Emcgb 1 2

INTRODUCTION
Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi's support pro-
service your machine correctly. Failure to do so could gram for customers who operate and maintain their
result in personal injury or machine damage. equipment as described in this manual. The warranty is
explained on the warranty certificate which you should
This standard specification machine can be operated have received from your dealer.
under the following conditions without being modified. This warranty provides you the assurance that Hitachi will
Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F) back its products where defects appear within the war-
Altitude: Up to 2000 m (to 6600 ft) ranty period. In some circumstances, Hitachi also provides
field improvements, often without charge to the custom-
In case the machine is used under conditions other than er, even if the product is out of warranty.
described above, consult your nearest Hitachi dealer. Should the equipment be abused, or modified to
change its performance beyond the original factory
This manual should be considered a permanent part of specifications, the warranty will become void and field
your machine and should remain with the machine when improvements may be denied.
you sell it. Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
This machine is of metric design. Measurements in this
manual are metric. Use only metric hardware and tools as Only qualified, experienced operators officially licensed
specified. (according to local law) should be allowed to operate
the machine. Moreover, only officially licensed personnel
Right-hand and left-hand sides are determined by fac- should be allowed to inspect and service the machine.
ing in the direction of forward travel.
PRIOR TO OPERATING THIS MACHINE, INCLUDING
Write product identification numbers in the Machine SATELLITE COMMUNICATION SYSTEM, IN A COUNTRY
Numbers section. Accurately record all the numbers to OTHER THAN A COUNTRY OF ITS INTENDED USE, IT
help in tracing the machine should it be stolen. Your MAY BE NECESSARY TO MAKE MODIFICATIONS TO IT
dealer also needs these numbers when you order parts. If SO THAT IT COMPLIES WITH THE LOCAL REGULATORY
this manual is kept on the machine, also file the identifica- STANDARDS (INCLUDING SAFETY STANDARDS) AND
tion numbers in a secure place off the machine. LEGAL REQUIREMENTS OF THAT PARTICULAR COUN-
TRY. PLEASE DO NOT EXPORT OR OPERATE THIS MA-
Use only diesel fuel with quality specified in JIS K-2204, CHINE OUTSIDE OF THE COUNTRY OF ITS INTENDED
EN-590, ASTM D-975, GOST R52368 or GB252. USE UNTIL SUCH COMPLIANCE HAS BEEN CONFIRMED.
Failure to use diesel fuel with quality as specified above PLEASE CONTACT HITACHI CONSTRUCTION MACHIN-
may allow the engine to emit exhaust gas which clean- ERY CO., LTD. OR ANY OF OUR AUTHORIZED DISTRIBU-
ness can not conform to the requests in various relevant TOR OR DEALER IF YOU HAVE ANY QUESTIONS CON-
regulations. In addition, serious damage to the engine CERNING COMPLIANCE.
may result. Consult with your nearest Hitachi dealer for
detailed information.
Hitachi machine models are classified into 1 model and 1 type as shown in
the table below. When referring to the texts and/or illustrations indicated with
the applicable machine class names in this manual, check that the machine
models concerned are included using this table. Unless specially described, all
models explained in this manual include “F Type”.
Model
Std. Model ZX140W-3, 170W-3, 190W-3, 210W-3
Type
F Type ZX140W-3F, 170W-3F, 190W-3F, 210W-3F
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.
©2008 Hitachi Construction Machinery Co., Ltd.

All rights reserved.
INDEX MACHINE NUMBERS
SAFETY
SAFETY SIGNS
COMPONENTS NAME
OPERATOR’S STATION
BREAK-IN
OPERATING THE ENGINE
DRIVING THE MACHINE
OPERATING THE MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONST
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
OPTIONAL ATTACHMENTS AND DEVICES
INDEX
MACHINE NUMBERS
The manufacturing Nos. explained in this group is the individ-
ual 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
SS3100862
1. Model/Type
2. Homologation Number (Italy only)
3. Vehicle Identification Number MCBB-01-011
4. Operating mass (standard version)

5. Year of Manufacturing
6. Engine power in kW according to ISO9249
VEHICLE IDENTIFICATION NUMBER

VEHICLE
IDENTIFICATION
NUMBER:
M157-12-008
NOTE: Marks to indicate the

start and end of the VIN
∗JK6CGB04200002001∗
Model Code
CE: ZX140W-3
CG: ZX170W-3
CH: ZX190W-3
CJ: ZX210W-3
ZX140W-3 M178-00-002
ENGINE
TYPE:
MFG. NO.:
M178-00-001
ZX170W-3, 190W-3, 210W-3
MACHINE NUMBERS
HYDRAULIC PUMP
TYPE:
MFG. NO.:
ZX140W-3 MCBB-00-001
ZX170W-3, 190W-3, 210W-3 MCBB-00-002

SWING MOTOR
TYPE:
MFG. NO.:
M178-07-086
TRAVEL MOTOR
TYPE:
MFG. NO.:
MCBB-00-003
ZX140W-3
ZX170W-3, 190W-3, 210W-3 MCBB-07-021

MACHINE NUMBERS
TRANSMISSION
TYPE:
MFG. NO.:
MCBB-00-004
ZX140W-3
MCBB-00-007
FRONT AXLE ZX170W-3, 190W-3, 210W-3
TYPE:
MFG. NO.:
ZX140W-3 MCBB-00-008
MCBB-00-005
ZX170W-3, 190W-3, 210W-3
MACHINE NUMBERS
REAR AXLE
TYPE:
MFG. NO.:
ZX140W-3 MCBB-00-006
ZX170W-3, 190W-3, 210W-3 MCBB-07-053

CONTENTS
MACHINE NUMBERS Evacuating in Case of Fire........................................................... S-25
Beware of Exhaust Fumes.......................................................... S-25
SAFETY Precautions for Welding and Grinding.................................. S-25
Recognize Safety Information.....................................................S-1 Avoid Heating Near Pressurized Fluid Lines........................ S-26
Understand Signal Words..............................................................S-1 Avoid Applying Heat to Lines Containing
Follow Safety Instructions.............................................................S-2 Flammable Fluids................................................................... S-26
Prepare for Emergencies................................................................S-3 Remove Paint Before Welding or Heating............................ S-26
Wear Protective Clothing..............................................................S-3 Beware of Asbestos Dust............................................................ S-27
Protect Against Noise.....................................................................S-3 Prevent Battery Explosions........................................................ S-27
Inspect Machine...............................................................................S-4 Service Air Conditioning System Safely................................ S-27
General Precautions for Cab.........................................................S-4 Handle Chemical Products Safely............................................ S-28
Use Handholds and Steps.............................................................S-5 Dispose of Waste Properly.......................................................... S-28
Adjust the Operator’s Seat............................................................S-5
Ensure Safety Before Rising From or SAFETY SIGNS............................................................................... S-29
Leaving Operator’s Seat..........................................................S-5
Fasten Your Seat Belt.......................................................................S-6 COMPONENTS NAME.................................................................. 1-1
Move and Operate Machine Safely............................................S-6
Handle Starting Aids Safety..........................................................S-6 OPERATOR’S STATION
Operate Only From Operator’s Seat...........................................S-7 Cab Features (Standard Model).................................................. 1-2
Jump Starting....................................................................................S-7 Steering Column Console............................................................ 1-3
Keep Riders Off Machine...............................................................S-7 Steering Wheel and Travel Horn Switch.................................. 1-4
Precautions for Operations...........................................................S-8 Accelerator Pedal............................................................................. 1-4
Investigate Job Site Beforehand.................................................S-9 Brake Pedal........................................................................................ 1-5
Equipment of Head Guard, Rops, Fops ................................ S-10 F-N-R Lever........................................................................................ 1-6
Provide Signals for Jobs Involving Multiple Forward/Reverse Travel Switch.................................................. 1-7
Numbers of Machines........................................................... S-10 Combination Switch
Confirm Direction of Machine to Be Driven......................... S-10 (Turn Signal Switch, Light and Dimmer Switches)....... 1-8
Drive Machine Safely.................................................................... S-11 Brake Switch....................................................................................1-11
Avoid Injury From Rollaway Accidents.................................. S-11 Working Brake................................................................................1-12
Avoid Injury From Back-over and Swing Accidents.......... S-12 Auto Axle Lock................................................................................1-12
Keep Person Clear From Working Area.................................. S-13 Hazard Switch.................................................................................1-13
Never Position Bucket Over Anyone...................................... S-13 Operator’s Station.........................................................................1-14
Avoid Undercutting...................................................................... S-13 Engine Control Dial................................................................1-15
Avoid Tipping.................................................................................. S-14 Travel Mode Switch................................................................1-15
Never Undercut a High Bank..................................................... S-14 Engine Speed Control Mode Selection Switch............1-16
Dig with Caution............................................................................ S-15 Power Mode Switch . ............................................................1-17
Operate with Caution.................................................................. S-15 Work Light Switch..................................................................1-18
Avoid Power Lines......................................................................... S-16 Wiper/Washer Switch............................................................1-19
Precautions for Lightning........................................................... S-16 Front Attachment Pilot/Blade/Outrigger Switch........1-20
Object Handling............................................................................ S-16 Auto-idle Switch.....................................................................1-21
Protect Against Flying Debris................................................... S-17 Switch Panel (Optional)........................................................1-21
Park Machine Safely...................................................................... S-17 Travel Alarm Deactivation Switch (Optional)...............1-22
Handle Fluids Safely−avoid Fires............................................. S-17 Swing Alarm Switch (Optional).........................................1-22
Transport Safely............................................................................. S-18 Electric Control Main Switch..............................................1-22
Practice Safe Maintenance......................................................... S-19 Overload Alarm Switch (Optional)...................................1-23
Warn Others of Service Work.................................................... S-20 Revolving Light Switch (Optional)....................................1-23
Support Machine Properly......................................................... S-20 Seat Heater Switch (Optional)............................................1-23
Stay Clear of Moving Parts......................................................... S-20 Key Switch........................................................................................1-24
Prevent Parts From Flying.......................................................... S-21 Right/Left Control Levers............................................................1-25
Store Attachments Safely........................................................... S-21 Lever Switch....................................................................................1-26
Support Maintenance Properly................................................ S-21 Lighter...............................................................................................1-27
Prevent Burns.................................................................................. S-22 Cab Light..........................................................................................1-28
Replace Rubber Hoses Periodically......................................... S-22 Pilot Control Shut-off Lever.......................................................1-29
Avoid High-pressure Fluids........................................................ S-23 Engine Stop Switch.......................................................................1-29
Prevent Fires.................................................................................... S-24 Multi Function Monitor...............................................................1-30
CONTENTS
Basic Screen.....................................................................................1-31 BREAK-IN
Monitor Operation........................................................................1-32 Observe Engine Operation Closely........................................... 2-1
Displaying Basic Screen........................................................1-32 Every 8 Hours or Daily.................................................................... 2-1
Trip Meter (7)............................................................................1-34 After the First 50 Hours................................................................. 2-1
Odometer (8)............................................................................1-34 After the First 100 Hours............................................................... 2-1
Hour Meter (9).........................................................................1-34
Clock (18)...................................................................................1-34 OPERATING THE ENGINE
Fuel Gauge (25).......................................................................1-34 Inspect Machine Daily Before Starting.................................... 3-1
Coolant Temperature Gauge (30).....................................1-34 Before Starting Engine.................................................................. 3-2
Brake Oil Pressure Gauge (33)............................................1-35 Starting the Engine in Ordinary Temperature....................... 3-3
Travel Speed Meter (34).......................................................1-35 Starting in Cold Weather.............................................................. 3-6
Tachometer (35)......................................................................1-35 Starting in Cold Weather (ZX140W-3)...................................... 3-8
Back Monitor Screen Selector (22)...................................1-36 Check Instruments After Starting.............................................. 3-9
Menu Key (23)..........................................................................1-39 Using Booster Batteries...............................................................3-10
Optional Function Keys (24, 27, 29 and 31)...................1-39 Stopping the Engine....................................................................3-12
Return-basic Screen Key (32)..............................................1-39
Menu Screen............................................................................1-42 DRIVING THE MACHINE
Displaying Basic Screen by Inputting Password Traveling............................................................................................. 4-1
(Optional)..................................................................................1-43 Engine Speed Control.................................................................... 4-2
Corrective Measures to be Taken when a Wrong Travel Mode Switch........................................................................ 4-3
Password is input...............................................................1-45 Stopping and Restarting.............................................................. 4-4
Extending Password Validity Time....................................1-47 Instructions for Traveling on a Slope........................................ 4-6
Alarm Occurrence Screen...........................................................1-48 Traveling In Water or On Soft Terrain........................................ 4-7
Clock Setting...................................................................................1-52 Extrication From Soft Ground..................................................... 4-7
Work Mode (Attachment Selection).......................................1-53 Parking................................................................................................ 4-8
Attachment Adjustment Emergency Parking Due to Machine Failure......................... 4-9
(Pump 2 Flow Rate Adjustment).......................................1-57 Travel Alarm (Optional)...............................................................4-10
Operating Status............................................................................1-59
Maintenance Setting....................................................................1-60 OPERATING THE MACHINE
Mail (Optional)................................................................................1-66
Control Lever (ISO Pattern) (Standard).................................... 5-1
Meter Display Control..................................................................1-68
Control Lever (Hitachi Pattern)................................................... 5-2
Password Revising (Optional)...................................................1-70
Pilot Control Shut-off Lever......................................................... 5-3
Back Monitor Setting...................................................................1-73
Steering Wheel Column................................................................ 5-4
Language Setting..........................................................................1-76
Warming-up Operation................................................................. 5-5
Meter Combination Setting.......................................................1-78
Engine Speed Control.................................................................... 5-6
Unit Setting.....................................................................................1-80
Auto-idle . .......................................................................................... 5-7
Fuse Box............................................................................................1-82
Work Mode........................................................................................ 5-9
Additional Fuse Box......................................................................1-82
Power Digging (Only ZX210W-3).............................................5-11
Auto Air Conditioner Operation...............................................1-83
Power Mode ...................................................................................5-12
Tips for Optimal Air Conditioner Usage................................1-90
Parking/Stopping the Machine on a Slope
Heater (Optional) Operation.....................................................1-91
(In Case of Emergency).........................................................5-14
AM/FM Radio Operation . ..........................................................1-95
Raising the Machine Front Above the Ground with the
Digital Clock Setting Procedure...............................................1-96
Boom and Arm Function.....................................................5-14
Cab Door Release Lever..............................................................1-97
Excavation........................................................................................5-15
Opening Upper Front Window.................................................1-97
Face Shovel Operation................................................................5-16
Closing Upper Front Window....................................................1-98
Grading Operation........................................................................5-17
Removing and Storing Lower Front Window......................1-99
Do Not Slam the Bucket Teeth into the Ground.................5-17
Opening Door Windows...........................................................1-100
Do Not Use the Bucket as a Hammer.....................................5-17
Opening/Closing Overhead Window
Avoid Increasing Digging Force Forcibly..............................5-18
(Std. Model)............................................................................1-101
Avoid Using Swing Power..........................................................5-18
Emergency Exit............................................................................1-102
Boom Lowering Procedure in Emergency or
Adjusting the Seat .....................................................................1-103
when the Engine Stalls.........................................................5-19
Seat with a Built-in Heater.......................................................1-104
Overnight Storage Instructions................................................5-21
Adjusting the Air-suspension Seat (Optional)..................1-105
Seat with a Built-in Heater.......................................................1-106
Seat Belt..........................................................................................1-107
CONTENTS
TRANSPORTING Replace Fuel Main Filter Element......................................7-60
Transporting by Road.................................................................... 6-1 Replace Fuel Pre-filter Element ........................................7-61
Loading/Unloading on a Trailer................................................. 6-2 Clean Fuel Solenoid Pump Strainer.................................7-62
Transporting...................................................................................... 6-4 Check Fuel Hoses....................................................................7-63
Unloading.......................................................................................... 6-5 H. Air Cleaner.................................................................................7-64
Towing Machine.............................................................................. 6-6 Clean the Air Cleaner Outer Element..............................7-64
Replace the Air Cleaner Outer and Inner Elements....7-64
MAINTENANCE I. Cooling System.......................................................................7-66
Correct Maintenance and Inspection Procedures............... 7-1 Check Coolant Level..............................................................7-67
Check the Hour Meter Regularly................................................ 7-2 Check and Adjust Fan Belt Tension.....................................7-67
Use Correct Fuels and Lubricants.............................................. 7-2 Change Coolant......................................................................7-68
Layout.................................................................................................. 7-3 Clean Radiator Interior.........................................................7-68
Maintenance Guide Table............................................................. 7-4 Clean Radiator, Oil Cooler Core and Inter Cooler........7-69
Prepare Machine for Maintenance............................................ 7-6
Clean Oil Cooler, Radiator and Inter
Hood and Access Covers............................................................... 7-7
Cooler Front Screen..........................................................7-69
Periodic Replacement of Parts.................................................... 7-8
Clean Air Conditioner Condenser.....................................7-69
Maintenance Guide........................................................................ 7-9
Clean Fuel Oil Cooler ............................................................7-69
A. Greasing.....................................................................................7-15
Clean Air Conditioner Front Screen (Opt.) . ..................7-69
Front Joint Pins........................................................................7-15
J. Electrical System.....................................................................7-70
Swing Bearing..........................................................................7-18
Batteries.....................................................................................7-70
Swing Internal Gear...............................................................7-19
Replace Battery.......................................................................7-73
Front Axle..................................................................................7-20
Remove and Installing Battery..........................................7-74
Propel Shaft (Front and Rear).............................................7-21
Replacing Fuses.......................................................................7-74
Equalizer Pin.............................................................................7-22
K. Miscellaneous .........................................................................7-76
B. Engine.........................................................................................7-23
Check Bucket Teeth................................................................7-76
Engine Oil Level.......................................................................7-23
Change Bucket........................................................................7-78
Change Engine Oil.................................................................7-24
Convert Bucket Connection Into Face Shovel..............7-79
Replace Engine Oil Filter......................................................7-24
Adjust the Bucket Linkage..................................................7-80
C. Transmission.............................................................................7-26
Check and Replace Seat Belt Check.................................7-81
Pump Transmission................................................................7-26
Check Windshield Washer Fluid Level.............................7-82
Swing Reduction Gear..........................................................7-27
Clean and Replace Air Conditioner Filter
Transmission Gear Oil...........................................................7-28
Clean Filter...........................................................................7-83
Front Axle..................................................................................7-29
Replace Filter.......................................................................7-83
Rear Axle....................................................................................7-30
Check the Air Conditioner...................................................7-85
Front and Rear Hub Reduction Devices.........................7-31
Clean Cab Floor.......................................................................7-86
D. Brake (Traveling).....................................................................7-32
Retighten Cylinder Head Bolt............................................7-87
Check Brake Accumulator...................................................7-33
Inspect and Adjust Valve Clearance.................................7-87
Check Wear on Brake Lining...............................................7-34
Measure Engine Compression Pressure.........................7-87
E. Tire...............................................................................................7-35
Check Starter and Alternator.............................................7-87
Tire Inspection and Replacement Procedure...............7-36
Check Tightening Torque of Bolts and Nuts.................7-88
F. Hydraulic System....................................................................7-37
Inspection and Maintenance of
MAINTENANCE UNDER SPECIAL
Hydraulic Equipment.......................................................7-37
ENVIRONMENTAL CONDITIONS
Breaker Maintenance............................................................7-39
Maintenance Under Special Environmental Conditions... 9-1
Check Hydraulic Oil Level....................................................7-40
Change Hydraulic Oil............................................................7-41
STORAGE
Suction Filter Cleaning.........................................................7-41
Storing the Machine.....................................................................10-1
Replace Hydraulic Tank Oil Filter (Std. Model)..............7-45
Removing the Machine from Storage....................................10-2
Replace Pilot Oil Filter...........................................................7-47
Replace Air Breather Element............................................7-48
TROUBLESHOOTING
Check Hoses and Lines.........................................................7-49
Service Recommendations for Hydraulic Fittings......7-52 Troubleshooting............................................................................11-1
G. Fuel System...............................................................................7-54 Engine.........................................................................................11-1
Drain Fuel Tank Sump...........................................................7-55 Engine Auxiliaries...................................................................11-1
Check Water Separator.........................................................7-56 Engine is Hard to Start..........................................................11-2
Control Lever............................................................................11-3
CONTENTS
Hydraulic System....................................................................11-4 OPTIONAL ATTACHMENTS AND DEVICES
Travel...........................................................................................11-5 Blade and Outrigger.....................................................................13-1
Swing..........................................................................................11-8 Maintenance...................................................................................13-5
Engine Speed...........................................................................11-9
Blade/outrigger.....................................................................11-10 INDEX................................................................................................14-1
Others.......................................................................................11-10
SPECIFICATIONS
Specifications (ZX140W-3)
(Standard CHASSIS, REAR BLADE)....................................12-1
(Standard CHASSIS, REAR OUTRIGGER)..........................12-2
(FRONT BLADE REAR OUTRIGGER)...................................12-3
(FRONT OUTRIGGER REAR BLADE)...................................12-4
(FRONT OUTRIGGER REAR OUTRIGGER).........................12-5
Working Ranges
ZX140W-3 MONOBLOCK BOOM.......................................12-6
(Standard GAUGE, Standard CHASSIS, REAR BLADE)......12-7
(Standard GAUGE, Standard CHASSIS, REAR OUTRIGGER) 12-8
(Standard GAUGE, FRONT BLADE REAR OUTRIGGER)....12-9
(Standard GAUGE, FRONT OUTRIGGER REAR BLADE)..12-10
(Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER) 12-11
Working Ranges
ZX170W-3 MONOBLOCK BOOM.....................................12-12
(Standard CHASSIS, REAR BLADE)..................................12-13
(Standard CHASSIS, REAR OUTRIGGER)........................12-14
(FRONT BLADE REAR OUTRIGGER).................................12-15
(FRONT OUTRIGGER REAR BLADE).................................12-16
(FRONT OUTRIGGER REAR OUTRIGGER).......................12-17
Working Ranges
(Standard GAUGE, REAR BLADE).....................................12-19
(Standard GAUGE, REAR OUTRIGGER)...........................12-20
(Standard GAUGE, FRONT BLADE REAR OUTRIGGER)..12-21
(Standard GAUGE, FRONT OUTRIGGER REAR BLADE)..12-22
(Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER) 12-23
Working Ranges
SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001
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 spe-
cific 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 ma- SA-1223
chine.
• NOTE indicates an additional explanation for an element

of information.
002-E01A-1223
S-
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
• Learn how to operate the machine and its controls correctly
and safely.
• Allow only trained, qualified, authorized personnel to oper- SA-003
ate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equip-
ment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003
S-
SAFETY
PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher at
the recommended intervals as specified in the fire extin-
guisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance service,
SA-437
hospital, and fire department posted near your tele-
phone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appropri-
ate to the job.
You may need:

A hard hat
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.
005-E01A-0438
PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.
006-E01A-0434
SA-434
S-
SAFETY
INSPECT MACHINE
• Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435 SA-435
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal ac-
cident.
• Do not leave parts and/or tools lying around the opera-
tor’s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the tem-
perature in the cab increases, the lighter may explode.
524-E01A-0000
S-
SAFETY
USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or dis-
mount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
SA-439
008-E01A-0439
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
misoperations.
• The seat should be adjusted whenever changing the op-
erator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAV-

ING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
• 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.
S-
SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the opera-
tor may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine web-
bing, buckle and attaching hardware. If any item is dam-
aged or worn, replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident. SA-237
• We recommend that the seat belt be replaced every three

years regardless of its apparent condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine. SA-083
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-293
036-E01A-0293-3
S-
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING THE ENGINE” chap-
ter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
S013-E01A-0032
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-091
S-
SAFETY
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M202-05-014
S-
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from fall-
ing 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 excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em- SA-085
ploy a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
• Make sure the work site has sufficient strength to firmly sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
• Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm M202-05-015
enough to easily support the machine.
• Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with ma-
chine movements.
S-
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-686
PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

TIPLE NUMBERS OF MACHINES
• 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.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

• Incorrect steering wheel/forward/reverse pedal operation
may result in serious injury death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when steering wheel is operated to
the front.
SA-092
017-E01A-0491
S-10
SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-
ing wheel/forward/reverse switch 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 over-

SA-090
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 degrees or steep-
er slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket fac-
ing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.
SA-288
AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the ground.
• Place shift switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 min-
utes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
S-11
SAFETY
AVOID INJURY FROM BACK-OVER AND SWING

ACCIDENTS
• If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW SA-383
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 con-
dition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384
decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the
operator’s manual.
021-E01A-0494
S-12
SAFETY
KEEP PERSON CLEAR FROM WORKING AREA

• A person may be hit severely by the swinging front attach-
ment or counterweight and/or may be crushed against an
other object, resulting in serious injury or death.
• Keep all persons clear from the area of operation and
machine movement.
• Before operating the machine, set up barriers to the sides
and rear area of the bucket swing radius to prevent any-
one from entering the work area.
022-E01A-0386
M202-05-014
NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
SA-682
023-E01A-0487
AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.
SA-683
024-E01A-0488
S-13
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the ma-
chine.
SA-088
• 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-E03B-0463
SA-684
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
026-E01A-0519
SA-685
S-14
SAFETY
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-086
027-E01A-0382
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.
028-E01A-0389 SA-087
S-15
SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or front at-
tachments are not kept a safe distance from electric lines.
• When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
• Check and comply with any local regulations that may ap-
ply.
• 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-089
029-E01A-0381
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop op-
eration, 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 repair-
ing them.
SA-1241
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, result-
ing in serious injury or death.
• When using the machine for craning operations, be sure
to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the travel
motors at the rear.
• Move the load slowly and carefully. Never move it sud-
denly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
032-E01A-0132
SA-014
S-16
SAFETY
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, serious
injury may result.
• Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
• Keep bystanders away from the working area before strik-
ing any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place shift switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093
• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY−AVOID FIRES

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

• Store flammable fluids well away from fire hazards. SA-018
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
S-17
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• Select an appropriate truck or trailer for the machine to
be transported.
• Be sure to use a signal person.
• Always follow the following precautions for loading or
unloading:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
machine weight.
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck or
trailer using the front attachment functions when driving
up or down the ramp.
6. Never steer the machine while on the ramp. If the travel-
ing direction must be changed while the ramp, unload
the machine from the ramp, reposition the machine on
the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a Less than 15°
sudden bump. Take care when traveling over it.
SA-095
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the TRANS-

PORTING section.
035-E07A-0454
S-18
SAFETY
PRACTICE SAFE MAINTENANCE

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

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5 min-
utes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving SA-028
the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
• If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
• If the machine must be raised, maintain a 90 to 100˚ angle
between the boom and arm. Securely support any ma-
chine elements that must be raised for service work.
• Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the SA-527
“MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable detergent
oil. Never use highly flammable oil such as fuel oil and
gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520
S-19
SAFETY
• Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
• Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.
• Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SS3076175 SS2045102
SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing
the machine first.
• Always lower the attachment to the ground before you
work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not sup-
port the machine on cinder blocks, hollow tires, or props
that may crumble under continuous load. Do not work
under a machine that is supported solely by a jack.
SA-527
519-E01A-0527
STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
502-E01A-0026
SA-026
S-20
SAFETY
PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
503-E01B-0344
SA-344
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. Keep children and bystanders away from storage
areas.
504-E01A-0034 SA-034
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause seri-
ous injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and exten-sion
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and SA-249
may result in tire explosion.
521-E02A-0249
S-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pres-
sure to be released before removing the cap.
SA-039
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
505-E01B-0498
REPLACE RUBBER HOSES PERIODICALLY

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

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019
S-22
SAFETY
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 disconnect-
ing hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
SA-031
must be surgically removed within a few hours or gan-
grene may result.
507-E03A-0499
SA-292
SA-044
S-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.
SA-019
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
• Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc..
Clean up 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.
Check Key Switch:

• If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the ma-
chine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
S-24
SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following
way:
• Stop the engine by turning the key switch to the OFF
position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• an emergency, if the cab door or front window can not
In
be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab. SA-393
Refer the explanation pages on the Emergency Evacuation
Method.
18-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause sick-
ness or death.
• If you must operate in a building, be sure there is ad-
equate 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.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and pre-
pared area. Store flammable objects in a safe place before
starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
• After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
523-E01A-0818
S-25
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-
surized 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..
AVOID APPLYING HEAT TO LINES CONTAINING SA-030
FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore welding or flame cutting them.
510-E01B-0030
REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area. Dis-
pose of paint and solvent properly.
• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
S-26
SAFETY
BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site. Inha-
lation of asbestos fibers may be the cause of lung cancer.
• Depending on the wok site conditions, the risk of inhaling
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 asbes-
tos 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 SA-029
genuine Hitachi Parts.
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 elec-
trolyte level is lower than specified. Explosion of the bat-
tery may result.
• Loose terminals may produce sparks. Securely tighten all SA-032
terminals.
• Battery electrolyte is poisonous. If the battery should ex-

plode, battery electrolyte may be splashed into eyes, pos-
sibly resulting in blindness.
• Be sure to wear eye protection when checking electrolyte
specific gravity.
512-E01B-0032
SERVICE AIR CONDITIONING SYSTEM SAFELY

• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
S-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your ma-
chine include such items as lubricants, coolants, paints, and
adhesives.
• A Material Safety Data Sheet (MSDS) provides specific de-
tails on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
• Check the MSDS before you start any job using a hazard-
ous chemical. That way you will know exactly what the
risks are and how to do the job safely. Then follow proce-
dures and use recommended equipment.
SA-309
• See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.
515-E01A-0309
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the environ-
ment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
516-E01A-0226
S-28
SAFETY SIGNS/Oceania Model Only
All safety signs and their locations affixed on the machine are
illustrated in this group. Make sure of the contents described
in the safety signs through reading actual ones affixed on the
machine to ensure safe machine operation. Always keep the
safety signs clean. In case a safety sign is broken or lost, imme-
diately, obtain a new replacement and affix it again in position
on the machine. Use the part No. indicated under the right
corner of each safety sign illustration when placing an order of
it to the Hitachi dealer.
3
RIGHT WINDOW
1
18
2
8
19 17
6
10
7
11
4 13
14
12
13
15
16 LEFT DOOR
SS-3106
S-29
1.
WARNING!
Prior to operation, maintenance, disassembling, and trans-
portation of the machine, be sure to read and understand
the Operator’s Manual.
SS-1616
2.
Sign indicates an electrocution hazard if machine is brought
too near electric power lines.
Keep a safe distance from electric power lines.
SS-862
3.
Sign indicates a hazard form falling window.
After raising window, be sure to lock it in place with lock
pins.
SS-863
4.
When moving the seat height/tilt lever downward, press the
lever grip with a palm from the top side. Do not grasp the
lever grip to operate the lever, possibly resulting in pinch of
your fingers into the seat stand.
SS-955
S-30
5.
If the machine should overturn, the operator may become
injured and/or throw from the cab and/or crushed by the
overturning machine.
SS3088058
6.
Do not extend your hands or head from the window. Your
hands or head may come in contact with the boom.
SS-859
7.
SS3111971
S-31
8.
Sign indicates a hazard of being hit by the working device
of the machine.
Keep away from machine during operation.
SS3092349
9.
SS3099277
S-32
10. A
Sign indicates a burn hazard from compressed air and spurt-
ing hot oil if the oil inlet is uncapped during or right after
operation.
Read manual for safe and proper handling.
SS4371799
Sign indicates a burn hazard from spurting hot water or oil if B

radiator or hydraulic tank is uncapped while hot.
Allow radiator or hydraulic tank to cool before removing
cap.
SS-864
11.
Sign indicates a hazard of falling.
Do not stand on this place.
SS3092351
12.
Sign indicates a hazard of falling off the fender or hood.
Never stand close to the edge.
SS3092350
S-33
13.
Sign indicates a crush hazard by rotation of upper structure
of the machine.
Keep away from swinging area of machine.
SS-024
14.
Sign indicates a burn hazard from spurting hot water or oil if
cap.
SS4456963
15.
Sign indicates a hazard of rotating parts, such as belt.
Turn off before inspection and maintenance.
SS3092352
S-34
16.
Sign indicates an explosion hazard.
Keep fire and open flames away from this area.
Skin contact with electrolyte will cause burns. Splashed
electrolyte into eyes will cause blindness. Take care not to
touch electrolyte.
SS-411
17.
SS4467093
18.
SS3114852
19.
SS4701825
S-35
SAFETY SIGNS/Asia/Middle and Near East Model Only
All safety signs and their locations affixed on the machine are
illustrated in this group. Make sure of the contents described
in the safety signs through reading actual ones affixed on the
machine to ensure safe machine operation. Always keep the
safety signs clean. In case a safety sign is broken or lost, imme-
diately, obtain a new replacement and affix it again in position
on the machine. Use the part No. indicated under the right
corner of each safety sign illustration when placing an order of
it to the Hitachi dealer.
4
8 RIGHT WINDOW 1
9 19 7
20 18
11
3
12
5 14
15
13
14
16
17 LEFT DOOR
10
SS-3105
S-36
1.
WARNING!
Prior to operation, maintenance, disassembling, and trans-
portation of the machine, be sure to read and understand
the Operator’s Manual.
SS-1616
2.
If the parked machine is unexpectedly moved, serious injury
or death due to crushing may result. Be sure to lower the
front attachment to the ground, lock the control levers, and
remove the engine key before leaving the machine unat-
tended.
SS4420333
3.
Sign indicates an electrocution hazard if machine is brought
too near electric power lines.
Keep a safe distance from electric power lines.
SS-1613
4.
Sign indicates a hazard form falling window.
After raising window, be sure to lock it in place with lock
pins.
SS-1618
S-37
5.
When moving the seat height/tilt lever downward, press the
lever grip with a palm from the top side. Do not grasp the
lever grip to operate the lever, possibly resulting in pinch of
your fingers into the seat stand.
SS-955
6.
If the machine should overturn, the operator may become
injured and/or throw from the cab and/or crushed by the
overturning machine.
SS4654287
7.
Do not extend your hands or head from the window. Your
hands or head may come in contact with the boom.
SS4459990
8.
SS3111971
S-38
9.
Sign indicates a hazard of being hit by the working device
of the machine.
Keep away from machine during operation.
SS3089581
10.
SS3099277
S-39
11. A
Sign indicates a burn hazard from compressed air and spurt-
ing hot oil if the oil inlet is uncapped during or right after
operation.
SS4459928
Sign indicates a burn hazard from spurting hot water or oil if B

cap.
SS4420336
12.
Sign indicates a hazard of falling.
Do not stand on this place.
SS3092126
13.
Sign indicates a hazard of falling off the fender or hood.
Never stand close to the edge.
SS3092125
S-40
14.
Sign indicates a crush hazard by rotation of upper structure
of the machine.
Keep away from swinging area of machine.
SS-1614
15.
Sign indicates a burn hazard from spurting hot water or oil if
cap.
SS4420336
16.
Sign indicates a hazard of rotating parts, such as belt.
Turn off before inspection and maintenance.
SS3092127
S-41
17. A
Sign indicates an electrical hazard from handing the cable.
SS4459714
B
Sign indicates an explosion hazard.
Keep fire and open flames away from this area.
SS4460067
C
Skin contact with electrolyte will cause burns. Splashed
electrolyte into eyes will cause blindness. Take care not to
touch electrolyte.
SS4460056
18.
SS4467093
S-42
19.
SS3114852
20.
SS4701825
S-43
MEMO
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S-44
COMPONENTS NAME
COMPONENTS NAME 1
1- Bucket Cylinder 2
2- Arm Cylinder
3- Boom 3
4- Boom Cylinder
5
5- Arm 4
6
6- Bucket
7- Cab
8- Center Joint
9- Swing Device
MCBB-01-031
10- Control Valve
19 17
11- Fuel Tank 18
12- Hydraulic Oil Tank 16 20
13- Pilot Filter 7
14
14- Steering Filter
15- Hydraulic Pump
16- Engine
17- Radiator and Oil Cooler
18- Air Cleaner
19- Counterweight
20- Battery
13
21- Blade Cylinder (Optional) 15
10
22- Rear Axle 12
23- Axle Cylinder 11
9
24- Front Axle 8
25- Stabilizer Cylinder (Optional) TCJB-01-02-013
26- Transmission
27- Travel Motor 21
22
NOTE: The typical machine model is illus-

trated to the right. Some portions
may differ on other models. 23
24
Rear
26
27
25
Front
TCJB-01-02-011
1-
OPERATOR'S STATION
CAB FEATURES (Standard Model)

1 2 3 4 5 6
1- Left Control Lever / Horn / Attachment selection Switch
2- Attachment Pedal (Optional)
3- Steering Wheel and Steering Column Console
4- Brake Pedal 7
5- Accelerator Pedal 8
6- Right Control Lever / Attachment Switch
9
Power Digging Switch (ZX210 W-3)
15
7- Multifunction Monitor
8- Blade & Outrigger Lever
23 10
9- Switch Panel
10- Key Switch 11
14
11- Air Conditioner Switch / Heater Switch (Optional)
12
12- FM/AM Radio
13- Operator's Seat
14- Cab Door Lock Release Lever
15- Pilot Control Shut-Off Lever
16- Tray 13
MCGB-01-008
17- Fuse Box
18- Lighter 16
20
19- Switch Panel (Optional) 17
Glove Compartment (When no optional equipment is
equipped) 18
20- Glove Compartment (Hot & Cool Box)
21- Engine Stop Switch 19
22- Swing Lock Lever
23- Hazard Light Switch
M1U1-01-002
22 21 MCGB-01-001
1-
OPERATOR'S STATION
STEERING COLUMN CONSOLE

1- Left Turn Indicator
2- Forward Travel Indicator
3- Right Turn Indicator
4- Neutral Indicator
5- Front Attachment Control Pilot Pressure shut-Off Indica-
tor
6- Reverse Travel Indicator
7- Hazard Light Indicator
8- Travel Mode Indicator 2 MCGB-01-002
9- Auxiliary
1 3
10- Clearance Light Indicator
4
11- High-Beam Indicator
11 5
12- Combination Switch
• Turn Signal Switch 6
• Light Switch
• Dimmer Switch 7
• Passing Switch 10
13- Brake Switch

14- Horn Switch 9
15- Tilt Pedal
16- FNR-Lever 8 TCJB-01-02-004
12
14 13
MCGB-01-003
16
MCGB-01-058 15 MCGB-01-004
1-
OPERATOR'S STATION
STEERING WHEEL AND TRAVEL HORN SWITCH Front
WARNING: When the upperstructure is rotated 180°,

travel and steering control directions are reversed.
Use extra care when traveling. Steering Axle
Knob (3) is located on steering wheel (2). Use knob (3) for one
hand steering or for quick turns.
• Be sure to grip the steering wheel with both hands when

traveling at fast speeds or on rough terrain.
Left Right
• If the engine stalls during traveling, the steering wheel
becomes very heavy to operate due to malfunction of the
steering device. Restart the engine immediately.
• Push horn switch (1) at the left side of the steering column
console to sound the horn.
NOTE: When the upperstructure is rotated 180°, the steering
axle is positioned behind the operator’s cab.
Rear M202-01-003
MCGB-01-002
ACCELERATOR PEDAL
Use extra care when traveling.
Travel speed can be smoothly controlled by operating accel-

erator pedal (4).
4
When accelerator pedal (4) is quickly released during traveling
at a fast speed, the hydraulic brake will emit loud noise. In ad-
dition, the engine speed won’t be reduced immediately. How-
ever, this is a normal symptom of the machine. Quick decelera-
tion is quite hazardous so do try to release accelerator pedal (4)
as smoothly as possible. MCGB-01-004
IMPORTANT: Do not repeatedly step ON/OFF the accel-

erator pedal quickly. Damage to the travel
motors may result.
1-
OPERATOR'S STATION
BRAKE PEDAL
1
WARNING: Be aware of the following points.
· When returning brake pedal (1), don’t quickly re-
lease your foot from the pedal. By failure to do so,
all hydraulic oil in the circuit is discharged, possibly 2
causing the machine to start moving. Use extra
care when operating the brake.
· If brake pedal (1) is repeatedly stepped on/off more
than necessary, the hydraulic oil will be temporari-
ly discharged from the accumulator, causing the oil
pressure to decrease. Therefore, carefully operate
the brake as brake performance may be reduced.
A full-hydraulic brake system is employed on this machine MCGB-01-004

so that powerful braking force is applied by lightly touching
brake pedal (1). Accordingly, only use sudden brake operation
in case of emergency.
1. Operate the brake pedal in the following procedures to

smoothly stop the machine:
3
1.1 Slowly release brake pedal (2) when the machine ap-
proaches 25 to 35 m before the target area to stop.
1.2 Lightly depress brake pedal (1) when the machine ap-
proaches 5 to 6 m before the target area to stop.
1.3 Slightly release brake pedal (1) just before the machine
reaches the target area and re-depress the pedal to
completely stop the machine.
2. In case the brake becomes inoperable, turn brake switch
(3) to the P (parking brake) position to stop the machine. MCGB-01-003
However, only use this operation in case of emergency.
After using this operation, sufficiently check that the
parking brake has no failure.
1-
OPERATOR'S STATION
F-N-R LEVER Front
[Domestic or Asia/Middle and Near East/Oceania Mod-

els]
Steering Axle

Use extra care when travel in.
Change forward/reverse travel direction by operating this Left Right

lever.
When F-N-R lever (1) is operated, corresponding indicator (2,
3, or 4) will come ON.
2- F (Forward)
3- N (Neutral) M202-01-003
Rear
4- R (Reverse)
1. Place F-N-R lever (1) in neutral during machine operation

or when to park or stop the machine.
2. Avoid shifting F-N-R lever (1) to neutral or to the reverse
direction of travel quickly during traveling. In case brak-
ing performance is reduced during traveling, the machine 1
can be stopped by operating F-N-R lever (1) reversely.
However, only use this operation in case of emergency.
NOTE: The engine does not start unless F-N-R lever (1) is in the
neutral position. MCGB-01-058
IMPORTANT: While traveling, do not turn the forward/re-

verse travel switch to neutral or to the oppo-
site direction of travel. Failure to do so may
result in damage to the travel motor.
MCGB-01-002
TCJB-01-02-004
1-
OPERATOR'S STATION
FORWARD/REVERSE TRAVEL SWITCH Front
[European Models]
Steering Axle
Use extra care when travel in.
Change forward/reverse travel direction by operating this

switch.
Left Right
1. Turn forward/reverse travel switch (1) to neutral during
machine operation or when to park or stop the machine.
2. Avoid turning forward/reverse travel switch (1) to neu-
tral or to the reverse direction of travel quickly during
traveling. In case braking performance is reduced dur-
ing traveling, the machine can be stopped by operating
forward/reverse travel switch (1) reversely. However, only
Rear M202-01-003
use this operation in case of emergency.
NOTE: The engine does not start unless forward/reverse travel

switch (1) is in the neutral position.
NOTE: Turn forward/reverse travel switch (1) to [N] position,

when turning key switch OFF. Alarm will activate if
forward/reverse travel switch (1) is kept in [F] or [R]
position.
IMPORTANT: While traveling, do not turn the forward/re-

verse travel switch to neutral or to the oppo-
site direction of travel. Failure to do so may
result in damage to the travel motor.
MCGB-01-013
F (Forward)
N (Neutral)
R (Reverse)
TCJB-01-02-004 MCGB-01-026
1-
OPERATOR'S STATION
COMBINATION SWITCH (TURN SIGNAL SWITCH,

