Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Operational Principle+Troubleshooting+Parts+ Operator’s Manual – PDF DOWNLOAD

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Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Operational Principle+Troubleshooting+Parts+ Operator’s Manual

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Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Operational Principle+Troubleshooting+Parts+ Operator’s Manual

This Listing includes all of the manuals mentioned below:

1. Hitachi ZAXIS 400R-3 400LCH-3 Hydraulic Excavator Parts Catalog
2. Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Electrical-Hydraulic Circuit Diagram
3. Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Technical Operational Principle Manual
4. Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Technical Operator’s Manual
5. Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual

DESCRIPTION:

Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Operational Principle+Troubleshooting+Parts+ Operator’s Manual

INTRODUCTION:

TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.

ADDITIONAL REFERENCES:

• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material

MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

TABLE OF CONTENTS:

Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Operational Principle+Troubleshooting+Parts+ Operator’s Manual

• Hitachi ZAXIS 400R-3 400LCH-3 Hydraulic Excavator Parts Catalog

COVER
MEMORANDUM
FOREWORD
CONTENTS
UPPER STRUCTURE
UNDER CARRIAGE
FRONT—END ATTACHMENTS
BREAKER, CRUSHER PARTS
NAME-PLATE
PARTS INDEX

• Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual

SECTION 4 OPERATIONAL PERFORMANCE
TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 e-Shovel
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection

• Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Technical Operator’s Manual

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
CONTENTS
Horn Switch 1-54
Cigar Lighter 1-55
Cab Light 1-56
Installing Fire Extinguisher (Optional) 1-56
Pilot Control Shut-off Lever 1-57
Engine Stop Switch 1-57
Fuse Box 1-58
Additional 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 (Optional) 1-71
Closing Upper Front Window (Optional) 1-72
Removing and Storing Lower Front Window (Optional) 1-73
Opening Side Windows 1-73
Opening/Closing Overhead Window (Optional) 1-74
Emergency Exit 1-75
Emergency Exit (Optional) 1-76
Adjusting the Mechanical Suspension Seat 1-77
Seat With a Built-in Heater 1-78
Adjusting the Air-suspension Seat (Optional) 1-79
Seat With a Built-in Heater 1-80
Adjusting the Fixed Seat (Optional) 1-81
Adjusting Console Height 1-83
Seat Belt 1-84
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) (Optional) 5-2
Attchement Pedal (Hydraulic Breaker) (Optional) 5-3
Attchement Pedal (Accelerator Type) 5-4
Attchement Pedal (Common Use Type)
in the Unlock Position 5-5
Attchement Pedal (Hydraulic Crusher) 5-6
Pilot Control Shut-off Lever 5-7
Engine Speed Control 5-9
Auto-idle 5-10
Work Mode 5-11
Work Mode Select 5-12
Power Boost 5-13
Power Mode 5-14
Operating Backhoe 5-15
Grading Operation 5-15
Avoid Abusive Operation 5-16
Operating Tips 5-17
Select Correct Track Shoes 5-17
Hydraulic Breaker and Hydraulic Crusher 5-18
Pipings for Breaker and Crusher 5-19
Secondary Relief Pressure Adjustment 5-20
Precautions for Breaker Operation 5-21
Breaker Maintenance 5-24
Precautions for Crusher Operation 5-26
Attachment 5-28
Attachment Connection Parts 5-32
Precaution for Arm Roll-in/Bucket Roll-in
Combined Operation 5-33
When Installing an Attachment Longer
Than Standard Bucket 5-33
Shackle Hole Usage 5-34
Overnight Storage Instructions 5-34
Emergency Boom Lowering Procedure 5-35
Object Handling 5-36
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
CONTENTS
Maintenance Guide Table 7-4
Prepare Machine for Maintenance 7-6
Hood and Access Covers 7-7
Periodic Replacement of Parts 7-8
Maintenance Guide 7-9
A Greasing 7-14
Front Joint Pins 7-14
Swing Bearing 7-19
Swing Internal Gear 7-20
Electric Grease Gun 7-21
B Engine 7-29
Engine Oil Level 7-29
Change Engine Oil 7-30
Replace Engine Oil Filter 7-30
C Transmission 7-32
Pump Transmission 7-32
Swing Reduction Gear 7-33
Travel Reduction Gear 7-34
D Hydraulic System 7-36
Inspection and Maintenance of Hydraulic
Equipment 7-36
Breaker Maintenance 7-38
Check Hydraulic Oil Level 7-39
Change Hydraulic Oil 7-40
Suction Filter Cleaning 7-40
Replace Hydraulic Tank Oil Filter 7-43
Replace Pilot Oil Filter 7-45
Replace Air Breather Element 7-46
Check Hoses and Lines 7-47
Service Recommendations for Hydraulic Fittings 7-50
E Fuel System 7-52
Drain Fuel Tank Sump 7-54
Check Water Separator 7-55
Replace Fuel Main Filter Element 7-59
Replace Fuel Pre-Filter Element 7-60
Clean Fuel Solenoid Pump Strainer 7-61
Check Fuel Hoses 7-62
F Air Cleaner 7-63
Clean the Air Cleaner Outer Element 7-63
Replace the Air Cleaner Outer and Inner Elements 7-63
G Cooling System 7-65
Check Coolant Level 7-67
Check and Adjust Fan Belt Tension 7-68
Change Coolant 7-69
Clean Radiator, Oil Cooler Core and Inter Cooler 7-70
Clean Oil Cooler, Radiator and Inter
Coller Front Screen 7-70
Clean Air Conditioner Condenser 7-70
Clean Fuel Oil Cooler 7-70
Clean Air Conditioner Front Screen (Opt) 7-70
H Electrical System 7-71
Replace Batteries 7-74
Replacing Fuses 7-75
I Miscellaneous 7-77
Check Bucket Teeth 7-77
Change Bucket 7-80
Adjust the Bucket Linkage (Backhoe) 7-81
Remove the Travel Levers 7-82
Check and Replace Seat Belt Check 7-82
Check Windshield Washer Fluid Level 7-83
Check Track Sag 7-84
Clean and Replace Air Conditioner Filter 7-86
Check the Air Conditioner 7-88
Clean Cab Floor 7-89
Retighten Cylinder Head Bolt 7-90
Inspect and Adjust Valve Clearance 7-90
Check Fuel Injection Timing 7-90
Measure Engine Compression Pressure 7-90
Check Starter and Alternator 7-90
Check Water Pump 7-90
Check Tightening Torque of Bolts and Nuts 7-91
HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT
Hydraulic Circuit 8-1
Electrical Circuit 8-2
Electrical Diagram 8-3
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 (ZAXIS400R-3, ZAXIS400LCH-3) 12-1
Working Ranges (ZAXIS400R-3, ZAXIS400LCH-3) 12-2
Bucket Types and Applications
(ZAXIS400R-3, ZAXIS400LCH-3) 12-3
Sound Level Results (2000/14/EC) 12-4
Vibration Level 12-4
OPTIONAL ATTACHMENTS AND DEVICES
Lifting Capacities 13-1
INDEX 14-1

• Hitachi ZX400R-3 400LCH-3 Hydraulic Excavator Technical Operational Principle Manual

SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)

HITACHI ZX400R-3 400LCH-3 HYDRAULIC EXCAVATOR OPERATIONAL PRINCIPLE+TROUBLESHOOTING+PARTS+ OPERATOR’S MANUAL – PDF DOWNLOAD:

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