Hitachi ZX200-3,ZX240-3,ZX270-3,ZX330-3 Excavator Pdf Operator Manual (EM1U1-1-2)

Hitachi ZX200-3,ZX240-3,ZX270-3,ZX330-3 Excavator Pdf Operator Manual (EM1U1-1-2)

This manual provides essential guidance for operators and maintenance personnel to ensure safe, efficient, and reliable machine performance. This comprehensive manual includes detailed operating instructions, safety guidelines, maintenance schedules for Hitachi ZX200-3,ZX240-3,ZX270-3,ZX330-3 Excavator model.

SAFETY
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
General Precautions for Cab ………………………………………………. S-4
Use Handholds and Steps ………………………………………………….. S-5
Adjust the Operator’s Seat …………………………………………………. S-5
Ensure Safety Before Rising from or
Leaving Operator’s Seat ……………………………………………….. S-5
Fasten Your Seat Belt …………………………………………………………… S-6
Move and Operate Machine Safely …………………………………… S-6
Handle Starting Aids 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 Head Guard, Rops, Fops ………………………….. S-10
Provide Signals for Jobs Involving
Multiple Numbers of 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 Person 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-18
Precautions for Lightening ………………………………………………. S-18
Object Handling ………………………………………………………………… S-18
Protect Against Flying Debris ………………………………………….. S-19
Park Machine Safely …………………………………………………………… S-19
Handle Fluids Safely−avoid Fires …………………………………….. S-19
Transport Safely …………………………………………………………………. 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-22
Prevent Parts from Flying …………………………………………………. S-23
Store Attachments Safely …………………………………………………. S-23
Prevent Burns ……………………………………………………………………… S-24
Replace Rubber Hoses Periodically …………………………………. S-24
Avoid High-pressure Fluids ………………………………………………. S-25
Prevent Fires ……………………………………………………………………….. S-26
Evacuating in Case of Fire …………………………………………………. S-27
Beware of Exhaust Fumes ………………………………………………… S-27
Precautions for Welding and Grinding …………………………… S-27
Avoid Heating Near Pressurized Fluid Lines ………………….. S-28
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………………………………… S-28
Remove Paint Before Welding or Heating ……………………… S-28
Beware of Asbestos Dust ………………………………………………….. S-29
Prevent Battery Explosions ………………………………………………. S-29
Service Air Conditioning System Safely …………………………. S-29
Handle Chemical Products Safely ……………………………………. S-30
Dispose of Waste Properly ………………………………………………… S-30
SAFETY SIGNS …………………………………………………………………… S-31
COMPONENTS NAME ……………………………………………………….. 1-1
OPERATOR’S STATION
Cab Features …………………………………………………………………………. 1-2
Multi Function Monitor ………………………………………………………. 1-4
Outline …………………………………………………………………………………… 1-5
Menu Screen (23) …………………………………………………………… 1-8
Hour Meter ……………………………………………………………………… 1-9
Fuel Gauge ……………………………………………………………………… 1-9
Clock ………………………………………………………………………………… 1-9
Back Monitor Selector …………………………………………………… 1-9
Menu Key ……………………………………………………………………….1-10
Optional Function Key …………………………………………………1-10
Return to Basic Screen Key …………………………………………1-10
Alarm Light ……………………………………………………………………1-10
Optional Function Display …………………………………………1-10
Coolant Temperature Gauge ………………………………………1-11
Operating Status Icon Display ……………………………………1-11
Alarm Occurrence Screen ………………………………………………….1-16
Contents of Alarms …………………………………………………………….1-18
Clock Setting ……………………………………………………………………….1-20
Attachment Selection
(Only Machines Equipped with Optional Parts) ………1-21
Pump 2 Flow Rate Adjustment
(Only Machines Equipped with Optional Parts) ………1-25
Displaying Operating Conditions …………………………………….1-26
Fuel Rate Display/No Display ……………………………………………1-27
Back Monitor Settings ……………………………………………………….1-35
Maintenance Settings ………………………………………………………..1-37
Mail (Optional) …………………………………………………………………….1-42
Language Settings ……………………………………………………………..1-44
Switch Panel ………………………………………………………………………..1-46
Engine Control Dial …………………………………………………………….1-47
Auto-idle Switch …………………………………………………………………1-47
Power Mode Switch …………………………………………………………..1-48
Travel Mode Switch ……………………………………………………………1-48
Work Light Switch ………………………………………………………………1-49
Wiper/Washer Switch …………………………………………………………1-50
Switch Panel (Optional) ……………………………………………………..1-52
Key Switch ……………………………………………………………………………1-54
Power Boost Switch ……………………………………………………………1-54

Horn Switch …………………………………………………………………………1-54
Cigar Lighter ………………………………………………………………………..1-55
Cab Light ……………………………………………………………………………..1-56
Installing Fire Extinguisher ……………………………………………….1-56
Pilot Control Shut-off Lever ………………………………………………1-57
Engine Stop Switch …………………………………………………………….1-57
Fuse Box ……………………………………………………………………………….1-58
Auto Air Conditioner ………………………………………………………….1-59
Cab Heater Operation ………………………………………………………..1-62
Cooling Operation ……………………………………………………………..1-63
Defroster Operation …………………………………………………………..1-63
Tips for Optimal Air Conditioner Usage ………………………….1-65
Cab Heater (Optional) ………………………………………………………..1-66
Cab Heater Operation ………………………………………………………..1-67
Defroster Operation …………………………………………………………..1-68
AM/FM Radio Operation …………………………………………………..1-69
Digital Clock Setting Procedure ……………………………………….1-70
Cab Door Release Lever …………………………………………………….1-71
Opening Upper Front Window …………………………………………1-71
Closing Upper Front Window ……………………………………………1-72
Removing and Storing Lower Front Window …………………1-73
Opening Side Windows ……………………………………………………..1-73
Opening/Closing Overhead Window ………………………………1-74
Emergency Exit …………………………………………………………………..1-75
Adjusting the Seat ……………………………………………………………..1-76
Adjusting the Air-suspension Seat (Optional) ……………….1-78
Adjusting Console Height …………………………………………………1-80
Seat Belt ……………………………………………………………………………….1-81
BREAK-IN
Observe Engine Operation Closely …………………………………… 2-1
Every 8 Hours or Daily …………………………………………………………. 2-1
After the First 50 Hours ………………………………………………………. 2-1
After the First 100 Hours …………………………………………………….. 2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting …………………………….. 3-1
Before Starting Engine ……………………………………………………….. 3-2
Starting the Engine in Ordinary Temperature …………………. 3-3
Starting in Cold Weather ……………………………………………………. 3-5
Check Instruments After Starting ……………………………………… 3-7
Using Booster Batteries ………………………………………………………. 3-8
Stopping the Engine ………………………………………………………….3-10
DRIVING THE MACHINE
Drive the Machine Carefully ………………………………………………. 4-1
Steering the Machine Using Pedals ………………………………….. 4-2
Steering the Machine Using Levers ………………………………….. 4-3
Travel Mode Switch …………………………………………………………….. 4-4
Travel Alarm (Optional) ………………………………………………………. 4-4
Operating on Soft Ground …………………………………………………. 4-5
Raise One Track Using Boom and Arm …………………………….. 4-5
Towing Machine a Short Distance …………………………………….. 4-6
Operating in Water or Mud ………………………………………………… 4-7
Parking the Machine on Slopes …………………………………………. 4-8
Parking the Machine …………………………………………………………… 4-8
OPERATING THE MACHINE
Control Lever (Iso Pattern) …………………………………………………. 5-1
Control Lever (HITACHI Pattern) ………………………………………… 5-2
Attchement Pedal (Hydraulic Breaker) …………………………….. 5-3
Attchement Pedal (Hydraulic Crusher) …………………………….. 5-4
Pilot Control Shut-off Lever ……………………………………………….. 5-5
Engine Speed Control …………………………………………………………. 5-7
Auto-idle ………………………………………………………………………………. 5-8
Work Mode …………………………………………………………………………… 5-9
Work Mode Select ………………………………………………………………5-10
Power Boost ………………………………………………………………………..5-11
Power Mode ……………………………………………………………………….5-12
Operating Backhoe …………………………………………………………….5-13
Grading Operation ……………………………………………………………..5-13
Face Shovel Operation ………………………………………………………5-14
Avoid Abusive Operation ………………………………………………….5-14
Operating Tips …………………………………………………………………….5-15
Select Correct Track Shoes ………………………………………………..5-15
Hydraulic Breaker and Hydraulic Crusher ……………………….5-16
Pipings for Breaker and Crusher ………………………………………5-17
Secondary Relief Pressure Adjustment …………………………..5-18
Precautions for Breaker Operation …………………………………..5-19
Breaker Maintenance …………………………………………………………5-22
Precautions for Crusher Operation ………………………………….5-23
Attachment ………………………………………………………………………….5-25
Attachment Connection Parts ………………………………………….5-29
Precaution for Arm Roll-in/bucket Roll-in
Combined Operation — If Headguard-integrated
Cab or Raingard Is Equipped ………………………………………5-30
When Installing an Attachment Longer
Than Standard Bucket ………………………………………………….5-30
Shackle Hole Usage ……………………………………………………………5-31
Overnight Storage Instructions ………………………………………..5-31
Emergency Boom Lowering Procedure
(Without Hose-rupture Safety Valve) ………………………..5-32
Object Handling — If Equipped ……………………………………….5-33
TRANSPORTING
Transporting By Road …………………………………………………………. 6-1
Loading/unloading on a Trailer …………………………………………. 6-1
Machine Lifting Procedure …………………………………………………. 6-5
MAINTENANCE
Correct Maintenance and Inspection Procedures ………….. 7-1
Check the Hour Meter Regularly ……………………………………….. 7-2
Use Correct Fuels and Lubricants ……………………………………… 7-2
Layout ……………………………………………………………………………………. 7-3
Maintenance Guide Table …………………………………………………… 7-4
Prepare Machine for Maintenance ……………………………………. 7-6
Hood and Access Covers …………………………………………………….. 7-7
Periodic Replacement of Parts …………………………………………… 7-8
CONTENTS
Maintenance Guide …………………………………………………………….. 7-9
A. Greasing …………………………………………………………………………..7-14
Front Joint Pins ……………………………………………………………..7-14
Swing Bearing ……………………………………………………………….7-16
Swing Internal Gear ……………………………………………………..7-17
B. Engine ………………………………………………………………………………7-18
Engine Oil Level …………………………………………………………….7-18
Change Engine Oil ……………………………………………………….7-19
Replace Engine Oil Filter ……………………………………………..7-19
C. Transmission ……………………………………………………………………7-21
Pump Transmission ………………………………………………………7-21
Swing Reduction Gear …………………………………………………7-22
Travel Reduction Gear ………………………………………………….7-23
D. Hydraulic System ……………………………………………………………7-25
Inspection and Maintenance of Hydraulic
Equipment …………………………………………………………………….7-25
Breaker Maintenance …………………………………………………..7-27
Check Hydraulic Oil Level ……………………………………………7-28
Change Hydraulic Oil …………………………………………………..7-29
Suction Filter Cleaning ………………………………………………..7-29
Replace Hydraulic Tank Oil Filter ………………………………..7-32
Replace Pilot Oil Filter ………………………………………………….7-33
Replace Air Breather Element …………………………………….7-34
Check Hoses and Lines ………………………………………………..7-35
Service Recommendations for Hydraulic Fittings …..7-38
E. Fuel System ……………………………………………………………………..7-40
Drain Fuel Tank Sump …………………………………………………7-42
Check Water Separator ………………………………………………..7-43
Replace Fuel Main Filter Element ……………………………….7-47
Replace Fuel Pre-filter Element …………………………………7-48
Clean Fuel Solenoid Pump Strainer …………………………..7-49
Check Fuel Hoses ………………………………………………………….7-50
F. Air Cleaner ………………………………………………………………………..7-51
Clean the Air Cleaner Outer Element ………………………..7-51
Replace the Air Cleaner Outer and Inner Elements …7-51
G. Cooling System ………………………………………………………………7-53
Check Coolant Level …………………………………………………….7-55
Check and Adjust Fan Belt Tension ………………………………7-56
Change Coolant ……………………………………………………………7-57
Clean Radiator Interior ………………………………………………..7-57
Clean Radiator, Oil Cooler Core and Inter Cooler …….7-58
Clean Oil Cooler, Radiator and Inter
Coller Front Screen ……………………………………………………….7-58
Clean Air Conditioner Condenser ………………………………7-58
Clean Fuel Oil Cooler …………………………………………………..7-58
Clean Air Conditioner Front Screen (Opt.) ……………….7-58
