INTRODUCTION
Read this manual carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or machine damage.
This standard specification machine can be
operated under the following conditions without being
modified.
Atmospheric Temperature: −20°C to 40°C (−4°F to
104°F)
Altitude: to 2000 m (to 6600 ft)
In case the machine is used under conditions other
than described above, consult your nearest Hitachi
dealer.
This manual should be considered a permanent
part of your machine and should remain with the
machine when you sell it.
This machine is of metric design. Measurements in
this manual are metric. Use only metric hardware and
tools as specified.
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the
Machine Numbers section. Accurately record all the
numbers to help in tracing the machine should it be
stolen. Your dealer also needs these numbers when
you order parts. If this manual is kept on the machine,
also file the identification numbers in a secure place
off the machine.
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.
Warranty is provided as a part of Hitachi's support
program for customers who operate and maintain
their equipment as described in this manual. The
warranty is explained on the warranty certificate which
you should have received from your dealer.
This warranty provides you the assurance that Hitachi
will back its products where defects appear within the
warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to
the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original
factory specifications, the warranty will become
void and field improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
Only qualified, experienced operators officially
licensed (according to local law) should be allowed to
operate the machine. Moreover, only officially licensed
personnel should be allowed to inspect and service
the machine.
This machine is a Japanese domestic model. It
has been manufactured in accordance with the
standards and requirements of Japan. Please do
not operate this machine outside of Japan.
©2006 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
SAFETY OPERATION AND CORRECT MACHINE CONTROL
MACHINE NUMBERS
PRACTICE OF SIGN /GUIDE
SAFETY
SAFETY SIGNS
COMPONENTS NAME
SAFETY DEVICE FUNCTIONS AND OPERATION
OPERATION
MAINTENANCE
TROUBLESHOOTING
SPECIFICATIONS
INDEX
 CONTENTS
SAFETY OPERATION AND CORRECT
MACHINE CONTROL
MACHINE NUMBERS
PRACTICE OF SIGN / GUIDE
SAFETY
Recognize Safety Information ............................ S-1
Understand Signal Words................................... S-1
Follow Safety Instructions................................... S-2
Operator’s Qualification ...................................... S-2
Inspect Machine Daily Before Starting ............... S-3
Precautions for Starting Operation ..................... S-3
Appoint Signal Person ........................................ S-3
Investigate Job Site Beforehand......................... S-4
Safety Device is Not Absolute ............................ S-5
Avoid Overloading .............................................. S-5
Precautions for Lifting Load ................................ S-6
Never Allow Anyone to Ride Hook or Load ........ S-6
Precautions for Strong Wind............................... S-6
Avoid Abrupt Operation ...................................... S-7
Avoid Fast Speed Swing..................................... S-7
Avoid Traveling with Suspended Loads ............. S-7
Avoid Operating Machine on Slopes .................. S-7
Avoid Operation on Soft Ground ........................ S-8
Avoid Pulling Loads Sideways
and/or Diagonally ............................................ S-8
Do Not Leave Machine in Operation .................. S-8
Precautions for After Completing Operation....... S-9
During Storing..................................................... S-9
SAFETY SIGNS ................................... S-11
COMPONENTS NAME .......................... 1-1
SAFETY DEVICE FUNCTIONS AND
OPERATION
Safety Device Functions and Operation ..............1-2
Monitor Panel.......................................................1-3
LCD.................................................................1-4
Display Selector..............................................1-4
Crane Switch Indicator ...................................1-4
Crane Switch ..................................................1-4
Alarm Indicator ..............................................1-5
Stroke End Indicator .......................................1-6
Hook Collision Indicator..................................1-6
Offset Indicator ...............................................1-6
Angle Sensor .......................................................1-7
Boom Pressure Sensor........................................1-7
Free Fall Prevention Valve ..................................1-8
Bucket Lock Valve ...............................................1-9
Hook (Link Stored Type)......................................1-9
Level .................................................................1-10
External Crane Mode Indicator..........................1-10
OPERATION
Taking Out/In Hook (Link Stored Type) .............. 2-1
Precautions for Crane Operation ........................ 2-2
Crane Operation Procedure ................................ 2-4
MAINTENANCE
Maintenance........................................................ 3-1
Legal Inspection .................................................. 3-2
Check Boom and Arm
Angle Sensor Operation .............................. 3-3
Check Free Fall Prevention Valve
and Bucket Lock Valve for Any Oil Leaks,
Abnormal Noise and Damage ..................... 3-4
Check Boom Cylinder Pressure Sensor
for Any Oil Leaks and Damage ................... 3-5
Check Hydraulic Pipe and Hose Lines
for Any Oil Leaks and Damage ................... 3-5
Check that All Safety Signs and Other Signs
are Correctly Installed Undamaged............. 3-6
Check Operation of External
Crane Mode Indicator .................................. 3-6
Check Angle and Pressure Sensor
Harnesses for Damage
and Failure in Connection ........................... 3-7
Check Link (5), Hook (2) and Pins (1, 3, and 4)
for Any Incomplete Installation,
Damage and Insufficient Lubrication ........... 3-8
Check Link (5), Hook (2) and Pins
(1, 3, and 4) for Wear .................................. 3-8
Check Hook (2) for Cracks, Deformation
and Damage ................................................ 3-8
Check Latch (6) of Hook (2) for Malfunction
and Damage ................................................ 3-8
Check that Hook (2) is Correctly Stored
in Position .................................................... 3-8
Check Monitor Panel for Damage
and Incorrect Installation ............................. 3-9
Check Wire Harness and Connectors
for Any Damage and
Incomplete Connection................................ 3-9
Check Alarm Buzzer for Malfunction ............. 3-9
Check Working Position Display
and Actual Load Display for Malfunction ... 3-10
Perform Loading Test................................... 3-12
Perform Stability Test................................... 3-12
TROUBLESHOOTING
Troubleshooting................................................... 4-1
SPECIFICATIONS
Working Ranges
ZAXIS110,110-E ........................................... 5-1
Rated Load
ZAXIS110,110-E ........................................... 5-2
Working Ranges
ZAXIS120,120-E,130K.................................. 5-3
 CONTENTS
Rated Load
ZAXIS120,120-E,130K ..................................5-4
Working Ranges
ZAXIS160LC..................................................5-5
Rated Load
ZAXIS160LC..................................................5-6
Working Ranges
ZAXIS200,200-E,210K ..................................5-7
Rated Load
ZAXIS200,200-E,210K ..................................5-8

INDEX ................................................................6-1
 SAFETY OPERATION AND CORRECT MACHINE CONTROL
SAFETY OPERATION

Ensuring Safety
• Fundamental instructions regarding safety operation are described on the opening yellow pages in this man-
ual. In addition, safety messages in response to practices in the texts are described in this manual as needed
after the safety alert symbol and heading of “ CAUTION.”
• Thoroughly read and understand the meanings of these safety messages together with the safety signs to
safely operate the machine.

• The following laws and regulations have been prescribed to prevent labor accidents:
Work safe hygienic method:
Establishment of the protection standard to prevent labor accidents from occurring, workers’ safety and
health control, and promotion of labor under comfortable working environment.
Work safe hygienic rule
Specifying installation of headlights and head guard, conduct of inspection, taking inspection result records,
making plan of work procedures, limit of travel speeds, protection of falling and collision, use of signs,
measures to be taken before leaving the operator’s seat, transportation of the machines, prohibition of al-
lowing co-worker to ride on the machine, restriction of machine applications, prohibition of special machine
uses other than major applications, repairing methods, protection against dangers of boom falling, etc.
Refer to the Work safe hygienic rule provision 164 for the detailed information regarding the prohibition of
special machine uses other than the major applications. The ML crane specification machines are catego-
rized in the small size walking cranes so that this rule is not applied to lifting load work with the ML crane
specification machines.
Work safe hygienic method enforcement regulation
The government ordinance specifying the machine models, types and definitions of machines, types of
machines to be voluntarily checked at regular intervals, kinds of work restricted to engage in, and en-
forcement of this regulation.
Crane safety rule
Labor ministry ordinance specifying notifications regarding the manufacturing, installation, applications and
operation of cranes, and qualification of inspectors and operators.

• Keep in mind that this manual does not cover all safety practices. Pay close attention further to practices
other than described in this manual to ensure your own safety.

Operator’s Qualification
• Operator of this machine must be eligible to the specified qualification.
Work safe hygienic method:
When performing crane work:
Operator must have completed the small size movable crane operator’s training session or must possess
the movable crane operator’s license.

When performing sling work:

Only the persons who have completed the slinging skill training session are allowed to engage in this work.

When performing excavation and /or loading work:

Operator must have completed the vehicle type constriction machinery (for ground leveling, carrying, load-
ing and excavating) operator’s training session.

Mine safety method:

Mining work:
Must be engaged by personnel who have completed the safety education and have been qualified by the
mining safety director or manager.
 SAFETY OPERATION AND CORRECT MACHINE CONTROL
ACQUISITION OF QUALIFICATION

Hitachi Construction Machinery Co., Ltd provides the small size movable crane operator’s training session, the
vehicle type constriction machinery operator’s training session, and other kinds of training sessions for customers.
Consult your nearest Hitachi dealer to take part in these training sessions.

CORRECT MACHINE CONTROL

Inspection/Maintenance
• In this manual, important information on handling the machine is described under the heading of “IMPOR-
TANT.” Correctly inspect and service the machine in accordance with this manual to utilize full machine per-
formance.
• Qualified persons, who can inspect and/or service the machine, are prescribed in laws and regulations.
Work safe hygienic rule
Prescribing to perform daily pre-start inspection, voluntary regular interval inspection, (monthly and annual
inspections). Annual inspection is designated as Specific voluntary inspection to be performed by a
state-qualified person or a registered inspection agency. Failure to follow this rule will result in punishment.

Mine safety rule

Prescribing to perform daily pre-start inspection, regular interval inspection, and exact inspection. Refer to
the MAINTENANCE section for the details.

SPECIFIC VOLUNTARY INSPECTION

Consult your nearest Hitachi dealer for the Specific Voluntary Inspection.

DIRECTION

Determination of Front/Rear and Right/Left

Machine direction is determined by facing forward from the operator’s seat with the front idlers positioned in
front in this manual.
Front

Front Idler
Operator’s Seat

Left Right

Travel Motor

Rear M104-01-038
 MACHINE NUMBERS
MACHINE

MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:

M157-00-001

PRODUCT IDENTIFICATION NUMBER

PRODUCT
IDENTIFICATION
NUMBER:

NOTE:
Marks to indicate the start and
∗14HP100001∗ end of the PIN

PRODUCT IDENTIFICATION
NUMBER (PIN) M157-12-008
 MACHINE NUMBERS
MEMO

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 PRACTICE OF SIGN / GUIDE
PRACTICE OF SIGN/GUIDE

In principle, operate a movable crane in accordance with

signs from the signal or guide person.

Points of Concern in Signaling

• Appoint only one signal person.
• Make and send signals clearly.
• Signal person must take a position from which the
slinging work process can be easily seen as well as it
is visible from the machine operator.
• Signal person must sends signals from a safety loca-
tion.

Signaling Methods
• Hand signals
• Vocal expression
• Whistling
Safe: Repeating short 2 whistles
Stop: Long whistling

Signals by Whistling
① Calling

② Hoist － － － －

③ Lower － － － － － －

④ Stop

Costume Example of Signal/Guide Person

M131-00-005
 PRACTICE OF SIGN / GUIDE
Hand Signals

1. Calling 2. Indication of position 3. Hoist 4.Lower

Raise one arm and move With palm facing down,

Point-out the place as arm in horizontal circle. With horizontally extend arm
Raise one arm straight. closely as possible. palm facing up, move arm forward. Move arm down-
upward repeatedly. ward repeatedly.

5. Extend boom 6. Retract boom 7. Raise boom 8. Lower boom

With thumb pointing up With thumb pointing With thumb pointing up With thumb pointing
(with other fingers down (with other fingers (with other fingers down (with other fingers
flexed), diagonally raise flexed), diagonally lower flexed), raise straight flexed), lower straight
thumb more than level. thumb more than level. thumb more than level. thumb more than level.

9. Horizontal movement 10. Slight movement 11. Overturn 12. Stop

Continuously move little

With palm pointing direction
finger or forefinger in pattern Extent both arms in Clearly raise palm. With all
of movement, extend arm to fingers flexed in this posi-
corresponding to motion parallel and rotate arms
visible position and move tion, signal for slight
signals for hoist, lower, or in the same direction of
arm several times. movement can be made.
horizontal movement. turning.

13. Emergency stop 14. Stop operation

With arms extended wide, Give a salute, or cross both

wave rapidly. arms over the head.

M131-00-006
 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

001-E01A-0001

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

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

•DANGER indicates an imminently hazardous situation

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

• CAUTION also calls attention to safety messages in this

manual.

• 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.

002-E01A-1223

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
ordering). 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.
003-E01B-0003

OPERATOR’S QUALIFICATION

• Operator of this machine must be eligible to the both

qualifications described below.

•When performing crane work:

Operator must have completed the small size mov-
able crane operator’s training session or must pos-
sess the movable crane operator’s license.
•When performing excavation and /or loading work:
Operator must have completed the vehicle type con-
struction machinery (for ground leveling, carrying,
loading and excavating) operator’s training session.
•When performing sling work:
Only the persons who have completed the slinging
skill training session are allowed to engage in this
work.

S-2
 SAFETY
INSPECT MACHINE DAILY BEFORE START-
ING

• Operate the machine only after conducting daily inspec-

tion and repairing abnormality if any.

• Safety devices and Overload alarm device

• Hook and Hook latch

• Wire rope, Lifting chain, Sling wire rope, etc.

• Engine control system

SA-435

PRECAUTIONS FOR STARTING OPERATION

• Unless the safety devices are correctly operated, dam-

age to the machine and/or serious personal injury or
death may result.

•Before performing crane work, be sure to extend the

bucket cylinder to the maximum stroke end and turn
the crane switch ON. Unless the crane switch is
turned ON, all safety devices are inoperable, possibly
creating a hazardous situation. After turning the crane
switch ON, check that the overload alarm device op-
erates normally. If any error code is displayed on the
monitor panel LCD or no indication is displayed, the
machine is in trouble. Do not operate the machine.

M131-00-001

APPOINT SIGNAL PERSON

• During crane work, when working with a co-worker such

as a person who slings a load, obey the directions from
the signal person.

• Never operate the machine without receiving clear in-

structions from the signal person or without under-
standing the meaning of the signals.

• Before performing jobs with multiple numbers of ma-

chines involved, coordinate the signals to be commonly
used in the job and appoint the signal person.
SA-481

S-3
 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
falling and to prevent the ground, stockpiles, or banks
from collapsing.
•Make a work plan. Use machines appropriate to the
work and job site.
SA-380
•Reinforce ground, edges, and road shoulders as nec-
essary. Keep the machine well back from the edges
of excavations and road shoulders.
•When working on an incline or on a road shoulder,
employ a signal person as required.
•Keep all persons clear from the area of operation and
machine movement.
•When the footing is weak, reinforce the ground before
starting work.
•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. SA-829

•When working on frozen ground, be extremely alert.

