Name: Hitachi 120-3 class
Brand: Hitachi
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MAINTENANCE

7-54

16. When replacing the air cleaner filter element, replace

both outer (1) and inner (3) elements together. Remove

outer element (1). Clean the filter interior before remov-

ing inner element (3). Remove inner element (3). First

install inner element (3) and then install outer element (1).

IMPORTANT: Do not reuse the inner element. Always re-

place the new one.

M157-07-061

Air Restriction Switch

1 2

Valve

Cover

Table of Contents7
Safety13
Recognize Safety Information13
Understand Signal Words13
Follow Safety Instructions14
Prepare for Emergencies15
Wear Protective Clothing15
Protect against Noise15
Inspect Machine16
General Precautions for Cab16
Use Handholds and Steps17
Adjust the Operator's Seat17
Ensure Safety before Rising from or Leaving Operator's Seat17
Fasten Your Seat Belt18
Move and Operate Machine Safely18
Handle Starting Aids Safely18
Operate Only from Operator's Seat19
Jump Starting19
Keep Riders off Machine19
Precautions for Operations20
Investigate Job Site Beforehand21
Equipment of Head Guard, Rops, Fops22
Provide Signals for Jobs Involving Multiple Numbers of Machines22
Confirm Direction of Machine to be Driven22
Drive Machine Safely23
Avoid Injury from Rollaway Accidents25
Avoid Injury from Back-Over and Swing Accidents26
Keep Person Clear from Working Area27
Never Position Bucket over Anyone27
Avoid Undercutting27
Avoid Tipping28
Never Undercut a High Bank28
Dig with Caution29
Operate with Caution29
Avoid Power Lines30
Precautions for Lightning30
Object Handling30
Protect against Flying Debris31
Park Machine Safely31
Handle Fluids Safely−Avoid Fires31
Transport Safely32
Practice Safe Maintenance33
Warn Others of Service Work34
Support Machine Properly34
Stay Clear of Moving Parts34
Prevent Parts from Flying35
Store Attachments Safely35
Prevent Burns36
Replace Rubber Hoses Periodically36
Avoid High-Pressure Fluids37
Prevent Fires38
Evacuating in Case of Fire39
Beware of Exhaust Fumes39
Precautions for Welding and Grinding39
Avoid Heating Near Pressurized Fluid Lines40
Avoid Applying Heat to Lines Containing Flammable Fluids40
Remove Paint before Welding or Heating40
Beware of Asbestos Dust41
Prevent Battery Explosions41
Service Air Conditioning System Safely41
Handle Chemical Products Safely42
Dispose of Waste Properly42
Safety Signs43
Components Name51
Operator's Station52
Cab Features52
Multi Function Monitor53
Outline54
Menu Screen (23)57
Hour Meter58
Fuel Gauge58
Clock58
Back Monitor Selector58
Menu Key59
Optional Function Key59
Return to Basic Screen Key59
Alarm Light59
Optional Function Display59
Coolant Temperature Gauge60
Operating Status Icon Display60
Alarm Occurrence Screen65
Contents of Alarms67
Clock Setting69
Attachment Selection (Only Machines Equipped with Optional Parts)70
Pump 2 Flow Rate Adjustment (Only Machines Equipped with Optional Parts)74
Displaying Operating Conditions75
Fuel Rate Display/No Display76
Back Monitor Settings84
Maintenance Settings86
Mail (Optional)91
Language Settings93
Switch Panel95
Engine Control Dial96
Auto-Idle Switch96
Power Mode Switch97
Travel Mode Switch97
Work Light Switch98
Wiper/Washer Switch99
Switch Panel (Optional)101
Key Switch103
Power Boost Switch103
Horn Switch103
Cigar Lighter104
Cab Light105
Installing Fire Extinguisher (Optional)105
Pilot Control Shut-Off Lever106
Engine Stop Switch106
Fuse Box107
Auto Air Conditioner108
Cab Heater Operation112
Cooling Operation112
Defroster Operation113
Tips for Optimal Air Conditioner Usage114
Cab Heater (Optional)115
Cab Heater Operation116
Defroster Operation117
AM/FM Radio Operation118
Digital Clock Setting Procedure119
Cab Door Release Lever120
Opening Upper Front Window120
Closing Upper Front Window121
Removing and Storing Lower Front Window122
Opening Side Windows122
Opening/Closing Overhead Window123
Emergency Exit124
Adjusting the Seat125
Seat with a Built-In Heater126
Adjusting the Air-Suspension Seat (Optional)127
Seat with a Built-In Heater128
Adjusting Console Height129
Seat Belt130
Break-In131
