Hitachi ZX 40U-3 class 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]
E-mail: [email protected]
ADDITIONAL REFERENCES
•Please refer to the other materials (operator’s
manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.
MANUAL COMPOSITION
•This manual consists the Technical Manual and the
Workshop Manual.
•Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, operational performance 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
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.
SA-688
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 in-
jury.
• 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
specific hazards. General precautions are listed on
CAUTION safety signs.
• Some safety signs do not 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 machine.
•NOTE indicates an additional explanation for an
element of information.
SA-1223
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SAFETY
SA-2
FOLLOW SAFETY INSTRUCTIONS
•Carefully read and follow all safety signs on the machine
as well as all safety messages in this manual.
•Safety signs must be installed, maintained and replaced
if damaged.
• 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 or-
dering).
•Allow only properly trained, qualified, authorized per-
sonnel to operate the machine.
•Learn how to correctly operate and service the machine.
•Keep your machine in proper working condition.
•Always operate the machine within the specification.
• Unauthorized modifications of the machine may impair
the functions and/or safety and affect machine life and
the warranty will become void.
•The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every possible hazardous situation you may en-
counter. If you have any questions concerning safety,
you should first consult your supervisor and/or your au-
thorized dealer before operating or performing mainte-
nance work on the machine.
SA-003
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 and use it properly.
• To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extin-
guisher at the recommended intervals as specified in
the fire-extinguisher manual.
• Establish emergency procedure guidelines to cope
with any fire or accidents which may occur.
• Keep emergency numbers for doctors, ambulance
service, hospitals, and fire department posted near
your telephone.
SA-437
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SAFETY
SA-3
WEAR PROTECTIVE CLOTHING
•Wear close fitting clothing and safety equipment appro-
priate to the job.
You may need:
A hard hat
Safety belt
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.
SA-438
PROTECT AGAINST NOISE
•Prolonged exposure to loud noise can cause impairment
or loss of hearing.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.
SA-434
INSPECT MACHINE
•If any abnormality is found, be sure to repair it immedi-
ately before operating the machine.
• In the walk-around inspection, be sure to cover all
points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.
SA-435
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SAFETY
SA-4
TIDY UP INSIDE OPERATOR’S SPACE
•Always keep inside the cab clean by observing instruc-
tions below, to prevent any personal accidents from oc-
curring.
•Remove mud and/or oily material from the shoe soles
before entering the operator’s space. If pedals are oper-
ated without removing mud or oily matter, the foot may
slip off the pedal, possibly creating a hazardous situa-
tion.
•Do not leave parts and/or tools around the operator’s
seat.
•Do not keep a transparent water bottle in the cab. The
transparent water bottle may concentrate the sun light
like a lens, possibly causing a fire.
•Do not wear radio or music headphones and do not use
a cell phone while traveling or operating the machine.
•Never allow hazardous materials such as combustible
and/or explosive material in the operator’s space.
•Do not leave cigarette lighters in the cab. If the tem-
perature in the cab increases, the lighter may explode.
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.
• Maintain a three-point contact with the steps and
handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms,
thoroughly remove such material.
SA-439
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SAFETY
SA-5
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
mis-operation of the machine.
• The seat should be adjusted whenever the operator for
the machine changes.
• The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back firmly against the seat back.
• If not, readjust the seat forward or backward, and
check again.
SA-378
ENSURE SAFETY BEFORE RISING FROM OR
LEAVING OPERATOR’S SEAT
•Before rising from the operator’s seat to open/close cab
front 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.
FASTEN YOUR SEAT BELT
•If the machine should overturn, the operator may be-
come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.
• Be sure to remain seated with the seat belt securely
fastened whenever operating the machine.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine. Replace the seat belt at
least once every 3 years regardless of appearance
SA-237
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SAFETY
SA-6
MOVE AND OPERATE MACHINE SAFELY
•Always be aware that there is a potential danger around
the machine while operating the machine.
• Take extra care not to run over bystanders. Confirm
the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped).
• Before starting to move or operate the machine, sound
the travel alarm and horn to alert bystanders.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Locate the
signal person so that the operator can always witness
the signal person.
• Coordinate the meanings of all safety signs, hand
signals and marks before starting the machine. Ap-
point a person who is responsible to make a signal
and/or guidance.
• Never allow any persons or obstacles to enter the
machine operation areas.
• Use appropriate illuminations.
SA-1291
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SAFETY
SA-7
OPERATE ONLY FROM OPERATOR'S SEAT
•Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury
or death.
• Start the engine only when seated in the operator's
seat.
• NEVER start the engine while standing on the tracks or
on ground.
• Do not start engine by shorting across starter terminals.
A hazardous situation may be created and/or possible
damage to the machine may result.
• Before starting the engine, confirm that all control lev-
ers are in neutral.
SA-444
JUMP STARTING
•Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
• If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• The operator must be seated in the operator’s seat so
that the machine will be under control when the engine
starts. Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
KEEP RIDERS OFF MACHINE
•Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the
machine.
• Riders also obstruct the operator’s view, resulting in
the machine being operated in an unsafe manner.
• Only allow the operator is allowed on the machine.
Keep riders off.
SA-1292