As ambient temperatures rise, footing becomes loose
and slippery.
•Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
•Beware the possibility of fire when operating the ma-
chine near flammable objects such as dry grass.
015-E01A-0380

S-4
 SAFETY
SAFETY DEVICE IS NOT ABSOLUTE

• This machine is equipped with safety devices such as

an overload alarm device. However these devices can-
not detect if such devices are correctly installed or ad-
justed, or the possibility of ground collapse under the
machine. In addition, the safety devices cannot modify
the influence of wind power.

•No safety device is absolute. Before operating the

machine, thoroughly understand this Operator’s
Manual to prevent accidents from occurring.

AVOID OVERLOADING

• Overloading may cause the machine to turnover and/or

damage the boom.

•The machine stability in the sideways direction is

smaller than that in the front and rear direction. Oper-
ate the machine only within the range of the rated
loads. Carefully operate the machine when perform-
ing crane work facing perpendicularly to the crawler.
•Do not lift loads over the rated loads.
SA-839

•The rated load table is displayed in the operator’s cab.

The rated load values are decided based on both as-
pects of the machine strength and stability.
•It is required for an operator to operate the machine so
that the lifted load does not exceed the rated load.
Lifting loads heavier than the rated load or lowering
the boom beyond the allowable working radius may
cause the machine frame to deform and/or the ma-
chine to overturn, possibly resulting in a serious ac-
cident.

S-5
 SAFETY
PRECAUTIONS FOR LIFTING LOAD

• Fall of the lifted load may cause a serious accident.

•Lift a load according to the rule.

•Allow only the qualified person to sling a load.
•Do not allow any person to enter the area under the
lifted load.
•Do not pass the lifted load over the truck operator’s
cab.
•When operating this machine to lift a load, be sure to
use a hook equipped with a latch.
•Do not use inadequate sling wire rope, hook, lifting
chain, and/or shackle.

SA-842

NEVER ALLOW ANYONE TO RIDE HOOK OR

LOAD

• Fall of person from an elevated area may result in seri-

ous personal injury or death.

•Never allow anyone to ride the hook or load, or to work

on the lifted load.

SA-831

PRECAUTIONS FOR STRONG WIND

• When the machine is operated in a strong wind, serious

casualty may result due to overturning of the machine or
kickback of the lifted load.

•Refrain from performing crane work when strong wind

faster than 10 m/sec is blowing.
•Before starting operation, check the wind velocity and
direction. If strong wind is expected, do not operate
the machine.
•After starting operation, in case wind conditions
change leading to a likely hazardous situation, imme-
diately stop operating the machine. Especially be alert
to possible danger when working in a job site be-
tween high story buildings.
•Take safety measures appropriate to the wind velocity
when a strong wind is blowing.

S-6
 SAFETY
AVOID ABRUPT OPERATION

• While lifting a load, if a control lever is abruptly operated,

possibly resulting in turning over or damage of the ma-
chine.

•Slowly operate the machine so that the lifted load does

not sway. Especially, lifting the load off the ground is a
very hazardous point. Avoid abrupt operation.
•Avoid operating each hydraulic cylinder near the SA-838

stroke ends to reduce the impacts developed when

the cylinder piston comes in contact with the cylinder
bottom or head.

AVOID FAST SPEED SWING

• Fast speed swing will increase centrifugal force so that

the lifted load is forced to move outward, possibly cre-
ating a hazardous situation.

•Always swing the machine at slow speed.

SA-841

AVOID TRAVELING WITH SUSPENDED

LOADS
• If the machine is driven while suspending loads, the
suspended load may sway, possibly causing the ma-
chine to become unstable.

SA-862

AVOID OPERATING MACHINE ON SLOPES

• If crane work is made with the machine inclined, not

only reducing the machine stability but also creating
swing drift may result, possibly inducing a hazardous
situation.

S-7
 SAFETY
AVOID OPERATION ON SOFT GROUND

• Performing crane work on soft ground where the ma-

chine is difficult to maintain level position may cause the
machine to slip or overturn, possibly resulting in per-
sonal injury or death.

SA-836

AVOID PULLING LOADS SIDEWAYS AND/OR

DIAGONALLY

• Diagonal load pulling and/or sideways load pulling may

damage the machine, possibly resulting in personal in-
jury or death.

•Operate the machine so that the load can be lifted

from the position just below the hook.

SA-840

DO NOT LEAVE MACHINE IN OPERATION

• Leaving machine in operation can cause a serious

casualty.

•Never leave the machine while holding loads above

the ground and/or without stopping the engine.
•Be sure to follow the instructions below:
1. Park the machine on solid level ground.
2. Lower the loads and the bucket on the ground. SA-847

3. Stop the engine and remove the key.

S-8
 SAFETY
PRECAUTIONS FOR AFTER COMPLETING
OPERATION

• Park the machine in a safe area.

•Park the machine on solid level ground.

•Cool the machine by running the engine at slow idle
speed for about 5 minutes.
•Before leaving the machine, lower the loads and the
bucket on the ground. Turn all control levers to neu-
tral.
•Turn the key switch OFF. Stop the engine and remove SA-847

the key.
•When leaving the machine, be sure to remove the en-
gine key.
•Be sure to move the pilot control shut-off lever to the
LOCK position.
•Before leaving the machine, close and lock all win-
dows, cab doors, and maintenance access covers.

DURING STORING

• Be sure to conduct daily inspection and maintenance on

level ground.

•Sufficiently check the hook and the hook related parts

for any abnormality.
•Change hydraulic oil or lubricants and replace con-
sumable parts at regular intervals.
•Adjustment of hydraulic component is prohibited. In-
adequate adjustment of them may result in serious
casualty. Be sure to consult your nearest Hitachi
dealer.
•Perform monthly and yearly machine inspection at
your own responsibility according to the specified in-
spection list and keep the records for three years.

S-9
 SAFETY
MEMO

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S-10
 SAFETY SIGNS

CAUTION
1. Operators of movable crane must possess the
movable crane operator’s license or must have
completed the small size movable crane opera-
tor’s training session.
2. This machine is equipped with a load meter and
overload alarm, which have been set to match
the machine’s specification when the machine
was shipped from the factory. Never perform
crane work after replacing the original standard
front attachment with other size bucket, quick
hitch, or hydraulic breaker.
3. The monitor unit is not a water-resistant type.
Take care not to expose the monitor unit to rain
or water.
4. Be sure to conduct the Pre-start Check as de-
scribed in the Operator’s Manual before operat- SS3091888

ing the machine.

Precautions for Crane Work

1. Activate the overload alarm by pressing the
Crane Switch on the monitor panel. (Fully roll in
the bucket.)
2. Check that the footing under the machine is solid
and level.
3. Never lift a load heavier than the rated load.
4. Do not travel the machine while lifting a load.
5. Never use the machine to pull a load sideways,
lift a load in diagonal direction, or pull piles out of
the ground. SS-2183

6. Perform crane work only in the specified working

range.
7. When the monitor mode was shifted to indicate
the position display and after the displayed posi-
tion was checked, be sure to reset the monitor to
the load display mode.
8. This machine conforms to the Movable Crane
Construction Standard and the Crane Safety
Rule and is equipped with the overload alarm
meeting the requirements specified in
JCAS-2205-98 (Overload prevention system for
machines, which can be used both as a hydrau-
lic excavator and a folding jib type movable
crane)

S-11
 SAFETY SIGNS

SS3086892

SS-2061

Max. Working Radius Rated Load

ZAXIS110、110-E SS3091859

Max. Working Radius Rated Load

SS-2061

ZAXIS120、120-E、130K SS3091860

Max. Working Radius Rated Load

ZAXIS160LC SS3094551

Max. Working Radius Rated Load

ZAXIS200、200-E、210K SS3091895

S-12
 SAFETY SIGNS

Max. Lifting Capacity

SS4421360

SS-2062

SS1029235
On both sides of boom

Movable Crane Specification Model

ZAXIS110、110-E:
Parts No.1029235
ZAXIS120、120-E、130K、160LC、200、200-E、210K:
Parts No.1029236

SS-2182

SS3042530

Hydraulic Crawler Crane

SS-2184

Lifting Capacity
Manufacturing Date

Hitachi Construction Machinery Co., Ltd

S-13
 SAFETY SIGNS
MEMO
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S-14
 COMPONENTS NAME
COMPONENTS NAME

1- Hook (Link stored type) 2

2- Arm free fall prevention valve

3- Boom angle sensor
4- External crane mode indicator 11
5- Bucket lock valve
6- Level 9 3

7- Monitor panel 10
1 4
8- Boom pressure sensor 8

9- Boom free fall prevention valve

7
10- Arm angle sensor
11- Rated load table 6
5

M131-01-007

1-1
 SAFETY DEVICE FUNCTIONS AND OPERATION
SAFETY DEVICE FUNCTIONS AND OPERA-
TION

Besides the safety devices equipped on the standard

specification machines, HITACHI ML crane specification
machines have additional safety devices required to con-
form to the CRANE regulations

CAUTION: Although many safety devices are

equipped on the machine, the operator is re-
sponsible for preventing accidents from occur-
ring. Before operating the machine, be sure to
check that all safety devices correctly operate.

Safety devices for the ML cranes are an overload alarm

device, free fall prevention valves, angle sensors, and
boom pressure sensors.

According to the data sent from various kinds of the sen-

sors, the overload alarm device calculates the working ra-
dius, and height in the working position, actual load value
and the rated load. Then, comparing the rated load with
the actual load value, the overload alarm device emits ap-
propriate alarm sound as needed. If the hook enters the
range where the hook comes in contact with the bucket,
caution is advised by flashing the light. During this condi-
tion, the machine becomes operable only to the safety
side.

1-2
 SAFETY DEVICE FUNCTIONS AND OPERATION
MONITOR PANEL
1
1- Liquid crystal display (LCD)
2- Display selector
3- Crane switch indicator 2

4- Crane switch
8
5- Alarm indicator 3
6- Offset indicator 7
7- Hook collision indicator
4
8- Stroke end indicator

5 M131-01-001

1-3
 SAFETY DEVICE FUNCTIONS AND OPERATION
LCD
1
LCD (1) can display two kinds of information, load value
and working position by operating the display selector.

4
Display Selector
Each time display selector (2) is pressed, the display is
shifted as shown in the table below.
Upper column Lower column
display display
Load value Actual load (t) Rated load (t)
Working position Working radius (m) Height (m)

M131-01-001

Datum Point

Crane Switch Indicator

During crane operation, green light (3) stays ON.

Height

Working Radius

Crane Switch M131-01-016

CAUTION: Before performing crane work, be

3
sure to turn crane switch (4) ON. All safety de-
vices are not activated until crane switch (4) is
turned ON, possibly creating hazardous condi-
M131-01-003
tions. After turning the crane switch ON, check Crane Switch
that the overload alarm device correctly operates.
If the LCD on the monitor panel displays any fault
code or no indication is displayed, the machine
is abnormal. Do not operate the machine.

Before performing crane work, press crane switch (4) to

activate all safety devices such as the overload alarm
device, bucket lock valve, etc. Refer to the Operating
the Machine Section for the detailed information.

1-4
 SAFETY DEVICE FUNCTIONS AND OPERATION
Alarm Indicator 5

When the crane switch is ON, if the machine is operated

under hazardous conditions, the alarm is emitted by
flashing alarm indicator (5) and LCD (1) and sounding Alarm M131-01-004
the buzzer.
1

CAUTION: In case the alarm is emitted when

lifting a load, change the load lifting position or
reduce the load value. When the alarm is emitted
due to collision of the hook with the bucket, de-
activate the alarm system by operating the boom
or arm control lever to change the load lifting po- 8
sition. When the boom cylinder stroke end alarm 7
is emitted, lower the boom by operating the
boom control lever. The load display calculation
accuracy becomes inferior when the boom cyl-
inder is operated near the stroke end.

5 M131-01-001

• Alarm indicators and buzzer operation conditions list

Indicator
Alarm operation condition Buzzer
Alarm (5) Stroke end (8) Hook collision (7)
Ratio of actual load per rated load is lower
Stop Off Off Off
than 95%.
Ratio of actual load per rated load is 95%
Intermittent sound Flashing Off Off
or over.
Ratio of actual load per rated load is 100%
Continuous sound Flashing Off Off
or over.
Boom cylinder is in the stroke end range. Stop Off Flashing Off
Load sling is in the collision range with the
Stop Off Off Flashing
bucket.

• LCD alarm operation conditions list

LCD
Alarm operation condition
Indication item Indication style
Actual load Continuous
Ratio of actual load per rated load is lower than 95%.
Rated load Continuous
Actual load Flashing
Ratio of actual load per rated load is 95% or over.
Rated load Continuous
Actual load Flashing
Ratio of actual load per rated load is 100% or over.
Rated load Flashing
Boom cylinder is in the stroke end range. Selected data Continuous
Load sling is in the collision range with the bucket. Selected data Continuous

1-5
 SAFETY DEVICE FUNCTIONS AND OPERATION
Stroke End Indicator
When the boom cylinder is extended to near the stroke
end, red stroke end indicator (8) flashes to emit the
alarm.

Hook Collision Indicator

8
When the hook comes close to the bucket, red hook 4
collision indicator (7) flashes to emit the alarm.
7

Offset Indicator (Operates only when the machine is

equipped with an offset front attachment.)

CAUTION: Never perform crane work with the

6
boom offset; it is very dangerous. Failure to obey
may cause the machine to overturn.

When the machine with the offset front attachment is

operated in the offset position with crane switch (4) ON, M131-01-001

red offset indicator (6) flashes to emit the alarm. Never

perform crane work with the boom offset.

1-6
 SAFETY DEVICE FUNCTIONS AND OPERATION
ANGLE SENSOR

Two angle sensors are provided on the machine. One is a

boom angle sensor to monitor the boom motion. The other
is an arm angle sensor to monitor the arm motion. Based Link
on the information from each angle sensor, the real-time
hook position is calculated.

Boom Angle Sensor

Is located on the boom right side pin.

IMPORTANT: If the link is broken, the bolt is lost, or

wire harness is disconnected, the boom
angle cannot be monitored.
Boom Angle Sensor
M131-01-005

Arm Angle Sensor

Is located on the arm left side pin.

IMPORTANT: If the link is broken, the bolt is lost, or

wire harness is disconnected, the arm
angle cannot be monitored.

Link

BOOM PRESSURE SENSOR

The boom pressure sensors are installed on the boom cyl- Arm Angle Sensor
inder to check the oil pressure in both the rod and bottom M131-01-006
sides of the boom cylinder.
Boom Pressure Sensor
IMPORTANT: If the boom pressure sensor harness is
broken or incompletely connected, the
boom load cannot be detected. Before
operating the machine, check the sen-
sor harness for breakage and discon-
nection.

M131-01-017

1-7
 SAFETY DEVICE FUNCTIONS AND OPERATION
FREE FALL PREVENTION VALVE

Two free fall prevention valves are provided on the ma-

chine. The boom free fall prevention valve prevents the
boom from free falling. The arm free fall prevention valve
prevents the arm from free falling. Even if the hydraulic
hose breaks during crane work, when the operator returns
the control lever to neutral, the valve prevents the lifted
load from free falling.

CAUTION: Even if the free fall prevention valve

is provided, the lifted load may fall due to oil leak
in the valve. Do not hold the front attachment or
the lifted load above the ground for a long time.

If hydraulic oil is sprayed from the boom and/or

arm cylinder hose or a hose breaks during crane
work, be sure to return the control lever to neu-
tral. Failure to do so allows the front attachment
to free-fall, possibly creating a hazardous situa-
tion. Boom Free Fall Prevention Valve

Boom Free Fall Prevention Valve

Is located on the bottom side of the boom cylinder.

