Page 1 PART NO. ENMADC-1-3 Operator’s Manual 65USB Hydraulic Excavator URL:http://www.hitachi-c-m.com Serial No. ZX33U 030002 and up ZX38U 050002 and up ZX48U 030002 and up ZX55U 050002 and up ZX65USB 020001 and up This book is printed on recycled paper. PRINTED IN JAPAN (E) 2014, 12...
Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or equipment damage.
Page 3: Enmadc
MACHINE NUMBERS INDEX SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONAL ATTACHMENT INDEX ENMADC-1-3...
Page 5: Table Of Contents
CONTENTS MACHINE NUMBERS ................1 Avoid Applying Heat to Lines Containing Flammable Fluids ................... S-35 SAFETY ....................S-1 Precautions for Handling Accumulator and Gas Recognize Safety Information ............S-1 Damper ..................S-35 Understand Signal Words .............S-1 Remove Paint Before Welding or Heating ......S-36 Follow Safety Instructions ............S-2 Beware of Asbestos and Silicon Dust and Other Prepare for Emergencies ...............S-3 Contamination ................. S-36 Wear Protective Clothing..............S-3 Prevent Battery Explosions ............S-37 Protect Against Noise ..............S-4 Service Air Conditioning System Safely .......
Page 6 CONTENTS Displaying Trip Meter (2) ............ 1-27 Towing Machine ................4-7 Change Trip Meter Set Time ..........1-28 Operating in Water or Mud ............4-8 Brightness Adjustment ............... 1-30 Precautions for Traveling on Slopes..........4-9 Heater Operation (ZX33U-5A, 38U-5A, 48U-5A, Parking the Machine on Slopes ..........4-10 55U-5A) ..................1-32 Parking the Machine ..............4-10 Name and Function of Each Part of Control Panel ..1-32 OPERATING THE MACHINE ............5-1 Heating Operation ..............1-33 Control Lever (ISO Pattern) ............5-1 Defroster Operation ............... 1-33 Boom-Swing Pedal ................5-2 Tips for Optimal Heater Usage..........
Page 7 CONTENTS A. Greasing ..................7-19 Installing Rubber Crawler ............ 7-82 Front Joint Pins ................ 7-19 Check Track Sag (Steel Crawler) (Optional) ....7-83 Bucket ..................7-19 Converting the Track ............. 7-85 Swing Post and Others ............7-19 Check and Replace Seat Belt ..........7-86 Blade Pins ................... 7-21 Check Air Conditioner (Cab equipped machine) ..7-87 Swing Bearing ................7-22 Clean and Replace Heater / Air Conditioner Filter ..7-90 Swing Internal Gear..............7-23 Clean Circulating Air Filter ........... 7-90 Control Lever Universal Joint ..........
Page 8 Coupler ..................13-1 Attachment ..................13-2 Piping for Breaker and Crusher (Optional) ......13-3 Attachment Pedal (Hydraulic Breaker) (Optional) .... 13-4 Precautions for Breaker Operation ......... 13-5 Attachment Pedal (Hydraulic Crusher) (Optional) .... 13-9 Precautions for Crusher Operation ........13-10 AUX Function Lever for Extra Piping (Optional) ....13-13 Auxiliary Flow Rate Control (Optional) .......13-14 Control Lever (H-pattern: HITACHI Excavator Pattern) ..13-15 Control Lever (SAE-backhoe Pattern) ........13-16 Fuel Feed Device (Optional) (ZX48U-5A, 55U-5A, 65USB-5A) ................13-17 Numeric Keypad Lock (Optional) ........13-18 Additional Counterweight ............13-25 Cab Tilting Mechanism .............13-26 Maintenance ................13-33 Check Tilt Mechanism Fulcrum Bolts and Working Screw Lock Nut ...............13-33...
Page 9: Machine Numbers
MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request. Machine MODEL/TYPE: PRODUCT IDENTIFICATION NUMBER: MADB-00-002 Product Identification Number PRODUCT IDENTIFICATION NUMBER: NOTE: Marks to indicate the *HCMADC00X00050002* start and end of the PIN PRODUCT IDENTIFICATION NUMBER (PIN) MADB-00-003 ZX33U-5A, 38U-5A MADB-00-002 ZX48U-5A, 55U-5A, 65USB-5A...
Page 10 MACHINE NUMBERS Engine TYPE: MFG. NO.: MADB-00-020 MADC-00-010 Travel Motor TYPE: MFG. NO.: M1M0-00-004...
Page 11 MACHINE NUMBERS Swing Motor TYPE: MFG. NO.: ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADB-00-005 MADC-00-001 ZX65USB-5A...
Page 12 MACHINE NUMBERS Hydraulic Pump TYPE: MFG. NO.: ZX33U-5A, 38U-5A MADB-00-006 MADB-00-021 ZX48U-5A, 55U-5A MADC-00-002 ZX65USB-5A...
Page 13: Safety
SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Page 14: Follow Safety Instructions
 Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines.
Page 15: Prepare For Emergencies
SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  Establish emergency procedure guidelines to cope with fires and accidents.  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.
Page 16: Protect Against Noise
SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.  In the walk-around inspection be sure to cover all points described in the "Inspect Machine Daily Before Starting" section in the operator’s manual.
Page 17: General Precautions For Cab
SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator’s seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control...
Page 18: Use Handrails And Steps
SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always use the crawler instead of the step for safety. Also get on and off from the position of the crawler that can secure your feet space enough.
Page 19: Ensure Safety Before Rising From Or Leaving Operator's Seat
SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.
Page 20: Move And Operate Machine Safely
SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.  Use a signal person when moving, swinging, or operating the machine in congested areas.
Page 21: Jump Starting
SAFETY Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.
Page 22: Precautions For Operations
SAFETY Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.  Clear all persons and obstacles from area of operation and machine movement. Do not permit persons other than the operator to enter areas where there is danger such as flying objects.
Page 23: Investigate Job Site Beforehand
SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.
Page 24: Install Opg Guard
 Reduce the engine speed.  Select slow travel speed mode.  Operate the machine slowly and be cautious with machine movements. Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, equip Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. The guard can be compliant with ROPS standards depending on the machine specifications. In order not to impair operator protective structure: Replace damaged ROPS or OPG guard. Never attempt to repair or modify the guard.
Page 25: Restriction Of Attachment Installation
SAFETY Restriction of Attachment Installation  Do not install an attachment which exceeds specified weight for the machine structure. Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions. SA-481 Confirm Direction of Machine to Be Driven  Incorrect travel pedal/lever operation may result in serious injury or death.
Page 26: Drive Machine Safely
SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling. SA-1295  Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.  Never attempt to ascend or descend 35 degrees or steeper slopes.  Be sure to fasten the seat belt.
Page 27 SAFETY  When the machine descends a slope at high speed, machine weight accelerates descending speed. It may cause collision accident due to misjudging of braking distance or machine turnover due to running on an unexpected obstacle. Always ensure that travel mode display (1) on the monitor , and then reduce the engine speed before descending a slope.  Be sure to thoroughly warm up the machine before ascending steep slopes.
Page 28: Avoid Injury From Rollaway Accidents
SAFETY Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways:  Select level ground when possible to park the machine.  Do not park the machine on a grade.  Lower the bucket and/or other work tools to the ground.  Turn the auto-idle switch OFF and the power mode switch E or P.  Run the engine at slow idle speed without load for 5 minutes to cool down the engine.  Stop the engine and remove the key from the key switch.  Pull the pilot control shut-off lever to LOCK position.  Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade.
Page 29: Avoid Injury From Back-Over And Swing Accidents
SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents:  Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.  Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.  USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN SA-383 VIEW.
Page 30: Keep Person Clear From Working Area
SAFETY Keep Person Clear from Working Area  A person around the operating machine may be hit severely by the swinging front attachment or counterweight, be caught in other objects, and/or be struck by flying objects, resulting in serious injury or death.  Set up barriers and/or put a NO ADMISSION sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area.  Check that all personnel or obstacles other than the signal person are not present in the working area before operating the machine.
Page 31: Avoid Undercutting
SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases. SA-1300 Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP...
Page 32: Never Undercut A High Bank
SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-1302 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging check the location of cables, gas lines, and water lines.
Page 33: Avoid Power Lines
SAFETY Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.  Check and comply with any local regulations that may apply.  Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all SA-1305 bystanders or co-workers away from the site. Precautions for Lightning  Lightning may strike the machine. If lightning comes close, immediately stop the operation, and take the following action.  When you are around the machine or operating cab- less machine, evacuate to a safe place far away from the machine.
Page 34: Object Handling
SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.  Do not use damaged chains or frayed cables, sables, slings, or ropes.  Before craning, position the upperstructure with the travel motors at the rear. ...
Page 35: Park Machine Safely
SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket to the ground.  Turn auto-idle switch OFF and power mode switch E or P.  Run engine at slow idle speed without load for 5 minutes.  Turn key switch to OFF to stop engine.  Remove the key from the key switch.  Pull the pilot control shut-off lever to the LOCK position.  Close windows, roof vent, and cab door.  Lock all access doors and compartments. SA-1306 Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.
Page 36: Transport Safely
SAFETY Transport Safely  Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to SA-1307 be transported.  Be sure to use a signal person.  Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Push auto-idle switch (1) to turn A/I display (2) OFF. 4. Select the slow travel mode for loading or unloading the machine. Always ensure that travel mode display (3) on the monitor is , before traveling the machine.
Page 37: Practice Safe Maintenance
SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving.  Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving SA-028 the control levers several times.
Page 38: Warn Others Of Service Work
SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.  When the floor tilt mechanism check and/or maintenance is conducted, the operator’s station is tilted upward. Before conducting maintenance work, refer to page 7-76 in this manual for the detailed operation procedures and correctly operate the machine.  When required to work under the floor, support the raised SA-037 operator’s station with the fall prevention bars (red color) to ensure safety.
Page 39: Support Machine Properly
SAFETY Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. SA-527 Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.
Page 40: Prevent Parts From Flying
SAFETY Prevent Parts from Flying  Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death.  Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY.  As pieces may fly off, be sure to keep body and face away from valve.  Never attempt to disassemble the track adjuster. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death.
Page 41: Prevent Burns
SAFETY Prevent Burns Hot spraying fluids:  After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.  To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.  The hydraulic oil tank is pressurized. Again, be sure to SA-039 release all pressure before removing the cap.
Page 42: Replace Rubber Hoses Periodically
SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.  Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a SA-019 person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.
Page 43: Prevent Fires
SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes, or hoses.  Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance.
Page 44 SAFETY Clean up Flammable Materials:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire. ...
Page 45: Evacuating In Case Of Fire
SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time.  Exit the machine.  In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency SA-393 Evacuation Method.
Page 46: Precautions For Welding And Grinding
SAFETY Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.  Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.
Page 47: Avoid Heating Near Pressurized Fluid Lines
Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death. Strictly comply with the following items:  Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not attempt to bore a hole or cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. S-35...
Page 48: Remove Paint Before Welding Or Heating
 Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts. S-36...
Page 49: Prevent Battery Explosions
SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 ˚C ( 60 ˚F ) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all SA-032 terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.
Page 50: Handle Chemical Products Safely
 See your authorized dealer for SDS’s (available only in SA-2579 English) on chemical products used with your machine. Dispose of Waste Properly  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.  Do not pour waste onto the ground, down a drain, or into any water source.
Page 51: Never Ride Attachment
SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice. Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.
Page 52: Precaution For Communication Terminal Equipment
SAFETY Precaution for Communication Terminal Equipment A mobile communication terminal which transmits radio wave is located in the monitor cover at front right of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment. A person who is using a medical device should adjust the operator's seat before operating the machine so that the distance from the monitor cover with the communication...
Page 53 SAFETY  Never attempt to disassemble, repair, modify or displace the communication terminal, antennas or cables. Failure to do so may result in damage and/or fire to the base machine or to the communication terminal. (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.)  Do not pinch or forcibly pull cables, cords or connectors. Failure to do so may cause short circuit or broke circuit that may result in damage and/or fire to the base machine or to the communication terminal. S-41...
Page 54: Safety Signs
SAFETY SIGNS All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean. In case a safety sign is broken or lost, immediately, obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when ordring it at your authorized dealer. SS3079466 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADG-00-018 ZX65USB-5A MADG-00-002 SS-1495 SS4387711 S-42...
Page 55 SAFETY SIGNS SS4642518 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADG-00-018 ZX65USB-5A MADG-00-002 SS3090482 CANOPY MADG-00-019 MADG-00-006 S-43...
Page 56 SAFETY SIGNS SS-024 MADG-00-005 SS-259 CANOPY MADC-00-016 MADG-00-004 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADG-00-004 ZX65USB-5A S-44...
Page 57 SAFETY SIGNS SS4604981 MADC-00-012 ZX33U-5A, 38U-5A MADB-00-010 ZX48U-5A, 55U-5A MADG-00-007 ZX65USB-5A S-45...
Page 58 SAFETY SIGNS (Cab-Equipped Machines) SS-2641 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A SS-1832 ZX65USB-5A MADG-00-009 (2 Way Multi Lever Equipped Machines) SS4605065 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADG-00-018 ZX65USB-5A MADG-00-002 S-46...
Page 59 SAFETY SIGNS SS4433590 ZX33U-5A, 38U-5A MADG-00-020 ZX48U-5A, 55U-5A MADB-00-012 ZX65USB-5A MADG-00-011 ZX33U-5A, 38U-5A ZX48U-5A, 55U-5A MADB-00-026 MADB-00-027 S-47...
Page 60 SAFETY SIGNS SS4430516 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADB-00-017 ZX65USB-5A MADG-00-012 SSYD00005435 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADB-00-019 ZX65USB-5A MADG-00-016 S-48...
Page 61 SAFETY SIGNS CANOPY MADB-00-014 SS3088058 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADB-00-015 ZX65USB-5A MADG-00-015 S-49...
Page 62 SAFETY SIGNS SS4439187 MADG-00-020 ZX33U-5A, 38U-5A MADB-00-012 ZX48U-5A, 55U-5A MADG-00-008 ZX65USB-5A SSYD00006176  To those Person fixed with any medical device, including impantable device such as a cardiac pacemaker, please read the instruction manual carefully and follow the instructions before using this machine. MADB-00-025 S-50...
Page 63 SAFETY SIGNS  A worker may be crushed by the cab floor when using the floor tilt mechanism, causing serious injury or death. Read the operator's manual for safe and proper operation. SSYD00003167 CANOPY MADB-00-029 MADB-00-030 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A ZX65USB-5A MADC-00-018 S-51...
Page 64 SAFETY SIGNS SS4387344 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADC-00-013 ZX65USB-5A MADG-00-005 (Cab-Equipped Machine) ZX33U-5A, 38U-5A, 48U-5A, 55U-5A SS4642980 MADB-00-015 ZX65USB-5A MADG-00-013 S-52...
