Description
Hitachi ZX200-3,ZX240-3,ZX270-3,ZX330-3 Excavator Operator’s Manual (EM1U1-1-2)
Hitachi ZX200-3,ZX240-3,ZX270-3,ZX330-3 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
Ensure Safety Before Rising from or
Leaving 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
Precautions for Operations ………………………………………………… S-8
Investigate Job Site Beforehand ……………………………………….. S-9
Equipment of Head Guard, Rops, Fops ………………………….. S-10
Provide Signals for Jobs Involving
Multiple Numbers of Machines …………………………………. S-10
Confirm Direction of Machine to Be Driven …………………… S-10
Drive Machine Safely …………………………………………………………. S-11
Avoid Injury from Rollaway Accidents ……………………………. S-13
Avoid Injury from Back-over and Swing Accidents ………. S-14
Keep Person Clear from Working Area …………………………… S-15
Never Position Bucket Over Anyone ………………………………. S-15
Avoid Undercutting …………………………………………………………… S-15
Avoid Tipping ……………………………………………………………………… S-16
Never Undercut a High Bank ……………………………………………. S-16
Dig with Caution ………………………………………………………………… S-17
Operate with Caution ……………………………………………………….. S-17
Avoid Power Lines ……………………………………………………………… S-18
Precautions for Lightening ………………………………………………. S-18
Object Handling ………………………………………………………………… S-18
Protect Against Flying Debris ………………………………………….. S-19
Park Machine Safely …………………………………………………………… S-19
Handle Fluids Safely−avoid Fires …………………………………….. S-19
Transport Safely …………………………………………………………………. S-20
Practice Safe Maintenance ……………………………………………….. S-21
Warn Others of Service Work …………………………………………… S-22
Support Machine Properly ……………………………………………….. S-22
Stay Clear of Moving Parts ……………………………………………….. S-22
Prevent Parts from Flying …………………………………………………. S-23
Store Attachments Safely …………………………………………………. S-23
Prevent Burns ……………………………………………………………………… S-24
Replace Rubber Hoses Periodically …………………………………. S-24
Avoid High-pressure Fluids ………………………………………………. S-25
Prevent Fires ……………………………………………………………………….. S-26
Evacuating in Case of Fire …………………………………………………. S-27
Beware of Exhaust Fumes ………………………………………………… S-27
Precautions for Welding and Grinding …………………………… S-27
Avoid Heating Near Pressurized Fluid Lines ………………….. S-28
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………………………………… S-28
Remove Paint Before Welding or Heating ……………………… S-28
Beware of Asbestos Dust ………………………………………………….. S-29
Prevent Battery Explosions ………………………………………………. S-29
Service Air Conditioning System Safely …………………………. S-29
Handle Chemical Products Safely ……………………………………. S-30
Dispose of Waste Properly ………………………………………………… S-30
SAFETY SIGNS …………………………………………………………………… S-31
COMPONENTS NAME ……………………………………………………….. 1-1
OPERATOR’S STATION
Cab Features …………………………………………………………………………. 1-2
Multi Function Monitor ………………………………………………………. 1-4
Outline …………………………………………………………………………………… 1-5
Menu Screen (23) …………………………………………………………… 1-8
Hour Meter ……………………………………………………………………… 1-9
Fuel Gauge ……………………………………………………………………… 1-9
Clock ………………………………………………………………………………… 1-9
Back Monitor Selector …………………………………………………… 1-9
Menu Key ……………………………………………………………………….1-10
Optional Function Key …………………………………………………1-10
Return to Basic Screen Key …………………………………………1-10
Alarm Light ……………………………………………………………………1-10
Optional Function Display …………………………………………1-10
Coolant Temperature Gauge ………………………………………1-11
Operating Status Icon Display ……………………………………1-11
Alarm Occurrence Screen ………………………………………………….1-16
Contents of Alarms …………………………………………………………….1-18
Clock Setting ……………………………………………………………………….1-20
Attachment Selection
(Only Machines Equipped with Optional Parts) ………1-21
Pump 2 Flow Rate Adjustment
