ZX 40 U-2 Hitachi excavator specs & dimensions (2005 - 2010)

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.
Warranty is provided as part of Hitachi's support programme for customers who operate and maintain their equipment as described in this manual. The warranty is stated on the guarantee certificate that you should have received from your dealer. This warranty gives you the assurance that Hitachi will return its products if defects occur within the warranty period. Under certain circumstances, Hitachi also provides field improvements, often at no charge to the customer even when the product is not guaranteed. Adjustment of fuel delivery via specifications or other overloading machines results in such an action. Only qualified, experienced (under local law) officially approved operators should be allowed to service the machine. In addition, only officially licensed personnel should be permitted to inspect and maintenance the machine. Prior to operating this machine in a country other than his intended country of use it may be necessary to make changes so they comply with any local standards (including safety standards) and requirements laid down by these countries. Please do not serve this machine outside the country of planned operation until such compliance has been confirmed.

S-1 Follow safety instructions................................................................S-1 Follow the safety advices................................................................,.2 Prepare for emergencies before emergicallypreparing to all Emergants and regulations to verse 2 Wear Protective Cloth of S-2 Wevermouth Protective Harnesses...
OPERATOR'S STATION BREAK-IN OPERATING THE ENGINE
Beware of Welding and Grinding.........................................................................................................................1-5 Coolant Temperature Gauge Measurement Gauge 1-5Cool temperature gauges etc.1-5 KOLANT Temperature Check Process for Handling Refligerentallers, lines containing flammable fluids avoid keeping a heat on piping Applying an Inflammable Fluid......) 3-2 Starting in Normal Temperature....3-2 Starting in Cold Weather....4-4 (cab-equipped machines) 4-18
DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING
The Use of Booter Batteries..............................5-6 Travel Levers and Pedals.....4-1 Traveller Operation Switch Switch (extended or on soft ground, etc. to travel in smooth ground.................................................................................6-6 Precautions for the Path (2 Ways - Multi Valve 2 Ausgedo-7 Parking and Displacement (2-3-2 Boom-Sech-8 5-25 Transporting On Road.
MAINTENANCE
Insuring the machine to the trailer for transport............................ 6-3 Unloading,....7-47 Batteries
FOLLOW SAFETY INSTRUCTIONS
(cid:129) If a safety sign or this manual is damaged or missing, order an exchange from your authorized dealer in the same way as you order other spare parts (safeguard when ordering the machine model and serial number). Allow only properly trained, qualified personnel to operate the machine. Learn proper operation and service of the machine. Keep your machine in perfect working condition. Always operate the machine within specification. (cid:129) Unauthorized modifications on the machine may affect functions and/or safety and impact the life of the machine along with the warranty will become invalid. Safety messages in this SAFETY chapter are used to represent basic safety procedures of machines. However, it is impossible that these safety reports cover any possible hazard situations you might encounter. In case you have any questions relating to safety, first consult your superior and/or authorised dealer before performing maintenance work on the machine respectively PREPARATION:12 FOR EMERGENCIES, Be ready if a fire extinguisher has been installed; fire-resistant equipment must be fitted (12)
ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR'S SEAT
Before going up from the operator's seat to open/close the cab front window or adjust the seat position, you should first lower the front attachment down to the ground and then move the pilot control lock-off lever into LOCK position. Failure can allow the machine to unexpectedly move when a body part comes in unintentionally with a control lever which may result in serious personal injury or death. Prior to leaving the machine, it is essential that you make sure there is a front armature lowered on the floor before leaving the machine followed by moving the driver control locking lever towards loCK position. Turn off the key switch to stop the engine. Connect all windows, doors and access covers and lock them upwards. FAST YOUR SEAT BELT, Should the machine be overspeeded, the operator will be able to get hurt and/or thrown out of the cab. In addition, the operator can be crushed through the tilting machine causing severe injuries or fatalities (cid:129) Keep seated safely at the seat belt whenever the machine is operated (12).
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of a trench or on a road shoulder, the machine could tilt over due to a collapse of ground which may lead to serious injury or death. (cid:129) First explore the configuration and underground conditions of the construction site so that the machine does not fall down and prevent the soil, supplies or banks from collapsing. (cid:129) Make a work plan. Use machines appropriate to the workplace. (cid:129) Improve floor, edges and road shoulder as needed. Keep the machine well back from the margins during excavations and road shoulders. (cid:129) If the foot leg is weak, reinforce it before starting work. (cid:129) When working on frozen ground be extremely alert. As ambient temperatures rise, support can never be entered when working among others through swing radius or travel range. (cid:129) If there is a weak foundation, amplify the ground before they work. (cid:129) Treat one signal person according to demand.

Use a signal person when driving the machine along road shoulder or in clogged areas. Leading the machine into the wrong direction may result in serious injury or death and/or severe damage to property. Before you drive the machine, always confirm that the travel pedals/blocking direction matches your direction of travel. Make sure to disengage all obstacles. Avoid overrunning obstructions. Ground, rock fragments and/or metal parts can spread around the machine. Do not allow personnel to sit on the machine while traveling about. On one downhill it is possible to slip off or tip over which might lead to grave injury or death. Never try to climb up 30 degrees or descend or steeper slopes. Be careful to tighten the safety belt. When travelling down or down an slope keep the bucket looking at its direction approximately 200-300 mm (8 through 12 inside), above ground. If the machine begins to loose or becomes unstable, immediately lower the floor and stop using the bucket.
SAFETY
Choose a travel route that is as flat as possible. Steer the machine straight as you can and make small step changes again and again towards it. Check out the strengths of bridges and road shoulders before traveling on them, and reinforce them when needed. When the machine is equipped with steel shoes, cover the road surface with wood panels to prevent damage to the road surface. Ensure that steering must be done while operating on asphalt roads in summer. When crossing the haul path, place wooden sheets over the tracks for the machine not only being able to drive onto the rails. See if the machine can pass under a bridge and electric lines before controlling the machine. If passing through a river, let the machine slowly at the control course while measuring depth of flow using the bucket. Then do not ride the machine through the watercourse unless the depth of the stream lies deeper than the upper shoe surface. Decrease engine rotation rate after travelling on rough terrain. Select a slower travel speed. Slower speed reduces potential damage to the machine by having no loosely running rock engines.
AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS
When a person is present near the machine while underlaying or swinging the upperstructure, the machine can hit that person or drive over resulting in serious injury or death. To prevent reverse and swivel accidents: Always look around Before looking up and blurring the combine harvester. Make sure ALL BYSTANDERS ARE CLEARING. Keep the ride alarm in working condition (if equipped). ALWAYS FOR BYSTANDERS ON THE WORK ROOM OTHER USE OF HORN OR OTHER SITUATED TO WARRENT BE AGAINST MOVING MACHINE. APPLICATION A LOOK PERSON WHEL IF IT IS IMPLEMENTED IN ACCORDANCE WITH YOUR OVERVIEW. AS GENEFIT THAT GRANT PERSÖHNlich IN VIEW. Use hand signals to meet your local regulations when work conditions require a signal individual. No machine movements are made unless signals are understood clearly by both Signal Man and operator.

Provided the machine is not properly parked, hazard situations such as leaking out of the machine or damage caused by vandalism can cause the machine to operate insecurely when the engine is restarted. Follow the instructions described below while parking the machine. Park the machine on a solid level surface to prevent the machine from running away. Lower the bucket and/or blade down to ground. Pull the lock lever into LOCK position. Turn off the auto-idle switch. Inconvenient may create traveluos condition because the engine speed could unexpectedly increase (except ZX27U-2), Guide the engine with slow idle speed without load for 5 minutes. Use the key switch after OF to shut up the engine. Remove the key from the button switch. Before leaving the machine close all windows, roof fan and cab doors. Lock all access doors and compartments.
SAFETY TRANSPORTING
The risk of tipping exists when loading/unloading the machine to/from a truck or trailer bed. Be sure to observe local regulations while transporting the machine on public roads. Provide an appropriate truck or trailer for carrying the machine. Make sure there is one signal person present. Take the following precautions during loading/unloading the machine. Select firm level ground. Be aware, with a loader ramp respectively ramp strong enough to support the machine weight. Rams must be sufficient in width, length and strength. Ensure that the slope of the ramp is less than 15 degrees. Load docks have to be sufficiently wide and stronger to assist the machine and have a gradient below 15 degrees. Always turn off the auto Idle switch (13) OFF. (except ZX27U-2), drive slowly through the machine. Avoid steering whilst driving up or down the ramp as it's extremely dangerous. If steering is unavoidable, first move back towards the ground you will change flat again after your travel upwards.
PRACTICE SAFE MAINTENANCE
Inspection/maintenance work may result in a moving, high pressure and/or high temperature part of the machine by means of contacting and/or access to one part of the body. To avoid serious personal injury or death, please follow the instructions described below. Work routines that should be taken up afterwards with the personnel are coordinated thoroughly prior to start working such as checking/operating the machine respectively replacing the attachment. Safely park the machine according to the directions for Park Machine, Keep the area of work clean and orderly. Attach a DO NOT OPERATE day at an easy-to-reach location like on a door or control lever. When moisture enters the electrical system, malfunction and/or mismovement of the machine can result. Clean no sensors, cable connectors and into the cab inside using water and/or steam. Wait until cooled down parts have reached the engine and hydraulic oil temperature. If testing/preparation needs to be carried out, it is necessary to perform under compliance with a predetermined safety range; if need not exist (for cleaning components: see details).
Check Key Switch:
When a fire breaks out, the fire escalates due to engine failure and hinders fire fighting. Always check the key switch function before operating the machine every day: Start the engine and run it off at slow idle. Turn the button switch into OFF position to confirm that the engine has stopped.
REMOVE PAINT BEFORE WELDING OR HEATING
Dangerous fumes can be generated when the paint is heated by welding, soldering or using a burner. When inhaled, these fumes may cause disease. Remove paints before welding or heating. Avoid potentially toxic fumes and dust. Do all such jobs outside or in a well ventilated area. Dispose of paint and solvent properly. Allow exhaust gases to disperse at least 15 minutes after welding or heating. Never check battery charge if you are using sand or abrasive colors avoid breathing resulting dust. Wear an approved breather. Maintain sparks, ignited ignition games and flames away from the upper part of your battery. Never put a metal object over the posts. Use a voltmeter or hydrometer. Store no frozen battery; it can explode.

OPERATORS STATION 1- Lever left control lever 2- Left travellever 3- Right movelever 5- Blade Lever 6 key switch 4- Right control lever / Horn switch 7- Engine control (ZX30U-2, ZX35U-2, ZX40U-2, ZX50U‐2) Engine control lever (ZX27U–2) 8- Operator seat 9- Boom Swing Pedal 10- Monitor Panel 11- Pilot Control Shut-Off Lever 12- Door lock Release Lever (Cab equipped machine) 13- Switch panel 14- Tool box 15- Operating manual 16- Attachment pedal (optional)

