Table of Contents
Related Manuals for Hitachi ZW 100-G
Summary of Contents for Hitachi ZW 100-G
- Page 3 E-mail: [email protected] ADDITIONAL REFERENCES • Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual. MANUAL COMPOSITION • • Information included in the Workshop Manual: This manual consists the Technical Manual and the Workshop Manual.
- Page 4 INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS • In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the Indicated potentially hazardous situation which potential for personal injury of machine damage. could, if not avoided, result in personal injury or death.
- Page 5 SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in operator`s manual, be alert to the potential for personal injury. • Follow recommended precautions and safe oper- ating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS...
- Page 6 Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to...
- Page 7 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. SA-438 Be sure to wear the correct equipment and clothing for the job.
- Page 8 SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
- Page 9 SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds.
- Page 10 SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Addi- tionally the operator may be crushed by the over- turning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly ex- amine webbing, buckle and attaching hardware.
- Page 11 SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in seri- ous injury or death. • Start the engine only when seated in the opera- tor's seat. • NEVER start the engine while standing on the track or on ground.
- Page 12 SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground condi- tions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
- Page 13 SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the poten- tial hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure...
- Page 14 SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as be- ing struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
- Page 15 SAFETY DRIVE SAFELY WITH BUCKET LOADED • If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions in- dicated below. • When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.
- Page 16 SAFETY AVOID INJURY FROM ROLLAWAY ACCI- DENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park ma- chine. • Do not park the machine on a grade. •...
- Page 17 SAFETY AVOID ACCIDENTS FROM BACKING UP AND TURNING • Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine. •...
- Page 18 SAFETY AVOID POSITIONING BUCKET OVER ANYONE • Never allow the bucket to pass over co-workers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine. •...
- Page 19 SAFETY NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death. 026-E01A-0519 SA-519 DIG WITH CAUTION Before digging, check the location of cables, gas lines, and water lines. 027-E01A-0396 SA-396 PERFORM TRUCK LOADING SAFELY •...
- Page 20 SAFETY AVOID POWER LINES Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. 29-E01A-0455 SA-455 PRECAUTIONS FOR OPERATION...
- Page 21 SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object.
- Page 22 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. Keep children and bystanders away from storage areas. 504-E01A-0034 SA-034 TRANSPORT SAFELY •...
- Page 23 SAFETY HANDLE FLUIDS SAFELY-AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possi- bly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks.
- Page 24 SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.
- Page 25 SAFETY • Sufficiently illuminate the work site. Use a main- tenance 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, anti- freeze fluid, or window washer fluid may catch fire.
- Page 26 SAFETY SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death. • Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service.
- Page 27 SAFETY 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. •...
- Page 28 SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing se- rious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. •...
- Page 29 SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
- Page 30 SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the fol- lowing way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. •...
- Page 31 SAFETY 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.
- Page 32 Keep bystanders out of the work site during op- SA-029 eration. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.
- Page 33 DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the en- vironment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
- Page 34 SAFETY BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced. S517-E01A-0435 SA-435 SA-30...
- Page 35 The right is Group 5 Propeller Shaft reserved to make changes at any time without notice. Group 6 Tire SECTION 4 ATTACHMENT Group 1 Front Attachment Group 2 Cylinder COPYRIGHT(C)2010 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...
- Page 36 TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specification Group 1 Pump Device Group 2 Component Layout Group 2 Control Valve Group 3 Component Specifications Group 3 Priority Valve SECTION 2 SYSTEM Group 4 Steering Valve Group 1 Controller Group 5 HST Motor Group 2 Control System...
- Page 37 SECTION 1 GENERAL ⎯ CONTENTS ⎯ Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ..........W1-1-1 Group 2 Tightening Tightening Bolts and Nuts......W1-2-1 Piping Joint..........W1-2-8 Group 3 Painting Painting ........... W1-3-1 Group 4 Bleeding Air from Hydraulic Circuit Bleeding Air from Hydraulic Oil Tank..
- Page 38 (Blank) 4FKW-1-2...
- Page 39 GENERAL / Precautions for Dissembling and Assembling PRECAUTIONS DISASSEMBLING • Store common parts, such as bolts and nuts with AND ASSEMBLING reference to where they are to be used and in a manner that will prevent loss. • Precautions for Disassembling Inspect the contact or sliding surfaces of •...
- Page 40 GENERAL / Precautions for Dissembling and Assembling Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures: • Keep seal rings together as a matched set with seal ring (1) surfaces together.
- Page 41 GENERAL / Precautions for Dissembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners.
- Page 42 GENERAL / Precautions for Dissembling and Assembling Damaged Appearance CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the a-Broken Sewing Thread W162-01-01-002 nylon sling for any damage corresponding to...
- Page 43 GENERAL / Precautions for Dissembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary. “Allowable Limit” 1. Normal machine performance cannot...
- Page 44 GENERAL / Precautions for Dissembling and Assembling (Blank) W1-1-6...
- Page 45 GENERAL / Tightening TIGHTENING BOLTS AND NUTS CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure.
- Page 46 GENERAL / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. • Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it) •...
- Page 47 GENERAL / Tightening Precautions for Spilt Flange IMPORTANT: • Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring. • Use only specified O-rings. Inspect O-rings for any damage.
- Page 48 GENERAL / Tightening PIPING JOINT IMPORTANT: The torque given in table below are for general use only, however, a different torque is given for a specific application. specified torque. Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil.
- Page 49 GENERAL / Tightening Piping Joint Pipe connection (metal joint) (Union Nut Wrench size 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil. • Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.
- Page 50 GENERAL / Tightening Quick Coupler 1. Coupling procedure • Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you. • Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2).
- Page 51 GENERAL / Tightening Screw-In Connection 30° Depending on types of screw and sealing, different types of screw-in connection are used. IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any a - Male Tapered Thresd b - Male Straight Thread screw-in connection.
- Page 52 CAUTION: When replacing the hoses, use Incorrect Correct only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked.
- Page 53 GENERAL / Painting PAINTING M4FJ-01-001 Surfaces to Be Painted Painting Color Surfaces to Be Painted Painting Color 1 Front Attachment YR-01[TAXI Yellow] 12 Rear Grill Not painted 2 Front Fender YR-01[TAXI Yellow] 13 Side Cover HG Beige Deep 3 Lamp Bracket Warm Gray 14 Counter weight YR-01[TAXI Yellow]...
- Page 54 GENERAL / Painting M4FJ-01-002 Surfaces to Be Painted Painting Color Surfaces to Be Painted Painting Color 1 Front Attachment YR-01[TAXI Yellow] 12 Rear Grill Not painted 2 Front Fender YR-01[TAXI Yellow] 13 Side Cover HG Beige Deep 3 Lamp Bracket Warm Gray 14 Counter weight YR-01[TAXI Yellow]...
- Page 55 GENERAL / Bleeding Air from Hydraulic Circuit BLEEDING AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before disconnecting hydraulic piping removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns.
- Page 56 GENERAL / Bleeding Air from Hydraulic Circuit BLEED FROM HYDRAULIC SYSTEM Bleed air from the hydraulic system as follows when hydraulic oil has been drawn, the suction filter and suction pipe have been replaced, or the pump device, cylinders have been removed/ installed. INPORTANT: If air is accumulated inside of the INPORTANT: If air is accumulated inside of the pump and if the engine starts in...
- Page 57 GENERAL / Hydraulic Circuit Pressure Release Procedure HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE Release the remaining pressure in hydraulic circuit as follows when front attachment etc. have been removed / installed. 1. Set front control lever lock (1) to the UN LOCK position.
- Page 58 GENERAL / Hydraulic Circuit Pressure Release Procedure (Blank) W1-5-2...
- Page 59 GENERAL / Preparation PREPARATIONS FOR INSPECTION AND MAINTENANCE CAUTION: If ride control switch (1) is kept ON, the lift arm may unexpectedly rise. To Lock avoid accident unexpected movement of the lift arm, always turn ride control switch (1) OFF before beginning the UnLock inspection and/or...
- Page 60 GENERAL / Preparation Lock Frames CAUTION: Before beginning to work near the front rear frames (4), (5), install articulation lock bar (3) to securely lock and prohibit movement between the front and rear frames (4), (5). Avoid accidents due to unexpected movement of the machine.