H. Electrical System …………………………………………………………….7-59
Replace Batteries ………………………………………………………….7-62
Remove and Installing Battery …………………………………..7-63
Replacing Fuses …………………………………………………………….7-63
I. Miscellaneous ………………………………………………………………….7-65
Check Bucket Teeth ………………………………………………………7-65
Change Bucket ……………………………………………………………..7-69
Convert Bucket Connection Into Face Shovel ………….7-70
Adjust the Bucket Linkage ………………………………………….7-71
Remove the Travel Levers ……………………………………………7-72
Check and Replace Seat Belt Check …………………………..7-72
Check Windshield Washer Fluid Level ……………………….7-73
Check Track Sag …………………………………………………………….7-74
Clean and Replace Air Conditioner Filter
Clean Filter …………………………………………………………………….7-76
Check the Air Conditioner …………………………………………..7-78
Clean Cab Floor …………………………………………………………….7-79
Retighten Cylinder Head Bolt …………………………………….7-80
Inspect and Adjust Valve Clearance …………………………..7-80
Measure Engine Compression Pressure ……………………7-80
Check Starter and Alternator ……………………………………..7-80
Check Tightening Torque of Bolts and Nuts …………….7-81
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special Environmental Conditions .. 9-1
STORAGE
Storing the Machine …………………………………………………………..10-1
Removing the Machine from Storage ……………………………..10-2
TROUBLESHOOTING
Impossible to Start the Engine …………………………………………11-1
Engine …………………………………………………………………………………..11-2
Electrical System …………………………………………………………………11-6
Mode Selection …………………………………………………………………..11-8
Control Levers ……………………………………………………………………..11-9
Hydraulic System ………………………………………………………………..11-9
SPECIFICATIONS
Specifications (ZAXIS200-3, ZAXIS200LC-3,
ZAXIS210H-3, ZAXIS210LCH-3) ……………………………………12-1
Working Ranges (ZAXIS200-3, ZAXIS200LC-3,
ZAXIS210H-3, ZAXIS210LCH-3) ……………………………………12-2
Shoe Types and Applications (ZAXIS200-3,
ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3) ………….12-3
Bucket Types and Applications (ZAXIS200-3,
ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3) ………….12-5
Specifications (ZAXIS210K-3, 210LCK-3) …………………………..12-6
Working Ranges (ZAXIS210K-3, 210LCK-3) ………………………12-7
Shoe Types and Applications
(ZAXIS210K-3, 210LCK-3) ………………………………………………12-8
Bucket Types and Applications
(ZAXIS210K-3, 210LCK-3) ………………………………………………12-9
Specifications (ZAXIS240-3, 240LC-3, 250H-3,
250LCH-3) ……………………………………………………………………. 12-10
Working Ranges (ZAXIS240-3, 240LC-3,
250H-3, 250LCH-3) ……………………………………………………… 12-10
Shoe Types and Applications (ZAXIS240-3, 240LC-3,
250H-3, 250LCH-3) ……………………………………………………… 12-11
Bucket Types and Applications (ZAXIS240-3,
240LC-3, 250H-3, 250LCH-3) ……………………………………… 12-12
Specifications (ZAXIS250K-3, 250LCK-3) ……………………….. 12-15
Working Ranges (ZAXIS250K-3, 250LCK-3) …………………… 12-16

Shoe Types and Applications (ZAXIS250K-3,
250LCK-3) ……………………………………………………………………. 12-17
Bucket Types and Applications
(ZAXIS250K-3, 250LCK-3) …………………………………………… 12-18
Specifications (ZAXIS270-3, 270LC-3) ……………………………. 12-19
Working Ranges (ZAXIS270-3, 270LC-3) ……………………….. 12-20
Shoe Types and Applications (ZAXIS270-3, 270LC-3) …. 12-21
Bucket Types and Applications
(ZAXIS270-3, 270LC-3) ……………………………………………….. 12-22
Specifications (ZAXIS330-3, 330LC-3,
350H-3, 350LCH-3) ……………………………………………………… 12-23
Working Ranges (ZAXIS330-3, 330LC-3,
350H-3, 350LCH-3) ……………………………………………………… 12-24
Shoe Types and Applications (ZAXIS330-3, 330LC-3,
350H-3, 350LCH-3) ……………………………………………………… 12-25
Bucket Types and Applications
(ZAXIS330-3, 330LC-3, 350H-3, 350LCH-3) ………………. 12-27
Specifications (ZAXIS350K-3, 350LCK-3) ……………………….. 12-28
Working Ranges (ZAXIS350K-3, 350LCK-3) …………………… 12-29
Shoe Types and Applications (ZAXIS350K-3, 350LCK-3) 12-30
Bucket Types and Applications
(ZAXIS350K-3, 350LCK-3) …………………………………………… 12-31
INDEX …………………………………………………………………………………..14-1

Language: English
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