Description
Hitachi ZX140W-3, ZX145W-3, ZX170W-3, ZX190W-3, ZX210W-3 Wheeled Excavator Operator’s Manual (EMCGB-EN2-1, EMCGB-EN2-2)
Hitachi ZX140W-3, ZX145W-3, ZX170W-3, ZX190W-3, ZX210W-3 Wheeled Excavator Index:
MACHINE NUMBERS ………………………………………………………………1
SAFETY …………………………………………………………………………………..S-1
Recognize Safety Information……………………………………………..S-1
Understand Signal Words……………………………………………………..S-1
Follow Safety Instructions…………………………………………………….S-2
Prepare for Emergencies……………………………………………………….S-3
Wear Protective Clothing……………………………………………………..S-3
Protect Against Noise……………………………………………………………S-3
Inspect Machine…………………………………………………………………….S-4
General Precautions for Cab…………………………………………………S-4
Use Handrails and Steps……………………………………………………….S-5
Never Ride Attachment…………………………………………………………S-5
Adjust Operator’s Seat…………………………………………………………..S-5
Ensure Safety Before Rising from
or Leaving Operator’s Seat………………………………………………S-6
Fasten Your Seat Belt……………………………………………………………..S-6
Move and Operate Machine Safely……………………………………..S-6
Handle Starting Aids Safely………………………………………………….S-7
Operate Only from Operator’s Seat…………………………………….S-7
Jump Starting…………………………………………………………………………S-7
Keep Riders Off Machine………………………………………………………S-8
Precautions for Operations…………………………………………………..S-8
Investigate Job Site Beforehand………………………………………….S-9
Equipment of OPG………………………………………………………………S-10
Provide Signals for Jobs Involving Multiple Machines….S-10
Confirm Direction of Machine to Be Driven…………………….S-10
Drive Machine Safely…………………………………………………………..S-11
Avoid Injury from Rollaway Accidents……………………………..S-11
Avoid Injury from Back-over and Swing Accidents………..S-12
Keep Person 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-16
Precautions for Lightning…………………………………………………..S-16
Object Handling………………………………………………………………….S-17
Protect Against Flying Debris……………………………………………S-17
Park Machine Safely…………………………………………………………….S-18
Handle Fluids Safely−avoid Fires………………………………………S-18
Transport Safely…………………………………………………………………..S-19
Practice Safe Maintenance…………………………………………………S-20
Warn Others of Service Work…………………………………………….S-21
Support Machine Properly…………………………………………………S-21
Stay Clear of Moving Parts…………………………………………………S-21
Prevent Parts from Flying…………………………………………………..S-22
Store Attachments Safely…………………………………………………..S-22
Support Maintenance Properly…………………………………………S-22
Prevent Burns……………………………………………………………………….S-23
Replace Rubber Hoses Periodically…………………………………..S-23
Avoid High-pressure Fluids………………………………………………..S-24
Prevent Fires…………………………………………………………………………S-25
Evacuating in Case of Fire…………………………………………………..S-26
Beware of Exhaust Fumes………………………………………………….S-26
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
Beware of Asbestos and Silicon Dust and Other Contamination………………………………………………………………..S-28
Prevent Battery Explosions………………………………………………..S-28
Service Air Conditioning System Safely…………………………..S-28
Handle Chemical Products Safely……………………………………..S-29
Dispose of Waste Properly………………………………………………….S-29
Precaution for Communication Terminal Equipment……S-30
SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only …………………………………………………………………………S-31
COMPONENTS NAME …………………………………………………………1-1
Cab Features (Standard Model)……………………………………………1-2
OPERATOR’S STATION ………………………………………………………..1-2
Steering Column Console…………………………………………………….1-3
Steering Wheel and Travel Horn Switch……………………………..1-4
Accelerator Pedal……………………………………………………………………1-4
Brake Pedal……………………………………………………………………………..1-5
Forward/Reverse Travel Switch……………………………………………1-6
Combination Switch (Turn Signal Switch, Light Switch, Dimmer Switch, Passing Switch)…………………………………….1-7
Brake Switch…………………………………………………………………………1-10
Working Brake (Axle Lock/Auto Axle Lock)……………………..1-11
Auto Axle Lock……………………………………………………………………..1-11
Hazard Switch………………………………………………………………………1-12
Operator’s Station……………………………………………………………….1-13
Engine Control Dial………………………………………………………..1-14
Travel Mode Switch………………………………………………………..1-14
