This document is a Workshop Manual for the Hitachi ZAXIS 650LC-3 and 670LCH-3 Hydraulic Excavators. It is part of a larger Service Manual, which also includes a Technical Manual (Operational Principle) and a Technical Manual (Troubleshooting).
Function Description:
The Workshop Manual provides comprehensive technical information necessary for the maintenance and repair of the Hitachi ZAXIS 650LC-3 and 670LCH-3 Hydraulic Excavators. It covers various aspects including maintenance procedures, required tools and devices, maintenance standards, and detailed instructions for removal, installation, assembly, and disassembly of components. This manual is specifically designed for experienced technicians to ensure correct product information and service procedures are followed, ultimately contributing to the machine's proper functioning, safety, and longevity.
Important Technical Specifications (Inferred from Manual Structure):
While specific numerical technical specifications are not directly listed on the introductory pages, the manual's structure implies a focus on:
- Operational Principle (Technical Manual): This separate volume would detail the fundamental workings of the excavator's systems, including hydraulic circuits, engine operation, electrical systems, and control mechanisms. It would cover the "how" and "why" of the machine's functions, essential for understanding its design and intended performance.
- Troubleshooting (Technical Manual): This volume would provide information for diagnosing and resolving operational performance issues. It would likely include diagnostic charts, fault codes, testing procedures, and methods to identify the root cause of malfunctions.
- Maintenance and Repair (Workshop Manual): The current document, the Workshop Manual, focuses on the practical aspects of keeping the machine in optimal condition. This includes:
- Maintenance Standards: Guidelines for acceptable wear limits, torque specifications, fluid capacities, and other critical parameters for various components.
- Removal/Installation Procedures: Step-by-step instructions for detaching and reattaching major and minor components.
- Assembly/Disassembly Procedures: Detailed guides for taking apart and putting together complex sub-assemblies.
- Required Tools and Devices: Information on specialized tools needed for specific maintenance and repair tasks.
The manual emphasizes several key usage and safety features, which are crucial for the safe and effective operation of the excavator:
- Safety Alert Symbols and Signal Words: The manual prominently features safety alert symbols (an exclamation mark within a triangle) and signal words (DANGER, WARNING, CAUTION, IMPORTANT, NOTE) to highlight potential hazards and critical information.
- DANGER: Indicates an imminently hazardous situation that will result in death or serious injury if not avoided.
- WARNING: Indicates a potentially hazardous situation that could result in death or serious injury if not avoided.
- CAUTION: Indicates a potentially hazardous situation that could result in minor or moderate injury if not avoided.
- IMPORTANT: Indicates situations that could result in machine damage if instructions are not followed.
- NOTE: Provides supplementary technical information or know-how.
- Protective Equipment: Operators and maintenance personnel are instructed to wear appropriate personal protective equipment (PPE) such as hard hats, safety shoes, safety glasses/goggles/face shields, heavy gloves, hearing protection, reflective clothing, wet weather gear, and respirators/filter masks. Loose clothing, jewelry, and headphones are to be avoided during operation.
- Machine Inspection: Daily or shift-based walk-around inspections are mandated to prevent personal injury and ensure all lights are operable.
- Cab Precautions: Strict rules for cab use include removing dirt/oil from boots, avoiding loose parts/tools, not storing transparent bottles or decorations (due to fire risk), refraining from using radios/mobile phones during operation, and keeping flammable objects away.
- Handholds and Steps: Emphasizes maintaining three-point contact when entering/exiting the machine, avoiding controls as handholds, and never jumping on/off a moving machine.
- Operator's Seat Adjustment: The seat must be properly adjusted for the operator to fully depress pedals and operate control levers with their back against the seat, preventing fatigue and mis-operations. Rearview mirrors also need correct adjustment.
- Pilot Control Shut-Off Lever: Before rising from the seat or leaving the machine, the front attachment must be lowered to the ground, and the pilot control shut-off lever moved to the LOCK position to prevent unintended machine movement.
- Seat Belt Usage: Operators must fasten their seat belts at all times to minimize injury risk in case of overturn. Regular inspection and replacement (every three years) of the seat belt are recommended.
- Safe Machine Movement and Operation:
- Bystander Awareness: Extreme caution is required to avoid running over bystanders; their location must be confirmed before any movement. Travel alarms and horns should be functional.
- Signal Person: A signal person is required in congested areas, with coordinated hand signals.
- Starting Aids: Starting fluid is highly flammable and must be handled with care, away from sparks, flames, batteries, and cables.
- Operator's Seat Only: The engine should only be started from the operator's seat, with all control levers in neutral, and after confirming safety around the machine.
- Jump Starting: Specific procedures must be followed for jump starting, emphasizing a two-person operation and never using a frozen battery.
- No Riders: Only the operator should be on the machine to prevent injury from foreign objects or being thrown off, and to avoid obstructing the operator's view.
- Work Site Investigation: Thorough investigation of ground conditions, potential collapses, and work plans is required before operation, especially near excavations, road shoulders, or on soft/frozen ground.
- ROPS/FOPS: The machine should be equipped with a head guard, ROPS (Roll-Over Protective Structure), or FOPS (Falling Object Protective Structure) in areas with falling object risks.
- Multi-Machine Operations: Signals known by all personnel and a designated signal person are required for jobs involving multiple machines.
- Travel Direction Confirmation: Operators must confirm the travel pedal/lever direction corresponds to the desired machine movement, especially considering the position of the travel motors relative to the cab.
- Slope Operation: Driving across slopes or steering on slopes is discouraged due to skid/turnover risk. If direction changes are needed, move to level ground first. Ascending/descending steep slopes (over 35 degrees) is prohibited. The bucket should be kept low (0.5 to 1.0 m) above ground when on slopes.
- Obstruction Avoidance: Detouring around obstructions is advised, and personnel should not be near the machine during travel.
- Road/Track Protection: Use wood plates when crossing roads or train tracks to prevent damage.
- Water Crossing: Measure river depth with the bucket and cross slowly, ensuring depth does not exceed the upper edge of the upper roller.
- Rough Terrain: Reduce engine speed and select slow travel speed to prevent damage to the machine and undercarriage.
- Winter Operations: Clean snow and ice from track shoes to prevent slipping.
- Rollaway Prevention: Park on level ground, lower the bucket, turn off auto-idle and H/P mode, cool down the engine, stop the engine, remove the key, and engage the pilot control shut-off lever to LOCK. Block tracks and thrust bucket teeth into the ground if parking on a grade.
Maintenance Features (Specific to this Workshop Manual):
The Workshop Manual is the primary resource for all maintenance-related activities. It provides:
- Detailed Procedures: Step-by-step instructions for routine maintenance, inspections, adjustments, and repairs.
- Component-Specific Information: Dedicated sections for various machine components (engine, hydraulics, undercarriage, etc.), detailing their maintenance requirements.
- Troubleshooting Integration: While a separate Troubleshooting Manual exists, the Workshop Manual will likely include practical repair steps once a problem has been diagnosed.
- Replacement Guidelines: Instructions for replacing worn or damaged parts, including specifications for new components.
- Safety During Maintenance: The manual implicitly includes safety warnings relevant to maintenance tasks, such as proper lifting techniques for heavy parts and precautions when working with hazardous materials (e.g., battery gas, hydraulic oil).
- Unit Conversion Table: A table is provided for converting SI units (International System of Units) to MKSA system units and English units, which is essential for technicians working with different measurement systems. This ensures accuracy in measurements and specifications during maintenance and repair.
In summary, the Hitachi ZAXIS 650LC-3 and 670LCH-3 Hydraulic Excavator Workshop Manual is an indispensable guide for technicians, ensuring the safe, efficient, and correct maintenance and repair of these heavy machinery models. It complements the other volumes of the Service Manual by providing the practical "how-to" for keeping the excavators in optimal working condition.
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