Observe Engine Operation Closely131
Every 8 Hours or Daily131
After the First 50 Hours131
After the First 100 Hours131
Operating the Engine133
Inspect Machine Daily before Starting133
Before Starting Engine134
Starting the Engine in Ordinary Temperature135
Starting in Cold Weather137
Check Instruments after Starting139
Using Booster Batteries140
Stopping the Engine142
Driving the Machine143
Drive the Machine Carefully143
Steering the Machine Using Pedals144
Steering the Machine Using Levers145
Travel Mode Switch146
Travel Alarm (Optional)146
Operating on Soft Ground147
Raise One Track Using Boom and Arm147
Towing Machine a Short Distance148
Operating in Water or Mud149
Parking the Machine on Slopes150
Parking the Machine150
Operating the Machine151
Control Lever (Iso Pattern)151
Attachment Pedal (Hydraulic Breaker) (Optional)152
Attachment Pedal (Hydraulic Crusher) (Optional)153
Pilot Control Shut-Off Lever154
Engine Speed Control156
Auto-Idle157
Work Mode158
Work Mode Select159
Power Boost160
Power Mode161
Operating Backhoe162
Grading Operation162
Face Shovel Operation163
Avoid Abusive Operation163
Operating Tips164
Select Correct Track Shoes164
Hydraulic Breaker and Hydraulic Crusher165
Pipings for Breaker and Crusher166
Secondary Relief Pressure Adjustment168
Precautions for Breaker Operation170
Breaker Maintenance173
Precautions for Crusher Operation174
Attachment176
Attachment Connection Parts180
Precaution for Arm Roll-In/Bucket Roll-In Combined Operation181
When Installing an Attachment Longer than Standard Bucket181
Shackle Hole Usage182
Overnight Storage Instructions182
Emergency Boom Lowering Procedure (Without Hose-Rupture Safety Valve)183
Object Handling185
Transporting187
Transporting by Road187
Loading/Unloading on a Trailer187
Machine Lifting Procedure191
Maintenance193
Correct Maintenance and Inspection Procedures193
Check the Hour Meter Regularly194
Use Correct Fuels and Lubricants194
Layout195
Maintenance Guide Table196
Prepare Machine for Maintenance198
Hood and Access Covers (ZX120-3, 180-3 Class)199
Hood and Access Covers (ZX200-3, 270-3, 330-3 Class)200
Periodic Replacement of Parts201
Maintenance Guide202
Front Joint Pins202
Swing Bearing210
Swing Internal Gear211
Engine212
Engine Oil Level212
Change Engine Oil213
Replace Engine Oil Filter213
Transmission215
Pump Transmission215
Swing Reduction Gear216
Travel Reduction Gear217
Hydraulic System219
Inspection and Maintenance of Hydraulic Equipment219
Breaker Maintenance221
Check Hydraulic Oil Level222
Change Hydraulic Oil223
Suction Filter Cleaning223
Replace Hydraulic Tank Oil Filter226
Replace Pilot Oil Filter227
Replace Air Breather Element228
Check Hoses and Lines229
Service Recommendations for Hydraulic Fittings232
Fuel System234
Drain Fuel Tank Sump236
Drain Fuel Filter237
Replace Fuel Main Filter Element241
Replace Fuel Pre-Filter Element242
Clean Fuel Solenoid Pump Strainer243
Check Fuel Hoses244
Air Cleaner245
Clean Air Cleaner Outer Element245
Replace Air Cleaner Outer and Inner Elements245
Cooling System247
Check Coolant Level249
Check and Adjust Fan Belt Tension (ZX120-3, 180-3 Class)250
Check and Adjust Fan Belt Tension (ZX200-3, ZX270-3, ZX330-3 Class)251
Change Coolant252
Clean Radiator Interior252
Clean Radiator, Oil Cooler Core and Inter Cooler Outside253
Clean Oil Cooler, Radiator and Inter Cooler Front Screen253
Clean Air Conditioner Condenser253
Clean Fuel Oil Cooler253
Clean Air Conditioner Front Screen (Opt.)253
Electrical System254
Replace Batteries257
Remove and Installing Battery258
Replacing Fuses258
Miscellaneous260
Check Bucket Teeth260
Change Bucket264
Convert Bucket Connection into Face Shovel265
Adjust Bucket Linkage266
Remove Travel Levers267
Check Windshield Washer Fluid Level268
Check Track Sag269
Clean and Replace Air Conditioner Filter271
Check Air Conditioner273
Clean Cab Floor274
Retighten Cylinder Head Bolt275
Inspect and Adjust Valve Clearance275
Measure Engine Compression Pressure275
Check Starter and Alternator275
Check and Replace EGR Device275
Check Tightening Torque of Bolts and Nuts276
Hydraulic Circuit and Electrical Circuit291
Hydraulic Circuit291
Electrical Circuit292
Electrical Diagram292
Maintenance under Special Environmental Conditions295
Storage297
Storing the Machine297
Removing the Machine from Storage298
Troubleshooting299
Impossible to Start the Engine299
Engine300
Electrical System304
Mode Selection306
Control Levers307
Hydraulic System307
Specifications311
Specifications (ZX110-3, 110M-3)311
Working Ranges (ZX110-3, 110M-3)312
Shoe Types and Applications (ZX110-3)313
(Zx110M-3)315
Bucket Types and Applications (ZX110-3, 110M-3)315
Specifications (ZX130-3, 130LCN-3)315
Working Ranges (ZX130-3, 130LCN-3)317
Shoe Types and Applications (ZX130LCN-3)318
Bucket Types and Applications (ZX130-3, 130LCN-3)320
Specifications (ZX160LC-3)321
Working Ranges (ZX160LC-3)322
Shoe Types and Applications (ZX160LC-3)324
Bucket Types and Applications (ZX160LC-3)325
Specifications (ZX180LC-3, 180LCN-3)325
Working Ranges (ZX180LC-3, 180LCN-3)327
Shoe Types and Applications (ZX180LC-3, 180LCN-3)329
Bucket Types and Applications (ZX180LC-3, 180LCN-3)330
Specifications (ZX210-3, 210LC-3)330
Working Ranges (ZX210-3, 210LC-3)332
Shoe Types and Applications (ZX210-3, 210LC-3)333
Bucket Types and Applications (ZX210-3, 210LC-3)334
Specifications (ZX210LCN-3, 240N-3)335
Working Ranges (ZX210LCN-3, 240N-3)336
Zx210Lcn-3, 240N-3336
Bucket Types and Applications (ZX210LCN-3, 240N-3)338
Specifications (ZX250LC-3, 250LCN-3)338
Working Ranges (ZX250LC-3, 250LCN-3)340
Shoe Types and Applications (ZX250LC-3, 250LCN-3)341
Bucket Types and Applications (ZX250LC-3, 250LCN-3)342
Specifications (ZX280LC-3, 280LCN-3)342
Working Ranges (ZX280LC-3, 280LCN-3)344
Shoe Types and Applications (ZX280LC-3, 280LCN-3)345
Bucket Types and Applications (ZX280LC-3, 280LCN-3)346
Specifications (ZX350LC-3, 350LCN-3)346
Working Ranges (ZX350LC-3, 350LCN-3)348
Shoe Types and Applications (ZX350LC-3, 350LCN-3)349
Bucket Types and Applications350
Sound Level Results (2000/14/EC)351
Vibration Level351
Optional Attachments and Devices353
Using Pad Crawler Shoe353
Traveling and Other Cautions354
Transporting355
Precautions for Transporting Machines with Pad Crawler Shoes355
Long Arm Operation358
Blade Lever359
Precautions for Blade Operation359
Avoid Hitting Blade with Front-End Attachment360
Avoid Hitting Blade with Bucket360
Avoid Striking the Blade into a Rock360
Blade Maintenance361
Specifications (ZX110-3 with Blade)362
ZX110-3 with Blade362
Specifications (ZX130-3 with Blade)365
ZX130-3 with Blade365
Offset Arm Front368
Offset Direction and Working Range369
Precautions for Operating with the Offset Function370
Maintenance371
Specifications (ZX110-3, 110M-3 Offset)372
Working Ranges (ZX110-3, 110M-3 Offset)373
Bucket Teeth (Transverse-Type-Pin-Used Type)374
2-Piece Boom375
Maintenance (2-Piece Boom)376
Specifications379
ZX130-3, 130LCN-3 2-Piece Boom379
Working Ranges380
ZX130-3, 130LCN-3 2-Piece Boom380
Shoe Types and Applications381
ZX130-3 2-Piece Boom381
ZX130LCN-3 (2-Piece Boom)382
Specifications383
ZX210-3, 210LC-3 2-Piece Boom383
Working Ranges384
ZX210-3, 210LC-3 2-Piece Boom384
Shoe Types and Applications385
ZX210-3 2-Piece Boom385
ZX210LC-3 2-Piece Boom385
Specifications386
ZX210LCN-3, 240N-3 2-Piece Boom386
Working Ranges387
ZX210LCN-3, 240N-3 2-Piece Boom387
Shoe Types and Applications388
ZX210LCN-3 2-Piece Boom388
ZX240N-3 2-Piece Boom388
Specifications389
ZX250LC-3, 250LCN-3 2-Piece Boom389
Working Ranges390
ZX250LC-3, 250LCN-3 2-Piece Boom390
Shoe Types and Applications391
ZX250LC-3 2-Piece Boom391
ZX250LCN-3 2-Piece Boom391
Specifications392
ZX280LC-3, 280LCN-3 2-Piece Boom392
Working Ranges393
ZX280LC-3, 280LCN-3 2-Piece Boom393
Shoe Types and Applications394
ZX280LC-3 2-Piece Boom394
ZX280LCN-3 2-Piece Boom394
Specifications395
ZX350LC-3, 350LCN-3 2-Piece Boom395
Working Ranges396
ZX350LC-3, 350LCN-3 2-Piece Boom396
Shoe Types and Applications397
ZX350LC-3 2-Piece Boom397
ZX350LCN-3 2-Piece Boom397
Lifting Hook398

Hitachi 120-3 class User Manual

Table of Contents

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Hitachi 120-3 class Specifications

Related product manuals

Brand	Hitachi
Model	120-3 class
Category	Excavators
Language	English