Hitachi Zaxis-14-3, Zaxis16-3, Zaxis18-3, Zaxis27-3 Operator Manual

-3

• ZX16

-3

• ZX18

PART NO.

EM1NC-EN3-1

-3

• ZX27

-3

HYDRAULIC EXCAVATOR OPERATOR’S MANUAL

Operator's Manual

14 16

-3

URL:http://www.hitachi-c-m.com

PRINTED IN THE NETHERLANDS (ACI) 2009, 12

EM1NC-EN3-1ZX14

18 27

-3

Hydraulic Excavator

Serial No. ZX14-3 001001 and up

ZX16-3 003001 and up ZX18-3 005001 and up ZX27-3 007001 and up

INTRODUCTION

Read this manual carefully to learn how to operate and

service your machine correctly. Failure to do so could result in personal injury or equipment damage.

This standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: −20°C to 40°C (−4°F to 104°F) Altitude: 0 m to 1500 m (0 ft to 4900 ft)

In case the machine is used under conditions other than described above, consult your authorized dealer.

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

• SI Units (International System of Units) are used in this manual.

 For reference MKS system units and English units are

also indicated in parentheses after the SI units.

 Example : 24.5 MPa (250 kgf/cm², 3560 psi)

Right-hand and left-hand sides are determined by facing in the direction of forward travel.

Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of Hitachi’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.

Prior to operating this machine in a country other than a country of its intended use, it may be necessary to make modifications to it so that it complies with the local regulatory standards (including safety standards) and legal requirements of that particular country. Please do not export or operate this machine outside of the country of its intended use until such compliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized distributor or dealer if you have any questions concerning compliance.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

INDEX

MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING ENGINE DRIVING MACHINE OPERATING MACHINE TRANSPORTING MAINTENANCE

CONSUMABLE PARTS LIST MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS STORAGE

EM1NC-EN3-1

TROUBLESHOOTING SPECIFICATIONS

OPTIONAL ATTACHMENT AND DEVICE INDEX

CONTENTS

MACHINE NUMBERS ........................................................................1

SAFETY ...............................................................................................S-1

Recognize Safety Information ....................................................S-1

Understand Signal Words .............................................................S-1

Follow Safety Instructions ............................................................S-2

Prepare for Emergencies ...............................................................S-2

Wear Protective Clothing..............................................................S-3

Protect Against Noise ....................................................................S-3

Inspect Machine ..............................................................................S-3

Tidy Up Inside Operator’s Space ................................................S-4

Use Handrails and Steps ...............................................................S-4

Never Ride Attachment .................................................................S-4

Adjust Operator’s Seat ...................................................................S-5

Ensure Safety Before Rising from or

Leaving Operator’s Seat ...........................................................S-5

Fasten Your Seat Belt ......................................................................S-5

Move and Operate Machine Safely ...........................................S-6

Operate Only from Operator’s Seat ..........................................S-7

Jump Starting ...................................................................................S-7

Keep Riders Off Machine ..............................................................S-7

Precautions for Operations ..........................................................S-8

Investigate Job Site Beforehand ................................................S-9

Equipment of OPG ....................................................................... S-10

Provide Signals for Jobs Involving

Multiple Machines ..................................................................S-10

Confirm Direction of Machine to be Driven .......................S-10

Drive Machine Safely ................................................................... S-11

Avoid Injury from Rollaway Accidents ..................................S-13

Avoid Injury from Back-over and Swing Accidents ..........S-14

Keep Personnel Clear from Working Area ...........................S-15

Never Position Bucket Over Anyone .....................................S-15

Avoid Undercutting .....................................................................S-15

Avoid Tipping ................................................................................. S-16

Never Undercut a High Bank ....................................................S-16

Dig with Caution ...........................................................................S-17

Operate with Caution ................................................................. S-17

Avoid Power Lines ........................................................................ S-17

Precautions for Lightning .......................................................... S-18

Do Not Use for Craning Operations .......................................S-18

Protect Against Flying Debris ..................................................S-18

Park Machine Safely ..................................................................... S-19

Handle Fluids Safely−Avoid Fires............................................S-19

Safety Transporting .....................................................................S-20

Practice Safe Maintenance ........................................................S-21

Warn Others of Service Work ................................................... S-22

Support Machine Properly ........................................................ S-22

Stay Clear of Moving Parts ........................................................S-23

Prevent Parts from Flying ..........................................................S-23

Store Attachments Safely .......................................................... S-24

Prevent Burns ................................................................................. S-24

Replace Rubber Hoses Periodically ........................................ S-25

Avoid High-pressure Fluids ....................................................... S-25

Prevent Fires ................................................................................... S-26

Evacuating in Case of Fire .......................................................... S-27

Beware of Exhaust Fumes..........................................................S-28

Beware of Asbestos and Silicon Dust and

Other Contamination ............................................................S-28

Precautions for Welding and Grinding .................................S-29

Avoid Heating Near Pressurized Fluid Lines .......................S-29

Avoid Applying Heat to Lines Containing

Flammable Fluids .................................................................... S-29

Remove Paint Before Welding or Heating ........................... S-30

Prevent Battery Explosions ....................................................... S-30

Handle Chemical Products Safely ........................................... S-31

Dispose of Waste Properly ......................................................... S-31

SAFETY SIGNS ............................................................................ S-33

COMPONENTS NAME ................................................................1-1

OPERATOR’S STATION ...............................................................1-3

Pedals, Levers and Monitor Panel ..............................................1-3

Switch Panel .................................................................................1-4

Key Switch ....................................................................................1-5

Monitor Panel ...................................................................................1-6

Alternator Indicator ...................................................................1-6

Fuel Level Indicator ...................................................................1-6

Preheat Indicator ........................................................................1-6

Overheat Indicator ....................................................................1-6

Engine Oil Pressure Indicator.................................................1-7

Hour Meter ...................................................................................1-7

Fuel Gauge (ZX14-3, 16-3, 18-3) ...........................................1-7

Fuel Gauge (ZX27-3) .................................................................1-7

Coolant Temperature Gauge (ZX27-3) ...............................1-7

Coolant Temperature Indicator .............................................1-7

Cab Heater Operation (Cab Equipped Machines) ...............1-8

Heater Operation .......................................................................1-8

Blower Operation .......................................................................1-8

Defroster Operation ..................................................................1-8

Radio (ZX14-3, 16-3, 18-3 Cab Equipped Machines) ..........1-9

AM/FM Radio Operation (Cab Equipped Machine, When

Genuine Radio is Installed) .................................................. 1-10

Part Name and Function ......................................................1-10

Radio Operation ......................................................................1-11

Tuning Procedure ...................................................................1-11

Station Presetting Procedure ..............................................1-12

Deletion of Preset Memory .................................................1-12

Clock Setting Procedure .......................................................1-12

Opening/Closing Cab Front Window (ZX14-3, 16-3, 18-3

Cab Equipped Machines) ..................................................... 1-13

Opening/Closing Cab Front Window (ZX27-3) ..................1-14

Emergency Exit (ZX14-3, 16-3, 18-3 Cab Equipped

Machines) ..................................................................................1-15

Emergency Exit (ZX27-3) ...........................................................1-16

Adjusting Operator’s Seat .........................................................1-17

Seat Fore-Aft Adjustment ....................................................1-17

Tool and Operator’s Manual Box ............................................. 1-18

Seat Belt ........................................................................................... 1-19

Cab Light (Cab Equipped Machines) .....................................1-20

Cab Door Release Lever

(ZX14-3, 16-3, 18-3 Cab Equipped Machines) ..............1-21

Cab Door Release Button (ZX27-3) ........................................1-21

CONTENTS

BREAK-IN .........................................................................................2-1

Breaking in New Machine ............................................................2-1

OPERATING ENGINE ...................................................................3-1

Before Starting Engine ..................................................................3-1

Starting Engine ................................................................................3-2

Check Machine After Starting Engine ......................................3-5

Using Booster Battery ....................................................................3-6

Stopping Engine ..............................................................................3-7

DRIVING MACHINE .....................................................................4-1

Travel Levers .....................................................................................4-1

Travel Mode Switch (ZX16-3, 18-3, 27-3).................................4-3

Traveling on Soft Ground .............................................................4-4

Raise One Track Using Boom and Arm ....................................4-4

Towing Machine ..............................................................................4-5

Driving in Water or on Soft Ground ..........................................4-6

Parking and Stopping on Slopes ...............................................4-7

Parking on Slopes ............................................................................4-7

OPERATING MACHINE ...............................................................5-1

Control Lever (ISO Excavator Pattern) ......................................5-1

Boom-Swing Pedal ..........................................................................5-2

Auxiliary Pedal ..................................................................................5-3

Blade Lever ........................................................................................5-4

Precautions for Blade Operation ................................................5-5

Blade and Track Width

Control Lever Operation (ZX18-3) ........................................5-6

Extending / Retracting Blade Width

(ZX18-3) .........................................................................................5-7

Pilot Control Shut-Off Lever ........................................................5-8

Warming Up Operation .............................................................. 5-10

Warming Up in Cold Weather ..................................................5-10

Operating Backhoe ...................................................................... 5-11

Grading Operation .......................................................................5-12

Avoid Driving Bucket Teeth into Ground ............................. 5-12

Avoid Abusive Operation ..........................................................5-12

Avoid Striking with Bucket ........................................................ 5-13

Avoid Excavation Using Upperstructure and/or

Boom Swing Power ................................................................5-13

Use Correct Track Shoe ...............................................................5-13

Avoid Other Than Specified Machine Operations ............5-14

Precautions for Using Bucket Hook .......................................5-15

Boom Cylinder May Hit Blade ..................................................5-15

