-3
TRANSPORTING
3. When the front attachment is fitted
3.1 Determine a position for the bucket in line with the
trailer. Adjust the angle of the boom and the arm at 90
to 110 °.
3.2 Lower the bucket onto to the deck of the trailer before
the machine passes over the end of the ramp for
support.
3.3 Lift the bucket slightly off the deck of the trailer after
the machine has moved to the designated space. With
M107-06-012
the arm lifted inwards, slowly swing the upperstructure
around 180 °.
3.4 Rest the front attachment on supports such as wooden
blocks placed on the trailer flatbed. Also lower the
blade onto the deck at this time (if fitted).
4. Stop the engine. Remove the key from the key switch.
6. Close cab windows, roof vent and door, and cover the
exhaust opening, to prevent entry of wind and water.
Place a cover over the exhaust outlet. Lock all doors, M107-06-013
covers and caps if they have a lock.
7. House all mirrors and the radio antenna away correctly.
dCAUTION: In cold weather, be sure to warm up the

machine before loading or unloading it.
6-4
TRANSPORTING
Fastening Machine for Transporting
dsecurely
WARNING: Fasten the machine frame to the deck
with chains and cables. While traveling, loads
may shake around, move forward or backward or to
the sides.
1. Place cog stoppers or blocks in front of and behind the

tracks to help secure the machine.
2. Fasten each corner of the machine and front attachment M1V1-06-001
to the trailer with appropriate strength of chains or
cables.
Unloading
dthe
WARNING: The rear end of the flatbed where it meets
ramp is a sudden bump. Take care when traveling
over it.
IMPORTANT: Make sure that the angle of the boom and

the arm is kept between 90 to 110 ° when unloading
the machine.
Damage to the machine is possible if the arm is kept in M107-06-014
a suspended state during unloading.
1. Travel extremely slowly with the bucket on the ground

and the angle of the arm and the boom kept at between
90 to 110 ° when moving from the edge of the trailer
onto the ramp.
IMPORTANT: When driving the machine over the ramp,
do not allow the machine to hit the ground too hard
with the arm. Possible damage to the hydraulic
cylinders may result.
6-5
TRANSPORTING
2. The bucket must be on the ground before the machine
begins to tip forward.
3. As the machine moves forward, raise the boom and
extend the arm until the machine is completely off the
ramp.
M107-06-015
6-6
TRANSPORTING
Lifting Machine
d WARNING:
 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 (shift)
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.
6-7
TRANSPORTING
Lifting
1. Fully extend the arm and bucket cylinders. Lower
the boom until the bucket comes in contact with the Support Bar
ground.
Center of
2. Pull the pilot control shut-off lever to the LOCK position. Gravity
4. Close and lock all doors and covers.
5. Use wire ropes and support bar of sufficient length so M1G6-06-001
that they do not come in contact with the machine while
lifting.
Wrap some protectors around wire ropes and/or support
bar as required to prevent the machine from being
damaged.
6. Set a crane in an appropriate position.
7. Thread the wire rope through and under both sides of
the track frames as illustrated. Attach the wire ropes to
the crane.
6-8
MAINTENANCE
Correct Maintenance and Inspection Procedures

Learn how to service your machine correctly. Follow the
correct maintenance and inspection procedures shown in this
manual.
Inspect machine daily before starting.

 Check controls and instruments.
 Check coolant, fuel and oil levels.
 Check for leaks, kinked, frayed or damaged hoses and
lines.
 Walk around machine checking general appearance,
noise, heat, etc.
 Check for loose or missing parts. SA-005
If there is any problem with your machine, repair it before

operating or contact your authorized dealer.
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 parts, leading to malfunction.
 Use Hitachi genuine high performance filter.
7-1
MAINTENANCE
 Body Information Controller
This machine provides a body information controller that stores machine operation information for preventive
maintenance.
When maintaining the machine, our authorized service man may download the stored information.
Consult with your authorized dealer for detailed function of this device.
 Communication Terminal Operation
It is not necessary to check or operate the communication terminal however if any abnormality is found, consult your
authorized dealer.
Before installing any covering attachment such as a head guard, consult your authorized dealer.
Never spray water on the communication terminal and the wirings.
 Inquire on the proper way to recycle or dispose of oil, fuel, coolant, filters, batteries and other waste from your local
environmental or recycling center, or from your authorized dealer.
 Hitachi machine models described in this manual are classified as shown in the table below.
Model
ZX130-5A
ZX160LC-5A
Std. Model
ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A

Std. Specification
ZX240-5A, 240LC-5A, 250H-5A, 250LCH-5A
ZX300-5A, 300LC-5A
ZX330-5A, 330LC-5A, 350H-5A, 350LCH-5A
K. Model
ZX210K-5A, 210LCK-5A
7-2
MAINTENANCE
Layout
7 9
10
6 11
42 12
5 13
41
4 40 14
15
16
3 17
2 18
1 19
39 20
38
21
37
22
36
23
35
24
34 25
33 26
32
31 27 MDC1-07-037
30 28
29
1- Tooth 12- Swing Bearing 23- Counterweight 33- Fuel Cooler

2- Side Cutter 13- Swing Reduction Gear 24- Radiator, Oil Cooler, Inter 34- Expansion Tank
3- Bucket 14- Fuel Tank Cooler 35- Track Frame
4- Link A 15- Control Valve 25- Air Conditioner Condenser 36- Track Adjuster
5- Link B 16- Hydraulic Oil Tank 26- Battery 37- Front Idler
6- Bucket Cylinder 17- Muffler 27- Track Link 38- Air Cleaner
7- Arm 18- Fuel Filter 28- Shoe 39- Control Lever
8- Arm Cylinder 19- Engine Oil Filter 29- Travel Device 40- Cab
9- Boom 20- Pilot Filter 30- Washer Tank 41- Boom Cylinder
10- Center Joint 21- Pump 31- Lower Roller 42- Work Light
11- Tools 22- Engine 32- Upper Roller
7-3
MAINTENANCE
Check the Hour Meter Regularly

Refer to the List of Check and Maintenance for information
about lubricants, check and adjustment intervals. The
maintenance guide table is affixed in the back of the tool box
cover. Refer to the next page.
This manual recommends grouping the intervals into three

categories as follows:
Daily Check : To be conducted daily before operation
Monthly check : To be regularly conducted once per month
Annual check : To be regularly conducted once per year
Check and maintenance intervals shown in this manual

are those for the machines to be operated under normal
conditions. In case the machine is operated under more severe
conditions, shorten the intervals.
7-4
MAINTENANCE
Maintenance Guide Table
The maintenance guide table is affixed to the reverse side
of the tool box cover. Lubricate and/or service the parts at
the intervals as instructed in the table so that all necessary
maintenance can be performed regularly.
 Symbol Marks
The following marks are used in the maintenance guide
table.
Grease Hydraulic oil filters

(Front Joint Pin, Swing Bearing, Swing (Pilot Filter, Hydraulic Oil Tank Filter,
Gear) Suction Filter)
Gear Oil
(Pump Transmission, Travel Reduction Air Cleaner Element
Device, Swing Reduction Device)
Coolant
Engine Oil
(Long-Life Coolant)
Fuel Filter
Engine Oil Filter
(Fuel Main Filter, Pre-Filter)
Hydraulic Oil
7-5
MAINTENANCE
 Maintenance Guide Table
15 9 11 6 4
10
12
13
14 4
8
1
2
7
17
4 16
Lubrication Interval
(hours) 4 5 3
MDAK-07-036
Item Page Item Page

1 Engine Oil 7-37 10 Hydraulic Oil Filter (Pilot) 7-57
2 Coolant (Long-Life Coolant) 7-82 11 Hydraulic Oil Filter (Air Breather) 7-58
3 Grease 7-22 12 Engine Oil Filter 7-37
4 Grease (Every 500 hours. Only first time at 250 7-20 13 Gear Oil (Pump Transmission) 7-41
hours)
5 Grease 7-23 14 Fuel Filter (Main/Pre) 7-71
6 Hydraulic Oil 7-49 15 Fuel Solenoid Pump Filter 7-75
7 Gear Oil (Travel Device) 7-43 16 Gear Oil (Swing Reduction Gear) 7-42
8 Hydraulic Oil Filter (Suction) 7-53 17 Air Cleaner Element 7-78
9 Hydraulic Oil Filter (Full-Flow) 7-54
7-6
MAINTENANCE
Preparations for Inspection and Maintenance

Except in special cases, park the machine by following the
procedure before servicing the machine.
1. Park machine on a firm, level surface.

M104-07-021
3. Turn the auto-idle switch OFF.
4. Turn engine control dial to the slow idle position and run
the engine for 5 minutes to cool the engine.
5. Turn the key switch OFF to stop the engine. Remove the
key. Be sure to place pilot control shut-off lever (1) to the
LOCK position.
6. After putting a tag (2) for "Under Serving" on the easy-to- 1
see cab door or control lever, begin the work.
2
dWARNING: Never attempt to maintain the machine
when the engine is running in order to prevent the
accident. If maintenance work while engine running is
unavoidable, strictly comply with the following items.
 One person should take the operator’s seat
to be ready to stop the engine any time while
communicating with other workers.
MDAA-07-028
 When working around moving parts is unavoidable,
pay special attention to ensure that hands, feet, and
clothing do not become entangled.
 If parts or tools are dropped or inserted into the fan
or the belt, they may fly off or be cut off. Do not drop
or insert parts and tools into the moving parts.
 Move pilot control shut-off lever (1) to LOCK position
so that the front attachment will not move.
 Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, signal co-workers to evacuate to safer
place.
SA-2294
SA-026
7-7
MAINTENANCE
Hood and Access Covers

ZX120-5, 160-5 Class 1
dWARNING:
 Do not keep the hood and access covers open when
the machine is parked on a slope, or while the wind
is blowing hard. The hood or access covers may close
accidentally, possibly resulting in personal injury.
 When opening or closing the hood and access covers,
take extra care not to catch fingers between the base
MDAK-07-001
machine and the hood or access covers. Engine CoverZX120-5 Class
 Holding the handle on the access cover, raise the cover until 1
the cover is secured with catch (1).
 After opening the right and/or left access cover, be sure to

insert rod (2) into cover lock hole (3) to hold the cover.
MDAK-07-027
Engine Cover ZX160-5 Class
2 3 MDAK-07-028
Right Cover ZX120-5 Class
2 3
MDAK-07-029
Right Cover ZX160-5 Class
2 3
2 3 MDAA-07-064
MDAA-07-067
Left Cover ZX120-5 Class Left Cover ZX160-5 Class
7-8
MAINTENANCE
ZX200-5, 240-5 class
dWARNING: 2 1
the machine is parked on a slope, or while the wind
Engine Cover MDAK-07-011
machine and the hood or access covers.
3 4
 Holding the handle on the access cover, raise the cover until
 After opening the right and/or left access cover, be sure to

insert rod (3) into cover lock hole (4) to hold the cover.
 When opening the rear left cover, open the front left cover
first. Then, pull to open the rear left cover as illustrated. MDAK-07-037
Rear Right Cover
 When opening the front right cover, open the rear right
cover first. Then, pull to open the front right cover as
illustrated.
 Do not attempt to start the engine when fan guard (2) is

open.
Front Right Cover MDAK-07-038
Rear Left Cover MDAK-07-049
3 4
Front Left Cover MDAA-07-019
7-9
MAINTENANCE
ZX300-5, 330-5 class
dWARNING:
the machine is parked on a slope, or while the wind 1
machine and the hood or access covers.
 Holding the handle on the access cover, raise the cover until MDAK-07-030
Engine Cover
2 3
 After opening the rear right cover, front left cover or rear
left cover, be sure to insert rod (2) into cover lock hole (3) to
hold the cover.
 When opening the front right cover, open the rear right
cover first. Then, pull to open the front right cover as
illustrated.
Rear Right Cover MDAK-07-039
Front Right Cover MDAK-07-040
2 3
3 2
Rear Left Cover MDAA-07-032 Front Left Cover MDAK-07-041
7-10
MAINTENANCE
Maintenance Guide
A. Greasing
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
Bucket and Link Pins 9   7-20
1. Front Joint Pins
Others 11   7-20
2. Swing Bearing 2 7-22
3. Swing Internal Gear 1  7-23
 : Add grease daily during first 50 hours of operation.
In case excavations are performed in water, grease the pin after operation is complete.
Shorten greasing intervals when the machine is operated under severe conditions or when the machine is
continuously operated for a long period of time.
 : 250 hours for only first time.
 : Check and add grease if necessary.
IMPORTANT:
Grease bucket and link pivots every day until break-in operation (50 hours) is complete.

When a bucket which does not have clearance adjustment mechanism such as slope-finishing bucket or

V-type bucket, or a genuine Hitachi hoe bucket before EX-5 model, or an attachment other than genuine
Hitachi bucket is used, grease two pins every 250 hours.
B. Engine
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
1. Engine Oil Check Oil Level 1 7-35
ZX120-5, 160-5 class 17 L
2. Engine Oil Change ZX200-5, 240-5 class 23 L 7-37
ZX300-5, 330-5 class 41 L
3. Engine Oil Filter Replace 1 7-37
4. Check and Clean Around the Engine − As required 7-40
7-11
MAINTENANCE
C. Transmission
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
Check Oil Level 1 7-41
Pump ZX160-5, 200-5, 240-5 class 1.0 L
1. 7-41
Transmission ZX300-5, 330-5 class 1.4 L
Air Breather Cleaning 1 7-41
ZX120-5 class 3.2 L
Swing Reduction ZX160-5, 200-5 class 6.2 L
2.
Gear Change ZX240-5 class 9.1 L 7-42
ZX300-5 class 11.7 L
ZX120-5 class 4.0 L×2
Travel Reduction
3. ZX160-5, 200-5 class 6.8 L×2
Gear Change 7-44
ZX240-5 class 7.8 L×2
ZX300-5, 330-5 class 9.2 L×2
D. Hydraulic System
Interval (hours)
Parts Quantity Page
8 50 100 250 300 1000 1500 2000 2500 5000
1. Check Hydraulic Oil Level 1 7-49
ZX120-5 class 130 L
ZX160-5 class 190 L
2. Change Hydraulic Oil ZX200-5 class 200 L   7-50
ZX240-5, 300-5 class 243 L
ZX330-5 class 298 L
3. Suction Filter Cleaning 1 Each time when hydraulic oil is changed 7-53
Replacement of full- Std. Model 1  7-54
4.
flow filter K. Model 1  7-55
5. Replace Pilot Oil Filter 1 7-57
6. Replace Air Breather Element 1 7-58
7. Replace Line Filter 1 * 7-59
for leaks, loose − 7-61
8. Check Hoses and Lines
for cracks, bend, etc. − 7-61
 : Changing interval differs according to the brand of hydraulic oil used, kind of filter element or average attachment
operating availability.
Refer to the "changing intervals of hydraulic oil and full flow filter element". See recommended oil chart.
* : Replace every 200 hours. (Breaker operating hours)
7-12
MAINTENANCE
E. Fuel System
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
1. Drain Fuel Tank Sump 1 7-67
2. Drain Fuel Pre-Filter 1 7-68
3. Replace Fuel Main Filter Element 1 (or when indicator lit) 7-71
ZX120-5, 160-5, 200-5,
Replace Fuel Pre-Filter 1 (or when indicator lit) 7-73
4. 240-5 class
Element
ZX300-5, 330-5 class 2 7-73
Type A 1
5. Replace Fuel Solenoid Pump Filter Element 7-75
Type B − No maintenance
for leaks, cracks − 7-77
6. Check Fuel Hoses
for cracks, bend, etc. − 7-77
F. Air Cleaner
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
Clean 1 (or when indicator lit) 7-78
1. Air Cleaner Outer Element
Replace 1 After cleaning 6 times or 1 year 7-78
2. Air Cleaner Inner Element Replace 1 When outer element is replaced 7-80
7-13
MAINTENANCE
G. Cooling System
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000
1. Check Coolant Level 1 7-82
2. Check and Adjust Fan Belt Tension 1  7-84
ZX120-5, 160-5 class 24 L
3. Change Coolant ZX200-5, 240-5 class 31 L Twice a year * 7-86
ZX300-5, 330-5 class 35 L
4. Clean Radiator, Oil Cooler and Inter Cooler Outside 1  7-88
Core Inside 1 Once a year 7-88
5. Clean Oil Cooler, Radiator and Inter Cooler Front Screen 1  7-90
6. Clean Air Conditioner Condenser 1  7-90
7. Clean Fuel Oil Cooler 1  7-90
: 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 is used, change every two years or 4000 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 60 %. If a coolant mixed with less than 30 % of Hitachi Long-Life
Coolant 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 2 Every month 7-94
1. Battery
Check electrolyte specific gravity 2 Every month 7-96
2. Replacing Fuses Replace − As required 7-97
7-14
MAINTENANCE
I. Miscellaneous
Interval (hours)
Parts Quantity Page
8 50 100 250 500 1000 2000 4500
1. Check and Replace Bucket Teeth − 7-100
2. Change Bucket − As required 7-106
3. Convert Bucket Connection Into Face Shovel − As required 7-107
4. Adjust Bucket Linkage 1 As required 7-108
5. Remove Travel Levers 2 As required 7-109
6. Check and Replace Seat Belt 1 Every 3 years 7-109
7. Check Windshield Fluid Level 1 As required 7-110
8. Check Track Sag 2 7-111
Circulating Air Clean 1 7-114
Clean and Replace Air Filter Replace 1 After cleaning 6 times or so 7-114
9.
Conditioner Filter Clean 1 7-114
Fresh Air Filter
Replace 1 After cleaning 6 times or so 7-114
10. Check Air Conditioner − 7-117
11. Clean Cab Floor − As required 7-118
12. Retighten Cylinder Head Bolt − *As required 7-119
13. Inspect and Adjust Valve Clearance − * 7-119
14. Measure Engine Compression Pressure − * 7-119
15. Check Starter and Alternator − * 7-119
16. Check and Replace EGR Device − *As required 7-119
17. Check Gas Damper − *As required 7-120
Tightening and Retightening Torque of Nuts and
18. −  7-120
Bolts
: Maintenance required only during first time check.
fNOTE: * Contact your authorized dealer for maintenance. Instruction plate for the recommended grease and lubricants is
affixed inside the tool box cover.
7-15
MAINTENANCE
Periodic Replacement of Parts

To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards.
These parts may cause serious safety/fire hazards due to
deterioration, wear, or fatigue being attributed to material
aging or repeated operation. It is very difficult to gauge the
extent of deterioration, fatigue, or weakening of the parts
listed below simply by visual inspection alone. For this reason,
replace these parts at the intervals shown in the table below.
Consult your authorized dealer for correct replacement.
Periodic Replacement Parts Replacement Intervals

Fuel hose (Fuel tank, Filter to Engine) Every 2 years
Engine
Fuel hose (Engine, Fuel cooler to Fuel tank) Every 2 years

Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years or 4000 hours whichever comes first
Pump delivery hose
Base Machine
Every 2 years or 4000 hours whichever comes first

Swing hose Every 2 years or 4000 hours whichever comes first
Travel high pressure hose Every 2 years or 4000 hours whichever comes first
Hydraulic System
Tail Hose Every 2 years or 4000 hours whichever comes first

Attachment Line Hose Every 2 years or 4000 hours whichever comes first
Working Device
Boom cylinder line hose Every 2 years or 4000 hours whichever comes first
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
Seat Belt Every 3 years
fNOTE: Be sure to replace seals, such as O-rings and gaskets,

when replacing hoses.
7-16
MAINTENANCE
Kind of Oils
Brand Names of Recommended Grease
Kind of Grease Lithium Grease

Application Front Attachment Joint Pins, Swing Bearing, Swing Gear
Air Temp.
Manufacturer -20 to 40 °C (-4 to 104 °F)
Hitachi Grease SEP2
Hitachi
Hitachi Grease EP-2
Daphne Eponex Grease EP No.2
Idemitsu Kosan
Daphne Eponex Grease No.2
JX Nippon Oil & Energy EPINOC GREASE AP(N)2
Corporation LISONIX GREASE EP2
Alvania Grease EP2 (Shell Gadus S2 V220 2)
Shell
Cartridge Grease EP2
ExxonMobil Mobilux EP2
KIGNAS Oil KIGNAS MP GREASE No.2
COSMO Oil COSMO GREASE DYNAMAX EP2
BP Energrease LS-EP2
Castrol Spheerol EPL2
Chevron Multifax EP2
Recommended Engine Oil

IMPORTANT: Use only genuine Hitachi engine oil as
shown below. Or use JASO DH-1 or equivalent engine
oil. Never use JASO DH-2 or equivalent engine
oil. 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 JASO DH-2 or equivalent engine oil are excluded
from Hitachi Warranty Policy. Consult your authorized
dealer for any unclear points.
Kind of Oil Engine Oil
Application Engine Crank Case
Air Temp. -20 to 30 ˚C -15 to 40 ˚C
(-4 to 86 ˚F) (5 to 104 ˚F)
Manufacturer JASO
Super Wide Super Wide
DH1-10W30 DH1-15W40
Hitachi DH1
Super Wide
DH1-10W40
7-17
MAINTENANCE
Brand Names of Recommended Oil
Application Swing and Travel Reduction Gear Pump Transmission

Kind of Oil Gear Oil Engine Oil
Air Temp.
Manufacturer –20 to 40 °C (–4 to 104 °F) –20 to 40 °C (–4 to 104 °F)
Super Wide DH-1 10W40*
Hitachi Hitachi Gear Oil GL-4 90 Super Wide DH-1 15W40
Super Wide DH-1 10W30
Idemitsu Kosan Apolloil Gear Oil HE90 Apolloil Super Wide 15W-40
HYPOID GEAR 90 DIESEL CF/DH-1 15W-40
JX Nippon Oil & Energy Corporation
GEAR4 90 DIESEL CF4/DH-1 15W-40H
Shell Spirax S2 G 90 Rimula D Multi 15W-40
ExxonMobil Mobilube GX80W-90 Delvac Super DH-2 15W-40
BP Energear EP 80W-90 Vanellus C3 Multigrade 15W-30
Castrol Manual GL-4 80W-90
Chevron Thuban SAE 90 DELO 400 Multigrade 15W-30
Remarks API GL4 Class API CD Class, JASO DH-1, JASO DH-2
fNOTE: * ZX160-5 class
Brand Names of Recommended Hydraulic Oil
Kind of Lubricant Hydraulic Oil

Where to be applied Hydraulic System
Change Interval 5000 hours 2000 hours
Environmental Temp.
Manufacturer –20 to 40 °C (–4 to 104 °F)
Hitachi Super EX 46HN
Idemitsu Kosan Super Hydro 46X
SUPER HYRANDO WP46
JX Nippon Oil & Energy Corporation
HYDLUX 46H
Tellus ST 46
Shell
(Tellus S3 V 46)
ExxonMobil Mobil DTE 10 Excel 46
BP Bartran HV46
Castrol Hyspin HVI 46
Chevron RANDO Ashless 46HD
Others Product Conforming to JCMAS HK VG46W
fNOTE: Consult the authorized dealer for the conditions of use and hydraulic oil other than those described above. Refer to
Japan Lubricating Oil Society (JALOS) home page for JCMAS HK qualified product.
7-18
MAINTENANCE
Recommended Oil Viscosity
Air Temperature (degrees Celsius)

Where to be Applied Kind of Oil
-30 -20 -10 0 10 20 30 40
Engine Oil Pan Engine Oil Super Wide DH-1 10W40
Pump Transmission Engine Oil API CD Class
Swing Device
Gear Oil Hitachi Gear Oil GL-4_90
Travel Device
Hydraulic System
Hydraulic Oil Super EX46HN
(Hydraulic Oil Tank)
JIS No.1 S
JIS No.1
JIS No.2
JIS No.3
JIS No.3 S
ASTM Grade No.2-DS15
Fuel Tank Diesel Fuel EN590 Class A
EN590 Class B
EN590 Class C
EN590 Class D
EN590 Class E
EN590 Class F
GB 0 #
GB -10 #
GB -20 #
GB -35 #
Lithium
Grease fitting SEP Grease
Grease
Genuine Hitachi LLC
Radiator Coolant
(Long-Life Coolant)
7-19
MAINTENANCE
A. Greasing
Front Joint Pins
--- 500 hours
Lubricate all fittings shown in the figure.
M178-07-007
 Boom Cylinder Bottom Side
M157-07-156
 Boom Foot
M157-07-155
7-20
MAINTENANCE
 Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket
Cylinder Bottom Pin
M157-07-157
 Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin
M157-07-155
7-21
MAINTENANCE
Swing Bearing
--- every 500 hours
dCAUTION: Lubricating both the swing bearing and

gear and rotating the upperstructure must be done by
one person. Before you lubricate the swing bearing,
clear the area of all persons.
Each time you leave the cab

 Lower the bucket to the ground.
 Stop the engine.
M157-07-159
 Pull the pilot control shut-off lever to the LOCK
position.
 Use handrails.

IMPORTANT: The turbocharger may be damaged if the
4. Run the engine at slow idle speed without load for five
minutes.
5. Turn the key switch OFF. Remove the key from the key
switch. MDCR-07-015
7. With the upperstructure stationary, apply grease via the
two grease fittings.
8. Start the engine. Raise the bucket several inches off the
ground and rotate the upperstructure 45 ° (1/8 turn).
10. Repeat the procedure three times, beginning with step
3.
11. Apply grease to the swing bearing until grease can be
seen escaping from the swing bearing seals.
Model Capacity
ZX160-5, 200-5 class 0.30 L
ZX240-5, 300-5 class 0.35 L
12. Take care not to supply excessive grease.
7-22
MAINTENANCE
Swing Internal Gear
--- every 500 hours
dCAUTION: Before lubricating the machine, lower the

bucket on the ground, stop the engine and pull the
1. Remove cover (1) from upperstructure. Check if the

swing gear is properly lubricated by grease. Add
approximately 0.5 kg of grease, if required.
1
If the grease is contaminated, remove grease by opening cover
(2) at the undercarriage side and replace with clean grease. MDAA-07-094
ZX120-5, 200-5, 240-5, 300-5, 330-5 class
Model Grease Capacity
ZX120-5 class 9L
ZX160-5, 200-5, 240-5, 300-5 class 17 L
ZX330-5 class 19 L
1 M104-07-002
ZX160-5 class
M157-07-161
7-23
MAINTENANCE
Electric Grease Gun (Only ZX330-5 class)
dCAUTION:
 Since the electric grease gun is not a water-
resistance type, avoid leaving it in a place exposed to
rain and water. Do not use the electric grease gun in
rain fall. Failure to do so may lead to an unexpected
accident such as leak.
 No specified daily maintenance is required. Take care
not to allow any part of the grease gun, especially
motor section, to come in contact with other objects
or do not leave the grease gun contaminated,
possibly resulting in unexpected injury such as
electric shock.
 Always keep the grease gun clean by wiping off
contamination. Failure to do so may cause the grease
gun to slip down resulting in possible personal
injury.
d WARNING:
 Do not operate an electric grease gun in explosive
atmosphere.
 An electric tool may create sparks and ignite
combustible fluid, dust, or fumes.
 Avoid electrifying the grease gun in damp or wet
locations.
 The grease gun develops high pressure up to 41.4
MPa (422 kgf/cm2). Use goggles and heavy gloves for
protection during operation.
7-24
MAINTENANCE
IMPORTANT:
In case the grease gun becomes inoperable, do

not continuously operate it further. Damage to the
motor or a risk of fire may result.
When a battery pack is not in use, store the battery

pack keeping away from a metallic product such as
a paper clip, coin, key, nail, or screw. Short circuit of
the battery may create sparks leading to hazards
such as burns, or fires.

Always be sure to use the attached battery pack.

Using a battery pack other than the attached one
may cause a risk of fire.
7-25
MAINTENANCE
Electric Grease Gun

Specifications
Operating voltage 12 V
Maximum operating pressure 41.4 MPa (422 kgf/cm2)
Grease cartridge capacity 411 cc
Operating temperature range -18~50 ° C
Operating current
(at pressure 6.9 MPa (70 kgf/cm2) 4 A
Grease Consistency: 2 or less
Grease delivery flow
(at pressure 6.9 MPa (70 kgf/cm2) 194 cc/minute
Weight 3.76 kg
Attachments
Battery pack
Output voltage 12 V
Capacity 1300 mAh
Charger
Charge time 1 hour
Output voltage ( at1.7 A) 14.5 V
Input voltage (at 350 mA) 100 V, 50 Hz
7-26
MAINTENANCE
Components Name
2
1- Switch
2- Motor assembly
3- Nozzle (CNP-2)
4- Cap
5- Cartridge grease 1
3
6- Grease cartridge cylinder
7- Chain (Lever)
6
8- Battery pack
9- Battery charger
10- Code
11- Plug
8
12- Band
7
13- Holding bracket
M1U1-07-115
12
13
10
9
11 M1U1-07-112
4 M16J-07-043
7-27
MAINTENANCE
Battery Charger Operation
Charging the Battery Pack General
Before using an electric grease gun for the first time, charge
the battery pack. (for approx. 12 hours)
Refer to the descriptions on "Install/remove Battery Pack"
for installing the battery pack to the electric grease gun.
When the battery pack is almost discharged, the battery

performance sharply drops.
In case greasing becomes difficult, it indicates the time to
recharge the battery pack.
If the battery is recharged before this condition is reached,
the total work life of the battery pack is reduced.
fNOTE: The battery pack temperature will increase during

or immediately after operation. Do not recharge the battery
pack soon after operation. The battery pack may not be
fully recharged. Recharge the battery pack only after the
battery pack temperature is approximately lowered to room
temperature.
dCAUTION: Do not plug the vent holes at the top and

bottom of the battery charger. When the atmospheric
temperature is below 0°C or above 40 °C, do not
charge the battery pack.
7-28
MAINTENANCE
Charger Lamp
1. Green LED flashes.
The signal indicates that it is ready for charging and the
battery pack is not mounted yet.
2. Red LED is lit.
This signal indicates that the battery pack is charging up.
3. Green LED lit.
This signal indicates that the battery pack is fully
charged.
4. Red LED and green LED alternately flash.
This signal indicates that the battery pack is under
inspection when the voltage of connected battery pack
is 9 V or less. This process may need up to 5 minutes.
5. Red LED flashes.
This signal indicates that the battery pack is unusable
due to the end of its service life or trouble. The battery
pack should be replaced.
7-29
MAINTENANCE
Normal Charging Method
After checking that the electric source voltage meets the
voltage shown on the battery charger specification plate,
connect the battery charger to the electric source.
Conduct the first battery charge for 12 hours before using

the battery pack.
Install the battery pack in the battery charger.
As long as the red light is kept ON, it indicates that the
battery pack is being charged.
When the red light goes OFF and the green light comes ON,
charging of the battery pack is complete. As long as the
green light is ON, the battery charger is kept operated in the
trickle charging mode.
The trickle charging mode is maintained until the battery is
used.
Disconnect the plug from the electric source after using the
battery charger.
fNOTE: Trickle charge means auto-maintenance charge
operation to compensate the self-discharge of the battery
pack.
Installing/Removing Battery Pack

Removing Battery Pack
Depress 2 battery release buttons on each side of the
battery pack and pull the battery back out of the electric
grease gun.
Installing Battery Pack

After aligning the battery pack with the specified location
on the electric grease gun handle, push the battery pack
into the handle until it locks in place.
Power Source
Supply the power to the battery charger through the lighter
receptacle with the output of 12 V or 24 V.
7-30
MAINTENANCE
IMPORTANT:
Do not use the attached battery charger except for

charging the attached battery pack. If a battery
other than the attached one is charged personal
injury and damage may result due to explosion.
Never attempt to charge the attached battery pack
by a battery charger other than attached one under
any circumstances.
Prevent the battery charger from being exposed to

rain, snow or frost.
Do not abuse the cord. Never carry the battery

charger with the cord. Take care not to break the
cord by pulling it from the receptacle.
When disconnecting the battery charger, pull on

the plug. Do not pull the cord. Immediately replace
the damaged or worn power cord and the damaged
relief valve. Do not operate the battery charger with
a damaged cord or plug connected. Never attempt to
repair the power cord.
Do not disassemble the battery charger and/or

battery pack. Risk of electric shock or fire may result
if incorrectly reassembled.
Do not incinerate the battery pack. It can explode in

a fire.
Never attempt to charge any other cordless tool or

battery pack with this battery charger.
Never short-circuit between the battery terminals

Damage and/or fires may result due to effect of very
high temperature.
Properly dispose the expended battery pack. The

battery pack is a chargeable nickel-cadmium battery.
This type of battery is required to be recycled
or disposed of in a proper method. Drop off the
expended battery pack at your local replacement
battery retailer or your recycling center.
Do not store the battery charger and/or battery pack

in locations where the atmospheric temperature may
reach or exceed more than 50°C. The battery pack
will deteriorate.
7-31
MAINTENANCE
Preparation for Using Electric Grease Gun
2
Installing cartridge grease
IMPORTANT: Take care not to allow sand and/or dust to

mix in grease when installing cartridge grease (5).
1. Turn to remove grease cartridge cylinder (6) from motor

assembly (2).
2. Fully pull out chain (7) from grease cartridge cylinder
(6). Attach chain (7) to a notch on the bottom of grease
cartridge cylinder (6). 6
3. After removing cap (4) from cartridge grease (5), install

cartridge grease (5) to the screw threads on motor
assembly (2).
IMPORTANT: Be alert that if cartridge grease (5) is

diagonally or forcibly screwed in, damage to the screw 7
threads may result so that the cartridge grease may
not be installed to motor assembly (2).
M1U1-07-115
4. Screw grease cartridge cylinder (6) in the original

position on motor assembly (2). Detach chain (7) from
the notch. 6
M16J-07-042
4 M16J-07-043
7-32
MAINTENANCE
Greasing Method
IMPORTANT: When lubricating a closed space with
grease, the motor rotation becomes slow as soon as
grease is sufficiently filled in the lubrication space
End greasing by releasing switch (1). If greasing is
continued further, burning of the motor may result.
1
1. Drive the motor by pulling switch (1). Grease is
discharged from the tip of nozzle (3). 3
fNOTE: When the grease gun is first used, it takes some time
before discharging grease until air is bled from the motor
assembly.
2. After cleanly wiping the tips of the grease fitting through

which grease is added and gun nozzle (3), press the tip
of nozzle (3) to chuck the grease fitting.
3. Pull switch (1) to discharge grease.
When grease is normally added, old grease is discharged
through the clearance around the grease fitting. M1U1-07-115
4. After completing greasing, allow the inner pressure to

release from the grease fitting by tilting nozzle (3) before
disconnecting the tip of nozzle (3) from the grease
fitting. 3
Certain amount of grease escapes at this time. Grease Fitting
fNOTE: M16J-07-045
 If the motor rotation becomes very slow or stops during

greasing, immediately release switch (1).
 The electric grease gun is a high speed type so that slight

amount of grease may escape from the plunger. This is not
a fault. 3
Grease Fitting
M16J-07-046
7-33
MAINTENANCE
After Using Grease Gun
IMPORTANT: Securely fasten the single battery charger
or the battery charger with the battery pack installed
to the holding bracket with a band attached to the
holding bracket so that the battery charger and/or the
battery pack does not come off the bracket. Failure
to do so may cause the battery pack and/or battery
charger to come off the holding bracket, possibly
resulting in damage to the battery pack and/or battery
charger.
M1U1-07-061
M1U1-07-062
M1U1-07-063
7-34
MAINTENANCE
B. Engine 1
Engine Oil Level

--- check daily
position.
3. Insert key switch (2). Turn it to ON position. Press and
hold switch (3) with the engine stopped.
The engine oil indicator (4) must be displayed in green.
LOCK position MDAA-01-295

IMPORTANT: Do not rely only on the monitor display for
checking the machine conditions; visually check them
yourself as required such as oil level.
2
Always check the machine on a firm, level surface.
Never attempt to start the engine while checking the
machine.
fNOTE: If the security function is enabled, a password is
required.
MDCD-01-030
MDCD-01-026
MDAK-01-043
7-35
MAINTENANCE
--- Visual Inspection
2
IMPORTANT: An incorrect engine oil level may cause
trouble on the engine (The oil level should be between
the upper and lower marks on dipstick (1)).
Even if the engine oil level exceeds the upper limit,
control the oil level to the proper quantity before
starting the engine.
1
Check oil level before starting the engine.

Open the engine cover and pull out dipstick (1). Wipe dipstick MDAK-07-012
ZX120-5 class
(1) with cloth, re-insert it into the pipe to the end, and then
pull it out again. 2
The oil level should be between the upper and lower marks
on dipstick (1).
If oil level is below the lower limit mark, add the recommended
engine oil via oil filler (2).
If oil level exceeds the upper limit mark, remove cap (4) of
drain valve (3) at the bottom of the engine oil pan, and then
open drain valve (3) by turning drainer (5) to drain oil.
dCAUTION: Do not spill oil while changing oil. Spilled

fuel and oil, and trash, grease, debris, accumulated
1
ZX160-5 class MDAK-07-013

coal dust, and other flammable materials may cause
fires.
2
After refilling, make sure oil filler cap (2) is securely
closed.
IMPORTANT: Install drainer (5) to the drain valve slowly.

Oil may exhaust in large quantity when tightened at
once.
1
ZX200-5, 240-5, 300-5, 330-5 class MDAK-07-014

1
Max.
Min.
M178-07-011
5 3, 4
M1U1-07-046 M1U1-07-045
7-36
MAINTENANCE
Change Engine Oil
--- every 500 hours
Replace Engine Oil Filter

--- every 500 hours
dCAUTION: Engine oil may be hot just after operation.

Take extra care to avoid burns.
After refilling, make sure oil filler cap (2) is securely

closed.
1. Run the engine to warm oil.
DO NOT run the engine until oil is hot.

minutes.
switch.
7-37
MAINTENANCE
IMPORTANT: Install drainer (5) to drain valve (3) slowly.
Oil may exhaust in large quantities when suddenly 2
tightened.
8. Remove oil filler cap (2).

9. Remove cap (4) from oil pan drain valve (3). Install
drainer (5) to drain valve (3).
10. Screw drainer (5) into drain valve (3). Drain valve (3) will
be opened to drain oil.
11. Remove oil filler cap (2). Then, allow oil to drain through
a clean cloth into a container.
ZX120-5 to 240-5 class : 50-liter (13 US gal)
ZX300-5, 330-5 class : 60-liter (16 US gal)
12. After all oil has been drained, inspect the cloth for any
debris such as small pieces of metal.
13. Remove drainer (5). Install cap (4) to drain valve (3).
ZX200-5, 240-5, 300-5, 330-5 class

MDAK-07-014
3, 4
Oil Oil
M1U1-07-045
Oil Pan Oil Pan
3 5
Clean Cloth
Container
Screw
5
Oil
M104-07-010 M1U1-07-002 M1U1-07-046
7-38
MAINTENANCE
14. Open the right access cover and secure the cover with
rod.
15. Remove the filter cartridges of engine oil filter (6) by
turning it counterclockwise with the filter wrench.
16. Clean the filter gasket contact area on the engine.
17. Put new oil in from primary side (7) of new cartridge
element (6) so it does not overflow. Take care not to
insert it from secondary side (8).
18. Apply a thin film of clean oil on the gasket (O-ring) of
new filter (6). Install new filter (6). Turn the filter cartridge 6
clockwise by hand until the gasket touches the contact
MDAK-07-015
area. Be sure not to damage the gasket when installing ZX120-5 class
filter (6).
19. Tighten engine oil filter (6) 3/4 to 1 turn more using the
filter wrench. Be careful not to overtighten.
20. Remove the oil filler cap. Fill the engine with
recommended oil. Check that oil level is between the
circle marks on the dipstick after 15 minutes.
21. Install the oil filler cap securely.
22. Start the engine. Run the engine at slow idle for 5
minutes. Check no oil is leaking from the sealling surface.
6
23. Check that the engine oil pressure indicator on the
monitor panel goes out immediately. If not, stop the MDAK-07-016
ZX160-5 class
engine immediately and find the cause.
7 8
6 ZX200-5, 240-5 class MDAK-07-017
MDCR-07-007
6
ZX300-5, 330-5 Class MDAK-07-018
7-39
MAINTENANCE
25. Check for any leakage at the drain plug.
26. Check oil level on the dipstick and add or drain oil
to maintain proper oil level. (The oil level should be
between the upper and lower limit marks on the
dipstick.) (Refer to 7-36)
IMPORTANT:
When putting new oil in cartridge element (6), take

care that no foreign objects get in from secondary
side (8).
Do not re-use cartridge element (6).
 6
An incorrect engine oil level may cause trouble

 MDAK-07-015
ZX120-5 class
on the engine. Even if the engine oil level exceeds
the upper limit, control the oil level to the proper
quantity before starting the engine.
Do not overtighten the engine oil pan mounting

bolts of ZX120-5 and ZX160-5 class machines Failure
to do so may damage the packing seal.
Check and Clean Around the Engine

----- As required
6
IMPORTANT: Check for flammable objects in the area
around the engine and clean that area. ZX160-5 class MDAK-07-016
When the machine is operated in dusty areas, refer to "9-1
Maintenance Under Special Environmental Conditions".
6 ZX200-5, 240-5 class MDAK-07-017
MDCR-07-007
6
ZX300-5, 330-5 Class MDAK-07-018
7-40
MAINTENANCE
C. Transmission 1
2
Pump Transmission 4
(Except ZX120-5 class)
Check Oil Level --- every 250 hours
minutes. 3 MDAA-07-108
ZX160-5, 200-5, 240-5 class
7. Remove dipstick (1). Oil must be within the specified
range.
8. If necessary, remove filler plug (2) and add oil. (See gear
oil chart)
9. Recheck oil level.
2
Change Oil --- every 1000 hours
Air Breather Cleaning --- every 1000 hours
1
IMPORTANT: The turbocharger may be damaged if the 3
minutes. M110-07-015
ZX300-5, 330-5 Class
6. Pull the pilot control shut-off lever to the LOCK position. Specified Range
dCAUTION: Oil may be hot just after operation. Wait

for oil to cool before starting work. 1
7. Remove filler plug (2).
8. Remove drain plug (3). Allow oil to drain through a clean
cloth into a 2-liter (2.1 US qt) container.
9. After all oil has drained, inspect cloth for any debris such M1G6-07-004
as small pieces of metal.
10. Reinstall drain plug (3).
11. Add oil via filler plug (2) until it is within the specified
range on dipstick (1).
12. Reinstall filler plug (2).
13. Remove air breather (4) and perform cleaning. After
cleaning, install air breather (4).
7-41
MAINTENANCE
Swing Reduction Gear
Check Oil Level --- every 500 hours

2 1
minutes.
M178-07-086
6. Pull the pilot control shut-off lever to the LOCK position. 1
7. Remove dipstick (1). Oil must be between marks.

8. If necessary, remove oil filler cap (2) and add oil. (See
gear oil chart)
9. Recheck oil level. Specified Range
M104-07-017
Change Gear Oil --- every 1000 hours

minutes.
dCAUTION: Gear oil may be hot just after operation.

Wait for gear oil to cool before starting work.
7. Remove the drain plug mounted on the end of drain

pipe to drain oil.
8. Reinstall the drain plug.
9. Remove oil filler cap (2) and add oil until it is between
the marks on dipstick (1).
10. Reinstall oil filler cap (2).
7-42
MAINTENANCE
Travel Reduction Gear
Air Release Plug 1

Check Oil Level --- every 500 hours (Oil Supply Plug)
1. Park the machine on a level surface. Oil Level Check
Plug 2
2. Rotate the travel motor until the imaginary line through
plug (1) and plug (3) is vertical. Horizontal Oil Level

4. Turn the auto-idle switch off. Drain Plug 3
IMPORTANT: The turbocharger may be damaged if the MDAA-07-047

minutes. 1
7. Pull the pilot control shut-off lever to the LOCK position. 2
dCAUTION: 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
air release plug to release pressure.
3
8. After gear oil has cooled, slowly loosen air release plug M157-07-170
(1) to release pressure.
9. Remove air release plug (1) and oil level check plug (2).
Oil must be up to the bottom of hole.
10. If necessary, add oil until oil flow out of oil level check
plug (2) hole. (See gear oil chart)
11. Wrap the plug threads with sealing-type tape. Install
plugs (1) and (2).
Tighten plugs (1) and (2) to 50 N·m (5 kgf·m).
12. Check the gear oil level in the other travel reduction
gear.
7-43
MAINTENANCE
Change Gear Oil --- every 2000 hours
2. Rotate the travel motor until the imaginary line through 1
plug (1) and plug (3) is vertical.
2
engine is not properly shut down. 3
minutes. M157-07-170
dCAUTION: 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
air release plug to release pressure.
8. After gear oil has cooled, slowly loosen air release plug
(1) to release pressure, and temporarily retighten plug
(1).
9. Remove drain plug (3) and plug (1), in that order, to drain
oil.
10. Clean drain plug (3). Wrap the threads of drain plug (3)
with sealing-type tape. Install plug (3). Tighten plug (3).
11. Remove oil level check plug (2).
12. Add oil until oil flows out of oil level check plug (2) hole.
(See gear oil chart)
13. Clean plugs (1) and (2). Wrap the threads of oil level
check plug (2) and air release plug (1) with sealing-type
tape. Reinstall the plugs (1) and (2). Tighten the plugs (1)
and (2).
14. Repeat steps 8. to 13. for the other travel reduction gear.
7-44
MAINTENANCE
D. Hydraulic System
Inspection and Maintenance of Hydraulic
Equipment
IMPORTANT: Never adjust parts of engine fuel system or
hydraulic equipment.
dCAUTION: When checking and/or servicing the

hydraulic components, pay special attention to the
following points.
1. Be sure that the machine is parked on a level, firm
surface before servicing hydraulic equipment.
2. Lower the bucket to the ground and stop the engine.
3. Begin servicing hydraulic components only after
components, hydraulic oil and lubricants are completely
cooled, and after releasing residual pressure.
3.1 Before checking and/or servicing the hydraulic system,
be sure to release the residual pressure from the
cylinder circuits of the boom, arm and the bucket,
swing piping and pilot piping. An accumulator can be
installed on some models of this machine as an option
to be capable of moving the front attachment for
specified time (around 10 seconds) after stopping the
engine.
3.2 Bleed air from the hydraulic oil tank to release internal
pressure.
3.3 Immediately after operation, all hydraulic components
and hydraulic oil or lubricants are hot and highly
pressurized. Begin inspection and/or maintenance
work only after the machine has cooled down.
Servicing heated and pressurized hydraulic
components may cause plugs, screws and/or oil to fly
off or escape suddenly, possibly resulting in personal
injury. Hydraulic components may be pressurized even
when cooled.
Keep body parts and face away from the front of plugs
or screws when removing them.
3.4 Even after air pressure in the hydraulic oil tank is
released, when the machine is parked on a slope, the
oil pressure in the travel motor and the swing motor
circuits are maintained at high pressure as the reaction
force of the machine weight is constantly applied
to the travel motor. Never check and/or service the
machine when it is parked on a slope.
7-45
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 "Brand names of 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.
The new machine is filled with hydraulic oil of Super

EX 46HN (change interval: every 5000 hours). When
adding or changing the hydraulic oil, continue to use
the Super EX 46HN.
Never run the engine without oil in the hydraulic oil

tank.
7-46
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.
Check machine service hours by using the breaker hour
meter. (Refer to the Breaker Operation in the "OPERATOR’S
STATION" chapter.)
Changing intervals for the high performance element (micro-glass)

Breaker Operating
0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
Availability
Full-Flow Filter 1000 670 510 410 340 290 250 230 200 190 170
Hydraulic oil: 2000 hours
2000 1590 1320 1130 990 880 790 710 650 600 560
life time
5000 2790 1930 1480 1200 1010 870 760 680 610 560
life time
When Using High Performance Element

100
90
Average Breaker Operating Availability (%)
80
Element Replacement Intervals
70
60
50
Changing Interval when using 2000-hour life time hydraulic oil
40
30
20
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Changing Intervals (hour) MDAA-07-050
7-47
MAINTENANCE
Changing intervals for the standard filter paper
Breaker Operating
0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
Availability
Full-Flow Filter 1000 340 210 150 120 100 80 70 60 60 50
2000 1310 980 780 650 550 480 430 380 350 320
life time
5000 2030 1270 930 730 600 510 440 390 350 320
life time
When using filter-paper element

100
90
Average Breaker Operating Availability (%)
80
70
Element Replacement Intervals
60
50
40
30
20
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Changing Intervals (hour) MDAA-07-051
fNOTE: K Model is equipped with a full-flow filter restriction

indicator. However, if a filter-paper element is used, this
indicator does not operate. (Refer to the Hydraulic System in
the Maintenance section.)
7-48
MAINTENANCE
Check Hydraulic Oil Level
--- daily
IMPORTANT: Never run the engine without oil in

hydraulic oil tank.
1. Park machine on a firm, level surface. M104-07-021
2. Position the machine with the arm cylinder fully

retracted and the bucket cylinder fully extended.
3. Lower the bucket to the ground. 1

minutes.
switch. ZX120-5 class MDAK-07-015

8. Open the access door in front of the main pump. Check
oil level with level gauge (1) on hydraulic oil tank. Oil 1
must be between marks on gauge (1). If necessary, add
oil.
dCAUTION: The hydraulic oil tank is pressurized. Push

the pressure release button on the tank cap to release
pressure, and carefully remove the cap.
To add oil:
9. Push the pressure release button on the air breather to
release pressure. Remove the cover.
10. Add oil. Recheck oil level with level gauge (1).
11. Install the cover. Make sure the filter and rod assembly is
1
in correct position.
MDAK-07-019
ZX200-5, 240-5, 300-5, 330-5 class
7-49
MAINTENANCE
Change Hydraulic Oil
dCAUTION: Hydraulic oil may be hot just after

operation. Wait for oil to cool before starting work.
IMPORTANT: Hydraulic oil changing intervals differ

according to kind of hydraulic oils used. (See
Recommended Oil Chart in this group) M104-07-117
2 1
1. Park machine on a firm, level surface with the
upperstructure rotated 90 ° for easier access.
2. Position the machine with the arm cylinder fully
retracted and the bucket cylinder fully extended.
4. Turn the auto-idle switch off. Level Gauge
IMPORTANT: The turbocharger may be damaged if the Specified Range

5. Run the engine at slow idle speed without load for five M157-07-016
minutes.
2 1
8. Clean the top of the hydraulic oil tank to keep dirt out of
the hydraulic system.

pressure release button (1) on the air breather before
removing the air breather.
9. Push pressure release button (1) on the air breather. MDAA-07-037
10. Remove cover (2).

11. Remove oil using a suction pump. The hydraulic oil tank 3
capacity, up to specified oil level, is approximately A.
Model A
ZX120-5 class 130 L (34.3 US gal)
ZX160-5 class 190 L (50.2 US gal)
ZX200-5 class 200 L (52.8 US gal)
ZX240-5, 300-5 class 243 L (64.2 US gal)
ZX330-5 class 298 L (78.7 US gal)
M1U1-07-047
7-50
MAINTENANCE
12. Remove drain plug (3). Allow oil to drain.
3
13. Clean, install and tighten drain plug (3).
14. Add oil until it is between the marks on the oil level
gauge.
15. Install cover (2). Tighten the bolts to 50 N·m (5 kgf·m, 36
lbf·ft).
16. Be sure to bleed air form the system following the
procedures shown next page.
M1U1-07-047
M157-07-062
7-51
MAINTENANCE
Air Bleeding Procedures 5
IMPORTANT: If the hydraulic pump is not filled with oil, it

will be damaged when the engine is started.
The machine is equipped with two main pumps. Bleed air

from these pumps after changing hydraulic oil.
1. Remove air bleed plug (5) on each pump.

2. Fill the pump with oil through air bleed plug (5) port on
each pump until oil flows out of air bleed plug (5) hole.
MDAA-07-072
3. Temporarily tighten air bleed plug (5) on each pump, ZX120-5 class
start the engine and run at slow idle. Loosen one of air 5
bleed plugs (5) slightly until oil flows from plug port to
release trapped air completely. Tighten air bleed plug (5).
Repeat this step for the rest of plugs (5).
Tightening torque: 95 N·m (9.5 kgf·m)
4. Purge air from the hydraulic system by running the
engine at slow idle and operating the control levers
slowly and smoothly for 15 minutes.
5. Position the machine as illustrated in the oil level
checking procedure.
8. Stop the engine. Remove the key from the key switch. ZX160-5, 200-5, 240-5 class MDCD-07-009

10. Check the hydraulic oil tank gauge. Remove cover to add 5
oil if necessary.
ZX300-5, 330-5 class M1U1-07-035
7-52
MAINTENANCE
Suction Filter Cleaning
---each time when hydraulic oil is changed
1
The suction filter is located on the bottom of the hydraulic oil

tank.
Clean the suction filter when changing hydraulic oil. 4
1. After removing hydraulic oil from the hydraulic oil tank,

remove cover (1) and rod assembly (2).
2. Clean the inside of the hydraulic oil tank and the suction
filter. 2
3. Before installing the suction filter, check the dimension

of rod assembly (2) shown in figure right. Securely insert
rod assembly (2) into pipe (3).
4. Before securing cover (1) with bolts, ensure the top edge
of the rod assembly (2) is completely inserted into the
hole of support (4).
5. Bleed air from the hydraulic system. 3
(Refer to the descriptions for " Bleed air from the
hydraulic system")
M157-07-062
892 mm (35.1 in) (ZX120-5 class)

889 mm (35.0 in) (Except ZX120-5 class)
20 mm
Rod Assembly M107-07-070
7-53
MAINTENANCE
Replacement of Full-Flow Filter
--- every 1000 hours
Std. Model
dCAUTION: 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 M104-07-021
before starting any maintenance work.
1 2 3
Procedures:
1. Park the machine on solid and level ground. Fully extend
the bucket cylinder, fully retract the arm cylinder, and
lower the bucket to the ground as illustrated in the right. 4
Stop the engine.
2. Before replacing the element, be sure to bleed air
pressure from the hydraulic oil tank by pressing the air
bleed valve on the hydraulic oil tank.
3. Loosen bolts (1) (6 used) to remove cover (2) and O-ring
(3). When removing cover (2), slowly remove it while 5
pressing the cover downward so that spring (4) does not
fly out.
4. Remove the spring (4) and element (5).
5. Take extra care never to allow water or dust to enter the
filter case.
6. Replace element (5) and O-ring with new ones. Install
them into the hydraulic oil tank. Be careful not to
damage element (5) and O-ring (3).
Broken element (5) is unusable.
7. Install cover (2) with bolt (1) (6 used).
Tightening Torque: 50 N·m (5 kgf·m) M178-07-069
8. Bleed air from the pump after replacing the element.
(Refer to the descriptions for " Bleed air from the
hydraulic system")
If the machine is operated with air mixed in the hydraulic
circuit, damage to the pump may result.
IMPORTANT Replace element (5) at the regular interval
to keep hydraulic oil clean and to extend the service
life of the hydraulic components.
7-54
MAINTENANCE
Replacement of Full-Flow Filter
K. Model
When the hydraulic oil filter alarm on the monitor panel is lit,
immediately replace the filter element.

during operation. Severe burns may result if M104-07-021
immediately after operation. Wait for the oil to cool
before starting any maintenance work.
IMPORTANT: Changing interval differs according to the

brand of hydraulic oil used, kind of filter element or
average attachment operating availability.
IMPORTANT: Precautions for the filter element

Excavators engaged in demolition and logging work

use full-flow filter with high performance (micro-
glass) element.
When replacing the element, use the same kind of

high performance element.
In case a filter-paper element is unavoidably used,

change hydraulic oil and replace full-flow filter
element by referring to the “Change Hydraulic
Oil and Replace Full-Flow Filter Element” in the
OPERATING THE MACHINE section.
6
If a filter-paper element is used, the full-flow filter

restriction indicator does not operate. Isolate the
circuit for full-flow filter restriction indicator (6).
MDAA-07-005
7-55
MAINTENANCE
Procedures:
1. Park the machine on solid and level ground with the
bucket cylinder fully extended and the arm cylinder fully
retracted. Lower the bucket on the ground as shown to
the right. Stop the engine.
2. Before replacing element (5), be sure to bleed air 1
bleed valve on the hydraulic oil tank. 2
3. Loosen bolts (1) (6 used) to remove cover (2) and O-ring
(3).When removing cover (2), slowly remove the cover
while pressing the cover downward so that spring (4)
does not fly off. MDAA-07-005
4. Remove spring (4), and element (5).
4 2 3 1
5. When installing new element (5) into the hydraulic oil
tank, replace O-ring (3) with a new one at the same time.
6. Install cover (2) with bolts (1) (6 used).
Tightening Torque: 50 N·m (5 kgf·m) 5
MDAA-07-004
7-56
MAINTENANCE
Replace Pilot Oil Filter
1. Park machine on a firm, level surface.
M104-07-021
Pilot Filter
minutes.

the pressure release button on the air breather before
ZX120-5 class MDAA-07-073
Pilot Filter
removing the air breather.
7. Remove the filter cartridges of pilot oil filter (2) by

turning it counterclockwise with the filter wrench.
8. Clean the filter O-ring contact area on filter head (1).
9. Apply a thin film of clean oil to the gasket of new filter
(2).
10. Install new filter (2). Turn the filter cartridge clockwise by
hand until the O-ring touches the contact area. Be sure
not to damage the O-ring when installing filter (2). ZX160-5 class MDAA-07-071
IMPORTANT: Do not re-use the filter cartridge.
Pilot Filter
6
ZX200-5, 240-5 class MDAK-07-017
Pilot Filter
MDAA-07-106
ZX300-5, 330-5 class MDAA-07-022
7-57
MAINTENANCE
Replace Air Breather Element

before starting any maintenance work. M104-07-021
Procedures:
1. Park the machine on solid and level ground with the
bucket cylinder fully extended and the arm cylinder fully
retracted. Lower the bucket on the ground as shown to
the right. Stop the engine.
2. Before replacing element (3), be sure to bleed air
MDAA-07-037
3. Rotate cover (2) clockwise approx. 1/4 turns. Remove cap
(1) by rotating it counterclockwise.
1
4. Rotate cover (2) counterclockwise and remove it.
Remove element (3).
5. Install new element (3). Tighten to install cover (2) until
cover (2) comes in contact with element (3). Then,
further tighten the cover (2) 1/4 turn. 2
6. Securely tighten cap (1) clockwise by hand. While
holding cap (1) by hand so that cap (1) does not rotate,
3
securely tighten cover (2) by rotating counterclockwise 5
to 10° by hand.
7. Take care never to allow water and/or contaminant to
stay between cover (2) and body (4) (air breathing port). 4
8. Replace element (3) at the regular interval to keep
hydraulic oil clean and to extend the service life of the
hydraulic components. M1G6-07-001
7-58
MAINTENANCE
Replace Line Filter Element (Optional)
--- every 200 hours ( Breaker Operating Hours)
ZX200-5, 240-5, 300-5, 330-5 class

before starting any maintenance work. M104-07-021
1. Park the machine according to the instruction on

PREPARE MACHINE FOR MAINTENANCE (7-7).
2. Before replacing the element, be sure to bleed air
3. Place 6 liters or larger capacity container under the filter
to collect drain.
IMPORTANT: In order to minimize discharge oil amount,
turn the selector valve to the crusher operation
position (return to the valve).
After replacing the element, be sure to turn the valve
back to the breaker operation position (return to the
tank).
Line Filter Element
MDCD-07-063
Selector Valve
MDAK-07-058
Valve Valve
Tank Tank
Front Front
Crusher Operation Position Breaker Operation Position
(Return to the Valve) (Return to the Tank)
MDAK-07-059
7-59
MAINTENANCE
4. Loosen drain plug (5) to drain hydraulic oil from case (2).
5. Rotate the bottom of filter case (2) counterclockwise by
using a wrench to remove filter case (2) from head (1). 1
6. When case (6) is removed, element (3) is exposed.
Remove the element by hand. 4
7. Replace element (3) and O-ring (4) with new one. Use
new parts for replacement if drain plug O-ring (6) 3
appears worn or damaged.
8. Install case (2) into head (1) by rotating the bottom
side of case (2) clockwise by using a tool to a torque of
100±10 N·m. 2
9. Tighten drain plug (5) to a torque of 60±5 N·m.

6
10. After replacing the filter element, bleed air from the
5
hydraulic system and check the oil level in the hydraulic
oil tank. MDAK-07-060
(Refer to " Bleed Air from the Hydraulic System".)

