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HITACHI ZAXIS 225USR-3 CLASS EXCAVATOR Service Repair Manual

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The document is a comprehensive safety manual for operating and maintaining a machine, detailing essential protocols for safe operation, emergency preparedness, and proper equipment usage. It includes guidelines for daily inspections, appropriate clothing, and the handling of potential hazards, equipped with safety symbols and terminology. Additionally, it emphasizes the importance of following safety instructions and manufacturer recommendations to prevent personal injury and equipment damage.

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                        
INTRODUCTION IN-01 ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog • The Engine Manual • Parts Catalog of the Engine • Hitachi Training Material MANUAL COMPOSITION This manual consists of three portions: the Techni- cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man- ual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems. • Information included in the Technical Manual (Troubleshooting): technical information needed for operational per- formance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assem- ble/disassemble procedures. PAGE NUMBER Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual
INTRODUCTION IN-02 SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts.  CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.  NOTE: Indicates supplementary technical information or know-how. UNITS USED SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees. Quantity To Convert From Into Multiply By MPa kgf/cm 2 10.197Pressure MPa psi 145.0 kW PS 1.360Power kW HP 1.341 Temperature C F C1.8+32 km/h mph 0.6214Velocity min -1 rpm 1.0 Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0 Quantity To Convert From Into Multiply By mm in 0.03937Length mm ft 0.003281 L US gal 0.2642 L US qt 1.057 Volume m 3 yd 3 1.308 Weight kg lb 2.205 N kgf 0.10197Force N lbf 0.2248 N m kgf m 1.0197Torque N m lbf ft 0.7375
SAFETY SA-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 per- sonal injury. • Follow recommended precautions and safe oper- ating 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 desig- nated signal words above after the safety alert symbol are occasionally used on this machine. To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indi- cates 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
SAFETY SA-2 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 replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your author- ized dealer in the same way you order other re- placement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly 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 ma- chine life. • Do not modify any machine parts without au- thorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addi- tion, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attach- ments and/or optional parts or equipment will void Hitachi Warranty Policy. The safety messages in this SAFETY chapter are intended 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 au- thorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003 SA-003
SAFETY SA-3 PREPARE FOR EMERGENCIES Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label at- tached on the fire extinguisher to use it properly. • To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambu- lance service, hospital, and fire department posted near your telephone. 004-E01A-0437 SA-437 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. • Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Operating equipment safely requires the full atten- tion of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438 SA-428
SAFETY SA-4 PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause im- pairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objec- tionable or uncomfortably loud noises. 006-E01A-0434 SA-434 INSPECT MACHINE Inspect your machine carefully each day or shift by walking around it before you start it to avoid per- sonal injury. • In the walk-around inspection be sure to cover all points described in the "RE-START INSPEC- TION" chapter in the operator's manual. 007-E01A-0435 SA-435
SAFETY SA-5 GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator's work boots the operator's foot may slip off the pedal, possibly resulting in a personal accident. • Do not leave parts and/or tools lying around the operator's seat. Store them in their specified loca- tions. • Avoid storing transparent bottles in the cab. Do not attach any transparent type window decora- tions on the windowpanes as they may focus sunlight, possibly starting a fire. • Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. • Keep all flammable objects and/or explosives away from the machine. • After using the ashtray, always cover it to extin- guish the match and/or tobacco. • Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000
SAFETY SA-6 USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. 008-E01A-0439 SA-439 ADJUST THE OPERATOR'S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to mis-operations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. • Adjust the rear view mirror position so that the best rear visibility is obtained from the operator's seat. If the mirror is broken, immediately replace it with a new one. 009-E01A-0462 SA-462
SAFETY SA-7 ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR'S SEAT Before rising from the operator's seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the ma- chine to unexpectedly move when a body part un- intentionally comes in contact with a control lever, possibly resulting in serious personal injury or death. • Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK posi- tion. Turn the key switch OFF to stop the engine. • Before leaving the machine, close all windows, doors, and access covers and lock them up. FASTEN YOUR SEAT BELT If the machine should overturn, the operator may become injured and/or thrown from the cab. Addi- tionally the operator may be crushed by the over- turning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly ex- amine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt se- curely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. We recommend that the seat belt be replaced every three years regardless of its apparent con- dition. 010-E01A-0237 SA-237
SAFETY SA-8 MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. • Take extra care not to run over bystanders. Con- firm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coor- dinate hand signals before starting the machine. • Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it. 011-E01A-0398 SA-426 HANDLE STARTING AIDS SAFELY Starting fluid: Starting fluid is highly flammable. • Keep all sparks and flame away when using it. • Keep starting fluid well away from batteries and cables. • Remove container from machine if engine does not need starting fluid. • To prevent accidental discharge when storing a pressurized container, keep the cap on the con- tainer, and store it in a cool, well-protected loca- tion. • Do not incinerate or puncture a starting fluid con- tainer. 036-E01A-0293-3 SA-293
SAFETY SA-9 OPERATE ONLY FROM OPERATOR'S SEAT Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in seri- ous injury or death. • Start the engine only when seated in the opera- tor's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. • Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders. 012-E01B-0431 SA-444 JUMP STARTING Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the "OPERATING THE ENGINE" chapter in the operator's manual. • The operator must be in the operator's seat so that the machine will be under control when the engine starts. Jump starting is a two-person op- eration. • Never use a frozen battery. • Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. S013-E01A-0032 SA-032
SAFETY SA-10 KEEP RIDERS OFF MACHINE Riders on machine are subject to injury such as be- ing struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner. 014-E01B-0427 SA-379 PRECAUTIONS FOR OPERATIONS Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine. • Clear all persons and obstacles from area of op- eration and machine movement. Always beware of the surroundings while operat- ing. When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles. • When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person. M104-05-015
SAFETY SA-11 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 condi- tions 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. • Reinforce ground, edges, and road shoulders as necessary. 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. • Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist. • When the footing is weak, reinforce the ground before starting work. • When working on frozen ground, be extremely alert. As ambient temperatures rise, footing be- comes loose and slippery. • Beware the possibility of fire when operating the machine near flammable objects such as dry grass. Make sure the worksite has sufficient strength to firmly support the machine. When working close to an excavation or at road shoulders, operate the machine with the tracks po- sitioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses. If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area. Soft ground may collapse when operating the ma- chine on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine. Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes: • Reduce the engine speed. • Select slow travel speed mode. • Operate the machine slowly and be cautious with machine movements. SA-380
SAFETY SA-12 EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the poten- tial hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure SA-490 PROVIDE SIGNALS FOR JOBS INVOLV- ING MULTIPLE NUMBERS OF MACHINES For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person's directions. 018-E01A-0481 SA-481 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal/lever operation may result in serious injury death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator's position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. 017-E01A-0491 SA-491
SAFETY SA-13 DRIVE MACHINE SAFELY Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the di- rection you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don't allow personnel to stay around the machine while traveling. Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • Never attempt to ascend or descend 35 degrees or steeper slopes. • Be sure to fasten the seat belt. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop. SA-657 SA-658 SA-441 SA-442
SAFETY SA-14 DRIVE MACHINE SAFELY • Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the ma- chine to level ground, then, change the direction to ensure safe operation. • Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure down- hill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed. • If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control lev- ers to neutral. Then, restart the engine. • Be sure to thoroughly warm up the machine be- fore ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained. • Use a signal person when moving, swinging or operating the machine in congested areas. Coor- dinate hand signals before starting the machine. • Before moving machine, determine which way to move travel pedals/levers for the direction you want to go. When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers. An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction. • Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction. • Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if nec- essary. M104-05-008 M178-03-001 Travel Motor Arrow-Mark
SAFETY SA-15 • Use wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer. • When crossing train tracks, use wood plates in order not to damage them. • Do not make contact with electric wires or bridges. • When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller. • When traveling on rough terrain, reduce engine speed. Select slow travel speed. Slower speed will reduce possible damage to the machine. • Avoid operations that may damage the track and undercarriage components. • During freezing weather, always clean snow and ice from track shoes before loading and unloading machine, to prevent the machine from slipping. SA-011
SAFETY SA-16 AVOID INJURY FROM ROLLAWAY ACCI- DENTS Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park ma- chine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Turn the auto-idle switch and the H/P mode switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK posi- tion. • Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines. 020-E02A-0493 SA-391 SA-392
SAFETY SA-17 AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOV- ING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and mark- ings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator's manual. 021-E01A-0494 SA-383 SA-384
SAFETY SA-18 KEEP PERSON CLEAR FROM WORKING AREA A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and machine movement. • Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area. 022-E01A-0386 SA-386 NEVER POSITION BUCKET OVER ANY- ONE Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket. 023-E01A-0487 SA-487 AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the footing should collapse, always position the un- dercarriage perpendicular to the edge of the exca- vation with the travel motors at the rear. • If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases. 024-E01A-0488 SA-488
SAFETY SA-19 AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING IN- JURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when oper- ating on a grade, possibly resulting in serious injury or death. To avoid tipping: Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine. • Reduce operating speeds to avoid tipping or slip- ping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is un- avoidable. • Reduce swing speed as necessary when swing- ing loads. Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E03B-0463 SA-012 SA-440 NEVER UNDERCUT A HIGH BANK The edges could collapse or a land slide could occur causing serious injury or death. 026-E01A-0519 SA-489
