Hitachi ZX27U-2, ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2 Operator's Manual

INTRODUCTION

Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage.

This standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: −20°C to 40°C (−4°F to 104°F) Altitude: 0 m to 1500 m (0 ft to 4900 ft)

In case the machine is used under conditions other than described above, consult your authorized dealer.

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

• SI Units (International System of Units) are used in

this manual. For reference MKS system units and English units are also indicated in parentheses after the SI units. Example : 24.5 MPa (250 kgf/cm

2

, 3560 psi)

Right-hand and left-hand sides are determined by facing in the direction of forward travel.

Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of Hitachi's support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.

Prior to operating this machine in a country other than a country of its intended use, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of that particular country. Please do not operate this machine outside of the country of its intended use until such compliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized distributor or dealer if you have any questions concerning compliance.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME

OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE

TRANSPORTING MAINTENANCE CONSUMABLE PARTS LIST

MAINTENENCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

OPERATING THE MACHINE

STORAGE TROUBLESHOOTING SPECIFICATIONS REFERENCE INDEX

CONTENTS

MACHINE NUMBERS

SAFETY

Recognize Safety Information ............................ S-1

Understand Signal Words................................... S-1

Follow Safety Instructions................................... S-2

Prepare for Emergencies.................................... S-2

Wear Protective Clothing .................................... S-3

Protect Against Noise ......................................... S-3

Inspect Machine.................................................. S-3

Tidy Up Inside Operator’s Space........................ S-4

Use Handholds and Steps.................................. S-4

Adjust the Operator’s Seat.................................. S-5

Ensure Safety Before Rising From or

Leaving Operator’s Seat............................... S-5

Fasten Your Seat Belt......................................... S-5

Move and Operate Machine Safely .................... S-6

Operate Only from Operator’s Seat.................... S-7

Jump Starting...................................................... S-7

Keep Riders Off Machine.................................... S-7

Precautions for Operations................................. S-8

Investigate Job Site Beforehand......................... S-9

Protect Against Falling Stones and Debris....... S-10

Provide Signals for Jobs Involving

Multiple Numbers of Machines ................... S-10

Confirm Direction of Machine to be Driven....... S-10

Drive Machine Safely........................................ S-11

Avoid Injury from Rollaway Accidents .............. S-13

Avoid Injury from Back-Over

and Swing Accidents .................................. S-14

Keep Person Clear from Working Area ............ S-15

Never Position Bucket Over Anyone ................ S-15

Avoid Undercutting ........................................... S-15

Avoid Tipping .................................................... S-16

Never Undercut a High Bank............................ S-16

Dig with Caution................................................ S-17

Operate with Caution ........................................ S-17

Avoid Power Lines ............................................ S-17

Precautions for Lightening................................ S-18

Do Not Use for Craning Operations.................. S-18

Protect Against Flying Debris ........................... S-18

Park Machine Safely......................................... S-19

Handle Fluids Safely – Avoid Fires................... S-19

Safety Transporting .......................................... S-20

Practice Safe Maintenance............................... S-21

Warn Others of Service Work........................... S-22

Support Machine Properly ................................ S-23

Stay Clear of Moving Parts ............................... S-23

Prevent Parts from Flying ................................. S-23

Store Attachments Safely ................................. S-24

Prevent Burns ................................................... S-24

Replace Rubber Hoses Periodically................. S-25

Avoid High-Pressure Fluids .............................. S-25

Prevent Fires .................................................... S-26

Evacuating in Case of Fire................................ S-28

Beware of Exhaust Fumes................................ S-28

Beware of Asbestos Dust..................................S-28

Precautions for Welding and Grinding ..............S-29

Avoid Heating Near Pressurized Fluid Lines ....S-29

Avoid Applying Heat to Lines

Containing Flammable Fluids .....................S-29

Remove Paint before Welding or Heating.........S-30

Prevent Battery Explosions ...............................S-30

Precautions for Handling Refrigerant................S-31

Handle Chemical Products Safely ....................S-31

Dispose of Waste Properly................................S-32

SAFETY SIGNS...........................................S-33

COMPONENTS NAME ............................... 1-1

OPERATOR’S STATION

Pedals, Levers and Monitor Panel ...................... 1-2

Key Switch........................................................... 1-4

Switch Panel........................................................ 1-4

Monitor Panel ...................................................... 1-5

Coolant Temperature Gauge ........................ 1-5

Fuel Gauge ................................................... 1-5

System Failure Indicator ............................... 1-6

Engine Oil Pressure Indicator ....................... 1-6

Overheat Indicator......................................... 1-6

Fuel Level Indicator....................................... 1-6

Alternator Indicator........................................ 1-7

Preheat Indicator........................................... 1-7

Fast Travel Mode Indicator ...........................1-7

Liquid Crystal display (LCD),

Display Selection Switch, and Set Switch..... 1-8

How to Operate Trip Meter.................................. 1-9

Auto-Idle Switch (Except ZX27U

-2) ................... 1-11

Air Conditioner Operation.................................. 1-12

Tips for Air Conditioner Usage .......................... 1-14

Radio (Cab Equipped Machines) ...................... 1-15

AM/FM Radio Operation ................................... 1-16

Cab Door Release lever

(Cab-equipped machines)........................... 1-18

Opening/Closing Cab Front Window

(Cab-equipped machines) ......................... 1-19

Adjusting Operator’s Seat ................................. 1-20

Tool and Operator’s manual Boxes .................. 1-20

Emergency Exit (Cab-equipped machines) ......1-21

Seat Belt (Optional) ........................................... 1-22

Cab Light (Cab-equipped machines) ................ 1-22

BREAK-IN

Breaking in New Machine ................................... 2-1

OPERATING THE ENGINE

Before Starting Engine ........................................ 3-1

Starting Engine.................................................... 3-2

Starting in Ordinary Temperature ................. 3-2

Starting in Cold Weather............................... 3-3

Check Machine After Starting Engine ................. 3-4

CONTENTS

Using Booster Batteries .......................................3-5

Stopping the Engine ............................................3-6

DRIVING THE MACHINE

Travel Levers and Pedals....................................4-1

Travel Mode Switch .............................................4-3

Traveling on Soft Ground.....................................4-4

Raise One Track Using Boom and Arm ..............4-4

Towing Machine...................................................4-5

Driving In Water or on Soft Ground .....................4-6

Precautions for Traveling on Slopes....................4-7

Parking and Stopping on Slopes .........................4-8

Parking on Slopes................................................4-8

OPERATING THE MACHINE

Control Lever (ISO Excavator Pattern)................5-1

Control Lever

(H-Pattern: HITACHI Excavator Pattern).......5-2

Control Lever (SAE-Backhoe Pattern)

--- If Equipped (2 Way Multi Valve) ...............5-3

Boom-Swing Pedal ............................................5-4

Auxiliary Pedal (Optional) ....................................5-5

Blade Lever..........................................................5-6

Precautions for Blade Operation .........................5-7

Pilot Control Shut-Off Lever.................................5-8

Warming Up Operation ........................................5-9

Warming Up in Cold Weather..............................5-9

Auto-Idle Control (Except ZX27U

-2) ..................5-10

Operating Backhoe ............................................5-11

Grading Operation .............................................5-12

Avoid Driving Bucket Teeth Into Ground ...........5-12

Avoid Abusive Operation ...................................5-12

Avoid Striking with Bucket .................................5-13

Avoid Excavation Using Upperstructure

and/or Boom Swing Power ..........................5-13

Use Correct Track Shoe ....................................5-13

Avoid Other than Specified Machine

Operations ...................................................5-14

Boom Cylinder May Hit Blade............................5-15

Avoid Hitting Blade with Bucket.........................5-16

Avoid Colliding Blade Against Rocks.................5-16

Avoid Colliding Boom Cylinder with Track.........5-16

Precautions for Installing Wide Bucket

or Special Type Bucket................................5-16

Using Rubber Crawler .......................................5-17

Hydraulic Breaker (Optional) .............................5-19

Crusher Operation (Optional) ............................5-22

Precautions for After Operating the Machine ....5-23

Auxiliary Flow Rate Control (Optional) (Except ZX27U

-2)........................5-24

Emergency Boom Lowering Procedure.............5-25

TRANSPORTING

Transporting by Road ..........................................6-1

Trailer Loading/Unloading ...................................6-1

Loading ................................................................6-2

Securing the Machine to the Trailer

for Transportation.......................................... 6-3

Unloading ............................................................ 6-4

Lifting Machine with Crane.................................. 6-5

MAINTENANCE

Procedures........................................................... 7-1

Prepare Machine for Inspection/Maintenance ....7-2

Opening/Closing Engine Access Covers ............ 7-3

Opening/Closing Tank Covers ............................ 7-4

Daily Inspection ................................................... 7-5

Periodic Replacement of Parts............................ 7-6

Maintenance Guide ............................................. 7-7

The Brand Names of Recommended

Oils and Lubricants .....................................7-10

A. Greasing...................................................... 7-11

Front Joint Pins ........................................... 7-11

Bucket and Link Pins................................... 7-14

Blade Pins ................................................... 7-14

Precautions for Front Attachment and

Blade Removal ......................................7-14

Swing Bearing ............................................. 7-15

Swing Internal Gear .................................... 7-16

Control Lever Universal Joint...................... 7-16

Tilt Mechanism ............................................ 7-17

B. Engine ......................................................... 7-18

Engine Oil.................................................... 7-18

Change Engine Oil ...................................... 7-18

Replace Engine Oil Filter ............................7-18

C. Transmission............................................... 7-20

Travel Reduction Gear................................ 7-20

D. Hydraulic System ........................................ 7-22

Inspection and Maintenance of

Hydraulic Equipment ............................. 7-22

Check Hydraulic Oil Level........................... 7-23

Drain Hydraulic Oil Tank Sump................... 7-24

Change Hydraulic Oil .................................. 7-25

Clean Suction Filter..................................... 7-28

Replace Full Flow Filter Element ................ 7-29

Replace Pilot Filter Element........................ 7-30

Check Hoses and Lines .............................. 7-32

E. Fuel System ................................................ 7-37

Check Water Separator .............................. 7-38

Drain Fuel Tank Sump ................................ 7-38

Replace Fuel Filter ...................................... 7-39

Check Fuel Hoses....................................... 7-40

F. Air Cleaner .................................................. 7-41

Clean the Air Cleaner Element ................... 7-41

Replace the Air Cleaner Element................ 7-41

G. Cooling System ........................................... 7-42

Check Coolant Level................................... 7-43

Check and Adjust Fan Belt Tension............ 7-44

Change Coolant .......................................... 7-45

Clean Radiator Core ...................................7-46

H. Electrical System......................................... 7-47

Batteries ...................................................... 7-47

CONTENTS

Replacing Fuses..........................................7-50

I. Miscellaneous..............................................7-51

Check Bucket Teeth for Looseness

and/or Wear...........................................7-51

Replace Bucket ...........................................7-53

Adjust Track Sag (Rubber Crawler)

