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120-3 class
Hitachi 120-3 class User Manual
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MAINTENANCE
7-83
12
Retighten C
ylinder Head Bolt
--- as required
See your authorized dealer
.
13
Inspec
t and Adjust
V
alve Clearance
--- ev
ery 1000 hours
See your authorized dealer
.
14
Measure Engine Compression P
ressure
--- ev
ery 1000 hours
See your authorized dealer
.
15
Check Starter and Alternator
--- ev
ery 1000 hours
See your authorized dealer
.
16
Check and Replace EGR Device
--- as required
See your authorized dealer
.
274
276
Table of Contents
Table of Contents
7
Safety
13
Recognize Safety Information
13
Understand Signal Words
13
Follow Safety Instructions
14
Prepare for Emergencies
15
Wear Protective Clothing
15
Protect against Noise
15
Inspect Machine
16
General Precautions for Cab
16
Use Handholds and Steps
17
Adjust the Operator's Seat
17
Ensure Safety before Rising from or Leaving Operator's Seat
17
Fasten Your Seat Belt
18
Move and Operate Machine Safely
18
Handle Starting Aids Safely
18
Operate Only from Operator's Seat
19
Jump Starting
19
Keep Riders off Machine
19
Precautions for Operations
20
Investigate Job Site Beforehand
21
Equipment of Head Guard, Rops, Fops
22
Provide Signals for Jobs Involving Multiple Numbers of Machines
22
Confirm Direction of Machine to be Driven
22
Drive Machine Safely
23
Avoid Injury from Rollaway Accidents
25
Avoid Injury from Back-Over and Swing Accidents
26
Keep Person Clear from Working Area
27
Never Position Bucket over Anyone
27
Avoid Undercutting
27
Avoid Tipping
28
Never Undercut a High Bank
28
Dig with Caution
29
Operate with Caution
29
Avoid Power Lines
30
Precautions for Lightning
30
Object Handling
30
Protect against Flying Debris
31
Park Machine Safely
31
Handle Fluids Safely−Avoid Fires
31
Transport Safely
32
Practice Safe Maintenance
33
Warn Others of Service Work
34
Support Machine Properly
34
Stay Clear of Moving Parts
34
Prevent Parts from Flying
35
Store Attachments Safely
35
Prevent Burns
36
Replace Rubber Hoses Periodically
36
Avoid High-Pressure Fluids
37
Prevent Fires
38
Evacuating in Case of Fire
39
Beware of Exhaust Fumes
39
Precautions for Welding and Grinding
39
Avoid Heating Near Pressurized Fluid Lines
40
Avoid Applying Heat to Lines Containing Flammable Fluids
40
Remove Paint before Welding or Heating
40
Beware of Asbestos Dust
41
Prevent Battery Explosions
41
Service Air Conditioning System Safely
41
Handle Chemical Products Safely
42
Dispose of Waste Properly
42
Safety Signs
43
Components Name
51
Operator's Station
52
Cab Features
52
Multi Function Monitor
53
Outline
54
Menu Screen (23)
57
Hour Meter
58
Fuel Gauge
58
Clock
58
Back Monitor Selector
58
Menu Key
59
Optional Function Key
59
Return to Basic Screen Key
59
Alarm Light
59
Optional Function Display
59
Coolant Temperature Gauge
60
Operating Status Icon Display
60
Alarm Occurrence Screen
65
Contents of Alarms
67
Clock Setting
69
Attachment Selection (Only Machines Equipped with Optional Parts)
70
Pump 2 Flow Rate Adjustment (Only Machines Equipped with Optional Parts)
74
Displaying Operating Conditions
75
Fuel Rate Display/No Display
76
Back Monitor Settings
84