SAFETY SA-20 DIG WITH CAUTION Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines. • If a fiber optic cable should be accidentally sev- ered, do not look into the end. Doing so may re- sult in serious eye injury. • Contact your local "diggers hot line" if available in your area, and/or the utility companies directly. Have them mark all underground utilities. 027-E01A-0382 SA-382 OPERATE WITH CAUTION If the front attachment or any other part of the ma- chine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well. • Take care to avoid hitting overhead obstacles with the boom or arm. 028-E01A-0389 SA-389
SAFETY SA-21 AVOID POWER LINES Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. 029-E01A-0381 SA-381 PRECAUTIONS FOR LIGHTENING The machine is vulnerable to lighting strikes. • In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. • After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the ma- chine only after repairing them. SA-1088 OBJECT HANDLING If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed under- neath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the travel motors at the rear. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0132 SA-014
SAFETY SA-22 PROTECT AGAINST FLYING DEBRIS If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. 031-E01A-0432 SA-432 PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch OFF. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull the pilot control shut-off lever to the LOCK position. • Close windows, roof vent, and cab door. • Lock all access doors and compartments. SA-390 HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possi- bly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the ma- chine. • Fill the fuel tank outdoors. All fuels, most lubricants, and some coolants are flammable. • Store flammable fluids well away from fire haz- ards. • Do not incinerate or puncture pressurized con- tainers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten the fuel and oil filler cap. 034-E01A-0496 SA-018 SA-019
SAFETY SA-23 TRANSPORT SAFELY Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the ma- chine to be transported. • Be sure to use a signal person. • Always follow the following precautions for load- ing or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Turn auto-idle switch OFF. 4. Always select the slow speed mode with the travel mode switch. 5. Never load or unload the machine onto or off a truck or trailer using the front attachment func- tions when driving up or down the ramp. 6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, repo- sition the machine on the ground, and then try loading again. 7. The top end of the ramp where it meets the flat- bed is a sudden bump. Take care when traveling over it. 8. Place blocks in front of and behind the tracks. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANSPORTING section in the operator's manual. 035-E07A-0454 SA-395
SAFETY SA-24 PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a "Do Not Operate" tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. 500-E02C-0520 SA-028 SA-527
SAFETY SA-25 • If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • If the machine must be raised, maintain a 90 to 100° angle between the boom and arm. Securely support any machine elements that must be raised for service work. • Inspect certain parts periodically and repair or re- place as necessary. Refer to the section discuss- ing that part in the "MAINTENANCE" chapter of this manual. • Keep all parts in good condition and properly in- stalled. • Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or de- bris. • When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. • Disconnect battery ground cable (-) before mak- ing adjustments to electrical systems or before performing welding on the machine. • Sufficiently illuminate the work site. Use a main- tenance work light when working under or inside the machine. • Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, anti- freeze fluid, or window washer fluid may catch fire. SA-037 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury. • Before performing any work on the machine, at- tach a "Do Not Operate" tag on the control lever. This tag is available from your authorized dealer. 501-E01A-0287 T1J1-01-01-001
SAFETY SA-26 SUPPORT MACHINE PROPERLY Never attempt to work on the machine without se- curing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attach- ment, securely support the machine or attach- ment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a ma- chine that is supported solely by a jack. 519-E01A-0527 SA-527 STAY CLEAR OF MOVING PARTS Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. 502-E01A-0026 SA-026
SAFETY SA-27 PREVENT PARTS FROM FLYING Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. • As pieces may fly off, be sure to keep body and face away from valve. • Never attempt to disassemble the track adjuster. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death. Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. • GEAR OIL is hot. Wait for GEAR OIL to cool, and then gradually loosen AIR RELEASE PLUG to release pressure. 503-E01B-0344 SA-344 STORE ATTACHMENTS SAFELY Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas. 504-E01A-0034 SA-034
SAFETY SA-28 PREVENT BURNS Hot spraying fluids: After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces: Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. • Wait for the oil and components to cool before starting any maintenance or inspection work. 505-E01B-0498 SA-039 SA-225 REPLACE RUBBER HOSES PERIODI- CALLY Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. • Periodically replace the rubber hoses. (See the page of "Periodic replacement of parts" in the operator's manual.) • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019 SA-019
SAFETY SA-29 AVOID HIGH-PRESSURE FLUIDS Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing se- rious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or gog- gles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. 507-E03A-0499 SA-031 SA-292 SA-044
SAFETY SA-30 PREVENT FIRES Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts: Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. • Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: Spilled fuel and oil, and trash, grease, debris, ac- cumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the ma- chine daily and by removing spilled or accumu- lated flammables immediately. Check Key Switch: If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to con- firm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019 Check Heat Shields: Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be re- paired or replaced before operating the machine. 508-E02A-0393 SA-019
SAFETY SA-31 EVACUATING IN CASE OF FIRE If a fire breaks out, evacuate the machine in the fol- lowing way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine. In an emergency, if the cab door or front window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method in the op- erator's manual. 18-E02B-0393 SA-393 SS-1510 BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016 SA-016 PRECAUTIONS FOR WELDING AND GRINDING Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. After finishing welding and grinding, recheck that there are no abnormalities such as the area sur- rounding the welded area still smoldering. 523-E01A-0818 SA-818
SAFETY SA-32 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. In- stall temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.. SA-030 AVOID APPLYING HEAT TO LINES CON- TAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030 REMOVE PAINT BEFORE WELDING OR HEATING Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. • Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 511-E01A-0029 SA-029
SAFETY SA-33 BEWARE OF ASBESTOS DUST Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Don't use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos. • Keep bystanders out of the work site during op- eration. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. SA-029 PREVENT BATTERY EXPLOSIONS Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hy- drometer. • Do not charge a frozen battery or start engine with frozen battery. There is fear of explosion. If battery electrolyte is frozen, wait until it is liquefied completely in an atmospheric temperature room. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals. Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01B-0032 SA-032
SAFETY SA-34 SERVICE AIR CONDITIONING SYSTEM SAFELY If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the con- tainer for proper use when handling the refriger- ant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405 SA-405 HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know ex- actly what the risks are and how to do the job safely. Then follow procedures and use recom- mended equipment. • See your authorized dealer for MSDS's (available only in English) on chemical products used with your machine. 515-E01A-0309 SA-309
SAFETY SA-35 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the en- vironment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Govern- ment regulations may require a certified air condi- tioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer. 516-E01A-0226 SA-226 BEFORE RETURNING THE MACHINE TO THE CUSTOMER After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced S517-E01A-0435 SA-435
SECTION AND GROUP CONTENTS WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Pilot Shut-Off Solenoid Valve Group 9 Signal Control Valve Group 10 4-Spool Solenoid Valve Unit Group 11 Engine SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Holding Valve
TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage) TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PER- FORMANCE TEST Group 1 Diagnosing Procedure Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test SECTION 5 TROUBLESHOOTING Group 1 General Group 2 Monitor Unit Group 3 Dr. ZX Group 4 e-Shovel Group 5 Component Layout Group 6 Troubleshooting A Group 7 Troubleshooting B Group 8 Electrical System Inspection
1V1W-1-1 SECTION 1 GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology........ W1-1-7 Group 2 Tightening Tightening Torque Specification (ZX200-3 class) .................................. W1-2-1 Tightening Torque Specification (ZX225US-3 class, 225USR-3 class) .. W1-2-2 Tightening Torque Specification (ZX240-3 class, 270-3 class) .............. W1-2-3 Torque Chart .......................................... W1-2-5 Piping Joint ............................................ W1-2-8 Periodic Replacement of Parts ............. W1-2-12 Group 3 Painting Painting.................................................. W1-3-1 Group 4 Bleeding Air from Hydraulic Oil Tank Bleeding Air from Hydraulic Oil Tank....... W1-4-1
1V1W-1-2 (Blank)
GENERAL / Precautions for Disassembling and Assembling W1-1-1 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Precautions for Disassembling and Assembling Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. Inspect the Machine Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.
GENERAL / Precautions for Disassembling and Assembling W1-1-2 Precautions for Assembling • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine. Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and instal- lation of the pump, swing motor, travel motor or cyl- inder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump hous- ing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine. Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the en- gine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug. Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.
GENERAL / Precautions for Disassembling and Assembling W1-1-3 Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each op- eration (never fully stroke the cylinders during ini- tial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydrau- lic oil level. • Stop the engine. Recheck hydraulic oil level. Re- plenish oil as necessary. M104-07-021
GENERAL / Precautions for Disassembling and Assembling W1-1-4 Floating Seal Precautions 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating. W105-03-05-019 W105-03-05-020 W110-03-05-004 a b b b aa a=b C A B IncorrectCorrect Incorrect Correct A B
GENERAL / Precautions for Disassembling and Assembling W1-1-5 Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 C (212 F). If unavoidably lifting a load with a temperature of 100 C (212 F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t dete- riorate with heat, sun light, or chemicals. W102-04-02-016 W105-04-01-008 W162-01-01-009 Correct Eyehole Lifting Method Incorrect Eyehole Lifting Method Bent Sling
GENERAL / Precautions for Disassembling and Assembling W1-1-6 CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may re- sult. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the ny- lon sling for any damage corresponding to exam- ples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years. Damaged Appearance W162-01-01-002 W162-01-01-003 W162-01-01-004 W162-01-01-005 W162-01-01-006 W162-01-01-007 W162-01-01-008 Broken Sewing Thread Scuffing Broken Sewing Thread Fuzz Broken Sewing Thread Separation of Belt Broken Sewing Thread Scuffing Scoring Broken Warp Fuzz
GENERAL / Precautions for Disassembling and Assembling W1-1-7 MAINTENANCE STANDARD TERMINOL- OGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. “Allowable Limit” 1. Normal machine performance cannot be accom- plished after exceeding this limit. 2. Repair or adjustment is impossible after exceed- ing this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allow- able Limit”.
GENERAL / Precautions for Disassembling and Assembling W1-1-8 (Blank)
GENERAL / Tightening W1-2-1 TIGHTENING TORQUE SPECIFICATIONS (ZX200-3 Class) Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) Engine cushion rubber mounting nut (Pump side) 18 4 27 400 (40) 1 Engine cushion rubber mounting nut (Fan Side) 14 4 22 180 (18) Engine bracket mounting bolt (Pump side) 16 8 24 270 (27) 2 Engine bracket mounting bolt (Fan side) 10 8 17 65 (6.5) 3 Hydraulic oil tank mounting bolt 20 4 30 550 (55) 4 Fuel tank mounting bolt 16 4 24 270 (27) Radiator mounting bolt (Upper Side) 16 4 24 210 (21) 5 Radiator mounting bolt (Lower Side) 16 3 24 210 (21) 6 Pump mounting bolt 10 8 17 65 (6.5) Control valve mounting bolt 16 4 24 210 (21) 7 Control valve bracket mounting bolt 16 4 24 270 (27) 8 Swing device mounting bolt 20 14 30 500 (50) 9 Swing motor mounting bolt 12 8 10 90 (9) 10 ORS fittings for hydraulic hoses and piping 17 19 22 27 32 36 41 25 30 40 95 140 180 210 (2.5) (3) (4) (95) (14) (18) (21) 11 Battery mounting nut 10 4 17 50 (5) Cab mounting nut 16 4 24 210 (21) Cab mounting anchor bolt 22 2 32 550 (55)12 Cab cushion rubber mounting bolt 12 8 19 110 (11) 6 10 10 (1) 8 13 10 17 50 (5) 13 Cover mounting bolt 12 19 90 (9) 13 10.3 to 12.4 (1.05 to 1.26) Flexible master coupling of piping 8 1/4-28UNF 4 pair 11 6 (0.6) 9 7 6 (0.6) 11 7 6 (0.6)Jubilee clamp of low pressure piping 4 8 6 (0.6) 14 T-bolt clamp of low pressure piping 9 10 6 (0.6) (Upperstructure) 20 37 30 510 (51) 15 Swing bearing mounting bolt (Undercarriage) 20 36 30 490 (49) 20 32 30 630 (63) Travel device mounting bolt 20 40 30 630 (63) Travel reduction device cover mounting bolt 14 12 22 180 (18) 20 40 30 550 (55) 16 Sprocket mounting bolt 20 48 30 550 (55) 17 Upper roller mounting bolt 16 16 24 270 (27) ZAXIS200-3, 210H-3, 210K-3 18 64 27 460 (46) 18 Lower roller mounting bolt ZAXIS200LC-3, 210LCH-3,210LCK-3 18 72 27 460 (46) ZAXIS200-3, 210H-3, 210K-3 20 368 27 804 (82) 19 Track shoe bolt ZAXIS200LC-3, 210LCH-3,210LCK-3 20 392 27 804 (82) ZAXIS200-3, 210H-3, 210K-3 18 8 27 500 (50) 20 Track guard mounting bolt ZAXIS200LC-3, 210LCH-3,210LCK-3 18 16 27 500 (50)
GENERAL / Tightening W1-2-2 TIGHTENING TORQUE SPECIFICATIONS (ZX225US-3 class, ZX225USR-3 Class) Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) Engine cushion rubber mounting nut (Pump side) 18 4 27 400 (40) 1 Engine cushion rubber mounting nut (Fan Side) 14 4 22 180 (18) Engine bracket mounting bolt (Pump side) 16 8 24 270 (27) 2 Engine bracket mounting bolt (Fan side) 10 8 17 65 (6.5) 3 Hydraulic oil tank mounting bolt 20 4 30 550 (55) 4 Fuel tank mounting bolt 16 4 24 270 (27) Radiator mounting bolt (Upper Side) 16 4 24 210 (21) 5 Radiator mounting bolt (Lower Side) 16 3 24 210 (21) 6 Pump mounting bolt 10 8 17 65 (6.5) Control valve mounting bolt 16 4 24 210 (21) 7 Control valve bracket mounting bolt 16 4 24 270 (27) 8 Swing device mounting bolt 20 14 30 500 (50) 9 Swing motor mounting bolt 12 8 10 90 (9) 10 ORS fittings for hydraulic hoses and piping 17 19 22 27 32 36 41 25 30 40 95 140 180 210 (2.5) (3) (4) (95) (14) (18) (21) 11 Battery mounting nut 10 2 17 50 (5) Cab mounting nut 16 4 24 210 (21) Cab mounting anchor bolt 22 2 32 550 (55)12 Cab cushion rubber mounting bolt 12 8 19 110 (11) 6 10 10 (1) 8 13 10 17 50 (5) 13 Cover mounting bolt 12 19 90 (9) 13 10.3 to 12.4 (1.05 to 1.26) Flexible master coupling of piping 8 1/4-28UNF 4 pair 11 6 (0.6)14 T-bolt clamp of low pressure piping 8 10 6 (0.6) (Upperstructure) 20 37 30 510 (51) 15 Swing bearing mounting bolt (Undercarriage) 20 36 30 490 (49) Travel device mounting bolt 20 32 30 630 (63) Travel reduction device cover mounting bolt 14 12 22 180 (18)16 Sprocket mounting bolt 20 40 30 550 (55) 17 Upper roller mounting bolt 16 16 24 270 (27) ZAXIS225US-3, 225US-3, 225USR-3 18 64 27 460 (46) 18 Lower roller mounting bolt ZAXIS225USLC-3,225USRLC-3,225USRLCK-3 18 72 27 460 (46) ZAXIS225US-3, 225US-3, 225USR-3 20 368 27 804 (82) 19 Track shoe bolt ZAXIS225USLC-3,225USRLC-3,225USRLCK-3 20 392 27 804 (82) ZAXIS225US-3, 225US-3, 225USR-3 18 8 27 500 (50) 20 Track guard mounting bolt ZAXIS225USLC-3,225USRLC-3,225USRLCK-3 18 16 27 500 (50)
GENERAL / Tightening W1-2-3 TIGHTENING TORQUE SPECIFICATIONS (ZX240-3 Class, ZX270-3 class) Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) ZX240-3 class 18 4 27 400 (40)Engine cushion rubber mounting bolt and nut (Pump side) ZX270-3 class 18 2 27 400 (40) ZX240-3 class 14 4 22 180 (18) 1 Engine cushion rubber mounting bolt and nut (Fan Side) ZX270-3 class 18 2 27 400 (40) ZX240-3 class 16 8 24 270 (27)Engine bracket mounting bolt (Pump side) ZX270-3 class 12 12 19 110 (11) ZX240-3 class 10 8 17 65 (6.5) 2 Engine bracket mounting bolt (Fan side) ZX270-3 class 12 6 19 110 (11) 3 Hydraulic oil tank mounting bolt 18 4 27 400 (40) 4 Fuel tank mounting bolt 20 4 30 550 (55) Radiator mounting bolt (Upper Side) 16 4 24 210 (21) 5 Radiator mounting bolt (Lower Side) 16 3 24 270 (27) 6 Pump mounting bolt 10 8 17 65 (6.5) Control valve mounting bolt 16 4 24 210 (21) 7 Control valve bracket mounting bolt 16 4 24 270 (27) 8 Swing device mounting bolt 22 14 32 650 (65) 9 Swing motor mounting bolt 12 8 10 90 (9) 10 ORS fittings for hydraulic hoses and piping - - 17 19 22 27 32 36 41 25 30 40 95 140 180 210 (2.5) (3) (4) (95) (14) (18) (21) 11 Hycolin tube mounting nut - - 17 35 (3.5) 12 Battery mounting nut 10 4 17 25 (2.5) Cab mounting nut 16 4 24 210 (21) Cab mounting anchor bolt 22 2 32 550 (55)13 Cab cushion rubber mounting bolt 12 8 19 110 (11) 6 - 10 10 (1) 8 - 13 10 (1)14 Cover mounting bolt 10 - 17 50 (5) 13 10.3 to 12.4 (1.05 to 1.26) Flexible master coupling of piping - 4 pair 11 6 (0.6) - 9 7 6 (0.6) Jubilee clamp of low pressure piping - 4 8 6 (0.6) 15 T-bolt clamp of low pressure piping - 9 10 6 (0.6) (Upperstructure) 22 35 32 650 (65) 16 Swing bearing mounting bolt (Undercarriage) 22 36 32 650 (65) ZX240-3 class 20 32 30 630 (63) Travel device mounting bolt ZX270-3 class 20 40 30 630 (63) Travel reduction device cover mounting bolt 14 12 22 180 (18) ZX240-3 class 20 40 30 550 (55) 17 Sprocket mounting bolt ZX270-3 class 20 48 30 550 (55) ZX240-3 class 16 16 24 270 (27) 18 Upper roller mounting bolt ZX270-3 class 18 16 27 460 (46) ZAXIS240-3, 250H-3, 250K-3 18 64 27 460 (46) ZAXIS240LC-3, 250LCH-3,250LCK-3 18 72 27 460 (46) ZAXIS270-3 22 56 32 840 (84) 19 Lower roller mounting bolt ZAXIS270LC-3 22 64 32 840 (84)
GENERAL / Tightening W1-2-4 Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) ZAXIS240-3, 250H-3, 250K-3 20 376 27 860 (86) ZAXIS240LC-3, 250LCH-3,250LCK-3 20 408 27 860 (86) ZAXIS270-3 22 360 32 1160 (116) 20 Track shoe bolt ZAXIS270LC-3 22 384 32 1160 (116) ZAXIS240-3, 240LC-3, 250K-3, 250LCK-3 18 8 27 500 (50) ZAXIS250H-3, 250LCH-3 18 16 27 500 (50)21 Track guard mounting bolt ZAXIS270-3, 270LC-3 22 8 32 750 (75) NOTE 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. 2. Make sure bolt and nut threads are clean before installing.
GENERAL / Tightening W1-2-5 TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and proce- dures can create safety hazards. For loosen- ing and tightening nuts and bolts, use cor- rect size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or compo- nents. SA-040 M552-07-091 Socket Bolt M552-07-090 M552-07-092 Bolt Dia. Wrench Size Hexagon Wrench Size N m (kgf m) (lbf ft) N m (kgf m) (lbf ft) N m (kgf m) (lbf ft) M6 10 5 3.3 to 4.2 (0.3 to 0.4)(2.4 to 3.0) M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2) M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5) M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5) M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40) M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58) M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87) M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123) M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159) M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205) M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290) M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400) M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540) M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)
GENERAL / Tightening W1-2-6 IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lu- bricant. 2. Torque tolerance is 10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific ap- plication. 5. Make sure that nut and bolt threads are clean before install- ing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them al- ternately, as shown, to ensure even tightening. W105-01-01-003 1 6 4 2 3 Equally tighten upper and lower alternately Tighten diagonally Tighten from center and diagonally 1st to 4th 2nd to 3rd 13 1110 1412 7614 3258 9 5
GENERAL / Tightening W1-2-7 Service Recommendations for Spilt Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extru- sion. If defects cannot be pol- ished out, replace the compo- nent. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and di- agonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tight- ening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Locking Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tight- ening, not while loosening. Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction. W105-01-01-015 W105-01-01-016 W105-01-01-008 W105-01-01-009 W105-01-01-010 Bend along edge sharply Do not bend it round Bend along edge sharply Loosen Tighten WRONG RIGHTRIGHT RIGHT WRONG WRONG RIGHT WRONG WRONGRIGHTRIGHT
GENERAL / Tightening W1-2-8 PIPING JOINT IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a differ- ent torque is given for a specific ap- plication. Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: 1. Do not over-tighten nut (3). Ex- cessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifi- cations. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting. M202-07-051 W105-01-01-017 Wrench Size mm Wrench Size mm Tightening Torque Description Union Nut Hose Fittings N m (kgf m, lbf ft) 30 male 17 17 24.5 (2.5, 18) 19 19 29.5 (3.0, 21.5) 22 22 39 (4.0, 28.5) 27 27 93 (9.5, 69) 32 32 137 (14.0, 101) 36 36 175 (18.0, 129) 41 41 205 (21.0, 151) 37 female 17 14 24.5 (2.5, 18) 19 17 29.5 (3.0, 21.5) 22 19 39 (4.0, 28.5) 27 22 93 (9.5, 69) 32 27 137 (14.0, 101) 36 32 175 (18.0, 129) 41 36 205 (21.0, 151) NOTE: Tightening torque of 37 male coupling without union is similar to tightening torque of 37 female. 37 30 Female Union JointMale Union Joint 1 3 5 2 Joint Body 4
GENERAL / Tightening W1-2-9 O-ring Seal Joint O-ring (6) seats against the end face of adapter (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (8) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leak- ing, do not re-tighten nut (9). Re- place O-ring (6) with a new one and check that O-ring (6) is cor- rectly seated in place, tighten nut (9). M104-07-033 Wrench Size mm Wrench Size mm Tightening Torque Union Nut Hose Fittings N m (kgf m, lbf ft) 19 17 29.5 (3.0,21.5) 22 19 69 (7.0,51) 27 22 93 (9.5,69) 32 27 137 (14.0,101) 36 30,32 175 (18.0,129) 41 36 205 (21.0,151) 46 41 205 (21.0,151) 7 6 9 8 1 Hose Fittings
GENERAL / Tightening W1-2-10 Screw-In Connection Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks be- tween threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. Application Procedure Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads. Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N m (0.45 kgf m, 3.25 lbf ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N m (0.6 to 0.7 kg m, 4.3 to 5.1 lbf ft) W105-01-01-018 Male Tapered Thread Wrench Size mm Tightening Torque N m (kgf m, lbf ft) Hose Fittings FC material SS material 19 14.5 (1.5,10.5) 34 (3.5,25) 22 29.5 (3.0,21.5) 49 (5.0,36) 27 49 (5.0,36) 93 (9.5,69) 36 69 (7.0,51) 157 (16,116) 41 108 (11,80) 205 (21,151) 50 157 (16,116) 320 (33,235) 60 195 (20,144) W105-01-01-019 M114-07-041 M114-07-043 M114-07-042 PF 30 PT Male Straight ThreadMale Tapered Thread Clearance External Thread Internal Thread Leave one to two pitch threads uncovered T-Bolt Type Worm Gear Type
GENERAL / Tightening W1-2-11 Connecting Hose CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the ma- chine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rup- ture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked. If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects. W105-01-01-011 W105-01-01-012 W105-01-01-013 W105-01-01-014 Rubbing Against Each Other RIGHT RIGHT RIGHT RIGHT WRONG WRONG WRONG WRONG Rubbing Against Each Other Rubbing Against Each Other Clamp ClampClamp
GENERAL / Tightening W1-2-12 PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire haz- ards. It is very difficult to gauge the extent of deteriora- tion, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, re- place these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for de- formation, cracks, or other deterioration, and replace as necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary. Consult your authorized dealer for correct replace- ment. Periodic Replacement Parts Replacement Intervals Oil filter hose (Engine to oil filter) Every 2 years or Every 6000 hours Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hoursEngine Heater hose (Heater to engine) Every 2 years or Every 6000 hours Pump suction hose Every 2 years or Every 6000 hours Pump delivery hose Every 2 years or Every 6000 hours Swing hose Every 2 years or Every 6000 hours Basic Machine Travel hose Every 2 years or Every 6000 hours Boom cylinder line hose Every 2 years or Every 6000 hours Arm cylinder line hose Every 2 years or Every 6000 hours Bucket cylinder line hose Every 2 years or Every 6000 hours Hydraulic System Front-End Attachment Pilot hose Every 2 years or Every 6000 hours NOTE: Replace seals, such as O-rings and gas- kets, when replacing hoses.