LIGHT AND DIMMER SWITCHES) 1
TURN SIGNAL SWITCH

The turn signal switch is used to indicate the steering direc- A
tion to other vehicles.
Turn signal switch (1) in the (A) position: To make right turn,
turn signal light R (2) lights. B
Turn signal switch (1) in the (B) direction: To make left turn,
turn i signal light L (3) lights.
When the steering wheel is returned in the straight travel

position, turn signal switch (1) automatically returns to neu-
MCGB-01-002
tral.
3 2
TCJB-01-02-004
1-
OPERATOR'S STATION
Light Switch
Light switch (1) has 3 positions. Depending on which switch 1
position is selected, each light comes ON ( ) or goes OFF (×)
as shown below.
License-
Headlight Clearance
Lamp
Tail
Light
Switch
Box Light Plate
Light
× MCGB-01-002
OFF × × × × ×
Equipped
machine 3 3
only
2- Headlight
3- Clearance light / Turn signal light 2 2
4- Tail light, Brake light /Turn signal light / Backup light
5- License plate light
MCGB-01-037
4 4
MCGB-01-059
1-
OPERATOR'S STATION
Dimmer Switch
Use this switch when controlling the high/low headlight
beam position.
CAUTION: Use the low beam position when following 1 High

other vehicles or when other vehicles approach from
the opposite direction.
Low
When light switch (1) is pulled downward with the head-

light ON, the high beam and high beam indicator (2) come
ON. As long as light switch (1) is kept raised, the passing
light (high headlight beam) comes ON regardless of the
light switch position.
MCGB-01-007
TCJB-01-02-004
1-10
OPERATOR'S STATION
BRAKE SWITCH
Brake switch (1) has 4 control positions, OFF (traveling),
(axle lock), auto axle lock, and P (parking).
1
WARNING: Use the axle lock position only when op-
erating the machine. Never use the axle lock position
during traveling. Failure to do so may create danger-
ous situations.
Work Parking Axle

Brake switch position
brake brake lock
OFF (Traveling) OFF OFF OFF
(Released)
MCGB-01-003
• (Axle lock) ON OFF ON

(Applied) 2 2
Auto axle lock ON OFF ON
P (Parking) OFF ON ON
NOTE: The axle lock system locks the front axle. When re-
quired to prevent the front axle from oscillating (such
case as to swing the upperstructure while traveling on
a flat road during operation), turn the brake switch to
the axle lock position. When normally traveling, always
turn the brake switch to the OFF (traveling) position.
Each time brake switch (1) is operated, monitor indicator (2)

displays the icon of axle lock, parking brake, and work brake in
order. Whenever the machine is operated, use brake switch (1) MCGB-01-038
in either the axle lock or auto axle lock position. Do not oper-
ate the machine with the brake switch in the P (parking) posi-
tion. If a control lever is operated with the brake switch in the
P (parking) position, the buzzer sounds. Before turning the key
OFF, turn brake switch (1) to the P (parking) position. Unless
brake switch (1) is in the P (parking) position, the engine is not
started. Even if key switch is turned OFF with brake switch (1)
OFF (traveling), the parking brake is applied to ensure safety.
IMPORTANT: Do not operate the machine with brake

switch (1) in the P (parking). Possibly dam-
age to the parking brake may result.
NOTE: When brake switch (1) is in the OFF (traveling) position,

auto axle lock position, or axle lock position, the engine
does not start.
1-11
OPERATOR'S STATION
WORKING BRAKE
WARNING:
• The work brake is not a parking brake. Do not leave
the machine with the work brake applied.
• Before leaving the operator’s seat, be sure to park
the machine correctly according to the parking
procedures.
(Refer to the PARKING THE MACHINE group in the
DRIVING THE MACHINE section and/or the PARK-
ING THE MACHINE ON SLOPES group in the OPER-
ATING THE MACHINE section.)
This system holds the lock and release of the brake along with
the movement of the Brake Pedal.
“If you press the pedal down once, it holds the brake until the
next time you press the pedal”
Confirm the operating state by the monitor.
Working Brake Operating Condition

Be after Selected either of following item, [Axle Lock] or
[Auto Axle Lock] position.
• Default:
Working brake OFF
• Step brake-pedal to the end-stroke:
Working brake ON
• Step brake-pedal to the end-stroke again:
Working brake OFF
• Above repetition
Confirmation 1
Indicator (S) (1) on Main-Monitor
• Light up: Working brake ON
• Light down: Working brake OFF
AUTO AXLE LOCK

CAUTION: When the accelerator pedal is operated
with the auto axle lock applied, the axle-lock is re-
leased.
Do not use the auto axle lock function when operat-
ing the machine under unsteady conditions.
MCGB-01-062
The axle cylinder automatically locks when you release your

foot from the accelerator.
Axle-lock Operating Condition

Be after Selected [Auto Axle Lock] position
• Release accelerator pedal: Axle cylinder is Locked
(Under 3 km/h Travel-speed)
• Step accelerator pedal: Axle cylinder is Unlocked
1-12
OPERATOR'S STATION
HAZARD SWITCH Armrest
IMPORTANT: The battery power will be reduced if hazard

light switch (1) is kept ON for a long time
without running the engine.
The hazard switch is provided to inform to other vehicles that

this machine is in trouble when the machine fails. Raise the
arm rest to operate hazard switch (1). When hazard switch (1) is
depressed, both right and left turn signal indicators (2), hazard
light indicator (3), and hazard switch stop-side indicator (4) 1
start flashing.
MCGB-01-022
MCGB-01-014
TCJB-01-02-004
1-13
OPERATOR'S STATION
Operator’s STATION
1. Engine Control Dial
2. Travel Mode Switch
3. Engine Speed Control Mode Selection Switch 1
4. Power Mode Switch
5. Work Light Switch
6. Wiper/Washer Switch 2
7. Blade/Outrigger/Front Attachment Control Pilot Shut-off
Switch 3
6 5
8. Auto-Idle Switch
8 7 TCJB-01-02-003
1-14
OPERATOR'S STATION
Engine Control Dial
Turn engine control dial (1) to adjust the engine speed.
Fast Idle
Clockwise : Fast idle
Counterclockwise : Slow idle
Slow Idle
1
M1U1-01-033
Travel Mode Switch 2

Select travel modes, FAST or SLOW by turning travel mode
switch (1) to either position.
Mark (Fast Speed Mode)

Mark (Slow Speed Mode)
When travel mode switch (2) is shifted to the desired mode

MCJB-01-005
position, corresponding travel mode indicator (3) comes
ON.
IMPORTANT: Shifting the travel mode ↔ can

be achieved while the machine is traveling.
During traveling, when the Fast travel mode
is shifting down to the SLOW mode
, the transmission is shifted after the actual
travel speed becomes slower to some extent.
TCJB-01-02-004
3
1-15
OPERATOR'S STATION
Engine Speed Control Mode Selection Switch
The engine speed control mode, pedal, dial, or creeper, is
selected by operating engine control mode selection switch
(1). Depending on machine operating conditions, select the
appropriate engine control mode.
• Pedal Mode
This mode suits normal travel operation best. Adjusting
the stroke of the accelerator pedal controls the engine MCBB-01-024
speed. When the pedal is stepped on, the engine speed
increases. When the pedal is returned to neutral, the
engine speed is reduced. After the engine speed is set
to run at the slow idle speed by fully turning the engine
control dial counterclockwise before traveling the ma-
chine, when traveling is started by stepping the accelera-
tor pedal, the engine speed increases in proportion to
the pedal stroke. When the pedal is returned to neutral to
temporarily stop the machine, the engine speed is re-
duced to the slow idle speed, decreasing fuel consump-
tion and travel noise level.
1
• Dial Mode
This mode suits traveling in the job site best. Only the en-
gine control dial can control the engine speed irrespective
of how much the accelerator pedal is stroked. The engine
speed is kept constant while traveling short distance in the
same job site during operation of the front attachment, no
readjustment of the engine speed is required. However,
the maximum travel speed is slightly slower than the pedal
mode.
• Creeper Mode
The machine can travel at very slow speed. The engine
speed is controlled with the engine control dial only. Even TCJB-01-02-003
if the engine control dial is turned fully clockwise to set the
engine speed to fast idle speed and the accelerator pedal is
fully stepped on, the machine can travel at very slow speed.
1-16
OPERATOR'S STATION
Power Mode Switch
One of three engine speed modes, E, P or H/P mode, can be
selected by operating power mode switch (1).
• E (Economy) Mode
Although production rate slightly decreases than the P
mode, the machine can be operated with less fuel con-
sumption and noise levels.
• P Mode M178-01-013
Operate the machine in this mode when performing normal
work.
• H/P (High Power) Mode

When rolling in the arm while digging deep trenches for
example, more power may be required. In such cases, use
the H/P mode.
1-17
OPERATOR'S STATION
Work Light Switch
After turning light switch (2) on column box (1) to either
2
or position, set the work light switch to the
desired position.
1
Position 1: Work light (3) on the boom and the work
light indicator on the column box come ON.
Position 2: In case optional work light is provided on the

cab, this optional work light will come ON.
Position 3: In case optional work light is provided on the

cab rear section, this optional work light will
come ON. Work light (3) on the boom and the
work light indicator come ON in this case. MCGB-01-016
Position OFF: Work light (3) and the work light indicator go
OFF.
MCJB-01-003
MCBB-01-015
1-18
OPERATOR'S STATION
Wiper/washer Switch
Operate the wiper and the window washer using the wiper/
washer switch. Slow
• Wiper Mid
Turn the wiper/washer switch to the desired position to
Fast
operate the wiper.
OFF position: The wiper stops and is retracted to the origi-

nal position.
INT position: The wiper operates intermittently at the inter-
val selected in three positions as follows:
INT (Slow): The wiper operates at 8-second interval.
MCJB-01-004
INT (Mid): The wiper operates at 6-second interval.
INT (Fast): The wiper operates at 3-second interval.
ON position: The wiper continuously operates.
NOTE: When the upper front window is opened, the wiper

does not operate. If the front window is opened during Wiper
wiper operation, the wiper stops.
• Washer
Press and hold the wiper/washer switch to squirt washer
fluid onto the front window. When the wiper/washer switch
is pressed for more than 2 seconds, the wiper operates until
the switch is released. Then, the wiper automatically retracts
to the original position. While operating the wiper in the INT
mode, when the wiper/washer switch is pressed, the wiper
operation mode is changed to the continuous operation
mode.
IMPORTANT: Washer motor may be damaged if wiper/

washer switch is held for more than 20 sec-
onds, or continually operated with no fluid
in the washer tank.
M1U1-01-018
1-19
OPERATOR'S STATION
Front Attachment Pilot/blade/outrigger Switch
By operating blade/outrigger switch (1), blade/outrigger
operation is controlled. In addition, the front attachment
pilot is regulated to restrict front attachment operation. Pilot Pressure
Shut-off Position
Switch position
1
Front attachment/ Inoperable Operable Operable

swing operation
Blade/outrigger Inoperable Inoperable Operable MCGB-01-021
operation
When front attachment/swing operation are inoperable,

pilot shut-off indicator (2) comes ON.
TCJB-01-02-004
1-20
OPERATOR'S STATION
Auto-Idle Switch
Auto-idle switch (2) sets the engine speed control mode to
Auto-Idle.
• Auto-Idle Mode 2
When auto-idle switch (2) is turned to the A/I ON posi-
tion, the engine speed is reduced to slow idle speed 4
seconds after releasing all control levers (neutral), reduc-
ing the fuel consumption. When the auto-idle mode is
MCBB-01-043
selected, auto-idle indicator (3) on the multi monitor
3
panel lights. The auto-idle indicator flashes for 10 sec-
onds when the key is turned ON.
MCGB-01-038
Switch Panel (Optional)

NOTE: The optional switch position may differ depending on Armrest
the kinds of the optional attachment to be installed.
Use the optional switch after checking the kinds of the
installed optional attachment. Operate the optional
switch after raising the armrest. The following kinds of
optional attachment switches are provided. However,
the type of the installed optional attachments will dif-
fer according to the market requirements.
• Travel alarm deactivation switch

• Swing alarm switch Optional Switch
• Electric control main switch
• Overload alarm switch
MCGB-01-022
• Revolving light switch
• Seat heater switch
1-21
OPERATOR'S STATION
Travel Alarm Deactivation Switch (Optional) 1
The travel alarm buzzer sounds during traveling operation.
Press ( ) side on travel alarm deactivation switch (1) to
stop the buzzer.
M1U1-01-035
Swing Alarm Switch (Optional)
2
The swing alarm sounds the buzzer and rotates the revolv-
ing light during swing operation. Press ( ) swing alarm
switch (2) to stop the buzzer.
Electric Control Main Switch M1U1-01-036

The electric control main switch activates the assist circuit
flow control valve so that the pilot flow rate is adjusted. 3
Press ( ) side on electric control main switch (3) to use the
grip switch. When not required to use the grip switch, press 2 0 1
( ) side on electric control main switch (3) to prevent
misoperation.
1: When the assist flow valve is provided, the assist circuit

flow rate control valve (optional) restricts the pilot flow MCGB-01-017
rate so that the attachment connected to the assist circuit
(optional) is slowly operated.
0: Assist is deactivated (OFF)
2: The attachment connected to the assist circuit (optional)
is operated at fast speed.
1-22
OPERATOR'S STATION
Overload Alarm Switch (Optional)
4
Turn overload alarm switch (4) ON to sound the buzzer and
light the overload warning indicator (5) on the multi moni-
tor when overload is detected during lifting work. When not
required to sound the overload alarm buzzer, turn overload
alarm switch (4) OFF.
5 M1U1-01-010
MCGB-01-038
Revolving Light Switch (Optional)
Turn revolving light switch (6) ON to rotate the revolving 6
light on the top of the cab.
M1U1-01-012
Seat Heater Switch (Optional)

7
Turn seat heater switch (7) ON to warm the seat. When the
heat temperature becomes to the specified temperature,
heating is automatically stopped.
M1U1-01-011
1-23
OPERATOR'S STATION
KEY SWITCH
1- OFF (Engine OFF) 1 2 3 4
2- ACC (Horn, Radio etc.)

3- ON (Engine ON)
4- START (Engine Start)
M178-01-049
1-24
OPERATOR'S STATION
RIGHT/LEFT CONTROL LEVERS

6 4 3 1
[Domestic or Asia/Middle and Near East/Oceania Mod-
els] 5 2
Various kinds of switches are provided on the top of each
control lever.
1- Attachment switch (Assist control)

2- Power digging (Only ZX210W-3 Models)
3- Attachment switch (Assist control)
4- Auxiliary MCGB-01-034 MCGB-01-034
5- Horn Left Control Lever Right Control Lever
6- Auxiliary
[European Models]
6 1
1- Auxiliary 4 3
2- Power digging (Only ZX210W-3)
5 2
3- Attachment analog switch (Assist control)
4- Auxiliary (Analog switch)
5- Auxiliary pedal selection switch (Attachment)
6- Auxiliary pedal selection switch
(Positioning, 2-piece boom spec only)
7- Forward/reverse travel switch
MCGB-01-029 MCGB-01-030
8- Horn
Left Control Lever Right Control Lever
for European Models for European Models
7
8
MCGB-01-031 MCGB-01-032
Back Face of the Left Control Back Face of the Right Control
Lever for European Models Lever for European Models
1-25
OPERATOR'S STATION
LEVER SWITCH
The following kinds of lever switches are provided.
· Power digging (Only ZX210W-3 Models)
· Horn
· Attachment switch (Assist control)
• Power digging (Only ZX210W-3 Models)

Increases the maximum digging force as long as the switch
is kept pressed (for approx. maximum 8 seconds).
• Horn
Continuously sounds as long as the switch is kept pressed.
• Attachment switch (Assist control) 1
Mainly operates a rotary or tilting type optional attachment.
The attachment is activated as long as the switch is kept
pressed. 2 0 1
NOTE: When required to use each lever switch, press the

side of electrical control main switch (1) to activate the
electrical control switches (grip switches).
MCGB-01-017
1-26
OPERATOR'S STATION
LIGHTER
Operation
1
IMPORTANT: In case the lighter doesn’t pop out automati-
cally 30 seconds after pushing the lighter in,
pull out the lighter manually. Then, consult
the your nearest Hitachi dealer.
1. Turn key switch (1) to the ACC or ON position.

2. Press and release the lighter knob.
3. The lighter knob will return to the original position
when the lighter becomes usable. Pull the lighter out
M178-01-049
to use.
4. After using the lighter, insert the lighter into the panel
until the knob is seated in the original position.
Lighter
Using Lighter Port as External Power Source

Use the lighter port to supply power to some equipment Left Control Lever
such as lighting equipment for servicing the machine.
IMPORTANT: Only 24 V electric power is available from the

lighter port on this machine. Never connect
accessories that use power other than 24
V. Damage to the batteries and accessories
may result. M1U1-01-021
Don’t supply power to accessories for a long
time without running the engine. Failure to
do so may discharge the batteries.
1. Pull the lighter knob out.

2. Correctly insert the accessory socket into the lighter
port.
3. Turn key switch (1) to the ACC or ON position. Power is
supplied to the connected accessory.
4. After using the accessory, disconnect the accessory
socket and insert the lighter knob into the port.
1-27
OPERATOR'S STATION
CAB LIGHT
Turn the cab light ON or OFF by operating switch (1) provided 1
beside the cab light.
ON position: The cab light comes ON. (The cab light stays
OFF when the key switch is OFF.)
OFF position: The cab light goes OFF.
DOOR position: The cab light comes ON or goes OFF in con-
nection with opening or closing the cab door.
30 seconds after the door is kept open, the
cab light automatically goes OFF.
(Even when the key switch is OFF, the cab light
comes ON.)
M1U1-01-022
CAB LIGHT
ON
OFF
DOOR
MCGB-01-023
INSTALLING FIRE EXTINGUISHER (Optional)

A fire extinguisher can be installed at the left rear corner inside
the cab. Consult your nearest HITACHI dealer for installing a fire
extinguisher.
Fire Extinguisher M1U1-01-023
1-28
OPERATOR'S STATION
PILOT CONTROL SHUT-OFF LEVER

1
Pilot control shut-off lever (1) prevents the machine from be-
ing mistakenly operated even if an operator unintentionally
touches the control lever when the operator is getting on or
off the machine.
WARNING:
• Be sure to fully pull shut-off lever (1) to the LOCK
position when shutting off the pilot control pres-
sure. The pilot control pressure will not be shut-off
unless pilot control shut-off lever (1) is completely
pulled-up to the LOCK position.
• Before leaving the operator's seat, always stop the
engine and pull the pilot control shut-off lever up LOCK Position MCGB-05-001
to the LOCK position.
• Also, pull the pilot control shut-off lever up to the
LOCK position when transporting the machine or
when the day's work is complete.
• Confirm that the pilot control shut-off lever is in
the LOCK position before starting the engine. The
engine is not started unless pilot control shut-off
lever (1) is in the LOCK position.
• Even though the console is pushed down, the pilot
control shut-off lever is not lowered. Be sure to
operate the lever by holding the lever grip.
1 UNLOCK Position MCGB-05-002
ENGINE STOP SWITCH

If the engine does not stop when the key switch is turned to
the OFF position, (due to a machine or key switch malfunc-
tion), push switch (6) located on the left side of the seat stand
all the way down to the stop. The engine will stop. After using
switch (6), pull the switch up to the raised position.
6 MCGB-03-002
1-29
OPERATOR'S STATION
MULTIFUNCTION MONITOR
Function
The multifunction monitor on this machine functions as fol-
lows:
1. Displaying various kinds of meters and indicators
2. Operating TEN- key lock function
3. Setting the back monitor
4. Selecting work mode
5. Control of maintenance data
Screen
The monitor screen is organized as shown below. The main
menu screen consists of 12 kinds of individual function
screen.
Basic Screen Main Menu Screen Clock Setting Clock adjustment
ATT Mode Adjusting attachment specification

Selection
Operating Displaying operating status such as operating hours, fuel

Status consumption and average fuel consumption rate
Maintenance Maintenance item setting, Maintenance information ON/

Setting OFF function, Change interval setting
Work Mode Attachment selection
Mail Sending/receiving mail
HOUR↔ODO↔TRIP Meter display control
Password A Password revising

Revising
Back Monitor Auto activation setting

Setting
Language Language selection
km/h↔min-1 Meter combination setting
km↔Mile Unit setting
1-30
OPERATOR'S STATION
BASIC SCREEN
1- Work mode indicator
7
2- Auto-idle indicator
8
3- Overload alarm indicator (Optional)
1 2 3 4 5 6 9
4- Auto-axle lock indicator
10
5- Auxiliary
11
6- Preheat indicator
7- Trip meter 12
8- Odometer 13
9- Hour meter
10- Parking brake indicator 14
11- Work brake indicator 15
12- Axle lock indicator 16
33
13- Work light indicator 17
14- Auxiliary 1 (Attachment)
selection indicator 32
15- Blade/Outrigger/
Brake status indicator
19 18
16- Mail indicator (Optional)
20
17- Clock
18- Trip meter indicator
19- Odometer indicator MCGB-01-039
31 30 29 28 27 26 25 24 23 22 21
20- Hour meter indicator
21- Back monitor screen selector
22- Menu key
23- Meter display selector
24- Fuel gauge
25- Auxiliary
26- Mail selector (Optional) 34
27- Work mode display indicator
28- Auxiliary selector
29- Coolant temperature gauge
30- Work mode selector
31- Return-to-basic screen key
32- Brake oil pressure gauge
33- Travel speed meter
34- Tachometer
MCGB-01-040
1-31
OPERATOR'S STATION
MONITOR OPERATION
Displaying Basic Screen
IMPORTANT: Start the engine after displaying the basic
screen.
When the key switch is turned ON, the starting screen is

displayed for about two seconds and the basic screen is
displayed in series.
Key Switch ON (Starting screen)

T1V1-05-01-115
Basic Screen MCGB-01-041
IMPORTANT: After the engine starts, the alternator indica-

tor is displayed on the basic screen until the
alternator starts generating power.
Alternator
Indicator
MCGB-01-042
1-32
OPERATOR'S STATION
• Displaying meters 7
Items to be displayed
7- Trip meter
8- Odometer
18
9- Hour meter
18- Clock
25- Fuel gauge
30- Coolant temperature gauge
33- Brake oil pressure gauge
34- Travel speed meter 34 33 30 25 MCGB-01-043
35- Tachometer 8
MCGB-01-044
MCGB-01-038
MCGB-01-040
35
1-33
OPERATOR'S STATION
Trip meter (7)
After the trip meter is selected with key F4, the travel dis-
tance is displayed in the unit of “km.”
MCGB-01-010
Odometer (8)
Total (accumulated) travel distance since the machine stated
traveling is displayed in the unit of “km.”
MCGB-01-011
Hour meter (9)

Total (accumulated) machine operation hours counted since
the machine started working, are displayed in the unit of
“Hour.” One digit after the decimal point indicates the tenth
of an hour (6 minutes). MCGB-01-012
Clock (18)
Indicates the present time.
M1U1-01-040
Fuel gauge (25)

The fuel amount in the fuel tank is indicated. Refuel before 30 25
the needle reaches “E.”
Coolant temperature gauge (30)

Indicates the engine coolant temperature. Normally the
needle displays about center during operation.
MCGB-01-041
1-34
OPERATOR'S STATION
Brake oil pressure gauge (33) 34 33
Indicates the oil pressure in the brake oil pressure circuit.
Travel speed meter (34)

Indicates the machine travel speed.
NOTE: While setting other functions on the monitor unit,

when the machine travels forward, the basic screen is
displayed.
MCGB-01-041
Tachometer (35) 35
Indicates the engine speed.
NOTE: According to setting operation, either travel speed

meter (34) or tachometer (35) is displayed.
MCGB-01-045
1-35
OPERATOR'S STATION
• Indicators
Items to be displayed 1 2 3 4 6 10 11 12
1- Work mode
2- Auto-idle 13
3- Overload alarm
4- Auto-axle lock
5- Preheat
14
10- Parking brake
15
11- Work brake
12- Axle lock
13- Work light
14- Auxiliary 1 (attachment) selection
15- Blade/Outrigger/Brake status
MCGB-01-043
• Work mode indicator (1)

Selected attachment is displayed.
Digging mode
T1V1-05-01-108
Attachment mode
Breaker
T1V1-05-01-104
Pulverizer
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibration hammer
T1V1-05-01-107
Other
T1V1-05-02-003
1-36
OPERATOR'S STATION
• Auto-idle indicator (2)

Is displayed when the auto-idle switch on the switch panel 2 3 4 10 11 12
is turned ON. In addition, this indicator flashes for 10 sec-
onds after the key switch is turned ON.
• Overload alarm indicator (3)
TCJB-05-02-061
Displays the alarm when the boom cylinder bottom pres-

sure sensor detects overloading.
• Auto-axle lock indicator (4)

Is displayed when the brake switch is turned to the auto-
axle lock position. MCGB-01-038
• Parking brake indicator (10)

Comes ON in red when the parking brake is activated. [Brake
switch: P (parking) position]
• Work brake indicator (11)

Comes ON in red when the work brake is activated.
• Axle lock indicator (12)

Comes ON in red when the axle lock is activated. [Brake
switch: Axle lock or auto-axle lock position]
NOTE: When the front attachment control levers are in neutral

with the brake switch in the auto-axle lock, auto-axle
indicator (4) and axle lock indicator (12) come ON. At
this time, when the accelerator pedal is stepped on, the
axle lock is released by the auto-axle control system,
turning axle lock indicator (12) OFF. However, auto-
axle lock indicator (4) is kept ON as the brake switch is
in the auto-axle lock position.
1-37
OPERATOR'S STATION
• Work light indicator (13)

Comes ON in green when the work light switch is turned 14
ON.
• Auxiliary 1 (attachment) selection indicator (14) 13

Comes ON in green when the auxiliary/positioning selector 15
is set in the auxiliary (attachment) position.
• Blade/Outrigger/Brake status indicator (15)

Displays the combination of the blade and the outrigger. In
addition, activated parking brake or work brake is indicated
in green. The blade and/or outrigger selected by operating
the selector [19-switch panel (optional) shown on page 1-2]
is indicated in green. MCGB-01-038
NOTE: The illustrations show a machine equipped with the

front stabilizer and rear blade as an example.
Lights in Green
When the parking brake is activated

TCJB-05-02-074
Lights in Green
Lights in Green
When the work brake is activated

TCJB-05-02-075
Lights in Green
Lights in Green
When the blade/outrigger are activated

TCJB-05-02-102
1-38
OPERATOR'S STATION
• Key function
Items to be displayed
22- Back monitor screen selector
23- Menu key
24- Optional function (Optional)
27- Optional function
32- Back-to-basic screen key
32 31 29 27 24 23 22
MCGB-01-043
Back monitor screen selector (22) (Optional)

Shifts the monitor screen to the back monitor screen and
vice versa.
M1U1-01-041
Menu key (23)

Shift the basic screen to the menu screen.
M1U1-01-042
Optional function keys (24, 27, 29 and 31)

Without operating the menu selector, the pre-set function is
selected.
F1: Work mode selection
F2: Auxiliary selection
F3: Mail (optional) selection M1U1-01-043
F4: Meter display selection
Return-to- basic screen key (32)

Allows any screen to return to the basic screen.
M1U1-01-044
1-39
OPERATOR'S STATION
• Others
Optional function display
Fuel sensor error display
Coolant sensor error display
Selection keys
TEN-keys
Alarm light
• Optional function display

Displays the optional function that was preset with the
optional function keys.
F1: Work mode selection
F2: Auxiliary
F3: Mail (Optional)
F4: Meter selection
MCJB-01-002
• Fuel sensor error display
TCJB-05-02-104
Is displayed in the fuel gauge screen when the fuel sensor

fails or harness between the fuel sensor and the monitor
unit is broken. Coolant sensor error display Fuel sensor error display
• Coolant sensor error display
TCJB-05-02-103
Is displayed in the coolant temperature gauge screen when

the coolant temperature sensor fails.
MCGB-01-046
1-40
OPERATOR'S STATION
• Selection keys
Push the key located under the attachment icon to be se-
lected.
T1V5-05-01-109
• TEN-keys
Use to enter numerals (0 to 9) such as the password.
TEN-keys
MCGB-01-043
• Alarm light
Comes ON when any abnormality arises.
M1U1-01-045
1-41
OPERATOR'S STATION
Menu Screen
Press menu key (2) when the basic screen is displayed to 1
move to the main menu screen (1). Select the desired menu
by operating key either (3) or (4).
4 2
T1V5-05-01-019
1-42
OPERATOR'S STATION
Displaying Basic Screen by Inputting Password
(Optional) 1
IMPORTANT: When required to activate the TEN-key func-

tion, consult your nearest Hitachi dealer. If
the password ever escapes the customer’s
memory, the machine must be modified. Be
extra careful not to forget the password.
1. Turn the key switch ON. After the starting screen is dis-
played, basic screen (2) is displayed.
NOTE: Under this condition, any machine operation other

than starting the engine or operating monitor key (3) is
not performed. Starting Screen
T1V1-05-01-115
2. Press key (3) or turn the key switch to the START position
to display password input screen (4). 2
Password
Icon
Basic Screen
MCGB-01-047
Password Input Screen

T1V5-05-01-093
1-43
OPERATOR'S STATION
3. Using TEN keys (5) located underside of the screen, input
the password. Press determination key (6). The monitor
unit verifies the input password and the registered one.
When they match, the basic screen is displayed.
NOTE: When required to correct the password, press key (7) to

erase the entered characters.
5 6 7 T1V5-05-01-002
Basic Screen
MCGB-01-041
1-44
OPERATOR'S STATION
Corrective measures to be taken when a wrong pass-
word is input:
1. If a wrong password is input, the message “Password is

incorrect” is displayed by pressing the determination key.
6 7 T1V5-05-01-002
2. Press key (7) to return to password input screen (4).
NOTE: When performing password input operation again,

press key (7) to erase the entered password.
7 T1V5-05-01-004
T1V5-05-01-093
1-45
OPERATOR'S STATION
3. If wrong password is input three times, security lock
screen (8) appears and the buzzer sounds. As long as the 8
key switch is ON, the security screen is displayed and the
buzzer continues to sound. When the key switch is turned
OFF, the security screen disappears but the buzzer con-
tinues to sound for more 30 seconds and stops afterward.
Security Lock Screen

T1V5-05-01-005
4. After the buzzer stops sounding, turn the key switch
ON. After the starting screen is displayed, basic screen
2
(2) is displayed again. Then, press key (3) or turn the key
switch to the START position. Password input screen (4)
appears again so that password input operation can be
performed.
However, if incorrect password is input once more, the se- Password
curity lock screen appears again and the buzzer sounds. Icon
The buzzer continues to sound as long as the key switch
is kept ON. The buzzer sounds for more 30 seconds after
3
the key switch is turned OFF.
Basic Screen
MCGB-01-047
5. After the buzzer stops sounding, the password can be

input. Turn the key switch ON. After displaying password 4
input screen (4), input the correct password.
6. If an incorrect password is input again, the security lock

screen is displayed once over and the buzzer sounds. The
buzzer continues to sound as long as the key switch is
ON. The buzzer sounds for more 30 seconds after the key
switch is turned OFF.
Password Input Screen

T1V5-05-01-093
1-46
OPERATOR'S STATION
Extending password validity time
1
IMPORTANT: This operation is applicable only to those
machines that display the basic screen based
on password input.
The password validity time that was input when starting the
engine on extension screen (1), is extended. Accordingly,
the monitor can be operated without inputting the pass-
word when the engine is restarted in the extended validity
time.
1. Turn the key switch OFF. The monitor unit displays exten-
sion screen (1) for 10 seconds.
2 3 4 5 6
T1V1-05-01-012
Extension Screen (Key Switch OFF)
2. Press a time extension key before extension screen (1)
7
disappears to assign the password validity extension time
as follows:
Key (2): 0 minute
Key (3): 30 minutes
Key (4): 60 minutes
Key (5): 90 minutes
Key (6): 120 minutes
NOTE: In case time extension operation is not done, 0-minute

extension time is set.
Key Switch ON
T1V1-05-01-115
3. When the key switch is turned ON before the password 8

validity time expires, the monitor unit displays starting
screen (7) and basic screen (8) in series.
Basic Screen
MCGB-01-041
1-47
OPERATOR'S STATION
ALARM OCCURRENCE SCREEN 1
In case any abnormality occurs, alarm mark (2) is displayed on

basic screen (1).
• When the number of alarms is three or less: 2
MCGB-01-048
• When the number of alarms is four to five:
MCGB-01-049
• When the number of alarms is six to seven:
MCGB-01-050
• When the number of alarms is eight or more:

Arrow mark (3) is displayed. Scroll the screen to display
the more alarm marks by pressing key (4).
2 3
MCGB-01-051
1-48
OPERATOR'S STATION
When any alarm marks are displayed, press the key located
under the alarm mark concerned to display the corrective
measure to be applied to the corresponding abnormality.
MCGB-01-048
T1V5-05-01-013
1-49
OPERATOR'S STATION
Alarm List
Icon Content of Alarm Cause and Solution
Overheat Abnormally increased engine coolant temperature Stop operation.

Run the engine at slow idle to cool the coolant.
M178-01-036
Engine warning Abnormal engine and/or engine related parts Consult four nearest
Hitachi dealer.
M183-01-080
Engine oil pressure Reduced engine oil pressure

Immediately stop the engine. Check the engine oil pressure sys-
tem and engine oil level.
M178-01-037
Alternator Abnormal electrical system
Check the alternator and battery systems.
M183-01-071
Remaining fuel Reduced fuel remaining in the fuel tank

Refill fuel as soon as possible.
M178-01-034
Hydraulic oil filter Clogged hydraulic oil filter
Clean or replace.
M1CC-01-039
Air filter restriction Restricted air filter
Clean or replace
M183-01-067
Hydraulic oil temperature Abnormally increased hydraulic oil temperature
Stop operation or traveling. Run the engine at slow idle to cool the
hydraulic oil temperature.
T1JB-05-02-001
1-50
OPERATOR'S STATION
Icon Content of Alarm Cause and Solution
Brake oil pressure Reduced oil pressure in the brake oil circuit
Consult your nearest Hitachi dealer.
TCJB-05-02-032
Attachment control signal Abnormal attachment control pedal signal

TCJB-05-02-033
Outrigger and blade control Abnormal blade and outrigger control lever signal Consult your
signal nearest Hitachi dealer.
TCJB-05-02-034
Assist control signal Abnormal assist control signal

TCJB-05-02-035
Electric lever solenoid valve out- Abnormal electric lever solenoid output
put Consult your nearest Hitachi dealer.
TCJB-05-02-036
Network Abnormal network system

TCJB-05-02-037
Work mode Abnormal network system

T1V1-05-01-102
Pilot control shut-off lever Abnormal pilot control shut-off lever system
T1V1-05-01-103
1-51
OPERATOR'S STATION
CLOCK SETTING 1
1. After displaying basic screen (1), press menu key (2) to

display main menu (3).
2
2. Select clock set menu (4) on main menu (3) by operating

key (7 or 8). Press determination key (6) to display clock 3
setting screen (9).
8 7 6 T1V5-05-01-019
3. Select items of Year, Month, Day and/or Time to be set by

operating key (7 or 8) on clock setting screen (9). Reduce
9
or increase the displayed figure as needed by operating
key (11 or 12).
10
4. After the setting is complete, select icon (10) and
press determination key (6) to finalize the setting.
5
NOTE: When required to return the previous screen, press key
(5).
8 7 12 11 6 T1V5-05-01-021
5. Press key (13) to return to basic screen (1).
13
T1V5-05-01-022
1-52
OPERATOR'S STATION
WORK MODE (ATTACHMENT SELECTION)

1
NOTE: The monitor unit is operable only when the machine is
equipped with an optional attachment.
IMPORTANT: Select the attachment on the work mode

screen. Display the work mode screen by
pressing F1 key (2) after displaying the basic
screen, or by selecting the menu on the main
menu screen.
Selecting an attachment by pressing key F1

1. After displaying basic screen (1), press key (2) to display
2 Basic Screen
work mode screen (3). MCGB-01-041
2. Select the attachment to be used. (Example: Press key (8) 3

to select crusher 1.)
4- Digging
5- Breaker 1
6- Breaker 2
7- Pulverizer 1
8- Crusher 1
4 5 6 7 8 T1V5-05-01-109
NOTE: When digging (4) is selected, basic screen (1) is dis-
played. Work Mode Screen
3. Referring to attachment specification screen (9), check

that the specifications of the installed attachment agree
with those of the displayed attachment. 9
NOTE: Press key (10) to go back to the previous screen.
4. Press determination key (11) to go back to basic screen (1).

10
11
Attachment Specification Screen

TCJB-05-02-084
1-53
OPERATOR'S STATION
Selecting Attachment on Main Menu Screen 1
display the main menu screen.
2. Select work mode menu (10) on the main menu by oper-

ating key (4 or 5).
3. Select the attachment to be used on the work mode

screen. (Example: Press key (8) to select crusher 1.)
4- Digging 2
5- Breaker 1
6- Breaker 2
7- Pulverizer 1 3
8- Crusher 1
10
NOTE: When digging (4) is selected, main menu screen (3) is
displayed.
4. Referring to attachment specification screen (12), check 13

that the specifications of the installed attachment agree
with those of the displayed attachment.
4 5 9 TCHB-05-02-001
NOTE: Press key (13) to go back to the previous screen.
5. Press determination key (9) to go back to main menu

screen (3).
11
13
4 5 6 7 8 T1V5-05-01-109
Work Mode Screen
12
13

TCJB-05-02-084
1-54
OPERATOR'S STATION
Breaker 1
Maximum Pump 2 Flow Rate
Maximum Engine Speed

Accumulator Control Solenoid Valve:
OFF
Secondar y Relief Selec tor Control

Solenoid Valve: ON
Three way Valve Control Solenoid Valve:

ON
The three way valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combining Solenoid

Valve: OFF
TCJB-05-02-081
Breaker 2 Maximum Pump 2 Flow Rate

ON

Solenoid Valve: OFF

ON
hydraulic oil tank.

Valve: OFF
TCJB-05-02-082
1-55
OPERATOR'S STATION
Pulverizer 1
Maximum Pump 1 and 2 Flow Rate

OFF

Solenoid Valve: OFF

OFF
control valve.

Valve: ON
TCJB-05-02-083
Crusher 1
Maximum Pump 1 and 2 Flow Rate

OFF

Solenoid Valve: OFF

OFF
control valve.

Valve: ON
TCJB-05-02-084
1-56
OPERATOR'S STATION
ATTACHMENT ADJUSTMENT (PUMP 2 FLOW RATE

ADJUSTMENT) 1

equipped with an optional attachment.
IMPORTANT: This operation is effective when an optional

attachment is installed.
When breaker 1 or 2 is used:

2
2. Select attachment adjustment menu (7) on the main

menu screen by operating key (4 or 5). Press determina- 3
tion key (6) to display attachment adjustment screen (8).
4 5 6 T1V5-05-01-019
3. Adjust pump 2 flow rate by operating keys (4 and 5).

When using breaker 1 or 2, the pump 2 flow rate is re-
duced by pressing key (4) or increased by pressing key (5). 8
NOTE: Press key (10) to return to the previous screen.
4. Press key (9) to display basic screen (1).
4 9 5 10 T1V5-05-01-111
1-57
OPERATOR'S STATION
equipped with an optional attachment. 1
IMPORTANT: This operation is effective when an optional

attachment is installed.
When a pulverizer or a crusher is used:

2
2. Select attachment adjustment menu (7) on the main

menu screen by operating key (4 or 5). Press determina- 3
tion key (6) to display attachment adjustment screen (8).
4 5 6 T1V5-05-01-019
3. When a pulverizer or a crusher is used, press key (4) to

increase pump 2 flow rate to the boom raise, arm roll-out,
swing and travel circuits. Press key (5) to increase pump 2 8
flow rate to the attachment.
4 9 5 10 T1V5-05-01-024
1-58
OPERATOR'S STATION
OPERATING STATUS 1
Display of Operating Status

Operating hours and/or fuel consumption is displayed.

display main menu screen (3).
2
2. Select operating status menu (7) on the main menu

screen by operating key (4 or 5). Press determination key 3
(6) to display operating status screen (8).
4 5 6 T1V5-05-01-019
3. Pres reset key (9) to display data reset confirmation

screen (10). When resetting the data, press determination
8
key (6).
IMPORTANT: The fuel consumption and average fuel cost

differ depending on the circumstances in
which the machine operates and the operat-
ing methods. The numerical value displayed
on the screen is a value to be referred. Toler-
ance between the actual fuel consumption
and the corresponding value displayed on 9 T1V5-05-01-025
the monitor unit may extend up to ± 20 %.
4. Press key (11) to return to basic screen (1). 10
12
11 6 T1V5-05-01-026
1-59
OPERATOR'S STATION
MAINTENANCE SETTING
1
2. Select maintenance set menu (7) on main menu screen (3)
by operating keys (4 and 5). Press determination key (6)
to display maintenance set screen (8).
3. Select a menu desired to set on maintenance set screen
(8) by operating keys (4 and 5). Press determination key (6)
to display interval ON/OFF set screen (9). (As an example,
selecting the menu for Engine oil is explained in this sec-
tion.)
Maintenance menu items to be set in the monitor Basic Screen 2

• Engine oil MCGB-01-041
• Engine oil filter 3

• Hydraulic oil
• Hydraulic oil pilot filter
• Hydraulic oil full-flow filter 7
• Pump transmission
• Swing device oil
• Swing bearing greasing
• Travel device oil
• Air cleaner element
• Engine / Air conditioner V-belt
• Fuel filter
• Air conditioner filter 4 5 6 TCHB-05-02-001
4 5 6 T1V5-05-01-049
1-60
OPERATOR'S STATION
Maintenance Information ON/OFF Setting
When required to display “maintenance information” on the
monitor, set ON/OFF function.
ON setting: When maintenance time arrives, the moni-
tor displays the corresponding maintenance
required items.
OFF setting: No maintenance information is displayed.
1. Select an item desired to be informed with keys (1 and 2).

The item displayed in yellow is set ON. 1
Interval ON/OFF Set Screen

T1V5-05-01-052
2. Press key (4) to execute ON setting.
3 4
T1V5-05-01-052
3. When completing set-operation, press key (3). The screen 5

is returned to basic screen (5).
Basic Screen
MCGB-01-041
1-61
OPERATOR'S STATION
Change (Replacement) Interval Setting
IMPORTANT: Change (replacement) interval setting can

only be achieved when maintenance infor-
mation function is set ON.
1. Select “Change Interval” by operating keys (1 and 2).

1
2. Set the change interval hours by operating keys (3 and 4).
2
3. Select “Remaining Hours” by operating keys (1 and 2).
Press determination key (5). 3 4
Interval ON/OFF Set Screen T1V5-05-01-052
4. As the monitor displays the message “Remaining hour is

reset. OK?”, press determination key (5).
2 5
T1V5-05-01-138
5
6
TCHB-05-02-010
Menu Key
Baxic Screen
MCGB-01-041
1-62
OPERATOR'S STATION
Data Resetting
When required to reset data, press key (2) on the interval
ON/OFF set screen. The monitor displays the message “Data 1
is reset. OK?” Then, press determination key (3). The remain-
ing hour display becomes equal to the change interval
hours. The previous change date and hour are updated to
the present date and hour.
Interval ON/OFF Set Screen

T1V5-05-01-052
3 T1V5-05-01-140
1-63
OPERATOR'S STATION
Screen Display when ON-set Maintenance Information is Notice
Present
1
• When single ON-set information is present:
1. When the key switch is turned ON, the starting screen
and basic screen (1) are displayed in series. When the
machine operation hours reach the ON-set maintenance
item hours, the notice of displaying the maintenance in-
formation screen is shown at the top of the basic screen
for three seconds. Then, the basic screen is automatically
shifted to maintenance information screen (2). (Hydraulic
oil maintenance information is shown as an example in
this section.)
NOTE: In case a machine is set to display the basic screen only

after the password is entered, input the password first. 2
Then, press the determination key to display the basic
screen.
2. When data resetting is required, press key (4) on mainte-

nance information screen (2) before maintenance infor-
mation screen (2) disappears. The message “Data is reset.
OK?” and reset screen (5) are displayed. Press key (4). The 3
remaining hour display becomes equal to the change
interval hours. The previous change date and hour are
4
updated to the present date and hour.
Maintenance Information Screen
T1V5-05-01-170
NOTE: When key (3) is pressed on maintenance information
screen (2), basic screen (1) is displayed. 5
NOTE: When key (3) is pressed on reset screen (5), mainte-

nance information screen (2) is displayed.
3. After displaying the maintenance information screen (2)

for 10 seconds, basic screen (1) is displayed.
3
4
Reset Screen
T1V5-05-01-171
1-64
OPERATOR'S STATION
• When two or more ON-set information are present: Notice
1. When the key switch is turned ON, the starting screen

and basic screen (1) are displayed in series. When the 1
machine operation hours reach the ON-set maintenance
item hours, the notice of displaying the maintenance in-
formation screen is shown at the top of the basic screen
for three seconds. Then, the basic screen is automatically
shifted to maintenance required item screen (2).
NOTE: In case a machine is set to display the basic screen only

after the password is entered, input the password first.
Then, press the determination key to display the basic
screen.
2. When data resetting is required, select the maintenance
item by operating keys (5 and 6) on maintenance re- 2
quired item screen (2) before maintenance required item
screen (2) disappears. Press key (4) to display mainte-
nance information screen (7) for the selected mainte-
nance item. (Hydraulic oil is selected as an example in
this section.)
5
3
NOTE: When key (3) is pressed on maintenance required item
screen (2), basic screen (1) is displayed.
6
4
3. After displaying maintenance information screen (7),
press key (4). The message “Data is reset. OK?” and reset Maintenance Required Item Screen
T1V5-05-01-169
screen (8) are displayed. Press key (4). The remaining hour
display becomes equal to the change interval hours. The 7
previous change date and hour are updated to the pres-
ent date and hour.
NOTE: When key (3) is pressed on maintenance information

screen (7), maintenance required item screen (2) is
displayed.
3
NOTE: When key (3) is pressed on reset screen (8), mainte-
nance information screen (7) is displayed.
4
Maintenance Information Screen
4. After displaying the maintenance information screen (7) TCHB-05-02-011
for 10 seconds, basic screen (1) is displayed.