and Check for Damage .........................7-54

Replace Rubber Crawler .............................7-56

Check Track Sag

(Steel Crawler) (Optional)......................7-58

Check and Replace Seat Belt .....................7-61

Check Air conditioner

(Machine with Cab) ...............................7-62

Clean and Replace Air Conditioner

Re-circulation Filter ...............................7-63

Clean Re-circulation Filter ...........................7-63

Replace Re-circulation Filter .......................7-63

Clean Cab Floor ..........................................7-65

Check Injection Nozzle ................................7-66

Check and Adjust Valve Clearance.............7-66

Check Injection Timing ................................7-66

Measure Engine Compression Pressure ....7-66

Check Starter and Alternator.......................7-67

Check Radiator Cap ....................................7-67

Check Tightening Torque of

Bolts and Nuts .......................................7-68

Check Tilt Mechanism Fulcrum

Bolts for Looseness .....................................7-71

Preparation for Inspection and Maintenance.....7-72

Tilting Floor Down..............................................7-74

CONSUMABLE PARTS LIST....................8-1

MAINTENANCE UNDER SPECIAL

ENVIRONMENTAL CONDITIONS.......9-1

STORAGE

Storing the Machine...........................................10-1

Removing the Machine From Storage...............10-2

TROUBLESHOOTING...............................11-1

SPECIFICATIONS

Specifications.....................................................12-1

Working Ranges ................................................12-6

Shoe Types and Applications ..........................12-11

Bucket Types and Applications .......................12-16

REFERENCE

Additional Counterweight...................................13-1

INDEX..............................................................14-1

CONTENTS

MEMO

.....................................................................................................................................................................................

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:

PRODUCT IDENTIFICATION NUMBER

PRODUCT IDENTIFICATION NUMBER:

NOTE:

∗HCM1M700X00010001∗

PRODUCT IDENTIFICATION

NUMBER (PIN)

M1M7-00-001

M1M7-00-002

Marks to indicate the start and end of the PIN

MACHINE NUMBERS

MEMO

.....................................................................................................................................................................................

SAFETY

S-1

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.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

• NOTE indicates an additional explanation for an

element of information.

SA-1223

SAFETY

S-2

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine

as well as all safety messages in this manual.

• Safety signs must be installed, maintained and replaced

if damaged.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Allow only properly trained, qualified, authorized per-

sonnel to operate the machine.

• Learn how to correctly operate and service the machine.

• Keep your machine in proper working condition.

• Always operate the machine within the specification.

• Unauthorized modifications of the machine may impair the functions and/or safety and affect machine life and the warranty will become void.

• The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every possible hazardous situation you may encounter. If you have any questions concerning safety, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

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 and 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 any fire or accidents which may occur.

• Keep emergency numbers for doctors, ambulance service, hospitals, and fire department posted near your telephone.

SA-437

SAFETY

S-3

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat Safety belt Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of

the operator.

• Do not wear radio or music headphones while operating the machine.

SA-438

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

• If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.

• In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

SA-435

SAFETY

S-4

TIDY UP INSIDE OPERATOR’S SPACE

• Always keep inside the cab clean by observing instruc-

tions below, to prevent any personal accidents from occurring.

• Remove mud and/or oily material from the shoe soles

before entering the operator’s space. If pedals are operated without removing mud or oily matter, the foot may slip off the pedal, possibly creating a hazardous situation.

• Do not leave parts and/or tools around the operator’s

seat.

• Do not keep a transparent water bottle in the cab. The

transparent water bottle may concentrate the sun light like a lens, possibly causing a fire.

• Do not wear radio or music headphones and do not use

a cell phone while traveling or operating the machine.

• Never allow hazardous materials such as combustible

and/or explosive material in the operator’s space.

• Do not leave cigarette lighters in the cab. If the tem-

perature in the cab increases, the lighter may explode.

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the machine.

• Maintain a three-point contact with the steps and handrails.

• Do not use any controls as handholds.

• Never jump on or off the machine. Never mount or

dismount a moving machine.

• In case adhered slippery material such as oil, grease, or mud is present on steps, handrails, or platforms, thoroughly remove such material.

SA-439

SAFETY

S-5

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to mis-operation of the machine.

• The seat should be adjusted whenever the operator for the machine changes.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back firmly against the seat back.

• If not, readjust the seat forward or backward, and check again.

SA-378

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT

• Before rising from the operator’s seat to open/close cab

front 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.

• Before leaving the machine, be sure to first lower the

front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors,

and access covers and lock them up.

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Be sure to remain seated with the seat belt securely fastened whenever operating the machine.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Replace the seat belt at least once every 3 years regardless of appearance

SA-237

SAFETY

S-6

MOVE AND OPERATE MACHINE SAFELY

• Always be aware that there is a potential danger around

the machine while operating the machine.

• 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).

• Before starting to move or operate the machine, sound the travel alarm and horn to alert bystanders.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Locate the signal person so that the operator can always witness the signal person.

• Coordinate the meanings of all safety signs, hand signals and marks before starting the machine. Appoint a person who is responsible to make a signal and/or guidance.

• Never allow any persons or obstacles to enter the machine operation areas.

• Use appropriate illuminations.

SA-1291

SAFETY

S-7

OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the operator's seat.

• NEVER start the engine while standing on the tracks or on ground.

• Do not start engine by shorting across starter terminals. A hazardous situation may be created and/or possible damage to the machine may result.

• Before starting the engine, confirm that all control levers are in neutral.

SA-444

JUMP STARTING

• Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.

• If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter.

• The operator must be seated in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway machine.

SA-032

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

struck by

foreign objects and being thrown off the

machine.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

• Only allow the operator is allowed on the machine. Keep riders off.

SA-1292

SAFETY

S-8

PRECAUTIONS FOR OPERATIONS

• Thoroughly make certain safety at the work site before

starting operations. Especially always observe the following points.

• Be sure to wear close fitting clothing and required

safety items, such as a hard hat, when operating the machine.

• Keep all bystanders and unnecessary objects out of

and away from the machine working areas. Always beware of the surroundings while operating the machine. Take care not to allow the rear part of the upperstructure to come in contact with objects when swinging the machine in a small area.

• When loading a dump truck, bring the bucket from the

rear side of the dump truck to avoid moving the bucket over the dump truck cab or over any co-workers.

M586-12-012

SAFETY

S-9

INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road

shoulder, the machine could tip over due to collapse of the ground, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Never allow bystanders to enter the working area such as swing radius or traveling range.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing may become loose and slippery.

• When operating the machine near open flame, sparks,

and/or dead grass, a fire may easily break out. Use special care not to cause a fire.

• Make sure the work site ground has sufficient strength

to firmly support the machine. When working close to an excavation or on road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear and with the blade at the front, so that the machine can more easily evacuate if the cliff face collapses.

• If working at the bottom of a cliff or on a high bank is

required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work in that area.

• Soft ground may collapse when operating the machine

on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong enough and firm to easily support the machine.

• Note that there is always a possibility of machine tip-

ping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. Operate the machine slowly to ensure safe operation.

SA-1293

M586-05-021

SAFETY

S-10

PROTECT AGAINST FALLING STONES AND DEBRIS

• Confirm that your machine is FOPS cab equipped before

working in areas where the possibility of falling stones or debris exist.

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES

• In case more than one machine is operated in the same

job site, accidental collision between machines may cause serious injury or death.

• For jobs involving multiple numbers of 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 seri-

ous injury or death.

• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position.

• If the travel motors are located towards the front of the

cab, the machine will move in the reverse direction when travel pedals/levers are operated.

SA-1294

SAFETY

S-11

DRIVE MACHINE SAFELY

• Use a signal person when traveling the machine along

road shoulders or in congested areas.

• Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to property.

• Before driving the machine, always confirm that the

travel pedals/levers 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.

• 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 30 degrees or

steeper slopes.

• Be sure to fasten the seat belt.

• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to 300 mm (8 to 12 in) (A) above the ground.

• If machine starts to skid or becomes unstable, imme-

diately lower the bucket to the ground and stop.

• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

• Avoid swinging the upperstructure on slopes. Never

attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.

• If the engine stalls on a slope, immediately lower the

bucket to the ground. Return the control levers to neutral. Then, restart the engine.

• Be sure to thoroughly warm up the machine before

ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

SA-1295

SA-1296

SA-441

SA-442

A

SAFETY

S-12

• Select a travel route that is as flat as possible. Steer

the machine as straight as possible, making small gradual changes repeatedly in direction.

• Check the strengths of bridges and road shoulders

before traveling on them, and reinforce if necessary.

• When the machine is equipped with steel shoes, cover

the road surface with wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer.

• When crossing train tracks, lay wood plates over the

tracks not to allow the machine to ride on only the rails.

• Check that the machine can pass under a bridge and

electric lines before driving the machine.

• When crossing a river, drive the machine slowly while

measuring the depth of the river using the bucket. Do not cross the river when the depth of the river is deeper than the upper track shoe surface.

• Reduce the engine speed when traveling on rough

terrains. Select a slow travel speed. Slower speed will reduce possible damage to the machine.

• Drive the machine so that the travel motors do not

come in contact with loose rocks. If the machine crosses over an obstruction, abnormally large loads may be loaded on the machine. Avoid contact with an obstruction while traveling the machine.

• During freezing weather, always clean snow and ice

from track shoes before driving the machine on snowy and/or frozen roads, or loading and unloading the machine for transportation, to prevent the machine from slipping.

SA-673

SA-1305

M586-05-002

SAFETY

S-13

AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.

• Park the machine in compliance with the safe parking

procedures described on page S-19 to prevent the machine from running away.

• Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park on a grade.

• Park a reasonable distance from other machines.

SA-1297

SAFETY

S-14

AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS

• If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP AND

SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

• Keep the travel alarm in working condition (if

equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

• USE A SIGNAL PERSON WHEN BACKING UP IF

YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person.

• No machine motions shall be made unless signals are

clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings

used on the job and confirm who has the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in good

condition.

• Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the

operator’s manual.

021-E01A-0494-8

SA-383

SA-384

SAFETY

S-15

KEEP PERSON CLEAR FROM WORKING AREA

• If a person is present near the operating machine, the

person may come in contact with the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

• Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

• Make sure that no personnel other than the signal

person or no obstacles are present in the working area before operating the machine.

SA-667

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a

truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

• Never allow the bucket to pass over anyone to avoid

personal injury or death.

SA-668

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 raise the front attachment with a panic. Lowering the front attachment may be safer in most cases.

SA-1300

SAFETY

S-16

AVOID TIPPING

• The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.

To avoid tipping:

• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the

machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than

15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging

loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.

025-E01A-0540-4

SA-1301

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

SA-1302

SAFETY

S-17

DIG WITH CAUTION

• Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging check the location of cables, gas lines,

and water lines.

• Keep the minimum distance required, by law, from

cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed,

do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your

area, and/or the utility companies directly. Have them mark all underground utilities.

SA-672

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the

boom or arm.

SA-673

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 (10 ft) plus twice the line insulator length.

• Check and comply with any local regulations that may

apply.

• Wet ground will expand the area that could cause any

person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

SA-1305

SAFETY

S-18

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop

operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the

machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-1805

DO NOT USE FOR CRANING OPERATIONS

• NEVER use the machine for craning operations. If the

machine is used for craning operations, the machine may tip over and/or lifted load may fall, possibly resulting in serious injury or death.

• This machine has been exclusively designed to engage

in excavation and loading works.

• This machine is not equipped with any of the necessary

safety devices that could allow the machine to be used for craning operation.

SA-014

PROTECT AGAINST FLYING DEBRIS

• If flying debris such as soil, rock fragments or metal

pieces hit eyes or any other part of the body, serious injury may result.

• Guard against such injuries when working in a job site

where possibility of flying pieces of metal or debris exist, or when removing or installing pins using a hammer; wear goggles or safety glasses.

• Keep bystanders away from the working area before

striking any object.

SA-432

SAFETY

S-19

PARK MACHINE SAFELY

• Unless the machine is not correctly parked, any haz-

ardous situations such as running away of the machine or damage by vandalism may result, causing the machine to operate unsafely when the engine is re-started. Follow instructions described below when parking the machine.

• Park the machine on solid level surface to prevent the

machine from running away.

• Lower the bucket and/or blade to the ground.

• Pull the lock lever to the LOCK position.

• Turn the auto-idle switch OFF. Failure to do so may

create a hazarduos condition as the engine speed may unexpectedly increase. (Except ZX27U

-2)

• 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.

• Before leaving the machine, close all 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 ig-

nites, 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.

• Always stop the engine before refueling the machine.

• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flam-

mable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn spon-

taneously.

• Securely tighten the fuel and oil filler cap.

SA-018

SA-019

SAFETY

S-20

SAFETY TRANSPORTING

• The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads.

• Provide an appropriate truck or trailer for transporting

the machine.

• Be sure to have a signal person.

• Take the following precautions when

loading/unloading the machine.

1. Select firm level ground.

2. Be sure to use a loading dock or ramp strong enough to support the machine weight.

3. Ramps must be sufficient in width, length, and strength. Be sure that the incline of the ramp is less than 15 degrees.

4. Loading docks must be sufficient in width and strength to support the machine and have a gradient of less than 15 degrees.

5. Be sure to turn the auto-idle switch (13) OFF. (Except ZX27U

-2)

6. Slowly drive the machine.

7. Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again.

8. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

9. Wedge the front and rear of tracks. Securely fasten the machine to the trailer bed with chain or cables.

10. Do not operate any levers besides the travel levers when driving up or down the ramp.

11. Prevent possible injury from machine tipping while the upperstructure is rotating.

12. Keep the arm tucked under and rotate the upperstructure slowly for best stability.

Refer to "transporting" chapter in this manual for details

SA-1307

ZX27U-2

M1M7-01-031

ZX30U-2, ZX35U-2 ZX40U

-2, ZX50U-2

M1M7-01-028

M1M7-01-033

M1M7-01-032

13

ZX27U

-2 (Canopy)

ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2

(Canopy)

SAFETY

S-21

PRACTICE SAFE MAINTENANCE

• Inspection/maintenance work may produce hazardous

situations by contacting and/or accessing a part of body to a moving, high pressure, and/or high temperature part of the machine. To avoid serious personal injury or death, follow the instructions described below.

• Thoroughly coordinate the working procedures to be

taken hereafter with the co-workers before beginning work such as inspecting/servicing the machine, or replacing the attachiment .

• Safely park the machine in accordance with the

instructions for “Park Machine Safely.”

• Keep the work area clean and orderly.

• Attach a “DO NOT OPERATE” tag in an easy-to-see

location such as on a door or a control lever.

• If moisture permeates into the electrical system,

malfunction and/or erroneous movement of the machine may result. Do not clean sensors, cable connectors, and the cab inside using water and/or steam.

• Wait to begin to work until the engine and hydraulic oil

temperatures have cooled down to the safety range.

• In case inspection/maintenance must be performed

with the engine runnning, be sure to appoint an overseer.

• Never lubricate or service the machine while moving it.

• Repair the cracked windowpane before servicing the

machine. Failure to do so may cause personal injury.

• When raising the machine above the ground using the

front attachment function, maintain the angle between the boom and the arm in the range of 90 to 110°. Never allow anyone to enter under the machine raised with the front attachment function.

• In case working under the machine raised above the

ground is unavoidably required, securely hold the machine with stays or blocks strong enough to support the machine weight.

• Never work under the raised bucket.

• Keep all parts in good condition and properly installed.

• Always use the specified tools correctly.

• Always use a clean tool.

• Fix any damage found immediately. Replace worn or

broken parts.

• Remove any buildup of grease, oil, or debris.

• When cleaning parts, use a non-combustible cleaning

solvent. Never use an inflammable fluid such as dieasel fuel, or gasoline.

SA-028

M1M7-04-006

SA-527

90 to 110°

SAFETY

S-22

• Disconnect battery ground cable (−) before making

adjustments to electrical systems or before welding on the machine.

• 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 mainte-

nance is conducted, the operator’s station is tilted upward. Before conducting maintenance work, refer to page 7-72 in this manual for the detailed operation procedures and correctly operate the machine.

• When required to work under the floor, support the

raised operator’s station with the fall prevention bars (red color) to ensure safety.

• When the inspection/maintenance work is complete,

tilt the operator’s station downward after housing the fall prevention bars. Be sure to slowly lower the operator’s station at the time.

• Be careful not to allow the operator’s station to tilt

down without first stowing the fall prevention bars. Damage to the tilt mechanism may result.

SA-037

M1MW-07-031

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine, attach a

“Do Not Operate” tag in an easy-to-see place such as on the cab door or control lever.

• Never attempt to operate the machine with a “Do Not

Operate” tag attached.

• Make it a rule for the inspection/service person to hold

the engine start key during inspection/service work.

SA-287

SS2045102

SAFETY

S-23

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 with stays or blocks strong enough to support the machine and/or attachment weight.

SA-527

STAY CLEAR OF MOVING PARTS

• Contact with moving parts can cause serious injury or

death due to amputation or entanglement.

• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

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 FITTINGS or

VALVE ASSEMBLIES.

• As pieces of parts may fly off, be sure to keep body

and face away from the valve.

• Travel reduction gears are under pressure.

• As pieces of parts may fly off, be sure to keep body

and face away from AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for gear oil to cool, then

gradually loosen the air release plug to release pressure.

SA-344

SAFETY

S-24

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent

falling accidents.

• Keep children and bystanders away from storage

areas.

SA-034

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

• To prevent possible injury from hot spraying water,

stop the engine. Begine to work after the engine and radiator are sufficiently cooled

• 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 release before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to

release all pressure by slowly removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also becomes hot

during operation. The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-039

SA-225

SAFETY

S-25

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids such as

hydraulic oil or fuel 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 visual inspection alone.

• Periodically replace the rubber hoses.(Refer to the

Periodical Replacement Parts section.)

• Failure to periodically replace rubber hoses may cause a

fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. Make sure that all connectors are completely connected before applying pressure.

• Search for leaks with a piece of cardboard; take care

to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this

type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

SA-292

SA-044

SAFETY

S-26

PREVENT FIRES

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires,

possibly resulting in personal injury or death.

• Check for 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, for oil leaks.

• 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.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)

hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10)

hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are

loose, kinked, etc.

SA-019

SAFETY

S-27

Precautions for Handling Flammables

• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated flammables immediately.

• Don’t store flammable fluid near open flames.

• Don’t burn or crush a pressurerized container.

• Don’t store oily cloths. They are liable to catch fire.

• Don’t wind easy-to-absorb-oil asbestos or glass wool

around high-temperature parts such as a muffler or exhaust pipe.

Check Heat Shield Covers around Engine Compartment

• If the engine compartment heat shield cover becomes

broken or lost, fire may break out.

• If the engine compartment heat shield cover becomes

broken or lost, repair or replace it before operating the machine.

Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate

the fire, hampering fire fighting.

• Always check key switch function before operating the

machine every day:

1) Start the engine and run it at slow idle.

2) Turn the key switch to the OFF position to confirm that the engine has stopped.

• If any abnormalities are found, be sure to repair them

before operating the machine.

SAFETY

S-28

EVACUATING IN CASE OF FIRE

• If fire breaks out during machine operation, evacuate the

machine in the following way:

• Stop the engine by turning the key switch to the OFF

position.

• Use a fire extinguisher if there is time.

• Exit the machine using handrails and/or steps.

• 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 Evacuation Method.

SA-393

(Cab-Equipped Machines)

SS4642980

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must operate the machine in a building, be sure

there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer.

• Depending on the wok site conditions, the risk of in-

haling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

• When operating the machine in a work site where

asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during operation.

Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

SA-029

SAFETY

S-29

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 a fire hazard. 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.

SA-818

AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.

• Remove flammable fluids thoroughly with

nonflammable solvent before welding or flame cutting pipes or tubes that contained flammable fluids.

SAFETY

S-30

REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Remove paint before welding or heating.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.

• Allow fumes to disperse at least 15 minutes after

welding or heating.

• Use attention to the following points when removing

paint.

1.

If you sand or grind paint, avoid breathing the dust which is created. Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper

with soap and water before welding.

3. Remove solvent or paint stripper containers and

other flammable material from area.

SA-029

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 the

electrolyte level is lower than specified. Explosion of the battery may result.

• When a terminal become loose, it may induce sparks.

Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If electrolyte is splashed into eyes, flush your eyes continuosly with water for about 15 minutes. Seek medical attention immediately.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

SA-032

SAFETY

S-31

PRECAUTIONS FOR HANDLING REFRIGERANT

• If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.

• Refer to the precautions described on the refrigerant

container for handling refrigerant.

• Use a recovery and recycling system to avoid venting

refrigerant into the atmosphere.

• Never allow the skin to directly come in contact with

refrigerant.

SA-405

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, electrolyte, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a

hazardous chemical. Then follow the correct procedures and use recommended equipment.

• See your authorized dealer for MSDS.

SA-309

SAFETY

S-32

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.

• When draining fluid, use a leakproof container with a

capacity larger than the drained fluid volume to receive it.

• Do not pour waste onto the ground, down a drain, or

into any water source.

• Inquire on the proper way to dispose of harmful waste

such as oil, fuel, coolant, brake fluid, filters, and batteries from your local environmental or recycling center.

SA-226

SAFETY SIGNS

S-33

All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean. In case a safety sign is broken or lost, immediately, obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to your authorized dealer.

SS3079466

SS-2640

SS4642518

M1M7-03-002

SAFETY SIGNS

S-34

SS-259

SS-2684

SS-2652

SS-024

SS-2639

SS3090482

M1M7-07-021

CANOPY

CAB

SAFETY SIGNS

S-35

SS3088058

SS-2651

M1M7-01-021

SS4433590

SS-2636

SS-2753

CAB

CANOPY

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2

ZX27U-2

SAFETY SIGNS

S-36

SS4604981

SS-2685

SS4642517

SS-2685

SS4430516

SS-2686

SS-2687

ZX27U-2, ZX30U-2, ZX35U-2

ZX40U-2, ZX50U-2

SAFETY SIGNS

S-37

• When using the floor tilt

mechanism, consult your authorized dealer. If bolts

are removed or installed by unauthorized personnel, mismatch to ROPS may occur. Remove bolts

(not covered with resin caps) in the rear section of the operator’s seat. Be careful. When bolts

are removed, the canopy or the cab may come off the floor.

SS4644686

SS4664139

M1M7-07-063

SS-2798

SS4664709

SS-2927

CAB

CANOPY

SAFETY SIGNS

S-38

(Cab-Equipped Machines)

SS4642980

M1M7-01-020

(Cab-Equipped Machines)

SS-1832

M1M7-01-013

(2Way Multi Lever Equipped Machines)

SS4605065

SS-2640

SAFETY SIGNS

S-39

ROPS/TOPS/FOPS Canopy and Cab

• To maintain unimpaired operator protection and manu-

facture’s protective structure

• Damaged Roll Over Protective Structure (ROPS), Tip

Over Protective Structure (TOPS), Falling Object Protective Structure (FOPS) must be replaced, not repaired or revised.

• Any alternation to the ROPS or TOPS or FOPS must

be approved by the manufacturer.

SS3107469

SS3107610

ROPS/FOPS

SS3107593

SS-2651

SS-2652

CANOPY

ROPS/FOPS ROPS/FOPS

CAB

SAFETY SIGNS

S-40

MEMO

.....................................................................................................................................................................................

COMPONENTS NAME

1-1

COMPONENTS NAME

M1M7-01-001

1- Bucket

2- Arm

3- Bucket Cylinder

4- Arm Cylinder

5- Work Light

6- Boom

7- Boom Cylinder

8- Canopy

9- Track Shoe

10- Counterweight

11- Travel Device

12- Track Frame

13- Front Idler

14- Blade Cylinder

15- Blade

16- Boom-Swing Cylinder

8

9

10

11

14

12

16

13

15

1

4

5

6

3 2

7

OPERATOR’S STATION

1-2

PEDALS, LEVERS AND MONITOR PANEL

1- Left Control Lever

2- Left Travel Lever

3- Right Travel Lever

4- Right Control Lever / Horn Switch

5- Blade Lever

6- Key Switch

7- Engine Control Dial

(ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2)

Engine Control Lever (ZX27U

-2)

8- Operator’s Seat

9- Boom Swing Pedal

10- Monitor Panel

11- Pilot Control Shut-Off Lever

12- Door Lock Release Lever

(Cab equipped machine)

13- Switch Panel

14- Tool Box

15- Operator’s Manual Box

16- Attachment Pedal (Optional)

M1M7-01-034

M1M7-01-002

M1M7-01-003

2

3

4

10

8

11

1

9

5

7

13

15

14

12

16

6

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2

2

3

4

1

9

5

7

6

ZX27U

-2

10

13

8

16

15

OPERATOR’S STATION

1-3

17- Air Conditioner Control Panel

(Cab equipped machine)

18- Ash Tray (Cab equipped machine)

19- Radio (AM/FM, Cab equipped machine)

20- Cup Holder

21- Fuse Box

M1M7-01-035

M1M7-01-004

M1LA-01-005

21

20 17 19

18

ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2

2019 18

17

ZX27U

-2

OPERATOR’S STATION

1-4

KEY SWITCH

1- OFF (Engine OFF)

2- ON (Engine ON)

3- START (Engine Start)

4- HEAT (Engine Preheat)

SWITCH PANEL

5- Work Light Switch

Press the top side of switch (5) to turn work lights (9) located on the boom and cab roof front ON. Press the bottom side of switch (5) to turn work lights (9) OFF.

6- Travel Mode Switch

Press the rabbit-mark side of switch (6) to select the fast travel mode. However, when the travel load becomes heavy, the slow travel mode will automatically be selected. Press the turtle-mark side of switch (6) to select the slow travel mode.

7- Wiper Switch (Cab equipped machine)

Three-operation positions are provided on this switch.

OFF: Both the wiper and washer do not operate.

Center: The wiper operates.

WASHER: The washer operates together with the

wiper.

8- Auxiliary Flow Control Switch

(Optional: Except ZX27U

-2)

The hydraulic oil flow in the auxiliary pipe line can be controlled.

M1M7-01-025

M1M7-01-007

M1M7-01-033

M1M7-05-026

M1M7-01-036

M1M7-01-024

6

5

5 6 7 8

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2 (Cab)

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2 (Canopy)

8

9

6 5

ZX27U-2 (Canopy)

6

ZX27U-2 (Cab)

5 7

3

2

1

4

OPERATOR’S STATION

1-5

MONITOR PANEL

1- Coolant Temperature Gauge

2- Fuel Gauge

3- Liquid Crystal Display (Hour Meter, etc)

4- Set Switch

5- Display Control Switch

6- Auto-Idle Indicator (Except ZX27U

-2)

7- Auto-Idle Switch (Except ZX27U

-2)

8- Fast Travel Mode Indicator

9- Preheat Indicator

10- Alternator Indicator

11- Fuel Level Indicator

12- Overheat Indicator

13- Engine Oil Pressure Indicator

14- System Failure Indicator

Coolant Temperature Gauge

The gauge segment position indicates the engine coolant temperature. When the first three segments come ON, the coolant temperature is normal.

NOTE: When the coolant temperature is lower than

20

°

C (68°F), the first segment will flash.

Fuel Gauge

The gauge segment position indicates the fuel level. Refill the fuel before only the E-marked segment comes ON.

NOTE: Even though the key switch is OFF, when the

display control switch is continuously pressed for more than 0.5 seconds, the fuel level is displayed. As long as the display control switch is kept pressed, the gauge indicates the fuel level. When the switch is released, the gauge stops indication the fuel level.

IMPORTANT: In case all segments flash, the machine

is abnormal. Immediately, contact your authorized dealer.

M1M7-01-031

M1M7-01-028

M1SM-05-008

M1SM-01-003

1 2

3

4

5

6

14

13

12

11

10

9

8

7

1 2

3

4

5

14

13

12

11

10

9

8

ZX27U

-2

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2

OPERATOR’S STATION

1-6

System Failure Indicator

The system failure indicator comes ON or flashes an abnormality may be present in the engine control system (optional: Except ZX27U

-2). If the system failure indicator

comes ON or flashes, immediately contact your authorized dealer for repair.

Engine Oil Pressure Indicator

The red indicator will light when the engine oil pressure is low. If the red indicator comes ON, the engine oil pressure warning buzzer will sound at the same time. Immediately stop the engine. Check the engine oil pressure system and the oil level for any abnormality.

Overheat Indicator

If the coolant temperature rises extremely high, this indicator operates. If the red light comes ON, the buzzer sounds at the same time. Immediately stop machine operation and reduce engine speed to the slow idle speed to lower the coolant temperature.

Fuel Level Indicator

When the fuel level indicator comes ON while the machine is operating on level ground, the remaining fuel amount in the fuel tank is as shown in the table below. Refill the fuel as soon as possible.

Model Remaining Fuel Amount

ZX27U-2, ZX30U-2, ZX35U-2 6.5 litters (1.7 US gal) ZX40U-2, ZX50U-2 11 litters(2.9 US gal)

M1M7-01-008

M178-01-037

M178-01-036

M178-01-034

OPERATOR’S STATION

1-7

Alternator Indicator

The red indicator will light when low alternator output is present. Check the electrical system such as the alternator and/or battery system.

Preheat Indicator

When the key switch is turned to the HEAT position, orange indicator will light. Light will turn off after approx. 15 seconds has passed.

Fast Travel Mode Indicator

When the rabbit-mark (fast mode) side of the travel mode switch on the switch panel is pressed, the indicator comes ON.

M178-01-038

M178-01-041

M1M7-01-022

OPERATOR’S STATION

1-8

LIQUID CRYSTAL DISPLAY (LCD), DISPLAY SELECTION SWITCH, AND SET SWITCH

LCD (3) indicates 3 types of meters, Hour Meter, Trip Meter 1 or Trip Meter 2.

NOTE: After the key switch is turned ON, LCD always

indicates the hour meter.

• How to Select Display

Each time display control switch (5) is pressed, LCD alternately displays Hour Meter, Trip Meter 1, and Trip meter 2 in this order.

• Hour Meter Display

The hour meter displays the total accumulated machine operation hours in hour (h) units since the machine started operation. One digit beyond the decimal point indicates tenths of an hour (six minutes). When the hour meter is displayed, the hour meter mark is lit. While the machine is operating, the decimal point flashes.

NOTE: Even though the key switch is OFF, the hour

meter reading can be checked by depressing and holding display selection switch (5) for more than 0.5 seconds. The hour meter reading can be displayed as long as display selection switch (5) is held and disappears as soon as the switch is released.

• Trip Meter Display (Trip Meter 1 and Trip Meter 2)

The remaining hours until the trip mark flashes from the set-hours are indicated in hour (h) unit. (See page 1-9.) As long as the trip meter is displayed, trip mark (TRIP 1 or TRIP 2) lights on the screen.

M1M7-01-031

M1M7-01-028

M1SM-01-005

M1SM-01-006

M1SM-01-007

3

5

3

5

ZX27U

-2

ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2

When Trip meter 1 is displayed

Trip Mark

Hour Meter Mark

When the hour meter is displayed

Hour Meter

Mark

When Trip meter 2 is displayed

Hour Meter Mark

Trip Mark

OPERATOR’S STATION

1-9

HOW TO OPERATE TRIP METER

• Trip Meter Function

The trip meter flashes the trip mark (TRIP 1 or TRIP 2) to inform the operator that the machine operation hours have reached the preset hour. The trip mark continues to flash for 30 seconds when the machine operation hours reach the preset hours. Unless the trip meter is reset, each time when the key switch is turned ON, the trip mark repeatedly flashes for 30 seconds.

IMPORTANT: The trip meter indicates the machine

operation hours which are counted from the time when the trip meter is set. Therefore, the machine operation hours indicated by the trip meter are different from the accumulated operation hours indicated by the hour meter.

NOTE: Once the trip meter has been set, its function is

kept activated even though other types of information is displayed on the LCD afterward. Therefore, when the operation hours reach the preset hours in the trip meter, the trip mark will start flashing regardless of the current LCD operation status. If the trip mark starts flashing when the trip meter is being indicated, the trip mark will stay ON after trip mark stops flashing. In case information other than the trip meter is being indicated on the LCD, the trip mark will be extinguished after the flashing ceases.

• Trip Meter Setting

1. Turn the key switch ON. Display either trip meter 1 or trip meter 2 by operating display selection switch (5).

NOTE: Trip meter 1 and trip meter 2 can be independ-

ently set by different operation hours.

2. Each time set switch (4) is pressed, the set-hour is shifted in the following order: 50>100>150>200>250>300>400>500>750>1000>12 50>1500>2000>2500>3000 Select the desired time to set by operating set switch (4). When the set switch is pressed for more than 2 seconds, the set-hour will be quickly shifted.

3. While displaying the desired time to be set, press display selection switch (5) to set the trip meter.

NOTE: When either trip meter 1 or 2 is set and is kept

displayed on the LCD, the remaining operation hours of the machine are displayed on the LCD until the operation hours reach the set-hour. Accordingly, when the trip mark starts flashing, the trip meter displays 0 hour. Then the trip meter will continue to display the operation overtime from the set-hour with minus (-) mark until the trip meter is reset.

M1M7-01-031

M1M7-01-028

M1SM-01-006

M1SM-01-007

3

4

5

3

4

5

ZX27U

-2

ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2

When Trip meter 1 is displayed

Trip Mark

When Trip meter 2 is displayed

Trip Mark

OPERATOR’S STATION

1-10

• Set Time Change

1. Turn the key switch ON. Display the trip meter you wish to change the set time by operating display selection switch (5). The trip meter will display the remaining time until the trip mark starts flashing at this time.

2. Press set switch (4) once. The remaining time display can be changed as follows:

Present Display Time

Time to be Displayed After

being Changed

35.2 → 50.0

184.7 → 200.0

3. When set switch (4) is pressed further, the set time will be changed as follows each time the switch is pressed. 50>100>150>200>250>300>400>500>750>1000>12 50>1500>2000>2500>3000 When the set switch is pressed for more than 2 seconds, the set-hour will be quickly shifted.

4. After the time you wish to change to, is displayed, press display selection switch (5) to reset the trip meter.

IMPORTANT: Once the set time is changed, the trip

meter restarts counting down the time. Accordingly, note that the displayed time is different from the operation hours counted from the first-set time.

• When no trip meter is used:

When no trip meter is used, set the trip meter for a sufficiently long time (example: 3000 hrs) by following the procedures described above.

NOTE: The trip meters are set at 10000 hours when the

machine is shipped from the factory.

M1M7-01-031

M1M7-01-028

M1SM-01-006

M1SM-01-007

3

4

5

3

4

5

ZX27U

-2

ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2

When Trip meter 1 is displayed

Trip Mark

When Trip meter 2 is displayed

Trip Mark

OPERATOR’S STATION

1-11

AUTO-IDLE SWITCH (Except ZX27U-2)

• Auto-Idle Operation

When pressing auto-idle switch (13), the engine speed is reduced to the slow idle speed approx. 4 seconds after returning all control levers to neutral. Thereby, the fuel consumption is reduced. When the auto-idle mode is selected, auto-idle indicator (14) on the monitor panel lights.

M1CF-01-002

M1M7-01-028

14

13

OPERATOR’S STATION

1-12

AIR CONDITIONER OPERATION

1- Control Panel

2- Right Front Air Vent 1

3- Right Front Air Vent 2

4- Foot Air Vent

NOTE: Control air-flow from right front air vents (1 and

2) by rotating the louver in the horizontal direction so that the air vents can be used as a defroster.

5- Air Conditioner Power Switch

Press air conditioner power switch (5) to turn the power ON.

Controller Part Names and Functions

6- Air Conditioner Switch

Press air conditioner switch (6) to turn the air conditioner and indicator (11) ON.

7- Mode Switch

The air vent location is selected. Each time mode switch (7) is pressed, the mode indicator (10) changes in the order shown below.

Air will blow out from right front vents 1(2) and 2 (3)

Air will blow out from right front vents 1(2) and 2(3), and the foot vent (4).

Air will blow out from the foot vent (4).

8- Temperature Control Switch

The set temperature decreases each time the switch with

mark is pressed, and increases each time

the switch with

mark is pressed.

9- Blower Switch

The blower speed can be adjusted in 3 stages from Slow, Medium, and Fast.

M1M7-01-004

M1M7-01-009

M1M7-01-039

1

2

3

4

7 8 9 5

611 10

OPERATOR’S STATION

1-13

Heating Operation

Although warm air will blow out from all three vents, normally the foot vent is used for heating operation. After selecting the foot vent by operating vent mode switch (7), press temperature control switch (8) to set the temperature indicator toward the right end side. Adjust the inside cab temperature using temperature control switch (8). The blower speed can be adjusted manually using blower switch (9). When air conditioner switch (6) is turned ON during heating operation, air in the cab will be dehumidified.

Cooling Operation

Although cool air will blow out from all three vents, normally the foot vent is used for cooling operation. After selecting the foot vent by operating vent mode switch (7), press temperature control switch (8) to set the temperature indicator toward the left end side. Adjust the inside cab temperature using temperature control switch (8). The blower speed can be adjusted manually using blower switch (9). When air conditioner switch (6) is turned ON during cooling operation, cool air will also blow out from the right front vent.

Defroster Operation

Select the right front vents by operating vent mode switch (7). Adjust the louvers on right front vents 1 and 2 as required. The blower speed can be adjusted manually using blower switch (9). Adjust the inside cab temperature using temperature control switch (8). Turn air conditioner switch (6) ON if the windows become clouded, or if dehumidifying in the cab is required.

M1M7-01-039

M1M7-01-009

2

3

4

7 8 9 5

610

7 8 9 5

610

OPERATOR’S STATION

1-14

TIPS FOR AIR CONDITIONER USAGE

Rapid Cooling

Temperature in the cab may rise over 80°C when the machine is exposed to direct sunlight with the cab windows closed. Under this condition, in case temperature in the cab is required to be rapidly cooled, ventilate air from the cab first by opening the windows. After starting the engine, set the temperature control toward the far left end using temperature control switch (8). Select the right front vent mode. Run the blower at the slow speed position. Turn air conditioner switch (6) ON. After keep the engine running at slightly faster speed (over 1000 min

-1

[rpm]) for a few minutes, increase the blower speed. When the air temperature in the cab is decreased to the atmosphere temperature, close the windows.

If Windows Become Clouded

The windows will become cloudy if the humidity in the cab become high. Operate the air conditioner to keep the windows clear. When the atmosphere is very damp, the outside of the windows may become clouded if the air conditioner is operated for long periods. In this case, stop the air conditioner and/or adjust the air temperature in the cab.

When the air conditioner is not used

When the air conditioner is not used, to protect each part of the compressor from a lack of lubricant, operate the air conditioner at least once a month for several minutes with the engine running at a slow speed. When the cab temperature is lower than 15°C (59 °F), the air conditioner may not operate. In this case, warm the cab inside using the heater first to increase the cab temperature.

IMPORTANT:

• Do not suddenly increase the engine speed,

failure to do so possibly result in damage to the compressor.

• Keep fire hazards away from the control panel.

• Refer to the descriptions in Clean/Replace Air

Conditioner Filter in the Maintenance Section for the maintenance of the air conditioner filters.

M1M7-01-039

7 8 9 5

610

OPERATOR’S STATION

1-15

RADIO (Cab Equipped Machines)

1- Radio/Clock

M1M7-01-004

1

OPERATOR’S STATION

1-16

AM/FM RADIO OPERATION

Part Name and Function

1- Power Switch/Volume Control Knob

Rotate the knob to the right to supply electric power (a click sound will be heard when the unit is turned ON). Rotate the knob further to turn up the volume. Rotate the knob in the reverse direction to turn down the volume and the unit OFF.

2- Tone Control Knob

Rotate the knob to the right to intensify the treble. Rotate the knob to the left to reduce the treble.

3- Display

Time, receiving radio wave frequency, or operation mode is displayed.

4- Clock Button

Press this button to display the time. Repress this button to display the receiving radio wave frequency.

5- Auto-Store/ Scan Preset Button (AST)

Press this button to receive the preset frequency station for every 5 seconds sequentially. While you receive the station you wish to listen to, press this button again to receive the station under normal state (scan is interrupted). Press and hold this button for 2 seconds to automatically store the station.

6- Station Preset Buttons (1 to 6)

One FM and MW (AM) station per button can be preset using these respective buttons.

7- Seek Button

Press this button to automatically seek the next receivable station. When a station is received, the auto-seeking function is deactivated.

8- Band Button

Select FM or MW (AM) by pressing this button. The display indicates the receiving station frequency.

9- Tuning Button

Tap the TUNE ∧ button to increase the frequency. Tap the TUNE ∨ button to decrease the frequency. Tap and hold the button to change the frequency continuously.

Radio Operation

1. Turn the key switch to the ACC or ON position to switch the radio ON.

2. Select either MW (AM) or FM by operating the brand button.

3. Select the station desired to listen using the preset or tuning button.

4. Adjust the volume and tone according to your preference.

5. When turning the radio OFF, rotate the VOL knob to the left until a click sound is heard.

M1M7-01-011

2 6 9

1 3 8 5 7 4

OPERATOR’S STATION

1-17

Tuning Procedure

1. Tap the TUNE ∧ button (9) to increase the frequency. Tap the TUNE ∨ button (9) to decrease the frequency. Tap and hold the button to change the frequency continuously.

2. Automatic Tuning Press this button to automatically move the frequency up and to seek a receivable station. When a station is received, the auto-seeking function is deactivated so that the received frequency station is tuned in.

Station Presetting Procedure

1. Select MW (AM) or FM by pressing BAND button (8). Select a station by pressing either TUNE button (9) or SEEK button (7).

2. Continuously press one of PRESET button (6) by which you desire to preset the station for more than 2 seconds. When presetting is complete, the preset button No. is indicated on the display.

3. Repeat the above same procedure steps (1) and (2) to preset other stations with other PRESET buttons (6).

NOTE: After presetting is complete, if the preset button

is pressed again and held for more than 2 seconds, the preset station is changed.

• Auto-Storing

Press and hold the AST button (5) for more than 2 seconds with the radio switch ON, preset buttons (1 to

6) automatically search receivable frequency stations in the selected frequency band (AM or FM) and memorize each station in one button.

NOTE: When auto-store operation is made, the pre-

ciously memorized stations are deleted. If it is difficult to set the memory of the desired station to the desired button, conduct preset operation.

• Preset Scanning

Press and release the AST button (5) in 2 seconds with the radio switch ON, preset station frequencies are received one by one for 5 seconds. Press the button again to resume normal radio operation.

Deletion of Preset Memory

If the battery power is disconnected such as when the machine is serviced or the radio is removed, the preset memory in the preset buttons will be deleted. Repeat the preset operation again.

M1M7-01-011

2 6 9

1 3 8 5 7 4

2 6 9

1 3 8 5 7 4

OPERATOR’S STATION

1-18

Clock Setting Procedure

In case the frequency is indicated on the display, press the CLOCK button (4) to display the time. While pressing the CLOCK button (4) press TUNE∧M button to change the minute display. While pressing the CLOCK button (4), press TUNE∨H button to change the hour display. Release the CLOCK button (4) to resume the original mode.

CAB DOOR RELEASE LEVER (Cab-equipped machines)

CAUTION: Open the cab door all the way until

the two latches on the side of the cab securely lock.

To unlock the door, push down on lever (1) located on the left side of the operator’s seat.

M1M7-01-012

M1M7-01-003

M1M7-01-027

While pressing CLOCK button

Minute is adjusted

Hour is adjusted

1

Second Latch

First Latch

OPERATOR’S STATION

1-19

OPENING/CLOSING CAB FRONT WINDOW (Cab-equipped machines)

Front Window

1. Disengage lock lever (1) provided at the upper right and left corner of the front window.

2. Hold the handles (in two places) on the front window frame and raise the window until the lock lever engages with the window frame.

CAUTION:

• When closing the front window, slowly lower

the window. Be alert not to pinch your fingers.

• Switch (2) is provided on the front window

frame to prevent the wiper from operating when the front window is opened. Before closing the front window, check that the wiper switch is OFF.

• After opening the front window, check that both

side lock levers are securely engaged in the window frame.

3. When closing the front window, follow the same steps 1 and 2 above in the reverse order.

M1M7-01-013

M1M7-01-014

M1M7-01-015

1

1 1

2

OPERATOR’S STATION

1-20

ADJUSTING OPERATOR’S SEAT

Seat Fore-Aft Adjustment

Operate seat fore-aft slide lever (1). Seat fore-aft position can be adjusted at the interval of 20 mm (0.8 in) in 6 steps (120 mm (5 in) in total).

TOOL AND OPERATOR’S MANUAL BOXES

Tool box (2) (4) and operator’s manual box (3) are located under the operator’s seat, under the floor mat and behind the backrest of the operator’s seat respectively.

M1M7-01-016

M1M7-01-017

M1M7-01-018

1

4 2

3

OPERATOR’S STATION

1-21

EMERGENCY EXIT (cab-equipped machines)

If the operator’s cab door can not be opened in an emergency, escape in the following methods.

1. When required to escape from the cab when the door is difficult or impossible to open in an emergency, open the front window.

NOTE: Refer to the descriptions in OPEN-

ING/CLOSING CAB FRONT WINDOW for the opening method of the front window.

WARNING: Be sure to wear safety glasses when

require to break the windowpane.

2. In case opening the front window is impossible, break the front window glass with emergency evacuation hammer (1) provided on the rear side in the cab to escape through the broken window.

3. If the front window is not available for escaping, break the rear window glass with emergency evacuation hammer (1). Then, escape through the broken window.

NOTE: Emergency exit decal is affixed on the front and

left rear window.

M1M7-01-020

M1M7-01-037

M1M7-01-038

1

Front

Rear

OPERATOR’S STATION

1-22

SEAT BELT (OPTIONAL)

WARNING: Be sure to use the seat belt when op-

erating the machine. Before operating the machine, be sure to examine seat belt (1), buckle (2), or attaching hardware. Replace seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn. Replace seat belt (1) every three years, regardless of appearance.

Seat Belt

1. Confirm that seat belt (1) is not twisted and securely insert the end of seat belt (1) into buckle (2). Lightly pull on the belt to confirm that the buckle latches securely.

2. Adjust tightness of the seat belt (1) so that the belt is snug but comfortable.

3. Push button (3) on buckle (2) to unfasten seat belt (1).

CAB LIGHT (cab-equipped machines)

Move cab light switch (4) to turn the cab light ON or OFF. (The cab light comes ON only when the key switch is turned ON.)

M573-01-014

M107-01-045

M573-01-015

M1M7-01-021

4

1

2 1

3

2

1

BREAK-IN

2-1

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 break-in operation.

The service life and performance of the machine can be greatly affected by operation and maintenance of the machine during the initial stage of operation. Perform break-in operation with the engine output less than 80% of the maximum output for the first 50 hours.

BREAK-IN

2-2

MEMO

.....................................................................................................................................................................................

OPERATING THE ENGINE

3-1

BEFORE STARTING ENGINE

1. Check that pilot control shut-off lever (1) in the LOCK position.

2. Confirm that all control levers are placed in neutral.

3. Check indicator bulbs as follows: Turn key switch (2) to the ON position. All indicator lights and warning lamps will come on. They will stay on for approximately 3 seconds, except for alternator (3) and engine oil pressure (4) indicator, which will continue to stay on further.

IMPORTANT: The monitor panel indicates the machine

operating conditions. If the machine is operated with an indicator bulb or a warning lamp burned out, the alarm will not be displayed even if any abnormality occurs on the machine. Accordingly, in case any of the indicator bulbs or the warning lamps doesn’t come ON, immediately contact your authorized dealer for repair. If any of alternator (3), or engine oil pressure (4) fails to light after indicator light check is completed, the machine may have trouble. Immediately contact your authorized dealer for repair.

4. Adjust the seat position so that all pedals and control levers can be fully stroked to any position when seated in the operator’s seat with the operator’s back kept in contact with the backrest. Fasten the seat belt.

NOTE: The monitor surfaces are resin. Wipe the sur-

face only with a damp cloth when dusty to keep them clean. Never use an organic solvent.

M1M7-03-001

M1M7-01-007

ZX27U-2

M1M7-01-031

ZX30U-2, ZX35U-2 ZX40U

-2, ZX50U-2

M1M7-01-028

2

1

4

3

4

3

OPERATING THE ENGINE

3-2

STARTING ENGINE

Starting in Ordinary Temperature

1. Check that pilot control shut-off lever (1) in the LOCK position.

2. Turn engine control dial (3) or engine control lever (3) to the slow idle position.

3. Sound the horn to alert bystanders.

4. Turn key switch (2) to rotate the starter. The engine will be started.

IMPORTANT: Prevent starter damage and/or battery

over discharge. Never run the starter for more than 20 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

5. Release key switch (2) immediately after the engine has started. It will automatically return to the ON position.

NOTE: The horn sounds even though the key switch is

turned OFF. The engine doesn’t start unless the pilot control shut-off lever is in the LOCK position.

IMPORTANT: Avoid operating key switch (2) with

stained hands or gloves.

M1M7-03-001

M1M7-03-006

M1M7-03-002

M1M7-01-007

2

1

3

ZX30U

-2, ZX35U-2, ZX40U-2, ZX50U-2

3

ZX27U-2

OPERATING THE ENGINE

3-3

Starting in Cold Weather

1. Check that pilot control shut-off lever (1) is in the LOCK position.

2. Turn engine control dial (3) or engine control lever (3) to around the middle between the slow and fast idle positions.

3. Turn key switch (2) to the HEAT position and hold it in that position for approx. 15 seconds until preheat indicator (4) goes OFF.

4. Sound the horn to alert bystanders.

5. As soon as preheat indicator (4) goes OFF, return key switch (2) to the START position to run the starter.

IMPORTANT: Prevent starter damage and/or battery

over discharge. Never run the starter for more than 20 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

6. Release key switch (2) immediately after the engine has started. It will automatically return to the ON position.

NOTE: Set the engine control dial or lever to the fast

idle position to start the engine in an extreme cold weather district. After the engine is started, gradually reduce the engine speed and perform warm-up operation at the medium speed range.

M1M7-01-007

M1M7-03-001

M1M7-03-006

M1M7-03-002

ZX27U-2

M1M7-01-031

ZX30U-2, ZX35U-2 ZX40U

-2, ZX50U-2

M1M7-01-028

1

2

3

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2

4

3

ZX27U

-2

OPERATING THE ENGINE

3-4

CHECK MACHINE AFTER STARTING ENGINE

IMPORTANT: In case any abnormality is found in the

monitor, immediately stop the engine. Trace the cause of the problem.

Check Using the Monitor

After the engine has started, check the following points through the monitor.

1. Check that alternator indicator (3) is OFF. In case alternator indicator (3) stays ON, immediately stop the engine. Then, check the alternator and/or battery system for any abnormality.

2. Check that engine oil pressure indicator (2) is OFF. In case engine oil pressure indicator (2) stays ON, immediately stop the engine. Then, check the engine oil pressure system and/or the oil level for any abnormality.

ZX27U-2

M1M7-01-031

ZX30U-2, ZX35U-2 ZX40U-2, ZX50U-2

M1M7-01-028

2

3

2

3

OPERATING THE ENGINE

3-5

USING BOOSTER BATTERIES

WARNING: An explosive gas is produced while a

battery is in use or being charged. Keep flames or sparks away from the battery area. Park the machine and booster battery machine on a dry, firm or concrete surface, not on steel plates. If the machine and/or the booster battery machine are parked on steel plates, dangerous sparks may be unexpectedly created on the machine. Never connect a positive terminal to a negative terminal, as a dangerous short circuit will occur.

IMPORTANT: The machine electrical system is a 12

volt negative (-) ground. Use only 12 volt booster battery with the capacity enough to start this machine.

When the machine battery is exhausted, start the engine using a booster battery as shown below.

Connecting Booster Cables

1. Stop the engine of the booster battery machine.

2. Connect one end of red cable (1) to the positive (+) terminal of the machine battery and the other end to the positive (+) terminal of the booster battery.

3. After connecting one end of the black cable (2) to the negative (-) terminal of the booster battery, connect the other end to hydraulic oil tank cover hinge (3) on the machine. Be alert to sparks that may be produced in the last connection to the hydraulic oil tank cover hinge.

4. After securely connecting the booster cables, start the engine of the booster battery machine. Run the engine at a middle speed. Then, start the engine of this machine.

5. After the engine is started, disconnect booster cables (1 and 2) following the procedures below.

Disconnecting Booster Cables

1. Disconnect black booster negative (-) cable (2) from hydraulic oil tank cover hinge (3) first.

2. Disconnect the other end of black booster negative (-) cable (2) from the booster battery.

3. Disconnect red booster positive (+) cable (1) from the booster battery.

4. Disconnect red booster positive (+) cable (1) from the machine battery.

M503-03-002

M1LA-03-003

M1M7-03-004

1

2

Connect one end of red cable (1) to the positive (+) terminal

(Red)

Machine Battery

Booster Battery

(Black)

Connect one end of black cable (2) to the machine frame.

3

ZX27U

-2, ZX30U-2, ZX35U-2

ZX40U

-2, ZX50U-2

3

OPERATING THE ENGINE

3-6

STOPPING THE ENGINE

Stop the engine following the steps below.

1. Before stopping the engine, lower the bucket and blade to the ground unless specified.

2. Return the engine control dial or the engine control lever to the slow idle position and keep the engine running at slow idle speed for 5 minutes.

3. Turn the key switch (2) OFF to stop the engine.

4. Pull up pilot control shut-off lever (1) to the LOCK position.

M1M7-01-007

M1M7-03-001

2

1

DRIVING THE MACHINE

4-1

TRAVEL LEVERS AND PEDALS

Travel operation can be performed with either the levers or pedals.

WARNING: In the standard traveling position, the

front idlers are located in front of the operator’s seat and the travel motors at the rear. If the travel motors are positioned at the front of the machine, when the travel levers or pedals are operated in the direction as illustrated on the operation decals, the travel direction of the machine will be reversed. Be sure to confirm the position of the travel motors before traveling.

NOTE: Travel lever dampers are provided for smooth

control. In extremely cold weather (lower than

-20 °C (-68 °F)), the travel lever (or pedal) will become heavy to operate. This is caused by increase in oil viscosity which is not abnormal.

• Forward/Reverse Travel

Move both levers (or pedals) forward together to travel forward. Pull the levers (or pedals) back together to travel in reverse. The travel speed can be controlled by adjusting the lever (or pedal) operating stroke.

• Ascending/Descending Slopes

The machine gradeability is 30° (58%). Slowly operate the travel levers (or pedals) when descending a slope. When the travel levers are placed in neutral, the travel brakes are automatically applied to stop the machine.

NOTE: The travel pedal on this machine is a folding

type. When traveling the machine using the travel pedals, unfold the pedals.

M571-01-001

M1LA-04-001

M1M7-04-010

Front

Left

Operator’s Seat

Rear

Travel Motor

Right

Blade

M1M7-04-011

M104-04-003

Forward/Reverse Travel Direction

DRIVING THE MACHINE

4-2

• Pivot Turn

Steer the machine by driving only one side crawler. Operate either of the travel levers (or pedals).

• Spin Turn

Steer the machine in a position by driving both side crawlers in opposite directions each other. Move one lever (or pedal) forward and pull the other back at the same time.

CAUTION: 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.

M1M7-04-012

M104-04-005

M1M7-04-013

M104-04-007

Pivot Turn

S

p

in Turn

DRIVING THE MACHINE

4-3

TRAVEL MODE SWITCH

WARNING: Never attempt to shift the travel mode

from the slow to fast while descending a slope. Return the travel levers (pedals) to neutral once before shifting the travel mode.

Press the RABBIT mark side on travel mode switch (1) to select the fast travel mode. (The slow travel mode will automatically be selected if the traveling loads increase.) Press the TURTLE mark side on travel mode switch (1) to select the slow travel mode.

WARNING: In cold weather season, when the

machine is traveling with the travel mode switch in the fast travel mode position, the slow travel mode may not automatically be selected even if the traveling loads increase. This symptom is not abnormal. Drive the machine after conducting sufficient warm-up operation.

M1M7-01-033

M1M7-01-032

M1M7-01-036

M1M7-01-024

1

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2

(Canopy)

ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2

(Cab)

1

ZX27U-2 (Canopy)

1

ZX27U-2 (Cab)

DRIVING THE MACHINE

4-4

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

own propelling power. Towing machine may become necessary. Don’t drive the machine to a deeper location than towing machine is possible.

• In case it becomes impossible for the machine to

travel by own propelling power, lower the bucket to the ground. While supporting the machine weight with the boom and the arm, slowly pull the arm to evacuate the machine. Operate the boom, arm, and travel levers simultaneously at this time to prevent the machine from being loaded abnormally.

• If the track frame bottom come in contact with the

ground, or if mud and/or grabbles are tightly packed into the undercarriage, the machine may become impossible to travel. Raise one side track above the ground with the boom and arm extended, remove mud and/or grabbles from the track. Then, evacuate the machine. Rotate the raised track in forward or reverse directions alternately to remove the packed rocks and/or mud from the track.

• Tow the machine with other machine if the machine

becomes stuck in soft ground and impossible to evacuate by own propelling power. Refer to the descriptions for TOWING MACHINE on the next page for the correct rope attaching method.

RAISE ONE TRACK USING BOOM AND ARM

WARNING: Operate the machine carefully. The

machine may slide. Keep the angle between boom and arm 90° to 110° and position the bucket’s round side on the ground.

1. Swing the upperstructure 90°

2. Position the boom and the arm so that the angle between them becomes to 90° to 110°. Push the ground with the round bucket bottom to raise track off ground.

3. Do not raise the track with the boom and the arm when the boom is swung.

M1M7-04-005

M1M7-04-006

90 to 110°

DRIVING THE MACHINE

4-5

TOWING MACHINE

In case it is difficult for the machine to evacuate from a soft terrain by own propelling power, attach wire ropes as illustrated to the right. Tow the machine using another machine. Be sure to attach the wire ropes around the track frames. To prevent the wire ropes from being damaged, place pieces of soft protective material between the wire ropes and the edge corners of the frame.

IMPORTANT: Do not tow the machine using the

light-weight part towing holes provided on the blade. Damage to the towing holes may result.

M104-05-010

Wire Ropes

DRIVING THE MACHINE

4-6

DRIVING IN WATER OR ON SOFT GROUND

1. If the footing is even and the water slow running, the machine can drive in water up to the upper track shoe surface (A) at the top of the front idler. In case the footing is uneven and the water is flowing fast, be careful not to submerge the swing bearing, swing pinion gears, and/or center joint in water or mud.

2. The machine may enter deeper areas gradually. Check the machine’s position often. Reposition the machine if necessary.

IMPORTANT: If the swing bearing, swing gears and

center joint are submerged in water or mud by mistake, premature wearing on parts such as the swing bearing may result. Grease must be changed or overhauling will be required immediately. Stop operating the machine as soon as possible, and contact your authorized dealer.

M1M7-04-004

Machine Model Operable Water Depth (A)

ZX27U-2 480 mm (19 in)

ZX30U-2, ZX35U-2 485 mm (19 in)

ZX40U-2, ZX50U-2 545 mm (21 in)

A

DRIVING THE MACHINE

4-7

PRECAUTIONS FOR TRAVELING ON SLOPES

WARNING: Avoid possible injury from traveling

on slopes. Tipping over or skidding down of the machine may result. Be sure to travel at slow speed on slopes. Never attempt to travel on slopes with the bucket loaded or any load suspended by the bucket.

• Never attempt to ascend or descend 30 degrees or

steeper slopes.

• Be sure to fasten the seat belt.

(Cab equipped machine)

• Keep the bucket pointed in the direction of travel, ap-

proximately 200 to 300 mm (8 to 12 in) (A) above the ground. If the machine skids or becomes unstable, immediately lower the bucket to the ground to stop traveling.

• Traveling across the face of slope or steering on a

slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

• Avoid swinging the upperstructure downhill. The ma-

chine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.

• If the engine stalls on a slope, immediately lower the

blade to the ground. Return the control levers to neutral. Then, restart the engine.

• Be sure to thoroughly warm up the machine before

ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient driving power to ascend may not be obtained.

IMPORTANT: Traveling down a slope in the fast mode

requires a longer time to stop the machine. When traveling down a slope, placing travel mode switch (1) in the TURTLE

position is recommended.

M1M7-04-007

M1M7-04-008

M1M7-01-023

A

1

DRIVING THE MACHINE

4-8

PARKING AND STOPPING ON SLOPES

WARNING: Parking and/or stopping on slopes is

extremely dangerous. Avoid parking and/or stopping the machine on slopes.

If parking and/or stopping on slopes is unavoidable, lower both the bucket and the blade to the ground, and place all levers in the neutral position. Also, put blocks at the downhill end of the tracks.

PARKING ON SLOPES

1. Park the machine on a level, solid surface. Position the arm vertically and lower the bucket and blade to the ground.

2. Turn the engine control dial or the engine control lever to the slow idle position. Run the engine at the slow idle speed for approx. 5 minutes to cool the engine.

3. Turn the key switch to OFF to stop the engine. Remove the key from the switch.

4. Pull pilot control shut-off lever (1) into the fully LOCK position.

5. Close the window and cab door, if a cab is provided. Be sure to lock all the cab doors and windows.

M1M7-04-009

M1M7-03-001

1

OPERATING THE MACHINE

5-1

CONTROL LEVER (ISO EXCAVATOR PATTERN)

WARNING: Be sure to check the location and

function of each control lever before operating. The upper structure and/or front attachment may unexpectedly move when attempting to turn and look behind the machine as a part of operator’s body may come into contact with the control lever(s). Take care not to come into contact with the control levers when turning and looking behind the machine.

Labels showing the lever control pattern are provided on the operator’s right. As illustrated below, the labels indicate the ISO Excavator Pattern.

M588-05-050

When a control lever is released, it automatically returns to neutral, stopping the function in that position.

1- Arm Roll-Out

2- Arm Roll-In

3- Swing Left

4- Swing Right

5- Boom Lower

6- Boom Raise

7- Bucket Roll-In

8- Bucket Roll-Out

M1M7-01-002

M1M7-05-001

M1M7-05-002

4

3

1

2

8

7

5

6

43

2

1

6

5

7

8

OPERATING THE MACHINE

5-2

CONTROL LEVER (H-PATTERN: HITACHI EXCAVATO R PAT T E R N)

WARNING: Make sure to check the location and

function of each control lever before operating. The upperstructure and/or front attachment may unexpectedly move in an attempt to look back because a part of operator’s body may come into contact with the control lever(s). Take care not to come into contact with the control levers when looking back.

Labels displaying the available lever control patterns are provided at the right of the operator. As illustrated below, the labels with H pattern mark at the right bottom corner indicate the HITACHI Excavator Pattern.

M1LA-05-014

When a control lever is released, it automatically returns to neutral, stopping the function in that position.

1- Swing Right

2- Swing Left

3- Arm Roll-Out

4- Arm Roll-In

5- Boom Lower

6- Boom Raise

7- Bucket Roll-In

8- Bucket Roll-Out

M1M7-01-002

M1M7-05-001

M1M7-05-002

4

3

2

1

6

5

7

8

1

2

3

4

8

7

5

6

OPERATING THE MACHINE

5-3

CONTROL LEVER (SAE-BACKHOE PATTERN) --- IF EQUIPPED (2 Way Multi Valve)

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). Take care not to come into contact with the control levers when looking back.

Labels showing the SAE-BACKHOE pattern are provided on the operator’s right.

M1M7-05-028

When a control lever is released, it automatically returns to neutral, stopping the function in that position.

1- Boom Lower

2- Boom Raise

3- Swing Left

4- Swing Right

5- Arm Roll-Out

6- Arm Roll-In

7- Bucket Roll-In

8- Bucket Roll-Out

M1M7-01-002

M1M7-05-001

M1M7-05-002

4

2

3

8

6

7

4

3

1

2

8

7

5

6

1 5

OPERATING THE MACHINE

5-4

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 the pedal to swing right.

3. Turn cover (2) backward over boom-swing pedal (1) when boom-swing operation is no longer required.

3- Swing Left

4- Swing Right

M1M7-05-005

M1M7-05-006

M571-01-001

2

3

4

Unlock Position

1

2

Lock Position

OPERATING THE MACHINE

5-5

AUXILIARY PEDAL (OPTIONAL)

Use the auxiliary pedal (2) located at the operator’s left front, as illustrated to the right, to operate hydraulic breaker, crusher, etc.

Operation

1. Turn auxiliary pedal cover (1) forward.

2. Step on the right or the left side of the auxiliary pedal (2) to operate the front-end attachment such as a hydraulic breaker

3. When the auxiliary pedal (2) is not used, turn cover (1) backward on the pedal.

M1M7-05-007

M1M7-05-008

2

1

OPERATING THE MACHINE

5-6

BLADE LEVER

Use blade lever (1) on the operator’s right to raise and lower the blade. When the lever is released, it automatically returns to neutral, holding the blade in the present position until the lever is operated again.

2- Blade Raise

3- Blade Lower

M1M7-05-009

M1M7-04-004

2

3

2

1

OPERATING THE MACHINE

5-7

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. Failure to do so may result in damage to the blade and the undercarriage.

• When jacking up the machine with this blade, the

surface beneath the blade comes under high pressure, increasing the risk of surface collapse. Always be sure that the surface is strong enough to support the weight of the machine before jacking up the machine. Avoid dangerous uneven distribution of weight to the blade by maintaining even contact between the blade and the ground.

• While digging with the blade positioned in the front of

the machine, take care not to allow the bucket to come into contact with the blade.

• When digging, take care not to allow the boom cylin-

der to come in contact with the blade.

M586-05-016

M586-05-017

OPERATING THE MACHINE

5-8

PILOT CONTROL SHUT-OFF LEVER

The pilot control shut-off lever is a device to prevent the machine from being unexpectedly operated even if the control levers are accidentally moved, such as with a part of the body or when the operator is getting in or out of the operator’s station. 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 and pedal functions,

be sure to pull pilot control shut-off lever (1) and raise console (2) to the fully locked position. To reactivate control lever (3) function, always hold and push pilot control shut-off lever (1) down. Never attempt to lower raised console (2) or control levers (3) to reactivate control lever (3) function without holding pilot control shut-off lever (1).

• Always stop the engine and pull pilot control

shut-off lever (1) to the full LOCK position before exiting the operator’s station, even when exiting temporarily.

• Be sure to move the pilot control shut-off lever

to the LOCK position before exiting the machine after each shift. Pilot Control Shut-off Lever Operation

Before Leaving the Machine:

1. Park the machine on a firm, level surface. Lower the bucket and blade to the ground. Return all control levers to neutral. Stop the engine.

2. To deactivate control lever (3) function, be sure to pull pilot control shut-off lever (1) and raise console (2) to the fully locked position.

Before Starting Operation:

WARNING: Never attempt to lower the raised

console (to reactivate the pilot control shut-off function) by holding and pushing down control lever (3) and/or console (2). Always lower the console using pilot control shut-off lever (1).

Be sure to hold pilot control shut-off lever (1) in LOCK (raised) position when starting the engine. Slowly lower pilot control shut-off lever (1) to UNLOCK position before starting operation. After moving the pilot control shut-off lever to the UNLOCK position, check that no activators move when all control levers and pedals are in neutral before starting operation. If any actuator moves after moving the pilot control shut-off lever (1) to the UNLOCK position with all control levers and pedals in neutral, the machine may be experiencing trouble. Immediately return pilot control shut-off lever (1) to the LOCK position and stop the engine. Contact your authorized dealer for repair.

M1M7-05-010

M1M7-05-011

2

3

Lock Position

Unlock Position

1

OPERATING THE MACHINE

5-9

WARMING UP OPERATION

The normal operating temperature of hydraulic oil is between 50 and 80 °C (122 and 176 °F). Hydraulic compo- nents may be seriously damaged if the machine is operated when the hydraulic oil temperature is below 20 °C (68 °F). Before starting work, be sure to follow these warm-up procedures until the temperature of the hydraulic oil reaches above 20 °C (68 °F).

Warm-Up Procedures:

1. Run the engine at 100 to 200 min

-1

(rpm) above slow

idle speed for 5 minutes.

2. With the engine speed control lever or the engine speed control dial at the medium position, run the engine for 5 to 10 minutes.

3. Extend and retract each cylinder several times and lightly operate the swing and travel motors to warm up them.

WARMING UP IN COLD WEATHER

IMPORTANT: In case the hydraulic oil temperature is

low, never operate the machine until all actuator speeds become normal after warming up operation.

1. Run the engine at intermediate speed for 5 minutes (longer if the air temperature is extremely low).

2. Do not run the engine at either slow or fast speed during this time.

3. Extend and retract each cylinder several times and lightly operate the swing and travel motors to warm up them.

4. Extend the bucket cylinder to the stroke end. Be sure not to hold the bucket lever in this position for more than 30 seconds.

5. Retract the bucket cylinder to the other stroke end. Be sure not to hold the bucket lever in this position for more than 30 seconds.

6. Repeat steps 4 to 5 until the bucket cylinder cycle time becomes normal.

OPERATING THE MACHINE

5-10

AUTO-IDLE CONTROL (Except ZX27U-2)

Auto-Idle Function

During operation, approximately 4 seconds after all control levers have been returned to neutral, this system reduces the engine speed to the auto-idle setting until any control lever is operated again to improve fuel consumption. The engine speed immediately increases to the speed set by the engine control dial when any control lever is operated.

CAUTION:

• Always check if auto-idle indicator (2) is turned

ON or OFF before starting operation. When the indicator is ON, the auto-idle function will operate.

• When any control lever is operated from the

neutral position with auto-idle switch (1) turned ON, the engine speed will increase to the speed set by the engine control dial. Therefore, always be aware of engine control dial setting before starting operation to prevent the engine speed from increasing unexpectedly.

• When unexpected machine movement could be

dangerous, such as when loading/unloading the machine for transportation, or when the machine is engaging in lifting work, turn auto-idle switch (1) OFF to ensure safe operation.

• Use the auto-idle function only after warm-up

operation is complete. Failure to do so may not reduce the engine speed.

Note that the auto-idle function can be turned ON or OFF only when the key switch is in the ON position. Check if the auto-idle function is turned ON or OFF with auto-idle indicator (2).

Auto-Idle Switch

ON: Auto-idle indicator (2) ON. OFF: Auto-idle indicator (2) OFF.

After the key switch is turned OFF when the auto-idle function is activated [with auto-idle indicator (2) ON], when the engine is restarted, the auto-idle indicator flashes for 10 seconds and the auto-idle function becomes activated later.

M1M7-01-028

2

1

OPERATING THE MACHINE

5-11

OPERATING BACKHOE

• Select an arm and bucket whose specifications match

the working conditions. (Refer to “Kinds and Applications of Buckets” in the specification 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 a few times.

• While facing the bucket tooth tip toward the direction

of excavation as straight as possible, excavate the ground with the teeth penetrating shallowly using the arm and bucket cylinder full strokes.

• Position the tracks parallel to the trench. After digging

to the desired depth, move the machine backward to continue the trench.

• Operate each cylinder with a slight allowance left at

both stroke ends.

IMPORTANT:

• Do not dig the ground in the diagonal direction

toward the track frame. Failure to do so may cause the bucket teeth to come in contact with the crawler.

• When lowering the boom, avoid sudden stops

that may create shock load damage to the machine. Always smoothly lower the boom so that shock loads may not be created.

• When digging deep below the ground level, be

careful not to allow boom cylinder, boom bottom, and/or bucket cylinder hoses to come in contact with the ground.

• When digging with the blade positioned to-

wards the front or when digging at an angle, avoid hitting the blade.

• When the bucket load is dumped with the boom

raised, falling material may hit the base machine and/or the canopy. Always be aware of loads in the bucket during operation.

OPERATING THE MACHINE

5-12

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: When grading the ground with the

bucket, do not pull or push dirt with the bucket while traveling the machine like a bulldozer. Every part of machine may receive excessively large loads, possibly resulting in damage to the machine.

When grading by operating the boom, arm, and bucket simultaneously:

1. When grading from the forward to the backward, slowly roll in the arm while slightly raising the boom. As soon as the arm passes the vertical position, slowly lower the boom so that the bucket can be horizontally moved.

2. When grading from the backward to the forward, operated the arm and bucket rolled back, as shown.

Grading a slope surface can be performed by operating the machine in the same method as mentioned above.

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 lifetimes of all front attachment parts may be shortened.

If the bucket teeth are forcedly driven into the ground, the service lifetime of all front attachment parts (especially the bucket) may be severely shortened. When excavating tightly fastened gravelly soil, use the bucket digging out force. Operate the boom, arm, and bucket simultaneously so that the bucket teeth can be effectively penetrated into the excavation surface. Carefully operate the machine to prevent crushed material from spattering, possibly resulting in injury to the operator and/or co-workers around the machine.

AVOID ABUSIVE OPERATION

If digging force is increased by driving the machine while pushing the bucket into the ground, or by raising the rear of the machine to apply the machine weight to the bucket teeth, severe machine damage may result due to excessive overloading.

M1M7-05-012

M1M7-05-013

WRONG

Hitachi ZX27U-2, ZX30U-2, ZX35U-2, ZX40U-2, ZX50U-2 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual