PART NO.

EM1U1-1LCB1-2

200-3
240-3
330-3
450-3
High-Mount Cab
(Single Link Type)
(BOX Type)
URL:http://www.hitachi-c-m.com

Serial No.
ZX200-3 200001 and up
ZX240-3 020001 and up
ZX330-3 050002 and up
This book is printed on recycled paper. PRINTED IN JAPAN (E) 2012, 04 ZX450-3 020001 and up
 INTRODUCTION
Read this manual carefully to learn how to operate Warranty is provided as a part of Hitachi's support
and service your machine correctly. Failure to do so program for customers who operate and maintain their
could result in personal injury or machine damage. equipment as described in this manual. The warranty
is explained on the warranty certificate which you
This standard specification machine can be should have received from your dealer.
operated under the following conditions without being This warranty provides you the assurance that Hitachi
modified. will back its products where defects appear within the
Atmospheric Temperature: �20�C to 40�C (�4�F to warranty period. In some circumstances, Hitachi also
104�F) provides field improvements, often without charge to
Altitude: 0 m to 2000 m (0 ft to 6600 ft) the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
In case the machine is used under conditions other change its performance beyond the original
than described above, consult your nearest Hitachi factory specifications, the warranty will become
dealer. void and field improvements may be denied.
Setting fuel delivery above specifications or otherwise
This manual should be considered a permanent overpowering machines will result in such action.
part of your machine and should remain with the
machine when you sell it. Only qualified, experienced operators officially
licensed (according to local law) should be allowed to
This machine is of metric design. Measurements in operate the machine. Moreover, only officially licensed
this manual are metric. Use only metric hardware and personnel should be allowed to inspect and service
tools as specified. the machine.

Right-hand and left-hand sides are determined by Prior to operating this machine in a country other than
facing in the direction of forward travel. a country of its intended use, it may be necessary to
make modifications to it so that it complies with the
Write product identification numbers in the local standards (including safety standards) and
Machine Numbers section. Accurately record all the requirements of that particular country. Please do not
numbers to help in tracing the machine should it be operate this machine outside of the country of its
stolen. Your dealer also needs these numbers when intended use until such compliance has been
you order parts. If this manual is kept on the machine, confirmed. Please contact Hitachi Construction
also file the identification numbers in a secure place Machinery Co., Ltd. or any of our authorized distributor
off the machine. or dealer if you have any questions concerning
compliance.

CALIFORNIA

Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

©2012 Hitachi Construction Machinery Co., Ltd.

All rights reserved.
INDEX MACHINE NUMBERS
SAFETY
SAFETY SIGNS
COMPONENTS NAME
OPERATOR'S STATION
OPERATING THE MACHINE
MAINTENANCE
SPECIFICATIONS
INDEX
 MACHINE NUMBERS
The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and
hydraulic components. These numbers are requested
when inquiring any information on the machine and/or
components. Fill these serial Nos. in the blank spaces in
this group to immediately make them available upon
request.

MACHINE
M157-00-001

SS3097499

1. MODEL/TYPE M157-12-008

2. Product Identification Number

3. Year of Manufacturing
4. Operating mass (standard version)
5. Engine power in KW according to ISO9249
 MACHINE NUMBERS
MEMO
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 CONTENTS
MACHINE NUMBERS

SAFETY
Recognize Safety Information..............................S-1
Understand Signal Words....................................S-1
Follow Safety Instructions....................................S-2
Inspect Machine...................................................S-2
Getting On/Off the Machine.................................S-3
Use Handholds and Steps ...................................S-4
Fasten Your Seat Belt..........................................S-4
Move and Operate Machine Safely .....................S-5
Keep Riders Off Machine ....................................S-5
Avoid Collision with Front Attachment .................S-5
Investigate Job Site Beforehand..........................S-6
Drive Machine Safely...........................................S-7
Park Machine Safely............................................S-8
Transport Machine Safely....................................S-9
Avoid Digging Work ...........................................S-10
Precautions for Swing Operation .......................S-10
Precautions for Lifting Cab ................................S-11
Practice Safe Maintenance................................S-12
Warn Others of Service Work ...........................S-12
Stay Clear of Moving Parts ................................S-12

SAFETY SIGNS ...........................................S-13

COMPONENTS NAME
Components Name.............................................. 1-1

OPERATOR’S STATION
Layout .................................................................. 1-2
Emergency Exit (From Raised Link Cab) ............ 1-3

OPERATING THE MACHINE

Precautions for Lifiting Cab ................................. 2-1
Single Link Cab Operation................................... 2-3
Operation of Cab Emergency Lowering Switch
(External) ....................................................... 2-4
Transporting by Road .......................................... 2-5

MAINTENANCE
Correct Maintenance and Inspection Procedures . 3-1
Practice Safe Maintenance.................................. 3-2
Daily Inspection ................................................... 3-3
A. Greasing ........................................................ 3-4
Cab Bed Stopper Pin....................................... 3-4
Cylinder Rod Side, Bottom Side ...................... 3-4
Periodic Replacement of Parts ............................ 3-6

SPECIFICATIONS
Specifications ............................................................4-1

INDEX ..................................................................... 5-1

 CONTENTS
MEMO
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 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 in-
jury.
• Follow recommended precautions and safe operating
practices.

SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs do not use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine. SA-1223

• To avoid confusing machine protection with personal

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

• NOTE indicates an additional explanation for an

element of information.

S-1
 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 re-

placed 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 or-
dering). SA-003

• Learn how to operate the machine and its controls cor-

rectly and safely.

• Allow only trained, qualified, authorized personnel to

operate 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.

• The safety messages in this SAFETY chapter are in-

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

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.

SA-435

S-2
 SAFETY
GETTING ON/OFF THE MACHINE

WARNING:
• Never attach a wire on the foot holds to lift the
cab or main body or while transporting the
machine on a truck or trailer as it is dangerous.
• The door knob is not a handrail. Do not use the
door knob as a handrail when getting on and
off the machine.
• Do not hold the control levers or control SA-2306
shut-off lever when getting on and off the ma-
chine.

• Always lower the cab to the bottom position when getting

on and off the machine. Failure to do so may result in fall
from the machine.

SA-2303

• Follow the steps below to get on and off the machine. 3

1. Open the door.

1
2. Hold the handrail in the cab.
3. Hold the handrail outside the cab.
6
4. Step on the truck step.
5. Step on the shoe. 5
6. Step on the bed step. SA-2306

4
7. Come into the cab.
* Follow the steps in reverse sequence of steps 1 to 7
7
above when getting off the machine.
2

M1U1-01-025

S-3
 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 handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may

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

• Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.

S-4
 SAFETY
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate
hand signals before starting the machine. SA-426

• Operator’s visibility is obstructed when the machine is

operated with the cab tilted. Use extra care when
swinging and/or driving the machine.

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 allow the operator on the machine. Keep riders

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

SA-379

AVOID COLLISION WITH FRONT

ATTACHMENT

• The front attachment work tool may come in contact with

the cab.
Operate the machine with care so as to avoid collision.

SA-2309

S-5
 SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from fal-
ling 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 nec-
essary.
Keep the machine well back from the edges of excava- SA-380
tions and road shoulders.
• When working on an incline or on a road shoulder, em-
ploy a signal person as required.
• Confirm that your machine is equipped a FOPS cab be-
fore 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 ma-
chine near flammable objects such as dry grass.
• Make sure the worksite has sufficient strength to firmly
support 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
a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
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.
• When operating the machine with the cab raised, it may
be difficult for the operator to notice even if the machine
is inclined. Use special care not to cause the machine to
fall or turnover.
• Use special care. Operator’s visibility is obstructed when
the machine is operated with the cab raised.

S-6
 SAFETY
DRIVE MACHINE SAFELY
RIGHT
• When the cab is raised, drive the machine with extra
care. Since the operator’s visibility is obstructed, driving
the machine may result in personal injury or death and/or
damage to objects around the machine.

• When operating the machine with the cab raised, it

may be difficult for the operator to notice even if the
machine is inclined, possibly resulting in overturn of
the machine.
• During driving operation, significant vibration loads
may be applied to the machine, possibly introducing SA-2306
mis-operation. Drive the machine so that vibration is
reduced as much as possible. If the machine is driven WRONG
with the cab held in the raised position, damage to the
cab lifting mechanism may result.

SA-2304

S-7
 SAFETY
PARK MACHINE SAFELY
RIGHT
• Do not park the machine with the cab raised. Attempt to
get on and off the cab held in the raised position may
result in falling accident. In addition, if the machine is
parked with the cab raised, the cab may drift during
parking, possibly creating a crushing hazard.

SA-2306

WRONG

SA-2304

S-8
 SAFETY
TRANSPORT MACHINE SAFELY
RIGHT
• Never load / unload the machine with the cab raised on
to / from a trailer. Failure to do so may result in personal
injury or death.

SA-2306

WRONG
• Do not transport the machine with the cab raised. Cab
drift may create an unexpected accident.

SA-2304

S-9
 SAFETY
AVOID DIGGING WORK

• Do not allow the machine to engage in heavy-duty

works such as digging or breaker operation. Great
impact loads will be applied to the machine during
these operations. Especially, great impact loads may
damage the cab lifting mechanism during digging
work.

PRECAUTIONS FOR SWING OPERATION

• Swing the machine with care.

WRONG
• Never attempt to stop swinging by allowing the front
attachment to come in contact with other object during
swing operation. The cab on this machine is located in
a more forward position from the swing center than the
cab on the standard model so that the cab is
vulnerable to large impact loads due to inertia. In
addition, large impact loads may be applied to the cab
lifting mechanism, possibly resulting in damage to the
cab lifting mechanism. M104-05-056

S-10
 SAFETY
PRECAUTIONS FOR LIFTING CAB

• When operating the cab, make sure safety around the

machine. Before raising the cab, check that no front
attachment, power line and/or object is present above
the cab. Before lowering the cab, check that no front
attachment, object and/or person is present under the
cab.

SA-2307

S-11
 SAFETY
PRACTICE SAFE MAINTENANCE

• Checking and/or maintaining the machine with the cab

tilted is very hazardous.

• Be sure to work on the machine only after the cab is

fully lowered.
• If working on the machine with the cab held in a tilted
position is unavoidably conducted, securely support
the cab with a safety stay or block.

SA-527

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.

SS3076175 SS2045102

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.

SA-1357

S-12
 SAFETY SIGNS
All safety signs and their locations affixed on the machine
are illustrated in this group. Make sure of the contents
described in the safety signs through reading actual ones
affixed on the machine to ensure safe machine operation.
Always keep the safety signs clean. In case a safety sign is
broken or lost, immediately, obtain a new replacement and
affix it again in position on the machine. Use the part No.
indicated under the right corner of each safety sign
illustration when placing an order of it to the Hitachi dealer.

(1)

1
2

3
SS3113156

(2)

SS-3349

SS4683568

(3)

SS4683567

S-13
 SAFETY SIGNS

(4)

6 7

SS3108370

• When the cab is raised or when the cab moves and if the
worker stands on the step outside the cab, worker may 5
fall down. When the cab is raised, stay inside the cab. In SS-3350
4
addition, while the cab is raised or lowered, sit down on
the seat.

(5)

SS3108908

• When the cab moves, the worker under the cab is in

danger. When the cab moves, keep away from the cab.

(6)

SS3088571

• The area between the cab bed and the frame is a pinch
point in which hands and/or feet may be entangled. Keep
hands and/or feet away from this area.

(7)

SSYA00014562

S-14
 COMPONENTS NAME
COMPONENTS NAME

1- Cab 1

2- Cab Bed
3- Lift Cylinder 8

4- Tower
5
5- Upper Link
6- Lower Link 7
2 6
7- Upperstructure
3
8- Emergency Ladder
4
NOTE: A typical model is shown in the right. Some
parts may differ depending on the model of the
machine.

SA-2304

1-1
 OPERATOR’S STATION
LAYOUT

1. Switch Panel
2. Switch (for Raise/Lower Operation)
3. Switch (for Emergency Lowering) 1

M1U1-LC1-001

Emergency
Lowering
3

Raise
Lower

M1U1-LC1-002

1-2
 OPERATOR’S STATION
EMERGENCY EXIT 1
(FROM RAISED LINK CAB)

CAUTION: Take care not to get injured by pieces

of broken glass when escaping through the
broken window.

