Hitachi 160LC-3 User manual

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INTRODUCTION

IN-01

TO THE READER



x 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.

(Note: Do not tear off the form. Copy it for us-

age.):

Publications Marketing & Product Support

Hitachi Construction Machinery Co. Ltd.

TEL: 81-298-32-7173

FAX: 81-298-31-1162

ADDITIONAL REFERENCES



x Please refer to the materials listed below in addition

to this manual.

• The Operator’s Manual

• The Parts Catalog

• Operation Manual of the Engine

• Parts Catalog of the Engine

• Hitachi Training Material

MANUAL COMPOSITION



x This manual consists of three portions: the Techni-

cal Manual (Operational Principle), the Technical

Manual (Troubleshooting) and the Workshop Man-

ual.

• 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 per-

formance 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 assem-

ble/disassemble procedures.

PAGE NUMBER

x Each page has a number, located on the center

lower part of the page, and each number contains

the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number

Section Number

T: Technical Manual W: Workshop Manual

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INTRODUCTION

IN-02

SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS

In this manual, the following safety alert symbol and

signal words are used to alert the reader to the

potential for personal injury of machine damage.

This is the safety alert symbol. When you see this

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed

along with the safety alert symbol.

The safety alert symbol is also used to draw attention

to component/part weights.

To avoid injury and damage, be sure to use appropri-

ate lifting techniques and equipment when lifting heavy

parts.

x CAUTION:

Indicated potentially hazardous situation which could,

if not avoided, result in personal injury or death.

x IMPORTANT:

Indicates a situation which, if not conformed to the

instructions, could result in damage to the machine.

x NOTE:

Indicates supplementary technical information or

know-how.



UNITS USED

x SI Units (International System of Units) are used in

this manual.

MKSA system units and English units are also

indicated in parenthheses just behind SI units.

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

A table for conversion from SI units to other system

units is shown below for reference purposees.

Quantity To Convert

From Into Multiply By

MPa kgf/cm210.197Pressure

MPa psi 145.0

kW PS 1.360Power

kW HP 1.341

Temperature qC qF qCu1.8+32

km/h mph 0.6214Velocity

min-1 rpm 1.0

Flow rate L/min US gpm 0.2642

mL/rev cc/rev 1.0

Quantity To Convert

From Into Multiply By

mm in 0.03937Length

mm ft 0.003281

L US gal 0.2642

L US qt 1.057

Volume

m3yd31.308

Weight kg lb 2.205

N kgf 0.10197Force

N lbf 0.2248

Nm kgfm 1.0197Torque

Nm lbfft 0.7375

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SAFETY

SA-1

RECOGNIZE SAFETY INFORMATION

x These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or

in this manual, be alert to the potential for per-

sonal injury.

• Follow recommended precautions and safe oper-

ating practices.

001-E01A-0001

SA-688

UNDERSTAND SIGNAL WORDS

x On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,

or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death

or serious injury.

• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor

or moderate injury.

• DANGER or WARNING safety signs are located

near specific hazards. General precautions are

listed on CAUTION safety signs.

• Some safety signs don't use any of the desig-

nated signal words above after the safety alert

symbol are occasionally used on this machine.

x To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indi-

cates a situation which, if not avoided, could result in

damage to the machine.

x NOTE indicates an additional explanation for an

element of information.

002-E01A-1223

SA-1223

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SAFETY

SA-2

FOLLOW SAFETY INSTRUCTIONS

x Carefully read and follow all safety signs on the

machine and all safety messages in this manual.

x Safety signs should be installed, maintained and

replaced when necessary.

• If a safety sign or this manual is damaged or

missing, order a replacement from your author-

ized dealer in the same way you order other re-

placement parts (be sure to state machine model

and serial number when ordering).

x Learn how to operate the machine and its controls

correctly and safely.

x Allow only trained, qualified, authorized personnel to

operate the machine.

x Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-

chine life.

• Do not modify any machine parts without au-

thorization. Failure to do so may deteriorate the

part safety, function, and/or service life. In addi-

tion, personal accident, machine trouble, and/or

damage to material caused by unauthorized

modifications will void 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

material caused by using unauthorized attach-

ments and/or optional parts or equipment will void

Hitachi Warranty Policy.

x The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of

machines. However it is impossible for these safety

messages to cover every hazardous situation you

may encounter. If you have any questions, you

should first consult your supervisor and/or your au-

thorized dealer before operating or performing

maintenance work on the machine.

003-E01B-0003

SA-003

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SAFETY

SA-3

PREPARE FOR EMERGENCIES

x Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-

tached on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always

used when necessary, check and service the

fire-extinguisher at the recommended intervals as

specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to

cope with fires and accidents.

• Keep emergency numbers for doctors, ambu-

lance service, hospital, and fire department

posted near your telephone.

004-E01A-0437

SA-437

WEAR PROTECTIVE CLOTHING

x 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.

Be sure to wear the correct equipment and clothing

for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other

parts of the machine.

x Operating equipment safely requires the full atten-

tion of the operator. Do not wear radio or music

headphones while operating the machine.

005-E01A-0438

SA-428

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SAFETY

SA-4

PROTECT AGAINST NOISE

x Prolonged exposure to loud noise can cause im-

pairment or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objec-

tionable or uncomfortably loud noises.

006-E01A-0434

SA-434

INSPECT MACHINE

x Inspect your machine carefully each day or shift by

walking around it before you start it to avoid per-

sonal injury.

• In the walk-around inspection be sure to cover all

points described in the "RE-START INSPEC-

TION" chapter in the operator's manual.

007-E01A-0435

SA-435

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SAFETY

SA-5

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.

• Do not leave parts and/or tools lying around the

operator's seat. Store them in their specified loca-

tions.

• Avoid storing transparent bottles in the cab. Do

not attach any transparent type window decora-

tions on the windowpanes as they may focus

sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab

while operating the machine.

• Keep all flammable objects and/or explosives

away from the machine.

• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.

• Do not leave cigarette lighters in the cab. When

the temperature in the cab increases, the lighter

may explode.

524-E01A-0000

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SAFETY

SA-6

USE HANDHOLDS AND STEPS

x 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.

• Never jump on or off the machine. Never mount or

dismount a moving machine.

• Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.

008-E01A-0439

SA-439

ADJUST THE OPERATOR'S SEAT

x A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator

leading to mis-operations.

• The seat should be adjusted whenever changing

the operator for the machine.

• The operator should be able to fully depress the

pedals and to correctly operate the control levers

with his back against the seat back.

• If not, move the seat forward or backward, and

check again.

• Adjust the rear view mirror position so that the

best rear visibility is obtained from the operator's

seat. If the mirror is broken, immediately replace it

with a new one.

009-E01A-0462

SA-462

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