If the machine is operated with air mixed in the hydraulic
circuit, damage to the pump may result.
IMPORTANT: Replace element (3) at the regular interval

to keep hydraulic oil clean and to extend the service
life of the hydraulic components.
7-60
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.
According to the check points shown below, check hoses and

SA-292
lines for oil leaks and damage.
If any abnormality is found, replace or retighten as instructed
in the table.
SA-044
Hose
Interval 3 2 3 2
Check Points Abnormalities Remedies
(hours)
Daily Hose covers Leak (1) Replace 1 1
Hose ends Leak (2) Replace 2 2
Fittings Leak (3) Retighten or replace hose 3 3

or O-ring
M137-07-008 M115-07-145
7-61
MAINTENANCE
7
Interval 4
Check Points Abnormalities Remedies 6
(hours)
5
Every 250 Hose covers Damage or leak (4) Replace
hours Hose ends Damage or leak (5) Replace
Hose covers Exposed reinforcement (6) Replace
M115-07-146 M115-07-147
Hose covers Crack or blister (7) Replace
Hose Bend (8), Collapse (9) Replace 9
8
Hose ends and Deformation or corrosion (10) Replace
Fittings
10
M115-07-148 M115-07-149
Lines
Interval
(hours) 12 12
13 13
Daily Contact surfaces of Leak (11) Replace 11
flange joints
Bolts Loose or leak (11) Retighten or
M137-07-001 M137-07-007
replace O-ring
Welded surfaces on Leak (12) Replace
flange joints
Every 250 Flange joint neck Crack (13) Replace
hours Welded surfaces on Crack (12) Replace
flange joints
Clamps Missing or Replace or
deformation Loose retighten
bolts
14
MDCD-07-044
Hose and Lines

Interval
(hours)
Daily Flexible master Leak (14) Replace or
Check coupling retighten
Every 250 Constant torque Leak (15) Replace or
hours clamp retighten MDC1-07-050
15
Oil Cooler
16
Interval
(hours)
Every 250 Oil Cooler Leak (16) Replace
hours
M1U1-07-051
7-62
MAINTENANCE
Service Recommendations for Hydraulic Fittings
Two hydraulic fitting designs are used on this machine.
 Flat Face O-ring Seal Fitting (ORS Fitting)

O-ring (1) is used on the sealing surfaces of adapter (2) to 2 1 4 5
prevent oil leakage.
Precautions for Use

1. Replace O-ring (1) with a new one when assembling
fittings.
2. Check that O-ring (1) is properly fitted in O-ring groove 3 6
M104-07-033
(3). Tighten union (4).
Tightening union (4) with O-ring (1) out of the groove
may damage O-ring (1) and cause oil leak.
3. When assembling fittings, take care not to make a dent
on O-ring groove (3) of adaptor (2) and sealing surface
(6) on hose (5) or valve side. Failure to do so may result in
damage to O-ring (1) leading to oil leak.
4. If oil leaks from a loose connection of union (4), do not
tighten fitting (2). Open the connection, replace O-ring
(1) with new one and check for correct O-ring position
before tightening the connection.
Tightening Torque:
Tighten fittings to the torque values shown below.
±10 %
Wrench size (mm) 27 32 36 41, 46
Tightening N·m 95 140 180 210
Torque: (kgf·m) (9.5) (14) (18) (21)
7-63
MAINTENANCE
 Metal Face Seal Fittings
7 9 8 10 5
Tight contact between metal flares on adaptor (7) and metal
connector (8) of hose (5) prevents pressure oil leakage. This
type of fittings is used on smaller diameter joint.
Precautions for Use

Connect or disconnect fittings with care not to damage seat
surfaces (9 and 10).
M202-07-051
Tightening Torque:
Tighten fittings to the torque values shown below.
Wrench size (mm) 17 19 22 27
N·m 25 30 40 80
Torque
(kgf·m) (2.5) (3) (4) (8)
 Bent Tube
Tighten bent tube (11) mounted on the signal control valve 11
to the torque values shown below.
Wrench size (mm) 17, 19
Tightening N·m 35
torque (kgf·m) (3.5)
To Signal Control Valve
M1U1-07-043
7-64
MAINTENANCE
E. Fuel System
dCAUTION: Beware of fire. Fuel is flammable. Keep fuel

away from fire hazards.
Recommended Fuel
Use high quality DIESEL FUEL only (JIS K-2204) (ASTM D-975)
(EN-590) (GB252). 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.
7-65
MAINTENANCE
Refueling
1. Park the machine on a level surface. Lower the bucket to
the ground. Check the fuel level with fuel gauge (1). 1
If the fuel level is low, stop the engine. Refuel by

removing cap (2) on the fuel tank.
2. Remove cap (2) of filler port.
[Cap (2) unlock procedures]
 Release the key lock.
 Pull up handle (3) and turn handle (3)
counterclockwise for releasing cap (2) lock.
 Remove cap (2). MDAA-01-001
3. To avoid condensation, fill the tank at the end of each 2

day's operation. Tank capacity is as follows.
Model Tank Capacity

ZX120-5 class 280 L
ZX160-5 class 320 L
ZX200-5 class 400 L
ZX240-5, 300-5 class 500 L
ZX330-5 class 630 L
Do not fill the tank more than specified. Stop filling when
a yellow mark on fuel level gauge (4) becomes visible.
Position the oil filler gun so that the gun will not MDCF-07-032
encumber the movement of the level gauge (4) float.
4. Immediately after fueling, install and lock filler cap (2) to LOCK UNLOCK
prevent vandalism and loss.
5. Install cap (2) of filler port. 3
[Cap (2) lock procedures]
 If Install cap (2).
 Turn handle clockwise until cap (2) is locked,
and push down handle (3).
 Lock the key.
IMPORTANT:
MLBA-07-094 MLBA-07-093
Take care not to allow dirt and/or water to enter the

fuel tank.
Wipe off any spilled fuel.
 4
Never fail to remove filler cap (2) when refueling with

the automatic fueling device and be sure to stop Yellow Mark
fueling when the yellow mark on the float of level
gauge (4) becomes visible.
M157-07-060
7-66
MAINTENANCE
Drain Fuel Tank Sump
--- daily
1. Park machine on a firm, level surface with the
upperstructure rotated 90 ° for easier access.
M104-07-117
4. Run the engine at slow idle speed without load for 5

minutes.
switch.
7. Place a container with a capacity of 0.5 liters or larger
under drain hose (2) to collect the drained water.
8. Open drain valve (1) to drain water and/or sediment 2 1 MDAA-07-015
through the drain hose.
9. After draining water, securely tighten drain valve (1).
7-67
MAINTENANCE
Drain Fuel Pre-Filter
--- daily
IMPORTANT: Drain fuel pre-filter daily before starting

operation. The engine may be damaged if you do not
drain fuel filter daily.
Fuel pre-filter have water separator functions, these allow float Main Filter
to rise as water accumulates.
Be sure to drain daily the water accumulated in the filter until
float (4) goes to the bottom of case.
Pre-Filter ZX120-5 class MDAK-07-031
Draining Procedures
1. Place a container with a capacity of 0.5 liters or larger
under drain hose (6) to collect the drained water.
2. Rotate drain plug (5) on the bottom of the filter Pre-Filter
counterclockwise. Drain the water accumulated in the
filter until float (8) goes to the bottom of case. If it is
difficult to drain, loosen plug (7) on the top of the fuel
pre-filter.
3. After draining water, securely tighten drain plug (5) and
plug (7).
4. Start the engine. Check drain plug (5) and plug (7) for
fuel leaks. Main Filter
MDAK-07-032
IMPORTANT: After draining water mixed in fuel, bleed air ZX160-5 class
from the fuel supply system.
Main Filter
Wrench size: 14 mm
Pre-Filter
Pre-Filter MDAK-07-033
MDAK-07-050 ZX200-5, 240-5 class
Main Filter
MDAK-07-051 Pre-Filter
ZX300-5, 330-5 class MDAK-07-042
7-68
MAINTENANCE
Bleed Air from the Fuel System
Air in the fuel system may make the engine hard to start or
make it run irregularly.
After draining water and sediment from the fuel filter,
replacing the fuel filter, cleaning the fuel solenoid pump
strainer or running the fuel tank dry, be sure to bleed the air
from the fuel system.
Main Points to Bleed Air

This machine is equipped with a fuel solenoid pump.
d CAUTION: Fuel leaks may lead to fires.
1. Check that fuel cock (1) on the bottom of the fuel tank is
opened. 1
2. Turn the key switch ON and hold it in that position for
approx. 3 minutes. Thereby, the electrical fuel pump
operates, starting to bleed air.
3. Loosen air bleed plug (2) on the fuel main filter while MDAA-07-007
the key switch is in the ON position. After no air bubbles
are spouted through air bleed plug (2), tighten air bleed
plug (2).
4. After the main filter is filled with fuel, hold the key switch
in the ON position for 30 seconds.
5. Start the engine. Check the fuel supply system for fuel
leaks.
Main Filter
IMPORTANT: Even if air is not thoroughly bled, do not
hold the key switch in the ON position for more than
5 minutes. In case air is not thoroughly bled, first
return the key switch to the OFF position. Then, after
waiting for more than 30 seconds, turn the key switch
ON again. Failure to do so may cause damage to the
electrical pump and/or discharging the batteries.
MDC1-07-047
Main Filter
2
MDC1-07-046
7-69
MAINTENANCE
If Air Mixed After Common Rail
In case air mixed in the fuel system due to lack of fuel and
the engine is difficult to start, release air by following the
procedure given below.
1. Bleed air until the engine supply pump entrance enough
according to the above-mentioned procedures.
2. Operate starter motor for long cranking within 20
seconds. If engine falls to start, return key switch to OFF.
Wait more than about 60 seconds, and then try again.
7-70
MAINTENANCE
Replace Fuel Main Filter Element
--- every 1000 hours or when fuel filter restriction
alarm is lit
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 Main Filter
the engine service life. Please be noted that all
engine failures caused by using other manufacturers'
elements are excluded from Hitachi Warranty Policy.

fuel tank.
Procedures:
1. Close cock (1) on the bottom of the fuel tank. Pre-Filter
(to next page)
Main Filter
MDAK-07-032
ZX160-5 class
Main Filter
ZX200-5, 240-5 class
Main Filter
Pre-Filter
MDAA-07-007 ZX300-5, 330-5 class MDAK-07-042
7-71
MAINTENANCE
2. Place 1 liter or larger capacity container under the drain
hose.
3. Rotate the bottom of filter cartridge element (2)
counterclockwise by using a spanner to remove
cartridge element (2) from head cover (3).
4. Apply a thin layer of fuel to the cartridge gasket (O-ring).
5. Install new cartridge element (2) on head cover (3) while
rotating cartridge element (2) clockwise. Tightening
torque: 25±2 N·m (2.5±0.2 kgf·m) Main Filter
6. Open cock (1) on the bottom of the fuel tank.

7. Bleed Air from the Fuel System
MDC1-07-046
After replacing the fuel filter element, bleed air from the
fuel supply system.
(Refer to " Bleed Air from the Fuel System".)
Wrench size: 24 mm
3
MDC1-07-047
MDAA-07-007
Open Position
7-72
MAINTENANCE
Replace Fuel Pre-Filter Element
--- every 1000 hours or when fuel filter restriction
alarm 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

fuel tank.
Procedures:
1. Close cock (1) on the bottom of the fuel tank.
Pre-Filter
(to next page)
ZX160-5 class
MDAK-07-032
ZX200-5, 240-5 class
MDAA-07-007 Pre-Filter
ZX300-5, 330-5 class MDAK-07-042
7-73
MAINTENANCE
2. Place 1 liter or larger capacity container under drain hose Pre-Filter
(3).
3. Loosen air bleed plug (1) and drain plug (2). Drain fuel
until fuel does not flow out of the filter.
After draining fuel, remove drain plug (2) and replace
1
O-ring.
4. Remove the harness connected to sensor (7).
IMPORTANT: The harness connector has a lock (8). Press MDAK-07-050

lock (8) and disconnect the connector. If an attempt is
made to disconnect the connector without releasing
lock (8), it may damage the connector.
5. Remove transparent filter case (4) using the exclusive
Pre-Filter
tool.
6. When transparent filter case (4) is removed, the O-ring
for transparent filter case (4) is exposed. Remove the
element by hand.
6
7. Remove filter cartridge (6) by using a band wrench.
8. Install new cartridge (6). When the upper gasket of
cartridge (6) contacts to the head, further tighten
cartridge (6) for 3/4 turns by hand.
4
9. Replace O-ring with new one and tighten transparent 2
filter case (4) to 10 +/- 1 N·m using the special tool. 7
3
10. Tighten air bleed plug (1) and drain plug (2).
11. Reconnect the harness that was disconnected from
sensor (7).
MDAK-07-056
IMPORTANT: Fit the parts together until lock (8) of the

5
harness connector is locked in place.
13. Bleed Air from Fuel System
After replacing the fuel filter element, bleed air from the Open Position
fuel supply system. MDAA-07-007

8
Wrench size: 14 mm
MDAK-07-057
7-74
MAINTENANCE
Replace Fuel Solenoid Pump Filter Element
--- every 1000 hours (Only Type A)
IMPORTANT:
Type of the fuel solenoid pump differs according to

the model of the base machine. Type B fuel solenoid
pump in maintenance free. For type A fuel solenoid
pump, replace the filter by following the procedure Fuel
below. Solenoid
Pump
Be sure to use only genuine Hitachi filter elements
 Filter
for the fuel solenoid pump. Failure to do so may
deteriorate the engine performance and/or shorten

fuel tank.
Procedures:
1. Close cock (1) on the bottom of the fuel tank.
(to next page)
Fuel Solenoid
Pump Filter
ZX160-5 class
MDAK-07-032
Fuel Solenoid
Pump Filter
MDAK-07-033
ZX200-5, 240-5 class
Type B Type A Fuel

Solenoid
MDAK-07-061 Pump Filter
MDAA-07-007
ZX300-5, 330-5 class MDAK-07-042
7-75
MAINTENANCE
2. Place 1 liter or larger capacity container under drain hose
Fuel Solenoid Pump Filter
(3).
3. Loosen drain plug (2). Drain fuel until fuel does not flow
out of the filter.
4. Remove transparent filter case (4) using the exclusive
tool.
5. When transparent filter case (4) is removed, the O-ring
for the element and transparent filter case (4) is exposed.
Remove the element by hand. 4
6. Install a new element. Replace O-ring and tighten
2
transparent filter case (4) to 30 +/- 2 N·m using the
special tool.
3
7. Tighten drain plug (2).
MDC1-07-019
9. Bleed Air from Fuel System
After replacing the fuel filter element, bleed air from the 5
fuel supply system.
MDAA-07-007
Wrench size: 14 mm Open Position
7-76
MAINTENANCE
Check Fuel Hoses
---daily
--- every 250 hours
dCAUTION: Fuel leaks can lead to fires that may result

in serious injury.
 Escaping combustible fluid can cause fires. Check for
kinked hoses, hoses that rub against each other, and
any fuel leaks.
 Repair or replace any loose or damaged hoses.
 Never reinstall bent or damaged hoses.
According to the check points shown below, check hoses for

oil leaks and damage.
If any abnormality is found, replace or retighten as instructed
in the table.
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
7-77
MAINTENANCE
F. Air Cleaner
Clean and Replace Air Cleaner Element (Outer)
Clean --- every 250 hours or when the restriction
indicator comes ON 2
Replace --- after cleaning 6 times or after one year
d than
CAUTION: When using compressed air pressure (less
0.69 MPa (7 kgf/cm )), dust may scatter. Wear
2
goggles or safety glasses, gloves and face shield.

MDAA-07-079
IMPORTANT: Clean and replace the air cleaner element ZX120-5, 160-5 class
by following the procedure below. If following 2
procedures are not followed, dirt may enter into the
system and engine trouble may result.
 Clean and replace the air cleaner element when the
engine is stopped.
 Do not remove the inner element when cleaning the
outer element.
 Replace the inner element when replacing the outer
element. Do not reuse elements.
 Use clean and dried compressed air.
 When blowing compressed air, be sure to keep the
air nozzle away from the element.
 Otherwise filter paper may be broken by the
ZX200-5, 240-5, 300-5, 330-5 class M1U1-07-027
pressure of air.
Clean or replace the outer element

Stop the engine before servicing outer element (1).
1
1. Remove clamp (2) of the cover. Remove the cover.
Remove any dirt from the case.
2. Remove outer element (1) by holding its edge and slowly
shaking it left to right, up and down while twisting it. Do
not scatter dirt while removing outer element (1).
ZX120-5, 160-5 class M1U1-07-080
ZX200-5, 240-5, 300-5, 330-5 class M1U1-07-028
7-78
MAINTENANCE
3. At this time, do not remove the inner element.
IMPORTANT: Do not hit or clash outer element (1) against
other object to clean the element.
4. Allow compressed air pressure [less than 0.69 MPa (7 2
kgf/cm2)] to blow out of the inside of outer element (1)
to clean the element. After that, blow compressed air
along the pleats, and then blow out from the inside.
When blowing compressed air, be sure to keep the air
nozzle 50 mm or away from the element.
5. After cleaning is complete, be sure to check outer
element (1) for any damage such as holes or worn of MDAA-07-079
filter paper. If any damage is found, replace the element ZX120-5, 160-5 class
with new one. 2
6. Press outer element (1) into the air cleaner body
straightly by hand. Ensure that outer element (1) is
properly installed by pushing its bottom edge.
7. Install cover and tighten clamps (2).
8. In case the air filter restriction indicator lights soon after
cleaning outer element (1) even if the cleaning times are
less than 6 times, replace both outer and inner elements
with new ones.
IMPORTANT: Do not install outer element (1) and/or the
cover forcibly when installing the clamps. Failure to do
so may result in deformation of clamps (2), element,
and/or cover. M1U1-07-027
ZX200-5, 240-5, 300-5, 330-5 class
ZX120-5, 160-5 class M1U1-07-080
ZX200-5, 240-5, 300-5, 330-5 class M1U1-07-028

MJAE-07-059
7-79
MAINTENANCE
Replace Air Cleaner Element (Inner)
Air Cleaner Restriction Alarm Switch
Replace --- When outer element is replaced
1 2
IMPORTANT: Do not clean and reuse the inner element.
Cover
1. After removing outer element (1). Clean inside the air
cleaner body (2) with clean cloth before removing inner
element (3).
2. Remove inner element (3). Replace it with new one.
3 Valve
M157-07-061
7-80
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 60 %.
If a coolant mixed with less than 30 % of Hitachi
Long-Life Coolant is used, service life of the cooling
parts may be shortened due to damage by freezing or
corrosion of coolant system parts.
Antifreeze Mixing Ratio
ZX120-5, 160-5 class ZX200-5, 240-5 class ZX300-5, 330-5 class

Air Temperature Mixing Ratio
[°C] [%] Antifreeze Soft water Antifreeze Soft water Antifreeze Soft water
[L] [L] [L] [L] [L] [L]
-1 30 7.2 16.8 9.3 21.7 10.5 24.5
-15 35 8.4 15.6 10.8 20.2 12.3 22.7
-20 40 9.6 14.4 12.4 18.6 14.0 21.0
-25 45 10.8 13.2 14.0 17.0 15.7 19.3
-30 50 12.0 12.0 15.5 15.5 17.5 17.5
-40 60 14.4 9.6 18.6 12.4 21.0 14.0
Precautions for handling antifreeze
dCAUTION: Antifreeze is poisonous.

 Antifreeze is poisonous; if ingested, it can cause
serious injury or death. Induce vomiting and get
emergency medical attention immediately.
 If antifreeze is accidentally splashed into eyes, flush
with water for 10 to 15 minutes and get emergency
medical attention.
 When storing antifreeze, be sure to keep it in a
clearly marked container with a tight lid. Always
keep ANTIFREEZE out of the reach of children.
 Use attention to fire hazards. LLC is specified as a
dangerous substance in the fire protection law.
 When disposing of LLC, be sure to comply with
all local regulations. When storing or disposing
of antifreeze, be sure to comply with all local
regulations.
7-81
MAINTENANCE
Check Coolant Level 1
--- daily
position.
3. Insert key switch (2). Turn it to ON position. Press and
hold switch (3) with the engine stopped.
Coolant indicator (4) must be displayed in green.
IMPORTANT: Do not rely only on the monitor display for

checking the machine conditions; visually check them MDAA-01-295
LOCK position
yourself as required such as oil level.
Always check the machine on a firm, level surface.
2
fNOTE: If the security function is enabled, a password is
required.
MDC1-01-502
MDCD-01-026
MDAK-01-043EN
7-82
MAINTENANCE
--- visual inspection
When the engine is cold, the coolant level must be between
the FULL (3) and LOW (4) marks on expansion tank (2).
If the coolant level is below the Low (4) mark, add coolant to 1
2
expansion tank (2).
d CAUTION: Do not remove 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 expansion tank (2) level is below the LOW (4) line, add
coolant through expansion tank cap (2) side.
2
3
1 2
4
ZX120-5, 160-5 class MDAK-07-047
3 ZX200-5, 240-5 class MDAK-07-025

1 2
ZX200-5, 240-5, 300-5, 330-5 class MDAK-07-048 ZX300-5, 330-5 class MDAK-07-026
7-83
MAINTENANCE
Check and Adjust Fan Belt Tension
--- every 250 hours (50 hours at first time only) 7 to 8 mm
1 98 N (10 kgf)
Fan Pulley
ZX120-5, 160-5 class 2
Alternator
IMPORTANT: Loose fan belt may result in insufficient Pulley
battery charging, engine overheating, as well as a
rapid, abnormal belt wear. Belts that are too tight,
however, can damage both bearings and belts.
Inspection
Check fan belt tension by depressing the midpoint between
the fan pulley and the alternator pulley by your thumb with 3
Crank Pulley
a depressing force of approximately 98 N (10 kgf, 22 lbf ).
ZX120-5, 160-5 class M1U1-07-089
Deflection must be within the value illustrated in the right.
Visually check the belt for wear. Replace if necessary.
Adjust Drive Belt Tension

1. Loosen lock nut (1) and alternator lower mounting bolt
(3).
2. Rotate tension adjust bolt (2) to adjust the belt tension.
3. After completing adjustment, tighten lock nut (1) and
alternator lower mounting bolt (3) to specifications.
Standard Tightening Torque:
Nut : 25 N·m (2.5 kgf·m, 18 lbf·ft)
Bolt : 52 N·m (5.2 kgf·m, 38 lbf·ft)
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.
7-84
MAINTENANCE
ZX200-5, 240-5, 300-5, 330-5 Class
5 to 6 mm
98 N (10 kgf) Fan Pulley
IMPORTANT: Loose fan belt may result in insufficient
battery charging, engine overheating, as well as
premature belt wear. Belts that are too tight, however,
can damage both bearings and belts. Alternator Pulley
Inspect
Check fan belt tension by depressing the midpoint between Crank Pulley
the fan pulley and the alternator pulley by your thumb with ZX200-5, 240-5 class M1GR-07-006
a depressing force of approximately 98 N (10 kgf, 22 lbf ).
Deflection must be within the value illustrated in the right.
Visually check the belt for wear. Replace if necessary. 5 to 6 mm
Fan Pulley
98 N (10 kgf)
Adjust Drive Belt Tension

1. Loosen lock nut (1) at the top of alternator (3), and lock
nut (4) at the bottom of alternator (3).
2. Adjust belt tension by moving alternator (3) forward or
backward by using adjustment bolt (2). Alternator Pulley
3. Securely tighten lock nut (1) and (4).

IMPORTANT: When a new belt is installed, be sure to re- Crank Pulley
adjust the tension after operating the engine for 3 to 5 ZX300-5, 330-5 class M1HM-07-001
minutes at slow idle speed to be sure that the new belt
is seated correctly.
1 2
M197-07-072
4
7-85
MAINTENANCE
Change Coolant
--- twice a year (in spring and autumn)
fNOTE: When genuine Hitachi Long-Life Coolant is used,

change interval is once every two years (in autumn every
other year) or every 4000 hours whichever comes first.
dCAUTION: Do not loosen the cap on the expansion

tank when coolant temperature in the radiator is high.
Hot steam may spout out, possibly causing severe
burns. Loosen the cap slowly to the stop. Release all
pressure before removing the cap.
Procedure:
1. Park the machine on a solid level surface. Lower the
breaker to the ground. Stop the engine.
2. Remove the under cover. Remove the cap from the
expansion tank. Open drain cock (1) on the radiator
to allow the coolant to drain completely. Remove
impurities such as scale at the same time. 1
3. Close drain cock (1). Refill soft water containing fewer

impurities or tap water and radiator cleaner agent. Close
the cap on the expansion tank. Start the engine and
run at a speed slightly higher than slow idle; when the
needle of the temperature gauge reaches the green
zone (5), run the engine for about ten or more minutes.
4. Stop the engine and open radiator drain cock (1). Flush
out the cooling system with tap water, until draining
water is clear. This helps remove rust and sediment.
M1U1-07-029
7-86
MAINTENANCE
5. Close the radiator drain cock (1). Fill the radiator with tap
water and LLC at the specified mixing ratio. When adding 1
coolant, do so slowly to avoid mixing air bubbles in the
system.
Fill coolant in the expansion tank until its level comes at
the upper limit line.
IMPORTANT: If coolant is filled above the upper limit line,
air in the cooling system may not be bled from the
expansion tank. Do not fill coolant above the upper
limit line.
6. Run the engine for several minutes to stabilize the
coolant temperature, and then sufficiently bleed air from
M1U1-07-029
the cooling system.
Stop the engine. Ensure that coolant level is in between
the upper and lower limit line.
Add coolant if necessary. Check the coolant level again
(The coolant level should be between the upper and
lower limit lines.)
7-87
MAINTENANCE
Clean Radiator/Oil Cooler/Inter Cooler Core
Inter
Outside --- every 500 hours Cooler
Inside --- once a year
dCAUTION: Use reduced compressed air pressure

(Less than 0.2 MPa, 2 kgf/cm ) for cleaning purposes.
2
Wear personal protection equipment including eye

Air
protection. Conditioner
Condenser
IMPORTANT: 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/
Fuel Cooler Oil Cooler Radiator MDAK-07-020
inter cooler fins may result.
ZX120-5 class
The radiator, the oil cooler and the inter cooler are arranged in Oil Cooler Inter Cooler
parallel.
If dirt or dust is accumulated on them, cooling system
performance decreases. Clean the radiator/oil cooler/inter
cooler cores with compressed air pressure (less than 0.2 MPa
(2 kgf/cm2)) or tap water. It will prevent a reduction in cooling
system performance.
Fuel Cooler Radiator Air Conditioner Condenser

Oil Cooler Inter Cooler
Fuel Cooler Radiator Air Conditioner Condenser

ZX200-5, 240-5, 300-5, 330-5 class
MDAK-07-022
7-88
MAINTENANCE
dWARNING:
 Entanglement in moving parts can cause serious 1
injury.
 Before servicing, stop the engine and the fan to
prevent any accident.
 Never attempt to start the engine when the cover is
open. 2
 In case tools or parts are dropped into the radiator/
oil cooler/inter cooler core, remove them before
starting the engine.
Twist screw (1) to open cover (2) and perform cleaning.
Take care not to break the fin during clean operation.

2
Close cover (2) and tighten screw (1) after cleaning.
1
IMPORTANT: Check the core periodically and replace it
if necessary when the machine is operated in dusty
areas.
MDAK-07-024
ZX160-5, 200-5, 240-5, 300-5, 330-5 class
7-89
MAINTENANCE
Clean Oil Cooler, Radiator and Inter Cooler Front
Screen
--- every 500 hours
IMPORTANT: Check the screen daily and replace it if

necessary when the machine is operated in dusty
areas.
Pull the clip lever on the screen to remove the screen.
Insert the clip into the cover hole and turn over the clip lever
to hold the screen.
The screen can not be held properly if the clip nut is too tight
or loose. Adjust the tightening torque of the clip nut to hold
the screen.
For rough indication of the tightening torque, refer to the

below.
Tightening Torque: 0.5 N·m
or
A: 23 ± 0.5 mm
Clean Air Conditioner Condenser

--- every 500 hours
ZX160-5, 200-5, 240-5, 300-5, 330-5 class
MDAA-07-024
IMPORTANT: Check the screen daily and replace it if
necessary when the machine is operated in dusty Screen
areas.
Cover
Rubber
Clean Fuel Oil Cooler
--- every 500 hours Lever Nut
IMPORTANT: Check the screen daily and replace it if A (Open)

necessary when the machine is operated in dusty
areas.
MDCS-07-003
7-90
MAINTENANCE
H. Electrical System
IMPORTANT:
Improper radio communication equipment and

associated parts, and/or improper installation
of radio communication equipment affects the
machine's electronic parts, causing involuntary
movement of the machine.
Also, improper installation of electrical equipment

may cause machine failure and/or a fire on the
machine.
Be sure to consult your authorized dealer when

installing 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.
7-91
MAINTENANCE
Battery
d WARNING:
 Battery gas can explode. Keep sparks and flames
away from batteries.
 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,
SA-032
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.
IMPORTANT:
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

SA-036
upper level. Electrolyte may spill, damaging the
painted surfaces and/or corroding other machine
parts.
fNOTE: In case electrolyte is refilled more than the specified

upper level line or beyond the bottom end of the sleeve,
remove the excess electrolyte until the electrolyte level
is down to the bottom end of the sleeve using a pipette.
After neutralizing the removed electrolyte with sodium
bicarbonate, flush it with plenty of water, otherwise, consult
the battery manufacturer.
1
ZX120-5, 160-5 class
Batteries Locaion MDAK-07-002
ZX200-5, 240-5, 300-5, 330-5 class

Batteries Locaion MDAK-07-022
7-92
MAINTENANCE
Precautions for Handling Batteries
 If electrolyte spills on your skin and/or clothes,
immediately flush the skin and/or clothes with water and
then wash further with soap.
If splashed in eyes, flush with water for approximately 15
minutes and seek immediate medical attention.
 Avoid using fire hazards such as matches lighters and
tobacco near the batteries. Do not allow sparks to fly.
 Check or service the battery only after stopping the
engine, turning the key OFF and removing the battery
caps.
 Contact with the battery immediately after operation may
cause personal injury.
Wait for the battery to cool.
 When the battery is recharged, inflammable hydrogen
gas is created. Remove the battery from the base
machine. Recharge the battery after removing the caps in
a well ventilated area.
 When disconnecting the battery terminals, first
disconnect the battery minus (-) side terminal. When
connecting the battery terminals, connect the battery
minus (-) side terminal last. If a piece of metal, such as
a tool comes in contact with the battery plus (+) side
terminal and the vehicle frame when both terminals
are connected, the electrical system may short-circuit,
possibly creating a dangerous situation.
 If a new battery is used along with an old battery, the
service life of the new battery may be shortened. Replace
two batteries at one time.
 Loose terminal may allow sparks to fly. Securely tighten
the terminals.
7-93
MAINTENANCE
Electrolyte Level Check --- every one month
Check the electrolyte level at least once a month.
1. Park the machine on level ground and stop the engine.

2. Check the electrolyte level.
2.1 When checking the level from the battery side:
Clean around the level check lines with a wet towel.
Do not use a dry towel. Static electricity may be
developed, causing the battery gas to explode. Check U.L (Upper Level)
if the electrolyte level is between U.L (Upper Level) and L.L (Lower Level)
L.L (Lower Level). M146-07-109
Filler Port
In case the electrolyte level is lower than the middle
level between the U.L and L.L, immediately refill with
distilled water or commercial battery fluid.
After refilling, securely tighten the filler plug. Sleeve
U.L (Upper Level)
Be sure to refill with distilled water before recharging L.L (Lower Level)
(operating the machine). Separator Top
M146-07-110
2.2 When impossible to check the level from the battery
side or no level check mark is indicated on the side:
Proper
After removing the filler plug from the top of the
Since the electrolyte surface touches the bottom end of
battery. Check the electrolyte level by viewing through the sleeve, the electrolyte surface is raised due to surface
the filler port. It is difficult to judge the accurate tension so that the electrode ends are seen curved.
electrolyte level in this case. Therefore, when the M146-07-111
electrolyte level is flush with the U.L, the level is judged
to be proper. Then, referring to the right illustrations,
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
or commercial battery fluid up to the bottom end of end of the sleeve, the electrode ends are seen straight.
the sleeve. M146-07-112
After refilling, securely tighten the filler plug.

Be sure to refill with distilled water before recharging
(operating the machine).
2.3 When an indicator is available to check the level, follow
the checking results.
7-94
MAINTENANCE
3. 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.
Replace Battery
IMPORTANT: Turn the battery disconnect switch to OFF
before replacing the battery.
M409-07-072
This machine is equipped with two 12V batteries. Negative

terminal is connected to the ground.
If one battery is damaged on the 24V system, replace the
damaged battery with the same type of new battery. If a
maintenance free battery is damaged, replace it with new
maintenance free battery. Battery charger differs depending
on the type of battery. If improper battery is connected,
the battery becomes overloaded possibly resulting in
malfunction.
7-95
MAINTENANCE
Check Electrolyte Specific Gravity
--- every one 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.
Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing, and
3. If splashed in eyes, flush with water for
10 to 15 minutes. Get medical attention
cause blindness if splashed into the eyes. immediately.
Never check the battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer. If acid is swallowed:
1. Do not induce vomiting.
Always remove the grounded (-) battery clamp first
and replace it last.
2. Drink large amounts of water or milk.
3. Get medical attention immediately.
Avoid hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves. fNOTE: Check the specific gravity of the electrolyte
after it is cooled, not immediately after operation.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte. Check the electrolyte specific gravity in each battery
cell.
5. Using proper booster battery starting procedures.
The lowest limit of the specific gravity for the
electrolyte varies depending on electrolyte
temperature. The specific gravity should be kept
within the range shown below. Charge the battery if
the specific gravity is below the limit.
Recommended range of specific gravity by electrolyte temperature

40 °C
(104 °F)
20 °C
(68 °F) Working Range
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
Specific gravity of battery fluid
7-96
MAINTENANCE
Replacing Fuses
--- as necessary
If any electrical equipment fails to operate, first check the
fuses. Fuse box is located behind the operator's seat.
fNOTE:
 One each spare fuse for respective fuse capacities is

provided in the fuse box.
 A fuse removing jig is provided in the fuse box.

7-97
MAINTENANCE
Fuse Box
A
10- CONTROLLER 20- OPT.3 (ALT)

5A 5A
9- BACKUP 19- HORN
10 A 10 A
A
8- ECM 18- IDLE STOP B
30 A 5A
7- START 17- POWER ON
5A 5A
6- OPT.2 (ALT) 16- GLOW RELAY
MDAA-01-297
20 A 5A
5- OPT.1 (ALT) 15- AUX A
5A 10 A Spare Fuses
4- SOLENOID 14- MONITOR
20 A 5A 10 20
3- HEATER 13- LIGHTER 9 19
20 A 10 A 8 18
2- WIPER 12- RADIO 7 17
10 A 5A 6 16
1- LAMP 11- FUEL PUMP 5 15
20 A 5A
4 14
B 3 13
2 12
30- - 40- -
1 11

29- - 39- -

28- SENSOR_UNIT 38- -
Tool M1GR-01-003
10 A
27- AUX.3 37-
5A B
26- QUICK HITCH 36- Spare Fuses
5A
30 40
25- IMMOBI 35- DCU
5A 20 A 29 39
24- 12VUNIT 34- AUX.2 28 38
10 A 10 A 27 37
23- CAB LAMP REAR 33- WARNING LAMP 26 36
10 A 10 A 25 35
22- CAB LAMP FRONT 32- CAB LAMP FRONT +2 24 34
10 A 10 A
23 33
21- SEAT HEATER 31- SEAT COMPR.
22 32
10 A 10 A
21 31
Tool M1GR-01-003
7-98
MAINTENANCE
 Fusible Link (Main Fuse)
In case the starter won't rotate even if the key switch is
turned to the START position, fusible link may be the cause
of the trouble. Remove the cover next to the battery to
check the fuse. Replace it if blown.
21- + Side (Red)
45 A
22- – Side (Black)
65 A
21 22 M1U1-07-023
Battery
7-99
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.
A (mm)
Model New Limit of Use A
ZX120-5 class M104-07-056
166 85
ZX160-5 class
ZX200-5 class 200 95
ZX240-5 class 2
230 110
ZX300-5 class
ZX330-5 class 230 115 3
Replace
dCAUTION:
 Guard against injury from flying pieces of metal.
 Wear goggles or safety glasses, and safety
equipment appropriate to the job.
M104-07-116
1. Use hammer (2) and drift (3) to drive out locking pin (5).
Take care not to damage lock rubber (4). RIGHT WRONG
5
2. Check lock pin (5) and lock rubber (4). Short locking pins
and damaged rubber pin locks must be replaced with
new ones.
Flush one end of the locking

pin to evaluate. In this instance,
the locking pin is too short.
M104-07-118 M104-07-058
WRONG
Crack on the rubber. The steel ball dents

The steel ball may when pushing the
come out. ball.
M104-07-059
7-100
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
5. Position new tooth (1) over shank (6).
RIGHT WRONG
6 1
M104-07-061
6. Drive locking pin (5) fully into the hole as shown.
RIGHT WRONG
1 5
M104-07-062
7-101
MAINTENANCE
Check Bucket Teeth for H and Super V Type Bucket Teeth
--- daily
1 2
Check bucket teeth (1) for wear and looseness.
When tooth points (1) wear beyond the service limit, replace
them.
ZX330-5 class Parts No. New Limit of Use
A Rock Bucket
4400253 229 112
(mm) 1.50 m3
fNOTE: When tooth point (1) is used in excess of the service

limit, a hole will be made on the tooth point, which makes the
nose exposed and worn out, and will eventually break or let M116-07-124
the tooth point fall off.
dCAUTION: Guard against injury from flying pieces

of metal. Wear goggles or safety glasses, and safety
equipment appropriate to the job.
Procedures:
Removing the tooth point
1. Preparations for removing tooth point
Hit the left and right top ends and the left and right lugs
of tooth point (1) alternately with hammer to knock off
pebbles, soil, etc., stuck in the gap between tooth point
(1) and adapter (2).
1
M116-07-125
7-102
MAINTENANCE
2. Driving out locking pin
Remove pebbles, dirt, etc., completely from the gap
between lock pin (3) and adapter (2). Place pin-removing
jig on the top end of lock pin (3) and hit it with hammer
to remove lock pin (3).
When driving out the pin, first hit with a shorter jig until
top end of lock pin (3) comes to the upper end position
of the lug of tooth point (1), and then use the longer jig
to remove lock pin (3).
3 2
3 M116-07-126
7-103
MAINTENANCE
3. Removing the tooth point
Turn tooth point (1) to the left, twist and pull it toward
you to remove it.
IMPORTANT: Check if lock pin (3) has cracks. If it has,

replace the rubber with new one. While the pin and
plug can withstand several replacements of the tooth
point, be sure to check whether they are usable or not
1
when replacing tooth point (1).
Mounting the tooth point

1. Mounting the tooth point M113-07-078
Clean the top end of the adapter nose.

Also check that lock pin (3) has no cracks.
If pebbles, dirt, etc., are stuck to the adapter nose, tooth
point (1) will not insert properly and the pin cannot be
driven in.
Insert tooth point (1) slowly until the tooth point comes
to the end of the adapter nose while twisting and
turning it to the right. 1
2. Inserting the pin

M113-07-080
Insert lock pin (3) with take-up facing toward the adapter
nose.
With tooth point (1) fully inserted onto adapter (2), tap
lock pin (3) into tooth point (1) with a hammer until the
top of lock pin (3) comes flat with the nose surface. (i.e.
until the take-up on lock pin (3) fits into the grooves of
tooth point (1).)
3
(i.e. until the take-up on lock pin (3) fits into the grooves Take-up
of tooth point (1).)
1
M173-07-001
M116-07-128
7-104
MAINTENANCE
Other Precautions
1. Since rubber is susceptible to corrosion, do not use
grease, oil and other oily materials when inserting the
lock pin.
2. In mounting welding-type nose and the adapter onto
the bucket, lock pin (3) should be removed from the
nose when preheating and welding. Otherwise the
rubber will be spoiled.
7-105
MAINTENANCE
Change Bucket
dCAUTION: When driving the connecting pins in or

out, guard against injury from flying pieces of metal
or debris. Wear goggles or safety glasses, hard hat and
face shield.
Before starting converting work, keep bystanders clear of the

machine. Slowly move the front attachment. When using a
signal person, coordinate hand signals before starting.
Removal
1. Place the bucket in a stable position.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm and O-Ring Shift
bucket.
Installation
1. Clean the pins and pin bores. Apply sufficient grease to
the pins and pin bores.
Bucket Boss
2. Place the new bucket in stable position as shown in the
figure.
Link
3. Fit the arm and alternate bucket. Be sure the bucket will
not roll. Install bucket pins A and B.
B
4. Install the locking pins and snap rings on pins A and B. A
5. Install O-rings to the specified positions.
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. M104-07-063
7-106
MAINTENANCE
Convert Bucket Connection Into Face Shovel

O-Ring Shift
dCAUTION: When driving the connecting pins in or

out, guard against injury from flying pieces of metal
or debris. Wear goggles or safety glasses, hard hat and
face shield.
Converting the bucket connection allows you to use the Bucket Boss
machine as a face shovel. Before starting converting work,
keep bystanders clear of the machine. Slowly move the front
attachment. When using a signal person, coordinate hand Link
signals before starting. B
Procedure: A
1. Place the bucket in a stable position.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm and
bucket.
Clean the pins and pin bores. Apply sufficient grease to
the pins and pin bores.
4. Turn the bucket 180°. Be sure the bucket will not roll.
5. Fit the arm and alternate bucket. Be sure the bucket will
not roll. Install bucket pins A and B.
6. Install the locking pins and snap rings on pins A and B.
7. Install O-rings to the specified positions.
Convert Bucket
8. Apply grease to each pin.
9. Start the engine and run at slow idle. Slowly operate the
bucket in both directions to check for any interference in
bucket movement. Link
M104-07-064
7-107
MAINTENANCE
Adjust Bucket Linkage
The machine is provided with a bucket adjustment system to

take up play in the linkage. When play in the linkage increases,
remove and install shims as follows:
1. Place the bucket in a stable position. Clearance Adjust Part
2. Run the engine at slow idle. With the bucket on the

ground, slowly swing counterclockwise slightly until the
top of the left bucket boss contacts the arm.
3. Stop the engine. Pull the pilot control shut-off lever to
the LOCK position. M503-07-056
4. Slightly loosen three bolts (1) using a 22 mm wrench.

4
Remove all shims (2) from clearance (c) between plate Bucket Pin Arm Top Boss A Bucket
(3) and bucket. As shim (2) is a dual partitioning type, it d 2
can be easily removed by slightly loosening bolt (1) and
inserting tip of a screw driver into the contact surface of 3
left and right shims (2).
5. Push and hold bolts (1) to remove all clearance (a)
between arm and boss (4). Holding boss (4) against arm
1
increases clearance (b). Install as many shims (2) into
clearance (b) as possible.
a
6. Install remaining shims (2) into clearance (c) and tighten
b c
bolts (1) to 140 N·m (14 kgf·m).
A
fNOTE: The total number of shims (2) used in clearance (b)
and (c) are 6×2=12. Remaining shims (2) must be installed in
clearance (c) to prevent arm end face or bolt damage. Replace
boss (4) with new one if measurement (d) is 5 mm (0.2 in) or
less.
Section A M1G6-07-010
7-108
MAINTENANCE
Remove Travel Levers
The travel levers may be removed if desired.
Procedure: 3
4
Remove bolts (1) and (2) to remove travel levers (3) and (4)
from brackets. 2
fNOTE: Wrench size: 17 mm

M178-07-077
Check and Replace Seat Belt

Check --- daily
Replace --- every 3 years
Prior to operating the machine, thoroughly examine belt (5),
buckle (6) and attaching hardware (7). If any item is damaged 5
or materially worn, replace the seat belt or component before
6
We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
7
M1U1-07-008
6 5
M1U1-07-009
7-109
MAINTENANCE
Check Windshield Fluid Level

2
Check fluid in windshield washer tank (1). If the fluid level is

low, remove cap (2) and add fluid via the opening.
1
ZX200-5, 240-5 class MDAK-07-004
1
ZX300-5, 330-5 class MDAK-07-043
7-110
MAINTENANCE
Check Track Sag
--- every 50 hours
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.
M104-07-067
dCAUTION: To prevent accidents, care should be taken

to ensure that hands, feet, and any body parts do not
become entangled when working around the tracks.
Model Appropriate sag A (mm)

ZX120-5 class 250 to 280
ZX160-5 class 285 to 320
ZX200-5 class
300 to 335
ZX240-5 class
ZX300-5 class
340 to 380
ZX330-5 class M107-07-068
fNOTE: Check track sag after thoroughly removing soil stuck

on the track area by washing.
Adjust Track Sag

1. If track sag is not within specifications, loosen or tighten
the track following the procedures shown on the next
page.
2. When adjusting track sag, lower the bucket to the
ground to raise one track off the ground. Repeat this
procedure to raise the other track. Each time, be sure to
place blocks under the machine frame to support the
machine. To prevent accidents, care should be taken
to ensure that hands, feet, and any body parts do not
become entangled when working around the tracks.
3. After adjusting both side track sags, rotate the tracks
backward and forward to equalize both side track sags.
4. Recheck the track sag once more. Readjust as necessary.
7-111
MAINTENANCE
Loosen the Track
ZX120-5
dCAUTION:
 The pressure inside the cylinder of the track adjuster
is high. Do not loosen valve (1) quickly or loosen it
too much as valve (1) may fly out or high-pressure
grease in the adjusting cylinder may spout out.
Slowly loosen valve (1) while keeping body parts and
face away from valve (1). Never loosen grease fitting
M107-07-075
(2).
 To prevent accidents, care should be taken to ensure
that hands, feet, and any body parts do not become
entangled when working around the tracks. 1
IMPORTANT: When gravel or mud is packed between 2

sprockets and track links, remove it before loosening.
1. To loosen the track, slowly turn valve (1)

counterclockwise using long socket 19; grease will
escape from the grease outlet.
2. Between 1 to 1.5 turns of valve (1) is sufficient to loosen
the track.
Grease Outlet
3. If grease does not drain smoothly, slowly rotate the
raised track. M104-07-119
4. When proper track sag is obtained, turn valve (1)

clockwise and tighten to 90 N·m (9 kgf·m).
Tighten the Track
dCAUTION: It is abnormal if the track remains tight

after turning valve (1) counterclockwise or if the track
is still loose after charging grease to fitting (2). In such
cases, NEVER ATTEMPT TO DISASSEMBLE the track or
track adjuster, because of dangerous high-pressure
grease inside the track adjuster. See your authorized
dealer immediately.
To tighten the track, connect a grease gun to grease fitting

(2) and add grease until the sag is within specifications.
7-112
MAINTENANCE
ZX160-5, ZX200-5, ZX240-5, ZX300-5, ZX330-5
dCAUTION:
 The pressure inside the cylinder of the track adjuster
is high. Do not loosen valve (1) quickly or loosen it
too much as valve (1) may fly out or high-pressure
grease in the adjusting cylinder may spout out.
Slowly loosen valve (1) while keeping body parts and
face away from valve (1). Never loosen grease fitting
(2).
 To prevent accidents, care should be taken to ensure
that hands, feet, and any body parts do not become
entangled when working around the tracks. MDAA-07-013
IMPORTANT: When gravel or mud is packed between


3
1
2. Between 1 to 1.5 turns of valve (1) is sufficient to loosen
the track. When valve (1) comes in contact with stop 2
plate (3), do not loosen valve (1) further.
raised track. Grease Outlet
MDAA-07-014
clockwise to the original condition.
Do not remove valve stop plate (3). Do not loosen bolt (4)
while adjusting the track sag.
dCAUTION: Consult your authorized dealer if grease is

not sufficiently drained. 4
MDAA-07-057
7-113
MAINTENANCE
Tighten the Track
dCAUTION: It is abnormal if the track can not be

adjusted. The strong force acts on the spring in track
adjuster. Therefore, the grease in the cylinder is
highly pressurized. In such cases, NEVER ATTEMPT
TO DISASSEMBLE the track or track adjuster, because
of dangerous high-pressure grease inside the track
adjuster. See your authorized dealer immediately.

2
MDAA-07-057
7-114
MAINTENANCE
Clean and Replace Air Conditioner Filter 1
Clean Circulating/Fresh Air Filters

Circulating Air Filter --- every 500 hours
Fresh Air Filter --- every 500 hours
2
Replace Circulating/Fresh Air Filters
Circulating Air Filter --- After cleaning 6 times or so
Fresh Air Filter --- After cleaning 6 times or so
Removing Fresh Air Filter

1. Insert the key into keyhole (2) on left cab side cover (1). MDAA-07-040
Then, rotate the key counterclockwise to unlock cover
(1). Open cover (1).
2. While pressing knobs (4) on both sides of fresh air filter
(3) inward, horizontally remove fresh air filter (3).
3 M1U1-07-011
Removing Recirculation Filter
1. Recirculation filter (5) is located under the rear tray. 5
2. Holding grips (6), pull them toward you to remove.
MDAA-07-039
7-115
MAINTENANCE
dWARNING: When using compressed air pressure, wear

safety glasses or goggles.
Cleaning
Clean the circulating and fresh air filters.
Clean both the external and internal filters by blowing
compressed air or washing with water.
Washing procedure with water is as follows:

1. Use tap water.
2. Submerge the filter in water containing a neutral
detergent for about 5 minutes.
3. Clean the filter with water again.
4. Dry the filters.
Installation
When installing the cleaned circulating/fresh air filter or
new filters, follow the reverse order of the Removing Filter
procedures described on the previous page.
7-116
MAINTENANCE
Check Air Conditioner
Oil Seepage
Check pipe connections for refrigerant gas leakage
If oil seepage is found around pipe connections, it indicates
possible gas leakage.
Detail
Check Refrigerant
Start the engine and run at approximately 1500 min−1 (rpm). M1CD-07-038
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 2 to 3 minutes. Check if cool air comes out from
the vent in the cab.
Kind of refrigerant and amount when shipping the M157-07-041

machine
Model Type Amount

ZX120-5 class 0.75±0.05 kg
ZX160-5 class 0.80±0.05 kg
HFC134a
ZX200-5, 240-5 class 0.85±0.05 kg
ZX300-5, 330-5 class 0.9±0.05 kg
Check the condenser

If the condenser fins become clogged with dirt or insects,
the cooling effect will be decreased.
Be sure to keep it clean at all times. (Refer to "Clean Radiator
Core" in Maintenance Section.)
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.
Check mounting bolts for looseness

Confirm that the compressor mounting bolts and other
mounting/fastening bolts are securely tightened.
7-117
MAINTENANCE
Inspect belt, check and adjust tension Tension Pulley
Compressor Pulley
--- every 250 hours
Fan Pulley
Visually check the compressor and fan belts for wear.
Check fan belt tension by depressing the midpoint of the
belt with the thumb. Deflection must be shown in the right
figure with a depressing force of approximately 98 N (10 9 to 12 mm
kgf ). 98 N (10 kgf)
If cool air does not come out, or any other abnormalities are Crank Pulley
found in air conditioner system, see your authorized dealer
ZX120-5, 160-5 class M1U1-07-086
for inspection.
Alternator Pulley Fan Pulley
17 to 21 mm
98 N (10 kgf)
Crank Pulley
Air Compressor
10 to 14 mm Pulley
98 N (10 kgf)
ZX200-5, 240-5 class M1GR-07-007
8 to 12 mm
98 N (10 kgf)
Crank Pulley Air Compressor Pulley

ZX300-5, 330-5 class MDAA-07-030
Adjust Compressor Belt Tension

1. Loosen lock nut (2) of tension pulley (1).
2. Move the tension pulley by adjusting bolt (3) under
tension pulley (1) until tension is correct.
3. Securely tighten bolt (2) of tension pulley (1).
4. Securely tighten adjusting bolt (3).
IMPORTANT: When a new belt is installed, be sure to re- 1
adjust the tension after operating the engine for 3 to 5
minutes at slow idle speed to be sure that the new belt 2
is seated correctly. 3
Air Compressor Pulley M1G6-07-013
7-118
MAINTENANCE
Clean Cab Floor
--- as required
IMPORTANT: When cleaning the cab floor with tap

water, spray the floor only. Take care not to splash
the surrounding area. Do not increase water spray
speed by restricting the hose end, and do not use high
pressure steam for cleaning. Be sure to completely
remove any moisture from the surrounding area.
1. Park the machine on solid and level surface. Lower the

bucket to the ground. Before cleaning, stop the engine.
2. Sweep the cab floor clean using a brush, and brush dust
MDAA-07-041
from the cab floor while spraying water.
3. When cleaning the floor mat, sweep dust (water) along
the grooves on the floor mat.
4. When cleaning after removing the floor mat, sweep dust
(water) through one cleaning hole.
7-119
MAINTENANCE
Retighten Cylinder Head Bolt
--- as required
See your authorized dealer.
Inspect and Adjust Valve Clearance

Measure Engine Compression Pressure

Check Starter and Alternator

Check and Replace EGR Device

--- as required
7-120
MAINTENANCE
Check Gas Damper
--- as required
dCAUTION: The gas damper has been charged with

high-pressure nitrogen gas. Inappropriate handling
may cause explosion, possibly resulting in serious
injury or death.
The gas dampers are used in the tool box cover and the cab
overhead window. Contact your nearest authorized dealer
immediately at any of the following situations.
 The cover or window can not be opened with normal
operating force.
 The cover or window can not maintain its open position.
 Oil or gas leak is found.
Tightening and Retightening Torque of Nuts and

Bolts
--- every 250 hours (first time after 50 hours)
Tighten or retighten nuts and bolts used on this machine in
accordance with the torque values shown in the following
table. Bolts and nuts should be replaced with those of the
same or higher grade.
Check tightness after the first 50 hours then every 250 hours.
For tightening nuts and bolts other than specified in the table
below, refer to the Tightening Torque Chart at the end of this
section.
7-121
MAINTENANCE
ZX120-5 class
Wrench Torque
No. Descriptions Bolt Dia Q'ty
size N·m (kgf·m)
1. Engine cushion rubber mounting bolt and nut 16 4 24 235 (23.5)
2. Engine bracket mounting bolt (Pump side) 12 8 19 110 (11)
3. Hydraulic oil tank mounting bolt 16 4 24 270 (27)
4. Fuel tank mounting bolt 16 4 24 270 (27)
Radiator mounting bolt (Upper side) – – – – –
5.
Radiator mounting bolt (Lower side) 12 3 19 90 (9)
6. Pump transmission mounting bolt 10 8 17 65 (6.5)
Control valve mounting bolt 16 4 24 210 (21)
7.
Control valve bracket mounting bolt 16 4 24 270 (27)
8. Swing device mounting bolt 20 10 30 500 (50)
9. Swing motor mounting bolt (Hexagon wrench) 10 7 8 64 (6.4)
– – 17 25 (2.5)
– – 19 30 (3)
– – 22 40 (4)
10. ORS fittings for hydraulic hoses and piping – – 27 95 (9.5)
– – 32 140 (14)
– – 36 180 (18)
– – 41 210 (21)
11. Hycolin tube mounting nut – – 17 35 (3.5)
12. Battery mounting nut 10 8 17 25 (2.5)
Cab mounting nut 16 4 24 210 (21)
13. Cab mounting anchor bolt (Optional) 20 1 32 550 (55)
Cab cushion rubber mounting bolt 12 8 19 110 (11)
6 – 10 3.3 to 4.2 (0.33 to 0.42)
8 – 13 10 (1)
14. Cover mounting bolt
10 – 17 50 (5)
12 – 19 90 (9)
Constant torque clamp of low pressure piping – 8 10 14 (1.4)
For the I/C pipe – 6 7 6 (0.6)
For the radiator – 4 8 6 (0.6)
Jubilee clamp of low pressure piping
15. For the air duct (air cleaner
– 1 8 6 (0.6)
side)
For the air duct (engine side) – 1 11 10 (1)
T-bolt clamp of low pressure piping
Suction piping – 4 11 10 (1)
(Upperstructure) 18 30 27 390 (39)
16. Swing bearing mounting bolt to
(Undercarriage) 16 36 24 265 (26.5)
Travel device mounting bolt 16 28 24 310 (31)
17. Travel cover mounting bolt 14 8 22 180 (18)
Sprocket mounting bolt 16 32 24 270 (27)
18. Upper roller mounting bolt 12 8 19 110 (11)
19. Lower roller mounting bolt 16 56 24 310 (31)
20. Track shoe mounting bolt 16 352 24 410 (41)
22. Front pin-retaining bolt 18 2 27 400 (40)
Upper 12 2 19 130 (13.0)
23. Handrail mounting bolt
Lower 12 2 19 130 (13.0)
7-122
MAINTENANCE
ZX160-5 class
Wrench Torque
size N·m (kgf·m)
(Pump side) 18 4 27 400 (40)
1. Engine cushion rubber mounting bolt and nut
(Fan side) 16 4 24 270 (27)
2. Engine bracket mounting bolt and nut (Pump side) 12 8 19 110 (11)
Radiator mounting bolt (Right side, Left side) 10 8 17 50 (5)
5.
7.
9. Swing motor mounting bolt (Hexagon wrench) 12 8 12 90 (9)
– – 17 25 (2.5)
– – 19 30 (3)
– – 22 40 (4)
– – 32 140 (14)
– – 36 180 (18)
– – 41 210 (21)
6 – 10 3.3 to 4.2 (0.33 to 0.42)
8 – 13 10 (1)
10 – 17 50 (5)
12 – 19 90 (9.0)
Jubilee clamp of low pressure piping For the radiator – 4 8 6 (0.6)
15.
For the air duct (air cleaner side) – 1 8 6 (0.6)
For the air duct (engine side) – 1 11 10 (1.0)
Suction piping – 8 11 10 (1.0)
16. Swing bearing mounting bolt to
(Undercarriage) 20 36 32 500 (50)
Sprocket mounting bolt 20 36 30 485 (48.5)
19. Lower roller mounting bolt 18 64 27 460 (46)
20. Track shoe mounting bolt 20 344 27 804 (80.4)
21. Track guard mounting bolt 18 8 27 500 (50)
Upper 12 2 19 110 (11.0)
Lower 14 2 22 180 (18.0)
7-123
MAINTENANCE
ZX200-5 class
Wrench Torque
size N·m (kgf·m)
1. Engine cushion rubber mounting bolt and nut 22 4 32 550 (55)
Engine bracket mounting bolt (Pump side) 16 8 24 270 (27)
2.
Engine bracket mounting bolt (Fan side) 10 8 17 65 (6.5)
5.
7.
– – 17 25 (2.5)
– – 19 30 (3)
– – 22 40 (4)
– – 32 140 (14)
– – 36 180 (18)
– – 41 210 (21)
6 – 10 3.3 to 4.2 (0.33 to 0.42)
8 – 13 10 (1)
10 – 17 50 (5)
12 – 19 90 (9.0)
Jubilee clamp of low pressure For the radiator
– 4 8 6 (0.6)
15. piping
For the air duct (air cleaner side) – 1 8 10 (1)
T-bolt clamp of low pressure For the air duct (engine side) – 1 11 10 (1)
piping Suction piping – 8 11 10 (1)
Swing bearing mounting bolt (Upperstructure) 20 37 30 510 (51)
16.
to (Undercarriage) 20 36 30 490 (49)
ZX200-5A, 210H-5A, 210K-5A 18 56 27 460 (46)
19. Lower roller mounting bolt
ZX200LC-5A, 210LCH-5A, 210LCK-5A 18 64 27 460 (46)
ZX200-5A, 210H-5A, 210K-5A 20 368 27 804 (80.4)
20. Track shoe mounting bolt
ZX200LC-5A, 210LCH-5A, 210LCK-5A 20 392 27 804 (80.4)
ZX200-5A (One mounted on one 18 8 27 500 (50)
side of crawler)
21. Track guard mounting bolt ZX200LC-5A, 210H-5A, 210K-5A,
210LCH-5A, 210LCK-5A (Two 18 16 27 500 (50)
mounted on one side of crawler)
Upper 12 2 19 110 (11.0)
Lower 14 2 22 180 (18.0)
7-124
MAINTENANCE
ZX240-5 class
Wrench Torque
No. Descriptions Bolt Dia Quantity
size N·m (kgf·m)
2.
3. Hydraulic oil tank mounting bolts 18 4 27 400 (40)
4. Fuel tank mounting bolts 16 6 24 270 (27)
5.
6. Pump mounting bolt 10 8 17 65 (6.5)
7.
Control valve bracket mounting bolts 16 4 24 270 (27)
8. Swing device mounting bolts 22 14 32 650 (65)
− − 17 25 (2.5)
− − 19 30 (3)
− − 22 40 (4)
10. ORS fittings for hydraulic hoses and piping − − 27 95 (9.5)
− − 32 140 (14)
− − 36 180 (18)
− − 41 210 (21)
11. Hycolin tube mounting nut − − 17 35 (3.5)
Cab mounting nuts 16 4 24 210 (21)
6 − 10 3.3 to 4.2 (0.33 to 0.42)
8 − 13 10 (1)
10 − 17 50 (5)
12 – 19 90 (9.0)
Jubilee clamp of low pressure
For the radiator – 4 8 6 (0.6)
15. piping
T-bolt clamp of low pressure For the air duct (engine side) – 1 11 10 (1)
piping Suction piping – 8 11 10 (1)
16. Swing bearing mounting bolts
(Undercarriage) 22 36 32 715 (71.5)
Travel device mounting bolts 20 32 30 630 (63)
18. Upper roller mounting bolts 16 16 24 270 (27)
ZX240-5A, 250H-5A, 250K-5A 18 64 27 460 (46)
19. Lower roller mounting bolts
ZX240LC-5A, 250LCH-5A, 250LCK-5A 18 72 27 460 (46)
ZX240-5A, 250H-5A, 250K-5A 20 376 27 804 (80.4)
20. Track shoe mounting bolts
ZX240LC-5A, 250LCH-5A, 250LCK-5A 20 408 27 804 (80.4)
ZX240-5A (Two mounted on one side of
18 16 27 500 (50)
crawler)
21. Track guard mounting bolts ZX240LC-5A, 250H-5A, 250K-5A, 250LCH-
5A, 250LCK-5A (Three mounted on one 18 24 27 500 (50)
side of crawler)
18 1 27 400 (40)
22. Front pin-retaining bolt
22 1 32 750 (75)
Upper 12 2 19 110 (11.0)
Lower 14 2 22 180 (18.0)
7-125
MAINTENANCE
ZX300-5 class
Wrench Torque
size N·m (kgf·m)
2.
Radiator mounting bolts (left and right) 10 7 17 50 (5)
5.
7.
− − 17 25 (2.5)
− − 19 30 (3)
− − 22 40 (4)
− − 27 95 (9.5)
10. ORS fittings for hydraulic hoses and piping
− − 32 140 (14)
− − 36 180 (18)
− − 41 210 (21)
− − 50 260 (26)
6 − 10 10 (1)
8 − 13 20 (2)
10 − 17 50 (5)
12 − 19 90 (9.0)
Constant torque clamp of low pressure piping − 8 10 14 (1.4)
Flexible master coupling of low pressure piping − 1 1 20.5 to 22.6 (2.05 to 2.26)
For the I/C pipe − 8 7 6 (0.6)
For the radiator − 4 8 6 (0.6)
15. For the I/C pipe (engine side) − − 7 6.9 (0.69)
piping
For the radiator (engine side) − − 8 6.9 (0.69)
Suction piping − 8 11 10 (1)
(Undercarriage) 22 36 32 715 (71.5)
19. Lower roller mounting bolts 22 64 32 840 (84)
20. Track shoe mounting bolts 22 360 32 1130 (113)
21. Track guard mounting bolts 22 24 32 750 (75)
22 2 32 750 (75)
18 5 27 400 (40)
Upper 12 2 19 110 (11)
Lower 14 2 22 180 (18)
7-126
MAINTENANCE
ZX330-5 class
Wrench Torque
size N·m (kgf·m)
2.
Radiator mounting bolts (left and right) 10 7 17 50 (5)
5.
7.
− − 17 25 (2.5)
− − 19 30 (3)
− − 22 40 (4)
− − 27 95 (9.5)
− − 32 140 (14)
− − 36 180 (18)
− − 41 210 (21)
− − 50 260 (26)
6 − 10 3.3 to 4.2 (0.33 to 0.42)
8 − 13 10 (1)
10 − 17 50 (5)
12 − 19 90 (9.0)
Constant torque clamp of low pressure piping − 8 10 14 (1.4)
Flexible master coupling of low pressure piping − 1 1 20.5 to 22.6 (2.05 to 2.26)
For the I/C pipe − 8 7 6 (0.6)
For the radiator − 4 8 6 (0.6)
15. For the I/C pipe (engine side) − − 7 6.9 (0.69)
piping
For the radiator (engine side) − − 8 6.9 (0.69)
Suction piping − 8 11 10 (1)
(Upperstructure) 27 36 41 1230 (123)
(Undercarriage) 27 36 41 1230 (123)
19. Lower roller mounting bolts 22 56 32 840 (84)
20. Track shoe mounting bolts 22 360 32 1130 (113)
ZX350K-5A 22 24 32 750 (75)
21. Track guard mounting bolts ZX350H-5A Full track guard mounting bolts 22 24 32 750 (75)
Full track guard through bolts 20 16 30 500 (50)
Front pin-retaining bolt 22 2 32 750 (75)
22. Boom cylinder bottom, Boom top, Arm cylinder bottom and lod pin-retaining
18 7 27 400 (40)
bolt
Upper 12 2 19 110 (11.0)
Lower 14 2 22 180 (18.0)
7-127
MAINTENANCE
Tightening Torque Chart
Hexagon Wrench Socket Bolt
Bolt Dia.
Wrench size Socket Bolt Wrench size
mm
mm mm
N·m (kgf·m) N·m (kgf·m) N·m (kgf·m) N·m (kgf·m)
3.3 to 4.2 (0.3 to 10 5
6
0.4)
8 30 (3.0) 20 (2.0) 10 (1.0) 13 20 (2.0) 6
10 65 (6.5) 50 (5.0) 20 (2.0) 17 50 (5.0) 8
12 110 (11) 90 (9) 35 (3.5) 19 90 (9) 10
14 180 (18) 140 (14) 55 (5.5) 22 140 (14) 12
16 270 (27) 210 (21) 80 (8.0) 24 210 (21) 14
18 400 (40) 300 (30) 120 (12) 27 300 (30) 14
20 550 (55) 400 (40) 170 (17) 30 400 (40) 17
22 750 (75) 550 (55) 220 (22) 32
24 950 (95) 700 (70) 280 (28) 36
27 1400 (140) 1050 (105) 400 (40) 41
30 1950 (195) 1450 (145) 550 (55) 46
33 2600 (260) 1950 (195) 750 (75) 50
36 3200 (320) 2450 (245) 950 (95) 55
dCAUTION: If fixing bolts for counterweight are

loosened, consult your nearest authorized dealer.
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.
7-128
MAINTENANCE
1. Engine cushion rubber mounting bolt and nut
Pump Side M1U1-07-040
Fan Side M1U1-07-034
2. Engine bracket mounting bolt
Pump Side M1U1-07-040
Fan Side M1U1-07-034
7-129
MAINTENANCE
3. Hydraulic oil tank mounting bolt
MDAA-07-026
4. Fuel tank mounting bolt
MDAA-07-026
5. Radiator mounting bolt
MDAA-07-101
Lower side
ZX160-5, 200-5, 240-5, 300-5, 330-5 class (Left and right)
MDAK-07-044
7-130
MAINTENANCE
6. Pump transmission mounting bolt
ZX120-5, 160-5 class ZX200-5, 240-5, 300-5, 330-5 class MDAK-07-007

M1U4-07-050
7. Control valve mounting bolt
MDAA-07-111
Control valve bracket mounting bolt
M1U1-07-041
7-131
MAINTENANCE
8. Swing device mounting bolt
M1U1-07-053
ZX120-5 class ZX160-5, 200-5, 240-5, 300-5, 330-5 class
M175-00-002
9. Swing motor mounting bolt
M1U1-07-053
ZX120-5 class M175-00-002 ZX160-5, 200-5, 240-5, 300-5, 330-5 class
M104-07-079
7-132
MAINTENANCE
11. Hycolin tube mounting nut
ZX120-5 class M1U1-07-111
ZX160-5, 200-5, 240-5 class MDAK-07-009
ZX300-5, 330-5 class M1U1-07-035
12. Battery mounting nut
MDAA-07-088
ZX160-5, 200-5, 240-5, 300-5, 330-5 class
7-133
MAINTENANCE
13. Cab mounting nut
M1U1-07-026
Anchor Bolts (Optional) M1U1-07-054
Cab cushion rubber mounting bolt
14. Cover mounting bolt MDC1-07-052
MDCF-07-031
7-134
MAINTENANCE
15. Constant torque clamp of low pressure piping
MDC1-07-093
Flexible master coupling of low pressure piping
ZX300-5, 330-5 class MDCD-07-018
MDC1-07-094
Suction piping
ZX120-5 class
MDFT-07-005
Suction piping
For the air duct (engine cleaner side) ZX160-5, 200-5, 240-5, 300-5, 330-5 class
MDAK-07-053
7-135
MAINTENANCE
Jubilee clamp of low pressure piping
ZX200-5A, 240-5A, 300-5A, 330-5A MDFT-07-009
ZX120-5A, 160-5A MDAK-07-064
MDFT-07-010
For the air duct (air cleaner side) MDAK-07-053
7-136
MAINTENANCE
16. Swing bearing mounting bolt
Upperstructure Side M107-07-088
M1U1-07-113 M107-07-089
Undercarriage Side Undercarriage Side
ZX120-5 class ZX160-5, 200-5, 240-5, 300-5, 330-5 Class
7-137
MAINTENANCE
17. Travel device mounting bolt
M164-07-005
Travel moter cover mounting bolt
M1G6-07-007
Sprocket mounting bolt
M154-07-050
18. Upper roller mounting bolt
M157-07-224
7-138
MAINTENANCE
19. Lower roller mounting bolt
M107-07-092
20. Track shoe mounting bolt
M107-07-093
7-139
MAINTENANCE
21. Track guard mounting bolt
MDAA-07-058
Full track guard mounting bolt
MDAA-07-059
Full track guard through bolt
MDAA-07-059
7-140
MAINTENANCE
MDCS-07-004
MDCS-07-005
Boom cylinder bottom pin-retaining bolt

(ZX330-5 class only)
M173-07-016
Boom top, Arm cylinder bottom and lod pin-retaining bolt

(There are three bolts on the boom top.)
(ZX240-5, 330-5 class only)
MDCA-07-001
7-141
MAINTENANCE
Upper MDFT-07-006
Lower MDFT-07-011
7-142
MAINTENANCE
List of Consumable Parts

ZX120-5, 160-5 class
Filter Elements
ZX120-5 class ZX160-5 class
Quantity
Part No. Part No.
Full-Flow Filter (with O-ring) 4448401 YA00033065 1
High Performance Full-Flow Filter 4450002 YA00033064 1
Hydraulic Air Breather Element 4437838  1
Pilot Oil Filter (with O-ring) 4630525  1
Engine Oil Filter 4658521  1
Fuel Main Filter Element YA00033486  1
Fuel Pre-Filter Element YA00037134  1
Air Cleaner Element (outer) 4486002  1
Air Cleaner Element (inner) 4486014  1
Air Conditioner Circulating Air Filter 4643580  1
Air Conditioner Fresh Air Filter YA00032683  1
Drive Belts
Quantity
Part No. Part No.
Engine Fan Belt 4668374  1
Air Conditioner Compressor Belt 4686087  1
Bucket Parts
Quantity
Part No. Part No.
Tooth 963228  5
Tooth Lock Pin 963229  5
Lock Rubber 963227  5
Side Cutter (right side) 2015428  1
Side Cutter (left side) 2015429  1
Side Cutter Bolt J932060  8
Nut J951020  8
Spring Washer A590920  8
O-ring 4276696 4089028 4
fNOTE: Quantity row on the above table represents number of parts used for one bucket. The parts quantity of O-ring
includes connection part of arm and link.
7-143
MAINTENANCE
Optional Parts
Part No. Quantity Part No. Quantity
Tooth 971377 1 971377 1
One Point Ripper Pin 971378 1 971378 1
Bushing Rubber 971379 1 971379 1
7-144
MAINTENANCE
ZX200-5 class
Filter Elements
Part No. Quantity
Full-Flow Filter (with O-ring) YA00033065 1
High Performance Full-Flow Filter YA00033064 1
Line Filter YA00013067 1
Hydraulic Air Breather Element 4437838 1
Pilot Oil Filter (with O-ring) 4630525 1
Engine Oil Filter 4658521 1
Fuel Main Filter Element YA00033486 1
Fuel Pre-Filter Element YA00037134 1
Air Cleaner Element (outer) 4286128 1
Air Cleaner Element (inner) 4286130 1
Air Conditioner Circulating Air Filter YA00001490 1
Air Conditioner Fresh Air Filter YA00032683 1
Drive Belts
Part No. Quantity
Engine Fan Belt 4642643 1
Air Conditioner Compressor Belt YA00007116 1
Bucket Parts
Part No. Quantity
Tooth 4427919 5
Tooth Lock Pin 4501627 5
Lock Rubber 4501625 5
Side Cutter (right side) 2014503 1
Side Cutter (left side) 2014504 1
Side Cutter Bolt J932270 12
Nut J951022 12
Spring Washer A590922 12
O-ring 4089028 4
7-145
MAINTENANCE
Optional Parts
Part No. Quantity
Tooth 971377 1
One Point Ripper Pin 971378 1
Bushing Rubber 971379 1
Tooth 971377 1
Pin 971378 1
Ripper Bucket
Tooth 4427919 2
Lock Pin 4501627 2
Tooth 4427919 5
Reinforced Hoe Bucket
Lock Pin 4501627 5
HD Type
Reinforced Hoe Bucket Tooth 4364121 5
HD Type (Transverse-
Type-Pin) Pin 4364125 5
with Super V type Tooth 4383048 5
Bucket Teeth
Reinforced Hoe Bucket Pin 4383069 5
fNOTE: * The parts quantity of items with * mark.

 Four parts are required per each bucket of 0.30, 0.35, and 0.40 m3.
 Seven parts are required per one ditch cleaning bucket with teeth.
7-146
MAINTENANCE
ZX240-5 class
Filter Elements
ZX240-5 class
Quantity
Part No.
Drive Belts
ZX240-5 class
Quantity
Part No.
Engine Fan Belt YA00006855 1
Air Conditioner Compressor Belt YA00007116 1
Bucket Parts
Part No. Quantity
Tooth 4512365 5
Nut J951022 12
O-ring 4089028 4
7-147
MAINTENANCE
Optional Parts
Part No. Quantity
Tooth 4507888 1
Tooth 4507888 1
Pin 4507890 1
Ripper Bucket Bushing Rubber 4507891 1
Tooth 4383048 2
Lock Pin 4383069 2
Tooth 4400253 5
Lock Pin 4383465 5
Shroud 4435856 1
Rock Bucket Shroud 4435857 1
Bolt J932780 6
Nut J951027 6
Washer 4085857 6
Tooth 4512365 5
Reinforced Hoe Bucket HD
Lock Pin 4512366 5
Type
*2 Tooth 4380343 5
Type (Transverse-Type-Pin) Pin 4380344 5

 An item with * 2 mark is for ZX240-5 class.
7-148
MAINTENANCE
ZX300-5 class
Filter Elements
Part No. Quantity
Drive Belts
Part No. Quantity
Engine Fan Belt 4603925 1
Air Conditioner Compressor Belt 4612331 1
Bucket Parts
Part No. Quantity
Tooth 4512365 5
Nut J951022 12
O-ring 4089028 4
7-149
MAINTENANCE
Optional Parts
Part No. Quantity
Tooth 4507888 1
Tooth 4507888 1
Pin 4507890 1
Tooth 4383048 2
Lock Pin 4383069 2
Tooth 4400253 5
Lock Pin 4383465 5
Shroud 4435856 1
Bolt J932780 6
Nut J951027 6
Washer 4085857 6
Tooth 4512365 5
Lock Pin 4512366 5
Type
*2 Tooth 4380343 5
Type (Transverse-Type-Pin) Pin 4380344 5

 An item with * 2 mark is for ZX240-5 class.
7-150
MAINTENANCE
ZX330-5 class
Filter Elements
Part No. Quantity
Drive Belts
Part No. Quantity
Engine Fan Belt YA00011518 1
Air Conditioner Compressor Belt 4612331 1
Bucket Parts
Part No. Quantity
Tooth 4512365 5
Nut J951022 12
O-ring 4100180 4
7-151
MAINTENANCE
Optional Parts
Part No. Quantity
Tooth 4507888 1
Tooth 4507888 1
Pin 4507890 1
Tooth 4400253 2
Lock Pin 4383465 2
Tooth 4400253 5
Lock Pin 4383465 5
Shroud 4435856 1
Bolt J932780 6
Nut J951027 6
Washer 4085857 6
Tooth 4400250 5
Hoe Bucket (Super V)
Lock Pin 4400252 5
Rock Bucket (Transverse- Tooth 4380343 5
Type-Pin) Pin 4380844 5

7-152
Maintenance Under Special Environmental Conditions
Operating Conditions Precautions for Maintenance

Muddy Soil, Rainy or After Operation : Clean the machine and check for cracks, damaged, loose or missing bolts
Snowy Weather and nuts. Lubricate all necessary parts without delay.
Near the Ocean After Operation : The following salt pollution measures must be taken when the machine is
operated at sea or at coastline.
(1) After completing the work, extend/retract the hydraulic cylinders
several times to form oil film on the rod surface. Store the machine
with cylinders retracted as much as possible.
(2) Thoroughly clean the machine with fresh water to wash off salt.
(3) Perform touch up painting periodically on hose fittings, lubrication
piping and inserting position of cover, where sea water is easily
collected, in order to prevent corrosion.
(4) During storage of the machine, cover the machine by tarps to prevent
sea water from entering into the cab vent. Apply rust prevention oil
(example: ANTIRUST P-1300NP-3 JX Nippon Oil & Energy Corporation)
onto plated part of the cylinder rods.
Dusty Atmosphere Radiator : Clean the oil cooler screen to prevent clogging of the radiator core.
Engine, Muffler : Clean earlier than the normal interval to prevent dust from sticking and
accumulating.
Rocky Ground Tracks : Carefully operate while checking for cracks, damage and loose bolts and
nuts. Loosen the tracks a little more than usual.
Front Attachment : Standard attachment may be damaged when digging rocky ground.
Reinforce the bucket before using it, or use a heavy duty bucket.
Falling Stones Cab Head Guard : Provide a cab guard to protect the machine from falling stones. Consult
your nearest Hitachi dealer.
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.
9-1
MEMO
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9-2
STORAGE
Storing the Machine

In case the machine is to be stored for longer than one month, pay attention to the following points to prepare next
operation.
Precautions for Long-Term 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. Turn the
battery disconnect switch to the OFF position.
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
and Moisture Store the machine in a dry storage area using a protective cover.
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.
fNOTE:
 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.
Precautions for Disconnecting or Connecting Batteries

In case the batteries are kept disconnect for more than one month or the battery disconnect switch is turned off, data
in the information controller or preset data of the radio may be initialized.
Consult your authorized dealer before restarting operation of the machine after the batteries are disconnected for one
month or more.
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 authorized 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 authorized dealer for the engine troubleshooting.
Engine Auxiliaries
Problem Cause Solution
Batteries will not be charged Broken battery separator Replace
Faulty regulator * Adjust and replace
Faulty ground line * Repair
Faulty alternator * Repair or replace
Batteries discharge quickly after being Shorted cable * Repair or replace
charged Shorted battery separator * Repair or replace
Increased sediment in battery * Replace
Coolant temperature is too high Low coolant level Refill
Insufficient fan belt tension Adjust
Damaged rubber hose * Replace
Faulty thermostat * Replace
Faulty coolant temperature gauge * Replace
Items with * mark: Consult your authorized dealer.
11-1
TROUBLESHOOTING
Impossible to Start the Engine
Starter does not rotate or is not Discharged battery Charge or replace battery
powerful Disconnected, loose, or corroded battery After repairing the corroded
terminals area, securely tighten the
connectors
Lowered pilot control shut-off lever Pull pilot control shut-off lever
up
Disconnected, loose, or corroded starter After repairing the corroded
ground line terminals area, securely tighten the
connectors
Faulty pilot control shut-off lever electrical Repair
system
Engine will not start
Too high engine oil viscosity Change engine oil with

appropriate viscosity
Faulty starter and/or electrical system * Repair and replace
Battery disconnect switch is in the OFF Turn the battery disconnect
position switch to the ON position
Starter rotates No fuel After checking that no fuel is
leaking, refill fuel
Air in the fuel system Bleed air
Clogged fuel filter Replace the element
Clogged pre-fuel filter Replace the element
Frozen fuel Warm the fuel pump with
hot water or wait until the
atmospheric temperature rises
Engine stop switch is ON Turn the switch to the OFF
position
Faulty preheat system * Repair and replace
Even though the engine is started, the Too low idle speed * Repair and replace
engine stalls soon Clogged fuel filter After draining water, replace
the element
Clogged pre-fuel filter Clean or replace the element
Faulty engine control system * Repair and replace
Clogged air cleaner Clean or replace the element
Faulty fuel system * Repair and replace
Engine runs irregularly Faulty fuel system * Repair and replace
Water or air in the fuel system Drain water or bleed air
Faulty engine control system * Repair and replace
11-2
TROUBLESHOOTING
Control Lever
Lever is heavy to operate Rusted joint * Lubricate or repair
Worn pusher * Replace
Does not move smoothly Worn pusher * Repair or replace
Faulty pilot valve * Replace
Does Not Return to Neutral Faulty pilot valve * Replace
The lever is tilted in the neutral position Worn joint * Repair or replace
due to increase in play Faulty pilot valve * Replace
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.
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
Faulty pressure sensor * Replace
Faulty solenoid valve * Replace
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 circuit line * Repair or replace
Faulty pilot solenoid valve * Repair or replace
11-4
TROUBLESHOOTING

Only one actuator is inoperable Broken control valve spool * Replace
Embedded foreign matter in valve spool * Repair or replace
Broken pipe and/or hose * Repair or replace
Loose pipe line joint Retighten
Broken O-ring at pipe line joint * Replace
Broken actuator * Repair or replace
Only one cylinder is inoperable or has Broken oil seal in cylinder * Repair or replace
no power Oil leak due to damage to cylinder rod * Repair or replace
Hydraulic oil temperature increases Stained oil cooler Clean
Insufficient engine fan belt tension Adjust
Oil leak from low pressure hose Loose clamps Retighten
Faulty suction manifold * Repair or replace
11-5
TROUBLESHOOTING
Drive Function
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
Does not travel smoothly Overly tensioned or slackened crawler sag Adjust
Lack of lubricant in front idler and/or roller Refill
Deformed track frame * Repair or replace
Embedded foreign matter such as rock Remove
fragments
Dragged parking brake * Repair
Travel speed does not change Faulty travel mode switch * Replace
Pump 1 and 2 delivery pressure sensors * Replace
Pumps 1, 2 control pressure sensors * Replace
Poor contact in connector * Repair or replace
Damaged wire harness * Repair
Faulty controller (MC) * Replace
Faulty solenoid valve * Repair or replace
Faulty motor * Repair or replace
11-6
TROUBLESHOOTING
Swing Function
Upperstructure does not swing Faulty swing parking brake * Repair or replace
Faulty swing parking brake release valve * Repair or replace
Broken swing motor * Repair or replace
Swing is not smooth Worn swing gear * Repair or replace
Damaged swing bearing and bearing balls * Repair or replace
Lack of grease Refill
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
Even if operating the engine control Blown fuse Replace
dial, the engine speed does not change Faulty engine control dial * Replace
Damaged wire harness (between EC dial and * Repair
MC, or MC and ECM)
Faulty controller (MC, ECM) * Replace
Work mode does not change Faulty mode switch * Replace
Damaged wire harness (between MC and * Repair
monitor)
Faulty controller (MC) * Replace
Faulty solenoid valve * Repair or replace
Auto-idle is inoperable or not released Faulty pressure sensor * Replace
Faulty controller * Replace
Pump Control
Front attachment and/or travel speed Blown control fuse Replace
is slow Poor contact in connector * Repair or replace
Faulty controller * Replace
Faulty pump solenoid valve * Replace
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
Specifications
ZX130-5A
A
G C
E
D
K J
I H
MDAK-12-001
Model ZX130-5A
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
Bucket Capacity (Heaped) 0.50 m3 (0.65 yd3), (CECE 0.45 m3)
Operating Weight 12200 kg (26900 lb)
Base Machine Weight 9500 kg (21000 lb)
Engine Type ISUZU GI-4JJ1XKSA-03
ISO 14396 73 kW at 2000 min-1
Engine Power
ISO 9249 69.4 kW at 2000 min-1
Overall Width
A: 2490 mm (8 ft 2 in)
(Excluding back mirrors)
B: Cab Height 2790 mm (9 ft 2 in)
C: Rear End Swing Radius 2190 mm (7 ft 2 in)
D: Minimum Ground Clearance *410 mm (1 ft 4 in)
E: Counterweight Clearance *840 mm (2 ft 9 in)
F: Engine Cover Height *2020 mm (6 ft 8 in)
G: Overall Width of Upperstructure 2460 mm (8 ft 1 in)
H: Undercarriage Length 3580 mm (11 ft 9 in)
I: Undercarriage Width 2490 mm (8 ft 2 in)
J: Sprocket Center to Idle Center 2880 mm (9 ft 5 in)
K: Track Shoe Width 500 mm (20 in) (Grouser shoe)
Ground Pressure 38 kPa (0.39 kgf/cm2, 5.5 psi)
Swing Speed 13.7 min–1 (rpm)
Travel Speed (fast/slow) 5.5/3.3 km/h (3.4/2.1 mph)
Gradeability 35 ° (tanθ = 0.70)
fNOTE: * The dimensions do not include the height of the shoe lug.
12-1
SPECIFICATIONS
Working Ranges (Grouser shoe)

ZX130-5A
A
B
MDAK-12-002
Category 2.10 m (6 ft 11 in) Arm 2.52 m (8 ft 3 in) Arm 3.01 m (9 ft 11 in) Arm
Backhoe Backhoe Backhoe
Item mm ft·in mm ft·in mm ft·in
A: Maximum Digging Reach 7940 26’ 1” 8300 27’ 3” 8770 28’ 9”
B: Maximum Digging Depth 5120 16’ 10” 5540 18’ 2” 6030 19’ 9”
C: Maximum Cutting Height 8400 27’ 7” 8600 28’ 3” 8930 29’ 4”
D: Maximum Dumping Height 5990 19’ 8” 6190 20’ 4” 6520 21’ 5”
E: Overall Height 2790 9’ 2” 2790 9’ 2” *2790 9’ 2”
F: Overall Length 7700 25’ 3” 7700 25’ 3” *7710 25’ 4”
G: Minimum Swing Radius 2350 7’ 9” 2400 7’ 11” 2620 8’ 7”
fNOTE: The dimensions do not include height of the shoe lug (except Item E). * The dimensions asterisked are for transport
pin position.
12-2
SPECIFICATIONS
Shoe Types and Applications

ZX130-5A
500 mm (20”) 600 mm (24”) 700 mm (28”) 510 mm (20”)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe Flat Shoe
For Ordinary Ground For Weak Footing For Weak Footing For Paved Road
Application
(Standard) (Option) (Option) (Option)
kg 12200 12500 12700 12700
Operating Weight
(lb) (26900) (27600) (28000) (28000)
kg 9500 9800 10000 10000
Base Machine Weight
(lb) (20950) (21610) (22050) (22050)
mm 2790 2790 2790 2800
Cab Height
(ft·in) (9’ 2”) (9’ 2”) (9’ 2”) (9’ 2”)
Minimum Ground mm *410 *410 *410 *440
Clearance (ft·in) (1’ 4”) (1’ 4”) (1’ 4”) (1’ 5”)
mm 3580 3580 3580 3600
Undercarriage Length
(ft·in) (11’ 9”) (11’ 9”) (11’ 9”) (11’ 10”)
mm 2490 2590 2690 2500
Undercarriage Width
(ft·in) (8’ 2”) (8’ 6”) (8’ 10”) (8’ 2”)
38 kPa 32 kPa 28 kPa 39 kPa
Ground Pressure
(0.39 kgf/cm2, 5.5 psi) (0.33 kgf/cm2, 4.6 psi) (0.29 kgf/cm2, 4.1 psi) (0.40 kgf/cm2, 5.7 psi)
500 mm (20”)
700 mm (28”) 500 mm (20”) 500 mm (20”)
Shoe Width Rubber Pad Grouser
Triangular Shoe Single Grouser Shoe Pad Crawler Shoe
Shoe
For Weak Footing For Weak Footing For Paved Road For Paved Road
Application
(Option) (Option) (Option) (Option)
kg 12600 12500 12300 12700
Operating Weight
(lb) (27800) (27600) (27200) (28000)
kg 9800 9800 9600 10000
Base Machine Weight
(lb) (21700) (21610) (21200) (22100)
mm 2820 2820 2830 2830
Cab Height
(ft·in) (9’ 3”) (9’ 3”) (9’ 3”) (9’ 3”)
Minimum Ground mm *410 410 *470 *470
Clearance (ft·in) (1’ 4”) (1’ 4”) (1’ 7”) (1’ 7”)
mm 3650 3650 3660 3660
(ft·in) (12’) (12’) (12’) (12’)
mm 2490 2490 2490 2490
Undercarriage Width
(ft·in) (8’ 2”) (8’ 2”) (8’ 2”) (8’ 2”)
Ground Pressure
fNOTE:
 The specification for the front-end attachment is for 2.52 (8 ft 3 in) m arm with PCSA 0.50 m3 (0.65 yd3) bucket.
 Other than 500 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
Bucket Types and Applications

Use a bucket and arm in combination shown in the below table. If a mass excavation bucket or extreme service
excavations bucket which are not described in the table is used, machine stability will not be ensured and strong force
may apply to the main body, front attachment and cylinders, resulting in damage to the machine.
Use the bucket and the arm in combination only described in the below table.
ZX130-5A
Bucket Capacity Bucket Width

Front-End Attachment
m3 (yd3) mm (in)
Bucket 2.52 m
2.10 m 2.52 m 3.01 m
PCSA CECE With Side Without (8’ 3”)
(6’ 11”) (8’ 3”) (9’ 11”)
(Heaped) (Heaped) Cutter side cutter Arm and
Arm Arm Arm
extension
0.19 (0.25) 0.17 (0.22) 570 (22”) 450 (18”)    
0.30 (0.39) 0.25 (0.33) 700 (28”) 580 (23”)    
0.40 (0.52) 0.33 (0.43) 840 (31”) 720 (27”)    
Hoe Bucket 0.45 (0.59) 0.40 (0.52) 920 (38”) 800 (33”)    
0.50 (0.65) 0.45 (0.59) 1010 (40”) 890 (35”)   * 
0.59 (0.77) 0.50 (0.65) 1070 (42”) 950 (37”)    
0.66 (0.86) 0.55 (0.72) - 1030 (41”)    
Reinforced Hoe Bucket 0.50 (0.65) 0.45 (0.59) 1010 (40”) 890 (35”)   * 
Reinforced Hoe Bucket 0.59 (0.77) 0.50 (0.65) 1070 (42”) 950 (37”)    
One Point Ripper - -    
Slope-Finishing Bucket - 1000 (39”)×1600 (63”)    
Side board angle: 45
V-Type Bucket -    
degree
: For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.
fNOTE: : For light duty excavating (digging and loading operation of dry, loosened earth, sand, mud and so on.
The bulk density shall be less than 1600 kg/m3 (2700 lb/yd3) as a standard.)
: Rock digging (For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and
so on.)
: Loading work (For loading operation of dry, loosened earth and sand. The bulk density shall be less than
1,100 kg/m3 (2700 lb/yd3) as a standard.)
: Slope-finishing work
: Not Applicable (Not Warrantable)
* Applicable only to 700 mm (28 in) grouser shoe.
12-4
SPECIFICATIONS
Specifications
ZX160LC-5A
A
G C
F' B
F
E
D
K
J
I H
MDAK-12-003
Model ZX160LC-5A
Bucket Capacity (Heaped) PCSA 0.60 m3 (0.79 yd3), CECE 0.55 m3
Engine Type ISUZU GI-4JJ1XKSA-01
ISO 14396 84 kW at 2200 min-1
Engine Power
ISO 9249 79.2 kW at 2200 min-1
A: Overall Width (Excluding back mirrors) 2500 mm (8 ft 2 in)
F': Handrail Height 3010 mm (9 ft 11 in)
12-5
SPECIFICATIONS

ZX160LC-5A
A
B
MDAK-12-004
2.22 m (7 ft 3 in) Arm 2.58 m (8 ft 6 in) Arm 3.08 m (10 ft 1 in) Arm
Category
Item
mm ft·in mm ft·in mm ft·in
D: Maximum Dumping Height 5940 19’ 6” 6170 20’ 3” 6400 21”
E: Overall Height 3190 10’ 6” 3010 9’ 11” 3110 10’ 2”
F: Overall Length 8720 28’ 7” 8620 28’ 3” 8650 28’ 5”
fNOTE: The dimensions do not include height of the shoe lug (except Item E).
12-6
SPECIFICATIONS

ZX160LC-5A
500 mm (20”) 600 mm (24”) 700 mm (28”) 600 mm (24”)
Shoe Width
Application
kg 16600 16800 17100 17600
Operating Weight
(lb) (36600) (37100) (37700) (38900)
kg 13200 13400 13600 14200
Base Machine Weight
(lb) (29100) (29550) (29990) (31400)
mm 2950 2950 2950 2990
Cab Height
(ft·in) (9’ 8”) (9’ 8”) (9’ 8”) (9’ 10”)
Clearance (ft·in) (1’ 7”) (1’ 7”) (1’ 7”) (1’ 8”)
mm 3920 3920 3920 3950
(ft·in) (12’ 10”) (12’ 10”) (12’ 10”) (13’)
mm 2490 2590 2690 2590
Undercarriage Width
(ft·in) (8’ 2”) (8’ 6”) (8’ 10”) (8’ 6”)
Ground Pressure
fNOTE:
 The specification for the front-end attachment is for 2.58 m (8 ft 6 in) arm with PCSA 0.60 m3 (0.79 yd3) bucket.
 Other than 500 mm (20 in) 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.
12-7
SPECIFICATIONS

ZX160LC-5A

m3 (yd3) mm (in)
Bucket 2.22 m 2.58 m 3.08 m
With Side Without side
Heaped CECE (7’ 3”) (8’ 6”) (10’ 1”)
Cutter cutter
Arm Arm Arm
0.52 (0.68) 0.45 (0.59) 910 (36”) 790 (31”)   
0.60 (0.79) 0.55 (0.72) 1045 (41”) 925 (36”)   *
Hoe Bucket
0.70 (0.92) 0.60 (0.79) 1125 (44”) 1005 (40”)   *
0.82 (1.07) 0.70 (0.92) 1260 (50”) 1140 (45”)   
Reinforced Hoe Bucket 0.60 (0.79) 0.55 (0.72) 1045 (41”) 925 (36”)   *
Reinforced Hoe Bucket 0.70 (0.92) 0.60 (0.79) 1120 (44”) 1000 (39”)   *
One Point Ripper - -   
Slope-Finishing Bucket - 1000 (39”)×1700 (67”)   
V-Type Bucket - Side board angle: 45 degree   
so on.)
* Applicable only to 700 mm (28 in) grouser shoe.
12-8
SPECIFICATIONS
Specifications
ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A
A C
G
B
F
E
D
K J
I H MDAK-12-005
Model ZX200-5A ZX200LC-5A ZX210H-5A ZX210LCH-5A

Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm 2.91 m (9 ft 7 in) H Arm
Operating Weight 19700 kg (43500 lb) 20200 kg (44600 lb) 20900 kg (46100 lb) 21400 kg (47200 lb)
Base Machine Weight 15200 kg (33600 lb) 15800 kg (34900 lb) 16200 kg (35800 lb) 16700 kg (36900 lb)
Engine Type ISUZU GI-4HK1XKSA-02
ISO 14396 120 kW at 2000 min-1
Engine Power
ISO 9249 113 kW at 2000 min-1
Overall Width
A: 2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in) 2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in)
(Excluding back mirrors)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4470 mm (14 ft 8 in) 4170 mm (13 ft 8 in) 4470 mm (14 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in) 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idle Center 3370 mm (11 ft 1 in) 3660 mm (12 ft) 3370 mm (11 ft 1 in) 3660 mm (12 ft)
600 mm (24 in)
(Reinforced Grouser shoe)
44 kPa (0.45 kgf/ 42 kPa (0.43 kgf/ 47 kPa (0.48 kgf/ 44 kPa (0.45 kgf/
Ground Pressure
cm2, 6.4 psi) cm2, 6.1 psi) cm2, 6.8 psi) cm2, 6.4 psi)
Swing Speed 13.5 min (rpm)
–1

12-9
SPECIFICATIONS

ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A
G
F
A
MDAK-12-006
Model ZX200-5A, 200LC-5A ZX210H-5A, 210LCH-5A

2.42 m (7 ft 11 in) Arm 2.91 m (9 ft 7 in) Arm 2.91 m (9 ft 7 in) H Arm
Category
Item
mm ft·in mm ft·in mm ft·in
D: Maximum Dumping Height 6830 22’ 5” 7180 23’ 7” 7180 23’ 7”
E: Overall Height 3180 10’ 5” 3010 9’ 11” 3010 9’ 11”
F: Overall Length 9750 32’ 0” 9660 31’ 8” 9660 31’ 8”
fNOTE: The dimensions do not include the height of the shoe lug (except Item E).
12-10
SPECIFICATIONS

ZX200-5A
600 mm (24”) 700 mm (28”) 800 mm (31”)
Shoe Width
Grouser Shoe Grouser Shoe Grouser Shoe
For Ordinary Ground For Weak Footing For Weak Footing
Application
(Standard) (Option) (Option)
kg 19700 20000 20300
Operating Weight
(lb) (43500) (44100) (44800)
kg 15200 15600 15900
Base Machine Weight
(lb) (33600) (34400) (35100)
mm 2950 2950 2950
Cab Height
(ft·in) (9’ 8”) (9’ 8”) (9’ 8”)
Minimum Ground mm *450 *450 *450
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4170 4170 4170
(ft·in) (13’ 8”) (13’ 8”) (13’ 8”)
mm 2800 2900 3000
Undercarriage Width
(ft·in) (9’ 2”) (9’ 6”) (9’ 10”)
44 kPa 38 kPa 34 kPa
Ground Pressure
(0.45 kgf/cm2, 6.4 psi) (0.39 kgf/cm2, 5.5 psi) (0.35 kgf/cm2, 4.9 psi)
600 mm (24”) 760 mm (30”) 600 mm (24”)

Shoe Width
Pad Crawler Shoe Triangular Shoe Flat Shoe
For Paved Road For Weak Footing For Paved Road
Application
(Option) (Option) (Option)
kg 20000 20700 20500
Operating Weight
(lb) (44100) (45700) (45200)
kg 15500 16300 16100
Base Machine Weight
(lb) (34200) (36000) (35500)
mm 3030 2960 2990
Cab Height
(ft·in) (9’ 11”) (9’ 9”) (9’ 10”)
Clearance (ft·in) (1’ 9”) (1’ 7”) (1’ 7”)
mm 4290 4300 4200
(ft·in) (14’ 1”) (14’ 1”) (13’ 9”)
mm 2800 2960 2800
Undercarriage Width
(ft·in) (9’ 2”) (9’ 9”) (9’ 2”)
Ground Pressure
fNOTE:
12-11
SPECIFICATIONS

ZX200LC-5A
600 mm (24”) 700 mm (28”) 800 mm (31”)
Shoe Width
Application
kg 20200 20600 20900
Operating Weight
(lb) (44600) (45500) (46100)
kg 15800 16200 16500
Base Machine Weight
(lb) (34900) (35800) (36400)
mm 2950 2950 2950
Cab Height
(ft·in) (9’ 8”) (9’ 8”) (9’ 8”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4470 4470 4470
(ft·in) (14’ 8”) (14’ 8”) (14’ 8”)
mm 2990 3090 3190
Undercarriage Width
(ft·in) (9’ 10”) (10’ 2”) (10’ 6”)
Ground Pressure
600 mm (24”) 760 mm (30”) 900 mm (35”) 600 mm (24”)

Shoe Width
Pad Crawler Shoe Triangular Shoe Triangular Shoe Flat Shoe
For Paved Road For Weak Footing For Weak Footing For Paved Road
Application
kg 21000 21300 22400 21100
Operating Weight
(lb) (46300) (47000) (49400) (46600)
kg 16600 16900 18000 16700
Base Machine Weight
(lb) (36600) (37300) (39700) (36900)
mm 3030 2960 2960 2990
Cab Height
(ft·in) (9’ 11”) (9’ 9”) (9’ 9”) (9’ 10”)
Clearance (ft·in) (1’ 9”) (1’ 7”) (1’ 7”) (1’ 7”)
mm 4590 4600 4600 4490
(ft·in) (15’ 1”) (15’ 1”) (15’ 1”) (14’ 9”)
mm 2990 3150 3290 2990
Undercarriage Width
(ft·in) (9’ 10”) (10’ 4”) (10’ 10”) (9’ 10”)
Ground Pressure (0.44 kgf/cm2, (0.35 kgf/cm2, (0.31 kgf/cm2, (0.45 kgf/cm2,
6.2 psi) 4.9 psi) 4.4 psi) 6.4 psi)
fNOTE:
12-12
SPECIFICATIONS

ZX210H-5A
600 mm (24”)
700 mm (28”) 800 mm (31”)
Shoe Width Reinforced Grouser
Grouser Shoe Grouser Shoe
Shoe
Application
kg 20900 21200 21400
Operating Weight
(lb) (46100) (46800) (47200)
kg 16200 16400 16700
Base Machine Weight
(lb) (35800) (36200) (36900)
mm 2950 2950 2950
Cab Height
(ft·in) (9’ 8”) (9’ 8”) (9’ 8”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4170 4170 4170
(ft·in) (13’ 8”) (13’ 8”) (13’ 8”)
mm 2800 2900 3000
Undercarriage Width
(ft·in) (9’ 2”) (9’ 6”) (9’ 10”)
Ground Pressure
600 mm (24”) 760 mm (30”) 600 mm (24”)

Shoe Width
Pad Crawler Shoe Triangular Shoe Flat Shoe
For Paved Road For Weak Footing For Paved Road
Application
kg 21100 21800 21600
Operating Weight
(lb) (46600) (48100) (47700)
kg 16400 17100 16900
Base Machine Weight
(lb) (36200) (37700) (37300)
mm 3030 2960 2990
Cab Height
(ft·in) (9’ 11”) (9’ 9”) (9’ 10”)
Clearance (ft·in) (1’ 9”) (1’ 7”) (1’ 7”)
mm 4290 4300 4200
(ft·in) (14’ 1”) (14’ 1”) (13’ 9”)
mm 2800 2960 2800
Undercarriage Width
(ft·in) (9’ 2”) (9’ 9”) (9’ 2”)
Ground Pressure
fNOTE:
 The specification for the front-end attachment is for 2.91 m (9 ft 7 in) H arm with PCSA 0.80 m3 (1.05 yd3) bucket.
 Other than 600 mm (24 in) reinforced 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.
12-13
SPECIFICATIONS

ZX210LCH-5A
600 mm (24”)
700 mm (28”) 800 mm (31”)
Shoe
Application
kg 21400 21700 22000
Operating Weight
(lb) (47200) (47900) (48600)
kg 16700 16900 17200
Base Machine Weight
(lb) (36900) (37300) (38000)
mm 2950 2950 2950
Cab Height
(ft·in) (9’ 8”) (9’ 8”) (9’ 8”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4470 4470 4470
(ft·in) (14’ 8”) (14’ 8”) (14’ 8”)
mm 2990 3090 3190
Undercarriage Width
(ft·in) (9’ 10”) (10’ 2”) (10’ 6”)
Ground Pressure
600 mm (24”) 760 mm (30”) 900 mm (35”) 600 mm (24”)

Shoe Width
Pad Crawler Shoe Triangular Shoe Triangular Shoe Flat Shoe
For Paved Road For Weak Footing For Weak Footing For Paved Road
Application
kg 22000 22400 23500 22200
Operating Weight
(lb) (48600) (49400) (51900) (49000)
kg 17300 17700 18700 17400
Base Machine Weight
(lb) (38200) (39100) (41300) (38400)
mm 3030 2960 2960 2990
Cab Height
(ft·in) (9’ 11”) (9’ 9”) (9’ 9”) (9’ 10”)
Clearance (ft·in) (1’ 9”) (1’ 7”) (1’ 7”) (1’ 7”)
mm 4590 4600 4600 4490
(ft·in) (15’ 1”) (15’ 1”) (15’ 1”) (14’ 9”)
mm 2990 3150 3290 2990
Undercarriage Width
(ft·in) (9’ 10”) (10’ 4”) (10’ 10”) (9’ 10”)
6.5 psi) 5.2 psi) 4.6 psi) 6.7 psi)
fNOTE:
12-14
SPECIFICATIONS

ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A
The mark in the arc ( ) is for ZX200LC-5A.

ZX210H- ZX210LCH-
m3 (yd3) mm (in) ZX200-5A, 200LC-5A
5A 5A
Bucket
Without 2.42 m 2.91 m
With Side 2.91 m (9’ 7”)
Heaped CECE side (7’ 11”) (9’ 7”)
Cutter H Arm
cutter Arm Arm
0.51 0.45
850 (33”) 720 (28”)    
(0.67) (0.59)
0.80 0.70 1140 1030
   
(1.05) (0.92) (45”) (41”)
0.91 0.80 1280 1150 
Hoe Bucket   
(1.19) (1.05) (50”) (45”) ()
1.10 0.90 1440 1330  
 
(1.44) (1.18) (57”) (52”) () ()
1.20 1.00 1450
-    
(1.57) (1.31) (57”)
0.80 0.70 1140 1030
Reinforced Hoe Bucket    
(1.05) (0.92) (45”) (41”)
Reinforced Hoe Bucket 0.80 0.70 1140 1030
   
(Transverse-Type-Pin) (1.05) (0.92) (45”) (41”)
0.80 0.70 1140 1030
Reinforced Hoe Bucket (HD Type)    
(1.05) (0.92) (45”) (41”)
0.91 0.80 1260 1150 
Reinforced Hoe Bucket   
(1.19) (1.05) (50”) (45”) ()
0.60 0.50
Ripper Bucket - 800 (31”)    
(0.79) (0.65)
One Point Ripper - -    
1100 (43”)×1800
Slope-Finishing Bucket -    
(71”)
Side board angle: 45
V-Type Bucket 0.4 (0.52)    
degree
so on.)
12-15
SPECIFICATIONS
Specifications
A C
G
B
F
E
D
K J
I H MDAK-12-005
Model ZX210K-5A ZX210LCK-5A

Type of Front-End Attachment 2.91 m (9 ft 7 in) K Arm
Operating Weight 21000 kg (46300 lb) 21500 kg (47400 lb)
Base Machine Weight 16300 kg (36000 lb) 16800 kg (37100 lb)
Engine Type ISUZU GI-4HK1XKSA-02
ISO 14396 120 kW at 2000 min-1
Engine Power
ISO 9249 113 kW at 2000 min-1
A: Overall Width (Excluding back mirrors) 2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4470 mm (14 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idle Center 3370 mm (11 ft 1 in) 3660 mm (12 ft)
K: Track Shoe Width 600 mm (24 in) (Reinforced Grouser shoe)
Ground Pressure 47 kPa (0.48 kgf/cm2, 6.8 psi) 44 kPa (0.45 kgf/cm2, 6.4 psi)
–1

12-16
SPECIFICATIONS

G
F
A
MDAK-12-006
2.91 m (9 ft 7 in) K Arm

Category
Backhoe
Item
mm ft·in
A: Maximum Digging Reach 9920 32’ 7”
B: Maximum Digging Depth 6670 21’ 11”
C: Maximum Cutting Height 10040 32’ 11”
D: Maximum Dumping Height 7180 23’ 7”
E: Overall Height 3010 9’ 11”
F: Overall Length 9660 31’ 8”
G: Minimum Swing Radius 3180 10’ 5”
fNOTE: The dimensions do not include the height of the shoe lug (except Item E).
12-17
SPECIFICATIONS

ZX210K-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Grouser Shoe Grouser Shoe Flat Shoe
Shoe
For Ordinary For Weak Footing For Weak Footing For Paved Road
Application Ground (Standard) (Option) (Option) (Option)
kg 21000 21300 21500 21700
Operating Weight (46300) (47000) (47400)
(lb) (47900)
kg 16300 16500 16800 17000
Base Machine Weight (36000) (36400) (37100)
(lb) (37500)
mm 2950 2950 2950 2990
Cab Height (9’ 8”) (9’ 8”) (9’ 8”)
(ft·in) (9’ 10”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”) (1’ 7”)
mm 4170 4170 4170 4200
Undercarriage Length (13’ 8”) (13’ 8”) (13’ 8”)
(ft·in) (13’ 10”)
mm 2800 2900 3000 2800
Undercarriage Width (9’ 2”) (9’ 6”) (9’ 10”)
(ft·in) (9’ 2”)
6.8 psi) 5.9 psi) 5.2 psi) 7.0 psi)
ZX210LCK-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
For Ordinary For Weak Footing For Weak Footing For Paved Road
Application Ground (Standard) (Option) (Option) (Option)
kg 21500 21800 22100 22300
Operating Weight (47400) (48100) (48800) (49200)
(lb)
kg 16800 17000 17300 17500
Base Machine Weight (37100) (37500) (38200) (38600)
(lb)
mm 2950 2950 2950 2990
Cab Height (9’ 8”) (9’ 8”) (9’ 8”) (9’ 10”)
(ft·in)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”) (1’ 7”)
mm 4470 4470 4470 4490
Undercarriage Length (14’ 8”) (14’ 8”) (14’ 8”) (14’ 9”)
(ft·in)
mm 2990 3090 3190 2990
Undercarriage Width (9’ 10”) (10’ 2”) (10’ 6”) (9’ 10”)
(ft·in)
6.4 psi) 5.5 psi) 4.9 psi) 6.7 psi)
f NOTE:
 The specification for the front-end attachment is for 2.91 m (9 ft 7 in) K arm with PCSA 0.80 m3 (1.05 yd3) bucket.
12-18
SPECIFICATIONS

The mark in the arc ( ) is for ZX210LCK-5A.
Bucket Capacity Bucket Width Front-End
m3 (yd3) mm (in) Attachment
Bucket
Without side 2.91 m (9’ 7”)
Heaped CECE With Side Cutter
cutter K Arm
0.51 (0.67) 0.45 (0.59) 850 (33”) 720 (28”) 
0.80 (1.05) 0.70 (0.92) 1140 (45”) 1030 (41”) 
Hoe Bucket 
0.91 (1.19) 0.80 (1.05) 1280 (50”) 1150 (45”)
()
1.10 (1.44) 0.90 (1.18) 1460 (57”) 1330 (52”)  ()
Reinforced Hoe Bucket 0.80 (1.05) 0.70 (0.92) 1140 (45”) 1030 (41”) 
0.80 (1.05) 0.70 (0.92) 1140 (45”) 1030 (41”) 
(Transverse-Type-Pin)
Reinforced Hoe Bucket (HD
0.80 (1.05) 0.70 (0.92) 1140 (45”) 1030 (41”) 
Type)

Reinforced Hoe Bucket 0.91 (1.19) 0.80 (1.05) 1280 (50”) 1150 (45”)
()
fNOTE: : For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.
: For light duty excavating (digging and loading operation of dry, loosened earth, sand, mud and so on.
12-19
SPECIFICATIONS
Specifications
ZX240-5A, 240LC-5A
A
C
G
B
F
E
D
K J
I H MDAK-12-007
Model ZX240-5A ZX240LC-5A

Engine Type Isuzu GH-4HKSA-01
ISO 14396 133 kW at 2000 min-1
Engine Power
ISO 9249 127 kW at 2000 min-1
A : Overall Width (Excluding back mirrors) 2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in)
B : Cab Height 3010 mm (9 ft 11 in)
C : Rear End Swing Radius 3140 mm (10 ft 4 in)
D : Minimum Ground Clearance *460 mm (18 in)
E : Counterweight Clearance *1080 mm (3 ft 7 in)
F : Engine Cover Height *2560 mm (8 ft 5 in)
G : Overall Width of Upperstructure 2870 mm (9 ft 5 in)
H : Undercarriage Length 4260 mm (14 ft) 4640 mm (15 ft 3 in)
I : Undercarriage Width 2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in)
J : Sprocket Center to Idler Center 3460 mm (11 ft 5 in) 3850 mm (12 ft 8 in)
K : Track Shoe Width 600 mm (24 in) (Grouser shoe)
–1

12-20
SPECIFICATIONS
Specifications
ZX250H-5A, 250LCH-5A
A
C
G
B
F
E
D
K J
I H MDAK-12-007
Model ZX250H-5A ZX250LCH-5A

Type of Front-End Attachment 2.96 m (9 ft 9 in) H Arm
Engine Type Isuzu GH-4HK1XKSA-01
ISO 14396 133 kW at 2000 min-1
Engine Power
ISO 9249 127 kW at 2000 min-1
K : Track Shoe Width 600 mm (24 in) (Reinforced Grouser shoe)
Ground Pressure 55 kPa 51 kPa
(0.56 kgf/cm2, 8.0 psi) (0.52 kgf/cm2, 7.4 psi)
12-21
SPECIFICATIONS
Specifications
A
C
G
B
F
E
D
K J
I H MDAK-12-007

ISO 14396 133 kW at 2000 min-1
Engine Power
ISO 9249 127 kW at 2000 min-1
12-22
SPECIFICATIONS
Working Ranges
ZX240-5A, 240LC-5A
MDAK-12-008
A : Maximum Digging Reach 9880 32’ 5” 10290 33’ 9” 10910 35’ 10”
B : Maximum Digging Depth *6500 *21’ 4” *6960 *22’ 10” *7610 *25’ 0”
C : Maximum Cutting Height *9950 *32’ 8” *10160 *33’ 4” *10560 *34’ 8”
D : Maximum Dumping Height *6990 *22’ 11” *7200 *23’ 8” *7580 *24’ 10”
E : Overall Height 3370 11’ 1” 3080 10’ 1” 3320 10’ 11”
F : Overall Length 10470 34’ 4” 10360 34’ 0” 10400 34’ 1”
G : Minimum Swing Radius 3480 11’ 5” 3440 11’ 3” 3430 11’ 3”
fNOTE: The dimensions do not include height of the shoe lug (except Item E.).
12-23
SPECIFICATIONS
Working Ranges
ZX250H-5A, 250LCH-5A, 250K-5A, 250LCK-5A
MDAK-12-008
Model ZX250H-5A, 250LCH-5A ZX250K-5A, 250LCK-5A

Category 2.96 m (9 ft 9 in) H Arm 2.96 m (9 ft 9 in) K Arm
Backhoe Backhoe
Item mm ft·in mm ft·in
A : Maximum Digging Reach 10290 33’ 9” 10290 33’ 9”
B : Maximum Digging Depth *6960 *22’ 10” *6960 *22’ 10”
C : Maximum Cutting Height *10160 *33’ 4” *10160 *33’ 4”
D : Maximum Dumping Height *7200 *23’ 8” *7200 *23’ 8”
E : Overall Height 3080 10’ 1” 3080 10’ 1”
F : Overall Length 10360 34’ 0” 10360 34’ 0”
G : Minimum Swing Radius 3440 11’ 3” 3440 11’ 3”
fNOTE: The dimensions do not include height of the shoe lug (except Item E.).
12-24
SPECIFICATIONS

ZX240-5A
600 mm (24”) 700 mm (28”) 800 mm (31”)
Shoe Width
For Ordinary
For Weak Footing For Weak Footing
Application Ground
(Option) (Option)
(Standard)
kg 23600 24000 24200
Operating Weight
(lb) (52100) (53000) (53400)
kg 18000 18400 18700
Base Machine Weight
(lb) (39700) (40600) (41300)
mm 3010 3010 3010
Cab Height
(ft·in) (9’ 11”) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4260 4260 4260
(ft·in) (15’ 3”) (15’ 3”) (15’ 3”)
mm 2990 3090 3190
Undercarriage Width
(ft·in) (9’ 10”) (10’ 2”) (10’ 6”)
Ground Pressure (0.53 kgf/cm2, 7.5 (0.46 kgf/cm2, 6.5 (0.40 kgf/cm2, 5.7
psi) psi) psi)
600 mm (24”) 760 mm (30”) 900 mm (35”)

Shoe Width
Flat Shoe Triangular Shoe Triangular Shoe
For Paved Road For Weak Footing For Weak Footing
Application
kg 24400 24600 25600
Operating Weight
(lb) (53800) (54300) (56500)
kg 18800 19000 20000
Base Machine Weight
(lb) (41500) (41900) (44100)
mm 3050 3020 3020
Cab Height
(ft·in) (10’) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 8”) (1’ 7”) (1’ 7”)
mm 4280 4370 4370
(ft·in) (14’ 1”) (14’ 4”) (14’ 4”)
mm 2990 3150 3290
Undercarriage Width
(ft·in) (9’ 10”) (10’ 4”) (10’ 10”)
psi) psi) psi)
fNOTE:
12-25
SPECIFICATIONS

ZX240LC-5A
600 mm (24”) 700 mm (28”) 800 mm (31”)
Shoe Width
For Ordinary
Application Ground
(Option) (Option)
(Standard)
kg 24200 24600 25000
Operating Weight
(lb) (53400) (54300) (55200)
kg 18600 19100 19400
Base Machine Weight
(lb) (41100) (42200) (42800)
mm 3010 3010 3010
Cab Height
(ft·in) (9’ 11”) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4640 4640 4640
(ft·in) (15’ 3”) (15’ 3”) (15’ 3”)
mm 3190 3290 3390
Undercarriage Width
(ft·in) (10’ 6”) (10’ 10”) (11’ 2”)
psi) psi) psi)
600 mm (24”) 760 mm (30”) 900 mm (35”)

Shoe Width
Application
kg 25100 25300 26400
Operating Weight
(lb) (55400) (55800) (58300)
kg 19500 19700 20900
Base Machine Weight
(lb) (43000) (43500) (46100)
mm 3050 3020 3020
Cab Height
(ft·in) (10’) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 8”) (1’ 7”) (1’ 7”)
mm 4660 4750 4750
(ft·in) (15’ 4”) (15’ 7”) (15’ 7”)
mm 3190 3350 3490
Undercarriage Width
(ft·in) (10’ 6”) (11’) (11’ 5”)
psi) psi) psi)
fNOTE:
12-26
SPECIFICATIONS

ZX250H-5A
600 mm (24”)
700 mm (28”) 800 mm (31”)
Shoe
Application
kg 25000 25300 25600
Operating Weight
(lb) (55200) (55800) (56500)
kg 19100 19400 19700
Base Machine Weight
(lb) (42200) (42800) (43500)
mm 3010 3010 3010
Cab Height
(ft·in) (9’ 11”) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4260 4260 4260
(ft·in) (14’) (14’) (14’)
mm 2990 3090 3190
Undercarriage Width
(ft·in) (9’ 10”) (10’ 2”) (10’ 6”)
Ground Pressure
600 mm (24”) 760 mm (30”) 900 mm (35”)

Shoe Width
Application
kg 25700 25900 27000
Operating Weight
(lb) (56700) (57100) (59600)
kg 19800 20000 21100
Base Machine Weight
(lb) (43700) (44100) (46600)
mm 3050 3020 3020
Cab Height
(ft·in) (10’) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 8”) (1’ 7”) (1’ 7”)
mm 4280 4370 4370
(ft·in) (14’ 1”) (14’ 4”) (14’ 4”)
mm 2990 3150 3290
Undercarriage Width
(ft·in) (9’ 10”) (10’ 4”) (10’ 10”)
Ground Pressure
fNOTE:
12-27
SPECIFICATIONS

ZX250LCH-5A
600 mm (24”)
700 mm (28”) 800 mm (31”)
Shoe
Application
kg 25500 25800 26100
Operating Weight
(lb) (56300) (56900) (57600)
kg 19600 20000 20300
Base Machine Weight
(lb) (43300) (44100) (44800)
mm 3010 3010 3010
Cab Height
(ft·in) (9’ 11”) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”)
mm 4640 4640 4640
(ft·in) (15’ 3”) (15’ 3”) (15’ 3”)
mm 3190 3290 3390
Undercarriage Width
(ft·in) (10’ 6”) (10’ 10”) (11’ 2”)
Ground Pressure
600 mm (24”) 760 mm (30”) 900 mm (35”)

Shoe Width
Application
kg 26300 26500 27600
Operating Weight
(lb) (58000) (58500) (60900)
kg 20400 20600 21700
Base Machine Weight
(lb) (45000) (45500) (47900)
mm 3050 3020 3020
Cab Height
(ft·in) (10’) (9’ 11”) (9’ 11”)
Clearance (ft·in) (1’ 8”) (1’ 7”) (1’ 7”)
mm 4660 4750 4750
(ft·in) (15’ 4”) (15’ 7”) (15’ 7”)
mm 3190 3350 3490
Undercarriage Width
(ft·in) (10’ 6”) (11’) (11’ 5”)
Ground Pressure
fNOTE:
12-28
SPECIFICATIONS

ZX250K-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
Application
kg 25400 25700 26000 26100
Operating Weight
(lb) (56000) (56700) (57400) (57600)
kg 19500 19800 20100 20200
Base Machine Weight
(lb) (43000) (43700) (44400) (44600)
mm 3140 3140 3140 3180
Cab Height
(ft·in) (10’ 4”) (10’ 4”) (10’ 4”) (10’ 5”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”) (1’ 8”)
mm 4260 4260 4260 4280
(ft·in) (14’) (14’) (14’) (14’ 1”)
mm 2990 3090 3190 2990
Undercarriage Width
(ft·in) (9’ 10”) (10’ 2”) (10’ 6”) (9’ 10”)
Ground Pressure
ZX250LCK-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
Application
kg 25900 26300 26600 26700
Operating Weight
(lb) (57100) (58000) (58700) (58900)
kg 20100 20400 20700 20800
Base Machine Weight
(lb) (44400) (45000) (45700) (45900)
mm 3140 3140 3140 3180
Cab Height
(ft·in) (10’ 4”) (10’ 4”) (10’ 4”) (10’ 5”)
Clearance (ft·in) (1’ 6”) (1’ 6”) (1’ 6”) (1’ 8”)
mm 4640 4640 4640 4660
(ft·in) (15’ 3”) (15’ 3”) (15’ 3”) (15’ 4”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’ 6”) (10’ 10”) (11’ 2”) (10’ 6”)
Ground Pressure
fNOTE:
12-29
SPECIFICATIONS

ZX240-5A, 240LC-5A

m3 (yd3) mm (in)
Bucket 2.50 m 2.96 m 3.61 m
With Side Without
Heaped CECE (8’ 2”) (9’ 9”) (11’ 10”)
Cutter side cutter
Arm Arm Arm
0.80 (1.05) 0.70 (0.92) 1080 (43”) 950 (37”)   

1.00 (1.31) 0.90 (1.18) 1260 (50”) 1130 (44”)  
()

Hoe Bucket 1.10 (1.44) 1.00 (1.31) 1350 (53”) 1220 (48”)  
()

1.25 (1.64) 1.10 (1.44) 1490 (59”) 1360 (54”)  
()
1.40 (1.83) 1.20 (1.57) 1630 (64”) 1500 (59”)   

Reinforced Hoe Bucket 1.00 (1.31) 0.90 (1.18) 1260 (50”) 1130 (44”)  
()
Reinforced Hoe Bucket 
1.00 (1.31) 0.90 (1.18) 1270 (50”) 1140 (45”)  
(Transverse-Type-Pin) ()

Reinforced Hoe Bucket (HD Type) 1.00 (1.31) 0.90 (1.18) 1270 (50”) 1140 (45”)  
()

Reinforced Hoe Bucket 1.10 (1.44) 1.00 (1.31) 1350 (53”) 1220 (48”)  
()
Rock Bucket 0.92 (1.20) 0.80 (1.05) 1180 (46”) 1130 (44”)   
Ripper Bucket 0.80 (1.05) 0.70 (0.95) - 1000 (39”)   
One Point Ripper - -   
so on.)
12-30
SPECIFICATIONS

ZX250H-5A, 250LCH-5A, 250K-5A, 250LCK-5A

ZX250H-5A, ZX250K-5A,
m3 (yd3) mm (in)
Bucket 250LCH-5A 250LCK-5A
With Side Without 2.96 m (9’ 9”) 2.96 m (9’ 9”)
Heaped CECE
Cutter side cutter H Arm K Arm
0.80 (1.05) 0.70 (0.92) 1080 (43”) 950 (37”)  
1.00 (1.31) 0.90 (1.18) 1260 (50”) 1130 (44”)  
Hoe Bucket 1.10 (1.44) 1.00 (1.31) 1350 (53”) 1220 (48”)  
1.25 (1.64) 1.10 (1.44) 1490 (59”) 1360 (54”)  
1.40 (1.83) 1.20 (1.57) 1630 (64”) 1500 (59”)  
Reinforced Hoe Bucket 1.00 (1.31) 0.90 (1.18) 1260 (50”) 1130 (44”)  
1.00 (1.31) 0.90 (1.18) 1270 (50”) 1140 (45”)  
(Transverse-Type-Pin)
Reinforced Hoe Bucket (HD Type) 1.00 (1.31) 0.90 (1.18) 1270 (50”) 1140 (45”)  
Reinforced Hoe Bucket 1.10 (1.44) 1.00 (1.31) 1350 (53”) 1220 (48”)  
Rock Bucket 0.92 (1.20) 0.80 (1.05) 1180 (46”) 1130 (44”)  
Ripper Bucket 0.80 (1.05) 0.70 (0.95) - 1000 (39”)  
One Point Ripper - -  
so on.)
12-31
SPECIFICATIONS
Specifications
ZX300-5A, 300LC-5A
A
G C
B
F
E
D
K J
I H
MDAK-12-013

ISO 14396 178 kW at 1900 min-1
Engine Power
ISO 9249 171 kW at 1900 min-1
A : Overall Width (Excluding back mirrors) 3190 mm (10 ft 6 in)
D : Minimum Ground Clearance *510 mm (1 ft 9 in)
H : Undercarriage Length 4640 mm (15 ft 3 in) 4940 mm (16 ft 3 in)
I : Undercarriage Width 3190 mm (10 ft 6 in)
–1

12-32
SPECIFICATIONS
Working Ranges
ZX300-5A, 300LC-5A
F
A
MDAK-12-010
A: Maximum Digging Reach 10060 33’ 10710 35’ 2” 11270 37’
B: Maximum Digging Depth *6530 *21’ 5” *7220 *23’ 8” *7870 *25’ 10”
C: Maximum Cutting Height *9910 *32’ 6” *10270 *33’ 8” *10470 *34’ 4”
D: Maximum Dumping Height *6980 *22’ 11” *7330 *24’ 1” *7540 *24’ 9”
E: Overall Height 3450 11’ 4” 3200 10’ 6” 3380 11’ 1”
F: Overall Length 10710 35’ 2” 10620 34’ 10” 10670 35’
12-33
SPECIFICATIONS

ZX300-5A
600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe Width
Application
kg 28100 28700 29100 29000
Operating Weight
(lb) (62000) (63300) (64200) (64000)
kg 21900 22500 22900 22800
Base Machine Weight
(lb) (48300) (49700) (50500) (50300)
mm 3120 3120 3120 3160
Cab Height
(ft·in) (10’3”) (10’3”) (10’3”) (10’4”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’10”)
mm 4640 4640 4640 4720
(ft·in) (15’3”) (15’3”) (15’3”) (15’6”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’1”) (10’6”)
Ground Pressure
ZX300LC-5A
600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe Width
Application
kg 28900 29500 29900 29800
Operating Weight
(lb) (63800) (65100) (66000) (65700)
kg 22600 23200 23700 23600
Base Machine Weight
(lb) (49900) (51200) (52300) (52100)
mm 3120 3120 3120 3160
Cab Height
(ft·in) (10’3”) (10’3”) (10’3”) (10’4”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’10”)
mm 4940 4940 4940 5020
(ft·in) (16’3”) (16’3”) (16’3”) (16’6”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’2”) (10’6”)
Ground Pressure
fNOTE:
12-34
SPECIFICATIONS

ZX300-5 class
The mark in the arc ( ) is for ZX300LC-5A
m3 (yd3) mm (in)
Bucket 3.2 m 3.2 m
With Side Without 2.42 m
Heaped CECE (10’3”) (12’4”)
Cutter side cutter (7’11”) Arm
Arm K Arm
1.10 1.00 1350 1220 
 
(1.44) (1.31) (53”) (48”) ()
1.25 1.10 1490 1360 
 
(1.64) (1.44) (59”) (54”) ()
Hoe Bucket
1.40 1.20 1630 1500 
 
(1.83) (1.57) (64”) (59”) ()
1.62 1.40 1830 1700
  
(2.12) (1.83) (72”) (67”)
1.10 1.00 1350 1220 
Reinforced Hoe Bucket  
(1.44) (1.31) (53”) (48”) ()
Reinforced Hoe Bucket 1.10 1.00 1360 1230 
 
(HD Type) (1.44) (1.31) (54”) (48”) ()
1.40 1.20 1630 1500 
Reinforced Hoe Bucket  
(1.83) (1.57) (64”) (59”) ()
Rock Bucket 0.92 0.80 1180 1130
  
(1.20) (1.05) (46”) (44”)
0.80 0.70 1000
Ripper Bucket -   
(1.05) (0.92) (39”)
One Point Ripper - -   
fNOTE: : For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.
: For light duty excavating (digging and loading operation of dry, loosened earth, sand, mud and so on.
so on.)
12-35
SPECIFICATIONS
Specifications
ZX330-5A, 330LC-5A
A
G C
B
F
E
D
K J
I H
MDAK-12-009

Type of Front-End Attachment 3.20 m (10 ft 6 in) Arm 3.20 m (10 ft 6 in) Arm
ISO 14396 200 kW at 1900 min-1
Engine Power
ISO 9249 190 kW at 1900 min-1
–1

12-36
SPECIFICATIONS
Specifications
ZX350H-5A, 350LCH-5A
A
G C
B
F
E
D
K J
I H
MDAK-12-009
Model ZX350H-5A ZX350LCH-5A

Type of Front-End Attachment 3.20 m (10 ft 6 in) H Arm
ISO 14396 200 kW at 1900 min-1
Engine Power
ISO 9249 190 kW at 1900 min-1
–1

12-37
SPECIFICATIONS
Specifications
A
G C
B
F
E
D
K J
I H
MDAK-12-009

ISO 14396 200 kW at 1900 min-1
Engine Power
ISO 9249 190 kW at 1900 min-1
K : Track Shoe Width 600 mm (24 in) (High Grouser shoe)
12-38
SPECIFICATIONS
Working Ranges
ZX350-5A, 350LC-5A
F
A
MDAK-12-010
B: Maximum Digging Depth *6840 *22’ 5” *7380 *24’ 3” *8180 *26’ 10”
C: Maximum Cutting Height *9990 *32’ 9” *10360 *34’ 0” *10750 *35’ 3”
D: Maximum Dumping Height *6940 *22’ 9” *7240 *23’ 9” *7630 *25’
E: Overall Height 3470 11’ 5” 3270 10’ 9” 3600 11’ 10”
F: Overall Length 11350 37’ 3” 11220 36’ 10” 11310 37’ 1”
12-39
SPECIFICATIONS
Working Ranges
ZX350H-5A, 350LCH-5A, 350K-5A, 350LCK-5A
F
A
MDAK-12-010
Model ZX350H-5A, 350LCH-5A ZX350K-5A, 350LCK-5A

Category 3.20 m (10 ft 6 in) H Arm 3.20 m (10 ft 6 in) K Arm
Backhoe
Item mm ft·in mm ft·in
A: Maximum Digging Reach 11100 36’ 5” 11000 36’ 5”
B: Maximum Digging Depth *7380 *24’ 3” *7380 *24’ 3”
C: Maximum Cutting Height *10360 *34’ 0” *10360 *34’ 0”
D: Maximum Dumping Height *7240 *23’ 9” *7240 *23’ 9”
E: Overall Height 3270 10’ 9” 3290 10’ 10”
F: Overall Length 11220 36’ 10” 11220 36’ 10”
G: Minimum Swing Radius 4460 14’ 8” 4460 14’ 8”
12-40
SPECIFICATIONS

ZX330-5A
600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe Width
Application
kg 31800 32300 32700 32600
Operating Weight
(lb) (70200) (71300) (72100) (71900)
kg 24200 24800 25100 25100
Base Machine Weight
(lb) (53400) (55400) (58700) (55400)
mm 3160 3160 3160 3200
Cab Height
(ft·in) (10’4”) (10’4”) (10’4”) (10’6”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’10”)
mm 4650 4650 4650 4650
(ft·in) (15’3”) (15’3”) (15’3”) (15’3”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’1”) (10’6”)
Ground Pressure
ZX330LC-5A
600 mm (24”) 700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe Width
Application
kg 32300 32900 33300 33200
Operating Weight
(lb) (71300) (72600) (73500) (73200)
kg 24700 25300 25700 25600
Base Machine Weight
(lb) (54500) (55800) (56700) (56500)
mm 3160 3160 3160 3200
Cab Height
(ft·in) (10’4”) (10’4”) (10’4”) (10’6”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’10”)
mm 4950 4950 4950 4670
(ft·in) (16’3”) (16’3”) (16’3”) (15’4”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’2”) (10’6”)
Ground Pressure
fNOTE:
12-41
SPECIFICATIONS

ZX350H-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
Application
kg 33900 34200 34600 34500
Operating Weight
(lb) (74800) (75400) (76300) (76100)
kg 25600 26000 26300 26300
Base Machine Weight
(lb) (56500) (57400) (58000) (58000)
mm 3160 3160 3160 3200
Cab Height
(ft·in) (10’4”) (10’4”) (10’4”) (10’6”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’9”)
mm 4650 4650 4650 4670
(ft·in) (15’3”) (15’3”) (15’3”) (15’4”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’1”) (10’6”)
Ground Pressure (0.70 kgf/cm2, 10.0 (0.60 kgf/cm2, 8.6 psi) (0.53 kgf/cm2, 7.5 psi) (0.71 kgf/cm2, 10.2
psi) psi)
ZX350LCH-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
Application
kg 34400 34800 35200 35100
Operating Weight
(lb) (75900) (76800) (77700) (77400)
kg 26100 26500 26900 26800
Base Machine Weight
(lb) (57600) (58500) (59400) (59100)
mm 3160 3160 3160 3200
Cab Height
(ft·in) (10’4”) (10’4”) (10’4”) (10’6”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’9”)
mm 4950 4950 4950 4970
(ft·in) (16’3”) (16’3”) (16’3”) (16’4”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’2”) (10’6”)
Ground Pressure
fNOTE:
12-42
SPECIFICATIONS

ZX350K-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
Application
kg 34200 34500 34900 34800
Operating Weight
(lb) (75400) (76100) (77000) (76800)
kg 26100 26400 26800 26700
Base Machine Weight
(lb) (57600) (58300) (59100) (58900)
mm 3290 3290 3290 3330
Cab Height
(ft·in) (10’10”) (10’10”) (10’10”) (10’11”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’9”)
mm 4650 4650 4650 4670
(ft·in) (15’3”) (15’3”) (15’3”) (15’4”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’2”) (10’6”)
Ground Pressure (0.72 kgf/cm2, 10.3 (0.63 kgf/cm2, 9.0 psi) (0.56 kgf/cm2, 7.8 psi) (0.53 kgf/cm2, 7.5 psi)
psi)
ZX350LCK-5A
600 mm (24”)
700 mm (28”) 800 mm (31”) 600 mm (24”)
Shoe
Application
kg 34800 35200 35600 35500
Operating Weight
(lb) (76800) (77700) (78500) (78300)
kg 26700 27100 27500 27400
Base Machine Weight
(lb) (58900) (59800) (60700) (60500)
mm 3290 3290 3290 3330
Cab Height
(ft·in) (10’10”) (10’10”) (10’10”) (10’11”)
Clearance (ft·in) (1’8”) (1’8”) (1’8”) (1’9”)
mm 4950 4950 4950 4970
(ft·in) (15’3”) (15’3”) (15’3”) (15’4”)
mm 3190 3290 3390 3190
Undercarriage Width
(ft·in) (10’6”) (10’10”) (11’2”) (10’6”)
Ground Pressure
fNOTE:
12-43
SPECIFICATIONS

ZX330-5 class

m3 (yd3) mm (in)
ZX350H-5A, ZX350K-5A,
ZX330-5A, 330LC-5A
Bucket With Without 350LCH-5A 350LCK-5A
Heaped CECE Side side 2.67 m 3.2 m 4m 3.2 m 3.2 m
Cutter cutter (8’9”) (10’6”) (13’2”) (10’6”) (10’6”)
Arm Arm Arm H Arm K Arm
1.15 1.00 1230 1100
    
(1.50) (1.31) (48”) (43”)
1.40 1.20 1410 1280
  ()  
(1.83) (1.57) (56”) (50”)
1.62 1.40 1590 1460
Hoe Bucket   ()  
(2.12) (1.83) (63”) (57”)
1.86 1.60 1640
-     
(2.43) (2.09) (65”)
1.40 1.20 1410 1280
(Super V)   ()  
(1.83) (1.57) (56”) (50”)
1.40 1.20 1410 1280
Reinforced Hoe Bucket   ()  
(1.83) (1.57) (56”) (50”)
1.40 1.20 1410 1280
  ()  
(1.83) (1.57) (56”) (50”)
1.62 1.40 1590 1460
(Super V)   ()  
(2.11) (1.83) (63”) (57”)
Rock Bucket 1.15 100 1200
-     
(1.50) (1.31) (47”)
1.38 1.20 1360
(Super V) -     
(1.81) (1.57) (54”)
1.38 1.20 1360
(Transverse-Type-Pin) -     
(1.81) (1.57) (54”)
1.50 1.30 1470
(Super V) -     
(1.96) (1.70) (58”)
1.50 1.30 1470
(Transverse-Type-Pin) -     
(1.96) (1.70) (58”)
0.90 0.80 1010
Ripper Bucket -     
(1.18) (1.05) (40”)
One Point Ripper - -     
so on.)
12-44
SPECIFICATIONS
(This page is only applicable to machines with CE marking.)
Sound Level Results

(2000/14/EC)
(2006/42/EC)
LwA: guaranteed sound power level of airborne noise (ISO
6395: 1988)
LpA: sound pressure level at operator’s station (ISO 6396: 2008)
Unit: dB(A)
LwA LpA
ZX130-5A 99 71
ZX160LC-5A 100 72
ZX200-5A, 200LC-5A,
210H-5A, 210LCH-5A, 102 70
210K-5A, 210LCK-5A
ZX240-5A, 240LC-5A,
250H-5A, 250LCH-5A, 102 71
250K-5A, 250LCK-5A
ZX300-5A, 300LC-5A,
330-5A, 330LC-5A, 350H-
105 73
5A, 350LCH-5A, 350K-5A,
350LCK-5A
Vibration Level
Vibration level for the earth-moving machinery transmitted
from the operator's seat are lower than or equal to the tested
vibrations for the relative machinery class, i.e. excavator at
EM6, in accordance to ISO 7096 when used as its intended use.
Hands/Arms: The acceleration to which the operator's hands

and arms will be exposed is lower than 2.5 m/s2.
Entire body: The acceleration to which the operator's entire
body will be exposed is lower than 0.5 m/s2.
fNOTE: The acceleration is measured in accordance with ISO

2631/1; ISO 5349 and SAE J1166.
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 because
the energy supply recharging the battery is not continuous
nor at a constant level.
12-45
SPECIFICATIONS
MEMO
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12-46
USING PAD CRAWLER SHOE
Using Pad Crawler Shoe

ZX120-5 class
Pad crawler is a track link on which a rubber pad is installed
so the machine does not damage road surfaces when
traveling. Be sure to observe all precautions for handling
pad crawler. Avoid operating the machine in the following
conditions:
Forbidden Operations
Do not operate on sharp, rocky, uneven surfaces, such as
river rock, gravel, etc.
M107-05-051
Do not allow engine oil, gasoline, etc. to remain on the
track, and avoid traveling in oil in order to reduce the
danger of slipping.
While raising the machine using the front attachment do

not allow the other side track to drive, possibly causing
personal injury, damaging or displacing pad crawler.
13-1
Traveling and Other Cautions

Do not keep the pad crawler shoe under direct sunlight for
more than three months.
Avoid reckless steering operations on concrete road to the

extent possible, as this will cause wear to the shoe lug. Also,
avoid running on asphalt road of more than 60 °C (140 °F)
in temperature, as this will cause wear to the shoe as well as
damage to the road surface.
Ease the machine down from the jacked-up position.

Do not let it drop.
M107-05-052
Pad crawler has large friction force. Therefore to avoid
damaging the pad crawler slowly operate the control levers to
gradually turn the machine.
After raising one side track with the front attachment, slowly
lower the pad crawler equipped machine.
If the pad crawler becomes severely damaged, contact your

nearest Hitachi Dealer for replacement.
13-2
Transporting
Transporting
dCAUTION: Fasten chains or cables to the machine

frame. Do not place chains or cables over or against
the hydraulic lines or hoses.
1. Place blocks in front of and behind the tracks.

2. Fasten each corner of the machine and front attachment M107-06-013
to the trailer with a chain or cable.
Precautions for Transporting Machines with Pad

Crawler Shoes
When transporting a machine with pad crawler shoes, be sure
to fasten the right and left track frames securely to the flatbed
with wire ropes and soft protectors, as shown. Do not allow
wire ropes to come into direct contact with pad crawler shoes.
Wire Rope
Soft Protector
Side Frame
Lower Roller
Pad Crawler Shoe
Flatbed M102-06-004
13-3
Check Track Sag --- every 50 hours

the track off the ground as shown.
Keep the angle between the boom and arm 90 to 110 ° and
position the bucket’s round side on the ground. Place blocks
under the machine frame to support the machine.
Rotate the raised track in reverse two full rotations and then
forward two full rotations. M104-07-067
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.
Track sag specifications

Model A
ZX120-5 class 250 to 280 mm (9.8 to 11.0 in)
fNOTE: Check track sag after thoroughly removing soil stuck

on the track area by washing. M107-07-068
Adjust Track Sag

Precautions for Adjusting Track Sag
1. If track sag is not within specifications, loosen or tighten
the track following the procedures shown on the next
page.
2. When adjusting track sag, lower the bucket to the
ground to raise one track off the ground. Repeat this
procedure to raise the other track. Each time, be sure to
place blocks under the machine frame to support the
machine.
3. After adjusting track sag of both tracks, move the
machine back and forth several times.
4. Check track sag again. If track sag is not within
specifications, repeat adjustment until correct sag is
obtained.
13-4
Loosen the Track
dCAUTION: Do not loosen valve (1) quickly or loosen

it 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).
IMPORTANT: When gravel or mud is packed between

M107-07-075
2. Between 1 to 1.5 turns of valve (1) is sufficient to loosen 1
the track. 2
raised track.
clockwise and tighten to 90 N·m (9 kgf·m, 66 lbf·ft).
Tighten the Track

Grease Outlet
d CAUTION: It is abnormal if the track remains tight
after turning valve (1) counterclockwise or if the track M104-07-119
is still loose after charging grease to fitting (2). In such
cases, NEVER ATTEMPT TO DISASSEMBLE the track or
track adjuster, because of dangerous high-pressure
grease inside the track adjuster. See your authorized
dealer immediately.

13-5
CONTROL LEVER
Control Lever (Hitachi Pattern) (Optional)
dWARNING:
 Never place any part of the body beyond window
frame. It could be crushed by the boom if boom 1 5
control lever is accidentally bumped or otherwise
engaged.
Never remove the window sash bar. 4 3 7 8
 Make sure you know the location and function of

each control before operating. 2 6
A label showing the control patterns of the levers and pedals is

attached on the right side in the cab.
When a lever is released, it will automatically return to neutral,

and that machine function will stop.
1- Swing Right
2- Swing Left
3- Arm Roll-In
4- Arm Roll-Out MDAA-01-288
5- Boom Lower
6- Boom Raise
1
7- Bucket Roll-In 4
8- Bucket Roll-Out 2
M104-05-001
7 5
8
M104-05-002
13-6
BLADE LEVER
Blade Lever
ZX130-5A
Use blade lever (1) on the operator’s right to raise and lower
the blade.
4
When the lever is released, it automatically returns to
neutral, keeping the blade in its position until the lever is
operated again.
3
1- Blade Lever 1
2- Blade Raise 2
3- Neutral
4- Blade Lower
MDAA-13-001
Precautions for Blade Operation

This blade is designed as a light service attachment for the
hydraulic excavator. Please keep the following points in
mind:
2
1. This blade is designed to be used for dozing work only.
Do not attempt to dig deeply with the blade. Doing so
will damage not only the blade but the undercarriage as
well. 4
2. Do not apply intensive or uneven loads. Never apply M155-14-008
high-speed impact to the blade by running the machine
into a load.
3. Jacking up the machine with this blade, the surface
beneath the blade comes under high pressure,
increasing the risk of surface collapse.
Always be sure that the surface is strong enough to
support the weight of the machine during operation.
Avoid dangerously uneven distribution of weight on the
blade by maintaining even contact between the blade
and the ground.
4. Never use this blade as an outrigger.
5. Avoid contact between the bucket and the blade while
digging.
13-7
BLADE LEVER
Avoid Hitting Blade with Front-End Attachment

When operating the machine with the blade positioned
towards the front, the bucket or boom cylinder may come into
contact with the blade if you are not careful. Be sure to prevent
this from happening.
MZX5-13-025
MZX5-13-026
Avoid Hitting Blade with Bucket

When crowding the arm into a traveling or transporting
position, be careful not to let the bucket hit the blade.
MZX5-13-026
Avoid Striking the Blade into a Rock

Do not attempt to strike large rocks with the blade, as
doing so will damage the blade and the blade cylinders,
shortening their operating lives.
MZX5-13-027
13-8
BLADE LEVER
Blade Maintenance
Greasing --- every 250 hours
Lubricate all fittings shown in the figure.
 Blade Joint Pins (2 points)

 Blade Cylinder Rod (2 points)
 Blade Cylinder Bottom (2 points)
M175-13-002
Transportation Figure for Machine Equipped with Blade

When transporting the machine equipped with a blade
and a long arm front attachment on a trailer, place the
blade in the opposite position toward the front attachment.
Otherwise, the bucket may come in contact with the blade.
M175-13-005
13-9
BLADE LEVER
Specifications
ZX130-5A with Blade
A
G C
E
D
K J
I H
MDAK-12-011
Model ZX130-5A with Blade

Engine Type ISUZU GJ-4JJ1XKSA-03
ISO 14396 73 kW at 2000 min-1
Engine Power
ISO 9249 69.4 kW at 2000 min-1
A: Overall Width (Excluding back mirrors) 2490 mm (8 ft 2 in)
K: Track Shoe Width 500 mm (Grouser Shoe) (20 in)
13-10
BLADE LEVER
Working Ranges
ZX130-5A with Blade
E J
H
I
F
A
B
MDAK-12-012
Model ZX130-5A with Blade

Category
2.10 m (6 ft 11 in) Arm 2.52 m (8 ft 3 in) Arm 3.01 m (9 ft 11 in) Arm
Item
A: Maximum Digging Reach mm 7940 8300 8770
(ft·in) (26' 1”) (27' 3”) (28' 9”)
B: Maximum Digging Depth mm 5120 5540 6030
(ft·in) (16' 10”) (18' 2”) (19' 9”)
C: Maximum Cutting Height mm 8400 8600 8930
(ft·in) (27' 7”) (28' 3”) (29' 4”)
D: Maximum Dumping Height mm 5990 6190 6520
(ft·in) (19' 8”) (20' 4”) (21' 5”)
E: Overall Height mm 2790 2790 *2790
(ft·in) (9' 2”) (9' 2”) (9' 2”)
F: Overall Length mm 8030 8030 *8040
(ft·in) (26' 4”) (26’ 4”) (26' 5”)
G: Minimum Swing Radius mm 2350 2400 2620
(ft·in) (7' 9”) (7' 11”) (8' 7”)
H: Max. Raising Height mm 480
(ft·in) (1' 7”)
I: Max. Digging Depth mm 530
(ft·in) (1' 9”)
J: Blade Angle degree 25
fNOTE: The dimensions do not include height of the shoe lug (except Item E). * The dimensions asterisked are for transport
pin position.
13-11
BLADE LEVER

ZX130-5A with Blade
500 mm (20”) 600 mm (24”) 700 mm (28”)
Shoe Width
For Ordinary
Application Ground
(Option) (Option)
(Standard)
kg 13400 13700 13800
Operating Weight
(lb) (29600) (30300) (30500)
kg 10700 10900 11100
Base Machine Weight
(lb) (23600) (24100) (24500)
mm 2790 2790 2790
Cab Height
(ft·in) (9’ 2”) (9’ 2”) (9’ 2”)
Clearance (ft·in) (1’ 4”) (1’ 4”) (1’ 4”)
mm 3580 3580 3580
(ft·in) (11’ 9”) (11’ 9”) (11’ 9”)
mm 2490 2590 2690
Undercarriage Width
(ft·in) (8’ 2”) (8’ 6”) (8’ 10”)
psi) psi) psi)
fNOTE:
 The specifications for the front-end attachment are for a 2.52 m (8 ft 3 in) arm with PCSA 0.50 m3 (0.65 yd3) standard
bucket.
 600 mm (24 in) and 700 mm (28 in) grouser shoe should not be used on gravel or rocky ground.
13-12
BUCKET TEETH
Bucket Teeth (Transverse-Type-Pin-Used Type)

ZX200-5, 240-5, 300-5, 330-5 Class
Replacement Procedure
dCAUTION: Guard against injury from flying pieces of

metal. Wear goggles or safety glasses. 5 1 2 3
1. Securely lower the bucket to the ground.

2. Use hammer (3) and drift (2) to drive out transverse-type
locking pin (1) to remove tooth (4).
fNOTE: Be sure to use a drift (2) thinner than pin (1).
3. Clean shank (5) surface. Attach a new tooth (4) onto

shank (5). Insert pin (1) as deep as it goes. Then, drive pin
(1) using hammer (3) and drift (2) to securely lock tooth
(4). 4 M157-14-013
13-13
ATTACHMENT PEDAL
Attachment Pedal (Hydraulic Breaker) (Optional)

1
The Breaker can be operated using attachment pedal (1)
located on the right front of the seat, as illustrated.
dCAUTION: Be sure to lock attachment pedal (1) with

pedal lock (2) when the attachment pedal is not in
use. Do not allow your foot to rest on the pedal when
the attachment pedal (1) is not in use. When changing
pedal lock (2) position, pull the pilot control shut-off
lever up to the LOCK position.
1. Select the hydraulic breaker icon on monitor work mode MDAA-05-001

selection screen (3). Refer to the descriptions about
the work mode on page 5-10 for work mode setting
procedures.
3
2. Move pedal lock (2) forward to the UNLOCK position.
3. Push down on attachment pedal (1) to operate the
breaker.
Loosen stopper bolt (4) until stopper bolt (4) comes in
contact with the bracket in attachment pedal (1) neutral
to prevent attachment pedal (1) from being stepped
backward.
4. Remove foot from attachment pedal (1) to stop the
breaker.
MDAK-01-101EN
5. Always keep attachment pedal (1) locked with pedal lock
(2) when attachment pedal (1) is not in use.
1
M1J1-13-002
Locked Attachment Pedal
Unlocked Attachment Pedal

M1J1-13-003
13-14
ATTACHMENT PEDAL
Attachment Pedal (Hydraulic Crusher) (Optional)

1
The crusher can be operated using attachment pedal (1)
located on the right front of the seat, as illustrated.
dCAUTION: Be sure to lock attachment pedal (1) with

pedal lock (2) when the attachment pedal is not in
use. Do not allow your foot to rest on the pedal when
the attachment pedal (1) is not in use. When changing
pedal lock (2) position, pull the pilot control shut-off
lever up to the LOCK position.
1. Select the proper hydraulic crusher icon on work mode MDAA-05-001

selection screen (3). Refer to the descriptions about
the work mode on page 5-10 for work mode setting
procedures.
2. Move pedal lock (2) forward to the UNLOCK position. 3
3. Push down on attachment pedal (1) either forward or
backward to open or close the crusher.
4. Remove foot from attachment pedal (1) to stop the
crusher.
5. Always keep attachment pedal (1) locked with pedal lock
(2) when attachment pedal (1) is not in use.
MDAK-01-101EN
Locked Attachment pedal (Crusher)

M1J1-13-012
2
Fully Tighten
the Stopper
Bolt
Unlocked Attachment pedal (Crusher)

M1J1-13-006
13-15
HYDRAULIC BREAKER, HYDRAULIC CRUSHER AND QUICK COUPLER
Hydraulic Breaker, Hydraulic Crusher and Quick

Coupler
Selecting a Breaker or Crusher
Select a breaker, crusher or quick coupler with the correct
size and weight for your machine, considering the stability
of the machine, hydraulic oil pressure and flow rate of the
breaker, crusher or quick coupler. See your authorized
dealer for correct breaker information.
Precautions for Operation

Carefully study the operation manuals of the breaker,
crusher and quick coupler.
To avoid damaging the machine, hydraulic breaker, crusher
or quick coupler, follow the precautions given below.
Precautions for Connecting Breaker or Crusher Piping.

Do not allow impurities to enter into the system when
switching the breaker, crusher or the quick coupler with the
bucket.
When the breaker, crusher or quick coupler is not used,
apply the cover to the pipe opening on the arm top and
install the plug or cap into the hose end of the breaker,
crusher or the quick coupler to prevent impurities from
entering the system.
Be sure to provide spare covers and plugs in the tool box so
that they will be available when needed.
After connecting, check the connecting seal fitting for oil
leakage, and pipe clamp bolts for looseness.
13-16
Piping for Breaker and Crusher

Operational Procedures for Stop Valves and
Selection Valve.
Close
Stop Valves A
Open
A
Stop Valve A
Close: When not using attachment or is detached. M1U1-05-007
Open: When using attachment
MAIN BODY BOOM ARM ATTACHMENT
ATTACHMENT PEDAL 2nd RELIEF

CONTROL VALVE
VALVE
PUMP
ACCUMULATOR STOP VALVE (Only ZX200-5,

240-5, 300-5, 330-5 class)
SELECTOR VALVE
ACCUMULATOR (Only ZX200-5, 240-5, 300-5, 330-5 class)
SOLENOID VALVE
MONITOR
MAIN CAN MONITOR SWITCH

CONTROLLER CONTROLLER BOX
MDAA-05-006
13-17
Secondary Relief Pressure Adjustment

Depending on the breaker model, the secondary relief valve
relief set pressure differs.
Consult your nearest Hitachi dealer for installing a breaker.
13-18
Precautions for Breaker Operation
dbreaker
WARNING: Machine stability is reduced as the
is much heavier than the bucket. When using
a breaker, the machine is more apt to tip over. Also,
flying objects may hit the cab or other part of the
machine. Observe the following precautions and take
any other precautions necessary to prevent accidents
and machine damage from occurring.
Avoid Hitting Objects with Breaker

The breaker is heavier than the bucket, causing the breaker
to lower faster.
Take care not to hit any objects with the breaker. Doing so
will result in damage to the breaker, the front attachment,
and/or the upperstructure. Always move (lower) the breaker
slowly to position the tip of the chisel on the object to be
MZX5-13-019
broken before starting breaker operation.
Avoid Moving Objects with Breaker

Do not use the breaker and/or the bracket to move objects.
Damage to the boom, arm, and/or breaker may result.
Do not use the breaker and/or the swing function to move
objects. Damage to the boom, arm, and/or breaker may
result.
Avoid Operating Breaker at Cylinder Stroke End

MZX5-13-020
Always operate the breaker by positioning the cylinder rods
100 mm or longer before the stroke end position.
When operating the breaker with cylinders fully retracted
or extended, hydraulic cylinders, arm or boom may be
damaged.
MZX5-13-021
13-19
Stop Operation If Breaker Hydraulic Hoses Jump Hose jumping

Abnormally abnormally
Accumulator
Change in breaker accumulator pressure or a damaged
accumulator will cause abnormal hose jumping and may
cause breaker and/or machine damage.
Immediately stop the machine operation. Failure to do
so may result in serious failure in the hydraulic system
including pumps. Hose jumping
abnormally
Contact your nearest Hitachi dealer.
M104-05-058
Do Not Operate the Breaker in Water Do not operate the

breaker in water.
Doing so will cause rust and seal damage, resulting in
damage to the hydraulic system components.
Rust, dust and water may enter into the hydraulic oil
through the broken seal, damage to the hydraulic system Rod
may result.
MZX5-13-017
Do Not Use Breaker for Lifting Operation

The machine tipping over and/or breaker damage may
result.
Do Not Operate the Breaker to the Side of the Machine

MZX5-13-022
The machine may become unstable and undercarriage
component life may shorten as a result from operating the
breaker to the side of the machine.
OK OK
MZX5-13-023
13-20
Operate the Hydraulic Excavator Carefully to Avoid

Hitting the Boom
When the arm rolled in with the breaker equipped, the
chisel may come in contact with the boom.
Watch Out!
Take care not
to hit the boom
with the crusher
MZX5-13-024
Do Not Operate Breaker with the Arm Positioned
Vertically
Excessive vibration to the arm cylinder will occur, causing oil
leakage.
Press the Breaker So That the Chisel (The Axis) Is

Positioned and Thrusted Perpendicular to the Object
Failure to do so may damage the chisel or may cause seized MZX5-13-006
piston.
Do Not Operate the Breaker Continuously Longer Than

One Minute
Failure to do so may result in premature wear of the chisel.
If an object could not be broken within one minute, apply MZX5-13-007
the chisel to other locations, less than one minute for each
location.
If an object could not

be broken within one
minute, apply the chisel
to other locations.
M147-05-015
13-21
Raising the Front Part of the Undercarriage by Pressing

Down the Breaker May Cause Damage to the Front
Attachment
Never raise the front edge of the undercarriage higher than
150 mm (6 in) by pressing the breaker down.
Pressing Raising
Down 100 to 150 mm
M147-05-016
13-22

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.
(Refer to the “Hydraulic System” in the “MAINTENANCE”
Chapter.)
Replacement intervals differ depending on the brand of

hydraulic oil used. Refer to the Hydraulic System in the
MAINTENANCE Chapter.
Use the high performance element (micro-glass) on excavators
engaged in demolition and logging work.
fNOTE: Full-flow filter restriction indicator is optional. If a

filter-paper element is used, this indicator does not operate.
(Refer to the "Hydraulic System" in the "MAINTENANCE"
Section.)
13-23
Precautions for Crusher Operation