Avoid Hitting Blade with Bucket .............................................5-16

Avoid Colliding Blade Against Rocks ..................................... 5-16

Avoid Colliding Boom Cylinder with Track ......................... 5-16

Using Rubber Crawler .................................................................5-17

Pipings for Breaker and Crusher ..............................................5-19

Precautions for Breaker Operation ......................................... 5-20

Precautions for Crusher Operation ........................................ 5-23

Precautions for After Operating Machine............................5-24

Emergency Boom Lowering Procedure ...............................5-25

TRANSPORTING ...........................................................................6-1

Transporting by Road ....................................................................6-1

Trailer Loading/Unloading ...........................................................6-1

Loading ...............................................................................................6-2

Securing Machine to Trailer for Transportation ....................6-3

Unloading ..........................................................................................6-4

Lifting Machine with Crane .........................................................6-5

MAINTENANCE .............................................................................7-1

Procedures .........................................................................................7-1

Prepare Machine for Inspection/Maintenance .....................7-2

Opening/Closing Engine Access Covers .................................7-3

Opening/Closing Tank Covers (ZX27-3) ..................................7-4

Opening/Closing Right Side Covers (ZX27-3) .......................7-5

Daily Inspection ...............................................................................7-6

Periodic Replacement of Parts ....................................................7-8

Maintenance Guide ........................................................................7-9

Brand Names of Recommended

Oil and Lubricants ................................................................... 7-12

A. Greasing ......................................................................................7-15

Front Joint Pins (Incl. Swing Post Joint Pins) .................7-15

Bucket and Link Pins .............................................................. 7-18

Blade Pins (ZX27-3).................................................................7-18

Swing Bearing .........................................................................7-19

Swing Internal Gear ...............................................................7-20

Control Lever Universal Joint ..............................................7-20

B. Engine .......................................................................................... 7-21

Engine Oil .................................................................................7-21

Change Engine Oil / Replace Engine Oil Filter .............7-22

C. Transmission ..............................................................................7-24

Travel Reduction Gear ...........................................................7-24

D. Hydraulic System ..................................................................... 7-27

Check Hydraulic Oil Level ...................................................7-28

Drain Hydraulic Oil Tank Sump ..........................................7-29

Change Hydraulic Oil ............................................................7-30

Clean Suction Filter ................................................................7-33

Replace Full Flow Filter ........................................................7-34

Replace Pilot Filter ................................................................. 7-35

Check Hoses and Lines .........................................................7-37

E. Fuel System ................................................................................ 7-44

Check Water Separator .........................................................7-45

Drain Fuel Tank Sump ...........................................................7-46

Replace Fuel Filter ...................................................................7-47

Check Fuel Hoses ....................................................................7-48

F. Air Cleaner ................................................................................... 7-49

Clean Air Cleaner Element ................................................... 7-49

Replace Air Cleaner Element...............................................7-49

G. Cooling System ........................................................................ 7-51

Check Coolant Level .............................................................7-53

Check and Adjust Fan Belt Tension ...................................7-53

Change Coolant ....................................................................... 7-56

Clean Radiator ..........................................................................7-58

Clean Air Conditioner Condenser ..................................... 7-58

H. Electrical System ......................................................................7-59

Battery .........................................................................................7-59

Replacing Fuses ....................................................................... 7-63

I. Miscellaneous ............................................................................. 7-64

Check Bucket Teeth for Looseness and/or Wear ......... 7-64

Replace Bucket.........................................................................7-66

Adjust Track Sag (Rubber Crawler) and Check for

Damage ................................................................................7-67

CONTENTS

Replace Rubber Track ............................................................7-69

Check Track Sag (Steel Crawler) (Optional)

(ZX27-3 Only) ...................................................................... 7-71

Check and Replace Seat Belt ............................................... 7-74

Clean Cab Floor (Cab Equipped Machines) ................... 7-75

Check Injection Nozzle .........................................................7-76

Adjust Valve Clearance ..........................................................7-76

Measure Engine Compression Pressure..........................7-76

Check Starter and Alternator .............................................. 7-76

Check Radiator Cap ................................................................ 7-76

Check Crankcase Breather ................................................... 7-76

Check Tightening Torque of Bolts and Nuts ..................7-77

CONSUMABLE PARTS LIST ......................................................8-1

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL

CONDITIONS ..................................................................................9-1

STORAGE ...................................................................................... 10-1

Storing Machine............................................................................10-1

Removing Machine from Storage ..........................................10-2

TROUBLESHOOTING ...............................................................11-1

Impossible to Start Engine ........................................................ 11-1

Engine ............................................................................................... 11-2

Electrical System ........................................................................... 11-5

Mode Selection .............................................................................11-6

Control Levers ................................................................................ 11-7

Hydraulic System ..........................................................................11-7

SPECIFICATIONS .......................................................................12-1

Specifications ZX14-3 ................................................................

Working Ranges ZX14-3 ........................................................... 12-2

Bucket Types and Applications ZX14-3 ...............................12-3

Specifications ZX16-3 ................................................................ 12-4

Working Ranges ZX16-3 ........................................................... 12-5

Bucket Types and Applications ZX16-3 ..............................12-6

Specifications ZX18-3 ................................................................ 12-7

Working Ranges ZX18-3 ........................................................... 12-8

Bucket Types and Applications ZX18-3 ...............................12-9

Specifications ZX27-3 ..............................................................12-10

Working Ranges ZX27-3 .........................................................12-11

Bucket Types and Applications ZX27-3 .............................12-12

Noise Level Results (2000/14/CE, art. VI) ............................12-13

Vibration Level .............................................................................12-13

Special Specification .................................................................12-14

OPTIONAL ATTACHMENT AND DEVICE ..........................13-1

Ignition Block System (Optional) ............................................ 13-1

INDEX ............................................................................................. 14-1

12-1

CONTENTS

MEMO

..................................................................................................................................................................................................

MACHINE NUMBERS

The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

Machine

MODEL/TYPE:________________

PRODUCT IDENTIFICATION NUMBER:

___________________________

Product Identification Number

PRODUCT IDENTIFICATION NUMBER:

___________________________

NOTE:

f

*HCM1NC00X00001001*

Marks to indicate the start and end of the PIN

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-001

M1N7-00-001

PRODUCT IDENTIFICATION NUMBER (PIN)

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-002

M1N7-00-002

1

Engine

TYPE:

MFG. NO.:

MACHINE NUMBERS

Travel Motor

TYPE:

MFG. NO.:

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-003

M1NC-00-015

Swing Motor

TYPE:

MFG. NO.:

M1NC-00-004

M1NC-00-005

2

Hydraulic Pump

TYPE:

MFG. NO.:

MACHINE NUMBERS

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-006

M1NC-00-016

3

MACHINE NUMBERS

MEMO

..................................................................................................................................................................................................

4

SAFETY

Recognize Safety Information

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

Understand Signal Words

• On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION

- are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

SA-688

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

• fNOTE indicates an additional explanation for an element of information.

SA-1223

S-1

SAFETY

Follow Safety Instructions

• Carefully read and follow all safety signs on the machine as well as all safety messages in this manual.

• Safety signs must be installed, maintained and replaced if damaged.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Allow only properly trained, qualified, authorized personnel to operate the machine.

• Learn how to correctly operate and service the machine.

• Keep your machine in proper working condition.

• Always operate the machine within the specification.

• Unauthorized modifications of the machine may impair the functions and/or safety and affect machine life and the warranty will become void.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every possible hazardous situation you may encounter. If you have any questions concerning safety, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

Prepare for Emergencies

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

S-2

SAFETY

Wear Protective Clothing

• Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator.

• Do not wear radio or music headphones while operating the machine.

SA-438

Protect Against Noise

• Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

Inspect Machine

• If any abnormality is found, be sure to repair it immediately before operating the machine.

• In the walk-around inspection, be sure to cover all points described in the “Before Starting Engine” section in the operator’s manual.

SA-434

S-3

SA-435

SAFETY

Tidy Up Inside Operator’s Space

• Always keep inside the operator’s space clean by observing instructions below, to prevent any personal accidents from occurring.

• Remove mud and/or oily material from the shoe soles

before entering the operator’s space. If pedals are operated without removing mud or oily matter, the foot may slip off the pedal, possibly creating a hazardous situation.

• Do not leave parts and/or tools around the operator’s

seat.

• Avoid storing transparent bottles in the cab. Do not

attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Do not wear radio or music headphones and do not use a

cell phone while traveling or operating the machine.

• Never allow hazardous materials such as combustible

and/or explosive material in the operator’s space.

• Do not leave cigarette lighters in the cab. If the

temperature in the cab increases, the lighter may explode.

Use Handrails and Steps

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always use the

crawler instead of the step for safety. Also get on and off from the position of the crawler that can secure your feet space enough.

• When you get on and off the machine, always face the

machine.

• Maintain a three-point contact with the steps and

handrails.

• Do not use any controls as handholds.

• Never jump on or off the machine. Never mount or

dismount a moving machine.

• In case adhered slippery material such as oil, grease,

or mud is present on steps, handrails, or platforms, thoroughly remove such material.

Never Ride Attachment

• Never allow anyone to ride attachments or the load. This is an extremely dangerous practice.

SA-439

S-4

SAFETY

Adjust Operator’s Seat

• A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperation of the machine.

• The seat should be adjusted whenever the operator for the machine changes.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back firmly against the seat back.

• If not, readjust the seat forward or backward, and check again.

Ensure Safety Before Rising from or Leaving Operator’s Seat

• Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes into contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors, and access covers and lock them up.

