Description

Hitachi ZX130W,ZX160W,ZX180W,ZX210W Excavator Operator’s Manual (EMCBB-EN2-1, EMCBB-EN3-1)

Hitachi ZX130W,ZX160W,ZX180W,ZX210W Excavator Index:

MACHINE NUMBERS
SAFETY
Recognize Safety Information ………………………. S-1
Understand Signal Words …………………………… S-1
Follow Safety Instructions …………………………… S-2
Prepare for Emergencies…………………………….. S-2
Wear Protective Clothing…………………………….. S-3
Protect Against Noise………………………………… S-3
Inspect Machine……………………………………….. S-3
General Precautions for Cab………………………… S-4
Use Handholds and Steps…………………………… S-5
Adjust the Operator’s Seat ………………………….. S-5
Fasten Your Seat Belt ……………………………….. S-6
Move and Operate Machine Safely………………… S-6
Handle Starting Aids Safely…………………………. S-6
Operate Only from Operator’s Seat ……………….. S-7
Jump Starting ………………………………………….. S-7
Keep Riders Off Machine ……………………………. S-7
Investigate Job Site Beforehand ……………………. S-8
Protect Against Falling Stones and Debris………. S-8
Provide Signals for Jobs Involving Multiple
Numbers of Machines …………………………… S-9
Confirm Direction of Machine to be Driven……….. S-9
Drive Machine Safely (Work Site)………………… S-10
Avoid Injury from Rollaway Accidents …………… S-11
Avoid Injury from Back-Over
and Swing Accidents ………………………….. S-12
Keep 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 Safe Maintenance ……………………….. S-19
Warn Others of Service Work …………………….. S-20
Support Machine Properly…………………………. S-20
Stay Clear of Moving Parts………………………… S-20
Prevent Parts from Flying ………………………… S-21
Store Attachments Safely …………………………. S-21
Support Maintenance Properly……………………. S-21
Prevent Burns ………………………………………… S-22
Replace Rubber Hoses Periodically …………….. S-22
Avoid High-Pressure Fluids ……………………….. S-23
Prevent Fires …………………………………………. S-24
Evacuating in Case of Fire…………………………. S-25
Beware of Exhaust Fumes ………………………… S-25
Precautions for Welding and Grinding…………… S-26
Avoid Heating Near Pressurized Fluid Lines …… S-27
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………. S-27
Remove Paint Before Welding or Heating………. S-27
Prevent Battery Explosions ……………………….. S-28
Service Air Conditioning System Safely………… S-28
Handle Chemical Products Safely……………….. S-29
Dispose of Waste Properly………………………… S-29
SAFETY SIGNS………………………………… S-30
COMPONENTS NAME…………………………1-1
OPERATOR’S STATION
Cab Features …………………………………………….1-2
Steering Column Console……………………………..1-3
Steering Wheel and Horn Switch……………….1-4
Forward/Reverse Traveal Pedal …………………1-4
Brake Pedal…………………………………………1-5
Brake Oil Pressure Gauge and Indicator ……..1-6
Sift Lever …………………………………………….1-7
Combination Switch With Turn Signal
Switch, Light and Dimmer Switches………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
Overload Alarm Indicator (Optional) ………….1-15
Liquid Crystal Display (LCD), Display
Selection Switch, Set Switch…………….1-16
Hour Meter…………………………………………1-16
Trip Meter (Trip Meter 1 and Trip Meter 2) ….1-17
Engine Speed …………………………………….1-17
Hydraulic Oil Temperature ……………………..1-17
Trip Meter Function………………………………1-18
Work Mode Switch………………………………1-20
Switch Panel ………………………………………….1-21
Engine Control Dial………………………………1-21
Engine Control Mode Selection Switch……..1-22
Work Light Switch……………………………….1-23
Power Mode Switch……………………………..1-24
Auto-Idle/Acceleration Selector……………….1-24
Switch Panel (Optional) ……………………………..1-25
CONTENTS
Key Switch……………………………………………..1-26
Power Boost Switch………………………………….1-26
Attachement Switch (When Optional
Attachment is Equipped)……………………….1-26
Horn Switch…………………………………………….1-27
Attachment Selection Switch (When the
2-piece Boom and an Optional
Attachment are Installed) ………………………1-27
Cigar Lighter ……………………………………………1-28
12-V Power Source (Optional) ……………………..1-29
Cab Light………………………………………………..1-30
Installing Fire Extinguisher ………………………….1-30
First Aid Kid ……………………………………………1-30
Pilot Control Shut-Off Lever …………………………1-31
Engine Stop Knob …………………………………….1-31
Swing Lock Lever ……………………………………..1-32
Fuse Box ……………………………………………….1-33
Auto Air Conditioner ………………………………….1-34
Cab Heater Operation ………………………………..1-37
Cooling Operation……………………………………..1-38
Defroster Operation …………………………………..1-38
Tips for Optimal Air Conditioner Usage …………..1-39
Auto Air Conditioner ………………………………….1-40
Cab Heater Operation ………………………………..1-44
Cooling Operation……………………………………..1-45
Defroster Operation …………………………………..1-45
Tips for Optimal Air Conditioner Usage …………..1-47
Cab Heater (Optional) ………………………………..1-48
Cab Heater Operation ………………………………..1-49
Defroster Operation …………………………………..1-50
AM/FM Radio Operation …………………………….1-51
Digital Clock Setting Procedure ……………………1-52
Cab Door Release Lever……………………………..1-53
Opening Upper Front Window………………………1-53
Closing Upper Front Window ……………………….1-54
Removing and Storing Lower Front Window …….1-55
Opening Side Windows………………………………1-55
Opening/Closing Overhead Window……………….1-56
Emergency Exit ……………………………………….1-57
Adjusting the Seat…………………………………….1-58
Seat with a Built-In Heater (Optional)……………..1-59
Adjusting the Air-Suspension Seat (Optional)…..1-60
Seat with a Built-In Heater…………………………..1-61
Seat Belt………………………………………………..1-62
BREAK-IN
Observe Engine Operation Closely………………….2-1
Every 8 Hours or Daily …………………………………2-1
After the First 50 Hours………………………………..2-1
After the First 100 Hours ………………………………2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting……………..3-1
Before Starting Engine…………………………………3-2
Starting The Engine in Ordinary Temperature …….3-3
Starting in Cold Weather………………………………3-4
Check Instruments After Starting ……………………3-5
Using Booster Batteries ……………………………….3-6
Stopping the Engine ……………………………………3-8
DRIVING THE MACHINE
Traveling…………………………………………………..4-1
Engine Speed Control………………………………….4-5
Stopping and Restarting While Traveling
on a Public Road…………………………………..4-7
Instructions for Traveling on a Slope ………………..4-9
Traveling in Water or on Soft Terrain………………4-10
Extrication from Soft Ground ……………………….4-10
Parking ………………………………………………….4-11
Emergency Parking…………………………………..4-12
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
Power Boost……………………………………………5-10
Power Mode ……………………………………………5-11
Engine Speed Control Mode Selection Switch….5-12
Precaustions for Operations ………………………..5-13
Operate the Machine Safely ………………………..5-14
Traveling/Operating 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
Face Shovel Operation……………………………….5-18
Avoid Excavation While Striking
with the Bucket Teeth…………………………..5-18
Grading ………………………………………………….5-19
Do Not Use The Bucket Instead of a Hammer….5-19
Avoid Increasing Digging Force Forcibly …………5-20
Avoid Using Swing Power……………………………5-20
Emergency Boom Lowering Procedure…………..5-21
Object Handling — If Equipped …………………….5-24
Overnight Storage Instructions ……………………..5-26
TRANSPORTATION
General Transportation Hints …………………………6-1
Loading/Unloading The Machine …………………….6-2
Towing Machine …………………………………………6-5
Machine Lifting Procedure…………………………….6-6
MAINTENANCE
Correct Maintenance and Inspection Procedures ..7-1
Check the Hour Meter Regularly …………………….7-2
Use Correct Fuels and Lubricants…………………..7-2
Layout ……………………………………………………7-3

Maintenance Guide Table……………………………..7-4
Prepare Machine for Maintenance…………………..7-6
Hood and Access Covers ……………………………..7-7
Periodic Replacement of Parts ………………………7-8
Maintenance Guide …………………………………….7-9
A. Greasing ………………………………………….7-15
Front Joint Pins …………………………………..7-15
Swing Bearing…………………………………….7-18
Swing Internal Gear ……………………………..7-19
Front Axle………………………………………….7-20
Propel Shaft ……………………………………….7-21
Equalizer Pin ……………………………………..7-22
B. Engine………………………………………………7-23
Engine Oil Level ………………………………….7-23
Change Engine Oil……………………………….7-24
Replace Engine Oil Filter……………………….7-24
C. Transmission …………………………………….7-26
Pump Transmission……………………………..7-26
Swing Reduction Gear ………………………….7-27
Transmission Gear Oil ………………………….7-28
Front Axle………………………………………….7-29
Rear Axle ………………………………………….7-30
Front and Rear Hub Reduction 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 System………………………………..7-37
Inspection and Maintenance of Hydraulic
Equipment…………………………………….7-37
Replacement of Hydraulic Oil and Filter …….7-39
Check Hydraulic Oil Level………………………7-40
Drain Hydraulic Oil Tank Sump ……………….7-41
Change Hydraulic Oil ……………………………7-42
Clean the Suction Filter…………………………7-45
Replace Hydraulic Tank Oil Filter
(Std. Model) ………………………………….7-46
Replace Full-Flow Filter (Optional)……………7-47
Replace Pilot×Brake and Steering Filter……..7-48
Replace Air Breather Element…………………7-49
Clean Steering Suction Filter Element ………7-50
Check Hoses and Lines ………………………..7-51
Service Recommendations for
Hydraulic Fittings ……………………………7-54
G. Fuel System ………………………………………7-56
Drain Fuel Tank Sump ………………………….7-58
Check Water Separator…………………………7-58
Replace Fuel Filter ………………………………7-60
Clean Feed Pump Strainer …………………….7-61
Check Fuel Hoses ……………………………….7-62
H. Air Cleaner…………………………………………7-63
Clean Air Cleaner Outer Element …………….7-63
Replace Inner Element (Optional)…………….7-64
I. Cooling System…………………………………..7-65
Check Coolant Level …………………………….7-66
Check and Adjust Fan Belt Tension …………7-66
Change Coolant…………………………………..7-67
Clean Radiator, Oil Cooler Core
and Inter Cooler ……………………………..7-68
Clean Oil Cooler Front Screen ………………..7-68
Clean Air Conditioner Condenser……………..7-68
J. Electrical System ………………………………7-69
Batteries……………………………………………7-69
Replace Batteries ………………………………..7-72
Remove and Installing Battery…………………7-73
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 Seat Belt ……………….7-80
Check Windshield Washer Fluid Level………7-80
Clean and Replace Air Conditioner
Filter Clean Filter ……………………………7-81
Check the Air Conditioner………………………7-83
Clean Cab Floor ………………………………….7-84
Check Injection Nozzle …………………………7-85
Retighten Cylinder Head Bolt………………….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
Check Tightening Torque of Bolts
and Nuts ………………………………………7-86
HYDRAULIC CIRCUIT AND
ELECTRICAL CIRCUIT
Hydraulic Circuit…………………………………………8-1
Electrical Circuit…………………………………………8-2
Electrical Diagram………………………………………8-3
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions ………………………..9-1
STORAGE
Storing the Machine ………………………………….10-1
Removing the Machine from Storage ……………..10-2
Installing Vandal-Proof Covers ……………………..10-3
Help Prevent Crime……………………………………10-4
Record Identification Numbers ……………………..10-4
Keep Proof of Ownership…………………………….10-4
Park Indoors Out of Sight ……………………………10-4
When Parking Outdoors……………………………..10-5
Reduce Vandalism ……………………………………10-5
Report Thefts Immediately…………………………..10-5
CONTENTS
TROUBLESHOOTING
Troubleshooting………………………………………..11-1
SPECIFICATIONS
ZAXIS130W
Specifications ……………………………………12-1
Working Ranges………………………………….12-6
ZAXIS160W
Specifications ……………………………………12-8
Working Ranges……………………………….. 12-13
ZAXIS180W
Specifications …………………………………. 12-15
Working Ranges……………………………….. 12-20
ZAXIS210W
Specifications …………………………………. 12-22
Working Ranges……………………………….. 12-27
Sound level results (2000/14/EC) ……………….. 12-29
OPTIONAL ATTACHMENTS AND
DEVICES
Blade and stabilizer…………………………………..13-1
Maintenance……………………………………………13-5
2-Piece Boom………………………………………….13-6
Maintenance (2-Piece Boom) ………………………13-7
Specifications (ZAXIS130W)……………………… 13-10
Specifications (ZAXIS160W)……………………… 13-12
Specifications (ZAXIS180W)……………………… 13-21
Specifications (ZAXIS210W)……………………… 13-23
Lifting Capacities (ZAXIS130W) …………………. 13-28
Lifting Capacities (ZAXIS160W) …………………. 13-34
Lifting Capacities (ZAXIS180W) …………………. 13-46
Lifting Capacities (ZAXIS210W) …………………. 13-52
Attachment Pedal (Breaker) ……………………… 13-68
Precautions for Breaker Operation ……………… 13-69
Replacement of Hydraulic Oil and Filter……….. 13-71
Attachment Pedal (Hydraulic Crusher)…………. 13-72
Precautions for Crusher Operation ……………… 13-73
Electronic Key Lock Operation Manual………… 13-74
Registration/Registration Cancellation of
Ordinary Operation Key………………………. 13-77
Additional Registration Procedure ………………. 13-78
Registration Cancellation Procedure……………. 13-79
INDEX…………………………………………………14-1

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