Hitachi ZAXIS 170W-3 - User Manual

This document is a Technical Manual for Troubleshooting the Hitachi ZAXIS 170W-3 and 190W-3 Wheeled Excavators. It provides comprehensive information for experienced technicians to maintain and repair these machines, focusing on operational performance tests and troubleshooting procedures.

Function Description:

The Hitachi ZAXIS 170W-3 and 190W-3 are wheeled excavators designed for various construction and excavation tasks. This technical manual specifically addresses the troubleshooting and operational performance testing aspects of these machines. It is part of a larger service manual series that includes an Operational Principle manual and a Workshop Manual, providing a holistic view of the machine's operation, maintenance, and repair. The manual aims to help technicians diagnose and resolve issues efficiently, ensuring the machine operates at optimal performance and safety standards.

Important Technical Specifications:

The manual outlines a detailed "Operational Performance Test" section (Section 4) to quantitatively check all systems and functions. This section includes:

• Engine Test (Group 3): Covers engine speed, engine compression pressure, valve clearance, and lubricant consumption.
• Excavator Test (Group 4): Includes travel speed, brake control function, parking brake control function, swing speed, swing function drift check, swing motor leakage, maximum swingable slant angle, swing bearing play, hydraulic cylinder cycle time, hydraulic cylinder drift check, control lever operating control force, control lever stroke, and combined operation boom raise/swing function check.
• Component Test (Group 5): Details primary pilot pressure, secondary pilot pressure, solenoid valve set pressure, main pump delivery pressure, main relief set pressure, relief pressure (when relieving swing), overload relief valve set pressure, main pump flow rate measurement, swing motor drainage, travel motor drainage, steering valve relief pressure, brake pressure (front and rear), brake accumulated pressure, and brake warning set pressure (decrease/increase).

The "Performance Standard" values are provided for new machines and components adjusted to specifications, with allowable errors indicated as necessary. The manual emphasizes evaluating test data based on machine operation hours, work loads, and maintenance conditions.

Usage Features:

The manual is structured to guide technicians through diagnosing and resolving issues. It includes:

• Diagnosing Procedure (Group 1, Section 5): Provides a systematic approach to identify problems.
• Monitor Unit (Group 2, Section 5): Explains how to use the machine's monitor unit for diagnostics.
• Dr. ZX (Group 3, Section 5): Details the use of the Dr. ZX diagnostic tool.
• ICF (Group 4, Section 5): Refers to the "Integrated Control Function" for troubleshooting.
• Component Layout (Group 5, Section 5): Helps locate and identify various components for inspection and repair.
• Troubleshooting A and B (Group 6 & 7, Section 5): Offers specific troubleshooting steps for different issues.
• Electrical System Inspection (Group 8, Section 5): Guides through checking the electrical system.

The manual also contains an "Introduction" section with important information for the reader, including how to contact Hitachi Construction Machinery Co. Ltd. for questions or errors, and notes that the manual contains revision information up to June 18, 2007.

Maintenance Features:

The manual emphasizes safety throughout, with a dedicated "SAFETY" section (SA-1 to SA-30) that covers:

• Recognizing Safety Information: Explains safety alert symbols (DANGER, WARNING, CAUTION, IMPORTANT, NOTE).
• Following Safety Instructions: Stresses reading and following all safety signs, maintaining the machine in proper working condition, and avoiding unauthorized modifications or attachments.
• Preparing for Emergencies: Advises on having a first aid kit and fire extinguisher, establishing emergency procedures, and keeping emergency numbers handy.
• Wearing Protective Clothing: Recommends appropriate safety gear like hard hats, safety shoes, glasses, gloves, and hearing protection.
• Protecting Against Noise: Warns about prolonged exposure to loud noise and advises wearing hearing protection.
• Inspecting Machine: Recommends daily walk-around inspections.
• General Precautions for Cab: Covers cleanliness, storage of tools, avoiding transparent objects, and refraining from distractions like radios or mobile phones.
• Using Handholds and Steps: Emphasizes three-point contact and avoiding jumping on/off the machine.
• Adjusting Operator's Seat: Guides on proper seat adjustment for comfort and control.
• Ensuring Safety Before Rising from or Leaving Operator's Seat: Instructs on lowering attachments and engaging the pilot control shut-off lever.
• Fastening Seat Belt: Highlights the importance of seat belt use to prevent injury in case of overturn.
• Moving and Operating Machine Safely: Advises confirming bystander locations, using travel alarms/horns, and coordinating with signal persons.
• Handling Starting Aids Safely: Warns about the flammability of starting fluid.
• Operating Only from Operator's Seat: Prohibits starting the engine from outside the cab.
• Jump Starting: Provides instructions for safe jump-starting procedures.
• Keeping Riders Off Machine: States that only the operator should be on the machine.
• Precautions for Operations: Emphasizes investigating work sites, clearing obstacles, and careful loading.
• Investigating Job Site Beforehand: Advises on checking ground conditions, making work plans, and reinforcing weak ground.
• Equipment of Head Guard, ROPS, FOPS: Recommends appropriate head guards for falling object protection.
• Providing Signals for Jobs Involving Multiple Numbers of Machines: Stresses clear communication and signal persons.
• Confirming Direction of Machine to Be Driven: Ensures correct steering wheel/pedal operation.
• Driving Machine Safely: Covers safe travel on slopes and around obstructions.
• Avoiding Injury from Rollaway Accidents: Provides steps to prevent unintended machine movement when parked.
• Avoiding Injury from Back-Over and Swing Accidents: Emphasizes looking around, using alarms, and signal persons.
• Keeping Person Clear from Working Area: Instructs on setting up barriers around the swing radius.
• Never Positioning Bucket Over Anyone: Warns against lifting or swinging the bucket over people or truck cabs.
• Avoiding Undercutting: Advises on confirming ground strength near cliffs.
• Avoiding Tipping: Provides precautions for operating on grades.
• Never Undercut a High Bank: Warns about the risk of collapse.
• Digging with Caution: Advises on checking for underground cables and gas lines.
• Operating with Caution: Warns about overhead obstacles.
• Avoiding Power Lines: Specifies safe distances from electric lines.
• Precautions for Lightening: Advises on stopping operation and evacuating during electrical storms.
• Object Handling: Covers safe practices for craning operations.
• Protecting Against Flying Debris: Recommends wearing goggles and keeping bystanders away.
• Parking Machine Safely: Provides steps for secure parking.
• Handling Fluids Safely—Avoid Fires: Warns about flammable fluids and proper refueling.
• Preventing Parts from Flying: Advises caution when releasing pressure from travel reduction gears.
• Storing Attachments Safely: Recommends securing attachments to prevent falling.
• Supporting Maintenance Properly: Covers safe tire mounting and maintenance.
• Preventing Burns: Warns about hot fluids and surfaces.
• Replacing Rubber Hoses Periodically: Emphasizes regular replacement to prevent leaks and fires.
• Avoiding High-Pressure Fluids: Advises on relieving pressure and protecting against fluid injection injuries.
• Preventing Fires: Covers checking for oil leaks, shorts, cleaning flammables, and checking the key switch and heat shields.
• Evacuating in Case of Fire: Provides steps for emergency evacuation.
• Beware of Exhaust Fumes: Warns about asphyxiation and the need for ventilation.
• Precautions for Welding and Grinding: Covers safety measures for welding and grinding, including ventilation and fire prevention.
• Avoiding Heating Near Pressurized Fluid Lines: Warns against welding or heating near fluid lines.
• Avoiding Applying Heat to Lines Containing Flammable Fluids: Instructs on cleaning lines before heating.
• Removing Paint Before Welding or Heating: Advises on avoiding toxic fumes from heated paint.
• Beware of Asbestos Dust: Warns about asbestos fibers and recommends protective measures.
• Preventing Battery Explosions: Covers safe battery handling and charging.
• Servicing Air Conditioning System Safely: Advises on handling refrigerant safely.
• Handling Chemical Products Safely: Recommends consulting Material Safety Data Sheets (MSDS).
• Disposing of Waste Properly: Emphasizes environmentally responsible waste disposal.
• Before Returning the Machine to the Customer: Ensures all repairs and safety checks are complete.

The page numbering system (e.g., T1-3-5) indicates the manual type (T for Technical Manual, W for Workshop Manual), section, group, and consecutive page number within the group. This systematic approach ensures that technicians can quickly locate relevant information for specific maintenance and troubleshooting tasks.