SA-378

Fasten Your Seat Belt

• If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Be sure to remain seated with the seat belt securely fastened whenever operating the machine.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Replace the seat belt at least once every 3 years regardless of appearance.

S-5

SA-237

SAFETY

Move and Operate Machine Safely

• Always be aware that there is a potential danger around the machine while operating the machine.

• Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped).

• Before starting to move or operate the machine, sound the travel alarm and horn to alert bystanders.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Locate the signal person so that the operator can always witness the signal person.

• Coordinate the meanings of all safety signs, hand signals and marks before starting the machine. Appoint a person who is responsible to make a signal and/or guidance.

• Never allow any persons or obstacles to enter the machine operation areas.

• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-1291

S-6

SAFETY

Operate Only from Operator’s Seat

• Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the operator’s seat.

• NEVER start the engine while standing on the tracks or on ground.

• Do not start engine by shorting across starter terminals. A hazardous situation may be created and/or possible damage to the machine may result.

• Before starting the engine, confirm that all control levers are in neutral.

Jump Starting

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

• If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING ENGINE” chapter.

• The operator must be seated in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

SA-444

Keep Riders Off Machine

• Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

• Only the operator is allowed on the machine. Keep riders off.

SA-032

SA-1292

S-7

Precautions for Operations

WARNING: Thoroughly make certain safety at the

d

work site before starting operations. Especially always observe the following points.

• Be sure to install the overhead cab guard before operating the machine in areas where the possibility of falling stones or debris exists.

• If operation on soft ground is required, sufficiently reinforce the ground beforehand.

• Be sure to wear close fitting clothing and required safety items, such as a helmet, when operating the machine.

• Keep all bystanders and unnecessary objects out of and away from the machine working areas. Always beware of the surroundings while operating the machine. Take care not to allow the rear part of the upperstructure to come into contact with objects when swinging the machine in a small area.

• When loading a dump truck, bring the bucket from the rear side of the dump truck to avoid moving the bucket over the dump truck cab or over any co-workers.

SAFETY

M586-12-012

S-8

SAFETY

Investigate Job Site Beforehand

• When working at the edge of an excavation or on a road shoulder, the machine could tip over due to collapse of the ground, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Never allow bystanders to enter the working area such as swing radius or traveling range.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing may become loose and slippery.

• When operating the machine near open flame, sparks, and/or dead grass, a fire may easily break out. Use special care not to cause a fire.

• Make sure the work site ground has sufficient strength to firmly support the machine. When working close to an excavation or on road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear and with the blade at the front, so that the machine can more easily evacuate if the cliff face collapses.

• If working at the bottom of a cliff or on a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work in that area.

• Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong enough and firm to easily support the machine.

• Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. Operate the machine slowly to ensure safe operation.

SA-1293

M586-05-021

S-9

Equipment of OPG

• In case the machine is operated in areas where the possibility of falling stones or debris exists, equip genuine Hitachi OPG guard. Contact your nearest Hitachi dealer for installation method of the OPG guard. Depending on the specifications applied to your machine, modification of the machine to meet ROPS standards will be possible.

• To maintain unimpaired operator protection and manufacture's protective structure.

• Damaged ROPS, OPG guard must be replaced, not repaired or revised.

• Any alternation to the ROPS or OPG guard must be approved by the manufacturer.

ROPS : Roll Over Protective Structure OPG : Operator Protective Guard

Provide Signals for Jobs Involving Multiple Machines

SAFETY

• In case more than one machine is operated in the same job site, accidental collision between machines may cause serious injury or death.

• For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

Confirm Direction of Machine to be Driven

• Incorrect travel pedal/lever operation may result in serious injury death.

• Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position.

• If the travel motors are located towards the front of the cab, the machine will move in the reverse direction when travel pedals/levers are operated.

SA-481

SA-1294

S-10

SAFETY

Drive Machine Safely

• Use a signal person when traveling the machine along road shoulders or in congested areas.

• Driving the machine in the incorrect direction may result in serious injury or death and/or severe damage to property.

• Before driving the machine, always confirm that the travel pedals/levers direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

• Never attempt to ascend or descend (B) degrees or steeper slopes.

B : ZX14-3, 16-3, 18-3 : 25˚

ZX27-3 : 30˚

• Be sure to fasten the seat belt.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (8 to 12 in) (A) above the ground.

• If machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

• Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

• Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.

• If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral. Then, restart the engine.

• Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

A

SA-1295

A

SA-1296

SA-441

WRONG

S-11

SA-590

SAFETY

• Traveling down a slope in the fast mode requires a longer time to stop the machine.

When traveling down a slope, place engine control lever

(1) in the TURTLE position.

• Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Before moving machine, determine which way to move travel pedals/levers for the direction you want to go. When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers.

• Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.

• Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.

• Do not make contact with electric wires or bridges.

• When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.

• When traveling on rough terrain, reduce engine speed. Select slow travel speed. Slower speed will reduce possible damage to the machine.

• Avoid operations that may damage the track and undercarriage components.

• During freezing weather, always clean snow and ice from track shoes before driving the machine on snowy and/or frozen roads, or loading and unloading the machine for transportation, to prevent the machine from slipping.

1

M1NC-00-007

Travel Motor

M104-05-008

S-12

SA-673

M586-05-002

SAFETY

Avoid Injury from Rollaway Accidents

• Death or serious injury may result if you attempt to mount or try to bodily stop a moving machine.

• Park the machine in compliance with the safe parking procedures described on page S-19 to prevent the machine from running away.

• Block both tracks and lower the bucket to the ground, thrust the bucket teeth into the ground if you must park on a grade.

• Park at a reasonable distance from other machines.

SA-1297

S-13

SAFETY

Avoid Injury from Back-over and Swing Accidents

• If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

• Keep the travel alarm in working condition (if equipped).

ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE

WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW.

Use hand signals, which conform to your local regulations,

when work conditions require a signal person.

• No machine motions shall be made unless signals are clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in good condition.

• Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the operator’s manual.

SA-383

SA-384

S-14

SAFETY

Keep Personnel Clear from Working Area

• If a person is present near the operating machine, the person may come into contact with the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

• Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

• Make sure that no personnel other than the signal person or no obstacles are present in the working area before operating the machine.

Never Position Bucket Over Anyone

• Never lift, move, or swing bucket above anyone or a truck cab.

 Serious injury or machine damage may result due to bucket

load spill or due to collision with the bucket.

• Never allow the bucket to pass over anyone to avoid personal injury or death.

SA-667

Avoid Undercutting

• In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not possible, do not raise the front attachment in a panic. Lowering the front attachment may be safer in most cases.

SA-668

SA-1300

S-15

SAFETY

Avoid Tipping

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:

• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

Never Undercut a High Bank

• The edges could collapse or a land slide could occur causing serious injury or death.

SA-1301

SA-1302

S-16

SAFETY

Dig with Caution

• Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging check the location of cables, gas lines, and water lines.

• Keep the minimum distance required, by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your area, and/or the utility companies directly.

Have them mark all underground utilities.

Operate with Caution

• If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the boom or arm.

SA-672

Avoid Power Lines

• Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.

• When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length.

• Check and comply with any local regulations that may apply.

• Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

SA-673

SA-1305

S-17

SAFETY

Precautions for Lightning

• The machine is vulnerable to lightning strikes.

• In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

Do Not Use for Craning Operations

• NEVER use the machine for craning operations. If the machine is used for craning operations, the machine may tip over and/or lifted load may fall, possibly resulting in serious injury or death.

• This machine has been exclusively designed to engage in excavation and loading works.

• This machine is not equipped with any of the necessary safety devices that could allow the machine to be used for craning operation.

SA-1805

Protect Against Flying Debris

• If flying debris such as soil, rock fragments or metal pieces hit eyes or any other part of the body, serious injury may result.

• Guard against such injuries when working in a job site where possibility of flying pieces of metal or debris exist, or when removing or installing pins using a hammer; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

S-18

SA-014

SA-432

SAFETY

Park Machine Safely

• Unless the machine is correctly parked, any hazardous situations such as running away of the machine or damage by vandalism may result, causing the machine to operate unsafely when the engine is restarted. Follow instructions described below when parking the machine.

• Park the machine on solid level surface to prevent the machine from running away.

• Lower the bucket and/or blade to the ground.

• Pull the lock lever to the LOCK position.

• Run the engine at slow idle speed without load for 5 minutes.

• Turn key switch to OFF to stop engine. Remove the key from the key switch.

• Before leaving the machine, close all windows, roof vent, and cab door. Lock all access doors and compartments.

Handle Fluids Safely−Avoid Fires

• Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine.

• Fill the fuel tank outdoors.

SA-1306

• All fuels, most lubricants, and some coolants are flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn spontaneously.

SA-018

SA-019

S-19

SAFETY

Safety Transporting

• The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting the machine on public roads.

• Provide an appropriate truck or trailer for transporting the machine.

• Be sure to have a signal person.

• Take the following precautions when loading/unloading the machine.

1. Select firm level ground.

2. Be sure to use a loading dock or ramp strong enough to

support the machine weight.

3. Ramps must be sufficient in width, length, and strength.

Be sure that the incline of the ramp is less than 15 degrees.

4. Loading docks must be sufficient in width and strength

to support the machine and have a gradient of less than 15 degrees.

5. Slowly drive the machine.

SA-1307

6. Avoid steering while driving up or down the ramp as it

is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, change traveling direction, and begin to drive again.

7. The top end of the ramp where it meets the flatbed is a

sudden bump. Take care when traveling over it.