(Only Machines Equipped with Optional Parts) ………1-25
Displaying Operating Conditions …………………………………….1-26
Fuel Rate Display/No Display ……………………………………………1-27
Back Monitor Settings ……………………………………………………….1-35
Maintenance Settings ………………………………………………………..1-37
Mail (Optional) …………………………………………………………………….1-42
Language Settings ……………………………………………………………..1-44
Switch Panel ………………………………………………………………………..1-46
Engine Control Dial …………………………………………………………….1-47
Auto-idle Switch …………………………………………………………………1-47
Power Mode Switch …………………………………………………………..1-48
Travel Mode Switch ……………………………………………………………1-48
Work Light Switch ………………………………………………………………1-49
Wiper/Washer Switch …………………………………………………………1-50
Switch Panel (Optional) ……………………………………………………..1-52
Key Switch ……………………………………………………………………………1-54
Power Boost Switch ……………………………………………………………1-54
Horn Switch …………………………………………………………………………1-54
Cigar Lighter ………………………………………………………………………..1-55
Cab Light ……………………………………………………………………………..1-56
Installing Fire Extinguisher ……………………………………………….1-56
Pilot Control Shut-off Lever ………………………………………………1-57
Engine Stop Switch …………………………………………………………….1-57
Fuse Box ……………………………………………………………………………….1-58
Auto Air Conditioner ………………………………………………………….1-59
Cab Heater Operation ………………………………………………………..1-62
Cooling Operation ……………………………………………………………..1-63
Defroster Operation …………………………………………………………..1-63
Tips for Optimal Air Conditioner Usage ………………………….1-65
Cab Heater (Optional) ………………………………………………………..1-66
Cab Heater Operation ………………………………………………………..1-67
Defroster Operation …………………………………………………………..1-68
AM/FM Radio Operation …………………………………………………..1-69
Digital Clock Setting Procedure ……………………………………….1-70
Cab Door Release Lever …………………………………………………….1-71
Opening Upper Front Window …………………………………………1-71
Closing Upper Front Window ……………………………………………1-72
Removing and Storing Lower Front Window …………………1-73
Opening Side Windows ……………………………………………………..1-73
Opening/Closing Overhead Window ………………………………1-74
Emergency Exit …………………………………………………………………..1-75
Adjusting the Seat ……………………………………………………………..1-76
Adjusting the Air-suspension Seat (Optional) ……………….1-78
Adjusting Console Height …………………………………………………1-80
Seat Belt ……………………………………………………………………………….1-81
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 ……………………………………………………. 3-5
Check Instruments After Starting ……………………………………… 3-7
Using Booster Batteries ………………………………………………………. 3-8
Stopping the Engine ………………………………………………………….3-10
DRIVING THE MACHINE
Drive the Machine Carefully ………………………………………………. 4-1
Steering the Machine Using Pedals ………………………………….. 4-2
Steering the Machine Using Levers ………………………………….. 4-3
Travel Mode Switch …………………………………………………………….. 4-4
Travel Alarm (Optional) ………………………………………………………. 4-4
Operating on Soft Ground …………………………………………………. 4-5
Raise One Track Using Boom and Arm …………………………….. 4-5
Towing Machine a Short Distance …………………………………….. 4-6
Operating in Water or Mud ………………………………………………… 4-7
Parking the Machine on Slopes …………………………………………. 4-8
Parking the Machine …………………………………………………………… 4-8
OPERATING THE MACHINE
Control Lever (Iso Pattern) …………………………………………………. 5-1
Control Lever (HITACHI Pattern) ………………………………………… 5-2
Attchement Pedal (Hydraulic Breaker) …………………………….. 5-3
Attchement Pedal (Hydraulic Crusher) …………………………….. 5-4
Pilot Control Shut-off Lever ……………………………………………….. 5-5
Engine Speed Control …………………………………………………………. 5-7
Auto-idle ………………………………………………………………………………. 5-8
Work Mode …………………………………………………………………………… 5-9
Work Mode Select ………………………………………………………………5-10
Power Boost ………………………………………………………………………..5-11
Power Mode ……………………………………………………………………….5-12