In case escaping from raised link cab is unavoidable, follow

the procedure below.

1. Turn the key switch OFF.

2. Pull the pilot control shut-off lever to the LOCK M1U1-01-022

position.
3. Break the rear window glass using the emergency
evacuation tool (1). Then escape through the broken
window.
2
4. Come down emergency ladder (2). Step on
upperstructure (3) after ensuring safety.

SA-2304

1-3
 OPERATOR’S STATION
MEMO
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1-4
 OPERATING THE MACHINE
PRECAUTIONS FOR LIFITING CAB

The cab is designed to move vertically by using a switch

mounted in the cab.
Ensure the following items before raising/lowering the cab.

WARNING:
• Before raising the cab, check that no front at-
tachment, power line and/or object is present
above the cab.

SA-1769

WRONG
• Before lowering the cab, check that no front
attachment, object and/or person is present
under the cab.

SA-2305

• The front attachment work tool may come in

contact with the cab.
Operate the machine with core so as to avoid
collision.

SA-2309

2-1
 OPERATING THE MACHINE
• Cab raise/lower range (A) is 2500 mm. Operate
the machine by moving the cab at the highest
or the lowest position. Otherwise the cab and
front attachment can collide. Care should be
taken when operating the machine.

M1U1-1LCB1-001

• Vibration while operating the machine can

cause the operator to be struck by internal
objects of the cab and to be thrown off from the
machine that can cause serious injury or death.
Be sure to close the door and remain seated
with the seat belt securely fastened when the
machine is in operation.

• Cab emergency lowering operation should be

performed only in a time of emergency such as
abnormal engine stop.
SA-237

2-2
 OPERATING THE MACHINE
SINGLE LINK CAB OPERATION 1

1. Start the engine by following the Operator’s Manual

that accompanies the base machine.
IMPORTANT: The cab will not move up or down unless
the pilot control shut-off lever is in the
LOCK position.

2. Confirm that pilot control shut-off lever (1) is in the

LOCK position.
3. Turn engine control dial (2) to the slow idle position.
4. Close the cab door.
M1U1-01-025
5. Sound horn to alert bystanders LOCK Position
6. After confirming safety around the machine, operate
the lift cab by turning cab raise/lower switch (4) on
switch panel (3). 2
IMPORTANT: Warning buzzer keeps buzzing while
raising/lowering the cab.

Slow Idle
7. Surely lower the cab and stop the engine after
finishing the work.
8. Emergency lowering switch (5) is provided to lower M1U1-01-033
3
the cab when the cab cannot be lowered by using cab
raise/lower switch (3) due to engine stop or trouble of
hydraulic oil system. Turn cab emergency lowering 5
switch (5) forward to lower the cab.
IMPORTANT: Warning buzzer sounds while
raising/lowering the cab.

4
NOTE: When hydraulic oil temperature is low, lowering
speed of the lift cab is slow. It is not a
malfunction. The cab lowers at normal speed
when hydraulic oil temperature increases after Raise
warming up the machine sufficiently Lower
Refer to the “Warming-up Operation” in the
M1U1-LC1-002
OPERATING THE MACHINE section of the
operator’s manual.
WARNING: In case the cab moves only by
starting the engine when cab raise/lower switch
(4) is in neutral, it is malfunction. Immediately
stop the engine and consult your nearest Hitachi
dealer.
CAUTION: Use the cab emergency lowering
switch only when trouble occurred such as
abnormal engine stop.

2-3
 OPERATING THE MACHINE
OPERATION OF CAB EMERGENCY 2
LOWERING SWITCH (EXTERNAL)
3
The cab emergency lowering switch is located outside as
well as inside the cab.
External cab emergency lowering switch (1) is located on
valve (4) inside left side door (3) of machine tower (2). The
cab will slowly lower while the switch is pushed hard.

CAUTION:
• Use cab emergency lowering switch (1) only SA-2306

when the operator can not lower the cab due to

1
trouble of engine, hydraulic or electrical
system.
• Before operating the cab emergency lowering
switch, ensure that there is no front attachment,
person or any obstacles under the cab.
• The cab will slowly lower while cab emergency
lowering switch (1) on valve (4) is pushed hard.
• Warning buzzer does not sound while lowering 4
the cab. Take extra care for safety.