7
4
Reset Screen
T1V5-05-01-171
1-65
OPERATOR'S STATION
MAIL (OPTIONAL)
1
IMPORTANT: This function is available only to machines
equipped with a satellite communication
terminal. When using the mail function, con-
sult your nearest Hitachi dealer.
1. After displaying basic screen (1), press mail selection key

F3 (2) to display mail screen (3).
2 Basic Screen MCGB-01-053

2. Press a corresponding request key as shown below to
send mail information to the satellite communication 3
terminal.
4- General request
5- Fuel replenishment request
6- Service maintenance request
7- Forwarding request
4 5 Mail Screen 6 T1V5-05-01-037
3. When sending mail information to the satellite communi-

cation terminal, the message “Mail is being sent” is dis- 8
played on screen (8).
T1V5-05-01-038
4. When satellite communication terminal receives mail

information, the massage “Mail has arrived” is displayed
9
on screen (9). Press key (10) to return to mail screen (3).
5. Then, the mail is sent to the central server from the satel-
lite communication terminal via a satellite.
NOTE: Mail may not be sent depending on machine’s operat- 10

ing circumstances or the satellite position on its orbit.
T1V5-05-01-039
1-66
OPERATOR'S STATION
NOTE: If the satellite communication terminal fails to send
a mail, the message “Mail transmission failed” is dis-
played on screen (11). 11
T1V5-05-01-040
1-67
OPERATOR'S STATION
METER DISPLAY CONTROL

IMPORTANT: To display the meter display control screen, 1
press key F4 on the basic screen or select
the meter to be displayed on the main menu
screen.
Displaying the meter display control screen with key F4:

1. After displaying basic screen (1), press key (2) to display
2
meter display control screen (3).
NOTE: By pressing key (2) for more than two seconds, the me-
ter display is also shifted on the basic screen as follows:
Hour meter → Odometer → Trip meter Basic Screen MCGB-01-041
2. After selecting a meter to be displayed by operating 3

keys (4 and 5), press key (7). (Trip meter is selected as an
example in this section.) Data Reset
Icon
3. Only when the trip meter is selected, the data reset icon
4 8
is displayed. When resetting the data, press key (6).
4. The message “Data is reset. OK?” is displayed. Press key (7). 7
5
9 6
Meter Display Control Screen
TCJB-05-02-012
NOTE: The meter display instruction set on the meter display
screen is maintained until the key switch is turned OFF.
When the key switch is turned OFF, the meter display
instruction is rest to the meter display request selected
on the meter combination setting screen.
9 7
TCHB-05-02-006
1-68
OPERATOR'S STATION
Selecting the meter display on the main menu screen:
1
2. Select HOUR↔ODO↔TRIP menu (8) on main menu

screen (3) by operating keys (4 and 5). Press key (6) to
display meter display control screen (9).
2
5 6 7 TCJB-05-02-007
3. After selecting the meter to be displayed by operating

9
keys (4 and 5), press key (6). (Hour meter is selected as an
example in this section.)
4. Press key (10) to display basic screen (1). 4

7
NOTE: The meter display instruction set on the meter display 5

screen is maintained until the key switch is turned OFF. 6
When the key switch is turned OFF, the meter display 10
instruction is rest to the meter display request selected Meter Display Control Screen TCHB-05-02-072
on the meter combination setting screen.

1
1-69
OPERATOR'S STATION
PASSWORD REVISING (OPTIONAL)

1

2. Select password revision menu (7) on main menu screen
(3) by operating keys (4 and 5). Press key (6) to display 3
password revision screen (8).
7
TCHB-05-02-002
5 6
Password Revision Screen T1V5-05-01-041
Registered Password
3. Enter the registered password with the TEN-keys. Press
key (6).
4. When retrying password input operation, press key (10)

to erase the previously input password.
6
10
T1V5-05-01-042
1-70
OPERATOR'S STATION
NOTE: After pressing key (6), if the entered password is incor-
rect, the massage “Password is incorrect” is displayed.
Press key (10) to return to the previous screen. Enter the
password again.
6 10 T1V5-05-01-044
5. When the message “Enter new password to be registered”

is displayed, enter a new password in three or four digits.
Press key (6).
6. When retrying password input operation, press key (10).
T1V5-05-01-130
New Password
6 10 T1V5-05-01-131
Password Revision Screen
1-71
OPERATOR'S STATION
7. The message “Re-enter password” is displayed. After en-
tering a new password, press key (6).
8. When retrying password input operation, press key (10).
T1V5-05-01-132
6 10 T1V5-05-01-133
9. When the message “New password has been registered”

is displayed, password revising operation is complete.
11
T1V5-05-01-043

1
1-72
OPERATOR'S STATION
BACK MONITOR SETTING (OPTIONAL)

1
IMPORTANT: The image displayed on the back monitor
is to be used as an assist view. Operate the
machine while paying thorough attention to
the surroundings.
Auto activation: ON 2
When the forward/reverse switch is shifted to the R (reverse)
position, the image on the monitor unit is automatically
shifted to the back monitor image.

display main menu screen (3). Basic Screen MCGB-01-041
3
2. Select the back monitor setting (8) menu on main menu
8
display back monitor set screen (9).
3. In case the auto activation is set OFF (10), the “ON” col-
umn is displayed in yellow. Press key (6) to set the auto
activation ON. 4
4. Press key (11) to return to basic screen (1). TCHB-05-02-003

5 6 7
10
T1V5-05-01-173
6 7
11
T1V5-05-01-174
1-73
OPERATOR'S STATION
5. When the forward/reverse switch is shifted to the R (re-
verse) position, the monitor unit screen shows the image
viewed through the back monitor.
IMPORTANT: Once the rear view image is displayed on the

monitor screen, even after the accelerator
pedal is returned to neutral, the rear view
image is kept displayed for three seconds. If
the forward/reverse switch is turned to the
R (reverse) position within three seconds
after the displayed rear view image screen
is shifted to the basic screen, the rear view
image will not be displayed on the monitor.
Wait for more than three seconds until the
rear view image is displayed again.
1-74
OPERATOR'S STATION
Auto activation: OFF
Even though the forward/reverse switch is shifted to the R 1
(reverse) position, the monitor unit image is not automati-
cally shifted to the back monitor image.

2. Select the back monitor setting (8) menu on main menu 3

display back monitor set screen (9).
8
TCHB-05-02-003
5 6 7
3. In case the auto activation is set ON (10), the “OFF” col-

umn is displayed in yellow. Press key (6) to set the auto 9
activation OFF.
NOTE: Press key (7) to return to the previous screen. 10
T1V5-05-01-174
6 7
11
T1V5-05-01-173
1-75
OPERATOR'S STATION
LANGUAGE SETTING
1
Basic Screen 2 MCGB-01-041
2. Select the language menu on main menu screen (3) by

3
operating keys (5 and 6). Press key (7) to display language
set screen (9).
5 6 7 8 TCHB-05-02-003
3. Select the language to be set by operating keys (5 and 6).

9
NOTE: Initially set language to be displayed on the monitor

unit is selected from twelve languages listed in display-
language table 1 or 2. (Refer to the next page.)
5 10 6 7 8 T1V1-05-01-137
1-76
OPERATOR'S STATION
Lists of Display Language
Display Languages 1
Language Screen Display
Japanese
T1V1-05-01-141
English
T1V1-05-01-142
Chinese (Simplified)
T1V1-05-01-143
Chinese (Traditional)
T1V1-05-01-144
Korean
T1V1-05-01-145
Indonesian
T1V1-05-01-146
Thai
T1V1-05-01-147
Vietnamese
T1V1-05-01-148
Myanmarese
T1V1-05-01-149
Arabic
T1V1-05-01-150
Persian
T1V1-05-01-151
Turkish
T1V1-05-01-152
Display Languages 2
Language Screen Display
English
T1V1-05-01-142
Spanish
T1V1-05-01-153
Italian
T1V1-05-01-154
French
T1V1-05-01-155
German
T1V1-05-01-156
Dutch
T1V1-05-01-157
Russian
T1V1-05-01-158
Portuguese
T1V1-05-01-159
Finnish
T1V1-05-01-160
Swedish
T1V1-05-01-161
Norwegian
T1V1-05-01-162
Danish
T1V1-05-01-163
1-77
OPERATOR'S STATION
METER COMBINATION SETTING

1

2. Select km/h↔min -1 menu (8) by operating keys (4 and 5)
on main menu screen (3). Press key (6) to display meter 3
combination set screen (9).
NOTE: When ”mile” is selected on the km↔mile menu, the

screen with the title of mph↔ min -1 is displayed. 8
TCHB-05-02-003
5 6 7
3. After selecting the meter combination menu by operat- 9

ing keys (4 and 5), press key (6).

4
7
5
6
10
Meter Combination Set Screen TCJB-05-02-015
4
7
5
6
10
Meter Combination Set Screen TCJB-05-02-068
1-78
OPERATOR'S STATION
NOTE: Example displays of meter combinations Odometer
• When travel speed meter (km/h) and odometer are se-

lected:
Travel Speed
MCGB-01-055
Meter (km/h)
Hour
• When tachometer (min-1) and hour meter are selected: Meter
Tachometer
MCGB-01-045
Trip
• When travel speed meter (mph) and trip meter are select- Meter
ed (When the unit is set in mile):
Travel Speed
MCGB-01-056
Meter (mph)
1-79
OPERATOR'S STATION
UNIT SETTING
1
Basic Screen 2 MCGB-01-041
2. Select km/h↔mile menu (8) by operating keys (4 and 5) 3

on main menu screen (3). Press key (6) to display unit set
screen (9).
4 5 6 7 TCHB-05-02-003
3. Select the unit menu by operating keys (4 and 5) on unit 9

set screen (9). Press key (6).
4 7
5
6
10
Unit Set Screen TCJB-05-02-016
1-80
OPERATOR'S STATION
NOTE: Display Examples
• When “km” is selected:
MCGB-01-055
• When “mile” is selected:
MCGB-01-056
1-81
OPERATOR'S STATION
FUSE BOX Fuse Box Additional Fuse Box
10- CONTROLLER 20- OPTION3 (BATT)

5A 5A
9- BACKUP 19- SW. BOX
10A 5A
8- ECM 18- POWER ON
30A 5A
7- LUBRICATOR 17- AIRCON
10A 5A
6- OPTION2 (ALT) 16- GLOW RELAY
10A 5A
5- OPTION1 (ALT) 15- AUXILIARY M1J1-01-021
5A 10A
4- SOLENOID 14- AUXILIARY
10 20
10A 5A
9 19
3- HEATER 13- LIGHTER
20A 10A 8 18
2- WIPER 12- ROOM LAMP/RADIO 7 17

10A 5A 6 16
1- LAMP 11- HORN 5 15
20A 10A 4 14
3 13
2 12
1 11
ADDITIONAL FUSE BOX
30- ASSIST CONTROL 40- CAB LAMP

M1GR-01-003
10A 5A
29- O/R CONTROL 39- OPU (URF)
10A 5A
30 40
28- P/SW OTHER 38- QUICK HITCH 29 39
10A 5A
28 38
27- COLUMN BOX 37- SOLENOID
27 37
10A 10A
26 36
26- BACK LAMP 36- CAB LAMP REAR
10A 10A 25 35
25- STOP LAMP 35- WARNING LAMP 24 34

15A 10A 23 33
24- TURN L-R 34- SEAT COMPRESSOR 22 32
10A 10A 21 31
23- UPPER BEAM 33- SEAT HEATER
10A 10A
22- HEAD LAMP R 32- HEAD LAMP L
10A 10A M1GR-01-003
21- CLEARANCE LAMP R 31- CLEARANCE LAMP L

10A 10A
1-82
OPERATOR'S STATION
AUTO AIR CONDITIONER OPERATION

Designed Character of Auto Air Conditioner
• Full-Automatic Control:
Air flow-in temperature and the blower speed are
automatically controlled so that the cab temperature
is maintained at the temperature set by the tempera-
ture control switch irrespective of change in outside air
temperature and insolation.
• Max. Cooling and Heating:
Maximum cooling or heating can be selected by oper-
ating the temperature control switch so that the set-
temperature shows FH (FULL HOT) or FC (FULL COOL).
• Preheating Control:
During cold weather season, large amount of cool air will
flows in the cab when the front, foot and rear vents are
selected immediately after the engine is started until the
coolant temperature is warmed. Therefore, the blower
speed is maintained at LO until the coolant temperature
rises to prevent cool air from entering the cab.
NOTE: Even in warmer season, if the coolant temperature is

low, the engine fast idle speed may increase more than
normal due to the function of the preheating system
mentioned above.
1-83
OPERATOR'S STATION
Part Location
1- Front Vent
2- Foot Vent 1
3- Defroster Vent
4- Rear Vent
5- Control Panel
6- Blower Switch
7- Liquid-Crystal Display (LCD)
8- Air Conditioner Switch
9- AUTO Switch MCGB-01-018
10- OFF Switch
11- Temperature Control Switch
12- Circulation Mode Switch
13- Fresh Air Mode Switch
14- Mode Switch
NOTE: Except for the foot vent, all vents are provided with lou-
vers to adjust the airflow direction. The louvers on the
front vent and defroster vent can be manually opened
and closed.
3 2 MCGB-01-001
M1U1-01-027
5 6 7 8 9
14 13 12 11 10
M178-01-073
1-84
OPERATOR'S STATION
Controller Part Name and Function 9
• Mode Switch (14)
Selects the air vent in the four modes as shown below.
The selected air vent is displayed on the LCD.
: Front/Defroster Vent Mode
: Front/Rear/Defroster Vent Mode 14 M178-01-074
Display when AUTO switch (9) is pressed.

: Front/Rear/Foot/Defroster Vent Mode
: Foot Vent Mode
Each time mode switch (14) is pressed, the air vent is

selected in 4 stages.
AUTO → → → →
• When AUTO switch (9) is selected, the blower speed,

vent mode, and ventilation mode are automatically 7 11
controlled in response to the set-temperature.
• Temperature Control Switch (11)

Sets the temperature in the cab. The air temperature can
be set in the range of 18.0 to 32.0 °C. Temperature can be
adjusted by 0.5 °C increments. The set-temperature is dis-
played on the LCD (7).
M178-01-075
• FC (FULL COOL) Display when the button is pressed
When the button with mark on temperature control after displaying 25.0 °C (77 °F).
switch (11) is pressed after setting air temperature to 18.0
°C, air flow temperature is set to the lowest and LCD panel
(7) indicates “FC”.
• FH (FULL HEAT)
When the button with mark on temperature control 7
switch (11) is pressed after setting air temperature to 32.0 AUTO Indicator
°C, air flow temperature is set to the highest and LCD

panel (7) indicates “FH”.
1. When the AUTO indicator is ON, air temperature at the
vents is automatically controlled so that the temperature
in the cab is maintained at the set-temperature.
2. When the AUTO indicator is OFF, air temperature at the M178-01-076
vents is automatically maintained at the set-temperature. Display when the LCD displays “FC” symbol.
3. When LCD panel (7) indicates “FC”, air flow-in tempera-
ture at the vent, air vent (front and rear) locations, circula-
tion air suction port, and blower speed are maintained
at the lowest cooling conditions. However, in case the
circulation indicator is ON before the LCD indicates “FC”,
the circulation mode is maintained.
1-85
OPERATOR'S STATION
4. When LCD panel (7) indicates “FH”, air flow-in temperature 7
at the vent, air foot vent location, fresh air suction port,
and blower speed are maintained at the highest heating
conditions. However, in case the circulation indicator is
ON before the LCD indicates “FH”, the circulation mode is
maintained.
• Blower Switch (6) M178-01-077

• When the AUTO indicator is ON, the blower speed is auto- Display when the LCD displays “FH” symbol.
matically controlled.
• When the AUTO indicator is OFF, the blower speed is
controlled in 4 stages. When the button is pressed
6
with the blower OFF, the blower starts running in the AUTO Indicator
HI mode. Then, each time the button is pressed, the
blower speed is reduced by one stage. The LCD indi-
cates the blower fan numbers corresponding to the
blower speed. When the button is pressed with the
blower OFF, the blower starts running in the LO mode.
Then, each time the button is pressed, the blower M178-01-075
speed is increased by one stage. The LCD indicates
the blower fan numbers corresponding to the blower
speed.
• Circulation Mode Switch (12):

• Fresh Air Mode Switch (13):
The air circulation mode and the air suction port open/close
are automatically set by operating these switches. When
fresh air mode switch (13) is pressed, the indicator comes
ON and the fresh air circulation mode is selected, allow-
ing fresh air to flow in. When fresh air mode switch (13)
is pressed again, the indicator goes OFF and the fresh air M178-01-078
suction port is closed. When circulation mode switch (12) is 13 12
pressed, the indicator comes ON and the circulation mode Display when fresh air vent switch (13) is pressed.
is selected. When circulation mode switch (12) is pressed
again, the indicator goes OFF and the fresh air suction port
is opened.
NOTE: Operating the above switches controls the fresh air suc-
tion port manually or automatically. Therefore, even if
the AUTO switch is turned ON, the fresh air suction port
open/close will change.
1-86
OPERATOR'S STATION
• Air Conditioner (A/C) Switch (8) 8 A/C Indicator
Press A/C switch (8) to turn the air conditioner and the
A/C indicator ON. However, unless the blower is running
(the fan display of blower switch (6) is lit), the air condi-
tioner will not be turned ON.
• OFF Switch (10) M178-01-075

6 10
Press OFF switch (10) to turn the blower and the air con-
Display when Air Conditioner Switch (8) is pressed.
ditioner OFF.
9 AUTO Indicator
• AUTO Switch (9)
Press AUTO switch (9) to turn the AUTO and the A/C indi-
cators ON so that the air flow-in temperature at the vent,
blower speed, vent locations, and fresh air suction port
are automatically controlled.
M178-01-075
Display when AUTO Switch (9) is pressed.
Selecting Display between Celsius and Fahrenheit

1. While depressing both A/C (8) and mode (14) switches,
turn the key switch ON. Indicator
6 8
2. The LCD will display “Sd” for approx. 5 seconds.
3. After display “Sd” disappears, all indicators will come ON.
4. After all indicators come ON, repeat to press the but-
ton of blower switch (6) four times.
5. Sequentially, press A/C switch (8) and the button of
blower switch (6) at the same time. Indicator M178-01-075
14 13
6. Then, the selection mode between Celsius and Fahrenheit
starts. Each time fresh air mode switch (13) is pressed, the
display is shifted between Celsius and Fahrenheit.
When Celsius is selected, the LCD displays “C.”
When Fahrenheit is selected, the LCD displays “F.”
Select either one to be preferred.
7. After selection is complete, end by turning the key switch
“OFF”.
The LCD will display in the selected mode when the ma-
chine is operated next time.
Display on LCD
Celsius (°C) 18.0 to 32.0
Fahrenheit (°F) 63 to 91
1-87
OPERATOR'S STATION
Cab Heater Operation
1. Operate AUTO switch (9). 8 9
According to information sent from various sensors,
the air conditioner controller automatically selects the
appropriate air flow-in vents, blower speed, air flow-in
temperature, and air suction port open/close.
2. Operate temperature control switch (11).
“25.0” is indicated on the LCD. Adjust the cab inside tem-
perature using this switch as needed. M178-01-079
6 14 13 12 11
3. As necessary:
• Operate mode switch (14) to manually select the air vent.
• Operate blower switch (6) to manually control the blower
speed.
• Operate fresh air mode switch (13) to maintain the air suc-
tion port in the fresh air circulation mode.
• Operate circulation mode switch (12) to maintain the air
suction port in the circulation mode.
When the A/C indicator is ON, the air conditioner normally

works as a dehumidifier. Press A/C switch (8) to deactivate
the dehumidifier function.
Cooling Operation
8 9
1. Operate AUTO switch (9).
According to information sent from various sensors,
the air conditioner controller automatically selects the
appropriate air flow-in vents, blower speed, air flow-in
temperature, and air suction port open/close.
2. Operate temperature control switch (11).
“25.0” is indicated on the LCD. Adjust the cab inside tem- M178-01-075
6 14 13 12 11
perature using this switch as needed.
3. As necessary:
• Operate mode switch (14) to manually select the air vent.
• Operate blower switch (6) to manually control the blower
speed.
• Operate fresh air mode switch (13) to maintain the air suc-
tion port in the fresh air circulation mode.
• Operate circulation mode switch (12) to maintain the air
suction port in the circulation mode.
In case the outside of the front lower window becomes

cloudy, manually close defroster vent (3).
3 2 MCGB-01-001
1-88
OPERATOR'S STATION
Defroster Operation
1. Press AUTO Switch (9). Temperature-controlled air 8 9
blows out. During cold weather season when starting
the engine, the engine coolant temperature and air
temperature in the cab are low. Then, cool air is re-
stricted not to flow in the cab to the minimum (LO) by
the Preheating Control System.
2. Set temperature control switch (11) so that “25.0” is
indicated on the LCD. Set fresh air vent switch (13) to
M178-01-074
the fresh air circulation mode. 14 13 11
3. Select the front vents or the front and rear vents
using MODE switch (14).
1
Control the airflow direction by adjusting the louvers at the
front vent (1) and the defroster vent (3).
Control the air temperature in the cab by operating tem-

perature control switch (11). If the windowpanes become
cloudy in rainy season or when dehumidifying, turn the
indicator of A/C switch (8) ON.
MCGB-01-018
3 2 MCGB-01-001
Cool Head / Warm Feet Operation

Cool and warm air is simultaneously supplied through the 6 8
head vents and feet vents respectively.
1. Press blower switch (6) to adjust the blower speed.

2. Press MODE switch (14) to display the front
and rear vent mark on the LCD. Then,
turn A/C switch (8) ON (indicator lights).
M178-01-080
14 11
Control air temperature inside the cab by operating tem-
perature control switch (11).
1-89
OPERATOR'S STATION
TIPS FOR OPTIMAL AIR CONDITIONER USAGE

9
For Rapid Cooling
Temperature in the cab may rise over 80 °C (176 °F) when
the machine is exposed to sunlight in the summer.
In this case, ventilate air in the cab first by opening the
windows for rapid cooling. After starting the engine, press
AUTO switch (9). Set temperature to “18.0” on LCD (7) us-
ing temperature control switch (11). Turn circulation mode
switch (12) ON. When the air temperature in the cab is 12 11
M178-01-081
cooled almost down to the atmospheric temperature, close
the windows.
When Windows Become cloudy:

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

To protect each part of the compressor from a lack of lubri-
Auto Air Conditioner Sensor
cant, operate the air conditioner at least once a month for
several minutes with the engine running at a slow speed
during off-season. When the cab temperature is lower than
15 °C (59 °F), the air conditioner may not operate. If this hap-
pens, warm the cab using the heater first.
IMPORTANT: Do not suddenly increase the engine speed.

Damage to the compressor may result.
Refer to the item “Check Air Conditioner
Filter” in the Maintenance Section for main-
tenance of the air conditioner filters.
Always clean the auto air conditioner sensor
to effectively operate air conditioner per-
formance. Avoid placing any obstructions MCGB-01-018
that may disturb the sensor operation in the

vicinity of the sensor.
1-90
OPERATOR'S STATION
HEATER (Optional) OPERATION

Part Location
1
1- Front Vent
2- Foot Vent
3- Defroster Vent
4- Rear Vent
5- Control Panel
6- Mode Switch
7- Fresh Air Mode Switch
8- Temperature Control Switch MCGB-01-018
9- Blower Switch
10- OFF Switch
NOTE: Except for the foot vent, all vents are provided with lou-
vers to adjust the airflow direction. The louvers on the
front vent and defroster vent can be manually opened
and closed.
3 2 MCGB-01-001
Controller Part Name and Function 4

• Mode Switch (6)
Selects the air vent in the three modes as shown below.
Front/Defroster Vent Mode
Front/Rear/Defroster Vent Mode
Foot Vent Mode
• Temperature Control Switch (8)

One of 8 indicators lights. The air flow-in temperature at M1U1-01-027
the vent becomes lower or higher as the indicator closer
to the left or right end lights respectively. 5 6 7
10 9 8
M178-01-072
1-91
OPERATOR'S STATION
• Blower Switch (9)
The blower speed is controlled from Lo to Hi in 4 stages.
When the button is pressed first, the blower starts
running in the Hi mode. Then, each time the but-
ton is pressed, the blower speed decreases by one step.
The blower speed indicator corresponding to the blower
speed is lit. When the button is pressed first, the
blower starts running in the Lo mode. Then, each time the
button is pressed, the blower speed increases by M178-01-072
one step. 10 9
Press OFF switch (10) to stop the blower.
7
• Fresh Air Mode Switch (7)
The air circulation mode is shifted with this switch. When
fresh air mode switch (7) is pressed, the indicator comes
ON and the fresh air circulation mode is selected, allow-
ing fresh air to flow in. When fresh air mode switch (7) is
pressed again, the indicator goes OFF and the circulation
mode is selected.
M178-01-072
1-92
OPERATOR'S STATION
Heater Operation
6
Warm air flows in even though any mode switch (6)
, , is pressed, normally the foot vent mode switch
is used.
When foot mode switch (6) is pressed, warm air flows

in through the foot vent. Adjust the air temperature in
the cab by operating temperature control switch (8) and
blower switch (9). When required to quickly warm the air M178-01-072
temperature in the cab, use the air circulation mode. How- 9 8
ever, if the air circulation mode is operated for a long time,
the windowpanes will become cloudy due to difference in
temperature between outside and inside the cab. Occasion-
ally ventilate the cab. (When the fresh air circulation mode 1
is used, the windowpanes will be prevented from becoming
cloudy.)
MCGB-01-018
3 2 MCGB-01-001
1-93
OPERATOR'S STATION
Defroster Operation
6 7
Press mode switch (6) (either the front or front/rear
vent mode switch). Set temperature control switch (8)
to the heat operation position. Press fresh air mode switch
(7).
Press blower switch (9). Warm air will flow in from the front
or front/ rear vents.
M178-01-072
Adjust airflow direction from front vent (1) and defroster 9 8
vent (3) by controlling the louver direction.
Use temperature control switch (8) and blower switch (9) to

adjust air temperature in the cab.
1
MCGB-01-018
3 2 MCGB-01-001
1-94
OPERATOR'S STATION
AM/FM RADIO OPERATION

Controls on the Radio
4 7 2
1- Power Switch/Volume Control Knob
2- Tone Adjustment Ring
3- AM/FM Switch
Each time this button is pressed, “AM” or “FM” is selected.
4- Station Presets
5- Tuning Switches
6- Display Mode Change Switch
3 6 8 5 1
Each time this button is pressed, the display indicates the
M1G6-01-026
clock or the receiving channel frequency.
7- Digital Display
8- Time Set Switches
IMPORTANT: Refrain from listening to the radio while

traveling or operating the machine. Being
distracted can possibly create a hazardous
situation.
Tuning Procedure
• Manual Tuning Procedure
Tap (within half second intervals) one of tuning switches
(5) until the desired station is detected.
Each time the tuning switch is pressed, the frequency
changes at an interval. 5
Tap the tuning switch to increase the frequency. M1G6-01-026
Tap the tuning switch to decrease the frequency.

Digital display (7) will return to the setting (the clock or
the frequency, whichever one is set by the display mode
change switch) approximately 5 seconds after tuning
switches (5) are no longer tapped or pressed.
• Automatic Search Function

Press and hold one tuning switch (5) for more than half a
second, then release. The frequency display will automati-
cally stop as soon as the next frequency station is detect-
ed.
To search the next higher frequency station, press and
hold the tuning switch ).
To search the next lower frequency station, press and hold
the tuning switch .
In order to deactivate the automatic search function, sim-
ply tap tuning switch (5) again.
If the receiving radio waves are weak, i. e. such as when
the machine is located between high rising buildings,
etc., manually select the desired station.
1-95
OPERATOR'S STATION
Station Presetting Procedure
1. Select the desired station using tuning switches (5). (Refer
4 7
to the “Tuning Procedure” section.)
2. When the desired station is confirmed, press and hold
one station preset button (4) for more than 1 second until
an electronic tone is heard. Now, the selected station fre-
quency is preset. After presetting is complete, the preset
button No will be indicated on digital display (7).
Once the presetting is complete, press the preset button
(4) for less than 1 second and release. The preset station
can be searched. To change the preset station, repeat the
5
procedures used when presetting a new station. M1G6-01-026
• Preset Deletion
If the batteries are disconnected when the machine is
serviced or the radio is removed, the memory by preset
button (4) is deleted. Then, repeat the preset procedures
in this case.
DIGITAL CLOCK SETTING PROCEDURE

When radio display (7) is in the time display mode, clock set-
ting can be done. 7
1. Press display mode button (6) to indicate the hour on

digital display (7).
2. Press and hold time set button (RST) (8) for longer than 1
second. The hour display will start flashing and the time
set mode will be selected.
3. Press time set button (8) to set the clock. Each time the
time set button (8) is pressed, the time display will in-
crease by one digit. If time set button (8) is continuously 6 8 M1G6-01-026
pressed, the time display will continuously change.

• When setting the hour, press time set button (H) (8).
• When setting the minute, press time set button (M) (8).
The time is displayed in 12 hour standard.
4. When the hour display is “12,” if time set button (H) (8) is
pressed, the hour display will be reset to “1.” When the
minute display is “59,” if time set button (M) (8) is pressed,
the minute display will be reset to “00.” However, the hour
display remains unchanged in this case.
5. After the clock setting is complete, press and hold time
set button (RST) (8) again for longer than 1 second, or
turn the power switch (1) OFF to end the clock time
setting procedure. Digital display (7) stops flashing and
changes to stay ON.
1-96
OPERATOR'S STATION
CAB DOOR RELEASE LEVER 1

CAUTION: When desired to open the cab door, open
the cab door all the way until it securely locks in the
latch on the side of the cab.
To unlock the door from this position, push down on lever (1).
OPENING UPPER FRONT WINDOW

WARNING: Open or close the upper-front cab window
only after pulling up the pilot control shut-off lever M1J1-07-051
to the LOCK position. Failure to do so may allow the
machine to move unexpectedly if a control lever is
touched with a part of the body by mistake, possibly
resulting in personal injury or death.
1. Press lock release lever (2) at the upper center of the

inside cab to release the upper front window lock.
2
2. While holding upper lock release lever (2) and the lower 3
handles on the upper front window, pull the upper front
window up and back until auto locks (4) provided at the
upper section of the front window frame securely catches
into strikers on the cab ceiling.
CAUTION: Always secure lock pin (3) in the lock posi- M1U1-01-028
tion after the upper front window is opened.
3. After confirming that the auto locks (4) securely catches

into strikers, slide lock pin (3) into the right bracket boss
hole to lock the window in position.
NOTE: When the upper front window is opened, the wiper and
washer are inoperable.
IMPORTANT: If the front window is opened or closed with

the steering wheel column in the upright
position, the steering wheel will come in
contact with the front window. Always tilt
the steering wheel column backward before
opening or closing the front window. M1CC-01-020
CAUTION: When closing the upper front window,

slowly lower the window while taking care not to
pinch your fingers. After upper front window is
opened, always slide lock pin (3) to the LOCK position.
4. When closing the upper front window, reversely follow

the procedures in steps 1, 2 and 3. Release auto lock (4)
by lowering the lock release lever.
NOTE: Unless the upper front window is completely closed, the 4

wiper is inoperable.
M1CC-01-031
1-97
OPERATOR'S STATION
CLOSING UPPER FRONT WINDOW

CAUTION: Avoid possible injury while closing win-
dow.
Upper front window comes down very forcefully.
Close window only when sitting in the operator's seat.
Guide window down slowly.
2
1. Pull out lock pin (3) to unlock window.
3
2. Slightly move the window forward while pushing lock
release levers (2) to release auto lock (4).
3. Pull window down slowly until it securely catches into
auto lock (4).
M1U1-01-028
NOTE: The wiper and washer won’t operate until the upper
front window is completely closed.
M1CC-01-031
1-98
OPERATOR'S STATION
REMOVING AND STORING LOWER FRONT WIN-

DOW
CAUTION: Take care not to pinch yours fingers when
handling the lower front window.
1. Open the upper front window beforehand when remov-

ing the lower front window.
2. While pushing the lower front widow outward, raise it to
remove.
3. Install the removed windowpane in the rear storing posi-
tion. After installing rubbers (2 and 3), slide the window-
pane and install rubber (1). Then, push the windowpane
toward lock (4) to secure the window in position.
MCGB-01-057
4 1
2
3
M1U1-01-056
1-99
OPERATOR'S STATION
OPENING DOOR WINDOWS

Holding handles (1), slide the windowpane to open/close the
cab door window.
1
MCGB-01-024
Cab Door Window
1-100
OPERATOR'S STATION
OPENING/CLOSING OVERHEAD WINDOW 1

(Std. Model)
Opening
1. Move lock levers (1) toward center of window.
2. Hold handle (2) and lift window until it rises upright. With
the window positioned upright, it will be secured in posi-
tion by dampers (3).
2
Closing
1. Hold handle (2) and pull window down until “click” sound
is heard from locks (1).
Note that the overhead window can be used as an emer-

gency exit.
MCGB-01-025
M1U1-01-054
1-101
OPERATOR'S STATION
EMERGENCY EXIT
1
If the operator’s cab door should not open in an emergency,
escape in the following methods:
1. Open the front windows. Escape through the windows.
NOTE: See page “OPENING UPPER FRONT WINDOWS” for the

opening method of the front windows.
CAUTION: Take care not be injured with pieces of
broken glass.
2. If the front window is difficult to open, break the front

window glass using the emergency evacuation tool (1).
M1U1-01-022
Then, escape through the broken window.
3. If the front window is not available for escaping, break
the rear window glass using the emergency evacuation
tool. Then, escape through the broken window.
NOTE: Emergency exit decals (2) are affixed to the front and
rear windows.
4. If neither of front and rear windows are available for

emergency exit, open the overhead window to escape
from the cab.
MCGB-01-025
MCGB-01-020
1-102
OPERATOR'S STATION
ADJUSTING THE SEAT

CAUTION: Avoid possible injury while operating
height/tilt lever (1). When pushing down height/tilt
lever (1), be sure to push on the upper face of height/
tilt lever (1). Do not grab it. Fingers may be pinched
between lever (1) and the seat stand.
Seat Height and Cushion Angle Adjustment

Front and rear parts of the seat height and cushion angle
are independently adjustable in the range of 60 mm (2.4 in)
with 5 steps every 15 mm by operating height/tilt lever (1).
Caution: Possibility Push down with
Pushing lever (1) downward:
of pinched fingers the palm.
Front part of the cushion can be raised or lowered. SS-955
Pulling lever (1) upward:

Rear part of the cushion can be raised or lowered.
Console and Seat Fore-aft Adjustment

Operate console and seat slide lever (2) to adjust the con-
sole and seat fore-aft position.
Seat and console fore-aft adjustment range is 120 mm with
7 steps every 20 mm.
1
5
Seat Fore-Aft Adjustment
Operate seat fore-aft slide lever (3) to adjust the seat fore-aft
position.
Seat fore-aft adjustment range is 160 mm with 11 steps 2
every 16 mm.
4 3
M178-01-065
Suspension Adjustment
Turn knob (4) clockwise to increase suspension stiffness.
Turn knob (4) counterclockwise to decrease suspension stiff-
ness.
Backrest Adjustment
Pull backrest adjustment lever (5) to release backrest lock.
Move the backrest to the desired position and release the
lever to lock the backrest in position.
1-103
OPERATOR'S STATION
Armrest Adjustment
Armrest (5) can be pulled upward and rotated 90° by hand.
When getting on and off the machine, pull it upward.
The angle of armrest (5) can be adjusted to the desired posi-
5
tion by turning adjusting dial (6) located on the bottom of
armrest (5).
M1G6-01-017
SEAT WITH A BUILT-IN HEATER (OPTIONAL)

The heater installed inside the seat activates by operating seat 8
heater switch (8) on the optional equipment control switch
panel.
NOTE: Depending on what kinds of optional equipments are

installed, the switch button function may differ. Use the
switch only after confirming the kinds of the installed
optional equipment.
M1U1-01-011
1-104
OPERATOR'S STATION
ADJUSTING THE AIR-SUSPENSION SEAT

(Optional)
CAUTION: Avoid possible injury while operating

height/tilt lever (1). When pushing down height/tilt
lever (1), be sure to push on the upper face of height/
tilt lever (1). Do not grab it. Fingers may be pinched
between lever (1) and the seat stand.
Seat Height and Cushion Angle Adjustment

Front and rear parts of the seat height and cushion angle
are independently adjustable in the range of 60 mm (2.4 in) Caution: Possibility Push down with
with 5 steps every 15 mm by operating height/tilt lever (1). of pinched fingers the palm.
Pushing lever (1) downward: SS-955
Front part of the cushion can be raised or lowered.

Pulling lever (1) upward:
Rear part of the cushion can be raised or lowered.
Console and Seat Fore-aft Adjustment

Operate console and seat slide lever (2) to adjust the con-
sole and seat fore-aft position.
Seat and console fore-aft adjustment range is 120 mm with
7 steps every 20 mm.
5 1
Seat Fore-Aft Adjustment

Operate seat fore-aft slide lever (3) to adjust the seat fore-aft 2
position.
Seat fore-aft adjustment range is 160 mm with 11 steps
M1U1-01-014
every 16 mm. 4 3
Suspension Adjustment
Push knob (4) to increase suspension stiffness.
Pull knob (4) to decrease suspension stiffness.
Backrest Adjustment
Pull backrest adjustment lever (5) to release backrest lock.
Move the backrest to the desired position and release the
lever to lock the backrest in position.
1-105
OPERATOR'S STATION
Armrest Adjustment
Armrest (6) can be pulled upward and rotated 90° by hand.
When getting on and off the machine, pull it upward.
The angle of armrest (6) can be adjusted to the desired posi-
6
tion by turning adjusting dial (7) located on the bottom of
armrest (6).
M1G6-01-017
SEAT WITH A BUILT-IN HEATER

The heater installed inside the seat activates by operating seat 8
heater switch (8) on the optional equipment control switch
panel.
NOTE: Depending on what kinds of optional equipments are

installed, the switch button function may differ. Use the
switch only after confirming the kinds of the installed
optional equipment.
M1U1-01-011
1-106
OPERATOR'S STATION
SEAT BELT
CAUTION: Be sure to use the seat belt when operat- 1 2
ing the machine. Before operating the machine, be
sure to examine the seat belt, buckle, and attaching
hardware. Replace the seat belt, buckle, or attaching
hardware if they are damaged, or worn. Replace seat
belt every three years, regardless of appearance.
Fastening and Unfastening Seat Belt

1. Confirm that seat belt (1) is not twisted. Securely insert
the end of seat belt (1) into buckle (2). Lightly pull on the
belt to confirm that the buckle latches securely.
2. Push button (3) on buckle (2) to unfasten seat belt (1).
MCGB-01-027
2 1
3
MCGB-01-028
1-107
OPERATOR'S STATION
MEMO
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1-108
BREAK-IN
OBSERVE ENGINE OPERATION CLOSELY

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

the engine horsepower up to about 80 % of full load.
2. Avoid excess engine idling.
3. Check indicator lights and gauges frequently during
operation.
EVERY 8 HOURS OR DAILY

1. Perform 8-hour or daily service. (See Maintenance guide
-- 8 hours.)
2. Watch for fluid leaks.
3. Lubricate working tool pivots every 8 hours for the first
50 hours, and every 8 hours when working in mud and
water.
AFTER THE FIRST 50 HOURS

1. Perform 50-hour service. (See Maintenance guide -- 50
hours.)
2. Check accessible hardware torque. (See Hardware Torque
Specifications in Maintenance chapter.)
AFTER THE FIRST 100 HOURS

Perform 50-hour and 100-hour service. (See Maintenance
Guide -- 50 hours and 100 hours.)
2-
BREAK-IN
MEMO
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2-
INSPECT MACHINE DAILY BEFORE STARTING

Be sure to inspect the machine daily before starting the en-
gine.
• Refer to the MAINTENANCE section for the detailed inspec-
tion procedures.
Inspection Points Inspection Points

Brake device 1. Service brake pedal stroke is appro- Upperstructure 1. Fuel level and leaks, mixing of for-
priate, and brake works effectively eign matter in fuel tank, and drain-
and evenly. ing water from fuel tank
2. Brake oil pressure normally increases. 2. Hydraulic oil level and leaks, mixing
3. Parking brake works effectively. of foreign matter in hydraulic oil tank
3. Control lever function, play in stroke,
and operating force
4. Function of individual hydraulic
Tire 1. All tires are inflated with appropri- component, oil leaks and damage of
ated air pressure. hoses and/or pipes
2. No cracks and damage are present. 5. Deformation, break, noise in any sec-
3. No abnormal wear is found tions
4. No fragmented metal pieces, stones, 6. Loose or missing bolts and nuts
or other foreign matter are found on 7. Window washer fluid
tire surfaces.
Undercarriage 1. Oil leaks from driving device

2. Loose or missing bolts and nuts
Lighting system All lights and indicators normally oper- Work tools 1. Oil leaks, damage in cylinders, pipes,
and turn signal ate to light and extinguish. No contami- and hoses
indicators nation and/or damage are found. 2. Wear or damage on bucket
3. Loose, worn, or missing bucket tooth
Rear view mirror Normal images are displayed. 4. Lubrication status
and side mirror 5. Damage to pins, stoppers, links, bolts
for pin locking
Reflector, license No contamination and/or damage are 6. Loose or missing bolts and nuts
number plate or found.
vehicle number
plate (if equipped)
Area found abnor- No abnormality is present in corre- Others 1. Functions of instruments, switches,
mal during opera- sponding area. and horn
tion on previous 2. Pilot control shut-off lever function
day 3. Swing parking brake and swing lock
lever functions
Engine 1. Engine oil and coolant level, and 4. Damage and/or deformation of head
contamination cover
2. V-belt slackness and damage 5. Abnormal machine appearance
3. Starting easiness, exhaust gas color, 6. Wear and/or damage of seat belt
and abnormal noise
4. Oil and water leaks, and damaged
hoses and pipes
5. Damage to radiator, oil cooler, inter-
cooler and clogged cores
6. Loose and missing bolts and nuts
3-
BEFORE STARTING ENGINE 1
1. Confirm that pilot control shut-off lever (1) is in the

LOCK position.
2. Confirm that forward/reverse switch (3) is placed in “N”
(neutral).
3. Confirm that brake switch (2) is in “P” (parking) posi-
tion.
4. Confirm that right and left control levers are placed in
neutral.
5. Take the seat. Adjust the seat position so that the ped-
als and control levers can be easily operated full stroke Lock Position MCGB-05-001
with operator’s back against the backrest. Fasten the 2
seat belt.
NOTE: Use a wet cloth when wiping dust off monitor or switch
panels to prevent damaging the panel face.
Rubber is used on the switch parts. Take care not to tear
the rubber-made parts with sharp-edged tool, such as
3
a screwdriver.
CAUTION: If the security lock screen is displayed
when turn the key switch to ON position, return key
switch to OFF. Wait for more than 30 seconds (the
buzzer stopped), then try again. If the security lock
screen is displayed again, contact your nearest HITA-
CHI dealer.
MCGB-01-008
M178-01-049
Security Lock Screen

T1V5-05-01-005
3-
STARTING THE ENGINE IN ORDINARY TEMPERA- 1

TURE
1. Check that the pilot control shut-off lever (1) is in the
LOCK position.
2. Turn engine control dial (3) to the slow idle position.
3. Sound horn to alert bystanders.
4. Insert key switch (2). Turn it in the ON position.
5. The monitor displays “WAIT” screen (Nothing is dis-
played) for 2 seconds. Regardless of the pilot control
shut-off lever position, the engine is not cranked at
this time.
Lock Position MCGB-05-001
Slow Idle
3
M178-01-049 M1U1-01-033
3-
6. After starting screen (4) is displayed, basic screen (5) is

displayed. 4
7. When the password input screen (7) is displayed on the
monitor, input the password. Unless the TEN-key func-
tion (ignition block system) is activated, this screen is not
displayed.

tion (ignition block system), consult your
nearest Hitachi dealer. T1V1-05-01-115
NOTE: When maintenance information display is ON with Password

Icon 5
maintenance setting, the scheduled maintenance
screen for the item whose change interval has expired
displays for three to ten seconds. Then, the basic screen
displays.
8. When basic screen (8) is displayed on the monitor,

6
check that preheat indicator (9) is not ON.
9. Turn key switch (2) to the START position to rotate the
starter. The engine starts running. Basic Screen MCGB-01-047
IMPORTANT: Prevent starter damage. 7

Never operate starter motor for more than
10 seconds at a time. If engine fails to start,
return key switch to OFF. Wait for more than
30 seconds, and then try again. Failure to do
so may result in damage to the starter and
/or causing the batteries to discharge.
Password Input Screen T1V5-05-01-002
T1V5-05-01-170
9
MCGB-03-004
3-
10. Release key switch (2) immediately after the engine has
started. It will automatically return to ON position.
NOTE: In case the oil pressure in the brake accumulator is low,

when the key is turned ON, the buzzer continues to
sound and brake oil pressure indicator (10) comes ON.
However, this is not a failure, advising that the brake
does not work effectively even if the brake pedal is
depressed as the oil pressure in the accumulator is low.
10
Brake oil pressure indicator (10) will go OFF and the
buzzer will stop sounding after a short time.
MCGB-03-005
3-
STARTING IN COLD WEATHER 1
Preheating
1. Check that pilot control shut-off lever (1) is in the LOCK
position.
2. Turn engine control dial (3) to around the middle be-
tween the L and H positions.
3. Sound horn to alert bystanders.
4. Insert key (2) into the key switch. Turn the key switch ON.
5. The monitor displays “WAIT” screen (Nothing is dis-
played) for 2 seconds. Regardless of the pilot control
shut-off lever position, the engine is not cranked at
this time.
Slow Idle
3
M178-01-049
M1U1-03-003
3-
6. After starting screen (4) is displayed, basic screen (5) is

displayed. 4
7. When the password input screen (7) is displayed on the
monitor, input the password. Unless the TEN-key func-
tion (ignition block system) is activated, this screen is not
displayed.

tion (ignition block system), consult your
nearest Hitachi dealer. T1V1-05-01-115
NOTE: When maintenance information display is ON with Password

Icon 5
maintenance setting, the scheduled maintenance
screen for the item whose change interval has expired
displays for three to ten seconds. Then, the basic screen
displays.
8. When basic screen (8) is displayed on the monitor, the

machine will automatically check if preheating is required 6
or not. When preheating is required, preheat indicator (9)
is automatically lit. Basic Screen MCGB-01-047
NOTE: In case, preheat indicator (9) doesn’t come ON, pre- 7

heating is not required. Follow the same starting proce-
dures as taken in ordinary temperature.
9. As soon as preheat indicator (9) goes OFF, turn the key

switch (2) to the START position to rotate the starter.
IMPORTANT: Prevent starter damage.
Never operate starter motor for more than
10 seconds at a time. If engine fails to start,
return key switch to OFF. Wait for more than Password Input Screen T1V5-05-01-002
30 seconds, and then try again. Failure to do

so may result in damage to the starter and
/or causing the batteries to discharge.
10. Release key switch (2) immediately after the engine has
started. It will automatically return to ON position.
T1V5-05-01-170
9
MCGB-03-004
3-
STARTING IN COLD WEATHER (ZX140W-3)

1
In extremely low temperature, the engine may not readily
start.
If this is the case, follow the procedure below.
Pre-cranking
Turn key switch (1) to START position for 30 seconds.
Then, turn key switch (1) OFF.
M178-01-049
2
Without Cranking
To prevent starter damage, turn key switch (1) to ON posi-
tion for 15 seconds until preheat indicator (2) goes OFF.
Cranking for Engine Start

Again, turn key switch (1) to START position.
MCGB-03-003
3-
CHECK INSTRUMENTS AFTER STARTING

Check through Monitor
After starting the engine, check the following points.
1. Check if alternator indicator (1) is off. If no, immedi-
ately stop the engine. Check the alternator and battery 1
systems for any problems.
2. Check if engine oil pressure indicator (2) is off and the
buzzer stops sounding. In case engine oil pressure 2
indicator (2) is ON (the buzzer will simultaneously
sound), immediately stop the engine. Check the en-
gine oil pressure system and the engine oil level.
3. Engine noise and exhaust gas are normal.
MCGB-03-006
IMPORTANT: Prevent possible damage to engine. If in-
dicator lights do not go out after starting
engine, IMMEDIATELY STOP THE ENGINE and
correct the cause.
Operate machine at less-than-normal loads

and speeds until engine is at normal operat-
ing temperature.
Check Engine Noise and Exhaust Color

Check if engine noise and exhaust color is normal.
NOTE: Exhaust color checking guide (Check with no load after

warming up operation.)
No color or light blue: Normal (complete combus-
tion)
Black: Abnormal (incomplete combustion)
White: Abnormal (oil leaks into the combustion
chamber)
3-
USING BOOSTER BATTERIES

WARNING:
• An explosive gas is produced while batteries are in
use or being charged. Keep flames or sparks away
from the battery area. Charge the batteries in a
well ventilated area.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion
of the battery may result.
Park the machine on a dry, firm or concrete surface,
not on steel plates, if the machine is parked on
SA-032
steel plates, dangerous sparks may be unexpect-
edly created on the machine.
Never connect a positive terminal to a negative
terminal, as a dangerous short circuit will occur.
• The operator must be in the operator’s seat so that
the machine will be under control when the engine
starts. Jump starting is a two-person operation.
IMPORTANT: The machine electrical system is a 24 volt

negative (–) ground. Use only 24 volt boost-
er batteries.
When the machine batteries are exhausted, start the engine

using booster batteries as shown below.
Connect First
1
Connecting the Booster Batteries
(Red)
1. Stop the engine of the booster battery mounted
machine.
2. Connect one end of red cable (1) to the positive (+)
terminal of the machine batteries, and the other
end to the positive (+) terminal of the booster bat-
teries.
3. Connect one end of black cable (2) to the negative Booster Batteries Machine Batteries
(–) terminal of the booster batteries, and then make (Black)

ground connection to the upperstructure frame To Upperstructure of the Machine
of the machine to be started with the other end of 2
black (–) cable (2). In the last connection to frame, Connecting the Booster Batteries
M104-03-002
sparks will be generated. Be sure to connect the
cable end as far away from the machine batteries as
possible.
4. After securely connecting the booster cables, start
the engine of the booster battery mounted ma-
chine.
5. Start the engine of the machine with batteries to be
boosted.
6. After the engine starts, disconnect cables (2) and (1),
following the procedure below.
3-10
Disconnecting the Booster Batteries
1. Disconnect black negative (–) cable (2) from the ma- 1
chine upperstructure frame first.
(Red)
2. Disconnect the other end of black negative (–) cable (2)
from the booster batteries.
3. Disconnect red positive (+) cable (1) from the booster
batteries.
4. Disconnect red positive (+) cable (1) from the machine
batteries.
Booster Batteries Machine Batteries
(Black)
To Upperstructure of the Machine
2
Connecting the Booster Batteries
M104-03-002
3-11
STOPPING THE ENGINE 1
Engine Stop Procedure

1. Except for a special case, before stopping the engine,
Lower the bucket to the ground.
2. Shift forward/reverse switch (3) to “N” (neutral). Turn
brake switch (2) to the “P” (parking) position.
3. Pull pilot control shut-off lever (1) to the LOCK posi-
tion.
4. Turn engine control dial (4) to the slow idle position
and run the engine for 5 minuets to cool the engine.
IMPORTANT: If an engine equipped with a turbocharger is 2

quickly stopped without being cooled, the
lubrication area on the turbocharger will
become dry due to intense heat, possible
resulting in damage to the turbocharger.
5. Turn key switch (5) OFF to stop the engine. 3
NOTE: Turn forward/reverse travel switch (3) to [N] position,

when turning key switch OFF. In the European models,
Alarm will activate if forward/reverse travel switch (3) is
kept in [F] or [R] position.
MCGB-01-008
Slow
Idle
M1U1-01-033 M178-01-049
If the engine does not stop with the key switch turned in
the OFF position
If the engine does not stop when the key switch is turned
OFF due to any malfunction of the machine or key switch,
lower engine stop switch (6). The engine will stop. Return
engine stop switch (6) to the original position after the en-
gine stops.
CAUTION: Do not use engine stop switch (6) except
when unavoidable. Moreover, do not operate the ma-
chine until the machine is completely repaired in case
the engine was stopped due to machine failure.
6 MCGB-03-002
3-12
DRIVING THE MACHINE
TRAVELING
Correct machine operation will extend all part/component ser-
vice life and save fuel and lubricants. To operate the machine
safely and economically, follow the instructions below.
1. Check the tires for any damage, such as scratches, cracks,

etc.. Check the pressure of each tire. Check for obstruc-
tions or danger around the machine.
2. Sufficiently raise the stabilizers and/or the blade.
3. Position the front attachment to the front of the machine,
then insert the swing lock lever.
4. When traveling on a public road, attach the bucket and
position the front attachment as illustrated below, then
place the pilot control shut-off lever in the “LOCK” posi-
tion so that the front attachment wouldn’t move even if
the control lever mistakenly comes in contact with other
object.
5. When traveling, fully rotate the engine control dial coun-
terclockwise to let the engine run at the slow idle. Use
the accelerator pedal to regulate the engine speed.
Unit: mm
3960
3680
3850 2550 4595 2550
MCGB-04-003 MCGB-04-005
ZX140W-3 Monoblock Boom ZX170W-3 Monoblock Boom
3980
3980
4950 2650 5420 2750
MCGB-04-007 MCGB-04-009
ZX190W-3 Monoblock Boom ZX210W-3 Monoblock Boom
4-
DRIVING THE MACHINE
ENGINE SPEED CONTROL

The engine speed control mode is selected with engine control
mode selector (1). Depending on machine operating condi-
tions, select the proper engine control mode.
• Pedal Mode
This mode suits normal travel operation best. Adjusting the
stroke of the accelerator pedal controls the engine speed.
When the accelerator pedal is stepped on, the engine speed
increases. When the pedal is returned to neutral, the engine
speed is reduced. After the engine speed is set to run at slow 1
idle speed by fully turning the engine control dial counter-
clockwise before traveling the machine, when traveling is
started by stepping the accelerator pedal, the engine speed
increases in proportion to the pedal stroke. When the pedal
is returned to neutral to temporarily stop the machine, the
engine speed is reduced to slow idle speed, decreasing fuel
consumption and travel noise level.
• Dial Mode
This mode suits traveling in the job site best. Only the en- TCJB-01-02-003
readjustment of the engine speed is required. However, the
maximum travel speed is slightly slower than that of the
pedal mode.
• Creeper Mode
speed is controlled with the engine control dial only. Even
4-
DRIVING THE MACHINE
TRAVEL MODE SWITCH

WARNING: Tipping-over accidents can cause serious
personal injury. Do not change travel mode while
traveling; especially, changing to the fast mode when
descending slopes will create a very dangerous situ-
ation. Always stop the machine before changing the
travel speed mode.
Turn travel mode switch (1) on the switch panel to the speci-
fied position to select the travel mode (Fast/Slow). 1
2
• Fast Mode: Turn travel mode switch (1) to mark (2) 3
position.
• Slow Mode: Turn travel mode switch (1) to mark (3)
position.
Mark (Fast Speed Mode)

Mark (Slow Speed Mode)
Starting to Travel
1. Be sure that brake oil pressure gauge needle remains M1U1-01-015
within the white range.
2. Check for safety around the machine. Place the forward/
reverse switch in the forward or the reverse position. Turn
the brake switch OFF (traveling) to release the parking
brake. Engine speed (travel idle speed) will increase at
this time. Slowly step on the accelerator pedal to start
traveling. Use the accelerator pedal to accelerate or de-
celerate the travel speed.
3. In a safe place, confirm that the brakes function properly.
WARNING: When the upperstructure is rotated 180

˚, travel and steering control directions are reversed.
Use extra care when traveling.
4-
DRIVING THE MACHINE
STOPPING AND RESTARTING

Use this operation method when requiring temporally stop-
ping or moving the machine for a short distance.
1. After smoothly releasing the accelerator pedal, gently
step on the brake pedal to stop the machine.
2. Slowly depress the accelerator pedal to start the machine
moving again.
3. When stopping the machine for long period, always place
forward/reverse switch in neutral, turn the brake switch
to the P (parking) position and apply the parking brake
for your safety.
4. Front attachment may lower while driving because of
natural, internal hydraulic oil leakage. When this happens,
stop the machine in a safe place. Return the forward/re-
verse switch to neutral, turn the brake switch to the axle
lock or auto axle lock position and apply the working
brake. Always keep in mind to hold the front attachment
in the correct traveling position.
Driving Instructions
For your safety and the safety of others, keep in mind the
following instructions, and obey all traffic regulations while
driving.
WARNING:
• Should you have a flat tire while driving, hold
the steering wheel tightly, and stop the machine
gradually. Do not apply the brake suddenly. Doing
so may cause the steering wheel to become out of
control, possibly creating serious accidents.
• Do not try to get on or off the machine while trav-
eling. Allow only the operator on the machine. Do
not give rides.
• When installing a 2-way radio, locate an antenna
outside the cab.
• If the antenna is located in the cab, travel speed
may become out of control due to radio wave inter-
ference.
IMPORTANT:
• Stop the machine immediately if the warning
buzzer sounds, the brake oil pressure indicator or
the abnormal travel motor indicator comes on.
• Even after the break-in period is over, avoid running the

engine at high speeds with no load.
• If you notice any abnormal sounds or smells while travel-
ing, immediately stop the machine and the engine, and
check for causes.
• Do not quickly turn the steering wheel or do not suddenly
apply the brake. Doing so may cause accidents involving
your machine and/or following vehicles.
4-
DRIVING THE MACHINE
• This machine is slow-moving vehicle. Always drive to the
side of the road and yield to faster vehicles.
• Front attachment reduces visibility to the right and right
front of the machine. Before approaching a curve, reduce
speed and drive with extra care for the right side and
right front side visibility.
• Make it customary to check monitor (especially brake oil
pressure gauge). If any abnormality is indicated, stop the
machine immediately, and check for causes.
• Use a signal person when driving on the shoulder of a
road or in congested areas.
• Before restarting at an intersection or turning right, be
sure to check the right and right front of the machine for
any obstructions. After confirming safety, slowly restart
driving.
4-
DRIVING THE MACHINE
INSTRUCTIONS FOR TRAVELING ON A SLOPE

WARNING:
• Primarily use hydraulic pressure brake (relief pres-
sure) when descending a slope. Step on the brake
pedal only when required. If only the foot brake
is used, the brake will overheat, decreasing brake
performance and possibly causing a personal ac-
cident. In case the brake system overheats, imme-
diately park the machine in a safe area. Wait for the
brake system to cool before restating to travel the
machine.
• When descending a long slope continuously, hy-
draulic oil temperature in the travel circuit may in-
crease. Occasionally step on the accelerator pedal
to slacken increasing oil temperature sharply.
CAUTION:
• Do not descend a slope with the forward/reverse
switch kept in neutral. Damage to the travel motor
may result.
• If hydraulic oil temperature in the travel circuit
overheats, damage to the hydraulic components
may result.
• In case the engine stalls on a slope, be sure to depress

the brake pedal and turn the brake switch to “P” (parking)
position. Then, restart the engine.
• Before descending a slope, operate the brake to check
that the brake operates normally.
• When hydraulic oil and/or lubricant is not warmed up,
gradeability may be reduced. Before ascending a steep
slope, sufficiently perform warm up operation of the ma-
chine.
4-
DRIVING THE MACHINE
TRAVELING IN WATER OR ON SOFT TERRAIN

1. Do not operate the machine with the front and rear axles,
transmission, parking brake or front and rear propel
shafts submerged in water. Avoid traveling in water if
possible.
2. When traveling in water is unavoidable, the machine may
be submerged up to a depth of A: 300 mm (11.8”) as long
as the stream bed is even and the water flows slowly.
If the bed is uneven and the water flow is rapid, leave a A
safety margin in order to guarantee the machine will not
be submerged deeper than 300 mm (11.8”). MCHB-04-001
3. When operating the machine on muddy ground, mud will
easily accumulate on the chassis frame even if the chassis
is seldom submerged in muddy water.
Check regularly and clean as necessary.
IMPORTANT: Once the axles, transmission, parking brake,

etc. are submerged, they should be recon-
ditioned immediately. Otherwise excessive
wear on revolving parts such as gears and
bearings will result in and/or the brake will
become inoperable.
Consult the nearest your authorized dealer.
EXTRICATION FROM SOFT GROUND

Avoid traveling on soft terrain. In case the machine has to un-
avoidably travel on soft train, follow the instruction below:
If the wheels start spinning, lower the bucket to the ground

and raise the machine front off the ground using the boom
and arm function. Then, try to extricate the machine while roll-
ing the arm in. Operate the boom, arm, and accelerator pedal
simultaneously so that excessive loads will not be applied to
the machine.
4-
DRIVING THE MACHINE
PARKING
WARNING:
the machine correctly according to the parking
procedures.
Park the machine in the following steps:

M202-04-002
1. Slowly release accelerator pedal (1).
2 1
2. Depress brake pedal (2) to stop the machine.
3. Place forward/reverse travel switch (3) or FNR-lever (9) in
neutral.
4. Turn auto-idle switch (5) OFF.
5. After checking that the swing lock is in the LOCK posi-
tion, lower the bucket to the ground. 8 4
6. Turn brake switch (4) to the P (parking) position.
7. Fully turn engine control dial (6) counterclockwise. Run 3
the engine at slow idle speed for approx. 5 minutes to
cool the engine.
8. Turn key switch (7) OFF to stop the engine. Remove the
key.
9. Raise pilot control shut-off lever (8) to the LOCK position. 7
10. Turn the brake switch (7) to “P” (parking) position.
11. Before leaving the machine, close and lock all windows,
cab door, and service access covers. Secure the wheels
with wedges.
MCGB-04-001
IMPORTANT: Protect cab electrical components from bad
weather. Always close windows, roof vent
and cab door when parking the machine.
5
MCGB-01-058 TCJB-01-02-003
4-
DRIVING THE MACHINE
EMERGENCY PARKING DUE TO MACHINE FAILURE

• Look out for following vehicles. Slow down gradually. Ma-
neuver the machine to the side of the road. Stop the ma-
chine, turn the brake switch to the P (parking) position and
apply the parking brake. If trouble should occur in a short
tunnel, keep driving if possible, through the tunnel, then
park the machine.
• Use one or more of the methods below to indicate that your
machine is disabled. Failure to do so may cause accidents,
such as passing vehicle (s) colliding into your machine.
• Place a hazard mark, indicating emergency parking, be-
hind your machine.
• Turn on hazard lights.
• Use an emergency signal device such as an emergency
signal flare.
• Place a red flag or a red light on the machine.
• Tie a handkerchief on the most visible, rear part of your
machine.
WARNING:
• Avoid spilling oil on the road. Oil on the road can
cause vehicles passing by to slip, resulting in acci-
dents.
• When hydraulic oil is leaking, stop the leak as soon
as possible. Should a large amount of oil be spilled
on the road, warn following vehicles first. Then,
remove the oil from the road.
• Inspect the failed section and if possible, conduct
repairing on site. Before and while repairing, pay
attention to safety conditions around the machine,
and be aware of traffic of other vehicles.
• If the machine is parked in a tunnel, do not attempt
to repair the machine even if it appears easy as
working outside the machine is very hazardous.
• When repairing alone is difficult, contact a nearby
authorized dealer.
4-
DRIVING THE MACHINE
TRAVEL ALARM (OPTIONAL) Armrest
The travel alarm sounds the buzzer during traveling to notify

the personnel around the machine that the machine is travel-
ing.
Travel Alarm Deactivation Method

When 12 seconds or more have passed after the machine
started traveling, press the right side of travel alarm deac-
tivation switch (4) to stop the buzzer from sounding. (The Optional Switch
travel alarm is not deactivated even if it is pressed within 12 Location
seconds.) When the machine restarts traveling, the buzzer
will sound again. When desired to stop the buzzer from
sounding, press travel alarm deactivation switch (4) again. MCGB-01-022
NOTE: An optional switch location may differ according to the 4

type of the attached optional equipment. Operate the
optional switch after confirming the type of the at-
tached optional equipment.
M1U1-01-035
4-10
Control Lever (ISO Pattern) (STANDARD)

WARNING:
• Never extend your head and/or limb beyond the
window frame when operating the boom. Never
remove the grate from the window. Failure to do
so may cause your head and/or limb to be crushed
between the boom and the cab frame.
• Always check each lever control pattern before 1 5
operating the machine to prevent possible injury
from unexpected machine movement.
• Do not attempt to change the lever control pat- 4 3 7 8
terns, possibly inducing malfunction of the ma-
chine.
2 6
The lever control pattern label is affixed on the left side wall in
the cab when the machine is shipped from the factory.
IMPORTANT: When digging, avoid hitting tracks with

boom cylinders.
When digging over the end of the tracks,
travel motors should be at the rear to maxi-
MCGB-01-008
mize machine stability and lift capacity.
When a lever is released, it will automatically return to neutral,

stopping the corresponding machine function such as upper-
structure swing, arm, boom or bucket in that position.
3
1
1- Arm Roll-Out 4
2- Arm Roll-In
3- Swing Right 2
4- Swing Left
M202-05-001
5- Boom Lower
6- Boom Raise 6
7- Bucket Roll-In.
8- Bucket Roll-Out 8
7
5
M202-05-002
5-
Control Lever (HITACHI Pattern)

WARNING:
• Never extend your head and/or limb beyond the
window frame when operating the boom. Never
remove the grate from the window. Failure to do
so may cause your head and/or limb to be crushed
between the boom and the cab frame to prevent
possible injury from unexpected machine move- 1 5
ment.
• Always check each lever control pattern before op-
erating the machine. 4 3 7 8
The lever control pattern label is affixed on the left side wall in
the cab when the machine is shipped from the factory. 2 6
IMPORTANT: When digging, avoid hitting tracks with

boom cylinders.
When digging over the end of the tracks,
travel motors should be at the rear to maxi-
mize machine stability and lift capacity.
MCGB-01-008
When a lever is released, it will automatically return to neutral,
stopping the corresponding machine function such as upper-
structure swing, arm, boom or bucket in that position.
1
1- Swing Right 4
2- Swing Left
2
3- Arm Roll-In
4- Arm Roll-Out 3
M202-05-001
5- Boom Lower
6- Boom Raise 6
7- Bucket Roll-In.
8- Bucket Roll-Out 8
7
5
M202-05-002
5-
PILOT CONTROL SHUT-OFF LEVER

1
Pilot control shut-off lever (1) prevents misoperation of the
machine from occurring if the control levers are accidentally
moved when leaving the operator’s seat or when entering the
cab.
WARNING:
• Always pull pilot control shut-off lever (1) into the
full LOCK position. The pilot control shut-off func-
tion will not be activated otherwise.
• When leaving the machine, be sure to stop the en-
gine. Then, pull the pilot control shut-off lever up
to the LOCK position.
• Always pull the pilot control shut-off lever up to the LOCK Position MCGB-05-001
LOCK position after operation is complete or before
transporting the machine.
Before Leaving the Machine:

1. Park the machine on firm, level surface. Lower the bucket
to the ground. Place all control levers to neutral. Turn the
brake switch to the “P” (parking) position. Properly shut
down the engine. 1
2. Pull pilot control shut-off lever (1) up to the full LOCK

position.
Before Starting Operation:

1. Place pilot control shut-off lever (1) in the LOCK position
before starting the engine. UNLOCK Position MCGB-05-002
After starting the engine:

1. When starting operation, slowly lower pilot control
shut-off lever (1) to the UNLOCK position from the LOCK
position. Confirm that all control levers and pedals are in
neutral and that no part of the machine is in motion.
WARNING: When pilot control shut-off lever (1) is

lowered to the UNLOCK position, if any part of the
machine (any actuator) moves with all controls in
neutral, the machine is malfunctioning. Immediately
pull the pilot control shut-off lever back to the LOCK
position, and stop the engine. Then, consult your
nearest Hitachi dealer. The travel system is operable
even though pilot control shut-off lever (1) is placed
in the LOCK position. When traveling, always place
pilot control shut-off lever (1) in the LOCK position.
Failure to do so may cause the front attachment to
unexpectedly move if the control levers are moved
by mistake, possibly resulting in personal injury or
death.
5-
STEERING WHEEL COLUMN

1
The tilt angle of the steering wheel column on this machine
can be adjusted. When tilting steering wheel column (1) back-
ward, pull steering wheel column (1) while depressing tilt
pedal (2). Release tilt pedal (2) to lock steering wheel column (1)
in that position. When desired to stand steering wheel column
(1) upright, push down tilt lever (2). The steering wheel column
is automatically tilted back to the upright position. When tilt
pedal (2) is released on a half way, the steering wheel column
is automatically locked in that position.
IMPORTANT: If the front window is opened or closed with

the steering wheel column upright, the
steering wheel comes in contact with the
MCGB-05-001
front window. Be sure to open or close the
front window with the steering wheel col-
umn tilted backward.
MCGB-01-004
2
5-
WARMING-UP OPERATION
During cold weather season, warm up the engine in the follow-
ing procedures until the coolant and hydraulic oil temperature
increases to the appropriate operating temperature. 1
Slow Idle
IMPORTANT: The appropriate hydraulic oil operating tem-
perature on this machine is 50 to 80 °C.
Hydraulic components may be seriously
damaged if the machine is operated with
low temperature hydraulic oil.
In case warming up the machine by relieving
M1U1-01-033
the hydraulic system, continuously relieve
the relief valve for 10 to 15 seconds while 2
taking a pause for 5 to 10 seconds.
1. Turn engine control dial (1) to the slow idle position. (Do
not operate the machine until the needle of coolant tem-
perature gauge (2) starts swinging.
2. After the needle of coolant temperature gauge (2) starts
swinging, turn engine control dial (1) to approx. medium
position.
3. Slowly reciprocate the boom, arm, and bucket cylinders
full stroke several times.
4. Operate the travel and swing functions slowly to allow
hydraulic oil to circulate through the systems.
5. Warming up operation ends after the above operation is MCGB-01-053
completed.
NOTE: During cold weather season, the warm-up operation

system automatically operates so that the engine
speed may increase for a moment even though the
engine control dial is in the slow idle position.
M1U1-03-006
5-
ENGINE SPEED CONTROL

Increase and decrease the engine speed using engine control
dial (1) located on the switch panel. 1
• Turn engine control dial (1) clockwise to increase the en-

gine speed. Turn engine control dial (1) counterclockwise
to decrease the engine speed.
• Note that the auto-idle function will be deactivated if
engine control dial (1) is operated while the engine is run-
ning in the auto-idle mode.
• Before stopping the engine, always turn engine control
dial (1) counterclockwise to the stop (to the slow idle
setting). Run the engine five minutes to cool the engine.
Then, turn key switch to OFF position to stop the engine.
TCJB-01-02-003
Fast Idle
1
Slow Idle
M1U1-01-033
5-
AUTO-IDLE 1
Auto-Idle Function
With auto-idle switch (3) turned to the A/I ON position, ap-
proximately 4 seconds after all control levers are returned to
neutral, the engine speed decreases to the auto-idle setting
to save fuel consumption. The engine speed will immediate-
ly increase to the speed set by engine control dial (2) when
any control lever is operated.
IMPORTANT: • Always check if auto-idle indicator (1) is

turned ON or OFF before starting opera-
tion. If the indicator is ON, the auto-idle
function will be activated.
MCGB-01-038
• When any control lever is operated from
the neutral position with auto-idle switch
(3) in the A/I ON position, the engine
speed increases up to the speed set by 2
engine control dial (2). Therefore, caution
is advised that in case the engine speed is
set high with engine control dial (2), if the
operator is not aware of the high engine
speed setting, the engine speed will un-
expectedly increase, causing unexpected
machine movement, thus possibly result-
ing in serious personal injury.
WARNING: Prevent the machine from unexpected
movement. Be sure to turn off auto-idle selector (3)
when unexpected machine movement is undesirable,
especially when loading/unloading the machine for 3
transportation.
TCJB-01-02-003
5-
Auto-Idle Mode Operation 1
Select the auto-idle mode by operating auto-idle switch
(3) with the key switch ON. Check if the auto-idle mode is
selected or not with auto-idle indicator (1).
Auto-Idle mode ON : Auto-Idle Indicator (1) ON

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

indicator (1) ON, indicator (1) will go OFF and the auto-
idle system is deactivated.
• Even if the engine is stopped by turning the key switch
OFF when auto-idle switch (3) is in the A/I ON position
[indicator (1) ON], the auto-idle system is not deactivated.
When the engine is restarted, the auto-idle system re-
MCGB-01-038
mains activated, allowing auto-idle indicator (1) to flash
for 5 seconds and stay ON later.
TCJB-01-02-003
5-
WORK MODE
The machine can be operated in five work modes by operat-
ing the work mode selector. By this way the most appropriate 1
2
hydraulic circuit and pump flow rate matching the front at-
tachment operation can be selected.
When the engine is started, the digging mode is automatically

set. Each time work mode switch is pressed, the five following
modes are selected alternately.
• Digging Mode
• Breaker 1
• Breaker 2
• Pulverizer 1 MCGB-01-041
• Crusher 1
The selected work mode is indicated by attachment mode

indicator (2) on basic screen (1). Select the work mode mostly
appropriate to the front attachment with which the machine is
operated while referring to the table below.
Work Mode Description

Digging Mode Select this mode when using bucket or fork grapple.
Breaker 1 Mode Select this mode when using breakers other than NPK breaker.
Breaker 2 Mode Select this mode when using NPK breaker.
Pulverizer 1 Mode Select this mode when using pulverizer.
Crusher 1 Mode Select this mode when using crusher.
NOTE: Five work modes shown above are designated as the

standard specifications. Five attachment modes other
than the digging mode can be designated. When
desired to add or modify the attachment mode, consult
your nearest Hitachi dealer.
5-
Work Mode Select
Press menu key (3) on basic screen (1) to display main menu 1
screen (4). After selecting work mode menu (11) on menu
screen (4) by operating keys (5 and 6), press key (10). Select
the work mode appropriate to the work in which the ma-
chine is engaged on work mode selection screen (12) with
key (5 to 9). Then, press key (10).
3
MCGB-05-008
11
10
5 6 TCHB-05-02-001
12
10
5 6 7 8 9 T1V5-05-01-109
5-10
Power Digging (Only ZX210W-3)

The power boost switch (1) is used to gain maximum digging
power, and is located on the top of the right control lever.
When the power boost switch (1) is pushed, increased front

attachment power will be supplied for about 8 seconds.
MCGB-05-007
5-11
POWER MODE
One of three engine speed modes, E, P or H/P mode, can be
selected by operating power mode switch (1).
E (Economy) Mode
The engine speed is slightly reduced. Even if the engine
speed is reduced, digging force remains unchanged from
the P mode. Although production rate slightly decreases
than the P mode, the machine can be operated with less
fuel consumption and noise levels.
1
P Mode
Operate the machine in this mode when performing normal
work.
H/P (High Power) Mode
WARNING: In the H/P mode, the engine speed will TCJB-01-02-003
change quickly. To ensure safety, be sure to turn

power mode switch (1) to the P or E mode position be-
fore starting such works as loading the machine on or
off a trailer or lifting a load with the front attachment,
which may result in personal accidents if the engine
speed is suddenly changed.
When rolling in the arm while digging deep trenches for

example, more power may be required. In such cases, use
the H/P mode. The maximum power of the machine can be
utilized in this mode, allowing the machine to operate ef-
ficiently when more power is required than the P mode.
The H/P mode is activated and the engine speed increases

when the boom raise or the arm rolled-in operation is made
with the engine control dial set nearly in the maximum posi-
tion.
NOTE: In the H/P mode, the engine speed changes depending

on the degree of loads applied to the machine.
5-12
Engine Speed Control Mode Selection Switch
The engine speed control mode, pedal, dial, or creeper, is
selected by operating engine control mode selection switch
(1). Depending on machine operating conditions, select the
appropriate engine control mode.
• Pedal Mode
This mode suits normal travel operation best. Adjusting the
stroke of the accelerator pedal controls the engine speed.
When the pedal is stepped on, the engine speed increases.
MCBB-01-024
When the pedal is returned to neutral, the engine speed
is reduced. After the engine speed is set to run at the slow
idle speed by fully turning the engine control dial counter-
clockwise before traveling the machine, when traveling is
started by stepping the accelerator pedal, the engine speed
increases in proportion to the pedal stroke. When the pedal
is returned to neutral to temporarily stop the machine, the
engine speed is reduced to the slow idle speed, decreasing
fuel consumption and travel noise level.
• Dial Mode
This mode suits traveling in the job site best. Only the en-
readjustment of the engine speed is required. However,
the maximum travel speed is slightly slower than the pedal
mode.
• Creeper Mode
speed is controlled with the engine control dial only. Even
5-13
PARKING/STOPPING THE MACHINE ON A SLOPE

(IN CASE OF EMERGENCY)
WARNING: Parking or stopping the machine on a
slope is hazardous. Avoid parking or stopping the
machine on a slope.
WARNING:
the machine correctly according to the parking M202-05-013
procedures.
In case parking or stopping the machine on a slope is un-

avoidable, insert the bucket into the ground to stabilize the
machine. After returning all levers to neutral, place the brake
switch in the P (parking) position. Place blocks against the
wheels.
RAISING THE MACHINE FRONT ABOVE THE

GROUND WITH THE BOOM AND ARM FUNCTION
WARNING: Prevent the machine from skidding. Keep
the angle between the boom and arm 90 to 110°. 90 to 110°
1. Apply the parking brake.

2. Push the ground with the bucket round bottom while
holding the angle between the boom and arm 90 to 110°.
SA-096
IMPORTANT: When the machine is modified as a face
shovel by installing the hoe bucket in re-
verse, avoid raising the machine above the
ground using the front attachment with the
bucket cylinder fully extended. Excessive
loads will be applied to the pins around the 90 to 110°
bucket and the bucket cylinder, resulting in
breakage of the pins.
SA-097
WRONG
MCGB-04-002
5-14
EXCAVATION
• Select the arm and bucket sizes matching the applica-
tion. (Refer to the kinds and applications of buckets in
the specification section.)
• Mainly use the arm function for excavations.
• Vibrate the arm and bucket a few strokes to remove soil
stuck to the bucket.
• Position the bucket teeth as parallel as possible with the
direction of excavation. Utilize the arm stroke as much as
possible with the bucket teeth inserted shallowly.
• Face the rear side of the undercarriage in the same direc-
tion as the excavation. Move the machine backward as
excavation progresses.
• Do not operate each cylinder full stroke. Give a small al-
lowance before the stoke end.
IMPORTANT: • Take care not to allow the bucket teeth to

contact with tires when excavating diago-
nally toward the undercarriage.
• If the boom lowering is suddenly stopped,
an excessive impact will be applied to the
machine. Smoothly lower the boom to
reduce impact loads.
• When excavating deep, take care not to hit
the boom bottom face or the bucket cylin-
der hose to the ground.
• When the machine is equipped with the
blade (optional), be careful not to hit the
blade with the bucket teeth when excavat-
ing with the bucket near the blade posi-
tion.
5-15
FACE SHOVEL OPERATION

In contrast with that the backhoe rolls the bucket in to exca-
vate, the face shovel rolls the bucket out. WRONG
WARNING: When the bucket is reversely installed in
face shovel operation, the bucket may come in con-
tact with the cab when the arm is fully rolled in. Be
careful not to allow the bucket to hit the cab when the
arm is fully rolled in.
Be careful not to
allow the bucket
IMPORTANT: When the bucket with a hook is installed, op- to hit the cab
erate the bucket and arm with care so as not
to allow the bucket hook to come in contact
with the arm.
• For face shovel operation, dig the ground using the arm
M202-05-040
cylinder in a scraping motion.
• When underground water is expected, make a slope angle
of 2 to 3° to drain this water as shown.
NOTE: When the bucket is installed reversely, the bucket dig-

ging force is less than the backhoe due to the design
construction of the hydraulic cylinder.
2 to 3°
M202-05-019
5-16
GRADING OPERATION
While operating the boom, arm, and bucket simultaneously,
move the bucket parallel to the ground so that the bucket
teeth face perpendicularly toward the ground surface.
IMPORTANT: Avoid grading with a bucket while driving

the machine like a bulldozer. Excessive loads
may be applied, resulting in damage to
parts/components.
1. When grading from the front to the rear, slowly roll in

the arm while raising the boom. After the arm passes the M202-05-016
upright position, roll in the arm further so that the bucket
is moved horizontally while slowly lowering the boom.
2. When grading from the rear to the front, operate the
boom, arm, and bucket in the reverse order as mentioned
in step 1.
3. Perform slope surface finishing work in the same meth-
ods as mentioned in steps 1 and 2 above.
DO NOT SLAM THE BUCKET TEETH INTO THE

GROUND
WARNING: Avoid aggressively ramming the bucket
tooth tips into ground. Operator or personnel in the
vicinity of the machine may be injured by scattering
fragments. In addition, shortening service life of the
front attachment may result.
Do not slam the bucket into a hard ground, possibly decreas-

ing the service life of the front attachment (mainly bucket).
When digging a tightly compacted ground such as gravel soil,

use the bucket digging force while simultaneously operating
the boom, arm, and bucket so that the bucket teeth can be
effectively inserted into the ground. The operator or people
around the machine may be injured with shattered material.
Carefully operate the machine to avoid potential hazards.
DO NOT USE THE BUCKET AS A HAMMER

WRONG
IMPORTANT: Do not use the bucket bottom as a hammer
or pile driver. Hitting or driving with the
curved surface bucket bottom is dangerous.
In addition, damage to the bucket and/or
front attachment may result.
Do not hit the chassis with the bucket when digging.

Whenever possible, position your machine on a level surface.
Do not use the bucket as a hammer or pile driver. Do not at-
tempt to shift rocks and break walls using swing motion. M202-05-018
5-17
AVOID INCREASING DIGGING FORCE FORCIBLY

Avoid increasing digging force by driving the machine with the WRONG
bucket kept inserted into the ground or by excavating while
the machine rear end is kept raised off the ground to utilize
the machine weight. Excessive load will be applied to the base
machine and personal injury and/or death may result.
WRONG
M202-05-017
AVOID USING SWING POWER WRONG

Avoid using swing power to move rocks or to hit and crush the
cutting face with bucket side. Damage to the front attachment
and swing system may result.
M216-05-001
5-18
BOOM LOWERING PROCEDURE IN EMERGENCY

OR WHEN THE ENGINE STALLS
Rear Boom I
(ZX140W-3, 170W-3, 190W-3)
1
WARNING: Never allow anyone to enter under the
boom while performing the emergency boom lower-
ing procedure.
If the engine stalls and cannot be restarted, lower the boom 2

and the bucket to the ground referring to the emergency
boom lowering procedure stated below.
1. Remove rubber caps (1) and (2) from the boom I section
of the 4-spool control valve.
2. Remove lock nut (8) using a wrench (17 mm). Be sure to
turn the wrench counterclockwise to remove lock nut (8).
3. Turn socket-head screw (7) clockwise to the stop using
hexagonal wrench (4 mm).
4. Turn lock nut (5) counterclockwise to loosen it, using a
wrench (17 mm).
Control Valve M175-05-001
5. Loosen socket-head screw (6) clockwise using hexagonal
wrench (4 mm) while closely watching the boom lower.
Note that the loosened degree of screw (6) determines
6
the boom lowering speed. Adjust the boom lowering
speed with the hexagonal wrench as required. 3
Take care not to remove snap ring (3) and washer (4) at
4
this time. Also, do not loosen screw (6) excessively or
cause washer (4) to be deformed. 1
6. After the bucket is lowered to the ground, turn screws (6) 5

and (7) counterclockwise to the stop. Loosen screw (7)
1/8 of a turn clockwise. Tighten lock nuts (5) and (8).
Tightening Torque: 20 N·m (2 kgf·m)
7
2
7. Re-install rubber caps (1) and (2). Be sure to return them
to their original positions. 8
NOTE: Be sure to work on screw (7) first, then, on screw (6), as

stated above.
M154-05-001
5-19
BOOM LOWERING PROCEDURE IN EMERGENCY

OR WHEN THE ENGINE STALLS 2
(ZX210W-3) 1
WARNING: Never allow anyone to enter under the
Front
boom while performing the emergency boom lower- Attachment Side
ing procedure.
If the engine stalls and cannot be restarted, lower the boom

and the bucket to the ground referring to the emergency
boom lowering procedure described below.
1. Loosen lock nut (1) on the control valve as illustrated to

the right. Then, loosen screw (2) half a turn. Depending
on the loosening extent of screw (2), the boom lowering
speed can be adjusted.
NOTE: If screw (2) is loosened more than two turns, the screw
will come off. Avoid turning the screw more than two T1V1-03-03-073
turns.
2. After the boom is lowered, tighten screw (2) and lock nut
(1) in this order.
3. Turn socket-head screw (2) clockwise to the stop using
hexagonal wrench (4 mm).
Lock nut (1) Emergency Valve
Tightening torque: 13 N·m (1.3 kgf·m)
Screw (2)
Tightening torque: 7.0 N·m (0.7 kgf·m)
1
NOTE: If tightening of the lock nut and screw is not sufficient,
oil leakage may increase. Securely tighten the lock nut 2
and screw to the specifications described above.
T1V1-03-03-038
5-20
OVERNIGHT STORAGE INSTRUCTIONS

• After finishing the day’s operation, drive the machine to
firm, level ground where no possibility of falling stones,
ground collapse, or floods is expected.
• Park the machine referring to the instruction for “PARKING
THE MACHINE” in the “DRIVING THE MACHINE” section.
• Fill the fuel tank with fuel.
• Clean the machine.
• If anti-freeze or long life coolant is not used in cold weath-
er, be sure to drain the coolant from the radiator and the
engine jacket. Also, be sure to put a tag in a visible place
telling “No coolant in the Radiator.”
MCGB-05-006
5-21
MEMO
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5-22
TRANSPORTING
TRANSPORTING BY ROAD
When transporting the machine on public roads, be sure to
first understand and follow all local regulations.
• When transporting the machine using a trailer, check the

width, height, length and weight of the trailer with the
machine loaded. Note that the weight and transporting
dimensions will vary depending on the type of stabilizer/
blade or arm to be installed on the machine. Refer to the
mass (weight) shown in the specifications and take care
that the trailer is not overloaded.
• Investigate beforehand the conditions of the route to be
traveled, such as dimensional limits, weight limits, and
traffic regulations.
CAUTION: The auxiliary bar attached to the rear sec-

tion of the hand rail can be installed in two positions
to adjust its height. Install the auxiliary bar in the
transportation position when transporting the ma-
chine.
IMPORTANT: After transporting the machine, reinstall the

auxiliary bar in the normal operation posi-
tion before operating the machine.
Obtain special permission from the authorities concerned or

disassemble the machine to meet the transportation dimen-
sional limits as needed. Consult your nearest Hitachi dealer Transportation Position M1U4-06-001
when transporting the machine by road is required.
M1U4-06-002
Normal Operation Position
6-
TRANSPORTING
LOADING/UNLOADING ON A TRAILER
Load or unload the machine on a solid and level ground.
WARNING: Be sure to use ramps or loading docks
when loading/unloading the machine.
Never load or unload the machine onto or off a trailer
using the front attachment functions when driving up
or down the ramp.
Ramp/Loading Dock
1. Before loading, thoroughly clean the ramp/loading dock
and flatbed. Dirty ramps/loading deck or flatbed with oil,
mud, or ice is slippery and dangerous.
2. Place blocks against the trailer wheels to prevent the
trailer from moving unexpectedly.
3. Ramps must be sufficient in width, length, and strength.
Securely install the ramp with an incline of 15° or less.
4. When using a loading dock, the loading dock must be
sufficient in width and strength and have an incline of 15°
or less.
5. When loading or unloading the machine equipped with
a blade, take care not to collide the blade against other
objects.
6-
TRANSPORTING
Loading
WARNING:
• Be sure to turn the auto-idle switch OFF. Failure to
do so may cause the engine speed to change sud-
denly.
Otherwise, turn the power mode switch to the “P”
or “E” position whenever loading the machine.
Set the gear shift switch in the slow position.
Steering on a slope may cause the machine to turn
over. Never attempt to steer the machine on a
slope.
Personal injury or death may result due to loss of
machine stability. If the travel direction must be
changed on a slope, move the machine to the flat
ground.
The top end of the ramp where it meets the flatbed
is a sudden bump, possibly reducing the machine’s
stability. Be sure to travel over this joint area at
slow speed.
• When the machine is equipped with the front at-
tachment:
Take care to prevent the machine from turning
over. Before rotating the upperstructure on a
trailer, turn the brake switch to either the axle lock
or auto axle lock position to lock the axle. Less than 15°
• When the machine is not equipped with the front SA-094
attachment:
Do not swing the upperstructure. Failure to do so
may cause the machine to turn over.
1. When loading the machine with the front attachment,

travel the machine forward onto the trailer with the front
attachment positioned in the front. When loading the
machine without the front attachment, back the machine
onto the trailer.
2. Load the machine so that the longitudinal centerline of Less than 15°
the machine aligns with that of the trailer.
SA-095
3. Slowly drive the machine forward on ramps until the
machine reaches the specified position.
4. Always turn the brake switch to the axle lock or auto axle
lock position. After slightly raising the bucket above the
flatbed, slowly rotate the upperstructure 180°.
5. Rest the front attachment onto the wooden block laid on
the trailer. When the machine is equipped with a blade,
lower the blade onto the flatbed.
M202-06-003
6-
TRANSPORTING
6. Stop the engine. Remove the key from the key switch.
7. Operate the control levers several times to release any
remaining pressure from the cylinders.
8. Place the pilot control shut-off lever in the LOCK position.
9. Be sure to close the cab windows, overhead window, and
door to prevent entry of wind and rain into the cab. Put a
cover on the exhaust opening.
10. Store the mirror, handrails, and radio antenna in the spec-
ified positions.
NOTE: In cold weather, be sure to warm up the machine be-

fore loading or unloading the machine.
TRANSPORTING
WARNING: During transportation, the machine car-
ried with a trailer is vibrated or swayed in all direc-
tions.
Securely fasten the machine to the trailer deck using
chains or cables.
1. Turn the brake switch to the P (parking) position.