Operating Backhoe …………………………………………………………….5-13
Grading Operation ……………………………………………………………..5-13
Face Shovel Operation ………………………………………………………5-14
Avoid Abusive Operation ………………………………………………….5-14
Operating Tips …………………………………………………………………….5-15
Select Correct Track Shoes ………………………………………………..5-15
Hydraulic Breaker and Hydraulic Crusher ……………………….5-16
Pipings for Breaker and Crusher ………………………………………5-17
Secondary Relief Pressure Adjustment …………………………..5-18
Precautions for Breaker Operation …………………………………..5-19
Breaker Maintenance …………………………………………………………5-22
Precautions for Crusher Operation ………………………………….5-23
Attachment ………………………………………………………………………….5-25
Attachment Connection Parts ………………………………………….5-29
Precaution for Arm Roll-in/bucket Roll-in
Combined Operation — If Headguard-integrated
Cab or Raingard Is Equipped ………………………………………5-30
When Installing an Attachment Longer
Than Standard Bucket ………………………………………………….5-30
Shackle Hole Usage ……………………………………………………………5-31
Overnight Storage Instructions ………………………………………..5-31
Emergency Boom Lowering Procedure
(Without Hose-rupture Safety Valve) ………………………..5-32
Object Handling — If Equipped ……………………………………….5-33
TRANSPORTING
Transporting By Road …………………………………………………………. 6-1
Loading/unloading on a Trailer …………………………………………. 6-1
Machine Lifting Procedure …………………………………………………. 6-5
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
CONTENTS
Maintenance Guide …………………………………………………………….. 7-9
A. Greasing …………………………………………………………………………..7-14
Front Joint Pins ……………………………………………………………..7-14
Swing Bearing ……………………………………………………………….7-16
Swing Internal Gear ……………………………………………………..7-17
B. Engine ………………………………………………………………………………7-18
Engine Oil Level …………………………………………………………….7-18
Change Engine Oil ……………………………………………………….7-19
Replace Engine Oil Filter ……………………………………………..7-19
C. Transmission ……………………………………………………………………7-21
Pump Transmission ………………………………………………………7-21
Swing Reduction Gear …………………………………………………7-22
Travel Reduction Gear ………………………………………………….7-23
D. Hydraulic System ……………………………………………………………7-25
Inspection and Maintenance of Hydraulic
Equipment …………………………………………………………………….7-25
Breaker Maintenance …………………………………………………..7-27
Check Hydraulic Oil Level ……………………………………………7-28
Change Hydraulic Oil …………………………………………………..7-29
Suction Filter Cleaning ………………………………………………..7-29
Replace Hydraulic Tank Oil Filter ………………………………..7-32
Replace Pilot Oil Filter ………………………………………………….7-33
Replace Air Breather Element …………………………………….7-34
Check Hoses and Lines ………………………………………………..7-35
Service Recommendations for Hydraulic Fittings …..7-38
E. Fuel System ……………………………………………………………………..7-40
Drain Fuel Tank Sump …………………………………………………7-42
Check Water Separator ………………………………………………..7-43
Replace Fuel Main Filter Element ……………………………….7-47
Replace Fuel Pre-filter Element …………………………………7-48
Clean Fuel Solenoid Pump Strainer …………………………..7-49
Check Fuel Hoses ………………………………………………………….7-50
F. Air Cleaner ………………………………………………………………………..7-51
Clean the Air Cleaner Outer Element ………………………..7-51
Replace the Air Cleaner Outer and Inner Elements …7-51
G. Cooling System ………………………………………………………………7-53
Check Coolant Level …………………………………………………….7-55
Check and Adjust Fan Belt Tension ………………………………7-56
Change Coolant ……………………………………………………………7-57
Clean Radiator Interior ………………………………………………..7-57
Clean Radiator, Oil Cooler Core and Inter Cooler …….7-58
Clean Oil Cooler, Radiator and Inter
Coller Front Screen ……………………………………………………….7-58
Clean Air Conditioner Condenser ………………………………7-58
Clean Fuel Oil Cooler …………………………………………………..7-58
Clean Air Conditioner Front Screen (Opt.) ……………….7-58