SAFETY
SA-8
PRECAUTIONS FOR OPERATIONS
•Thoroughly make certain safety at the work site before
starting operations. Especially always observe the fol-
lowing points.
• Be sure to wear close fitting clothing and required
safety items, such as a hard hat, when operating the
machine.
• Keep all bystanders and unnecessary objects out of
and away from the machine working areas. Always
beware of the surroundings while operating the ma-
chine. Take care not to allow the rear part of the up-
perstructure to come in contact with objects when
swinging the machine in a small area.
• When loading a dump truck, bring the bucket from the
rear side of the dump truck to avoid moving the bucket
over the dump truck cab or over any co-workers.
M586-12-012

SAFETY
SA-9
INVESTIGATE JOB SITE BEFOREHAND
•When working at the edge of an excavation or on a road
shoulder, the machine could tip over due to collapse of
the ground, possibly resulting in serious injury or death.
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as nec-
essary. Keep the machine well back from the edges of
excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Never allow bystanders to enter the working area such
as swing radius or traveling range.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing may become
loose and slippery.
• When operating the machine near open flame, sparks,
and/or dead grass, a fire may easily break out. Use
special care not to cause a fire.
• Make sure the work site ground has sufficient strength
to firmly support the machine. When working close to
an excavation or on road shoulders, operate the ma-
chine with the tracks positioned perpendicular to the
cliff face with travel motors at the rear and with the
blade at the front, so that the machine can more easily
evacuate if the cliff face collapses.
• If working at the bottom of a cliff or on a high bank is
required, be sure to investigate the area first and con-
firm that no danger of the cliff or bank collapsing exists.
If any possibility of cliff or bank collapsing exists, do
not work in that area.
• Soft ground may collapse when operating the machine
on it, possibly causing the machine to tip over. When
working on a soft ground is required, be sure to rein-
force the ground first using large pieces of steel plates
strong enough and firm to easily support the machine.
• Note that there is always a possibility of machine tip-
ping over when working on rough terrain or on slopes.
Prevent machine tipping over from occurring. Operate
the machine slowly to ensure safe operation.
SA-1293
M586-05-021

SAFETY
SA-10
PROTECT AGAINST FALLING STONES AND
DEBRIS
•Confirm that your machine is FOPS cab equipped before
working in areas where the possibility of falling stones or
debris exist.
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
•In case more than one machine is operated in the same
job site, accidental collision between machines may
cause serious injury or death.
•For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s direc-
tions.
SA-481
CONFIRM DIRECTION OF MACHINE TO BE
DRIVEN
•Incorrect travel pedal/lever operation may result in seri-
ous injury or death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position.
• If the travel motors are located towards the front of the
cab, the machine will move in the reverse direction
when travel pedals/levers are operated.
SA-1294