8. Wedge the front and rear of the tracks. Securely fasten

the machine to the trailer bed with chain or cables.

9. Do not operate any levers besides the travel levers when

driving up or down the ramp.

10. Prevent possible injury from machine tipping while the upperstructure is rotating.

11. Keep the arm tucked under and rotate the upperstructure slowly for best stability.

Refer to “transporting” chapter in this manual for details.

S-20

SAFETY

Practice Safe Maintenance

• Inspection/maintenance work may produce hazardous situations by contacting and/or accessing a part of body to a moving, high pressure, and/or high temperature part of the machine. To avoid serious personal injury or death, follow the instructions described below.

• Thoroughly coordinate the working procedures to be taken hereafter with the co-workers before beginning work such as inspecting/servicing the machine, or replacing the attachment .

• Safely park the machine in accordance with the instructions for “Park Machine Safely.”

• Keep the work area clean and orderly.

• Attach a “DO NOT OPERATE” tag in an easy-to-see location such as on a door or a control lever.

• If moisture permeates into the electrical system, malfunction and/or erroneous movement of the machine may result. Do not clean sensors, cable connectors, and the cab inside using water and/or steam.

• Wait to begin to work until the engine and hydraulic oil temperatures have cooled down to the safety range.

• In case inspection/maintenance must be performed with the engine running, be sure to appoint an overseer.

• Never lubricate or service the machine while moving it.

• Repair the cracked windowpane before servicing the machine. Failure to do so may cause personal injury.

• When raising the machine above the ground using the front attachment function, maintain the angle between the boom and the arm in the range of 90 to 110°. Never allow anyone to enter under the machine raised with the front attachment function.

• In case working under the machine raised above the ground is unavoidably required, securely hold the machine with stays or blocks strong enough to support the machine weight.

• Never work under the raised bucket.

• Keep all parts in good condition and properly installed.

• Always use the specified tools correctly.

• Always use a clean tool.

• Fix any damage found immediately. Replace worn or broken parts.

• Remove any buildup of grease, oil, or debris.

• When cleaning parts, use a non-combustible cleaning solvent. Never use an inflammable fluid such as diesel fuel, or gasoline.

SA-028

90 to 110°

M1M7-04-006

SA-527

S-21

SAFETY

• Disconnect battery ground cable (−) before making adjustments to electrical systems or before welding on the machine.

• Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

Warn Others of Service Work

• Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag in an easy-to-see place such as on the cab door or control lever.

• Never attempt to operate the machine with a “Do Not Operate” tag attached.

• Make it a rule for the inspection/service person to hold the engine start key during inspection/service work.

SA-037

Support Machine Properly

• Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you

work on the machine.

• If you must work on a lifted machine or attachment,

securely support the machine or attachment with stays or blocks strong enough to support the machine and/or attachment weight.

SS2045102

SA-527

S-22

SAFETY

Stay Clear of Moving Parts

• Contact with moving parts can cause serious injury or death due to amputation or entanglement.

• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

Prevent Parts from Flying

• Grease in the track adjuster is under high pressure.  Failure to follow the precautions below may result in serious

injury, blindness, or death.

• Do not attempt to remove GREASE FITTINGS or VALVE ASSEMBLIES.

• As pieces of parts may fly off, be sure to keep body and face away from the valve.

SA-026

• Travel reduction gears are under pressure.

• As pieces of parts may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for gear oil to cool, then gradually loosen the air release plug to release pressure.

SA-344

S-23

SAFETY

Store Attachments Safely

• Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling accidents.

• Keep children and bystanders away from storage areas.

Prevent Burns

Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines.

 Skin contact with escaping hot water or steam can cause

severe burns.

• To prevent possible injury from hot spraying water, stop the engine. Begin to work after the engine and radiator are sufficiently cooled.

• DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure by slowly removing the cap.

SA-034

SA-039

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also becomes hot during operation.

 The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

S-24

SAFETY

Replace Rubber Hoses Periodically

• Rubber hoses that contain flammable fluids such as hydraulic oil or fuel under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by visual inspection alone.

• Periodically replace the rubber hoses. (Refer to the Periodical Replacement Parts section.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

Avoid High-pressure Fluids

• Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Make sure that all connectors are completely connected before applying pressure.

• Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours, or gangrene may result.

SA-019

SA-031

S-25

SA-292

SA-044

SAFETY

Prevent Fires

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires, possibly resulting in personal injury or death.

• Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oilcooler, and loose oil-cooler flange bolts, for oil leaks.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes or hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

SA-019

Precautions for Handling Flammables

• Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately.

• Do not store flammable fluid near open flames.

• Do not burn or crush a pressurized container.

• Do not store oily cloths. They are liable to catch fire.

• Do not wind easy-to-absorb-oil asbestos or glass wool around high-temperature parts such as a muffler or exhaust pipe.

S-26

SAFETY

Check Heat Shield Covers around Engine Compartment

• If the engine compartment heat shield cover becomes broken or lost, fire may break out.

• If the engine compartment heat shield cover becomes broken or lost, repair or replace it before operating the machine.

Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

• Always check key switch function before operating the machine every day:

1) Start the engine and run it at slow idle.

2) Turn the key switch to the OFF position to confirm that

the engine has stopped.

If any abnormalities are found, be sure to repair them before operating the machine.

Evacuating in Case of Fire

• If fire breaks out during machine operation, evacuate the machine in the following way:

• Stop the engine by turning the key switch to the OFF position.

• Use a fire extinguisher if there is time.

• Exit the machine using handrails and/or steps.

• In an emergency, if the cab door or front or rear window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Exit.

SA-393

SS-1510

S-27

SAFETY

Beware of Exhaust Fumes

• Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

• If you must operate the machine in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

Beware of Asbestos and Silicon Dust and Other Contamination

• Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silicon dust and other contamination may cause sickness.

• Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contamination may exist.

Spray water to prevent asbestos, silicon dust or other

contamination from airborne. Do not use compressed air.

• When operating the machine in a work site where asbestos, silicon dust or other contamination might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contamination.

• Keep bystanders out of the work site during operation.

• Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

SA-016

SA-029

S-28

SAFETY

Precautions for Welding and Grinding

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.

• Grinding on the machine may create a fire hazard. Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

Avoid Heating Near Pressurized Fluid Lines

• Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-818

Avoid Applying Heat to Lines Containing Flammable Fluids

• Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Remove flammable fluids thoroughly with nonflammable solvent before welding or flame cutting pipes or tubes that contained flammable fluids.

SA-030

S-29

SAFETY

Remove Paint Before Welding or Heating

• Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Remove paint before welding or heating.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

• Allow fumes to disperse at least 15 minutes after welding or heating.

• Use attention to the following points when removing paint.

1. If you sand or grind paint, avoid breathing the dust

which is created.

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with

soap and water before welding.

3. Remove solvent or paint stripper containers and other

flammable material from area.

SA-029

Prevent Battery Explosions

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when the electrolyte level is lower than specified. Explosion of the battery may result.

• When a terminal become loose, it may induce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If electrolyte is splashed into eyes, flush your eyes continuously with water for about 15 minutes. Seek medical attention immediately.

• Be sure to wear eye protection when checking electrolyte specific gravity.

SA-032

S-30

SAFETY

Handle Chemical Products Safely

• Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, electrolyte, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. Then follow the correct procedures and use recommended equipment.

• See your authorized dealer for MSDS.

Dispose of Waste Properly

• Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and battery.

• When draining fluid, use a leakproof container with a capacity larger than the drained fluid volume to receive it.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Inquire on the proper way to dispose of harmful waste such as oil, fuel, coolant, brake fluid, filters, and battery from your local environmental or recycling center.

SA-309

SA-226

S-31

SAFETY

MEMO

..................................................................................................................................................................................................

S-32

SAFETY SIGNS

All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean. In case a safety sign is broken or lost, immediately, obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when ordering it at your authorized dealer.

SS4420332

• Always read the Operator’s Manual before operating, servicing, disassembling, assembling, and transporting the machine.

ZX14-3, 16-3, 18-3

M1NC-00-008

S-33

ZX27-3

M1NC-00-017

SAFETY SIGNS

SS4420333

• If the parked machine is unexpectedly moved, serious injury or death due to crushing may result. Be sure to lower the front attachment to the ground, lock the control levers, and remove the engine key before leaving the machine unattended.

ZX14-3, 16-3, 18-3

M1NC-00-008

• Electrocution is possible if the machine is operated too close to power lines. Always keep a safe distance from power lines.

SS-1613

ZX27-3

ZX14-3, 16-3, 18-3

M1NC-00-017

M1NC-00-008

S-34

ZX27-3

M1NC-00-017

• Stand clear of the equipment. If knocked over by the equipment, serious injury may result.

SAFETY SIGNS

• Hot coolant or oil may spout if the radiator or hydraulic oil cap is removed while the machine temperature is still high, possibly causing a burn. Wait until the machine has cooled to remove the cap.

SS-1702

SS-1703

ZX14-3, 16-3, 18-3

SS-1494

M1NC-00-009

S-35

ZX27-3

M1NC-00-018

• Sign indicates the hazard of rotating parts, such as fan, etc that could cause injury by being caught. Turn it off completely before inspection and maintenance.

SAFETY SIGNS

SS-1704

ZX14-3, 16-3, 18-3

M1NC-00-009

• Sign indicates the hazard of rotating parts, such as belt, etc that could cause injury by being caught. Turn it off completely before inspection and maintenance.

SS-1705

ZX27-3

ZX14-3, 16-3, 18-3

M1NC-00-019

M1NC-00-009

S-36

ZX27-3

M1NC-00-019

SAFETY SIGNS

• Serious injury may result if the plug flies off the track adjuster. Read the Operator’s Manual before loosening the track, and adjust the track sag following the correct procedure.