Page 65 SAFETY SIGNS SS-3546 SS-3547 ROPS/FOPS CANOPY MADB-00-029 SS-3548 SS-3549 ROPS/FOPS MADB-00-030 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A SS-3550 ROPS/FOPS MADG-00-015 ZX65USB-5A S-53...
Page 66 SAFETY SIGNS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................S-54...
Page 67: Components Name
COMPONENTS NAME Components Name MADB-01-001 1- Bucket 7- Boom Cylinder 13- Track Frame 2- Bucket Cylinder 8- Boom Swing Cylinder 14- Front Idler 3- Arm 9- Canopy 15- Blade 4- Arm Cylinder 10- Counterweight 16- Blade Cylinder 5- Work Light 11- Track Shoe 6- Boom 12- Travel Device...
Page 68: Getting On/Off The Machine
GETTING ON/OFF THE MACHINE Getting ON/OFF the Machine Foot holds (1) and handrails (4) are provided around the entrance. These are used to get on and off the cab safely as well as to do inspection and maintenance of the machine safely.
Page 69: Operator's Station
OPERATOR'S STATION Layout 1- Left Control Lever 2- Left Travel Lever 3- Right Travel Lever 4- Swing Pedal 5- Monitor 6- Right Control Lever/Horn Switch 7- Arm Rest (Optional) 8- Seat Back Box 9- Operator's Seat 10- Auxiliary Pedal (Optional) 11- Seat Belt 12- Drink Holder MADB-01-002 13- Tool Box MADB-01-003...
Page 70 OPERATOR'S STATION 14- Numeric Keypad Lock System (Optional) 15- Key Switch 16- Heater/Air Conditioner Control Panel (Cab equipped machine) 17- Switch Panel 18- Engine Control Dial 19- Blade Lever 20- Door Lock Release Lever (Cab equipped machine) 21- Door Opener (Cab equipped machine) 22- Pilot Control Shut-Off Lever MADC-01-001 23- Fresh Air Filter (Cab equipped machine) 24- FM/AM Radio (Cab equipped machine) (Optional) 25- Circulating Air Filter (Cab equipped machine) 26- Fuse Box 27- 2-Way Multi Lever (Optional) MADB-01-005 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MADB-01-006 ZX65USB-5A MADC-01-002...
Page 71: Key Switch
OPERATOR'S STATION Key Switch 1- OFF (Engine Off ) 2- ON 3- START (Engine Start) Switch Panel 4- Work Light Switch MADB-01-007 When the upper part of switch (4) is pushed, work lights (8) located on the front side of the boom and canopy (cab) come ON. When the lower part of switch (4) is pushed, work lights (8) go OFF. 5- Wiper Switch (Cab equipped machine) Three (operational) positions are provided on this switch. OFF: Neither the wiper nor the washer operates. Center: The wiper operates. WASHER: The washer operates together with the wiper. 6- Travel Mode Switch MADC-01-003 Push side of switch (6) to select the fast speed...
Page 72: Monitor
OPERATOR'S STATION Monitor Feature The monitor displays various meters, warning indicators and work mode selection. Screen Configuration The monitor consists of the following screens. Basic Screen MENU Alarm List Clock Trip Brightness ADJ.
Page 73: Basic Screen
OPERATOR'S STATION Basic Screen 1- Overheat Indicator 2- Engine Oil Pressure Indicator 3- Alternator Indicator 4- Fuel Level Indicator 5- Preheat Indicator 6- Clock 7- Security Status Indicator (Optional) 8- Auxiliary 9- Fuel Gauge 10- Hour Meter 11- Overload Alarm Selector/Set Switch 12- ECO/PWR Mode Selector/Selector Switch 13- Auto-Idle/Selector Switch 14- Menu/Return Switch 15- Coolant Temperature Gauge 16- Travel Mode Indicator 17- Work Light Indicator 18- Auxiliary MADC-01-010...
Page 74: Indicators
OPERATOR'S STATION Indicators Overheat Indicator (1) This indicator warns abnormally increased coolant temperature. The red light comes ON and the buzzer sounds simultaneously. When the red light comes ON and the buzzer sounds, immediately stop the machine operation, run the engine at slow idle speed and lower the coolant temperature. Engine Oil Pressure Indicator (2) This indicator warns low engine oil pressure. The red light comes ON and the buzzer sounds simultaneously. When the red light comes ON and the buzzer sounds, immediately stop the engine, check the engine oil system and the oil...
Page 75: How To Use Screens
OPERATOR'S STATION How to Use Screens Displaying Basic Screen IMPORTANT: Start the engine after the basic screen is displayed. When the key switch is turned to the ON position, the starting screen and the indicators display for about two seconds. After that, the basic screen will be displayed. Starting Screen MADB-01-010 IMPORTANT: When the key switch is turned to the ON position, engine oil pressure indicator (2) and alternator indicator (3) will be lit.
Page 76 OPERATOR'S STATION  Display of Meters Items to be displayed 6- Clock 9- Fuel Gauge 10- Hour Meter 15- Coolant Temperature Gauge MADB-01-011 1-10...
Page 77 OPERATOR'S STATION  Preheat Indicator (5) The machine will automatically check if preheating is required or not. When preheating is required, preheat indicator (5) is lit automatically.  Security Status Indicator (Optional) (7) This indicator is displayed when the numeric key pad is connected. (Refer to the Numeric Key Pad Lock section.) : Locked State : Unlocked State  ECO/PWR Mode Selector Switch (11) Two engine speed modes, ECO and PWR modes, are selected and displayed by operating this mode switch. MADC-01-010 ECO (Economy) Mode Although production is slightly reduced than in the PWR mode, the fuel consumption and noise levels are reduced, allowing the machine to operate efficiently.
Page 78 OPERATOR'S STATION  Overload Alarm Selector (Optional) (12) This selector is displayed when the machine is equipped with the overload alarm device. Push selector (12) to turn the overload alarm ON/OFF. : Overload Alarm "OFF" : Overload Alarm "ON"  Auto-Idle Switch (14) When the auto-idle switch is turned ON, the indicator displays ON and the function is enabled.  Travel Mode Indicator (16) The travel mode selected by the travel mode switch located on the end of the blade lever is displayed.  Work Light Indicator (17) The indicator is displayed while the work light switch on the MADC-01-010...
Page 79: Hour Meter
IMPORTANT: If all segments flash, the machine is abnormal. Immediately consult your authorized Hitachi dealer. MADB-01-018 Coolant Temperature Gauge Indicates the engine coolant temperature. Normally the segment shows around the center of the scale during operation. All segments will flash when the coolant temperature sensor malfunctions or the CAN data can not be received.
Page 80: Alarm Occurrence Screen
(1) and the buzzer sounds continuously. Alarm mark (2), error code (3) and hour meter (4) are displayed on error display (1). When error display (1) is shown, you can not change the screen. In case error display (1) is shown, move the machine to the safe place and consult your authorized Hitachi dealer. Error Display MADB-01-023 Warning Display Screen In case abnormality occurs on the machine, warning mark (5) and warning code (6) are displayed on the middle of the screen.
Page 81: Alarm List Display
Alarm List Display IMPORTANT: Warning code (15) that has "ENG" at the code top indicates the engine failure. If it is displayed, immediately consult your authorized Hitachi dealer. NOTE:  Alarm list (13) will be displayed on MENU screen (12) only when an alarm occurs.
Page 82: Contents Of Alarms
OPERATOR'S STATION Contents of Alarms Error Code Display Code Contents of Remedy Alarms E: 1100 Engine Trouble Engine or engine related parts are abnormal. Alarm Consult your authorized Hitachi dealer. Warning Codes Display Code Contents of Remedy Alarms W: 1100 Engine Warning Engine or engine related parts are abnormal. Stop operation, check the detailed code and check the machine. W: 2201 Overheat Alarm Engine coolant temperature has abnormally increased. Stop operation. Run the engine at slow idle speed to lower the coolant temperature. W: 2202 Engine Oil Engine oil pressure has decreased.
Page 83 Display Alarms W: 2306 Boom Bottom Boom bottom pressure sensor is malfunction or abnormal. Pressure Sensor Repair or replace. Failure W: 1303 Combustion Engine or engine related parts are abnormal. Temperature Consult your authorized Hitachi dealer. Sensor Failure W: 1310 CAN CAN communication device is abnormal. Communication Stop operation. Check the sensors and controllers for any abnormalities. Failure W: 2310 EEPROM Failure Communication system is abnormal. Consult your authorized Hitachi dealer. 1-17...
Page 84: Dtc Code List
OPERATOR'S STATION DTC Code List Monitor Display Code Error Contents ENG: 00000-00 004BA-04 Rack position sensor error (low voltage) 004BA-03 Rack position sensor error (high voltage) 0005B-04 Accelerator sensor error (low voltage) 0005B-03 Accelerator sensor error (high voltage) 0005B-02 Accelerator sensor intermittent failure 0001D-04 Spare accelerator sensor error (low voltage) 0001D-03 Spare accelerator sensor error (high voltage) 0001D-02 Spare accelerator sensor intermittent failure 0001D-08 Spare accelerator sensor error (pulse communication) 00470-04 ECU temperature sensor error (low voltage) 00470-03 ECU temperature sensor error (high voltage) 00470-02...
Page 85 OPERATOR'S STATION Monitor Display Code Error Contents ENG: 00000-00 7F803-04 Start assist relay error A 7F803-03 Start assist relay error B 7F803-02 Start assist relay intermittent failure 7F802-04 CSD solenoid valve error A 7F802-03 CSD solenoid valve error B 7F802-02 CSD solenoid valve intermittent failure 00064-04 Oil pressure switch error 00064-01 Oil pressure descend error 000A7-04 Charge switch error 000A7-01 Charge alarm 7F84A-00 Abnormal water temperature 7F853-00 Air cleaner clogging alarm 000BE-00 Overspeed error 0027E-04 Rack actuator error (low current) 0027E-03...
Page 86: Main Menu (Menu)
OPERATOR'S STATION Main Menu (MENU) Push menu switch (2) while displaying basic screen (1) to display main menu (MENU) screen (3). Main menu screen (3) contains the items shown in the right figure. Alarm list (4) is displayed only when an alarm is generated. MADB-00-007 MADB-01-028EN MADB-01-069EN 1-20...
Page 87: Clock
OPERATOR'S STATION Clock Clock Adjustment 1. Push menu switch (2) while displaying basic screen (1) to display MENU (3). MADB-01-035 2. Select Clock (7) by pushing switch (4) or (5). 3. Push set switch (6) to display Clock Setting screen (8). MADB-01-036EN MADB-01-037EN 1-21...
Page 88 OPERATOR'S STATION 4. Select Hour or Minute (9) by pushing switch (4) or (5), and then push set switch (6) to make the change. MADB-01-037EN 5. Push switch (4) or (5) to adjust the clock. Push switch (4) to adjust the number downward, and push switch (5) to increase it. 6. Push set switch (6) to end the time setting procedure. MADB-01-038EN MADB-01-039EN 1-22...
Page 89: Display Mode Setting
OPERATOR'S STATION Display Mode Setting 1. Display Clock setting screen (8). Select Display (10) by pushing switch (4) or (5), and then push set switch (6) to make the change. MADB-01-040EN 2. Each time switch (4) or (5) is pushed, Display (11) is changed as follows: 24h  12h  No display. 3. Push switch (6) to make the change. 4. Push menu switch (2) to return to MENU (3) and reflect the setting. MADB-01-041EN MADB-01-042EN 1-23...
Page 90: Trip
OPERATOR'S STATION Trip Functions of Trip Meter The trip meter allows the operator to know that the machine operation hour has reached the preset hour by Trip Mark blinking the Trip mark (Trip 1 or Trip 2). The Trip mark blinks for 30 seconds when the machine operation hour reaches Trip Meter the preset hour. After that, every time the key switch is turned ON, the Trip meter blinks for 30 seconds until the meter is reset. IMPORTANT: This "Operation Hour" means the machine operation time counted from the point at which the Trip meter is set.
Page 91: Displaying Trip Meter (1)
OPERATOR'S STATION Displaying Trip Meter (1) 1. Turn the key switch to ON position. Push menu switch (2) while displaying basic screen (1) to display MENU (3). MADB-00-007 2. Select Trip (7) by pushing switch (4) or (5). MADB-01-043EN 3. Push set switch (6) to display Trip Setting screen (8). MADB-01-044EN 1-25...
Page 92 OPERATOR'S STATION 4. Select Display (9) by pushing switch (4) or (5), and then push set switch (6) to make the change. MADB-01-044EN 5. Each time switch (4) or (5) is pushed, the display will be changed as follows: Hour  Trip 1  Trip 2. If Hour is selected, the hour meter is displayed on the basic screen. If Trip 1 is selected, the set time for Trip 1 is displayed; and if Trip 2 is selected, the set time for Trip 2 is displayed.
Page 93: Displaying Trip Meter (2)
OPERATOR'S STATION Displaying Trip Meter (2) 1. Turn the key switch to ON position. Keep pushing menu switch (2) while basic screen (1) is displayed. 2. When menu switch (2) is held down, "Trip" will be MADB-00-007 displayed on short cut key (4). When switch (3) is pushed while holding down menu switch (2), the display will change to Trip 1 (5). Each time switch (3) is pushed while menu switch (2) is held down, the display will change as follows: Trip 2  Hour Meter ...
Page 94: Change Trip Meter Set Time
OPERATOR'S STATION Change Trip Meter Set Time 1. Turn the key switch to ON position. Push menu switch (2) while displaying basic screen (1) to display MENU (3). MADB-00-007 2. Select Trip (7) by pushing switch (4) or (5). 3. Push set switch (6) to display Trip Setting screen (8). MADB-01-043EN MADB-01-044EN 1-28...
Page 95 OPERATOR'S STATION 4. Select Trip 1 (10) or Trip 2 (11) by pushing switch (4) or (5), and then push set switch (6) to make the change. NOTE: Time for "Trip 1" and "Trip 2" can be set individually. 5. Each time switch (4) or (5) is pushed, the set time will be changed as follows. By using switch (4) to change Current value Changed set time (example)  35.2 3000  184.7 MADB-01-044EN By using switch (5) Current value Changed set time (example) ...
Page 96: Brightness Adjustment
OPERATOR'S STATION Brightness Adjustment 1. Push menu switch (2) while displaying basic screen (1) to display MENU (3). MADB-00-007 2. Select Brightness Adjusment (7) by pushing switch (4) or (5). 3. Push set switch (6) to display Brightness Adjustment (8). MADB-01-053EN MADB-01-054EN 1-30...
Page 97 OPERATOR'S STATION 4. Select Brightness (9) by pushing switch (4) or (5), and then push set switch (6) to make the change. The brightness is adjusted in 5 levels. High 5>4>3>2>1 MADB-01-055EN 5. Night mode can be set on Brightness Adjustment screen (8) by performing steps 1 through 4 after turning the work light switch ON. MADB-01-056EN MADB-01-057EN 1-31...
Page 98: Heater Operation (Zx33U-5A, 38U-5A, 48U-5A, 55U-5A)
OPERATOR'S STATION Heater Operation (ZX33U-5A, 38U-5A, 48U-5A, 55U-5A) 1- Control Panel 2- Right Rear Vent 3- Foot Vent 4- Right Front Vent 5- Right Front Vent (and Defroster) NOTE: Adjust the air flow direction by rotating right front MADB-01-004 vent (5) horizontally. It can be used as a defroster. Name and Function of Each Part of Control Panel 6- Heater Power Switch Push heater power switch (6) to turn the heater ON.
Page 99: Heating Operation
OPERATOR'S STATION Heating Operation Push mode switch (10) to select the vent position, and then push temperature control switch (8) to the set temperature display rightward. Control air temperature in the cab by operating temperature control switch (8). Control blower speed by using blower switch (7). Defroster Operation MADB-01-073 Select the right front vent by operating defroster switch (9). Adjust the louvers on right front vent (5) as required. Control blower speed by using blower switch (7). Control the air temperature in the cab by using temperature control switch (8).
Page 100: Tips For Optimal Heater Usage
OPERATOR'S STATION Tips for Optimal Heater Usage When Windows Become Clouded If inside of the windows becomes clouded during rainy season or on humid days, operate the heater to aid in keeping the windows clear. When the atmosphere is very damp and if the heater has run excessively, outside of the windows may become clouded. If this happens, turn OFF the heater to adjust the temperature in the cab. IMPORTANT: ...
Page 101: Air Conditioner Operation (Optional)
OPERATOR'S STATION Air Conditioner Operation (Optional) 1- Control Panel 2- Right Rear Vent 3- Foot Vent 4- Right Front Vent 5- Right Front Vent (and Defroster) NOTE: Adjust the air flow direction by rotating right front vent (5) horizontally. It can be used as a defroster. MADB-01-004 Name and Function of Each Part of Control Panel 6- Air Conditioner Power Switch Push air conditioner power switch (6) to turn it ON.
Page 102: Heating Operation
OPERATOR'S STATION Heating Operation Push mode switch (11) to select the vent position, and then push temperature control switch (9) to set the temperature display rightward. Control the air temperature in the cab by operating temperature control switch (9). Control the blower speed by using blower switch (8). When air conditioner switch (7) is turned ON during heating operation, air in the cab will be dehumidified. MADB-01-066 Cooling Operation Push mode switch (11) to select the vent position, and then push temperature control switch (9) to set the temperature...
Page 103: Tips For Optimal Air Conditioner Usage
OPERATOR'S STATION Tips for Optimal Air Conditioner Usage For Rapid Cooling The temperature in the cab may rise 80°C and over (176°F) when the machine is exposed to sun light in the summer. In this case, ventilate the air in the cab first by opening the windows for rapid cooling. After starting the engine, set the temperature control toward the far left end using temperature control switch (9). Set mode switch (11) to the right front and rear vents.
Page 104: Radio (Cab Equipped Machine) (Optional)
OPERATOR'S STATION Radio (Cab equipped machine) (Optional) 1- Radio/Clock MADB-01-005 1-38...
Page 105: Am/Fm Radio Operation (Cab Equipped Machine)
OPERATOR'S STATION AM/FM Radio Operation (Cab equipped machine) Part Name and Function 1- Power Switch Push this switch to turn ON/OFF the radio. 2- Sound Control Switch (SOUND) Push this switch to adjust sound (Balance/Bass/Treble). 3- Up/Down Buttons (UP/DOWN) M1NE-01-003 This button is used to change the radio wave frequency, adjust the sound parameter and the clock setting. 4- Display Time, radio receiving frequency and operation mode are displayed.
Page 106: Tuning Procedure
OPERATOR'S STATION Tuning Procedure 1. Manual Tuning Procedure Push UP button (3) to increase the frequency by one step. Push DOWN button (3) to decrease the frequency by one step. 2. Automatic Tuning (Auto-Seeking) Push UP button (3) or DOWN button (3) long to scan the frequency upward or downward. When a station is received, the auto-seeking function is deactivated so M1NE-01-003 that the received frequency station is tuned in. Station Presetting Procedure 1. Select MW (AM) or FM by pushing AM/FM switch (5). 2. Push one of PRESET buttons (7) long to save the receiving frequency in memory. When the preset procedure completes, the PRESET button No. flashes 3 times and frequency display becomes ON. 3. Repeat steps 1 and 2 for other PRESET buttons (7).
Page 107: Sound Adjustment
OPERATOR'S STATION Sound Adjustment When SOUND control switch (2) is pressed with the radio switch ON, It will be in the sound adjustment state. Each time SOUND control switch (2) is pressed, the adjustment item can be changed as below. BAL  TRE  BAS  BAL  TRE  BAS When SOUND control switch (2) is pressed with the BAS state, the sound adjustment is deactivated. • Sound Adjustment (Balance Control) When UP button (3) is pressed with the BAL state, M1NE-01-003 loudspeaker output is increased from R output by one step. When DOWN button (3) is pressed with the BAL state, loudspeaker output is decreased from L output by one step. • Sound Adjustment (Treble Control) When UP button (3) is pressed with the TRE state, treble level is increased by one step. When DOWN button (3) is pressed with the TRE state, treble level is decreased by one step. • Sound Adjustment (Bass Control) When UP button (3) is pressed with the Bas state, bass level is increased by one step. When DOWN button (3) is pressed with the Bas state, bass level is decreased by one...
Page 108: Door Lock Release Lever (Cab Equipped Machine)
OPERATOR'S STATION Door Lock Release Lever (Cab equipped machine) CAUTION: Open the door all the way until it securely locks in the latch on the side of the cab. To unlock the door, push down door lock release lever (1) located at the left side of the operator's seat. MADB-03-001 1-42...
Page 109: Opening Upper Front Window (Cab Equipped Machine)
OPERATOR'S STATION Opening Upper Front Window (Cab equipped machine) Front Window 1. Hold handle (1) at upper part of the front door and pull lock lever (2) with your finger. Release the lock to open the front window. 2. Pull the upper front window up and back along the rail until it securely activates lock lever (2) at the rear end. This time, use handle (3) on the lower front window. 3. After confirming that lock lever (2) is securely activated, slide lock pin (6) to lock the window in position. MADB-01-058 CAUTION:  Slowly close the upper front window so as not to catch a finger.
Page 110: Adjusting The Seat
OPERATOR'S STATION Adjusting the Seat Seat Fore-aft Adjustment Release the seat lock by pulling in adjuster bar (1) horizontally. Move the seat backward and forward. Seat fore-aft is adjustable in 120mm range in 6 steps, 20mm per step. Tool Box The tool box is located at the right side in cover (2). MADB-01-071 Seat Back Box Pocket (4) is located at the back side of the seat. Put the operator’s manual inside. MADB-01-062 1-44...
Page 111: Emergency Exit (Cab Equipped Machine)
OPERATOR'S STATION Emergency Exit (Cab equipped machine) Escape from the cab in emergency in the following methods: CAUTION: There is always a danger of downfall when escaping from the cab in emergency, which may result in serious personal injury. Escape from the cab as safely as possible, depending on the posture of machine and the external situation.
Page 112: Seat Belt
OPERATOR'S STATION Seat Belt WARNING:  Be sure to use seat belt (1) when operating the machine.  Before operating the machine, be sure to examine seat belt (1) and the hardware attached for any failure. Replace the seat belt and the hardware attached if they are dameged and/ or worn.
Page 113: Break-In
BREAK-IN Breaking in New Machine IMPORTANT: Operating a new machine at full load without first breaking in can cause scratches and/or seizures, consequently affecting the service life of the machine. Thoroughly perform the break-in operation. The service life and the performance of the machine can be greatly affected by operation and maintenance of the machine during the initial stage of operation. Perform the break- in operation with the engine output less than 80% of the...
Page 114 BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 115: Operating The Engine
OPERATING THE ENGINE Inspect Machine Daily Before Starting Perform the required daily check before starting the engine.  Refer to "Maintenance" section for detailed information. Engine  Level and contamination of engine oil and coolant  Starting easiness, exhaust gas color, and noise  Oil and water leaks, damage to hoses and pipe lines  Clogging and damage to radiator, oil cooler  Looseness and missing of mounting bolts and nuts Upperstructure  Fuel level, leaks and contamination of fuel in tank  Hydraulic oil level, leaks and contamination of hydraulic oil tank...
Page 116: Before Starting Engine
OPERATING THE ENGINE Before Starting Engine 1. Confirm that pilot control shut-off lever (1) is in the LOCK position. 2. Confirm that all control levers are placed in neutral. 3. Insert key switch (2). Turn it to ON position. The starting screen is displayed on the monitor. All warning indicators are ON. They stay on for 2 seconds, and the basic screen is displayed. Alternator indicator (4) and engine oil pressure indicator (3) stay ON. IMPORTANT: The monitor panel indicates the machine MADB-03-001 operating conditions.
Page 117: Starting The Engine
OPERATING THE ENGINE Starting the Engine Starting the Engine at Normal Temperature 1. Confirm that pilot control shut-off lever (1) is in the LOCK position. 2. Turn engine control dial (3) to the slow idle position. 3. Sound horn to alert bystanders. 4. Insert key switch (2). Turn it to ON position. 5. The basic screen (4) will be displayed on the monitor. MADB-03-001 6. Turn key switch (2) to START position to rotate the starter. The engine will start. IMPORTANT: Never operate the starter for more than 15 seconds at a time.
Page 118 OPERATING THE ENGINE Starting in Cold Weather Preheating 1. Confirm that pilot control shut-off lever (1) is in the LOCK position. 2. Turn engine control dial (3) to around the middle between the slow idle and fast idle position. 3. Sound the horn to alert bystanders. 4. Insert key switch (2). Turn it to ON position. M1M7-03-001 5. The basic screen will be displayed on the monitor. The machine will automatically check if preheating is required or not. When preheating is required, preheat indicator (4) is lit automatically. 6. As soon as preheat indicator (4) goes OFF, turn key switch (2) to START position to rotate the starter.
Page 119: Check Instruments After Starting Engine
OPERATING THE ENGINE Check Instruments After Starting Engine Checking instruments through monitor functions After starting the engine, check the following points through the monitor functions. 1. Check that alternator alarm indicator (2) is OFF. In case alternator alarm indicator (2) stays ON, immediately stop the engine. Inspect the alternator and the battery system for any abnormality. 2. Check that low engine oil pressure indicator (1) is OFF. In case low engine oil pressure indicator (1) stays ON, immediately stop the engine. Inspect the engine oil pressure system and the oil level.
Page 120: Using Booster Battery
OPERATING THE ENGINE Using Booster Battery WARNING:  An explosive gas is produced while battery is in use or being charged. Keep open flames and sparks away from the battery area. Do not continue to use or charge the battery when electrolyte level is lower than specified.
Page 121 OPERATING THE ENGINE Disconnecting the booster cables 1. Disconnect black booster negative (-) cable (2) from hinge (3) of the machine cover first. 2. Disconnect the other end of black booster negative (-) cable (2) from the booster battery. (Red) 3. Disconnect red booster positive (+) cable (1) from the booster battery. Machine Battery Booster Battery 4. Disconnect red booster positive (+) cable (1) from the (Black) Disconnect First machine battery. To hinge (3) of the machine tank cover M503-03-002...
Page 122: Stopping The Engine
OPERATING THE ENGINE Stopping the Engine Engine Stop Procedure 1. Except for special cases, before stopping the engine, lower the bucket and the blade to the ground. 2. Pull pilot control shut-off lever (1) to LOCK position. 3. Turn the engine control dial to the slow idle position and run the engine for 5 minutes to cool the engine. 4. Turn key switch (2) OFF to stop the engine. MADB-03-001 MADB-03-002...
Page 123: Driving The Machine
DRIVING THE MACHINE Travel Levers and Pedals (Optional) Front Travel operation can be performed with either the levers or pedals. Blade WARNING: In the standard travel position, the front idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are Left Right positioned at the front of the machine, the control...
Page 124 DRIVING THE MACHINE • Pivot Turn Steer the machine by driving only one side crawler. Operate either of the travel levers (or pedals). M1M7-04-012 M104-04-005 Pivot Turn • Spin Turn Steer the machine by driving each crawler in the opposite directions. Push one lever (or pedal) forward and pull the other back at the same time. WARNING: During pivot or spin turn machine operations, the base machine may shake. When turning the machine in a tight area, slowly operate the machine while taking care not to allow the machine to come in contact with the surrounding objects.
Page 125: Travel Mode Switch
DRIVING THE MACHINE Travel Mode Switch WARNING: Tipping-over accidents can cause serious personal injury. Do not change travel mode switch (1) while traveling; especially, changing to fast mode when descending slopes will create a very dangerous situation. Always stop the machine before changing the travel speed mode.
Page 126: Traveling
DRIVING THE MACHINE Traveling CAUTION: Use a signal person when traveling the machine along road shoulders or in congested areas. Coordinate hand signals before starting the machine.  Be sure to confirm the position of travel motors before traveling and operate the travel levers/pedals.  Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.  Before traveling on them, check the strengths of bridges Travel Motor and road shoulders, and reinforce if necessary.
Page 127: Traveling On Soft Ground
DRIVING THE MACHINE Traveling on Soft Ground Avoid traveling on soft ground as much as possible. If traveling on a soft ground is unavoidable, carefully operate the machine while observing the following points. • Drive the machine as far as the machine can move by its own propelling power. Towing the machine may become necessary. Do not drive the machine to a deeper location than towing the machine is possible.
Page 128: Raise One Track By Using Boom And Arm
DRIVING THE MACHINE Raise One Track by Using Boom and Arm WARNING: Operate the machine carefully. The machine may slide. Keep the angle between the boom and the arm at 90 to 110° and position the bucket’s round side on the ground. 1. Swing the upperstructure 90°.
Page 129: Towing Machine
DRIVING THE MACHINE Towing Machine CAUTION: Cables, straps or ropes can break causing serious injury. Do not tow machine with damaged chains, frayed cables, slings, straps or wire ropes. Always wear gloves when handling cable, straps or wire ropes. When your machine becomes struck but the engine is still operational, attach wire ropes to the machine as illustrated on the right side, and slowly tow your machine to firm ground by using another machine.
Page 130: Operating In Water Or Mud
DRIVING THE MACHINE Operating in Water or Mud The machine can be operated in water up to the upper edge of the upper rollers only if worksite footing has sufficient strength to prevent the machine from sinking under the upper edge of the upper roller, and only if the water is flowing slowly. When operating in such conditions, check the machine’s position often. Reposition the machine if necessary. Avoid submerging the swing bearing, swing gears and center joint.
Page 131: Precautions For Traveling On Slopes
DRIVING THE MACHINE Precautions for Traveling on Slopes CAUTION: Avoid possible injury from traveling on slopes. Tipping over or skidding down of the machine may result. Thoroughly read and understand precautions below and be sure to travel at slow speed on slopes.
Page 132: Parking The Machine On Slopes
DRIVING THE MACHINE Parking the Machine on Slopes WARNING: Avoid parking and/or stopping the machine on slopes. The machine may tip over, possibly resulting in personal injury. If parking the machine on a slope is unavoidable:  Thrust the bucket teeth into the ground.  Return the control levers to neutral and pull pilot control shut-off lever (1) to the LOCK position.  Block both tracks. M1M7-04-009 Parking the Machine 1. Park the machine on a level surface. 2. Lower the bucket and the blade to the ground.
Page 133: Operating The Machine
OPERATING THE MACHINE Control Lever (ISO Pattern) WARNING:  Never place any part of body beyond window frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. Never remove the window sash bar. ...
Page 134: Boom-Swing Pedal
OPERATING THE MACHINE Boom-Swing Pedal Use the boom swing function to efficiently operate the machine when excavating grooves along roadsides or near walls. The boom swing operation is performed using boom-swing pedal (1) located at the operator’s right foot as illustrated to the right. Boom-Swing Operation 1. Turn cover (2) for boom-swing pedal (1) forward. 2. Step on the left side of boom-swing pedal (1) to swing left. Step on the right side of pedal (1) to swing right. 3. Turn cover (2) backward over boom-swing pedal (1) when boom-swing operation is no longer required. Unlock Position MADB-01-062 3- Swing Left 4- Swing Right...
Page 135: Blade Lever
OPERATING THE MACHINE Blade Lever Use blade lever (1) on the operator’s right to raise and lower the blade. When blade lever (1) is released, it automatically returns to neutral, holding the blade in the present position until lever (1) is operated again. MADB-05-002 2- Blade Raise 3- Blade Lower MADB-05-005...
Page 136: Precautions For Blade Operation
OPERATING THE MACHINE Precautions for Blade Operation This blade is designed as a light service attachment of the hydraulic excavator. Please keep the following points in mind:  This blade is designed for bull dozing work only. Do not attempt to dig deeply with the blade. Doing so may damage not only the blade but the undercarriage as well.  Do not apply concentrated or uneven loads to the blade. Never allow the blade to forcefully collide with a load by running the machine into the load.
Page 137: Pilot Control Shut-Off Lever
OPERATING THE MACHINE Pilot Control Shut-Off Lever Pilot control shut-off lever (1) functions to prevent misoperation of the machine from occurring if the control levers are accidentally moved when leaving the operator's seat or when entering the cab. Pilot control shut-off lever (1) is linked to console (2) latch mechanism so that console (2) is raised in the LOCK position to aid in entering and exiting the operator’s station and for maintenance. WARNING:  To deactivate control lever (3) and pedal functions, be sure to pull pilot control shut-off lever (1) and raise console (2) to the fully locked position.
Page 138 OPERATING THE MACHINE Before Starting Operation: Confirm that pilot control shut-off lever (1) is pulled up to the LOCK position before starting the engine. Slowly push down control shut-off lever (1) to UNLOCK position before starting operation. Confirm that all control levers and pedals are in neutral and that no part of the machine is in motion. WARNING: If any part of the machine (any actuator) moves when pilot control shut-off lever (1) is lowered to the UNLOCK position despite the fact that all controls are placed in neutral, the machine is...
Page 139: Warming Up Operation
OPERATING THE MACHINE Warming Up Operation In cold weather, warm up the machine until coolant and Fast Idle hydraulic oil temperature increase to the appropriate operating temperature. IMPORTANT: The appropriate hydraulic oil operating temperature on this machine is 50 to 80 °C. Hydraulic Slow Idle components may be seriously damaged if the machine is operated with low temperature hydraulic oil.
Page 140: Engine Speed Control
OPERATING THE MACHINE Engine Speed Control Increase and decrease the engine speed using engine control dial (1) located on the switch panel, as illustrated.  Turn engine control dial (1) clockwise to increase the engine speed. Turn engine control dial (1) counterclockwise to decrease the engine speed.  Note that the auto-idle function will be deactivated if engine control dial (1) is operated while the engine is running at the auto-idle setting.
Page 141: Auto-Idle
OPERATING THE MACHINE Auto-Idle Auto-Idle Function With the auto-idle function turned to the ON position, approximately 4 seconds after all control levers are returned to neutral, the engine speed decreases to the auto-idle setting to save fuel consumption. The engine speed will immediately increase to the speed set by the engine control dial when the engine control dial is operated with the pilot control shut-off lever pulled, or when either the control lever or engine control dial is operated with the pilot control shut-off lever pushed down.
Page 142: Auto-Idle On/Off