1- Aus (Motor OFF) 2- Ein (Motor ON) 3- START (Motor Start) 4- HEAT (Motor Preheating) SWITCH PANEL 5- Working Light Switch Press the top of the switch to turn the worklight located on the boom and at the cab canopy front side AN. Push the underside of the switch to shut off the working light, 6- Travel Mode Switch Actuate the rabbit marker side of the switch to select quick travel mode. However, when travelling load becomes heavy, slow travel mode is automatically selected. press the turtle mark side of the switch to select Slow Ride modes. 7- Wipe Switch (Kab equipped machine) On this switch three operating positions are provided. OF: Both windshield wipers and washer do not work. WASHER: The washing machine works together with the wiper. 8-Auxiliary flow control switch ZX1-1030Z0 M1-2 2-340 Hydraulic oil flow in the auxiliary line can be controlled.
Preheat Indicator
When the key switch is turned to HEAT position, orange indicator becomes easy. Light turns off after about 15 seconds.
Fast Travel Mode Indicator
When rabbit mark (fast mode) side of travel mode switch is pressed on the shift panel, display comes ON. M178-01-041 M178-038 M1M7-01-022
AUTO-IDLE SWITCH (Except ZX27U-2)
Auto-idle operation When pressing the auto-idle switch (13) engine rpm is reduced to slow idle speed by approximately 4 seconds after return of all control levers in neutral. This reduces fuel consumption. If your auto-idle mode is selected, the auto-idle (14) indicates on the monitor panel lights. M1CF-01-002 M1M7-01-028
AIR CONDITIONER OPERATION
1- Control panel 2- Right front air fan 1 3- Right front air fan 2 4-foot air fan
NOTE: Control air-flow from right front air vents (1 and, by rotating the louver in the horizontal direction so that the air vents can be used as a defroster.
5- Air Conditioner Power Switch Press the air conditioner power switch to turn on performance.
Controller Part Names and Functions
6- Air Conditioner Switch Press the air conditioner switch to rotate the air conditioning and display (11) ON. 7- Mode switches The air vent location is selected. Each time mode switch is pressed, the mode indicator (10) changes in the order shown below. Air blows out from right front vents 1, and 2,The air blows out from right front vents 1 and 2 (3), and the foot valve (4).
Heating Operation
Although the warm air blows out from all three vents, usually the foot fan is used for heating operation. After selecting the foot fan by operating ventilation mode switch (7) press a temperature control switch to set the temperature indicator towards the right side. Set the cabin interior temperature with a temperature control switch (8). The blower speed can be adjusted manually using a blower switch (9).
Cooling Operation
Although the cooling air blows out of all three vents, usually the foot fan is used for cooling operation. After selecting the foot fan by operating-ventilation mode switch (7) press a temperature control switch to set the temperature indicator towards the left hand side. Adjust internal temperature with the temperature control switch (8). The blower speed can be manually adjusted per blower switch (9). When an air conditioner switch is engaged during the cooling process, cool air also blows from the right front fan.
Defroster Operation
Select the right-hand front vents by operating fan mode switch (7). Adjust the louvres to the right-hand front vents 1 and 2 as needed. The blower speed can be adjusted manually via blower switch (9). Via temperature control switch (8), the cabin interior temperature is adjusted. Turn on an air conditioner switch ON when windows are cloudy or if dehumidification in the cab is required. M1M7-01-039 M1M7-01-039
Rapid Cooling
The temperature in the cabin can rise above 80 C when the machine is exposed to direct sunlight with enclosed cab windows. Under this condition, if the temperature needs to be quickly cooled down in the Cab, air from the Cabin first by opening the windows. After starting the engine set the temperature control on the wide left end using a temperature control switch (8). Select the right front ventilation mode. Perform the blower at slow speed position. Turn on an air conditioner switch, ON. Keep the Engine running for several minutes at slightly faster speed (over 1000 min-1[rpm]), increase fan rpm. If the air temperature in the compartment is lowered to the atmosphere, close the windows.
If Windows Become Clouded
The windows become turbid when the moisture in the cab gets high. Operate the air conditioner to keep the windows clear. If the atmosphere is very damp, the exterior of the windows can be clouded if the air conditioning system is operated over longer time periods. In this case stop the air-conditioning and/or adjust the air temperature in the cabin.
When the air conditioner is not used
If the air conditioner is not used to protect each part of the compressor from a lack of lubricant, operate the air conditioning system at least once a month for several minutes with the engine running at a slow speed. When the cab temperature is lower than 15 C (59 F), it must not work. In this case, warm up the cabin inside using the heater first to raise the canopy temperature.
Part Name and Function
1- Power Switch/Volume Control Knob Turn the button to the right to deliver electrical power (a click sound is heard when the unit is ON). Rotate the knob further to turn up the volume. Turning the button in reverse direction to shut off the volume and display the device OFF. 2- Sound control knuckle Turn the button to the right to reinforce height amplification level. Spin the button to the left to reduce scraping angle. 3- Display time, reception of radio wave frequency or operating mode is displayed. 4- Clock Button Press this button to show timing. Actuate this button to indicate receiving radio shaft frequency. 5- Auto Storage / Scan Presetting Key (AST) Press this key box to receive preset frequency station for every 5 seconds sequentially. While you get the station you want to listen to press again with this button to receive under normal condition of the transmitter (can be interrupted).
1. Disengage lock lever, provided at the upper right
and left corner of the front window. Hold the handles (at two points) on the front window frame and raise the window until the lock lever engages with the window frame.
BEFORE STARTING ENGINE
1. Check pilot's shut-off lever in the LOCK position. Confirm that all control levers are neutrally placed. Control indicator lamps as follows: Turn key switch to ON position. All indicators and warning lights arrive. They remain on for about 3 seconds, with the exception of alternator plus engine oil pressure gauge which will persist.
Starting in Ordinary Temperature
1. Check the pilot's shut-off lever in LOCK position. Turn the engine control dial or motor control lever into slow idle position. Actuate the horn to warn bystanders. Switch on key switches to turn the starter. The engine is started.
over discharge. Never run the starter for more than 20 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.
5. Unlock the key switch immediately after starting the engine. It automatically returns to ON position.
Starting in Cold Weather
1. Check if the pilot's shut-off lever is in LOCK position. Rotate the engine control dial or motor control lever around the center between the slow and fast idle positions. Turn the key switch to the HEAT position and hold it off for about 15 seconds in this position until preheat indicator goes OFF. Ring with the horn to alarmbystanders. As soon as the preheating indicator is turned off, there will be a return button back to the START position when performing the starter.
over discharge. Never run the starter for more than 20 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.
6. Unlock the key switch immediately after starting the engine. It automatically returns to ON position.
STOPPING THE ENGINE
Stop the engine by following the steps below. Before stopping the engine, lower bucket and blade to the ground unless otherwise stated. Resetting the engine control clock or control lever into the slow idle position keeping the engine running at slower idle speed for 5 minutes. Rotate the key switch, OFF to stop the engine. Pull pilot control shut-off levers up in loCK position. M1M7-01-007
NOTE: Travel lever dampers are provided for smooth control. In extremely cold weather (lower than -20 °C (-68 °F)), the travel lever (or pedal) will become heavy to operate. This is caused by increase in oil viscosity which is not abnormal.
Forward/Reverse Travel Move both levers (or pedals) together forward. Pull the levers (or pedals) back together to travel in reverse direction. The travel speed can be controlled by adjusting the operator lift on the lever (or pedal). Ascending/Degressing Slopes Gradability of machine is 30 (58%) when lowering a slope, ride levers (or pedals) can be operated slowly. When driving levers are neutrally placed, travel brakes are automatically applied to stop the machine.
DRIVING THE MACHINE
Pivot Rotate Steer the machine by driving just one side crawler. Actuate either the travel lever (or pedals). Spin Switch Steer the machine to each other in one position by driving both sideworms in opposite directions. Move one lever (or pedal) forward and pull back the other at the same time.
WARNING: Never attempt to shift the travel mode from the slow to fast while descending a slope. Return the travel levers (pedals) to neutral once before shifting the travel mode.
Press the RABBIT marker side on the travel mode switch to select quick travel mode. (The slow travel mode is automatically selected when travelling loads increase.) Push the TURTLE indicator side at the travel mode switch to choose slow travel mode.
TRAVELING ON SOFT GROUND
Avoid travelling on soft ground as far as possible. If traveling on a soft ground is unavoidable, operate the machine carefully when observing the following points. Travel with the machine up to the machine can move through its own drive force. Towing machine may become necessary. Do not guide the machine to a deeper place than hauling machine is possible. In case it becomes impossible for the machine to travel by self-handling power, lower the bucket down to the ground. Support the machine weight with the boom and arm, slowly pull out the arm around the machine clearance. Press Boom, arm and travel levers simultaneously at this time to prevent abnormal loading of the machine. Step into contact with the ground or mud and/or diggers are tightly packaged in the undercarriage, then the machine could be impossibly mobile. Raise a side track over the floor with an extended boom and arm, remove mud and/or ditches firmly packed into the undercarriage.
M1M7-04-004
Machine model ZX27U-2 ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 Operatable water depth, 480 mm (19 in) 485 mm (19 in) 545 mm (21 in)
WARNING: Parking and/or stopping on slopes is extremely dangerous. Avoid parking and/or stopping the machine on slopes.
When parking and/or stopping on slopes is unavoidable, both lower the bucket and blade to the ground; place all levers in neutral position. Also put blocks at the downhill end of tracks. Park the machine on a level, solid surface. Set the arm vertically and lower the bucket and knife to the ground. Turn the engine control dial or control lever to slow idle position. Run the engine with the slower idle speed for about 5 minutes to cool off the En3. Use the key switch after shutting down to stop the engine. Remove the key from the switch. Pull pilot control lock-off lever into full LOCK position. Close windows and cabin gate if there is a cab available.
WARNING: Be sure to check the location and function of each control lever before operating. The upper structure and/or front attachment may unexpectedly move when attempting to turn and look behind the machine as a part of operator's body may come into contact with the control lever(s). Take care not to come into contact with the control levers when turning and looking behind the machine.
The labels showing the lever control pattern are located on the right hand side of the operator. As shown below, the labels indicate the ISO Excavator Pattern. When a control lever is released, it automatically returns to neutral and stops the function in that position.
M588-05-050
1- Arm Roll-Out 2- arm Roll-In 3- Swing Left 4- Swing Right 5- Boom Lower 6- Boom Raise 7- Bucket Roll-in 8- Bucket Roll-Out
WARNING: Make sure to check the location and function of each control lever before operating. The upperstructure and/or front attachment may unexpectedly move in an attempt to look back because a part of operator's body may come into contact with the control lever(s). Take care not to come into contact with the control levers when looking back.
The labels with the available lever control patterns are located to the right of the operator. As shown below, H-patterns on the bottom right hand corner display the HITACHI Excavator Pattern. When a control lever is released, it automatically returns to neutral and stops the function in that position.
M1LA-05-014
1- Swing right 2 swing left 3 arm Roll-out 4 arm Roll-in 5 Boom Lower 6- Boom Raise 7- Bucket Roll-in 8- Bucket Roll-
M1M7-05-028
When a control lever is released, it automatically returns to neutral and stops the feature in this position. 1- Boom Lower 2- Boom Raise 3- Swing Left 4- Swing Right 5- Arm Roll-Out 6- arm Roll-In 7- Bucket Roll-in 8- Bucket Roll-Out

Use the boom swing function to efficiently operate the machine when excavating grooves along road edges or close to walls. Boom oscillation is performed with the boom swing pedal located at the right foot of the operator, as shown to the right.
Boom-Swing Operation
1. Rotating lid, for boom swing pedal, forward. Steps on the left side of outriggers swing pedal to swing left. Step on the right side of the pedal towards oscillation right. Turning cover, reverse over boom swing pedal when boom swing operation is no longer required. Position unlock 3-Swing Left 4-Swing Right Lock position

Use the auxiliary pedal on the operator's left-hand front, as shown to the right in order to operate hydraulic breakers, breakers etc.
Operation
1. Rotate the auxiliary pedal cover, forward. Enter right or left of the auxiliary pedal to operate the front end attachment like a hydraulic breaker, If the auxiliary pedal is not used, turn the cover backwards on the pedal.

Use the blade lever, on the right hand side of the operator to raise and lower the blade. When released, it automatically returns to neutral; so it holds the leaf in the present position until the lever is re-operated. 2- Blade Raise 3- Blade Lower
PILOT CONTROL SHUT-OFF LEVER
The pilot control shut-off lever is a device to prevent the machine from operating unexpectedly, even if the control levers are accidentally moved, such as with one part of the body or when the operator enters into/from the operator's station. Pilot control cut-off lever, connected to consoles, locking mechanism so that the console increases in LOCK position for help on entering and exiting the operator‘s station plus maintenance.
Before Leaving the Machine:
1. Park the machine on a firm, level surface. Lower the bucket and blade to ground. Return all control levers in neutral. Stop the engine. For deactivating Control Lever, feature, be sure to pull pilot-control shut off lever, and increase console, into the fully locked position.
WARNING: Never attempt to lower the raised console (to reactivate the pilot control shut-off function) by holding and pushing down control lever, and/or console (2). Always lower the console using pilot control shut-off lever (1).
When starting the engine, absolutely keep the pilot control shut-off lever, in LOCK (increased) position. Slowly lower pilot control shutdown lever, to UNLOCK position before operation starts. After moving the pilot control shift lever into Unlock position check if no activators move when all control levers and pedals are in neutral condition before operating is started. If an actuator moves onto unlock position after pressing the driver control lock lever with all control levers and pedals in neutral position, then the machine can get problems.
1. Run the engine at 100 to 200 min-1 (rpm) above slow
Idle speed for 5 minutes. Run through the engine five to 10 minutes with the Engine Speed Control Lever or Mid-position Engine Speed Control Clock. Extend and pull out each cylinder several times, easily operating the swing and travel motors to warm it up.
IMPORTANT: In case the hydraulic oil temperature is low, never operate the machine until all actuator speeds become normal after warming up operation.
1. Run the engine with an intermediate speed for 5 minutes (longer when air temperature is extremely low). Do not let the engine run at either slower or faster speed during this time. Extend and pull out each cylinder several times, making it easy to warm up swinging and travel motors. Expand the bucket cylinder down to the lifting end. Don't hold onto the bucket lever in that position for more than 30 seconds any longer. Pull back the bucket cylinder to the other lift end. Be sure to keep the bucket lever here within over 30 seconds. Repeat steps 4 through 2.