• Possible severe burns. Do not touch the engine components while they are hot.

SS-1710

SS-1495

SS4392289

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-009

M1NC-00-020

S-37

• Hot coolant or oil may spout if the radiator or hydraulic oil cap is removed while the machine temperature is still high, possibly causing a burn. Wait until the machine has cooled to remove the cap.

SAFETY SIGNS

SS-1703

SS-1714

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-010

M1NC-00-018

• Personnel in the swing radius may be crushed by the upperstructure when the machine swings. Stand clear of the swing radius.

S-38

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-00-011

M1NC-00-021

• Personal injury may result if the stored front window slips off. Always securely lock the window in the stored position (on the cab equipped machine).

SAFETY SIGNS

• Sign indicates the hazard of rotating parts, such as fan, etc that could cause injury by being caught. Turn it off completely before inspection and maintenance.

SS-1706

SS-1719

ZX14-3, 16-3, 18-3

SS-2641

M1NC-00-011

S-39

ZX27-3

M1NC-00-021

SAFETY SIGNS

ROPS/TOPS/TOP GUARD Canopy and Cab

• To maintain unimpaired operator protection and manufacture’s protective structure.

• Damaged Roll Over Protective Structure (ROPS), Tip Over Protective Structure (TOPS), Operator Protective Guard Top Guard (TOP GUARD) must be replaced, not repaired or revised.

• Any alternation to the ROPS or TOPS or TOP GUARD canopy and cab must be approved by the manufacturer.

ZX14-3

SS3115731

SS3116740

ZX16-3, 18-3

SS3117290

ZX16-3, 18-3

SS3117293

ROPS Canopy

ZX14-3, 16-3, 18-3

ROPS Cab

ZX14-3, 16-3, 18-3

M1NC-01-013

M1MS-00-004

ZX14-3

SS3116078

ZX16-3, 18-3

SS3117804

S-40

TOPS Canopy

ZX14-3, 16-3, 18-3

M1NC-00-014

SAFETY SIGNS

ZX27-3

SS3118030

ROPS Cab

ZX27-3

M1NC-00-022

S-41

SAFETY SIGNS

MEMO

..................................................................................................................................................................................................

S-42

Components Name

ZX14-3, 16-3, 18-3

COMPONENTS NAME

1- Counterweight

2- Canopy

3- Boom

4- Work Light

5- Arm Cylinder

6- Bucket Cylinder

7- Arm

8- Bucket

9- Boom Cylinder

10- Blade

11- Blade Cylinder

12- Front Idler

1

13- Boom-Swing Cylinder

14- Track Shoe

15- Track Frame

16- Travel Device

2

43

5

9

816 15 14 13 12 11 10

7 6

M1NC-01-001

1-1

ZX27-3

1- Counterweight

2- Cab

3- Boom

4- Work Light

5- Arm Cylinder

6- Bucket Cylinder

7- Arm

8- Bucket

9- Boom Cylinder

10- Blade

11- Blade Cylinder

12- Front Idler

7

13- Boom-Swing Cylinder

COMPONENTS NAME

2

5

34

1

9

13

14- Track Shoe

15- Track Frame

16- Travel Device

6

8

16

10 11 12

14

15

M1NC-01-019

1-2

OPERATOR’S STATION

Pedals, Levers and Monitor Panel

1- Left Control Lever

2- Pilot Control Shut-Off Lever

3- Attachment Pedal

4- Left Travel Lever

5- Right Travel Lever

6- Right Control Lever / Horn Switch

7- Boom-Swing Pedal

8- Blade Lever

9- Key Switch

10- Engine Control Lever

11- Monitor Panel

12- Operator’s Seat

13- Fuse Box

14- Pilot Control Shut-Off Lever (Canopy Spec Only)

NOTE: The typical machine model is illustrated to the right.

f

Some portions may differ on other models.

1 2 3 4 5 6 7

12

M1NC-01-002

14

8

9

10

11

13

ZX14-3, 16-3, 18-3

ZX27-3

M1NC-01-003

13

M1NC-01-020

1-3

OPERATOR'S STATION

Switch Panel

5- Work Light Switch

Press the switch (5) to turn work lights (10) located on

the boom ON, and External electrical outlet (11) on.

6- Track-width Control Switch (ZX18-3)

7- Travel Mode Indicator (ZX16-3, 18-3, 27-3)

8- Heater Control Panel (Cab equipped machine)

9- Wiper Switch (Cab equipped machine)

Three-operation positions are provided on this switch.

OFF: Both the wiper and washer do not operate. Center: The wiper operates. WASHER: The washer operates together with the wiper.

11

9 8

7

6 5

ZX14-3, 16-3, 18-3

9

5

8

M1NC-01-004

ZX14-3, 16-3, 18-3

11

ZX27-3

10

M1NC-01-024

M1NC-01-025

ZX27-3

M1NC-01-021

7

M1NC-01-022

10

ZX27-3

M1M7-01-025

1-4

ZX14-3, 16-3, 18-3

M1NC-01-001

OPERATOR'S STATION

Key Switch

1- OFF (Engine OFF)

2- ON (ZX14-3, 16-3, 18-3 : Engine ON, ZX27-3 : Engine ON,

Preheat)

3- START (Engine Start)

4- HEAT (Engine Preheat) (ZX14-3, 16-3, 18-3)

3

2

1

4

M1M7-01-007

1-5

OPERATOR'S STATION

Monitor Panel

1- Alternator Indicator

2- Fuel Level Indicator

3- Preheat Indicator

4- Overheat Indicator

5- Engine Oil Pressure Indicator

6- Hour Meter

7- Fuel Gauge

8- Coolant Temperature Indicator

9- Coolant Temperature Gauge (ZX27-3)

10- Travel Mode Indicator (ZX27-3)

8

4 5 7

9

8

7

6

162 3

M1NC-01-005

ZX14-3, 16-3, 18-3

1

2

10

4 5

3

Alternator Indicator

The red indicator will light when low alternator output is present. Check the electrical system such as the alternator and/or battery system.

Fuel Level Indicator

When the fuel level indicator lights while the machine is operating on level ground, the remaining fuel amount in the fuel tank is 3.6 L (1.0 US gal). Refill the fuel as soon as possible.

Preheat Indicator

When the key switch is turned to the HEAT position, orange indicator will light. Light will turn off after approx. 3 seconds have passed.

Overheat Indicator

If the coolant temperature rises extremely high, this indicator lights. If the red light comes ON, the buzzer sounds at the same time. Immediately stop machine operation and reduce engine speed to the slow idle speed to lower the coolant temperature.

ZX27-3

M1NC-01-022

M178-01-038

M178-01-034

M178-01-041

M178-01-036

1-6

OPERATOR'S STATION

Engine Oil Pressure Indicator

The red indicator will light when the engine oil pressure is low. If the red indicator comes ON, the engine oil pressure warning buzzer will sound at the same time. Immediately stop the engine. Check the engine oil pressure system and the oil level for any abnormality.

Hour Meter

Total (accumulated) machine operation hours counted since the machine started working, are displayed in the unit of HOUR (h). One digit after the decimal point indicates the tenths of an hour (6 minutes).

Fuel Gauge (ZX14-3, 16-3, 18-3)

The gauge segment position indicates the fuel level. Refill the fuel before only the E-marked segment comes ON.

M178-01-037

M1NC-01-006

M1NC-01-007

Fuel Gauge (ZX27-3)

The gauge needle position indicates the fuel level. When the needle reaches the E-point in the white range, the remaining fuel is approximately 10 liters.

Coolant Temperature Gauge (ZX27-3)

The gauge needle position indicates the engine coolant temperature. Coolant temperature is normal when the needle stays in white zone while operating.

Coolant Temperature Indicator

M1MW-01-007

M1MW-01-008

When the key switch is turned to the ON position, the indicator will light when the engine coolant temperature is low.

1-7

M1NC-01-008

OPERATOR'S STATION

Cab Heater Operation (Cab Equipped Machines)

Heater Operation

Turn heater cock (1) in the engine compartment counterclockwise. Adjust air flow by turning heater adjust knob (2) located at the right- rear in the operator’s station.

Blower Operation

Turn heater cock (1) in the engine compartment clockwise to close it. Adjust air flow following the same method as mentioned in the Heater Operation.

Defroster Operation

Adjust air flow by operating heater adjust knob (2). Remove clouding on the window pane by directing air flow from air vent (3) and (4) toward the window pane.

1

ZX14-3, 16-3, 18-3

1

M1NC-01-009

ZX27-3

4

3

ZX14-3, 16-3, 18-3

3

2

M1NC-01-023

2

M1NC-01-004

1-8

4

ZX27-3

M1NC-01-021

OPERATOR'S STATION

Radio (ZX14-3, 16-3, 18-3 Cab Equipped Machines)

1- Radio/Clock

1

M1MS-01-014

1-9

OPERATOR'S STATION

AM/FM Radio Operation (Cab Equipped Machine, When Genuine Radio is Installed)

Part Name and Function

1- Power Switch/Volume Control Knob

Rotate the knob to the right to supply electric power (a click

sound will be heard when the unit is turned ON). Rotate the knob further to turn up the volume. Rotate the knob in the reverse direction to turn down the volume and the unit OFF.

2- Tone Control Knob

Rotate the knob to the right to intensify the treble.

Rotate the knob to the left to reduce the treble.

3- Display

Time, receiving radio wave frequency, or operation mode

is displayed.

4- Clock Button

Press this button to display the time. Repress this button

to display the receiving radio wave frequency.