Place blocks in front of and behind the tires. MCGB-06-001
2. Fasten the base machine and the front attachment to the
trailer using wire ropes.
6-
TRANSPORTING
UNLOADING
WARNING:
• Be sure to turn the auto-idle switch OFF. Failure to
do so may cause the engine speed to change sud-
denly.
• Be sure to turn the gear shift switch to the SLOW
position ( ).
• Steering on a ramp is hazardous. Never attempt to
steer the machine on the ramp. Personal injury or
death may result due to loss of machine stability.
• The top end of the ramp where it meets the flatbed
is a sudden bump, possibly reducing the machine’
s stability. Carefully operate the machine at this
point.
• Keep in mind that the control directions (forward/
reverse, left/right) will be reversed when the up-
perstructure is rotated 180°. When the steering
axle is located behind the cab, the upperstructure
is rotated 180°.
90 to 110°
IMPORTANT: Whenever unloading the machine, keep the
angle between the boom and arm 90 to 110°.
Unloading the machine with the arm fully
rolled in may damage the machine.
M202-06-006
1. Before driving the machine onto the ramp from the trailer
flatbed end, slightly raise the bucket above the ground
and slowly drive down the ramps while taking care so
that the machine does not go off the ramps.
IMPORTANT: Prevent possible damage to the hydraulic

cylinders. Do not allow the machine to hit
the ground with the bucket.
2. The bucket must be on the ground before the machine

begins to tip forward
3. As the machine moves forward, slowly operate the boom
and arm until the machine is completely off the ramp.
6-
TRANSPORTING
TOWING MACHINE
When towing the machine, be sure to only use the towing
hook point.
IMPORTANT: Do not tow the machine with the parking

brake still applied. Damage to the transmis-
sion may result.
Be sure to release the parking brake before towing the ma-

chine.
This machine is equipped with a negative-type parking brake
so that when the engine is stopped by turning the key switch
OFF, the parking brake is automatically applied. Depending on
the current machine conditions, parking brake release proce-
dures differ. Follow the procedures below to release the park-
ing brake.
• When the engine is operable:

When the engine and the electrical system operate normal-
ly, start the engine and turn the brake switch OFF to release MCGB-06-002
the parking brake.
• When the engine is not operable:

1
When the engine or the electrical system is inoperable so
that the parking brake cannot be released with the brake
switch, manually release the parking brake located in the
travel transmission by following the procedures below.
WARNING: Be sure to secure the wheels with wedges 2
before releasing the parking brake.
1. Arrange the attached grease gun.

3
2. Supply grease through nipple (1).
3. Continuously supply grease until grease flows out of
relief valve (3). ZX170W-3, 190W-3, 210W-3 T21W-03-05-014
2
1
ZX140W-3 MCGB-06-003
6-
TRANSPORTING
Engaging Parking Brake (After repair work is complete)
1. Loosen bleeder (2) to allow grease to be discharged.

1
2. Start the engine. Select the fast travel mode ( ).
3. Tighten bleeder (2).
WARNING: When engaging the parking brake, grease

is discharged. If the discharged grease is kept left on
2
the ground, the following cars may slip, possibly caus-
ing dangerous situation. Take the most priority to
notice the following cars and remove the discharged
grease as soon as possible.
3
DANGER: When the parking brake is released, the
machine becomes free to move, possibly creating haz-
ardous conditions. Be sure to secure the wheels with ZX170W-3, 190W-3, 210W-3 T21W-03-05-014
wedges before releasing or starting work to engage
the parking brake.
CAUTION: Do not loosen valve (2) quickly or loosen it
3
too much as high-pressure grease in the transmission
may spout out, Loosen carefully and keep away from
(2).
2
1
ZX140W-3 MCGB-06-003
6-
TRANSPORTING
Machine Lifting Procedures
WARNING:
• Use only lifting wire ropes and other lifting tools
having sufficient strength and being free from
damage and/or deterioration.
• Be sure to contact your authorized dealer for get-
ting information about correct lifting procedures,
and size and kinds of lifting wire ropes and lifting
tools.
• Pull the pilot control shut-off lever to the LOCK
position so that the machine does not accidentally
move while being lifted.
• Incorrect lifting procedures and/or incorrect wire
rope attachment will cause the machine to move
(shift) while being lifted, resulting in machine dam-
age and/or personal injury.
• Do not lift the machine quickly. Excessive load will
be applied to the lifting wire ropes and/or lifting
tools, possibly causing them to break.
• Do not allow anyone to come close to or under the
lifted machine.
• The indicated gravity center is for the standard
specification machine. The gravity center will vary
depending on the kinds of attachments and/or op-
tional equipment to be installed or their position
to be taken. Therefore, take care not to lose the
balance of the machine while lifting.
Lifting Support
1. While fully extending the bucket and arm cylinder, slowly Bar
lower the boom.
Center of
2. Move the pilot control shut-off lever to the LOCK posi- Gravity
tion.
4. Use wire ropes and a supporting bar with sufficient
length to avoid the wire ropes and the supporting bar
from coming in contact with the machine when the ma-
chine is lifted. Cover the wire rope with cloth as needed MCBB-06-002
to protect the machine from being damaged.
5. Move a crane to a location appropriate to lifting work.
6. Attach the lifting wire ropes to the front and rear of the
machine track frame. Lift the machine with the crane.
6-
MAINTENANCE
CORRECT MAINTENANCE AND INSPECTION PRO-

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

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

erating or contact your authorized dealer.
IMPORTANT: • Use only recommended fuel and

lubricants.
• Be sure to use only genuine Hitachi parts.
Failure to do so may result in serious injury
or death and/or machine breakdown.
• Use only genuine HITACHI parts.
• Failure to use recommended fuel,
lubricants, and genuine Hitachi parts will
result in loss of Hitachi product warranty.
• Never adjust engine governor or hydraulic
system relief valve.
• Protect electrical parts from water and
steam.
• Never disassemble electrical components
such as main controller, sensors, etc.
7-
MAINTENANCE
CHECK THE HOUR METER REGULARLY

• Lubricate, make service checks and adjustments at in-
tervals shown on periodic maintenance guide table (see
page 7-4 and 7-5).
• Intervals on the periodic maintenance chart are for oper-
ating in normal conditions. If you operate your machine
in more adverse conditions, you should service it at
SHORTER INTERVALS.
USE CORRECT FUELS AND LUBRICANTS

IMPORTANT: Always use recommended fuels and lubri-
cants. Failure to do so will result in machine
damage and loss of Hitachi product war-
ranty.
7-
MAINTENANCE
LAYOUT
Bucket Cylinder
Arm Cylinder
Boom
Arm
Boom
Bucket Cylinder
MCBB-01-031
Counterweight Radiator, Oil Cooler

Air Cleaner
Engine Battery
Cab
Steering Filter
Pilot Filter
Hydraulic Pump
Control Valve
Hydraulic Oil Tank
Fuel Tank
Swing Device
Center Joint
TCJB-01-02-013
Blade Cylinder Rear Axle
Axle Cylinder
Front Axle
Transmission
Travel Motor
Stabilizer Cylinder
TCJB-01-02-011
7-
MAINTENANCE
MAINTENANCE GUIDE TABLE

The maintenance guide table is affixed to the reverse side of
the tool box cover. Lubricate and/or service the parts at the
intervals as instructed in the table so that all necessary mainte-
nance can be performed regularly.
• Symbol Marks
The following marks are used in the maintenance guide
table.
Hydraulic Oil Filter

Grease
(Pilot Filter, Steering•Brake Filter, Hydraulic
(Front Joint Pin, Swing Bearing, Swing
Oil Tank Filter, Suction Filter, steering
Gear)
Suction Filter)
Gear Oil
(Transmission, Axle, Swing Reduction Air Cleaner Element
Device, Pump Transmission)
Coolant
Engine Oil
(Long-Life Coolant)
Fuel Filter
Engine Oil Filter
(Fuel Filter Cartridge)
Hydraulic Oil
7-
MAINTENANCE
Maintenance Guide Table
Sample: ZX170W-3
22 23 24 25 26 11
21
1
20
2
19
18
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3
MCGB-07-102
Item Page Item Page

1 Engine Oil 7-23 14 Grease 7-21
2 Coolant (Long-Life Coolant) 7-66 15 Grease 13-5
3 Air Cleaner Element 7-64 16 Grease 13-5
4 Gear Oil (Rear Axle) 7-30 17 Hydraulic Oil 7-41
5 Gear Oil (Rear Hub Reduction) 7-31 18 Hydraulic Oil Filter (Suction) 7-41
6 Gear Oil (Travel Transmission) 7-28 19 Hydraulic Oil Filter (Main) 7-45
7 Grease 7-18 20 Fuel Filter 7-60
8 Grease 7-19 21 Engine Oil Filter 7-24
9 Gear Oil (Front Axle) 7-29 22 Hydraulic Oil Filter (Pilot) 7-47
10 Gear Oil (Front Hub Reduction) 7-31 23 Gear Oil (Pump Transmission) 7-26
11 Grease 7-15 24 Hydraulic Oil Filter (Steering•Brake) 7-47
12 Grease 7-22 25 Hydraulic Oil Filter (Air Breather) 7-48
13 Grease 7-20 26 Gear Oil (Swing Device) 7-27
7-
MAINTENANCE
PREPARE MACHINE FOR MAINTENANCE

Before performing the maintenance procedures given in the
following chapters, park the machine as described below, un-
less otherwise specified.

3. Turn brake switch (3) on the column console to the P M202-07-028
(parking) position.
4. Turn the auto-idle switch OFF.
5. Place forward/reverse switch (2) to N (neutral).
IMPORTANT: The turbocharger may be damaged if the 3

engine is not properly shut down.
6. Turn the engine control dial to the slow idle position.

Place accelerator pedal to neutral. Run the engine at slow
idle speed to cool the engine for 5 minutes. 2
7. Turn the key switch OFF. Remove key from switch. (If
maintenance must be performed with engine running,
do not leave machine unattended.)
8. Pull the pilot control shut-off lever (1) to the LOCK posi-
tion.
9. Before starting repair work, attach a Do Not Operate tag
in an easy-to-see place such as on the cab door or control
lever. MCGB-01-008
SS3076175 SS2045102
7-
MAINTENANCE
HOOD AND ACCESS COVERS 1
WARNING:
• Do not keep the hood and access covers open when
the machine is parked on a slope, or while the wind
is blowing hard. The hood or access covers may
close accidentally, possibly resulting in personal
injury.
• When opening or closing the hood and access cov-
ers, take extra care not to catch fingers between
the base machine and the hood or access covers. ZX140W-3 Engine Cover MCGB-07-002
1
• Remove locks (2 used) to open the engine access cover.
Holding the handle on the access cover, raise the cover
until the cover is secured with catch (1).
• After opening the right and/or left access cover, be sure to
insert rod (2) into cover lock hole (3) to hold the cover.
ZX170W-3, 190W-3, 210W-3

• When opening the rear left cover, open the front left cover
ZX170W-3, 190W-3, 210W-3 Engine Cover
first. Then, pull to open the rear left cover as illustrated. MCGB-07-003
3
2
2 3
ZX140W-3 Left Cover MCGB-07-004
2
3
ZX170W-3, 190W-3, 210W-3 Front Left Cover

MCGB-07-007
MCGB-07-005
ZX140W-3, 170W-3, 190W-3 Right Cover
2
3
2
3
ZX170W-3, 190W-3, 210W-3 Rear Left Cover

MCGB-07-008 ZX210W-3 Right Cover MCGB-07-006
7-
MAINTENANCE
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic inspec-
tion of the machine. In addition, the parts listed below, if defec-
tive, may pose serious safety/fire hazards. It is very difficult to
gauge the extent of deterioration, fatigue, or weakening of the
parts listed below simply by visual inspection alone. For this
reason, replace these parts at the intervals shown in the table
below. However, if any of these parts are found to be defective,
replace before starting operation, regardless of the interval.
Also, when replacing hoses, check the clamps for deformation,
cracks, or other deterioration, and replace as necessary.
Be sure to perform periodic inspection of all hoses, as shown
below, and replace or retighten any defective parts found, as
necessary.
Consult your authorized dealer for correct replacement.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to supply pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Brake valve seals (Rubber parts) Every 2 years
Upper-
Brake hose Every 2 years
structure
Brakes Stop light switch Every 2 years
Under- Center joint seals (Rubber parts) Every 2 years
carriage Brake hose Every 1 years
Steering hose Every 2 years
Steering Mechanism Steering cylinder seals (Rubber parts) Every 2 years
Steering valve seals (Rubber parts) Every 2 years
Pump suction hose Every 2 years
Base Machine Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front
Arm cylinder line hose Every 2 years
Attachment
Bucket cylinder line hose Every 2 years
Seat Belt Every 3 years
NOTE: Be sure to replace seals, such as O-rings and gaskets,

when replacing hoses.
7-
MAINTENANCE
MAINTENANCE GUIDE
A. GREASING (See Page 7-15)
Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Front Front attach- Monoblock ZX140W-3 15 H HH
Joint ment joint pins Boom ZX170W-3,190W-3, 210W-3 16 H HH
Pins excluding those ZX140W-3 19 H HH
2-piece
for bucket and ZX170W-3,190W-3 20 H HH
Boom
link. ZX210W-3 22 H HH
Bucket and link joint pins 4 H HH
2. Swing Bearing 2
3. Swing Internal Gear 1 HHH
4. Front Axle 4 Every one month
ZX140W-3, 170W-3 6
5. Propel Shaft (Front and Rear)
ZX190W-3, 210W-3 4
6. Equalizer Pin 1
NOTE: H Maintenance required when operating in water or mud and under extremely severe condition.
★★ Maintenance required only during first time check.
★★★ Check and add grease.
IMPORTANT: Grease bucket and link pivots every day until break-in operation (50 hours) is complete. When the
bucket joint boss end faces are not finished with WC thermal spraying, grease the bucket two joint
pin sections at an interval of every 250 hrs.
WARNING: There is no regular greasing point on the transmission.
Please never inject grease into the nipple with which the transmission side is equipped excluding the emer-
gency for urgent release of the Parking-brake.
(Refer to 6-6, 6-7)
B. ENGINE (See Page 7-23)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Engine Oil Oil Level Check -
ZX140W-3 16.0 L (4.2 US gal) H
2. Engine Oil Change
ZX170W-3, 190W-3, 210W-3 23.0 L (6.1 US gal) H
3. Engine Oil
Replacement 1 H
Filter
NOTE: ★ Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more.
Consult your nearest Hitachi dealer for the details.
7-
MAINTENANCE
C. TRANSMISSION (See Page 7-26)
Interval (hours)
Parts Quantity
8 50 100 250 500 800 1000 2000
Oil Level Check 1
1. Pump Transmission
Change 1.0 L (1.1 US qt)
Oil Level Check 1
2. Swing Reduction ZX140W-3 3.2 L (3.4 US qt)
Gear Change ZX170W-3, 190W-3,
210W-3 6.2 L (1.6 US gal)
Oil Level Check 1 Every week
3. Transmission ZX140W-3 3.0 L (3.2 US qt) H
Change ZX170W-3, 190W-3,
210W-3 2.5 L (2.7 US qt) H
Oil Level Check 1 Every one month
ZX140W-3 10.5 L (2.8 US gal) H
STD. 10.5 L (2.8 US gal) H
ZX170W-3
WD. 10.5 L (2.8 US gal) H
4. Front Axle
Change STD. 10.5 L (2.8 US gal) H
ZX190W-3
WD. 10.5 L (2.8 US gal) H
STD. 11.0 L (2.9 US gal) H
ZX210W-3
WD. 11.0 L (2.9 US gal) H
ZX140W-3 13.5 L (3.6 US gal) H
STD. 14.0 L (3.7 US gal) H
ZX170W-3
WD. 14.0 L (3.7 US gal) H
5. Rear Axle
Change STD. 14.0 L (3.7 US gal) H
ZX190W-3
WD. 14.0 L (3.7 US gal) H
STD. 14.5 L (3.8 US gal) H
ZX210W-3
WD. 14.5 L (3.8 US gal) H
Front 3.6 L×2 (3.8 US qt×2) H
ZX140W-3
Rear 3.5 L×2 (3.7 US qt×2) H
Front 2.5 L×2 (2.7 US qt×2) H
STD.
Rear 2.5 L×2 (2.7 US qt×2) H
ZX170W-3
Front 2.5 L×2 (2.7 US qt×2) H
WD.
Rear 2.5 L×2 (2.7 US qt×2) H
6. Front and Rear Hub Front 2.5 L×2 (2.7 US qt×2)
Reduction Device Change H
STD.
Rear 2.5 L×2 (2.7 US qt×2) H
ZX190W-3
Front 2.5 L×2 (2.7 US qt×2) H
WD.
Rear 2.5 L×2 (2.7 US qt×2) H
Front 2.5 L×2 (2.7 US qt×2) H
STD.
Rear 2.5 L×2 (2.7 US qt×2) H
ZX210W-3
Front 2.5 L×2 (2.7 US qt×2) H
WD.
Rear 2.5 L×2 (2.7 US qt×2) H
NOTE: ★ Maintenance required only during first time check.
D. BRAKE (TRAVELING) (See Page 7-32)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Check Brake Accumulator −
2. Check Brake Lining for Wear − As required
7-10
MAINTENANCE
E. TIRE (See Page 7-35)
Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
Inspection 8
1. Tire
Replacement − As required
F. HYDRAULIC SYSTEM (See Page 7-37)

Interval (hours)
Parts Quantity
8 50 100 250 300 500 1000 1500 2500 5000
1. Check Hydraulic Oil Level 1
170 L
ZX140W-3 ✸ ✸ ✸ ✸
(45 US gal)
170 L
ZX170W-3 ✸ ✸ ✸ ✸
2. Change (45 US gal)
Hydraulic Oil 170 L
ZX190W-3 ✸ ✸ ✸ ✸
(45 US gal)
170 L
ZX210W-3 ✸ ✸ ✸ ✸
(45 US gal)
3. Suction Filter Cleaning 1 When changing hydraulic oil
4. Replace Hydraulic Tank Oil Filter 1 HH ✸ ✸
5. Replace Pilot and Steering•Brake
1
Oil Filter
6. Replace Air Breather Element 1
7. Check Hoses for leaks -
and Lines for cracks, bend, etc. -
NOTE: ✸ Hydraulic oil changing interval differs according to the kind of hydraulic oil used.
See recommended oil chart.
★★ While demolition work.
G. FUEL SYSTEM (See Page 7-54)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Drain Fuel Tank Sump 1
2. Check Water Separator 1
3. Replace Main Fuel Cartridge Filter 1
4. Replace Pre-Fuel Cartridge Filter 1
5. Clean Fuel Solenoid Pump Strainer 1
for leaks, cracks, etc. –
6. Check Fuel Hoses
for cracks, bend, etc. –
H. AIR CLEANER (See Page 7-64)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Air Cleaner Outer Cleaning 1 (Or when indicator lit)
Element Replacement 1 After cleaning 6 times or 1 year
2. Air Cleaner Inner
Replacement 1 When outer element is replaced
Element (Optional)
7-11
MAINTENANCE
I. COOLING SYSTEM (See Page 7-66)
Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
1. Check Coolant Level 1
2. Check and Adjust Fan Belt Tension 1 HH
ZX140W-3 19.2 L (5.1 US gal) Twice a year ✸1
3. Change Coolant ZX170W-3, 190W-3 19.2 L (5.1 US gal) Twice a year ✸1
ZX210W-3 26.0 L (6.9 US gal) Twice a year ✸1
4. Clean Inter Cooler Oil Cooler and Outside 1 ✸2
Radiator Core Inside 1 Once a year
5. Clean Oil Cooler Front Screen 1 ✸2
6. Clean Air Conditioner Condenser 1 ✸2
7. Clean Fuel Oil Cooler 1
8. Clean Air Conditioner Front Screen (Opt.) 1
NOTE: ★★ Maintenance required only during first time check.
✸1 When genuine Hitachi coolant is used, change every two years or 4000 operating hours, whichever comes first.
✸2 Shorten the maintenance interval when the machine is operated in dusty areas.
IMPORTANT: Use fresh water or normal tap water as a coolant. Do not use strong acid or alkaline water.
Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %.
J. ELECTRICAL SYSTEM (See Page 7-70)
K. MISCELLANEOUS (See Page 7-76)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000 4000
1. Check Bucket Teeth for Wear and Looseness —
2. Change Bucket — As required
3. Convert Bucket Connection Into Face Shovel — As required
4. Adjust Bucket Linkage 1 As required
5. Check and Replace Seat Belt 1 Every 3 years (Replace)
6. Check Windshield Fluid Level 1 As required
Circulating Air Cleaning 1
7. Check Air Filter Replacement 1 After cleaning 6 times or so
Conditioner
Filter Cleaning 1
Fresh Air Filter
Replacement 1 After cleaning 6 times or so
8. Check Air Conditioner —
9. Clean Cab Floor — As required
10. Retighten Cylinder Head Bolt — ✸As required
11. Inspect and Adjust Valve Clearance — ✸
12. Measure Engine Compression Pressure — ✸
13. Check Starter and Alternator — ✸
14. Check Tightening Torque of Bolts and Nuts — HH
NOTE: ★★ Maintenance required only during first time check.
✸✸ Contact your authorized dealer for maintenance.
7-12
MAINTENANCE
Brand Names of Recommended Grease
Where to be • Bucket, Arm and Boom, Swing Gear, Swing Where to be
applied Bearing, Propel Shaft, Blade, Stabilizer applied Front Axle, Equalizer Pin
(ZX140W-3/170W-3/190W-3/210W-3) (ZX140W-3)
• Front Axle, Equalizer Pin
(ZX170W-3/190W-3/210W-3) Manufacturer –20 to 40 °C (–4 to 104 °F)
Manufacturer –20 to 40 °C (–4 to 104 °F) Molykote Molykote vn2461c
Nippon Koyu SEP 2 ✸2 Molykote BR2 Plus *2
British Petroleum BP Energrease LS-EP2 Nippon Koyu HCM Genuine Grease Molybdenum No.2 *1
Caltex Oil Multifax EP2 British Petroleum BP Energrease L-21M
Esso Beacon EP2 Caltex Oil Molitex EP2
Idemitsu Kosan Daphne Coronex Grease EP2 Idemitsu Kosan Daphne Grease M2
Mobil Oil Mobilux EP2 Nippon Oil Molynoc Grease AP2
Nippon Oil Epinoc Grease AP2 Shell Oil Alvania Grease HDX
Shell Oil Shell Alvania EP2✸1 Retinax HDX
NOTE: The machine shipped from the factory is filled with Kyodo Yushi Molylex MP No2
lubricants marked with . NOTE: The machine shipped from the factory is filled
✸1 Front Joint Pin and Swing Bearing with lubricants marked with .
✸2 Swing Gear *1 Japanese factory use grease
*2 European factory use grease
Recommended Engine Oil
IMPORTANT: Use only genuine Hitachi engine oil as

shown below or engine oil equivalent to
DH-1 specified in JASO. Failure to do so may
deteriorate the engine performance and/or
shorten the engine service life. Please be
noted that all engine failures caused by
using engine oil other than specified are
excluded from Hitachi Warranty Policy.
Consult your nearest Hitachi dealer for the
unclear points.
Brand Names of Recommended Engine Oil

Kind of Oil Engine Oil
Application
Engine Crank Case
Air Temp.
-20 to 30 ˚C -15 to 40 ˚C
(-4 to 86 ˚F) (5 to 104 ˚F)
Manufacturer JASO
Super wide Super wide
Hitachi DH-1
DH-1 10W-30 DH-1 15W-40
7-13
MAINTENANCE
The Brand Names of Gear Oil Recommended
Application Swing Reduction Gear Pump Transmission, Transmission
Kind of Oil Gear oil Engine Oil
Air Temp. –20 to 40 °C –10 to 35 °C 25 to 40 °C
–20 to 40 °C (–4 to 104 °F) (–4 to 104 °F) (14 to 95 °F) (77 to 104 °F)
Manufacturer
BP Vanellus C3
British Petroleum BP Gear oil SAE80W-90
30 40
RPM DELO 300 Oil
Caltex Oil Thuban SAE 90
30 40
Essolube D-3
Esso Esso Gear Oil GP80W-90
30 40
Apolloil super wide Apolloil diesel motive
Idemitsu Kosan Apollo Gear HE90 S-340
15W-40 S-330
Mobil Delvac
Mobil Oil Mobilube GX80W-90
1330 1340
Hidiesel S3
Nippon Oil Gear Lube SP90 X2 –20 to 35 °C
15W-40 X1 (–4 to 95 °F)
10W-30
Rymla D
Shell Oil Shell Spirax EP90 30 40
Shell Universal Engine Oil 15W-40 X3
Remarks API GL 4 Class API CD Class
Application Front and Rear Axle. Hub Reduction Device. NOTE: The machine shipped from the factory is filled
Kind of Oil Gear oil with oil marked .
Air Temp. X1 Engine oil or gear oil for pump transmission
–20 to 40 °C (–4 to 104 °F) X2 Gear oil for swing reduction device
Manufacturer
FUCHS Titan Gear LS90 X3 Engine oil for transmission.
Shell Oil Shell Donax TD Engine/gear oil can be used for pump transmission.
Brand Names of Recommended Hydraulic Oil

Kind of Lubricant Hydraulic Oil
Where to be applied Hydraulic System
Change Interval 5000 hours 2500 hours 1500 hours
Environmental –20 to 40 °C –10 to 40 °C –20 to 40 °C –10 to 40 °C –20 to 40 °C –10 to 40 °C
Temp. (–4 to 104 °F) (14 to 104 °F) (–4 to 104 °F) (14 to 104 °F) (–4 to 104 °F) (14 to 104 °F)
Manufacturer
Hitachi Super EX 46HN
Idemitsu Kosan Super Hydro 46 WRHU
British Petroleum Bartran HV46
Caltex Oil Rando Oil HD46
Texaco INC. Rando Oil HD46
Chevron U.S.A INC. Chevron AW46
Esso NUTO H46
Mobil Oil DTE 25
Shell Oil Tellus Oil S46 Tellus Oil 46
Remarks Anti-wear type hydraulic oil
NOTE: Use proper hydraulic oil in accordance with the atmospheric temperature.
The machine shipped from the factory is filled with oil marked.
When the atmospheric temperature is between -40 °C and +20 °C: Use the proper hydraulic oil having high and low
temperature characteristics by referring to the values shown below.
Low Temperature Viscosity: Less than 4000 cSt at -40 °C
High Temperature Viscosity: More than 6.5 cSt at +80 °C
The above values are approximately equivalent to ISO viscosity grade #22. However, low temperature viscosity will
differ depending on each product. Contact each hydraulic oil manufacture directly.
When the atmospheric temperature is below -40 °C: Contact your authorized dealer.
7-14
MAINTENANCE
A. GREASING
1 Front Joint Pins
Bucket --- every 250 hours

ZX Genuine Bucket --- every 500 hours
Link Pins --- every 500 hours
M178-07-007
Others --- every 500 hours

• Boom Cylinder Bottom
M157-07-156
M104-07-002
• Boom Foot
M154-07-002 M157-07-157
7-15
MAINTENANCE
• Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket
Cylinder Bottom Pin.
M157-07-157
• Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin.
(Centralized greasing system)
M157-07-155
7-16
MAINTENANCE
MEMO
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7-17
MAINTENANCE
2 Swing Bearing --- every 500 hours
CAUTION: Lubricating both the swing bearing and

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

• Lower the bucket to the ground.
• Stop the engine.
position.
• Use handrails.
1. Park the machine on a level surface. MCGB-07-009

3. Turn the brake switch on the steering column console to
the P (parking) position.
IMPORTANT: The turbocharger may be damaged if the
5. Run the engine at slow idle speed without load for five
minutes.
6. Turn the key switch OFF. Remove the key from the key
switch.
8. With the upperstructure stationary, apply grease via the
two grease fittings.
9. Start the engine. Raise the bucket several inches off the
ground and rotate the upperstructure 180°.
11. Repeat the procedure two times, beginning with step 3.
12. Apply grease to the swing bearing until grease can be
seen escaping from the swing bearing seals.
Model Capacity
ZX140W-3,170W-3, 190W-3, 0.30 L (0.32 US qt)
210W-3
13. Take care not to supply excessive grease.
7-18
MAINTENANCE
3 Swing Internal Gear --- every 500 hours
CAUTION: Adding or changing swing internal gear

grease and rotating the upperstructure must be done
by one person. Before you start, clear the area of all
1
persons.
Each time you leave the cab

• Lower the bucket to the ground.
• Stop the engine.
position.
• Use handrails.
ZX140W-3 MCGB-07-010
3. Turn the brake switch on the steering column console to 1
the P (parking) position.
4. Turn the auto-idle and auto-acceleration selector off.
minutes.
switch.
ZX170W-3, 190W-3 M1U1-07-058
8. Remove cover (1) from the upperstructure.
9. Grease must be to the top of all internal gear teeth of the
swing bearing and be free of contamination. 1
Add approximately 0.5 kg (1.1 lb) of grease, if required. If
the grease is contaminated, remove grease and replace
with clean grease.
IMPORTANT: If water or mud is found in the swing gear
area, see Operating in Water or Mud in the
“Driving the Machine” section.
10. Install the cover (1).

11. If grease shows any sign of water or mud, replace all the ZX210W-3 M178-07-008
grease on the internal gear.
Remove cover (2) from the bottom of the swing gear 2
housing, located near the center joint.
Model Capacity
ZX140W-3 14 L (3.7 US gal)
ZX170W-3, 190W-3, 210W-3 17 L (4.5 US gal)
M157-07-161
7-19
MAINTENANCE
4 Front Axle --- every one month
Grease all the fittings shown in the figure.

(4 used, 2 fittings on both side)
MCBB-07-044
7-20
MAINTENANCE
5 Propel Shaft (Front and Rear)

--- every 500 hours
ZX140W-3 Front MCGB-07-011
MCGB-07-012
ZX170W-3, 190W-3, 210W-3 Front
ZX140W-3 Rear MCGB-07-013
ZX170W-3, 190W-3, 210W-3 Rear MCGB-07-014
7-21
MAINTENANCE
6 Equalizer Pin
--- every 250 hours
ZX140W-3 MCGB-07-015
ZX170W-3 MCGB-07-016
ZX190W-3 MCGB-07-017
ZX210W-3 MCGB-07-018
7-22
MAINTENANCE
B. ENGINE
1 Engine Oil Level --- check daily
IMPORTANT: For most accurate readings, check the oil

level every day before starting the machine.
Be sure the machine is on a level surface.
1. Remove dipstick (1). Wipe oil off with a clean cloth. Rein- 1
sert dipstick (1).
2. Remove dipstick (1) again. Read level. Oil level must be 2
between the circle marks.
3. If necessary, add oil via oil filler cap (2). Be sure to use ZX140W-3 MCGB-07-019
only recommended oil (see Recommended Engine Oil
Chart).
2
NOTE: Checking the oil level immediately after shut down will
result in inaccurate readings.
Be sure to allow the oil to settle for at least 10 minutes 1
before checking.
ZX170W-3, 190W-3, 210W-3 MCGB-07-020
Max.
Min.
M178-07-011
7-23
MAINTENANCE
2 Change Engine Oil --- every 500 hours
IMPORTANT: Change 250 operating hours, if the content

of sulfur of fuel is 2000 ppm or more. Consult
your nearest Hitachi dealer for the details. 4
Replace Engine Oil Filter

3
--- every 500 hours
3
IMPORTANT: Change 250 operating hours, if the content
of sulfur of fuel is 2000 ppm or more. Consult
your nearest Hitachi dealer for the details.
1. Run the engine to warm oil. ZX140W-3 MCGB-07-021
DO NOT run the engine until oil is hot.
3
4. Turn the auto-idle switch off. 4

minutes.
ZX170W-3, 190W-3, 210W-3 MCGB-07-022
switch.
CAUTION: Engine oil may be hot. Take extra care to

avoid burns.
IMPORTANT: Install drainer (5) to the drain valve slowly.

Oil may exhaust in large quantities when 5
suddenly tightened.
8. Remove oil filler cap (2).

9. Remove cap (4) from oil pan drain valve (3). Install drainer
(5) to the drain valve. M1U1-07-046
10. Screw drainer (5) into drain valve. Drain valve (3) will be
Oil Oil
opened to drain oil.
Oil
11. Remove oil filler cap (2). Then, allow oil to drain through a Pan
clean cloth into a 50 liter (13 US gal) container. Oil Pan
12. After all oil has been drained, inspect the cloth for any 3
debris such as small pieces of metal.
13. Remove drainer (5). Install cap (4) to drain valve (3). Clean Cloth
Container Screw
5
Oil
M104-07-010 M1U1-07-002
7-24
MAINTENANCE
14. Open the right and left access covers and secure the
cover with rod.
15. Remove the filter cartridges of engine oil filter (5) by turn-
ing it counterclockwise with the filter wrench.
16. Clean the filter gasket contact area on the engine.
5
17. Apply a thin film of clean oil to the gasket of the new
filter.
18. Install new filter. Turn the filter cartridge clockwise by
hand until the gasket touches the contact area. Be sure
not to damage the gasket when installing the filter.
19. Tighten engine oil filter (5) 3/4 to 1 turn more using the
filter wrench. ZX140W-3 MCGB-07-023
Be careful not to overtighten.
20. Remove the oil filler cap. Fill the engine with recom-
mended oil. Check that oil level is between the circle
marks on the dipstick after 15 minutes.
21. Install the oil filler cap. 5
22. Start the engine. Run the engine at slow idle for 5 min-
utes.
23. Check that the engine oil pressure indicator on the moni-
tor panel goes out immediately. If not, stop the engine
immediately and find the cause.
25. Check for any leakage at the drain plug. ZX170W-3, 190W-3 MCGB-07-024
26. Check oil level on the dipstick.

NOTE: Don’t re-use the cartridge element
ZX210W-3 MCGB-07-025
7-25
MAINTENANCE
C. TRANSMISSION
1 2
1 Pump Transmission
Check Oil Level --- every 250 hours

minutes. MCGB-07-026
7. Remove dipstick (1). Oil must be within the specified
range.
8. If necessary, remove filler plug (2) and add oil. (See gear
oil chart)
9. Recheck oil level.
Change Oil --- every 1000 hours
3. Turn the auto-idle switch off. 3 MCGB-07-025
minutes.
Oil Pan
CAUTION: Oil may be hot. Wait for oil to cool before Clean Cloth
starting work.
Container
7. Remove filler plug (2).

8. Remove drain plug (3). Allow oil to drain through a clean
cloth into a 2 liter (0.52 US gal) container. M104-07-010
9. After all oil has drained, inspect cloth for any debris such
as small pieces of metal. Specified Range
10. Reinstall the drain plug (3). 1
11. Add oil via filler plug (2) until it is within the specified
range on dipstick (1).
12. Reinstall filler plug (2).
M1G6-07-004
7-26
MAINTENANCE
2 Swing Reduction Gear 2
Check Oil Level --- every 250 hours

minutes.
6. Pull the pilot control shut-off lever to the LOCK position. ZX140W-3 MCGB-07-027
7. Remove dipstick (1). Oil must be between marks.
8. If necessary, remove oil filler cap (2) and add oil. (See 1
gear oil chart)
9. Recheck oil level.
2
Change Gear Oil --- every 1000 hours

engine is not properly shut down. MCGB-07-028
ZX170W-3, 190W-3, 210W-3
minutes.
CAUTION: Gear oil may be hot. Wait for gear oil to
1
cool before starting work.
Specified Range
7. Remove the drain plug mounted on the end of drain pipe

to drain oil.
8. Reinstall the drain plug.
9. Remove oil filler cap (2) and add oil until it is between the
marks on dipstick (1).
10. Reinstall the oil filler cap.
7-27
MAINTENANCE
3 Transmission Gear Oil
WARNING: The components of the undercarriage

and also gear oil are very hot just after the engine is
stopped. Begin inspection/maintenance after travel
device has cooled off.
Check Oil Level --- every week

1. Park the machine on a firm, level surface and lower
bucket to ground, as illustrated. Put the brake switch in M202-07-028
the P (Parking) position and stop the engine.
2. Remove level plug (1) (Which also servers as the oil filler
plug ) oil should flow out of the plug hole. If it does not,
supply oil.
3. Clean level plug (1), re-install plug (1) with a new O-ring
1
and tighten them to specified torque.
Torque specifications : 50 N·m (5.1 kgf·m, 37 lbf·ft)
Replace Gear Oil --- every 2000 hours (first time after
500 hours)
ZX140W-3 MCGB-07-029
IMPORTANT: Change the travel transmission oil at least

once a year.
1. Park the machine on a firm, level surface and lower

bucket to ground as illustrated. Put the brake switch in
the P (Parking) position and stop the engine.
2. Remove drain plug (2) and level plug (1). Allow all gear oil
to drain. 1
3. After the gear oil is drained, clean drain plug (2). Re-
install drain plug (2) with a new O-ring and tighten it to
specified torque.
2
4. Supply new oil until it flows out of level plug hole (1).
ZX170W-3, 190W-3, 210W-3 MCGB-07-030
5. After few minutes, check oil level with level plug (1) on
transmission. If necessary, add oil.
6. Re-install level plug (1) with a new O-ring and tighten
them to specified torque.
7-28
MAINTENANCE
4 Front Axle
WARNING: The components of the under carriage

M202-07-028
Check Oil Level --- every one month
1. Park the machine on firm, level surface and lower bucket
to ground, as illustrated. Put the brake switch in the P
(Parking) position and stop the engine.
2. Remove level plug (1) (Which also serves as the oil filler
supply oil.
2 ZX140W-3 1 MCGB-07-031
Replace Gear Oil

ZX140W-3:
--- every 800 hours (first time after 100 hours)
ZX170W-3, 190W-3, 210W-3:

once a year.
2
ZX210W-3 MCBB-07-059
to ground as illustrated. Put the brake switch in the P
2. Remove drain plug (2) and level plug (1).
Allow all gear oil to drain.
install drain plug (2) with a new O-ring and tighten them
to specified torque.
5. After few minutes, check oil level with level plug (1) on ZX170W-3 MCGB-07-032
front axle. If necessary, add oil.
ZX170W-3, 190W-3, 210W-3 MCBB-07-051
7-29
MAINTENANCE
5 Rear Axle
WARNING: The components of the under carriage and

also gear oil are hot just after the engine is stopped.
Begin inspection/maintenance after travel device has
cooled off.

to ground, as illustrated. Put the brake switch in the P M202-07-028
2. Remove level plug (1) (Which also serves as the oil filler
supply oil.
Replace Gear Oil

ZX140W-3:
--- every 800 hours (first time after 100 hours) 2 1
ZX170W-3, 190W-3, 210W-3: ZX140W-3 MCGB-07-033
1 2

once a year.

to ground as illustrated. Put the brake switch in the P
2. Remove drain plug (2) and level plug (1).
Allow all gear oil to drain.
install drain plug (2) with a new O-ring and tighten them
to specified torque.
Torque specifications : 50 N·m (5.1 kgf·m, 37 lbf·ft) ZX170W-3, 190W-3, 210W-3 MCGB-07-034
7-30
MAINTENANCE
6 Front and Rear Hub Reduction Devices
WARNING: The components of the undercarriage


1. Park the machine on a firm, level surface .
2. Bring plug (1) (used to check oil level, drain oil and add M202-07-028
oil) on the hub reduction device end to the “Check Posi-

tion” shown at right. Lower the bucket to the ground. Put 1
the brake switch in the P (Parking) position and stop the
engine.
3. Remove plug (1). At this time, oil should flow out of the
plug hole. If it does not, supply oil.
4. Clean plug (1), re-install plug (1) with a new O-ring and
tighten them to torque.
Torque specifications : 50 N·m (5.1 kgf·m, 37 lbf·ft) 1
Check Position Drain Position
MCGB-07-035
Replace Gear Oil
ZX140W-3:
ZX170W-3, 190W-3, 210W-3:

once a year.
1

2. Bring plug (1) on the hub reduction device end to the
“Drain Position” shown at right. Lower the bucket to the
ground. Put the brake switch in the P (Parking) position MCGB-07-036
and stop the engine.
3. Remove plug (1). Allow all gear oil to drain.
4. Bring plug (1) on the hub reduction device end to the
“Check Position” shown at right. Lower the bucket to the
ground. Put the brake switch in the P (Parking) position
and stop the engine.
5. Supply new oil until it flows out of the plug (1) hole.
7. Re-install plug (1) with a new O-ring and tighten them to
specified torque.
Torque specifications: 50 N·m (5.1 kgf·m, 37 lbf·ft)
7-31
MAINTENANCE
D. BRAKE (TRAVELING)
Bleed Air From the Brake System
WARNING:
1
• If air is remaining in the brake system, the brake per-
formance will be reduced, possibly creating hazard-
ous conditions. After disassembling the brake line or
replacing the hydraulic oil, be sure to bleed air from
the brake system.
• After air bubbles in the hydraulic oil disappear dur-
ing air bleeding work, continue to bleed air until
approx. 500 mL (0.13 US gal) hydraulic oil is drained
from each wheel. If air bubbles are still present after
draining oil approx. 500 mL (0.13 US gal), continue to
bleed air until air bubbles disappear.
Bleed air from all wheels with a teamwork of two persons

following the procedures shown below. Four air bleeders
are provided in total [one air bleeder (1) per wheel]. MCBB-07-044
1. Turn the brake switch in the column box to the P (parking) 1

position. Start the engine to increase the hydraulic oil
pressure.
2. Connect a transparent vinyl tube (2) to the tip of air
bleeder (1). Put the other end of the tube into transpar-
ent container (3) filled with hydraulic oil. 2
3. One person moves the brake pedal (4) several times and
holds the pedal in the stepped position.
4. While holding the brake pedal (4) in the stepped posi-
tion, the other person loosens air bleeder (1) to allow
the hydraulic oil and air to discharge for several seconds.
Then, tighten air bleeder (1).
3
5. Repeat this procedure until air bubbles disappear in the
discharged oil.
M202-07-023
6. After air bubbles disappear in the discharged oil, con-
tinue to perform this procedure until approx. 500 mL
(0.13 US gal) hydraulic oil is drained. If air bubbles are
still present after discharging oil approx. 500 mL (0.13 US
gal), continue to perform this procedure until air bubbles
disappear.
7. Securely tighten air bleeder (1).
8. Bleed air from all other wheel brakes in the same proce-
dure.
9. After completing to bleed air from four bleeders, repeat
above steps 3 to 5 twice in each bleeder to check that air
is fully bled.
4 MCGB-01-004
7-32
MAINTENANCE
1 Check Brake Accumulator
1. Start the engine with the brake switch in the column box
turned to the P (parking brake) position.
2. After performing warm up operation, move the brake
pedal four to five strokes. Then, stop the engine.
1
3. Turn the key switch ON.
4. Fully step on the brake pedal from 2 to 3 strokes. The
buzzer will sound and brake pressure indicator (1) will
light when normal. If the buzzer sounds and the brake
pressure indicator lights before the brake pedal is
stepped on one stroke, the pressure charged in the accu-
mulator is abnormal. Don’t travel the machine. Ask your
nearest Hitachi dealer to replace the brake accumulator. MCGB-03-005
5. Repeat the above procedures three times to obtain the

correct result and check that no abnormality is present.
7-33
MAINTENANCE
2 Check Wear on Brake Lining --- As required
In case any abnormality is found in brake performance such

as:
• The brake doesn’t work effectively,
• A noise is heard when the brake is applied,
Contact your nearest Hitachi Dealer.
The brake lining must be checked for wear.
7-34
MAINTENANCE
E. TIRE
Tire/Size
Use tires of either of the following sizes.
IMPORTANT: Be sure to use tires of the same specifica-

tions made by the same manufacturer.
Check Tire Pressure.

