Hitachi ZW 100-G Instruction manual

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

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

SAFETY
SA-1
RECOGNIZE SAFETY INFORMATION
•These are the SAFETY ALERT SYMBOLS.
•When you see these symbols on your machine or
in operator`s manual, be alert to the potential for
personal injury.
•Follow recommended precautions and safe oper-
ating practices.
001-E01A-0001
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 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 specific hazards. General precautions are
listed on CAUTION safety signs.
•Some safety signs don’t use any of the desig-
nated signal words above after the safety alert
symbol are occasionally used on this machine.
•To avoid confusing machine protection with per-
sonal safety messages, a signal word IMPOR-
TANT indicates a situation which, if not avoided,
could result in damage to the machine.
•NOTE indicates an additional explanation for
an element of information.
002-E01A-1223
SA-1223

SAFETY
SA-2
FOLLOW SAFETY INSTRUCTIONS
•Carefully read and follow all safety signs on the
machine and all safety messages in operator`s
manual.
•Safety signs should be installed, maintained and
replaced when necessary.
•If a safety sign or operator`s manual is damaged
or missing, order a replacement from your au-
thorized 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
operate the machine.
•Keep your machine in proper working condition.
•Unauthorized modifications of the machine may
impair its function and/or safety and affect ma-
chine life.
•Do not modify any machine parts without au-
thorization.
Failure to do so may deteriorate the part safety,
function, 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
equipment 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 attach-
ments 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 hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
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 at-
tached 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, ambu-
lance service, hospital, and fire department
posted near your telephone.
004-E01A-0437
SA-437

SAFETY
SA-3
WEAR PROTECTIVE CLOTHING
•Wear close fitting clothing and safety equipment
appropriate 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 atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
SA-438
PROTECT AGAINST NOISE
•Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
•Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objec-
tionable or uncomfortably loud noises.
006-E01A-0434
SA-434
NSPECT MACHINE
•Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
•In the walk-around inspection be sure to cover all
points described in the “PRE-START INSPEC-
TION” chapter in the operator’s manual.
007-E01A-0435
SA-435

SAFETY
SA-4
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 accident.
•Do not leave parts and/or tools lying around the
operator’s seat. Store them in their specified lo-
cations.
•Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions on the windowpanes as they may focus
sunlight, possibly starting a fire.
•Refrain from listening to the radio, or using music
headphones 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 extin-
guish the match and/or tobacco.
•Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000

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
dismount a moving machine.
•Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
008-E01A-0439
SA-439
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 operator 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
SA-462
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING 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 ma-
chine to unexpectedly move when a body part un-
intentionally 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 posi-
tion. Turn the key switch OFF to stop the engine.
•Before leaving the machine, close all windows,
doors, and access covers and lock them up.

SAFETY
SA-6
FASTEN YOUR SEAT BELT
•If the machine should overturn, the operator may
become injured and/or thrown from the cab. Addi-
tionally the operator may be crushed by the over-
turning machine, resulting in serious injury or death.
•Prior to operating the machine, thoroughly ex-
amine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
•Be sure to remain seated with the seat belt se-
curely 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 con-
dition.
010-E01A-0237
SA-237
MOVE AND OPERATE MACHINE SAFELY
•Bystanders can be run over.
•Take extra care not to run over bystanders. Con-
firm the location of bystanders before moving, or
operating the machine.
•Always keep the travel alarm and horn in working
condition (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. Coor-
dinate hand signals before starting the machine.
•Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
011-E01A-0398
SA-398
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
pressurized container, keep the cap on the con-
tainer, and store it in a cool, well-protected loca-
tion.
•Do not incinerate or puncture a starting fluid con-
tainer.
036-E01A-0293-3
SA-293

