All-Inclusive Factory Service Technical manual for Hitachi Wheel Excavators Models Zaxis 145W-3.

This manuals will assist you in diagnosing, repairing, troubleshooting, performing perfomance checks, repairing engine, maintaining, operating, and other for your wheel excavator.
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Covered Models:
   Zaxis 145W-3

The manual comprises 12 documents, including the Workshop Manual, Troubleshooting Manual, Perfomance Check and Troubleshooting Manual, Engine Technical Manual, Maintenance Manual, two Operational Principle Manuals, two Operators Manuals, two Wiring Diagrams, and Aditional Service Information

1. Workshop Manual (WCFA-E-00(20120323))
Format: PDF, 730 pages
Language: English
Table of Contents:
   GENERAL
      Precautions for Disassembling and Assembling
      Tightening
      Painting
      Bleeding Air from Hydraulic Oil Tank
   UPPERSTRUCTURE
      Cab
      Counterweight
      Main Frame
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Electric Lever
      Signal Control Valve
      Shockless Valve
      Solenoid Valve
      Pilot Shut-Off Solenoid Valve
      Steering Valve
      Brake Valve
      Accumulator Charge Valve
   UNDERCARRIAGE
      Swing Bearing
      Travel Motor
      Center Joint
      Transmission
      Axle
      Axle Lock Cylinder
      Operate Check Valve
      Suspension Cylinder
      Pilot Check Valve
      Solenoid Valve
      Transmission Changeover Solenoid Valve
      Propeller Shaft
   ATTACHMENT
      Front Attachment
      Cylinder
      Hose Rupture Valve
      Operate Check Valve

2. Troubleshooting Manual (TTCFA-E-00(20150213))
Format: PDF, 624 pages
Language: English
Table of Contents:
   OPERATIONALPERFORMANCE TEST
      Introduction
      Engine Test
      Excavator Test
      Component Test
   TROUBLESHOOTING
      Diagnosing Procedure
      Monitor Unit
      Dr. ZX
      ICF
      Troubleshooting A
      Troubleshooting B
      Electrical System Inspection

3. Perfomance Check and Troubleshooting Manual (TTLA0722)
Format: PDF, 583 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Excavator Test
      Componebt Test
   SCTION 5 TROUBLESHOOTING
      Diagnosing Procedure
      Monitor Unit
      Dr. ZX
      ICF
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Electrical System Inspection

4. 4JJ1 Engine Technical Manual (KM-4JJ1-E-01)
Format: PDF, 804 pages
Language: English
Table of Contents:
   4JJ1 Electronic Control Fuel Injection System (Common Rail Type)
      How to Use This Manual
      Precautions on Service Work
      Procedure of Trouble Diagnosis
      How to Inspect Injector
      How to Use Breaker Box
      Engine Control System
      List of Function Checks
      List of Diagnostic Trouble Codes
      List of Trouble Symptom
      Special Tool
   4JJ1 Engine Mechanical
      ISUZU Diesel Engine
      Engine Foot
      Cylinder Head Cover
      Intake Manifold
      Exhaust Manifold
      Timing Gear Train
      Camshaft
      Rocker Arm
      Valve Stem Seal, Valve Spring
      Cylinder Head
      Piston, Connecting Rod
      Flywheel
      Gear Case ASM
      Crankshaft Front Oil Seal
      Crankshaft Rear Oil Seal
      Crankshaft
      Cylinder Block
      Special Tool
   4JJ1 Cooling System
      Cooling System
      Water Pump
      Thermostat
      Drive Belt
      Fan Clutch, Cooling Fan
   4JJ1 Fuel System
      Fuel System
      Fuel Filter ASM
      Fuel Filter Element
      Fuel Injector
      Common Rail
      Fuel Supply Pump
      Strainer
      Suction Control Valve
      Electromagnetic Pump Filter
      Special Tool
   4JJ1 Electrical System
      Electrical System
      Charging System
      Generator (24V model)
      Generator (12V model)
      Starting System
      Starter (24V model)
      Starter (12V model)
   4JJ1 Exhaust System
      EGR System
      EGR Cooler
      Exhaust System
      Turbocharger
      Turbocharger Inlet Duct
   4JJ1 Lubrication System
      Lubrication System
      Oil Filter
      Oil Port Cover ASM
      Oil Cooler
      Oil Relief Valve
      Crankcase, Oil Pan
      Oil Pump
      Oil Pressure Switch
      Special Tool
   4JJ1 Preheating System
      Preheating System

5. Maintenance Manual (TTLA0735)
Format: PDF, 213 pages
Language: English
Table of Contents:
   MAINTENANCE
      Correct Maintenance and Inspection Procedures
      Check the Hour Meter Regularly
      Use Correct Fuels and Lubricants
      Layout
      Maintenance Guide Table
      Prepare Machine for Maintenance
      Hood and Access Covers
      Periodic Replacement of Parts
      Maintenance Guide
   HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT
      Hydraulic Circuit
      Electrical Circuit
      Electrical Diagram
   MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
      Maintenance Under Special Environmental Conditions
   STORAGE
      Storing the Machine
      Removing the Machine from Storage
   TROUBLESHOOTING
      Troubleshooting
   SPECIFICATIONS
      Specifications (ZAXIS140W-3) (Standard CHASSIS, REAR BLADE)
      Specifications (ZAXIS140W-3) (Standard CHASSIS, REAR OUTRIGGER)
      Specifications (ZAXIS140W-3) (FRONT BLADE REAR OUTRIGGER)
      Specifications (ZAXIS140W-3) (FRONT OUTRIGGER REAR BLADE)
      Specifications (ZAXIS140W-3) (FRONT OUTRIGGER REAR OUTRIGGER)
      Working Ranges ZAXIS140W-3 MONOBLOCK BOOM
      Working Ranges ZAXIS140W-3 2-PIECE BOOM
      Specifications (ZAXIS170W-3) (Standard GAUGE, Standard CHASSIS, REAR BLADE)
      Specifications (ZAXIS170W-3) (Standard GAUGE, Standard CHASSIS, REAR OUTRIGGER)
      Specifications (ZAXIS170W-3 (Standard GAUGE, FRONT BLADE REAR OUTRIGGER)
      Specifications (ZAXIS170W-3) (Standard GAUGE, FRONT OUTRIGGER REAR BLADE)
      Specifications (ZAXIS170W-3) (Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER)
      Working Ranges ZAXIS170W-3 MONOBLOCK BOOM
      Working Ranges ZAXIS170W-3 2-PIECE BOOM
      Specifications (ZAXIS190W-3 )(Standard CHASSIS, REAR BLADE)
      Specifications (ZAXIS190W-3) (Standard CHASSIS, REAR OUTRIGGER)
      Specifications (ZAXIS190W-3) (FRONT BLADE REAR OUTRIGGER)
      Specifications (ZAXIS190W-3) (FRONT OUTRIGGER REAR BLADE)
      Specifications (ZAXIS190W-3) (FRONT OUTRIGGER REAR OUTRIGGER)
      Working Ranges ZAXIS190W-3 MONOBLOCK BOOM
      Working Ranges ZAXIS190W-3 2-PIECE BOOM
      Specifications (ZAXIS210W-3) (Standard GAUGE, REAR BLADE)
      Specifications (ZAXIS210W-3) (Standard GAUGE, REAR OUTRIGGER)
      Specifications (ZAXIS210W-3) (Standard GAUGE, FRONT BLADE REAR OUTRIGGER)
      Specifications (ZAXIS210W-3) (Standard GAUGE, FRONT OUTRIGGER REAR BLADE)
      Specifications (ZAXIS210W-3) (Standard GAUGE, FRONT OUTRIGGER REAR OUTRIGGER)
      Working Ranges ZAXIS210W-3 MONOBLOCK BOOM
      Working Ranges ZAXIS210W-3 2-PIECE BOOM
      Sound Level Results (2000/14/EC)
   OPTIONAL ATTACHMENTS AND DEVICES
      Blade and Outrigger
      Maintenance
      2-Piece Boom
      Maintenance (2-piece Boom)
      Lifting Capacities (ZAXIS140W-3)
      Lifting Capacities (ZAXIS170W-3)
      Lifting Capacities (ZAXIS190W-3)
      Lifting Capacities (ZAXIS210W-3)

6. Operational Principle Manual (TTLA0721)
Format: PDF, 517 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Layout
      Component Specifications
   SYSTEM
      Controller
      Control System
      ECM System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Electric Lever
      Transmission
      Axle
      Travel Motor
      Signal Control Valve
      Steering Valve
      Brake Valve
      Others (Upperstructure)
      Others (Undercarriage)

7. Operational Principle Manual (TOCFA-E-00(20120323))
Format: PDF, 530 pages
Language: English
Table of Contents:
   Specifications
      Specifications
      Working Ranges
   Component Specifications
      Engine
      Engine Accessories
      Hydraulic Component
      Electrical Component
   Component Layout
      Main Component Layout
      Electrical System (Overview)
      Electrical System (Monitors and Switches)
      Electrical System (Controllers and Relays)
      Engine
      Pump Device
      Swing Device
      Signal Control Valve
      Control Valve
      Brake Valve
      Spool Solenoid Valve Unit
      Solenoid Valve Unit (For Electric Lover)
      Travel Shockless Valve
      TransmissionChangeover Solenoid Valve
      Travel Device
      Filter
   SYSTEM
      Controller
      Control System
      ECM System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Electric Lever
      Transmission
      Axle
      Travel Motor
   Signal Control Valve
      Outline
      Pilot Port
      Shuttle Valve
      Shockless Valve
      Pump 1 and Pump 2 Flow Rate Control Valves
      Bucket Flow Rate Control Valve Control Spool, Swing Parking Brake Release Spool
   Steering Valve
      Outline
      Steering Valve
      Operation
      Overload Relief Valve
      Make-Up Valve
      Priority Valve
      Operation
      Relief Valve
   Brake Valve
      Outline
      Operation
   Others (Upperstructure)
      Pilot Shut-Off Solenoid Valve
      Transmission Changeover Solenoid Valve
      Solenoid Valve
      Travel Shockless Valve
      Accumulator Charging Valve
      Hose Rupture Valve
      Accumulator
      Pilot Relief Valve
      Machine Height Control Valve(Optional)
   Others (Undercarriage)
      Swing Bearing
      Center Joint
      Slip Ring
      Cylinder
      Suspension Cylinder (Optional)
      Accumulator (Optional)

8. Operators Manual (TTLA0734)
Format: PDF, 161 pages
Language: English
Table of Contents:
   OPERATION
      COMPONENTS NAME
      Cab Features (Standard Model)
      Steering Column Console
      Steering Wheel and Travel Horn Switch
      Accelerator Pedal
      Brake Pedal
      Forward/Reverse Travel Switch
      Combination Switch(Turn Signal Switch, Light and Dimmer Switches)
      Brake Switch
      Hazard Switch
      Operator’s Station
      Key Switch
      Right/Left Control Levers
      Lever Switch
      Lighter
      Cab Light
      Installing Fire Extinguisher (Optional)
      Pilot Control Shut-off Lever
      Engine Stop Switch
      Multi Function Monitor
      Basic Screen
      Monitor Operation
      Displaying Basic Screen
      Trip Meter (7)
      Odometer (8)
      Hour Meter (9)
      Clock (18)
      Fuel Gauge (25)
      Coolant Temperature Gauge (30)
      Brake Oil Pressure Gauge (33)
      Travel Speed Meter (34)
      Tachometer (35)
      Back Monitor Screen Selector (22)
      Menu Key (23)
      Optional Function Keys (24, 27, 29 and 31)
      Return-basic Screen Key (32)
      Menu Screen
      Displaying Basic Screen by Inputting Password (Optional)
      Corrective Measures to be Taken when a Wrong Password is input
      Extending Password Validity Time
      Alarm Occurrence Screen
      Clock Setting
      Work Mode (Attachment Selection)
      Attachment Adjustment (Pump 2 Flow Rate Adjustment)
      Operating Status
      Maintenance Setting
      Mail (Optional)
      Meter Display Control
      Password Revising (Optional)
      Back Monitor Setting
      Language Setting
      Meter Combination Setting
      Unit Setting
      Fuse Box
      Additional Fuse Box
      Auto Air Conditioner Operation
      Tips for Optimal Air Conditioner Usage
      Heater (Optional) Operation
      Am/Fm Radio Operation
      Digital Clock Setting Procedure
      Cab Door Release Lever
      Opening Upper Front Window
      Closing Upper Front Window
      Removing and Storing Lower Front Window
      Opening Door Windows
      Opening/Closing Overhead Window (Std. Model)
      Opening/Closing Polycarbonate Type Roof Overhead Window (Clear Hatch: If Equipped)
      Emergency Exit
      Adjusting the Air-suspension Seat (Optional)
      Seat with a Built-in Heater
      Adjusting the Air-suspension Seat(Optional)
      Seat with a Built-in Heater
      Seat Belt
   BREAK-IN
      Observe Engine Operation Closely
      Every 8 Hours or Daily
      After the First 50 Hours
      After the First 100 Hours
   OPERATING THE ENGINE
      Inspect Machine Daily Before Starting
      Before Starting Engine
      Starting the Engine in Ordinary Temperature
      Starting in Cold Weather
      Check Instruments After Starting
      Using Booster Batteries
      Stopping the Engine
   DRIVING THE MACHINE
      Traveling
      Engine Speed Control
      Travel Mode Switch
      Stopping and Restarting
      Instructions for Traveling on a Slope
      Parking
      Emergency Parking Due to Machine Failure
      Travel Alarm (Optional)
   OPERATING THE MACHINE
      Control Lever (ISO Pattern) (Standard)
      Control Lever (Hitachi Pattern)
      Pilot Control Shut-off Lever
      Steering Wheel Column
      Warming-up Operation
      Engine Speed Control
      Auto-idle
      Work Mode
      Power Digging (Only ZAXIS210W-3)
      Power Mode
      Parking/Stopping the Machine on a Slope (In Case of Emergency)
      Raising the Machine Front Above the Ground with the Boom and Arm Function
      Excavation
      Face Shovel Operation
      Grading Operation
      Do Not Slam the Bucket Teeth into the Ground
      Do Not Use the Bucket as a Hammer
      Avoid Increasing Digging Force Forcibly
      Avoid Using Swing Power
      Boom Lowering Procedure in Emergency or when the Engine Stalls
      Overnight Storage Instructions
   TRANSPORTING
      Transporting by Road
      Loading/Unloading on a Trailer
      Transporting
      Unloading
      Towing Machine

9. Operators Manual (EMCGB-EN2-1)
Format: PDF, 494 pages
Language: English

10. Wiring Diagram (ZX145W-3_circuit_attach(20140414))
Format: PDF, 25 pages
Language: English
Table of Contents:
   ELECTRICAL CIRCUIT DIAGRAM (STANDARD)(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
   ELECTRICAL CIRCUIT DIAGRAM (STANDARD)(ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
   ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
   ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)(ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
   CONNECTORS
   CAB HARNESS(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
   CAB HARNESS (PRODUCTION APRIL 2010 AND UP)(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
   CAB HARNESS(ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
   ENGINE HARNESS
   FLOOR HARNESS
   MONITOR HARNESS
   CHASSIS HARNESS
   LEFT CONSOLE HARNESS(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
   LEFT CONSOLE HARNESS(ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
   AUXILIARY / POSITIONING SELECT HARNESS
   BLADE / OUTRIGGER HARNESS
   LICENSE PLATE HARNESS
   POSITIONING HARNESS
   PRESSURE SENSOR (POSITIONING) HARNESS
   SWING PARKING BRAKE RELEASE HARNESS
   ENGINE SUB HARNESS (1)
   ENGINE SUB HARNESS (2)
   BACK LAMP RELAYHARNESS(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
   BACK LAMPRELAY HARNESS(ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
   HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)

11. Wiring Diagram (ZX145W-3_circuit)
Format: PDF, 14 pages
Language: English
Table of Contents:
   ZX145W-3 SELECTOR VALVE / SECONDARY PILOT RELIEFSELECTOR HARNESS (OPTIONAL)
   ZX145W-3 FLOW RATE ADJUSTMENT ASSIST HARNESS (OPTIONAL)
   ZX145W-3 ASSIST HARNESS (1) (OPTIONAL)
   ZX145W-3 ASSIST HARNESS (2) (OPTIONAL)
   ZX145W-3 ASSIST HARNESS (OPTIONAL)
   ZX145W-3 BOOM BOTTOM PRESSURE SENSOR HARNESS (OPTIONAL)
   Z145W-3 GRIP EXTENSION HARNESS (OPTIONAL)
   ZX145W-3 GRIP EXTENSION HARNESS (FNR)
   ZX145W-3 HEATER SEAT HARNESS (OPTIONAL)
   ZX145W-3 OVERLOAD ALARM HARNESS (OPTIONAL)
   ZX145W-3 OVERLOAD ALARM SUB HARNESS (OPTIONAL)
   ZX145W-3 FLOW RATE SELECTOR HARNESS (OPTIONAL)
   ZX145W-3 FRONT ATTACHMENT HARNESS (OPTIONAL)
   ZX145W-3 MACHINE HEIGHT CONTROL SUB HARNESS (OPTIONAL)

12. Aditional Service Information (ZX145W-3_add)
Language: English