M1M7-01-028 OPERATING THE MASCHINE AUTO-IDLE CONTROL (Except ZX27U-2) Auto-idle Function During operation, about 4 seconds after all control levers have been returned to neutral, this system reduces the engine speed to self-return setting until each control lever is operated again to improve fuel consumption. The engine rpm immediately increases to the speed set by the engine control selector when a control lever is operating. NOTE: Always check whether an automatic on/off switch indicator is engaged, or OFF prior to operation. When the display is turned on, the auto Idle function functions instantly. If activated from any control lever from its neutral position with an auto idl switch, then the engine RPM will rise to the adjusted rev rate through the engine control dial. Therefore, always keep in mind the adjustment of an engine control circuit before starting operations to prevent unexpected increased engine rotation. When unscheduled machine movements could be dangerous such as during loading/unloading and unloading your machine respectively

OPERATING THE MACHINE OPERATING BACKHOE, Choose an arm and bucket whose specifications match the working conditions. (Referring to types and applications of buckets in the specification section.), Pull the bucket with the arm as main digging force towards the machine. When soil sticks on the bucket, quickly remove it by moving the arm and/or bucket back again and a few more times. While the shovel tooth tip digs forward just as possible, relieve the ground with teeth that penetrate flat using arm and bucket cylinders full strokes. Position the tracks parallel to the trench. After excavating to the desired depth move the machine backwards to continue the ditch. Operate each cylinder with a minor addition left at both impact ends. IMPORTANT: Do not dig the ground into diagonal direction against the track frame. Failure can cause the bucket teeth to be in contact with the crawler. When lowering the boom sudden stops can be avoided, always causing shock when the machine is being laid down or producing damage during one-boilt operation.
GRADING OPERATION
Use the blade for soil fill and general grading after excavation. Grading can also be done by simultaneous operation of the boom, arm and bucket.
When grading by operating the boom, arm, and bucket simultaneously:
1. When grading from forward to reverse, roll slowly in the arm while easily raising the boom. As soon as the arm passes the vertical position, let the boom lower more slowly so that the bucket can be moved horizontally. When grading from rear to front, operate arms and buckets rolled back like shown. Single-leveling of an incline surface may take place by operating the machine using the same method as mentioned above.
WARNING: The bucket bottom is curved. Therefore, hammering or piling work with the bucket is very hazardous. In addition, damage to the bucket and the front attachment parts may result.
Hammering or cutting work with the bucket can cause dangerous situations. Never try to perform hammer or pilling jobs with the bucket. Damages on the bucket and front attachments also result. Never shift rocks or lift a cliff by hitting the bucket using upperstructure and/or boom swing force. Harm the front attachment respectively shorten the life of the swing systems. Do not use rubber crawlers or wide track shoes in rough terrain with scattered stones, gravel or rock blocks. Failure may lead to breakage of rubber sledges, shoe bending, lotion of shoe bolts or damage follow-up parts such as rail links or rollers during travel operation on sandy ground (referred to table for types and applications of track shoes in specification).
2000
9. Lubrication Front Attachment When using a hydraulic breaker, all greasing points on the front attachment lubricate every 50 hours of operation.
OPERATING THE MACHINE
When crushing objects in high positions such as a ceiling, press the machine carefully so that falling objects do not come into contact with the machine. Before operating the machine on a floor of a building, check whether the ground is strong enough to support the machine weight. Depending on the type of work being done, the machine will be engaged, fragile responsive force can be added next to the machine weight to the ground. Start operation only after the machine has parked horizontally and stabilized one foot. Never operate the machine positioned on debris piles or sloped ground. Moving/loading shredded material using the quencher. If you replace the breaker with other work tools like a bucket or burglar, the hydraulic oil can easily be contaminated. Change the hydraulic oil and replace the full-flow filter element at same intervals as during hydraulic subruption. Prior to transporting the machine onto a trailer remove the crawler from the front attachment. Position the shovel cylinder so that the cylinder cannot be fully extended during transportation (no more than 1 dynamometer should be displayed for travel) No swing system was installed; no lifting device could have been fitted when any suspension mounted either:

TRANSPORTUNLOADING WARNING: Always turn the Auto Idle Switch OUT. (Except ZX27U-2) Failure can cause engine speed to suddenly change. Drive always slowly through the machine. Push the travel mode switch towards TURTLE, steering at a ramp may cause a risk of tipping over. Never try to change direction on a ramp and thus possibly cause an instabilization of the machine. The upper end of the ramp where it corresponds to the flat bed is a sudden bump. Slowly drive over it. Watch out when you rotate the superstructure around the flatbed to prevent possible injury from machine tilting away. Slowly spin with under the boom fully rolled arm in the lower arm to maintain the machine in good stability. IMPORTIG: Keep angle between boom and arm during loading process at 90 – 110 o'clock. When the machine gets unloaded with the completely rolled arm, damage to the base machine can not be seen as being positioned before the front dumper for more than long time after mounting up until the rear axles have been moved forward so that there are no longer any signs of rollout or slippery points above this level!
Be sure to set the blade position with the engine running. Failure to do so may cause the blade to be moved from the set-position when lifted with a crane.
1. Swing the upper design, so that the blade is positioned at the rear of the counterweight. Put the blade cylinder fully in place. Fully extend the boom, arm and bucket cylinders, as illustrated to the right. Pull the pilot control shut-off lever into LOCK position. Set the boom straight ahead of the upper structure. Apply the boom swing pedal lock. Attach shackles on the boom and shovel hook. Safely tie threaded wire ropes through the handles. Raise the machine slowly for shock loads not to be applied with the machine. Be careful not to lose any balance of the machine. ZX50U-2: 2400 mm (94 in) ZX30U-2: 2000 mm (79 in) ZX35U-2: 2000 mm (79 in) ZX40U-2: 1900 mm (75 in) ZX50U-2: 1700 mm (67 in) ZX27U-2: 4450 mm (175 in) ZX30U-2: 4200 mm (165 in) ZX60U-2: 4300 mm (165 in) ZX45U-1): 400 U-2: 1800 mm (170 in) ZX500U-2: 1,700 mm (269 in) ZX25U-2: 700 mm (192 in) ZX31U-53)
PREPARE MACHINE FOR INSPECTION/MAINTENANCE
Before performing the machine inspection/maintenance, park the machine as described below unless otherwise stated. Park the machine on a fixed level surface. Lower the work tools such as the bucket and/or blade to the ground. Rotate the auto-ideal switch OFF. (except ZX27U-2), Run the engine with slow idle speed without load for about 5 minutes to cool down the engine. Switch off the key switch. Unlock the key from the switch. If testing/maintenance has to be performed during running engine, absolutely set an outstand so that the machine is not accidentally operated by other people. Make sure pilot control lock levers are placed in LOCK position. Attach a subINSPECTION/MAINTENANCE tag at a visible location like e.g.
DAILY INSPECTION
Bucket Cylinder Link B Link A Bucket Side Cutter Work Light Cylinder Control Lever Cylinder Solenoid Valve Activator Front Idler Fuel Filter Track Adjuster Track Frame Hydraulic Oil Tank Full Flow Filter Suction Filter Swing Device Radiator, Oil Cooler Center Joint Water Separator Muffler Engine Engine Oil Filter Counterweight Upper Roller Travel Device Pilot-Filter Control Valve Machine Oberbau Unterwagen Checkpoint M1M7-07-059, quantity and contamination of engine oil and coolant, Easily starting the engine, exhaust paint, abnormal noise, oil and coolant leaks. Damage to hoses and piping lines, clogging or damaging radiator/oil coolers, lots or missing nuts and bolts, fuel level, leakage and contamination Foreign material, hydraulic oil level, unsealed as well as contamination of foreign materials, control lever lift, lever play, operating power, operating condition hydraulic components, damage / oil leak points in hoses and lines, damage
PERIODIC REPLACEMENT OF PARTS
To ensure safe and long trouble-free operation, perform regular inspections of the machine. In addition, the parts listed below refer directly to safety operations so that they are recommended to be periodically replaced. These partial material properties change due to aging or repeated operation may cause wear, wear and/or fatigue of these parts, possibly resulting in serious safety / fire hazards. It is very difficult to estimate the remaining life of those parts by sight check alone. For this reason replace these parts at intervals shown in the tables below. If any of these parts have been found defective by checking, immediately replace it independently from the recommended intervals. Turn to your authorized dealer for correct replacement. Periodic Replacement Parts Interval Engine Base Machine Hydraulic System Front Attachment Fuel Hose (Fiuel tank to filter) Fuel hose (fuel tank to inject pump) Heater (Heating device to engine) Engine rubber vibration Isolator Ground attachment Rubber Pump Coupler Pump suction hose Suction hose Swivel hose Auxiliary hose Oil cooler hose (Cowlable oil cylinder). All Boom Cylinders & Armsticks: 2 Years Excavator - Cooling system with full power supply The following steps can also be used when you need more detailed information on how many different types of maintenance work performed during
Front Joint Pins (Incl. Swing Post Joint Pins) --- every 500 hours or every year (every 100 hours up to 500 hours of operation)
1st position machine with the arm cylinder fully retracted and the bucket cylinder completely extended. Lower bucket to ground (front attachment control position). All greasing points can be lubricated from ground level. Grease all grease fittings shown below. Boom cylinder rod end, boom cylinder bottom
Precautions for Front Attachment and Blade Removal
1. When pins are removed to replace the front attachment or blade, you should not try to clean the bores of the bushing interiors. Before installing the front attachment or blade put grease sufficiently on the pin boom ends or dust seals of cylinders. Be sure to use at least one shim on either side of the fore-joint pins. When disassembly a swing post coat the pins and push plates with grease before making rebuild.
WARNING: Before lubricating the swing bearing, lower the bucket and the blade to the ground, stop the engine, and place the pilot control shut-off lever to the LOCK position. Lubrication and rotation of the upperstructure must be done by one person only. Be sure to check that no personnel are present around the machine before starting to work.
Lubricate over grease fittings (1). Lower the bucket and blade to the ground, stop the engine as well as put the pilot control shut-off lever into LOCK position. Add grease with a grease gun by two or three strokes. Lower the bucket and blade to the ground. Raise the bucket about 200 mm (8 in) above soil. When turning top construction style, add grease at approximately every 90 intervals on 8 sites until the upper structure is made up of two revolutions.
WARNING: Before lubricating the swing bearing, lower the bucket and the blade to the ground, stop the engine, and place the pilot control shut-off lever to the LOCK position. Lubrication and rotation of the upperstructure must be done by one person only. Be sure to check that no personnel are present around the machine before starting to work.
1. Remove the cover from the bottom center of the undercarriage. Check whether grease is cloudy inside by mixing water or dirt. Apply grease via lubrication to add the amount shown in the table, To apply grease evenly on the swing gear, raise the bucket about 200 mm (8 In) above ground level. When swivelling the upperstructure at approximately 90 intervals up to a full turn, add grease at each interval. ZX27U-2 ZX30U-2 ZX35U-2 ZX40U-2 ZX50U-2 GREAT quantity (0.21 US qt) (0.21 US qt) (0.21 US qt) Total Grease Capacity 3.0 to 3.3 L (3.1 to 3.5 qt) 3.2 to 3.5 L (3,4
Control Lever Universal Joint --- every 500 hours or every year
Pull the rubber boots up under the right and left control levers, remove two screws to remove bracket (2). After shifting the rubber boots upwards add grease to the four locations of the pilot valve pusher as indicated by arrows.
WARNING: Be sure to work only after oil temperature is low or before operation. Failure to do so may allow high temperature oil to spray, possibly causing severe burns.
1. Park the machine on a firm level surface. Position the machine with the arm cylinder fully retracted and the bucket cylinder completely extended. Lower the bucket and blade to the ground. Stop the engine. Before replacing the element, absolutely disengage the hydraulic oil tank cap to release air pressure from the hydraulic oil tank. Disconnect four bolts to remove cover as well as O-ring (3). When pressing the lid slowly take away cover so that this spring does not fly out. Remove Spring (4), Valve and Element (6). Make sure water and/or dirt are not allowed to enter into the filter housing. Do not consider any damage element or O-ring (3). Don't use broken element. Install new item (6), and O-ring, install protective cover in the hydraulic oil tank, with four bolts (1). Reinforcement torque: 49 Nm (5 kgf m, 36 lb ft) After replacing the element, vent ventilation from the pump. Check the oil level in the hydraulic oil tank (see below
Procedure of Coolant Change
1. Remove the radiator cap. Open the drain cock, on the radiator and empty the drain valve to the water jacket so that the coolant can be completely drained. Drain contaminants such as a water leveling device at the same time. Enclose a radiator drain tap along with the drain valve on the water coat. Fill the radiator with fresh water including less impurities or normal tap water and a radiator cleaner. Start the engine and perform it at a speed slightly higher than slow idle to raise the refrigerant temperature until the needle of the temperature blade enters the white zone. Then continue running the engine for about ten minutes. Stop the engine and open the cooler drain bar allowing the cooling agent to run off. Rinse the cooling system with fresh water including less impregnability or normal piping water until it becomes clear. This helps remove the strainer from the water scalar. Tight-cooler drain fag (1). Replenish the chiller after few uncleaners respectively