SAFETY
SA-11
DRIVE MACHINE SAFELY
•Use a signal person when traveling the machine along
road shoulders or in congested areas.
•Driving the machine in the incorrect direction may result
in serious injury or death and/or severe damage to
property.
•Before driving the machine, always confirm that the
travel pedals/levers direction corresponds to the direc-
tion you wish to drive.
•Be sure to detour around any obstructions.
•Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Do not allow personnel to stay around the
machine while traveling.
•Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
•Never attempt to ascend or descend 30 degrees or
steeper slopes.
•Be sure to fasten the seat belt.
•When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 200 to 300
mm (8 to 12 in) (A) above the ground.
•If machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.
•Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If the
direction must be changed, move the machine to level
ground, then, change the direction to ensure safe op-
eration.
•Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
•If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neu-
tral. Then, restart the engine.
•Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not
warmed up sufficiently, sufficient performance may not
be obtained.
SA-1295
SA-1296
SA-441
SA-589
A
A

SAFETY
SA-12
•Traveling down a slope in the fast mode requires a
longer time to stop the machine. When traveling down
a slope, place travel mode switch (1) in the TURTLE
position.
•Select a travel route that is as flat as possible. Steer
the machine as straight as possible, making small
gradual changes repeatedly in direction.
•Check the strengths of bridges and road shoulders
before traveling on them, and reinforce if necessary.
•When the machine is equipped with steel shoes, cover
the road surface with wood plates in order not to
damage the road surface. Be careful of steering when
operating on asphalt roads in summer.
•When crossing train tracks, lay wood plates over the
tracks not to allow the machine to ride on only the
rails.
•Check that the machine can pass under a bridge and
electric lines before driving the machine.
•When crossing a river, drive the machine slowly while
measuring the depth of the river using the bucket. Do
not cross the river when the depth of the river is
deeper than the upper track shoe surface.
•Reduce the engine speed when traveling on rough
terrains. Select a slow travel speed. Slower speed will
reduce possible damage to the machine.
•Drive the machine so that the travel motors do not
come in contact with loose rocks. If the machine
crosses over an obstruction, abnormally large loads
may be loaded on the machine. Avoid contact with an
obstruction while traveling the machine.
•During freezing weather, always clean snow and ice
from track shoes before driving the machine on snowy
and/or frozen roads, or loading and unloading the
machine for transportation, to prevent the machine
from slipping.
M1M7-01-033
M1M7-01-032
M104-05-008
SA-673
M586-05-002
Travel Motor
ZX27U-3 (Canopy)
ZX30U-3, 35U-3, 40U-3, 50U-3 (Canopy)
1
1

SAFETY
SA-13
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
•Death or serious injury may result if you attempt to
mount or try to bodily stop a moving machine.
•Park the machine in compliance with the safe parking
procedures described on page SA-19 to prevent the
machine from running away.
•Block both tracks and lower the bucket to the ground,
thrust the bucket teeth into the ground if you must park
on a grade.
•Park a reasonable distance from other machines.
SA-1297

SAFETY
SA-14
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
•If any person is present near the machine when backing
or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
•Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
•Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
•USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
•No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
•Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the responsibility
for signaling.
•Keep windows, mirrors, and lights clean and in good
condition.
•Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
•Read and understand all operating instructions in the
operator’s manual.
021-E01A-0494-8
SA-383
SA-384

SAFETY
SA-15
KEEP PERSON CLEAR FROM WORKING
AREA
•If a person is present near the operating machine, the
person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
•Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
•Make sure that no personnel other than the signal
person or no obstacles are present in the working area
before operating the machine.
SA-667
NEVER POSITION BUCKET OVER ANYONE
•Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
•Never allow the bucket to pass over anyone to avoid
personal injury or death.
SA-668
AVOID UNDERCUTTING
•In order to retreat from the edge of an excavation if the
footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.
•If the footing starts to collapse and if retreat is not
possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.
SA-1300

SAFETY
SA-16
AVOID TIPPING
•The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.
To avoid tipping:
•Be extra careful before operating on a grade.
•Prepare machine operating area flat.
•Keep the bucket low to the ground and close to the
machine.
•Reduce operating speeds to avoid tipping or slipping.
•Avoid changing direction when traveling on grades.
•NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
•Reduce swing speed as necessary when swinging
loads.
•Be careful when working on frozen ground.
•Temperature increases will cause the ground to
become soft and make ground travel unstable.
025-E01A-0540-4
SA-1301
NEVER UNDERCUT A HIGH BANK
•The edges could collapse or a land slide could occur
causing serious injury or death.
SA-1302