Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Operator’s Manual (EM1JK-1-1) – PDF Download

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Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Operator’s Manual (EM1JK-1-1)

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Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Operator’s Manual (EM1JK-1-1)

• Manual Language:English
• Pages: 331 
• Size: 9.37 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZX400R-3 ZX400LCH-3 HYDRAULIC EXCAVATOR TECHNICAL OPERATOR’S MANUAL (EM1JK-1-1) – PDF DOWNLOAD:

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Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Operator’s Manual (EM1JK-1-1)

• Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage.
• 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.
• 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, including satellite communication system, 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.

Table Of Contents:

Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Operator’s Manual (EM1JK-1-1)

EM1JK-1-1............................................................................  1
	INTRODUCTION.....................................................................  2
	MACHINE NUMBERS..................................................................  3
	CONTENTS.........................................................................  7
	SAFETY........................................................................... 11
		RECOGNIZE SAFETY INFORMATION................................................. 11
		UNDERSTAND SIGNAL WORDS...................................................... 11
		FOLLOW SAFETY INSTRUCTIONS................................................... 12
		PREPARE FOR EMERGENCIES...................................................... 12
		WEAR PROTECTIVE CLOTHING..................................................... 13
		PROTECT AGAINST NOISE........................................................ 13
		INSPECT MACHINE.............................................................. 13
		GENERAL PRECAUTIONS FOR CAB.................................................. 14
		USE HANDHOLDS AND STEPS...................................................... 15
		ADJUST THE OPERATOR'S SEAT................................................... 15
		ENSURE SAFETY BEFORE RISING FROM OR LEAVING
OPERATOR’S SEAT................. 15
		FASTEN YOUR SEAT BELT........................................................ 16
		MOVE AND OPERATE MACHINE SAFELY.............................................. 16
		HANDLE STARTING AIDS SAFELY.................................................. 16
		OPERATE ONLY FROM OPERATOR'S SEAT............................................ 17
		JUMP STARTING................................................................ 17
		KEEP RIDERS OFF MACHINE...................................................... 17
		PRECAUTIONS FOR OPERATIONS................................................... 18
		INVESTIGATE JOB SITE BEFOREHAND.............................................. 19
		EQUIPMENT OF HEAD GUARD, ROPS, FOPS.......................................... 20
		PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE
NUMBERS OF MACHINES............. 20
		CONFIRM DIRECTION OF MACHINE TO BE DRIVEN.................................... 20
		DRIVE MACHINE SAFELY......................................................... 21
		AVOID INJURY FROM ROLLAWAY ACCIDENTS......................................... 23
		AVOID INJURY FROM BACK-OVER AND SWING
ACCIDENTS............................. 24
		KEEP PERSON CLEAR FROM WORKING AREA.......................................... 25
		NEVER POSITION BUCKET OVER ANYONE............................................ 25
		AVOID UNDERCUTTING........................................................... 25
		AVOID TIPPING................................................................ 26
		NEVER UNDERCUT A HIGH BANK................................................... 26
		DIG WITH CAUTION............................................................. 27
		OPERATE WITH CAUTION......................................................... 27
		AVOID POWER LINES............................................................ 28
		PRECAUTIONS FOR LIGHTENING................................................... 28
		OBJECT HANDLING.............................................................. 28
		PROTECT AGAINST FLYING DEBRIS................................................ 29
		PARK MACHINE SAFELY.......................................................... 29
		HANDLE FLUIDS SAFELY.AVOID FIRES............................................. 29
		TRANSPORT SAFELY............................................................. 30
		PRACTICE SAFE MAINTENANCE.................................................... 31
		WARN OTHERS OF SERVICE WORK.................................................. 32
		SUPPORT MACHINE PROPERLY..................................................... 32
		STAY CLEAR OF MOVING PARTS................................................... 32
		PREVENT PARTS FROM FLYING.................................................... 33
		STORE ATTACHMENTS SAFELY..................................................... 33
		PREVENT BURNS................................................................ 34