GENERAL / Painting W1-3-1 PAINTING Painting specification Surfaces to Be Painted Painting Colour • Main surface of upperstructure (except cab) YR-01 [TAXI yellow] Bed cover HG Beige Deep Inner Grey • Front attachment YR-01 [TAXI yellow] • Track (including swing ring) N1.0 [Black] • Floor plate M/F Cation (allowed) Final painted color • Inside and outside surface of cab HG Beige Deep • Shaded area on cab outside Shining Silver • Right window beam, U-Bolt [KASAI PAINT LF-113-230B (Charcoal series black, half glossy)] • Suspension lifter (chair bottom) [N2.0 (Black)] • Lever (Travel, pilot shut-off, foot rest) High Grade Brack • Engine cover High Grade Brack • Tool box, Tool box cover HG Beige Deep • Cover, Step HG Beige Deep • Handrail on upperstructure right side HG Beige Deep • Nonslip cover KANSAI PAINT ALAMIC 1400 (Deep Black) • Mirror stay High Grade Brack • Rear camera assembly HG Beige Deep
GENERAL / Painting W1-3-2 ZX200-3 class, ZX240-3 class, ZX270-3 class W1V1-01-03-001 ZX225USR-3 class W1V1-01-03-002 ZX225US-3 class W1V1-01-03-003 1 - Handrail on Upperstructure Right Side 4 - Tool Box Cover 7 - Decal (Shining Silver) 10 - Camera Cover 2 - Cover 5 - Mirror Stay 8 - Decal (TAXI Yellow) 11 - Decal (TAXI Yellow) 3 - Step 6 - Tool Box 9 - Engine Cover 12 - Control Valve Cover 1 2 3 4 9 10 118 7 6 5 1 12 9 10 118 7 5 1 12 9 118 7 5 10
GENERAL / Painting W1-3-3 ZX200-3 class, ZX240-3 class, ZX270-3 class ZX225US-3 class, ZX225USR-3 class W1V1-01-03-004 B Align with the panel. (Shining Silver) Panel (Shaded Area) Shining Silver Paint all circumference in the hinge swing position shining silver Section B (Door) (Door) Rear Panel Shining Silver Painted Range on Door 10 (Shaded Area) Shining Silver Paint all circumference in the hinge swing position shining silver
GENERAL / Painting W1-3-4 (Blank)
GENERAL / Bleeding Air from Hydraulic Oil Tank W1-4-1 BLEEDING AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation, and may spurt, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if re- moved without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Preparation 1. Place the machine on a firm, level surface. 2. Stop the engine. Push the pressure release but- ton on top of the hydraulic oil tank to release any remaining pressure. 3. Remove hydraulic oil tank cap. Connect a vac- uum pump to maintain negative pressure in the hydraulic oil tank. NOTE: Be sure to run the vacuum pump continu- ously while working. M104-07-021 W1V1-04-01-008 W562-02-03-008 Adapter Vacuum Pump Hose Pressure Release Button
GENERAL / Bleeding Air from Hydraulic Oil Tank W1-4-2 (Blank)
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1V1W-2-1 SECTION 2 UPPERSTRUCTURE — CONTENTS — Group 1 Cab Remove and Install Cab (ZX200-3 class, 240-3 class, 270-3 class)....................W2-1-1 Remove and Install Cab (ZX225US-3 class, 225USR-3 class) ................................W2-1-9 Dimensions of Cab Glass (ZX200-3 class, 240-3 class, 270-3 class)..................W2-1-21 Dimensions of Cab Glass (ZX225US-3 class, 225USR-3 class) ..............................W2-1-25 Group 2 Counterweight Remove and Install Counterweight ........W2-2-1 List of Weight .........................................W2-2-4 Group 3 Main Frame Remove and Install Main Frame ............W2-3-1 List of Weight .........................................W2-3-9 Group 4 Pump Device Remove and Install Pump Device (ZX200-3 class, 240-3 class, 270-3 class)........................................W2-4-1 Remove and Install Pump Device (ZX225US-3 class) .............................W2-4-7 Remove and Install Pump Device (ZX225USR-3 class).........................W2-4-17 Disassemble Pump Device ..................W2-4-26 Assemble Pump Device.......................W2-4-38 Disassemble Regulator........................W2-4-56 Assemble Regulator.............................W2-4-58 Disassemble Solenoid Valve................W2-4-60 Assemble Solenoid Valve.....................W2-4-62 Structure of Pilot Pump ........................W2-4-64 Maintenance Standard .........................W2-4-66 Group 5 Control Valve Remove and Install Control Valve (ZX200-3 class, 240-3 class, 270-3 class) ........................................W2-5-1 Remove and Install Control Valve (ZX225US-3 class, 225USR-3 class)..W2-5-3 Disassemble Control Valve (4-Spool Side) ...................................W2-5-10 Assemble Control Valve (4-Spool Side) ...................................W2-5-22 Disassemble Control Valve (5-Spool Side) ...................................W2-5-40 Assemble Control Valve (5-Spool Side) ...................................W2-5-52 Disassemble Housing...........................W2-5-64 Assemble Housing................................W2-5-66 Remove and Install Auxiliary Control Valve (Optional)..............................................W2-5-69 Disassemble Auxiliary Control Valve ..............................................................W2-5-72 Assemble Auxiliary Control Valve .........W2-5-76
1V1W-2-2 Group 6 Swing Device Remove and Install Swing Device (ZX200-3 class, 240-3 class, 270-3 class)........................................W2-6-1 Remove and Install Swing Device (ZX225US-3 class, 225USR-3 class).W2-6-3 Disassemble Swing Device....................W2-6-8 Assemble Swing Device.......................W2-6-16 Disassemble Swing Motor (ZX200-3 class, ZX225US-3 class, 225USR-3 class, 240-3 class)..........W2-6-30 Disassemble Swing Motor (ZX270-3 class) ................................W2-6-34 Assemble Swing Motor (ZX200-3 class, ZX225US-3 class, 225USR-3 class, 240-3 class) ........W2-6-38 Assemble Swing Motor (ZX270-3 class) ................................W2-6-42 Structure of Swing Parking Brake Switch Valve (ZX270-3 class).................................W2-6-46 Maintenance Standard .........................W2-6-47 Group 7 Pilot Valve Remove and Install Pilot Valve...............W2-7-1 Disassemble Right and Left Pilot Valves .......................................W2-7-18 Assemble Right and Left Pilot Valves .......................................W2-7-22 Disassemble Travel Pilot Valve ............W2-7-26 Assemble Travel Pilot Valve.................W2-7-30 Disassemble Positioning Pilot Valve (2-Piece Boom Only) ........................W2-7-36 Assemble Positioning Pilot Valve (2-Piece Boom Only) ........................W2-7-38 Group 8 Pilot Shut-Off Solenoid Valve Remove and Install Pilot Shut-Off Solenoid Valve..............W2-8-1 Disassemble Pilot Shut-Off Solenoid Valve....................................W2-8-2 Assemble Pilot Shut-Off Solenoid Valve....................................W2-8-4 Group 9 Signal Control Valve Remove and Install Signal Control Valve (ZX200-3 class, 240-3 class, 270-3 class) ........................................W2-9-1 Remove and Install Signal Control Valve (ZX225US-3 class, 225USR-3 class).................................W2-9-3 Structure of Signal Control Valve............W2-9-8 Group 10 4-Spool Solenoid Valve Unit Remove and Install 4- Spool Solenoid Valve Unit (ZX200-3 class, 240-3 class, 270-3 class)..................W2-10-1 Remove and Install 4- Spool Solenoid Valve Unit (ZX225US-3 class, 225USR-3 class)...............................W2-10-2 Structure of 4-Spool Solenoid Valve Unit ...........................W2-10-4 Group 11 Engine Remove and Install Engine (ZX200-3 class, 240-3 class, 270-3 class)..................W2-11-1 Remove and Install Engine (ZX225US-3 class)..........................W2-11-24 Remove and Install Engine (ZX225USR-3 class).......................W2-11-49
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HITACHI ZAXIS 225USR-3 CLASS EXCAVATOR Service Repair Manual

  • 1.                         