OPERATING THE MACHINE Auto-Idle ON/OFF Note that auto-idle function can be turned ON or OFF by pushing auto-idle switch (2). Check if the auto-idle function is turned ON or OFF with auto-idle indicator (1). Auto-Idle Switch Auto-Idle Indicator (1) ON : Auto-Idle Function ON Auto-Idle Indicator (1) OFF : Auto-Idle Function OFF After the key switch is turned OFF when the auto-idle function is activated [with auto-idle indicator (1) ON], when the engine is restarted, auto-idle indicator (1) flashes for 10 seconds and the auto-idle function becomes activated. MADB-00-007 5-10...
Page 143: Power Mode
OPERATING THE MACHINE Power Mode Two engine speed modes, ECO and PWR modes are selected by pushing ECO/PWR mode switch (2) while displaying basic screen (1). ECO (Economy) Mode This mode slightly reduces the engine speed according to the operating condition. Digging power is same as the PWR mode. Although production is slightly reduced more than in the PWR mode, the fuel consumption and noise levels are reduced, allowing the machine to operate efficiently. PWR (Power) Mode Operate the machine in this mode when performing normal work.
Page 144: Overload Alarm Selector (Optional)
OPERATING THE MACHINE Overload Alarm Selector (Optional) This selector is displayed (1) when the machine is equipped with the overload alarm device. Push selector (2) to turn the overload alarm ON/OFF. : Overload Alarm "OFF" : Overload Alarm "ON" MADC-01-010 If the overload alarm is “ON”, the buzzer sounds when the boom bottom pressure sensor (3) detects a defined pressure. The buzzer will not sound if the overload alarm is “OFF”. The machine keeps the settings at previous key “OFF” until the next key ON. MADC-05-001 5-12...
Page 145: Operating Backhoe
OPERATING THE MACHINE Operating Backhoe  Use the appropriate arm and bucket for the work. (Refer to the "Bucket Types and Applications" in the Specifications section.)  Pull the bucket toward the machine using the arm as the main digging force.  When soil sticks to the bucket, remove it by moving the arm and/or bucket rapidly back and forth.  Place the bucket teeth on the ground with the bottom of the bucket at a 45 degree angle to the ground.  When trenching a straight line, position the tracks parallel M107-05-037 to the trench. After digging to the desired depth, move the machine as required to continue the trench.  When operating the arm, avoid bottoming the cylinder to prevent cylinder damage.
Page 146: Grading Operation
OPERATING THE MACHINE Grading Operation Use the blade for soil refilling and general grading operations after excavation. Grading operation can be also performed by operating the boom, arm, and bucket simultaneously. IMPORTANT: Do not pull or push dirt with the bucket when traveling. Excess force will be applied on each part, and the machine may be damaged. When grading by operating the boom, arm, and bucket simultaneously: 1. When grading from the forward to the backward, slowly...
Page 147: Avoid Abusive Operation
OPERATING THE MACHINE Avoid Abusive Operation Do not travel while thrusting the bucket teeth into the ground and do not raise the rear of the machine to use the machine's weight as additional digging force. Severe machine damage may result. MZX5-05-002 Avoid Excavation Using Upperstructure and/or Boom Swing Power Never attempt to move rocks or excavate a cliff face by hitting the bucket using upperstructure and/or boom swing power. Damage to the front attachment, or shortening of the service life of the swing systems may result. 5-15...
Page 148: Avoid Driving Bucket Teeth Into Ground
OPERATING THE MACHINE Avoid Driving Bucket Teeth into Ground WARNING: If the bucket teeth are forcedly driven into the ground, crushed material may spatter, possibly resulting in injury of the operator and/or co-workers around the machine. Furthermore, the service lifetime of all front attachment parts may be shortened.
Page 149: Boom Cylinder May Hit Blade
OPERATING THE MACHINE Boom Cylinder may Hit Blade When digging deeply with the blade positioned at the front, the boom cylinder or bucket may accidentally hit the blade, causing damage. Take care to prevent this from happening. MZX5-13-014 MZX5-13-015 5-17...
Page 150: Avoid Hitting Blade With Bucket
OPERATING THE MACHINE Avoid Hitting Blade With Bucket When rolling in the arm in a travel or transportation position, be careful not to hit the blade with the bucket. MZX5-13-015 Avoid Colliding Blade Against Rocks Do not attempt to allow the blade to collide with rocks. Premature damage to the blade and the blade cylinders may result. MZX5-13-016 Avoid Colliding Boom Cylinder With Track When digging deeply with the front attachment positioned at an angle, as illustrated, the boom cylinder may accidentally collide with the track, causing damage. Take extra care to prevent this from happening. MZX5-13-018 Precautions for Installing Wide Bucket or Special Type Bucket...
Page 151: Use Correct Track Shoe
OPERATING THE MACHINE Use Correct Track Shoe Never use rubber crawlers or wide track shoes on rough terrain with scattered rocks, gravel or boulders. Failure to do so may cause breakages of rubber crawlers, shoe bending, looseness of shoe bolts, or damage to track parts such as track links, or rollers. (Refer to the table for Shoe Types and Applications in the specification chapter.) Soil may easily become packed into the crawler during travel operation on sandy ground. If the machine is driven without removing the packed soil from the crawlers, the rubber crawlers will be overloaded, possibly resulting in breakage of the crawlers. Avoid causing the crawlers to become packed with soil by removing soil as often as possible. M1M7-05-015 5-19...
Page 152: Using Rubber Crawler
OPERATING THE MACHINE Using Rubber Crawler Rubber crawlers are designed to allow the machine to travel without damaging road surfaces such as paved road surfaces. Avoid damage to the rubber crawlers by following the precautions below: Forbidden Operations 1. Do not operate or steer the machine on or near river- terrace, boulder and boulder mixed ground, crushed- stone ground, uneven hardpan surfaces, stumps, reinforcing bars, scraps, and steel plate edges. Failure to do so may shorten the service life of the rubber crawlers to a great extent.
Page 153 OPERATING THE MACHINE 3. Operating the machine with rubber crawlers sagging on uneven surfaces can result in derailment of rubber crawler, possibly causing the rubber crawlers to be damaged. M586-05-024 4. When lowering the machine raised above the ground using the front attachment, slowly lower the machine to Roller the ground. Film 5. The new rubber crawler has a thin rubber film (shown in dotted line) on its roller tread. During operation of a new machine, or immediately after the rubber crawlers are replaced, the rubber film may come off due to contact...
Page 154: Avoid Other Than Specified Machine Operations
OPERATING THE MACHINE Avoid other than Specified Machine Operations This machine has been exclusively designed for excavation and loading works. Do not apply this machine to works other than excavation and loading. Do not operate the machine under any conditions beyond these specifications. CAUTION: Precautions for Lifting Work  Operate the machine on level ground. Operating the machine on a slope may cause the machine to become unstable, possibly resulting in tipping accident.
Page 155: Shackle Bracket Usage
OPERATING THE MACHINE Shackle Bracket Usage Shackle bracket for towing A shackle bracket is provided on the track frame to tow light lightweight objects weight objects as specified below. IMPORTANT: Be sure to conform to the restrictions and precautions stated below when towing a light weight object using the shackle bracket provided on the track frame.
Page 156: Emergency Boom Lowering Procedure
OPERATING THE MACHINE Emergency Boom Lowering Procedure WARNING: Prevent personal injury. Confirm that no one is under the front attachment before starting the procedure below. If the engine stalls and cannot be restarted, lower the boom to lower the bucket to the ground referring to the emergency boom lowering procedure stated below. 1. Remove the cover above the hydraulic oil tank. Loosen filler cap (1) on the hydraulic oil tank to release air pressure from the hydraulic oil tank.
Page 157: Releasing Hose Rupture Valve (Machine Equipped With Hose Rupture Valve) (Optional)
OPERATING THE MACHINE Releasing Hose Rupture Valve (Machine Equipped with Hose Rupture Valve) (Optional) The hose rupture valve prevents sudden falling of the front attachment in the event of hose breaks during machine operation. It is located on the rod side of the arm cylinder and Hose Rupture Valve for Boom bottom side of the boom cylinder.
Page 158 OPERATING THE MACHINE Releasing Overload Relief Valve ZX33U-5A/38U-5A • If the front attachment is not loaded 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.
Page 159: Precautions For After Operations
OPERATING THE MACHINE Precautions for After Operations  After finishing the day's operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse or floods are present. (Refer to the group for "PARKING THE MACHINE" in the DRIVING THE MACHINE section.)  Fully refill the fuel in the fuel tank.  Clean the machine. M1M7-05-024 5-27...
Page 160 OPERATING THE MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 161: Transporting
TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations.  When transporting the machine using a truck, check the width, height, length and weight of the trailer with the machine loaded. Note that transporting weight and dimensions may vary depending on the type of shoe or front attachments installed.
Page 162: Loading/Unloading On A Truck
TRANSPORTING Loading/Unloading on a Truck Always load and unload the machine on a firm, level surface. WARNING: Be sure to use a loading dock or a ramp for loading/unloading. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp.
Page 163 TRANSPORTING Loading WARNING:  Push auto-idle switch (3) to turn A/I display (2) OFF. If the machine is operated with A/I display (2) ON, it may cause the engine speed to suddenly change.  Always select the slow speed mode with the travel mode switch.
Page 164 TRANSPORTING 1. Load the machine so that the centerline of the machine aligns with the centerline of the trailer flatbed. 2. Drive the machine onto the ramp slowly. 3. Determine a position for the bucket in line with the truck. Adjust the angle of the boom and the arm at 90 to 110 °. MADB-06-001 4. Lower the bucket onto to the deck of the truck before the unit passes over the end of the ramp for support. 5.
Page 165: Fastening Machine For Transporting
TRANSPORTING Fastening Machine for Transporting CAUTION: Transportation Bracket  Securely fasten the machine to the flatbed with wire ropes.  Fasten the machine using the transportation bracket of the truck frame to the truck flatbed with wire ropes. Be careful not to allow the wire rope to come in contact with the track shoe.
Page 166: Unloading
TRANSPORTING Unloading WARNING:  Always turn the auto-idle switch (2) OFF when loading or unloading the machine. In the auto-idle mode, speed may automatically increase.  Always select the slow speed mode (1) with the travel mode switch.  Never steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turnover.
Page 167: Lifting Machine
 Use lifting cables and other lifting tools being free from any damage and/or aging, and having sufficient strength.  Consult your nearest Hitachi dealer for correct lifting procedures, and the size and types of lifting cable and tools.  Pull the pilot control shut-off lever to the LOCK position so that the machine does not accidentally move while being lifted.
Page 168 TRANSPORTING 1. Swing the upperstructure so that the blade is positioned ZX33U-5A: 2000 mm (79 in) ZX33U-5A: 4200 mm (165 in) ZX38U-5A: 2000 mm (79 in) ZX38U-5A: 4200 mm (165 in) at the rear of the counterweight. ZX48U-5A: 1700 mm (67 in) ZX48U-5A: 4100 mm (161 in) ZX55U-5A: 1600 mm (63 in) ZX55U-5A: 4100 mm (161 in) 2. Fully retract the blade cylinder. ZX65USB-5A: 1300 mm (51 in) ZX65USB-5A: 3900 mm (154 in) 3. Fully extend the boom, arm and bucket cylinders, as illustrated to the right. 4. Position the boom straight ahead of the upperstructure. Apply the boom swing pedal lock. 5. Pull the pilot control shut-off lever to the LOCK position. 6. Stop the engine. Remove the key from the key switch. 7. Set a crane in an appropriate position. 8. Attach shackles to the boom and blade hooks. Securely thread wire ropes through the shackles.
Page 169: Maintenance
IMPORTANT:  Use only recommended fuel and lubricants.  Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown.  Failure to use recommended fuel, lubricants, and genuine Hitachi parts will result in loss of Hitachi product warranty.
Page 170: Check The Hour Meter Regularly
MAINTENANCE Check the Hour Meter Regularly Refer to the List of Check and Maintenance for information about lubricants, check and adjustment intervals. The maintenance guide table is affixed under the seat. Refer to page 7-5. Check and maintenance intervals shown in this manual are those for the machines to be operated under normal conditions. In case the machine is operated under more severe conditions, shorten the intervals.
Page 171: Layout
MAINTENANCE Layout MADB-01-001 Arm Cylinder Air Cleaner 17- Lower Roller 25- Bucket Boom 10- Swing Bearing 18- Control Valve 26- Link Work Light 11- Canopy 19- Upper Roller 27- Tooth Boom Swing Cylinder 12- Control Lever 20- Track Adjuster 28- Bucket Cylinder Swing Device 13- Pump 21- Front Idler 29- Fuel Tank 14- Counterweight...
Page 172: Maintenance Guide Table
MAINTENANCE Maintenance Guide Table The maintenance guide table is affixed under the seat. Lubricate and/or service the parts at the intervals as instructed in the table so that all necessary maintenance can be performed regularly.  Symbol Marks The following marks are used in the maintenance guide table. Grease Hydraulic oil filters (Front Joint Pin, Swing Bearing, Swing (Pilot Filter, Hydraulic Oil Tank Filter, Gear) Suction Filter) Gear Oil Air Cleaner Element (Travel Reduction Device) Coolant Engine Oil (Long-Life Coolant) Fuel Filter Engine Oil Filter (Fuel Main Filter, Pre-Filter) Hydraulic Oil...
Page 173 MAINTENANCE  Maintenance Guide Table Lubrication Interval ZX33U-5A, 38U-5A (hours) MADC-07-026 Item Page Item Page 1 Engine Oil 7-25 10 Hydraulic Oil Filter (Pilot) 7-43 2 Coolant (Long-Life Coolant) 7-67 11 Engine Oil Filter 7-25 3 Grease (Swing Bearing) 7-22 12 Fuel Main Filter 7-56 4 Grease (Every 100 hours during first time 7-19 13 Air Cleaner Element 7-60 operation up to 500 hours) 5 Grease (Swing Gear) 7-23 14 Grease (Control Lever)
Page 174 MAINTENANCE  Maintenance Guide Table ZX48U-5A, 55U-5A, 65USB-5A MADC-07-021 Lubrication Interval (hours) Item Page Item Page 1 Engine Oil 7-25 9 Hydraulic Oil Filter (Full Flow) 7-41 2 Coolant (Long-Life Coolant) 7-67 10 Hydraulic Oil Filter (Pilot) 7-43 3 Grease (Swing Bearing) 7-22 11 Engine Oil Filter 7-25 4 Grease (Every 100 hours during first time 7-19 12 Fuel Main Filter 7-56 operation up to 500 hours) 5 Grease (Swing Gear) 7-23 13 Air Cleaner Element...
Page 175: Preparations For Inspection And Maintenance
MAINTENANCE Preparations for Inspection and Maintenance Except in special cases, park the machine by following the procedure before servicing the machine. 1. Park the machine on a level surface. 2. Lower the bucket and the blade to the ground. 3. Turn the auto-idle switch OFF. 4. Turn engine control dial to the slow idle position and run M1M7-05-024 the engine for 5 minutes to cool the engine. 5. Turn the key switch OFF to stop the engine. Remove the key.
Page 176: Access Covers
MAINTENANCE Access Covers Engine Cover WARNING:  Do not keep the access covers open when the machine is parked on a slope, or while the wind is blowing hard. The access covers may close accidentally, possibly resulting in personal injury. ...
Page 177 MAINTENANCE Tank Cover WARNING:  Do not keep the access covers open when the machine is parked on a slope, or while the wind is blowing hard. The access covers may close accidentally, possibly resulting in personal injury.  When opening or closing the access covers, take extra care not to catch fingers between the base machine and the access covers.
Page 178 MAINTENANCE Radiator front Cover WARNING:  Do not keep the access covers open when the machine is parked on a slope, or while the wind is blowing hard. The access covers may close accidentally, possibly resulting in personal injury.  When opening or closing the access covers, take extra care not to catch fingers between the base machine and the access covers.
Page 179: Maintenance Guide
MAINTENANCE Maintenance Guide A. Greasing Interval (hours) Parts Quantity Page 100 250 500 1000 2000 ZX33U-5A, 38U-5A, 7-19  Bucket and 48U-5A, 55U-5A Link Pins 1. Front Joint Pins ZX65USB-5A  7-19 Swing Post and Others   or every year 7-19 2. Blade Pins or every year 7-21 3. Swing Bearing 7-22 4.
Page 180 MAINTENANCE D. Hydraulic System Interval (hours) Parts Quantity Page 100 250 500 1000 1500 2000 3000 1. Check Hydraulic Oil Level 7-35 2. Drain Hydraulic Oil Tank Sump 7-36 43 L ZX33U-5A, 38U-5A (13.2 US gal) 66 L 3. Change Hydraulic Oil ZX48U-5A, 55U-5A  7-37    (17.4 US gal) 107.5 L ZX65USB-5A (28.4 US gal) 4. Clean Suction Filter Each time when hydraulic oil is changed 7-37 Filter-Paper Element...
Page 181  Use soft water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %. If a coolant mixed with less than 30 % of genuine Hitachi Long- Life Coolant (LLC) is used, service life of the cooling parts may be shortened due to damage by freezing or corrosion of coolant system parts.
Page 182 − 7-95 15. Check Crankcase Breather − 7-95 16. Check Radiator Cap − 7-95 Tightening and Retightening Torque of Nuts and −  7-96 Bolts : Maintenance required only during first time check. NOTE: * Contact your nearest Hitachi dealer for maintenance. Instruction plate for the recommended grease and lubricants is affixed under the seat. 7-14...
