HITACHI ZAXIS ZX 27U 30U 35U 40U 50U Excavator Operators Manual

INTRODUCTION © 2003 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 equipment 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. SI Units (International System of Units) are used in this manual. For reference MKS system units and English units are also indicated in parentheses after the SI units. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) 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. 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 MODEL/TYPE: PRODUCT IDENTIFICATION NUMBER: PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER: NOTE: HCM1LA00000005001 PRODUCT IDENTIFICATION NUMBER (PIN) M589-01-001 M570-07-009 Marks to indicate the start and end of the PIN

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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 Use Handholds and Steps................................... S-4 Adjust the Operator’s Seat .................................. S-4 Fasten Your Seat Belt ......................................... S-5 Move and Operate Machine Safely ..................... S-5 Operate Only from Operator’s Seat .................... S-6 Jump Starting ...................................................... S-6 Keep Riders Off Machine .................................... S-6 Investigate Job Site Beforehand ......................... S-7 Protect Against Falling Stones and Debris .......... S-7 Provide Signals for Jobs Involving Multiple Numbers of Machines ...................... S-8 Confirm Direction of Machine to be Driven ......... S-8 Drive Machine Safely........................................... S-9 Avoid Injury from Rollaway Accidents ............... S-10 Avoid Injury from Back-Over and Swing Accidents ................................... S-11 Keep Person Clear from Working Area............. S-12 Never Position Bucket Over Anyone ................. S-12 Avoid Undercutting ............................................ S-12 Avoid Tipping..................................................... S-13 Never Undercut a High Bank............................. S-13 Dig with Caution ................................................ S-14 Operate with Caution......................................... S-14 Avoid Power Lines ............................................. S-14 Do Not Use for Craning Operation .................... S-15 Protect Against Flying Debris ............................ S-15 Park Machine Safely ......................................... S-15 Handle Fluids Safely – Avoid Fires.................... S-16 Safety Transporting ........................................... S-17 Practice Safe Maintenance ............................... S-18 Support Machine Properly ................................. S-19 Stay Clear of Moving Parts ................................ S-19 Warn Others of Service Work ........................... 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 Avoid Harmful Asbestos Dust ........................... 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 Pedals and Levers ............................................... 1-2 Monitor Panel and Switch Panel .......................... 1-3 Key Switch ........................................................... 1-4 Work Light Switch ................................................ 1-4 Monitor Panel ....................................................... 1-5 Alternator Indicator .............................................. 1-5 Engine Oil Pressure Indicator .............................. 1-5 Preheat Indicator ................................................. 1-6 Coolant Temperature Gauge and Overheat Indicator .................................. 1-6 Fuel Gauge and Fuel Level Indicator ................... 1-7 Hour Meter ........................................................... 1-7 Cab Heater (Optional unit for the cab-equipped machine) ........................................................ 1-8 Wiper/Washer Switch (Only on cab-equipped machines) ...................................................... 1-8 Opening and Closing Front Window (Only on cab-equipped machines) ........................ 1-9 Air Conditioner Operation (Optional unit for cab-equipped machines) ........................ 1-10 Cooling Operation .............................................. 1-11 Tips For Optimal Air Conditioner Usage ............ 1-12 Emergency Exit (Only on cab-equipped machines) .................................................... 1-13 Tool Box and Operator’s Manual Box ................ 1-14 Cab Door Release Lever (Only on cab- equipped machines) .................................... 1-14 Cab Light............................................................ 1-14 Adjusting the Operator’s Seat ............................ 1-15 Seat Belt ............................................................ 1-16 BREAK-IN Breaking in a New Machine ................................. 2-1 Correct Break-In Procedures ............................... 2-1 OPERATING THE ENGINE Before Starting Engine......................................... 3-1 Engine Speed Control Lever ................................ 3-1 Starting the Engine .............................................. 3-2 Check Instruments after Starting ......................... 3-2 Using Booster Batteries ....................................... 3-3 Stopping the Engine............................................. 3-4 DRIVING THE MACHINE Travel Levers ....................................................... 4-1 Fast Speed Travel Pedal ..................................... 4-2

CONTENTS Traveling.............................................................. 4-3 Operating on Soft Ground ................................... 4-4 Raise One Track Using Boom and Arm .............. 4-4 Towing Machine a Short Distance....................... 4-5 Operating in Water or Mud .................................. 4-6 Precautions for Traveling on Slopes ................... 4-7 Parking and Stopping on a Slope ........................ 4-8 Parking the Machine............................................ 4-8 OPERATING THE MACHINE Control Lever (ISO Excavator Pattern)................ 5-1 Control Lever (HITACHI Pattern) --- If Equipped ............................................... 5-2 Control Lever (SAE-Backhoe Pattern) --- If Equipped ............................................... 5-3 Control Lever Pattern Conversion --- If Equipped ............................................... 5-4 Boom-Swing Pedal ............................................ 5-5 Optional Pedal ..................................................... 5-6 Blade Lever ......................................................... 5-8 Pilot Control Shut-Off Lever ................................ 5-9 Warming Up Operation ..................................... 5-11 Warming Up in Cold Weather ........................... 5-11 Precautions for Operations ............................... 5-12 Avoid Tipping..................................................... 5-13 Operating Backhoe............................................ 5-14 Grading Operation ............................................. 5-15 Avoid Abusive Operation ................................... 5-15 Select Correct Track Shoes .............................. 5-16 Operating Tips ................................................... 5-16 Object Handling --- If Equipped ......................... 5-17 Avoid Hitting Blade with Front Attachment ........ 5-18 Avoid Hitting Blade with Bucket ......................... 5-18 Avoid Striking Blade into a Rock ....................... 5-18 Boom Cylinder May Hit Track............................ 5-19 Precautions for Installing Wide Bucket or Special Type Bucket ............................... 5-19 Operate the Machine Safely .............................. 5-20 Using Rubber Crawler ....................................... 5-21 Traveling and Other Cautions ........................... 5-22 Emergency Stop Procedure to Lower Front Attachment .............................. 5-23 Hydraulic Breaker Operating Tips --- Optional .................................................. 5-25 Replacement of Hydraulic Oil and Filter Element ....................................... 5-27 Operating Hydraulic Crusher --- If Equipped ..... 5-28 After Finishing Work .......................................... 5-29 TRANSPORTING Transporting by Road .......................................... 6-1 Transporting the Machine by Truck ..................... 6-1 Precautions for Transporting Machines with Rubber Tracks ....................................... 6-3 Lifting the Entire Machine with a Crane Using Eye Plates on Boom and Blade .......... 6-5 MAINTENANCE Correct Maintenance and Inspection Procedures ... 7-1 Service Your Machine at Specified Intervals ....... 7-2 Check the Hour Meter Regularly ......................... 7-2 Prepare Machine for Maintenance....................... 7-3 Hood and Access Covers .................................... 7-4 Daily Inspection.................................................... 7-9 Daily Inspection Check List ................................ 7-10 Periodic Replacement of Parts .......................... 7-11 Maintenance Guide............................................ 7-12 The Brand Names of Recommended Oils and Lubricants ...................................... 7-14 A. Greasing ...................................................... 7-15 Front Joint Pins ............................................ 7-15 Bucket and Link Pins ................................... 7-17 Blade Pins.................................................... 7-17 Precautions for Front Attachment and Blade Removal ....................................... 7-17 Swing Bearing.............................................. 7-18 Swing Internal Gear ..................................... 7-19 Control Lever Universal Joint....................... 7-20 B. Engine.......................................................... 7-21 Engine Oil Level........................................... 7-21 Change Engine Oil....................................... 7-22 Replace Engine Oil Filter ............................. 7-22 C. Transmission ............................................... 7-24 D. Hydraulic System ......................................... 7-26 Inspection and Maintenance of Hydraulic Equipment .............................. 7-26 Check Hydraulic Oil Level............................ 7-27 Drain Hydraulic Oil Tank Sump ................... 7-28 Change Hydraulic Oil ................................... 7-29 Clean Suction Filter ..................................... 7-29 Replace Hydraulic Oil Tank Filter ................ 7-34 Replace Pilot Filter....................................... 7-36 Check Hoses and Lines............................... 7-38 Service Recommendations for Hydraulic Fittings ................................... 7-42 E. Fuel System................................................. 7-45 Drain Fuel Tank Sump................................. 7-46 Check Water Separator ............................... 7-47 Replace Fuel Filter....................................... 7-48 Check Fuel Hoses ....................................... 7-49 F. Air Cleaner ................................................... 7-50 Clean the Air Cleaner Element .................... 7-50 Replace the Air Cleaner Element ................ 7-50 G. Cooling System............................................ 7-51 Check Coolant Level ................................... 7-52 Check and Adjust Fan Belt Tension ............ 7-53 Change Coolant ........................................... 7-54 Clean Radiator ............................................. 7-55 H. Electrical System ......................................... 7-56 Replacing Fuses .......................................... 7-58 Electrical Socket .......................................... 7-59 I. Miscellaneous .............................................. 7-60 Check Bucket Teeth .................................... 7-60

CONTENTS Replace Bucket ........................................... 7-62 Adjusting Bucket Linkage............................ 7-63 Check Track Sag (rubber crawler) .............. 7-64 Replace Rubber Track ................................ 7-66 Check Track Sag (steel crawler) ................. 7-67 Check and Replace Seat Belt ..................... 7-70 Check Fuel Injection Nozzles ...................... 7-70 Check and Adjust Valve Clearance............. 7-70 Check Injection Timing................................ 7-71 Measure Engine Compression Pressure .... 7-71 Check Starter and Alternator....................... 7-71 Check Radiator Cap .................................... 7-71 Check Tightening Torque of Bolts and Nuts ....................................... 7-72 Often-Replaced Parts ........................................ 7-75 Maintenance Under Special Environmental Conditions ........................... 7-76 STORAGE Storing the Machine .......................................... 10-1 Removing the Machine From Storage .............. 10-2 TROUBLESHOOTING Troubleshooting................................................. 11-1 SPECIFICATIONS Specifications .................................................... 12-1 Working Ranges................................................ 12-6 Shoe Types and Applications .......................... 12-11 Bucket Types and Applications ....................... 12-16 Special Specification (Option) ......................... 12-20 INDEX ............................................................. 14-1

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SAFETY S-1 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 injury. • Follow recommended precautions and safe operating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious 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. 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 SA-1223

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HITACHI ZAXIS ZX 27U 30U 35U 40U 50U Excavator Operators Manual

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