		REPLACE RUBBER HOSES PERIODICALLY............................................ 34
		AVOID HIGH-PRESSURE FLUIDS................................................... 35
		PREVENT FIRES................................................................ 36
		EVACUATING IN CASE OF FIRE................................................... 37
		BEWARE OF EXHAUST FUMES...................................................... 37
		PRECAUTIONS FOR WELDING AND GRINDING......................................... 37
		AVOID HEATING NEAR PRESSURIZED FLUID LINES................................... 38
		AVOID APPLYING HEAT TO LINES CONTAINING
FLAMMABLE FLUIDS.................... 38
		REMOVE PAINT BEFORE WELDING OR HEATING....................................... 38
		BEWARE OF ASBESTOS DUST...................................................... 39
		PREVENT BATTERY EXPLOSIONS................................................... 39
		SERVICE AIR CONDITIONING SYSTEM SAFELY....................................... 39
		HANDLE CHEMICAL PRODUCTS SAFELY.............................................. 40
		DISPOSE OF WASTE PROPERLY.................................................... 40
	SAFETY SIGNS/Oceania Model Only.................................................. 41
	SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only......................... 47
	COMPONENTS NAME.................................................................. 55
		COMPONENTS NAME.............................................................. 55
	OPERATOR'S STATION............................................................... 56
		CAB FEATURES................................................................. 56
		CAB FEATURES
(Only Machines Equipped with Optional Attachments)............. 57
		MULTI FUNCTION MONITOR....................................................... 58
		OUTLINE...................................................................... 59
		ALARM OCCURRENCE SCREEN...................................................... 70
		CONTENTS OF ALARMS........................................................... 72
		ATTACHMENT SELECTION
(Only Machines Equipped with Optional Parts)........... 75
		PUMP 2 FLOW RATE ADJUSTMENT
(Only Machines Equipped with Optional Parts).... 79
		DISPLAYING OPERATING CONDITIONS.............................................. 80
		FUEL RATE DISPLAY/NO DISPLAY................................................. 81
		BACK MONITOR SETTINGS........................................................ 89
		MAINTENANCE SETTINGS......................................................... 91
		Mail
(Optional)............................................................. 96
		LANGUAGE SETTINGS............................................................ 98
		SWITCH PANEL.................................................................100
		ENGINE CONTROL DIAL..........................................................101
		AUTO-IDLE SWITCH.............................................................101
		POWER MODE SWITCH............................................................102
		TRAVEL MODE SWITCH...........................................................102
		WORK LIGHT SWITCH............................................................103
		WIPER/WASHER SWITCH..........................................................104
		SWITCH PANEL (Optional)......................................................106
		KEY SWITCH...................................................................108
		POWER BOOST SWITCH...........................................................108
		HORN SWITCH..................................................................108
		CIGAR LIGHTER................................................................109
		CAB LIGHT....................................................................110
		INSTALLING FIRE EXTINGUISHER (Optional)......................................110
		PILOT CONTROL SHUT-OFF LEVER.................................................111
		ENGINE STOP SWITCH...........................................................111
		FUSE BOX.....................................................................112
		ADDITIONAL FUSE BOX..........................................................112
		AUTO AIR CONDITIONER.........................................................113
		CAB HEATER OPERATION.........................................................116
		COOLING OPERATION............................................................117
		DEFROSTER OPERATION..........................................................117
		TIPS FOR OPTIMAL AIR CONDITIONER USAGE.......................................119
		CAB HEATER (Optional)........................................................120
		CAB HEATER OPERATION.........................................................121
		DEFROSTER OPERATION..........................................................122
		AM/FM RADIO OPERATION........................................................123
		DIGITAL CLOCK SETTING PROCEDURE..............................................124
		CAB DOOR RELEASE LEVER.......................................................125
		OPENING UPPER FRONT WINDOW (Optional)........................................125
		CLOSING UPPER FRONT WINDOW (Optional)........................................126
		REMOVING AND STORING LOWER FRONT
WINDOW (Optional)..........................127
		OPENING SIDE WINDOWS.........................................................127
		OPENING/CLOSING OVERHEAD WINDOW
(Optional)..................................128
		OPENING/CLOSING OVERHEAD WINDOW
(Clear Hatch: Optional).....................128
		EMERGENCY EXIT...............................................................129
		EMERGENCY EXIT (Optional)....................................................130
		ADJUSTING THE MECHANICAL SUSPENSION SEAT.....................................131
		SEAT WITH A BUILT-IN HEATER..................................................132
		ADJUSTING THE AIR-SUSPENSION SEAT
(Optional)................................133
		SEAT WITH A BUILT-IN HEATER..................................................134
		ADJUSTING THE FIXED SEAT (Optional)..........................................135
		ADJUSTING CONSOLE HEIGHT.....................................................137
		SEAT BELT....................................................................138
	BREAK-IN.........................................................................139
		OBSERVE ENGINE OPERATION CLOSELY.............................................139
		EVERY 8 HOURS OR DAILY.......................................................139
		AFTER THE FIRST 50 HOURS.....................................................139
		AFTER THE FIRST 100 HOURS....................................................139
	OPERATING THE ENGINE.............................................................141
		INSPECT MACHINE DAILY BEFORE STARTING........................................141
		BEFORE STARTING ENGINE.......................................................142
		STARTING THE ENGINE IN ORDINARY TEMPERATURE..................................143
		STARTING IN COLD WEATHER.....................................................145
		CHECK INSTRUMENTS AFTER STARTING.............................................147
		USING BOOSTER BATTERIES......................................................148
		STOPPING THE ENGINE..........................................................150
	DRIVING THE MACHINE..............................................................151
		DRIVE THE MACHINE CAREFULLY..................................................151
		STEERING THE MACHINE USING PEDALS............................................152
		STEERING THE MACHINE USING LEVERS............................................153
		TRAVEL MODE SWITCH...........................................................154
		TRAVEL ALARM (Optional)......................................................154
		OPERATING ON SOFT GROUND.....................................................155
		RAISE ONE TRACK USING BOOM AND ARM...........................................155
		TOWING MACHINE A SHORT DISTANCE..............................................156
		OPERATING IN WATER OR MUD....................................................157
		PARKING THE MACHINE ON SLOPES................................................158
		PARKING THE MACHINE..........................................................158
	OPERATING THE MACHINE............................................................159
		CONTROL LEVER (ISO PATTERN)..................................................159
		CONTROL LEVER (HITACHI PATTERN) (OPTIONAL)...................................160
		ATTACHMENT PEDAL (HYDRAULIC BREAKER)
(OPTIONAL).............................161
		ATTACHMENT PEDAL (ACCELERATOR TYPE)..........................................162
		ATTACHMENT PEDAL (COMMON USE TYPE) IN
THE UNLOCK POSITION...................163
		ATTACHMENT PEDAL (HYDRAULIC CRUSHER).........................................164
		PILOT CONTROL SHUT-OFF LEVER.................................................165
		ENGINE SPEED CONTROL.........................................................167
		AUTO-IDLE....................................................................168
		WORK MODE....................................................................169
		WORK MODE SELECT.............................................................170
		POWER BOOST..................................................................171
		POWER MODE...................................................................172
		OPERATING BACKHOE............................................................173
		GRADING OPERATION............................................................173
		AVOID ABUSIVE OPERATION......................................................174
		OPERATING TIPS...............................................................175
		SELECT CORRECT TRACK SHOES...................................................175
		HYDRAULIC BREAKER AND HYDRAULIC CRUSHER......................................176
		PIPINGS FOR BREAKER AND CRUSHER..............................................177
		SECONDARY RELIEF PRESSURE ADJUSTMENT.........................................178
		PRECAUTIONS FOR BREAKER OPERATION............................................179
		BREAKER MAINTENANCE..........................................................182
		PRECAUTIONS FOR CRUSHER OPERATION............................................184
		ATTACHMENT...................................................................186
		ATTACHMENT CONNECTION PARTS..................................................190
		PRECAUTION FOR ARM ROLL-IN/BUCKET ROLL-IN
COMBINED OPERATION................191
		WHEN INSTALLING AN ATTACHMENT LONGER
THAN STANDARD BUCKET...................191
		SHACKLE HOLE USAGE...........................................................192
		OVERNIGHT STORAGE INSTRUCTIONS...............................................192
		EMERGENCY BOOM LOWERING PROCEDURE
(Without hose-rupture safety valve).......193
		OBJECT HANDLING --- IF EQUIPPED..............................................194
		OBJECT HANDLING --- IF EQUIPPED..............................................195
	TRANSPORTING.....................................................................197
		TRANSPORTING BY ROAD.........................................................197
		LOADING/UNLOADING ON A TRAILER...............................................197
		MACHINE LIFTING PROCEDURE....................................................201
	MAINTENANCE......................................................................203
		CORRECT MAINTENANCE AND INSPECTION
PROCEDURES...............................203
		CHECK THE HOUR METER REGULARLY...............................................204
		USE CORRECT FUELS AND LUBRICANTS.............................................204
		LAYOUT.......................................................................205
		MAINTENANCE GUIDE TABLE......................................................206
		PREPARE MACHINE FOR MAINTENANCE..............................................208
		HOOD AND ACCESS COVERS.......................................................209
		PERIODIC REPLACEMENT OF PARTS................................................210
		MAINTENANCE GUIDE............................................................211
		A. GREASING..................................................................216
			ELECTRIC GREASE GUN......................................................223
		B. ENGINE....................................................................231
		C. TRANSMISSION..............................................................234
		D. HYDRAULIC SYSTEM..........................................................238
			INSPECTION AND MAINTENANCE OF HYDRAULIC
EQUIPMENT.......................238
			BREAKER MAINTENANCE......................................................240
			SERVICE RECOMMENDATIONS FOR HYDRAULIC
FITTINGS..........................252
		E. FUEL SYSTEM...............................................................254
		F. AIR CLEANER...............................................................265
		G. COOLING SYSTEM............................................................267
		H. ELECTRICAL SYSTEM.........................................................273
			REPLACE BATTERIES........................................................276
			FUSE BOX.................................................................277
			ADDITIONAL FUSE BOX......................................................277
		I. MISCELLANEOUS.............................................................279
	HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT.........................................303
		HYDRAULIC CIRCUIT............................................................303
		ELECTRICAL CIRCUIT...........................................................304
	MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS...............................307
		MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS...........................307
	STORAGE..........................................................................309
		STORING THE MACHINE..........................................................309
		REMOVING THE MACHINE FROM STORAGE............................................310
	TROUBLESHOOTING..................................................................311
		IMPOSSIBLE TO START THE ENGINE...............................................311
		ENGINE.......................................................................312
		ELECTRICAL SYSTEM............................................................316
		MODE SELECTION...............................................................318
		CONTROL LEVERS...............................................................319
		HYDRAULIC SYSTEM.............................................................319
	SPECIFICATIONS...................................................................323
		SPECIFICATIONS...............................................................323
		WORKING RANGES...............................................................324
		BUCKET TYPES AND APPLICATIONS................................................325
		SOUND LEVEL RESULTS
(2000/14/EC)............................................326
		VIBRATION LEVEL..............................................................326
	OPTIONAL ATTACHMENTS AND DEVICES.................................................327
		LIFTING CAPACITIES...........................................................327
		LIFTING CAPACITIES...........................................................328
	INDEX............................................................................329

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
•  The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
•  Any queries / doubts regarding your purchase, please feel free to contact [email protected]