Hitachi ZAXIS 160W Wheeled Excavator operator’s manual SN 002001 and up.pdf

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INTRODUCTION Read this manual carefully manual carefully to learn how to operate and service your machine correctly. correctly. Failure to d o so could result in personal injury or machine damage. This standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: 20C to 40C (4F to 104F) Altitude: Up to 2000 m (to 66 00 ft) In case the machine is used under conditions other than described above, consult your nearest Hitachi dealer. This manual should be considered a permanent part of your machine and should remain with the machine when you sell it. This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified. Right-hand and left-hand sides are determined by facing in the direction of forward travel. Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of Hitachi's support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer. This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action. Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine. Prior to operating this machine in a country other than a country of its intended use, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of that particular country. Please do not operate this machine outside of the country of its intended use until such compliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized distributor or dealer if you have any questions concerning compliance.

All information, illustr ations and specifications in this ma nual are based on the latest prod uct information available at the time of publication. The right is reserved to make changes at any time without notice.













MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

MACHINE

SS3100862

1. 2. 3. 4. 5. 6.

Model/Type Homologation Number (Italy only) Vehicle Identification Number Operating mass (standard version) Year of Manufacturing Manufacturing Engine power in kW according to ISO9249

MCBB-01-011

VEHICLE IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER: NOTE: 

JK6CBB04200002001

Marks to indicate the start and end of the VIN

Manufacturer Code A: Amsterdam Factory Made B: Tsuchiura Factory Made Model Code CA: ZAXIS130W CB: ZAXIS160W CC: ZAXIS180W CD: ZAXIS210W

M157-12-008

Serial Number

Country Code 0: Japan 1: Germany 2: Italy 3: USA 4: EU (Exc. Germany and Italy) 9: Others Engine Type

ZAXIS130W, ZAXIS130W, 160W, 180W

ENGINE TYPE: MFG. NO.:

ZAXIS210W

M175-00-001







MACHINE NUMBERS HYDRAULIC PUMP TYPE: MFG. NO.:

ZAXIS130W, ZAXIS130W, 160W

SWING MOTOR


MCBB-00-001

MCBB-00-002

TYPE: MFG. NO.:

TRAVEL TRAVEL MOTOR

M178-07-086

TYPE: MFG. NO.:



MCBB-00-003

MCBB-07-021







MACHINE NUMBERS TRANSMISSION TYPE: MFG. NO.:

FRONT AXLE


MCBB-00-004


MCBB-00-007

TYPE: MFG. NO.:


ZAXIS210W

MCBB-00-008









MACHINE NUMBERS REAR AXLE TYPE: MFG. NO.:

MCBB-00-006


ZAXIS210W

MCBB-07-053







CONTENTS MACHINE NUMBERS SAFETY Recognize Safety Information ............................. S-1 Understand Understand Signal Words ............. ................... ............. .............. ......... .. S-1 Follow Safety Instructions ................................... S-2 Prepare for Emergencies Emergencies .............. ..................... .............. .............. ......... S-2 Wear Protective Protective Clothing .............. .................... ............. ............. ......... ... S-3 Protect Against Noise..........................................S-3 Inspect Machine .................................................. S-3 General Precautions for Cab.............. Cab.............. ................. S-4 Use Handholds and Steps...................................S-5 Adjust the Operator’s Seat .................................. S-5 Fasten Your Seat Belt ......................................... S-6 Move and Operate Machine Safely.....................S-6 Handle Starting Aids Safely.................................S-6 Operate Only from Operator’s Seat ............... ....................S-7 .....S-7 Jump Starting ................................................... ... S-7 Keep Riders Off Machine .................................... S-7 Investigate Investigate Job Site Beforehand ............. ................... ............S-8 ......S-8 Protect Against Falling Stones and Debris..........S-8 Provide Signals for Jobs Involving Multiple Numbers of Machines ................................... S-9 Confirm Direction Direction of Machine to be Driven ......... ......... S-9 Drive Machine Safely (Work Site) .............. .................... ........ S-10 Avoid Injury from Rollaway Accidents ............... S-11 Avoid Injury from Back-Over and Swing Accidents...................................S-12 Keep Personnel Personnel Clear from Working Area........S-13 Never Position Bucket Over Anyone ................. S-13 Avoid Undercutting ............................................ S-13 Avoid Tipping. .................................................... S-14 Never Undercut a High Bank.............................S-14 Dig with Caution ................................................ S-15 Operate with Caution.................... ..................... S-15 Avoid Power Lines.......... ................................... S-15 Object Handling ........................................... ...... S-16 Protect Against Flying Debris ............................ S-16 Park Machine Safely ............. ................... ............. .............. .............. ......... S-17 Handle Fluids Safely  Avoid Fires....................S-17 Safety Transporting ........................................... S-18 Practice Practice Safe Maintenance Maintenance .............. .................... ............ ...........S-19 .....S-19 Warn Others of Service Service Work .............. .................... .............S-20 .......S-20 Support Machine Properly.................................S-20 Stay Clear of Moving Moving Parts................................ S-20

Avoid Applying Heat to Lines Containing Flammable Fluids .............. ...................... ............... ............. .......... .... S-27 Remove Paint Paint Before Welding or Heating........ Heating........ S-27 Prevent Battery Explosions ............................... S-28 Service Air Air Conditioning System Safely............ S-28 Handle Chemical Products Products Safely ............ ................... ......... S-29 Dispose Dispose of Waste Properly............... Properly...................... .............. ......... .. S-29

SAFETY SIGNS................................... SIGNS ................................... S-30 COMPONENTS NAME .......................... 1-1 OPERATOR’S OPERATOR’S STA STATION Cab Features ......................................... .............. 1-2 Steering Column Console....................................1-3 Steering Wheel and Horn Switch...................1-4 Forward/Reverse Travel Pedal......................1-4 Brake Pedal ................................................... 1-5 Brake Oil Pressure Gauge and Indicator.......1-6 Shift Lever......................................................1-7 Combination Switch With Turn Signal Switch, Switch, Light and Dimmer Switches Switches ........1-8 ........1-8 Brake Switch.................. ................................ 1-9 Hazard Light Switch.....................................1-10 Abnormal Travel Motor Indicator ................. 1-10 Wiper Switch................................................1-11 Speedometer ............................................... 1-11 Monitor Panel.....................................................1-12 Coolant Temperature Gauge ..................... 1-13 Fuel Gauge ................................................ 1-13 Auto-Idle Indicator.......................... .............. 1-13 Auto-Acceleration Indicator ......................... 1-13 Fuel Level Indicator ..................................... 1-14 Air Filter Restriction Indicator ...................... 1-14 Overheat Indicator ....................................... 1-14 Engine Oil Pressure Indicator......................1-14 Alternator Indicator ...................................... 1-15 Preheat Indicator ......................................... 1-15 Hydraulic Oil Filter Restriction Indicator (If equipped) ............. .................... ............. ............. ............. .........1-15 ...1-15 Liquid Crystal Display (LCD), Display Selection Selection Switch, Switch, Set Switch ............. .................1-16 ....1-16 Hour Meter...................................................1-16 Trip Meter (Trip Meter Meter 1 and Trip Meter 2).. 1-17 Engine Speed 1-17







CONTENTS Power Boost Switch .............. ..................... ............. .............. ............... ....... 1-26 Attachement Switch (W hen Optional Attachment is Equipped) ............................. 1-26 Horn Switch ........................................... ............ 1-27 Attachment Selection Switch (Optional ) ............ 1-27 Cigar Lighter .................................................. .... 1-28 Cab Light ............................................... ............ 1-29 Installing Installing Fire Extinguisher Extinguisher .............. ..................... .............. ........... .... 1-29 First Aid Kit ........................................... ............. 1-29 Pilot Control Shut-Off Lever .............. ...................... ............... ......... 1-30 Engine Stop Knob ............. ................... .............. ............... ............. ........... ..... 1-30 Swing Lock Lever................... Lever.......................... ............. ............. ............. ........ 1-31 Fuse Box .............. ..................... .............. ............. .............. ............... ............... .......... .. 1-32 Auto Air Conditioner .......................................... 1-33 Cab Heater Operation Operation ............. ..................... ................ .............. .......... .... 1-36 Cooling Operation Operation .............. ..................... ............... ................ ............... ......... 1-37 Defroster Operation.. ......................................... 1-37 Tips for Optimal Air Conditioner Usage......... Usage............. .... 1-38 Auto Air Conditioner .......................................... 1-39 Cab Heater Operation Operation ............. ..................... ................ .............. .......... .... 1-44 Cooling Operation Operation .............. ..................... ............... ................ ............... ......... 1-44 Defroster Operation.. ......................................... 1-45 Tips for Optimal Air Conditioner Usage......... Usage............. .... 1-46 Cab Heater (Optional) (Optional) .............. ..................... ............. .............. ............ .... 1-47 Cab Heater Operation Operation ............. ..................... ................ .............. .......... .... 1-48 Defroster Operation.. ......................................... 1-49 AM/FM Radio Operation............. ....................... 1-50 Digital Clock Setting Procedure......................... 1-51 AM/FM Radio Operation............. ....................... 1-52 Digital Clock Setting Procedure......................... 1-53 Cab Door Release Lever................... Lever.......................... .............. ......... .. 1-54 Opening Upper Front W indow......... indow............... .............. ............ .... 1-54 Closing Upper Front Window .............. ..................... .............. ....... 1-55 Removing Removing and Storing Lower Front Window..... Window..... 1-56 Opening Side Windows................. Windows....................... .............. .............. ...... 1-56 Opening/Closing Opening/Closing Overhead Window ............. ................. .... 1-57 Emergency Exit ............. ..................... ............... ............. ............. .............. ......... 1-58 Adjusting the Seat ............................................. 1-59 Seat with a Built-In Built-In Heater (Optional)................ (Optional)................ 1-60 Adjusting the Air-Suspension Seat ( Optional) ... 1-61 Seat with with a Built-In Heater................................. 1-62 Seat Belt ............................................................ 1-63

Stopping the Engine.............................................3-8

DRIVING THE MACHINE Traveling ....................................................... ....... 4-1 Engine Speed Control..........................................4-2 Stopping and Restarting While Traveling on a Public Road ........................................... 4-4 Instructions Instructions for Traveling on a Slope ............ ...................4-6 .......4-6 Traveling Traveling in W ater or on Soft Terrain ............. ..................4-7 .....4-7 Extrication Extrication from Soft Ground .............. ..................... ............. ..........4-7 ....4-7 Parking.................................................................4-8 Emergency Parking ............................................. 4-9

OPERATING THE MACHINE Control Lever (ISO Pattern) ............................... 5-1 Pilot Control Shut-Off Lever.................................5-2 Steering Wheel Column.......................................5-3 Engine Speed Control..........................................5-6 Auto-Idle............................... ................................ 5-7 Auto Acceleration ................................................. 5-8 Work Mode ............... ..................... .............. ............... ............... ................ ............5-10 ....5-10 Power Boost.......................................................5-10 Power Mode.......................................................5-11 Engine Speed Control Control Mode Selection Selection Switch ..5-12 Precaustions for Operations .............................. 5-13 Operate the Machine Safely .............................. 5-14 Traveling/Oper Traveling/Operating ating the Machine on a Slope ....5-15 Parking/Stopping the Machine on a Slope (in Case of Emergency)...............................5-16 Raising the Machine Front Using the Boom and Arm ....................................................... 5-16 Excavation ...................................................... ...5-17 ... 5-17 Face Shovel Operation ...................................... 5-18 Avoid Excavation While Strik ing with the Bucket Teeth..................................5-18 Grading ......................................... ..................... 5-19 Do Not Use The Bucket Instead Instead of a Hammer ..5-19 Avoid Increasing Digging Force Forcibly ........... 5-20 Avoid Using Swing Power .................................. 5-20 Emergency Boom Lowering Lowering Procedure.. ........... 5-21 Overnight Overnight Storage Instructions Instructions ............. ................... ............ ........ 5-23

TRANSPORTATION BREAK-IN Observe Observe Engine Operation Closely

2-1

General Transportation Hints...............................6-1 Loading/Unloading The Machine 6-2