  • 2. INTRODUCTION IN-01 ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog • The Engine Manual • Parts Catalog of the Engine • Hitachi Training Material MANUAL COMPOSITION This manual consists of three portions: the Techni- cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man- ual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems. • Information included in the Technical Manual (Troubleshooting): technical information needed for operational per- formance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assem- ble/disassemble procedures. PAGE NUMBER Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual
  • 3. INTRODUCTION IN-02 SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts.  CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.  NOTE: Indicates supplementary technical information or know-how. UNITS USED SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees. Quantity To Convert From Into Multiply By MPa kgf/cm 2 10.197Pressure MPa psi 145.0 kW PS 1.360Power kW HP 1.341 Temperature C F C1.8+32 km/h mph 0.6214Velocity min -1 rpm 1.0 Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0 Quantity To Convert From Into Multiply By mm in 0.03937Length mm ft 0.003281 L US gal 0.2642 L US qt 1.057 Volume m 3 yd 3 1.308 Weight kg lb 2.205 N kgf 0.10197Force N lbf 0.2248 N m kgf m 1.0197Torque N m lbf ft 0.7375
  • 4. SAFETY SA-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 per- sonal injury. • Follow recommended precautions and safe oper- ating 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 desig- nated signal words above after the safety alert symbol are occasionally used on this machine. To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indi- cates 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
  • 5. SAFETY SA-2 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 replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your author- ized dealer in the same way you order other re- placement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly 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 ma- chine life. • Do not modify any machine parts without au- thorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addi- tion, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attach- ments and/or optional parts or equipment will void Hitachi Warranty Policy. The safety messages in this SAFETY chapter are intended 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 au- thorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003 SA-003
  • 6. SAFETY SA-3 PREPARE FOR EMERGENCIES Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label at- tached on the fire extinguisher to use it properly. • To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambu- lance service, hospital, and fire department posted near your telephone. 004-E01A-0437 SA-437 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. • Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Operating equipment safely requires the full atten- tion of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438 SA-428
  • 7. SAFETY SA-4 PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause im- pairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objec- tionable or uncomfortably loud noises. 006-E01A-0434 SA-434 INSPECT MACHINE Inspect your machine carefully each day or shift by walking around it before you start it to avoid per- sonal injury. • In the walk-around inspection be sure to cover all points described in the "RE-START INSPEC- TION" chapter in the operator's manual. 007-E01A-0435 SA-435
  • 8. SAFETY SA-5 GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator's work boots the operator's foot may slip off the pedal, possibly resulting in a personal accident. • Do not leave parts and/or tools lying around the operator's seat. Store them in their specified loca- tions. • Avoid storing transparent bottles in the cab. Do not attach any transparent type window decora- tions on the windowpanes as they may focus sunlight, possibly starting a fire. • Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. • Keep all flammable objects and/or explosives away from the machine. • After using the ashtray, always cover it to extin- guish the match and/or tobacco. • Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000
  • 9. SAFETY SA-6 USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. 008-E01A-0439 SA-439 ADJUST THE OPERATOR'S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to mis-operations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. • Adjust the rear view mirror position so that the best rear visibility is obtained from the operator's seat. If the mirror is broken, immediately replace it with a new one. 009-E01A-0462 SA-462
  • 10. SAFETY SA-7 ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR'S SEAT Before rising from the operator's seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the ma- chine to unexpectedly move when a body part un- intentionally comes in contact with a control lever, possibly resulting in serious personal injury or death. • Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK posi- tion. Turn the key switch OFF to stop the engine. • Before leaving the machine, close all windows, doors, and access covers and lock them up. FASTEN YOUR SEAT BELT If the machine should overturn, the operator may become injured and/or thrown from the cab. Addi- tionally the operator may be crushed by the over- turning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly ex- amine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt se- curely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. We recommend that the seat belt be replaced every three years regardless of its apparent con- dition. 010-E01A-0237 SA-237
  • 11. SAFETY SA-8 MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. • Take extra care not to run over bystanders. Con- firm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coor- dinate hand signals before starting the machine. • Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it. 011-E01A-0398 SA-426 HANDLE STARTING AIDS SAFELY Starting fluid: Starting fluid is highly flammable. • Keep all sparks and flame away when using it. • Keep starting fluid well away from batteries and cables. • Remove container from machine if engine does not need starting fluid. • To prevent accidental discharge when storing a pressurized container, keep the cap on the con- tainer, and store it in a cool, well-protected loca- tion. • Do not incinerate or puncture a starting fluid con- tainer. 036-E01A-0293-3 SA-293
  • 12. SAFETY SA-9 OPERATE ONLY FROM OPERATOR'S SEAT Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in seri- ous injury or death. • Start the engine only when seated in the opera- tor's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. • Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders. 012-E01B-0431 SA-444 JUMP STARTING Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the "OPERATING THE ENGINE" chapter in the operator's manual. • The operator must be in the operator's seat so that the machine will be under control when the engine starts. Jump starting is a two-person op- eration. • Never use a frozen battery. • Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. S013-E01A-0032 SA-032
  • 13. SAFETY SA-10 KEEP RIDERS OFF MACHINE Riders on machine are subject to injury such as be- ing struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner. 014-E01B-0427 SA-379 PRECAUTIONS FOR OPERATIONS Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine. • Clear all persons and obstacles from area of op- eration and machine movement. Always beware of the surroundings while operat- ing. When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles. • When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person. M104-05-015
  • 14. SAFETY SA-11 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 condi- tions 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. • Reinforce ground, edges, and road shoulders as necessary. 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. • Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist. • When the footing is weak, reinforce the ground before starting work. • When working on frozen ground, be extremely alert. As ambient temperatures rise, footing be- comes loose and slippery. • Beware the possibility of fire when operating the machine near flammable objects such as dry grass. Make sure the worksite has sufficient strength to firmly support the machine. When working close to an excavation or at road shoulders, operate the machine with the tracks po- sitioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses. If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area. Soft ground may collapse when operating the ma- chine on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine. Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes: • Reduce the engine speed. • Select slow travel speed mode. • Operate the machine slowly and be cautious with machine movements. SA-380
  • 15. SAFETY SA-12 EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the poten- tial hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure SA-490 PROVIDE SIGNALS FOR JOBS INVOLV- ING MULTIPLE NUMBERS OF MACHINES For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person's directions. 018-E01A-0481 SA-481 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal/lever operation may result in serious injury death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator's position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. 017-E01A-0491 SA-491
  • 16. SAFETY SA-13 DRIVE MACHINE SAFELY Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the di- rection you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don't allow personnel to stay around the machine while traveling. Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • Never attempt to ascend or descend 35 degrees or steeper slopes. • Be sure to fasten the seat belt. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop. SA-657 SA-658 SA-441 SA-442
  • 17. SAFETY SA-14 DRIVE MACHINE SAFELY • Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the ma- chine to level ground, then, change the direction to ensure safe operation. • Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure down- hill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed. • If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control lev- ers to neutral. Then, restart the engine. • Be sure to thoroughly warm up the machine be- fore ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained. • Use a signal person when moving, swinging or operating the machine in congested areas. Coor- dinate hand signals before starting the machine. • Before moving machine, determine which way to move travel pedals/levers for the direction you want to go. When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers. An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction. • Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction. • Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if nec- essary. M104-05-008 M178-03-001 Travel Motor Arrow-Mark
  • 18. SAFETY SA-15 • Use wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer. • When crossing train tracks, use wood plates in order not to damage them. • Do not make contact with electric wires or bridges. • When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller. • When traveling on rough terrain, reduce engine speed. Select slow travel speed. Slower speed will reduce possible damage to the machine. • Avoid operations that may damage the track and undercarriage components. • During freezing weather, always clean snow and ice from track shoes before loading and unloading machine, to prevent the machine from slipping. SA-011
  • 19. SAFETY SA-16 AVOID INJURY FROM ROLLAWAY ACCI- DENTS Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park ma- chine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Turn the auto-idle switch and the H/P mode switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK posi- tion. • Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines. 020-E02A-0493 SA-391 SA-392
  • 20. SAFETY SA-17 AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOV- ING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and mark- ings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator's manual. 021-E01A-0494 SA-383 SA-384
  • 21. SAFETY SA-18 KEEP PERSON CLEAR FROM WORKING AREA A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and machine movement. • Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area. 022-E01A-0386 SA-386 NEVER POSITION BUCKET OVER ANY- ONE Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket. 023-E01A-0487 SA-487 AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the footing should collapse, always position the un- dercarriage perpendicular to the edge of the exca- vation with the travel motors at the rear. • If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases. 024-E01A-0488 SA-488
  • 22. SAFETY SA-19 AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING IN- JURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when oper- ating on a grade, possibly resulting in serious injury or death. To avoid tipping: Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine. • Reduce operating speeds to avoid tipping or slip- ping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is un- avoidable. • Reduce swing speed as necessary when swing- ing loads. Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E03B-0463 SA-012 SA-440 NEVER UNDERCUT A HIGH BANK The edges could collapse or a land slide could occur causing serious injury or death. 026-E01A-0519 SA-489
  • 23. SAFETY SA-20 DIG WITH CAUTION Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines. • If a fiber optic cable should be accidentally sev- ered, do not look into the end. Doing so may re- sult in serious eye injury. • Contact your local "diggers hot line" if available in your area, and/or the utility companies directly. Have them mark all underground utilities. 027-E01A-0382 SA-382 OPERATE WITH CAUTION If the front attachment or any other part of the ma- chine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well. • Take care to avoid hitting overhead obstacles with the boom or arm. 028-E01A-0389 SA-389
  • 24. SAFETY SA-21 AVOID POWER LINES Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. 029-E01A-0381 SA-381 PRECAUTIONS FOR LIGHTENING The machine is vulnerable to lighting strikes. • In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. • After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the ma- chine only after repairing them. SA-1088 OBJECT HANDLING If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed under- neath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the travel motors at the rear. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0132 SA-014
  • 25. SAFETY SA-22 PROTECT AGAINST FLYING DEBRIS If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. 031-E01A-0432 SA-432 PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch OFF. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull the pilot control shut-off lever to the LOCK position. • Close windows, roof vent, and cab door. • Lock all access doors and compartments. SA-390 HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possi- bly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the ma- chine. • Fill the fuel tank outdoors. All fuels, most lubricants, and some coolants are flammable. • Store flammable fluids well away from fire haz- ards. • Do not incinerate or puncture pressurized con- tainers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten the fuel and oil filler cap. 034-E01A-0496 SA-018 SA-019
  • 26. SAFETY SA-23 TRANSPORT SAFELY Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the ma- chine to be transported. • Be sure to use a signal person. • Always follow the following precautions for load- ing or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Turn auto-idle switch OFF. 4. Always select the slow speed mode with the travel mode switch. 5. Never load or unload the machine onto or off a truck or trailer using the front attachment func- tions when driving up or down the ramp. 6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, repo- sition the machine on the ground, and then try loading again. 7. The top end of the ramp where it meets the flat- bed is a sudden bump. Take care when traveling over it. 8. Place blocks in front of and behind the tracks. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANSPORTING section in the operator's manual. 035-E07A-0454 SA-395
  • 27. SAFETY SA-24 PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a "Do Not Operate" tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. 500-E02C-0520 SA-028 SA-527
  • 28. SAFETY SA-25 • If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • If the machine must be raised, maintain a 90 to 100° angle between the boom and arm. Securely support any machine elements that must be raised for service work. • Inspect certain parts periodically and repair or re- place as necessary. Refer to the section discuss- ing that part in the "MAINTENANCE" chapter of this manual. • Keep all parts in good condition and properly in- stalled. • Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or de- bris. • When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. • Disconnect battery ground cable (-) before mak- ing adjustments to electrical systems or before performing welding on the machine. • Sufficiently illuminate the work site. Use a main- tenance work light when working under or inside the machine. • Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, anti- freeze fluid, or window washer fluid may catch fire. SA-037 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury. • Before performing any work on the machine, at- tach a "Do Not Operate" tag on the control lever. This tag is available from your authorized dealer. 501-E01A-0287 T1J1-01-01-001
  • 29. SAFETY SA-26 SUPPORT MACHINE PROPERLY Never attempt to work on the machine without se- curing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attach- ment, securely support the machine or attach- ment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a ma- chine that is supported solely by a jack. 519-E01A-0527 SA-527 STAY CLEAR OF MOVING PARTS Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. 502-E01A-0026 SA-026
  • 30. SAFETY SA-27 PREVENT PARTS FROM FLYING Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. • As pieces may fly off, be sure to keep body and face away from valve. • Never attempt to disassemble the track adjuster. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death. Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. • GEAR OIL is hot. Wait for GEAR OIL to cool, and then gradually loosen AIR RELEASE PLUG to release pressure. 503-E01B-0344 SA-344 STORE ATTACHMENTS SAFELY Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas. 504-E01A-0034 SA-034
  • 31. SAFETY SA-28 PREVENT BURNS Hot spraying fluids: After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces: Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. • Wait for the oil and components to cool before starting any maintenance or inspection work. 505-E01B-0498 SA-039 SA-225 REPLACE RUBBER HOSES PERIODI- CALLY Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. • Periodically replace the rubber hoses. (See the page of "Periodic replacement of parts" in the operator's manual.) • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019 SA-019
  • 32. SAFETY SA-29 AVOID HIGH-PRESSURE FLUIDS Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing se- rious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or gog- gles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. 507-E03A-0499 SA-031 SA-292 SA-044
  • 33. SAFETY SA-30 PREVENT FIRES Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts: Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. • Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: Spilled fuel and oil, and trash, grease, debris, ac- cumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the ma- chine daily and by removing spilled or accumu- lated flammables immediately. Check Key Switch: If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to con- firm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019 Check Heat Shields: Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be re- paired or replaced before operating the machine. 508-E02A-0393 SA-019
  • 34. SAFETY SA-31 EVACUATING IN CASE OF FIRE If a fire breaks out, evacuate the machine in the fol- lowing way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine. In an emergency, if the cab door or front window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method in the op- erator's manual. 18-E02B-0393 SA-393 SS-1510 BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016 SA-016 PRECAUTIONS FOR WELDING AND GRINDING Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. After finishing welding and grinding, recheck that there are no abnormalities such as the area sur- rounding the welded area still smoldering. 523-E01A-0818 SA-818
  • 35. SAFETY SA-32 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. In- stall temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.. SA-030 AVOID APPLYING HEAT TO LINES CON- TAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030 REMOVE PAINT BEFORE WELDING OR HEATING Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. • Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 511-E01A-0029 SA-029
  • 36. SAFETY SA-33 BEWARE OF ASBESTOS DUST Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Don't use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos. • Keep bystanders out of the work site during op- eration. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. SA-029 PREVENT BATTERY EXPLOSIONS Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hy- drometer. • Do not charge a frozen battery or start engine with frozen battery. There is fear of explosion. If battery electrolyte is frozen, wait until it is liquefied completely in an atmospheric temperature room. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals. Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01B-0032 SA-032
  • 37. SAFETY SA-34 SERVICE AIR CONDITIONING SYSTEM SAFELY If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the con- tainer for proper use when handling the refriger- ant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405 SA-405 HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know ex- actly what the risks are and how to do the job safely. Then follow procedures and use recom- mended equipment. • See your authorized dealer for MSDS's (available only in English) on chemical products used with your machine. 515-E01A-0309 SA-309
  • 38. SAFETY SA-35 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the en- vironment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Govern- ment regulations may require a certified air condi- tioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer. 516-E01A-0226 SA-226 BEFORE RETURNING THE MACHINE TO THE CUSTOMER After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced S517-E01A-0435 SA-435
  • 39. SECTION AND GROUP CONTENTS WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Pilot Shut-Off Solenoid Valve Group 9 Signal Control Valve Group 10 4-Spool Solenoid Valve Unit Group 11 Engine SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Holding Valve
  • 40. TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage) TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PER- FORMANCE TEST Group 1 Diagnosing Procedure Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test SECTION 5 TROUBLESHOOTING Group 1 General Group 2 Monitor Unit Group 3 Dr. ZX Group 4 e-Shovel Group 5 Component Layout Group 6 Troubleshooting A Group 7 Troubleshooting B Group 8 Electrical System Inspection
  • 41. 1V1W-1-1 SECTION 1 GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology........ W1-1-7 Group 2 Tightening Tightening Torque Specification (ZX200-3 class) .................................. W1-2-1 Tightening Torque Specification (ZX225US-3 class, 225USR-3 class) .. W1-2-2 Tightening Torque Specification (ZX240-3 class, 270-3 class) .............. W1-2-3 Torque Chart .......................................... W1-2-5 Piping Joint ............................................ W1-2-8 Periodic Replacement of Parts ............. W1-2-12 Group 3 Painting Painting.................................................. W1-3-1 Group 4 Bleeding Air from Hydraulic Oil Tank Bleeding Air from Hydraulic Oil Tank....... W1-4-1
  • 43. GENERAL / Precautions for Disassembling and Assembling W1-1-1 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Precautions for Disassembling and Assembling Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. Inspect the Machine Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.
  • 44. GENERAL / Precautions for Disassembling and Assembling W1-1-2 Precautions for Assembling • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine. Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and instal- lation of the pump, swing motor, travel motor or cyl- inder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump hous- ing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine. Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the en- gine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug. Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.
  • 45. GENERAL / Precautions for Disassembling and Assembling W1-1-3 Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each op- eration (never fully stroke the cylinders during ini- tial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydrau- lic oil level. • Stop the engine. Recheck hydraulic oil level. Re- plenish oil as necessary. M104-07-021
  • 46. GENERAL / Precautions for Disassembling and Assembling W1-1-4 Floating Seal Precautions 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating. W105-03-05-019 W105-03-05-020 W110-03-05-004 a b b b aa a=b C A B IncorrectCorrect Incorrect Correct A B
  • 47. GENERAL / Precautions for Disassembling and Assembling W1-1-5 Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 C (212 F). If unavoidably lifting a load with a temperature of 100 C (212 F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t dete- riorate with heat, sun light, or chemicals. W102-04-02-016 W105-04-01-008 W162-01-01-009 Correct Eyehole Lifting Method Incorrect Eyehole Lifting Method Bent Sling
  • 48. GENERAL / Precautions for Disassembling and Assembling W1-1-6 CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may re- sult. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the ny- lon sling for any damage corresponding to exam- ples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years. Damaged Appearance W162-01-01-002 W162-01-01-003 W162-01-01-004 W162-01-01-005 W162-01-01-006 W162-01-01-007 W162-01-01-008 Broken Sewing Thread Scuffing Broken Sewing Thread Fuzz Broken Sewing Thread Separation of Belt Broken Sewing Thread Scuffing Scoring Broken Warp Fuzz
  • 49. GENERAL / Precautions for Disassembling and Assembling W1-1-7 MAINTENANCE STANDARD TERMINOL- OGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. “Allowable Limit” 1. Normal machine performance cannot be accom- plished after exceeding this limit. 2. Repair or adjustment is impossible after exceed- ing this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allow- able Limit”.
  • 50. GENERAL / Precautions for Disassembling and Assembling W1-1-8 (Blank)
  • 51. GENERAL / Tightening W1-2-1 TIGHTENING TORQUE SPECIFICATIONS (ZX200-3 Class) Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) Engine cushion rubber mounting nut (Pump side) 18 4 27 400 (40) 1 Engine cushion rubber mounting nut (Fan Side) 14 4 22 180 (18) Engine bracket mounting bolt (Pump side) 16 8 24 270 (27) 2 Engine bracket mounting bolt (Fan side) 10 8 17 65 (6.5) 3 Hydraulic oil tank mounting bolt 20 4 30 550 (55) 4 Fuel tank mounting bolt 16 4 24 270 (27) Radiator mounting bolt (Upper Side) 16 4 24 210 (21) 5 Radiator mounting bolt (Lower Side) 16 3 24 210 (21) 6 Pump mounting bolt 10 8 17 65 (6.5) Control valve mounting bolt 16 4 24 210 (21) 7 Control valve bracket mounting bolt 16 4 24 270 (27) 8 Swing device mounting bolt 20 14 30 500 (50) 9 Swing motor mounting bolt 12 8 10 90 (9) 10 ORS fittings for hydraulic hoses and piping 17 19 22 27 32 36 41 25 30 40 95 140 180 210 (2.5) (3) (4) (95) (14) (18) (21) 11 Battery mounting nut 10 4 17 50 (5) Cab mounting nut 16 4 24 210 (21) Cab mounting anchor bolt 22 2 32 550 (55)12 Cab cushion rubber mounting bolt 12 8 19 110 (11) 6 10 10 (1) 8 13 10 17 50 (5) 13 Cover mounting bolt 12 19 90 (9) 13 10.3 to 12.4 (1.05 to 1.26) Flexible master coupling of piping 8 1/4-28UNF 4 pair 11 6 (0.6) 9 7 6 (0.6) 11 7 6 (0.6)Jubilee clamp of low pressure piping 4 8 6 (0.6) 14 T-bolt clamp of low pressure piping 9 10 6 (0.6) (Upperstructure) 20 37 30 510 (51) 15 Swing bearing mounting bolt (Undercarriage) 20 36 30 490 (49) 20 32 30 630 (63) Travel device mounting bolt 20 40 30 630 (63) Travel reduction device cover mounting bolt 14 12 22 180 (18) 20 40 30 550 (55) 16 Sprocket mounting bolt 20 48 30 550 (55) 17 Upper roller mounting bolt 16 16 24 270 (27) ZAXIS200-3, 210H-3, 210K-3 18 64 27 460 (46) 18 Lower roller mounting bolt ZAXIS200LC-3, 210LCH-3,210LCK-3 18 72 27 460 (46) ZAXIS200-3, 210H-3, 210K-3 20 368 27 804 (82) 19 Track shoe bolt ZAXIS200LC-3, 210LCH-3,210LCK-3 20 392 27 804 (82) ZAXIS200-3, 210H-3, 210K-3 18 8 27 500 (50) 20 Track guard mounting bolt ZAXIS200LC-3, 210LCH-3,210LCK-3 18 16 27 500 (50)
  • 52. GENERAL / Tightening W1-2-2 TIGHTENING TORQUE SPECIFICATIONS (ZX225US-3 class, ZX225USR-3 Class) Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) Engine cushion rubber mounting nut (Pump side) 18 4 27 400 (40) 1 Engine cushion rubber mounting nut (Fan Side) 14 4 22 180 (18) Engine bracket mounting bolt (Pump side) 16 8 24 270 (27) 2 Engine bracket mounting bolt (Fan side) 10 8 17 65 (6.5) 3 Hydraulic oil tank mounting bolt 20 4 30 550 (55) 4 Fuel tank mounting bolt 16 4 24 270 (27) Radiator mounting bolt (Upper Side) 16 4 24 210 (21) 5 Radiator mounting bolt (Lower Side) 16 3 24 210 (21) 6 Pump mounting bolt 10 8 17 65 (6.5) Control valve mounting bolt 16 4 24 210 (21) 7 Control valve bracket mounting bolt 16 4 24 270 (27) 8 Swing device mounting bolt 20 14 30 500 (50) 9 Swing motor mounting bolt 12 8 10 90 (9) 10 ORS fittings for hydraulic hoses and piping 17 19 22 27 32 36 41 25 30 40 95 140 180 210 (2.5) (3) (4) (95) (14) (18) (21) 11 Battery mounting nut 10 2 17 50 (5) Cab mounting nut 16 4 24 210 (21) Cab mounting anchor bolt 22 2 32 550 (55)12 Cab cushion rubber mounting bolt 12 8 19 110 (11) 6 10 10 (1) 8 13 10 17 50 (5) 13 Cover mounting bolt 12 19 90 (9) 13 10.3 to 12.4 (1.05 to 1.26) Flexible master coupling of piping 8 1/4-28UNF 4 pair 11 6 (0.6)14 T-bolt clamp of low pressure piping 8 10 6 (0.6) (Upperstructure) 20 37 30 510 (51) 15 Swing bearing mounting bolt (Undercarriage) 20 36 30 490 (49) Travel device mounting bolt 20 32 30 630 (63) Travel reduction device cover mounting bolt 14 12 22 180 (18)16 Sprocket mounting bolt 20 40 30 550 (55) 17 Upper roller mounting bolt 16 16 24 270 (27) ZAXIS225US-3, 225US-3, 225USR-3 18 64 27 460 (46) 18 Lower roller mounting bolt ZAXIS225USLC-3,225USRLC-3,225USRLCK-3 18 72 27 460 (46) ZAXIS225US-3, 225US-3, 225USR-3 20 368 27 804 (82) 19 Track shoe bolt ZAXIS225USLC-3,225USRLC-3,225USRLCK-3 20 392 27 804 (82) ZAXIS225US-3, 225US-3, 225USR-3 18 8 27 500 (50) 20 Track guard mounting bolt ZAXIS225USLC-3,225USRLC-3,225USRLCK-3 18 16 27 500 (50)
  • 53. GENERAL / Tightening W1-2-3 TIGHTENING TORQUE SPECIFICATIONS (ZX240-3 Class, ZX270-3 class) Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) ZX240-3 class 18 4 27 400 (40)Engine cushion rubber mounting bolt and nut (Pump side) ZX270-3 class 18 2 27 400 (40) ZX240-3 class 14 4 22 180 (18) 1 Engine cushion rubber mounting bolt and nut (Fan Side) ZX270-3 class 18 2 27 400 (40) ZX240-3 class 16 8 24 270 (27)Engine bracket mounting bolt (Pump side) ZX270-3 class 12 12 19 110 (11) ZX240-3 class 10 8 17 65 (6.5) 2 Engine bracket mounting bolt (Fan side) ZX270-3 class 12 6 19 110 (11) 3 Hydraulic oil tank mounting bolt 18 4 27 400 (40) 4 Fuel tank mounting bolt 20 4 30 550 (55) Radiator mounting bolt (Upper Side) 16 4 24 210 (21) 5 Radiator mounting bolt (Lower Side) 16 3 24 270 (27) 6 Pump mounting bolt 10 8 17 65 (6.5) Control valve mounting bolt 16 4 24 210 (21) 7 Control valve bracket mounting bolt 16 4 24 270 (27) 8 Swing device mounting bolt 22 14 32 650 (65) 9 Swing motor mounting bolt 12 8 10 90 (9) 10 ORS fittings for hydraulic hoses and piping - - 17 19 22 27 32 36 41 25 30 40 95 140 180 210 (2.5) (3) (4) (95) (14) (18) (21) 11 Hycolin tube mounting nut - - 17 35 (3.5) 12 Battery mounting nut 10 4 17 25 (2.5) Cab mounting nut 16 4 24 210 (21) Cab mounting anchor bolt 22 2 32 550 (55)13 Cab cushion rubber mounting bolt 12 8 19 110 (11) 6 - 10 10 (1) 8 - 13 10 (1)14 Cover mounting bolt 10 - 17 50 (5) 13 10.3 to 12.4 (1.05 to 1.26) Flexible master coupling of piping - 4 pair 11 6 (0.6) - 9 7 6 (0.6) Jubilee clamp of low pressure piping - 4 8 6 (0.6) 15 T-bolt clamp of low pressure piping - 9 10 6 (0.6) (Upperstructure) 22 35 32 650 (65) 16 Swing bearing mounting bolt (Undercarriage) 22 36 32 650 (65) ZX240-3 class 20 32 30 630 (63) Travel device mounting bolt ZX270-3 class 20 40 30 630 (63) Travel reduction device cover mounting bolt 14 12 22 180 (18) ZX240-3 class 20 40 30 550 (55) 17 Sprocket mounting bolt ZX270-3 class 20 48 30 550 (55) ZX240-3 class 16 16 24 270 (27) 18 Upper roller mounting bolt ZX270-3 class 18 16 27 460 (46) ZAXIS240-3, 250H-3, 250K-3 18 64 27 460 (46) ZAXIS240LC-3, 250LCH-3,250LCK-3 18 72 27 460 (46) ZAXIS270-3 22 56 32 840 (84) 19 Lower roller mounting bolt ZAXIS270LC-3 22 64 32 840 (84)
  • 54. GENERAL / Tightening W1-2-4 Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) ZAXIS240-3, 250H-3, 250K-3 20 376 27 860 (86) ZAXIS240LC-3, 250LCH-3,250LCK-3 20 408 27 860 (86) ZAXIS270-3 22 360 32 1160 (116) 20 Track shoe bolt ZAXIS270LC-3 22 384 32 1160 (116) ZAXIS240-3, 240LC-3, 250K-3, 250LCK-3 18 8 27 500 (50) ZAXIS250H-3, 250LCH-3 18 16 27 500 (50)21 Track guard mounting bolt ZAXIS270-3, 270LC-3 22 8 32 750 (75) NOTE 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. 2. Make sure bolt and nut threads are clean before installing.
  • 55. GENERAL / Tightening W1-2-5 TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and proce- dures can create safety hazards. For loosen- ing and tightening nuts and bolts, use cor- rect size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or compo- nents. SA-040 M552-07-091 Socket Bolt M552-07-090 M552-07-092 Bolt Dia. Wrench Size Hexagon Wrench Size N m (kgf m) (lbf ft) N m (kgf m) (lbf ft) N m (kgf m) (lbf ft) M6 10 5 3.3 to 4.2 (0.3 to 0.4)(2.4 to 3.0) M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2) M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5) M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5) M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40) M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58) M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87) M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123) M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159) M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205) M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290) M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400) M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540) M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)
  • 56. GENERAL / Tightening W1-2-6 IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lu- bricant. 2. Torque tolerance is 10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific ap- plication. 5. Make sure that nut and bolt threads are clean before install- ing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them al- ternately, as shown, to ensure even tightening. W105-01-01-003 1 6 4 2 3 Equally tighten upper and lower alternately Tighten diagonally Tighten from center and diagonally 1st to 4th 2nd to 3rd 13 1110 1412 7614 3258 9 5
  • 57. GENERAL / Tightening W1-2-7 Service Recommendations for Spilt Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extru- sion. If defects cannot be pol- ished out, replace the compo- nent. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and di- agonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tight- ening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Locking Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tight- ening, not while loosening. Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction. W105-01-01-015 W105-01-01-016 W105-01-01-008 W105-01-01-009 W105-01-01-010 Bend along edge sharply Do not bend it round Bend along edge sharply Loosen Tighten WRONG RIGHTRIGHT RIGHT WRONG WRONG RIGHT WRONG WRONGRIGHTRIGHT
  • 58. GENERAL / Tightening W1-2-8 PIPING JOINT IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a differ- ent torque is given for a specific ap- plication. Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: 1. Do not over-tighten nut (3). Ex- cessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifi- cations. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting. M202-07-051 W105-01-01-017 Wrench Size mm Wrench Size mm Tightening Torque Description Union Nut Hose Fittings N m (kgf m, lbf ft) 30 male 17 17 24.5 (2.5, 18) 19 19 29.5 (3.0, 21.5) 22 22 39 (4.0, 28.5) 27 27 93 (9.5, 69) 32 32 137 (14.0, 101) 36 36 175 (18.0, 129) 41 41 205 (21.0, 151) 37 female 17 14 24.5 (2.5, 18) 19 17 29.5 (3.0, 21.5) 22 19 39 (4.0, 28.5) 27 22 93 (9.5, 69) 32 27 137 (14.0, 101) 36 32 175 (18.0, 129) 41 36 205 (21.0, 151) NOTE: Tightening torque of 37 male coupling without union is similar to tightening torque of 37 female. 37 30 Female Union JointMale Union Joint 1 3 5 2 Joint Body 4
  • 59. GENERAL / Tightening W1-2-9 O-ring Seal Joint O-ring (6) seats against the end face of adapter (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (8) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leak- ing, do not re-tighten nut (9). Re- place O-ring (6) with a new one and check that O-ring (6) is cor- rectly seated in place, tighten nut (9). M104-07-033 Wrench Size mm Wrench Size mm Tightening Torque Union Nut Hose Fittings N m (kgf m, lbf ft) 19 17 29.5 (3.0,21.5) 22 19 69 (7.0,51) 27 22 93 (9.5,69) 32 27 137 (14.0,101) 36 30,32 175 (18.0,129) 41 36 205 (21.0,151) 46 41 205 (21.0,151) 7 6 9 8 1 Hose Fittings
  • 60. GENERAL / Tightening W1-2-10 Screw-In Connection Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks be- tween threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. Application Procedure Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads. Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N m (0.45 kgf m, 3.25 lbf ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N m (0.6 to 0.7 kg m, 4.3 to 5.1 lbf ft) W105-01-01-018 Male Tapered Thread Wrench Size mm Tightening Torque N m (kgf m, lbf ft) Hose Fittings FC material SS material 19 14.5 (1.5,10.5) 34 (3.5,25) 22 29.5 (3.0,21.5) 49 (5.0,36) 27 49 (5.0,36) 93 (9.5,69) 36 69 (7.0,51) 157 (16,116) 41 108 (11,80) 205 (21,151) 50 157 (16,116) 320 (33,235) 60 195 (20,144) W105-01-01-019 M114-07-041 M114-07-043 M114-07-042 PF 30 PT Male Straight ThreadMale Tapered Thread Clearance External Thread Internal Thread Leave one to two pitch threads uncovered T-Bolt Type Worm Gear Type
  • 61. GENERAL / Tightening W1-2-11 Connecting Hose CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the ma- chine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rup- ture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked. If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects. W105-01-01-011 W105-01-01-012 W105-01-01-013 W105-01-01-014 Rubbing Against Each Other RIGHT RIGHT RIGHT RIGHT WRONG WRONG WRONG WRONG Rubbing Against Each Other Rubbing Against Each Other Clamp ClampClamp
  • 62. GENERAL / Tightening W1-2-12 PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire haz- ards. It is very difficult to gauge the extent of deteriora- tion, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, re- place these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for de- formation, cracks, or other deterioration, and replace as necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary. Consult your authorized dealer for correct replace- ment. Periodic Replacement Parts Replacement Intervals Oil filter hose (Engine to oil filter) Every 2 years or Every 6000 hours Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hoursEngine Heater hose (Heater to engine) Every 2 years or Every 6000 hours Pump suction hose Every 2 years or Every 6000 hours Pump delivery hose Every 2 years or Every 6000 hours Swing hose Every 2 years or Every 6000 hours Basic Machine Travel hose Every 2 years or Every 6000 hours Boom cylinder line hose Every 2 years or Every 6000 hours Arm cylinder line hose Every 2 years or Every 6000 hours Bucket cylinder line hose Every 2 years or Every 6000 hours Hydraulic System Front-End Attachment Pilot hose Every 2 years or Every 6000 hours NOTE: Replace seals, such as O-rings and gas- kets, when replacing hoses.
