Hitachi ZAXIS 210W - User Manual

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Summary

INTRODUCTION

To The Reader

Information for experienced technicians on maintaining and repairing the machine.

Additional References

Lists other manuals and materials to refer to for additional information.

Manual Composition

Details the three volumes comprising the service manual.

Page Numbering System

Explains the format and components of page numbers within the manual.

Safety Alert Symbols and Notations

Explains safety symbols (Caution, Important, Note) and their meanings.

Units of Measurement Used

Lists SI units and conversions to MKSA and English units used in the manual.

SAFETY

Recognize Safety Information

Explains the safety alert symbol and the importance of recognizing it.

Understand Signal Words

Defines signal words like DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.

Follow Safety Instructions

Emphasizes reading and following all safety signs and messages in the manual.

Prepare For Emergencies

Advises on preparing for emergencies like fires or accidents with first aid and fire extinguishers.

Wear Protective Clothing

Lists necessary protective clothing and safety equipment for various jobs.

Protect Against Noise

Explains the risk of hearing impairment from loud noise and recommends protective devices.

Inspect Machine Before Operation

Stresses the importance of daily walk-around inspections to prevent personal injury.

General Precautions For Cab

Provides precautions for maintaining safety within the operator's cab.

Use Handholds and Steps Safely

Advises on safe mounting and dismounting procedures using handholds and steps.

Adjust Operators Seat Correctly

Explains the importance of properly adjusting the operator's seat for comfort and control.

Fasten Your Seat Belt Securely

Details the importance of wearing a seat belt to prevent injury during overturns or accidents.

Move and Operate Machine Safely

Provides guidelines for safe movement and operation, including bystander awareness.

Operate Only From Operators Seat

Warns against starting the engine improperly to prevent runaway machines.

Jump Starting Procedures

Covers safety procedures for jump starting the engine to avoid explosions.

Keep Riders Off Machine

Instructs to keep unauthorized persons off the machine for safety and visibility.

Provide Signals For Multiple Machines

Advises on using signals for coordinated operations with multiple machines.

Confirm Machine Direction Before Driving

Explains how to confirm the machine's direction of travel before driving.

Drive Machine Safely on Work Site

Provides safety instructions for driving the machine on work sites, including slopes.

Avoid Injury From Rollover Accidents

Details procedures to prevent machine rollaways when mounting, stopping, or parking.

Avoid Injury From Back-Over and Swing Accidents

Covers precautions against back-over and swing accidents, emphasizing bystander awareness.

Avoid Tipping Hazards

Warns about tipping hazards, especially on grades, and provides preventative measures.

Avoid Power Lines

Advises on maintaining safe distances from electric lines to prevent electrocution.

Object Handling Safety

Provides safety guidelines for handling loads, including using proper equipment and procedures.

Protect Against Flying Debris

Recommends wearing eye protection to guard against injury from flying debris.

Park Machine Safely

Outlines steps for safely parking the machine to prevent accidents.

Summary

INTRODUCTION

To The Reader

Information for experienced technicians on maintaining and repairing the machine.

Additional References

Lists other manuals and materials to refer to for additional information.

Manual Composition

Details the three volumes comprising the service manual.

Page Numbering System

Explains the format and components of page numbers within the manual.

Safety Alert Symbols and Notations

Explains safety symbols (Caution, Important, Note) and their meanings.

Units of Measurement Used

Lists SI units and conversions to MKSA and English units used in the manual.

SAFETY

Recognize Safety Information

Explains the safety alert symbol and the importance of recognizing it.

Understand Signal Words

Defines signal words like DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.

Follow Safety Instructions

Emphasizes reading and following all safety signs and messages in the manual.

Prepare For Emergencies

Advises on preparing for emergencies like fires or accidents with first aid and fire extinguishers.

Wear Protective Clothing

Lists necessary protective clothing and safety equipment for various jobs.

Protect Against Noise

Explains the risk of hearing impairment from loud noise and recommends protective devices.

Inspect Machine Before Operation

Stresses the importance of daily walk-around inspections to prevent personal injury.

General Precautions For Cab

Provides precautions for maintaining safety within the operator's cab.

Use Handholds and Steps Safely

Advises on safe mounting and dismounting procedures using handholds and steps.

Adjust Operators Seat Correctly

Explains the importance of properly adjusting the operator's seat for comfort and control.

Fasten Your Seat Belt Securely

Details the importance of wearing a seat belt to prevent injury during overturns or accidents.

Move and Operate Machine Safely

Provides guidelines for safe movement and operation, including bystander awareness.

Operate Only From Operators Seat

Warns against starting the engine improperly to prevent runaway machines.

Jump Starting Procedures

Covers safety procedures for jump starting the engine to avoid explosions.

Keep Riders Off Machine

Instructs to keep unauthorized persons off the machine for safety and visibility.

Provide Signals For Multiple Machines

Advises on using signals for coordinated operations with multiple machines.

Confirm Machine Direction Before Driving

Explains how to confirm the machine's direction of travel before driving.