2

1 3 8 75 4

6 9

M1M7-01-011

5- Auto-Store/ Scan Preset Button (AST)

Press this button to receive the preset frequency station

for every 5 seconds sequentially. While you receive the station you wish to listen to, press this button again to receive the station under normal state (scan is interrupted). Press and hold this button for 2 seconds to automatically store the station.

6- Station Preset Buttons (1 to 6)

One FM and MW (AM) station per button can be preset

using these respective buttons.

7- Seek Button

Press this button to automatically seek the next

receivable station. When a station is received, the autoseeking function is deactivated.

8- Band Button

Select FM or MW (AM) by pressing this button. The

display indicates the receiving station frequency.

9- Tuning Button

Tap the TUNE

TUNE ∨ button to decrease the frequency. Tap and hold the button to change the frequency continuously.

∧ button to increase the frequency. Tap the

1-10

OPERATOR'S STATION

Radio Operation

1. Turn the key switch to the ACC or ON position to switch

the radio ON.

2. Select either MW (AM) or FM by operating the band

button.

3. Select the station desired to listen using the preset or

tuning button.

4. Adjust the volume and tone according to your

preference.

5. When turning the radio OFF, rotate the VOL knob to the

left until a click sound is heard.

Tuning Procedure

1. Tap the TUNE ∧ button to increase the frequency. Tap the

TUNE ∨ button to decrease the frequency. Tap and hold the button to change the frequency continuously.

2. Automatic Tuning

M1M7-01-011

Press this button to automatically move the frequency

up and to seek a receivable station. When a station is received, the auto-seeking function is deactivated so that the received frequency station is tuned in.

1-11

OPERATOR'S STATION

Station Presetting Procedure

1. Select MW (AM) or FM by pressing BAND button (8).

Select a station by pressing either TUNE button (9) or SEEK button (7).

2. Continuously press one of PRESET button (6) by which

you desire to preset the station for more than 2 seconds. When presetting is complete, the preset button No. is indicated on the display.

3. Repeat the above same procedure steps (1) and (2) to

preset other stations with other PRESET buttons (6).

NOTE: After presetting is complete, if the preset button is

f

pressed again and held for more than 2 seconds, the preset station is changed.

• Auto-Storing

Press and hold the AST button for more than 2 seconds

with the radio switch ON, preset buttons (1 to 6) automatically search receivable frequency stations in the selected frequency band (AM or FM) and memorize each station in one button.

NOTE: When auto-store operation is made, the preciously

f

memorized stations are deleted. If it is difficult to set the memory of the desired station to the desired button, conduct preset operation.

2

1 3 8 75 4

2

1 3 8 75 4

6 9

M1M7-01-011

• Preset Scanning

Press and release the AST button in 2 seconds with the

radio switch ON, preset station frequencies are received one by one for 5 seconds. Press the button again to resume normal radio operation.

Deletion of Preset Memory

If the battery power is disconnected such as when the machine is serviced or the radio is removed, the preset memory in the preset buttons will be deleted. Repeat the preset operation again.

Clock Setting Procedure

In case the frequency is indicated on the display, press the CLOCK button to display the time. While pressing the CLOCK button, press TUNE ∧ M button to change the minute display. While pressing the CLOCK button, press TUNE ∨ H button to change the hour display. Release the CLOCK button to resume the original mode.

While pressing CLOCK button

Minute is adjusted

Hour is adjusted

M1M7-01-012

1-12

OPERATOR'S STATION

Opening/Closing Cab Front Window (ZX14-3, 163, 18-3 Cab Equipped Machines)

CAUTION:

d

• When closing the front window, slowly lower the window. Be alert not to pinch your fingers.

• After opening the front window, check that both side lock levers are securely engaged in the window frame.

Opening:

1. Hold the handles (1) (in two places) on the front window and disengage lock lever (2).

2. Hold the handles (in two places) on the front window frame and raise the window until the lock lever (2) engages with the window frame.

Closing:

3. When closing the front window, follow the same steps 1 and 2 above in the reverse order.

1

M1NC-01-010

M1NC-01-011

1-13

22

M1NC-01-012

OPERATOR'S STATION

Opening/Closing Cab Front Window (ZX27-3)

CAUTION: The front window comes down forcefully.

d

Close the front window only when sitting on the operator’s seat. Guide the front window down slowly.

Opening:

1. Push in lock switches (1) to unlock the front window.

2. Pull the front window up and back until slide lock switches (1) fall into boss holes and Lock.

Closing:

3. To close the front window, perform procedures shown in steps (1) to (2) in reverse. These are:

a. Push in lock switches (1), to unlock the front window

b. Pull the front window down slowly

c. Be sure that the front window is locked

1

M1LN-01-007

1-14

OPERATOR'S STATION

Emergency Exit (ZX14-3, 16-3, 18-3 Cab Equipped Machines)

If the operator’s cab door can not be opened in an emergency, escape in the following methods.

1. When required to escape from the cab when the door is difficult or impossible to open in an emergency, open the front window.

NOTE: Refer to the descriptions in Opening/Closing Cab

f

Front Window for the opening method of the front window.

CAUTION: Take care not to be injured with pieces of

d

broken glass.

2. In case opening the front window is impossible, break the front window glass with emergency evacuation hammer (1) provided on the rear side in the cab to escape through the broken window.

1

M1MS-01-015

3. If the front window is not available for escaping, break the rear window glass with emergency evacuation hammer (1). Then, escape through the broken window.

NOTE: Emergency exit decal is affixed on the front and rear

f

window.

Front

Rear

M1MW-01-015

M1MS-01-016

1-15

OPERATOR'S STATION

Emergency Exit (ZX27-3)

If the operator’s cab door should not open in an emergency, escape in the following methods:

1. Open the front window. Escape through the window.

NOTE: Refer to the descriptions in Opening/Closing Cab

f

Front Window for the opening method of the front window.

CAUTION: Be sure to wear safety glasses before

d

breaking the window glass.

2. If the front window is difficult to open, break the front window glass using emergency evacuation tool (1). Then, escape through the broken window.

3. If the front window is not available for escaping, break the rear window glass using emergency evacuation tool (1). Then, escape through the broken window.

NOTE: The emergency exit decals are affixed to the front and

f

rear windows.

1

M1LS-01-008

Front Window

Rear Window

SS-2470

M1LS-01-008

1-16

OPERATOR'S STATION

Adjusting Operator’s Seat

Seat Fore-Aft Adjustment

Operate seat fore-aft slide lever (1). Seat fore-aft position can be adjusted at the interval of 10 mm (ZX14-3, 16-3, 18-3: 14 steps to 140 mm in total /ZX27-3: 12 steps to 120 mm in total).

1

M1NC-01-013

1-17

OPERATOR'S STATION

Tool and Operator’s Manual Box

• ZX14-3, 16-3, 18-3 Tool and operator’s manual box (2) is located under the operator’s seat.

• ZX27-3 Tool box (2) and operator’s manual box (3) are located under the operator’s seat, under the floor mat and behind the backrest of the operator’s seat respectively.

ZX14-3, 16-3, 18-3

ZX27-3

2

M1NC-01-013

M1NC-07-035

3

1-18

ZX27-3

M1M7-01-018

OPERATOR'S STATION

Seat Belt

WARNING: Be sure to use the seat belt when

d

operating the machine.

Before operating the machine, be sure to examine

seat belt (1), buckle (2), or attaching hardware. Replace seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn.

Replace seat belt (1) every three years, regardless of

appearance.

1. Confirm that seat belt (1) is not twisted and securely insert the end of seat belt (1) into buckle (2).

Lightly pull on the belt to confirm that the buckle latches

securely.

2. Adjust tightness of the seat belt (1) so that the belt is snug but comfortable.

3. Push button (3) on buckle (2) to unfasten seat belt (1).

12

M1NC-01-014

1

M1NC-01-015

12

3

M1NC-01-016

1-19

OPERATOR'S STATION

Cab Light (Cab Equipped Machines)

Move cab light switch (4) to turn the cab light ON or OFF. (The cab light comes ON only when the key switch is turned ON.)

4

ZX14-3, 16-3, 18-3

ZX27-3

M1MS-01-017

4

M585-01-021

1-20

OPERATOR'S STATION

Cab Door Release Lever (ZX14-3, 16-3, 18-3 Cab Equipped Machines)

CAUTION: Open the cab door all the way until the

d

latch on the side of the cab securely locks.

To unlock the door, push down on lever (5) located on the left side of the operator’s seat.

5

Cab Door Release Button (ZX27-3)

CAUTION: Open the cab door all the way until the

d

latch on the side of the cab securely locks.

Pull button (3) to unlock the door.

ZX14-3, 16-3, 18-3

M1M0-01-006

3

1-21

ZX27-3

M1LN-01-004

OPERATOR'S STATION

MEMO

..................................................................................................................................................................................................

1-22

BREAK-IN

Breaking in New Machine

IMPORTANT: Operating a new machine at full load

without first breaking in can cause scratches and/or seizures, consequently affecting the service life of the machine. Thoroughly perform break-in operation.

The service life and performance of the machine can be greatly affected by operation and maintenance of the machine during the initial stage of operation. Perform break-in operation with the engine output less than 80% of the maximum output for the first 50 hours.

2-1

BREAK-IN

MEMO

..................................................................................................................................................................................................

2-2

OPERATING ENGINE

Before Starting Engine

1. Check that pilot control shut-off lever (1) is in the LOCK position.

2. Confirm that all control levers are placed in neutral.

3. Check indicator bulbs as follows:

Turn key switch to the ON position. All indicator lights

and warning lamps will come on. They will stay on for approximately 3 seconds, except for alternator (3) and engine oil pressure (4) indicator, which will continue to stay on further.