Prevent machine tipping over and damage to the front
attachment. Observe the following precautions for crusher
operation.
disWARNING: Machine stability is reduced as a crusher

much heavier than a bucket. When operating with
a crusher, the machine is more apt to tip over. Falling
or flying objects may hit the cab or other part of the
machine. Observe the following precautions and take
any other precautions necessary to prevent accidents
and machine damage from occurring.
 Do not allow the machine's weight to be supported by

the crusher or bucket cylinder with the bucket cylinder
fully extended or retracted. Failure to do so may result
in damage to the front attachment. In particular, avoid
doing so with the bucket cylinder fully extended, as the
front attachment will be easily damaged.
Take care to prevent this from happening when
dismantling foundation structures using the crusher.
 Using the front attachment, do not raise the base

machine off the ground with the arm cylinder fully MZX5-13-008
extended. Failure to do so may result in damage to the
arm cylinder.
 When a heavyweight attachment such as a crusher is

installed, avoid quickly starting or stopping the front
attachment. Failure to do so may result in damage to the
front attachment.
 Do not attempt to perform crushing on either side of the

machine. Always perform crushing operations to the fore
or rear, parallel with the tracks. Otherwise, tipping over
may occur.
MZX5-13-009
13-24
 When the arm rolled in with the crusher equipped, the

crusher may come in contact with the boom.
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.
 When operating the crusher on a floor in a building, first

confirm that the floor has sufficient strength to support
the load caused by crushing, in addition to the machine
weight. MZX5-13-011
The load equivalent or higher than the machine weight
may be applied on the floor depending on the operation
method.
MZX5-13-012
13-25
 Always operate the crusher on a stable, level surface, not

on a slope or on crushed scraps.
 Do not use the crusher to haul or load crushed scraps.
 To prevent the attachment from falling accident, use a
platform when replacing the attachment.
 If a multiple number of attachments, such as crusher
and bucket, or crusher and breaker, are used, replacing
them with each other at intervals, impurities are more
apt to enter the hydraulic system and the hydraulic oil
deteriorates quickly. For this reason, replace the hydraulic
oil tank filter and change the hydraulic oil at the intervals
specified in the breaker time sharing diagram in the
previous section.
 Always remove the crusher from the excavator before
transporting the machine. Do not fully extend the bucket
cylinder when transporting, as this may damage the front
attachment, when vibrations arise during transportation.
13-26
Attachment
Allowable Weight Limits of Installed Attachment
d WARNING:
 When an attachment other than the standard bucket  According to the specifications of installed
is installed on the machine, the machine stability will attachment and the base machine, the
be different. machine weight may exceed the allowable
maximum operating weight of the ROPS,
If a heavy attachment is used, not only will making the ROPS unable to assure the
controllability be affected but also machine stability protective function for operator. Refer to the
will be reduced, possibly causing safety hazard. ROPS certification affixed in the cab for the
 Before installing attachments such as hydraulic allowable maximum operating weight.
breaker, crusher (concrete crusher), or pulverizer,
take machine controllability into account when
selecting the weight of the attachment by referring
to the table below.
(Unit: kg)
Base Machine Breaker Crusher/Pulverizer
Specification
Model Arm Std.Weight Max.Weight Std.Weight Max.Weight
ZX210K-5A Std. 1650 1800 1950 2300

ZX210LCK-5A Std. 1850 2000 2200 2550
K Model
ZX250K-5A Std 2200 2450 2650 3100

ZX250LCK-5A Std 2450 2700 2950 3450
ZX350K-5A Std. 2950 3250 3500 4100
ZX350LCK-5A Std. 3000 3300 3600 4200
ZX130-5A Std. 1000 1150 1250 1450
ZX160LC-5A Std. 1250 1350 1500 1750
ZX200-5A Std. 1550 1750 1900 2200
ZX200LC-5A Std. 1750 1950 2100 2450
ZX210H-5A Std. 1650 1800 2000 2300
ZX210LCH-5A Std. 1850 2000 2200 2600
ZX240-5A Std. 1950 2150 2350 2700
Std. Model
ZX240LC-5A Std. 2150 2400 2600 3050

ZX250H-5A Std. 2150 2350 2550 3000
ZX250LCH-5A Std. 2350 2600 2850 3300
ZX300-5A Std. 2350 2600 2850 3300
ZX300LC-5A Std. 2400 2650 2900 3400
ZX330-5A Std. 2600 2850 3100 3600
ZX330LC-5A Std. 2650 2900 3150 3700
ZX350H-5A Std. 2750 3000 3250 3800
ZX350LCH-5A Std. 2800 3050 3350 3900
13-27
 Breaker operation speed is faster than crusher operation

so that the recommended breaker max. weights are
reduced more than those of the crushers.
 The weight is not the only factor to be considered when
selecting a breaker. Select proper manufacturer's breaker
models while referring to the table on the next page.
 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.
 Always contact your authorized dealer before installing
attachments of other manufacturers.
13-28
Attachment Connection Parts

The attachment hydraulic line and connection parts are
located as illustrated below.
When the attachment is disconnected, be sure to install caps
or plugs to the ends of both the arm and attachment side
hydraulic lines to prevent dust from entering or from sticking.
Adapter tightening torque:

G1: 210 N·m (21 kgf·m)
G1-1/4: 340 N·m (34 kgf·m) (ZX330-5 class only right side
piping)
Plug
Plug Thread Size: JIS B2351 O-Type G1
Plug Thread Size: JIS B2351 O-Type G1-1/4
(ZX330-5 class only right side piping)
Adapter Plug
Hose
Cap
When the attachment is disconnected
M175-05-005
13-29
Part No. List (Fill attachment manufacturer's part Nos. in the blank spaces.)
Adapter Size Adapter Cap Plug Hose
G-UNF UNF
Form / Size 37 ° 37 °
Male-Type
37 ° UNF
G UNF
ZX120-5 Class G1-1-1/16UN 4456399 4222711 4222264

ZX160-5, 200-5, 240-5,
300-5, 330-5 Class left side G1X1-5/16UN 4214444
piping 4222712 4222265
ZX330-5 class right side G1-1/4X1-
4314094
piping 5/16UN
G
G-G30° G
Form / Size
Female-Type 30 °
30 ° 30 °
G UNF
ZX120-5 Class G1-G3/4 4129457 9718916 4222047
ZX160-5, 200-5, 240-5,
300-5, 330-5 Class left side G1XG1 4042034
piping 9718917 4168177
ZX330-5 class right side
G1-1/4XG1 4317614
piping
G-G30° G
Form / Size
Male-Type 30 ° 30 °
30 °
G G G
ZX120-5 Class G1-G3/4 4456120 4222715 4222044
ZX160-5, 200-5, 240-5,
300-5, 330-5 Class left side G1XG1 4456118
piping 4222716 4222045
ZX330-5 class right side
G1-1/4XG1 4653961
piping
13-30
Precaution for Arm Roll-In/Bucket Roll-In

Combined Operation
When Installing an Attachment Longer Than Standard
Bucket
dbreaker,
WARNING: When an attachment (such as a hydraulic
crusher or quick coupler), the overall length of Watch Out!
Take care not to hit the
which is longer than that of the bucket, is installed, the boom with the crusher
attachment may come in contact with the cab and/or
the boom. Operate the machine with care not to allow
the tip of the front attachment to hit the cab and/or MZX5-13-010
the boom while rolling in the front attachment.
13-31
MEMO
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13-32
INDEX
A Battery .............................................................................................. 7-92
Acting Time Setting ..................................................................... 1-39 Battery Charger Operation........................................................ 7-28
Actual operation ........................................................................... 1-66 Battery Disconnect Switch ......................................................1-127
Adjust Bucket Linkage ..............................................................7-108 Before Starting Engine ..................................................................3-2
Adjust the Operator’s Seat ...........................................................S-6 Beware of Asbestos and Silicon Dust and Other
Adjusting Operator’s Seat .......................................................1-117 Contamination ......................................................................... S-35
Adjusting Operator’s Seat (Optional) .................... 1-119, 1-121 Beware of Exhaust Fumes.......................................................... S-32
Adjusting Procedures................................................................1-123 Blade Lever ..................................................................................... 13-7
Adjusting Seat Height...............................................................1-121 Blade Maintenance ...................................................................... 13-9
Adjusting the Position of the Side Camera Monitor ......1-108 Breaker Operation ........................................................................ 1-60
After the First 100 Hours ...............................................................2-1 Brightness Adjustment............................................................... 1-48
After the First 50 Hours .................................................................2-1 Bucket Teeth (Transverse-Type-Pin-Used Type) ..............13-13
Air Bleeding Procedures............................................................. 7-52 Bucket Types and Applications
Air Cleaner ...................................................................................... 7-78 ZX130-5A ................................................................................... 12-4
Air Conditioner .............................................................................. 1-20 ZX160LC-5A .............................................................................. 12-8
Air Conditioner ON/OFF............................................................. 1-20 ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A ................12-15
Alarm Occurrence Screen .......................................................... 1-14 ZX210K-5A, 210LCK-5A .......................................................12-19
Allowable Weight Limits of Installed Attachment ..........13-27 ZX240-5A, 240LC-5A ............................................................12-30
AM/FM Radio Operation ..........................................................1-100 ZX250H-5A, 250LCH-5A, 250K-5A, 250LCK-5A ...........12-31
AM/FM Selector/Tuning Switch (Radio) ............................... 1-76 ZX300-5 class ..........................................................................12-35
Angle Adjustment of Seat Surface .......................................1-122 ZX330-5 class ..........................................................................12-44
Armrest Adjustment .......................................1-118, 1-120, 1-122 C
Attachment...................................................................................13-27
COMPONENTS NAME .....................................................................1-1
Attachment Adjustment ............................................................ 1-32
Cab Door Release Lever ...........................................................1-109
Attachment Connection Parts ...............................................13-29
Cab Features ............................................................................ 1-3, 1-4
Attachment Name Input............................................................ 1-36
Cab Heater Operation ................................................................. 1-96
Attachment Operation ............................................................... 1-62
Cab Light Switch ........................................................................... 1-88
Attachment Pedal (Hydraulic Breaker) (Optional) ..........13-14
Change Bucket ............................................................................7-106
Attachment Pedal (Hydraulic Crusher) (Optional)..........13-15
Change Coolant ............................................................................ 7-86
Attachment Selection ................................................................. 1-22
Change Engine Oil ...................................................................... 7-37
Audio Input (Optional) .............................................................1-104
Change Hydraulic Oil .................................................................. 7-50
Auto Air Conditioner ................................................................... 1-91
Auto Shut-Down ...................................................................1-38, 5-7
Element ....................................................................................13-23
Auto Shut-Down: ON/OFF......................................................... 1-38
Charger Lamp ................................................................................ 7-29
AUTO/OFF Switch/Fan Switch (Air Conditioner) ............... 1-75
Check Air Conditioner ..............................................................7-117
Auto-Idle .............................................................................................5-5
Check and Adjust Fan Belt Tension ....................................... 7-84
Auto-Idle Switch ........................................................................... 1-77
Check and Clean Around the Engine .................................... 7-40
AUX Function Lever 3.................................................................. 1-86
Check and Replace Bucket Teeth ..........................................7-100
Avoid Abusive Operation .......................................................... 5-20
Check and Replace EGR Device .............................................7-120
Avoid Applying Heat to Lines Containing Flammable
Check and Replace Seat Belt ..................................................7-109
Fluids ........................................................................................... S-34
Check Coolant Level .................................................................... 7-82
Avoid Hammer Work ................................................................... 5-19
Check Fuel Hoses .......................................................................... 7-77
Avoid Heating Near Pressurized Fluid Lines ....................... S-34
Check Gas Damper ....................................................................7-121
Avoid High-Pressure Fluids ....................................................... S-29
Check Hoses and Lines ............................................................... 7-61
Avoid Hitting Blade with Front-End Attachment.............. 13-8
Check Hydraulic Oil Level .......................................................... 7-49
Avoid Injury from Attachment Falling Accident ............... S-28
Check Instruments After Starting ..............................................3-8
Avoid Injury from Back-Over and Swing Accidents ......... S-17
Check Starter and Alternator .................................................7-120
Avoid Injury from Rollaway Accidents .................................. S-16
Check the Hour Meter Regularly................................................7-4
Avoid Power Lines ........................................................................ S-21
Check Track Sag ..........................................................................7-111
Avoid Side Load the Bucket ...................................................... 5-20
Check Windshield Fluid Level ................................................7-110
Avoid Tipping................................................................................. S-19
Cigar Lighter................................................................................... 1-87
Avoid Undercutting ..................................................................... S-19
Circulation Air Mode ................................................................... 1-20
B Clean Air Conditioner Condenser........................................... 7-90
BREAK-IN.............................................................................................2-1 Clean and Replace Air Cleaner Element (Outer)................ 7-78
Backrest Adjustment ......................................1-117, 1-120, 1-122 Clean and Replace Air Conditioner Filter ...........................7-115
Basic Screen .......................................................................................1-7 Clean Cab Floor ...........................................................................7-119
14-1
INDEX
Clean Fuel Oil Cooler.................................................................... 7-90 F
Clean Oil Cooler, Radiator and Inter Cooler Front Fasten Your Seat Belt.......................................................................S-7
Screen.......................................................................................... 7-90 Fastening Machine for Transporting.........................................6-5
Clean or replace the outer element........................................ 7-78 Features:........................................................................................... 1-91
Clean Radiator/Oil Cooler/Inter Cooler Core....................... 7-88 Flow Rate Adjustment................................................................. 1-32
Clock.................................................................................................. 1-11 Follow Safety Instructions.............................................................S-2
Components Name...................................................1-1, 1-92, 7-27 For Rapid Cooling.......................................................................... 1-99
Confirm Direction of Machine to Be Driven......................... S-13 Fore-Aft Position Adjustment of Seat Surface..................1-122
Console and Seat Fore-aft Adjustment....1-117, 1-119, 1-121 Front Joint Pins............................................................................... 7-20
Console Height Adjustment....................................................1-123 Fuel Consumption......................................................................... 1-58
Content of Monitor Display.....................................................1-107 Fuel Gauge....................................................................................... 1-11
Control Lever (Hitachi Pattern) (Optional)............................ 13-6 Fuel System...................................................................................... 7-65
Control Lever (ISO Pattern)...........................................................5-1 Fuse Box................................................................................. 1-90, 7-98
Controller Part Name and Function........................................ 1-93
Controls on the Radio................................................................1-100 G
Convert Bucket Connection Into Face Shovel...................7-107 GETTING ON/OFF THE MACHINE................................................1-2
Cool Head/Warm Feet Operation............................................ 1-98 General Precautions for Cab.........................................................S-5
Coolant Temperature Gauge..................................................... 1-11 Grading Operation........................................................................ 5-18
Cooling Operation........................................................................ 1-97 Greasing............................................................................................ 7-20
Cooling System.............................................................................. 7-81 H
Correct Maintenance and Inspection Procedures................7-1 Handle Chemical Products Safely............................................ S-37
D Handle Fluids Safely−Avoid Fires............................................. S-23
DRIVING THE MACHINE..................................................................4-1 Hood and Access Covers................................................................7-8
Date Adjustment........................................................................... 1-28 Horn Switch..................................................................................... 1-84
Date and Time................................................................................ 1-26 Hour Meter....................................................................................... 1-11
Default Setting..................................................................................1-6 How to Lower Boom in Case of Emergency and When
Defroster Operation..................................................................... 1-98 Engine Stops.............................................................................. 5-24
Dig with Caution............................................................................ S-20 How to operate the disconnect switch...............................1-127
Display Mode Setting.................................................................. 1-30 How to Use Screens.........................................................................1-8
Displaying Basic Screen.................................................................1-8 Hydraulic Breaker, Hydraulic Crusher and Quick
Dispose of Waste Properly.......................................................... S-37 Coupler......................................................................................13-16
Do Not Strike the Ground with Bucket Teeth...................... 5-19 Hydraulic System........................................................................... 7-45
Do Not Use Wide Track Shoes on Rough Ground.............. 5-21 I
Drain Fuel Pre-Filter...................................................................... 7-68 Information Menu......................................................................... 1-57
Drain Fuel Tank Sump.................................................................. 7-67 Input Password............................................................................... 1-12
Drive Machine Safely.................................................................... S-14 Inspect and Adjust Valve Clearance......................................7-120
Drive the Machine Carefully.........................................................4-1 Inspect Machine...............................................................................S-4
E Inspect Machine Daily Before Starting.....................................3-1
Electric Fans...................................................................................12-45 Inspection and Maintenance of Hydraulic Equipment.... 7-45
Electric Grease Gun....................................................................... 7-26 Install OPG Guard.......................................................................... S-12
Electric Grease Gun (Only ZX330-5 class)............................. 7-24 Installation and Adjustment of Mirrors...............................1-124
Electrical Control Main Switch (Optional)................. 1-83, 1-85 Installing Fire Extinguisher (Optional)................................... 1-88
Electrical System............................................................................ 7-91 Investigate Job Site Beforehand.............................................. S-11
Emergency Exit............................................................................1-116 J
Engine................................................................................................ 7-35 Jump Starting....................................................................................S-9
Engine Control Dial....................................................................... 1-76
Engine Oil Level............................................................................. 7-35 K
Engine Speed Control.....................................................................5-4 K. Model...............................................................................................1-4
Engine Stop Switch....................................................................... 1-89 Keep Person Clear from Working Area.................................. S-18
Ensure Safety Before Rising from or Leaving Operator’s Keep Riders off Machine................................................................S-9
Seat..................................................................................................S-7 Key Switch........................................................................................ 1-84
Evacuating in Case of Fire........................................................... S-32 Kind of Oils....................................................................................... 7-17
Every 8 Hours or Daily.....................................................................2-1 L
Extending Password Duration Time....................................... 1-13
Language Settings........................................................................ 1-50
Layout...................................................................................................7-3
14-2
INDEX
Lifting Machine.................................................................................6-7 Overload Alarm Switch (Optional).......................................... 1-82
List of Consumable Parts..........................................................7-143
P
Lists of Display Language........................................................... 1-52
Loading/Unloading on a Trailer..................................................6-2 Park Machine Safely...................................................................... S-23
Parking the Machine.......................................................................4-8
M Parking the Machine on Slopes...................................................4-8
MACHINE NUMBERS............................................................................1 Password Change (Optional)..................................................... 1-40
MAINTENANCE..................................................................................7-1 Periodic Replacement of Parts.................................................. 7-16
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL Pilot Accumulator Functions (Optional)................................ 5-23
CONDITIONS.................................................................................9-1 Pilot Control Shut-Off Lever..............................................1-89, 5-2
Mail (Optional)................................................................................ 1-23 Piping for Breaker and Crusher..............................................13-17
Main Menu....................................................................................... 1-19 Power Boost Switch........................................................... 1-84, 5-13
Main Menu Sequence Change................................................. 1-55 Power Mode.................................................................................... 5-14
Maintenance................................................................................... 1-68 Power Mode Switch...................................................................... 1-78
Maintenance Guide...................................................................... 7-11 Power Switch/Volume Control Knob (Radio)...................... 1-76
Maintenance Under Special Environmental Conditions....9-1 Practice Safe Maintenance......................................................... S-25
Measure Engine Compression Pressure..............................7-120 Precaution for Arm Roll-In/Bucket Roll-In Combined
Mirror Installation Diagram.....................................................1-125 Operation..................................................................................13-31
Miscellaneous...............................................................................7-100 Precautions for After Operations............................................. 5-25
Monitoring....................................................................................... 1-72 Precautions for Breaker Operation........................................13-19
Move and Operate Machine Safely............................................S-8 Precautions for Communication Terminal............................ S-38
Multi Function Monitor..................................................................1-5 Precautions for Communication Terminal Equipment.... S-39
Precautions for Crusher Operation.......................................13-24
N
Precautions for Excavation (K. Model)................................... 5-15
Never Allow Machine to Engage in Crane Work................ S-22 Precautions for Handling Accumulator and Gas
Never Position Bucket Over Anyone...................................... S-18 Damper........................................................................................ S-34
Never Ride Attachment............................................................... S-38 Precautions for Lightning........................................................... S-21
Never Undercut a High Bank..................................................... S-20 Precautions for Operations........................................................ S-10
Notes on Protection of Operator’s Station when the Precautions for Transporting Machines with Pad
Machine Rolls Over.................................................................. S-41 Crawler Shoes............................................................................ 13-3
Numeric Keypad............................................................................ 1-80 Precautions for Welding and Grinding.................................. S-33
O Preparations for Inspection and Maintenance......................7-7
OPERATING THE ENGINE................................................................3-1 Prepare for Emergencies................................................................S-3
OPERATING THE MACHINE............................................................5-1 Prevent Battery Explosions........................................................ S-36
OPERATOR’S STATION.....................................................................1-3 Prevent Burns.................................................................................. S-28
OPTIONAL ATTACHMENTS AND DEVICES............................. 13-1 Prevent Fires.................................................................................... S-30
Observe Engine Operation Closely............................................2-1 Prevent Parts from Flying........................................................... S-27
Off-Season Air Conditioner Maintenance............................ 1-99 Priority (arm roll-out) (Except ZX330-5A class)................... 1-34
ON/OFF Operation Switch (Optional)......................... 1-83, 1-86 Protect Against Flying Debris................................................... S-22
Opening Side Window...............................................................1-113 Protect Against Noise.....................................................................S-4
Opening Upper Front Window...............................................1-111 Provide Signals for Jobs Involving Multiple Machines.... S-13
Opening/Closing and Removing Cab Inside Pump Transmission ..................................................................... 7-41
Window.....................................................................................1-110 R
Opening/Closing Overhead Window (Clear Hatch: If Radio.................................................................................................. 1-21
Equipped).................................................................................1-115 Raise One Track Using Boom and Arm.....................................4-5
Opening/Closing Overhead Window (Std. Model).........1-114 Rear Light Switch (Optional)..................................................... 1-82
Operate Only from Operator’s Seat...........................................S-8 Rear View Camera Monitor........................................................ 1-46
Operate with Caution.................................................................. S-20 Rear View Camera ON (Factory Setting: ON)....................... 1-46
Operating Backhoe....................................................................... 5-16 Recognize Safety Information.....................................................S-1
Operating in Water or Mud...........................................................4-7 Recommended Engine Oil......................................................... 7-17
Operating on Soft Ground............................................................4-5 Recommended Fuel..................................................................... 7-65
Operating Status Icon Display.................................................. 1-11 Remaining Time and Maintenance Interval......................... 1-70
Operation......................................................................................... 1-58 Remedy............................................................................................. 1-16
Operational Procedures for Stop Valves and Selection Remove Paint Before Welding or Heating............................ S-35
Valve...........................................................................................13-17 Remove Travel Levers.................................................................7-109
Overhead Window Wiper and Washer Switch Removing and Storing Lower Front Window....................1-112
(K Model)..................................................................................... 1-80
14-3
INDEX
Replace Air Breather Element................................................... 7-58 ZX350K-5A................................................................................12-43
Replace Air Cleaner Element (Inner)....................................... 7-80 ZX350LCH-5A..........................................................................12-42
Replace Battery.............................................................................. 7-95 ZX350LCK-5A...........................................................................12-43
Replace Engine Oil Filter............................................................. 7-37 Shovel................................................................................................ 5-17
Replace Fuel Main Filter Element............................................ 7-71 Side View Camera System (Optional)...................................1-105
Replace Fuel Pre-Filter Element............................................... 7-73 Sound Level Results....................................................................12-45
Replace Fuel Solenoid Pump Filter Element........................ 7-75 Specifications
Replace Line Filter Element (Optional).................................. 7-59 ZX130-5A.................................................................................... 12-1
Replace Pilot Oil Filter.................................................................. 7-57 ZX130-5A with Blade............................................................13-10
Replace Rubber Hoses Periodically......................................... S-29 ZX160LC-5A............................................................................... 12-5
Replacement of Full-Flow Filter................................................ 7-54 ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A................... 12-9
Replacing Fuses............................................................................. 7-97 ZX210K-5A, 210LCK-5A........................................................12-16
Restriction of Attachment Installation.................................. S-13 ZX240-5A, 240LC-5A.............................................................12-20
Retighten Cylinder Head Bolt.................................................7-120 ZX250H-5A, 250LCH-5A.......................................................12-21
Retracting the Arm and Bucket................................................ 5-21 ZX250K-5A, 250LCK-5A........................................................12-22
Return to Basic Screen Switch (Monitor).............................. 1-75 ZX300-5A, 300LC-5A.............................................................12-32
Return to Previous Screen Switch (Monitor)....................... 1-75 ZX330-5A, 330LC-5A.............................................................12-36
Rotating Lamp Switch (Optional)............................................ 1-83 ZX350H-5A, 350LCH-5A.......................................................12-37
ZX350K-5A, 350LCK-5A........................................................12-38
S
Starting the Engine..........................................................................3-3
SAFETY.................................................................................................S-1 Station Auto-Presetting Procedure.......................................1-102
SAFETY SIGNS/Asia/Middle and Near East Model Station Presetting Procedure..................................................1-101
Only............................................................................................... S-49 Stay Clear of Moving Parts......................................................... S-27
SAFETY SIGNS/Oceania Model Only....................................... S-42 Std. Model...........................................................................................1-3
SPECIFICATIONS............................................................................. 12-1 Steering the Machine Using Levers...........................................4-3
STORAGE........................................................................................... 10-1 Steering the Machine Using Pedals...........................................4-2
Seat Belt..........................................................................................1-126 Stopping the Engine.................................................................... 3-11
Seat Fore-Aft Adjustment..............................1-117, 1-119, 1-121 Storing the Machine..................................................................... 10-1
Seat Heater Switch . ..................................................................... 1-83 Sub Meter......................................................................................... 1-44
Seat Height and Angle Adjustment........................ 1-117, 1-119 Suction Filter Cleaning................................................................ 7-53
Secondary Relief Pressure Adjustment...............................13-18 Support Machine Properly......................................................... S-26
Security Functions (Optional)................................................... 1-12 Suspension Adjustment.............................................. 1-119, 1-122
Selector Knob (Monitor)............................................................. 1-75 Swing Alarm Deactivation Switch (Optional)...................... 1-82
Service Air Conditioning System Safely................................ S-36 Swing Bearing................................................................................. 7-22
Setting Menu.................................................................................. 1-25 Swing Internal Gear...................................................................... 7-23
Shackle Hole Usage...................................................................... 5-22 Swing Reduction Gear................................................................. 7-42
Shoe Types and Applications Switch Panel.................................................................................... 1-74
ZX130-5A.................................................................................... 12-3 Switch Panel (for Optional Equipment)................................. 1-81
ZX130-5A with Blade............................................................13-12
ZX160LC-5A............................................................................... 12-7 T
ZX200-5A..................................................................................12-11 TRANSPORTING.................................................................................6-1
ZX200LC-5A.............................................................................12-12 TROUBLESHOOTING..................................................................... 11-1
ZX210H-5A...............................................................................12-13 Temperature Control Switch/Mode Switch
ZX210K-5A................................................................................12-18 (Air Conditioner)....................................................................... 1-75
ZX210LCH-5A..........................................................................12-14 Tightening and Retightening Torque of Nuts and
ZX210LCK-5A...........................................................................12-18 Bolts............................................................................................7-121
ZX240-5A..................................................................................12-25 Time Adjustment........................................................................... 1-26
ZX240LC-5A.............................................................................12-26 Tips for Optimal Air Conditioner Usage................................ 1-99
ZX250H-5A...............................................................................12-27 TONE Control................................................................................1-103
ZX250K-5A................................................................................12-29 Towing Machine a Short Distance..............................................4-6
ZX250LCH-5A..........................................................................12-28 Transmission................................................................................... 7-41
ZX250LCK-5A...........................................................................12-29 Transport Safely............................................................................. S-24
ZX300-5A..................................................................................12-34 Transporting.................................................................................... 13-3
ZX300LC-5A.............................................................................12-34 Transporting by Road.....................................................................6-1
ZX330-5A..................................................................................12-41 Travel Alarm (Optional)..................................................................4-4
ZX330LC-5A.............................................................................12-41 Travel Alarm Deactivation Switch (Optional)...................... 1-82
ZX350H-5A...............................................................................12-42 Travel Mode Switch..............................................................1-77, 4-4
14-4
INDEX
Travel Operation............................................................................ 1-64
Travel Reduction Gear................................................................. 7-43
Traveling and Other Cautions................................................... 13-2
Troubleshooting............................................................................ 11-1
Tuning Procedure........................................................................1-100
U
Understand Signal Words..............................................................S-1
Unit Selection................................................................................. 1-53
Unloading...........................................................................................6-5
Use Handholds and Steps.............................................................S-6
Using Booster Batteries..................................................................3-9
Using Cigar Lighter ...................................................................... 1-87
Using Cigar Lighter Port as External Power Source.......... 1-87
Using Pad Crawler Shoe.............................................................. 13-1
V
Vibration Level..............................................................................12-45
W
Warming-Up Operation.................................................................5-3
Warn Others of Service Work.................................................... S-26
Wear Protective Clothing..............................................................S-3
When Windows Become Clouded........................................... 1-99
Wiper/Washer Switch................................................................... 1-79
Work Light Switch......................................................................... 1-78
Work Mode........................................................................... 1-22, 5-10
Working Ranges
ZX130-5A with Blade............................................................13-11
ZX240-5A, 240LC-5A.............................................................12-23
ZX250H-5A, 250LCH-5A, 250K-5A, 250LCK-5A............12-24
ZX300-5A, 300LC-5A.............................................................12-33
ZX350-5A, 350LC-5A.............................................................12-39
ZX350H-5A, 350LCH-5A, 350K-5A, 350LCK-5A............12-40
ZX130-5A.................................................................................... 12-2
ZX160LC-5A............................................................................... 12-6
ZX200-5A, 200LC-5A, 210H-5A, 210LCH-5A.................12-10
ZX210K-5A, 210LCK-5A........................................................12-17
14-5
INDEX
MEMO
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14-6
CONFORMITY
The EC Declaration of Conformity includes the machine
without accessory, unless fitted with accessories approved
by Hitachi Construction Machinery.
The EC Declaration of Conformity will lose its validity for
any modification of the machine without approval.
Legal Provisions; Manufacturer;

The machine fulfills all relevant provisions of the following Hitachi Construction Machinery Co., Ltd.
directives (and their amendments)
2014/30/EU Electromagnetic compatibility 650, Kandatsu-machi, Tsuchiura-shi, Ibaraki-ken, 300-0013
2006/42/EC Machine Japan
2000/14/EC Noise emission
Notified body for 2000/14/EC

SNCH
Société Nationale de Certification et d’Homologation
S.à.r.l. 11, route de Luxembourg L-5230 Sandweiler
Conformity assessment procedure followed;

Annex VI

ZX350H-5A Operation Manual

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PART NO.

ZX120-5 • 160-5 • 200-5 • 240-5 • 300-5 • 330-5 class

URL:http://www.hitachi-c-m.com 330-5 class

ZX200-5 class 300001 and up

©2017 Hitachi Construction Machinery Co., Ltd.

Product Identification Number

fNOTE: Marks to indicate the

PRODUCT IDENTIFICATION NUMBER (PIN)

(ZX200-5, 240-5, 300-5, 330-5 class) MDAK-00-001

Recognize Safety Information

Understand Signal Words

 NOTE: indicates an additional explanation for an

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handholds and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

OPG: Operator Protective Guard

Restriction of Attachment Installation

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

 Driving on a slope may cause the machine to slip or SA-657

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep Person Clear from Working Area

Never Position Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

If lightning comes close, immediately stop the operation,

Never Allow Machine to Engage in Crane Work

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

 All fuels, most lubricants, and some coolants are flammable.

3. Turn auto-idle switch OFF.

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Remove the key from the key switch.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying

 Travel reduction gears are under pressure.

Avoid Injury from Attachment Falling Accident