Hitachi ZAXIS 290F-3 Road Builder Operator’s Manual – PDF DOWNLOAD

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Hitachi ZAXIS 290F-3 Road Builder Operator’s Manual – PDF DOWNLOAD

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Hitachi ZAXIS 290F-3 Road Builder Operator’s Manual – PDF DOWNLOAD

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TABLE OF CONTENTS:

Hitachi ZAXIS 290F-3 Road Builder Operator’s Manual – PDF DOWNLOAD

Contents 7
Safety—Safety and Operator Conveniences 11
Safety and Operator Convenience Features 11
Safety—General Precautions 12
Recognize Safety Information 12
Follow Safety Instructions 12
Operate Only If Qualified 12
Wear Protective Equipment 12
Inspect Machine 13
Stay Clear of Moving Parts 13
Avoid High-Pressure Fluids 13
Avoid High-Pressure Oils 14
Work In Ventilated Area 14
Prevent Fires 15
In Case of Machine Fire 15
Clean Debris From Machine 16
Prevent Battery Explosions 16
Handle Chemical Products Safely 16
Dispose of Waste Properly 17
Prepare for Emergencies 17
Control Pattern 17
Safety—Operating Precautions 18
Use Steps and Handholds Correctly 18
Start Only From Operator’s Seat 18
Use and Maintain Seat Belt 18
Prevent Unintended Machine Movement 18
Operate Machine Safely 18
Avoid Work Site Hazards 19
Keep Riders Off Machine 19
Use Care When Swinging Machine 20
Travel Safely 20
Operate Booms With Care 20
Avoid Power Lines 21
Avoid Backover Accidents 21
Avoid Machine Tip Over 21
Use Special Care When Lifting Objects 22
Operating On Slopes 22
Add and Operate Attachments Safely 22
Keep the Operator Protective Structure (OPS) in Place 23
Inspect and Maintain Operator Protective Structures and Guards 23
Safety—Maintenance Precautions 24
Park and Prepare for Service Safely 24
Service Machines Safely 24
Service Cooling System Safely 24
Prevent Acid Burns 24
Remove Paint Before Welding or Heating 25
Make Welding Repairs Safely 25
Drive Metal Pins Safely 26
Safety—Safety Signs 27
Safety Signs 27
Operation—Operator’s Station 29
Pedals, Levers, and Panels 29
Control Lever Switches 29
Monitor Panel 30
Monitor Panel Functions 30
Front Switch Panel 31
Front Switch Panel Functions 32
Switch Panel 33
Pilot Shutoff Lever 34
Power Boost Button 34
Travel Alarm and Travel Alarm Cancel Switch 34
Seat Heater Switch—If Equipped 35
Reversing Cooling Fan Switch—If Equipped 35
Cab Heater and Air Conditioner—Side Entry Cab 35
Selecting Display Between Celsius and Fahrenheit—Side Entry Cab 37
Cab Heater and Air Conditioner—Rear Entry Cab 37
Operating the AM/FM Radio 37
Side Entry Cab Door Handles 38
Rear Entry Cab Door Handles 38
Opening Side Windows 39
Secondary Exit 39
Adjusting the Mechanical Suspension Seat 40
Adjusting the Air Suspension Seat—If Equipped 41
Adjusting Pilot Control Lever Console Height 43
Fire Extinguisher 43
Hydraulic Oil Tank Pressure Vent—If Equipped 43
Operation—Operating the Machine 45
Before Starting Work 45
Operator’s Daily Machine Check Before Starting 45
Starting Engine 45
Timer Operation 47
Preset Timer for Heater Start 47
Cold Weather Warm-Up 47
Travel Pedals and Levers 48
Control Levers 50
Control Lever Pattern Operation 50
Operating In Water and Mud 51
Driving Up a Steep or Slippery Slope 51
Lifting 52
Lower Boom With Engine Stopped 52
Parking the Machine 53
Loading Machine On Trailer 54
Cab Tilting Procedure 54
Towing Machine 55
Tiedown Points 56
Machine Recovery 56
Maintenance—Machine 57
Diesel Fuel 57
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 57
Drain Intervals for Diesel Engine Coolant 58
John Deere COOL-GARD™ II Coolant Extender 59
Supplemental Coolant Additives 59
Operating in Warm Temperature Climates 60
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 60
Testing Diesel Engine Coolant 61
Low Sulfur Diesel Fuel Conditioner 62
Handling and Storing Diesel Fuel 62
Alternative and Synthetic Lubricants 62
Diesel Engine Oil — Tier 3 and Stage IIIA 63
Diesel Engine Oil and Filter Service Intervals 64
Hydraulic Oil 65
Swing Gear Case, Travel Gear Case and Pump Gear Case Oils 68
Track Adjuster, Working Tool Pivots, Swing Bearing, and Swing Gear Grease 68
Cab and Riser Tilt Power Pack Oil 68
Maintenance—Periodic Maintenance 70
Service Machine at Specified Intervals 70
Check the Hour Meter Regularly 70
Prepare Machine for Maintenance 70
Open Access Doors for Service 70
Open Engine Cover for Service 70
Fuel Tank 71
Periodic Maintenance Record Keeping System 71
Maintenance—As Required 75
Drain Water Separators 75
Clean Fuel Tank Inlet Screen 75
Clean Fuel Suction Screen 76
Drain Fuel Tank Sump 76
Windshield Washer Fluid Level 76
Clean Air Cleaner Dust Valve 77
Clean Air Inlet Screen and Cooling Package 77
Check Track Sag 78
Adjust Track Sag 78
Check Coolant 79
Maintenance—Every 10 Hours or Daily 80
Lubricate Front End Pin Joints 80
Check Hydraulic Tank Oil Level 80
Check Engine Oil Level 84
Check Coolant Level 84
Maintenance—Every 50 Hours 85
Lubricate Swing Bearing 85
Inspect and Re-Torque Track Hardware 85
Maintenance—Every 250 Hours 86
Check Swing Gear Case Oil Level 86
Drain Hydraulic Tank Sump 86
Check Pump Drive Gear Case Oil Level 88
Clean Primary Air Cleaner Element 88
Check Battery Electrolyte Level and Terminals 90
Check Travel Gear Case Oil Level 91
Inspect and Re-Torque Track Hardware 93
Take Engine Oil Sample 93
Maintenance—Every 500 Hours 94
Lubricate Swing Bearing Gear 94
Change Engine Oil and Replace Filter 95
Replace Fuel Prefilter Element 96
Replace Fuel Main Filter Element 96
Check Air Intake Hoses 96
Clean Cab Fresh Air and Recirculating Air Filters—Side Entry Cab 96
Take Fluid Samples 97
Maintenance—Every 1000 Hours 99
Change Swing Gear Case Oil 99
Replace Hydraulic Oil Tank Oil Filter 99
Replace Pilot Oil Filter 101
Clean the Engine Crankcase Ventilation Tube 103
Change Pump Drive Gear Case Oil 104
Inspect Fan Belt 104
Replace Air Cleaner Elements 105
Replace Air Cleaner Dust Valve 106
Check Coolant 106
Replace Fuel Tank Breather (S N 290054— ) 107
Maintenance—Every 1500 Hours 108
Change Hydraulic Tank Zinc-Based Oil, Clean Suction Screen 108
Maintenance—Every 2000 Hours 110
Check and Adjust Engine Valve Lash 110
Change Travel Gearbox Oil 110
Maintenance—Every 5000 Hours 111
Change Hydraulic Tank Zinc-Free Oil, Clean Suction Screen 111
Replace Hydraulic Cap Breather Element—If Equipped 113
Replace Hydraulic Tank Vent Cap Filter—If Equipped 113
Maintenance—Every 6000 Hours 115
Drain Cooling System 115
Cooling System Fill and Deaeration Procedure 116
Miscellaneous—Machine 117
Inspect and Clean Polycarbonate Windows 117
Check and Adjust Air Conditioner Belt 117
Bleed Fuel System 118
Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump 119
Do Not Service Control Valves, Cylinders, Pumps, or Motors 119
Precautions for Alternator and Regulator 119
JDLink™ Machine Monitoring System (MMS)—If Equipped 119
Using Booster Batteries—24-Volt System 120
Handling, Checking, and Servicing Batteries Carefully 121
Using Battery Charger 122
Replacing Batteries 122
Adding 12—Volt Accessories 123
Replacing Fuses 123
Fluid Sampling Test Ports—If Equipped 127
Welding On Machine 128
Clean Machine Regularly 128
Check and Clean Windshield Regularly 128
Track Sag General Information 129
Unified Inch Bolt and Screw Torque Values 129
Metric Bolt and Screw Torque Values 130
Miscellaneous—Operational Checkout 132
Operational Checkout 132
Diagnostic Trouble Codes Check 132
Operational Checks—Key Switch OFF, Engine OFF 132
Operational Checks—Key Switch ON, Engine OFF 133
Operational Checks—Key Switch ON, Engine ON Checks 140
Miscellaneous—Troubleshooting 171
Using Troubleshooting Charts 171
Engine 171
Electrical System 174
Front Attachments Electrical Controls 177
Hydraulic System 177
Miscellaneous—Storage 180
Prepare Machine for Storage 180
Monthly Storage Procedure 180
Miscellaneous—Machine Numbers 182
Record Product Identification Number (PIN) 182
Record Engine Serial Number 182
Record Travel Motor Serial Numbers 182
Record Swing Motor Serial Number 182
Record Hydraulic Pump Serial Number 183
Keep Proof of Ownership 183
Keep Machines Secure 183
Miscellaneous—Specifications 185
Zaxis 290F-3 Engine Specifications 185
Zaxis 290F-3 Drain and Refill Capacities 185
Zaxis 290F-3 Builder Machine Specifications 185
Zaxis 290F-3 Road Builder Working Ranges 187
Zaxis 290F-3 Road Builder—Lift Capacity, kg (lb) 190
Page Number 7
Section 1-1 11
Section 1-2 12
Section 1-3 18
Section 1-4 24
Section 1-5 27
Section 2-1 29
Section 2-2 45
Section 3-1 57
Section 3-2 70
Section 3-3 75
Section 3-4 80
Section 3-5 85
Section 3-6 86
Section 3-7 94
Section 3-8 99
Section 3-9 108
Section 3-10 110
Section 3-11 111
Section 3-12 115
Section 4-1 117
Section 4-2 132
Section 4-3 171
Section 4-4 180
Section 4-5 182
Section 4-6 185

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