IMPORTANT: The monitor panel indicates the machine’s

operating conditions. If the machine is operated with an indicator bulb or a warning lamp burned out, the alarm will not be displayed even if any abnormality occurs on the machine. Accordingly, in case any of the indicator bulbs or the warning lamps do not come ON, immediately contact your authorized dealer for repair. If any of alternator (3) or engine oil pressure (4) fails to light after indicator light check is completed, the machine may have trouble. Immediately contact your authorized dealer for repair.

1

M1NC-05-004

2

4. Adjust the seat position so that all pedals and control levers can be fully stroked to any position when seated in the operator’s seat with the operator’s back kept in contact with the backrest. Fasten the seat belt.

NOTE: The monitor surfaces are resin. Wipe the surface only

f

with a damp cloth when dusty to keep them clean. Never use an organic solvent.

ZX14-3, 16-3, 18-3

M1M7-01-007

34

M1NC-01-005

3

4

3-1

ZX27-3

M1NC-01-022

OPERATING ENGINE

Starting Engine

Starting in Ordinary Temperature

1. Check that pilot control shut-off lever (1) is in the LOCK position.

2. Turn engine control lever (3) to the slow idle position.

3. Sound the horn to alert bystanders.

4. Turn key switch (2) to rotate the starter. The engine will be started.

IMPORTANT: Prevent starter damage and/or battery

over discharge. Never run the starter for more than 10 or 15 seconds at a time (ZX14-3, 16-3, 18-3: 15 seconds, ZX27-3 : 10 seconds). If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

5. Release key switch (2) immediately after the engine has started. It will automatically return to the ON position.

NOTE: The horn sounds even though the key switch is turned

f

OFF. The engine does not start unless the pilot control shut-off lever is in the LOCK position.

1

M1NC-05-004

3

Fast IdleSlow Idle

IMPORTANT: Avoid operating key switch (2) with stained

hands or gloves.

M1NC-00-007

2

M1M7-01-007

3-2

OPERATING ENGINE

Starting in Cold Weather ZX14-3, 16-3, 18-3

1. Check that pilot control shut-off lever (1) is in the LOCK position.

2. Turn engine control lever (3) to around the middle between the slow and fast idle positions.

3. Turn key switch (2) to the HEAT position and hold it in that position for approx. 3 seconds until preheat indicator (4) goes OFF.

4. Sound the horn to alert bystanders.

5. As soon as preheat indicator (4) goes OFF, return key switch (2) to the START position to run the starter.

IMPORTANT: Prevent starter damage and/or battery over

discharge. Never run the starter for more than 15 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

6. Release key switch (2) immediately after the engine has started. It will automatically return to the ON position.

NOTE: Set the engine control lever to the fast idle position to

f

start the engine in an extreme cold weather district. After the engine is started, gradually reduce the engine speed and perform warm-up operation at the medium speed range.

1

M1NC-05-004

2

3

M1M7-01-007

M1NC-00-007

3-3

4

M1NC-01-005

OPERATING ENGINE

ZX27-3

1. Check that pilot control shut-off lever (1) is in the LOCK position.

2. Turn engine control lever (3) to around the middle between the slow and fast idle positions.

3. Turn the key switch (2) to ON position. The preheat indicator (4) will light.

4. Sound the horn to alert bystanders.

5. As soon as preheat indicator (4) goes OFF, return key switch (2) to the START position to run the starter.

IMPORTANT: Prevent starter damage and/or battery over

discharge. Never run the starter for more than 10 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

6. Release key switch (2) immediately after the engine has started. It will automatically return to the ON position.

NOTE: This machine is equipped with Auto Glow System.

f

Sensing the coolant temperature, the duration of preheating is automatically set. Be sure to wait until the preheat indicator goes off with the key switch turned to the ON position, as specified above. When atmospheric temperature is low, it is possible to operate the starter motor for within 15 seconds at a time.

1

M1NC-05-004

2

M1M7-01-007

3

M1NC-00-007

4

M1NC-01-022

3-4

Check Machine After Starting Engine

OPERATING ENGINE

IMPORTANT: In case any abnormality is found in the

monitor, immediately stop the engine. Trace the cause of the problem.

Check Using the Monitor

After the engine has started, check the following points through the monitor.

1. Check that alternator indicator (1) is OFF.

In case alternator indicator (1) stays ON, immediately

stop the engine. Then, check the alternator and/or battery system for any abnormality.

2. Check that engine oil pressure indicator (2) is OFF.

In case engine oil pressure indicator (2) stays ON,

immediately stop the engine. Then, check the engine oil pressure system and/or the oil level for any abnormality.

Check Engine Noise and Exhaust Gas

Check that engine noise and exhaust gas are normal.

NOTE: Checking exhaust gas (With no load, after warming up)

f

Colorless or faint blue normal (complete

combustion)

Black abnormal (incomplete

combustion)

White abnormal (burning oil or

coolant leakage into cylinder)

ZX14-3, 16-3, 18-3

ZX27-3

12

M1NC-01-005

3

4

M1NC-01-022

3-5

Using Booster Battery

OPERATING ENGINE

WARNING: An explosive gas is produced while a

d

battery is in use or being charged. Keep flames or sparks away from the battery area. Park the machine and booster battery machine on a dry, firm or concrete surface, not on steel plates. If the machine and/or the booster battery machine are parked on steel plates, dangerous sparks may be unexpectedly created on the machine. Never connect a positive terminal to a negative terminal, as a dangerous short circuit will occur.

IMPORTANT: The machine electrical system is a 12

volt negative (-) ground. Use only 12 volt booster battery with the capacity enough to start this machine.

When the machine battery is exhausted, start the engine using a booster battery as shown below.

Connecting Booster Cables

1. Stop the engine of the booster battery machine.

2. Connect one end of red cable (1) to the positive (+) terminal of the machine battery and the other end to the positive (+) terminal of the booster battery.

Connect one end of red cable (1) to the positive (+) terminal of

1

Booster Battery

2

Connect one end of black cable (2) to the upperstructure frame.

(Black)

the machine battery.

(Red)

Machine Battery

M503-03-002

3. After connecting one end of the black cable (2) to the negative (-) terminal of the booster battery, connect the other end to upperstructure frame on the machine. Be alert to sparks that may be produced in the last connection to the hydraulic oil tank cover hinge.

4. After securely connecting the booster cables, start the engine of the booster battery machine. Run the engine at a middle speed. Then, start the engine of this machine.

5. After the engine is started, disconnect booster cables (1 and 2) following the procedures below.

Disconnecting Booster Cables

1. Disconnect black booster negative (-) cable (2) from upperstructure frame first.

2. Disconnect the other end of black booster negative (-) cable (2) from the booster battery.

3. Disconnect red booster positive (+) cable (1) from the booster battery.

4. Disconnect red booster positive (+) cable (1) from the machine battery.

3-6

OPERATING ENGINE

Stopping Engine

Stop the engine following the steps below.

1. Before stopping the engine, lower the bucket and blade to the ground unless specified.

2. Return the engine control lever to the slow idle position and keep the engine running at slow idle speed for 5 minutes.

3. Turn the key switch (2) OFF to stop the engine.

4. Pull up pilot control shut-off lever (1) to the LOCK position.

2

M1M7-01-007

1

M1NC-05-004

3-7

OPERATING ENGINE

MEMO

..................................................................................................................................................................................................

3-8

Travel Levers

DRIVING MACHINE

Travel operation can be performed with the mechanical levers.

WARNING: In the standard traveling position, the

d

front idlers are located in front of the operator’s seat and the travel motors at the rear. If the travel motors are positioned at the front of the machine, when the travel lever’s are operated in the direction as illustrated on the operation decals, the travel direction of the machine will be reversed. Be sure to confirm the position of the travel motors before traveling.

NOTE: Travel lever dampers are provided for smooth

f

control. In extremely cold weather (lower than -20 °C), the travel lever will become heavy to operate. This is caused by increase in oil viscosity which is not abnormal.

• Forward/Reverse Travel

Move both levers forward together to travel forward. Pull the levers back together to travel in reverse. The

travel speed can be controlled by adjusting the lever operating stroke.

Left Right

Operator’s Seat

Front

Rear

Blade

Travel Motor

M571-01-001

• Ascending/Descending Slopes

The machine gradeability is ZX14-3, 16-3, 18-3: 25° (47%)

ZX27-3: 30° (58%). Slowly operate the travel levers when descending a slope. When the travel levers are placed in neutral, the travel brakes are automatically applied to stop the machine.

M1LA-04-001

M1MF-04-001

M104-04-003

Forward/Reverse Travel Direction

4-1

DRIVING MACHINE

• Pivot Turn

Steer the machine by driving only one side crawler.

Operate either of the travel levers.

• Spin Turn

Steer the machine in a position by driving both side

crawlers in opposite directions each other. Move one lever forward and pull the other back at the same time.

CAUTION: During pivot or spin turn machine

d

operations, the base machine may shake. When turning the machine in a tight area, slowly operate the machine while taking care not to allow the machine to come into contact with the surrounding objects.

M1MF-04-001

M104-04-005

Pivot Turn

Spin Turn

M1MF-04-001

M104-04-007

4-2

DRIVING MACHINE

Travel Mode Switch (ZX16-3, 18-3, 27-3)

WARNING: Shifting the travel speed mode from the

d

slow to the fast while traveling a down slope is very dangerous. Be sure to shift the travel mode to the fast mode while traveling a down slope only after returning the travel levers to neutral.