Engine Speed Control Mode Selection Switch………….1-15
Power Mode Switch……………………………………………………….1-16
Work Light Switch…………………………………………………………..1-17
Wiper/Washer Switch…………………………………………………….1-18
Blade/Outrigger/Front Attachment Pilot Control
Shut-off Switch…………………………………………………………..1-19
Auto-Idle Switch……………………………………………………………..1-20
Switch Panel (Optional)………………………………………………………1-21
Electric Control Main Switch…………………………………………1-21
Travel Alarm Deactivation Switch (1) (Optional)……….1-22
Front/Rear Attachment Selection Switch (4)
(Optional)……………………………………………………………………1-22
Right/Left Selection Switch (5) (Optional)………………….1-22
Swing Alarm Switch (2) (Optional )……………………………..1-22
Overload Alarm Switch (Optional)……………………………….1-23
Revolving Light Switch (Optional)……………………………….1-23
Seat Heater Switch (Optional)………………………………………1-23
Key Switch…………………………………………………………………………….1-24
Right/Left Control Levers (AFL*)……………………………………….1-25
AUX Function Lever Switch………………………………………………..1-27
Cigar Lighter…………………………………………………………………………1-29
Cab Light………………………………………………………………………………1-30
Installing Fire Extinguisher (Optional)……………………………..1-30
Pilot Control Shut-off Lever……………………………………………….1-31
Engine Stop Switch…………………………………………………………….1-31
Machine Height Control Switch (ZX145W-3, Optional)..1-32
Multifunction Monitor……………………………………………………….1-33
Basic Screen…………………………………………………………………………1-34
Monitor Operation……………………………………………………………..1-35
Displaying Basic Screen………………………………………………..1-35
Trip Meter (7)…………………………………………………………………..1-37
Odometer (8)…………………………………………………………………..1-37
Hour Meter (9)………………………………………………………………..1-37
Clock (18)…………………………………………………………………………1-37
Fuel Gauge (25)………………………………………………………………1-37
Coolant Temperature Gauge (30)………………………………..1-37
Brake Oil Pressure Gauge (33)………………………………………1-38
Travel Speed Meter (34)………………………………………………..1-38
Tachometer (35)……………………………………………………………..1-38
Back Monitor Screen Selector (22)………………………………1-42
Menu Key (23)…………………………………………………………………1-42
Optional Function Keys (24, 27, 29 and 31)……………….1-42
Return to Basic Screen Key (32)……………………………………1-42
Menu Screen…………………………………………………………………..1-45
Displaying Basic Screen by Inputting Password (Optional)……………………………………………………………………1-46
Corrective Measures to be Taken When a Wrong Password is Input………………………………………………………1-48
Extending Password Validity Time………………………………1-50
Alarm Occurrence Screen………………………………………………….1-51
Clock Setting……………………………………………………………………….1-55
Work Mode (Attachment Selection)………………………………..1-56
Attachment Adjustment
(Pump 2 Flow Rate Adjustment)………………………………….1-60
Operating Status…………………………………………………………………1-62
Maintenance Setting………………………………………………………….1-63
Mail (Optional)…………………………………………………………………….1-69
Meter Display Control………………………………………………………..1-72
Password Revising (Optional)……………………………………………1-74
Back Monitor Setting………………………………………………………….1-77
Language Setting……………………………………………………………….1-80
Meter Combination Setting………………………………………………1-82
Unit Setting………………………………………………………………………….1-84
Fuse Box……………………………………………………………………………….1-86
Additional Fuse Box……………………………………………………………1-86
Auto Air Conditioner Operation……………………………………….1-87
Tips for Optimal Air Conditioner Usage…………………………..1-94
Heater (Optional) Operation……………………………………………..1-95
AM/FM Radio Operation (If Equipped)…………………………….1-99
AM/FM Radio Operation (If Equipped)…………………………..1-101
Cab Door Release Lever……………………………………………………1-104
Opening Upper Front Window……………………………………….1-104
Closing Upper Front Window………………………………………….1-105
Removing and Storing Lower Front Window……………….1-106
Opening Door Windows…………………………………………………..1-107
Opening/Closing Overhead Window (Std. Model)………1-108
Opening/Closing Polycarbonate Type Roof Overhead Window (Clear Hatch: If Equipped)……………………………1-108
Emergency Exit………………………………………………………………….1-109
Adjusting Seat……………………………………………………………………1-110
Seat with a Built-in Heater……………………………………………….1-111
Adjusting Air-suspension Seat (Optional)……………………..1-112
Seat with a Built-in Heater……………………………………………….1-113