MAINTENANCE, ELECTRICAL SYSTEM IMPORTANT: Improper radio communication equipment and associated parts as well as improper installation of the radio communications equipment impact on the electronic parts of the machine. They cause involuntary movements of the machine. Plus, faulty installation of the electrical attachments may result in machine failure and/or fire to the machine. Be sure to ask your authorized dealer when installing radios or additional electric parts or when replacing electrical parts. Never try to disengage or modify the electrical/electronic components. If necessary, please turn to your authorised dealer. Batteries ATTENTION: Battery produces explosive gas during operation or loading. Keep spark plugs and flames away from the battery. Do not continue to use it or charge if the electrolyte level is lower than indicated. Exploitation of the battery can result. Charging battery in a well ventilated area. Sulfuric acid in the battery electrolyte is toxic. It's strong enough to burn skin, drain holes into clothing; blind eye-blind
Electrolyte Level Check
1. Check the electrolyte level at least once a month. Park the machine on level ground and stop the en3. Check the electrolyte level. 3.1 When checking the level from the battery side: clean around level control lines with a wet towel. Do not use dry towel. Static electricity may develop, causing the battery throttle to explode. Make sure that the electrolyte level is between U.L (upper level) and L.L (lower grade). If the electrolyte level is below the middle level between U.L and L.L, fill immediately distilled water or commercially available accumulator fluid. Pay attention to refilling before recharging (operating the machine) with distilled water (operation of the machine). After filling, the filler stub will be safely tightened. 3.2 If it's impossible to take out this level from U.L (Up Level) L.L (underlevel) M146-07-109 Filler Port Sleelch batteries side or without any check mark on the side when they can be filled up more easily than you can get off top end-to-end respectively lower down/low surface levels
Precautions for Handling Batteries
When electrolyte spills onto your skin or clothing, immediately rinse the spilled skin or clothes with water. Then wash them sufficiently with soapy water. If electrolyte squirts into your eyes, conduct your eyes for 10 to 15 minutes with water. Let yourself be supplied medically without delay. Do not use fire hazards such as matches or tobacco respectively do not let sparks fly close to the batteries. Perform battery maintenance only after turning the key switch OUT and removing Battery Caps. Touch the batteries shortly after operation is dangerous. Wait for the batteries to cool. During charging Batteries produce flammable Hydrogen Gas. Take out the batteries from the base machine. Load up then in the well ventilated area only after taking off the lids. When disconnecting the battery clamps you should necessarily first separate the negative (ground) terminal plus make a final connection to the negative (hub factory) terminal when reconnecting to the battery terminals.
Installation
1. Clean the remote pins and pin bores. Put sufficient grease on the pins and needle bores. Place a new bucket in a stabilized position. Add the arm to hole A and link to hole B with plug-in pins. Safely place the lock plates all bolts. Reinstall the seal O-ring to the specified position. Apply greasing grease onto all post joints. Start the engine and run it through in slow idle. Operate the bucket slowly in both directions to check any interference during shovel movement. Push the o-rings out of the predetermined position to the Buckel Boast side. Remove Bucket Bolts A and B to disconnect the arm and Bucket Boss O-ring Shift.
Check the refrigerant level
After operating air conditioning in cooling mode for 2 to 3 minutes, with the engine running at 1500 min-1 (rpm), check refrigerant level through sight glass (inspection window), on receiver dryer (1).
water. Take care not to splash other parts of the cab with water. Don't increase the water pressure speed by squeezing the hose end. Never use steam to clean the cab floor. Always clean the cab floor only after closing ducts (1, 2, and, to prevent water from entering the duct. Failure to do so may result in malfunction of the air conditioner. If the box located under the seat is splashed with water, failure of the inside electrical parts may result.
1. Park the machine on a level surface. Lower the bucket to the ground. Stop the engine. Wipe the dust from the cab floor and pedals with a brush, or use a brush when straightening the water. (Slip out the mud and bust away with a brush as far as possible before applying water.), When cleaning the floor mat sweep off the dust and/or water along the grooves at the floor mat. When cleaning the cabin soil with remote floor mat remove only the rear mat. Then return the dust and/or water through the steps. If serious dirt is stained during cleaning by using lots of water, check whether no water is permeated into the air conditioner unit by removing the floor plates. In addition, clean the recirculated air filter. Once a water penetration is detected, continue in the blower for a few minutes until water drops disappear.

IMPORTANT: The operating torque of the variable displacement bolt MAINTENANCE, must be less than 24.5 N m (2.5 kgfm, 18 lbf ft). If operation torque exceeds 24.5 N m (2.5 kgfm, 18 Lbf ft), bolts need not yet be completely removed. Check again if all bolts are taken out completely. When the canopy or cabin is tilted without removing bolts (3), a variable displacement bolt may be deformed, cracked or damaged. Then the adjustment bolt (4) will be replaced. 10. Turning adjusting screw to tilt forward for roofing or cab construction attachment. Bolt size: 17 mm 11. Turning-rearranged set screws, clockwise up to the disc plate, at the side of the ground slope mechanism moved to the end of the floor tipping mechanism. ATTENTION: Should the cab be mounted, stop flipping on the bottom before the windscreen panel reaches the scraped area. If the soil becomes inclined into the striped area, then it's possible to exit from the driver‘s house and drop off under any circumstances when there is no longer room space in which has been used as an auxiliary feature that
STORING THE MACHINE
1. Wash the machine thoroughly to remove dirt, soil and debris from the machine. Investigate the machine. Repair worn or damaged parts. Install new parts if necessary. Clean the primary air cleaner element. Lubricate all grease points. Pull back all hydraulic cylinders as far as possible. If not, coat exposed cylinder bars with grease. Park tracks on long stable blocks. Remove the batteries and store them completely in a dry protected place after loading. If not removed, disconnect the negative battery cable from ( ) terminal. Add an anti-rust agent. In cold weather, add a freeze guard device respectively drain the coolant completely down. Pay attention when leaving the system hang up No Water in Radiator Day at a clearly visible location when the system is watered out. Solve the light change belt and fan belt. 10. Paint essential areas to prevent rust.11 Maintain the machine in a dry, protected space.
INDEX
AM/FM Radio operation................................................1-16 Additional counterweight.................................................16 Additional Counterweight...................................................................................................................................................................................................., FM MAM/FM Radio radio operating....M Am/FM Radio Operator's Mode of Radio Operating....VOM/FM Radio Operation (Robber Crawler) 1-1 Adjusting Track-Sag (Rubber crabr Crawler) and Check for Damage damage to the against Wed(Rubber Crawler) And Verify for damage You must not miss the operator‘s seat in the operator? Seat is missing The operator ́s seat: Be Missed H from the operator : See V To Any Damage.... ... All Optional) (heart zX1218Replacement) (Auß (2 zur Ausweise ZX20690C40l ) ( Excluding ZXXXX XXXx26RU 2) ( 7-40 Verify the Air Conditioning (Machmaschinen)............................7-25 Test air system (Machin mit Kabine)....170-725 Check of airver check hoses and lines etc, HITACHI Excavator Pattern).......5-2 Control Lever (ISO Excavator Pattern), 5-1 Control Lever (SAE-Backhoe Pattern); --- If Equipped (2 Way Multi Valve).................5-3 Control Lever Universal linkage with control levers 7-16 Coolant Temperature Gauges 1-5 Coolant System 2-4 Crusher Operation (optional): which are inspected daily is not suitable only for use in craning operations S-18 Drain Fuel Tank Sumps starting from 6-20 Dewatering Hydraulic Oil Tank Splashed water and on soft ground 7.-24 Drive Machine Safely Fitted under Water Level 4 or lower emergency level 6.6-6 Engine RH 2 -6 The following test can be carried out at least once a few hours before you have to see if necessary information about this:
INDEX
The engine oil pressure gauge................................1-6 Ensure safety before the operator's seat is raised or receding..................................................19 S-5 Evacuate in case of a fire event for evaporation by means of an explosion,...1-6 Before removing From or departing from the driver‘s seat 1-6 Attach your safety girth parts wearers to be added................................................................................18 EVALUATED IN THE CASE OF A FIRE FOR VALIDATION BY A FRONT INDICATORY DEPARTMENTS TO YOUR SAFETY DISTRIBUTION WITHOUT CONSTRUCTION FROM DRIVING HARD AND ENVIRONMENT
INDEX
Heating up in cold weather................................ 5-9 Warnings Other of service work................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................., 3Starting: Starting on the Cold Seat Belt20 Aller-3-Driving under Ordinary Temperature starts at normal temperature Do not stop at standard temperature If there is no fault you will find an option to start after a removal process You are entitled to choose between 1 and 2 Excavator 4 (Cold Seat Belt 20

.................................................... [,4
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure. Non-compliance with the precautions below may result in serious injury, blindness or death. Do not try to remove SIZE FOUNDATIONS or VALVE ASSEMBLIES. As parts can fly from it, keep body and face safely away from the valve. Travel reduction gears are pressurized. How parts of parts can be fl ow, make sure that body and face stay away from AIR RELEASE PLUG to avoid injuries. GEAR OIL is hot. Wait for transmission oil cooling down; then gradually trigger the air outlet plug to clear
Hot spraying fluids:
After operation, the engine coolant is hot and pressurized. Hot water or steam located in the machine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. To prevent a possible injury from hot spraying water stop the engine. Begin work on the engine and cooler are sufficiently cooled, do not remove the radiator cap until the engine is coold. When opening turn the cap slowly to stops. Allow all pressure to be released before removal of that, The hydraulic oil tank is depressed.
Hot fluids and surfaces:
Also engine oil, transmission oil and hydraulic oil becomes hot during operation. Engine, hoses, lines and other parts become as hot as: Wait for the oil and components to cool down before maintenance or inspection work starts.
Check for Oil Leaks:
Fuel, hydraulic oil and greasing leaks can result in fires that may cause personal injury or death. Check for missing or loose brackets, articulated hoses, lines or hoses rubbing against each other, damage to the oil cooler as well as loose oil radiator flange bolts, for oil leaks. Attach, repair or replace missing, disengaged or damaged clamps, lines, hoses, oilcooler and oil cooler flange bolts. Bend or do not hit high pressure lines. Never build curved or damaged lines, pipes or hoses.
Check for Shorts:
Short circuits can result in fires. Clean and tighten all electrical connections. Check before each shift or after eight, to ten (10) hours of operation for loose, articulated, hardened or frayed electric cables and wires. Inspect missing or damaged terminal caps prior to each shifting process or after eight, to ten (10) hours of operation. OPERATE MACHINE DO NOT if cables or wires are loose, pinch etc.
Check Heat Shield Covers around Engine Compartment
If the heat shield cover of the engine compartment is broken or lost, a fire may break out. When the heat shield lid of the engine compartment gets busted or loses, repair or replace it before operating the machine.
BEWARE OF EXHAUST FUMES
Prevent suffocation. Engine exhausts can cause disease or death. If you need to operate the machine in a building, be sure that there is sufficient ventilation available. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to provide enough outside air into the

...................................................................................................................................................................................................., and/or any other type of equipment that can be used for this purpose in the event of a failure to comply with EU legislation or regulations (e.g. those relating to civil aviation) as referred to in Article 4(a)(i).

1- Coolant temperature gauge 2- Fuel gauge 3- Liquid crystal gauge (hour blade, etc) 4- Set Switch 5- Display Control switch 6- Auto Idle indicator (except ZX27U-2) 7- Auto Idle switches (except ZX27U‐2) 8- Quick travel mode display 9- Preheating Indicator 10- Alternator Indicator 11- Fuel level indicators 12- Overheating Gauge 13- Engine oil pressure gauge 14- System failure indication
Coolant Temperature Gauge
The track segment position indicates the engine coolant temperature. When the first three segments EIN come, the coolant temperature is normal.
20°C (68°F), the first segment will flash.
The track segment position indicates fuel level. Fill up the fuel before only the e-marked segment comes
System Failure Indicator
The system failure indicator comes ON or flashes an abnormality may be present in the engine control system (optional: Except ZX27U-2). If the system failure indicator is ON or blink, immediately contact your authorized dealer for repair.
Engine Oil Pressure Indicator
The red indicator lights up when the engine oil pressure is low. If the red indicator ON, simultaneously sounds the engine oil pressure warning buzzer. Stop the engine immediately. Check the engine oil pressure system and level of oil for any abnormalities.
Overheat Indicator
When coolant temperature rises extremely high, this indicator works. If the red light ON, the buzzer sounds simultaneously. Stop machine operation immediately and reduce engine rpm to slow idle speed to lower coolant temperature.
Fuel Level Indicator
When the fuel level gauge ON comes while the machine is working on ground level, the remaining proportion of fuel in the fuel tank is shown as shown in the table below. Replenish your fuel as quickly as possible. ZX27U-2, ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 Other amount of fuel 6.5 Wk (1.7 US-Gal) 11 Wk(2.9 US-Gal) M1M7-01-008 M178-037 M170-1-036 M1780-024
Alternator Indicator
The red indicator lights up when a low generator output is available. Check the electrical system such as the alternator and/or battery system.
M1M7-03-006
ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2 M1M7-03-002 ZX27U-2 M1M7-01-031 ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 M1M7-01-028 M1M7-01-007
Check Using the Monitor
After starting the engine check the following points through the monitor. Check that generator indicator is OFF. In case of alternator display, ON stays, immediately stop the engine. Then check the alternator and / or battery system for any abnormality. Check that engine oil pressure gauge is OFF. If engine oil pressure gauge remains on, immediately finish the engine. Afterwards check the engine oil pressure system and/or level for eventual abnormalities. ZX27U-2 M1M7-01-031 ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 M1M7-01-028
volt negative (-) ground. Use only 12 volt booster battery with the capacity enough to start this machine.
When the machine battery is exhausted, start the engine with a booster battery as shown below.
Connecting Booster Cables
1. Stop the engine of the booster battery machine. Connect one end of the red cable, the positive (+) terminal of the machine battery and the other end to the positive (+) terminal of the booster battery. After connecting one end of the black cable to the negative (-) terminal of the booster battery connect the other end with hydraulic oil tank lid hinge on the machine. Make sure sparks can be made that could be produced in the last connection to the hydraulic oil tank cover hinge. Once you have securely connected the booster cables start the engine of the booster battery machine. Run the engine at a medium speed. Then restart the engine of this machine. When the engine is started disconnect Boster Cable (1 and follow the procedures below).
Disconnecting Booster Cables
1. Separate black booster negative (-) cables, from hydraulic oil tank cover hinge, first. Disconnect the other end of Black Booster negative (-) cable, from the booster battery. Disconnect red booster positive (+) cables, from the booster battery. Machine battery. Disconnect red booster positive (+) cables, from which