Page 183: Periodic Replacement Of Parts
MAINTENANCE Periodic Replacement of Parts To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. These parts may cause serious safety/fire hazards due to deterioration, wear, or fatigue being attributed to material aging or repeated operation. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone.
Page 184: Kind Of Oils
Mobilux EP2 KIGNAS Oil KIGNAS MP GREASE No.2 COSMO Oil COSMO GREASE DYNAMAX EP2 Energrease LS-EP2 Castrol Spheerol EPL2 Chevron Multifax EP2 Recommended Engine Oil IMPORTANT: Use only genuine Hitachi engine oil as shown below. Or use JASO DH-1 or equivalent engine oil. Brand Names of Recommended Engine Oil Kind of Oil Engine Oil Application Engine Crankcase Air Temp. –20 to 30 °C –15 to 40 °C (5 to 104 °F)
Page 185 MAINTENANCE Brand Names of Recommended Transmission Oil Application Travel Reduction Gear Kind of Oil Gear Oil Air Temp. –20 to 40 °C (–4 to 104 °F) Manufacturer Hitachi Hitachi Gear Oil GL-4 90 Idemitsu Kosan Apolloil Gear Oil HE90 HYPOID GEAR 90 JX Nippon Oil & Energy Corporation GEAR4 90 Shell Spirax S2 G 90 ExxonMobil Mobilube GX80W-90 Energear EP 80W-90 Castrol Manual GL-4 80W-90 Chevron Thuban SAE 90 Remarks API GL4 Class Brand Names of Recommended Hydraulic Oil...
Page 186 MAINTENANCE Recommended Oil Viscosity Air Temperature (degrees Celsius) Where to be Applied Kind of Oil Super Wide DH-1 10W30 Engine Oil Pan Engine Oil Super Wide DH-1 15W40 Travel Device Gear Oil Hitachi Gear Oil GL-4_90 Hydraulic System Hydraulic Oil Super EX46HN (Hydraulic Oil Tank) ASTM Grade No.2-DS15 ASTM Grade No.2-DS500 Fuel Tank Diesel Fuel ASTM Grade No.1-DS15 ASTM Grade No.1-DS500 Lithium Grease Nipple SEP Grease Grease Genuine Hitachi Radiator Coolant Long-Life Coolant (LLC) 7-18...
Page 187: Greasing
MAINTENANCE A. Greasing Front Joint Pins Bucket --- every 100 hours Swing Post and Others --- every 500 hours or every year (every 100 hours during first time operation up to 500 hours) Lubricate all fittings shown in the figure. M1M7-05-024  Bucket ZX33U-5A, 38U-5A, 48U-5A, 55U-5A...
Page 188 MAINTENANCE  Boom Cylinder Bottom Side M1M7-07-021  Boom Foot MADB-07-048  Boom Swing Cylinder M1M7-07-023  Boom Cylinder Rod Side M1M7-07-020 7-20...
Page 189: Blade Pins
MAINTENANCE  Arm Cylinder Rod Side, Bucket Cylinder Bottom Side M571-07-006  Boom and Arm Joint Pin, Arm Cylinder Bottom Side M585-07-046 Blade Pins --- every 500 hours or every year  Blade Joint Pins  Blade Cylinder Rod and Bottom Side MADB-07-008 7-21...
Page 190: Swing Bearing
MAINTENANCE Swing Bearing --- every 250 hours CAUTION: Lubricating both the swing bearing and gear and rotating the upperstructure must be done by one person. Before you lubricate the swing bearing, clear the area of all persons. Lower the bucket to the ground.
Page 191: Swing Internal Gear
MAINTENANCE Swing Internal Gear --- every 500 hours CAUTION: Lubricating both the swing bearing and gear and rotating the upperstructure must be done by one person. Before you lubricate the swing bearing, clear the area of all persons. Lower the bucket to the ground.
Page 192: Engine
MAINTENANCE B. Engine Engine Oil Level --- check daily (Before starting the engine) IMPORTANT: This machine adopts the closed air breather system. An incorrect engine oil level may cause trouble on the engine (The oil level should be between the upper and lower marks on oil level gauge (1)).
Page 193: Change Engine Oil
MAINTENANCE Change Engine Oil --- every 500 hours Replace Engine Oil Filter --- every 500 hours 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. CAUTION: Engine may be hot just after operation. Wait for engine to cool before starting work. 2. Place 10 liter (ZX65USB-5A: 15 liter) container under the engine oil pan. Remove oil filler cap (2). MADB-07-011 3. Remove drain plug (3) to drain oil.
Page 194 MAINTENANCE 7. Remove the filter cartridges of engine oil filter cartridge (4) by turning it counterclockwise with the filter wrench. ZX33U-5A, 38U-5A, 48U-5A, 55U-5A The oil may spill from filter (4) bottom bracket at this time. Use an empty container to catch the spilled oil. 8. Clean the filter cartridge contact area on the engine. IMPORTANT:  When filling new oil, take care not to allow foreign matter to enter the engine.  Do not re-use engine oil filter (4). Be sure to use only genuine engine oil filter (4).
Page 195 MAINTENANCE CAUTION: Do not spill oil while adding oil. Spilled oil may cause fires. 12. Fill the engine with recommended oil via oil filler (2). Check that oil level is between the minimum and maximum on oil level gauge (1) after 15 minutes. Model Quantity ZX33U-5A, 38U-5A 6.7 L (1.8 US gal) ZX48U-5A, 55U-5A 7.4 L (2.0 US gal) ZX65USB-5A 10.5 L (2.8 US gal) NOTE: Refer to the recommended oil and grease chart on page 7-16 for the brand names of oils.
Page 196: Transmission
MAINTENANCE C. Transmission Travel Reduction Gear Check Oil Level --- every 500 hours 1. Park the machine on a level surface. 2. Rotate the travel motor until the plugs are positioned as illustrated on the right. 3. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. WARNING: Keep body and face away from the air M503-07-015 release plug. Gear oil may be hot just after operation. Wait for gear oil to cool and then gradually loosen the air release plug to release pressure.
Page 197 MAINTENANCE Change Gear Oil --- every 1000 hours IMPORTANT: Do not use gear oils other than those listed in the "Brand Names of Recommended Oil". 1. Park the machine on a level surface. 2. Rotate the travel motor until the plugs are positioned as illustrated on the right. 3. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. WARNING: Keep body and face away from the air release plug.
Page 198 MAINTENANCE 7. Remove oil level check plug (2). 8. Add oil until oil flows out of oil level check plug (2) hole. Model Oil Quantity ZX33U-5A, 38U-5A 0.6 L (0.63 US qt) ZX48U-5A, 55U-5A, 0.9 L (0.95 US qt) 65USB-5A NOTE: Refer to the recommended oil and grease chart on page 7-17 for the brand names of oils. 9. Clean and tighten the plugs (1) and (2). M585-07-080 Model Tightening Torque 46 to 51 N∙m (4.6 to 5.1 kgf∙m,...
Page 199: D. Hydraulic System
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment IMPORTANT: Never adjust parts of hydraulic equipment. CAUTION: When checking and/or servicing the hydraulic components, pay special attention to the following points. 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. 2. Begin servicing hydraulic components only after components, hydraulic oil and lubricants are completely cooled, and after releasing residual pressure.
Page 200 MAINTENANCE IMPORTANT:  When connecting hydraulic hoses and pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them.  Wash hoses, pipes, and the tank interior with a washing liquid and thoroughly wipe it out before reconnecting them.
Page 201 MAINTENANCE Change Hydraulic Oil and Replace Full-Flow Filter Element Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to quickly deteriorate the hydraulic oil. Failure to adhere to proper maintenance intervals may result in damage to the base machine and the breaker. In order to extend the service life particularly of the hydraulic pump, change the hydraulic oil and the full-flow filter element at the specified frequency given below. (Refer to the "Hydraulic System" in the "MAINTEMANCE" chapter.) Changing intervals differ depending on the brand. (Refer to the "Hydraulic System") Changing intervals for the high performance element (micro-glass) Breaker Operation 10 % 20 % 30 % 40 %...
Page 202 MAINTENANCE Changing intervals for the standard filter paper Breaker Operation 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 % Availability Full-Flow Filter Hydraulic oil: 1000 hours 1000 life time Hydraulic oil: 2000 hours 2000 1310 life time When using filter-paper element Element Replacement Intervals Changing Interval when using 1000-hour life time Hydraulic Oil Changing Interval when using 2000-hour life time Hydraulic Oil 1000 1200 1400...
Page 203: Check Hydraulic Oil Level
MAINTENANCE Check Hydraulic Oil Level --- daily IMPORTANT: If the oil level is not viewed in level gauge (1), immediately refill hydraulic oil up to the appropriate level. Failure to do so may result in a serious failure in the hydraulic system. If the oil level is higher than level gauge (1), remove oil down to the appropriate level using a pump.
Page 204: Drain Hydraulic Oil Tank Sump
MAINTENANCE Drain Hydraulic Oil Tank Sump --- every 250 hours CAUTION: Hydraulic oil may be hot just after operation. Wait for oil to cool before starting work. 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. M1M7-05-024 2. Leave the machine without operating the machine until hydraulic oil becomes cool.
Page 205: Change Hydraulic Oil
MAINTENANCE Change Hydraulic Oil --- every 1000 hours or 2000 hours (when using the filter-paper element) --- every 1500 hours or 3000 hours (when using the high performance element) Suction Filter Cleaning --- when hydraulic oil is changed M1M7-05-024 CAUTION: Hydraulic oil may be hot just after operation.
Page 206 MAINTENANCE ZX33U-5A, 38U-5A, 48U-5A, 55U-5A 6. Slowly loosen drain plug (3). Allow oil to drain. 7. Remove rod assembly (5) from the hydraulic oil tank. IMPORTANT: When changing hydraulic oil, take care not to enter foreign matters such as dirt, water, and/or sand into the hydraulic oil tank. 8. Clean the filter and tank interior. If suction filter (6) is to be replaced, install new filter on rod (5) as shown. 9. Before installing the suction filter, check the dimension of rod assembly (5) shown in figure below. Securely insert rod assembly (5) into the pipe.
Page 207 MAINTENANCE ZX65USB-5A 6. Loosen bolts (7). Rotate drain valve cover (8) to open the check port. Slowly loosen drain plug (3). Allow oil to drain. 7. Remove rod assembly (5) from the hydraulic oil tank. IMPORTANT: When changing hydraulic oil, take care not to enter foreign matters such as dirt, water, and/or sand into the hydraulic oil tank. 8. Clean the filter and tank interior. If suction filter (6) is to be replaced, install new filter on rod (5) as shown. 9. Before installing the suction filter, check the dimension MADB-07-014 of rod assembly (5) shown in figure below. Securely...
Page 208 MAINTENANCE Bleed Air from Hydraulic System After changing hydraulic oil, bleed air from the hydraulic system by following the procedure described below. Bleed Air from Pump IMPORTANT: If the engine is started when the pump is not filled with hydraulic oil, damage to the pump may result.
Page 209: Replace Full-Flow Filter
MAINTENANCE Replace Full-Flow Filter --- every 500 hours (first time after 250 hours) (when using the filter-paper element) --- every 1000 hours (first time after 500 hours) (when using the high performance element) IMPORTANT: Changing interval differs according to the brand of hydraulic oil, filter element and attachments used, kind of filter element or average attachment operating availability.
Page 210 MAINTENANCE 6. Replace O-ring (3) and element (6) with new ones. Be careful not to damage element (6) and O-ring (3). Broken element (6) is unusable. 7. Install element (6), valve (5), spring (4) and O-ring (3). 8. Install cover (2) with bolts (1) (4 used). Tightening Torque ZX33U-5A, 38U-5A, 48U-5A, 55U-5A : 10 N·m (1 kgf∙m) ZX65USB-5A : 50 N·m (5 kgf∙m) 9. Bleed air from the hydraulic system and check the hydraulic oil level after replacing the element. MADB-07-017 (Refer to the descriptions for "Bleed Air from Hydraulic System") If the machine is operated with air mixed in the hydraulic circuit, damage to the pump may result. NOTE: Replace element (6) at the regular interval to keep hydraulic oil clean and to extend the service life of the hydraulic components.
Page 211: Replace Pilot Oil Filter Element
MAINTENANCE Replace Pilot Oil Filter Element --- every 1000 hours CAUTION: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
Page 212 MAINTENANCE 4. Rotate filter case (6) of pilot filter (4) counterclockwise to remove filter case (6). 5. While rotating filter element (7), pull to remove filter element (7) downward. 6. Replace O-ring (8) with a new one. 7. Clean the filter O-ring (8) contact area on filter head (5). 8. Securely install O-ring (8) in the O-ring groove on head cover (5). 9. Coat the seal on new filter element (7) with clean hydraulic oil. Completely install filter element (7) into head cover (5) while rotating filter element (7) taking care not to damage filter element (7). MADB-07-020 10. Take care not to allow dust and/or water enter filter case (6). 11. Install case (6) into head cover (5) while rotating case (6) clockwise. Tightening Torque: 2 5 to 35 N∙m (2.5 to 3.5 kgf∙m, 18.0 to 26 lbf∙ft) 12. After replacing filter element (7), bleed any remaining air from the hydraulic circuit. Check the oil level in the hydraulic oil tank. Add oil as needed. M503-07-031 (Refer to the descriptions for "Bleed Air from Hydraulic System")
Page 213: Check Hoses And Lines
MAINTENANCE Check Hoses and Lines --- daily --- every 250 hours WARNING:  Hydraulic oil and lubricant leaks can lead to fire that may result in serious injury. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damaged oil cooler, and loose oil cooler flange bolts, for leaks.
Page 214 MAINTENANCE Interval (hours) Check Points Abnormalities Remedies Every 250 Hose covers Damage or leak (4) Replace hours Hose ends Damage or leak (5) Replace Hose covers Exposed reinforcement (6) Replace M115-07-146 Hose covers Crack or blister (7) Replace Hose Bend (8), Collapse (9) Replace Hose ends and Deformation or corrosion (10) Replace Fittings M115-07-147 M115-07-148 Lines M115-07-149 Interval (hours) Check Points Abnormalities Remedies...
Page 215 MAINTENANCE  Metal Face Seal Fittings Fittings are used on smaller diameter joint and consist of a metal flare (10) and a metal flare seat (9). 1. Inspect flare (10) and flare seat (9). They must be free of dirt or obvious defects. 2. Tighten fitting (7) by hand.
Page 216 MAINTENANCE Service Recommendations for Hydraulic Fittings Two hydraulic fitting designs are used on this machine.  Flat Face O-ring Seal Fitting (ORS Fitting) O-ring (1) is used on the sealing surfaces of adapter (2) to prevent oil leakage. Precautions for Use 1. Replace O-ring (1) with a new one when assembling fittings. 2. Check that O-ring (1) is properly fitted in O-ring groove M104-07-033 (3). Tighten union (4). Tightening union (4) with O-ring (1) out of the groove may damage O-ring (1) and cause oil leak. 3. When assembling fittings, take care not to make a dent on O-ring groove (3) of adaptor (2) and sealing surface (6) on hose (5) or valve side. Failure to do so may result in damage to O-ring (1) leading to oil leak. 4. If oil leaks from a loose connection of union (4), do not tighten fitting (2). Open the connection, replace O-ring (1) with a new one and check for correct O-ring position before tightening the connection. Tightening Torque: Tighten fittings to the torque values shown below.
Page 217 MAINTENANCE Quick Coupler 1. Connection Procedure 1.1 While pulling and fully turning socket ring (1) counterclockwise, insert socket ring (1) onto plug (3) until the end face of socket ring (1) comes in contact with plug (3). 1.2 Release socket ring (1). Check that socket ring (1) is slightly moved backward by the spring force and that the coupler is held in position with balls (2). Be sure to check that socket ring (1) has been moved back fully to the right original position. M1M7-07-006 2. Disconnection Procedure 2.1 While pulling and fully turning socket ring (1) counterclockwise, disconnect the coupler. As no check valve is provided in the coupler, take care that oil may flow out of the coupler when the coupler is disconnected. 2.2 After the coupler is disconnected, plug the holes with the exclusively prepared plugs.
Page 218 MAINTENANCE Quick Coupler 1. Connecting Coupler Always grasp the coupler by its clamp section. Push the body straight until the dust prevention cover retracts approx. 2 mm. Then, pull the clamp section straight to make sure that the coupler is properly connected and will not be disconnected. Dust Prevention Clamp Section Cover CAUTION: If the coupler is grasped and pushed by M1LA-07-014 the dust prevention cover, or not pushed until the dust prevention cover retracts, incomplete connection of the coupler may result, causing the coupler to disconnect when oil pressure increases.
Page 219 MAINTENANCE NOTE: When disconnecting a coupler located in a narrow space that is difficult for your hand to enter, use a screwdriver following the procedures as described below. Using Screwdriver A screwdriver with a tip thickness of less than 1 mm and a tip width of approx. 5 mm is appropriate to this work.  Slightly push the hose toward the coupler approx. 2 mm.  While pushing the hose toward the coupler, insert a M1LA-07-021 screwdriver in the position as illustrated to the right. Twist the screwdriver about 90º. After making the gap between Dust Prevention Cover Adapter...
Page 220: E. Fuel System
MAINTENANCE E. Fuel System WARNING: Beware of fire. Fuel is flammable. Keep fuel away form fire hazards. IMPORTANT: Always fill the fuel tank with the specified diesel fuel. Failure to do so may cause engine trouble and also make it difficult for the engine to start. Recommended Fuel Use only super high quality or high quality DIESEL FUEL (JIS K-2204) (ASTM 2-D). Kerosene must NOT be used.
Page 221: Check Fuel Level
MAINTENANCE Check Fuel Level --- every 8 hours (daily) CAUTION: Handle fuel carefully. Shut the engine off before fueling. Do not smoke while you fill the fuel tank or work on fuel system. 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. 2. Check fuel level gauge (3) and fuel gauge (1) of the monitor panel. When necessary to add fuel, remove cap (2) and refill fuel.
Page 222: Check Water Separator