M131-01-008

Arm Free Fall Prevention Valve Arm Free Fall Prevention Valve

Is located on the rod side of the arm cylinder.

M131-01-009

1-8
 SAFETY DEVICE FUNCTIONS AND OPERATION
BUCKET LOCK VALVE

The bucket lock valve is located inside the cover in the

rear of the cab. When the crane switch is turned ON, the
bucket lock valve restricts the bucket rolling out motion,
preventing occurrence of mis-operation in crane work.

IMPORTANT: Before starting crane work, fully extend

the bucket cylinder. Then, turn the crane
switch ON. If crane work is performed
without extending the bucket cylinder
full stroke, the hook may come in con-
tact with the bucket, possibly causing
the hook collision alarm to malfunction
or damage to the hook.
Bucket Lock Valve
M131-01-015

HOOK (LINK STORED TYPE)

The hook can be stored in link (A) connecting the bucket

cylinder to the bucket.
Before performing crane work, take out the hook. When
performing excavation work, store the hook. The hook is
equipped with a latch to prevent a lifting tool from coming
Link A
off.

Crane work
Before performing crane work, take the hook out of the
link as illustrated to the right.

Excavation work
M131-01-011
CAUTION: If excavation work is performed Lock Pin
Link A
without storing the hook, the hook may come in
contact with the bucket, possibly resulting in
damage to the hook swivel joint pin. If lifting load Ring Pin
work is performed with the damaged hook swivel
joint pin, the lifted load may fall, possibly result-
ing in personal injury or death. Hook

As illustrated to right, before performing excavation work,

store the hook inside the link and secure the hook with a
lock pin and a ring pin.

IMPORTANT: During excavation work, use care not to

pack the hook stored space inside link
(A) with soil. M131-01-010

1-9
 SAFETY DEVICE FUNCTIONS AND OPERATION
LEVEL

The level is located under the right control lever. The level
indicates the machine inclination (in both lengthwise and
sideways). Use the level when setting the machine for
performing crane work.

NOTE: One scale on the level corresponds to approx.

0.5 degrees.

Level

M131-01-012

EXTERNAL CRANE MODE INDICATOR

External Crane Mode Indicator
The external crane mode indicator is located at the top of
the counterweight. Before performing crane work, when
the crane switch on the monitor panel is turned ON, the
external crane mode indicator comes ON, advising people
around the machine that the machine is performing crane
work.

M131-01-013

1-10
 OPERATION
TAKING OUT/IN HOOK (LINK STORED TYPE)

When performing excavation works other than crane

works or when transporting the machine, store the hook in
the link. When performing crane work, take out the hook
by following the procedure below.

CAUTION: If excavation work is performed

without storing the hook, the hook may come in
contact with the bucket, possibly resulting in
damage to the hook and/or the swivel joint pin. If
lifting load work is performed with the damaged
hook and/or the swivel joint pin, the lifted load
may fall, possibly resulting in personal injury or
death.

Taking out the hook:

Remove ring pin (1). Move lock pin (2) to the right side. 1 2
Take out the hook. Reinstall lock pin (2) and ring pin (1)
to the original positions so that they are not lost.

Hook

M131-01-010

Storing the hook:

Remove ring pin (1). Move lock pin (2) to the right side.
Install the hook in the link. Install lock pin (2) in the hook.
Secure the lock pin with ring pin (1).

2-1
 OPERATION
PRECAUTIONS FOR CRANE OPERATION

Perform crane work safely by following the instruction be-

low.

• To activate the overload alarm device, press the

crane switch on the monitor panel to turn it ON. Never
attempt to operate the machine in the working range
in which the overload alarm device is activated.

CAUTION: When the lifted load exceeds 95% of

the maximum rated load, an intermittent
pre-warning sound is emitted. If the lifted load
exceeds 100% of the maximum rated load, a con-
tinuous alarm sound is emitted.

• During load lifting work, sudden working

speed change may be very hazardous. Be sure
to turn the auto-idle switch and
auto-accelerator selector OFF.
• Check that the footing under the machine is
level and solid.
• Before operating the machine, check that all
safety devices (such as the overload alarm de-
vice and the hook latch) correctly operate. If
any failure is found, do not operate the ma-
chine. Immediately consult your nearest Hi-
tachi dealer for repair.
• After displaying and checking the working po-
sition by pressing the display selector on the
monitor panel, press the switch again to reset
the monitor to the load display screen.
• Never perform lifting load work with the front
attachment offset (only the offset front at-
tachment).
• Do not operate the machine in such a working
position as the hook comes in contact with the
bucket. When the hook enters the range in
which the hook collides the bucket, the hook
collision indicator flashes.
• Avoid abrupt control lever operation. The over-
load alarm device calculates the lifting load
value according to the oil pressure in the boom
cylinder. If the control lever is abruptly
operated, the calculation value is widely
changed.
• Avoid diagonal load lifting, or sideways load
pull.

2-2
 OPERATION
• When the boom cylinder is extended too close
to the stroke end, error in the actual load cal-
culation will increase. When the stroke end in-
dicator starts flashing, do not operate the ma-
chine in this working range.
• Whenever leaving the operator’s seat, be sure
to lower the lifting load on the ground and stop
the engine. Do not stop the engine while hold-
ing a load above the ground. When required to
stay off the operator’s seat for a long time,
lower the front attachment on the ground.
• Be careful that when the working position dis-
play mode is selected, the working position
below the ground level is displayed with only
the actual depth value. Minus mark (-) to indi-
cate the depth below the ground level is not
shown on the screen.
• The arm free fall prevention valve is installed
only on the arm cylinder rod side. When crane
work is done with the arm rolled in toward the
cab more than vertical line, the oil pressure on
the arm cylinder bottom side increases. Avoid
performing crane work in this position. (Refer
to the working range diagram in the Specifica-
tion section.)

2-3
 OPERATION
CRANE OPERATION PROCEDURE 1

When operating the machine as a crane, follow the pro-

cedure described below.

1. Setting the machine

After confirming safety in the surrounding area, set
the machine on solid level ground using level (1) lo-
cating in the cab.

NOTE: One scale on the level corresponds to approx.

0.5 degrees.

2. Taking out the hook

Remove ring pin (2). Move lock pin (4) to the right to M131-01-012

take out the hook. Install the lock pin (4) and ring pin
(2) in the original positions to prevent them from 2 3 4
missing. Check the hook, ring pin (2), spring pin (3),
and lock pin (4) for any damage or deformation.

M131-01-010
3. Positioning the machine for crane work
Fully extend the bucket cylinder so that the bucket is
fully rolled in. When the machine is equipped with an
offset type front attachment, be sure not to operate
the machine with the front attachment being offset.
IMPORTANT: Before performing crane work, turn the
crane switch ON only after fully extend-
ing the bucket cylinder. Unless the
bucket cylinder is fully extended, when
crane work is performed, the hook may
come in contact with the bucket, possi-
bly resulting in damage to the hook col-
lision alarm system and/or the hook.
M131-01-007

2-4
 OPERATION

CAUTION: Be sure to turn crane switch (5) ON

before starting crane work. Unless crane switch
(5) is turned ON, all safety devices are deacti-
vated, possibly creating very hazardous situa-
tions.
During load lifting work, sudden working speed
change may be very hazardous. Be sure to turn
auto-idle / auto-accelerator selector switch (6)
OFF.
Never turn crane switch (5) OFF during crane 5
operation.

4. Crane switch operation

Turn crane switch (5) on the monitor panel to activate
the overload alarm device. At the same time, the ex-
ternal crane mode indicator comes ON, reducing the
engine speed down to the speed appropriate to
crane work [Engine speed: 1500 min-1 (1500 rpm) or M131-01-001
slower]

Perform crane work under this condition.

T178-01-01-002

2-5
 OPERATION
5. Shifting the display of load and position
Each time display selector (7) on the monitor panel is 8
pressed, the display on LCD (8) is shifted as shown
in the table below.
Upper column Lower column 7
display display
Load value Actual load (t) Rated load (t)
Working position Working radius (m) Height (m) 5

Types of alarms
If the machine is overloaded or the machine is in a haz-
ardous working position, the alarm signals are emitted
by flashing the indicators and LCD (8), and sounding the
buzzer.

CAUTION: In case the alarm is emitted when Working Posi- Alarm Indicator M131-01-001

tion
lifting a load, change the load lifting position or
reduce the load value. When the alarm is emitted
due to collision of the hook with the bucket, de-
activate the alarm system by operating the boom
or arm control lever to change the load lifting po-
sition. When the boom cylinder stroke end alarm
is emitted, lower the boom by operating the
boom control lever. The load display calculation
accuracy becomes inferior when the boom cyl-
inder is operated near the stroke end.

Corrective measures to be taken when the alarm is emitted:

Type of alarm
Alarming information Corrective measure
LCD Buzzer Indicator
Actual load value: Continuous Alarm indicator Actual load is Very dangerous situation. Immediately
Flashing sound comes ON. exceeding the rated lower the lifting load. Reduce the work-
Rated load value: load. ing radius or load.
Flashing
Actual load value: Intermittent Alarm indicator Actual load is 95% to Move the lifting load close to the ma-
Flashing sound flashes. under 100 % of the chine until the buzzer stops sounding.
rated load.
Continuous actual Silent Working position The hook is in con- Roll-in the arm or lower the boom until
load value display alarm indicator tact with the bucket. the working position alarm indicator goes
flashes. OFF.
Continuous rated The boom cylinder is Accurate load calculation is difficult at
load value display fully extended. the boom cylinder stroke end. Lower the
boom until the working position alarm
indicator goes OFF.

2-6
 MAINTENANCE
MAINTENANCE

Check and service the following points to thoroughly utilize

machine performance.

1. Check all controls and instruments for any abnormal-

ity.
2. Check the machine appearance and sounds for any
abnormality.
3. Check mounting nuts and bolts for looseness.
4. Check parts for breakage, wear, or missing.
5. Check all motions for abnormality.
If any abnormality is found during inspection or operation,
immediately trace the cause of the problem and repair it.
In case it is difficult for you to trace the cause of the prob-
lem, consult your nearest Hitachi dealer.

Precautions for Maintenance

IMPORTANT: Never disassemble the electronic part
(Controller).

• Pay extra caution to safety.

• Perform maintenance matching the conditions and
circumstances of the machine operation.
• Use recommended lubricants.
• Use only genuine Hitachi parts.
• Do not spray water or steam to electrical parts (in-
cluding sensors, and connectors). Do not clean the
cab inside with water and/or steam.
• Never disassemble the electronic part (Controller).
• Do not modify the machine without authorization.
• Hitachi Warranty Policy does not cover machine fail-
ure due to using of unspecified parts or incorrect op-
eration of the machine.

3-1
 MAINTENANCE
LEGAL INSPECTION

As specified in the Crane Safety Rule, performing pre-start

inspection and monthly and annually periodic voluntary
inspection of the crane section is mandatory. Conduct
these inspections together with periodic voluntary inspec-
tion for the standard hydraulic excavator.

Crane Sections Inspection Items

on
nn
ua
Inspection Item Note Page

thl
e-
st
Interval
1 Check boom and arm angle sensor operation ○ 3-3
Check free fall prevention valve and bucket lock valve for any oil 3-4
2 ○
leaks, abnormal noise and damage
Check boom cylinder pressure sensor for any oil leaks and dam- 3-5
3 ○
age
4 Check hydraulic pipe and hose lines for any oil leaks and damage ○ 3-5
Check that all safety signs and other signs are correctly installed 3-6
5 ○
undamaged
6 Check operation of external crane mode indicator ○ 3-6
Check angle and pressure sensor harnesses for damage and fail-
7 ○ 3-7
ure in connection
Check link, hook and pins for any incomplete installation, damage 3-8
8 ○
and insufficient lubrication
Hook section

9 Check link, hook and pins for wear ○ 3-8

10 Check hook for cracks, deformation and damage ○ 3-8
11 Check latch of hook for malfunction and damage ○ 3-8
12 Check that hook is correctly stored in position ○ 3-8
13 Check monitor panel for damage and incorrect installation ○ 3-9
Monitor panel

Check wire harness and connectors for any damage and incom- 3-9
14 ○
plete connection
15 Check alarm buzzer for malfunction ○ 3-9
Check working position display and actual load display for mal- 3-10
16 ○
function
17 Perform loading test ○ 3-12
Loading test

18 Perform stability test ○ 3-12

3-2
 MAINTENANCE

Check Boom and Arm Angle Sensor Operation

--- daily before starting
1. After turning crane switch (2) ON, check that no error
code is displayed on the LCD.
2. Shift the LCD screen to the position display by press- 1
ing display selector (1).
3. While operating the boom, check the variation of the
2
displayed boom angle sensor output value.
4. Shift the LCD screen to the load display by pressing
display selector (1). While operating the arm, check
the variation of the displayed load value.

M131-01-001

3-3
 MAINTENANCE

Check Free Fall Prevention Valve and Bucket Boom Free Fall Prevention Valve
Lock Valve for Any Oil Leaks, Abnormal Noise
and Damage
--- daily before starting
The free fall prevention valve is provided in the boom
and arm cylinder circuits. Bucket lock valve (1) is lo-
cated inside the left cover behind the cab.

1. Visually check the valve unit, and connections of the

adapters, pipes, and hoses for any oil leaks and
damage.
2. Check if the boom and the arm operate normally
without emitting an abnormal sound. M131-01-008

Arm Free Fall Prevention Valve

M131-01-009

ZAXIS110, 110-E, 120, 120-E, 130K

M131-01-015

3-4
 MAINTENANCE

Check Boom Cylinder Pressure Sensor for Any 1

Oil Leaks and Damage
--- daily before starting
Cylinder bottom side pressure sensor (1) is installed on
the boom free fall prevention valve. Cylinder rod side
pressure sensor (2) is installed in the hydraulic pipe line
to the boom cylinder. Visually check the sensors for any
oil leaks and damage.

M131-01-008

M131-01-017

Check Hydraulic Pipe and Hose Lines for Any

Oil Leaks and Damage
--- daily before starting
Visually check the hydraulic pipe and hose lines to the
cylinder free fall prevention valves and bucket lock valve
(3) for any oil leaks and damage.

3
ZAXIS110, 110-E, 120, 120-E, 130K

M131-01-015

3-5
 MAINTENANCE

Check that All Safety Signs and Other Signs

1
are Correctly Installed Undamaged --- monthly
Visually check that the safety signs and other signs (1)
of which installation are mandatory, for any damage.
Refer to page S-11 and after for safety signs and other
signs.

SS-2183

Check Operation of External Crane Mode Indi- 2

cator --- daily before starting
Check external crane mode indicator (orange color) (2)
comes ON when the crane switch on the monitor panel
is pressed.

M131-01-013

3-6
 MAINTENANCE

Check Angle and Pressure Sensor Harnesses

for Damage and Failure in Connection ---
monthly
Check the harnesses for any damage. Check all har-
ness connectors for incomplete connection.

Wire Harness Connector

M131-01-005

1. Boom angle sensor (3) is located on the boom right

side pin. After removing the cover, visually check link
4
(4) for breakage or bending, for bolts missing, and
harness for integrity.

ZAXIS110, 110-E, 120, 120-E, 130K

M131-01-005

2. Arm angle sensor (5) is located in the arm left side

cover. After removing the cover, visually check link
(6) for breakage or bending, for bolts missing, and
harness for integrity.

5 M131-01-006

3-7
 MAINTENANCE
1 2 3 4
Check Link (5), Hook (2) and Pins (1, 3, and 4)
for Any Incomplete Installation, Damage and
Insufficient Lubrication
--- daily before starting

Check Link (5), Hook (2) and Pins (1, 3, and 4)

for Wear --- annually Lubrication (5 places) M131-01-010

Check Hook (2) for Cracks, Deformation and

Damage --- daily before starting
M131-03-001

Check Latch (6) of Hook (2) for Malfunction

and Damage --- monthly

Check that Hook (2) is Correctly Stored in Po-

sition --- daily before starting

3-8
 MAINTENANCE

Check Monitor Panel for Damage and Incorrect

Installation
--- daily before starting
Check if monitor panel (1) is not damaged and the
mounting bracket is securely installed.
1

Check Wire Harness and Connectors for Any

Damage and Incomplete Connection
--- monthly M131-03-002

Check if the wire harness and connectors for monitor

panel (1) are not damaged or completely connected.

Check Alarm Buzzer for Malfunction

--- daily before starting
As illustrated to right, roll the arm in and extend the
boom close to the stroke end. When the boom cylinder
is extended close to the stroke end, the displayed actual
load value increases. When the boom cylinder hydraulic
pressure is relieved, the actual load exceeds the maxi-
mum rated load, sounding the buzzer continuously and
flashing the alarm indicator on the monitor panel and the Boom cylinder
extended close to
LCD. the stroke end

M131-03-006

3-9
 MAINTENANCE

Check Working Position Display and Actual 3

Load Display for Malfunction
--- monthly
Display of Working Position
1. Fully roll the bucket in (fully extend the bucket cylin-
der).
2. Turn crane switch (1) on the monitor panel ON. 2

3. Press display selector (2) on the monitor panel to

shift LCD (3) display to the “Working Position” dis-
play. 1

4. Fully extend the bucket cylinder, fully retract the arm

cylinder, and lower the bucket on the ground, then,
check the displayed working position values.

Specification:
Working Position Value
Machine Model
Working Radius Height
ZAXIS 110, 110-E 6.4 to 6.8 m 0.3 to 0.7 m M131-01-001

ZAXIS 120, 120-E, 130K 6.9 to 7.3 m 0.3 to 0.7 m

Working Radius
ZAXIS 160LC 7.4 to 7.8 m 0.3 to 0.7 m
ZAXIS 200, 200-E, 210K 8.4 to 8.8 m 0.3 to 0.7 m

NOTE: In case the correct working position values are

not indicated, consult your nearest Hitachi
dealer.

Height
Rest on the Ground
M131-03-007

3-10
 MAINTENANCE
Display of Load Value 3

NOTE: When the boom cylinder is extended too close

to the stroke end, the correct load value cannot
be measured as the cushion device is installed
in the cylinder. Do not measure the load value
with the boom cylinder fully extended.
2
If any residual pressure is remaining in the cyl-
inder, the displayed load value may vary. In
case this situation occurs, slowly lower the 1
boom to release the remaining pressure from
the boom cylinder circuit.

1. Fully roll the bucket in (fully extend the bucket cylin-

der) without lifting a load.
2. Turn crane switch (1) on the monitor panel ON.
3. Press display selector (2) on the monitor panel to
shift LCD (3) display to the “Lifting Value” display.
M131-01-001
4. As illustrated to right, while slowly operating the
boom and arm, check the displayed load value at 1
m-interval in the working radius. In case the dis-
played load value exceeds the specifications, slowly
lower the boom to allow the residual pressure to re-
lease. Then, recheck the displayed load value.
Specification (standard) value = 0 to 0.2 t

NOTE: After the bucket and/or the arm are reinforced,

the front attachment weight increases. There-
fore, the displayed load value increases by the
reinforced weight. In case the displayed load 1m 1m
value is outside the specifications, consult your
nearest Hitachi dealer. M131-03-004

3-11
 MAINTENANCE

Perform Loading Test --- annually

Consult your nearest Hitachi dealer.

Perform Stability Test --- annually

Consult your nearest Hitachi dealer.

3-12
 TROUBLESHOOTING
TROUBLESHOOTING

When any abnormality is found with the machine, take

immediate corrective measures. Check the cause of the
trouble and prevent reoccurrence of the same trouble. If
tracing the trouble cause is difficult, or any corrective
measures shown with mark (∗) are required, consult your
nearest Hitachi dealer. Never adjust, disassemble, or re-
pair the hydraulic components, and/or electric/electronic
parts.

Front Attachment

Symptom Cause Solution

Only rolling out of the bucket is in- The crane switch is in the ON position. Turn the crane switch OFF.
operable. (During excavation)
＊
The bucket is rolled out. Malfunction of the bucket lock valve Repair or replace
＊
(During crane work) Broken harness between the bucket lock Repair or replace
valve and the controller
Faulty controller ＊
Replace
The crane switch is in the OFF position. Turn the crane switch ON.
＊
The boom or arm automatically de- Damaged cylinder seals Repair or replace
scends. Malfunction of free fall prevention valve ＊
Repair or replace
＊
External oil leaks Replace seals or repair
＊
Lifting or lowering load operation is Malfunction of free fall prevention valve Repair or replace
not smoothly started. Power is insuf- Unsuitable operating oil pressure ＊
Adjust
ficient. Faulty control valve ＊
Repair or replace
The crane hydraulic circuit selector (crane Turn the crane switch ON.
switch) is in the OFF position.

External Crane Mode Indicator

Symptom Cause Solution

＊
The external crane mode indicator Broken harness between the indicator and Repair or replace
(orange color) does not come ON. the controller ＊
Replace
Faulty controller ＊
Replace
Faulty indicator

4-1
 TROUBLESHOOTING
Error Codes
If any abnormality occurs in a safety device, the LCD on
the monitor panel displays the corresponding error code.
In case any error code shown in the table below is dis-
played on the LCD, consult your nearest Hitachi dealer.

Example of Error Code Display

M131-01-019

Error Code List

Abnormality Error code During crane work

Incomplete sensor initialization 000 Flashing
Faulty offset angle sensor (Machines with offset front attachment) 002 Flashing
Faulty boom angle sensor 003 Flashing
Faulty arm angle sensor 004 Flashing
Faulty boom cylinder bottom pressure sensor 005 Flashing
Faulty boom cylinder rod pressure sensor 006 Flashing
Abnormal memory data in EEPROM 007 Flashing
No normal data is delivered for a specified period of time
011 Lightening
(Overload alarm device original function)
No data is delivered for a specified period of time
012 Lightening
(Overload alarm device original function)
Normal data or any data is not delivered for a specified period of time
013 Lightening
(Overload alarm device original function)
Abnormal installation of the boom angle sensor 080 Flashing
Abnormal installation of the arm angle sensor 081 Flashing
Faulty boom angle sensor 083 Flashing
Faulty arm angle sensor 084 Flashing
Abnormal memory data in EEPROM 087 Flashing
Failure in turning Key Off 088 Flashing
Accomplished overload alarm device initialization 111 

4-2
 SPECIFICATIONS
WORKING RANGES

ZAXIS 110, 110-E

[With Standard 2.26 m arm and 0.45 m3 bucket (corresponding new JIS)]

Unit：mm

Perform crane work

in this range only
Rear-end Swing
Radius

M131-05-001

5-1
 SPECIFICATIONS
RATED LOAD

ZAXIS 110, 110-E

[With Standard 2.26 m arm and 0.45 m3 bucket (corresponding new JIS)]

Working Radius (m) Rated Load (t)

6.7 1.0
6.5 1.0
6.0 1.1
5.5 1.3
5.0 1.6
4.5 1.9
4.0 2.3
3.5 2.8
3.4 or less 2.9

Rated Load W (t)

Working Radius R (m)

M131-05-004

NOTE: The rated loads shown above correspond to

the stationary loads to be measured on solid
level ground, satisfying the value of 78% or
less than machine overturning load and the
forward direction stability of 1.15 specified in
the Mobile Crane Construction Standard.