M1U1-1LCB1-002

2-4
 OPERATING THE MACHINE
TRANSPORTING BY ROAD

WARNING:
• Never load or unload the machine onto or off a
truck or trailer with the cab been raised.
• Never transport the machine with the cab been
raised. If the cab is raised, transporting height
increases and the cab may lower by itself,
causing unexpected accident.

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 transporting weight and
dimensions may vary depending on the type of shoe
or front attachments installed. Take care not to
overload.
• Investigate beforehand the conditions of the route to
be traveled, such as dimensional limits, weight limits,
and traffic regulations. Bed Step

In some cases, getting the permission from the local

authority concerned or disassembling the machine to
bring it within dimensional limits or weight limits of local M1U1-1LCB1-004
regulations may become necessary.
Notify the nearest dealer that you are transporting the Truck Step
unit.

WARNING: If the machine is equipped with the

bed step and/or the truck step, transporting
dimension may exceed the local regulation. If so,
remove the steps before transporting the
machine.

2-5
 OPERATING THE MACHINE
MEMO
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 MAINTENANCE
CORRECT MAINTENANCE AND INSPECTION
PROCEDURES

Learn how to service your machine correctly. Follow the

correct 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 SA-005
lines.
• Walk around machine checking general appearance,
noise, heat, etc.
• Check for loose or missing parts.

If there is any problem with your machine, repair it before

operating or contact your authorized dealer.

IMPORTANT: y Use only recommended fuel and lu-

bricants.
y Be sure to use only genuine Hitachi
parts. Failure to do so may result in
serious injury or death and/or ma-
chine breakdown.
y Use only genuine HITACHI parts.
y Failure to use recommended fuel, lu-
bricants, and genuine Hitachi parts
will result in loss of Hitachi product
warranty.
y Never adjust engine governor or hy-
draulic system relief valve.
y Protect electrical parts from water and
steam.
y Never disassemble electrical compo-
nents such as main controller, sen-
sors, etc.

3-1
 MAINTENANCE

PRACTICE SAFE MAINTENANCE

When carrying out inspection and maintenance, the cab

should be completely lowered to the bottom end or be se- 2
curely fixed by the following method.

CAUTION:
• Do not carry out the cab raise/lower operation
while item 2 to 3 (described below) are per-
forming. Hole A

• Securely insert and fasten bolt (1) to the in-

nermost position.
M1U1-1LC1-003

1. Loosen bolt (1), and then remove pins (2) (2 used).

2
2. Raise the cab to the highest position.
3. Insert pins (2) (2 used) to hole A, and then tighten bolt
(1).
4. Slowly lower the cab until it contacts pin (2).

M1U1-1LC1-004

Before performing any work on the machine, attach a

“Do Not Operate” tag (3) on the control lever.

3
M1V1-07-001

SS3076175 SS2045102

3-2
 MAINTENANCE
DAILY INSPECTION

Inspection Items

1. Deformation, Damage, Noise in all sections

2. Loose and/or Missing of Bolts and Nuts
3. Damage to Stopper Pins, Rings, and Bolts for Lock
Pins
4. Lubrication of Pins
5. Operation of All Hydraulic Components, and Oil
Leaks and/or Damages of Cylinders, Pipe Lines, and
Hoses
6. Operation of All Instruments, Control Switches, Lights,
and Alarms
7. Operation of Engine Stop Handle
8. Any Abnormalities on Machine Exterior
9. Cab Raise/Lower rail malfunction
10. Operation of cab emergency lowering switch (inside
the cab)
11. Operation of cab emergency lowering switch (outside
the cab)

Perform the daily inspection before operating the ma-

chine.

3-3
 MAINTENANCE
A. GREASING

Cab Bed Stopper Pin --- every 500 hours

Cylinder Rod Side, Bottom Side

--- every 500 hours
Lubricate fittings (1) to (6) shown in the figure.