MAINTENANCE Check Water Separator Drain water --- every 8 hours (before starting operation) Water separator (1) is a device designed to separate water from the fuel. There is a float inside the case which buoys when water accumulates. When the float rises to the water draining level, drain water. Drain Procedures 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. 2. Place a 0.5 liters or larger capacity container under drain plug (3) to collect the drained water. MADB-07-022 3. Close cock (2) at upper part of water separator (1). Loosen drain plug (3) at lower part of water separator (1) to drain water.
Page 223: Drain Fuel Tank Sump
MAINTENANCE Drain Fuel Tank Sump --- As reguired 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. 2. Loosen bolts (2) to remove drain valve cover (3) from right-front under cover (1). Rotate drain valve cover (3) to open the checking port. 3. Place a 0.5 liters or larger capacity container under drain valve (4) to collect the drained water. 4. Open drain valve (4) to drain water and/or sediment. 5. After draining water, securely tighten drain valve (4). 6. Return drain valve cover (3) to original position and MADB-07-024 tighten bolts (2). MADB-07-025 7-55...
Page 224: Replace Fuel Main Filter Element
Replace Fuel Main Filter Element --- every 500 hours IMPORTANT:  Be sure to use only genuine Hitachi elements for the fuel main filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be noted that all engine failures caused by using other manufacturers' elements are excluded from Hitachi Warranty Policy.
Page 225: Replace Fuel Pre-Filter Element (Optional)
--- every 500 hours or when fuel filter clogging lamp is lit IMPORTANT:  Be sure to use only genuine Hitachi elements for the fuel pre-filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be noted that all engine failures caused by using other manufacturers' elements are excluded from Hitachi Warranty Policy.
Page 226 MAINTENANCE Procedures: 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. 2. Close cock (1). 3. Place a 1 liter or larger capacity container under drain plug (2). 4. Loosen air bleed plug (3) and drain plug (2). Drain fuel until fuel does not flow out of the filter. 5. Loosen bolt (4) and remove filter case (5). MADC-07-022 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A 6. Remove filter element (6). 7. Replace O-ring (7) and packing (8) with new ones. 8. Install a new element. Tighten bolt (4). Tightening Torque : 30 to 40 N∙m (3.0 to 4.0 kgf∙m, 22 to 29 lbf·ft).
Page 227: Check Fuel Hoses
MAINTENANCE Check Fuel Hoses --- every 8 hours (before starting operation) --- every 250 hours CAUTION: Fuel leaks can lead to fires that may result in serious injury.  Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that rub against each other and any fuel leaks.
Page 228: Air Cleaner
MAINTENANCE F. Air Cleaner Clean Air Cleaner Outer Element --- every 250 hours or when the air filter restriction alarm (5) comes ON Replace Air Cleaner Outer and Inner Elements --- after cleaning six times or after one year Replace Air Cleaner Inner Element (Optional) --- when outer element is replaced M555-07-023 1. Park the machine following the same procedures as...
Page 229 MAINTENANCE 7. Clean the filter interior before installing outer element (1). Cover 8. Install outer element (1). IMPORTANT: Do not install the element and/or the cover forcibly when installing the clamps. Failure to do so may result in deformation of the clamps, element, and/ or cover. 9. When installing cover (3), position cover (3) so that valve (4) faces downward. Tighten clamps (2). 10. Start the engine and run at slow idle.
Page 230: G. Cooling System
50 %. If a coolant mixed with less than 30 % of genuine Hitachi Long-Life Coolant (LLC) is used, service life of the cooling parts may be shortened due to damage by freezing or corrosion of coolant system parts.
Page 231: Check Coolant Level
MAINTENANCE Check Coolant Level --- daily With the engine cold, the coolant level must be between the FULL and LOW marks on coolant reservoir (2). If the coolant level is below the low mark, remove the cap of coolant reservoir (2) and add coolant to coolant reservoir (2). CAUTION: Do not loosen cap (1) until the coolant temperature in the radiator becomes cool. Hot steam may spout out, possibly causing severe burns. After the coolant temperature has lowered, slowly loosen cap (1) to release the inside air pressure before removing cap (1).
Page 232: Check And Adjust Fan Belt Tension
MAINTENANCE Check and Adjust Fan Belt Tension 98 N (10 kgf) 7 to 9 mm --- every 100 hours (first time after 50 hours) IMPORTANT: Loose fan belt may result in insufficient battery charging, engine overheating, as well as premature belt wear. Belts that are too tight, however, can damage both bearings and belts.
Page 233 MAINTENANCE ZX48U-5A, 55U-5A 1. Remove bolts (1) (5 used). Remove cover (2) to open checking port. 2. Loosen mounting bolts (6) and nut (3) of alternator (5). 3. Adjust belt tension by moving alternator (5) forward or backward by using adjusting screw (4). 4. Securely tighten bolts (6) and nut (3). IMPORTANT: When a new belt is installed, be sure to re- adjust the tension after operating the engine for 3 to 5 minutes at slow idle speed to be sure that the new belt is seated correctly.
Page 234 MAINTENANCE ZX65USB-5A 1. Remove bolts (1) (6 used). Remove cover (2) to open checking port. 2. Loosen mounting bolts (6) and nut (3) of alternator (5). 3. Adjust belt tension by moving alternator (5) forward or backward by using adjusting screw (4). 4. Securely tighten bolts (6) and nut (3). IMPORTANT: When a new belt is installed, be sure to re- adjust the tension after operating the engine for 3 to 5 minutes at slow idle speed to be sure that the new belt is seated correctly.
Page 235: Change Coolant
Release all pressure before removing the cap. IMPORTANT: Use soft water as a coolant. Do not use MADB-07-028 ZX33U-5A, 38U-5A strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %. MADB-07-029 ZX48U-5A, 55U-5A, 65USB-5A 7-67...
Page 236 MAINTENANCE Procedure: 1. Park the machine following the same procedures as described on page 7-7 for preparation for inspection and maintenance. 2. Remove the under cover. Remove radiator cap (1). Open drain cock (2) on the radiator and the drain cock on the water jacket to allow the coolant to drain completely. Remove impurities such as scale at the same time. 3. Close drain cock (2) and the drain cock on the water jacket. Fill the radiator with soft water containing fewer impurities and a radiator cleaner agent. Run the engine at a speed slightly higher than slow idle to raise the MADB-07-033 ZX33U-5A, 38U-5A coolant temperature until the first two segments come on. Then, run the engine further for about 10 minutes. 4. Stop the engine and open radiator drain cock (2). Flush out the cooling system with tap water, until draining water is clear.
Page 237: Clean Radiator/Oil Cooler Core
MAINTENANCE Clean Radiator/Oil Cooler Core Outside --- every 500 hours Inside --- when coolant is changed CAUTION: Use reduced compressed air pressure (Less than 0.2 MPa, 2 kgf/cm ) for cleaning purposes. Wear personal protection equipment including eye protection. WARNING: ...
Page 238: Clean Air Conditioner Condenser
MAINTENANCE Clean Air Conditioner Condenser --- every 500 hours IMPORTANT: When operating the machine in a dusty environment, check the air conditioner condenser every day for dirt and clogging. If clogged, remove, clean and reinstall the air conditioner condenser. Clean Air Conditioner Condenser Front Screen --- every 500 hours (Optional : ZX33U-5A, 38U-5A, 48U-5A, 55U-5A) IMPORTANT: When operating the machine in a dusty...
Page 239: H. Electrical System
MAINTENANCE H. Electrical System IMPORTANT: Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment effects the machine's electronic parts, causing involuntary movement of the machine. Also, improper installation of electrical equipments may cause machine failure and/or a fire on the machine.
Page 240 MAINTENANCE If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. If splashed in eyes, flush with water for 15 to 30 minutes. Get medical attention immediately. If acid is swallowed: 1.
Page 241 MAINTENANCE Electrolyte Level Check --- every month 1. Check the electrolyte level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte level. 3.1 When checking the level from the battery side: U.L (Upper Level) Clean around the level check lines with a wet towel. L.L (Lower Level) Do not use a dry towel. Static electricity may be developed, causing the battery gas to explode. Check M146-07-109 if the electrolyte level is between U.L (Upper Level) and L.L (Lower Level). In case the electrolyte level Filler Port is lower than the middle level between the U.L and L.L, immediately refill distilled water or commercial...
Page 242: Check Electrolyte Specific Gravity
MAINTENANCE Check Electrolyte Specific Gravity --- every month If you spill acid on yourself: 1. Flush your skin with water. WARNING: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check 2. Apply baking soda or lime to help neutralize the battery electrolyte level.
Page 243: Replacing Fuses
MAINTENANCE Replacing Fuses --- as required If any electrical equipment fails to operate, first check the fuses. IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. NOTE:  One each spare fuse for respective fuse capacities is provided in the fuse box. MADB-07-036 ZX33U-5A, 38U-5A, 48U-5A, 55U-5A MONITOR ACC HORN A/C PANEL, CAB...
Page 244: Miscellaneous
MAINTENANCE I. Miscellaneous Check and Replace Bucket Teeth --- daily Check bucket teeth (1) for wear and looseness. Replace teeth (1) if tooth wear exceeds the designated service limit shown below. Limit of Use A (mm) M104-07-056 Replace CAUTION:  Guard against injury from flying pieces of metal.  Wear hard hat or safety glasses, and safety equipment appropriate to the job.
Page 245 MAINTENANCE 3. Clean shank (6) surface. 4. Install rubber pin lock (4) into shank (6) hole as shown. RIGHT WRONG M104-07-060 5. Position new tooth (1) over shank (6). RIGHT WRONG M104-07-061 6. Drive locking pin (5) fully into the hole as shown. RIGHT WRONG M104-07-062 7-77...
Page 246: Change Bucket
MAINTENANCE Change Bucket --- as required CAUTION: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris. Wear hard hat or safety glasses, and safety equipment appropriate to the job. Before starting converting work, keep bystanders clear of the machine. Slowly move the front attachment. When using a signal person, coordinate hand signals before starting.
Page 247: Adjust Track Sag (Rubber Crawler) And Check For Damage
MAINTENANCE Adjust Track Sag (Rubber Crawler) and Check for Damage --- daily Swing the upperstructure 90 ° and lower the bucket to raise the track off the ground as shown. Rotate the rubber track so that the track joint is positioned at the upper center of the track. Measure distance (A) from the bottom of the lower roller tread to the inner ridge of the rubber track. Each time, be sure to place blocks under the track frame to support the machine. M1M7-04-006 CAUTION: To prevent accidents, care should be taken to ensure that hands, feet, and any body parts do not become entangled when working around the tracks.
Page 248 MAINTENANCE Loosen the Track (Rubber Crawler) CAUTION: The pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or loosen it too much as valve (1) may fly out or high- pressure grease in the adjusting cylinder may spout out.
Page 249: Replace Rubber Crawler
MAINTENANCE Replace Rubber Crawler --- as required WARNING:  Do not loosen valve (1) too quickly or too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2).
Page 250: Installing Rubber Crawler
MAINTENANCE Installing Rubber Crawler Grease Outlet 1. Lower the bucket and blade to raise one track off ground. Place blocks under machine frame to support the machine. 2. Slowly turn valve (1) counterclockwise to allow grease to escape from the grease outlet. 3. Engage the rubber track with the sprocket and position the other end of the rubber track on the front idler. M1LA-07-036 4. While rotating the sprocket in reverse, apply horizontal force to the rubber track to seat it on the idler. Direction of Rotation 5. Insert a steel pipe into gaps among lower rollers, track frame and rubber track and rotate the rubber track slowly to correctly seat the rubber track on the idler. 6. Confirm that the rubber track is correctly engaged with the sprocket and idler. 7. Adjust track sag. (Refer to "Adjust Track Sag".) Steel Pipe M503-07-063 8. After checking that the rubber track is correctly engaged with the sprocket and idler and the track sag is correctly adjusted, lower the machine to the ground. 7-82...
Page 251: Check Track Sag (Steel Crawler) (Optional)
MAINTENANCE Check Track Sag (Steel Crawler) (Optional) --- every 50 hours Swing the upperstructure 90 ° and lower the bucket to raise the track off the ground as shown. Measure distance (A) at the middle of the track frame from the bottom of the track frame to the back face of the track shoe. Each time, be sure to place blocks under the machine frame to support the machine. CAUTION: To prevent accidents, care should be taken to ensure that hands, feet, and any body parts do not M1M7-04-006 become entangled when working around the tracks. Model Appropriate sag A (mm) ZX33U-5A, 38U-5A...
Page 252 MAINTENANCE Loosen the Track (Steel Crawler) CAUTION: The pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or loosen it too much as valve (1) may fly out or high- pressure grease in the adjusting cylinder may spout out.
Page 253: Converting The Track
MAINTENANCE Converting the Track WARNING:  Consult your authorized dealer for converting the track. Extremely strong force is being applied. Do not allow anyone to stand in front of the front idler.  After the rubber track is removed, the front idle will become free to remove.
Page 254: Check And Replace Seat Belt
MAINTENANCE Check and Replace Seat Belt Check --- daily Replace --- every 3 years Prior to operating the machine, thoroughly examine belt (1), buckle (2) and attaching hardware (3). If any item is damaged or materially worn, replace the seat belt or component before operating the machine. We recommend that the seat belt be replaced every three years regardless of its apparent condition. MADB-01-003 7-86...
Page 255: Check Air Conditioner (Cab Equipped Machine)
MAINTENANCE Check Air Conditioner (Cab equipped machine) --- daily ZX33U-5A Serial No. 030001-031466 ZX38U-5A Serial No. 050001-050476 ZX48U-5A Serial No. 030001-031086 ZX55U-5A Serial No. 050001-050782 ZX65USB-5A Serial No. 020001 and up Check pipe connections for refrigerant gas leakage If oil seepage is found around pipe connections, it indicates possible gas leakage.
Page 256 MAINTENANCE ZX33U-5A Serial No. 031467 and up ZX38U-5A Serial No. 050477 and up ZX48U-5A Serial No. 031087 and up ZX55U-5A Serial No. 050783 and up Check pipe connections for refrigerant gas leakage Pipe Connections If oil seepage is found around pipe connections, it indicates possible gas leakage.
Page 257 MAINTENANCE Check mounting bolts for looseness Confirm that the compressor mounting bolts and other mounting/fastening bolts are securely tightened. Check compressor and fan belt Fan Pulley Depress Visually check the compressor and fan belts for looseness [Approx. 98N and wear. (10 kgf, 22 lbf)] Check fan belt tension by depressing the midpoint of the Tension Pulley Sag: belt with the thumb. Deflection must be shown in the right 8 to 10 mm figure with a depressing force of approximately 98 N (10 (0.32 to 0.39 in) kgf ). If any abnormalities are found in air conditioner system, see Alternator your authorized dealer for inspection.
Page 258: Clean And Replace Heater / Air Conditioner Filter
MAINTENANCE Clean and Replace Heater / Air Conditioner Filter Clean Circulating Air Filter --- every 500 hours Replace Circulating Air Filter --- After cleaning 6 times or so NOTE: The recommended maintenanse hour is a reference value. Shorten the maintenance interval when the machine is operated in dusty areas.
Page 259 MAINTENANCE Cleaning IMPORTANT: Clean filter (2) by using a vacuum cleaner. Do not clean it by blowing compressed air or washing with water. 1. With side "a" of filter (2) facing downward, lightly tap the filter (2) frame to let large dirt drop. 2. Clean side "a" of filter (2) by using a vacuum cleaner. Installation 1.
Page 260: Clean Fresh Air Filter
MAINTENANCE Clean Fresh Air Filter --- every 500 hours Replace Fresh Air Filter --- After cleaning 6 times or so ZX33U-5A, 38U-5A, 48U-5A, 55U-5A Removing Fresh Air Filter 1. Pull out fresh air filter (1) upward, which is located at bottom left of the seat. MADB-07-045 Cleaning IMPORTANT: Clean filter (3) by using a vacuum cleaner. Do not clean it by blowing compressed air or washing with water.
Page 261 MAINTENANCE Clean Fresh Air Filter --- every 500 hours Replace Fresh Air Filter --- After cleaning 6 times or so ZX65USB-5A Removing Fresh Air Filter 1. Pull out fresh air filter (1) upward, which is located at bottom left of the seat. MADC-07-023 Cleaning IMPORTANT: Clean filter (3) by using a vacuum cleaner. Do not clean it by blowing compressed air or washing with water.
Page 262: Clean Cab Floor
MAINTENANCE Clean Cab Floor --- as required IMPORTANT: Only the cab floor can be washed with water. Take care not to splash other parts of the cab with water. Do not increase the water pressure speed by squeezing the hose end. Never use steam to clean the cab floor.
Page 263: Check, Clean And Function Check Of Injection Nozzle
MAINTENANCE Check, Clean and Function Check of Injection Nozzle --- every 1500 hours Consult your authorized dealer for inspection and repair. Inspect and Adjust Valve Clearance --- every 1000 hours Consult your authorized dealer for inspection and repair. Check and Adjust Injection Timing --- every 1500 hours Consult your authorized dealer for inspection and repair.