Press switch (1) once at the top of the blade lever grip to select the fast travel mode. Check that indicator (2) with the

mark comes ON at this time. When switch (1) is pressed again, the slow travel mode is selected and indicator (2) goes OFF. In case the engine is stopped when the fast travel mode is selected and when the engine is restarted, the slow travel mode is automatically selected.

1 2

M1NC-04-002

ZX16-3, 18-3

2

1

ZX27-3

M1NC-01-026

2

M1NC-01-022

4-3

DRIVING MACHINE

Traveling on Soft Ground

Avoid traveling on soft ground as much as possible. If traveling on a soft ground is unavoidable, carefully operate the machine while observing the following points.

• Drive the machine as far as the machine can move by own propelling power. Towing machine may become necessary. Do not drive the machine to a deeper location than towing machine is possible.

• In case it becomes impossible for the machine to travel by own propelling power, lower the bucket to the ground. While supporting the machine weight with the boom and the arm, slowly pull the arm to evacuate the machine. Operate the boom, arm, and travel levers simultaneously at this time to prevent the machine from being loaded abnormally.

• If the track frame bottom comes into contact with the ground, or if mud and/or grabbles are tightly packed into the undercarriage, the machine may become impossible to travel. Raise one side track above the ground with the boom and arm extended, remove mud and/or grabbles from the track. Then, evacuate the machine. Rotate the raised track in forward or reverse directions alternately to remove the packed rocks and/or mud from the track.

• Tow the machine with other machine if the machine becomes stuck in soft ground and impossible to evacuate by own propelling power. Refer to the descriptions for Towing Machine on the next page for the correct rope attaching method.

M1M7-04-005

Raise One Track Using Boom and Arm

WARNING: Operate the machine carefully. The

d

machine may slide. Keep the angle between boom and arm 90 to 110 ° and position the bucket’s round side on the ground.

1. Swing the upperstructure 90 °.

2. Position the boom and the arm so that the angle

between them becomes to 90 to 110 °. Push the ground with the round bucket bottom to raise track off ground.

3. Do not raise the track with the boom and the arm when

the boom is swung.

90 to 110˚

M1M7-04-005

4-4

DRIVING MACHINE

Towing Machine

In case it is difficult for the machine to evacuate from a soft terrain by own propelling power, Attach wire ropes as illustrated to the right. Tow the machine using another machine. Be sure to attach the wire ropes around the track frames. To prevent the wire ropes from being damaged, place pieces of soft protective material between the wire ropes and the edge corners if the frame.

IMPORTANT: Do not tow the machine using the light-

weight part towing holes provided on the blade. Damage to the towing holes may result.

Wire Rope

M585-05-035

4-5

DRIVING MACHINE

Driving in Water or on Soft Ground

1. If the footing is even and the water slow running, the

machine can drive in water up to the upper track shoe surface (A) at the top of the front idler. In case the footing is uneven and the water is flowing fast, be careful not to submerge the swing bearing, swing pinion gears, and/or center joint in water or mud.

Operable Water Depth (A)

ZX14-3, 16-3, 18-3 370 mm

ZX27-3 465 mm

2. The machine may enter deeper areas gradually. Check

the machine’s position often. Reposition the machine if necessary.

A

IMPORTANT: If the swing bearing, swing gears and

center joint are submerged in water or mud by mistake, premature wearing on parts such as the swing bearing may result. Grease must be changed or overhauling will be required immediately. Stop operating the machine as soon as possible, and contact your authorized dealer.

M1NC-04-001

4-6

DRIVING MACHINE

Parking and Stopping on Slopes

WARNING: Parking and/or stopping on slopes

d

is extremely dangerous. Avoid parking and/or stopping the machine on slopes.

If parking and/or stopping on slopes is unavoidable, lower both the bucket and the blade to the ground, and place all levers in the neutral position. Also, put blocks at the downhill end of the tracks.

M1M7-04-009

Parking on Slopes

1. Park the machine on a level, solid surface. Position the

arm vertically and lower the bucket and blade to the ground.

2. Turn the engine control dial or the engine control lever

to the slow idle position. Run the engine at the slow idle speed for approx. 5 minutes to cool the engine.

3. Turn the key switch to OFF to stop the engine. Remove

the key from the switch.

4. Pull pilot control shut-off lever (1) into the fully LOCK

position.

5. Close the window and door, if a cab is provided.

Be sure to lock all the cab doors and windows.

1

M1NC-05-004

4-7

DRIVING MACHINE

MEMO

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4-8

OPERATING MACHINE

Control Lever (ISO Excavator Pattern)

WARNING: Be sure to check the location and

d

function of each control lever before operating. The upperstructure and/or front attachment may unexpectedly move when attempting to turn and look behind the machine as a part of operator’s body may come into contact with the control lever (s). Take care not to come into contact with the control levers when turning and looking behind the machine.

Labels showing the lever control pattern are provided on the operator’s right. As illustrated below, the labels indicate the ISO Excavator Pattern.

1

3

2

4

7

5

8

6

M1MS-05-003

M588-05-050

When a control lever is released, it automatically returns to neutral, stopping the function in that position.

1- Arm Roll-Out

2- Arm Roll-In

3- Swing Left

4- Swing Right

5- Boom Lower

6- Boom Raise

7- Bucket Roll-In

8- Bucket Roll-Out

4 3

1

2

M1M7-05-001

6

8

5

5-1

7

M1M7-05-002

OPERATING MACHINE

Boom-Swing Pedal

Use the boom swing function to efficiently operate the machine when excavating grooves along roadsides or near walls. The boom swing operation is performed using boom-swing pedal (1) located at the operator’s right foot as illustrated to the right.

Boom-Swing Operation

1. Turn cover (2) for boom-swing pedal (1) forward.

2. Step on the left side of boom-swing pedal (1) to swing

left. Step on the right side of the pedal to swing right.

3. Turn cover (2) backward over boom-swing pedal (1)

when boom-swing operation is no longer required.

1

2

M1NC-05-001

2

3- Swing Left

4- Swing Right

M1NC-05-002

43

M571-01-001

5-2

OPERATING MACHINE

Auxiliary Pedal

Use the auxiliary pedal (2) located at the operator’s left front, as illustrated to the right, to operate hydraulic breaker, crusher, etc.

Operation

1. Turn auxiliary pedal cover (1) forward.

2. Step on the right or the left side of the auxiliary pedal (2)

to operate the front-end attachment such as a hydraulic breaker.

3. When the auxiliary pedal (2) is not used, turn cover (1)

backward on the pedal.

21

M1NC-05-003

1

M1NC-05-002

5-3

Blade Lever

OPERATING MACHINE

Use blade lever (1) on the operator’s right to raise and lower the blade. When the lever is released, it automatically returns to neutral, holding the blade in the present position until the lever is operated again.

2- Blade Raise

3- Blade Lower

3

2

M1NC-01-002

1

2

M1NC-04-001

3

5-4

OPERATING MACHINE

Precautions for Blade Operation

This blade is designed as a light service attachment of the hydraulic excavator. Please keep the following points in mind:

• This blade is designed for bull dozing work only.

Do not attempt to dig deeply with the blade. Doing so

may damage not only the blade but the undercarriage as well.

• Do not apply concentrated or uneven loads to the blade. Never allow the blade to forcefully collide with a load by running the machine into the load. Failure to do so may result in damage to the blade and the undercarriage.

• When jacking up the machine with this blade, the surface beneath the blade comes under high pressure, increasing the risk of surface collapse. Always be sure that the surface is strong enough to support the weight of the machine before jacking up the machine. Avoid dangerous uneven distribution of weight to the blade by maintaining even contact between the blade and the ground.

• While digging with the blade positioned in the front of the machine, take care not to allow the bucket to come into contact with the blade.

• When digging, take care not to allow the boom cylinder to come into contact with the blade.

M586-05-016

M586-05-017

5-5

OPERATING MACHINE

Blade and Track Width Control Lever Operation (ZX18-3)

CAUTION:

d

• Be sure to set the track width to either 1280 mm (fully extended) or 970 mm (fully retracted). If the machine is operated with the track width set to a dimension other than 1280 mm or 970 mm, the track width will not be secured so that the machine upper structure will move unstably.

• Never attempt to adjust the track width on a slope. Failure to follow these instructions will cause the machine to turn over or skid, possibly resulting in personal injury.

IMPORTANT: • Check the sliding surfaces on the track

frame for any accumulated debris. If any debris such as soil has accumulated, remove the accumulated debris and clean the surfaces.

• Check the ground surface under the machine. In case the surface is not flat or if any protruding obstructions exist, move the machine to a flat surface area or remove the obstruction before adjusting the track width.

• Do not use the track width control function to move or tow any objects.

Machine failure or damage may result.

1

3

2

Track-width control switch

ZX18-3(Canopy)

3

Track-width

1

control switch

ZX18-3(Cab)

M1NC-05-014

SS4706712

2

M1NC-04-003

Blade (When the track-width control switch is OFF:)

Use lever (1) to raise and lower the blade. When the lever is released, it automatically returns to its neutral position, keeping the blade in its position until the lever is operated again. (2) Blade raise (3) Blade lower

Track width (When the track-width control switch is ON:)

Use lever (1) to change the width of the track (under carriage). When the lever is released, it automatically returns to its neutral position, keeping the width in its position until the lever is operated again. (2) Narrow width (3) Extend width

2

M1NC-04-001

3

2 3

M1NC-05-015

5-6

Hitachi Zaxis-14-3, Zaxis16-3, Zaxis18-3, Zaxis27-3 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual