Hitachi ZAXIS 120-6 class

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INDEX

ENMDC1-MX2-7

MACHINE NUMBERS

SAFETY

VISIBILITY MAP

SAFETY SIGNS

NAME OF COMPONENTS

GETTING ON AND OFF THE MACHINE

OPERATOR’S STATION

BREAK-IN

OPERATING THE ENGINE

DRIVING THE MACHINE

OPERATING THE MACHINE

TRANSPORTING

MAINTENANCE

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

STORAGE

TROUBLESHOOTING

SPECIFICATIONS

OPTIONAL ATTACHMENTS AND DEVICES

INDEX

Main Page

Table of Contents5
Machine Numbers12
Safety17
Recognize Safety Information17
Understand Signal Words17
Follow Safety Instructions18
Prepare for Emergencies19
Wear Protective Clothing19
Protect against Noise20
Inspect Machine20
General Precautions for the Cab21
Use Handholds and Steps22
Adjust the Operator's Seat22
Ensure Safety before Rising from or Leaving Operator's Seat23
Fasten Your Seat Belt23
Move and Operate Machine Safely24
Operate Only from Operator's Seat24
Jump Starting25
Keep Riders off Machine25
Precautions for Operations26
Investigate Job Site Beforehand27
Install OPG Guard28
Restriction of Attachment Installation28
Provide Signals for Jobs Involving Multiple Machines29
Confirm Direction of Machine to be Driven29
Drive Machine Safely30
Avoid Injury from Rollaway Accidents32
Avoid Injury from Back-Over and Swing Accidents33
Keep People Clear from Working Area34
Never Position the Bucket over Anyone34
Avoid Undercutting35
Avoid Tipping35
Never Undercut a High Bank36
Dig with Caution36
Operate with Caution36
Avoid Power Lines37
Precautions for Lightning37
Object Handling38
Protect against Flying Debris and Falling Object39
Park Machine Safely40
Handle Fluids Safely−Avoid Fires40
Transport Safely41
Practice Safe Maintenance42
Warn Others of Service Work43
Support Machine Properly43
Stay Clear of Moving Parts44
Prevent Parts from Flying44
Avoid Injury from Attachment Falling Accident45
Prevent Burns45
Replace Rubber Hoses Periodically46
Avoid High-Pressure Fluids46
Prevent Fires47
Evacuating in Case of Fire49
Beware of Exhaust Fumes49
Precautions for Welding and Grinding50
Avoid Heating Near Pressurized Fluid Lines51
Avoid Applying Heat to Lines Containing Flammable Fluids51
Precautions for Handling Accumulator and Gas Damper51
Remove Paint before Welding or Heating52
Beware of Asbestos and Silica Dust and Other Contamination52
Prevent Battery Explosions53
Service Air Conditioning System Safely53
Handle Chemical Products Safely54
Dispose of Waste Properly54
Never Ride Attachment55
Notes on Aftertreatment Device55
Precautions for Communication Terminal55
Precaution for Communication Terminal Equipment56
Notes on Protection of Operator's Station When the Machine Rolls over58
Visibility Map59
Safety Signs75
Name of Components83
Getting on and off the Machine84
Operator's Station85
About Aftertreatment Device85
Cab Features88
Multi Function Monitor89
Default Setting90
Basic Screen92
How to Use Screens92
Displaying Basic Screen92
Hour Meter95
Clock95
Fuel Gauge95
Def/Adblue® Gauge96
Def/Adblue® Level Alarm96
Coolant Temperature Gauge97
Operating Status Icon Display97
Security Functions (Optional)98
Input Password98
Extending Password Duration Time99
Alarm Occurrence Screen100
Remedy102
Urea SCR System Remedy105
Aftertreatment Device107
Aftertreatment Device Condition Display107
Aftertreatment Device Manual Regeneration Request108
Manual Regeneration Procedure109
Main Menu110
Engine Output Restriction Suspend111
Urea SCR System Troubleshooting113