Drive Machine Safely on Work Site

Provides safety instructions for driving the machine on work sites, including slopes.

Avoid Injury From Rollover Accidents

Details procedures to prevent machine rollaways when mounting, stopping, or parking.

Avoid Injury From Back-Over and Swing Accidents

Covers precautions against back-over and swing accidents, emphasizing bystander awareness.

Avoid Tipping Hazards

Warns about tipping hazards, especially on grades, and provides preventative measures.

Avoid Power Lines

Advises on maintaining safe distances from electric lines to prevent electrocution.

Object Handling Safety

Provides safety guidelines for handling loads, including using proper equipment and procedures.

Protect Against Flying Debris

Recommends wearing eye protection to guard against injury from flying debris.

Park Machine Safely

Outlines steps for safely parking the machine to prevent accidents.

Overview

Function Description
Important Technical Specifications (General Information from Manual Structure)
Units Used
Usage Features (Safety and Operational Guidelines)
Maintenance Features (General Information from Manual Structure)

This document is a Technical Manual (Troubleshooting) for the HITACHI ZAXIS 210W Wheeled Excavator. It is part of a larger Service Manual (Manual No. KM-CDBE), specifically identified as Volume No. TTCDBE-00. The complete Service Manual also includes a Technical Manual (Operational Principle) (Vol. No. TOCDBE) and a Workshop Manual (Vol. No. WCDBE).

Function Description:

This Technical Manual focuses on troubleshooting procedures for the ZAXIS 210W Wheeled Excavator. It is designed for experienced technicians to provide the necessary technical information for maintaining and repairing the machine, particularly concerning operational performance tests and problem diagnosis. The manual emphasizes safety throughout its initial sections, providing guidelines and warnings to prevent personal injury and machine damage during operation and maintenance.

Important Technical Specifications (General Information from Manual Structure):

While specific technical specifications for the ZAXIS 210W are not detailed in the introductory pages, the manual's structure indicates that comprehensive information is provided across the three volumes of the Service Manual.

Technical Manual (Operational Principle) (Vol. No. TOCDBE): This volume would contain detailed technical information regarding the redelivery and delivery of the machine, as well as the operation and activation of all its devices and systems. This would likely include specifications for the engine, hydraulic system, electrical system, and other core components.
Technical Manual (Troubleshooting) (Vol. No. TTCDBE - this document): This volume focuses on operational performance tests and troubleshooting procedures. This implies that it will contain diagnostic charts, fault codes, test procedures, and expected performance values for various systems.
Workshop Manual (Vol. No. WCDBE): This volume would detail maintenance and repair procedures, including information on tools and devices required, maintenance standards, and removal/installation and assembly/disassembly procedures for various machine parts.

Units Used:

The manual primarily uses SI Units (International System of Units). MKSA system units and English units are also provided in parentheses for reference. A conversion table is included for common quantities such as:

Length: mm (in, ft)
Volume: L (US gal, US qt, yd³)
Weight: kg (lb)
Force: N (kgf, lbf)
Torque: N·m (kgf·m, lbf·ft)
Pressure: MPa (kgf/cm², psi)
Power: kW (PS, HP)
Temperature: °C (°F)
Velocity: km/h (mph)
Rotational Speed: min⁻¹ (rpm)
Flow rate: L/min (US gpm)
Displacement: mL/rev (cc/rev)

Usage Features (Safety and Operational Guidelines):

The manual provides extensive safety guidelines crucial for operating and maintaining the ZAXIS 210W Wheeled Excavator. These include:

To the Reader: Emphasizes that the manual is for experienced technicians and advises thorough reading for correct product information and service procedures. It also provides contact information for reporting errors or questions.
Safety Alert Symbol and Headline Notations: Explains the use of the safety alert symbol (a triangle with an exclamation mark) and signal words (DANGER, WARNING, CAUTION, IMPORTANT, NOTE) to indicate potential hazards, personal injury risks, and machine damage.
- DANGER: Imminently hazardous situation, resulting in death or serious injury if not avoided.
- WARNING: Potentially hazardous situation, resulting in death or serious injury if not avoided.
- CAUTION: Potentially hazardous situation, resulting in minor or moderate injury if not avoided. Also used for general precautions.
- IMPORTANT: Indicates a situation that could result in damage to the machine if instructions are not followed.
- NOTE: Provides supplementary technical information or know-how.
Recognize Safety Information: Instructs users to be alert to the safety alert symbol and follow recommended precautions.
Understand Signal Words: Clarifies the meaning and application of DANGER, WARNING, CAUTION, IMPORTANT, and NOTE in safety signs and messages.
Follow Safety Instructions: Stresses the importance of reading and following all safety signs and messages, ensuring signs are maintained, operating the machine correctly and safely, allowing only trained personnel to operate, keeping the machine in proper working condition, and avoiding unauthorized modifications.
Prepare for Emergencies: Recommends having a first aid kit and fire extinguisher readily available, understanding their use, establishing emergency procedures, and posting emergency contact numbers.
Wear Protective Clothing: Advises wearing close-fitting clothing and appropriate safety equipment such as hard hats, safety shoes, safety glasses, heavy gloves, hearing protection, reflective clothing, wet weather gear, and respirators. Warns against loose clothing, jewelry, and operating with headphones.
Protect Against Noise: Warns of hearing impairment from prolonged loud noise and recommends wearing earmuffs or earplugs.
Inspect Machine: Emphasizes daily or shift-based walk-around inspections before starting to avoid personal injury, referring to the "PRE-START INSPECTION" chapter in the operator's manual.
General Precautions for Cab: Instructions for maintaining a safe cab environment, including removing dirt/oil from boots, storing tools properly, avoiding transparent bottles or window decorations that could focus sunlight, refraining from listening to radio/music headphones or using mobile phones while operating, keeping flammable objects away, and properly extinguishing cigarettes.
Use Handholds and Steps: Advises facing the machine and maintaining three-point contact when mounting/dismounting, not using controls as handholds, never jumping on/off, and being careful of slippery conditions.
Adjust the Operator's Seat: Highlights the importance of a properly adjusted seat to prevent fatigue and misoperations, ensuring the operator can fully depress pedals and operate control levers with their back against the seat.
Fasten Your Seat Belt: Stresses the importance of wearing a seat belt to prevent injury or death in case of overturn, and recommends inspecting and replacing the seat belt every three years.
Move and Operate Machine Safely: Warns against running over bystanders, emphasizing confirming bystander locations, keeping travel alarms and horns working, using a signal person in congested areas, and coordinating hand signals.
Operate Only From Operator's Seat: Prohibits starting the engine from outside the operator's seat or by shorting starter terminals, and requires confirming all control levers are in neutral before starting.
Jump Starting: Provides warnings about battery gas explosion and instructs to follow specific jump-starting procedures from the operator's manual, ensuring the operator is in the seat and never using a frozen battery.
Keep Riders Off Machine: States that only the operator should be on the machine to prevent injury from being struck by objects or thrown off, and to avoid obstructed views.
Provide Signals for Jobs Involving Multiple Numbers of Machines: Recommends using common signals and appointing a signal person for multi-machine job sites.
Confirm Direction of Machine to Be Driven: Advises confirming the steering wheel/shift lever direction and the undercarriage position relative to the cab to avoid incorrect movement.
Drive Machine Safely (Work Site): Provides guidelines for driving on slopes, including keeping the bucket low, reducing speeds, avoiding direction changes on slopes, and immediately lowering the bucket if the machine skids or becomes unstable.
Avoid Injury From Rollaway Accidents: Details steps to prevent rollaways, such as parking on level ground, lowering the bucket, engaging the parking brake, turning off auto-idle/H/P mode, cooling down the engine, stopping the engine, removing the key, pulling the pilot control shut-off lever to LOCK, blocking tires, and positioning the machine to prevent rolling.
Avoid Injury From Back-Over and Swing Accidents: Emphasizes looking around, ensuring bystanders are clear, using travel alarms and horns, employing a signal person if the view is obstructed, understanding signals, keeping windows/mirrors/lights clean, and reducing speed in low visibility.
Avoid Tipping: Warns of the danger of tipping, especially on grades, and advises fastening the seat belt. Instructions include preparing a flat operating area, keeping the bucket low, reducing operating speeds, avoiding direction changes on grades, not traveling across grades steeper than 5 degrees, reducing swing speed with loads, and being careful on frozen ground.
Avoid Power Lines: Stresses maintaining a safe distance (at least 3 m (10 ft) plus twice the line insulator length) from electric lines and complying with local regulations. Warns that wet ground expands the area of electric shock risk.
Object Handling: Provides safety guidelines for craning operations, including complying with local regulations, not using damaged chains/cables/slings/ropes, positioning the upperstructure with travel motors at the rear, moving loads slowly, keeping persons away from the load, not moving loads over people, not allowing anyone near the load until it's safely supported, and never attaching slings/chains to bucket teeth.

Maintenance Features (General Information from Manual Structure):

This specific troubleshooting manual (TTCDBE-00) focuses on diagnostic and performance testing, which is a critical part of maintenance. The broader Service Manual (KM-CDBE) covers all aspects of maintenance:

Technical Manual (Troubleshooting): Contains procedures for operational performance tests and troubleshooting, which are essential for identifying issues that require maintenance or repair.
Workshop Manual (Vol. No. WCDBE): This volume is dedicated to the practical aspects of maintenance and repair, including:
- Detailed maintenance and repair procedures for the machine.
- Information on specialized tools and devices required for these tasks.
- Maintenance standards to ensure proper servicing.
- Step-by-step removal/installation and assembly/disassembly procedures for components.

The emphasis on safety throughout the introduction indicates that all maintenance and repair activities must be conducted with strict adherence to safety protocols to protect technicians and prevent further machine damage.