Front Wheel Rear Wheel
Size BRIDGESTONE 10.00-20 16PR
Air Pressure
700 kPa (7.1 kgf/cm2, 102 psi)
Specification
Date Shipped Standard
Follow correct procedures when removing or installing tire
from/to wheel or rim.
WARNING:
• Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire if you do not have SA-249
the proper equipment and experience to perform
the job. Have it done by your authorized dealer or
a qualified repair service.
• The inside tire is different from the outside tire in
rim offset dimension. Therefore, if both tires are in-
stalled in reverse, the tire width will become wider
than the overall width of the vehicle. Pay attention
so that both inside and outside tires are installed in
their correct positions.
7-35
MAINTENANCE
1 Tire Inspection and Replacement Procedure
Inspection
1. If the tread of any part of a tire has worn down, replace
the tire.
2. Each day before starting work, be sure to check the tires
for cracks, damage, foreign matter, etc.
3. Confirm that the tire pressure is within specifications.
Remove and Install tires following these procedures

Removal
1. Loosen the wheel nuts with a wheel wrench. Right-hand-
ed Screws are used for both the right-hand and left-hand
wheels.
2. Jack up the machine body until the tire clears the ground.
Remove tire.
3. Stop the engine. Put the shift lever in the neutral posi-
tion. Turn the key switch to the ON position.
4. Remove tire.
Installation
1. To avoid excessive tightening torque, Do not use the oil
containing molybdenum dioxide.
2. Apply engine oil to thread of nut and washer facing sur-
face of nut slightly.
3. Must not apply engine oil to disk wheel facing surface of
the washers (Spherical surface: ✩).
4. Pre-tightening the wheel nut diagonally with 2-3 pro-
cesses, then apply regular tightening torque.
MCBB-07-023
1
5 7
Detail
9 3 Spring Washer
Washer Wheel Unit
4 10
8 6
2
The Example of the Order of
Wheel Nut Bolting.
Engine Oil
Applying Position
Must Not Apply Engine Oil

(Same to Other Area: ✩ ) MCGB-07-103
7-36
MAINTENANCE
F. HYDRAULIC SYSTEM
INSPECTION AND MAINTENANCE OF HYDRAULIC
EQUIPMENT
CAUTION: During operation, the parts of the hydrau-
lic system become very hot. Allow the machine to cool
down before beginning inspection or maintenance.
1. Be sure that the machine is parked on a level, firm surface

before servicing hydraulic equipment.
2. Lower the bucket to the ground and stop the engine.
3. Begin servicing hydraulic components only after compo-
nents, hydraulic oil and lubricants are completely cooled,
and after releasing residual pressure.
3.1 Bleed air from the hydraulic oil tank to release internal
pressure.
3.2 Allow the machine to cool down.
Note that servicing heated and pressurized hydraulic
components may cause hot parts and/or oil to fly off or
escape suddenly, possibly resulting in personal injury.
3.3 Keep body parts and face away from plugs or screws
when removing them.
Hydraulic components may be pressurized even when
cooled.
3.4 Never attempt to service or inspect the travel and swing
motor circuits on slopes. They are highly pressurized
due to self-weight.
4. When connecting hydraulic hoses and pipes, take spe-

cial care to keep seal surfaces free from dirt and to avoid
damaging them. Keep these precautions in mind:
4.1 Wash hoses, pipes, and the tank interior with a washing
liquid and thoroughly wipe it out before reconnecting
them.
4.2 Only use O-rings that are free of damage or defects. Be
careful not to damage them during reassembly.
4.3 Do not allow high pressure hoses to twist when con-
necting them. The life of twisted hoses will be short-
ened considerably.
4.4 Carefully tighten low pressure hose clamps.
Do not overtighten them.
7-37
MAINTENANCE
5. When adding hydraulic oil, always use the same brand of
oil; do not mix brands of oil. As the machine is filled with
Super EX 46 HN when it is shipped from the factory, use
it as a general rule. When selecting to use another brand
of oil listed in the table “Brand names of recommended
hydraulic oil”, be sure to completely replace the oil in the
system.
6. Do not use hydraulic oils other than those listed in the
table “Brand names of recommended hydraulic oil”.
7. Never run the engine without oil in the hydraulic oil tank.
7-38
MAINTENANCE
BREAKER MAINTENANCE
Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter
Hydraulic breaker operation subjects the hydraulic system to related hydraulic system components. Recommended
become contaminated faster and to quickly deteriorate the hy- changing intervals are shown below. For filter replace-
draulic oil. For this reason, hydraulic oil must be changed and ment and oil changing intervals are shown below. (For
the hydraulic oil tank filter must be replaced more often than filter replacement and oil changing procedures, refer to
the machine equipped with a bucket. Failure to do so may the “Hydraulic System” in the “MAINTENANCE” Section.)
result in damage to the breaker, hydraulic oil pump, and other
Changing intervals (Hours)
Attachment Availability
*Hydraulic Oil Full Flow Filter Element **Element Type
1500
Standard Filter Paper
Bucket 100% 2500 1000
High Performance Element
5000
600 100 Standard Filter Paper
Hydraulic Breaker 100%
1000 300 High Performance Element
* : Replacement intervals differ depending on the brand of hydraulic oil used. Refer to the Hydraulic System in the MAIN-
TENANCE section.
** : Use the high performance element (micro-glass) on excavators engaged in demolition work.
Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element
Hours to Replace Hours to Replace
Element Hydraulic Oil
100
: When using high performance element (micro-glass)
: When using filter-paper element
Replacement Interval when using

80 1500-hour life time hydraulic oil
60 Replacement Interval when using

Average 2500-hour life time hydraulic oil
Breaker
Operating
Availability
(%) Replacement Interval when
40 using 5000-hour life time
hydraulic oil
20
0
0 1000 2000 3000 4000 5000
M1U1-05-006
Excavator Operating Hours
IMPORTANT: Use a high performance element (micro- NOTE: Full-flow filter restriction indicator is optional.
glass) on excavators engaged in demolition If a filter-paper element is used, this indicator
work. In case using a filter-paper element is does not operate. (Refer to the Hydraulic System
unavoidable, replace hydraulic oil and the in the Maintenance section.)
filter element at the intervals as illustrated
with dotted lines.
7-39
MAINTENANCE
1 Check Hydraulic Oil Level --- daily
IMPORTANT: Never run the engine without oil in hydraulic

oil tank.

2. Position the machine with the arm cylinder fully retracted
and the bucket cylinder fully extended.
M202-07-028
4. Turn the auto-idle switch off. Turn the brake switch on
the steering column console to the P (parking) position.
Stop the engine.
IMPORTANT: The turbocharger may be damaged if the 1
minutes.
switch.
ZX140W-3 MCGB-07-037
8. Open the access door in front of the main pump. Check
oil level with level gauge (1) on hydraulic oil tank. Oil
must be between marks on the gauge. If necessary, add
oil.
CAUTION: The hydraulic oil tank is pressurized.
Push the pressure release button on the tank cap to
1
release pressure, and carefully remove the cap.
To add oil:
9. Push the pressure release button on the air breather to
release pressure. Remove the cover.
10. Add oil. Recheck oil level with level gauge (1).
11. Install the cover. Make sure the filter and rod assembly is
in correct position. ZX170W-3, 190W-3 MCBB-07-038
ZX210W-3 MCGB-07-039
7-40
MAINTENANCE
2 Change Hydraulic Oil
3 Suction Filter Cleaning

--- every 5000 hours, 2500 hours
or 1500 hours
CAUTION: Hydraulic oil may be hot. Wait for oil to

cool before starting work.
IMPORTANT: Hydraulic oil changing intervals differ ac- M202-07-028
cording to kind of hydraulic oils used. (See 2 1

Recommended Oil Chart in this group)
1. Park the machine on a level surface with the upperstruc- Level Gauge
ture rotated 90° for easier access.
2. Position the machine with the arm cylinder fully retracted
and the bucket cylinder fully extended.
3. Lower the bucket to the ground. Turn the brake switch on
the steering column console to the P (parking) position.
Stop the engine.

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

the pressure release button on the air breather before
removing the air breather.
9. Push pressure release button (1) on the air breather. 2

M1U1-07-042
10. Remove cover (2).
11. Remove oil using a suction pump. The hydraulic oil tank
capacity, up to specified oil level, is approximately A.
Model A
ZX140W-3, 170W-3, 190W-3, 170 L (44.9 US gal)
210W-3
7-41
MAINTENANCE
12. Remove drain plug (3). Allow oil to drain.
3
13. Remove suction filter and rod assembly (4).
14. Clean the filter and tank interior. If the filter is to be re-
placed, install new filter on the rod as shown. Tighten nut
to 14.5 to 19.5 N•m (1.5 to 2.0 kgf•m, 11.0 to 14.5 lbf•ft).
Model A
ZX140W-3 837 mm
ZX170W-3, 190W-3, 210W-3 856 mm
15. Install filter and rod assembly (4). Make sure the filter is
positioned correctly on the outlet. M1U1-07-047
16. Replace the hydraulic tank oil filter. (See “Maintenance
Every 500 Hours” Section)
17. Clean, install and tighten drain plug (3).
18. Add oil until it is between the marks on the oil level
gauge.
2
19. Install cover (2). Make sure filter and rod assembly (4) are
in correct positions. Tighten the bolts to 49 N·m (5 kgf·m,
36 lbf•ft).
20. Be sure to bleed air form the system following the proce-
dures shown next page.
M157-07-062
20 mm (0.79 in)
4
M107-07-070
7-42
MAINTENANCE
Air Bleeding Procedures
5
IMPORTANT: If the hydraulic pump is not filled with oil, it
will be damaged when the engine is started.
The machine is equipped with two main pumps. Bleed air

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

2. Fill the pump with oil through air bleed plugs (5) port on
each pumps until oil flows out of air bleed plug (5) hole.
3. Temporarily tighten air bleed plugs (5) on each pumps,
start the engine and run at slow idle. Loosen one of air
bleed plugs (5) slightly until oil flows from plug port to
release trapped air completely. Tighten air bleed plug (5).
Repeat this step for the rest of plugs.
M1U1-07-035
4. Purge air from the hydraulic system by running the en-
gines at slow idle and operating the control levers slowly
and smoothly for 15 minutes.
5. Position the machine as illustrated in the oil level check-
ing procedure.
9. Pull the pilot control shut-off lever to the LOCK position
10. Check the hydraulic oil tank gauge. Remove cover (2) to
add oil if necessary.
7-43
MAINTENANCE
• Bleed Air from Travel Transmission 2 1

IMPORTANT: Air trapped in the travel transmission gear-
shift hydraulic circuit will cause erratic
operation in the gearshift system. When the
transmission gearshift hydraulic line is disas-
sembled and/or hydraulic oil is changed, be
sure to bleed air.
NOTE: Bleed the air by two or more persons.

ZX140W-3 TCJB-01-02-020
1. Start the engine, park the machine on level firm ground, 1
and lower the bucket to the ground.
2. Perform the following operation, apply the work brakes 2
• Set the brake switch into auto axle lock or axle locking po-
sition.
• Depress the brake pedal to stroke end.
NOTE: If the brake switch is P (parking brake) position, air

bleeding work cannot be performed.
3. Insert a transparent vinyl tube (3) at the end of air bleed

plug (1 and 2) of transmission, and put the other one end
into the transparent container (4) filled with hydraulic oil. T21W-03-05-014
ZX170W-3, 190W-3, 210W-3
4. Switch the travel mode switch (5) fast speed «slow speed
4 to 5 times.
5. Fast speed side:
Put the travel mode switch (5) into fast speed position,
and loosen air bleed plug (1).
Slow speed side: 3
Put the travel mode switch (5) into slow speed position,
and loosen air bleed plug (2).
6. Discharge the air in hydraulic oil, and tighten air bleed

plug (1 and 2) after 15 to 20 seconds.
7. Repeat steps 4 to 6 until the air bubbles stop coming out 4
with the hydraulic oil. (About 4 to 5 times)
8. Tighten air bleed plug (1 and 2).
M202-07-023
Fast 5
Slow
TCJB-04-03-001
7-44
MAINTENANCE
4 Replace Hydraulic Tank Oil Filter (Std. Model)
--- every 1000 hours

minutes.
5. Stop the engine. Remove the key from the key switch. SA-039
1 2 3
removing the air breather.
7. Push the pressure release button on the hydraulic oil tank

to release pressure.
NOTE: There is spring tension under the cover. Hold down the 4
cover when removing last two bolts.
8. Hold down filter cover (2) against light spring load when
removing the last two bolts (1). Remove filter cover (2).
9. Remove spring (4), and element (5). 5
NOTE: Remove the element and inspect for metal particles
and debris in the bottom of the filter can. Excessive
amounts of brass and steel particles can indicate a
failed hydraulic pump, motor, valve or an impending
failure. A rubber type of material can indicate cylinder
packing failure.
10. Discard element (5) and O-ring (3).

11. Install a new element (5) and spring (4).
12. Install filter cover (2) with a new O-ring (3).
13. Install and tighten bolts (1) to 49 N·m (5 kgf·m, 36 lbf·ft).
M178-07-069
7-45
MAINTENANCE
4 Replace Full-Flow Filter (Optional)

--- every 300 hours
In case the hydraulic oil filter indicator on the monitor panel
comes ON, immediately replace the filter even if operation
hours are shorter than 300 hours after replacing the filter
previously.
CAUTION: :Immediately after operating the machine
if hydraulic system or line is opened, hot and high
pressure hydraulic oil may spout, possibly causing
severe burns. Wait for the hydraulic oil to cool before M202-07-028
starting any maintenance work.

7
IMPORTANT: Replacement intervals differ according to
the brand of hydraulic oil used and the kind
of the filter element used, as well as the
operating hour ratio of the installed attach-
ment.
IMPORTANT: Precautions for Using Element 1

• High performance element (micro-glass)
is used in the full-flow filter element on
Excavators for Demolition Work. Be sure
to replace the filter with the same type of
high performance element. In case using a
filter-paper element is unavoidable, refer
to the descriptions for replacing hydraulic
oil and full-flow filter element in the MAIN-
TENANCE section.
• In case the same filter paper element as
used on Std. Model, the filter restriction
indicator will not operate. Insulate the har- 4 2 3 1
ness to indicator (7).
Replacement
1. Park the machine on solid and level ground. After extend-
ing the bucket cylinder, retracting the arm cylinder, and
lowering the bucket on the ground, as illustrated to the
right, stop the engine.
2. Be sure to push the air vent valve to release any air pres-
5
sure from the hydraulic oil tank before replacing the ele-
ment.
3. Remove bolts (1) (6 used) to remove cover (2) and O-ring
(3). When removing cover (2), slowly remove it while
pressing the cover downward so that spring (4) doesn’t
fly out.
4. Remove spring (4) and element (5).
5. Replace element (5) and O-ring (3) with new ones. Install
them into the hydraulic oil tank.
6. Install cover (2). Tighten bolts (1) (6 used) to specification.
Tightening Torque: 50 N·m (5.1 kgf·m, 37 lbf·ft)
M175-07-035
7-46
MAINTENANCE
5 Replace Pilot Oil Filter --- every 1000 hours

M202-07-028
minutes.
Pilot Filter

removing the air breather. Steering Filter
7. Remove the filter cartridges of pilot oil filter (2) by turn-

ing it counterclockwise with the filter wrench.
8. Clean the filter O-ring contact area on the filter head (1).
9. Apply a thin film of clean oil to the gasket of the new
filter. ZX140W-3 MCGB-07-023
10. Install new filter. Turn the filter cartridge clockwise by

hand until the O-ring touches the contact area. Be sure
not to damage the O-ring when installing the filter.
Steering Filter
NOTE: Do not re-use the filter cartridge.
Pilot Filter
ZX170W-3, 190W-3 MCGB-07-024
Steering Filter
1
Pilot Filter ZX210W-3 MCGB-07-046
M1U1-07-050
7-47
MAINTENANCE
6 Replace Air Breather Element

CAUTION: Hydraulic oil may be hot just after opera-

tion. Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool before
starting work.
Replacement Procedures
1. Park the machine on solid and level ground. Fully extend M202-07-028
the bucket cylinder, fully retract the arm cylinder, and
lower the bucket to the ground as illustrated to the right.
Stop the engine. Turn brake switch on the column con-
sole to the P (parking) position.
2. Before replacing the element, be sure to bleed air pres-
sure from the hydraulic oil tank by pressing the air bleed
valve on the hydraulic oil tank.
3. Turn cover (2) clockwise about 1/4 turn. Turn cap (1)
counterclockwise to remove it.
4. Turn cover (2) counterclockwise to remove it. Then, re-
move element (3).
5. Install new element (3). Tighten to install cover (2) until
cover (2) comes in contact with the element. Then, fur- MCGB-07-040
ther tighten the cover 1/4 turn.
6. Securely tighten cap (1) clockwise by hand. While hold-
ing cap (1) by hand so that cap (1) doesn’t rotate, securely
tighten cover (2) by rotating counterclockwise 5 to 10° by
hand. 1
7. Take care never to allow water and/or contaminant to

stay between cover (2) and body (4) (air breathing port).
2
8. Replace the element periodically to keep hydraulic oil
clean and to extend hydraulic components service life.
3
M1G6-07-001
7-48
MAINTENANCE
7 Check Hoses and Lines

--- daily
--- every 250 hours
CAUTION: Escaping fluid under pressure can pen-

etrate the skin causing serious injury.
To avoid this hazard, search for leaks with a piece of
cardboard.
Take care to protect hands and body from high-pres-
sure fluids.
If an accident occurs, see a doctor familiar with this
type of injury immediately.
Any fluid injected into the skin must be surgically
SA-031
removed within a few hours or gangrene may result.
CAUTION: Hydraulic oil and lubricant leaks can lead
to fire that may result in serious injury.
To avoid this hazard :
• Park the machine on a firm, level surface.
Lower the bucket to the ground.
Stop the engine. Remove key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position.
• Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, dam-
aged oil cooler, and loose oil cooler flange bolts,
SA-292
for leaks.
Check hoses, lines and oil cooler at the check points
indicated below for leaks and other damage that
may result in future leaks.
If any abnormalities are found, replace or retighten
them, as shown in Tables 1-3.
• Tighten, repair or replace any missing, loose or
damaged clamps, hoses, lines, oil cooler, and loose
oil cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged hoses or lines. SA-044
7-49
MAINTENANCE
3 2
Table 1. Hoses
1
Interval (hours) Check Points Abnormalities Remedies
Daily Hose covers Leak (1) Replace 2
Hose ends Leak (2) Replace
3
Fittings Leak (3) Retighten or replace
hose or O-ring
Every 250 Hose covers Crack (4) Replace M137-07-008
hours Hose ends Crack (5) Replace
3 2
1
Hose covers Exposed reinforcement (6) Replace
2
Hose covers Blister (7) Replace
3
M115-07-145
Hose Bend (8) Replace 4
M115-07-146
Hose Collapse (9) Replace

(Use proper bend 7
radius) 6
Hose ends and Deformation or Replace

fittings corrosion (10)
NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the M115-07-147
abnormality. Use genuine Hitachi parts.
8
M115-07-148
10
M115-07-149
Fig. 1
7-50
MAINTENANCE
Table 2. Lines
Daily Contact surfaces of Leak (11) Replace 13 12
flange joints O-ring
and/or 11
retighten bolts
M137-07-001
Welded surfaces on Leak (12) Replace
joints
Every 250 hours Joint neck Crack (13) Replace 13 12
Welded surfaces Crack (12) Replace
on joints
Clamps Missing Replace
Deformation Replace
M137-07-007
Loose Retighten
NOTE: Refer to the illustrations in Fig.2 for each check point location or for a description of the Fig. 2
abnormality. Use genuine Hitachi parts.
Table 3. Oil cooler 15

Every 250 hours Contact surfaces of Leak (14) Replace
flange joints O-ring
and/or
retighten bolts 16
Oil cooler Leak (15) Replace

Coupling and Leak (16) Retighten or
rubber hose replace
NOTE: Refer to the illustrations in Fig.3 for each check point location . 14 ZX140W-3
M137-07-002
ZX170W-3, 190W-3, 210W-3

M1U1-07-051
Fig. 3
7-51
MAINTENANCE
SERVICE RECOMMENDATIONS FOR HYDRAULIC

FITTINGS 2 6 1 4 5
Two hydraulic fitting designs are used on this machine.
Flat Face O-ring Seal Fitting (ORS Fitting)

An O-ring is used on the sealing surfaces to prevent oil leak-
age.
6
1. Inspect fitting sealing surfaces (6). They must be free of 3 M104-07-033
dirt or defects.
2. Replace O-ring (1) with a new one when assembling fit-
tings.
3. Lubricate O-ring (1) and install it into groove (3) using
petroleum jelly to hold it in place.
4. Tighten fitting (2) by hand, pressing the fitting joint
together to ensure O-ring (1) remains in place and is not
damaged.
5. Tighten fitting (2) or nut (4) to the torque values shown.
Do not allow hose (5) to twist when tightening fittings.
6. Check for leaks. If oil leaks from a loose connection, do
not tighten fitting (2). Open the connection, replace
O-ring (1) and check for correct O-ring position before
tightening the connection.
Torque specifications ±10%
Width across flats (mm) 27 32 36 41, 46
N·m 93 137 175 205
Fastening torque (kgf·m) (9.5) (14) (18) (21)
(lbf·ft) (69) (101) (130) (152)
7-52
MAINTENANCE
Metal Face Seal Fittings
Fittings are used on smaller hoses and consist of a metal 7 9 8 10 5
flare and a metal flare seat.
1. Inspect flare (10) and flare seat (9). They must be free of
dirt or obvious defects.
IMPORTANT: Defects in the tube flare cannot be repaired.

Overtightening a defective flare fitting will
not stop a leak. M202-07-051
2. Tighten fitting (7) by hand.

3. Tighten fitting (7) or nut (8) to the torque values shown.
Do not allow hose (5) to twist when tightening fittings.
Width across flats

17 19 22 27
(mm)
Fastening N·m 24.5 29.5 39 78
(kgf·m) (2.5) (3) (4) (8.0)
torque (lbf·ft) (18) (21.5) (29) (58)
Pilot Piping Fittings (For shuttle valve) MCGB-07-047
Width across flats (mm) 19

N·m 34.3
Fastening torque (kgf·m) (3.5)
(lbf·ft) (25.3)
7-53
MAINTENANCE
G. FUEL SYSTEM 1
Recommended Fuel
Use high quality DIESEL FUEL only (JIS K-2204) (EN 590)
(ASTM 2-D) (GOST-R 52368) (GB 252). Kerosene must NOT be
used.
Refueling
3. Turn the auto-idle switch off. Turn the brake mode switch
to P (parking) position.
MCGB-01-041
minutes.
CAUTION: Handle fuel carefully. Shut the engine off

before fueling. Do not smoke while you fill the fuel 2
tank or work on fuel system.
7. Check fuel level gauge (3) or fuel gauge (1) of the moni-
tor panel. Add fuel if necessary. MCGB-07-040
IMPORTANT: Keep all dirt, dust, water and other foreign 3

materials out of the fuel system.
Yellow
8. To avoid condensation, fill the tank at the end of each Mark
day’s operation. Take care not to spill fuel on the machine
or ground.
Model Tank Capacity
ZX140W-3 250 L (66 US gal)
ZX170W-3, 190W-3 290 L (77 US gal)
ZX210W-3 355 L (94 US gal)
Do not fill the tank more than specified. Stop filling when M157-07-060
a yellow mark on fuel level gauge (3) becomes visible. Be
sure to position the fuel service nozzle so that any part of
the nozzle does not obstruct rising of the float-type fuel
level gauge (3).
9. Reinstall filter cap (2) on the filler tube. Be sure to lock

filter cap (2) with the key to prevent the cap from being
lost as well as to prevent vandalism.
7-54
MAINTENANCE
1 Drain Fuel Tank Sump --- daily
1. Park the machine on a level surface with the upperstruc-

ture rotated 90° for easier access.
3. Turn the auto-idle off. Turn brake switch on the column
console to the P (parking) position.
M202-07-028
1
minutes.
switch.
7. Open drain cock (1) for several seconds to drain water
and sediment. Close the drain cock.
M1U1-07-015
7-55
MAINTENANCE
2 Check Water Separator
--- daily
Water separator (4) separates any water that may get mixed
with the fuel. Water separator (4) contains a float which rises
as water accumulates.
Be sure to drain the sediment when the float rises up to the
“Drain Water” mark written on the outside of water separa-
tor (4).
IMPORTANT: If the fuel contains an excessive amount of

water, shorten the interval between water
Main Filter
separator checks.
Draining Procedures (Main Filter)

1. Place 0.5 liters or larger capacity container under drain Pre-Filter ZX140W-3 MCGB-07-093
plug (3) to collect the drained water.

2. Shut off the fuel supply by closing cock (3) on the bottom
of the fuel tank.
3. Loosen plug (1) on the top of the fuel main filter.
4. Rotate drain plug (2) on the bottom of the filter about
4-turns counterclockwise to drain the water accumulated
in the filter.
5. After draining water, securely tighten drain plug (2) and
plug (1). Return fuel cock (3) to the original position. Main Filter
6. Start the engine. Check drain plug (3) and plug (1) for fuel
leaks.
Pre-Filter ZX170W-3, 190W-3
MCGB-07-094
Wrench size: 10 mm
Main Filter
Pre-Filter
ZX210W-3 MCGB-07-095
Main
Filter
1
2
M1U1-07-015
M1GR-07-002 M1GR-07-010
7-56
MAINTENANCE
Draining Procedures (Pre-Filter)
1. Place 0.5 liters or larger capacity container under drain
plug (5) to collect the drained water.
2. Shut off the fuel supply by closing cock (5) on the bottom
of the fuel tank.
3. Loosen plug (4) on the top of the fuel pre-filter.
4. Rotate drain plug (5) counterclockwise to completely
drain water.
5. After draining water, securely tighten drain plug (5) and
plug (3). Return fuel cock (3) to the original position. Main Filter
6. Start the engine. Check drain plug (5) and plug (4) for fuel
leaks.
NOTE: After draining water mixed in fuel, bleed air from the Pre-Filter ZX140W-3 MCGB-07-093
fuel supply system.
Wrench size: 14 mm
Main Filter
Pre-Filter ZX170W-3, 190W-3

MCGB-07-094
Main Filter
Pre-Filter
ZX210W-3 MCGB-07-095
M1U1-07-015
M1U1-07-005 M1U1-07-004
7-57
MAINTENANCE
Air Bleeding Procedures
IMPORTANT: Air in the fuel system may make the engine

hard to start or make it run irregularly. After
3
draining water and sediment from the water
separator, replacing the fuel filter, cleaning
the fuel solenoid pump strainer or running
the fuel tank dry, be sure to bleed the air
from the fuel system.
This machine is equipped with a fuel solenoid pump.

M1U1-07-015
CAUTION: Fuel leaks may lead to fires. 6
1. Check that fuel cock (3) on the bottom of the fuel tank is
opened.
2. Turn the key switch ON and hold it in that position for ap-
prox. 3 minutes. Thereby, the electrical fuel pump oper-
ates, starting to bleed air.
3. While holding the key switch in the ON position, recip-
rocate fuel main filter priming pump (6). After air is bled
from the main filter, return priming pump (6) to the origi-
nal position.
4. After the main filter is filled with fuel, hold the key switch
in the ON position for 30 seconds.
M1GR-07-002
5. Start the engine. Check the fuel supply system for fuel
leaks.
CAUTION: Even if air is not thoroughly bled, do not
hold the key switch in the ON position for more than
5 minutes. In case air is not thoroughly bled, first
return the key switch to the OFF position. Then, after
waiting for more than 30 seconds, turn the key switch
ON again. Failure to do so may cause damage to the
electrical pump and/or discharging the batteries.
7-58
MAINTENANCE
Air Bleeding by Priming Pump
In case air is not bled due to malfunction of the fuel sole-
noid pump, operating the priming pump only can bleed air.
3
1. Check that fuel cock (3) on the bottom of the fuel tank is
opened.
2. Loosen air bleed plug (1) on the fuel main filter.
3. Supply fuel by reciprocating priming pump (6). After no
air bubbles are spouted through air bleed plug (1), tight-
en air bleed plug (1). M1U1-07-015
4. After tightening air bleed plug (1), reciprocate priming

pump (6) approx. 150 strokes.
Main Filter
5. Wipe off any spilled fuel.
6. Start the engine. Check that no fuel leaks are present. If
the engine does not start, repeat the above procedures
from step .
Wrench size: 10 mm
1
M1GR-07-010
M1GR-07-002
7-59
MAINTENANCE
3 Replace Fuel Main Filter Element
--- every 500 hours
IMPORTANT: Be sure to use only genuine Hitachi elements
for the main fuel cartridge and the pre-
cartridge. Failure to do so may deteriorate
the engine performance and/or shorten the
engine service life. Please be noted that all
engine failures caused by using other manu-
facturers’ elements are excluded from Hita-
chi Warranty Policy.
Procedures: Main Filter
1. Close cock (3) on the bottom of the fuel tank.

2. Place a 1-liter or larger capacity drain container under
ZX140W-3 MCGB-07-093
drain plug (2).
3. Loosen air bleed plug (1) and drain plug (2). Drain fuel
until fuel does not flow out of the filter.
4. Remove transparent filter case (7) using the exclusive
tool.
5. When transparent filter case (7) is removed, the element
is exposed. Remove the element by hand.
6. Install a new element. Tighten transparent filter case (7) Main Filter
to 29.4 ± 2 N·m using the exclusive tool.
7. Tighten air bleed plug (1) and drain plug (2).
8. Open cock (5) on the bottom of the fuel tank.
ZX170W-3, 190W-3
9. Bleed air from the fuel supply system. MCGB-07-094
After replacing the fuel filter element, bleed air from the
fuel supply system. (Refer to the air bleed procedures
described on page 7-45.)
Wrench size: 10 mm
Main Filter
ZX210W-3 MCGB-07-095
Main
Filter
1
2
M1U1-07-015
M1GR-07-002 M1GR-07-010
7-60
MAINTENANCE
4 Replace Fuel Pre-filter Element
--- every 500 hours
IMPORTANT: Be sure to use only genuine Hitachi elements
for the main fuel cartridge and the pre-
cartridge. Failure to do so may deteriorate
the engine performance and/or shorten the
engine service life. Please be noted that all
engine failures caused by using other manu-
facturers’ elements are excluded from Hita-
chi Warranty Policy.
Procedures: Pre-Filter
1. Close cock (3) on the bottom of the fuel tank.
2. Place a 1-liter or larger capacity container under drain
ZX140W-3 MCGB-07-093
plug (5).
Pre-Filter
3. Loosen air bleed plug (4) and drain plug (5). Drain fuel
until fuel does not flow out of the filter.
4. Remove transparent filter case (8) using an exclusive tool.
5. When transparent filter case (8) is removed, the element
is exposed. Remove the element by hand.
6. Install a new element. Tighten transparent filter case (8)
to 30 ± 2 N·m using the exclusive tool.
7. Tighten air bleed plug (4) and drain plug (5).
8. Open cock (3) on the bottom of the fuel tank.
9. Bleed air from the fuel supply system.
ZX170W-3, 190W-3
MCGB-07-094
After replacing the fuel filter element, bleed air from the
fuel supply system. (Refer to the air bleed procedures
described on page 7-45.)
Wrench size: 14 mm
Pre-Filter
ZX210W-3 MCGB-07-095
M1U1-07-015
M1U1-07-005 M1U1-07-004
7-61
MAINTENANCE
5 Clean Fuel Solenoid Pump Strainer:
--- every 500 hours
Cleaning
When the strainer is disassembled, be sure to replace the
gasket. Install the cover and the magnet only after suffi- 1
ciently cleaning them. After being assembled, closely check
the air-tightness of the strainer.
Disassembling/Assembling
MCGB-07-092
To remove cover (1), loosen with a spanner. After the cover 5 4 3
is removed, gasket (2), strainer (3), and gasket (4) are easily
removed in order. Wash removed strainer (3) with light oil.
Install the strainer in the reverse order of disassembling. At
that time, install gasket (2) into cover (1) first. Then, securely M178-07-102
tighten cover (1) to pump (5) using a spanner.
Fuel Solenoid
Pump
NOTE: Wrench size: 17 mm
ZX140W-3 MCGB-07-093
Fuel Solenoid
Magnet 1 2 3 4 5 Pump
ZX170W-3, 190W-3
MCGB-07-094
M1GR-07-004
Fuel Solenoid
Pump
36 mm 3 2.7 mm 1 mm
28 mm 2 4
ø18
ø40
ø24
ø51
ø41
M1U1-07-006
ZX210W-3 MCGB-07-095
7-62
MAINTENANCE
6 Check Fuel Hoses

--- daily
--- every 250 hours
CAUTION: Fuel leaks can lead to fires that may result

in serious injury.
To avoid this hazard :
1. Park the machine on a firm, level surface. Lower the

bucket to the ground. Stop the engine. Remove key from
the key switch. Pull the pilot control shut-off lever to the
LOCK position.
2. Check for kinked hoses, and hoses that rub against each
other parts for leaks.
Check hoses at the check points indicated below for leaks
and other damage that may result in future leaks. If any
abnormalities are found, replace or retighten them, as
shown in Table 4.
3. Repair or replace any loose or damaged hoses. Never
install bent or damaged hoses.
Table 4. Hoses
1
Daily Hose ends Leak (1) Retighten or replace
Soutache braid Friction (2) Replace 2
hose Crack (2) Replace
Every 250 hours Soutache braid Crack (3) Replace
hose
Hose ends Crack (4) Replace 1
M137-07-003
Hose Bend (5) Replace
4
M137-07-004
5
Hose Collapse (6) Replace

(Use proper bend radius)
Hose ends and fittings Deformation or Replace

corrosion (7) M137-07-005
NOTE: Refer to the illustrations in Fig.1 for each check point 6

location or for a description of the abnormality. Use
genuine Hitachi parts.
7
M137-07-006
Fig. 1
7-63
MAINTENANCE
H. AIR CLEANER
1 Clean the Air Cleaner Outer Element

--- every 250 hours or when the restriction
indicator comes ON
2
2 Replace the Air Cleaner Outer and Inner
Elements
--- after cleaning six times or after one year

ZX140W-3 MCGB-07-048

minutes.
5. Stop the engine. Remove the key from the key switch. 1

7. Loosen clamps (2) to remove the cover.
IMPORTANT: Do not install the element and/or the cover
forcibly when installing the clamps. Failure
to do so may result in deformation of the
clamps, element, and/or cover. ZX140W-3 MCGB-07-101
8. Remove outer element (1).
9. Tap outer element (1) with the palm of your hand, NOT
ON A HARD SURFACE.
CAUTION: Use reduced compressed air pressure.
(Less than 0.2 MPa, 2 kgf/cm2). Clear area of bystand-
ers, guard against flying chips, and wear personal 2
protection equipment including goggles or safety
glasses.
10. Clean outer element (1) using compressed air. Direct the
air to the inside of the filter element, blowing out.
11. Clean the filter interior before installing outer element (1).
12. Install outer element (1). ZX170W-3, 190W-3 MCGB-07-049
13. Install cover and tighten clamps (2).

14. Start the engine and run at slow idle.
15. Check the air filter restriction indicator on the monitor
panel. If the air filter restriction indicator comes ON, stop 1
the engine and replace the outer element (1).
Turn brake switch on the column console to the P (park-
ing) position.
ZX170W-3, 190W-3 MCGB-07-051
7-64
MAINTENANCE
16. When replacing the air cleaner filter element, replace
both outer (1) and inner (3) elements together. Remove
outer element (1). Clean the filter interior before remov-
ing inner element (3). Remove inner element (3). First
install inner element (3) and then install outer element (1).
2
IMPORTANT: Do not reuse the inner element. Always re-
place the new one.
ZX210W-3 MCGB-07-050
ZX210W-3 MCGB-07-052
Air Restriction Switch 1 2
Cover
3 Valve
M157-07-061
7-65
MAINTENANCE
I. COOLING SYSTEM
Coolant
Use fresh water or normal tap water as a coolant. Don’t use
strong acid or alkaline water. Use the coolant with genuine
Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %.
If the air temperature is expected to fall below 0 °C (32 °F),

fill the cooling system with an genuine Hitachi Long-Life
Coolant (LLC) and soft water mix. As a general rule, the ratio
of LLC should range between 30% and 50% as shown in the
table below. If the ratio is below 30%, the system may devel-
op rust, and if it is above 50%, the engine may overheat.
LLC Mixing Table

Mixing ZX140W-3 ZX170W-3, 190W-3 ZX210W-3
Air temperature
ratio LLC Soft water LLC Soft water LLC Soft water
°C % liters liters liters liters liters liters
−1 30 5.8 13.4 7.3 16.9 7.8 18.2
−4 30 5.8 13.4 7.3 16.9 7.8 18.2
−7 30 5.8 13.4 7.3 16.9 7.8 18.2
−11 30 5.8 13.4 7.3 16.9 7.8 18.2
−15 35 6.7 12.5 8.5 15.7 9.1 16.9
−20 40 7.7 11.5 9.7 14.5 10.4 15.6
−25 45 8.7 10.5 10.9 13.3 11.7 14.3
−30 50 9.6 9.9 12.1 12.1 13.0 13.0
CAUTION:
• Antifreeze is poisonous; if ingested, it can cause
serious injury or death. Induce vomiting and get
emergency medical attention immediately.
• When storing antifreeze, be sure to keep it in a
clearly marked container with a tight lid. Always
keep antifreeze out of the reach of children.
• antifreeze is accidentally splashed into eyes,
If
flush with water for 10 to 15 minutes and get emer-
gency medical attention.
• When storing or disposing of antifreeze, be sure to
comply with all local regulations.
7-66
MAINTENANCE
1 Check Coolant Level --- daily
CAUTION: Do not loosen radiator filler cap (1) unless

the system is cool. Loosen the cap slowly to the stop.
Release all pressure before removing the cap.
With the engine cold, the coolant level must be between

the FULL and LOW marks on coolant reservoir (2), located
behind the radiator access door. If the coolant level is below 1
the low mark, add coolant to coolant reservoir (2).
If coolant reservoir (2) is empty, add coolant to the radiator
and then to coolant reservoir (2).
MCGB-07-053
2
FULL
LOW
2 Check and Adjust Fan Belt Tension

--- every 100 hours (first time after 50 hours) MCGB-07-054
IMPORTANT: Loose fan belt may result in insufficient bat-

tery charging, engine overheating as well as
a rapid, abnormal belt wear. Belts that are
too tight, however, can damage both bear-
ings and belts.
Visually check the belt for wear. Replace if necessary. Check

fan belt tension by depressing the midpoint between fan
pulley (3) and alternator pulley (4) with the thumb. Deflec-
tion must be A with a depressing force of approximately 98
N (10 kgf, 22 lbf ).
Model A
Deflection
ZX140W-3 7 to 8 mm (0.28 to 0.32 in) 3 5 to 6 mm
ZX170W-3, 190W-3, 210W-3 5 to 6 mm (0.20 to 0.24 in) 98 N (10 kgf )
4
If tension is not within specifications, loosen nuts (5) and

(7) for the adjusting plate and alternator bracket. Move the
alternator by bolt (6) until tension is correct. Tighten the
adjusting plate and nuts (5) and (7).
NOTE: When a new belt is installed, be sure to re-adjust the M178-07-030

tension after operating the engine for 3 to 5 minutes ZX170W-3, 190W-3, 210W-3
at slow idle speed to be sure that the new belt is seated
correctly.
7-67
MAINTENANCE
3 Change Coolant
--- every two years or 4000 hours whichever
comes first.
Clean Radiator Interior

--- when changing coolant
CAUTION: Do not loosen the radiator cap until the

system is cool. Loosen the cap slowly to the stop. Re-
lease all pressure before removing the cap.
IMPORTANT: Use fresh water or normal tap water as a

coolant. Don’t use strong acid or alkaline
water. Use the coolant with genuine Hitachi
1
Long-Life Coolant (LLC) mixed by 30 to 50 %. ZX140W-3 M178-07-032
1. Remove the radiator cap. Open drain cocks (1) on the

radiator to allow the coolant to drain completely.
2. Close drain cocks (1). Fill the radiator with tap water and
a radiator cleaner agent. Start the engine and run at a
speed slightly higher than slow idle; when the needle of
the temperature gauge reaches the green zone, run the
engine for about ten more minutes.
3. Stop the engine and open drain cock (1). Flush out the
cooling system with tap water, until draining water is
clear. This helps remove rust and sediment.
4. Close drain cock (1). Fill the radiator with tap water and 1
LLC at the specified mixing ratio. When adding coolant,
ZX170W-3, 190W-3, 210W-3 M1U1-07-095
do so slowly to avoid mixing air bubbles in the system.
5. Run the engine to sufficiently bleed the air from the cool-
ing system.
6. After adding coolant, operate the engine for several
minutes. Check the coolant level again, and add coolant
if necessary.
7-68
MAINTENANCE
4 Clean Radiator, Oil Cooler Core and Inter Inter Cooler

Cooler
Outside --- every 500 hours
Inside --- once a year
Air Conditioner
5 Clean Oil Cooler, Radiator and Inter Cooler Condenser
Front Screen
--- every 500 hours
6 Clean Air Conditioner Condenser
--- every 500 hours
--- every 500 hours
7 Clean Fuel Oil Cooler
--- every 500 hours ZX140W-3
MCGB-07-096
8 Clean Air Conditioner Front Screen

(Opt.) --- every 500 hours
CAUTION: Use reduced compressed air pressure (Less

than 0.2 MPa, 2 kgf/cm2) for cleaning purposes. Clear
the area of bystanders, guard against flying chips,
Fuel Oil
and wear personal protection equipment including Cooler
eye protection.
IMPORTANT: When operating the machine in a dusty envi-

ronment, check the screen every day for dirt
and clogging. If clogged, remove, clean and
reinstall the screen.
ZX140W-3 MCGB-07-097
1. Open the radiator access door and hood.
2. Clean the air conditioner condenser.
3. Remove the oil cooler front screen and clean it. Inner Cooler
Oil Cooler
4. Clean both the radiator and oil cooler using compressed
air (Less than 0.2 MPa, 2 kgf/cm2) or water.
Oil Cooler Inner Cooler
Radiater
ZX170W-3, 190W-3 M1U1-07-083
Radiater
ZX210W-3 M1U1-07-016
Air Conditioner
Fuel Oil Condenser
Cooler
Air Conditioner
Condenser
Fuel Oil
Cooler
ZX170W-3, 190W-3 M1U1-07-084

ZX210W-3 M1U1-07-016
7-69
MAINTENANCE
J. ELECTRICAL SYSTEM
IMPORTANT: Improper radio communication equipment
and associated parts, and/or improper
installation of radio communication equip-
ment effects the machine's electronic parts,
causing involuntary movement of the ma-
chine.
Also, improper installation of electrical
equipment’s may cause machine failure and/
or a fire on the machine.
Be sure to consult your authorized dealer
when installing a radio communication
equipment or additional electrical parts, or
when replacing electrical parts. SA-036
Batteries Location
Never attempt to disassemble or modify the
electrical/electronic components. If replace-
ment or modification of such components is
required, contact your authorized dealer.
BATTERIES
CAUTION: Battery gas can explode. Keep sparks and
flames away from batteries. Use a flashlight to check
the battery electrolyte level.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of
the battery may result. ZX140W-3 MCGB-07-058
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into the eyes.
Avoid hazard by:

1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper booster battery starting procedures.
ZX170W-3, 190W-3 MCGB-07-058

If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. If splashed in eyes, flush with water for 10 to 15 minutes.
Get medical attention immediately.
ZX210W-3 MCGB-07-050
7-70
MAINTENANCE
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or vegetable
oil.
3. Get medical attention immediately.
IMPORTANT: Add water to batteries in freezing weather

before you begin operating your machine
for the day, or else charge the batteries.
IMPORTANT: If the battery is used with the electrolyte

level lower than the specified lower level,
the battery may deteriorate quickly.
IMPORTANT: Do not refill electrolyte more than the speci-

fied upper level. Electrolyte may spill, dam-
aging the painted surfaces and/or corroding
other machine parts.
NOTE: In case electrolyte is refilled more than the specified

upper level line or beyond the bottom end of the sleeve,
remove the excess electrolyte until the electrolyte level
is down to the bottom end of the sleeve using a pipette.
After neutralizing the removed electrolyte with sodium
bicarbonate, flush it with plenty of water, otherwise,
consult the battery manufacturer.
7-71
MAINTENANCE
Electrolyte Level Check --- every one month
1. Check the electrolyte level at least once a month.
2. Park the machine on level ground and stop the engine.
3. Check the electrolyte level.
3.1 When checking the level from the battery side:
Clean around the level check lines with a wet towel.
Do not use a dry towel. Static electricity may be devel-
oped, causing the battery gas to explode. Check if the
U.L (Upper Level)
electrolyte level is between U.L (Upper Level) and L.L
L.L (Lower Level)
(Lower Level). In case the electrolyte level is lower than
the middle level between the U.L and L.L, immediately M146-07-109
refill distilled water or commercial battery fluid. Be sure
Filler Port
to refill with distilled water before recharging (operating
the machine). After refilling, securely tighten the filler
plug.
3.2 When impossible to check the level from the battery Sleeve
side or no level check mark is indicated on the side: U.L (Upper Level)
After removing the filler plug from the top of the bat- L.L (Lower Level)
Separator Top
tery. Check the electrolyte level by viewing through the M146-07-110
filler port. It is difficult to judge the accurate electrolyte Proper
level in this case. Therefore, when the electrolyte level is Since the electrolyte surface touches the bottom end of
flush with the U.L, the level is judged to be proper. Then, the sleeve, the electrolyte surface is raised due to surface
referring to the right illustrations, check the level. When tension so that the electrode ends are seen curved.
the electrolyte level is lower than the bottom end of the M146-07-111
sleeve, refill with distilled water or commercial battery Lower
fluid up to the bottom end of the sleeve. Be sure to refill When the electrolyte surface is lower than the bottom
with distilled water before recharging (operating the end of the sleeve, the electrode ends are seen straight.
machine). After refilling, securely tighten the filler plug.
M146-07-112
3.3 When an indicator is available to check the level, follow
its check result.
4. Always keep around the battery terminals clean to pre-
vent battery discharge. Check terminals for loose and/or
rust. Coat terminals with grease or petroleum jelly to
prevent corrosion build up.
M409-07-072
7-72
MAINTENANCE
Check electrolyte specific gravity
CAUTION: Battery gas can explode. Keep sparks and If you spill acid on yourself:
flames away from batteries. Use a flashlight to check 1. Flush your skin with water.
the battery electrolyte level. 2. Apply baking soda or lime to help neutral-
ize the acid.
Sulfuric acid in battery electrolyte is poisonous. It is
3. If splashed in eyes, flush with water for 10
strong enough to burn skin, eat holes in clothing, and
to 15 minutes. Get medical attention imme-
cause blindness if splashed into the eyes.
diately.
Never check the battery charge by placing a metal ob- If acid is swallowed:
ject across the posts. Use a voltmeter or hydrometer. 1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
Always remove the grounded (−) battery clamp first or vegetable oil.
and replace it last. 3. Get medical attention immediately.
Avoid hazard by: IMPORTANT: Check the specific gravity of the elec-
1. Filling batteries in a well-ventilated area.
trolyte after it is cooled, not immedi-
2. Wearing eye protection and rubber gloves. ately after operation.
3. Avoiding breathing fumes when electrolyte is
added. Check the electrolyte specific gravity in each battery
4. Avoiding spilling or dripping electrolyte. cell.
The lowest limit of the specific gravity for the elec-
5. Using proper booster battery starting procedures.
trolyte varies depending on electrolyte temperature.
The specific gravity should be kept within the range
shown below. Charge the battery if the specific grav-
ity is below the limit.
Recommended range of specific gravity by electrolyte temperature
Working Range
Fluid Temp.
Specific Gravity of Battery Fluid MCGB-07-059
REPLACE BATTERIES
Your machine has two 12-volt batteries with negative (−)
ground.
If one battery in a 24-volt system has failed but the other is still
good, replace the failed battery with one of the same type. For
example, replace a failed maintenance-free battery with a new
maintenance-free battery. Different types of batteries may
have different rates of charge. This difference could overload
one of the batteries and cause it to fail.
7-73
MAINTENANCE
REMOVE AND INSTALLING BATTERY Battery Tool
CAUTION: When removing the battery disconnect Insert these

Sections Completely
the negative (−) terminal (ground) first, while taking into the grooves
care not to cause a short circuit. When installing the
battery, connect the positive (+) terminal before con- Groove
necting the negative (−) terminal.
Use the battery tool to remove and install the battery. After
installing the battery, remove the battery tool from the battery.
(ZX140W-3)
Groove
REPLACING FUSES
If any electrical equipment fails to operate, first check the
fuses. Fuse box is located behind the operator’s seat. A fuse
location/specification decal is attached to the fuse box cover.
Remove the fuse box cover by lifting it upward. Spare fuses are ZX140W-3 M1CC-07-040
located on the underside of the cover.
IMPORTANT: Be sure to install fuses with correct amper-

age ratings to prevent electrical system
damage due to overload.
10- CONTROLLER 20- OPTION3 (BATT)

5A 5A
9- BACKUP 19- SW. BOX
10A 5A
8- ECM 18- POWER ON
30A 5A
M1J1-01-021
7- LUBRICATOR 17- AIRCON
10A 5A Spare Fuses
6- OPTION2 (ALT) 16- GLOW RELAY

10A 5A
10 20
5- OPTION1 (ALT) 15- AUXILIARY
9 19
5A 10A
8 18
4- SOLENOID 14- FUEL PUMP
10A 5A 7 17
6 16
3- HEATER 13- LIGHTER
20A 10A 5 15
2- WIPER 12- ROOM LAMP/RADIO 4 14

10A 5A 3 13
1- LAMP 11- HORN 2 12
20A 10A 1 11
Tool
M1GR-01-003
7-74
MAINTENANCE
Spare Fuses
30- ASSIST CONTROL 40- CAB LAMP
10A 5A
29- O/R CONTROL 39- OPU (URF) 30 40
10A 5A 29 39
28- P/SW OTHER 38- QUICK HITCH 28 38
10A 5A
27 37
27- COLUMN BOX 37- SOLENOID
26 36
10A 10A
25 35
26- BACK LAMP 36- CAB LAMP REAR
10A 10A 24 34
23 33
25- STOP LAMP 35- WARNING LAMP
15A 10A 22 32
24- TURN L-R 34- SEAT COMPRESSOR 21 31
10A 10A
Tool
23- UPPER BEAM 33- SEAT HEATER
10A 10A
M1GR-01-003
22- HEAD LAMP R 32- HEAD LAMP L
10A 10A
21- CLEARANCE LAMP R 31- CLEARANCE LAMP L
10A 10A
• Fusible Link (Main Fuse)

In case the starter won’t rotate even if the key switch is
turned to the START position, fusible link may be he cause
of the trouble. Remove the cover next to the engine coolant
reservoir to check the fuse. Replace it if blown.
41- + Side (Red) 45A

42- − Side (Black) 65A 41 42 MCGB-07-060
7-75
MAINTENANCE
K. MISCELLANEOUS
1 4 5
1 Check Bucket Teeth --- daily
Check the bucket teeth for wear and looseness

Replace teeth (1) if tooth wear exceeds the designated ser-
vice limit shown below.
Dimension A in mm (in) A
Model New Limit of Use
ZX140W-3, 170W-3 166 (6.3) 85 (3.4) M104-07-056
ZX190W-3, 210W-3 200 (7.9) 95 (3.7)
2
Replacing procedure 3
CAUTION: Guard against injury from flying pieces
of metal. Wear goggles or safety glasses, and safety
equipment appropriate to the job.
1. Use hammer (2) and drift (3) to drive out locking pin (5).
Be careful not to damage rubber pin lock (4) while re-
moving locking pin (5).
M104-07-116
2. Remove tooth (1). Inspect locking pin (5) and rubber pin
lock (4) for damage, replace if necessary. Short locking
pins and damaged rubber pin locks must be replaced RIGHT WRONG
with new ones.
Flush one end of the locking pin

to evaluate. In this instance, the
locking pin is too short. M104-07-118
M104-07-058
WRONG WRONG
M104-07-059
7-76
MAINTENANCE
3. Clean shank (6) surface.
4. Install rubber pin lock (4) into shank (6) hole as shown.
RIGHT WRONG WRONG
6 4
M104-07-060
5. Position new tooth (1) over shank (6).
RIGHT WRONG WRONG
6 4 M104-07-061
6. Drive locking pin (5) fully into the hole as shown.
WRONG
RIGHT
M104-07-062
1 5
NOTE: Check the bucket teeth periodically to ensure that wear

does not exceed the designed service limit.
7-77
MAINTENANCE
2 Change Bucket
O-Ring Shift
CAUTION: When driving the connecting pins in or
out, guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses, and safety
1. Park the machine on a level surface. Lower the bucket to

the ground and position it with the flat surface resting on
the ground. Be sure the bucket will not roll when the pins Bucket Boss
are removed.
2. Slide the O-rings out of the way, as shown. Link
3. Remove bucket pins A and B to separate the arm and

bucket. Clean the pins and pin bores. Apply sufficient B
A
grease to the pins and pin bores.
4. Align the arm and alternate bucket. Be sure the bucket
will not roll.
5. Install bucket pins A and B.
6. Install the locking pins and snap ring on pins A and B.
M104-07-063
7. Adjust bucket linkage clearance for pins A. See adjusting
bucket linkage clearance procedure.
8. Apply grease to pin joints A and B.
9. Start the engine and run at slow idle. Slowly operate the
bucket in both directions to check for any interference
in bucket movement. Do not operate a machine that has
any movement interference. Correct interference prob-
lem.
7-78
MAINTENANCE
3 Convert Bucket Connection Into Face Shovel
CAUTION: When driving the connecting pins in or O-Ring Shift
out, guard against injury from flying pieces of metal

or debris; wear goggles or safety glasses, and safety
IMPORTANT: Provide ample space for turning the bucket

180°. Before starting converting work, keep Bucket Boss
bystanders clear of the machine. When using
a signal person, coordinate hand signals
before starting. Link
B
the ground and position it with the flat surface resting on
A
the ground. Be sure the bucket will not roll when the pins
are removed.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm and
bucket. Clean the pins and pin bores. Apply sufficient
grease to the pins and pin bores.
4. Turn the bucket 180°. Be sure the bucket will not roll.
5. Align the arm and bucket. Install bucket pins A and B,
then install the locking pins and snap rings on pins A and
B.
6. Apply grease to pin joints A and B.
7. Start the engine and run at slow idle. Slowly operate the
bucket in both directions and check for any interference
in bucket movement. Do not operate a machine that has
any movement interference. Correct interference prob-
lem.
Link
M104-07-064
7-79
MAINTENANCE
4 Adjust the Bucket Linkage
The machine is provided with a bucket adjustment system

to take up play in the linkage. When play in the linkage
increases, remove and install shims as follows:

the ground with the flat side down so that the bucket will
not roll.
2. Run the engine at slow idle. With the bucket on the
ground, slowly swing counterclockwise slightly until the
top of the left bucket boss contacts the arm.
3. Stop the engine. Pull the pilot control shut-off lever to
the LOCK position.
NOTE: Bolt (1) does not need to be removed to remove shims.
Shims are of a split type that can be easily pushed off
with a screwdriver after bolts (1) have been loosened.
4. Slightly loosen three (M14) bolts (1) using a 22 mm Clearance

wrench. Remove all shims (2) from clearance (c) between Adjust Part
plate (3) and bucket.
5. Push and hold bolts (1) to remove all clearance (a) be-
tween arm and boss (4). Holding boss (4) against arm
increases clearance (b). Measure distance (b) using a
feeler gauge. This distance should not be adjusted below M503-07-056
0.5 mm (0.02 in).

II 4 Bucket
6. Install as many shims (2) into clearance (b) as possible. Bucket Pin Arm
d 2
NOTE: Remaining shims (2) must be installed in clearance (c)
to prevent arm end face or bolt damage. 3
7. Install remaining shims (2) into clearance (c) and tighten

bolts (1) to 140 N·m (14.3 kgf·m, 103 lbf·ft).
NOTE: The total number of shims (2) used is A. 1
A : 12 (6 pairs)
a
8. Replace boss (4) if measurement (d) is 5 mm (0.2 in) or b c
less.
II
SECTION II M104-07-066
7-80
MAINTENANCE
5 Check and Replace Seat Belt

Check --- daily
Replace --- every 3 years
Always maintain the seat belt in a functional condition and

replace when necessary to ensure proper performance. 2
Prior to operating the machine, thoroughly examine belt 1

(1), buckle (2). If any item is damaged or materially worn,
replace the seat belt or component before operating the
machine.
We recommend that the seat belt be replaced every three

years regardless of its apparent condition.
MCGB-07-061
1 2
MCGB-07-062
7-81
MAINTENANCE
6 Check Windshield Washer Fluid Level

--- as required.
Check fluid in windshield washer tank (3).

If the fluid level is low, remove cap (4) and add fluid via the
opening.
During winter season, use all season windshield washer
which will not freeze.
4
ZX140W-3 MCGB-07-058
ZX170W-3, 190W-3 MCGB-07-064
ZX210W-3 MCGB-07-065
7-82
MAINTENANCE
4 Clean and Replace Air Conditioner Filter

1
Clean Filter
Circulating Air Filter --- every 500 hours
Fresh Air Filter --- every 500 hours
2
Replace Filter
Circulating Air Filter --- After cleaning 6 times
or so
Fresh Air Filter --- After cleaning 6 times or so
Removing Fresh Air Filter M1U1-07-010

1. While pushing the cover side above the rear deck, raise
the upper cover to remove.
2. After removing the upper cover, hold the grip of fresh air 4
filter (1) and pull it out in the vertical direction.
3 M1U1-07-011
Removing Recirculation Filter
1. Recirculation filter (2) is located under the rear deck. 5
2. Holding grips (3), pull them toward you to remove.
M1U1-07-012
7-83
MAINTENANCE
CAUTION: Use reduced compressed air pressure (less
than 0.2 MPa, 2 kgf/cm2) for cleaning purposes. Clear
the area of bystanders, guard against flying chips,
and wear personal protection equipment including
eye protection.
Cleaning
Clean both the external and internal filters by blowing com-
pressed air or washing with water.
When washing the filters with water, follow the procedures

below:
1. Wash with tap water.

2. Soak the filters in neutral detergent-mixed water for ap- Arrow
prox. 5 minutes.
Rear Side of Cab
3. Wash the filters with water again.
4. Dry the filters.
Installation
When installing the cleaned recirculation and/or ventilation Air Conditioner Side
filter or new filters, follow the reverse order of the Removing M1U1-07-013
Filter procedures described on the front page. Support
• Fresh Air Filter

Use attention when installing the filter so that the notch
faces the back of the cab and the stamped arrows face
the air conditioner unit. After installing the filter, install
the upper cover while aligning it with the duct.
• Recirculation Filter
While contacting the attached filter plate onto the duct,
install the filter so that the clips align with the duct
mounting holes.
M1U1-07-012
7-84
MAINTENANCE
8 Check the Air Conditioner --- daily

Oil Seepage 2
1. Check pipe connections for refrigerant gas leakage.
If oil seepage is found around pipe connections, as illus-
trated, it indicates possible gas leakage.
2. Check refrigerant quantity.
After running the engine at 1500 min-1 (rpm) for 2 to 3
minutes, check refrigerant quantity through the sight
Detail
glass (2) on the receiver tank (1).
3. Check the condenser. 1
M157-07-041
If the condenser fins become clogged with dirt or insects, M1CD-07-038
the cooling effect will be decreased. Be sure to keep it
clean at all times. (Refer to “Clean Radiator Core” in Main-
tenance Section.)
4. Check the compressor. No Refrigerant Insufficient
After operating the air conditioner for 5 to 10 minutes, Empty Quantity
touch the high-pressure side and low-pressure side pipes
with your hand. If normal, the high-pressure side pipe will
Almost clear. A few
be hot, and the low-pressure side cold. Sufficient bubbles may appear
Quantity when the engine speed
5. Check mounting bolts for looseness. is raised or lowered.
Confirm that the compressor mounting bolts and other
mounting/fastening bolts are securely tightened. M107-01-050
6. Inspect belt, check and adjust tension. Tension Pulley
Visually check the compressor and fan belts for wear. Compressor Pulley
Check and adjust belt tension, referring to the illustration
(right).
Fan Pulley 150

If any abnormalities are found in air conditioner operation, 8 to 12 mm
see your authorized dealer for inspection. 98 N (10 kgf )
Crank Pulley
ZX140W-3 M1U1-07-086
Fan Pulley
5 to 6 mm
Alternator Pulley 98 N (10 kgf )
Crank Pulley
Compressor Pulley
ZX170W-3, 190W-3, 210W-3 M1GR-07-007
7-85
MAINTENANCE
Adjust Compressor Belt Tension
Visually check the belt for wear. Replace if necessary. Check
compressor belt tension by depressing the midpoint be-
tween compressor pulley and crank pulley with the thumb.
Deflection must be ZX140W-3: 8 to 12 mm, ZX170W-3,
190W-3, 210W-3: 5 to 6 mm with a depressing force of ap- Crank Pulley
proximately 100 N (10 kgf, 22 lbf ).
If tension is not within specifications, loosen bolt (1). Move Tension Pulley
the tension pulley by bolt (2) until tension is correct. Tighten
bolt (1).
NOTE: When a new belt is installed, be sure to re-adjust the

tension after operating the engine for 3 to 5 minutes 1
2 Compressor Pulley Compressor
at slow idle speed to be sure that the new belt is seated
MCGB-07-066
correctly.
9 Clean Cab Floor --- as necessary
IMPORTANT: When cleaning the cab floor with tap water,

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

bucket to the ground. Before cleaning, stop the engine.
2. Sweep the cab floor clean using a brush, and brush dust 3 MCGB-07-067
from the cab floor while spraying water.
3. When cleaning the floor mat, sweep dust (water) along
the grooves on the floor mat.
4. When cleaning after removing the floor mat, sweep dust
(water) through two cleaning holes (3).
7-86
MAINTENANCE
10 Retighten Cylinder Head Bolt

--- As required
See your authorized dealer.
11 Inspect and Adjust Valve Clearance

--- every 1 000 hours
12 Measure Engine Compression Pressure

13 Check Starter and Alternator

7-87
MAINTENANCE
14 Check Tightening Torque of Bolts and Nuts

Check tightness after the first 50 hours then every 250 For tightening nuts and bolts other than specified in
hours. Tighten to torque shown if any are loose. Bolts and the table below, refer to the Tightening Torque Chart
nuts should be replaced with those of the same or higher at the end of this section.
grade.
IMPORTANT: Check and tighten bolts and nuts us-
ing a torque wrench.
ZX140W-3
Bolt Dia Wrench Torque
No. Descriptions Q’ty
(mm) Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
Engine cushion rubber mounting nut (Fan side) 16 2 24 240 (24) (177)
1
Engine cushion rubber mounting nut (Pump side) 18 4 27 400 (41) (295)
2 Engine bracket mounting bolt (Pump side) 12 8 19 110 (11) (81)
3 Hydraulic oil tank mounting bolt 16 4 24 270 (28) (199)
4 Fuel tank mounting bolt 16 4 24 210 (21) (155)
Radiator mounting bolt (Lower side) 12 4 19 90 (9.2) (66)
5
Radiator mounting bolt (Side) 16 2 24 210 (21) (155)
6 Pump mounting bolt 10 8 17 65 (6.6) (48)
7 Control valve mounting bolt 14 6 22 180 (18) (133)
8 Control valve bracket mounting bolt 16 4 24 270 (28) (199)
9 Swing device mounting bolt 20 10 30 500 (51) (369)
17 25 (2.5) (18)
19 30 (3.1) (22)
22 40 (4) (30)
ORS and metal face seal fittings for hydraulic hoses
10 − − 27 95 (9.7) (70)
and piping
32 140 (14) (103)
36 180 (18) (133)
41 210 (21) (155)
11 Hycolin tube mounting nut − − 17 35 (3.6) (26)
12 Battery mounting nut 10 2 17 25 (2.5) (18)
Cab mounting nut 16 4 24 210 (21) (155)
13 Cab mounting anchor bolt 22 1 32 550 (56) (406)
Cab cushion rubber mounting bolt 12 8 19 110 (11) (81)
6 − 10 5 (0.5) (3.7)
8 − 13 10 (1) (7.4)
14 Cover mounting bolt
10 − 17 50 (5.1) (3.7)
12 − 19 90 (9.2) (66)
15 Flexible master coupling of piping − 5 pairs 13 10.3 to 12.4 (1.05 to 1.26) (7.60 to 9.15)
7 6 (0.6) (4.4)
Jubilee clamp − −
16 8 6 (0.6) (4.4)
T-bolt clamp 1/4-28UNF − 11 6 (0.6) (4.4)
(Upperstructure) 18 30 27 400 (41) (295)
17 Swing bearing mounting bolt to
(Chassis) 16 36 24 270 (28) (199)
18 Center joint lock mounting bolt 16 5 24 270 (28) (199)
Transmission mounting bolt * 20 3 30 430 (44) (317)
19
Transmission bracket mounting bolt * 20 3 30 550 (56) (406)
20 Transmission B-port, K-port adapter (2 Pieces) 16 2 22 20 (2) (15)
16
21 Travel motor mounting bolt * 4 14 270 (28) (199)
(HEX. Wrench)
22 Propel shaft mounting nut * 10 32 14 76 (7.7) (56)
25 Rear axle mounting bolt * 20 8 30 560 (57) (413)
26 Wheel pin nut ✩ 22 40 30 650 (66) (479)
* Apply “LOCTITE 262” to the Threads.
✩ Refer “Tire Inspection and Replacement Procedure” in E. TIRE 1 .
7-88
MAINTENANCE

grade.
ZX170W-3
1
Engine bracket mounting bolt (Fun side) 10 8 17 65 (6.6) (48)
2
Engine bracket mounting bolt (Pump side) 16 8 24 270 (28) (199)
Radiator mounting bolt (Upper side) 16 2 24 210 (21) (155)
5
Radiator mounting bolt (Lower side) 16 3 24 270 (28) (199)
17 25 (2.5) (18)
19 30 (3.1) (22)
22 40 (4) (30)
10 − − 27 95 (9.7) (70)
and piping
32 140 (14) (103)
36 180 (18) (133)
41 210 (21) (155)
Cab mounting nut 16 4 24 210 (21) (155)
6 − 10 5 (0.5) (3.7)
8 − 13 10 (1) (7.4)
10 − 17 50 (5.1) (37)
12 − 19 90 (9.2) (66)
7 6 (0.6) (4.4)
16 8 6 (0.6) (4.4)
T-bolt clamp 1/4-28UNF − 11 6 (0.6) (4.4)
(Upperstructure) 20 36 30 520 (53) (384)
(Chassis) 20 36 30 500 (51) (369)
16
(HEX. Wrench)
23 Center bearing mounting bolt * 10 2 17 50 (5.1) (46)
10
24 Propel shaft connection bolt * 4 8 62 (6.3) (46)
(HEX. Wrench)
26 Wheel pin nut ✩ 22 40 30 650 (66) (479)
7-89
MAINTENANCE

grade.
ZX190W-3
1
2
5
17 25 (2.5) (18)
19 30 (3.1) (22)
22 40 (4) (30)
10 − − 27 95 (9.7) (70)
and piping
32 140 (14) (103)
36 180 (18) (133)
41 210 (21) (155)
Cab mounting nut 16 4 24 210 (21) (155)
6 − 10 5 (0.5) (3.7)
8 − 13 10 (1) (7.4)
10 − 17 50 (5.1) (37)
12 − 19 90 (9.2) (66)
7 6 (0.6) (4.4)
16 8 6 (0.6) (4.4)
T-bolt clamp 1/4-28UNF − 11 6 (0.6) (4.4)
(Upperstructure) 20 36 30 520 (53) (384)
(Chassis) 20 36 30 500 (51) (369)
16
(HEX. Wrench)
10
(HEX. Wrench)
26 Wheel pin nut ✩ 22 40 30 650 (66) (479)
7-90
MAINTENANCE

grade.
ZX210W-3
1
2
5
17 25 (2.5) (18)
19 30 (3.1) (22)
22 40 (4) (30)
10 − − 27 95 (9.7) (70)
and piping
32 140 (14) (103)
36 180 (18) (133)
41 210 (21) (155)
Cab mounting nut 16 4 24 210 (21) (155)
6 − 10 5 (0.5) (3.7)
8 − 13 10 (1) (7.4)
10 − 17 50 (5.1) (37)
12 − 19 90 (9.2) (66)
7 6 (0.6) (4.4)
16 8 6 (0.6) (4.4)
T-bolt clamp 1/4-28UNF − 11 6 (0.6) (4.4)
(Upperstructure) 20 36 30 520 (53) (384)
(Chassis) 20 36 30 500 (51) (369)
16
(HEX. Wrench)
10
(HEX. Wrench)
26 Wheel pin nut ✩ 22 40 30 650 (66) (479)
7-91
MAINTENANCE
Tightening Torque Chart
Hexagon
Bolt Dia. Wrench Wrench
Size Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M8 13 6 30 (3) (21.5) 20 (2) (14.5) 10 (1) (7.2)
M10 17 8 65 (6.5) (47) 50 (5) (37) 20 (2) (14.5)
M12 19 10 110 (11) (80) 90 (9) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 17 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 19 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 19 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 22 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 24 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 27 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)
CAUTION: If fixing bolts for counterweight are loos-

ened, consult your nearest authorized dealer.
IMPORTANT: Make sure bolt and nut threads are clean

before installing.
Apply lubricant (e. g. white zinc B solved
into spindle oil) to bolts and nuts to stabilize
their friction coefficient.
NOTE: Tightening torque required is shown in N·m.

For example, when tightening a bolt or nut with a
wrench of 1 m length, turning the end of it with a force
of 120 N, the torque produced will be:
1 m ×120 N = 120 N·m
To produce the same torque with a wrench of 0.25 m:

0.25 m × N = 120 N·m
Necessary force will be:

120 N⋅m ÷ 0.25 m = 480 N
7-92
MAINTENANCE
1. Retighten the engine cushion rub-
ber mounting bolts and nuts.
1
2. Retighten the engine bracket 1

mounting bolt.
ZX140W-3 (Fan Side) ZX140W-3 (Fan Side)

MCGB-07-104 MCGB-07-105
2 2
ZX140W-3 (Pump Side) ZX140W-3 (Pump Side)

MCGB-07-106 MCGB-07-107
2
1 2
1
ZX170W-3, 190W-3, 210W-3 (Fan Side) ZX170W-3, 190W-3, 210W-3 (Fan Side)
MCGB-07-108 MCGB-07-109
2 2
ZX170W-3, 190W-3, 210W-3 (Pump Side) ZX170W-3, 190W-3, 210W-3 (Pump Side)
MCGB-07-110 MCGB-07-111
7-93
MAINTENANCE
3. Retighten the hydraulic oil tank
mounting bolt.
ZX140W-3 ZX170W-3, 190W-3

MCGB-07-112 MCGB-07-113
ZX210W-3 MCGB-07-114
4. Retighten the fuel tank mounting

bolts.
MCGB-07-077
ZX140W-3
ZX170W-3, 190W-3 MCGB-07-078 ZX210W-3 MCGB-07-079
7-94
MAINTENANCE
5. Retighten the radiator mounting
bolt.
ZX140W-3 (Lower Side) ZX140W-3 (Side)

MCGB-07-115 MCGB-07-116
ZX170W-3, 190W-3 ZX210W-3

MCGB-07-117 MCGB-07-118
6. Retighten the pump mounting

bolts.
MCGB-07-119
7. Retighten the control valve mount-

ing bolts.
ZX140W-3, 170W-3, 190W-3 ZX210W-3

MCGB-07-081 MCGB-07-082
7-95
MAINTENANCE
8. Retighten the control valve
bracket mounting bolts.
ZX140W-3, 170W-3, 190W-3 ZX210W-3

MCGB-07-081 MCGB-07-083
9. Retighten the swing device

mounting bolts.
MCGB-07-084
10. Retighten the ORS and metal face

seal fittings for hydraulic hoses and
piping.
M107-07-081
11. Retighten the hycolin tube mount-

ing nut.
ZX140W-3, 170W-3, 190W-3 ZX210W-3

MCGB-07-120 MCGB-07-121
7-96
MAINTENANCE
12. Retighten the battery mounting
nut.
ZX140W-3 ZX170W-3, 190W-3, 210W-3

MCGB-07-122 MCGB-07-123
13. Retighten the cab mounting nut.
Retighten the cab mounting anchor

bolt.
Retighten the cab cushion rubber

mounting bolt.
(Mounting Nut) (Anchor Bolt) MCGB-07-125

MCGB-07-124
(Cushion Rubber Mounting Bolt)

MCGB-07-126
14. Retighten the cover mounting bolts.
MCGB-07-040
7-97
MAINTENANCE
15. Retighten flexible master coupling
of piping.
M1G6-07-008
Jubilee Clamp
16. Retighten, Jubilee and T-bolt clamp.
T-bolt Clamp
MCGB-07-127 MCGB-07-128
17. Retighten the swing bearing mount-

ing bolts to the upperstructure.
MCBB-07-041
Retighten the swing bearing

mounting bolt to the chassis.
MCGB-07-129 MCBB-07-042
ZX140W-3 ZX170W-3, 190W-3, 210W-3
7-98
MAINTENANCE
18. Retighten center joint lock mounting bolt.
MCGB-07-130
19. Retighten transmission mounting bolt. (ZX140W-3)
Retighten transmission bracket mounting bolt.

(ZX140W-3)
MCGB-07-131
20. Retighten transmission B-port,

K-port adapter.
ZX140W-3 ZX170W-3, 190W-3, 210W-3

MCGB-07-132 MCGB-07-133
21. Retighten travel motor mounting

bolt.
ZX140W-3 ZX170W-3, 190W-3, 210W-3

MCGB-07-134 MCGB-07-135
7-99
MAINTENANCE
22. Retighten propel shaft mounting
and nut.
ZX140W-3 MCGB-07-136
ZX140W-3 MCGB-07-137
ZX170W-3, 190W-3, 210W-3 ZX170W-3, 190W-3, 210W-3

MCGB-07-138 MCGB-07-139
23. Retighten center bearing mounting bolt.

(ZX170W-3, 190W-3, 210W-3)
MCGB-07-090
24. Retighten propel shaft connection bolt.

(ZX170W-3, 190W-3, 210W-3)
MCGB-07-140
7-100
MAINTENANCE
25. Retighten rear axle mounting bolt.
ZX140W-3 ZX170W-3, 190W-3, 210W-3

MCGB-07-033 MCGB-07-088
26. Retighten wheel pin nuts.

1
5 7
9 3
4 10
MCBB-07-023
8 6
2
The Order of Wheel Nut bolting
MCGB-07-141
7-101
MAINTENANCE
MEMO
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7-102
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
Operating Conditions Precautions for Maintenance

Muddy Soil, Rainy or Before Operation: Check the tightness of plug and all drain cocks.
Snowy Weather After Operation: Clean the machine and check for cracks, damaged, loose or missing bolts
and nuts. Lubricate all necessary parts without delay.
Near the Ocean Before Operation: Check tightness of plugs and all drain cocks.
After Operation: Thoroughly clean the machine with fresh water to wash off salt. Service elec-
trical equipment often to prevent corrosion.
Dusty Air Cleaner: Clean the element regularly at shorter service intervals.
Atmosphere Radiator: Clean the oil cooler screen to prevent clogging of the radiator core.
Fuel System: Clean the filter element and strainer regularly at shorter service intervals.
Electrical Equipment: Clean them regularly, in particular, the commutator surface of the alternator
and starter.
Rocky Ground Chassis: Carefully operate while checking for cracks, damage and loose bolts and
nuts.
Front Attachment: Standard attachment may be damaged when digging rocky ground. Rein-
force the bucket before using it, or use a heavy duty bucket.
Freezing Weather Fuel: Use high quality fuel suitable for low temperature.
Lubricant: Use high quality low viscosity hydraulic oil and engine oil.
Engine Coolant: Be sure to use antifreeze.
Battery: Fully charge the batteries regularly at shorter service intervals. If not fully
charged, electrolyte may freeze.
Chassis: Keep the chassis clean. Park the machine on a hard surface to prevent the
tire from freezing to the ground.
Falling Stones Cab: Provide a cab guard to protect the machine from falling stones when neces-
sary.
9-
MEMO
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9-
STORAGE
STORING THE MACHINE

1. Inspect the machine. Repair worn or damaged parts.
Install new parts if necessary.
2. Clean the primary air cleaner element.
3. Retract all hydraulic cylinders, if possible. If not, coat
exposed cylinder rods with grease.
4. Lubricate all grease points.
5. Park the tracks on long stable blocks.
6. Wash the machine.
7. Remove the batteries and store them in a dry protected
place after charging fully. If not removed, disconnect the
negative battery cable from the (−) terminal.
8. Add an antirust agent to the coolant. In cold weather, add
an antifreeze, or drain the coolant completely. Be sure
to attach a “No Water in Radiator” tag on a clearly visible
location if the system is drained.
9. Loosen the alternator belt and fan belt.
10. Paint necessary areas to prevent rust.
11. Store the machine in a dry, protected place. If stored
outside, cover with a waterproof cover.
12. If the machine is stored for a long time, operate hydraulic
functions for travel, swing and digging two to three times
for lubrication, at least once a month.
Be sure to check the coolant level and lubrication condi-
tions before operating.
Precautions for Disconnecting or Connecting

Batteries
In case the batteries are kept disconnected for more than
one month or when the batteries are reconnected, contact
your nearest Hitachi dealer. Resetting of the ICF (Information
Controller) may be required.
10-
STORAGE
REMOVING THE MACHINE FROM STORAGE

CAUTION: Start the engine ONLY in a well-ventilated
place.
1. Remove grease from the cylinder rods if coated.

2. Adjust alternator and fan belt tension.
3. Fill the fuel tank. Bleed air from the fuel system. Check all
fluid levels.
4. Start the engine.
Run the engine at half speed for several minutes before
full load operation.
5. Cycle all hydraulic functions several times.
6. Carefully check all systems before operating the machine
at full load.
NOTE: When the machine has been stored for a long time, be
sure to perform the following steps as well:
(a) Check condition of all hoses and connections.
(b) Warm up the engine.
(c) Stop the engine.
(d) Install new fuel filters. Replace the engine oil filter
and fill the engine with oil.
IMPORTANT: If the machine has not been used for a long

time, oil films on sliding surfaces may have
broken down. Cycling hydraulic functions for
travel, swing and digging two to three times
is necessary to lubricate the sliding surfaces.
10-
TROUBLESHOOTING
TROUBLESHOOTING
If any machine trouble has occurred, immediately repair it.
Make certain the cause of the trouble and take necessary mea-
sures to prevent the reoccurrence of the same trouble. In case
troubleshooting is difficult, or measures marked with * must
be taken, consult the nearest Hitachi dealer. Never attempt to
adjust, disassemble, or repair the hydraulic and/or electrical/
electronic parts/components.
1. Engine
Consult the nearest Hitachi dealer for the engine trouble-
shooting.
2. Engine Auxiliaries
Problem Cause Solution
Batteries will not be Broken battery separator Replace
charged. Faulty regulator * Adjust and replace
Faulty ground line * Repair
Faulty alternator * Repair and replace
Batteries discharges Shorted cable * Repair and replace
quickly after being charged. Shorted battery separator * Repair and replace
Increased sediment in battery * Clean
Coolant temperature is Low coolant level Add
too high. Loose engine fan V-belt Adjust
Damaged rubber hose * Replace
Faulty thermostat * Replace
Faulty coolant temperature gauge * Replace
11-
TROUBLESHOOTING
3. Engine is hard to start.

Starter does not rotate or is Discharged battery Charge or replace battery.
not powerful Disconnected, loose, or corroded battery After repairing the corroded
terminals area, securely tighten the con-
nectors.
Lowered pilot control shut-off lever. Pull pilot control shut-off lever
up.
Disconnected, loose, or corroded starter After repairing the corroded
ground line terminals. area, securely tighten the con-
nectors.
Faulty pilot control shut-off lever electrical * Repair.
system
Too high engine oil viscosity Change engine oil with appro-
Engine will not start
priate viscosity.
Faulty starter and/or electrical system * Repair and adjust.
Brake switch is not in P (parking) Place brake switch to P (parking)
Forward/Reverse switch is not in N Place forward/reverse switch to
(neutral) N (neutral)
Starter rotates No fuel After checking that no fuel is
leaking, refill fuel.
Air in the fuel system Bleed air.
Clogged fuel filter After draining water, replace the
element.
Frozen fuel Warm the fuel pump with hot
water or wait until the
atmospheric temperature rises.
Faulty injection pump * Repair and adjust.
Faulty engine control system * Repair and adjust.
The emergency engine stop SW is ON. * Repair and adjust.
Faulty preheat system * Repair and adjust.
Even though the engine is started, Too low idle speed * Repair and adjust.
the engine stalls soon Clogged fuel filter After draining water, replace the
element.
Clogged pre-fuel filter Clean or replace the element.
Clogged air cleaner Clean or replace the element.
Faulty injection pump
* Repair and adjust.
Engine runs irregularly Faulty fuel system * Repair and adjust.
Water or air in the fuel system Drain water or bleed air.
11-
TROUBLESHOOTING
4. Control Lever

Moves hard Corroded out joint * Grease and repair
Worn pusher * Replace
Lever can not be moved Worn pusher * Repair and replace
smoothly. Faulty pilot valve * Replace
Lever can not return to neutral. Faulty pilot valve * Replace
Play increased so that lever can- Rusted joint * Repair and replace
not be held upright in neutral. Faulty pilot valve * Replace
11-
TROUBLESHOOTING
5. Hydraulic System
After the machine has been kept stowed for a long time, air
in the oil may be separated and accumulate in the upper
section in the cylinder, causing slow response time in opera-
tion or reducing cylinder power. In case these symptoms
appear, repeatedly operate all actuators several times.
All actuators of front attach- Faulty hydraulic pump * Repair and replace
ment, swing, and travel will not Low hydraulic oil level Refill.
operate. (Hydraulic pump noise Broken suction pipe and/or hose * Repair and replace
level increased.)
All actuators of front attach- Faulty pilot pump * Replace
ment, swing, and travel will not Faulty solenoid valve * Replace
operate. (Hydraulic pump noise Pilot control shut-off lever is in the LOCK Move to the UNLOCK position.
level unchanged.) position
Front attachment pilot/blade/outrigger Place front attachment pilot/blade/out-
switch is OFF position rigger switch to ON position.
All actuators are weak in power. Reduced pump performance due to * Replace
wear in hydraulic pump
Reduced set pressure of main relief * Adjust
valve in control valve
Low hydraulic oil level Refill
Clogged suction strainer in hydraulic oil Clean
tank
Drawn air from suction side Retighten
Inoperable or weak in power Faulty relief valve in control valve * Repair and replace
only when one control lever is Broken pipe and/or hose * Repair and replace
operated. Loose pipe line joint Retighten
Broken O-ring at pipe line joint * Replace
Faulty hydraulic pump * Repair and replace
Faulty pilot valve * Replace
Faulty pilot pipe line * Repair and replace
Faulty solenoid valve of pilot line * Repair and replace
Only one movement is inoper- Broken control valve spool * Replace
able. Seized foreign matter in valve spool * Repair and replace
Broken pipe and/or hose * Repair and replace
Loose pipe line joint Retighten
Broken O-ring at pipe line joint * Replace
Broken actuator * Repair and replace
Only one cylinder is inoperable. Broken oil seal in cylinder * Repair and replace
Oil leak due to broken cylinder rod. * Repair and replace
11-
TROUBLESHOOTING

Hydraulic oil temperature in- Contaminated oil cooler Clean
creases. Loose engine fan V-belt Adjust
Oil leaks from low pressure hose Loose clamp Retighten
Faulty suction manifold * Repair and replace
6. Travel

Machine does not travel both Broken center joint * Repair and replace
forward and backward Parking brake is not released. * Repair and replace
The parking brake release system Turn the parking brake release system OFF.
remains ON.
Broken transmission * Repair and replace
Broken travel motor * Repair and replace
Broken brake valve * Repair and replace
Faulty pilot line * Repair and replace
The travel speed doesn’t change. Faulty shift lever * Replace
Incomplete connection of connector * Repair and replace
Faulty wire harness * Repair
Faulty controller * Replace
Faulty solenoid valve * Repair and replace
Faulty transmission control valve * Repair and replace
Faulty transmission * Repair and replace
11-
TROUBLESHOOTING

Steering wheel is Faulty steering pump * Repair and replace
heavy to operate. Faulty steering valve * Repair and replace
Malfunction of steering cylinder * Repair and replace faulty parts.
Reduced set pressure of relief valve * Adjust
Reduced air pressure in tire Refill
Incorrect wheel alignment * Adjust
Steering wheel vi- Play in bearing * Repair and replace
brates. Incorrect wheel alignment * Adjust
Steering
Unbalance between right and left * Adjust and replace
tires
Worn king pin bushing * Repair and replace
Steering wheel is Incorrect wheel alignment * Adjust
uncontrolled. Uneven performance and dragging * Adjust
of brake
Unbalance between right and left * Adjust and replace
tires
Brake does not Worn brake lining * Replace
operate effectively. Faulty brake valve * Repair and replace
Oil leaks from wheel cylinder * Repair and replace
Oil leaks from or drawn air in brake * Repair and Bleed
Brake piping.
Brake drags Permanent set or breakage of return * Replace
spring
Service and/or parking brake is Release
applied.
11-
TROUBLESHOOTING

Brake operates Worn brake lining * Replace
unevenly. Oil leaks from wheel cylinder * Repair and replace
Brake
Brake squeaks when Worn lining * Replace and repair
applied
Noisy Lack of gear oil or deteriorated qual- Refill or change oil.
ity of oil
Worn transmission inner parts * Repair and/or replace faulty parts.
Broken gear and/or bearing * Repair and/or replace faulty parts.
Gearshift is not Oil leaks from transmission circuit * Repair and replace
Trans- achieved. Mixed air in transmission circuit Bleed air.
mission Faulty transmission control valve * Repair or replace.
Faulty shift interlock section * Repair or replace faulty parts.
Power is not trans- The parking brake release system Discharge the parking brake release grease.
mitted. remains ON
Broken clutch * Replace.
Broken shafts and/or gears * Replace.
11-
TROUBLESHOOTING

Propeller Propeller shaft Bent propeller shaft * Repair and replace faulty part.
Shaft vibrates. Loose parts and/or unbalance * Retighten and Adjust
Propeller shaft Excessively worn spline * Replace
makes noise. Worn or seized spider bearing * Replace
Loose parts * Retighten
Insufficient greasing Grease
Front/ Noise is heard. Worn or broken gears * Replace
Rear Axle Low gear oil level or improper property Refill and Change oil.
oil
Worn bearing or increased bearing play * Replace
Increased gaps on shaft spline * Repair and replace
Power is not Broken shaft * Replace
transmitted. Broken gear * Replace
7. Swing
Swing function is inoperable Swing lock is engaged. * Release
Malfunction of swing parking brake * Repair and replace
Faulty swing parking brake release valve * Repair and replace
Broken swing motor * Repair and replace
Faulty pilot piping * Repair and replace
Machine does not swing Worn swing gear * Repair and replace
smoothly Broken swing bearing or balls. * Repair and replace
Insufficient grease * Add
Swing noise may be heard or swing system may not operate

smoothly immediately after the control valve, swing motor
relief valve, and/or swing motor is replaced. This is caused
by air trapped in the swing hydraulic circuit. Therefore,
this symptom will disappear after the machine is operated
slowly for approx. 10 minutes. After repairing, be sure to
check the oil level in the hydraulic oil tank. Refill hydraulic
oil as necessary.
11-
TROUBLESHOOTING
8. Engine Speed

Engine speed cannot be con- Blown fuse Replace
trolled by operating engine Faulty engine control dial * Replace
control dial. Incomplete connection of connector * Repair and replace
Faulty EC motor * Repair and replace
Work mode cannot be selected. Faulty mode switch * Replace
Engine speed is uncontrolled with Faulty engine control selection switch * Replace
forward/reverse travel pedal in Faulty travel pilot pressure sensor * Replace
the pedal mode. Faulty connecter * Repair and replace
Faulty controller * Repair
Faulty travel pilot valve * Repair and replace
Faulty brake switch * Repair
Auto-idle or auto-acceleration Faulty pressure sensor * Replace
function is inoperable. Incomplete connection of connector * Repair and replace
Faulty EC motor * Repair and replace
Front attachment and travel func- Blown fuse corresponding to function Replace
tion speeds are slow. control in trouble
Faulty pump control solenoid valve * Replace
11-
TROUBLESHOOTING
9. Blade/outrigger

Blade/outrigger is inoperable. Refer to Hydraulic system Refer to Hydraulic system
Other hydraulic actuators are also
inoperable.)
Blade/outrigger is inoperable. Broken attachment pedal or control * Replace
(Other hydraulic actuators nor- switch
mally operate.) Faulty wire harness * Replace
(Blade/Outrigger-Controller-Solenoid
valve)
Broken control valve spool * Replace
Seized foreign matter in valve spool * Repair and replace
Faulty relief valve in control valve * Repair and replace
Broken pipe, pipe line and/or hose * Repair and replace
Broken cylinder * Repair and replace
10. Others
The machine trouble may induce the cause of noise, exces-
sive vibration, and/or smell. Always be careful during opera-
tion.
11-10
SPECIFICATIONS
SPECIFICATIONS
ZX140W-3 (Standard CHASSIS, REAR BLADE)
C
H D
B
G
P
F
E N
K J O L
Q I R A
MCGB-12-001
Type of Front-End Attachment Monoblock boom

Type of Arm − 2.52 m (8 ft 3 in)
Bucket Capacity (Heaped) m3 (yd3) PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Operating Weight kg (lb) 14700 (32400)
Basic Machine Weight kg (lb) 12500 (27600)
Engine ISUZU AI-4JJ1X
Engine Power SAE J1349 net
ISO 9249 net 90.2 kW/2200 min-1 (123 PS/2200 rpm)
EEC 80/1269 net
A: Overall Width
(Excluding Rearview Mirrors) mm (ft·in) 2530 (8' 4")
B: Cab Height mm (ft·in) 3130 (10' 3")
C: Rear End Swing Radius mm (ft·in) 2120 (7' 0")
D: Rear End Length mm (ft·in) 2120 (7' 0")
E: Minimum Ground Clearance mm (ft·in) 350 (1'2")
F: Counterweight Clearance mm (ft·in) 1215 (4' 0")
G: Engine Cover Height mm (ft·in) 2360 (7' 9")
H: Overall Width of Upperstructure mm (ft·in) 2450 (8' 1")
I: Wheelbase mm (ft·in) 2550 (8' 4")
J: Swing-center to Rear Axle mm (ft·in) 1000 (3' 3")
K: Front Wheel Tread mm (ft·in) 1875 (6' 2")
L: Rear Wheel Tread mm (ft·in) 1875 (6' 2")
M: Outrigger Spread mm (ft·in) −
N: Max. Raising Height mm (ft·in) 445 (1' 6")
O: Max. Digging Depth mm (ft·in) 145 (6")
P: Blade Height mm (ft·in) 590 (1' 11")
Q: Front Axle to Front of Chassis mm (ft·in) 570 (1' 10")
R: Rear Axle to Rear of Chassis mm (ft·in) 980 (3' 3")
Tire Size − 10.00-20 16PR
Swing Speed min-1(rpm) 13.7
Travel Speed (fast/slow/creeper) * km/h (mph) 35/8.6/2.2 (21.7/5.3/1.4)
Gradeability degree (%) 35 (70)
NOTE: * The specification not matching the local regulation is excluded.
12-
SPECIFICATIONS
Specifications
ZX140W-3 (Standard CHASSIS, REAR OUTRIGGER)
C
H D
B
G
F
E
K J
L
A Q I R M
MCGB-12-002

EEC 80/1269 net
A: Overall Width
E: Minimum Ground Clearance mm (ft·in) 350 (1' 2")
M: Outrigger Spread mm (ft·in) 3380 (11' 1")
N: Max. Raising Height mm (ft·in) −
O: Max. Digging Depth mm (ft·in) −
P: Blade Height mm (ft·in) −
12-
SPECIFICATIONS
Specifications
ZX140W-3 (FRONT BLADE REAR OUTRIGGER)
C
H D
B
G
P F
N E
K O J L
A Q I R M
MCGB-12-003

EEC 80/1269 net
A: Overall Width
12-
SPECIFICATIONS
Specifications
ZX140W-3 (FRONT OUTRIGGER REAR BLADE)
C
H D
B
G
P
F
E N
K J O L
M
A Q I R
MCGB-12-004

EEC 80/1269 net
A: Overall Width
12-
SPECIFICATIONS
Specifications
ZX140W-3 (FRONT OUTRIGGER REAR OUTRIGGER)
C
H D
B
G
F
E
K J L
A Q I R M
MCGB-12-005

EEC 80/1269 net
A: Overall Width
12-
SPECIFICATIONS
WORKING RANGES
ZX140W-3
MONOBLOCK BOOM
A
B
MCGB-12-006
Type of Front-End Attachment Monoblock Boom

Category 2.10 m (6 ft 11 in) Arm 2.52 m (8 ft 3 in) Arm 3.01 m (9 ft 11 in) Arm
Item Backhoe Backhoe Backhoe
A: Maximum Digging Reach mm (ft·in) 8040 (26’ 5”) 8410 (27’ 7”) 8870 (29’ 1”)
B: Maximum Digging Depth mm (ft·in) 4610 (15’ 2”) 5030 (16’ 6”) 5520 (18’ 1”)
C: Maximum Cutting Height mm (ft·in) 8660 (28’ 5”) 8850 (29’ 0”) 9160 (30’ 1”)
D: Maximum Dumping Height mm (ft·in) 6240 (20’ 6”) 6440 (21’ 2”) 6760 (22’ 2”)
E: Transport Height mm (ft·in) 3130 (10’ 3”) 3130 (10’ 3”) 3240 (10’ 8”)
F: Overall Transport Length
Std. Chassis Rear BL. mm (ft·in) ✸ 7690 (25’ 3”) ✸ 7730 (25’ 4”) ✸ 7710 (25’ 4”)
Std. Chassis Rear O/R. mm (ft·in) ✸ 7690 (25’ 3”) ✸ 7730 (25’ 4”) ✸ 7710 (25’ 4”)
Front BL. Rear O/R. mm (ft·in) ✸ 8140 (26’ 9”) ✸ 8180 (26’ 10”) ✸ 8160 (26’ 9”)
Front O/R. Rear BL. mm (ft·in) ✸ 8235 (27’ 0”) ✸ 8275 (27’ 2”) ✸ 8255 (27’ 1”)
Front O/R. Rear O/R. mm (ft·in) ✸ 8235 (27’ 0”) ✸ 8275 (27’ 2”) ✸ 8255 (27’ 1”)
G: Minimum Swing Radius mm (ft·in) 2610 (8’ 7”) 2650 (8’ 8”) 2910 (9’ 7”)
NOTE: ✸ Transport the machine with the rear side facing forward.
12-
SPECIFICATIONS
SPECIFICATIONS
ZX170W-3 (Standard GAUGE, Standard CHASSIS, REAR BLADE)
C
H D
B
G
P
F
E N
K J O L
Q I R A
MCGB-12-008

Bucket Capacity (Heaped) m3 (yd3) PCSA 0.60m3 (0.78yd3), CECE 0.55m3
Engine ISUZU AI-4HK1X
ISO 9249 net 107 kW/2000 min-1(145 PS/2000 rpm)
EEC 80/1269 net
A: Overall Width
12-
SPECIFICATIONS
Specifications
ZX170W-3 (Standard GAUGE, Standard CHASSIS, REAR OUTRIGGER)
C
H D
B
G
F
E
K J
L
A Q I R M
MCGB-12-009

EEC 80/1269 net
A: Overall Width
12-
SPECIFICATIONS
Specifications
ZX170W-3 (Standard GAUGE, FRONT BLADE REAR OUTRIGGER)
C
H D
B
G
P F
N E
K O J L
A Q I R M
MCGB-12-010

EEC 80/1269 net
A: Overall Width
12-
SPECIFICATIONS
Specifications
ZX170W-3 (Standard GAUGE, FRONT OUTRIGGER REAR BLADE)
C
H D
G
P F
E N
K J L
O
A Q I R M
MCGB-12-011

EEC 80/1269 net
A: Overall Width
12-10
SPECIFICATIONS
Specifications
ZX170W-3 (Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER)
C
H D
B
G
F
E
K J L
A Q I R M
MCGB-12-012

EEC 80/1269 net
A: Overall Width
12-11
SPECIFICATIONS
WORKING RANGES
ZX170W-3
MONOBLOCK BOOM
MCGB-12-013

Category 2.22 m (7 ft 3 in) Arm 2.58 m (8 ft 6 in) Arm
Item Backhoe Backhoe
A: Maximum Digging Reach mm (ft·in) 8690 (28’ 6”) 9050 (29’ 8”)
B: Maximum Digging Depth mm (ft·in) 4960 (16’ 3”) 5330 (17’ 6”)
C: Maximum Cutting Height mm (ft·in) 8820 (28’ 11”) 9100 (29’ 10”)
D: Maximum Dumping Height mm (ft·in) 6130 (20’ 1”) 6360 (20’ 10”)
E: Transport Height mm (ft·in) 3190 (10’ 6”) 3130 (10’ 3”)
Std. Chassis Rear BL. mm (ft·in) ✸ 8375 (27’ 6”) ✸ 8265 (27’ 1”)
Std. Chassis Rear O/R. mm (ft·in) ✸ 8375 (27’ 6”) ✸ 8265 (27’ 1”)
Front BL. Rear O/R. mm (ft·in) ✸ 8825 (28’ 11”) ✸ 8715 (28’ 7”)
Front O/R. Rear BL. mm (ft·in) ✸ 8920 (29’ 3”) ✸ 8810 (28’ 11”)
Front O/R. Rear O/R. mm (ft·in) ✸ 8920 (29’ 3”) ✸ 8810 (28’ 11”)
G: Minimum Swing Radius mm (ft·in) 3380 (11’ 1”) 2940 (9’ 8”)
12-12
SPECIFICATIONS
SPECIFICATIONS
ZX190W-3 (Standard CHASSIS, REAR BLADE)
C
H D
B
G
P F
E N
K J O L
Q I R A
MCGB-12-015

ISO 9249 net 122 kW/2000 min-1 (166 PS/2000 rpm)
EEC 80/1269 net
A: Overall Width
Swing Speed min-1 (rpm) 12.2
12-13
SPECIFICATIONS
Specifications
ZX190W-3 (Standard CHASSIS, REAR OUTRIGGER)
C
H D
B
G
F
E
K J L
A Q I R M
MCGB-12-016

EEC 80/1269 net
A: Overall Width
12-14
SPECIFICATIONS
Specifications
ZX190W-3 (FRONT BLADE REAR OUTRIGGER)
C
H D
B
G
P F
N E
K J L
O
A M
Q I R
MCGB-12-017

EEC 80/1269 net
A: Overall Width
12-15
SPECIFICATIONS
Specifications
ZX190W-3 (FRONT OUTRIGGER REAR BLADE)
C
H D
B
G
P F
E N
K J L
O
A M
Q I R
MCGB-12-018

EEC 80/1269 net
A: Overall Width
12-16
SPECIFICATIONS
Specifications
ZX190W-3 (FRONT OUTRIGGER REAR OUTRIGGER )
C
H D
B
G
F
E
K J L
A Q I R M
MCGB-12-019

EEC 80/1269 net
A: Overall Width
12-17
SPECIFICATIONS
WORKING RANGES
ZX190W-3
MONOBLOCK BOOM
MCGB-12-020

Category 2.26 m (7 ft 5 in) Arm 2.71 m (8 ft 11 in) Arm
Item Backhoe Backhoe
A: Maximum Digging Reach mm (ft·in) 9220 (30’ 3”) 9580 (31’ 5”)
B: Maximum Digging Depth mm (ft·in) 5390 (17’ 8”) 5830 (19’ 2”)
C: Maximum Cutting Height mm (ft·in) 9160 (30’ 1”) 9250 (30’ 4”)
D: Maximum Dumping Height mm (ft·in) 6340 (20’ 10”) 6450 (21’ 2”)
E: Transport Height mm (ft·in) 3150 (10’ 4”) 3130 (10’ 3”)
Std. Chassis Rear BL. mm (ft·in) ✸ 9155 (30’ 0”) ✸ 9135 (30’ 0”)
Short Chassis Rear BL. mm (ft·in) ✸ 8650 (28’ 5”) ✸ 8630 (28’ 4”)
Std. Chassis Rear O/R. mm (ft·in) ✸ 9155 (30’ 0”) ✸ 9135 (30’ 0”)
Short Chassis Rear O/R. mm (ft·in) ✸ 8650 (28’ 5”) ✸ 8630 (28’ 4”)
Front BL. Rear O/R. mm (ft·in) ✸ 9500 (31’ 2”) ✸ 9480 (31’ 1”)
Front O/R. Rear BL. mm (ft·in) ✸ 9560 (31’ 4”) ✸ 9540 (31’ 4”)
Front O/R. Rear O/R. mm (ft·in)) ✸ 9560 (31’ 4”) ✸ 9540 (31’ 4”)
G: Minimum Swing Radius mm (ft·in) 3510 (11’ 6”) 3480 (11’ 5”)
12-18
SPECIFICATIONS
SPECIFICATIONS
ZX210W-3 (Standard GAUGE, REAR BLADE)
C
H D
B
G
P F
E N
K J O L
Q I R A
MCGB-12-022

EEC 80/1269 net
A: Overall Width
Travel Speed (fast/slow/creeper) * km/h (mph) 27.5/7.4/2.9 (17.1/4.6/1.8)
12-19
SPECIFICATIONS
Specifications
ZX210W-3 (Standard GAUGE, REAR OUTRIGGER)
C
H D
B
G
F
E
K J
L
A Q I R M
MCGB-12-023

EEC 80/1269 net
A: Overall Width
12-20
SPECIFICATIONS
Specifications
ZX210W-3 (Standard GAUGE, FRONT BLADE REAR OUTRIGGER)
C
H D
B
G
P F
N E
K O J L
A Q I R M
MCGB-12-024

EEC 80/1269 net
A: Overall Width
12-21
SPECIFICATIONS
Specifications
ZX210W-3 (Standard GAUGE, FRONT OUTRIGGER REAR BLADE)
C
H D
B
G
P
F
E N
K J O L
M
A Q I R
MCGB-12-025

EEC 80/1269 net
A: Overall Width
12-22
SPECIFICATIONS
Specifications
ZX210W-3 (Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER)
C
H D
B
G
F
E
K J L
A M
Q I R
MCGB-12-026

EEC 80/1269 net
A: Overall Width
12-23
SPECIFICATIONS
WORKING RANGES
ZX210W-3
MONOBLOCK BOOM
F
A
MCGB-12-027
Category 2.03 m (6 ft 8 in) Arm 2.42 m (7 ft 11 in) Arm 2.91 m (9 ft 7 in) Arm
Item Backhoe Backhoe Backhoe
A: Maximum Digging Reach mm (ft·in) 9470 (31’ 1”) 9670 (31’ 9”) 10170 (33’ 4”)
B: Maximum Digging Depth mm (ft·in) 5410 (17’ 9”) 5800 (19’ 0”) 6290 (20’ 8”)
C: Maximum Cutting Height mm (ft·in) 10020 (32’ 11”) 9840 (32’ 3”) 10190 (33’ 5”)
D: Maximum Dumping Height mm (ft·in) 7110 (23’ 4”) 7000 (23’ 0”) 7350 (24’ 1”)
E: Transport Height mm (ft·in) 3220 (10’ 7”) 3230 (10’ 7”) 3170 (10’ 5”)
Rear BL. mm (ft·in) ✸ 9145 (30’ 0”) ✸ 9155 (30’ 0”) ✸ 9005 (29’ 7”)
Rear O/R. mm (ft·in) ✸ 9145 (30’ 0”) ✸ 9155 (30’ 0”) ✸ 9005 (29’ 7”)
Front BL. Rear O/R. mm (ft·in) ✸ 9895 (32’ 6”) ✸ 9905 (32’ 6”) ✸ 9755 (32’ 0”)
Front O/R. Rear BL. mm (ft·in) ✸ 9915 (32’ 6”) ✸ 9925 (32’ 7”) ✸ 9775 (32’ 1”)
Front O/R. Rear O/R. mm (ft·in) ✸ 9915 (32’ 6”) ✸ 9925 (32’ 7”) ✸ 9775 (32’ 1”)
G: Minimum Swing Radius mm (ft·in) 3650 (12’ 0”) 3520 (11’ 7”) 3430 (11’ 3”)
12-24
BLADE AND OUTRIGGER

CAUTION:
Pay attention to the following:
• Check that no obstructions are present in the work-
ing range of the outrigger and blade.
• Confirm the relationship between the control lever
operation direction and the movement direction of
the outrigger and blade.
• Before traveling, always fully retract the outrigger
and secure it in position with the lock pin, and fully
raise the blade. Check that the blade/outrigger/
front control pilot pressure shut off switch is in the
OFF position.
WARNING: Terms of “front or rear” and “right-hand
or left–hand side” used in the description are deter-
mined by facing in the direction of forward travel
from the operator’s seat. When the upperstructure is
rotated 180°, front/rear and right/left directions are
reversed. When operating the machine, use extra cau- B
tion to avoid misoperation. 1
Operating Blade/Outrigger
The blade and outrigger attachments are installed on the
front and rear of the chassis in many combinations. All
attachments are operated with blade/outrigger lever (1), 3 A
blade/outrigger/front control pilot shut off switch (2), front/
rear selection switch (3) and right/left selection switch (4). 4
2
• Blade/Outrigger Lever
Operating this lever performs raising and lowering the
blade, and extending and retracting the outrigger.
MCGB-01-008
A
A B
MCBB-13-001 MCBB-13-002
13-
• Blade/Outrigger/Front Control Pilot Pressure Shut off Switch

By operating blade/outrigger switch (2), blade/outrigger
operation is controlled. In addition, the front attachment
pilot is regulated to restrict front attachment operation.
• When operating both blade and stabilizer, rotate blade/
stabilizer switch (2) to the ON position. When not required
to operate both blade and stabilizer, rotate blade/stabi- 2
lizer switch (2) to the OFF position.
• Front/Rear Attachment Selection Switch (3)

The front/rear attachment selector selects the operable MCGB-01-021
attachments installed on either the front or rear, or both
sides of the machine.
: Only attachment installed on the front is oper-
able. 3
: Attachments installed on both front and rear
are operable simultaneously.
: Only attachment installed on the rear is oper-
able.
• Right/Left Selection Switch (4)

The right/left selector selects the operable attachments MCGB-13-001
installed on either right-hand or left-hand side, or both
sides of the machine. (The blade is operable irrespective
of this selector position.)
: Only outrigger installed on the left-hand side is

operable. 4
: Stabilizer installed on both right and left-hand

sides are operable simultaneously.
: Only outrigger installed on the right-hand side

is operable.
MCGB-13-002
13-
• Blade/Outrigger status indicator (5)

Display the combination of the blade and the outrigger. The
blade and/or outrigger selected by operating the front/rear
attachment selection switch and right/left selection switch
is indicated in green.
5
NOTE: The illustration show a machine equipped with the
front outrigger and rear blade as an example.
IMPORTANT: Consult your nearest Hitachi dealer for set-

ting the combination of the blade and the
outrigger.
TCJB-05-02-042
Lights in Green
Lights in Green
When the blade/outrigger are activated

TCJB-05-02-102
13-
Outrigger
CAUTION: Securely hold the outrigger with pins (1 Hole A 2 (Cross Pin)
and 2) before traveling.
1 (Lock Pin)
Install/Remove outrigger Lock Pins
1. Install Lock Pins
(1) After raising the outrigger, always securely hold the
outrigger with lock pin (1) and cross pin (2).
2. Remove Lock Pins

(1) Use hole A to stow the removed lock pins.
(2) After removing pins (1 and 2), securely hold them in
hole A.
M202-05-032
13-
MAINTENANCE
Blade Pin (Option) --- every 500 hours
Outrigger Pin (Option) --- every 500 hours
MCBB-13-029
MCBB-13-030
M202-07-044
13-
MEMO
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13-
INDEX
A Change Hydraulic Oil...................................................................7-41
Accelerator Pedal............................................................................. 1-4 Check Brake Accumulator..........................................................7-33
Additional Fuse Box......................................................................1-82 Check Bucket Teeth......................................................................7-76
Adjust the Bucket Linkage.........................................................7-80 Check Coolant Level.....................................................................7-67
Adjust the Operator’s Seat............................................................S-5 Check Fuel Hoses...........................................................................7-63
Adjusting the Air-suspension Seat (Optional)..................1-105 Check Hoses and Lines................................................................7-49
Adjusting the Seat .....................................................................1-103 Check Hydraulic Oil Level...........................................................7-40
After the First 100 Hours............................................................... 2-1 Check Instruments After Starting.............................................. 3-9
After the First 50 Hours................................................................. 2-1 Check Starter and Alternator....................................................7-87
Air Cleaner.......................................................................................7-64 Check Tightening Torque of Bolts and Nuts........................7-88
Alarm Occurrence Screen...........................................................1-48 Check Water Separator................................................................7-56
AM/FM Radio Operation . ..........................................................1-95 Check Wear on Brake Lining......................................................7-34
Attachment Adjustment Check Windshield Washer Fluid Level....................................7-82
(Pump 2 Flow Rate Adjustment).......................................1-57 Check and Adjust Fan Belt Tension.........................................7-67
Auto Air Conditioner Operation...............................................1-83 Check and Replace Seat Belt Check........................................7-81
Auto Axle Lock................................................................................1-12 Check the Air Conditioner..........................................................7-85
Auto-idle . .......................................................................................... 5-7 Check the Hour Meter Regularly................................................ 7-2
Auto-idle Switch............................................................................1-21 Clean Air Conditioner Condenser............................................7-69
Avoid Applying Heat to Lines Containing Clean Air Conditioner Front Screen (Opt.)............................7-69
Flammable Fluids................................................................... S-26 Clean Cab Floor..............................................................................7-86
Avoid Heating Near Pressurized Fluid Lines........................ S-26 Clean Fuel Oil Cooler . .................................................................7-69
Avoid High-pressure Fluids........................................................ S-23 Clean Fuel Solenoid Pump Strainer........................................7-62
Avoid Increasing Digging Force Forcibly..............................5-18 Clean Oil Cooler, Radiator and Inter
Avoid Injury From Back-over and Swing Accidents.......... S-12 Cooler Front Screen...............................................................7-69
Avoid Injury From Rollaway Accidents.................................. S-11 Clean Radiator Interior................................................................7-68
Avoid Power Lines......................................................................... S-16 Clean Radiator, Oil Cooler Core and Inter Cooler...............7-69
Avoid Tipping.................................................................................. S-14 Clean and Replace Air Conditioner Filter
Avoid Undercutting...................................................................... S-13 Clean Filter................................................................................7-83
Avoid Using Swing Power..........................................................5-18 Replace Filter............................................................................7-83
Clean the Air Cleaner Outer Element.....................................7-64
B Clock (18)..........................................................................................1-34
Back Monitor Screen Selector (22)..........................................1-36 Clock Setting...................................................................................1-52
Back Monitor Setting...................................................................1-73 Closing Upper Front Window....................................................1-98
Basic Screen.....................................................................................1-31 Combination Switch
Batteries............................................................................................7-70 (Turn Signal Switch, Light and Dimmer Switches)....... 1-8
Before Starting Engine.................................................................. 3-2 Components Name........................................................................ 1-1
Beware of Asbestos Dust............................................................ S-27 Confirm Direction of Machine to Be Driven......................... S-10
Beware of Exhaust Fumes.......................................................... S-25 Control Lever...................................................................................11-3
Blade and Outrigger.....................................................................13-1 Control Lever (Hitachi Pattern)................................................... 5-2
Blade/outrigger............................................................................11-10 Control Lever (ISO Pattern) (Standard).................................... 5-1
Boom Lowering Procedure in Emergency or Convert Bucket Connection Into Face Shovel.....................7-79
when the Engine Stalls.........................................................5-19 Coolant Temperature Gauge (30)............................................1-34
Brake (Traveling)............................................................................7-32 Cooling System..............................................................................7-66
Brake Oil Pressure Gauge (33)...................................................1-35 Correct Maintenance and Inspection Procedures............... 7-1
Brake Pedal........................................................................................ 1-5 Corrective Measures to be Taken when a Wrong
Brake Switch....................................................................................1-11 Password is input....................................................................1-45
Breaker Maintenance...................................................................7-39
D
C Dig with Caution............................................................................ S-15
Cab Door Release Lever..............................................................1-97 Digital Clock Setting Procedure...............................................1-96
Cab Features (Standard Model).................................................. 1-2 Displaying Basic Screen..............................................................1-32
Cab Light..........................................................................................1-28 Displaying Basic Screen by Inputting Password
Change Bucket...............................................................................7-78 (Optional)..................................................................................1-43
Change Coolant.............................................................................7-68 Dispose of Waste Properly.......................................................... S-28
Change Engine Oil........................................................................7-24 Do Not Slam the Bucket Teeth into the Ground.................5-17
14-
INDEX
Do Not Use the Bucket as a Hammer.....................................5-17 Hydraulic System................................................................ 7-37, 11-4
Drain Fuel Tank Sump..................................................................7-55
Drive Machine Safely.................................................................... S-11 I
Inspect Machine...............................................................................S-4
E Inspect Machine Daily Before Starting.................................... 3-1
Electric Control Main Switch.....................................................1-22 Inspect and Adjust Valve Clearance........................................7-87
Electrical System............................................................................7-70 Inspection and Maintenance of
Emergency Exit............................................................................1-102 Hydraulic Equipment............................................................7-37
Emergency Parking Due to Machine Failure......................... 4-9 Instructions for Traveling on a Slope........................................ 4-6
Engine..................................................................................... 7-23, 11-1 Investigate Job Site Beforehand.................................................S-9
Engine Auxiliaries..........................................................................11-1
Engine Control Dial.......................................................................1-15 J
Engine Oil Level.............................................................................7-23 Jump Starting....................................................................................S-7
Engine Speed..................................................................................11-9
Engine Speed Control............................................................4-2, 5-6 K
Engine Speed Control Mode Selection Switch...................1-16 Keep Person Clear From Working Area.................................. S-13
Engine Stop Switch.......................................................................1-29 Keep Riders Off Machine...............................................................S-7
Engine is Hard to Start.................................................................11-2 Key Switch........................................................................................1-24
Ensure Safety Before Rising From or
Leaving Operator’s Seat.................................................................S-5 L
Equalizer Pin....................................................................................7-22 Language Setting..........................................................................1-76
Equipment of Head Guard, Rops, Fops ................................ S-10 Layout.................................................................................................. 7-3
Evacuating in Case of Fire........................................................... S-25 Lever Switch....................................................................................1-26
Every 8 Hours or Daily.................................................................... 2-1 Lighter...............................................................................................1-27
Excavation........................................................................................5-15 Loading/Unloading on a Trailer................................................. 6-2
Extending Password Validity Time..........................................1-47
Extrication From Soft Ground..................................................... 4-7 M
Mail (Optional)................................................................................1-66
F
Maintenance...................................................................................13-5
F-N-R Lever........................................................................................ 1-6 Maintenance Guide........................................................................ 7-9
Face Shovel Operation................................................................5-16 Maintenance Guide Table............................................................. 7-4
Fasten Your Seat Belt.......................................................................S-6 Maintenance Setting....................................................................1-60
Follow Safety Instructions.............................................................S-2 Maintenance Under Special Environmental
Forward/Reverse Travel Switch.................................................. 1-7 Conditions................................................................................... 9-1
Front Attachment Pilot/Blade/Outrigger Switch...............1-20 Measure Engine Compression Pressure................................7-87
Front Axle.............................................................................. 7-20, 7-29 Menu Key (23).................................................................................1-39
Front Joint Pins...............................................................................7-15 Menu Screen...................................................................................1-42
Front and Rear Hub Reduction Devices................................7-31 Meter Combination Setting.......................................................1-78
Fuel Gauge (25)..............................................................................1-34 Meter Display Control..................................................................1-68
Fuel System......................................................................................7-54 Miscellaneous ................................................................................7-76
Fuse Box............................................................................................1-82 Monitor Operation........................................................................1-32
Move and Operate Machine Safely............................................S-6
G Multi Function Monitor...............................................................1-30
General Precautions for Cab.........................................................S-4
Grading Operation........................................................................5-17 N
Greasing............................................................................................7-15 Never Position Bucket Over Anyone...................................... S-13
Never Undercut a High Bank..................................................... S-14
H
Handle Chemical Products Safely............................................ S-28 O
Handle Fluids Safely−avoid Fires............................................. S-17 Object Handling............................................................................ S-16
Handle Starting Aids Safety..........................................................S-6 Observe Engine Operation Closely........................................... 2-1
Hazard Switch.................................................................................1-13 Odometer (8)...................................................................................1-34
Heater (Optional) Operation.....................................................1-91 Opening Door Windows...........................................................1-100
Hood and Access Covers............................................................... 7-7 Opening Upper Front Window.................................................1-97
Hour Meter (9)................................................................................1-34 Opening/Closing Overhead Window (Std. Model).........1-101
14-
INDEX
Operate Only From Operator’s Seat...........................................S-7 Replacing Fuses.............................................................................7-74
Operate with Caution.................................................................. S-15 Retighten Cylinder Head Bolt...................................................7-87
Operating Status............................................................................1-59 Return-basic Screen Key (32)....................................................1-39
Operator’s Station.........................................................................1-14 Revolving Light Switch (Optional)..........................................1-23
Optional Function Keys (24, 27, 29 and 31).........................1-39 Right/Left Control Levers............................................................1-25
Others..............................................................................................11-10
Overload Alarm Switch (Optional)..........................................1-23 S
Overnight Storage Instructions................................................5-21 Safety....................................................................................................S-1
Safety Signs..................................................................................... S-29
P Seat Belt..........................................................................................1-107
Park Machine Safely...................................................................... S-17 Seat Heater Switch (Optional)..................................................1-23
Parking................................................................................................ 4-8 Seat with a Built-in Heater......................................... 1-104, 1-106
Parking/Stopping the Machine on a Slope Service Air Conditioning System Safely................................ S-27
(In Case of Emergency).........................................................5-14 Service Recommendations for Hydraulic Fittings.............7-52
Password Revising (Optional)...................................................1-70 Specifications (ZX140W-3)
Periodic Replacement of Parts.................................................... 7-8 (FRONT BLADE REAR OUTRIGGER)...................................12-3
Pilot Control Shut-off Lever...............................................1-29, 5-3 Specifications (ZX140W-3)
Power Digging (Only ZX210W-3).............................................5-11 (FRONT OUTRIGGER REAR BLADE)...................................12-4
Power Mode ...................................................................................5-12 Specifications (ZX140W-3)
Power Mode Switch . ...................................................................1-17 (FRONT OUTRIGGER REAR OUTRIGGER).........................12-5
Practice Safe Maintenance......................................................... S-19 Specifications (ZX140W-3)
Precautions for Lightning........................................................... S-16 (Standard CHASSIS, REAR BLADE)....................................12-1
Precautions for Operations...........................................................S-8 Specifications (ZX140W-3)
Precautions for Welding and Grinding.................................. S-25 (Standard CHASSIS, REAR OUTRIGGER)..........................12-2
Prepare Machine for Maintenance............................................ 7-6 Specifications (ZX170W-3)
Prepare for Emergencies................................................................S-3 (Standard GAUGE, FRONT BLADE REAR OUTRIGGER)....12-9
Prevent Battery Explosions........................................................ S-27 Specifications (ZX170W-3)
Prevent Burns.................................................................................. S-22 (Standard GAUGE, FRONT OUTRIGGER REAR BLADE)....12-10
Prevent Fires.................................................................................... S-24 Specifications (ZX170W-3)
Prevent Parts From Flying.......................................................... S-21 (Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER)...12-11
Propel Shaft (Front and Rear)....................................................7-21 Specifications (ZX170W-3)
Protect Against Flying Debris................................................... S-17 (Standard GAUGE, Standard CHASSIS, REAR BLADE).....12-7
Protect Against Noise.....................................................................S-3 Specifications (ZX170W-3)
Provide Signals for Jobs Involving Multiple (Standard GAUGE, Standard CHASSIS, REAR OUTRIGGER)....12-8
Numbers of Machines........................................................... S-10 Specifications (ZX190W-3)
Pump Transmission.......................................................................7-26 (FRONT BLADE REAR OUTRIGGER).................................12-15
R (FRONT OUTRIGGER REAR BLADE).................................12-16
Raising the Machine Front Above the Ground with the Specifications (ZX190W-3)
Boom and Arm Function.....................................................5-14 (FRONT OUTRIGGER REAR OUTRIGGER).......................12-17
Rear Axle...........................................................................................7-30 Specifications (ZX190W-3)
Recognize Safety Information.....................................................S-1 (Standard CHASSIS, REAR BLADE)..................................12-13
Remove Paint Before Welding or Heating............................ S-26 Specifications (ZX190W-3)
Remove and Installing Battery.................................................7-74 (Standard CHASSIS, REAR OUTRIGGER)........................12-14
Removing and Storing Lower Front Window......................1-99 Specifications (ZX210W-3)
Removing the Machine from Storage....................................10-2 (Standard GAUGE, FRONT BLADE REAR OUTRIGGER).....12-21
Replace Battery..............................................................................7-73 Specifications (ZX210W-3)
Replace Engine Oil Filter.............................................................7-24 (Standard GAUGE, FRONT OUTRIGGER REAR BLADE).....12-22
Replace Fuel Main Filter Element............................................7-60 Specifications (ZX210W-3)
Replace Fuel Pre-filter Element ...............................................7-61 (Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER)...12-23
Replace Hydraulic Tank Oil Filter (Std. Model)....................7-45 Specifications (ZX210W-3)
Replace Pilot Oil Filter..................................................................7-47 (Standard GAUGE, REAR BLADE).....................................12-19
Replace Air Breather Element...................................................7-48 Specifications (ZX210W-3)
Replace Rubber Hoses Periodically......................................... S-22 (Standard GAUGE, REAR OUTRIGGER)...........................12-20
Replace the Air Cleaner Outer and Inner Elements..........7-64 Starting in Cold Weather.............................................................. 3-6
14-
INDEX
Starting in Cold Weather (ZX140W-3)...................................... 3-8 Work Mode........................................................................................ 5-9
Starting the Engine in Ordinary Temperature....................... 3-3 Work Mode (Attachment Selection).......................................1-53
Stay Clear of Moving Parts......................................................... S-20 Working Brake................................................................................1-12
Steering Column Console............................................................ 1-3 Working Ranges
Steering Wheel Column................................................................ 5-4 ZX140W-3 MONOBLOCK BOOM.......................................12-6
Steering Wheel and Travel Horn Switch.................................. 1-4 Working Ranges
Stopping and Restarting.............................................................. 4-4 ZX170W-3 MONOBLOCK BOOM.....................................12-12
Stopping the Engine....................................................................3-12 Working Ranges
Store Attachments Safely........................................................... S-21 ZX190W-3 MONOBLOCK BOOM.....................................12-18
Storing the Machine.....................................................................10-1 Working Ranges
Suction Filter Cleaning................................................................7-41 ZX210W-3 MONOBLOCK BOOM.....................................12-24
Support Machine Properly......................................................... S-20
Support Maintenance Properly................................................ S-21
Swing.................................................................................................11-8
Swing Alarm Switch (Optional)................................................1-22
Swing Bearing.................................................................................7-18
Swing Internal Gear......................................................................7-19
Swing Reduction Gear.................................................................7-27
Switch Panel (Optional)...............................................................1-21
T
Tachometer (35).............................................................................1-35
Tips for Optimal Air Conditioner Usage................................1-90
Tire......................................................................................................7-35
Tire Inspection and Replacement Procedure......................7-36
Towing Machine.............................................................................. 6-6
Transmission...................................................................................7-26
Transmission Gear Oil..................................................................7-28
Transport Safely............................................................................. S-18
Transporting...................................................................................... 6-4
Transporting by Road.................................................................... 6-1
Travel..................................................................................................11-5
Travel Alarm (Optional)...............................................................4-10
Travel Alarm Deactivation Switch (Optional)......................1-22
Travel Mode Switch..............................................................1-15, 4-3
Travel Speed Meter (34)..............................................................1-35
Traveling............................................................................................. 4-1
Traveling In Water or On Soft Terrain........................................ 4-7
Trip Meter (7)...................................................................................1-34
Troubleshooting............................................................................11-1
U
Understand Signal Words..............................................................S-1
Unit Setting.....................................................................................1-80
Unloading.......................................................................................... 6-5
Use Correct Fuels and Lubricants.............................................. 7-2
Use Handholds and Steps.............................................................S-5
Using Booster Batteries...............................................................3-10
W
Warming-up Operation................................................................. 5-5
Warn Others of Service Work.................................................... S-20
Wear Protective Clothing..............................................................S-3
Wiper/Washer Switch...................................................................1-19
Work Light Switch.........................................................................1-18
14-

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INTRODUCTION

©2008 Hitachi Construction Machinery Co., Ltd.

4. Operating mass (standard version)

VEHICLE IDENTIFICATION NUMBER

NOTE: Marks to indicate the

ZX170W-3, 190W-3, 210W-3 MCBB-00-002

ZX170W-3, 190W-3, 210W-3 MCBB-07-021

ZX170W-3, 190W-3, 210W-3 MCBB-07-053

RECOGNIZE SAFETY INFORMATION

UNDERSTAND SIGNAL WORDS

• To avoid confusing machine protection with personal safety

• NOTE indicates an additional explanation for an element

FOLLOW SAFETY INSTRUCTIONS

PREPARE FOR EMERGENCIES

WEAR PROTECTIVE CLOTHING

You may need:

• Avoid wearing loose clothing, jewelry, or other items that

PROTECT AGAINST NOISE

GENERAL PRECAUTIONS FOR CAB

USE HANDHOLDS AND STEPS

ADJUST THE OPERATOR'S SEAT

ENSURE SAFETY BEFORE RISING FROM OR LEAV-

FASTEN YOUR SEAT BELT

• We recommend that the seat belt be replaced every three

MOVE AND OPERATE MACHINE SAFELY

HANDLE STARTING AIDS SAFELY

• Starting fluid is highly flammable.

OPERATE ONLY FROM OPERATOR'S SEAT

KEEP RIDERS OFF MACHINE

PRECAUTIONS FOR OPERATIONS

INVESTIGATE JOB SITE BEFOREHAND

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

ROPS: Roll-Over Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

DRIVE MACHINE SAFELY

• Driving on a slope may cause the machine to slip or over-

AVOID INJURY FROM ROLLAWAY ACCIDENTS

AVOID INJURY FROM BACK-OVER AND SWING

decreases, reduce speed and use proper lighting.

KEEP PERSON CLEAR FROM WORKING AREA

NEVER POSITION BUCKET OVER ANYONE

• Be careful when working on frozen ground.

NEVER UNDERCUT A HIGH BANK

DIG WITH CAUTION

OPERATE WITH CAUTION

AVOID POWER LINES

PRECAUTIONS FOR LIGHTENING

PROTECT AGAINST FLYING DEBRIS

PARK MACHINE SAFELY

• Close windows, roof vent, and cab door.

HANDLE FLUIDS SAFELY−AVOID FIRES

• All fuels, most lubricants, and some coolants are flammable.

Be sure to further follow the details described in the TRANS-

PRACTICE SAFE MAINTENANCE

Before servicing the machine:

• If a maintenance procedure must be performed with the

WARN OTHERS OF SERVICE WORK

SUPPORT MACHINE PROPERLY