HITACHI ZAXIS 120 180 200 225 270 330 Class Excavator Operator Manual

INTRODUCTION ©2004 Hitachi Construction Machinery Co., Ltd. All rights reserved. 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: 0 m to 2000 m (0 ft 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. 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. Prior to operating this machine in a country other than a country of its intended use, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of that particular country. Please do not operate this machine outside of the country of its intended use until such compliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized distributor or dealer if you have any questions concerning compliance. Hitachi machine models are classified into 7 classes and 2 models as shown in the table below. When referring to the texts and/or illustrations indicated with the applicable machine class names in this manual, check that the machine models concerned are included using this table. Class ZX120 Class ZAXIS110, 110M, 120, 130H, 130K, 130L ZX180 Class ZAXIS160LC, 180LC, 180LCN ZX200 Class ZAXIS200, 200LC, 210H, 210LCH, 210K, 210LCK, ZX225 Class ZAXIS225USR, 225USRLC, 225USRK, 225USRLCK ZX270 Class ZAXIS230, 230LC, 240H, 240LCH, 240K, 240LCK, 270, 270LC ZX330 Class ZAXIS330, 330LC, 350H, 350LCH, 370MTH, 350K, 350LCK Model Std. Model ZAXIS110, 110M, 120, 130H, 160LC, 180LC, 180LCN, 200, 200LC, 210H, 210LCH, 225USR, 225USRLC, 230, 230LC, 240H, 240LCH, 270, 270LC, 330, 330LC, 350H, 350LCH, 370MTH K Model ZAXIS130K, 210K, 210LCK, 225USRK, 225USRLCK, 240K, 240LCK 350K, 350LCK L Model ZAXIS130L 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.

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 SS3097499 1. MODEL/TYPE 2. Product Identification Number 3. Year of Manufacturing 4. Operating mass (standard version) 5. Engine power in kW according to ISO9249 PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER: NOTE: !HCM1G600L00100001! PRODUCT IDENTIFICATION NUMBER (PIN) ENGINE TYPE: MFG. NO.: M157-00-001 M157-12-008 M175-00-001 M178-00-001 M1HH-07-001 Marks to indicate the start and end of the PIN Serial Number Engine Type ZX120, 180 class ZX200, 225, 270 class ZX330 class

MACHINE NUMBERS TRAVEL MOTOR TYPE: MFG. NO.: SWING MOTOR TYPE: MFG. NO.: M178-07-047 M175-00-002 M178-07-014 M1HH-07-002 ZX120, 180 class ZX200, 225, 270 class ZX330 class

MACHINE NUMBERS HYDRAULIC PUMP TYPE: MFG. NO.: M175-00-003 M1F1-00-001 M157-00-004 M1HH-07-003 ZX120 class ZX180 calss ZX200, 225, 270 class ZX330 class