Maintenance Settings
86
Mail (Optional)
91
Language Settings
93
Switch Panel
95
Engine Control Dial
96
Auto-Idle Switch
96
Power Mode Switch
97
Travel Mode Switch
97
Work Light Switch
98
Wiper/Washer Switch
99
Switch Panel (Optional)
101
Key Switch
103
Power Boost Switch
103
Horn Switch
103
Cigar Lighter
104
Cab Light
105
Installing Fire Extinguisher (Optional)
105
Pilot Control Shut-Off Lever
106
Engine Stop Switch
106
Fuse Box
107
Auto Air Conditioner
108
Cab Heater Operation
112
Cooling Operation
112
Defroster Operation
113
Tips for Optimal Air Conditioner Usage
114
Cab Heater (Optional)
115
Cab Heater Operation
116
Defroster Operation
117
AM/FM Radio Operation
118
Digital Clock Setting Procedure
119
Cab Door Release Lever
120
Opening Upper Front Window
120
Closing Upper Front Window
121
Removing and Storing Lower Front Window
122
Opening Side Windows
122
Opening/Closing Overhead Window
123
Emergency Exit
124
Adjusting the Seat
125
Seat with a Built-In Heater
126
Adjusting the Air-Suspension Seat (Optional)
127
Seat with a Built-In Heater
128
Adjusting Console Height
129
Seat Belt
130
Break-In
131
Observe Engine Operation Closely
131
Every 8 Hours or Daily
131
After the First 50 Hours
131
After the First 100 Hours
131
Operating the Engine
133
Inspect Machine Daily before Starting
133
Before Starting Engine
134
Starting the Engine in Ordinary Temperature
135
Starting in Cold Weather
137
Check Instruments after Starting
139
Using Booster Batteries
140
Stopping the Engine
142
Driving the Machine
143
Drive the Machine Carefully
143
Steering the Machine Using Pedals
144
Steering the Machine Using Levers
145
Travel Mode Switch
146
Travel Alarm (Optional)
146
Operating on Soft Ground
147
Raise One Track Using Boom and Arm
147
Towing Machine a Short Distance
148
Operating in Water or Mud
149
Parking the Machine on Slopes
150
Parking the Machine
150
Operating the Machine
151
Control Lever (Iso Pattern)
151
Attachment Pedal (Hydraulic Breaker) (Optional)
152
Attachment Pedal (Hydraulic Crusher) (Optional)
153
Pilot Control Shut-Off Lever
154
Engine Speed Control
156
Auto-Idle
157
Work Mode
158
Work Mode Select
159
Power Boost
160
Power Mode
161
Operating Backhoe
162
Grading Operation
162
Face Shovel Operation
163
Avoid Abusive Operation
163
Operating Tips
164
Select Correct Track Shoes
164
Hydraulic Breaker and Hydraulic Crusher
165
Pipings for Breaker and Crusher
166
Secondary Relief Pressure Adjustment
168
Precautions for Breaker Operation
170
Breaker Maintenance
173
Precautions for Crusher Operation
174
Attachment
176
Attachment Connection Parts
180
Precaution for Arm Roll-In/Bucket Roll-In Combined Operation
181
When Installing an Attachment Longer than Standard Bucket
181
Shackle Hole Usage
182
Overnight Storage Instructions
182
Emergency Boom Lowering Procedure (Without Hose-Rupture Safety Valve)
183
Object Handling
185
Transporting
187
Transporting by Road
187
Loading/Unloading on a Trailer
187
Machine Lifting Procedure
191
Maintenance
193
Correct Maintenance and Inspection Procedures
193
Check the Hour Meter Regularly
194
Use Correct Fuels and Lubricants
194
Layout
195
Maintenance Guide Table
196
Prepare Machine for Maintenance
198
Hood and Access Covers (ZX120-3, 180-3 Class)
199
Hood and Access Covers (ZX200-3, 270-3, 330-3 Class)
200
Periodic Replacement of Parts
201
Maintenance Guide
202
Front Joint Pins
202
Swing Bearing
210
Swing Internal Gear
211
Engine
212
Engine Oil Level
212
Change Engine Oil
213
Replace Engine Oil Filter
213
Transmission
215
Pump Transmission
215
Swing Reduction Gear
216
Travel Reduction Gear
217
Hydraulic System
219
Inspection and Maintenance of Hydraulic Equipment
219
Breaker Maintenance
221
Check Hydraulic Oil Level
222
Change Hydraulic Oil
223
Suction Filter Cleaning
223
Replace Hydraulic Tank Oil Filter
226
Replace Pilot Oil Filter
227
Replace Air Breather Element
228
Check Hoses and Lines
229
Service Recommendations for Hydraulic Fittings
232
Fuel System
234
Drain Fuel Tank Sump
236
Drain Fuel Filter
237
Replace Fuel Main Filter Element
241
Replace Fuel Pre-Filter Element
242
Clean Fuel Solenoid Pump Strainer
243
Check Fuel Hoses
244
Air Cleaner
245
Clean Air Cleaner Outer Element
245
Replace Air Cleaner Outer and Inner Elements
245
Cooling System
247
Check Coolant Level
249
Check and Adjust Fan Belt Tension (ZX120-3, 180-3 Class)
250
Check and Adjust Fan Belt Tension (ZX200-3, ZX270-3, ZX330-3 Class)
251
Change Coolant
252
Clean Radiator Interior
252
Clean Radiator, Oil Cooler Core and Inter Cooler Outside
253
Clean Oil Cooler, Radiator and Inter Cooler Front Screen
253
Clean Air Conditioner Condenser
253
Clean Fuel Oil Cooler
253
Clean Air Conditioner Front Screen (Opt.)
253
Electrical System
254
Replace Batteries
257
Remove and Installing Battery
258
Replacing Fuses
258
Miscellaneous
260
Check Bucket Teeth
260
Change Bucket
264
Convert Bucket Connection into Face Shovel
265
Adjust Bucket Linkage
266
Remove Travel Levers
267
Check Windshield Washer Fluid Level
268
Check Track Sag
269
Clean and Replace Air Conditioner Filter
271
Check Air Conditioner
273
Clean Cab Floor
274
Retighten Cylinder Head Bolt
275
Inspect and Adjust Valve Clearance
275
Measure Engine Compression Pressure
275
Check Starter and Alternator
275
Check and Replace EGR Device
275
Check Tightening Torque of Bolts and Nuts
276
Hydraulic Circuit and Electrical Circuit
291
Hydraulic Circuit
291
Electrical Circuit
292
Electrical Diagram
292
Maintenance under Special Environmental Conditions
295
Storage
297
Storing the Machine
297
Removing the Machine from Storage
298
Troubleshooting
299
Impossible to Start the Engine
299
Engine
300
Electrical System
304
Mode Selection
306
Control Levers
307
Hydraulic System
307
Specifications
311
Specifications (ZX110-3, 110M-3)
311
Working Ranges (ZX110-3, 110M-3)
312
Shoe Types and Applications (ZX110-3)
313
(Zx110M-3)
315
Bucket Types and Applications (ZX110-3, 110M-3)
315
Specifications (ZX130-3, 130LCN-3)
315
Working Ranges (ZX130-3, 130LCN-3)
317
Shoe Types and Applications (ZX130LCN-3)
318
Bucket Types and Applications (ZX130-3, 130LCN-3)
320
Specifications (ZX160LC-3)
321
Working Ranges (ZX160LC-3)
322
Shoe Types and Applications (ZX160LC-3)
324
Bucket Types and Applications (ZX160LC-3)
325
Specifications (ZX180LC-3, 180LCN-3)
325
Working Ranges (ZX180LC-3, 180LCN-3)
327
Shoe Types and Applications (ZX180LC-3, 180LCN-3)
329
Bucket Types and Applications (ZX180LC-3, 180LCN-3)
330
Specifications (ZX210-3, 210LC-3)
330
Working Ranges (ZX210-3, 210LC-3)
332
Shoe Types and Applications (ZX210-3, 210LC-3)
333
Bucket Types and Applications (ZX210-3, 210LC-3)
334
Specifications (ZX210LCN-3, 240N-3)
335
Working Ranges (ZX210LCN-3, 240N-3)
336
Zx210Lcn-3, 240N-3
336
Bucket Types and Applications (ZX210LCN-3, 240N-3)
338
Specifications (ZX250LC-3, 250LCN-3)
338
Working Ranges (ZX250LC-3, 250LCN-3)
340
Shoe Types and Applications (ZX250LC-3, 250LCN-3)
341
Bucket Types and Applications (ZX250LC-3, 250LCN-3)
342
Specifications (ZX280LC-3, 280LCN-3)
342
Working Ranges (ZX280LC-3, 280LCN-3)
344
Shoe Types and Applications (ZX280LC-3, 280LCN-3)
345
Bucket Types and Applications (ZX280LC-3, 280LCN-3)
346
Specifications (ZX350LC-3, 350LCN-3)
346
Working Ranges (ZX350LC-3, 350LCN-3)
348
Shoe Types and Applications (ZX350LC-3, 350LCN-3)
349
Bucket Types and Applications
350
Sound Level Results (2000/14/EC)
351
Vibration Level
351
Optional Attachments and Devices
353
Using Pad Crawler Shoe
353
Traveling and Other Cautions
354
Transporting
355
Precautions for Transporting Machines with Pad Crawler Shoes
355
Long Arm Operation
358
Blade Lever
359
Precautions for Blade Operation
359
Avoid Hitting Blade with Front-End Attachment
360
Avoid Hitting Blade with Bucket
360
Avoid Striking the Blade into a Rock
360
Blade Maintenance
361
Specifications (ZX110-3 with Blade)
362
ZX110-3 with Blade
362
Specifications (ZX130-3 with Blade)
365
ZX130-3 with Blade
365
Offset Arm Front
368
Offset Direction and Working Range
369
Precautions for Operating with the Offset Function
370
Maintenance
371
Specifications (ZX110-3, 110M-3 Offset)
372
Working Ranges (ZX110-3, 110M-3 Offset)
373
Bucket Teeth (Transverse-Type-Pin-Used Type)
374
2-Piece Boom
375
Maintenance (2-Piece Boom)
376
Specifications
379
ZX130-3, 130LCN-3 2-Piece Boom
379
Working Ranges
380
ZX130-3, 130LCN-3 2-Piece Boom
380
Shoe Types and Applications
381
ZX130-3 2-Piece Boom
381
ZX130LCN-3 (2-Piece Boom)
382
Specifications
383
ZX210-3, 210LC-3 2-Piece Boom
383
Working Ranges
384
ZX210-3, 210LC-3 2-Piece Boom
384
Shoe Types and Applications
385
ZX210-3 2-Piece Boom
385
ZX210LC-3 2-Piece Boom
385
Specifications
386
ZX210LCN-3, 240N-3 2-Piece Boom
386
Working Ranges
387
ZX210LCN-3, 240N-3 2-Piece Boom
387
Shoe Types and Applications
388
ZX210LCN-3 2-Piece Boom
388
ZX240N-3 2-Piece Boom
388
Specifications
389
ZX250LC-3, 250LCN-3 2-Piece Boom
389
Working Ranges
390
ZX250LC-3, 250LCN-3 2-Piece Boom
390
Shoe Types and Applications
391
ZX250LC-3 2-Piece Boom
391
ZX250LCN-3 2-Piece Boom
391
Specifications
392
ZX280LC-3, 280LCN-3 2-Piece Boom
392
Working Ranges
393
ZX280LC-3, 280LCN-3 2-Piece Boom
393
Shoe Types and Applications
394
ZX280LC-3 2-Piece Boom
394
ZX280LCN-3 2-Piece Boom
394
Specifications
395
ZX350LC-3, 350LCN-3 2-Piece Boom
395
Working Ranges
396
ZX350LC-3, 350LCN-3 2-Piece Boom
396
Shoe Types and Applications
397
ZX350LC-3 2-Piece Boom
397
ZX350LCN-3 2-Piece Boom
397
Lifting Hook
398
4
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Hitachi 120-3 class Specifications
General
Brand
Hitachi
Model
120-3 class
Category
Excavators
Language
English
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