  • 63. GENERAL / Painting W1-3-1 PAINTING Painting specification Surfaces to Be Painted Painting Colour • Main surface of upperstructure (except cab) YR-01 [TAXI yellow] Bed cover HG Beige Deep Inner Grey • Front attachment YR-01 [TAXI yellow] • Track (including swing ring) N1.0 [Black] • Floor plate M/F Cation (allowed) Final painted color • Inside and outside surface of cab HG Beige Deep • Shaded area on cab outside Shining Silver • Right window beam, U-Bolt [KASAI PAINT LF-113-230B (Charcoal series black, half glossy)] • Suspension lifter (chair bottom) [N2.0 (Black)] • Lever (Travel, pilot shut-off, foot rest) High Grade Brack • Engine cover High Grade Brack • Tool box, Tool box cover HG Beige Deep • Cover, Step HG Beige Deep • Handrail on upperstructure right side HG Beige Deep • Nonslip cover KANSAI PAINT ALAMIC 1400 (Deep Black) • Mirror stay High Grade Brack • Rear camera assembly HG Beige Deep
  • 64. GENERAL / Painting W1-3-2 ZX200-3 class, ZX240-3 class, ZX270-3 class W1V1-01-03-001 ZX225USR-3 class W1V1-01-03-002 ZX225US-3 class W1V1-01-03-003 1 - Handrail on Upperstructure Right Side 4 - Tool Box Cover 7 - Decal (Shining Silver) 10 - Camera Cover 2 - Cover 5 - Mirror Stay 8 - Decal (TAXI Yellow) 11 - Decal (TAXI Yellow) 3 - Step 6 - Tool Box 9 - Engine Cover 12 - Control Valve Cover 1 2 3 4 9 10 118 7 6 5 1 12 9 10 118 7 5 1 12 9 118 7 5 10
  • 65. GENERAL / Painting W1-3-3 ZX200-3 class, ZX240-3 class, ZX270-3 class ZX225US-3 class, ZX225USR-3 class W1V1-01-03-004 B Align with the panel. (Shining Silver) Panel (Shaded Area) Shining Silver Paint all circumference in the hinge swing position shining silver Section B (Door) (Door) Rear Panel Shining Silver Painted Range on Door 10 (Shaded Area) Shining Silver Paint all circumference in the hinge swing position shining silver
  • 67. GENERAL / Bleeding Air from Hydraulic Oil Tank W1-4-1 BLEEDING AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation, and may spurt, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if re- moved without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Preparation 1. Place the machine on a firm, level surface. 2. Stop the engine. Push the pressure release but- ton on top of the hydraulic oil tank to release any remaining pressure. 3. Remove hydraulic oil tank cap. Connect a vac- uum pump to maintain negative pressure in the hydraulic oil tank. NOTE: Be sure to run the vacuum pump continu- ously while working. M104-07-021 W1V1-04-01-008 W562-02-03-008 Adapter Vacuum Pump Hose Pressure Release Button
  • 68. GENERAL / Bleeding Air from Hydraulic Oil Tank W1-4-2 (Blank)
  • 69. MEMO .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... ....................................................................................................................................................................
  • 70. MEMO .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... ....................................................................................................................................................................
  • 71. 1V1W-2-1 SECTION 2 UPPERSTRUCTURE — CONTENTS — Group 1 Cab Remove and Install Cab (ZX200-3 class, 240-3 class, 270-3 class)....................W2-1-1 Remove and Install Cab (ZX225US-3 class, 225USR-3 class) ................................W2-1-9 Dimensions of Cab Glass (ZX200-3 class, 240-3 class, 270-3 class)..................W2-1-21 Dimensions of Cab Glass (ZX225US-3 class, 225USR-3 class) ..............................W2-1-25 Group 2 Counterweight Remove and Install Counterweight ........W2-2-1 List of Weight .........................................W2-2-4 Group 3 Main Frame Remove and Install Main Frame ............W2-3-1 List of Weight .........................................W2-3-9 Group 4 Pump Device Remove and Install Pump Device (ZX200-3 class, 240-3 class, 270-3 class)........................................W2-4-1 Remove and Install Pump Device (ZX225US-3 class) .............................W2-4-7 Remove and Install Pump Device (ZX225USR-3 class).........................W2-4-17 Disassemble Pump Device ..................W2-4-26 Assemble Pump Device.......................W2-4-38 Disassemble Regulator........................W2-4-56 Assemble Regulator.............................W2-4-58 Disassemble Solenoid Valve................W2-4-60 Assemble Solenoid Valve.....................W2-4-62 Structure of Pilot Pump ........................W2-4-64 Maintenance Standard .........................W2-4-66 Group 5 Control Valve Remove and Install Control Valve (ZX200-3 class, 240-3 class, 270-3 class) ........................................W2-5-1 Remove and Install Control Valve (ZX225US-3 class, 225USR-3 class)..W2-5-3 Disassemble Control Valve (4-Spool Side) ...................................W2-5-10 Assemble Control Valve (4-Spool Side) ...................................W2-5-22 Disassemble Control Valve (5-Spool Side) ...................................W2-5-40 Assemble Control Valve (5-Spool Side) ...................................W2-5-52 Disassemble Housing...........................W2-5-64 Assemble Housing................................W2-5-66 Remove and Install Auxiliary Control Valve (Optional)..............................................W2-5-69 Disassemble Auxiliary Control Valve ..............................................................W2-5-72 Assemble Auxiliary Control Valve .........W2-5-76
  • 72. 1V1W-2-2 Group 6 Swing Device Remove and Install Swing Device (ZX200-3 class, 240-3 class, 270-3 class)........................................W2-6-1 Remove and Install Swing Device (ZX225US-3 class, 225USR-3 class).W2-6-3 Disassemble Swing Device....................W2-6-8 Assemble Swing Device.......................W2-6-16 Disassemble Swing Motor (ZX200-3 class, ZX225US-3 class, 225USR-3 class, 240-3 class)..........W2-6-30 Disassemble Swing Motor (ZX270-3 class) ................................W2-6-34 Assemble Swing Motor (ZX200-3 class, ZX225US-3 class, 225USR-3 class, 240-3 class) ........W2-6-38 Assemble Swing Motor (ZX270-3 class) ................................W2-6-42 Structure of Swing Parking Brake Switch Valve (ZX270-3 class).................................W2-6-46 Maintenance Standard .........................W2-6-47 Group 7 Pilot Valve Remove and Install Pilot Valve...............W2-7-1 Disassemble Right and Left Pilot Valves .......................................W2-7-18 Assemble Right and Left Pilot Valves .......................................W2-7-22 Disassemble Travel Pilot Valve ............W2-7-26 Assemble Travel Pilot Valve.................W2-7-30 Disassemble Positioning Pilot Valve (2-Piece Boom Only) ........................W2-7-36 Assemble Positioning Pilot Valve (2-Piece Boom Only) ........................W2-7-38 Group 8 Pilot Shut-Off Solenoid Valve Remove and Install Pilot Shut-Off Solenoid Valve..............W2-8-1 Disassemble Pilot Shut-Off Solenoid Valve....................................W2-8-2 Assemble Pilot Shut-Off Solenoid Valve....................................W2-8-4 Group 9 Signal Control Valve Remove and Install Signal Control Valve (ZX200-3 class, 240-3 class, 270-3 class) ........................................W2-9-1 Remove and Install Signal Control Valve (ZX225US-3 class, 225USR-3 class).................................W2-9-3 Structure of Signal Control Valve............W2-9-8 Group 10 4-Spool Solenoid Valve Unit Remove and Install 4- Spool Solenoid Valve Unit (ZX200-3 class, 240-3 class, 270-3 class)..................W2-10-1 Remove and Install 4- Spool Solenoid Valve Unit (ZX225US-3 class, 225USR-3 class)...............................W2-10-2 Structure of 4-Spool Solenoid Valve Unit ...........................W2-10-4 Group 11 Engine Remove and Install Engine (ZX200-3 class, 240-3 class, 270-3 class)..................W2-11-1 Remove and Install Engine (ZX225US-3 class)..........................W2-11-24 Remove and Install Engine (ZX225USR-3 class).......................W2-11-49
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