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CONTENTS MACHINE NUMBERS SAFETY Recognize Safety Information ............................. S-1 Understand Signal Words ................................... S-1 Follow Safety Instructions ................................... S-2 Prepare for Emergencies .................................... S-2 Wear Protective Clothing .................................... S-3 Protect Against Noise .......................................... S-3 Inspect Machine .................................................. S-3 General Precautions for Cab............................... S-4 Use Handholds and Steps................................... S-5 Adjust the Operator’s Seat .................................. S-5 Fasten Your Seat Belt ......................................... S-6 Move and Operate Machine Safely ..................... S-6 Handle Starting Aids Safely................................. S-6 Operate Only from Operator’s Seat .................... S-7 Jump Starting ...................................................... S-7 Keep Riders Off Machine .................................... S-7 Investigate Job Site Beforehand ......................... S-8 Protect Against Falling Stones and Debris .......... S-8 Provide Signals for Jobs Involving Multiple Numbers of Machines ................................... S-9 Confirm Direction of Machine to be Driven ......... S-9 Drive Machine Safely......................................... S-10 Avoid Injury from Rollaway Accidents ............... S-11 Avoid Injury from Back-Over and Swing Accidents ................................... S-12 Keep Person Clear from Working Area............. S-13 Never Position Bucket Over Anyone ................. S-13 Avoid Undercutting ............................................ S-13 Avoid Tipping..................................................... S-14 Never Undercut a High Bank............................. S-14 Dig with Caution ................................................ S-15 Operate with Caution......................................... S-15 Avoid Power Lines ............................................. S-15 Object Handling ................................................. S-16 Protect Against Flying Debris ............................ S-16 Park Machine Safely ......................................... S-17 Handle Fluids Safely ! Avoid Fires.................... S-17 Practice Safe Maintenance ............................... S-18 Warn Others of Service Work ........................... S-19 Support Machine Properly ................................. S-19 Stay Clear of Moving Parts ................................ S-19 Prevent Parts from Flying ................................ S-20 Store Attachments Safely.................................. S-20 Prevent Burns.................................................... S-21 Replace Rubber Hoses Periodically .................. S-21 Avoid High-Pressure Fluids ............................... S-22 Prevent Fires ..................................................... S-23 Evacuating in Case of Fire ................................ S-24 Beware of Exhaust Fumes ................................ S-24 Precautions for Welding and Grinding .............. S-25 Avoid Heating Near Pressurized Fluid Lines ..... S-26 Avoid Applying Heat to Lines Containing Flammable Fluids ........................................ S-26 Remove Paint Before Welding or Heating ........ S-26 Prevent Battery Explosions ............................... S-27 Service Air Conditioning System Safely............ S-27 Handle Chemical Products Safely .................... S-28 Dispose of Waste Properly ............................... S-28 SAFETY SIGNS ................................... S-29 COMPONENTS NAME .......................... 1-1 OPERATOR’S STATION Cab Features ....................................................... 1-2 Monitor Panel ....................................................... 1-4 Coolant Temperature Gauge ....................... 1-5 Fuel Gauge .................................................. 1-5 Auto-Idle Indicator.......................................... 1-5 Auto-Acceleration Indicator ........................... 1-5 Fuel Level Indicator ....................................... 1-6 Air Filter Restriction Indicator ........................ 1-6 Overheat Indicator ......................................... 1-6 Engine Oil Pressure Indicator ........................ 1-6 Alternator Indicator ........................................ 1-7 Preheat Indicator ........................................... 1-7 Hydraulic Oil Filter Restriction Indicator (K Model) ................................................. 1-7 Liquid Crystal Display (LCD), Display Selection Switch, Set Switch ................... 1-8 Hour Meter ..................................................... 1-8 Trip Meter (Trip Meter 1 and Trip Meter 2) .... 1-9 Engine Speed ................................................ 1-9 Hydraulic Oil Temperature............................. 1-9 Trip Meter Function ..................................... 1-10 Work Mode Switch ...................................... 1-12 Switch Panel .................................................... 1-13 Engine Control Dial ...................................... 1-13 Auto-Idle/Acceleration Selector ................... 1-14 Power Mode Switch ..................................... 1-15 Travel Mode Switch ..................................... 1-15 Work Light Switch........................................ 1-16 Wiper/Washer Switch .................................. 1-17 Switch Panel (Optional) ..................................... 1-20 Key Switch ......................................................... 1-21 Power Boost Switch ........................................... 1-21 Horn Switch........................................................ 1-21 Cigar Lighter ...................................................... 1-22 Cab Light............................................................ 1-23 Installing Fire Extinguisher ................................. 1-23 Pilot Control Shut-Off Lever ............................... 1-24 Engine Stop Knob .............................................. 1-24 Fuse Box............................................................ 1-25 Auto Air Conditioner (Optional) .......................... 1-26 Cab Heater Operation........................................ 1-29 Cooling Operation .............................................. 1-30 Defroster Operation ........................................... 1-30 Tips for Optimal Air Conditioner Usage ............. 1-31 Auto Air Conditioner (Optional) .......................... 1-32