Air Conditioner115
Circulation Air Mode115
Air Conditioner ON/OFF115
Radio116
Work Mode117
Attachment Selection117
Mail (Optional)118
Setting Menu120
Date and Time121
Time Adjustment121
Date Adjustment123
Display Mode Setting125
Attachment Adjustment127
Flow Rate Adjustment127
Priority (Arm Roll-Out) (Except ZX330-6 Class)129
Priority (Arm Roll-In) (Except ZX120-6, 160-6 Class)131
Attachment Name Input133
Auto Shut-Down135
Auto Shut-Down: ON/OFF135
Auto Shut-Down: Setting Time136
Aftertreatment Device Regeneration Inhibited137
Setting Procedure137
Password Change (Optional)139
Sub Meter143
Brightness Adjustment145
Language Settings147
Lists of Display Language149
Unit Selection150
Display Item Selection (Rear View Camera OFF)152
Main Menu Sequence Change154
Information Menu156
Operation157
Fuel Consumption157
Breaker Operation159
Attachment Operation161
Travel Operation163
Actual Operation165
Maintenance167
Remaining Time and Maintenance Interval169
Monitoring171
Switch Panel173
Return to Previous Screen Switch (Monitor)174
Return to Basic Screen Switch (Monitor)174
Selector Knob (Monitor)174
Temperature Control Switch/Mode Switch (Air Conditioner)174
AUTO/OFF Switch/Fan Switch (Air Conditioner)174
AM/FM Selector/Tuning Switch (Radio)175
Power Switch/Volume Control Knob (Radio)175
Engine Control Dial175
Auto-Idle Switch176
Travel Mode Switch176
Power Mode Switch177
Work Light Switch177
Wiper/Washer Switch178
USB Power Supply Port179
Numeric Keypad180
Switch Panel181
Rear Light Switch181
Perimeter Lights Switch181
Travel Alarm Deactivation Switch181
Seat Heater Switch181
Electrical Control Main Switch181
Key Switch185
Power Boost Switch185
Horn Switch185
Electrical Control Main Switch186
Cigar Lighter187
Using Cigar Lighter187
Cab Light Switch188
Pilot Control Shut-Off Lever189
Control Lever Auto-Lock190
Engine Stop Switch191
Fuse Box192
Auto Air Conditioner193
Features193
Name of Components194
Controller Part Name and Function195
Cab Heater Operation197
Cooling Operation198
Defroster Operation199
Cool Head/Warm Feet Operation199
Tips for Optimal Air Conditioner Usage200
For Rapid Cooling200
When Windows Become Misty200
Off-Season Air Conditioner Maintenance200
AM/FM Radio Operation201
Controls on the Radio201
Tuning Procedure201
Station Presetting Procedure202
Station Auto-Presetting Procedure203
TONE Control204
Audio Input205
Aerial Angle Monitor206
Switching the Screen Display208
Description of Images209
Cab Door Release Lever213
Opening/Closing and Removing Cab Inside Window214
Opening Upper Front Window215
Removing and Storing Lower Front Window216
Opening Side Window217
Opening and Closing the Roll Screen (for Front and Right Windows) (Optional)218
How to Use on the Front Window218
How to Store on Right Window Side220
How to Use on Right Window Side220
How to Clean the Screen220
Opening/Closing Overhead Window (Clear Hatch)221
Emergency Exit222
Opening and Closing the OPG Front Guard (Optional)223
Adjusting Operator's Seat224
Seat Height and Angle Adjustment224
Console and Seat Fore-Aft Adjustment224
Seat Fore-Aft Adjustment224
Suspension Adjustment224
Backrest Adjustment225
Armrest Adjustment225
Adjusting Operator's Seat (Optional)226
Adjusting Seat Height226
Console and Seat Fore-Aft Adjustment226
Seat Fore-Aft Adjustment226
Suspension Adjustment227
Fore-Aft Position Adjustment of Seat Surface227
Angle Adjustment of Seat Surface227
Backrest Adjustment227
Armrest Adjustment227
Console Height Adjustment228
Adjusting Procedures228
Installation and Adjustment of Mirrors229
Mirror Installation Diagram230
Seat Belt233
Battery Disconnect Switch234
Switch Operation235
Break-In237
Observe Engine Operation Closely237
Every 8 Hours or Daily237
After the First 50 Hours237
After the First 100 Hours237
Operating the Engine239
Inspect Machine Daily before Starting239
Before Starting Engine241
Starting the Engine242
Check Instruments after Starting248
Using Booster Batteries249
Stopping the Engine251
Engine Auto-Stop in Extremely Low Temperature252
Driving the Machine253
Travel Levers and Pedals253
Travel Mode Switch255
Travel Alarm (Optional)255
Operating on Soft Ground256
Raising the Machine with Boom and Arm256
Retrieval257
Operating in Water or Mud258
Parking the Machine on Slopes259
Parking the Machine259
Prohibition of Traveling for Long Periods260
Prohibition of Sudden Control Operations When Traveling at High Speed260
Do Not Travel the Machine for a Long Period of Time260
Operating the Machine261
Control Lever (ISO Pattern)261
Pilot Control Shut-Off Lever262
Warming-Up Operation263
Engine Speed Control264
Auto-Idle265
Auto-Idle Function265
Auto-Idle ON/OFF266
Auto Shut-Down267
Aftertreatment Device Manual Regeneration270
Work Mode272
Power Boost Switch275
Power Mode276
Operating Backhoe277
Face Shovel278
Grading Operation279
Do Not Strike the Ground with Bucket Teeth280
Avoid Hammer Work280
Avoid Abusive Operation281
Never Move an Object Sideways with the Bucket281
Retracting the Arm and Bucket282
Do Not Use Wide Track Shoes on Rough Ground282
Shackle Hole Usage283
Pilot Accumulator Functions (Optional)284
How to Lower Boom in Case of Emergency and When Engine Stops285
Precautions for after Operations286
Transporting287
Transporting by Road287
Loading/Unloading on a Trailer288
Fastening Machine for Transporting291
Unloading292
Lifting Machine293
Maintenance295
Correct Maintenance and Inspection Procedures295
Layout297
Check the Hour Meter Regularly298
Maintenance Guide Table299
Preparations for Inspection and Maintenance302
Hood and Access Covers303
Maintenance Guide306
Periodic Replacement of Parts312
Kind of Oils313
Brand Names of Recommended Grease313
Recommended Engine Oil313
List of Consumable Parts316
Greasing324
Front Joint Pins324
Swing Bearing326
Swing Internal Gear327
Electric Grease Gun (Nickel-Cadmium Battery) (Only ZX330-6 Class)329
Electric Grease Gun331
Components Name332
Battery Charger Operation333
Charger Lamps333
Electric Grease Gun (Lithium-Ion Battery) (Only ZX330-6 Class)338
Electric Grease Gun340
Components Name341
Battery Charger Operation342
Charger Lamps342
Engine347
Check Engine Oil Level347
Change Engine Oil349
Replace Engine Oil Filter349
Sampling the Engine Oil351
Check and Clean Around the Engine352
Replace Oil Separator Element352
Transmission353
Pump Transmission (Except ZX120-6 Class)353
Swing Reduction Gear354
Travel Reduction Gear355
Hydraulic System357
Inspection and Maintenance of Hydraulic Equipment357
Check Hydraulic Oil Level360
Change Hydraulic Oil361
Bleed Air from the Hydraulic System363
Suction Filter Cleaning364
Replace Full-Flow Filter365
Replace Pilot Oil Filter366
Replace Air Breather Element367
Check Hoses and Lines368
Fuel System372
Recommended Fuel372
Drain Fuel Tank Sump374
Drain Fuel Pre-Filter375
Replace Fuel Main Filter Element378
Replace Fuel Pre-Filter Element380
Check Fuel Hoses382
Air Cleaner383
Clean and Replace Air Cleaner Element (Outer)383
Replace Air Cleaner Element (Inner)385