Seat Belt………………………………………………………………………………1-114
BREAK-IN ……………………………………………………………………………….2-1
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 ENGINE ……………………………………………………………3-1
Inspect Machine Daily Before Starting……………………………….3-1
Before Starting Engine………………………………………………………….3-2
Starting Engine in Ordinary Temperature………………………….3-3
Starting in Cold Weather………………………………………………………3-6
Starting in Cold Weather (ZX140W-3, 145W-3)…………………3-8
Check Instruments After Starting………………………………………..3-9
Using Booster Batteries………………………………………………………3-10
Stopping Engine………………………………………………………………….3-12
DRIVING MACHINE ……………………………………………………………..4-1
Traveling………………………………………………………………………………….4-1
Engine Speed Control……………………………………………………………4-3
Check for Machine Height (ZX145W-3)
(Only Machines Equipped with Optional Parts)…………..4-4
Machine Height Adjusting Procedures (ZX145W-3)
(Only Machines Equipped with Optional Parts)…………..4-5
Travel Mode Switch……………………………………………………………….4-6
Stopping and Restarting………………………………………………………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 Due to Machine Failure…………………..4-12
Travel Alarm (Optional)………………………………………………………4-13
OPERATING MACHINE ………………………………………………………..5-1
Control Lever (ISO Pattern) (Standard)……………………………….5-1
Control Lever (Hitachi Pattern)…………………………………………….5-2
Pilot Control Shut-off Lever………………………………………………….5-3
Steering Wheel Column………………………………………………………..5-4
Warming-up Operation…………………………………………………………5-5
Engine Speed Control……………………………………………………………5-6
Auto-Idle………………………………………………………………………………….5-7
Work Mode……………………………………………………………………………..5-9
Power Boost (Only ZX210W-3)………………………………………….5-11
Power Mode…………………………………………………………………………5-12
Parking/Stopping Machine on a Slope
(In Case of Emergency)………………………………………………….5-14
Raising Machine Front Above Ground
with Boom and Arm Function………………………………………5-14
Operating Differential Gear at High-speed for a Long Periods of Time is Prohibited………………………………………..5-15
Excavation…………………………………………………………………………….5-16
Face Shovel Operation……………………………………………………….5-17
CONTENTS
Grading Operation………………………………………………………………5-18
Do Not Slam Bucket Teeth Into Ground…………………………..5-18
Do Not Use Bucket as a Hammer………………………………………5-18
Avoid Increasing Digging Force Forcibly…………………………5-19
Avoid Using Swing Power………………………………………………….5-19
Boom Lowering Procedure in Emergency or When
Engine Stalls (Only ZX140W-3, ZX145W-3, 170W-3
and 190W-3 without Hose Rupture Valve)………………….5-20
Boom Lowering Procedure in Emergency or When the Engine Stalls (Only ZX210W-3 without Hose Rupture Valve)………………………………………………………………………………..5-21
Overnight Storage Instructions…………………………………………5-22
Attachment Pedal (Hydraulic Breaker) (Optional)………….5-23
Attachment Pedal (Hydraulic Crusher) (Optional)………….5-25
Hydraulic Breaker and Hydraulic Crusher………………………..5-27
Pipings for Breaker and Crusher (Optional)…………………….5-28
ZX140W-3/145W-3…………………………………………………………5-28
ZX170W-3/190W-3…………………………………………………………5-29
ZX210W-3………………………………………………………………………..5-30
Secondary Relief Pressure Adjustment……………………………5-31
Pressure Measurement………………………………………………….5-32
Precautions for Breaker Operation……………………………………5-33
Precautions for Crusher Operation…………………………………..5-36
Attachment…………………………………………………………………………..5-38
Allowable Weight Limits of Installed Attachment…….5-38
Attachments……………………………………………………………………5-41
Attachment Connection Parts…………………………………………..5-42
Precaution for Arm Roll-in/Bucket Roll-in Combined Operation…………………………………………………………………………5-43
When Installing an Attachment Longer Than Standard Bucket………………………………………………………………………………5-43
Object Handling — If Equipped………………………………………..5-44
TRANSPORTING …………………………………………………………………..6-1
Transporting by Road……………………………………………………………6-1
Loading/Unloading on a Trailer…………………………………………..6-2
Ramp/Loading Dock…………………………………………………………6-2
Transporting……………………………………………………………………………6-4
Unloading……………………………………………………………………………….6-5
Towing Machine…………………………………………………………………….6-6
MAINTENANCE …………………………………………………………………….7-1
Correct Maintenance and Inspection Procedures…………….7-1
Check 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……………………………………………………………………………7-16
Front Joint Pins……………………………………………………………….7-16
Swing Bearing…………………………………………………………………7-18
Swing Internal Gear……………………………………………………….7-19
Front Axle…………………………………………………………………………7-20
Propel Shaft (Front and Rear)……………………………………….7-21
Equalizer Pin……………………………………………………………………7-22
Suspension Cylinder (ZX145W-3) (Optional)……………..7-22
Suspension Link Pin (ZX145W-3) (Optional)………………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 Oil……………………………………………………………..7-28
Front Axle…………………………………………………………………………7-29
Rear Axle………………………………………………………………………….7-30
Front and Rear Hub Reduction Devices ……………………..7-31
D. Brake (Traveling)……………………………………………………………..7-33
Check Brake Accumulator……………………………………………..7-34
Check Brake Lining for Wear…………………………………………7-35
Check and Clean Brake Oil Pipings………………………………7-35
E. Tire……………………………………………………………………………………..7-36
Tire Inspection and Replacement Procedure…………….7-37
F. Hydraulic System……………………………………………………………..7-38
Breaker Maintenance……………………………………………………..7-40
Check Hydraulic Oil Level……………………………………………..7-41
Change Hydraulic Oil……………………………………………………..7-42
Suction Filter Cleaning…………………………………………………..7-42
Replace Hydraulic Oil Tank Filter (Std. Model) …………..7-46
Replace Full-Flow Filter (Optional)……………………………….7-47
Replace Pilot and Steering · Brake Oil Filter………………..7-48
Replace Air Breather Element……………………………………….7-49
Check Hoses and Lines………………………………………………….7-50
Service Recommendations for Hydraulic Fittings……..7-53
G. Fuel System……………………………………………………………………..7-55
Drain Fuel Tank Sump…………………………………………………….7-57
Drain Fuel Filter……………………………………………………………….7-58
Replace Fuel Main Filter Element…………………………………7-62
Replace Fuel Pre-filter Element…………………………………….7-63
Clean Fuel Solenoid Pump Strainer……………………………..7-64
Check Fuel Hoses……………………………………………………………7-65
H. Air Cleaner……………………………………………………………………….7-66
Clean Air Cleaner Outer Element…………………………………7-66
Replace Air Cleaner Outer and Inner Elements………….7-66
I. Cooling System…………………………………………………………………7-68
Check Coolant Level………………………………………………………7-69
Check and Adjust Fan Belt Tension
(ZX140W-3, 145W-3)………………………………………………….7-70
Check and Adjust Fan Belt Tension
(ZX170W-3, 190W-3, 210W-3)………………………………….7-71
Change Coolant………………………………………………………………7-72
Clean Radiator Interior…………………………………………………..7-72
Clean Inter Cooler Oil Cooler and Radiator Core……….7-73
Clean Oil Cooler Front Screen………………………………………7-73
Clean Air Conditioner Condenser………………………………..7-73
Clean Fuel Oil Cooler……………………………………………………..7-73
Clean Air Conditioner Front Screen (Opt.)………………….7-73
J. Electrical System………………………………………………………………7-74
Batteries…………………………………………………………………………..7-74
Replace Batteries…………………………………………………………….7-77
Remove and Installing Battery……………………………………..7-78
Replacing Fuses………………………………………………………………7-78
K. Miscellaneous………………………………………………………………….7-80
Check Bucket Teeth………………………………………………………..7-80
Change Bucket………………………………………………………………..7-82
Convert Bucket Connection Into Face Shovel……………7-83
Adjust Bucket Linkage…………………………………………………..7-84
Check and Replace Seat Belt…………………………………………7-85
Check Windshield Washer Fluid Level…………………………7-86
Clean and Replace Air Conditioner Filter……………………7-87
Check Air Conditioner……………………………………………………7-89
Clean Cab Floor………………………………………………………………7-90
Retighten Cylinder Head Bolt……………………………………….7-91
Inspect and Adjust Valve Clearance…………………………….7-91
Measure Engine Compression Pressure……………………..7-91
Check Starter and Alternator………………………………………..7-91
Check and Replace EGR Device……………………………………7-91
Check Suspension Accumulator (ZX145W-3)
(Optional)……………………………………………………………………7-91
Check Tightening Torque of Bolts and Nuts……………….7-92
HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT …………8-1
Hydraulic Circuit…………………………………………………………………….8-1
Electrical Circuit……………………………………………………………………..8-2
Electrical Diagram …………………………………………………………………8-3
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS ………………………………………9-1
STORAGE …………………………………………………………………………….10-1
Storing Machine………………………………………………………………….10-1
Removing Machine from Storage…………………………………….10-2
TROUBLESHOOTING ………………………………………………………..11-1
Troubleshooting………………………………………………………………….11-1
1. Engine…………………………………………………………………………..11-1
2. Engine Auxiliaries……………………………………………………….11-1
3. Engine is Hard to Start……………………………………………….11-2
4. Control Lever……………………………………………………………….11-3
5. Hydraulic System………………………………………………………..11-4
6. Travel…………………………………………………………………………….11-5
7. Swing……………………………………………………………………………11-8
8. Engine Speed………………………………………………………………11-9
9. Blade/Outrigger………………………………………………………..11-10
10. Positioning………………………………………………………………11-10
11. Others………………………………………………………………………11-10
SPECIFICATIONS ……………………………………………………………….12-1
Specifications ZX140W-3
(Rear Blade)……………………………………………………………………..12-1
Specifications ZX140W-3
(Rear Outrigger)………………………………………………………………12-2
Specifications ZX140W-3
(Front Blade Rear Outrigger)…………………………………………12-3
Specifications ZX140W-3
(Front Outrigger Rear Blade)…………………………………………12-4
Specifications ZX140W-3
(Front Outrigger Rear Outrigger)…………………………………12-5
Working Ranges ZX140W-3 Monoblock Boom………………12-6
Working Ranges ZX140W-3 2-Piece Boom……………………..12-7
Specifications ZX145W-3
(Standard Chassis, Rear Blade)……………………………………..12-8
Specifications ZX145W-3
(Standard Chassis, Rear Outrigger)………………………………12-9
Specifications ZX145W-3
(Front Blade Rear Outrigger)……………………………………….12-10
Specifications ZX145W-3
(Front Outrigger Rear Blade)……………………………………….12-11
Specifications ZX145W-3
(Front Outrigger Rear Outrigger)……………………………….12-12
Working Ranges ZX145W-3 2-Piece Boom……………………12-13
Specifications ZX170W-3
(Standard Gauge, Rear Blade)……………………………………..12-14
Specifications ZX170W-3
(Standard Gauge, Rear Outrigger)……………………………..12-15
Specifications ZX170W-3 (Standard Gauge,
Front Blade Rear Outrigger)………………………………………..12-16
Specifications ZX170W-3 (Standard Gauge,
Front Outrigger Rear Blade)………………………………………..12-17
Specifications ZX170W-3 (Standard Gauge,
Front Outrigger Rear Outrigger)………………………………..12-18
Working Ranges ZX170W-3 Monoblock Boom…………….12-19
Working Ranges ZX170W-3 2-Piece Boom……………………12-20
Specifications ZX190W-3
(Standard Gauge, Rear Blade)……………………………………..12-21
Specifications ZX190W-3
(Standard Gauge, Rear Outrigger)……………………………..12-22
Specifications ZX190W-3 (Standard Gauge,
Standard Chassis, Front Blade Rear Outrigger)………..12-23
Specifications ZX190W-3 (Standard Gauge,
Standard Chassis, Front Outrigger Rear Blade)………..12-24
Specifications ZX190W-3 (Standard Gauge,
Standard Chassis, Front Outrigger Rear Outrigger)…12-25
Working Ranges ZX190W-3 Monoblock Boom…………….12-26
Working Ranges ZX190W-3 2-Piece Boom……………………12-27
Specifications ZX210W-3
(Standard Gauge, Rear Blade)……………………………………..12-28
Specifications ZX210W-3 (Standard Gauge,
Rear Outrigger)……………………………………………………………..12-29
Specifications ZX210W-3 (Standard Gauge,
Front Blade Rear Outrigger)………………………………………..12-30
Specifications ZX210W-3 (Standard Gauge,
Front Outrigger Rear Blade)………………………………………..12-31
Specifications ZX210W-3 (Standard Gauge,
Front Outrigger Rear Outrigger)………………………………..12-32
Working Ranges ZX210W-3 Monoblock Boom…………….12-33
Working Ranges ZX210W-3 2-Piece Boom……………………12-34
Sound Level Results (2000/14/EC)………………………………….12-35
Vibration Level……………………………………………………………………12-35
OPTIONAL ATTACHMENTS AND DEVICES ………………….13-1
Blade and Outrigger……………………………………………………………13-1
CONTENTS
Maintenance………………………………………………………………………..13-5
2-Piece Boom……………………………………………………………………….13-6
Maintenance (2-Piece Boom)…………………………………………….13-7
Lifting Hook………………………………………………………………………..13-11
Lifting Capacities (ZX140W-3)…………………………………………13-13
Lifting Capacities (ZX145W-3)…………………………………………13-25
Lifting Capacities (ZX170W-3)…………………………………………13-28
Lifting Capacities (ZX190W-3)…………………………………………13-52
Lifting Capacities (ZX210W-3)…………………………………………13-62
INDEX …………………………………………………………………………………..14-1