Page 264: Tightening And Retightening Torque Of Bolts And Nuts
MAINTENANCE Tightening and Retightening Torque of Bolts and Nuts --- every 250 hours (first time after 50 hours) Check tightness after the first 50 hours then every 250 hours. Tighten to torque shown if any are loose. Bolts and nuts should be replaced with those of the same or higher grade. For tightening nuts and bolts other than specified in the table below, refer to the Tightening Torque Chart at the end of this section.
Page 265 MAINTENANCE ZX33U-5A, 38U-5A Bolt Dia. Wrench Size Torque Descriptions Q’ty N·m (kgf∙m) (lbf·ft) 1. Engine cushion rubber mounting bolt (65) 2. Engine bracket mounting bolt (Front) (36) 3. Hydraulic oil tank mounting bolt (65) 4. Fuel tank mounting nut (36) 7/16-20UNF (2.5) (18) Metal face (22) 9/16-18UNF seal fitting for (29) Union joints for 3/4-16UNF (6.5) (47) hydraulic hoses hydraulic hoses and 1-1/16-12UNF...
Page 266 MAINTENANCE ZX48U-5A, 55U-5A Bolt Dia. Wrench Size Torque Descriptions Q’ty N·m (kgf∙m) (lbf·ft) Engine cushion rubber mounting bolt (14) (101) Engine bracket mounting bolt (Front) (36) Hydraulic oil tank mounting bolt (11) (80) Fuel tank mounting nut (15) 7/16-20UNF (2.5) (18) Metal face (22) 9/16-18UNF seal fitting for (29) Union joints for hydraulic hoses 3/4-16UNF (6.5) (47) hydraulic hoses and 1-1/16-12UNF (18)
Page 267 MAINTENANCE ZX65USB-5A Torque Bolt Dia. Wrench Size Descriptions Q’ty N·m (kgf∙m) (lbf·ft) 1. Engine cushion rubber mounting bolt (14) (101) 2. Engine bracket mounting bolt (Front) (6.5) (47) 3. Muffler mounting U-bolt fixing nut (single nut) 4. Muffler mounting U-bolt fixing nuts (double nuts) (3.5) (26) 5. Hydraulic oil tank mounting bolt (27) (195) 6. Fuel tank mounting nut (14) PF1/8 (22) PF3/8 (29) PF1/2 (6.5) (47) Joint PF3/4 (18) (130) (21)
Page 268 MAINTENANCE ZX65USB-5A Torque Bolt Dia. Wrench Size Descriptions Q’ty N·m (kgf∙m) (lbf·ft) 20. Upper roller mounting bolt (21) (151) 21. Lower roller mounting bolt (62) (455) 22. Shoe bolt (optional) (16.5) (121) (0.5) (3.5) 23. Cover mounting bolt (36) 24. Counterweight mounting bolt (95) (685) 25.
Page 269 MAINTENANCE Tightening Torque Chart Hexagon Bolt Dia. Wrench Wrench Size Size M552-07-091 M552-07-090 M157-07-225 Socket Bolt N·m (kgf∙m) (lbf·ft) N·m (kgf∙m) (lbf·ft) N·m (kgf∙m) (lbf·ft) (3.0) (22) (2.0) (15) (1.0) (7.4) (6.5) (48) (5.0) (37) (2.0) (15) (11) (81) (66) (3.5) (26) (18) (135) (14)
Page 270 MAINTENANCE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-102...
Page 271: Maintenance Under Special Environmental Conditions
Track Keep the track clean. Park the machine on a hard surface to prevent the tracks from freezing to the ground. High Altitude Engine Oil Change at 1/2 of normal service interval. Engine Oil Filter Change at 1/2 of normal service interval. (Altitude: 1500 m or higher) When the machine is operated at the altitude 1500 m or higher, the ignition of the engine may deteriorate, possibly resulting in significant decrease in durability or function. If the machine is unavoidably operated under these conditions, consult your authorized Hitachi dealer.
Page 272: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 273: Storage
STORAGE Storing the Machine In case the machine is to be stored for longer than one month, pay attention to the following points to prepare next operation. Item Remedy Machine Cleaning Wash the machine. Remove soil or other debris adhered to the machine. Lubrication/Greasing Check lubricant's level and contamination. Fill up or change if necessary. Lubricate all grease points. Coat grease to exposed metal surfaces which are subject to rust (i.e. cylinder rods etc.). Battery Remove the batteries and store them in a dry protected place after charging fully. If not removed, disconnect the negative battery cable from the ( ) terminal. Coolant Add anti-rusting agent. If storing in extremely cold areas, either add extra anti-freeze or drain coolant completely to avoid freezing. In this case, place a sign reading "NO COOLANT". Protection Against Dust Store the machine in a dry storage area using a protective cover. and Moisture Tools Inspect and repair, then store. Lubrication Operation If oil film on the metal surfaces is lost, rust may begin, possibly causing abnormal wear of the machine when the machine operation is restarted.
Page 274 STORAGE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-2...
Page 275: Troubleshooting
Troubleshooting If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest Hitachi dealer. Never attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components. IMPORTANT: Never attempt to disassemble or modify the electrical/electronic components. Engine Consult the nearest Hitachi dealer for the engine troubleshooting. Engine Auxiliaries Problem Cause Solution Batteries will not be charged. Broken battery separator...
Page 276 After draining water, replace the element. Clogged pre-fuel filter (Optional) Clean or replace the element. Faulty engine control system * Repair and adjust Clogged air cleaner Clean or replace the element. Faulty injection pump * Repair and adjust Engine runs irregularly. Faulty fuel system * Repair and adjust Water or air in the fuel system Drain water or bleed air. Faulty engine control system * Repair and adjust * Mark: Consult your authorized Hitachi dealer. 11-2...
Page 277 Rusted joint * Lubricate or repair Worn pusher * Replace Does not move smoothly Worn pusher * Repair or replace Faulty pilot valve * Replace Does not return to neutral. Faulty pilot valve * Replace The lever is tilted in the neutral position Worn joint * Repair or replace due to increase in play. Faulty pilot valve * Replace * Mark: Consult your authorized Hitachi dealer. 11-3...
Page 278 Retighten Only one side lever is inoperable or has Faulty relief valve in the valve * Repair or replace no power. Broken pipe and/or hose * Repair or replace Loose pipe line joint Retighten Broken O-ring at pipe line joint * Replace Faulty hydraulic pump * Repair or replace Faulty pilot valve * Replace Faulty pilot circuit line * Repair or replace Faulty pilot solenoid valve * Repair or replace * Mark: Consult your authorized Hitachi dealer. 11-4...
Page 279 Faulty pilot valve * Replace Faulty pilot circuit line * Repair or replace Low set pressure of main or port relief valve * Adjust and replace (boom, arm and bucket) Hydraulic oil temperature increases. Stained oil cooler Clean Insufficient engine fan belt tension Adjust Oil leak from low pressure hose Loose clamps Retighten * Mark: Consult your authorized Hitachi dealer. 11-5...
Page 280 Faulty counter balance valve * Replace Does not travel smoothly. Overly tensioned or slackened crawler sag Adjust Deformed track frame * Repair or replace Embedded foreign matter such as rock Remove fragments Dragged parking brake * Repair Faulty counter balance valve * Replace Travel speed does not change. Faulty travel speed switch. * Replace Poor contact in connector * Repair or replace Damaged wire harness * Repair Faulty solenoid valve * Repair or replace Faulty motor * Repair or replace * Mark: Consult your authorized Hitachi dealer. 11-6...
Page 281 Faulty pilot circuit line * Repair or replace Low set pressure of swing relief valve * Adjust and replace Swing is not smooth. Worn swing gear * Repair or replace Damaged swing bearing and bearing balls * Repair or replace Lack of grease Refill Low set pressure of swing relief valve * Adjust and replace * Mark: Consult your authorized Hitachi dealer. Immediately after the control valve, swing motor relief valve and/or the swing motor is replaced, a noise may be emitted and/or operation may not be performed smoothly due to air trapped in the hydraulic line. Slowly continue to operate the machine for approx. 10 minutes to bleed air. After repair work is complete, be sure to check the oil level in the hydraulic oil tank. Refill hydraulic oil as needed. 11-7...
Page 282 Work mode does not change. Faulty mode switch * Replace Poor contact in connector * Repair or replace Damaged wire harness (between ECU and * Repair monitor) Faulty controller (ECU) * Replace Faulty solenoid valve * Repair or replace Auto-idle is inoperable or not released. Faulty pressure sensor * Replace Poor contact in connector * Repair or replace Damaged wire harness * Repair Faulty controller * Replace * Mark: Consult your authorized Hitachi dealer. Others The machine may have a noise, excessive vibration, and abnormal smell when any trouble occurs. Always beware of the machine conditions during operation. 11-8...
Page 283: Specifications
SPECIFICATIONS Std. Specification ZX33U-5A MADG-12-001 Model ZX33U-5A Specification Canopy Type of Front-End Boom Swing Type, 1.52 m (5 ft) Arm Attachment Bucket Capacity (Heaped) 0.08 (0.11) Operating Weight kg (lb) 3330 (7340) 3510 (7740) Base Machine Weight kg (lb) 2520 (5560) 2700 (5950) 3TNV88 Engine kW/min 21.2/2400 (PS/rpm) (28.8/2400) A: Overall Width mm (ft·in) 1550 (5' 1'') B: Overall Height mm (ft·in) 2480 (8' 2'') C: Rear End Swing Radius mm (ft·in) 875 (2' 10") D: Minimum Ground...
Page 284: Working Ranges
SPECIFICATIONS Working Ranges ZX33U-5A K (Left) K (Right) MADC-12-004 ZX33U-5A Category Canopy Item 1.17 m Arm 1.52 m Arm 1.17 m Arm 1.52 m Arm Maximum Digging Reach mm (ft·in) 4890 (16' 1") 5170 (17') 4890 (16' 1") 5170 (17') Maximum Digging Depth mm (ft·in) 2790 (9' 2") 3130 (10' 3") 2790 (9' 2") 3130 (10' 3") Maximum Cutting Height mm (ft·in) 4620 (15' 2") 4700 (15' 5") 4420 (14' 6") 4470 (14' 8") Maximum Dumping Height mm (ft·in)
Page 285: Shoe Types And Applications
SPECIFICATIONS Shoe Types and Applications ZX33U-5A (Canopy) Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe Shoe Width 300 mm 300 mm 300 mm 300 mm For Paved Road For Ordinary Ground For Paved Road For Paved Road Application (Standard) (Optional) (Optional) (Optional) Operating (kg) 3330 3470 3570 3540 Weight Minimum Ground (mm) Clearance Undercarriage (mm) 2110 2130 2170 2180 Length...
Page 286: Bucket Types And Applications Zx33U-5A
SPECIFICATIONS Bucket Types and Applications ZX33U-5A Bucket Width mm Front-End Attachment Bucket Capacity 1.17 m 1.52 m Bucket m³ (yd³) (With side cutter) (Without side cutter) (3'10") (5'0") ISO (Heaped) mm (in) mm (in) Hoe Bucket 0.04 (0.052) 300 (12") 250 (10")   0.055 (0.072) 350 (14") 300 (12")   0.065 (0.085) 400 (16") 350 (14") ...
Page 287: Std. Specification
SPECIFICATIONS Std. Specification ZX38U-5A MADG-12-001 Model ZX38U-5A Specification Canopy Type of Front-End Boom Swing Type, 1.72 m (5 ft 8 in) Arm Attachment Bucket Capacity (Heaped) 0.10 (0.13) Operating Weight kg (lb) 3790 (8360) 3960 (8730) Base Machine Weight kg (lb) 2930 (6460) 3100 (6830) 3TNV88 Engine kW/min 21.2/2400 (PS/rpm) (28.8/2400) A: Overall Width mm (ft·in) 1550 (5' 1'') B: Overall Height mm (ft·in) 2480 (8' 2'') C: Rear End Swing Radius mm (ft·in) 980 (3' 3") D: Minimum Ground...
Page 288: Working Ranges
SPECIFICATIONS Working Ranges ZX38U-5A K (Left) K (Right) MADC-12-004 ZX38U-5A Category Canopy Item 1.32 m Arm 1.72 m Arm 1.32 m Arm 1.72 m Arm Maximum Digging Reach mm (ft·in) 5210 (17' 1") 5520 (18' 1") 5210 (17' 1") 5520 (18' 1") Maximum Digging Depth mm (ft·in) 3060 (10') 3460 (11' 4") 3060 (10') 3460 (11' 4") Maximum Cutting Height mm (ft·in) 4870 (16') 4950 (16' 3") 4700 (15' 5") 4740 (15' 7") Maximum Dumping Height mm (ft·in) 3460 (11' 4") 3570 (11' 9") 3310 (10' 10")
Page 289: Shoe Types And Applications
SPECIFICATIONS Shoe Types and Applications ZX38U-5A (Canopy) Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe Shoe Width 300 mm 300 mm 300 mm 300 mm For Paved Road For Ordinary Ground For Paved Road For Paved Road Application (Standard) (Optional) (Optional) (Optional) Operating (kg) 3790 3930 4030 4000 Weight Minimum Ground (mm) Clearance Undercarriage (mm) 2110 2130 2170 2180 Length...
Page 290: Bucket Types And Applications Zx38U-5A
SPECIFICATIONS Bucket Types and Applications ZX38U-5A Bucket Width mm Front-End Attachment Bucket Capacity 1.32 m 1.72 m Bucket m³ (yd³) (With side cutter) (Without side cutter) (4'4") (5'8") ISO (Heaped) mm (in) mm (in) Hoe Bucket 0.04 (0.052) 300 (12") 250 (10")   0.055 (0.072) 350 (14") 300 (12")   0.065 (0.085) 400 (16") 350 (14")  ...
Page 291: Std. Specification
SPECIFICATIONS Std. Specification ZX48U-5A MADG-12-003 Model ZX48U-5A Specification Canopy Type of Front-End Boom Swing Type, 1.69 m (5 ft 7 in) Arm Attachment Bucket Capacity (Heaped) 0.11 (0.14) Operating Weight kg (lb) 4770 (10520) 4900 (10800) Base Machine Weight kg (lb) 3540 (7800) 3670 (8090) 4TNV88 Engine kW/min 28.2/2400 (PS/rpm) (38.3/2400) A: Overall Width mm (ft·in) 1850 (6' 1'') B: Overall Height mm (ft·in) 2530 (8' 4'') C: Rear End Swing Radius mm (ft·in) 1080 (3' 6") D: Minimum Ground...
Page 292: Working Ranges
SPECIFICATIONS Working Ranges ZX48U-5A K (Left) K (Right) MADC-12-005 ZX48U-5A Category Canopy Item 1.38 m Arm 1.69 m Arm 1.38 m Arm 1.69 m Arm Maximum Digging Reach mm (ft·in) 5760 (18' 11") 6060 (19' 11") 5760 (18' 11") 6060 (19' 11") Maximum Digging Depth mm (ft·in) 3320 (10' 11") 3630 (11' 11") 3320 (10' 11") 3630 (11' 11") Maximum Cutting Height mm (ft·in) 5590 (18' 4") 5820 (19' 1") 5590 (18' 4") 5820 (19' 1") Maximum Dumping Height mm (ft·in) 3910 (12' 10") 4140 (13' 7") 3910 (12' 10")
Page 293: Shoe Types And Applications
SPECIFICATIONS Shoe Types and Applications ZX48U-5A (Canopy) Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe Shoe Width 400 mm 400 mm 400 mm 400 mm For Paved Road For Ordinary Ground For Paved Road For Paved Road Application (Standard) (Optional) (Optional) (Optional) Operating (kg) 4770 4880 5070 4940 Weight Minimum Ground (mm) Clearance Undercarriage (mm) 2500...
Page 294: Bucket Types And Applications Zx48U-5A
SPECIFICATIONS Bucket Types and Applications ZX48U-5A Bucket Width mm Front-End Attachment Bucket Capacity 1.38 m 1.69 m Bucket m³ (yd³) (With side cutter) (Without side cutter) (4'6") (5'7") ISO (Heaped) mm (in) mm (in) Hoe Bucket 0.10 (0.13) 450 (18") 400 (16")   0.11 (0.14) 500 (20") 450 (18")   0.13 (0.17) 550 (22") 500 (20") ...
Page 295: Std. Specification
SPECIFICATIONS Std. Specification ZX55U-5A MADG-12-003 Model ZX55U-5A Specification Canopy Type of Front-End Boom Swing Type, 1.69 m (5 ft 7 in) Arm Attachment Bucket Capacity (Heaped) 0.14 (0.18) Operating Weight kg (lb) 5080 (11200) 5210 (11490) Base Machine Weight kg (lb) 3840 (8470) 3970 (8750) 4TNV88 Engine kW/min 28.2/2400 (PS/rpm) (38.3/2400) A: Overall Width mm (ft·in) 1850 (6' 1'') B: Overall Height mm (ft·in) 2530 (8' 4'') C: Rear End Swing Radius mm (ft·in) 1100 (3' 7") D: Minimum Ground...
Page 296: Working Ranges
SPECIFICATIONS Working Ranges ZX55U-5A K (Left) K (Right) MADC-12-005 ZX55U-5A Category Canopy Item 1.38 m Arm 1.69 m Arm 1.38 m Arm 1.69 m Arm Maximum Digging Reach mm (ft·in) 5960 (19' 7") 6260 (20' 7") 5960 (19' 7") 6260 (20' 7") Maximum Digging Depth mm (ft·in) 3530 (11' 7") 3830 (12' 7") 3530 (11' 7") 3830 (12' 7") Maximum Cutting Height mm (ft·in) 5750 (18' 10") 6000 (19' 8") 5750 (18' 10") 6000 (19' 8") Maximum Dumping Height mm (ft·in) 4070 (13' 4") 4310 (14' 2") 4070 (13' 4")
Page 297: Shoe Types And Applications
SPECIFICATIONS Shoe Types and Applications ZX55U-5A (Canopy) Rubber Shoe Grouser Shoe Rubber Pad Shoe Pad Crawler Shoe Shoe Width 400 mm 400 mm 400 mm 400 mm For Paved Road For Ordinary Ground For Paved Road For Paved Road Application (Standard) (Optional) (Optional) (Optional) Operating (kg) 5080 5190 5380 5250 Weight Minimum Ground (mm) Clearance Undercarriage (mm) 2500...
Page 298: Bucket Types And Applications Zx55U-5A
SPECIFICATIONS Bucket Types and Applications ZX55U-5A Bucket Width mm Front-End Attachment Bucket Capacity 1.38 m 1.69 m Bucket m³ (yd³) (With side cutter) (Without side cutter) (4'6") (5'7") ISO (Heaped) mm (in) mm (in) Hoe Bucket 0.10 (0.13) 450 (18") 400 (16")   0.11 (0.14) 500 (20") 450 (18")   0.13 (0.17) 550 (22") 500 (20") ...
Page 299: Std. Specification
SPECIFICATIONS Std. Specification ZX65USB-5A MADC-12-001 Model ZX65USB-5A Specification Type of Front-End Boom Swing Type, 1.85 m (4 ft 11 in) Arm Attachment Bucket Capacity (Heaped) 0.22 (0.29) Operating Weight kg (lb) 6470 (14260) Base Machine Weight kg (lb) 4740 (10450) 4TNV94L Engine kW/min 34.1/2000 (PS/rpm) (46.4/2000) A: Overall Width mm (ft·in) 1930 (6' 4") B: Overall Height mm (ft·in) 2540 (8' 4'') C: Rear End Swing Radius mm (ft·in) 1410 (4' 8") D: Minimum Ground mm (ft·in)
Page 300: Working Ranges
SPECIFICATIONS Working Ranges ZX65USB-5A K (Left) K (Right) MADC-12-002 ZX65USB-5A Category Item 1.50 m Arm 1.85 m Arm Maximum Digging Reach mm (ft·in) 6230 (20' 5") 6560 (21' 6") Maximum Digging Depth mm (ft·in) 3770 (12' 4") 4120 (13' 6") Maximum Cutting Height mm (ft·in) 5960 (19' 7") 6190 (20' 4") Maximum Dumping Height mm (ft·in) 4170 (13' 8") 4410 (14' 6") Overall Height mm (ft·in) 2540 (8' 4") Overall Length mm (ft·in) 5760 (18' 11") 5790 (19')
Page 301: Shoe Types And Applications
SPECIFICATIONS Shoe Types and Applications ZX65USB-5A (Cab) Rubber Shoe Grouser Shoe Pad Crawler Shoe Shoe Width 400 mm 400 mm 400 mm For Ordinary For Paved Road For Paved Road Application Ground (Standard) (Optional) (Optional) Operating (kg) 6470 6570 6600 Weight Minimum Ground (mm) Clearance Undercarriage (mm) 2500 2480 2530 Length Undercarriage (mm)
Page 302: Bucket Types And Applications Zx65Usb-5A
SPECIFICATIONS Bucket Types and Applications ZX65USB-5A Bucket Width mm Front-End Attachment Bucket Capacity 1.50 m 1.85 m Bucket m³ (yd³) (With side cutter) (Without side cutter) (4' 11") (6' 1") ISO (Heaped) mm (in) mm (in) Hoe Bucket 0.22 (0.29) 735 (29") 650 (26")   0.24 (0.31) 785 (31") 700 (28")   NOTE:  Symbols in the above table have the following meanings. : General excavating : Light duty excavating : Loading work...
Page 303: Optional Attachment