Connect one end of the red cable, with the positive (+) Terminal Booster Battery (Black) Machine Battery Connect one end of the black cable to the machine frame.
WARMING UP OPERATION
The normal operating temperature of the hydraulic oil lies between 50 and 80 C (122 and 176 F). Hydraulic components can be severely damaged if the machine is operated at a hydraulic oil temperature below 20 C (68 Before you start working, be sure to follow these warm-up operations until the temperature of the hydraulic oil exceeds 20 C (68 F
When disconnecting or reconnecting the hydraulic
Breaker hoses from or to the hydraulic piping lines on the arm tip, be sure that dust is not stained or penetrated into the inner side of pipes and tubing. If the hydraulic breaker is not installed, necessarily attach caps or plugs onto the arm tip pipe open ends and Hydraulic break-out lateral hose ends to prevent contamination of the hydraulic system due to dust. Be careful not to lose the lids and plug connections. Always keep the auxiliary parts in the tool box. Check if the pipe clamp bolts are tight, and no oil leaks out of the tube and hose joint before operating the hydraulic breaker.
OPERATING THE MACHINE
7. Do not let the breaker chisel come into contact with the boom when it rolls in the arm and breaking. Be careful! Make sure that the booms are not hit during crusher, Change hydraulic oil and replace the full flow filter element at regular intervals. Hydraulic brake operation undergoes hydraulic oil contaminants and/or deteriorates faster than bucket operation. Failure to maintain the hydraulic oil properly may result in a malfunction on the base machine and/or disconnect switch. Ensure you change hydraulic oil and swap the whole flow filter element at interval shown below, especially for extending the life of the hydraulic pump (see Hdraulic System Group in the maintenance area).
WARNING: Prevent personal injury. Confirm that no one is under the front attachment before starting the procedure below.
When the engine stalls and cannot be restarted, lower the boom to sink the bucket referring to the emergency boom lowering process referred to below. Remove cover above the hydraulic oil tank. Disengage filler cap on the hydraulic oil tank to release air pressure from the hydraulic oil tank.
WARNING: Be sure to work only after oil temperature is low or before operation. Failure to do so may allow high temperature oil to spray, possibly causing severe burns.
2. Remove bolts from the front and left side of the lid to remove cover (3). ZX27U-2, ZX30U-2, ZX35U-2
WARNING: Loosen overload relief valve slowly. If it is loosened rapidly, the boom may also lower rapidly. Do not loosen it more than 3/4 turns, as the hydraulic oil may spout.
1. Slowly disengage the overload relief valve by checking the movement of the boom. Torque : 24 mm : 59 to 69 N m (6 to 7 kgf m, 43 to 51 lbf ft), after you have checked that the boom is fully lowered, tighten the overload relief valve.
If the front attachment is loaded.
1. Put the matching marks on lock nut in overload relief valve and adjustment bolt in boom raise circuit (cylinder lower side).
WARNING: Loosen the adjusting screw slowly. If it is loosened rapidly, the boom may also lower rapidly.
2. Disengage the lock nut. Loose adjustment bolt slowly by checking the movement of the boom. Torque : 17 mm (Lock Nut) : 27 to 31 N m (2.8 to 3.2 kgf m, 20 to 23 lbf ft), After checking that the boom is fully lowered, align the appropriate marks and tighten the lock nut. Overload relief valve in Boom Raise Circuit Fig, 1 T1LA-03-001 Valve Body Adjustment Screw ZX40U-2-50U-2
T152-03-03-015
overload relief valve in Boom Raise Circuit Lock Nut T1M9-03-04-001 Adjustment bolt
governor and/or hydraulic components.
Learn how to operate your machine properly. Follow the correct maintenance and inspection procedures shown in this User Manual. Check daily before starting the machine. Check controls and instruments. Check coolant, fuel and oil levels, check leaks, articulated, frayed or damaged hoses and lines. Noise, heat etc. Go all around machine checking of general appearance, check for loose or missing parts.
When opening/closing the engine access covers, take care not to allow your fingers to be become pinched with the covers.
Pull up the latch to open cover (1). The cover is raised by link mechanism (3). Be sure to raise the lid completely. After checking this plug provided on the left-hand side, located in LOCK position (5), remove your hand from the cover. Cover, be locked at location. When closing protective cap (1), when lifting a clasp (1), push off Stoppers at arrowed position (cid:214). With the sliding plug (4), let down this cover while pressing. If the reference is lowered through the 1/4 stroke, leave a stopper (4). Then lower cover further until complete closure. Make sure that your sheet which bounces (4) will be totally removed from the envelope at present time.
machine is parked on a slope, or while the wind is blowing hard. The tank cover may close accidentally, possibly resulting in personal injury. When opening/closing the tank cover, take care not to allow your fingers to be pinched with the cover.
1. Press button, and raise cover to open cover (1). Cover, opening is stopped with wire (3). Take stoppers, from holder (5). Install Stoppers, in locking dump (6). Cover, is kept in position. When closing the cover (1) follow the reverse order of the above procedure.
WARNING: Each component of the engine may be hot immediately after operation. Allow components to cool before starting to work on them.
1. Prepare a 10-litre (2.6 US-Gal) container to get the drain oil. Drain the oil. After removing the drain plugs from the engine oil pan, let it be emptied through a clean cloth to determine if any debris like small pieces of metal are present on the cloth. After all oil has dripped off, reinstall and tighten drainage plug (2). : 19 mm Bolt size Reinforcement torque: 88 N m (9 kgf m, 65 lbf ft) Oil Pan Clean Cloth Container
MAINTENANCE
5. Remove the oil filter by turning it counter-clockwise with a filter key. The oil can spill out of the filter undercarriage at that time. Use an empty container to capture the spilled oil. Coat the seal of the new filter and use engine oil. Turn the filter clockwise by hand until the seal touches the sealing surface. Strengthen the oil filter, 3/4 turns more over the filter key. Pay attention when an oil filter is deformed if it is excessively articulated.
on page 7-10 for the brand names of oils.
9. Check if the oil level is located between the upper and lower limit signs on the dipstick (5). Start the engine. 10. Check that no oil runs out of the seal joints.11. Perform the engine in slow idle for 5 minutes. Stop the engine. After 15 minutes later, check again the oil level. Add as needed.
Check Oil Level --- every 250 hours
1. Park the machine on a level surface. Rotate the travel motor until plugs are positioned as shown to the right. Stop the engine. Slowly disengaging plug to release pressure. Remove bobbins (1 and 2). Make sure that oil flows out of the threaded bore for plug (2). If no oil pours out, add oil until the oil drains from the pinhole. After cleaning hoppers (1 and 2) wrap the jack threads with sealing tape. Bolt torque: 29 to 39 N m (3 to 4 kgf m, 21,5 to 29 lbf ft) M503-07-015
Change Gear Oil --- every 1000 hours
1. Park the machine on a level surface. Rotate the travel motor until plugs are positioned as pictured to the right. Stop the engine. Slowly disengage plugs, for releasing pressure. Remove drain plug and plug to empty oil. Plug completely clean after sucking out oil (3). Unwrap the threads of the plug with sealing tape. Bolt stud Pull up Torque: 29 to 39 N m (3 to 4 kgf m, 21.5 to 29 lbf ft). Feed oil through the threadhole for plug (1).
NOTE: Refer to the recommended oil and grease chart on page 7-10 for the brand names of oils.
7. Remove plug (2). Add oil until the oil flows out of the profile hole for the plug (2). ZX27U-2, ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 Oil quantity 0.6 L (0.63 US qt) 0.9 L (0.95 US qt), After cleaning plugs (1 and 2) wrap the connectors' threads with sealing tape. Reinstall the plugs. Adjustment torque: 29 to 39 N m (3 to 4 kgf m, 21.5 to 29 lbf ft).
WARNING: When inspecting and/or maintaining hydraulic equipment, pay special attention to the following points.
1. Make sure the machine is parked on a level, solid surface. Lower the bucket and blade to the ground and stop the engine. Start servicing hydraulic components only after the components, hydraulic oil and lubricants are fully cooled as well as after releasing residual pressure. 3.1 Bleed air pressure from the hydraulic oil tank. 3.2 Any component, hydraulic oil and lubricant can be placed hot and/or under pressure immediately after operation. Allow the machine to cool down before beginning of inspection or maintenance. Defects may cause burns caused by contact with hot parts and/or oil, or injury due to being touched by skidding plugs respectively screws. Hydraulic components can also be actuated when cooling off. Keep body parts and face away from shocks or bolts slowly loosening
Check Hydraulic Oil Level --- daily
1. Park the machine on a solid level surface. Position the machine with the fully retracted arm cylinder and full spread bucket cylinder. Lower the bucket and blade to the ground. Stop the engine. Check oil level gauge, at the side of the hydraulic oil tank. Oil must be in predetermined height along the gauge.
WARNING: Be sure to work only after oil temperature is low or before operation. Failure to do so may allow high temperature oil to spray, possibly causing severe burns.
1. Park the machine on a fixed level surface. Position the machine fully retracted with the arm cylinder and the bucket cylinder fully extended. Lower the bucket and blade to the ground. Stop the engine. Leave the machine without operating the machine until hydraulic oil becomes cool. Then vent air pressure from the hydraulic oil tank. Slowly disengage drain plugs, drain water and sediment at the bottom of the hydraulic oil tank.
IMPORTANT: When changing hydraulic oil, take care not to allow foreign matter such as dirt, water or soil to enter the hydraulic system. Hydraulic oil changing intervals differ according to kind of hydraulic oil used.
1. Park the machine on a fixed level surface. Position the machine with the fully retracted arm cylinder and bucket cylinder fully extended. Lower the bucket and blade to ground. Stop engine. Remove cover above hydraulic oil tank. Disengage filler cap, at hydraulic oil tank to release air pressure from hydraulic oil tank. Take off cap (1) by means of one suction pump. ZX27U-2, ZX30U-2 ZX40U-2, ZX50U-2 amount of oil, 60 L (15.9 US-Gal) 90 L (23.8 US-Gal), Arrange a container with capacity (A). Draining oil ZX27U-2, ZX30U-2, ZX35U-2, ZX35U-2, ZX35U-2, ZX35U-2
MAINTENANCE
5. Slowly disengage drain plugs, on the underside of the hydraulic oil tank. Allow oil to drain thoroughly, clean, install and tighten drain plug into the original position. ZX27U-2 ZX30U-2 and ZX35U-2 wrenches Size Reinforcement torque : 49 N m (5 kgf m, 36 lbf ft) : 12 mm (PT3/8 Square Head Plug) ZX40U-2 and ZX50U-2 Key size : 27 mm (G1/2 Hexagonal Head Plug with O-ring) Clamping device : 95 N m (9.7 kgf m, 70 lbf ft), delivery of hydraulic oil via filler port at top of the hydraulic oil tank while checking Oil level with Level Indicator (3).
Bleed Air from Hydraulic System
After changing the hydraulic oil, air out of the hydraulic system by following the procedure described below.
not filled with hydraulic oil, damage to the pump may result.
1. Connect all hydraulic lines with the hydraulic pump. Fill any hydraulic components that can be filled with hydraulic oil, with as much hydraulic oil as possible at this time. Add hydraulic oil into the hydraulic oil tank to the specified level. Check all line connections for eventual oil leaks. Set in slow idle position of the engine control selector or the engine control lever. Start the engine. Wait 5 to 10 seconds. Stop en5. Check the hydraulic oil level on the level gauge along the side of the hydraulic oil tank. Add hydraulic oil if necessary. Restart the engine. Confirm your hydraulic oil level is sufficient in the hydraulic oil tank. Run the engine about 1 minute. This is the end of the procedure for air declutch of the hydraulic pump.
Bleed Air from hydraulic circuits
1. After filling hydraulic oil in the hydraulic oil tank, start the engine. Actuate each cylinder and swing motor again for 10 to 15 minutes to clean air from the hydraulic system. Position the machine into the hydraulic oil level checker3. Stop the engine. Check the hydraulic oil level. Add oil asing position.
Clean Suction Filter--- when changing hydraulic oil
The suction filter is located on the underside in the hydraulic oil tank. Clean the suction filter when changing the hydraulic oil. After draining of hydraulic oil remove the cover (1). Make sure that the O-ring must not come from the lid at this time. Remove the suction filter together with rod (3). Clean the hydraulic oil tank interior and vacuum filter. Suction pipe. Install a suction filter together with a stick to the cover, making it safe to use in support, based on reference (1). Safe coverage, with four bolts. Key size: 13 mm Adjustmentorque : 49 N m (5 kgf m, 36 lbf ft) ZX27U-2, ZX30U-2, ZX35U-2 M1M7-07-002 ZX40U-2, ZX50U-2
WARNING: Be sure to work only after oil temperature is low or before operation. Failure to do so may allow high temperature oil to spray, possibly causing severe burns.
1. Park the machine on a fixed level surface. Position the machine with the arm cylinder fully retracted and the bucket cylinder completely extended. Lower the bucket and blade to the ground. Stop the engine. Before replacing the element, you should be sure that a hydraulic oil tank cap disengages in order to release air pressure from the hydraulic oil tank. Remove bolts to remove them under cover away from the rear left side of the base machine. Wrench size: 17 mm
MAINTENANCE
4. Rotate the hexagonal part at the bottom of the filter, fall anti-clockwise by means of a tool like a wrench to remove filter housings from head cover (5). While rotatable filter elements (7) pull out the filter element down. Replace O-ring, with a new one. Safely install O-ring, into the o-ring groove on top lid (5). Coat the seal onto new filter element, with clean hydraulic oil. Build up an entire filter element while simultaneously adding a rotating filter element, keeping in mind that the filter element is not damaged. Make sure no dust and/or water enter the filter 10. Fitted case, turn over inside a head envelope whilst turning clockwise. Pulling torque: 25 to 34 N m (2.5 to 3.5 kgf m, 18.0 to 25.5 lbf ft) 11. After replacing the filter element, vent any remaining air from the hydraulic circuit when running engine at a slow speed for approximately 3 minutes check your oil level in the hydraulic tank.
Repair or replace any missing, loose or damaged clamps, hoses, and lines.
Do not bend or beat high pressure lines. Never attach curved or damaged hoses or lines. Check hoses and lines for oil leaks and/or damage with reference to the following tables. If an abnormality is found, repair it as per the instructions in the remedy column. Interval (hours) Check Point Abnormality Remedy Hose Surface Hose End Link Oil Leck, Oil Lick, Oil Lack, Hose Underlay Hose End Hose Oberflächigkeit Hose Attachment Oil Liqueurs, Oil Lice, Exponated Reinforcement, Blister, Acute Knick (8), Collapse, Deformation or Corrosion Replace Replacement Reconsolidation or Replace Hose respectively O-Ring
Refueling
After parking the machine on a level surface, check fuel level with fuel gauge and fill level indicator (2). If necessary to add fuel, remove the tank cap and refill it.
level can be checked by pressing and holding display selector, for longer than 0.5 seconds. As long as display selector, is kept pressed, the fuel level is displayed. As soon as the switch is released, the display disappears.
1. To avoid condensation, fill the tank at the end of daily operation. Be sure not to add more fuel than the specified level. ZX27U-2, ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 Fuel tank capacity 40 L (10.6 US-Gal) 70 L (18.5 US-Gal), After filling fuel close Panzer cover (4). Urgently lock the cover to prevent vandalism.
Bleed Air from Fuel System
Air in the fuel system causes the engine to start hard and/or run rough. Ensure air from the system is ventilated after it replaces the fuel filter or drained the tank. An automatic de-venting device is provided on this machine. Confirm that fuel levels are more than half of the tank capacity. When lower fuel level, no auto ventilation system will operate. Add fuel. Turn on the key switch and hold for 10 to 15, starting the engine and checking the fuel system for fuel seconds. Leak leaks. ZX27U-2 M1M7-01-031 ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2 M1M7-01-028 ZX27U-2, ZX30U-2, ZX35U-2
Check Water Separator --- daily
When water is accumulated in the water separator (2), lote drain plug to release water and sediment. If dumping of water is difficult, disengage air venting plug (4).
Drain Fuel Tank Sump --- as required
Parking the machine on a fixed level surface. Solve bolts to remove drain valve cover, from right front cover (7). Turn off the drain valve lid to open the control port. Open the drain valve at the bottom of the fuel tank and let water and sediments be emptied out of the fuel tank sump.
Replace Fuel Filter --- every 500 hours
1. Close stop valve (1). Remove fuel filter, with a fuel filter key. Clean the attachment area for fuel filters (2). Install new fuel filters while turning the fuel filter clockwise until the fuel filter comes into contact with the mounting surface. Strengthen the fuel filter approximately 1/2 turns more over the filter key.
kgf⋅m, 9 to 11.5 lbf⋅ft)
5. Open the stop valve (1). Turn on the key switch and hold for 10 to 15 seconds. Leak leaks. Start the engine and check the fuel system for fuel.
WARNING: Escaping fuel may cause fire. Check for kinked hoses, or hoses that rub against each other and/or come in contact with other components, and any oil leaks.
Repair or replace loose or damaged hoses. Never put exactly curved or damaged on top of it.
hoses.
Check hoses for oil leaks and/or damage by referring to the following tables. If any abnormality is detected, repair it as described in the remedy column. Control point Abnormality Interval (hours) All 250 Hose fittings Soutache braided hose surface Soutache braided hose surface Hoses fittings Tubing ends and fittings Leak, Rubbed marks, Crack, Crack, Acute bend, Collapse, Corrosion, Remedy Retighten or replace Replace Replace Replace
Check Coolant Level --- daily
Check if the coolant level is located between the FULL and LOW brands on the coolant reservoir (2). If the coolant level is below the low mark, remove the container cap and add the coolant to the coolant reservoir (2).
WARNING: Do not loosen radiator filler cap, unless the system is cool. Hot steam may escape, possibly causing severe burns. Loosen the cap, slowly to the stop after the coolant becomes cool. Release all pressure before removing the cap (1).
When the coolant reservoir is empty, add the coolant through the radiator cap (1). ZX27U-2, ZX30U-2, ZX35U-2 M1M7-07-043