Cooling System386
Check Coolant Level387
Check and Adjust Fan Belt Tension389
Change Coolant391
Clean Radiator/Oil Cooler/Inter Cooler Core393
Clean Oil Cooler, Radiator and Inter Cooler Front Screen395
Clean Air Conditioner Condenser395
Clean Fuel Oil Cooler395
Drain Intercooler (Only ZX120-6)396
Electrical System397
Battery398
Replace Battery401
Check Electrolyte Specific Gravity402
Replacing Fuses403
Fuse Box404
Miscellaneous406
Check and Replace Bucket Teeth406
Change Bucket408
Convert Bucket Connection into Face Shovel409
Adjust Bucket Linkage410
Remove Travel Levers411
Check and Replace Seat Belt411
Check Windshield Washer Fluid Level412
Check Track Sag413
Clean and Replace Air Conditioner Filter418
Check Air Conditioner420
Clean Cab Floor422
Retighten Cylinder Head Bolt423
Inspect and Adjust Valve Clearance423
Measure Engine Compression Pressure423
Check Starter and Alternator423
Check and Replace EGR Device423
EGR Cooler Cleaning423
Check Turbo Charger423
Check and Clean Injector424
Check Gas Damper424
Tightening and Retightening Torque of Nuts and Bolts424
Aftertreatment Device449
Check and Clean Aftertreatment Device449
Urea SCR System450
Check Def/Adblue452
Refill Def/Adblue452
Extendable Filler Neck454
Clean Filler Port Strainer455
Change Def/Adblue456
Replace Def/Adblue® Supply Module Main Filter457
Replace Def/Adblue® Tank Water Supply Inlet Filter459
Replace the Def/Adblue® Back Flow Line Filter460
Aerial Angle461
Daily Checks of Aerial Angle Camera Images461
Checking Aerial Angle Camera Images462
Maintenance under Special Environmental Conditions463
Maintenance under Special Environmental Conditions464
Storage465
Storing the Machine465
Troubleshooting467
Specifications476
Shoe Types and Applications477
Bucket Types and Applications478
Specifications478
Zx160Lc-6480
Working Ranges (Grouser Shoe)480
Shoe Types and Applications481
Bucket Types and Applications482
Specifications482
Working Ranges (Grouser Shoe)484
Shoe Types and Applications485
Bucket Types and Applications486
Specifications486
Working Ranges488
Shoe Types and Applications489
Bucket Types and Applications490
Specifications490
Working Ranges492
Shoe Types and Applications493
Bucket Types and Applications494
Specifications494
Working Ranges (Grouser Shoe)496
Shoe Types and Applications497
Bucket Types and Applications498
Optional Attachments and Devices499
Using Pad Crawler Shoe499
Traveling and Other Cautions500
Transporting501
Precautions for Transporting Machines with Pad Crawler Shoes501
Long Arm Operation505
Blade Lever506
Avoid Hitting Blade with Front-End Attachment507
Blade Maintenance508
Specifications509
ZX130-6 with Blade509
Working Ranges510
ZX130-6 with Blade510
Shoe Types and Applications511
ZX130-6 with Blade511
Bucket Teeth (Transverse-Type-Pin-Used Type)512
ZX200-6, 240-6, 300-6, 330-6 Class512
Control Lever (4 Way Multi Valve) (Optional)513
Hydraulic Breaker, Hydraulic Crusher and Quick Coupler514
Piping for Breaker and Crusher515
Operational Procedures for Stop Valves and Selector Valve515
Secondary Relief Pressure Adjustment516
Precautions for Breaker Operation517
Change Hydraulic Oil and Replace Full-Flow Filter Element521
Precautions for Crusher Operation522
Attachment525
Allowable Weight Limits of Installed Attachment525
Attachment Connection Parts527
Precautions for Arm Roll-In/Bucket Roll-In Combined Operation529
Index532

Hitachi ZAXIS 120-6 class - Page 3

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