Hitachi ZAXIS 210W-3 User manual

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INTRODUCTION
IN-01
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: [phone]
FAX: [phone]
• This manual contains the revision information
to the 18, June 2007.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Techni-
cal Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Man-
ual.
• Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
• Information included in the Technical Manual
(Troubleshooting):
technical information needed for operational per-
formance tests, and troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual W: Workshop Manual
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INTRODUCTION
IN-02
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting heavy
parts.
• CAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
• SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity To Convert
From Into Multiply By
MPa kgf/cm210.197Pressure
MPa psi 145.0
kW PS 1.360Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214Velocity
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
Quantity To Convert
From Into Multiply By
mm in 0.03937Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
Volume
m3yd31.308
Weight kg lb 2.205
N kgf 0.10197Force
N lbf 0.2248
N⋅m kgf⋅m 1.0197Torque
N⋅m lbf⋅ft 0.7375
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SAFETY
SA-1
SA-688
SA-1223
RECOGNIZE SAFETY INFORMATION
•These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001
UNDERSTAND SIGNAL WORDS
•On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located near spe-
cific hazards. General precautions are listed on CAUTION
safety signs.
• Some safety signs don’t use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
•To avoid confusing machine protection with personal safety
messages, a signal word IMPORTANT indicates a situation
which, if not avoided, could result in damage to the ma-
chine.
• NOTE indicates an additional explanation for an element
of information.
002-E01A-1223
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SAFETY
SA-2
FOLLOW SAFETY INSTRUCTIONS
•Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
•Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
•Learn how to operate the machine and its controls correctly
and safely.
•Allow only trained, qualified, authorized personnel to oper-
ate the machine.
•Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equip-
ment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
•The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003
SA-003
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SAFETY
SA-3
PREPARE FOR EMERGENCIES
•Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the fire-extinguisher
at the recommended intervals as specified in the fire-
extinguisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance service,
hospital, and fire department posted near your tele-
phone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING
•Wear close fitting clothing and safety equipment appropri-
ate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
•Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
•Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.
006-E01A-0434
SA-437
SA-434
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SAFETY
SA-4
INSPECT MACHINE
•Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal ac-
cident.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the tem-
perature in the cab increases, the lighter may explode.
524-E01A-0000
SA-435
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SAFETY
SA-5
USE HANDHOLDS AND STEPS
•Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or dis-
mount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
008-E01A-0439
ADJUST THE OPERATOR'S SEAT
•A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the op-
erator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAV-
ING OPERATOR’S SEAT
•Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
• Before leaving the machine, be sure to first lower the
front attachment to the ground and then move the pilot
control shut-off lever to the LOCK position. Turn the key
switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors, and
access covers and lock them up.
SA-439
SA-378
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SAFETY
SA-6
FASTEN YOUR SEAT BELT
•If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the opera-
tor may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine web-
bing, buckle and attaching hardware. If any item is dam-
aged or worn, replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
•Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY
Starting fluid:
•Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3
SA-237
SA-083
SA-293
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