MAINTENANCE Clean Radiator Core --- every 500 hours ATTENTION: Always wear safety glasses or goggles when using compressed air [less than 0.2 MPa (2 kgf/cm2, 29 psi)] up to the clean radiator core. IMPORTANT: cover air cleaner inlet opening to prevent dust and water from entering while cleaning the radiator. High pressure air [less than 0.2 MPa (2 kgf/cm2, 29 psi)] or water can damage radiator fins. Keep the pressurized nozzle 500 mm (19,7 in) or more away from the core face. The radiator and oil cooler are arranged serieswise. Should dust or dirt settle on the radiator core, clean the radiator with compressed air and/or water to maintain cooling capability of the cooling system.
Check for refrigerant leaking from the pipe joints
If an oil seer mark is found on the right-hand side of the pipe joints, refrigerant may leak.
Check the condenser
If the condenser surface is contaminated with foreign substances such as dust or dead insects, cooling performance can be reduced. Keep the condenser clean (referred to descriptions for Clean Radiator in MAINTENANCE section).
Check the compressor
After operating the air conditioning system for 5 to 10 minutes, touch both high and low pressure lines with your hands. Normally, the high pressure side should be hot and the lower pressure side cooled.
M1M7-07-057
Alternator Pulley No Refrigerant Insufficient amount Sufficient quantity Almost clear. Some bubbles may appear when the engine rpm is raised or lowered.
Cleaning
Clean the re-circulation filter by blowing in compressed air or with water. When cleaning the filter with water follow the procedure below. Clean the filter using tap water. Keep the filter in water with a neutral detergent that is dissolved for about 5 minutes. Clean it again with water. Dry the filter.
Installation
Install the cleaned or new filters by following the sampling procedure described on the previous page in reverse. Insert filters (4 and, in the grooves of both sides. Install filter, into center channel.
WARNING: Start the engine ONLY in a well-ventilated place.
1. Remove grease from cylinder rods when coated. Customize alternator and fan tape tension. Fill the fuel tank. Blooded air out of the fuel system. Check all fluid levels. Start the engine. Run the engine at half speed for a few minutes before starting full load operation. Operate all hydraulic functions multiple cycles. Carefully check all systems before operating the machine with full load.
Cause
Starter doesn't turn, engine is too cold, Incomplete air bleed out of the fuel system, No fuel in the fuel tank, Fuel filter restriction, No fuel in the fuel tank, Air in the fuel system, Not sufficient engine oil, Oil leak on connections, Oil pressure switch failure, Fuel filter restriction, Air in the fuel system, Air cleaner restriction, Insufficient coolant and/or coolant.
Solution
When battery power is low, charge or replace the battery, Has the starter failed, repair or replace, Are connections loose or corroded, clean and tighten, preheat engine or warm up coolant (pour some hot water into the cooling system), Thoroughly bled air, fuel, cleaning or replacing the fuel filter, fuel, compacting linkages and bolt-on, add oil, repair, replace, cleaner or replace filters, reconsolidate ports and vents, purifier or replace element, add coolant. Repair light weight, lots of fan tape or oil to the fan belt, radiator ribs are clogged or curved, thermostat failure, adjust/replace fan belt, clean adjustment and/or repair engine stalls. Low engine oil pressure (engine oil pressure gauge comes on) Engine knocks or runs off irregularly. Engine overheating, electric equipment overhaulers:
Solution
Harness failure, Low battery power, Lose or corroded Battery Con, Inspection and Repair, Load The Battery, Clean And Tighten Alternator Indicator does not go off after the engine has been started. Monitor indicators do not arrive or gauges don't work. Travel Mode doesn‘t shift from Quick Mode to Slow Mode and/or vice versa. nections, Keywitch fail, Generator Failure, Harness Failure, Blown Backup, Sensor Failure, Harness Failure, Burned Display Lightbulb, Switch Outage, Harness Failure, Switch Valve Mistake, Replace, Replacement, Exchange, Inspection & Repair, Replace, Replace, Observe AND Repair, Replace, Replace, Replace, Rebuke, Under-explore und Repair, Replace

DIG WITH CAUTION
Accidental disconnecting of underground cables or gas lines may result in an explosion and/or fire, possibly resulting in serious injury or death. Before digging check the location of the cables, gas lines and water lines. Keep the minimum legal spacing of cables, gas lines and water lines. If a glass-fibre cable should accidentally be separated, do not look to the end. This can cause severe eye injuries. Contact your local Digger hotline when it is available near you, and/or directly to utility companies
HANDLE FLUIDS SAFELY --- AVOID FIRES
Treat fuel with care; it is highly flammable. When fuel ignites, there may be an explosion and/or a fire which might result in serious injury or death. Do not refuel the machine when smoking or near open flame or sparks. Always stop the engine before you refuel the machine. Fill up the fuel tank outdoors. All fuels, most lubricants and some coolant are combustible. Store flammable fluids well away from hazards of fire. Burn respectively puncture no pressure containers. Do not store oily rags; they can spontaneously ignite and burn.
SAFETY
Rubber hoses that contain flammable fluids such as hydraulic oil or fuel under pressure can break through aging, fatigue and abrasion. It is very difficult to estimate the extent of deterioration due to ageing, fatigue and abrasion of rubber hoses alone by visual inspection. Regularly replace the rubber hoses (referred to Periodical Replacement Parts section). Unregularly replaced rubber hoses may result in a fire, fluid injection into the skin or front attachment to fall down onto one person nearby, resulting in severe burns, gangren's or otherwise serious injury or death.
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil pressurized penetrate the skin or eyes, causing serious injury, blinding or death. Avoid this risk by releasing pressure before disconnecting hydraulic lines or other lines. Make sure all connections are fully connected before you exert pressure. Look for leaks with a piece of cardboard; be careful to protect hands and body from high-pressure fluids. Wear a face shield or glasses to protect your eyes. In case of an accident, you can immediately see a doctor familiar with that type of injury.
Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust and other flammables can result in fires. Prevent fires by checking the machine daily, cleaning as well as removing spilled or accumulated fuel elements immediately. Store non-inflammable fluid close to open flames. Do not burn or crush pressurized container. Keep no oiled cloth up. You might catch fire. Don't wind any simply suck off asbestos or glass wool around high temperature parts such as a muffler or an exhaust pipe.
AVOID HEATING NEAR PRESSURIZED FLUID LINES
Flammable spray can be generated by heating close to pressure fluid lines, resulting in severe burns for itself and bystanders. Do not heat by welding, soldering or using a burner near pressurized fluid lines or other flammable materials. Printed lines may accidentally cut if the heat goes beyond immediate flame range.
AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS
Do not weld or inflammable tubes or hoses that contain flammable fluids. Inflammable fluids before welding or burning cutting of pipes or tubes containing flammable fluids thoroughly remove with non-inflammable solvent.
PRECAUTIONS FOR HANDLING REFRIGERANT
If refrigerant is injected into the eyes or spilled onto the skin, blindness or cold contact fire may occur. Refer to the precautions described when handling the refrigerant container. Use a recovery and recycling system to avoid venting refrigerants into the atmosphere.
DISPOSE OF WASTE PROPERLY
Improper disposal of waste can threaten the environment and ecology. Possibly harmful waste used with HITACHI equipment includes items such as oil, fuel, coolant, brake fluid, filters and batteries. When emptying fluid you use an spill-proof container that is larger than the drained fluid volume to receive it. Do not pour any waste onto the ground, down a drain device or into any source of water. Enquire on the right way to dispose of harmful waste like oil, fuel, coolant, brake fluid, filter and batteries from your local environmental or recycling center.
AUXILIARY FLOW RATE CONTROL (OPTIONAL) (Except ZX27U-2)
The maximum and minimum hydraulic flow rate in the auxiliary piping can be controlled as follows: ZX30U-2 ZX35U-2 (11US-Gal)/min (17 US-Gal)/min ZX40U-2 ZX50U-2 (12 US-Gal)/min (22 US-Gal)/min ZX27U-2 (14 US-Gal)/min Minimum flow rate Maximum flow rate
Flow Rate Control Selector,
LOW: sets for minimum flow. HIGH: uses maximum flow rate. When shifting the flow rate from LOW to HIGH, operate the switch while pulling the lock button towards arrow mark.
Coolant
Use fresh water that contains less contaminants or normal tap water for the coolant. Avoid using strong acid or alkali water. Be sure to use genuine Hitachi Long Life Coolant (LLC).
Long Life Coolant (LLC)
LLC has two features, antifreeze and anti-rust. As a rule, the ratio of antifreeze should be between 30% and 60%. If the ratio is below 30%, the system can develop rust, and if it's above 60%, the engine may overheat.
WARNING: LLC is poisonous.
1. When taken, induce vomiting and immediately receive emergency doctor. If an anti-freeze guard is accidentally injected into the eyes, rinse your eyes sufficiently with water and get emergency medical assistance. When storing anti-freeze agents you should be sure that it is stored in a clearly marked container with tight cap. Always keep frost guards out of reach of children. Keep open flames or sparks away from LLC.

PROTECT AGAINST NOISE
Longer exposure to loud noise can result in impairment or hearing loss. (cid:129) Wear an appropriate ear protector such as earplugs or ear plugs for protection from offensive or uncomfortable noisy sounds.
Tilt Mechanism --- every 250 hours
1. Remove bolts, from top of tipping mechanism and remove cover (2). Coat the full operating screw with grease. Recommended Grease: MOLYKOTE EM-30L made by Dow Corning Toray Co., Ltd.