H. Electrical System …………………………………………………………….7-59
Replace Batteries ………………………………………………………….7-62
Remove and Installing Battery …………………………………..7-63
Replacing Fuses …………………………………………………………….7-63
I. Miscellaneous ………………………………………………………………….7-65
Check Bucket Teeth ………………………………………………………7-65
Change Bucket ……………………………………………………………..7-69
Convert Bucket Connection Into Face Shovel ………….7-70
Adjust the Bucket Linkage ………………………………………….7-71
Remove the Travel Levers ……………………………………………7-72
Check and Replace Seat Belt Check …………………………..7-72
Check Windshield Washer Fluid Level ……………………….7-73
Check Track Sag …………………………………………………………….7-74
Clean and Replace Air Conditioner Filter
Clean Filter …………………………………………………………………….7-76
Check the Air Conditioner …………………………………………..7-78
Clean Cab Floor …………………………………………………………….7-79
Retighten Cylinder Head Bolt …………………………………….7-80
Inspect and Adjust Valve Clearance …………………………..7-80
Measure Engine Compression Pressure ……………………7-80
Check Starter and Alternator ……………………………………..7-80
Check Tightening Torque of Bolts and Nuts …………….7-81
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
TROUBLESHOOTING
Impossible to Start the Engine …………………………………………11-1
Engine …………………………………………………………………………………..11-2
Electrical System …………………………………………………………………11-6
Mode Selection …………………………………………………………………..11-8
Control Levers ……………………………………………………………………..11-9
Hydraulic System ………………………………………………………………..11-9
SPECIFICATIONS
Specifications (ZAXIS200-3, ZAXIS200LC-3,
ZAXIS210H-3, ZAXIS210LCH-3) ……………………………………12-1
Working Ranges (ZAXIS200-3, ZAXIS200LC-3,
ZAXIS210H-3, ZAXIS210LCH-3) ……………………………………12-2
Shoe Types and Applications (ZAXIS200-3,
ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3) ………….12-3
Bucket Types and Applications (ZAXIS200-3,
ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3) ………….12-5
Specifications (ZAXIS210K-3, 210LCK-3) …………………………..12-6
Working Ranges (ZAXIS210K-3, 210LCK-3) ………………………12-7
Shoe Types and Applications
(ZAXIS210K-3, 210LCK-3) ………………………………………………12-8
Bucket Types and Applications
(ZAXIS210K-3, 210LCK-3) ………………………………………………12-9
Specifications (ZAXIS240-3, 240LC-3, 250H-3,
250LCH-3) ……………………………………………………………………. 12-10
Working Ranges (ZAXIS240-3, 240LC-3,
250H-3, 250LCH-3) ……………………………………………………… 12-10
Shoe Types and Applications (ZAXIS240-3, 240LC-3,
250H-3, 250LCH-3) ……………………………………………………… 12-11
Bucket Types and Applications (ZAXIS240-3,
240LC-3, 250H-3, 250LCH-3) ……………………………………… 12-12
Specifications (ZAXIS250K-3, 250LCK-3) ……………………….. 12-15
Working Ranges (ZAXIS250K-3, 250LCK-3) …………………… 12-16
Shoe Types and Applications (ZAXIS250K-3,
250LCK-3) ……………………………………………………………………. 12-17
Bucket Types and Applications
(ZAXIS250K-3, 250LCK-3) …………………………………………… 12-18
Specifications (ZAXIS270-3, 270LC-3) ……………………………. 12-19
Working Ranges (ZAXIS270-3, 270LC-3) ……………………….. 12-20
Shoe Types and Applications (ZAXIS270-3, 270LC-3) …. 12-21
Bucket Types and Applications
(ZAXIS270-3, 270LC-3) ……………………………………………….. 12-22
Specifications (ZAXIS330-3, 330LC-3,
350H-3, 350LCH-3) ……………………………………………………… 12-23
Working Ranges (ZAXIS330-3, 330LC-3,
350H-3, 350LCH-3) ……………………………………………………… 12-24
Shoe Types and Applications (ZAXIS330-3, 330LC-3,
350H-3, 350LCH-3) ……………………………………………………… 12-25
Bucket Types and Applications
(ZAXIS330-3, 330LC-3, 350H-3, 350LCH-3) ………………. 12-27
Specifications (ZAXIS350K-3, 350LCK-3) ……………………….. 12-28
Working Ranges (ZAXIS350K-3, 350LCK-3) …………………… 12-29
Shoe Types and Applications (ZAXIS350K-3, 350LCK-3) 12-30
Bucket Types and Applications
(ZAXIS350K-3, 350LCK-3) …………………………………………… 12-31
INDEX …………………………………………………………………………………..14-1