Coupler Selecting a breaker or crusher Select a breaker, crusher or quick coupler with the correct size and weight for your machine, considering the stability of the machine, hydraulic oil pressure and flow rate of the breaker, crusher or quick coupler. Consult your authorized Hitachi dealer for correct breaker information. Precautions for Operation Carefully study the operation manuals of the breaker, crusher and quick coupler. To avoid damaging the machine, hydraulic breaker, crusher or quick coupler, follow the precautions given below. Precautions for connecting breaker, crusher or quick...
Page 304: Attachment
OPTIONAL ATTACHMENT HYDRAULIC BREAKER, HYDRAULIC CRUSHER AND QUICK COUPLER Attachment Allowable Weight Limits of Installed Attachment WARNING:  When an attachment other than the standard bucket is installed on the machine, the machine stability will be different. If a heavy attachment is used, not only will controllability be affected but also machine stability will be reduced, possibly causing safety hazard.
Page 305: Piping For Breaker And Crusher (Optional)
OPTIONAL ATTACHMENT PIPING FOR BREAKER AND CRUSHER Piping for Breaker and Crusher (Optional) Operational procedures for stop valves and selection valve. MADB-13-002 MADB-13-001 A: Selection Valve Remove a rubber cap and change the attachment. ZX33U-5A, 38U-5A ZX48U-5A, 55U-5A ZX65USB-5A MADB-13-003 MADB-13-004 MADC-12-003 B, C: Stop Valves Pedal Operation and Hydraulic Oil Flow When the pedal is depressed to “D” side, hydraulic oil flows into line “B”. Close When the pedal is depressed to “E” side, hydraulic oil flows into line “C”.
Page 306: Attachment Pedal (Hydraulic Breaker) (Optional)
OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC BREAKER) Attachment Pedal (Hydraulic Breaker) (Optional) The hydraulic breaker can be operated by using attachment pedal (2) located on the left front of the seat, as illustrated. CAUTION: Do not allow your foot to rest on attachment pedal (2) when the pedal is not in use. 1.
Page 307: Precautions For Breaker Operation
OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC BREAKER) Precautions for Breaker Operation WARNING: Machine stability is reduced as the breaker is much heavier than the bucket. When using a breaker, the machine is more apt to tip over. Also, flying objects may hit the cab or other part of the machine.
Page 308 Immediately stop the machine operation. Failure to do so may result in serious failure in the hydraulic system Hose jumping including pumps. abnormally Immediately consult your authorized HITACHI dealer. M104-05-058 Do not operate the breaker in water. Doing so will cause rust and seal damage, resulting in damage to the hydraulic system components.
Page 309 OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC BREAKER) Operate the chisel carefully to avoid hitting the machine. When the arm rolled in with the breaker equipped, the chisel may come in contact with the boom. Watch Out! Take care not to hit the boom with the crusher M1M7-05-023 Do not operate breaker with the arm positioned vertically.
Page 310 OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC BREAKER) Raising the front part of the undercarriage by pressing down the breaker may cause damage to the front attachment. Do not raise the front part of the undercarriage 150 mm or more by pressing down the breaker. Pressing Raising Down 10 to 15 cm M147-05-016 Do not operate breaker with the boom swing operation Do not operate the breaker for long period of time while swinging the boom.
Page 311: Attachment Pedal (Hydraulic Crusher) (Optional)
OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC CRUSHER) Attachment Pedal (Hydraulic Crusher) (Optional) The hydraulic crusher can be operated by using attachment pedal (2) located on the left front of the seat, as illustrated. CAUTION: Do not allow your foot to rest on attachment pedal (2) when the pedal is not in use.
Page 312: Precautions For Crusher Operation
OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC CRUSHER) Precautions for Crusher Operation Prevent machine tipping over and damage to the front attachment. Observe the following precautions for crusher operation. WARNING: Machine stability is reduced as crusher is much heavier than the bucket. When operating with a crusher, the machine is more apt to tip over. Falling or flying objects may hit the cab or other part of the machine.
Page 313 OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC CRUSHER)  When the arm rolled in with the crusher equipped, the crusher may come in contact with the boom. Watch Out! Take care not to hit the boom with the crusher MZX5-13-010  When operating the crusher up high with the boom fully raised, be careful of falling objects.  When operating the crusher on a floor in a building, first confirm that the floor has sufficient strength to support MZX5-13-011 the load caused by crushing, in addition to the machine weight.
Page 314 OPTIONAL ATTACHMENT ATTACHMENT PEDAL (HYDRAULIC CRUSHER)  Always operate the crusher on a stable, level surface, not on a slope or on crushed scraps.  Do not use the crusher to haul or load crushed scraps.  To prevent the attachment from falling accident, use a platform when replacing or detaching the attachment. ...
Page 315: Aux Function Lever For Extra Piping (Optional)
OPTIONAL ATTACHMENT AUX FUNCTION LEVER FOR EXTRA PIPING AUX Function Lever for Extra Piping (Optional) WARNING:  Switches on the AUX function lever are provided for operating attachments of this machine. Never use these switches for unauthorized application or modify them, which may cause serious injury or death.
Page 316: Auxiliary Flow Rate Control (Optional)
OPTIONAL ATTACHMENT AUXILIARY FLOW RATE CONTROL Auxiliary Flow Rate Control (Optional) The maximum and minimum hydraulic flow rate in the auxiliary pipe line can be controlled as follows: ZX33U-5A ZX48U-5A ZX38U-5A ZX55U-5A ZX65USB-5A Minimum 40 L 45 L Flow Rate (11 US gal)/min (12 US gal)/min Maximum 66 L 85 L Flow Rate (17 US gal)/min (22 US gal)/min Flow Rate Control Switch (1) LOW: sets to the minimum flow rate. HIGH: sets to the maximum flow rate. When shifting the flow rate from the LOW to HIGH, operate switch (1) while pulling the lock knob toward the arrow mark.
Page 317: Control Lever (H-Pattern: Hitachi Excavator Pattern)
OPTIONAL ATTACHMENT CONTROL LEVER (H-PATTERN: HITACHI EXCAVATOR PATTERN) Control Lever (H-pattern: HITACHI Excavator Pattern) 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...
Page 318: Control Lever Sae-Backhoe Pattern
OPTIONAL ATTACHMENT CONTROL LEVER SAE-BACKHOE PATTERN Control Lever (SAE-backhoe Pattern) WARNING:  Make sure you know 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).
Page 319: Fuel Feed Device (Optional) (Zx48U-5A, 55U-5A, 65Usb-5A)
OPTIONAL ATTACHMENT FUEL FEED DEVICE Fuel Feed Device (Optional) (ZX48U-5A, 55U-5A, 65USB-5A) This device feeds fuel by electrical pump (3). CAUTION: This device is not incorporated with an auto-stop function when fuel is filled up. Be sure to manually stop filling while monitoring fuel level with level gauge (5). Fuel Feeding Operation 1. Park the machine following the same procedures as described on page 7-7 Preparation for Inspection and...
Page 320: Numeric Keypad Lock (Optional)
It is recommended to change the password frequently to prevent snooping. If the customer forgets the password, contact your authorized Hitachi dealer.  Keep open flames including burning cigarette away from the numeric keypad. Use soft cloth to wipe the surface of the numeric keypad.
Page 321 OPTIONAL ATTACHMENT NUMERIC KEYPAD LOCK Description of Security Functions This system enables starting the engine only when the input password accords with the one predetermined by the customer. Unlocking 1. Turn key switch (1) ON. Then, all numeric keys (2) are lit. Input the password within 15 seconds. 2. Buzzer will sound and unlocking indicator (3) (green LED) will be lit. When security indicator (4) is displayed on the monitor screen, the engine is able to start.
Page 322 OPTIONAL ATTACHMENT NUMERIC KEYPAD LOCK Description of Numeric Keypad 1. Unlocking indicator (3) (green LED) While this indicator (3) is blinking or kept ON, the engine can be started without inputting the password. Indicator (3) will be lit when the 2nd digit is entered at input of password. 2. Locking indicator (6) (red LED) When locked, indicator (6) slowly blinks. Indicator (6) is lit when the 1st and 3rd digits are entered at the input of password. 3. Numeric keys (2) (1 – 9 and 0) Used for inputting the password and making various other kinds of setting. MADB-13-010 4. Key F (4) Used for function setting. 5.
Page 323 OPTIONAL ATTACHMENT NUMERIC KEYPAD LOCK Unlocking 1. Turn key switch (1) ON. Then, all numeric keys (2) are lit. 2. Input the 1st digit of the four-digit password. 3. Similarly, input the 2nd digit. 4. Similarly, input the 3rd digit. 5. Similarly, input the 4th digit. 6. If the input numerals coincide with those of the MADB-01-007 password, the buzzer sounds twice, and unlocking is done. In this condition, when key switch (1) is turned ON, the engine will start. NOTE: If mis-input the password, the entered numbers can be cancelled by pushing Key C (3). Alternatively, redo from the beginning by turning key switch (1) OFF.
Page 324 OPTIONAL ATTACHMENT NUMERIC KEYPAD LOCK Change Password Cancel the registered password, and set a new password. 1. Turn key switch (1) to the ON position. 2. Unlock the numeric keypad. 3. Push Key F (2) and Key 1 (3) simultaneously for more than 2 seconds. 4. Two indicators (4) and (5) blink simultaneously, and the MADB-01-007 buzzer sounds. 5. Input new 4-digit password. After inputting, two indicators (4) and (5) are lit, and the buzzer sounds twice. 6. Once again, re-enter the new password. (the same password as that in Item 5) When the new password is properly input, two indicators...
Page 325 OPTIONAL ATTACHMENT NUMERIC KEYPAD LOCK Changing Lock Timer Setting The lock timer can be changed in this mode. 1. Turn key switch (1) to ON position. 2. Unlock the numeric keypad. 3. Push Key F (2) and Key 2 (7) simultaneously for more than 2 seconds. 4. Two indicators (4) and (5) blink simultaneously, and the MADB-01-007 buzzer sounds. 5. Push a relevant key to set the lock delay timer. List of lock time assigned to each key as timer Key 1: 15 seconds (Factory default) Key 2: 3 minutes Key 3: 5 minutes Key 4: 10 minutes Key 5:...
Page 326 After that, horn and buzzer will sound to warn the operator every time key switch (1) is turned ON until the correct password is input. MADB-01-007 System Error Display In case any abnormality occurs on the system, two indicators blink alternately. Consult your authorized Hitachi dealer. Factory Default Setting Factory default setting is shown below. (1) Password 0000 (2) Lock delay timer set time 15 seconds...
Page 327: Additional Counterweight
OPTIONAL ATTACHMENT ADDITIONAL COUNTERWEIGHT Additional Counterweight The mass values of additional counterweights (1) are shown in the table below. Model Weight Overhang from the end of the base machine ZX33U-5A 190 kg 100 mm ZX38U-5A 230 kg 110 mm ZX48U-5A 200 kg 100 mm ZX55U-5A 200 kg 100 mm ZX65USB-5A 270 kg 110 mm...
Page 328: Cab Tilting Mechanism
OPTIONAL ATTACHMENT CAB TILTING MECHANISM Cab Tilting Mechanism CAUTION:  Wear safety equipments appropriate to the job such as a hard hat, gloves and protective shoes.  Sufficiently illuminate the work site and work under well-lighted area. Work under low light condition can lead misoperation.
Page 329 OPTIONAL ATTACHMENT CAB TILTING MECHANISM Floor Tilt Up Procedure 1. After operating the machine, wait for the machine to sufficiently cool. 2. Park the machine on a level surface. 3. Lower the blade. Ground Level 4. After rolling the arm and the bucket in, lower the bucket on a wooden block down to the ground. 5. Face the front attachment straightforward toward the machine without swinging the front attachment at this MADB-13-045 time.
Page 330 OPTIONAL ATTACHMENT CAB TILTING MECHANISM 10. Remove bolts (6) (not covered with resin caps) in the rear ZX33U-5A, 38U-5A, 48U-5A, 55U-5A section of the operator's seat. CAUTION:  If bolts other than bolt (6) are removed, the canopy or the cab (optional) may come off the floor, resulting in unexpected accident.  Care should be taken that if the floor is tilted upward while raising the front attachment, the canopy or cab (optional) may come in contact with the boom.
Page 331 OPTIONAL ATTACHMENT CAB TILTING MECHANISM IMPORTANT: Do not tilt the canopy or cab by using other than the cab tilting device (such as a crane). Failure to do so may result in breakage of the cab tilting mechanism and/or floor. 11. Install hose protection rubber (8) while taking care not to damage hose (7) at the cab tilting device mounting area.
Page 332 OPTIONAL ATTACHMENT CAB TILTING MECHANISM 13. Install pin (11) to holder (12). 14. Install align locating pin (13) to hole (14). IMPORTANT:  Do not attempt to tilt up the cab after the stoppers (15) contact each other. Failure to do so may result in breakage of the cab tilting device and/or floor. ...
Page 333 OPTIONAL ATTACHMENT CAB TILTING MECHANISM 16. Raise fall prevention bar (17) in the arrowed direction until it comes in contact with bracket (18) mounted on the cab floor reverse surface. Insert fall prevention bar (17) into the hole of base (19). 17. Before starting to work under the tilted cab floor, make sure if fall prevention bar (17) does not come off by jolting fall prevention bar (17) by hand. WARNING: Fall prevention bar (17) is a redundant safety device to be functioned in case the floor tilt mechanism fails.
Page 334 OPTIONAL ATTACHMENT CAB TILTING MECHANISM Floor Tilt Down Procedure WARNING:  Be sure to tilt down the cab after checking or Fall Prevention Bar servicing. At this time, be sure to store the fall prevention bar first, and then slowly tilt down the cab.
Page 335: Maintenance
OPTIONAL ATTACHMENT CAB TILTING MECHANISM Maintenance Check Tilt Mechanism Fulcrum Bolts and Working Screw Lock Nut --- Before Use 1. Check tilt mechanism fulcrum bolts (1) for looseness. If bolt (1) is loose, retighten bolt (1) to 10 N∙m (1.0 kgf∙m). 2. Check working screw lock nut (2) for looseness. If lock nut (2) is loose, retighten nut (2) to 140 N∙m (14kgf∙m). MADB-13-035 13-33...
Page 336: Greasing
OPTIONAL ATTACHMENT CAB TILTING MECHANISM Greasing --- Before Use 1. Rotate adjuster (1) counterclockwise to fully extend the tilt device. MADB-13-029 2. Apply grease all over the thread part of screw (2) of adjuster (1). Dow Corning Toray Co., Ltd.  Recommended grease: MOLYKOTE EM-30L ® MADB-13-036 13-34...
Page 337: Index
Before Starting Engine ..............3-2 Components Name ................1-1 Beware of Asbestos and Silicon Dust and Other Confirm Direction of Machine to Be Driven ......S-13 Contamination ................. S-36 Contents of Alarms ..............1-16 Beware of Exhaust Fumes............S-33 Control Lever (H-pattern: HITACHI Excavator Pattern) ..13-15 Blade Lever ..................5-3 Control Lever (ISO Pattern) ............5-1 Blade Pins ..................7-21 Control Lever (SAE-backhoe Pattern) ........13-16 Bleed Air from Fuel System ............7-54 Control Lever Universal Joint ........... 7-23 Boom Cylinder may Hit Blade ..........5-17 Converting the Track ..............
Page 338 INDEX Heating Operation ............1-33, 1-36 Hour Meter ..................1-13 DRIVING THE MACHINE ..............4-1 How to Use Screens ................1-9 Defroster Operation ............1-33, 1-36 Hydraulic Breaker, Hydraulic Crusher and Quick Deletion of Preset Memory ............1-40 Coupler ..................13-1 Dig with Caution ................S-20 Hydraulic System ................7-31 Digital Clock Setting Procedure ..........1-41 Display Mode Setting..............1-23 Displaying Basic Screen ..............1-9 Indicators ....................1-8 Displaying Trip Meter (1) ............1-25 Inspect and Adjust Valve Clearance ........
Page 339 INDEX Object Handling ................S-22 Removing Rubber Crawler ............7-81 Off-Season Air Conditioner Maintenance ......1-37 Replace Air Cleaner Inner Element (Optional) ....7-60 Opening Upper Front Window (Cab equipped Replace Air Cleaner Outer and Inner Elements ....7-60 machine) ................... 1-43 Replace Circulating Air Filter ............ 7-90 Operate Only from Operator's Seat ..........S-8 Replace Engine Oil Filter ............7-25 Operate with Caution ..............S-20 Replace Fresh Air Filter ............ 7-92, 7-93 Operating Backhoe ..............5-13 Replace Fuel Main Filter Element ........... 7-56 Operating in Water or Mud ............4-8 Replace Fuel Pre-Filter Element (Optional) ......
Page 340 INDEX Travel Reduction Gear ..............7-28 Traveling .....................4-4 Traveling on Soft Ground .............4-5 Trip ..................... 1-24 Troubleshooting ................11-1 Tuning Procedure ................. 1-40 Understand Signal Words .............S-1 Unloading ..................6-6 Use Correct Track Shoe ............... 5-19 Use Handrails and Steps ...............S-6 Using Booster Battery ..............3-6 Using Rubber Crawler ..............5-20 Warming Up Operation ..............5-7 Warn Others of Service Work ........... S-26 Warning Codes ................1-16 Warning Display Screen ............. 1-14 Wear Protective Clothing..............S-3 When Windows Become Clouded .......

This manual is also suitable for:

Zaxis 38u-5a Zaxis 65usb-5a Zaxis 48u-5a Zaxis 55u-5a

Hitachi Zaxis 33U-5A Operator's Manual

Machine Numbers

Safety

Safety Signs

Components Name

Getting On/Off the Machine

Operator's Station

Break-In

Operating the Engine

Driving the Machine

Operating the Machine

Transporting

Maintenance

Maintenance under Special Environmental Conditions

Storage

Troubleshooting

Specifications

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Summary of Contents for Hitachi Zaxis 33U-5A