To pull back from the edge of a trench if foundation should collapse, always position the undercarriage perpendicular to the excavating edge with the travel motors at the rear. When there is a breakdown of the foot and in case retraction is not possible, do not raise panic in front of the front attachment with a panic. In most cases reducing the front component can be safer.

If it is difficult for the machine to evacuate from soft terrain by its own drive force, attach wire ropes as pictured to the right. Pull on the machine with another machine. Be sure to hang the cable ropes around the track frames. To prevent damage to the ropes, place parts of soft protective material between the line lines and edge corners of the frame.

Rubber crawlers are designed to allow the machine to travel without damaging road surfaces such as paved roads. Avoid damage to rubber crawlers by following precautions:
Forbidden Operations
1. Do not operate or steer the machine up or close to river terrace, boulder and rock mix ground, crushed stone floor, uneven hard paving surfaces, stumps, reinforcement bars, scratches and steel plate edges. Failure can greatly reduce rubber crawler life. Do not leave engine oil, fuel and other lubricants that remain on the rubber rougheners back and avoid traveling on road surface loaded with oil in order to lessen the risk of pushing. Don't travel the machine when lifting a side crawler off the ground using the front attachment. Shears or damage may result from rubber roughening.
WARNING: The rubber crawler machine is less stable than the steel crawler machine, as the edge of the rubber crawler is easier to deform more than steel crawler. Pay attention when operating the machine at an angle to the tracks.
1. Rubber crawlers must not be stored in a place where they are directly exposed to sunlight for more than three months. Avoid unnecessary steering operations on concrete roads, possibly resulting in premature wear of shoe haulers and core metals. Also avoid machine operation at high temperatures [over 60 C (140 F)] road surfaces during asphalt paving work; this can cause premature wear of rubber caterpillars as well as damage to the road surface.
OPERATING THE MACHINE
3. Operating the machine with rubber crawlers that flabbergasted on uneven surfaces can lead to a derailment of the rubber crawler and could cause damage to the rubber crawlers. When lowering the machine raised above the ground by the front attachment, the machine can be slowly lowered down to the ground. The new rubber crawler has a thin rubber foil (shown in dotted line) on its running surface. While operating a new machine or immediately after replacing the rubber crawlers, the rubber films can be turned off due to contact with the rollers. This is not uncommon(See right-hand illustration.), If the rubber roughing blade is damaged and the rubber roughening rod rust becomes short. In case of damage, the rubber crawler must be repaired. Turn to your authorized dealer.
WARNING: Securely tighten the machine to the flatbed with wire ropes.
During transport, the machine is moved back and forth or sideways. Fold forward and rear of the crawlers to secure the machine in position.
Transporting the machine equipped with rubber crawlers
When backing the machine to the flatbed, do not tighten the rubber crawler directly with wire ropes. As shown below, attach the ropes on the tape down brackets to securely tighten the machine before transporting the unit.
Adjust Track Sag (rubber crawler) and Check for Damage --- daily
A proper track-sag adjustment is required to extend the life of the rubber track and travel equipment. As shown on the right, lift up the one-sided track which should be measured from the ground. Place blocks under the machine frame to support the machine. Rotate the rubber track so that the track joint is located in the upper center of the line. Measure distance, from below at the lower running surface to the inner ridge of the rubber track. Track Say specifications A in mm dimension 10 to 15 (0.39 to 0.59) Adjustable rail train if route gear is not included, loosen or solidify the track according to the procedures shown on the next side. Before adjusting a track saw Lower bucket and blade to the ground to raise both tracks from the ground. Be careful to place blocks underneath the machine frame to assist the machine.
Check Rubber Track for Damage
Check the rubber track for damage. If present, consult your authorized dealer for repair.
IMPORTANT: When gravel or mud is packed around the components in the undercarriage, remove it before loosening valve (1).
1. To loosen the track, slowly turn the valve counter-clockwise with a socket key (long pedestal 19); grease escapes from the grease outlet. Between 1 and 1.5 turns of the valve it is enough to loosen the track. Never try to disengage the valve fur3. If the grease does not run smoothly, lift the track away from the ground and rotate more slowly in motion. When an appropriate track sag is reached, switch the valve clockwise and pull it over to 88 N m (9 kgf m, 65 lbf ft).
WARNING: In case the track sag is not adjustable, this is a very hazardous situation. Since the track adjuster spring is excessively loaded, the grease pressure inside the track adjuster cylinder is very high. Incorrect adjustment or disassembly may result in personal injury and/or death. Immediately consult your authorized dealer for repair.
To tighten the track, connect a grease gun to a cylinder grease fitting located in the side frame and add grease until sag is within specifications.
After the rubber track is removed, the front idle will become free to remove. If the front idle comes off unexpectedly, personal injury and/or death may result. Be sure to remove the rubber track only after taking appropriate measures to prevent the front idler from coming off.
1. Lower the bucket and blade to lift both tracks off the ground as shown. Place blocks under machine frame to support the machine. Slowly turn the valve counter-clockwise so that grease can escape from the grease outlet. Insert two or three steel pipes into the intermediate spaces between lower rollers, track frame and rubber track gradually turning the track backwards to remove the rubber track from idling. Apply horizontal force to pull the rubber track away from the idler.
Installing Rubber Crawler
1. Lower the bucket and blade to lift both tracks from the ground. Place blocks under machine frame to support the machine. Turn the valve slowly counterclockwise so that grease can escape from the grease outlet. Engage the rubber track with the sprocket and position the other end of the rubber track on the front Idleler. When turning back in reverse, apply the horizontal force onto the rubber track to put it into idle. Insert a steel tube between under rollers a gap, introduce frames and rubber lineways slowly twisting down the rubber path allowing the rubber gun to be properly positioned. Make sure the rubber chain is correctly linked to pike and impeller. Adjust Track Say. (See pages 7-54.)
Check Track Sag (steel crawler) (optional) --- every 50 hours
The correct adjustment of the track saga is vital for extending the lifespan of the track and travel device. As shown to the right, take one side track which Sage is measured off the ground. Place blocks under machine frame to support the machine. Dimension Track Sag SpecificaA in mm (in.) ZX27U-2 ZX30U-2 ZX35U-2 ZX40U-2 ZX50U-2 120 up to 140 (4.7 to 5.5) 140 down 160 (5.5 to 6.3)
Adjusting Track Sag
1. If Spursag is not within specifications, disengage or tighten the track according to the procedures shown on the next page. When setting Spursag lower the bucket to the ground to lift one track from the ground. Repeat this procedure to raise the other track. Every time you set blocks under machine frame to assist the machine. After adjusting both tracks' trailing saga, move the machine back and forth several times to compensate for spursag on either side of track.
WARNING: In case the track sag is not adjustable, this is a very hazardous situation. Since the track adjuster spring is excessively loaded, the grease pressure inside the track adjuster cylinder is very high. Incorrect adjustment or disassembly may result in personal injury and/or death. Immediately consult your authorized dealer for repair.
To tighten the track, connect a grease gun to a cylinder grease fitting located in the side frame and add grease until sag is within specifications.

MAINTENANCE Convert the Track Warning: Consult your nearest authorized dealer for converting the track. It is applied extremely strong force. Do not let yourself stand in front of the front idling. After removing the rubber track, it will be free to remove the front idle gear. If unexpectedly turned off personal injury and/or death may occur. Be sure to remove the rubber track only after a suitable measure has been taken to prevent dumping of the front muffle.
SPECIFICATIONS
...................................................................................................................................................................................................., and/or any other type of equipment that can be used for this purpose in the event of a failure to comply with EU legislation or regulations (e.g. those relating to civil aviation) as referred to in Article 4(a)(i).

CONTENTS
(Machine with Cab)...........................7-62 Adjust Track Sag (Rubber Crawler) Replace backups....... 7.50, Miscellaneous and much more.
CONTENTS
...................................................................................................................................................................................................., and/or any other type of equipment that can be used for this purpose in the event of a failure to comply with EU legislation or regulations (e.g. those relating to civil aviation) as referred to in Article 4(a)(i).
ADJUST THE OPERATOR'S SEAT
A poorly-set seat, either for the operator or for the job at hand, can quickly be fatigued to the operator resulting in machine misoperation. (cid:129) The seat should be adapted to the machine whenever the operator changes into one of them. (cid:129) The operator should be able to fully depress the pedals and operate the control levers with his back firmly on the backrest properly. (cid:129) If not, reverse the seat forward or reverse check again.
EVACUATING IN CASE OF FIRE
If a fire breaks out during machine operation, evacuate the machine as follows: Stop the engine in OFF position by turning the key switch. Use a fire extinguisher when time is available. Leave the machine with handrails and/or steps. If the cab door or front window cannot be opened in case of an emergency, break off the front or rear windows at the Emergency Room Hammer to escape from the cabin.

OPERATORS STATION 17- Air Conditioner Control Panel (Cab Equipped Machine) 18- Ash Tray (Cab Equipped Machine) 19- Radio (AM/FM, Cab Equipped Machine) 20- Cup Holder 21- Fuse Box
CAUTION: Open the cab door all the way until the two latches on the side of the cab securely lock.
To unlock the door, press down the lever and are located on the left side of the operating seat.
After opening the front window, check that both side lock levers are securely engaged in the window frame.
3. When closing the front window, follow the same steps 1 and 2 above in reverse order.
Seat Fore-Aft Adjustment
Operator seat Front-aft Sliding lever (1). Seat template can be adjusted in 6 steps (120 mm (5 in) total) at a distance of 20 mm (0.8 in). TOOL AND OPERATORS MANUAL BOXES tool box and operator manual box are located under the driver's seat, under the floor mat.
EMERGENCY EXIT (cab-equipped machines)
If the operator's cabin door cannot be opened in case of an emergency, escape using the following methods. Escape from the cab if necessary when the door is difficult or impossible to open in case of an emergency, open the front window.
WARNING: Be sure to wear safety glasses when require to break the windowpane.
2. If opening the front window is impossible, use Emergency Evacuation Hammer to break the front window glass provided on the back in the cab to escape through the broken window. When the front window is not available for escape, break the rear window glass with Emergency Evacuation hammers (1). Then get away from it by breaking profit.
Seat Belt
1. Confirm that the seat belt is not twisted and safely insert the end of the seat belt into the buckle (2). Slip lightly on the belt to confirm that the buckle securely tie down. Adjust the tightness of the seat belt so it lies narrow but comfortable. Press the push-button onto a buckle to activate the seat belt CAB LIGHT (cab equipped machines) Move cabin light switches to turn off the cab lights ON or OFF.
MAINTENANCE
(Width Across areas of Union nuts: 17, 19, 22 and 27 M202-07-051.
Hose Fitting
Metal wall sealing fittings are used in smaller hoses. Metal torch seat, on adapter and metal torch, on hose, ends seal pressure oil. Be careful for application Make sure not to damage the torch seat as well as flatten it when disconnecting or connecting. Solidifying Torque Reinforcement Adapter and nut with torque values shown in the table below. Wide over flat surfaces (mm) Tension moment 24.5 29.5 (21.5) (kgf m) (lbf ft), Pipe Metal Seal Fitting (Width Across Flats of Union Nut: 17) Metal torch seat, on adaptor and metal torch, on pipe, end seal pressure oil. Precautions For use Do not pre-fit during separation or connect any damage sensing seat; fl ow can also be used. Maintaining Torque TightenAdapters and Nunches are some of the torque ratings specified in the table below. Width transverse through flat surfaces (mm) (lbf m) (lbf m) (lbf )
MAINTENANCE
Flat O-Ring Seal Attachment (ORS Fitting) O-Ring, is used on the front side of the adapter to prevent oil leaks between joints. Precautions for application, Replace O-Ring, with a new one when retrofitting fittings. Before bolt nuts (4) are checked that O-Ring properly sits in O-Ringrille (3). When rubbing nut is tightened if O-Ring not correctly seated in O-Ringrille (3), damage to O-Ring and oil leakage from fittings may occur. Make sure you don't make dents on an O-Ringrut, adaptor and seal face, even once fixed during reequipments. Inapplicably, damage can arise in the O-Ring as well as spillage due to mold pieces. If the oil runs out of a loose union cut 4th, open the port, replace O-Ring (1) check whether or not the O-Ring is properly located prior to reconsolidation of the connection.
Quick Coupler
1. Connecting procedure counterclockwise, inserting the socket ring, on plugs, up to the end surface of the pedestal ring comes in contact with plug-in connection (3). 1.2 Solution power socket ring (1). Check this bushing ring is easily moved back by the spring force and that the clutch ring is held at position with balls (2). Make sure that this version ring has been completely shifted back into the correct starting position. Separation process 2.1 While pulling and fully turning the muff ring, counterclockwise, disconnect the coupler. Since no control valve is present in the coupler, make sure oil can flow out of the coupler when the hitch was separated. 2.2 After disconnecting the coupling you plug off the holes using the exclusively prepared connectors.
Check
Check fan band tension by depressing the fan belt centre point with the thumb's power [ca. 98 N (10kgf, 22 lbf)]. Deflection must be at a centerpoint between fan roller 7 to 9 mm (0.28 to 0.35 in) and alternator roller. In addition, check the fan belt for any damage. If the belt has cracks replace the belt with a new one.
Adjustment of Fan Belt Tension
1. Remove wing bolts from the right side of the seat and switch box to open the inspection door. Loose fixing bolts, from alternator (5). Move generator to set fan belt tension correctly. Safely tightening bolts (6).
is difficult to be correctly seated from the beginning. Be sure to readjust the tension after operating the engine for 3 to 5 minutes at slow idle speed.
Deflection 7 to 9 mm (0.28 to 0.35 in) [approximately 98 N (10 kgf, 22 lbf)] M589-07-014
Replacing Fuses
1. If an electrical equipment does not work, first check the fuses in the fuse box. Any capacity of spare fuses is provided in the fuse box.
Check Bucket Teeth for Looseness and/or Wear --- daily
Check bucket teeth for wear and lotion. Replace teeth if tooth wear exceeds the operating limit shown below. Dimension A in mm (in.) 128 (5.0 ) Operating limit 65 (2.6 )
Check and Replace Seat Belt Check --- daily Replace --- every 3 years
Before operating the machine, thoroughly check the belt (1), buckle and attachment of hardware (3). If an item is damaged or materially worn out, replace a damaged or worn object before operating the implement. Replace the seat belt every three years regardless of apparent condition.
Check each bolt for looseness
Check that the compactor mounting bolts and all other tensioning bolts are securely tightened.
Check the compressor belts and fan belts
Check all belts for lotion and/or wear. If an error is found, consult your authorized dealer for a detailed inspection.
M107-01-050
Depress [ca. 98N (10 kgf, 22 lbf)] Tension Pulley 8 to 10 mm (0.32 to 0.39 in) Compressor Pulley Crank Pulley
Removal of Re-circulation Filter
1. Remove floor mat (1). Remove bolts to remove bottom plate (2). Grab and pull the handles of recirculation filters (4, 5) and stand down for removal.

