Hitachi Zaxis 160LC, Workshop Manual

Page 1: ...N Excavator Workshop Manual 160LC 180LC 180LCN Service Manual Manual No KM 1F1E consists of the following three separate volumes Technical Manual Operational Principle Vol No TO1F1E Technical Manual Troubleshooting Vol No TT1F1E Workshop Manual Vol No W1F1E Zaxis160LC 180LC 180LCN WSh 17 1 03 9 48 AM 1 ...

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Page 3: ...AL 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 tec...

Page 4: ...uation 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...

Page 5: ...ch 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 designated signal words above after the safety alert symbol are occasio...

Page 6: ...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 The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines However it is impossible for these safety message...

Page 7: ...ce hospital and fire department posted near your telephone 004 E01A 0437 SA 437 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 fo...

Page 8: ...gainst objectionable or uncomfortably loud noises 006 E01A 0434 SA 434 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 S007 E01A 0435 SA 435 Find manuals at https best manuals com ...

Page 9: ...specified lo cations Avoid storing transparent bottles in the cab Don t attach any transparent type window decorations 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 ashtr...

Page 10: ...latforms steps and handrails when mounting and dis mounting the machine 008 E01B 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 ope...

Page 11: ...t 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 SA 237 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 operating the machine ...

Page 12: ...nfirm that all control levers are in neutral 012 E01B 0444 SA 444 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...

Page 13: ...g multiple numbers of machines provide signals commonly known by all personnel involved Also appoint a signal person to coordi nate the job site Make sure that all personnel obey the signal person s directions 018 E01A 0481 SA 481 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal lever operation may result in serious injury death Before driving the machine confirm the position of th...

Page 14: ...pe 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 approxi mately 200 to 300 mm A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop traveling Driving across the face of a slope or steering on a slope may cause th...

Page 15: ...n the auto idle acceleration seleclter and the H P mode switch off 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 pilot control shut off lever to LOCK position Block both tracks and lower the bucket to the ground Thrust the bucket teeth into the ground if you must park on a grade Position the mach...

Page 16: ...NDERS 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 ...

Page 17: ...ul 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 wor...

Page 18: ...ted load should fall any person nearby may be struck by the falling load or may be crushed underneath 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 travel motors at the rear Move the load slowly an...

Page 19: ... object 031 E01A 0432 SA 432 PARK MACHINE SAFELY To avoid accidents Park machine on a firm level surface Lower bucket to the ground Turn auto idle acceleration selector and H P mode switch off Run engine at slow idle speed without load for 5 minutes Turn key switch to OFF to stop engine Remove the key from the key switch Pull the pilot control shut off lever to the LOCK position Close windows roof...

Page 20: ...le smoking or when near open flame or sparks Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flammable Store flammable fluids well away from fire hazards Do not incinerate or puncture pressurized containers Do not store oily rags they can ignite and burn spontaneously Securely tighten the fuel and oil filler cap 034 E0...

Page 21: ...operation of a control lever 5 Always select the slow speed mode with the travel mode switches In the high speed mode travel speed may automatically increase 6 Avoid steering while driving up or down the ramp as it is extremely dangerous If steering is unavoidable first move back to the ground or flatbed modify traveling direction and begin to drive again 7 Do not operate any levers besides the tr...

Page 22: ...ing the machine 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Turn the auto idle acceleration selecltor off 4 Run the engine at slow idle speed without load for 5 minutes 5 Turn the key switch to OFF to stop engine 6 Relieve the pressure in the hydraulic system by moving the control levers several times 7 Remove the key from the switch 8 Attach a Do Not Operate tag on th...

Page 23: ...ase oil or debris When cleaning parts always use nonflammable detergent oil Never use highly frammable oil such as fuel oil and gasoline to clean parts or surfaces Disconnect battery ground cable before making adjustments to electrical systems or before welding on the machine Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make su...

Page 24: ...e ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment Do not support the machine on cinder blocks hollow tires or props that may crumble under continuous load Do not work under a machine that is supported solely by a jack 519 E01A 0527 SA 527 STAY CLEAR OF MOVING PARTS Entanglement in moving parts can cause serious inj...

Page 25: ...L to cool then gradually loosen AIR RELEASE PLUG to release pressure 503 E01B 0344 SA 344 STORE ATTACHMENTS SAFELY Stored attachments such as buckets hydraulic hammers and blades can fall and cause serious injury or death Securely store attachments and implements to prevent falling Keep children and bystanders away from storage areas 504 E01A 0034 SA 034 USE TOOLS PROPERLY Use tools appropriate fo...

Page 26: ...o become hot during operation The engine hoses lines and other parts become hot as well Wait for the oil and components to cool before starting any maintenance or inspection work 505 E01B 0498 SA 039 SA 225 REPLACE RUBBER HOSES PERIODICALLY Rubber hoses that contain flammable fluids under pressure may break due to aging fatigue and abrasion It is very difficult to gauge the extent of deterioration...

Page 27: ...ulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard take care to protect hands and body from high pressure fluids Wear a face shield or goggles for eye protection If an accident occurs see a doctor familiar with this type of injury immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may r...

Page 28: ... lines Never install bent or damaged lines pipes or hoses Check for Shorts Short circuits can cause fires Clean and tighten all electrical connections Check before starting work for loose kinked hardened or frayed electrical cables and wires Check before starting work for missing or damaged terminal caps DO NOT OPERATE MACHINE if cable or wires are loose kinked etc Clean up Flammables Spilled fuel...

Page 29: ...e to release pressurized air inside the hydraulic tank will escalate fire hamper ing fire fighting Check the emergency engine stop switch func tion every 250 hours 1 Start the engine and run it at slow Idle 2 Turn the emergency engine stop switch to the EMERG STOP position 3 Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released a hissing sound should be ...

Page 30: ...break the front or rear window panes with the emergency evacuation hammer to escape from the cab Refer to the explanation page on EMERGENCY EXIT in Operator s Manual 518 E02B 0393 SA 393 SS 1510 BEWARE OF EXHAUST FUMES Prevent asphyxiation Engine exhaust fumes can cause sickness or death If you must operate in a building be sure there is adequate ventilation Either use an exhaust pipe extension to...

Page 31: ...area still smoldering 523 E01A 0818 SA 818 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate fl...

Page 32: ... fumes to disperse at least 15 minutes before welding or heating 511 E01A 0029 SA 029 PREVENT BATTERY EXPLOSIONS Battery gas can explode Keep sparks lighted matches and flame away from the top of battery Never check battery charge by placing a metal object across the posts Use a voltmeter or hy drometer Do not charge a frozen battery it may explode Warm the battery to 16 C 60 F first Do not contin...

Page 33: ...DUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with your machine include such items as lubricants coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques Check the MSDS before you start any job usin...

Page 34: ...or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center S516 E01A 0226 SA 226 BEFORE RETURNING THE MA...

Page 35: ...nd Assembling W1 1 1 Maintenance Standard Terminology W1 1 7 Group 2 Tightening Torque Tightening Torque Specification W1 2 1 Torque Chart W1 2 2 Piping Joint W1 2 5 Periodic Replacement of Parts W1 2 9 Group 3 Painting Painting W1 3 1 Group 4 Bleeding Air from Hydraulic Oil Tank Bleed Air from Hydraulic Oil tank W1 4 1 ...

Page 36: ...1F1W 1 2 Blank ...

Page 37: ... condition of lubricants Loose or damaged parts Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work Precautions for Disassembling To prevent dirt from entering cap or plug the removed pipes Before disassembling clean the exterior of the components and place on a work bench Before disassembling drain gear oil from the reduction gea...

Page 38: ...r from Hydraulic System When hydraulic oil is drained the suction filter or the suction lines are replaced or the removal and in stallation of the pump swing motor travel motor or cylinder is done bleed air from the hydraulic system in the following procedures IMPORTANT If the engine is started with air trapped in the hydraulic pump housing damage to the pump may result If the hydraulic motor is o...

Page 39: ...der light loads for 10 to 15 minutes Slowly start each op eration never fully stroke the cylinders during ini tial operation stage As the pilot oil circuit has an air bleed device air trapped in the pilot oil circuit will be bled while performing the above operation for approx 5 minutes Reposition the front attachment to check hydrau lic oil level Stop the engine Recheck hydraulic oil level Re ple...

Page 40: ...eakage or damage will occur Be sure to do the following to prevent trouble 1 Clean the floating seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt After cleaning thoroughly dry parts with compressed air 2 Clean the floating seal and seal mounting bores Check the bore surface for scuffing or scoring by touching the surface 3 Check that the O ring is not t...

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