SA-2306
CAUTION: If the lift cab is not used for long
period of time, lubricate it every 500 hours or
every 1 month whichever comes first.
Otherwise, inside of the cab may become
corroded, malfunction or damage to the machine 1
may result.
2 3

4 5
1- Bed Pin (Inside, Bottom Side)
2- Cylinder (Inside, Bottom Side) 6

3- Bed Pin (Inside, Top Side)

4- Cylinder (Outside, Bottom Side) M1U1-1LCB1-005

5- Bed Pin (Outside, Bottom Side)

6- Bed Pin (Outside, Top Side)

1
6
2
5
4

M1U1-1LCB1-006

3-4
 MAINTENANCE
1- Tower Pin (Both Sides, Outside)
2- Tower Pin (Both Sides, Inside)
3- Tower Pin (Both Sides, Outside)
4- Cylinder (Both Sides, Inside)
5- Cylinder (Both Sides, Outside)
6- Tower Pin (Both Sides, Inside)

SA-2306

M1U1-1LCB1-007

1 2 3 4 5 6

4 2 6
1

M1U1-1LCB1-008

3-5
 MAINTENANCE
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic in-

spection of the machine. In addition, the parts listed below,
if defective, 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 in-
spection 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 op-
eration, regardless of the interval.
Also, when replacing hoses, check the clamps for defor-
mation, cracks, or other deterioration, and replace as nec-
essary.
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.

Periodic Replacement Parts Replacement Intervals

Engine Heater Heater hose Every 2 years
ZX200-3, 240-3,
Lift cylinder Every 2 years or 4000 hours whichever comes first
330-3
line hose
Hydraulic Working ZX450-3 Every 2 years or 6000 hours whichever comes first
System Device ZX200-3, 240-3,
Every 2 years or 4000 hours whichever comes first
Pilot hose 330-3
ZX450-3 Every 2 years or 6000 hours whichever comes first

NOTE: Be sure to replace seals, such as O-rings and

gaskets, when replacing hoses.

3-6
 SPECIFICATIONS

SPECIFICATIONS

M1U1-1LCB1-001

Description High-Mount Cab Single Link Type

A: Raise/Lower
mm ZX200-3 to ZX450-3 2500
range of cab

4-1
 SPECIFICATIONS

MEMO
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 INDEX
A R
Avoid Collision with Front Attachment .................S-5 Recognize Safety Information ............................. S-1
Avoid Digging Work ...........................................S-10
S
C SAFETY .............................................................. S-1
COMPONENTS NAME ....................................... 1-1 SAFETY SIGNS ................................................ S-13
Cab Bed Stopper Pin ........................................... 3-4 SPECIFICATIONS ...............................................4-1
Components Name.............................................. 1-1 Single Link Cab Operation ...................................2-3
Correct Maintenance and Inspection Specifications .....................................................4-1
Procedures .................................................... 3-1 Stay Clear of Moving Parts................................ S-12
Cylinder Rod Side, Bottom Side .......................... 3-4
T
D Transport Machine Safely ................................... S-9
Daily Inspection ................................................... 3-3 Transporting by Road...........................................2-5
Drive Machine Safely...........................................S-7
U
E Understand Signal Words ................................... S-1
Emergency Exit (From Raised Link Cab) ............ 1-3 Use Handholds and Steps .................................. S-4

F W
Fasten Your Seat Belt..........................................S-4 Warn Others of Service Work ........................... S-12
Follow Safety Instructions....................................S-2

G
Getting On/Off the Machine.................................S-3
Greasing .............................................................. 3-4

I
Inspect Machine...................................................S-2
Investigate Job Site Beforehand..........................S-6

K
Keep Riders Off Machine ....................................S-5

L
Layout ................................................................ 1-2

M
MAINTENANCE................................................... 3-1
Move and Operate Machine Safely .....................S-5

O
OPERATING THE MACHINE.............................. 2-1
OPERATOR’S STATION..................................... 1-2
Operation of Cab Emergency Lowering Switch
(External) ....................................................... 2-4

P
Park Machine Safely............................................S-8
Periodic Replacement of Parts ............................ 3-6
Practice Safe Maintenance........................ S-12, 3-2
Precautions for Lifiting Cab ................................. 2-1
Precautions for Lifting Cab ................................S-11
Precautions for Swing Operation .......................S-10

5-1
 INDEX
MEMO
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