Hitachi ZAXIS 75US-A Excavator operator’s manual SN: 040001 and up

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  This is the most complete Operation and Maintenance Manual for the HITACHI ZAXIS 75US-A EXCAVATOR . Operation and Maintenance Manual can come in handy especially when you have to do immediate repair to your HITACHI ZAXIS 75US-A EXCAVATOR .Operation and Maintenance Manual comes with comprehensive details regarding technical data. Diagrams a complete list of HITACHI ZAXIS 75US-A EXCAVATOR parts and is a must for the will not be dissatisfied. Operation Manual Covers: Machine Numbers Safety Safety Signs Components Name Operator’s Station Break-In Operating the Engine Driving the Machine Operating the Machine Transporting Maintenance Maintenance under Special Environmental Conditions Storage Troubleshooting Specifications Optional Attachments and Devices Index File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader All pages are run off what you need & take it with you into the garage or save money $$ By doing your own repairs!These manuals make it easy for any skill level with these very easy to by step instructions! Looking for some other Operation and Maintenance Manual, Please see the below link: https://www.aservicemanualpdf.com/
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  • 1. INTRODUCTION ©2002 Hitachi Construction Machinery Co., Ltd. All rights reserved. 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 standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: 20 C to 40 C ( 4 F to 104 F) Altitude: 0 m to 2000 m (0 ft to 6600 ft) In case the machine is used under conditions other than described above, consult your nearest Hitachi dealer. 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. 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. This Operator’s Manual only applies to machines for export to Asian and Oceanian countries. Prior to operating this machine 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 standards (including safety standards) and requirements of that particular country. Please do not 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. All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. ZAXIS75US-A
  • 2. MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request. MACHINE MODEL/TYPE: PRODUCT IDENTIFICATION NUMBER: PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER: NOTE: 1CDP060001 PRODUCT IDENTIFICATION NUMBER (PIN) ENGINE TYPE: MFG. NO.: TRAVEL MOTOR TYPE: MFG. NO.: M1CD-01-002 M1CD-01-003 M1CD-01-004 M1CD-01-005 Marks to indicate the start and end of the PIN
  • 3. MACHINE NUMBERS SWING MOTOR TYPE: MFG. NO.: HYDRAULIC PUMP TYPE: MFG. NO.: M1CD-07-004 M1CD-07-013
  • 4. CONTENTS MACHINE NUMBERS 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 Fasten Your Seat Belt .........................................S-6 Move and Operate Machine Safely.....................S-6 Operate Only from Operator’s Seat ....................S-7 Jump Starting ......................................................S-7 Keep Riders Off Machine....................................S-7 Investigate Job Site Beforehand .........................S-8 Protect Against Falling Stones and Debris..........S-8 Provide Signals for Jobs Involving Multiple Numbers of Machines ...................................S-9 Confirm Direction of Machine to be Driven .........S-9 Drive Machine Safely.........................................S-10 Avoid Injury from Rollaway Accidents ...............S-11 Avoid Injury from Back-Over and Swing Accidents...................................S-12 Keep Personnel Clear from Working Area........S-13 Never Position Bucket Over Anyone.................S-13 Avoid Undercutting............................................S-13 Avoid Tipping.....................................................S-14 Never Undercut a High Bank.............................S-14 Dig with Caution ................................................S-15 Operate with Caution.........................................S-15 Avoid Power Lines.............................................S-15 Object Handling.................................................S-16 Protect Against Flying Debris ............................S-16 Park Machine Safely .........................................S-17 Handle Fluids Safely Avoid Fires....................S-17 Safety Transporting...........................................S-18 Practice Safe Maintenance ...............................S-19 Warn Others of Service Work...........................S-20 Support Machine Properly.................................S-20 Stay Clear of Moving Parts................................S-20 Prevent Parts from Flying ................................S-21 Store Attachments Safely..................................S-21 Prevent Burns....................................................S-22 Replace Rubber Hoses Periodically..................S-22 Avoid High-Pressure Fluids...............................S-23 Prevent Fires.....................................................S-24 Evacuating in Case of Fire ................................S-25 Beware of Exhaust Fumes ................................S-25 Precautions for Welding and Grinding ..............S-26 Avoid Heating Near Pressurized Fluid Lines.....S-27 Avoid Applying Heat to Lines Containing Flammable Fluids........................................S-27 Remove Paint Before Welding or Heating........ S-27 Prevent Battery Explosions............................... S-28 Service Air Conditioning System Safely............ S-28 Handle Chemical Products Safely .................... S-29 Dispose of Waste Properly............................... S-29 SAFETY SIGNS...................................S-31 COMPONENTS NAME..........................1-1 OPERATOR’S STATION Cab Features .......................................................1-2 Monitor Panel.......................................................1-3 Coolant Temperature Gauge .......................1-4 Fuel Gauge ..................................................1-4 Auto-Idle Indicator..........................................1-4 Fuel Level Indicator .......................................1-4 Air Filter Restriction Indicator ........................1-4 Overheat Indicator .........................................1-5 Engine Oil Pressure Indicator........................1-5 Alternator Indicator ........................................1-5 Preheat Indicator ...........................................1-5 Hydraulic Oil Filter Restriction Indicator (ZAXIS80LCK).........................................1-5 Liquid Crystal Display (LCD), Display Selection Switch, Set Switch ...................1-6 Hour Meter.....................................................1-6 Trip Meter (Trip Meter 1 and Trip Meter 2)....1-7 Trip Meter Function .......................................1-8 Switch Panel ....................................................1-10 Engine Control Dial......................................1-10 Auto-Idle Switch...........................................1-11 Power Mode Switch.....................................1-12 Travel Mode Switch .....................................1-12 Work Light Switch........................................1-13 Wiper/Washer Switch..................................1-14 Switch Panel (Optional) .....................................1-16 Key Switch .........................................................1-17 Horn Switch........................................................1-17 Ciger Lighter ......................................................1-18 Cab Light............................................................1-18 Installing Fire Extinguisher.................................1-19 Pilot Control Shut-Off Lever...............................1-20 Engine Stop Knob..............................................1-20 Fuse Box............................................................1-21 Air Conditioner Operation ................................1-22 Cab Heater Operation........................................1-27 Cooling Operation..............................................1-27 Defroster Operation ...........................................1-28 Tips for Optimal Air Conditioner Usage .............1-29 Cab Heater Operation (Optional).......................1-30 Cab Heater Operation........................................1-32 Defroster Operation ...........................................1-33 AM/FM Radio Operation ....................................1-34 Digital Clock Setting Procedure.........................1-35 Cab Door Release Lever ...................................1-36
  • 5. CONTENTS Opening Upper Front Window........................... 1-36 Closing Upper Front Window ............................ 1-37 Removing and Storing Lower Front Window..... 1-38 Opening Side Windows..................................... 1-39 Opening/Closing Overhead Window................. 1-40 Emergency Exit ................................................. 1-41 Adjust the Seat.................................................. 1-43 Adjusting the Seat --- If Equipped ..................... 1-44 Adjusting Console Height.................................. 1-46 Seat Belt............................................................ 1-47 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 ..................................... 3-4 Check Instruments After Starting ........................ 3-5 Using Booster Batteries....................................... 3-6 Stopping the Engine ............................................ 3-8 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 Traveling.............................................................. 4-5 Operating on Soft Ground ................................... 4-6 Raise One Track Using Boom and Arm.............. 4-6 Towing Machine a Short Distance....................... 4-7 Operating in Water or Mud.................................. 4-8 Precautions for Traveling on Slopes ................... 4-9 Parking the Machine on Slopes......................... 4-10 Parking the Machine.......................................... 4-10 OPERATING THE MACHINE Horn ................................................................ 5-1 Control Lever (ISO Pattern) ............................... 5-2 Control Lever (HITACHI Pattern) ...................... 5-3 Attachment Pedal (Breaker)................................ 5-4 Attachment Pedal (Hydraulic Crusher)................ 5-5 Pilot Control Shut-Off Lever ................................ 5-6 Engine Speed Control ......................................... 5-8 Auto-Idle.............................................................. 5-9 Power Mode ...................................................... 5-10 Precautions for Operation Using a Bucket........ 5-11 Precautions for Operations ............................... 5-12 Operate the Machine Safely.............................. 5-13 Operating Backhoe............................................ 5-14 Grading Operation............................................. 5-14 Face Shovel Operation ......................................5-15 Avoid Abusive Operation ...................................5-15 Operating Tips ...................................................5-16 Hydraulic Breaker and Hydraulic Crusher..........5-17 Pipings for Breaker and Crusher .......................5-18 Secondary Relief Pressure Adjustment.............5-19 Precautions for Breaker Operation ....................5-20 Breaker Maintenance.........................................5-23 Precautions for Crusher Operation....................5-24 Attachment.........................................................5-26 Attachment Connection Parts............................5-28 Object Handling --- If Equipped .........................5-29 Emergency Boom Lowering Procedure.............5-30 Shackle Hole Usage ..........................................5-31 Overnight Storage Instructions ..........................5-31 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 ............................7-9 Use Electrical Outlet ..........................................7-10 Maintenance Guide............................................7-11 A. Greasing ....................................................7-16 Front Joint Pins............................................7-16 Swing Bearing..............................................7-18 Swing Internal Gear.....................................7-19 B. Engine..........................................................7-20 Engine Oil Level...........................................7-20 Change Engine Oil.......................................7-20 Replace Engine Oil Filter.............................7-20 C. Transmission .............................................7-22 Travel Reduction Gear ................................7-22 D. Hydraulic System.........................................7-24 Inspection and Maintenance of Hydraulic Equipment .........................7-24 Replacement of Hydraulic Oil and Filter ......7-26 Check Hydraulic Oil Level............................7-27 Drain Hydraulic Tank Sump.........................7-28 Change Hydraulic Oil...................................7-29 Suction Filter Cleaning.................................7-29 Replace Hydraulic Tank Oil Filter ................7-32 Replace Pilot Oil Filter .................................7-34 Replace Swing Drain Filter Element............7-35 Replace Air Breather Element.....................7-36
  • 6. CONTENTS Check Hoses and Lines .............................. 7-37 Service Recommendations for Hydraulic Fittings................................... 7-40 E. Fuel System ................................................ 7-42 Drain Fuel Tank Sump................................ 7-44 Check Water Separator .............................. 7-45 Replace Fuel Filter...................................... 7-46 Clean Feed Pump Strainer.......................... 7-48 Check Fuel Hoses....................................... 7-49 F. Air Cleaner .................................................. 7-50 Clean the Air Cleaner Element.................... 7-50 G. Cooling System ........................................... 7-52 Check Coolant Level................................... 7-53 Check and Adjust Fan Belt Tension............ 7-53 Change Coolant .......................................... 7-54 Clean Radiator Interior ................................ 7-54 Clean Radiator and Oil Cooler Core ........... 7-55 Clean Oil Cooler Front Screen.................... 7-55 Clean Air Conditioner Condenser ............... 7-55 H. Electrical System......................................... 7-56 Batteries ...................................................... 7-56 Replace Batteries........................................ 7-60 Replacing Fuses ......................................... 7-61 I. Miscellaneous ............................................. 7-62 Check Bucket Teeth.................................... 7-62 Change Bucket............................................ 7-64 Convert Bucket Connection Into Face Shovel .......................................... 7-65 Adjust the Bucket Linkage .......................... 7-66 Remove the Travel Levers.......................... 7-67 Check and Replace Seat Belt ................... 7-67 Check Windshield Washer Fluid Level ....... 7-67 Check Track Sag ........................................ 7-68 Adjust Track Sag......................................... 7-68 Loosen the Track ........................................ 7-69 Tighten the Track ........................................ 7-69 Clean and Replace Air Conditioner Filter.... 7-70 Replace Filter.............................................. 7-70 Check the Air Conditioner ........................... 7-72 Clean Cab Floor .......................................... 7-74 Check Injection Nozzle................................ 7-75 Retighten Cylinder Head Bolt...................... 7-75 Inspect and Adjust Valve Clearance ........... 7-75 Check Fuel Injection Timing........................ 7-75 Check Starter and Alternator....................... 7-75 Change Water Pump Grease ..................... 7-75 Measure Engine Compression Pressure................................................ 7-75 Check Tightening Torque of Bolts and Nuts................................................ 7-76 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 Engine ...............................................................11-1 Electrical System ...............................................11-6 Mode Selection ..
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