Hitachi Zaxis 250

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Table of Contents7
Safety-Safety Features11
Safety Features11
Safety-General Precautions12
Recognize Safety Information12
Follow Safety Instructions12
Operate Only if Qualified12
Wear Protective Equipment13
Avoid Unauthorized Machine Modifications13
Inspect Machine13
Stay Clear of Moving Parts14
Avoid High-Pressure Fluids14
Avoid High-Pressure Oils15
Beware of Exhaust Fumes15
Prevent Fires16
Prevent Battery Explosions16
Handle Chemical Products Safely17
Dispose of Waste Properly17
Prepare for Emergencies17
Safety-Operating Precautions18
Use Steps and Handholds Correctly18
Start Only from Operator's Seat18
Use and Maintain Seat Belt18
Prevent Unintended Machine Movement19
Avoid Work Site Hazards20
Keep Riders off Machine20
Avoid Backover Accidents21
Avoid Machine Tip over21
Use Special Care When Lifting Objects22
Add and Operate Attachments Safely22
Keep the Operator Protective Structure (OPS) in Place23
Safety-Maintenance Precautions24
Park and Prepare for Service Safely24
Service Cooling System Safely24
Remove Paint before Welding or Heating25
Make Welding Repairs Safely26
Drive Metal Pins Safely26
Safety-Safety Signs27
Safety Signs27
Operation-Operator's Station39
Pedals, Levers, and Panels39
Control Lever Switches Road Builder40
Live Heel Grapple40
Front Switch Panel43
Front Switch Panel Functions44
Switch Panel45
Pilot Control Shut-Off Lever45
Horn46
Power Boost Switch47
Travel Alarm and Travel Alarm Cancel Switch-If Equipped48
Cab Heater and Air Conditioner- Side Entry Cab49
Cab Heater and Air Conditioner-Rear Entry Cab51
Operating the AM/FM Radio51
Side Entry Cab Door Handles52
Side Entry Cab Door Release Lever52
Rear Entry Cab Door Handles53
Secondary Exit54
Adjusting the Seat55
Fire Extinguisher56
Hydraulic Oil Tank Pressure Vent57
Operation-Operating the Machine58
Before Starting Work58
Operator's Daily Machine Check before Starting58
Starting Engine59
Starting in Cold Weather61
Cold Weather Warm-Up62
Travel Pedals and Levers63
Control Levers-Road Builder64
Control Levers-Live Heel Grapple66
Control Levers-Processor68
Control Levers-Articulated Grapple/Valve in Head70
Control Lever Pattern Operation-Machine Equipped with Excavator Front71
Backhoe Control Lever Pattern71
Excavator Front Only-Zaxis 200LC72
Operating in Water and Mud73
Driving up a Steep or Slippery Slope74
Lifting74
Lower Boom with Engine Stopped-Zaxis 200LC, 25075
Lower Boom with Engine Stopped-Zaxis 35075
Parking the Machine77
Loading Machine on a Trailer78
Cab Tilting Procedure79
Shipping Dimensions-Zaxis 200LC Forester Road Builder with 2.39 M (7 Ft 10 In.) Track Width, Side Entry Cab81
Shipping Dimensions-Zaxis 200LC Forester Live Heel Grapple with 2.92 M (9 Ft 7 In.) Track Width, Rear Entry Cab83
Shipping Dimensions-Zaxis 200LC Forester Articulated Grapple, Rear Entry Cab85
Shipping Dimensions-Zaxis 250 Forester Road Builder, Side Entry Cab87
Forester Road Builder, Side Entry Cab-High Drawbar88
Forester Live Heel Grapple, Rear Entry Cab90
Forester Butt-N-Top Grapple, Rear Entry Cab91
Shipping Dimensions-Zaxis 350 Forester Road Builder, Side Entry Cab92
Forester Road Builder, Side Entry Cab-High Drawbar93
Forester Live Heel Grapple, Rear Entry Cab94
Forester Butt-N-Top Grapple, Rear Entry Cab95
Towing Machine96
Maintenance-Machine97
Diesel Fuel97
Low Sulfur Diesel Fuel Conditioner97
Handling and Storing Diesel Fuel98
Alternative and Synthetic Lubricants98
Diesel Engine Oil99
Hydraulic Oil100
Swing Gearbox, Travel Gearbox and Pump Gearbox Oils101
Track Roller, Front Idler, and Carrier Roller Oil102
Track Adjuster, Working Tool Pivots, Swing Bearing, and Swing Gear Grease102
Cab and Riser Tilt Power Pack Oil103
Maintenance-Periodic Maintenance104
Service Your Machine at Specified Intervals104
Check the Hour Meter Regularly104
Prepare Machine for Maintenance104
Open Access Doors for Service105
Open Engine Hood for Service105
Fuel Tank105
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit107
Maintenance and Repair Record Keeping System108
Maintenance-As Required113
Clean Fuel Tank Inlet Screen113
Drain Fuel Tank Sump113
Clean Radiator Air Inlet Screen114
Drain Water Separator114
Bleed Air from Fuel System115
Clean Air Cleaner Dust Valve115
Check Track Sag116
Adjust Track Sag117
Windshield Washer Fluid Level118
Check Hydraulic Oil Level in Cab Tilt Power Pack118
Vent Hydraulic Oil Tank Pressure119
Replace Oil Cooler Debris Screen-Zaxis 200LC, Zaxis 250120
Maintenance-Every 10 Hours or Daily121
Check Engine Oil Level121
Check Recovery Tank Coolant Level122
Check Hydraulic Oil Level123
Grease Working Tool Pivots125
Maintenance-Every 50 Hours126
Grease Swing Bearing126
Maintenance-After First 50 Hours127
Inspect and Re-Torque Track Hardware127
Maintenance-Every 250 Hours129
Check Swing Gearbox Oil Level129
Drain Hydraulic Tank Sump129
Check Pump Drive Gearbox Oil Level130
Check Radiator Coolant Level131
Check Battery Electrolyte Level and Terminals132
Check Travel Gearbox Oil Level134
Clean or Replace Dusty Primary Element135
Inspect and Re-Torque Track Hardware136
Clean Spark Arrester (if Equipped)136
Maintenance-Every 500 Hours137
Change Engine Oil and Replace Filter137
Grease Swing Bearing Gear139
Replace Fuel Filter140
Replace Water Separator140
Check Air Intake Hoses141
Maintenance-Every 1000 Hours142
Change Swing Gearbox Oil142
Replace Hydraulic Tank Oil Filter143
Replace Pilot System Oil Filter145
Change Pump Drive Gearbox Oil146
Replace Air Cleaner Elements147
Replace Air Cleaner Dust Valve147
Check and Adjust Fan Belt Tension148
Maintenance-Every 2000 Hours149
Drain Cooling System149
Diesel Engine Coolant150
Cooling System Fill and Deaeration Procedure151
Change Travel Gearbox Oil152
Clean the Engine Crankcase Ventilation Tube152
Adjust Engine Valve Clearance153
Replace High Pressure Supply Filter-Zaxis 200LC, Zaxis 250153
Replace Case Drain Filter-Zaxis 200LC, Zaxis 250154
Replace Return Oil Filter-Zaxis 200LC, Zaxis 250154
Maintenance-Every 4000 Hours155
Change Hydraulic Tank Oil, Clean Suction Screen-Zaxis 200LC, 250155
Change Hydraulic Tank Oil, Clean Suction Screen-Zaxis 350158
Miscellaneous-Machine161
Do Not Service or Adjust Injection Nozzles or Injection Pump161
Do Not Service Control Valves, Cylinders, Pumps or Motors161
Precautions for Alternator and Regulator161
Handling, Checking and Servicing Batteries Carefully162
Using Booster Batteries-24-Volt System164
Using Battery Charger165
Replacing Batteries165
Welding on Machine166
Clean the Machine Regularly166
Check and Clean Windshield Regularly167
Adding 12-Volt Accessories167
Replacing Fuses168
Drain Air Compressor Accumulator172
Adjusting Bucket to Arm Joint172
Track Sag General Information173
Unified Inch Bolt and Cap Screw Torque Values174
Metric Bolt and Cap Screw Torque Values175
Miscellaneous-Operational Checkout176
Operational Checkout176
Operator Station Checks-Key Switch On, Engine off176
Operator Station Checks-Engine on177
Miscellaneous Checks187
Miscellaneous-Troubleshooting191
Using Troubleshooting Charts191
Engine192
Electrical System196
Front Attachments Electrical Controls (Live Heel Grapple, Thumb)198
Hydraulic System199
Miscellaneous-Storage201
Prepare Machine for Storage201
Miscellaneous-Machine Numbers202
Record Product Identification Number (PIN)202
Record Engine Serial Number202
Record Travel Motor Serial Numbers202
Record Swing Motor Serial Number203
Keep Proof of Ownership203
Keep Machines Secure203
Miscellaneous-Specifications204
Engine Specifications204
Drain and Refill Capacities206
Zaxis 200LC Forester Road Builder-Machine Specifications208
Zaxis 200LC Forester Live Heel Grapple-Machine Specifications210
Zaxis 200LC Forester Articulated Grapple-Machine Specifications212
Zaxis 200LC Forester Road Builder-Working Ranges214
Zaxis 200LC Forester Live Heel Grapple-Working Ranges215
Zaxis 200LC Forester Articulated Grapple-Working Ranges216
Zaxis 200LC Forester Road Builder-Lift Capacity, Kg (Lb)217
Zaxis 200LC Forester Live Heel Grapple, 9 Ft 7 In. Track Width-Lift Capacity, Kg (Lb)219
Zaxis 200LC Forester Articulated Grapple, 9 Ft 2 In. Track Width-Lift Capacity, Kg (Lb)220
Zaxis 200LC Forester Articulated Grapple, 9 Ft 7 In. Track Width- Lift Capacity, Kg (Lb)221
Zaxis 250 Forester Road Builder-Machine Specifications222
Zaxis 250 Forester Live Heel Grapple-Machine Specifications224
Zaxis 250 Forester Butt-N-Top Grapple-Machine Specifications226
Zaxis 250 Forester Road Builder, 9 Ft 9 In. Arm-Working Ranges228
Zaxis 250 Forester Road Builder, 10 Ft 2 In. Arm-Working Ranges229
Zaxis 250 Forester Live Heel Grapple-Working Ranges230
Zaxis 250 Forester Butt-N-Top Grapple-Working Ranges231
Zaxis 250 Forester Road Builder-Lift Capacity, Kg (Lb)232
Zaxis 250 Forester Road Builder High Drawbar-Lift Capacity, Kg (Lb)233
Zaxis 250 Forester Live Heel Grapple234
Zaxis 250 Forester Articulated Grapple235
Zaxis 350 Forester Road Builder-Machine Specifications236
Zaxis 350 Forester Live Heel Grapple-Machine Specifications238
Zaxis 350 Forester Butt-N-Top Grapple-Machine Specifications240
Zaxis 350 Forester Live Heel Grapple-Working Ranges242
Zaxis 350 Forester Butt-N-Top Grapple-Working Ranges243
Zaxis 350 Forester Road Builder-Lift Capacity, Kg (Lb)244

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