SAFETY
SA-7
OPERATE ONLY FROM OPERATOR'S
SEAT
•Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
•Start the engine only when seated in the opera-
tor's seat.
•NEVER start the engine while standing on the
track or on ground.
•Do not start engine by shorting across starter
terminals.
•Before starting the engine, confirm that all control
levers are in neutral.
•Before starting the engine, confirm the safety
around the machine and sound the horn to alert
bystanders.
012-E01B-0431
SA-431
JUMP STARTING
•Battery gas can explode, resulting in serious injury.
•If the engine must be jump started, be sure to
follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
•The operator must be 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.
S013-E01A-0032 SA-032
SA-032

SAFETY
SA-8
INVESTIGATE JOB SITE BEFOREHAND
•When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
•Investigate the configuration and ground condi-
tions 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
necessary. 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.
•Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
•When the footing is weak, reinforce the ground
before starting work.
•When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
•Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
015-E01B-0447
SA-447

SAFETY
SA-9
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
SA-521
PROVIDE SIGNALS FOR JOBS INVOLV-
ING MULTIPLE NUMBERS OF MACHINES
•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 directions.
018-E01A-0481
SA-481

SAFETY
SA-10
KEEP RIDERS OFF MACHINE
•Riders on machine are subject to injury such as be-
ing struck by foreign objects and being thrown off
the machine.
•Only the operator should be on the machine.
Keep riders off.
•Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0427
SA-427
DRIVE SAFELY
•Beware of the possibility of slipping and/or turning
over the machine when driving on a slope.
•When driving on level ground, hold the bucket at
mark (A) 400 to 500 mm above the ground as il-
lustrated.
•Avoid driving over any obstacles.
•Drive the machine slowly when driving on rough
terrain.
•Avoid quick direction changes. Failure to do so
may cause the machine to turn over.
•If the engine stops while driving, the steering
function becomes inoperative. Immediately stop
the machine by applying the bake to prevent
personal accident.
019-E07A-0448
SA-448
DRIVE MACHINE SAFELY (WORK SITE)
•Before driving the machine, always confirm that the
steering wheel/F-N-R lever direction corresponds to
the direction you wish to drive.
•Be sure to detour around any obstructions.
•Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or
death.
•When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 200 to
300 mm (approximately 8 to 12 in) (A) above the
ground.
•If the machine starts to skid or becomes unstable,
immediately 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 overturn. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
safe operation.
019-E05B-0515
SA-449
SA-450
SA-451

SAFETY
SA-11
DRIVE SAFELY WITH BUCKET LOADED
•If the machine is incorrectly operated while driving
with the bucket loaded, turning over of the machine
may result. Be sure to follow all the instructions in-
dicated below.
•When driving the machine on a job site with the
bucket loaded, hold the bucket as low as possible
to keep the machine balanced and to have good
visibility.
•Do not exceed the rated load capacity. Always
operate the machine within the rated load capac-
ity.
•Avoid fast starts, stops, and quick turns. Failure to
do so may result in personal injury and/or death.
•Avoid rapid drive direction changes which could
possibly cause personal injury and/or death.
051-E02A-0400
SA-400
DRIVE ON SNOW SAFELY
•Beware of the possibility of slipping or turning over
the machine when driving on frozen snow surfaces.
•The machine may slip more easily than expected
on frozen snow surfaces even if the inclination is
small. Reduce speed when driving. Avoid fast
starts, stops and quick turns.
•Road shoulder and/or set-up utilities covered with
snow are difficult to locate. Be sure where they
are before removing snow.
•Be sure to use tire chains when driving on snow.
•Avoid applying the brake for quick stops on snow.
If a quick stop is required, lower the bucket to the
ground.
052-E02A-0452
SA-452
TRAVEL ON PUBLIC ROADS SAFELY
•This machine is not allowed to drive on public loads
with the bucket loaded.
•Be sure to empty the bucket.
•Hold the bucket at mark (A) 400 to 500 mm above
the road surface as illustrated.
053-E02A-0453
SA-453

SAFETY
SA-12
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
•Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
•Select level ground when possible to park ma-
chine.
•Do not park the machine on a grade.
•Lower the bucket to the ground.
•Place the F-N-R lever in neutral, and put the park
brake switch in the ON (parking brake) position.
•Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
•Stop the engine and remove the key from the key
switch.
•Pull the lock lever to LOCK position.
•Block both tires and lower the bucket to the
ground.
•Position the machine to prevent rolling.
•Park a reasonable distance from other machines.
020-E02A-0516
SA-457
SA-458

SAFETY
SA-13
AVOID ACCIDENTS FROM BACKING UP
AND TURNING
•Make sure no one is working under or close to the
machine before backing up or turning the machine
to avoid personal injury and/or death by being run
over or entangled in the machine.
•Keep all personnel away from the machine by
sounding the horn and/or using hand signals. Use
extra care to be sure no one is in from the articu-
lation area before turning the machine.
•Keep windows, mirrors, and lights in good condi-
tion.
•Reduce travel speed when dust, heavy rain, fog,
etc., reduce the visibility.
•In case good visibility is not obtained, use a signal
person to guide you.
021-E02A-0517
SA-383
SA-312

SAFETY
SA-14
AVOID POSITIONING BUCKET OVER
ANYONE
•Never allow the bucket to pass over co-workers
and/or the dump truck operator’s cab. Falling soil
from the bucket or contact with bucket may cause
serious personal accidents and/or damage to the
machine.
•Avoid carrying the bucket over the co-workers to
ensure safe operation.
023-E02A-0518
SA-518
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE. MACHINE WILL TIP OVER FASTER
THAN YOU CAN JUMP FREE, POSSIBLY RE-
SULTING IN SERIOUS PERSONAL INJURY OR
DEATH. IF TIPPING OVER OF THE MACHINE IS
PREDICTED, SECURELY HOLD THE STEERING
WHEEL TO PREVENT YOUR BODY FROM BEING
THROWN OUT OF THE MACHINE.
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
•The danger of tipping is always present when oper-
ating 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 slip-
ping.
•Avoid changing direction when traveling on
grades.
•NEVER attempt to travel across a grade steeper
than 5 degrees if crossing the grade is unavoid-
able.
•Reduce swing speed as necessary when swing-
ing loads.
•Be careful when working on frozen ground.
•Temperature increases will cause the ground to
become soft and make ground travel unstable.
SA-463

SAFETY
SA-15
NEVER UNDERCUT A HIGH BANK
•The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0519
SA-519
DIG WITH CAUTION
Before digging, check the location of cables, gas lines,
and water lines.
027-E01A-0396
SA-396
PERFORM TRUCK LOADING SAFELY
•Do not operate the machine involuntarily. Unex-
pected machine movement may cause personal in-
jury and/or death.
•Do not lower the bucket with the loader control
lever in the FLOAT position. The bucket may free
fall, possibly causing personal injury and/or death.
•Always select a level surface for truck loading.
028-E01A-397
SA-397

SAFETY
SA-16
AVOID POWER LINES
Serious injury or death can result from contact with
electric lines.
Never move any part of the machine or load closer to
any electric line than 3 m (10 ft) plus twice the line
insulator length.
29-E01A-0455
SA-455
PRECAUTIONS FOR OPERATION
•If the front attachment or any part of the machine
comes in contact with an overhead obstacle, both
the machine and the overhead obstacle may be-
come damaged, and personal injury may result.
•Take care to avoid coming in contact with over-
head obstacles with the bucket or arm during op-
eration.
PRECAUTIONS FOR LIGHTENING
•The machine is vulnerable to lighting strikes.
•In the event of an electrical storm, immediately
stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
•After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the ma-
chine only after repairing them.
OBJECT HANDLING
•If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath it, resulting in serious injury or death.
•When using the machine for craning operations,
be sure to comply with all local regulations.
•Do not use damaged chains or frayed cables,
sables, slings, or ropes.
•Before craning, position the upperstructure with
the position of the bucket support located on the
chassis at the front.
•Move the load slowly and carefully. Never move it
suddenly.
•Keep all persons well away from the load.
•Never move a load over a person's head.
•Do not allow anyone to approach the load until it
is safely and securely situated on supporting
blocks or on the ground.
•Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0132
SA-132