1. Check the tilting mechanism Fulcrum pin nut, for lotion every 250 hours. If the nut is found loosely, remove on the right hand side the operator's seat access cover. Then pull back the nut until 49 N m (5.0 kgf m, 36 lbf ft).
M1M7-07-079
2. Tilt the cab floor forward. Support the ground with a fall pre-diffuse bar. Reinforced arrow bolts (3, 4 and 5). Attaching torque: 9,8 N m (1.0 kgf m, 7 lbf ft), clamping torque: 49 N m (5.0 kgf m, 36 lbf ft), parking torque: 49 N m (5.0 kgf m, 36 lbf ft) ZX27U-2, ZX30U-2, ZX35U-2 M1M7-07-080 ZX40U-2, ZX50U-2 M1MH-07-014
MAINTENANCE
5. Safe mounting of canopy or cab with three bolts (3). Key size: 19 mm Reinforcement torque: 90 N m (9.2 kgf m, 67 lbf ft)

This standard specification machine can be This manual should be considered a permanent This machine is of metric design. Measurements in
Read this User Manual carefully to learn how your machine can be properly operated and serviced. Failure could result in personal injury or equipment damage occurring under the following conditions being operated without any change. Atmospheric temperature: 20 C to 40 C ( 4 F to 104 F) Height: 0 m to 1500 m (0 ft to 4900 ft) If the machine is used subject to conditions other than those described above, consult your authorized dealer. Part of your machine and should remain with the machine when you sell it. This manual is metric. Use only metric hardware and tools as per specifications. SI Units (International System of Units) come into use in this handbook. Referencing FMS system units and English units are also included according to the SI units in brackets. Example : 24.5 MPa (250 kgf/cm2, 3560 psi

MACHINE NUMBERS SECURITY BUSINESS COMPONENT NAMES OPERATORS STATE CONSUMPTION-IN OVERATING THE ENGINE DRIVING THE MACHINE OPERATING THE Machine TRANSPORTING WARTNING CONSUMBLE PARTS LIST MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS LABOUR MATERIAL PROFESSIONS REFERENCE
STORAGE SPECIFICATIONS REFERENCE
Storage of the machine....................10-1 Removing the machine from memory..........10-2 TROUBLESHOOTING.......111-1 Technical data.................................12-1 Working areas etc. 12-6 Shoe types and applications 12.1-11 Bucket types and application types 12.2-16 Additional counterweight 13-1 INDEX etc.14-1

The manufacturing numbers explained in this group are the individual numbers (serial number) for each machine and hydraulic components. These figures are requested when requesting information about the machine or components. Fill out these serial numbers in the empty spaces within this group to make them immediately available upon request. MODELL/TYP: PRODUCT IDENTIFICATION NUMBER: PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER :
NOTE:
HCM1M700X00010001 Markers indicating the start and end of PIN PRODUCT IDENTIFICATION NUMBER (PIN)
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, consider the potential for personal In(cid:129) Follow recommended precautions and safe operating practices.
UNDERSTAND SIGNAL WORDS
With the machine safety signs, signal words are used with the security warning symbol to determine grade or hazard level - DANGER, WARNING and CAUTION respectively. (cid:129) DANGER indicates an immediate dangerous situation which, if not avoided, could lead to death or serious in(cid:129) ATTENTION leads to a potentially dangerous situation that might cause death or serious injury when it is not avoided. (cid:129) CAUTION points out any potentially dangerous situation capable of causing only minor or moderate injuries unless this can be avoided. (cid:129) DANGER or NOTE Safety Signs are close to certain hazards. General precautions are listed (cid:129) Some safety instructions do not use any of the above signals after the safety alarm symbol has occasionally been used on this machine. In order to avoid confusing machine protection with personal safety messages, a sign IMPORTANT gives a situation likely to result without prevention damage to the machine. NOTE suggests there is additional information available.
WEAR PROTECTIVE CLOTHING
Wear tight-adjustable clothing and safety equipment to fit the job. Possibly you need: A Harthut seat belt Seat shoes Safety glasses, protective goggles or face shield Heavy gloves Hearing guard Reflective clothing Wet weather clothing Breather or filter mask. Be sure to wear the right equipment and clothing for the job. Do not take any risks. (cid:129) Avoid wearing loose clothes, jewellery or other items that can grab control levers or other parts of the machine. Operating equipment safely requires the full attention of the operator. (cid:129) When operating the machine, do not use radio or music headphones.
TIDY UP INSIDE OPERATOR'S SPACE
Always keep clean inside the cabin by following the instructions below to prevent personal accidents from occurring. Remove mud and/or oily material from the shoe soles before entering the operator's room. If pedals are operated without removing mud or greasy matter, the foot can slip away from the pedal; possibly creating a dangerous situation: Do not leave parts and/or tools around the operator‘s house, do not store any transparent water bottle in the cab. The transparent water bottle may concentrate sunlight like a lens (possibly it causes fire). Wear neither radio nor music head hearers and use no cell phone when traveling or operating the machine. Never allow hazardous materials such as combustible and/or explosive material on the operator ́s place. Leave behind at all times if you want to be sure that your car is working properly for good reasons of health
USE HANDHOLDS AND STEPS
Falling is one of the main causes for personal injury. (cid:129) When you get on and off the machine, always face handrails. (cid:129) Maintain a three-point contact with the steps and (cid:129) Do not use any controls as grab handles. (cid:129) Never jump up or off the machine. Fix or deactivate never a moving machine.(cid:129) If slippery material such as oil, grease or mud exists in increments, handrails or platforms, thoroughly remove this material.

Always be aware that there is a potential danger around the machine when operating the machine.
SAFETY
(cid:129) Always stop the travel alarm and horn in working condition (if any). (cid:129) Before starting to move or operate the machine, call the travel alarm and horn system to alert it. (cid:129) When moving, swinging or operating the machine use a signal person in congested areas. Locate the signal person so that the operator can always witness the signal person(cid:129) Coordinate all safety signs, hand signals and markers before starting the machine. Enquire one person who is responsible for providing a signal and/
KEEP RIDERS OFF MACHINE
Drivers on the machine are subject to injury as they are hit by foreign bodies and thrown out of the machine. (cid:129) Even drivers hinder operator visibility, making the machine operate in an unsafe manner. (cid:129) Only allow the operator to be allowed at the machine.
PRECAUTIONS FOR OPERATIONS
Make sure that certain safety is given at the workplace before starting. Always pay particular attention to following points. Wear tight-fitting clothing and required safety items such as a hard hat when operating the machine absolutely aside. Keep all bystanders and unnecessary objects out of the machine work areas and away from them. Always keep an eye on the surrounding during operation of the machine. Be careful not to touch any object if the rear part of the top design swings in a small area. When loading a dump truck, bring the bucket here from the back of the dump tipper to avoid moving the bucket over the dump hauler cabin or via any employee.
PROTECT AGAINST FALLING STONES AND DEBRIS
Confirm that your machine is FOPS cab before working in areas where the possibility of falling stones or debris exists. PROVIDE SIGNALS FOR JOBS INVOLVING MULTIFIGURES OF MACHINES, If more than one machine is operated on the same job site, accidental collision between machines may result in serious injury or death. For work involving multiple numbers of machines, provide signals which all involved personnel generally know.

If one person is present near the operating machine, the person may come into contact with the oscillating front attachment or counterweight and/or be crushed against another object resulting in serious injury or death. Set up barriers on the sides and rear of the shovel radius before operation of the machine to prevent everyone from entering the working area. Make sure that no other personnel than the signaling individual or obstacles are present in the work area before you operate the machine.
OPERATE WITH CAUTION
When the front attachment or any other part of the machine encounters an overhead obstacle, such as a bridge, both the machine and upper head obstruction are damaged and personal injury can also result.
AVOID POWER LINES
Serious injury or death may result if the machine or front attachments are not safely kept away from electrical lines. When operating near an electric line, NEVER move a part of the machine or load closer than 3 m (10 ft) plus twice the row isolator length. Check and follow any local regulations. Wet soil will expand the area that could cause each person to be affected by electroshock on it.
PROTECT AGAINST FLYING DEBRIS
When flying debris such as soil, rock fragments or metal pieces hit eyes or any other part of the body may result in serious injury. Protect from such injuries when working at a job site where there is the possibility to fly parts of metal or debris, or while removing or laying pins with a hammer; wear goggles and safety glasses. Stay away from work area before hitting any object. SA-1805 SA-014
STAY CLEAR OF MOVING PARTS
Contact with moving parts can cause serious injury or death by amputation or entanglement. To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewellery and hair are not involved when working around rotating parts.

Stored attachments such as buckets, hydraulic hammers and blades can fall causing serious injury or death. Maintain attachments and equipment safely to prevent falling accidents.
BEWARE OF ASBESTOS DUST
Make sure that no dust generated in the work site is inhaled. Breathing asbestos fibers can be the cause of lung cancer. Depending on the wok conditions, there may be a risk of inhalation of asbestos fibre. Spray water to prevent air from entering asbestos. Do not use compressed air. When operating the machine on a workplace where perhaps asbestos is present, you should absolutely operate the machine from the wind-up side and wear a protective mask designed to prevent an penetration of asbestos. Don't let yourself be kept away from the job place during operation. Asbestos could be included in imitation parts. Use only genuine Hitachi Parts (Cab-Equipped Machines) SA-393 SS4642980
PRECAUTIONS FOR WELDING AND GRINDING
Welding can produce throttle and/or small fires. Ensure that welding is performed in a well ventilated and prepared area. Maintain flammable objects in a safe place before starting to weld. Only qualified personnel should carry out welding. Never allow an unqualified person to perform welding. Grinding on the machine may cause risk of fire.
HANDLE CHEMICAL PRODUCTS SAFELY
Direct irradiation with hazardous chemicals can result in serious injury. Potentially dangerous chemicals used on your machine include items such as lubricants, electrolyte, coolant, paints and adhesives. A Material Safety Data Sheet (MSDS) contains specific information about chemical products: physical and health hazards, safety procedures plus emergency response techniques. Check the MSDS before starting any work with a harmful chemical.

All safety signs and their locations affixed to the machine are displayed in this group. Make sure that the contents described in the security sign is done by reading actual contents installed on the machine, ensuring safe machine operation. Always keep the safety signs clean. If a safety sign is broken or lost, you will immediately receive a new replacement and reattach it to the unit again. When ordering from your authorized dealer, take advantage of the part no. of any safety sign illustration specified under the right corner. SS-2640 M1M7-03-002

BREAK-IN BREAKING IN NEW MACHINE IMPORTANT: Operating a new machine at full load without first breaking in can cause scratches and/or seizures, thus affecting the life of the machine. Comprehensively perform burglary operation. Machine service life and performance can be greatly compromised by operating and maintaining the machine in its first stage of operation.
WARNING: Guard against injury from flying pieces of metal. Use safety equipment such as a hard hat and safety glasses. Procedure of Bucket Teeth Change
1. Use hammer and drift to drive out locking pin (5). Be sure not to damage the rubber needle lock while removing the lock pin (5). Inspect latch pin and rubber clamp lock, for eventual damage. Replace short or damaged tie bolts as shown below by new ones. M104-07-056 Fill up the lower surfaces. The lockpin length is too short. M104-07-118 M104-07-058 Steel balls almost get off due to damage of castle rubber. Steel ball can be depressed with finger force. M104-07-059
WARNING: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris; wear a hard hat, goggles or safety glasses, heavy gloves and safety equipment appropriate for the job.
Choose a spacious job site with good standing. Start work only after ensuring the safety of other people around the machine. Avoid fast operation of the front attachment. When engaged in teamwork, give top priority by strict replacement of safety signs. Park the machine on a level surface. Lower the bucket to the ground and position it with the flat area resting at bottom.
TROUBLESHOOTING
When a problem is found, troubleshoot to locate the cause and take appropriate action so that the problem does not recur.
REFERENCE
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