5-2
 SPECIFICATIONS
WORKING RANGES

ZAXIS 120, 120-E, 130K

[With Standard 2.25 m arm and 0.50 m3 bucket (corresponding new JIS)]

Unit：mm

Perform crane work Rear-end Swing

in this range only Radius

M131-05-002

5-3
 SPECIFICATIONS
RATED LOAD

ZAXIS 120, 120-E, 130K

[With Standard 2.25 m arm and 0.50 m3 bucket (corresponding new JIS)]

Working Radius (m) Rated Load (t)

7.2 1.1
7.0 1.1
6.5 1.2
6.0 1.3
5.5 1.3
5.0 1.9
4.5 2.3
4.0 2.8
3.9 or less 2.9

Rated Load W (t)

Working Radius R (m)

M131-05-005

NOTE: The rated loads shown above correspond

to the stationary loads to be measured on
solid level ground, satisfying the value of
78% or less than machine overturning load
and the forward direction stability of 1.15
specified in the Mobile Crane Construction
Standard.

5-4
 SPECIFICATIONS
WORKING RANGES

ZAXIS 160LC
[With Standard 2.60 m arm and 0.60 m3 bucket (corresponding new JIS)]

Unit：mm
7600
5680
350

Perform crane work

in this range only

2440
Rear-end Swing
Radius
5190

2780

1000
3100
3920
4830

2830
4010

M131-05-007

5-5
 SPECIFICATIONS
RATED LOAD

ZAXIS 160LC
[With Standard 2.60 m arm and 0.60 m3 bucket (corresponding new JIS)]

Working Radius (m) Rated Load (t)

7.6 1.3
7.5 1.3
7.0 1.5
6.5 1.6
6.0 1.9
5.5 2.2
5.0 2.5
4.6 or less 2.9

Rated Load W (t)

Working Radius R (m)

M131-05-008

NOTE: The rated loads shown above correspond

to the stationary loads to be measured on
solid level ground, satisfying the value of
78% or less than machine overturning load
and the forward direction stability of 1.15
specified in the Mobile Crane Construction
Standard.

5-6
 SPECIFICATIONS
WORKING RANGES

ZAXIS 200, 200-E, 210K

[With Standard 2.91 m arm and 0.80 m3 bucket (corresponding new JIS)]

Unit：mm

Perform crane work

in this range only

Rear-end Swing
Radius

M131-05-003

5-7
 SPECIFICATIONS
RATED LOAD

ZAXIS 200, 200-E, 210K

[With Standard 2.91 m arm and 0.80 m3 bucket (corresponding new JIS)]

Working Radius (m) Rated Load (t)

8.7 1.7
8.5 1.7
8.0 1.8
7.5 2.0
7.0 2.2
6.5 2.5
6.0 or less 2.9

Rated Load W (t)

Working Radius R (m)

M131-05-006

NOTE: The rated loads shown above correspond

to the stationary loads to be measured on
solid level ground, satisfying the value of
78% or less than machine overturning load
and the forward direction stability of 1.15
specified in the Mobile Crane Construction
Standard.

5-8
 INDEX
A Crane Switch.................................................. 1-4
Alarm Indicator ...................................................1-5
Angle Sensor .......................................................1-7
Appoint Signal Person ........................................ S-3
Avoid Abrupt Operation ...................................... S-7
Avoid Fast Speed Swing..................................... S-7
Avoid Operating Machine on Slopes .................. S-7
Avoid Operation on Soft Ground ........................ S-8
Avoid Overloading .............................................. S-5
Avoid Pulling Loads Sideways
and/or Diagonally ............................................ S-8
Avoid Traveling with Suspended Loads ............. S-7
B
Boom Pressure Sensor........................................1-7
Bucket Lock Valve ...............................................1-9
C
Components Name..............................................1-1
Check Alarm Buzzer for Malfunction ...................3-9
Check Angle and Pressure Sensor
Harnesses for Damage
and Failure in Connection ............................3-7
Check Boom and Arm
Angle Sensor Operation...............................3-3
Check Boom Cylinder Pressure Sensor
for Any Oil Leaks and Damage ....................3-5
Check Free Fall Prevention Valve
and Bucket Lock Valve for Any Oil Leaks,
Abnormal Noise and Damage......................3-4
Check Hook (2) for Cracks, Deformation
and Damage.................................................3-8
Check Hydraulic Pipe and Hose Lines
for Any Oil Leaks and Damage ....................3-5
Check Latch (6) of Hook (2) for Malfunction
and Damage.................................................3-8
Check Link (5), Hook (2) and Pins
(1, 3, and 4) for Wear...................................3-8
Check Link (5), Hook (2) and Pins (1, 3, and 4)
for Any Incomplete Installation,
Damage and Insufficient Lubrication ...........3-8
Check Monitor Panel for Damage
and Incorrect Installation..............................3-9
Check Operation of External
Crane Mode Indicator ..................................3-6
Check that All Safety Signs and Other Signs
are Correctly Installed Undamaged .............3-6
Check that Hook (2) is Correctly Stored
in Position.....................................................3-8
Check Wire Harness and Connectors
for Any Damage and
Incomplete Connection ................................3-9
Check Working Position Display
and Actual Load Display for Malfunction ...3-10
Crane Operation Procedure ................................2-4
Crane Switch Indicator ...................................1-4
6-1
D
Display Selector .................................................. 1-4
Do Not Leave Machine in Operation...................S-8
During Storing .....................................................S-9
E
External Crane Mode Indicator ......................... 1-10
F
Follow Safety Instructions ...................................S-2
Free Fall Prevention Valve.................................. 1-8
H
Hook (Link Stored Type) ..................................... 1-9
Hook Collision Indicator ...................................... 1-6
I
Inspect Machine Daily Before Starting................S-3
Investigate Job Site Beforehand .........................S-4
L
LCD ..................................................................... 1-4
Legal Inspection .................................................. 3-2
Level ................................................................ 1-10
M
Maintenance........................................................ 3-1
Monitor Panel ...................................................... 1-3
N
Never Allow Anyone to Ride Hook or Load.........S-6
O
Offset Indicator .................................................... 1-6
Operator’s Qualification.......................................S-2
P
Perform Loading Test........................................ 3-12
Perform Stability Test ........................................ 3-12
Precautions for After Completing Operation .......S-9
Precautions for Crane Operation ........................ 2-2
Precautions for Lifting Load ................................S-6
Precautions for Starting Operation......................S-3
Precautions for Strong Wind ...............................S-6
R
Rated Load
ZAXIS110,110-E ........................................... 5-2
Rated Load
ZAXIS120,120-E,130K.................................. 5-4
Rated Load
ZAXIS160LC ................................................. 5-6
Rated Load
ZAXIS200,200-E,210K.................................. 5-8
 INDEX
Recognize Safety Information ............................ S-1

S
Safety Device Functions and Operation ..............1-2
Safety Device is Not Absolute ............................ S-5
Safety Singns.................................................... S-11
Stroke End Indicator ............................................1-6

T
Taking Out/In Hook (Link Stored Type) ...............2-1
Troubleshooting ...................................................4-1

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

W
Working Ranges
ZAXIS110,110-E............................................5-1
Working Ranges
ZAXIS120,120-E,130K ..................................5-3
Working Ranges
ZAXIS160LC..................................................5-5
Working Ranges
ZAXIS200,200-E,210K ..................................5-7

6-2
 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.