CONTENTS Cab Heater Operation ....................................... 1-36 Cooling Operation ............................................. 1-37 Defroster Operation........................................... 1-37 Tips for Optimal Air Conditioner Usage............. 1-39 Cab Heater (Optional) ....................................... 1-40 Cab Heater Operation ....................................... 1-41 Defroster Operation........................................... 1-42 AM/FM Radio Operation.................................... 1-43 Digital Clock Setting Procedure......................... 1-44 AM/FM Radio Operation.................................... 1-45 Digital Clock Setting Procedure......................... 1-46 Cab Door Release Lever ................................... 1-47 Opening Upper Front Window........................... 1-47 Closing Upper Front Window ............................ 1-48 Removing and Storing Lower Front Window .............................................. 1-49 Opening Side Windows ..................................... 1-50 Opening/Closing Overhead Window ................. 1-51 Emergency Exit ................................................. 1-52 Adjusting the Seat ............................................. 1-53 Adjusting Console Height .................................. 1-57 Seat Belt ............................................................ 1-58 BREAK-IN Observe Engine Operation Closely ..................... 2-1 Every 8 Hours or Daily......................................... 2-1 After the First 50 Hours ....................................... 2-1 After the First 100 Hours ..................................... 2-1 OPERATING THE ENGINE Inspect Machine Daily Before Starting ................ 3-1 Before Starting Engine ........................................ 3-2 Starting The Engine in Ordinary Temperature .... 3-3 Starting in Cold Weather ..................................... 3-4 Check Instruments After Starting ........................ 3-5 Using Booster Batteries....................................... 3-6 Stopping the Engine ............................................ 3-8 DRIVING THE MACHINE Drive the Machine Carefully ................................ 4-1 Steering the Machine Using Pedals .................... 4-2 Steering the Machine Using Levers .................... 4-3 Travel Mode Switch ............................................. 4-4 Travel Alarm (Optional) ....................................... 4-4 Traveling.............................................................. 4-5 Operating on Soft Ground ................................... 4-6 Raise One Track Using Boom and Arm .............. 4-6 Towing Machine a Short Distance....................... 4-7 Operating in Water or Mud .................................. 4-8 Precautions for Traveling on Slopes ................... 4-9 Parking the Machine on Slopes......................... 4-10 Parking the Machine.......................................... 4-10 OPERATING THE MACHINE Control Lever (ISO Pattern) ............................... 5-1 Control Lever (HITACHI Pattern) ...................... 5-2 Attachment Pedal (Breaker) ................................ 5-3 Attachment Pedal (Hydraulic Crusher) ................ 5-4 Pilot Control Shut-Off Lever ................................. 5-5 Engine Speed Control .......................................... 5-8 Auto-Idle............................................................... 5-9 Auto Acceleration............................................... 5-10 Work Mode ........................................................ 5-12 Power Boost....................................................... 5-12 Power Mode ....................................................... 5-13 Precautions for Operation Using a Bucket ........ 5-14 Precaustions for Operations .............................. 5-15 Operate the Machine Safely .............................. 5-16 Operating Backhoe ............................................ 5-17 Grading Operation ............................................. 5-17 Face Shovel Operation ...................................... 5-18 Avoid Abusive Operation ................................... 5-18 Operating Tips ................................................... 5-19 Select Correct Track Shoes............................... 5-19 Hydraulic Breaker and Hydraulic Crusher.......... 5-20 Pipings for Breaker and Crusher ....................... 5-21 Secondary Relief Pressure Adjustment ............. 5-23 Precautions for Breaker Operation .................... 5-24 Breaker Maintenance......................................... 5-27 Precautions for Crusher Operation .................... 5-28 Attachment......................................................... 5-30 Attachment Connection Parts ............................ 5-35 Precaution for Arm Roll-In/Bucket Roll-In Combined Operation .................................. 5-36 When Installing an Attachment Longer than Standard Bucket .................................. 5-36 Shackle Hole Usage .......................................... 5-37 Overnight Storage Instructions .......................... 5-37 Emergency Boom Lowering Procedure ............. 5-38 Object Handling --- If Equipped ......................... 5-42 TRANSPORTING Transporting by Road .......................................... 6-1 Loading/Unloading on a Trailer ............................ 6-1 Machine Lifting Procedure ................................... 6-5 MAINTENANCE Correct Maintenance and Inspection Procedures ............................ 7-1 Check the Hour Meter Regularly ......................... 7-2 Use Correct Fuels and Lubricants ....................... 7-2 Layout ................................................................. 7-3 Maintenance Guide Table.................................... 7-4 Prepare Machine for Maintenance....................... 7-6 Hood and Access Covers (ZX120, 180 Class)........................................ 7-7 Hood and Access Covers (ZX200, 225, 270, 330 Class)........................ 7-8 Periodic Replacement of Parts ............................ 7-9 Maintenance Guide............................................ 7-10 A. Greasing .................................................... 7-15 Front Joint Pins ............................................ 7-15

CONTENTS Swing Bearing ............................................. 7-18 Swing Internal Gear .................................... 7-19 Lubricator .................................................... 7-20 B. Engine ......................................................... 7-22 Engine Oil Level .......................................... 7-22 Change Engine Oil ...................................... 7-23 Replace Engine Oil Filter ............................ 7-23 C. Transmission ............................................. 7-25 Pump Transmission .................................... 7-25 Swing Reduction Gear ................................ 7-26 Travel Reduction Gear ................................ 7-27 D. Hydraulic System ........................................ 7-29 Inspection and Maintenance of Hydraulic Equipment ......................... 7-29 Replacement of Hydraulic Oil and Filter...... 7-31 Check Hydraulic Oil Level ........................... 7-32 Drain Hydraulic Tank Sump ........................ 7-33 Change Hydraulic Oil .................................. 7-34 Suction Filter Cleaning ................................ 7-34 Replace Full-Flow Filter .............................. 7-37 Replace Full-Flow Filter (K/L Model) ........... 7-38 Replace Pilot Oil Filter ................................. 7-39 Replace Air Breather Element..................... 7-41 Check Hoses and Lines .............................. 7-42 Service Recommendations for Hydraulic Fittings................................... 7-45 E. Fuel System ................................................ 7-47 Drain Fuel Tank Sump ................................ 7-49 Check Water Separator .............................. 7-50 Replace Fuel Filter ...................................... 7-53 Clean Feed Pump Strainer.......................... 7-54 Check Fuel Hoses ....................................... 7-55 F. Air Cleaner .................................................. 7-56 Clean the Air Cleaner Outer Element.......... 7-56 Replace the Air Cleaner Outer and Inner Elements ............................... 7-56 G. Cooling System ........................................... 7-59 Check Coolant Level ................................... 7-61 Check and Adjust Fan Belt Tension............ 7-62 Change Coolant .......................................... 7-63 Clean Radiator Interior ................................ 7-63 Clean Radiator, Oil Cooler Core and Inter Cooler .................................... 7-64 Clean Oil Cooler Front Screen .................... 7-64 Clean Air Conditioner Condenser ............... 7-64 Clean Inter Cooler Front Screen ................. 7-64 H. Electrical System ....................................... 7-65 Batteries ...................................................... 7-65 Replacing Fuses ......................................... 7-69 Additional Fuse Box (Optional) ................... 7-70 I. Miscellaneous ............................................ 7-71 Check Bucket Teeth.................................... 7-71 Change Bucket .......................................... 7-75 Convert Bucket Connection Into Face Shovel .......................................... 7-76 Adjust the Bucket Linkage .......................... 7-77 Remove the Travel Levers .......................... 7-78 Check and Replace Seat Belt .................... 7-78 Check Windshield Washer Fluid Level ........ 7-79 Check Track Sag ......................................... 7-80 Adjust Track Sag ......................................... 7-80 Loosen the Track ......................................... 7-81 Tighten the Track......................................... 7-81 Clean and Replace Air Conditioner Filter....................................................... 7-82 Check the Air Conditioner ............................ 7-84 Clean Cab Floor........................................... 7-85 Check Injection Nozzle ................................ 7-86 Retighten Cylinder Head Bolt ...................... 7-86 Inspect and Adjust Valve Clearance............ 7-86 Check Fuel Injection Timing ........................ 7-86 Measure Engine Compression Pressure ................................................ 7-86 Check Starter and Alternator ....................... 7-86 Change Water Pump Grease ...................... 7-86 Check Tightening Torque of Bolts and Nuts ................................................ 7-87 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions .............................. 9-1 STORAGE Storing the Machine ........................................... 10-1 Removing the Machine from Storage ................ 10-2 TROUBLESHOOTING Engine ............................................................... 11-1 Electrical System ............................................... 11-6 Mode Selection .................................................. 11-8 Control Levers ................................................... 11-9 Hydraulic System ............................................... 11-9 SPECIFICATIONS ZAXIS110, 110M Specifications ............................................. 12-1 Working Ranges .......................................... 12-2 Shoe Types and Applications ...................... 12-3 Bucket Types and Applications .................................... 12-4 ZAXIS120, 130H Specifications ............................................. 12-5 Working Ranges .......................................... 12-6 Shoe Types and Applications ...................... 12-7 Bucket Types and Applications ................... 12-8 ZAXIS130K Specifications ............................................. 12-9 Working Ranges ........................................ 12-10 Shoe Types and Applications .................... 12-11 Bucket Types and Applications ................. 12-12

HITACHI ZAXIS 120 180 200 225 270 330 Class Excavator Operator Manual

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