CONTENTS Periodic Replacement of Parts............................ 7-8 Maintenance Maintenance Guide .............. ..................... ............... ............... ............. ......... ... 7-9 A. Greasing ................................................. ... 7-15 Front Joint Pins ............. ..................... ............... ............. .............. .......... 7-15 Swing Bearing.................... Bearing........................... .............. .............. ........... .... 7-18 Swing Internal Gear ............ ................... .............. .............. .......... ... 7-19 Front Axle .................................................... 7-20 Propel Shaft ............. .................... ............. ............. ............. .............. .......... 7-21 Equalizer Equalizer Pin ............. .................... .............. .............. ............. ............. ....... 7-22 B. Engine ............. .................... ............. .............. ................ ............... ............. ........ .. 7-23 Engine Oil Level ............. ................... ............. ............... ............... ......... 7-23 Change Engine Oil ............. .................... ............. .............. ............ .... 7-24 Replace Replace Engine Oil Filter ............. .................... .............. ......... 7-24 C. Transmission ......................................... .... 7-26 Pump Transmission Transmission ................ ...................... ............. .............. ....... 7-26 Swing Reduction Gear .............. .................... ............. ............ ..... 7-27 Transmission Transmission Gear Oil .............. ..................... .............. ........... .... 7-28 Front Axle .................................................... 7-29 Rear Axle .............. ..................... .............. ............. ............. .............. ........... .... 7-30 Front and Rear Rear Hub Reduction Reduction Devices Devices ..... 7-31 D. Brake (Traveling)....................... .................. 7-32 Check Brake Accumulator .............. .................... ............ ...... 7-33 Check Wear on Brake Lining ............... ...................... ....... 7-34 E. Tire .............. ..................... ............... ................ ............... ............... ............... .......... ... 7-35 Tire Inspection and Replacement Procedure . 7-36 F. Hydraulic Hydraulic System System ............ .................... ............... .............. ............. ...... 7-37 Inspection and Maintenance of Hydraulic Equipment............... Equipment....................... ............... .............. .............. ......... 7-37 Replacement Replacement of Hydraulic Oil and Filter...... Filter...... 7-39 Check Hydraulic Hydraulic Oil Level................... Level......................... ........ .. 7-40 Drain Hydraulic Hydraulic Oil Tank Sump ............. ................... ...... 7-41 Change Hydraulic Hydraulic Oil ............. ..................... ............... ............. ...... 7-42 Clean the Suction Suction Filter............... Filter....................... ............... ......... 7-45 Replace Hydraulic Tank Oil Filter (Std. Model)........................................... 7-46 Replace Replace Full-Flow Full-Flow Filter (Optional)............ (Optional).............. .. 7-47 Replace PilotBrake and and Steering Steering Filter Filter ...... 7-48 Replace Air Breather Element..................... 7-49 Clean Steering Steering Suction Suction Filter Element Element ........ ........ 7-50 Check Hoses and Lines ............. .................... ............. .......... .... 7-51 Service Recommendations for Hydraulic Fittings.................... ............... 7-54 G. Fuel System System ............ .................... ............... .............. .............. .............. ....... 7-56 Drain Fuel Tank Sump ............. .................... ............. ............ ...... 7-58 Check Water Separator 7-58

Clean Radiator, Oil Cooler Core and Inter Cooler.....................................7-68 Clean Oil Cooler Front Screen .............. ....................7-68 ......7-68 Clean Air Conditioner Condenser................7-68 J. Electrical System ....................................... 7-69 Batteries.......................................................7-69 Replace Batteries ........................................ 7-72 Replacing Fuses..........................................7-73 K. Miscellaneous ............................................7-75 Check Bucket Teeth .................................... 7-75 Change Bucket .......................................... 7-77 Convert Bucket Connection Into Face Shovel...........................................7-78 Adjust the Bucket Linkage ........................... 7-79 Check and Replace Replace Seat Belt .................... 7-80 Check Windshield Washer Fluid Level........7-80 Level........7-80 Clean and Replace Air Conditioner Filter Clean Filter ............. ................... ............. .............. .........7-81 ..7-81 Check the Air Conditioner............................7-83 Clean Cab Floor...........................................7-84 Check Injection Nozzle ................................ 7-85 Retighten Retighten Cylinder Cylinder Head Bolt ............ ................... ..........7-85 ...7-85 Inspect and Adjust Valve Clearance............7-85 Check Fuel Injection Timing ................ ....................... ......... 7-85 Measure Engine Compression Pressure ..................................... ........... 7-85 Check Starter and Alternator ....................... 7-85 Change Water Pump Grease ............. .................... .........7-85 ..7-85 Check Tightening Torque of Bolts and Nuts .............................................. .. 7-86

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions..............................9-1

STORAGE Storing the Machine...........................................10-1 Removing Removing the Machine from Storage ............... ................. 10-2

TROUBLESHOOTING Troubleshooting ................................................. 11-1

SPECIFICATIONS ZAXIS130W







CONTENTS ZAXIS210W Specifications .......................................... 12-22 Working Ranges ............. ..................... ............... .............. ........... .... 12-27 Bucket Types and Applications................. Applications................. 12-28

OPTIONAL ATTACHMENTS AND DEVICES Blade and stabilizer stabilizer ............. ................... .............. ............... .............. ......... .. 13-1 Maintenance .................................................... .. 13-5 Attachment Pedal (Breaker ) .............................. 13-6 Precautions Precautions for Breaker Operation........... Operation.................. ......... .. 13-7 Replacement Replacement of Hydraulic Hydraulic Oil and Filter............ Filter............ 13-9 Attachment Pedal (Hydraulic Crusher) ............ 13-10 Precautions Precautions for Crusher Operation Operation ............. ................. .... 13-11 Electronic Electronic Key Lock Operation Manual Manual ........... ........... 13-12 Registration/Registration Cancellation of Ordinary Operation Key............................. 13-15 Additional Registration Procedu re................... re ................... 13-16 Registration Registration Cancellation Cancellation Procedure.......... Procedure............... ..... 13-17

INDEX ......................................... .................... 14-1









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Hitachi ZAXIS 160W Wheeled Excavator operator’s manual SN 002001 and up.pdf

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