Hitachi ZAXIS 120-5, 160-5, 200-5, 240-5, 300-5, 330-5 Class Hydraulic Excavator Operator’s Manual PDF

Description

File Details

• Manual type: Operator’s Manual
• Brand: Hitachi Construction Machinery Co., Ltd.
• Equipment: ZAXIS hydraulic excavator, 5-series
• Part number: ENMDAK-2-3
• Language: English
• Page count: 484
• File format: PDF
• Publication: Printed in Japan, April 2016

Machine Coverage

This Hitachi ZAXIS hydraulic excavator operator’s manual covers six excavator classes and every model built on them. The front cover lists the full range, and the serial-number table on the same page tells you which build each class applies to.

• ZX120-5 class — ZX130-5A
• ZX160-5 class — ZX160LC-5A
• ZX200-5 class — ZX200-5A, ZX200LC-5A, ZX210H-5A, ZX210LCH-5A, ZX210K-5A, ZX210LCK-5A
• ZX240-5 class — ZX240-5A, ZX240LC-5A, ZX250H-5A, ZX250LCH-5A, ZX250K-5A, ZX250LCK-5A
• ZX300-5 class — ZX300-5A, ZX300LC-5A
• ZX330-5 class — ZX330-5A, ZX330LC-5A, ZX350H-5A, ZX350LCH-5A, ZX350K-5A, ZX350LCK-5A

Serial number ranges printed on the cover: ZX120-5 class 090001 and up, ZX160-5 class 020001 and up, ZX200-5 class 300001 and up, ZX240-5 class 030001 and up, ZX300-5 class 060001 and up, ZX330-5 class 070001 and up. The engine data in the specifications section identifies the Isuzu units used across the range: GJ-4JJ1XKSA-03 (ZX130-5A), GI-4JJ1XKSA-01 (ZX160LC-5A), GI-4HK1XKSA-02 (ZX200-5A through ZX210LCK-5A), GH-4HK1XKSA-01 (ZX240-5A through ZX250LCK-5A), GH-6HK1XKSA-02 (ZX300-5A, ZX300LC-5A) and GH-6HK1XKSA-01 (ZX330-5A through ZX350LCK-5A). A separate specification page covers the ZX130-5A with blade, powered by the GJ-4JJ1XKSA-03 at 69.4 kW.

Chapters Covered

• Introduction — operating conditions, fuel specification, warranty notes, Proposition 65 warning
• Safety — safety alert symbols, signal words, protective clothing, noise protection, machine inspection, cab precautions, handholds and steps, seat adjustment, seat belt, machine movement, jump starting, rider restrictions, job-site investigation, OPG guard, attachment installation limits, signals for multiple machines, driving safely, rollaway/back-over/swing accidents, working area clearance, undercutting, tipping, high banks, digging near services, power lines, lightning, object handling, flying debris, parking, fluid handling, transport, maintenance safety, moving parts, flying parts, falling attachments, burns, rubber hose replacement, high-pressure fluids, fire prevention, emergency evacuation, exhaust fumes, welding and grinding, pressurized fluid lines, accumulator and gas damper handling, paint removal, asbestos and silicon dust, battery explosions, air conditioning service, chemical handling, waste disposal, riding attachments, communication terminal precautions, ROPS operator station protection
• Safety Signs — Oceania model sign locations, Asia/Middle and Near East model sign locations, sign part numbers
• Components Name — bucket, bucket cylinder, arm, arm cylinder, boom cylinder, boom, fuel tank, hydraulic oil tank, engine, counterweight, travel device, track, front idler, cab, expansion tank, battery disconnect switch
• Getting On/Off the Machine — access and dismount procedure
• Operator’s Station — cab features (standard and K model), multi function monitor, default settings, basic screen, hour meter, clock, fuel gauge, coolant temperature gauge, security functions (optional), password input and duration, alarm occurrence screens, remedy table, main menu, air conditioner, radio, work mode, attachment selection, mail (optional), setting menu, date and time, attachment adjustment, flow rate adjustment, priority, attachment name input, auto shut-down, password change, sub meter, rear view camera monitor, brightness adjustment, language settings, unit selection, display item selection, main menu sequence, information menu, fuel consumption, breaker operation, attachment operation, travel operation, actual operation, maintenance, monitoring, switch panel, selector knob, engine control dial, auto-idle, travel mode, power mode, work light, wiper and washer, numeric keypad, optional switch panel, pilot control shut-off lever, engine stop switch, fuse box, auto air conditioner, cab heater, cooling, defroster, cool head/warm feet, AM/FM radio, tone control, audio input, cab door release lever, window opening and closing, emergency exit, seat adjustment, mirrors, seat belt
• Break-In — first 8 hours, first 50 hours, first 100 hours, ECO mode running
• Operating the Engine — daily inspection, starting in ordinary temperature, starting in cold weather and preheating, checking instruments after starting, using booster batteries, stopping the engine, emergency stop
• Driving the Machine — driving carefully, steering with pedals, steering with levers, travel mode switch, travel alarm, operating on soft ground, towing, operating in water or mud, parking on slopes, parking procedure
• Operating the Machine — control lever ISO pattern, pilot control shut-off lever, warming-up operation, engine speed control, auto-idle, auto shut-down, work mode, attachment selection, power boost switch, power mode, precautions for excavation, operating backhoe, shovel, grading, avoiding abusive operation, shackle hole usage, pilot accumulator functions, lowering boom in an emergency
• Transporting — transporting by road, loading and unloading on a trailer, fastening for transport, lifting the machine
• Maintenance — correct maintenance and inspection procedures, hour meter checks, maintenance guide table, preparations, hood and access covers, greasing, engine oil and filter, pump transmission, swing reduction gear, travel reduction gear, hydraulic system, suction filter, full-flow filter, pilot oil filter, air breather, line filter, hoses and lines, hydraulic fittings, fuel system, fuel tank sump, fuel pre-filter, fuel main filter, fuel solenoid pump filter, fuel hoses, air cleaner, cooling system, coolant level, fan belt tension, coolant change, radiator and oil cooler cleaning, electrical system, battery, fuses, bucket teeth, bucket change, face shovel conversion, bucket linkage, travel levers, seat belt, windshield fluid, track sag, air conditioner filter, air conditioner check, cab floor, cylinder head bolts, valve clearance, compression pressure, starter and alternator, EGR device, gas damper, tightening torques
• Maintenance Under Special Environmental Conditions — muddy soil, rain and snow, ocean-side operation, dusty atmosphere, rocky ground, falling stones, freezing weather
• Storage — long-term storage precautions, lubrication during storage, battery disconnect and reconnect
• Troubleshooting — engine auxiliaries, engine starting, control lever, hydraulic system, drive function, swing function, engine speed, pump control
• Specifications — dimensional data, working ranges, shoe types and applications, bucket types and applications, sound level, vibration level for every covered model
• Optional Attachments and Devices — pad crawler shoe, blade lever, bucket teeth (transverse pin type), attachment pedals, hydraulic breaker, hydraulic crusher, quick coupler, stop valves, secondary relief pressure, attachment weight limits, connection parts
• Index

What This Manual Gives You

The Hitachi ZAXIS 120-5 to 330-5 class operator’s manual is the document that ships in the cab of every machine in this family, and it is written for the person actually running the excavator. It walks through the complete daily routine — pre-start walk-around, fluid and coolant checks, battery condition, track sag, bucket teeth and seat belt inspection — then moves into the engine starting procedure in both normal and cold-weather conditions, the preheat cycle, and how to shut down cleanly so the turbocharger is not cooked by trapped heat.

Machine operation is covered in detail. The ISO control lever pattern is diagrammed, the pilot control shut-off lever is explained, and the warming-up sequence for cold hydraulic oil is spelled out with the correct relief-valve timing. Travel is covered with pedal and lever steering, pivot turns, spin turns and travel-mode selection. Auto-idle, auto shut-down, power mode and power boost are all documented with the exact conditions that trigger them, and the work mode screen is explained for anyone running a breaker, pulverizer, crusher, vibrating hammer, grapple or clamshell instead of a bucket.

The maintenance chapter is the largest single section. It gives the full greasing chart with intervals in hours, engine oil and filter change procedure with capacities for each class, hydraulic oil and full-flow filter replacement, pilot filter, air breather, fuel pre-filter and main filter, fuel solenoid pump filter, air cleaner element cleaning and replacement, coolant change with the antifreeze mixing ratio table, fan belt tension deflection values, battery electrolyte checks, fuse box layout, track sag adjustment, and the tightening torque tables for every major fastener on the machine.

For diagnosis, the troubleshooting chapter works through no-start conditions, weak hydraulics, slow travel, rough swing and engine speed faults with cause and remedy columns. The specifications chapter closes with dimensional drawings, working ranges, shoe and bucket application tables, and sound and vibration level data for each model.

Why This Manual Matters

Every torque value, service interval, fluid capacity and adjustment limit in this book is the one Hitachi published for these machines. Running a ZAXIS 5-series excavator without the correct track sag, the wrong hydraulic oil change interval, or an ungreased swing bearing is how undercarriage components and pumps get destroyed early. The safety chapter alone is worth the download — it covers power line clearance distances, undercutting, rollaway prevention and the correct way to lift or transport the machine.

IMAGES PREVIEW

Instant PDF Delivery

The manual is delivered as a PDF the moment payment clears. No shipping, no waiting. Read it on a phone, tablet or laptop in the cab, or print the pages you need for the workshop. Bookmark the maintenance chapter, print the torque tables, keep the troubleshooting section open while you diagnose.